1 Burner PDF

2017
MACCHI MHM-DRL XP BURNERS
OPERATION AND MAINTENANCE INSTRUCTIONS
SOFINTER SPA - Largo Buffoni 3 – 21013 Gallarate (VA) – Italy

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Contents
1 GENERAL .......................................................................................................................................................................... 4
1.1 Information on the operating manual ...................................................................................................................... 4
1.2 Explanation of symbols ............................................................................................................................................. 4
1.3 Liability disclaimer .................................................................................................................................................... 5
1.4 Copyright protection ................................................................................................................................................. 6
1.5 Spare parts ................................................................................................................................................................ 6
1.6 Warranty Regulations ............................................................................................................................................... 6
1.7 After-sales service ..................................................................................................................................................... 6
2 SAFETY ............................................................................................................................................................................. 7
2.1 Owner’s responsibility .............................................................................................................................................. 7
2.2 Operating personnel ................................................................................................................................................. 8
2.3 Intended purpose of the equipment ........................................................................................................................ 9
2.4 Personal protective gear ......................................................................................................................................... 10
2.5 SPECIAL DANGERS ................................................................................................................................................... 11
2.6 Securing against unauthorized switching use ......................................................................................................... 15
2.7 response in case of danger or accident .................................................................................................................. 16
3 TRANSPORT, PACKAGING AND STORAGE ...................................................................................................................... 17
3.1 Safety instructions for transport ............................................................................................................................. 17
3.2 Transport inspection ............................................................................................................................................... 17
3.3 Packaging ................................................................................................................................................................ 18
3.4 storage conditions .................................................................................................................................................. 18
4 SPECIFICATIONS ............................................................................................................................................................. 19
4.1 BURNER DESCRIPTION ............................................................................................................................................ 19
4.2 BURNER MAIN COMPONENTS ................................................................................................................................ 21
4.3 PRINCIPLE OF OPERATION ...................................................................................................................................... 22
5 OPERATION .................................................................................................................................................................... 24
6.1 Preparation before gas firing .................................................................................................................................. 24
6.2 ROUTINE INSPECTIONS ........................................................................................................................................... 25
6 BASIC FAULT AND FINDING............................................................................................................................................ 26
7 GENERAL CARE AND MAINTENANCE ............................................................................................................................. 28
8 WEARING PARTS ............................................................................................................................................................ 30
MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

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10 PRESERVATION ............................................................................................................................................................ 31
11 APPENDIX ..................................................................................................................................................................... 32

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1 GENERAL
1.1 INFORMATION ON THE OPERATING MANUAL
This operating manual provides important information on working with
the Macchi MHM-DRL XP Burner. Safe working can only be ensured by
adhering to all the safety remarks and instructions provided.
In addition, the locally applicable accident prevention legislation and
general safety regulations with validity for the place of operation must be
adhered to.
Read through the operating manual carefully before starting any work.
These instructions form a constituent part of the product and must be
kept in the immediate vicinity of the equipment at all times within easy
reach for personnel.
When the Macchi MHM-DRL XP Burner is passed on to third parties, it
must always be accompanied by the operating instructions.
The illustrations in this operating manual are intended to aid
understanding of the content. They are not necessarily true to scale and
may differ slightly in some details from the actual configuration of the
Macchi MHM-DRL XP Burner.
1.2 EXPLANATION OF SYMBOLS

WARNING INSTRUCTIONS Warning instructions are indicated in this operating manual by symbols.
The remarks are introduced by the use of signal words which indicate the
degree of severity of the hazard. The instructions must be adhered to
without fail and acted upon prudently in order to prevent accidents,
personal injury or material damage.
DANGER!
… denotes a hazardous situation which results in
death or serious injury unless prevented.
WARNING!
… denotes a hazardous situation which could
result in death or serious injury unless prevented.
CAUTION!
result in minor or slight injury unless prevented.
NOTE!
result in material damage unless prevented.

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RECOMANDATIONS
REMARK!
… highlights useful recommendations and
information designed to permit efficient, trouble-
free operation.
SPECIAL SAFETY REMARKS In order to draw attention to special hazards, the following symbol is used
in conjunction with safety remarks:
DANGER!
Fatal danger due to electrical current!
… denotes a potentially fatal situation due to
electrical current. Failure to adhere to the safety
instructions can give rise to the danger of serious
injury or death.
The work to be performed may only be carried out
by a suitably qualified electrician.
1.3 LIABILITY DISCLAIMER

All instructions and remarks contained in this operating manual are collated
taking into account applicable standards and regulations, the state of the art
and our many years of experience and expertise. The manufacturer is
consequently unable to accept any liability for damage caused as a result of
failure to adhere to the instructions:
 Use for any other than the designated purpose

 Deployment of untrained personnel
 Internally executed modifications or conversion work
 Technical modifications
 Use of unapproved spare parts
The actual scope of the delivery may differ in some details from the
explanations and illustrations provided here in the case of special version,
where additional optional features are made use of or due to the latest
technical modifications. Otherwise, the obligations agreed in the Supply
Agreement, the General Terms and Conditions and the Manufacturer’s
Conditions of Supply and the statutory regulations in force at the time of
conclusion of contract shall be applicable.

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1.4 COPYRIGHT PROTECTION

These operating instructions must be treated in confidence. They are
exclusively intended for the persons operating the Macchi MHM-DRL XP
Burner and may not be made available to third parties without the prior
written consent of the manufacturer.
REMARK!
The information, texts, drawings, illustrations and
other representations are protected by copyright
and are subject to industrial property rights.
Utilization for any other than their intended
purpose renders the perpetrator liable to
prosecution
The contents of all or part of these operating instructions may not be

duplicated in any form, nor may they be used and/or communicated to any
third party without the written consent of the Manufacturer. Any breach of
this obligation shall render the perpetrator liable to compensation of
damages, without prejudice to any further-reaching claims.
1.5 SPARE PARTS

Order only original spare parts directly through the manufacturer
WARNING!
Incorrect or faulty spare parts can result in
damage, malfunctions or total failure of the
equipment as well as posing a safety hazard.
1.6 WARRANTY REGULATIONS

The warranty regulations are provided as a separate document in the
General Terms and Conditions.
1.7 AFTER-SALES SERVICE

For any technical information, consult our after-sales service.
Information can be obtained through the responsible contact at any time by
phone, fax, e-mail or Internet. For the manufacturer’s address, see the cover
sheet on the table of contents. Our employees are always interested to
receive any new information or experience arising from application which
could be of use in the further development of our products.

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2 SAFETY
This section provides an overview of all important safety aspects for
optimum protection of personnel as well as safe, trouble free operation.
Failure to observe the operating instructions and safety remarks contained
in this manual can cause serious injury.
When reading the instructions contained herein always make reference to
instructions given by manufacturers of any associated equipment.
2.1 OWNER’S RESPONSIBILITY

As the Macchi MHM-DRL XP Burner is used commercially, the owner of the
Macchi MHM-DRL XP Burner is obliged to adhere to occupational safety
regulations as well as any other applicable directives, legislation and
standards.
Alongside the occupational safety remarks contained in these operating
instructions, the safety, environmental and accident prevention regulations
governing the field of application of the Macchi MHM-DRL XP Burner must
be adhered to, whereby the following regulations in particular apply:
 The operator shall record in the document on the protection from

explosions all measures taken to protect the employees.
 The owner must be aware of the valid occupational safety regulations
and also determine any additional potential hazards arising as a
result of the specific working conditions applicable at the location in
which the burner is used, by performing a risk assessment. This must
be implemented in the form of operating instructions governing
operation of the Macchi MHM-DRL XP Burner.
 The owner must test, throughout the service life of the Macchi MHM-
DRL XP Burner, whether the operating instructions drawn up by him
still correspond with the latest revision of the relevant rules and
regulations, and must update these where applicable.
 The owner must clearly regulate and define fields of responsibility for
installation, operation, maintenance and cleaning.
 The owner must ensure that all employees involved in working with
the Macchi MHM-DRL XP Burner have read and understood the
operating instructions. Furthermore, the owner must provide
personnel training at regular intervals and inform staff of potential
hazards.

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As the owner is also responsible for ensuring that the Macchi MHM-DRL XP
Burner is always in good technical working order the following requirements
additionally apply:
 The owner must ensure that maintenance work is performed

regularly.
 The owner must regularly check that all safety devices are fully
functional and complete.
 The owner must provide the necessary protective gear for personnel
2.2 OPERATING PERSONNEL

REQUIREMENTS
WARNING!
Danger of injury due to insufficient
qualification
Incorrect handling of the equipment can result in
severe personal injury and material damage.
– Only allow activities to be performed by suitably
qualified specialist personnel.
The following qualifications are required for the various fields of activity:
 Qualified personnel: are capable on the basis of their specialist

training, knowledge and experience as well as their knowledge of
the applicable regulations of executing the work assigned to them
and of independently recognizing possible hazards.
 Electrical specialists: are capable on the basis of their specialist
training, knowledge and experience as well as their knowledge of
the applicable regulations of working on electrical installations and
of independently recognizing possible hazards. Electrical specialists
have received training specifically for the work environment in
which they are employed and are familiar with the relevant
standards and regulations.
 Gas specialists: are capable on the basis of their specialist training,
knowledge and experience as well as their knowledge of the
applicable regulations of working on gas installations and of
independently recognizing possible hazards. Gas specialists have
received training specifically for the work environment in which
they are employed and are familiar with the relevant standards and
regulations.

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Only persons who may be expected to perform their task reliably may be
authorized to use the equipment. Persons whose reaction capacity is
impaired, for example due to drugs, alcohol or medicine use, may not be
authorized.
When selecting suitable personnel, observe the age and profession-specific

regulations applicable at the place of use.
UNAUTHORIZED PERSONS
WARNING!
Danger for unauthorized persons!
Persons who do not comply with the requirements
described here are not aware of the dangers
inherent in the work area.
– Keep unauthorized persons away from the work
area.
– In case of doubt, approach the person in
question and direct them out of the work area.
– Interrupt work for as long as any unauthorized
person remains in the work area.
2.3 INTENDED PURPOSE OF THE EQUIPMENT
The Macchi MHM-DRL XP Burner is exclusively designed to perform the

intended purpose described here:
The Macchi MHM-DRL XP Burner It is an equipment intended to be

equipped within the specific combustion chamber for which it has been
designed, with the fuel and at the conditions specified in the burner data
sheet.
The equipment cannot be used by itself or for purposes other than the
intended one.
We recommend that the burner be operated in strict accordance with

National Fire Protection Association 85 (NFPA) Boiler and Combustion
Systems Hazards Code in addition to all local codes and regulations.
Instructions contained in this manual are an addition to and do not replace

the operating company’s and owner’s existing safety and operating
procedures and policies regarding burner system operation

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WARNING!
Danger due to use not in accordance with the
intended purpose!
Any application beyond and/or not in accordance
with the intended purpose of the Macchi MHM-
DRL XP Burner can result in the occurrence of
hazardous situations.
The manufacturer cannot be held liable for physical or material harm caused
by misuse of equipment or use for anything other than its intended purpose.
2.4 PERSONAL PROTECTIVE GEAR
Personal protective gear must be worn while working with the equipment
in order to minimize potential health hazards.
 Wear the protective gear necessary for performance of the

relevant task at all times while working.
 Observe all signs relating to personal protective gear in the work
area.
To be worn at all times Wear the following for the performance of all work:
Protective work clothing

This comprises tight-fitting work clothes which are resistant to tearing,
have tight-fitting sleeves and no projecting parts. This is required primarily
to protect against burns.
Safety shoes
To protect the feet against heavy falling articles and to prevent slipping on
floors.
Protection helmet
Protection helmets protect the head from falling parts, swinging loads or
bumping it against stationary equipment.

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To be worn for special types of work When performing special types of work, special safety equipment is
required. This is covered in depth in the individual chapters of this
instruction manual. These types of special protective gear are described in
the following:
Face protection
To protect one’s eyes and face from flames, sparks or embers as well as
hot particles or flue gases.
Protective gloves
To protect one’s hands from rubbing, chafing, puncturing or deeper
injuries and from contact with hot surfaces.
2.5 SPECIAL DANGERS

Remaining dangers are listed in the section below.
The remarks provided here and the safety instructions in the subsequent
chapters of this operating manual must be observed in order to reduce the
possible risk to health and prevent the occurrence of dangerous situations.
INCORRECT TRANSPORT
WARNING!
Danger of injury as a result of incorrect
transport!
In the case of incorrect transport, considerable
material damage can occur.
– Note the intrinsic weight of the Macchi MHM-
DRL XP Burner or the components. Always use
suitable hoisting gear.
– Use several lashing points or a suitable hoisting
gear with supports.
– Please mind the center of gravity.
– Secure the Macchi MHM-DRL XP Burner from
dropping down or falling over.
– Do not stand under the load while lifting or
lowering it and stay out of the danger zone.
LIGHT OFF FAILURE

DANGER!
Do not make repeated attempts to light the
burner
If a flame cannot be established after two
consecutive attempts, carry out an investigation
into the cause.
A succession of abortive attempts to fire the
burner, may result in the build-up of an explosive
mixture at some point in the gas passes.

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FUEL LEAKS
DANGER!
Danger of fuel leaks
Attend to fuel leaks as they are reported. Do not

delay. Make no attempt to operate the associated
equipment while fuel is escaping.
ELECTRICAL CURRENT
DANGER!
Potentially fatal injury due to electrical
current!
Contact with live components can cause fatal
injury. Damage to the insulation or individual
components can have potentially life-threatening
consequences.
 In the event of damage to the insulation of
the power supply, switch off immediately and
arrange for repairs to be carried out.
 Work on the electrical system may only be
carried out by suitably qualified electricians.
 Before performing any work at the electrical
system, disconnect it from the power supply
and check that it is no longer live.
 Before starting work, switch off the power
supply and make sure it cannot be
inadvertently switched back on.
 Never bypass or decommission fuses. When
changing fuses, adhere to the correct
amperage and the correct characteristics.
 Keep moisture away from live components.
This can create a short circuit.
 Do not leave control panels and/or junction
boxes uncovered while power is on

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HIGHLY INFLAMMABLE MATERIALS

WARNING!
Danger of burns due to flammable materials!
Highly flammable materials, liquids or gases can
catch fire and cause serious to fatal injuries.
 Do not smoke in the danger area and in the
close vicinity. Do not use any naked flames or
ignition sources.
 Keep a fire extinguisher on hand.
 Report suspicious substances, liquids or gases
immediately to the responsible officer.
 In case of fire, stop work immediately. Leave
the danger area until the all-clear is given.
HOT SURFACES CAUTION!

Danger of burns due to hot surfaces!
Contact with hot components can cause burns.
Ensure that hot pipes such as steam or hot oil
pipes are lagged. Restrict access to any areas
where hot metalwork or gases may be
encountered.
 When carrying out any work near hot
components, always wear protective work
clothing and safety gloves.
 Before performing any work, ensure that all
components have cooled to ambient
temperature.
SHARP EDGES AND POINTED CORNERS

CAUTION!
Danger of injury on edges and corners!
Sharp edges and pointed corners can cause
chafing of the skin and cuts.
 Take particular care when performing work
near to sharp edges and pointed corners.
 In unsure, wear safety gloves.

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SPECIAL ENVIRONMENTAL INFLUENCES

NOTE!
Danger of damage due to special environmental
influences!
Vibrations affecting the Macchi MHM-DRL XP
Burner or welding
work performed in the area of the Macchi MHM-
DRL XP Burner
can result in damage.
In order to prevent damage to the Macchi MHM-
DRL XP Burner, it must not be exposed to any
vibrations.
When carrying out any welding work in the area of
the Macchi MHM-DRL XP Burner, it must be set in
safe conditions.
Before welding work on the outer of the Macchi
MHM-DRL XP Burner can be carried out, this must
first be disconnected from the power head and gas
lines must be secured.
HOUSEKEEPING
NOTE!
Danger! Poor housekeeping results in increased
safety hazards
A neat boiler room indicates a well-run plant. A
clean and orderly environment will foster safety.
The boiler room should be kept free of all material
and equipment not necessary to operate the
boiler. Good housekeeping should be encouraged,
and procedures should include routine inspection
to maintain a desired level of cleanliness. The
plant inspector should report improper
housekeeping to his immediate supervisor.
Materials for repair or maintenance should not be
stored in a manner that will obstruct proper access
to the boiler, furnace or ﬁring equipment. Any
steam or water leaks should be reported to his
supervisor. If the leak is from the shell, drum, or
other than from a tube or pipe joint, it may be
cause for immediate shutdown for investigation.
Spills of oil or chemicals should be cleaned up
as they occur.

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2.6 SECURING AGAINST UNAUTHORIZED SWITCHING USE
DANGER!
Risk of fatal injury due to unauthorized use!
When working in the danger area, there is a risk
that the energy supply could be switched on by an
unauthorized person. This creates a potentially
fatal hazard for persons working in the danger
area.
 Observe the instructions provided on securing
against unauthorized switching back on in the
chapters of this operating manual.
 Always observe the procedure described
below to secure against unauthorized
switching back on.
Securing against unauthorized use
Switch safeguarded by lock This comprises tight-fitting work clothes which are resistant to tearing,
on: …….. at ……hours have tight-fitting sleeves and no projecting parts. This is required primarily
to protect against burns.
DO NOT SWITCH ON
The lock may only be removed 1. Switch off the power supply.
by: …………………
once steps have been taken to 2. If possible, secure the switch with a lock and attach a sign in an easily
ensure that no persons are located visible location at the switch.
in the danger area.
3. Have the key looked after by the employee named on the sign.
Switched off
on: …….. at ……hours 4. Should it not be possible to secure a switch using a lock, set up a sign.
DO NOT SWITCH ON 5. Once all the work has been carried out, ensure that there are no
The lock may only be removed
longer any persons located in the danger area.
by: …………………
once steps have been taken to
6. Ensure that all safety devices are installed and are fully functional.
ensure that no persons are located
in the danger area.
7. Only then may the sign be removed.

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2.7 RESPONSE IN CASE OF DANGER OR ACCIDENT
PREVENTIVE ACTIONS
 Always be prepared for accidents and for fires!

 Keep first aid equipment (first aid kit, blankets etc.) and a fire
extinguisher on hand.
 Familiarize personnel with accident alarm, first aid and rescue
facilities.
 Ensure that access paths for emergency vehicles are kept
unobstructed.
IN CASE OF ACCIDENT: REACT CORRECTLY
 Initiate first aid measures.

 Evacuate any persons located in the danger area.
 Inform those responsible at the incident location.
 Alert the emergency medical / fire services.
 Clear access paths for emergency vehicles.

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3 TRANSPORT, PACKAGING AND STORAGE

3.1 SAFETY INSTRUCTIONS FOR TRANSPORT
INCORRECT TRANSPORT
WARNING!
Danger of injury as a result of incorrect
transport!
In the case of incorrect transport, considerable
material damage can occur.
 When unloading packaged items on delivery,
and when transporting within the premises,
take extreme care and observe the symbols
and instructions on the packaging.
 Depending on the length of the product and
the scope of delivery suitable lifting
equipment should be used for unloading. The
load capacity of the lifting equipment should
exceed the total weight of the delivery.
 The center of gravity is assumed to be in the
middle of the longitudinal axis.
 Only use the provided lashing points.
 Do not stand under the load while lifting or
lowering it and stay out of the danger zone.
3.2 TRANSPORT INSPECTION
Check the delivery on receipt without delay for completeness and

transport damage.
In the case of externally recognizable transport damage, report the
damage immediately, adopting the following procedure:
 Only conditionally accept the delivery.

 Note the extent of the damage on the transport documents or on
the shipping agent’s delivery note.
 Initiate a complaint.
Concealed transport damage must be immediately reported.
REMARK!
Report any defect immediately it is noticed. Claims
for damages can only be asserted within the
applicable deadlines for the filing of complaints.

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3.3 PACKAGING
Packaging The individual products are packaged in accordance with the transport
conditions expected for the consignment. Exclusively environmentally
friendly materials are used for the packaging.
The packaging should protect the individual components from transport
damage, corrosion and other damage up until such time as they are
assembled. For this reason, do not destroy the packaging and only remove
it shortly before assembly.
Handling packaging materials If no outline agreement has been reached for packaging, separate the
materials according to type and size, and send for re-use or recycling.
NOTE!
Environmental damage due to incorrect
disposal!
Packaging materials are valuable raw materials and
in many cases can be reused or usefully processed
and recycled.
– Ensure environmentally responsible disposal of
packaging materials.
– Observe locally applicable disposal regulations.
3.4 STORAGE CONDITIONS
Storage Store the Macchi MHM-DRL XP Burner and the spare parts under the
following conditions:
 The unit shall be stored neither outdoors nor in the hazardous area.
 Store in dry, dust-free conditions.
 Do not expose to any corrosive substances.
 Avoid any drop in temperature below the dew point.
 Protect the Macchi MHM-DRL XP Burner from mechanical damage.
 Storage temperature: 0 °C to 60 °C
 Relative humidity: max. 60 %
 When storing for longer than 3 months, regularly check the
condition of all parts and the packaging. If necessary refresh or
replace the conservation.
REMARK!
The packaging units may come with storage
instructions applicable in addition to the
requirements outlined here. These must be adhered
to.

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4 SPECIFICATIONS
4.1 BURNER DESCRIPTION
The burner type MHM-DRL XP is equipped with the following main
components:
 No. 1 front plate that forms the structural attachment basis of the
assembly. The front plate has provision for the mounting of flame
monitors, sight glass.
 No. 2 air register with on-off air door.
 No. 12 fuel gas spuds.
 No. 1 support tube complete with air swirler.
 No. 1 burner igniter (spark type, fed by fuel gas).
 No. 2 flame scanners UV type.
 No. 1 flame viewers.
 No.2 double acting pneumatic cylinder and mounting for actuation of
the air door sleeve.
 No.1 limit switch for air register "open" position for each air register
 No.1 limit switch for air register "closed" position for each air register
In figure 1 is possible to see a general overview of the burner and, in
detail:
1. the primary air swirler
2. the internal gas guns
3. the external gas guns
4. the auxiliary gas spuds
5. the main air register
6. the auxiliary air register
7. the air register actuators
8. the igniter
9. the main fuel gas inlet
10. the auxiliary fuel gas inlet
11. the radial baffles
4
1
11 2
3
1
3
8

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BURNER FRONT VIEW BURNER REAR VIEW
8 1
2
3
7
2 3
9
4
10
BURNER LATERAL SECTION VIEW
7 5 6 4 2
Figure 1 - Burner typical configuration

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4.2 BURNER MAIN COMPONENTS
AIR REGISTERS
The burner air register is “barrel type”. It slides across the air opening and
can have only an “open/close” position.
Like the main one, the auxiliary air register is “barrel type”. It slides across
the air opening and can have only an “open/close” position. In normally
operating condition is closed (air leakage is foreseen for cooling)
FUEL GAS DISTRIBUTION HEADER AND GAS GUNS

The header provides to distribute the fuel gas to 12 spuds which carry the
fuel gas from the header to the frontal section of the burner very close to
the air swirler
PRIMARY AIR SWIRLER

The air swirler is designed to produce a strong recirculation downstream
the burner throat in order to improve the flame stability

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4.3 PRINCIPLE OF OPERATION
The Macchi MHM-XP type Burner is, in its main part, an air-staging burner
suitable for gaseous fuels combustion.
The burner main part is designed to achieve low NOx emissions. The
following figure shows a schematic representation of the working
principles; it is possible to see the air staging (the internal primary zone
and the external secondary zone).
Aux. Air
FUEL STAGING Secondary Air

ZONE
Primary Air
Radial Baffles
Fuel Gas
FUEL STAGING
ZONE Fuel Gas
The most important devices in terms of NOx reduction are the 12 radial
baffles positioned across the gas spuds. These devices create a high-
turbulence recirculation zone (see figure 3).
The primary and secondary air enter the burner from the windbox through
the main air register.
Each stream flows in the respective section (see above figure) in which is
accelerated to establish a uniform flow.
The primary air passes through the swirler which imparts a centrifugal spin
to the air.

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The air swirler gives the air a trajectory which is outward from the center
line of the burner. This trajectory creates a low pressure zone immediately
in front of the swirler. This zone promotes the recirculation of flue gas
from the zone surrounding back to the low pressure zone to guarantee the
flame stability.
Flame stability means the ability of the fire to stay anchored at a location
near the fuel injection point.
It is also the ability to retain the desired flame shape.
The secondary air passes outside the swirler and it continues to the
furnace where it reacts with the unburned/partially burned fuel in order to
complete the combustion and achieve the required emissions.
Fuel gas is introduced through the gas spuds located both in the primary
and secondary air section.
The tips of the gas spuds are drilled with proper sized injection orifices.
The number and the orientation of injection orifices are designed to obtain
proper flame shape and emissions. The direction of the fuel injection from
each spud is important in creating fuel rich and fuel lean zones ahead the
burner to minimize NOx formation.
Staged combustion involves the creation of an initial fuel-rich combustion
zone. The remaining air added downstream completes the combustion. In
the fuel rich zone, NOx is reduced by the limitation of available oxygen as
well as by the lower temperatures that result from the slower heat
release. In the fuel lean zone downstream, NOx formation is reduced due
to the lower temperatures that result from the higher amounts of air.
Consequently the total NOx formation is reduced significantly as the two
zones combine and combustion is completed.
Staged combustion principle are not applied to the auxiliary combustion
system.
For the burner auxiliary combustion system (used only during “N-1”
operation), a “rapid mixing” concept is applied, with a large number of
orifices uniformly distributed in the auxiliary air section.
The stability of the auxiliary flame is based on the presence of the main
flame.
For this reason, the use of the auxiliary combustion system is subordinated
to the main one: it cannot be used if its main system is not in operation.
The opening of the auxiliary gas circuit is subordinated to the opening of
the relative (auxiliary) air register.
The use of the auxiliary combustion system is intended expressly aimed at
achieving the required boiler load in the event of one burner out of
service, and is considered an emergency condition, sustainable only for
short periods.

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5 OPERATION
The following hints have been prepared as a guide for burner start-up. The
listed checks/activities are general, for all operating information (e.g.:
start-up sequences, BMS logics) concerning a specific application refer to
the Boiler operating manual and relevant appendix.
6.1 PREPARATION BEFORE GAS FIRING

Before the very first start-up or after maintenance activities the following
checks should be performed:
1. Ensure that all electrical supplies are securely connected and power at
Local Panel is switched on.
2. Ensure that the required gas pressure is available.
3. Ensure that manual vent valves, if fitted, are ‘CLOSED’.
Opening/closing of actuated vents is managed by BMS.
4. Check igniter is fitted and connected. During the very first burner
light-off or after a maintenance shutdown it is necessary to verify the
correct operation of the igniter. Provide for the igniter set-up as
described in the relevant manual.
5. Verify the correct alignment of the flame scanners.
6. Open instrument and/or plant air and ignition gas isolating valve(s)
and ensure correct pressure is available.
7. Open main isolating manual valve(s) on main gas line and ensure
correct pressure is available.
8. During the very first burner light-off the fuel gas flow to central gas
spuds will be adjusted acting on the relevant manual valve
(highlighted in the picture below), until stable operating conditions
are achieved. When stable conditions are achieved do not change the
opening of this valve.
9. Refer to the Boiler Operating Manual for light-off procedures.

25
6.2 ROUTINE INSPECTIONS

This chapter gives a guide for routine checks for boiler and equipment
furnished by MACCHI during operation.
It is neither intended to cover all possible variations in equipment nor to
provide for specific operating problems which may arise.
Should additional information be required, MACCHI or its field
representatives should be contacted.
Inspection is the first step in a preventive maintenance program. The early
detection of a problem can greatly reduce the amount of damage, simplify
maintenance and prolong equipment life. The key to effective inspection is
a complete understanding of the equipment’s operating characteristics.
Any change in normal characteristics should be immediately reported,
investigated and corrected.
PRECAUTIONS
 The maintenance crew shall be skilled on and informed about the

operations to be carried out.
 Operators shall be equipped with proper dressing and personal
protection devices.
 Operators shall be equipped with proper tools.
 All local rules on labor safety must be applied.
GENERAL RULES
 Verify any leakage from valves. If any, tight a little the packing screws
(if this activity doesn’t represent a hazard for operator safety). If it is
not sufficient take note of valve tag and position and provide to
change the packing at next boiler stop and cooling.
 Verify any leakage from flanges. If any, take note of flange position,
size and rating and provide to change the gasket at next boiler stop
and cooling
DAILY
 Check for fuel or air leaks. Repair immediately.

 Check for proper fuel and air pressures.
 Check burner flame for proper shape, color and stability.
WEEKLY
 Check for flame signal.

 Check for cooling air supply to flame scanners.
 Perform BLP lamp test.

26
6 BASIC FAULT AND FINDING

The faults which arise in connection with the automatic sequence controls,
or burner management control can, in general, be located by reference to
the instructions from the main contractor for the plant. The following is
only given as a guide for basic fault finding.
1. Burner will not light

a) Ignition failure
I) Ignition gas line isolating valves closed or pressure too low
II) Ignition gas shut-off valves failure
III) Ignition transformer failure
IV) Ignition electrode damage, worn, or dirty
V) Incorrect air/ignition gas ratio
VI) HT lead damaged or disconnected.
b) Flame monitoring cell dirty or faulty
c) Fuel / air ratio incorrect
d) Fuel isolating valves closed
e) Automatic fuel shut off valves not operating
f) No fuel available, or incorrect fuel pressure
g) Draught too high
h) Blocked fuel filter (if provided)
2. Burner starts but fails to establish

a) Flame monitor not supplying amplifier with signal to operate relay
I) Monitor obscured by dirt or moisture
II) Monitor damaged
III) Polarity of electrical connections reversed.
IV) Open circuit or ground between monitor and amplifier
V) Alignment of monitor and flame incorrect
VI) Flame too small or too dark to be viewed, i.e. incorrect fuel/air
ratio.
b) Fuel Starvation
I) Manual or auto valves not open fully
II) Filter partially blocked (if provided)
III) Fuel control valve set too low
IV) Low fuel pressure
V) Fuel pressure regulator fault
c) Excessive forced draught air pressure

27
3. Lockout during normal firing

a) As section 2a above.
b) As section 2b above
c) Failure of a running interlock
4. Burner will not shut off

a) Auto valve sticking in open position.
5. Burner lights semi-explosively

a) Delayed ignition
I) Ignition flame too small
II) Igniter wrongly positioned
III) Forced draught pressure too high
b) Incorrect fuel/air ratio
6. Incorrect combustion
a) Incorrect fuel/air ratio
b) Inconsistent fuel or air pressure
c) Impurities in fuel
7. Burner fails to meet load

a) As section 6.
b) Incorrect full fire setting
c) Load demand higher than burner capability

28
7 GENERAL CARE AND

MAINTENANCE
Regular inspection and maintenance of the
equipment allows avoiding potentially
hazardous situations. Here below are
listed the main components of each
burner with some recommendations
and suggestions for their care and
maintenance.
Burners front piping

During normal operation it is
suggested to inspect to the burner
front in order to detect any eventual leaks.
Inspection interval: once a shift
Flame scanners
Check the intensity of the flame
signal. Furthermore check for
cooling air supply to flame scanners.
Inspection interval: weekly
Peepholes
Check the tightness of the peephole on the burner front. If the sight glass
of the peepholes is removed for any reason, it is suggested to replace the
gasket.
Inspection interval: annual

29
Pneumatic actuator for air register

The pneumatic actuator must be:
 correctly installed
 used with dry and clean air
 adequately lubricated
Before to remove the cylinder, ensure that it is completely de-pressurized.
Disconnect the pneumatic connections and cover up to avoid dust
entering. Unbolt the cylinder from its support and carry out the required
maintenance in the workshop.
Air register
It is important that registers are kept in clean and good conditions.
Inspection should be carried out at regular intervals, preferably on a
planned maintenance basis.
Large quantities of dust laden air pass through the register, particularly on
some industrial sites, and inevitably this tends to build up deposits. These
deposits should be brushed off using a soft brush.
Air Swirler
Primary air swirler should be checked for correct position and
condition, and if damaged, repair or replace with a new one.
Igniter
See section relevant to igniter

30
8 WEARING PARTS
Some components of the burner are considered parts subjected to wear
because of their particular operating conditions (e.g.: continuous exposure
to radiation of the flame, continuous contact with the flue gas).
Consequently it will be necessary to inspect at least once a year and in
case of wear/damage proceed with their replacement.
The concerned components are listed below:
 Air swirler
 Refractory of burner throat
 Gas nozzles
 Igniter hood (if provided)
 Flexible hoses

31
10 PRESERVATION
For short (idle period up to 3 months) and long (idle period > 3 months)
term preservation the burners will remain installed on the boiler
1. Remove the flame scanners and the pilot burners (only for long
term preservation). After dismantling inspect and clean
thoroughly the components and store them in warehouse.
2. Inspect, clean, lubricate where required and apply rust
prevention oil on the equipment.
3. Seal the burner sight glasses tightly.
4. In case the flame scanners and the igniter are removed tightly
seal the their openings on burner front plate.
5. In case the flame scanners and the igniter remain installed on the
burner protect them against humidity with kraft paper.
6. The application of vapor corrosion inhibitor on the terminal boxes
and electronic will be evaluated according to the environment
conditions and the duration of the idle period.

