INSTALLATION AND OPERATION MANUAL FOR THE PILOTEYE 2000

Transcription

1 Installation & Operation Manual Page 1 INSTALLATION AND OPERATION MANUAL FOR THE PILOTEYE 2000 Release East Apache P.O. Box Tulsa Oklahoma (918) other offices located in major cities around the world-

2 Installation & Operation Manual Page 2 LIMITED WARRANTY The manufacturer warrants to the purchaser of each PilotEye system that any part thereof which proves to be defective in material or workmanship, within two (2) years from date of manufacture, will be repaired or replaced at no charge, if the instrument is returned to the manufacturer with all freight charges prepaid. If a performance problem should occur, contact the John Zink sales office. This warranty does not cover defects resulting from accident, alteration, improper use, or failure of the purchaser to follow normal operating procedures as outlined in the instruction manual. This warranty is in lieu of any warranty of merchantability and of all other warranties, expressed or implied, all of which are hereby excluded. The manufacturer shall, in no event, be liable for any special, indirect, or consequential damages whatsoever and neither assumes nor authorizes any person to assume for it any other obligation or liability. Standard UPS ground transportation, or equivalent, is utilized unless otherwise specified by the customer. Please ensure that the system is properly packaged to avoid damage during shipment.

3 Installation & Operation Manual Page 3 TABLE OF CONTENTS 1.0 INTRODUCTION PURPOSE OF THE MANUAL SYSTEM DESCRIPTION Overview System Configuration SYSTEM SPECIFICATIONS GENERAL SPECIFICATIONS AND FUNCTIONS PILOTEYE OPTIONS AND ACCESSORIES INSTALLATION PROCEDURES PLANNING THE SENSOR INSTALLATION MECHANICAL INSTALLATION Mounting and Site Selection Aligning the Sensor to the Target Verifying The Proper Operation Mounting the Optional Interface Module ELECTRICAL INSTALLATION CONFIGURE AND OPERATE THE SYSTEM OVERVIEW OF PILOTEYE CAPABILITIES THE PILOTEYE MENU SYSTEM Overview of the Menu System Operator Interface Navigating The Menu System Editing Sensor Parameters in the Setup Mode SYSTEM STATUS MESSAGES SIGNAL CONDITIONING FUNCTIONS Overview Alarm Delay Temperature Scale ( F or C) Pilot Warning Level Low Energy Gain and Level OUTPUTS AND ALARMS Programming The Analog Outputs Programming The Alarms Using the Digital Outputs SYSTEM DIAGNOSTICS TROUBLESHOOTING AND MAINTENANCE GENERAL MAINTENANCE SYSTEM TROUBLESHOOTING SPARE PARTS KIT...32

4 Installation & Operation Manual Page 4 LIST OF FIGURES Figure 1 - Typical PilotEye Installation... 5 Figure 2 - System Components and NEMA 4 Dimensions... 7 Figure 3 - NEMA 7 Dimensions Figure 4 - Avoiding Interference from the Sun Figure 5 - Interface Module Dimensions Figure 6 - Analog/Digital Jumper in Sensor Figure 7 - Interface Module Connections Figure 8 - Sensor Terminal Connections Figure 9 - Sensor and Interface Module Layouts Figure 10 - Menu System Summary LIST OF TABLES Table 1 - Standard Functions... 8 Table 2 - Sensor and Interface Module Specifications... 8 Table 3 - Sensor Options and Accessories... 9 Table 4 - PilotEye Field of View Table 5 - Wiring Diagram - Analog Configuration Table 6 - Wiring Diagram - Digital Configuration Table 7 - Interface Module Wiring Connections and Specifications Table 8 - PilotEye Capabilities Table 9 - Types of Menu Items Table 10 - System Status Messages Table 11 - Signal Conditioning Group Menu Table 12 - Programmable Output and Alarm Parameters Table 13 - Alarm Specifications Table 14 - Digital Output Table 15 - Diagnostics Group Menu Table 16 - Troubleshooting Guidelines Table 17 - Spare Parts Kit Table 18 Gain and Low Energy Threshold Settings... 32

5 Installation & Operation Manual Page INTRODUCTION 1.1 PURPOSE OF THE MANUAL This manual provides a description of the installation and operation of a PilotEye pilot flame monitor. It includes detailed information about!" the sensor specifications!" sensor options and accessories!" installation and operating procedures!" maintenance and calibration procedures 1.2 SYSTEM DESCRIPTION Overview The flare stack is designed to burn off hazardous gases during normal operation as well as emergency situations. If the flare pilot flame is out, hazardous gases may be vented accidentally to the environment. Continuous operation of the flare pilot flame is a critical requirement for the proper operation of the system in order to prevent a major safety hazard. A dependable and maintenance-free pilot flame monitor is an important system component. Currently, many pilot flames are monitored using thermocouples that must be mounted at the flame. This system, though effective, proves to be cumbersome when a thermocouple failure occurs. Thermocouple failure is likely for some stacks from a combination of heat and oxidation. Access to these failed components is often difficult and expensive. While the system is down, no pilot safety status is provided. The John Zink PilotEye is a noncontact dual-wavelength infrared sensor that monitors the presence of pilot flames on flare stacks and provides an alarm signal when a flame-out condition occurs. The sensor is typically located at ground level (see Figure 1) which enables quick installation, easy operational checkout, and minimizes maintenance expenses ft. Maximum Distance (500 mtrs) Maximum 60 deviation from horizontal Figure 1 - Typical PilotEye Installation

