Safe Flame Scan I (Manual)

SAFE FLAME SCAN I
HT- FLAME SENSING SYSTEM

Description Operation Maintenance

HINDUSTHAN THERMOMETERS
5 Industrial Estate, Ambala Cantt 133 006 India
Ph: +91-171-2699237, Fax: +91-171-2699037
SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

E-mail: ignitor@rediffmail.com
SAFE FLAME SCAN I

FLAME SENSING SYSTEM

TABLE OF CONTENTS

INTRODUCTION......................................................................................... Page 1

DESCRIPTION AND OPERATION............................................................ Page 2
Mechanical Components.............................................................................. Page 2
Flame Scanner Guide Pipe........................................................................ Page 2
Flame Scanner Assembly.......................................................................... Page 2
Cooling Air Requirements........................................................................... Page 3
Electrical Requirements............................................................................... Page 4
Power supply to Safe Scan System........................................................... Page 4
Wiring Requirements................................................................................... Page 5
Other Requirements..................................................................................... Page 6
Electronic Components................................................................................ Page 6
Scanner Housing Electronics.................................................................... Page 6
Intensity and Fault Detection Card........................................................... Page 7
Frequency Detection Card........................................................................ Page 8
Preamplifiers............................................................................................. Page 9
AC amplifiers............................................................................................ Page 9
Comparator Amplifier............................................................................... Page 9
IC302 Quad 2 Input NAND Gate............................................................. Page 10
IC303 Monostable Multivibrator.............................................................. Page 10
Frequency Permissive Time Delay........................................................... Page 10
Frequency LED L302 and TP305 TP308.............................................. Page 10
Lamp and Meter Card............................................................................... Page 11
2/4 Flame Indication and Fault Alarm...................................................... Page 12
Power Supply Card Assembly.................................................................. Page 13

INSTALLATION AND START-UP PROCEDURES.................................. Page 14
Cooling Air.................................................................................................. Page 14
Electrical Components................................................................................. Page 14
System Operation Test................................................................................. Page 15
Preliminary Adjustments............................................................................. Page 15
Intensity..................................................................................................... Page 16
Frequency.................................................................................................. Page 16
Calibration of Scanner Head Electronics.................................................. Page 17
Gain and Offset Adjustments................................................................. Page 17
Dark Furnace Bias Adjustments............................................................ Page 17

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MAINTENANCE AND TROUBLESHOOTING......................................... Page 19
Scanner Head............................................................................................ Page 19
Fiber-Optic Cable...................................................................................... Page 19
Electrical Components................................................................................. Page 19
Troubleshooting Guide................................................................................ Page 19

TABLES
Frequency Detection Adjustments............................................................... Table 1

ILLUSTRATIONS
Scanner Positioning and System.................................................................. Figure 1
Card Rack Assembly.................................................................................... Figure 2
Safe Scan Scanner Assembly....................................................................... Figure 3
Safe Scan Scanner Head Assembly............................................................. Figure 4
Intensity and Fault Detection Card.............................................................. Figure 5
Frequency Detection Card........................................................................... Figure 6
Lamp and Meter Card Assembly................................................................. Figure 7
2/4 Flame Indication and Fault Alarm......................................................... Figure 8
Power Supply Card Assembly..................................................................... Figure 9
Scanner Housing Electronics....................................................................... Figure 10
Functional Block Diagram........................................................................... Figure 11
Voltage Follower Low Frequency Model.................................................... Figure 12
Non-Inverting Amplifier High Frequency Model........................................ Figure 13
Relationship between Analog and Digital Flame Signals............................ Figure 14

RECOMMENDED SPARE LISTS

ENGINEERING DRAWINGS
Flame Scanner Guide Pipe Assembly..........................................................HT-D-982-0140
Flame Scanner Assembly with Optical Head..............................................HT-D-982-0141
Flame Scanner Head Assembly with Quartz Lens......................................HT-C-984-0663
Assembly & Details of Lens & Lens Barrel ................................................HT-B-984-0318
Fiber Optic Cable 110 for Safe Flame Scanner .........................................HT-B-984-0322
Terminal Block Assembly...........................................................................HT-B-20-0-0386
Back Plane Wiring.......................................................................................HT-D-20-0-0499
External Connection Diagram - Front Terminal ..........................................HT-C-20-0-0390
Flame Scanner Housing Electronic Card.....................................................HT-D-984-0577
Hexagon Coupler Assembly........................................................................HT-B-984-0326
Intensity & Fault Detection Card.................................................................HT-D-984-0578
Frequency Detection Card...........................................................................HT-D-984-0579
Lamp & Meter Card.....................................................................................HT-D-984-0721
Lamp Driver Card Assembly.......................................................................HT-D-20-0-0259
2/4 Flame & Fault Alarm Card....................................................................HT-D-984-0581
Power Supply Card Assembly.....................................................................HT-D-984-0582
Card Extender 35 Pin Card Assembly.........................................................HT-D-984-0284
Remote Meter Assembly..............................................................................HT-4M-168-01

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SAFE FLAME SCAN I

FLAME SENSING SYSTEM

INTRODUCTION

The Safe Flame Scan I flame sensing system is designed primarily for use on coal fireball and
stable oil flame ignited by high energy arc (HEA) ignitors. It senses the visible light given off by
the flame and can recognize a coal flame by its characteristics fluctuations.

The Safe Flame Scan I system consists of a fiber-optic scanner head and a chassis containing
electronic signal conditioning modules. The scanner head is located at the boiler and the chassis
is mounted in and instrument rack. The rack may be up to 5000 ft from the boiler. A shielded
four-conductor cable sends power to the scanner head electronics and returns an electronic signal
representing flame to the chassis.

The scanner is normally installed in the windbox assembly (Figure 1). Refer to the Windbox
Arrangement drawing to determine the location of the scanners in your system.

The prime output of the flame sensing system is called the two-out-of-four (2/4) output. The
system will indicate flame only when at least two of the four scanners see flame. When fewer
than two scanners see flame, the system will indicate no flame. The output is represented by
the positioning of a set of form C contacts (break before make).

Individual flame signals are available for each scanner head. Theses signals are also available
through form C contacts.

The load ratings for these contacts are shown in the Electrical Requirements section.

The system contains a self-checking feature which actuates a fault alarm (contact closure) and
a light-emitted diode (LED) on the control panel when the intensity or frequency of any one
scanner falls out of preset limits.

As an optional feature, a remote meter output is available to indicate flame intensity. A
description of the meter circuits, if provided, is covered in the instruction brochure Meter
Output Safe Scan Scanner.

- 1 -

DESCRIPTION AND OPERATION

MECHANICAL COMPONENTS

The complete mechanical assembly is composed of a stationary part, called the flame scanner
guide pipe assembly, and a removable part, called the flame scanner assembly.

