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In continuous control of combustion process, it is required to adjust fuel and air in right proportioncontinuously according to the variation in the signal from pressure / temperature controller. However,relationship between fuel valve actuator and damper opening does not remain linear due to complex nature ofcombustion process. Hence, control signal received from controller has to be modified for optimum results ofcombustion. For this purpose, complete range is split in number of steps and each step can be multiplied byfactor which is expected to give optimum combustion results. Multiplying factor can be set at any valuebetween 0.5 – 1.5 independently for each step. Output signal is clamped to either minimum or maximumvalues whenever it tries to go beyond these values in any step. Diligent RATIOCON 4-20I 16 is one suchcontroller designed by M/s Diligent Micro Controls to accept 4 – 20 mA dc signal from either pressure /temperature controller and provide modified signal which is also lying in 4 – 20 mA range.This controller is housed in standard 96 x 96 mm plastic enclosure and it works on 230 V +/-10%, 50 hz, 1 phac supply.1. Description:‘Diligent Ratiocon 4-20 I 16’ accepts 4-20 mA signal at the input terminals on the rear panel of thebox. This range is split in 16 steps and 16 presets are provided to modify each step independentlywith multiplier between 0.5 to1.5. 16 LEDs are also provided and LED lights when the input signalcrosses the step value. Modified output of 4-20 mA, is provided at the out put terminals on the rearpanel of the box. When ever out put tries either to go below 4 mA or to go above 20 mA as a result ofmultiplying factor setting, internal circuit clamps output to 4 mA in the first case and 20 mA in thesecond case. Clamped status of <4 mA and > 20 mA is indicated by respective LED on the frontpanel. Rear panel has two terminals which have to be shorted together during Calibration Mode.Power supply Phase, Neutral & Earth are connected at the respective terminals on the rear panel. Thiscould either be 230 V or 110 V +/-10%, 50 hz, 1 phase AC. RATIOCON has 3 digit display whichnormally indicates the out put current signal and when the switch on left top corner is pressed itindicates the input current; either actual or calibration.2. Operation:Diligent RATIOCON becomes operational as soon as the a.c. power supply is connected to it.RATIOCON has two modes of operation; namely Calibration Mode and Normal Mode.MICRO CONTROLSRATIOCON operates in Calibration mode when corresponding terminals on the rear panel are loopedtogether. In this mode internal variable current source is connected to the input stage of RATIOCONand its out put can be varied by the knob located on right top corner. The value of this current can beread on the digital display by pressing the push button. Calibration procedure is as follows –a. Turn Calibration Adjustment knob fully anticlockwise till the current value drops below 4 mA.‘<4 MA’ LED will light as soon as out put current drops below 4 mA and out put current will beclamped to 4 mA.b. Turn the Cal. Adj. slowly in clockwise direction till the first step LED (marked ‘4’ on the panel)lights.c. Adjust preset below this LED to read the desired out put value on the digital display.d. Repeat ‘b’ & ‘c’ above for all the remaining steps.e. Continue to increase the calibration current beyond 20 mA. ‘>20 mA’ LED will light as soon asthe out put current tries to go beyond 20 mA. Out put current will be clamped beyond this at 20mA.f. This completes the calibration and the loop wired between two terminals on the rear panel cannow be removed.RATIOCON enters NORMAL Mode as soon as the loop wired for calibration, is removed. In thiscase input stage of RATIOCON now receives input signal directly and will generate out put signalaccording to the preset program.3. The connections details are given on the rear panel and are self explanatory.4. This instrument is not site maintainable.5. Diligent RATIOCON carries warranty for twelve months from the date of its delivery from ourworks. During this period, we undertake to repair/replace free of cost our defective unit in part or fullat our total discretion provided that such unit is brought to our works for rectification and collectedthere from after satisfactory inspection by the customer at his cost & risk and provided that the defectis due to poor material and/or workmanship and not due to misuse and/or mishandling. This warrantyis exclusively limited to the unit supplied by us and we shall not be responsible in any ways for any ofthe consequences of its use and/or misuse any where. This warranty shall automatically become null& void if our unit is opened/tampered by person not authorised by us.6. Specifications:Power Supply 230V or 110 V, 50 hz, 1 ph AC supplyInput Signal 4 – 20 mA dc.Input burden 100 ohms.Output Signal 4 – 20 mA dc.Output burden 400 ohms.Calibration current source InternalDigital Display 3 digitsOutput under / over range Output clamped to respective limits. ( Minimum at 4 mA& Maximum at 20 mA). Status LEDs providedModes of Operation Calibration and NormalSize Standard size 96 mm x 96 mm x 150 mm
DILIGENT RATIOCON 4-20 I 16
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1. Discription:Stabmon is customized protection unit for 3-phase ac stabiliser. It is housed in strong & sleek m.s.enclosure. It operates on 230 V, 1 phase ac supply. Status & Fault LED display is provided on theunit and is very useful during commissioning and fault finding. Over load adjustment over 95% to105% of rated current, is provided on the unit. Local Reset Switch is provided to reset Stabmon afterit trips on fault. A toggle switch is provided to enable and disable ‘Single Phasing Protection’ andits status is indicated by the two-color LED.2. Operation:Stabmon require 230 V, 1 phase ac supply for its operation. 3-phase supply enters the unit atterminals Rs, Ys & Bs and leaves from terminals Rl, Yl & Bl for connection to load. Phase currentof each phase is monitored continuously. So long the current is present in all the three phases and isbelow the set limit, control relay inside is in energised state. Mains, Load and Fault LEDs arelighted. Status of ‘Single Phasing Protection’ is indicated by last LED. When the switch on the rearpanel is pressed, this LED becomes red and when that switch is released, color changes to green.3. Time-delayed Overload Protection :When any of the phase current exceeds preset limit for more than the permitted preset time (5sec.)continuously, Stabmon switches off internal control relay and latches it in this state. ‘Overload’ LEDlights. ‘T.DLY’ LED lights as soon as overload takes place and stays on till it last or till the elapse ofthe preset time, whichever is earlier. Overload adjustment is provided to adjust trip level from 95%to 105% of the rated current.4. Single Phasing Protection :Each phase carries current under normal condition and Stabmon continuously monitors it. Internalrelay remains energised so long all the three-phase carry current. However, when either one or twophases become open, internal relay switches off and is latched in this state. ‘Single PhasingProtection’ feature is different from the one understood conventionally. This is so because ACstabiliser is required to feed different loads from its phases and, therefore, currents in the phasescould be different. In extreme case, it may be required to operate with current in its one or two phasebeing zero or below the minimum sense level set for the circuit. In such case, Stabmon will notpermit its operation. Loads may be switched on/off randomly and this can cause load current to dipMICRO CONTROLS2below the minimum sense level momentarily. A short time delay of 2-3 sec. is provided to allowoperation with such short lasting dips in phase current.5. Reverse Phase Sequence Protection :Phase sequence of the 3-phase supply is continuously monitored. If the sequence is normal, Stabmonrelay stays in on state. However, whenever this sequence becomes reverse, relay switches off andstays off until sequence is corrected by interchanging any of the two phases. LED designated as‘REV. PH. SEQ.’ on the display, indicates this fault.6. Local Reset :Once Stabmon switches off internal relay and latches it in that state due to overload or single phasingfault, ‘Fault’ LED starts flashing and stabiliser is switched off. This state prevails until local resetpush button on the front panel, is pressed by operator.7. Calibration :Stabmon upto 10 Amps rating are directly calibrated and offered in our standard enclosures. For anyother higher current ratings, standard 5Amp Stabmon is calibrated with customer-specified auxiliarycurrent transformer.8. Status & Fault Display :Status & Fault display, is described below-Title DescriptionMains Lights when 230 V,1ph., ac supply is connected.Load Lights when one or more phases carry current.S. ing Lights when one or two phases are lost and current through thembecomes zero. It remains on even after tripping of Stabiliser, untilmanually reset by pressing local reset push button.O.Load Lights when current in any of the phases, exceeds preset limit beyondpreset delay (5 sec.). It remains on even after tripping of Stabiliseruntilfault is rectified and Reset Push Button is pressed.Rev.Ph.Seq. Lights when phase sequence is negative and remains on till it is madepositive by interchanging any of the two phases. It switches off onlyafter local reset push button is pressedT.DLY Lights as soon as current exceeds preset limit and remains on tillelapse of preset overload period or dropping of current below the limit.NOR- Steady This LED lights steady under normal condition and startsFLT - Blinks flashing after unit trips on fault.RED- S.ing Disabled This LED turns red when single phasing protection is disabledGRN- S.ing Enabled and it turns green, when single phasing protection, is enabled.
