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TECHNICAL TRAINING
July 2013
Technical Training
TECHNICAL TRAINING
TABLE OF CONTENTS
SECTION I: INTRODUCTION
25
TECHNICAL TRAINING
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TECHNICAL TRAINING
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161
TECHNICAL TRAINING
TECHNICAL TRAINING
Glossary
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SECTION I: INTRODUCTION
TECHNICAL TRAINING
TRAINING OBJECTIVES
1. Gain awareness of fired vessel applications.
2. Work to have an understanding of the components related to natural draft production
equipment.
3. Establish competence in the installation and operations of Platinum Controls Burner
Management Systems.
NOTE
At all times we will consider Safety, Efficiency, and Regulatory requirements. Please consult and follow
appropriate OSHA, NFPA, Canadian Standard, Industry and Company specific safety practices. Always
wear appropriate PPE including, but not limited to the following items:
Hard hat
Safety glasses
FR clothing
Steel-toe boots
Hearing protection
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ABOUT PLATINUM
Our team has decades of experience in the oil & gas field and a thorough understanding of all the
production equipment involved. That knowledge has driven our development of the most
technologically advanced, reliable and user-friendly BMS on the market.
Beyond a great product, we value and continue to build strong partnerships with our clients. Always
committed to 100% satisfaction, we provide 24/7 technical support for the life of the unit.
PLATINUM CONTROL: IMS & BMS
Ignition Management System
Platinum Controls Ignition Management System is specifically designed to light, monitor, and re-ignite
natural draft burners used in heating systems for oil and gas production equipment and gas flares.
Burner Management System
Platinum Controls Burner Management System provides remote burner access, automated ignition and
temperature control for oil and gas production. The system records essential data and safely automates
heating processes, decreasing injury risk, maximizing well production and facilitating environmental
compliance.
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HOW IT WORKS
BMS & IMS (IGNITER Mode)
Both the BMS and IMS monitor for the presence of a pilot flame through an igniter rod which
feeds the signal back to a microcontroller to determine a safe sequence of events based on the
signal.
Both the BMS and IMS control the pilot, main solenoids and ESD solenoids. In the absence of a
lit pilot, the system will shut all gas sources feeding the pilot and main burner and wait for a
user set wait time before attempting a re-ignition sequence.
Both systems, in the event of a positive ignition will sense the flame and proceed with
monitoring. If either system senses a flame ignition failure, they will lock out the ignition process
after three failed attempts and wait for an operator to troubleshoot and reset the system.
In flare mode, the IMS does not control solenoids. In the absence of a flame, the IMS will wait
for a fixed delay time of 5 seconds before attempting a re-ignition sequence.
In the event of a positive ignition, the system will sense the flame and proceed with monitoring.
In the event of flame ignition failure, the IMS will restart automatically without any limitations.
BMS
In addition to the features shared with IMS, the BMS has temperature control to establish and
maintain operator adjustable temperature set points.
Remote capability allowing personnel to monitor and adjust operations from off site.
The ability to communicate an alarm in shutdown conditions to notify operators of upset
conditions.
Image of Platinums ignition module, wiring, and pilot installed in a flame arrestor.
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THE BRAINS
Manufactured under the strictest production parameters, the control panel is the brain of our BMS/IMS.
Each is precision engineered and rigorously tested to withstand the harshest weather conditions, while
ensuring reliable uptime. We simply do not take shortcuts in the quality we put into every controller.
The system is designed to easily integrate with your other monitoring and data systems to allow
complete visibility into your production site.
A simple interface with intuitive alerts, the system is designed to be very user-friendly in the field and
provide the control to remotely manage your production site.
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APPLICATIONS
Platinum Controls Burner Management Systems support any natural draft burner up to 10MMBtu/Hr
on oil & gas production equipment. Whether you need one unit or want to integrate all of your burner
systems, Platinum Control can give you the insight to manage your:
Production Units
Treaters
Dehydrators
VOC Combustors
Heated Separators
Oil Stabilizers
Line Heaters
Amine Plants
Combination Units
Multiwell Units
Tank Heaters
Flares
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INSTALLATIONS
In yard installations are easier, but will require adjustments in the field after final installation. On
location installations are more involved, but maximize the opportunity for optimum operations.
In retrofit applications always examine flame arrestor to insure free of plugging, check burner fuel train
for proper operations in addition to inspecting firetube for obstructions, sooting, or hot spots.
All of these items can lead to issues with burner capability and flame quality.
The end result can be improper operation, damage to production equipment, lost revenue or injury.
ADDITIONAL CONSIDERATIONS
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POTENTIAL CONSEQUENCES
Failure to use Burner Management Systems could result in damaged equipment, lost revenue, legal
claims, injury or fatality.
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INCREASE SAFETY
GAIN PRODUCTION
MINIMIZE ENVIRONMENTAL
EFFICIENCIES
IMPACT
Reduces production shut- BMS temperature
downs due to burner
controlled burning
failure
prevents explosions
Remote control of the
Positions your company for
BMS decreases need for
current and future
field engineers to go on
compliance requirements
site to monitor systems
BMS delivers accurate
Increases visibility into
temperature and pressure
your systems
control to ensure complete
incineration of unusable or
performance
harmful gases
Prevents harmful gases
from releasing into the
environment
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Platinum 500
BMS 731
BMS BTEX
Applications
Gas Flares
Production
Equipment
Production Equipment
Production Equipment
Operation Mode
Flare
Igniter
---
---
Ignition Control
Yes
Yes
Yes
Yes
Valve Control
---
Yes
Yes
Yes
K-Type Thermocouple
(Can be used to measure
temperature at three
different points)
Temperature
Control
---
---
RTD
K-Type Thermocouple
Typical Power
Connections
(Not including
valves)
12/24 V
0.08 W
12/24 V
0.19 W
12/24 V
9.6 W
12/24 V
9.6 W
Internal Battery
Option
12 V sealed lead-acid
Up to 14 AH
---
---
Internal Solar
Charge Controller
Vmp: 17.3 V
Power: Up to 30 W usable
---
---
Solar Enabled
Yes
Yes
Yes
Redundant
Shutdown
Yes
Yes
Yes
Yes
---
---
Yes
---
---
Yes
Yes
Yes
---
Yes
Yes
Certification
Pending
Classification
Class I, Division II
Class I, Division II
Class I, Division II
Auto-Restart After
Power Failure
Input(s) for Safety
Devices
Communications
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Distributors
o
OEMs
o
End Users
o
Field Personnel
Corporate Engineering
Corporate Management
Safety Officer
COMPETITORS
Canalta
ACL Manufacturing
Profire
SureFire
Patton
Platinum Control offers a more consistent, technologically advanced product with the following
benefits:
CSA/UL Certified for its intended use the entire unit versus components
Remote monitoring
Centrally located
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SUPERIOR MANUFACTURING
65,000 square feet of manufacturing space virtually unlimited capacity to produce upon
demand
Typically we can meet the demand for nearly any order quantity in days, not weeks, in
conjunction with our distribution network
Main distribution hub and is centrally located near the Dallas-Fort Worth International Airport
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CSA/UL Certified for its intended use the entire unit versus components
Centrally located
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We succeed. No Excuses.
We strive to exceed our clients expectations.
We provide our clients with excellent experiences.
We solve our clients problems, even if they are not directly our problems.
We obsess about service.
We dont assume, we listen.
We always operate with integrity.
We are not always right. We admit it when we are wrong and act to solve the problem
as quickly as possible.
Success is never a solitary venture.
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SECTION II:
COMBUSTION FUNDAMENTALS
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FIRE TRIANGLE
Fuel
Energy
Oxygen
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Fuel
Many types of fuels can be used in the fire triangle. The primary fuels we will utilize are
natural gas and propane. Both of these fuels are desirable for our application as little
heat is required for ignition and the combustion process is controllable. In natural gas
applications, the fuel supply is commonly provided from the working processes of the
gas stream being generated at the location. There are times when this gas stream may
be sent from an auxiliary location, or central battery. In some instances propane may be
utilized. This occurs when there is little or no natural gas available for burner operations
or the percentage of impurities in the gas stream such as CO2, H2S, etc. prevent burning
the available gas. It is important to be sure of where the fuel stream is coming from, the
type of fuel being used, and British Thermal Unit (BTU) value.
Heat
The final component of the triangle is energy (heat). We are seeking to provide this
component to instigate the process of combustion. This is accomplished by utilizing an
ignition source to generate the necessary heat to complete the chemical reaction. This
component is most safely and conveniently provided by a Platinum Burner Management
System (BMS) ignition device.
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CONTROLLED COMBUSTION
Fuel
Exhaust
Oxygen
Heat
Heat
We have established a goal of providing energy (heat) as a chemical treating process. It is then critical to
be able to control this heat to insure safe and efficient operation. By providing the necessary ignition,
and regulating the oxygen and fuel combination, we can harness available heat energy provided by the
chemical reaction. This dictates that we must have the power to control initial ignition and the
individual oxygen and fuel components brought together as a combined mixture. This control is
imperative for a safe and sustained reaction.
The ratio of oxygen to fuel for efficient operation can change subject to the BTU content. Without the
proper ratio, the reaction can burn rich or lean. This affects the available heat energy, operation
efficiency, sustainability, and maintenance issues relating to burner operation.
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Control By Design
It is desired for the combustion chamber to be able to operate without the continuous assistance of
personnel. Therefore, the combustion chamber, and supporting devices are designed to be operated
with minimal field operator assistance. The primary assistance comes from startup operations providing
the initial ignition source and adjustment of valves, regulators and oxygen/fuel mixing devices, and is
not ongoing.
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Control By Instruments
Control of the ongoing heating process is required. Once again, it is desirable to minimize human
contact. By utilizing electrical and pneumatic instrumentation for fuel supply and ignition, we can safely
and efficiently decrease the need for personal attention and adjustment to the components utilized in
burner operation.
It is crucial that field personnel are aware and trained in the operation of the devices utilized on their
field locations. There is a variety of components that may provide similar functions, but with different
operating adjustment parameters. It is our recommendation for affected personnel to review the
operations manuals for any component utilized. This is necessary to insure familiarity and an
understanding of safe work practices related to each piece of equipment and the instrumentation
associated.
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Emulsion Inlet
Gas Outlet
Oil Outlet
Water Outlet
There are many different sizes, shapes, styles, and types of fired production equipment. We are
primarily concerned with the most common types utilized in the oil and gas industry. These are direct
fired and indirect fired.
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Clean Oil
In the operation of a direct fired device, the area of heat generated energy is directly in contact with the
product to be affected. The heat contact is made in a fluid section. Examples of these types of
production equipment would be emulsion heater treaters, heated separators, tank heaters, and glycol
dehydration regen units.
In a direct fired unit, the generated heat energy from the combustion chamber radiates from the
firetube directly to the process stream to be affected, such as the inlet emulsion, or glycol to be
recycled. Routine maintenance and inspections are recommended as extra precaution. This is due to
the nature of the process fluid usually being flammable, and the direct proximity of the heat source.
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Heated
Outlet
Fluid Media
Gas or
Emulsion
Inlet
In the operation of an indirect fired device, the area of heat generated energy is now providing heat
energy to a media fluid. This media fluid, is heated, and transmits the heat energy to the process
stream. This can be a gas or fluid stream. Examples of these types of production equipment would be
water baths on gas production units, salt bath heaters, or line heaters.
An indirect fired unit is an example of heat exchange in which heat is applied to one media, and then
this heat is transferred to the process stream to gain the desired results.
It is important to know whether the equipment being used is direct or indirect fired. This will assist in
having a full understanding of safe, correct, and efficient operation.
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BURNER CATEGORIES
The majority of fired equipment contains a fuel train, combustion chamber, the firetube, and stack. We
will discuss the additional components which make up the fuel train and combustion chamber later.
There are many different varieties of burner assemblies. The two most common are liquid fueled and
gas fueled. For our purposes we are only concerned with gas fueled, and more specifically gas fueled
natural draft burners.
Liquid Fueled Burners These are burners that use oil, crude oil, diesel, gasoline, kerosene, etc. for
burner fuel. The units are not typically practical in our area of operational
requirements due to the availability and ease of operation of natural gas
burners. In addition there is a requirement for forced oxygen supply and less
stability resulting in more intensive equipment for operation.
Gas Fueled Burners
There are two types of gas fueled burners usually found in petroleum industry
production applications. These are forced draft and natural draft.
Forced draft burners require a blower or fan to force oxygen through the air
intake to be combined with fuel.
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This is the area of focus for us. Natural draft burners utilize oxygen supplied by the draft created due to
the heat inside the firetube. The oxygen is drafted into the firetube through a flame arrestor
(sometimes called burner front). The most commonly used fuel is natural gas produced on the site of
the burner systems. There is a broad spectrum of usable natural gas from 850 BTU/scf to 1400 BTU/scf.
The difference in supply gas BTU values will affect the heating capability of the burner. Propane may
also be used as fuel for a natural draft burner. Propane has a higher heating value of 2512BTU/scf.
When using propane, or high BTU natural gas, it may be necessary to reduce the fuel gas pressure up to
40% , or reduce the orifice size up to 40% due to the higher heating value of propane. While not
common, it is not out of the question to find landfill gases, or waste gases being burned in the
petrochemical industry. The btu values of such gases can vary greatly, and may require using supplied
propane to maintain a stable flame. It is essential to have a gas analysis to confirm heating value and
combustibility to use landfill or waste gas as a supply.
The most common type of burner found in the field in petrochemical applications is the gas fired natural
draft burner. These burners are used for convenience and ease of operations. When properly sized and
maintained gas fired natural draft burners will perform reliably. Key components are the fuel gas train,
flame arrestor, burner mixer, burner nozzle, pilot mixer, pilot nozzle, burner management or ignition
device, firetube, and stack. There are additional components that may be found on some installations
such as secondary air adjustment, turbulators, shutters, combustion air controllers, but we will discuss
these later. The burner should be sized according to the expected flow conditions of the location. It is
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always preferential to have a gas analysis and Btu content of the gas supply to be used. Note it is a
common practice to move equipment from location to location as wells deplete. This can create a
situation in which improperly sized equipment designed for a completely different set of conditions is on
the site. This can result in poor heating capacity, unsatisfactory equipment performance, or even safety
concerns.
