Flame Scanners

BHARAT HEAVY ELELCTRICALS
LIMITED
HIGH PRESSURE BOILER PLANT
TIRUCHIRAPPALLI-620 014.
Operation & Maintenance Manual

of
BHELSCAN
FLAME SCANNER SYSTEM (BN10)
Project: NEW PARLI TPS
Cust. No.:0361
BHARAT HEAVY ELELCTRICALS LIMITED, HIGH PRESSURE BOILER PLANT

Controls And Instrumentation / Fossil Boilers), Tiruchirapalli - 620 014, INDIA
Phone: 91 (0431) 257 5218 , 257 5027
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TABLE OF CONTENTS :
1.
Introduction
2.
System specification
3.
Mechanical components
4.
Cooling air requirements
5.
Electrical components
6.
Description of modules
6.1
Flame processor module
6.2
2/4 output module
6.3
Power supply module
6.4
Scanner head electronics
7.
Communication interface
8.
Installation and start up procedures
8.1
Mechanical components
8.2
Cooling air
8.3
8.4
System operation test
8.5
DIP switch setting procedures
8.6
Calibration of scanner head electronics
9.
Maintenance & troubleshooting
9.1
Scanner head
9.2
Fibre Optic cable
9.3
10.
List of Figures
Figure-1 : Windbox arrangement showing Flame scanner system
Figure-2 : Flame Scanner Guide pipe assembly
Figure-3 : Flame scanner assembly with optical head
Figure-4 : Collimeter lens with barrel assembly
Figure-5 : Functional block diagram
Figure-6A : BHELSCAN - General arrangement
Figure-6B : BHELSCAN - General arrangement
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Figure-6C : Schematic of processor motherboard

Figure-7A : Block diagram of Flame processor
Figure-7B : BHELSCAN Flame processor module
Figure-8A : Block diagram of 2/4 output module
Figure-8B : BHELSCAN 2/4 module
Figure-9A : Block diagram of power supply
Figure-9B : BHELSCAN Power supply module (Front view)
Figure-9C : BHELSCAN Power supply module (Rear view)
Figure-9D : Schematic of power supply motherboard
Figure-10 : Block diagram of Scanner Head electronic module
Figure-11A : Flame scanner interconnection diagram
Figure-11B : TB wiring details (Front mounted TB version)
Figure-11C : TB wiring details (Rear mounted TB version)
Figure-11D : BHELSCAN TB arrangement (Rear mounting)
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1.
INTRODUCTION :
The microcontroller based flame sensing system is designed primarily for use on
coal fireball and stable oil flame ignited by high energy arc (HEA) ignitor. It senses the
visible light given off by the flame and can recognize a coal/oil flame by its characteristic
fluctuations.
The system consists of a fibre-optic connected scanner head assembly and a
chassis containing electronic signal processing modules. The scanner head assy. is
located at the boiler and the chassis with electronics is mounted in the control room.
The chassis may be located up to 200 metre 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 head assy. is normally installed in the wind box assembly (Figure1). Refer to the respective project wind box arrangement drawing to determine the
location of scanner head assy. in the system.
The prime output of flame sensing system is called the two out of four flame ON
for coal, when two or more than two coal flame in an elevation is detected and individual
flame ON for oil.
The output is represented by the positioning of a set of form C
contacts (break before make). A current signal is also available to indicate the individual
flame intensity corresponding to each corner. RS232C serial output is available for
computer/DCS connectivity.
2.
SYSTEM SPECIFICATION :
Specifications
Power supply
110/230V AC, 50/60 Hz (Refer name plate)
Input signal
0 to 2mA AC from Head Electronics
Signal Processor
4 Microcontroller Modules for 1 elevation
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2/4 Processor
1 Microcontroller Module 2/4 logic detection &

fault alarm
Programmable Parameters
Pull in, Pull out, Flicker frequency for oil, Flicker

frequency for coal
Display
2 digit LED display
Display mode selection
By Push button
Parameter setting
4 x 8 bit DIP switch
Communication
Serial interface
Enclosure
19 Rack with 3U size cards
BHELSCAN comes in two versions - one with terminal blocks for field interconnection
fitted in the front; another with terminal blocks fitted in the back side. Version with TB
fitted in the front is recommended for panels in which BHELSCAN rack assemblies fitted
has only front doors and no back doors provision. Version with TB fitted in back is
recommended for panels having back doors also. All other components are same for
both versions.
3.
MECHANICAL COMPONENTS :
The complete mechanical assembly is comprised of a stationary part, called the
flame scanner guide pipe assembly and a removable part, called the flame scanner
assembly.
3.1
Flame Scanner Guide Pipe Assembly

