Quemadores RSFC Burners EB0-007991 Rev 1

RSFC Burners
Instruction LIMELIGHT Gas Ignitors

High Energy Ignitors
Manual Exacta Flame Scanners
Pampa Energy
Central Termica Units 29 & 30
Piedra Buena
Buenos Aires, Argentina
Alstom Power Inc.

Contract EB0-007991
abcd
Alstom Power Inc. Instruction Manual
Pampa Energy
Piedra Buena
Buenos Aires, Argentina
Alstom Power Inc.

Contract EB0-002598
COPYRIGHT 2015 Alstom Power Inc. All rights

reserved. This manual, or any part thereof, may not be
reproduced in any form without written permission of the
publisher.
 COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 I

CONTRACT: EB0-007991 11/6/15
INTRODUCTION
This instruction manual has been prepared to serve as a guide in operating and
maintaining the referenced equipment which has been furnished by Alstom Power
Inc. (Alstom). This instruction manual is not intended to cover all possible
variations in such equipment nor is this instruction manual intended to provide for
specific problems that may arise from the use of such equipment. Should
additional information regarding such equipment be required, Alstom or its field
representatives should be contacted.
Only competent personnel, trained in the operations and maintenance of the

equipment and familiar with the hazards and required precautions, should be
allowed in the equipment area to operate and maintain the system.
Alstom makes no warranty, express or implied, nor assumes any legal liability or
responsibility for the accuracy, completeness, or usefulness of any information,
apparatus, product, or process disclosed in this instruction manual, nor does it
represent that the use of any such information, apparatus, product, or process
would not infringe privately owned rights.
No amount of written instructions can replace intelligent thinking and reasoning

on the part of the equipment operators, especially when coping with unforeseen
operating conditions. Thus, it is the operator’s responsibility to become thoroughly
familiar not only with the immediate equipment, but also with all of the pertinent
control equipment applicable thereto as well. Satisfactory performance and safety
of such equipment depends to a great extent on the proper functioning of such
controls as well as the auxiliary equipment furnished by someone other than
Alstom.
© ALSTOM 2015. Alstom, the Alstom logo and any alternative version thereof are trademarks and service marks of Alstom. The other names mentioned,
registered or not, are the property of their respective companies. The technical and other data contained in this document is provided for information only.
Neither Alstom, its officers and employees accept responsibility for or should be taken as making any representation or warranty (whether express or implied)
as to the accuracy or completeness of such data or the achievement of any projected performance criteria where these are indicated. Alstom reserves the right
to revise or change this data at any time without further notice.
 COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 II

CONTRACT: EB0-007991 11/6/15
TABLE OF CONTENTS
TITLE TAB
RSFC™ Burners Low NOx Firing System ........................................................................................... 1
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor .................................................................................... 2
High Energy Ignitor Retractable (HEIR) .............................................................................................. 3
Exacta Flame Scanner System Upgrade ............................................................................................. 4
Vendor Supplied Equipment ................................................................................................................ 5
 COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 III

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TAB 1
RSFC™ Burners Low NOx Firing System
TABLE OF CONTENTS
DESCRIPTION PAGE NUMBER
Introduction.................................................................................................................................................... 1
RSFC Burner Description .............................................................................................................................. 2

Tertiary and Primary Combustion Air Shutoff/Biasing Dampers................................................................ 2
Three-zone Combustion Air Register ........................................................................................................ 2
Air Swirler Vane Positioners ...................................................................................................................... 3
Burner Throat Refractory ........................................................................................................................... 3
RSFC Fuel Assembly .................................................................................................................................... 3
Operation....................................................................................................................................................... 4
Commissioning .......................................................................................................................................... 4
Start-up ...................................................................................................................................................... 4
Normal Operation ...................................................................................................................................... 6
Flame Shaping........................................................................................................................................... 6
Multi-burner Balancing ............................................................................................................................... 7
Shutdown ................................................................................................................................................... 7
Gas or Oil Firing......................................................................................................................................... 7
RSFC Burner Handling and Maintenance ..................................................................................................... 8

Introduction ................................................................................................................................................ 8
RSFC Burner Hardware............................................................................................................................. 8
Vendor-Supplied Equipment ...................................................................................................................... 8
Receiving and Unloading Instructions ....................................................................................................... 9
Special Handling Instructions .................................................................................................................... 9
Maintenance ............................................................................................................................................ 10
General ................................................................................................................................................ 10
Air Register Assembly.......................................................................................................................... 10
Throat ................................................................................................................................................... 10
WRHI Air Cooled Oil Gun............................................................................................................................ 10

General .................................................................................................................................................... 10
Load Carrying Oil Guns........................................................................................................................ 11
Description ............................................................................................................................................... 11
Stationary Union ................................................................................................................................... 12
Removable Oil Gun .............................................................................................................................. 13
Operation ................................................................................................................................................. 13
Maintenance ............................................................................................................................................ 16
© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 i

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RSFC™ BURNERS LOW NOX FIRING SYSTEM
Orifice Tip Wear Classification and Flow Calibration ........................................................................... 16
SAMA Control Logic Operating Description ................................................................................................ 17

Background ............................................................................................................................................. 17
References .............................................................................................................................................. 18
System Configuration & Overview ........................................................................................................... 18
Air Flow Control.................................................................................................................................... 18
Control Scheme Review .......................................................................................................................... 21
Sheet 1 – EB0-007991-1D9328 – Index of Sheets and Symbols ............................................................ 22
Sheet 2 – EB0-007991-1D9329 – Burner Counts (El. 1 – 3) ................................................................... 22
Sheet 3 – EB0-007991-1D9330 – Burner Counts (El. 4) and Air Flow Feedback ................................... 22
Sheet 4 – EB0-007991-1D9331 – Air Flow Setpoint Development – General ........................................ 22
Sheet 5 – EB0-007991-1D9332 – Set RSFC Burner Outer Drive to Minimum Signals........................... 23
Sheet 6 – EB0-007991-1D9333 – RSFC Burner Outer Damper Purge Flag and Miscellaneous
Signals ..................................................................................................................................................... 23
Sheet 7 – EB0-007991-1D9334 – Outer (Tertiary) RSFC Damper – Air Flow Control Setpoint –
Final (El. 1) .............................................................................................................................................. 24
Sheet 8 – EB0-007991-1D9335 – RSFC Burner Outer Damper Control (El. 1) ...................................... 24
Sheet 9 – EB0-007991-1D9336 – Header Air Damper (K10) Control ..................................................... 25
Sheet 10 – EB0-007991-1D9337 – RSFC Burner Inner Damper Control ............................................... 26
Other Considerations ............................................................................................................................... 26
Fuel Flow Demand ............................................................................................................................... 26
Fuel/Air Cross-Limiting......................................................................................................................... 27
Reference 5 (Case Studies)................................................................................................................. 27
LIST OF TABLES
Table 1: RSFC Burner Operating Parameters at MCR ................................................................................. 6

Table 2: RSFC Burner Flame Shape versus NOx Emissions ....................................................................... 6
Table 3: Air Flow Scheme Summary (Present State to Future State)......................................................... 21
LIST OF FIGURES
Figure 1: Typical Low NOx RSFC Burner Air/Fuel Flow Fields ..................................................................... 2
Figure 2: Flow vs Pressure for No. 2 Oil with N19 Tip ................................................................................ 11
Figure 3: Flow vs Pressure for No. 6 Oil with N2 Tip .................................................................................. 12
Figure 4: Spray Parts for Oil Gun Nozzle Tip .............................................................................................. 14
Figure 5: Unit Burner Firing Arrangement ................................................................................................... 18
Figure 6: Current Airflow Schematic (Legacy Installation) .......................................................................... 19
Figure 7: RSFC Burner Configuration ......................................................................................................... 20
Figure 8: Future State Airflow Schematic (Post Installation) ....................................................................... 21
PAMPA AIR DAMPER CONTROL METHODOLOGY ........................................................................ REV B
© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 ii

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DRAWINGS DRAWING NUMBER
RSFC Burner General Arrangement – Sheet 1 ..............................................................EB0-007991-1E9250

RSFC Burner General Arrangement – Sheet 2 (Demolition) .........................................EB0-007991-1E9251
RSFC Burner General Arrangement – Sheet 3 (Restoration) ........................................EB0-007991-1E9252
RSFC Burner General Arrangement – Sheet 4 (Burner Locations) ...............................EB0-007991-1E9253
RSFC Burner Arrangement ............................................................................................EB0-007991-1E9258
RSFC Burner Final Assembly ........................................................................................EB0-007991-1E9259
RSFC Throat Refractory.................................................................................................EB0-007991-1E9306
RSFC Fuel Assembly .....................................................................................................EB0-007991-1E9320
SAMA Control Logic Diagram – Sheet 1 ....................................................................... EB0-007991-1D9328
SAMA Control Logic Diagram – Sheet 10 ..................................................................... EB0-007991-1D9337
© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 iii

CONTRACT: EB0-007991 11/6/15
RSFC™ Burners Low NOx Firing System
INTRODUCTION
The ALSTOM Power, Radially Stratified Flame Core (RSFC) burner is designed
to burn atomized oil, and/or natural gas in industrial and utility wall-fired boilers
while maintaining unit performance and meeting environmental requirements for
opacity, nitric oxide (NOx), and carbon monoxide (CO) emission levels.
The RSFC burner applies three principles associated with low NOx fossil fuel
firing.
• Early ignition of the fuel under fuel-rich conditions
• Staging the combustion process
• Increasing the residence time of fuel
To apply the above principles, the RSFC burner injects the fuel in a concentrated
stream via a fuel nozzle surrounded by three concentric air zones. Near burner
ignition is accomplished by creating a recirculation area near the fuel nozzle exit
where there is a fuel-rich zone.
To stage the combustion process, the RSFC burner swirls the cooler, higher
density combustion air around the hotter, lower density, fuel core. Centrifugal
forces created by the swirling combustion air delay the mixing process with the
fuel. Fuel residence time within the flame zone is increased by controlling the
velocities exiting the fuel nozzle and the three combustion air zones. Differences
in the velocities create internal recirculation patterns within the flame. Refer to
Figure 1.
The RSFC burner system for Pampa Energy Units 29 and 30 are composed of
the following: Refer to drawings EB0-007991-1E9250, EB0-007991-1E9251,
EB0-007991-1E9252, EB0-007991-1E9253, EB0-007991-1E9258 and EB0-
007991-1E9259.
• Three-zone Combustion Air Registers
• Combustion Air Shutoff/Biasing Damper
• Shutoff/biasing Air Damper Actuator
• Primary & Tertiary Swirl Vane Positioners
• Refractory Burner Throat
• Observation Ports
• 3” Bluff Body Ignitor
• Air Cooled Oil gun
• Natural Gas Gun Assembly
• Flame Scanner(s)
© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 1

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II. Macro-Mixing
I. Stratification
Air
Tertiary Air
Secondary Air
Primary Air
Fuel Gun Fuel-Rich Core
Flame Front
Primary Air & Fuel Mix
to Create Fuel-Rich
Flame Core Unique Throat
Design
Figure 1: Typical Low NOx RSFC Burner Air/Fuel Flow Fields
RSFC BURNER DESCRIPTION
Tertiary and Primary Combustion Air Shutoff/Biasing Dampers

The combustion air shutoff/biasing dampers are circular dampers designed to
bias the combustion air between the three air zones in the RSFC register. There
are two shutoff/biasing dampers per burner. One damper is used to control the
airflow into the tertiary air zone, while the other shutoff/biasing damper controls
the airflow into the primary zone.
The primary and tertiary air zone biasing dampers are controlled by two Rotork
electrically operated linear actuators. The linear actuator positions the
combustion biasing air damper between two positions (closed or an optimized
open position that may not be the full open position) in order to optimize the
RSFC burner flame shape and emissions.
NOTE
Optimum position of the combustion air-biasing damper will be

determined during commissioning.
Three-zone Combustion Air Register

Combustion air is supplied to the RSFC burner through three concentric air
zones. The concentric air zones are defined as the primary, secondary, and
tertiary air zones.
Tertiary air is supplied to the outermost concentric air zone. Swirl is induced by
the use of swirler vanes and fixed block assemblies. The adjustable swirler
vanes, located between fixed block assemblies, control the direction of the airflow
through the tertiary air zone. Depending on the position of the vanes, the tertiary
air will be introduced tangentially or radially into the tertiary air zone, creating
more or less swirl respectively.
Secondary air is supplied to the middle concentric air zone through a space
provided between the primary and tertiary air assemblies. Swirl is created by
fixed axial swirler blades. The secondary air zone produces a consistent swirl
over the entire load range of the RSFC burner.

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Primary air is supplied to the inner concentric air zone. Swirl is generated by the
use of swirler vanes and block assemblies, similar to those used in the tertiary air
zone.
The adjustable swirler vanes, located between block assemblies, control the
direction of the airflow through the primary air zone. Swirler vane position is used
to vary the swirl in the primary air zone between a minimum setting to a maximum
setting (0% setting will be tangential flow and 100% is axial flow).
Depending on the position of the vanes, the primary air will be introduced
tangentially or axially into the primary air zone.
Air Swirler Vane Positioners

The tertiary and primary air swirler vanes are positioned by manual, gear-driven,
linkage mechanisms located externally on the face of the burner. The vanes are
positioned based on optimum flame structure and burner performance
established during commissioning.
Burner Throat Refractory

The burner throat refractory is designed and shaped for optimal burner
performance. The design of the refractory throat is very important for proper
flame shaping and stability. ALSTOM Power Inc. strongly recommends that "Blu-
Ram HS" plastic ramming refractory, manufactured by Vesuvius, Inc. should be
used for the refractory throats.
This refractory has proven to be durable and low maintenance when installed and
cured as recommended. Refer to drawing EB0-007991-1E9306 for the proper
throat shape and recommended curing procedure.
RSFC FUEL ASSEMBLY
The centrally located fuel assembly is capable of firing oil, or natural gas. The
fuel assembly is located in the center of the air register.
The fuel assembly consists of a flanged outer assembly, that that allows gas to
flow between the outer wall and an inner guide pipe. Natural gas is supplied
through the flanged inlet on the side of the fuel assembly and flows between the
outer wall and inner guide pipe, the gas is discharged into the furnace through a
low momentum gas nozzle at the furnace end of the fuel assembly. The center
guide pipe, allows an oil gun to be mounted in the center of the fuel assembly.
Cooling air is supplied through a connection on the center guide pipe. The
cooling air allows the oil gun to remain in the guide pipe even when the oil gun is
not in service.
Combustion air is supplied around the fuel nozzle through the three concentric air
zones. This arrangement provides for stable combustion and eliminates furnace
pulsation typically associated with multi-burner installations.

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OPERATION
The following instructions are intended to serve as a guide to the sequence of

events that should occur during the commissioning of the RSFC burner. It is not
intended to give specific instructions regarding original equipment transporting
fuel and air to the burner. Operating parameters, setpoints, and curves
necessary to operate the RSFC burners will be established during
commissioning of the burner. ALSTOM Power recommends that plant
personnel become familiar with the equipment and associated controls prior to
initial start-up and commissioning.
NOTE
The Burner Management System and Unit Combustion Control

System (supplied by others) provides for the safe
startup/shutdown sequences and operation of the RSFC burner.
The control systems incorporate required interlocks necessary to
ensure safe and correct operation of the RSFC burners and the
unit.
Commissioning
Prior to initial unit start-up, conduct a general check of all RSFC burner
components. This check should include at least the following:
1. Check the RSFC burner primary and tertiary swirler vane mechanisms to
ensure full range of travel. Stroke and calibrate the positioners.
2. Check and stroke the combustion air shutoff/biasing damper from full
open to full closed position to ensure that is does not bind.
3. Ensure that all associated trim piping to the burner has been blown clear
of debris.
4. Verify that the RSFC burner and refractory throat area is clear of debris.
5. Ensure that all commissioning checks for the fuel nozzles have been
completed.
6. Ensure that the burner components (ignitor, oil gun, gas gun, and flame
scanners etc.) are installed per the manufacturer’s instructions.
Start-up
1. The initial commissioning lightoff procedure requires that the primary
dampers are typically positioned 25.4mm (1”) open and the tertiary air
dampers are closed for the out-of-service burners.
2. Note that it may be necessary to open some of the primary and tertiary
air dampers on some of the out of service burners in order to establish
the minimum 30% airflow through the unit in preparation for the furnace
purge.
3. Maintain the primary air damper 1” open while keeping the tertiary air
dampers closed on the RSFC burner(s) that will initially be started first.
As a starting point until commissioning determines the optimum
positions, the manual gear driven primary air swirl vanes should be
positioned to the 20% tangential position. The manual gear driven

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tertairy swirl air vanes should be positioned to 15% tangential position for
ignitor light off.
4. Establish the minimum 30% unit airflow and purge the furnace. As
required by the burner management system (supplied by others) A unit
purge will typically require a five minute purge period.
NOTE
The minimum windbox-to-furnace differential for the RSFC

burner is approximately 25.4mm (1.0" w.g.) with preheated
combustion air.
5. At the completion of the purge, leave the burner dampers and swirl vanes
in the position set during the boiler purge.
NOTE
Operate all boiler vents and drains in accordance with the original
boiler manufacturer’s operating instructions.
5. Light the gas ignitors. (Refer to the Tab 2).
NOTE
The ignitor pipe trains have been designed to light one RSFC
burner each. All damper and operation permissives must be
satisfied for ignitors and associated burners before an ignitor
start can be initiated. Refer to the burner management system
for details concerning the burner management start permissives.
6. Operate the oil gun or gas gun through the burner management and
combustion control system per manufacturer recommendations.
7. Control the firing rate to bring the unit up to temperature and pressure
according to the manufacturer’s recommendations.
8. Additional burners may be brought into service as dictated by unit load

and heat rate requirements.
9. Adjust fuel flow (firing rate) to achieve the desired steam pressure rise,
while monitoring boiler oxygen level and adjusting unit air flow as
required.
At steam flows above 30%, air flow should begin to be adjusted so that at
maximum boiler steam flow the measured oxygen operating level is
typically maintained at approximately 3%.
10. Using the appropriate safety measures, the boiler operator should inspect
the furnace conditions to ensure stable and safe combustion
11. With safe, stable combustion in the furnace having been confirmed,
remove the appropriate ignitors from service on that elevation and
operate main gas or oil as required.

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NOTE
The following parameters should be used as a guideline for
operation and tuning of the RSFC burner during normal full load
operation:
Tertiary Air Shutoff Damper Modulates with load to maintaining

windbox to furnace delta- P
Primary Air Swirl Vanes (% Tangential) 20
Tertiary Air Swirl Vanes (% Tangential) 15
Furnace Pressure ( wg) -7.62 (-0.30)
Windbox Pressure ( wg) 101.6 mm (4.0 – 4.5)
Oxygen @ Furnace Outlet (%) 3%
Table 1: RSFC Burner Operating Parameters at MCR
Normal Operation
Normal operation is defined as boiler conditions that are steady and stable at or
near full load capacity. This is the condition when RSFC burner adjustments
should be made to optimize emissions and unburned carbon loss. The following
notes should be used as guidelines to tune the burners.
Flame Shaping
The RSFC burner has been specially designed to allow control of the burner
flame shape. The physical appearance of the flame shape can be used as an
indication of NOx emission levels, opacity and/or unburned carbon levels.
Individual RSFC burner tuning can be performed by adjusting the RSFC burner
components based on visual inspection of the flame shape.
The following table characterizes the RSFC burner flame shape with respect to
NOx emissions.
Flame Shape NOx UBC/Opacity Discussion

Emissions
Long and Narrow Lower Moderate This is the desired RSFC flame condition.
This flame condition will usually occur with the
primary vanes set to 0 – 20% tangential
position, and the tertiary air vanes adjusted to
0 – 15% tangential.
Short and Wide Higher Lower This is not the optimum RSFC flame
condition. Temporarily moving the primary air
vanes to the 100% tangential position will
usually re-establish the proper flame shape.
Once the longer flame shape is present, the
primary air vanes can be reset to 75 - 100%
tangential.
Table 2: RSFC Burner Flame Shape versus NOx Emissions

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Essential requirements that must be met when tuning RSFC burners by flame
shaping are:
• The flame must be stable
• The ignition point should be within 6” of the burner throat
• The burner flame should fit within the physical constraints of the
furnace and should not contact the furnace walls or other burners
• Superheater outlet temperature constraints must be maintained
Multi-burner Balancing
Wall fired boilers often produce combustion conditions that may be stratified
across the boiler.
In order to minimize oxygen and carbon monoxide stratification across the boiler,
several variables can be checked to determine how well the fuel/air ratios are
balanced on a per burner basis. Those variables are:
• Percent O2 and CO across the airheater gas inlet duct of the unit
• Unburned carbon loss and/or particulate loading
• Superheater temperature profile
• Individual gas or oil gun firing rate
Specific methods to gather this data will vary with unit geometry and equipment.
Two suggested methods to achieve balanced burner air/fuel ratios are:

• Balance the fuel flow to each burner
• Bias the primary and/or tertiary shut off dampers from burner to burner to
redistribute the air to the side of the furnace with the highest CO
measurements, or the lowest O2 measurements. Biasing of the
combustion air involves balancing the amount of combustion air going to
burners.
NOTE
Biasing the combustion air between burners may be effective at
reducing the impact of unequal fuel distribution between burners.
However, for maximum efficiency, it is often preferable to
balance the fuel flow to each burner before adjusting the biasing
air dampers.
Shutdown
Burner shutdown is essentially the reverse of the start-up procedure. When
reducing total fuel input into the furnace, ensure that the combustion airflow is
reduced in proportion to unit load reductions.
Gas or Oil Firing

1. To shutdown the burner begin reducing fuel flow to the associated
burners. Re-light the burner’s associated ignitors just before the oil or
gas gun become unstable. This will stabilize the burner at low loads to
prevent a flame failure trip due to loss of flame indication by the flame
Scanners..

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2. When minimum burner firing condition is reached shutdown the oil or gas
gun in service. If oil firing was in service it will be necessary to scavenge
the oil guns on the burners being shut down.
3. When scavenging the oil guns the ignitors should remain in service
during the scavenge period to burn the fuel being purged from the oil
guns.
4. At the end of an oil gun scavenging period (assuming oil guns were in
service on the pair of burners being shut down), shutdown the ignitors. If
gas firing was in service the igniters can be removed from service
immediately after the gas guns have been shutdown.
5. If oil guns were in service they may now be removed for cleaning and/or
maintenance (as required) while the associated burners are out of
service.
Exercise caution when removing hot oil guns from the

burners as they can cause injury to personnel if not properly
handled.
RSFC BURNER HANDLING

AND MAINTENANCE
Introduction
Each burner is equipped with two manual rotary actuators for the control of the
primary and tertiary swirled vanes, and two Rotork electrically operated actuators
for the control of the primary and tertiary shut-off/biasing air damper.
RSFC Burner Hardware

The frequency of maintenance will vary from unit to unit and is best determined
from the actual experience. The RSFC burner hardware should not require
routine maintenance other than the repair of the refractory throat. However, the
following items should be routinely inspected during periodic outages.
• Full range stroke the swirl vanes and biasing air damper
• Warping or cracking of combustion air swirl vanes; swirl vane connecting
shafts and linkages; secondary air axial swirled; concentric annuli; etc.
• Stress cracking in the welds
• Condition of metal Throat
Vendor-Supplied Equipment
For operation and maintenance instructions on vendor-supplied equipment for the
RSFC burner, refer to Tab 4 of this manual.

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Receiving and Unloading Instructions

Upon arrival at the job site, each RSFC burner should be closely inspected for
damage that may have occurred as a result of shipping or handling. Any damage
or unusual conditions should be reported to the shipping company and ALSTOM
Power Customer Services at once.
Each burner should be inspected for satisfactory rotation of both the primary and
tertiary manual swirled vanes. The primary and tertiary linear shut-off/biasing
damper should move back and forth on the wheeled track with minimal effort.
Any problems that are observed should be reported immediately.
The RSFC burners should be carefully unloaded from the shipping truck and
uncovered.
Each burner and all associated packages should be carefully inventoried and
compared to the shipping bill of materials and pertinent drawings to ensure that
all parts have been received. Any missing parts should be reported to ALSTOM
Power Customer Services immediately.
NOTE
If the RSFC burners must be stored on-site prior to installation, it

is recommended that they be kept covered in a dry indoor
location. Outside covered storage is not recommended without
the express written approval of ALSTOM Power Customer
Services.
During storage, it is recommended that the primary and tertiary shut-off/biasing

air damper electric linear actuators, that are shipped loose, be protected and
stored in the original shipping boxes in a dry environment. The manual rotary
vane actuators for both the primary and tertiary air swirled vanes should be kept
fully lubricated and protected from damage and moisture. The RSFC air registers
should be kept covered and dry with protection from damage and moisture during
storage.
Special Handling Instructions

Each RSFC burner is equipped with two lifting lugs that are to be utilized for
moving the burner from the ground floor of the plant up to the main operating
floor.
CAUTION
Proper rigging and lifting practices consistent with safe
industry practices must be followed when moving and
installing the RSFC burner. Use extreme care when
handling of the RSFC burner. Do not dent, bend or twist the
air register assembly.
Each RSFC burner is also equipped with a shipping block welded to the bottom of
the tertiary air inlet zone. This block, which must be removed during installation,
is provided to maintain the burner in a level and horizontal position during storage
and shipping.

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To ensure trouble free operation of the RSFC burner, with no binding or

interference, the RSFC burner should be handled carefully. A great deal of effort
has gone into the design and fabrication of each RSFC burner in order to
maintain trouble free characteristics. ALSTOM power, Customer Services shall
not be held liable for damage caused by inadequate storage or handling
practices.
Maintenance
General
The RSFC burner is designed for minimal maintenance requirements. The

primary and tertiary air swirled vane actuators should be maintained as described
by the manufacturer. The primary and tertiary shut-off/biasing air damper electric
actuator should be maintained as recommended by the manufacturer. Reference
Tab 4 of this manual.
The RSFC burner uses premium materials and design in order to provide the
user with long operational life.
Parts of the burner that are subject to high temperatures are manufactured from
various grades of stainless steel. It is strongly recommended that the entire
RSFC burner assembly be closely inspected during each boiler outage for
erosion, wear, overheating, warpage or other signs of damage. Regular
inspection and burner maintenance will maintain the RSFC burner in good
operational condition and prevent major damage from occurring.
Air Register Assembly
The RSFC Air register assembly is designed with minimal maintenance

requirements. Other than routine outage inspections, no maintenance should be
required unless an unusual operational problem results in burner damage.
All RSFC air register linkages may be replaced from outside the windbox.
Externally replaceable spring loaded Teflon seals surround each swirler vane
stainless steel shaft, and the primary zone shut-off/biasing air damper adjustment
rod.
All swirler vanes and shut-off/biasing air dampers should be operated during each
outage to ensure that full stroke operation is possible. Any binding should be
investigated and repaired immediately.
Throat
The RSFC burner utilizes a unique throat design. Any repairs to the throat should
conform to the design as shown on the contract specific drawing EB0-007991-
1E9306.
WRHI AIR COOLED OIL GUN
General
Each RSFC burner assembly is equipped with a wide range horizontal Internal
Mix (WRHI), parallel pipe, air-cooled, oil gun for the firing of oil atomized by either
air or steam.

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The guide pipe can accommodate either a air atomized warm-up oil gun firing No.
2 oil or a steam atomized load carrying oil gun firing No. 6 oil. The basic
differences between the two oil gun assemblies are in the removable sections:
Load Carrying Oil Guns
Load carrying oil guns have been supplied for operating the boiler at full load
when gas firing is not in service.
The load carrying oil gun’s will fire No. 6 oil and use an N-2 oil gun tip with a 60
degree spray angle. These tips require a 103 kPa (15 psig) differential between
the oil pressure and the atomizing steam pressure. Refer to the curves in Figure
3.
Description
The oil gun consists of two major sub assemblies; the oil gun stationary union
and air-cooled oil gun removable part. Removable sections for the warm-up and
load carrying are of two sizes, but their appearance in illustrations are basically
identical.
Figure 2: Flow vs Pressure for No. 2 Oil with N19 Tip

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Figure 3: Flow vs Pressure for No. 6 Oil with N2 Tip
Stationary Union
The stationary union is attached to the 88.9 (3.5") O.D. x 4.0 (0.157”) wall oil gun
guide pipe. This air-cooled pipe is welded to the RSFC burner’s front plate.
Oil gun cooling air is provided through a 60.3 (2.37") connection on the guide tube
assembly. The cooling air passes through the inside of the connecting tube and
stationary guide pipe to provide cooling at the oil gun spray nozzle tip.
3
Cooling air supplied to each oil gun should be 2.1m /m (75 SCFM) at 1.5 to 2 kPa
(6 to 8" wg) above furnace pressure.
The stationary union, seal welded to the guide pipe assembly, admits oil,
atomizing, and scavenging air/steam to the oil gun, and serves as a coupling for
the removable oil gun. A hinged cover assembly on the stationary union provides
sealing for the connecting tube when the oil gun is removed for maintenance.
A safety air latch assembly consisting of a spring-loaded pin located at the

stationary union provides a means of latching the stationary union cover plate into
the stationary union internally.

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CAUTION
Stationary union cover plate must be latched in place whenever

the oil gun is removed. This will prevent the other oil guns and
scanners from losing their cooling air due to an open flow path
from the guide pipe.
The gun engagement limit switch, mounted on the stationary union, is actuated by
oil gun guide pin attached to the removable union of the oil gun and provides
feedback to the BMS, indicating that an oil gun is coupled.
A short pin is used with the No. 6 load carrying oil guns and provides indication
when the oil gun is coupled in place.
When coupling an oil gun into the stationary union, ensure that new gaskets are
inserted between the stationary and removable unions. The gaskets seal off the
joints between the oil and atomizing air/steam ports in the stationary and
removable unions.
Removable Oil Gun
The removable part of the oil gun consists of the removable union, two parallel oil
pipes, a flexible hose section, and a spray nozzle assembly. The purpose of the
parallel arrangement of the oil gun pipes is to separate the air/steam and oil until
the mixing point in the nozzle is reached, and to minimize the temperature effect
of one medium on the other.
The flexible hose section serves to absorb differences in expansion between the
pipes. A guide on the oil gun pipes maintains the concentric position of the gun in
the guide pipe.
The load carrying oil gun has an N-2 tip. The gun consists of a spray plate and a
back plate, which are secured to the nozzle body by means of an air cooling
nozzle cap made of type AISI 416 Stainless Steel.
The nozzle cap has a series of slots located around the outer perimeter of the
nozzle cap that allows the cooling air in the guide pipe to pass through the nozzle
cap for cooling purposes.
The atomizing air/steam entering the oil gun through the upper port of the union,
and oil entering through the lower port are carried separately through the entire
length of the gun by two parallel oil gun pipes. Oil connects to the nozzle body
outer ports and the atomizing steam connects to the inner port of the nozzle body.
The oil passes through the small inner holes in the backplate. Atomizing
air/steam passes through the outer holes of the backplate and then across the
radial cuts in the backplate where it mixes with the oil. The steam/air atomized
oil mixture is then forced from the center of the sprayplate out into the furnace.
Operation
Oil gun operation should be controlled by the BMS (BMS not supplied by
ALSTOM Power), which provides for proper operating sequences such as valve
opening and closing. The BMS also monitors operating conditions such as

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pressure, flow, gun and valve positions, and generates an automatic shutdown
when unsatisfactory conditions are detected.
Figure 4: Spray Parts for Oil Gun Nozzle Tip
In addition to any features provided by the control system, the following basic
rules always apply:
1. Prior to initial firing:

• Purge the furnace for at least five minutes.
• Check fan and damper regulating equipment manually for proper
operation through the entire range.
2. If light oil preheat is required [minimum 38°C (100°F)], throttle the
recirculating valve (if manual) after placing the oil gun in service to
maintain proper oil temperature and pressure consistent with system
requirements.
3. Make sure that the ignitors associated with the oil guns to be started are
operating properly. Always use an ignitor to ignite an oil gun. Never
attempt to light off one gun from another gun in service.
4. Use proper setting of the secondary air dampers.
5. Before inserting an oil gun, inspect the gun for proper assembly of
backplate and sprayplate. Make sure stationary union gaskets are in

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place. When lighting a gun, verify by visual observation that ignition

takes place immediately after opening the oil supply valve.
If ignition does not take place or is very unstable, shut off the oil and
remove the gun for servicing after scavenging.
NOTE
Do not relight the same gun unless the cause of non-ignition has
been determined and corrected.
6. When placing an oil gun in service, always admit air/steam to the gun
before the oil.
7. When taking the oil gun out of service, it must be scavenged. Shut off
the oil first, then open the air/steam crossover (scavenge) valve,
admitting air through both ports immediately after shutdown. After
scavenging, close all valves. Cooling air to the oil gun should remain in
service whether or not the oil gun is in operation.
Exercise Caution when removing a hot oil gun from the guide pipe for
servicing. Stationary union cover must be latched in the closed position
over the guide pipe whenever the oil gun assembly has been removed.
NOTE
• Before an oil gun can be scavenged, the adjacent ignitor must be

in operation. If the adjacent ignitor is not available, do not
scavenge the gun. Attempt to re-establish ignitor and then
scavenge. If the oil gun is left unscavenged in a hot furnace the
oil gun tip may coke and it will be necessary to remove,
disassemble and manually clean.
• If the oil gun is tripped due to an MFT the furnace should be

purged, ignition energy re-established then start the oil gun. If
the oil gun is to be shutdown scavenge the oil gun and then
shutdown.
If the oil gun must be removed without scavenging, exercise

extreme caution as hot oil can burn. During the removal of
un-scavenged oil gun from the guide pipe, hot oil may leak
into guide pipe. This oil has the potential to ignite.
8. It is essential to give careful attention to oil combustion conditions during

initial firing of a cold furnace. Potential damaging deposits of oil vapors
and carbon on surfaces may occur by carryover of un-burned fuel during
this critical period.
9. Poor combustion conditions are generally indicated by the following:

• Unstable ignition point
• Smoky tails on the flame
• Visible haze in the furnace outlet

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10. Incomplete combustion can be caused by the following:

• Inadequate atomization due to low oil temperature and/or improper
oil or atomizing steam pressures
• Fouled nozzle parts due to insufficient cleaning
• Improper secondary air distribution due to less than optimum position
of the oil compartment damper
Maintenance
Uniform oil flow distribution throughout the furnace greatly influences satisfactory
unit operation. Uniform oil flow is a function of pressure deviations between guns,
gun cleanliness, and out-of-tolerance tip orifice dimensions due to wear.
Consequently, periodic tip calibrations and oil gun maintenance procedures are
recommended to ensure equal flow from each oil gun assembly, consistent
quality of atomization, and minor deviations in spray angle.
The resultant flow increase associated with atomizer orifice tip wear directly
influences uniform oil gun flow rate. Periodic measurement of tip orifices to
determine the degree of wear will eliminate the possibility of using tips which
exhibit wide ranges in oil flows. Classifying tips with regard to wear permits
extended usage of worn tips, provided that tips in the same percentage-of-wear
category are used uniformly in the unit.
Orifice Tip Wear Classification and Flow Calibration
The purpose of classifying orifice tips in groups, based on wear, is to define a

maximum allowable degree of wear, and to prevent simultaneous use of tips that
exhibit differing ranges of wear. Tip orifices are to be classified into three groups,
using the resultant flow increase due to wear as the criteria for group
classification. A 10% flow increase defines the maximum allowable degree of
wear. Discard tips exhibiting this level of wear.
Wear Classification Effective Flow Increase
A 3 to 5%
B 5 to 7%
C 7 to 10%
The effective flow increase is approximately equal to the percentage of increase

of the orifice tip diameter squared.
Do not use worn tips from different wear groups (A, B, and C) simultaneously;
use of worn tips within a particular wear group, however, is permissible.
Experience and wear measurement for fuel oil and/or fuel additives causes
erosion patterns. Again, as noted above, wear measurement is not based on an
internal mechanical ID measurement. Rather, it is based on pressure versus flow
measurement results. Refer to Figures 2 and 3. This usually dictates the time
span between detailed maintenance inspections. During the initial operating
period of new oil gun tips, adhere to the following detailed maintenance
procedure every four to six weeks.

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1. Disassemble atomizer assembly (cap nut, sprayplate, and backplate) and

tag disassembled items with gun number.
2. Hang gun in rack with the nozzle body in solvent.
3. Clean oil gun parts using a solvent or similar cleaning agent.
4. Inspect nozzle body and hoses.
Clean nozzle body return holes with appropriate drill size. (Do not use a drill
motor; a "T" handle is recommended.)
To clean the spray plates, secure the front portion of the nozzle body in the vise
jaw and remove the nozzle cap.
1. Clean face of nozzle body and lap to true surface removing any
bypassing marks.
2. Check the nozzle cap cooling air holes to ascertain they are free from
obstruction.
3. Wear from bypassing can be determined by a light lapping of gun parts.

Worn parts are to be replaced or lapped true.
4. Reassemble gun with gun nut cap tightened 270 N-m (200 ft-lb torque
maximum).
5. Appropriately mark reassembled gun with wear classification data (when

maintenance procedures and wear classification records are complete).
Experience has proven that satisfactory unit operation is influenced by oil gun
maintenance and the regulation of pressure deviations between guns within the
allowable limits for the respected design of fuel atomization.
Do not disturb the seal formed by the machined surfaces of nozzle plates by
scraping these surfaces with a sharp object or by insufficient cleaning. When
making up a gun after cleaning, be sure that the nozzle plates are properly
assembled. Avoid overtightening the nozzle cap 270 N-m (200 ft-lb) is
recommended. Apply high temp Antiseize (Bostik Antiseize V00-1888 or
equal) compound sparingly to the nozzle threads to avoid binding under
excessive heat.
After a few weeks of operation, a proper cleaning schedule can be established

which will result in reliable operation of the oil firing equipment.
SAMA CONTROL LOGIC

OPERATING DESCRIPTION
Background
The 2015/16 project by Alstom at Pampa Units 29 and 30 involves installation of
new RSFC burners in the boilers. The burners will be able to fire natural gas or
fuel oil based on supply availability and needs at any given time.
This new equipment requires proper direction in order to run as designed. This
document explains the air flow control scheme to be used for the burners. The
reader is directed to Reference 1 to explore the specific logic implementation

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details. It may prove useful to cross reference those drawings while reading
through each section of this write-up.
References
1. SAMA Control Logic Drawings; EB0-007991-1D9328 through EB0-
007991-1D9337 [Alstom Drawings]
2. RSFC Burner Final Assembly; EB0-007991-1E9259; [Alstom Drawing]
3. Pampa P&ID for Air and Exhaust Lines; B52B-1246-080(A) h2/3; [Pampa
Drawing]
4. Pampa P&ID for Fuel Oil and Gas Burners; B53B-1246-093(A); [Pampa
Drawing]
5. Pampa Air Damper Control Methodology (PowerPoint Slides); 6/24/2015;

[Alstom Transmittal]
System Configuration & Overview

The main control definition provided to accommodate the new equipment being
provided is:
1. Air flow control
Air Flow Control
References 2 and 3 are the most relevant information sources to be considered

with regard to controlling air flow to the System.
The burner layout for both Units is as shown in Figure 5. There are four (4)
elevations of burners. Each elevation has six (6) individual burner registers.
Figure 5: Unit Burner Firing Arrangement
The legacy control scheme throttles air flow on an elevation basis and utilizes
“K10” header dampers to modulate delivery to the furnace feeds. A large
manifold or plenum is fed with secondary air from two separate sources (left and

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right). That manifold is directly tied to each of the six burners on a given
elevation. Both the left side K10 and right side K10 drives may be simultaneously
adjusted to drive the desired airflow on an elevation basis at any instant in time.
Individual air flow measurements are made on both the left hand and right hand
sides of each elevation; a total record of air flow feedback is available for each
elevation.
The present layout of actuators and primary components is shown in the Figure 6
sketch for a representative elevation.
Figure 6: Current Airflow Schematic (Legacy Installation)
In the current project each of the burners (1 through 6 in Figure 6) will be

replaced with Alstom’s RSFC burner design. Each RSFC burner contains two
actuators that may be used to modulate air flow/distribution. A 3-D rendering of
the actual burner and a corresponding simplified sketch of the control
components is shown in Figure 7.
The outer (tertiary) slide damper is shown at the left of Figure 7 shaded in red,
while the inner (primary) slide damper appears in green on the three dimensional
view. Each linear actuator drives a rod down the central axis of the burner to
modulate the slide damper. Air flowing through the slide damper enters the
burner swirl block assembly which translates the airflow into a radial or axial flow.
The manual swirl block drives are used to set what percentage of burner airflow is
radial and what percentage is axial as it leaves the burner. When fully open the
outer damper accounts for approximately 70-75% of the total airflow to the RSFC
burner, while the inner damper achieves 10-15% of the total. Approximately 10%
of air flows through an intermediate zone in between the two dampers. There is
no actuator on that “middle” cross section.

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Figure 7: RSFC Burner Configuration
The small diagram on the right-hand side of Figure 7 is a means to represent the
RSFC in two dimensions and re-iterate that there are two actuated dampers
present per burner assembly. The dampers are not physically “butterfly” in type
or design; they are shown in that fashion simply to represent the fact that two
actuators are present.
Once the new burners have been installed the future state for a typical elevation
of burners is as displayed in Figure 8.

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Figure 8: Future State Airflow Schematic (Post Installation)
Once the new burners are installed, having actuators at each burner register
allows air flow control to be made more directly at individual furnace fuel supply
points as opposed to being at the more coarse elevation level.
A summary of the air flow control scheme present and future state considerations
is given in Table 3.
Table 3: Air Flow Scheme Summary (Present State to Future State)
Control Scheme Review

The details of the control logic will be covered in this section of the Operating
Description document. A drawing number reference will be listed that can be
found in the Reference 1 content. A description will follow that explains what
function is shown on the specific logic page.

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Sheet 1 – EB0-007991-1D9328 – Index of Sheets and Symbols

This page provides a list of all symbols that are used throughout the logic
drawings. A table of contents is also shown stating what logic content is found on
each Sheet.
Sheet 2 – EB0-007991-1D9329 – Burner Counts (El. 1 – 3)

A series of counts is made on this page with respect to Boiler operating status for
burner Elevations 1, 2, and 3. Each burner may be operated with either natural
gas or fuel oil at the discretion of the operator. A burner may be fully off (no fuel
being supplied), or it may be in service firing gas or in service firing oil.
Typically a burner is identified as being “in service” when the following conditions
are true:
1. All shutoff valves are proven open and the corresponding vent valve
(where applicable) is proven closed based on limit switch feedback from
the devices.
2. The control logic is directing the burner to run.
3. There is proof of flame or sufficient ignition energy available to ensure

combustion is occurring.
The final definition for “Burner in Service” should be available within the system
BMS logic.
The number of burners in service for an elevation are counted here, for both oil
and gas. Elevations that have at least one burner in service are identified. All of
these simple math counts are used as part of the balance of the logic
development on other sheets.
Sheet 3 – EB0-007991-1D9330 – Burner Counts (El. 4) and Air Flow

Feedback
The same logic shown on Sheet 2 is repeated here for Elevation 4. On a single
11 x 17” drawing it was not possible to show the same information for all four
elevations and have it be legible. As a result the material was split between two
separate drawings.
Additional count logic is used to check how many elevations have no burners
operating (not burning any fuel).
The bottom section of the sheet takes the feedback information from all of the
header air flow rate transmitters (for both the right and left hand header sides;
see purple flow elements in Figures 6 and 8) and performs some simple addition.
The total secondary air flow rates to each elevation, and to the overall boiler are
computed.
Sheet 4 – EB0-007991-1D9331 – Air Flow Setpoint Development – General

A series of calculations is made on this page that tracks the preferred air flow
rates required for individual burner firing based on fuel type (oil/gas), fuel flow rate
per burner, and overall Unit load level.
These computed values indicate how much air flow would be necessary to
achieve exactly proper combustion throughout the Unit’s full load range. In
practice, proper air-to-fuel cross-limiting must be incorporated into the logic to

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ensure safe operation at all times. As such, these individual calculations are
strictly available for comparison, reference information. They are not directly
used within the Logic, itself, to set individual air flow setpoint values. The reader
is directed to the Sheet 7 description to learn more about air flow setpoint
development for individual levels (elevations).
Sheet 5 – EB0-007991-1D9332 – Set RSFC Burner Outer Drive to Minimum

Signals
Some high level overrides are incorporated into the RSFC burner outer (tertiary)
drive control actions. These high level overrides will drive individual RSFC
burners to fixed output percentages under the conditions that are explained in this
section.
A tertiary air damper will be set to a minimum percentage open position when
either of the following conditions is true:
1. Boiler load is greater than 30% MCR AND the burner under consideration
is not in service
2. Boiler load is less than 30% MCR AND the burner under consideration is
not in service AND at least one of the other burners on the same
elevation is operational AND at least one of the other boiler elevations
has no burners running
The Unit has a minimum constraint where total airflow must never fall below a set
low threshold number (there must always be a minimum airflow provided
sweeping through the furnace). To help achieve the minimum airflow when the
Unit is fully off, air is directed through all elevations to ensure the requirement is
achieved. An additional air flow constraint is related to air flow transmitter
capability on each elevation (see the purple FM meters as shown in Figures 6
and 4). These transmitters can only physically register flow with any degree of
accuracy down to a minimum threshold rate. Anything lower than that value, and
the meter cannot output a usable air flow number for use in closed loop control
(the device signal output is constrained to 0 standard cubic meters per hour).
Once individual burners on some elevations begin to be activated, the control

scheme attempts to fix the other damper drives on those same elevations at a
minimum percentage open position. This helps to deliver sufficient air flow to the
elevation to maintain proper transmitter operation, while simultaneously trying to
route the local airflow required to support combustion.
To compensate for those actions, air must then be supplied to other regions
within the furnace in order to make sure the total minimum airflow constraint to
the Unit is still satisfied. That is why point 2. above is defined in the manner that it
is.
Sheet 6 – EB0-007991-1D9333 – RSFC Burner Outer Damper Purge Flag and

Miscellaneous Signals
Five minutes after an MFT occurrence each of the RSFC outer damper positions
are set at a fixed percentage open “purge position”. The RSFC outer dampers
help set the Unit airflow for purging during this period. NFPA code requires a
furnace to be sufficiently purged before an MFT may be cleared. Once a
successful purge execution has taken place via receipt of the “Purge Complete”
signal from the BMS, the dampers are released from this operating condition.

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In the second half of the page, total air flow based on flow meter feedback is
made for elevations where at least some combustion is taking place. If an
elevation has at least one burner in service, then the corresponding air flow for
that elevation is added to any other elevations that have at least one burner in
service. This yields an overall Unit air flow for the elevations that have some
combustion ongoing. If no combustion is occurring whatsoever throughout the
furnace then this total computed value is 0.
Sheet 7 – EB0-007991-1D9334 – Outer (Tertiary) RSFC Damper – Air Flow

Control Setpoint – Final (El. 1)
The existing DCS control logic as supplied in drawing C30B-1636-002(A) shows
the development of a boiler master signal that generates individual elevation air
flow setpoints that are fuel-cross limited. These setpoint(s) [four total, one
representative logic shown] help drive damper positions to achieve the necessary
Unit airflow for combustion. These existing signals should be re-used and
properly integrated with the new Alstom equipment.
If an elevation has combustion ongoing, or will have combustion progressing

soon, then the air flow setpoint for the DCS shall provide the value to feed the
downstream PI controller.
In the event that no airflow is required to support combustion (all burner fuel
feeds are closed and no combustion is expected) a check is made at the bottom
of the control loop with transfer switch T4. If total Unit operation is at or below
30% MCR, and no burners are in service on the given elevation, then a minimum
elevation airflow setpoint is generated. This value is used to ensure that the
minimum, overall Unit airflow need is still achieved. The minimum threshold air
flow for the entire Unit is taken and the actual air flow being delivered to any
elevations with at least some combustion ongoing is subtracted. That results in
the balance of airflow that must be passed through the Unit to ensure enough
sweep airflow is still present. The number is then divided by the number of
elevations that have no burners in service to compute the individual airflow
setpoint for those elevations.
The computed airflow rate for the elevation is conditioned one last time prior to
being finalized for outgoing signal 2/8 (on Sheet 7 defined as Elevation 1 Air Flow
Setpoint). A correction to the computed signal is made based on O2 trim. Within
the flue gas of the Boiler piping O2 sensors should be installed. The O2 sensors
continuously monitor the amount of oxygen present in the discharge gas to
atmosphere. If the detected O2 content is too low, the O2 trim computation
requests additional airflow via an increase in the feed setpoint. Conversely if the
O2 content is too high, the O2 trim computation directs less airflow via a
reduction in the feed setpoint.
O2 trim is used on boilers to help correct for for uncertainty in air flow sensor
measurement.
Sheet 8 – EB0-007991-1D9335 – RSFC Burner Outer Damper Control (El. 1)

This page provides the final control loop for the outer (tertiary) RSFC dampers.
Recall from Table 1 that these devices are used to set the air flow rate to
individual burner registers.
During full “auto” operating periods a PI computation is used to set the damper
position (via T1 transfer switch at the top of the drawing). The feedback for the
signal is the sum of the two flow meters for a given elevation (shown in purple on
Figures 6 and 8). The air flow setpoint is based on the outgoing signal labeled

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2/8 on Sheet 7 (read previous section for more information about that signal),
processed one final time in order to cross check the value to the sensor
capability. The cross check is described in the next paragraph.
When the following conditions are all true:
The elevation under consideration has no burners in service –AND–
Boiler operation is at or below 30% MCR
the logic takes the computed elevation air flow rate setpoint from Sheet 7 and
compares it to the minimum transmitter capability threshold value. Whichever
number is greater passes through and becomes the setpoint for the PI block. By
being defined in this manner the setpoint a given elevation requires will never be
below the transmitter range. Therefore the transmitter may be used in a true PI
block feedback implementation.
If the two bulleted conditions on the previous page are not both true, then the
setpoint to the PI block is simply the computed air flow rate setpoint that comes
directly from Sheet 7.
By defining the logic in this fashion, in conjunction with the minimum position
override for the tertiary dampers, the Unit airflow minimum of 30% may always be
achieved even with the air flow measurement capable range constraint.
There are four other potential damper positions possible based on logic, and as
follows:
• The burner tertiary dampers are driven to a minimum percentage open
position when the “Set Burner XY Tertiary Air Damper to Minimum
Position” signal is true. A full discussion on the conditions that make up
that signal is given in the Sheet 5 discussion.
• Selection of an appropriate “Minimum position” damper value will be
made during tuning of the Unit. The damper position must allow
sufficient airflow through the Unit elevation to drive enough flow where it
can be properly registered by the corresponding level’s flow transmitters.
• The burner tertiary dampers are driven to a “Purge Position” (a fixed
percentage open) 5 minutes after a MFT has been tripped, but prior to
“Purge Complete” being delivered by the BMS. These fixed positions are
set to allow for sufficient airflow to fully Purge the Unit and help clear the
Master Fuel Trip latch.
• When an MFT occurs, for five minutes from the instance of the trip the
tertiary (outer) air dampers are all fixed at the position they resided in
immediately preceding the trip. This is to drive compliance with NFPA
code; devices that help drive air flow to the Unit are to remain at their pre-
trip output conditions during this 5 minute period.
• In the event of a MFT event where the System fans are compromised, a
post-purge fan trip is initiated. Here natural draft through the Unit is
promoted by setting all tertiary air dampers to their full open positions.
They remain that way until the post-purge fan trip has been cleared within
the BMS logic.
Sheet 9 – EB0-007991-1D9336 – Header Air Damper (K10) Control

The K10 header dampers in the future state implementation (with new Alstom
RSFC burners) no longer modulate to control air flow rate to the Unit. That

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function is now controlled via the RSFC outer (tertiary) air dampers. As a result,
the K10 header damper control is highly simplified.
The new scheme is as follows:
The K10 dampers are set to a wide open position (100% open) for the majority of
the time. The only time the K10 dampers are not full open is as follows:
• If all burners on a given elevation are not in service, and the Unit is above
30% of MCR then the associated K10 dampers are not full open, but
rather are set to some minimum position (15% for initial commissioning.
Note that the final percentage open value may be adjusted during tuning.)
When airflow is required to any burner the K10 dampers must be full open. If
airflow must be routed through an elevation to help achieve the minimum Unit
airflow then they must also be wide open.
Sheet 10 – EB0-007991-1D9337 – RSFC Burner Inner Damper Control

This sheet provides the control direction to the inner RSFC dampers as shown in
green on Figure 7. Recall that these dampers are being used to help set the
airflow distribution within a single RSFC burner. As mentioned in Table 2, the
control of these devices is based on an open loop schedule for operation. There
is no closed loop control with feedback from a sensor helping drive these
component’s movements.
The control for these devices is as follows:

• If the burner is firing oil, the inner (primary) air damper position is set to a
fixed position based on a schedule tied to the total oil flow rate to the
burner. Oil flow to the burner at one rate will set one damper percentage
open, while a different oil flow rate will result in another output value.
• If the burner is firing gas, the inner (primary) air damper position is set to
a fixed position based on a schedule tied to the total gas flow rate to the
burner. Gas flow to the burner at one rate will set one damper
percentage open, while a different gas flow rate will result in another
output value.
• Immediately after a MFT trip the primary air dampers will remain frozen in
the position that they were sitting in just before the event took place.
They will stay at that percentage open value for five full minutes before
being released from that control mode.
• If none of the above conditions is true, the inner dampers will be set to
their full closed, 0.0% open positions.
Note that since a flow meter is present on each elevation that measures the total
oil flow rate, and a separate flow meter is present on each elevation that
measures the total gas flow rate, the rate going to an individual burner is simply
computed by dividing by the number of burners that are active and firing the fuel.
Other Considerations
Fuel Flow Demand
Typically Unit operation is driven by an overall Boiler Master control. The Boiler
Master tries to maintain the required steam pressure to support desired electrical
generating output. If the steam pressure is not high enough, the Boiler Master
directs additional fuel to be fired, thereby generating more steam and helping

CONTRACT: EB0-007991 11/6/15
achieve the necessary Unit output. Similarly if the header steam pressure is in
excess, less steam is required. To generate less steam, less fuel needs to be
combusted in the furnace. The system throttling occurs via the Boiler Master.
The logic defined in this document and the Reference 1 drawings presumes that
a Boiler Master implementation already exists within the DCS. The airflow rates
required are all based on supporting the amount of fuel routed to each elevation,
and subsequently to each burner register.
It is assumed the Boiler Master also helps distribute where fuel is being burned
within the Overall Unit. Based on component sizing and design considerations, to
achieve full Unit MCR all 24 burners must be active. Throughout the process
going from full cold, full off conditions to rated MCR at different points in time
more burners must be brought online. How the controller determines how much
fuel to fire at the different elevations is assumed to already be defined within the
DCS control logic.
Fuel/Air Cross-Limiting
Another key element that should be incorporated into the Control logic is fuel/air
cross-limiting constraints. It is important when going from Unit full off conditions
toward greater and greater load, that airflow control should lead the fuel ramp-up
process. Feedback data from the air system should be the basis for authorizing
increases in setpoints of fuel operation. To prevent any safety concerns there
should always be more air present than fuel to allow for full reactant combustion
during the start-up or ramp up process. When shutting down from high load
levels, fuel flow should always be reduced before air flows are lowered. Again it
is critical to maintain excess air over fuel.
Alstom expects that fuel/air cross-limiting has been, or will be, included in the
control logic design. Inclusion of cross-limiting is required to ensure safe boiler
operation.
The C30B-1636-002(A) drawing appears to incorporate cross-limiting and forms

the basis for the individual elevation air flow rate setpoint content. This type of
functionality should continue to be used.
Reference 5 (Case Studies)
The PowerPoint slides developed in Reference 5 help summarize the overall

control action for the Unit in a visual manner. Because there are 24 individual
burners spread over 4 elevations there are quite a large number of different
scenarios that might occur with regard to Unit Operation. The different cases
shown in that reference documentation may help provide additional
understanding of how the air flow control works. It is strongly recommended that
Reference 5 be reviewed and compared to this write-up and the logic drawings
themselves.

CONTRACT: EB0-007991 11/6/15
PAMPA
AIR DAMPER
CONTROL METHODOLOGY
REV B
A. Fitting
10/16/2015
ALSTOM US 1
RSFC AIR DAMPER OVERVIEW
• Each RSFC burner (Qty 24 per Unit) has
two automated actuators
• 1) Outer (Tertiary Damper)
• This damper will be used to
control 70 – 75% of the total
burner air flow
• 2) Inner (Primary Damper)
• This damper is used to control 10 1. Outer (Tertiary)
Damper
to 15% of the total burner
airflow at the oil and gas gun 2. Inner (Primary)
zone within the burner. Damper
• A more wide open primary

damper directs more
RSFC BURNER
airflow to the central region
of the RSFC closest to the
fuel feed. A more closed
primary damper directs less Note: damper appearance here is
airflow to the central region for diagrammatic purposes only –
within the RSFC. actual physical damper design uses
linear actuation instead of butterfly
2
style dampers – See slide 3
RSFC AIR DAMPER – PHYSICAL CONFIGURATION
Axis of actuator movement

Outer and inner damper actuators
Damper drives give linear actuation

3
HEADER & INDIVIDUAL BURNER
DAMPER LAYOUT (Per Elevation)
One elevation of
burners
FROM (representative)
FD FAN This layout is
K10 Damper repeated four
(Left Side) (4) times to give
the full Unit
• There are four (4) elevations of six (6) burners

• Each elevation is fed by two header air feeds;
each header has a damper
• K10 Damper (Left Side)
• K10 Damper (Right Side)
FROM
FD FAN
K10 Damper
(Right Side) 4
AIRFLOW LOGIC (OUTER DAMPER) – QUICK SUMMARY
• MFT – from MFT initiation until 5 minutes post-occurrence RSFC outer dampers are held in their last
previous position from just before the trip
• MFT Post Purge Fan Trip – for instances when the fan operation has been compromised a post-purge
fan trip is conducted where all outer dampers are held 100% open
• Purge – 5 minutes post-MFT until “purge complete” has been achieved…. RSFC outer dampers are
set open loop to fixed percentage open values to give desired overall unit purge airflow
• Auto
• RSFC outer dampers are driven to a minimum percent open when:
• 1) Unit is at or above 30% MCR & the burner under consideration is not in service (no
fuel flowing)
• 2) Unit is below 30% MCR & At least 1 elevation has no burners active & the burner
under consideration is on an elevation that has at least one burner active & the specific
burner under review is not in service (no fuel is active)
• RSFC outer dampers modulate per the following:
• 1) If no fuel is being burned on a particular elevation (and unit is running at ≤ 30% MCR)
these dampers move to bring overall Unit air flow up to the minimum required Unit
airflow rate; note that the Unit air flow rate here is constrained and may never be less
than the minimum air flow transmitter output possible
• 2) If fuel is burning on an elevation or will be fired soon then the Boiler Master already
present within the DCS will help set the necessary airflow demand for individual
elevations; this construct will be incorporated with Alstom’s new equipment - the outer
damper drives actuate to give the desired flow rates
5
AIRFLOW LOGIC (OUTER DAMPER) – Sample Cases
Slides 7 through 13 give different operating

scenarios and describe the RSFC outer damper
control function
The descriptions on those pages are with regard

to the outer (tertiary) RSFC dampers
6
ELEV.
4 FIRING GAS
3
FIRING OIL
2
NO COMBUSTION
1
BRN. 6 5 4 3 2 1
OUTER (TERTIARY DAMPER)
I. PURGE CONDITION
ELEV.
2
• All 24 RSFC outer dampers set to
1
fixed positions for purging – open
BRN. 6 5 4 3 2 1 loop % open values
7
ELEV.
4 FIRING GAS
3
FIRING OIL
2
NO COMBUSTION
1
BRN. 6 5 4 3 2 1
ELEV.
II. PURGE COMPLETE –
4 PRE/LOAD
3
• All 4 Elevations – no fuel firing
2 • Boiler load < 30%
1
• Total 30% airflow split evenly amongst 4
elevations; 7.5% of total flow to El. 1,2,3, &
BRN. 6 5 4 3 2 1 4
• All RSFC outer dampers move together (1
through 6 to achieve 7.5% elevation flow
8
on each level)
ELEV.
4 FIRING GAS
3
FIRING OIL
2
NO COMBUSTION
1
BRN. 6 5 4 3 2 1
III. FIRST BURNER FIRE

ELEV.
• 1 elevation – fuel firing; 3 no firing
3
• El. 1  Airflow to sustain gas firing on 11 burner
2 will be set and provided; burners 12, 13, 14, 15,
1 16 will have outer dampers set to minimum
positions
BRN. 6 5 4 3 2 1
• Elevations 2,3, and 4 will have balance airflow
needed to achieve total 30% airflow equally split
• All elevation 2, 3, and 4 burner RSFC outer air9
dampers move together to satisfy setpoint
ELEV.
4 FIRING GAS
3
FIRING OIL
2
NO COMBUSTION
1
BRN. 6 5 4 3 2 1
IV. FIRST BURNERS FIRE

ELEV.
• 1 elevation – fuel firing; 3 no firing
3
• El. 1  Airflow to sustain gas firing on 11 & 16
2 burner will be set and provided – closed loop
1 control; burners 12, 13, 14, and 15 will have
outer dampers set to minimum positions
BRN. 6 5 4 3 2 1
• Elevations 2,3, and 4 will have balance airflow
needed to achieve total 30% airflow equally split
• All elevation 2, 3, and 4 burner outer dampers10
move together to satisfy setpoint
ELEV.
4 FIRING GAS
3
FIRING OIL
2
NO COMBUSTION
1
BRN. 6 5 4 3 2 1 OUTER (TERTIARY DAMPER)
V. MULTIPLE ELEVATIONS
• 2 elevations – fuel firing; 2 no firing
ELEV. • Boiler load < 30%
4 • El. 1  Airflow to sustain gas firing on 11 through 16 will

3
be provided; El. 2 airflow for 21 will be provided; 22
through 26 outer dampers will be set to minimum
2 positions
• Elevations 3 and 4 will balance airflow through all 6 of
1
their respective registers to ensure total Unit 30%
BRN. 6 5 4 3 2 1 minimum airflow is achieved
• All elevation 3 and 4 RSFC outer dampers move together;
if the individual air flow setpoints for 3 or 4 fall below the
minimum transmitter capability the 3&4 flow setpoints 11
will be increased to the readable range
ELEV.
4 FIRING GAS
3
FIRING OIL
2
NO COMBUSTION
1
BRN. 6 5 4 3 2 1 OUTER (TERTIARY DAMPER)
VI. MULTIPLE ELEVATIONS (Cont.)

• 2 elevations – fuel firing; 2 no firing
ELEV. • Boiler load > 30%
4
• El. 1  Airflow to sustain gas firing on 11 through 16 will be
3 provided; El. 2 airflow for 21 through 26 will be provided
• All burners receiving fuel will have their RSFC outer
2
dampers move together on an elevation basis (11 is at x%,
1 12 is at same percent, 15 is at same percent…etc.; 26 is at
y%, 25 is at y% also, same with 23…etc.)
BRN. 6 5 4 3 2 1 • All elev. 3 and 4 burners are at minimum positions (also see
K10 control – minimal airflow to top elevations)
Note: When less than 30% boiler load at
least one elevation must not have any fuel 12
being fired.
ELEV.
4 FIRING GAS
3
FIRING OIL
2
NO COMBUSTION
1
BRN. 6 5 4 3 2 1
VII. MULTIPLE FUELS

• 1 elevation – fuel firing; 3 no firing; 2 fuels
• Boiler load < 30%
ELEV.
• El. 1 horizontally includes 2 burners, each firing
4 different fuel; controls compute overall elevation air
3
flow rate to support combustion (DCS elevation
master). 11 and 16 RSFC outer dampers move to the
2 same percentage open at all times in Auto.
1 • El. 2, 3, and 4 have airflow balance equally to give
30% minimum. Outer dampers 12, 13, 14, and 15
BRN. 6 5 4 3 2 1 are all set to minimum percent open position.
13
HEADER K10 DAMPER CONTROL – SUMMARY
• Position of K10 dampers is based on

checking RSFC operating status for a
given elevation
• If all six RSFC burners are out of
service and boiler load > 30% then
both K10 damper drives are driven
to a minimum percentage open
K10 HEADER DAMPERS
position of approximately 10-15%
(final value will be field tuned during
commissioning)
• If any one RSFC burner is in service
then both K10 damper drives will be
100% open
• When boiler load is less than 30% all
K10 dampers are 100% open
• Control of the K10 devices is fully open
loop – no feedback PI computation is Per Elevation
used here
14
BURNER AIRFLOW DISTRIBUTION LOGIC (INNER DAMPER)
• MFT – from MFT initiation until 5

minutes post-occurrence RSFC inner
dampers are driven closed
• Purge – 5 minutes post-MFT until “purge
complete” has been achieved RSFC inner
dampers continue to be directed closed
• Auto occurs at all other times
• In Auto if no fuel is being delivered NATURAL
OIL
to the burner under consideration GAS
then its corresponding RSFC inner
damper is maintained closed
• In Auto if fuel is being delivered to
the burner under consideration then
its RSFC inner damper moves to the
defined open loop % open position
based on the amount and type of
fuel being supplied to that burner
register
15
AIRFLOW DAMPER CONTROL SUMMARY
• Present control scheme uses K10 header dampers to control air flow to each
elevation of burners; air flow is equivalently provided to all 6 burners on a given
elevation
• New control scheme as defined by Alstom US assigns air flow control to each,
individual burner via the outer air damper actuator associated with each RSFC
assembly
• This scheme allows for more direct air flow control to individual burners
• Alstom RSFC outer dampers control the majority of the air flow, while RSFC
inner dampers control a smaller amount of air flow proportional to the fuel flow
• New control loop for K10 header dampers is simplified now that air flow control
is handled using actuators within the individual burners themselves
16
B I L L O F M A T E R I A L Q u a n t it ie s L is t e d a r e fo r 1 A s s e m b ly 1 - 2 4 2 9 6 - A A O R 1 - 2 4 2 9 6 - B A
C IT E M N O PART N O . N O . R E Q 'D D R A W IN G N O . D E SC R IP T IO N M A T 'L I T E M
101 M D 8-0 0 0 2 2 -1 6 5 4 8 M D 80 -1 C 0 0 2 2 W A S H E R - P L A I N T Y P E A .6 2 5 " (N ) ---
102 1 1 -2 0 0 8 8 M D 80 -1 C 0 0 0 3 N U T - H E X .6 2 5 - 1 1 U N C - 2 B ---
* 103 V 0 0 -9 3 6 8 1 ----- L I N E A R A C T U A T O R - S T R O K E 1 6 .6 " ---
* 104 V 0 0 -9 3 6 9 1 ----- LIN E A R A C T U A T O R ---
126 * 105 9 0 3 -2 0 1 1 2 B -9 0 3 -2 0 1 1 R O D E N D C LE V IS ---
* 106 M D 8-0 0 0 85 -A A 2 M D 80 -1 C 0 0 85 H E X JA M N U T ---
117 2X * 107 1 3 -4 1 3 6 8 M D 80 -1 C 0 0 0 9 S C R - C A P H E X S O C H D .3 1 2 X 2 .0 0 0 " ---
108 V 0 0 -1 6 1 3 2 ----- C L E V E L A N D M O D S P E E D R E D U C E R P /N ---
2X 115 2X 116
M 1311AA-50 C
109 V 0 0 -1 5 5 1 2 ----- A L U M I N U M K N U R L E D H A N D C R A N K W .M . ---
118 2X 128 B E R G . IN C - P /N C N 1 2 -1 0
110 9 0 3 -1 9 82 -2 2 B -9 0 3 -1 9 82 T E R T IA R Y SU PPO R T B R A C K E T ---
111 9 0 3 -1 9 81 -2 2 B -9 0 3 -1 9 81 PR IM A R Y SU PPO R T B R A C K E T ---
112 1 3 -3 0 2 1 8 M D 80 -1 C 0 0 0 5 S C R E W - H E X H E A D C A P .3 1 2 5 - 1 8 ---
U N R C - 2 A x .7 5 L G
113 1 5 -1 0 0 1 8 M D 80 -1 C 0 0 2 2 W A S H E R - P L A I N T Y P E A .3 1 2 " (W ) ---
1 [19]
114 2X 16 114 9 0 2 -1 4 2 2 2 A -9 0 2 -1 4 2 2 M O D IF IE D PIP E C A P T H R E A D E D F IT T IN G ---
C CLASS 150
S E C T IO N C -C 115 9 0 2 -1 4 2 3 4 A -9 0 2 -1 4 2 3 F A B R IC A T E D W A SH E R ---
S E C T IO N B -B 116 M D 8-0 0 0 3 2 -B F 4 M D 80 -1 C 0 0 3 2 W A S H E R - P LA IN T Y P E A W ID E 3 /8 ---
D RIV E SH A FT LO C A T IO N 2X
S P R IN G D E T A IL - - - - - ---
117 V 0 0 -1 5 4 7 2 C O M P R E S S I O N S P R I N G (4 .5 6 L G )
SEE NO TE 1 ---
118 1 2 -6 0 0 0 4 M D 80 -1 C 0 1 0 5 P L U G S - S Q U A R E H E A D P I P E .1 2 5 - 2 7 ,
(I N S T R U C T I O N S F O R S P R I N G S E A L I N S T A L L A T I O N )
SO LID
119 9 0 3 -6 3 0 0 -A A 1 B -9 0 3 -6 3 0 0 R SFC BU RN ER N AM EPLATE ---
* 120 9 0 2 -1 82 0 -1 1 2 B -9 0 2 -1 82 0 P IN 5 /8" W /C O T T E R P IN S ---
* 121 V 0 0 -1 5 5 2 4 -------- H A I R P I N (1 .8 " D I A X 1 - 1 5 / 1 6 L G ) ---
122 M D 8-0 0 2 0 0 -A N 4 M D 80 -1 C 0 2 0 0 SLO T T E D PA N H E A D T A PP IN G SC R E W - ---
T Y P E "A B "
127 B I L L O F M A T E R I A L Q u a n t itie s L is t e d a r e fo r 1 A s s e m b ly 1 - 2 4 2 9 6 - A A
112 113 4X IT E M N O PA R T N O . N O . R E Q 'D D R A W IN G N O . D E SC R IP T IO N M A T 'L I T E M
108 123 1 -2 4 2 9 7 -A A 1 E B 0 -0 0 7 9 9 1 -1 E 9 2 6 0 R S F C B U R N E R & D A M P E R A S S E M B L Y ---
111 2X
* 124 1 -2 4 3 0 4 -A A 1 E B 0 -0 0 7 9 9 1 -1 D 9 2 6 7 D A M P E R T U B E A S S E M B L Y ---
* 125 1 -2 4 3 2 0 -A A 1 E B 0 -0 0 7 9 9 1 -1 D 9 2 86 D A M P E R T U B E A S S E M B L Y ---
109
B I L L O F M A T E R I A L Q u a n t itie s L is t e d a r e fo r 1 A s s e m b ly 1 - 2 4 2 9 6 - B A
IT E M N O PA R T N O . N O . R E Q 'D D R AW IN G N O . D E SC R IP T IO N M A T 'L I T E M
P /N 1 -2 4 2 9 6 -B A (C W ) 126 1 -2 4 2 9 7 -B A 1 E B 0 - 0 0 7 9 9 1 - 1 E 9 2 6 0 R S F C B U R N E R & D A M P E R A S S E M B L Y (C W ) ---
FO R O TH ER PARTS ---
* 127 1 -2 4 3 2 0 -B A 1 E B 0 - 0 0 7 9 9 1 - 1 D 9 2 8 6 D A M P E R T U B E A S S E M B L Y (C W )
A N D D IM E N SIO N S
* 128 1 -2 4 3 0 4 -B A 1 E B 0 - 0 0 7 9 9 1 - 1 D 9 2 6 7 D A M P E R T U B E A S S E M B L Y (C W ) ---
S E E P /N 1 -2 4 2 9 6 -A A
.1 9 4X 110 /111 * D EN O T ES IT EM S SH IPPED LO O SE
.1 9 T O 1 2 3 /1 2 6
123
GEN ERAL N O TES:
1 . D I M E N S I O N I N G A N D T O L E R A N C I N G P E R A S M E Y 1 4 .5 M - 1 9 9 4
4X 102 U N LE SS O T H E R W ISE SPE C IF IE D :
a . A LL D IM E N SIO N S A R E IN F E E T A N D IN C H E S.
4X 101 b . T O L E R A N C E S O N L I N E A R D I M E N S I O N S ± .0 6 .
110 2X c . T O L E R A N C E S O N A N G U L A R D I M E N S I O N S ± 0 ° - 3 0 '.
4X 102 2 . A L L W E L D I N G P E R A W S D .1 .1 , L A T E S T E D I T I O N .
U S E E -7 0 1 8 E L E C T R O D E U N L E S S O T H E R W IS E S P E C IF IE D .
4X 101 3 . W H E R E N O T E D , E - 3 0 9 E L E C T R O D E S H A L L B E U S E D . I N A D D I T I O N T O C O M P L Y I N G W I T H A W S D 1 .1 : L A T E S T
E D IT IO N .
a . A LL W E LD S SH A LL B E Q U A LIF IE D IN A C C O R D A N C E W IT H A SM E B O ILE R & PR E SSU R E V E SSE L C O D E SE C T IO N IX
125 O R E Q U IV A LE N T ST A N D A R D .
112 113 4X b. W E LD E R Q U A LIF IC A T IO N A N D C E R T IF IC A T IO N SH A LL B E A V A ILA B LE F O R R E V IE W A T T H E SU PPLIE R S S H O P.
124
c. W E LD PR O C E D U R E S PE C IF IC A T IO N S A N D PR O C E D U R E Q U A LIF IC A T IO N R E C O R D S SH A LL B E A V A ILA B LE F O R
R E V IE W A N D A PPR O V A L B Y A LST O M PO W E R .
108 109 d . A LL W E LD S SH A LL B E G IV E N A V ISU A L IN SPE C T IO N A N D W ILL M E E T T H E A C C E PT A N C E R E Q U IR E M E N T S O F
A .W .S . D 1 .1 : L A T E S T E D I T I O N .
IN ST R U C T IO N S F O R SPR IN G SE A L IN ST A LLA T IO N :
4X 107 1 . C U T S P R I N G (I T E M 1 1 7 ) T O R E Q U I R E D L E N G T H A N D B E N D B O T H E N D S U P I N T O S P R I N G T O P R E V E N T
G O U G I N G T H E W A S H E R S (I T E M 1 1 6 ) A F T E R A S S E M B L Y .
D E T A IL G 2 . A S S E M B L E B E A R I N G H O U S I N G S P E R S E C T I O N C - C (A - 7 ) D O N O T O V E R T I G H T E N B E A R I N G H O U S I N G P I P E C A P
S C A L E 1 :6 G
(I T E M 1 1 4 ) . W A S H E R S S H O U L D B E A B L E T O M O V E I N A S S E M B L Y A F T E R T I G H T E N I N G .
3 . T H R E A D JA M N U T (I T E M 1 0 6 ) A N D C L E V I S (I T E M 1 0 5 ) O N T E R T I A R Y D A M P E R S H A F T (I T E M 2 0 6 - R E F . D W G
1 ).
4 . P R IO R T O A T T A C H IN G IT E M 1 0 3 /1 0 4 , S T R O K E T E R T IA R Y /P R IM A R Y D A M P E R A S S E M B L Y O V E R IT S F U L L
D IS T A N C E O F T R A V E L B Y P U S H IN G /P U L LIN G IT E M 1 0 5 . D A M P E R A S S E M B L Y S H O U L D M O V E F R E E L Y W IT H O U T
B IN D IN G .
107 4X 5 . A F T E R F IN A L A S S E M B L Y & P A IN T IN G , R E M O V E IT E M S 1 0 3 , 1 0 4 , 1 0 7 , 1 2 0 , 1 2 1 , 1 2 4 /1 2 7 , & 1 2 5 /1 2 8. B A G &
L A B E L O R T A G R E M A I N I N G L O O S E I T E M S W I T H T H E B U R N E R T A G N O . F R O M T H E B U R N E R N A M E P L A T E (I T E M
1 1 9 ).
6 . A F T E R F I N A L A S S E M B L Y E N S U R E 1 1 .7 5 " O .D . T U B E S L I D E S F R E E L Y A N D C O N C E N T R I C A L L Y , W I T H O U T
O BSTR U CTIO N , TH R U CEN TER O F BU R N E R .
I N S T R U C T I O N S F O R G E A R D R I V E A S S E M B L Y (S E E D E T A I L G ) :
1 . (O P T I O N A L ) F I L L A L L G E A R D R I V E S (I T E M 1 0 8 ) W I T H 8 0 - 9 0 W O I L P R I O R T O S H I P P I N G T H E B U R N E R S .
2 . F I T K E Y (P R O V I D E D W I T H O U T P U T S H A F T O N G E A R D R I V E S (I T E M 1 0 8 ) I N T O C O U P L I N G K E Y W A Y O N D I R E C T
P /N /1 -2 4 2 9 6 -A A (C C W ) C R A N K A S SE M B LIE S . T IG H T E N SE T SC R E W IN C O U PLIN G .
3 . P R E A S S E M B L E A N D A L I G N G E A R D R I V E A S S E M B L I E S (I T E M S 1 0 8 , 1 0 9 , 1 1 0 , 1 1 2 & 1 1 3 A N D 1 0 8 , 1 0 9 , 1 1 1 , 1 1 2 ,
& 1 1 3 ) PR IO R T O W E LD IN G SO T H A T F U LL ST R O K E O F LIN K A G E A N D C R A N K A SSE M B LIE S IS PE R M IT T E D .
P O S IT IO N G E A R D R IV E S A S S E M B LIE S A S S H O W N IN V IE W S A -A A N D A 1 -A 1 .
(5 '- 2 116 " [ 1 5 7 6 ] )
IN ST R U C T IO N S FO R A C T U A T O R IN ST A LLA T IO N
1 . P R I O R T O R E M O V I N G T H E E I G H T (8 ) Y E L L O W S H I P P I N G T A B S F R O M T H E S H R O U D S , T H R E A D O N T H E JA M B
(1 '- 3 78 " [ 4 0 4 ] ) N U T A N D T H E N T H E C L E V I S (I T E M 'S 1 0 5 & 1 0 6 ) T O A L L O W 6 0 - 6 5 m m O F T H R E A D F R O M T H E D A M P E R S H A F T S
TO BE EXPO SED .
119 122 103 120 121 105 106 2 . I N S T A L L T H E D A M P E R T U B A S S E M B L I E S (I T E M 'S 1 2 4 & 1 2 5 ) . S E C U R E W I T H I T E M S 1 0 1 & 1 0 2 . E N S U R E T H E
123 126 W E LD M E N T IS H O R IZO N T A L - T H E U SE O F F LA T W A SH E R S IS PE R M IT T E D .
(7 '- 1 196 " [ 2 1 7 3 ] ) 3 . R E M O V E T H E F O U R (4 ) 1 .5 " L O N G C A P - S C R E W S F R O M T H E B A C K O F E A C H A C T U A T O R A N D D I S C A R D . U S E T H E
A
F O U R (4 ) 2 ” L O N G C A P - S C R E W S F R O M T H E S M A L L B O X I N S I D E T H E S H I P P I N G C R A T E . H O L D T H E A C T U A T O R I N
3 " [7 6 ] A1 PA IN T LU G P L A C E (1 8 k g .) A N D S E C U R E W I T H C A P - S C R E W S . E N S U R E T H E W E L D M E N T I S H O R I Z O N T A L - T H E U S E O F F L A T
YELLO W W A SH E R S IS PE R M IT T E D .
4 . R E M O V E T H E S H I P P I N G T A B S (P A I N T E D Y E L L O W ) , R E T R A C T T H E S H R O U D U N T I L T H E C L E V I S A N D T H E D R I V E
5" [127] PIN H O LE S A R E A LIG N E D . SE C U R E W IT H IT E M S 1 2 0 & 1 2 1 .
5 . T E S T E A C H D R I V E (E L E C T R I C A L L Y ) T O E N S U R E F U L L S T R O K E . E A C H D R I V E M A Y B E A D JU S T E D , I F R E Q U I R E D ,
F O R T R A V E L. C O N SU LT R O T O R K IN S T R U C T IO N M A N U A L.
B B 6 . O N C E P R O P E R O P P E R A T I O N H A S B E E N C O N F I R M E D C I N C H E A C H JA M B N U T (I T E M 1 0 6 ) .
PA IN T N O T E S:
1 . S T A M P / S T E N C I L " A S S 'Y N O . 1 - 2 4 2 9 6 - A A " O R " A S S 'Y N O . 1 - 2 4 2 9 6 - B A " . I N C L U D E R O T A T I O N (C C W O R C W ) I N
S T A M P O N B A C K P L A T E A N D O N N A M E P L A T E (I T E M 1 1 9 ) .
2 . D O N O T P A IN T IN SID E O F H O LE S, A N Y S T A IN LE SS ST E E L C O M PO N E N T S, D A M PE R B E A R IN G H O U SIN G S, O R
63°
H A N D W H E E L A N D G E A R D R IV E B O X E S.
ITEM 108
3 . SH O P PR IM E A LL O T H E R SU R F A C E S O F M A IN B O D Y , E X C E PT A S SPE C IF IE D IN N O T E T W O , W IT H R E D O X ID E
P R I M E R (1 .7 ) . R E D O X I D E P R I M E R T O B E P E R A L S T O M S T D . D W G . C - 9 8 5 - 0 6 6 9 , I T E M N O . 9 .0 . R E F E R T O
D R A W IN G N O . B -9 85 -0 3 0 8 F O R C O A T IN G S P E C IF IC A T IO N S .
34°
4 . P A I N T O U T S I D E O F B A C K P L A T E W I T H A L U M I N U M H E A T R E S I S T A N T P A I N T (1 .1 .3 ) P E R A L S T O M S T D . D W G .
IT E M 1 0 8
C - 9 8 5 - 0 6 6 9 I T E M N O . 9 .0 . R E F E R T O D W G . N O . B - 9 8 5 - 0 3 0 8 F O R C O A T I N G S P E C I F I C A T I O N S .
Ø (3 '- 1 176 " [ 9 5 1 ] )