All natural draft burners operate on a gas fuel supply, and are not designed for liquid fuels. The fuel gas
supply will flow from the source. This could actually be the equipment that the burner is situated on.
An example would be a heat treater, or gas production unit. The gas supply flows through a scrubber to
remove liquids, possibly a filter and/or a Y strainer to remove impurities, then to a pressure reducing
regulator to maintain between 5 to 15 pounds average pressure, and then a fuel gas supply valve to
allow for gas flow when required, and to shut gas flow off when not needed. A pilot gas supply is usually
taken from the fuel gas scrubber as well; however this usually operates from ounces, possibly up to 8
pounds (average 2-5 lbs.). In addition there can be relief valves, isolation valves, and gauges in the fuel
gas train. The supply gas then goes into the combustion chamber to be mixed with oxygen which, is
drafted into the firetube via the flame arrestor.
There are a variety of brands of manufacture of all of the components in the fuel gas train and burner
components in the combustion chamber.
It is critical to have an understanding of correct burner adjustment procedures specific to the
components being utilized to insure safe, reliable, and efficient burner performance. Proper burner
tuning is essential to minimize heat release rate and allow for maximum combustion efficiency.
There are several variables to be considered to allow for optimum burner adjustment:
BTU content
Orifice sizing
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Primary air
Correct operation of the burner will prevent excess cycling or excessive heat transfer. Both of these
situations cause inefficient or wasted gas consumption.
Thermal efficiency can be reviewed in some cases using a thermal heat gun. A complete analysis should
be performed using a flue gas analyzer.
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Electrostatic Treater
A vessel that receives emulsion flows and resolves
the emulsion to oil, water, and usually gas, by using
heat, chemicals, and a high-voltage electric field.
This field, produced by grids placed perpendicular to
the flow of fluids in the treater, aids in breaking the
emulsion. The electrostatic treater is also called the
Chemelectric or electrochemical treater.
Heated Separator
An item of production equipment used to separate
liquid components of the well stream from the
gaseous elements. Separators are vertical or
horizontal and are cylindrical or spherical in shape.
Separation is accomplished principally by gravity, the
heavier liquids falling to the bottom and the gas
rising to the top. In this vessel a firetube or heating
element has been added to prevent freezing or assist
with emulsion separation.
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Glycol Dehydrator
A unit used to remove minute water particles from
natural gas if dehydration has not been attained
using separators. A glycol dehydrator unit is
composed of an absorber, reboiler, and supporting
components.
Amine Unit
An Amine Unit is a combination of a contactor
tower, surge drum, regenerator, condenser, and
accumulator assembled together with associated
instrumentation for the removal of the acid gases
CO2, H2S, plus additional contaminants from a
natural gas stream. The sour gas is absorbed by
Amine in the contactor tower. Hydrocarbon is
separated from the solution in the surge drum. The
acid gases are stripped from the rich amine in the
regenerator. The now lean amine is circulated
back to the contactor, while the acid gas and
condensed liquids are sent to the condenser for
cooling and then collected in the accumulator. This
process can be found in both field and plant
operations.
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Line Heater
A container or vessel enclosing an arrangement of
tubes and a firebox in which an emulsion is heated
before further treating, or in which natural gas is
heated in the field to prevent the formation of
hydrates.
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Combustor
A device used to incinerate waste gas emissions
VOCs (Volatile Organic Compounds), and BTEX
(Benzene, Toluene, Ethyl Benzene, Xylenes)
resulting from the production process. It
eliminates and vaporizes these hazardous
emissions by maintaining a certain temperature
at the flash point. Maximum destruction
efficiency is paramount.
Combination Unit
These units may be the combination of a gas
production unit and a dehydration system
combined on the same skid and enclosed.
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Multi-well Unit
These units are essentially two or more gas
production units on the same skid and are usually
enclosed. They are designed for use on multiple well
pad locations.
Tank Heater
These are firetubes designed to be mounted in the
door of storage tanks. The units are found primarily
in colder climates.
Flare
A device designed to ignite vent gas and other
emissions. The flare does not have the destruction
efficiency of an incinerator.
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THE FIRETUBE
Wildlife Protector
Stack Arrestor
Turbulators
Flame
Arrestor
Firetube
Flange
Main Burner
Return
Bend
The firetube is an integral part of the burner assembly. As discussed earlier, it allows for control by
design. Without the firetube there would be no requirement for a burner assembly. While we are
discussing fired vessels, it is important to note that fired vessels fall into a category of heated vessels.
Not all heated vessels use an actual fire. We distinguish the equipment in our conversation as fired
vessels, because they do in fact have a fire contained within the combustion chamber and firetube. The
firetube itself houses the flame, a barrier from the process fluids or media, and provides for heat
exchange. The heat produced in the firetube is communicated to the media or process fluids, thereby
raising their temperature.
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When properly adjusted, the flame in the firetube should not reach further than the beginning of the
first bend of the firetube. It is an important consideration that the flame from the burner does not
contact the firetube wall. Prolonged contact with the firetube wall can weaken the firetube causing
hot spots or weak areas in the firetube that are subject to failure. If a firetube fails, the results could
be catastrophic. A potential for explosion or fire would be possible if for example crude oil came in
contact with the flame from the burner. A serious threat would be posed to safety, the environment,
additional equipment, and revenue in the case of such an event.
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Heat Transfer
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Be very cautious of hot spots developing on the firetube, as well as scale or paraffin buildup on the
outside of the firetube. This paraffin buildup will prevent heat transfer to the liquid, but will cause the
metal to superheat and development of hot spots or weak points in the firetube.
When liquid hydrocarbon is present, it will not completely burn. This results in coke forming inside the
firetube. This coke will insulate the firetube and prevent well dispersed heat transfer. This will decrease
the bath temperature, and increase the stack temperature. Thereby efficiency is decreased.
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Square Miter
Smooth Return
4 Miter
There are 4 different types of return bend designs for firetubes. It is worth noting that the square miter
is the least expensive of the firetube designs, however it is the weakest. The longer the firetube leg,
larger the diameter, and the more temperature cycling, the more susceptible to stress cracking the
firetube becomes. It is also useful to note the firetube miter design for cleaning purposes and whether
the firetube is a horizontal or vertical configuration.
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Not all fired vessels come equipped from the manufacturer with these devices. They are important
considerations for safe and efficient operations. Flash and stack arrestors are designed to be mounted
at the top of the firetube stack to prevent sparks, flashes, or any burning material from escaping the
stack. Any escaping burning debris could ignite any combustibles that could be around or near the
burner or stack assembly. Sparks are basically burning carbon remnants. An inefficient burner will
generate the burning carbon. This carbon becomes attached to the firetube walls which can decrease
drafting efficiency. This carbon can also crack, fall off, and re-ignite, potentially igniting any
combustible material in proximity. The flash/stack arrestor can prevent these from escaping, but the
burning carbon will cause soot buildup on the inside of the firetube, which leads to additional problems.
The flash arrestor and stack arrestor are mounted on the stack head if the vessel is so equipped. These
devices consist of an arresting element to prevent short duration sparks or flashes. These devices are
designed of sufficient size to not add to backpressure on the stack which would prevent proper drafting.
The stack head is utilized to minimize the possibility of pilot or main burner flame blowouts due to down
drafts, or wind issues. Stack arrestor size must be at least as large as flame arrestor. Accurate sizing
requires BTU requirement, firetube diameter, length, and stack height.
NOTE
Not all fired production equipment is supplied with stack heads, stack arrestors, flash arrestors. Installation of these devices is
usually determined by the producer, purchased from equipment manufacturer, and determined by state and federal land
regulations.
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Turbulators
Wildlife Protector
Stack Arrestor
Turbulators
Flame Arrestor
Flange
Firetube
Return Bend
Main Burner
A firetube turbulator is a component installed in the second leg of the firetube past the return bend.
The purpose of the turbulator is increase heat transfer on the back side of the firetube. The turbulator
directs flue gas outward towards the wall of the firetube. This increases heat retention and heat
transfer from the firetube, lowers stack temperatures, decreases pressure loss, increases efficiency,
while decreasing operating expense.
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Flange
Fuel Gas
Flame
Arrestor
Burner
Nipple
Burner Mixer
Inspection
Port
Air
Flow
Ignition
Module
Ground
Cable
Pilot Mixer
Pilot Nozzle
Pilot Nipple
High Voltage
Cable
Burner
Nozzle
Igniter Rod
Ten-Conductor
Cable
The combustion chamber is the front end portion of the firetube adjoined with the flame arrestor. This
is where oxygen from outside the firetube is combined with the supplied pilot and main burner gas for
ignition and sustained combustion. The combustion chamber consists of piping coming in to the
chamber from the fuel gas train, the pilot orifice, mixer and nozzle, the main mixer, and burner nozzle,
in addition to burner ignition components. It is recommended the burner nozzle extend from the flame
cell into the firetube 4.
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Burner Mixer
Firetube Flange
Burner Mixer
Burner Nozzle
Inspection
Port
Pilot Nozzle
Pilot Mixer
Flame Arrestor
The purpose of the flame arrestor is to insure that combustion stays in the combustion chamber. In
case of an explosion, the flame arrestor cools the vapors from inside the combustion chamber to
prevent a potential ignition on the outside of the arrestor. The flame arrestor is the shell that holds the
flame cell. The flame cell is a tortuous path of passages that serves as heat exchanger. This path arrests
all flames providing safety and protection. The flame cell is sized to deliver an excess air level of 15
percent considering the lowest draft amount available for ignition and sustained reaction. This also
serves to dissipate the heat generated internally in the combustion chamber to below ignition
temperature on the outside of the flame arrestor. The flame arrestor flame cell or element is
engineered with sufficient mass to endure being positioned near the burning flame inside the
combustion chamber.
It is important to know that there are two different types of combustions that occur within a
combustion chamber near the flame arrestor. These two types of combustions are deflagration and
detonation. The controlled burning that takes place at the burner tip is known as deflagration. A
substantial flame velocity fed by high internal pressures with extreme gas turbulence is known as
detonation.
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The flame arrestor element is designed to withstand explosions (detonations) in the firetube or prevent
flashes from passing through the element that could potentially ignite outside the flame arrestor. To do
so the wrap density of the flame arrestor must be sufficiently tight utilizing alternating wraps of flat and
corrugated metal. The flame arrestor housing is engineered with the same considerations in mind. In
addition, considerations are made in regards to the design being able to withstand adverse hot and cold
weather conditions. Most modern flame arrestors are made of aluminum or stainless steel in offshore
applications. In the past arrestors were made of carbon steel, and many of these are still in service.
Gaskets used between all jointed components of the flame cell are critical. These gaskets must be in
good shape and provide a seal to prevent fugitive combustible material from exiting the flame arrestor
area.
It is recommended to service flame arrestors and the combustion chamber on a regular basis to be
determined by the equipment usage. It is important to inspect these components for damage, plugging,
debris, wear, holes, leaks, etc..
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Flame arrestors have not always been used, and it is possible to find vessels in the field that still do not
have flame arrestors on them. These have what was called a burner front. These can be dangerous as
an open flame may be exposed. These units should be replaced for safety and to be compliant with
regulations in most areas.
The flame arrestor itself provides many benefits:
Corrosion resistant.
Explosion resistant retaining band which when maintained allows for a long service life.
Designed to prevent debris and other materials from entering the firetube.
Decreases potential for downdrafts or wind to blow out the burner or pilot flame.
Total combustion of fuel gas by providing steady oxygen feed to the main and pilot burners.
An important additional component of the flame arrestor is the inspection port. The inspection port is
typically on the front of most modern flame arrestors and may contain a temperature resistant window.
This port is beneficial for inspection of flame, burner components, and can assist in troubleshooting.
NOTE
NEVER REMOVE INSPECTION PORT COVER WHILE A FLAME IS PRESENT IN THE COMBUSTION CHAMBER. A HAZARDOUS
FLASHBACK CAUSING INJURY COULD RESULT.
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O-Type
Barrel-Type
A-Type
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MM Btu/Hr.
0.05
0.10
0.25
0.40
0.50
0.75
1.00
1.25
1.50
1.75
2.00
2.50
3.00
3.50
4.00
4.50
5.00
6.00
7.00
Standard Model #
SB 12-6-1
SB 12-6-1
SB 12-8-1-1/2
SB 16-8-2
SB 16-8-2
SB 20-10-3SS
SB 24-12-3SS
SB 26/18-14/3CI
SB 28/18-14/3CI
SB 32/18-20/4SS
SB 34/18-20/4SS
SB 30-20B-4CI
SB 32-20B-5CI
SB 36-24B-5CI
SB 38-24B-5CI
SB 40-24B-5CI
SB 30-18B-4CI
SB 32-20B-5CI
SB 36-24B-5CI
Mixer Style
Mixer Head
Mixer Head
Mixer Head
Mixer Head
Mixer Head
Single Stage
Single Stage
Compound
Compound
Compound
Compound
Compound
Compound
Compound
Compound
Compound
Two Compound
Two Compound
Two Compound
NOTE:
Low noise burner applications use the same arrestor, mixer and nozzle combinations, but use a larger orifice.
SB 12 / 16 6B 1CI (TWO) - Firetube Count
Compound Mixer
Burner Size
Box Type
Firetube Size
Body Length (12 is Standard)
Element Diameter
Single Burner
MB-MultiBurner
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Flange
Fuel Gas
Flame
Arrestor
Air
Flow
Burner Mixer
Inspection
Port
Ground
Cable
Ignition
Module
Air
Flow
Pilot Mixer
Pilot Nipple
High Voltage
Cable
Burner
Nipple
Burner
Nozzle
Pilot Nozzle
Igniter Rod
Ten-Conductor
Cable
Sketch of flame arrestor with burner components.
The burner assembly housed inside the flame arrestor/combustion chamber is made up of the following
components:
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Keep in mind when adding a Platinum Burner Management System or Igniter, you will also see the
following components in the combustion chamber and firetube area. These items will be discussed later
at length.
Igniter module
Ground wiring
When installing or performing burner maintenance, make sure and inspect each of these components to
confirm working condition.
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The burner nipple, burner tip, pilot nipple, and pilot tip are all non-adjustable and designed according to
manufacturer specifications. They only need to be inspected and cleaned periodically or replaced if
needed.
