1

BHARAT HEAVY ELELCTRICALS LIMITED

HIGH PRESSURE BOILER PLANT
TIRUCHIRAPPALLI-620 014.

Operation & Maintenance Manual

of
BHELSCAN
FLAME SCANNER SYSTEM (BN10)

BHARAT HEAVY ELELCTRICALS LIMITED, HIGH PRESSURE BOILER PLANT

(Controls and Instrumentation / Fossil Boilers), Tiruchirappalli - 620 014, INDIA
Phone: 91 (0431) 257 5218, 257 5027

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 BHELSCAN O & M MANUAL

CONTENTS

Section 1 INTRODUCTION
Section 2 SYSTEM SPECIFICATION
Section 3 MECHANICAL COMPONENTS
Section 4 COOLING AIR REQUIREMENTS
Section 5 ELECTRICAL COMPONENTS
Section 6 DESCRIPTION OF MODULES
Section 6.1 FLAME PROCESSOR MODULE
Section 6.2 2/4 OUTPUT MODULE
Section 6.3 POWER SUPPLY MODULE
Section 6.4 SCANNER HEAD ELECTRONICS
Section 7 COMMUNICATION INTERFACE
Section 8 INSTALLATION AND START UP PROCEDURES
Section 8.1 MECHANICAL COMPONENTS
Section 8.2 COOLING AIR
Section 8.3 ELECTRICAL COMPONENTS
Section 8.4 SYSTEM OPERATION TEST
Section 8.5 DIP SWITCH SETTING PROCEDURES
Section 8.6 CALIBRATION OF SCANNER HEAD ELECTRONICS
Section 9 FLAME SCANNER CABLE
Section10 MAINTENANCE & TROUBLESHOOTING
Section 10.1 SCANNER HEAD
Section 10.2 FIBRE OPTIC CABLE
Section 10.3 ELECTRICAL COMPONENTS
Section 11 LIST OF FIGURES

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 BHELSCAN O & M MANUAL

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
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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 BHELSCAN O & M MANUAL

Section 1 – INTRODUCTION
The prime output of flame sensing
The microcontroller based flame system is called the “two out of four flame
sensing system is designed primarily for ON” for coal, when two or more than two
use on coal fireball and stable oil flame coal flame in an elevation is detected and
ignited by high energy arc (HEA) ignitor. It “individual flame ON” for oil. The output is
senses the visible light given off by the represented by the positioning of a set of
flame and can recognize a coal/oil flame by form C contacts (break before make). A
its characteristic fluctuations. current signal is also available to indicate
the individual flame intensity corresponding
The system consists of a fibre-optic to each corner. RS232C serial output is
connected scanner head assembly and a available for computer/DCS connectivity.
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
(Figure-1). Refer to the respective project
wind box arrangement drawing to
determine the location of scanner head
assy. in the system.

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 5

Section 2 – SYSTEM SPECIFICATION

Specifications

Input signal : 0 to 2mA AC from Head BHELSCAN comes in two versions - one
Electronics with terminal blocks for field

Signal : 4 Microcontroller interconnection fitted in the front; another

Processor Modules for 1 elevation with terminal blocks fitted in the back

2/4 Processor : 2/4 logic detection & fault side. Version with TB fitted in the front is

alarm recommended for panels in which

Programmable : Pull in, Pull out, BHELSCAN rack assemblies fitted has

Parameters Flicker frequency for oil, only front doors and no back doors

Flicker frequency for coal provision. Version with TB fitted in back

is recommended for panels having back
Display : 2 ½ digit LED display
doors also. All other components are
Display mode : By Push button
same for both versions.
selection
Parameter : 4 x 8 bit DIP switch
setting
Communication : Serial interface
Enclosure : 19” Rack with 3U size cards

