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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 E-mail: ignitor@rediffmail.com

SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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

Mechanical Components

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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SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

MAINTENANCE AND TROUBLESHOOTING

Page 19

Mechanical Components

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 - HINDUSTHAN THERMOMETERS

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”.

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SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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.

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SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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 ½-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 300°F without cooling air.

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SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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 120°F (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.

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SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

The output contacts have the following characteristics:

Material:

Mercury-wetted platinum contacts, hermetically sealed in an inert

Rating:

atmosphere. 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.

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SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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

Operating temperature Storage temperature Operating relative humidity Storage relative humidity

0°C to 60°C 65°C to +125°C Less than 95% 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.

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SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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.

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SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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.

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SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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).

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SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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.

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SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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 board’s 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 -

SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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

 

4

A average for 10 seconds

2

A average for 100 seconds

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 -

SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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 :

- 25°C to +71°C (no derating)

Storage temperature range

:

- 40°C to +85°C

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 Underwriter’s 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 -

SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

INSTALLATION AND START-UP PROCEDURES

MECHANICAL COMPONENTS

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 ½-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 300°F. 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 -

SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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 -

SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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 -

SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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. 1µA 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 1µA 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 -

SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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 -

SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

MAINTENANCE AND TROUBLESHOOTING

MECHANICAL COMPONENTS

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 -

SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

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

Intensity and Fault Detection

Frequency Detection

Frequency Detection

Frequency Detection

SYMPTOMS

PROBABLE CAUSE

Intensity signal lamp is always “on” or always “off”.

Trim and frequency lamps are on together. 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.

Neither the frequency nor the Trim lamps are “on”.

IC206 (CD4023BD)

IC302 (CD4011BD)

IC303 (CD4047BD)

Trim Lamp will not change its Pulsing rate

even with a change in the DIP switch settings

IC303 (CD4047BD)

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” and “off” at the same rate.

IC302 (CD4011BD)

Lamp and meter

Flame lamp will not respond; TP404 reads approximately 0 VDC

IC401 (CD4023BD) 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 and the fault lamp is “on.

B + fuse.

Lamp and meter

Needle remains in the middle of the scale And the frequency lamp on the frequency detection card is “off”. Intensity fault detection card is “on”.

B – fuse.

- 20 -

SAFE FLAME SCAN I - HINDUSTHAN THERMOMETERS

Table 1. Frequency Detection Adjustments

Detected

 

SWITCH POSITION X = ON (see Note)

 

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 - HINDUSTHAN THERMOMETERS

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 Detection Card

4

HT-D-984-0578

2

3

4

5

Frequency Detection Card

4

HT-D-984-0579

2

3

4

5

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 - HINDUSTHAN THERMOMETERS