POWER INSTRUMENTS
SPECTRATM BC11 FLAME SENSOR
INSTALLATION AND OPERATIONS MANUAL
1085-150 Rev. A
Disclosure Notice
THE INFORMATION (INCLUDING TECHNICAL DATA) CONTAINED IN
THIS DOCUMENT IS THE PROPERTY OF AMETEK POWER
INSTRUMENTS. IT IS DISCLOSED IN CONFIDENCE. THEREFORE,
NONE OF THE INFORMATION MAY BE DISCLOSED TO OTHER THAN
THE RECIPIENT, OR USED FOR PURPOSES OTHER THAN TO RENDER
SERVICES TO AMETEK, WITHOUT THE EXPRESS PRIOR WRITTEN
AUTHORIZATION OF AMETEK.
Spectra and the Spectra logo are trademarks of Ametek Power
Instruments. Ametek, and the Ametek logo are trademarks of Ametek Inc.
Copyright © 2005.
By Ametek Inc.
All Rights Reserved
Warranty
AMETEK warrants equipment of its own manufacture to be free from
defects in material and workmanship, under normal conditions of use
and service. AMETEK will replace any component found to be defective,
upon its return, transportation charges prepaid, within one year of its
original purchase. AMETEK will extend the same warranty protection on
accessories that is extended to AMETEK by the original manufacturer.
AMETEK assumes no responsibility, expressed or implied, beyond its
obligation to replace any component involved. Such warranty is in lieu
of all other warranties expressed or implied.
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SpectraTM BC11 Installation and Operations Manual
Contents
1. Introduction and Installation .....................................................................1-1
General ................................................................................................................................ 1-1
Sensor Construction........................................................................................................ 1-1
Optical Sensitivity........................................................................................................... 1-2
General Notes on Flame Sensor Installation.................................................................... 1-4
Installation ........................................................................................................................... 1-8
2. Operation ..................................................................................................2-1
Inspection ............................................................................................................................ 2-1
Testing and Fault Isolation .................................................................................................... 2-2
Current Measurement ..................................................................................................... 2-3
Voltage Measurement ..................................................................................................... 2-4
3. Cleaning and Storage .................................................................................3-1
Cleaning and Preparation for Storage or Shipment................................................................ 3-1
Sensor Cleaning.............................................................................................................. 3-1
Preparation for Shipment or Storage................................................................................ 3-2
Appendix A. Specifications and Accessories ................................................. A-1
Specifications .......................................................................................................................A-1
Compliance Tests .................................................................................................................A-2
Optional Accessories............................................................................................................A-3
Appendix B. Schematics ................................................................................B-1
1085-150 Rev. A 1/05
iii
iv
1085-150 Rev. A 1/05
Preface
Purpose and Scope
This manual describes the AMETEK SpectraTM BC11 Flame Sensor
operation, maintenance and installation procedure. The manual
contains information to support the use of the sensor for flame
monitoring of a burner in the boiler of an industrial power utility or
other application. If more data is necessary or special problems occur
that are not covered in this manual, refer inquiries to:
AMETEK Power Instruments
255 North Union Street
Rochester, NY 14605
Phone: 585-263-7700
Fax: (585) 454-7805
Website: http://www.ametekpower.com
Reference Documents
ANSI/ISA-1995 (S50.1)
Compatibility of Analog Signals for Electronic
Industrial Process Instruments
ANSI/ISA-1995 (S71.01)
Environmental Conditions for Process Measurement and Control Systems: Temperature and
Humidity
ANSI/ISA-1995 (S71.03)
Environmental Conditions for Process Measurement and Control Systems: Mechanical Influences
ANSI/ASME CSD-1-195
Controls and Safety Devices for Automatically
Fired Boilers by ASME
FACTORY MUTUAL Approval Standards for Combustion Safeguards
NFPA 70
1085-150 Rev. A 1/05
National Electrical Code by NFPA
v
Notes, Cautions, and Warnings
Note, Caution, and Warning icons denote information of special interest.
