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 Page 1 of 26 BHELSCAN O & M MANUAL NEW PARLI TPS 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 Electrical components 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 Electrical components 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 Page 2 of 26 BHELSCAN O&M MANUAL BHELSCAN O & M MANUAL NEW PARLI TPS 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) Page 3 of 26 BHELSCAN O&M MANUAL A current signal is also available to indicate the individual flame intensity corresponding to each corner. SYSTEM SPECIFICATION : Specifications Power supply : 110/230V AC. The prime output of flame sensing system is called the “two out of four flame ON” for coal.BHELSCAN O & M MANUAL NEW PARLI TPS 1. RS232C serial output is available for computer/DCS connectivity. The output is represented by the positioning of a set of form C contacts (break before make). It senses the visible light given off by the flame and can recognize a coal/oil flame by its characteristic fluctuations. The chassis may be located up to 200 metre from the boiler. 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. is located at the boiler and the chassis with electronics is mounted in the control room. Refer to the respective project wind box arrangement drawing to determine the location of scanner head assy. The scanner head assy. The system consists of a fibre-optic connected scanner head assembly and a chassis containing electronic signal processing modules. is normally installed in the wind box assembly (Figure1). 50/60 Hz (Refer name plate) Input signal : 0 to 2mA AC from Head Electronics Signal Processor : 4 Microcontroller Modules for 1 elevation Page 4 of 26 BHELSCAN O&M MANUAL . 2. The scanner head assy. when two or more than two coal flame in an elevation is detected and “individual flame ON” for oil. in the system. A shielded four-conductor cable sends power to the scanner head electronics and returns an electronic signal representing flame to the chassis. 1 Flame Scanner Guide Pipe Assembly The flame scanner guide pipe assembly consists of a scanner head housing. 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. another with terminal blocks fitted in the back side.BHELSCAN O & M MANUAL NEW PARLI TPS 2/4 Processor : 1 Microcontroller Module – 2/4 logic detection & fault alarm Programmable Parameters : Pull in. called the “flame scanner assembly”. Pull out. 3. The end ring in the housing forms a mechanical stop for the scanner head. Flicker frequency for oil.one with terminal blocks for field interconnection fitted in the front. All other components are same for both versions. a flexible metal hose. Version with TB fitted in back is recommended for panels having back doors also. 3. a rigid guide pipe section. 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. called the “flame scanner guide pipe assembly” and a removable part. The flexible hose assembly and the flexible guide pipe Page 5 of 26 BHELSCAN O&M MANUAL . Flicker frequency for coal Display : 2 ½ 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 . MECHANICAL COMPONENTS : The complete mechanical assembly is comprised of a stationary part. The guide pipe is normally fixed in the wind box front by means of a packing gland. which contains the collimator tube and shield. The flame scanner head assembly (Figure . the collimating lens and barrel. 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 scanner opening must be closed with the cover plate when the assembly is removed for maintenance. The cooling air manifold is screwed (NPT) onto the guide pipe. flexible metal hose. The flexible hose is brazed to the guide pipe and scanner head housing. a compression spring. THEY ARE MOUNTED WITH THE FLEXIBLE HOSE COMPRESSED TO ITS MINIMUM LENGTH (HORIZONTAL) TILT. Page 6 of 26 BHELSCAN O&M MANUAL . There is a flame scanner head assembly. one end of the fibre-optic and a plug. 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. a mounting plate.3 ) consists of the scanner head body. CAUTION WHEN SCANNER ASSEMBLIES ARE SHOP-INSTALLED.2 Flame Scanner Assembly The flame scanner assembly has four sections similar to those found on the flame scanner guide pipe. WHEN THE WIND BOX IS AT ZERO IF A SCANNER GUIDE PIPE IS FIELD- INSTALLED. rigid pipe and the scanner housing assembly. 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. 