Many different styles of burner nozzles are available. These diverse nozzles provide specific flame
shapes to meet the firetube application. Single port nozzles that produce long cylindrical flames work
well on equipment with long firetubes. These nozzles may not work as well on firetubes with shorter
firetubes that may require more modest fuel gas supply pressures. Nozzles with smaller ports are more
suited to shorter firetube applications. For example a rosebud style nozzle produces a shorter bushier
flame suited to vertical heat treaters with firetubes typically less than 6 long. Just as with the pilot
nozzle, main burner nozzles have a ring of smaller ports around the main burner port. These ports serve
to keep the flame by continuing to ignite fuel as it is diverted through these ports.
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The Mixer
Mixer Head
Primary Air
Adjustable Orifice
The main burner mixer is designed to mix the oxygen supply and fuel gas for ignition of the main burner.
This component can see fuel gas pressures between 5 psig to 30 psig. An average is more likely to be
between 8 psig and 15 psig. This varies due to the type of equipment, size of burners, and btu value of
the gas.
The mixer for the main burner gas is adjustable with gas flow stem, orifice and usually an air shutter.
This is by design to allow for mixing of primary oxygen and fuel. Flame adjustment is performed utilizing
the fuel flow stem and air shutter and pressure from the fuel gas supply regulator. Most manufacturers
recommend a main burner flame that is mostly blue with flecks or fingers of red and yellow at the flame
tips. The burner pictured above uses primary air, or a single air source being drafted in through the
flame arrestor. This air volume is adjusted using the primary air shutter. In cases where it is difficult to
establish anything but a long yellow potentially smoky flame a secondary air source should be
considered. Note there are other circumstances that can cause similar symptoms such as restrictions of
the orifice, mixer, or burner nozzle. The nozzle pictured above comes equipped with venturi. Many
modest size burners do not have these. The venturi can increase burner efficiency. Much like an orifice
the venturi regulates the flow going to the burner and disperses the gas stream at a lower velocity than
the mixer inlet.
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The Pilot
The pilot assembly is a similar but smaller version of the main burner. The majority of pilot mixers are
non-adjustable however, there are adjustable pilot mixers available that can be used to improve
operations with very rich or very lean gas mixtures. Positioning of the pilot tip is crucial as main burner
ignition cannot be achieved otherwise. Additionally the position of the flame ionization rod used to
ignite the pilot is just as critical
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There are many pilot nozzles available from a variety of brands. Platinum uses the RHSB Pilot nozzle.
The flame retention ports assist this nozzle in working under a variety of conditions. The shroud with
strategically placed ports helps to minimize the effect of wind and turbulence by helping to keep the
flame in place. The RHSB nozzle also maintains enough heat to relight the pilot in the event of a short
duration flameout.
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The fuel gas train is an assembly of components that transports, removes liquids and impurities, allows
monitoring, and regulates the fuel gas stream to the burner section inside the combustion chamber.
Please follow appropriate API, OSHA, Canadian Standard, industry and company specific safety practices.
In Canada reference Canadian Standard B149.1 and B149.3-10 burner code, Alberta OHS, Alberta Gas
Code Regulation AR 113/2005. In the US, reference API RP 12N. Both the Canadian Standards and API
recommended practice address the installation, operations, and maintenance of fuel gas delivery
systems. The Canadian burner code also sets the baseline for burner management systems.
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The fuel gas train is typically supplied by the gas outlet stream on the equipment utilizing the burner
section such as treaters, dehys, gas units, amine systems, etc. In some cases, the gas supply may come
from another piece of equipment on location. In other circumstances, the gas supply on location may
not be usable due to contaminants, poor btu content, or low volume. In those instances, another fuel
gas such as propane may be piped in to the location, or a propane bullet set nearby. It is important to
understand where the gas stream is coming from, before installation considerations are made, or
adjustment to the burner system is attempted.
Emulsion Inlet
Gas Outlet
Oil Outlet
Water Outlet
Sketch of an average fired vessel.
In the diagram shown above, the fuel gas stream would be taken from the gas outlet in the top right
area of the vessel.
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Gas supply from the production vessel or alternative source is piped to the fuel gas scrubber. This piping
is typically one inch pipe, but can vary depending on equipment sizing. When the scrubber inlet
pressure exceeds 125 psig from the supply, a pressure reducing regulator such as the Fisher 630 Big Joe
regulator or Fisher 627 Little Joe regulator should be used to reduce the pressure to below 125psig from
the gas source, before entering the fuel gas scrubber. The fuel gas scrubber is used as volume pot for
liquids and impurities from the gas stream to drop out via gravity. The fuel gas scrubber should
contain a mechanical float valve that automatically shuts off the gas supply if the scrubber pot fills with
liquids. This scrubber pot, should be drained regularly depending on inlet fuel gas conditions. A relief
valve (PSV) should be installed on the fuel gas scrubber, and a backup on the fuel gas piping train going
to the burner system. Many fuel gas trains also have a regulator such as the Fisher 67CFR installed on a
pipe T or pipe cross on the top of the fuel gas scrubber. This device is installed to divert supply gas to
other instrumentation devices such as liquid level controls and liquid dump valves.
Once the gas supply has left through connection on the top of the fuel gas scrubber it should pass
through an isolation valve, and pressure gauge. Depending on quality of fuel gas a Y-Strainer or self
draining filter may be used next to remove any intrained liquids or impurities that may have escaped the
fuel gas scrubber. Regular draining of fuel gas scrubber minimizes this issue.
The next step of fuel gas flow would be through a pressure reducing regulator such as the Fisher 627
Little Joe to drop pressure to a burner usable pressure below 20 psig. From this regulator, gas will flow
through a control valve, thermostat valve, or burner valve such as a Kimray 112SMTDAB burner valve
which is controlled by a Kimray T-12 thermostat. The thermostat will be immersed in the production
vessel or process bath. Note when using a Burner Management System, the burner control valve will
remain in place, but the thermostat will be replaced by the RTD or Thermocouple tied to the Burner
Management System.
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At this point a pipe T would be placed to allow for straight flow to an additional isolation valve, and then
into the main burner mixer. The diverted flow may be through pipe, or even tubing. This flow would
then go through an isolation valve and pressure gauge. A regulator such as the Fisher 912 would be
used to step the pressure down to an amount usable for the pilot. Typically between 3 ounces and 5
psig depending on btu content and volume. From this regulator there is one more isolation valve, and
then piping through the flame arrestor and to the pilot mixer.
In Canadian applications you will find an Emergency Shutdown Device (ESD), high pressure switch, and
high temp shutdown. Many of these items apply to NFPA 87 as well. Therefore, while they are not
always found on US installations, they are becoming more common in pursuit of improved safe work
operations.
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It is extremely important to conduct regular inspections on all production equipment. The importance is
even greater when fired components are utilized. Maintaining regular inspections is recommended. It
would also be encouraged to add additional inspections whenever variables change such as flow
conditions, equipment being added or removed, extreme temperature changes, weather changes such
as hail, blowing dirt, etc.
Operational
Inspections
Internal
Components
Inspections
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Corrosion
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Obstructions
Cell
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Gaskets
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Burner Systems
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The Stack
Gauges and
Temperature
Controls
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Be sure the area surrounding the flame arrestor is free of obstacles in order to complete a quick
evacuation if necessary.
2.
Visually inspect the flame cell for deformation or impediments. Inspect the flame arrestor
housing to insure all connections are free of leaks. Check to confirm that all gaskets are in place
and in good condition with fasteners properly tightened. A combustible gas indicator can be used
to find leaks or other fugitive combustible gas sources in the area.
3.
Ensure firebox, stack, and stack arrestor (if equipped) are clear of debris or impediments.
4.
5.
Close all supply gas valves, drain fuel gas scrubber, and clear firetube of all combustible vapors.
6.
7.
Determine that the only air path supply into the firebox is through the flame arresting element.
8.
Check for the presence of combustible gas. Wait at least 5 minutes for firetube to clear. It is
preferable to use a combustible gas indicator. If a positive indication is made, re-check all valves,
piping, and instrumentation for leaks. If no combustible gas is indicated, then proceed.
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9.
10. Adjust all controls, valves, instrumentation, and gauges to proper operating parameters. Fuel gas
pressures are usually set between 5 and 15 psig depending on BTU value of gas. The lower the
BTU value, the higher the pressure.
11. Open air shutter on air gas mixer approximately 1/8 for the mixer to receive primary air. If
mixer has internal orifice adjustment pin, make sure it is backed out to not disrupt gas flow. Do
not operate the unit with the pin backed out so that the threads are inadequate to secure.
12. Open pilot gas and main burner gas supply isolation valve. Average 2-5 lbs.
DO NOT STAND IN FRONT OF THE LIGHTING PORT, FLAME ARRESTOR ELEMENT, OR FIRETUBE DURING IGNITION.
STAND TO THE SIDE AND UPWIND (IF POSSIBLE) OF THE LIGHTING PORT AND END PLATE OF THE FLAME ARRESTOR
13. Engage the BMS/IMS to ignite the pilot. Once pilot is established, the burner system will open
main burner valve to interact with pilot and ignite main burner.
14. The flame should be centered in the firetube, the burner should be regulated for continuous
firing. The air gas mixer should be set to provide proper combustion and to prevent hazardous
firetube carbon deposits. Visual flame setting is a blue flame exiting the burner nozzle and to red
and yellow fingers. Proper adjustment fine tuning can be performed with a stack gas analyzer.
Adjust fuel gas volume and pressure for desired efficiency.
15. Re-inspect equipment once start-up is completed and with heat at operating temperature. It is
important to check bolts for tightness and to check for any leaks in system as equipment warms
up, and once it is at operating temperature.
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SHUTDOWN PROCEDURE
1.
Locate On/Off button below on right of BMS screen and turn off.
2.
3.
4.
5.
6.
Allow at least 5 minutes for firetube to clear before removing inspection cover on arrestor.
7.
CAUTION
LOCKOUT TAGOUT ELECTRICAL POWER AND FUEL GAS SUPPLY, THEN CLEAR COMBUSTION CHAMBER, BURNER ASSEMBLY, AND
FIRETUBE BEFORE ATTEMPTING TO CLEAN, SERVICE OR REPAIR EQUIPMENT.
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RECOMMENDED MAINTENANCE
FREQUENCY
DETAILED TASKS
Observe gauges and temperature controls for
accuracy
Drain fuel gas scrubber
Daily
Monthly
Semi-Annually
Inspect firetube
LOCKOUT TAGOUT ELECTRICAL POWER AND FUEL GAS SUPPLY, THEN CLEAR COMBUSTION CHAMBER, BURNER ASSEMBLY, AND
FIRETUBE BEFORE ATTEMPTING TO CLEAN, SERVICE OR REPAIR EQUIPMENT.
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SECTION III:
PLATINUM CONTROLS BMS
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The most hazardous part of operating fired vessels has historically been ignition of the pilot flame. In
the past, many burner assemblies were constructed so that the operator was required to open the
combustion chamber and manually ignite the pilot. This has proven repeatedly to be a hazardous
situation. A method to ignite the burner without exposing the operator to the hazard of being burned
and critically injured while performing this function was needed.
Platinum Control Technologies has the solution to this problem.
Our Burner Management System (BMS) allows for a pilot operated ignition system that will
automatically light the pilot flame with no attending personnel. This ignition device works in
conjunction with the safety system and will automatically shut off the fuel supply in the event of failure
for the pilot to establish after 3 tries. This CSA/UL compliant system has many other functions such as
temperature control and communication via modbus. In addition to being the safe work solution, this
equipment has positive environmental and regulatory benefits.
We are now ready to proceed to the installation portion of our training program. But first, there are a
few questions that need to be answered. The answers to these questions will assist in identifying the
equipment needed and considerations for the scope of the installation.
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PRE-INSTALLATION QUESTIONS
1.
2.
3.
4.
What type of production equipment is the BMS unit being installed on? (Dehy, Combustor,
etc...)
What size BTU unit or arrestor size will BMS be used with?
5.
6.
7.
How many temperature points are needed? (1,2,3) More than 1 requires thermocouple.
8.
9.
10.
11.
12.
13.
If thermowell is available, what is insertion length, and thread size and type? (ex. NPT)
14.
Is communications/Modbus needed?
15.
Where does the customer prefer to have panel mounted in proximity to equipment?
16.
Confirm panel can be mounted within 15 of arrestor, otherwise longer cable needed.
17.
On retrofit units has the unit been running, or decommissioned? Has firetube and flame
arrestor been inspected/cleaned?
Is a level switch being used? If so, pneumatic or electric?
18.
19.
Electrical and pipefitting work to be performed. Insure qualified personnel are available, or
we are accommodating.
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WARRANTY STATEMENT
Platinum Control Technologies (PCT) warrants all its manufactured products to be free from defects in
material and workmanship, under normal use intended for the product, for a period of twelve (12)
months from the date of installation, not to exceed eighteen (18) months from the date of shipment.
The warranty does not cover damage to attached or ancillary devices.
The warranty shall be void for the following reasons:
1. Product is installed or modified by personnel not trained by, or considered representatives of,
Platinum Control Technologies.
2. Damage to the product caused by misuse.
3. Willful or intentional damage to the product.
4. Product neglect.
5. Product is damaged or destroyed by Acts of God (i.e., hurricane, tornado, etc.).
Warranty repairs are FOB (Freight On Board) origin; the customer is responsible for shipping costs to
Platinums facility. All repairs are to be mailed to the below address:
Platinum Control Technologies
Technical Services Department
2822 West 5th Street
Fort Worth, Texas 76107
If you have technical support questions, please contact 877.374.1115 or 817.529.6485 for help. Onsite
calls are subject to labor and travel charges to and from site.
WARNING
A. Platinum Burner Management Systems (BMS) are certified for Class I, Division II, Groups C and D and any
areas considered unclassified.
B. A Platinum BMS controller is Class I, Division II rated and therefore MUST be mounted in an appropriate
area compliant with its classification. Adherence to local classification of areas is crucial to safety and
operation.
C. DO NOT install a Platinum BMS in a Class I, Division I area.
D. DO NOT open the Platinum BMS unless the area has been declassified by qualified personnel.
E. Any substitution of parts or assemblies may compromise suitability of classification, causing injury or
death.