Flame Scanner Guide Pipe Assembly

The flame scanner guide pipe assembly consists of scanner head housing, a flexible metal hose, a
rigid pipe section, a cooling air manifold and cover plate.

The scanner head housing is a stainless steel tube located in the windbox nozzle. It is welded to
the nozzle with the face of the housing 2 in from the furnace end. Guide inside the scanner head
housing center the scanner head and provide a uniform passage for the external cooling air. The
end ring in the housing forms a mechanical stop for the scanner head.

The flexible hose assembly forms a flexible connection between the scanner head housing and
the guide pipe. It adapts the scanner to tilting of the windbox nozzle and angle mounting. The
flexible hose is brazed to the guide pipe and scanner head housing.

CAUTION
When scanner assemblies are shop installed, they are mounted so that the flexible
hose is compressed to its minimum length when the windbox is at zero (horizontal)
tilt. If a scanner is field installed, be sure it is mounted in the same manner to prevent
damage to the flexible hose and connections when the nozzle is tilted through its
range. Any radius of curvature greater than 18in. May be utilized as long as its cross
section is circular and does not restrict free movement of the scanner head within the
curved portion.

The guide pipe is normally fixed in the windbox front by means of a packing gland. The cooling
air manifold is screwed (NPT) onto the guide pipe.

The cooling air manifold is drilled and tapped to accept a flexible hose connection at its cooling
air inlet and has an opening for the flame scanner head assembly. The scanner opening must be
closed with the cover plate when the assembly is removed for maintenance.

Flame Scanner Assembly (Figure 3 and 4)

The flame scanner assembly has four sections similar to the four sections of the flame scanner
guide pipe assembly. They are the flame scanner head assembly, the flexible metal hose the rigid
pipe and the scanner housing assembly.

The flame scanner head assembly (Figure 4) consists of the scanner head body, which contains
the collimator tube and shield, the collimating lens and barrel, a mounting plate, a compression
spring one end of the fiber-optic cable and a plug.

- 2 -

Assemble the flame scanner head assemblies as follows:
1. Slip fit the collimator tube and shield assembly into the scanner head body and holds it in
place by a single Allen head screw. Position the shield on the collimator with spacers to
allow cooling air to flow through the head assembly.

NOTE
A wind box structure will sometimes restrict the location of the guide pipe scanner
head housing. To permit the scanner to see the flame, a prism may be installed in
place of the collimator shield. Use care when placing the scanner in the guide pipe to
assure proper orientation of the scanner head assembly.

2. Thread the fiber-optic cable, which is normally coiled inside the scanner head body plug.
Make sure the jam nut is in place on the cable, before installing the compression spring
and mounting plate. Then screw the collimating lens barrel onto the cable.

3. Lock the mounting plate to the lens barrel with the jam nut.

4. Insert the lens barrel in the scanner head body until the mounting plate rests against the
stop pins.

5. Insert the compression spring and plug. Three socket head screws hold the plug in the
scanner head body.

When the scanner assembly is inserted in the guide pipe, cooling air from the cooling air
manifold enters the scanner housing through two holes. This air flows down the rigid pipe and
flex metal hose to cool the fiber-optic cable. Air is discharged into the furnace through the
scanner head assembly because of the pressure differential between the cooling air inside the
scanner and the furnace. There should be no reason to disassemble the scanner head assembly,
except to clean the collimator shield (see maintenance and troubleshooting section).

The scanner housing holds the flame scanner assembly in the guide pipe and contains the
electronics for conditioning the fiber-optic signal. It is equipped with a polarized mounting flange
so that when a prism is used in the scanner head, the prism will have the correct orientation.

A weatherproof disconnect coupling is provided to conveniently connect external wiring. A
hexagon adapter adapts the connector to a -in. pipe thread. Sealtite flexible hose or a similar
weatherproof conduit should be used between the disconnect coupling and the rigid conduit
leading from the windbox assembly.

COOLING AIR REQUIREMENTS
The external cooling air passes through the guide pipe, the flexible hose and the annulus between
the scanner head and housing. The air is discharged in to the furnace at the top of the scanner
head, thereby removing any heat picked up by the scanner from the hot combustion air. The
scanner head should not be exposed to a continuous temperature above 300F without cooling
air.

- 3 -

NOTE
When the scanner assembly housing adapter flange is disconnected, the scanner
assembly must be removed from the guide pipe immediately. Wrap a cloth around the
scanner support pipe and hold it firmly against the cooling air manifold to minimize
the escape of cooling air while the head is being removed. The head should then be
held in the rag to protect it from damage. Install the cover plate to retain the cooling
airflow within the scanner guide pipe. This prevents a reduction of cooling air
pressure at the remaining scanners.

Cooling airflow requirements per scanner are 55 cfm at 120F (maximum temperature measured
at the scanner air booster fan inlet). Air manifold pressure at the scanner guide pipe must ne
6.00in. w.g. above furnace pressure for all operating conditions. After shutting down the unit,
scanner cooling air must be maintained until furnace conditions are such that the scanner
assembly (Figure 3) cannot overheat.

NOTE
Shutoff valves must not be installed in cooling air lines to the scanner.

ELECTRICAL REQUIREMENTS

Power Supply to Safe Scan System

There are five eight-position terminal boards on the back of the card rack assembly. A reliable
power source should be connected to terminals TB1 and TB2 in slots 39-38 (see drawing
HT-D-984-0593 or HT-C-984-0661).

Input power requirements are as follows:

Voltage: 105 to 125 V AC, RMS
Current: 0.250 A, RMS
Frequency: 50 to 440 Hz

Overload Protection is supplied by the circuit breaker on the power supply module. The circuit
breaker rating is selected to provide adequate protection to the field wiring and to allow 0.250 a
continuous system input current as requires by the system.

The 2/4 output occurs whenever two of the four scanners in a system see flame. The 2/4 output of
the system is represented by the making or breaking of a set of form C contacts (break before
make). Connections to these contacts are made on TB3 TB4 TB5 in slots 39-38, with TB4 as
common. The TB4 TB5 contact is open when a 2/4 signal is present; at the same time, the TB3
TB4 contact is closed.

- 4 -

The output contacts have the following characteristics:
Material: Mercury-wetted platinum contacts, hermetically sealed in an inert
atmosphere.
Rating: Switched load - 2 A maximum
500 V maximum
100 VA maximum
Inrush load - 20 A average for 10 microseconds
4 A average for 10 seconds
2 A average for 100 seconds.

The system also provides an individual set of output contracts for each scanner. Connections to
these contacts are made through the four terminal strips on the back of the chassis. These
terminals, located in slots 32-31 (channel 4), 24-23 (channel 3), 16-15 (channel 2), and 8-7
(channel 1), all have their contacts at TB1, TB2 and TB3. TB2 is common. TB1 is open when
there is no flame, and TB3 is closed with no flame.