The flame scanner guide pipe assembly consists of a scanner head housing, a
flexible metal hose, a rigid guide pipe section, a cooling air manifold and a cover
plate.(Figure 2)
Guides inside the 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 and the flexible guide pipe
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adapt the scanner to the tilting of the wind box 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 WITH THE FLEXIBLE HOSE COMPRESSED TO ITS
MINIMUM
LENGTH
(HORIZONTAL) TILT.
WHEN
THE
WIND
BOX
IS
AT
ZERO
IF A SCANNER GUIDE PIPE 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 18-IN 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 wind box 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.
3.2
Flame Scanner Assembly

The flame scanner assembly has four sections similar to those found on the
flame scanner guide pipe. There is a flame scanner head assembly, flexible metal hose,
rigid pipe and the scanner housing assembly.
The flame scanner head assembly (Figure - 3 ) 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 fibre-optic and a plug.
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The fibre optic cable is installed in the flexible metal hose and rigid pipe sections.
It transfers the visible light flame signal from the lens to the photodiode mounted in the
scanner housing assembly.
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 fibre-optic cable. Air is discharged into the
furnace through the scanner head body and collimator tube.
No seal gaskets are
required in 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 the
Maintenance and Trouble shooting section of this manual).
The scanner housing couples the flame scanner assembly to the guide pipe and
contains the electronics for conditioning the fibre-optic-transmitted signal.
A weatherproof disconnect coupling is provided to conveniently connect external
wiring. A hexagon adapter adapts the connector to a in. pipe thread. Sealtite flexible
hose or a similar weatherproof conduit should be used between the disconnect coupling
and the rigid conduit leading from the wind box assembly.
The flame scanner head assembly can be assembled in the following manner :
1.
Slip fit the collimator tube and shield assembly into the scanner head body and
hold it in place with a single Allen head screw. Using spacers, position the shield
on the collimator to a allow cooling air to flow through the head assembly. (
Figure 4)
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
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the scanner in the guide pipe to assure proper orientation of the scanner
head assembly.
2.
Thread the fibre-optic cable, which is normally coiled inside the scanner housing
assembly, through the rigid pipe, flex metal hose and 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.
4.
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 into the furnace at the top
of the scanner head, thereby removing any heat picked up by the scanner from the hot
combustion air. The scanner head should not be exposed to a continuous temperature
above 300F without cooling air.
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 air flow within the
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scanner guide pipe. This prevents a reduction of cooling air pressure at

the remaining scanners.
Cooling air flow requirements are (per scanner) 55 cfm at 120F (maximum
temperature measured at the scanner air booster fan inlet). Air manifold pressure at the
scanner guide pipe must be 150mmwc.(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 cannot overheat. Shut off valves
must not be installed in cooling air lines to the scanners.
5.
ELECTRICAL COMPONENTS :
The electrical components of the BHELSCAN system are contained in the

scanner housing assemblies and the card rack assembly. A photo diode located in each
scanner housing assembly converts visible light (flame signal) observed by the scanner
head into an electrical equivalent signal.
The electrical signal is conditioned by
amplifiers located in the scanner housing assembly.
The scanner housing output
signal is an AC current signal, which is sent to the card rack assembly for processing.
Refer functional block diagram. ( Figure 5 )
In the card rack assembly, each current flame signal is converted into a voltage
flame signal. The voltage flame signal is then separated into intensity and frequency
components. The intensity component of the signal varies between no flame value (dark
furnace) and a normal flame value based on the actual flame intensity. The frequency
component of the signal is used to prove that an active flame exists.
(a)
An intensity signal indicates the magnitude of the flame brightness. A 2

digit LED display in the front facia of flame scanner module displays intensity
in percentage. Range is 0-100%.
(b)
A fault signal is established if the intensity component is less than its