DILIGENT * STABMON
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Diligent Thermocouple Welding Unit is housed in strong powder coated m.s. enclosure which hasshoulder strap for ease of carrying on site. It has rechargeable 12 V 4.5 Ah heavy duty Battery withinbuilt SMPS Battery Charger cum Power Supply. 1 meter long multi-strand thick copper cable withSilicon Sheath, Heavy duty Plier and strong circular Magnet are used to connect the Welding Powerto the Thermocouple Wires & the surface on which TC is to be welded. the unit has facility to set theWeld Energy Charge Level to suit different gages of Thermocouple wires. The SET Value andCHARGED Value are displayed on Bar Graph display. The desired Charge Level is set on the SETBar Graph using UP/DOWN push button. This Setting is remembered during operation. Wheneverwelding is to be done, command is given to start charging the unit to SET value by pressingmomentarily the CHARGE Button. Once the Charge level is reached to SET Value, the AUDIOalarm sounds indicating the readiness for welding. Welding operation is performed either inMANUAL mode or AUTO Mode. In Manual mode, the Thermocouple to be welded is firmly held inPliers at the desired spot, Magnet with wire is located nearer to this spot and then press the WELDButton after getting READY AUDIO ALARM.In AUTO Mode, Pliers holding TC Wires and the Magnet are positioned at the scheduled spot. Pressthe CHARGE Button. The charge builds up to the SET value and Audio Alarm sounds. Few secondsof this, WELD command is automatically given by Auto Circuit and Weld occurs. The pliers ismoved to next spot and the complete cycle repeats automatically. This is carried out till all the TCsare welded.A Bar Graph Display is also provided to indicate the CHARGE Level of battery when Battery PushButton is pressed. An Audio Signal sounds when battery drains below 10.5V (approx). It requiresrecharge for proper welding quality.The unit can also be operated directly from mains AC Supply if Battery is not available.Diligent Thermocouple Welding Unit size is 240 mm (L) x 170 mm (W) x 170 mm (H) and weighs4.5 kgs without battery12 V DC Battery is rated for 4.5 Ah. Its size is 90 mm (L) x 70 mm (W) x 100 mm (H) and it weighs1.5Kgs.Its useful Charge Level is 60 Volts and can reach up to 80 Volts under supply voltage conditions. Themaximum charge can be reached to 0.60 Coulombs.
DILIGENT THERMOCOUPLE WELDING UNIT
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1. Diligent Protector for AC applicationsDiligent AC relays are available for Over Load (OL), Single Phasing (SP), Phase Reversal(PR), etc. The overload relays are available in 1ph and 3ph types. 1ph-relays are useful onsingle phase load and can also used as economical solution for 3 ph applications wheneverload is balanced. These are classified depending on the response to the overload condition andthe classification is as follows -a. INStantaneous (INS) type. In this relay changes the state as soon as overload occurs.b. Time-Delayed (DLY) type. In this the relay changes the state only after elapse of presentperiod from the time overload occurred & stayed.c. Jam (JAM) type. In this, the control relay does not respond to the overload condition fora preset time from switching on the load but after elapse of this time, the relay respondsimmediately to any overload.MICRO CONTROLS2Instantaneous type is primarily made for AC loads other then motor such as: transformer,heater etc. However, it has been also used along with other logic to control motor.Time-Delayed overload relay find wide use. The tie delay provided in the relay avoidsnuisance tripping in response to transient overloads but switches off the load if overloadpersists beyond the specified time. Most of the loads in actual practice increase temporarilyand the drive is usually designed to handle this type of overloads.Jam type overload relay is quite unique and has made possible very reliable protection ofloads such as Blower, Fans, Stirrer motors which was rather difficult to achieve withconventional thermal relay. Jam relay not only saves the motor, but restricts the possibledamage to the equipment & loss of production by advance intimation before catastrophicfailure takes place. Such situation, for example, can arise when ‘oil-starved bearings’ startsslowly seizing and if not attended in time can get heated and tear out the housing. Repair notonly costs in term of money but looses precious time. Similarly, jamming of conveyor can beeffectively responded by the Jam relay and catastrophic failure there of can be averted.Single Phasing (SP) protection in Diligent Protector relay is either Current Operated SinglePhasing (COSP) or Voltage Operated Single Phasing (VOSP). COSP is realised by sensingeach of the phase current continuously. As soon as current in any one phase is lost, controlrelay changes the state. This greatly limits the heavy thermal stresses due to large currentflowing in the connected phase-windings of motor. VOSP protection monitors all three supplyphases and acts when one of the phases of 3 phase supply is missing. However, Should phasebe lost while 3 phase motor has already running, VOSP may not trip the motor because of theinduced voltage in the motor winding. However, COSP is effective even when the phase islost while the motor is in operation.2. Diligent Protectors for DC ApplicationsDiligent Micro Controls has also developed protection relays for DC loads such as DC motor,DC generator, Rectifier sets, DC electromagnet etc. These relays are available in three types:namely INStantaneous, Time-Delayed and Jam type similar to the AC relays. DC relayoperates from “75 mV standard DC shunt” and requires auxiliary supply for its operation.Optionally the relay can be made suitable to work with User-specified shunt.3. Diligent Protectors for AC or DC Under-/ Over-VoltageDiligent Protector for AC or DC Under-/Over-Voltage fault is designed to monitor the voltagelevel continuously and whenever it exceeds set limits for more than the set time, the relayinside picks up. This relay can be made auto reset type or manual reset type.4. Diligent Protector for Neutral-Earth VoltageDiligent Protector for Neutral-Earth voltage monitors this voltage continuously and wheneverit exceeds set limits for more than the set time, the