The logic arrangement provides for continuous fault monitoring of the flame scanner, fiber-
optic bundle and signal conditioning circuits. Fault monitoring is based upon the signal input to
the frequency and intensity logic cards being within a preset band of levels. Fault signal output
connections are made to the relay contacts on terminals in slot locations 39-38. TB7 is common,
TB6 is opened with no fault, and TB8 is closed with no fault.

These fault contacts are mercury wetted and load rated as above.

WIRING REQUIREMENTS (See drawing HT-C-984-0661)

Four wires are required for each scanner head (channels 1, 2, 3, and 4); two supply power to the
electronics at the scanner head (B+to TB5 and B- to TB6), and two send the optical signal to the
chassis electronics (SIG to TB7 and GND to TB8). These wires must be supplies in a two-twisted
pair, foil shielded cable to reduce noise susceptibility of the system. The shield must be grounded
at the chassis end (TB8).

The maximum recommended cable length for No.16 awg is 5000ft. This length should be
reduced when using progressively smaller wire. It is advisable to keep this wire as short as
possible.

It is recommended that a dedicated conduit/ cable tray be run from the boiler to the Safe Flame
Scan I chassis for scanner wiring. If this is not possible, scanner wiring may be routed with other
low voltage instrumentation cable.

NOTE

Do not run scanner wiring in cables or trays carrying general purpose power wiring
for motors or lights. All wiring connections should be thoroughly checked before
energizing the scanner circuits. Erroneous wiring may damage semiconductors or
other components.

- 5 -

OTHER REQUIREMENTS
Specification ratings of other parameters for the Safe Flame Scan I system are as follows.

Operating temperature 0C to 60C
Storage temperature 65C to +125C
Operating relative humidity Less than 95%
Storage relative humidity Less than 95%

ELECTRONIC COMPONENTS

Scanner Housing Electronics (see drawing HT-D-984-0577)

The printed circuit board converts the light transmitted from the boiler (via a fiber-optic light
guide) to an electrical signal. Light from the light guide strikes photodiode PD101 and is directly
converted to a small electrical current. The current generated by PD101 is a linear function of
illumination and covers a five-decade range of foot-candle intensities.

Integrated circuit IC101 is a temperature compensated log amplifier. It converts the photodiode
current signal at pin 2 to a voltage signal at pin 10. The output voltage swings between the
approximate range of 1.5 V (intense brightness) and 6.4 V (no visible light). A family of curves
exists for the output voltage versus input current characteristics. Selection of a particular output
voltage curve is determined by the reference current magnitude at pin 16. A field-effect current
regulator diode CR101 supplies a reference current for output voltage scaling. Amplifier offset
and gain adjustments are factory set by potentiometers R101 and R103 respectively.

As flame brightness reduces, PD101 current reduces and IC101 output voltage increases. If the
boiler was not in operation, PD101 current would be zero. Since the log of zero approaches
minus infinity the log amplifier output would normally saturate. However, a feedback path,
consisting of CR102, R105 and L101, provides a means to stimulate PD101. As the output
voltage at pin 10 increases towards saturation, Zener diode CR103 conducts, allowing LED L101
to emit light on the surface of PD101, thus closing the feedback loop. Amplifier output voltage
will stabilize at approximately 6.4 V.

This feedback loop is the key circuit in the electronic fault detection scheme. By limiting the dark
furnace voltage to a known level and knowing the minimum amplifier output voltage for
maximum brightness, a range of good signal voltages is established. This signal range is
continuously monitors by the fault detection comparator amplifier on the intensity and fault
detection printed circuit (PC) board (see drawing HT-D-984-0578).

Integrated circuit IC102 is a silicon monolithic dual operational amplifier. The first amplifier is
configured as an inverting amplifier with a gain of 1/3. Capacitor C104 provides high frequency
roll off. The second amplifier is configured as a current injector. It converts the first amplifier
output voltage (pin12) to a current signal (point C), which is transmitted to the remote scanner
chassis. Signal current to the remote chassis is calculated by dividing the first amplifier output
voltage (pin 12) by the resistor value of R109.

The +-15 V power supply, shown on the Power Supply Card Assembly Drawing
HT-D-984-0582, is the power source for the scanner housing electronics. A four-wire, two-
twisted pair, and foil shielded cable originates for each electronic module scanner channel
terminal block. This cable terminates at the approximate scanner housing in a five-pin, quarter-
turn, and quick-disconnect coupling.

- 6 -

But wires from the housing coupling (A-D) are soldered to turrets on the circular printed circuit
board. Turret terminals A and B supply the circuit board with +15V and -15V, respectively.
Power to these turrets originates from the associated electronic module shown on the Lamp and
Meter Card Assembly Drawing HT-D-984-0721. To remove power to the scanner head
electronics, simply pull the lamp and meter card from its connector. Note that two fuses on this
board isolate the boiler mounted electronics from the electronic, check for proper lamp and meter
board insertion first. Next check fuses for an open circuit.

Intensity and Fault Detection Card (see Drawing HT-D-984-0578)

The scanner head current signal enters the intensity and fault detection card on pin 19. This
current signal is transformed into a millivolt signal at the function of R202 and R203. At this
point a high voltage represents low intensity and low voltage represents high intensity. Two
important functions are performed by the first half of IC201.

1. The intensity slope is inverted. Low voltage equals low intensity and high voltage equals
high intensity.
2. The intensity level is multiplied by a factor of three to equalize the 1/3 division by IC102
in the scanner housing electronics.

The result is a signal identical in magnitude to the log amplifier output (IC102). Both intensity
and ac components are transmitted to the intensity circuit via R206 and the frequency detection
card via pin 21.

A low pass filter (R206 and C201) eliminates the flame signal ripple component, reducing the
signal at TP201 to only intensity information. Measurements at TP201 reveal a signal range from
approximately -0.5 V when the boiler is out of service to -6.0 V under fireball conditions.

A fault alarm circuit, consisting of two comparator amplifiers, makes sure the intensity signal
stays within fixed limits. When the boiler is out of service, an LED feedback circuit in the
scanner electronics housing maintains the intensity magnitude at TP201 above a minimum level.
Tests have placed an upper limit on the brightness magnitude as well. Therefore, if the intensity
level exceeds either the low or high limits, it is a clear indication of a malfunction.