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 BHELSCAN O & M MANUAL

Section 3 – MECHANICAL COMPONENTS

The complete mechanical assembly COMPRESSED TO ITS MINIMUM

is comprised of a stationary part, called the LENGTH WHEN THE WIND BOX IS AT
“flame scanner guide pipe assembly” and a ZERO (HORIZONTAL) TILT. IF A
removable part, called the “flame scanner SCANNER GUIDE PIPE IS FIELD-
assembly”. INSTALLED, BE SURE IT IS MOUNTED
IN THE SAME MANNER TO PREVENT
3.1 Flame Scanner Guide Pipe DAMAGE TO THE FLEXIBLE HOSE AND
Assembly CONNECTIONS WHEN THE NOZZLE IS
TILTED THROUGH ITS RANGE. ANY
The flame scanner guide pipe
RADIUS OF CURVATURE GREATER
assembly consists of a scanner head
THAN 18-IN MAY BE UTILIZED AS LONG
housing, a flexible metal hose, a rigid guide
AS ITS CROSS SECTION IS CIRCULAR
pipe section, a cooling air manifold and a
AND DOES NOT RESTRICT FREE
cover plate.(Figure –2)
MOVEMENT OF THE SCANNER HEAD
WITHIN THE CURVED PORTION.
Guides inside the housing center
the scanner head and provide a uniform
The guide pipe is normally fixed in
passage for the external cooling air. The
the wind box front by means of a packing
end ring in the housing forms a mechanical
gland. The cooling air manifold is
stop for the scanner head. The flexible
screwed (NPT) onto the guide pipe. The
hose assembly and the flexible guide pipe
cooling air manifold is drilled and tapped
adapt the scanner to the tilting of the wind
to accept a flexible hose connection at its
box nozzle and angle mounting. The
cooling air inlet and has an opening for
flexible hose is brazed to the guide pipe
the flame scanner head assembly. The
and scanner head housing.
scanner opening must be closed with the
cover plate when the assembly is
CAUTION
removed for maintenance.

WHEN SCANNER ASSEMBLIES ARE

SHOP-INSTALLED, THEY ARE
MOUNTED WITH THE FLEXIBLE HOSE

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 BHELSCAN O & M MANUAL

reason to disassemble the scanner head

3.2 Flame Scanner Assembly
assembly, except to clean the collimator
shield (see the “Maintenance and Trouble
The flame scanner assembly has
shooting” section of this manual).
four sections similar to those found on the
flame scanner guide pipe. There is a flame
The scanner housing couples the
scanner head assembly, flexible metal
flame scanner assembly to the guide pipe
hose, rigid pipe and the scanner housing
and contains the electronics for
assembly.
conditioning the fibre-optic-transmitted
signal.
The flame scanner head assembly
(Figure - 3 ) consists of the scanner head
A weatherproof disconnect coupling
body, which contains the collimator tube
is provided to conveniently connect
and shield, the collimating lens and barrel,
external wiring. A hexagon adapter adapts
a mounting plate, a compression spring,
the connector to a ½ in. pipe thread.
one end of the fibre-optic and a plug.
Sealtite flexible hose or a similar
weatherproof conduit should be used
The fibre optic cable is installed in
between the disconnect coupling and the
the flexible metal hose and rigid pipe
rigid conduit leading from the wind box
sections. It transfers the visible light flame
assembly.
signal from the lens to the photodiode
mounted in the scanner housing assembly.
The flame scanner head assembly can be
assembled in the following manner :
When the scanner assembly is
inserted in the guide pipe, cooling air from
1. Slip fit the collimator tube and
the cooling air manifold enters the scanner
shield assembly into the scanner
housing through two holes. This air flows
head body and hold it in place with
down the rigid pipe and flex metal hose to
a single Allen head screw. Using
cool the fibre-optic cable. Air is discharged
spacers, position the shield on the
into the furnace through the scanner head
collimator to a allow cooling air to
body and collimator tube. No seal gaskets
flow through the head assembly.
are required in the scanner head assembly
(Figure – 4).
because of the pressure differential
between the cooling air inside the scanner
and the furnace. There should be no

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 BHELSCAN O & M MANUAL

NOTE
A wind box structure will sometimes 3. Lock the mounting plate to the lens
restrict the location of the guide pipe barrel with the jam nut.
scanner head housing. To permit the 4. Insert the lens barrel in the scanner
scanner to see the flame, a prism may head body until the mounting plate
be installed in place of the collimator rests against the stop pins.
shield. Use care when placing the 5. Insert the compression spring and
scanner in the guide pipe to assure plug. Three socket head screws hold
proper orientation of the scanner head the plug in the scanner head body.
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.

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Section 4 – COOLING AIR REQUIREMENTS

The external cooling air passes temperature measured at the scanner air
through the guide pipe, the flexible hose booster fan inlet). Air manifold pressure at
and the annulus between the scanner head the scanner guide pipe must be
and housing. The air is discharged into the 150mmwc.(g). above furnace pressure for
furnace at the top of the scanner head, all operating conditions. After shutting
thereby removing any heat picked up by down the unit, scanner cooling air must be
the scanner from the hot combustion air. maintained until furnace conditions are
The scanner head should not be exposed such that the scanner assembly cannot
to a continuous temperature above 300°F overheat. Shut off valves must not be
without cooling air. installed in cooling air lines to the
scanners.
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 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 120°F (maximum

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Section 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 2½ digit LED display in the front
facia of flame scanner module
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BHELSCAN O & M MANUAL
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.
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
BHELSCAN O&M -2

