FLAME MONITOR FOR MULTI BURNER CONTROL

(New Generation Flame Monitoring System)

03B2
Application:

Flame monitors can warn when the flame is below the adjusted standard , if the
flame is well , and if the flame exists or not in different forms with appropriate
flame electrodes.
The main purpose of the production of the 03B2 Flame Monitors is to determine the
presence of the flame in low capacity , atmospheric and excess air burners which are
being used in most fields of the industry.
03B2 Flame monitor can fix the problems very easily with two , three or four
flame signal inputs where heat distribution needs to be equal or where multi burner
using is needed and burners cannot ignite each other.
As seen in Drawing 2 , the number of the burners that will be controlled can be
increased very easily by making a serial connection with other 03B2 flame monitors
with the signal output of 03B2.
Picture 1: 03B2 Front View

Application Fields :

 Flame control in multi burner systems,

 Flame monitoring in half automatic combustion systems,
 Providing “Flame On” or “No Flame” signal to PLCs ,
 Multi flame monitoring in control of a burner programming relay ( ERA-01G… or equivalent)

New Features of 03B2 Flame Monitor :

03B2 Flame monitor is the new version of 03B1 Model which has been used in different kinds of industrial fields since 1990.
Since 03B1 Models are produced with semiconductor materials , 03B2 models are produced with microprocessors to be more
suitable fort he improving technology. The subbase connection is the same as the old versions and easy access menus are
added to be more user friendly :
* Easy configuration with programming button ,
* “Power On” or “Operating Normally” message on the display which is located in the front ,
* Delay Adjustment for output relay while switch on and off ,
* Zone numbers can be programmed as 2 - 3 – 4 ,
* Limited Precision adjustment where flame perception can be a problem .

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Structure of 03B2 Flame Monitor:

03B2 Flame Monitor consists of; power supply ,microproccesor that commands electronical flame monitoring current , main
flame relay that has double pole – double direction free circuit output , four lamps that are integrated to the electronical
circuit which are turned on depending on the presence or intensity of the flame , one digit 7 mm. red display and outer box.
The outer box is manufactured from heat resistant plastic , and there are two membrane buttons that is used for
porgramming.

Operation : Electrical connections of 03B2 can be seen in the schemes section . When 220 VAC voltage is

connected to the terminal no 1 and neutral is connected to the terminal no 2 , “0” message is seen on the display. If
you have not specified the operation system when ordering , you can make the configuration yourself. Please see
programming menü for the configuration!
If you have connected the same amount of electrodes to the monitor as the selected channels , ionisation electrodes
should be able to sense the flame in set norms. The warning lamp of the related channel on the outer box turns on
when the flame on information comes to the channels selected . Approximately 500ms. after all the channels got the
flame on information , the main relay inside 03B2 turns to “ON” position and at the same time letter “F” displays on
the screen. Terminal no 4 and 5 are free circuit outputs as seen in the Drawing 2 . When the main relay turns on you
can get rectified signal output from terminal no 3 ; this signal output should be connected to the ionisation electrode
input of the control unit which you would like to use as seen in Drawing 5. When the sensing of flame is cut from any
of the ionisation electrodes , signal output will also be cut ; “0” message will be displayed , and at the same time ,
connected lamp in front of the monitor will turn off.

Ionisation Electrodes : 03B2 Flame Monitors are suitable for operating with gas fueled burners with

ionisation electrodes. In some cases , it can also operate with UV photocells which have low operating current
rectification outputs . Gas flame generates a rectified line between the grounded burner and ionisation electrode. In
this condition current rectifying effect of the flame and electrical conductivity principle is used. Drawing 4
When the flame is formed far from the burner tube flame electrodes cannot work. Flame detector that is used for
ionisation current , is a high end steel wire , coated with a few mm.s aluminium oxide. It should have porcelain or
similar outer casing which has more than 50Mega Ohms of isolation resistance.
When the flame is formed far from the burner tube , ( in this condition ions won’t occur since the
burner is not grounded ) when the burner tube is made of non-conductive material (refractory etc..) the flame should
be grounded by using a second electrode as seen in Picture 3.

Picture :4 Equivalent current scheme for flame

Picture : 3 Secondary electrode mounting for burners
with refractory head or non-grounded flame

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03B2 Programming :

03B2 Flame Monitors are as standard, supplied as shown below if not informed otherwise while ordering.