The icons appear in the column to the left of the text and are reproduced
below, along with explanations of their meanings.
NOTE
The NOTE icon signifies a cautionary statement, an operating tip or
maintenance suggestion.
CAUTION
The CAUTION icon signifies information that, if ignored, could lead to
instrument damage.
WARNING
The WARNING icon signifies information that denotes a potentially
hazardous situation, which, if not avoided, may result in death or serious
injury.
Document Conventions
Bold type indicates an item (button, etc.) on which an action is
performed.
Italics is used for emphasis.
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1085-150 Rev. A 1/05
SpectraTM BC11 Installation and Operations Manual
1. Introduction and Installation
General
The Spectra™ BC11 Flame Sensor is a two-wire loop-powered optical
flame sensor that receives either IR or UV energy from the combustion
process and transmits a 4-20 mA analog signal proportional to flame
intensity. The Spectra™ BC11 operates continuously up to 125 °C
(257 °F). The Spectra™ BC11 is mounted directly to the burner or on a
short standoff pipe via an internal 1" NPT thread.
Sensor Construction
Sensor models and differences among them are given in Table 1.1. The
housing of the sensor has a viewing port at one end with installation
threads. The sensor is attached to the application using the 1" NPT female
thread.
The other end of the housing has a MAIN electrical connector that mates
with the interconnection cable. The housing, environmentally sealed for
operation in a relative humidity from 0 to 95% non-condensing, contains
the optics and electronics that convert the radiation collected at the
viewing port to a variety of output formats.
Table 1.1 Flame Sensor Model Differences
Model
Radiation
Sensitivity
Threads
Electrical
Code Class
Ambient
Temperature
BC11-UV
UV
200 nm 380 nm
1" NPT
Class 1
Div 2
-40 to
125° C
BC11-IR
IR 700 nm 1100 nm
1" NPT
Class 1
Div 2
-40 to
125° C
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1-1
Optical Sensitivity
The intensity of optical energy, emitted by heated bodies, varies with
temperature and wavelength.
Figure 1.1 shows the relation of emission intensity to wavelength for an
ideal black body at several temperatures in the visible (400 to 700 nm)
and ultraviolet range (200 to 400 nm). Emission of optical energy by
flames is similar to that of a black body, except that, additional optical
energy is generated by the chemical reaction that results from
combustion of the fuel that produces the flame.
Figure 1.1 Black Body Emissions
Coal and Oil
Burners
In burners of coal and oil droplets, heat emission from flames is much
greater than chemical emission at all wavelengths, so their flames act like
a black body. Emission intensity is greatest in the IR range (700 to 1100
nm). Therefore, sensors for monitoring flames from the burning of coal
and oil have optical detectors with greatest sensitivity to IR radiation.
Natural Gas
Burners
In burners of natural gas, optical energy from chemical emission is more
significant, especially in the UV/Visible region.
Figure 1.2 on page 1-3 shows the relative intensity of optical energy at a
range of wavelengths. Narrow peaks, or lines of optical energy, resulting
from chemical action are superimposed on the more uniform response
characteristic of heat emission. The lines give the natural gas flame a
unique signature. The line at 310 nm is important in discriminating
between flame emission and heat emission at longer wavelengths from
hot metal parts. Because of the unique characteristics of optical energy
emitted by gas flames, the BC11-UV sensors have detectors with greatest
sensitivity to UV radiation.
1-2
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SpectraTM BC11 Installation and Operations Manual
Figure 1.2 Gas Flame Emissions
Spectral Response
of Detectors
Figure 1.3 shows the response of three types of optical detectors.
Figure 1.3 Differences in Detector Responses
Silicon sensitivity includes much of the visible and IR range with greatest
sensitivity in the IR range. This type of detector is satisfactory for
monitoring coal and oil flames. It is used in the BC11-IR sensor.
