DEVELOPMENT OF TRAINING AID FOR FLAME DETECTOR

BY

MOHD FAIZZUDIN BIN ANUAR

UNIVERSITI KUALA LUMPUR

MALAYSIAN INSTITUTE OF AVIATION TECHNOLOGY

DECEMBER 2010
 ABSTRACT

University Kuala Lumpur Malaysian Institute of Aviation Technology is a university that

provides Aircraft Maintenance Technology courses for student. The syllabus contains all of the
knowledge that personnel should know if they want to be a License Aircraft Engineer (LAE).
Flame Detector is one of the important subtopic in the syllabus under the subject of Aircraft Fire
Detection System and Aircraft Electrical System.

Since the university only provides the theory knowledge on this equipment, it must be a need to
have training aid or mock up on this equipment to ensure the students gain a better understanding
about how this equipment operates since this equipment is one of the most important equipment
in aircraft. By building up this project, it will develop a good and low cost training aid to be used
in class, so that the students will have an idea about this equipment when they are going through
the working environment. It also will help the lecturer to give a better lecture to the student with
the presence of this training aid.

For student especially student of University Kuala Lumpur Malaysian Institute Of Aviation
Technology, it is important for us to understand about its function and how its operate in order to
prevent fire from occur during on aircraft during flight.
 ACKNOWLEDGEMENT

Alhamdulillah, praise to the Almighty Allah S.W.T the most merciful and most benevolent for
giving me strength and patience in completing this project entitled Flame Detector Training
Aid.

First of all, I would like to take this opportunity to express my sincere gratitude to my
supervisor, Miss Munirah, my co-supervisor, Mr Faizal Shariff and also to everybody who
involved in the development of this project. I would like to thank to all of them for their morals,
supports, ideas, suggestions, assistance, supervision and continued guidance throughout the
period of the study in order to complete this project. Without them, this thesis would not have
seen the light of day.

I also would like to thanks to all the lecturers and assistance lecturers in University Kuala
Lumpur Malaysian Institute of Aviation Technology (UniKL MIAT) for their valueable
guidance and knowledge since I studied here. These thanks also goes to all staffs of UniKL
MIAT library, for giving a help to find all the materials needed to complete this project.

Particularly important in this research project is my fellow buddy, Muhammad

Dhiyauddin bin Md Jaki. His commitments have indeed made this project able to be completed
smoothly.

Last but not least, I would like to thank my parents and family members for their love,
encouragement, and support to me in my studies. Without their prayers, supports and
encouragement, this project paper would not have been possible.

For to all of my friends, your morals and supports are much appreciated. Without the
morals and supports, this project could be just a dream.

MOHD FAIZZUDIN BIN ANUAR

TABLE OF CONTENT
 CHAPTER 1

1.1 INTRODUCTION

According to Law, C. K. (2006), Flame is the visible (light-emitting) gaseous part of a

fire. Its occurred caused by a highly exothermic reaction (for example combustion, a self-
sustaining oxidation reaction) which taking place in a thin zone.

From the National Wildfire Coordinating Group.(2009) stated that Fire is the rapid
oxidation of a material in the chemical process of combustion, releasing heat, light, and various
reaction products. Usually, before fire can occur, it will undergo a form which known as flame.
Flame can be said as an early sign for fire to occur.

REQUIREMENTS REGARDING THE PROVISION OF FIRE AND OVERHEAT

DETECTION EQUIPMENT Chapter D5-8 and K5-8 of British Civil Airworthiness
Requirements prescribe the conditions under which fire and overheat detection equipment should
be fitted to aircraft (Civil Aircraft Inspection Procedures, September 1988)

In aircraft especially on the powerplant section, the presence of flame is vital. Study
shows that flame usually occurs when aircraft powerplant running in overheat condition or there
are malfunction on the ignition system. The presence of flame will brought to the formation of
fire. If flames were not detected at its early stage, it will spread becomes fire. When fire occurs,
it can give threats to the safe operation of aircraft and it might jeopardize many peoples life in
that aircraft. Since flame can occur at any time without notices especially during overheat
condition or malfunction on the ignition system on aircraft powerplant and it is impossible for us
to detect flame at aircraft powerplant because it is located at area were the crew do not have
access during flight, flame detection system has been utilized at the powerplant section to detect
the presence of flame.

Most flame detector consists of Photoelectric Sensor or Photoconductive Cell. This type
of transducer changes light into electrical energy and it measures the amount of visible light or
radiation in an enclosed area (dark area). The sensors action is depends on the fact that the
resistance of certain semiconductors, such as cadmium sulphide, decreases as the intensity of
light falling on them increase. The sensor operates by placing it on an area so it can see the
surrounding area (dark area) and anytime there is increase in amount of light that strikes the
Photoelectric Sensor, resistance on it will decrease and it will allow electrical current to channel
through it. Once current is channeled through it, it will complete a flame detector electrical
circuit (current flow through over the circuit), a fire warning light and horn are activated.

