Archive for category Flame Safety

Get More Combustion System Data into your PLC

Written by: A.J. Piskor

Traditionally, combustion control panels have been living in a hard-wired world. More often than not, the status of a burner system is communicated by indicator lights on a Flame Safeguard (FSG) terminal.

With the increased use of Programmable Logic Controllers (PLCs) controlling all aspects of a combustion system, customers are demanding more information from the FSG, as many operators manage their systems from a centralized control room.

While some customers have traded in their indicator lights for relays with dry contacts that feed back into their PLC, other customers are looking to simplify the communication between the FSG and PLC, while extracting more information on the operation of their burner system.

Here, we will go over some examples of technologies that are available today, and how you can get the information you need to where you need it.

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Tuning a Process Heater vs. Tuning a Boiler

Written by: A.J. Piskor

I was talking to a customer a few weeks ago, helping him with a Honeywell Flame Safeguard/scanner inquiry on a thermal oxidizer application.  We started talking about the burner and he mentioned that he was tuning the burner based on the oxygen coming out of the stack.

This is a common practice for technicians working on boilers, radiant tubes, and immersion tube applications where 100% of the exhaust is coming from the burner and is not diluted by any process air.  However, this is a bad practice to apply when working on an oxidizer, oven, dryer, or a multi-burner application.

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Combustion control systems go modular with Honeywell Slate

A typical combustion system is complex to say the least.  It is usually made up of various devices from multiple vendors that have to be combined and connected in order for the system to work.  These systems are not typically flexible and are hard to change once the system has been set up.

Honeywell has come up with a completely new system that provides limitless flexibility with fewer components.  This product has been designed as a fresh start for the combustion industry or in Honeywell’s words, “It’s time to wipe the SLATE clean.”

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How do I read the Modbus fault code in my Honeywell RM7800 flame safety controller?

More and more people are using Modbus to get data from their instruments and controllers back into their control systems for reporting, alarming and troubleshooting.

And while I can’t be there to help you set up your Modbus master, I can give you 13 rules and some general practice advice for communicating to any Modbus RTU device.

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Honeywell 7800 flame safety controller fails to execute Modbus remote reset

This one qualifies as a “Page the manufacturer left out of the manual”, and was brought to my attention by a customer who was having problems with remote reset on his flame safeguard system.

A typical multi-burner furnace has Honeywell 7800 flame safety controls on each burner as shown below.  Modbus is used to fetch fault codes for the plant’s HMI system, and to allow the control system to remotely reset the flame safety controls.

The reported problem was that Modbus did everything as advertised except remote reset on the one control that had a S7800A keyboard display module attached (colored orange in the network image on the right, or as shown in the controller image below).  

That unit would only do a reset when an operator pressed the reset button on the RM7838C controller.   Modbus failed to get the controller to execute a remote reset. 

The problem wasn’t communications – all Modbus read functions worked and Modbus writes to all the other controls worked as expected.  But somehow, the write command to do a reset action was ignored by the S7800 keyboard display.  

So, what’s causing the problem?

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Which temperature sensor do I need? An RTD or a thermocouple?

Temperature is probably the most measured parameter across applications and industries we work with on a daily basis. But there’s still confusion as to what temperature sensor to use.

I very often hear the Lesman inside sales team talking a customer through the selection process, so I thought I’d provide a quick tutorial on temperature sensor selection.

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Flame detection failures in industrial applications

“My UV flame detector worked last week, and now it keeps shutting down the system, even though the flame is there.  I ran diagnostics, and it’s not the detector. Can you help?”

When an instrument or technology works, it’s frustrating when all of a sudden, it stops… especially when it causes your burner or boiler process to stop unexpectedly and without reason. What’s the cause?  Is it the flame detector? The control? Wiring? A valve or switch in the fuel train? Or might it be caused by the flame?

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