SmartScan Manual Issue 2.5

Hamworthy Combustion Engineering Ltd SmartScan 121
SmartScan® 121
Flame Scanning
System
Hamworthy Combustion Engineering Ltd

Fleets Corner
Poole
Dorset
England
BH17 0LA
Tel +44 (0)1202 662700
Fax +44 (0)1202 665333
Manual Reference: 3439017/040 15-10-00
Page 1 Issue 2.5 Dated 09-04-09

Table of Contents.
Common Abbreviations. ............................................................. 3

Commissioning....................................................24
Dismantling the Amplifier......................................................... 27
Important Information................................................................ 4
Dismantling the Case. .........................................27
Warnings................................................................4 Mains Selection. ..................................................27
Health and Safety. .................................................4 Changing Power and Relay Fuses......................27
Intended Use..........................................................4
Fault Identification..................................................................... 29
Training. ................................................................4
Introduction.................................................................................. 5 Preventative Maintenance. ........................................................ 30
System Overview. .................................................5 Specification. ............................................................................... 31

Features and Benefits. ...........................................6
Flame Viewing Heads. ........................................31
Flame Viewing Heads. ................................................................. 7
Specification common to all Flame Viewing
Fuel / Flame Characteristics..................................7 Heads. ..................................................................31
Head Operating Principle......................................7 Ultra-Violet Head. ...............................................31
Corrosion and the effects of Aggressive Ultra-Violet / Visible Head. ................................31
Substances. ............................................................7 Infra-Red Head. ...................................................31
Selecting the Flame Viewing Head. .....................8 Hazardous Area FlameViewing Heads...............31
Hazardous Area Applications. ..............................8 Head Accessories. ...............................................32
Mounting the Flame Viewing Head......................9 Head Mount. ........................................................32
Head Mount.........................................................10 Head Mount including Sliding Glass Assembly.32
Sliding Glass Assembly . ....................................11 Sight Tube. ..........................................................32
Sight Tube. ..........................................................11 Head Cable – common specification for all cables.
Aperture Discs. (Part Number 747602291). .......12 .............................................................................32
Detector Head Cable Assembly. .........................13 Safe Area Head Cable. ........................................32
Head Cable Junction Box (Part Number 650-WM- Hazardous Area Head Cable. ..............................33
0001)....................................................................14 Flame Retardant Cable........................................33
Head Selector Module. (For use in safe area) ....14 Hazardous Area Flame-Retardant Cable. ...........33
Flame Amplifier. ........................................................................ 15
Flame Amplifier. .................................................33
General Specification. .........................................33
Operating Principle. ............................................15 Power Supply Input.............................................33
Safety Integrity. ...................................................15 Flame On / Off Relay Contacts...........................33
Operating Voltage. ..............................................15 4-20mA Flame Strength Output..........................33
Fascia Layout and Functional Description. ........16 Automatic Threshold Adjust Input / Output.......33
Enclosure. ............................................................17 Fuel Profile Select Input......................................33
Enclosure Location..............................................20 Safe Area Flame Amplifier. ................................34
Panel and Field Wiring........................................21 Fascia Mount Enclosure......................................34
Fuel Profile Selection..........................................23 Wall Mount Enclosure. .......................................34
Low Frequency and High Frequency Gain Rack Mount. ........................................................34
Adjustment. .........................................................23 Application / Installation Checklist. ...................35
Threshold.............................................................23 Serial Number Identification...............................35
Analog Output. ....................................................24

Table of Figures.
Figure 1: Flame Viewing Head Dimensions........................................................................................................ 7
Figure 2: Flame Viewing Head Type Selection Table......................................................................................... 8
Figure 3: Flame Viewing Head Part Number Table. ........................................................................................... 8
Figure 4: Flame Viewing Head Sighting Position. .............................................................................................. 9
Figure 5: Head Mount (also shows optional Sight Tube). ................................................................................. 10
Figure 6: Head Mount with Sliding Glass (Also shows optional Sight Tube).................................................. 11
Figure 7: Head Mount Selection Table. ............................................................................................................. 11
Figure 8: Sight Tube Selection Table................................................................................................................. 11
Figure 9: Detector Head Cable Assembly Selection Table. .............................................................................. 13
Figure 10: Head Cable Junction Box showing Cable Terminations. ................................................................ 14
Figure 11: Head Selector Module Part Numbers. .............................................................................................. 14
Figure 12: Head Selector Module Connection Diagram. .................................................................................. 14
Figure 13: SmartScan 121 Fascia. ...................................................................................................................... 16
Figure 14: Fascia Mount Enclosure.................................................................................................................... 17
Figure 15: Wall Mount Enclosure. (Not suitable for FM approved installation)............................................. 18
Figure 16: Rack Mount for fitting into panel or stand-alone enclosure ............................................................ 19
Figure 17: Enclosure Part Number Selection Table. ......................................................................................... 20
Figure 18: Suggested Hole Positions for Cable Entry. ...................................................................................... 21
Figure 19: Wiring Diagram. ............................................................................................................................... 22
Figure 20: Fuel Profile Selection........................................................................................................................ 23
Figure 21: Filter Frequencies and Flame Strength............................................................................................. 23
Figure 22: Commissioning Procedure; Flame On.............................................................................................. 25
Figure 23: Commissioning Procedure; Flame Off, ATA and Flame On / Off Verification. ............................ 26
Figure 24: Screw Location for Dismantling and Mains selection / Fuse Location........................................... 27
Figure 25: Fuse Replacement Types and Ratings.............................................................................................. 28
Figure 26: Part Number and Order Form. .......................................................................................................... 36
Figure 27: Hazardous Area Cable Calculation Example for Galvanic Isolator. ............................................... 37
Figure 28: Hazardous Area Cable Calculation Example for Zener Barrier. ..................................................... 38
Common Abbreviations.
LED Light Emitting Diode
LF Low Frequency 20Hz to 200Hz filter response
HF High Frequency 100Hz to 400Hz filter response
UL Underwriters Laboratory
FM Factory Mutual
CSA Canadian Standards Authority
Note: Although every effort has been made to ensure the accuracy of this manual, errors and omissions.
typographical, clerical and otherwise, sometimes do occur. Hamworthy Combustion Engineering accepts
no responsibility for any loss, damage, or misinterpretation of contents of this manual.

Important Information.
Warnings.
Incorrect operation or failure to follow instructions and heed caution information in the manual may
! result in property damage, severe personal injury or death.
When the Flame Scanner is removed from its case or rack, dangerous voltages may be present on the
! backplane connector and backplane circuit board.
The Flame Scanner cover may only be opened when withdrawn from the case or rack and when power
! is isolated.
The Flame Scanner contains electrostatic sensitive components. Observe anti-static handling
! precautions when handling the Flame Scanner with the cover removed.
Potentiometers shall always be adjusted using a non-metallic potentiometer adjustment tool.

! If any adjustments are made to potentiometers or flame characteristics Flame On / Off Verification must
be performed.
! This Flame Amplifier case must be connected to Protective Earth.
This Flame Amplifier is supplied for 230Vac operation. Change internal mains selector switch for
! 115Vac operation.
The Flame Viewing Head, Connector, Head Mount and Sliding Glass may be hot. Wear suitable
! protective gloves when removing from furnace and allow to cool before handling.
Hot air and dust may be emitted from the furnace when the head is removed. Ensure furnace pressure is
! acceptable and wear suitable protection when removing any parts from the furnace / burner.
Health and Safety.
Before attempting to carry out any work on this equipment it is important that:
• This manual is read and fully understood.
• Manuals relating to the system to which this equipment is installed are read and fully understood.
• You are competent (through training and experience) to carry out the work.
• Sound engineering and safety principles are observed at all times.
• You ensure the personal safety of yourself and other personnel within the work area.
• Any applicable warning notices are placed in accordance with site regulations.
• All work is authorised by the work permit system in place on the site.
Intended Use.
This equipment described is intended for use on Industrial, Marine and Offshore Burner Equipment for the
detection of burner flames in single or multi-burner applications. This equipment must not be used for any
purpose other than that described in this manual.
Training.
Training courses for a full range of burner, boiler and control equipment are available from:
Hamworthy Combustion Engineering.