Most students of UniKL only get the pictures how the Flame Detectors is being operated
theoretically, but they might still wondering how it is been triggered in the real emergency
situation. This may become a problem when the students reach the field of aviation industry,
where the practical experience is same important as the theory knowledge. Many of the learning
process can only be known after going through the practical session, which is the one of the
objective of this project.

This project will build a mock up Flame Detector, so that the students will know about
the construction of the Flame Detector, the material, the circuit being used in the Flame Detector
and also how the Flame Detector operates. The details about it will be explained in the other
chapters.

Figures 1.1 Example Picture Of Flames.

Figures 1.2 This example pictures shows different flame types on Bunsen burner. The types of
flame depend on oxygen supply. On the left a rich fuel with no premixed oxygen
produces a yellow sooty diffusion flame; on the right a lean fully oxygen
premixed flame produces no soot and the flame color is produced by molecular
radicals, especially CH and C2 band emission. The purple color is an artifact of
the photographic process
1.2 OBJECTIVE

To develop a training aid for Flame Detectors.

To increase the understanding among students about the Flame Detectors.

To aid the lecturers of University Kuala Lumpur Malaysian Institute Of Aviation

Technology when teach about the Flame Detector to students

To produce personnel that knows about this equipment, theoretically and practically.

To give exposure to student about how important the flame detector it is in preventing
fires from happening to aircraft.

To promote the university into outside world, by introducing this training aid to other
Aviation school.

Writer can improve the knowledge in Flame Detector and experience in developing the
training aid.

1.3 CHAPTER SUMMARY

1.3.1 CHAPTER 1

In this chapter, it elaborate about what is the Flame Detector generally, what is purpose and how
its activated. It also describe the whole making of this project in order to make the project
become a reality. It is introductory chapter that introduces the problem and indicates its
importance and validity.

1.3.2 CHAPTER 2

This chapter describes more about the literature review for this project. All the literature reviews
were collected from books, journals and information from internet. In this chapter also describes
about types of Flame Detector that used today in various industries.
1.3.3 CHAPTER 3

1.3.4 CHAPTER 4

1.3.5 CHAPTER 5

1.3.6 CHAPTER 6
 CHAPTER 2

2.1 LITERATURE REVIEW

As we all know, flame are dangerous threats for aircraft especially at the powerplant section.
From study, flame usually occurs when aircraft powerplant running in overheat condition or
there are malfunction on the ignition system. Therefore, the flame must be detected and
overcome as soon as it occurs before it accumulate and then spread become fire.

According to Law, C.K. (2006), he stated that A flame (from Latin flamma) is the visible
(light-emitting) gaseous part of a fire. It is caused by a highly exothermic reaction (for example,
combustion, a self-sustaining oxidation reaction) taking place in a thin zone.

From the phrase above, we can tell that flames are one of the early sign for fire to occur.
If the flame are not detected and overcome at it early stage, it will started to spread and become
fire. When fire occurred, it can burn the whole aircraft powerplant components within few
minutes without notices.

One of the reason why fire will burn violently because it is natural state that it will burn
anything to complete it combustion process and releasing heat which can increase the aircraft
powerplant temperature and causes fire to occur. When fire occur, it may jeopardize the safety of
the aircraft passengers. Theory about the fire combustion process is stated in the phrase below by
the National Wildfire Coordinating Group (2009).

National Wildfire Coordinating Group (2009) stated that Fire is the rapid oxidation of a
material in the chemical process of combustion, releasing heat, light, and various reaction
products.

So, based on this statement, thats why Flame Detector has been invented more than 190
years ago to detect the flame. Then the Flame Detector has been utilized at aircraft to overcome
that such problem.

The definition for the Flame Detector has been explain by Harriette Halepis in his
journal. Harriette Halepis (2007) stated that A flame detector is a type of device that uses
optical sensors in order to detect flames.
 Based on what has been stated by Harriette Halepis, Flame Detector is a radiant energy-
sensing fire detector that detects the radiant energy emitted by a flame. It uses optical sensor to
detect it. It will respond either to radiant energy visible to human eye or outside the range of
human vision. It is also sensitive to glowing embers, coals, or flames which radiate energy of
sufficient intensity and spectral quality to actuate the alarm.

The definition about the Flame Detector also has been stated on A & P Technician
Powerplant Textbook. It stated that, Most flame detectors consist of a photoelectric sensor that
measures amount of visible light or infrared radiation in an enclosed area. The sensor is placed
so it can see the surrounding area, and anytime there is an increase in the amount of light that
strike the cell, an electrical current is produced and channeled.

In Flame Detector, there is a component that very important for it to detect the flame. It is
Optical Sensor. Optical sensor is a sensor device that measures a physical quantity and converts
it into a signal which can be read by an observer or by an instrument.