minimum preset limit or greater than its maximum preset limit. If a fault signal
is established, a fault LED is lit and flame signal cannot be established for
that corner. Hence oil flame or coal flame lights will not come ON.
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(c)
When the value of intensity component exceeds the field adjusted limits (pull
in, pull out settings), an intensity light will come ON at the associated scanner
channel. A flame signal will be established only if no fault (fault LED is OFF)
signal exists and a predetermined frequency component (frequency F1, F2
setting) is proven to exist.
The frequency of the fire ball (coal flame) is normally lower than the frequency of the
individual oil gun flame. Therefore, when at least 2 out of 4 scanner channels show coal
flame, the system 2/4 flame light will come ON in the front facial of 2/4 module. If any
scanner channel indicates a fault, the associated scanner channel fault LED will come
along with the system fault LED and that channels flame output will be disabled. The 2/4
module gives 2 changeover contacts for 2/4 flame and one changeover contact output
for system fault. Description of the various modules are given in the following sections:
6.
DESCRIPTION OF MODULES:
The flame scanner card rack assembly consists of the following modules:
1. Flame processor module
- 4 Nos.
2. 2/4 output module
- 1 No.
3. Power supply unit
- 1 No.
Refer BHELSCAN general arrangement drawing. ( Figure 6A & 6B )

The flame processor modules and 2/4 output module are mounted in processor
motherboard, assembled in the card rack. Refer Schematic diagram of
Processor
mother board.( Figure 6C ) The power supply unit is mounted in the power supply
motherboard, assembled in the card rack.
6.1 Flame Processor Module : (Refer block diagram Figure - 7A & 7B) :
This module is a standard euro card suitable for 19 rack assembly. Flame
processor module is located in the slots 1 to 4 in the processor module. These modules
can be interchanged within them. The set values can be verified before putting into its
slots. The scanner head current signal (0 2.0 mA) enters flame processor module and
is converted to voltage. The voltage is signal is normalized in signal conditioner such
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that, a high voltage represents the bright furnace and low voltage represents the dark
furnace.
This signal is divided into three parts. One signal goes to intensity monitoring
circuit. This consists of a voltage amplifier and an ADC. The output of this ADC is
connected to Microcontroller.
The second and third signals are fed to frequency detection circuit. This circuit
consists of an AC amplifier and a wave shaper. One output represents the coal flame
fluctuation and the other output represents the oil flame fluctuation. The outputs are fed
to microcontroller. The AC gain can be adjusted to suit the furnace flame condition
independently for coal and oil flame flicker levels by RP1 and RP6 single turn
potentiometers respectively.
The +/-15 V DC and GND are extended to scanner head electronics located at
furnace front in the field from this module. There are two semiconductor fuses rated for
63mA are available in the flame processor motherboard to protect the DC supply to
scanner head electronics. The removal of this module blocks the DC supply to field.
DO NOT REMOVE ANY MODULE WITH POWER ON
There are 4 DIP switches (each switch with 8 bits) are available to set the
following data in binary form to the microcontroller. For DIP switch settings, refer DIP
SWITCH SETTING PROCEDURE.
a. Pull in value (typical value is 40%)
b. Pull out value (typical value is 30%)
c. Coal frequency set value (typical value is 5 Hz.)
d. Oil frequency set value (typical value is 30 Hz.)
The front facia of this module consists of a 7-segment display, 9 status LEDs and
one Push Button. Card pullers are available to remove the card from the rack. A mode
PB can change the display mode to scroll the various values.
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The heart of the system is an 8-bit microcontroller. This receives the signals from
ADC, wave shaping circuit, mode PB and DIPswitches. From these signals, the
microcontroller decides the flame status and energies the relay. Also, the status of
flame1 and flame 2 and fault are transferred to the 2/4 output module. The
microcontroller updates the display and LED status according to the input.
The digital outputs of flame1 (coal) and flame2 (oil) status are fed to the 2/4
output module. A 4-20 mA current output is available to represents the intensity of the
flame. This circuit consists of a DAC and current converter.
Relay outputs are available in form of change over contact for flame 2(oil) output
to use in BMS of boiler. For the location of DIP switches and AC gain potentiometers,
refer Figure - 7B.
6.2
2/4 Output Module : (Refer block diagram Figure 8A & 8B ) :

