Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.

™
SmartPilot
Gas burning Pilot with
Combined ignitor and Flame
Ionisation Detection Unit

Operating and Maintenance Manual

Hamworthy Combustion Engineering
Fleets Corner, Poole, Dorset.
England. BH17 0LA
Telephone U.K. +44 (0)1202 662700
Manual Number HCE 300A O&M / rev 1.2
10/11/04

1180
ATEX certified EN 298 certified
Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

Section Index

SmartPilot

Section Contents Page

1 REVISION LIST: .............................................................................................................................. 3

2 CONTRACT SPECIFICATION DETAILS.................................................................................... 5

3 HEALTH AND SAFETY .................................................................................................................. 6

3.1 GENERAL SAFETY ................................................................................................................... 6

3.2 HAZARDOUS AREA USE......................................................................................................... 8
3.3 COMBUSTION AND CONTROLS:........................................................................................... 9
3.4 OPERATORS .............................................................................................................................. 9
3.5 ELECTRICAL ........................................................................................................................... 10
4 "VENTURI" INJECTOR ............................................................................................................... 11

4.1 Introduction................................................................................................................................ 11
4.2 Description ................................................................................................................................. 11
5 SPECIFICATIONS.......................................................................................................................... 12

6 VARIANTS....................................................................................................................................... 13

7 ELECTRICAL CONNECTIONS................................................................................................... 14

7.1 Wiring instructions..................................................................................................................... 14

7.2 FIDU connections ...................................................................................................................... 14
7.3 Example Configurations............................................................................................................. 15
8 PILOT COMMISSIONING & OPERATING INSTRUCTIONS ............................................... 16

8.2 Maintenance ............................................................................................................................... 17

8.3 Daily Checks .............................................................................................................................. 17
8.4 Pilot Failure................................................................................................................................ 17
8.5 Unscheduled Maintenance Operations Removal, Cleaning and Refitting ................................. 18
8.6 Refitting Flame Detection Rod .................................................................................................. 18
9 CERTIFICATES.............................................................................................................................. 19

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

1 Revision List:

Manual Number HCE 300A

Rev 1.0 Original
Rev 1.1 Amended for Advantica EN298 Certification
Min/Max Ionisation Current added, p.g 12.
Ingress protection added, p.g 12.
EN298 classification added, p.g 12.
Flame Signal Output Impedance changed, p.g 12.
Rev 1.2 Change company logo on front cover
Add EN 298 certified to front cover
Added EN 298 certificate to section 7

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

Published by

HAMWORTHY COMBUSTION ENGINEERING LIMITED

(“HAMWORTHY”)
OF
FLEETS CORNER, POOLE, DORSET. BH17 OLA
First Published: 27/08/2003

Copyright and Design Right ©

Hamworthy Combustion Engineering Limited 2003

No part of this manual may be reproduced, stored in a retrieval system or transmitted in any
form or by any other means, electronic, electrostatic, magnetic tape, mechanical, photocopying,
recording or otherwise without the prior written permission of Hamworthy.
This manual may not be lent, sold, hired out or otherwise disposed of
by way of trade in any form whatsoever.

PRINTED IN THE UK.

NOTES:
1/ The information contained in this manual is intended as a guide only for use by suitably
trained and qualified personnel. Hamworthy can provide training. If in doubt about the
interpretation of this guide the user should contact Hamworthy.

2/ Hamworthy has made every effort to ensure that the information contained in this
manual is accurate at the time of publication. Its contents should be used however as
guidance material only and not as a replacement of current regulations or any
contractual specifications.

3/ As the application of the subject matter of this manual will differ dependent upon the
particular circumstances Hamworthy accept no liability for any loss of any kind
(including consequential or indirect loss) occasioned by any person relying upon this
manual.