C.A. Grimes, E.C. Dickey, and M.V. Pishko (2006) stated about the Optical Sensor in
Encyclopedia of Sensors (10-Volume Set), American Scientific Publishers. It stated that the
Optical Sensor is A sensor is a device that measures a physical quantity and converts it into a
signal which can be read by an observer or by an instrument.

Most of the Flame Detector utilized Optical Sensor to detect the flame. The type of
Optical Sensor that been used in Flame Detector is Photoelectric Cell. This Photoelectric Cell is
the main component in the Flame Detectors. Without this component, Flame Detector could not
perform its function.

This Photoelectric Cell has a function which is it will detect any incident radiation,
especially to visible light then it producing an electrical output that varies in response to incident
radiation (the more incident radiation it detect, the more electrical output it produce).

The definition of the Photoelectric Cell has been stated by Houghton Mifflin Company
(2009). They defined that the Photoelectric cell in The American Heritage Dictionary of the
English Language, Fourth Edition, Photoelectric cell is an electronic device having an
electrical output that varies in response to incident radiation, especially to visible light. Its also
called electric eye. They also stated that Photoelectric cell is an electronic device having an
electrical output that varies in response to the strength of incident electromagnetic radiation,
especially visible light. Photoelectric cells make use of the photoelectric effect, in which
electrons are displaced by photons in substances such as silicon or selenium to generate a
voltage in response to radiation. Photoelectric cells are used to detect light electronically in
cameras and night vision apparatus and to generate electrical power in solar cells. Its also
called photovoltaic cell.
From the Columbia Encyclopedia, Sixth Edition (2008) also has stated about the
Photoelectric Cell. It stated that, P

hotoelectric cell or photocell, device whose electrical characteristics (e.g., current, voltage, or
resistance) vary when light is incident upon it. The most common type consists of two electrodes
separated by a light-sensitive semiconductor material. A battery or other voltage source
connected to the electrodes sets up a current even in the absence of light; when light strikes the
semiconductor section of the photocell, the current in the circuit increases by an amount
proportional to the intensity of the light. In the phototube, an older type of photocell, two
electrodes are enclosed in a glass tubean anode and a light-sensitive cathode, i.e., a metal that
emits electrons in accordance with the photoelectric effect . Although the phototube itself is now
obsolete, the principle survives in the photomultiplier tube, which can be used to detect and
amplify faint amounts.

So, based on what has been stated on phrase above, the Photoelectric Cell that have on
Flame Detector will detect any presence of flame. After detect, it will convert the signal into
electrical power. Then the electrical power will be channeled through wires to the bus bar. Then
it will distribute to the fire warning light as visual warning indicator and bell or horn as sound
warning indicator to warn the pilot and the flight crew that there are presence of flame on certain
area.

For the development of this project, the Flame Detector Training Aid, Light Dependent
Resistance (LDR) will be used as an Optical Sensor to detect the flame. From the Electronics For
Today And Tomorrow, Second Edition (2004) has stated about the LDR. It stated that, this type
of transducer changes light into electrical energy and is also called Photoconductive Cell. Its
action depends on the fact that the resistant of certain semiconductor, such as Cadmium
Sulphide, decrease as the intensity of the light falling on them increases. The effect (also given
by infrared and ultraviolet radiation) is due to light supplying the energy to set free charge
carries from atoms of the semiconductor, so increasing its conductivity, i.e. reducing its
resistance.

Figure 2.1 This figure show the LDR that been used in this Flame Detector Training
Aid.

From what has been stated from the phrase above, LDR a type of transducer. It changes light into
electrical energy and it also were known as Photoconductive Cell. It function only depends on
the resistant of certain semiconductor, such as Cadmium Sulphide. The resistance will decrease
as the intensity of the light falling on them increases.
Figure 2.2 This figure show where the Semiconductor material, Cadmium Sulphide,
located on the LDR and its symbol.
2.2 TYPES OF FLAME DETECTORS

Essentially, from my research, there are eight different types of flame detectors that been usually
utilized in various industries. These types include :-

1. Ultraviolet (UV) Flame Detector

2. Near Infrared (IR) Array Flame Detector

3. Infrared (IR) Flame Detector

4. Combination of Ultraviolet and Infrared (UV/IR) Flame Detector

5. Dual Infrared (IR/IR) Flame Detector

6. Triple Infrared (IR/IR/IR) Flame Detector

7. Visible Sensors Flame Detector

8. Video Cameras Flame Detector.

Table 2.1 Show The Information About All Types Of Flame Detectors.

TYPES OF FLAME DETECTORS DESCRIPTIONS

1. Ultraviolet (UV) Flame Detector Works with wavelengths shorter than

300 nm.

Detect fires and explosions within 34

milliseconds due to the UV radiation
emitted at the instant of their ignition.

False alarms can be triggered by UV

sources such as lightning, welding,
radiation, and sunlight.