As described above, two comparator amplifiers constantly monitor the voltage level at TP201. If
the level of intensity drops below the value formed by voltage divider R214 and R215 (0.1 V
DC), IC202 will go onto positive saturation (logic one). Alternately, if the intensity level exceeds
the value formed by voltage divider R218 and R219 (-7.1 V DC), IC203 will go into positive
saturation. Pin 25, on later design, is wired for -15V through a fuse on the lamp and meter card.
Also pin 27 is wired to ground. B- is supplied through R243 if the above change is not wired into
the chassis. If the B- fuse on the lamp and meter card is open, the ground from pin 27 forces pin
6 of IC203 to ground. This forces pin 10 of IC203 again into positive saturation. A logic one
generated by either IC202 or IC203 indicates a fault condition.

NOTE

This fault logic leaves the intensity and fault detection card on pin 13 and is
transmitted to both the lamp and meter card and the 2/4 flame indication and fault
alarm card.

- 7 -

Test point TP201 is also common to the pull-in and dropout comparator amplifiers. Voltage
divider R223 and R224 determines the pull-in threshold. Resistors R230 and R231 form the
voltage divider that determines the dropout threshold. Resistors R224 and R231 are cermets-type
trimming potentiometers with 15 adjustment turns.

In the description of the operation of IC203, IC204 and IC206, the boiler condition will progress
from out of service to fireball and back to out of service. On an intensity scale of 0 to 100%,
typical pull-in and dropout adjustments might be 40% and 30%, respectively.

Assuming that the boiler os out of service, the intensity meter will indicate approximately 0%
(deviations from zero are caused by variations in the dark furnace bias). With zero intensity, TP
202 and TP203 will register 0V (zero volts). As the intensity increases, TP203 will be the first
test point to switch from zero to a logic one. This is because the dropout threshold is set lower
than the pull-in threshold. When the intensity exceeds the pull-in threshold, TP202 will switch to
a logic one. With TP202 and TP203 both at logic one (pins 3, 4 and 5 of IC206 at logic one),
IC206 NAND gates cause pins 9 to 10 to switch to logic one and pins 1,2,6,8,11,12, and 13 to
switch to logic zero.

A logic one on IC206 pin 9 is the intensity permissive logic signal. It leaves the intensity and
fault detection card on pin 17 and goes to the lamp and meter card. Feedback from IC206 pin 10
to pins 3 and 4 forms a volatile latching circuit. This latch maintains the intensity level must drop
below the dropout threshold before the intensity permissive signal goes to a logic zero.
Components R244 and C215 form a 2-second delay on intensity permissive signal goes to logic
zero. Components R244 and c215 form a 2-second delay on intensity permissive dropout to
allow momentary signal excursions below the dropout threshold set point.

Integrated circuit IC207 is configured as a comparator amplifier. When the intensity permissive
signal switches from a logic zero to a logic zero one, IC207 will go into negative saturation
energizing L201.

Switches SW201 and SW202 are PC board mounted toggle switches. They are spring return,
normally closed with SPDT contacts. The switches are arranged in series. The intensity signal is
transmitted to the lamp and meter card through the series switches when both are in the de-
energized position. The pull-in threshold adjustment is transmitted to the intensity meter when
SW201 is energized. Alternately, when SW202 is energized, the dropout threshold adjustment is
displayed on the intensity meter. The intensity level signal and both threshold adjustments are
buffered from the intensity meter by IC204 and both halves of IC205, respectively.

Frequency Detection Card (see drawing HT-D-984-0579)

The flame signal, consisting of both frequency and intensity information, enters the frequency
detection card on pin 21 (TP301) from the intensity card Pin 21. Transistor Q301 is ac-coupled to
this flame signal (the intensity or the dc level is blocked by capacitor C301, the signal processing
can be broken down into seven blocks:

1. Q301 is the signal preamplifier with an approximate gain of seven.
2. The first half of IC301 is a variable gain (4 to 17) ac amplifier.
3. The second half of IC301 is configured as a comparator amplifier. Its function is to
change the analog signal into a square wave.
4. The first half of IC302 improves the square wave leading edge generated by IC301.

- 8 -

5. IC303 compares the flame signal frequency with an internal reference frequency. If the
flame frequency is greater than the reference frequency, IC303 will respond with a logic
one (frequency permissive).
6. The block of components between TP306 and TP307 configures a 2-second delay on
frequency permissive drop-out.
7. IC303 between TP307 and TP308 provides the frequency detection card logic level
interface with the lamp and meter card.

Detailed explanations of the seven components blocks are offered below.

Preamplifiers

The bias arrangement for Q301 is a self-biasing or emitter bias circuit, consisting of R301, R302
and R304. This configuration was selected because of its stability when there are variations in
temperature and manufacturing tolerances.

In order to avoid the loss of signal gain due to the degenerative feedback from R304, bypass
capacitor C303 is placed around this resistor. The reactance of C303 is very small at the
frequencies within the amplifier bandwidth. The preamplifier bandwidth is a function of C301
and C302. Tests have confirmed the usable bandwidth is between 5Hz and 4 kHz.

AC Amplifiers

The first half of IC301 is configured as an ac-coupled amplifier. The circuit arrangement is called
a bootstrapped as amplifier or, more simply, a high pass filter.

Two simplified circuits (Figures 12 and 13) explain the amplifier operation. As shown in
figure12. the amplifier output is biased at 7.5 V DC. In other words, 7.5 V becomes an elevated
zero. The amplified analog flame signal will swing this level above or below 7.5V.

Resistors R308 and R309 form a 7.5V voltage divider. Figure 12 shows the low frequency model
when capacitors look like open circuits. Resistors R307 and R305 are not considered in this
simplified circuit, since there is no current flow into pin2. Therefore the 7.5V created by R308
and R309 appears at pin2. Since C306 blocks the only ground return path for feedback current
from pin 12 to pin 1, resistors R306 and R333 are eliminated as factors in this low frequency
model. With these simplifying assumptions, the amplifier becomes a voltage follower with a
+7.5 V output.

With the same amplifier and the high frequency model, the circuit in figure 13 becomes a non-
inverting amplifier. In this high frequency analysis the capacitors are considered short circuits.
The alternating flame signal enters the non-inverting port (pin2). Feedback from pin 12, to pin 1
and then to ground, is through R333, R306 and R307, respectively. An equation for amplifier
gain is given in figure 13. Potentiometer R333 can be adjusted to permit a swing in ac amplifier
gain from approximately 4 to 17.

Comparator Amplifier IC301

An 8.3V voltage divider is formed by resistors R311 and R312 and is connected directly to
IC301 inverting input pin 7. Tp303 will be 0 V (zero volts) until the voltage on the non-inverting
input (IC301 pin 6) exceeds 8.3V (Figure 14).

- 9 -

The input to IC301 pin 6 is a 7.5 VDC signal modulated by the amplified flame signal. Every
time this fluctuating signal amplitude exceeds 8.3 V, test point TP303 swings to positive
saturation. The resulting signal at TP303 is a square wave of varying pulse width. Figure 14
illustrates the relationship between the flame signal at IC301 pin 12 and the square wave at
TP303.