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

2 Contract Specification Details

SmartPilot
CONTRACT NO/ :

PILOT MODEL NO/ :

APPLICATION DETAILS :
boiler/appliance manufacturer :

Heat input rating : System Protection: IP

Air system : System Operating Max/Min oC

Appliance working pressure/temp :

GAS FUEL DETAILS :

Gas Fuel Type : :

Specific Gravity :

Gross Calorific Value :

Maximum Volume :

Maximum Pressure :
IGNITION SYSTEM DETAILS:
Fuel Type :

Maximum Pressure :

CONTROL SYSTEM DETAILS:

Mains Supply Voltage : v hz

Control System Voltage : v hz

Control Circuit Diagrams No/

CONTRACTS ENGINEER
Name :
Date:

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

Section 1

3 Health and Safety

3.1 GENERAL SAFETY

Read this section before undertaking ANY work on the pilot

Before attempting to assemble, install or commission the Pilot it is

important that this document is read and understood completely.

It is essential that any maintenance, fault finding or commissioning

operations carried out on this equipment is performed only by a
competent Engineer, i.e. one that is adequately trained, experienced and
qualified with this equipment and associated processes, i.e. gas and
electricity requirements and regulations.

It is strongly recommended that Operators and maintenance staff are trained in

the correct and safe use of the pilot. Training courses are available from
Hamworthy.

It is important that the pilot supplied in this contract is used only on the fuel for
which it was designed and at flows and pressures which are suitable for the
pilot and the appliance on which the pilot is fitted.

It is also imperative that the pilot and burner geometry, design and ratings are
not altered or modified in any way other than by a Hamworthy Engineer or
under the specific direction of Hamworthy.
No responsibility can be accepted by Hamworthy for the outcome of
unauthorised tampering with these crucial parts.

The ‘Health and Safety at work Act’ requires both the Manufacturer and the end
user of the equipment ensure that the equipment supplied can be, and is,
operated safely. If the pilot/burner is fitted to a boiler or heater not
manufactured by Hamworthy, then due regard MUST also be given to the
operating instructions supplied with the appliance.

Hamworthy Combustion Engineering cannot be held responsible for any

consequential damage, loss or injury resulting from improper commissioning or
the failure to follow these instructions.

At all times the equipment should be installed and operated with due regard to
good engineering and safety principles. This cannot be over emphasised when
dealing with inflammable or explosive fuels.

Due attention must also be given to any regulations applicable to the storage
and handling of fuels.

The equipment has been designed to operate with the fuels and at the
conditions detailed in the contract specification sheet.
Proposed changes to any part of this specification must be referred to this
company for prior approval, as must any other questions relating to the safe
operation of the supplied equipment.

When reading these instructions always make reference to instructions given by

manufacturers of any associated plant, or appliance.

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

Hand protection must be worn if contact with the fuel oil is expected, eg. during
servicing work. Clean up any spillage’s immediately.

Keep the area surrounding the combustion equipment and its associated
equipment clear of debris. Never remove any guards whilst the burner is
operating.

It is recommended that adequate lighting and access is available around the burners, especi

All subsequent settings must progress from a fuel lean condition.

If the plant is operating at noise levels in excess of 80dBA it is recommended
that the operators use ear defenders.

If the burner is under repair or being serviced, ensure that warning notices are
placed on the burner, eg. “Do not operate, machine being serviced”.

Attend to fuel leaks as they are reported. Do not delay.

Make no attempt to operate the associated plant whilst fuel is escaping, since
this is both dangerous and unlawful.

The burner machine must not be run with the belt guards removed if applicable.

Regular maintenance of the flue ductwork is essential to provide a safe

environment within the plant room.

Ensure that hot pipes, such as those containing steam or water are lagged.
Restrict access to any area where hot metalwork or gases may be
encountered.

Always adhere to the rigors of the site Permit-To-Work system.

Never stand directly in front of or below a pilot or burner whilst it is

lighting-up.

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

3.2 HAZARDOUS AREA USE

SmartPilot’s that are required for use in potentially explosive atmospheres will
have the following label attached to the Exd enclosure:-

Special conditions of use

The burner control system must be such that unit is electrically isolated unless
the burner and the local area is known to be free of any potentially explosive
gas mixture.