Combustion Training Centre.
Telephone +44 (0)1202 663904

Introduction.
System Overview.
The SmartScan 121 system consists of:

• Flame Viewing Head.
The heads are characterised to respond to either ultra-violet only (UV), ultra-violet and visible (blue) light
(UVVIS) or infra-red emissions (IR). In all cases the flicker signal generated within the flame is detected.
The Flame Viewing Heads can accommodate a very large increase in flame brightness without any
adjustment. In extreme cases, Aperture Discs can be fitted to the head in order to reduce the brightness
level.
Stainless steel versions are available for use in corrosive atmospheres.
• Flame Head Mounting.
A ball swivel arrangement allows for correct alignment of the Flame Viewing Head to the flame. The heat
barrier allows the introduction of purge air if required and the option to fit a sliding glass assembly to ease
maintenance.
• Head Cable.
A correctly terminated cable (typically 2m in length, longer options available on request) to connect the
head to the local junction box. The junction box acts as a termination point for the field cabling. Field
cabling between the Amplifier and the Flame Viewing Head can be up to 500m in length and must be
either a 3-core screened cable or a twin twisted pair screened cable. Additional restrictions apply for
Hazardous Area Systems – see section on Hazardous Area Applications.
Stainless steel heads are supplied with a permanently wired 2m cable.
• Flame Amplifier Case / Rack.
The method for mounting the Flame Amplifier. This can be a panel fascia mount, wall mount or rack
system depending upon the application.
• Flame Amplifier.
The control unit which interprets the signal from the Flame Viewing Head and generates a Flame On or
Flame Off signal to the Burner Management System (BMS). This is also indicated on the fascia.
Commissioning of the SmartScan is accomplished by adjusting potentiometers on the fascia. The Flame
Threshold and Flame Strength are viewed on the fascia mounted bargraph displays. In order to promote
efficient diagnostics Internal Fault and Shutter Fault displays are provided. The Internal Fault is latched
(apart from head disconnection which automatically resets when the head is reconnected) and must be
reset before the SmartScan can generate a Flame On condition. The Shutter Fault indication is latched (for
indication purposes only) but the Amplifier will continue to operate as soon as the fault is cleared (i.e. a
valid Flame Off condition is detected).
In order to accommodate large multi-burner installations and further improve discrimination the threshold
can be biased to increase as the flame strength on the firing burners increase.
• Flame Synthesiser.
Available as a commissioning aid to simulate a flame either through the Flame Viewing Head or directly
down the Head Cable to the Amplifier.

Features and Benefits.
• Dual Channel Relay Operation with Watchdog providing high safety integrity. The watchdog
continually monitors the operation of the dual channels, shutter and relay operation.
• Easy to read bargraph displays simultaneously showing Threshold and Flame Strength.
• Mechanical Shutter for self-check which provides a reliable self check of all components including the
sensing element itself. It can not be defeated by excessive vibration as can an electronic shutter.
• 4-20mA Analog Flame Strength output.
• LED indication for Internal Fault, Shutter Fault, Fuel selection and Flame On.
• Flame On / Off relay output for interface to Burner Management System.
• 300m maximum cable distance from Flame Viewing Head to Amplifier.
• UV, UVVIS and IR head options for different fuels.
• Fuel Select Input for two fuel parameter sets.
• Variable Flame On threshold to accommodate wide-ranging furnace conditions.
• Selectable dropout times - 1.0 second or 3.0 second.
• Intrinsically Safe Heads available for Hazardous Area Operation (Zone 0).
• Proven Discrimination techniques.
• Intuitive Commissioning Procedure.
• Lock on case to prevent unauthorised adjustment (optional).
• Stainless steel heads available for corrosive atmospheres.

Flame Viewing Heads.

Fuel / Flame Characteristics.
The SmartScan 121 is designed to monitor oil and gas flames ranging from crude / heavy oils through diesel
oils, natural gas and process waste gases such as blast furnace gas.
The Flame Viewing Heads contain no user serviceable parts and must be returned to Hamworthy
Combustion Engineering for repair / service.
Head Operating Principle.

All turbulent flames generate a light signal that flickers at frequencies ranging from approximately 1Hz to
400Hz. A lens focuses the light onto a photodiode which generates a varying voltage signal containing
information about the brightness of the flame and flame flicker frequencies. In order to accommodate a
wide ranging flame brightness, a proportion of the brightness signal is removed and added to the amplified
flicker signal before transmission as a 4-20mA current signal to the Amplifier.
The head contains a Located Switch. The switch operates when the head is correctly located on the head
mount. If the head is not correctly located the head will not generate a flame signal and “Internal Fault” will
be identified on the amplifier.
117mm
Standard Versions require
cable assembly for 54mm
connection
223mm
54mm
Stainless Steel Versions

M 20x1.5
complete with 2m cable
thread and stainless steel cable
gland
2m
Figure 1: Flame Viewing Head Dimensions.
Corrosion and the effects of Aggressive Substances.

The heads are manufactured from zinc plate and passivate mild steel and passivate brass for normal
operation. If corrosive or aggressive atmospheres or substances are present a stainless steel version is
available. Care must be taken to ensure that the atmosphere or substances present will not impair the
function of the flame viewing head.

Selecting the Flame Viewing Head.

The head is primarily selected on the type of fuel being fired.
Burner Type Head Type

Oil Only poor atomising steam quality IR
Oil (pressure jet) on coal burners IR
Oil Only good atomising steam quality UV
Gas Only UV
Oil and Gas UV
Low brightness gas flames UV-VIS
Gas flames with >40% Hydrogen UV-VIS
Figure 2: Flame Viewing Head Type Selection Table.
Hazardous Area Applications.

The environment where the head is to be operated must be examined to determine whether it falls into the
category of safe area or Hazardous Area. If explosive mixtures of gas may be present in the atmosphere
surrounding the flame head then a Hazardous Area Flame Head must be selected.
Head Type Part Number

Safe Area Hazardous Area Stainless Steel
IR 363920852/P 363920860/P 363921084/P
UV 363920794/P 363920802/P 363921068/P
UVVIS 363920828/P 363920836/P 363921076/P
Figure 3: Flame Viewing Head Part Number Table.
The Hazardous Area Heads and the stainless steel heads are certified to operate in potentially explosive
atmospheres by Baseefa(2001). The details of the approval are given below:
Certificate Number BAS01ATEX1020

ATEX code II 1 G
Cenelec Code EEx ia IIC T4 (-400C <= Tamb <= +600C)
UI 28V
II 150mA
PI 0.8W
CI 0.032µF (32nF)
LI 0.07mH (70µH)
In order to satisfy Hazardous Area Installation requirements, the Flame Viewing Head must be powered
from the Amplifier via a safety barrier. Two types of barrier are available for use with the Hazardous Area
Heads: -
1) Galvanic Isolator (747832607). This is used on a site where no Intrinsically Safe Earth exists. The
output from the galvanically isolating barrier is 28V. Due to the maximum capacitance allowed for this
type of barrier, the cable length is restricted. Maximum (but cable type dependent) 300m.
2) Zener Barrier (747832043). This is used where the site has a dedicated Intrinsically Safe Earth that
provides the reference potential for the barrier. This has a lower output voltage (15V) however slightly
longer cable lengths can be achieved, but are limited due to the maximum inductance allowed.
Maximum (but cable type dependent) 380m.
Note: the barriers must be ordered in addition to the Flame Viewing Head.
In order to comply with the Hazardous Area Installation the cable characteristics (capacitance and
Inductance) must be taken into account in order to determine the maximum cable length allowed. It is the
Application / Installation Engineers responsibility to ensure the system complies with the Hazardous Area
System Certificate.
If galvanic isolators are required and the cable is insufficient in length it is recommended to fit the galvanic
isolators in a flameproof enclosure local to the flame viewing heads.
Cable calculation examples for Hazardous Areas are shown in Figures 27 and 28 at the rear of this manual.

Mounting the Flame Viewing Head.
SmartScan 121 offers excellent discrimination characteristics through the optics employed in the head. The
Viewing Head should be mounted on the burner front plate so as to look at the root of the flame. There must
be a clear view of the flame to be detected. This may necessitate alignment through gaps in swirler blades
or the addition of cut-outs.
Discrimination (detecting the correct flame as opposed to adjacent flames) can be enhanced by fitting flame
scanners on the burner at a point where they cannot view adjacent or opposite flames. For installations
where separate scanners are used for pilot and main flame detection, the scanners must be aligned so that
they can only detect the intended flame.
When determining the sighting position consideration should be given to the swirl direction of the burner to
ensure that the Flame Viewing Head is positioned correctly. It should be aligned to ensure a good view of
the gas flame and oil flame (if dual fuel) bearing in mind that the fuel is generally admitted to the burner in
different positions. The air velocity and likely positions of flames must be taken into account.
Sunlight can increase the brightness level detected by the head and cause it to saturate. When saturated the
head will not detect the flicker signal from the flame and will indicate Flame Off. For this reason the head
must not be aligned so that it can see sunlight either through the stack or boiler viewing ports.
Swirl Direction
Missing Swirler Blade to

ensure adequate view of the
flame
Main High Frequency Flicker region

Direction of
Gas Pilot / View
Spud Stabilising
Gas
Spud
Figure 4: Flame Viewing Head Sighting Position.