(5 '- 3 34 " [ 1 6 1 9 ] )
R E F E R E N C E D R A W IN G S:
104 1 . R S F C B U R N E R & D A M P E R A S S E M B L Y .....................E B 0 - 0 0 7 9 9 1 - 1 E 9 2 6 0
2 . R S F C B U R N E R & L I N K A G E A S S E M B L Y .....................E B 0 - 0 0 7 9 9 1 - 1 E 9 2 6 1
3 . R S F C B A C K P L A T E A N D S W I R L E R A S S S E M B L Y ..........E B 0 - 0 0 7 9 9 1 - 1 E 9 2 6 2
4 . R S F C B U R N E R G E N E R A L A R R A N G E M E N T - S H 1 ......E B 0 - 0 0 7 9 9 1 - 1 E 9 2 5 0
5 . R S F C B U R N E R G E N E R A L A R R A N G E M E N T - S H 4 ......E B 0 - 0 0 7 9 9 1 - 1 E 9 2 5 3
6 . R S F C B U R N E R A R R A N G E M E N T ................................E B 0 - 0 0 7 9 9 1 - 1 E 9 2 5 8
2 '- 7 78 " [ 8 1 0 ]
SE E D E T A IL 6
REF DW G 6
F O R IN ST A LLA T IO N P A IN T IT E M 2 0 9
D E T A ILS YE LLO W
A P A IN T IT E M 2 1 0 Y E LLO W
A1 A LL PLACES
PA IN T T U B E
YELLO W
(5 '- 3 43 " [ 1 6 1 9 ] )
8 '- 6 176 " [ 2 6 0 2 ]

V IE W A -A 9 8 .1 3 [ 2 4 9 3 ] E N D O F S H A F T W / O C L E V I S
P /N 1 -2 4 2 9 6 -A A (C C W A S S H O W N )
V IE W A 1 -A 1
P /N 1 -2 4 2 9 6 -B A (C W O P P O S IT E H A N D )
BILL O F M AT ERIALS Q U A N T I T I E S L I S T E D A R E F O R (1 ) A S S E M B L Y
IT EM N O PART NO . NO . REQ D R AW IN G N O . D ESC RIPT IO N M A T 'L I T E M
1 1 -2 4 2 6 8 -A A 1 E B 0 -0 0 7 9 9 1 -1 E 9 3 2 1 RSFC G A S PIPE A SSEM BLY ---
2 1 -2 4 5 2 4 -A A 1 E B 0 -0 0 7 9 9 1 -1 E 9 3 2 6 RSFC O IL & H EI G U ID E PIPE ASSEM BLY ---
3 1 -2 4 2 6 9 -A A 1 E B 0 -0 0 7 9 9 1 -1 E 9 3 2 2 C O RE AIR ASSEM BLY ---
4 1 5 -1 0 0 6 24 M D 8 0 -1 C 0 0 2 2 W A S H E R -P L A I N T Y P E A .6 2 5 " (w ) ---
5 1 1 -2 1 0 4 12 M D 8 0 -1 C 0 0 0 1 N U T -H E X .7 5 0 I N ---
6 M D 8 -0 0 0 4 4 -F G 12 M D 8 0 -1 C 0 0 4 4 B O L T -H E X .7 5 0 X 2 .0 0 0 I N ---
7 G P -2 8 7 6 -A U 1 C -G P -2 8 7 6 1 0" 1 5 0# PIPE FLAN G E G ASK ET ---
Ø 7 .5 0 Ø 9 .5 0 I .D . Ø 1 0 .0 0 O .D . Ø 1 1 .0 0 I .D .
D IFFU SER C O RE AIR C O RE AIR G AS
D E T A IL B 1 V IE W C -C
SCALE 1 / 3 SCALE 1 / 3
1 2 3 .8 7
1 2 3 .8 7
5 4 6 7 C
B1
S E C T IO N B -B C
SCALE 1 / 6
SEAL
.1 9 E -7 0 1 8
1 1 .6 9 (1 1 2 .1 5 )
B B
G EN ERAL N O TES:
1 . D I M E N S I O N I N G A N D T O L E R A N C I N G P E R A S M E Y 1 4 .5 - 1 9 9 4 U N L E S S O T H E R W I S E S P E C I F I E D
a . A LL D IM E N SIO N S A R E IN IN C H E S
b . T O L O R A N C E O N D I M E N S I O N S ± .0 6
c. T O LE R A N C E S O N A N G U LA R D IM E N SIO N S ± 0 º3 0 '
2 . A L L W E L D S P E R A W S D 1 .1 L A T E S T E D I T I O N . U S E E - 7 0 1 8 E L E C T R O D E U N L E S S O T H E R W I S E
SPE C IF IE D .
a . A LL W E LD S SH A LL B E Q U A LIF IE D IN A C C O R D A N C E W IT H A S M E B O ILE R & PR E SSU R E V E SSE L
C O D E SE C T IO N IX O R E Q U IV A LE N T ST A N D A R D .
b. W E LD E R Q U A LIF IC A T IO N A N D C E R T IF IC A T IO N SH A LL B E A V A ILA B LE F O R R E V IE W A T T H E
SU PPLIE R S SH O P.
1 4 .0 0 c. W E LD PR O C E D U R E SP E C IF IC A T IO N S A N D P R O C E D U R E Q U A LIF IC A T IO N R E C O R D S SH A LL B E
4" G AS IN LET
A V A ILA B LE F O R R E V IE W A N D A P PR O V A L B Y A LST O M PO W E R .
d . A LL W E LD S SH A LL B E G IV E N A V ISU A L IN SPE C T IO N A N D W ILL M E E T T H E A C C E PT A N C E
R E Q U I R E M E N T S O F A .W .S . D 1 .1 1 9 9 8
3 . W H E R E N O T E D , E -3 0 9 A N D E -3 1 6 E LE C T R O D E S H A L L B E U S E D . IN A D D IT IO N T O C O M P L Y IN G
W I T H A W S D 1 .1 L A T E S T E D I T I O N.
4" C O R E A IR IN LET
1 2 .0 0
45°
45°
V IE W A -A V IE W A - A
P /N 1 -2 4 2 6 7 -A A P /N 1 -2 4 2 6 7 -B A
CCW
CW
TAB 2
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
TABLE OF CONTENTS

LIMELIGHT™ 3” Bluff Body GAS pipe Ignitor General Description .............................................................. 1
IGNITOR COMPONENT FUNCTIONAL ....................................................................................................... 2

Main Gas Connection ................................................................................................................................ 2
Spark/Flame Rod Connector and Wire Train Assembly............................................................................ 3
Spark/Flame Rod Assembly .................................................................................................................. 4
Bluff Body .................................................................................................................................................. 5
Gas Pipe Tip Assembly ............................................................................................................................. 6
IGNITOR WINDBOX PRESSURE TAPS...................................................................................................... 7
IGNITOR OPERATION - GENERAL............................................................................................................. 7
IGNITOR CONTROL CABINET .................................................................................................................... 8

Gas Ignitor Control Cabinet Indicating Lights and Pushbuttons ............................................................ 8
IGNITOR COMBUSTION AIR SYSTEM (supplied by Others) ...................................................................... 8
GAS PIPE TRAIN .......................................................................................................................................... 8
IGNITOR SYSTEM CARE - GENERAL ........................................................................................................ 9

Foreign Material ......................................................................................................................................... 9
Inspection ............................................................................................................................................... 9
Shop Service and Handling.................................................................................................................... 9
Risk of Electrical Component Damage .................................................................................................. 9
Gas Ignitor Control Cabinet Panel Arrangement ..................................................................................... 10
OPERATION ............................................................................................................................................... 10
INSTALLATION/COMMISSIONING CHECK LIST ..................................................................................... 11

Gas Header Trip Switch Set Points ......................................................................................................... 12
SUMMARY .................................................................................................................................................. 12
UNIT DATA / CUSTOMER INFORMATION ............................................................................................... 13
TROUBLESHOOTING GUIDE.................................................................................................................... 14
Starting ................................................................................................................................................. 14
TROUBLESHOOTING GUIDE (Cont.)........................................................................................................ 15
Combustion Air and Gas ...................................................................................................................... 15
TROUBLESHOOTING GUIDE (Cont.)........................................................................................................ 16
Detection .............................................................................................................................................. 16
COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 i

CONTRACT: EB0-007991 11/6/15
LIST OF FIGURES
Figure 1: Gas Pipe Ignitor Side and Plan View ............................................................................................. 2

Figure 2: Gas Connection and Pressure Test Tap........................................................................................ 3
Figure 3: Dust Plug Termination at Air Inlet Assembly.................................................................................. 4
Figure 4: Connector and Wire Train Assembly Wiring at Dust Plug ............................................................. 5
Figure 5: Spark/Flame Rod Assembly Inserted into the Bluff Body .............................................................. 5
Figure 6: Bluff Body Construction.................................................................................................................. 6
Figure 7: Gas Pipe Tip Assembly .................................................................................................................. 7
Figure 8: Ignitor ........................................................................................................................................... 11

3" Bluff Body Gas Pipe Ignitor ....................................................................................... EB0-007991-1D9314
Gas Ignitor Control Cabinet Schematic ......................................................................... EB0-007991-1D9315
Gas Ignitor Valve Train – De-Energize To Trip, High Capacity ..................................... EB0-007991-1D9362
Gas Ignitor Control Cabinet Schematic ......................................................................... EB0-007991-1D9363
LIMELIGHT™ Diagnostic Flame

Indicator Model 100 Rev 4 ...............................................................................................................5001 R1
COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 ii

CONTRACT: EB0-007991 11/6/15
LIMELIGHT™ 3” BLUFF
BODY GAS PIPE IGNITOR
GENERAL DESCRIPTION
The LIMELIGHT™ 3” Gas Pipe ignitor is designed to serve as an ignition torch for
gas, oil or coal burners in industrial and utility boiler applications. The ignitor itself
consists of the ignitor gas nozzle, spark rod, flame rod, bluff body and dust
plug/gas inlet. These components are housed inside the ignitor housing which is
called the “Air Inlet Assembly”. The LIMELIGHT™ ignitor design provides
improved combustion airflow with minimum pipe obstruction and pressure drop.
The gas ignitor uses a Diagnostic Flame Indicator for proving flame. The ignitor
utilizes a ceramic insulated solid rod design for both spark rod and flame rod
sensor. These solid rods remove all wiring and associated connections from
inside the ignitor’s air inlet assembly. This ignitor and Alstom’s associated flame
proving devices were designed to meet all code requirements including the
National Fire Protection Association (NFPA) and Black Liquor Recovery Boiler
Advisory Committee (BLRBAC) guidelines.
Gas is admitted through the main gas pipe out to and into the bluff body. The
majority of the gas exits the gas nozzle tip. However, inside the bluff body a
machined orifice creates a slight backpressure to the gas flow. This
backpressure forces a small percentage of the main gas to flow through weep
holes machined in the bluff body.
This weep hole gas exits the bluff body behind the bluff body diffuser ring and
enters a recirculation zone created by the flow of combustion air around the bluff
body. Combustion air is admitted through the air inlet on the existing ignitor guide
pipe and is forced around the bluff body and out into the boiler. The sudden
increase in flow area on the downstream side of the bluff body creates a
recirculation zone for the combustion air. This recirculation zone provides mixing
for the gas and air and allows the pilot flame front to stabilize just downstream of
the bluff body. As long as the gas and air flows are properly maintained after
ignition, the recirculation zone creates a self stabilizing flame of weep gas that
exits the air inlet assembly around the main gas tip. The gas tip is setback 2”
from the existing ignitor guide pipe end to properly shape the flame. Reference
Figure 1 and drawing EB0-007991-1D9314.
The weep gas then ignites the main gas flow as it leaves the gas pipe tip
assembly. The burning weep gas inside the air inlet assembly creates an ionized
gas pocket that can be detected by Alstom’s LIMELIGHT™ Diagnostic Flame
Indicator (DFI).
COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 1

CONTRACT: EB0-007991 11/6/15
Figure 1: Gas Pipe Ignitor Side and Plan View
IGNITOR COMPONENT
FUNCTIONAL
The stainless steel ignitor was designed for quick and easy maintenance by
incorporating modularized construction reducing the need for spare parts. The
major components are described below.
Main Gas Connection

The main gas connection utilizes a 1” pipe coupling (reference Figure 2) to allow
for removal of the ignitor from the air inlet assembly. Gas pressure at the ignitor
is measured using the ¼” gas static pressure tap located downstream of the gas
inlet to the ignitor. When properly instrumented, this tap and its resulting
pressure reading when gas is supplied will indicate the Btu rating of the ignitor.
There is a second static pressure tap (combustion/cooling air pressure tap)

located on the air inlet assembly. Refer to Figure 2 and drawing EB0-007991-
1D9314.
This tap is used to measure the combustion air pressure and its resulting flow
when the ignitor is being commissioned. These two taps, gas pressure and
combustion air pressure, are the test measurement locations needed to insure
the proper commissioning of the ignitor.

CONTRACT: EB0-007991 11/6/15
Figure 2: Gas Connection and Pressure Test Tap
Spark/Flame Rod Connector and Wire Train Assembly

The Spark/Flame Rod Connector and Wire Train assemblies are factory
assembled and are supplied with 10 feet of flex conduit and 30 feet of ground and
signal wire. There are two assemblies required per ignitor, one for spark and one
for the flame rod.
The loose field wires are terminated inside the respective local junction box for
the ignitor on the designated terminal strips. The wiring train’s connector housing
is attached to either the spark or the flame rod assembly at the ignitor dust plug
by securing the swivel adapter to the connector housing. Refer to Figure 3.
Grounding connections are pre-connected at the assembly’s connector as shown
in Figure 4.
The design of the system allows for the spark or flame rods to be
interchangeable, therefore it does not matter which connector is secured to the
spark or flame rod.

CONTRACT: EB0-007991 11/6/15
Figure 3: Dust Plug Termination at Air Inlet Assembly
NOTE:
Flexible conduit and flexible electrical connections are provided
at the ignitor to permit expansion and movement. The existing
flexible gas hose connects to the ignitor using a 1” pipe union.
When piping and wiring are run to the ignitor, care should be
taken to keep torque forces to a minimum so that components
are not stressed at the ignitor. Field piping and wiring should be
arranged to provide maintenance and operator accessibility.
Spark/Flame Rod Assembly

The spark/flame rod assembly comes as a factory assembled component and is
made to specific “E” dimensions for each ignitor contract. The rod assembly
screws into the dust plug and is supported and protected by Double Rod Standoff
Clips. The clips are permanently aligned and welded to the gas piping that is
down stream of the dust plug.
If replacement of the spark/flame rod assembly is required, the solid rod must be
unthreaded and pulled out of the ignitor from the bluff body side. Then the swivel
adapter is unscrewed from the dust plug, which allows removal of the ceramics
and protective sheath. The replacement parts are then inserted through the dust
plug and rod standoff clips and aligned into the bluff body.
CAUTION:
Care must be taken to re-install the spacer between the dust
plug and the threaded swivel adapter. If the spacer is not re-
installed, it is possible that the ceramics inside the
assembly will be broken when the adapter is tightened.
The spark/flame rod assembly’s sheath will lightly press-fit inside the bluff body
with approximately 1” of ceramic protruding from the downstream face of the bluff
body. The spark or flame rod should extend approximately 6” from the
downstream face of the bluff body.

CONTRACT: EB0-007991 11/6/15
Figure 4: Connector and Wire Train Assembly Wiring at Dust Plug
Bluff Body
The bluff body (Figures 5 and 6) is a machined component designed to produce
minimum pressure drop to the combustion air system while providing superior
fuel and air mixing. The outside of the body has four alignment fins that align the
ignitor inside the air inlet assembly. Two bore holes are drilled towards the
outside of the bluff body. These holes guide and allow for proper positioning of
the spark and flame rods. In the center of the body on the upstream side, a
reduced bore in the bluff body provides the inlet connection and mechanical stop
for the gas supply piping.
Figure 5: Spark/Flame Rod Assembly Inserted into the Bluff Body

CONTRACT: EB0-007991 11/6/15
NOTE:
The ceramics used can be damaged or broken if mishandled or
dropped. Care should be taken when replacing or removing
these devices to minimize any mechanical or impact damage.
The ceramics are great insulators and with the proper care
should provide excellent dielectric properties for many years.
However, as with any electronics, care should be taken to avoid
water from being sprayed into the ignitor assembly or wiring train
as the potential for developing an unwanted system ground
exists. This is especially true in boiler maintenance operations
where water washing is performed. Prior to any water washing, if
practical, the ignitor along with its air inlet assembly and
spark/flame rod wiring train should be removed from the furnace
and away from the aqueous environment. This method will
protect the spark and flame rods as an assembly. If this is not
possible, protection from the wash water should be made by
covering the removed air inlet assembly and ignitor with plastic.
There is a removable orifice, accessible from the downstream side of the bluff
body that provides for a small amount of gas to exit the bluff body through the
weep holes that discharge behind the diffuser plate. The downstream side of the
bluff body is threaded to allow for insertion and replacement of the gas pipe tip,
as well as access to the orifice.
Figure 6: Bluff Body Construction
Gas Pipe Tip Assembly

The gas pipe tip is available as a replacement part and can be replaced by
unthreading the tip from the bluff body, taking care to first remove any tack welds.
Refer to Figure 7. After commissioning, or upon replacement of the gas pipe tip,
it must be tack welded at the junction of the tip and bluff body. The gas pipe tip is
310 stainless steel, and when fully threaded into the bluff body should extend
8.00” from the face.

CONTRACT: EB0-007991 11/6/15
The replacement tips should be installed into the bluff body as far as the threaded
hole allows. Prior to re-installing a gas tip, make sure that all of the gas weep
holes and center orifice are free and clear of debris. The attachment of an ignitor
flame diffuser assembly is used for horn ignitor applications.
Figure 7: Gas Pipe Tip Assembly
IGNITOR WINDBOX
PRESSURE TAPS
The ignitor assembly has two ¼” pressure taps. Gas pressure at the ignitor is
measured using the ¼” gas static pressure tap located at the gas inlet to the
ignitor. When properly instrumented, this tap and its resulting pressure reading
will indicate the Btu rating of the ignitor when gas is supplied. A combustion/
cooling air pressure tap is located on the air inlet assembly which measures the
combustion air pressure and its resulting flow rate.
IGNITOR OPERATION -
GENERAL
The LIMELIGHT™ three inch ignitor system is a permanently mounted fixed

arrangement where the individual ignitor components such as the flame rod,
spark rod, and gas assembly are mounted on an ignitor front plate. The spark
rod and flame rod components are secured on locating pipes with Camlock style
quick disconnects and can be removed while the unit is on line. During normal
operation the individual ignitor components should be locked in the ignitor front
plate locating pipes. Should maintenance or cleaning be required, the DFI flame
rod and spark rod can be removed by way of these quick disconnect fittings.
With the ignitor components installed on the ignitor windbox front plate, the gas
pipe connections are typically left installed to allow for the use of the ignitor at any
time.
The combustion air fan should typically be left running to keep the ignitor ready
for operation.

CONTRACT: EB0-007991 11/6/15
IGNITOR CONTROL CABINET
Reference drawings EB0-007991-1D935 and EB0-007991-1D9363.
An ignitor control cabinet is installed at each corner to serve an individual ignitor.

The cabinet is installed conveniently near the ignitor installation, but in a cooler
location away from the furnace wall casing.
The cabinet houses the components required to operate and monitor the ignitor,
such as the DFI circuits, a spark transformer power supply, and all the necessary
electrical components and connection points for tying into the burner
management system for control room operation of the ignitor system. The DFI
System proof of flame is also housed in the cabinet.
Note:
This system was designed to be De-Energize-to-Trip
A window located on the front of the gas ignitor control cabinet allows the DFI
module to be viewed without opening the cabinet door.
The ignitor control cabinet contains the necessary electrical equipment to operate
and control the ignitor. This includes the following:
• Spark Transformer
• DFI System LIMELIGHT™ Diagnostic Flame Indicator Model DFI-100-40001
• Indicating Light
• Main Terminal Board
Gas Ignitor Control Cabinet Indicating Lights and Pushbuttons

The following Indicating Lights and pushbuttons are located on the front of the
ignitor control Cabinet:
• RED “FLAME PROVEN” Indicating Light is located on the front of the gas
ignitor control cabinet. This light will illuminate if the DFI flame module
indicates flame plus gas pressure or flow is proven. This light provides visual
indication of the status of the ignitor.
IGNITOR COMBUSTION AIR

SYSTEM (SUPPLIED BY
OTHERS)
Combustion air to the ignitors is typically supplied by a scanner cooling/ignitor

combustion air fan.
The dampers should typically be set to achieve a 3” w.g. pressure drop across
the ignitor. This differential pressure between the ignitor windbox and furnace is
required to produce a stable ignitor flame.
GAS PIPE TRAIN
Reference drawing EB0-007991-1D9362.

CONTRACT: EB0-007991 11/6/15
Each of the ignitors has been supplied with an ignitor gas pipe train rated at 13
million Btu’s/hr and consists of a 1-1/2” 100 mesh strainer, two (2) 1-1/2”
pneumatically operated block valves, One (1) 3/4" pneumatically operated vent
valve and a 1-1/2” manual globe valve.
• The strainer removes any final contaminants that might be in the gas before
the gas passes through the block valve into the ignitor.
• Two 1-1/2" block valves provide positive isolation of gas from the ignitor when
the ignitor is not in service.
• A 3/4" vent valve located between the block valves is open when the block
valves are closed, and will close when the block valves open.
• A 1-1/2” manual globe valve is located in the gas pipe to provide final gas
pressure adjustment at an individual ignitor.
IGNITOR SYSTEM CARE -

GENERAL
Foreign Material
After the initial installation of the fuel piping is completed, all piping should be
blown out using steam or compressed air to remove mill scale and other foreign
material. This should be done again if future maintenance requires extensive
supply piping replacement or repair.
During initial operation the ignitor air inlet assembly and nozzle tip should be
inspected for furnace slagging when the opportunity presents.
Inspection
After the ignitor is removed from the furnace, always, inspect the burner openings
and remove any slag that may be present.
Shop Service and Handling

If the ignitor is removed from the boiler, it is recommended that the assembly be
placed in a protective rack. This rack system will protect the ignitor ceramics and
other components from potential damage.
If maintenance is performed on the ignitor, care must be given to ensure that the
ceramics are not damaged along with the ceramic sleeves. It is recommended
that all maintenance be performed using the maintenance rack.
If the ignitor is removed for the boiler, check the cleanliness of the flame rod, and
spark rod tip. Clean the flame rod or spark rod using a wire brush. Be careful to
not damage the ceramics or ceramic insulator sleeves.
Risk of Electrical Component Damage

When re-inserting the ignitor components, care must be taken to ensure that the
flame rod and spark rod are not damaged by the re-insertion process. If the
electrical connections were removed or are loose, they should be firmly tightened
to insure good electrical contact is made.

CONTRACT: EB0-007991 11/6/15
Gas Ignitor Control Cabinet Panel Arrangement

An ignitor control cabinet panel arrangement has been supplied that contains the
spark rod transformer, the DFI module and the wiring bus for the spark rod and
DFI connections and BMS interface.
The ignitor control cabinet panel is installed inside an existing ignitor control
cabinet conveniently near the ignitor installation, but in a cooler location away
from the furnace wall casing.
The panel supports the components required to operate and monitor the ignitor,
the ignitor has a DFI circuit, a spark transformer, and all the necessary electrical
components and connection points for tying into the burner management system
for control room operation of the ignitor system.
Note:
This system was designed to be De-Energize-to-Trip.
OPERATION
The ignitor is a fixed mount ignitor system that can be removed from the ignitor
air inlet assembly for cleaning and maintenance. The ignitor is locked in the
ignitor air inlet assembly using a 3” quick disconnect D-Coupler.
CAUTION:
If Ignitor is removed from boiler for maintenance while boiler
is in operation, care should be observed as the boiler
furnace pressure could go positive. A plug should be put in
the guide pipe assembly while the ignitor is removed this
will prevent short circuiting of the combustion air from the
guide pipe and prevent any furnace gases from escaping
should the furnace go positive.
With the ignitor installed in the windbox, the gas is typically left connected to allow
for the use of the ignitor at any time. The ignitor combustion air fan is left running
to keep the ignitor ready for operation and to keep it cool and clean during idle
periods.
To start the ignitor the boiler should have a purge complete permissive
established and the Ignitor gas supply header system lined up for service through
the Burner Management System. Ignitor operation is controlled from the existing
BMS.
Permissives for firing the ignitor require that the ignitor have a “no flame” signal
from the DFI electronics. There also should be “no furnace MFT” or no master
fuel trip.
When an Ignitor “Start” is initiated typically a ten second trial timer is started and
the ignitor gas shut-off valve is opened, the HEI spark exciter is energized begins
a ten second trial time. The spark ignites fuel air mixture. Flame is detected by
the flame rod, which then sends a “flame signal” to the local control cabinet.
The “flame detected” signal issued from the DFI. The “Ignitor Proven” signal is
sent to the Burner Management System and is then typically used as a start
permit for the adjacent gas gun.

CONTRACT: EB0-007991 11/6/15
The ignitor will trip on loss of flame proven, loss of power to the local ignitor
cabinet, or an MFT is initiated. The existing ignitor valve train is a “de-energized
to trip”.
Figure 8: Ignitor
INSTALLATION/COMMISSIONING
CHECK LIST
1. Verify “A” dimension is matching the existing 3” furnace guide pipe
Centerline of air inlet assembly to end of guide tube in furnace (Figure 8).
2. Remove shipping tape and foam block before installing the flame rod.
3. Install tab for Ignitor Engagement switch, if required.
4. Make sure the gas line is sized to maintain sufficient pressure,
remove in-line orifice if reusing original valve trains (as required).
5. Clean strainer and solenoid valve, if required.
6. Install a new test gauge on the gas line, Ignitor Firing pressure – 0 to 15
PSIG.
7. Install a new test gauge on the Combustion air inlet – 0 to 10 “WG.
8. Position the ignitor in a secure location where sparking of the spark rod can
safely be observed. Charge the 10,000 VAC ignition transformer. Verify that
sparks occur from the spark rod disk to the side of the gas pipe.
WARNING:
DO NOT TOUCH THE IGNITOR WHILE THE TRANSFORMER
IS CHARGED.
9. Verify that the combustion air pressures for the ignitor are set properly.
10. Start the ignitor. Set the gas pressure as required for proper BTU rating for
the ignitor. Refer to the ignitor manual for the required flows and pressures.
11. Verify the ignitor start and stop control is functioning properly.

CONTRACT: EB0-007991 11/6/15
Gas Header Trip Switch Set Points

Pressure switch settings for the high and low trip points are based upon the
nominal header pressure that produces the desired flow at the gas ignitors or gas
nozzles, as applicable. The primary purpose of the trip switches is to trip the gas
header for either of the following reasons:
• High pressure: to prevent over firing of the gas ignitor/burner which may
result in damage to the components of same or excessive fuel velocities
which may cause the flame to become unstable and result in a loss of flame.
• Low pressure: to prevent under firing of the gas ignitor/burner which may
cause the flame to become unstable and result in a loss of flame.
Typically, the trip set points are determined as follows:
• High pressure trip is set at a pressure that results in a flow of approximately
125% of rated capacity.
• Low pressure trip is set at a pressure that results in a flow of approximately
75% of rated capacity.
As an example the following is offered:
• Rated capacity is achieved at a nominal pressure of 20 PSIG.
• High pressure trip set point is at 31.25 PSIG (156% of nominal pressure
resulting in 125% of rated flow).
• Low pressure trip set point is at 11.25 PSIG (56% nominal pressure resulting
in 75% of rated flow).
For calculative purposes, use the following:
•
2
High pressure set point = nominal pressure((1.25) ).
•
2
Low pressure set point = nominal pressure((0.75) ).
SUMMARY
1. Adjust ignitor firing pressures according to the ignitor firing charts.
2. Adjust combustion air pressures according to the ignitor firing charts.
3. Fill in the start-up settings chart for future reference.
4. Review the ignitor operation with operators and maintenance staff.

CONTRACT: EB0-007991 11/6/15
UNIT DATA / CUSTOMER

INFORMATION
Customer: Date:
Station: Tech Service Eng:

Unit #: Ignitor Location:
Original Contract #: CANBUS Address:
Services Contract #: CANBUS Used: (yes/no)
Heat Input (MMBTU/hr): Software Revision:
Ignitor Serial #: DFI Serial #:
Table 2: DFI / Ignitor Operational Data
Test Data Ignitor # Ignitor # Ignitor # Ignitor #
DCV Trip Setpoint (F02)
ACV Trip Setpoint (F03)
AVG DCV Reading (F15)
AVG ACV Reading (F16)
Ignitor Combustion Air

Pressure (" wc)
Ignitor Inlet Gas Pressure
(psig)
Test Data Ignitor # Ignitor # Ignitor # Ignitor #
DCV Trip Setpoint (F02)
ACV Trip Setpoint (F03)
AVG DCV Reading (F15)
AVG ACV Reading (F16)
Ignitor Combustion Air
Pressure (" wc)

Ignitor Inlet Gas Pressure
(psig)

CONTRACT: EB0-007991 11/6/15
TROUBLESHOOTING GUIDE
Starting

CONTRACT: EB0-007991 11/6/15
TROUBLESHOOTING GUIDE (CONT.)
Combustion Air and Gas

CONTRACT: EB0-007991 11/6/15
TROUBLESHOOTING GUIDE (CONT.)
Detection

CONTRACT: EB0-007991 11/6/15
P A R T S L IS T
IT E M PART NUM BER QTY D R A W IN G D E S C R IP T IO N M TL
1 9 9 6 0 2 9 -C 1 C -9 9 -6 0 2 9 G A S IN L E T A S S E M B L Y 0
2 9 9 6 0 9 8 -F 1 C -9 9 -6 0 9 8 R E P L A C E A B L E O R IF IC E B L U F F B O D Y A S S Y . 0
3 9 9 6 1 0 4 -0 1 1 C -9 9 -6 1 0 4 R E M O V A B L E G A S P I P E T IP 0
4
4 9 9 -6 0 0 8 B 2 C -9 9 -6 0 0 8 S P A R K /F L A M E R O D A S S E M B L Y 0
5 15 14 11 12 12 5 0 5 -0 5 5 4 -0 1 1 D -0 5 -0 5 5 4 W IR E T R A IN A S S E M B L Y - D F I 0
12 2 3 6 0 5 -0 5 5 4 -0 3 1 D -0 5 -0 5 5 4 W IR E T R A IN A S S E M B L Y - S S P K 0
7 9 9 6 0 1 5 -0 1 1 B -9 9 -6 0 1 5 1 .2 5 O .D . G A S P IP E O F F S E T B E N D 0
5
9 9 9 6 0 0 1 -0 9 C 1 G -9 9 -6 0 0 1 Q U IC K D IS C O N N E C T C O U P L IN G P L U G 1 .0 0 N P T 0
10 9 9 6 0 0 1 -1 0 C 1 G -9 9 -6 0 0 1 Q U IC K D IS C O N N E C T C O U P L IN G S O C K E T 1 .0 0 N P T 0
11 9 9 6 0 1 7 -0 1 1 C -9 9 -6 0 1 7 D O U B L E R O D L O N G S T A N D O F F C L IP 0
6
12 9 9 6 0 1 8 -0 1 8 C -9 9 -6 0 1 8 D O U B L E R O D S H O R T S T A N D O F F C L IP 0
1 4 .5 0 7 X 1 0 .0 0 13 9 9 6 0 0 1 -1 3 J 1 G -9 9 -6 0 0 1 1 .5 0 " N P T D O U B L E B R A ID E D F L E X G A S H O S E 6 0 " L G 0
14 996034 2 A -9 9 -6 0 3 4 SPACER W ASH ER 0
4
6 15 15 E P S D -0 3 2 1 2 D -E P S D -0 3 2 1 CO N N ECTO R ASSEM BLY 0
14 16 9 9 6 0 3 3 -0 0 1 C -9 9 -6 0 3 3 D UST PLUG ASSEM BLY 0
1 / 4 " N P T C O M B U S T IO N A IR
P R E S S U R E T A P L O C A T IO N .
V IE W B -B 17 9 9 -6 0 2 2 1 C -9 9 -6 0 2 2 3 .0 0 K A M L O C K D -C O U P L E R M O D IF IC A T IO N 0
S C A L E 1 :5
(9 1 .5 8 ) (1 0 .0 0 )
17
(4 .5 0 ) (9 3 .9 9 )
A
B B
( 2 .0 0 )
6
5
1 7 T A C K G A S P IP E T IP
(1 P L A C E ) A F T E R
.0 6
A C O M M IS S IO N I N G IS C O M P L E T E
10
16
1 /4 " N P T G A S P R E S S U R E T A P L O C A T IO N
9 S E E IN S T A L L A T IO N N O T E # 8
13 P /N 9 9 6 0 0 1 P 9 3 .9 F C J
15 IN S T A L L A T IO N N O T E S :
14
1. M E A S U R E G U ID E P IP E T O E N S U R E G A S P IP E T IP IS S E T B A C K 2 " A S S H O W N
5 6 2. I N S E R T N E W IG N IT O R IN T E R N A L S
3. I G N IT O R O R IE N T A T IO N IN K A M L O K D -D O U P L E R IS N O T C R IT IC A L
4. A T T A C H D F I A N D S P A R K R O D W IR E C O N N E C T O R S A T B A C K O F IG N IT O R
5. D F I A N D S O L ID S P A R K R O D W IR E T R A IN A S S E M B L IE S A R E IN T E R C H A N G E A B L E
4 6. H IG H V O L T A G E C O N D U C O R F R O M S O L I D S P A R K R O D S H O U L D B E T E R M IN A T E D A T H IG H V O L T A G E O U T P U T O F
IG N IT IO N T R A N S F O R M E R . G R O U N W IR E R E T U R N S H O U L D B E T E R M IN A T E D A T C A B IN E T G R O U N D B U S B A R
7 . G R O U N D W IR E R E T U R N F R O M D F I F L A M E R O D S H O U L D B E T E R M IN A T E D D IR E C T L Y T O C A B IN E T G R O U N D B U S B A R .
8 . R E M O V E 1 /4 " P IP E P L U G IN G A S IN L E T E L B O W A N D A T T A C H D IG IT A L G A U G E T O P R E S S U R E T A P F O R C O M M IS S IO N IN G
9 . I N S E R T D U S T P L U G C A P A F T E R R E M O V IN G G A S IN L E T A S S E M B L Y .
T H IS D R A W IN G D O E S N O T C O N T A IN A L L IN F O R M A T IO N N E C E S S A R Y F O R
M F G . T H IS P A R T . R E F E R T O P /N C O M M E N T S & P R O D U C T S T R U C T U R E
G RO UN D SET SCREW GEN ERAL N OTES:
F O R C O M P L E T E M A T E R IA L ID E N T IF IC A T IO N A N D P R O C E S S IN G .
1 0 . N A T U R A L G A S IG N IT O R C A P A C I T Y 1 2 ,0 0 0 S C F H @ 2 .5 P S I @ G A S IN L E T P R E S S U R E T A P
1 1 . (2 4 ) T O T A L IG N IT O R S O N C O N T R A C T . (" A " D IM = 9 3 .9 9 " )
R E F E R E N C E D R A W IN G S :
S E C T IO N A -A 1 . 3 .0 0 D R B L U F F B O D Y G A S F R O N T IG N IT O R A R R A N G E M E N T & D E T A IL S : G -9 9 -6 0 0 1 (P R O P R IE T A R Y )
A L L D IM E N S IO N S A R E IN IN C H E S
V IE W R O T A T E D
IT E M S R E M O V E D F O R C L A R IT Y T O L E R A N C E S U N L E S S O T H E R W IS E N O T E D
SCALE 1 : 1
X .X X ± .0 6
IG N IT IO N /D F I GROUND AN G ULAR: ± 0°30'
S U R F A C E T E X T U R E : 1 0 0 0 M IC R O IN C H E S
R O U G H N E S S A V E R A G E -R a
T H IS D R A W IN G IS IN A C C O R D A N C E W IT H
A S M E Y 1 4 .5 M -1 9 9 4
1 2
R C 6 R C 6
U PD A T ED Q U A N T IT Y FO R IT EM 9 , A N D R EM O V ED IT EM 12 , A N D D ELET ED
25 29
L J 15 A D D ED IT EM 15 L J 15 W ELD SY M BO LS PER EN G IN EER IN G
BOM
IT E M PART NUM BER QTY D R A W IN G D E S C R IP T IO N M A T E R IA L
1 V 0 0 -9 7 8 9 2 - 1 -1 /2 " B A L L V L V . W /S O L E N O ID & A C T U A T . 0
2 V 0 0 -9 8 0 4 1 - 3 /4 " B A L L V L V . W /S O L E N O ID & A C T U A T O R 0
3 V 0 0 -8 7 8 4 1 - 3 /4 " B A L L V A L V E 0
( 6[125.3812 .7 m m ]) 4 7 6 -Y S T R -0 3 1 -
-
1 1 /2 " Y S T R A IN E R 0
5 V 0 0 -2 5 8 9 2 1 -1 /2 " X 3 /4 " H E X R E D U C IN G B U S H IN G 0
6 E P S -9 2 - T E E , 1 -1 /2 " X 1 -1 /2 " X 1 -1 /2 " 0
7 E B 0 -0 0 7 9 9 1 -9 3 6 2 -7 1 E B 0 -0 0 7 9 9 1 -1 D 9 3 6 2 N IP P L E -L G .7 5 X 1 4 .0 0 S C H 8 0 N P T 151
8 M D 8 -0 0 1 5 5 -H K 5 M D 8 0 -1 C 0 1 5 5 N IP P L E -L G 1 .5 0 X 6 .0 0 S C H 8 0 N P T 151
9 7 6 -G M V L -0 2 1 - G L O B E V A L V E 1 -1 /2 " 0
10 M D 8 -0 0 1 5 5 -H D 1 M D 8 0 -1 C 0 1 5 5 N IP P L E -L G 1 .5 0 X 3 .0 0 S C H 8 0 N P T 151
11 M D 8 -0 0 1 5 5 -E B 3 M D 8 0 -1 C 0 1 5 5 N IP P L E -L G .7 5 X 2 .0 0 S C H 8 0 N P T 151
2
13 1 2 -2 0 0 3 1 M D 8 0 -1 C 0 1 0 2 C A P -P IP E .7 5 C L 1 5 0 N P T 213
14 M D 8 -0 0 1 1 7 -B E 1 M D 8 0 -1 C 0 1 1 7 P L U G - H E X H D .7 5 N P T 210
15 V 0 0 -9 8 3 5 1 - 1 -1 /2 " B A L L V A L V E 0
M A T E R IA L S P E C IF IC A T IO N C H A R T
F O R IN D E X T O M A T E R IA L S P E C IF IC A T IO N R E F E R T O
S T A N D A R D N O . 1 7 -6 4 , IN D E X N O . 1 4 .2
P U R C H A S IN G
IT E M SPEC. NU M BER C O M P O S IT IO N GRADE IN S T R U C T IO N S
S A -1 0 6 C A R B O N S T E E L P -1 ,
151 B P1A12
G r. N o . 1
C A R B O N S T E E L .3 5 C A R B O N P -1
210 S A -1 0 5 G r. N o . 2 NONE NONE
213 A -1 9 7 M A L L E A B L E IR O N NONE NONE

13
11
2
3
11 GENERAL NOTES:
1 . V A L V E T R A IN A S S E M B L Y T O B E P R O T E C T E D F R O M W E A T H E R D U R IN G S T O R A G E A N D
P R IO R T O IN S T A L L A T IO N .
2 . L IG H T L Y A P P L Y P IP E JO IN T C O M P O U N D (P E R M A T E X N O . 5 1 -D ) T O A L L P IP E J O IN T S A T
ASSEM BLY. D O N O T U SE TEFLO N TAPE.
3 . N A T U R A L G A S S P E C IF IC A T IO N S = .0 4 2 lb /ft, H IG H H E A T V A L U E = 1 0 0 0 B T U /ft.
4 . G L O B E V A L V E (IT E M N O . 9 ) T O B E A D J U S T E D T O O B T A IN T H E G A S P R E S S U R E R E Q U IR E D
A T T H E IG N IT O R IN L E T .
5 . P L U G A L L H O L E S W IT H P L A S T IC C A P S P R IO R T O S H IP M E N T .
6 . A L L U N IT S IN IN C H E S .
3 /4 " V E N T 7 . IN L E T A N D O U T L E T C O N N E C T IO N S A R E T H R E A D E D .
11
( 2[514.325.2 m m ]) 7
1 1
( 1[218.37 1.2 m m ]) 5
8 5 10 8 8 8
FLO W F O R C O M P L E T E M A T E R IA L ID E N T IF IC A T I O N A N D P R O C E S S IN G .
15 6 8 4 6 2 9
14
P /N : E B 0 -0 0 7 9 9 1 -9 3 6 2
BILL O F M A TE R IA L
16.0 0 .75 14 .50 16.0 0
Ø .50 (T Y P ) ITE M Q TY . PART NO. D E S C R IP TIO N
4 1 3 8 9 10 11 4 .70 2.30
1 1 V 00-2643 N EM A 4 EN C LO S U R E 20" H X 16" W X 6" D
2 1 V 00-2644 EN C LO S U R E B A C K P A N E L
1.55
3 1 75-W K IT -01 W IN D O W K IT - N EM A 4
2
12 4 1 V 00-2645 M O U N T IN G FO O T K IT - 4 FEE T /K IT
14
POW ER
FLAME
5 2 V 00-6610 R ELA Y, 2 FO R M C , 24 V D C C O IL
REL
1 F A UL T
6.70
2
3 6 3 V 00-6611 R ELA Y, S O C KE T , D IN R A IL M O U N T
4
13 5
C B -0 2 A
7 1 E P S -6 N A M E P LA T E - "A LS T O M P O W ER IN C ."
15 C B -0 2 B
N
W IR IN G D U C T 1" W X 2" H (3' LEN G T H )

N
16 V DC-
2A
8 1 V 00-2652
3A
4A
17 5A
6A
20.00 21.50 7A
8A 20 .0 0 DOOR 9 4 V 00-2650 EN D S T O P
18 9A
10A
11A
12A
10 18 V 00-2647-IN M O U N T IN G R A IL - P R 30 (P E R IN C H , 18" R EQ 'D .)
W A R N IN G
11 2 V 00-2648 R A IL O FFS ET B R A C KE T - T S 0706
6 23 H IG H V O LT A G E
12 1 D FI-100-41105 LIM E LIG H T D IA G N O S T IC FLA M E IN D IC A T O R
22
6 5 13 14 V 00-2646 T ER M IN A L B LO C K M 4/6
21 14 2 75-C B 10-01 C IR C U IT B R EA K ER - 1 P O LE
9
15 1 V 00-2665 M E T A L O X ID E V A R IS T O R - 135V
10
16 2 V 00-2649 EN D S E C T IO N
17 2 V 00-9725 EN D S E C T IO N (FO R FU S ED T ER M IN A L B LO C K)
7 19 20
18 1 V 00-2929 M A R KIN G T A G S - B LA N K
F R O N T V IE W 19 1 V 00-2662 C O P P E R B US S B A R
F R O N T V IE W - D O O R R E M O V E D F R O N T V IE W - D O O R C U T O U T S
A S S E M B L Y P /N E B 0 -0 0 7 9 9 1 -9 3 6 3 20 1 V 00-2666 LU G - B U R N D Y S IN G LE H O LE G R O U N D LU G
21 1 V 00-10032 IG N IT O R T R A N S FO R M E R 220V / 50H Z 10,000 V A C
22 1 V 00-2656 N A M E P LA T E - "W A R N IN G H IG H V O LT A G E "
23 1 V 00-10033 R ELA Y, 10A 240V A C C O IL
6.75 3.75
NO TES:
1.0 6 1. IN S T A LL A S T A N D A R D 5.88" D IN R A IL (W IT H O FFS E T ) O N B A C K P A N EL O F T H E C A B IN ET IN
T H E V ER T IC A L P O S IT IO N . M O U N T T H E D FI O N T H E D IN R A IL A N D IN S T A LL E N D S T O P S
3.50
A B O V E A N D B E LO W T H E D FI T O K EE P IT S E C U R E.
2. Q U A N T IT IE S S H O W N A R E FO R O N E C O N T R O L C A B IN E T .
3. P R O T EC T C A B IN ET FR O M W EA T H ER D U R IN G S T O R A G E .
5.88 4. A LL U N IT S A R E IN IN C HE S .
5. R EFE R T O S C H EM A T IC D R A W IN G FO R W IR IN G D E T A ILS A N D IN S T R U C T IO N S .
6. A LL IN T ER N A L W IR IN G A S S H O W N O N R EF D R A W IN G 2 T O B E C O M P LE T ED B Y S H O P V EN D O R .
7. LO C A T E EQ U IP M EN T O N B A C K P A N EL A P P R O X IM A T ELY A S S H O W N .
8. V EN D O R T O S U P P LY A P P R O P R IA T E M O U N T IN G H A R D W A R E.
12.00
1. IG N IT O R C O N T R O L C A B IN E T W IR IN G S C H E M A T IC - - - - - - - - - - - - - - - - EB 0-007991-1D 9315
11.76
W A R N IN G
H IG H V O LT A G E
6.88
T H IS D W G . D O E S N O T C O N T A IN A LL IN FO R M A T IO N N E C ES S A R Y FO R M A N U FA C T U R IN G T H IS
P A R T . R E FER T O P /N C O M M E N T S & P R O D U C T S T R U C T U R E FO R C O M P LE T E M A T E R IA L
ID EN T IFIC A T IO N A N D P R O C E S S IN G .
2.25
1.50
A L L D IM E N S IO N S A R E IN IN C H E S
.62 T O L E R A N C E S U N L E S S O T H E R W IS E N O T E D
.88 3.88 1.50 X .X X X ±.0 1 5

X .X X ±.0 6
D R IL L E D H O L E S : Ø 0-1 IN +.01 0/-.000

3.75
X .X X X O V E R 1 IN +.020/-.000
BACK PANEL LAYOUT A S M E Y 1 4 .5 M -1 9 9 4
Instruction Manual
LIMELIGHTTM Diagnostic Flame Indicator
Model DFI-100 Revision 4
abcd

DOCUMENT 5001 R2 5/1/15
TM
LIMELIGHT Diagnostic Flame Indicator Model 100
PROPRIETARY MARKS
CANbus
The CANbus network specification, written by Bosch, has been

standardized by ISO and SAE. The entire CAN specification is
standardized in ISO 11898-1 & ISO 11898-2 contains the CAN
physical layer specification.
NOTICE
This instruction manual has been prepared to serve as a guide in

operating and maintaining the equipment supplied by ALSTOM Power
Inc. It is not intended to cover all possible variations in equipment or
all specific problems that may arise.
It must be recognized that no amount of written instructions can

replace intelligent thinking and reasoning on the part of the operators,
especially when coping with unforeseen operating conditions. It is the
operator’s responsibility to become thoroughly familiar with the
equipment.

CONTRACT: E2B-000109 5/1/15
TM
TABLE OF CONTENTS
INTRODUCTION........................................................................................................................................... 1
OVERVIEW OF OPERATION....................................................................................................................... 1
FLAME DETECTION ................................................................................................................................ 1
Flame Rod ............................................................................................................................................ 1
Optical Detector Head .......................................................................................................................... 2
Flame Quality ....................................................................................................................................... 2
SPARK STATUS ....................................................................................................................................... 2
RELAY OUTPUTS .................................................................................................................................... 3
COMMUNICATIONS ................................................................................................................................. 3
RS485 ................................................................................................................................................... 3
CANbus ................................................................................................................................................ 4
4 to 20 mA Current Loop ...................................................................................................................... 4
FIRST OUT ............................................................................................................................................... 4
DIAGNOSTICS.......................................................................................................................................... 4
DISPLAY AND INTERFACE ......................................................................................................................... 5
FACEPLATE DISPLAYS ........................................................................................................................... 5
OLED Display ....................................................................................................................................... 6
FACEPLATE PUSHBUTTONS ................................................................................................................. 6
USER INTERFACE ................................................................................................................................... 6
Normal Mode ........................................................................................................................................ 6
Program Mode ...................................................................................................................................... 6
WIRING ....................................................................................................................................................... 14
EQUIPMENT SPECIFICATIONS ................................................................................................................ 18
PART NUMBERING / REVISIONS ............................................................................................................. 18
CUSTOMER SERVICE CONTACTS .......................................................................................................... 19
LIST OF FIGURES
Figure 1: DFI Display and Interface .............................................................................................................. 5

Figure 2: DFI Faceplate Pushbuttons ........................................................................................................... 6
Figure 3 - Ground Wiring............................................................................................................................. 15
Figure 4: Terminal Block Connections and Layout ..................................................................................... 16
Figure 5: Optical Head Wiring ..................................................................................................................... 17

CONTRACT: E2B-000109 5/1/15
Limelight™ Diagnostic Flame Indicator Model 100
INTRODUCTION
This manual provides information on the installation, operation and
troubleshooting of the ALSTOM Limelight Diagnostic Flame Indicator,
(henceforth referred to as the 'DFI'.) The Limelight DFI is an ignitor flame-sensing
device, which is able to discriminate between a “Flame” and a “No Flame”
condition for an ignitor. The electronic package is self-contained and is mounted
in the Ignitor Control Cabinet or a nearby junction box. The DFI offers the latest
“next generation” technology, including a number of added benefits and features
for ignitor reliability, diagnostics and ease of maintenance.
OVERVIEW OF OPERATION
FLAME DETECTION
Flame Rod
When configured to use a flame rod input, the DFI applies a 40V bias voltage to
a flame rod located within the ignitor. This flame rod is positioned so that the
ignitor flame impinges on the rod providing a current path through the flame to
ground. Ionized particles, present in all flames, cause a flame to conduct
electricity.
The DFI monitors flame rod current. Due to turbulence in the ignitor flame, and
natural flame flicker, the current signal is a complex time varying waveform.
Every 100mS the current signal is analyzed and the results are used to
determine the status of the flame. The measurements taken from the 100mS of
accumulated current data are as follows:
• Intensity: This is the average value of the flame current during the
sample period. Its value can range from 0 to 100%. Earlier
revisions of the DFI referred to this value as “DC”.
• AC: This is the difference between the minimum and maximum

flame current values found during the sample period. Its
value can range from 0 to 100%.
• Frequency: This is the frequency of the AC component of the flame

current signal. It is measured in Hz.
The AC value, and optionally Intensity and Frequency, are compared to

predetermined pull in and drop out values to determine the flame status.
If an excessive Intensity value is detected, a fault condition is indicated, and both

relays are de-energized. This check occurs even when the Intensity value is not
used for flame determination. An excessive Intensity value is indicative of carbon
bridging on the flame rod, or damage to the wire train allowing an alternate
current path to ground.

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Optical Detector Head

When the DFI is configured to use an optical detector input, an Exacta Flame
Scanner detector head is mounted on the ignitor.
The detector head converts light energy from the flame into a current signal. An
internal 1,000 ohm resistor in the DFI converts this current signal to a voltage,
and the resultant voltage is monitored by the DFI.
Due to turbulence in the ignitor flame, and natural flame flicker, this signal is a
complex time varying waveform. Every 100mS the signal is analyzed and the
results are used to determine the status of the flame. The measurements taken
from the 100mS of accumulated data are as follows:
• Intensity: This is the average value of the voltage during the sample
period. Its value can range from 0 to 100%.
• AC: This is the difference between the minimum and maximum

values found during the sample period. Its value is
measured in mV.
• Frequency: This is the frequency of the AC component of the flame

signal. It is measured in Hz.
Intensity, Frequency, and optionally AC, are compared to predetermined pull in

and drop out values to determine the flame status.
If the voltage measured across the 1000 ohm resistor exceeds 2.35V, or is less
than 0.125V, a fault condition is indicated, and both relays are de-energized.
Flame Quality
While the DFI is proving flame a flame quality value is continuously calculated.
Flame quality is a value that ranges from 0 to 100%. A flame quality value of 0%
occurs at the point where the DFI drops the flame relay, indicating loss of flame.
The algorithm used to calculate flame quality takes into account all of the
measured values and drop out values that are being used for flame
determination. For the flame quality value to have meaning it must be calibrated
during DFI commissioning.
SPARK STATUS
Spark status is a new feature added to the DFI with revision 4. This feature can
only be used when using a flame rod, and when using a spark transformer to
light the ignitor.
The spark status indication uses the flame rod as an antenna to receive the radio
frequency energy produced by the spark during ignitor light off.
This radio frequency signal is monitored by the DFI, and when it determines that
a spark is occurring the text “Sparking” appears on the DFI’s OLED display. This
aids troubleshooting in the event that an ignitor fails to light off. Additionally, this
feature can optionally be used to block flame proving while the spark is occurring.
Another feature of the spark status indication is the calculation of a spark health
value. This feature analyzes the radio frequency signature of the spark, and can
give an indication of a gradually weakening spark, so that maintenance can be

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performed prior to a failure of the ignitor to light off. For the spark health value to
be meaningful it must be calibrated during DFI commissioning.
RELAY OUTPUTS
The DFI contains 2 output relays each having 2 sets of FORM C contacts. These
contacts are rated at 5A at a maximum of 250VAC / 30VDC when switching a
resistive load.
The main relay is a dedicated flame proving relay. It energizes on flame proven,
de-energizes on loss of flame. The main relay should be used to provide the
flame signal for the ignitor trip logic.
The auxiliary relay can be configured for any one of the following purposes:
• Flame: The relay behaves the same as the main relay, energizing
on flame, de-energizing on loss of flame. When configured
as a flame relay the auxiliary relay should be used for
informational purposes only. It should not be used to supply
a flame proven signal to the ignitor trip logic.
• Ready: The relay energizes when the DFI is operating normally, de-
energizes on fault, or loss of DFI power.
• Spark: The relay is used to control a spark transformer during

ignitor lightoff. Upon assertion of the “run” digital input the
relay will energize, and remain energized until a
configurable time period expires.
COMMUNICATIONS
RS485
The DFI has an RS-485 port for MODBUS RTU communication. The port is fixed
at 19200 baud, 8 bits, no parity. The DFI’s MODBUS slave address is a
configuration parameter.
The following variables are exposed via this port:
Register Description
1000 Flame Proven

1001 Fault
1002 Spark Detected
1003 Signal Strength Alarm
1004 Unused
1005 Intensity
1006 AC
1007 Frequency
1008 Flame Quality
1009 Spark Quality
1010 First Out

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Note:
The register addresses shown are zero based. You may have to
add an offset depending on the requirements of your MODBUS
master.
CANbus
A CANbus port is provided for communication with an Alstom Network Interface
Module. The CAN address is a configuration parameter. Please see the Alstom
IM200 instruction manual for additional detail.
4 to 20 mA Current Loop
The DFI provides one analog output via a 4 to 20 mA current loop. As is typical of
field devices, this output is loop powered. In other words, power for this output
must be provided by the reading device, or by an external power supply.
This output can be configured to provide the current value of any one of the
following variables:
• Intensity
• Frequency
• AC
• Flame Quality
The choice of variable to output, and full scale value are set with configuration
parameters.
FIRST OUT
The first out feature is a simple sequence of events recorder that records the first
event that occurs before loss of ignitor flame.
To use this feature, at a minimum a set of dry contacts that are closed when the
ignitor is in the “run” state must be wired across digital input DI 1.
The following digital inputs are optional when using this feature:
• DI 2 Wire a set of dry contacts that close with combustion air

pressure/flow.
• DI 3 Wire a set of dry contacts that close when ignitor trip valve is open.
• DI 4 Wire a set of dry contacts that close with fuel pressure/flow.
The recorder is armed when all used inputs are closed, and the DFI proves the
ignitor flame. The DFI will then record the first digital input that opens before the
loss of flame. If an input opens and then closes again before loss of flame the
event is ignored.
DIAGNOSTICS
The DFI performs extensive internal self tests both on system startup, and
periodically during normal operation. Should a self test fail, power is removed
from both relays forcing them to de-energize, and the system immediately
reboots. If the reboot does not correct the problem, the DFI will continuously
cycle between reboot and self test.

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DISPLAY AND INTERFACE
Figure 1: DFI Display and Interface
FACEPLATE DISPLAYS
POWER LED The power LED is lit when AC power is supplied to the
DFI.
FLAME LED The flame LED is lit when the programmed flame proving
criteria is satisfied.
REL LED The reliability LED is lit when flame quality is below a
predefined threshold.
FAULT LED The fault LED is lit when a fault condition has been
detected by the DFI.
LED BAR The LED bar graph is used to represent the current value
GRAPH of one of the following variables:
Intensity
Frequency
ACV
Flame Quality
The selection of which variable to use is a configuration parameter. The default

selection is Flame Quality.

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OLED Display
The OLED display, along with the 5 faceplate pushbuttons, allow the user to
monitor and configure the DFI. It should be noted that the DFI has a screen saver
that will cause the display to turn off after 20 minutes of inactivity. When the
screen saver is active pressing any of the keypad keys will turn off the screen
saver. On DFI-100s with V06 or newer firmware, a change of state of any of the
digital inputs, or a change in flame status will also turn off the screen saver.
FACEPLATE PUSHBUTTONS
Each pushbutton has an associated numerical value, i.e. 1 to 5, that allows the
user to enter an access code prior to changing the function codes. The numerical
designation and description of the pushbuttons are identified in Figure 2 below.
Figure 2: DFI Faceplate Pushbuttons
USER INTERFACE
Normal Mode
Upon power up the DFI display is in a “normal” informational mode. In this mode
several screens of information are available to the user. Pressing the up (Key 2)
or down (Key 4) arrow keys will cycle through the available displays.
Program Mode
To enter program mode at the local keypad depress Key 1 (Program On/Off).

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NOTE:
The DFI is equipped with an interlock that prevents simultaneous
editing of parameters from two locations. An attempt to enter
program mode, while parameters are being edited remotely with
the PC interface, displays a warning message and returns the
DFI to normal mode.
After pressing Key 1 the user is prompted for a password. The factory default
password is 11111. After successfully entering the password the following menu
is displayed:
• Edit Parameters
• Cal Analog Out
• Force Relays
• Save Norm Fact
• Save Spark Fact
• Next Page
If you wish to exit program mode and return to normal mode press Key 1.
Otherwise use the up and down arrow keys (Key 2 & Key 4) to scroll to the
desired selection. When the desired selection is highlighted press Key 5
(Enter/Store).
Edit Parameters
Selecting “Edit Parameters” causes the configuration parameters to be
displayed one at a time. Use the up and down arrow keys (Key 2 & Key 4) to
cycle between the available parameters. To change the value of a displayed
parameter press Key 5 (Enter/Store). This will highlight the value indicating
that it can be changed.
If the entire value is highlighted, use the up and down arrow keys (Key 2 &
Key 4) to cycle between the available values.
If a single digit is highlighted, use the up and down arrow keys (Key 2 & Key
4) to increment/decrement the value of that digit. Use Key 2 to change the
highlighted digit.
After editing the parameter use Key 5 to store your change, or Key 1 to
discard your change and return to the original value.
The DFI configuration parameters are as follows:
• Detector Type: Selects either Flame Rod, or Optical input. It should

be noted that the minimum, maximum and default
values for some of the flame proving parameters are
dependent on the type of input selected.
• Ignitor Identifier: Eight character alpha numeric identifier for ignitor.

This is only for documentation purposes, and has no
effect of flame proving.

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• Intensity Pull In: When flame intensity rises above this value, the
intensity flame proving criteria is met.
Flame Rod Optical Head

Min Value 0 10
Max Value 100 100
Default 0 10
• Intensity Drop Out: When flame intensity drops below this value, the
intensity flame proving criteria is no longer met.
Separate pull-in and drop-out values allow for
hysterisis preventing relay from chattering as value
approaches the pull-in or drop-out level. Drop out
value cannot differ from pull in by more than 15.

Min Value 0 10
Max Value 100 100
Default 0 10
• AC Pull In: When the AC component of the flame signal rises

above this value, the AC requirement for proving
flame is met.

Min Value 10 0
Max Value 100 100
Default 10 0
• AC Drop Out: When the AC component of the flame signal drops

below this value, the AC requirement for proving
flame is not met. Separate pull-in and drop-out
values allow for hysterisis preventing relay from
chattering as value approaches the pull-in or drop-
out level. Drop out value cannot differ from pull in by
more than 15.

Min Value 10 0
Max Value 100 100
Default 10 0
• Freq Pull In: When flame flicker frequency rises above this value,
the frequency flame proving criteria is met..

Min Value 0 5
Max Value 250 250
Default 0 5

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• Freq Drop Out:: When flame flicker frequency drops below this
value, the frequency flame proving criteria is no
longer met. Separate pull-in and drop-out values
allow for hysterisis preventing relay from chattering
as value approaches the pull-in or drop-out level.
Drop out value cannot differ from pull in by more
than 6.

Min Value 0 5
Max Value 250 250
Default 0 5
• Freq Sensitivity: Minimum peak-to-peak value, in mV, that the signal

must change to be included in the flicker frequency
calculation.
Min Value 10
Max Value 100
Default 10
• Pull In Time Delay: Time delay, in seconds, from the time that all flame
proving criteria is met, and the flame relay closes.
Min Value 0
Max Value 10
Default 0
• Drop Out Time Time delay, in seconds, from the time that a flame
Delay: proving requirement is lost, and the flame relay
opens.
Min Value 0
Max Value 2
Default 2
• Intensity Gain: Multiplier applied to the measured intensity value

when using a flame rod. This parameter is ignored
when using an optical head.
Min Value 1
Max Value 10
Default 9
• AC Gain: Multiplier applied to the measured AC value when

using a flame rod. This parameter is ignored when
using an optical head.
Min Value 1
Max Value 10
Default 6

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• Intensity Filter Smoothing filter applied to the measured intensity

Fact: value. A value of 0 equals no filter, a value of 12
equals the maximum filter.
Min Value 0
Max Value 12
Default 3
• AC Filter Factor: Smoothing filter applied to the measured AC value.

A value of 0 equals no filter, a value of 12 equals the
maximum filter.
Min Value 0
Max Value 12
Default 3
• Freq Filter Factor: Smoothing filter applied to the measured frequency

value. A value of 0 equals no filter, a value of 12
equals the maximum filter.
Min Value 0
Max Value 12
Default 3
• Quality Filter Smoothing filter applied to the calculated flame

Factor: quality value. A value of 0 equals no filter, a value of
12 equals the maximum filter.
Min Value 0
Max Value 12
Default 3
• 4 to 20ma Source: Selects the value that will be output on the 4-20mA
current loop. Available choices are: Intensity, ACV,
Quality, and Frequency. The default value is Quality.
• 4 to 20ma Full Value that will cause a full scale output on the 4-
Scale: 20mA current loop
• Aux (B) Relay Defines the purpose of the auxiliary relay. Available
Configuration: choices are: Flame, Ready, Spark, and None.
Default value is Flame.
• MODBUS Port Sets the slave address of the MODBUS port.

Address:
• CANBUS Address: Sets the address of the CANbus port
• CANBUS Baud Sets the baud rate of the CANbus port. Available
Rate:: choices are 62.5K, 125K and 250K. Default is 125K.

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• Enable Flame Defines additional criteria to enable flame proving.

Proving: Choices are as follows:
“Always” Close the flame relay whenever the flame proven

criteria is met.
“Run Spark” Used when the aux relay is controlling a spark
transformer. Only close the flame relay if the “run”
digital input is asserted, aux relay is de-energized (
No spark), and the flame proving criteria is met.
“Run” Only close the flame relay if the “run” digital input
is asserted, and the flame proving criteria is met.
“No Spark” Only close the flame relay if spark is not detected,
and the flame proving criteria is met.
The default value is “Always”.
• First Out Enables the first out feature and defines which
inputs will be used. When the first out feature is
enabled, Din1, the “run” input is required. The other
3 digital inputs are optional. Choices are as follows:
“432” Monitor all digital inputs for “first out”

“XXX”- Monitor only the “run” input Din1. All other digital
inputs are ignored.
“Off”- The first out feature is disabled.
“43X”- Monitor “run”, Din3, and Din4. Din2 is ignored.
“4X2“ Monitor “run”, Din2, and Din4. Din3 is ignored.
“4XX“ Monitor “run”, and Din4. Din2 and Din3 are
ignored.
“X3X“ Monitor “run”, and Din3. Din2 and Din4 are
ignored.
“XX2“ Monitor “run”, and Din2. Din4 and Din4 are
ignored.
The default value is “Off”.
• Spark Trans On Defines the time, in seconds, that the auxiliary relay
Time will remain energized, after the assertion of the run
input, when using the auxiliary transformer to control
the spark transformer.
Min Value 0
Max Value 10
Default 8
• Signal Strength When flame quality is less than this value a reliability
Alarm Setpoint alarm occurs. Setting this parameter to zero
disables the reliability alarm.
Min Value 0
Max Value 100
Default 0

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• Spark Source Used by the spark health algorithm. Choices are

“Transformer” and “HEI”. If HEI is selected, the
spark health calculation is not performed. The
default value is “transformer”
• Spark Det Setpoint Used by the spark detection algorithm. Do not

change unless instructed to do so by Alstom
• Spark Width Used by the spark detection algorithm. Do not

Threshold change unless instructed to do so by Alstom
• Spark Det Filt Used by the spark detection algorithm. Do not

Factor change unless instructed to do so by Alstom
• Intensity Norm Normalization factors should be calculated

Factor automatically using the “Save Norm Factor” menu
selection. Do not manually change this value unless
instructed to do so by Alstom.
• AC Norm Factor Normalization factors should be calculated

automatically using the “Save Norm Factor” menu
• Frequency Norm Normalization factors should be calculated

Factor automatically using the “Save Norm Factor” menu
• Bar Graph Source Defines the variable that will be output on the bar
graph display. Available choices are “Intensity”,
“ACV”, “Quality”, and “Frequency”. When using a
flame rod input the default value is “ACV”, and when
using an optical head the default value is “Quality”.
• Line Frequency When this feature is enabled the DFI will not prove
Rejection flame if the AC component of the input signal is a
sine wave with the same frequency as the power
line. Use of this feature will prevent false flame
proving from a line powered light source, or from line
frequency electrical noise. The default is to disable
this feature.
• Line Frequency Selects the power line frequency used by the line
frequency rejection feature. Available choices are
50Hz and 60Hz. The default value is 60Hz.
Cal Analog Out

“Cal Analog Out” allows calibrating the 4-20 mA outputs. Selecting this item
will cause the 4ma calibration value to be forced on the 4 to 20 mA output,
and to be displayed on the screen.

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Use the up and down arrow keys (Key 2 & Key 4) to adjust the calibration
value until the reading device reads 4mA.
When the 4mA calibration is complete press Key 3 . The 20mA calibration
value is forced on the selected output, and displayed on the screen. Use the
up and down arrow keys (Key 2 & Key 4) to adjust the calibration value.
When the calibration is complete press Key 1 (Program On/Off) to return to
the previous menu.
Force Relays
“Force Relays” allow the user to force a relay into the energized state. This
feature is used during commissioning to verify the relay field wiring. When a
relay is placed into the “forced” mode the other relay is de-energized.
After selecting “Force Relays” the following is displayed:
Press Key 5
(Enter/Store) to
Force Relay 1
Use the up and down arrow keys (Key 2 & Key 4) to change the relay to
“force”. Selecting Key 5 (Enter/Store) will energize the relay. When a relay
is “forced”, pressing any key causes that relay to de-energize, and returns to
the above display. A relay can be forced for a maximum of 20 minutes. After
force mode expires, the DFI returns to normal operation.
Save Norm Fact

“Save Norm Fact” is used to save normalization factors. The normalization
factor is used in the flame quality calculation. The normalization factor should
be saved when the ignitor is in operation.
After selecting “Save Norm Factor” the following message is displayed:
Norm Fact Saved
Press any key

to continue
Save Spark Fact

“Save Spark Fact” is used to calibrate the spark health algorithm. When
selected this routine uses data collected during the last successful ignitor
lightoff to perform this calibration. If the data is suspect or if the ignitor has
not been run since the last DFI reboot, an error message is displayed, and
calibration is not performed.
Next Page
“Next Page” is used to access page 2 of 2 of the parameters. Selecting it
with Key 5 (Enter/Store) will show the following menu:
Restore Default
Change Password
Previous Page

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Use the up and down arrow keys (Key 2 & Key 4) to scroll to the desired
selection. When the desired selection is highlighted press Key 5
(Enter/Store).
Restore Default
“Restore Default” is used to clear all of the settings on the DFI and return it to the
original factory state. Selecting Key 5 (Enter/Store) will clear the memory and
display the following message:
Def Vals Loaded
Press any key

to continue
Change Password
After selecting “Change Password” the user is prompted for a new password.
The password must be 5 characters in length, and can be any combination of
Keys 1 through 5. A second prompt requires the new password be entered a
second time for confirmation.
Previous Page
“Previous Page,” when selected, takes the user back to page one of the
configuration screen.
WIRING
NOTE:
• The DFI ground connection, terminal 17, must be
connected directly to cabinet ground.
• Do not connect the flame rod wire train ground wire
directly to terminal 17.
• For proper operation of the DFI the flame rod wire train
ground wire must be connected directly to cabinet
ground

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Figure 3 - Ground Wiring

NOTE:
The Metal Oxide Varistor sometimes installed, between pins 17
and 18, on Revision 3 and older DFIs is not required on Revision
4 and newer DFIs (Part Number DFI-100-40000 and higher).