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

3.3 COMBUSTION AND CONTROLS:

Setting or adjusting the fuel/air ratio must only be carried out by Hamworthy or
other competent personnel.

Do not make repeated attempts to light the pilot or burner. If a flame cannot be
established after two consecutive attempts, carry out an investigation into the
cause. A succession of abortive attempts to fire the pilot or burner may result in
the build up of an explosive mixture within the boiler or heater

Pre-purge and post purge procedures agreed during commissioning must not
be subsequently altered.

It is essential to ensure that, prior to initial light up during the commissioning

phase, all fuel control valves, proportioning valves, and similar devices are set
to their minimum flow positions before any source of ignition is introduced into
the combustion space.

The initial fuel flow adjustments necessary to provide light-up conditions must
only be made whilst the burner is switched OFF.
Subsequent light up attempts being made each time progressing from a fuel
lean condition until a good light up is achieved. Once adequate fuel flow exists
to enable the burner to light, then the fuel flow to the flame may be optimised
whilst the burner is lit.

3.4 OPERATORS

HCEL recommend that all plant operators and personnel take sufficient care to
avoid the possibility of a dangerous situation. In particular they should avoid
being in the vicinity of the burner or burner sight ports during the ignition period.
Only suitably qualified personnel should be allowed to commission and operate
the equipment.

Always ensure that the furnace is air purged and that no unburnt fuel is present
before attempting to start a burner.

Make sure the burner is at negative pressure i.e. below atmospheric.

Always ensure that a burners fuel supply is at the minimum setting possible
before attempting to start the burner for the first time.

If the burner does not have automatic ignition or flame scanning devices
extreme caution should be exercised to ensure safe operating procedure. At
least two people should be controlling the ignition sequence from a suitably
remote position, which ensures that they can observe the ignition process and
operate the fuel valve system.

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

3.5 ELECTRICAL
Do not leave control panels or junction boxes uncovered whilst power is on.
Should it become necessary to do so, in the interest of rectifying faults, then
only competent personnel should be involved and they MUST adhere to the
requirements of the Electricity at Work regulations.
Warning notices must be posted and the covers must be replaced as soon as
possible.

Safety interlocks are mandatory. Once a fault on an interlock has been

detected, then the fault(s) must be corrected before the unit is operated.
DO NOT LOOP OUT INTERLOCKS.

Isolate electrical supplies and fuel lines before attempting to work on the
combustion equipment. Post warning notices as necessary and ensure plant is
sufficiently cooled and ventilated, etc.

Ensure that the protective earth bonding of the complete burner machine and
gas train and associated gas pipework remains intact and continuous at all
times.
Continuity of the bonding must be maintained when a part, e.g. a gas valve, is
removed from the gas train. Jumper cables of adequate size, (no smaller cross
section than the existing bonding cable), must be connected across the gap.

Whilst the burner is under repair, ensure that the power cannot be reinstated by
locking-off electrical isolators.

High voltages, up to 14,000 volts, exist around the ignitor plug caps.

This equipment must be earthed via the protected earth terminal.

! Caution !
The installation and commissioning of electronic equipment, must be carried out
correctly to avoid damage to plant. Ensure full Electrostatic discharge, (ESD)
protection equipment is used during all phases of handling and installation of
this equipment.
When this symbol appears the associated section within the product manual must
be read and fully understood before any work is undertaken. Failure to do so may
result in plant damage and/or a hazardous situation for personnel.

Protective Earth Connection.

d.c. - Direct Current

a.c. - Alternating Current

It is recommended that operators of the Combustion equipment are trained

in its proper and safe use and the principles of combustion.
Courses are available from:-
Hamworthy Combustion Engineering,
Telephone Poole (01202) 662574 - Training department.

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

4 "VENTURI" INJECTOR

4.1 Introduction

The permanent pilot comprises a gas tube that is fitted with a venturi (air entrainment)
injector, a gas nozzle (flame retention head) and a centre ignition and/or flame detection
rod. The centre flame detection rod is connected to a flame detection device via a flame
proof gland mounted on the pilot body tube three way adapter.

