Honeywell WATCHDOG III - User Manual

CONTENTS
1 SAFETY
1.1 Please read and keep in a safe place
Please read through these instructions carefully before
installing or operating. Following the installation, pass the instruc-
tions on to the operator. This unit must be installed and commis-
sioned in accordance with the regulations and standards in force.
These instructions can also be found at www.docuthek.com.
1.2 Explanation of symbols
1
,
2
,
3
,
a
,
b
,
c
= Action
➔ = Instruction
1.3 Liability
We will not be held liable for damage resulting from non-obser-
vance of the instructions and non-compliant use.
1.4 Safety instructions
Information that is relevant for safety is indicated in the instructions
as follows:
DANGER
Indicates potentially fatal situations.
WARNING
Indicates possible danger to life and limb.
CAUTION
Indicates possible material damage.
All interventions may only be carried out by qualified gas techni-
cians. Electrical interventions may only be carried out by qualified
electricians.
1.5 Conversion, spare parts
All technical changes are prohibited. Only use OEM spare parts.
EN – www.docuthek.com
“WATCHDOG III”
Flare Stack Monitoring System
1 Safety .......................................1
2 Checking the usage ............................2
3 Installation ...................................2
4 Commissioning................................4
5 Assistance in the event of malfunction ..............6
6 Technical data ................................6
7 Certification...................................8
8 Disposal .....................................8
OPERATING INSTRUCTIONS
· Edition 01.24 · 32-00034-03 · EN

Summary

1 Safety Precautions

1.1 Please Read and Keep Safe

General safety instruction before installation and operation.

1.2 Explanation of Symbols

Defines symbols used for actions and instructions in the manual.

1.3 Liability Disclaimer

States no liability for damage due to non-compliance.

1.4 Safety Indication Methods

Explains how DANGER, WARNING, and CAUTION are indicated.

1.5 Conversion and Spare Parts Policy

Prohibits technical changes and mandates OEM parts.

2 System Overview and Components

2.1 Relay R1 Operation and Wiring

Configuration and function of the R1 flame relay.

2.2 Relay R2 Operation and Wiring

Configuration and function of the R2 alarm relay.

2.3 P222 Terminal Layout

Diagram illustrating terminal connections on the P222 processor.

2.4 Viewing Head Connection Point

Indicates the connection point for the viewing head.

3 Installation Procedures

3.1 Power Requirements Specification

Details the AC and DC power input requirements for the P222.

3.2 Signal Processor Wiring Guide

Instructions for connecting power and signals to the P222.

3.3 S256 BE Viewing Head Connection

Steps for physically attaching the viewing head connector.

3.4 Viewing Head Mounting Location

Guidelines for choosing an optimal installation site for the viewing head.

3.5 Viewing Head Aiming Technique

Procedures for aiming the viewing head for accurate flame detection.

4 System Commissioning

4.1 Self-Check Functionality

Describes the system's self-test and error indication.

4.2 P222 Control Panel Features

Overview of all LEDs, displays, and push buttons on the processor.

4.3 P222 Configuration Settings

Guides for setting R1 and R2 relay delays.

4.3.3 UV Gain Adjustment

Steps for manually setting the UV signal gain.

4.3.4 Analog Output Gain Calibration

Using Gain Set for adjusting the 4-20mA output.

4.3.5 Analog Output Range Selection

Procedure to switch between 0-20mA and 4-20mA outputs.

4.3.6 Viewing Head Temperature Monitoring

How to check viewing head temperature and warnings.

4.4 Modbus Communication Setup

Configuration of Modbus RTU settings like baud rate and address.

4.5 Registers Map

List of internal registers accessible via Modbus.

4.5.1 Programming UV Gain Flow Chart

Visual guide for programming the UV gain parameter.

4.5.2 Programming Relay Settings Flow Chart

Visual guide for programming relay settings and checking temperature.

5 Troubleshooting

5.1 P222 Display Shows S256

Troubleshooting when P222 displays 'S256'.

5.2 P222 Display Shows Loop

Troubleshooting when P222 displays 'loop'.

5.3 Flame Signal Lost

Diagnosing loss of flame signal, likely due to misalignment.

6 Technical Data

6.1 Electrical Input to Processor

Specifications for AC and DC power input.

6.2 Environmental Specifications

Ambient temperature ranges for processor and viewing head.

6.3 Outputs

Details of relay contacts and analog output specifications.

6.4 Inputs

Specifications for manual clear and channel select inputs.

6.5 Serial Communication

Supported serial communication protocols and baud rates.

6.6 Viewing Head Specifications

Details on viewing distance, field of view, and cable requirements.

6.7 Dimensions

Physical dimensions of the viewing head and mounting yoke.