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
Section 6 – DESCRIPTION OF MODULES
The flame scanner card rack assembly
consists of the following modules:
1. Flame processor - 4 Nos.
module
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
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BHELSCAN O & M MANUAL
changeover contact output for system fault.
Description of the various modules are
given in the following sections:
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 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
BHELSCAN O&M -2

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. ∗)
∗ - Adjustable at site.
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.
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
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BHELSCAN O & M MANUAL
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
BHELSCAN O&M -2

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.
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
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BHELSCAN O & M MANUAL
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
BHELSCAN O&M -2
 BHELSCAN O & M MANUAL

through potentiometers R101, R103. This or dark furnace conditions. This feedback
voltage signal is converted to current signal loop is the key circuit in the electronic fault
(0 – 2.0 mA) for transmission to flame detection scheme. The light emitted by the
processor module. feedback LED is adjusted by R114
A feedback LED is mounted in the potentiometer during calibration at
photo diode holder, to avoid the saturation laboratory / factory.
of log amplifier in the event of very low light

Section 7 – COMMUNICATION INTERFACE

Serial communication (RS232C) a . Intensity set value

output is provided in each BHELSCAN b . Pull in set value
covering four corners of one elevation. C . Pull out set value
Terminal block (TB5) in system mother D . Frequency 1 (coal) set value
board has 3 terminals viz. 10, 11, 12 for E . Frequency 2 (oil) set value
Transmit (Tx), Receive (Rx) and ground.
F . Actual frequency of flame 1 (coal)
Prepare a cable (2 pair twisted 0.5 Sq.mm
G . Actual frequency of flame 2 (oil)
shielded cable) with one side soldered to 9
H . Fault status
pin D type connector suitable for inserting
i . Flame 1 status
into COM1 or COM2 serial port of personal
computer and connect the other side to
Load and run the PC2Scanner.exe
these terminals. The 2/4 output module
programme supplied with the system. This
periodically interrupts each flame scanner
program will display the following :
and collect the following data. This data
will be communicated via serial output
Baud Rate = 9600
approximately once in a second.
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. Communication will be
established and PC will display the
following corresponding to 4 corners.

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15

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.

Section 8 – INSTALLATION AND START-UP PROCEDURES

coupling and the rigid conduit. The flexible

8.1 Mechanical Components
hose should be long enough (4 or 5 ft) to

Make sure the Safe Scan head assembly withdraw the scanner from the guide pipe

is properly inserted in the flame scanner without disconnecting the coupling.

guide pipe assembly and that sufficient 8.2 Cooling Air

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 ½-in. pipe
thread attachment. Sealtite flexible hose
or a similar weatherproof conduit should be
used between the quick-disconnect
CAUTION
THE SCANNER HEADS MUST BE
COOLED WHENEVER THERE IS A FIRE
IN THE FURNACE OR THE BOILER
INTERIOR IS ABOVE 300ºF. A COOLING
AIR SYSTEM MUST BE PROVIDED AND
CHECKED OUT BEFORE THE BOILER IS
LIT OFF.

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 BHELSCAN O & M MANUAL

On balanced draft units, the cooling air for

8.3 Electrical Components
the scanners is frequently supplied by a
separate fan and piped to the scanner
Input and output connections to the flame
cooling air manifolds. The scanner cooling
scanner card rack assembly are to be done
air supply is taken from the forced draft
as per the Flame scanner interconnection
(FD) fan discharge duct in combination
diagram Figure – 11A and as per the
with combustion air to the ignitors. In this
following table: (Also refer for detailed TB
case an emergency damper, a low air
wiring, Figure –11B for front mounted TB
pressure switch, a high air pressure switch
version & Figures – 11C & 11D for rear
and a scanner fan are also provided. The
mounted TB version )
scanner fan starts when the air pressure
gets too low, usually at 6 in. w.g.
Power supply mother board
Most air systems are supplied with air
filters between the scanner fan and the TB Terminal DESCRIPTION
cooling air manifold. A differential pressure No. No.
gauges and switches to actuate an alarm TBP1 1 Phase (230V or 110V
are installed across the filter to provide as given in the name
information on filter condition. Filters plate)
should be checked periodically for TBP1 2 Neutral
cleanliness. TBP1 3 Earth

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.