4.2 Description

The Venturi injector is fitted to the gas inlet end of the gas tube. It comprises a calibrated
gas injector, an air control device and a venturi shaped injection tube. The gas injector air
control consists of a rotatable ring or slide device, which is fixed in position by a locking
device, the control ring is adjusted to either open or close the air inlet gap. The gas inlet
nozzle is supplied with a connection to the gas supply piping.

The momentum of the gas exiting the gas jet induces combustion air into the venturi. Air is
mixed with the incoming gas within the venturi section of the injector.

After passing through the pilot body tube the gas/air mixture enters the burner/furnace via
the gas nozzle flame retention head central orifice. The gas nozzle is also formed with
an integral outer sleeve and one set of (8) holes to ensure flame stability.

During the ignition phase a high frequency impulse generator produces a nominal 14k volt
supply in the centre electrode. This arcs across the spark gap and ignites the gas air
mixture flowing into the pilot nozzle.

The pilot may also be fitted with a flame ionisation system. In this case the centre flame
detection rod is designed to work on the principle that if a voltage is applied across two
electrodes in the blue portion of a flame the ionised gas of the flame behaves like a high
value of resistance in series with a diode. If the applied sensing signal is a reasonably high
AC voltage, a measurable DC current will flow between the electrodes when the flame is
alight.

No DC current will flow if the flame is not present. A device, which detects the ionisation
current, can be used to give a reliable indication that a flame is present.

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

5 Specifications

5.1.1 Electrical Specification

Power Supply Input

Voltage 230Vac (+10%,-15%)
or 115Vac (+10%,-15%)
or 24Vdc(±10%)

Power 0.5VA

Ignitor
Ignitor Control 230Vac (+10%,-15%)
or 115Vac (+10%,-15%)
or 24Vdc(±10%)

Ignitor Output Amplitude 14KV@40mArms

Ignitor Duty 33% in 3mins
Ignitor Output Frequency 20Khz

FIDU Input
Min Ionisation Current 0.7uAdc
Max Ionisation Current 24uAdc

FIDU Output
Flame ON/OFF Output Volt Free Contact 5A@230Vac SPCO
Flame ON/OFF Lamp Output Volt Free Contact 5A@230Vac SPCO
Flame Signal Output 0 to 20Vdc ± 10%
Flame Signal Output Impedance100KΩ

5.1.2 Environmental Specification

Operating Temperature -20°C to +60°C

Humidity 10 – 95%rh non-condensing
Vibration 10Hz – 150Hz at 1G (Subject to Approval)
Ingress Protection IP66

Hazardous Area approval EEx d 11C T6(-200C<= Tamb <= +600C)

Compliance EN50014, EN50018,

EN61010-1,
BS EN298; 2003 – Class ‘S’

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

5.1.3 Cable Specification

Core Size 1.5mm2 multi-strand or solid core with insulation

suitable
for the supply voltage used.

6 Variants

Supply Voltage Control Voltage Variant Part Number

115Vac 24Vdc C2792002
115Vac 115Vac C2792003
230Vac 24Vdc C2792004
230Vac 230Vac C2792005
115Vac 115Vdc C2792006
EN 298 compliant
115Vac 24Vdc C2792008
115Vac 115Vac C2792009
230Vac 24Vdc C2792010
230Vac 230Vac C2792011
115Vac 115Vdc C2792012

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

7 Electrical Connections

7.1 Wiring instructions

Wiring to all terminals should use crimped ferules if multi-stranded wire is used.
The internal protective earth must be connected to earth in all installations.

7.2 FIDU connections

1 Earth

2 Igniter Earth (Electrode)

3 Spark Control +

4 Spark Control -

5 Live

6 Neutral

7 HT generator Live

8 Flame On Lamp (COM)

9 Flame On Lamp (NO)

10 Flame On Relay (NC)

11 Flame On Relay (COM)

12 Flame On Relay (NO)

13 GND (Flame Signal)

14 Flame Signal

Note: Flame signal can only provide indication of flame strength. Signal is not calibrated or
linearised.