relay inside picks up. This relay can bemade auto reset type or manual reset type.5. Diligent Protector for Conveyor JammingDiligent Protector for jamming of conveyor is unique. It allows conveyor motor to startnormally and monitors continuously current drawn by it during operation. It trips the motorimmediately when current exceeds the set JAM limit. This averts catastrophic failure andconsequential loss of production. This relay can be made auto reset type or manual reset type.6. Diligent Protector Shear Pin ReplacementDiligent Protector for shear pin replacement is unique. Shear pin disengages the motor fromthe load by breaking itself when load increases beyond the permissible level. However,replacement of shear pin is associated with inherent uncertainties of material quality. Thisrenders shear pin protection less reliable. Diligent Protector Replacement for shear pin isunique. Not only it provides precise and repeatable protection but it also has provision toadjust the protection level which enables to match the protection to the load. This relay can bemade auto reset type or manual reset type.7. Diligent Protector for Lifting ElectromagnetDiligent Protector for Lifting Electromagnet allows electromagnet to be switched on undernormal condition but when its current drops below the set level for more than prescribedperiod, Diligent Protector alarms the operator.8. Diligent Protector for Grinder Under-/Over-loadThis is very special type of protection. Whenever grinders are working with full charge, itdraws large current initially and drops as grinding completes. Any prolonged operation aftercompleting grinding, the material can burn due to over heating as well as energy will beconsumed without any useful work. Diligent Protector for ‘Grinder Under load’ will trip themotor as soon as current drops below the set limit.9. Diligent Unique Protector for Blower / FanConventional Overload protection is not at all suitable for Blower / Fans due to their startingcharacteristic. Diligent Unique Protector for Blower / Fan is really unique. It allows normalblower start up successfully; however, if blower motor draws more current than set limit, itimmediately trips the motor. This is very useful as blower/fan is most ignored equipment inmost of the industries and they suffer consequential catastrophic failure due to this negligence.Diligent Protector will trip the blower even at the onset of faults such as starving forlubrication, impeller unbalance, excessive vibration, interference due to broken parts, etc.10. Diligent Monitor for Solenoid CoilSolenoid valves are very critical in the process control and their healthiness is of utmostimportance. Diligent Monitor for Solenoid Valve, monitors the healthiness of solenoid coilduring operation. Should coil become open during operation, a potential-free contact closes totransfer this information to centralized SKADA system or sound an alarm.11. Diligent Monitor for HeaterIn some applications like sterilizing system in pharmaceutical industries, numbers of electricheater elements are used in banks to achieve acceptable sterilizing temperature. However,failure of some elements does not become known until when finished goods start gettingrejected during quality control. Loss is large at this stage. Diligent Heater Monitor gives alarmwhen number of available heater drop below the acceptable number.12. Auxiliary Supply:Standard auxiliary supply 230V, 110V, 24V AC or 24V DC can be specified. Relays can be made tooperate on any other user-specified supply.413. Output Contact:One Change-over contact rated at 4 Amps (resistive) at 230V ac, is provided. This contact stays inactuated state as long as long fault does not exist.14. Status & Fault Display:Relay carried unique display which indicates various status and also the fault on which the load hasbeen switched off. It also has LED which glows steady under normal condition but starts flashingwhen relay trips. This is very useful feature where the tripped relay has to be spotted among the clusterof relays & contactors. This along with the type of fault indication immensely simplifies faultdiagnosis by identifying the defaulted zone. This results in considerable reduction in MTTR (MeanTime to Repair) and improving system availability.15. Post Fault Reset:Relay tripped in response to the fault, has to be restored for normal use again. Depending in the natureof fault and requirement of particular application, this restoring can be effected either automatically(AUTO) or manually (MAN) or combination of auto-manual (A/M). The faults which are not seriousare cleared by known corrective action and the relay in such case is made to reset by itself or clearingthe fault. Operator does not have to go to control panel to reset the relay and he can switch on the load.Such faults are, for example, phase reversal, normal overload etc. However, serious faults, such as,single phasing, mechanical jamming, bearing seizure, short circuit etc. required to be properlyinvestigated before switching on the load again. Hence in such cases, relay is designed to disallowrestart unless relay is manually reset by an operator-in-charge. The 3rd type of ‘fault reset’ is veryinteresting since Diligent Relays combine multiple protection in single unit. Some protection featurecould be serious while other may not. It is possible to built user-specified combination of reset logic inour relay. Thus, the relay is made very user-friendly.16. Warranty:“Diligent Protection Relay carries warranty for a period of twelve months from the day of deliveryfrom our works. During this period, we undertake to repair/replace our defective unit free of cost inpart or full at our total desecration provided that the unit is brought to our works for rectification andcollected there from after satisfactory inspection by the Customer at his cost & risk and provided thatthe defect is found to be due to poor material and / or workmanship and not due to misuse and/ormishandling. This warranty is exclusively restricted to the unit supplied by us and we shall not beresponsible in any way for any of the consequences arising due to the use and/or misuse of our unitanywhere. This warranty shall become automatically null & void, if our unit is opened and / ortampered by person not authorised by us.”