F. The Platinum BMS Ignition Module is not rated and therefore MUST be mounted in an unclassified area,
such as inside the spark arrestor.
G. There can be NO substitution or splicing of the ignition wire or other components of the Platinum BMS.
Substitution may impair the operation of the system, which could cause faulty operation, injury or death.
H. Before beginning the installation or operation of a Platinum BMS, please read this entire Manual.
NOTE
All Platinum BMS units are intended for oil and gas industry, direct and indirect natural draft fired heaters only, and are not to
be used for residential or commercial buildings of any kind.
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INTRODUCTION
Platinum 731 Burner Management System (BMS) model SF731 has been designed to meet the following
CSA/UL codes:
UL372
UL873
UL1998
They are specifically designed to monitor and re-ignite natural draft gas burners used in heating systems
rated up to 10 MMBtu/hr. Our systems operate on 10VDC to 30VDC power. Your model is designed to
operate in a specific configuration and should NEVER be used alternately.
The Platinum BMS monitors for the presence of a pilot flame through an igniter rod which feeds a signal
back to a processor to determine a safe sequence of events based on the signal. In the absence of a
flame the BMS will shut off all gas sources feeding the pilot and main flame assembly and wait for a user
set delay time before attempting a re-ignition sequence. In the event of a positive ignition, the system
will sense the ion path of the flame and proceed with monitoring. In the event of a flame ignition failure,
the system will lock out the ignition process after three attempts and await an operator to troubleshoot
and reset the system.
Platinum BMS systems have temperature control that allows the installer to replace the temperature
indicator with an optional RTD (Resistance Temperature Detector) or an optional type K thermocouple.
With the addition of temperature control, the BMS has the ability to precisely control the process
temperature and perform high temperature shutdowns.
Examples where Platinum Burner Management Systems are used:
Dehydrator Re-boilers
Treaters
Heated Free Water Knockouts
Amine and Glycol Re-boilers
Salt Bath Heaters
Utility Heaters
Tank Burners
VOC Incinerators
BTEX Incinerators
Oil Stabilizers
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Platinum
BMS-731
Main Control Box
Pilot Assembly
Ignition Module
6 Black Ground
Cable
Mounting
Hardware
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Microprocessor Board
Manual Reset
Button
100ma Fuse
Factory Setup
Button
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Valves/Termination Board
8A Spare Fuses
8A
Main Power Fuse
Power Connector
ESD Valve
Connector
Main Valve
Connector
External Devices
Connector
Ignition Module
Connector
RTD/
Thermocouple
Connector
Pilot Valve
Connector
ESD Out
Connector
Modbus
Connector
Platinum BMS-731 Valves/Termination Board.
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Pilot Assembly
The Platinum Pilot Assembly consists of the Igniter Rod, Pilot Nozzle, and Pilot Mixer.
Igniter Rod
3/16 Spacing
Pilot Nozzle
pipe or nipple
length as required
(Not included)
Site of High
Voltage Cable
Connection
Mounting Bracket
Pilot Mixer
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INSTALLATION
Pre-Installation Requirements
In order to properly install the Platinum Burner Management Systems the following will be required:
a. Fuel Train Requirements:
i. Main regulator
ii. Pilot regulator
iii. Main control valve (pneumatic valve ideally)
iv. Pressure gauge for main valve
v. Pressure gauge for pilot valve
vi. Main Ball valve, recommended but not necessary
b. Unistrut to mount the Main Control Box. The unit must be mounted within 15 feet of
the arrestor. (Longer cables available, if needed.)
c. Arrestor needs to be large enough to mount the Ignition Module inside of the arrestor.
d. Thermowell in vessel for RTD or Thermocouple. (Platinum recommends a pneumatic
high temperature shutdown for redundancy, i.e. T-12.)
e. Power Requirements: 10-30 Volts allowed. (24 volts is recommended.)
f.
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Platinum Burner Management Systems (BMS) are certified for Class I, Division II, Groups C and D and any
areas considered unclassified.
DO NOT install a Platinum BMS Main Control Box in a Class I, Div. I area.
DO NOT open the Platinum BMS Main Control Box unless the area has been declassified by qualified
personnel.
Adherence to local classification of areas is crucial to safety and operation.
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DO NOT install Solenoid Valves that are in excess of 14 Watts 24 VDC or below 1.4 Watts 24 VDC. Low watt solenoid
valves are recommended for solar applications. Any substitutions of solenoid valves must be reviewed and approved
by Platinum. Solenoid Valves outside these parameters will impair the operation of the system, potentially causing
injury or death.
As there are a number of different solenoid valve system configurations, suitable solenoid valve
types will vary based on the application. Typical types are:
1.
24 volt high-power single coil Solenoid Valve (11.6 Watts) (Platinum BMS 731 Only)
2.
24 volt low-power single coil Solenoid Valve (1.4 Watts) (Platinum BMS 731 Only)
It is very important that you use the appropriate Solenoid Valves. DO NOT try to substitute Solenoid Valves outside
the above specifications without first consulting with Platinum.
STEPS:
1. Install the Pilot Solenoid Valve into the tubing between the pilot pressure regulator and
the arrestor in the tubing line. Install the Main Solenoid Valve into the tubing before the
main temperature control valve in the tubing line. Install the ESD Solenoid Valve as the
first thing after the inlet pressure regulator into the tubing line controlling the
pneumatic ESD Valve.
TIP
Be sure to orient Solenoid Valves correctly with the respective valve flow direction. ASCO Solenoids are
configured port 1 out, port 2 in and port 3 vent.
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2. Open the lid of the Main Control Box by simply unlatching the two (2) latches.
WARNING
DO NOT pull open the box lid forcefully. Two (2) multi-conductor flat cables connect the Valves/Termination
Board and the Processor Board, and opening the lid forcefully could potentially cause damage to the boards.
3. Safely unplug the two (2) multi-conductor flat cables from the Valves/Termination Board
and unscrew the 4 screws holding the Valves/Termination board to the box. Place the
Valves/Termination board in a safe, anti-static location.
WARNING
DO NOT drill any holes in the Main Control Box without at least removing the Valves/Termination board. Any
damage to the circuit boards while drilling holes is not covered under the warranty.
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4. Determine the best method to run the wiring to each solenoid. This will typically be flex
conduit or rigid conduit. The conduit can be run directly to each solenoid or preferably
to each in series through conduit Ts attached to each solenoid. It is preferable to have
the fewest penetrations possible into the Main Control Box. Locate all holes in the Main
Control Box to the front edge so as not to interfere with the circuit board.
Wiring solenoids.
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Always follow local codes for sealing, electricity, etc. Proper sealing methods will need to be used when
changing areas of classification.
6. Pull wires through conduit and connect to solenoids as required. Be sure to pull ground
wires to terminate the solenoid grounds as well.
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7. When installing flex conduit it is good practice to install a service or drip loop where
warranted.
8. On the right hand side of the Valves/Termination board there are three connectors for
the 3 different Solenoid Valves. Each connector is labeled for the respective valve; ESD,
PILOT, or MAIN.
WARNING
Be sure to insert the ESD wires into the connector labeled ESD, the Pilot wires into the connector labeled
PILOT, and the Main wires into the connector labeled MAIN.
9. To install a wire into a connector, strip 0.3 (7mm) of insulation off of the wire. The
connector has a removable top for easy insertion of wires. Remove the top portion of
the connector, turn screw counter-clockwise to open the terminal slot, insert the
stripped wire into the terminal slot until it bottoms out. Turn the screw clockwise to
shut the terminal slot and tug on the wire to ensure that it is firmly in place.
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10. Single coil (S.Coil) Solenoid Valves are hooked up as in the figure below.
NOTE
On the Main Solenoid Connector, there are two (2) connections for the single coil Main Solenoid Valve, and
two (2) connections for the optional High Fire Solenoid Valve.
11. There are also two (2) output connections for an optional forced air purge contactor on
the Emergency Shutdown (ESD) Solenoid valve output. (Refer to connection diagram in
Addendum Drawings for termination requirements.)
12. Push the removable connector back onto the connector base on the Valves/Termination
board.
TIP
If polarity sensitive Solenoid Valves are used, terminal #3 on the solenoid connector is the negative
connection and terminal #4 on the solenoid connector is the positive connection.
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Igniter Rod
3/16 Spacing
Pilot Nozzle
pipe or nipple
length as required
(Not included)
Site of High
Voltage Cable
Connection
Mounting Bracket
Pilot Mixer
STEPS:
1. Open flame arrestor or remove the flame cell. You will want enough room to properly
mount the pilot assembly to the burner.
2. The pilot assembly needs to be mounted so that the nozzle tip is positioned at the flame
end of the burner and the pilot mixer is partially positioned inside of the arrestor to
allow enough air to the mixer.
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3. Determine the length of pipe/nipple that will be needed for the extension of the
pilot assembly. The length of the pipe/nipple will depend on the length of the burner
and positioning of pilot assembly, as mentioned previously.
4. Slide the igniter rod and mounting bracket onto the pipe/nipple before screwing the
pipe/nipple into the nozzle tip end of the pilot assembly.
5. The igniter rod will need to be positioned so that the tip of the igniter rod is 3/16 away
from the top opening of the pilot nozzle within the gas stream. (See Pilot Assembly
Diagram)
6. Secure the igniter rod to the pipe/nipple by tightening the 2 black screws on the
mount with a 1/8 Allen key.
WARNING
Dont over tighten the set screws on the bracket that mounts the igniter rod to the nipple on the pilot
assembly. Over tightening can stripe screws or crack insulator.
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7. Attach the black Ground Cable to the pilot assembly by removing the small screw
located on the end of the pilot mixer. Place the screw through the hole located in the
Ground Cable followed by the bonding washer and screw back into the pilot mixer.
WARNING
To prevent stripping the threads or breaking the screw, dont over tighten the screw.
8. Pull back the boot on the blue High Voltage cable to expose the connector. Push the
connector into the end of the igniter rod and you will hear a small click. Then pull the
boot over the connector and onto the igniter rod ending.
Pilot assembly with ground wire (black) already attached and high voltage cable (blue) is being inserted.
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100
9. Position the pilot assembly to the burner. The igniter rod will need to be positioned on
top of the Pilot Assembly and adjacent to the burner. Once the pilot assembly is in the
correct position on the burner, securely fasten the pilot assembly tip approximately 1
behind the tip of the burner. Make sure that the securing device isnt touching the
igniter rod.
NOTE
Platinum Control Technologies does not tune burners or guarantee efficiency. We strongly recommend that
a qualified burner technician inspect and tune the burners upon completion of the installation.
TECHNICAL TRAINING
101
The Ignition Module itself is not rated and MUST therefore be mounted inside the flame arrestor (unclassified area).
STEPS:
1. The Ignition Module must be mounted on the inside sidewall of the arrestor.
WARNING
DO NOT mount the Ignition Module on the bottom inside wall of the arrestor. The Ignition Module must be
mounted up and away from any possible water accumulation.
2. Using the ignition module as a template, mark suitable mounting holes on the side of
the arrestor. Drill holes and mount the module with suitable mounting hardware
making sure to capture the ground wire under the head of the mounting bolt.
NOTE
TECHNICAL TRAINING
102
3. Attach the two high voltage wires from the pilot assembly to the ignition module and
secure.
4. Determine the best placement to drill a hole through the arrestor to run the tenconductor wire through to the Main Control Box and then drill a hole through the
arrestor and install a Meyers hub. Be sure the screw on the locking ring is facing out
so you can reach the screw attachment.
5. BE SURE THE VALVES/TERMINATION BOARD HAS BEEN REMOVED FROM THE MAIN
CONTROL BOX.
WARNING
DO NOT drill any holes in the Main Control Box without removing the circuit boards. Any damage to the
circuit boards while drilling holes is not covered under the warranty.
6. Drill a hole through the bottom of the Main Control Box and install the Meyers hub
and run Flex Conduit from the Meyers hub on the arrestor to the Meyers hub on the
Main Control Box. Install seal if required.
TIP
Leave a drip loop or service loop when installing the flex conduit.
TECHNICAL TRAINING
103
WARNING
Always follow local codes for sealing, electricity, etc. Proper sealing methods will need to be used when
changing areas of classification.
7. Run a ground wire with the Ten-Conductor through the flex conduit connection from
the arrestor to the Main Control Box.
TIP
It is good practice to run the ground wire with the Ten-Conductor wire and terminate at each end of the
Meyers hub. If possible, separate and secure the high voltage cable from the ten-conductor cable.
8. Once the Ten-Conductor wire and ground wire have been run through the flex conduit
into the Main Control Box, wrap the bare Drain wire in the ten-conductor wire around
the base of the remaining 10 colored wires and tape off.
TECHNICAL TRAINING
104
The ten-conductor cable interconnects the Main Controller Box and the Ignition Module. The ten connectors
are labeled by number from the top down. Later production units may have the connector color coded.
TECHNICAL TRAINING
105
10. Insert the each wire from the ten-conductor wire into the terminal on the connector
with the following color order(see images below for reference):
a. Black Wire
b. Brown Wire
c. Red Wire
d. Orange Wire
e. Yellow Wire
f.
Green Wire
g. Blue Wire
h. Purple Wire
i.
Gray Wire
j.
White Wire
TECHNICAL TRAINING
106
11. Push the removable connector back onto the connector base on the Valves/Termination
Board.
TECHNICAL TRAINING
107
TECHNICAL TRAINING
108
2. Three (3) connection wires (typically, 2 red and 1 white) and one (1) ground wire will
need to run from the RTD to the Main Control Box. Drill a hole through the bottom of
the Main Control Box and install a Meyers hub.
WARNING
DO NOT drill any holes in the Main Control Box without removing the circuit boards. Any damage to the
circuit boards while drilling holes is not covered under the warranty.
3. Attached a flex conduit connector to the RTD. Run Flex Conduit from the Meyers
hub on Main Control Box to the hub on the RTD. Be sure to run all of the three (3)
connection and ground wires through before securing the flex conduit to the Meyers
hub. Install seal if required.
TIP
Leave a drip loop or service loop when installing the flex conduit.
WARNING
Always follow local codes for sealing, electricity, etc. Proper sealing methods will need to be used when
changing areas of classification.