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

7.3 Example Configurations

There are many different configurations for wiring up the SmartPilot. Here are two simple
examples:-

HT Generator
E
1
2
3
N 4
L 5
6
7
8
9
10
Spark button 11
12
13
FIDU
14
Pilot on

Local Control Unit

To Burner Control

Figure 1. (230Vac/ 230Vac control)

HT Generator
E
1
Spark 2
Control + 3
24Vdc - 4
L 5
115 Volt
N 6
Pilot on 7
8
9
Volt Free NC 10
COM 11
Contacts NO 12
13
FIDU
14

Figure 2. (115Vac/ 24Vdc control)

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

8 Pilot Commissioning & Operating Instructions

8.1.1 Pilot Commissioning and Air Control Ring Set-up

Prior to start-up the air pilot control setting on each of the pilot burners must be
determined and set.

A series of ignition trials should then be undertaken to determine the optimum operating
position for the air control. This should be done in accordance with the following light-up
procedure and the air control set-up procedure.

This exercise can be made easier if the pilot can be operated outside of the burner with
the approved site permit to work in place i.e. “a hot work permit.”

8.1.2 Pilot Burner Light-up Procedure

It is strongly advised that on natural draft heaters especially that the area around the
heater and the combustion chamber (furnace or radiant section ) are checked with an
explosi-meter before attempting ignition. Ignition should not be attempted if an explosive
mixture is present.

The burner pilot is designed to be ignited by the integral high voltage unit if fitted or an
external flame or spark. The pilots are designed to operate at a gas pressure as stated in
the contract data and this pressure should be used unless otherwise stated. The pilot
light-up sequence should be started only after the Furnace Air Purge sequence is
complete.

ENSURE THAT PERSONNEL ARE AS FAR AS POSSIBLE FROM THE VICINITY OF

THE BURNER FRONT PLATE, SIGHT GLASSES OR VIEWING PORTS DURING THE
IGNITION PERIOD. DO NOT STAND UNDER UPFIRED BURNERS.

i. Adjust the pilot gas pressure to the contract specified value.

ii. Energise the spark.

iii. With the ignition present open the pilot gas isolation valve.

The pilot should light almost immediately and after a short delay to allow gas to fill
the line up to the pilot.

With the pilot lit and stable de-energise the spark.

iv. If the pilot does not light within 5 seconds STOP THE PILOT GAS SUPPLY, STOP
THE IGNITION SOURCE AND WAIT FOR A PERIOD OF APPROXIMATELY
10 SECONDS.

Repeat from step (iii) to ignite the pilot. If the pilot does not light after the second
attempt, allow the heater or boiler to air purge and clear all combustible gases before
further attempts at pilot ignition. If the pilot still fails to light, investigate that the pilot
gas supplies are correct and check that the pilot gasket and air inlet are clear.

Typical reasons for non-ignition are nitrogen or liquid in the gas line and jets blocked
by pipeline debris

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8.1.3 Air Control Setting

To determine the optimum air control setting for the pilot, the air control should be
adjusted until the pilot has well defined flame with a blue cone at the pilot outlet nozzle
flame shroud. The flame shape and character can be tuned by adjusting the venturi air
control device to either increase or reduce the amount of inspiration (opening the gap will
increase and closing it will reduce air inspiration).

Once the optimum air control gap has been set and secured in position by the
locking device, there should not be any need to readjust the air control after this
initial set-up procedure.

8.1.4 Subsequent Light-up Attempts & Normal Pilot Operation

After the air control has been set and secured in position, for any subsequent light-up
attempts there is no need to adjust the air control . However, the above light procedure
points (I) to (iv) should be followed at all times.

Note: On fired heater applications HCEL recommend that all pilots are alight before
the first main burner is lit.