This card is a standard euro card suitable for 19 rack assembly. This is located
in the 5th slot of processor motherboard.
The heart of the module is an 8-bit
microcontroller. This receives digital signals corresponding to flame1 ON from all four
flame processor modules. Whenever, two or more than two flame 1 (coal) inputs are
available, this module gives output for 2/4 flame ON output. This indicates the presence
of fireball. There are two relays available. One relay is for the 2/4 output of coal flame.
The other relay is for fault alarm to DCS. RS232C serial communication circuit, transfer
the flame parameters for all processor modules to computer on-line via serial port. Two
sets of 2/4 output relay contacts are available at the terminal. These are changeover
contacts. In the front facia, two status LEDs are available for 2/4 output indication and
fault status. Refer Figure 8B for the location of 2/4 relay (Fireball flame ) and fault
relay.
6.3
Power Supply Module : (Refer Figures - 9A, 9B, 9C & 9D ) :

This is a linear power supply suitable for 19 rack assembly. This is mounted in
power supply motherboard. This will work in 110V AC or 230V AC as given in the
nameplate. This is factory set. There are three DC outputs produced in this module.
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1. +15 V DC @ 0.75 Amps maximum

2. 15V DC @ 0.25 Amps maximum
3. +5.0V DC @ 1.5 Amps maximum
All the above DC outputs are over voltage and short circuit protected. There is a
fuse available in the power supply motherboard, whose rating is 2 Amps. A DPDT
toggle switch is provided in the power supply motherboard to switch ON the AC
power supply to this module. In the front facia, four status LEDs are available for
presence of AC power ON, -15V DC ON, +15V DC ON and +5 V DC ON. All four
LEDs should glow for the normal operation of flame scanner.
6.4
Scanner Head Electronics : (Refer figure 10 ) :

This is a circular module available inside the flame scanner head assembly. This
is mounted at furnace front in the windbox. A special triple shielded flame scanner cable
connects this module to respective flame processor module in the flame scanner card
assembly at flame scanner panel located at remote control room.
This module converts the light transmitted from the furnace flame. (via a fibre
optic cable) to an electrical signal. Visible light from the flame strikes photo diode and is
converted into a current signal. This current is linear function of illumination (intensity)
and covers five-decade range of lux. Photo diode signal is converted to log signal
voltage in the temperature log amplifier to cover the entire range of intensity. Amplifier
offset and gain adjustments are factory set through potentiometers R101, R103. This
voltage signal is converted to current signal (0 2.0 mA) for transmission to flame
processor module.
A feedback LED is mounted in the photo diode holder, to avoid the saturation of
log amplifier in the event of very low light or dark furnace conditions. This feedback loop
is the key circuit in the electronic fault detection scheme. The light emitted by the
feedback LED is adjusted by R114 potentiometer during calibration at laboratory /
factory.
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7.
COMMUNICATION INTERFACE :
Serial communication (RS232C) output is provided in each BHELSCAN covering
four corners of one elevation. Terminal block (TB5) in system mother board has 3
terminals viz. 10, 11, 12 for Transmit (Tx), Receive (Rx) and ground. Prepare a cable (2
pair twisted 0.5 Sq.mm shielded cable) with one side soldered to 9 pin D type connector
suitable for inserting into COM1 or COM2 serial port of personal computer and connect
the other side to these terminals. The 2/4 output module periodically interrupts each
flame scanner and collect the following data. This data will be communicated via serial
output approximately once in a second.
a.
Intensity set value
b.
Pull in set value
c.
Pull out set value
d.
Frequency 1 (coal) set value
e.
Frequency 2 (oil) set value
f.
Actual frequency of flame 1 (coal)
g.
Actual frequency of flame 2 (oil)
h.
Fault status
i.
Flame 1 status
Load and run the PC2Scanner.exe programme supplied with the system. This
program will display the following :
Baud Rate
9600
Stop Bit
Parity
No parity
To select COM1 or COM2 (Enter 1 or 2)
Now enter the COM port Number 1 or 2 in which the communication cable is
connected.
Communication will be established and PC will display the following
corresponding to 4 corners.
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FLAME SCANNER
CORNER1
CORNER2
CORNER3
CORNER4
Actual Intensity
Pull in set
Pull out set
Frequency 1 set
Frequency 2 set
Actual frequency 1
Actual frequency 2
Flame 1
Flame 2
The above table will be updated automatically every second approximately.
8.
INSTALLATION AND START-UP PROCEDURES :
8.1
Mechanical Components :
Make sure the Safe Scan head assembly is properly inserted in the flame scanner guide
pipe assembly and that sufficient clearance exists directly behind each guide pipe to
allow easy removal.
A weatherproof quick-disconnect electrical coupling (Figure 3) is provided for the
external wiring. A hexagonal adapter provides for the connection of a -in. pipe thread
attachment. Sealtite flexible hose or a similar weatherproof conduit should be used
between the quick-disconnect coupling and the rigid conduit. The flexible hose should
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be long enough (4 or 5 ft) to withdraw the scanner from the guide pipe without
disconnecting the coupling.
8.2
Cooling Air :
CAUTION
THE SCANNER HEADS MUST BE COOLED WHENEVER THERE IS A FIRE IN
THE FURNACE OR THE BOILER INTERIOR IS ABOVE 300F. A COOLING
AIR SYSTEM MUST BE PROVIDED AND CHECKED OUT BEFORE THE
BOILER IS LIT OFF.
On balanced draft units, the cooling air for the scanners is frequently supplied by a
separate fan and piped to the scanner cooling air manifolds. The scanner cooling air
supply is taken from the forced draft (FD) fan discharge duct in combination with
combustion air to the ignitors. In this case an emergency damper, a low air pressure
switch, a high air pressure switch and a scanner fan are also provided. The scanner fan
starts when the air pressure gets too low, usually at 6 in. w.g.
Most air systems are supplied with air filters between the scanner fan and the cooling air
manifold. A differential pressure gauges 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.
8.3
Electrical Components :
Input and output connections to the flame scanner card rack assembly are to be done as
per the Flame scanner interconnection diagram Figure 11A and as per the following
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table: (Also refer for detailed TB wiring, Figure 11B for front mounted TB version &
Figures 11C & 11D for rear mounted TB version )
Power supply mother board