4. Secure the three (3) connection wires and one (1) ground wire to the inside of the RTD
by adding a crimp connector to the end of each wire. The ground wire will need to be
secured to the RTD with the screw located on the inside case of the RTD marked ground.
RTD wiring.
TECHNICAL TRAINING
109
5. Loosen the three screws located on the inside of the RTD. Gently place one (1) of the
connection wires underneath one of the loosened screws and tighten screw back.
6. Repeat #5 for all three connection wires.
7. Place the RTD lid back on the top by screwing on clock wise.
8. Locate the terminal connector labeled RTD on the Valves/Termination Board. To install a
wire into a connector, strip 0.3 (7mm) of insulation off of the wire. The connector has a
removable top for easy insertion of wires. Remove the top portion of the connector,
turn screw counter-clockwise to open the terminal slot, insert the stripped wire into the
terminal slot until it bottoms out. Turn the screw clockwise to shut the terminal slot and
tug on the wire to ensure that it is firmly in place.
9. Recommended wiring scheme: two common, one differentiated color. Insert the 3
connection wires into the terminals on the connector with the following order:
a. Red Wire
Terminal #3
b. Red Wire
Terminal #4
c. White Wire
Terminal #5
TECHNICAL TRAINING
110
10. Push the removable connector back onto the connector base on the Valves/Termination
Board.
TIP
If the temperature read out on the Main Control Box says 32 degrees and 0 degrees, you have one of your
red wires crossed with the white wire or actual temperature is below 32 degrees Fahrenheit, as unit will not
read temperature lower than 32 degrees Fahrenheit.
STEPS:
1. The Type-K Thermocouple will need to be placed in a thermowell in the vessel. The use
of thermal grease is recommended. Once the Type-K Thermocouple is secure in the
thermowell of the vessel, open the top of the Thermocouple by simply twisting the lid
counter clockwise.
Type-K thermocouple.
TECHNICAL TRAINING
111
2. Type-K connection wire (1 red-negative and 1 yellow-positive) will need to run from the
Thermocouple to the Main Control Box.
WARNING
Only type-K wire (not supplied) can be used with the Type-K Thermocouple.
3. Drill a hole through the bottom of the Main Control Box and install a Meyers hub.
WARNING
DO NOT drill any holes in the Main Control Box without removing the circuit boards. Any damage to the
circuit boards while drilling holes is not covered under the warranty.
4. Attach flex conduit connector to the Thermocouple. Run Flex Conduit from the
Meyers hub on Main Control Box to hub on the Thermocouple. Be sure to run the 2
connection wires through before securing the flex conduit to the Meyers hub.
TIP
Leave a drip loop or service loop when installing the flex conduit.
WARNING
Always follow local codes for sealing, electricity, etc. Proper sealing methods will need to be used when
changing areas of classification.
5. Gently place one of the connection wires underneath one of the loosened screws and
tighten screw back. The yellow wire (positive) should be secured to the yellow screw
and the red wire (negative) should be secured to the red screw. Place the Thermocouple
lid back on the top by screwing clock wise.
TECHNICAL TRAINING
112
Terminal #1
b. Yellow Wire
Terminal #2
8. Push the removable connector back onto the connector base on the Valve Board.
TECHNICAL TRAINING
113
1. Spare Switch: This signal will ESD the burner when the switch is open. This switch can be
enabled in the factory settings:
a. Spare switch
b. Suggested uses: level switch
2. Remote ON/OFF Switch: This signal will direct the microcomputer to enter the OFF
state. The burner is ON when the switch is closed. Open the switch only in the NORMAL
burning state. If the contacts are closed, the burner will start. If the contacts are open,
the burner will stop. A remote system should be used to control the burner.
NOTE
The Platinum BMS must be placed in the NORMAL state to enable this feature. (The local interface overrides
the feature if the system is in OFF or ESD.)
3. External ESD Switch: This signal will direct the microcomputer to ESD the burner when
the switch is open. A remote system should be used to shut down the burner.
NOTE
TECHNICAL TRAINING
114
4. Low Pressure Switch: This contact looks for an open when the pressure is low, causing
an ESD state.
5. High Pressure Switch: This contact looks for an open when the pressure is high, causing
an ESD state.
6. ESD Valve Switch (Proof of Closure): This contact looks for an open when the ESD valve
is closed. Optional proximity switches on the valve or a downstream pressure switch on
the pneumatic signal can be used for the input.
7. Main Valve Switch (Proof of Closure): This contact looks for an open when the Main
valve is closed. Optional proximity switches on the valve or a downstream pressure
switch on the pneumatic signal can be used for the input.
8. Unsafe Condition: This signal ties directly to the Watchdog Processor, in order to ESD
the burner on an open circuit. This function resets the Processor directly and produces a
Watchdog failure.
NOTE
TECHNICAL TRAINING
115
Terminal 1
Normally Closed
Terminal 2
Common
Terminal 3
Normally Open
WARNING
Grounding Wires
STEPS:
1. You should have multiple disconnected ground wires in the Main Control Box. The
number of ground wires will depend on the specific setup.
2. Create a termination site inside of the Main Control Box.
3. Connect all of the ground wires to this termination site.
WARNING
TECHNICAL TRAINING
116
Grounded vessel.
TECHNICAL TRAINING
117
Only connect the Valves/Termination Board to the Main Control Box if all drilling into the Main Control Box is
complete.
TECHNICAL TRAINING
Terminal #2
118
4. Turn each screw clockwise to close the connector terminal and lightly tug on the wire to
make sure it is securely connected to the connector.
5. Push the removable connector back onto the connector base on the Valves/Termination
board.
TECHNICAL TRAINING
119
TECHNICAL TRAINING
120
OPERATING
WARNING
Prior to powering up the Platinum BMS-731, a second inspection of wiring, solenoid flow direction and setup is recommended.
The Platinum BMS-731 power terminates in the two (2) terminals supplied on the top left of the Valves/Termination Board.
POWERING UP
Close the Main and Pilot gas source valves and proceed to power up the system.
The startup display will read Initializing valve control, then after several seconds will read SYSTEM IS
OFF.
The ESD solenoid (if turned on in the programming) will now be energized, and the remaining Pilot and
Main solenoids will be in the OFF state.
The Platinum BMS-731 will be in the OFF position, waiting for the system to be turned ON.
The following display will appear if the
Temperature Control option is enabled:
Temperature
70F
Input voltage
24.0
SYSTEM IS OFF
SETUP
ON
NOTE
The Main Burner is in the OFF STATE and the Pilot flame is OFF.
TECHNICAL TRAINING
121
FACTORY SETUP
Prior to startup, enter the Factory Setup Mode and determine what inputs are being used in the system.
The Factory Setup mode does not allow you to exit and save before viewing each screen. To enter the
Factory Setup Mode, press the Factory Setup button on the Process Board in the Main Control Box (see
image below), located under the multi-conductor flat cable, while the system is in the OFF state.
Manual Reset
Button
Factory Setup
Button
The following screens will appear in this order, prompting you to choose which functions are required.
NOTE
If an ESD Solenoid has not been installed, the following message will appear: ESD Control Failure. The factory setup button will
need to be pressed twice to enter factory setup.
If at any time you want to exit the Factory Setup menu without saving, press the ESD button on the
front panel.
TECHNICAL TRAINING
122
Version 4.32
Mar 15 2012 11:59:14
NEXT
EXIT
DEFAULTS
Temperature Control
The Temperature Control option is enabled for the
Temperature Control
default setting.
ENABLED
NEXT
CHANGE
DISABLED
NEXT
CHANGE
TECHNICAL TRAINING
123
Hi Pressure Switch
The Hi Pressure switch can be set to open on rising
Hi Pressure Switch
DISABLED
NEXT
CHANGE
ENABLED
NEXT
CHANGE
TECHNICAL TRAINING
124
NEXT
RTD Jumper
Placement
Thermocouple
Jumper
Placement
TECHNICAL TRAINING
125
Spare Switch
Spare Switch
1. If you want to enable the Spare Switch option,
press the CHANGE button. Select normally open
DISABLED
NEXT
CHANGE
or normally closed
2. Hit the NEXT button to go to continue on to the
next screen.
CHANGE
NOTE
Any ESD condition will require the operator to restart the unit
from the front panel.
TECHNICAL TRAINING
126
Pilot Operation
Pilot Operation
Pilot always on
NEXT
CHANGE
DISABLED
NEXT
CHANGE
startup.
NOTE
CHANGE
TECHNICAL TRAINING
127
CHANGE
NEXT
5
UP
DOWN
TECHNICAL TRAINING
128
Backlight Always On
The feature allows you to enable or disable the
Backlight Always On
DISABLED
NEXT
CHANGE
TECHNICAL TRAINING
129
OPERATING PARAMETERS
The Operation Parameters Menu allows you to specify how certain functions/parameters are
characterized within the Platinum BMS-731. In the Setup Menu, press SETUP to set the options for the
displayed parameter. Press the NEXT and PREV to navigate between operational parameters. When
adjusting the various operation parameters, press ACCEPT to accept the parameter and return to the
Operation Parameters Menu.
NOTE
If at any time you want to exit the Operating Setup without saving, press the ESD button on the front panel. If you would like to
exit and save the Operating Setup early, press the Accept button twice on the front panel.
Temperature
70F
Input voltage
24.0
SYSTEM IS OFF
SETUP
ON
TECHNICAL TRAINING
130
Temperature Scale
(Thermocouple Unit Only; RTD Displays both
SETUP
Temperature Scale
EDIT
NEXT
PREV
2.
3.
TECHNICAL TRAINING
131
EDIT
NEXT
PREV
Set Temperature
ESD Alarm
Setpoint 1804 F
UP
DOWN
2.
3.
TECHNICAL TRAINING
132
OFF.
1.
2.
NEXT
PREV
Set Temperature
Main ON>
762F
Main OFF
808F
SWITCH
UP
DOWN
3.
4.
5.
TECHNICAL TRAINING
133
SETUP
Ignition Delay Time
EDIT
NEXT
PREV
ignition sequence.
1.
2.
EDIT
NEXT
PREV
2.
3.
TECHNICAL TRAINING
134
EDIT
NEXT
PREV
Delay screen.
2.
3.
EDIT
NEXT
PREV
the High Fire comes on. The High Fire Delay can be
set anywhere from 1 to 60 seconds. The default delay
is 10 seconds.
1.
screen.
2.
3.
TECHNICAL TRAINING
135
EDIT
NEXT
PREV
2.
Set Temperature
Hire fire set point
High fire off
808F
UP
DOWN
3.
EDIT
NEXT
PREV
DOWN
delay screen.
2.
3.
TECHNICAL TRAINING
136
Time Log
SETUP
Time Log
SETUP
NEXT
PREV
Pilot on Time
Changing date resets
0:00
CONTINUE
hours
EXIT
Main on Time
Changing date resets
0:00
hours
CONTINUE
EXIT
screen.
2.
3.
4.
TECHNICAL TRAINING
137
5.
6.
SETUP
Press DONE to exit
DONE
NEXT
PREV
TECHNICAL TRAINING
138
Ignition Procedure
WARNING
WARNING
Temperature
70F
Input voltage
24.0
SYSTEM IS OFF
SETUP
ON
Temperature
Relights
Ignition delay
109F
Temperature
Relights
IGNITING
109F
XX
OFF
OFF
Temperature
Relights
Waiting for pilot
109F
OFF
TECHNICAL TRAINING
139
Temperature
109F 43C
Relights
0 FR 4.77
PILOT ON
MAIN ON
0:01
0:01
OFF
The first time the burner tries to ignite the Pilot, it may take
several attempts to purge air out of the Pilot line.
Platinum Control Technologies does not set burners, and strongly recommends that a qualified burner technician inspect and
tune the burner upon completion of the installation.
TECHNICAL TRAINING
140
TROUBLESHOOTING
Display Error Codes
SCREEN ERROR
PROBABLE CAUSE
REMEDY
TECHNICAL TRAINING
141
SCREEN ERROR
PROBABLE CAUSE
REMEDY
Overtemp Aux A
(only on BTEX units)
Overtemp Aux B
(only on BTEX units)
Overtemp Main
TECHNICAL TRAINING
142
SCREEN ERROR
PROBABLE CAUSE
REMEDY
Shutdown by Operator
Watchdog Failure
WD Unsafe Input
TECHNICAL TRAINING
143
Microprocessor Codes
Key for Microprocessor Codes
xx=08
xx=10
CODE
xx-01
xx-02
xx-03
xx-04
xx-05
xx-06
xx-07
xx-08
xx-09
xx-0A
xx-0B
xx-0C
xx-0D
xx-0E
xx-0F
xx-10
xx-11
xx-12
xx-13
xx-14
xx-15
xx-16
xx-17
xx-18
xx-19
xx-1A
xx-1B
xx-1C
xx-2C
xx-33
DESCRIPTION
Manual reset, not a fault
Checks state_flag to see if the state is entered correctly
State exited with state_flag clear
The state was entered and state_flag was set
The reference voltage did not measure correctly
Bad ADC control register
Bad ADC channel pointer
MUX control register failure
The buffer used to hold the ADC counts failed
Executing code outside the code space
A state procedure exited with the state_flag cleared
The stack pointer is incorrect when the state machine runs
ADC had not finished a scan when the next scan started
Checks to see if the a non state procedure was call outside a state procedure
Failure of the keyboard flag memory
Measure counter memory failed
Temperature look table was generated incorrectly
Memory containing the start voltages for the pulse capacitors failed
Debounce counter failed
Memory adc_flag failed
A register in register bank 0 failed
Memory purge_cntr failed
One of the following timer registers failed CKCON,TMOD, RCAP2H and RCAP2L
Check the state was entered properly
Not used
Check the state flag at the end of the watchdog state
Stack pointer is corrupted when watchdog state machine runs
Checks the state flag on entry to a watchdog state
The value in return state was corrupted
Check the values in the XBAR registers
TECHNICAL TRAINING
144
CODE
xx-34
xx-35
xx-36
xx-37
xx-38
xx-39
xx-3A
xx-3B
xx-3C
xx-3D
xx-3E
xx-3F
xx-40
xx-41
xx-42
xx-43
xx-44
xx-45
xx-46
xx-47
xx-48
xx-49
xx-4A
xx-4B
xx-4C
xx-4D
DESCRIPTION
Port0 configuration failed
Port1 configuration failed
Port2 configuration failed
Port3 configuration failed
Port4 to port7 configuration failed
Code byte CRC failure
The temperature table check failed
The state pointer against failed
The control flags failed
Set point data failed
The high_voltage_flag failed
Comparator zero has an incorrect value
Not used
Comparator 1 did not enable properly
Comparator 1 did not disable properly
Comparator 0 did not enable properly
Comparator 0 did not disable properly
Bad reference control
Invalid burning state pointer
The main system is not stable and caused a system reset
The crystal oscillator would not start
The internal watchdog caused a reset
The sensor short counter failed
The no flame time out counter failed
The delay on the spare input failed
This is the end of the error list
TECHNICAL TRAINING
145
POSSIBLE SOLUTIONS
immediately.
resistance readings.