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L1 RS485 +
N
Unused
Unused
Aux Relay C1
Aux Relay C2
Figure 4: Terminal Block Connections and Layout
Digital Input Connections
DI1 Ignitor Run

DI2 Combustion Air
DI3 Trip Valve
DI4 Fuel Flow/Pressure

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LIMELIGHTTM Diagnostic Flame Indicator Model 100
1 +15V (Red)
Figure 5: Optical Head Wiring

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EQUIPMENT
SPECIFICATIONS
Power: 2A max @ 85-250 VAC, 50-60 Hz

Ambient Temperature: -18 – 70º C (0 – 160º F)
Flame Relay: 2 Form C contacts, 5 AMP @ 250 VAC / 30VDC
Auxilliary Relay: 2 Form C contacts, 5 AMP @ 250 VAC / 30VDC
Digital Inputs: 4 - Dry contacts only
Analog Output: 4-20 mA (loop powered)
Dimensions: 4.38” Wide x 4.13” Tall x 2.38” Deep
Mounting: Standard DIN 3 Rail
PART NUMBERING /
REVISIONS
The part number for the revision 4 DFI100 takes the format of
DFI-100-4xyzz
Where:
4  Indicates the overall product major revision.

x  Indicates the internal processor board hardware revision.
y  Indicates the internal IO board hardware revision.
zz  Indicates the firmware revision.
As an example a DFI with a part number of DFI-100-40001 is a revision 4 DFI

with a rev 0 processor board, a revision 0 IO board, and a firmware revision of
01.
All DFI-100s are backwards compatible with previous revisions, so a newer

revision DFI-100 can be used to replace an older one.

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CUSTOMER SERVICE
CONTACTS
For questions regarding the DFI-100 or to obtain replacements, repair service, or
for warranty issues please contact the appropriate Customer Service
Representative noted below.
IN USA:
Alstom Power Inc.
200 Great Pond Drive
Windsor, CT 06095
(866) 257-8664
E-Mail: windsorparts@power.alstom.com
IN CANADA:
Alstom Power Canada
1430 Blair Place
Ottawa, ON K1J 9N2
CANADA
(613) 747-5779
E-Mail: canadianaftermarketparts@power.alstom.com

CONTRACT: EB0-000665 5/1/15
TAB 3
LIMELIGHT™ High Energy Ignitor Retractable (HEIR)
TABLE OF CONTENTS

Scope of Supply ............................................................................................................................................ 1
Limelight ™ High Energy Ignitor Retractable (HEIR) ................................................................................. 1
Major Components ........................................................................................................................................ 1
Solenoid Valve ........................................................................................................................................... 1
Proximity Switches ..................................................................................................................................... 1
Stroke Limiting Ignitor Clamp .................................................................................................................... 2
Pneumatic Retract ..................................................................................................................................... 2
Features & Benefits ....................................................................................................................................... 2
Easy Connections ...................................................................................................................................... 3
Small Profile............................................................................................................................................... 3
Easy Mounting ........................................................................................................................................... 3
Pneumatic Actuator and Proximity Switch Operation .................................................................................... 4
HEIR Exciter .................................................................................................................................................. 5
Advanced Ignition Technology................................................................................................................... 5
Exciter Theory of Operation ....................................................................................................................... 6
Ignitor Connection Diagram ....................................................................................................................... 7
Equipment Specifications .............................................................................................................................. 7
Ignition Exciter ........................................................................................................................................... 7
Mechanical: ............................................................................................................................................ 7
Igniter Tip ................................................................................................................................................... 8
Mechanical:................................................................................................................................................ 8
FAQ (Frequently asked Questions) ............................................................................................................... 8
Retraction Needed? ................................................................................................................................... 8
What Type of Proximity Switch is Used? ................................................................................................... 8
What are the Specifications of the Pneumatic Tubing?............................................................................. 8
What Air Pressure is Required? ................................................................................................................ 8
How long will the Igniter Tips Last? ........................................................................................................... 8
How long will the Exciters Last? ................................................................................................................ 8
Exciter Trouble Shooting ............................................................................................................................... 9
Intermittent or No Spark ............................................................................................................................ 9
Weak Spark ............................................................................................................................................... 9
MAINTENANCE .......................................................................................................................................... 10
Exciter Module Replacement .................................................................................................................. 10
HEIR Tip Inserted Position - Location And Adjustment ........................................................................... 10
HEIR Tip Positioning – Field Installation Procedure ................................................................................ 12
Recommended Spare Parts List ................................................................................................................. 13
LIST OF FIGURES
Figure 1: Limelight™ High Energy Ignitor Retractable (HEIR) Side View ..................................................... 2
Figure 2: Limelight™ High Energy Ignitor Retractable (HEIR) Bottom View ................................................. 3
Figure 3: Limelight™ High Energy Ignitor Retractable (HEIR) Bottom View showing Ignitor Stroke
Limiting Clamp............................................................................................................................................... 4
Figure 4: Junction Box Wiring Diagram ........................................................................................................ 4
Figure 5: Wiring Schematic for Local Exciter Cabinet................................................................................... 5
Figure 6: Exciter ............................................................................................................................................ 6
 COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 i

CONTRACT: E2B-000109 11/6/15
LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
Figure 7: HEI Block Diagram ......................................................................................................................... 7

Figure 8: Flex Ignitor Cable and Flex Spark Rod .......................................................................................... 7
Figure 9: HEI Spark Tip Locating Guide ..................................................................................................... 11
Figure 10: HEI Spark Tip Set-Up Requirements ......................................................................................... 12

High Energy Ignitor Assembly with Retract ....................................................................EB0-007991-1E9327
HEI Exciter and Cabinet ........................................................................................................... C-EPSC-0133
 COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 ii

CONTRACT: EB0-007991 11/6/15
LIMELIGHT™ High Energy Ignitor Retractable (HEIR)
SCOPE OF SUPPLY
Limelight ™ High Energy Ignitor Retractable (HEIR)

The new spark ignitor includes Alstom’s state of the art high energy exciter that
discharges 12 Joules of energy to the spark tip at a rate of 4 times per second.
The exciter is supplied in a junction box that is configured to accept switched 120
VAC. The Spark rod is mounted to a pneumatic advance/retract mechanism
complete with solenoid operation and proximity switch feedback. The spark rod
assembly utilizes Alstom’s solid rod technology which eliminates wires in the
spark rod and incorporates ceramic insulators inside the rod assembly. Further
details of this supply are:
LIMELIGHT™ Retractable HEA Ignitor hardware supplied consisting of 32

assemblies 16 left hand and 16 right hand configurations. Each complete with
stainless steel mechanical retract assembly. HEIR Ignitors are located in each of
the eight corner windboxes at the AB elevation, CD elevation, EF elevation, and
the GH elevation. Each consisting of the following:
• Heavy oil high energy exciter complete with NEMA 4X junction boxes, 12
joules, 4 sparks per second, solid state design.
• High energy arc ignitor (HEA) tip complete with wand assembly and 20 feet
(6096mm) of electrical wiring.
• Pneumatic Retract Assembly, 5” (127mm) stroke, 120 Vac solenoid, 2

proximity switches. (Cylinder is capable of 8" (203.2mm) retraction currently
set to 5"(127mm) travel)
• Guide pipe assembly
MAJOR COMPONENTS
The figures on the following pages show the highlights, major parts and air
system requirements for the HEIR Actuator Assembly.
Solenoid Valve
Air is supplied to the actuator assembly at 75 PSIG (5.1 bar)at 1
SCFM(28L/min)for 3-5 sec electronically controlled solenoid valves direct the air
to the pneumatic cylinder. The exhaust ports on the solenoid valves are supplied
with mufflers and have dedicated variable speed control orifices. These orifices
can be adjusted to allow for smooth, positive advance and retract of the spark rod
system. This is needed to insure that mechanical damage to the system does not
occur due to abrupt cylinder actions. Reference Drawings EB0-007991-1E9327
and Figures 1, 2, and 3.
Proximity Switches
Proximity switches are mounted on the pneumatic cylinder and are wired to the
NEMA 4X junction box. Proximity switches provide feedback as to whether the
 COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 1

CONTRACT: E2B-000109 11/6/15
flex spark rod is advanced or retracted. Reference Drawing EB0-007991-1E9327

Stroke Limiting Ignitor Clamp

The stroke limiting ignitor clamp attached to the cylinder rod positions the flexible
spark rod relative to the advance/retract mechanism. Changing the clamp
location on the flex spark rod determines the spark tip insertion position when
advanced. This assembly will utilize a 5” stroke for the flexible spark. Reference
Drawing EB0-007991-1E9327 and Figure 3.
Figure 1: Limelight™ High Energy Ignitor Retractable (HEIR) Side View
Pneumatic Retract
Retraction is only used to prevent damage to the igniter tip. The last inch of the
igniter tip can withstand 1000°C. The maximum temperature of the connector
end of the igniter tip is 649°C. Retraction is used if these temperature limits are
exceeded; in general, this only applies for direct ignition of a main fuel.
Reference Drawing EB0-007991-1E9327 and Figure 1
FEATURES &
BENEFITS
The design incorporates many features requested by field personnel. Consider

the following common performance advantages.

CONTRACT: EB0-007991 11/6/15
Easy Connections
All electrical connections are in a single NEMA 4X junction box, complete with
wiring schematic on the inside of the enclosure cover. The solenoid ports are
1/4" NPT with quick connect terminations.
Figure 2: Limelight™ High Energy Ignitor Retractable (HEIR) Bottom View
Small Profile
The entire assembly is compact to minimize the retractor profile on the burner
front. From the end view, the entire assembly can fit within an 8" (203mm)
diameter. This compact design allows easy retrofits and is readily incorporated
into new burner designs.
Easy Mounting
Mounting options include either a 5" OD flange. The assembly includes an
adjustable clamp to set the igniter tip position in the furnace. These features
allow fast and easy mounting with minimum changes.

CONTRACT: EB0-007991 11/6/15
Figure 3: Limelight™ High Energy Ignitor Retractable (HEIR) Bottom View showing Ignitor Stroke
Limiting Clamp
PNEUMATIC ACTUATOR AND

PROXIMITY SWITCH OPERATION
The double acting pneumatic cylinders use air pressure to move the spark rod in
both directions. A five port, four-way solenoid valve controls the cylinder. When
power is applied, the spark rod inserts. When power is removed, the rod retracts.
The proximity switches are positioned to confirm full insertion or retraction. Each
NEMA 4X junction box includes a schematic reference figure 4 , which is affixed
to the enclosure cover. This internal label provides a quick and easy reference to
simplify installation or maintenance. Also reference Drawing EB0-007991-1E9327
Figure 4: Junction Box Wiring Diagram

CONTRACT: EB0-007991 11/6/15
HEIR EXCITER
Reference Drawing C-EPSC-0133 and Figures 5, 6 and 7.
Direct Ignition of No. 2 Fuel Oil
Special Ignition Fuels Are Not Needed.
Our Oil ignition system is an ideal solution when gas or diesel is not available.
Alternatively, in the case of marine application where gas is not permissible, High
Energy ignition is an ideal replacement for the carbon arc rod. Direct ignition of
the main fuel lowers costs and reduces complexity.
Direct spark ignition eliminates ignition fuel controls & valves.
Direct spark ignition eliminates the need for separate fuel storage.
Direct spark ignition increases reliability since there are fewer parts that last
longer.
The high-energy spark clears fouling and is capable of igniting bunker grade fuel
oil. It even fires under water.
This system provides reliable light off of Light oil in the following conditions:
Advanced Ignition Technology

Standard HEI systems are capable of providing light off of light oil in optimum
conditions. Critical factors include fuel temperature, quality of fuel atomization
and a low loss discharge path. Our high-energy ignition system has additional
enhancements, which our research has shown to provide significant
improvements to light off capability. The exciter is solid-state. The elimination of
tubes increases the flexibility to provide various output characteristics while
increasing life. The exciter provides approximately 300 watts output, which is not
practical for the old gas tube technology.
Figure 5: Wiring Schematic for Local Exciter Cabinet

CONTRACT: EB0-007991 11/6/15
Figure 6: Exciter
Exciter Theory of Operation

The High Energy Ignition Exciter operates without gas discharge tubes. Energy
accumulates on storage capacitor CSTG, as the exciter draws power from the
input power line. The capacitor slowly accumulates a charge to a preset voltage
during the interval between sparks. The capacitor charging circuit is a power
factor converter, PFC, which forces line current to approximate a sine wave in
phase with the line voltage. The resultant high power factor (>0.95) minimizes
line current amplitude and line voltage distortion.
Additionally, the power factor converter provides galvanic isolation between the
line and the discharge circuit potentials.
When the capacitor has charged to a preset voltage, an electronic switch rapidly
discharges the capacitor through a pulse-forming network into the ignitor.
Although the discharge current amplitude can vary from several hundred to
several thousand amperes (depending on the application), the life of the
electronic switch is not affected by the accumulation of these pulses.
The pulse-forming network controls the amplitude and duration of the discharge
current pulse to provide characteristics, which enhance ignition and extend the
life of the storage capacitor and igniter. Where the exciter output is typically
2000V the pulse-forming network can provide a 5000V-trigger voltage as needed.

CONTRACT: EB0-007991 11/6/15
Power Factor Converter Electronic Switch

To Spark
85 to 265 VRMS CSTG with Ignitor Tip
50 to 60 Hertz Pulse Forming Network
Figure 7: HEI Block Diagram
Ignitor Connection Diagram

The flex spark rod is 99.875 inches (2536 mm) total length. The harness has a
supplied spark and ground wire length of 20 feet (6096mm). The flex conduit
from the connector is typically supplied at a length of 10 feet (3048mm). Wand
Assemblies are built to length as required.
Figure 8: Flex Ignitor Cable and Flex Spark Rod
EQUIPMENT SPECIFICATIONS
Ignition Exciter
Mechanical:
Enclosure NEMA 4X,
NEMA 4X, 7/8" (22mm) Entrance Hole for input power access
Box dimensions: 10" X 8" X 6" [254mm X 203.2mm X 152.4
mm]
Net Weight: 26 Lb. [12 kg]
Input Power: 85-265 Vac, 50-60 Hz, 5A @ 100V
Stored Energy: 12 Joules Minimum
Spark Rate: 4 Sparks per Second minimum
Duty Cycle: (2 minutes ON, 5 minutes OFF) X 4, followed by 60 minutes OFF

CONTRACT: EB0-007991 11/6/15
Temperature: Operating -25°C to 75°C
Igniter Tip
Mechanical:
Net Weight: 0.35 Lb. [.23 kg]
Shipping Weight: 0.75 Lb. [.34 kg]
Temperature: 1200°F MAX [649°C]
Angle: Straight is standard, angles available up to 90° maximum
Length: 7.3 inches (185.42mm)
CAUTION:
Do not operate open circuit.
FAQ (FREQUENTLY ASKED

QUESTIONS)
Retraction Needed?
Retraction is only used to prevent damage to the igniter tip. The last inch of the
igniter tip can withstand 1000°C. The maximum temperature of the connector
end of the igniter tip is 649°C. Retraction is used if these temperature limits are
exceeded; in general, this only applies for direct ignition of a main fuel. On a
Recovery Boiler, retraction is required to prevent chemical attack on the spark tip
while firing black liquor.
What Type of Proximity Switch is Used?

A reed type. magnetic positioning switch is used it has L.E.D.display, which
illuminates when engaged and power has been applied. Switching current is
100mA max. Switching voltage is 10 to 120VAC, 10 to 30VDC. Function normally
open. Enclosure type IP68.
What are the Specifications of the Pneumatic Tubing?

The tubing material is high temperature polyamide rated to 250psi and 194°F
(90°C).
What Air Pressure is Required?

The solenoid control valve pressure rating is 14.5-145 PSIG (1-10 BAR). It has a
flow capacity of 79 SCFM (2237l/min). The cylinder and tubing is rated 250 P.S.I
(17.2 bar). Maximum.
How long will the Igniter Tips Last?

Oil Igniter Tips (P/N 1G-5900-2), and are expected to last 250,000 to 350,000
sparks. As igniter tips wear, the spark energy increases (spark size and intensity)
until complete failure. Actual life will depend on the temperature, environment
and duty-cycle.
How long will the Exciters Last?

The exciter is warranted for one year. The most likely component to wear out is
the energy storage capacitor. The expected capacitor life is approximately five

CONTRACT: EB0-007991 11/6/15
million output pulses. The exciters are designed to allow replacement of

capacitor assemblies. The typical useful life of many of our exciters is
approximately ten years.
EXCITER TROUBLE SHOOTING
WARNING:
ALL POWER TO THE IGNITION EXCITER SHOULD BE
TURNED “OFF” AND PRECAUTIONS TAKEN TO MAKE
SURE IT IS NOT ACCIDENTALLY TURNED “ON” AT
LEAST FIVE (5) MINUTES PRIOR TO TOUCHING THE
EXCITER MODULE. THIS WILL ALLOW TIME FOR
THE STORED ENERGY IN THE CAPACITORS TO
DISSIPATE. FAILURE TO DO THIS WILL RESULT IN
SEVERE PERSONNEL HAZARD. DANGEROUS AND
POTENTIAL LETHAL VOLTAGES ARE PRESENT.
Intermittent or No Spark
Before proceeding, ensure that the system is connected properly.
Igniter tips wear out over time. A worn igniter tip is the most likely reason for the
system to stop sparking. Remove power and replace the igniter tip.
After replacing the igniter tip, if the system is still not operating properly, ensure power
has been applied to the exciter module. This can be confirmed by observing the AC power
applied to the input power terminals L1 and L2 with a voltmeter. Often, you can hear the
exciter module operating. If it is ticking (at approximately 5 Hz), then it is likely that the
problem is downstream of the module. If the module is not ticking, remove power and
replace the module, per the directions below.
If the exciter appears to be generating pulses, and the igniter tip does not spark, remove
power and replace system components in the following order:
• Igniter Tip
• Rod
• Harness
• Exciter module
Weak Spark
Before proceeding, ensure that the system is connected properly.
Worn igniter tips generate a larger spark than a new tip because the air-gap
(distance between the center electrode and the shell) is larger.
As the igniter tip wears, the electrode material erodes. In effect the system
becomes more powerful as it ages. Eventually, the air-gap becomes too large for
the pulse to bridge the gap.
New igniter tips still have enough spark energy to ignite diesel or No. 2 oil, although
the spark may appear “weaker”.

CONTRACT: EB0-007991 11/6/15
If the spark is exceptionally weak, even with a worn igniter tip (with air-gap of
approximately 2mm or 0.040” between the center electrode and shell), replace the
exciter module.
MAINTENANCE
Exciter Module Replacement
WARNING:
ALL POWER TO THE IGNITION EXCITER SHOULD
BE TURNED “OFF” AND PRECAUTIONS TAKEN TO MAKE
SURE IT IS NOT ACCIDENTALLY TURNED “ON” AT LEAST
FIVE (5) MINUTES PRIOR TO TOUCHING THE
EXCITER MODULE. THIS WILL ALLOW TIME FOR THE
STORED ENERGY IN THE CAPACITORS TO
DISSIPATE. FAILURE TO DO THIS WILL RESULT IN
SEVERE PERSONNEL HAZARD. DANGEROUS AND
POTENTIAL LETHAL VOLTAGES ARE PRESENT.
CAUTION:
In the unlikely event that the charge on the capacitor
has not dissipated the capacitor may be charged
with high voltage. Confirm the removal of all charge
with a DC VOLTMETER before proceeding. Measure the
DC voltage between the output terminals and case
ground to confirm that all charge is dissipated.
After confirmation that no voltage is present on the terminal connections, the

modular assembly can be removed for replacement. Remove all electrical connections
by unscrewing the terminal lugs and removing the wires from the input and output
terminal blocks.
WARNING:
THE INTERNAL EXCITER MODULE IS NOT
REPAIRABLE. IT MUST BE RETURNED TO THE
FACTORY TO BE REFURBISHED. FAILURE TO DO THIS
CAN RESULT IN SEVERE PERSONNEL HAZARD.
DANGEROUS AND POTENTIAL LETHAL VOLTAGES
ARE PRESENT.
HEIR Tip Inserted Position - Location And Adjustment

The attached illustrations outline the procedure for setting the ignitor tip in the
flame spray pattern of the oil gun during the outage. Correct placement of the
HEI tip is critical for the successful light-off of the oil gun. As shown the tip should
be inserted such that it is ½” to 1” (12.7mm to 25.4mm) within the oil spray
pattern. An external setting should be scribed on the external wand assembly to
ensure the correct placement of the HEI tip past the oil gun assembly.

CONTRACT: EB0-007991 11/6/15
Figure 9: HEI Spark Tip Locating Guide

CONTRACT: EB0-007991 11/6/15
Figure 10: HEI Spark Tip Set-Up Requirements
HEIR Tip Positioning – Field Installation Procedure

The photograph below shows the suggested method of verification for tip
insertion in the advanced mode. With the oil gun fully advanced, loosen the
clamping device, advance and maintain the advanced position on the pneumatic
cylinder. Advance the spark tip to an approximate firing position. While inside
the furnace, install a welding rod that fits snug into the sprayer plate of the oil gun
tip. Align the spark tip to where it is advanced into the spray pattern between ½”
and 1” (12.7-25.4mm). Once the tip is in the proper position, tighten the clamping
device on the advance retract mechanism. With the cylinder retracted, measure
the position of the Spark Rod/HEI guide Pipe relative to the advance retract
mechanism and record for future use. In addition, it is suggested that the position
be scribed on the spark rod so that a quick review of the installation would reveal
that the proper location has been maintained.

CONTRACT: EB0-007991 11/6/15
RECOMMENDED SPARE PARTS LIST
Pampa Energy
Contract EB0-007991
Retractable HEI Ignitor (Short Stroke) Assembly Drawing EB0-007991-1E9327

Item Quantity Description Part No.
2 5 Pneumatic Cylinder (8” Unit Air Assembly) V00-7385
5 6 Solenoid Valve V00-9756
6 6 Cylinder Position Sensor V00-2715
15 3 Flexible Spark Rod EPSD-0457-164-T
16 3 HEI Wire Train Assembly EPSD-0305-3-20-20
26 6 Ignitor Tip 1G-5900-2
HEI Exciter and Cabinet Drawing C-EPSC-0133
- 3 High Energy Exciter 75-HEI-01

CONTRACT: EB0-007991 11/6/15
01 CHANG E NO TE # 7 FRO M REF DW G TO
D 7 L
E 10
D 15 W C H EN T R O N IC S M AN U AL
P A R T S C O M M O N T O P /N E B 0 -0 0 7 9 9 1 -9 3 2 7 -A A N D P /N E B 0 -0 0 7 9 9 1 -9 3 2 7 -B
IT EM PA RT N U M BER QTY D RA W IN G D ESC R IPT IO N MTL
2 V 0 0 -7 3 8 5 1 8" U N IT A IR A SSEM BLY 0
4 E P S C -0 1 5 6 2 C -E P S C -0 1 5 6 PAC K IN G R ET AIN ER ASSEM BLY 0
PORT 2 5 V 0 0 -9 7 5 6 1 SO LEN O ID V A LV E 0
PO RT 4 C O N N EC T IT EM # 9 FR O M PO RT 2 T O 6 V 0 0 -2 7 1 5 2 C YLIN D ER PO SIT IO N SEN SO R 0
6 FRO N T O F C YLIN D ER. SEE N O T E # 1 0.
C O N N EC T IT EM # 9 FRO M PO RT 4 T O 7 V 0 0 -8 0 3 0 2 M A L E C O N N , 1 /4 "O D X 1 /4 " M A L E N P T -S S 0
R EAR O F C YLIN D ER. SEE N O T E # 1 0. 8 V 0 0 -8 0 3 1 2 M A L E E L B O W -1 /4 "O D X 3 /8 " M A L E N P T -S S 0
9 V 0 0 -8 0 3 5 2 T U B I N G .2 5 " O .D . X .0 3 5 " W A L L - S S 0
6
10 V 0 0 -8 0 3 2 2 1 /4 " N P T F L O W R E D U C E R - S S 0
PO RT 2 PO RT 4 11 V 0 0 -9 7 9 0 1 1 /2 " 9 0 D E G . E L B O W 0
C O N N EC T IT EM # 9 FRO M PO RT 2 T O C O N N EC T IT EM # 9 FRO M PO RT 4 T O 12 V 0 0 -9 7 9 4 1 1 /2 " 9 0 D E G . E L B O W 0
FR O N T O F C YLIN D ER. SEE N O T E # 1 0. R EAR O F C YLIN D ER. SEE N O T E # 1 0. 13 V 0 0 -8 0 3 4 2 LIQ U ID T IG H T ST RAIN RELIEF C O N N EC T O R 0
14 E P S D -0 4 9 2 1 D -E P S D -0 4 9 2 ST RO K E LIM IT IN G IG N IT O R C LAM P 0
15 E P S D -0 4 5 7 -1 6 4 -T 1 FLEXIBLE SPA R K R O D A SSEM BLY 0
16 E P S D -0 3 0 5 -3 -2 0 -3 0 1 D -E P S D -0 3 0 5 -3 H EI W IRE T RA IN A SSEM BLY 0
17 M D 8 -0 0 0 4 4 -E C 4 M D 8 0 -1 C 0 0 4 4 B O L T -H E X .3 7 5 X 1 .2 5 0 I N 295
18 M D 8 -0 0 2 1 8 -A N 4 M D 8 0 -1 C 0 2 1 8 W A S H E R -P L A I N T Y P E B .3 7 5 N 276
19 1 5 -2 0 0 2 2 M D 8 0 -1 C 0 0 2 6 W A S H E R -L O C K R E G S P G .3 7 5 " 289
20 1 1 -2 0 0 6 2 M D 8 0 -1 C 0 0 0 3 N U T -H E X .3 7 5 I N 540
21 1 5 -2 0 0 4 1 M D 8 0 -1 C 0 0 2 6 W A S H E R -L O C K R E G S P G .5 0 0 " 289
22 1 1 -2 0 0 7 1 M D 8 0 -1 C 0 0 0 3 N U T -H E X .5 0 0 I N 540
23 M D 8 -0 0 0 6 4 -C H 2 M D 8 0 -1 C 0 0 6 4 S C R -C A P H E X S O C H D # 1 0 X 1 .2 5 0 " 551
3 31 24 M D 8 -0 0 0 2 6 -A M 2 M D 8 0 -1 C 0 0 2 6 W A S H E R -L O C K R E G S P G # 1 0 .1 9 0 " 289
25 M D 8 -0 0 0 4 2 -A H 2 M D 8 0 -1 C 0 0 4 2 N U T -H E X M A C H S C R # 1 0 .1 9 0 I N 297
27 26 1 G -5 9 0 0 -2 1 B -9 0 2 -8 1 0 2 IG N IT O R T IP 0
27 V 0 0 -9 8 2 4 2 PRO T EC T IVE T U BE 1 8" LO N G 0
27 28 G P -1 3 2 7 6 1 1 /2 " F L E X I B L E C O N D U I T 0
29 1 G -1 1 9 2 1 1 /4 " F L E X . M E T A L H O S E X 3 '-0 " L G
1 30 6
P A R T S O N L Y F O R P / N E B 0 -0 0 7 9 9 1 -9 3 2 7 -A
D E T A IL B IT EM
1
PART NUM BER
E P S E -0 0 3 2 -A
QTY
1
D RAW IN G
E -E P S E -0 0 3 2
D ESC R IPT IO N
FRAM E ASSEM BLY - 5 " & 8" ST RO K E
MTL
0
D E T A IL A 6 P O S I T I O N S E N S O R S W I T C H E S (I T E M # 6 ) T O B E P R E S S E D
I N T O R E C E S S E D G R O O V E I N B O D Y O F C Y L I N D E R (I T E M # 2 ).
P /N E B 0 -0 0 7 9 9 1 -9 2 3 7 -B 3 E P S D -0 3 9 3 -A 1 D -E P S D -0 3 9 3 JU N C T IO N BO X A SSEM BLY 0
O PPO SIT E H A N D P A R T S O N L Y F O R P /N E B 0 -0 0 7 9 9 1 -9 3 2 7 -B
P /N E B 0 -0 0 7 9 9 1 -9 2 3 2 -A PO SIT IO N SEN SO R SW IT C H # 1 LO C AT ED AT R EAR O F
S C A L E 1 :2
AS SH O W N C Y LIN D ER. PO SIT IO N SEN SO R SW IT C H # 2 LO C A T ED A T RO D IT EM PART NU M BER QTY D R AW IN G D ESC RIPT IO N MTL
S C A L E 1 :2 EN D O R FRO N T O F C YLIN D ER. 30 E P S E -0 0 3 2 -B 1 E -E P S E -0 0 3 2 FRAM E ASSEM BLY - 5" & 8" STRO KE 0
31 E P S D -0 3 9 3 -B 1 D -E P S D -0 3 9 3 JU N C T IO N BO X A SSEM BLY 0
1 /4 " N P T F E M A L E C O N N E C T O R
1 /4 " N P T F E M A L E C O N N E C T O R 8 0 -1 0 0 P S I G F I L T E R E D A I R .
8 0 -1 0 0 P S I G F I L T E R E D A I R . SEE N O TE # 6
SEE N O TE # 6 M AT ERIAL SPEC IFIC A T IO N C H A RT
IT EM SPEC N O C O M PO SIT IO N GRADE PU RC H ASIN G IN ST RU C T IO N S
276 A -3 2 5 A -5 6 3 F -4 3 6 C A R BO N ST EEL BO LT S N U T S W A SH ER S T YPE 1 C NONE
289 A -5 1 0 CARBO N STEEL NONE NONE
295 A -3 0 7 A -5 6 3 C A R BO N ST EEL BO LT S N U T S AA NONE
(3 1 .1 0 ) 297 A -3 0 7 CARBO N STEEL A NONE
540 A -5 6 3 CARBO N STEEL A NONE
(2 5 .2 5 ) 551 A -1 9 3 1 8 C r-8 N i S T A I N L E S S B8 NONE
18 17
17 18 19 20 1
30
B
A
(4 .0 0 )
3 31
6
4 3
5
7 7
27 27
13 P / N E B 0 -0 0 7 9 9 1 -9 3 2 7 -A P /N E B 0 -0 0 7 9 9 1 -9 3 2 7 -B
AS SH O W N O P P O S IT E H A N D
6
(8 .9 0 ) 8 9 9 8
22 21
16
26 15
(1 .3 7 )
(7 .1 7 )
4
23 24 25
14
10 10 SEE NO TE # 11
12
11
28 29
S P A R K R O D "A " D I M E N S I O N = (1 6 4 .0 0 )
R E T R A C T E D P O S IT IO N P / N E B 0 -0 0 7 9 9 1 -9 3 2 7 -A
S C A L E 1 :2
SO LEN O ID
TO BM S 4 5 TO BM S
T O H E I E X C IT E R
P .S . # 1 C A B IN E T
RETRACTED
N O TES: R E F E R E N C E D R A W IN G S :
TO BM S 1 1 2 2 TO BM S
1 ) M A X IM U M T E M PE R A T U R E R A N G E - 3 2 F T O 1 6 7 F C - E P S C - 0 1 3 3 ..........H E I E X C I T E R A N D C A B I N E T
01
P .S . # 2 7 ) F O R H E A E N C L O S U R E A S S 'Y D E T A I L S , S E E C H E N T R O N I C S R A P I D F I R E H E I E X C I T E R
2) CO M PO N ENT PARAM ETERS: O PE R A T IO N S & M A IN T E N A N C E M A N U A L.
TO BM S 7 1 2 ADVANCED 8 TO BM S A . A LL C O M PO N E N T S A R E W A T E R T IG H T .
B . S IN G L E , 4 W A Y S O L E N O ID : 1 /4 " N P T , P R E S S U R E P O R T - 8) A N E PO X Y PA IN T SH O U LD B E A PPLIE D T O IT E M # 1 F O R W E A T H E R
1 3 0 P S I . M A X . P R E S S U R E , C O I L R A T E = 0 .5 5 W A T T S , 2 4 V D C PR O O F IN G PU R PO SE S. T H E P A IN T SH A LL B E IN T E R N A T IO N A L , IN T E R G A R D 3 4 5 O R E Q U IV .
C . P R O X IM IT Y S W IT C H - 1 0 -3 0 V D C
10 C O N T IN U O U S C A R R Y IN G C U R R E N T - 1 0 0 M A M A X . 9) N A M EPLA T ES, O PER AT O R PA N ELS & G A U G E FAC ES: ALL N A M E PLAT ES AN D EQ U IPM EN T
D . A IR C Y LIN D E R - S IN G LE R O D E N D ST Y LE N F PA IN T E R C H A N G E A B LE , O PER AT O R PA N ELS AR E T O H A V E T H E IN FO RM AT IO N SH O W N IN T H E EN G LISH LA N G U AG E
7 0 -1 2 5 P S I, O P E R A T IN G P R E S S U R E , 2 5 0 P S I M A X . W IT H SI M ET R IC U N IT S O F M EA SU R EM EN T . T A G S SH A LL BE C O N ST R U C T ED O F ST A IN LESS A LL D IM EN SIO N S A R E IN IN C H ES
ST EEL, LA M IN A T ED PH EN O LIC , O R PLA ST IC . T H E ST A IN LESS ST EEL T A G S SH ALL H A VE
SPA R K R O D PO SIT IO N 3 ) A L L D I M E N S I O N S A R E I N I N C H E S . (M I L L I M E T E R S S P E C I F I E D I N B R A C K E T S ) ID EN T IFIC A T IO N C H A R A C T ER S ST A M PED O R EN G R A V ED T H ER EO N . FO R LA M IN A T ED T O LER A N C ES U N LESS O T H ER W ISE N O T ED
PR O X IM IT Y
PH E N O LIC O R PLA ST IC , T A G S SH A LL H A V E BLA C K C H A R A C T ER S A N D T H E BA C K G RO U N D
SW ITCH
4 ) F IN A L LO C A T IO N O F SPA R K R O D T O B E D E T E R M IN E D IN F IE LD A T T IM E O F C O L O R S H A L L B E W H I T E . F I G U R E H E I G H T S H A L L B E A M I N I M U M O F 3 /1 6 ". T A G S S H A L L B E X .X X ± .0 6
CONTACTS ADVANCE IN T E R IM RETRACT AT T AC H ED U SIN G RIV ET S, ST AIN LESS ST EEL M AC H IN E SC R EW S, O R ST AIN LESS ST EEL
IG N IT O R IN S T A L LA T IO N (S E E B U R N E R O R W IN D B O X F O R IN F O ).
W IRE. EN C LO SU RE T A G A T T A C H M EN T S SH A LL N O T D EG RA D E T H E EN C LO SU R E R A T IN G . ANG ULAR: ± 0°30'
SW . # 1 1, 2 O PEN OPEN CLO SED 5 ) W I R I N G D I A G R A M I N D I C A T E S L I M I T S W I T C H E S W I T H T H E R E T R A C T A S S 'Y I N
T H E F U LLY R E T R A C T E D PO SIT IO N . 1 0 ) I T E M # 9 (T U B I N G ) S H A L L B E I N S T A L L E D I N S U C H A F A S H I O N T H A T T H E B E N D S F O L L O W T H E SU RFAC E T EXT U RE: 1 000 M IC RO IN C H ES
C U R V A T U R E O F T H E A SSEM BLY A S M U C H A S PO SSIBLE T O M IN IM IZ E T H E EN V ELO PE O F T H E R O U G H N E S S A V E R A G E -R a
SW . # 2 1, 2 CLO SED OPEN O PEN EQ U IPM EN T .
6 ) F LE X IB LE H O SE T O B E PR E SE T A T 5 0 % O F T O T A L B O ILE R V E R T IC A L &
H O R IZO N T A L O R C U B IC A L E X P A N SIO N . SE E R SF C B U R N E R A R R A N G E M E N T T H IS D RAW IN G IS IN AC C O RD AN C E W IT H
1 1 ) S E T T I N G F O R F L O W R E D U C E R (I T E M # 1 0 ) C A N B E A D JU S T E D A S R E Q U I R E D I N F I E L D . A S M E Y 1 4 .5 M -1 9 9 4
S H E E T 1 . E B 0 -0 0 7 9 9 1 -1 E 9 2 5 0 F O R E X P A N S IO N .
TAB 4
Exacta Flame Scanner System Upgrade
TABLE OF CONTENTS
Exacta Flame Scanner System Upgrade ...................................................................................................... 1

Scope of Supply......................................................................................................................................... 1
DRAWINGS .................................................................................................................. DRAWING NUMBER
Exacta Flame Scanner Assembly – Gas ....................................................................... EB0-007991-1D9274

Exacta Flame Scanner Assembly – Oil ......................................................................... EB0-007991-1D9300
Exacta Flame Scanner Analyzer Cabinet Arrangement ................................................ EB0-007991-1D9317
Exacta Flame Scanner Analyzer Cabinet Schematic .................................................... EB0-007991-1D9318
Exacta Flame Scanner Cabinet Extensions Connection Diagram ................................ EB0-007991-1D9319
LIMELIGHT™ Exacta Flame Scanner System

For Tangential and Wall Fired Applications ............................................................................ 5002 RSFC
LIMELIGHT™ Exacta Flame

Scanner PC Interface Users Manual .................................................................................................... 2009

CONTRACT: EB0-007991 10/6/15
Exacta Flame Scanner System Upgrade
EXACTA FLAME SCANNER

SYSTEM UPGRADE
An Exacta Flame Scanner System upgrade has been supplied. This Flame
scanner system has been developed as a low cost installation option while
continuing to focus on the critical electronic technology of flame failure protection.
Scope of Supply
The base offer scope of supply listed below represents a flame scanner system
that utilizes an electronic module system that provides the signal generation (to
the plant’s Burner Management System (BMS) for flame presence.

CONTRACT: EB0-007991 10/6/15
1 E X T E N S IV E C H A N G E T O D R A W IN G P E R
R 06 C
09
L 15 J E N G IN E E R IN G , S E E R E V 1 F O R R E C O R D C H A N G E S
P A R T S L IS T
1 IT E M PART NUM BER QTY D R A W IN G D E S C R IP T IO N M A T E R IA L
1 E S H -7 0 0 -U V -L S -W 1 D -E P S D -0 6 3 8 U V L IN E O F S IG H T W ID E A N G L E 0
2 E F -C A -2 5 1 C -E P S C -0 0 6 1 P IG T A I L , 2 5 F T 0
3 E P S B -0 0 8 6 1 B -E P S B -0 0 8 6 E X A C T A M O U N T I N G A D A P T E R & O -R IN G A S S Y - M O D IF IE D 0
4 E P S C -0 2 2 9 1 C -E P S C -0 2 2 9 C O O L IN G A IR M A N IF O L D A S S E M B L Y 0
1 1
(.6 9 ) W R E N C H T IG H T
IN S T A L L A T IO N N O T E S :
1 . V E R IF Y F L A S H IN G L E D W H E N C O N N E C T E D T O P IG T A IL A N D F S A M O D U L E S A R E P O W E R E D U P .
1 . D -E P S D -0 3 7 1 ...................... E X A C T A F IE L D W IR IN G D IA G R A M
4 3 1 2
F O R C O M P L E T E M A T E R IA L ID E N T IF IC A T IO N A N D P R O C E S S IN G .
P /N : E B 0 -0 0 7 9 9 1 -9 2 7 4 A L L D IM E N S IO N S A R E I N IN C H E S
T O L E R A N C E S U N L E S S O T H E R W IS E N O T E D
X .X X ± .0 6
AN G ULAR: ± 0°30'
A S M E Y 1 4 .5 M -1 9 9 4
1 E X T E N S IV E C H A N G E T O D R A W IN G P E R
R 06 C
09
L 15 J E N G IN E E R IN G . S E E P R E V IO U S R E V F O R R E C O R D C H A N G E S
P A R T S L IS T
IT E M PART NUM BER QTY D R A W IN G D E S C R IP T IO N M A T E R IA L
1 1 E S H -7 0 0 -V L -L S -W 1 D -E P S D -0 6 3 8 V IS IB L E L IG H T L IN E O F S IG H T W ID E A N G L E 0
2 E F -C A -2 5 1 C -E P S C -0 0 6 1 P IG T A IL , 2 5 F T 0
3 E P S B -0 0 8 6 1 B -E P S B -0 0 8 6 E X A C T A M O U N T IN G A D A P T E R & O -R IN G A S S Y - M O D IF IE D 0
4 E P S C -0 2 2 9 1 C -E P S C -0 2 2 9 C O O L IN G A IR M A N IF O L D A S S E M B L Y 0
1 1
(.6 9 ) W R E N C H T IG H T
IN S T A L L A T IO N N O T E S :
1 . V E R IF Y F L A S H IN G L E D W H E N C O N N E C T E D T O P I G T A IL A N D F S A M O D U L E S A R E P O W E R E D U P .
1 . D -E P S D -0 3 7 1 ...................... E X A C T A F IE L D W IR IN G D I A G R A M
4 3 1 2
T H IS D R A W IN G D O E S N O T C O N T A IN A L L IN F O R M A T I O N N E C E S S A R Y F O R
M F G . T H IS P A R T . R E F E R T O P / N C O M M E N T S & P R O D U C T S T R U C T U R E
F O R C O M P L E T E M A T E R IA L ID E N T I F IC A T IO N A N D P R O C E S S IN G .
P /N : E B 0 -0 0 7 9 9 1 -9 3 0 0 A L L D IM E N S IO N S A R E I N IN C H E S
T O L E R A N C E S U N L E S S O T H E R W IS E N O T E D
X .X X ± .0 6
AN G ULAR: ± 0°30'
A S M E Y 1 4 .5 M -1 9 9 4
Instruction Manual
LIMELIGHTTM Exacta Flame Scanner System

For
Tangential and Wall Fired Applications

DOCUMENT 5002 RSFC 10/6/15
Exacta Flame Scanner System
PROPRIETARY MARKS
CANbus
The CANbus network specification, written by Bosch, has been standardized
by ISO and SAE. The entire CAN specification as standardized in ISO 11898-
1 & ISO 11898-2 contains the CAN physical layer specification.
MODBUS Protocol
The MODBUS Protocol was originally developed by Modicon. In 1979

Schneider bought Modicon. In 2004 Modbus-IDA acquired MODBUS
Protocol transferring the entire “right, title and interest” in the protocol
copyright.
CERTIFICATIONS
CE Mark
This product conforms to:
IEC 6030-1 – Automatic electrical controls for household and similar use.
Canadian Standards Association (CSA)
This product conforms to:
CAN / CSA – C22.2 No. 199-M89 – Combustion Safety Controls and Solid-
State Igniters for Gas and Oil Burning Equipment.
NOTICE
This instruction manual has been prepared to serve as a guide in operating

and maintaining the equipment supplied by Alstom Power Inc. It is not
intended to cover all possible variations in equipment or all specific problems
that may arise.
It must be recognized that no amount of written instructions can replace

intelligent thinking and reasoning on the part of the operators, especially when
coping with unforeseen operating conditions. It is the operator’s responsibility
to become thoroughly familiar with the equipment.

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TABLE OF CONTENTS

INTRODUCTION........................................................................................................................................... 1
Acronyms and Uncommon Words............................................................................................................. 2
Benefits of the Flame Scanner System ..................................................................................................... 3
Features of the Flame Scanner System .................................................................................................... 3
EQUIPMENT DESCRIPTION ....................................................................................................................... 4

Scanner Head ............................................................................................................................................ 4
UVH Head Jumper Setting ........................................................................................................................ 5
Mechanical Components (Fiber Optic (FO)) ............................................................................................. 6
Mechanical Components (Line of Sight (LOS)) ......................................................................................... 6
Flame Signal Analyzer (FSA) Overview .................................................................................................... 6
Modes of Operation ............................................................................................................................... 7
Inputs ..................................................................................................................................................... 7
Outputs .................................................................................................................................................. 8
Communication .......................................................................................................................................... 9
Read/Write Registers ............................................................................................................................. 9
Read Only Registers .............................................................................................................................. 9
INSTALLATION ........................................................................................................................................... 11
Scanner Head Installation Requirements ................................................................................................ 11
Temperature Limits .............................................................................................................................. 11
Cooling and Purge Air .......................................................................................................................... 11
Line of Sight (LOS) Installations .............................................................................................................. 12
Selecting Location................................................................................................................................ 12
Adjusting for Optimal Signal .................................................................................................................... 12
Fiber Optic Installations ........................................................................................................................... 12
Flame Signal Analyzer (FSA) Installation ................................................................................................ 13
Temperature Limits .............................................................................................................................. 13
Mounting .............................................................................................................................................. 13
Power Requirements ........................................................................................................................... 14
Wiring Instructions ............................................................................................................................... 14
OPERATION ............................................................................................................................................... 14
Programming ........................................................................................................................................... 15
Edit Parameters ................................................................................................................................... 16
Cal Analog Out..................................................................................................................................... 17
Force Relays ........................................................................................................................................ 18
Save Norm Fact ................................................................................................................................... 18
Change Password................................................................................................................................ 19
Restore Defaults .................................................................................................................................. 19
Parameters .............................................................................................................................................. 19

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SYSTEM STARTUP .................................................................................................................................... 33

Initial Software Configuration .................................................................................................................. 33
Adjustment of Trip Points ........................................................................................................................ 33
MAINTENANCE .......................................................................................................................................... 33
Lens Cleaning, Fiber Optic (FO) Head .................................................................................................... 34
Disassembling the Lens Body ............................................................................................................. 34
Assembling the Lens Body .................................................................................................................. 34
Lens Cleaning, Line of Sight (LOS) Head ........................................................................................... 34
Inspecting the Fiber Optic Cable ......................................................................................................... 35
Replacing the Fiber optic Cable........................................................................................................... 35
CUSTOMER SERVICE CONTACTS .......................................................................................................... 36
RECOMMENDED SPARE PARTS (RSP) AND SPECIAL TOOLS LISTS ................................................. 37
GENERAL SPECIFICATIONS .................................................................................................................... 44

Scanner Head .......................................................................................................................................... 44
Flame Signal Analyzer............................................................................................................................. 44
APPENDIX I – FLAME SCANNER SYSTEM SELECTION SHEET ........................................................... 45
APPENDIX II – EXACTA FLAME SCANNER REMOTE HEAD ................................................................. 46

Mechanical Components ......................................................................................................................... 47
Exacta Remote Head Assembly Instructions .......................................................................................... 48
RECOMMENDED SPARE PARTS LIST .................................................................................................... 53
APPENDIX III – EXPLOSIVE ATMOSPHERE APPLICATION .................................................................. 55

Explosive Atmosphere Label Information ................................................................................................ 55
Intrinsic Safety Certification Standards ................................................................................................ 56
Entity Parameters ................................................................................................................................ 56
Approved Class Ratings ...................................................................................................................... 57
Special Conditions for Safe Use .......................................................................................................... 58
LIST OF TABLES
Table A: Head Selection for Fiber Optic Cable Applications ........................................................................ 6

Table B: Line of Sight Applications ............................................................................................................... 6
Table C: Exacta Flame Signal Analyzer ....................................................................................................... 6
Table D: Minimum, Maximum And Default Parameter Values ................................................................... 29
Table E: RSP List, Scanner Head (VL - Visible Light, BR – Broad Range) LOS
– Standard Viewing Angle .............................................................................................................. 37
Table F: RSP List, Scanner Head (VL - Visible Light, BR – Broad Range, UV – Ultraviolet,
UVH – Ultraviolet High-Gain) LOS – Wide Viewing Angle............................................................. 37
Table G: RSP List, Flame Scanner Assembly (VL - Visible Light, BR - Broad Range),
110” or 130” Fiber Optic Cable with Vortex Lens Body ................................................................. 39
© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 iv

CONTRACT: EB0-007991 10/6/15
Table H: RSP List, Flame Scanner Assembly (UV – Ultraviolet or UVH – Ultraviolet High-Gain), 110” or
130” Fiber Optic Cable with Vortex Lens Body .............................................................................. 41
Table I: Accessory Parts ............................................................................................................................. 43
Table J: Special Tools ................................................................................................................................. 43
LIST OF FIGURES
Figure 1: Flame Scanner Head Assembly .................................................................................................... 4

Figure 2: Jumper Setting For Standard Gain ................................................................................................ 5
Figure 3: Jumper Setting For High Gain ....................................................................................................... 5
Figure 4: Spool Piece with Adjustable Length ............................................................................................ 13
Figure 5: Flame Signal Analyzer (FSA) ...................................................................................................... 15
Figure 6: Vortex Lens Body Assembly Details ............................................................................................ 34
Figure 7: Scanner Head (LOS) Parts .......................................................................................................... 38
Figure 8: Flame Scanner Assembly Parts (VL/BR) – 110” or 130” ............................................................. 40
Figure 9: Flame Scanner Assembly Parts (UV and UVH) – 110” or 130” ................................................. 42
Figure 10: Special Tools ............................................................................................................................. 43
Figure 11: Exacta Flame Scanner Remote Head Assembly ...................................................................... 46
Figure 12: Exacta Flame Scanner Remote Head Assembly for Ignitor Applications ................................. 46
Figure 13: Exacta Flame Scanner Remote Head Components.................................................................. 47
Figure 14: Exacta Flame Scanner Remote Head Assembly Instructions (1 of 5) ...................................... 48
Figure 15: Recommended spare parts list .................................................................................................. 54
Figure 16: Sample ATEX label .................................................................................................................... 55
LIST OF DRAWINGS
Drawing 1: Exacta FSA Field Wiring Diagram, D-EPSD-0371 ................................................................... 59

Drawing 2: Exacta FSA Configuration, VL or BR FOC Variable Length, D-EPSD-0382 ............................ 60
Drawing 3: Exacta FSA, LOS VL or BR Standard Lens, D-EPSD-0384 .................................................... 61
Drawing 4: Exacta FSA, LOS VL/BR/UV-Wide Lens, D-EPSD-0397 ......................................................... 62
Drawing 5: Exacta FSA UV with Quartz FOC Variable Length, D-EPSD-0445 .......................................... 63
Drawing 6: Exacta Flame Scanner Remote Head Configuration, D-EPSD-0481....................................... 64
Drawing 7: Exacta Remote Head 3” Bluff Body Ignitor Installation, D-EPSD-0484.................................... 65
© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 v

CONTRACT: EB0-007991 10/6/15
INTRODUCTION
This manual provides information on the installation, operation and required
TM
maintenance for the LIMELIGHT Exacta Flame Scanner. The Exacta Flame
Scanner System is a burner flame-sensing device designed for flame supervisory
applications as described in the National Fire Protection Association Codes. The
Flame Scanner has the important feature of being able to discriminate between a
flame and a no-flame condition for both the main and auxiliary support burners.
The Exacta Flame Scanner consists of a scanner head and a separate signal-
processing module. This configuration places minimal electronics in the heat-
affected areas of the burner front. The more sensitive signal conditioning
components are mounted away from the burner front.
Light from the flame is converted to an electrical signal in the scanner head. This
signal is then sent to the Flame Signal Analyzer (FSA) via a 2-0mA current loop.
Each FSA accepts the signal from two scanner heads. The signal from the head
is evaluated to determine flame intensity and flicker frequency. A third value, AC
amplitude, is also calculated, although this is only used for flame proving in a few
unusual applications.
There are two major configurations for Exacta Flame Scanner Heads, Line of
Sight (LOS), and Fiber Optic (FO). In general, FO heads are used for tilting
tangential applications, and LOS heads are used for wall-fired applications. In
some wall-fired applications it is necessary to use a FO scanner, due to
obstructions or excessive ambient temperature. Both of these configurations are
available with four different detector types: Ultraviolet (UV), Ultraviolet High-Gain
(UVH), Visible Light (VL), and Broad Range (BR). The detector type is chosen
based on the fuel(s) being fired.
The Flame Signal Analyzer (FSA) provides relay outputs and input signals to the
associated burner management system. The flame relays have adjustable trip
thresholds. The FSA is compatible with legacy flame scanner heads previously
supplied by the OEM boiler manufacturer. The Exacta Scanner System is
compatible with previously installed wiring, adapter cables and guide pipes. It
TM
can be provided as an in-kind component upgrade for SAFE SCAN and SAFE
TM
FLAME Scanners or as a new complete flame scanning system.

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Acronyms and Uncommon Words
BMS Burner Management System.
BR Broad Range, an acronym used to describe the sensitivity range of the photo
detector, i.e. 400 nm to 1100 nm.
Fireball This is a specific application-based philosophy. Flame scanner fireball

monitoring of boiler combustion is provided when discrimination of individual
burner flames is not practical.
FO FO refers to the application of the conditioning electronics in concert with a

fiber optic cable assembly. Also, FO can refer to the optical fiber strands
used in the cable that transmits light energy from the burner flame to the
photo detector.
FOC Fiber Optic Cable refers to the cable that transmits light energy from the
burner flame to the photo detector.
FSA Flame Signal Analyzer, the flame scanner control module.
FSH Flame Sensor Head, the hardware that monitors boiler flame.
ESA Exacta Signal Analyzer, the flame scanner control module.
ESH Exacta Sensor Head, the hardware that monitors boiler flame.
LOS Line of Sight refers to the scanner head model that has an unobstructed view
of the burner flame. No fiber optic cable required.
-9
nM Nanometer, a unit of length equal to 10 meters.
NPT National Pipe Thread, a US standard for tapered pipe threads.
OEM Original Equipment Manufacture.
Scanner Refers to the Exacta flame-monitoring device employed as a first line of

defense in a boiler explosion.
SCFM Standard Cubic Feet per Minute, a unit of flow.
UV Ultra Violet, an acronym used to describe the sensitivity range of the photo
UVH High Gain version of the UV head with the ability to increase the sensitivity
by 20% for special applications.
VL Visible Light, an acronym used to describe the sensitivity range of the photo
-W Wide, used to describe hardware with extra wide-angle field of view.
RoHS Restriction of Hazardous Substances RoHS Directive 2002/95/EC restricts

the use of six hazardous materials found in electrical and electronic products.

CONTRACT: EB0-007991 10/6/15
Benefits of the Flame Scanner System
Safe, reliable flame detection, easily interfaced to the plant safety system.
One flame scanner can monitor main and auxiliary fuels. This reduces the
amount of equipment required.
Superior sensitivity and dynamic range enables operating at the lowest possible
boiler load.
Adjustable digital filters for optimum flexibility.
Flexible communication options simplify integration into existing plant systems.
Compatible with previously installed OEM equipment, which reduces the cost of
installation.
Features of the Flame Scanner System
State of the art burner flame proving device.
Variable length Adjustable Fiber Optic Cable Scanner.
Quick disconnect mechanical and electrical connectors for easy replacement

without wiring changes.
Built-in auctioneering supports redundant power supplies.
Flame proven relay outputs, for interfacing with Burner Management Systems
(BMS).
MODBUS communication port, and four 4-20mA outputs, allow easy monitoring
of the flame signal.
RoHS Compliant, lead-free components.

CONTRACT: EB0-007991 10/6/15
EQUIPMENT DESCRIPTION
Scanner Head
The Flame Scanner Head shown in Figure 1 contains the light detection PC
Board. The head displays a power/active light. The head will blink slowly when
powered and no flame is being detected. Blinking rate will increase as flame
intensity increases.
Figure 1: Flame Scanner Head Assembly
The Exacta Scanner Head assemblies are offered in various configurations

based on the intended application. The light wavelengths detected by the
various sensors are as follows:
UV 210 to 380 nM
UVH 210 to 380 nM
VL 400 to 700 nM
BR 400 to 1100 nM
The model number changes based on the type of sensor, and the light path.
Tilting tangential burners should use a fiber optic head. This allows the lens
body to tilt with the burners, ensuring a clear view of the flame.
Wall fired burners typically use a line of site head. Wide-angle lens heads are
used for opposed wall fired installations for improved discrimination between
near field, and far field flames. Wide-angle lenses can also be used to improve
low light intensity performance. UV and UVH LOS heads always use a wide-
angle lens.

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UVH Head Jumper Setting
The UVH head has a jumper setting to switch between standard and high-gain
operation. When the jumper is set to standard gain it is in the location shown in
Figure 2.
Figure 2: Jumper Setting For Standard Gain
The high gain setting for the UVH head will increase the intensity of the flame
signal by about 20%. This increase is useful primarily for LOS heads where the
gas flame is far enough from the head or where the flame is partially obstructed
and intensity is reduced. To set the UVH head to high-gain operation, move the
jumper to the location shown in Figure 3.
Figure 3: Jumper Setting For High Gain

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Table A: Head Selection for Fiber Optic Cable Applications
Part No Description Typical Application
ESH-700-UV-FO Ultraviolet Gas
ESH-700-UVH-FO Ultraviolet Gas
ESH-700-VL-FO Visible Light Coal / Oil
ESH-700-BR-FO Broad Range Gas Fireball
Table B: Line of Sight Applications
Standard Lens
ESH-700-VL-LS Visible Light Coal / Oil
Wide Angle Lens
ESH-700-UV-LS-W Ultraviolet Gas / Oil
ESH-700-UVH-LS-W Ultraviolet Gas / Oil
ESH-700-VL-LS-W Visible Light Coal / Oil
Table C: Exacta Flame Signal Analyzer
EPSD-0375 Digital Signal Analyzer All Fuel Types
Mechanical Components (Fiber Optic (FO))
Refer to Alstom Drawing D-EPSD-0382 for FO scanner head mounting details.
Mechanical Components (Line of Sight (LOS))
Refer to Alstom Drawing D-EPSD-0384 for standard lens LOS scanner head
mounting details, and D-EPSD-0397 for wide-angle lens LOS scanner head
mounting details.
Flame Signal Analyzer (FSA) Overview
The Flame Signal Analyzer (FSA) accepts signal from up to two scanner heads.
Heads with different sensor types can be freely mixed. Due to the current loop

CONTRACT: EB0-007991 10/6/15
nature of the signal from the head and the high quality cable used, head to FSA
cable lengths up to 5000 feet are supported.
Modes of Operation
The FSA has four modes of operation. They are Single Fuel, Discriminate, Fuel
Switching, and Load Switching. Mode is set individually for each head, and can
be different for the two configurations.
In the Single Fuel mode, flame relay “A“ will close when the pull-in conditions of
parameter set “A” are met. Relay “B” and parameter set “B” are not used.
External inputs are not required for operation.
In the Discriminate mode, flame relay “A“ will close when the pull-in conditions
of parameter set “A” are met. Relay “B” will close when the pull-in conditions of
parameter set “B” are met. External inputs are not required for operation.
In the Fuel Switching mode flame relay “A” will close when the pull-in conditions
of parameter set “A” are met and the digital input indicating fuel “A” firing is pulled
low. Also, relay “B” will close when the pull-in conditions of parameter set “B” are
met and the fuel “B” digital input is low. If both inputs are high, flame proving is
disabled, so this mode can be used for installations where “blinding” is required.
In the Load Switching mode, when the “load profile” input is high parameter set
“A” controls the operation of relay ”A”. When the “load profile” input is low,
parameter set “B” controls the operation of relay “A”. In this mode, relay “B” is
disabled, and will remain open at all times.
Inputs
The FSA has four digital inputs. These inputs are intended to be driven by dry
contacts. The functions of the inputs are:
DIN 1 Digital input used to indicate firing of fuel “A” on head
1 when pulled low.
DIN 2 Digital input used to indicate firing of fuel “B” on head

1 when pulled low. Alternate function indicates load
profile “B” when pulled low.
DIN 3 Digital input used to indicate firing of fuel “A” on head

2 when pulled low.
DIN 4 Digital input used to indicate firing of fuel “B” on head

2 when pulled low. Alternate function indicates load
profile “B” when pulled low.

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Outputs
The FSA has eight relay outputs and four 4-20mA current loop outputs. The 4-20
mA outputs are loop powered, 18 to 32 V. These outputs can be configured to
transmit any of the following values:
Head 1 Intensity
Head 1 Set A Frequency
Head 1 Set B Frequency
Head 1 Set A AC Amplitude
Head 1 Set B AC Amplitude
Head 1 Active Quality
Head 2 Intensity
Head 2 Set A Frequency
Head 2 Set B Frequency
Head 2 Set A AC Amplitude
Head 2 Set B AC Amplitude
Head 2 Active Quality
The eight relay outputs are FORM-C contacts rated at 2A, 250V. The functions
of these relays are:
Relay 1 Head 1, Flame Relay 1, see “Modes of Operation”.
Relay 3 Head 1, Pre-trip Relay, will de-energize when quality

drops below the pre-trip pull-in value specified in the
parameter set. In the DISCRIMINATE mode, the
user can select whether parameter set “A” quality,
parameter set “B” quality, or worst-case quality is
used.
Relay 4 Head 1, Fault Relay 4, as well as Flame Relays 1 and

2, will de-energize whenever a fault occurs that will
prevent the scanner from reliably proving flame on
Head 1.
Relay 7 Head 2, Pre-trip Relay, will de-energize when quality

drops below the pre-trip pull-in value specified in the
parameter set. When in DISCRIMINATE mode the
user can select whether parameter set “A” quality,
parameter set “B” quality, or worst-case quality is
used.
Relay 8 Head 2, Fault Relay 8, as well as Flame Relays 5

and 6, will de-energize whenever a fault occurs that
will prevent the scanner from reliably proving flame
on Head 2.

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Communication
The Exacta flame scanner is equipped with two RS-485 ports. The first port is
intended for remote communication using Alstom's Exacta PC Configuration
software. The second RS-485 port is intended for communication with a remote
system using MODBUS RTU protocol. MODBUS slave address, Baud rate, and
parity are user configurable. Baud rates of 9600, 19200, 38400 and 57600 bps
are supported. The FSA uses base–0 addressing. Therefore the first MODBUS
register is 0. The data available via MODBUS, and its MODBUS register
assignment is as follows:
Read/Write Registers
501 Head 1 Fuel A input. When in fuel switching mode

writing 0xFF00 indicates firing fuel “A”. Writing
zero indicates fuel “A” not firing. Can also be
set/reset as a MODBUS digital value
502 Head 2 Fuel A input. When in fuel switching mode

writing 0xFF00 indicates firing fuel “A”. Writing
zero indicates fuel “A” not firing. Can also be
set/reset as a MODBUS digital value
503 Head 1 Fuel B input. When in fuel switching mode

writing 0xFF00 indicates firing fuel “B”. Writing
zero indicates fuel “B” not firing. This register is
also used to select load profile “B” in load switching
mode. Can also be set/reset as a MODBUS digital
value
504 Head 2 Fuel B input. When in fuel switching mode

writing 0xFF00 indicates firing fuel “B”. Writing
zero indicates fuel “B” not firing. This register is
also used to select load profile “B” in load switching
mode. Can also be set/reset as a MODBUS digital
value
Read Only Registers

1001 Head 1 Flame A status. 0xFF00 indicates flame

proven. Zero indicates flame not proven. Can
also be read as a MODBUS digital value.
1002 Head 2 Flame A status. 0xFF00 indicates flame

1003 Head 1 Flame B status. 0xFF00 indicates flame


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1004 Head 2 Flame B status. 0xFF00 indicates flame

1005 Head 1 Marginal Flame. 0xFF00 indicates

marginal flame. Zero indicates we do not have
marginal condition. Can also be read as a
MODBUS digital value.
1006 Head 2 Marginal Flame. 0xFF00 indicates

marginal flame. Zero indicates we do not have
marginal condition. Can also be read as a
MODBUS digital value.
1007 Head 1 FAULT. 0xFF00 indicates a fault condition.

Zero indicates fault not present. Can also be read
as a MODBUS digital value.
1008 Head 1 FAULT. 0xFF00 indicates a fault condition.

Zero indicates fault not present. Can also be read
as a MODBUS digital value.
1009 Reserved for future use.
1010 Head 1 Intensity (%)
1011 Head 2 Intensity (%)
1012 Head 1 Active Frequency (Hz)
1013 Head 2 Active Frequency (Hz)
1014 Head 1 Active Quality
1015 Head 2 Active Quality
1016 Head 1 Active AC Amplitude (mV)
1017 Head 2 Active AC Amplitude (mV)
1018 Head 1 parameter set A frequency (Hz)
1019 Head 2 parameter set A frequency (Hz)
1020 Head 1 parameter set B frequency (Hz)
1021 Head 2 parameter set B frequency (Hz)
1022 Head 1 parameter set A AC amplitude (mV)
1023 Head 2 parameter set A AC amplitude (mV)
1024 Head 1 parameter set B AC amplitude (mV)
1025 Head 2 parameter set B AC amplitude (mV)

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1026 Head 1 parameter set A Quality
1027 Head 2 parameter set A Quality
1028 Head 1 parameter set B Quality
1029 Head 2 parameter set B Quality
The FSA also has a CANbus port. The port uses a proprietary data-encoding
scheme for use with an Alstom IM200 network interface module.
INSTALLATION
Scanner Head Installation Requirements
Temperature Limits
The scanner head should be installed in a location where the ambient

temperature is less than 185 deg F (85 deg C).
Cooling and Purge Air
The flame scanner heads require a maximum allowed cooling air temperature of
120 deg F (49 deg C) at the cooling air manifold. This can be accomplished with
a low-pressure blower system or with compressed air and an orifice. Refer to
“General Specifications”, “Scanner Head”.
CAUTION:
The scanner head must be supplied with cooling air

whenever there is fire in the furnace, or the boiler interior is
greater than 800 deg F (427 deg C).
Note:
Installing Shutoff Valves or Manual Adjustable Orifices in cooling

air feed lines is not recommended. If required for balancing the
air system, locking devices or removable handles should be
considered to eliminate air system tampering.
Each LOS Flame Scanner Head assembly requires 10 SCFM of cooling airflow.
Each FO Flame Scanner Head assembly requires 30 SCFM of cooling airflow. In
the FO scanner head, a secondary effect of the cooling air is to provide purge air
through the Fiber Optic Extension to the Lens Body. This prevents particles from
depositing onto the lens in the lens body assembly. If multiple flame scanners
are connected to a common cooling air supply, install the supplied cover plate
whenever a LOS scanner head, or a fiber optic assembly is removed. This
prevents a reduction in cooling airflow to the remaining scanners.

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Line of Sight (LOS) Installations
Selecting Location
The scanner head requires a clear view to the root of the flame. If an air
deflector plate surrounds the burner tip, aim the flame scanner at the edge of the
plate. If the furnace wall or other object prevents the scanner from sighting at the
edge of the deflector plate, a minimum 3” diameter hole in the plate may be
required. If a hole is required, place the hole as close to the edge of the plate as
possible.
Mounting Options
Refer to Alstom drawings D-EPSD-0384 and D-EPSD-0397 for possible LOS

scanner mounting arrangements.
Adjusting for Optimal Signal

Swivel mount
Loosen the three screws on the swivel mount. Rock the scanner head through
its range of motion to find the location where the “winker” LED is blinking the
fastest. Tighten the three screws on the swivel mount.
Sighting pipe
Loosen the three locking nuts on the adjusting screws. Move the three adjusting
screws until the scanner head “winker” LED is flashing at its fastest rate. Tighten
the three lock nuts.
Fiber Optic Installations
The guide pipe is normally fixed in the windbox front by means of a seal plate.
The cooling air manifold is screwed (2" NPT) onto the guide pipe and is threaded
to accept a flexible hose connection at its cooling air inlet with an opening for the
Flame Scanner Fiber Optic Extension. The furnace end of the guide pipe is tack
welded to the air nozzle tip, which normally is set two inches back from the end
of the nozzle.
Note:
In order to prevent a reduction in cooling airflow to other

scanners, the guide pipe opening must be closed with the cover
plate when the fiber optic extension is removed for maintenance.
The Flame Scanner Fiber Optic Extension Assembly passes through the cooling
air manifold and slides into a fully inserted position. It is strongly recommended
that the tilts be in a horizontal position (Zero Tilt) prior to installing the Flame
Scanner Fiber Optic Extension Assembly.
CAUTION:
Experience has shown that there is potential for the

assembly to get stuck, partially installed, if the tilt position
is not horizontal. Once stuck, removal may damage the
equipment.

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The installer should “feel” the lens body assembly contact the grip area at the
end of the guide on the guidepipe. This area is designed to center the lens body
assembly and prevent it from changing position when the tilts are stroked. Once
the lens body is in contact with the grip area, the scanner assembly should
require approximately ½” of compression to fully engage the Scanner Head with
the Air Cooling manifold, with the tilts at horizontal.
If there is insufficient compression, the Lens Body may slip out of the Guide at
the furnace end of the guide pipe when the tilts are moved up or down. This
would impact the sighting to the flame and consequently the operation of the
scanner. If there is excessive compression, the Fiber Optic Extension may be
difficult to insert. This could also shorten the life of the flex hose.
The amount of flex hose compression can be adjusted by removing the two
setscrews in the spool piece. The ribbed sleeve can then be slid in and out to
adjust the amount of compression. Refer to Figure 4.
Figure 4: Spool Piece with Adjustable Length
Flame Signal Analyzer (FSA) Installation
Temperature Limits
The FSA should be mounted in an area where the maximum ambient

temperature is less than 160 deg F (70 deg C).
Mounting
The FSA is designed to mount vertically to a standard 35mm DIN rail. End stops
are required to prevent slippage. The FSA should be mounted in an enclosure
that provides adequate physical and environmental protection.

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Power Requirements
The FSA requires 24VDC. The power supply should have a capacity of 12W per
FSA. This value contains an adequate safety factor. Redundant power supplies
are supported.
Wiring Instructions
Refer to Alstom drawing D-EPSD-0371 for field wiring details. The cable
connecting the FSA with the scanner heads has a maximum length of 5000 feet.
In most installations, a local junction box is mounted near the scanner head.
This junction box is used to transition from the scanner head pigtail to bulk cable.
OPERATION
The FSA has a local display and a 5-key keypad. Refer to Figure 5. There are
also two sets of five LED’s that indicate the status of the burners being monitored
by the two heads. The functions of the status LED’s are:
Flame A Lights when the parameter set A flame
proving requirements are met.
Flame B Lights when the parameter set B flame

proving requirements are met.
Marginal Flame Lights when flame quality is less than

the marginal pull-in value.
Fault Lights when a fault condition is

present. A fault condition forces a “No
Flame” signal.
Signal Strength Duplicates the function of the “winker”

LED on the back of the Exacta scanner
head. The blink rate is a function of
flame intensity.
If a scanner head is disabled, all of its LED’s are turned off. During normal
operation five screens of information can be displayed on the local FSA display.
Use the up arrow (Key 2) and the down arrow (Key 4) to scroll through these
screens.
Screen 1 displays a summary of the current values from both heads.
Screen 2 and Screen 3 display detailed information for each head individually.
If a head is disabled, its detailed screen is skipped when scrolling through the
displays.
Screen 4 displays the status of the four digital inputs, and the three
communication ports.
Screen 5 displays the amount of time the FSA has been running.
The display is equipped with a screen saver. After 20 minutes of inactivity, the
display goes dark. Pressing any keypad key restores the display.

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Figure 5: Flame Signal Analyzer (FSA)
Programming
To enter program mode at the local keypad depress Key 1 (Program On/Off).
NOTE:
The FSA is equipped with an interlock that prevents

simultaneous editing of parameters from two locations. An
attempt to enter program mode, while parameters are being
edited remotely with the PC interface, displays a warning
message and returns the FSA to normal mode.
After pressing Key 1 the user is prompted for a password. The factory default
password is 11111. After successfully entering the password the following menu
is displayed:
Edit Parameters
Cal Analog Out
Force Relays
Save Norm Fact
Change Password
Restore Defaults
selection. When the desired selection is highlighted press Key 5 (Enter/Store).

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Edit Parameters
Selecting “Edit Parameters” causes the following menu to be displayed:

Communication Parameters
Head 1 Parameters
Head 1 Mode
Head 2 Parameters
Head 2 Mode
4-20ma Output Parameters
The display is truncated at 20 characters. To display the rest of the line, press
key 3 (Head select). Use the up and down arrow keys (Key 2 & Key 4) to scroll
to the desired selection. When the desired selection is highlighted press Key 5
(Enter/Store).
Communication Parameters
Selecting “Communication Parameters” causes the first communication

parameter to be displayed. Use the up and down arrow keys (Key 2 & Key 4) to
scroll through all of the communication parameters. Press Key 1 (Program
On/Off) to return to the “Edit Parameters” menu.
To change a parameter, press key 5 (Enter/Store) while that parameter is

displayed. The value of the parameter is highlighted. Use the up and down
arrow keys (Key 2 & Key 4) to change the value of the parameter. If only one
digit of the parameter is highlighted, the arrow keys act on that digit. In this case
Key 3 (Head Select) changes the digit that is highlighted.
After the parameter is changed to the desired value, press Key 5 (Enter / Store)
to save the new value. The display returns to the mode of scrolling between
values. To return to this mode without storing new value press Key 1 (Program
On / Off).
Head 1 Parameters, Head 2 Parameters
Selecting “Head 1 Parameters”, or “Head 2 Parameters” allows the user to view

/edit the parameters for that head that are common to both parameter sets. The
keys perform the same functions described under “Communication
Parameters” above.
Head 1 Mode, Head 2 Mode
Selecting “Head 1 Mode”, or “Head 2 Mode” displays the following menu:

Single Fuel
Discriminate
Fuel Switching
Load Switching
operating mode. When the desired selection is highlighted press Key 5
(Enter/Store). Press key 1 (Program On / Off) to return to the previous menu.
Single Fuel
Selecting “Single Fuel” displays the following menu:

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Basic Parameters
Expert Parameters
Marginal Relay Parameters
selection. When the desired selection is highlighted press Key 5 (Enter/Store).
Press key 1 (Program On / Off) to return to the previous menu.
Basic Parameters are those most likely changed in a typical installation. Expert
Parameters are modified only under unusual circumstances. Marginal Relay
Parameters define the operation of the marginal relay. The marginal relay warns
the operator that the flame quality is degrading, and a trip is imminent. After
making a selection, the parameters are edited or viewed as described under
“Communication Parameters” above.
Discriminate, Fuel Switching, Load Switching
Selecting “Discriminate”, “Fuel Switching”, or “Load Switching” causes the

following menu to be displayed:
Set A Basic Parameters
Set A Expert Parameters
Set B Basic Parameters
Set B Expert Parameters
Marginal Relay Parameters
The FSA has the ability to store two independent sets of parameters, Parameter
Set “A” and Parameter Set “B”. Two independent sets of parameters permit the
operator to detect two significantly different firing conditions. For example one
instance would be a change in fuel.
Another instance may be a change in firing equipment. In the first instance, set
“A” may be configured for #6 fuel oil guns, where set “B” parameters are tuned to
match natural gas firing. The two parameter sets extend the dynamic range of
the flame scanner. This improves the flame scanner’s ability to discriminate
between two different types of fuels or firing conditions.
4-20 mA Output Parameters
Selecting “4-20mA Output Parameters” allows viewing or editing the parameters

that define the operation of the 4 to 20 mA current loop outputs. The parameters
are edited or viewed as described under “Communication Parameters” above.
Cal Analog Out
“Cal Analog Out” allows calibrating the 4-20 mA outputs. Selecting this item
displays the following:
Cal Analog Out 1
Cal Analog Out 2
Cal Analog Out 3
Cal Analog Out 4
Select the Head to calibrate. The selected Head is forced to its current 4mA
calibration value. This value is also displayed on the screen. Use the up and
down arrow keys (Key 2 & Key 4) to adjust the calibration value.