 Flame Input : All channels are open and ready for use for 4 zone burners .
 Flame Detection Precision : Set as 3 for all zones.
 Flame detection duration : 1 Second
 Duration before cut – Off after : 1 Second
Flame disappears

User , may programme 03B2 Flame Monitor by himself. To programme the monitor , first electrical connections should be
made correctly. Drawing:2

If power and neutral are reverse connected

FS1… FS4 : Iyonizasyon Elektrotları Ters the monitor won’t work..

L : 220 VAC Supply Voltage

N : Neutral
L1 : Free Circuit Output
R : Fuse (2 Amp)
S1 : Signal Output

Drawing 2 : 03B2 4 Channel Standard Electrical Connection

220 VAC should be connected to Terminal No 1 and Neutral should be connected to Terminal No 2 of 03B2 Flame Monitor.
Flame sensing electrodes can not operate if power and neutral are reversed. “0” message will be displayed on the screen
when power is sent to the monitor. According to the burner quantity , requested channels can be made active. To make
the channel choice , follow the instructions below :

Channel 1 can not be active single in 03B2 Monitors , minimum channel number should be two.

Choosing Channels According to Burner Quantity:

When you push Up and Down buttons at the same time for 5 seconds , the number of
channels which are set before , will display on the screen. (2 – 3 – 4)
The red dot located on the right bottom side of “0” message will flash while programming.
If you do not make any changes , the programme will turn back.
The programming is complete when you set the number of channels you will operate by
Up and Down buttons .
To make the channel choice
push Up and Down buttons together.

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Connecting Flame Electrodes :

Be sure that the power is Off BEFORE connecting the sensing electrode cables.

The cables between electrodes and 03B2 monitor , should be heat resistant and should have high insulation resistance. The
silicone + silicone cables resistant to 170 ºC which are used in high voltage ignition transformers can be suitable. The
connection between electrode and monitor should be seperate from the high voltage cables.
The burner bodies should be grounded. Otherwise , while operating , flame on information will not come to the monitor. The
reason for grounding the burner body was explained in page 2 , ionisation electrodes section. If the flame electrodes are
connected in order according to the channel numbers you chose , 03B2 monitor is ready for operation.

You can see the front panel of a monitor with two active channels on the left .
Letter “F” will be displayed on the screen when ionisation electrodes send
Flame on information and related channels lamps will turn on , on the front.
At the same time , the monitor will release Terminal no 3-4-5 control output
signals free.
There are many reasons if flame on information cannot be transmitted to chosen channels of
03B2 monitor even flame is occurs in the burners .
Some of the reasons can be : the grounding of the burner can be unsufficient
or not correct , the flame can occur far away from
the burner head , the mounting of the
electrode can not be correct , etc.
Please see application notes for other
possibilities!

Drawing 6: Two Zone Connection

Except the explanations about the negative issues above you can upgrade 03B2 monitor as explained
in “Supporter Programs” section.

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Supporter Programs :

Precision Adjustment :

You can increase the precision for the sensing problem when there is not enough ionisation generation in burner flame or when
there is decayed signal in the wires which transmit the flame information .
Precision adjustment limit is minimum “0” and maximum “9” . Please see corresponding uA. for ON-OFF of 03B2 below !

0 Precision = 2.1 uA. ON. / 1.9 uA. OFF

9 Precision = 0.8 uA. ON. / 0.5 uA. OFF

Please do every possible adjustment for better burner flame to the authorised personelle BEFORE adjusting
the precision. Do not increase the precision level unless you are obliged to.
To adjust the precision when needed , first push the up button , while still pushing up
button , push down button at the same time , wait 4 seconds and adjust a setting between
0 to 9 by up and down buttons.

Time Adjustment for Flame Information Output:

03B2 Flame Monitors are supplied , 1 second pre-delay and 1 second last-delay as default.

Pre-Delay :

It is the time that passes from the detector senses the flame to monitor gets “Flame On! = F “ command. Flame monitor will

ignore the flame during this time.

 Pre-Delay Adjustment : Push button on the monitor for 4 seconds , than release the button and set a value
between 0-9 by pushing the buttons.
0 = 0 ms. ; 9 = 4 Seconds

Last Delay :

It is the time that permits “Flame On” command even the detector does not detect a flame for some reason during normal
combustion. 03B2 Monitor will behave as the flame exists even the flame does not exist .