6 Installation & Operation Manual Page System Configuration The system consists of an optical sensor and an optional remote interface module (see Figure 2). The optical sensor features a unique dual-wavelength design that determines flame presence by computing the radiant energy emitted by the flame in two adjacent narrow spectral bands. Utilizing the ratio of these signals, the sensor measures the hottest target in the field of view. Hence, this design is not affected by:!" the low and varying emissivity (luminosity) of the flames!" the unsteady movement of the flame in the field of view!" intervening fog, rain and snow. In addition, the John Zink PilotEye features a unique single-detector design for added sensitivity, long-term stability, and drift-free operation. The sensor and its optics have been optimized to function efficiently at the low energy levels typically encountered with small, distant pilot flames, thus ensuring accuracy regardless of distance from the flare stack. A built-in alarm system includes an adjustable setpoint alarm and a continuous 4-20mA output signal indicating the presence of the pilot flames. The PilotEye uses optical lenses to focus the energy emitted from the pilot flame onto an infrared detector. This detector is sensitive to the energy emitted by pilot flames just as the detector in a solar calculator is sensitive to energy from the sun. The signal from the detector is electronically processed and the system output signal is generated. To eliminate an alarm condition from intermittent interruptions, which may temporarily block the flame from the sensor, an alarm delay function has been included in the design to eliminate false alarms. The system is available in NEMA4X (IP65) and NEMA7/4 enclosures. The NEMA4X version is suitable for areas classified as non-hazardous. The NEMA7/4 version is suitable for use in areas designated as NFPA496, Class I, Groups B, C & D and Class II, Groups E, F, & G. The system may be installed as a stand-alone transmitter with an input power of 24Vdc, or with an optional remote interface module that includes a universal power supply of Vac. An optional AC power supply is available for the stand-alone configuration. Conduit connections are ¾-inch.

7 Installation & Operation Manual Page 7 Stand Alone (NEMA 4X) 12.0 Rated for NEMA 4X (IPGS) Sighting Eyepiece with cover Pilot Stat Pilot Lit 2 x 10 LCD Display and three menu control buttons Horizontal/ Vertical Adjusting Bracket 2.75 (typ) Ø (4 holes) 1-1/2" NPS pipe thread Optional Remote Interface Module 3.75 (95.3) 3.75 (95.3) 100 PilotEye2000 Pilot Status Pilot Lit Main Display Functional Display Power and signal connections with quick release connectors 6-32 set screws for panel mounting clamps (top and bottom) WILLIAMSON CORPORATION (90.4) MENU RS232 L-GND-N NEMA 12 front panel Four Menu Control Buttons Panel thickness " ( cm) Panel Mounting Clamps (top and bottom) 3.56 (90.4) 6.25 (158.8) 6.63 (168.4) Figure 2 System Components and NEMA 4 Dimensions

8 Installation & Operation Manual Page SYSTEM SPECIFICATIONS 2.1 GENERAL SPECIFICATIONS AND FUNCTIONS The following two tables provide a quick reference to all of the PilotEye Functions and Specifications. Measured Parameters Signal Conditioning Status Messages Diagnostics STANDARD PILOTEYE FUNCTIONS Each parameter can be easily programmed for use with all of the system outputs and alarms. Pilot Signal (all signal conditioning filters applied) Unfiltered Pilot Signal (no signal conditioning filters applied use for diagnostics) Ambient Temperature Signal Dilution Alarm Delay Low Energy Adjustment Pilot Warning Level Pilot Status Message: Pilot Lit, Pilot Out Ambient Warning (above ambient limit of the sensor) Check Sensor Cable (communication problem with remote interface module) System Test (enabled during power up of the system) Analog Output Test (force outputs to specific values to verify proper operation) Alarm Tests (change the state to verify the alarm functions) Menu Access (for security, can delay access to the menu system) Table 1 Standard Functions PILOTEYE 2000 SPECIFICATIONS Energy Sensitivity 0 to 100% Type of Sighting Visual (SLR) Sighting, D/40 standard optics (D/75 precision optics option) Field of View 14ft at 500ft (4.3m at 152m) Working Distance 0 to 1500 feet (0 to 475m) CE Certification EMI / RFI for heavy industry, LVD (Low Voltage Directive) Ambient Temperature Limits PilotEye: -40 to 120 F (-40 to 50 C), Interface Module: 120 F (50 C) max. Input Power Stand-Alone PilotEye: 24Vdc (300mA) With Interface Module: Vac Stand Alone Configuration: an internal jumper is used to select the analog or digital mode. Analog Mode 4-20mA or 0-20mA (1000ohm max. impedance. Shunt resistors produce voltage outputs.) Digital Mode Bi-directional RS485 communications RS232 w/ a converter Select output parameter, scale, and range TTL Alarm (rating 2mA at 5Vdc) Select alarm parameter and set point Input and Output Signals Mounting Enclosure Rating Dimensions Nominal Weight System Configuration with Interface Module 2 Programmable Analog Outputs 4-20mA or 0-20mA (1000ohm max. impedance. Shunt resistors produce voltage outputs.) Select parameter, scale, and range Bi-directional Serial Communications RS232 and RS485 2 Programmable Relay Alarms Form C (4A at 250Vac or 2.5A at 30Vdc) Select alarm parameter and set point 1 Programmable TTL Alarm TTL rating is 2 ma at 5Vdc Select alarm parameter and set point Adjustable swivel bracket that mounts on a 1-1/2 inch pipe thread, or a four bolt mount. PilotEye NEMA 4X (IP65): Corrosion Resistant Casting (Optional NEMA 7X) Interface Module: NEMA 12X front panel - Anodized Housing PilotEye NEMA 4: 8.50in x 5.25in x 6.00in (216mm x 133 mm x 152 mm) PilotEye NEMA 7: 11.5in x 8.5in x 14.5in (292mm x 216 x 368mm) Interface Module: 7.0in x 3.78in x 3.78in (177.8 mm x 96 mm x 96 mm) PilotEye NEMA 4: 7 lbs. (3.5 kg) Interface Module: 2.2 lbs. (1kg) PilotEye NEMA 7: 20 lbs (9.5 kg) Table 2 Sensor and Interface Module Specifications