TB No.
Terminal DESCRIPTION
No.
TBP1
Phase (230V or 110V as given in the name plate)
TBP1
Neutral
TBP1
Earth
Processor mother board

TB No.
Terminal DESCRIPTION
MARKING
No.
TB1 Corner 1
+15V to Head Electronics
B+
TB1 Corner 1
-15V to Head Electronics
B-
TB1 Corner 1
Signal from Head Electronics
SIG
TB1 Corner 1
Signal ground from Head Electronics
GND
TB1 Corner 1
Power supply shield & overall shield
Sh.
TB1 Corner 1
Flame-2 relay contact - NO
NO
TB1 Corner 1
Flame-2 relay contact common
COM
TB1 Corner 1
Flame-2 relay contact NC
NC
TB1 Corner 1
Current output negative
I-
TB1 Corner 1
10
Current output positive
I+
TB2 - Corner 2
B+
TB2 Corner 2
B-
TB2 Corner 2
SIG
TB2 Corner 2
GND
TB2 Corner 2
Sh.
TB2 Corner 2
NO
TB2 Corner 2
COM
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TB2 Corner 2
NC
TB2 Corner 2
I-
TB2 Corner 2
10
I+
TB3- Corner 3
B+
TB3 Corner 3
B-
TB3 Corner 3
SIG
TB3 Corner 3
GND
TB3 Corner 3
Sh.
TB3 Corner 3
NO
TB3 Corner 3
COM
TB3 Corner 3
NC
TB3 Corner 3
I-
TB3 Corner 3
10
I+
TB4 - Corner 4
B+
TB4 Corner 4
B-
TB4 Corner 4
SIG
TB4 Corner 4
GND
TB4 Corner 4
Sh.
TB4 Corner 4
NO
TB4 Corner 4
COM
TB4 Corner 4
NC
TB4 Corner 4
I-
TB4 Corner 4
10
I+
TB5
2/4 flame contact NO
NO1
TB5
2/4 flame contact common
COM1
TB5
2/4 flame contact NC
NC1
TB5
2/4 flame contact NO
NO2
TB5
2/4 flame contact common
COM2
TB5
2/4 flame contact NC
NC2
TB5
System fault contact NO/NC jumper NO/NC