In order to reduce false alarm, a time

delay of 2-3 seconds is often included
 in the UV Flame detector design.

2. Near Infrared (IR) Array Flame Detector Also known as visual flame detector.

Employ the flame recognition

technology to confirm fire by analyzing
near IR radiation via the pixel array of a
Charge-Coupled Device (CCD).

3. Infrared (IR) Flame Detector Work within the infrared spectral band.

Hot gases emit a specific spectral

pattern in the infrared region, which can
be sensed with a thermal imaging
camera (TIC) a type of thermographic
camera.

False alarms can be caused by other hot

surfaces and background thermal
radiation in the area as well as blinding
from water and solar energy.

Typical frequency where single

frequency IR flame detector is sensitive
is in the 4.4 micrometer range.

Typical response time is 3-5 seconds.

4. Combination of Ultraviolet and Infrared Compare the threshold signal in two
(UV/IR) Flame Detector ranges in "AND" configuration and
their ratio to each other to confirm the
fire signal and minimize false alarms.

5. Dual Infrared (IR/IR) Flame Detector Compare the threshold signal in two
infrared ranges.

In this case one sensor looks at the 4.4

micrometer range and the other sensor at a
reference frequency.

6. Triple Infrared (IR/IR/IR) Flame Compare three specific wavelength

Detector bands within the IR spectral region and
their ratio to each other to reliably
detect flames while attempting to
reduce false alarms.

In this case one sensor looks at the 4.4

micrometer range and the other sensors
at a reference frequencies.

Triple IR detectors are also susceptible

to blinding by water and reduced
sensitivity from sunlight.

7. Visible Sensors Flame Detector A sensor for visible radiation is added

to the design in order to be able to
discriminate against false alarms better
or improve the detection range.
 8. Video Cameras Flame Detector It used Closed-circuit television or a
web camera.

Can be used for video detection

(wavelength between 0.4 and 0.7 m).

The camera can be blinded by smoke or

fog.

The most common type that been used in aircraft powerplant or engine are Ultraviolet and
Infrared type Flame Detector.
 CHAPTER 3

3.1 METHODOLOGY

3.1.1 ACTUAL FLAME DETECTOR CONSTRUCTION

In the real Flame Detector, it is built with a complete circuit which connected to the Aircraft Bus
Bar. The Aircraft Bus Bar will supply electrical power directly to the circuit to make it operate.
Usually in the circuit, it may consist of:-

Circuit Breaker (CB) to protect the circuit from any

electrical surge or short circuit.

Test Switch its function is to check the continuity of the circuit or to

carried out a functional test on the circuit.

Control Unit the function of this unit is to control the electrical flow
to entire circuit.

Indicator Light to indicate that if there are current flow or not in the
entire circuit.

Warning Light And Horn warning light will act as a

visual warning indicator to the crew member in the
aircraft while horn will act as aural warning indicator.
 Wires and Switches wires is used to connect all of the
components in the circuit while switches it used to make
or break the circuit.

Basically these are the things that are built in a complete Flame Detector circuit in an aircraft.

The real Flame Detector also may utilize one or more Photoelectric Sensor as the Optical
Sensor. This Photoelectric Sensor measures the amount of visible light or infrared radiation in an
enclosed dark area. The Photoelectric Sensor will be placed at the location where the potential of
flame to occur is high especially at the powerplant or engine section. It placed at the enclosed
dark area. Any time flame occurred, the intensity of the light from the flame will strike to the
Photoelectric Sensor which it will triggered the Warning Light and Horn to indicate that the
flame occurred in that area.

3.1.2 FLAME DETECTOR TRAINING AID CONSTRUCTION

This training aid construction will be divided into two sections. First section is about the
designing of the circuit which it will be carried out by me. The second section is about the
process of assembling the circuit and it will be carried by my partner, Muhammad Dhiyauddin
bin Md Jaki. Then about the functional test and operation test will be carried out by both of us.

After I completed the designing of the whole entire Flame Detector Training Aid circuit,
we both had decided the components and materials that will be used for this project. I will
assemble all of the components and materials according to the design to make it become a
complete Flame Detector circuit. Me and my partner design and built this Flame Detector
Training Aid circuit 70% according to the real Flame Detector circuit that been used in aircraft.
The reason why we design and built in such way because we want that student or colleges can
visualize how the Flame Detector operate and function in real situation.

Masukan design circuit

This training aid consists of two circuit, which are the major circuit, The Flame Detector Circuit
and the minor circuit, which consists of three circuits, Light Sensitivity circuit ( Light ON Relay
and Light ON Alarm circuit) and Light Dimmer Circuit.

3.1.2.1 THE FLAME DETECTOR CIRCUIT

This circuit consists of AC to DC converter, circuit breakers, switches, indicator lamps, Light
Sensitivity circuit, Light Dimmer circuit, light bulb and speaker or amplifier.