8.2 Maintenance
Ref.: Pilot GA Drawing
a. Observe safety precautions listed in the main instruction manual.
b. Manually isolate gas supplies before commencing maintenance.
c. Manually isolate any electrical supplies before commencing maintenance.

8.3 Daily Checks

a. Visually ensure security and for gas leakage.
b. Ensure 'Venturi' air inlet ports are clean and unobstructed.
c. Visually check any electrical cable and gland end connections for cleanliness,
deterioration and signs of obvious damage.

No attempt at maintenance should be made without the appropriate safety precautions.

Refer to the site safety regulations, work procedures and permits ). If the pilot is to be
removed a special permit may be required.

8.4 Pilot Failure

In the event of failure to ignite the pilot the following should be checked:
1. Gas pressures - see technical data
2. Check pilot flame characteristics are correct as described previously - adjust
inspiration rate if necessary by using the pilot venturi air control ring.

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

8.5 Unscheduled Maintenance Operations Removal, Cleaning and

Refitting
1. Isolate gas and electrical supplies.
2. Disconnect gas inlet connection.
3. Disconnect any electrical connections at the control box from the pilot cable.
4. Unscrew the ignitor securing pinch screws and withdraw the pilot assembly from the
housing tube located on the burner windbox mounting plate. Remove to a servicing
bench.
5. Visually check air entrainment nozzles and the gas tube nozzle for cleanliness.
Remove all carbon deposits. If ignitor orifice or nozzle holes are obstructed, soft
copper wire may be used to clean them.
6. After cleaning, blow through with high-pressure air from the gas inlet end to remove
any foreign matter.
7. Check flame detection rod is serviceable for a further period of service. Check flame
ionisation gap is correct at 2.5mm and 4.0mm respectively.
8. Reassemble in reverse order to removal.
9. Remove assembly from windbox as detailed above.
10. Unscrew the Venturi air injector (7) complete with hex brush (8) from the body tube
three way adapter (9).
11. Remove the electrode centralising screws on the pilot nozzle end.
12. Unscrew the encapsulated nipple complete with the electrode assembly and
enclosure.
13. When the nipple is clear of the threads gently withdraw the electrode and its insulator
from the pilot body.
Note: The encapsulent nipple and electrode assembly is not capable of being
disassembled. If the insulation sleeve is damaged the complete electrode assembly
with the nipple must be replaced otherwise the pressure tightness of the nipple cannot
be guaranteed and the hazardous area rating is invalidated.
14. The unit can be cleaned of deposits, the centralising springs can be replaced and the
final high temperature section of the electrode (outside the insulation) can be
replaced.

8.6 Refitting Flame Detection Rod

1. Slide the electrode assembly complete with nipple and enclosure gently into the pilot
body.
2. Screw the nipple into the pilot body using 12" Stillson wrenches until it is tight. Use
sealing compound.
3. Check that the resistance of the pilot body from the flame nozzle to the earth
connection in the enclosure is less than 0.1Ω.
4. Adjust the electrode centralising screws until the spark gap and the ionisation gap are
the correct dimensions (see contract data). Do not over tighten.
5. Refit and tighten Venturi injector (7), complete with bush (8) to the three-way adapter
(9).
6. Refit pilot to the support tube and tighten the securing screws.

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9 CERTIFICATES

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Hamworthy Combustion Engineering SmartPilot HCE 300A O&M Issue 1.2

Word Index

air
control, 11, 16, 17
inlet, 11, 16, 17
Commissioning, 16
DAILY CHECKS, 17
Electrical Connections, 14
flame, 9, 11, 16, 17, 18
characteristics, 17
detection, 11, 18
ionisation, 11, 18
shape, 17
stability, 11
Hazardous Area, 12
,8
ignition, 9, 11, 16
Ignitor, 12
interlocks, 10
maintenance, 6, 7, 17, 18
Power Supply, 12
protective earth, 10, 14
safety, 6, 17
Safety, 6, 10
Safety, 17
Venturi, 11, 17, 18

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