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When the 4mA calibration is complete press Key 3 (Head Select). The 20mA
calibration value is forced on the selected output, and displayed on the screen.
Use the up and down arrow keys (Key 2 & Key 4) to adjust the calibration value.
When the calibration is complete press Key 1 (Program On/Off) to return to the
previous menu.
Force Relays
“Force Relays” allow the user to force a relay into the energized state. This
feature is used during commissioning to verify the relay field wiring. When a
relay is placed into the “forced” mode all other relays are de-energized. This
prevents using the force feature to create an unsafe condition. Since the fault
relay de-energizes on fault, a minimum of two relays have to be energized to
prove flame (Fault relay energized to indicate a non-fault condition, and a flame
relay energized).
CAUTION:
Entering into “Force Relays” mode during normal operation

will switch the scanner to a “No Flame” state, and can result
in a unit trip.
After selecting “Force Relays” the following is displayed:

Press Key 5
(Enter/Store) to
Force Relay 1
Use the up and down arrow keys (Key 2 & Key 4) to change the relay to “force”.
Selecting Key 5 (Enter/Store) will energize the relay. When a relay is “forced”,
pressing any key causes that relay to de-energize, and returns to the above
display. A relay can be forced for a maximum of 20 minutes. After force mode
expires, the FSA returns to normal operation.
Save Norm Fact
“Save Norm Fact” is used to save normalization factors. The normalization factor
is used in the flame quality calculation. A separate normalization factor is stored
for each parameter set. The normalization factor should be saved when the
burner has the brightest flame for the fuel being proven by a parameter set, i.e., if
parameter set “A” is proving coal, save the set “A” normalization factor at full load
firing coal.
After selecting “Save Norm Factor” the following menu is displayed.

Save Hd 1A Norm
Save Hd 1B Norm
Save Hd 2A Norm
Save Hd 2B Norm
selection. Press Key 5 (Enter/Store) to save the normalization factor for the
highlighted head and parameter set.

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Change Password
After selecting “Change Password” the user is prompted for a new password.
The password must be 5 characters in length, and can be any combination of
Keys 1 through 5. A second prompt requires the new password be entered a
second time for confirmation.
Restore Defaults
Selecting this item causes all parameters, including the password, to be reset to
factory default values.
Parameters
The FSA configuration parameters include:
Configuration Port Address
When multiple FSA’s have their configuration ports tied to a common bus, each
configuration port must have a unique address
MODBUS Port Address
FSA’s MODBUS slave address. Must be unique for every MODBUS device on
the network.
MODBUS Port Baud Rate
Communication speed of the MODBUS network. Set per the requirements of the
MODBUS master.
MODBUS Port Parity
Set per the requirements of the MODBUS master.
CANbus Port Address
Each device connected to a single IM200 must have a unique address.
CANbus Port Baud Rate
Set to match the IM200.
Head 1 Enable/Disable
Used to disable an input port if only one head will be connected to an FSA.
Head 1 Identifier
Two alphanumeric characters that identify the head’s location on the boiler.

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Head 1 Mode
Sets the operating mode of the head. Possible values are Single Fuel,
Discriminate, Fuel Switching, and Load Switching.
Head 1 Marginal Source
Value that controls the marginal flame relay/alarm. Possible values are Worst
Quality, Parameter Set “A” Quality, Parameter Set "B” Quality.
Head 1 Marginal Pull-in
When value of marginal source falls below this value the marginal flame relay will
close.
Head 1 Marginal Drop-out
When value of marginal source rises above this value the marginal flame relay
will open. Separate pull-in and drop-out values allow for hysterisis preventing
relay from chattering as value approaches the pull-in or drop-out level.
Head 1 Set “A” Intensity Pull-in
When flame intensity rises above this value, the intensity flame proving criteria
for parameter set “A” is met.
Head 1 Set “A” Intensity Drop-out
When flame intensity drops below this value, the intensity flame proving criteria
for parameter set “A” is no longer met. Separate pull-in and drop-out values
allow for hysterisis preventing relay from chattering as value approaches the pull-
in or drop-out level.
Head 1 Set “A” Frequency Pull-in
When flame flicker frequency rises above this value, the frequency flame proving
criteria for parameter set “A” is met.
Head 1 Set “A” Frequency Drop-out
When flame flicker frequency drops below this value, the frequency flame proving
criteria for parameter set “A” is no longer met. Separate pull-in and drop-out
values allow for hysterisis preventing relay from chattering as value approaches
the pull-in or drop-out level.
Head 1 Set “A” Frequency Sensitivity
Minimum peak-to-peak value, in mV, that the signal must change to be included
in the flicker frequency calculation.
Head 1 Set “A” Intensity Filter Factor
Smoothing filter applied to the flame intensity. A value of 0 equals no filter, a

value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.

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Head 1 Set “A” Intensity Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
Head 1 Set “A” Frequency Filter Factor
Smoothing filter applied to the flicker frequency. A value of 0 equals no filter, a

Head 1 Set “A” Frequency Normalization Factor
Head 1 Set “A” AC Pull-in
When the peak-to-peak amplitude of the AC component of the flame signal rises
above this value, the AC requirement for proving flame is met. This is an expert
value, normally not used in most installations. It is disabled by defaulting to a
value of zero.
Head 1 Set “A” AC Drop-Out
When the peak-to-peak amplitude of the AC component of the flame signal drops
below this value, the AC requirement for proving flame is not met. This is an
expert value, normally not used in most installations. It is disabled by defaulting
to a value of zero.
Head 1 Set “A” AC Filter Factor
Smoothing filter applied to the AC component. A value of 0 equals no filter, a

Head 1 Set “A” AC Normalization Factor
Head 1 Set “A” Bandpass Cutoff
Sets the characteristics of the digital filter applied to the flame signal. This is an
expert parameter normally left at the default value for most installations.
Head 1 Set “A” Pull-in Time Delay
Time delay, in seconds, from the time that all flame proving criteria is met, and
the flame relay closes. This is an expert parameter normally left at the default
value for most installations.

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Head 1 Set “A” Drop-out Time Delay
Time delay, in seconds, from the time that a flame proving requirement is lost,
and the flame relay opens. This is an expert parameter normally left at the
default value for most installations.
Head 1 Set “A” High Frequency Drop-out
When enabled, Head 1 Flame A relay de-energizes when frequency exceeds

Head 1 Set “B” frequency pull-in.
Head 1 Set “B” Intensity Pull-in
for parameter set “B” is met.
Head 1 Set “B” Intensity Drop-out
for parameter set “B” is no longer met. Separate pull-in and drop-out values
Head 1 Set “B” Frequency Pull-in
criteria for parameter set “B” is met.
Head 1 Set “B” Frequency Drop-out
criteria for parameter set “B” is no longer met. Separate pull-in and drop-out
Head 1 Set “B” Frequency Sensitivity
Head 1 Set “B” Intensity Filter Factor

Head 1 Set “B” Intensity Normalization Factor

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Head 1 Set “B” Frequency Filter Factor

Head 1 Set “B” Frequency Normalization Factor
Head 1 Set “B” AC Pull-in
value normally not used in most installations. It is disabled by defaulting to a
value of zero.
Head 1 Set “B” AC Drop-out
expert value normally not used in most installations. It is disabled by defaulting
to a value of zero.
Head 1 Set “B” AC Filter Factor

Head 1 Set “B” AC Normalization Factor
Head 1 Set “B” Bandpass Cutoff
Head 1 Set “B” Pull-in Time Delay
Head 1 Set “B” Drop-out Time Delay
default value for most installations

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Head 2 Enable/Disable
Used to disable an input port if only one head will be connected to an FSA.
Head 2 Identifier
Two alphanumeric characters that identify the head’s location on the boiler.
Head 2 Mode
Sets the operating mode of the head. Possible values are Single Fuel,
Discriminate, Fuel Switching, and Load Switching.
Value that controls the marginal flame relay/alarm. Possible values are Worst
Quality, Parameter Set “A” Quality, Parameter Set "B” Quality.
Head 2 Marginal Pull-in
When value of marginal source falls below this value the marginal flame relay will
close.
Head 2 Marginal Drop-out
When value of marginal source rises above this value the marginal flame relay
will open. Separate pull-in and drop-out values allow for hysterisis preventing
relay from chattering as value approaches the pull-in or drop-out level.
Head 2 Set “A” Intensity Pull-in
for parameter set “A” is met.
Head 2 Set “A” Intensity Drop-out
for parameter set “A” is no longer met. Separate pull-in and drop-out values
Head 2 Set “A” Frequency Pull-in
criteria for parameter set “A” is met.
Head 2 Set “A” Frequency Drop-out
criteria for parameter set “A” is no longer met. Separate pull-in and drop-out

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Head 2 Set “A” Frequency Sensitivity
Head 2 Set “A” Intensity Filter Factor

Head 2 Set “A” Intensity Normalization Factor
Head 2 Set “A” Frequency Filter Factor

Head 2 Set “A” Frequency Normalization Factor
Head 2 Set “A” AC Pull-in
value of zero.
Head 2 Set “A” AC Drop-out
to a value of zero.
Head 2 Set “A” AC Filter Factor

Head 2 Set “A” AC Normalization Factor

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Head 2 Set “A” Bandpass Cutoff
Head 2 Set “A” Pull-in Time Delay
Head 2 Set “A” Drop-out Time Delay
Head 2 Set “A” High Frequency Drop-out
When enabled, Head 2 Flame A relay de-energizes when frequency exceeds

Head 1 Set “B” frequency pull-in.
Head 2 Set “B” Intensity Pull-in
for parameter set “B” is met.
Head 2 Set “B” Intensity Drop-out
for parameter set “B” is no longer met. Separate pull-in and drop-out values
Head 2 Set “B” Frequency Pull-in
criteria for parameter set “B” is met.
Head 2 Set “B” Frequency Drop-out
criteria for parameter set “B” is no longer met. Separate pull-in and drop-out
Head 2 Set “B” Frequency Sensitivity

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Head 2 Set “B” Intensity Filter Factor

Head 2 Set “B” Intensity Normalization Factor
Head 2 Set “B” Frequency Filter Factor

Head 2 Set “B” Frequency Normalization Factor
Head 2 Set “B” AC Pull-in
value of zero.
Head 2 Set “B” AC Drop-out
to a value of zero.
Head 2 Set “B” AC Filter Factor

Head 2 Set “B” AC Normalization Factor
Head 2 Set “B” Bandpass Cutoff

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Head 2 Set “B” Pull-in Time Delay
Head 2 Set “B” Drop-out Time Delay

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Table D: Minimum, Maximum And Default Parameter Values
Parameter Minimum Maximum Default As Set
Configuration Port Address 1 255 1
MODBUS Port Address 1 255 1
MODBUS Port Baud Rate 9600, 19200, 38400, 57600 19200
MODBUS Port Parity Odd, Even, None None
CANbus Port Address 10 255 10
CANbus Port Baud Rate 62.5K, 125K , 250K 125K
Head 1 Enable/Disable Enable, Disable Enable
Head 1 Identifier Any 6 alphanumeric characters A1

Single Fuel, Discriminate, Fuel Discriminat
Head 1 Mode
Switching, Load Switching e
Worst Quality, Quality “A”, Quality Worst
“B” Quality
Head 1 Marginal Pull-in 0 100 10
Head 1 Marginal Drop-out 0 100 15
Head 1 Set “A” Intensity Pull-in 5 100 25
Head 1 Set “A” Intensity Drop-out 5 100 25
Head 1 Set “A” Frequency Pull-in 5 250 20
Head 1 Set “A” Frequency Drop-out 5 250 20
Head 1 Set “A” Frequency Sensitivity 10 100 30
Head 1 Set “A” Intensity Filter Factor 0 3 1
Head 1 Set “A” Intensity Normalization

0 100 80
Factor
Head 1 Set “A” Frequency Filter Factor 0 3 1

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Head 1 Set “A” Frequency Normalization

0 250 75
Factor
Head 1 Set “A” AC Pull-in 0 1000 0
Head 1 Set “A” AC Drop-out 0 1000 0
Head 1 Set “A” AC Filter Factor 0 3 1
Head 1 Set “A” AC Normalization Factor 0 1000 100
Head 1 Set “A” Bandpass Cutoff No Filter, 10Hz Hi 10 - 200Hz

Pass, 10 - 100Hz, 10
- 200Hz, 0 - 100Hz, 0
- 200Hz
Head 1 Set “A” Pull-in Time Delay 0 4 0
Head 1 Set “A” Drop-out Time Delay 0 4 2
Head 1 Set “A” High Frequency Drop-out Enable, Disable Disable
Head 1 Set “B” Intensity Pull-in 5 100 25
Head 1 Set “B” Intensity Drop-out 5 100 25
Head 1 Set “B” Frequency Pull-in 5 250 20
Head 1 Set “B” Frequency Drop-out 5 250 20
Head 1 Set “B” Frequency Sensitivity 10 100 30
Head 1 Set “B” Intensity Filter Factor 0 3 1
Head 1 Set “B” Intensity Normalization 0 100 80

Factor
Head 1 Set “B” Frequency Filter Factor 0 3 1
Head 1 Set “B” Frequency Normalization 0 250 75

Factor
Head 1 Set “B” AC Pull-in 0 1000 0
Head 1 Set “B” AC Drop-out 0 1000 0
Head 1 Set “B” AC Filter Factor 0 3 1

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Head 1 Set “B” AC Normalization Factor 0 1000 100
Head 1 Set “B” Bandpass Cutoff No Filter, 10Hz Hi 10 - 200Hz

Pass, 10 - 100Hz, 10
- 200Hz, 0 - 100Hz, 0
- 200Hz
Head 1 Set “B” Pull-in Time Delay 0 4 0
Head 1 Set “B” Drop-out Time Delay 0 4 2
Head 2 Enable/Disable Enable, Disable Enable

Head 2 Identifier Any 6 alphanumeric characters A2
Head 2 Mode Single Fuel, Discriminate, Fuel Discriminat
Switching, Load Switching e
Head 2 Marginal Source Worst Quality, Quality “A”, Quality Worst
“B” Quality
Head 2 Marginal Pull-in 0 100 10
Head 2 Marginal Drop-out 0 100 15
Head 2 Set “A” Intensity Pull-in 5 100 25
Head 2 Set “A” Intensity Drop-out 5 100 25
Head 2 Set “A” Frequency Pull-in 5 250 20
Head 2 Set “A” Frequency Drop-out 5 250 20
Head 2 Set “A” Frequency Sensitivity 10 100 30
Head 2 Set “A” Intensity Filter Factor 0 3 1
Head 2 Set “A” Intensity Normalization 0 100 80

Factor
Head 2 Set “A” Frequency Filter Factor 0 3 1
Head 2 Set “A” Frequency Normalization 0 250 75

Factor
Head 2 Set “A” AC Pull-in 0 1000 0

Head 2 Set “A” AC Drop-out 0 1000 0
Head 2 Set “A” AC Filter Factor 0 3 1
Head 2 Set “A” AC Normalization Factor 0 1000 100

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Head 2 Set “A” Bandpass Cutoff No Filter, 10Hz Hi Pass, 10 - 10 - 200Hz
100Hz, 10 - 200Hz, 0 - 100Hz, 0 -
200Hz
Head 2 Set “A” Pull-in Time Delay 0 4 0
Head 2 Set “A” Drop-out Time Delay 0 4 2
Head 2 Set “A” High Frequency Drop-out Enable, Disable Disable
Head 2 Set “B” Intensity Pull-in 5 100 25
Head 2 Set “B” Intensity Drop-out 5 100 25
Head 2 Set “B” Frequency Pull-in 5 250 20
Head 2 Set “B” Frequency Drop-out 5 250 20
Head 2 Set “B” Frequency Sensitivity 10 100 30
Head 2 Set “B” Frequency Filter Factor 0 3 1

Head 2 Set “B” Intensity Filter Factor 0 3 1
Head 2 Set “B” Intensity Normalization 0 100 80

Factor
Head 2 Set “B” Frequency Normalization 0 250 75
Factor
Head 2 Set “B” AC Pull-in 0 1000 0
Head 2 Set “B” AC Drop-out 0 1000 0

Head 2 Set “B” AC Filter Factor 0 3 1
Head 2 Set “B” AC Normalization Factor 0 1000 100
Head 2 Set “B” Bandpass Cutoff No Filter, 10Hz Hi 10 - 200Hz

Pass, 10 - 100Hz, 10
- 200Hz, 0 - 100Hz, 0
- 200Hz
Head 2 Set “B” Pull-in Time Delay 0 4 0
Head 2 Set “B” Drop-out Time Delay 0 4 2

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SYSTEM STARTUP
Initial Software Configuration
If the Flame Signal analyzer, (FSA), configuration ports are networked, each FSA
must be given a unique configuration port address. This address must initially be
set using the local keypad. After this address is set, all other parameters can be
configured locally, or remotely using the PC interface software.
If the MODBUS network is being used each FSA must be assigned a unique
MODBUS slave address. It is permitted for the MODBUS port to use the same
address as the configuration port. The MODBUS baud rate and parity must be
set to match the requirements of the MODBUS master.
When using an IM-200 network interface module for network communications,

each FSA must be given a unique CANbus address. The CANbus baud rate
must be set to match the configuration of the IM-200.
The FSA has a parameter for storing a 2-character identifier for each head. This
is usually set to a letter number combination that identifies the elevation and
location of the scanner head. This identifier is only used by the PC interface
software, and has no effect on scanner operation.
After the scanner has been properly installed and configured it is ready for
startup. For ‘line of sight’ applications it may be necessary to make alignment
adjustments to properly ‘sight’ the scanner. Adjustment screws have been
provided. Rotate the three (3) adjusting screws until the scanner head ‘winker’
diode flashes at its fastest rate.
Adjustment of Trip Points
Trip set points or parameters can be adjusted by trained technicians or by Alstom

Power Inc. Technical Service Personnel. In many cases, different Scanners will
have different trip points because of Fireball location and unit specific variations.
If major adjustments are needed, Alstom Power Inc. recommends that Alstom
Power Inc. perform the adjustments or review the proposed changes. Generally
it is difficult to adjust set points in such a way that safety might be compromised
because of built-in safety features, but there is no substitute for experience and
knowledge in achieving reliable performance.
MAINTENANCE
The frequency of periodic maintenance varies from application to application.
Generally, cleaning of the Lens assembly should be scheduled annually. The
fiber optic cables should be inspected if there is a reduction of intensity or
frequency or suspect fiber breakage.

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Lens Cleaning, Fiber Optic (FO) Head
Disassembling the Lens Body

• Verify removal of the scanner head assembly from the guidepipe without
impacting unit operations or plant safety.
• Remove the Flame Scanner Head (It is not necessary to disconnect the
electrical connector).
• Remove the Fiber Optic Extension from the Guide Pipe.
• Disassemble the Vortex Lens Body Assembly by removing the socket
head cap screws between the Lens Body and Plug, shown in Figure 6.
• Remove the lens assembly and clean or replace the lens. Various fuels
cause different types of deposits. Isopropyl alcohol is typically effective
in removing deposits.
Figure 6: Vortex Lens Body Assembly Details
Assembling the Lens Body
The Flame Scanner lens body Assembly, shown in Figure 6, is assembled in the
following manner:
• Slide the spring over the Fiber Optic cable, then thread the Jam Nut
approximately 3/4 down the end of the Fiber Optic Cable, sliding the Star
Washer and Flat Washer on after.
• Screw the Fiber Optic Cable into the focusing lens assembly; bottom out
the Fiber Optic Cable to the Focusing Lens.
• Lock the cable to the focusing lens assembly with the jam nut and
optional lock washer. Care should be taken not to twist the Fiber Optic
Cable excessively during this assembly as the fibers could be damaged.
• Assemble the Vortex Body Assembly to the Plug, Secure with three
Socket Head Cap Screws. Use anti-seize compound on threads at
assembly.
Lens Cleaning, Line of Sight (LOS) Head

• Verify removal of the scanner head assembly from the guidepipe without
impacting unit operations or plant safety.
• Remove the Flame Scanner Head. The lens will not be accessible at the
end of the scanner head.
• Clean the lens. Various fuels cause different types of deposits.
Isopropyl alcohol is typically effective in removing deposits.

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• If the lens is scratched or pitted, it can be replaced by carefully prying out

the truarc ring. Always use a new o-ring and truarc ring when replacing
the lens.
• Replace the scanner head onto the guide pipe.
Inspecting the Fiber Optic Cable

• Remove the scanner head and fiber optic extension as described above.
• Shine a flashlight into the focusing lens in the lens body.
• Observe the light pattern at the scanner end of the fiber optic extension.
If there is a significant number of dark spots (representing 15% or more
of the fibers) the fiber optic cable should be replaced.
Replacing the Fiber optic Cable

• Remove the scanner head and fiber optic extension as described above.
• Disassemble the lens body as described above.
• Rock the plastic light guide to one side to detach it from the spool piece.
• Pull the fiber optic cable from the spool piece.
• Loosen the two setscrews, and unscrew the plastic light guide from the
fiber optic cable.
• Remove the spring from the fiber optic cable.
• Place the spring on the end of the new fiber optic cable.
• Screw the plastic light guide onto the new fiber optic cable. The light
guide should be threaded on until the end of the fiber optic cable is flush
with the recess in the light guide. Tighten the two setscrews.
• Feed the opposite end of the new fiber optic cable into the spool piece
and out the flex hose. Leave any excess cable extending out of the
spool piece.
• Reassemble the lens body.
• Push the excess fiber optic cable into the spool piece.
• Span the light guide onto the spool piece.
• Reinstall the fiber optic extension into the guide pipe.
• Reinstall the scanner head.

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CUSTOMER SERVICE CONTACTS

For questions regarding the Flame Scanner or to obtain replacements, spare
parts (see Table E, F, and G below), repair service or for warranty issues for any
of the components described within this Manual, please contact the appropriate
Customer Service Representative noted below.
IN USA
Alstom Power Inc.
2000 Day Hill Road
Windsor, CT 06095
(866) 257-8664
E-Mail: windsorparts@power.alstom.com
IN CANADA:
Alstom Power Canada
1430 Blair Place
Ottawa, ON K1J 9N2
CANADA
(613) 747-5779
E-Mail: canadianaftermarketparts@power.alstom.com

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RECOMMENDED SPARE PARTS (RSP) AND SPECIAL TOOLS LISTS

The following tables list spare parts which are recommended for both essential
spares and commissioning / start-up spares. Housing and the associated
electronics are sold in three configurations, Visible Light (VL), Broad Range (BR)
and Ultraviolet. The application of these parts may require a Fiber Optic Cable
(FOC) or Line of Sight (LOS) Lenses.
Table E: RSP List, Scanner Head (VL - Visible Light, BR – Broad Range) LOS –
Standard Viewing Angle
Item Description Part No. Qty Commissioning 1-4 5-16 17-24 25-
No. * Spares Per Above
Unit
1A Flame Scanner Head (VL) ESH-700-VL-LS 1 1 1 2 2 3
1B Flame Scanner Head (BR) ESH-700-BR-LS 1 1 1 2 2 3
2 Connector Assembly C36-92130 1 0 0 1 2 4
3 Connector Gasket EPSA-0003 1 0 0 1 2 4
4 Spring Pull Pin V00-4211 1 0 0 1 1 2
5 Locking Pull Pin V00-4212 1 0 0 1 1 2
6S Quartz Lens (Standard) EPSB-0071 1 0 0 1 2 4
7 O-Ring Gasket V00-4218 1 0 0 1 1 2
8 Lens Retaining Ring V00-4214 1 0 0 1 1 2
* Refer to Figure 7.
Table F: RSP List, Scanner Head (VL - Visible Light, BR – Broad Range, UV –
Ultraviolet, UVH – Ultraviolet High-Gain) LOS – Wide Viewing Angle
Item Description Part No. Qty Commissioning 1-4 5-16 17-24 25-
No. * Spares Per Above
Unit
1C Flame Scanner Head (VL) ESH-700-VL-LS-W 1 1 1 2 2 3
1D Flame Scanner Head (BR) ESH-700-BR-LS-W 1 1 1 2 2 3
1E Flame Scanner Head (UV) ESH-700-UV-LS-W 1 1 1 2 2 3
Flame Scanner Head
1F ESH-700-UVH-LS-W 1 1 1 2 2 3
(UVH)
4 Spring Pull Pin V00-4211 1 0 0 1 1 2
6W Quartz Lens (Wide Angle) EPSC-0107 1 0 0 1 1 2
7 O-Ring Gasket V00-4218 1 0 0 1 1 2
8 Lens Retaining Ring V00-4214 1 0 0 1 1 2

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Figure 7: Scanner Head (LOS) Parts

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Table G: RSP List, Flame Scanner Assembly (VL - Visible Light, BR - Broad Range), 110”
or 130” Fiber Optic Cable with Vortex Lens Body
Commissioning 25-
Item Description Part No. Qty Spares Per 1-4 5-16 17-24 Above
No. * Unit
1A Flame Scanner Head (VL) ESH-700-VL-FO 1 1 1 2 2 3
1B Flame Scanner Head (BR) ESH-700-BR-FO 1 1 1 2 2 3
2A Exacta Shaft & Cover EPSD-0363-110 1 1 0 1 1 2
Assembly, 110” FOC
2B Exacta Shaft & Cover EPSD-0363-130 1 1 0 1 1 2
Assembly 130” FOC
3 Light Guide EPSB-0100 1 0 1 2 2 3
4A Fiber Optic Cable 110” Long FS-FC-110 1 1 0 1 2 4
4B Fiber Optic Cable 130” Long FS-FC-130
5A Vortex Body Assembly 3 Deg EPSD-0400 1 1 0 0 0 0
(consists of items 6 through 12
below)
5B Vortex Body Assembly 9 Deg EPSD-0404 1 1 0 0 0 0
below)
5C Vortex Body Assembly 18 Deg EPSD-0405 1 1 0 0 0 0
below)
6A Lens Barrel 3 Deg EPSD-0401 1 0 0 1 2 3
6B Lens Barrel 9 Deg EPSD-0402 1 0 0 1 2 3
6C Lens Barrel 18 Deg EPSD-0403 1 0 0 1 2 3
7 Vortex Body EPSD-0420 1 0 0 1 2 3
8 NPT Adapter EPSC-0082 1 0 0 0 0 1
9 Socket Head Cap Screw V00-4236 1 0 3 6 12 24
10 Spring EPSB-0118 1 0 0 1 2 3
11 Star Washer V00-4235 1 0 0 1 2 3
12 Hex Nut V00-4237 1 0 0 1 2 3
13 Washer V00-5050 1 0 0 1 2 3
16 Spring Pull Pin V00-4211 1 0 0 1 1 2
Note: Select 1A for Visible Light (VL) Applications
Select 1B for Broad Range (BR) Applications
Select 2A for 110” fiber optic cable designs
Select 2B for 130” fiber optic cable designs
When ordering a complete assembly as a spare it is important to have the length dimension (L=xx.xx).
Refer to drawing D-EPSD-0382 below when ordering a replacement fiber optic scanner assembly.

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Figure 8: Flame Scanner Assembly Parts (VL/BR) – 110” or 130”

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Table H: RSP List, Flame Scanner Assembly (UV – Ultraviolet or UVH – Ultraviolet High-
Gain), 110” or 130” Fiber Optic Cable with Vortex Lens Body
Commissioning 25-
Item Description Part No. Qty Spares Per Unit 1-4 5-16 17-24 Above
No. *
1A Flame Scanner Head (UV) ESH-700-UV-FO 1 1 1 2 2 3
1B Flame Scanner Head (UVH) ESH-700-UVH-FO 1 1 1 2 2 3
Exacta Shaft & Cover
2A Assembly, 110” FOC Quartz EPSD-0363-110-Q 1 1 0 1 1 2
Cable
Exacta Shaft & Cover
2B Assembly, 130” FOC Quartz EPSD-0363-130-Q 1 1 0 1 1 2
Cable
3 Light Guide EPSB-0100 1 0 1 2 2 3
4A Fiber Optic Cable 110” EPSB-0110-110 1 1 0 1 2 4
4B Fiber Optic Cable 130” EPSB-0110-130 1 1 0 1 2 4
Vortex Body Assembly 12 Deg
5A (consists of items 6 through 12 EPSD-0415 1 1 0 0 0 0
below)
5B (consists of items 6 through 12 EPSD-0416 1 1 0 0 0 0
below)
Vortex Body Assembly 6.5 Deg
5C (consists of items 6 through 12 EPSD-0417 1 1 0 0 0 0
below)
5D (consists of items 6 through 12 EPSD-0418 1 1 0 0 0 0
below)
6A Lens Barrel 12 Deg EPSD-0406 1 0 0 1 2 3
6B Lens Barrel 9 Deg EPSD-0407 1 0 0 1 2 3
6C Lens Barrel 6.5 Deg EPSD-0413 1 0 0 1 2 3
6D Lens Barrel 3 Deg EPSD-0414 1 0 0 1 2 3
7 Vortex Body EPSD-0420 1 0 0 1 2 3
8 NPT Adapter EPSC-0082 1 0 0 0 0 1
9 Socket Head Cap Screw V00-4236 1 0 3 6 12 24
10 Spring EPSB-0118 1 0 0 1 2 3
11 Star Washer V00-4235 1 0 0 1 2 3
12 Hex Nut V00-4237 1 0 0 1 2 3
13 Washer V00-5050 1 0 0 1 2 3
16 Spring Pull Pin V00-4211 1 0 0 1 1 2
Note: Select 1A for Ultraviolet (UV) Applications
Select 1B for Ultraviolet High-Gain (UVH) Applications
Select 2A for 110” quartz fiber optic cable designs
Select 2B for 130” quartz fiber optic cable designs
When ordering a complete assembly as a spare it is important to have the length dimension (L=xx.xx).
Refer to drawing D-EPSD-0445 below when ordering a replacement fiber optic scanner assembly.

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Figure 9: Flame Scanner Assembly Parts (UV and UVH) – 110” or 130”

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Table I: Accessory Parts
Commissioning 25-
No. Unit
1 Connector Adapter Cable EF-CA-10 1 1 1 2 2 3
10 Ft
1A Connector Adapter Cable EF-CA-25 1 1 1 2 2 3
25 Ft
1B Connector Adapter Cable EF-CA-50 1 1 1 2 2 3
50 Ft
1C Connector Adapter Cable EF-CA-100 1 1 1 2 2 2
100 Ft
Table J: Special Tools
Commissioning 25-
No. Unit
1 External Retaining Ring EPSB-0107-02 1 1 1 1 2 2
Set Tool
Refer to Figure 10.

Fiber optic cable assemblies require a 0.050 hex key to service the light guide.
Figure 10: Special Tools

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GENERAL SPECIFICATIONS
Scanner Head
Temperature Rating 14 to 185 Degrees F (-10 to 85 Degrees C)

Sealing Wash down waterproof
Cooling Air 30 SCFM. Pressure should be adequate to
Requirements for overcome furnace or windbox pressure. Generally
FO Heads 5-6” WC above furnace or windbox pressure will
generate approximately 30 SCFM of flow. Cooling
Air temperature shall be a maximum of 120 deg F
(49 deg C).
Cooling Air 10 SCFM. Use Alstom engineered orifice to
Requirements for generate 10 SCFM of flow with supply pressure
LOS Head with range of 80 to 120 PSI.
Compressed air systems
Power Supplied by Flame Signal Analyzer
Overall Dimensions 5.7” (145mm) L x 2.4” (61mm) W x 4.4” (112mm) H
Flame Signal Analyzer
Temperature 14 to 160 Degrees F (-10 to 70 Degrees C)

Rating
Power 21.5 - 26Volts DC(+/- 10% Maximum Ripple), 12W
Mounting 35mm DIN Rail, vertical mount with end stops
Overall 6.18” (157mm) Lx 3.38 ”(86mm) W x 2.28” (58mm) H
Dimensions

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APPENDIX I – FLAME SCANNER SYSTEM SELECTION SHEET

abcd Power Inc. - Boiler and Environmental Plant Services
Flame Scanner Selection / Specification Sheet
Customer: Plant Contact:
Location: Title:
Station: Tel:
Unit No.:
OEM:
Original Contract No.: PSS Contract No.:
Plant Type: Unit Rating:
Unit Type: No. Of Corners:
Main Fuel: Main Fuel Elevations:

Aux/Support Fuels: Aux/Support Fuel
Elevations:
Ignitor Type: Ignitor Fuel:
Number of Elevations: Scanner Application:
Scanner Model: NIM Model:

No. Of Scanner's: No. Of NIM Modules
Scanner Firmware Version No.: NIM Firmware Version No.:
Scanner Hardware Version No.: NIM Hardware Version No.:
PC Interface Software Version No.
Scanner Power Supply:

BMS Interface: (Scanner Head Contacts, NIM
Contacts)
DCS Interface: (MODBUS Connection,
DeviceNet Connection, 4-20mA)
Drawings Critical Dimensions

Flame Scanner Assembly- Tilting
Fabrication:
Flame Scanner Assembly- Guide Pipe Length:
Customer:
Make-up Nipple Length (If
Retrofit):
Scanner Head Wiring: Fiber Optic Length:
Scanner / NIM Interconnection Flexible Metal Hose
Wiring Dwg: Length:
Rigid Pipe Length:
Junction Box-Mechanical:
Junction Box-Electrical: Line of Sight
Rigid Nipple Length:
IM Cabinet-Mechanical: Nipple Material:
IM Cabinet-Electrical:
Selection By: Date:

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APPENDIX II – EXACTA FLAME SCANNER REMOTE HEAD
Figure 11: Exacta Flame Scanner Remote Head Assembly
Figure 12: Exacta Flame Scanner Remote Head Assembly for Ignitor Applications

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The Exacta Scanner Head assembly is offered in a Remote Head configuration

that can be installed on 3” Bluff Body Oil or Gas Ignitors. The Remote Head
Assembly can be easily mounted on existing Bluff Body Ignitors by removing the
Ignitor Flame Rod and putting a Fiber Optic Cable Assembly in its place.
The Ignitor Flame Light is propagated through the Fiber Optic cable and in turn
converted to an electrical signal that is sent to the Flame Signal Analyzer (FSA)
via a 2-0mA current loop. This signal is in turn evaluated using the same
characteristics outlined in this manual (i.e. Flame Intensity, Flicker Frequency,
and in certain cases AC amplitude).
Mechanical Components
Figure 13: Exacta Flame Scanner Remote Head Components
Item Description
1 EXACTA REMOTE HEAD ASSY
2 EXACTA CONNECTOR ADAPTER CABLE ASSEMBLY
3 1/2" FLEX CONDUIT
4 1/2" STRAIGHT CONDUIT CONNECTOR
5 PIPE IGNITOR ADAPTER FOR REMOTE HEAD
6 FIBER OPTIC CABLE

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For the complete Exacta Flame Scanner Remote Head Components Identification, refer to Drawing No.
D-EPSD-0481. The drawing includes Assembly Part Numbers along with a complete list of the Product
structure options associated with this particular Exacta Assembly configuration.
For Installation Instructions, refer to Drawing No. D-EPSD-0484
Exacta Remote Head Assembly Instructions
1.) Disconnect wire trains and fuel supply. Remove Pipe Ignitor and unthread IFM rod at furnace
end. For Gas Ignitors, save IFM rod and ceramics as spare parts for spark rod and ceramics.
2.) Remove Spark/IFM Connector & Wire Train Assembly including Ceramic. Rod Sheath (IFM
guide tube) is left in place.
Figure 14: Exacta Flame Scanner Remote Head Assembly Instructions (1 of 5)
3.) Insert Pipe Nipple & Kamlock Coupling threading Kamlock to a rotation angle that allows full
motion and access to Kamlock levers.

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4.) Remove 1/2" Flex Conduit (i.e FO Cable fits inside Conduit for Final Assy), and Insert Fiber Optic
Cable down IFM Guide Tube until Cable stops in Bluff Body.

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5.) Cut Flex Conduit to desired length so as to cover exposed length of FO Cable.
6.) Remove entire Remote Head Assembly from Bluff Body Ignitor, Re-assemble Modified/Cut Flex
Conduit & re-attach to Remote Head Assembly. Place Entire Assembly back into the Ignitor.

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7.) Once Remote Head Assembly is in place, prior to fully inserting the FOC Guide Sleeve into the
Kamlock tighten Set Screw (until fiber optic cable is secure, using caution to prevent collapsing of
jacket armor) to allow 0.5 to 0.75” FOC compression. Clamp FOC Guide Sleeve into Kamlock.

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RECOMMENDED SPARE PARTS LIST
Item Commissioning 25-

Description Part No. Qty Spares Per Unit 1-4 5-16 17-24
No. Above
1A Exacta Visible Light (VL) Remote Head Assy EPSD-0467-VL

1B Exacta Broad Range (BR) Remote Head Assy EPSD-0467-BR
1 1 1 2 2 3
1C Exacta Ultra-Violet (UV) Remote Head Assy EPSD-0467-UV
1D Exacta Ultra-Violet (UVH) Remote Head Assy EPSD-0467-UVH
2A 110" Fiber Optic Cable C10-94501

2B 130" Fiber Optic Cable C10-94502
2C 30' Fiber Optic Cable C10-94503 1 1 1 2 2 3
2D 110" Quartz for UV EPSB-110 (Gas Only)
2E 120" Quartz for UV EPSB-130 (Gas Only)
3A Sealtite Conduit 94" V00-5553-94

3B Sealtite Conduit 112" V00-5553-112 1 0 0 1 1 2
3C Sealtite Conduit 342" V00-5553-342
4A Exacta Connector Pigtail – 10 FT Long EF-CA-10

4B Exacta Connector Pigtail – 25 FT Long EF-CA-25
1 0 0 1 1 2
4C Exacta Connector Pigtail – 50 FT Long EF-CA-50
4D Exacta Connector Pigtail – 100 FT Long EF-CA-100
5 FOC Guide Sleeve EPSC-0146 1 0 0 1 1 2
6 Screw Set #1/4 - 20 x .50 LG V00-5555 1 0 0 1 1 2
7 Coupling 1/2 NPT Kamlock V00-5551 1 0 0 1 1 2
8 1/2" Straight Conduit Connector V00-5552 2 0 0 2 2 4
9A 1/2" PIPE NIPPLE x 4.00" LG (GAS) MD8-00131-FD

1 0 0 1 1 2
9B 1/2" PIPE MODIFIED NIPPLE 4.00" LG (OIL) EPSB-0140
10 Exacta Flame Signal Analyzer EPSD-0375 1 1 0 1 1 2

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Figure 15: Recommended spare parts list

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APPENDIX III – EXPLOSIVE ATMOSPHERE APPLICATION
Explosive Atmosphere Label Information

Exacta scanner heads with the following label information (Figure 16) are
certified as intrinsically safe for use in an explosive atmosphere when
they are wired in accordance with drawing DEPSD- 0536 Exacta
Intrinsically Safe Terminal Barrier External Connection Diagram (for
ESH-700 model heads) using the Intrinsically Safe Terminal Barrier
Assembly (D-EPSD-0545) to isolate the scanner heads from the signal
analyzers.
Figure 16: Sample ATEX label
The Exacta Scanner Head (ESH-700) has been ATEX certified for use in
explosive gas and dust atmospheres. The following scanner models
share this rating information:
• ESH-700-BR-FO
• ESH-700-BR-LS
• ESH-700-BR-LS-W
• ESH-700-UV-FO

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• ESH-700-UV-LS-W
• ESH-700-VL-FO
• ESH-700-VL-LS
• ESH-700-VL-LS-W
• ESH-700-UVH-FO
• ESH-700-UVH-LS-W
Labels for the Exacta heads that are approved for explosive
environments contain the following information:
• Manufacturer Address:
ALSTOM Power, Inc. 200 Great Pond Drive, P.O. Box 500, Windsor,
CT, 06095
• Flame Scanner Model Number
• Input Voltage (Ui), Current (Ii), and Power (Pi)
• Explosion Protection Marking
o ATEX II 1 G Ex ia IIC T5 -10ºC ≤ Ta ≤ +85ºC
o ATEX II 2 D Ex iaD 21 T100ºC
• TÜV ATEX certificate number: XXXXX
• CE Mark
• CSA Mark
Intrinsic Safety Certification Standards
Exacta scanner heads that are ATEX approved as intrinsically safe have
examination certificates issued by TÜV and are compliant with the
following standards:
• IEC EN 60079-0 – Electrical apparatus for explosive gas
atmospheres (Ex ia)
• IEC EN 60079-11 – Equipment protection by intrinsic safety “i” (Ex
ia)
• IEC EN 61241-0 – Electrical apparatus for use in the presence of
combustible dust (Ex iaD)
• IEC EN 61241-11 – Equipment protection by intrinsic safety “iD” (Ex
iaD)
Entity Parameters
+15 V circuit:
Connector J1: Pin 1 to pin 4
Ui = +22.0 V
Ii = 150 mA
Ci = 0,057 μF
Li = negligible
-15V circuit:
Ui = -22.0 V
Ii = 150 mA
Ci = 0,138 μF
Li = negligible
Signal circuit:
Ui = 9.56 V

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Ii = 195 mA
Ci = negligible
Li = negligible
Approved Class Ratings
a. Device Group
The Exacta scanner heads belong to Equipment Group II, which is
suitable for non-mining (above ground) applications.
b. Device Category / Atmosphere

The Exacta scanner heads are ATEX category 1 compliant for gas (G)
and category 2 for dust (D)
ATEX Zone
Equipment Gas & Definition of Zone
Dust
Category Vapors
1 0 20 Explosive atmospheres are present continuously, for long
periods or frequently.
2 1 21 Explosive atmospheres are likely to occur under normal
operation, occasionally.
3 2 22 Explosive atmospheres may occur under abnormal
operation and persist for a short period only
c. Protection Type
The scanner heads are rated for Explosion Protection (Ex) by means of
Intrinsic Safety (ia). Devices that are rated to be intrinsically safe do not

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require an explosion-proof enclosure because they do not contain

enough energy to cause ignition.
d. Equipment Group
The scanner heads are suitable for use in a IIC (most hazardous)
equipment group.
Gas Group Hazard Category Ignition Energy

Ethane IIA >180μJoules
Ethylene IIB >60μJoules
Hydrogen IIC >20μJoules
e. Temperature Class and Ambient Temperature Range

The temperature class of the Exacta scanner head is depending on the
surrounding ambient temperature.
Temperature Maximum Surface Maximum Surface Operating

Class Temperature Temperature (Dust) Temperature Range
T5 100ºC T95ºC -10ºC to 85ºC
Special Conditions for Safe Use

• The flame scanner head has to be mounted in a way, that sparking
from friction or impact will not occur.
• The power has to be provided by IS barriers complying with the
defined input values.
• The installation has to be done according to IEC 60079-14.
Notes on the Safe Use of the ATEX approved Flame Scanner Head
The Alstom Exacta Flame Scanner Head was designed in accordance with the
technical and safety regulations of the EU when it is used for its intended
purpose.
The installation, commissioning, and operation of these scanner heads must be

performed by authorized and qualified personnel who have read and understand
the manual and will follow the instructions and drawings provided.

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Drawing 1: Exacta FSA Field Wiring Diagram, D-EPSD-0371

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Drawing 2: Exacta FSA Configuration, VL or BR FOC Variable Length, D-EPSD-0382

CONTRACT: EB0-007991 10/6/15
Drawing 3: Exacta FSA, LOS VL or BR Standard Lens, D-EPSD-0384

CONTRACT: EB0-007991 10/6/15
Drawing 4: Exacta FSA, LOS VL/BR/UV-Wide Lens, D-EPSD-0397

CONTRACT: EB0-007991 10/6/15
Drawing 5: Exacta FSA UV with Quartz FOC Variable Length, D-EPSD-0445

CONTRACT: EB0-007991 10/6/15
Drawing 6: Exacta Flame Scanner Remote Head Configuration, D-EPSD-0481

CONTRACT: EB0-007991 10/6/15
Drawing 7: Exacta Remote Head 3” Bluff Body Ignitor Installation, D-EPSD-0484

CONTRACT: EB0-007991 10/6/15
User Manual
Limelight™ Exacta Flame
Scanner PC Interface
POWER SERVICE
Table of Contents
EXACTA PC INTERFACE SOFTWARE ......................................................................................... 1
System Requirements.................................................................................................................. 1
Installation .................................................................................................................................... 1
BEFORE RUNNING THE SOFTWARE .......................................................................................... 2
Modifying the Config Port Address .............................................................................................. 2
RUNNING THE PROGRAM FOR THE FIRST TIME ...................................................................... 3
Initializing the Network ................................................................................................................. 5
BASIC OPERATION........................................................................................................................ 6
Head Status ................................................................................................................................. 6
Reading Parameters .................................................................................................................... 6
Writing Parameters ...................................................................................................................... 7
Applying Parameter Changes ...................................................................................................... 8
Saving Parameters to a File......................................................................................................... 8
Load FSA parameters................................................................................................................ 11
Calibrating 4-20ma Outputs ....................................................................................................... 12
Displaying Scanner Data ........................................................................................................... 13
Logging Scanner Data ............................................................................................................... 15
Event Triggered Data Logging ................................................................................................... 16
SIMULATION MODE..................................................................................................................... 20
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to ii
third parties without express authority is strictly forbidden.
© ALSTOM Power Inc. 2009
Table of Figures
Figure 1: Password Dialog .............................................................................................................. 3

Figure 2: RS485 Wiring Diagram..................................................................................................... 3
Figure 3: Daisy-Chain of FSA's ....................................................................................................... 4
Figure 4: Windows Device Manager................................................................................................ 4
Figure 5: Tools Menu - Options ....................................................................................................... 5
Figure 6: Options Window ............................................................................................................... 5
Figure 7: PC Interface Showing Flame Proven ............................................................................... 6
Figure 8: Head "CH 1" Marginal Flame and "CH 2" Fault ............................................................... 6
Figure 9: Active Module List ............................................................................................................ 6
Figure 10: Configuration Tabs ......................................................................................................... 7
Figure 11: Text Box Input Field ....................................................................................................... 7
Figure 12: Pull-Down Input Field ..................................................................................................... 7
Figure 13: Modified Parameter not yet applied ............................................................................... 8
Figure 14: Globally applied parameter ............................................................................................ 8
Figure 15: Apply Buttons ................................................................................................................. 8
Figure 16: File Menu – Save One FSA ........................................................................................... 9
Figure 17: Save As Dialog Box........................................................................................................ 9
Figure 18: File Menu – Save All FSA’s.......................................................................................... 10
Figure 19: File Menu – Load FSA Params .................................................................................... 11
Figure 20: Open Configuration Dialog........................................................................................... 11
Figure 21: Tools Menu – Calibrate 4-20ma Outputs ..................................................................... 12
Figure 22: Calibration Window ...................................................................................................... 12
Figure 23: View Menu – Current Values ....................................................................................... 13
Figure 24: Current Values Display Screen .................................................................................... 13
Figure 25: Current Values Screen Showing Data ......................................................................... 14
Figure 26: File Menu – Log All Data .............................................................................................. 15
Figure 27: Save As Dialog Box...................................................................................................... 15
Figure 28: Data Logging in Progress............................................................................................. 16
Figure 29: File Menu – Event Triggered Log................................................................................. 16
Figure 30: Save As Dialog Box...................................................................................................... 17
Figure 31: Event Logging Data window......................................................................................... 17
Figure 32: Waiting for Trigger window........................................................................................... 18
Figure 33: Event Log Triggered Data window ............................................................................... 18
Figure 34: Logging Complete window ........................................................................................... 19
Figure 35: Tools Menu – Log Out.................................................................................................. 20
Figure 36: Tools Menu – Log In..................................................................................................... 20
Figure 37: Sim Control Window..................................................................................................... 20
Figure 38: Active Modules Showing Flame Proven....................................................................... 21
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to iii
EXACTA PC INTERFACE SOFTWARE
The Exacta PC Interface software allows for remote configuration of the Flame Signal Analyzer.
The following sections should provide assistance in using the software and some minor
troubleshooting.
System Requirements
The Exacta PC Interface requires a PC with a minimum of a 500MHz processor, 128Mb of RAM,
10Mb of disk space for installation, and running Windows 2000 or Windows XP Professional.
Installation
To install the Exacta PC Interface software, navigate to the folder where the Exacta PC
Interface.msi installer file exists.
Steps:
1. Double-Click the installer icon. A window will appear for the setup wizard.
2. Click the “Next >” button to continue
3. The Installation Folder window allows the user to change the installation folder location
from the default “C:\Program Files\Alstom Power\Exacta PC Interface\” as well as to set
up users that can run the software
5. The Confirm Installation screen is the last chance to go back and make changes before
the software is installed.
7. A progress bar will appear showing the progress of the installation. A successful
installation will show the Installation Complete screen.
8. Press “Close” to finish
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to 1
Before Running the Software
Before the Exacta PC Interface software is able to communicate with the Flame Scanner
modules, the modules must be connected to the computer running the PC Interface software by
means of an RS485 connection and each Flame Scanner module must have a unique Config
Port Address.
The only parameter that the PC Interface software cannot configure remotely is the Config Port
Address. This parameter is the identifier for each Flame Scanner Module. Setting available
Flame Scanner Modules port addresses to be in sequence will speed up the Initialize Network
process.
Modifying the Config Port Address

1. Enter the configuration mode on the Flame Scanner Module
a. Press the “Program” (1) key
b. Enter the 5 character password using the number keys
2. Select the Edit Parameters option
3. Select Communication Parameters
4. Press the "Enter" key to allow modification to the address value
5. Use the arrow keys to change the value
6. Press the "Enter" key to set address at desired value
7. Press the "Program" button 3 times to exit from local configuration
Running the Program for the first time
The Exacta PC Interface can be launched by either double-clicking the desktop icon Exacta PC
Interface or navigating to the Start menu folder Start > Programs > Alstom > Exacta PC Interface.
Each time the program is run, a dialog box opens asking for the password (Figure 1). Initially,
there are only two passwords. Entering no password or an incorrect password will run the
software in read-only mode where no values can be changed.
Figure 1: Password Dialog
• “Exacta” – this password allows the user to change configurable values and upload them
to the flame signal analyzer.
• “simulate” – this password starts the software in simulation mode where the software
operates as if two FSA’s are connected and there is flame signal that is read (see the
section on “Simulation Mode”).
There are some settings that need to be configured before you can start communicating with your
Flame Signal Analyzers.
First, ensure that you are properly connected to the configuration port on TB4 of the FSA
(reference drawing D-EPSD-0371 Exacta Flame Scanner Field Wiring Diagram) and that your
RS485 connection is wired appropriately (Figure 2).
Figure 2: RS485 Wiring Diagram
If you are wiring to multiple FSA’s, ensure that you have correctly wired your devices in a daisy-
chain (Figure 3).
Figure 3: Daisy-Chain of FSA's
Once devices are connected, the appropriate Windows COM port needs to be selected for
communications. This is done by first checking the Windows device manager to find what COM
port was assigned for the RS485 adapter (this should be the same port as the serial port if a
serial RS232 to RS485 adapter is used and a new number if a USB to RS485 adapter is used)
(Figure 4).
COM Port for

USB to RS485
Figure 4: Windows Device Manager
Initializing the Network
Once the Flame Scanner Modules have been connected to the computer running the
configuration software. The software needs to be configured to use the appropriate port to
communicate with the devices. The communications port is set using the tools pull-down menu
(Figure 5).
Figure 5: Tools Menu - Options

When the options window opens, the appropriate communications (COM) port can be selected
from the drop-down of active COM ports. The port address search range should also be set to
reflect the port addresses of the attached Flame Scanner Modules. This is the port found in the
Windows device manager (Figure 6).
Figure 6: Options Window

Once the communications port and port address ranges have been set. The software should
automatically send a request through the communications port to identify the attached Flame
Scanner Modules that are within the selected range. The PC Interface software will store this
information, so the above steps will not need to be repeated each time the software is run.
Basic Operation
Head Status
The PC Interface software is constantly polling the Flame Signal Analyzers to find and report their
status. The software will show conditions of flame proven, marginal flame, and a fault with
different colors in the Active Module List. Flame proven has a red background and labels to show
the head that is proving and flame A or B depending on if discrimination mode is set (Figure 7).
Figure 7: PC Interface Showing Flame Proven

Marginal flames are displayed as a yellow background on the head identifier and faults are
displayed as a purple background (Figure 8).
Figure 8: Head "CH 1" Marginal Flame and "CH 2" Fault
Reading Parameters
The result of a successful network initialization is a populated tree control on the left side of the
application. That area of the application controls what detailed information is seen for one device.
Clicking on a 'FSA-n' node results in two consecutive actions; reading all 'setting related'
information, for the device indicated, and then, using the read information, populating it as new
information appearing on the right side.
The information in the parameters section of the software is separated into eleven groups
represented with an individual tab. The user clicks on the tabs to see the parameter information.
Here is the above restated as a series of steps:
1. Determine the FSA node of interest

2. Click on that “FSA-n” in the Active Module list (Figure 9)
Figure 9: Active Module List

3. Observe the data that has populated the twelve (12) tabs and the FSA status bar reads
"FSA-n Communication Parameters." (Figure 10)
Figure 10: Configuration Tabs

The tabs available are as following:
• Communication
• Head 1 Common
• Head 2 Common
• Head 1 Set A Basic
• Head 1 Set B Basic
• Head 2 Set A Basic
• Head 2 Set B Basic
• Head 1 Set A Expert
• Head 1 Set B Expert
• Head 2 Set A Expert
• Head 2 Set B Expert
• 4-20ma
You can freely click the tabs to observe device settings for the FSA indicated.
Writing Parameters
There are two types of fields used for updating parameters values: pull-down menus (Figure 12),
and text boxes (Figure 11). The pull-down menus are for parameters that have limited or very
specific values. Text boxes are used for parameters that have a wide range of acceptable integer
inputs.
Figure 11: Text Box Input Field
Figure 12: Pull-Down Input Field

Many parameter values are related to other parameter values by a specific range. Changing the
driving of these values outside of the range will change the driven value to be equal. There are
also limits for changing the driven value. If values entered into a driven parameter are outside of
the range, the software will display a pop-up message indicating the problem with the value and
will change it to the extents of the range.
Parameter values and the tabs that contain them that have been modified, but not applied are
marked with a “*” (Figure 13).
Figure 13: Modified Parameter not yet applied

NOTE: Many parameters have the ability to be changed globally on all detected Flame Scanner
modules. These parameters are identified by a check box in the left column (Figure 14). Not all
values may be modified in a global way. Foremost among these are the head identifiers.
Figure 14: Globally applied parameter
Applying Parameter Changes

When all desired parameters have been changed, the updates are applied to the Flame Scanner
Module by clicking one of the apply buttons (Figure 15).
Figure 15: Apply Buttons

Apply Global: The "Apply Global" button will remain grayed-out until a "Global Update" check box
is checked. When the "Apply Global" button is clicked, all parameters with the "Global Update"
check box checked will be updated on all detected Flame Scanner Modules. Any modified
parameters that do not have a "Global Update" check box or the box is unchecked will be
ignored.
Apply Local: The "Apply Local" button will remain grayed-out until a parameter is modified. When
this button is clicked, if any parameters are selected for a "Global Update", the software will
present a dialog allowing the update locally or stopping the update so that it may be performed
globally.
Reload: Like the "Apply Local" button, the "Reload" button will remain grayed-out until a
parameter is modified. This button will clear all modified parameters that haven't been applied
and will replace them with the values from the Flame Scanner Module.
Saving Parameters to a File

It is often desired to back up files and settings for computers and equipment and the Exacta PC
Interface allows for the backup of FSA settings. This can be done for individual FSA’s as well as
for all recognized FSA’s in the program.
Save a single FSA's parameters:

1. Select the desired FSA in the network tree view in the left pane.
2. From the top menu select “File” and then “Save One FSA” (Figure 16)
Figure 16: File Menu – Save One FSA
A window will then pop up allowing the destination folder and filename to be selected (Figure 17).
Figure 17: Save As Dialog Box

Upon clicking “Save” the selected FSA’s configuration parameters will be written to a file.
Save all FSA’s parameters
1. From the top menu bar select “File” and then “Save All FSA’s” (Figure 18)
Figure 18: File Menu – Save All FSA’s

A window will pop up as above to allow selection of the destination folder and filename. It should
be noted that a separate file is created for each FSA in the network, and that the FSA’s
configuration address will be appended to the selected filename.
Load FSA parameters
Select the target FSA from the network tree in the left pane of the display. From the top menu
bar, select “File” and then “Load FSA Params” (Figure 19).
Figure 19: File Menu – Load FSA Params

A window will pop up to allow the file containing the parameters to be selected (Figure 20).
Figure 20: Open Configuration Dialog

Upon clicking Open the parameter values from the file will be loaded in to the parameter property
sheets in the configuration window. Once the parameter property sheets have their new values,
the “Apply Local” button can be used to upload the parameters to the selected FSA or the
“Reload” button can be used to discard the loaded values and return to the current values stored
in the FSA.
Calibrating 4-20ma Outputs
The 4-20ma analog outputs from the FSA are already factory calibrated, however, slight
variances in hardware and installation may require calibration to display desired values in the
DCS. The PC Interface software has the ability to adjust the calibration values. The calibration
screen is initiated through the tools menu after selecting the appropriate FSA in the active module
list (Figure 21).
Figure 21: Tools Menu – Calibrate 4-20ma Outputs

When the calibration window opens, the appropriate channel can be selected from the drop-down
of analog output channels. The counts / output current can be adjusted up or down and there are
test buttons for verifying the calibration (Figure 22).
Figure 22: Calibration Window
Displaying Scanner Data
From the top menu bar select “View”, and then select “Current Values” from the drop down list
(Figure 23).
Figure 23: View Menu – Current Values

This will cause the right side pane to display the following screen (Figure 24).
Figure 24: Current Values Display Screen

To display values to plot in the displayed graph, select the desired FSA from the network tree
displayed in the left side pane then select the checkbox next to the value(s) that you wish to
trend. The trend will be displayed in the color of the text next to the check box. You can also
show the pull in and drop out values for each value being trended. Pull in /drop out values are
shown as a dotted line the same color as the trend (Figure 25).
Figure 25: Current Values Screen Showing Data
Each trace on the trend window has its own scale. The full-scale value is shown beside the trend
window in a color matching the trace. You can change the scale of a trace by simply clicking on
the full-scale value, and entering a new number. If you enter a non-numeric value, the software
will resume auto-ranging the trace scale.
Thirty minutes of trend data is available. Data collection begins when the FSA is selected.
Three levels of zoom are available on the trend screen. The zoom level is selected from the drop
down box below the trend screen. At the highest zoom level 10 minutes of data is displayed in the
trend window. The full 30 minutes of trend data is available at this resolution. The 10-minute trend
window can be shifted back in time using the scroll bar under the trend window. Medium zoom
will show 20 minutes of data in the trend window, and low zoom will display the entire 30-minute
data set in the trend window.
By default, the latest value is shown to the left of the check box for each measured variable. If the
Min or Max radio button is selected, the minimum or maximum value, in the collected data, will be
displayed in place of the latest value.
If the reset button is pressed, the minimum and maximum values are reset, and will be calculated
only with data from that point foreword.
Pressing the stop button will stop the acquisition of new data, freezing the trend data set at the
current point in time.
After stopping the store button will be enabled. Pressing the store button will save the 30-minute
trend data for all variables to a comma-delimited file.
Logging Scanner Data
From the top menu bar, select “File” and then “Log All Data” (Figure 26).
Figure 26: File Menu – Log All Data

A pop up window will appear, allowing the destination file to be selected (Figure 27).

All measured variables from each FSA on the network will be saved. A separate comma delimited
file is created for each FSA. Upon clicking “Save” data logging will begin. The following window
will pop up to indicate that data logging is in progress (Figure 28).
Figure 28: Data Logging in Progress
Logging will continue until the “Stop” button is clicked.
Event Triggered Data Logging

Data can be stored centered on a change of state of the flame / fault relays. Using this feature, 6
minutes of data before the event, and 6 minutes of data after the event is written to a file for each
scanner in the network.
To start this data logging, select “File” and then “Event Triggered Log” from the top menu bar
(Figure 29).
Figure 29: File Menu – Event Triggered Log

A pop up window will appear allowing the destination folder and filename to be selected (Figure
30).
A separate file will be created for each FSA in the network. The configuration port address of the
FSA will be appended to the filename. Then, a pop up window will appear to allow the triggering
event to be defined (Figure 31).
Figure 31: Event Logging Data window

Select the desired trigger condition using the drop down boxes. Upon selecting start the software
will begin waiting for the trigger event, and the following message will appear (Figure 32).
Figure 32: Waiting for Trigger window
When the triggering even occurs the following message will be displayed (Figure 33).
Figure 33: Event Log Triggered Data window

When data collection is complete the following message will be displayed (Figure 34).
Figure 34: Logging Complete window
Simulation Mode
The Exacta PC Interface software also includes a simulation mode that can run as if it was
connected to an Exacta Flame Scanner system that is seeing an actual flame. The simulation
mode can be accessed by typing the password “simulate” on software startup or if the program is
already running, selecting “Log Out” from the Tools pull-down (Figure 35), then selecting “Log In”
from the same menu and entering “simulate” as the password (Figure 36).
Figure 35: Tools Menu – Log Out
Figure 36: Tools Menu – Log In

Once you are logged in to simulation mode, the first noticeable difference from the configuration
mode is the addition of the Sim Control window (Figure 37).
Figure 37: Sim Control Window

The Sim Control window gives the user the choice of simulating flame signal from two different
fuels: coal and oil. Clicking a fuel button starts that particular fuel simulation. The fuel
simulations can be activated independently or combined.
When the fuels are selected, the software will not only show the flame data in the Current Values
screen, but will show “flame proven” status by highlighting red the scanner head that is proving
flame in the active module list just like when connected to scanners that are seeing flame (Figure
38).
Figure 38: Active Modules Showing Flame Proven
The simulation mode of the Exacta PC Interface is a useful tool for learning the affect of set
points and flame proving with multiple fuels. All of the features of the PC Interface software are
available in the simulation mode, making it a valuable training tool.
TAB 5
Vendor-Supplied Equipment
TABLE OF CONTENTS
DESCRIPTION
Chentronics
Rapid Fire High Energy Ignition Exciter............................................................................................ 10SEP09
Maxon
Series 8000 Pneumatic Shut-off Valves ............................................................................50111985-001/A01
Rosemont
3051 Pressure Transmitter Product Data Sheet ................................................................. 00813-0100-4001
Rotork
LA-2400 Liner Actuators........................................................................................................ PUB045-003-00

CONTRACT: EB0-007991 17/6/15
OPERATIONS & MAINTENANCE MANUAL
Chentronics Corporation

Rapid‐Fire

High Energy Ignition Exciter

ITEM Part Number REV
Exciter Internals with Standard Base Plate 07000102-1 A
Exciter Internals with Compact Base Plate 07600102-1 A
Exciter Internals with Standard Base Plate and Diagnostics 07000102D-1 A
Exciter Internals with Compact Base Plate and Diagnostics 07600102D-1 A
Chentronics Spark Diagnostic Module 07002038 A

THIS EQUIPMENT IS SUITABLE FOR NON‐HAZARDOUS LOCATIONS ONLY
UNLESS EXCITER IS PLACED IN A RATED EXPLOSION PROOF ENCLOSURE

CHENTRONICS OPERATION & MAINTENANCE MANUAL Page 1 of 23

PO BOX 368, Norwich N.Y., U.S.A. www.chentronics.com 10SEP09
TEL: +1.607.334.5531 FAX: +1.607.336-.7447 EMAIL: info@chentronics.com
Table of Contents
TABLE OF CONTENTS .................................................................................................................................................................. 2
REVISIONS .......................................................................................................................................................................................... 3
SAFETY INFORMATION .......................................................................................................................................................................... 4
Area Certification ....................................................................................................................................................................... 4
Replacement of Components ..................................................................................................................................................... 4
Disconnection of Equipment ...................................................................................................................................................... 4
Branch Circuit Installation ......................................................................................................................................................... 4
Equipment Duty Cycle ................................................................................................................................................................ 4
EXCITER DESCRIPTION OF OPERATION ........................................................................................................................................ 5
EXCITER CONFIGURATION AND MODES OF OPERATION ................................................................................................................................. 6
Factory Default Mode: Immediate Excitation ........................................................................................................................... 6
External Control Mode A: Controlling with a Zero Voltage Contact: ......................................................................................... 6
External Control Mode B: Controlling with a 24VDC Supply. ..................................................................................................... 6
External Switch Control: ............................................................................................................................................................ 6
EXCITER OUTPUT INDICATORS ................................................................................................................................................................. 7
Main Power Indicator ................................................................................................................................................................ 7
Attempting to Fire Indicator ...................................................................................................................................................... 7
Spark Indicator (If equipped with Diagnostic Module ONLY) ..................................................................................................... 7
Fault Present Indicator (If equipped with Diagnostic Module ONLY) ......................................................................................... 7
Fault Last Run Indicator (If equipped with Diagnostic Module ONLY) ....................................................................................... 8
CONNECTIONS PN 07000102‐1 OR 07600102‐1 ................................................................................................................................... 9
CONNECTIONS FOR PN 07000102D‐1 OR PN 07600102D‐1 ................................................................................................................... 9
EQUIPMENT SPECIFICATIONS ................................................................................................................................................... 10
INPUT POWER CHARACTERISTICS ........................................................................................................................................................... 10
INSTALLATION INSTRUCTIONS .................................................................................................................................................. 11
SAFETY ............................................................................................................................................................................................ 11
MOUNTING ...................................................................................................................................................................................... 11
OUTPUT CONNECTIONS ....................................................................................................................................................................... 11
EXCITER QUICK CONNECTION TABLE ...................................................................................................................................................... 12
IGNITION CONNECTION DIAGRAM .......................................................................................................................................................... 13
SYSTEM MAINTENANCE ........................................................................................................................................................... 14
INSPECTION ...................................................................................................................................................................................... 14
CLEANING ........................................................................................................................................................................................ 15
REPAIR ............................................................................................................................................................................................ 16
SEMI‐CONDUCTOR IGNITER RESISTANCE MEASUREMENTS .......................................................................................................................... 17
DRAWINGS ............................................................................................................................................................................... 18
INTERNAL EXCITER, P/N 07000102D‐1, STANDARD BASE‐PLATE FOR SAFE AREA ENCLOSURE .......................................................................... 18
EXCITER WITH NEMA4 ENCLOSURE, PN 07000102D ............................................................................................................................. 19
INTERNAL EXCITER, P/N 07600102D‐1, STANDARD BASE‐PLATE FOR HAZARDOUS AREA ENCLOSURE ................................................................ 20
EXCITER WITH EEXD ENCLOSURE, PN 07600102D ................................................................................................................................. 21
DIAGNOSTIC MODULE QUICK CONNECTION TABLE .................................................................................................................................... 22
DIAGNOSTIC MODULE, P/N 07002038 ................................................................................................................................................ 23

Revisions

REV DESCRIPTION OF CHANGE PAGE DATE
A First Published Version 10SEP09


Safety Information

Area Certification
THIS EQUIPMENT IS SUITABLE FOR USE IN NON‐HAZARDOUS LOCATIONS ONLY UNLESS INSTALLED IN A
PROPERLY RATED EXPLOSION PROOF ENCLOSURE

Replacement of Components
WARNING – EXPLOSION HAZARD – DO NOT REPLACE IGNITER UNLESS POWER HAS BEEN SWITCHED
OFF.
AVERTISSEMENT – RISQUE D’EXPLOSION – COUPER LE COURANT AVANT DE REPLACEER L’ IGNITER

Disconnection of Equipment
WARNING – EXPLOSION HAZARD – DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN
SWITCHED OFF.
AVERTISSEMENT – RISQUE D’EXPLOSION – AVANT DE DÉCONNECTER L’EQUIPMENT, COUPER LE
COURANT

Branch Circuit Installation
WARNING – RAPIDFIRE EXCITER REQUIRES A CIRCUIT BREAKER ON POWER INPUT BRANCH. THE
EXCITER HAS AN ADDIONAL SAFETY FUSE RATED TO 10A IS INSTALLED.

Equipment Duty Cycle
WARNING – DO NOT OPERATE THE EXCITER OUTSIDE THE POWER ON / POWER OFF DUTY CYCLE.
THE MAXIMUM ALLOWABLE DUTY CYCLE AS FOUND ON THE EQUIPMENT MAIN NAMEPLATE IS:

2 MINUTES ON / 5 MINUTES OFF
CAN BE OPERATED A MAXIMUM OF 4 TIMES IN SUCCESSION (28 MIN).
ALLOW 60 MINUTES BEFORE REPEATING DUTY CYCLE.

NEVER REPEATEDLY APPLY AND REMOVE POWER OUTSIDE THIS DUTY CYCLE RANGE.

Diagnostic Indicator
The diagnostic feature IS NOT a safety feature, and WILL NOT PROVE SPARK OR FLAME. The
diagnostic is a convenience feature for early warning of igniter plug wear only. The diagnostic
feature is unable to determine if the pulse discharge occurs at the tip or inside the igniter shell.

Exciter Description of Operation
The High Energy Ignition Exciter operates without gas discharge tubes. Energy accumulates on storage
capacitor CSTG, as the exciter draws power from the input power line. The capacitor slowly accumulates
charge to a preset voltage during the interval between sparks. The capacitor charging circuit is a power
factor converter, PFC, which forces line current to approximate a sine wave in phase with the line voltage.
The resultant high power factor (>0.95) minimizes line current amplitude and line voltage distortion.
Additionally, the power factor converter provides galvanic isolation between the line and the discharge
circuit potentials. It operates over a wide input voltage range (100 to 240Vac, 50‐60 Hz).
When the capacitor has charged to a preset voltage, an electronic switch rapidly discharges the capacitor
through a pulse‐forming network into the igniter. Although the discharge current amplitude can vary from
several hundred to several thousand amperes (depending on the application), the life of the electronic
switch is not affected by the accumulation of these pulses.
The pulse‐forming network controls the amplitude and duration of the discharge current pulse to provide
characteristics, which enhance ignition and extend the life of the storage capacitor and igniter. While the
exciter output is typically 2000V, the pulse‐forming network can provide a 5000V‐trigger voltage as
needed.


Exciter Configuration and Modes of Operation

Factory Default Mode: Immediate Excitation
The RapidFire Exciter series factory default configuration has a jumper wire across the CLOSE TO
START terminals (terminals 3 and 4). With the CLOSE TO START terminals shorted with a jumper,
the RapidFire will energize and begin firing immediately when input power is applied. This allows
the user to control the exciter by turning the main power input on and off. If the enclosure has
been supplied with an external switch, then this jumper will be removed in the factory before
shipping.

External Control Mode A: Controlling with a Zero Voltage Contact:
By removing the jumper from the CLOSE TO START input (terminals 3 and 4) it is possible to
control the RapidFire using a Zero Voltage Contact across the CLOSE TO START input. This can be
done using either the contacts of a relay or a transistorized system. If a transistor system is used,
an NPN type must be used with terminal 3 being the ground reference. The ratings of the device
used to close pins 3 and 4 must be a min of 24VDC at 50mA.

External Control Mode B: Controlling with a 24VDC Supply.
By removing the jumper from the CLOSE TO START input (terminals 3 and 4) it is possible to
control the RapidFire using a 24VDC Supply across the +24V TO START input terminals 1 and 2.
24VDC can be applied in either polarity using a relay or transistorized system. Note that this
connection is made directly to the coil of a relay internal to the exciter with no other devices in
parallel or series with the coil. The load current of the coil is 20mA.

Only one external control scheme should be used at a time.
Do not use the +24V TO START and CLOSE TO START inputs at the same time.

External Switch Control:
If the RapidFire enclosure has been equipped with an external switch, then the exciter can be fired by
pressing the switch when the RapidFire has Mains power available. Note that the CLOSE TO START terminal
jumper must be removed to use the external switch; otherwise the exciter will begin to fire as soon as it
receives Mains power.


Exciter Output Indicators

Main Power Indicator

Whenever Mains power is supplied to the RapidFire, the green POWER light will come on,
indicating the unit has power and is ready to fire. Additionally, the exciter provides an external Zero
Voltage Contact signal on terminals 5 and 6 that can be used to send a “ready to fire” signal to
other equipment. This output labeled POWER IND (NO) is open when exciter does not have power
and short when exciter is powered up. If the RapidFire enclosure has been equipped with a lighted
switch, the switch will light up when Mains power is applied as an additional ready to fire indicator.
Attempting to Fire Indicator

Whenever the RapidFire is powered up and receives a run signal, the red FIRING light will come on
indicating the RapidFire is attempting to fire the igniter plug. The RapidFire can receive a run signal
in one of three ways:
1) The CLOSE TO START terminals are shorted by either a jumper or external Contact
2) The +24V TO START terminals are supplied with 24VDC
3) If equipped, the Fire button on the enclosure is pressed.

Spark Indicator (If equipped with Diagnostic Module ONLY)

When equipped with a Diagnostic Module, a Blue LED spark indicator is available. This indicator will
flash OFF whenever the RapidFire releases an energy pulse. If this indicator remains ON solid, it is
an indication that the igniter is worn and is ceasing to fire or there is a problem with the harness
leading to the igniter. Additionally, if the RapidFire enclosure is equipped with both a lighted switch
and a Diagnostic Module, the external lighted switch will flash OFF in the same manner.
Fault Present Indicator (If equipped with Diagnostic Module ONLY)

When equipped with a Diagnostic Module, a FAULT PRESENT indicator is provided on terminals 7
and 8 with a Zero Voltage Contact. This output is OPEN when a fault is present at ANY TIME (run
signal independent) and SHORT when the igniter is firing normally. Additionally there is a red
FAULT WHEN OFF light that mimics the condition of this output with the light OFF indicating a
FAULT. Note that the FAULT PRESENT and FAULT LAST RUN outputs share terminal number 8 as a
common terminal.


Fault Last Run Indicator (If equipped with Diagnostic Module ONLY)

When equipped with a Diagnostic Module, a latching FAULT LAST RUN indicator is provided on
terminals 8 and 9 with a Zero Voltage Contact. This output is maintained OPEN when a fault is
detected at ANYTIME DURING AND AFTER A RUN (when a run signal is applied and after it is
removed). This output is reset when new run signal is applied to the exciter or by cycling the exciter
main power. Additionally there is a red FAULT LAST RUN WHEN OFF light that mimics the
condition of this output with the light OFF indicating a FAULT LAST RUN. Note that the FAULT
PRESENT and FAULT LAST RUN outputs share terminal number 8 as a common terminal.
IMPORTANT NOTE: THE DIAGNOSTIC OUTPUTS ARE MASKED TO AN “OK” STATE FOR 3 SECONDS
EVERY TIME A NEW RUN SIGNAL IS APPLIED. THIS DELAY IS REQUIRED BY THE EXCITER TO COLLECT
DATA ON SPARK CONDITION AND PROCESS THE RESULTS.
*WARNING*

Connections PN 070001021 or 076001021
Terminals 1‐6 available accepting up to size 16AWG (1.3mm diameter) wire. Note that the
terminal block can be removed from the top board with wires attached for ease of installation
into a replacment exciter if neccesary.
Connections for PN 07000102D1 or PN 07600102D1
Terminals 1‐9 available accepting up to size 16AWG (1.3mm diameter) wire. Note that the
terminal block can be removed from the top board with wires attached for ease of installation
into a replacment exciter if neccesary.