9 Installation & Operation Manual Page PILOTEYE OPTIONS AND ACCESSORIES Each PilotEye includes options and accessories that have been designed to simplify the sensor installation and operation or to provide additional protection for the sensor in hostile operating conditions. Table 3 provides a narrative description of each of these items. PILOTEYE OPTIONS AND ACCESSORIES Code Description Remote ¼ DIN Programmable Interface Module!" Universal Power Supply: Vac 50-60Hz!" Programmable Analog Outputs: 4-20mA and 0-20mA 23P!" Bi-directional Digital Outputs: RS232 and RS485!" Programmable Dual Set Point Form C Alarms, and one TTL Alarm!" NEMA 12 Front Panel Refer to sections for additional details. Universal Power Supply for Stand Alone Sensors: PS!" Output: 24Vdc (700mA)!" Input: Vac, 50-60HZ (110 and 220Vac) nc Interconnecting electrical cable (six-conductor, shielded with copper braid, and a Teflon jacket) High Resolution Optics. Usually not required, this option allows the system to view a smaller D/75 area for use when two or more stacks are very close together. NEMA7X NEMA7/4X (NFPA497 Class I, Groups B, C & D; Class II, Groups E, F & G) Table 3 Sensor Options and Accessories

10 Installation & Operation Manual Page INSTALLATION PROCEDURES 3.1 PLANNING THE SENSOR INSTALLATION For many applications, the proper installation planning and operating procedures can provide improved performance, reduced maintenance, and a longer operating life for the PilotEye. The basic installation steps are: 1. Mount the sensor in a location to properly view the target (sections and 3.2.2). 2. Mount the optional interface module for easy viewing and operation (section 3.2.4). 3. Connect the PilotEye power and signal cables (section 3.3). The system will power on once the proper connections are established. 4. Verify proper PilotEye operation. For most applications, no adjustments are required. (section 3.2.3) 5. When required, review the sensor adjustments in section 4 and the troubleshooting procedures in section 5.

11 Installation & Operation Manual Page MECHANICAL INSTALLATION Mounting and Site Selection The PilotEye flare monitor is designed to mount to a standard 1-1/2" pipe thread or a base plate located at or near ground level allowing for convenient access. The dimensions for the NEMA 4X and NEMA 4/7 configurations are shown in Figure 2 and 3 respectively. Some recommended guidelines for mounting the PilotEye are as follows:!" The sensor must be mounted such that it has a clear line-of-sight view of the flare pilot flame and shroud.!" The closer the sensor is mounted to the flame, the lower the likelihood of interference from heavy snow, rain, or fog.!" If mounted too close to the base of the stack, then the pilot may be hidden from sight. Therefore, the PilotEye should be mounted away from the stack, at a distance of at least 1.25 times the height of the stack, to ensure an unobstructed view of the pilot. Since the sensor responds to the highest temperature within its field of view, care should be taken to ensure that the sun does not pass within the sensor's view. The sensor will not signal an alarm for a pilot flame outage at any time while a direct or reflected image of the sun is within the sensor's field of view (see Figure 4). Sunlight that does not enter the sensor's field of view, directly or via reflection, has no effect upon sensor performance. If direct alignment with the sun is unavoidable, no damage to the sensor will occur. If the selected mounting location is designated as "hazardous", then the optional NEMA7/4 explosion-proof enclosure should be selected. To minimize the likelihood of damage due to lightening strikes, the PilotEye (including electrical conduit) should be electrically isolated from surrounding metal structures /4" NPT conduit threads Pilot Statu Pilot Lit 14.5 Horizontal/ Vertical Adjusting Bracket 2.75 (typ) Ø (4 holes) 1-1/2" NPS pipe thread Figure 3 NEMA 7 Dimensions

12 Installation & Operation Manual Page 12 Figure 4 Avoiding Interference from the Sun Aligning the Sensor to the Target The PilotEye features a visual aiming system for alignment to the pilot flame (see Figure 1). As illustrated in Table 4, the diameter of the target area (d) is determined by dividing the distance (D) from the PilotEye to the pilot flame by the optical resolution of 40. At any distance, D, the target diameter, d, equals the distance divided by 40; d = D/40. Mounting Distance Sensor Target Diameter Feet Meters Feet Meters Table 4 PilotEye Field of View To align the sensor, remove the cover from the eyepiece on the rear of the sensor and adjust the mounting bracket so that the pilot flame is centered in the target area with a clear line of sight Verifying The Proper Operation Under most conditions, once the system has been aligned so that the flare pilot flame appears within the sensor's field of view, no adjustments are required. To verify the proper system operation follow these steps: 1. Remove the rear cover on the sensor to view the Pilot Status, Pilot Signal, and the Unfiltered Signal parameters on the sensor display (see section 4 for navigating the display). 2. As a starting point, verify that the PilotEye is properly aligned to the pilot flame. The Pilot Status should be Pilot Lit, and the Pilot Signal should be 100%. If these conditions do not exist, then review section and Cover the sensor's lens and verify the proper change to the displayed sensor output. The system includes a delayed response to avoid false alarms. The factory default setting for the alarm delay is 2.5 minutes (see section 4.0 if the alarm delay value requires an adjustment).