Head Mount.
The Flame Viewing Head must be mounted on a Head Mount. This provides a positive location for the
Flame Viewing Head and enables the Located Switch in the head. The Head Mount includes the Ball
Swivel Assembly and Heat Barrier / Purge Air Inlet and may optionally include the Sliding Glass Assembly
and / or Sight Tube.
The Ball Swivel assembly must be used in all cases to ensure optimum alignment with the root of the flame
in order to provide a reliable flame flicker signal. The ball swivel back plate is mounted to the burner plate
via three 6mm holes, equi-spaced (120o) on a 60.0mm pcd in the ball-swivel back plate, alternatively, it
may be welded.
In order to provide thermal isolation between the hot burner front plate and the Flame Viewing Head a Heat
Barrier is used which has a very low thermal conductivity. It also allows clean dry air to flow through the
ball swivel. This performs two functions:
• Prevents hot combustion air circulating in the ball swivel / head assembly and so reduces the
temperature at the Flame Viewing Head.
• Reduces the amount of dirt that can build up on the Head Lens.
Typically a flow rate of 150 l/min (5.3ft3/min) at 250mm H2O (10in H2O, 24mbar, 0.35psi) above Wind
Box pressure is required. Idealy, purge air temperature should not exceed 450C
7 5 mm 1 0 3 mm 4 2 8 mm
1 7 D e gr e e s
S i g h t Tu b e ( o p t i o n a l )
P u r g e A i r Fi t t i n g
B a l l S wi v e l
Figure 5: Head Mount (also shows optional Sight Tube).

Sliding Glass Assembly .
If dirt or dust is a serious problem then the head mount can be fitted with a Sliding Glass which can be
cleaned without the need to shut down the burner or remove the Viewing Head. The sliding glass contains
two quartz glass windows. One window can be cleaned, the slide clamp undone and the clean window slid
into the sight path. This must be performed within the Flame Off Delay Time to prevent tripping the burner.
After a period of time the other window can be cleaned and slid back as described above.
The sliding glass option is of greater benefit where combustion air contains a large amount of particulate
matter or the head is mounted vertically upwards.
75m 120m 428m
17 Degrees
120mm
Sliding Glass
Figure 6: Head Mount with Sliding Glass (Also shows optional Sight Tube)
Standard With
Head Mount Sliding
Glass
Zinc plate and passivate 363920752 363920760
mild steel
Stainless Steel 363921092 363921100
Figure 7: Head Mount Selection Table.
Sight Tube.
Where the burner is firing vertically upwards the possibility of dust / debris falling on the lens / sliding glass
is increased. Fitting a sight tube can reduce this. This is a 450mm long tube that screws into the heat barrier.
When the heat barrier is removed from the ball swivel the sight tube will come with it.
A secondary function of the sight tube is to aid alignment. When looking through the sight tube it gives an
image similar to that seen by the Flame Viewing Head and allows the Ball Swivel to be aligned more
accurately. If purge air is not used to clear the sight tube it should be angled downwards to prevent dust
collecting in the tube.
Sight Tube Standard Stainless Steel

Part Number CS40034 CS40049
Figure 8: Sight Tube Selection Table

Aperture Discs. (Part Number 747602291).

The intensity of the burner flame varies considerably. In some cases the flame is so bright that the automatic
brightness adjustment limits and the head saturates. This becomes apparent when the flame is very bright
and yet the flame signal is very low even though the Flame Viewing Head has a clear view of the flame. It
may be that to obtain a better signal the Flame Viewing Head is aligned so that metalwork within the burner
obscures some of the field of view. A better method is to use an aperture disc that fits into the front of the
Flame Viewing Head. The discs come in a pack of 5 discs of differing sizes. The number on each disc
indicates the factor that the light area is reduced by.
To fit or change an aperture disc:

1) Remove the Flame Viewing Head from the Head Mount.
2) Remove the circlip (using circlip pliers).
3) Fit a suitable aperture (either increasing or decreasing depending on the brightness of the flame).
4) Refit the circlip, ensuring that it fits into the groove correctly.
5) Refit the Flame Viewing Head to the Head Mount.
6) Recheck the Flame Scanner performance and Flame On / Off Verification.

Detector Head Cable Assembly.
The connector on the head must only be connected to a Hamworthy supplied cable. Generally this cable is
2m long which allows connection to a local junction box. The cable assembly includes a straight connector
and crimped cable ends for termination in the junction box. Where the Amplifier is located within a
reasonable distance to the Head, longer cables are available to order.
Where site wiring is used between the Amplifier and the Head Junction Box the cable must be selected
from the following Cable Types:-
• Three core with an overall screen. Each core must be 0.75mm2 or greater. The screen should be
braided with at least 75% coverage or a foil type.
• Twin twisted pair with a screen per pair or per twin pair. Each core must be 0.75mm2 or greater.
The screen should be braided with at least 75% coverage or a foil type. Each pair must contain a
0V connection. One pair will be Signal and 0V, the other pair will be Vs (Supply Voltage) and 0V.
Maximum Cable Length (length of cable from Head to Amplifier):

• Safe Area:
500m.
• Hazardous Area:
Cable capacitance and inductance must be checked to be within the Hazardous Area System
certification for the SmartScan 121. This may limit the Maximum Cable Length to less than 200m.
It is the Application / Installation Engineers responsibility to ensure the system complies with the
Hazardous Area System Certificate.
Cable Segregation. The signal is a low voltage signal and should only be carried in low voltage signal
wiring cable trays / harnesses. It should be separate from power cables.
Application Description Standard 2m Length Special Length

Standard 3 core. PVC/ PVC. 363920611 363920611 /V
Safe Area Overall Braid. where V is the length in
metres
I.S. 3 core. PVC/ PVC. 363920629 363920629 /V
Hazardous Area Overall Braid. where V is the length in
Blue Sheath metres
Flame Retardant 3 core. PVC/ PVC. 363920637 363920637 /V
Safe Area Overall Braid. Flame where V is the length in
Retardant, Low Emission metres
I.S. Flame 3 core. PVC/ PVC. 363920645 363920645 /V
Retardant Overall Braid. Flame where V is the length in
Hazardous Area Retardant, Low Emission metres
Blue Sleeves
Figure 9: Detector Head Cable Assembly Selection Table.
NOTE: The stainless steel heads come complete with a 2m IS Flame Retardant cable with an M20 x 1.5
stainless steel gland fitted. A detector head cable assembly is not required with these heads.

Head Cable Junction Box (Part Number 650-WM-0001).
The Junction Box, suitable for use in Safe Areas and Hazardous Area Zones 1 and 2, should be installed
local to the Flame Viewing Head.
The Junction Box should be earthed locally in order to provide a satisfactory Protective Earth. The cable
screen must use one of the terminals and pass straight through the junction box. The screen must NOT be
connected to the Junction Box Earth.
75m m 57m m
1 Pow er
2 Signal
3 Ov 80mm
4 Screen
Figure 10: Head Cable Junction Box showing Cable Terminations.
Head Selector Module. (For use in safe area)

The head selector module allows one of two heads to be connected to the SmartScan Amplifier. Although the
SmartScan can only monitor one single head at a time the selector module allows the selection of one head or the
other to be connected to the monitor. The module is available in three voltages and must be ordered specifically
for the required operating voltage.
Operating Voltage Part Number

24Vdc 363920022
115Vac 363920030
230Vac 363920048
Figure 11: Head Selector Module Part Numbers.
Screen 34 B4 Screen
Vs 33 B3 Vs
Head B
Signal 32 B2 Signal
0V 31 B1 0V
43 A4 Screen
Select 42 A3 Vs
Head A
Common 41 A2 Signal
A1 0V
Figure 12: Head Selector Module Connection Diagram.

Flame Amplifier.
Operating Principle.
The 4-20mA flame flicker signal is received at the Amplifier and decoded into two frequency bands. The
gain of each band is adjusted to allow the correct proportion of each signal to be added together to form the
flame strength signal. This is compared to the threshold value and if the signal is higher than the threshold,
the Flame On relays will be energised. If the signal drops below the Threshold, for greater than the Flame
Off Delay Time, the Flame On relay contact will be broken and the Flame Off relay contact made.
Adjusting the Threshold potentiometer on the fascia sets the Flame On threshold. As the potentiometer is
adjusted the Threshold level will be displayed on the left-hand bargraph.
The SmartScan allows two Fuel Profiles to be selected. This accommodates two different fuel
characteristics. It also allows a Flame Off delay of either 1.0second or 3.0 second to be set.
Safety Integrity.
The Viewing Head and Amplifier have a self-check function which ensures safe operation of the system.
Every 5 seconds a shutter blade interrupts the light signal to the sensing element (photodiode) in the head,
which should cause the signal to drop to approximately 4mA for 0.5 seconds. The Amplifier will detect this
drop in signal. If the signal drops to less than the threshold level commissioned for Flame On the Amplifier
will pass the self-test and continue operation as normal. If the signal fails to drop or the shutter fails to
operate within a 12-second time interval the Amplifier will generate a Shutter Fault and register Flame Off
to the BMS.
Flame On / Off indication to the BMS is generated through two series connected relay contacts (internally
fused). A relay test is also performed (triggered by the shutter test) which ensures that the Amplifier can
remove power to the Flame On relays. If either relay cannot be de-energised the Amplifier will generate an
Internal Fault and indicate Flame Off to the BMS.
Operating Voltage.
The Amplifier can operate on two different voltage types:-
• Alternating Current (ac):
Power is supplied through the AC Mains Power Supply connections. An internal switch must be
configured to select either: -
• 115V ac operation. Refer to the Dismantling the Amplifier section of the manual to check and if
necessary, change the switch position.
• 230Vac operation. Refer to the Dismantling the Amplifier section of the manual to check and if
necessary, change the switch position.
• Direct Current (dc):
Power is supplied through the External 24Vdc Input terminals.