Diligent Protectors & Monitors
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Heat has always been very useful to man kind. One of the basic and common ways to obtain heat is byburning combustible fuels. However, such combustion must be controlled and safe. Safety of combustion isensured by monitoring flame. Flame is characterized by emission of wide spectrum of electromagneticradiation starting from infra red, visible light to ultra-violet radiations. Flame is also known to generate ionsin its envelope. Type of fuel and that of burner decides which one of these radiations predominate. Forexample; flame of coal or oil is usually very bright and yellow in color, flame of light oil like kerosene or thatof hydrocarbon gas is light blue and flames of some gases may be even dull reddish. In addition to this,intensity of flame could differ widely depending on the type and size of flame. Hence different techniqueshave evolved and new are being developed to detect and monitor flames. DILIGENT MICRO CONTROLShas developed wide range of flame monitors “Diligent Flameye”. In addition to the basic flame monitor wehave developed intelligent versions which provideBuilt in delay for flame ON or OFF status change,Multiple contacts out puts,Dual flame monitor,Dual flame monitor with AND logic,Dual flame monitors with OR logic,Dual flame monitor with mixed sensor types,Inverse Mode of operation of control relay,Weatherproof enclosure flame monitor.AC power supply of 230V +/- 10 %, 50 Hz, 1ph ac is required for operation of all Standard Flameye models.However, versions suitable to work with other standard AC or DC supplies can be provided on request. Onechange-over potential free relay contact rated at 4 amps (resistive) at 230 V ac, is provided in all standardunits. Multiple potential free contacts can be provided as optional.Diligent Flameye are classified based upon sensing technique used and these are as described below-Diligent Flameye PRFlame produced while burning diesel, furnace oil, HSD, LHSH, etc., is bright and yellow. PhotoResistor typephotocell have excellent response to the visible light spectrum and, therefore, is the most reliable and costeffective choice to detect such flame. Diligent Flameye PR provides appropriate bias to the basic PR sensorwhich generates change in its resistance commensurate with the amount of visible light radiations received byit. This change is received by Flameye which conditions and amplifies it before comparing with presetreference. When signal level crosses the reference, internal relay picks up. This relay goes back to off state assoon as the radiations falling on PR sensors cease. Basic signal from PR sensor is very small and should betransmitted over screened cable to Diligent Flameye and his cable should be preferably laid away from powercable.MICRO CONTROLS2Diligent Flameye PVPhotoVoltaic photocell is another basic sensor which has excellent response over visible portion ofelectromagnetic radiations. It produces electric dc voltage in mV range in response to the intensity of lightfalling on it. This small signal from PV sensor is conditioned & amplified by Diligent Flameye PV and thencompared with preset reference. When signal level crosses the reference, internal relay picks up. This relaygoes back to off state as soon as the radiations falling on PV sensors cease. Basic signal from PV sensor isvery small and should be transmitted over screened cable to Diligent Flameye and his cable should bepreferably laid away from power cable.Diligent Flameye UVPR and PV sensors are excellent choice when the flame is bright yellow. However these sensor hardlyrespond to a flame which is blue, light blue or nearly invisible like the one that exist while burning of lightoil, LPG gas, Natural gas, propane, butane, methane, etc. Such flame is sensed by sensing the radiations inultra-violet range which are associated with all combustion processes. Gas filled UV photocell orsemiconductor type UV photocell is used to receive these radiations from flame. These cells require correctbiasing voltage which is provided by Diligent Flameye UV. Tiny signal in micro ampere is generated by UVsensor and is then transmitted over screened cable to Diligent Flameye UV. This cable must be of very goodquality having low capacitance and high grade insulation. This small signal from PV sensor is conditioned &amplified by Diligent Flameye UV and then compared with preset reference. When signal level crosses thereference, internal relay picks up. This relay goes back to off state as soon as the radiations falling on PVsensors cease.Diligent Flameye IONIons are produced in the envelope of all types of flames due high temperature in side. This technique picks upthese ions under the influence of appropriate bias voltage and generate tiny signal which is then transmittedover screened cable to Diligent Flameye ION. This cable must be of very good quality having lowcapacitance and high grade insulation. This small signal from ION sensor is conditioned & amplified byDiligent Flameye ION and then compared with preset reference. When signal level crosses the reference,internal relay picks up. This relay goes back to off state as soon as flame extinguishes. This technique relieson collecting of ions in the flame and hence the sensor electrode must always be in good contact with theflame and flame must also be in continuous contact with electrically earthed body. Any violation of this willmake the flame signal disappear.Flame SensorsAll the flame sensor except ION sensor are electronic sensors and hence their operating environmenttemperature must not exceed 55 deg C. Higher temperature, though may not lead to malfunctions, canseverely affect the useful life of the sensor. All of the sensors, therefore, carry any testing warranty and noneof these carry conventional warranty. ION sensor is electrode with high grade insulator and high temperaturecollecting rod. Care is necessary to ensure that the scaling on rod is periodically removed, contamination thatcould reduce insulation level of rod, should be avoided and cleaned if noticed.WarrantyDiligent*FLAMEYE carry a warranty for period of 12 months from the date of delivery. During warranty period weundertake repair/replace free of cost part pr full unit found defective at our total discretion provided that such unit isbrought to our works for rectification & collected there from after satisfactory inspection by the customer at his total cost& risk and provided that the defect is due to poor material/ workmanship and not due to misuse/mishandling. Thiswarranty is exclusively limited to the unit supplied by us and we shall not be responsible in any ways for any of theconsequences arising due to its use/misuse any where. This warranty shall automatically become null & void if our unitis opened/tampered by person not authorized by us.Due to the operating environment of flame sensor, all types of flame sensor carry only TEST WARRANTY i.e. theoperational status of the sensor will be demonstrated while taking delivery from our works.
Diligent “Flameye” Flame Monitors
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Diligent Micro Controls offers wide range of controllers for automatic control of all types ofburners. Classifications of these controllers are based on type of fuel burnt, design of burner, modeof operation, technique of flame sensing, starting pre-requisite interlocks, security interlocks, etc.Diligent Autocon controllers are completely solid state types and use standard and time-provencomponents. This ensures their continuous & reliable operation over long period even under adverseconditions of electric power and environment. Each Autocon has its unique & user friendly “Status& Fault” display that displays status of various equipments and that of faults that leads to burnerfailure. This feature is very useful during commissioning and fault finding of burner. A diligentAutocon controller work on 230 V +/- 10%, 50 Hz, 1 phase ac supply and provides live operatingcommands to switch on or off various equipment related to the burner operation. Alternately, it canbe made suitable for operation on 110 V or any other power supply specified by the customer. It hasbeen our experience over past two and half decades that the time delays in the controllers should bepreset in the factory rather than in the field. However, we can offer some delays as “field settable” toour new OEMs for their initial trials on their system and later on these can be factory set at the valuespecified by the OEM.Diligent Autocons are housed in strong m.s. or plastic enclosures. It is provided with eitherscrewable or pluggable connectors for connecting with rest of the burner. These are made in eitherbase mounting type or door mounting type. Salient categories of Diligent Autocon are given below –1. Diligent Autocon for various fuels.a. Gas fired burnerb. Oil fired burner.c. Coal fired burner.d Bagass fired burner.e. Multiple fuel fired burner.f. Customised burners such as for Flame Treatment for plastic printing, for Flame welding ofplastic coated paper articles, etc.2. Diligent Autocon for various modes of operation.a. No process-parameter control. Only operation with safety monitoring.b. Process parameter control by single stage ON/OFF of burner.c. Process parameter control by multi-stage ON/OFF of burner but without damper control.d. Process parameter control by multi-stage ON/OFF of burner but with damper positioncontrol.MICRO CONTROLS2e. Process parameter control by continuous modulation of single stage burner whichcontinuously adjusts gas & air proportion commensurate with the heat demand.f. Process parameter control by continuous modulation of multi-stage burner whichcontinuously adjusts gas & air quantity commensurate with the heat demand.3. Diligent Autocon with various techniques of flame detection and flame sensor.a. Photo-Resistor type flame sensor; most cost effective solution for oil fired burner.b. Photo-Voltaic type flame sensor; alternate for oil fired burner.c. Infra-Red type flame sensor; preferred for coal-fired or low calorific fuel burner.d. Ultra-Violet type flame sensor; most reliable but expensive technique of flame detectionespecially for invisible / blue flames.e. Dual flame sensing technique especially when multiple fuels tend to generate flames withdifferent predominant characteristics.4. Diligent Autocon for multiple burners in same combustion chamber.