Equipment Specifications
Mechanical: NEMA4 (IP56) enclosure
Box dimensions: 12" X 12" X 7" [305 X 305 X 178 mm]
Illuminated ON/OFF switch (rated NEMA4) available
Net Weight: 20 Lb. [9 kg]
Input Power: 85 ‐ 265 VAC / 50‐60 Hz / 5 Amps @ 100 V
Stored Energy: 12 Joules Minimum
Spark Rate: 20 Sparks per Second minimum
Temperature: ‐25C to 75C
Duty Cycle: 2 MINUTES ON, 5 MINUTES OFF (28%), OPERATED A MAXIMUM OF 4
TIMES IN SUCCESSION (28 MIN). ALLOW 60 MINUTES BEFORE
REPEATING DUTY CYCLE.
Input Power Characteristics
SUPPLY NORMAL OPERATING CURRENT NORMAL IN‐RUSH CURRENT
VRMS ARMS APEAK APEAK APEAK APEAK APEAK APEAK
OVER BEFORE AFTER FIRST SECOND THIRD FOURTH
SPARK SPARK SPARK CYCLE CYCLE CYCLE CYCLE
PERIOD
85 7.5 15 10 ‐ ‐ ‐ ‐
120 5 10 6.7 7.5 5.9 4.6 3.6
240 2.5 5 3.3 15 11.7 9.1 7.1

In‐rush current peaks can be less than operating peaks because In‐rush is completed before sparking begins.
In‐rush is defined as the initial peak current drawn by the input capacitor when power is first applied to the
exciter. A resistor that is in series with the capacitor during turn‐on and shorted out once the capacitors are
charged limits the current. Because the capacitor must be fully charged before the exciter is allowed to
operate, it is possible to limit the inrush current to less than the operating current. Limiting the current to a
lower value requires a longer time for the capacitors to charge and a longer time for the exciter to provide the
first spark. An interval of 0.5 seconds or less between “power on” and “first spark” is generally accepted.

As can be seen in the above table, in‐rush peaks for 120Vrms are less than the operating peaks. However, the
same in‐rush resistor at 240Vrms produces twice the in‐rush current peak (which is larger than the operating
current).

The input terminal can accept up to AWG #12 (4‐mm2) wire. Input power wiring should be as large as possible,
taking into consideration the normal operating current noted above.
The exciter has an internal 10AMP Fast Acting fuse with an interrupt capability of 10kA. The dimensions are
10mm X 38mm. The fuse is CE marked and complies with IEC 269‐2‐1.

Installation Instructions
Safety
WARNING – EXPLOSION HAZARD – DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN
SWITCHED OFF.
AVERTISSEMENT – RISQUE D’EXPLOSION – AVANT DE DÉCONNECTER L’EQUIPMENT, COUPER LE

COURANT
WARNING! Dangerous and potentially LETHAL voltages are present. READ DIRECTIONS BEFORE
PROCEEDING. DO NOT OPEN THE EXCITER ENCLOSURE for FIVE (5) MINUTES after operating the
exciter. This time is required to "bleed off" any high voltage residual charge left on the energy storage
capacitor.

Please follow the order of installation shown in this manual:
1. Mount Exciter
2. Exciter Output Wiring
3. Rod Termination
4. Input Wiring

*WARNING*
Mounting
For mounting dimensions, refer to drawing “Exciter Installation”. The exciter should be mounted to a
firm structure. It will function properly in either a vertical or horizontal position. The exciter has two
7/8" [22 mm] OD hole located on the side, one for Input Power the other for signal and control wires.
It is suitable for use with a hub and conduit. If the optional input power cord is not provided, complete
the input power connection as follows. Be sure to provide weatherproof connections.
WARNING – RAPIDFIRE EXCITER REQUIRES CIRCUIT BREAKER ON POWER INPUT BRANCH. NO
INTERNAL CIRCUIT BREAKERS ARE PROVIDED IN THE EQUIPMENT.
Output Connections
Attach the igniter to the rod. Please note that an anti‐seize compound is coated on the male threads of
the igniter at the factory to aid in maintenance removal. Attach the OUTPUT HARNESS to the rod.
Attach the OUTPUT HARNESS to the exciter.

Exciter Quick Connection Table
A hole positioned alongside the output connector for input power entrance. The Mains power input wires
should be AWG #14 minimum. Input power should be turned ‘OFF” at the source and
steps should be taken to ensure that it remains “OFF” before proceeding with the
input wiring. Be sure to provide weatherproof connections. Inside the exciter, connect the single‐
phase input power to the L1 (Line), N (L2 Neutral) and G (Ground) terminations.

INPUT TERM. TERMINAL DESCRIPTION
L1 Input power (HOT) wire, should be a minimum of 14AWG (600V).
L2 Input power (NEUTRAL) wire, should be a minimum of 14AWG (600V).
GND Input (GROUND) wire, should be a minimum of 14AWG (600V).

OUTPUT TERM. TERMINAL DESCRIPTION
HI Output, Igniter center wire, should be a minimum of 16AWG (2400V).
LO Output, Igniter shell return, should be a minimum of 16AWG (2400V).
Return wire must connect directly from this output to harness/igniter shell,
NOT to enclosure chassis. (ground return is to be through harness and not
though the building ground).

+24V START TERM. TERMINAL DESCRIPTION
1‐2 Input Start/Stop Control – Applying a 24VDC signal to these pins will
energize the exciter. Polarity is not important.

CLOSE TO START TERM TERMINAL DESCRIPTION
3 ‐4 Input Start/Stop Control – Applying a ZVC signal to these pins will
energize the exciter. WARNING! Do not connect to the +24V to Start
terminals and the Close to Start terminals at the same time.

LINE STATUS TERM. TERMINAL DESCRIPTION
5‐6 Provides a closed contact signal when has proper input voltage to operate.

FAULT STATUS TERM. TERMINAL DESCRIPTION
7‐ 8 Provides a closed contact signal spark rate is greater than 20SPS .
Provides an open contact signal spark rate is less than 20SPS .

FAULT LAST RUN TERM. TERMINAL DESCRIPTION
8 ‐ 9 Provides a latched open contact signal when a fault occurs during the
current run. Contacts will reset closed when a start signal is applied. Pin 8
is a shared in Common between “Fault status” and “Fault Latch status”.

Ignition Connection Diagram IGNITER TIP
The standard Igniter Tip length is 12” (305 mm). WEATHERPROOF
The Rod base section has a Military style twist connector
that allows connection with a gloved hand. Rod extension
pieces are also available for restricted access applications.
The harness is insulated conduit with two conductors.
BASE ROD
WEATHERPROOF
OUTPUT HARNESS
WEATHERPROOF
EXCITER
ENCLOSURE: NEMA4
75 C MAX
P/N 07000102(D)

System Maintenance
WARNING –DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF.
AVERTISSEMENT –AVANT DE DÉCONNECTER L’EQUIPMENT, COUPER LE COURANT

WARNING –DO NOT REPLACE IGNITER UNLESS POWER HAS BEEN SWITCHED OFF.
AVERTISSEMENT –COUPER LE COURANT AVANT DE REPLACEER L’ IGNITER
Inspection
EXCITER – Visually inspect the inside of the exciter enclosure for any debris such as loose screws or nuts
that would be indicative of damage. Check to ensure that the sub‐assembly is firmly mounted. Check
the electrical connections to ensure that they are secure.
CABLE – Check to ensure that the pins on the connectors are straight and intact. Check to ensure that
the connectors are secured to the cable hose. Using an ohmmeter, check the cable conductors to
ensure continuity and insulation integrity by making the measurements in the table below:
MEASUREMENT POINTS REQUIRED VALUE
Pin “A” to Pin “A” Less than one (1) ohm
Pin “B” to Pin “B” Less than one (1) ohm
Pin “A” to Pin “B” Greater than ten (10) meg‐

ohms

ROD – Check to ensure that the rod has not been bent or damaged during transport. Using an
ohmmeter, check the conduction paths in the rod to insure insulation integrity.
MEASUREMENT POINTS REQUIRED VALUE
Pin “B” to the center conductor Less than one (1) ohm
Pin “A” to the rod connector outer shell Less than one (1) ohm
Pin “A” to the center conductor Greater than ten (10) meg‐

ohms
IGNITER TIP – Visually inspect to ensure that the firing end is not damaged or cracked.

Cleaning
WARNING! All power to the ignition exciter should be turned “OFF” and precautions
taken to make sure it is not accidentally turned “ON” at least five (5) minutes prior to
the opening of the Ignition Exciter Enclosure. This will allow time for the stored
energy in the capacitors to dissipate. Failure to do this will result in severe personnel
hazard. Dangerous and potential lethal voltages are present.
EXCITER ‐ Remove debris that may have accumulated inside the exciter enclosure with a vacuum or
non‐metallic brush.
CABLE – CAUTION: do not use acid or carbon tetrachloride as cleaning agents on conduit. Clean
the exterior with a stiff non‐metallic brush moistened in cleaning solvents. Protect cable
terminations from solvent contamination during cleaning. Heat or oil stains, which persist on the
conduit after cleaning, are permissible.
SPARK BASE ROD – The ceramic well at the Base Rod end of the rod should be sprayed with a
cleaning solvent or alcohol and if necessary, cleaned with a lint free rag.
EXTENSION ROD – The ceramic well at the igniter end of the rod should be sprayed with a cleaning
solvent or alcohol and if necessary, cleaned with a lint free rag. The ceramic terminal end should be
cleaned with a cleaning solvent or alcohol.
IGNITER TIP – The ceramic terminal end should be cleaned with a cleaning solvent or alcohol. The
tip should be sprayed to remove oil or other hydrocarbons that may contaminate the ceramic
surface.

Repair
WARNING! All power to the ignition exciter should be turned “OFF” and precautions
taken to make sure it is not accidentally turned “ON” at least five (5) minutes prior to
the opening of the Ignition Exciter Enclosure. This will allow time for the stored
energy in the capacitors to dissipate. Failure to do this will result in severe personnel
hazard. Dangerous and potential lethal voltages are present.
CAUTION – In the unlikely event that the charge on the capacitor has not dissipated
the capacitor may be charged with high voltage. Confirm the removal of all charge with
a DC VOLTMETER before proceeding. Measure the DC voltage between the output
terminals and case ground to confirm that all charge is dissipated.
After confirmation that no voltage is present on the terminal connections, the modular
assembly can be removed for replacement. Remove all electrical connections by
unscrewing the terminal lugs and removing the wires from the input and output
terminal blocks.
WARNING! The internal exciter module is NOT REPAIRABLE. It must be returned to
the Factory to be refurbished. Failure to do this can result in severe personnel hazard.
Dangerous and potential lethal voltages are present.
The internal ON/OFF control relay is manufactured by Potter & Brumfield. Please reference their P/N
KUIP‐14D15‐24 for replacements.
In summary:
 3 pole, double throw (Form 3C)
 95°C maximum operating temperature (with clear polycarbonate dust cover)
 24 VDC coil voltage (Class B coil insulation)
 PC board quick connect mounting
 Silver‐cadmium oxide contacts, rated 10A
VDE approved design (0435), Registration 1792

SemiConductor Igniter Resistance Measurements
Depending on construction, semiconductor igniters are classified as thin film or bulk. The resistance of thin
film semiconductor is typically 10 to 100 times greater than the resistance of bulk semiconductors when
both are new. Chentronics manufactures thin film semiconductor igniters. Resistance for a new igniter is
typically 10kΩ to 30kΩ when measuring current is near 1mA. A constant current source is required to
measure resistance.
Megohmmeter: (Biddle Model BM200, Fluke Model 1520) ‐ The electronic megohmmeter provides a
constant measuring current for measurements below 100k when using the 1kV scale.

IGNITER TIP CONDITION MAXIMUM TYPICAL
NEW 30 KΩ 10 KΩ
USED 300 KΩ 30 KΩ to 300 KΩ

Multimeter: (Fluke Model 87) ‐ Semiconductor material resistance decreases logarithmically as measuring
current increases. Measuring current for the Fluke Model 87 Multimeter varies from 2 μA to 20 μA.
Therefore resistance measurements with the Fluke Multimeter are approximately 50% greater than the
Biddle Megohmmeter.

CURRENT (μA) RESISTANCE (kΩ Typical)
10 13.7
100 12.7
1000 10.5
10000 8.1

Using a Multimeter to measure resistance of new igniters is normally not a problem. Igniters that have
been placed in service and occasionally new igniters can develop a hairline crack, such that contact is lost
between the semiconductor and the center electrode. When this happens, the 0.6V source voltage of the
Multimeter cannot bridge the hairline crack, and the resistance appears as an open circuit. During igniter
operation, it is normal for hairline cracks to develop. A long as the trigger voltage from the exciter is within
specification; these cracks can be bridged and healed over. (That is, an electrode that has lost contact with
the semiconductor material will, after further operation, make contact again). As igniters age, the
resistance of the semiconductor material can increase by a factor of 25. Measuring current from the
Multimeter is similarly decreased while the current from the Megohmmeter remains nearly constant. For
worn semiconductors, the Multimeter can read 10 to 20 times higher than the Megohmmeter. The high
source voltage, 1000V, and the constant current make the Megohmmeter a better choice for measuring
semiconductor igniter resistance.


Drawings
Internal Exciter, P/N 07000102D1, Standard Baseplate for Safe Area Enclosure


Exciter with NEMA4 Enclosure, PN 07000102D


Internal Exciter, P/N 07600102D1, Standard Baseplate for Hazardous Area Enclosure


Exciter with EExD Enclosure, PN 07600102D

Diagnostic Module Quick Connection Table


Diagnostic Module, P/N 07002038


MAXON Series 8000
Pneumatic Shut-off Valves
Technical Catalog
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
TABLE OF CONTENTS
Product overview .................................................................................................................................. 1
Features & benefits .................................................................................................................................. 1

Body styles .............................................................................................................. 2
Valve body material and trim selections .................................................................. 2
Fire safe valves ........................................................................................................ 2
Valve cycle requirements ......................................................................................... 3
Agency approvals and certifications .................................................................................................................................. 4
Valve model number description .................................................................................................................................. 5

Options and accessories ......................................................................................... 6
Valve body assembly options & specifications ..................................................................................................................... 7
Valve body assembly specifications .................................................................................................................................. 9
Valve body assembly - gas compatibility ............................................................................................................................... 10
Valve actuator assembly specifications ................................................................................................................................. 11
Electrical data .................................................................................................................................. 12

General Purpose - Series 8011, 8111, 8021 & 8121 ............................................... 13
Non-incendive Valves - Series 8012, 8112, 8022 & 8122 ....................................... 13
Dimensions & weights .................................................................................................................................. 17

Series 8100 valve bodies: .75” (DN20) to 3” (DN80) ............................................... 17
Series 8100 actuator: .75” (DN20) to 3” (DN80) ...................................................... 18
Series 8000 valve body: 2.5” CP (DN65), 3” CP (DN80), 4” CP (DN100) ............... 19
Series 8000 actuator: 2.5” CP (DN65), 3” CP (DN80), 4” CP (DN100) ................... 20
Series 8100 valve body: 2.5” CP, 3” CP, 4” CP ........................................................ 21
Series 8100 actuator: 2.5” CP, 3” CP, 4” CP ............................................................ 22
Series 8000 and 8100: 6” and 8” ............................................................................. 23
Accessories .................................................................................................................................. 24
Installation, operation and maintenance instructions .......................................................................................................... 27

Component identification ......................................................................................... 29
Installation ............................................................................................................... 30
Electrical data .................................................................................................................................. 36

Normally-Closed Shut-Off Valves ............................................................................ 36
Normally-Open Vent Valves ..................................................................................... 38
Operating instructions .................................................................................................................................. 40
Maintenance instructions .................................................................................................................................. 43

Solenoid replacement procedure ............................................................................. 44
Actuator assembly rotation/replacement ................................................................. 47
Field installation of valve position switch ................................................................. 48
IEC 61508 Instruction Requirements .................................................................................................................................. 50
FITTING CERTIFICATE .................................................................................................................................. 51
0 www.maxoncorp.com 32M-05003E
PRODUCT OVERVIEW
• Pneumatically actuated valves with powerful closing spring for reliable operation
• Compact design with integral solenoid, quick exhaust and position switches that protects components, simplifies piping and mini-
mizes space requirements
• Factory Mutual, CSA, CE, IECEx, INMETRO and KTL (KC mark) approved safety shut-off and vent valves
• Hazardous Location approved: Intrinsically Safe and Non-Incendive constructions available
• Full assessment to IEC 61508 as SIL 3 capable
• Large top mounted 360-degree open-shut visual position indication, configurable in red/green or yellow/black color schemes
• Cast iron, carbon steel, low temperature carbon steel and stainless steel body assemblies with internal trim options to handle
general purpose or corrosive gases; oxygen compatibility, NACE compliance, and fire safe conformance to API 6FA
• Ambient temperature ranges of -58°F (-50°C) to 140°F (60°C); Gas temperature range of -58°F (-50°C) to 212°F (100°C)
• Actuator assemblies are field-replaceable and available in 120VAC 50/60 Hz, 240VAC 50/60 Hz, and 24VDC (with low power
option), rated for NEMA 4, NEMA 4X and IP65
• Unique bonnet design eliminates packing adjustments, reducing maintenance and minimizing drag on closing
• Series 8000 Valves meet Fluid Control Institute (FCI) 70-2 control valve standard for Class VI seat leakage
• Option available to utilize customer-supplied, externally mounted solenoids. When used in hazardous locations, the component must
be rated for the Class and Division of the hazardous area.
FEATURES & BENEFITS
MAXON Series 8000 Pneumatic Safety Shut-off

Valves combine a unique space-saving design with a
maintenance-free bonnet seal and a replaceable
actuator for easy installation and smooth, trouble-free
operation.
The valve's quick exhaust and powerful closing

spring provide valve closure in less than one second
and reliable, long-life operation.
Series 8000 Valve's compact design simplifies piping

design and minimizes space requirements.
The field-replaceable actuator provides easier

maintenance and reduced downtime. The actuator can
also be rotated around the valve body in 90° increments
to fit your specific application requirements.
A unique bonnet design eliminates packing

adjustments for reduced maintenance and minimized
drag on closing.
The large top-mounted open-shut indicator is visible

from all angles for easy proof of valve position. SIL 3
capable design provides easy design for safety
instrumented systems in the IEC 61508 and 61511
process. FM, CSA and CE approvals for use as a fuel
safety shut-off valve making easy integration with
worldwide certifications.
MAXON offers MAXON PSCheck partial stroke test

technology designed especially for Series 8000 valves,
to minimize probability of failure on demand by testing
valve function without line shutdown. The combination of
MAXON PSCheck and SIL 3 capable Series 8000
valves will help ensure safe, reliable operation of your
process.
32M-05003E 1
Body styles
Normally-closed shut-off valves use instrument air to open quickly. Removal of electrical signal
allows release of control air through solenoid and quick exhaust valve allowing the powerful
closing spring in the Series 8000 Valve to close the valve in less than one second. Optional
speed control set available for slower opening adjustment.
Series 8011, 8012 & 8013
require 40-100 psig instrument air
Series 8111, 8112 & 8113
Normally-open vent valves use instrument air to close quickly. Removal of electrical signal
allows release of control air through solenoid and quick exhaust valve allowing the Series 8000
Valve to open in less than one second. Optional speed control set available for slower closing
adjustment.
Series 8021, 8022 & 8023
Series 8121, 8122 & 8123
Valve body material and trim selections

Cast iron, carbon steel and stainless steel body assemblies feature metal-to-metal seating that meets the FCI 70-2 control valve standard
for Class VI seat leakage. Various trim options are available depending on the fuel gas used in your application. Industrial strength trim
options are available with a stainless steel seat and disc and PEEK follower for corrosive fuels that may contain traces of H2S and/or CO2
which meet NACE MR0175 requirements. Contact MAXON with your specific application details.
Valve bodies are available in your choice of threaded, flanged, and socket-welded connections. Bodies are currently available in 3/4”
(DN20) through 8” (DIN200) sizes. MAXON valve bodies are designed in accordance with many ASME/ANSI piping and valve standards.
While no one ASME/ANSI specification covers our valve in its entirety, our valve pipe connections comply with the applicable standard(s)
listed below.
• NPT threaded connections (end connections, test connections) ASME/ANSI B.1.20.2

• Cast iron valve flanged ends (125# Class end connections) ASME/ANSI B.16.1
• Cast iron valve threaded connections (end connections) ASME/ANSI B.16.4
• Steel & stainless steel valve flanged ends (Class 150# ends) ASME/ANSI B.16.5
• Face-to-face and end-to-end dimensions ASME/ANSI B.16.10
• Flanged facings MSS SP-6
• Valve body wall thickness ASME/ANSI B16.34
Fire safe valves

Fire safe valves are offered with carbon steel and stainless steel body and
bonnet materials. Fire safe trim options feature a stainless steel seat, disc
and follower, preserving the high quality MAXON metal-to-metal seating
and providing tight shut-off according to FCI 70-2 seat leakage
requirements. A fire safe trim option is also available for those applications
which necessitate NACE MR0175 compliance. All fire safe trims include
graphite packing which provides a redundant seal to prevent leakage in
case of a fire. The graphite packing used in fire safe trims is maintenance-
free and requires no adjustment, allowing for the long life and reliability
inherent to MAXON valves. MAXON fire safe design is validated against
API 6FA requirements.
3
1) O-rings
1
2) Retaining ring 4
3) Packing washer 5
4) Graphoil stem ring
5) Flat washer
6) Graphoil body-to-bonnet ring
6
Valve cycle requirements

This is based on the standards that MAXON valves are approved to and the corresponding minimum number of cycles to be completed
without failure as shown in the chart below.
CSA (CSA 6.5) FM (FM 7400) European (EN161)

Automatic - Normally Closed <= 1” 200,000
Series 8011, 8111, 8012, 8112, 8013, 8113 100,000 20,000 <= 3” 100,000
<= 8” 50,000
Vent Valves No special No special No special
Series 8021, 8121, 8022, 8122, 8023, 8123 requirements requirements requirements
32M-05003E 3
AGENCY APPROVALS AND CERTIFICATIONS
VALVE MODEL NUMBER DESCRIPTION

Every MAXON Series 8000 Valve can be accurately identified by the model number shown on the valve nameplate. The example below
shows a typical Series 8000 Valve model number, along with the available choices for each item represented in the model number. The
first five choices determine the valve’s configured item number. Valve body and actuator options are identified by the next nine characters
in the model number. Options and accessories are listed on the next page.
Configured Item Number Valve Body Actuator
Classification
Internal Trim
Body Seals
Connection
Instruction
Indication
Enclosure
Language
Capacity
Package
Pressure
Position
Material
Primary
Voltage
Normal
Rating
Switch
Option
Rating
Visual
Valve
Body
Body
Area
Flow
Size
300 C 81 1 1 - A A 1 1 - B 1 A 1 1
Valve Size Body Connection Primary Voltage

075 – 3/4” (DN 20) A – NPT A – 120VAC 50Hz
100 – 1” (DN 25) B – ANSI Flanged (ISO 7005 PN 20) B – 120VAC 60Hz
125 – 1-1/4” (DN 32) C – ISO 7-1 Threaded D – 240VAC 50Hz
150 – 1-1/2” (DN 40) D – DIN PN 16 Flanged E – 240VAC 60Hz
200 – 2” (DN 50) E – Socket Welded Nipple G – 24VDC
250 – 2-1/2” (DN 65) F – Socket Welded Nipple w/Class 150 H – 24VDC IS [1]
300 – 3” (DN 80) Flange (ISO 7005 PN 20) J – 24VDC IS-ATEX [1]
400 – 4” (DN 100) G – Socket Welded Nipple w/Class 300 X – Special
600 – 6” (DN 150) Flange (ISO 7005 PN 50) Z – None (customer-supplied,
800 – 8” (DN 200) H – EN1092-1 PN16 (ISO 7005-1 PN16) external mount)
J – ANSI Class 300 Flange (ISO 7005 * - Valve Body Only
Flow Capacity PN 50)
S – Standard * - Actuator Only Switch Option
C – CP Body Construction 0 – None
Body Seals 1 – VOS1/VCS1 - V7
Operating Pressure Rating A – Buna-N 2 – VOS2/VCS2 - V7
80 – Pneumatic Standard Pressure B – Viton 3 – VOS1/VCS1 - IP67
81 – Pneumatic High Pressure C – Ethylene Propylene [2] 4 – VOS2/VCS2 - IP67
F – Omniflex X – Special
Normal Position X – Special * - Valve Body Only
1 – Normally-Closed Shut-Off Valve * - Actuator Only
2 – Normally-Open Vent Valve Enclosure Rating
Body Material A – NEMA 4, IP65
Area Classification 1 – Cast Iron B – NEMA 4X, IP65
1 – General Purpose 2 – Carbon Steel X – Special
2 – Non-incendive, Class I, II and III Division 2 5 – Stainless Steel * - Valve Body Only
3 – Intrinsically Safe, Class I, II and III Division 1 6 – Low Temp Carbon Steel
(and ATEX Zone 1/21 when ordered with the X – Special Instruction Language
ATEX IS solenoid) [1] * - Actuator Only 0 – English
4 – Valve Body Only 1 – French
Internal Trim Package 3 – German
1 – Trim Package 1 4 – Portuguese
2 – Trim Package 2 5 – Spanish
3 – Trim Package 3 (NACE)
4 – Trim Package 2, oxy clean [2] Visual Indication
5 – Trim Package 3, oxy clean [2] 1 – Red closed/green open
6 – Trim 2 fire safe 2 – Green closed/red open
7 – Trim 3 fire safe 3 – Black closed/yellow open
X – Special [2]
* - Actuator Only
[1] 122°F maximum ambient temperature limit

[2] 0°F minimum ambient temperature limit
32M-05003E 5
Options and accessories
Certifications [1] Inspections Accessories

Material Cert Required
Casting Inspection
Casting Inspection
Casting Inspection
Final Verification
Weld Inspection
Weld Inspection
Weld Inspection
Speed Control
Specification
Specification
Material FAT
Redundant
Pre-build
Solenoid
(NDE) 1
(NDE) 2
(NDE) 1
(NDE) 2
FAT
N 1 1 1 1 1 0 N N 1 2
Material Cert Required Weld Inspection Specification Redundant Solenoid [2]

N – No 0 – None 0 – None
Y – Yes 1 – Weld per ASME B31.1 1 – External Redundant Solenoid
2 – Weld per ASME B31.3 2 – External Redundant Manual
Casting Inspection Specification Reset Solenoid
0 – None Weld Inspection (NDE) 1 [1]
1 – Casting per ASME B31.1 0 – None Speed Control
2 – Casting per ASME B31.3 1 – Liquid Penetrant Inspection (PT) 0 – None
3 – Casting per ASME B16.34 2 – Magnetic Particle Inspection (MT) 1 – Speed Control Valve, Steel
4 – MSS-SP55 2 – Speed Control Valve, Stainless
Weld Inspection (NDE) 2 [1] Steel
Casting Inspection (NDE) 1 [1] 0 – None
0 – None 1 – Liquid Penetrant Inspection (PT)
1 – Liquid Penetrant Inspection (PT) 2 – Magnetic Particle Inspection (MT)
2 – Magnetic Particle Inspection (MT)
4 – Positive Material Identification (PMI) Pre-build Material FAT
N – No
Casting Inspection (NDE) 2 [1] X – Special
0 – None
1 – Liquid Penetrant Inspection (PT) Final Verification FAT
2 – Magnetic Particle Inspection (MT) N – No
4 – Positive Material Identification (PMI) X – Special
[1] Material certifications provided for valve body, bonnet, pipe nipples (when applicable) and flanges (when applicable). Material certifications for other
components may be available by special request.
[2] Agency approvals and certifications apply to valve only and do not apply to optional external accessories, such as redundant solenoids.
VALVE BODY ASSEMBLY OPTIONS & SPECIFICATIONS
Series 8000 Normally-Closed Shut-Off Valves

Nominal Flow Actuator Body Connections Body Trim Package Cv MOPD Rating
Pipe Size Capacity Pressure Class Available Material Options Rating (psig)
A, C 1, Cast Iron 1, 2, 3, 4, 5 200
.75” Std. High Press. 2, 6 Carbon Steel 19
A, C, E, F, G 2, 3, 4, 5, 6, 7 255
5, Stainless Steel
A, C 1, Cast Iron 1, 2, 3, 4, 5 200
1” Std. High Press. 2, 6 Carbon Steel 20
A, C, E, F, G 2, 3, 4, 5, 6, 7 255
5, Stainless Steel
1.25” Std. High Press. A, C 1, Cast Iron 1, 2, 3, 4, 5 45 200
A, C 1, Cast Iron 1, 2, 3, 4, 5 200
1.5” Std. High Press. 2, 6 Carbon Steel 53
A, C, E, F, G 2, 3, 4, 5, 6, 7 255
5, Stainless Steel
A, B, C, D, H 1, Cast Iron 1, 2, 3, 4, 5 200
A, C, E, F, G 2, 3, 4, 5, 6, 7 255
5, Stainless Steel
Std. High Press. 1, Cast Iron 1 127 150
A, B, C, D
1, Cast Iron 1, 2, 3, 4, 5
Std. 2, 6 Carbon Steel 50
B, D, H G 2, 3, 4, 5
2.5” 5, Stainless Steel
CP 304
A, B, C, D, H 1, Cast Iron 1, 2, 3, 4, 5
High Press. 2, 6 Carbon Steel 175
B, D, H, G 2, 3, 4, 5, 6, 7
5, Stainless Steel
Std. High Press. A, C 1, Cast Iron 1 173 150
A, B, C, D, H 1, Cast Iron 1, 2, 3, 4, 5
B, D, H, G 2, 3, 4, 5
3” 5, Stainless Steel
CP 423
A, B, C, D, H 1, Cast Iron 1, 2, 3, 4, 5
B, D, H, G 2, 3, 4, 5, 6, 7
5, Stainless Steel
1, Cast Iron 1, 2, 3, 4, 5
2, 3, 4, 5
5, Stainless Steel
4” CP B, D, H, G 490
1, Cast Iron 1, 2, 3, 4, 5
2, 3, 4, 5, 6, 7
5, Stainless Steel
1, Cast Iron 1, 2, 3, 4, 5
2, 3, 4, 5, 6, 7
5, Stainless Steel
6” Std. B, D, H 1172
1, Cast Iron 1, 2, 3, 4, 5
2, 3, 4, 5, 6, 7
5, Stainless Steel
2, 6 Carbon Steel 2, 3, 4, 5, 6, 7
Std. 60
5, Stainless Steel
8” Std. B, D, H, J 1320
2, 6 Carbon Steel 2, 3, 4, 5, 6, 7
High Press. 100
5, Stainless Steel
Body Connections: Body Material: Trim Package Options and Typical Material:
A - NPT 1 - Cast Iron 1 - 400 Series Stainless Steel Seat, Hardened Ductile Iron Disc, PEEK Follower Ring
B - ANSI Flanged (ISO 7005 PN20) 2 - Carbon Steel 2 - 300 Series Stainless Steel Seat, 300 Series Stainless Steel Disc, PEEK Follower
C - ISO 7-1 Threaded 5 - Stainless Steel Ring
D - DIN PN16 Flanged 6 - Low Temp Carbon 3 - 300 Series Stainless Steel Seat, 300 Series Stainless Steel Disc, 300 Series Stain-
E - Socket Welded Nipple Steel less Steel Stem, PEEK Follower Ring (NACE compliant)
F - Socket Welded Nipple w/Class 150 Flange 4 - Oxy Clean, Trim 2
(ISO 7005 PN20) 5 - Oxy Clean, Trim 3
G - Socket Welded Nipple 6 - Trim 2 fire safe
w/Class 300 Flange (ISO 7005 PN50) 7 - Trim 3 fire safe
H - EN1092-1 PN16 (ISO 7005-1 PN16)
J - ANSI Class 300 Flange (ISO 7005 PN50) Body Seals:
All configurations allow for Buna-N and Viton elastomers as standard. Omniflex and
Ethylene Propylene are available for special services. Consult MAXON for proper
application.
32M-05003E 7
Series 8000 Normally-Open Vent Valves

Actuator Body Trim MOPD
Nominal Flow Body Cv
Pressure Connections Package Rating
Pipe Size Capacity Material Rating
Class Available Options (psig)
A, C 1, Cast Iron 1, 2, 3, 4, 5 200
.75” Std. High Press. 2, 6 Carbon Steel 19
A, C, E, F, G 2, 3, 4, 5, 6, 7 255
5, Stainless Steel
A, C 1, Cast Iron 1, 2, 3, 4, 5 200
A, C, E, F, G 2, 3, 4, 5, 6, 7 255
5, Stainless Steel
A, C 1, Cast Iron 1, 2, 3, 4, 5 200
1.5” Std. High Press. 2, 6 Carbon Steel 53
A, C, E, F, G 2, 3, 4, 5, 6, 7 255
5, Stainless Steel
A, B, C, D, H 1, Cast Iron 1, 2, 3, 4, 5 200
A, C, E, F, G 2, 3, 4, 5, 6, 7 255
5, Stainless Steel
A, B, C, D 1, Cast Iron 1, 2, 3, 4, 5
B, D, H 2, 3, 4, 5
5, Stainless Steel
2.5” CP 304
A, B, C, D, H 1, Cast Iron 1, 2, 3, 4, 5
B, D, H 2, 3, 4, 5, 6, 7
5, Stainless Steel
A, B, C, D, H 1, Cast Iron 1, 2, 3, 4, 5
B, D, H 2, 3, 4, 5
5, Stainless Steel
3” CP 423
A, B, C, D, H 1, Cast Iron 1, 2, 3, 4, 5
B, D, H 2, 3, 4, 5, 6, 7
5, Stainless Steel
1, Cast Iron 1, 2, 3, 4, 5
2, 3, 4, 5
5, Stainless Steel
4” CP B, D, H 490
1, Cast Iron 1, 2, 3, 4, 5
2, 3, 4, 5, 6, 7
5, Stainless Steel
Body Connections: Body Material: Trim Package Options and Typical Material:
A - NPT 1 - Cast Iron 1 - 400 Series Stainless Steel Seat, Hardened Ductile Iron Disc, PEEK Follower Ring
B - ANSI Flanged 2 - Carbon Steel 2 - 300 Series Stainless Steel Seat, 300 Series Stainless Steel Disc, PEEK Follower Ring
(ISO 7005 PN20) 5 - Stainless Steel 3 - 300 Series Stainless Steel Seat, 300 Series Stainless Steel Disc, 300 Series Stainless Steel
C - ISO 7-1 Threaded 6 - Low Temp Carbon Steel Stem, PEEK Follower Ring (NACE compliant)
D - DIN PN16 Flanged 4 - Oxy Clean, Trim 2
E - Socket Welded Nipple 5 - Oxy Clean, Trim 3
F - Socket Welded Nipple w/ 6 - Trim 2 fire safe
Class 150 Flange (ISO 7005 7 - Trim 3 fire safe
PN20)
G - Socket Welded Nipple w/ Body Seals:
Class 300 Flange (ISO 7005 All configurations allow for Buna-N and Viton elastomers as standard. Omniflex and
PN50) Ethylene Propylene are available for special services. Consult MAXON for proper
H - EN1092-1 PN16 (ISO 7005-1 application.
PN16)
VALVE BODY ASSEMBLY SPECIFICATIONS
10 13 11 19
12
A
16
3
17
15 5 18
2
DETAIL A
8 1
6
7
Body Seal Material

Item No. Description Material
1 Seat O-Ring Standard material options are Buna-N and Viton.
2 Body O-Ring Omniflex and Ethylene Propylene are available for special service.
Consult MAXON for proper material selection.
3 Stem O-Ring
Body and Bonnet Materials

Material Code
Item No. Description
1 2 5 6
4 Body Cast Iron Cast Steel Stainless Steel Low Temp Carbon Steel
5 Bonnet ASTM A126, Class B ASTM A216 Gr. WCB ASTM A351 Gr. CF8M ASTM A352 Gr. LCB
Trim Package Materials

Internal Trim Package
Item No. Description
1 2 3 6 7
Hardened 400 Series
6 Seat 300 Series Stainless Steel
Stainless Steel
7 Disc Hardened Ductile Iron 300 Series Stainless Steel
8 Follower Ring PEEK 300 Series Stainless Steel
9 Wavy Spring 300 Series Stainless Steel
300 Series 17-4 PH Stainless 300 Series
10 Stem 17-4 PH Stainless Steel
Stainless Steel Steel Stainless Steel
11 Spring Retainer Blackened Carbon Steel
12 Compression Spring 17-7 PH Stainless Steel
13 Jam Nut Zinc Plated Carbon Steel
14 Spring Pin (when req’d.) Carbon Steel
15 Body Graphite Ring --- --- --- Flexible Graphite
16 Packing Washer --- --- --- 300 Series Stainless Steel
17 Stem Graphite Ring --- --- --- Flexible Graphite
18 Flat Washer --- --- --- 300 Series Stainless Steel
19 Retaining Ring --- --- --- Zinc Plated Carbon Steel
32M-05003E 9
VALVE BODY ASSEMBLY - GAS COMPATIBILITY
Agency Approvals and

Suggested Material Options
Gas MOPD Certifications
Gas
Code Body & Trim Rating CSA CE [4]
Body Seal FM
Bonnet Package [5] [3] GAD MD
Air AIR A, B, C, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X NA X
Ammonia AMM A, C, F 1, 2, 5, 6 1, 2, 3, 6 ,7 Std. X X NA X
Butane Gas BUT A, B, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X X X
Coke Oven Gas COKE B, F 5 Analysis Required Std. X X NA X
Delco DEL A, B, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X NA X
Digester [1] DIG Analysis Required 5 Analysis Required Std. X X NA X
Endothermic AGA ENDO A, B, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X NA X
Exothermic Gas EXO A, B, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X NA X
Hydrogen Gas HYD A, B, C, F 1, 2, 5, 6 1, 2, 3, 6, 7 [2] X X NA X
Manufactured [1] MFGD Analysis Required 5 Analysis Required Std. X X NA X
Natural Gas NAT A, B, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X X X
Nitrogen NIT A, B, C, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X NA X
Oxygen High OXYH B, C, F 2, 5, 6 4, 5 200 psig max X X NA X
Oxygen Low OXYL B, C, F 1, 2, 5, 6 4, 5 30 psig max X X NA X
Oxygen X OXYX B, C, F 2, 5, 6 4, 5 Std. X X NA X
Propane PROP A, B, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X X X
Refinery [1] REF Analysis Required 5 Analysis Required Std. X X NA X
Sour Natural [1] SOUR Analysis Required 5 Analysis Required Std. X X NA X
Town Gas [1] TOWN Analysis Required 5 Analysis Required Std. X X X X
Land Fill Gas LAND Analysis Required 5 Analysis Required Std. X X NA X
Notes:
[1] Other body and trim packages may be acceptable pending fuel analysis. For pricing inquiry, Viton body seals will be standard option. Contact MAXON for details.
[2] Valve maximum operating pressure (MOPD) to be reduced by 25% from standard ratings.
[3] ISO connections are not recognized by CSA standards.
[4] All 8000 Valves do meet the essential requirements of the Low Voltage (73/23/EC) and the EMC (89/336/EC) Directives. GAD refers to the Gas Appliances Direc-
tive (2009/142/EC): this Directive only covers the use of commercially available fuels (natural gas, butane, town gas and LPG). MD stands for Machinery Directive
(2006/42/EC). All Series 8000 valves meet the essential requirements for fuel shut-off on Industrial Thermal Equipment as specified in EN746-2.
[5] Trim Package 1 is only allowed with body and bonnet 1.
Body Seals: Body & Bonnet: Trim Package:

A - Buna-N 1 - Cast Iron 1 - Trim Package 1
B - Viton 2 - Carbon Steel 2 - Trim Package 2
C - Ethylene Propylene 5 - Stainless Steel 3 - Trim Package 3 (NACE)
F - Omniflex 6 - Low Temp Carbon Steel 4 - Trim Package 2, Oxy Clean
5 - Trim Package 3, Oxy Clean
6 - Trim 2 fire safe
VALVE ACTUATOR ASSEMBLY SPECIFICATIONS
50 28 51 34
13
22
16
29 15 3
27
26
25
20
35
19
21 23
30
20
17 18
View Without Top Plate
12 24
7
14
36
5 48A 46A
9 48 46 45 47 47A
5
8
32
34 49
31 7
10 36
36B
11 29 6 42
29 6
36A
43
12 12
4
1 44
1
38
2 4 40 41 39 37
Typical Actuator Assembly Typical Cylinder Assembly Mounting General Purpose Switch Assembly
Item Number Description Item No. Description

1 Base Plate 29 M6-1.0 x 20 Cap Screw
2 Bonnet Gasket 30 3/4” Pipe Plug
3 Drive Pin 31 .125 Inlet Pipe Plug
4 Filter Vent 32 Info Plate
5 Cylinder Assembly 33 Actuator Bolts (not shown)
6 M6 Lock Washer 34 Switch Assembly
7 M5-0.8 x 40 Hex Screw 35 Liquid Tight Connector
8 O-Ring 36 Solenoid w/Quick Exhaust Assembly
9 O-Ring 36A Solenoid Coil
10 Solenoid Adapter Inlet 36B Solenoid Cap
11 Housing 37 Switch & Terminal Bracket
12 Housing Gasket 38 DIN Rail
13 M6-1.0 x 60 Soc HD Cap Screw 39 End Stop
14 O-Ring 40 Terminal Block
15 Top Plate 41 End Cover
16 Switch Indicator 42 Marker Strips
17 Washer 43 M4-0.7 x 6 Slotted Screw
18 M5-0.8 x 10 Ground Screw 44 Switch Bracket
19 Top Housing 45 Switch Insulator
20 M4-0.7 x 6 Slotted Screw 46 V7 Switch
21 Terminal Block Cover Gasket 46A IP67 Switch
22 Info Label 47 #4-40 x .75 Slotted Screw
23 Terminal Block Cover 47A #2-56 x .437 Slotted Screw
24 M5-0.8 x 12 Cap Screw 48 #4-40 Hex Nut
25 Top Housing Gasket 48A #2-56 Hex Nut
26 External Retaining Ring 49 Wire
27 O-Ring 50 Visual Indicator
28 Indicator Cover 51 Spring
32M-05003E 11
ELECTRICAL DATA
GENERAL
Series 8000 Valves are pneumatically operated and a solenoid valve controls the air supply. The solenoid valve is directly wired into the
control system.
Position switch wiring diagrams (reproduced below) are part of each valve assembly, summarizing electrical data and wiring for a
valve equipped with terminal block and a full complement of optional switches.
Good practice normally dictates that auxiliary switches in valves should be used for signal duty only, not to operate additional safety
devices.
Valve position switches are offered in SPDT (Single Pole/Double Throw). Recommended packages include one open switch and one
closed switch (VOS1/VCS1) and additional auxiliary switches designated by VOS2/VCS2.
VCS (Valve Closed Switch) is actuated at the end of the closing stroke.
VOS (Valve Open Switch) is actuated at the end of the opening stroke.
Switch amperage ratings are shown on the schematic wiring diagrams below. DO NOT EXCEED rated amperage or total load shown.
Diagrams show valve with a full complement of switches. The indicated internal wiring is present only when the appropriate auxiliary
switches are specified.
Figure 1: Normally-Closed Shut-Off Valve
VOS-1 VCS-1 VOS-2 VCS-2
1 2 3 4 5 6 7 8 9 10 11 12 13 14
L N
VOS-1 VCS-1 VOS-2 VCS-2
3-4 3-5 6-7 6-8 9-10 9-11 12-13 12-14
V7 IP67
24VDC 0.5 Amps 24VDC 2.0 Amps
120VAC 11 Amps 120VAC 2.0 Amps
Figure 2: Normally-Open Vent Valve
VCS-1 VOS-1 VCS-2 VOS-2
1 2 3 4 5 6 7 8 9 10 11 12 13 14
L N
VCS-1 VOS-1 VCS-2 VOS-2
3-4 3-5 6-7 6-8 9-10 9-11 12-13 12-14
V7 IP67
24VDC 0.5 Amps 24VDC 2.0 Amps
General Purpose - Series 8011, 8111, 8021 & 8121

Solenoid valve power ratings
Amperage (A) Power
Voltage
In-Rush Holding In-Rush Holding
24VDC 0.20 0.20 4.8 W 4.8 W
120VAC 50 Hz 0.09 0.07 11 VA 8.5 VA
120VAC 60 Hz 0.08 0.05 9.4 VA 6.9 VA
240VAC 50 Hz 0.05 0.04 11 VA 8.5 VA
240VAC 60 Hz 0.04 0.03 9.4 VA 6.9 VA
Standard switch amperage ratings
as shown on the valve switch wiring diagram
Voltage Maximum Amperage (A)
24VDC 0.5
120VAC 50/60 Hz 11
240VAC 50/60 Hz 11
Non-incendive Valves - Series 8012, 8112, 8022 & 8122

Solenoid valve power ratings
Amperage (A) Power
Voltage
In-Rush Holding In-Rush Holding
24VDC 0.20 0.20 4.8 W 4.8 W
120VAC 50 Hz 0.09 0.07 11 VA 8.5 VA
120VAC 60 Hz 0.08 0.05 9.4 VA 6.9 VA
240VAC 50 Hz 0.05 0.04 11 VA 8.5 VA
240VAC 60 Hz 0.04 0.03 9.4 VA 6.9 VA
24VDC IS 0.09 0.09 2.1 W 2.1 W
IP67 switch amperage ratings
as shown on the valve switch wiring diagram
Voltage Maximum Amperage (A)
24VDC 2.0
120VAC 50/60 Hz 2.0
240VAC 50/60 Hz 2.0
32M-05003E 13
INTRINSICALLY SAFE VALVES - SERIES 8013, 8023, 8113 & 8123

The Series 8000 Valve achieves Class I Div.1 hazardous location certification through the Intrinsically Safe (IS) protection method. Below
is a representation of the Control Drawing. The MAXON standard offering does not include the barriers/isolators that are depicted below
in the non-hazardous location; however, they can be provided as an additional accessory. Consult MAXON for details.
The intrinsic safety and operational criteria for most applications can be met with a 24 VDC supply and the barriers described in the
Control Drawing. Specific installations with long cable runs, low power requirements, or other complications may require a barrier with
different parameters.
HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION

CLASS I, DIVISION 1, GROUPS A,B,C,D
CLASS II, DIVISION 1, GROUPS E,F,G
CLASS III, DIVISION 1
Factory Mutual/CSA Approved
Barrier(s) used in an Approved Configuraton
with “V” max. greater than “VI” or
“Voc” and “I” max. greater than “I t” or “I sc”
Power
Supply
Solenoid
Valve
250 RMS max.
Solenoid Entity Parameters CSA/FM/ATEX certified Barrier

V max. = 28 VDC rated 28 V max. / 300 Ohms
I max. = 115 mA min. or equivalent
Pi = 1.6 W
Ci = O µF
Li = O µH
Valve
Position
Switch
Switch Entity Parameters

V max. = 30 VDC
I max. = 500 mA “CSA/FM/ATEX certified Barrier
Pi = 2 W for a simple apparatus”
Ci= O µF
Li = O µH
NOTES:
1) The Intrinsic Safety Entity concept allows the interconnection of two FM approved (CSA Certified when installed in Canada) Intrinsically Safe
devices with entity parameters not specifically examined in combination as a system when:
Voc or Uo or Vt Vmax, Isc or Io or It Imax, Ca or Co Ci+ Ccable, La or Lo Li + Lcable, and for FM only: Po Pi.
2) Dust-tight conduit seal must be used when installed in Class II and Class III environments.
3) Control equipment connected to the Associated Apparatus must not use or generate more than 250 Vrms or Vdc.
4) Installation in the U.S. should be in accordance with ANSI/ISA RP12.06.01 “Installation of Intrinsically Safe Systems for Hazardous (Classi-
fied) Locations” and the National Electric Code® (ANSI/NFPA 70) Sections 504 and 505.
5) Installation in Canada should be in accordance with the Canadian Electrical Code, CSA C22.1, Part 1, Appendix F.
6) Installation in the European Union should be in accordance to Directive 94/9/EC (ATEX 95).
7) The configuration of associated Apparatus must be FM Approved (CSA Certified when in Canada) under Entity Concept.
8) Associated Apparatus manufacturer’s installation drawing must be followed when installing this equipment.
9) No revision to drawing without prior authorization from FM Approval and CSA International.
CONTROL DRAWING FOR CUSTOMER-SUPPLIED, EXTERNALLY MOUNTED SOLENOIDS

CLASS II, DIVISION 1, GROUPS E,F,G

Barrier(s) used in an Approved con-
figuration with "V" max. greater than "Vt"
or "Voc" and "I" max. greater than "I t" or "I sc"
Power
supply
Solenoid
Valve
see note 3
Customer Supplied Solenoid Valve
-To be mounted external to valve actuator.
-Component must be rated for the Class
and Division of the hazardous environment
as stated above.
-Component must be rated for instrinsic
safety and be interconnected with other
intrinsically safe devices as required under
the Intrinsic Safety Entity Concept (see note 1).
Valve
Position
Switch

V max.=30 VDC
I max.=500 mA "CSA/FM/ATEX certified Barrier
Pi= 2 W for a simple apparatus"
Ci= O µF
Li= O µH
NOTES:
1) The Intrinsic Safety Entity concept allows the interconnection of two FM approved (CSA Certified when installed in Canada) Intrinsically Safe
devices with entity parameters not specifically examined in combination as a system when:
Voc or Uo or Vt Vmax, Isc or Io or It Imax, Ca or Co Ci+ Ccable, La or Lo Li + Lcable, and for FM only: Po Pi.
2) Dust-tight conduit seal must be used when installed in Class II and Class III environments.
3) Control equipment connected to the Associated Apparatus must not use or generate more than the maximum permissible safe area voltage
(Um) for the barrier.
4) Installation in the U.S. should be in accordance with ANSI/ISA RP12.06.01 “Installation of Intrinsically Safe Systems for Hazardous (Classi-
fied) Locations” and the National Electric Code® (ANSI/NFPA 70) Sections 504 and 505.
5) Installation in Canada should be in accordance with the Canadian Electrical Code, CSA C22.1, Part 1, Appendix F.
6) Installation in the European Union should be in accordance to Directive 94/9/EC (ATEX 95).
7) The configuration of associated Apparatus must be FM Approved (CSA Certified when in Canada) under Entity Concept.
8) Associated Apparatus manufacturer’s installation drawing must be followed when installing this equipment.
9) No revision to drawing without prior authorization from FM Approval and CSA International.
32M-05003E 15
To select a different safety barrier, choose a design that limits voltage, current, and power under worst-case fault conditions to values less
than the IS entity parameters, while still meeting the minimum operational requirements under worst-case non-fault conditions. The IS
entity parameters and operational requirements are listed in the following tables.
The barrier will specify a maximum voltage peak Voc 1, a maximum short-circuit current, Isc 2 and maximum power output Po 3. These
barrier ratings must be less than or equal to the IS entity parameters of the field device, i.e., Voc  Vmax, Isc  Imax, and Po  Pi.The
barrier will also specify a maximum allowed capacitance Ca and inductance La, which must be greater than or equal to the sum of those
of the load device and field wiring, i.e., Ca  Ci + Ccable and La  Li + Lcable.
The solenoid requires a minimum current (Imin) to operate properly. The nominal barrier input voltage (Vworking, as specified by the
barrier) must be adequate to provide Imin through the maximum barrier resistance, the maximum wiring resistance, the resistance of any
fuses, and the maximum solenoid resistance (Ri).
NOTE: Vworking will always be less than Vmax or Voc. Never intentionally supply Voc to the barrier, as this
could blow an internal fuse and ruin the barrier.
[1] The maximum voltage possible at the barrier input or output under a no-load condition.
[2] Found when the barrier input is at Voc and a short-circuit appears on the barrier output.
[3] Found when the barrier input is at Voc and a matched load appears on the barrier output. Note that this value is the transmitted power, and does not
include the power dissipated by the barrier itself.
BARRIER SELECTION CRITERIA FOR SOLENOID
IS entity parameters 4
Maximum voltage input (Vmax) 28 V 5
Maximum current input (Imax) 115 mA
Maximum power input (Pi) 1.6 W
Internal capacitance (Ci) 0 μF
Internal inductance (Li) 0 μH
Operational Parameters
Minimum operational current (Imin) 37 mA
Solenoid internal resistance (Ri) 275 ohms ± 8%
BARRIER SELECTION CRITERIA FOR SWITCH
IS entity parameters (simple apparatus)

Maximum voltage input (Vmax) 30 V 6
Maximum current input (Imax) 500 mA 6
Maximum power input (Pi) 1.3 W 7
Internal capacitance (Ci) 0 μF
Internal inductance (Li) 0 μH
Operational Parameters
Minimum operational current (Imin) Application specific
Switch internal on-resistance (Ri) < 1 ohm
[4] Obtained from the manufacturer’s published entity parameters.

[5] Never intentionally supply Vmax to the barrier, as this could blow an internal fuse and ruin the barrier.
[6] Obtained from the switch’s safety ratings.
[7] Standard Pi for a simple apparatus.
DIMENSIONS & WEIGHTS

Series 8100 valve bodies: .75” (DN20) to 3” (DN80)
Body Connection A & C Body Connection B, D & H
1 1
N
P
H H
R
K S K
L L
1) 2x 1/4” NPT test
connection Body Connection E Body Connection F & G
1
1
N
P
H
H
R K
K S L
L
Body/ Approximate Dimensions (inches) Approximate Weight (lbs)

Valve Flow Body
Bonnet N P R S Body Actuator
Size Capacity Connection H K L Total Weight
Material Ø Ø Ø # of holes Assembly Assembly
A, C Cast Iron 1.9 3.8 N/A 8 20
A, C 1.9 3.8 N/A 9 21
.75” S E Carbon Steel 6.9 13.8 N/A 11 23
& Stainless
F Steel 3.88 2.75 0.62 15 27
7.3 14.5 4
G 4.62 3.25 0.75 17 29
2.0
A, C Cast Iron 1.9 3.8 N/A 8 20
A, C 1.9 3.8 N/A 9 21
1” S E Carbon Steel 6.9 13.8 N/A 11 23
& Stainless
F Steel 4.3 3.1 0.62 15 27
7.3 14.5 4
G 4.9 3.5 0.75 17 29
1.25” S A, C Cast Iron 2.4 N/A 9 21
A, C Cast Iron 2.0 4.0 N/A 11 23
A, C N/A 11 23
1.5” S E Carbon Steel 2.7 6.8 13.6 N/A 14 12 26
& Stainless
F Steel 5.0 3.9 0.62 21 33
7.2 14.4 4
G 6.1 4.5 0.88 26 38
A, C 2.2 4.4 N/A 16 28
B Cast Iron 6.0 4.8 0.75 26 38
3.5 7.0 4
D, H 6.5 4.9 0.71 26 38
2” S A, C 3.3 2.2 4.4 N/A 18 30
E Carbon Steel 6.9 13.8 N/A 23 35
& Stainless
F Steel 6.0 4.8 0.75 4 33 45
7.3 14.5
G 6.5 5.0 0.75 8 37 49
A, C 2.9 2.5 5.0 N/A 19 31
2.5” S B Cast Iron 7.0 5.5 0.75 30 42
3.1 3.8 7.5 4
D 7.3 5.7 0.71 30 42
3” S A, C Cast Iron 3.0 2.6 5.2 N/A 20 32
Flow Capacity: Body Connection: D - DIN PN16 Flanged

S - Standard A - NPT E - Socket Welded Nipple
C - CP Body Construction B - ANSI Flanged (ISO 7005 PN20) F - Socket Welded Nipple w/ Class150 Flange (ISO 7005 PN20)
C - ISO 7-1 Threaded G - Socket Welded Nipple w/ Class 300 Flange (ISO 7005 PN50)
H - EN1092-1 PN16 (ISO 7005-1 PN16)
32M-05003E 17
Series 8100 actuator: .75” (DN20) to 3” (DN80)

A B H H
C
1
1) 1/8” NPT air inlet connection
2) Visual indication of valve G
position
3) Air exhaust - do not block F
4) 2x 3/4” conduit connection
5) 2x 1/4” NPT test connection E
3
Approximate dimensions (inches)

Valve Size
A B C D E F G H
.75”
7 15
1”
1.25”
8 16
1.5” 3.5 2.8 12 2.6 4 2.5
2”
2.5” 9 17
3”
Series 8000 valve body: 2.5” CP (DN65), 3” CP (DN80), 4” CP (DN100)

1 1
N
P
H H
R
K S K
L L
1) 2x 1/4” NPT
test connec-
Body Connection E Body Connection F & G
tion
1
1
N
P
H
H
R K
K S L
L
Approximate Dimensions (inches) Approximate Weight (lbs)

Valve Flow Body Body/Bonnet S
N P R Body Actuator Total
Size Capacity Connection Material H K L # of
Ø Ø Ø Assembly Assembly Weight
holes
A, C 4.3 2.5 5.0 N/A 19 32
B 7.0 5.5 0.75 31 44
Cast Iron 4
D 7.3 5.7 0.75 31 44
C H 7.3 5.7 0.75 8 31 44
2.5” 4.5 3.8 7.5
B 7.0 5.5 0.75 34 47
Carbon Steel & 4
D 7.3 5.7 0.71 34 47
Stainless Steel
H 7.3 5.7 0.71 8 30 43
C G CS & SS 4.4 6.1 12.3 7.5 5.9 0.88 8 39 51
A, C 5.1 2.8 5.5 N/A 24 37
B Cast Iron 7.5 6.0 0.75 4 46 13 59
C D, H 7.9 6.3 0.75 8 46 59
3” 5.2 4.0 8.0
B Carbon Steel & 7.5 6.0 0.75 4 47 60
D, H Stainless Steel 7.9 6.3 0.71 8 47 60
C G CS & SS 5.2 6.6 13.3 8.3 6.6 0.88 8 56 68
B 9.0 7.5 0.75 64 77
Cast Iron
D, H 8.7 7.1 0.75 64 77
C 5.5 4.5 9.0 8
4” B Carbon Steel & 9.0 7.5 0.75 64 77
D, H Stainless Steel 8.7 7.1 0.71 64 77
C G CS & SS 5.1 7.4 15.3 10 7.9 0.88 8 83 96
Body Connection
Flow Capacity:
A - NPT
S - Standard
B - ANSI Flanged (ISO 7005 PN20)
C - CP Body Construction
C - ISO 7-1 Threaded
D - DIN PN16 Flanged
E - Socket Welded Nipple
F - Socket Welded Nipple w/ Class 150 Flange (ISO 7005 PN20)
G - Socket Welded Nipple w/ Class 300 Flange (ISO 7005 PN50)
H - EN1092-1 PN16 (ISO 7005-1 PN16)
32M-05003E 19
Series 8000 actuator: 2.5” CP (DN65), 3” CP (DN80), 4” CP (DN100)
A B H
H
2
C
1
position
4) 2x 3/4“ conduit connection
3
Flow Approximate Dimensions (inches)

Valve Size
Capacity A B C D E F G H
2.5” CP 11.1 20.6
3” CP 3.5 2.8 14.8 2.6 5.3 2.5
11.8 21.3
4” CP
Series 8100 valve body: 2.5” CP, 3” CP, 4” CP

1 1
N
P
H H
R
K S K
L L
1) 2x 1/4” NPT
test connec-
Body Connection E Body Connection F & G
tion
1
1
N
P
H
H
R K
K S L
L
Approximate Weight
Approximate Dimensions (inches)
(lbs)
Valve Flow Body Body/Bonnet
S
Size Capacity Connection Material N P R Body Actuator Total
H K L # of
holes
A, C 4.3 2.5 5.0 N/A 19 32
B 7.0 5.5 0.75 31 44
Cast Iron 4
D 7.3 5.7 0.75 31 44
C H 7.3 5.7 0.75 8 31 44
2.5” 4.5 3.8 7.5
B 7.0 5.5 0.75 34 47
Carbon Steel & 4
D 7.3 5.7 0.71 34 47
Stainless Steel
H 7.3 5.7 0.71 8 34 47
C G CS & SS 4.4 6.1 12.3 7.5 5.9 0.88 8 39 51
A, C 5.1 2.8 5.5 N/A 27 40
B Cast Iron 7.5 6.0 0.75 4 48 13 61
C D, H 7.9 6.3 0.75 8 48 61
3” 5.2 4.0 8.0
B Carbon Steel & 7.5 6.0 0.75 4 49 62
D, H Stainless Steel 7.9 6.3 0.71 8 49 62
C G CS & SS 5.2 6.6 13.3 8.3 6.6 0.88 8 56 68
B 9.0 7.5 0.75 66 79
Cast Iron
D, H 8.7 7.1 0.75 66 79
C 5.5 4.5 9.0 8
4” B Carbon Steel & 9.0 7.5 0.75 67 80
D, H Stainless Steel 8.7 7.1 0.71 67 80
C G CS & SS 5.1 7.4 15.3 10 7.9 0.88 8 83 96
Flow Capacity: Body Connection:

S - Standard A - NPT
C - CP Body Construction B - ANSI Flanged (ISO 7005 PN20)
C - ISO 7-1 Threaded
D - DIN PN16 Flanged
E - Socket Welded Nipples
F - Socket Welded Nipples w/ Class 150 Flange (ISO 7005 PN20)
G - Socket Welded Nipples w/ Class 300 Flange (ISO 7005 PN50)
H - EN1092-1 PN16 (ISO 7005-1 PN16)
32M-05003E 21
Series 8100 actuator: 2.5” CP, 3” CP, 4” CP
A B H H
2
1
C

position
Flow Approximate Dimensions (inches)

Valve Size
Capacity A B C D E F G H
2.5” CP 12.2 22.1
3” CP 4.5 3.3 16.3 3.6 6.4 3.0
12.9 22.8
4” CP
Series 8000 and 8100: 6” and 8”
A B E
C E
2
1) 1/8” NPT air inlet connec-

tion D
2) Visual indication of valve J
position
3
3) 1/8” NPT air exhaust - do
not block M
5) 2x 1/4” NPT test connec-
tion
N
5
P
OUTLET
INLET
R H
S
K
L
Approximate Dimensions (inches) Approximate Weight (lbs)

Valve Flow Body Body/Bonnet S
Size Capacity Conn. Material N P R Body Actuator Total
A B C D E H J K L M #of
holes
B 11.0 9.5 0.88 117 140
Cast Iron
D, H 11.2 9.5 0.86 117 140
6” S 4.6 3.3 3.6 6.5 3.0 8.6 33.1 5.25 10.5 21.8 8 23
B Carbon Steel & 11.0 9.5 0.88 126 149
D Stainless Steel 11.2 9.5 0.86 126 149
B 13.5 11.75 0.88 8
Carbon Steel & 5.75 11.5 170 193
8” S D, H 4.6 3.3 3.6 6.5 3.0 8.6 33.1 21.8 13.38 11.61 0.86 12 23
Stainless Steel
J 5.75 11.5 15.0 13.0 1.0 12 217 240
Body Connection:
Flow Capacity: B - ANSI 150 lbs (ISO7005 - PN20)
S - Standard D - DIN PN16 Flanged
H - EN1092-1 PN16 (ISO 7005-1 PN16)
J - ANSI Class 300 Flange (ISO 7005 PN50)
32M-05003E 23
ACCESSORIES
SPEED CONTROL SET
Manually adjustable valve restricts flow to the actuator inlet and so reduces opening speed of the normally-
closed shut-off valve or reduces the closing speed of normally-open vent valves.
• Available in carbon steel and stainless steel construction
• 90° mating elbow provided for easy assembly
• Tamper-proof set screw prevents accidental misadjustment
Carbon Steel construction Stainless Steel construction
A
B
1) Speed control adjustment

knob
C
D
1
E
Speed Control Set A B C D E

Carbon Steel 5.6 4.2 1.3 2.6 1.0
Stainless Steel 6.2 4.6 1.7 2.8 1.0
EXTERNAL REDUNDANT SOLENOID WITH MANUAL RESET

Combination of both external redundant solenoids and manual reset option. If either solenoid trips, the valve will close and cannot be
reset until it is done manually at the site of the valve before operations can resume.
1) Manual reset latching

C
pin A
D F
2) Manual reset button E
3) 1/8” NPT exhaust filter

(do not block)
4) Speed control
(optional) 7
5) Speed adjustment lock 1
screw 6
6) Speed control adjust- B 2
5
ment knob
7) 1/8” NPT air inlet con-
nection 4
3
A B C D E F
7.5 2.7 4.9 3.6 2.1 5.3
EXTERNAL REDUNDANT SOLENOID

Dual shut-off solenoids provide additional SIL 2 certification levels to offer a higher level of protection against potential solenoid failure.
The double redundant solenoid valve will automatically trip as a series shut-down mode and will close or open the valve (depending on
set-up) if either of the solenoid valves trip.
General Purpose Intrinsically Safe
A D
A B
B D
E
F
F
Solenoid type A B C D E F
General Purpose 7.2 5.2 --- 1.0 2.2 1.0
Intrinsically Safe 7.2 5.1 5.9 1.0 3.8 0.4
32M-05003E 25
EXTERNAL REDUNDANT SOLENOID WITH SPEED CONTROL SET

Combination of both external redundant solenoids and speed control set option. If either solenoid trips, the valve will close and cannot be
reset until it is done manually. Speed control set features manually adjustable valve that restricts flow to the actuator inlet and so reduces
opening speed of the normally-closed shut-off valve or reduces the closing speed of normally-open vent valves.
General Purpose Intrinsically Safe
E G A
A E G
B
D
C D
C
F H
Solenoid type / speed control set type A B C D E F G H

General Purpose / carbon steel 5.2 2.2 2.7 1.1 1.0 0.5 8.7 5.2
General Purpose / stainless steel 5.2 2.2 2.8 1.1 1.0 0.5 8.9 5.2
Intrinsically Safe / stainless steel 5.1 --- 2.8 1.7 1.0 --- 8.9 ---
INTRINSIC SAFETY INTERFACES

Approved units interposed between the hazardous and safe area circuits limit parameters such as voltage, current or power.
• Suitable for use in Class I, Div. 2 areas
• DIN rail mounted
• Complements intrinsically safe Series 8000 Valves
Engineering recommendations for barriers and isolator option

Manufacturer IS interface type Model no. Application MAXON no.
MTL 7728+ Solenoid 1067656
Zener Diode [1]
MTL 7787+ Switch [2] 1067655
MTL
MTL 5025 Solenoid 1067660
Isolator [3]
MTL 5018 Switch [4] 1067659
[1] Circuit must be isolated from earth in hazardous area
[2] Two barriers required for VOS1 / VCS1
[3] Circuit may be earthed at one point in hazardous area
[4] One barrier required for VOS1 / VCS1
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
Please read the operating and mounting instructions before using the equipment. Install the equipment in
compliance with the prevailing regulations.
Bedrijfs- en montagehandleiding voor gebruik goed lezen! Apparaat moet volgens de geldende voorschriften
worden geïnstalleerd.
Lire les instructions de montage et de service avant utilisation! L’appareil doit imperativement être installé selon
les règlementations en vigueur.
Betriebs- und Montageanleitung vor Gebrauch lesen! Gerät muß nach den geltenden Vorschriften installiert
werden.
32M-05003E 27
The Installation, Operating and Maintenance Instructions contain important information that must be
read and followed by anyone operating or servicing this product. Do not operate or service this
equipment unless the instructions have been read. IMPROPER INSTALLATION OR USE OF THIS
PRODUCT COULD RESULT IN BODILY INJURY OR DEATH.
DESCRIPTION
The Series 8000 Valve is a pneumatically operated fuel shut-off valve. These valves require compressed air for actuation. The 8000
Series valve will open or close by the addition of a control voltage signal. Removal of the signal will cause a fast acting return to the at
rest position.Options are available in both normally-closed and normally-open versions.
Series 8*1* Normally-Closed will shut off flow when de-energized and pass flow when energized.
Series 8*2* Normally-Open will shut off flow when energized and pass flow when de-energized.
The Series 8000 Valve has optional configurations that meet hazardous locations.
The Series 8000 Valve has fire safe trim configurations that meet API 6FA.
NAMEPLATE AND ABBREVIATIONS

Consult the nameplate on your valve. This lists the maximum operating pressure, temperature limitations, voltage requirements and
service conditions of your specific valve. Do not exceed nameplate ratings.
Abbreviation or Symbol Description

M.O.P. (PS) Maximum Operating Pressure
PACT Required actuator pressure
TS(AMB) Ambient service temperature range
TS(FL) Fluid service temperature range
Visual indication determined by text, color and symbol; valve is shown in open
position
Visual indication determined by text, color and symbol; valve is shown in closed
position
Valve is shut
Valve is partially open
Valve is full open
VOS-1/2 Valve open switch(es)

VCS-1/2 Valve closed switch(es); proof of closure
Component identification
4
9
3
5
1) Flow arrow
2) Visual indication
8 10
3) Terminal block cover screws, M5 x 12
4) Switch access cover 11
5) Terminal block cover
6) Actuator bolts, M8 x 45 or M10 x 1.50
7) Valve body
8) Actuator
9) Switch access cover screws, M6 x 20
10) Nameplate
11) Nameplate screws, M4 x 6
6
32M-05003E 29
Installation
1. A gas filter or strainer of 40 mesh (0.6 mm maximum) or greater is recommended in the fuel gas piping to protect the downstream
safety shut-off valves.
2. Properly support and pipe the valve in the direction of the flow arrow on the valve body. Valve seats are directional. Sealing will be
maintained at full rated pressures in one direction only. Sealing will be provided in reverse flow only at reduced pressures.
3. Mount valve so that open/shut indicator will not face downward.
4. Series 8000 Valves require clean, dry compressed air or gas piped to the inlet of the actuator. Guidelines for various actuating gases:
A. Compressed Air
1. The vent, located on the underside of the base plate, should be protected from blockage.
2. Although MAXON Series 8000 Valves do not require lubrication, they do contain Buna-N (-40°F) or silicone (-58°F) seals in
the actuator sub-assembly. Compressed air supply must not contain any lubricant that is not compatible with Buna-N or
silicone elastomers.
B. Natural gas and other fuel gases can be used to actuate the Series 8000 Valve when the appropriate considerations are taken
into account.
1. Apply only the Intrinsically Safe Series 8000 Valve for the application. The general purpose and non-incendive options are not
suitable for fuel gas activation.
2. The activating fuel gas must be clean and free of moisture. The Series 8000 actuator contains Buna-N elastomers and brass
components that will come in contact with the activating gas. The quality of the gas must not contain any constituents that are
not compatible with Buna-N or brass.
3. The exhaust gas must be vented to the atmosphere in a safe manner by piping from the filtered vent, located on the underside
of the actuator’s base. A 1/8” NPT female connection in the base plate allows for proper piping.
4. The use of fuel gases for actuation is not permitted in EC areas due to ATEX Zone 2 restrictions.
5. Actuators for fuel gas activation are only rated from -40°F to 140°F.
C. For applications that are governed by the ATEX Directive (94/9/EC), use of fuel gas activation is not acceptable.
5. In some instances, it may be desired to utilize a slow opening feature for either application or code-related reasons. If a slow opening
feature is required for normally-closed shut-off valves, use MAXON’s optional speed control set.
6. Wire the valve in accordance with all applicable local and national codes and standards. In U.S. and Canada, wiring must conform to
the NEC ANSI/NFPA 70 and/or CSA C22.1, Part 1.
A. Supply voltages must agree with valve’s nameplate voltage within -15%/+10% for proper operation. For electrical wiring
schematic, see instructions or sample affixed inside valve terminal block cover.
B. Grounding is achieved with a grounding screw, which is located in the top assembly.
C. Customer connections are provided via terminal block located in the top assembly.
D. Main power wiring (120 VAC or 240 VAC) must be segregated from lower voltage 24 VDC signal wiring, when both are required.
E. WARNING: For Division 2 installations using the intrinsically safe solenoid, the power source is not to exceed 28VDC with a
minimum series resistance of 300 ohms.
7. Maintain integrity of the Series 8000 actuator enclosure by using the appropriate electrical connectors for the (2) 3/4” NPT conduit
threaded connections.The Series 8000 electrical enclosure is NEMA 4 and IP65 rated with an option for NEMA 4X.
8. All access cover plate screws should be tightened using an alternate cross-corner tightening pattern to the values shown in Table 1.
Table 1 - Torque Specifications

Item Number Description Torque
3 Terminal Block Cover Screws, M5 x 12 20 in-lbs
9 Switch Access Cover Screws, M6 x 20 20 in-lbs
6 Actuator Bolts, M8 x 45 13 ft-lbs
6 Actuator Bolts, M10 x 1.50 13 ft-lbs
11 Nameplate Screws, M4 x 6 10 in-lbs
9. Verify proper installation and operation by electrically actuating the valve for 10-15 cycles prior to the first introduction of gas.
10.When customer-supplied, externally mounted solenoids are used, the component must be rated for the Class and Division of the
hazardous area. MAXON 8112, 8122, 8012, 8022 valves will only carry FM approval to FM 3611, 3600 and 3810 standards. MAXON
8113, 8123, 8013, 8023 valves will only carry FM approval to 3610, 3600 and 3810 standards.
SPECIFICATIONS
Valve Body Assemblies
Flow Rate [2] MOP
Actuator Body
Body Cv cfh
Valve Size Flow Capacity Pressure Connections ------------- psig
Material Rating -----------
Class Available [1] m3 h bar
A, C Iron 200/13.8
.75” High
Std. Steel 19 1060 / 30
(DN 20) Pressure A, C, E, F, G 255/17.6
Stainless
A, C Iron 200/13.8
1” High
Std. Steel 20 1115 / 31
Stainless
1.25” HIgh
Std. A, C Iron 45 2510 / 71 200/13.8
(DN 32) Pressure
A, C Iron 200/13.8
1.5” High
Std. Steel 53 2956 / 83
Stainless
A, B, C, D, H Iron 200/13.8
2” High
Std. Steel 86 4796 / 135
Stainless
High
Std. A, B, C, D, H Iron 127 7083 / 200 150/10.3
Pressure
A, B, C, D, H Iron
2.5” Std. Steel 50/3.4
B, D, H
(DN 65) Stainless
CP 304 16955 / 480
A, B, C, D, H Iron
High
Steel 175/12.1
Pressure B, D, H
Stainless
High
Std. A, C Iron 173 9648 / 273 150/10.3
Pressure
A, B, C, D, H Iron
3” Std. Steel 40/2.7
B, D, H
(DN 80) Stainless
CP 423 23591 / 668
A, B, C, D, H Iron
High
Steel 135/9.3
Pressure B, D, H
Stainless
Iron
Std. Steel 40/2.7
4” Stainless
CP B, D, H 490 27328 / 773
(DN 100) Iron
High
Steel 135/9.3
Pressure
Stainless
Iron
Std. Steel 60/4.1
6” Stainless
Std. B, D, H 1172 65364 / 1850
(DN 150) Iron
High
Steel 100/6.9
Pressure
Stainless
Steel
Std. 60/4.1
8” Stainless
Std. B, D, H, J 1320 73406 / 2078
(DN 200) High Steel
100/6.9
Pressure Stainless
Note 1: Body Connections
E - Socket Welded Nipple
A - NPT
F - Socket Welded Nipple w/ANSI 150 lb flange (ISO 7005 PN20)
B - ANSI 150 lb Flange (ISO 7005 PN 20)
G - Socket Welded Nipple w/ANSI 300 lb flange (ISO 7005 PN50)
C - ISO Threaded
H - EN 1092-1 PN16 (ISO 7005-1 PN16)
D - DIN PN16 Flange
J - ANSI Class 300 Flange (ISO 7005 PN50)
Note 2: Flow for Natural Gas (S.G. 0.60) at differential pressure = 1” wc and standard temperature (68°F) and pressure (14.696 psi)
32M-05003E 31
OPERATING CHARACTERISTICS
• Opening time varies per valve size, 3 seconds or less for largest size. For slower opening, a speed control set can be supplied by
MAXON.
• Closing time is less than 1 second.
• Type of Gas
Gas Compatibility and Valve Approvals/Certifications

Agency Approvals and
Suggested Material Options
Gas MOPD Certifications
Gas
Code Body & Trim Rating CSA CE [4]
Body seals FM
bonnet Package [5] [3] GAD MD
Air AIR A, B, C, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X NA X
Ammonia AMM A, C, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X NA X
Butane Gas BUT A, B, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X X X
Coke Oven Gas COKE B, F 5 Analysis Required Std. X X NA X
Delco DEL A, B, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X NA X
Digester [1] DIG Analysis Required 5 Analysis Required Std. X X NA X
Endothermic AGA ENDO A, B, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X NA X
Exothermic Gas EXO A, B, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X NA X
Hydrogen Gas HYD A, B, C, F 1, 2, 5, 6 1, 2, 3, 6, 7 [2] X X NA X
Manufactured [1] MFGD Analysis Required 5 Analysis Required Std. X X NA X
Natural Gas NAT A, B, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X X X
Nitrogen NIT A, B, C, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X NA X
Oxygen High OXYH B, C, F 2, 5, 6 4, 5 200 psig max X X NA X
Oxygen Low OXYL B, C, F 1, 2, 5, 6 4, 5 30 psig max X X NA X
Oxygen X OXYX B, C, F 2, 5, 6 4, 5 Std. X X NA X
Propane PROP A, B, F 1, 2, 5, 6 1, 2, 3, 6, 7 Std. X X X X
Refinery [1] REF Analysis Required 5 Analysis Required Std. X X NA X
Sour Natural [1] SOUR Analysis Required 5 Analysis Required Std. X X NA X
Town Gas [1] TOWN Analysis Required 5 Analysis Required Std. X X X X
Land Fill Gas LAND Analysis Required 5 Analysis Required Std. X X NA X
Notes:
[1] Other body and trim packages may be acceptable pending fuel analysis. For pricing inquiry, Viton body seals will be standard option. Contact MAXON for details.
[2] Valve maximum operating pressure (MOPD) to be reduced by 25% from standard ratings.
[3] ISO connections are not recognized by CSA standards.
[4] All 8000 Valves do meet the essential requirements of the Low Voltage (73/23/EC) and the EMC (89/336/EC) Directives. GAD refers to the Gas Appliances Direc-
tive (2009/142/EC): this Directive only covers the use of commercially available fuels (natural gas, butane, town gas and LPG). MD stands for Machinery Directive
(2006/42/EC). All Series 8000 valves meet the essential requirements for fuel shut off on Industrial Thermal Equipment as specified in EN746-2.
[5] Trim Package 1 is only allowed with body and bonnet 1.
Body Seals: Body & Bonnet: Trim Package:

A - Buna-N 1 - Cast Iron 1 - Trim Package 1
B - Viton 2 - Carbon Steel 2 - Trim Package 2
C - Ethylene Propylene 5 - Stainless Steel 3 - Trim Package 3 (NACE)
F - Omniflex 6 - Low Temp Carbon Steel 4 - Trim Package 2, Oxy Clean
5 - Trim Package 3, Oxy Clean
AUXILIARY FEATURES
• Non-adjustable Proof of Closure Switch(es) with valve seal over travel interlock.
• Auxiliary switch for indication of full travel (open for normally-closed valves, closed for normally-open valves).
OPERATING ENVIRONMENT
• Fluid temperature range of -40°F to 212°F , with options available for -58°F to 212°F.
• Actuators are rated for NEMA 4, IP65 or optional NEMA 4X, IP65.
• Ambient temperature range of -40°F to 140°F for the 8011, 8111, 8021 and 8121 General Purpose and 8012, 8112, 8022 and 8122
Non-Incendive series valves; option of -58°F to 140°F also available.
• Ambient temperature range of -40°F to 122°F for 8013, 8113, 8023 and 8123 Intrinsically Safe series valves; option of -58°F to 122°F
also available.
• All valves for oxygen service or using Ethylene Propylene body seals are limited to a minimum ambient and fluid temperature of 0°F.
32M-05003E 33
PRODUCT APPROVALS
VALVE CYCLE REQUIREMENTS

This is based on the standards that MAXON valves are approved to and the corresponding minimum number of cycles to be completed
without failure as shown in the chart below.
CSA (CSA 6.5) FM (FM 7400) European (EN161)

Automatic - Normally-Closed <= 1” 200,000
Series 8011, 8111, 8012, 8112, 8013, 8113 100,000 20,000 <= 3” 100,000
<= 8” 50,000
Vent Valves No special No special No special
Series 8021, 8121, 8022, 8122, 8023, 8123 requirements requirements requirements
32M-05003E 35
ELECTRICAL DATA
Normally-Closed Shut-Off Valves
GENERAL PURPOSE NORMALLY-CLOSED VALVES
Series 8011 & Series 8111
Switches: V7
Solenoid Valve: Standard
24 VDC, 4.8W
120VAC, 50/60 Hz, 11/9.4 VA Peak, 8.5/6.9 VA Holding
See page 12 or inside valve cover for wiring schematic.
NON-INCENDIVE NORMALLY-CLOSED VALVES

Switches: IP67
24 VDC, 4.8W
24VDC IS, .09A, 2.1W
INTRINSICALLY SAFE NORMALLY-CLOSED VALVES

Switches: V7 with optional IP67
Solenoid Valve: Intrinsically Safe
NOTES:
1) The Intrinsic Safety Entity concept allows the interconnection of NON-HAZARDOUS LOCATION
HAZARDOUS (CLASSIFIED) LOCATION
two FM approved (CSA Certified when installed in Canada) CLASS I, DIVISION 1, GROUPS A,B,C,D
Intrinsically safe devices with entity parameters not specifically CLASS II, DIVISION 1, GROUPS E,F,G
examined in combination as a system when:
Voc or Uo or Vt Vmax, Isc or Io or It Imax, Ca or Co Ci+ Barrier(s) used in an Approved Config.
Ccable, La or Lo Li + Lcable, and for FM only: Po Pi. with “V” max. greater than “VI” or
“Voc” and “I” max greater than
2) Dust-tight conduit seal must be used when installed in Class II “I t” or “I sc”
and Class III environments.
3) Control equipment connected to the Associated Apparatus
Power
must not use or generate more than 250 Vrms or Vdc. Supply
4) Installation in the U.S. should be in accordance with ANSI/ISA
RP12.06.01 “Installation of Intrinsically Safe Systems for Solenoid
Valve
Hazardous (Classified) Locations” and the National Electric 250 RMS max.
Code® (ANSI/NFPA 70) Sections 504 and 505.
CSA/FM certified Barrier
5) Installation in Canada should be in accordance with the Solenoid Entity Parameters
V max = 28 VDC rated 28 V max./300 ohms
Canadian Electrical Code, CSA C22.1, Part 1, Appendix F. min. or equivalent
I max. = 115 mA
6) Installation in the European Union should be in accordance to Pi = 1.6 W
Directive 94/9/EC (ATEX 95). Ci = 0µF
Li = 0 µH
7) The configuration of associated Apparatus must be FM
Approved (CSA Certified when in Canada) under Entity
Concept. Valve
Position
8) Associated Apparatus manufacturer’s installation drawing must Switch
be followed when installing this equipment.
9) No revision to drawing without prior authorization from FM V max. = 30 VDC
“CSA/FM certified Barrier
Approval and CSA International. I max. = 500 mA for a simple apparatus”
Pi = 2 W
Ci = 0µF
Li = 0 µH
INTRINSICALLY SAFE NORMALLY-CLOSED VALVES

Solenoid Valve: Customer-supplied, externally mounted
NOTES:
1) The Intrinsic Safety Entity concept allows the interconnection of two HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION
FM approved (CSA Certified when installed in Canada) Intrinsically CLASS II, DIVISION 1, GROUPS E,F,G
safe devices with entity parameters not specifically examined in CLASS III, DIVISION 1
combination as a system when:

Voc or Uo or Vt Vmax, Isc or Io or It Imax, Ca or Co Ci+ Ccable, La Factory Mutual/CSA Approved
or Lo Li + Lcable, and for FM only: Po Pi. figuration with "V" max. greater than "Vt"
or "Voc" and "I" max. greater than "I t" or "I sc"
2) Dust-tight conduit seal must be used when installed in Class II and
Class III environments.
3) Control equipment connected to the Associated Apparatus must Power
not use or generate more than the maximum permissible safe area supply
voltage (Um) for the barrier.