3.BHELSCAN O & M MANUAL NEW PARLI TPS adapt the scanner to the tilting of the wind box nozzle and angle mounting. The flame scanner head assembly can be assembled in the following manner : 1. It transfers the visible light flame signal from the lens to the photodiode mounted in the scanner housing assembly. 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. When the scanner assembly is inserted in the guide pipe. The scanner housing couples the flame scanner assembly to the guide pipe and contains the electronics for conditioning the fibre-optic-transmitted signal. except to clean the collimator shield (see the “Maintenance and Trouble shooting” section of this manual). cooling air from the cooling air manifold enters the scanner housing through two holes. A weatherproof disconnect coupling is provided to conveniently connect external wiring. Using spacers. A hexagon adapter adapts the connector to a ½ in. a prism may be installed in place of the collimator shield. Slip fit the collimator tube and shield assembly into the scanner head body and hold it in place with a single Allen head screw. There should be no reason to disassemble the scanner head assembly. pipe thread. 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.BHELSCAN O & M MANUAL NEW PARLI TPS The fibre optic cable is installed in the flexible metal hose and rigid pipe sections. To permit the scanner to see the flame. position the shield on the collimator to a allow cooling air to flow through the head assembly. Air is discharged into the furnace through the scanner head body and collimator tube. ( Figure – 4) NOTE A wind box structure will sometimes restrict the location of the guide pipe scanner head housing. This air flows down the rigid pipe and flex metal hose to cool the fibre-optic cable. Use care when placing Page 7 of 26 BHELSCAN O&M MANUAL . Make sure the jam nut is in place on the cable before installing the compression spring and mounting plate.BHELSCAN O & M MANUAL NEW PARLI TPS the scanner in the guide pipe to assure proper orientation of the scanner head assembly. thereby removing any heat picked up by the scanner from the hot combustion air. 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. Insert the lens barrel in the scanner head body until the mounting plate rests against the stop pins. 4. Lock the mounting plate to the lens barrel with the jam nut. Three socket head screws hold the plug in the scanner head body. the scanner assembly must be removed from the guide pipe immediately. COOLING AIR REQUIREMENTS : The external cooling air passes through the guide pipe. through the rigid pipe. Install the cover plate to retain the cooling air flow within the Page 8 of 26 BHELSCAN O&M MANUAL . 2. The head should then be held in the rag to protect it from damage. Insert the compression spring and plug. Thread the fibre-optic cable. 5. the flexible hose and the annulus between the scanner head and housing. flex metal hose and the scanner head body plug. 3. NOTE When the scanner assembly housing adapter flange is disconnected. Then screw the collimating lens barrel onto the cable. The air is discharged into the furnace at the top of the scanner head. The scanner head should not be exposed to a continuous temperature above 300°F without cooling air. 4. which is normally coiled inside the scanner housing assembly. 5.(g). The scanner housing output signal is an AC current signal. After shutting down the unit. If a fault signal is established. This prevents a reduction of cooling air pressure at the remaining scanners. Cooling air flow requirements are (per scanner) 55 cfm at 120°F (maximum temperature measured at the scanner air booster fan inlet). The intensity component of the signal varies between no flame value (dark furnace) and a normal flame value based on the actual flame intensity. (a) An intensity signal indicates the magnitude of the flame brightness. Refer functional block diagram. A 2½ digit LED display in the front facia of flame scanner module displays intensity in percentage. Page 9 of 26 BHELSCAN O&M MANUAL . (b) A fault signal is established if the intensity component is less than its minimum preset limit or greater than its maximum preset limit. Air manifold pressure at the scanner guide pipe must be 150mmwc. Range is 0-100%. The frequency component of the signal is used to prove that an active flame exists. Shut off valves