32
11 APPENDIX
Appendix A – Pilot burner instruction manual
Appendix B – Flame scanners instruction manual
Appendix C – Pneumatic actuator instruction manual
Appendix D – Limit switches technical data sheet
Appendix E – Filter regulator technical data sheet

APPENDIX A

Largo Buffoni 3 – 21013 Gallarate (VA) – Italy
Phone: +39 0331 738111
Fax: +39 0331 738377
e-mail: macchi@macchiboiler.it
INSTRUCTION MANUAL
FOR
IGNITER MODEL T30-G-MAC 1
MACCHI IGNITER MODEL T30-G-MAC 1
INSTRUCTION MANUAL
TABLE OF CONTENTS
Page
1 INTRODUCTION ..............................................................................................................................................3
2 GENERAL DESCRIPTION ..............................................................................................................................4
3 CALIBRATION .................................................................................................................................................8
4 SAFETY PRESCRIPTION ...............................................................................................................................9
5 MAINTENANCE ...............................................................................................................................................9
6 WEARING PARTS .........................................................................................................................................11
7 TROUBLESHOOTING ...................................................................................................................................11
8 PRESERVATION ...........................................................................................................................................12
Rev. 0 – January 2014 Page 2 of 12

INSTRUCTION MANUAL
1 INTRODUCTION
The following instructions are relevant to the igniters designed and manufactured by MACCHI. These
Instructions and the information revealed by them is submitted with the understanding that it is the
confidential and proprietary property of MACCHI a division of Sofinter S.p.A. – Italy and is not to be
disclosed to others without written permission.

INSTRUCTION MANUAL
2 GENERAL DESCRIPTION
The igniter is designed for use with fuel gas and it has been conceived for lighting fuels of any type,
developing a stable flame in the burner throat.
This torch results from the union of two different gas torches:
a) Torch operating with fuel gas mixed with air (first stage).
b) Torch operating with fuel gas only (second stage).
The first stage uses a small fuel gas flow rate, mixed with combustion air supplied by a compressed
air line with an adequately reduced pressure.
The flame generated by the first stage is strong enough for lighting the second stage and keep it
stable.
Igniter typical section
(1) Igniter block (9) Igniter gun external tube

(2) Threaded cap for pre-mixed gas calibrated nozzle (10) Igniter gun internal tube
(3) Calibrated pre-mixed gas nozzle (11) Ignition electrode
(4) Gas needle valve (12) Ceramic insulator
(5) Gas needle valve guide (13) Sealing fitting
(6) Threaded cap for gas needle valve (14) Compressed air inlet
(7) Pre-mixed gas tip (15) Gas inlet
(8) Gas tip

INSTRUCTION MANUAL
The pilot burner consists of the following main parts:
I) Igniter block
The igniter block (pos. 1), is equipped with threaded connections for fuel gas and air supply.
The top of the block houses an on-off needle valve for second stage gas supply (4) and a
calibrated nozzle for the pre-mixed gas (3), both protected with threaded caps (2 and 6).
The lateral side is provided with the fuel gas (15) and compressed air (14) connections. On the
air connection is installed a calibrated orifice (O).

INSTRUCTION MANUAL
II) Igniter gun

The igniter gun is composed by:
Internal tube (10) for air and gas torch.
External tube (9) with gas tip.
The internal part, provided with threaded connection to the pilot gas block, is composed by a
cylindrical tube (10). Inside of the internal tube a pre-mix gas tip (7) is provided.
The external part, provided with threaded connection to the pilot gas block, is composed by
another cylindrical tube (9) equipped with a gas tip (8), concentric to the internal one.

INSTRUCTION MANUAL
III) Ignition spark

The ignition spark (11) is installed inside the igniter block and is composed by:
Internal electrode.
Ceramic insulation.

INSTRUCTION MANUAL
3 CALIBRATION
For a correct calibration of each igniter, follow the indications given below.
1) Check the correct installation and the tightness of the fuel gas and air hoses to the pilot.
2) Check the correct installation of spark igniter and relevant electric cables.
3) Remove the threaded cap (2) and check the correct installation of the pre-mixed gas calibration
nozzle (3).
4) Set the air and fuel gas pressures to igniter at following values:
Air: 1 bar(g)
Fuel gas: 1 bar(g)
5) Remove the threaded cap (6) and close fully the on-off needle valve (4) relevant to second stage
gas supply.
6) Ignite the torch by means of the spark and check the stability of the pre-mixed flame.
7) Repeat ignition several times and verify the stability of the pre-mixed flame.
8) When the pre-mixed flame is stable, open completely the on-off needle valve (4) and place in
position the threaded cap (6).
9) Repeat ignition several times and verify the stability of the igniter flames.

INSTRUCTION MANUAL
4 SAFETY PRESCRIPTION
1) Installation and maintenance procedures may only be carried out by authorized personnel.
2) All local regulations must be observed during installation.
3) Improper installation, alignment and maintenance, as well as modifications by the customer, can
all lead to personal injury or damage of equipment.
4) The igniter maintenance can be carried out when:
The igniter is out of operation.
The electric supply is switched off.
The valve for ignition gas is closed.
5 MAINTENANCE
These igniters do not require any special maintenance. They should, however, be checked
periodically (e.g. every 3 months) for proper operation.
If the igniters are operated using air that contains dust, this check must be performed at shorter
intervals, since electrically conductive dirt deposits or moisture on the ceramic insulators can lead to a
fault in the igniter.
Even after shut-down the pilot must be feed with air, in order to cool adequately the pilot when the
burner is in operation.
In case of system failure, it is advisable to carry out the following operations:
1) Calibrated nozzle cleaning

a) Remove the closing cap (pos. 2), using a spanner.
b) Using a 10 mm socket spanner, remove the nozzle (pos. 3).
c) Clean the calibrated hole, until the passage is completely free.
d) Reassemble in the reverse order.

INSTRUCTION MANUAL
2) Ignition spark replacement

a) Remove the junction box cover.
b) Disconnect the electric cables.
c) Remove the junction box body (the junction box body is secured to the igniter head with a
screw).
d) Unscrew the sealing fitting (13) with a socket spanner.
e) Extract the electrode assembly (EA).
f) Replace the electrode assembly with a new one.
g) Reassemble in the reverse order.

INSTRUCTION MANUAL
6 WEARING PARTS
Some components of the burner are considered parts subjected to wear. Consequently it will be
necessary to inspect at least once a year and in case of wear/damage proceed with their
replacement. The concerned components are listed below:
Ignition electrode assembly (EA)
7 TROUBLESHOOTING
In case the pilot burner does not operate properly, first check if the electrode shows a strong spark.
If despite a strong spark, no gas flame is obtained, check the gas supply for the following possible
causes:
1) A hand valve is closed.
Put it in open position.
2) The safety shut-off valves are closed or remained closed.
Check the wiring of these valves.
3) The gas pressure to the pilot is incorrect (air/gas mixture cannot be ignited).
Re-adjust the pressure.
4) The calibrated nozzle (pos. 3) is dirt or obstructed.
Clean the nozzle.
When very weak sparks or even no sparks are detected, check the electric system for the following
possible causes:
1) The electrode is fouled-up, causing short-circuit.
2) The ignition transformer is not operating properly.
3) Some fault is present in electric wiring and/or connections.

INSTRUCTION MANUAL
8 PRESERVATION
1) Short term preservation (idle period up to 3 months): the igniter will remain installed on burner.
2) Long term preservation (idle period > 3 months): the igniter has to be removed and stored in
warehouse.
After dismantling clean thoroughly and inspect. Replace the worn or damaged parts (if any) and
store in warehouse.

APPENDIX B


CU-95
NOVEMBER 9, 2016
TYPE 95IR/95UV/95DS
MODEL S1, S2
Integrated Flame Scanner

with Internal Flame Relay
TUV
SIL2
RoHS Compliant to EU Directive 2002/95/EC
DESCRIPTION
The FIREYE InSight Type 95IR, 95UV, and 95DS flame scanners are micro-processor based flame
scanners utilizing solid state infrared (IR) or ultraviolet (UV) or dual (IR and UV) sensors.
The FIREYE InSight Type 95 flame scanners incorporate an internal flame relay with adjustable
ON/OFF thresholds, thereby eliminating the need for a remote flame amplifier.
The InSight scanners are now a replacement to the FIREYE Type 45FS1 and 45UVFS1 Signature
Scanners™ as well as the Type 45RM4 to detect the presence or absence of a target flame in single
or multi-burner applications.
The InSight scanners measure the amplitude of the modulations (the flame “flicker”) that occur
within the targeted flame. During the scanner set-up procedure, the modulation frequency that yields
the best flame ON/OFF discrimination is selected. The appropriate modulation frequency and sensor
gain is either manually selected (S1 models), or automatically selected with manual override capa-
bility (S2 models).
The InSight 95IR, 95UV, and 95DS scanners are each available in two models differentiated by fea-
ture levels.
The Standard Model S1 has three choices of modulation frequency, adjustable sensor gain, adjust-
able flame relay ON/OFF thresholds, 4-20 mA analog signal strength output, fault relay, and two
selectable programmable files to store setpoints (for two different fuels or firing rates).
The Expanded Model S2 adds automatic programming (AutoTune) with manual override capability,
21 choices of flame flicker frequency, a total of four selectable programmable files to store setpoints,
plus adds remote communication capability via Fireye Windows 95/98/NT user software.
All FIREYE InSight scanner models are powered by 24 Vdc and contain electronic self-checking
(no mechanical shutter required). The scanners contain an eight character alpha-numeric LED dis-
play and a four (4) push-button keypad to enable the user to view operating parameters and select
setpoints.
“CG” models include a 10 ft. (3m) captive cable and gland. Non-“CG” models have a twelve-pin
electrical quick-disconnect. Fiber optic-mount versions of the InSight scanners are also available.
Refer to bulletin CU-101 for installation instructions.
1

TABLE OF CONTENTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MODEL LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MECHANICAL ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
SCANNER WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
REMOTE FILE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
ASSEMBLY INSTRUCTIONS, QUICK DISCONNECT KIT . . . . . . . . . . . . . . . .16
WIRING FOR REMOTE COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . .19
GROUNDING AND SHIELDING TECHNIQUES . . . . . . . . . . . . . . . . . . . . . .23
PROGRAMMING THE InSight SCANNER . . . . . . . . . . . . . . . . . . . . . . . . .23
INSIGHT MENU STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
THE STATUS MENU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
THE EDIT MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
FILE COPY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
THE PRE-EDIT MENU (“S1” Models only). . . . . . . . . . . . . . . . . . . . . . . . . .35
MANUAL SET-UP (“S1” Models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
THE AUTOTUNE MENU (“S2” Models only) . . . . . . . . . . . . . . . . . . . . . . . .38
SET-UP PROCEDURE (All Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
CONFIGURATION RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
REPLACEMENT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
ORDERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
2

OPERATION
The InSight scanners measure the amplitude of the modulations that occur within the targeted flame.
During the scanner set-up procedure, the modulation frequency that yields the best flame ON: OFF
discrimination is selected. The appropriate modulation frequency and sensor gain is either manually
selected (S1models), or automatically selected with manual override capability (S2 models).
With the appropriate modulation frequency selected, the flame relay’s ON and OFF thresholds are
then entered. (This selection is set automatically with S2 models). The scanner’s 4-20 mA signal
strength output is at minimum (4 mA) with a signal strength of “0”, and at maximum (20 mA) at a
signal strength of 100.
The FLAME RELAY is energized (and its normally open contacts close) when the signal strength is
at or above the programmed flame ON threshold. The flame relay is de-energized when the signal
strength is at or below the programmed flame OFF threshold. The flame relay contact circuit will
also open upon a power interruption or the detection of an internal fault (see below).
The FAULT RELAY is energized when the scanner is powered (24 vdc) and when the scanner had
successfully passed all internal self-checking routines. The Fault relay is de-energized if there is a
power interruption to the scanner or if the scanner has detected an internal fault. A normally open
(fault relay) contact is wired in series with the flame relay contact (internally), and a normally closed
contact is available for alarm indication.
APPLICATION
Type 95IR contains an infrared flame sensor, responding to infrared radiation from 700 to 1700
nanometers wavelength. This sensor is best suited to coal and oil applications.
Type 95UV contains an ultraviolet flame sensor, responding to ultraviolet radiation from 295 to 320
nanometers wavelength. This sensor is best suited to gas applications.
Type 95DS (Dual sensor) contains both the infrared and ultraviolet flame sensors described above.
This sensor is best suited to multi-fuel applications.
The Standard Model S1 is best suited to the many applications that do not require the level of
sophistication, or the remote communications capability of the Expanded Model S2 (e.g. single
burner boilers and furnaces, duct burners, etc.)
The Expanded Model S2 is best suited to the applications that require the highest level of sophisti-
cation and flexibility (addition choices of modulation frequencies, and the time-saving AutoTune
function), and remote communications capability (e.g. larger multi-burner boilers and furnaces).
InSight SCANNER FEATURES

Features Basic Models (S1) Expanded Models (S2)
95IRS1 95UVS1 95DSS1 95IRS2 95UVS2 95DSS2
Infrared Sensor X X X X
Ultraviolet Sensor X X X X
Flame Relay X X X X X X
Fault Relay X X X X X X
4-20 mA Output X X X X X X
Modulation Frequency 3 3 3 21 21 21
Selections
Memory Files 2 2 2 4 4 4
Communications X X X
AutoTune X X X
Pre-Edit X X X
3

DIMENSIONS
FIGURE 1. TYPE 95IR/95UV/95DS SCANNER, with ELECTRICAL QUICK-DISCONNECT (mounting flange ordered
separately)
10.89"
(276.68)
4.25"
(107.95) LOCKING 1" NPT OR 1 23/32" HEX
RING 1" BSP SIGHT (43.68)
MOUNTING PIPE CONNECTION
FLANGE
4.62"
(117.35)
75°
HOUSING MATERIAL: CAST ALUMINUM (A356)
PURGE AIR CONNECTION 1.72" FINISH: GREY POLYESTER POWDER COAT
12 - PIN ELECTRICAL CONNECTOR 3/8" NPT or (43.74)
3/8" BSP
FIGURE 2. TYPE 95IR/95UV/95DS SCANNER, “CG” MODEL with 10 FT CABLE (mounting flange ordered separately)
14.05"
(356.87)
MOUNTING FLANGE
11.30"
(287.02)
4.25"
(107.95) LOCKING 1" NPT OR 1 23/32" HEX
RING 1" BSP SIGHT (43.68)
MOUNTING PIPE CONNECTION
FLANGE
4.62"
(117.35)
75°
HOUSING MATERIAL: CAST ALUMINUM (A356)

PURGE AIR CONNECTION 1.72" FINISH: GREY POLYESTER POWDER COAT
CABLE GLAND WITH 10 FT (3 METER) CABLE 3/8" NPT or (43.74)
3/8" BSP
FIGURE 3. INSIGHT SCANNER in CENELEC HAZARDOUS AREA HOUSING (mounting flange kit ordered separately)
FOR WIRING INSTRUCTIONS REFER TO FIGURE 18
3/4" NPT THREADED OPENING FOR CABLE ENTRY
MOUNTING SCREWS (4 PLC.)

0.35" (9)
3/8" THREADED OPENING FOR COOLING AIR
VIEWING
WINDOW
5.28" 4.41" 1" FEMALE THREAD
(134) (112) SIGHT PIPE MOUNT
FLANGE GASKET
4.53" (115) 4.41" (112)
8.94" (227) 3.56" (90)
*HOUSING FLANGE KIT
DIMENSIONS IN INCHES (MM) *HOUSING FLANGE KIT, ORDERED SEPARATELY

(INCLUDES NPT OR BSP FLANGE, GASKET, MOUNTING SCREWS)
ASSEMBLY SHOWN WITH HOUSING FLANGE KIT, ORDERED SEPARATELY
P/N 129-168-1 (NPT)
P/N 129-168-2 (BSP)
4

MODEL LISTING
PART SENSOR FEATURES FIBER 12-PIN 10 FT (3M) MAXIMUM HOUSING AGENCY APPROVALS
NUMBER OPTIC CONNECTOR CABLE & CONTACT RATING
MOUNT GLAND RATING (see note) UL FM DIN-DVGW CE
(see note 4) C/US
95IRS1-1 IR BASIC NO YES NO 240 vac NEMA 4X, YES YES NO NO
IP66
95UVS1-1 UV CLASS I
DIV. 2
95DSS1-1 IR & UV GROUPS
A, B, C & D
95IRS2-1 IR EXPANDED CLASS II
DIV. 2
95UVS2-1 UV
GROUPS
95DSS2-1 IR & UV F&G
95IRS1-1CG IR BASIC NO NO YES 240 vac NEMA 4X, YES YES NO NO

IP66
95UVS1-1CG UV CLASS I
DIV. 2
95DSS1-1CG IR & UV GROUPS
A, B, C & D
95IRS2-1CG IR EXPANDED CLASS II
DIV. 2
95UVS2-1CG UV
GROUPS
95DSS2-1CG IR & UV F&G
95IRS1E-1 IR BASIC NO YES NO 50 vac NEMA 4X, NO YES YES YES

IP66
95UVS1E-1 UV
95DSS1E-1 IR & UV
II 3 G/D
95IRS2E-1 IR EXPANDED Ex nA IIC T6
95UVS2E-1 UV
95DSS2E-1 IR & UV
95IRS1E-1CG IR BASIC NO NO YES 240 vac NEMA 4X, NO YES YES YES
IP66
95UVS1E-1CG UV
95DSS1E-1CG IR & UV
II 3 G/D
95IRS2E-1CG IR EXPANDED Ex nA IIC T6
95UVS2E-1CG UV
95DSS2E-1CG IR & UV
95UVS2-3 UV EXPANDED NO YES NO 240 vac NEMA 4X, YES YES NO NO
IP66
95UVS2-3CG UV NO YES CLASS I
DIV. 2
GROUPS
A, B, C & D
CLASS II
DIV. 2
GROUPS
F&G
Note: Class I Division 2 Hazardous Area requirements for InSight scanners with electrical con-
nectors (non-CG models):
1. The connector coupling nut setscrew must be tightened after mating the cable to the scanner.
2. The red warning label must be adhered to the connector housing.
3. Evaluated by TUV that the flame detector device is suitable to be used as single device for
safety instrumented functions (SIF) according to DIN EN 61511-1 up to SIL2. The flame detec-
tor device also fulfills the applicable requirements of DIN EN 61508:2002 parts 2-3 for safety
integrity level SIL2
5

MODEL LISTING
PART SENSOR FEATURES FIBER 12-PIN 10 FT (3M) MAXIMUM HOUSING AGENCY APPROVALS
NUMBER OPTIC CONNECTOR CABLE & CONTACT RATING
MOUNT GLAND RATING (see note) UL FM DIN- CE
(see note 4) C/US DVGW
95IRS1-2 IR BASIC YES YES NO 240 vac NEMA 4X, YES YES NO NO
IP66
95IRS2-2 EXPANDED
CLASS I DIV.2
95IRS1-2CG BASIC NO YES GROUPS
A, B, C & D
95IRS2-2CG EXPANDED CLASS II
DIV. 2
GROUPS
F&G
95IRS1E-2 IR BASIC YES NO 50 vac NEMA 4X, NO YES YES YES
IP66
95IRS2E-2 EXPANDED
95IRS1E-2CG BASIC NO YES 240 vac
II 3 G/D
95IRS2E-2CG EXPANDED Ex nA IIC T6
95UVS2-2 UV EXPANDED YES YES NO 240 vac NEMA 4X, YES YES NO NO
IP66
95UVS2-2CG NO YES
CLASS I DIV.2
GROUPS
A, B, C & D
CLASS II
DIV. 2
GROUPS
F&G
95UVS2E-2 UV EXPANDED YES YES NO 50 vac NEMA 4X, NO YES YES YES
IP66
95UVS2E-2CG NO YES 240 vac
II 3 G/D
Ex nA IIC T6
95IRS1-1CEX IR BASIC NO NO NO 240 vac IP66 NO NO NO NO
(TWO INTER- CENELEC (see
95UVS1-1CEX UV NAL 8-POLE
Ex d IIC T6 Note)
95DSS1-1CEX IR & UV TERMINAL
BLOCKS)
95IRS2-1CEX IR EXPANDED
95UVS2-1CEX UV
95DSS2-1CEX IR & UV
95IRS1E-1CEX IR BASIC NO NO NO 240 vac IP66 NO NO YES YES
(TWO INTER- CENELEC (see
95UVS1E-1CEX UV NAL 8-POLE
Ex d IIC T6 Note)
95DSS1E-1CEX IR & UV TERMINAL
BLOCKS)
95IRS2E-1CEX IR EXPANDED
95UVS2E-1CEX UV
95DSS2E-1CEX IR & UV
Note: The housing into which the Model CEX InSight electronics are installed has been approved
by CENELEC and ATEX for use in Exd IIC T6 hazardous areas.
Note: Class I Division 2 Hazardous Area requirements for InSight scanners with electrical connec-
tors (non-CG models):
1. The connector coupling nu8t setscrew must be tightened after mating the cable to the scanner.
3. Evaluated by TUV that the flame detector device is suitable to be used as single device for safety
instrumented functions (SIF) according to DIN EN 61511-1 up to SIL2. The flame detector
device also fulfills the applicable requirements of DIN EN 61508:2002 parts 2-3 for safety integ-
rity level SIL2
6

SPECIFICATIONS
MECHANICAL:
Housing Material: Cast aluminum with gray polyester powder coat finish
Housing Weight: 4.3 1bs (1.96kg), non-“CG” models
5.9 lbs. (2.69kg) “CG” models
6.3 lbs. (2.89kg) “CEX” models
Environmental: NEMA 4X, IP66, Class I Division 2, Groups A, B, C & D, Class II
Division 2, Groups F& G (refer to agency approvals table)
Mounting: Requires one of two threaded mounting flanges, ordered separately
(see below). For fiber optic mount, refer to bulletin CU-101
Mounting Flange P/N 60-2692 1" NPT female pipe mount with 3/8" NPT female
Kit: cooling air connection, includes 1" NPT x 3" long heat insulating nipple
(P/N 35-127-1)
P/N 60-2693 1" BSP female pipe mount with 3/8" BSP female
cooling air connection, includes 1" BSP x 3"long heat insulating nipple
(P/N 35-127-3)
Mounting Flange
Shipping Weight: 0.62lbs. (0.28kg)
Cooling / Purge Air Requirements:
Source: Clean, dry, cool
Volume: 4 SCFM (113 l/min) at 3/8" threaded mounting flange, or 1 inch “Y” fitting,
mounted on scanner sight pipe. Temperature near the upper limit of the scanner operating
range and/or use with dirty/dusty fuels may require up to 15 SCFM (425 l/min).
Pressure: Adequate to overcome furnace or windbox pressure
Temperature Rating: -40°F to + 150°F (-40°C to +65°C), ambient; -40°F to 178°F (-40°C to
81°C), scanner internal temperature
Humidity: 0% to 95% relative humidity, non-condensing
ELECTRICAL:
Input Power: 24 Vdc, +10%, -15% supply current: 0.35 A, 8.5 VA
Electrical Connection: 12-pin quarter-turn quick-disconnect.
“CG” models have cable gland and 10 ft (3m) of captive cable
“CEX” models have 3/4” threaded opening and internal terminal blocks
Relay Output FLAME RELAY, SPST (N.O.)
FAULT RELAY, SPST (N.C.)
Contact Rating: Minimum: 10 mA @ 5 Vdc
Maximum: 2 A @ 30 Vdc
2 A @ 50 Vac (CE approved models)
2 A @ 240 Vac (FM & UL models and all “CG” models)
Analog Output: 4-20 mA dc current, referenced to 24Vdc common, maximum connected
1oad: 750 ohms
Status Indication: Eight (8) character alpha-numeric LED display (scrolling capability)
Operator Interface: Four (4) pushbutton style keys
Cable Specification: P/N 59-497:
Multi-core, 12 conductor (color coded), with foil wrap and overall braided shield
Six #18 AWG and four #22 AWG conductors, plus one #22 AWG twisted pair
Cable Jacket: Irradiated Modified Polyolefin (flame-retardant, low smoke, zero halogen)
Maximum Temperature: 257°F (125°C)
Nominal O.D. 0.41" (10.4 mm), Maximum O.D. 0.43" (10.9 mm)
Maximum cable length 1000 feet (305 meters)
7

INSTALLATION NOTES
The InSight flame scanners determine the presence or absence of flame by monitoring the frequency
spectrum of the flame. The scanner should initially be mounted so that the primary combustion zone
is within the scanner’s line of sight.
The location and sighting instructions listed in the following sections are rough guidelines for the
location of the scanner. The scanner provides feedback via its LED display to assist in the adjustment
and proper alignment of the flame scanner. Refer to the setpoint procedures described in this bulletin.
Note: An acceptable scanner location must ensure the following:
Reliable main flame and/or ignitor flame detection at all air flow and furnace loads (ranges of fuel
firing).
Rejection of the ignitor flame if too short or in the wrong position to ignite the main flame reliably,
thus prohibiting the delivery of fuel to the burner.
Note: Due to the microprocessor based design of the InSight scanner, the heat insulating nipple
(P/N 35-127-1 or 35-127-3) must be used to isolate the scanner from ground and to reduce con-
ducted energy and noise. See Figure 7. The nipple is included in mounting flange kit P/N 60-2692,
60-2693.
INSTALLATION PROCEDURE
WARNING: Protective filtered lenses should be worn when viewing flame. Infrared and
ultraviolet energy from the flame can be damaging to the eyes.
1. The best results are obtained when the scanner is aimed so that the scanner’s line of sight inter-
sects the burner center at a slight angle (e.g. 5 degrees) and sees a maximum of the primary com-
bustion zone, as shown in Figure 4. If only one scanner is used per burner, the line of sight
should also intersect the igniting flame.
2. For installations where separate scanners are used to monitor main and ignitor flames, the main
flame scanner should be sighted so it does not detect the ignitor flame.
3. The scanner should have an unrestricted view of flame as far as possible. Physical obstructions
such as air register blades, interfering vanes, or other hardware should be cut away or notched so
they do not fall within the scanner’s line of sight as shown in Figure 6.
Note: Always check with the burner manufacturer before you trim the register blades.
FIGURE 4. SINGLE BURNER SCANNER SIGHTING
AIR REGISTER FLAME
BLADES ENVELOPE
SCANNER
LINE OF
SIGHT
BURNER
BURNER
THROAT CENTER LINE
BASE PRIMARY
COMBUSTION
ZONE
4. Consideration must be given to burner secondary air rotation, some burners have clockwise
(CW) air rotation and others have counterclockwise (CCW) air rotation. If combustion air enters
the furnace with a rotational movement of sufficient velocity to deflect the ignitor flame in the
direction of rotation, position the scanner 10 to 30 degrees downstream of the ignitor as shown in
Figure 5 and close to the periphery of the burner throat (See Figure 4).
8

FIGURE 5. SCANNER LOCATION VS. SECONDARY AIR ROTATION

IGNITOR IGNITOR
SCANNER SCANNER
MAIN MAIN
BURNER BURNER
CCW ROTATION CW ROTATION
5. Having determined the approximate location for the sight pipe, cut a clearance hole for a 2 inch
pipe through the burner plate. Look through the hole. If register vanes interfere with the desired
line of sight, the interfering vane(s) should be trimmed to assure an unrestricted viewing path at
all firing levels as indicated in Figure 6.
Note: Always check with the burner manufacturer before you trim register vanes.
FIGURE 6. IF POSSIBLE FLAME SHOULD COMPLETELY COVER SIGHT OPENING
Obstruction Obstruction
NOT THIS NOT THIS BUT THIS OR THIS
6. The preferred method for mounting surface mounted scanners requires the use of a swivel
mount, P/N 60-1664-3 (NPT), shown in Figures 7, 8 and 9. Center the swivel mount over the two
inch hole in the burner plate and secure using three hexed cap screws (not provided). Install the
sight pipe on the swivel mount. If a swivel is not used, insert the end of the sight pipe into the
hole, align the hole to the desired viewing angle and tack weld (welding must be adequate to
temporarily support the weight of the installed scanner). The sight pipe should be arranged to
slant downward so that dirt and dust will not collect inside.
CAUTION: Use no more than one foot of one inch diameter sight pipe. Increase the sight
pipe diameter one inch for every additional foot of sight pipe length used to avoid restricting
the scanner’s field of view.
7. When a satisfactory sighting has been confirmed by operational testing, secure the swivel
mount’s ball position in place by tightening the three hex head cap screws located on the swivel
mount ring.
8. In larger multi-burner type applications such as power, kiln or refinery burners, it is recognized
that there may be several obstructions within the scanner overall range of view. The same princi-
ple of adjusting the scanner such that the flame is within the center of its field of view applies.
Use of a swivel mount allows the scanner to be adjusted to target the flame within the center of
the scanner range of view. (see obstructed view in figure 6 above)
9. For ease of use, the scanner should be installed on the sight pipe so the LED display can easily be
read.
Note: Operation of the LED display is independent of position.
Note: Due to the microprocessor based design of the InSight scanner, the heat insulating nipple
(P/N 35-127-1 or 35-127-3) must be used to isolate the scanner from ground and to reduce con-
ducted energy and noise. See Figure 7.
10. The scanner lens must be kept free of contaminants (oil, ash, soot, dirt) and the scanner housing
temperature must not exceed its maximum rating of 150° F (65° C). Excessive temperatures will
shorten scanner life. Both requirements will be satisfied by a continuous injection of purge air at
either the 3/8" housing inlet or the 1” “Y” connection ahead of the swivel mount as shown in
Figures 7, 8 and 9.
Note: Internal scanner temperature is available via the LED display. See “Status Menu” under
“Programming the Scanner.”
9