3.1.2.2 THE LIGHT SENSITIVITY CIRCUIT

The Light Sensitivity circuit consists of two circuit which are Light ON Relay and Light ON
Alarm circuit. These circuits interconnected with each other providing visual and aural warning
when there is the presence of light (flame).

a) Light ON Relay

Light ON Relay circuit consists of resistors, capacitors, and transistor with specific value.
It also consists of Integrated Circuit (IC), Light Emitting Diode (LED), Light Dependent
Resistor (LDR), Diode, Potentiometer and Relay. This circuit served as visual warning
which will give light indicator when there is the presence of light (flame).

b) Light ON Alarm

Light ON Alarm circuit consists of

3.1.2.3 THE LIGHT DIMMER CIRCUIT

This circuit consists of resistors, capacitors, and transistor with specific value. It also consists of
Potentiometer, Diode and MOSFET. This circuit controls the brightness of light bulb, which will
indicate the sensitivity of the Light Sensitivity circuit by controls the brightness of light (flame).
3.1.3 MATERIALS USED FOR THIS PROJECT

The materials that we needed for the construction of the Flame Detector Training Aid are
Perspex (Transparent type), Perspex Adhesives and Screw and Bolts. Below show the further
explanation about the reason and purpose of that such material used in this project.

1. Perspex

Basically, for our project we used transparent PERSPEX. Based on what we had
research, there are several advantages to use this materials. The advantages are listed on
the table below:-

Table 3.1 This table shows the advantages of using PERSPEX.

 High gloss and hard surface PERSPEX is one of the hardest
thermoplastics and remains aesthetically
attractive for much longer than many other
plastic sheet products.
Easy to clean The high gloss surface of PERSPEX makes it
easy to clean, keeping maintenance costs of this
project to a minimum.
High service temperature PERSPEX has a maximum service
temperature of 80-85C minimising the risks of
thermal distortion in service

Low density PERSPEX is half the weight of an equivalent

glass panel and is more easily transported,
installed and supported.

This PERSPEX will be used as the base of the main circuit and it also were used to
hold all of the components and all the other small circuit. The sizes of the Perspex that
will be used are:-

For base of the circuit 35cm X 29cm (1 unit)

For stand of the circuit 28.5cm X 5cm (2 unit)

35cm X 5cm (2 unit)

2. Perspex Adhesives

We used a solvent type adhesive which is PK-1 Glue Adhesive. This adhesives very
suitable to be used on Perspex & Acrylic. This adhesives are suitable for butt and lap
joints. To use it, we must use needle & syringe kit. It is important that appropriate
personal protection equipment (PPE) must be worn when using this product because this
adhesive is poisonous and corrosives.
 Figure 3.1 Perspex that been used for the project.

3. Screws and Bolts

Screw and Bolts are used basically is a small sizes type. It used to join components to the
Perspex and to connect all the wires to the components and small circuits.

Figure 3.2 Small size Screws and Bolts

3.1.4 COMPONENTS AND DEVICES USED FOR THIS PROJECT

 The components and devices that we used for the development of this project are Circuit
Breaker, Bus Bar, Switches, Indicator Lights, AC DC Electrical Source Adjustable
Commutator, 9V Lamp, Warning Light and Warning Speaker and Wires. All of these
components and devices are essential to make a complete circuit. These components and
devices used will make this training aid 70% identical to the real Flame Detector.

1. Circuit Breaker

- A Circuit Breaker is an automatically-operated electrical switch designed to protect an

electrical circuit from damage caused by overload or short circuit. Its basic function is to
detect a fault condition and, by interrupting continuity, to immediately discontinue
electrical flow. Unlike a fuse, which operates once and then has to be replaced, a circuit
breaker can be reset (either manually or automatically) to resume normal operation

- Type of Circuit Breaker that we used in this project is a Push Pull type Circuit Breaker.
The reason why we used this type of Circuit Breaker is that it can be easily manually or
automatically operated.

- The rating that we used is 5 Amps.

- Quantity of Circuit Breaker that we used in this project is 2.

Figure 3.3 This figure shows the Circuit Breaker that used in this project.
2. Bus Bar

- In electrical power distribution, a Bus Bar is a thick strip of copper or aluminum that
conducts electricity within a switchboard, distribution board, substation or other
electrical apparatus. Bus bars are used to carry very large currents, or to distribute
current to multiple devices within switchgear or equipment.

- Basically, for this project we used copper bar as a Bus Bar

- The length of the copper bar is 22.5cm

Figure 3.4 Copper bar that we used as our Bus Bar.

3. Switches

- According to the Free Dictionary. Farlex. (2008), In electronics, a switch is an electrical

component that can break an electrical circuit, interrupting the current or diverting it
 from one conductor to another. The most familiar form of switch is a manually operated
electromechanical device with one or more sets of electrical contacts.