must not be installed in cooling air lines to the scanners. The voltage flame signal is then separated into intensity and frequency components. scanner cooling air must be maintained until furnace conditions are such that the scanner assembly cannot overheat. above furnace pressure for all operating conditions. The electrical signal is conditioned by amplifiers located in the scanner housing assembly. each current flame signal is converted into a voltage flame signal. Hence oil flame or coal flame lights will not come ON. ELECTRICAL COMPONENTS : The electrical components of the BHELSCAN system are contained in the scanner housing assemblies and the card rack assembly. a fault LED is lit and flame signal cannot be established for that corner. ( Figure – 5 ) In the card rack assembly. which is sent to the card rack assembly for processing. A photo diode located in each scanner housing assembly converts visible light (flame signal) observed by the scanner head into an electrical equivalent signal.BHELSCAN O & M MANUAL NEW PARLI TPS scanner guide pipe. 2/4 output module . the associated scanner channel fault LED will come along with the system fault LED and that channels flame output will be disabled. Flame processor module is located in the slots 1 to 4 in the processor module.( Figure – 6C ) The power supply unit is mounted in the power supply motherboard. assembled in the card rack. A flame signal will be established only if no fault (fault LED is OFF) signal exists and a predetermined frequency component (frequency F1.4 Nos. ( Figure – 6A & 6B ) The flame processor modules and 2/4 output module are mounted in processor motherboard. Flame processor module . when at least 2 out of 4 scanner channels show coal flame.0 mA) enters flame processor module and is converted to voltage. Therefore. The 2/4 module gives 2 changeover contacts for 2/4 flame and one changeover contact output for system fault. 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. Refer BHELSCAN general arrangement drawing.1 No. The set values can be verified before putting into its slots. assembled in the card rack. 3. The scanner head current signal (0 – 2. Description of the various modules are given in the following sections: 6.1 No. Power supply unit .BHELSCAN O & M MANUAL NEW PARLI TPS (c) When the value of intensity component exceeds the field adjusted limits (pull in.1 Flame Processor Module : (Refer block diagram – Figure . pull out settings). DESCRIPTION OF MODULES: The flame scanner card rack assembly consists of the following modules: 1. These modules can be interchanged within them. the system 2/4 flame light will come ON in the front facial of 2/4 module. an intensity light will come ON at the associated scanner channel. 2.7A & 7B) : This module is a standard euro card suitable for 19” rack assembly. Refer Schematic diagram of Processor mother board. If any scanner channel indicates a fault. The voltage is signal is normalized in signal conditioner such Page 10 of 26 BHELSCAN O&M MANUAL . 6. One signal goes to intensity monitoring circuit. This signal is divided into three parts.BHELSCAN O & M MANUAL NEW PARLI TPS that. For DIP switch settings. 9 status LEDs and one Push Button. This consists of a voltage amplifier and an ADC.) The front facia of this module consists of a 7-segment display. a. The +/-15 V DC and GND are extended to scanner head electronics located at furnace front in the field from this module. The output of this ADC is connected to Microcontroller. One output represents the coal flame fluctuation and the other output represents the oil flame fluctuation. Page 11 of 26 BHELSCAN O&M MANUAL .) d. The outputs are fed to microcontroller. Coal frequency set value (typical value is 5 Hz. This circuit consists of an AC amplifier and a wave shaper. The second and third signals are fed to frequency detection circuit. A mode PB can change the display mode to scroll the various values. 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. a high voltage represents the bright furnace and low voltage represents the dark furnace. Card pullers are available to remove the card from the rack. Oil frequency set value (typical value is 30 Hz. There are two semiconductor fuses rated for 63mA are available in the flame processor motherboard to protect the DC supply to scanner head electronics. refer DIP SWITCH SETTING PROCEDURE. 