The detector used in an older tube detector has a narrow range of
sensitivity in the UV region, but is insensitive to the 310 nm line of
energy, characteristic of the natural gas flame. The AMETEK UV detector
has maximum sensitivity near 310 nm and has a narrow bandpass that
excludes higher wavelength energy, such as that in the IR region
generated by hot metal parts. It is used in the BC11-UV sensor.
1085-150 Rev. A 1/05
1-3
General Notes on Flame Sensor Installation
Flame sensor installation consists of:
• ”1. Flame Sensor Selection” :
• UV or IR (Based on Fuel)
• Environment
• ”2. Flame Sensor Sighting” :
• Which flame will the sensor be used to monitor
• Main burner Flame
• Igniter
• Main Fireball
1. Flame Sensor
Selection
Environment
IR and UV
Selection Based
On Fuels
BC 11 series flame sensors are used when temperatures are 125 °C
maximum.
As a general guide for sensor selection:
• IR is used for heavy fuel oils and coal.
• UV is used for light fuel oils and natural gas.
Most systems use 2 fuels
2. Flame Sensor
Sighting
NOTE
WARNING
1-4
An acceptable scanner location must ensure the following:
• Reliable pilot flame detection.
• Reliable main flame detection.
• Rejection of a pilot flame too short or in the wrong position to
ignite the main flame reliably, prohibiting main fuel admission.
Reliable signals must be obtained at all air flows and furnace loads
(ranges of fuel firing).
Incorrect sensor installation can cause the sensor to generate a false
flame signal. This can cause unburned fuel to collect in the combustion
chamber, resulting in explosions, injuries and property damage. Be
certain that the flame sensor detects only the pilot and main flames, not
glowing refractory or burner parts.
1085-150 Rev. A 1/05
SpectraTM BC11 Installation and Operations Manual
Use the following guidelines:
• The best results are obtained when the scanner is aimed so that
the scanner’s line of sight intersects the burner center at a slight
angle (e.g. 5 °) and sees a maximum of the primary combustion
zone (Figure 1.4). If only one scanner is used per burner, the line
of sight should also intersect the igniting flame.
• For installations where separate scanners are used to monitor
main and ignitor flames, the main flame scanner should be
sighted so it does not detect the ignitor flame.
The scanner should have an unrestricted view of flame, as far as possible.
Figure 1.4 Single Burner Scanner Sighting
• Consider burner secondary air rotation: clockwise (CW) or
counterclockwise (CCW) air rotation. If combustion air enters the
furnace with a rotational movement of sufficient velocity to
deflect the ignitor flame in the direction of rotation, position the
scanner 10 to 30 ° downstream of the ignitor (Figure 1.5) and
close to the periphery of the burner throat.
Figure 1.5 Scanner Location vs. Secondary Air Rotation
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1-5
Sighting
Inspection
Always check sighting prior to the installation of a flame sensor
(Figure 1.6).
Figure 1.6 Proper Sighting
WARNING
Wear protective filtered lenses when viewing the flame. Infrared and
ultraviolet energy from the flame can damage eyes.
Figure 1.7 shows an example ignitor and main flame setup.
• Setup A: Depicts a MAIN FLAME only sighting
• Setup B: Depicts a minimal IGNITOR and MAIN FLAME sighting.
• Setup C: Depicts a normal (RECOMMENDED) IGNITOR and
MAIN FLAME sighting.
Figure 1.7 Example Ignitor and Main Flame Setup
1-6
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SpectraTM BC11 Installation and Operations Manual
Additional
Considerations
CAUTION
Some considerations on BC11 placement include:
Use only isolated DC power supplies for the BC11. Do not use a Variac
power supply.
Burner Flame Considerations
A burner has main and igniter or pilot flames. If
one sensor is used to monitor both flames, the line
of sight should intersect both. If separate sensors
are used, the lines of sight should not intersect.