Solenoid
4) Installation in the U.S. should be in accordance with ANSI/ISA Valve
see note 3
RP12.06.01 “Installation of Intrinsically Safe Systems for Hazardous Customer Supplied Solenoid Valve
(Classified) Locations” and the National Electric Code® (ANSI/ -To be mounted external to valve actuator.
-Component must be rated for the Class
NFPA 70) Sections 504 and 505. and Division of the hazardous environment
as stated above.
5) Installation in Canada should be in accordance with the Canadian -Component must be rated for instrinsic
Electrical Code, CSA C22.1, Part 1, Appendix F. intrinsically safe devices as required under
6) Installation in the European Union should be in accordance to
Directive 94/9/EC (ATEX 95).
7) The configuration of associated Apparatus must be FM Approved
(CSA Certified when in Canada) under Entity Concept. Valve
Position
8) Associated Apparatus manufacturer’s installation drawing must be Switch
followed when installing this equipment. Switch Entity Parameters

9) No revision to drawing without prior authorization from FM Approval V max.=30 VDC
"CSA/FM/ATEX certified Barrier
I max.=500 mA
and CSA International. Pi= 2 W for a simple apparatus"
Ci= O µF
Li= O µH
32M-05003E 37
Normally-Open Vent Valves

GENERAL PURPOSE NORMALLY-OPEN VENT VALVES
Switches: V7
24 VDC, 4.8W
See page 12 or inside valve cover for wiring schematic.
NON-INCENDIVE NORMALLY-OPEN VENT VALVES

Switches: IP67
24 VDC, 4.8W
24VDC IS, .09A, 2.1W
INTRINSICALLY SAFE NORMALLY-OPEN VENT VALVES

Solenoid Valve: Intrinsically Safe
NOTES:
1) The Intrinsic Safety Entity concept allows the interconnection of
two FM approved (CSA Certified when installed in Canada) CLASS I, DIVISION 1, GROUPS A,B,C,D
Intrinsically safe devices with entity parameters not specifically CLASS II, DIVISION 1, GROUPS E,F,G
examined in combination as a system when: CLASS III, DIVISION 1
Voc or Uo or Vt Vmax, Isc or Io or It Imax, Ca or Co Ci+ Factory Mutual/CSA Approved
Barrier(s) used in an Approved Config.
Ccable, La or Lo Li + Lcable, and for FM only: Po Pi. with “V” max. greater than “VI” or
“Voc” and “I” max greater than
2) Dust-tight conduit seal must be used when installed in Class II “I t” or “I sc”
and Class III environments.
3) Control equipment connected to the Associated Apparatus
must not use or generate more than 250 Vrms or Vdc. Power
Supply
4) Installation in the U.S. should be in accordance with ANSI/ISA
RP12.06.01 “Installation of Intrinsically Safe Systems for Solenoid
Valve
Hazardous (Classified) Locations” and the National Electric 250 RMS max.
Code® (ANSI/NFPA 70) Sections 504 and 505.
5) Installation in Canada should be in accordance with the Solenoid Entity Parameters CSA/FM certified Barrier
rated 28 V max./300 ohm
Canadian Electrical Code, CSA C22.1, Part 1, Appendix F. V max = 28 VDC
min. or equivalents
I max. = 115 mA
6) Installation in the European Union should be in accordance to Pi = 1.6 W
Directive 94/9/EC (ATEX 95). Ci = 0µF
7) The configuration of associated Apparatus must be FM Li = 0 µH
Approved (CSA Certified when in Canada) under Entity
Concept. Valve
8) Associated Apparatus manufacturer’s installation drawing must Position
Switch
be followed when installing this equipment.
9) No revision to drawing without prior authorization from FM Switch Entity Parameters
V max. = 30 VDC
Approval and CSA International. I max. = 500 mA
“CSA/FM certified Barrier
for a simple apparatus”
Pi = 2 W
Ci = 0µF
Li = 0 µH
INTRINSICALLY SAFE NORMALLY-OPEN VENT VALVES

Solenoid Valve: Customer-supplied, externally mounted
NOTES:
1) The Intrinsic Safety Entity concept allows the interconnection of two HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION
FM approved (CSA Certified when installed in Canada) Intrinsically CLASS II, DIVISION 1, GROUPS E,F,G
safe devices with entity parameters not specifically examined in CLASS III, DIVISION 1
combination as a system when:
Voc or Uo or Vt Vmax, Isc or Io or It Imax, Ca or Co Ci+ Ccable, La Factory Mutual/CSA Approved
or Lo Li + Lcable, and for FM only: Po Pi. figuration with "V" max. greater than "Vt"
2) Dust-tight conduit seal must be used when installed in Class II and or "Voc" and "I" max. greater than "I t" or "I sc"
Class III environments.

3) Control equipment connected to the Associated Apparatus must
Power
not use or generate more than the maximum permissible safe area supply
voltage (Um) for the barrier.
4) Installation in the U.S. should be in accordance with ANSI/ISA Solenoid
Valve
RP12.06.01 “Installation of Intrinsically Safe Systems for Hazardous see note 3
(Classified) Locations” and the National Electric Code® (ANSI/ Customer Supplied Solenoid Valve
-To be mounted external to valve actuator.
NFPA 70) Sections 504 and 505. -Component must be rated for the Class
and Division of the hazardous environment
5) Installation in Canada should be in accordance with the Canadian as stated above.
Electrical Code, CSA C22.1, Part 1, Appendix F. -Component must be rated for instrinsic
6) Installation in the European Union should be in accordance to intrinsically safe devices as required under
Directive 94/9/EC (ATEX 95).
7) The configuration of associated Apparatus must be FM Approved
(CSA Certified when in Canada) under Entity Concept.
8) Associated Apparatus manufacturer’s installation drawing must be Valve
Position
followed when installing this equipment. Switch
9) No revision to drawing without prior authorization from FM Approval
and CSA International.
V max.=30 VDC
I max.=500 mA "CSA/FM/ATEX certified Barrier
Pi= 2 W for a simple apparatus"
Ci= O µF
Li= O µH
32M-05003E 39
OPERATING INSTRUCTIONS
Refer to appropriate catalog page for operating features applying to your specific valve. Never operate valve until all essential allied
equipment is operative and any necessary purges completed. Failure of valve to operate normally indicates that it is not powered or
supply air pressure is not adequate. Check this first!
Main system shut-off should always be accomplished with an upstream leak-tight manual fuel cock.
The Series 8000 Pneumatic Safety Shut-off Valve is not intended to be used for end of line service.
Users are responsible for providing protection against surface temperatures.

Users are responsible for providing suitable protective devices to protect against over pressure conditions.
Users are responsible for limiting momentary pressure surges to within 10% of the maximum allowed pressure in accordance with the
Pressure Equipment Directive.
• Normally-closed shut-off valves begin opening cycle immediately upon being powered.
• Normally-open vent valves begin to close immediately upon being powered.
ALTERNATE OPERATOR PRESSURES

Series 8000 Valves may be operated within a range of actuator pressures. Consult charts below for application fluid pressure and
corresponding required actuator pressure.
32M-05003E 41
MAINTENANCE INSTRUCTIONS
MAXON Series 8000 Valves are endurance tested far in excess of the most stringent requirements of the various approval agencies.
They are designed for long life even if frequently cycled, and to be as maintenance-free and trouble-free as possible.
A valve operational test should be performed on an annual basis. If abnormal opening or closing is observed, the valve should be
removed from service and your MAXON representative should be contacted. (See Valve Technical Data page 10-35.1.)
Valve leak test should be performed on an annual basis to assure continued safe and reliable operation. Every MAXON valve is
operationally tested and meets the requirements of FCI 70-2 Class VI Seat Leakage when in good operable condition. Zero leakage may
not be obtained in the field after it has been in service. For specific recommendations on leak test procedures, see MAXON Valve
Technical Data page 10-35.2. Any valve that exceeds the allowable leakage, as set forth by your local codes or insurance requirements,
should be removed from service and your MAXON representative should be contacted.
Actuator assembly components require no field lubrication and should never be oiled.
Auxiliary switches, solenoids or complete actuator may be replaced in the field.
Do not attempt field repair of valve body or actuator. Any alterations void all
warranties and can create potentially hazardous situations.
If foreign material or corrosive substances are present in the fuel line, it will be necessary to inspect the valve to make certain it is
operating properly. If abnormal opening or closing is observed, the valve should be removed from service. Contact your MAXON
representative for instructions.
Operator should be aware of and observe characteristic opening/closing action of the valve. Should operation ever become sluggish,
remove valve from service and contact MAXON for recommendations.
Address inquiries to MAXON. Local worldwide offices may be located at www.maxoncorp.com or by phoning 011-765-284-3304.
Include valve serial number and nameplate information.
32M-05003E 43
Solenoid replacement procedure

• All power sources, both pneumatic and electric, must be de-energized and follow all proper safety procedures prior to servicing valve.
• Use a 4 mm allen wrench to remove the top plate. A 3 mm allen wrench is used to remove the terminal block cover.
• Use a 5/16” open end wrench to hold the cylinder shaft, then use a pair of pliers to unthread the switch indicator from the cylinder shaft.
When using pliers, grab the indicator from the top.
1
2
3
1) Top plate screw M6 x 20

socket head cap screw 4
2) M6 Lock washer
3) Top plate
4) Switch indicator 5
5) Cylinder shaft
6
7) M5 Lock washer
screw M5 x 12 socket
head cap screw
7
8
• Loosen the liquid tight connector nut where the solenoid wires come into the top housing. Remove #1 and #2 wire from the terminal
block.
1) Liquid tight connector
• Use a 3/4” wrench to remove the solenoid inlet fitting. An adjustable wrench is used to loosen the housing collar. Slightly loosen the
housing collar but do not remove, due to the nut and o-ring located inside the housing becoming dislocated.
1
2
1) Housing collar
2) Solenoid inlet fitting
• Use a 4 mm allen wrench and remove the 4 screws that hold the housing to the base plate. Pull the housing straight up and remove.
Old solenoid wires will pass through liquid tight connector.
1) Housing
2) Base plate
3) Housing screws M6 x 20
cap screws 2
• Use a 4 mm allen wrench and remove the 2 screws that hold the solenoid on. Replace the solenoid ensuring that there are 2 o-rings,
one on the solenoid inlet and one on the solenoid outlet. The solenoid must be level when tightening screws.
1
1) Solenoid o-ring 2
2) Solenoid
3) M5 x 40 socket head cap
screw
4) Solenoid o-ring
3
4
32M-05003E 45
• Run the new solenoid wires back up through the liquid tight connector in the housing and align the cylinder shaft with the hole in the
housing. Carefully slide housing back into position. Replace the 4 housing screws and leave loose.
• Verify the o-ring is still on the solenoid inlet by looking through the housing collar. Reinstall solenoid inlet fitting tight. Leave the housing
collar loose.
• Reinstall solenoid wire #1 and #2 back to the terminal block and tighten down the liquid tight connector nut.
• A locking sealant must be used on the cylinder shaft threads and then reinstall the switch indicator. Make sure to remove any locking
sealant that runs down the cylinder shaft. Re-energize pneumatic and electric power and cycle the valve several times to ensure it
operates smoothly. Tighten down the 4 housing screws that hold the housing to the base plate using a cross pattern (see torque val-
ues in Table 1 on page 30). Then tighten the housing collar on the solenoid inlet fitting. The o-ring under the housing collar must not be
pinched while tightening the housing collar.
• Cycle valve several more times to see if it still operates smoothly. If not, loosen the 4 screws that hold the housing to the base plate and
cycle again. Retighten the 4 housing screws. Put the top plate and terminal block covers back on valve (see torque values in Table 1 on
page 30).
Actuator assembly rotation/replacement

MAXON Series 8000 Valves should be ordered in a configuration compatible with planned piping. If
valve orientation is not correct, the actuator assembly can be rotated in 90° increments around the
valve body centerline axis using the procedure below. This procedure should also be followed for field
replacement of the actuator.
• Shut off all electrical power and close off upstream manual cock.
• Remove terminal block access cover plate [4] and disconnect power lead wires. Caution: Label all wires prior to disconnection
when servicing valve. Wiring errors can cause improper and dangerous operation.
• Remove conduit and electrical leads.
• Remove all pneumatic lines.
• Unscrew the actuator/body bolts [5] screwed up from the bottom. These bolts secure the valve actuator [7] to the valve body [6].
• Gently lift the actuator [7] off valve body assembly enough to break the seal between body assembly and the rubber gasket adher-
ing to the bottom of the actuator base plate.
• Carefully rotate/replace actuator assembly to the desired position. Reposition the actuator back down onto the valve body casting.
• Realign holes in valve body casting with the corresponding tapped holes in the bottom of the actuator base plate. Be sure the gasket
is still in place between the body and actuator base plate.
• Reinsert the body bolts up from the bottom through the body and carefully engage threads of the actuator assembly. Tighten
securely referring to Table 1 on page 10-30.3-30 for appropriate torque specifications.
• Reconnect conduit, electrical leads, and all pneumatic lines, then check that signal switch wands are properly positioned. Failure
to correct any such misalignment can result in extensive damage to the internal mechanism of your valve.
• Energize valve and cycle several times from closed to full open position. Also electrically trip the valve in a partially opened position
to prove valve operates properly.
• Replace and secure cover plates.
• Verify proper operation after servicing.
3
8
2
1) Flow arrow on valve body

2) Open/shut indicator (see
Note 1 below)
3) Switch access cover
4) Terminal block cover and 4
screws
5) Actuator/body bolts 7
6) Valve body
7) Actuator assembly
8) Switch access cover
screws
6 5
Note 1: Open/Shut indication is 360°. If required, the observation window may be cleaned with a damp cloth.
32M-05003E 47
Field installation of valve position switch

Instructions below are written for normally-closed shut-off valves. For normally-open vent valves,
reverse switch nomenclature. (VOS becomes VCS and vice versa.)
General: Shut off fuel supply upstream of valve, then de-energize valve electrically.
Remove top cover and terminal block cover to provide access, being careful not to damage gasket.
See pages 48 and 49 for instructions on adding or replacing switches.
Substitution of components may affect suitability for Hazardous Locations.
FIELD REPLACEMENT ITEMS

• Position Switches
• Actuators
• Solenoids
Contact MAXON with valve serial numbers to locate appropriate switch kit assembly.
Figure 3: Typical switch sub-assemblies
V7 assembly for General Purpose and IP67 Switch assembly for Non-Incendive
Intrinsically Safe valves and optional Intrinsically Safe valves
REPLACEMENT SWITCHES:
• Carefully remove field wiring from the terminal block (see page 29, item 5). Insure field wires are clearly marked to correct terminal.
• Unwire the solenoid valve lead wires from terminals labeled #1 and #2.
• Remove screws that secure the switch sub-assembly to the actuator housing. The switch sub-assembly should be easily removable
from actuator assembly (see Figure 3: Typical Switch Sub-Assemblies).
• Note wand position and mounting hole location. Carefully remove the 2 screws and lift existing switch. Reference Figures 4 through 9
(page 49) to ensure correct switch location.
• Install replacement switch in same mounting holes on bracket and verify correct wand position.
• Replace existing wiring one connection at a time, following original route and placement.
• Reassemble switch sub-assembly in actuator housing. Dowel pins are provided to insure proper placement of switch sub-assembly.
• Wire the solenoid valve leads to terminals labeled #1 and #2.
• Cycle valve, checking switch actuation points carefully. VCS switch actuates at top of stem stroke and VOS at bottom for normally-
closed shut-off valves; vice-versa for normally-open vent valves.
• Replace covers using torque values in Table 1 on page 30, and then return valve to service.
ADD SWITCHES:
• Carefully remove field wiring from the terminal block (see page 29, item 5). Insure field wires are clearly marked to correct terminal.
• Unwire the solenoid valve lead wires from terminals labeled #1 and #2.
• Remove screws that secure the switch sub-assembly to the actuator housing. The switch sub-assembly should be easily removable
from actuator assembly (see Figure 3: Typical Switch Sub-Assemblies).
• Reference Figures 4 through 9 (below) to ensure correct switch location. Valve size is depicted in the model number by the first 4 dig-
its. For example, a 3” CP valve should have Model No. 300C.
• Install switch and insulators, when provided, to correct hole. Insure proper alignment. VCS switch should have activation wand pointed
upward and VOS activation wand should be pointed downward.
• Wire new switches to terminals provided.
• Reassemble switch sub-assembly in actuator housing. Dowel pins are provided to insure proper placement of switch sub-assembly.
• Wire the solenoid valve leads to terminals labeled #1 and #2.
• Cycle valve, checking switch actuation points carefully. VCS switch actuates at top of stem stroke and VOS at bottom for normally-
closed shut-off valves; vice-versa for normally-open vent valves.
• Replace covers using torque values in Table 1 on page 30, and then return valve to service.
2.5”CP, 3”CP, 4”CP
2.5”CP, 3”CP, 4”CP
.75”, 1”, 1.25”, 1.5”

2”, 2.5” & 3” VCS
.75”, 1”, 1.25”, 1.5”
2”, 2.5” & 3” VCS
.75” & 1” VOS
2.5”CP VOS
.75” & 1” VOS 2.5”CP VOS 1.25” VOS
1.5” VOS
3”CP, 4”CP
2”, 2.5” & 3” VOS
1.25” VOS
3”CP, 4”CP
1.5” VOS
2”, 2.5” & 3” VOS
Figure 6: Figure 7:
Figure 4: Figure 5:
General Purpose General Purpose
IP67 Switch Bracket IP67 Switch Bracket
Switch Bracket Switch Assembly
Figure 8: Figure 9:
6” & 8” Valve IP67 6” & 8” Valve General
Switch Bracket Purpose Switch Bracket
32M-05003E 49
IEC 61508 INSTRUCTION REQUIREMENTS

PRODUCT DESCRIPTION
A Failure Mode, Effects, and Diagnostics Analysis (FMEDA) report is available from MAXON. Detailed failure rate data is available in the
FMEDA reports. Data for Series 8000 Valves with internal solenoids only can be found in Exida Report MAX 08/09-07 R002. Data for
Series 8000 Valves with internal solenoid and redundant external solenoid can be found in Exida Report MAX 1208063 R002.
PRIMARY SAFETY FUNCTION

a. Series 8*1*, Normally Closed will pass flow when energized and shut off flow within the stated leakage specification when de-
energized.
b. Series 8*2*, Normally Open will pass flow when de-energized and shut off flow within the stated leakage specification when
energized.
c. The valves are designed for low demand applications.
d. The valve must be within specified operating conditions, as found in the instruction manual.
PROOF TEST
The objective of proof testing is to detect failures within the Series 8000 Valve that prevent the valve from performing its safety function.
The frequency of proof testing, or the proof test interval, is to be determined in reliability calculations for the safety instrumented functions
for which the Series 8000 Valve is applied. The proof tests must be performed more frequently or as frequently as specified in the
calculation in order to maintain the required safety integrity of the safety instrumented function.
Maintenance instructions include a Valve Leak Test. These instructions must be followed during the proof test. This Valve Leak Test will
detect approximately 99% of possible DU (Dangerous Undetected) failures resulting in a Proof Test Coverage of 99% for the valve. For
specific recommendations on leak test procedures, see MAXON Valve Technical Document 10-35.2-1.
The person(s) performing the proof test of the Series 8000 Valve should be trained in SIS (Safety Instrumented Systems) operations,
including bypass procedures, valve maintenance and Company Management of Change procedures.
If implementing partial stroke testing of Series 8000 Valves, see MAXON PSCheck documentation (Form Number 32M-05004) for
diagnostic coverage information related to Series 8000 Valves.
RELIABILITY DATA AND LIFETIME LIMIT

A detailed Failure Mode, Effects, and Diagnostics Analysis (FMEDA) report is available from MAXON. This report details all failure rates
and failure modes, common cause factors for applications with redundant devices and the expected lifetime of the Series 8000 Valve.
FITTING CERTIFICATE
We:
Maxon Corporation
Address:
201 E. 18th Street
Muncie, IN 47302
USA
Declare that all fittings produced at the above address within the following product group:
Maxon Series 8000 Air Actuated Valves
Conform to all applicable provisions of the European Gas Appliance Directive.
Certification: Product Identification Number C86CM45 applies
EC Surveillance: BSI (Notified Body Number 0086)
This certificate issued by: Maxon Corporation
Name: Lora Davis
Title/Position: Product Engineering Manager
Date of issue: April 15, 2011
32M-05003E 51
SERIES 8000 GAS SHUT-OFF VALVE
Commercial & Industrial Combustion

(C&IC)
Maxon
201 East 18th Street
P.O. Box 2068
Muncie, IN 47307-0068
Tel: 765.284.3304
Fax: 765.286.8394
Canada Sales Office
Maxon Industrial Equipment
3333 Unity Drive
Mississauga, Ontario L5L 3S6
Tel: 800.489.4111
Fax: 855.262.0792
European Sales Office
Maxon International BVBA
Luchthavenlaan 16-18
1800 Vilvoorde, Belgium
Tel: 32.2.255.09.09
Fax: 32.2.251.82.41
Asia/Pacific Sales Office
Maxon
Honeywell Building
17 Changi Business Park, Central 1
Singapore 486073
Tel: 65.6580.3358
Fax:65.6580.3345
China Sales Office
Maxon Combustion Equipment
(Shanghai) Co., Ltd.
1st Floor & Section A, 4th Floor
225 Meisheng Road
Wai Gao Qiao Free Trade Zone
Pudong New Area
Shanghai 200131, P.R. China
Tel: 86.21.5866.1166
Fax:86.21.5868.1569
India Sales Office
Maxon
53, 54, 56, 57 Hadapsar Industrial Estate
Environmental & Combustion Controls
Sapphire Building 2nd Floor, A Wing
Pune 411013 India
Tel: 91.98.50907894
91.20.66008330
91.20.66008509
Sales Offices &
Representatives Worldwide
www.maxoncorp.com
customer.honeywell.com
32M-05003E - Imperial version

Maxon P/N 50111985-001/A01
August 2014 Printed in USA
© 2014 Honeywell International Inc.
Product Data Sheet
September 2014
00813-0100-4001, Rev SA
Rosemount 3051 Pressure Transmitter
With the Rosemount 3051 Pressure Transmitter, you’ll gain more control over your plant. You’ll be able to
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Maximize installation and application

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 Detect on-scale failures caused by electrical loop issues before they impact your process
operation
 This capability is safety certified for your most critical applications
Local operator interface
 Straightforward menus and built-in configuration buttons allow you commission the device in less
than a minute
 Configure in hazardous-area locations without removing the transmitter cover using external
buttons
Contents
Rosemount 3051C Coplanar™ Pressure Transmitter . . . . . . 4 Rosemount 3051L Level Transmitter . . . . . . . . . . . . . . . . . . 38
Rosemount 3051T In-Line Pressure Transmitter . . . . . . . . . 11 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Rosemount 3051CF Flowmeter Selection Guide . . . . . . . . . 17 3051 Product Certifications . . . . . . . . . . . . . . . . . . . . . . . . 56
Rosemount 3051CFA Annubar Flowmeter . . . . . . . . . . . . . 18 Pipe I.D. Range Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Rosemount 3051CFC Compact Flowmeter . . . . . . . . . . . . . 26 Rosemount 3051 Dimensional Drawings . . . . . . . . . . . . . . 66
Rosemount 3051CFP Integral Orifice Flowmeter . . . . . . . . 32 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2 www.rosemount.com
September 2014 Rosemount 3051
Industry leading capabilities extended to IEC 62591

(WirelessHART®)
 Cost effectively implement wireless on the industry's most proven platform
 Optimize safety with the industry's only intrinsically safe power module
 Eliminate wiring design and construction complexities to lower costs by 40-60%
 Quickly deploy new pressure, level and flow measurements in 70% less time
Innovative, integrated DP Flowmeters

 Fully assembled, configured, and leak tested for out-of-the-box installation
 Reduce straight pipe requirements, lower permanent pressure loss and achieve accurate
measurement in small line sizes
 Up to 1.65% volumetric flow accuracy at 8:1 turndown
Proven, reliable, and innovative DP Level Technologies

 Connect to virtually any process with a comprehensive offering of process connections, fill
fluids, direct mount or capillary connections and materials
 Quantify and optimize total system performance with QZ option
 Operate at higher temperature and in vacuum applications
 Optimize level measurement with cost efficient Rosemount Tuned-System™ Assemblies
Instrument manifolds – quality, convenient, and easy

 Designed and engineered for optimal performance with Rosemount transmitters
 Save installation time and money with factory assembly
 Offers a variety of styles, materials and configurations
www.rosemount.com 3
Rosemount 3051C Coplanar™ Pressure Transmitter
Rosemount 3051C Coplanar Pressure Transmitters are the industry standard for Differential,
Gage, and Absolute pressure measurement. The Coplanar Platform enables seamless
integration with manifolds, flow and level solutions. Capabilities include:
 Power Advisory can proactively detect degraded electrical loop integrity issues (Option Code
DA0)
 Local Operator Interface with straightforward menus and built-in configuration buttons
(Option Code M4)
3051C Coplanar
Pressure Transmitter  Safety Certification (Option Code QT)
See Specifications and options for more details on each configuration. Specification and selection of product materials, options, or
components must be made by the purchaser of the equipment. See page 54 for more information on Material Selection.
Additional information:
Specifications: page 45
Certifications: page 56
Dimensional Drawings: page 66
Table 1. 3051C Coplanar Pressure Transmitters Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Model Transmitter type

3051C(1) Coplanar Pressure Transmitter
Measurement type
D Differential H
G Gage H
A(2) Absolute
Pressure range
Differential (3051CD) Gage (3051CG) Absolute (3051CA)
–25 to 25 inH2O –25 to 25 inH2O 0 to 30 psia
1 H
(-62,16 to 62,16 mbar) (-62,16 to 62,16 mbar) (0 to 2,06 bar)
2 H
(-621,60 to 621,60 mbar) (-621,60 to 621,60 mbar) (0 to 10,34 bar)
3 H
(-2,48 to 2,48 bar) (-0,97 to 2,48 bar) (0 to 55,15 bar)
–300 to 300 psi –14.2 to 300 psi 0 to 4000 psia
4 H
(-20,68 to 20,68 bar) (-0,97 to 20,68 bar) (0 to 275,79 bar)
–2000 to 2000 psi –14.2 to 2000 psi
5 N/A H
(-137,89 to 137,89 bar) (-0,97 to 137,89 bar)
–3 to 3 inH2O
0(3) N/A N/A
(-7,46 to 7,46 mbar)
Transmitter output
A(4) 4–20 mA with Digital Signal Based on HART Protocol H
F FOUNDATION™ fieldbus Protocol H
W(5) PROFIBUS® PA Protocol H
(6)
X Wireless (requires wireless options and engineered polymer housing) H
M(7) Low-Power, 1-5 Vdc with Digital Signal Based on HART® Protocol
4 www.rosemount.com

Materials of construction
Process flange type Flange material Drain/vent
2 Coplanar SST SST H
3(8) Coplanar Cast C-276 Alloy C-276 H
4 Coplanar Alloy 400 Alloy 400/K-500 H
5 Coplanar Plated CS SST H
7(8) Coplanar SST Alloy C-276 H
8(8) Coplanar Plated CS Alloy C-276 H
0 Alternate Process Connection H
Isolating diaphragm
2(8) 316L SST H
3(8) Alloy C-276 H
4(9) Alloy 400
5(9) Tantalum (available on 3051CD and CG, Ranges 2–5 only; not available on 3051CA)
6(9) Gold-plated Alloy 400 (use in combination with O-ring Option Code B)
7(9) Gold-plated 316 SST
O-ring
A Glass-filled PTFE H
B Graphite-filled PTFE H
Sensor fill fluid
1 Silicone H
2(9) Inert (Differential and Gage only) H
Housing material Conduit entry size
A Aluminum ½–14 NPT H
B Aluminum M20 × 1.5 H
J SST ½–14 NPT H
K SST M20 × 1.5 H
P(10) Engineered Polymer No Conduit Entries H
D(11) Aluminum G½
M(11) SST G½
Wireless options (requires Wireless Output Code X and Engineered Polymer Housing Code P)
Wireless transmit rate, operating frequency, and protocol
WA3 User Configurable Transmit Rate, 2.4GHz WirelessHART H
™
Antenna and SmartPower
WP5 Internal Antenna, Compatible with Green Power Module (I.S. Power Module Sold Separately) H
HART Revision configuration (requires HART Protocol Output Code A)

HR5(4) Configured for HART Revision 5 H
www.rosemount.com 5

Options (include with selected model number)
Extended product warranty
WR3 3-year limited warranty H
PlantWeb® control functionality
A01(12) FOUNDATION fieldbus Control Function Block Suite H
PlantWeb diagnostic functionality
DA0(13) Power Advisory HART Diagnostic H
D01(12) FOUNDATION fieldbus Diagnostics Suite H
(14)
Alternate flange
H2 Traditional Flange, 316 SST, SST drain/vent H
H3(8) Traditional Flange, Alloy C, Alloy C-276 drain/vent H
H4 Traditional Flange, Cast Alloy 400, Alloy 400/K-500 drain/vent H
H7(8) Traditional Flange, 316 SST, Alloy C-276 drain/vent H
HJ DIN-Compliant Traditional Flange,SST,7/16 in. Adapter/Manifold Bolting H
FA Level Flange, SST, 2 in., ANSI Class 150, Vertical Mount 316 SST drain/vent H
FB Level Flange, SST, 2 in., ANSI Class 300, Vertical Mount 316 SST drain/vent H
FC Level Flange, SST, 3 in., ANSI Class 150, Vertical Mount 316 SST drain/vent H
FD Level Flange, SST, 3 in., ANSI Class 300, Vertical Mount 316 SST drain/vent H
FP DIN Level Flange, SST, DN 50, PN 40, Vertical Mount 316 SST drain/vent H
FQ DIN Level Flange, SST, DN 80, PN 40, Vertical Mount 316 SST drain/vent H
HK(15) DIN Compliant Traditional Flange, SST, 10 mm Adapter/Manifold Bolting 316 SST
HL DIN Compliant Traditional Flange, SST, 12mm Adapter/Manifold Bolting 316 SST
Manifold assembly(16)
S5 Assemble to Rosemount 305 Integral Manifold H
S6 Assemble to Rosemount 304 Manifold or Connection System H
Integral mount primary element(15)(16)
S3 Assemble to Rosemount 405 Compact Orifice Plate H
(17) ®
S4 Assemble to Rosemount Annubar or Rosemount 1195 Integral Orifice H
(16)
Seal assemblies
S1(18) Assemble to one Rosemount 1199 seal H
S2(19) Assemble to two Rosemount 1199 seals H
Mounting bracket(20)
B4 Coplanar flange bracket, all SST, 2-in. pipe and panel H
B1 Traditional flange bracket, CS, 2-in. pipe H
B2 Traditional flange bracket, CS, panel H
B3 Traditional flange flat bracket, CS, 2-in. pipe H
B7 Traditional flange bracket, B1 with SST bolts H
BA Traditional flange bracket, B1, all SST H
BC Traditional flange bracket, B3, all SST H
6 www.rosemount.com

Product certifications
E8 ATEX Flameproof and Dust Certification H
(21)
I1 ATEX Intrinsic Safety and Dust H
IA ATEX FISCO Intrinsic Safety; for FOUNDATION fieldbus or PROFIBUS PA protocol only H
N1 ATEX Type n Certification and Dust H
K8 ATEX Flameproof, Intrinsic Safety, Type n, Dust (combination of E8, I1 and N1) H
E4(22) TIIS Flame-proof H
E5 FM Explosion-proof, Dust Ignition-Proof H
(23)
I5 FM Intrinsically Safe, Nonincendive H
IE FM FISCO Intrinsically Safe; for FOUNDATION fieldbus or PROFIBUS PA protocol only H
K5 FM Explosion-proof, Dust Ignition-Proof, Intrinsically Safe, and Division 2 H
C6 CSA Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2 H
I6(10) CSA Intrinsic Safety H
K6 CSA and ATEX Explosion-proof, Intrinsically Safe, and Division 2 (combination of C6, E8, and I1) H
E7 IECEx Flameproof, Dust Ignition-proof H
I7 IECEx Intrinsic Safety H
N7 IECEx Type n Certification H
K7 IECEx Flame-proof, Dust Ignition-proof, Intrinsic Safety, and Type n (combination of I7, N7, and E7) H
E2 INMETRO Flameproof H
I2 INMETRO Intrinsic Safety H
IB INMETRO FISCO intrinsically safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only H
K2 INMETRO Flameproof, Intrinsic Safety H
E3 China Flameproof H
I3 China Intrinsic Safety H
N3 China Type n H
EM Technical Regulations Customs Union (EAC) Flameproof H
IM Technical Regulations Customs Union (EAC) Intrinsic Safety H
KM Technical Regulations Customs Union (EAC) Flameproof and Intrinsic Safety H
KB FM and CSA Explosion-proof, Dust Ignition Proof, Intrinsically Safe, and Division 2 (combination of K5 and C6) H
KD FM, CSA, and ATEX Explosion-proof, Intrinsically Safe (combination of K5, C6, I1, and E8) H
Drinking water approval
DW(24) NSF drinking water approval H
Shipboard approvals
SBS(9) American Bureau of Shipping H
SBV(9)(25) Bureau Veritas (BV) H
SDN(9) Det Norske Veritas H
SLL(9)(25) Lloyds Register (LR) H
Custody transfer
Measurement Canada Accuracy Approval (limited availability depending on transmitter type and range;
C5(13) H
contact an Emerson Process Management representative)
www.rosemount.com 7

Bolting material
L4 Austenitic 316 SST Bolts H
L5 ASTM A 193, Grade B7M Bolts H
L6 Alloy K-500 Bolts H
Display and interface options
M4(26) LCD Display with Local Operator Interface H
M5 LCD Display H
Calibration certificate
Q4 Calibration Certificate H
QG(27) Calibration Certificate and GOST Verification Certificate H
QP Calibration certification and tamper evident seal H
Material traceability certification
Q8 Material Traceability Certification per EN 10204 3.1 H
Quality certification for safety
QS(13) Prior-use certificate of FMEDA data H
QT(13) Safety certified to IEC 61508 with certificate of FMEDA H
Configuration buttons
D4(13) Analog Zero and Span H
DZ(28) Digital Zero Trim H
Transient protection
T1(9)(29) Transient Protection Terminal Block H
Software configuration
Custom Software Configuration (completed CDS 00806-0100-4007 for wired and 00806-0100-4100 for
C1(28) H
Wireless required with order)
Low power output
C2 0.8-3.2 Vdc Output with Digital Signal Based on HART Protocol (available with Output code M only) H
Gage pressure calibration
C3 Gage Calibration (Model 3051CA4 only) H
Alarm levels
C4(13) Analog Output Levels Compliant with NAMUR Recommendation NE 43, Alarm High H
CN(13) Analog Output Levels Compliant with NAMUR Recommendation NE 43, Alarm Low H
CR(13) Custom alarm and saturation signal levels, high alarm (requires C1 and Configuration Data Sheet) H
CS(13) Custom alarm and saturation signal levels, low alarm (requires C1 and Configuration Data Sheet) H
CT(13) Rosemount standard low alarm H
Pressure testing
P1 Hydrostatic Testing with Certificate
8 www.rosemount.com

Cleaning process area

P2 Cleaning for Special Service
P3 Cleaning for <1 PPM Chlorine/Fluorine
Flange adapters
DF(30) 1
/2 -14 NPT flange adapter(s) H
Vent/drain valves
D7 Coplanar Flange Without Drain/Vent Ports
Conduit plug
DO(9)(31) 316 SST Conduit Plug H
1 1
RC /4 RC /2 process connection
D9(32) RC ¼ Flange with RC ½ Flange Adapter - SST
Max static line pressure
P9 4500 psig (310,26 bar) Static Pressure Limit (3051CD Ranges 2–5 only) H
Ground screw
V5(9)(33) External Ground Screw Assembly H
Surface finish
Q16 Surface finish certification for sanitary remote seals H
Toolkit total system performance reports
QZ Remote Seal System Performance Calculation Report H
Conduit electrical connector
GE(9) M12, 4-pin, Male Connector (eurofast®) H
GM(9) A size Mini, 4-pin, Male Connector (minifast®) H
NACE certificate
Q15(34) Certificate of Compliance to NACE MR0175/ISO 15156 for wetted materials H
Q25(34) Certificate of Compliance to NACE MR0103 for wetted materials H
Typical model number: 3051CD 2 A 2 2 A 1 A B4
(1) Select Configuration Buttons (option code D4 or DZ) or Local Operator Interface (option code M4) if local configuration buttons are required.
(2) If ordered with Wireless output code X, only Range 1-4, 316L SST diaphragm material (code 2), silicone fill fluid (code 1) and wireless housing (code P) are
available.
(3) 3051CD0 is only available with output code A and X. For output code A, only process flange code 0 (Alternate flange H2, H7, HJ or HK), isolating diaphragm code
2, O ring code A and bolting option L4 are available. For output code X, only process flange code 0 (Alternate flange H2), isolating diaphragm code 2, O ring code
A and bolting option L4 are available.
(4) Option HR5 configures the HART output to HART Revision 5. Option HR7 configures the HART output to HART Revision 7. The device can be field configured to
HART Revision 5 or 7 if desired. HART Revision 5 is the default HART output.
(5) For local addressing and configuration, M4 (Local Operator Interface) is required.
(6) Available approvals are FM Intrinsically Safe, (Option Code I5), CSA Intrinsically Safe (Option Code I6), ATEX Intrinsic Safety (Option Code I1), IECEx Intrinsic Safety
(Option Code I7) and EAC Intrinsic Safety (option code IM).
(7) Only available with C6, E2, E5, I5, K5, KB and E8 product certifications. Not available with GE, GM, SBS, DA0, M4, D4, DZ, QT, HR5, HR7, CR, CS, CT.
www.rosemount.com 9
(8) Materials of Construction comply with recommendations per NACE MR0175/ISO 15156 for sour oil field production environments. Environmental limits apply to
certain materials. Consult latest standard for details. Selected materials also conform to NACE MR0103 for sour refining environments.
(9) Not available with Wireless Output (code X).
(10) Only available with Wireless Output (code X).
(11) Not available with Product certifications options E8, K8, E5, K5, C6, K6, E7, K7, E2, K2, E3, KB, KD.
(12) Only valid with FOUNDATION fieldbus Output Code F.
(13) Only available with HART 4-20 mA Output (code A).
(14) Requires 0 code in Materials of Construction for Alternate Process Connection.
(15) Not valid with Option Code P9 for 4500 psi Static Pressure.
(16) “Assemble-to” items are specified separately and require a completed model number.
(17) Process flange limited to Coplanar (Option Codes 2, 3, 5, 7, 8) or Traditional (Option Codes H2, H3, H7).
(18) Not valid with Option Code D9 for RC1/2 Adapters.
(19) Not valid for Option Codes DF and D9 for Adapters.
(20) Panel mounting bolts are not supplied.
(21) Dust approval not applicable to Output Code X. See “IEC 62591 (WirelessHART Protocol)” on page 62 for wireless approvals.
(22) Only available with output codes A - 4-20mA HART, F - FOUNDATION fieldbus, and W - PROFIBUS PA. Also only available with G1/2 housing thread types.
(23) Nonincendive certification not provided with Wireless output option code (X).
(24) Not available with Alloy C-276 isolator (code 3), tantalum isolator (code 5), all cast C-276 flanges, all plated CS flanges, all DIN flanges, all Level flanges,
assemble-to manifolds (codes S5 and S6), assemble-to seals (codes S1 and S2), assemble-to primary elements (codes S3 and S4), surface finish certification (code
Q16), and remote seal system report (code QZ).
(25) Only available with product certifications E7, E8, I1, I7, IA, K7, K8, KD, N1, N7
(26) Not available with FOUNDATION fieldbus (Output Code F), Wireless (Output Code X), or Low Power Output (output code M).
(27) Contact an Emerson Process Management representative for availability.
(28) Only available with HART 4-20 mA Output (output code A) and Wireless Output (output code X)
(29) The T1 option is not needed with FISCO Product Certifications; transient protection is included in the FISCO product certification codes IA, IB, and IE.
(30) Not valid with Alternate Process Connection options S3, S4, S5, and S6.
(31) Transmitter is shipped with a 316 SST Conduit plug (uninstalled) in place of standard carbon steel conduit plug.
(32) Not available with Alternate Process Connection; DIN Flanges and Level Flanges.
(33) The V5 option is not needed with the T1 option; external ground screw assembly is included with the T1 option.
(34) NACE compliant wetted materials are identified by Footnote 8.
10 www.rosemount.com
Rosemount 3051T In-Line Pressure Transmitter
Rosemount 3051T In-Line Pressure Transmitters are the industry standard for Gage and
Absolute pressure measurement. The in-line, compact design allows the transmitter to
be connected directly to a process for quick, easy and cost effective installation.
Capabilities include:
 Power Advisory can proactively detect degraded electrical loop integrity issues
(Option Code DA0)
 Local Operator Interface with straightforward menus and built-in configuration

3051T In-Line buttons (Option Code M4)
Pressure Transmitter
 Safety Certification (Option Code QT)
See “Specifications” on page 45 and options for more details on each configuration. Specification and selection of product materials,
options, or components must be made by the purchaser of the equipment. See page 54 for more information on Material Selection.
Table 2. 3051T In-Line Pressure Transmitter Ordering Information


3051T(1) In-Line Pressure Transmitter
Pressure type
G Gage H
A(2) Absolute H
Pressure range
Gage (3051TG)(3) Absolute (3051TA)
1 -14.7 to 30 psi (-1,01 to 2,06 bar) 0 to 30 psia (0 to 2,06 bar) H
Transmitter output
F FOUNDATION fieldbus Protocol H
W(5) PROFIBUS PA Protocol H
X(6) Wireless (requires wireless options and engineered polymer housing) H
M(7) Low-Power 1-5 Vdc with Digital Signal Based on HART Protocol
Process connection style
1
2B /2–14 NPT Female H
2C(8) G½ A DIN 16288 Male (Range 1–4 only) H
2F(9) Coned and Threaded, Compatible with Autoclave Type F-250-C (Range 5 only)
61(9) Non-threaded Instrument flange (Range 1-4 only)
www.rosemount.com 11

Isolating diaphragm Process connection wetted parts material

2(10) 316L SST 316L SST H
3(10) Alloy C-276 Alloy C-276 H
Sensor fill fluid
1 Silicone H
2(9) Inert H
J SST ½–14 NPT H
K SST M20 × 1.5 H
P(11) Engineered polymer No conduit entries H
D(12) Aluminum G½
M(12) SST G½
Wireless options (requires wireless Output Code X and Engineered Polymer Housing Code P)


PlantWeb control functionality
Integral assembly
S5(14) Assemble to Rosemount 306 Integral Manifold H
Diaphragm seal assemblies
S1(14) Assemble to one Rosemount 1199 seal H
Mounting bracket(15)
B4 Bracket for 2-in. Pipe or Panel Mounting, All SST H
I1(16) ATEX Intrinsic Safety and Dust H

IA ATEX Intrinsic Safety for FISCO; for FOUNDATION fieldbus or PROFIBUS PA protocols only H
K8 ATEX Flame-proof, Intrinsic Safety, Type n, Dust (combination of E8, I1 and N1) H
E4(17) TIIS Flameproof H
E5 FM Explosion-proof, Dust Ignition-proof H
I5(18) FM Intrinsically Safe, Nonincendive H
IE FM FISCO Intrinsically Safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only H
K5 FM Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2 H
I6(11) CSA Intrinsic Safety H
K7 IECEx Flameproof, Dust Ignition-proof, Intrinsic Safety, and Type n (combination of I7, N7, and E7) H
N3 China Type n H
KB FM and CSA Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2 (combination of K5 and C6) H
Drinking water approval
DW(19) NSF drinking water approval H
Shipboard approvals
SBV(9)(20) Bureau Veritas (BV) H
SDN(9) Det Norske Veritas H
SLL(9)(20) Lloyds Register (LR) H
Custody transfer
Measurement Canada Accuracy Approval (Limited availability depending on transmitter type and range. Contact
C5 H
an Emerson Process Management representative)
Calibration certification
QP Calibration Certification and tamper evident seal H
QS(22) Prior-use certificate of FMEDA Data H

M5 LCD Display H
Wireless SST sensor module
WSM(11) Wireless SST Sensor Module H
Conduit plug
DO(9)(25) 316 SST Conduit Plug H
Transient terminal block
T1(9)(26) Transient Protection Terminal Block H
Custom Software Configuration (Completed CDS 00806-0100-4007 for wired and 00806-0100-4100 for
C1(23) H
wireless required with order)
Low power output
C2 0.8-3.2 Vdc Output with Digital Signal Based on HART Protocol (Available with Output code M only)
Alarm levels
C4(22) Analog Output Levels Compliant with NAMUR Recommendation NE 43, Alarm High H
CN(22) Analog Output Levels Compliant with NAMUR Recommendation NE 43, Low Alarm H
CT(22) Rosemount standard low alarm H
Pressure testing
Cleaning process area(27)
P2 Cleaning for Special Service
P3 Cleaning for <1 PPM Chlorine/Fluorine
Ground screw
Surface finish
Q16 Surface finish certification for sanitary remote seals H
QZ Remote Seal System Performance Calculation Report H
GE(9) M12, 4-pin, Male Connector (eurofast) H
GM(9) A size Mini, 4-pin, Male Connector (minifast) H

NACE certificate
Q15(29) Certificate of Compliance to NACE MR0175/ISO15156 for wetted materials H
Q25(29) Certificate of Compliance to NACE MR0103 for wetted materials H
Typical model number: 3051T G 5 F 2A 2 1 A B4
(2) Wireless Output (code X) only available in absolute measurement type (code A) in range 1-5 with 1/2 14 NPT process connection (code 2B), and polymer housing
(code P).
(3) 3051TG lower range limit varies with atmospheric pressure.
(6) Requires wireless options and engineered polymer housing. Available approvals are FM Intrinsically Safe, (Option Code I5), CSA Intrinsically Safe (Option Code I6),
ATEX Intrinsic Safety (Option Code I1), IECEx Intrinsic Safety (Option Code I7), and EAC Intrinsic Safety (Option Code IM).
(7) Only available with C6, E2, E5, I5, K5, KB and E8 product certifications. Not available with GE, GM, SBS, DA0, M4, D4, DZ, QT, HR5, HR7, CR, CS, CT.
(8) Wireless Output (code X) only available in G1/2 A DIN 16288 Male process connection (code 2C) with range 1-4, 316 SST isolating Diaphragm (code 2), Silicone
Fill Fluid (code 1) and Housing Code (code P).
(9) Not available with Wireless Output (output code X).
(10) Materials of Construction comply with recommendations per NACE MR0175/ISO 15156 for sour oil field production environments. Environmental limits apply to
certain materials. Consult latest standard for details. Selected materials also conform to NACE MR0103 for sour refining environments.
(11) Only available with Wireless Output (output code X).
(15) Panel mounting bolts are not supplied.
(16) Dust approval not applicable to output code X. See “IEC 62591 (WirelessHART Protocol)” on page 62 for wireless approvals.
(19) Not available with Alloy C-276 isolator (option code 3), Assemble-to manifolds (option code S5), assemble-to seals (option code S1), surface finish certification
(option code Q16), and remote seal system report (option code QZ).
(20) Only available with product certifications E7, E8, I1, I7, IA, K7, K8, KD, N1, N7.
(22) Only available with HART 4-20 mA output (output code A).
(23) Only available with HART 4-20 mA output (output code A) and Wireless output (output code X).
(24) Not available with FOUNDATION fieldbus (output code F) and Wireless output (output code X) or Low Power (output code M).
(25) Transmitter is shipped with 316 SST conduit plug (uninstalled) in place of standard carbon steel conduit plug.
(27) Not valid with Alternate Process Connection S5.
(28) The V5 option is not needed with T1 option; external ground screw assembly is included with the T1 option.
Rosemount 3051CF Flowmeter Selection Guide

Rosemount 3051CF Flowmeters combine the proven Rosemount 3051 Pressure Transmitter and the latest primary element
technologies. All flowmeters are fully assembled, calibrated, configured, and leak tested for out-of-the-box installation and are
available with wired or wireless capabilities to meet all of your application needs.
Rosemount 3051CFA Annubar Flowmeter

Rosemount Annubar technology minimizes permanent pressure loss
while delivering best in class accuracy.
 Lowest material costs for large line sizes
 Flo-tap enables installation without process shutdown
 Realize up to 96% less permanent pressure loss compared to

traditional orifice plate installations
Rosemount 3051CFC Compact Conditioning Flowmeter

Rosemount Compact Conditioning technologies provide
unprecedented performance with minimal straight-run requirements.
Solutions include Conditioning Orifice Plate or Annubar primary
elements.
 Conditioning Orifice requires only 2 pipe diameters up and

downstream
 Eliminate swirl and regular profiles resulting in more stable and

accurate flow measurement
 Savings up to 55% when compared to a traditional orifice plate

installation can be realized
Rosemount 3051CFP Integral Orifice Flowmeter

Rosemount Integral Orifice Flowmeters deliver highly accurate
small-bore flow measurement capability with minimal installation and
maintenance requirements.
 Best performance for small line sizes 1/2” (15 mm) to 11/2” (40 mm)
 Precision honed pipe section and tight machining tolerances deliver

higher installed performance
 Reduces uncertainty by up to 5% compared to traditional orifice plate

installation
Rosemount 3051CFA Annubar Flowmeter

The Rosemount 3051CFA Annubar Flowmeter utilizes the T-shaped sensor design that
delivers best in class accuracy and performance while meeting the needs of diverse
process applications, whether it is high accuracy for precision control or high strength
for severe flow applications. Main capabilities include:
 Up to 1.8% of flow rate accuracy
 Available in 2 to 96-in. (50 - 2400 mm) line sizes
 Fully assembled and leak tested for out-of-the-box installation
(Option Code DA0)

buttons (Option Code M4)
Table 3. Rosemount 3051CFA Annubar Flowmeter Ordering Information

Model Product description
3051CFA(1) Annubar Flowmeter
Measurement type
D Differential Pressure H
Fluid type
L Liquid H
G Gas H
S Steam H
Line size
020 2-in. (50 mm) H
1
025 2 /2-in. (63.5 mm) H
030 3-in. (80 mm) H
035 31/2-in. (89 mm) H
040 4-in. (100 mm) H
050 5-in. (125 mm) H
060 6-in. (150 mm) H
070 7-in. (175 mm) H
080 8-in. (200 mm) H
100 10-in. (250 mm) H
120 12-in. (300 mm) H
140 14-in. (350 mm)

160 16-in. (400 mm)
180 18-in. (450 mm)
200 20-in. (500 mm)
240 24-in. (600 mm)
300 30-in. (750 mm)
360 36-in. (900 mm)
420 42-in. (1066 mm)
480 48-in. (1210 mm)
600 60-in. (1520 mm)
720 72-in. (1820 mm)
780 78-in (1950 mm)
840 84-in. (2100 mm)
900 90-in. (2250 mm)
960 96-in (2400 mm)
Pipe I.D. range
C Range C from the Pipe I.D. Range Codes table H
D Range D from the Pipe I.D. Range Codes table H
A Range A from the Pipe I.D. Range Codes table
B Range B from the Pipe I.D. Range Codes table
E Range E from the Pipe I.D. Range Codes table
Z Non-standard Pipe I.D. Range Codes or Line Sizes greater than 12 inches
Pipe material/mounting assembly material
C Carbon steel (A105) H
S 316 Stainless Steel H
0 No Mounting (customer supplied) H
G Chrome-Moly Grade F-11
N Chrome-Moly Grade F-22
J Chrome-Moly Grade F-91
Piping orientation
H Horizontal Piping H
D Vertical Piping with Downwards Flow H
U Vertical Piping with Upwards Flow H
Annubar type
P Pak-Lok H
F Flanged with opposite side support H
L Flange-Lok
G Gear-Drive Flo-Tap
M Manual Flo-Tap
Sensor material
S 316 Stainless Steel H
H Alloy C-276

Sensor size
1 Sensor size 1 — Line sizes 2-in. (50 mm) to 8-in. (200 mm) H
2 Sensor size 2 — Line sizes 6-in. (150 mm) to 96-in. (2400 mm) H
3 Sensor size 3 — Line sizes greater than 12-in. (300 mm) H
Mounting type
T1 Compression or Threaded Connection H
A1 150# RF ANSI H
A3 300# RF ANSI H
A6 600# RF ANSI H
D1 DN PN16 Flange H
D3 DN PN40 Flange H
D6 DN PN100 Flange H
A9(2) 900# RF ANSI
AF(2) 1500# RF ANSI
AT(2) 2500 # RF ANSI
R1 150# RTJ Flange
R3 300# RTJ Flange
R6 600# RTJ Flange
R9(2) 900# RTJ Flange
RF(2) 1500# RTJ Flange
RT(2) 2500# RTJ Flange
Opposite side support or packing gland
0 No opposite side support or packing gland (required for Pak-Lok and Flange-Lok models) H
Opposite Side Support – Required for Flanged Models
C NPT Threaded Opposite Support Assembly – Extended Tip H
D Welded Opposite Support Assembly – Extended Tip H
Packing Gland – Required for Flo-Tap Models
Packing Gland Material Rod Material Packing Material
(3)
J Stainless Steel Packing Gland/Cage Nipple Carbon Steel PTFE
K(3) Stainless Steel Packing Gland/Cage Nipple Stainless Steel PTFE
L(3) Stainless Steel Packing Gland/Cage Nipple Carbon Steel Graphite
N(3) Stainless Steel Packing Gland/Cage Nipple Stainless Steel Graphite
R Alloy C-276 Packing Gland/Cage Nipple Stainless Steel Graphite
Isolation valve for Flo-Tap models
0 Not Applicable or Customer Supplied H
1 Gate Valve, Carbon Steel
2 Gate Valve, Stainless Steel
5 Ball Valve, Carbon Steel
6 Ball Valve, Stainless Steel
Temperature measurement
T Integral RTD – not available with Flanged model greater than class 600# H
0 No Temperature Sensor H
R Remote Thermowell and RTD

Transmitter connection platform
3 Direct-mount, Integral 3-valve Manifold– not available with Flanged model greater than class 600 H
5 Direct -mount, 5-valve Manifold – not available with Flanged model greater than class 600 H
1
7 Remote-mount NPT Connections ( /2-in. NPT) H
6 Direct-mount, high temperature 5-valve Manifold – not available with Flanged model greater than class 600
8 Remote-mount SW Connections (1/2-in.)
Differential pressure range
1 0 to 25 in H2O (0 to 62,16 mbar) H
2 0 to 250 in H2O (0 to 621,60 mbar) H
3 0 to 1000 in H2O (0 to 2,48 bar) H
Transmitter output
A(4) 4–20 mA with digital signal based on HART Protocol H
X(6) Wireless (Requires wireless options and engineered polymer housing) H
Transmitter housing material Conduit entry size
1
A Aluminum /2-14 NPT H
B Aluminum M20 x 1.5 H
1/2-14 NPT
J SST H
K SST M20 x 1.5 H
D(9) Aluminum G1/2
M(9) SST G1/2
Transmitter performance class
1 1.8% flow rate accuracy, 8:1 flow turndown, 5-yr. stability H



Pressure testing
P1(10) Hydrostatic Testing with Certificate
PX(10) Extended Hydrostatic Testing
Special cleaning
P2 Cleaning for Special Services
PA Cleaning per ASTM G93 Level D (Section 11.4)
Material testing
V1 Dye Penetrant Exam
Material examination
V2 Radiographic Examination
Flow calibration
W1 Flow Calibration (Average K)
Special inspection
QC1 Visual & Dimensional Inspection with Certificate H
QC7 Inspection & Performance Certificate H
Surface finish
RL Surface finish for Low Pipe Reynolds # in Gas & Steam H
RH Surface finish for High Pipe Reynolds # in Liquid H
Q8(11) Material Traceability Certification per EN 10474:2004 3.1 H
(12)
Code conformance
J2 ANSI/ASME B31.1
J3 ANSI/ASME B31.3
Materials conformance
J5(13) NACE MR-0175 / ISO 15156
Country certification
J6 European Pressure Directive (PED) H
J1 Canadian Registration
Installed in flanged pipe spool section
H3 150# Flanged Connection with Rosemount Standard Length and Schedule
Instrument connections for remote mount options
G2 Needle Valves, Stainless Steel H
G6 OS&Y Gate Valve, Stainless Steel H
G1 Needle Valves, Carbon Steel
G3 Needle Valves, Alloy C-276
G5 OS&Y Gate Valve, Carbon Steel
G7 OS&Y Gate Valve, Alloy C-276

Special shipment
Y1 Mounting Hardware Shipped Separately H
Special dimensions
VM Variable Mounting
VT Variable Tip
VS Variable length Spool Section
E8 ATEX Flameproof, Dust H
IA ATEX FISCO Intrinsic Safety; for FOUNDATION fieldbus or PROFIBUS PA protocols only H
N1 ATEX Type n and Dust H
K5 FM Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2 (combination of E5 and I5) H
I6 (8) CSA Intrinsically Safe H
N7 IECEx Type n H
K7 IECEx Flameproof, Dust Ignition-proof, Intrinsic Safety, and Type n (combination of I7, N7 and E7) H
KD CSA, FM, and ATEX Explosion-proof, Intrinsically Safe (combination of K5, C6, I1, and E8) H
Sensor fill fluid and O-ring options
L1(18) Inert Sensor Fill Fluid Note: Silicone fill fluid is standard. H
L2 Graphite-Filled (PTFE) O-ring H
LA(18) Inert Sensor Fill Fluid and Graphite-Filled (PTFE) O-ring H

Shipboard approvals
SLL(18)(19) Lloyds Register (LR)
M5 LCD Display H
Transmitter calibration certification
Q4 Calibration Certificate for Transmitter H
T1(18)(21) Transient terminal block H
Manifold for remote mount option
F2 3-Valve Manifold, Stainless Steel H
F1 3-Valve Manifold, Carbon Steel
F3 3-Valve Manifold, Alloy C-276
F5 5-Valve Manifold, Carbon Steel
F7 5-Valve Manifold, Alloy C-276
Lower power output
C2 0.8-3.2 Vdc Output with Digital Signal based on HART Protocol (Available with Output code M only)
Alarm levels
C4(15) NAMUR Alarm and Saturation Levels, High Alarm H
CN(15) NAMUR Alarm and Saturation Levels, Low Alarm H
CR(15) Custom alarm and saturation signal levels, high alarm H
CS(15) Custom alarm and saturation signal levels, low alarm H
CT(15) Rosemount Standard low alarm H
Ground screw
Typical model number: 3051CFA D L 060 D C H P S 2 T1 0 0 0 3 2 A A 1
(2) Available in remote mount applications only.
(3) The cage nipple is constructed of 304 SST.
(6) Requires wireless options and engineered polymer housing. Available approvals are FM Intrinsically Safe, (option code I5), CSA Intrinsically Safe (option code I6),
ATEX Intrinsic Safety (option code I1), and IECEx Intrinsic Safety (option code I7).
(7) Only available with C6, E2, E5, I5, K5, KB and E8 approval. Not available with GE, GM, SBS, DA0, M4, D4, DZ, QT, HR5, HR7, CR, CS, CT.
(10) Applies to assembled flowmeter only, mounting not tested.
(11) Instrument Connections for Remote Mount Options and Isolation Valves for Flo-tap Models are not included in the Material Traceability Certification.
(12) Not available with Transmitter Connection Platform 6.
(13) Materials of Construction comply with metallurgical requirements within NACE MR0175/ISO for sour oil field production environments. Environmental limits
apply to certain materials. Consult latest standard for details. Selected materials also conform to NACE MR0103 for sour refining environments.
(14) Only valid with FOUNDATION fieldbus output (output code F).
(15) Only available with 4-20 mA HART Output (output Code A).
(16) Dust approval not applicable to output code X. See “IEC 62591 (WirelessHART Protocol)” on page 62 for wireless approvals
(20) Not available with FOUNDATION Fieldbus (Output Code F) or Wireless Output (output code X) or Low Power (output code M).
(21) The T1 option is not needed with FISCO Product Certifications, transient protection is included with the FISCO Product Certification codes IA, IB, and IE.
(22) Only available with 4-20 mA HART Output (output code A) and Wireless output (Output Code X).
Rosemount 3051CFC Compact Flowmeter

Rosemount 3051CFC Compact Flowmeters provide a quick, reliable installation
between existing raised face flanges. Depending on your application needs, you can
reduce energy loss with the Compact Annubar or minimize straight run requirements
with the Conditioning Orifice.
 Available in 1/2 to 12-in. (15 - 300 mm) line sizes
 Power Advisory can proactively detect degraded electrical loop integrity issues.
(Option Code DA0)

Table 4. Rosemount 3051CFC Compact Flowmeter Ordering Information
3051CFC(1) Compact Flowmeter
Measurement type
Primary element technology
A Annubar Averaging Pitot Tube H
C Conditioning Orifice Plate H
P Orifice Plate H
Material type
S 316 SST H
Line size
005(2) 1/2-in. (15 mm) H
010(2) 1-in. (25 mm) H
015(2) 11/2-in. (40 mm) H
020 2-in. (50 mm) H
030 3-in. (80 mm) H
040 4-in. (100 mm) H
060 6-in. (150 mm) H
080 8-in. (200 mm) H
100(3) 10-in. (250 mm) H
120(3) 12-in. (300 mm) H

Primary element type
N000 Annubar Sensor Size 1 H
N040 0.40 Beta Ratio H
N050 0.50 Beta Ratio
N065(4) 0.65 Beta Ratio H
Temperature measurement
0 No Temperature Sensor H
R Remote Thermowell and RTD
3 Direct-mount H
7 Remote-mount, NPT Connections H
Differential pressure range
1 0 to 25 in H2O (0 to 62,16 mbar) H
2 0 to 250 in H2O (0 to 621,60 mbar) H
3 0 to 1000 in H2O (0 to 2,48 bar) H
Transmitter output
X(7) Wireless (Requires wireless options and engineered polymer housing) H
1
1
J SST /2-14 NPT H
K SST M20 x 1.5 H
D(10) Aluminum G1/2
M(10) SST G1/2
1 Up to ±1.65% flow rate accuracy, 8:1 flow turndown, 5-year stability H
HART Revision Configuration (requires HART Protocol Output Code A)



Installation accessories
AB ANSI Alignment Ring (150#) (Only required for 10-in. (250 mm) and 12-in. (300mm) line sizes) H
AC ANSI Alignment Ring (300#) (Only required for 10-in. (250 mm) and 12-in. (300mm) line sizes) H
AD ANSI Alignment Ring (600#) (Only required for 10-in. (250 mm) and 12-in. (300mm) line sizes) H
DG DIN Alignment Ring (PN16) H
DH DIN Alignment Ring (PN40) H
DJ DIN Alignment Ring (PN100) H
JB JIS Alignment Ring (10K)
JR JIS Alignment Ring (20K)
JS JIS Alignment Ring (40K)
Remote adapters
FE Flange Adapters 316 SST (1/2-in NPT) H
High temperature application
HT Graphite Valve Packing (Tmax = 850 °F)
Flow calibration
WC(11) Flow Calibration, 3 pt, Conditioning Orifice Option C (all pipe schedules)
WD(11)(12) Flow Calibration, 10 pt, Conditioning Option C (All Schedules), Annubar Option A (Schedule 40)
Pressure testing
Special cleaning
P2(13) Cleaning for Special Services
Special inspection
QC7 Inspection and Performance Certificate H
Q8 Material Traceability Certification per EN 10204:2004 3.1 H
Code conformance
J2 ANSI/ASME B31.1
J3 ANSI/ASME B31.3
J4 ANSI/ASME B31.8
J5(15) NACE MR-0175 / ISO 15156

I6(9) CSA Intrinsically Safe H
N7 IECEx Type n H
L1(18) Inert Sensor Fill Fluid H
Shipboard approvals
M5 LCD Display H
Manifold for remote mount option
D01(22) FOUNDATION fieldbus Diagnostic Suite H
Low power output
C2 0.8-3.2 Vdc Output with Digital Signal Based on HART Protocol (available with Output code M only)

Alarm levels
Ground screw
Typical model number: 3051CFC D C S 060 N 065 0 3 2 A A 1 WC E5 M5
(2) Available with Primary Element Technology P only.
(3) 10-in. (250 mm) and 12-in. (300 mm) line sizes not available with Primary Element Technology A.
(4) For 2-in. (50 mm) line sizes the Primary Element Type is 0.6 for Primary Element Technology Code C.
(11) Available with Primary Element Technology C only.
(12) For Annubar option A, consult factory for pipe schedules other than schedule 40.
(13) Available with Primary Element Technology C or P only.
(14) Only available with HART 4-20 mA Output (output code A).
(18) Not available with Wireless output (output code X).
(20) Not available with output code F - FOUNDATION fieldbus or Wireless output (output code X) or Low Power (output code M).
(21) The T1 option is not needed with FISCO Product Certifications, transient protection is included with the FISCO Product Certification code IA, IB, and IE.
(22) Only valid with FOUNDATION fieldbus (output code F).
(24) Only available with 4-20 mA HART Output (output code A) and Wireless output (output code X).
Rosemount 3051CFP Integral Orifice Flowmeter

Rosemount 3051CFP Integral Orifice Flowmeters enable highly accurate flow
measurement in small line sizes. Integral Orifice utilize precision honed pipe section
for increased accuracy and self-centering plate design to prevent alignment errors
that magnify measurement inaccuracies in small line sizes.
 Available in 1/2 to 11/2-in. (15 - 40 mm) line sizes
 Power Advisory can proactively detect degraded electrical loop integrity issues.
(Option Code DA0)

Table 5. Rosemount 3051CFP Integral Orifice Flowmeter Ordering Information
3051CFP(1) Integral Orifice Flowmeter
Measurement type
Body material
S 316 SST H
Line size
1
005 /2-in. (15 mm) H
010 1-in. (25 mm) H
015 11/2-in. (40 mm) H
Process connection
T1 NPT Female Body (Not Available with Remote Thermowell and RTD) H
S1(2) Socket Weld Body (Not Available with Remote Thermowell and RTD) H
P1 Pipe Ends: NPT Threaded H
P2 Pipe ends: Beveled H
D1 Pipe Ends: Flanged, DIN PN16, slip-on H
W1 Pipe Ends: Flanged, RF, ANSI Class 150, weld-neck H
A1 Pipe Ends: Flanged, RF, ANSI Class 150, slip-on