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 removal of this module blocks the DC supply to field. Pull out value (typical value is 30%) c. Pull in value (typical value is 40%) b. 6. Whenever. This receives the signals from ADC.7B. The microcontroller updates the display and LED status according to the input.BHELSCAN O & M MANUAL NEW PARLI TPS The heart of the system is an 8-bit microcontroller.9A. refer Figure . There are two relays available. These are changeover contacts. Refer Figure – 8B for the location of 2/4 relay (Fireball flame ) and fault relay. This receives digital signals corresponding to flame1 ON from all four flame processor modules. the microcontroller decides the flame status and energies the relay. Also. This indicates the presence of fireball. This is located in the 5th slot of processor motherboard. One relay is for the 2/4 output of coal flame. Page 12 of 26 BHELSCAN O&M MANUAL . the status of flame1 and flame 2 and fault are transferred to the 2/4 output module.2 2/4 Output Module : (Refer block diagram – Figure – 8A & 8B ) : This card is a standard euro card suitable for 19” rack assembly. For the location of DIP switches and AC gain potentiometers. This will work in 110V AC or 230V AC as given in the nameplate. transfer the flame parameters for all processor modules to computer on-line via serial port. RS232C serial communication circuit. 9C & 9D ) : This is a linear power supply suitable for 19” rack assembly. 9B. A 4-20 mA current output is available to represents the intensity of the flame. There are three DC outputs produced in this module. this module gives output for 2/4 flame ON output. This is factory set. wave shaping circuit. two or more than two flame 1 (coal) inputs are available. Relay outputs are available in form of change over contact for flame 2(oil) output to use in BMS of boiler. 6. The digital outputs of flame1 (coal) and flame2 (oil) status are fed to the 2/4 output module. The other relay is for fault alarm to DCS. In the front facia. The heart of the module is an 8-bit microcontroller. This is mounted in power supply motherboard. Two sets of 2/4 output relay contacts are available at the terminal. mode PB and DIPswitches.3 Power Supply Module : (Refer Figures . This circuit consists of a DAC and current converter. two status LEDs are available for 2/4 output indication and fault status. From these signals. 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. This current is linear function of illumination (intensity) and covers five-decade range of lux. Amplifier offset and gain adjustments are factory set through potentiometers R101. whose rating is 2 Amps. Photo diode signal is converted to log signal voltage in the temperature log amplifier to cover the entire range of intensity.0 mA) for transmission to flame processor module.5 Amps maximum All the above DC outputs are over voltage and short circuit protected. A DPDT toggle switch is provided in the power supply motherboard to switch ON the AC power supply to this module. There is a fuse available in the power supply motherboard. A feedback LED is mounted in the photo diode holder. +5.75 Amps maximum 2. Page 13 of 26 BHELSCAN O&M MANUAL . (via a fibre optic cable) to an electrical signal. This module converts the light transmitted from the furnace flame.25 Amps maximum 3. four status LEDs are available for presence of AC power ON. –15V DC @ 0. R103. This voltage signal is converted to current signal (0 – 2. Visible light from the flame strikes photo diode and is converted into a current signal. 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.BHELSCAN O & M MANUAL NEW PARLI TPS 1.4 Scanner Head Electronics : (Refer figure – 10 ) : This is a circular module available inside the flame scanner head assembly. All four LEDs should glow for the normal operation of flame scanner.0V DC @ 1. 6. -15V DC ON. This is mounted at furnace front in the windbox. +15V DC ON and +5 V DC ON. In the front facia. +15 V DC @ 0. to avoid the saturation of log amplifier in the event of very low light or dark furnace conditions. Prepare a cable (2 pair twisted 0. Frequency 2 (oil) set value f. 10. Actual frequency of flame 2 (oil) h. This data will be communicated via serial output approximately once in a second. Receive (Rx) and ground. Pull in set value c. Intensity set value b. 12 for Transmit (Tx). Frequency 1 (coal) set value e. Page 14 of 26 BHELSCAN O&M MANUAL . 