13 Installation & Operation Manual Page 13 While the sensor lens is covered, the following should occur: The pilot signal should change from 100% to 0% after the alarm delay time. The pilot status should change from Pilot lit to Pilot Out after the alarm delay time. The alarm(s) should trip after the alarm delay time. The alarms need to be programmed to the pilot signal parameter (the factory setting for the alarms is disabled). The unfiltered pilot signal should change from 100% to 0% without any delay (this is a quick way to check that the PilotEye is responding properly. It is also possible to adjust the alarm delay parameter to disabled to speed up the test time. When the test complete, the alarm delay should be returned to its original setting 4. Uncover the sensor s lens and the Pilot Signal should return to the 100% and the Pilot Status should change back to Pilot Lit with minimal delay. For troubleshooting procedures, see Section 5.

14 Installation & Operation Manual Page Mounting the Optional Interface Module The remote interface module may be placed on a counter or mounted to a panel. The module is standard 1/4 DIN dimensions with a NEMA12 front panel rating. For installations on a counter, the rear connections of the module must be protected from debris and moisture. For installations in a panel, air circulation must be adequate to maintain proper ambient temperature limits of 120 F (50 C). To mount the interface module to a panel: 1. Prepare a square 3.63 inches (92cm) panel cutout. If more than one display is being installed, allow 1 inch (2.5cm) between cutouts. 2. Remove the top and bottom mounting bars using the setscrews located on the rear panel (as well as the rubber feet on the bottom) 3. Slide the display module, terminal end first, into the front of the mounting panel. 4. Return the mounting bars into their original locations. 5. Tighten the mounting bars against the panel using the rear set screws (95.3) 3.75 (95.3) 100 PilotEye2000 Pilot Status Pilot Lit Main Display Functional Display Power and signal connections with quick release connectors 6-32 set screws for panel mounting clamps (top and bottom) WILLIAMSON CORPORATION (90.4) MENU RS232 L-GND-N NEMA 12 front panel Four Menu Control Buttons Panel thickness " ( cm) Panel Mounting Clamps (top and bottom) 3.56 (90.4) 6.25 (158.8) 6.63 (168.4) Figure 5 Interface Module Dimensions

15 Installation & Operation Manual Page ELECTRICAL INSTALLATION With the sensor s integrated processing electronics, each PilotEye is available in three different configurations. 1. Stand Alone Analog Configuration (Table 5) 2. Stand Alone Digital Configuration (Table 6) 3. Digital Configuration with optional interface module (Table 6) To change the sensor between the analog and digital configurations, the sensor signal connector must be switched internally between the J5 (A=Analog) and J6 (D=Digital) positions (see Figure 6). When power is properly applied to the sensor or the interface module, the system displays will illuminate and go through the power up routine. The stand-alone sensors must be powered using an external power supply of 24Vdc (300mA). An optional external AC power supply specifically selected to meet the sensor requirements is available. For use with the interface module, connect the sensor to the module and apply 90 to 260Vac power to the module on terminals 31, 32, and 33 to establish power for the entire system. Table 7 and Figure 7 provide complete details for making the connections to the interface module s rear panel. Alarm/Relay Outputs (J12 & J13) Pilot Statu Pilot On Display input, output, and alarm connections (J6) WILLIAMSON CORPORATION Sensor power and signal connection (J7) J6 J5 Sensor Signal Cable D/J6 =Digital Mode A/J5=Analog Mode RS232 Connection (J9/DB9) RS L-GND-N Universal power connection (J8) Rear of sensor shown with cover removed. Figure 6 Analog/Digital Jumper in Sensor Figure 7 - Interface Module Connections

16 Installation & Operation Manual Page 16 Analog Configuration (Stand Alone) Terminal Number Conductor Color Function Ribbon Cable Pigtail Cable Ribbon Cable Pigtail Cable Clear Earth Ground (Shield) D 25 Yellow Black ma Output Return C 26 Orange Green ma Output + (select 0-24mA or 4-20mA) F 27 Blue Orange TTL Alarm Output (0 / 5 Vdc) E 28 Green Blue Not Used B 29 Red White 24Vdc Return (Circuit Common) A 30 Brown Red +24Vdc (300mA) Wiring Notes Table 5 Wiring Diagram - Analog Configuration Digital Configuration (Stand Alone or with remote Interface Module) Remote Interface Module Terminal Number Conductor Color Function Terminal Number (J7) Ribbon Cable Pigtail Cable Ribbon Cable Pigtail Cable Clear Earth Ground (Shield) 25 D 25 Yellow Black RS485 Full Duplex Receive - 26 C 26 Orange Green RS485 Full Duplex Receive + 27 F 27 Blue Orange RS485 Full Duplex Transmit - 28 E 28 Green Blue RS485 Full Duplex Transmit + 29 B 29 Red White 24Vdc Return (Circuit Common) 30 A 30 Brown Red +24Vdc (300mA) Table 6 Wiring Diagram - Digital Configuration 1. The standard sensor signal cable length is 10ft (3m) with longer lengths available upon request. Use Beldon Cable #83606, or equivalent. This cable has six 20 AWG conductors with an overall braided shield and a Teflon Jacket. 2. A separate converter can be purchased to provide an RS232 connection directly to the sensor. Ribbon Cable BN R GN BL O Y A B E F C D To Interface R W BL O GN BK Pigtail Cable Figure 8 - Sensor Terminal Connections