IC302 Quad 2 Input NAND Gate

The purpose of IC302 is to improve the leading and trailing edges of imperfect square waves.
This wave shaping insures triggering on each logic signal by IC303 and IC401. The first half of
IC302, located between TP303 and TP304, takes the trapezoidal signals generated by IC301 and
forms a sharp train of square pulses. Similarly the slow rise and fall times of the observed signal
at TP307 is shaped into a respectable logic signal at TP308.

IC303 Monostable Multivibrator

The CE40478 (IC303) is a getable, astable multivibrator with logic techniques incorporated to
permit positive edge-triggered monostable multivibrator action with retriggering and external
counting options.

In the monostable mode, positive-edge triggering is accomplished by application of a leading-
edge pulse to the +Trigger input (pin 8) and a low level to the Trigger (pin 12) and +Trigger
(pin 8) inputs. In the retrigger mode the output pulse (pin 10) remains high as long as the input
pulse period (flame frequency) is shorter than the period determined by the RC components
(reference frequency).

An internal reference frequency is generated by an adjustable RC time constant. The capacitor
component is C311, and the resistor component equals the summation of active resistors R314
through R322. Refer to table 1 for reference frequencies vs. switch SW301 settings. If the flame
frequencies observed at TP304 are greater than the selected reference frequency, IC303 output at
TP305 will be high. Conversely, if the reference frequency is greater than the flame frequency,
Tp305 will measure 0 V (zero volts).

Note that when IC303 output (pin 10) is high, pin 11 is low and vice versa. Pin 11 drives LED
L301 (TRIM) through hex buffer IC304. The trim LED flashes at a rate proportional to the
difference between the reference frequencies to the selected filter frequency. This feature is
important when adjusting the electronics for discrimination between an individual oil gun and
background fireball. The filter frequency selected should be greater than fireball frequency but
less than oil gun frequencies. L301 should be flashing steadily when the oil gun is off but stay off
when the gun is in service.

Frequency Permissive Time Delay

Components between TP306 and TP307 delay the frequency permissive signal at TP308 on
initiation and drop-out. The initial time delay is a function of R326, C314 and C315. Drop-out
delay is a function of T327 and C315. Resistor R325 limits the discharge current from Capacitor
C314 when TP306 goes low to prevent exceeding the sink current capability of IC304.

- 10 -

Frequency LED L302 and TP305-TP308 Information

Integrated circuit IC305 is configured as a comparator amplifier. When the frequency
permissive signal at TP308 exceeds 7.5 V, IC 305 will go into negative saturation. This in turn
energizes L302, the frequency signal indicator.

Logic levels at TP305 through TP308 are all ones (initial pickup) or all zeros following a
2-second delay (dropout). If TP305 is a logic one, TP306, TP307 and TP308 must also be ones
and vice versa.

Lamp and Meter Card (see drawing HT-D-984-0721)

The following three functions are performed by this PC board:
1. The flame/ no flame logic signal and visual FAULT warning are generated on this
board.
2. The analog intensity meter is mounted on this board.
3. Fuses that limit current going to the associated wind box mounted scanner are located
here.

A three input NAND gate (IC401) receives logic level signals from the fault detection circuit (pin
13), the frequency circuit (pin 15), and the intensity circuit (pin 17). The output of IC401, as
measured at TP404, represents the flame/ no flame logic signal (+10 V DC =flame, 0 V =no
flame). IC401 will respond with a flame logic shall if the following signals exist
simultaneously:

1. Intensity logic input (TP401) is +10 V DC)
2. Frequency logic input (TP402) is +10 V DC).
3. Fault detection logic input (TP403) is 0 V (zero volts).

Three circuits respond to the flame/ no flame signal. The 2/4 flame logic on the 2/4 flame
indication and fault alarm board receives a logic one flame vote via pin 5 when IC401 output is
energized. In addition two comparator amplifiers (half of IC402 and IC403) go into negative
saturation whenever TP404 exceeds +7.5 V DC. A visual LED flame signal is energized by
half of IC402 and a relay signaling corner flame detection is energized by IC403. Specifications
for the relay coil and contact ratings may be found in the 2/4 flame detection and fault alarm
detailed description. One interesting feature about this relay which is not found on the 2/4 flame
and fault PC board is that both sets of form C contacts are available. One set of form C contacts
with voltage surge suppression is accessible via a chassis mounted terminal block. The other
contacts could become available with the addition of pins to slots 12, 14 and 16 in the lamp and
meter card 35-pin connector.

The other half of IC402 mentioned above is also configured as a voltage comparator amplifier. If
TP403 exceeds +7.5 V DC (a fault detection signal is greater than +10 V DC), the amplifier
drives into negative saturation. AN LED is energized with this negative voltage, which gives a
visual signal warning of a fault.

The boards second function is to provide an analog meter indication of flame intensity. AN
intensity signal leaves the intensity PC board on pin 3 and enters the lamp and meter board on pin
3. Meter deflection is scaled by the value of R417. Meter M401 has a 10mA movement. The
maximum voltage at pin 3 is expected to be 8 V. Therefore R417 has a value of 750 ohms
(subtracting 0.5 V for drop across CR405). An optional remote meter receives its current signal
through R418. The remote meter has a 1 mA movement. Therefore r418 has a value of 7.5
kilohms. - 11 -

Power is distributed to the associated corner flame scanner by way of two fuses, F401 and F402.
The fuses are subminiature, radial lead, pico fuses, each rated at 62mA. They are found in the
lower right corner and are press-fit into fuse jacks. One fuse protects the B+power source and
the other protects the B- power source. A spare fuse is found on the far right for convenience.

2/4 Flame Indication and Fault Alarm (see drawing HT-D-984-0581)

This card performs two functions. It provides a contact closure when at least 2 out of 4 scanners
are detecting flame. It also provides a contact closure when a fault is detected on any scanner
cable or scanner head electronics. The 2/4 flame and any fault relays have mercury-wetted
contacts and are therefore position sensitive. Relay operation is restricted to the vertical position.
Mounting the chassis in a canted panel (such as on overhead display above a control panel) is
prohibited.

Both relayK501 have form C contacts available for logic interface. Each normally open or
normally closed contact has an RC network across it for transient voltage protection. The
significant relay characteristics are:

Material : Mercury-wetted platinum contacts hermetically sealed in an inert atmosphere.

Rating : Switch load 2A maximum
500 V maximum
1000 VA maximum

Cary load 5amps maximum not switched

Inrush load 20 A average for 10 microseconds

Bridging and transfer time When operated by a single DC pulse, the bridging
or transfer time will be greater than 50
microseconds but less than 500 microseconds.