Fascia Layout and Functional Description.
Inte r nal F ault L E D an d R ese t push bu tton . Sh utte r F a ult L E D an d Re se t push bu tton. If
In dic a te s h e ad disc on ne c te d o r i nte rn al se lf ch e c k th e se lf-c he c k fu nc tio n fa ils to d et ec t th e Fl am e
fa ult . Pu sh b utto n to r ese t. Sig na l d rop pin g b el ow the th resh old for tw o
H AM W O R TH Y c on sec u tive shu tte r te st s, th e Sh utt er Fa u lt L E D
C O M BUSTIO N
w ill illu m ina te re d. T he A m p lifie r w ill re ma in in
ENG INEER ING
T hr e shold Ba r G r ap h D isplay . Fla me sign a ls In te r na l S hu tte r fa ult u nt il the Fla m e Sig na l St ren gt h dro ps b elo w
F a ul t Fa ult
a bo ve thi s w ill in di ca te Fla m e O n. th e Fl am e On T hre sh old , a t w hic h p o int th e fa u lt
w ill c le ar a n d th e A m plifi er re sum e n o rma l
o pe ra tion . T he L E D w ill re m a in o n u nti l re se t by
1 0 0% 1 0 0% o pe ra ting the bu tto n.
P o w er O ff P ush B utto n. P ush ing t he bu tton w ill S m artS can
p ow e r do wn the Sm a rtSc a n. T his w ill re sult in the
Fla m e O n rela y s d rop pi ng o ut a nd the a na log 80% 121 80%
o utp ut d rop pin g to 0m A .
60% 60%
fla m e sca n n e r F la m e Sig na l Str en gth B a r G r aph Di sp lay .
P o w er O n P ush B utto n. Push ing the bu tto n w ill
Th r e sh o ld Fl am e Sig n a l
Fla m e S ign a l stre n gth de te c ted by the Fla m e
p ow e r up th e S ma rtS ca n .
V ie w ing H ea d .
40% 40%
F la m e O n In dic ati on. E a c h Fla m e O n L E D w i ll
O ff
illu m ina te gre e n w he n i ts in te rna l re la y is e ne rgi se d .
O nl y w he n b oth L E D ’s are illu m ina te d w ill th e
20% 20% F ue l P r o file L E D ’s. E ithe r Fu e l 1 or Fu e l 2
Fla m e O n co nta c t be m ad e to ind ic a te to the B M S
On L E D w ill ill um ina te ye llo w t o in dic a te th e
th at a fla m e is esta b lishe d .
On c urre n tly se le ct ed fue l.
T hr e shold Ad just P ote nt iom e ter . R ota tin g th e F la m e H igh F re qu en cy Ga in A djust

F u el
p ote nt iom e te r c lo c kw ise w il l i nc re ase the th resh old P o te ntio m e te r. R ot at ing t he po te ntio me te r
se ttin g. Inc re asin g it a b ov e th e c u rren t Fla m e Si gn al 1 2
u nd er th e c u rren tly se le c te d fu el c lo ck w ise
Stre n gth w ill re su lt in F lam e O ff b e ing ind ic at ed . On w ill in cr ea se t he Hi gh F req u en c y ga in .
HF
A nt icl oc kw ise rota tio n w ill d e cre a se th e T hre sho ld A nt icl oc kw ise rota tio n w ill d e cre a se th e
se ttin g. Th re s ho ld B ia s Fi lte r G a in g ain .
LF
B ia s A dju st P ote ntio m e te r . R o ta tin g the L ow F r e que nc y G a in A djust

p ote nt iom e te r c lo c kw ise w il l i nc re ase the P o te ntio m e te r. R ota tin g th e p ot en tio me te r
T h re sh ol d set ting of a ll A .T .A . c on ne c ted u nd er th e c u rren tly se le c te d fu el c lo ck w ise
A m plifi ers. A ntic lo c kw ise r ota tio n w ill d ec re a se w ill in cr ea se t he L ow Fre q ue nc y g a in.
th e T h re sho ld. A nt icl oc kw ise rota tio n w ill d e cre a se th e
g ain .
Figure 13: SmartScan 121 Fascia.

Enclosure.
The Flame Amplifier Module may be installed in four different types of enclosure. Each type is discussed
below.
• Fascia Mount.
Requires a 68mm wide by 137mm high cut-out in the fascia to take the enclosure. The enclosure will
extend 216mm into the panel and stand proud of the fascia by 37mm. The enclosure has a hinged cover,
which provides IP65 protection to the Amplifier. Cable entry is at the rear of the enclosure through the
terminal compartment.
Figure 14: Fascia Mount Enclosure.

Wall Mount.
Note: The plastic enclosure offers mechanical protection for control room environments only, the other
mounting methods are recommended for machinery space environments.
The mounting requires a 72mm wide by 164mm high wall area. The enclosure protrudes 263mm from
the wall. Four 6mm-diameter holes are available for fixing the plate to the wall.
Figure 15: Wall Mount Enclosure. (Not suitable for FM approved installation)

• Rack Mount.
A 3U rack is required. Using a 84HP wide rack will allow 7 amplifiers to be mounted in one rack (each
amplifier being 61mm (12HP) wide by 129mm high). Each amplifier fitted into the rack will have a
Rack Backplane Assembly to allow the cables to be terminated correctly. When selecting the enclosure
for the rack, attention should be given to the use of a swing frame to allow suitable access for wiring.
Suitable enclosures to house the Rack are available from Hamworthy Combustion Eng Ltd.
Figure 16: Rack Mount for fitting into panel or stand-alone enclosure

Type Part Number Number of Amplifiers

Fascia Mount 363920652 – general latch 1 Per Enclosure Included in Part Number
Wall Mount 363920660 – general latch 1 Per Enclosure Included in Part Number
Rack Mount 3439017/008/ψ Maximum 7. ψ indicates number of

Amplifier Modules in the rack ie 01 to 07
Figure 17: Enclosure Part Number Selection Table.
Enclosure Location.
The enclosure must be situated to ensure that the ambient operating conditions for the Amplifier are not
exceeded; 0oC to +40oC. When assessing this, due consideration must be given to solar radiation and
radiation from hot surfaces.
A distance of 85mm is required between enclosures to accommodate cable glands and cable bend radius.
When siting the enclosure consideration should be given to allow the clear door to be opened on the front of
the enclosure and the Amplifier Module to be withdrawn.
The Amplifier should be mounted with the fascia vertical and clearly visible to the operator.
Cable entry and exit points should be protected for the local environment – suitable cable glands are
available from Hamworthy Combustion Eng Ltd (Part number 747830534 / 747830542). Cable glands
should be used to maintain the IP65 integrity of the enclosure. The suggested cut-out location is shown in
the Figure 19.
For the Fascia Mount and Wall Mount enclosures within a panel, holes can be cut in the terminal
compartment to accommodate cable entry relative to trunking etc.
Attention should be given to the categorisation and location of low voltage signal wiring and mains power
wiring. A minimum distance of 300mm should be maintained between parallel runs of low voltage and
power cables. Cables of different classifications should cross at 90o to ensure minimal interference.

Panel and Field Wiring.

The cables entering the Enclosure must be mechanically restrained so that external forces do not disturb the
wiring. This will require the cables to be fixed in cable trays or trunking. Entry into the fascia mount can be
through cut-outs in the top or bottom of the terminal cover. The Wall Mount Enclosure should use cable
glands (suitable type is 747830534). The cable glands must provide both mechanical restraint and
environmental protection for the intended environment.
The equipment has been designed for Installation Category II and Pollution Degree 2 (according to
EN61010 part 1). Over Voltage Protection to 2.5kV is inherent in the design; external Over Voltage
Protection shall be used to limit transient energy if these limits are likely to be exceeded.
Supply Protection.
The equipment must be fed from a supply via a control fuse (Rupture capacity HBC1500A) or mains circuit
breaker (mcb). Maximum rating 6Amp. If the circuit breaker is not fitted local to the unit, then a separate
isolator to isolate all poles of the supply should be installed adjacent to the Amplifier module, within reach
of the operator. The isolator must be marked as the disconnect device for the Amplifier. The Protective
earth must not be disconnected.
Wiring.
All wiring must comply with the requirements in this manual and additionally those in force in the country
where the equipment is installed. These are:-
IEE wiring regulations in the UK
NFPA 70 codes of practice in the US
CEC in Canada
The connectors will take a maximum conductor size of 1.5mm2 (16AWG). 0.5mm2 cable should be used as
a minimum.
The high voltage wires (mains input and possibly Flame On / Off Relay) must be prevented from becoming
loose and touching any low voltage wires / terminals (fuel select ATA and head etc) and vice-versa. This is
achieved by placing a cable tie (tie-wrap) around the wire tails , see Figure 19 below to ensure cable
segregation.
The earth rail on the Backplane assembly is to be used to terminate screens. No strands of the braid must be
allowed to touch the terminals; this is achieved by sleeving the braid prior to termination. The screen should
be twisted and placed under the bar and retained by the clamp. This method provides a good equipotential
bond for Electromagnetic Compatibility Purposes.
S ugge ste d Entry P oints

18.5mm
1 Head Cable Entry
2 Mains Cable Entry
1 3 A nalog Output Cable Entry
25mm 4 Fuel Selec t and A TA Cable Entry
5 Flame On / Of f Relay Cable Entry
65mm
3
32mm
4
32mm
5
V ie w Sho w ing Scr e e n T e r m ination
25mm on In s tr um e n t Ear th Bar
25mm Drill holes marked

20mm diameter
2 as required
f or number of c ables
18.5mm Cable tie to group s imilar v oltage c ables in a
terminal bloc k
Figure 18: Suggested Hole Positions for Cable Entry.