R1 Pipe Ends: Flanged, RTJ, ANSI Class 150, slip-on
Orifice plate material
S 316 SST H
H Alloy C-276
M Alloy 400
Bore size option
0066 0.066-in. (1.68 mm) for 1/2-in. Pipe H
0109 0.109-in. (2.77 mm) for 1/2-in. Pipe H
0160 0.160-in. (4.06 mm) for 1/2-in. Pipe H
0196 0.196-in. (4.98 mm) for 1/2-in. Pipe H
0260 0.260-in. (6.60 mm) for 1/2-in. Pipe H
0340 0.340-in. (8.64 mm) for 1/2-in. Pipe H
0150 0.150-in. (3.81 mm) for 1-in. Pipe H
0250 0.250-in. (6.35 mm) for 1-in. Pipe H
0345 0.345-in. (8.76 mm) for 1-in. Pipe H
0500 0.500-in. (12.70 mm) for 1-in. Pipe H
0630 0.630-in. (16.00 mm) for 1-in. Pipe H
0800 0.800-in. (20.32 mm) for 1-in. Pipe H
0295 0.295-in. (7.49 mm) for 1 1/2-in. Pipe H
0376 0.376-in. (9.55 mm) for 1 1/2-in. Pipe H
0512 0.512-in. (13.00 mm) for 1 1/2-in. Pipe H
0748 0.748-in. (19.00 mm) for 1 1/2-in. Pipe H
1022 1.022-in. (25.96 mm) for 1 1/2-in. Pipe H
1184 1.184-in. (30.07 mm) for 1 1/2-in. Pipe H
0010 0.010-in. (0.25 mm) for 1/2-in. Pipe
0014 0.014-in. (0.36 mm) for 1/2-in. Pipe
0020 0.020-in. (0.51 mm) for 1/2-in. Pipe
0034 0.034-in. (0.86 mm) for 1/2-in. Pipe
D3 Direct-mount, 3-Valve Manifold, SST H
D5 Direct-mount, 5-Valve Manifold, SST H
R3 Remote-mount, 3-Valve Manifold, SST H
R5 Remote-mount, 5-Valve Manifold, SST H
D4 Direct-mount, 3-Valve Manifold, Alloy C-276
D6 Direct-mount, 5-Valve Manifold, Alloy C-276
D7 Direct-mount, High Temperature, 5-Valve Manifold, SST
R4 Remote-mount, 3-Valve Manifold, Alloy C-276
R6 Remote-mount, 5-Valve Manifold, Alloy C-276
Differential pressure ranges
1 0 to 25 in H2O (0 to 62,16 mbar) H
2 0 to 250 in H2O (0 to 621,60 mbar) H
3 0 to 1000 in H2O (0 to 2,48 bar) H

Transmitter output
X(5) Wireless H
1
1
J SST /2-14 NPT H
K SST M20 x 1.5 H
D(8) Aluminum G1/2
M(8) SST G1/2
1 up to ±1.8% flow rate accuracy, 8:1 flow turndown, 5-year stability H
HART revision configuration (requires HART Protocol Output Code A)


Transmitter body/bolt material
GT High Temperature (850 °F / 454 °C)
Temperature sensor
RT(9) Thermowell and RTD
Optional connection
G1 DIN 19213 Transmitter Connection H
Pressure testing
P1(10) Hydrostatic Testing with Certificate
Special cleaning
P2 Cleaning for Special Services
Material testing
V1 Dye Penetrant Exam

Material examination
V2 Radiographic Examination
Flow calibration
WD(11) Discharge Coefficient Verification
Special inspection
QC7 Inspection and Performance Certificate H
Q8 Material Traceability Certification per EN 10204:2004 3.1 H
Code conformance
J2(12) ANSI/ASME B31.1
J5(13) NACE MR-0175 / ISO 15156
J6 European Pressure Directive (PED) H
I6(7) CSA Intrinsically Safe H
N7 IECEx Type n H

L1(17) Inert Sensor Fill Fluid H
Shipboard approvals
M5 LCD Display H
D01(21) FOUNDATION fieldbus Diagnostic Suite H
Low power output
C2 0.8-3.2 Vdc Output with Digital Signal Based on HART Protocol (Available with Output code M only)
Alarm levels
Ground screw
Typical model number: 3051CFP D S 010 W1 S 0500 D3 2 A A 1 E5 M5
(2) To improve pipe perpendicularity for gasket sealing, socket diameter is smaller than standard pipe O.D.
(9) Thermowell Material is the same as the body material.
(10) Does not apply to Process Connection codes T1 and S1.
(11) Not available for bore sizes 0010, 0014, 0020, 0034, 0066, or 0109.
(12) Not available with DIN Process Connection codes D1, D2, or D3.
(14) Only available with HART 4-20 mA output (Option code A).
(19) Not available with FOUNDATION fieldbus (Output Code F) or Wireless output (output code X) or Low Power (output code M).
(20) The T1 option is not needed with FISCO Product Certifications, transient protection is included with the FISCO Product Certification code IA, IB, and IE.
(23) Only available with 4-20 mA output (Output Code A) and Wireless output (Output Code X).
Rosemount 3051L Level Transmitter
The Rosemount 3051L Level Transmitter combines the performance and capabilities of
Rosemount 3051 Transmitters with the reliability and quality of a direct mount seal in
one model number. 3051L Level Transmitters offer a variety of process connections,
configurations, and fill fluid types to meet a breadth of level applications. Capabilities of
a Rosemount 3051L Level Transmitter include:
 Quantify and optimize total system performance (Option code QZ)
 Tuned-System Assembly (Option code S1)
3051L Level Transmitter (Option Code DA0)

See Specifications and options for more details on each configuration. Specification and selection of product materials, options, or
components must be made by the purchaser of the equipment. See page 54 for more information on Material Selection.
Table 6. Rosemount 3051L Level Transmitter Ordering Information

3051L(1) Level Transmitter
Pressure range
2 –250 to 250 inH2O (-621,60 to 621,60 mbar) H
3 –1000 to 1000 inH2O (-2,48 to 2,48 bar) H
4 –300 to 300 psi (-20,68 to 20,68 bar) H
Transmitter output
X(4) Wireless (requires wireless options and engineered polymer housing) H
Process connection size, material, extension length (high side)
Code Process connection size Material Extension length
G0(6) 2-in./DN 50/A 316L SST Flush Mount Only H
H0(6) 2-in./DN 50 Alloy C-276 Flush Mount Only H
J0 2-in./DN 50 Tantalum Flush Mount Only H
A0(6) 3-in./DN 80 316L SST Flush Mount H
A2(6) 3-in./DN 80 316L SST 2-in./50 mm H
(6)
A4 3-in./DN 80 316L SST 4-in./100 mm H

A6(6) 3-in./DN 80 316L SST 6-in./150 mm H
(6)
B0 4-in./DN 100 316L SST Flush Mount H
B2(6) 4-in./DN 100 316L SST 2-in./50 mm H
B4(6) 4-in./DN 100 316L SST 4-in./100 mm H
(6)
B6 4-in./DN 100 316L SST 6-in./150 mm H
C0(6) 3-in./DN 80 Alloy C-276 Flush Mount H
C2(6) 3-in./DN 80 Alloy C-276 2-in./50 mm H
D0(6) 4-in./DN 100 Alloy C-276 Flush Mount H
D2(6) 4-in./DN 100 Alloy C-276 2-in./50 mm H
E0 3-in./DN 80 Tantalum Flush Mount Only H
F0 4-in./DN 100 Tantalum Flush Mount Only H
Mounting flange size, rating, material (high side)
Size Rating Material
M 2-in. ANSI/ASME B16.5 Class 150 CS H
A 3-in. ANSI/ASME B16.5 Class 150 CS H
B 4-in. ANSI/ASME B16.5 Class 150 CS H
N 2-in. ANSI/ASME B16.5 Class 300 CS H
C 3-in. ANSI/ASME B16.5 Class 300 CS H
D 4-in. ANSI/ASME B16.5 Class 300 CS H
P 2-in. ANSI/ASME B16.5 Class 600 CS H
E 3-in. ANSI/ASME B16.5 Class 600 CS H
X(6) 2-in. ANSI/ASME B16.5 Class 150 316 SST H
F(6) 3-in. ANSI/ASME B16.5 Class 150 316 SST H
G(6) 4-in. ANSI/ASME B16.5 Class 150 316 SST H
Y(6) 2-in. ANSI/ASME B16.5 Class 300 316 SST H
H(6) 3-in. ANSI/ASME B16.5 Class 300 316 SST H
(6)
J 4-in. ANSI/ASME B16.5 Class 300 316 SST H
Z(6) 2-in. ANSI/ASME B16.5 Class 600 316 SST H
L(6) 3-in. ANSI/ASME B16.5 Class 600 316 SST H
Q DN 50 PN 10-40 per EN 1092-1 CS H
R DN 80 PN 40 per EN 1092-1 CS H
S DN 100 PN 40 per EN 1092-1 CS H
V DN 100 PN 10/16 per EN 1092-1 CS H
K(6) DN 50 PN 10-40 per EN 1092-1 316 SST H
T(6) DN 80 PN 40 per EN 1092-1 316 SST H
U(6) DN 100 PN 40 per EN 1092-1 316 SST H

Mounting flange size, rating, material (high side)

Size Rating Material
W(6) DN 100 PN 10/16 per EN 1092-1 316 SST H
7(6) 4 in. ANSI/ASME B16.5 Class 600 316 SST H
1 N/A 10K per JIS B2238 CS
4(6) N/A 10K per JIS B2238 316 SST
5(6) N/A 20K per JIS B2238 316 SST
(6)
6 N/A 40K per JIS B2238 316 SST
Seal fill fluid (high side) Specific gravity Temperature limits [ambient temperature of 70° F (21° C)]
D Silicone 200 0.93 -49 to 401 °F (-45 to 205 °C) H
Silicone 200 for For use in vacuum applications below 14.7 psia (1 bar-a), refer to
F Vacuum 0.93 vapor pressure curves in Rosemount DP Level Fill Fluid Specification H
Applications Technical Note (00840-2100-4016).
L Silicone 704 1.07 32 to 401 °F (0 to 205 °C) H
C Vacuum 1.07 vapor pressure curves in Rosemount DP Level Fill Fluid Specification H
R Silicone 705 1.09 68 to 401 °F (20 to 205 °C) H
V Vacuum 1.09 vapor pressure curves in Rosemount DP Level Fill Fluid Specification H
A SYLTHERM™ XLT 0.85 -102 to 293 °F (-75 to 145 °C) H
H Inert (Halocarbon) 1.85 -49 to 320 °F (-45 to 160 °C) H
G Glycerine and Water 1.13 5 to 203 °F (-15 to 95 °C) H
N Neobee® M-20 0.92 5 to 401 °F (-15 to 205 °C) H
Propylene Glycol and
P 1.02 5 to 203 F (-15 to 95 °C) H
Water
Low pressure side
Configuration Flange adapter Diaphragm material Sensor fill fluid
11(6) Gage SST 316L SST Silicone H
21 Differential SST 316L SST Silicone H
22(6) Differential SST Alloy C-276 Silicone H
2A(7) Differential SST 316L SST Inert (Halocarbon) H
(6)(7)
2B Differential SST Alloy C-276 Inert (Halocarbon) H
Tuned-System
Silicone
31(6) Assembly with None 316L SST H
(requires Option Code S1)
Remote Seal

O-ring
A Glass-filled PTFE H
J SST ½–14 NPT H
K SST M20 × 1.5 H
(8)
P Engineered polymer No conduit entries H
D(9) Aluminum G½
M(9) SST G½


(10)
D01 FOUNDATION fieldbus Diagnostics Suite H
Seal assemblies
S1(11) Assembled to One Rosemount 1199 Seal H
(12)
I1 ATEX Intrinsic Safety and Dust H
E4(13) TIIS Flameproof H
K5 FM Explosion-proof, Dust Ignition-Proof, Intrinsically Safe, and Division 2 H

(8)
I6 CSA Intrinsic Safety H
N3 China Type n H
KB FM and CSA Explosion-proof, Dust Ignition Proof, Intrinsically Safe, and Division 2 (combination of K5 and C6) H
Shipboard approvals
SBV(7)
(15) Bureau Veritas (BV)
SDN(7) Det Norske Veritas

Bolting material
L4 Austenitic 316 SST Bolts H
L5 ASTM A 193, Grade B7M bolts H
L6 Alloy K-500 Bolts H
L8 ASTM A 193 Class 2, Grade B8M Bolts H
M5 LCD Display H
Calibration certification
QP Calibration Certificate and tamper evident seal H


QZ Seal System Performance Calculation Report H
GE(7) M12, 4-pin, Male Connector (eurofast) H
GM(7) A size Mini, 4-pin, Male Connector (minifast) H
T1(7)(20) Transient Protection H
Custom Software Configuration (completed CDS 00806-0100-4007 for wired and 00806-0100-4100 for wireless
C1(19) H
required with order)
Low power output
C2 0.8-3.2 Vdc Output with Digital Signal Based on HART Protocol (available with Output code M only)
Alarm levels
C4(18) NAMUR alarm and saturation levels, high alarm H
CN(18) NAMUR alarm and saturation levels, low alarm H
Conduit plug
DO(7) 316 SST Conduit Plug H
Ground screw
Lower housing flushing connection options
Ring material Number Size (NPT)
1
F1 316 SST 1 /4-18 NPT H
F2 316 SST 2 1/4-18 NPT H
1
F3 Alloy C-276 1 /4-18 NPT H
1
F4 Alloy C-276 2 /4-18 NPT H
F7 316 SST 1 1/2-14 NPT H
1
F8 316 SST 2 /2-14 NPT H
1
F9 Alloy C-276 1 /2-14 NPT H
F0 Alloy C-276 2 1/2-14 NPT H
Lower housing intermediate gasket material
S0 No Gasket for lower housing H
SY(22) Thermo-Tork TN-9000 H

NACE certificate
Q15(23) Certificate of Compliance to NACE MR0175/ISO 15156 for wetted materials H
(23)
Q25 Certificate of Compliance to NACE MR0103 for wetted materials H
Typical model number: 3051L 2 A A0 D 21 A A F1
(3) Option code M4 - LCD Display with Local Operator Interface required for local addressing and configuration.
ATEX Intrinsic Safety (option code I1), IECEx Intrinsic Safety (option code I7) and EAC Intrinsic Safety (option code IM).
(6) Materials of Construction comply with metallurgical requirements highlighted within NACE MR0175/ISO 15156 for sour oil field production environments.
Environmental limits apply to certain materials. Consult latest standard for details. Selected materials also conform to NACE MR0103 for sour refining
environments.
(7) Not available with Wireless output (output code X).
(8) Only available with Wireless output (output code X).
(10) Only valid with FOUNDATION fieldbus output (output code F).
(12) Dust approval not applicable to output code X. See “IEC 62591 (WirelessHART Protocol)” on page 62 for wireless approvals.
(16) Not available with FOUNDATION fieldbus (Output Code F) or Wireless output (Output Code X) or Low Power (Output Code M).
(18) Only available with HART 4-20 mA output (output code A).
(19) Only available with 4-20 mA HART output (Output Code A) and Wireless output (Output Code X).
(22) Gasket provided when lower housing is ordered.
Specifications
Performance specifications
This product data sheet covers HART, Wireless, FOUNDATION fieldbus, and PROFIBUS PA protocols unless specified.
Conformance to specification [±3 (Sigma)]

Technology leadership, advanced manufacturing techniques, and statistical process control ensure specification conformance to at
least ±3.
Reference accuracy
Stated reference accuracy equations include terminal based linearity, hysteresis, and repeatability. For wireless, FOUNDATION fieldbus
and PROFIBUS PA devices, use calibrated range in place of span.
Models Rosemount 3051and WirelessHART
3051C +/-0.065% of span
 URL- % of Span
Range 5 For spans less than 10:1, accuracy =  0.015 + 0.005  --------------
Span
Ranges 2-4 ± 0.04% of span(1)

URL 
For spans less than 10:1(2), accuracy =  0.015 + 0.005  --------------
Span
- % of Span
Range 1 ± 0.10% of span

URL 
For spans less than 15:1, accuracy =  0.025 + 0.005  --------------
Span
- % of Span
Range 0 (CD) ± 0.10% of span

For spans less than 2:1, accuracy = ± 0.05% of URL
3051CA ± 0.04% of span(1)
URL
Ranges 1-4 For spans less than 10:1, accuracy =  0.0075  --------------- % of Span
Span
3051T ± 0.04% of span(1)

 URL- % of Span
Ranges 1-4 For spans less than 10:1, accuracy =  0.0075  --------------
Span
Range 5 ± 0.075% of span

URL 
For spans less than 10:1, accuracy =  0.0075  --------------
Span
- % of Span
3051L ± 0.075% of span

URL 
Ranges 2-4 For spans less than 10:1, accuracy =  0.025 + 0.005  --------------
Span
- % of Span
(1) For output code W and M, ±0.065% span.
(2) For output code F, for span less than 5:1.
Flow performance - flow reference accuracy(1)

3051CFA Annubar Flowmeter
Ranges 2-3 ±1.80% of Flow Rate at 8:1 flow turndown
3051CFC_A Compact Annubar Flowmeter – Annubar Option A
Uncalibrated ±2.10% of Flow Rate at 8:1 flow turndown
Ranges 2-3
Calibrated ±1.80% of Flow Rate at 8:1 flow turndown
3051CFC_C Compact Orifice Flowmeter – Conditioning Option C
 = 0.4 ±1.75% of Flow Rate at 8:1 flow turndown
Ranges 2-3
 = 0.50, 0.65 ±1.95% of Flow Rate at 8:1 flow turndown
Flow performance - flow reference accuracy(1)

3051CFC_P Compact Orifice Flowmeter – orifice type option P(2)
Ranges 2-3
3051CFP Integral Orifice Flowmeter
 <0.1 ±3.00% of Flow Rate at 8:1 flow turndown
0.1<  <0.2 ±1.95% of Flow Rate at 8:1 flow turndown
Ranges 2-3
(1) Accuracy over range of use is always application dependent. Range 1 flowmeters may experience an additional uncertainty up to 0.9%.
Consult your Emerson Process Management Representative for exact specifications.
(2) Applicable to 2-in. to 12-in. line sizes. For smaller line sizes, see the Rosemount DP Flowmeters and Primary Elements PDS
(00813-0100-4485).
Total performance
Total performance is based on combined errors of reference accuracy, ambient temperature effect, and static pressure effect at
normal operating conditions (70% of span typical reading, 740 psi (51,02 bar) line pressure).
For ±50 °F (28 °C) temperature changes; 0-100% relative humidity, from 1:1 to 5:1 rangedown
Models Total performance(1)
3051C
± 0.14% of span
Ranges 2-5
3051T
± 0.14% of span
Ranges 1-4
3051L Use Instrument Toolkit™ or the QZ option to quantify the total
Ranges 2-4 performance of a remote seal assembly under operating conditions.
(1) For output code W, F and M, total performance is ±0.15% of span.
Long term stability
Models Long term stability
3051C
±0.2% of URL for 10 years
Ranges 2-5
±50 °F (28 °C) temperature changes, and up to 1000 psi (68,95 bar) line pressure.
3051CD, 3051CG Low/Draft Range
±0.2% of URL for 1 year
Ranges 0-1
3051CA Low Range ±0.2% of URL for 10 years
Range 1 ±50 °F (28 °C) temperature changes, and up to 1000 psi (68,95 bar) line pressure.
3051T
±0.2% of URL for 10 years
Ranges 1-4
±50 °F (28 °C) temperature changes, and up to 1000 psi (68,95 bar) line pressure.
Dynamic performance
FOUNDATION fieldbus
Typical HART transmitter response
4 - 20 mA HART(1) and PROFIBUS PA
time
protocols(3)
Total Response Time (Td + Tc)(2):
3051C
100 ms
Ranges 2-5 152 ms
255 ms
Range 1 307 ms Transmitter Output vs. Time
700 ms
Range 0 N/A
100 ms Pressure
3051T 152 ms
See Instrument Toolkit Td = Dead Time
3051L See Instrument Toolkit Td Tc Tc = Time Constant
10 Response Time = Td +Tc
Dead Time (Td) 45 ms (nominal) 97 ms
Update Rate(4) 22 times per second 22 times per second 63.2% of Total
36. Step Change
(1) Dead time and update rate apply to all models and ranges; analog output only.
0% Time
(2) Nominal total response time at 75 °F (24 °C) reference conditions.
(3) Transducer block response time, Analog Input block execution time not included.
(4) Does not apply to wireless (output Code X). See “Wireless (output code X)” on page 52
for wireless update rate.
Line pressure effect per 1000 psi (68,95 bar)
For line pressures above 2000 psi (137,90 bar) and Ranges 4-5, see user manual
(Document number 00809-0100-4007 for HART, 00809-0100-4100 for WirelessHART, 00809-0100-4774 for
FOUNDATION fieldbus, and 00809-0100-4797 for PROFIBUS PA).
Models Line pressure effect
3051CD, 3051CF Zero Error
Ranges 2-3 ±0.05% of URL/1000 psi (68,95 bar) for line pressures from 0 to 2000 psi (0 to 137,90 bar)
Range 1 ±0.25% of URL/1000 psi (68,95 bar) for line pressures from 0 to 2000 psi (0 to 137,90 bar)
Range 0 ±0.125% of URL/100 psi (6,89 bar) for line pressures from 0 to 750 psi (0 to 51,71 bar)
Span Error
Ranges 2-3 ±0.1% of reading/1000 psi (68,95 bar)
Range 1 ±0.4% of reading/1000 psi (68,95 bar)
Range 0 ±0.15% of reading/100 psi (68,95 bar)
Ambient temperature effect per 50 °F (28 °C)
Models Ambient temperature effect
3051C
±(0.0125% URL + 0.0625% span) from 1:1 to 5:1
Ranges 2-5
±(0.025% URL + 0.125% span) from 5:1 to 150:1
±(0.1% URL + 0.25% span) from 1:1 to 30:1
Range 1
±(0.14% URL + 0.15% span) from 30:1 to 50:1
Range 0 ±(0.25% URL + 0.05% span) from 1:1 to 30:1
3051CA ±(0.025% URL + 0.125% span) from 1:1 to 30:1
Ranges 1-4 ±(0.035% URL + 0.125% span) from 30:1 to 150:1
3051T ±(0.025% URL + 0.125% span) from 1:1 to 30:1
Range 2-4 ±(0.035% URL + 0.125% span) from 30:1 to 150:1
±(0.025% URL + 0.125% span) from 1:1 to 10:1
Range 1
±(0.05% URL + 0.125% span) from 10:1 to 100:1
Range 5 ±(0.1% URL + 0.15% span) from 1:1 to 5:1
3051L See Instrument Toolkit software.
Mounting position effects
Models Mounting position effects

3051C Zero shifts up to ±1.25 inH2O (3,11 mbar), which can be calibrated out. No span effect.
3051CA, 3051T Zero shifts up to ±2.5 inH2O (6,22 mbar), which can be calibrated out. No span effect.
With liquid level diaphragm in vertical plane, zero shift of up to ±1 inH2O (2,49 mbar). With
3051L diaphragm in horizontal plane, zero shift of up to ±5 inH2O (12,43 mbar) plus extension length on
extended units. All zero shifts can be calibrated out. No span effect.
Vibration effect
Less than ±0.1% of URL when tested per the requirements of IEC60770-1: 1999 field or pipeline with high vibration level
(10-60 Hz 0.21 mm displacement peak amplitude / 60-2000 Hz 3g).
Power supply effect

Less than ±0.005% of calibrated span per volt change.
Electromagnetic compatibility (EMC)
Meets all relevant requirements of EN61326-1:2006 and Namur NE-21.(1)
(1) NAMUR NE-21 does not apply to wireless output code X.
Transient protection (option code T1)

Tested in accordance with IEEE C62.41.2-2002, Location Category B
6 kV crest (0.5 s - 100 kHz)
3 kA crest (8 × 20 s)
6 kV crest (1.2 × 50 s)
Functional specifications
Range and sensor limits
Table 7. 3051CD, 3051CG, 3051CF, and 3051L Range and Sensor Limits
Minimum span Range and sensor limits
Lower (LRL)
Range(1)
3051CD, 3051CD
Upper
3051CG, differential 3051CG 3051L
(URL) 3051L gage(3)
3051CF, 3051CF gage(3) differential
3051L(2) Flowmeters
0.10 inH2O 3.00 inH2O -3.00 inH2O
0 N/A N/A N/A
(0,24 mbar) (7,45 mbar) (-7,45 mbar)
0.50 inH2O 25.00 inH2O -25.00 inH2O -25.00 inH2O
1 N/A N/A
(1,24 mbar) (62,16 mbar) (-62,16 mbar) (-62,16 mbar)
1.67 inH2O 250.00 inH2O -250.00 inH2O -250.00 inH2O -250.00 inH2O -250.00 inH2O
2
(4,15 mbar) (621,60 mbar) (-621,60 mbar) (-621,60 mbar) (-621,60 mbar) (-621,60 mbar)
6.67 inH2O 1000.00 inH2O -1000.00 inH2O 0.50 psia -1000.00 inH2O 0.50 psia
3
(16,58 mbar) (2,48 bar) (-2,48 bar) (34,47 mbar) (-2,48 bar) (34,47 mbar)
2.00 psi 300.00 psi -300.00 psi 0.50 psia -300.00 psi 0.50 psia
4
(137,89 mbar) (20,68 bar) (-20,68 bar) (34,47 mbar) (-20,68 bar) (34,47 mbar)
13.33 psi 2000.00 psi - 2000.00 psi 0.50 psia
5 N/A N/A
(919,01 mbar) (137,89 bar) (-137,89 bar) (34,47 mbar)
(1) Range 0 only available with 3051CD. Range 1 only available with 3051CD, 3051CG, or 3051CF. inH2O referenced at 68 degrees Fahrenheit.
(2) For outputs options W and M, minimum span are: range 1 - 0.50 inH2O (1,24 mbar), range 2 - 2.50 inH2O (6,21 mbar), range 3 - 10.00 inH2O
(24,86 mbar), range 4 - 3.00 psi (0,21 bar), range 5 - 20.00 psi (1,38 bar).
(3) Assumes atmospheric pressure of 14.7 psig.
Table 8. 3051CA and 3051T Range and Sensor Limits

3051CA 3051T
Minimum span(1) Range and sensor limits Minimum span(1) Range and sensor limits
Range
Range
Lower Lower(2)
Upper Lower Upper (LRL) (gage)
(LRL)
(URL) (LRL) (URL)
(absolute)
0.30 psi 30 psia 0 psia 0.30 psi 30.00 psi 0 psia -14.70 psig
1 1
(20,68 mbar) (2,06 bar) (0 bar) (20,68 mbar) (2,06 bar) (0 bar) (-1,01 bar)
2 2
3 3
4 4
(1,83 bar) (275,79 bar) (0 bar) (1,83 bar) (275,79 bar) (0 bar) (-1,01 bar)
2000.00 psi 10000.00 psi 0 psia -14.70 psig
5 N/A N/A N/A 5
(137,89 bar) (689,47 bar) (0 bar) (-1,01 bar)
(1) For output options W and M, minimum span are: range 2 - 1.50 psi(0,10 bar), range 3 - 8.00 psi (0,55 bar), range 4 - 40.00 psi (2,75 bar), range 5 for 3051T
- 2000.00 psi (137,89 bar)
(2) Assumes atmospheric pressure of 14.7 psig.
Service Local operator interface

Liquid, gas, and vapor applications The LOI utilizes a 2 button menu with internal and external
configuration buttons. Internal buttons are always
4-20 mA HART (output code A) configured for Local Operator Interface. External Buttons can
be configured for either LOI (option code M4), Analog Zero
Power supply
and Span (option code D4) or Digital Zero Trim (option code
External power supply required. Standard transmitter (4-20mA) DZ). See Rosemount 3051 product manual
operates on 10.5-42.4 Vdc with no load (00809-0100-4007) for LOI configuration menu.
Load limitations FOUNDATION fieldbus (output code F)
Maximum loop resistance is determined by the voltage level of
the external power supply described by: Power supply
Max. Loop Resistance = 43.5 (Power Supply Voltage – 10.5) External power supply required; transmitters operate on 9.0 to
32.0 V dc transmitter terminal voltage. FISCO transmitters
operate on 9.0 to 17.5 V dc.
1387
Current draw
17.5 mA for all configurations (including LCD display option)
Load (s)
1000
Indication
500 Operating
Region Optional two line LCD display
0 FOUNDATION fieldbus block execution times
10.5 20 30
Voltage (Vdc) 42.4(1) Block Execution time
Communication requires a minimum
loop resistance of 250 ohms. Resource N/A
(1) For CSA approval, power supply must not exceed 42.4 V.
Sensor and SPM Transducer N/A
LCD Display N/A
Indication
Analog Input 1, 2 20 milliseconds
Optional two line LCD/LOI Display
PID 25 milliseconds
Optional configuration buttons
Configuration buttons need to be specified: Input Selector 20 milliseconds
Digital Zero trim (option code DZ) changes digital value of the Arithmetic 20 milliseconds
transmitter and is used for performing a sensor zero trim.
Signal Characterizer 20 milliseconds
Analog Zero Span (option code D4) changes analog value and
can be used to rerange the transmitter with an applied pressure. Integrator 20 milliseconds
Output Output Splitter 20 milliseconds

Two-wire 4-20mA, user selectable for linear or square root Control Selector 20 milliseconds
output. Digital process variable superimposed on 4-20 mA
signal, available to any host that conforms to HART protocol.
The 3051 comes with Selectable HART Revisions. Digital FOUNDATION fieldbus parameters
communications based on HART Revision 5 (default) or Revision
7 (option code HR7) protocol can be selected. The HART revision Links 25 (max.)
can be switched in the field using any HART based configuration Virtual Communications Relationships (VCR) 20 (max.)
tool or the optional local operator interface (M4).
FOUNDATION fieldbus function blocks (option A01)
Power advisory diagnostics
Power Advisory Diagnostics pro-actively detect and notify Resource block
you of degraded electrical loop integrity before it can affect The resource block contains diagnostic, hardware, and
your process operation. Example loop problems that can be electronics information. There are no linkable inputs or
detected include water in the terminal compartment, outputs to the Resource Block.
corrosion of terminals, improper grounding, and unstable Sensor transducer block
power supplies. The sensor transducer block contains sensor information
The Device Dashboard presents the diagnostics in a and the ability to calibrate the pressure sensor or recall
graphical, task-based interface that provides single-click factory calibration.
access to critical process/device information and descriptive
graphical troubleshooting.
LCD transducer block Output splitter block

The LCD transducer block is used to configure the LCD The output splitter function block provides the capability
display meter. to drive two control outputs from a single input. It takes
the output of one PID or other control block to control
Analog input block
two valves or other actuators.
The analog input (AI) function block processes the
measurements from the sensor and makes them available Backup Link Active Scheduler (LAS)
to other function blocks. The output value from the AI The transmitter can function as a Link Active Scheduler if the
block is in engineering units and contains a status
current link master device fails or is removed from the
indicating the quality of the measurement. The AI Block is
segment.
widely used for scaling functionality.
Input selector block FOUNDATION fieldbus Diagnostics Suite
The input selector (ISEL) function block can be used to (option code D01)
select the first good, hot backup, maximum, minimum, The 3051C FOUNDATION fieldbus Diagnostics Suite features
or average of as many as eight input values and place it at SPM technology to detect changes in the process, process
the output. The block supports signal status propagation. equipment, or installation conditions (such as plugged
Integrator block impulse lines) of the transmitter. This is done by modeling the
The integrator (INT) function block integrates one or two process noise signature (using the statistical values of mean
variables over time. The block compares the integrated or and standard deviation) under normal conditions and then
accumulated value to pre-trip and trip limits and comparing the baseline values to current values over time. If a
generates discrete output signals when the limits are significant change in the current values is detected, the
reached. transmitter can generate an alert.
The Integrator Block is used as a totalizer. This block will
accept up to two inputs, has six options how to totalize PROFIBUS PA (output code W)
the inputs, and two trip outputs.
Profile version
Arithmetic block 3.02
The arithmetic (ARTH) function block provides the ability
to configure a range extension function for a primary Power supply
input. It can also be used to compute nine different External power supply required; transmitters operate on 9.0
arithmetic functions including flow with partial density to 32.0 V dc transmitter terminal voltage. FISCO transmitters
compensation, electronic remote seals, hydrostatic tank operate on 9.0 to 17.5 V dc.
gaging, ratio control, and others.
Current draw
Signal characterizer block
The signal characterizer (SGCR) function block 17.5 mA for all configurations (including LCD display option)
characterizes or approximates any function that defines Output update rate
an input/output relationship. The function is defined by
Four times per second
configuring as many as twenty X,Y coordinates. The block
interpolates an output value for a given input value using Standard function blocks
the curve defined by the configured coordinates. Two
separate analog input signals can be processed Analog input (AI block)
simultaneously to give two corresponding separate The AI function block processes the measurements and
output values using the same defined curve. makes them available to the host device. The output
value from the AI block is in engineering units and
PID block contains a status indicating the quality of the
The PID function block combines all of the necessary logic measurement.
to perform proportional/integral/derivative (PID) control.
The block supports mode control, signal scaling and Physical block
limiting, feed forward control, override tracking, alarm The physical block defines the physical resources of the
limit detection, and signal status propagation. device including type of memory, hardware, electronics
and diagnostic information.
Control selector block
The control selector function block selects one of two or Transducer block
three inputs to be the output. The inputs are normally Contains actual sensor measurement data including the
connected to the outputs of PID or other function blocks. sensor diagnostics and the ability to trim the pressure
One of the inputs would be considered normal and the sensor or recall factory defaults.
other two overrides. Indication
Optional 2-line LCD display
Local operator interface Minimum load impedance

The LOI utilizes a 2 button menu with external configuration 100 k  (Vout wiring)
buttons.
Indication
Wireless (output code X) Optional 5-digit LCD display
Output Overpressure limits

IEC 62591 (WirelessHART), 2.4 GHz DSSS
Rosemount 3051CD/CG/CF
Wireless radio (internal antenna, WP5 option) • Range 0: 750 psi (51,71 bar)
• Frequency: 2.400 - 2.485 GHz • Range 1: 2000 psig (137,90 bar)
• Channels: 15 • Ranges 2-5: 3626 psig (250,00 bar)
• Modulation: IEEE 802.15.4 compliant DSSS 4500 psig (310,26 bar) for option code P9
• Transmission: Maximum of 10 dBm EIRP Rosemount 3051CA
Local display • Range 1: 750 psia (51,71 bar)
The optional 3-line, 7-digit LCD display can display • Range 2: 1500 psia (103,42 bar)
user-selectable information such as primary variable in • Range 3: 1600 psia (110,32 bar)
engineering units, scaled variable, percent of range, sensor • Range 4: 6000 psia (413,69 bar)
module temperature, and electronics temperature. The display
Rosemount 3051TG/TA
updates based on the wireless update rate.
• Range 1: 750 psi (51,71 bar)
Digital zero trim • Range 2: 1500 psi (103,42 bar)
Digital Zero trim (option DZ) is an offset adjustment to • Range 3: 1600 psi (110,32 bar)
compensate for mounting position effects, up to 5% of URL. • Range 4: 6000 psi (413,69 bar)
• Range 5: 15000 psi (1034,21 bar)
Update rate
User selectable 1 sec. to 60 min. For 3051L or Level Flange Option Codes FA, FB, FC, FD, FP, and
Wireless sensor module for in-line transmitters FQ, limit is 0 psia to the flange rating or sensor rating, whichever
is lower.
The 3051 Wireless transmitter requires the engineered polymer
housing to be selected. The standard sensor module will come
with aluminum material. If stainless steel is required, the option
Table 9. 3051L and Level Flange Rating Limits
WSM must be selected.
Standard Type CS rating SST rating
Power module ANSI/ASME Class 150 285 psig 275 psig
Field replaceable, keyed connection eliminates the risk of ANSI/ASME Class 300 740 psig 720 psig
incorrect installation, Intrinsically Safe Lithium-thionyl chloride ANSI/ASME Class 600 1480 psig 1440 psig
Power Module with PBT/PC enclosure. Ten-year life at one At 100 °F (38 °C), the rating decreases
minute update rate.(1) with increasing temperature, per ANSI/ASME B16.5.
DIN PN 10-40 40 bar 40 bar
(1) Reference conditions are 70 °F (21 °C), and routing data for three
additional network devices.
DIN PN 10/16 16 bar 16 bar
DIN PN 25/40 40 bar 40 bar
Note: Continuous exposure to ambient temperature limits of -40 °F or
185 °F (-40 °C or 85 °C) may reduce specified life by less than 20 At 248 °F (120 °C), the rating decreases
percent. with increasing temperature, per DIN 2401.
Static pressure limit

Low power output
Rosemount 3051CD only
1-5 Vdc HART Low Power (output code M)
Operates within specifications between static line pressures of
Output 0.5 psia and 3626 psig (4500 psig (310, 26 bar) for Option Code
Three-wire 1-5 Vdc (option code C2) user-selectable output. P9).
Also user selectable for linear or square root output Range 0: 0.5 psia and 750 psig (0,03 bar and 51,71 bar)
configuration. Digital process variable superimposed on voltage Range 1: 0.5 psia and 2000 psig (0,03 bar and 137, 90 bar)
signal, available to any host conforming to the HART protocol.
Low-power transmitter operates on 6-12 Vdc with no load.
Burst pressure limits
Power consumption 3051C, 3051CF Coplanar or

3.0 mA, 18-36 mW traditional process flange
10081 psig (695,06 bar)
3051T In-Line Process

Ranges 1-4: 11016 psi (759,53 bar) At atmospheric pressures and above. See Table 10.
Range 5: 26016 psig (1793,74 bar) Table 10. 3051 Process Temperature Limits
Failure mode alarm 3051CD, 3051CG, 3051CF, 3051CA
HART 4-20 mA (output option code A) Silicone Fill Sensor(1)
with Coplanar Flange –40 to 250 °F (–40 to 121 °C)(2)
If self-diagnostics detect a sensor or microprocessor failure, the
analog signal is driven either high or low to alert the user. High or with Traditional Flange –40 to 300 °F (–40 to 149 °C)(2)(3)
low failure mode is user-selectable with a jumper/switch on the with Level Flange –40 to 300 °F (–40 to 149 °C)(2)
transmitter. The values to which the transmitter drives its with 305 Integral
–40 to 300 °F (–40 to 149 °C)(2)
output in failure mode depend on whether it is configured to Manifold
standard, NAMUR-compliant, or custom levels (see Alarm Inert Fill Sensor(1)(4) –40 to 185 °F (–40 to 85 °C)(5)(6)
Configuration below). The values for each are as follows: 3051T (process fill fluid)
High alarm Low alarm Silicone Fill Sensor(1) –40 to 250 °F (–40 to 121 °C)(2)
Default 21.75 mA 3.75 mA Inert Fill Sensor(1) –22 to 250 °F (–30 to 121 °C)(2)
NAMUR compliant(1) 22.5 mA 3.6 mA 3051L low-side
Custom levels(2) 20.2 - 23.0 mA 3.4 - 3.8 mA temperature limits
(1) Analog output levels are compliant with NAMUR
Silicone Fill Sensor(1) –40 to 250 °F (–40 to 121 °C)(2)
recommendation NE 43, see option codes C4 or C5. Inert Fill Sensor(1) -40 to 185 °F (–40 to 85 °C)(5)
(2) Low alarm must be 0.1 mA less than low saturation and high 3051L high-side temperature limits (process fill fluid)
alarm must be 0.1 mA greater than high saturation.
SYLTHERM XLT –102 to 293 °F (–75 to 145 °C)
Output code M D.C. Silicone 704® 32 to 401 °F (0 to 205 °C)
If self-diagnostics detect a gross transmitter failure, the analog D.C. Silicone 200 –49 to 401 °F (–45 to 205 °C)
signal will be driven either below 0.94 V or above 5.4 V to alert Inert –49 to 320 °F (–45 to 160 °C)
the user (below 0.75 V or above 4.4 V for Option C2). High or low Glycerin and Water 5 to 203 °F (–15 to 95 °C)
alarm signal is user-selectable by internal jumper. Neobee M-20 5 to 401 °F (–15 to 205 °C)
Output code F, W, and X Propylene Glycol and
5 to 203 °F (–15 to 95 °C)
Water
If self-diagnostics detect a gross transmitter failure, that
information gets passed as an alert and a status along with the
(1) Process temperatures above 185 °F (85 °C) require derating the ambient
process variable. limits by a 1.5:1 ratio.
Temperature limits
(2) 220 °F (104 °C) limit in vacuum service; 130 °F (54 °C) for pressures
Ambient below 0.5 psia.
-40 to 185 °F (-40 to 85 °C)
(3) 3051CD0 process temperature limits are –40 to 212 °F (–40 to 100 °C).
With LCD display(1)(2): -40 to 176 °F (-40 to 80 °C)
(4) Inert fill with traditional flange on Range 0: limits are 32 to 185°F
(1) For the output code M and W, LCD display may not be readable and (0 to 85°C).
LCD display updates will be slower at temperatures below -22 °F
(-30 °C).
(5) 160 °F (71 °C) limit in vacuum service.
(2) Wireless LCD display may not be readable and LCD display updates
will be slower at temperature below -4 °F (-20 °C). (6) Not available for 3051CA.
Humidity limits
Storage(1) 0–100% relative humidity
-50 to 230 °F (-46 to 110 °C) Turn-on time
With LCD display: -40 to 185 °F (-40 to 85 °C)
With Wireless Output: -40 °F to 185 °F (-40 °C to 85 °C) Performance within specifications less than 2.0 seconds
(20.0 seconds for PROFIBUS PA and FOUNDATION fieldbus
(1) If storage temperature is above 85°C, perform a sensor trim prior to
protocols) after power is applied to the transmitter.(1)
installation.
(1) Does not apply to wireless option code X.
Volumetric displacement
Less than 0.005 in3 (0,08 cm3)
Damping For 3051CFC, see 00813-0100-4485 Rosemount 405 Compact

Orifice Plate
4-20 mA HART For 3051CFP, see 00813-0100-4485 Rosemount 1195 Integral
Analog output response to a step input change is user-enterable Orifice
from 0.0 to 60 seconds for one time constant. This software
damping is in addition to sensor module response time. Process-wetted parts
FOUNDATION fieldbus Drain/vent valves
Transducer block: User configurable 316 SST, Alloy C-276, or Alloy 400 material (Alloy 400 not
AI Block: User configurable available with 3051L)
PROFIBUS PA Process flanges and adapters

AI Block only: User configurable Plated carbon steel
SST: CF-8M (Cast 316 SST) per ASTM A743
Cast C-276: CW-12MW per ASTM A494
Physical specifications Cast Alloy 400: M-30C per ASTM A494
Material selection Wetted O-rings

Emerson provides a variety of Rosemount products with various Glass-filled PTFE or Graphite-filled PTFE
product options and configurations including materials of Process isolating diaphragms
construction that can be expected to perform well in a wide
3051CD
3051CA
3051CG
range of applications. The Rosemount product information
3051T
presented is intended as a guide for the purchaser to make an Isolating diaphragm material
appropriate selection for the application. It is the purchaser’s
sole responsibility to make a careful analysis of all process 316L SST (UNS S31603) • • •
parameters (such as all chemical components, temperature, Alloy C-276 (UNS N10276) • • •
pressure, flow rate, abrasives, contaminants, etc.), when Alloy 400 (UNS N04400) • •
specifying product materials, options, and components for the Tantalum (UNS R05440) •
particular application. Emerson Process Management is not in a
Gold-plated Alloy 400 • •
position to evaluate or guarantee the compatibility of the
Gold-plated 316L SST • •
process fluid or other process parameters with the product
options, configuration, or materials of construction selected. Rosemount 3051L process wetted parts
Electrical connections Flanged process connection (transmitter high side)
1
/2–14 NPT, G1/2, and M20 × 1.5 conduit. The polymer housing
(housing code P) has no conduit entries. HART interface Process diaphragms, including process gasket surface
connections fixed to terminal block for output code A and to 316L SST, Alloy C-276, or Tantalum
701P Power Module for Output Code X. Extension
CF-3M (Cast version of 316L SST, material per ASTM-A743),
Process connections or Alloy C-276. Fits schedule 40 and 80 pipe.
Rosemount 3051C Mounting flange
1
/4–18 NPT on 21/8-in. centers Zinc-cobalt plated CS or SST
1
/2–14 NPT on 2-, 21/8-, or 21/4-in. centers Reference process connection (transmitter low side)
Rosemount 3051L Isolating diaphragms
High pressure side: 2-, 3-, or 4-in., ASME B 16.5 (ANSI) Class 150, 316L SST or Alloy C-276
300 or 600 flange; 50, 80 or 100 mm, PN 40 or 10/16 flange Reference flange and adapter
Low pressure side: 1/4–18 NPT on flange 1/2–14 NPT on adapter CF-8M (Cast version of 316 SST, material per ASTM-A743)
Rosemount 3051T Non-wetted parts
1
/2–14 NPT female.
G1/2 A DIN 16288 Male (Range 1–4 only) Electronics housing
Autoclave type F-250-C (Pressure relieved 9/16–18 gland thread; Low-copper aluminum or CF-8M (Cast version of 316 SST).
1
/4 OD high pressure tube 60° cone; available in SST for Range 5 Enclosure Type 4X, IP 65, IP 66, IP 68
transmitters only). Housing Material Code P: PBT/PC with NEMA 4X and IP66/67/68
Rosemount 3051CF Coplanar sensor module housing
For 3051CFA, see 00813-0100-4485 Rosemount 485 Annubar SST: CF-3M (Cast 316L SST)
Bolts Table 12. 3051L Weights without Options

Plated carbon steel per ASTM A449, Type 1 Flush 2-in. Ext. 4-in. Ext. 6-in. Ext.
Austenitic 316 SST per ASTM F593 Flange
lb. (kg) lb. (kg) lb. (kg) lb. (kg)
ASTM A193, Grade B7M alloy steel DN 80/PN 22.5 23.5
Alloy K-500 19.5 (8,8) 21.5 (9,7)
40 (10,2) (10,6)
Sensor module fill fluid DN 100/
17.8 (8,1) 19.8 (9,0) 20.8 (9,5) 21.8 (9,9)
PN 10/16
Coplanar: silicone or Inert Halocarbon
DN 100/ 23.2 25.2 26.2 27.2
In-line: silicone or Fluorinert™ FC-43
PN 40 (10,5) (11,5) (11,9) (12,3)
Process fill fluid (3051L only)
SYLTHERM XLT, D.C. Silicone 704, D.C. Silicone 200, inert,
glycerin and water, Neobee M-20, or propylene glycol and water Table 13. Transmitter Option Weights
Paint Add
Code Option
Polyurethane lb. (kg)
Cover O-rings J, K, L, M Stainless Steel Housing (T) 3.9 (1,8)
Buna-N J, K, L, M Stainless Steel Housing (C, L, H, P) 3.1 (1,4)
Silicone (for wireless option code X) M4/M5 LCD display for wired transmitter 0.5 (0,2)
M5 LCD Display for Wireless Output 0.1 (0,04)
Power module
SST Mounting Bracket for Coplanar
Field replaceable, keyed connection eliminates the risk of B4 1.0 (0,5)
Flange
incorrect installation, Intrinsically Safe Lithium-thionyl chloride B1, B2,
Power Module with PBT enclosure. Mounting Bracket for Traditional Flange 2.3 (1,0)
B3
B7, B8,
Mounting Bracket for Traditional Flange 2.3 (1,0)
B9
Shipping weights
BA, BC SST Bracket for Traditional Flange 2.3 (1,0)
H2 Traditional Flange 2.4 (1,1)
Table 11. Transmitter Weights without Options(1) H3 Traditional Flange 2.7 (1,2)
Rosemount 3051 In H4 Traditional Flange 2.6 (1,2)
Transmitter Wireless In lb. (kg)
lb. (kg) H7 Traditional Flange 2.5 (1,1)
3051C 6.0 (2,7) 3.9 (1,8) FC Level Flange—3 in., 150 10.8 (4,9)
3051T 3.0 (1,4) 1.9 (0,86) FD Level Flange—3 in., 300 14.3 (6,5)
3051L Table 12 Table 12 FA Level Flange—2 in., 150 10.7 (4,8)
FB Level Flange—2 in., 300 14.0 (6,3)
(1) Transmitter weights include the sensor module and housing only FP DIN Level Flange, SST, DN 50, PN 40 8.3 (3,8)
(aluminum for Rosemount 3051 and polymer for wireless). FQ DIN Level Flange, SST, DN 80, PN 40 13.7 (6,2)
WSM SST Sensor Module 1.0 (0,45)
Table 12. 3051L Weights without Options Power Module (701PGNKF) 0.4 (0,18)
Flush 2-in. Ext. 4-in. Ext. 6-in. Ext.
Flange
lb. (kg) lb. (kg) lb. (kg) lb. (kg)
2-in., 150 12.5 (5,7) N/A N/A N/A
3-in., 150 17.5 (7,9) 19.5 (8,8) 20.5 (9,3) 21.5 (9,7)
23.5 26.5 28.5 30.5
4-in., 150
(10,7) (12,0) (12,9) (13,8)
2-in., 300 17.5 (7,9) N/A N/A N/A
22.5 24.5 25.5 26.5
3-in., 300
(10,2) (11,1) (11,6) (12,0)
32.5 35.5 37.5 39.5
4-in., 300
(14,7) (16,1) (17,0) (17,9)
2-in., 600 15.3 (6,9) N/A N/A N/A
25.2 27.2 28.2 29.2
3-in., 600
(11,4) (12,3) (12,8) (13,2)
DN 50/PN
13.8 (6,2) N/A N/A N/A
40
3051 Product Certifications

European Directive Information Special Conditions for Safe Use (X):
A copy of the EC Declaration of Conformity can be found at the 1. The Model 3051 transmitter housing contains aluminum
end of the Quick Start Guide. The most recent revision of the EC and is considered a potential risk of ignition by impact or
Declaration of Conformity can be found at friction. Care must be taken into account during
www.rosemount.com. installation and use to prevent impact and friction.
2. The Model 3051 transmitter with the transient terminal
Ordinary Location Certification for FM Approvals block (Option code T1) will not pass the 500Vrms
As standard, the transmitter has been examined and tested to dielectric strength test and this must be taken into
determine that the design meets the basic electrical, account during installation.
mechanical, and fire protection requirements by FM
Approvals, a nationally recognized test laboratory (NRTL) as C6 CSA Explosionproof, Dust-Ignitionproof, Intrinsic Safety
accredited by the Federal Occupational Safety and Health and Nonincendive
Administration (OSHA). Certificate: 1053834
Standards: ANSI/ISA 12.27.01-2003, CSA Std. C22.2 No. 30

-M1986, CSA Std. C22.2 No.142-M1987, CSA
North America Std. C22.2. No.157-92, CSA Std. C22.2 No. 213
- M1987, CAN/CSA C22.2 No. 0-10, CSA Std
E5 FM Explosionproof (XP) and Dust-Ignitionproof (DIP)
C22.2 No. 25-1966, CAN/CSA-C22.2 No.
Certificate: 0T2H0.AE
94-M91, CAN/CSA-E60079-0-07,
Standards: FM Class 3600 – 1998, FM Class 3615 – 2006, CAN/CSA-E60079-1-07
FM Class 3810 – 2005, ANSI/NEMA 250 – 2003
Markings: Explosionproof for Class I, Division 1, Groups B,
Markings: XP CL I, DIV 1, GP B, C, D; DIP CL II, DIV 1, GP E, F, C and D; Suitable for Class I, Zone 1, Group
G; CL III; T5(-50°C  Ta  +85°C); Factory Sealed; IIB+H2, T5; Dust-Ignitionproof Class II, Division
Type 4X 1, Groups E, F, G; Class III Division 1; Intrinsically
Safe Class I, Division 1 Groups A, B, C, D when
I5 FM Intrinsic Safety (IS) and Nonincendive (NI) connected in accordance with Rosemount
Certificate: 1Q4A4.AX drawing 03031-1024, Temperature Code T3C;
Standards: FM Class 3600 – 2011, FM Class 3610 – 2010, Suitable for Class I, Zone 0; Class I Division 2
FM Class 3611 – 2004, FM Class 3810 – 2005 Groups A, B, C and D, T5; Suitable for Class I
Zone 2, Group IIC; Type 4X; Factory Sealed;
Markings: IS CL I, DIV 1, GP A, B, C, D; CL II, DIV 1, GP E, F, G; Single Seal (See drawing 03031-1053)
Class III; DIV 1 when connected per Rosemount
drawing 03031-1019; NI CL 1, DIV 2, GP A, B, C, E6 CSA Explosionproof, Dust-Ignitionproof and Division 2
D; T4(-50°C  Ta  +70°C) [HART], T5(-50°C  Ta Certificate: 1053834
 +40°C) [HART]; T4(-50°C  Ta  +60°C) Standards: ANSI/ISA 12.27.01-2003, CSA Std. C22.2 No. 30
[Fieldbus/PROFIBUS]; Type 4x -M1986, CSA Std. C22.2 No.142-M1987, CSA
Std. C22.2 No. 213 - M1987, CAN/CSA C22.2
Special Conditions for Safe Use (X): No. 0-10, CSA Std C22.2 No. 25-1966,
1. The Model 3051 transmitter housing contains aluminum CAN/CSA-C22.2 No. 94-M91, CAN/CSA-C22.2
and is considered a potential risk of ignition by impact or No. 157-92, CAN/CSA-E60079-0-07,
friction. Care must be taken into account during CAN/CSA-E60079-1-07
installation and use to prevent impact and friction.
Markings: Explosionproof Class I, Division 1, Groups B, C
2. The Model 3051 transmitter with the transient terminal
and D; Suitable for Class I, Zone 1, Group
block (Option code T1) will not pass the 500Vrms
IIB+H2, T5; Dust-Ignitionproof for Class II and
dielectric strength test and this must be taken into
account during installation. Class III, Division 1, Groups E, F and G; Class I,
Division 2, Groups A, B, C and D; Suitable for
IE FM FISCO Class I Zone 2, Group IIC; Type 4X; Factory
Certificate: 1Q4A4.AX Sealed; Single Seal (See drawing 03031-1053)
Standards: FM Class 3600 – 2011, FM Class 3610 – 2010,
FM Class 3611 – 2004, FM Class 3810 – 2005
Markings: IS CL I, DIV 1, GP A, B, C, D when connected per

Rosemount drawing 03031-1019 (-50°C  Ta 
+60°C); Type 4x
Europe Special Conditions for Safe Use (X):

1. The apparatus is not capable of withstanding the 500 V
E8 ATEX Flameproof and Dust insulation test required by EN60079-11. This must be
taken into account when installing the apparatus.
Certificate: KEMA00ATEX2013X; Baseefa11ATEX0275X
2. The enclosure may be made of aluminum alloy and given a
Standards Used: EN60079-0:2012, EN60079-1:2007, protective polyurethane paint finish; however care should
EN60079-26:2007, EN60079-31:2009 be taken to protect it from impact or abrasion if located in
Zone 0.
Markings: II 1/2 G, Ex d IIC T6/T5 Ga/Gb, T6(-50°C  Ta 
+65°C), T5(-50°C  Ta  +80°C); 3. Some variants of the equipment have reduced markings
on the nameplate. Refer to the Certificate for full
II 1 D Ex ta IIIC T95°C T500 105°C Da (-20°C  Ta  +85°C)
equipment marking.
Process Temperature
IA ATEX FISCO
Temperature class Process temperature Certificate: BAS97ATEX1089X
T6 -50°C to +65°C Standards: EN60079-0:2012, EN60079-11:2009
T5 -50°C to +80°C
Markings: II 1 G Ex ia IIC Ga T4(-60°C  Ta  +60°C)
Special Conditions for Safe Use (X):

1. This device contains a thin wall diaphragm. Installation, Input parameters
maintenance and use shall take into account the FISCO
environmental conditions to which the diaphragm will be
subjected. The manufacturer’s instructions for installation Voltage Ui 17.5 V
and maintenance shall be followed in detail to assure
safety during its expected lifetime. Current Ii 380 mA
2. For information on the dimensions of the flameproof joints Power Pi 5.32 W

the manufacturer shall be contacted.
Capacitance Ci <5 nF
3. Some variants of the equipment have reduced markings
on the nameplate. Refer to the Certificate for full Inductance Li <10 μH
equipment marking.
I1 ATEX Intrinsic Safety and Dust Special Conditions for Safe Use (X):
Certificate: BAS97ATEX1089X; Baseefa11ATEX0275X 1. The apparatus is not capable of withstanding the 500 V
insulation test required by EN60079-11. This must be
Standards: EN60079-0:2012, EN60079-11:2012, taken into account when installing the apparatus.
EN60079-31:2009
Markings: HART: II 1 G Ex ia IIC T5/T4 Ga T5(-60°C  Ta  protective polyurethane paint finish; however care should
+40°C), T4(-60°C  Ta  +70°C) be taken to protect it from impact or abrasion if located in
Fieldbus/PROFIBUS: II 1 G Ex ia IIC Ga Zone 0.
T4(-60°C  Ta  +60°C) N1 ATEX Type n and Dust
DUST: II 1 D Ex ta IIIC T95°C T500105°C Da
(-20°C  Ta  +85°C) Certificate: BAS00ATEX3105X; Baseefa11ATEX0275X
Input parameters Standards: EN60079-0:2012, EN60079-15:2010,
EN60079-31:2009
HART Fieldbus/PROFIBUS
Markings: II 3 G Ex nA IIC T5 Gc (-40°C  Ta  +70°C);
Voltage Ui 30 V 30 V
II 1 D Ex ta IIIC T95°C T500105°C Da (-20°C 
Current Ii 200 mA 300 mA Ta  +85°C)
Power Pi 0.9 W 1.3 W Special Conditions for Safe Use (X):

Capacitance Ci 0.012 μF 0 μF 1. This apparatus is not capable of withstanding the 500V
insulation test that is required by EN60079-15. This must
Inductance Li 0 mH 0 mH be taken into account when installing the apparatus.
on the nameplate. Refer to the Certificate for full
equipment marking.
International Special Conditions for Safe Use (X):

1. If the apparatus is fitted with an optional 90V transient
E7 IECEx Flameproof and Dust suppressor, it is not capable of withstanding the 500V
insulation test required by IEC 60079-11. This must be
Certificate: IECEx KEM 09.0034X; IECEx BAS 10.0034X
taken into account when installing the apparatus.
Standards: IEC60079-0:2011, IEC60079-1:2007-04, 2. The enclosure may be made of aluminum alloy and given a
IEC60079-26:2006, IEC60079-31:2008 protective polyurethane paint finish; however, care should
be taken to protect it from impact or abrasion if located in
Markings: Ex d IIC T6/T5 Ga/Gb, T6(-50°C  Ta  +65°C), Zone 0.
T5(-50°C  Ta  +80°C);
Ex ta IIIC T95°C T500105°C Da (-20°C  Ta  IECEx Mining (Special A0259)
+85°C)
Certificate: IECEx TSA 14.0001X
Process Temperature
Standards: IEC60079-0:2011, IEC60079-11:2011
Temperature class Process temperature
Markings: Ex ia I Ma (-60°C  Ta  +70°C)
T6 -50°C to +65°C
Input parameters
T5 -50°C to +80°C
HART Fieldbus/PROFIBUS FISCO
Special Conditions for Safe Use (X): Voltage Ui 30 V 30 V 17.5 V
1. This device contains a thin wall diaphragm. Installation,
Current Ii 200 mA 300 mA 380 mA
maintenance and use shall take into account the
environmental conditions to which the diaphragm will be Power Pi 0.9 W 1.3 W 5.32 W
subjected. The manufacturer’s instructions for installation
and maintenance shall be followed in detail to assure Capacitance Ci 0.012 μF 0 μF <5 nF
safety during its expected lifetime.
Inductance Li 0 mH 0 mH <10 μH
2. For information on the dimensions of the flameproof joints
the manufacturer shall be contacted.
on the nameplate. Refer to the Certificate for full 1. If the apparatus is fitted with optional 90V transient
equipment marking. suppressor, it is not capable of withstanding the 500V
insulation test required by IEC60079-11. This must be
I7 IECEx Intrinsic Safety taken into account when installing the apparatus.
Certificate: IECEx BAS 09.0076X 2. It is a condition of safe use that the above input
parameters shall be taken into account during installation.
3. It is a condition of manufacture that only the apparatus
Markings: HART: Ex ia IIC T5/T4 Ga, T5(-60°C  Ta  +40°C), fitted with housing, covers and sensor module housing
T4(-60°C  Ta  +70°C) made out of stainless steel are used in Group I
Fieldbus/PROFIBUS: Ex ia IIC Ga T4(-60°C  Ta  applications.
+60°C) N7 IECEx Type n
Certificate: IECEx BAS 09.0077X
Input parameters
HART Fieldbus/PROFIBUS Markings: Ex nA IIC T5 Gc (-40°C  Ta  +70°C)
Voltage Ui 30 V 30 V Special Condition for Safe Use (X):

Current Ii 200 mA 300 mA 1. The apparatus is not capable of withstanding the 500V
insulation test required by IEC60079-15. This must be
Power Pi 0.9 W 1.3 W taken into account when installing the apparatus.
Capacitance Ci 0.012 μF 0 μF
Inductance Li 0 mH 0 mH
Brazil Certificate: UL-BR 13.0584X
Standards: ABNT NBR IEC60079-0:2008 + Errata 1:2011,

E2 INMETRO Flameproof
ABNT NBR IEC60079-11:2009
Certificate: UL-BR 13.0643X Markings: Ex ia IIC T4 Ga (-60°C  Ta  +60°C)
Standards: ABNT NBR IEC60079-0:2008 + Errata 1:2011,
ABNT NBR IEC60079-1:2009 + Errata 1:2011,
Input parameters
ABNT NBR IEC60079-26:2008 + Errata 1:2008
FISCO
Markings: Ex d IIC T6/T5 Ga/Gb, T6(-50°C  Ta  +65°C),
T5(-50°C  Ta  +80°C) Voltage Ui 17.5 V
Special Conditions for Safe Use (X): Current Ii 380 mA
1. This device contains a thin wall diaphragm. Installation, Power Pi 5.32 W

maintenance and use shall take into account the
environmental conditions to which the diaphragm will be Capacitance Ci <5 nF
subjected. The manufacturer’s instructions for installation
Inductance Li <10 μH
and maintenance shall be followed in detail to assure
safety during its expected lifetime.
2. In case of repair, contact the manufacturer for information Special Conditions for Safe Use (X):
on the dimensions of the flameproof joints. 1. If the equipment is fitted with an optional 90V transient
3. The capacitance of the wrap around label, being 1.6nF, suppressor, it is not capable of withstanding the 500V
exceeds the limit in Table 9 of ABNT NBR IEC 60079-0. The insulation test required by ABNT NBR IRC 60079-11:2008.
user shall determine suitability for the specific application. This must be taken into account when installing the
equipment.
I2 INMETRO Intrinsic Safety
Certificate: UL-BR 13.0584X protective polyurethane paint finish; however, care should
be taken to protect it from impact or abrasion if located in
Standards: ABNT NBR IEC60079-0:2008 + Errata 1:2011, Zone 0.
ABNT NBR IEC60079-11:2009
Markings: HART: Ex ia IIC T5/T4 Ga, T5(-60°C  Ta  +40°C), China

T4(-60°C  Ta  +70°C)
Fieldbus/PROFIBUS: Ex ia IIC T4 Ga (-60°C  Ta  E3 China Flameproof
+60°C)
Certificate: GYJ14.1041X; GYJ10.1313X [Flowmeters]
Input parameters
Standards: GB3836.1-2000, GB3836.2-2010,
HART Fieldbus/PROFIBUS
GB12476-2000
Voltage Ui 30 V 30 V
Markings: Ex d IIC T6/T5, T6(-50°C  Ta  +65°C), T5(-50°C 
Current Ii 200 mA 300 mA Ta  +80°C)
Power Pi 0.9 W 1.3 W Special Conditions for Safe Use (X):
Capacitance Ci 0.012 μF 0 μF 1. The relation between ambient temperature arrange and

temperature class is as follows:
Inductance Li 0 mH 0 mH
Ta Temperature class
-50°C~+80°C T5
1. If the equipment is fitted with an optional 90V transient
suppressor, it is not capable of withstanding the 500V -50°C~+65°C T6
insulation test required by ABNT NBR IRC 60079-11:2008.
When used in a combustible dust environment, the
This must be taken into account when installing the
maximum ambient temperature is 80°C.
equipment.
2. The earth connection facility in the enclosure should be
connected reliably.
protective polyurethane paint finish; however, care should
be taken to protect it from impact or abrasion if located in 3. Cable entry certified by notified body with type of
Zone 0. protection Ex d IIC in accordance with GB3836.1-2000 and
GB3836.2-2000, should be applied when installed in a
IB INMETRO FISCO
hazardous location. When used in combustible dust 3. Intrinsically Safe parameters:

environment, cable entry in accordance with IP66 or Input parameters
higher level should be applied.
HART Fieldbus/PROFIBUS FISCO
4. Obey the warning “Keep tight when the circuit is alive.”
5. End users are not permitted to change any internal Voltage Ui 30 V 30 V 17.5 V
components. Current Ii 200 mA 300 mA 380 mA

6. During installation, use and maintenance of this product,
observe the following standards: Power Pi 0.9 W 1.3 W 5.32 W
GB3836.13-1997 “Electrical apparatus for explosive gas
Capacitance Ci 0.012 μF 0 μF <5 nF
atmospheres Part 13: Repair and overhaul for apparatus
used in explosive gas atmospheres” Inductance Li 0 mH 0 mH <10 μH
atmospheres Part 15: Electrical installations in hazardous
area (other than mines)” Note 1: FISCO parameters apply to both Group IIC and IIB.
GB3836.16-2006 “Electrical apparatus for explosive gas Note 2: [For Flowmeters] When 644 Temperature
atmospheres Part 16: Inspection and maintenance of Transmitter is used, it should be used with Ex-certified
electrical installation (other than mines)” associated apparatus to establish explosion protection
GB50257-1996 “Code for construction and acceptance of system that can be used in explosive gas atmospheres.
electric device for explosion atmospheres and fire hazard Wiring and terminals should comply with the instruction
electrical equipment installation engineering”. manual of both 644 Temperature Transmitter and
GB12476.2-2006 “Electrical apparatus for use in the associated apparatus. The cables between 644
presence of combustible dust Part 1-2: Electrical apparatus Temperatures Transmitter and associated apparatus
protected by enclosures and surface temperature should be shielded cables (the cables must have insulated
limitation-Selection, installation and maintenance” shield). The shielded cable has to be grounded reliably in a
GB15577-2007 “Safety regulations for dust explosion non-hazardous area.
prevention and protection” 4. Transmitters comply with the requirements for FISCO field
devices specified in IEC60079-27:2008. For the connection
I3 China Intrinsic Safety of an intrinsically safe circuit in accordance with FISCO
Certificate: GYJ13.1362X; GYJ101312X [Flowmeters] Model, FISCO parameters are listed in the table above.
5. The product should be used with Ex-certified associated
Standards: GB3836.1-2010, GB3836.4-2010, apparatus to establish explosion protection system that
GB3836.20-2010, GB12476.1-2000 can be used in explosive gas atmospheres. Wiring and
terminals should comply with the instruction manual of
Markings: Ex ia IIC Ga T4/T5
the product and associated apparatus.
Special Conditions for Safe Use (X): 6. The cables between this product and associated apparatus
should be shielded cables (the cables must have insulated
1. Symbol “X” is used to denote specific conditions of use:
shield). The shielded cable has to be grounded reliably in a
a.If the apparatus is fitted with an optional 90V transient non-hazardous area.
suppressor, it is not capable of withstanding the 500V
insulation test for 1 minute. This must be taken into 7. End users are not permitted to change any intern
account when installing the apparatus. components but to settle the problem in conjunction with
the manufacturer to avoid damage to the product.
b.The enclosure may be made of aluminum alloy and
given a protective polyurethane paint finish; however, 8. During installation, use and maintenance of this product,
care should be taken to protect it from impact or observe the following standards:
abrasion if located in Zone 0. GB3836.13-1997 “Electrical apparatus for explosive gas
atmospheres Part 13: Repair and overhaul for apparatus
2. The relation between T code and ambient temperature
used in explosive gas atmospheres”
range is:
T Temperature
Model area (other than mines)”
code range GB3836.16-2006 “Electrical apparatus for explosive gas
HART T5 -60°C  Ta  +40°C atmospheres Part 16: Inspection and maintenance of
electrical installation (other than mines)”
HART T4 -60°C  Ta  +70°C GB50257-1996 “Code for construction and acceptance of
Fieldbus/PROFIBUS/FISCO T4 -60°C  Ta  +60°C electric device for explosion atmospheres and fire hazard
electrical equipment installation engineering”.
Flowmeter with 644 Temp GB12476.2-2006 “Electrical apparatus for use in the
T4 -40°C  Ta  +60°C
Housing presence of combustible dust Part 1-2: Electrical apparatus
protected by enclosures and surface temperature
limitation-Selection, installation and maintenance” Technical Regulations Customs Union

GB15577-2007 “Safety regulations for dust explosion
prevention and protection” (EAC)
N3 China Type n EM, IM, KM Contact an Emerson Process Management
Certificate: GYJ101111X representative for further information.
Standards: GB3836.1-2000, GB3836.8-2003

Combinations
Markings: Ex nA IIC T5 (-40°C  Ta  +70°C)
K2 Combination of E2 and I2
K5 Combination of E5 and I5
1. Symbol “X” is used to denote specific conditions of use:
The apparatus is not capable of withstanding the 500V test K6 Combination of C6, E8, and I1
to earth for one minute. The must be taken into
consideration during installation. K7 Combination of E7, I7, and N7
2. The ambient temperature range is -40°C  Ta  +70°C. K8 combination of E8, I1, and N1
3. Maximum input voltage: 55V.
KB Combination of E5, I5, and C6
4. Cable glands, conduit or blanking plugs, certified by NEPSI
with Ex e or Ex n protection type and IP66 degree of KD Combination of E8, I1, E5, I5, and C6
protection provided by enclosure, should be used on
external connections and redundant cable entries.
5. Maintenance should be done in non-hazardous location. Conduit Plugs and Adapters
6. End users are not permitted to change any internal
IECEx Flameproof and Increased Safety
components but to settle the problem in conjunction with
manufacturer to avoid damage to the product. Certificate: IECEx FMG 13.0032X
7. During installation, use and maintenance of this product,
Standards: IEC60079-0:2011, IEC60079-1:2007,
observe the following standards:
GB3836.13-1997 “Electrical apparatus for explosive gas IEC60079-7:2006-2007
atmospheres Part 13: Repair and overhaul for apparatus Markings: Ex de IIC Gb
used in explosive gas atmospheres”
GB3836.15-2000 “Electrical apparatus for explosive gas ATEX Flameproof and Increased Safety
area (other than mines)” Certificate: FM13ATEX0076X
GB3836.16-2006 “Electrical apparatus for explosive gas Standards: EN60079-0:2012, EN60079-1:2007,
atmospheres Part 16: Inspection and maintenance of
IEC60079-7:2007
electrical installation (other than mines)”
GB50257-1996 “Code for construction and acceptance of Markings: II 2 G Ex de IIC Gb
electric device for explosion atmospheres and fire hazard
electrical equipment installation engineering”
Conduit Plug Thread Sizes
Thread Identification mark
Japan M20 x 1.5 M20
E4 Japan Flameproof 1/2 - 14 NPT 1/2 NPT

G1/2A G1/2
Certificate: TC20577, TC20578, TC20583, TC20584
[HART]; TC20579, TC20580, TC20581,
TC20582 [Fieldbus]
Markings: Ex d IIC T5
Thread Adapter Thread Sizes Application:

Location classes
Male thread Identification mark
Type 3051
M20 x 1.5 – 6H M20
Temperature D
1/2 - 14 NPT 1/2 – 14 NPT
Humidity B
3/4 - 14 NPT 3/4 – 14 NPT
Vibration A
Female thread Identification mark
EMC B
M20 x 1.5 – 6H M20
Enclosure D
1/2 - 14 NPT 1/2 – 14 NPT
SLL Lloyds Register (LR) Type Approval
PG 13.5 PG 13.5
Certificate: 11/60002
Application: Environmental categories ENV1, ENV2, ENV3
1. When the thread adapter or blanking plug is used with an
and ENV5
enclosure in type of protection increased safety “e” the
entry thread shall be suitably sealed in order to maintain C5 Custody Transfer - Measurement Canada Accuracy
the ingress protection rating (IP) of the enclosure. Approval
2. The blanking plug shall not be used with an adapter.
Certificate: AG-0226; AG-0454; AG-0477
3. Blanking Plug and Threaded Adapter shall be either NPT or
Metric thread forms. G½ and PG 13.5 thread forms are
only acceptable for existing (legacy) equipment
installations.
IEC 62591 (WirelessHART Protocol)
Additional Certifications Approved Manufacturing Locations
SBS American Bureau of Shipping (ABS) Type Approval Rosemount Inc. — Chanhassen, Minnesota USA
Fisher-Rosemount GmbH & Co. — Wessling, Germany
Certificate: 09-HS446883A-PDA
Emerson Process Management Asia Pacific Private Limited —
Intended Use: Measure gauge or absolute pressure of Singapore
liquid, gas or vapor applications on ABS classed Beijing Rosemount Far East Instrument Co., LTD — Beijing, China
vessels, marine, and offshore installations.
European Directive Information
ABS Rules: 2014 Steel Vessels Rules 1-1-4/7.7, 4-8-3/13.1,
1-1-A3, 4-8-3/1.7, 4-8-3/1.11.1 The most recent revision of the EC declaration of conformity can
SBV Bureau Veritas (BV) Type Approval be found at www.rosemount.com.
Certificate: 23155/A3 BV Telecommunication Compliance

Requirements: Bureau Veritas Rules for the Classification of All wireless devices require certification to ensure that they
Steel Ships adhere to regulations regarding the use of the RF spectrum.
Nearly every country requires this type of product certification.
Application: Class notations: AUT-UMS, AUT-CCS,
AUT-PORT and AUT-IMS; Pressure transmitter Emerson is working with governmental agencies around the
type 3051 cannot be installed on diesel engines world to supply fully compliant products and remove the risk of
violating country directives or laws governing wireless device
SDN Det Norske Veritas (DNV) Type Approval
usage.
Certificate: A-13245
Intended Use: Det Norske Veritas’ Rules for Classification of

Ships, High Speed & Light Craft and Det Norske
Veritas’ Offshore Standards
FCC and IC CSA - Canadian Standards Association
This device complies with Part 15 of the FCC Rules. Operation is I6 CSA Intrinsically Safe
subject to the following conditions: This device may not cause Certificate No: 2526009
harmful interference. This device must accept any interference Applicable Standards: CSA C22.2 No. 0-M91, CSA C22.2
No. 94-M91, CSA C22.2 No. 142-M1987, CSA C22.2 No.
received, including interference that may cause undesired
157-92, CSA C22.2 No. 60529-05
operation. This device must be installed to ensure a minimum Markings: Intrinsically Safe For Class I, Division I, Groups A,
antenna separation distance of 20 cm from all persons. B, C, D
T4 (-40 °C to 70 °C)
Ordinary Location Certification for FM
Intrinsically safe when installed according to Rosemount
As standard, the transmitter has been examined and tested to drawing 03031-1063
determine that the design meets basic electrical, mechanical, Enclosure Type 4X/IP66/IP68
and fire protection requirements by FM, a nationally recognized European Certifications
testing laboratory (NRTL) as accredited by the Federal
I1 ATEX Intrinsic Safety
Occupational Safety and Health Administration (OSHA).
Certificate No: Baseefa12ATEX0228X
North American Certifications Applicable Standards: EN60079-11:2012,
EN60079-0:2012
Factory Mutual (FM) approvals Markings: Ex ia IIC T4 Ga (-40 °C Ta 70 °C)
II 1G
I5 FM Intrinsically Safe IP66/68
Certificate No: 3046325 1180
Applicable Standards: Class 3600:2011, Class 3610:2010,
Class 3810: 2005, ANSI/ISA 60079-0 2009,ANSI/ISA Special Conditions for Safe Use (X):
60079-11:2009
ANSI/NEMA 250:2003, ANSI/IEC
1. The plastic enclosure may constitute a potential
60529:2004
electrostatic ignition risk and must not be rubbed or
Markings: Intrinsically Safe for Class I, Division I, Groups A,
cleaned with a dry cloth.
B, C, D
Zone Marking: Class I Zone 0, AEx ia IIC I7 IECEx Intrinsic Safety
T4 (-40 °C to 70 °C) Certificate No: IECEx BAS 12.0124X
Intrinsically Safe when installed according to Rosemount Applicable Standards: IEC60079-11:2011,
Drawing 03031-1062 IEC60079-0:2011
Enclosure Type 4X/IP66/IP68/IP67 Markings: Ex ia IIC T4 Ga (-40 °C Ta 70 °C)
IP66/68
1. The inline pressure sensor may contain more than 10% Special Conditions for Safe Use (X):
aluminum and is considered a potential risk of ignition by 1. The plastic enclosure may constitute a potential
impact or friction. Care must be taken into account during electrostatic ignition risk and must not be rubbed or
installation and use to prevent impact and friction. cleaned with a dry cloth.
2. The surface resistivity of the transmitter is greater than 2. The Model 701PGNKF Power Module may be replaced in a
one gigaohm. To avoid electrostatic charge build-up, it hazardous area. The Power Module has a surface resistivity
must not be rubbed or cleaned with solvents or a dry cloth. greater than 1G  and must be properly installed in the
3. The Model 3051 Wireless Pressure Transmitter shall only wireless device enclosure. Care must be taken during
be used with the 701PGNKF Rosemount SmartPower transportation to and from the point of installation to
Battery Pack. prevent electrostatic charge build-up.
Pipe I.D. Range Codes

For pipes with an Inner Diameter (I.D.) Range/Pipe Wall Thickness not found in this table or with a line size greater than 12-in. (300
mm), choose option code Z and specify the exact pipe dimensions (I.D. and Pipe Wall Thickness) on the Configuration Data Sheet
(see document number 00806-0100-4010). The Emerson Process Management sizing program will determine this code, based on
the application piping.
Line size Pipe wall thickness I.D.