 Last Delay Adjustment : Push button on the monitor for 4 seconds , then release and set a value between 0-9
by pushing the buttons .
0 = 0 Second / 9 = 4 Seconds

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1- Pre-Delay adjustment should be made according to the structure of the process. It pretends the process to stop because
the detector electrode would be affected by short time , wrong or irregular flame
2- Last delay adjustment should be made according to the structure of the process. If there is flame control relay connected
to the flame monitor , the adjustment should be made according to the failure time of this relay ; because last delay time of
the monitor , will add to the failure time of the control relay.For example; if the failure time fort he control relay is 5 seconds ,
03B2 output will be cut off during the time you set for last delay time. This is very important.This means the fuel valve will stay
open even the burner has no flame. Last delay time is mostly for preventing the process to stop unnecessarily when the
detector can be affected by flame vibrations and air swirling.

Electrical Connection Schemes:

If all 4 inputs of 03B2 Flame Monitor is active , you can add one more zone and have 5 separate flame inputs as seen in
Drawing 7. In the drawing below : the information coming from FS5 flame electrode is connected to terminal no 4 of 03B2
monitor , when the flame information coming from other FS1..FS4 electrodes is perfect enough , information from terminal no
5 of the monitor will go to detector input terminal No 11 of control relay
( For example:01G..Series relays) . If the information between FS1…FS5 is cut off for some reason , control relay will close all
the outputs and will send an error info.

AL : Error lamp for control relay

EK : Reset button for control relay
BR : Burner
FS1…FS4 : Flame electrodes
FS5 : Additional flame electrode
L : 220 VAC. Supply
N : Neutral
PS : Pressure or temperature switch
R : Fuse (2Amp for monitor)
S1 : 03B2 Flame info output
V1… V2 : 1 & 2 Valves
Z : Ignition Transformer

Drawing 7 : 5 zone Operation connection for 03B2 and Control Relay

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 Drawing : 8 shows flame control system
for 12 burners. As seen in the drawing ,
serial connection of 1 burner output
allows controling all the burners.
The output information of the last
monitor should be connected to the ionisation
ionisation input of the burner control unit!
The monitors can be made min of 2
channeled and also 3 or 4 channelled
depending on the requested zones.

Technical Information :

Operation Voltage :220 / 240 VAC.

% -15 + 10
Frequency : 50 – 60 Hz. % 5
Power Consumption: 5 VA ( Approximately)
Detector Current : > 1 uA (Each Channel)
Curcuit Current : 2 Amp. Max. Cos.0,6
Wire Distance : 20m Max.(Sheilded)
Flame Signal OFF : Can be adjusted
between”1” and “5”
(curcuit closing time)

Environment Temp : - 5 + 60 ºC Max.

Mounting Position : Optional
Protection Class : IP 50

Outer Box Dimensions (mm. )

Drawing 8 : Control Scheme for 12 Zone combustion system

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Application Notes :
• The cables for detector should not be longer than 20 meters.

• Detector cables should be seperate from high voltage ( ignition transformer) and other control cables.

• The cables for detectors should have high conductivity capacity and isolation resistance.

• The resistance between detector electrode wire and isolation porcelain should not be less than
50 MΩ.

• The isolation porcelain should not be dirty or cracked. Dirt or vapor can pile up in these cracks and results as
isolation resistance and flame signal level to decrease .

• In excess air burners , too much of excess air will cause the electrones on the electrode to slide and poor air
will prevent the sufficient electrones to be generated in the combustion process , so the burner adjustment in
these systems should be done very carefully and correctly.

• Ionisation electrodes cannot be used where the flame does not touch the burner head sufficiently. (In this
condition the permeability between the flame and the burner is not sufficient. For refractory headed burners ,
grounding electrode should be used additional to UV photocell or detector electrode. The surface of the
electrode which will be used for grounding should be larger than the ionisation electrode.

• The surface of Ignition electrodes should have high alumina and should have perfect outer glazing.Otherwise ,
high frequency ignition tranformers can pierce the ceramic and arc to the burner. Burner body should be
grounded unconditionally.

 Detector electrode should be mounted as far as can be from the ignition electrodes

• If there is interference because of one electrode combustion system , relocating the terminals of the ignition
transformer generally works.

In short flames , ionisation flow

will be mostly generated near the flame
edge points.

Drawing 9: Ionisation electrode connection

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