Figure 19: Wiring Diagram.

Fuel Profile Selection.

SmartScan allows for two different fuel profiles to be selected which permits the settings to be
commissioned for different fuel characteristics.
The second fuel profile is selected by means of an external volt-free contact. Changing the Fuel profile also
changes the Flame Off Delay Time: Refer to local regulations for requirements.
Fuel Profile Typical Fuel Flame Off Delay Time

1 Gas 1.0 second
2 Oil 3.0 second
Figure 20: Fuel Profile Selection.
Low Frequency and High Frequency Gain Adjustment.

Once the Fuel Profile has been selected the gain potentiometers (below the illuminated Fuel LED) can be
adjusted to allow a proportion of each signal to be added to form the overall flame strength signal.
Generally both LF and HF potentiometers will be at maximum unless there are discrimination problems in
which case the LF potentiometer will be reduced first and if necessary the HF potentiometer until a reliable
Flame Off signal is achieved.
The operation of the two filters can be seen below.
F la m e F lic k e r S ig n a l
Low H ig h
F r e q u e n c y F ilt e r F r e q u e n c y F ilt e r
2 0 H z to 2 0 0 H z 1 0 0 H z to 4 0 0 H z
L F S ig n a l % H F S ig n a l %
F la m e S t r e n g t h = H F % + L F %
Figure 21: Filter Frequencies and Flame Strength.
Threshold.
The threshold can be adjusted in two ways:
• The most common is to simply use the Threshold potentiometer to set the threshold. As the
potentiometer is adjusted the Threshold level will be displayed on the left hand bargraph.
• In multi-burner installations the Bias potentiometer can be used to increase the Threshold as the overall
Furnace Flame Strength increases. In order to achieve this, all of the Automatic Threshold Adjust
(A.T.A) connections must be linked together in parallel. When the SmartScan detects a Flame On
condition, the A.T.A. rail voltage will be increased by the proportion dialled on the Bias Potentiometer,
this will increase the threshold of all SmartScans with a common A.T.A connection.

Analog Output.
The Flame Strength can be displayed remotely or monitored by a Distributed Control System (DCS) by
utilising the 4-20mA Flame Strength Output. The output will drive a 500ohm load, which is referenced, to
the 0V of the SmartScan. If an isolated output is required an isolation converter (part number 747832583)
can be used which will prevent signal degradation caused by ground loops etc.. If the Amplifier is mounted
out of sight of the Flame Viewing Head a local display at the burner can be connected to the 4-20mA output
to aid burner commissioning. This signal is derived from the detector head input providing external
indication over the maximum input range of the detector, as such this signal does not directly correspond to
the fascia bar graph display. It also provides indication of the shutter dip which is damped by internal
smoothing.
Commissioning.
In order to carry out commissioning successfully it will be necessary to fire each burner individually and
also shut down burners individually. This ensures that that Flame on Characteristics are tested for individual
burners and also Flame Off characteristics when a single burner is shut down.
Any changes made to the operation of the SmartScan system must be verified. It must be proven that Flame
Off can be reliably detected when the burner is shut down.
The basic procedure is detailed in the flow chart below.

Commissioning Procedure Commission

Flame On
Verify:
Head Selection, Head Sighting,
If HF Gain has to
Head Cable Length, Amplifier be reduced by
Mains Voltage Is it permiitted to N more than 50% to
and General Installation. start the burner? see shutter dips
at low fire fit a
With the Burner Switched Off Power up the SmartScan suitable Orifice
Y
Plate to reduce
Start the Burner signal
Slowly increase the hf Filter Gain
Is a reliable Flame On Y Commission

Verify Flame Strength at signal achieved? Flam e Off
much less than Threshold
N
Identify reason from the
Slowly increase the lf Filter Gain following selection
Relatively Relatively Average

Verify Flam e Strength at much dark flame bright flame brightness
less than Threshold
Adjust sighting
position to give a clear If HF Gain has to be
view of the flame. In reduced by more than Adjust sighting
Use a Flame Synthesiser to test the
extreme circumstances 50% to see shutter dips position to the first 1/3
system. The test shoud include:
this may require at low fire fit a suitable of the flame to increase
Remote Output (if used)
modification to the Orifice Plate to reduce the flicker intensity
Flame On / Off Contacts
sighting position or signal
burner geometry
Commission
Flame On
Figure 22: Commissioning Procedure; Flame On.

Com m is s ion Com m is s ion Automatic Threshold

Flame Off Adjust
Is it perm itted to Increas e Automatic Threshold Adjust on all other

N burners to give a reliable Flame Off
s top the burner?
Y
Prove new Threshold is not s et too high to prevent
Stop the Burner
reliable light up of burners
Prove that when this burner is lit, it does not s ignificantly

Flame On /
increas e the Threshold s o as to caus e unreliable Flam e
Is a reliable Flame Off
Y On conditions
Flame Off V erification
s ignal
Flame On / Flame Off V erification
achieved?
Y Prove Flame On for burners firing on their own (preferably

Is lf Filter Gain Reduce lf Filter
N in a dark furnace)
greater than zero? Gain
Prove Flame Off for burners individually turned off

Can N (preferably with all other burners firing)
im provem ent N
be m ade to Repeat the com m is s ioning proces s for the rem aining
Is hf Filter gain
sighting Y Reduce hf Fuel Profile (if us ed)
greater than
position? Filter Gain
25%?
Repeat Flame On / Flame Off V erification for all fuel
com binations
Y N
Com plete any neces s ary docum entation
Adjus t Sighting Position to N can Automatic Y Com m is s ion including Commissioning Log Sheet
Im prove dis crim ination. Threshold Automatic
Increas e hf and lf gain Adjust be us ed? Threshold Adjust
Com m is s ioning Com plete
Figure 23: Commissioning Procedure; Flame Off, ATA and Flame On / Off Verification.

Dismantling the Amplifier.
Dismantling the Case.

The SmartScan contains electrostatic sensitive devices that may be damaged unless the operator, wearing an
approved wristband, dismantles the Amplifier on static dissipative work-mat. Access to the fuses and mains
selector switch is possible without removing the pcbs and therefore without the requirement to observe full
anti-static handling precautions.
There should be no need to remove the pcbs from the metal enclosure. When handling the SmartScan out of
the enclosure take care not to damage any of the pins on the rear connector.
1. Turn off the Amplifier.

2. Undo the captive retaining screws (four in total) in each corner of the fascia.
3. Withdraw the SmartScan from the enclosure and transport to a work-mat in a location where there is no
possibility of static charges been applied to the pcb’s.
4. Undo the four screws that fix the back cover to the case.
5. Slide out the case bottom cover and the side cover adjacent to the Flame Signal Bar Graph Display.
6. The Earth Bonding screw adjacent to the bottom of the main rear connector must NOT be loosened.
7. If you only require to change or check fuses refer to the Changing Power and Relay Fuses section.
8. To change the mains input voltage refer to the Mains Selection section.
9. Re-assemble the case in the reverse order.
ribbon cable
connector
Fuse 2
Fuse 3
Fuse 4
fascia
ribbon
cable
captive
retaining
mains Flame Earth back
screws transformer
selector relays Bonding cover
Screw screw
115Vac
230Vac
Figure 24: Screw Location for Dismantling and Mains selection / Fuse Location.
Mains Selection.
The mains selector switch is situated on the power board. In order to gain access, follow the Dismantling the
Case procedure above and then: -
1. The mains selector switch is accessible through the panel removed from the bottom of the case.
2. Push the switch towards the centre of the board to select 115Vac.
3. Pull the switch towards the bottom of the board to select 230Vac.
4. Ensure the switch is fully located at one end or the other.
Changing Power and Relay Fuses.