Diligent Autocon Controllers
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In continuous control of combustion process, it is required to adjust fuel and air in right proportioncontinuously according to the variation in the signal from pressure / temperature controller. However,relationship between fuel valve actuator and damper opening does not remain linear due to complex nature ofcombustion process. Hence, control signal received from controller has to be modified for optimum results ofcombustion. For this purpose, complete range is split in number of steps and each step can be multiplied byfactor which is expected to give optimum combustion results. Multiplying factor can be set at any valuebetween 0.5 – 1.5 independently for each step. Output signal is clamped to either minimum or maximumvalues whenever it tries to go beyond these values in any step. Diligent RATIOCON 4-20I 16 is one suchcontroller designed by M/s Diligent Micro Controls to accept 4 – 20 mA dc signal from either pressure /temperature controller and provide modified signal which is also lying in 4 – 20 mA range.This controller is housed in standard 96 x 96 mm plastic enclosure and it works on 230 V +/-10%, 50 hz, 1 phac supply.1. Description:‘Diligent Ratiocon 4-20 I 16’ accepts 4-20 mA signal at the input terminals on the rear panel of thebox. This range is split in 16 steps and 16 presets are provided to modify each step independentlywith multiplier between 0.5 to1.5. 16 LEDs are also provided and LED lights when the input signalcrosses the step value. Modified output of 4-20 mA, is provided at the out put terminals on the rearpanel of the box. When ever out put tries either to go below 4 mA or to go above 20 mA as a result ofmultiplying factor setting, internal circuit clamps output to 4 mA in the first case and 20 mA in thesecond case. Clamped status of <4 mA and > 20 mA is indicated by respective LED on the frontpanel. Rear panel has two terminals which have to be shorted together during Calibration Mode.Power supply Phase, Neutral & Earth are connected at the respective terminals on the rear panel. Thiscould either be 230 V or 110 V +/-10%, 50 hz, 1 phase AC. RATIOCON has 3 digit display whichnormally indicates the out put current signal and when the switch on left top corner is pressed itindicates the input current; either actual or calibration.2. Operation:Diligent RATIOCON becomes operational as soon as the a.c. power supply is connected to it.RATIOCON has two modes of operation; namely Calibration Mode and Normal Mode.MICRO CONTROLSRATIOCON operates in Calibration mode when corresponding terminals on the rear panel are loopedtogether. In this mode internal variable current source is connected to the input stage of RATIOCONand its out put can be varied by the knob located on right top corner. The value of this current can beread on the digital display by pressing the push button. Calibration procedure is as follows –a. Turn Calibration Adjustment knob fully anticlockwise till the current value drops below 4 mA.‘<4 MA’ LED will light as soon as out put current drops below 4 mA and out put current will beclamped to 4 mA.b. Turn the Cal. Adj. slowly in clockwise direction till the first step LED (marked ‘4’ on the panel)lights.c. Adjust preset below this LED to read the desired out put value on the digital display.d. Repeat ‘b’ & ‘c’ above for all the remaining steps.e. Continue to increase the calibration current beyond 20 mA. ‘>20 mA’ LED will light as soon asthe out put current tries to go beyond 20 mA. Out put current will be clamped beyond this at 20mA.f. This completes the calibration and the loop wired between two terminals on the rear panel cannow be removed.RATIOCON enters NORMAL Mode as soon as the loop wired for calibration, is removed. In thiscase input stage of RATIOCON now receives input signal directly and will generate out put signalaccording to the preset program.3. The connections details are given on the rear panel and are self explanatory.4. This instrument is not site maintainable.5. Diligent RATIOCON carries warranty for twelve months from the date of its delivery from ourworks. During this period, we undertake to repair/replace free of cost our defective unit in part or fullat our total discretion provided that such unit is brought to our works for rectification and collectedthere from after satisfactory inspection by the customer at his cost & risk and provided that the defectis due to poor material and/or workmanship and not due to misuse and/or mishandling. This warrantyis exclusively limited to the unit supplied by us and we shall not be responsible in any ways for any ofthe consequences of its use and/or misuse any where. This warranty shall automatically become null& void if our unit is opened/tampered by person not authorised by us.6. Specifications:Power Supply 230V or 110 V, 50 hz, 1 ph AC supplyInput Signal 4 – 20 mA dc.Input burden 100 ohms.Output Signal 4 – 20 mA dc.Output burden 400 ohms.Calibration current source InternalDigital Display 3 digitsOutput under / over range Output clamped to respective limits. ( Minimum at 4 mA& Maximum at 20 mA). Status LEDs providedModes of Operation Calibration and NormalSize Standard size 96 mm x 96 mm x 150 mm
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DILIGENT RATIOCON 4-20 I
1. Discription:Stabmon is customized protection unit for 3-phase ac stabiliser. It is housed in strong & sleek m.s.enclosure. It operates on 230 V, 1 phase ac supply. Status & Fault LED display is provided on theunit and is very useful during commissioning and fault finding. Over load adjustment over 95% to105% of rated current, is provided on the unit. Local Reset Switch is provided to reset Stabmon afterit trips on fault. A toggle switch is provided to enable and disable ‘Single Phasing Protection’ andits status is indicated by the two-color LED.2. Operation:Stabmon require 230 V, 1 phase ac supply for its operation. 3-phase supply enters the unit atterminals Rs, Ys & Bs and leaves from terminals Rl, Yl & Bl for connection to load. Phase currentof each phase is monitored continuously. So long the current is present in all the three phases and isbelow the set limit, control relay inside is in energised state. Mains, Load and Fault LEDs arelighted. Status of ‘Single Phasing Protection’ is indicated by last LED. When the switch on the rearpanel is pressed, this LED becomes red and when that switch is released, color changes to green.3. Time-delayed Overload Protection :When any of the phase current exceeds preset limit for more than the permitted preset time (5sec.)continuously, Stabmon switches off internal control relay and latches it in this state. ‘Overload’ LEDlights. ‘T.DLY’ LED lights as soon as overload takes place and stays on till it last or till the elapse ofthe preset time, whichever is earlier. Overload adjustment is provided to adjust trip level from 95%to 105% of the rated current.4. Single Phasing Protection :Each phase carries current under normal condition and Stabmon continuously monitors it. Internalrelay remains energised so long all the three-phase carry current. However, when either one or twophases become open, internal relay switches off and is latched in this state. ‘Single PhasingProtection’ feature is different from the one understood conventionally. This is so because ACstabiliser is required to feed different loads from its phases and, therefore, currents in the phasescould be different. In extreme case, it may be required to operate with current in its one or two phasebeing zero or below the minimum sense level set for the circuit. In such case, Stabmon will notpermit its operation. Loads may be switched on/off randomly and this can cause load current to dipMICRO CONTROLS2below the minimum sense level momentarily. A short time delay of 2-3 sec. is provided to allowoperation with such short lasting dips in phase current.5. Reverse Phase Sequence Protection :Phase sequence of the 3-phase supply is continuously monitored. If the sequence is normal, Stabmonrelay stays in on state. However, whenever this sequence becomes reverse, relay switches off andstays off until sequence is corrected by interchanging any of the two phases. LED designated as‘REV. PH. SEQ.’ on the display, indicates this fault.6. Local Reset :Once Stabmon switches off internal relay and latches it in that state due to overload or single phasingfault, ‘Fault’ LED starts flashing and stabiliser is switched off. This state prevails until local resetpush button on the front panel, is pressed by operator.7. Calibration :Stabmon upto 10 Amps rating are directly calibrated and offered in our standard enclosures. For anyother higher current ratings, standard 5Amp Stabmon is calibrated with customer-specified auxiliarycurrent transformer.8. Status & Fault Display :Status & Fault display, is described below-Title DescriptionMains Lights when 230 V,1ph., ac supply is connected.Load Lights when one or more phases carry current.S. ing Lights when one or two phases are lost and current through thembecomes zero. It remains on even after tripping of Stabiliser, untilmanually reset by pressing local reset push button.O.Load Lights when current in any of the phases, exceeds preset limit beyondpreset delay (5 sec.). It remains on even after tripping of Stabiliseruntilfault is rectified and Reset Push Button is pressed.Rev.Ph.Seq. Lights when phase sequence is negative and remains on till it is madepositive by interchanging any of the two phases. It switches off onlyafter local reset push button is pressedT.DLY Lights as soon as current exceeds preset limit and remains on tillelapse of preset overload period or dropping of current below the limit.NOR- Steady This LED lights steady under normal condition and startsFLT - Blinks flashing after unit trips on fault.RED- S.ing Disabled This LED turns red when single phasing protection is disabledGRN- S.ing Enabled and it turns green, when single phasing protection, is enabled.