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Processor mother board

TB No. 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.
TB1 – Corner 1 6 Flame-2 relay contact - 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 - 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.
TB2 – Corner 2 6 Flame-2 relay contact - NO NO
TB2 – Corner 2 7 Flame-2 relay contact – common COM
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- 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.
TB3 – Corner 3 6 Flame-2 relay contact - NO NO
TB3 – Corner 3 7 Flame-2 relay contact – common COM

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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 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.
TB4 – Corner 4 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 COM
TB5 9 No connection
TB5 10 Transmit TX
TB5 11 Receive RX
TB5 12 Ground GND

Page 18 of 25 BHELSCAN O&M -2

19

6. Whenever the power is switched ON,

8.4 System Operation Test
the display will show the intensity. The
corresponding IN LED will glow.
After installation is completed, the following
7. The display mode can be changed by
tests can be done to verify proper
momentarily pressing and releasing the
operation of the system:
MODE PB (square PB).
8. The following display modes are
1. At one channel, disconnect the signal
available.
wire from the terminal block. With the
1. IN – intensity
power switch in ON position, the
2. PI-Pull in set value of intensity
intensity display should show input
3. PO-Pull out set value of intensity
open by flashing 100%. The channel
4. F1- coal frequency set value
fault light should be ON and the system
5. F2-oil frequency set value
fault light in 2/4 module should be ON.
6. AF & F1- actual frequency of coal
2. Reconnect the signal wire to the
7. AF & F2- actual frequency of oil
terminal block. The corner fault light
9. Select PI mode. The display should
now should be OFF. The system fault
read the pull-in set value in %.
alarm light in 2/4 module should also
Similarly, change the modes and verify
go OFF if none of the other corners
the other values as shown from 8.2 to
indicate fault. The intensity display
8.5 above.
should return to a normal indication.
10. Press mode PB again momentarily.
3. Repeat step 1 & 2 for all channels.
Now, LEDs corresponding to AF and
4. During furnace OFF condition, the
F1 both will glow simultaneously. The
display corresponding to all corners
display reads the actual coal frequency
shall show ‘00’ to indicate the dark
(F1).
furnace condition.
11. Press mode PB again momentarily.
5. If any power supply wire is cut or any
Now, LEDs corresponding to AF and
short circuit in the signal wire to
F2 both will glow simultaneously. The
ground, then the display will show ‘00’
display reads the actual oil frequency
flickering. The fault LED will glow.
(F2).
Switch OFF the power supply and
12. To change the set values of ‘IN’, ‘PI’,
check the wire continuity. This
‘PO’, ‘F1’ and ‘F2’ if needed, refer
condition shall be set right, before
“parameter setting procedures” given
proceeding further.
above.

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13. During boiler operation, the “Flame1” e. Oil frequency is less than F2 set value
LED in respective corner processor OR
module will be ON when the following f. Any fault conditions exits. (Fault LED
conditions are met. ON)
a. Flame intensity is more than PI set 15. 4-20 mA current output is available
value AND corresponding to 0 – 100% of flame
b. Coal frequency is more than F1 set intensity in respective corner at TB
value AND Nos. 9 & 10. If any fault condition
c. No Fault condition exists (Fault LED exists, (Fault LED ON), this current
OFF) output will go to 4 mA irrespective of
Flame1 LED will switch OFF, if any the intensity level shown in display.
one of the following conditions is met. 16. The 2/4 Flame LED indication in 2/4
a. Flame intensity is less than PO set flame module represents the presence
value OR of fireball during coal firing. This LED
b. Coal frequency is less than F1 set will be ON, whenever, two or more
value OR corner’s “Flame1” (coal flame) show
c. Any fault conditions exits. (Fault LED flame. The relay outputs in two sets of
ON) contacts are available at TB Nos.1,2&3
14. During boiler operation with oil, the and 4,5 & 6 of TB5.
“Flame2” LED will be ON when the 17. If any fault LED is ON in any of the
following conditions are met. The processor modules, Fault LED in 2/4
relay output is available at TB Nos. module will be ON. The Fault relay will
6,7 & 8 in the respective corner. get energized. The relay output is
a. Flame intensity is more than PI set available in TB Nos. 7&8 of TB5.
value AND 18. RS232-C serial communication output
b. Oil frequency is more than F2 set is available at TB Nos.10, 11 & 12 in
value AND TB5. This can be used to communicate
c. No fault condition exists. (Fault LED the flame parameters to Personal
OFF) Computer.
Flame2 LED will switch OFF, if any
one of the following conditions is met.
d. Flame intensity is less than PO set
value OR

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21

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: 8 7 6 5 4 3 2 1
Setting status OFF OFF ON OFF ON OFF 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.
DIP switch position: 8 7 6 5 4 3 2 1
Setting status OFF OFF OFF ON ON ON ON OFF

Locate S3 DIP switch as shown in Figure – 7B for coal frequency set value. Set ‘05’ by
keeping the individual switch as below.
DIP switch position: 8 7 6 5 4 3 2 1
Setting status OFF OFF OFF OFF OFF ON OFF ON

Locate S4 DIP switch as shown in Figure – 7B for oil frequency set value. Set ‘30’ by
keeping the individual switch as below.
DIP switch position: 8 7 6 5 4 3 2 1
Setting status OFF 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.