The fuses are situated on the power board. In order to gain access, follow the Dismantling the Case
procedure above and then: -

1. Remove the cap from the fuse to be checked and changed.
2. If necessary replace the fuse. This must only be with the correct type and rating as indicated in the table
below. All replacement fuses must be UL approved. Glass Fuses must not be used.
3. Re-assemble the case in the reverse order.
Description Part Fuse Current Type Size

Number Number
Mains Power 747228804 FS4 250mA T HBC 250Vac 1.5kA 20x5 mm
External 24Vdc C1682905 FS2 315mA T HBC 250Vac 1.5kA 20x5 mm
Flame On / Off output 747228820 FS3 3.15A FF HBC 250Vac 1.5kA 20x5mm
Figure 25: Fuse Replacement Types and Ratings

Fault Identification.
There are a number of simple diagnostic techniques that can be used to isolate and correct faults. These are
identified in the table below. Generally the possible causes and corrective actions are identified in the order in
which they should be checked in order to minimise down time.
Problem Description Possible Causes Corrective Action

Push ‘On’ button on the front of the
Amplifier turned off
Amplifier
Check external circuit breaker or fuse to
check 115Vac or 230Vac is available on
No Power to mains powered the backplane connector
Amplifier If power to the backplane connector –
see Dismantling the Amplifier to check
Mains Selection and Fuses 4
Check external fuse or circuit breaker to
check 24Vdc is available on the
No Power to 24Vdc powered backplane connector
No bargraphs or LEDs Amplifier If 24Vdc to the backplane connector –
illuminated on the Fascia see Dismantling the Amplifier to check
Fuse 2
If no fault is found with the fuses above
then there may be an internal fault
Internal auto-reset fuses
which is protected by auto-reset fuses.
Re-fit the Amplifier and check again.
Check the pins are not damaged on the
connector on the rear of the Amplifier,
this will prevent it being pushed in
Damaged Pins on the Connector
fully. Damaged pins can be straightened
with care or returned to Hamworthy for
connector replacement.
Power on / off buttons don’t Incorrect voltage selection Check the voltage selection and supply
work and flame relay will not (115Vac supply with 230Vac voltage as described in ‘Mains
pull in selection internally) Selection’
Transient Internal Fault during Press Internal Fault button to clear the
system checks fault.
Re-connect the Flame Viewing Head.
Check wiring on the backplane
connector, intermediate terminals and
junction boxes.
Head Connection Check the pins are not damaged on the
connector on the rear of the Amplifier.
Damaged pins can be straightened with
care or returned to Hamworthy for
Internal Fault ON continuously connector replacement.
If available fit another Flame Viewing
Head, if fault corrected return faulty
head to Hamworthy.
Head not functioning If fault remains fit another Amplifier, if
fault corrected return faulty Amplifier
to Hamworthy. If fault remains then see
Head Connection above.
Ensure locating lugs are correctly
Head not correctly fitted to Head
positioned see “Head Operation
Mount
Principle” on page 7.

Problem Description Possible Causes Corrective Action
Shutter Fault LED on but Press Shutter Fault button to clear the
Shutter fault occurred but Flame
SmartScan functioning fault indication. Check brightness level
Off has reset Fault
correctly as per Flame On commissioning. Fig 22
Shutter is not functioning. By looking
into the head it should be possible to see
Shutter self test is failing because the shutter operating. If not then if
Flame Signal does not drop below available fit another Flame Viewing
Threshold during a Shutter test Head to see if fault rectified. If rectified
return faulty head to Hamworthy. If not
rectified refer to next item.
The SmartScan system is very immune
to all external electromagnetic sources.
Shutter Fault LED on, flame
However incorrect installations i.e.
signal high but Flame Relays
signal cables not isolated from power
OFF External noise source
cables, poor earthing or incorrect
screening of signal cables will reduce
the SmartScans immunity. Check
Cabling.
Very high levels of vibration (in excess
of 5G) may generate a shutter fault.
Excessive Vibration This acts as a preventative measure to
stop physical damage to burners /
boilers.
See Automatic Threshold Adjust. If this
function is not used the backplane
Threshold Level increases /
Operation of ATA terminals should not be connected and
decreases automatically
the Bias potentiometer dialled fully
anticlockwise.
Adjust HF and LF gain as discussed in
Incorrect Gain
Commissioning.
Flame Strength is always Low Aperture too large (Head See Aperture Discs.
Saturated) or Aperture too Small
Poor Alignment See Mounting the Flame Viewing Head.
Check wiring for Fuel Select Input. This
should be a Volt Free Contact, which
Incorrect operation of Fuel Select
Fuel selection not changing shorts the two pins to select Fuel Profile
Input
2. If fault persists return Amplifier to
Hamworthy.
If a sliding glass is fitted, clean as
detailed below. If no sliding glass is
fitted, permits to shut down the burner
Gradual reduction in signal Lens or sliding glass window dirty
and remove the head for cleaning must
be obtained before the lens is cleaned as
detailed below.
Preventative Maintenance.
Minimal maintenance is required. Periodically it is advised that the following be checked: -
1) Cable glands and cable integrity at glands and connectors. The glands should be tight and there should be
no degradation of the cable sheath. The frequency to be determined from site installation checks.
2) Sliding glass windows should be wiped with a clean dry cloth and then the locking ring released to allow the
slide glass to be slid across. The action of sliding the glass across should be performed quickly (less than 1
second), to ensure the flame relays do not dropout and shut down the burner. The frequency for cleaning the
sliding glass will depend on site conditions. Generally coal fired plant and up-fired burners will require
more frequent cleaning than gas fired plant.
3) If no sliding glass is fitted the lens in the front of the head should be cleaned when the burner is shut down
for routine maintenance. Site outage programs will determine the maintenance period.

Specification.
Flame Viewing Heads.
Specification common to all Flame Viewing Heads.

Field of View +/-1.6o
Size 117mm long by 54mm diameter
Weight 0.89kg
Fixing M54 x 2 male Thread
Environmental Protection IP65.
Material: Standard Bright Zinc Plate and Passivate Steel.
Corrosion Resistant Stainless Steel
Temperature -40oC to +80oC (Safe Area and Hazardous Area)
Humidity 10-95% rh Non- condensing
Vibration 10Hz – 150Hz at 1.0g
Stainless Steel Heads Type Approved Lloyds Register ENV1, 2, 3 & 5
No user serviceable parts – Return to Hamworthy for repair
Ultra-Violet Head.
Spectral Response Peak 380nm
50% 330nm – 400nm
Fuel Types Oil / Gas with High Discrimination
Ultra-Violet / Visible Head.

50% 320nm – 480nm
Fuel Types Oil / Gas including Flue Gas Recirculation
Lower Discrimination
Infra-Red Head.
50% 650nm – 1050nm
Fuel Types Oil
Hazardous Area FlameViewing Heads.
European Hazardous Area covers the Flame Viewing Heads for

Intrinsic Safety EEx ia
Zone 0
Gas Group IIC
Temperature Class T4 (-40oC <= Ambient Temperature <= +80oC)
FM Hazardous Area covers the Flame Viewing Heads for

Intrinsic Safety
Class I
Group A,B,C,D
Temperature Class T4 (-40oC <= Ambient Temperature<= +60oC)

Head Accessories.
Head Mount.
Rotational Movement +/- 8.5 o

(Detailed at 0o and not allowing for Angular movement)
Weight 0.34kg
Maximum rated Temperature 120OC Continuous
130OC
Fixing 3 M6 studs, equi-spaced (120o) on a 60.0mm pcd
alternatively weld on outer 75mm diameter.
Head Mount including Sliding Glass Assembly.
Rotational Movement +/- 8.5 o

(Detailed at 0o and not allowing for angular movement)
Slide Glass protrudes 72mm from centre line – allow 72mm from
either side of centre line in one axis by 30mm wide.
Weight 0.6kg
Fixing 3 M6 studs, equi-spaced (120o) on a 60.0mm pcd.
Alternatively weld on outer 75mm diameter.
Sight Tube.
Size Protrudes 428mm from back face of ball swivel

Diameter 22.2mm
Weight 0.32kg
Fixing M27 x 2
Screws into Head Mount
Head Cable – common specification for all cables.
Length 2m
Weight 0.3kg
Core Size 0.75mm2
Number of Cores 3
Screen copper braid
Connector 3 way circular DIN 41524
Gland 20mm non earthing for 6.8 – 8.8 mm cable
Free Wires Ferrule crimps with numbered identification
Safe Area Head Cable.
Type Olflex 110CY

Colour Typically clear pvc

Hazardous Area Head Cable.
Type Olflex EB CY Blue

Colour Blue
Standards VDE 0165 for IS cables
Flame Retardant Cable.
Type Lapptherm 145+C
Hazardous Area Flame-Retardant Cable.
Type Lapptherm 145+C
Flame Amplifier.
General Specification.
Module Size 3U (129mm) x 12 HP (61mm) Fascia
Module Type 4 Rail
Fascia Membrane 4 Key Keypad with tactile feedback
IP20
Connector DIN41612 with selective loading
Weight 1kg
Humidity 10 – 95% rh Non-condensing
Vibration 10Hz – 150Hz at 1.0g (Subject to Approval)
Temperature -40oC to +60oC for the rack module de-rating to
-40oC to +50oC for the Fascia and Wall Mount units.
Power Supply Input.

Voltage 24Vdc (+/- 10%) < 200mV ripple
or 115Vac (+10%, - 15%) 47 – 63Hz
or 230Vac (+10%, -15%) 47 – 63Hz
Power 18VA / 24Watts Maximum
Flame On / Off Relay Contacts.