17 Installation & Operation Manual Page 17 ID FUNCTION NOTES J12 ALARM / RELAY OUTPUT 1 (Black Connector) 1 Normally Closed (N.C.) 2 Common (C.) 3 Common (C.) Relays are 4 amps at 250Vac, or 2.5 amps at 30Vdc 4 Normally Open (N.O.) Relay Activation Time: 15 ms max J13 ALARM / RELAY OUTPUT 2 Reset Time: 5 ms max (Black Connector) Select alarm parameter from Pilot Signal, Unfiltered Pilot Signal, Ambient 5 Normally Closed (N.C.) Temperature, Signal Dilution Value 6 Common (C.) 7 Common (C.) 8 Normally Open (N.O.) J6 9 Not Used 10 Circuit Common 11 Analog Output 2 12 Circuit Common 13 Analog Output 1 OUTPUT, & ALARM FUNCTIONS (Green Connector) Select output parameter from Pilot Signal, Unfiltered Pilot Signal, Ambient Temperature, Signal Dilution Value Select output scale of 4-20mA or 0-20mA. Generate a voltage output by using a shunt resistor (max 1000 ohms). 14 Circuit Common 15 TTL Alarm Output TTL output rating is 2mA at 5Vdc (same parameters as Alarm 1 and Alarm 2) 16 Circuit Common 17 Not Used 18 Circuit Common 19 Not Used 20 RS485 Full Duplex Receive - 21 R485 Full Duplex Receive + 22 RS485 Full Duplex Transmit - 23 RS485 Full Duplex Transmit + THIS RS485 CONNECTION IS NOT ACTIVITED FOR THIS SYSTEM Full Duplex RS485 communications for two-way communication with a computer, a data logging system, or another sensor. J7 SENSOR CONNECTION (Green Connector) 24 Earth Ground (shield) Clear Shield Isolated from circuit common 25 RS485 Full Duplex Receive - Black D 26 RS485 Full Duplex Receive + Green C 27 RS485 Full Duplex Transmit - Orange F 28 RS485 Full Duplex Transmit + Blue E Standard connection for all sensor communications Estimated distance limit of 4000 feet Vdc Return (circuit common) White B Vdc Red A Sensor Power J8 AC POWER LINE IN (Green Connector) 31 AC IN Hot (L) Isolated from circuit common. 32 AC IN Earth Ground 33 AC IN Neutral (N) Universal Power Supply. Input power Vac 50/60Hz (2.5 Amps). J9 RS232 CONNECTION (DB9 Connector) DB9 N.C. PC RS232 TX PC RS232 RX N.C. Circuit Common The RS232 connection offers bi directional communication with a computer, a data logging system, or another sensor. To make this connection with another device, use a standard straight-through serial cable (wired as DTE). The estimated distance limit for this connection is 50 feet. The line format is baud, no parity, 8 data bits, 1 stop bit. This is not currently adjustable. N.C. PC RS232 CTS Using the AUTO ON Command generates the following output: Unfiltered Pilot Signal, Filtered Pilot Signal, Signal Status, Ambient PC RS232 RTS Temperature, Ambient Status, Signal Dilution N.C. Table 7 - Interface Module Wiring Connections and Specifications

18 Installation & Operation Manual Page CONFIGURE AND OPERATE THE SYSTEM 4.1 OVERVIEW OF PILOTEYE CAPABILITIES The John Zink PilotEye system utilizes dual-wavelength technology with automatic output signal compensation that allows the sensor to view through fog, rain, snow and dirty lenses much more effectively than comparable single-wavelength systems. In fact, the John Zink PilotEye system can view through snow, rain and fog forty times more dense than can the single-wavelength systems. Since the dual-wavelength John Zink PilotEye system measures only the hottest temperature within the target area (not the average temperature), the system output automatically compensates for dirty optical windows and obscuring water droplets. Similarly, as the flame size, shape and luminescence varies, the sensor's output will remain constant. Proper alignment of a single-wavelength system is critical. If the sensor is bumped so that it is moved less than 0.4 degrees (1/900 of a revolution) the pilot flame will be out of the sensor's view. The John Zink PilotEye system offers a large field of view so that alignment of the sensor is not as critical. Item Single-Wavelength Systems John Zink PilotEye Target 25ft 3ft diameter 7.5ft diameter Target 500ft 6ft diameter 13ft diameter Target 1,000ft 12ft diameter 26ft diameter Precision Alignment Required Yes No Measurement Technique Single Wavelength Dual Wavelength Temperature Sensor Automatically compensates for: Rain Fog Snow Dirty Optics Flame Size & Shape Flame Luminescence (emissivity) Average Temperature within the Target Area No (1) No (1) No (1) No (1) No No Hottest Temperature within the Target Area Yes (2) Yes (2) Yes (2) Yes (2) Yes Yes Notes: Table 8 - PilotEye Capabilities 1. The single-wavelength technique measures the average temperature of everything within its target area. At a 1000 ft. distance, the pilot flame fills only about 0.2% of the target area. The resulting low energy levels account for tremendous signal noise that must be dampened by the system. When 1% of the viewing area is blocked by water droplets or dirt, the single-wavelength system's output will drop 1%; when 90% of the viewing area is blocked, then the output signal will drop 90%. 2. The dual-wavelength technique measures the hottest temperature within its target area. The system will measure accurately even with most of the flare blocked from the sensor's view.

19 Installation & Operation Manual Page THE PILOTEYE MENU SYSTEM Overview of the Menu System The PilotEye menu system is designed to simplify the sensor setup and operation by enabling easy access to the system s programming and diagnostics capabilities. Some important highlights about this menu system are:!" All menu items have text-based descriptions that make them easy to recognize and adjust. No manual is required to translate parameter codes and settings with this system.!" All of the outputs, and alarms can be programmed to represent any one of the sensor s measured parameters. Using the menu system, it is a simple procedure to select the parameter, the output scale, and/or the alarm set point value. This enables a variety of advanced capabilities to monitor and control on several process parameters.!" Many system status messages and diagnostics functions are included to assist with setup and troubleshooting procedures.!" The interface modules can be interchanged with different PilotEye sensors to simplify installation, maintenance, and calibration procedures. The PilotEye sensor is designed to automatically update the configuration information for any interface module. This simplifies the setup of spare sensors or interface modules as well as the testing of sensors Operator Interface Each PilotEye sensor is available in a stand-alone or a system configuration. Figure 9 illustrates the operator interface that is provided with each of these options. With the stand-alone sensor configuration, it is possible to setup the unit in either an analog or a digital mode by simply changing a jumper inside the sensor. The analog mode offers connections for one analog output and one TTL alarm, while the digital mode offers a bi-directional RS485 connection. With both of these stand-alone configurations, the menu adjustments are made using the three buttons and the display inside the sensor s rear cover. In order to protect the sensor electronics, this cover should be screwed back in place when the adjustments are complete. With the system configuration, the interface module offers an advanced user interface, additional input, output, and alarm functions, as well as a universal power supply. The user can install this module in a remote location away from the sensor for convenient access. When the sensor is setup in a system configuration, the operator can only change sensor settings from the interface module. For startup and troubleshooting purposes, the functional display on the back of the sensor still provides access to view parameters, but it is not possible to change the system settings from the sensor s integrated display when an interface module is connected.!" Bi-directional serial communications are provided to enable remote configuration and monitoring capabilities with all of the sensor parameters.