TECHNICAL TRAINING
146
ISSUE
The main burner is not
POSSIBLE SOLUTIONS
lighting.
Control Box.
out.
light.
TECHNICAL TRAINING
147
ISSUE
POSSIBLE SOLUTIONS
Make sure the rain cap on the arrestor is not causing back
pressure on the exhaust stack.
Make sure you have enough pressure on the main fuel gas
line.
TECHNICAL TRAINING
148
DESCRIPTION
SS-10L-24V
103011
202001DE8G30H
Y011930
9925340024
EF8320G202
2014328
2014326
2014040-PN
Pilot Nozzle
1000-11L
Igniter Rod
E9-SSN
Igniter Connector
2014302
2014040-PM
Pilot Mixer
2014040-PO
Pilot Orifice
EF8314G301
Y11927
Valve Board
Y11926
Microprocessor Board
Y012204
Door w/Keypad
2014310
2014320
2014242
8 amp fuse
246515
100 ma fuse
RT1099401
RTD
002K-4M-15-R06-04
Thermocouple
K20-5-502
Y012668
Y012671
Y012670
POT Kit
TECHNICAL TRAINING
149
169 ma @ 24vdc
204 ma @ 24vdc
813 ma
1.48A @ 24vdc
2.18A @ 24vdc
2.85A @ 24vdc
255 ma
400ma @ 24vdc
490ma @ 24vdc
580ma @ 24vdc
TECHNICAL TRAINING
150
ADDENDUM DRAWINGS
BMS 731/BTEX Interconnect Diagram
TECHNICAL TRAINING
151
Basic P&ID
TECHNICAL TRAINING
152
Full P&ID
TECHNICAL TRAINING
153
TECHNICAL TRAINING
154
The Piggyback Board can only be used with the BMS-731 configured for Thermocouple use. Multiple RTDs are not supported
at this time.
The board is mounted piggyback to the Valve Board in the Main Control Box. A single ribbon cable
connects the Piggyback Board to the Microprocessor Board.
BTEX Piggyback
Board
Thermocouple
Connector
Channel A
Thermocouple
Connector
Channel B
BTEX Piggyback
Board
Valves/
Termination Board
TECHNICAL TRAINING
155
INSTALLATION
Installing three (3) Type K Thermocouple
NOTE
STEPS
1. The Type-K Thermocouples will need to be placed in a thermowell in the vessel. The use of
thermal grease is recommended. Once the Type-K Thermocouples are secure in the thermowell
of the vessel, open the top of the Thermocouples by simply twisting the lid counter clockwise.
2. Type-K connection wires (1 red-negative and 1 yellow-positive) will need to run from the
Thermocouples to the Main Control Box.
WARNING
Only type-K wire (not supplied) can be used with the Type-K Thermocouple.
3. Drill a hole through the bottom of the Main Control Box and install a Meyers hub.
WARNING
DO NOT drill any holes in the Main Control Box without removing the circuit boards. Any damage to the circuit boards
while drilling holes is not covered under the warranty.
4. Attach flex conduit connector to the Thermocouples. Run Flex Conduit from the Meyers
hub on Main Control Box to hub on the Thermocouples. Be sure to run the 2 connection wires
through before securing the flex conduit to the Meyers hub.
TIP
Leave a drip loop or service loop when installing the flex conduit.
WARNING
Always follow local codes for sealing, electricity, etc. Proper sealing methods will need to be used when changing
areas of classification.
5. Gently place one of the connection wires underneath one of the loosened screw and tighten
screw back. The yellow wire (positive) should be secured to the yellow screw and the red wire
(negative) should be secured to the red screw. Place the Thermocouple lid back on the top by
screwing clock wise. Repeat for all three thermocouples.
TECHNICAL TRAINING
156
6. Locate the connector labeled RTD/Thermocouple on the Valves/Termination Board and the
Channel A and Channel B connectors on the Piggyback Board. To install a wire into a connector,
strip 0.3 (7mm) of insulation off of the wire. The connector has a removable top for easy
insertion of wires. Remove the top portion of the connector, turn screw counter-clockwise to
open the terminal slot, insert the stripped wire into the terminal slot until it bottoms out. Turn
the screw clockwise to shut the terminal slot and tug on the wire to ensure that it is firmly in
place.
7. Insert the connection wires into the terminals on the connectors with the following order:
1.
2.
Terminal #2
3.
Terminal #2
NOTE
Terminal #2
If using only one auxiliary channel, insert a jumper wire in the remaining connector to read ambient temperature on that
channel. If no jumper is installed that channel will read -1 degree.
8. Push the removable connectors back onto the connector base on the Valve Board and Piggyback
Board.
TECHNICAL TRAINING
157
OPERATING
WARNING
Prior to powering up the Platinum BMS-731, a second inspection of wiring, solenoid flow direction and setup is recommended.
The Platinum BMS-731 power terminates in the two (2) terminals supplied on the top left of the Valves/Termination Board.
POWERING UP
Close the Main and Pilot gas source valves and proceed to power up the system.
The startup display will read Initializing valve control, then after several seconds will read SYSTEM IS
OFF.
The ESD solenoid (if turned on in the programming) will now be energized, and the remaining Pilot and
Main solenoids will be in the OFF state.
The Platinum BMS-731 will be in the OFF position, waiting for the system to be turned ON.
For the BTEX option, when the BMS is powered up the microprocessor will see the attached Piggyback
Board and enable the software to read the additional inputs. The Alarm set point menu will change also
to allow the additional set points. The display will now show Ta and Tb on the screen along with Main
temperature. It will take approximately 20 seconds for the additional temperatures ratings to read-out
on the front display panel.
M 19 Ta
24 Tb
80C
Input voltage
24.0
SYSTEM IS OFF
SETUP
ON
TECHNICAL TRAINING
158
OPERATING PARAMETERS
The Operation Parameters Menu allows you to specify how certain functions/parameters are
characterized within the Platinum BMS-731. In the Setup Menu, press SETUP to set the options for the
displayed parameter. Press the NEXT and PREV to navigate between operational parameters. When
adjusting the various operation parameters, press ACCEPT to accept the parameter and return to the
Operation Parameters Menu.
NOTE
If at any time you want to exit the Operating Setup without saving, press the ESD button on the front panel. If you would like to
exit and save the Operating Setup early, press the Accept button twice on the front panel.
Press the NEXT key until the Alarm Setpoint menu appears.
Alarm Setpoint (High Temperature Shutdown)
This parameter allows you to enter a setpoint at which the Platinum BMS-731 will ESD on high
temperature shutdown. This parameter will only work with a Platinum BMS-731 that has the
Temperature Control option turned ON.
SETUP
Alarm Setpoint
EDIT
1.
NEXT
PREV
NXT
Set Temperature
ESD Alarm
Setpoint 1804 F
ALM
UP
DOWN
2.
3.
Press and hold UP or DOWN button to increase or decrease the setpoint faster.
4.
TECHNICAL TRAINING
159
NXT
Set Temperature
Ch A Alarm
Setpoint 1804 F
ALM
UP
DOWN
5.
6.
Press and hold UP or DOWN button to increase or decrease the setpoint faster.
7.
NXT
Set Temperature
Ch B Alarm
Setpoint 1804 F
ALM
UP
DOWN
8.
The third and final alarm setpoint that appears is the Ch B setpoint.
9.
Press and hold UP or DOWN button to increase or decrease the setpoint faster.
10. Press the ACCEPT button to save the changes and continue on to the next screen or press
the SELECT button on the main control box twice to save and exit.
TECHNICAL TRAINING
160
SECTION IV:
PLATINUM CONTROLS IMS
TECHNICAL TRAINING
161
PRE-INSTALLATION QUESTIONS
1.
2.
3.
4.
What type of production equipment is the BMS/IMS unit being installed on? (Dehy,
Combustor, etc...)
What size BTU unit or arrestor size will BMS/IMS be used with?
5.
6.
7.
8.
9.
Where does the customer prefer to have panel mounted in proximity to equipment?
10.
Confirm panel can be mounted within 15 of arrestor, otherwise longer cable needed.
11.
On retrofit units has the unit been running, or decommissioned? Has firetube and flame
arrestor been inspected/cleaned?
Electrical and pipefitting work to be performed. Insure qualified personnel are available, or
we are accommodating.
12.
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WARRANTY STATEMENT
Platinum Control warrants all of its manufactured products to be free from defects in material and
workmanship, under normal use intended for the product, for a period of twelve (12) months from the
date of installation, not to exceed twenty-four (24) months from the date of shipment from Platinum
Control facilities. The warranty does not cover damage to end devices. The warranty shall be void for
any one of the following reasons:
1. If the product is installed or modified by personnel not trained by, or considered representatives
of, Platinum Control.
2. If the product is installed improperly.
3. If there is damage to the product caused by misuse.
4. If there is willful or intentional damage to the product.
5. If the product is neglected.
6. If the product is damaged or destroyed by Acts of God (i.e., hurricane, tornado, lightning, etc.).
Warranty repairs are FOB (Freight On Board) origin; the customer is responsible for shipping costs to
Platinums facility. All repairs are to be mailed to the below address:
Platinum Control, Technical Services Department 2822 West 5th Street, Fort Worth, Texas 76107
If you have technical support questions, please contact 877.374.1115 or 817.529.6485 for help.
On-site calls are subject to labor and travel charges to and from site.
WARNING
A. Platinum Ignition Management Systems (IMS) are certified for Class I, Division II, Groups C and D
and any areas considered unclassified.
B. A Platinum IMS controller is Class I, Division II rated and therefore MUST be mounted in an
appropriate area compliant with its classification. Adherence to local classification of areas is
crucial to safety and operation.
C. DO NOT install a Platinum IMS in a Class I, Division I area.
D. DO NOT open the Platinum IMS unless the area has been determined to be non-hazardous.
E. Any substitution of parts or assemblies may compromise suitability of classification, causing
injury or death.
F. The Platinum IMS Ignition Module is not rated and therefore MUST be mounted in an
unclassified area or explosion proof Class I, Division I enclosure.
G. There can be NO substitution of the ignition wire or other components of the IMS. Substitution
may impair the operation of the system, which could cause faulty operation, injury or death.
H. Before beginning the installation or operation of a Platinum IMS, please read this entire Manual.
NOTE
All Platinum IMS systems are intended for oil and gas industry, direct and indirect natural draft fired
heaters only, and are not to be used for residential or commercial buildings of any kind.
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INTRODUCTION
The PLATINUM-500 Ignition Management System (IMS) is specifically designed to monitor and re-ignite
natural draft gas burners used in heating systems for oil and gas production equipment.
POWER
The PLATINUM-500 includes a built-in battery charger that has the ability to charge sealed lead acid
(SLA) batteries from either solar or line power. The battery charger automatically controls the solar
panel voltage and output current to provide maximum power point tracking (MPPT). The PLATINUM-500
IMS can be powered three different ways:
1. Line power from 12-28 VDC
2. Line power from 17-28 VDC with battery backup
3. Solar panel with battery backup
OPERATION
The Platinum IMS monitors for the presence of a pilot flame thro ugh an igniter rod which feeds a signal
back to a microcontroller to determine a safe sequence of events based on the signal.
IGNITER MODE
In IGNITER mode, the IMS controls the ESD, pilot, and main solenoids. In the absence of a lit pilot, the
IMS will shut off all gas sources feeding the pilot and main burner, and wait for a user set delay time
before attempting a re-ignition sequence. In the event of a positive ignition, the system will sense the
flame and proceed with monitoring. In the event of a flame ignition failure, the system will lock out the
ignition process after three (3) attempts and await an operator to troubleshoot and reset the system.
FLARE MODE
In FLARE mode, the IMS does not control solenoids. In the absence of a flame, the IMS will wait for a
fixed delay time (5 seconds) before attempting a re-ignition sequence. In the event of positive ignition,
the system will sense the flame and proceed with monitoring. In the event of a flame ignition failure, the
IMS will restart automatically without any limitations.
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APPLICATIONS
Treaters
Flares
Tank Heaters
Dehydrator Re-boilers
Heated Separators
Utility Heaters
VOC Incinerators
BTEX Incinerators
Oil Stabilizers
Multiwell Units
Combination Units
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Ignition Module
Mounting Hardware
High Voltage Cable (Blue)
Pilot Assembly
Anti-Static Bag
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MICROCONTROLLER BOARDS
PLATINUM-500 Display Board
The PLATINUM-500 Display Board is located in the door of the Main Control Box and provides the userinterface functions of the IMS, including the display and front panel keys. Two (2) push-button switches
are located on the board; the RESET push-button is used to reboot the system and the SETUP button
allows you to setup the various system options.
Display connector
(J3) connection to
Main Board
RESET Button
SETUP Button
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167
Display
Connector (J4)
Charger Power
Fuse (F1)
Solar-in/Line-in
Power Connector
(J3) Connection
for solar or line-in
ESD Valve
Connector (J2)
Main Valve
Connector
(J5)
Line-in/Battery
Power Connector
(J6) Connection
for line or battery
power
Pilot Valve
Connector
(J8)
External Devices
Connector (J10)
TECHNICAL TRAINING
ESD Out
Connector (J11)
Ignition Module
Connector (J12)
168
IGNITION MODULE
The Ignition Module is connected to the Main Control Box with the Four- Conductor Cable and to the
Pilot Assembly with the High Voltage Cable and Ground Cable.
PILOT ASSEMBLY
The Platinum Pilot Assembly consists of the Igniter Rod, Pilot Nozzle, and Pilot Mixer.