- Type of switches that we used in this project is Toggle type switch which identical to the
switch that been used in most of the aircraft.

- It is a single pole, single throw type (SPST) which is a switch with two terminals are
either connected together or disconnected from each other.

Figure 3.5 Toggle switch that been used in this project are single pole, single throw
type (SPST).

4. Indicator Light

- Indicator Light is been utilized in this project to indicate if there are electrical continuity
or not from Bus Bar to the Light On Relay circuit.

- The Indicator Light is green color and its rating is 12V DC.
 Figure 3.6 Figures of green color Indicator Light.

5. AC DC Electrical Source Adjustable Commutator

- For this project, we will use 9V DC voltage for the entire circuit. So, based on the
requirement that we need, we need some sort of device which capable for converting
the domestic power supply to our voltage requirement.

- With this device is used in this project we capable to convert the domestic power supply
voltage from 240V to 9V. It also will convert the AC voltage from the domestic power
supply to DC voltage.

- This device will be connected to Special Connector to connect the supply power to the
circuit.
 Figure 3.7 Special Connectors used to connect supply power from the AC DC
Electrical Source Adjustable Commutator to the entire circuit.

Figure 3.8 Figures of the device, an AC DC Electrical Source Adjustable

Commutator which been used to step down the voltage from domestic
power supply from 240V to 9V and convert AC voltage to DC voltage.

6. 9V Lamp
 - This lamp is used to replace the flame in this project.

- This lamp will give enough amount of visible light for the Flame Detector Training Aid
to operate.

- Its intensity can be adjusted by using DC Light Dimmer Kit.

7. Warning Light And Warning Speaker

- Warning Light used to give visual warning indication.

- Warning Speaker will give aural warning indication.

- Both Warning Light and Warning Speaker will initiate (Warning Light will illuminate
and Warning Speaker produces sound) as the light detected by the Light On Relay.

8. Wires

- Used to connect between all components and to complete the wiring on circuit.

3.1.5 CIRCUIT KITS USED FOR THIS PROJECT

In order to complete this project, there are three types of circuit kits used for this Flame Detector
Training Aid. First is the Light On Relay Kit, second is the Light Activated Alarm Kit and third
is the DC Light Dimmer Kit. All of these kits are combined with the other components and
devices to become a complete Flame Detector Training Aid circuit.

The Light On Relay Kit and the Light Activated Alarm Kit is used to detect the
intensity of light produce by the 9V lamp (act as a flame for this project) and it will produce
warning light and sound. For the DC Light Dimmer Kit, it used to control the amount of
intensity of light produce by the 9V lamp (used to replace the flame in this project).

1. Light On Relay Kit

This kit functions is to detect the visible light by using its various combinations of
components. Once it detects the light produce by the 9V lamp (used to replace the
flame in this project) it will produce a Warning Light Indication. The components that
contain in this kit are:-

Integrated Circuit (IC 555 8 Pin)

An IC is a densely populated miniature electronic circuit. Its contain transistors

and often diodes, resistors, and small capacitors, all made from, and connected
together on, a chip of silicon not more than 5mm square and 0.5mm thick.

Resistors (R)

Resistors basically used to limit the current in circuits. The primary characteristics
of a resistor are the resistance, the tolerance, the maximum working voltage and
the power rating. Other characteristics include temperature coefficient, noise, and
inductance. When we choosing the resistor which will be used in our project,
there are three factors that we need to be considered, which is:-

I. The tolerance: exact values cannot be guaranteed by mass production

method but this is not a disadvantage because in most electronic circuit s
the values of resistors are not critical. Example, a resistor stated (called
nominal) value of 100Ohm and tolerance +-10% could have any value
between 90 and 110Ohm.

II. The power rating: this is the maximum power which can be developed in
a resistor without damage occurring by overheating. For most electronic
circuit 0.25 W or 0.5 W ratings are adequate. The greater the physical size
of a resistor the greater its rating.

III. The stability: this is the ability to keep the same value with changes of
temperature and with age.

For this Light On Relay Kit, it used a Fixed Type Resistors and Variable Type
Resistors. There are four Fixed Type Resistors used. The values used are:-

I. R1 10K Ohm (Brown-Black-Orange)

 II. R2 1.2K Ohm (Brown-Red-Red)

III. R3 1.2K Ohm (Brown-Red-Red)

IV. R4 470 Ohm (Yellow-Violet-Brown)

For the Variables Type Resistors that used in this Light On Relay circuit is Preset
Potentiometer Type (22K VR).

Zener Diode (D)(4148 )

A Zener Diode is a silicon junction diode design for stabilizing, i.e. keeping
steady, the output voltage of a power supply.

Light Emitting Diode (LED)

In this Light On Relay Kit, the LED will be the Warning Light indicator for this
project. It will illuminate as the Light Dependent Resistor (LDR) in this Kit detect
the light produce by the 9V lamp (used to replace the flame in this project).