11. This program will display the following : Baud Rate = 9600 Stop Bit = 1 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.5 Sq. Pull out set value d.exe programme supplied with the system. a. Communication will be established and PC will display the following corresponding to 4 corners. Flame 1 status Load and run the PC2Scanner. Terminal block (TB5) in system mother board has 3 terminals viz.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.BHELSCAN O & M MANUAL NEW PARLI TPS 7. The 2/4 output module periodically interrupts each flame scanner and collect the following data. Actual frequency of flame 1 (coal) g. Fault status i. COMMUNICATION INTERFACE : Serial communication (RS232C) output is provided in each BHELSCAN covering four corners of one elevation. Sealtite flexible hose or a similar weatherproof conduit should be used between the quick-disconnect coupling and the rigid conduit. A hexagonal adapter provides for the connection of a ½-in. The flexible hose should Page 15 of 26 BHELSCAN O&M MANUAL .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. pipe thread attachment. 8. INSTALLATION AND START-UP PROCEDURES : 8.BHELSCAN O & M MANUAL NEW PARLI TPS 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. A COOLING AIR SYSTEM MUST BE PROVIDED AND CHECKED OUT BEFORE THE BOILER IS LIT OFF. a low air pressure switch.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 Page 16 of 26 BHELSCAN O&M MANUAL . In this case an emergency damper. On balanced draft units.g. a high air pressure switch and a scanner fan are also provided. Filters should be checked periodically for cleanliness. 8. The emergency damper opens to admit ambient air to the system when the FD fans are out of service. The scanner cooling air supply is taken from the forced draft (FD) fan discharge duct in combination with combustion air to the ignitors. A differential pressure gauges and switches to actuate an alarm are installed across the filter to provide information on filter condition. w. All components should be checked for proper operation. 8. The scanner fan starts when the air pressure gets too low. the cooling air for the scanners is frequently supplied by a separate fan and piped to the scanner cooling air manifolds.2 Cooling Air : CAUTION THE SCANNER HEADS MUST BE COOLED WHENEVER THERE IS A FIRE IN THE FURNACE OR THE BOILER INTERIOR IS ABOVE 300ºF. usually at 6 in.BHELSCAN O & M MANUAL NEW PARLI TPS be long enough (4 or 5 ft) to withdraw the scanner from the guide pipe without disconnecting the coupling. Most air systems are supplied with air filters between the scanner fan and the cooling air manifold. Terminal DESCRIPTION No. Figure –11B for front mounted TB version & Figures – 11C & 11D for rear mounted TB version ) Power supply mother board TB No. TBP1 1 Phase (230V or 110V as given in the name plate) TBP1 2 Neutral TBP1 3 Earth Processor mother board TB No. TB2 – Corner 2 6 Flame-2 relay contact . Terminal DESCRIPTION MARKING No. TB1 – Corner 1 1 +15V to Head Electronics B+ TB1– Corner 1 2 -15V to Head Electronics B- TB1 – Corner 1 3 Signal from Head Electronics SIG TB1 – Corner 1 4 Signal ground from Head Electronics GND TB1 – Corner 1 5 Power supply shield & overall shield Sh.BHELSCAN O & M MANUAL NEW PARLI TPS table: (Also refer for detailed TB wiring.Corner 2 1 +15V to Head Electronics B+ TB2 – Corner 2 2 -15V to Head Electronics B- TB2 – Corner 2 3 Signal from Head Electronics SIG TB2 – Corner 2 4 Signal ground from Head Electronics GND TB2 – Corner 2 5 Power supply shield & overall shield Sh.NO NO TB2 – Corner 2 7 Flame-2 relay contact – common COM Page 17 of 26 BHELSCAN O&M MANUAL .NO NO TB1 – Corner 1 7 Flame-2 relay contact – common COM TB1 – Corner 1 8 Flame-2 relay contact – NC NC TB1 – Corner 1 9 Current output – negative I- TB1 – Corner 1 10 Current output –positive I+ TB2 . TB1 – Corner 1 6 Flame-2 relay contact . NO NO TB4 – Corner 4 7 Flame-2 relay contact – common COM TB4 – Corner 4 8 Flame-2 relay contact – NC NC TB4 – Corner 4 9 Current output – positive I- TB4 – Corner 4 10 Current output – negative I+ TB5 1 2/4 flame contact – NO NO1 TB5 2 2/4 flame contact – common COM1 TB5 3 2/4 flame contact – NC NC1 TB5 4 2/4 flame contact – NO NO2 TB5 5 2/4 flame contact – common COM2 TB5 6 2/4 flame contact – NC NC2 TB5 7 System fault contact – NO/NC jumper NO/NC selectable TB5 8 System fault contact – common TB5 9 No connection Page 18 of 26 COM BHELSCAN O&M MANUAL . TB3 – Corner 3 6 Flame-2 relay contact . TB4 – Corner 4 6 Flame-2 relay contact .Corner 4 1 +15V to Head Electronics B+ TB4 – Corner 4 2 -15V to Head Electronics B- TB4 – Corner 4 3 Signal from Head Electronics SIG TB4 – Corner 4 4 Signal ground from Head Electronics GND TB4 – Corner 4 5 Power supply shield & overall shield Sh.BHELSCAN O & M MANUAL NEW PARLI TPS TB2 – Corner 2 8 Flame-2 relay contact – NC NC TB2 – Corner 2 9 Current output – positive I- TB2 – Corner 2 10 Current output – negative I+ TB3.NO NO TB3 – Corner 3 7 Flame-2 relay contact – common COM TB3 – Corner 3 8 Flame-2 relay contact – NC NC TB3 – Corner 3 9 Current output – positive I- TB3 – Corner 3 10 Current output – negative I+ TB4 .Corner 3 1 +15V to Head Electronics B+ TB3 – Corner 3 2 -15V to Head Electronics B- TB3 – Corner 3 3 Signal from Head Electronics SIG TB3 – Corner 3 4 Signal ground from Head Electronics GND TB3 – Corner 3 5 Power supply shield & overall shield Sh. The system fault alarm light in 2/4 module should also go OFF if none of the other corners indicate fault.coal frequency set value 5. 5. With the power switch in ON position.4 System Operation Test : After installation is completed. During furnace OFF condition. If any power supply wire is cut or any short circuit in the signal wire to ground. the display will show the intensity. At one channel. disconnect the signal wire from the terminal block. This condition shall be set right. the intensity display should show input open by flashing 100%. F1. 7. Whenever the power is switched ON. 4. Reconnect the signal wire to the terminal block. the display corresponding to all corners shall show ‘00’ to indicate the dark furnace condition. PO-Pull out set value of intensity 4. Switch OFF the power supply and check the wire continuity. IN – intensity 2. the following tests can be done to verify proper operation of the system: 1. then the display will show ‘00’ flickering. 8. The corresponding IN LED will glow. The channel fault light should be ON and the system fault light in 2/4 module should be ON. before proceeding further. F2-oil frequency set value Page 19 of 26 BHELSCAN O&M MANUAL . The corner fault light now should be OFF. The display mode can be changed by momentarily pressing and releasing the MODE PB (square PB). The fault LED will glow. 3. 2. The intensity display should return to a normal indication. Repeat step 1 & 2 for all channels. 1. 6.BHELSCAN O & M MANUAL NEW PARLI TPS TB5 10 Transmit TX TB5 11 Receive RX TB5 12 Ground GND 8. PI-Pull in set value of intensity 3. The following display modes are available. Coal frequency is more than F1 set value AND c. 6.5 above. Flame intensity is less than PO set value OR b. the “Flame1” LED in respective corner processor module will be ON when the following conditions are met. Press mode PB again momentarily. Now. 13. if any one of the following conditions is met. No fault condition exists. The relay output is available at TB Nos. Oil frequency is more than F2 set value AND c. a. a.BHELSCAN O & M MANUAL NEW PARLI TPS 6. change the modes and verify the other values as shown from 6. AF & F2. ‘F1’ and ‘F2’ if needed.7 & 8 in the respective corner.actual frequency of oil 9. Any fault conditions exits. During boiler operation with oil. LEDs corresponding to AF and F1 both will glow simultaneously. LEDs corresponding to AF and F2 both will glow simultaneously. Flame intensity is less than PO set value OR b. Flame intensity is more than PI set value AND b. Page 20 of 26 BHELSCAN O&M MANUAL . No Fault condition exists (Fault LED OFF) Flame1 LED will switch OFF. Select PI mode. The display reads the actual oil frequency (F2). (Fault LED ON) 15. 4-20 mA current output is available corresponding to 0 – 100% of flame intensity in respective corner at TB Nos. 12. Oil frequency is less than F2 set value OR c. the “Flame2” LED will be ON when the following conditions are met. if any one of the following conditions is met.actual frequency of coal 7. 9 & 10. Any fault conditions exits. (Fault LED ON) 14. 10. The display reads the actual coal frequency (F1). The display should read the pull-in set value in %. a. (Fault LED OFF) Flame2 LED will switch OFF. During boiler operation. ‘PI’. If any fault condition exists. To change the set values of ‘IN’.2 to 6. 