Honeywell U2 1010S-3 All-in-One Flame Scanner & Signal Processor

Honeywell U2-1010S (3-Sensor UV+, UVSS & IR) Integrated Viewing Head & Signal Processor

The Honeywell U2-1010S is an all-in-one optical flame monitor combining three discrete optical sensors and a high-speed digital signal processor within a single explosion-proof, IP66-rated housing. Engineered specifically for critical combustion installations where burner discrimination is complicated by background fireball interference, adjacent burner reflection, or multi-fuel firing (such as dual-fuel marine auxiliary boilers, recovery boilers, and power generation furnaces), the U2-1010S eliminates the need for external rack-mounted flame amplifier cabinets.

Operating on an isolated 24 VDC SELV supply, the unit samples radiant emissions along a single coaxial optical line using a UVTron tube (210 nm), a solid-state UV photodiode (310 nm), and a solid-state infrared photodiode (1400 nm). Onboard processing dynamically evaluates flicker frequency spectra (10 selectable electronic filter bands) and signal amplitude, ensuring fail-safe burner monitoring and immediate flame failure response time (FFRT) without mechanical shutters.

Technical Specifications

Key Features

1. True Tri-Spectrum Optical Sensing: Houses an ultraviolet discharge tube (UVTron, 210 nm), a solid-state UV photodiode (310 nm), and an infrared sensor (1400 nm) on a shared optical focal axis for universal fuel discrimination.
2. Integrated Processor Architecture: Eliminates external burner rail amplifiers; high-frequency digital signal filtering and relay trip decisions occur directly inside the viewing head.
3. Solid-State Electronic Self-Checking: Replaces failure-prone mechanical shutters with dynamic electronic self-checking once per second, achieving high availability and SIL 3 functional safety compliance.
4. Through-the-Glass TouchWheel Interface: Parameter commissioning, sensor threshold gain, and filter bands can be programmed on-site in hazardous zones via capacitive controls without opening the pressurized housing.
5. Dual-File Combustion Switching: Dual file configurations switch automatically via a discrete 24 VDC contact, facilitating immediate threshold parameter changes during burner fuel-swaps (e.g., MGO to HFO or natural gas to blast-furnace gas).

Compatibility

• Honeywell: Flame pack platforms, 7800 Series (via isolated dry contacts), Slate Combustion Management System.
• Yokogawa: ProSafe-RS Safety Instrumented Systems (SIL 3 architecture).
• Forney: IDD-IIU, UniFlame, and D-FORCS burner control systems.
• Coen / John Zink: InSight, MicroScan, and generic DCS combustion front-ends.
• Marine Auxiliary Boilers: Aalborg (Alfa Laval) Mission OL/OS, KangRim heavy oil boilers, SAACKE rotary-cup & steam-atomizing marine burners.

Part Number Cross-References

• Honeywell / Iris Systems: U2-1010S (Connector model), U2-1010S-PF (Pipe-fit 3/4″ NPT threaded lead model), U2-1010S-3.
• Single/Dual Sensor Variants: U2-1012S (IR only), U2-1016S (UVTron only), U2-1018S (Dual UVSS/IR).
• Mating Cable Assemblies: ASYU2S-050 (50 ft / 15 m), ASYU2S-100 (100 ft / 30 m), ASYU2S-200 (200 ft / 60 m).
• Mounting Hardware: Honeywell Swivel Mount (Part # 104-0010-N / 60-2720), Quartz Fiber-Optic Thermal Insulator (Part # 129-0120-N).

Industrial Applications

• Marine Dual-Fuel Propulsion & Steam Plant: Auxiliary boilers, composite exhaust-gas economizers, and LNG carrier cargo-gas dual-fuel combustion units.
• Petrochemical & Refining: Process heaters, hydrogen reformers, thermal oxidizers, sulfur recovery tail-gas units (SRU), and flare tips.
• Power Generation Utilities: Tangentially fired pulverized coal furnaces, wall-fired supercritical boilers, and supplementary HRSG duct burners.
• Heavy Manufacturing: Lime kilns, cement rotary kilns, blast furnace gas (BFG) burners, and black liquor recovery systems.

Frequently Asked Questions

What fuels can the Honeywell U2-1010S monitor?

The U2-1010S contains three separate sensors—UVtron, UV photodiode, and IR photodiode—allowing it to monitor natural gas, LNG, blast furnace gas, diesel (MGO), heavy fuel oil (HFO), crude oil, and pulverized coal simultaneously or selectively.

What is the advantage of the U2-1010S over the U2-1010S-PF model?

The U2-1010S features an industrial mil-spec quick-disconnect multi-pin socket, allowing rapid sensor changeouts during maintenance without rewiring conduits. The U2-1010S-PF (Pipe-Fit) model features a 3/4″ NPT threaded conduit hub designed for permanent, sealed explosion-proof conduit piping installations.

Does the U2-1010S require a mechanical shutter for self-checking?

No. The U2-1010S features an electronic self-checking system that continuously tests detector circuits and counts background pulse states electronically. This eliminates moving shutter solenoids, removing the most common mechanical point of failure found in older flame scanners.

Can the scanner change flame settings automatically when switching fuels?

Yes. The unit includes a “File Select” digital input that allows external automation (such as a DCS or Burner Management System) to switch between distinct parameter configurations (e.g., File 1 for heavy oil and File 2 for gas) on the fly without manual reprogramming.

How do I configure gain and thresholds on the U2-1010S?

Adjustments can be made directly in the field through the sealed viewing window using the integrated capacitive touch wheel and LED display, or remotely through an automation network using RS-485 Modbus RTU register commands.