20 Installation & Operation Manual Page 20 STAND ALONE SENSOR Eye Piece 2 x 10 LCD Display to view and edit sensor parameters Arrow Buttons 1. Scroll through menu items 2. Change parameter values Arrow Buttons simultaneously 1. Switch to setup mode 2. Switch to main menu or display mode Pilot Statu Pilot On J6 J5 Sensor Connector Enter Button 1. Select menu items 2. Edit/Save parameters Sensor Signal Cable D/J6 =Digital Mode A/J5=Analog Mode PROGRAMMABLE INTERFACE MODULE Main Display 5 LEDs to display measured parameters 100 PilotEye2000 Pilot Status Pilot Lit MENU Functional Display 2 x 16 backlit LCD to view and edit parameters Movement verifies sensor operation Menu Button 1. Switch to Setup Mode 2. Switch to Main Menu or Display Mode Arrow Buttons 1. Scroll through menu items 2. Change parameter values Enter Button 1. Switch Main Display parameter 2. Select menu item 3. Edit/Save parameters Figure 9 Sensor and Interface Module Layouts

21 Installation & Operation Manual Page Navigating The Menu System Figure 10 provides an overview of the menu system s organization as well as a complete list of all the menu items. The menu system is organized into a display mode and setup mode. The display mode is used for normal operation, and it includes the ability to view:!" all measured sensor parameters!" sensor settings and specifications!" system generated status messages The setup mode is used to view and edit all of the sensor parameters. It is organized into a main menu and several group menus that each contains a common set of parameters. The main menu provides a central point for navigation to the following group menus:!signal Conditioning!Configure Outputs!Configure Alarms!Diagnostics!System Specifications The menu button on the interface module is used to switch between the display mode and the setup mode. The arrow and enter buttons are used to navigate through the menu and edit parameters. Table 9 and Figure 9 provide the details about specific functions. Due to space limitations, the menu button is not included in the stand-alone sensor. To generate the menu button functions on the stand alone sensor, press the two outer arrow buttons simultaneously. The setup mode includes a timeout function to return the system back to the display mode when none of the buttons have been pressed for 15 minutes Editing Sensor Parameters in the Setup Mode To change a sensor parameter, press the menu button to enter into the setup mode and follow these steps. 1. Using the arrow and enter buttons, select the desired group menu from the main menu. 2. Press one of the arrow buttons to scroll to the desired item in the group menu. An E icon in the upper right hand corner of the display indicates that the item can be changed. 3. Press the enter button to enable the edit mode for the selected menu item. The angled brackets < > are removed, the E icon begins to blink, and a blinking cursor is activated. 4. Press one of the arrow buttons to scroll through the list of pre-defined options or to increase or decrease the parameter value. Press and hold the arrow button to accelerate the change of the value. 5. Once the final parameter value is selected, press the enter button again to end the editing process and save the selected value. The angled brackets <> are re-activated to indicate the final value. The output signal is not effected by the adjustment until the enter button has been pressed to save the new value. If the menu button is pressed before the change is entered, then the change is not saved and the original value is retained. 6. Continue on to change other items in the menu system or return to the display mode for normal operation by pressing the menu button twice (first to get to the main menu, and second to leave the setup mode and return to the display mode). TYPE OF MENU ITEM View Only Parameter: These items are either a factory specification or a measured value by the sensor. Adjustable Parameter: These are items that can be changed to configure the sensor or troubleshoot application issues. Reset Group Defaults: This function is included in each menu group to simplify editing procedures. When this item is selected, the user is prompted, to select yes to reset the default values of the respective group s parameters, or no if the user wants retain the current settings. Menu Navigation Item: These items direct the system to another part of the menu. They are typically located at the end of each menu group. DISPLAY FORMAT Description Description <xxxxxxx> Reset Group Default Values RETURN TO MAIN MENU xxxxxxx E Table 9 Types of Menu Items