Contact Resistance 14 milliohms typical, 20 milliohms maximum
Stable within +- 2 milliohms throughout life.

Life expectancy One billion operations minimum at rated load.

Coil Data : Coil resistance 1250 ohms
Must operate current 7.0 mAdc
Must operate voltage 9.6 VDC
Must release voltage 1.5 VDC
Maximum voltage 61.0 VDC

The 2/4 flame signal logic is implemented with IC501 through IC503. Individual channel flame
signals originating from the associated lamp and meter boards enter the 2/4 logic on pins 5, 7, 9,
11. Pin 5 represents the flame signal from channel 1, pin 7 from channel 2, pin 9 from channel 3
and pin 11 from channel 4. Voltage levels at TP501 through TP504 will be approximately +10
VDC when its associated channel is proving flame, or 0 V (zero volts) when that channel is not
detecting flame Test point TP505 will be approximately +10 VDC when any combination of two
or more channels are proving flame or 0 V (zero volts) otherwise.

- 12 -

Fault signals originating from the individual channel intensity cards enter the any fault logic on
pins 23, 25, 27 and 29. If any channel is proving fault, test point TP506 will be approximately
+10 VDC TP506 will be approximately 0 V (zero volts) only when all channels are signaling no
fault conditions on the scanner electronics and connecting cables.

Non-inverting type hex buffers IC504 and IC506 are used as current sources to drive relays K501
and K502 respectively. In parallel with each relay coil is an operational amplifier configured as a
voltage comparator. The two comparator amplifiers are located in IC505, a dual operational
amplifier. When the output of hex buffer IC504 or IC506 goes to a logic one (greater than 7.5 V),
the appropriate amplifier will energize LED L502 indicates a fault is detected on one or more
flame scanners or their connecting cables.

Power Supply Card Assembly (see drawing HT-D-984-0582)

Power for the electronic chassis and its four associated scanner head assemblies originates from
this PC board. Three power distribution rails transmit +15 VDC, and +15 VDC and provide a
common return. The rails are found extending the full width of the chassis on card connector
terminals 31 (B+), 33 (B-) and 35 (common).

The power supply (PS601) is a line operated, plug-in type, encapsulated switching regulator. The
typical ripple component is approximately 10 kHz, 5 to 10 mV peak to peak. General
specifications are as follows:
Input voltage and frequency : 105 to 125 VAC 50 to 440 Hz
Output voltage : +15 volts and -15 volts
Output current : +0.50 A and 0.50 A
Output voltage tolerance : +- 1% fixed
Regulation (line/ load) : 0.15 % / 0.15%
Temperature coefficient : 0.02 % /C (typical)
Operating temperature range : - 25C to +71C (no derating)
Storage temperature range : - 40C to +85C
I/O isolation : Voltage : 1500 V, rms
Resistance : 50 megohms
Over current protection : Power fold back

Line voltage L1 and L2 is connected to the card connector terminals 2 and 4, respectively. An
integral circuit breaker and ON-OFF switch is in series with L1 and PS601. The circuit breaker
CB601 is recognized by both Underwriters Laboratory and the Canadian standards Association.
It offers over current protection with a magnetic hydraulic type delay.

The power supply primary is protected against line voltage transients by a metal oxide varistor
(MOV). The energy of the incoming high voltage pulses is absorbed by the MOV TVS601.
When exposed to high energy voltage transients, the varistor impedance changes from a very
high standby value to a very low conducing value, thus clamping the transient voltage to a safe
level.
In review, the power supply card offers three modes of protection:

1. Over current protection on the power supply line voltage side by circuit breaker CB601.
2. Over current protection on the DC voltage side by an integral current fold back circuit.
3. Transient voltage protection from MOV TVS601.

- 13 -

INSTALLATION AND START-UP PROCEDURES


Check that the Safe Flame Scan head assembly is properly inserted in the flame scanner guide
pipe assembly and that there is sufficient clearance directly behind each guide pipe to allow for
its removal.

A weatherproof quick-disconnect electrical coupling (Figure 3) permits convenient connection of
external wiring. A hexagonal adapter provides for the connection of a -in. pipe thread
attachment. Sealtite flexible hose or a similar weatherproof conduit should be used between the
quick-disconnect coupling and the rigid conduit. The flexible hose should be long enough (4 or 5
ft) to permit the scanner to be withdrawn from the guide pipe without disconnecting the coupling.

COOLING AIR
CAUTION
THE SCANNER HEADS MUST BE COOLED WHENEVER THERE IS A FIRE IN
THE BOILER OR THE BOILER INTERIOR IS ABOVE 300F. A COOLING AIR
SYSTEM MUST BE PROVIDED AND CHECKED OUT BEFORE THE BOILER
IS LIT OFF.

On balanced draft units the cooling air for the scanners is frequently supplied by a separator fan
and piped to the scanner cooling air manifold. On pressure fired units and some balanced draft
units, the scanner cooling air supply is taken from the forced draft (FD) fan discharge duct in
combination with combustion air to the ignitors. In the latter case an emergency damper, a low
air pressure switch, a high air pressure gets too low, usually at 6in. w.g. The scanner fan stops
automatically when the air pressure reaches about 24in. w.g.

Most air systems are supplied with air filters between the scanner fan and the cooling air
manifold. A differential pressure gauge and switches to actuate an alarm are installed across the
filter to provide information on filter condition. Filters should be checked periodically for
cleanliness.

The emergency damper opens to admit ambient air to the system when the FD fans are out of
service.

All components should be checked for proper operation.

ELECTRICAL COMPONENTS (see drawing HT-C-981-0661 & HT-D-984-0593)

The 115 VAC (50 to 400Hz) power source should be connected to terminals TB1 and TB2 in
chassis slots 38-39.

The scanner head cable should be attached to terminals in chassis slot locations 32-31, 24-23, 16-
15, and 8-7, as follows:
Terminal Wire Color Nomenclature
TB5 Red B+(15 V)
TB6 Black B- (-15 V)
TB7 Green SIG
TB8 White, Drain GND
Before energizing the unit, check out the external wiring according to the referenced drawings.

- 14 -

SYSTEM OPERATION TEST

After installation is completed, the following tests are required to verify proper operation of the
system.

NOTE
Steps1 through 6 verify the performance and functioning of the intensity
circuits of the intensity and fault detection card, the frequency detection card,
the lamp and meter card, and the fault circuit of the 2/4 flame and fault alarm
card.

1. At one channel, disconnect the signal wire from the terminal strip (TB5). With the
POWER switch on, the intensity meter should read in the upper fault scale and the
corner (channel) FAULT light should be lit. The SYSTEM FAULT ALARM light should
also be on.