Obstruction Considerations
If possible, obstructions, such as, air register
blades, vanes, or other hardware, should be
modified so that they do not interfere with the line
of sight. Unwanted matter, resulting from
combustion in the burner, can also obscure the
viewing port of the sensor. Purge air is used to
direct such matter away from the sensor.
Air Rotation Considerations
If combustion air enters the furnace or burner with
a rotational movement of sufficient velocity to
deflect the igniter flame in the direction of rotation,
aim the sensor 10° to 30° downstream of the
igniter and close to the periphery of the burner
throat.
Load Considerations
Flame characteristics vary with burner load and firing rates. The optimum alignment of a sensor with
respect to a monitored flame is that which gives the
highest average output under all considerations.
1085-150 Rev. A 1/05
1-7
Installation
Installation of a the Spectra™ BC11 flame sensor includes installation of
the sensor to the burner, making connections to the sensor, and sighting
the sensor for best response.
Table 1.2 lists the tools required for either installation type.
Table 1.2 Installation Material and Equipment
Item
Description
Wrench
Adjustable to 15/8"
Anti-seize compound
High temperature grade
Screw driver
Standard tip
To install:
1. Attach the sensor to the installation pipe or mounting flange using the
internal 1" NPT thread connection at the sensor window, and tighten
using an adjustable wrench (Figure 1.8).
CAUTION
The use of high temperature anti-seize compound is recommended.
When using any anti-seize or thread sealant take care not to get any on
the sensor window, as it degrades sensor operation.
2. Attach the mating cable by aligning the keyways of the connectors
and tightening the coupling ring clockwise until the cable is fully
mated. The cable is fully mated when the red indicator band on the
receptacle connector is not visible.
Figure 1.8 BC11 Installation Diagram
1-8
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SpectraTM BC11 Installation and Operations Manual
3. Wire per National Electrical Code standards (Figure 1.9).
Figure 1.9 BC11 Installation Wiring
See Table A.3 on page A-3 for wire identification.
1085-150 Rev. A 1/05
1-9
1-10
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SpectraTM BC11 Installation and Operations Manual
2. Operation
Inspection
You must have a 3X magnifying glass to perform an inspection. Inspect
the sensor for conditions given in Table 2.1. If conditions are found
during inspection that cannot be repaired locally, return the unit to:
AMETEK Power Instruments
255 North Union Street
Rochester, NY 14605
Phone: 585-263-7700
Fax: 585-238-4945
Website: http://www.ametekpower.com
NOTE
CAUTION
Before returning any item you must call for a Return Material
Authorization (RMA).
Ametek takes no responsibility for field repairs.
Table 2.1 Inspection Criteria
Condition
Corrective Action
Sensor window: Surface
scratches on the sensor window
Return to AMETEK.
Sensor window: Unwanted
material/contamination on
window
Refer to ”Cleaning and Storage”
on page 3-1.
Sensor window: Damaged
threads
Repair damaged threads with thread
chaser or return to AMETEK for
repair.
Connector: Unwanted
material/contamination
Remove unwanted material; refer to
”Cleaning and Storage” on page 3-1.
Connector: Bent pins
Carefully straighten the pins so that
they fit into the mating receptacle.
Connector: Broken pins
Return to Ametek if pins A,B or C are
broken.
1085-150 Rev. A 1/05
2-1
Testing and Fault Isolation
The sensor and interconnection cable can be tested as a system. If the
result is not satisfactory, isolate the fault by testing the sensor and by
performing a continuity test of the system interconnections.
To aid in fault isolation, refer to ”Current Measurement” on page 2-3 or
”Voltage Measurement” on page 2-4. Table 2.2 lists the equipment
needed for Testing and Fault isolation.