Light Dependent Resistor (LDR)

As been stated before this, the Flame Detector will detect flame by using an
Optical Sensor. The type of Optical Sensor that commonly used in the Flame
Detector is Photoelectric Cell. This component has a function which is it will
detect any incident radiation, especially to visible light then it producing an
electrical output that varies in response to incident radiation (the more incident
radiation it detect, the more electrical output it produce).

For the development of this project, Light Dependent Resistance (LDR) will be
used as an Optical Sensor to detect the visible light. This LDR is used in the
Light On Relay Kit as an Optical Sensor to detect the 9V lamp (used to replace
the flame in this project).

LDR is a type of transducer changes light into electrical energy and is also called
Photoconductive Cell. Its action depends on the fact that the resistant of certain
semiconductor, such as Cadmium Sulphide, decrease as the intensity of the light
falling on them increases. It can be said that the more visible light falls on it, the
 more it resistant will decrease. The effect (also given by infrared and ultraviolet
radiation) is due to light supplying the energy to set free charge carries from
atoms of the semiconductor, so increasing its conductivity, i.e. reducing its
resistance. (Refer to figures 2.1 and 2.2).

Relay (RLY)

A relay is used in this Light On Relay Kit as a switches used to turn other circuits
on or off. It is a transducer which changes an electrical signal to movement and
then back to an electrical signal. It very useful if we want:-

I. A small current in one circuit to control another circuit containing a device

such a lamp or electrical motor which needs a large current.

II. Several different switch contacts to be operated simultaneously.

A relay that used in this Light On Relay Kit is a type of relay with nominal coil
voltage which may work off any voltage between 6 V and 9 V SPDT(Single Pole,
Double Throw).

Capacitors (C)

Capacitor is a component that stores electric charge. It basically consists of two

metal plates separated by an insulator called the dielectric. Usually there are two
type capacitors that widely been used in electrical circuit, which is:-

I. Fixed Capacitors.

II. Variable Capacitors.

When choosing a capacitor which to be used in our project, there are two factors
that need to be considered, apart from its value and tolerance:-

I. The voltage rating: this is the maximum voltage(dc or peak ac) it can
withstand before the dielectric breaks down(it is marked on it)

II. The leakage current: no dielectric is a perfect insulator but the loss of
charge by leakage through it should be small.
 Basically there are five types of fixed capacitor. There are polyester, mica,
ceramic, aluminum and tantalum. In the Light On Relay Kit, it used two units
fixed capacitors (C1-0.1F (104) and C2-1uF (Electrolytic)) and the used are
ceramic and aluminum type.

Transistor (Q)

Transistors are tiny semiconductor devices which have revolutionized electronics.

They have three connections and are made as separate (discrete) components and
also as part of Integrated Circuit (IC), where many thousands may be packed on a
chip of silicon.

There is only one Transistor used in this circuit and its arrangement is PNP.

Figure 3.9 Shows about the circuit for Light On Relay Kit used in the Flame Detector
Training Aid.
 Figure 3.10 Schematic diagrams for the Light On Relay Kit

2. Light Activated Alarm Kit

The function of this Light Activated Alarm Kit is to detect the visible light by using its
various combinations of components. Once it detects the light produce by the 9V lamp
(used to replace the flame in this project) it will produce a Warning Sound Indication.
The components that contain in this circuit are:-

Integrated Circuit (IC 555 8 Pin)

An IC is a densely populated miniature electronic circuit. Its contain transistors

and often diodes, resistors, and small capacitors, all made from, and connected
together on, a chip of silicon no more then 5mm square and 0.5mm thick.

Resistors (R)

Basically it used to limit the current in circuits. The primary characteristics of a

resistor are the resistance, the tolerance, the maximum working voltage and the
power rating. Other characteristics include temperature coefficient, noise, and
inductance.
 For this Light On Relay circuit, it used a Fixed Type Resistors and Variable Type
Resistors. There are three Fixed Type Resistors used. The values used are:-

I. R1 10K Ohm (Brown-Black-Orange)

II. R2 1.2K Ohm (Brown-Red-Red)

III. R3 390 Ohm (Orange-White-Brown)

The Variables Type Resistors that used in this Light On Relay circuit is Preset
Potentiometer Type (10K/25K VR).

Capacitors (C)

Capacitor is a component that stores electric charge. It basically consists of two

metal plates separated by an insulator called the dielectric. Usually there are two
type capacitors that widely been used in electrical circuit, which is:-

I. Fixed Capacitors.

II. Variable Capacitors.

In the Light Activated Alarm Kit, it used three units fixed capacitors (C1-10uF,
C2-0.1F (104) and C3-47uF (Electrolytic)) and the type used are ceramic and
aluminum type.

Light Dependent Resistor (LDR)

As been stated before this, the LDR used in this Light Activated Alarm Kit is the
same type LDR that been used in the Light On Relay Kit.