The scanner mounting may be made with provision for purge air through only the 3/8" opening as
shown in Figure 9 or for purge air through either the 3/8" opening or the 1” “Y” connection as shown
in Figure 8. In the latter arrangements, normally only one of the two connections is provided with
purge air and the other connection is plugged. When a sealing coupling is used as shown in Figure 7,
the 1" “Y” connection is used for the purge air and the 3/8" opening is plugged.
It is good practice to use the sealing coupling (P/N 60-1199-1 with NPT threads) on all installations
to insure against unwanted furnace pressures from damaging the scanner lens.
Under normal conditions, with clean burning fuels and moderate ambient temperature conditions,
purge air flow of approximately 4 SCFM (133l/min) is generally adequate. Up to 15 SCFM
(425 l/min) may be required for fuels that produce high levels of ash or soot, or for hot environments
to maintain the scanner’s internal temperature within specification. Flexible conduit should be used
to wire the scanner from a grounded service box to the scanner.
MECHANICAL ACCESSORIES
Surface Mounting Flange (Required)
P/N 60-2692 1" NPT female pipe mount with 3/8" NPT female cooling air connection,
includes 1" NPT x 3" long heat insulating nipple (P/N 35-127-1).
P/N 60-26931" BSP female pipe mount with 3/8" BSP female cooling air connection,
includes 1" BSP x 3" long heat insulating nipple (P/N 35-127-3).
Swivel Mount (Optional)

The scanner swivel mount, P/N 60-1664-3 (NPT) (see Figure 10, Item A), is used to adjust the scanner
sighting angle after the scanner has been installed, The swivel mount is shown in Figures 7, 8, and 9.
Heat Insulating Nipple (Required)

Heat Insulating nipple, P/N 35-127-1 (NPT), or P/N 35-127-3 (BSP) (see Figure 7, Item E), is used
to prevent heat transfer from the hot sight pipe to the scanner head as well as electrically isolate the
scanner from ground. The appropriate nipple (NPT or BSP) is shipped with the surface mounting
flange.
Sealing Coupling with Quartz Window (Optional)

The sealing coupling, P/N 60-1199-1 (see Figure 7, Item D), is used whenever a coupling or a seal is
required for scanner piping. The quartz window blocks furnace pressure, hot gases and soot from
coming in contact with the scanner and contaminating the lens. The size is one inch U.S. standard
taper pipe thread (Schedule 40, 1" - 11 1/2 NPT). When the sealing coupling is used, a 1 inch “Y” fit-
ting must be used downstream of it for connection of a purge air supply (plug 3/8" opening).
Orifice Kit (Optional)

An orifice may be used to restrict the scanner’s field of view aiding discrimination between the target
flame and other flames in the combustion chamber. An orifice may also be used to reduce the total
amount of radiation reaching the scanner, thereby avoiding the chance of saturation. Orifice kit (P/
N 53-121) contains nine different orifice sizes, and two retaining clips. The orifice can be installed
either within the 60-1664 swivel mount, within the 60-1199-x coupling, or within the 60-2692,-2693
surface mounting flange. Refer to figures 11 and 12.
Insulating Jacket/Vortex-Tube Cooler Kit (Optional)

For high ambient temperature applications, an insulating jacket (P/N 97-1048) and vortex-tube
cooler kit (P/N 60-2720) are available. Refer to bulletin CU-103 for details.
10

FIGURE 7.
PART NUMBER
23.8” (605mm)
A. SWIVEL MOUNT 60-1664-3 (NPT)
60-1664-4 (BSP) C E F
B. 1" WYE 35-200 (NPT)
C. 1” CLOSE NIPPLE 35-201 (NPT)
D. SEALING COUPLING W/QUARTZ WINDOW
60-1199-1 (NPT)
A
60-1199-2 (BSP) B
D
E. HEAT INSULATING NIPPLE 35-127-1 (NPT) G
35-127-3 (BSP)
F. 3/8" PLUG 35-202 (NPT)
G. SURFACE MOUNTING 60-2692 (1”NPT)
FIGURE 8.
PART NUMBER
20.6” (523mm)
D
60-1664-4 (BSP)
B. 1" WYE 35-200 (NPT)
C. HEAT INSULATING NIPPLE 35-127-1 (NPT)
35-127-3 (BSP)
D. 3/8" PLUG 35-202 (NPT)
A
E. SURFACE MOUNTING 60-2692 (1”NPT) B C
FLANGE (includes item C) 60-2693 (1”BSP) E
FIGURE 9.
15.3” (389mm)
PART NUMBER
B C
60-1664-4 (BSP)
B. HEAT INSULATING NIPPLE 35-127-1 (NPT)
35-127-3 (BSP)
C. 3/8" THREADED OPENING
D. SURFACE MOUNTING 60-2692 (1”NPT)
FLANGE (includes item B) 60-2693 (1”BSP) A D
11

FIGURE 10.
PART NUMBER
A
A. SWIVEL MOUNT 60-1664-3 (NPT) B
SWIVEL MOUNT 60-1664-4 (BSP)
B. SEALING COUPLING W/QUARTZ WINDOW
60-1199-1 (NPT)
60-1199-2 (BSP)
C. SCANNER CABLE 59-497
FIGURE 11.
A-I. Orifices: 0.062" - 0.5" DIA

J. Orifice Retainer 34-181
K. Heat Insulating Nipple 35-127-1 (NPT)
Heat Insulating Nipple 35-127-3 (BSP)
ORIFICES
Figure Qty. Part Number Description
11 1 53-121 Orifice Kit: Contains following items:
11A 1 53-121-2 Orifice: Diameter = 0.062"
11B 1 53-121-3 Orifice: Diameter = 0.078"
11C 1 53-121-4 Orifice: Diameter = 0.093"
11D 1 53-121-5 Orifice: Diameter = 0.109"
11E 1 53-121-6 Orifice: Diameter = 0.125"
11F 1 53-121-7 Orifice: Diameter = 0.187"
11G 1 53-121-8 Orifice: Diameter = 0.250"
11H 1 53-121-9 Orifice: Diameter = 0.375"
11I 1 53-121-10 Orifice: Diameter = 0.500"
11J 2 34-181 Orifice Retainer
12

FIGURE 12.
SWIVEL MOUNT
BALL
FIELD OF VIEW
ORIFICE ORIFICE RETAINER

PURGE
AIR SUPPLY
FIELD OF VIEW
60-1199-1,2
SEALING COUPLING
1" SWIVEL MOUNT 3/8" PLUG
ELECTRICAL ACCESSORIES (see note)

Note: Class I Division 2 Hazardous Area requirements for InSight scanners with electrical con-
nectors (non-CG models):
Scanner Cable, P/N 59-497
Fireye recommends P/N 59-497 multi-core, 12 conductor (color coded), foil wrap and overall
braided shield cable. This cable includes six #18 AWG and four #22 AWG conductors, plus one #22
AWG twisted pair. The cable jacket is Irradiated Modified Polyolefin (flame-retardant, low smoke,
zero halogen) with a maximum diameter of 0.43" (10.9 mm). Maximum temperature: 257°F
(125°C). The maximum cable length is 1000 feet (305 meters) per scanner. This raw stock cable
requires the Quick-Disconnect Kit described below. Refer to Figure 14 for color code and connec-
tion information.
Quick-Disconnect Kit, P/N 129-164, 129-164R, 129-164C, 129-164RC

A twelve-pin (male) electrical connector is factory installed on non-“CG” InSight scanners. Fireye
offers the mating (female) connector for field installation onto the 59-497 cable. Refer to Quick-Dis-
connect assembly instructions. P/N 129-164 is straight, P/N 129-164R is right-angle. P/N 129-164C
and 129-164RC are supplied with fittings for use with 1/2" flexible conduit.
Scanner Cable with Female Connector, P/N 59-497-XXX, -XXXR, -XXXC, -XXXRC
Fireye offers the 59-497 12-conductor cable in pre-cut lengths with the female quick-disconnect fac-
tory installed. These assemblies are offered in lengths from 10 feet (3m) to 300 feet (91m).
P/N 59-497-XXXR has a right-angle connector. P/N 59-497-XXXC and 59-497-XXXRC are sup-
plied with fittings for use with 1/2" flexible conduit.
Wiring Harness Assembly, P/N 61-6944-XXX, -XXXR

If remote communication is required (Model S2 only), and the distance between the InSight scanner
and the control room exceeds 200 feet (61m), then a small junction box must be installed near each
scanner.
The two communications wires must be separated out of the twelve-conductor scanner cable at the
junction box and wired independently in a multi-drop (“daisy-chain”) configuration to each scanner
in the loop, and finally to the computer. The Fireye Wiring Harness Assembly, available in lengths
from 3 to 50 feet (0.9 to 15.2m), provides a convenient method to accomplish this.
On one end, the harness has a female quick-disconnect to connect to the non-“CG” InSight scanner.
Harness part numbers ending in “R” have a 90° quick-disconnect. Fireye twelve-conductor cable, P/
13

N 59-497 is factory wired to the quick-disconnect, run through flexible conduit and connected to a
terminal strip within a junction box at the other end of the harness. The terminal strip accepts up to
14 AWG wires and uses push-type cage clamp connectors for quick and secure connections.
From the junction box, the installer would connect all but two wires of a length of Fireye 59-497
twelve-conductor cable that is run to the burner management system. The two communications wires
originating from the scanner would be connected from one junction box to the next, and finally to the
computer using a two-conductor communications cable (Belden #8761, 22 AWG or equal).
24 Volt DC Power Supplies

Fireye offers two DIN rail mounted 24 vdc power supplies for use with the InSight Integrated flame
scanner. Model 60-2685-25 (2 amp) can power up to five InSight scanners, model 60-2685-50 (4
amp) can power up to ten InSight scanners (see note 1). Refer to bulletin CU-118 for details.
PART NUMBER DESCRIPTION NOTES

60-2685-25 24 VDC Switching Power Supply, 100-240 vac 50/60 Hz. input, 1
2.5 A output at 24 vdc. Powers up to five scanners. Dimensions:
3.7"(95mm) high x 1.6" (40mm) wide x 4.3"(108mm) deep
60-2685-50 24 VDC Switching Power Supply, 100-240 vac 50/60 Hz. input, 1
5.0A output at 24 vdc. Powers up to ten scanners. Dimensions:
4.5" (115mm) high x 2.0" (50mm) wide x 4.8" (121mm) deep.
Notes:
1. Rated output is when power supply is vertically mounted, and with an ambient temperature of
104F (40C) maximum.
SCANNER WIRING
To reduce electrical noise interference, the scanner cable should be installed in rigid or flexible con-
duit. Take precautions to keep the scanner cable away from any high inductive wiring associated
with high inductive loads or high voltage, high energy spark ignition systems.
CAUTION: The InSight flame scanner requires 24 Vdc power for operation. Connection to
a 24 Vac or 120 Vac power source will damage the scanner. Refer to wiring diagrams.
External 2.0 Amp fuses are recommended to protect Flame Relay and Fault Relay contacts
All wiring to the scanner should be rated at 90°C. For runs less than 1000 feet, the use of
Fireye Scanner Cable, P/N 59-497, (12 wire) is recommended. For runs in excess of 1000
feet, consult the factory.
14

FIGURE 13. WIRING DIAGRAM, INSIGHT INTEGRATED FLAME SCANNER

TYPE 95IR/95UV/95DS QUICK-DISCONNECT FIREYE CABLE 59-497
PIN NUMBER COLOR CODE
(+) BLACK/RED (+)

INPUT A 24 VDC
POWER (-) INPUT
24VDC (-) WHITE/BLUE POWER
B
WHITE/BLACK
FLAME C
RELAY
(Note 1) TO BMS
FAULT INPUT
WHITE/RED FUSE (Notes 6, 7)
RELAY D
(Note 2)
RED
E
FAULT
RELAY TO BMS
(Note 2) INPUT
PINK FUSE (Notes 6, 7)
F
(+) VIOLET
4-20mA G
OUTPUT TO BMS
(-) METER
(Source) GREY/RED
H (Note 6)
Referenced
to Common
SW1
REMOTE BLUE/RED
J (Note 5)
FILE SELECT 1
SW2
REMOTE YELLOW
FILE SELECT 2 K (Note 5)
(Model S2 only)
(Note 4)
A
BROWN
REMOTE L
COMMUNICATIONS TO
(Model S2 only) B ORANGE COMPUTER
M
(Notes 3, 4)
(Note 8)
Notes:
1. Flame relay contacts are shown in de-energized (no flame) condition.
2. Fault relay contacts are shown in de-energized (fault) condition.
3. Brown and orange wires are a twisted pair.
4. Connect cable shield to earth ground at power source.
5. With Remote File Select programmed as “LINE”, external switches SW1/SW2 (not furnished) will
select between two (S1 Models) or four (S2 Models) internal memory files, when connected to 24Vdc
(-) supply.
6. BMS = Burner Management System (by others).
7. External 2.0 Amp fuses recommended.
8. A ground screw is provided on the scanner end plate. An external ground wire must be installed
if line voltage is applied to the relay contacts.
15

REMOTE FILE SELECTION

The InSight scanners have more than one internal memory file. The user has the option of storing
different scanner setpoints for different operating conditions (e.g. Gas / Oil, Pilot / Main, Low Fire /
High Fire, etc.) in these files. The “S1” models have two programmable files (A & B), and “S2”
models have four (A,B,C, & D). With RFS selected as “LINE”, one or two external switches (sup-
plied by user) will select between the files when the RFS1 or RFS2 wires are connected to
24 vdc (-).
RFS1 (Blue) RFS2 (Yellow) File Selected
(Note 1)
Open Open A
Closed Open B
Open Closed C
Closed Closed D
Note 1: RFS2 function is available in the “S2” models only.
Note 2: The user may also select RFS as “KEY” which will allow manual file selection at the
scanner keypad.
Note 3: With FM & UL approved “S2” models, the user may also select RFS as “COMM” which
will allow manual selection at a remote computer running Fireye software. This feature is not
available with CE approved “S2E” models.
Note 4: Fireye recommends the use of shielded cable for the two remote file select switches (or
relays). The switch contacts should be rated for low current operation (3mA dc).
ASSEMBLY INSTRUCTIONS, QUICK DISCONNECT KIT P/N 129-164

FIGURE 14. 59-497 CABLE, CONDUCTOR ORIENTATION
COLOR CODE:
RD BK = BLACK
PK WT/RD
RD = RED
WT = WHITE
BN WT/BK
VT PK = PINK
OR VT = VIOLET
GY = GREY
WT/BU
GY/RD BU = BLUE
YL = YELLOW For ease of assembly, install the 129-164 connector
BU/RD BK/RD BN = BROWN on the 59-497 cable end where the 3 white wires are
YL OR = ORANGE clockwise to the red wire, as shown.
PLUG CONNECTOR
ORANGE GROMMET INSTALLED
16

FIGURE 15. CONNECTOR ASSEMBLY INSTRUCTIONS

.87 ± .04 (22.1 ±1)
129-164C and 129-164RC ONLY
BRAID
.15 - .18 RUBBER WASHER 1/2” FLEXIBLE CONDUIT FITTING
(3.8 - 4.6)
1.75 ± .04
SCANNER CABLE
THREAD ADAPTER
(44.5 ±1)
Inches (mm) METAL WASHER
3.50 ± 0.125 (89 ± 3) (THESE PARTS REPLACE THE SEAL, GRIP AND NUT)
FOR RIGHT ANGLE VERSIONS
CLAMP NUT
HOUSING
(see note)
CABLE SEAL
GROUNDING RING
SCANNER CABLE
59-497
SUPPORT SLEEVE
COUPLING NUT O-RING

(See Note 2)
FEMALE CONTACTS
CABLE GRIP
PLUG CONNECTOR
WITH KIT 129-164R AND 129-164RC, THE RIGHT-ANGLE

ADAPTER IS INSTALLED BETWEEN THE SUPPORT SLEEVE
AND PLUG/COUPLING NUT
CONNECTOR ASSEMBLY STEPS

1. Select 59-497 cable end with the wire color orientation as shown in Figure 14.
2. Slide items along the cable as shown, including coupling nut and O-ring.
3. Remove and discard the black thread protector from the Plug Connector. Leave the orange grommet
installed (see photo, page 16).
4. Strip cable (connector end) in accordance with Figure 15. Slide braid back and forth to loosen, then fold
braid back over cable jacket. Cut and discard foil tape. Solder wires to contacts.
Note 1: To ease contact insertion, you may first pierce the orange grommet’s membrane with a small pin
tool.
5. Slide contacts through orange grommet and into plug connector, per Figure 16 wiring table, until contacts
lock in place.
6. Slide coupling nut up to plug connector and slide O-ring into groove on plug connector.
7. Slide support sleeve back over braid and drain wire then place braid over spring elements of support
sleeve. Clamp braid and drain wire by snapping on the metal grounding ring. Screw housing onto the plug
connector. Torque to 27 lb-in ± .25 lb-in, (3.05N-m ± 0.03 N-m).
8. Assemble cable seal and cable grip to the housing, screw clamp nut onto housing and tighten to 27 lb-in ±
.25 lb-in, (3.05N-m ± 0.03 N-m). “C” and “RC” Kits: Slide the Rubber and Metal Washers into the Hous-
ing and secure with the Thread Adapter. Install the Flexible Conduit Fitting.
Note 2: Class I Division 2 Hazardous Area requirements for InSight scanners with electrical connectors
(non CG models):
17

FIGURE 16. PLUG CONNECTOR PIN LOCATION

REAR VIEW (ORANGE GROMMET / PIN INSERTION SIDE) FRONT VIEW (TOWARDS SCANNER)
A A
J B J
B
K K
H M M H
C C
L L
G F D D F G
E E
FIGURE 17. QUICK DISCONNECT PINS
59-497 Cable Color Pin Number of Quick Function

Disconnect
Black/Red A Power (+) 24 Vdc
White/Blue B Power (-) 24 Vdc
White /Black C Flame Relay (COM)
White/Red D Flame Relay (N.O.)
Red E Fault Relay (COM)
Pink F Fault Relay (N.C.)
Violet G 4-20 mA (+)
Grey/Red H 4-20 mA (-)
Blue/Red J Remote File Select 1
*Yellow K Remote File Select 2
*Brown L Communications A
*Orange M Communications B
* “S2” models only

Note: Brown and orange wires are a twisted pair.
18

FIGURE 18. WIRING OF INSIGHT MODEL “CEX” SCANNERS

SCANNER FRONT PLATE
(SHOWN WITH “CEX” COVER REMOVED) FUNCTION TERMINAL INTERNAL FACTORY WIRE COLORS
COMMUNICATIONS B TB1-1 ORANGE (S2 MODELS ONLY)
KEYPAD/DISPLAY
COMMUNICATIONS A TB1-2 BROWN (S2 MODELS ONLY)
REMOTE FILE SELECT 2 TB1-3 YELLOW (S2 MODELS ONLY)
REMOTE FILE SELECT 1 TB1-4 BLUE
4-20 ma ( - ) TB1-5 GREY
4-20 ma ( + ) TB1-6 VIOLET
24 vdc input power ( - ) TB1-7 WHITE
TB1 TB2
GROUNDING STRAP 24 vdc input power ( + ) TB1-8 BLACK
8 7 6 5 4 3 2 1 (NOT USED) TB2-1 (NOT USED)
(KEYPAD END (NOT USED) TB2-2 (NOT USED)

TB1
OF SCANNER)
(NOT USED) TB2-3 (NOT USED)
INTERNAL FACTORY FLAME RELAY (COM) TB2-4 WHITE/BLACK
WIRING FLAME RELAY (N.O.) TB2-5 WHITE/RED
FAULT RELAY (COM) TB2-6 RED
(KEYPAD END
FAULT RELAY (N.C.) TB2-7 PINK
TB2 OF SCANNER)
(NOT USED) TB2-8 (NOT USED)
1 2 3 4 5 6 7 8
NOTE: Strip 8” (203mm) of the cable jacket and braided shield, leaving the shield drain wire intact. Connect the drain wire to the
scanner’s insulating grounding strap with a #8 (4mm) screw, nut and washer.
WIRING FOR REMOTE COMMUNICATIONS (“S2” models only)

Remote communications with the InSight scanner uses an RS485 Interface to carry the communica-
tion signals. An IBM compatible PC running Fireye software is required to communicate with the
flame scanners. The wiring configuration for remote communications is dependent on the dis-
tance between the scanner and amplifier. For distances less than 200 feet, wire the Fireye cable
P/N 59-497 to the female quick disconnect in the manner previously described, and run the cable
directly back to the burner management system.
For wiring distances greater than 200 feet, remote communications requires wiring a twisted,
shielded pair of wires in a “multi-drop” wiring configuration, and then use a terminating resistor at the
scanner located farthest from the communication source. See “Using Fireye Wiring Harness.”
Note: The maximum distance for the communication wiring for all associated InSight scanners is
4,000 feet. The maximum number of scanners connected to the communication link is 32 scanners.
Exceeding this total wiring length or number of scanners requires the installation of bi-directional
repeaters or amplifiers. Consult factory for additional information.
19

Using Fireye Wiring Harness (P/N 61-6944 -003, -010, -015, -020, -030, -050)
To provide an easy method to wire the non-“CG” model InSight scanners in a “Multi-drop” wiring
configuration for remote communications, Fireye offers a wiring harness in 5 different lengths (3, 10,
15, 20, 30 and 50 ft.). The harness has a pre-wired female quick disconnect to plug into the quick dis-
connect on the scanner. The other end of the wiring harness has a conduit box with a 16 connector ter-
minal strip. Twelve (12) connectors are pre-wired to the female quick disconnect.
Cable Color Function Wiring Harness Wire Cable

Black/Red Power (+) 24 VDC 1
White/Blue Power (-) 24 VDC 2
White /Black Flame Relay (N.O.) 3
White/Red Flame Relay (N.O.) 4
Back to Control Room
59-497 Red Fault Relay (N.C.) 5 (Burner Management System)
Cable
Pink Fault Relay (N.C.) 6
Violet 4-20 mA (+) 7
Grey/Red 4-20 mA (-) 8
Blue/Red File Select 1 9
Yellow File Select 2 10
Brown Communications A 11
Orange Communications B 12
Belden 8761 Black RS485 COM A 11
To next flame scanner
Clear RS485 COM B 12
Belden 8761 Black RS485 COM A 11 To previous flame scanner
(or IC485 converter)
Clear RS485 COM B 12
FIGURE 19. WIRING FOR REMOTE COMMUNICATIONS

1. WHEN THE DISTANCE FROM SCANNER TO CONTROL ROOM< 200 FEET.
59-497 59-497 59-497

CABLE CABLE CABLE
PC WITH
BELDEN 8761 BELDEN 8761 BELDEN 8761 FIREYE
SOFTWARE
RS485-RS232
BURNER BURNER BURNER CONVERTER, P/N IC485
MANAGEMENT MANAGEMENT MANAGEMENT
SYSTEM SYSTEM SYSTEM
2. WHEN THE DISTANCE FROM SCANNER TO CONTROL ROOM >200 FEET.
61-6944 BELDEN 8761 BELDEN 8761 BELDEN 8761 PC WITH

WIRING RS485 FIREYE
HARNESS
COM A RS485-RS232 SOFTWARE
COM B CONVERTER, P/N IC485
59-497 59-497 59-497
CABLE CABLE CABLE
BURNER BURNER BURNER
MANAGEMENT MANAGEMENT MANAGEMENT
SYSTEM SYSTEM SYSTEM
20

FIGURE 20. WIRING HARNESS ASSEMBLY
HARNESS ASSEMBLY NO
Length Part No.
3 ft. 61-6944-003, -003R
10 ft. 61-6944-010, -010R
15 ft. 61-6944-015, -015R
20 ft. 61-6944-020, -020R
30 ft. 61-6944-030, -030R
Safety Ground 50 ft. 61-6944-050, -050R
Belden 8761
Ground Screw for communication 59-497 CABLE (ordered separately)
to other scanners TO BURNER
Scanner Quick Disconnect MANAGEMENT SYSTEM
Connector and Flexible IN OUT
Metal Conduit. Part numbers
ending in “R” e.g.
61-6944-003R, have a 90° EMI CONNECTOR (not included)
quick disconnect. For FIREYE 59-497 cable
Housing Connected
to Earth Ground
1 2 3 4 5 6 7 8 9 10 11 12
Prewired by Factory
21

FIGURE 21. SUGGESTED WIRING FOR COMMUNICATIONS

RS485 communi-
cation; For each RS485 COMMUNICATIONS
individual wiring
TO NEXT WIRING
run, connect HARNESS
shields together. 59-497 to 59-497 to
Control Room Control Room
Connect one end
of the shield cir-
cuit to ground.
Tape and isolate
other end. See
next page for
more details.
BELDEN #8761
(Twisted, shielded
pair) to previous
wiring harness.
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
Flex Conduit Flex Conduit

to Scanner to Scanner
FIGURE 22. WIRING DIAGRAM FOR WIRING HARNESS
COM B — ORANGE
COM A — BROWN 1. CONNECT SHIELDS
RFS2— YELLOW TOGETHER.
2. TAPE SHIELD AT
RFS1— BLUE/RED
LAST WIRING HARNESS
4-20mA (-) — GREY/RED
CLEAR
4-20mA (+) — VIOLET
COM B TO NEXT
FAULT RELAY (N.C.) — PINK SCANNER
FAULT RELAY (C) — RED COM A
TO FLAME
FLAME RELAY (N.O.) —WHITE/RED BLACK
SCANNER
(prewired by FLAME RELAY (C) WHITE/BLACK
factory) (-)24VDC — WHITE/BLUE
(+) 24VDC — BLACK/RED
CONNECT SCANNER SHIELDS BELDEN

TOGETHER AND GROUND AT 8761
BURNER MANAGEMENT
SYSTEM 59-497 1 2 3 4 5 6 7 8 9 10 11 12
TO CONTROL BLACK/RED WHITE/BLUE

TO PREVIOUS
ROOM WHITE/BLACK SCANNER, OR
WHITE/RED CLEAR COM B IC 485 CONVERTER
RED
PINK BLACK COM A
VIOLET
GREY/RED
BLUE/RED
YELLOW
1. CONNECT SHIELDS TOGETHER

2. CONNECT SHIELD TO
EARTH GROUND AT
ORIGIN. (FIRST HARNESS OR PC)
22

GROUNDING AND SHIELDING TECHNIQUES

FOR USE ON SCANNERS OR SCANNER CABLE LOCATED WITHIN 12" OF A HIGH
ENERGY OR HIGH VOLTAGE SOURCE.
1. Connect a safety ground to scanner housing (Figure 13).
2. The scanner and scanner cable (preferably within flexible conduit) MUST be located at least 12"
from the ignition source.
3. Run a ground wire from the ignition transformer chassis to the ignitor assembly.
4. Replace all frayed, cracked, or dirty (oily) ignition wire. Ignition wire must be in good working
condition.
5. Electrically isolate the scanner from the burner using a heat insulating nipple provided with the
surface mounting flange.
6. Cooling/Purge Air must be electrically isolated from the scanner (e.g. isolated short rubber
hose).
SCANNER TO CONTROL ROOM SHIELDING TECHNIQUES

Scanner with scanner cable (59-497) wired Attach braided shield of 59-497 cable to scanner quick disconnect as described.
directly back to burner management system. Use heat insulating nipple on scanner. Connect braided shield of 59-497 cable to
See below for remote communications. earth ground at power supply.
REMOTE COMMUNICATIONS: LESS THAN 200 FEET
Scanner with scanner cable (59-497) wired Attach braided shield of 59-497 cable to scanner quick disconnect as described.
directly back to control room. Use heat insulating nipple on scanner. Connect braided shield of 59-497 cable to
earth ground at power supply.
REMOTE COMMUNICATIONS: GREATER THAN 200 FEET
RS485 communications for scanners wired in a Attach braided shield of 59-497 cable to scanner quick disconnect as described.
multi-drop configuration (Belden 8761) using Use heat insulating nipple on scanner. Connect braided shield of 59-497 to earth
wiring harness or junction box. ground at power supply. Twist together and tape (to electrically isolate) shield
drains from Belden 8761 cables inside each wiring harness or junction box. Con-
nect to earth ground at RS485 source (e.g. IBM computer).
PROGRAMMING THE INSIGHT SCANNER

Keypad/Display:
The InSight flame scanner uses an eight (8) character alphanumeric LED Display and four (4) push-
buttons to review and program the various setpoints and operating parameters. The functions of the
pushbuttons are:
UP/DOWN
The UP and DOWN buttons are used to scroll through the scanner menus. When in the EDIT menu,
after selecting a setpoint to edit, (see SELECT button), the UP and DOWN buttons are used to
change that setpoint.
23

SELECT
When in the EDIT menu, the UP / DOWN buttons are used to display the setpoints. Depressing the
SELECT button displays the stored value of the setpoint, allowing it to be changed.
PROGRAM
The PROGRAM button saves a change made to a setpoint. It is also used to execute the Auto Tune
function (“S2” Models only) or Pre-Edit function (“S1” Models only).
INSIGHT MENU STRUCTURE

For ease of operation, the InSight scanner contains three menus (or loops) accessed via the keypad
and viewed on the scanner’s display.
STATUS MENU
The Status menu is the default display, and appears as soon as power is applied. Use the UP and
DOWN buttons to scroll through the menu and view the current operating status. No operating
parameters can be changed from the Status menu. To change any setpoint, you must enter a four digit
password then enter the Edit, or Pre-Edit (“S1”) or AutoTune (“S2”) menus.
EDIT MENU
The Edit Menu contains all the user-selected setpoints for the InSight scanner. The Edit menu is
entered from the Status menu after first entering a four-digit password. In the Edit menu, the user is
allowed to change the setpoints to optimize the scanner performance.
PRE-EDIT MENU (“S1” Models only)

From the Pre-Edit menu, the user views the flame signal intensity and physically aims the scanner
for optimum signal. The user then commands the scanner to set an appropriate internal front-end
gain (FEG) level. As with the Edit menu, the Pre-Edit menu is entered from the Status menu after
first entering a four-digit password.
AUTOTUNE MENU (“S2” Models Only)

From the AutoTune menu, the user views the flame signal intensity and physically aims the scanner
for optimum signal.The user then commands the InSight scanner to analyze the flame ON and OFF
(background radiation) conditions, and automatically select the optimum setpoints. As with the Edit
menu, the AutoTune menu is entered from the Status menu after first entering a four-digit password.
24

FIGURE 23. INSIGHT SCANNER MENU STRUCTURE
STATUS
LOOP
FQ O PASSWORD
Note 1 AUTOTUNE (“S2”) EDIT Note 1

OR
NOTE 1: If the password is not entered, access to PRE-EDIT (“S1”)
the EDIT, PRE-EDIT and AUTO TUNE loops are
denied. Pressing the (s) UP KEY advances the
display directly to “FQ O”.
AUTOTUNE (“S2”) EDIT