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DILIGENT * STABMON
Diligent Thermocouple Welding Unit is housed in strong powder coated m.s. enclosure which hasshoulder strap for ease of carrying on site. It has rechargeable 12 V 4.5 Ah heavy duty Battery withinbuilt SMPS Battery Charger cum Power Supply. 1 meter long multi-strand thick copper cable withSilicon Sheath, Heavy duty Plier and strong circular Magnet are used to connect the Welding Powerto the Thermocouple Wires & the surface on which TC is to be welded. the unit has facility to set theWeld Energy Charge Level to suit different gages of Thermocouple wires. The SET Value andCHARGED Value are displayed on Bar Graph display. The desired Charge Level is set on the SETBar Graph using UP/DOWN push button. This Setting is remembered during operation. Wheneverwelding is to be done, command is given to start charging the unit to SET value by pressingmomentarily the CHARGE Button. Once the Charge level is reached to SET Value, the AUDIOalarm sounds indicating the readiness for welding. Welding operation is performed either inMANUAL mode or AUTO Mode. In Manual mode, the Thermocouple to be welded is firmly held inPliers at the desired spot, Magnet with wire is located nearer to this spot and then press the WELDButton after getting READY AUDIO ALARM.In AUTO Mode, Pliers holding TC Wires and the Magnet are positioned at the scheduled spot. Pressthe CHARGE Button. The charge builds up to the SET value and Audio Alarm sounds. Few secondsof this, WELD command is automatically given by Auto Circuit and Weld occurs. The pliers ismoved to next spot and the complete cycle repeats automatically. This is carried out till all the TCsare welded.A Bar Graph Display is also provided to indicate the CHARGE Level of battery when Battery PushButton is pressed. An Audio Signal sounds when battery drains below 10.5V (approx). It requiresrecharge for proper welding quality.The unit can also be operated directly from mains AC Supply if Battery is not available.Diligent Thermocouple Welding Unit size is 240 mm (L) x 170 mm (W) x 170 mm (H) and weighs4.5 kgs without battery12 V DC Battery is rated for 4.5 Ah. Its size is 90 mm (L) x 70 mm (W) x 100 mm (H) and it weighs1.5Kgs.Its useful Charge Level is 60 Volts and can reach up to 80 Volts under supply voltage conditions. Themaximum charge can be reached to 0.60 Coulombs.
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DILIGENT THERMOCOUPLE WE
1. Diligent Protector for AC applicationsDiligent AC relays are available for Over Load (OL), Single Phasing (SP), Phase Reversal(PR), etc. The overload relays are available in 1ph and 3ph types. 1ph-relays are useful onsingle phase load and can also used as economical solution for 3 ph applications wheneverload is balanced. These are classified depending on the response to the overload condition andthe classification is as follows -a. INStantaneous (INS) type. In this relay changes the state as soon as overload occurs.b. Time-Delayed (DLY) type. In this the relay changes the state only after elapse of presentperiod from the time overload occurred & stayed.c. Jam (JAM) type. In this, the control relay does not respond to the overload condition fora preset time from switching on the load but after elapse of this time, the relay respondsimmediately to any overload.MICRO CONTROLS2Instantaneous type is primarily made for AC loads other then motor such as: transformer,heater etc. However, it has been also used along with other logic to control motor.Time-Delayed overload relay find wide use. The tie delay provided in the relay avoidsnuisance tripping in response to transient overloads but switches off the load if overloadpersists beyond the specified time. Most of the loads in actual practice increase temporarilyand the drive is usually designed to handle this type of overloads.Jam type overload relay is quite unique and has made possible very reliable protection ofloads such as Blower, Fans, Stirrer motors which was rather difficult to achieve withconventional thermal relay. Jam relay not only saves the motor, but restricts the possibledamage to the equipment & loss of production by advance intimation before catastrophicfailure takes place. Such situation, for example, can arise when ‘oil-starved bearings’ startsslowly seizing and if not attended in time can get heated and tear out the housing. Repair notonly costs in term of money but looses precious time. Similarly, jamming of conveyor can beeffectively responded by the Jam relay and catastrophic failure there of can be averted.Single Phasing (SP) protection in Diligent Protector relay is either Current Operated SinglePhasing (COSP) or Voltage Operated Single Phasing (VOSP). COSP is realised by sensingeach of the phase current continuously. As soon as current in any one phase is lost, controlrelay changes the state. This greatly limits the heavy thermal stresses due to large currentflowing in the connected phase-windings of motor. VOSP protection monitors all three supplyphases and acts when one of the phases of 3 phase supply is missing. However, Should phasebe lost while 3 phase motor has already running, VOSP may not trip the motor because of theinduced voltage in the motor winding. However, COSP is effective even when the phase islost while the motor is in operation.2. Diligent Protectors for DC ApplicationsDiligent Micro Controls has also developed protection relays for DC loads such as DC motor,DC generator, Rectifier sets, DC electromagnet etc. These relays are available in three types:namely INStantaneous, Time-Delayed and Jam type similar to the AC relays. DC relayoperates from “75 mV standard DC shunt” and requires auxiliary supply for its operation.Optionally the relay can be made suitable to work with User-specified shunt.3. Diligent Protectors for AC or DC Under-/ Over-VoltageDiligent Protector for AC or DC Under-/Over-Voltage fault is designed to monitor the voltagelevel continuously and whenever it exceeds set limits for more than the set time, the relayinside picks up. This relay can be made auto reset type or manual reset type.4. Diligent Protector for Neutral-Earth VoltageDiligent Protector for Neutral-Earth voltage monitors this voltage continuously and wheneverit exceeds set limits for more than the set time, the