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8.6 Calibration of Scanner (DVM) between signal “C” and common

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
potentiometers and dark furnace bias will
be required.
8.6.1 Calibration of Scanner
Head Electronics
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 µA dc current source (1V dc in
series with a resistor; 1M, 1/8W, 1%)
d. Small soldering pencil
Disconnect the positive lead
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
“D” terminals on the electronics card; then
reconnect the scanner cable. Turn the
scanner power supply “on” and adjust
potentiometer R101 to provide a reading of
0.000 V on the DVM.
offset
Replace the 1 mA dc current source with a
1 µA 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
of 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.

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Connect a digital voltmeter (DVM) between approximately 2.1V. This completes the
the signal C and common D terminals on scanner head electronics adjustments.
the electronics card. Disconnect the test leads, reassemble the
scanner assembly and reinsert it in the
Reconnect the scanner cable to the guide pipe.
scanner assembly. The power supply All four scanner channels, under dark
switch should be turned on. Work under a furnace conditions, should have a similar
dark cloth to reduce he amount of ambient intensity meter reading.
light admitted to the scanner head. Adjust
potentiometer P114 so that the DVM reads

Section 9 – Flame Scanner Cable

This is a 1.3 sq.mm., Annealed, Tinned, Colour Code for Core/Pair :-
Copper Conductor, Elastomeric/ First Pair Æ Red & Black
Thermoplastic/Equivalent material This Pair is used to connect Power Supply
Insulated, Twisted pair, Aluminium Backed to field.
Mylar Tape Shielded with Drain Wire, 2 Second Pair Æ Green & White
such pairs laid up, Over all Aluminium This Pair is used to connect Signal to
Backed Mylar Tape Shielded with Drain Amplifier.
Wire, Elastomeric /
Thermoplastic/Equivalent material Over all
Sheathed Cable.

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 BHELSCAN O & M MANUAL

Section 10 - Maintenance And Trouble Shooting

10.1 Scanner Head : 10.1 Electrical components

The scanner head at the front of The electronic modules do not

the fibre-optic scanner assembly has an require periodic maintenance. If trouble

opening for viewing the flame. With does occur, the best way to troubleshoot

certain types of coal, slag may eventually the system is to substitute modules in the

build up and cover the opening. The card rack assembly and/or head

scanner head should be inspected electronic modules. Modules are to be

periodically and cleaned, if necessary. inserted only in the slots designated for

Hence, an inspection program should be them.

established based on operating If the scanner chassis is not

experience. working, check whether lamps in the

power supply module corresponding to
AC power ON, -15V ON, +15V ON and
10.1 Fibre optic cable
+5V ON. If AC power is not ON, check
the fuse F01 in the power supply mother
The collimator shield and the lens
board and the incoming AC power. If the
on the end of the fibre-optic cable should
DC supplies are not ON, check the
also be inspected periodically for
corresponding fuses at the rear side of
cleanliness. The degree of fouling will
the power supply module. If the fuses
depend on the type of fuel used, the plant
are alright and still any one of the above
operating characteristics and the
DC voltages are not present, power
cleanliness of the cooling air. An
supply module has to be replaced.
inspection program should be
established, based on operating
In flame processor module, fault
experience. Always check the shield and
lamp should be OFF. If this lamp is ON,
lens when the scanner head is inspected.
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

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 BHELSCAN O & M MANUAL

flame scanner cable connection between vanish. If this fault persists even then,
the terminal block and the head 2/4 flame module may need replacement.
electronics in the field. If continuity is
also alright, then head electronics may Do not insert or pull out any

need recalibration or replacement. For module from the connector when power

any other fault in this module like no is ON. This may damage the module. If

response for mode selection PB, any module has to be removed for

improper display, etc., the module is to examination or changing the settings, it is

be replaced. safe to switch OFF the power by

operating the toggle switch SO1 in the
In 2/4 flame module, the fault power supply mother board and wait till
lamp should be OFF for normal all the lamps in the power supply module
operation. If the fault lamp is ON, then go OFF. Then remove or insert the
fault lamp in any one or more of the module and then switch ON the toggle
flame processor modules may be ON. If switch SO1 if needed to power up the
that module is attended, this fault may system.

Page 25 of 25 BHELSCAN O&M -2