Description

HONEYWELL U2-1010S-PF

I. Basic Information

Model: U2-1010S-PF

Brand: Honeywell

Product Line: Integrated three-spectrum flame detector with built-in signal processor, PF version equipped with factory pre-installed 3m shielded pigtail cable. Adopting UVTron+UVSS+IR triple optical sensing technology, it realizes high-anti-interference flame identification for multi-fuel burners, complies with SIL3 functional safety and ATEX explosion-proof standards, widely used in boiler combustion safety interlock protection in power, petrochemical, metallurgical and heating industries.

Product Positioning

U2-1010S-PF integrates optical acquisition, signal processing and fault diagnosis into an explosion-proof housing, eliminating the need for an independent cabinet signal processor. With local capacitive touch parameter configuration, multi-mode signal output and Modbus RTU networking function, it can effectively distinguish real flame from furnace thermal reflection, ambient strong light interference, perfectly adapting to complex harsh combustion working conditions, and serves as a mainstream upgrade replacement solution for legacy Honeywell flame detection equipment.

Hardware Architecture

Silicone-free powder-coated explosion-proof aluminum housing, consisting of five core functional units: triple-spectrum optical sensor array, embedded signal processing unit, local touch HMI configuration unit, multi-signal output & Modbus communication unit, isolated power supply and explosion-proof protection unit. Electronic automatic self-check replaces mechanical shutter to achieve maintenance-free long-term operation, with independent gain and filter configuration for each optical channel.

Mounting Specification

3/4" NPT internal process thread installation, compatible with standard boiler flame viewing base, equipped with 3m factory prefabricated shielded cable, passing IEC vibration, humidity cycling and wide-temperature reliability tests for direct spare replacement without modification of original installation and wiring circuits.

Dimension: Φ117mm × 155mm, net weight: 2.8kg.

Compatible Systems

Hardware: Isolated 24VDC SELV power supply, twisted shielded communication cables, Honeywell RM7800/R7800 burner safety controller, DCS IO cabinet;
Software: FlameTools configuration software for parameter batch setting, data recording and remote fault diagnosis;
Field Equipment: Coal-fired/gas/oil boilers, industrial incinerators, metallurgical heating furnaces;
Application Industries: Thermal power, petrochemical, central heating, waste incineration, oil & gas hazardous process safety control.

Product Characteristics

Triple-spectrum composite flame identification technology effectively eliminates false detection caused by furnace high-temperature reflection and external strong light interference, adapting to all conventional fuel working conditions.
All-in-one integrated structure reduces intermediate wiring fault points, saves control cabinet installation space and shortens project commissioning cycle.
Electronic periodic self-check without mechanical wearing parts improves service life, with real-time fault latch and local + remote dual alarm mechanism.
Triple redundant output of analog signal, relay hard contact and Modbus bus meets functional safety interlock and centralized remote monitoring requirements.
IP66 explosion-proof wide-temperature design with multiple international safety certifications can be deployed in Class I Div1 hazardous explosive areas.
High compatibility with legacy Honeywell burner control systems, realizing plug-and-play renovation and replacement with minimal wiring modification.

II. Technical Specifications

2.1 Electrical Parameters

Power Supply: Isolated DC 22~26V SELV, max current 120mA, typical power consumption 3.5W
Relay Contact: 1A/30VDC resistive load, derate 1%/℃ above 50℃ ambient temperature
Analog Output: 4~20mA / 0~20mA selectable, maximum load resistance 500Ω
Dielectric Withstand Voltage: 1500VAC 1min for all ports, ±4kV ESD, ±2kV EFT surge protection.

2.2 Optical & Detection Parameters

Sensor: UVTron vacuum UV tube + UVSS solid-state UV + IR infrared triple independent channels
Flame Response Delay: 1s/2s/3s configurable
Filter: 10 selectable flame flicker frequency gears, 0~99 independent gain adjustment per channel
Flame Threshold Range: 50~3425 programmable intensity value.

2.3 Communication & Interface Parameters

RS485 Modbus RTU: Default 9600, 8N1, maximum 32 devices per bus
Local Operation: Capacitive touch wheel + LED display, 4-digit password lock, default 10-minute auto screen lock
Wiring Mode: 3m factory pre-installed shielded pigtail cable, 3/4" NPT mounting thread.

2.4 Environmental Specifications

Operating Temperature: -40℃ ~ +70℃; Storage Temperature: -40℃ ~ +85℃
Relative Humidity: 5%～95%RH, non-condensing, no corrosive gas
Vibration Compliance: IEC60068-2-6, explosion-proof grade Ex d IIC T6, IP66, SIL3 certified
Radiation Resistance: Immune to X-ray and gamma-ray ionizing radiation interference.

2.5 Mechanical Parameters

Mounting Thread: 3/4" NPT internal
Dimension: Φ117mm × 155mm, net weight: 2.8kg
Housing: Explosion-proof aluminum with silicone-free powder coating
Cable Outlet: Integrated 3m prefabricated shielded pigtail cable.

III. Key Features

3.1 Intelligent High-Accuracy Flame Recognition via Triple Spectrum

Multi-channel optical sensors capture flame characteristic flicker signals, filter furnace interference signals through proprietary algorithms, support fuel-adaptive parameter configuration to avoid mis-operation of safety interlock caused by smoke or light reflection.

3.2 Maintenance-Free Electronic Periodic Self-Diagnosis

Full-loop hardware self-test after power-on and cyclic runtime inspection detect sensor, wiring and power faults in real time, latch fault codes to eliminate blind spots in combustion safety protection.

3.3 Local Touch-Based On-Site Parameter Commissioning

All core parameters can be set on-site without upper computer software, password authority management prevents unauthorized parameter tampering, real-time flame intensity display facilitates rapid on-site calibration and troubleshooting.

3.4 Multi-Mode Redundant Signal Interconnection

Hard relay contact ensures emergency fuel cut-off interlock safety; analog signal realizes remote flame intensity monitoring; Modbus networking supports centralized data acquisition and remote batch parameter management for plant-wide combustion equipment.

3.5 Explosion-Proof Wide-Condition Continuous Safety Monitoring

High-sealing dustproof and waterproof explosion-proof housing adapts to harsh industrial environments such as high temperature, humidity, oil pollution and vibration, realizing 24-hour uninterrupted flame safety protection to prevent fuel leakage and explosion accidents.

IV. Working Principle

After power-on self-test, the triple optical sensors continuously collect flame spectral flicker signals, which are processed, filtered and calculated by the built-in processor. The real-time flame intensity is compared with the preset threshold to judge the flame status. The device outputs switch, analog and bus signals synchronously; in case of flame loss or hardware fault, the relay acts immediately to trigger the boiler fuel safety interlock, and fault information is latched for maintenance traceability.

V. Application Scenarios

Thermal Power Plants: Flame detection and safety interlock protection for coal-fired, gas-fired auxiliary boilers to prevent fuel leakage explosion accidents.
Petrochemical & Coal Chemical Industry: High-risk furnace flame monitoring in explosion-proof hazardous process areas.
Central Heating & Waste Incineration Power Plants: Large industrial boiler multi-burner flame closed-loop safety control.
Metallurgical Industry: High-temperature heating furnace combustion condition real-time monitoring and safety protection.
Legacy Automation System Renovation: Plug-and-place replacement of old single-spectrum flame detectors to upgrade combustion safety monitoring accuracy.