selectable
TB5
System fault contact common
TB5
No connection
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TB5
10
Transmit
TX
TB5
11
Receive
RX
TB5
12
Ground
GND
8.4
System Operation Test :
After installation is completed, the following tests can be done to verify proper operation
of the system:
1.
At one channel, disconnect the signal wire from the terminal block. With the
power switch in ON position, the intensity display should show input open by
flashing 100%. The channel fault light should be ON and the system fault
light in 2/4 module should be ON.
2.
Reconnect the signal wire to the terminal block. The corner fault light now
should be OFF. The system fault alarm light in 2/4 module should also go
OFF if none of the other corners indicate fault. The intensity display should
return to a normal indication.
3.
Repeat step 1 & 2 for all channels.
4.
During furnace OFF condition, the display corresponding to all corners shall
show 00 to indicate the dark furnace condition.
5.
If any power supply wire is cut or any short circuit in the signal wire to ground,
then the display will show 00 flickering. The fault LED will glow. Switch OFF
the power supply and check the wire continuity. This condition shall be set
right, before proceeding further.
6.
Whenever the power is switched ON, the display will show the intensity. The
corresponding IN LED will glow.
7.
The display mode can be changed by momentarily pressing and releasing the
MODE PB (square PB).
8.
The following display modes are available.

1. IN intensity
2. PI-Pull in set value of intensity
3. PO-Pull out set value of intensity
4. F1- coal frequency set value
5. F2-oil frequency set value
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6. AF & F1- actual frequency of coal

7. AF & F2- actual frequency of oil
9.
Select PI mode. The display should read the pull-in set value in %. Similarly,
change the modes and verify the other values as shown from 6.2 to 6.5
above.
10.
Press mode PB again momentarily. Now, LEDs corresponding to AF and F1

both will glow simultaneously. The display reads the actual coal frequency
(F1).
11.
Press mode PB again momentarily. Now, LEDs corresponding to AF and F2

both will glow simultaneously. The display reads the actual oil frequency (F2).
12.
To change the set values of IN, PI, PO, F1 and F2 if needed, refer
parameter setting procedures given above.
13.
During boiler operation, the Flame1 LED in respective corner processor

module will be ON when the following conditions are met.
a. Flame intensity is more than PI set value AND
b. Coal frequency is more than F1 set value AND
c. No Fault condition exists (Fault LED OFF)
Flame1 LED will switch OFF, if any one of the following conditions is met.
a. Flame intensity is less than PO set value OR
b. Coal frequency is less than F1 set value OR
c. Any fault conditions exits. (Fault LED ON)
14.
During boiler operation with oil, the Flame2 LED will be ON when the
following conditions are met. The relay output is available at TB Nos. 6,7 & 8
in the respective corner.
a. Flame intensity is more than PI set value AND
b. Oil frequency is more than F2 set value AND
c. No fault condition exists. (Fault LED OFF)
Flame2 LED will switch OFF, if any one of the following conditions is met.
a. Flame intensity is less than PO set value OR
b. Oil frequency is less than F2 set value OR
c. Any fault conditions exits. (Fault LED ON)
15.
4-20 mA current output is available corresponding to 0 100% of flame

intensity in respective corner at TB Nos. 9 & 10. If any fault condition exists,
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NEW PARLI TPS
(Fault LED ON), this current output will go to 4 mA irrespective of the intensity
level shown in display.
16.
The 2/4 Flame LED indication in 2/4 flame module represents the presence of
fireball during coal firing. This LED will be ON, whenever, two or more
corners Flame1 (coal flame) show flame. The relay outputs in two sets of
contacts are available at TB Nos.1,2&3 and 4,5 & 6 of TB5.
17.
If any fault LED is ON in any of the processor modules, Fault LED in 2/4
module will be ON. The Fault relay will get energized. The relay output is
available in TB Nos. 7&8 of TB5.
18.
RS232-C serial communication output is available at TB Nos.10, 11 & 12 in

TB5. This can be used to communicate the flame parameters to Personal
Computer.
8.5
DIP Switch Setting Procedure (Refer Figure 7B ) :

Switch OFF the power supply to BHELSCAN system. Remove the flame
processor module at corner 1.

Locate S1 DIP switch as shown in Figure 7B for intensity pull-in value. Set 40 by
keeping the individual switch as below.
DIP switch position:
Setting status
8
OFF
7
OFF
ON
ON
4
OFF
OFF
OFF OFF
Locate S2 DIP switch as shown in Figure 7B for intensity pull-out value. Set 30 by
Setting status
8
OFF
7
OFF
OFF
ON
ON
ON
ON
OFF
Locate S3 DIP switch as shown in Figure 7B for coal frequency set value. Set 05 by
Setting status
8
OFF
7
OFF
6
OFF
Page 21 of 26
5
OFF
OFF ON
2
OFF
1
ON
BHELSCAN O&M MANUAL