2. Reconnect the signal wire to terminal TB5. The FAULT light should go out. The
SYSTEM FAULT ALARM light should also go out if none of the other corners indicate
a fault.

3. Repeat Steps 1 and 2 for all four channels.
NOTE
A flame source can be simulated by using a 100W light bulb. With a 60Hz
power source, it will generate intensity fluctuations of 120 variations per
second. Installing a diode (IN 4003 or equal) in series with the power line will
change the intensity fluctuations to 60 variations per second.

4. Place a simulated flame source with a fluctuating intensity (120 per second) in front of a
flame scanner head assembly, about 1/2in. from the detector. The red frequency light-
emitting diode (LED) on the frequency card should light, and the channel intensity meter
should read approximately 60. If the red intensity LED on the intensity and fault detection
card is on (see Preliminary Adjustments section), the FLAME light on the lamp and meter
card should also be lit.

5. Reduce the fluctuating intensity of the flame source to 60 per second. The frequency LED
should go out and the intensity meter reading should drop below the reading in step 4.

6. Repeat steps 4 and 5 for all four channels.

7. Put a simulated flame source in front of any two of the four flame scanner heads. The 2/4
FLAME light should go on. This step checks the functioning of the 2/4 circuit on the 2/4
flame and fault alarm card.

Additional information is available in the Maintenance and Troubleshooting section.

PRELIMINARY ADJUSTMENTS (Refer to Table 1)

The Safe Flame Scan scanners can be used for coal fireball monitoring or distinguishing
individual flames of oil guns ignited with high energy arc (HEA) ignitors (discriminating flame
monitoring). To accommodate these different applications, adjustments must be made to the
switches and potentiometers in the intensity and frequency circuits.
- 15 -

INTENSITY (see drawing HT-D-984-0578 and Figure 5)

Intensity sensitivity is changed by adjusting potentiometers R224 and R231 on the intensity and
fault detection card. First, note the reading of the intensity meter at high and low loads. The
intensity pull-in point should be set approximately 5 units below the lower reading observed
under load. This ensures that the corner sees flame intensity at all loads. The dropout point
should be set 10 units below the pull-in point.

Adjust the pull-in point by holding the pull-in set point switch (SW201) in the on position. At
the same time, adjust the pull-in potentiometer (R224) to produce the desired settings on the
intensity meter (5units below the lowest observed load reading).

The drop-out point is similarly set by holding the drop-out set point switch (SW202) in the on
position while the drop-out potentiometer (R231) is adjusted to produce a meter reading 10 units
below the pull-in settings. If during operation an occasional intensity drop-out is experienced,
intensity LED L201 goes off; then the drop-out set point should be adjusted to a lower setting so
the intensity LED remains on.

Pull-in and drop-out adjustments can be made while the scanners are operating, without
interrupting the flame signal output.

FREQUENCY (see drawing HT-D-984-0579, Figure 6 and Table 1)

Eight switches on the lower front edges of the frequency card change the frequency sensitivity of
the flame sensing system. If all switches are in the on position, the card will detect flame
frequencies above 103Hz. Switch adjustments must be made to cause the red frequency LED
L302 to remain lit continuously. Table 1 is used to determine the switch combinations that select
particular high pass frequencies. Initially, choose a frequency at or below the highest frequency
anticipated.

Fireball frequencies often lie between 10 and 29Hz. For individual oil gun detection
(discriminating flame monitoring), the frequencies may be 60Hz or higher. To adjust for fireball
monitoring, turn switches 4, 5, 6, 7 and 8 on. The card should respond to flame frequencies
above 35Hz, and the yellow LED L301 should flash at a slower and slower rate as the cutoff
frequencies of the input is approached. Try other switch combinations to bring the cutoff
frequency down so the red frequency LED L302 comes on and remain lit. With switches 1, 2, 3,
5, 6, 7 and 8 in the on position, the card will respond to frequencies above 33Hz. At the final
setting, the red frequency light should be on and there should be only an occasional flash of the
trim light.

For discriminating flame monitoring, the frequency card adjustments should be made with the
associated oil gun in service. Select switches which will give a frequency above that of the
fireball and below the frequency of the associated oil guns.

If the adjustments of the intensity and frequency circuits are correct, the red flame LED L402 on
the lamp and meter card for the corner should light. Adjust intensity and frequency circuits for all
four corners.

The potentiometer (R333) may be used to adjust the AC amplifier gain by a factor of 3 to 1. it is
set at 20% during manufacturing. Normal scanner set-up procedures do not require deviation
from this setting.

- 16 -

The potentiometer (R333) provides an adjustment similar to the pull-in and drop-out adjustments
on the intensity and fault detection card. Adjustment of the potentiometer may be used, over a
restricted range; to vary background frequency amplitudes to within the detection thresholds
determines by the ratio of resistors R311 and R312. Normally adjustment of the potentiometer
does not critically affect scanner performance.

Calibration of Scanner Head Electronic (see drawing HT-D-984-0577 and Figure 10)

The scanner head electronics are adjusted during manufacturing. If a component on the
electronics card is replaced, field adjustment of the gain and offset potentiometers and dark
furnace bias will be required.

GAIN AND OFFSET ADJUSTMENT

The flame scanner assembly must be removed from its guide pipe. Turn the scanner power
supply off, disconnect the scanner cable and open the scanner housing assembly for access to
the scanner head electronics card.

The following equipment will be required:
A. Digital Voltmeter (DVM)
B. 1 m A DC current source [1 VDC in series with a resistor (1k, 1/8W, 1%)]
C. 1A DC current source [1 VDC in series with a resistor (1M, 1/8W, 1%)]
D. Small soldering pencil.

Disconnect the positive lead of the photodiode PD101 from its terminal. Simulate a photodiode
input by connecting the 1mA DC current source to the PD101 terminals. Connect the digital
voltmeter (DVM) between the signal C and common D terminals on the electronics card:
then reconnect the scanner cable. Turn the scanner power supply on and adjust potentiometer
R101 to provide a reading of 0.000V on the DVM.

Replace the 1 mA DC current source with a 1A source and adjust potentiometer R103 to
provide a reading of 1.000 V on the DVM. Disconnect the scanner cable and test leads, reconnect
the photodiode and proceed with the dark furnace bias adjustment.

DARK FURNACE BIAS ADJUSTMENT

To ensure proper operation of the Safe Flame Scan I, it is important that relatively uniform
voltages are input to the chassis by the four associated scanner assemblies during dark furnace,
no fire conditions. Total absence of a signal from the scanner assembly would generate a fault
condition. To prevent this from occurring, LED L101 is installed on the scanner housing
electronics card adjacent to photodiode PD101.

The flame scanner assembly should be removed from its guide pipe and the scanner cover plate
removed. Completely block all light from the furnace end of the fiber-optic cable.