3/16 Spacing
Pilot nozzle
Igniter Rod
Site of High
Voltage Cable
Connection
pipe or nipple
length as
required (not
included)
Mounting
bracket
Pilot Mixer
TECHNICAL TRAINING
169
INSTALLATION
Please visit platinumcontrol.com for the most current version of this manual and additional technical
resources.
PRE-INSTALLATION REQUIREMENTS
In order to properly install the IMS the following items will be required:
Unistrut or alternate hardware to mount the Main Control Box. The unit must be mounted
within 15 feet of the arrestor (longer cables available, if needed).
Arrestor needs to be large enough to mount the Ignition Module inside of the arrestor.
Power Requirements:
LINE POWER
SOLAR WITH
BATTERY
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171
Power consumption
Gas flow
Solenoid cost
The PLATINUM-500 can operate different solenoid types on each of the three (3) outputs: ESD, Pilot and
Main.
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172
The voltage rating for each solenoid must be the same as the other solenoids in the system.
11.6 W solenoids must be run with 24 V solenoid voltage and 24 V line system power.
23.6 W peak/hold solenoids must be run with 24 V solenoid voltage and 24 V line system
power.
Solar/Battery
POWER
Solar/Battery
SOLENOID VOLTAGE
12 V
SOLENOID VOLTAGE
12 V
ESD
None
ESD
Peak/hold 11.6 W
12 V
PILOT
0.55 W 12 V
PILOT
Latched 12 V
MAIN
0.55 W 12 V
MAIN
Latched 12 V
POWER
Line/Battery
POWER
Line - 24 V
SOLENOID VOLTAGE
24 V
SOLENOID VOLTAGE
24 V
ESD
None
ESD
Peak/hold 23.6 W
24 V
PILOT
1.4 W 24 V
PILOT
Peak/hold 10.6 W
24 V
MAIN
1.4 W 24 V
MAIN
Peak/hold 23.6 W
24 V
POWER
Line - 24 V
SOLENOID VOLTAGE
24 V
ESD
11.6 W 24 V
PILOT
11.6 W 24 V
MAIN
11.6 W 24 V
WARNING
DO NOT install Solenoid Valves that are in excess of 11.6 W single coil 12/24 VDC, 11.6 W peak/hold 12
VDC, 25.2 W (dual coil) latching 12 VDC, or 23.6 W peak/hold 24 VDC. Low watt or peak/hold solenoid
valves are recommended for solar applications. Any substitutions of solenoid valves must be reviewed
and approved by Platinum. Solenoid Valves outside these parameters will impair the operation of the
system, potentially causing injury or death.
As there are a number of different solenoid valve system configurations, suitable solenoid valve types
will vary based on the application. Supported types are:
1. 12/24 V low-power single coil Solenoid Valve (0.55 W)
TECHNICAL TRAINING
173
STEPS
1. Install the Pilot Solenoid Valve into the tubing between the pilot pressure regulator and the
arrestor in the tubing line. Install the Main Solenoid Valve into the tubing before the main
temperature control valve in the tubing line. If used, install the ESD Solenoid Valve as the first
thing after the inlet pressure regulator into the tubing line controlling the pneumatic ESD Valve.
TIP
Be sure to orient Solenoid Valves correctly with the respective valve flow direction. ASCO
Solenoids are configured port 1 out, port 2 in and port 3 vent.
2. Open the lid of the Main Control Box by simply unlatching the two (2) latches.
WARNING
DO NOT open the Main Control Box lid forcefully. The multi-conductor flat cable connects the
Main Board and the Display Board and opening the lid forcefully could potentially cause damage
to the boards.
3. Safely unplug the multi-conductor flat cable from the Main Board and unscrew the 4 screws
holding the Main Board to the box. Place the Main Board in a safe, anti-static location. Platinum
TECHNICAL TRAINING
174
recommends using the Anti-static Bag included in the shipping box. Fold over the bag for better
protection. ALWAYS practice safe anti-static methods, such as discharging your hands to earth
ground prior to handling electronics.
WARNING
DO NOT drill any holes in the Main Control Box without at least removing the Main Board. Any
damage to the microcontroller boards while drilling holes is not covered under the warranty.
4. Determine the best method to run the wiring to each solenoid. This will typically be flex conduit
or rigid conduit. The conduit can be run directly to each solenoid or preferably to each in series
through a three-way conduit junction box attached to each solenoid. It is preferable to have the
fewest penetrations possible into the Main Control Box. Locate all holes in the Main Control Box
to the front edge so as not to interfere with the microcontroller board.
TECHNICAL TRAINING
175
WARNING
Always follow local codes for sealing, electricity, etc. Proper sealing methods will need to be
used when changing areas of classification.
6. Pull wires through conduit and connect to solenoids as required. Be sure to pull ground wires to
terminate the solenoid grounds as well.
7. When installing flex conduit it is good practice to install a service or drip loop where warranted.
8. On the right hand side of the Main Board there are three (3) connectors for the different
solenoid valves. Each connector is labeled for the respective valve; ESD, PILOT, and MAIN.
WARNING
Be sure to insert the ESD wires into the connector labeled ESD, the Pilot wires into the
connector labeled PILOT and the Main wires into the connector labeled MAIN.
9. To install a wire into a connector, strip 0.3 (7mm) of insulation off of the wire. The connector
has a removable top for easy insertion of wires. Remove the top portion of the connector, turn
screw counter-clockwise to open the terminal slot, insert the stripped wire into the terminal slot
until it bottoms out. Turn the screw clockwise to shut the terminal slot and tug on the wire to
ensure that it is firmly in place.
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176
10. Single coil (S.Coil) solenoid valves are connected as in the figure below.
11. Single coil (S.Coil) peak/hold solenoid valves are connected as in the figure below.
12. Dual coil (latching) solenoid valves are connected as in the figure below.
13. Push the removable connector back onto the connector base on the Main Board.
TIP
If polarity sensitive Solenoid Valves are used, terminal #2 on the solenoid connector is the
negative connection and terminal #1 on the solenoid connector is the positive connection.
MOUNTING THE PILOT ASSEMBLY
STEPS
1. Open flame arrestor or remove the flame cell. You will want enough room to properly mount
the Pilot Assembly to the burner.
2. The Pilot Assembly needs to be mounted so that the Pilot Nozzle tip is positioned at the flame
end of the burner and the Pilot Mixer is partially positioned inside of the arrestor to allow
enough air to the mixer.
3. Determine the length of 1/2 pipe/nipple that will be needed for the extension of the Pilot
Assembly. The length of the pipe/nipple will depend on the length of the burner and positioning
of Pilot Assembly, as mentioned previously.
4. Slide the Igniter Rod and mounting bracket onto the 1/2 pipe/nipple before screwing the
pipe/nipple into the Pilot Nozzle tip end of the Pilot Assembly.
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177
5. The Igniter Rod will need to be positioned so that the tip of the rod is 3/16 away from the top
opening of the Pilot Nozzle within the gas stream. (See Pilot Assembly Diagram)
6. Secure the Igniter Rod to the 1/2 pipe/nipple by tightening the 2 black screws on the mount
with a 1/8 Allen key.
WARNING
Dont over tighten the set screws on the bracket that mounts the Igniter Rod to the nipple on
the Pilot Assembly.
7. Attach the black Ground Cable to the Pilot Assembly by removing the small screw located on the
end of the pilot mixer. Place the screw through the hole located in the Ground Cable followed
by the bonding washer and screw back into the Pilot Mixer.
WARNING
Dont over tighten screw to prevent stripping the threads or breaking the screw.
8. Pull back the boot on the blue High Voltage Cable to expose the connector. Push the connector
into the end of the Igniter Rod until you hear a small click. Then pull the boot over the connector
and onto the Igniter Rod ending.
9. Position the Pilot Assembly to the burner. The Igniter Rod will need to be positioned on top of
the Pilot Assembly and adjacent to the burner. Once the Pilot Assembly is in the correct position
on the burner, securely fasten the Pilot Assembly tip approximately 1 behind the tip of the
burner. Make sure that the securing device isnt touching the igniter rod.
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178
NOTE
Platinum Control does not tune burners or guarantee efficiency. We strongly recommend that a
qualified burner technician inspect and tune the burners upon completion of the installation.
INSTALLING THE IGNITION MODULE
The Ignition Module, common to all Platinum IMS models, is a small sealed module which houses
the High Voltage Ignition Transformer. The Ignition Module produces a high voltage spark through
the Igniter Rod, and senses the presence of a flame through the Igniter Rod.
STEPS
1. Attach the end of the gray Four-Conductor Cable with the connector to the matching connector
on the side of the Ignition Module and secure with the two built in screws.
WARNING
The Ignition Module itself is not rated and MUST therefore be mounted inside the flame
arrestor (unclassified area) or explosion pro of Class I, Division I rated enclosure for external
mounting.
2. The Ignition Module should be mounted on the inside sidewall when mounting inside the flame
arrestor.
WARNING
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179
DO NOT mount the Ignition Module on the bottom inside wall of the arrestor. The Ignition
Module must be mounted up and away from any possible liquid accumulation.
3. Using the Ignition Module as a template, mark suitable mounting holes on the side of the
arrestor. Drill 1/4 holes and mount the module with suitable mounting hardware making sure
to capture the ground wires from both the ignition module and the pilot assembly under the
head of the mounting bolt. Earth ground must be established.
4. Attach the blue High Voltage Cable from the Pilot Assembly to the Ignition Module and secure.
5. Run Four-Conductor Cable through auxiliary coupling on flame arrestor. When installing on
older flame arrestors, a spare coupling may not exist. In the event an auxiliary coupling is not
available, make arrangements to professionally install this connection or 1/2 Meyers hub into
the flame arrestor.
6. BE SURE THE MAIN BOARD HAS BEEN REMOVED FROM THE MAIN CONTROL BOX.
WARNING
DO NOT drill any holes in the Main Control Box without removing the microcontroller boards.
Any damage to the microcontroller boards while drilling holes is not covered under the
warranty.
7. Drill a hole through the bottom of the Main Control Box and install the 1/2 Meyers hub and run
1/2 Flex Conduit from the Meyers hub on the arrestor to the Meyers hub on the Main Control
Box. Install seal if required.
TIP
Leave a drip loop or service loop when installing the flex conduit.
WARNING
Always follow local codes for sealing, electricity, etc. Proper sealing methods will need to be
used when changing areas of classification.
8. Run a ground wire with the Four-Conductor Cable through the flex conduit connection from the
arrestor to the Main Control Box.
TIP
It is good practice to run the ground wire with the Four-Conductor Cable and terminate at each
end of the Meyers hub. If possible, separate and secure the high voltage cable from the FourConductor Cable.
9. Once the Four-Conductor Cable and ground wire have been run through the flex conduit into
the Main Control Box, wrap the bare drain wire in the Four-Conductor Cable around the base of
the remaining four (4) colored wires and tape off.
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180
10. Locate the connector labeled Ignition Module on the Main Board. To install a wire into a
connector, strip 0.3 (7mm) of insulation off of the wire. The connector has a removable top for
easy insertion of wires. Remove the top portion of the connector, turn screw counter-clockwise
to open the terminal slot, insert the stripped wire into the terminal slot until it bottoms out.
Turn the screw clockwise to shut the terminal slot and tug on the wire to ensure that it is firmly
in place.
NOTE
The Four-Conductor Cable interconnects the Main Controller Box and the Ignition Module.
11. Insert each wire from the Four-Conductor Cable into the terminal on the connector with the
following order:
a. Coil- Black Wire
b. Coil + White Wire
c. FLM + Red Wire
d. FLM - Green Wire
12. Push the removable connector back onto the connector base on the Main Board.
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181
Normally Open
Common
Normally Closed
WARNING
DO NOT connect voltage to any of these inputs.
DRY CONTACTS ONLY.
These contacts are used for an ESD OUT or Status signal. The contacts will change state when an
ESD occurs.
GROUNDING WIRES
STEPS
1. You should have multiple disconnected ground wires in the Main Control Box. The number of
ground wires will depend on the specific setup.
2. Create a termination site inside of the Main Control Box.
3. Connect all of the ground wires to this termination site.
WARNING
Always follow local codes for proper grounding methods.
TECHNICAL TRAINING
182
TECHNICAL TRAINING
183
STEPS
1. Locate power connector J3 (three (3) terminal) on the middle left hand side of the Main Board,
labeled Battery/10-30VB.
2. To install a wire into a connector, strip 0.3 (7mm) of insulation off of the wire. The connector
has a removable top for easy insertion of wires. Remove the top portion of the connector, turn
screw counter-clockwise to open the terminal slot, insert the stripped wire into the terminal slot
until it bottoms out. Turn the screw clockwise to shut the terminal slot and tug on the wire to
ensure that it is firmly in place.
3. Insert the positive, negative and earth ground wires from the power supply into the terminals
with the following order:
a. Positive Wire Terminal V+
b. Negative Wire Terminal GND
c. Earth Ground Wire Terminal EGND
4. Push the removable connector back onto the connector base on the Main Board.
SOLAR POWER WITH BATTERY BACKUP
TECHNICAL TRAINING
184
STEPS
1. Locate the first power connector J6 (three (3) terminal) on the middle left hand side of the Main
Board, labeled Battery/10-30 V.
2. To install a wire into a connector, strip 0.3 (7mm) of insulation off of the wire. The connector
has a removable top for easy insertion of wires. Remove the top portion of the connector, turn
screw counter-clockwise to open the terminal slot, insert the stripped wire into the terminal slot
until it bottoms out. Turn the screw clockwise to shut the terminal slot and tug on the wire to
ensure that it is firmly in place.
3. Insert the positive, negative and earth ground wires from the battery bank into the terminals
with the following order:
a. Positive Wire Terminal V+
b. Negative Wire Terminal GND
c. Earth Ground Wire Terminal EGND
4. Push the removable connector back onto the connector base on the Main Board.
5. Locate a second power connector J3 (two (2) terminal) on top left hand side of the Main Board,
labeled Solar/17-30V.
6. To install a wire into a connector, strip 0.3 (7mm) of insulation off of the wire. The connector
has a removable top for easy insertion of wires. Remove the top portion of the connector, turn
screw counter-clockwise to open the terminal slot, insert the stripped wire into the terminal slot
until it bottoms out. Turn the screw clockwise to shut the terminal slot and tug on the wire to
ensure that it is firmly in place.