22 Installation & Operation Manual Page 22 NAVIGATION FUNCTIONS Button Display Mode Main Menu Group Menus Switch back to the Switch to the main Switch back to the MENU (1) main menu in the menu in setup mode display mode. setup mode! " Scroll through the sensor parameters on the functional display. This is a view only mode. Press and hold the enter button to change the parameter output on the main LED display. Scroll through the main menu groups (groups of sensor parameters) Select the menu item. Scroll through to view or edit sensor parameters. During editing the arrows change the parameter value. If an E icon is displayed, then the enter button activates the editing mode and saves the selected value after changes are made. Main Display (LEDs) Functional Display (Back lit LCD) Status Messages DISPLAY MODE Pilot Signal Signal Dilution Pilot Status Pilot Signal Unfiltered Signal Signal Dilution Ambient Temperature Alarm Delay Alarm 1 Set Point Alarm 2 Set Point TTL Alarm Set Point Model Number Sensor S/N Field of View Module S/N Pilot Lit / Pilot Out Ambient Warning Check Sensor Cable Lockout Enabled 1. On the stand alone sensors press the two outside arrow buttons simultaneously to generate the menu button functions. Signal Conditioning Configure Outputs MAIN MENU Configure Alarms GROUP MENUS Alarm 1 Parameter Alarm 1 Set Point Alarm 2 Parameter Alarm 2 Set Point TTL Alarm Parameter TTL Alarm Logic TTL Alarm Set Point Reset Group Defaults Rtrn to Main Menu Rtrn to Display Mode Diagnostics System Specifications SETUP MODE Alarm Delay Temp Scale ( F / C) Pilot Warning Level Low Energy Gain Low Energy Level Reset Grp Defaults Rtrn to Main Menu Rtrn to Display Mode Output 1 Parameter Output 1 Scale Output 2 Parameter Output 2 Scale Reset Group Defaults Rtrn to Main Menu Rtrn to Display Mode Output 1 Test Output 2 Test TTL Test Alarm 1 Test Alarm 2 Test Menu Access Reset Group Defaults Rtrn to Main Menu Rtrn to Display Mode Customer ID Sensor Type Model Number Sensor S/N Field of View Manufactured Date Last Calibration Date Warranty Expiration Sensor Firmware Display S/N Module Firmware Rtrn to Main Menu Rtrn to Display Mode (not all menu items are included with the stand alone sensor configuration) Figure 10 Menu System Summary

23 Installation & Operation Manual Page SYSTEM STATUS MESSAGES The table below provides a list of the system status messages and their associated conditions. As verification that the system is running properly, a thermometer icon is continuously refilling in the upper right corner of the functional display when the menu system is in the display mode. If the operating conditions of the sensor are out of specification, then a status message is presented to help diagnose the problem. There is no reset requirement for any of these warning messages. If the warning condition reverts back to a normal state, then the status message is no longer displayed. Status Condition STATUS MESSAGES Main Display (5 LEDs) Functional Display (2x16 LCD) Pilot The filtered pilot signal is below 10%. No Change Pilot Out Status Messages The filtered pilot signal is above 10%. No Change Pilot Lit Analog Output No Change Ambient Warning Check Sensor Cable Menu Lockout Enabled Sensor s measured ambient temperature is above the sensor s ambient limit. The sensor does not respond to polling from the interface module. This message is also displayed as the initial communications are being established between the sensor and display. This feature prevents inadvertent access to the sensor menu system, and it is enabled by using the menu access item in the diagnostics menu group. When this item is set to delay, the operator is required to press and hold the menu button for 7 seconds in order to get into the menu system. During the first 5 seconds of this 7-second delay the lockout message is displayed. No Change Dashes on LEDs No Change Ambient Warning Check Sensor Cable Menu Lockout Enabled No Change 0 or 4mA No Change Table 10 System Status Messages

24 Installation & Operation Manual Page SIGNAL CONDITIONING FUNCTIONS Overview For most applications, the factory default settings are sufficient for out of the box Aim and Read operation. If adjustments are required, the text-based menu provides easy access to the sensor settings and parameters. SIGNAL CONDITIONING MENU GROUP Menu Item Parameter (w/ Default Value) Range / Options Alarm Delay Disabled, <150> sec 1 to 360 sec Temperature Scale Fahrenheit <Fahrenheit> Celsius Pilot Warning Level 0 to 100% <10> % Low Energy Gain 1 <100> Low Energy Level <6553> to 32,232,000ADC Table 11 Signal Conditioning Group Menu Alarm Delay The alarm delay function is used to eliminate false alarms due to intermittent obstruction of the sensor s view. The default setting is 150 seconds. If conditions exist that create false alarms, then the alarm delay time should be increased Temperature Scale ( F or C) This adjustment converts the ambient temperature scale between Fahrenheit and Celsius Pilot Warning Level If an interference were to exist that would not permit the signal level to drop below the 10% default value, then this value may be raised to a higher threshold Low Energy Gain and Level These two settings are used to adjust the low energy threshold for the PilotEye. The low energy threshold determines the PilotEye sensitivity. The higher the Low Energy Gain and Low Energy Level adjustment, the less sensitive the PilotEye. The Low Energy Gain adjustment increases the sensor sensitivity by factors of ten. The default setting is 100. Adjusting this setting to 10 will make the PilotEye ten times less sensitive. The 1000 gain setting should never be selected for this model. The Low Energy Level adjustment decreases the sensor sensitivity proportional to the displayed value. The default setting is 13,106. Adjusting this value to 26,212 will make the PilotEye half as sensitive. These adjustments may be made to eliminate interference from steam lines on steam-assisted smokeless flares or to eliminate interference from adjacent flares. [Note: PilotEye sensitivity may be increased from the factory default setting only when the PilotEye is installed in areas where the ambient temperature does not drop below 0 F (-17 C). ] When it is necessary to eliminate interference, these settings may be determined using the following procedure. 1. While the line is not running, turn off the pilot flame, but leave the interference (steam line or adjacent flare, for example) in place. 2. Record the signal dilution value that the sensor is reading with only the interference in place (see Figure 10). 3. Enter the setup mode, and access the current Low Energy Level setting in the signal conditioning group. 4. Multiply the current Low Energy Level value by the Signal Dilution Value obtained in step Adjust the Low Energy Level setting slightly above this calculated value. If this value is greater than 32,232, 000, then you will have to change gain stages, and divide your result by 10. See Table 18, page 32, for setting values.