OR LOOP
PRE-EDIT (“S1”)
LOOP
25

THE STATUS MENU

FIGURE 24. STATUS MENU LOOP
NOTE 3
Keypad Legend FILE A iO uO
UP Key (Scrolls through menu, clockwise)

T=46C COMM 0 NOTE 4
DOWN Key (Scrolls through menu, counter
clockwise)
SELECT Key
FLAME OFF SOFTWARE
REVISION
PROGRAM Key
NOTE 1: If the password is not entered,

access to the EDIT, PRE-EDIT and AUTO MAX 51C
TUNE loops are denied. Pressing the (s) UP START HERE
KEY advances the display directly to “FQ
O”. FQ 0
NOTE 2: Refer to PASSWORD section for PASSWORD NOTES 1 & 2
further details. NOTE 1
NOTE 3: Dual sensor model shown (IR & AUTOTUNE (“S2”)

UV). OR
PRE-EDIT (“S1”) EDIT
NOTE 4: Communications available in “S2”
models only.
TO PRE-EDIT (“S1”) TO EDIT MENU LOOP

OR AUTOTUNE (“S2”)
MENU LOOP
FIGURE 25. THE STATUS MENU
TEXT DISPLAYED DESCRIPTION POSSIBLE VALUES

FQ 0 Flame Quality (scanner output) 0-100
FLAME OFF Flame Relay status ON, OFF
T= 46C Present Scanner temperature +32°F to 212°F (0°C to 100°C)
File A Scanner file in operation A,B,C,D
i0 u0 Signal strength, IR and UV (dual sensor models) 0-999
COMM 0 Communication address (“S2” models only) 0-127
FIREYE INSIGHT 95XXXX Scanner part number and software revision
VX.X
MAX XXX°C (XXX°F) Scanner Temperature, exposure (stored) maximum -40° F to 185°F (-40°C to 85° C)
PASSWORD A Password is required to enter the EDIT, PRE-EDIT or AutoTune 0000-9999
menus. See PASSWORD section.
26

Flame Quality
The “Flame Quality” number can range from 0 to 100. It represents the scanner’s 4-20 mA analog
flame signal strength OUTPUT (in percent), and is the scale by which the internal Flame Relay ON
and OFF thresholds are set.
The “Flame Quality” number is determined by the input of the IR and / or UV sensor, (in dual sensor
models it is the sum of the two). This sensor signal strength value can be viewed in the Status menu
as “Signal Strength”, see description below.
For clarity, the “Flame Quality” number is capped at 100, while under certain firing conditions the
IR or UV “signal strength” (or their sum) may normally exceed 100 (maximum of 999).
In normal burner operation after the scanner has been properly setup, “FQ 100” will be displayed
with occasional movement depending on the stability of the flame.
Flame ON/OFF
This item refers to the energized / de-energized status of the internal Flame relay. “Flame ON” is dis-
played when the flame quality rises above the relay “On Threshold” set in the Edit menu. When the
flame quality drops below the relay “Off Threshold”, “Flame OFF” will be displayed.
Temperature
The scanner’s present temperature in degrees, expressed in either Fahrenheit or Centigrade depend-
ing on which was selected in the Edit menu.
File Selected
The current running file is displayed. Choices are files “A, B” for S1 Models, and files “A, B, C, D”
for S2 Models.
Signal Strength
The Signal Strength number represents the intensity of the “flame flicker”, as sensed by the IR and /
or UV sensor(s), and is a function of the individual sensor “Gain” and “Bandpass” (flicker fre-
quency) settings. The Signal Strength number is related to the Flame Quality number (see Signal
Strength expanded description on following page).
Comm Address (“S2” Models Only)

This number refers to the remote communications address of the scanner. The address can range
from 0 to 127, as selected in the Edit menu. No two scanners in a communications loop should have
the same address.
Software Revision
This displays the part number and internal software revision.
Maximum Temperature
This displays the highest scanner temperature recorded.
Password
A four-digit Password is required to enter the EDIT and AUTOTUNE menus. If a Password is not
entered, pressing the UP key will advance directly to the “Flame Quality” display, pressing the
DOWN key will return to the “Maximum Temperature” display.
To enter the EDIT or AUTOTUNE menus, you must enter the four-digit Password. The following
example is for the factory installed password of 0205:
27

1. With “PASSWORD” displayed, depress the SELECT key. “0xxx” will be displayed, the first
digit (“0”) is adjustable. (If the factory password was changed, use the UP/DOWN keys to select
the appropriate first digit).
2. With the first digit selected (e.g. “0xxx”) depress the PROGRAM key. “00xx” will be displayed,
the second digit (“0”) is adjustable. Depress the UP key twice to display “2”. (If the factory
password was changed, use the UP/DOWN keys to select the appropriate second digit).
3. With the second digit selected (e.g. “02xx”) depress the PROGRAM key. “020x” will be dis-
played, the third digit (“0”) is adjustable. (If the factory password was changed, use the UP/
DOWN keys to select the appropriate third digit).
4. With the third digit selected (e.g. “020x”) depress the PROGRAM key. “0200” will be dis-
played, the fourth digit (“0”) is adjustable. Depress the UP key five times to display “5”. (If the
factory password was changed, use the UP/DOWN keys to select the appropriate fourth digit).
5. With all four digits selected (e.g. “0205”) depress the PROGRAM key.
If the Password was not entered correctly, the display will read “Wrong Password”. Depress the
SELECT key to re-enter the password.
If the Password was entered correctly, the display will read “Valid Password. Press SELECT to
change password”. If you wish to change the password at this time, see the “Change Password” sec-
tion below. Otherwise, depress the UP key to advance to the EDIT and AUTOTUNE menus.
Entering the correct Password allows the user 20 minute access to the EDIT and AUTOTUNE
menus. Saving any parameter will re-start this 20 minute time-out period.
Change Password
The user may change the password (the factory set password is “0205”) to any four-digit code
desired. To change the password, you first enter the current password as described above.
When the display reads “Valid Password. Press SELECT to change password”, press the SELECT
key and “0xxx NEW” is displayed, the first digit (“0”) is adjustable. For example, enter a NEW pass-
word of “1357”. Use the UP/DOWN key and the PROGRAM key (as described in the above section)
to enter the new password. When complete, in this example the display will now read “New pass-
word 1357”. Depress the UP/DOWN keys to return to the menu loops.
Signal Strength & Flame Quality (FQ), Expanded Description

Single sensor models (Type 95IR, 95UV): The value of Signal Strength is the same as the “Flame
Quality” number except that the Signal Strength value is allowed to exceed 100 (maximum of 999)
while “Flame Quality” is capped at 100.
Dual sensor models (Type 95DS): This screen shows the individual sensor’s contribution to the
Flame Quality number. Each value is preceded by the corresponding lower case letter indicating
whether it is the IR (i) or UV (u) sensor. Under most firing conditions, the sum of these individual
values will exceed 100 (maximum of 999).
Important Note: The Flame Quality number is the Flame Signal number, but is capped at 100. In
dual sensor (95DS) models, it is the sum of the IR + UV Signal Strength numbers, but the sum is
capped at 100.
Example 1 (Single Sensor Model 95IR, infrared):
If “I 80” is displayed as signal strength, you would see a Flame Quality number of “FQ 80” dis-
played on the Flame Quality screen.
If “I 120” is displayed as signal strength, you would see a Flame Quality number of “FQ 100” on the
Flame Quality screen, because Flame Quality is capped at 100.
Example 2 (Dual Sensor Model 95DS):
If “i80 u15” is displayed as signal strength, you would see a Flame Quality number (the IR and UV
signal sum) of “FQ 95” displayed on the Flame Quality screen.
If “i70 u 40” is displayed as signal strength, although the sum is 110, you would see a Flame Quality
number of “FQ 100” on the Flame Quality screen, because Flame Quality is capped at 100.
28

THE EDIT MENU

FIGURE 26. EDIT MENU LOOP
DOWN Key (Scrolls through menu, counter clockwise)
SELECT Key
PROGRAM Key
P
IR RANGE IRR HIGH UV BAND u70/0
IR GAIN iG1/0 UV GAIN uG1/0
IR BAND i 70/0 UV RANGE UVR HIGH
SENSORS UV & IR ON THRESHOLD ONT 40
LANGUAGE ENGLISH OFF THRESHOLD OFFT 20
FILE COPY A
FFRT FFRT 1
REMOTE FILE SELECT RFS KEY

OTD OTD 1
COMM ADDRESS COMM O

--EXIT--
TEMPERATURE SCALE SCALE C
FILE SELECT FILE A
FROM “EDIT”
ON STATUS MENU
LOOP
NOTE 1: Dual Scanner model shown. If scanner is single sensor model (IR of UV) only the appropriate parameter will be displayed (e.g.
SENSORS, BAND, GAIN, RANGE).
NOTE 2: Communications available with “S2” models only.
NOTE 3: The PROGRAM Key is used to accept a value change for all parameters except IR/UV Gain and IR/UV Band. For these
parameters, the value change is accepted immediately.
29

FIGURE 27. THE EDIT MENU
TEXT DISPLAYED DEPRESS ‘SELECT’ KEY, TEXT DISPLAYED POSSIBLE VALUES (UP/DOWN KEYS)
File Select FILE A “S1” models: A.B
“S2” models: A.B, C, D
Temperature Scale Scale C C, F
Comm address (“S2” only) COMM 0 0-127
Remote File Select RFS KEY “S1” models: KEY, LINE
“S2” models: KEY, LINE, COMM*
*(Comm not available in “E” models)
File Copy A-> (See File Copy Section)
Language English English
Sensors (Dual Sensor Models UV + IR UV + IR, IR Only, UV Only
Only)
IR Band i70/ 0 (IR Frequency selected/Signal strength) “S1” Models: 23, 70, 117
“S2” Models: 23, 31, 39, 46, 54, 62,
70, 78, 85, 93, 101, 109, 117, 125,
132, 140, 148, 156, 164, 171, 179
Hz
IR Gain iG1 / 0 (IR Gain selected/ Signal strength) 1 - 31

IR Range IRR HIGH HIGH, LOW
UV Band u70/ 0 (UV Frequency selected/Signal strength) “S1” Models: 23, 70, 117
“S2” Models: 23, 31, 39, 46, 54, 62,
70, 78, 85, 93, 101, 109, 117, 125,
132, 140, 148, 156, 164, 171, 179
Hz
UV Gain uG1 / 0 (UV Gain selected/ Signal strength) 1 - 31

UV Range UVR HIGH HIGH, LOW
On Threshold ONT 40 5 - 100
Off Threshold OFFT 20 0 - 95
FFRT FFRT 1 1, 2, 3, 4, 5, 6 seconds
OTD OTD 1 1, 2, 3, 4, 5, 6 seconds
--EXIT-- Edit (Returns you to STATUS loop)
THE EDIT MENU

The values of the menu choices are viewed by pressing the SELECT button. (To exit the viewed
value without changing it, press the SELECT button again). To change a value, press the UP /
DOWN keys until the desired value is displayed. Depress the PROGRAM button. The display will
scroll “Parameter saved”, then automatically de-select the menu choice as if the SELECT button had
been pressed. See important note below.
IMPORTANT NOTE:
In order to immediately see the effect of a setpoint change upon the “Signal Strength” number, some
parameter values are changed and saved immediately via the UP / DOWN keys, and do not require
depressing the PROGRAM key. These parameters include IR Band, UV Band, IR Gain, and UV
Gain. The “Signal Strength” number is displayed to the right of the parameter value on the same
screen, providing the user instantaneous feedback.
Note: You may only Edit the File that the scanner is currently running. For example, to Edit file
“B”, you must be currently running file “B”. (See File Select section below).
Exceptions: A change made to the Temperature Scale, Comm Address, Remote File Select, and
Language parameters, can be made in any file and the new values will be automatically saved to
all files.
30

File Select
The user can manually choose which file to run (and to Edit) by selecting this menu choice provided
the Remote File Select “KEY” choice is selected (see below). If the user wants to Edit the contents of
a file, they must first select and run that particular file. (See “exceptions” in note above).
Temperature Scale
(Affects all files)
The scale may be selected to be Fahrenheit “F”, or Celsius “C”.
Comm Address (“S2” Models Only)

(Affects all files)
The communications address selected may range from 0 to 127. Each scanner must have a unique
address. No two scanners in a communications loop can have the same address.
Remote File Select

(Affects all files)
Choices are KEY, LINE, COMM*
KEY allows the file selection to be made only at the scanner keypad
(See File Select menu choice above).
LINE allows the file selection to be made only via an external switch or relay.
COMM allows the file selection to be made only via an external computer running Fireye Software.
This feature is only available with FM & UL approved “S2” models. This feature is not available
with CE approved “S2E” models.
FileCopy
This function allows the user to copy the contents of one internal scanner file to another. “S1”
Models have two user configurable files, “A,B”, plus two factory configured files, “F1, F2”. “S2”
Models add two additional user files, “C, D”.
Refer to “FILE COPY INSTRUCTIONS” for details.
Language
(Affects all files)
This allows the user to select which language the menu system will use. The available choice is
“English”.
Sensors (dual sensor units only, Type 95DS)

Choices include: UV only, IR only, or UV+IR
This parameter is used to manually select which sensor(s) are used in a particular file.
IR Band
The display is broken into two halves. The left side displays the selected IR flicker frequency (band-
pass). The right side displays the signal strength attributed to the IR sensor.
For example with a model “S2” scanner, “i 23 / 80” indicates that 23Hz is selected and the current
signal strength is 80 (as viewed in the Status loop).
Frequency choices range from 23Hz to 179Hz (“S2” models), or from 23Hz, 70Hz, 117Hz (“S1”
models). The signal strength number can range from 0-999.
Note: Remember that while the signal strength number can range to 999, the “Flame Quality” num-
ber viewed in the Status menu is capped at 100. In dual sensor models the “Flame Quality” number
is the sum of the IR and UV sensor signal strengths, capped at 100.
Pressing the UP and DOWN keys changes the frequency displayed and immediately stores the value
(pressing the PROGRAM key is not required). The user will immediately see the effect on the signal
strength number displayed on the right side of the display.
31

IR Gain
The display is broken into two halves. The left side displays the selected IR Gain. The right half dis-
plays the signal strength attributed to the IR sensor.
The IR sensor Gain is selectable from 1 (lowest) to 31 (highest). The signal strength number can
range from 0-999.
Pressing the UP and DOWN keys changes the IR Gain displayed and immediately stores the value
strength number displayed on the right side of the display. See MANUAL ADJUSTMENT note at
the end of this section.
IR Range
There are two selectable internal “ranges” for the IR sensor Gain, “High” and “Low”. If, when
“Aiming” the scanner, a flashing IR number is observed, then the signal is over-range and the
“Range” should be set to “LOW”. If, when “Aiming” the scanner, an IR number of less than 10 is
observed, then the gain Range should be set to “HIGH”. Refer to application note on page 36.
UV Band
The display is broken into two halves. The left side displays the selected UV flicker frequency
(bandpass). The right side displays the signal strength attributed to the UV sensor.
For example with a model “S2” scanner, “u 23 / 80” indicates that 23Hz is selected and the current
signal strength is 80 (as viewed in the Status loop).
Frequency choices range from 23Hz to 179Hz (“S2” models), or from 23Hz, 70Hz, 117Hz (“S1”
models). The signal strength number can range from 0-999.
Pressing the UP and DOWN keys changes the frequency displayed and immediately stores the value
strength number displayed on the right side of the display.
UV Gain
The display is broken into two halves. The left side displays the selected UV Gain. The right half dis-
plays the signal strength attributed to the UV sensor.
The UV sensor Gain is selectable from 1(lowest) to 31(highest). The signal strength number can
range from 0-999.
Pressing the UP and DOWN keys changes the UV Gain displayed and immediately stores the value
strength number displayed on the right side of the display. See MANUAL ADJUSTMENT note at
the end of this section.
UV Range
There are two selectable internal “ranges” for the UV sensor Gain, “High” and “Low”. If, when
“Aiming” the scanner, a flashing UV number is observed, then the signal is over-range and the
“Range” should be set to “LOW”. If, when “Aiming” the scanner, a UV number of less than 10 is
observed, then the gain Range should be set to “HIGH”. Refer to application note on page 36.
32

On Threshold
This refers to the “pull-in” threshold of the internal Flame Relay, in terms of “Flame Quality”. The
ON Threshold can be set from 5 to 100. The ON Threshold must be at least 5 units higher than the
OFF Threshold.
When the Flame Quality is equal to or greater than the ON Threshold (for a time equal to the “On
Time Delay setting, see below), the flame relay will energize.
Off Threshold
This refers to the “drop-out” threshold of the internal Flame Relay, in terms of “Flame Quality”. The
OFF Threshold can be set from 0 to 95. The OFF Threshold must be at least 5 units lower than the
ON Threshold.
When the Flame Quality is equal to or less than the OFF Threshold (for a time equal to the “Flame
Failure Response Time” setting, see below), the flame relay will de-energize.
FFRT
When the Flame Quality drops to or below the Flame Relay OFF Threshold, the Flame relay will de-
energize after the selected Flame Failure Response Time (FFRT). The choices range from 1 to 6 sec-
onds. The maximum allowable FFRT setting is determined by local safety code, and is factory
selected at 1 second.
OTD
When the Flame Quality rises to or above the Flame Relay ON Threshold, the Flame relay will ener-
gize after the selected On Time Delay (OTD). The choices, range from 1 to 6 seconds.
--EXIT--
Pressing the SELECT key will return the user to the “Edit” display in the Status menu.
FILE COPY INSTRUCTIONS

EXAMPLE:
This function allows the user to copy the contents of one internal scanner file to another. “S1” Mod-
els have two user configurable files, “A, B”, plus two factory configured files, “F1, F2”. “S2” Mod-
els add two additional user files, “C, D”.
You may copy from any file to a user file. You are not allowed to copy from a user file to a factory
file. You must first enter the source file, then the destination file.
The Factory Configured Files (“F1” and “F2”) contain factory default settings.
In File “F1”, the sensor gain is set at maximum (31) and the flicker frequency is set at 23 Hz. At
these settings the scanner will respond to flame but will not likely discriminate between the target
flame and other nearby flames.
In File “F2”, the sensor gain is set at minimum (1) and the flicker frequency is set at 70 Hz. At
these settings the scanner will not likely respond to flame until the scanner gain is increased.
Note: As shipped, all user files (A, B, C, D) contain the same setpoints as factory file “F2”.
EXAMPLE:
With “FileCopy” displayed (EDIT menu), depress the SELECT key. The display will read “AÔ”
with “A” being the source file. Use the UP/DOWN keys to select a different source file if desired.
With the desired source file displayed, press the PROGRAM key. The arrow will flash and the desti-
nation file will appear (e.g. “A Ô A”). Initially the destination is displayed is “A”. Use the UP/
DOWN keys to select the desired destination file (e.g. “A Ô B”).
Press the PROGRAM key to copy the source file to the destination file. The display will read “File
Copied”. (Pressing the SELECT key at any time before pressing the PROGRAM key for the second
time will cancel the operation).
Press the UP/DOWN keys to scroll through the EDIT loop.
33

Manual Adjustment of IR or UV Gain

When manually adjusting the IR and / or UV “Gain” in the EDIT loop, the display will show both the
selected gain (1-31), and the Signal Strength (Sensor Flame Quality) number (0-999) associated with
either the IR or UV sensor, e.g. “iG30 / 80”, “uG12 / 40”. (In this case, the total Flame Quality is
“120”, and the FQ number viewed in the Status loop would be 100 [capped at 100]).
Each increment of the gain will increase the Signal Strength (Sensor Flame Quality) number for the
selected sensor by 50%. In the above example, changing the UV sensor gain from 12 to 13 would
increase the UV Signal Strength from 40 to 60. Decreasing the IR sensor gain from 30 to 29 would
decrease the IR Signal Strength from 80 to 53. (In this case, the total Flame Quality is “113”, and the
FQ number as viewed in the Status loop would be 100 [capped at 100]).
For best scanner operation, the total Flame ON Signal Strength (IR Signal Strength + UV
Signal Strength) should be between 100 and 150 or higher even though the Flame Quality
display (Status Loop) is capped at 100.
34

THE PRE-EDIT MENU (“S1” Models only)

FIGURE 28. THE PRE-EDIT MENU LOOP (“S1” Models Only)
Keypad Legend
SELECT Key
PROGRAM Key
RUN FLAME AT
SET FEG LOWEST SETTING FEG IS SET
AND PRESS PROGRAM
AIM SCANNER IO UO
--EXIT--
FROM “PRE-EDIT”
ON STATUS MENU
FIGURE 29. THE PRE-EDIT MENU (“S1” Models Only)
TEXT DISPLAYED DEPRESS “SELECT” KEY DEPRESS “PROGRAM” KEY

TEXT DISPLAYED TEXT DISPLAYED
Aim Scanner I0 U0
(Possible values 0-60)
Set FEG Run flame at lowest setting and press PROGRAM FEG is set
--Exit-- Pre-Edit (Returns you to STATUS loop)
Pre-Edit is an automatic calibration function whereby the scanner sets an appropriate internal front-
end gain (FEG) level. The appropriate choice of modulation BAND (flame flicker frequency), and
sensor GAIN is later manually set up in the EDIT menu.
Pre-Edit and Manual Set-up is performed in 3 steps:
1. In the PRE-EDIT menu, run the target flame at the low firing rate and physically aim the scan-
ner for peak signal strength (as observed at the “Aim Scanner” prompt). Depress the Program
key at the “Set FEG” prompt and the scanner will set an appropriate internal front-end gain
(FEG) level.
2. In the EDIT menu, observe and record the flame ON and flame OFF sensor signal strength and
stability at each of the three modulation bands. Select the modulation band that yields the great-
est Flame ON to Flame OFF signal ratio and/or yields the greatest stability.
3. Adjust the sensor GAIN and flame relay ON and OFF thresholds for reliable on/off operation.
35

Aim Scanner
When SELECT is depressed, “Ix Ux” is displayed (dual sensor models). The value of “x” may range
from 0 to 60. The value displayed represents the flame flicker intensity of the flame for the entire
flicker frequency spectrum as individually sensed by the UV (U) sensor and/or IR (I) sensor(s).
The numbers should be at their peak (highest numerically) when the scanner is aimed at the primary
combustion zone (first 1/3) of the flame. If the scanner is equipped with both an IR and UV sensor,
priority should be given to maximizing the UV intensity.
Run the flame at low fire rate and observe the signal intensity.
Physically aim the scanner at the first 1/3 of the flame to maximize the intensity reading. (Allow the
scanner reading to stabilize two seconds after each movement.)
If the reading is l0 or less, the intensity is marginal. Verify that the appropriate sensor “Range”
parameter (IR Range or UV Range) in the Edit menu is set to “HIGH”.
If the reading is greater than 26 (the number will blink) the signal is excessive. Verify that the appro-
priate sensor “Range” parameter (IR Range or UV Range) in the Edit menu is set to “LOW”.
Application Note: In rare applications where the flame is extremely bright, it is possible to satu-
rate the sensor. The symptom could be a very low signal, an erratic signal, or no signal at all. If
this situation is suspected, the installation of a sight-pipe orifice (kit P/N 53-121) is recom-
mended.
Set FEG
Run the flame at low fire and press the PROGRAM button. The scanner will set an appropriate inter-
nal front-end gain (FEG) level based upon the flame intensity (brightness) then display “FEG is set”.
--EXIT--
Pressing the SELECT key will return the user to the “Pre-Edit” menu choice of the main status
menu.
Manual Set-up in Edit menu (“S1” Models only)

In the EDIT menu with the target flame ON (at low fire), observe and record the sensor signal
strength and stability at each of the three modulation BANDS: 23, 70, and 117 Hz. The signal
strength display has a range of 0-999.
During set-up it may be necessary to adjust the sensor GAIN in order to keep the signal strength
value on scale. If so, observe and record the sensor GAIN value (1-31) selected.
With dual sensor models, perform this step for each sensor.
In the EDIT menu with the target flame OFF (leaving other burners firing), observe and record
the sensor signal strength and stability at each of the three modulation BANDS: 23, 70, and 117 Hz.
Do not adjust the sensor GAIN at this time.
At each of the three modulation frequencies, compare the recorded Flame ON signal strength
to the recorded Flame OFF signal strength. Select the modulation BAND that yielded the greatest
Flame ON to Flame OFF signal ratio and/or yielded the greatest stability.
Adjust the sensor gain (1-31) so that the flame ON signal strength is well above the flame relay ON
threshold, and the flame OFF signal strength is well below the flame relay OFF threshold (see
“Flame Relay Thresholds” on following page).
When manually adjusting the IR and / or UV “Gain” in the EDIT loop, the display will show both the
selected gain (1-31), and the Signal Strength (Sensor Flame Quality) number (0-999) associated with
either the IR or UV sensor, e.g. “iG30 / 80”, “uG12 / 40”. (In this case, the total Flame Quality is
“120”, and the FQ number viewed in the Status loop would be 100 [capped at 100]).
36

Each increment of the gain will increase the Signal Strength (Sensor Flame Quality) number for the
selected sensor by 50%. In the above example, changing the UV sensor gain from 12 to 13 would
increase the UV Signal Strength from 40 to 60. Decreasing the IR sensor gain from 30 to 29 would
decrease the IR Signal Strength from 80 to 53. (In this case, the total Flame Quality is “113”, and the
FQ number as viewed in the Status loop would be 100 [capped at 100]).
For best scanner operation, the total Flame ON Signal Strength (IR Signal Strength + UV
Signal Strength) should be between 100 and 150 or higher even though the Flame Quality dis-
play (Status loop) is capped at 100.
Example:
At the selected BAND the Flame ON signal ranged from 800 to 999, and the Flame OFF signal
ranged from 50 to 130 (a 6:1 on/off ratio).
The user must reduce the sensor gain so that flame ON signal strength is well above the flame relay
ON threshold (factory programmed at 40), and the flame OFF signal strength is well below the flame
relay OFF threshold (factory programmed at 20).
In this example, the user may reduce the gain to have a flame OFF signal of 0, and a flame ON signal
of 150.
Special Note for Dual Sensor Models:
With dual sensor models, the flame relay and 4-20 mA output will operate on the SUM of both the
IR and UV signals. When setting the final GAIN adjustments, the user should favor the sensor (IR or
UV) which exhibited the greatest flame ON:OFF signal ratio, and/or greatest stability.
If the user chooses to use the input from only one sensor and disable the input from the other, he may
do so by selecting “IR ONLY” or “UV ONLY” as Sensors in the Edit menu.
Flame Relay Thresholds

The flame relay has a factory programmed FLAME ON threshold of 40, and a FLAME OFF thresh-
old of 20 (0-100 scale). With these settings, it is recommended that the flame ON signal normally be
at least 150. Other on and off thresholds may be selected to suit particular applications.
CAUTION: After selecting Sensor TYPE, Sensor BAND, Sensor GAIN, and Flame Relay
ON & OFF Thresholds, proper flame detection and flame discrimination must be verified
by starting and stopping the burner several times. The flame relay must reliably de-energize
for all flame out conditions. This testing should be done with various adjacent burners on
and off, and at various load levels. This is a requirement for proper operation.
37

THE AUTOTUNE MENU (“S2” Models only)

FIGURE 30. THE AUTOTUNE MENU LOOP (“S2” Models only)
Keypad Legend
SELECT Key
PROGRAM Key
TURN FLAME OFF WAIT 128 ‘ 0

LEARN OFF LEARN OFF
AND PRESS PROGRAM COMPLETE
WAIT 128 ‘ 0
RUN FLAME AT LEARN OFF
LEARN ON LOWEST SETTING COMPLETE
AND PRESS PROGRAM
AIM SCANNER IO UO
--EXIT--
TO “AUTOTUNE”
ON STATUS MENU
LOOP
FIGURE 31. THE AUTOTUNE MENU (“S2” Models Only)
TEXT DISPLAYED DEPRESS “SELECT” KEY DEPRESS “PROGRAM” KEY

TEXT DISPLAYED TEXT DISPLAYED
Aim Scanner I0 U0
(Possible Values 0-60)
Learn On Run Flame at Lowest setting and press WAIT 128 – 0
PROGRAM (Counts down to 0 within 20 seconds, then
displays “Learn ON complete“)
LearnOff (only displayed if Learn ON had Turn Flame OFF and press PROGRAM WAIT 128 – 0
been performed) (Counts down to 0 within 20 seconds, then
displays “Learn OFF complete”)
--Exit-- AutoTune (Returns you to STATUS loop)
AutoTune is an automatic calibration function whereby the InSight scanner scans the flame flicker
frequency spectrum with flame ON, and with flame OFF (background radiation present). The scan-
ner will then select the appropriate sensor gain, bandpass frequency, and sensor range for optimum
flame ON: OFF discrimination. The scanner will also select the optimum Flame Relay ON and OFF
thresholds.
38

AutoTune is performed in 3 steps:

1. Run the target flame at the low firing rate. Enter the AutoTune menu loop, press the UP key until
“AIM SCANNER” is displayed then press SELECT. Physically aim the scanner for peak signal
strength as described in the “Aim Scanner” section below. Press the UP key when complete.
2. Press the UP key until “LEARN ON” is displayed then press SELECT. Press PROGRAM and the
scanner will memorize the flame ON condition as described in the “Learn ON” section below. Press
the UP key when complete.
3. Turn the target flame off. Press the UP key until “LEARN OFF” is displayed then press SELECT.
Press PROGRAM and the scanner will memorize the flame OFF condition as described in the “Learn
OFF” section below. Press the UP key when complete.
Aim Scanner
Scroll to “AIM SCANNER” and press the SELECT key.
When SELECT is depressed, “Ix Ux” is displayed (dual sensor models). The value of “x” may range from
0 to 60. The value displayed represents the flame flicker intensity of the flame for the entire flicker fre-
quency spectrum as individually sensed by the UV (U) sensor and/or IR (I) sensor(s).
The numbers should be at their peak (highest numerically) when the scanner is aimed at the primary com-
bustion zone (first 1/3) of the flame. If the scanner is equipped with both an IR and UV sensor, priority
should be given to maximizing the UV intensity.
Run the flame at low fire rate and observe the signal intensity.
Physically aim the scanner at the first 1/3 of the flame to maximize the intensity reading. (Allow the scan-
ner reading to stabilize two seconds after each movement).
If the reading is l0 or less, the intensity is marginal. Verify that the appropriate sensor “Range” parameter
(IR Range or UV Range) in the Edit menu is set to “HIGH”.
If the reading is greater than 26 (the number will blink) the signal is excessive. Verify that the appropriate
sensor “Range” parameter (IR Range or UV Range) in the Edit menu is set to “LOW”.
When scanner is properly aimed, press the UP key.
Application Note: In rare applications where the flame is extremely bright, it is possible to saturate
the sensor. The symptom could be a very low signal, an erratic signal, or no signal at all. If this situ-
ation is suspected, the installation of a sight-pipe orifice kit (P/N 53-121) is recommended.
Learn ON
Scroll to “LEARN ON” and press the SELECT key.
Run the flame at low fire and press the PROGRAM button. The scanner will display “Wait” followed by a
number that will count down from 128 to 0 in about 20 seconds. This will temporarily store the spectrum
of the monitored flame and the adjacent flames. The front-end gain number, used in the ON/OFF calcula-
tion, will be stored at this time. Press the UP key when complete.
Learn OFF
Scroll to “LEARN OFF” and press the SELECT key.
Turn off the monitored flame leaving adjacent flames operating, then press the PROGRAM button. The
scanner will display “Wait” followed by a number that will count down from 128 to 0 in about 20 seconds.
This will temporarily store the spectrum of the adjacent flames.
The “ON” spectrum will then be compared to the “OFF” spectrum and the frequency and gain for opti-
mum discrimination will be selected.
The IR and UV gain settings will be automatically selected based on the proportionality of their flame
ON: OFF ratios. (On dual sensor models, the contribution of the IR and UV signal strengths to the Flame
Quality is also determined at this time by the selection of their respective gain numbers. The gain settings
will be selected to yield a total “signal strength” of between 100 and 150, which would yield a Flame
Quality number of 100.
The Flame relay ON and OFF thresholds will be automatically set to 40 and 20, respectively, unless the
“off” signal level is exceptionally high, which usually indicates poor aiming of the scanner.
Note: If after learning flame OFF, an insufficient on/off ratio is not found in at least one sensor, the dis-
play will show, “Warning: Poor discrimination, try re-aiming scanner”.
Press the UP key when complete.
--EXIT--
Pressing the SELECT key will return the user to the “AutoTune” menu choice of the main menu.
39