NEW PARLI TPS
Locate S4 DIP switch as shown in Figure 7B for oil frequency set value. Set 30 by
Setting status
8
OFF
7
OFF
OFF
ON
ON
ON
ON
OFF
For other values of above settings, convert the decimal value to 8 bit binary and
set the DIP switches accordingly. For 1 status, the switch shall be in ON position.
Repeat the same procedure for settings in other flame processor modules. Insert
the modules into the respective location and switch ON the AC power supply. Verify the
set values in individual flame processor module by selecting the display using mode PB.
8.6
Calibration of Scanner Head Electronics :
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.
8.6.1 Gain and Offset Adjustment :

The flame scanner assembly must be removed from its guide pipe. Turn both power
supplies off, disconnect the cable and open the head assembly for access to the
scanner head electronics card.
The following equipment will be required :
a.
Digital voltmeter (DVM)
b.
1 mA dc current source (1 V dc in series with a resistor; 1k, 1/8W, 1%)
c.
1 A dc current source (1V dc in series with a resistor; 1M, 1/8W, 1%)
d.
Small soldering pencil
Disconnect the positive lead of the photodiode from its terminal. Simulate a photodiode
input by connecting the 1 mA dc current source to the photodiode terminals. Connect
the digital volt meter (DVM) between signal C and common D terminals on the
Page 22 of 26
BHELSCAN O&M MANUAL

NEW PARLI TPS
electronics card; then reconnect the scanner cable. Turn the scanner power supply on
and adjust potentiometer R101 to provide a reading of 0.000 V on the DVM.
Replace the 1 mA dc current source with a 1 A 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.
8.6.2 Dark Furnace Bias Adjustment :

To ensure proper operation of the BHELSCAN relatively uniform voltages must be 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, feedback LED is installed on the scanner
head electronics card adjacent to photodiode.
The flame scanner assembly should be removed from its guide pipe and the scanner
cover plate should be installed. Completely block all light from the furnace end of the
fibre-optic cable and open the scanner housing.
Connect a digital voltmeter (DVM) between the signal C and common D terminals on the
electronics card.
Reconnect the scanner cable to the scanner assembly. The power supply switch should
be turned on. Work under a dark cloth to reduce he amount of ambient light admitted to
the scanner head. Adjust potentiometer P114 so that the DVM reads approximately
2.1V. This completes the scanner head electronics adjustments. Disconnect the test
leads, reassemble the scanner assembly and reinsert it in the guide pipe.
All four scanner channels, under dark furnace conditions, should have a similar intensity
meter reading.
9. FLAME SCANNER CABLE

This
is
1.3
sq.mm.,
Annealed,
Tinned,
Copper
Conductor,
Elastomeric/
Thermoplastic/Equivalent material Insulated, Twisted pair, Aluminium Backed Mylar
Page 23 of 26
BHELSCAN O&M MANUAL

NEW PARLI TPS
Tape Shielded with Drain Wire, 2 such pairs laid up, Over all Aluminium Backed Mylar
Tape Shielded with Drain Wire, Elastomeric / Thermoplastic/Equivalent material Over all
Sheathed Cable.
Colour Code for Core/Pair :First Pair Red & Black
This Pair is used to connect Power Supply to field.
Second Pair Green & White
This Pair is used to connect Signal to Amplifier.
9.
9.1
MAINTENANCE AND TROUBLE SHOOTING :

Scanner Head :
Page 24 of 26
BHELSCAN O&M MANUAL

NEW PARLI TPS
The scanner head at the front of the fibre-optic scanner assembly has an
opening for viewing the flame. With certain types of coal, slag may eventually build up
and cover the opening. The scanner head should be inspected periodically and cleaned,
if necessary. Hence, an inspection program should be established based on operating
experience.
9.2
Fibre-Optic Cable :
The collimator shield and the lens on the end of the fibre-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.
9.3
Electrical Components :
The electronic modules do not require periodic maintenance. If trouble does
occur, the best way to troubleshoot the system is to substitute modules in the card rack
assembly and/or head electronic modules. Modules are to be inserted only in the slots
designated for them.
If the scanner chassis is not working, check whether lamps in the power supply
module corresponding to AC power ON, -15V ON, +15V ON and +5V ON. If AC power
is not ON, check the fuse F01 in the power supply mother board and the incoming AC
power. If the DC supplies are not ON, check the corresponding fuses at the rear side of
the power supply module. If the fuses are alright and still any one of the above DC
voltages are not present, power supply module has to be replaced.
In flame processor module, fault lamp should be OFF. If this lamp is ON, check
the fuses corresponding to +15V and 15V feeding to head electronics in the processor
mother board. If the fuses are healthy, then check the continuity of flame scanner cable
connection between the terminal block and the head electronics in the field. If continuity
is also alright, then head electronics may need recalibration or replacement. For any
Page 25 of 26
BHELSCAN O&M MANUAL