11. Similarly. Now. Coal frequency is less than F1 set value OR c. Press mode PB again momentarily. AF & F1. refer “parameter setting procedures” given above. a. ‘PO’. Flame intensity is more than PI set value AND b. Set ‘05’ by keeping the individual switch as below. RS232-C serial communication output is available at TB Nos. Set ‘40’ by keeping the individual switch as below. 16. this current output will go to 4 mA irrespective of the intensity level shown in display. The Fault relay will get energized. This LED will be ON. Locate S1 DIP switch as shown in Figure – 7B for intensity pull-in value. two or more corner’s “Flame1” (coal flame) show flame. The 2/4 Flame LED indication in 2/4 flame module represents the presence of fireball during coal firing. Remove the flame processor module at corner 1. whenever. 8. DIP switch position: Setting status 8 OFF 7 OFF 6 5 OFF ON 4 3 2 1 ON ON ON OFF Locate S3 DIP switch as shown in Figure – 7B for coal frequency set value. If any fault LED is ON in any of the processor modules. The relay output is available in TB Nos. 18. Fault LED in 2/4 module will be ON. 11 & 12 in TB5.5 DIP Switch Setting Procedure (Refer Figure – 7B ) : Switch OFF the power supply to BHELSCAN system. DIP switch position: Setting status 8 OFF 7 OFF 6 OFF Page 21 of 26 5 OFF 4 3 OFF ON 2 OFF 1 ON BHELSCAN O&M MANUAL . 17.BHELSCAN O & M MANUAL NEW PARLI TPS (Fault LED ON).10.2&3 and 4. This can be used to communicate the flame parameters to Personal Computer. 7&8 of TB5. DIP switch position: Setting status 8 OFF 7 OFF 6 5 ON ON 4 OFF 3 2 OFF 1 OFF OFF Locate S2 DIP switch as shown in Figure – 7B for intensity pull-out value. Set ‘30’ by keeping the individual switch as below.1. The relay outputs in two sets of contacts are available at TB Nos.5 & 6 of TB5. the switch shall be in ON position. Repeat the same procedure for settings in other flame processor modules. Digital voltmeter (DVM) b. 1%) d. Small soldering pencil Disconnect the positive lead of the photodiode from its terminal. 8. Verify the set values in individual flame processor module by selecting the display using mode PB. Insert the modules into the respective location and switch ON the AC power supply. DIP switch position: Setting status 8 OFF 7 OFF 6 5 OFF ON 4 3 2 1 ON ON ON OFF For other values of above settings. Connect the digital volt meter (DVM) between signal “C” and common “D” terminals on the Page 22 of 26 BHELSCAN O&M MANUAL . field adjustment of the gain and offset potentiometers and dark furnace bias will be required. disconnect the cable and open the head assembly for access to the scanner head electronics card. 1/8W. Simulate a photodiode input by connecting the 1 mA dc current source to the photodiode terminals. Set ‘30’ by keeping the individual switch as below.6. For ‘1’ status. 1k. 1 µA dc current source (1V dc in series with a resistor.1 Gain and Offset Adjustment : The flame scanner assembly must be removed from its guide pipe. 1/8W. 1%) c. Turn both power supplies “off”. 1M. convert the decimal value to 8 bit binary and set the DIP switches accordingly. The following equipment will be required : a. If a component on the electronics card is replaced.BHELSCAN O & M MANUAL NEW PARLI TPS Locate S4 DIP switch as shown in Figure – 7B for oil frequency set value. 8.6 Calibration of Scanner Head Electronics : The scanner head electronics are adjusted during manufacturing. 1 mA dc current source (1 V dc in series with a resistor. Elastomeric/ Thermoplastic/Equivalent material Insulated. The flame scanner assembly should be removed from its guide pipe and the scanner cover plate should be installed. Total absence of a signal from the scanner assembly would generate a fault condition. Twisted pair. Aluminium Backed Mylar Page 23 of 26 BHELSCAN O&M MANUAL . Disconnect the scanner cable and test leads.6.3 sq. To prevent this from occurring. Tinned. no fire conditions. Adjust potentiometer P114 so that the DVM reads approximately 2. reassemble the scanner assembly and reinsert it in the guide pipe. FLAME SCANNER CABLE This is a 1. Annealed. Completely block all light from the furnace end of the fibre-optic cable and open the scanner housing. The power supply switch should be turned on.1V. This completes the scanner head electronics adjustments. 9.000 V on the DVM. Reconnect the scanner cable to the scanner assembly.000 V on the DVM. then reconnect the scanner cable. Work under a dark cloth to reduce he amount of ambient light admitted to the scanner head.