CAUTION: After selecting Sensor TYPE, Sensor BAND, Sensor GAIN, and Flame
Relay ON & OFF Thresholds, proper flame detection and flame discrimination must be
verified by starting and stopping the burner several times. The flame relay must reliably
de-energize for all flame out conditions. This testing should be done with various adja-
cent burners on and off, and at various load levels. This is a requirement for proper
operation.
FIGURE 32. INSIGHT SCANNER MENU STRUCTURE
STATUS
LOOP
FQ O PASSWORD
Note 1 AUTOTUNE (“S2”) EDIT Note 1

OR
NOTE 1: If the password is not entered, access to the EDIT, PRE-EDIT (“S1”)
PRE-EDIT and AUTO TUNE loops are denied. Pressing the (s)
UP KEY advances the display directly to “FQ O”.
AUTOTUNE (“S2”) EDIT

OR LOOP
PRE-EDIT (“S1”)
LOOP
Scanner Set-up Procedure (All Models)

The following programming steps should be taken after reading and understanding the Pro-
gramming and Menu Structure sections of this document.
When changing parameter values in the EDIT loop, it is necessary to depress the “Program” button
to save each change individually. (The only exceptions are when manually adjusting the IR or UV
Band or Gain; these changes are saved immediately). For example, to change the Temperature Scale
from “C” to “F”, perform the following steps:
A. With “Temperature Scale” displayed, depress the SELECT key. “Scale C” will be displayed.
B. Depress either the UP or the DOWN key until “Scale F” is displayed.
C. Depress the PROGRAM key. “Parameter Saved” will be displayed, then “Temperature Scale”
will be again displayed.
D. Depress the UP or DOWN key to advance to the next parameter.
The following procedure may be performed before placing the burner into service:
1. Depress the DOWN key until “Password” is displayed.
2. Depress the SELECT key and “0xxx” will be displayed. Enter the password, as described on
page 27, then depress the PROGRAM key. “Valid Password” will be displayed.
3. Depress the UP key and “Edit” will be displayed. Depress the SELECT key to enter the EDIT
loop. The first parameter “File Select” will be displayed.
4. Select the desired File (File Select), Temperature Scale, Communications (Comm) Address, and
Remote File Select method.
5. Select IR Range “High”, and/or UV Range “High”.
40

6. Select the desired Flame Failure Response Time (FFRT) and On-Time Delay (OTD).
7. Depress the UP key until “-Exit-” is displayed.
8. Depress the SELECT key to return to the status loop. (“Edit” will be displayed).
“S1” Models: The following procedure is performed with the burner operating (Review the
“PRE-EDIT” section of this document).
1. Depress the UP key until “PRE-EDIT” is displayed. (Note: If “PRE-EDIT” is not displayed, it
will be necessary to re-enter the password).
2. With “PRE-EDIT” displayed, depress the SELECT key to enter the Pre-Edit menu. “Aim Scan-
ner” will be displayed.
3. Depress the SELECT key and “Ix Ux” will be displayed. With the burner OFF, “x” will equal
zero, i.e. “I0 U0”.
4. Place the burner in service (at low firing rate). Physically aim the scanner until the highest AIM
numbers are displayed. Secure the scanner in position, then depress the SELECT key. “Aim
Scanner” will again be displayed. Refer to application note on page 39.
5. Depress the UP key until “SET FEG” is displayed.
6. Depress the SELECT key and “Run flame at lowest setting and press PROGRAM” will be dis-
played.
7. Depress the PROGRAM key and the scanner will display “FEG is SET”.
8. Depress the SELECT key and “-EXIT-” is displayed.
9. Depress the SELECT key to return to the Status menu. “PRE-EDIT” will be displayed.
10. Depress the DOWN key and “EDIT” will be displayed.
11. Depress the SELECT key to again enter the EDIT loop.
12. Record the flame signal strength at each of the three modulation BANDS (23, 70, and 117 Hz)
as described in the “Manual Set-Up in Edit Menu” section on page 36.
13. Turn the burner off and again record the flame signal strength at each of the three modulation
BANDS (23, 70, and 117 Hz).
14. Select the BAND and GAIN where the greatest flame ON / flame OFF signal ratio occurs.
15. Turn the burner ON then OFF again to verify proper detection and discrimination. If necessary,
you may further adjust the gain, or band, or enable or disable a sensor. For future reference, list
the final setpoints on the following Configuration Record.
“S2” Models: The following procedure is performed with the burner operating (Review the
“AutoTune” section of this document).
1. Depress the UP key until “AutoTune” is displayed. (Note: If “AutoTune” is not displayed, it will
be necessary to re-enter the password).
2. With “AutoTune” displayed, depress the SELECT key to enter the AutoTune menu. “Aim Scan-
ner” will be displayed.
3. Depress the SELECT key and “Ix Ux” will be displayed. With the burner OFF, “x” will equal
zero, i.e. “I0 U0”.
4. Place the burner in service (at low firing rate). Physically aim the scanner until the highest AIM
numbers are displayed. Secure the scanner in position, then depress the SELECT key. “Aim
Scanner” will again be displayed. Refer to application note on page 39.
5. Depress the UP key until “Learn ON” is displayed.
6. Depress the SELECT key and “Run flame at lowest setting and press PROGRAM” will be dis-
played.
7. Depress the PROGRAM key and the scanner will count down from 128 to 0 then display “Learn
ON complete”.
8. Depress the SELECT key and “Learn ON” is again displayed.
9. Depress the UP key and “Learn OFF” is displayed.
10. Depress the SELECT key and “Turn flame OFF and press PROGRAM” will be displayed.
11. Press the PROGRAM key (with the target burner turned OFF) and the scanner will count down
from 128 to 0, then display “Learn flame OFF complete”.
12. Depress the UP key and “-EXIT-” is displayed.
41

13. Depress the SELECT key to return to the Status menu. “AutoTune” will be displayed.
14. Depress the UP key and “FQ=0” will be displayed.
15. Turn the burner OFF then ON to verify proper detection and discrimination. If necessary, you
may enter the Edit menu and adjust the gain, or band, or enable or disable a sensor. For future
reference, list the final setpoints on the following Configuration Record.
InSight Configuration Record
Parameter FILE A FILE B FILE C FILE D

Temperature Scale
Comm Address
Remote File Select
Language
Sensors
IR Band
IR Gain
IR Range
UV Band
UV Gain
UV Range
ON Threshold
OFF Threshold
FFRT
OTD
Operating Conditions and Firing rate
at time of “LEARN ON” or “Set FEG”
InSight Replacement Procedure

This procedure may be followed when replacing a damaged InSight scanner. It assumes that the
InSight Configuration Record (above) was completed and kept as a reference when the original scan-
ner was installed and calibrated. If not, the replacement scanner must be completely reprogrammed
as describes earlier in this document.
1. Install the new scanner and apply power.
2. Enter the programming password and enter the EDIT menu.
3. Manually enter the values from the InSight Configuration Record into the new scanner.
Important Note: After Step 3, the scanner should detect flame ON, but may not properly indicate
flame OFF until Step 4 is performed.
4. Create the burner firing conditions that existed when the scanner was originally installed and
calibrated, typically the low-fire condition.
S1 models only:
a. Enter the PRE-EDIT menu.
b. Depress the Up button until “Set FEG” is displayed.
c . Depress the Select button then the Program button
d. The scanner will set its internal Front End Gain Reference, then display “FEG is Set”.
S2 models only:
a. Enter the AUTOTUNE menu.
b. Depress the Up button until “LEARN ON” is displayed.
42

c. Depress the Select button then the Program button.

d. The scanner will set its internal Front End Gain Reference, count down from 128 to 0, then
display “Learn On Complete”. Note: If the proper data was manually entered into the EDIT
menu, it should not be necessary to learn the flame OFF condition.
5. Turn the burner OFF and ON to verify proper flame detection and discrimination.
6. Repeat Steps 2 through 5 for each scanner memory file used (A, B, C, D).
Error Messages
In the event that an internal scanner fault is detected, the scanner will turn off its output and a four
digit error code will appear on the display. If the scanner’s internal temperature exceeds 80°C
(176°F), the scanner will turn off its output and “Too HOT!” will appear on the display.
To clear the error code and re-start the scanner, the 24 vdc power must be cycled off then on.
Each time power is applied to a scanner that had experienced a fault, the display will read “Errors”
followed by several digits indicating the scanner’s error history. Pressing any key will clear this mes-
sage.
ERROR CODE DESCRIPTION

1001 through 1027 RAM Error
2001 through 2003 ROM Error
3001 through 3003 EEPROM Error
4001 through 5201 CPU Error
6001 Relay Error
6002 Pulsed Output Error
6101 Voltage Error
6102 Fault Relay Error
6201 Overtemp
7001 through 7008 Program Sequence Error
ORDERING INFORMATION
PART NUMBER STRUCTURE
TYPE SENSOR MODEL HOUSING

95 = Integrated IR = Solid state infrared S1 = Basic features, FM & UL, 220 -1 = NEMA 4X/IP66 housing, 12 pin electri-
(internal flame Vac contact rating. cal connector, pipe mount.
relay) UV = Solid state ultraviolet S1E = Basic features, CE, 50 Vac -1CG = NEMA 4X/IP66 housing, cable gland
contact rating. and ten (10) feet (3m) of captive cable, pipe
mount.
-1CEX = CENELEC Exd IIC T6 housing, pipe
mount, internal terminal blocks.
DS = Dual sensor, IR + UV S2 = Expanded features, FM & UL, -2 = NEMA 4X/IP66 housing, 12 pin electri-
220 Vac contact rating, “Remote cal connector, fiber optic mount (not avail-
Command” user software. able for DS models).
S2E = Expanded features, CE, 50 -2CG = NEMA 4X/IP66 housing, cable gland
Vac contact rating, “Read Only” and ten (10) feet (3m) of captive cable, fiber
user Software. optic mount (not available for DS models).
Example 1
To select the Fireye equipment meeting the following specification:
InSight scanner, dual sensor, basic features, UL & FM approved, surface mounted NEMA 4X/IP66
enclosure with male electrical connector. Accessories to include 1" NPT mounting flange, 100 ft of
12-conductor cable and female electrical connector kit, right angle.
43

Order the following:
QUANTITY PART NUMBER DESCRIPTION

1 95DSS1-1 InSight Scanner, Dual Sensor
1 60-2692 1" NPT mounting flange kit
100 feet 59-497 12-Conductor Cable
1 129-164R Female electrical connector kit, right angle
Example 2
To select the Fireye equipment meeting the following specification:
Integrated InSight scanner, ultraviolet sensor, expanded features, CE approved, surface mounted
NEMA 4X/IP66 enclosure with cable gland and captive cable. Accessories to include 1" BSP mount-
ing flange, 24 VDC power supply: 2.1 Amp output, 12" DIN rail for power supply.
Order the following:
QUANTITY PART NUMBER DESCRIPTION

1 95UVS2E-1CG InSight Scanner, Ultraviolet
1 60-2693 1" BSP mounting flange kit
1 60-2685-25 24VDC Power Supply
2.5 Amp output
1 60-2539-12 DIN Mounting Rail, 12"
NOTICE
When Fireye products are combined with equipment manufactured by others and/or integrated into
systems designed or manufactured by others, the Fireye warranty, as stated it its General Terms and
Conditions of Sale, pertains only to the Fireye products and not to any other equipment or to the
combined system or its overall performance.
WARRANTIES
FIREYE guarantees for one year from the date of installation or 18 months from date of manufacture
of its products to replace, or, at its option, to repair any product or part thereof (except lamps and
photocells) which is found defective in material or workmanship or which otherwise fails to conform
to the description of the product on the face of its sales order. THE FOREGOING IS IN LIEU OF
ALL OTHER WARRANTIES AND FIREYE MAKES NO WARRANTY OF MERCHANT-
ABILITY OR ANY OTHER WARRANTY, EXPRESS OR IMPLIED. Except as specifically
stated in these general terms and conditions of sale, remedies with respect to any product or part
number manufactured or sold by Fireye shall be limited exclusively to the right to replacement or
repair as above provided. In no event shall Fireye be liable for consequential or special damages of
any nature that may arise in connection with such product or part.
FIREYE CU-95
3 Manchester Road NOVEMBER 9, 2016
Derry, New Hampshire 03038 USA Supersedes April 22, 2016
www.fireye.com
44
APPENDIX C

6 5 4 3 2 1
GENERAL DETAILS OF EQUIPMENT:
DESIGN CONDITION:
Process fluid: Pneumatic Air
190,00* 100,00* 20,00* 160,00* 20,00* Process fluid pressure max: 8 barg
Process fluid temperature max: 22/65,6 °C
D D
TP TP SITE DATA:
04 TP TP Atmospheric pressure: --
03
02 01
Air humidity: 100% Relative humidity non-condensing
Min/Max Allow. Ambient temperature: 22/43,3 °C
35,00*
NOTES:
*= Tollerance + - 5mm
1= j Centre of gravity
250,00*
68,00
n EQUIPMENT LIST
9,
60,00*
0 0 1 ITEM DESCRIPTION SERIES See MIO section
68,00 TP 1 PNEUMATIC CYLINDER 1605 1A
2A SOLENOID VALVE 1 ICO3S 1B
02 2B SOLENOID VALVE 2 ICO3S 1B
C 3 FILTER REGULATOR B38P 1C C
4 UNIDIR. FLOW REGULATOR FRX 1D
325,00* 5 304SS PANEL thk. 4mm -- --
6 SWAGELOK FITTINGS -- --
7 316SS TUBING 1/2" O.D. -- --
3D VIEW: 348,00
-- -- -- --
TIE-IN POINT
ITEM DESCRIPTION SIZE UTILITIES
6 5 TP01 Instrument Air Inlet 1/4" NPT f 8 bar max
7 TP02 Instrument Air Exhaust 2x1/4" NPT f --
TP03 Solenoid Valve 1 Cable Entry 1/2" NPT f 110 Vdc - 3,9W
95,00
-- -- -- --
BOILER JOB 1167

B B
TAG LIST
N° PNEUMATIC ACTUATOR SOLENOID VALVE 1 SOLENOID VALVE 2
PNEUMATIC DIAGRAM: (TP03)
2A
1 03-XV-221 03-XY-221A 03-XY-221B
2 03-XV-211 03-XY-211A 03-XY-211B
4
1
4 2B 2A 4 -- -- -- --
IN OUT
3 SET @ 4bar
(TP02)
EX 3
AIR SUPPLY YES YES
(TP01)
ELECTRICAL SUPPLY (TP03) YES NO
(TP04)
2B 688,00 ELECTRICAL SUPPLY (TP04) NO YES

CARRIAGE POSITION LEFT RIGHT
4
IN OUT
EX
WEIGHT 24 KG.
(TP02)
A A
REV DESCRIPTION DATE DWG APPROVED
4 AS BUILT 09/03/2017 RBA ELI M.B. VALVESERVICE S.R.L. Mod. DWG 02 Rev.0 Dimension: mm Client SOFINTER SPA Client P.O. no 8600020435
3 MODIFIED 31/01/2017 RBA ELI Via Zanica, 19 E Sheet UNI Material Code 09773 Our Job no
24050 Grassobbio (BG) 17/00019/C
2 MODIFIED 25/01/2017 RBA ELI A3
Tel 0039 (0)35 335621 Description PNEUMATIC ACTUATOR STROKE 250 Dwg no
1 MODIFIED 19/01/2017 RBA ELI Fax 0039 (0)35 3843864 Scale GDE17-00019-1
0 ISSUED 18/01/2017 RBA ELI info@mbvalveservice.it 1:6 Spec. no 1167-COMBENG 002 Sheet no 1 -1
6 5 4 3 2 1
(IT) - ISTRUZIONI DI INSTALLAZIONE USO E MANUTENZIONE PER CILINDRI SENZA STELO SERIE X1600 - 1600
Pneumax S.p.A. (GB) – INSTALLATION, USE AND MAINTENANCE INSTRUCTION FOR RODLESS CYLINDERS SERIES X1600 - 1600
Via Cascina Barbellina 10 (FR) - INSTRUCTION POUR LA MISE EN SERVICE ET LA MAINTENANCE DES VERINS SANS TIGE SERIE X1600 - 1600
24050 Lurano (BG) – Italy (DE) - ANLEITUNG ZUR MONTAGE, HANDHABUNG UND WARTUNG DER KOLBENSTANGENLOSE ZYLINDER SERIE X1600 - 1600
www.pneumaxspa.com TX040005/IST
(ES) - INSTRUCCIONES DE INSTALACIÓN, USO Y MANTENIMIENTO DE CILINDROS SIN VASTAGO SERIE X1600 - 1600
ITALIANO ENGLISH FRANCAIS

Note generali: General notes : Généralités:
Questo documento fornisce le indicazioni generali per l’installazione, l’utilizzo e la manutenzione del prodotto a cui è allegato destinato This document provides general advice for the installation, use and maintenance of products designated for use in potentially explosive Ce document fournit toutes les informations nécessaires pour la mise en service, l’utilisation et la maintenance du produit ci-joint et
all’impiego in atmosfere potenzialmente esplosive secondo quanto richiesto dalla Direttiva 2014/34/UE – ATEX. atmospheres as stipulated by the 94/9/EC – ATEX Directive. destiné à l’emploi dans une atmosphère potentiellement explosive selon les prescriptions de la Directive 2014/34/UE – ATEX.
Requisiti essenziali in materia di sicurezza e salute: Essential Health and Safety Requirements ( EHSRs): Principes essentiels en matière de sécurité et de santé:
Questi cilindri sono progettati secondo l’allegato II della Direttiva 2014/34/UE – ATEX These cylinders have been designed in accordance with Annex II of the 94/9/EC Ces vérins ont été étudiés selon le paragraphe II de la Directive 2014/34/UE – ATEX et selon la norme CEN EN 1127-1:2011, EN 13463-
e secondo le norme CEN EN 1127-1:2011, EN 13463-1:2009 e EN 13463-5:2011 e sono classificati nel seguente modo: ATEX Directive, CEN EN 1127-1:2011, EN 13463-1:2009 e EN 13463-5:2011 standards; the classification is as follows: 1:2009 e EN 13463-5:2011 et sont classés de la manière suivante:
II 2GD c T6 T85°C –5°C ≤ Ta ≤ 55°C II 2GD c T6 T85°C –5°C ≤ Ta ≤ 55°C II 2GD c T6 T85°C –5°C ≤ Ta ≤ 55°C
Tech File : TX04000A/DTP Tech File : TX04000A/DTP
Legenda: Tech File : TX04000A/DTP Légende :
II = gruppo II (superficie) Key: II = groupe II (surface)
2 = categoria 2 (zona 1/21) II = equipment group II (surface) 2 = catégorie 2 (zone 1/21)
G = atmosfera esplosiva con gas o vapori 2 = equipment category 2 (zone 1/21) G = atmosphère explosive avec gaz ou vapeur
D = atmosfera esplosiva con polveri G = explosive atmosphere with gas or vapours D = atmosphère explosive avec poussières
c = modo di protezione (sicurezza costruttiva) D = explosive atmosphere with dust c = mode de protection (sécurité constructive)
T6, T5 = classe di temperatura
c = Ignition protection category T6, T5 = classe de température
T85°C, T100°C = massima temperatura superficiale
T6, T5 = Temperature Classes T85°C, T100°C = température maximale superficielle
Ta = range di temperatura ambiente (in funzione della classe di temperatura/massima temperatura superficiale)
Tech File = nome fascicolo tecnico depositato c/o organismo notificato T85°C, T100°C = Max. surface temperature Ta = plage de température ambiante (en fonction de la classe de température/température optimale superficielle)
Il presente documento è valido per i seguenti prodotti: Ta = Temperature range Tech File = nom du fascicule technique déposé auprès de l’organisme déclaré
Cilindri senza stelo serie X1600 e 1600 e accessori. Tech File = deposited technical file name / certifying body name Ce document est valable pour les produits suivants:
Utilizzo: This document is valid for the following products: Vérins série X1600, 1600 ainsi que les accessoires.
Utilizzare il cilindro rispettando il range di temperatura indicato e la velocità massima di 1,5 m/sec. Cylinders series X1600, 1600 and accessories. Utilisation:
Alimentare il cilindro con aria filtrata 20 micron e lubrificata. Use: Le vérin doit être utilisé dans la plage de température indiquée et à une vitesse maximum de 1,5 m/sec.
Avvertenze per l’installazione: These cylinders must be used within the indicated temperature range and with a maximum speed of 1,5m/sec. The air supply must be Il doit être alimenté avec de l’air filtré à 20 microns. La lubrification est nécessaire.
Evitare urti violenti all’estremità della corsa, per la versione ammortizzata regolare l’apertura degli spilli in modo che non vi sia un filtered to 20 microns and Air lubricated Précautions d’emploi à la mise en service:
fenomeno di rimbalzo nella fase iniziale di ammortizzo. Advice for installation: Eviter les chocs violents en extrémité de course, pour la version amortie, régler l’ouverture des vis d’amortissement de manière à ne pas
Raccordare le bocche di scarico della valvola di comando in modo che l’aria in scarico possa essere evacuata in una zona al di fuori Avoid heavy impact at the ends of stroke. On cushioned versions adjust the flow control valve as necessary to avoid a “bounce effect” provoquer de rebond dans la phase d’amortissement.
dell’atmosfera potenzialmente esplosiva (in particolare in presenza di polveri). La presenza di scariche elettrostatiche potrebbe dare during the initial phase of cushioning. Relier les orifices d’échappement du distributeur de commande de manière à pouvoir collecter les échappements et les évacuer hors de la
origine a scintille. Connect the exhaust ports of the control valve to flow controllers outside the hazardous area (particularly in dust applications.) zone d’atmosphère potentiellement explosive (en particulier lors de la présence de poussières). Eviter de frapper les parties métalliques
Evitare di colpire le parti metalliche del cilindro con oggetti metallici che potrebbero generare scintille di origine meccanica (per esempio Avoid striking the surface of the cylinder with metallic objects that could generate mechanical spark (for example, a rusted iron part du vérin avec des objets qui pourraient générer des étincelles d’origine mécanique (par exemple les parties en acier rouillé contre les
parti in ferro arrugginito contro le testate o la camicia in alluminio del cilindro). Non effettuare modifiche al cilindro (qualsiasi modifica striking the aluminium cylinder end caps). flasques en aluminium du vérin). Tout composant électrique monté additionnellement sur le vérin doit posséder sa propre
porterà al decadimento della dichiarazione di conformità del prodotto). Any electrical components (optional) fitted to the cylinder must be certified with their own separate ATEX certification. This certification ATEX, celle-ci doit respecter la catégorie exigée (2GD ou mieux) et être appropriée pour l’installation dans
Eventuali componenti elettrici, opzionali, montati sul cilindro, devono essere oggetto di certificazione ATEX separata, idonei alla zona di must meet the required ATEX category (2GD or better) and be suitable for installation in the required environment, considering l’environnement concerné, en considération du groupe de gaz, la classe de température, la température optimale superficielle et
installazione e categoria (2GD o migliore), al gruppo di gas, alla classe di temperatura/massima temperatura superficiale e alla temp. the group of gas, the temperature class, maximum surface temperature and environmental temperature…… environnementale.
ambiente. In the case of use below 0°C, it is necessary to remove the moisture in the air with a compressed air dryer that has a dew point En cas d’utilisation de température ambiante < 0°C, il est nécessaire d’éliminer l’humidité de l’air avec un sécheur d’air
In caso di utilizzo a temperatura ambiente < 0°C, è necessario prevedere un essiccatore che possa garantire un punto di rugiada inferiore lower than the cylinders operating temperature. comprimé garantissant un point de rosée inférieur à la température d’exploitation des vérins.
alla temperatura di impiego. In order to prevent electrostatic charges from building up ensure that no metallic parts are isolated, at the same time ensure Afin d'éviter la formation de charges électrostatiques, veiller à ce que toutes les parties métalliques soient isolées. Dans le même
Per evitare la formazione di cariche elettrostatiche, verificare non esistano parti metalliche isolate e che sia sempre garantita e assicurata that the cylinder is earthed on the fixed structure(end caps, barrel, mountings) and on the moving parts (carriage). temps, veuillez vous assurer que le vérin soit relié à la terre (flasques, tube, fixations) et sur les parties en mouvement (chariot).
nel tempo la messa a terra del cilindro, sia della struttura fissa (testate/camicia/fissaggi cilindro) sia delle parti in movimento (stelo). The user must take appropriate measures to prevent the formation of dust layers with periodic and regular cleaning. L’utilisateur doit prendre les mesures nécessaires afin d’éviter le dépôt et la formation de couches de poussières avec un
L’Utilizzatore deve adottare idonee misure organizzative per evitare il deposito e la formazione di strati di polvere, come provvedere a Do not modify the cylinder in any way. Any modification will affect the certification of the product.
regolare e periodica pulizia per limitare la formazione di strati. nettoyage périodique ou par des actions préventives.
Installation should be performed in accordance with the safety requirements prescribed in the UNI EN 983 standard - Safety of machinery N’effectuer aucune modification du vérin (Toute modification quelque soit rendra caduc la déclaration de conformité du produit).
Effettuare l’installazione rispettando i requisiti di sicurezza indicati dalla norma UNI EN 983 - Requisiti di sicurezza relativi a sistemi e loro - Safety requirements for fluid power systems and their components: Pneumatics.
componenti per trasmissioni oleoidrauliche e pneumatiche. Effectuer l'installation en respectant les dispositions de sécurité indiquées dans la norme UNI EN 983 - Dispositions de sécurité relatifs
Maintenance: aux systèmes et leurs composants pour les transmissions pneumatiques et hydrauliques.
Manutenzione: We recommend that the function of the cylinder is checked after every 250 km of use.
Verificare ogni 250 km di percorrenza del cilindro il buon funzionamento dello stesso verificando che non vi siano travasi d’aria tra le Maintenance:
Ensure there is no leakage across the piston and that the external surfaces of the cylinder are undamaged Dès que le vérin a parcouru 250 Km, vérifier le bon fonctionnement de l’ensemble et contrôler qu’il n’y a pas de fuite d’air entre les deux
camere del pistone e che il cilindro non presenti ammaccature superficiali. In caso di presenza di una delle anomalie precedentemente If any of these checks discover a fault, the cylinder should be replaced.
descritte, sostituire il cilindro con uno nuovo. chambres et que le vérin ne présente pas d’impact superficiel. En cas de présence d’une de ces anomalies, remplacer le vérin usagé par un
Periodically remove any dust that has accumulated on the surfaces of the cylinder. vérin neuf.
Rimuovere periodicamente eventuali residui di polvere presenti sulle superfici esterne del cilindro. Accessories:
In caso di scorrimento irregolare del cilindro in seguito ad un urto avvenuto sulla superficie esterna, interrompere il funzionamento e Accessoires:
CODE DESCRIPTION MATERIAL REFERENCE DESCRIPTION MATERIAU
sostituire il cilindro stesso.
1600.Ø.05F Complete sliding shoes guide ALUMINIUM 1600.Ø.05F Guidage par paliers complet pour verin ALUMINIUM
Accessori: 1600.Ø.01F Mounting foot brackets Ø25-32 / Ø40-63 STEEL / ALUMINIUM 1600.Ø.01F Equerre basse Ø25-32 / Ø40-63 ACIER / ALUMINIUM
CODICE DESCRIZIONE MATERIALE 1600.Ø.02F Intermediate support ALUMINIUM 1600.Ø.02F Support intermediaire ALUMINIUM
1600.Ø.05F Guida con pattini completa per cilindro ALLUMINIO 1600.Ø.03F Oscillating hinge STEEL 1600.Ø.03F Chape oscillante ACIER
1600.Ø.01F Piedino Ø25-32 / Ø40-63 ACCIAIO / ALLUMINIO These accessories have been analyzed, with the conclusion that these single elements DO NOT HAVE A POTENTIAL IGNITION SOURCE, and Nous avons analysé de plus les accessoires de fixation des vérins, cette analyse des composants démontre que les éléments seuls NE SONT
1600.Ø.02F Supporto intermedio ALLUMINIO consequently DO NOT FALL WITHIN THE SCOPE OF THE DIRECTIVE for the use they are intended for.
1600.Ø.03F Cerniera oscillante ACCIAIO
PAS CONSIDERES COMME UNE SOURCE POTENTIEL A RISQUE et par conséquent N’ENTRE PAS DANS LE CHAMP D’APPLICATION DE LA
CORRESPONDENCES BETWEEN HAZARDOUS AREAS, substances and CATEGORIES ACCORDING TO DIRECTIVE 94/9/EC DIRECTIVE par rapport à leur utilisation.
Sono stati analizzati inoltre gli accessori per il fissaggio del cilindro e l’analisi dei componenti dimostra che i singoli elementi NON HANNO
POTENZIALI FONTI DI INNESCO e di conseguenza NON RIENTRANO NEL CAMPO DI APPLICAZIONE DELLA DIRETTIVA per l’impiego per cui
Substancer HAZARDOUS AREAS Categories CORRESPONDANCE ENTRE ZONES DANGEREUSES, SUBSTANCES ET CATÉGORIES SELON LA DIRECTIVE 2014/34/UE
sono previsti. gas, vapours or mists Zone 0 1G Substances Zones de danger Catégories
CORRISPONDENZE TRA ZONE PERICOLOSE, SOSTANZE E CATEGORIE SECONDO DIRETTIVA 2014/34/UE gas, vapours or mists Zone 1 2G or 1G Gaz, vapeur ou brouillard Zone 0 1G
Sostanza Zona pericolosa Categorie gas, vapours or mists Zone 2 3G, 2G or 1G Gaz, vapeur ou brouillard Zone 1 2G ou 1G
Gas, vapori o nebbie Zona 0 1G dust Zone 20 1D Gaz, vapeur ou brouillard Zone 2 3G, 2G ou 1G
Gas, vapori o nebbie Zona 1 2G oppure 1G dust Zone 21 2D or 1D Poussières Zone 20 1D
Gas, vapori o nebbie Zona 2 3G, 2G oppure 1G dust Zone 22 3D, 2D or 1D Poussières Zone 21 2D ou 1D
Polveri Zona 20 1D Production batch identification: Poussières Zone 22 3D, 2D ou 1D
Polveri Zona 21 2D oppure 1D The production date is indicated on the label by two numbers and a letter, representing the week (as a progressive number from 01 to 52) Identification des lots de production:
Polveri Zona 22 3D, 2D oppure 1D and year; La date de production est indiquée sur l’étiquette du produit au moyen de 2 chiffres suivis d’une lettre qui identifie dans l’ordre la
Identificazione lotto produzione: Example : 49Y (week 49, year 2011). semaine (chiffre progressif de 01 à 52) et l’année de production; Exemple 49Y (49ème semaine de l’année 2011).
La data di produzione è presente sull’etichetta del prodotto mediante 2 numeri seguiti da una lettera che identificano nell’ordine la Y = 2011 Z = 2012 A = 2013 B = 2014 C = 2015 D = 2016 E = 2017 Y = 2011 Z = 2012 A = 2013 B = 2014 C = 2015 D = 2016 E = 2017
settimana (numero progressivo da 01 a 52) e l’anno di produzione. Esempio 49Y: settimana 49, anno 2011.
Y = 2011 Z = 2012 A = 2013 B = 2014 C = 2015 D = 2016 E = 2017
TX040005/IST – REV 3 – 04/2016 1/2