relay inside picks up. This relay can bemade auto reset type or manual reset type.5. Diligent Protector for Conveyor JammingDiligent Protector for jamming of conveyor is unique. It allows conveyor motor to startnormally and monitors continuously current drawn by it during operation. It trips the motorimmediately when current exceeds the set JAM limit. This averts catastrophic failure andconsequential loss of production. This relay can be made auto reset type or manual reset type.6. Diligent Protector Shear Pin ReplacementDiligent Protector for shear pin replacement is unique. Shear pin disengages the motor fromthe load by breaking itself when load increases beyond the permissible level. However,replacement of shear pin is associated with inherent uncertainties of material quality. Thisrenders shear pin protection less reliable. Diligent Protector Replacement for shear pin isunique. Not only it provides precise and repeatable protection but it also has provision toadjust the protection level which enables to match the protection to the load. This relay can bemade auto reset type or manual reset type.7. Diligent Protector for Lifting ElectromagnetDiligent Protector for Lifting Electromagnet allows electromagnet to be switched on undernormal condition but when its current drops below the set level for more than prescribedperiod, Diligent Protector alarms the operator.8. Diligent Protector for Grinder Under-/Over-loadThis is very special type of protection. Whenever grinders are working with full charge, itdraws large current initially and drops as grinding completes. Any prolonged operation aftercompleting grinding, the material can burn due to over heating as well as energy will beconsumed without any useful work. Diligent Protector for ‘Grinder Under load’ will trip themotor as soon as current drops below the set limit.9. Diligent Unique Protector for Blower / FanConventional Overload protection is not at all suitable for Blower / Fans due to their startingcharacteristic. Diligent Unique Protector for Blower / Fan is really unique. It allows normalblower start up successfully; however, if blower motor draws more current than set limit, itimmediately trips the motor. This is very useful as blower/fan is most ignored equipment inmost of the industries and they suffer consequential catastrophic failure due to this negligence.Diligent Protector will trip the blower even at the onset of faults such as starving forlubrication, impeller unbalance, excessive vibration, interference due to broken parts, etc.10. Diligent Monitor for Solenoid CoilSolenoid valves are very critical in the process control and their healthiness is of utmostimportance. Diligent Monitor for Solenoid Valve, monitors the healthiness of solenoid coilduring operation. Should coil become open during operation, a potential-free contact closes totransfer this information to centralized SKADA system or sound an alarm.11. Diligent Monitor for HeaterIn some applications like sterilizing system in pharmaceutical industries, numbers of electricheater elements are used in banks to achieve acceptable sterilizing temperature. However,failure of some elements does not become known until when finished goods start gettingrejected during quality control. Loss is large at this stage. Diligent Heater Monitor gives alarmwhen number of available heater drop below the acceptable number.12. Auxiliary Supply:Standard auxiliary supply 230V, 110V, 24V AC or 24V DC can be specified. Relays can be made tooperate on any other user-specified supply.413. Output Contact:One Change-over contact rated at 4 Amps (resistive) at 230V ac, is provided. This contact stays inactuated state as long as long fault does not exist.14. Status & Fault Display:Relay carried unique display which indicates various status and also the fault on which the load hasbeen switched off. It also has LED which glows steady under normal condition but starts flashingwhen relay trips. This is very useful feature where the tripped relay has to be spotted among the clusterof relays & contactors. This along with the type of fault indication immensely simplifies faultdiagnosis by identifying the defaulted zone. This results in considerable reduction in MTTR (MeanTime to Repair) and improving system availability.15. Post Fault Reset:Relay tripped in response to the fault, has to be restored for normal use again. Depending in the natureof fault and requirement of particular application, this restoring can be effected either automatically(AUTO) or manually (MAN) or combination of auto-manual (A/M). The faults which are not seriousare cleared by known corrective action and the relay in such case is made to reset by itself or clearingthe fault. Operator does not have to go to control panel to reset the relay and he can switch on the load.Such faults are, for example, phase reversal, normal overload etc. However, serious faults, such as,single phasing, mechanical jamming, bearing seizure, short circuit etc. required to be properlyinvestigated before switching on the load again. Hence in such cases, relay is designed to disallowrestart unless relay is manually reset by an operator-in-charge. The 3rd type of ‘fault reset’ is veryinteresting since Diligent Relays combine multiple protection in single unit. Some protection featurecould be serious while other may not. It is possible to built user-specified combination of reset logic inour relay. Thus, the relay is made very user-friendly.16. Warranty:“Diligent Protection Relay carries warranty for a period of twelve months from the day of deliveryfrom our works. During this period, we undertake to repair/replace our defective unit free of cost inpart or full at our total desecration provided that the unit is brought to our works for rectification andcollected there from after satisfactory inspection by the Customer at his cost & risk and provided thatthe defect is found to be due to poor material and / or workmanship and not due to misuse and/ormishandling. This warranty is exclusively restricted to the unit supplied by us and we shall not beresponsible in any way for any of the consequences arising due to the use and/or misuse of our unitanywhere. This warranty shall become automatically null & void, if our unit is opened and / ortampered by person not authorised by us.”