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. feedback LED is installed on the scanner head electronics card adjacent to photodiode. should have a similar intensity meter reading. All four scanner channels. under dark furnace conditions. Copper Conductor. Disconnect the test leads.BHELSCAN O & M MANUAL NEW PARLI TPS electronics card. 8. Turn the scanner power supply “on” and adjust potentiometer R101 to provide a reading of 0.mm. Connect a digital voltmeter (DVM) between the signal C and common D terminals on the electronics card. reconnect the photodiode and proceed with the dark furnace bias adjustment.. Replace the 1 mA dc current source with a 1 µA source and adjust potentiometer R103 to provide a reading of 1. 9.BHELSCAN O & M MANUAL NEW PARLI TPS Tape Shielded with Drain Wire. Elastomeric / Thermoplastic/Equivalent material Over all Sheathed Cable. Second Pair Æ Green & White This Pair is used to connect Signal to Amplifier. Colour Code for Core/Pair :First Pair Æ Red & Black This Pair is used to connect Power Supply to field.1 MAINTENANCE AND TROUBLE SHOOTING : Scanner Head : Page 24 of 26 BHELSCAN O&M MANUAL . Over all Aluminium Backed Mylar Tape Shielded with Drain Wire. 9. 2 such pairs laid up. 9. the plant operating characteristics and the cleanliness of the cooling air. if necessary. An inspection program should be established. check whether lamps in the power supply module corresponding to AC power ON. based on operating experience. slag may eventually build up and cover the opening. then check the continuity of flame scanner cable connection between the terminal block and the head electronics in the field. +15V ON and +5V ON. If continuity is also alright. then head electronics may need recalibration or replacement. The scanner head should be inspected periodically and cleaned. the best way to troubleshoot the system is to substitute modules in the card rack assembly and/or head electronic modules.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. If the fuses are healthy. If the fuses are alright and still any one of the above DC voltages are not present.3 Electrical Components : The electronic modules do not require periodic maintenance. In flame processor module.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. check the corresponding fuses at the rear side of the power supply module. Modules are to be inserted only in the slots designated for them. If this lamp is ON. Always check the shield and lens when the scanner head is inspected. For any Page 25 of 26 BHELSCAN O&M MANUAL . check the fuses corresponding to +15V and –15V feeding to head electronics in the processor mother board. With certain types of coal. an inspection program should be established based on operating experience. Hence. fault lamp should be OFF. power supply module has to be replaced. If trouble does occur. If the DC supplies are not ON. -15V ON. If AC power is not ON. If the scanner chassis is not working. check the fuse F01 in the power supply mother board and the incoming AC power. 9. If this fault persists even then. etc. If the fault lamp is ON. 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. Do not insert or pull out any module from the connector when power is ON. the module is to be replaced.BHELSCAN O & M MANUAL NEW PARLI TPS other fault in this module like no response for mode selection PB.. the fault lamp should be OFF for normal operation. this fault may vanish. If any module has to be removed for examination or changing the settings. Then remove or insert the module and then switch ON the toggle switch SO1 if needed to power up the system. 2/4 flame module may need replacement. This may damage the module. then fault lamp in any one or more of the flame processor modules may be ON. If that module is attended. In 2/4 flame module. Page 26 of 26 BHELSCAN O&M MANUAL . improper display. . . . . . . 6B BHELSCAN – GENERAL ARRANGEMENT .Figure . . . 7B BHELSCAN –FLAME PROCESSOR MODULE AC gain pot.Figure . Set value AC gain pot.(Coal) Intensity pull in Coal freq. Set value Intensity pull out Oil freq.(Oil) . . 8B BHELSCAN –2/4 MODULE 2/4 Relay Fault Relay .Figure . . Figure .9C BHELSCAN –POWER SUPPLY MODULE (REAR VIEW) .9B BHELSCAN –POWER SUPPLY MODULE (FRONT VIEW) Figure . . . . . . FIGURE 11D:BHELSCAN – TB ARRANGEMENT (REAR MOUNTING) .