25 Installation & Operation Manual Page OUTPUTS AND ALARMS Programming The Analog Outputs A unique feature about the PilotEye is that it includes several measured parameters that can be used for advanced process monitoring and control. By using the menu system, it is easy to configure any one of the system outputs or alarms to use any one of the sensor s measured parameters (Tables 12 & 13). Both the displayed values and each of the linear output signals are scaled to the specified range of each parameter. This means that the 0 or 4mA signal corresponds to the bottom end of the sensor s scale, and the 20mA output signal corresponds to the top end of the sensor s scale with a linear relationship in between. Using the configure outputs group menu, it is a simple 2 step process to configure the analog outputs. 1. Selected the output parameter 2. Select the output scale (0-20mA or 4-20mA) The default settings for each output are:!" Stand-Alone Sensor: Pilot Signal with a 4-20mA scale!" Interface Module Output 1: Pilot Signal with a 4-20mA scale!" Interface Module Output 2: Pilot Signal with a 0-20mA scale The 0-20mA output scale can be used with a shunt resistor to drive various voltage outputs such as 0-1V (50 ohms) and 0-10V (500 ohms). The maximum load on the outputs is 1000 ohms Programming The Alarms Using the configure alarms group menu, it is a simple two step process to configure the alarms to use any of the sensor s measured parameters. 1. select the alarm parameter 2. adjust the alarm set point value All of the alarms are factory set to disabled. The stand alone sensor offers one TTL alarm when it is setup in the analog mode, while the interface module includes one TTL alarm and two relay alarms. The rating for each type of alarm is as follows:!" Relay Alarms: 4 amps at 250Vac, or 2.5 amps at 30Vdc, Relay Activation Time: 15 ms max, Reset Time: 5 ms max!" TTL Alarms: 2mA at 5Vdc Table 13 provides a description of the alarm conditions for each parameter, while section 3.4 provides additional details about the wiring connections for the alarms. Some important notes about the operation of the alarms are as follows: 1. Depending on the application requirements, the TTL alarm logic can be adjusted to obtain the normal or reversed logic settings. 2. For the relay alarms, wiring connections are provided for both normally open and normally closed to enable complete flexibility with setting up the alarms.

26 Installation & Operation Manual Page 26 Parameter Pilot Signal Unfiltered Signal Ambient Temperature Signal Dilution Default Range Description 0 to 100% The measured pilot signal with signal-conditioning filters (alarm delay time) applied. 0 to 100% 0 to 200 F (-17 to 93 C) 0 to 100 The measured pilot signal with no signal-conditioning filters applied. It is intended for use with setup and troubleshooting procedures and can be displayed simultaneously with the pilot signal on the interface module. Because it is the raw signal reading, none of the system status conditions are applied to this value. Consequently, when the sensor is out of range, this output can provide a random value. The ambient temperature measured inside the sensor enclosure. For installations with high ambient temperatures, this is a convenient feature for troubleshooting and preventative maintenance. While the sensor can operate properly in temperatures as low as 40 F/C, this output can only measure as low as 0 F (-17 C). A measurement of the remaining signal dilution that a sensor can tolerate. For example, a value of 100:1 indicates that the signal level can be diluted 100 more times and still provide a valid reading. This value indicates the severity of obstructions, such as rain, snow, and fog. Once this value drops below 1:1, then the Pilot Out alarm will trip. Table 12 Programmable Output and Alarm Parameters Alarm Parameter Power Off or Disabled Pilot Signal Ambient Warning Low Energy Range Of Set Point Condition (Default Value) TTL Logic Normal Relay Alarms Normally Open Normally Closed None None 0 Volts Open Closed 0 to 100% F ( C) Measured Pilot Signal < Signal Set Point Measured Pilot Signal > Signal Set Point (Default set point value is 10%) Measured Ambient Temp < Ambient Temp Set Point Measured Ambient Temp > Ambient Temp Set Point (Default value is 120 F) Signal Dilution > Signal Dilution Set Point Signal Dilution < Signal Dilution Set Point (Default value is 2: Two times the required signal) 0 Volts 5 Volts 0 Volts 5 Volts 0 Volts 5 Volts Open Closed Open Closed Open Closed Closed Open Closed Open Closed Open Table 13 Alarm Specifications **** (See notes about alarms on the previous page, section 4.5.2)****

27 Installation & Operation Manual Page Using the Digital Outputs The PilotEye sensors and interface module support bidirectional communications via RS232 and RS485 for communication with a computer or a data logging system. The RS485 outputs on terminals 20 through 23 are not active on this system. To make the RS232 connection on the interface module, use a standard straight-through serial cable (wired as DTE). The estimated distance limits for the serial connections are 50 feet for the RS232 and 4000 feet for the RS485. The line format is baud, no parity, 8 data bits, 1 stop bit. This is not currently adjustable. This output includes all of the sensor s measured parameters as follows:!" Unfiltered Signal!" Pilot Signal!" Ambient Temperature!" Ambient Status!" Signal Dilution. An example of the output format is as follows: AUTO= (followed by a carriage return and a line feed) Once a digital connection is established with the system, the AUTO ON command (followed by a carriage return) generates a continuous output that is updated every 50ms. PARAMETER Identifier AUTO= Unfiltered Signal (%) Pilot Signal (%) Ambient Temperature ( F) 838 Ambient Temperature Status Signal Dilution 500 DESCRIPTION This defines that this packet is an auto-update packet. The unit may return other types of packets, which will have a different name in front of the equals sign (=). A user application must handle these identifiers and ignore them. In this example, the unfiltered signal is 100%. In this example, the unfiltered signal is 100%. This temperature is scaled up by 10. In this example, the actual ambient temperature is 83.8 F. This can be one of the following: The ambient temperature is below the sensor s specified limit of 120 F (50 C). The ambient temperature is above the sensor s specified limit of 120 F (50 C). In this example, the signal dilution is 500:1. The signal dilution value represents the extent of additional signal dilution that a sensor can tolerate while still providing an accurate reading. Table 14 Digital Output