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Diligent Protectors & Mo
Heat has always been very useful to man kind. One of the basic and common ways to obtain heat is byburning combustible fuels. However, such combustion must be controlled and safe. Safety of combustion isensured by monitoring flame. Flame is characterized by emission of wide spectrum of electromagneticradiation starting from infra red, visible light to ultra-violet radiations. Flame is also known to generate ionsin its envelope. Type of fuel and that of burner decides which one of these radiations predominate. Forexample; flame of coal or oil is usually very bright and yellow in color, flame of light oil like kerosene or thatof hydrocarbon gas is light blue and flames of some gases may be even dull reddish. In addition to this,intensity of flame could differ widely depending on the type and size of flame. Hence different techniqueshave evolved and new are being developed to detect and monitor flames. DILIGENT MICRO CONTROLShas developed wide range of flame monitors “Diligent Flameye”. In addition to the basic flame monitor wehave developed intelligent versions which provideBuilt in delay for flame ON or OFF status change,Multiple contacts out puts,Dual flame monitor,Dual flame monitor with AND logic,Dual flame monitors with OR logic,Dual flame monitor with mixed sensor types,Inverse Mode of operation of control relay,Weatherproof enclosure flame monitor.AC power supply of 230V +/- 10 %, 50 Hz, 1ph ac is required for operation of all Standard Flameye models.However, versions suitable to work with other standard AC or DC supplies can be provided on request. Onechange-over potential free relay contact rated at 4 amps (resistive) at 230 V ac, is provided in all standardunits. Multiple potential free contacts can be provided as optional.Diligent Flameye are classified based upon sensing technique used and these are as described below-Diligent Flameye PRFlame produced while burning diesel, furnace oil, HSD, LHSH, etc., is bright and yellow. PhotoResistor typephotocell have excellent response to the visible light spectrum and, therefore, is the most reliable and costeffective choice to detect such flame. Diligent Flameye PR provides appropriate bias to the basic PR sensorwhich generates change in its resistance commensurate with the amount of visible light radiations received byit. This change is received by Flameye which conditions and amplifies it before comparing with presetreference. When signal level crosses the reference, internal relay picks up. This relay goes back to off state assoon as the radiations falling on PR sensors cease. Basic signal from PR sensor is very small and should betransmitted over screened cable to Diligent Flameye and his cable should be preferably laid away from powercable.MICRO CONTROLS2Diligent Flameye PVPhotoVoltaic photocell is another basic sensor which has excellent response over visible portion ofelectromagnetic radiations. It produces electric dc voltage in mV range in response to the intensity of lightfalling on it. This small signal from PV sensor is conditioned & amplified by Diligent Flameye PV and thencompared with preset reference. When signal level crosses the reference, internal relay picks up. This relaygoes back to off state as soon as the radiations falling on PV sensors cease. Basic signal from PV sensor isvery small and should be transmitted over screened cable to Diligent Flameye and his cable should bepreferably laid away from power cable.Diligent Flameye UVPR and PV sensors are excellent choice when the flame is bright yellow. However these sensor hardlyrespond to a flame which is blue, light blue or nearly invisible like the one that exist while burning of lightoil, LPG gas, Natural gas, propane, butane, methane, etc. Such flame is sensed by sensing the radiations inultra-violet range which are associated with all combustion processes. Gas filled UV photocell orsemiconductor type UV photocell is used to receive these radiations from flame. These cells require correctbiasing voltage which is provided by Diligent Flameye UV. Tiny signal in micro ampere is generated by UVsensor and is then transmitted over screened cable to Diligent Flameye UV. This cable must be of very goodquality having low capacitance and high grade insulation. This small signal from PV sensor is conditioned &amplified by Diligent Flameye UV and then compared with preset reference. When signal level crosses thereference, internal relay picks up. This relay goes back to off state as soon as the radiations falling on PVsensors cease.Diligent Flameye IONIons are produced in the envelope of all types of flames due high temperature in side. This technique picks upthese ions under the influence of appropriate bias voltage and generate tiny signal which is then transmittedover screened cable to Diligent Flameye ION. This cable must be of very good quality having lowcapacitance and high grade insulation. This small signal from ION sensor is conditioned & amplified byDiligent Flameye ION and then compared with preset reference. When signal level crosses the reference,internal relay picks up. This relay goes back to off state as soon as flame extinguishes. This technique relieson collecting of ions in the flame and hence the sensor electrode must always be in good contact with theflame and flame must also be in continuous contact with electrically earthed body. Any violation of this willmake the flame signal disappear.Flame SensorsAll the flame sensor except ION sensor are electronic sensors and hence their operating environmenttemperature must not exceed 55 deg C. Higher temperature, though may not lead to malfunctions, canseverely affect the useful life of the sensor. All of the sensors, therefore, carry any testing warranty and noneof these carry conventional warranty. ION sensor is electrode with high grade insulator and high temperaturecollecting rod. Care is necessary to ensure that the scaling on rod is periodically removed, contamination thatcould reduce insulation level of rod, should be avoided and cleaned if noticed.WarrantyDiligent*FLAMEYE carry a warranty for period of 12 months from the date of delivery. During warranty period weundertake repair/replace free of cost part pr full unit found defective at our total discretion provided that such unit isbrought to our works for rectification & collected there from after satisfactory inspection by the customer at his total cost& risk and provided that the defect is due to poor material/ workmanship and not due to misuse/mishandling. Thiswarranty is exclusively limited to the unit supplied by us and we shall not be responsible in any ways for any of theconsequences arising due to its use/misuse any where. This warranty shall automatically become null & void if our unitis opened/tampered by person not authorized by us.Due to the operating environment of flame sensor, all types of flame sensor carry only TEST WARRANTY i.e. theoperational status of the sensor will be demonstrated while taking delivery from our works.
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Diligent “Flameye” Flame
Diligent Micro Controls offers wide range of controllers for automatic control of all types ofburners. Classifications of these controllers are based on type of fuel burnt, design of burner, modeof operation, technique of flame sensing, starting pre-requisite interlocks, security interlocks, etc.Diligent Autocon controllers are completely solid state types and use standard and time-provencomponents. This ensures their continuous & reliable operation over long period even under adverseconditions of electric power and environment. Each Autocon has its unique & user friendly “Status& Fault” display that displays status of various equipments and that of faults that leads to burnerfailure. This feature is very useful during commissioning and fault finding of burner. A diligentAutocon controller work on 230 V +/- 10%, 50 Hz, 1 phase ac supply and provides live operatingcommands to switch on or off various equipment related to the burner operation. Alternately, it canbe made suitable for operation on 110 V or any other power supply specified by the customer. It hasbeen our experience over past two and half decades that the time delays in the controllers should bepreset in the factory rather than in the field. However, we can offer some delays as “field settable” toour new OEMs for their initial trials on their system and later on these can be factory set at the valuespecified by the OEM.Diligent Autocons are housed in strong m.s. or plastic enclosures. It is provided with eitherscrewable or pluggable connectors for connecting with rest of the burner. These are made in eitherbase mounting type or door mounting type. Salient categories of Diligent Autocon are given below –1. Diligent Autocon for various fuels.a. Gas fired burnerb. Oil fired burner.c. Coal fired burner.d Bagass fired burner.e. Multiple fuel fired burner.f. Customised burners such as for Flame Treatment for plastic printing, for Flame welding ofplastic coated paper articles, etc.2. Diligent Autocon for various modes of operation.a. No process-parameter control. Only operation with safety monitoring.b. Process parameter control by single stage ON/OFF of burner.c. Process parameter control by multi-stage ON/OFF of burner but without damper control.d. Process parameter control by multi-stage ON/OFF of burner but with damper positioncontrol.MICRO CONTROLS2e. Process parameter control by continuous modulation of single stage burner whichcontinuously adjusts gas & air proportion commensurate with the heat demand.f. Process parameter control by continuous modulation of multi-stage burner whichcontinuously adjusts gas & air quantity commensurate with the heat demand.3. Diligent Autocon with various techniques of flame detection and flame sensor.a. Photo-Resistor type flame sensor; most cost effective solution for oil fired burner.b. Photo-Voltaic type flame sensor; alternate for oil fired burner.c. Infra-Red type flame sensor; preferred for coal-fired or low calorific fuel burner.d. Ultra-Violet type flame sensor; most reliable but expensive technique of flame detectionespecially for invisible / blue flames.e. Dual flame sensing technique especially when multiple fuels tend to generate flames withdifferent predominant characteristics.4. Diligent Autocon for multiple burners in same combustion chamber.
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Diligent Autocon Control

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