Type Volt Free Changeover
Rating Resistive 3A max (internally fused)
Inductive 0.5A ∅ 0.7
4-20mA Flame Strength Output.

Type Current Source
Maximum Load 500 ohm
Automatic Threshold Adjust Input / Output.

Type 0-12V
Fuel Profile Select Input.

Type Volt Free
Powered Output 42Vdc Maximum
Load 70mA inductive

Safe Area Flame Amplifier.
Fascia Mount Enclosure.

Height 144 mm
Width 72mm
Protrusion from Panel front 37mm
Depth required inside panel 216mm
Panel cut out size 68mm by 137mm
Environmental Protection IP65 with door closed
Cable Entry Use suitable grommets and cut appropriate holes in terminal
section
Weight 1.7kg (including amplifier and backplane assembly)
Wall Mount Enclosure.

Height 164 mm
Width 72mm
Protrusion from Back Plate 263mm
Environmental Protection IP65 with door closed
Cable Entry Use suitable cable glands and cut appropriate holes in terminal
section.
Weight 1.6kg (including amplifier and backplane assembly)
Rack Mount.
Height 3U
Width 19” (482.6mm)
Depth 245mm
Environmental Protection IP20 Fascia. use suitable enclosure for rack
Maximum number of Amplifiers 7
Weight 1.3kg plus 1.1kg per Amplifier / backplane assembly.

Application / Installation Checklist.

1) Head selected for either :-
a) Safe Area use.
b) Hazardous Area use.
Hazardous Area Certification is suitable for intended installation zone.
Cable type and distance complies with Hazardous Area System Certificate.
Galvanic Isolator included for each Hazardous Area Flame Viewing Head where no IS earth is
available.
Zener barrier included for each Hazardous Area Flame Viewing Head where an IS earth is available.
2) Head correctly selected for fuel type; UV, UV-Vis or IR.
3) Stainless steel options used for corrosive atmospheres.
4) Head mount selected for each head:-
a) Standard.
b) Including Sliding Glass. Typically on up-fired or where dirt on the lens may cause a problem.
c) Stainless steel options used for corrosive atmospheres.
5) Sight tube included
a) For up-fired burners.
b) To improve discrimination on multi-burner furnaces.
c) To detect oil flames against a coal background.
d) Stainless steel option used for corrosive atmospheres.
6) Purge air fitted in order to reduce temperature at Flame Viewing Head or reduce dirt build up on the lens or
sliding glass.
7) Head Cable Assembly selected for : -
a) Hazardous Area or Safe Area.
b) Standard or flame retardant.
c) 2m length (standard) or customer specific length.
d) Not required for stainless steel head (comes complete with 2m cable).
8) Head Cable Junction Box selected to allow connection to Head Cable Assembly.
9) Additional 20mm metal cable gland selected to take field wiring into Head Cable Junction Box (if required).
10) Field cable selected (if required).
11) Head Changeover unit selected (if it is necessary for the Amplifier to monitor one of two heads). Check
voltage selection is correct.
12) Amplifier Enclosure selected:-
a) Fascia Mount
b) Wall Mount.
c) Rack Mount.
d) If the Amplifier has to be mounted in a Hazardous Area, this must be considered on a contract basis;
a number of suitable options are available from Hamworthy Combustion Eng Ltd.
13) Additional 20mm plastic cable glands selected to take cables into Wall Mount Enclosure.
14) Enclosure positioned to ensure maximum temperatures not exceeded.
Serial Number Identification.
All serial number follow the same format:
MMYYNNN
where
MM Month of manufacture
YY Year of manufacture
NNN Incremental number for the product within the manufactured batch number.

Single Amplifier Enclosure including Amplifier Module and Accessories Quantity
363920652 Fascia Mount General Latch
363920652/K Fascia Mount Key Latch
363920660 Wall Mount (use gland/nut below for cable entry max 4 plus head gland) General Latch
363920660/K Wall Mount Key Latch
747830534 20mm plastic cable gland to take 5mm to 10mm diameter cable
747830542 Nut for 20mm plastic cable gland
19" Rack Assembly including Amplifier Modules (state Number of Amplifiers Per Rack ψ)
3439017/008/ψ Rack Mount Up to 7 Amps ψ
Safe Area Flame Viewing Heads and cables including 20mm metal cable gland and head connector
363920794/P UV Flame Viewing head
363920828/P UV-Vis Flame Viewing head
363920852/P IR Flame Viewing head
363920611 Standard Cable Assembly 2m length
363920637 Flame Retardant Cable Assembly 2m length
363920611/V Standard Cable Assembly Customer Specified length m
363920637/V Flame Retardant Cable Assembly Customer Specified length m
Hazardous Area Viewing Heads and cables including 20mm metal cable gland and head connector
363920802/P IS UV Flame Viewing head
363920836/P IS UV-Vis Flame Viewing head
363920860/P IS IR Flame Viewing head
363920629 IS (blue Sheath) Standard Cable Assembly 2m length
363920645 IS (blue Sleeve) Flame Retardant Cable Assembly 2m length
363920629/V IS (blue Sheath) Standard Cable Assembly Customer Specified length m
363920645/V IS (blue Sleeve) Flame Retardant Cable Assembly Customer Specified length m
Viewing Heads for Corrosive Atmospheres (Stainless Steel) suitable for Hazardous Areas
363921068/P IS S/S UV Flame Viewing head (includes 2m of Flame retardant cable and s/s gland)
363921076/P IS S/S UV-Vis Flame Viewing head (includes 2m of Flame retardant cable and s/s gland)
363921084/P IS S/S IR Flame Viewing head (includes 2m of Flame retardant cable and s/s gland)
Isolators / Barriers for Hazardous Area Interface *1 required per Hazardous Area Flame Viewing head
747832043 Zener barrier for installations with an IS earth
747832607 Galvanic Isolation Barrier for installations with no IS earth
Head Cable Accessories
650-WM-0001 Junction Box (to connect Cable Assemblies above to field wiring)
747830229 20mm metal cable gland to take 6.8mm to 8.8mm diameter cable
747830187 Nut for 20mm metal cable gland
747830559 20mm Stainless Steel Cable gland to take 3.5mm to 8.4mm diameter cable
747290051 Standard Cable (clear PVC Sheath) Customer Specified length m
747290069 Intrinsically Safe Cable (Blue Sheath) Customer Specified length m
747290291 Flame Retardant cable Customer Specified length m
363920022 Head Changeover Module 24Vdc
363920030 Head Changeover Module 115Vac
363920048 Head Changeover Module 230Vac
Head Mount (including Ball Swivel Heat Barrier / Purge Air Inlet) *1 required per Flame Viewing Head
363920752 Standard (no sliding glass)
363920760 Standard Including Sliding Glass
363921092 Stainless Steel (no sliding glass)
363921100 Stainless Steel Including Sliding Glass
Sight Tube *1 required per Flame Viewing Head on Upfire Burners optional on Horizontal / Downfire
CS40034 Standard
CS40049 Stainless Steel
Commissioning Accessories
363920886 Flame Sighting Unit / Flame Synthesiser
363920235 Battery charger for Flame Synthesiser
CS40053 Head Alignment Tool
747705654 Optional key lock for Amplifier Enclosure
Spares only. Items below are included as standard with enclosures / heads etc
363920587 Amplifier Module 230Vac, 115Vac and 24Vdc
363920595 Backplane Assembly
747602289 Circlip to retain aperture disc in head
747602291 Aperture disc pack (5 discs)
CS40037 Replacement quartz window for sliding glass assembly (single)
Figure 26: Part Number and Order Form.

Intrinsically Safe Cable Calculations
Contract Num ber:

Data supplied by Nam e: Date:
Com pany:
Tel: Fax:
Barrier Type
Manufacturer MTL Verify thes e param eters
Model 5042
Safety Description Of Barrier
Voltage Vo 28 V According to
Res is tance Ro 300 ohm EN50020 Issue 1
Current Io 93 mA NOT ATEX
Maxim um Param eters specified for Barrier
Gas Group IIC IIB IIA
Capacitance Cm 0.13 0.39 1.04 uF
Inductance Lm 4.2 12.6 33.6 m H
Sm artScan 121 Flam e View ing head Specification
Voltage Ui 28 V
Current Ii 150 mA
power Pi 0.8 W
Capacitance Ci 0.032 uF
Inductance Li 0.07 mH
Cable Type
Manufacturer Olflex
Model EB CY 0012551 3x0.75
Cable param eters
Capacitance
Core to core Ccc 0.135 uF/km Enter thes e
Core to s creen Ccs 0.185 uF/km param eters from
Inductance cable m anufacturers
core Lc 0.65 m H/km data
Gas Group for InstallationArea
Gas Group IIC Enter the gas group
From Data above for the ins tallation -
Allowable cable capacitance refer to cus tom er
Ca=Cm - Ci = 0.098 uF s pecification
Allowable Cable inductance
La=Lm - Li = 4.13 m H
Cable lum ped capacitance

Ccc+Ccs = 0.32 uF/km
Maxim um Cable length

Capacitance Lim ited
Ca/(Ccc+Ccs ) = 0.30625 km
Inductance Lim ited
La/Lc = 6.353846 km
For Intrinsic Safety to be achieved for Gas Group IIC:

Capacitance is the lim iting factor.
The Maxim um cable length is 306m etres.
For correct operation, the m axim um length m ust be lim ited to 500m , irrespective of the value
calculated above.
The above calculation is based on available data and is provided as a guide only.
Figure 27: Hazardous Area Cable Calculation Example for Galvanic Isolator.