Table 2.2 Test Equipment
2-2
Item
Description
AC/DC Light Source
Quartz halogen lamp (100 W minimum) or
equivalent
DC Power Supply
0-30 VDC adjustable
Multimeter
0-5 VDC, 0.1% accuracy, 20 mA,1%
accuracy
Resistor
250 Ω, 1%, 1/4 W minimum
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SpectraTM BC11 Installation and Operations Manual
Current Measurement
To perform this test:
CAUTION
Ametek takes no responsibility for field repairs.
1. Connect the sensor as shown in Figure 2.1.
2. Block the sensor window to prevent any light from entering.
3. Vary the output of the DC power supply from 20 VDC minimum to
30 VDC maximum.
Ensure that the multimeter steadily reads 4.00±0.50 mA.
4. Shine direct light from the AC/DC light source into the sensor
window until the multimeter reads greater than 6.00 mA.
5. Vary the output of the DC power supply from 20 VDC minimum to
30 VDC maximum.
Ensure that the multimeter steadily reads greater than 6.00 mA.
Figure 2.1 Current Measurement
1085-150 Rev. A 1/05
2-3
Voltage Measurement
To perform this test:
CAUTION
Ametek takes no responsibility for field repairs.
1. Connect the sensor as shown in Figure 2.2.
2. Block the sensor window to prevent any light from entering.
3. Vary the output of the DC power supply from 20 VDC minimum to
30 VDC maximum.
Ensure that the multimeter steadily reads 1.00±0.13 VDC.
4. Shine direct light from the AC/DC light source into the sensor
window until the multimeter reads greater than 1.5 VDC.
5. Vary the output of the DC power supply from 20 VDC minimum to
30 VDC maximum.
Ensure that the multimeter steadily reads greater than 1.5 VDC.
Figure 2.2 Voltage Measurement
2-4
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SpectraTM BC11 Installation and Operations Manual
3. Cleaning and Storage
Cleaning and Preparation for Storage or Shipment
The sensor should always be cleaned:
• Before a test
• Before shipping or storing
Refer to Table 3.1 on page 3-2 for material and equipment used in
cleaning and preparing for shipment.
Sensor Cleaning
WARNING
Contact with liquid or particles propelled by compressed air can
permanently damage eyes.
Inhalation of air-blown particles or solvent vapor can damage lungs.
Cleaning fluids may be toxic and/or flammable. For safety, use only with
adequate ventilation; wear protective clothing; avoid contact with skin
and eyes; avoid breathing fumes. Do not expose to flame or sparks.
CAUTION
Do not direct compressed air flow at the lens; damage may result.
Do not let solvent come in contact with the window.
To clean the sensor:
1. Remove unwanted material from the external surface and threads
using filtered compressed air.
2. If residue remains, remove it from the external surface and threads
with a brush and a lint-free cloth moistened with cleaning solvent.
3. Dry the external surfaces and threads with filtered compressed air.
4. Clean the sensor window using a lint-free cloth or cotton swab and
glass cleaner.
5. Install protective covers on the sensor window and the connector.
1085-150 Rev. A 1/05
3-1
Preparation for Shipment or Storage
Table 3.1 lists items required to prepare for storage or shipment.
To perform this procedure:
1. Seal the unit in a clean plastic bag with a label indicating its part
number and serial number.
2. Pack the unit in a shipping box, protecting it with packing material.
3. Attach a label to the shipping box that indicates the part number and
serial number of the unit.
NOTE
Before returning any item you must call for a Return Material
Authorization (RMA).
NOTE
Store the unit in a location with low humidity.
Table 3.1 Material and Equipment
3-2
Item
Description
Plastic bag
12" by 8"
Cardboard box
12" by 6" by 6"
Brush
Non-metallic
Cloth
Soft, lint free
Compressed air
25-35 psig, filtered
Glass cleaner
#1 denatured alcohol
Safety goggles
GG-G-531 or equivalent
Safety gloves
ZZ-G-381 or equivalent
Dry cleaning solvent
P-D-680 Type II or equivalent
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SpectraTM BC11 Installation and Operations Manual
Appendix A. Specifications and Accessories
Specifications
The Spectra™ BC11 physical and operational specifications are listed in
Table A.1.