Connect a digital voltmeter (DVM) between the signal C and common D terminals on the
electronics card.

- 17 -

Reconnect the scanner cable to the scanner assembly. The power supply circuit breaker should be
turned on. Work under a dark cloth to reduce the amount of ambient light admitted to the scanner
housing. Use small needle nose pliers to bend the LED L101 leads and position the LED so that
the DVM reads approximately 2.1 V. This completes the scanner assembly and reinsert in the
guide pipe.

All four Scanner channels, under dark furnace conditions, should have similar intensity meter
readings.

- 18 -

MAINTENANCE AND TROUBLESHOOTING


Scanner Head

The scanner head at the front of the fiber-optic scanner assembly has an opening for viewing the
flame. With certain types of coal, slag may eventually build up and cover the opening. Hence, the
scanner head should be inspected periodically for cleanliness and cleared if necessary. An
inspection program should be established based on operating experience.

Fiber-Optic Cable

The collimator shield and the lens on the end of the fiber-optic cable should also be inspected
periodically for cleanliness. The degree of fouling will depend on the type of fuel used, the plant
operating characteristics and the cleanliness of the cooling air. An inspection program should be
established, based on operating experience. Always check the shield and lens when the scanner
head is inspected.

ELECTRICAL COMPONENTS

The electronic circuits do not require periodic maintenance. If trouble does occur, the best way to
troubleshoot the system is to substitute like printed circuit (PC) boards and/or scanner heads until
the trouble is isolated at a particular assembly. Do not place PC boards into slots in the chassis
that they are not designated for. When troubleshooting, it may be helpful to repeat the steps under
Electrical Components in the Start-up Procedures section.

If the scanner chassis is not working, begin by checking the power supply module. Verify with a
voltmeter that there is 15V on pin 31(pin 35 is ground) and -15V on pin 33 of the card connector
in the back of the chassis.

If, when the scanner head is wired to the chassis, there is a fault indication, check the fuses on the
lamp and meter board. A spare fuse (1/16 A pico fuse) is provided on each board. Before
replacing a fuse, check with an ohmmeter to see if any shorts to ground exist.

The FAULT light may also come on if the scanner head electronics falls out of calibration. The
adjustments are made at the factory and, once set, should not have to be made again. If a
component on the scanner housing electronics card fails and is replaced, it might be necessary to
readjust the settings of the trim potentiometers (see Calibration of Scanner Head Electronics).

If any of the problems described exist, see Electrical Components under the Description and
Operation section in conjunction with the Flame Sensing System schematic (Figure 11).

Troubleshooting Guide

This guide is a summary of the most common problems experienced and the corrective action
necessary to repair the cards.

- 19 -

CAUTION
WHILE WORKING ON THIS SYSTEM WITH IT POWERED UP, DO NOT
PULL THE LAMP AND METER CARD UNTIL THE ASSOCIATED
FREQUENCY DETECTION AND INTENSITY FAULT DETECTION CARDS
HAVE BEEN PULLED. FAILURE TO PULL THESE TWO CARDS FIRST
MAY CAUSE THE LOSS OF IC302 ON THE FREQUENCY DETECTION
CARD.

CARD TYPE SYMPTOMS PROBABLE CAUSE

Intensity and Fault Intensity signal lamp is always on or IC206 (CD4023BD)
Detection always off.

Frequency Detection Trim and frequency lamps are on together. IC302 (CD4011BD)
Card is sent into oscillation, which causes
the flame relay on the lamp and meter card
to change state rapidly. This causes the relay
to generate a humming noise.

Frequency Detection Neither the frequency nor the Trim lamps IC303 (CD4047BD)
are on.

Frequency Detection Trim Lamp will not change its Pulsing rate IC303 (CD4047BD)
even with a change in the DIP switch settings

Frequency Detection Frequency lamp is always on. C301, C304 OR C306
(luf @ 50V)
Capacitors can be
checked in circuit
with an ohmmeter.
Defective component
Will be shorted.

Frequency Detection Trim and frequency lamps alternate on IC302 (CD4011BD)
and off at the same rate.

Lamp and meter Flame lamp will not respond; TP404 reads IC401 (CD4023BD)
approximately 0 VDC Normal Condition
with Flame TP401,
TP402~10 VDC
TP403~0 VDC
TP404~10VDC. Flame
relay is energized and
flame lamp on.

Lamp and meter Needle on the meter is at the top of scale B +fuse.
and the fault lamp is on.

Lamp and meter Needle remains in the middle of the scale B fuse.
And the frequency lamp on the frequency
detection card is off. Intensity fault
detection card is on.

- 20 -

Table 1. Frequency Detection Adjustments

SWITCH POSITION
X = ON
(see Note)

Detected
Frequency
Hz

Switch No 1 2 3 4 5 6 7 8
3.5
4.3 X X X
5 X
6 X X X X X
7 X X X X X
8 X X X X X
9 X X X X
10 X X X X X X
11 X X X X X X
12 X X X X
13 X X X X X
15 X X X X X
16 X X X X X X
17 X X X X X X
19 X X X X X
20 X X X X X X
24 X X X X X
26 X X X X X X
29 X X X X X X
33 X X X X X X X
35 X X X X X
41 X X X X X X
47 X X X X X X
49 X X X X X X
57 X X X X X X X
59 X X X X X X X
75 X X X X X X X
103 X X X X X X X X

NOTE: The frequency adjustment switches are in the correct on or off position when the switch
rocker portion is depressed at the side of the switch housing labeled ON or the side labeled
OFF.

- 21 -

SAFE FLAME SCAN I

RECOMMENDED SPARE PARTS

FOR ELECTRONIC CHASSIS HT-D-984-0726

Certain cards require preliminary adjustments when inserted into the chassis. These adjustments
should be the same as are on the cards being replaced.

Recommended Spares
Item Quantity HT-Part per Numbers of Chassis
Per Chassis Number 1-3 4-10 11-20 21-40

Intensity & Fault 4 HT-D-984-0578 2 3 4 5
Detection Card

Frequency Detection 4 HT-D-984-0579 2 3 4 5
Card

Lamp & Meter Card 4 HT-D-984-0721 2 3 4 5

Lamp Card 4 HT-D-20-0-0259 2 3 4 5

Fuse, Littlefuse #256.062 8 Item 23 8 16 24 32
HT-D-984-0721

2/4 Flame Indication Card 1 HT-D-984-0581 1 2 3 4

Power Supply Card 1 HT-D-984-0582 1 1 2 3

35 Pin Extender 1 HT-C-984-0284 1 1 1 1

* Require installation adjustments, see instruction manual.

Safe Flame Scan I (Manual)

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SAFE FLAME SCAN I

HT- FLAME SENSING SYSTEM

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