DEUTSCH ESPAÑOL
Allgemeines: Notas generales:
Diese Produktinformation gibt allgemeine Ratschläge für die Anwendung , Installation und Wartung von Este documento facilita las indicaciones generales para la instalación, la utilización y el mantenimiento del producto al cual se adjunta,
Produkten zur Anwendung in potentiell explosiver Atmosphäre gemäß 2014/34/UE – ATEX Direktive. destinado al empleo en atmósfera potencialmente explosiva siguiendo las exigencias de la Directiva 2014/34/UE – ATEX.
Wichtige gesundheits und Sicherheitserfordernisse (EHSRs): Requisitos esenciales en materia de seguridad y salud:
Diese Zylinder werden hergestellt gemäß Anlage II der 2014/34/UE – ATEX Direktive, Estos cilindros están diseñados según el anexo II de la Directiva 2014/34/UE – ATEX y según las normas CEN EN 1127-1:2011, EN 13463-
CEN EN 1127-1:2011, EN 13463-1:2009 e EN 13463-5:2011 Standard. Die Klassifizierung ist wie folgt: 1:2009 e EN 13463-5:2011 y están clasificados del siguiente modo:
II 2GD c T6 T85°C –5°C ≤ Ta ≤ 55°C II 2GD c T6 T85°C –5°C ≤ Ta ≤ 55°C
Legende: Legenda:
II = Gruppe II (Oberfläche) II = grupo II (superficie)
2 = Kategorie 2 ( Zone 1/21) 2 = categoría 2 (zona 1/21)
G = explosive Atmosphäre durch Gase oder Dämpfe G = atmósfera explosiva con gas o vapores
D = explosive Atmosphäre durch Pulver oder Stäube D = atmósfera explosiva con polvos
c = modo de protección (seguridad constructiva)
c = Art der Sicherheit (Konstruktionssicherheit)
T6, T5 = clase de temperatura
T6, T5 = Temperaturklassen
T85°C, T100°C = máxima temperatura superficial
T85°C, T100°C = maximale Oberflächentemperatur Ta = range de temperatura entorno (en función de la clase de temperatura / máxima temperatura superficial)
Ta = Umgebungstemperaturbereich (an Abhängigkeit zur Temperaturklasse/max. Oberflächentemperatur) Tech Expediente = nombre fascículo técnico depositado y/o organismo notificado
Tech File = festgelegter Name des technischen Files El presente documento es válido para los siguientes productos:
Dieses Dokument ist gültig für folgende Produkte: Cilindos serie X1600, 1600 y accesorios.
Zylinder X1600, 1600 und Anbauteile. Utilización:
Einsatz: Utilizar el cilindro respetando el rango de temperatura indicado y la velocidad máxima de 1,5 m/seg.
Oben benannte Zylinder müssen innerhalb der vorgegebenen Temperaturbereiche eingesetzt werden und mit einer max. Geschw. Von Alimentar el cilindro con aire filtrado a 20 micras. La lubricación es necesaría
1,5m/sec. Advertencias para la instalación:
Die Druckluft muß bis auf 20ym gefiltert sein. Geölte Luft ist erforderlich. Evitar golpes violentos al final de carrera; para la versión amortiguada regular la apertura de los tornillos de modo que no se produzca un
Hinweise für den Einbau: efecto de rebote en la fase inicial de la amortiguación
Vermeiden Sie harte Schläge an den Hubenden. Bei Ausführungen mit einstellbarer Endlagendämpfung sollte die Abluftdrossel so Canalizar las vías de escape de la válvula de mando de forma que el aire de escape pueda ser evacuado en una zona fuera de la atmósfera
eingestellt werden, daß der „Aufprall Effekt“ während der Dämpfungsphase vermieden wird. Die Abluft der Drosseln sollte außerhalb der potencialmente explosiva (especialmente en presencia de polvo).
gefährlichen Bereiche geleitet werden (vor allem bei Staub). Vermeiden Sie mögliche Reibung zwischen den Zylindern und anderen Evitar golpear las partes metálicas del cilindro con objetos metálicos que pudieran generar chispas de origen mecánico (por ejemplo partes
Matallteilen, die eine Zündquelle sein können (zum Beispiel ein auf einen Zylinder fallendes Eisenteil). de hierro oxidado contra cabezas de aluminio del cilindro).
Die elektronischen Komponenten welche optional auf dem Zylinder montiert werden, müssen eine gesonderte ATEX Eventuales componentes eléctricos, opcionales, montados sobre el cilindro tienen que ser objeto de certificación ATEX separada, idóneos a
Zertifizierung besitzen, geeignet für den Einbaubereich und Kategorie (2GD oder höher), der Gasgruppe, Temperaturklasse / la zona de instalación y categoría (2GD o mejor), al grupo de gas, a la clase de temperatura/máxima temperatura superficial y al
maximale Oberflächentemperatur und der Umgebungstemperatur. temperatura del entorno.
Im Falle der Verwendung bei Umgebungstemperatur < 0° muss man einen Trockner vorsehen, der sicherstellt, dass der En caso de empleo a temperatura entorno <0°C, es necesario prever un secador que pueda garantizar un punto de rocío inferior a la
Taupunkt niedriger ist als die Arbeitstemperatur. Um elektrostatische Aufladungen zu vermeiden, muss sichergestellt werden, temperatura de empleo.
dass metallische Teile nicht isoliert werden. Außerdem muss eine Erdung des Zylinders (Zylinderkopf und -boden, Zylinderrohr) Para evitar la formación de cargas electrostáticas, verificar que no existan partes metálicas aisladas y que siempre este asegurada la toma a
und aller Anbauteile zu jeder Zeit garantiert sein. tierra del cilindro, sea de la estructura fija (camisa / fijaciones cilindro), sea de las partes en movimiento (carro).
Der Anwender muss geeignete organisatorische Maßnahmen ergreifen um die Bildung von Staubschichten zu vermeiden , sowie El utilizador tiene que adoptar medidas idóneas organizativas para evitar el depósito y la formación de capas de polvo, como proveer la
periódica limpieza, para limitar la formación de capas.
in festgelegten regelmäßigen Abständen eine Reinigung durchführen um die Bildung von Staubschichten einzugrenzen.
No efectuar modificaciones al cilindro (cualquier modificación llevará a la nulidad de la declaración de conformidad del producto).
Nehmen Sie keine baulichen Veränderungen am Zylinder vor. Jede Veränderung führt dazu, daß das Produkt die Zertifizierung
Efectuar la instalación respetando las medidas de seguridad indicadas por la norma UNI EN 983 - Requisitos de seguridad correspondientes
verliert.Nehmen Sie keine baulichen Veränderungen am Zylinder vor. Jede Veränderung führt dazu, daß das Produkt die Zertifizierung a sistemas y sus componentes para transmisiones oleohidraúlicas y neumáticas.
verliert. Beachten Sie bei der Inbetriebnahme die Sicherheitsbestimmungen gemäß DIN EN 983, Sicherheit von Maschinen - Mantenimiento:
Sicherheitstechnische Anforderungen an fluidtechnischen Anlagen und deren Bauteile - Pneumatik. Comprobar cada 250 km de recorrido del cilindro el buen funcionamiento del mismo verificando que no haya comunicación de aire entre
Wartung: las cámaras a través del pistón y que el cilindro no presente abolladuras superficiales. En caso de presencia de una de las anomalías
Wir empfehlen die Funktion des Zylinders alle 250 km Laufleistung zu überprüfen. anteriormente descritas, sustituir el cilindro por uno nuevo.
Vergewissern Sie sich daß Kolben keine Leckagen auftreten und das der Zylinder äußerlich nicht beschädigt ist. Accesorios:
Sollte einer dieser Fehler auftreten, dann sollte der Zylinder ausgetauscht werden CÓDIGO DESCRIPCIÓN MATERIAL
Zubehör: 1600.Ø.05F Patin guiado para cilindro ALUMINIO
ARTIKELNUMMER BEZEICHNUNG MATERIAL 1600.Ø.01F Pata Ø25-32 / Ø40-63 ACERO / ALUMINIO
1600.Ø.05F Gleitführung ALUMINIUM 1600.Ø.02F Soporte intermedio ALUMINIO
1600.Ø.01F Fuß Ø25-32 / Ø40-63 STAHL / ALUMINIUM 1600.Ø.03F Charnela oscillante ACERO
1600.Ø.02F Mittenünterstutzung ALUMINIUM Han sido analizados además los accesorios para la fijación del cilindro y los análisis de los componentes demuestran que los elementos
1600.Ø.03F Mitnehmer STAHL simples NO TIENEN FUENTES POTENCIALES DE IGNICIÓN y por consiguiente NO ENTRAN EN EL CAMPO DE APLICACIÓN DE LA DIRECTIVA
Diese Anbauteile wurden untersucht, mit dem Ergebnis DAS DIESE ELEMENTE KEINE POTENTIELLE ZÜNDQUELLE DARSTELLEN, UND en el empleo para el que han sido previstos.
DARUM NICHR UNTER DIE VORGABEN DER DIREKTIVE FALLEN. CORRESPONDENCIA ENTRE ZONA PELIGROSA, SUSTANCIA Y CATEGORÍA SEGÚN DIRECTIVA 2014/34/UE
Korrespondenz zwischen der Gefahrensubstanz/Umgebung, der Zone und Kategorie nach Direktive 2014/34/UE Sustancia Zona peligrosa Categoría
Substanz Gefahrenzone Kategorie Gas, vapores o nieblas Zona 0 1G
Gas, Dämpfe oder Nebel Zona 0 1G Gas, vapores o nieblas Zona 1 2G o bien 1G
Gas, Dämpfe oder Nebel Zona 1 2G oder 1G
Gas, vapores o nieblas Zona 2 3G, 2G o bien 1G
Gas, Dämpfe oder Nebel Zona 2 3G, 2G oder 1G
Polvos Zona 20 1D
Pulver oder Stäube Zona 20 1D
Polvos Zona 21 2D o bien 1D
Pulver oder Stäube Zona 21 2D oder 1D
Polvos Zona 22 3D, 2D o bien 1D
Pulver oder Stäube Zona 22 3D, 2D oder 1D
Identificación lotes de producción:
Produktidentification: La fecha de producción está presente en la etiqueta del producto mediante 2 números seguidos de una letra que identifican por orden la
Das Herstelldatum ist auf dem Label mit einer Zahlen – Buchstaben Kombination abzulesen, wobei die Nummer für die Kalenderwoche semana (número progresivo del 01 al 52) y el año de producción. Ejemplo: 49Y (semana 49, año 2011).
steht (fortlaufend von 1 bis 52) und der Buchstabe für das Jahr, zum Beispiel 49Y (Woche 49, Jahr 2011).
Y = 2011 Z = 2012 A = 2013 B = 2014 C = 2015 D = 2016 E = 2017
Y = 2011 Z = 2012 A = 2013 B = 2014 C = 2015 D = 2016 E = 2017
TX040005/IST – REV 3 – 04/2016 2/2

Marking Indicator Description
MARKING (TYPICAL) DESCRIPTION The ICO3S is an Ex certified solenoid valve used to control a
IMI Precision Engineering pressurised media (liquid or gas). The standard variant
WARNING: DO NOT OPEN WHEN AN COVER FORMS PART OF FLAMEPROOF ENCLOSURE AND SHOULD NOT BE
Thompson Valves Ltd EXPLOSIVE ATMOSPHERE IS PRESENT REMOVED WHEN AN EXPLOSIVE ATMOSPHERE IS PRESENT
(3/2 0.5-12 bar automatic) has the following characteristics.
17 Balena Close WARNING:MAXIMUM INTERNAL RISE 30K, THIS INDICATES THE MAX INTERNAL TEMPERATURE RISE,
USE SUITABLY RATED CABLE THIS CAN BE USED TO EVALUATE CABLE TEMPERATURE RATING.
Creekmoor Industrial Estate Ex I M2 ATEX MARKING: EQUIPMENT SUITABLE FOR MINING APPLICATIONS.
- Equipment weighs 2.0 kg (¼”) 2.5kg (1/2”) Typical.
EQUIPMENT GROUP 1, EQUIPMENT CATEGORY M2.
Poole - Valve’s typical speed <70ms pull in, <50ms drop out.
BH17 7EF Ex II 2 G D ATEX MARKING: EQUIPMENT SUITABLE FOR EXPLOSIVE GAS AND DUST
ENVIRONMENTS. EQUIPMENT GROUP 2, EQUIPMENT CATEGORY 2.
United Kingdom IP66 INGRESS PROTECTION RATING FOR BOTH ATEX AND IEC
66 = STRONG WATER JETS, DUST TIGHT
Standard ICO3 ¼” Installation Drawing
Ex d I EQUIPMENT RELIES ON Exd PROTECTION
SUITABLE FOR USE IN Ex GAS GROUP I (MINING APPLICATIONS)
Tel: +44 (0)1202 697521
Ex mbe IIC EQUIPMENT RELIES ON Exmbe PROTECTION
SUITABLE FOR USE IN Ex GAS GROUP IIC
sales@thompson-valves.com Ex d IIC EQUIPMENT RELIES ON Exd PROTECTION

www.imi-precision.com Ex tb IIIC EQUIPMENT RELIES ON Extb PROTECTION
SUITABLE FOR USE IN COMBUSTIBLE METAL DUST ENVIRONMENTS
ICO3S T4 Ta (-55°C to 90°C) T-CLASSIFIED EQUIPMENT SHOULD NOT BE EXPOSED TO TEMP OUTSIDE
THE SPECIFIED TEMPERATURE RANGES (Ta). TYPICAL MARKING SHOWN.
Y013AA1H1BS WORKING CONDITIONS SHOULD NOT EXEED THE CAPABILITIES OF
COMPONENTS /MATERIALS DETAILED IN THE CONSTRUCTION
WP 0 - 12BAR THE RANGE AND MAXIMUM MEDIA WORKING PRESSURE RATING
Installation, Operation and INLET, OUTLET, VENT PIPEWORK SHOULD BE CONNECTED SUCH THAT IT FUNCTIONS AS PORT
MARKINGS
Maintenance Instructions (MI0294 Rev.27) 24V DC 3W (1/4”) 8W (1/2”) THE ELECTRICAL SUPPLY LIMITS ARE NOMINAL VOLTAGE +/-10%
Serial No. FOR YEAR OF MANUFACTURE REFER TO CERTIFICATE OF CONFORMITY
Product certificate numbers can be found on the product datasheet or

contact sales@thompson-valves.com
Expected duty
The ICO3S should not be used in excess of the expected duty limits
THE ICO3S SHALL ONLY BE USED IN ACCORDANCE WITH as shown below. In special applications that exceed these duty limits,
REQUIREMENTS OF THIS DOCUMENT. READ ALL THE contact sales@thompson-valves.com before installing / operating an
INSTRUCTIONS CAREFULLY BEFORE USING THIS PRODUCT. ICO3S.
The ICO3S is designed and certified to meet the requirements of: CONDITIONS LIMITS
IEC61508:2010 as being suitable for use in safety-related applications FUNCTION The working temperature and pressure shall not exceed the marked label
up to and including SIL3 where safety operation of the valve is by de- rating. The valve should not be operated at a speed >6 cycles/min.
energisation of the solenoid. This manual covers all installation, ENVIRONMENT All external conditions shall not exceed IP66. External conditions shall not Install cable using an appropriate certified gland fit for duty.
maintenance and operation requirements for these applications. degrade the Exd enclosure or pressure boundary. Recommended Fitting as shown below - MAX. TORQUE 40 Nm
MAINTENANCE 6 years SIL rated safety systems,/ 10 years normal application / or 100,000
PERIOD cycles / 12 month Max Proof Test Interval.
Installation by suitably-trained personnel in accordance with the For best practice exercise the valve once per month.
applicable code of practice e.g. EN 60079-14: LIFE 20 years or 1million cycles. For correct disposal see end of equipment life
statement
Inspection and maintenance of equipment by trained personnel in MEDIA Media: Instrument air or non-corrosive hydraulic fluids - clean and free from
accordance with applicable code of practice e.g. EN 60079-17 particulate pollution. A suitable inlet filter should be fitted (eg. 20μm)
O-RINGS Application must not exceed temperature rating of o-rings as shown on valve
Repair of this equipment by suitably trained personnel in accordance label/datasheet. If in doubt contact Sales@thompson-valves.com.
with the applicable code of practice e.g. EN 60079-19
Part Number Details
Components to be incorporated into or used as replacement parts for
the equipment shall be fitted by suitably trained personnel in
accordance with this documentation.
End Of Equipment Life

WARNING undue torque forced on solenoid pot can damage or
The metallic elements of this equipment are made from material which loosen interface bolts.
can be recycled. At the end of the equipment’s service life it should
be sent to a recycling centre to be re-used.
The elastomeric elements that are not able to be recycled should be Storage and Handling
disposed of responsibly through a reputable waste disposal company.
Store the ICO3 in a clean and dry condition. Temperature 0 - 25 C,
humidity <75%. Storage areas shall be non-corrosive and not contain
ozone producing equipment (e.g. welding equipment, mercury vapour
lamps). Personal protection should be used during handling. All ports
should remain sealed and the valve markings made visible
Operation Only IMI Precision Thompson Valves spares kits should be used.
All ICO3S solenoid valves consist of an Ex enclosure. Exd flameproof The ICO3S has an IP66 rating. Degradation of the IP66 seals / Valve spares kit includes: seals and operating spring supply specially
joints shall not be damaged, all threaded joints shall be fully engaged. gaskets / sealing faces or failure to tighten all sealing joints, will allow designed for the duty. Incorrect seals will affect valve performance.
water to leak inside the enclosure. Lubrication: “Molykote 55” medium grease -55°C to 90°C:
For best practice, the valve should ideally be exercised at least Part A. Disassembling a standard valve
once a month. 1. Remove the Cap Head Bolts at the base of the valve body and
remove valve body and armature assembly.
Removing an existing valve 2. Remove C/Sunk screws holding valve to flange and remove
Tools: 3mm Electrical Screw Driver valve body.
Allen Keys: 2.5mm, 3mm, 4mm and 5mm. 3. Secure armature with a “Tommy bar” and using a spanner
5mm A/F spanner. 5mm “Tommy Bar”. remove the spool assembly.
4. Separate all valve assembly components, noting orientation,
1. Obtain work permit and check area for hazards. sequence and position of parts.
2. Isolate valve from all pipeline and electrical supplies.
3. Loosen M5 locking screw and unscrew cover. Part B. Examining a valve’s components
4. Disconnect supply cable and remove. Examine and replace all worn or damaged parts.
5. Remove pipe connections from valve assembly. The flameproof joints will retain their original certified clearances
6. Unscrew mounting bolts and remove the valve. provided they are not damaged.
Replace all seals, seats and operating spring with spare parts kit. All
seals should be lubricated and have no deformation. All seating and
Installing a valve sealing faces should be free from contamination, marks, scratches,
General requirements etc.
- Pipe work and media must be clean. DO NOT MODIFY OR RECLAIM FLAMEPROOF JOINTS.
- Suitable Inlet filters are recommended (e.g. <20 microns).
- Prevent pipe sealant from entering the system. Part C. Assembling a standard valve
- Use only correct tools (i.e. as listed above). Smear all seals with recommended grease.
- Do not use valve as a lever. Build assemblies in reverse order shown in part A.
The pressurised media is retained within the valve assembly (pressure - Earth equipment to prevent the build up of electrostatic charge. Torque settings:
boundary) by the mechanical strength of all its metal parts, seats and - Ensure all interfacing equipment is rated to the expected duty - Valve spool to 4Nm.
seals. Degradation of any of these components will cause the valve to conditions and will not degrade the integrity of the ICO3S. - Valve M5 bolts to 5.4Nm.
leak. - Ensure that valve lid and o-ring seal are fitted and the lid is tightened - Valve M4 bolts to 2.7Nm.
down after installation - Apply “loctite 243 thread-locker” to mentioned bolts.
The certification of this equipment relies upon 316 stainless steel -Contact sales@thompson-valves.com for valve orientation procedure
materials used for its construction. QACA-423 Part D. Adjusting & testing a standard valve
1. Loosen M5 locking screw and remove solenoid cover.
If the equipment is likely to come in contact with aggressive Mounting 2. Make connections to valve ports as per markings.
substances, then it is the responsibility of the user to take suitable An ICO3S will function satisfactorily when mounted inclined from the 3. Apply air to valve body and energise coil.
precautions, for which prevent it from being adversely affected, thus vertical. However for maximum life and efficiency mount vertically - Do 4. Using 3/16” AF Allen Key screw down core to the point
ensuring that the type of protection provided by the equipment is not not invert. The ICO3S is not designed for use in vibration just before ports leak.
compromised. applications. Do not mechanically stress the equipment. 5. Screw core back a further 1/10 of a turn.
- The user shall provide ventilation around the solenoid enclosure.
6. Ensure valve operates correctly at Nom Voltage  12%
Aggressive substances: e.g. acidic liquids or gases that may - The Exd enclosure shall not be lagged.
attack metals or solvents that may affect polymeric materials. - Ensure pipe work, cable glands and cabling are fit for rated duty. Part E. Problems
Procedure If the ICO3 does not function as intended, do not install valve. Repeat
Suitable precautions: e.g. regular checks as part of routine 1. Mount valve utilizing 2 off ø6mm mounting holes through body. the maintenance procedures Parts A to D.
inspections or establishing from them the material’s data sheets that it 2. Make connections to the valve ports as required. 1/4NPT max If the problem persists, contact Sales@thompson-valves.com for
is resistant to specific chemicals. torque 7NM. 1/2NPT max torque 30NM. assistance.
The flow path of the media is altered by moving the spool assembly 4. Install cable using an appropriate certified gland fit for duty. If you are not sure about any application, maintenance, or
and engaging / disengaging the seats. (MAXIMUM TORQUE 40 Nm) technical issue, contact Thompson Valves Sales for advice.
The spool assembly can be moved by either: 5. Make terminal connections as labelled. All terminals must be
 Energising the coil to produce an electromotive force. tightened before commissioning.
 Applying a pressure to a piston. 6. Replace solenoid cover and lock M5 locking screw.
 Applying a mechanical force to a linkage.
 Compressing a mechanical spring.
Maintenance
It is recommended that all products be returned to Thompson
Restricting the spool movement or allowing the seats to degrade, will Valves for refurbishment.
not allow the flow to be re-directed.
B38P
Installation & Maintenance
Instructions
Filter/Regulator
B38P-˙˙4-˙˙M˙
Port Temperature (Material) Diaphragm Drain Element Spring(Outlet Pressure Range)* Thread Form
2…1/4” 4…-40 to 80ºC (Nitrile) 4…Relieving A…Auto Drain 1…5µm M…0.5 to 10bar (7.3 to 145 psig) A…NPT
3…3/8” 5…-20 to +80ºC (FKM) B…Manual drain 2…25µm G…ISO G parallel
3…40µm
TECHNICAL DATA ADJUSTMENT

Fluid: Compressed air 1. Before applying inlet pressure to filter/regulator,
Maximum pressure: turnadjustment (2) counterclockwise to remove all
Manual drain: 31 bar (450 psig) forceon regulating spring (7). 1
Auto drain: 17 bar (247 psig) 2. Apply inlet pressure, then turn adjustment (2)
clockwise to increase and counterclockwise to
Operating temperature*:
decrease pressure setting.
-40° to +80°C (-40° to +176°F) 8
3. Always approach the desired pressure from a lower
* Air supply must be dry enough to avoid ice formation at pressure. When reducing from a higher to a lower
temperatures below +2°C (+35°F). setting, first reduce to some pressure less than that
2
Particle removal: 5µm, 25µm, or 40µm filter element desired, then bring up to the desired pressure.
Air quality: Within ISO 8573-1, Class 3 and Class 5 NOTE 9
(particulates) With non-relieving filter/regulators, make pressure
Typical flow with 10 bar (150 psig) inlet pressure, 6,3 bar reductions with some air flow in the system. If 11
made under no flow (dead-end) conditions, the
(90 psig) set pressure and 1 bar (15 psig) droop from 3
filter/regulator will trap the over-pressure in the
set: 40 dm³/s (85 scfm) downstream line. 12
Manual drain bowl size: 0.025 litre (1 fluid ounce) 4. ADJUSTING SCREW ADJUSTMENT. Turn the lock
Auto drain bowl size: 0,025 litre (1 fluid ounce) 4 10
nut(3) down to lock pressure setting.
Auto drain connection: 1/4 NPT 5. NECK MOUNTING ADJUSTMENT. Tighten panel nut 13
Automatic drain operating conditions (float operated): (1) to lock the B38P on the mounting bracket. 5
Bowl pressure required to close drain: Greater than 0,3 14
bar (5 psig) SERVICING 15
Bowl pressure required to open drain: Less than 0,2 bar 1. Open manual drain to expel accumulated liquids. 16
(3 psig) Keep liquids below element retainer (21). 17
Manual operation: Depress pin inside drain outlet to 2. At approximately 6 month intervals it is advisable to
remove the bowl assembly by removing 18
drain bowl
the securing screws (5) and unscrewing element
Gauge ports: 1/4 NPT as per main ports retainer (21) to remove the elements (19)
Materials: for inspection.Since the direction of air flow is from 6 19
Body: Stainless steel the inside of the element to outside, a clean exterior
Bonnet: Stainless steel is not an indication of freedom from contamination.
Valve: Stainless steel If the filter element shows evidence of blockage, 20
Bowl: replace with new element.
Metal: Stainless steel Clean the element retainer (21) and the upper and 7
lower gaskets (20) before replacing the filter 21
Element: Stainless steel
element –avoiding excessive overtightening of the retainer.
Elastomers: FKM or NBR Inspect the bowl O-ring (22, 28) for damage and
renew if necessary.
REPLACEMENT ITEMS 3. Clean or replace filter element when dirty.
Service Kit (includes items circled on exploded view): DISASSEMBLY
Filter element, 5µm (19) ................................................... 5984-01
Filter element, 25µm (19) ................................................. A080874-02 1. Filter/regulator can be disassembled without
Filter element, 40µm (19) ................................................. A080874-03 removal from air line. 24 22
Manual drain (FKM) 2. Shut off inlet pressure. Reduce pressure in inlet
( 8,12,13,14,15,16,17,22,24,26,27) ........................................ A080823-01 and outlet lines to zero. 23
Manual drain (NBR) 3. Turn adjustment (2) fully counterclockwise.
(8,12,13,14,15,16,17,22,24,26,27)......................................... A080823-03 4. Remove bowl – loosen screws (25 or 30)
Auto drain (FKM) counterclockwise with screw driver.
5. Disassemble in general accordance with the 25
(8,12,13,14,15,16,17,28,31) ................................................ A080823-02
Auto drain (NBR) item numbers on exploded view. Do not remove
(8,12,13,14,15,16,17,28,31) ................................................ A080823-04 the drains unless replacement is necessary.
Plastic adjusting knob........................................................ 74630-04 Remove and replace drains only if they malfunction. 26
PANEL MOUNTING DIMENSIONS
CLEANING
Panel mounting hole diameter: 54 mm (2.13”)
Panel thickness: 1.5 mm (0.06”) 1. Clean all the parts with warm water and soap. 27
2. Rinse and dry parts. Blow out internal passages in
body (9) with clean, dry compressed air. Blow air through
INSTALLATION filter element (19) to remove surface contaminants.
1. Shut off air pressure. Install filter/regulator
in air line -l vertically (bowl down), ASSEMBLY 28
l with air flow in direction of arrow on body, 1. Lubricate threads and nose of adjusting screw(2) and
l upstream of lubricators and cycling valves, bottom of upper spring rest (6) at regular intervals with 31
l as close as possible to the device being serviced. suitable grease MOLYCOTE 1000.
2. Connect piping to proper ports using pipe thread 2. Lubricate seals (12,16,20,22,28) with light coat of 29
sealant on male threads only. Do not allow sealant to lubricant MOLYCOTE DC111. 30
enter interior of unit. 2. Assemble the unit as shown on the exploded view.
3. Check and ensure all the screws are tightened 3. Torque Table
before pressurizing. Item Torque in Nm (Inch-Pounds) 31
4. Install a pressure gauge or plug the gauge ports. Gauge 5,25,30 (Screw) 4,9 to 5,9 (43,4 to 52,2)
ports can also be used as additional outlets for regulated air. 31
21 (Cent-post) 1,3 to 1,7 (11.5 to 15)
31 (Auto drain) 2,3 to 2,8 (20 to 25)
a subsidiary of IMI plc

B38P
Instructions
CAUTION
Water vapor will pass through these units and could
condense into liquid form downstream as air temperature
drops. Install an air dryer if water condensation could have
a detrimental effect on the application.
WARNING
These products are intended for use in industrial
compressed air systems only. Do not use these products
where pressures and temperatures can exceed those listed
under Technical Data.
If outlet pressure in excess of the filter/regulator
pressure setting could cause downstream equipment to
rupture or malfunction, install a pressure relief device
downstream of the filter/regulator. The relief pressure and
flow capacity of the relief device must satisfy system
requirements.
The accuracy of the indication of pressure gauges can
change, both during shipment (despite care in packaging)
and during the service life. If a pressure gauge is to be
used with these products and if inaccurate indications may
be hazardous to personnel or property, the gauge should be
calibrated before initial installation and at regular intervals
during use.
Before using these products with fluids other than air,
for non industrial applications, or for life-support systems
consult Norgren.