The Light Dependent Resistance (LDR) will be used as an Optical Sensor to

detect the visible light. This LDR is used in the Light Activated Alarm Kit as an
Optical Sensor to detect the 9V lamp (used to replace the flame in this project)..
(Refer to figures 2.1 and 2.2).

Speaker (SPK)

This component been used in the Light Activated Alarm Kit to give an a warning
sound indication. Basically it is a 8 Ohm Speaker. It will produce a warning sound
 as the LDR detected the light produce by the 9V lamp (act as a flame for this
project).

Figure 3.11

Figure 3.12 Schematic diagrams for the Light Activated Alarm Kit.

3. DC Light Dimmer Kit

This kit is used to controls the brightness of the light from 9V lamp (act as a flame for
this project). The circuit uses PWM (Pulse Width Modulation) to control the power of the
load. The components that utilized in this circuit is:-
 Resistors (R)

Resistors basically used to limit the current in circuits. The primary characteristics
of a resistor are the resistance, the tolerance, the maximum working voltage and
the power rating. Other characteristics include temperature coefficient, noise, and
inductance.

For this kit, it used a Fixed Type Resistors and Variable Type Resistors.

There are five Fixed Type Resistors were used. The values used are, all resistors,
R1-R5 4.7K Ohm (Yellow-Violet-Red)

For the Variable Type Resistors (VR), it uses the B linear taper Potentiometer.
The value used is 200~300K Ohm.

Capacitors (C)

Capacitor is a component that stores electric charge. It basically consists of two

metal plates separated by an insulator called the dielectric. Usually there are two
types capacitors that widely been used in electrical circuit, which is:-

III. Fixed Capacitors.

IV. Variable Capacitors.

In the DC Light Dimmer Kit, it used three units fixed capacitors (C1-470 uF (16V
min Electrolytic Capacitor and C2 and C3-0.047 uF or 0.1 uF Capacitors) and the
types we use are ceramic and aluminum type.

Rectifier Diode (D)

Rectifier Diodes that utilized in this kit are two-terminal electronic components
that allow current to flow in only one direction, from an anode (+) to a cathode
(-), and that convert AC to DC. These simple semiconductors are PN junctions
with a positive or P-region with positive ions and a negative or N-region with
 negative electrons. Applying voltage to the PN junction causes current to flow in
only one direction as electrons from the N-region fill holes in the P-region.
Typically, this Rectifier Diodes are made of semiconductor materials such as
silicon, germanium or selenium. The ratings use in this circuit is 1N400x.

Transistor (Q)

Transistors are tiny semiconductor devices which have revolutionized electronics.

They have three connections and are made as separate (discrete) components and
also as part of Integrated Circuit (IC), where many thousands may be packed on a
chip of silicon.

There are four Transistors used in this kit. Three of it (Q1, Q2 and Q3) have
arrangement in NPN. While the other one (Q4) is in Power MOSFET (MOS
Field Effect Transistor)
 Figure 3.13 Shows about the circuit for DC Light Dimmer Kit that been used to
control the intensity of the light produce by the 9V lamp (which been
use as flame).

Figure 3.14 Schematic diagrams for the DC Light Dimmer Kit.

3.1.6 PROCESS OF ASSEMBLING THE FLAME DETECTOR TRAINING AID

TO A COMPLETE CIRCUIT

After I have complete the designing of the Flame Detector Training Aid circuit and after both of
us gathered all of the materials, components, devices and circuit kits that decided to be used for
the project, it is time to assemble all of it into a complete electrical circuit. Assembling process
will be carried out following the circuit that has been designed.

I will give a brief explaination for the process of assembling the circuit and the training-aid. The
details explaination will be explain by my partner, Muhammad Dhiyauddin bin Md Jaki.
Figure 3.15 Perspex that been used as the base of the Flame Detector Circuit.

Figure 3.16 Drilling machine used to make a few holes on the Perspex.
Figure 3.17 Process of drilling on the Perspex to made holes on it.

Figure 3.18 Both of this figures show about the process of putting the components into
the holes.
Figure 3.19 Adhesives which been used to secured the Special Connectors to the holes
to prevent it from moving.

Figure 3.20 The Copper Bar (Bus Bar) is secured to the Perspex by using screws and
bolts
Figure 3.21 Toggle Switch and Circuit Breaker secured their body to holes on the
Perspex by using its own fasteners.

CHAPTER 5
5.1 CONCLUSION/RECOMMENDATION

After completed this project, it is found that the Flame Detector is very sophisticated and
amazing. It is not limited to only one type of Flame Detector, but it also has a few other types of
Flame Detector that is different from each other from the aspects in detecting flame. Ignoring of
their type, the Flame Detector will operate for only one purpose, which is to detect flame in area
that have high potential for flame to occur especially at the aircraft powerplant or engine area.

One of the objectives for our project which is to built a