See Table A.2 on page A-2 for a listing of Spectra™ BC11 compliance
tests and Table A.3 on page A-3 for a listing of optional accessories.
Table A.1 Specifications
Specification
Range
Physical
Wire connections
•
•
•
•
•
•
•
•
Pin A: +24 VDC nominal
Pin B: 4–20 mA current return
Pin C: Case ground
Pin D: No connection
Pin E: No connection
Pin F: No connection
Pin G: No connection
Pin H: No connection
Mounting flange
connection
1" NPT internal thread
Body
Anodized aluminum NEMA-4x
Weight
0.6 kg (~1.4 lbs)
Operational
Operating
temperatures
−40 to 125 °C (–40 °F to +257 °F)
Humidity
95% relative per MIL-STD-202F
Input
• IR or UV energy from flame
• 4° field of view
Power
requirement
1085-150 Rev. A 1/05
+24 VDC nominal power input (20–30 VDC range)
A-1
Table A.1 Specifications (Continued)
Specification
Range
Output
Output current
25 mA maximum
Signal output
Industry standard 4 to 20 mA current loop,
no light input (total darkness) = 4.0 mA, ± 0.5 mA
over entire temperature range
Compliance Tests
Table A.2 lists the compliance tests for the Spectra™ BC11.
Table A.2 Compliance Tests
A-2
Standard
Tests Conducted
CE
EN55011: Radiated emissions
EN61000-4-2: ESD
EN61000-4-3: Radiated immunity
EN61000–4–4: EFT
EN61000-4-6: Conducted immunity
Factory Mutual
(FM)
To standards:
FM7610
FM3611
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SpectraTM BC11 Installation and Operations Manual
Optional Accessories
Table A.3 lists the accessories available to perform unit installation.
NOTE
Consult factory for other cable options.
Table A.3 Optional Accessories
Part Number
Description
ET-1215
Relay Module
•
•
•
•
SC-7403-N
Relay Module
• Single Input
• Single Output (SPDT)
• Software Adjustable Trip only
(PC-7400-3 Required)
• Power 24 VDC, 48VDC, 110 VDC,
120 VAC 50/60 Hz
SC-7404-N
Relay Module
• Single Input
• Dual Output (SPDT)
• Software Adjustable Trip only
(PC-7400-3 Required)
• Power 24 VDC, 48VDC, 110 VDC,
120 VAC 50/60 Hz
SC-7405-N
Relay Module
• Single Input
• Single Output (SPDT)·Single 4-20mA Retransmit
Output
• Software Adjustable Trip only
(PC-7400-3 Required)
• Power 24 VDC, 48VDC, 110 VDC,
120 VAC 50/60 Hz
PC-7400-3
Configuration Kit
• Configuration software and cable
• Used on 7403-N, 7404-N, 7405-N
8998A31P002
Power Supply
• 24 VDC, 0.6A Output
• Din mount
• Power Input 115 VAC
1085-150 Rev. A 1/05
Single or double 4–20 mA inputs - specify
Two SPDT inputs
Trip mode to be specified
Power 115 VAC
A-3
Table A.3 Optional Accessories (Continued)
A-4
Part Number
Description
8998A31P003
Power Supply
• 24 VDC, 2.0A Output
• Din mount
• Power Input 115 VAC
8998A31P004
Power Supply
• 24 VDC, 5.0A Output
• Din mount
• Power Input 115 VAC
8TL41AAA1
Cable
• 10’ long
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SpectraTM BC11 Installation and Operations Manual
Appendix B. Schematics
Figure B.1 SpectraTM BC11 Flame Sensor
1085-150 Rev. A 1/05
B-1
Figure B.2 Cable Shield Drawing and Wiring
B-2
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