6 5 4 3 2 1
GENERAL DETAILS OF EQUIPMENT:
DESIGN CONDITION:
Process fluid: Pneumatic Air
Process fluid pressure max: 8 barg
190,00* 102,00* 170,00* 155,00* 20,00* Process fluid temperature max: 22/65,6 °C
D D
TP SITE DATA:
TP TP
04 Atmospheric pressure: --
02 TP 03 Air humidity: 100% Relative humidity non-condensing
Min/Max Allow. Ambient temperature: 22/43 °C
01
35,00*
NOTES:
*= Tollerance + - 5mm
1= j Centre of gravity
250,00*
68,00
EQUIPMENT LIST
n
65,00*
9, ITEM DESCRIPTION SERIES See MIO section
00 1 1 PNEUMATIC CYLINDER 1605 2A
2A SOLENOID VALVE 1 ICO3S 2B
68,00 TP 2B SOLENOID VALVE 2 ICO3S 2B
C 02
3 FILTER REGULATOR B38P 2C C
4 UNIDIR. FLOW REGULATOR FRX 2D
315,00* 5 304SS PANEL thk. 4mm -- --
6 SWAGELOK FITTINGS -- --
7 316SS TUBING 1/2" O.D. -- --
3D VIEW: -- -- -- --
TIE-IN POINT
448,00 ITEM DESCRIPTION SIZE UTILITIES
TP01 Instrument Air Inlet 1/4" NPT f 8 bar max
5 TP02 Instrument Air Exhaust 2x1/4" NPT f --
6 7
-- -- -- --
BOILER JOB 1167

B B
89,00
TAG LIST
PNEUMATIC DIAGRAM: N° PNEUMATIC ACTUATOR SOLENOID VALVE 1 SOLENOID VALVE 2
(TP03)
2A
1 03-XV-220 03-XY-220A 03-XY-220B
2 03-XV-210 03-XY-210A 03-XY-210B
4
-- -- -- --
3 SET @ 4bar
IN OUT
1
4
EX
(TP02)
2B AIR SUPPLY YES YES

(TP01)
3 2A 4 ELECTRICAL SUPPLY (TP03) YES NO
(TP04)
ELECTRICAL SUPPLY (TP04) NO YES
2B
CARRIAGE POSITION LEFT RIGHT
4
838,00
IN OUT
WEIGHT 27 KG.
EX
(TP02)
A A
REV DESCRIPTION DATE DWG APPROVED
4 AS BUILT 09/03/2017 RBA ELI M.B. VALVESERVICE S.R.L. Mod. DWG 02 Rev.0 Dimension: mm Client SOFINTER SPA Client P.O. no 8600020435
3 MODIFIED 31/01/2017 RBA ELI Via Zanica, 19 E Sheet UNI Material Code 09774 Our Job no
24050 Grassobbio (BG) 17/00019/C
2 MODIFIED 25/01/2017 RBA ELI A3
Tel 0039 (0)35 335621 Description PNEUMATIC ACTUATOR STROKE 400 Dwg no
1 MODIFIED 19/01/2017 RBA ELI Fax 0039 (0)35 3843864 Scale GDE17-00019-2
0 ISSUED 18/01/2017 RBA ELI info@mbvalveservice.it 1:6 Spec. no 1167-COMBENG 002 Sheet no 1 -1
6 5 4 3 2 1
ITALIANO ENGLISH FRANCAIS

Note generali: General notes : Généralités:
Questo documento fornisce le indicazioni generali per l’installazione, l’utilizzo e la manutenzione del prodotto a cui è allegato destinato This document provides general advice for the installation, use and maintenance of products designated for use in potentially explosive Ce document fournit toutes les informations nécessaires pour la mise en service, l’utilisation et la maintenance du produit ci-joint et
all’impiego in atmosfere potenzialmente esplosive secondo quanto richiesto dalla Direttiva 2014/34/UE – ATEX. atmospheres as stipulated by the 94/9/EC – ATEX Directive. destiné à l’emploi dans une atmosphère potentiellement explosive selon les prescriptions de la Directive 2014/34/UE – ATEX.
Requisiti essenziali in materia di sicurezza e salute: Essential Health and Safety Requirements ( EHSRs): Principes essentiels en matière de sécurité et de santé:
Questi cilindri sono progettati secondo l’allegato II della Direttiva 2014/34/UE – ATEX These cylinders have been designed in accordance with Annex II of the 94/9/EC Ces vérins ont été étudiés selon le paragraphe II de la Directive 2014/34/UE – ATEX et selon la norme CEN EN 1127-1:2011, EN 13463-
e secondo le norme CEN EN 1127-1:2011, EN 13463-1:2009 e EN 13463-5:2011 e sono classificati nel seguente modo: ATEX Directive, CEN EN 1127-1:2011, EN 13463-1:2009 e EN 13463-5:2011 standards; the classification is as follows: 1:2009 e EN 13463-5:2011 et sont classés de la manière suivante:
Legenda: Tech File : TX04000A/DTP Légende :
II = gruppo II (superficie) Key: II = groupe II (surface)
2 = categoria 2 (zona 1/21) II = equipment group II (surface) 2 = catégorie 2 (zone 1/21)
G = atmosfera esplosiva con gas o vapori 2 = equipment category 2 (zone 1/21) G = atmosphère explosive avec gaz ou vapeur
D = atmosfera esplosiva con polveri G = explosive atmosphere with gas or vapours D = atmosphère explosive avec poussières
c = modo di protezione (sicurezza costruttiva) D = explosive atmosphere with dust c = mode de protection (sécurité constructive)
T6, T5 = classe di temperatura
c = Ignition protection category T6, T5 = classe de température
T85°C, T100°C = massima temperatura superficiale
T6, T5 = Temperature Classes T85°C, T100°C = température maximale superficielle
Ta = range di temperatura ambiente (in funzione della classe di temperatura/massima temperatura superficiale)
Tech File = nome fascicolo tecnico depositato c/o organismo notificato T85°C, T100°C = Max. surface temperature Ta = plage de température ambiante (en fonction de la classe de température/température optimale superficielle)
Il presente documento è valido per i seguenti prodotti: Ta = Temperature range Tech File = nom du fascicule technique déposé auprès de l’organisme déclaré
Cilindri senza stelo serie X1600 e 1600 e accessori. Tech File = deposited technical file name / certifying body name Ce document est valable pour les produits suivants:
Utilizzo: This document is valid for the following products: Vérins série X1600, 1600 ainsi que les accessoires.
Utilizzare il cilindro rispettando il range di temperatura indicato e la velocità massima di 1,5 m/sec. Cylinders series X1600, 1600 and accessories. Utilisation:
Alimentare il cilindro con aria filtrata 20 micron e lubrificata. Use: Le vérin doit être utilisé dans la plage de température indiquée et à une vitesse maximum de 1,5 m/sec.
Avvertenze per l’installazione: These cylinders must be used within the indicated temperature range and with a maximum speed of 1,5m/sec. The air supply must be Il doit être alimenté avec de l’air filtré à 20 microns. La lubrification est nécessaire.
Evitare urti violenti all’estremità della corsa, per la versione ammortizzata regolare l’apertura degli spilli in modo che non vi sia un filtered to 20 microns and Air lubricated Précautions d’emploi à la mise en service:
fenomeno di rimbalzo nella fase iniziale di ammortizzo. Advice for installation: Eviter les chocs violents en extrémité de course, pour la version amortie, régler l’ouverture des vis d’amortissement de manière à ne pas
Raccordare le bocche di scarico della valvola di comando in modo che l’aria in scarico possa essere evacuata in una zona al di fuori Avoid heavy impact at the ends of stroke. On cushioned versions adjust the flow control valve as necessary to avoid a “bounce effect” provoquer de rebond dans la phase d’amortissement.
dell’atmosfera potenzialmente esplosiva (in particolare in presenza di polveri). La presenza di scariche elettrostatiche potrebbe dare during the initial phase of cushioning. Relier les orifices d’échappement du distributeur de commande de manière à pouvoir collecter les échappements et les évacuer hors de la
origine a scintille. Connect the exhaust ports of the control valve to flow controllers outside the hazardous area (particularly in dust applications.) zone d’atmosphère potentiellement explosive (en particulier lors de la présence de poussières). Eviter de frapper les parties métalliques
Evitare di colpire le parti metalliche del cilindro con oggetti metallici che potrebbero generare scintille di origine meccanica (per esempio Avoid striking the surface of the cylinder with metallic objects that could generate mechanical spark (for example, a rusted iron part du vérin avec des objets qui pourraient générer des étincelles d’origine mécanique (par exemple les parties en acier rouillé contre les
parti in ferro arrugginito contro le testate o la camicia in alluminio del cilindro). Non effettuare modifiche al cilindro (qualsiasi modifica striking the aluminium cylinder end caps). flasques en aluminium du vérin). Tout composant électrique monté additionnellement sur le vérin doit posséder sa propre
porterà al decadimento della dichiarazione di conformità del prodotto). Any electrical components (optional) fitted to the cylinder must be certified with their own separate ATEX certification. This certification ATEX, celle-ci doit respecter la catégorie exigée (2GD ou mieux) et être appropriée pour l’installation dans
Eventuali componenti elettrici, opzionali, montati sul cilindro, devono essere oggetto di certificazione ATEX separata, idonei alla zona di must meet the required ATEX category (2GD or better) and be suitable for installation in the required environment, considering l’environnement concerné, en considération du groupe de gaz, la classe de température, la température optimale superficielle et
installazione e categoria (2GD o migliore), al gruppo di gas, alla classe di temperatura/massima temperatura superficiale e alla temp. the group of gas, the temperature class, maximum surface temperature and environmental temperature…… environnementale.
ambiente. In the case of use below 0°C, it is necessary to remove the moisture in the air with a compressed air dryer that has a dew point En cas d’utilisation de température ambiante < 0°C, il est nécessaire d’éliminer l’humidité de l’air avec un sécheur d’air
In caso di utilizzo a temperatura ambiente < 0°C, è necessario prevedere un essiccatore che possa garantire un punto di rugiada inferiore lower than the cylinders operating temperature. comprimé garantissant un point de rosée inférieur à la température d’exploitation des vérins.
alla temperatura di impiego. In order to prevent electrostatic charges from building up ensure that no metallic parts are isolated, at the same time ensure Afin d'éviter la formation de charges électrostatiques, veiller à ce que toutes les parties métalliques soient isolées. Dans le même
Per evitare la formazione di cariche elettrostatiche, verificare non esistano parti metalliche isolate e che sia sempre garantita e assicurata that the cylinder is earthed on the fixed structure(end caps, barrel, mountings) and on the moving parts (carriage). temps, veuillez vous assurer que le vérin soit relié à la terre (flasques, tube, fixations) et sur les parties en mouvement (chariot).
nel tempo la messa a terra del cilindro, sia della struttura fissa (testate/camicia/fissaggi cilindro) sia delle parti in movimento (stelo). The user must take appropriate measures to prevent the formation of dust layers with periodic and regular cleaning. L’utilisateur doit prendre les mesures nécessaires afin d’éviter le dépôt et la formation de couches de poussières avec un
L’Utilizzatore deve adottare idonee misure organizzative per evitare il deposito e la formazione di strati di polvere, come provvedere a Do not modify the cylinder in any way. Any modification will affect the certification of the product.
regolare e periodica pulizia per limitare la formazione di strati. nettoyage périodique ou par des actions préventives.
Installation should be performed in accordance with the safety requirements prescribed in the UNI EN 983 standard - Safety of machinery N’effectuer aucune modification du vérin (Toute modification quelque soit rendra caduc la déclaration de conformité du produit).
Effettuare l’installazione rispettando i requisiti di sicurezza indicati dalla norma UNI EN 983 - Requisiti di sicurezza relativi a sistemi e loro - Safety requirements for fluid power systems and their components: Pneumatics.
componenti per trasmissioni oleoidrauliche e pneumatiche. Effectuer l'installation en respectant les dispositions de sécurité indiquées dans la norme UNI EN 983 - Dispositions de sécurité relatifs
Maintenance: aux systèmes et leurs composants pour les transmissions pneumatiques et hydrauliques.
Manutenzione: We recommend that the function of the cylinder is checked after every 250 km of use.
Verificare ogni 250 km di percorrenza del cilindro il buon funzionamento dello stesso verificando che non vi siano travasi d’aria tra le Maintenance:
Ensure there is no leakage across the piston and that the external surfaces of the cylinder are undamaged Dès que le vérin a parcouru 250 Km, vérifier le bon fonctionnement de l’ensemble et contrôler qu’il n’y a pas de fuite d’air entre les deux
camere del pistone e che il cilindro non presenti ammaccature superficiali. In caso di presenza di una delle anomalie precedentemente If any of these checks discover a fault, the cylinder should be replaced.
descritte, sostituire il cilindro con uno nuovo. chambres et que le vérin ne présente pas d’impact superficiel. En cas de présence d’une de ces anomalies, remplacer le vérin usagé par un
Periodically remove any dust that has accumulated on the surfaces of the cylinder. vérin neuf.
Rimuovere periodicamente eventuali residui di polvere presenti sulle superfici esterne del cilindro. Accessories:
In caso di scorrimento irregolare del cilindro in seguito ad un urto avvenuto sulla superficie esterna, interrompere il funzionamento e Accessoires:
CODE DESCRIPTION MATERIAL REFERENCE DESCRIPTION MATERIAU
sostituire il cilindro stesso.
1600.Ø.05F Complete sliding shoes guide ALUMINIUM 1600.Ø.05F Guidage par paliers complet pour verin ALUMINIUM
Accessori: 1600.Ø.01F Mounting foot brackets Ø25-32 / Ø40-63 STEEL / ALUMINIUM 1600.Ø.01F Equerre basse Ø25-32 / Ø40-63 ACIER / ALUMINIUM
CODICE DESCRIZIONE MATERIALE 1600.Ø.02F Intermediate support ALUMINIUM 1600.Ø.02F Support intermediaire ALUMINIUM
1600.Ø.05F Guida con pattini completa per cilindro ALLUMINIO 1600.Ø.03F Oscillating hinge STEEL 1600.Ø.03F Chape oscillante ACIER
1600.Ø.01F Piedino Ø25-32 / Ø40-63 ACCIAIO / ALLUMINIO These accessories have been analyzed, with the conclusion that these single elements DO NOT HAVE A POTENTIAL IGNITION SOURCE, and Nous avons analysé de plus les accessoires de fixation des vérins, cette analyse des composants démontre que les éléments seuls NE SONT
1600.Ø.02F Supporto intermedio ALLUMINIO consequently DO NOT FALL WITHIN THE SCOPE OF THE DIRECTIVE for the use they are intended for.
1600.Ø.03F Cerniera oscillante ACCIAIO
PAS CONSIDERES COMME UNE SOURCE POTENTIEL A RISQUE et par conséquent N’ENTRE PAS DANS LE CHAMP D’APPLICATION DE LA
CORRESPONDENCES BETWEEN HAZARDOUS AREAS, substances and CATEGORIES ACCORDING TO DIRECTIVE 94/9/EC DIRECTIVE par rapport à leur utilisation.
Sono stati analizzati inoltre gli accessori per il fissaggio del cilindro e l’analisi dei componenti dimostra che i singoli elementi NON HANNO
POTENZIALI FONTI DI INNESCO e di conseguenza NON RIENTRANO NEL CAMPO DI APPLICAZIONE DELLA DIRETTIVA per l’impiego per cui
Substancer HAZARDOUS AREAS Categories CORRESPONDANCE ENTRE ZONES DANGEREUSES, SUBSTANCES ET CATÉGORIES SELON LA DIRECTIVE 2014/34/UE
sono previsti. gas, vapours or mists Zone 0 1G Substances Zones de danger Catégories
CORRISPONDENZE TRA ZONE PERICOLOSE, SOSTANZE E CATEGORIE SECONDO DIRETTIVA 2014/34/UE gas, vapours or mists Zone 1 2G or 1G Gaz, vapeur ou brouillard Zone 0 1G
Sostanza Zona pericolosa Categorie gas, vapours or mists Zone 2 3G, 2G or 1G Gaz, vapeur ou brouillard Zone 1 2G ou 1G
Gas, vapori o nebbie Zona 0 1G dust Zone 20 1D Gaz, vapeur ou brouillard Zone 2 3G, 2G ou 1G
Gas, vapori o nebbie Zona 1 2G oppure 1G dust Zone 21 2D or 1D Poussières Zone 20 1D
Gas, vapori o nebbie Zona 2 3G, 2G oppure 1G dust Zone 22 3D, 2D or 1D Poussières Zone 21 2D ou 1D
Polveri Zona 20 1D Production batch identification: Poussières Zone 22 3D, 2D ou 1D
Polveri Zona 21 2D oppure 1D The production date is indicated on the label by two numbers and a letter, representing the week (as a progressive number from 01 to 52) Identification des lots de production:
Polveri Zona 22 3D, 2D oppure 1D and year; La date de production est indiquée sur l’étiquette du produit au moyen de 2 chiffres suivis d’une lettre qui identifie dans l’ordre la
Identificazione lotto produzione: Example : 49Y (week 49, year 2011). semaine (chiffre progressif de 01 à 52) et l’année de production; Exemple 49Y (49ème semaine de l’année 2011).
La data di produzione è presente sull’etichetta del prodotto mediante 2 numeri seguiti da una lettera che identificano nell’ordine la Y = 2011 Z = 2012 A = 2013 B = 2014 C = 2015 D = 2016 E = 2017 Y = 2011 Z = 2012 A = 2013 B = 2014 C = 2015 D = 2016 E = 2017
settimana (numero progressivo da 01 a 52) e l’anno di produzione. Esempio 49Y: settimana 49, anno 2011.
Y = 2011 Z = 2012 A = 2013 B = 2014 C = 2015 D = 2016 E = 2017
TX040005/IST – REV 3 – 04/2016 1/2

DEUTSCH ESPAÑOL
Allgemeines: Notas generales:
Diese Produktinformation gibt allgemeine Ratschläge für die Anwendung , Installation und Wartung von Este documento facilita las indicaciones generales para la instalación, la utilización y el mantenimiento del producto al cual se adjunta,
Produkten zur Anwendung in potentiell explosiver Atmosphäre gemäß 2014/34/UE – ATEX Direktive. destinado al empleo en atmósfera potencialmente explosiva siguiendo las exigencias de la Directiva 2014/34/UE – ATEX.
Wichtige gesundheits und Sicherheitserfordernisse (EHSRs): Requisitos esenciales en materia de seguridad y salud:
Diese Zylinder werden hergestellt gemäß Anlage II der 2014/34/UE – ATEX Direktive, Estos cilindros están diseñados según el anexo II de la Directiva 2014/34/UE – ATEX y según las normas CEN EN 1127-1:2011, EN 13463-
CEN EN 1127-1:2011, EN 13463-1:2009 e EN 13463-5:2011 Standard. Die Klassifizierung ist wie folgt: 1:2009 e EN 13463-5:2011 y están clasificados del siguiente modo:
Legende: Legenda:
II = Gruppe II (Oberfläche) II = grupo II (superficie)
2 = Kategorie 2 ( Zone 1/21) 2 = categoría 2 (zona 1/21)
G = explosive Atmosphäre durch Gase oder Dämpfe G = atmósfera explosiva con gas o vapores
D = explosive Atmosphäre durch Pulver oder Stäube D = atmósfera explosiva con polvos
c = modo de protección (seguridad constructiva)
c = Art der Sicherheit (Konstruktionssicherheit)
T6, T5 = clase de temperatura
T6, T5 = Temperaturklassen
T85°C, T100°C = máxima temperatura superficial
T85°C, T100°C = maximale Oberflächentemperatur Ta = range de temperatura entorno (en función de la clase de temperatura / máxima temperatura superficial)
Ta = Umgebungstemperaturbereich (an Abhängigkeit zur Temperaturklasse/max. Oberflächentemperatur) Tech Expediente = nombre fascículo técnico depositado y/o organismo notificado
Tech File = festgelegter Name des technischen Files El presente documento es válido para los siguientes productos:
Dieses Dokument ist gültig für folgende Produkte: Cilindos serie X1600, 1600 y accesorios.
Zylinder X1600, 1600 und Anbauteile. Utilización:
Einsatz: Utilizar el cilindro respetando el rango de temperatura indicado y la velocidad máxima de 1,5 m/seg.
Oben benannte Zylinder müssen innerhalb der vorgegebenen Temperaturbereiche eingesetzt werden und mit einer max. Geschw. Von Alimentar el cilindro con aire filtrado a 20 micras. La lubricación es necesaría
1,5m/sec. Advertencias para la instalación:
Die Druckluft muß bis auf 20ym gefiltert sein. Geölte Luft ist erforderlich. Evitar golpes violentos al final de carrera; para la versión amortiguada regular la apertura de los tornillos de modo que no se produzca un
Hinweise für den Einbau: efecto de rebote en la fase inicial de la amortiguación
Vermeiden Sie harte Schläge an den Hubenden. Bei Ausführungen mit einstellbarer Endlagendämpfung sollte die Abluftdrossel so Canalizar las vías de escape de la válvula de mando de forma que el aire de escape pueda ser evacuado en una zona fuera de la atmósfera
eingestellt werden, daß der „Aufprall Effekt“ während der Dämpfungsphase vermieden wird. Die Abluft der Drosseln sollte außerhalb der potencialmente explosiva (especialmente en presencia de polvo).
gefährlichen Bereiche geleitet werden (vor allem bei Staub). Vermeiden Sie mögliche Reibung zwischen den Zylindern und anderen Evitar golpear las partes metálicas del cilindro con objetos metálicos que pudieran generar chispas de origen mecánico (por ejemplo partes
Matallteilen, die eine Zündquelle sein können (zum Beispiel ein auf einen Zylinder fallendes Eisenteil). de hierro oxidado contra cabezas de aluminio del cilindro).
Die elektronischen Komponenten welche optional auf dem Zylinder montiert werden, müssen eine gesonderte ATEX Eventuales componentes eléctricos, opcionales, montados sobre el cilindro tienen que ser objeto de certificación ATEX separada, idóneos a
Zertifizierung besitzen, geeignet für den Einbaubereich und Kategorie (2GD oder höher), der Gasgruppe, Temperaturklasse / la zona de instalación y categoría (2GD o mejor), al grupo de gas, a la clase de temperatura/máxima temperatura superficial y al
maximale Oberflächentemperatur und der Umgebungstemperatur. temperatura del entorno.
Im Falle der Verwendung bei Umgebungstemperatur < 0° muss man einen Trockner vorsehen, der sicherstellt, dass der En caso de empleo a temperatura entorno <0°C, es necesario prever un secador que pueda garantizar un punto de rocío inferior a la
Taupunkt niedriger ist als die Arbeitstemperatur. Um elektrostatische Aufladungen zu vermeiden, muss sichergestellt werden, temperatura de empleo.
dass metallische Teile nicht isoliert werden. Außerdem muss eine Erdung des Zylinders (Zylinderkopf und -boden, Zylinderrohr) Para evitar la formación de cargas electrostáticas, verificar que no existan partes metálicas aisladas y que siempre este asegurada la toma a
und aller Anbauteile zu jeder Zeit garantiert sein. tierra del cilindro, sea de la estructura fija (camisa / fijaciones cilindro), sea de las partes en movimiento (carro).
Der Anwender muss geeignete organisatorische Maßnahmen ergreifen um die Bildung von Staubschichten zu vermeiden , sowie El utilizador tiene que adoptar medidas idóneas organizativas para evitar el depósito y la formación de capas de polvo, como proveer la
periódica limpieza, para limitar la formación de capas.
in festgelegten regelmäßigen Abständen eine Reinigung durchführen um die Bildung von Staubschichten einzugrenzen.
No efectuar modificaciones al cilindro (cualquier modificación llevará a la nulidad de la declaración de conformidad del producto).
Nehmen Sie keine baulichen Veränderungen am Zylinder vor. Jede Veränderung führt dazu, daß das Produkt die Zertifizierung
Efectuar la instalación respetando las medidas de seguridad indicadas por la norma UNI EN 983 - Requisitos de seguridad correspondientes
verliert.Nehmen Sie keine baulichen Veränderungen am Zylinder vor. Jede Veränderung führt dazu, daß das Produkt die Zertifizierung a sistemas y sus componentes para transmisiones oleohidraúlicas y neumáticas.
verliert. Beachten Sie bei der Inbetriebnahme die Sicherheitsbestimmungen gemäß DIN EN 983, Sicherheit von Maschinen - Mantenimiento:
Sicherheitstechnische Anforderungen an fluidtechnischen Anlagen und deren Bauteile - Pneumatik. Comprobar cada 250 km de recorrido del cilindro el buen funcionamiento del mismo verificando que no haya comunicación de aire entre
Wartung: las cámaras a través del pistón y que el cilindro no presente abolladuras superficiales. En caso de presencia de una de las anomalías
Wir empfehlen die Funktion des Zylinders alle 250 km Laufleistung zu überprüfen. anteriormente descritas, sustituir el cilindro por uno nuevo.
Vergewissern Sie sich daß Kolben keine Leckagen auftreten und das der Zylinder äußerlich nicht beschädigt ist. Accesorios:
Sollte einer dieser Fehler auftreten, dann sollte der Zylinder ausgetauscht werden CÓDIGO DESCRIPCIÓN MATERIAL
Zubehör: 1600.Ø.05F Patin guiado para cilindro ALUMINIO
ARTIKELNUMMER BEZEICHNUNG MATERIAL 1600.Ø.01F Pata Ø25-32 / Ø40-63 ACERO / ALUMINIO
1600.Ø.05F Gleitführung ALUMINIUM 1600.Ø.02F Soporte intermedio ALUMINIO
1600.Ø.01F Fuß Ø25-32 / Ø40-63 STAHL / ALUMINIUM 1600.Ø.03F Charnela oscillante ACERO
1600.Ø.02F Mittenünterstutzung ALUMINIUM Han sido analizados además los accesorios para la fijación del cilindro y los análisis de los componentes demuestran que los elementos
1600.Ø.03F Mitnehmer STAHL simples NO TIENEN FUENTES POTENCIALES DE IGNICIÓN y por consiguiente NO ENTRAN EN EL CAMPO DE APLICACIÓN DE LA DIRECTIVA
Diese Anbauteile wurden untersucht, mit dem Ergebnis DAS DIESE ELEMENTE KEINE POTENTIELLE ZÜNDQUELLE DARSTELLEN, UND en el empleo para el que han sido previstos.
DARUM NICHR UNTER DIE VORGABEN DER DIREKTIVE FALLEN. CORRESPONDENCIA ENTRE ZONA PELIGROSA, SUSTANCIA Y CATEGORÍA SEGÚN DIRECTIVA 2014/34/UE
Korrespondenz zwischen der Gefahrensubstanz/Umgebung, der Zone und Kategorie nach Direktive 2014/34/UE Sustancia Zona peligrosa Categoría
Substanz Gefahrenzone Kategorie Gas, vapores o nieblas Zona 0 1G
Gas, Dämpfe oder Nebel Zona 0 1G Gas, vapores o nieblas Zona 1 2G o bien 1G
Gas, Dämpfe oder Nebel Zona 1 2G oder 1G
Gas, vapores o nieblas Zona 2 3G, 2G o bien 1G
Gas, Dämpfe oder Nebel Zona 2 3G, 2G oder 1G
Polvos Zona 20 1D
Pulver oder Stäube Zona 20 1D
Polvos Zona 21 2D o bien 1D
Pulver oder Stäube Zona 21 2D oder 1D
Polvos Zona 22 3D, 2D o bien 1D
Pulver oder Stäube Zona 22 3D, 2D oder 1D
Identificación lotes de producción:
Produktidentification: La fecha de producción está presente en la etiqueta del producto mediante 2 números seguidos de una letra que identifican por orden la
Das Herstelldatum ist auf dem Label mit einer Zahlen – Buchstaben Kombination abzulesen, wobei die Nummer für die Kalenderwoche semana (número progresivo del 01 al 52) y el año de producción. Ejemplo: 49Y (semana 49, año 2011).
steht (fortlaufend von 1 bis 52) und der Buchstabe für das Jahr, zum Beispiel 49Y (Woche 49, Jahr 2011).
Y = 2011 Z = 2012 A = 2013 B = 2014 C = 2015 D = 2016 E = 2017
Y = 2011 Z = 2012 A = 2013 B = 2014 C = 2015 D = 2016 E = 2017
TX040005/IST – REV 3 – 04/2016 2/2

Marking Indicator Description
MARKING (TYPICAL) DESCRIPTION The ICO3S is an Ex certified solenoid valve used to control a
IMI Precision Engineering pressurised media (liquid or gas). The standard variant
WARNING: DO NOT OPEN WHEN AN COVER FORMS PART OF FLAMEPROOF ENCLOSURE AND SHOULD NOT BE
Thompson Valves Ltd EXPLOSIVE ATMOSPHERE IS PRESENT REMOVED WHEN AN EXPLOSIVE ATMOSPHERE IS PRESENT
(3/2 0.5-12 bar automatic) has the following characteristics.
17 Balena Close WARNING:MAXIMUM INTERNAL RISE 30K, THIS INDICATES THE MAX INTERNAL TEMPERATURE RISE,
USE SUITABLY RATED CABLE THIS CAN BE USED TO EVALUATE CABLE TEMPERATURE RATING.
Creekmoor Industrial Estate Ex I M2 ATEX MARKING: EQUIPMENT SUITABLE FOR MINING APPLICATIONS.
- Equipment weighs 2.0 kg (¼”) 2.5kg (1/2”) Typical.
EQUIPMENT GROUP 1, EQUIPMENT CATEGORY M2.
Poole - Valve’s typical speed <70ms pull in, <50ms drop out.
BH17 7EF Ex II 2 G D ATEX MARKING: EQUIPMENT SUITABLE FOR EXPLOSIVE GAS AND DUST
ENVIRONMENTS. EQUIPMENT GROUP 2, EQUIPMENT CATEGORY 2.
United Kingdom IP66 INGRESS PROTECTION RATING FOR BOTH ATEX AND IEC
66 = STRONG WATER JETS, DUST TIGHT
Standard ICO3 ¼” Installation Drawing
Ex d I EQUIPMENT RELIES ON Exd PROTECTION
SUITABLE FOR USE IN Ex GAS GROUP I (MINING APPLICATIONS)
Tel: +44 (0)1202 697521
Ex mbe IIC EQUIPMENT RELIES ON Exmbe PROTECTION
sales@thompson-valves.com Ex d IIC EQUIPMENT RELIES ON Exd PROTECTION

www.imi-precision.com Ex tb IIIC EQUIPMENT RELIES ON Extb PROTECTION
SUITABLE FOR USE IN COMBUSTIBLE METAL DUST ENVIRONMENTS
ICO3S T4 Ta (-55°C to 90°C) T-CLASSIFIED EQUIPMENT SHOULD NOT BE EXPOSED TO TEMP OUTSIDE
THE SPECIFIED TEMPERATURE RANGES (Ta). TYPICAL MARKING SHOWN.
Y013AA1H1BS WORKING CONDITIONS SHOULD NOT EXEED THE CAPABILITIES OF
COMPONENTS /MATERIALS DETAILED IN THE CONSTRUCTION
WP 0 - 12BAR THE RANGE AND MAXIMUM MEDIA WORKING PRESSURE RATING
Installation, Operation and INLET, OUTLET, VENT PIPEWORK SHOULD BE CONNECTED SUCH THAT IT FUNCTIONS AS PORT
MARKINGS
Maintenance Instructions (MI0294 Rev.27) 24V DC 3W (1/4”) 8W (1/2”) THE ELECTRICAL SUPPLY LIMITS ARE NOMINAL VOLTAGE +/-10%
Serial No. FOR YEAR OF MANUFACTURE REFER TO CERTIFICATE OF CONFORMITY
Product certificate numbers can be found on the product datasheet or

contact sales@thompson-valves.com
Expected duty
The ICO3S should not be used in excess of the expected duty limits
THE ICO3S SHALL ONLY BE USED IN ACCORDANCE WITH as shown below. In special applications that exceed these duty limits,
REQUIREMENTS OF THIS DOCUMENT. READ ALL THE contact sales@thompson-valves.com before installing / operating an
INSTRUCTIONS CAREFULLY BEFORE USING THIS PRODUCT. ICO3S.
The ICO3S is designed and certified to meet the requirements of: CONDITIONS LIMITS
IEC61508:2010 as being suitable for use in safety-related applications FUNCTION The working temperature and pressure shall not exceed the marked label
up to and including SIL3 where safety operation of the valve is by de- rating. The valve should not be operated at a speed >6 cycles/min.
energisation of the solenoid. This manual covers all installation, ENVIRONMENT All external conditions shall not exceed IP66. External conditions shall not Install cable using an appropriate certified gland fit for duty.
maintenance and operation requirements for these applications. degrade the Exd enclosure or pressure boundary. Recommended Fitting as shown below - MAX. TORQUE 40 Nm
MAINTENANCE 6 years SIL rated safety systems,/ 10 years normal application / or 100,000
PERIOD cycles / 12 month Max Proof Test Interval.
Installation by suitably-trained personnel in accordance with the For best practice exercise the valve once per month.
applicable code of practice e.g. EN 60079-14: LIFE 20 years or 1million cycles. For correct disposal see end of equipment life
statement
Inspection and maintenance of equipment by trained personnel in MEDIA Media: Instrument air or non-corrosive hydraulic fluids - clean and free from
accordance with applicable code of practice e.g. EN 60079-17 particulate pollution. A suitable inlet filter should be fitted (eg. 20μm)
O-RINGS Application must not exceed temperature rating of o-rings as shown on valve
Repair of this equipment by suitably trained personnel in accordance label/datasheet. If in doubt contact Sales@thompson-valves.com.
with the applicable code of practice e.g. EN 60079-19
Part Number Details
Components to be incorporated into or used as replacement parts for
the equipment shall be fitted by suitably trained personnel in
accordance with this documentation.
End Of Equipment Life