Intrinsically Safe Cable Calculations
Contract Num ber:

Data supplied by Nam e: Date:
Com pany:
Tel: Fax:
Barrier Type
Manufacturer MTL Verify these parameters
Model 765AC
Safety Description Of Barrier
Voltage Vo 15 V
According to EN50020
Resistance Ro 100 ohm
Issue 1 NOT ATEX
Current Io 150 mA
Maxim um Param eters specified for Barrier
Gas Group IIC IIB IIA
Capacitance Cm 0.75 2.25 6 uF
Inductance Lm 0.32 0.96 2.56 mH
Sm artScan 121 Flam e View ing head Specification
Voltage Ui 28 V
Current Ii 150 mA
pow er Pi 0.8 W
Capacitance Ci 0.032 uF
Inductance Li 0.07 mH
Cable Type
Manufacturer Olflex
Model EB CY 0012551 3x0.75
Cable param eters
Capacitance
Core to core Ccc 0.135 uF/km Enter these parameters
Core to screen Ccs 0.185 uF/km from cable
Inductance manufacturers data
core Lc 0.65 mH/km
Gas Group for InstallationArea
Gas Group IIC Enter the gas group for
From Data above the installation - refer to
Allow able cable capacitance customer specification
Ca=Cm - Ci = 0.718 uF
Allow able Cable inductance
La=Lm - Li = 0.25 mH
Cable lumped capacitance

Ccc+Ccs = 0.32 uF/km
Maxim um Cable length

Capacitance Limited
Ca/(Ccc+Ccs) = 2.24375 km
Inductance Limited
La/Lc = 0.3846154 km
For Intrinsic Safety to be achieved for Gas Group IIC:

Inductance is the lim iting factor.
The Maxim um cable length is 384m etres.
For correct operation, the m axim um length m ust be lim ited to 500m , irrespective of the value
calculated above.
The above calculation is based on available data and is provided as a guide only.
Figure 28: Hazardous Area Cable Calculation Example for Zener Barrier.

Index
alignment, 5, 9, 10, 11 Fuel Select, 6, 30

Amplifier Fuses, 27, 28, 29
Automatic Threshold Adjust, 23, 30, 33 Galvanic Isolator, 8, 35, 37
Bias, 23, 30 Gas Group, 8, 31
frequency bands, 15 Hazardous Area
HF, 3, 23, 30 explosive atmospheres, 8
High Frequency, 3, 23 Intrinsic Safety, 6, 31
LF, 3, 23, 30 Head Mount, 4, 5, 10, 11, 12, 32
Low Frequency, 3, 23 Head Selector Module, 14
Threshold, 5, 6, 15, 23, 30, 33 Health and Safety
Analog Output, 24 personal safety, 4
Aperture Discs, 5, 12, 30 training, 4
Ball Swivel, 5, 10, 11, 32 work permit, 4
bargraph, 5, 6, 15, 23 Heat Barrier, 5, 10, 11
Burner Management System (BMS), 5, 6, 15 High Frequency Gain Adjust, 23
Cable Installation Category, 21
capacitance, 8, 13 Intended Use, 4
Flame Retardant, 13, 33 junction box, 5, 13, 14, 29, 35
head cable assembly, 5, 13, 14, 32, 33, 35 Mains Selector Switch, 27, 29
inductance, 13 multi-burner installations, 5, 23
maximum length, 6, 13 Operating Voltage, 14, 15
screened, 5, 13, 14, 21 Over Voltage Protection, 21
segregation, 13 Pollution Degree, 21
twisted pair, 5, 13 potentiometer, 4, 15, 23, 30
circlip, 12 potentiometer
Commissioning, 5, 6, 24, 25, 26, 30 adjustment, 4, 5, 6, 12
discrimination, 5, 9, 23, 35 Power Supply, 15, 33
Dismantling the Amplifier, 15, 27, 29 Protective Earth, 4, 14
electrostatic sensitive, 4, 27 purge air, 5, 10, 11
Enclosure relay test, 15
Fascia Mount, 17, 20, 34 Safe Area, 8, 13, 14, 32, 34, 35
general latch, 20 Safety Integrity Level, 6, 15
key latch, 20 Self Check
Rack Mount, 19, 20, 34, 35 Dual Channel, 6
Wall Mount, 18, 20, 21, 34, 35 Mechanical Shutter, 6
Fault shutter blade, 15
Identification, 29 Sight Tube, 10, 11, 32
Faults Sliding Glass, 4, 5, 10, 11, 32, 35
Internal, 5, 6, 15, 29 swirl direction, 9
Latched, 5 Temperature Class, 8, 31
Shutter, 5, 6, 15, 30 terminal compartment, 17, 20
Flame thermal isolation, 10
brightness, 5, 7, 8, 9, 12 Threshold Adjust, 23, 30, 33
flicker, 5, 7, 9, 10, 15 Training, 3, 4
Flame On / Off Verification, 4, 12, 26 Warnings
Flame Strength Output, 24, 33 anti-static handling, 4, 27
Flame Synthesiser, 5 dangerous voltages, 4
Flame Viewing Head, 4, 5, 6, 7, 8, 9, 10, 11, 12, personal injury, 4
14, 24, 29, 30, 31, 35 Zener Barrier, 8, 38
Fuel Profile, 15, 23, 30, 33 Zone, 6, 8, 31

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SmartScan Manual Issue 2.5

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Hamworthy Combustion Engineering Ltd SmartScan 121

Hamworthy Combustion Engineering Ltd

Manual Reference: 3439017/040 15-10-00

Page 1 Issue 2.5 Dated 09-04-09

Common Abbreviations. ............................................................. 3

System Overview. .................................................5 Specification. ............................................................................... 31

Page 2 Issue 2.5 Dated 09-04-09

Page 3 Issue 2.5 Dated 09-04-09

Potentiometers shall always be adjusted using a non-metallic potentiometer adjustment tool.

! This Flame Amplifier case must be connected to Protective Earth.

Health and Safety.

Hamworthy Combustion Engineering.

Page 4 Issue 2.5 Dated 09-04-09

The SmartScan 121 system consists of:

Page 5 Issue 2.5 Dated 09-04-09

Features and Benefits.

Page 6 Issue 2.5 Dated 09-04-09

Flame Viewing Heads.

Head Operating Principle.

Stainless Steel Versions

Figure 1: Flame Viewing Head Dimensions.

Corrosion and the effects of Aggressive Substances.

Page 7 Issue 2.5 Dated 09-04-09

Selecting the Flame Viewing Head.

Burner Type Head Type

Hazardous Area Applications.

Head Type Part Number

Certificate Number BAS01ATEX1020

Page 8 Issue 2.5 Dated 09-04-09

Missing Swirler Blade to

Main High Frequency Flicker region

Figure 4: Flame Viewing Head Sighting Position.

Page 9 Issue 2.5 Dated 09-04-09

Figure 5: Head Mount (also shows optional Sight Tube).

Page 10 Issue 2.5 Dated 09-04-09

Sliding Glass Assembly .

75m 120m 428m

Sight Tube Standard Stainless Steel

Page 11 Issue 2.5 Dated 09-04-09

Aperture Discs. (Part Number 747602291).

To fit or change an aperture disc:

Page 12 Issue 2.5 Dated 09-04-09

Detector Head Cable Assembly.

Maximum Cable Length (length of cable from Head to Amplifier):

Application Description Standard 2m Length Special Length

Figure 9: Detector Head Cable Assembly Selection Table.

Page 13 Issue 2.5 Dated 09-04-09

Head Cable Junction Box (Part Number 650-WM-0001).

Figure 10: Head Cable Junction Box showing Cable Terminations.

Head Selector Module. (For use in safe area)

Operating Voltage Part Number

Figure 12: Head Selector Module Connection Diagram.

Page 14 Issue 2.5 Dated 09-04-09

Page 15 Issue 2.5 Dated 09-04-09

Fascia Layout and Functional Description.

T hr e shold Ad just P ote nt iom e ter . R ota tin g th e F la m e H igh F re qu en cy Ga in A djust

B ia s A dju st P ote ntio m e te r . R o ta tin g the L ow F r e que nc y G a in A djust

Figure 13: SmartScan 121 Fascia.

Page 16 Issue 2.5 Dated 09-04-09

Figure 14: Fascia Mount Enclosure.

Page 17 Issue 2.5 Dated 09-04-09

Page 18 Issue 2.5 Dated 09-04-09

Page 19 Issue 2.5 Dated 09-04-09

Type Part Number Number of Amplifiers