7 Certification

7.1 CSA Compliance

List of CSA standards the product complies with.

8 Disposal Instructions

WEEE Directive Compliance

Guidelines for disposing of electronic components according to WEEE.

Overview

1. Usage Features
2. Maintenance Features

The Honeywell "WATCHDOG III" Flare Stack Monitoring System is an electro-optical device designed to reliably detect the presence or absence of a flame at a flare tip. It utilizes an ultraviolet (UV) sensor to monitor the UV energy emitted by the flame. When UV energy is detected, the system indicates the presence of a flame. Conversely, if no flame is detected, two flame-proving relays will de-energize after a user-selected time delay.

This system is engineered to operate effectively under typical and harsh environmental conditions. The UVTron sensor in the S256BE viewing head is designed not to respond to wavelengths beyond 300nm, meaning it is unaffected by sun radiation. This allows the S256BE to be mounted anywhere around the flare stack, even when aiming directly towards the sun. The UVTron also performs satisfactorily in heavy rain, snow, dust storms, and fog. If the flare flame is visible to the human eye from the viewing head's location, the S256BE will function effectively.

The system comprises three main components: the S256BE viewing head, the P222 signal processor, and an ASY55XBE cable/connector assembly. The S256BE viewing head is designed for ground-mounting, allowing for easy access for maintenance personnel without interrupting flare stack operations. It can be positioned up to 1000 feet (300 meters) from the flare tip.

Usage Features:

The P222 signal processor features a front panel with LED indicators, a four-digit display, and push buttons for configuration and operation.

• Flame Detection Indication: The system's display indicates the current flame signal. The R1 RELAY ON and R2 RELAY ON LEDs illuminate when their respective relays are energized, signaling flame presence.
• Adjustable Relays: Two flame-proving relays, R1 and R2, offer adjustable time delays for flame failure response. R1's delay can be set from 0 to 60 seconds, often used for triggering an ignition system or an alarm for pilot loss. R2's delay can be set from 0 to 3,600 seconds and is typically used for alarm indication. The R2 delay must always be longer than the R1 delay.
• Manual and Auto Modes: The system supports both automatic and manual operation. In auto mode, flame relays R1 and R2 automatically energize when a flame is recognized after a flame-out condition. In manual mode, flame recognition requires manual acknowledgment by the operator via the RESET button.
• Channel Select: The system allows for storing and using two sets of configuration parameters (Channel A and Channel B) to accommodate different flame characteristics or configuration needs.
• UV Gain Adjustment: The UV gain (00-99) can be manually adjusted to optimize the system's sensitivity to the flame signal.
• Analog Output Gain Adjustment: The analog output gain (for remote meters) can be adjusted using the GAIN SET button and up/down arrows.
• Modbus Communication: The P222 signal processor can communicate with a host computer via RS422 data transmission, supporting Modbus RTU mode for remote monitoring and control. This allows for changing parameters, reading status, and acknowledging alarms from a central location.
• Viewing Head Aiming: The S256BE viewing head has a digital display on its back showing the two most significant digits of the UV signal value. This aids in aligning the viewing head to the target flame area for maximum signal.
• Remote Meter Connection: The system provides a current-driven output (0-20mA or 4-20mA) for connecting to remote meters, allowing for remote monitoring of the flame signal level.

Maintenance Features:

• Self-Checking Function: The system continuously performs self-checks. A flashing SELF-CHECK LED indicates normal operation, while a steady on or off LED signals a lockout condition or component failure, requiring a reset.
• Troubleshooting Indicators: The SELF-CHECK LED helps diagnose issues. A steady on LED typically points to a viewing head problem, while an off LED suggests an issue with the signal processor itself.
• Viewing Head Temperature Display: The internal temperature of the viewing head can be displayed, and a flashing temperature reading indicates excessively high temperatures that could reduce the viewing head's lifespan.
• Easy Access for Servicing: The ground-mounted design of the S256BE viewing head ensures easy access for maintenance personnel.
• Source Impedance Resistor: The manual emphasizes the importance of installing a source impedance matching resistor between the SC and SIG GND terminals for proper signal transmission, with specific resistance values depending on the distance between the signal processor and viewing head.
• Cable Shielding: Proper connection of the viewing head's signal wire and braided shield is crucial for the signal and self-checking circuit.
• Firmware Version Display: Upon power-up, the P222 displays the current software version and "S256" if the viewing head connections are correct, aiding in initial diagnostics.
• Error Codes: A "0000" display on power-up indicates a missing source impedance matching resistor, while "loop" indicates an older signal processor version requiring a jumper across external meter connections.

Honeywell WATCHDOG III Specifications