WARNING undue torque forced on solenoid pot can damage or
The metallic elements of this equipment are made from material which loosen interface bolts.
can be recycled. At the end of the equipment’s service life it should
be sent to a recycling centre to be re-used.
The elastomeric elements that are not able to be recycled should be Storage and Handling
disposed of responsibly through a reputable waste disposal company.
Store the ICO3 in a clean and dry condition. Temperature 0 - 25 C,
humidity <75%. Storage areas shall be non-corrosive and not contain
ozone producing equipment (e.g. welding equipment, mercury vapour
lamps). Personal protection should be used during handling. All ports
should remain sealed and the valve markings made visible
Operation Only IMI Precision Thompson Valves spares kits should be used.
All ICO3S solenoid valves consist of an Ex enclosure. Exd flameproof The ICO3S has an IP66 rating. Degradation of the IP66 seals / Valve spares kit includes: seals and operating spring supply specially
joints shall not be damaged, all threaded joints shall be fully engaged. gaskets / sealing faces or failure to tighten all sealing joints, will allow designed for the duty. Incorrect seals will affect valve performance.
water to leak inside the enclosure. Lubrication: “Molykote 55” medium grease -55°C to 90°C:
For best practice, the valve should ideally be exercised at least Part A. Disassembling a standard valve
once a month. 1. Remove the Cap Head Bolts at the base of the valve body and
remove valve body and armature assembly.
Removing an existing valve 2. Remove C/Sunk screws holding valve to flange and remove
Tools: 3mm Electrical Screw Driver valve body.
Allen Keys: 2.5mm, 3mm, 4mm and 5mm. 3. Secure armature with a “Tommy bar” and using a spanner
5mm A/F spanner. 5mm “Tommy Bar”. remove the spool assembly.
4. Separate all valve assembly components, noting orientation,
1. Obtain work permit and check area for hazards. sequence and position of parts.
2. Isolate valve from all pipeline and electrical supplies.
3. Loosen M5 locking screw and unscrew cover. Part B. Examining a valve’s components
4. Disconnect supply cable and remove. Examine and replace all worn or damaged parts.
5. Remove pipe connections from valve assembly. The flameproof joints will retain their original certified clearances
6. Unscrew mounting bolts and remove the valve. provided they are not damaged.
Replace all seals, seats and operating spring with spare parts kit. All
seals should be lubricated and have no deformation. All seating and
Installing a valve sealing faces should be free from contamination, marks, scratches,
General requirements etc.
- Pipe work and media must be clean. DO NOT MODIFY OR RECLAIM FLAMEPROOF JOINTS.
- Suitable Inlet filters are recommended (e.g. <20 microns).
- Prevent pipe sealant from entering the system. Part C. Assembling a standard valve
- Use only correct tools (i.e. as listed above). Smear all seals with recommended grease.
- Do not use valve as a lever. Build assemblies in reverse order shown in part A.
The pressurised media is retained within the valve assembly (pressure - Earth equipment to prevent the build up of electrostatic charge. Torque settings:
boundary) by the mechanical strength of all its metal parts, seats and - Ensure all interfacing equipment is rated to the expected duty - Valve spool to 4Nm.
seals. Degradation of any of these components will cause the valve to conditions and will not degrade the integrity of the ICO3S. - Valve M5 bolts to 5.4Nm.
leak. - Ensure that valve lid and o-ring seal are fitted and the lid is tightened - Valve M4 bolts to 2.7Nm.
down after installation - Apply “loctite 243 thread-locker” to mentioned bolts.
The certification of this equipment relies upon 316 stainless steel -Contact sales@thompson-valves.com for valve orientation procedure
materials used for its construction. QACA-423 Part D. Adjusting & testing a standard valve
If the equipment is likely to come in contact with aggressive Mounting 2. Make connections to valve ports as per markings.
substances, then it is the responsibility of the user to take suitable An ICO3S will function satisfactorily when mounted inclined from the 3. Apply air to valve body and energise coil.
precautions, for which prevent it from being adversely affected, thus vertical. However for maximum life and efficiency mount vertically - Do 4. Using 3/16” AF Allen Key screw down core to the point
ensuring that the type of protection provided by the equipment is not not invert. The ICO3S is not designed for use in vibration just before ports leak.
compromised. applications. Do not mechanically stress the equipment. 5. Screw core back a further 1/10 of a turn.
- The user shall provide ventilation around the solenoid enclosure.
6. Ensure valve operates correctly at Nom Voltage  12%
Aggressive substances: e.g. acidic liquids or gases that may - The Exd enclosure shall not be lagged.
attack metals or solvents that may affect polymeric materials. - Ensure pipe work, cable glands and cabling are fit for rated duty. Part E. Problems
Procedure If the ICO3 does not function as intended, do not install valve. Repeat
Suitable precautions: e.g. regular checks as part of routine 1. Mount valve utilizing 2 off ø6mm mounting holes through body. the maintenance procedures Parts A to D.
inspections or establishing from them the material’s data sheets that it 2. Make connections to the valve ports as required. 1/4NPT max If the problem persists, contact Sales@thompson-valves.com for
is resistant to specific chemicals. torque 7NM. 1/2NPT max torque 30NM. assistance.
The flow path of the media is altered by moving the spool assembly 4. Install cable using an appropriate certified gland fit for duty. If you are not sure about any application, maintenance, or
and engaging / disengaging the seats. (MAXIMUM TORQUE 40 Nm) technical issue, contact Thompson Valves Sales for advice.
The spool assembly can be moved by either: 5. Make terminal connections as labelled. All terminals must be
 Energising the coil to produce an electromotive force. tightened before commissioning.
 Applying a pressure to a piston. 6. Replace solenoid cover and lock M5 locking screw.
 Applying a mechanical force to a linkage.
 Compressing a mechanical spring.
Maintenance
It is recommended that all products be returned to Thompson
Restricting the spool movement or allowing the seats to degrade, will Valves for refurbishment.
not allow the flow to be re-directed.
B38P
Instructions
Filter/Regulator
B38P-˙˙4-˙˙M˙
Port Temperature (Material) Diaphragm Drain Element Spring(Outlet Pressure Range)* Thread Form
2…1/4” 4…-40 to 80ºC (Nitrile) 4…Relieving A…Auto Drain 1…5µm M…0.5 to 10bar (7.3 to 145 psig) A…NPT
3…3/8” 5…-20 to +80ºC (FKM) B…Manual drain 2…25µm G…ISO G parallel
3…40µm
TECHNICAL DATA ADJUSTMENT

Fluid: Compressed air 1. Before applying inlet pressure to filter/regulator,
Maximum pressure: turnadjustment (2) counterclockwise to remove all
Manual drain: 31 bar (450 psig) forceon regulating spring (7). 1
Auto drain: 17 bar (247 psig) 2. Apply inlet pressure, then turn adjustment (2)
clockwise to increase and counterclockwise to
Operating temperature*:
decrease pressure setting.
-40° to +80°C (-40° to +176°F) 8
3. Always approach the desired pressure from a lower
* Air supply must be dry enough to avoid ice formation at pressure. When reducing from a higher to a lower
temperatures below +2°C (+35°F). setting, first reduce to some pressure less than that
2
Particle removal: 5µm, 25µm, or 40µm filter element desired, then bring up to the desired pressure.
Air quality: Within ISO 8573-1, Class 3 and Class 5 NOTE 9
(particulates) With non-relieving filter/regulators, make pressure
Typical flow with 10 bar (150 psig) inlet pressure, 6,3 bar reductions with some air flow in the system. If 11
made under no flow (dead-end) conditions, the
(90 psig) set pressure and 1 bar (15 psig) droop from 3
filter/regulator will trap the over-pressure in the
set: 40 dm³/s (85 scfm) downstream line. 12
Manual drain bowl size: 0.025 litre (1 fluid ounce) 4. ADJUSTING SCREW ADJUSTMENT. Turn the lock
Auto drain bowl size: 0,025 litre (1 fluid ounce) 4 10
nut(3) down to lock pressure setting.
Auto drain connection: 1/4 NPT 5. NECK MOUNTING ADJUSTMENT. Tighten panel nut 13
Automatic drain operating conditions (float operated): (1) to lock the B38P on the mounting bracket. 5
Bowl pressure required to close drain: Greater than 0,3 14
bar (5 psig) SERVICING 15
Bowl pressure required to open drain: Less than 0,2 bar 1. Open manual drain to expel accumulated liquids. 16
(3 psig) Keep liquids below element retainer (21). 17
Manual operation: Depress pin inside drain outlet to 2. At approximately 6 month intervals it is advisable to
remove the bowl assembly by removing 18
drain bowl
the securing screws (5) and unscrewing element
Gauge ports: 1/4 NPT as per main ports retainer (21) to remove the elements (19)
Materials: for inspection.Since the direction of air flow is from 6 19
Body: Stainless steel the inside of the element to outside, a clean exterior
Bonnet: Stainless steel is not an indication of freedom from contamination.
Valve: Stainless steel If the filter element shows evidence of blockage, 20
Bowl: replace with new element.
Metal: Stainless steel Clean the element retainer (21) and the upper and 7
lower gaskets (20) before replacing the filter 21
Element: Stainless steel
element –avoiding excessive overtightening of the retainer.
Elastomers: FKM or NBR Inspect the bowl O-ring (22, 28) for damage and
renew if necessary.
REPLACEMENT ITEMS 3. Clean or replace filter element when dirty.
Service Kit (includes items circled on exploded view): DISASSEMBLY
Filter element, 5µm (19) ................................................... 5984-01
Filter element, 25µm (19) ................................................. A080874-02 1. Filter/regulator can be disassembled without
Filter element, 40µm (19) ................................................. A080874-03 removal from air line. 24 22
Manual drain (FKM) 2. Shut off inlet pressure. Reduce pressure in inlet
( 8,12,13,14,15,16,17,22,24,26,27) ........................................ A080823-01 and outlet lines to zero. 23
Manual drain (NBR) 3. Turn adjustment (2) fully counterclockwise.
(8,12,13,14,15,16,17,22,24,26,27)......................................... A080823-03 4. Remove bowl – loosen screws (25 or 30)
Auto drain (FKM) counterclockwise with screw driver.
5. Disassemble in general accordance with the 25
(8,12,13,14,15,16,17,28,31) ................................................ A080823-02
Auto drain (NBR) item numbers on exploded view. Do not remove
(8,12,13,14,15,16,17,28,31) ................................................ A080823-04 the drains unless replacement is necessary.
Plastic adjusting knob........................................................ 74630-04 Remove and replace drains only if they malfunction. 26
PANEL MOUNTING DIMENSIONS
CLEANING
Panel mounting hole diameter: 54 mm (2.13”)
Panel thickness: 1.5 mm (0.06”) 1. Clean all the parts with warm water and soap. 27
2. Rinse and dry parts. Blow out internal passages in
body (9) with clean, dry compressed air. Blow air through
INSTALLATION filter element (19) to remove surface contaminants.
1. Shut off air pressure. Install filter/regulator
in air line -l vertically (bowl down), ASSEMBLY 28
l with air flow in direction of arrow on body, 1. Lubricate threads and nose of adjusting screw(2) and
l upstream of lubricators and cycling valves, bottom of upper spring rest (6) at regular intervals with 31
l as close as possible to the device being serviced. suitable grease MOLYCOTE 1000.
2. Connect piping to proper ports using pipe thread 2. Lubricate seals (12,16,20,22,28) with light coat of 29
sealant on male threads only. Do not allow sealant to lubricant MOLYCOTE DC111. 30
enter interior of unit. 2. Assemble the unit as shown on the exploded view.
3. Check and ensure all the screws are tightened 3. Torque Table
before pressurizing. Item Torque in Nm (Inch-Pounds) 31
4. Install a pressure gauge or plug the gauge ports. Gauge 5,25,30 (Screw) 4,9 to 5,9 (43,4 to 52,2)
ports can also be used as additional outlets for regulated air. 31
21 (Cent-post) 1,3 to 1,7 (11.5 to 15)
31 (Auto drain) 2,3 to 2,8 (20 to 25)

B38P
Instructions
CAUTION
Water vapor will pass through these units and could
condense into liquid form downstream as air temperature
drops. Install an air dryer if water condensation could have
a detrimental effect on the application.
WARNING
These products are intended for use in industrial
compressed air systems only. Do not use these products
where pressures and temperatures can exceed those listed
under Technical Data.
If outlet pressure in excess of the filter/regulator
pressure setting could cause downstream equipment to
rupture or malfunction, install a pressure relief device
downstream of the filter/regulator. The relief pressure and
flow capacity of the relief device must satisfy system
requirements.
The accuracy of the indication of pressure gauges can
change, both during shipment (despite care in packaging)
and during the service life. If a pressure gauge is to be
used with these products and if inaccurate indications may
be hazardous to personnel or property, the gauge should be
calibrated before initial installation and at regular intervals
during use.
Before using these products with fluids other than air,
for non industrial applications, or for life-support systems
consult Norgren.

APPENDIX D

Operating Manual
ES-5x2x W / WL
Euroswitch proximity switches have been designed using the la test materials and production methods offering
industry a highly dependable hermetically sealed sensor for use in the most arduous and hazardous
application. Euroswitch sensors operate with the use of an external actuator and are ideal for all sensing
applications where a reliable signal is required, it is extremely small in size and has many variants.
Housing : 316L Stainless Steel

ES-5x2x-W ES-5x2x-WL
Contacts : SPDT or DPDT
IP Rating : IP66/67
Certificates : Exd // Ex ia
Dimensions Magnetic Actuator

ES-5x2x-W
MA-4S
Ø 5/8” UNF
M10 17
45
Conduit entry
½” NPT-F 16 6,5 19
55 10
MA-7S
120
M10 20
ES-5x2x-WL
16 11 22
Ø 5/8” UNF
45 Connections
Rodium sealed in inert gas (Gold plated, Tungsten on request)
55 10
SPDT DPDT LFM
Conduit entry NO NC NO NC NO NC Line Fault Monitoring
123
½” NPT-F Com. Com. Com. connect 2 & 3
1 2 3 1 2 3 4 5 6 2 3
Switches should be mounted on non ferrous materials otherwise sensing
ranger will be reduced, therefore the use of a spacer is recommended
Ratings *** Also available with DPDT contact - (put the suffix D after the sensor code, example : ES-5022-W becomes ES-5022 -D-W)
ATEX ATEX / IECEx IECEx CABLE MAX MAX MAGNETIC

STANDARD TEMP. CONTACTS POWER
Exd Exia Exd ENTRY CURRENT VOLT ACTUATOR
ES-5121W ES-5021W ES-5221W ES-5321W -20°C +70°C MA-4S MA-7S

1/2” NPT-F
ES-5122W ES-5022W ES-5222W ES-5322W -60°C +120°C 8mm 15mm
with with
24Vdc 2,5A SPDT SPDT
ES-5121WL ES-5021WL ES-5221WL ES-5321WL -20°C +70°C 400ac contact contact
SPDT 110Vac 540mA 60W.VA
400dc
ES-5122WL ES-5022WL ES-5222WL ES-5322WL -60°C +120°C 1/2” NPT-F 240Vac 250mA
6mm 9mm
(90°) with with
DPDT DPDT
contact contact
ES-5422WL UL / CSA Class I Division 1 Groups A, B, C, D -60°C +105°C
Certificates
A T E X / IECEx / INMETRO --- Certificate Exd Certificate N° TC RU C-GB.MIO62.B.01270
II 2GD Ex d IIC T6 Gb, Ex tb IIIC T85°C Db (Ta -20°C +70°C) IP66/67
II 2GD Ex d IIC T4 Gb, Ex tb IIIC T135°C Db (Ta -60°C +120°C) IP66/67 Certificate N° 20150821-E364212
Class I Division 1 Groups A, B, C, and D Hazardous Locations
A T E X / IECEx / INMETRO --- Certificate Ex ia
Ex ia IIC T6 Ga // Ex ia IIIC T85°C IP66/67 Da (-60°C +80°C)
Ex ia IIC T4 Ga // Ex ia IIIC T135°C IP66/67 Da (-60°C +125°C)
Available “Line Fault Monitoring” (LFM) version with resistors.
Landmark srl
+39.0331.596.037
V.07.15 UK Pag. 1
Operating Principals
Switch actuation
Euroswitch is actuated by the introduction of a magnetic actuator into the sensing envelope of the proximity switch.
The switch on, or the point at which the actuator causes the switch to operate, is given in mm and is often quoted as
the sensing range of the switch (sn). Once the switch has operated it will remain in that state until the actuator is
withdrawn, the actuator will need to be withdrawn by a greater distance to enable the switch to reset to its unoperated
state, the difference between the switch on and switch off points is known as the switch hysteresis.
Sensing range
The sensing range referred to for individual switch and magnetic actuator is given in ideal conditions, these distances
can vary due to several outside influence. It is first of all recommended that care is taken to ensure that both the
switch and the actuator are in line and that their magnetic centres are opposite each other, also that both the switch
and actuator are mounted away from ferro magnetic materials which could reduce the sensing range of the switch. If it
is not possible to keep away from ferro magnetic materials euroswitch offers a range of spacers in either Brass or
Stainless Steel to help reduce this effect.
Installation The actuator can approach the switch in two planes :
Rectangular types PARALLEL : where the magnet slides across the face of the switch
whilst keeping parallel to the switch until the point is reached where
the switch operates, if the travel is maintained after the switch on magnet
point, a second switch on point will be reached. This sequence of
events will repeat in reverse if the magnet is now reversed. euroswitch
PERPENDICULAR : where the magnet approaches the switch in a

magnet perpendicular direction with the magnetic centres in line with each
other. This is the method of approach on which the sensing ranges of
euroswitch individual swithes and magnets have been determined.
Installation The actuator can approach the switch in two planes :
Cylindrical types PARALLEL : where the magnet slides across the face of the switch
euroswitch
whilst keeping parallel to the switch until the point is reached where
the switch operates, when the magnet passes the switch will reset to
its off state.
euroswitch
magnet
PERPENDICULAR : where the magnet approaches the switch in a
perpendicular direction with the magnetic centres in line with each
other. This is the method of approach on which the sensing ranges of
individual switches and magnets have been determined.
magnet
Technical data
Contact type : 3A-24Vdc 2,5A-24Vdc 830mA-24Vdc 500mA-24Vdc

Max Current 3A 2,5A 830mA 500mA
Min Current 100µA 100µA 100µA 100µA
Max Operationr Full Load (Average) 1mil. 1mil. 1mil. 1mil.
Max Operationr Low Load (Average) 100mil. 100mil. 100mil. 100mil.
Max Operations (Mechanical) 100mil. 100mil. 100mil. 100mil.
Max switch speed 100Hz 100Hz 250Hz 250Hz
Max resistance to vibration 35G - 500Hz 35G - 500Hz 35G - 2000Hz 35G - 2000Hz
Max impact resistance with acceleration 50G - 11ms 50G - 11ms 50G - 11ms 50G - 11ms
All operation figures are given for ideal conditions
Landmark srl
+39.0331.596.037
V.07.15 UK Pag. 2
APPENDIX E

PRODUCTS
Aluminium Alloy 3/8”-1/2”NPT Pressure Regulator – R serie

Regolatore di pressione da 3/8” e 1/2”NPT in lega di alluminio – serie R
• Suitable for automation equipment to onshore, offshore,
pharmaceutical, medical and food applications
www.sitecna.eu
• Full material traceability

Relieving
• Excellent stability and repeatibility
• Accurate adjustement and high flow capacity
• ATEX 2014/34/UE - II2GD c IICT6 X / IP66
• & approved / SIL 3 - IEC 61508 SIL
IEC 61508
• Adatto per automazione in applicazioni marine, petrolchimiche, farmaceutiche,

medicali e alimentari Non Relieving
• Completa rintracciabilità dei materiali
• Eccellente stabilità e ripetibilità
• Precise regolazioni ed elevate portate
• ATEX 2014/34/UE - II2GD c IICT6 X / IP66
• Approvato ed / SIL 3 - IEC 61508 SIL
IEC 61508
Media / Fluido Air, inert gases, sweet and sour gases, clean water
Port thread / Connessioni 3/8”-1/2”NPT
Gauge Connection
1/8”NPT (1/4”NPT option)
Connessione manometro
Max inlet pressure
25bar
Pressione massima di ingresso
Relieving / Scarico sovrapressioni standard
Flow Rate (@10 bar inlet, 6bar
4500dm3/min Cv=4.5
regulated , delta P=1bar)/ Portata
Working Temperature -20°C up to 80°C (NBR); -25°C up to 90°C (FKM);
Temperatura di esercizio -40°C up to 80°C (EPDM) *
Regulated pressure 0/2, 0/4, 0/8, 0/10bar
Pressioni regolate
Air supply must be dry enough to avoid ice formation at temperatures below +2°C (+35°F).
*Special version available for -55°C up to 90°C
It provides excellent regulation for a wide range of applications. Rugged and
corrosion-resistant – made of aluminum alloy and SS AISI304/316. Compact small
package size – light weight / Permette una regolazione accurata per una vasta gamma di
applicazioni. Robusto e resistente alla corrosione – Costruito lega di alluminio ed AISI304/316
- Dimensioni di ingombro ridotte
BUILDING MATERIALS Materiali costruttivi

Corpo, coperchio, piastra inferiore in lega di
BT-R8AL/C16A
Body, bonnet, bowl in tropicalized alumi-

alluminio tropicalizzata, particolari interni in
num alloy, internals in stainless steel
acciaio inossidabile
Adjustment screw, bracket, lock and pa- Vite di regolazione, staffa, dadi di bloccaggio e
nel nuts, fixing screws in AISI316 stain- pannello, viti di fissaggio in acciaio inossidabile
less steel or galvanized steel AISI316 od acciaio galvanizzato
Diaphragm and valve assembly in elasto- Assieme diaframma ed assieme valvola in ela-
mer and AISI316 stainless steel stomero ed acciaio inossidabile AISI316
Valve spring, adjustment spring in
Molle valvola e di regolazione in acciaio inossi-
AISI316 stainless steel or galvanized
dabile AISI316 od acciaio galvanizzato
steel
Elastomeric seals Guarnizioni elastomeriche
Sitecna® srl
Via G. dI Vittorio, 22 - 20068 Peschiera Borromeo (MI) - ITALY - Tel. +39.02.547.5482 / 3182 - Fax. +39.02.55303713
Item description
Descrizione item
Pos. Description - Descrizione

1. Adjusting screw / Vite di regolazione
2. Lock nut / Dado bloccaggio vite
3. Panel nut / Dado staffa
4. Bracket / Staffa
5. Upper spring rest / Sede superiore molla
6. Spring / Molla di regolazione
7. Bonnet / Coperchio
8. Lower spring guide / Guida molla inferiore
9. Lower spring rest / Sede inferiore molla
10. Diapraghm / Diaframma
11. Valve seat / Sede valvola
12. Body / Corpo
14. O’ring (Bowl) / O’ring tazza
15. Valve stem / Stelo valvola
16. O’ring (valve stem) / O’ring stelo valvola
17. Valve / Corpo valvola
18. O’ring (valve body) / O’ring corpo valvola
20. Spring valve / Molla valvola
27. Bowl screw (M5x8) / Piastra inferiore
32. End plate / Piastra inferiore
34. Valve seat O’ring / O’ring sede inferiore valvola
Accessories and repair kit

Accessori e ricambi
BT-R8AL/17C
Items
Maintenance kit / Kit manutenzione K-R06-0-AL-** [3/8”]
K-R08-0-AL-** [1/2”]
Pressure gauge DN40mm, SS case, 0-2bar MBSNP4S2PN3S
Bar+psi+kpa range / Manometro 0-4bar MBSNP4S2PN05
DN40mm, cassa inox, scala Bar+psi+kpa 0-10bar MBSNP4S2PN07
Bracket and lock nut / Staffa e Dado SQ-FR04
** Refers to seals type:
FK>FKM NB>NBR LT>EPDM FL>Low temperature compound HN>HNBR
SITECNA® SRL www.sitecna.eu info@sitecna.eu

Our policy is one of continued research and improvement. We therefore reserve the right to amend,
without notice, the specifications given in this document.
PRODUCTS
Overall dimension
Dimensioni di ingombro
www.sitecna.eu
BT-R8AL/C16C
R06 A = 3/8”
R08 A = 1/2”
Sitecna® srl
PRODUCTS
Ordering information
Come ordinare
www.sitecna.eu
TYPE SIZE RANGE ACCESSORIES

F= Filter 04= 1/4” NPT* 0= None 0= None
FR= Filter Regulator 06= 3/8” NPT 1= 0.2-2 bar 2= SS bracket kit
R= Regulator 08= 1/2” NPT 2= 0.2-4 bar 3= Panel nut&handwheel
FM= Mini-filter* 12= 3/4” NPT 3= 0.4-8 bar 4= Customised Tag
TF= Tee Filter* 16= 1” NPT 4= 0.4-10 bar 5= SS bracket kit +
BP= Back Pressure* 20= 1” 1/4”NPT 6= 4-25 bar nut&hanwheel
SV= Switch Valve 2/2* 24= 1” 1/2”NPT 7= 4-35 bar 6= SS bracket kit+custom.Tag
S3= Switch Valve 3/2* 32= 2”NPT 8= CS bracket kit
* (only ¼”NPT)
Specials
FR 06 3 1 1S 5 6 SS FK 2 # #
DIAPHRAGM &
FILTER ELEMENT
0= None
SEALS MATERIAL
1= 5 micron FK= FKM ( WT-25° +90°C )
2= 25 micron NB= NBR ( WT-20° +80°C )
3= 40 micron LT= EPDM ( WT-40° +80°C )
4= coalescing FL= Special compound
(WT-55°+90°C)
HN= HNBR (WT from -55°)
PRESSURE GAUGE OPTION suitable for gas
0= None 00= None MATERIAL

1S= AISI316 case 05= No relieving
(SS316 connection) 06= 1/4” gauge port SS= 316-316L
1B= AISI304 case 07= Automatic drain Stainless steel
(brass connection) 56= No relieving AL= Copper free
1/4” gauge port aluminum alloy
57= No relieving SP= Special
Automatic drain
67= 1/4” gauge port
Automatic drain
X= Special
CODE EXAMPLES
FR 06 3 3 1S 0 7 SS FK 2
3/8”NPT, SS316, 0 to 8 bar range, filter regulator, with 40
micron filtering element, relieving, SS pressure gauge,
BT-APCD/C16A
automatic drain, ss bracket kit and FKM diaphragm & seals

Filtro regolatore da 3/8”NPT in AISI316, range regolato 0/8 bar,
elemento filtrante da 40 micron, manometro tutto inox, relieving,
scarico condensa automatico,staffa inox, diaframma e tenute in
FKM
FR 06 3 1 00 0 0 SS FK 0
3/8”NPT, SS316, 0 to 8 bar range, filter regulator, with 5

micron filtering element, relieving and FKM diaphragm &
seals
Filtro regolatore da 3/8”NPT in AISI316, range regolato 0/8 bar,
elemento filtrante da 5 micron, relieving, diaframma e tenute in
FKM
Sitecna® srl

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2017

MACCHI MHM-DRL XP BURNERS

OPERATION AND MAINTENANCE INSTRUCTIONS

SOFINTER SPA - Largo Buffoni 3 – 21013 Gallarate (VA) – Italy

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

1.2 EXPLANATION OF SYMBOLS

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

1.3 LIABILITY DISCLAIMER

 Use for any other than the designated purpose

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

1.4 COPYRIGHT PROTECTION

The contents of all or part of these operating instructions may not be

1.5 SPARE PARTS

1.6 WARRANTY REGULATIONS

1.7 AFTER-SALES SERVICE

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

2.1 OWNER’S RESPONSIBILITY

 The operator shall record in the document on the protection from

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

 The owner must ensure that maintenance work is performed

2.2 OPERATING PERSONNEL

 Qualified personnel: are capable on the basis of their specialist

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

When selecting suitable personnel, observe the age and profession-specific

2.3 INTENDED PURPOSE OF THE EQUIPMENT

The Macchi MHM-DRL XP Burner is exclusively designed to perform the

The Macchi MHM-DRL XP Burner It is an equipment intended to be

We recommend that the burner be operated in strict accordance with

Instructions contained in this manual are an addition to and do not replace

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

2.4 PERSONAL PROTECTIVE GEAR

 Wear the protective gear necessary for performance of the

Protective work clothing

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

2.5 SPECIAL DANGERS

LIGHT OFF FAILURE

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

Attend to fuel leaks as they are reported. Do not

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

HIGHLY INFLAMMABLE MATERIALS

HOT SURFACES CAUTION!

SHARP EDGES AND POINTED CORNERS

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

SPECIAL ENVIRONMENTAL INFLUENCES

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

2.6 SECURING AGAINST UNAUTHORIZED SWITCHING USE

Securing against unauthorized use

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

2.7 RESPONSE IN CASE OF DANGER OR ACCIDENT

 Always be prepared for accidents and for fires!

IN CASE OF ACCIDENT: REACT CORRECTLY

 Initiate first aid measures.

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

3 TRANSPORT, PACKAGING AND STORAGE

3.2 TRANSPORT INSPECTION

Check the delivery on receipt without delay for completeness and

 Only conditionally accept the delivery.

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

3.4 STORAGE CONDITIONS

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

MACCHI MHM-DRL XP BURNERS - Operation And Maintenance instructions

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