NEW PARLI TPS
other fault in this module like no response for mode selection PB, improper display, etc.,
the module is to be replaced.
In 2/4 flame module, the fault lamp should be OFF for normal operation. If the
fault lamp is ON, then fault lamp in any one or more of the flame processor modules may
be ON. If that module is attended, this fault may vanish. If this fault persists even then,
2/4 flame module may need replacement.
Do not insert or pull out any module from the connector when power is ON. This
may damage the module. If any module has to be removed for examination or changing
the settings, it is safe to switch OFF the power by operating the toggle switch SO1 in the
power supply mother board and wait till all the lamps in the power supply module go
OFF. Then remove or insert the module and then switch ON the toggle switch SO1 if
needed to power up the system.
Page 26 of 26
BHELSCAN O&M MANUAL
Figure - 6B
BHELSCAN GENERAL ARRANGEMENT
Figure - 7B
BHELSCAN FLAME PROCESSOR MODULE
AC gain
pot.(Coal)
Intensity
pull in
Coal freq.
Set value
Intensity
pull out
Oil freq.
Set value
AC gain
pot.(Oil)
Figure - 8B
BHELSCAN 2/4 MODULE
2/4 Relay
Fault Relay
Figure - 9B
BHELSCAN POWER SUPPLY MODULE (FRONT VIEW)
Figure - 9C
BHELSCAN POWER SUPPLY MODULE (REAR VIEW)
FIGURE 11D:BHELSCAN TB ARRANGEMENT (REAR MOUNTING)

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BHARAT HEAVY ELELCTRICALS

Operation & Maintenance Manual

BHARAT HEAVY ELELCTRICALS LIMITED, HIGH PRESSURE BOILER PLANT

BHELSCAN O & M MANUAL

Cooling air requirements

Flame processor module

2/4 output module

Power supply module

Scanner head electronics

Installation and start up procedures

System operation test

DIP switch setting procedures

Calibration of scanner head electronics

Maintenance & troubleshooting

Fibre Optic cable

BHELSCAN O&M MANUAL

BHELSCAN O & M MANUAL

Figure-6C : Schematic of processor motherboard

BHELSCAN O&M MANUAL

BHELSCAN O & M MANUAL

The output is represented by the positioning of a set of form C

110/230V AC, 50/60 Hz (Refer name plate)

0 to 2mA AC from Head Electronics

4 Microcontroller Modules for 1 elevation

BHELSCAN O&M MANUAL

BHELSCAN O & M MANUAL

1 Microcontroller Module 2/4 logic detection &

Pull in, Pull out, Flicker frequency for oil, Flicker

2 digit LED display

Display mode selection

4 x 8 bit DIP switch

19 Rack with 3U size cards

Flame Scanner Guide Pipe Assembly

The flexible hose assembly and the flexible guide pipe

BHELSCAN O&M MANUAL

BHELSCAN O & M MANUAL

IF A SCANNER GUIDE PIPE IS FIELD-

INSTALLED, BE SURE IT IS MOUNTED IN THE SAME MANNER TO

Flame Scanner Assembly

BHELSCAN O&M MANUAL

BHELSCAN O & M MANUAL

No seal gaskets are

There should be no reason to

BHELSCAN O&M MANUAL

BHELSCAN O & M MANUAL

COOLING AIR REQUIREMENTS :

BHELSCAN O&M MANUAL

BHELSCAN O & M MANUAL

scanner guide pipe. This prevents a reduction of cooling air pressure at

The electrical components of the BHELSCAN system are contained in the

The electrical signal is conditioned by

amplifiers located in the scanner housing assembly.

The scanner housing output

An intensity signal indicates the magnitude of the flame brightness. A 2

A fault signal is established if the intensity component is less than its

BHELSCAN O&M MANUAL

BHELSCAN O & M MANUAL

2. 2/4 output module