Option I.D. range range
Nominal Max. O.D. ANSI pipes Non-ANSI pipes code
code
1.784 to 1.841-in. 0.065 to 0.488-in.
A
(45.31 to 46.76 mm) (1.7 to 12.4 mm)
1.842 to 1.938-in. 0.065 to 0.449-in.
B
2-in. 2.625-in. (46.79 to 49.23 mm) 0.065 to 0.545-in. (1.7 to 11.4 mm)
020
(50 mm) (66.68 mm) 1.939 to 2.067-in. (1.7 to 13.8 mm) 0.065 to 0.417-in.
C
(49.25 to 52.50 mm) (1.7 to 10.6 mm)
2.068 to 2.206-in. 0.065 to 0.407-in.
D
(52.53 to 56.03 mm) (1.7 to 10.3 mm)
2.207 to 2.322-in. 0.083 to 0.448-in.
B
(56.06 to 58.98 mm) (2.1 to 11.4 mm)
2.323 to 2.469-in. 0.083 to 0.417-in.
C
21/2-in. 3.188-in. (59.00 to 62.71 mm) 0.083 to 0.563-in. (2.1 to 10.6 mm)
025
(63.5 mm) (80.98 mm) 2.470 to 2.598-in. (2.1 to 14.3 mm) 0.083 to 0.435-in.
D
(62.74 to 65.99 mm) (2.1 to 11.0 mm)
2.599 to 2.647-in. 0.083 to 0.515-in.
E
(66.01 to 67.23 mm) (2.1 to 13.1 mm)
2.648 to 2.751-in. 0.083 to 0.460-in.
A
(67.26 to 69.88 mm) (2.1 to 11.7 mm)
2.752 to 2.899-in. 0.083 to 0.416-in.
B
030
C
(73.66 to 77.93 mm) (2.1 to 10.0 mm)
3.069 to 3.228-in. 0.083 to 0.404-in
D
(77.95 to 81.99 mm) (2.1 to 10.3 mm)
3.229 to 3.333-in. 0.120 to 0.496-in.
B
(82.02 to 84.66 mm) (3.0 to 12.6 mm)
31/2-in. 4.25-in. 3.334 to 3.548-in. 0.120 to 0.600-in. 0.120 to 0.386-in.
035 C
(89 mm) (107.95 mm) (84.68 to 90.12 mm) (3.0 to 15.2 mm) (3.0 to 9.8 mm)
3.549 to 3.734-in. 0.120 to 0.415-in.
D
(90.14 to 94.84 mm) (3.0 to 10.5 mm)
3.735 to 3.825-in. 0.120 to 0.510-in.
B
(94.87 to 97.16 mm) (3.0 to 13.0 mm)
3.826 to 4.026-in. 0.120 to 0.400-in.
C
040
D
(102.29 to 107.62 mm) (3.0 to 9.9 mm)
4.238 to 4.437-in. 0.120 to 0.401-in.
E
(107.65 to 112.70 mm) (3.0 to 10.2 mm)
4.438 to 4.571-in. 0.134 to 0.481-in.
A
(112.73 to 116.10 mm) (3.4 to 12.2 mm)
4.572 to 4.812-in. 0.134 to 0.374-in.
B
050
C
(122.25 to 128.19 mm) (3.4 to 9.7 mm)
5.048 to 5.249-in. 0.134 to 0.413-in.
D
(128.22 to 133.32 mm) (3.4 to 10.5 mm)
5.250 to 5.472-in. 0.134 to 0.3919-in.

A
(133.35 to 138.99 mm) (3.4 to 9.9 mm)
5.473 to 5.760-in. 0.134 to 0.327-in.
B
Sensor
Size 1
060
C
(146.33 to 154.05 mm) (3.4 to 7.9 mm)
6.066 to 6.383-in. 0.134 to 0.297-in.
D
(154.08 to 162.13 mm) (3.4 to 7.5 mm)
5.250 to 5.472-in. 0.134 to 1.132-in.
A
(133.35 to 139.99 mm) (3.4 to 28.7 mm)
5.473 to 5.760-in. 0.134 to 1.067-in.
B
Sensor
Size 2
060
C
(146.33 to 154.05 mm) (3.4 to 26.7 mm)
6.066 to 6.383-in. 0.134 to 1.037-in.
D
(154.08 to 162.13 mm) (3.4 to 26.3 mm)
6.384 to 6.624-in. 0.134 to 0.374-in.
B
(162.15 to 168.25 mm) (3.4 to 9.5 mm)
Sensor
Size 1
7-in. 7.93-in. 6.625 to 7.023-in. 0.134 to 0.614-in. 0.134 to 0.216-in.

070 C
7.024 to 7.392-in. 0.134 to 0.246-in.
D
(178.41 to 187.76 mm) (3.4 to 6.2 mm)
6.384 to 6.624-in. 0.134 to 1.114-in.
B
(162.15 to 168.25 mm) (3.4 to 28.3 mm)
Sensor

Z2
070 C
7.024 to 7.392-in. 0.134 to 0.986-in.
D
(178.41 to 187.76 mm) (3.4 to 25.0 mm)
7.393 to 7.624-in. 0.250 to 0.499-in.
B
(187.78 to 193.65 mm) (6.4 to 12.6 mm)
7.625 to 7.981-in. 0.250 to 0.374-in.
C
Sensor
Size 1
080
D
(202.74 to 213.36 mm) (6.4 to 7.9 mm)
8.401 to 8.766-in. 0.250 to 0.364-in.
E
(213.39 to 222.66 mm) (6.4 to 9.2 mm)
7.393 to 7.624-in. 0.250 to 1.239-in.
B
(187.78 to 193.65 mm) (6.4 to 31.4 mm)
7.625 to 7.981-in. 0.250 to 1.114-in.
C
Sensor
Size 2
080
D
(202.74 to 213.36 mm) (6.4 to 26.7 mm)
8.401 to 8.766-in. 0.250 to 1.104-in.
E
(213.39 to 222.66 mm) (6.4 to 28.0 mm)
8.767 to 9.172-in. 0.250 to 1.065-in.
A
(222.68 to 232.97 mm) (6.4 to 27.1 mm)
9.173 to 9.561-in. 0.250 to 1.082-in.
B
(232.99 to 242.85 mm) (6.4 to 27.5 mm)
100 C
10.021 to 10.546-in. 0.250 to 0.945-in.
D
(254.53 to 267.87 mm) (6.4 to 24.0 mm)
10.547 to 10.999-in. 0.250 to 1.018-in.
E
(267.89 to 279.37 mm) (6.4 to 25.9 mm)
11.000 to 11.373-in. 0.250 to 1.097-in.
B
(279.40 to 288.87 mm) (6.4 to 27.9 mm)
120 C
11.939 to 12.250-in. 0.250 to 1.159-in.
D
(303.25 to 311.15 mm) (6.4 to 29.4 mm)
Rosemount 3051 Dimensional Drawings(1)

Figure 1. Rosemount 3051C Exploded View
F
E
D
C
B
A
G
H
I
J
K
N
L
O
M P
A. Cover G. Electronics Board L. Drain/Vent Valve

B. Cover O-ring H. Name Plate M. Flange Adapters
C. Terminal Block I. Housing Rotation Set Screw (180 degree maximum N. Process O-Ring
D. Electronics Housing rotation without further disassembly) O. Flange Adapter O-Ring
E. Configuration Buttons Cover J. Sensor Module P. Flange Alignment Screw (not pressure retaining)
F. Local Configuration Buttons K. Coplanar Flange Q. Flange Bolts
(1) This section contains dimensional drawings for output codes A, F and X. For output codes W and M, visit
http://www2.emersonprocess.com/en-US/brands/rosemount/Documentation-and-Drawings/Type-1-Drawings/Pages/index.aspx
Figure 2. Rosemount 3051C Coplanar Flange
4.09 4.29
(104) (109)
7.12
(181)
6.55
(166)
Dimensions are in inches (millimeters).
Figure 3. 3051 Wireless Housing with Coplanar Flange
4.196 5.49
(106.6)
(139)
7.41
(188)
Figure 4. Rosemount 3051C Coplanar Flange with Rosemount 305RC3 3-Valve Coplanar Integral Manifold
6.75
(171)
5.50 (140)
Max Open
9.20 (234)
Max Open
Figure 5. Coplanar Flange Mounting Configurations with Optional Bracket (B4) for 2-in. Pipe or Panel Mounting
2.81 A
(71)
3.35
PANEL (85)
MOUNTING
6.20
(157)
2.81
(71)
4.73
(120)
PIPE
3.35
MOUNTING (85)
6.25
(159)
3.50
(89)
A. 5/16 - 18 Bolts (not supplied) C. 2-inch U-Bolt

B. 3/8–16 Bolts D. 3/8–16 Bolts
Figure 6. Rosemount 3051C Coplanar with Traditional Flange
4.09
(104)
1.63
(41)
2.13
(54)
A
1.16 3.40 1.10
(29) (86) (28)
A. Flange Adapters (optional)
Figure 7. Rosemount 3051C Coplanar with Rosemount 305RT3 3-Valve Traditional Integral Manifold
6.28
(159)
A
3.63
(92)
2.13
0.91 3.50 1.10 6.38 (54) 2.52
(23) (89) (28) (162) (64)
A. 1/2–14 NPT Flange Adapter (optional)
Figure 8. Traditional Flange Mounting Configurations with Optional Brackets for 2-in. Pipe or Panel Mounting
Panel mounting bracket (option B2/B8) 2-in. pipe mounting bracket (option B1/B7/BA)
9.27
2.62 (235)
(67)
2.62
(67)
A
6.65 0.93
(169) (24)
2.81 4.12
(71) (105)
2-in. pipe mounting bracket (option B3/B9/BC)
6.65 4.85
(169) (123)
1.10
(28)
3.40
(86)
1.75
(44)
A. 5/16-18 Bolts (not supplied)

Figure 9. Rosemount 3051T Dimensional Drawings
4.09 4.29
(104) (109)
R1-4: 7.22 (183)

R5: 7.32 (186)
Figure 10. 3051T Wireless Housing Dimensional Drawings
4.20 5.49
(107) (139)
R1-4: 7.56 (192)

R5: 7.66 (195)
A
A. U-Bolt Bracket
Figure 11. Rosemount 3051T with Rosemount 306 2-Valve I Integral Manifold
4.13 4.88
(105) (124)
6.25 (159)
Max Open
Figure 12. Rosemount 3051T Typical Mounting Configurations with Optional Mounting Bracket
Pipe mounting Panel mounting
6.15
(156)
2.81
6.15 (71)
(156)
3.49
(89)
4.78
(121)
Figure 13. Rosemount 3051CFA Pak-Lok Annubar Flowmeter(1)
Front view Side view Top view
D
C
Table 14. Rosemount 3051CFA Pak-Lok Annubar Flowmeter Dimensional Data (Maximum Dimensions)
Sensor size A B C D
1 8.50 (215.9) 15.60 (396.9) 9.00 (228.6) 6.00 (152.4)
2 11.00 (279.4) 18.10 (460.4) 9.00 (228.6) 6.00 (152.4)
3 12.00 (304.8) 19.10 (485.8) 9.00 (228.6) 6.00 (152.4)
(1) The Pak-Lok Annubar model is available up to 600# ANSI [1440 psig at 100 °F (99 bar at 38 °C)].
Figure 14. Rosemount 3051CFC Compact Orifice Flowmeter
Orifice plate side view Orifice plate front view Orifice plate top view
(Primary element type code P)
Compact orifice plate
(Primary element type code C)
Conditioning orifice plate
Primary element type A B Transmitter height C D

7.75 (197) - closed 6.00 (152) - closed
Type P and C 5.62 (143) Transmitter Height + A 6.27 (159)
8.25 (210) - open 6.25 (159) - open
Figure 15. Rosemount 3051CFP Integral Orifice Flowmeter
Side view
Bottom view Front view
8.80
(223.46) 10.30
(261.81)
6.30
(160.55)
A
5.30
(134.51)
K J
Downstream Upstream
A. B.D. (Bore Diameter)
Line size
1
Dimension /2-in. (15 mm) 1-in. (25 mm) 11/2-in. (40 mm)
J (Beveled/Threaded pipe ends) 12.54 (318.4) 20.24 (514.0) 28.44 (722.4)
J (RF slip-on, RTJ slip-on, RF-DIN slip on) 12.62 (320.4) 20.32 (516.0) 28.52 (724.4)
J (RF 150#, weld neck) 14.37 (364.9) 22.37 (568.1) 30.82 (782.9)
J (RF 300#, weld neck) 14.56 (369.8) 22.63 (574.7) 31.06 (789.0)
J (RF 600#, weld neck) 14.81 (376.0) 22.88 (581.0) 31.38 (797.1)
K (Beveled/Threaded pipe ends) 5.74 (145.7) 8.75 (222.2) 11.91 (302.6)
K (RF slip-on, RTJ slip-on, RF-DIN slip on)(1) 5.82 (147.8) 8.83 (224.2) 11.99 (304.6)
K (RF 150#, weld neck) 7.57 (192.3) 10.88 (276.3) 14.29 (363.1)
K (RF 300#, weld neck) 7.76 (197.1) 11.14 (282.9) 14.53 (369.2)
K (RF 600#, weld neck) 8.01 (203.4) 11.39 (289.2) 14.85 (377.2)
B.D. (Bore Diameter) 0.664 (16.87) 1.097 (27.86) 1.567 (39.80)
(1) Downstream length shown here includes plate thickness of 0.162-in. (4.11 mm).
Figure 16. Rosemount 3051L Dimensional Drawings
2-in. flange configuration (flush mount only) 3- and 4-in. flange configuration
4.09 4.09
(104) (104)
D C
A
A
E B
B
A. Flange Thickness D. O.D. Gasket Surface
B. See Table 15. E. 2-in., 4-in., or 6-in. extension (only available with 3-in. and 4-in., DN80,
C. Extension Diameter and DN100 flange configurations)
Optional flushing connection ring (lower housing) Diaphragm assembly and mounting flange
G I
D. O.D. Gasket Surface

E. Lower Housing
F. Process Side
G. Bolt Circle Diameter
H. Flushing Connection
I. Outside Diameter
Diaphragm assembly and mounting flange
5.13
(130)
4.29
(109)
6.80
(173)
7.10
(181) 8.20
(209)
Table 15. 3051L Dimensional Specifications

Extension O.D.
Pipe Flange Bolt circle Outside No. of Bolt hole
Class(1) diameter(1) gasket
size thickness A diameter H diameter J bolts diameter
D surface E
2 (51) 0.69 (18) 4.75 (121) 6.0 (152) 4 0.75 (19) N/A 3.6 (92)
ASME B16.5 (ANSI)
3 (76) 0.88 (22) 6.0 (152) 7.5 (191) 4 0.75 (19) 2.58 (66) 5.0 (127)
150
4 (102) 0.88 (22) 7.5 (191) 9.0 (229) 8 0.75 (19) 3.5 (89) 6.2 (158)
2 (51) 0.82 (21) 5.0 (127) 6.5 (165) 8 0.75 (19) N/A 3.6 (92)
ASME B16.5 (ANSI)
3 (76) 1.06 (27) 6.62 (168) 8.25 (210) 8 0.88 (22) 2.58 (66) 5.0 (127)
300
4 (102) 1.19 (30) 7.88 (200) 10.0 (254) 8 0.88 (22) 3.5 (89) 6.2 (158)
ASME B16.5 (ANSI) 2 (51) 1.00 (25) 5.0 (127) 6.5 (165) 8 0.75 (19) N/A 3.6 (92)
600 3 (76) 1.25 (32) 6.62 (168) 8.25 (210) 8 0.88 (22) 2.58 (66) 5.0 (127)
DIN 2501 PN
DN 50 20 mm 125 mm 165 mm 4 18 mm N/A 4.0 (102)
10–40
DN 80 24 mm 160 mm 200 mm 8 18 mm 66 mm 5.4 (138)
DIN 2501 PN 25/40
DN 100 24 mm 190 mm 235 mm 8 22 mm 89 mm 6.2 (158)
DIN 2501 PN 10/16 DN 100 20 mm 180 mm 220 mm 8 18 mm 89 mm 6.2 (158)
(1) Tolerances are 0.040 (1.02), - 0.020 (0.51).
Pipe Process Lower housing F

Class(1) C
size side G 1
/4-in. NPT 1
/2 -in. NPT
2 (51) 2.12 (54) 0.97 (25) 1.31 (33) 5.65 (143)
ASME B16.5 (ANSI) 150 3 (76) 3.60 (91) 0.97 (25) 1.31 (33) 5.65 (143)
4 (102) 3.60 (91) 0.97 (25) 1.31 (33) 5.65 (143)
2 (51) 2.12 (54) 0.97 (25) 1.31 (33) 5.65 (143)
ASME B16.5 (ANSI) 300 3 (76) 3.60 (91) 0.97 (25) 1.31 (33) 5.65 (143)
4 (102) 3.60 (91) 0.97 (25) 1.31 (33) 5.65 (143)
2 (51) 2.12 (54) 0.97 (25) 1.31 (33) 7.65 (194)
ASME B16.5 (ANSI) 600
3 (76) 3.60 (91) 0.97 (25) 1.31 (33) 7.65 (194)
DIN 2501 PN 10–40 DN 50 2.40 (61) 0.97 (25) 1.31 (33) 5.65 (143)
DN 80 3.60 (91) 0.97 (25) 1.31 (33) 5.65 (143)
DIN 2501 PN 25/40
DN 100 3.60 (91) 0.97 (25) 1.31 (33) 5.65 (143)
DIN 2501 PN 10/16 DN 100 3.60 (91) 0.97 (25) 1.31 (33) 5.65 (143)
(1) Tolerances are 0.040 (1.02), - 0.020 (0.51).
Options
Standard configuration Custom configuration(1)
Unless otherwise specified, transmitter is shipped If Option Code C1 is ordered, the customer may specify the
as follows: following data in addition to the standard configuration
parameters.
ENGINEERING UNITS
Differential/Gage: inH2O (Range 0, 1, 2, and 3)  Output Information
psi (Range 4 and 5)
 Transmitter Information
Absolute/3051TA/3051TG: psi (all ranges)
 LCD Display Configuration
 Hardware Selectable Information

4 mA(1) 0 (engineering units above)
 Signal Selection
(1): Upper range limit
20 mA
 Wireless Information
Output: Linear
 Scaled Variable
External buttons: None
Flange type: Specified model code option  and more
Flange material: Specified model code option Refer to the “Rosemount 3051 Configuration Data Sheet”
O-ring material: Specified model code option document number 00806-0100-4007 for Rosemount 3051 HART
protocol.
Drain/vent: Specified model code option
For Wireless refer to the “Rosemount 3051 Wireless
LCD Display: None
Configuration Data Sheet” (document number
Alarm(1): High 00806-0100-4100).(1)
Software tag: (Blank)
Damping: 0.4 seconds(2) Tagging (3 options available)
 Standard SST hardware tag is wired to the transmitter. Tag
(1) Not applicable to FOUNDATION fieldbus, PROFIBUS PA, or wireless.
character height is 0.125 in. (3,18 mm), 56 characters
(2) For fieldbus protocols, default damping is 1 second. maximum.
 Tag may be permanently stamped on transmitter nameplate

upon request, 56 characters maximum.
 Tag may be stored in transmitter memory. Character limit is

dependent on protocol.
• HART Revision 5: 8 characters
• HART Revision 7 and Wireless: 32 characters
• FOUNDATION fieldbus: 32 characters
• PROFIBUS PA: 32 characters
(1) Not applicable to FOUNDATION fieldbus or PROFIBUS PA protocols.
Commissioning tag(1) M5 Digital Display

• 2-Line, 5-Digit LCD display for low power output
A temporary commissioning tag is attached to all transmitters.
• 2-Line, 8-Digit LCD display for 4-20 mA HART, FOUNDATION
The tag indicates the device ID and allows an area for writing the fieldbus and PROFIBUS PA
location. • 3-Line, 7-Digit LCD display for Wireless
• Direct reading of digital data for higher accuracy
Optional Rosemount 304, 305 or 306 Integral • Displays user-defined flow, level, volume, or pressure units
Manifolds • Displays diagnostic messages for local troubleshooting
• 90-degree rotation capability for easy viewing
Factory assembled to 3051C and 3051T transmitters. Refer to
the following Product Data Sheet (document number Configuration buttons
00813-0100-4839 for Rosemount 304 and 00813-0100-4733
Rosemount 3051 will ship with no buttons unless option D4
for Rosemount 305 and 306) for additional information.
(Analog Zero and Span), DZ (Digital Zero), or M4 (LOI) for local
Other seals configuration buttons are specified.
The Rosemount 3051 Wireless Transmitter is available with a
Refer to Product Data Sheet 00813-0100-4016 for additional Digital Zero button installed with or without the LCD display
information. digital display.
Output information Transient protection (option code T1)
Output range points must be the same unit of measure. Tested in accordance with IEEE C62.41.2-2002, Location
Category B
Available units of measure include:
6 kV crest (0.5 s - 100 kHz)
Pressure 3 kA crest (8 × 20 s)
6 kV crest (1.2 × 50 s)
atm inH2O@4 °C(2) g/cm2 psi
mbar mmH2O kg/cm2 torr Bolts for flanges and adapters
cmH2O
bar mmHg Pa  Options permit bolts for flanges and adapters to be obtained
@4 °C(1)(2)
in various materials
mmH2O mH2O
inH20 kPa
@4 °C(2) @4 °C(1)(2)  Standard material is plated carbon steel per ASTM A449, Type
ftH2O
inHg ftH20 MPa(2) 1
@60 °F(1)(2)
L4 Austenitic 316 Stainless Steel Bolts
cmHg
hPa(1)(2) inH2O@60 °F(2) kg/m2(1)(2) L5 ASTM A 193, Grade B7M Bolts
@0 °C(1)(2)
mHg ftH2O L6 Alloy K-500 Bolts
psf(1)(2)
@0 °C(1)(2) @4 °C(1)(2)
Conduit plug
(1) Field configurable only, not available for factory calibration or custom DO 316 SST Conduit Plug
configuration (option code C1 “Software configuration”).
Single 316 SST conduit plug replaces carbon steel plug
(2) Not available with Low Power (output option code M) or PROFIBUS PA Rosemount 3051C Coplanar Flange and 3051T
(output option code W).
Bracket Option
Display and interface options B4 Bracket for 2-in. Pipe or Panel Mounting
M4 Digital Display with Local Operator Interface (LOI) • For use with the standard coplanar flange configuration
• Available for 4-20 mA HART and PROFIBUS PA • Bracket for mounting of transmitter on 2-in. pipe or panel
• Stainless steel construction with stainless steel bolts
(1) Only applicable to FOUNDATION fieldbus.
Rosemount 3051C Traditional Flange Bracket

Options
B1 Bracket for 2-in. Pipe Mounting
• For use with the traditional flange option
• Bracket for mounting on 2-in. pipe
• Carbon steel construction with carbon steel bolts
• Coated with polyurethane paint
B2 Bracket for Panel Mounting

• Bracket for mounting transmitter on wall or panel
B3 Flat Bracket for 2-in. Pipe Mounting

• Bracket for vertical mounting of transmitter on 2-in. pipe
B7 B1 Bracket with SST Bolts

• Same bracket as the B1 option with Series 300 stainless steel
bolts

bolts

bolts
BA Stainless Steel B1 Bracket with SST Bolts

• B1 bracket in stainless steel with Series 300 stainless steel
bolts
BC Stainless Steel B3 Bracket with SST Bolts

• B3 bracket in stainless steel with Series 300 stainless steel
bolts
Rosemount 3051 Product Data Sheet
00813-0100-4001, Rev SA September 2014
Emerson Process Management Emerson Process Management

Rosemount Inc. Latin America
8200 Market Boulevard 1300 Concord Terrace, Suite 400
Chanhassen, MN 55317 USA Sunrise Florida 33323 USA
T (U.S.) 1-800-999-9307 Tel + 1 954 846 5030
T (International) (952) 906-8888 www.rosemount.com
F (952) 906 8889
www.rosemount.com
Emerson Process Management Asia Emerson Process Management Emerson FZE

Pacific Pte Ltd Blegistrasse 23 P.O. Box 17033
1 Pandan Crescent P.O. Box 1046 Jebel Ali Free Zone
Singapore 128461 CH 6341 Baar Dubai UAE
Tel +65 6777 8211 Switzerland Tel +971 4 811 8100
Fax +65 6777 0947 Tel +41 (0) 41 768 6111 Fax +971 4 886 5465
Service Support Hotline : +65 6770 8711 Fax +41 (0) 41 768 6300 www.rosemount.com
Email : Enquiries@AP.EmersonProcess.com www.rosemount.com
www.rosemount.com
Standard Terms and Conditions of Sale can be found at www.rosemount.com\terms_of_sale
The Emerson logo is a trade mark and service mark of Emerson Electric Co.
Tuned System, Coplanar, SmartPower, Annubar, Instrument Toolkit, Rosemount, and the Rosemount logotype are registered trademarks of
Rosemount Inc.
PlantWeb is a registered trademark of one of the Emerson Process Management group of companies.
HART and WirelessHART are registered trademarks of the HART Communication Foundation.
FOUNDATION fieldbus is a trademark of the Fieldbus Foundation.
PROFIBUS is a registered trademark of PROFINET International (PI).
Fluorinert is a trademark of 3M.
Neobee is a registered trademark of Stepan Speciality Products, LLC.
SYLTHERM is a trademark of Dow Corning Corporation.
eurofast and minifast are registered trademarks of TURCK.
All other marks are the property of their respective owners.
© 2014 Rosemount Inc. All rights reserved.
LA-2400 Series
Installation Manual
Linear Actuators
Established Leaders in Actuation Technology

Instruction Manual
IM-0443
LA-2400 Series
Linear Actuator
Table of Contents
General Information .............................................. 2-3
Introduction ....................................................... 2
Receiving/Inspection ......................................... 2
Storage ............................................................... 2
Equipment Return .............................................. 2
Identification Label ............................................ 3
Abbreviations Used in This Manual ................... 3
General Actuator Description ............................. 3
Basic Models ...................................................... 3
Product Specifications .............................................. 4
Installation ................................................................ 5
Typical Wiring Diagrams ...................................... 6-7
Start-up/Calibration ............................................... 8-9
Start-up/Calibration for Units with Amplifier.... 10-13
Amplifier Specifications .................................... 10
Amplifier Start-up ............................................. 11
Amplifier Parts Identification ............................ 12
Amplifier DIP Switch Chart .............................. 12
Typical Amplifier Wiring Diagram .................... 13
Amplifier Troubleshooting Chart ....................... 13
Troubleshooting Guide ...................................... 14-15
Component Location Drawing .......................... 16-17
Maintenance, Gear and Drive Nut Selection .... 18-19
Parts List and Recommended Spares ................ 20-22
Major Dimensions ............................................. 22-23
Due to wide variations in the terminal numbering

of actuator products, actual wiring of this device
should follow the print supplied with the unit.
GENERAL INFORMATION
INTRODUCTION WARNING - ELECTROSTATIC DISCHARGE

Rotork Process Controls, designs, manufactures, and This electronic control is static-sensitive. To protect
tests its products to meet many national and the internal components from damage, never touch
international standards. For these products to operate the printed circuit cards without using electrostatic
within their normal specifications, they must be properly discharge (ESD) control procedures.
installed and maintained. The following instructions
must be followed and integrated with your safety pro- RECEIVING/INSPECTION
gram when installing, using and maintaining Rotork Carefully inspect for shipping damage. Damage to the
Process Controls products: shipping carton is usually a good indication that it has
received rough handling. Report all damage immediately
• Read and save all instructions prior to installing, to the freight carrier and Rotork Process Controls
operating and servicing this product. Unpack the product and information packet—taking
care to save the shipping carton and any packing
• If you do not understand any of the instructions, material should return be necessary. Verify that the
contact your Rotork Process Controls representative items on the packing list or bill of lading agree with
for clarification. your own.
• Follow all warnings, cautions and instructions STORAGE

marked on, and supplied with, the product. If the product will not be installed immediately, it
should be stored in a clean, dry area where the ambient
• Inform and educate personnel in the proper temperature is not less than -20° F. The actuator
installation, operation and maintenance of the should be stored in a non-corrosive environment. The
product. actuator is not sealed to NEMA 4 until the conduit
entries are properly connected.
• Install equipment as specified in Rotork Process
Controls installation instructions and per applicable EQUIPMENT RETURN
local and national codes. Connect all products to the A Returned Goods authorization (RG) number is
proper electrical sources. required to return any equipment for repair. This
must be obtained from Rotork Process Controls.
• To ensure proper performance, use qualified (Telephone:
personnel to install, operate, update, tune and 414/461-9200) The equipment must be shipped,
maintain the product. freight prepaid, to the following address after the RG
number is issued:
• When replacement parts are required, ensure that
the qualified service technician uses replacement Rotork Process Controls
parts specified by Rotork Process Controls. 5607 West Douglas Avenue
Substitutions may result in fire, electrical shock, Milwaukee, Wisconsin 53218
other hazards, or improper equipment operation. Attn: Service Department
• Keep all product protective covers in place (except To facilitate quick return and handling of your
when installing, or when maintenance is being equipment, include:
performed by qualified personnel), to prevent • RG Number on outside of box
electrical shock, personal injury or damage to the • Company Name, Contact Person, Phone/Fax No.
actuator. • Address
• Repair Purchase Order Number
WARNING • Brief description of the problem
Before installing the actuator, make sure that it is
suitable for the intended application. If you are unsure
of the suitability of this equipment for your installation,
consult Rotork Process Controls prior to proceeding.
WARNING - SHOCK HAZARD

Installation and servicing must be performed only
by qualified personnel. 2
GENERAL INFORMATION
IDENTIFICATION LABEL GENERAL ACTUATOR DESCRIPTION
The LA-2400 series actuators are electrically operated,
bi-directional linear devices. They are designed for
strokes to 24 inches (610 mm) and thrusts to 1,500 lbf
(6672 N) and include a non-clutchable manual over-
LA-2410 ride handwheel. The drive motor may be single or
1627 C 01
120 / 50-60 / 1 / 1
three phase ac, or dc.
95C 036051 - 1
Options Include:
LA-2410
• Up to four independently adjustable limit switches
• Contactless position feedback
• Linear potentiometer position feedback
• Thermostatically controlled anti-condensation heater
• Integral or remote servo-amplifiers
• Trunnion mounting
MODEL NUMBER: LA24 10 Series
• 4 to 20mA position feedback
SERIAL NUMBER: 1627 C 01
• Shaft bellows
Sequential Number Year Built • Paint/coatings
Month Built
The LA-2400 series include 120/240 Vac single phase

models, 240/380/480 Vac three phase models and 24
Vdc models. These actuators are controlled by
ABBREVIATIONS USED IN THIS MANUAL “switched” power inputs or by a remotely installed
A or Amps Ampere servo-amplifier.
AC Alternating Current
The LA-2400 series is also available with an internal
°C Degrees Celsius
servo-amplifier. They require 120 or 240 Vac (depend-
CW Clockwise
ing on model) unswitched, single phase line voltage
CCW Counterclockwise
input and a dc analog command signal for a complete,
DC Direct Current
closed-loop positioning system in a compact enclosure.
°F Degrees Fahrenheit
G Earth Ground
Hz Hertz
kg Kilogram BASIC MODELS
L Line (power supply) LA-2410, LA-2420, LA-2450 and LA-2490 are all single
lbs. Pounds phase ac, three wire, plug reversible models. They are
lbf. Lbs. Force compatible with Jordan Controls remotely located
LVDT Linear Variable Differential Transformer AD-8240 Series servo amplifiers, or any bi-directional
mA Milliamp contact type control.
mfd Microfarad These actuators may also be equipped with an internal
mm Millimeters servo amplifier that features loss of signal detection for
N Newton (force) current command signal inputs and can be calibrated to
NEMA National Electrical Manufacturing Association allow the actuator to lock-in-place or drive to a preset
Nm Newton Meter position should the command signal drop below
NPT National Pipe Thread 3.8mA. Also included is a dynamic brake circuit to
Ph Phase increase positioning accuracy.
PL Position Limit Switch
RPM Revolutions per Minute The LA-2415 is a three phase ac, plug reversible model
sec. Second compatible with Jordan Controls remotely located AD-
TL Thrust Limit Switch 8900 servo amplifier or any bi-directional contact type
Vac Volts ac control. The LA-2440 is a dc plug reversible model and
Vdc Volts dc is compatible with Jordan Controls remotely located
VR Variable Resistance model AD-7530 servo amplifier or other compatible
W Watt control device.
-3-
LA-2400 SERIES PRODUCT SPECIFICATIONS
GENERAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS
Speed / Thrust: Power Requirements:

in. per sec. / lbf. Input Power Current (Amps)
Model Model
(mm per sec. / N) Volts/PH/Hz Run Stall
LA-2410 LA-2410 120/1/50-60 0.9 1.2
0.1/800 0.2/800 0.4/200 0.7/200
LA-2415 LA-2415 240/480/3/50-60 0.4/0.2 1.3/0.65
(2.5/3558) (5.1/3558) (10.2/890) (17.8/890)
LA-2450 LA-2415 380/3/50 0.3 0.9
LA-2420 0.1/1500 * 0.2/1500 * 0.4/550 0.7/450 LA-2420 120/1/50-60 2.5 2.9
LA-2490 (2.5/6672) (5.1/6672) (10.2/2446) (17.8/2002) LA-2440 24 Vdc 1.7 7.5
0.2/550 0.25/550 0.6/150 1/150 LA-2450 240/1/50-60 0.45 0.5
LA-2440
(5.1/2446) (6.4/2446) (15.2/667) (25.4/667) LA-2490 240/1/50-60 1.1 1.6
*1500 lbf. available in 6 in. stroke only.
Voltage Tolerance: +/-10%

Stroke: 6 to 24 in. (152 to 610 mm)
Conduit Entry: Two, 3/4 NPT.
Lubrication & Type: Permanently lubricated, Amoco-
Amolith Rykon All-Weather Field Wiring: To barrier terminal blocks.
Premium Grease #2.
Gearing: Hardened steel spur gear train, self-locking.
OPTIONS
Temperature: -40° F to 150° F. (-40° C to 65° C) Anti-condensation Heater: 120/240 Vac, 30W
Environment Rating: Dust ignition-proof for Class II, Two auxiliary position limit switches: 10A SPDT,
Division I, Groups E, F and G, 120/240 Vac
and Type 4 (IP65) indoor and
outdoor. 1000 ohm Feedback Potentiometer: 2 Watt Max. dc
Enclosure Material: Cast Aluminum Alloy. Contactless Feedback: Hall Effect
Approximate Weight: 40 lbs. (18kg) 4-20mA Feedback Transmitter:
Isolated, loop-powered 12-36 Vdc at 25 mA.
Mounting: Clevis mount in any position.
Trunnion (not available with 6 in. stroke). Maximum Load (ohms) = Power Supply Voltage - 8
When mounted vertically with the ram
0.020A
extending up, option D056 (vertical
moisture shield) must be used for wet Servo-Amplifier Model AD-8130: 120/240 Vac. (For
applications. more information
see Jordan Controls
Manual Handcrank: Permits local operation.
IM-0523).
Thrust Limiting: Bi-directional Accuracy: +/-1.0% of full rated travel
(factory set and not adjustable).
Repeatibility: 0.5% of full rated travel
Modulating Rate: (1% position changes) Hysteresis: 0.5% of full rated travel
LA-2415, 1200 starts/hour.
Linearity: +/-1.0% of full rated travel
All others, 2000 starts/hour.
Input Deadband: Adjustable
Duty Cycle:
Loss of Signal: Stays in place or runs to pre-set on cur-
Modulating: LA-2410, LA-2415, LA-2440, LA-2450.
rent command signals dropping below 3.8 mA (field
20%: LA-2420, LA-2490.
selectable)
Clevis: Non-rotating. Command Signal Inputs: Field selectable
4 to 20 mA (200 ohm impedance)
0 to 5 or 0 to 10 Vdc (100,000 ohm impedance)
High and Low Trim: Adjustable
-4-
INSTALLATION
MOUNTING WIRING
Refer to installation dimensions on the installation print The wiring diagram on page 6 shows the fundamental
sent with the actuator. The rear cover (opposite the connections for standard three-wire reversible single-
ram) must have clearance so it can be removed for phase ac motor, standard permanent magnet dc motor,
adjustments and interconnect wiring. and three phase AC models.
The actuator is mounted with pins through the rear and The wiring diagram on page 7 shows the fundamental
front clevises. The rear clevis is normally the stationary connections for single phase AC actuators with an
end. The device to be positioned must be such that it integral AD-8130 servo-amplifier, along with other
will allow retraction and extension. Side loading must options.
be avoided. Side loading will lead to excessive operat-
ing thrust which will cause premature bearing failure. A barrier type terminal strip is located under the rear
The device to be positioned must not require greater enclosure cover at the rear clevis end of the actuator.
thrust than the rating of the actuator. Mount the rear Two ¾ inch NPT conduit entries are available for field
clevis to the stationary actuator support device first, use. See the installation dimension drawing on the last
then move the traveling portion of the device to the page of this manual for their location.
front clevis and mount it. CAUTION: On standard single-phase wiring, the
The front clevis is non-rotating. The installation should position limit switches and the thrust switches are
place no torque upon the clevis or premature failure of wired directly in the motor circuit and protect it at
the actuator will result. the extremes of travel or at thrust cutout. Three
phase AC or DC units must have these thrust and
As an option, trunnion mounting is available on position limit switches wired into the controlling
actuators with 12 inch (305 mm) or greater strokes. device to cause end of travel or thrust shutdown.
Dimensional details of this style of mounting is shown Care must be taken in wiring these to the controlling
on page 18 of this manual. device so that the appropriate direction of control is
turned off when that direction’s limit switch is
When mounted vertically with the ram extending
actuated. If care is not taken in phasing the equip-
up, option D056 (vertical moisture shield) must be
ment, damage may occur to the actuator or driven
used for wet applications.
load.
• All wiring must be done in accordance with prevail-
ing codes by qualified personnel.
• Typical wiring diagrams are shown on pages 6-7.
Actual wiring should follow the wiring diagram
supplied with the actuator.
• Fusing must be installed in line power, and should be
of the slow blow type.
• Wiring must be routed to the actuator through the
two conduit openings. Generally, one conduit will
contain input power and earth ground wires. The
other conduit would then contain low level input and
output signal wiring.
• It is required that all low level signal wiring be a
shielded type with the shield grounded at source
common.
• After installation, it is recommended that all conduits
be sealed to prevent water damage and to maintain
NEMA 4 enclosure rating.
• Remote mounted servo amplifiers must maintain a
maximum of 50 feet of wire run to the actuator.
-5-
TYPICAL WIRING DIAGRAMS
ACTUATOR WITHOUT A BUILT-IN AMPLIFIER
LA-2410, LA-2420 (120 Vac) LA-2440 (24 Vdc)

LA-2450, LA-2490 (240 Vac)
Actuator AC Power Applied to Terminals DC Power Applied to Terminals

Action 1&2 1&3 1(+) & 2(-) 1(-) & 2(+)
Viewing Actuator Ram Extend Retract Extend Retract
LA-2415 SERIES ACTUATOR
Due to wide variations

in terminal numbering
of actuator products, actual
wiring should follow the print
Notes: 1. The thrust limit switches (TL1 & TL2) are factory set to trip if the thrust exceeds the actuator rating.
2. Shielded wire is required for command and position feedback signal wiring.
-6-
TYPICAL WIRING DIAGRAM
LA-2400 SERIES ACTUATORS WITH A BUILT-IN AD-8130 AMPLIFIER
(120/240 Vac, Single Phase, 50-60 Hz)

Notes:
1. All references to actuator ram movement are as viewed facing the front clevis.
2. An increasing command signal will result in ram extension.
3. The thrust limit switches are factory set to trip if the thrust exceeds the actuator rating.
4. Shielded wire is required for command and position feedback signal wiring.
5. Comand signal input:
4 to 20 mA into a 200 ohm impedance
0 to 5 or 0 to 10 Vdc into a 100,000 ohm impedance
6. Refer to amplifier instruction manual for proper DIP switch settings and amplifier setup.
-7-
START UP & CALIBRATION
A. LIMIT SWITCH ADJUSTMENT PROCEDURE
(see Figure 1)
The limit switch assembly features up to four indepen- 1K ohm potentiometer
dently adjustable position limit switches. The setting of
one switch does not affect the setting of the other.
Limit switch #1 (PL1) is set to stop the actuator at the Fiqure 1
actuator fully extended position. Limit switch #2 (PL2)
is always set to stop the actuator at the actuator fully
retracted position. Each limit switch is activated by an
aluminum cam with a detent. When the cam roller falls
into this detent, the limit switch goes to its normal state.
To readjust the limit switches for the required actuator
stroke, the following methods are recommended:
FOR ACTUATOR WITHOUT A POSITION

FEEDBACK DEVICE
1. With no power applied to the circuits, manually turn
the manual handwheel until there is a slight gap Note:
(1/32”) between the front clevis and the outer 1K ohm potentiometer
support tube with the clevis hole in the required and #3 and #4 limit
mounting plate. switches are options.
CAUTION: Do not energize the actuator while
manual positioning or attempt to engage the
manual handwheel while the unit is running.
Rotation of the manual handwheel by the motor
could inflict personal injury. 4. The end of travel position limits PL1 and PL2 are
now set for full stroke of the actuator.
2. Loosen both set screws in PL2 cam (set screws are
120° apart). Rotate PL2 cam until the indent of the 5. Apply electrical power and run the actuator through
cam and the roller begin to mate and the limit its range to check for proper limit switch adjustment.
switch activates (when you hear a “click”). Tighten
the set screws.
3. Energize the motor and run front clevis to the fully FOR ACTUATOR WITH A POSITION
extended position. Loosen both the set screws of FEEDBACK DEVICE
PL1 cam and manually rotate the cam until the 1. With no power applied to the circuits, connect an
indent of the cam and the roller begin to mate and ohm meter across the potentiometer wiper arm and
the limit switch activates (when you hear a “click”). the “zero” (retract) end of the pot.
Tighten the set screws.
2. Follow steps 1 through 5 in the previous section.
-8-
START UP & CALIBRATION
A. POSITION FEEDBACK ALIGNMENT C. 4 to 20mA TRANSMITTER ADJUSTMENT
(Potentiometer)
The ST-4130 (1000 ohm-input, 4 to 20mA output) two
Position feedback is provided through the use of a wire transmitter modulates the current on a direct
potentiometer attached to the limit switch assembly. As current supply proportional to the input resistance. It is
the switches are driven by the actuator gearing, the powered by a 12.0 to 36.0 Vdc unregulated power
potentiometer is simutaneously driven to provide supply line which is modulated from 4 to 20mA
position feedback. proportional to the resistance of the input.
1. Establish if full extend or full retract is to be used for
zero indication. On slide gate installations, zero
indication is normally used when the actuator is fully
extended and the gate closed.
2. Make sure end of travel limit switches are correctly
set for proper stroke length. 800 ohm maximum load when power supply is 24 Vdc
3. Use an ohmmeter to monitor the position of the

feedback potentiometer wiper to determine which For the unit to function properly the 4mA end of the
end of the pot gives a low ohm resistance indica- feedback potentiometer must be preset to 50 ohms.
tion. 1. Position the actuator to the desired 4mA setting.
4. If the reading is greater than 50 ohms, see Position Resistance of the potentiometer must be measured
Limit Switch Adjustment Procedure for actuators without the ST-4130 connected.
with a potentiometer. 2. With potentiometer resistance at 50 ohms, adjust
5. Run the actuator through its stroke range to ensure ELEVATION for 4.0mA output.
the potentiometer is tracking through its electrical 3. Position the actuator to the desired 20mA setting.
range. (Generally 60 to 90% of 1,000 ohms).
4. Adjust RANGE for 20mA output.
NOTE: On tandem potentiometer assembly, set the
bottom potentiometer to approximately 50 ohms. 5. Repeat steps 1 through 4 until no further adjustment
is necessary.
6. To reverse the 4 and 20mA output, interchange the
B. POSITION FEEDBACK ALIGNMENT BLUE and YELLOW wires at the terminal block and
(Contactless) return to step 1.
Position feedback can also be provided through the use
of a contactless feedback device attached to the limit
switch assembly. As the switches are driven by the
actuator gearing, the feedback device is simutaneously
driven to provide position feedback.
-9-
START UP & CALIBRATION FOR UNITS WITH AMPLIFIERS
Switch and feedback device alignment is accomplished If the actuator does not run to the limit switch but stops
in the same manner as actuator without amplifiers, short and both red lights are off on the amplifier board,
except motor power is supplied from the amplifier. the amplifier has nulled and adjustments of span,
Varying the command signal input to the amplifier will elevation, loss of signal, or feedback potentiometer
allow you to reverse the extension or retraction of the may be required.
shaft to run to the minimum/maximum switch settings.
Amplifier Specifications
Standard Line Voltage: 120/240Vac, ±10%, Field Wiring Terminations: Plugable terminal block,
50/60 Hz (Slide switch select) wire size range 26-14
(Voltage input MUST match AWG.
the actuator motor voltage
Command Signal Monitor: The amplifier’s loss-of-
rating).
signal circuitry monitors
Power Consumption: Less than 20 watts for amplifier the command signal
functions only. input. If the command
signal drops below or
Voltage Output: Identical to voltage input. above the rating, the
Current Output: 10 amps max. at 120 or 240 Vac. actuator will either lock
in place or run to a
Fuse protection: Customer supplied. Size based on preset position (user
actuator controlled and local codes. selectable).
Null output (AD-8240): Rated 2 ampers Limit Signals: Internal: Part of servo control.
@120/240Vac, 50/60Hz.
Output Shaft Motion: All models can go either
Command Signal Inputs: direction on an increasing
• 4-20mA, 4-12mA, 12-20mA into a 200Ω shunt command signal. This is
resistor determined by the ZERO and
• 0-5Vdc into 100,000Ω impedance SPAN settings.
• 0-10Vdc into 100,000Ω impedance
Temperature Limits: -40° to 150° F (-40° to 65° C).
Position Feedback Signal: 1000Ω potentiometer
4-20mA Duty Cycle: Unrestricted modulating duty.
(Cont. duty).
Position Output Signal: Isolated 4-20mA, loop
powered with 12-36Vdc Position Accuracy: 1% of full range.
external power supply. Deadband: Factory preset to 1%. Field adjustable.
-10-
Amplifier Start-Up
1) Power. Before applying AC power to TB2 set slide 5) Transmitter. This adjustment sets the endpoints of
switch to the correct voltage (120/240Vac) the 4-20 mA transmitter to account for variations in
accuracy of the input command.
A) Set command signal to low level, normally 4 mA.
2) Command Calibration. This procedure calibrates
the minimum and maximum command to the unit. B) Depress ZERO pushbutton (S1) and LOS
pushbutton (S4) until the SPARE LED illuminates.
A) Set command signal to low level, normally 4 mA. While depressing pushbuttons, turn adjusting
B) Depress ZERO pushbutton (S1) and LOS knob CW to increase the 4 mA point, or CCW to
pushbutton (S4) until the SPARE LED illuminates. decrease the 4 mA point.
C) Set command signal to high level, normally C) Set command signal to high level, normally
20 mA. 20 mA.
D) Depress SPAN pushbutton (S2) and LOS D) Depress SPAN pushbutton (S2) and LOS
pushbutton (S4) until the SPARE LED illuminates. pushbutton (S4) until the SPARE LED illuminates.
While depressing pushbuttons, turn adjusting
3) Auto/Manual (Option). If the unit has the Auto/ knob CW to increase the 20 mA point, or CCW
Manual switch option, place it in the auto position. to decrease the 20 mA point.
4) Setpoints. These are the end of travel extremes 6) Deadband. This adjustment establishes the actuator
corresponding to the actuator output shaft positions servo sensitivity. It is factory set at 1% and should not
for low (4mA) and high (20mA) command signal be field adjusted. If the actuator begins to oscillate
levels. They are set by the ZERO and SPAN (Green and Yellow LEDs turn on and off rapidly),
pushbuttons and adjusting knob. All settings require decrease the sensitivity by holding deadband push
the holding of a push button and the turning of the button (S3) and turning adjusting knob CW until
adjusting knob. oscillation stops. Release button.
A) Set the command signal to lowest level,
normally 4mA.
7) Loss of Signal Preset. This adjustment establishes
B) Adjust LO setpoint (ZERO) by holding ZERO the position to which the actuator will travel upon a
push button (S1) and turning adjusting knob to loss of command signal condition. To activate this
move actuator output shaft to desired position. setting, SW3 must be OFF. Adjust the setting by
Turn the adjusting knob CW to extend the ouput holding the LOS push button (S4) and turning the
shaft. Turn the adjusting knob CCW to retract adjusting knob to set the preset position. Turn the
the ouput shaft. Release button. adjusting knob CW to extend the ouput shaft for
linear actuators, or rotate the output shaft CW for
C) Set the command signal to highest level,
rotary actuators. Turn the adjusting knob CCW to
normally 20mA.
retract the ouput shaft for linear actuators, or rotate
D) Adjust HI setpoint (SPAN) by holding SPAN push the output shaft CCW for rotary actuators.
button (S2) and turning adjusting knob to move
actuator output shaft to desired position. Turn
the adjusting knob CW to extend the ouput 8) Verify all settings by running the actuator through its
shaft. Turn the adjusting knob CCW to retract travel range several times.
the ouput shaft. Release button.
-11-
Amplifier Parts Identification
Amplifier DIP Switch Chart

DIP Switch Configurations SW2
Switch Switch Position Function
ON (Up) Current Command
1
OFF (Down) 0-5V / 0-10V Voltage Command
ON (Up) 0-5V Voltage Command
2
OFF (Down) Current / 0-10V Command
ON (Up) LOS Lock-in-Place
3
OFF (Down) LOS Preset Position
ON (Up) Dynamic Brake On
4
OFF (Down) Dynamic Brake Off
-12-
Typical Amplifier Wiring Diagram
AD-8140

supplied with the unit.
Troubleshooting
For visual troubleshooting, LEDs are provided to display the status of the actuator.
These are located on the same side of the lower board as SW1.
The identification of these LEDs are shown in the table below.
LE D Functi on
This LED flashes when the microprocessor is running. If this is not on, verify
MICRO OK
power to the board.
This LED is on when the actuator is extending the ouput shaft for linear
INC.
actuators, or rotating the output shaft CW for rotary actuators.
This LED is on when the actuator is retracting the ouput shaft for linear
DEC.
actuators, or rotating the output shaft CCW for rotary actuators.
1 Flash - Indicates loss of 4-20 mA ignal (LOS).
L.O.S. 2 Flashes - Indicates loss of the feedback signal.
3 Flashes - Indicates indicates a stall condition.
-13-
TROUBLE POSSIBLE CAUSE REMEDY
a. No power to actuator a. Check source, fuses, wiring
b. Motor overheated and internal thermal switch tripped b. Let motor cool and determine why overheating occurred
(single phase AC motors only) (such as, excessive duty cycle or ambient temperature)
c. Motor defective c. Replace motor and determine cause of failure
d. Both end of travel position limit switches open or one

d. Adjust switch settings or replace defective switch
open and one defective
e. Actuator ram stalled (mechanically jammed) e. Check drive load for mechanical jam and correct cause
f. Defective motor run capacitor

Motor won’t operate f. Replace capacitor
(single phase ac motors only)
g. Reduce load or replace actuator with one with

g. Load exceeds actuator thrust rating
appropriate thrust rating
h. Power applied to extend & retract at same time h. Correct power input problem
i. Amplifier defective i. Replace amplifier
j. Check command signal to verify signal greater than

j. Amplifier is in Loss of Signal
3.8 mA is present
k. Amplifier deadband is too wide k. Reduce deadband setting
a. Wiring to actuator incorrect a. Correct field wiring

Ram positions in wrong
direction for extend and
retract input power
b. Wiring from motor to terminals or switches is reversed b. Correct internal actuator wiring
a. Power applied to extend & retract at the same time a. Correct power input problem
b. Damaged power gearing b. Repair gearing

Motor hums,
but does not run
c. Defective motor run capacitor
c. Replace capacitor
(single phase ac motors only)
d. Damaged servo amplifier d. Replace servo amplifier
a. Defective power gearing a. Repair gearing

Motor runs,
but ram does not move
b. Screw drive nut stripped or pulled out of tube b. Repair or replace screw drive nut
a. Switch wired wrong or is defective a. Correct wiring or replace switch

Motor does not shut off
at limit switch
b. Switches are not aligned b. Align switches
-14-
TROUBLE POSSIBLE CAUSE REMEDY
a. Thrust limit sw itch not properly w ired to control circuit a. Correct w iring per diagram
b. Thrust limit sw itch collars loose or not properly adjusted b. Adjust and tighten collars as required
c. Thrust limit sw itch defective c. Replace
Thrust limit sw itch d. Thrust limit sw itch bent and binding d. Replace shaft
operation
e. Thrust limit sw itch mounting or bushing is bent or
e. Replace as required
damaged
f. Thrust limit sw itch mounting block not aligned or secured f. Align and secure blocks as required
g. The actuator is overloaded g. Remove overload
a. Power not applied for other direction a. Correct power problem
b. Power always applied to one direction and electrically

b. Correct power problem
stalls when applied for opposite direction
c. Open limit switch for other direction c. Adjust or replace limit switch as required
Motor runs,
but only one way d. Actuator is in thrust overload d. Determine obstruction and correct
e. Motor has an open winding e. Replace motor
f. Motor and feedback potentiometer are out of phase f. Reverse potentiometer end leads
g. Amplifier is defective g. Replace amplifier
a. Amplifier deadband is too wide a. Reduce deadband setting
Poor response to command b. Amplifier is defective b. Replace amplifier

signal changes
c. Reduce noise. Also ensure that command signal wiring
c. Excessive noise on command signal
is shielded with shield grounded at source common only
a. Amplifier deadband is too narrow a. Increase deadband setting
Actuator oscillates b. Amplifier is defective b. Replace amplifier

at setpoint
c. Reduce noise. Also ensure that command signal wiring
c. Excessive noise on command signal
is shielded with shield grounded at source common only
a. Pot not aligned with end of travel extremes and is being
Pot feedback signal not a. Align pot to range of actuator
driven through its dead region
always present during
actuator ram movement b. Pot signal is erratic or nonexistent b. Replace pot
a. Defective pot a. Replace pot

Pot signal does not change
as actuator operates
b. Feedback gear not turning pot shaft b. Check gearing engagement and set screw in gear hub
Pot signal is reversed
a. Pot is wired wrong a. Reverse wiring from ends of pot at actuator terminal block
for output ram direction
a. Add heater and thermostat circuit and ensure that existing
a. Condensation caused by temperature variations and
circuit is continuously energized Check conduit entry and
humidity
seal to prevent water from entering via the conduit
Water droplets inside b. Ensure rear cover gasket is in place and replace if
motor area of actuator defective. Also ensure all cover bolts are in place and
b. Water entering actuator tightened. Check conduit entry and seal to prevent
water from entering via the conduit. Order optional
bellows kit if needed
Note: For actuators controlled by servo-amplifiers, refer to that servo-amplifier’s instruction manual for additional troubleshooting information.
-15-
COMPONENT IDENTIFICATION
1. Actuator Housing 20. Feedback Assembly
2. Feedback Housing 21. Thrust Limit Switch (2)
3. Motor Cover 22. Motor Pinion
4. Feedback Cover 23. Power Idler Gear Assembly
5. Outer Tube 24. Feedback Idler Gear Assembly
6. Inner Tube Assembly 25. Limit Switch Gear
7. Clevis, Stationary 26. Drive Screw Gear
8. Clevis, Tube 27. Drive Screw
9. Housing Gasket 28. Handcrank Gear
10. Cover Gasket 29. Handcrank
11. O’ Ring, Stationary Clevis 30. Spring Pack Assembly
12. O’ Ring, Tube Clevis 31. Drive Screw Guide
13. Seal, Handcrank 36. Tube Clevis Roll Pin
14. Tube Scraper 41. Limit Switch Gear Set Screws
15. Tube Seals 42. Limit Switch Assembly Mounting Screws
16. Tube Spacer 43. Tube Bearing and Seal Retaining Ring
17. Tube Bearing 44. Drive Screw Guide Retaining Ring
18. Motor 49. Drive Nut
19. Motor Top (1phase ac only) 50. Potentiometer
51. Noncontact Feedback Module
Optional
noncontact
feedback
device and
4 limit switches.
-16-
COMPONENT IDENTIFICATION
DC Motor Side Feedback Side with Amp
AC Motor Side (1 phase) Feedback Side
18. Motor 37. Housing Bolts

19. Motor Top (1 phase ac only) 38. Motor Cover Bolts
20. Feedback Assembly 39. Feedback Cover Bolts
21. Thrust Limit Switch Assembly 40. Motor Mounting Bolts
32. AC Motor Capacitor (1 phase ac only) 45. AD-8130 Amplifier
33. AC Motor Resistor (1 phase ac only) 46. Heater
34. ST-4130 Loop Powered 4-20 mA 47. Ground Screw
Transmitter or EC-10883 analog conver-
48. Thermo Switch
sion module for contactless feedback
35. Terminal Strip
-17-
MAINTENANCE
Under normal service conditions, the motor, gearing, To Remove Multi-turn Feedback Assembly 20:
bearings, and parts do not require periodic mainte- A. Separate housings.
nance. If for any reason the unit is disassembled in the B. Loosen set screws 41 and remove gear 25.
field, all Oilite bushings should be saturated with S.A.E. C. Remove screws 42.
20 or 30 non-detergent oil and all gearing heavily D. Remove feedback assembly 20.
coated with Amoco-Amolith Rykon all weather pre-
mium grease #2 or equal. To Remove Single-turn Feedback Assembly 20:
A. Separate housings.
Care should be taken to ensure that no foreign material
B. Loosen set screws 41 and remove gear 25.
is in the grease, which could cause premature failure.
C. Remove screws 42.
The screw shaft must be lubricated with Allex EP1L
D. Remove feedback assembly 20.
grease. DO NOT SUBSTITUTE.
To Change Tube Bearing 17 or Seals 15:
Refer to Pages 16 and 17 for component locations. A. Separate housings.
B. Remove outer retaining ring 43.
To Separate Housings: C. Remove scraper 14, spacer 16, seals 15 and tube
A. Disconnect motor wires which run through housing. bearing 17.
B. Extend front clevis to obtain access to roll pin 36.
C. Remove roll pin 36 and front clevis 8. To Remove Inner Tube Assembly 6:
D. Remove housing screws 37, 38 and 39. A. Separate housings.
E. Separate housing assemblies and remove gears 23 B. Remove retaining ring 44 and guide 31.
and 24. C. Hold screw shaft gear 26 and turn tube 6 to unscrew
from shaft.
To Remove Motor 18:
A. Separate housings.
B. If gear 22 is held to motor shaft with a retaining ring,
remove the ring and gear 22.
C. Remove screws 40.
D. Remove motor top 19. (ac motor only).
E. Remove motor stator and rotor 18.
POWER GEARING SELECTION CHART

(All Stroke Lengths)
Actuator Voltage Stroke Speed Motor Pinion Gear Power Idler Gear Assembly
120 or 240 Vac 0.1" + 0.2"/sec. 16A-017896-001 65A-016334-002
240/380/480 Vac 3 phase 0.4" + 0.7"/sec. 16A-017895-001 65A-016334-001
0.2" + 0.25"/sec. 16A-017896-001 65A-016334-002
24 Vdc
0.6" + 1.0"/sec. 16A-017895-001 65A-016334-001
-18-
Single Turn Feedback Gearing & Drive Nut Selection Charts
LA-2410, LA-2415, LA-2420, LA-2450, LA-2490 (0.1”/sec. & 0.4”/sec.); LA-2440 (0.2”/sec. & 0.6”/sec.)
Stroke 1st Stage Gear 2nd Stage Gear Feedback Gear Drive Nut (3/4 - 10)
3" 65B-025344-004 N/A 16B-003803-133 61A-039553-003
4" 65B-025344-009 N/A 16B-003803-151 61A-039553-003
5" 65B-025344-001 N/A 16B-003803-109 61A-039553-003
6" 65A-017619-001 65A-025339-001 16B-003803-130 61A-039553-003
7" 65A-017619-001 65A-021042-001 16A-021043-001 61A-039553-003
9" 65A-017619-001 65A-017620-003 16B-003803-042 61A-039553-003
12" 65A-017619-001 65A-017620-003 16B-003803-131 61A-039553-003
15" 65A-017619-001 65A-021042-004 16B-003803-042 61A-039553-003
18" 65A-017619-001 65A-021042-005 16B-003803-133 61A-039553-003
24" 65A-017619-001 65A-021042-006 16B-003803-132 61A-039553-003
Stroke 1st Stage Gear 2nd Stage Gear Feedback Gear Drive Nut (3/4 - 6)
3" 65B-025344-003 N/A 16B-003803-131 61A-039553-002
4" 65B-025344-007 N/A 16B-003803-149 61A-039553-002
5" 65B-025344-004 N/A 16B-003803-133 61A-039553-002
6" 65B-025344-002 N/A 16B-003803-132 61A-039553-002
7" 65B-025344-008 N/A 16B-003803-150 61A-039553-002
9" 65B-025344-001 N/A 16B-003803-109 61A-039553-002
12" 65A-017619-001 65A-021042-001 16A-021043-001 61A-039553-002
15" 65A-017619-001 65A-017620-003 16B-003803-042 61A-039553-002
18" 65A-017619-001 65A-017620-002 16B-003803-112 61A-039553-002
24" 65A-017619-001 65A-021042-002 16B-003803-050 61A-039553-002
Multi Turn Feedback Gearing & Drive Nut Selection Charts

Stroke 1st Stage Gear 2nd Stage Gear Limit Switch Gear Drive Nut (3/4 - 10)
6" 65B-025344-004 N/A 16B-003803-133 61A-016350-001
12" 65A-017619-001 65A-025339-001 16B-003803-130 61A-016350-001
18" 65A-017619-001 65A-017620-003 16B-003803-042 61A-016350-001
24" 65A-017619-001 65A-021042-003 16B-003803-131 61A-039553-003
Stroke 1st Stage Gear 2nd Stage Gear Limit Switch Gear Drive Nut (3/4 - 6)
6" 65B-025344-003 N/A 16B-003803-131 14A-016378-001
12" 65B-025344-002 N/A 16B-003803-132 14A-016378-001
18" 65B-025344-001 N/A 16B-003803-109 14A-016378-001
24" 65B-017619-001 65A-021042-001 16A-021043-001 61A-039553-002
-19-
PARTS LIST
Recommended Spare Parts Indicated in Bold
ID Description Part Number Quantity

1 Motor Housing - ac Units 60D-042926-002 1
Motor Housing - dc Units 60D-042926-003 1
2 Feedback Housing w/o Amp 60D-023767-001 1
Feedback Housing with Amp 60D-023767-001 1
3 Motor Cover 60C-016326-001 1
4 Feedback Cover w/o Amp 60C-016328-001 1
Feedback Cover with Amp 60C-016326-001 1
(or with 21P option)
5 Outer Tube, 6" stroke 61B-040118-001 1
Outer Tube, 12" stroke 61B-040118-002 1
6 Inner Tube, 6" stroke 61B-039536-001 1
Inner Tube, 12" stroke 61B-039536-002 1
Tube Bearing 61A-016376-001 1
Retaining Ring 58B-014184-102 2
Washer 74A-016377-001 2
Retaining Ring 58B-019899-016 2
Key 61A-012228-001 1
Shim Spacer 13A-014549-006 A/R
7 Rear Clevis 60B-016330-001 1
8 Front Clevis 60A-016346-001 1
9 Gasket, Main Housing 13C-016366-001 1
10 Gasket, Cover 13B-016367-001 2
11 O Ring, Rear Clevis 74B-010957-133 1
12 O Ring, Front Clevis 74B-010957-020 1
13 Seal, Handwheel Shaft 19B-003815-021 1
14 Scraper 13A-012877-001 1
15 Tube Seal 19A-012878-000 2
16 Tube Spacer 61A-012876-001 1
17 Tube Bearing 61A-016348-001 1
18 Motor, LA-2410, 0.1" or 0.2" / sec. 61B-042938-002 1
Motor, LA-2410, 0.4" or 0.7" / sec. 61B-042933-005 1
Motor, LA-2415, 0.1" or 0.2" / sec. 23B-037613-001 1
Motor, LA-2415, 0.4" or 0.7" / sec. 23B-0037614-001 1
Motor, LA-2420, 0.1" or 0.2" / sec. 61B-0042938-006 1
Motor, LA-2420, 0.4" or 0.7" / sec. 61B-042933-001 1
Motor, LA-2440, 0.2" or 0.25" / sec. 61B-026405-001 1
Motor, LA-2440, 0.6" or 1.0" / sec. 61B-026404-001 1
Motor, LA-2450, 0.1" or 0.2" / sec. 61B-042938-003 1
Motor, LA-2450, 0.4" or 0.7" / sec. 61B-042500-001 1
Motor, LA-2490, 0.1" or 0.2" / sec. 61B-042938-005 1
Motor, LA-2490, 0.4" or 0.7" / sec. 61B-042933-004 1
19 Motor Top (1 phase ac units only) 60C-042348-001 1
Belleville Washers (1 phase ac units only) 56A-005478-001 2
-20-
PARTS LIST

20 Single Turn Feedback:
Position Limit Switch, SPDT 46B-004053-405 2
Position Limit Switch, DPDT 46B-004053-414 2
1K Potentiometer 34B-0033104-001 1
1K/1K Potentiometer 34B-003956-160 1
Hall Effect Sensor 70B-039960-002 1
Multi Turn Feedback:
Travel Nut 14B-008602-001 1
Position Limit Switch, SPDT 46B-004053-409 2
Position Limit Switch, DPDT 46B-004053-414 2
1K Potentiometer 34B-100033-001 1
1K/1K 10 Turn Potentiometer 34B-100033-007 1
21 Thrust Limit Switch 46B-004053-405 2
22 Motor Pinion Gear See Selection Chart 1
23 Power Idler Gear Assembly See Selection Chart 1
24 Feedback Gearing See Selection Chart 1
25 Feedback Gear See Selection Chart 1
26 Screw Gear 16B-023764-001 1
27 Drive Screw:
6 inch, 3/4 - 10 62C-016356-001 1
12 inch, 3/4 - 10 62C-016356-002 1
18 inch, 3/4 - 10 62C-016356-003 1
24 inch, 3/4 - 10 62C-016356-004 1
6 inch, 3/4 - 6 62C-016355-001 1
12 inch, 3/4 - 6 62C-016355-002 1
18 inch, 3/4 - 6 62C-016355-003 1
24 inch, 3/4 - 6 62C-016355-004 1
28 Handwheel Gear Assembly 68A-018955-001 1
29 Handwheel 61A-016343-001 1
30 Thrust Spring Pack Assembly Consult Factory 1
31 Drive Screw Guide 14A-012868-001 1
32 Capacitor:
12.5 mfd, LA-2410, .1", .2", .4", .7" / sec. 24B-029812-027 1
35 mfd, LA-2420 24B-029812-026 1
5 mfd, LA-2450 24B-029812-028 1
7.5 mfd, LA-2490 24B-029812-030 1
33 Resistor, LA-2410, LA-2450 33B-003852-205 1
Resistor, LA-2420, LA-2490 33B-003852-305 1
34 ST-4130 Transmitter 70A-019948-001 1
35 Terminal Block 43B-003888-107 2
36 Roll Pin 57A-015215-125 1
37 Cap Screw 54A-015070-175 2
38 Cap Screw 54A-015070-200 4
39 Cap Screw 54A-015070-100 8
40 Screw, LA-2410 54A-015044-375 3
Screw, LA-2420, LA-2490 54A-015044-500 3
Screw, LA-2450 54A-015044-450 3
-21-
PARTS LIST

41 Set Screw 54A-015037-019 2
42 Screw, Truss Head 54A-015032-025 3
43 Retaining Ring 58B-014185-162 2
44 Retaining Ring 58B-014183-050 1
45 AD-8140 Amplifier 68C-041180-001 1
46 Heater, 120 Vac 74A-016946-001 1
Heater, 240 Vac 74A-031965-001 1
47 Ground Screw 58B-024244-152 1
48 Thermoswitch 74A-023565-001 1
49 Drive Nut See Selection Chart 1
50 Screw Shaft Grease 73A-032878-001 1
INSTALLATION DIMENSIONS
(Trunnion Mount)
-22-
LA-2400 MAJOR DIMENSIONS
Stroke C D
A B
in. (mm) Without Amp With amp Without Amp With amp
2 (51) 16.16 4.01 13.1 15.73 3.81 6.44
to 6 (152) (410) (102) (333) (400) (97) (164)
6.01 (153) 22.61 10.01 13.1 15.73 3.81 6.44
to 12 (305) (574) (254) (333) (400) (97) (164)
12.01 (305) 28.61 16.01 13.1 15.73 3.81 6.44
to 18 (457) (727) (407) (333) (400) (97) (164)
18.01 (457) 34.61 22.01 13.1 15.73 3.81 6.44
to 24 (610) (879) (559) (333) (400) (97) (164)
These dimensions are subject to change without notice and should not be used for preparation of drawings
or fabrication of installation mounting. Current installation dimension drawings are available upon request.
-23-
Electric Actuators and Control Systems
Fluid Power Actuators and Control Systems
Gearboxes and Gear Operators
Projects, Services and Retrofit
UK USA
Rotork plc Rotork Process Controls
tel +44 (0)1225 733200 tel +1 (414) 461 9200
fax +44 (0)1225 333467 fax +1 (414) 461 1024
email mail@rotork.com email rpcinfo@rotork.com
A full listing of our worldwide sales and

service network is available on our website.
www.rotork.com
As part of a process of on-going product development, Rotork reserves the right to amend and
change specifications without prior notice. Published data may be subject to change. For the
very latest version release, visit our website at www.rotork.com
PUB045-003-00
The name Rotork is a registered trademark. Rotork recognizes all registered trademarks.
Issue 08/11 Published and produced in the UK by Rotork Controls Limited. POWSH0811

Quemadores RSFC Burners EB0-007991 Rev 1

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RSFC Burners

Instruction LIMELIGHT Gas Ignitors

Alstom Power Inc.

Alstom Power Inc.

COPYRIGHT 2015 Alstom Power Inc. All rights

 COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 I

Only competent personnel, trained in the operations and maintenance of the

No amount of written instructions can replace intelligent thinking and reasoning

 COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 II

RSFC™ Burners Low NOx Firing System ........................................................................................... 1

LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor .................................................................................... 2

High Energy Ignitor Retractable (HEIR) .............................................................................................. 3

Exacta Flame Scanner System Upgrade ............................................................................................. 4

Vendor Supplied Equipment ................................................................................................................ 5

 COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 III

DESCRIPTION PAGE NUMBER

RSFC Burner Description .............................................................................................................................. 2

RSFC Fuel Assembly .................................................................................................................................... 3

RSFC Burner Handling and Maintenance ..................................................................................................... 8

WRHI Air Cooled Oil Gun............................................................................................................................ 10

© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 i

Orifice Tip Wear Classification and Flow Calibration ........................................................................... 16

SAMA Control Logic Operating Description ................................................................................................ 17

Table 1: RSFC Burner Operating Parameters at MCR ................................................................................. 6

PAMPA AIR DAMPER CONTROL METHODOLOGY ........................................................................ REV B

© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 ii

DRAWINGS DRAWING NUMBER

RSFC Burner General Arrangement – Sheet 1 ..............................................................EB0-007991-1E9250

© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 iii

© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 1

Figure 1: Typical Low NOx RSFC Burner Air/Fuel Flow Fields

RSFC BURNER DESCRIPTION

Tertiary and Primary Combustion Air Shutoff/Biasing Dampers

Optimum position of the combustion air-biasing damper will be

Three-zone Combustion Air Register

© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 2

Air Swirler Vane Positioners

Burner Throat Refractory

RSFC FUEL ASSEMBLY

© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 3

The following instructions are intended to serve as a guide to the sequence of

The Burner Management System and Unit Combustion Control

© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 4

The minimum windbox-to-furnace differential for the RSFC

5. Light the gas ignitors. (Refer to the Tab 2).

8. Additional burners may be brought into service as dictated by unit load

© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 5

Tertiary Air Shutoff Damper Modulates with load to maintaining

Table 1: RSFC Burner Operating Parameters at MCR

Flame Shape NOx UBC/Opacity Discussion

Table 2: RSFC Burner Flame Shape versus NOx Emissions

© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 6

• The flame must be stable

• The ignition point should be within 6” of the burner throat

• Superheater outlet temperature constraints must be maintained

Two suggested methods to achieve balanced burner air/fuel ratios are:

Gas or Oil Firing

© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 7

Exercise caution when removing hot oil guns from the

RSFC BURNER HANDLING

RSFC Burner Hardware

© COPYRIGHT 2015 ALSTOM POWER INC. REVISION: 0 8

Receiving and Unloading Instructions