7.
Insert the positive and negative wires from the solar panel into the terminals with the following
order:
a. Positive Wire Terminal V+
b. Negative Wire Terminal GND
8. Push the removable connector back onto the connector base on the Main Board.
TECHNICAL TRAINING
185
STEPS
1. Locate the first power connector J6 (three (3) terminal) on the middle left hand side of the Main
Board, labeled Battery/12-28 V.
2. To install a wire into a connector, strip 0.3 (7mm) of insulation off of the wire. The connector
has a removable top for easy insertion of wires. Remove the top portion of the connector, turn
screw counter-clockwise to open the terminal slot, insert the stripped wire into the terminal slot
until it bottoms out. Turn the screw clockwise to shut the terminal slot and tug on the wire to
ensure that it is firmly in place.
3. Insert the positive, negative and earth ground wires from the battery bank into the terminals
with the following order:
a. Positive Wire Terminal V+
b. Negative Wire Terminal GND
c. Earth Ground Wire Terminal EGND
4. Push the removable connector back onto the connector base on the Main Board.
TECHNICAL TRAINING
186
5. Locate a second power connector J3 (two (2) terminal) on top left hand side of the Main Board,
labeled Solar/17-28V.
6. To install a wire into a connector, strip 0.3 (7mm) of insulation off of the wire. The connector
has a removable top for easy insertion of wires. Remove the top portion of the connector, turn
screw counter-clockwise to open the terminal slot, insert the stripped wire into the terminal slot
until it bottoms out. Turn the screw clockwise to shut the terminal slot and tug on the wire to
ensure that it is firmly in place.
7. Insert the positive and negative wires from the power supply into the terminals with the
following order:
a. Positive Wire Terminal V+
b. Negative Wire Terminal GND
8. Push the removable connector back onto the connector base on the Main Board.
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187
SETUP
WARNING
Prior to powering up the PLATINUM-500, a second inspection of wiring, solenoid flow direction and
setup is recommended.
POWERING UP
Close the Main and Pilot gas source valves and proceed to power up the system. The following screens
will appear in sequence:
Platinum Control
PLATINUM-500
FW Version: 0.35
04/10/13
Testing System
.
INITIAL SETUP
When the PLATINUM-500 is initially powered up, the system will go through an initialization and testing
process and then into a short required setup. The screens will allow you to select the type of input
power, solenoid type and solenoid voltage.
Setup Information
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188
The following screens will appear in the below order, prompting you to choose the required selections.
Use the Up ()/Down () keys to cycle through to the desired selection, then press the Next button to
advance to the next screen.
(*) Menu screens marked with an asterisk are not accessible in FLARE mode. To learn more about FLARE
mode, please see the INTRODUCTION section.
POWER SELECTION
SETTING OPTIONS
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189
PILOT SOLENOID*
SETTING OPTIONS
Pilot
Pilot
Pilot
Pilot
Pilot
Sol:
Sol:
Sol:
Sol:
Sol:
<1W Next
1-10W Next
10-15W Next
P/H<12W Next
P/H 24W Next
NOTE
If P/H (Peak/Hold) is selected, you must
use the up/down ( / ) keys to set the
duty cycle on the next screen.
SETTING OPTIONS
Main
Main
Main
Main
Main
Sol:
Sol:
Sol:
Sol:
Sol:
<1W Next
1-10W Next
10-15W Next
P/H<12W Next
P/H 24W Next
NOTE
If P/H (Peak/Hold) is selected, you must
use the up/down ( / ) keys to set the
duty cycle on the next screen.
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IDLE STATE
When the PLATINUM-500 is idle and not running, it will display the current status of the power supply
and show the soft key to press to turn on the IMS. If the remote on/off function is enabled, its status will
also be displayed.
If line power is being utilized, the following screens may appear:
Remote Disabled Line:24.0V
If line and battery power are being utilized, the following screens may appear:
If solar and battery power are being utilized, the following screens may appear:
IGNITER standby* Bat:13.6V On
TECHNICAL TRAINING
191
STEPS
TECHNICAL TRAINING
SETTING OPTIONS
Default Setting: 15 s
Setting Range: 0-300 s
STEPS
1. To change the delay time, press the
Up or Down key to increase or
decrease the seconds.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen.
SETTING OPTIONS
Default Setting: 2 s
Setting Range: 0-5 s
STEPS
1. To change the delay time, press the
Up or Down key to increase or
decrease the seconds.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen
SETTING OPTIONS
Default Setting: 5 s
Setting Range: 1-300 s
STEPS
1. To change the delay time, press the
Up or Down key to increase or
decrease the seconds.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen.
192
SETTING OPTIONS
Default Setting: 3 s
Setting Range: 0-5 s
STEPS
1. To change the delay time, press the
Up or Down key to increase or
decrease the seconds.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen.
SETTING OPTIONS
Default Setting: Off
Setting Options: On (enabled)
Off (disabled)
STEPS
1. To change the Remote ON/OFF
function, press the Up or Down key
to enable or disable the function.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen.
NOTE
Any ESD condition will require the
operator to restart the unit from the front
panel.
SETTING OPTIONS
Default Setting: Off
Setting Options: On (enabled)
Off (disabled)
STEPS
1. To change the Auto On function,
press the Up or Down key to
enable or disable the function.
2. Press the Next or Prev soft-key
to continue on to the next or
previous screen.
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193
DISPLAY MODE
The PLATINUM-500 allows the user
to select whether to keep the display
on at all times or to turn off the
display three (3) minutes after the
last keypress.
TECHNICAL TRAINING
SETTING OPTIONS
Default Setting: On
Setting
Action
Current
Off
0 mA
Pulse
< 1 mA
Flash
~ 5 mA
On
~ 10 mA
STEPS
1. To change the Status LED mode,
press the Up or Down key to select
the desired setting option.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen.
SETTING OPTIONS
Default Setting: Pwr Down
Setting
Action
Pwr Down
Always On
Display always on
STEPS
1. To change the Display Mode
function, press the Up or Down key
to select the desired setting option.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen.
194
POWER MODE
The PLATINUM-500 can be powered
from line power, solar with a battery
backup, or line power with a battery
backup.
NOTE
Prior setup of this function is required
during initial setup (see INITIAL SETUP)
SETTING OPTIONS
Solar + Bat
STEPS
1. To change the Power mode, press
the Up or Down key to select the
correct power mode for your
installation.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen.
NOTE
Incorrect selection of the power mode
can result in emergency shutdown and/
or improper operation.
OPERATING MODE
The PLATINUM-500 can be
operated in two different modes:
FLARE and IGNITER.
In FLARE mode, ignition delay and
solenoid related screens are not
viewable. Smart start is not used in
FLARE mode.
TECHNICAL TRAINING
SETTING OPTIONS
FLARE
No solenoid control; up to
65535 relights; 5 second
delay before ignition
IGNITER
STEPS
1. To change the Operating Mode,
press the Up or Down key to select
the desired setting option.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen.
195
SOLENOID VOLTAGE*
SETTING OPTIONS
STEPS
1.
To change the Solenoid Voltage
function, press the Up or Down key to
select the desired setting option.
2.
Press the Next or Prev soft-key
to continue on to the next or previous
screen.
NOTE
NOTE
SETTING OPTIONS
None
No solenoid
Latch
<1W
1-10W
>10W
P/H <12W
Peak/hold solenoid
P/H 24W
STEPS
1. To change the ESD Solenoid Type,
press the Up or Down key to select
the desired setting option.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen.
3. If Peak/Hold is selected, the next
screen will allow you to select the
Duty Cycle for the ESD Solenoid.
TECHNICAL TRAINING
196
SETTING OPTIONS
None
No solenoid
Latch
<1W
1-10W
>10W
P/H <12W
Peak/hold solenoid
P/H 24W
STEPS
1. To change the Pilot Solenoid Type, press the Up or
Down key to select the desired setting option.
2. Press the Next or Prev soft-key to continue on to the
next or previous screen.
3. If Peak/Hold is selected, the next screen will allow you
to select the Duty Cycle for the ESD Solenoid.
SETTING OPTIONS
None
No solenoid
Latch
<1W
1-10W
>10W
P/H <12W
Peak/hold solenoid
P/H 24W
STEPS
1. To change the Main Solenoid Type, press the Up or
Down key to select the desired setting option.
2. Press the Next or Prev soft-key to continue on to the
next or previous screen.
3. If Peak/Hold is selected, the next screen will allow you
to select the Duty Cycle for the ESD Solenoid.
TECHNICAL TRAINING
197
FACTORY RESET
To reset the PLATINUM-500 to the
factory default settings, a specific key
sequence will need to be entered.
After reset, the system will require
reentry of the INITIAL SETUP
options.
TECHNICAL TRAINING
STEPS
1. To initiate Factory reset, press ( ,
, , ) Up, Down, Up and
then Down.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen.
SETTING OPTIONS
Default Setting: Off
Setting Options:
ON (enabled)
OFF (disabled)
STEPS
1. To change the Password function,
press the Up or Down key to enable
or disable the function.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen.
198
CLEAR LOG
The PLATINUM-500 allows the user
to clear the log of recorded errors
and ESDs.
Clear Log
Prev Next
STEPS
1. Press the Down key to start setting
the time.
2. Use the Up or Down key to change
the hour (24 hr format).
3. Press Next to move on to the
minutes.
4. Use the Up or Down key to change
the minutes.
5. Press Next to move on to the
seconds.
6. Use the Up or Down key to reset the
seconds to 00.
7. Press Next to move on to the month.
8. Use the Up or Down key to change
the month.
9. Press Next to move on to the day of
the month.
10. Use the Up and Down key to change
the day of the month.
11. Press Next to move on to the year.
12. Use the Up or Down key to change
the year.
13. Press Exit at any time to exit setting
the time and date.
STEPS
1. To initiate Clear Log, press ( , ,
, ) Up, Down, Up and then
Down.
2. Press the Next or Prev soft-key to
continue on to the next or previous
screen.
NOTE
The event record log is saved in nonvolatile memory and is maintained even
without power. The event log can be
cleared with the menu operation.
TECHNICAL TRAINING
199
VIEW LOG
The PLATINUM-500 allows the user
to view a list of logged events
including detected causes for errors
and ESDs. Events can include the
information about a burn cycle
including the number of relights, the
time the flame was on, and the total
time of the burn. Times are recorded
in seconds.
View Log w/
Prev Next
Example of an error or ESD:
Error @ 09:59:26
(10) 25 Feb 2013
Reason for error
or ESD
Example of Burn Off:
BurnOff @ 09:59:26
(3) 25 Feb 2013
Relights:
00000000
Flame Time:
00457800s
Total Time On:
00457819s
STEPS
1. Press the Down key to view the most
recent event. The time and date of
the event will be shown briefly before
the event is displayed. The number
of the event is displayed in
parenthesis. The oldest event is (1)
and the highest number is the
newest event.
2. Pressing the Down key shows the
next oldest event.
3. Pressing the Up key shows the
newest event.
4. When the oldest event is displayed,
pressing the Down key again will
briefly display Oldest Event.
5. When the newest event is displayed,
pressing the Up key again will briefly
display Latest Event.
6. Press the NEXT or PREV soft-key to
continue on to the next or previous
screen.
NOTE
The event log is a record of the last 256
recorded events. If more than 256 events
occur without clearing the log, the oldest
events will be lost.
When the unit is manually started using
keypresses to turn the unit on, then off,
the Total Time On indicates that entire
period.
When the unit is enabled for Remote On/
Off, the Total Time On indicates the time
that the unit was enabled to run by the
external input.
The Flame Time reflects the time that a
flame was detected during either of the
above periods.
EXIT SETUP
Move to the Exit Setup screen and press the down key to save and exit. Or you can press the SETUP
push-button switch on the back of the Display Board at any time to exit the setup mode. All changes will
be saved. Setup will automatically exit and save changes after three (3) minutes of no keypresses.
TECHNICAL TRAINING
200
OPERATING
WARNING
Prior to powering up the PLATINUM-500, a second inspection of wiring, solenoid flow direction and
setup is recommended. Verify all power connections to the PLATINUM-500 Main Board.
FRONT PANEL
SOFT KEYS
SELECT (left)
SELECT (right)
ESD
Up/Down Arrows
PANEL INDICATORS
STANDBY
Blue status LED indicates whether the PLATINUM-500 has
power and is not running.
RUN
Green status LED indicates the PLATINUM-500 is running
and in the burn condition.
ESD
Two white status LEDs indicate the PLATINUM-500 is in an
emergency shutdown condition.
TECHNICAL TRAINING
201
POWERING UP
Close the main and pilot gas source valves and proceed to power up the system. The OLED display will
show several product information screens then will display a test sequence.
If the system has not been previously configured, it will go into an abbreviated setup sequence. The
input power type, solenoid voltage and the type of each solenoid must be selected before the system
will become functional. Additional parameters may be set by pressing the SETUP push-button on the
Display Board any time the system is not running or during an ESD condition.
All solenoids will now be off and the display will show something similar to:
The power type text on the bottom left portion of the screen will vary depending on the type of power
input. The screen will update every 2 seconds with additional information.
SMART START
Smart Start is a way to reduce the startup time on a system that has already vented. The ignition delay
(wait time) in IGNITER mode is user selectable from 15 to 300 seconds. However, the system monitors
the time to determine how long the system has already been venting. The display will show a rotating
bar (|, /, -, \, |) while it is in a delay state and not turned on. After the delay time has expired, the
display will show * as above. If the PLATINUM-500 is then turned on, the system will delay for a
minimum of 15s. If the PLATINUM-500 ignition cycle starts before the wait time expires, the system will
delay for the time remaining. Smart Start is not used in FLARE mode since the ignition delay time is
fixed.
TECHNICAL TRAINING
202
RUNNING
After waiting a minimum of five (5) minutes for any gases in fire tube to dissipate, open the main and
pilot gas sources when ready to engage the IMS.
IGNITER & FLARE MODE
When you press the right select key (on), the PLATINUM-500 will operate through the user set delay
time while the system performs tests. The PLATINUM-500 will then follow the user set timing for the
ignition sequence.
(*) Menu screens marked with an asterisk are not accessible in FLARE mode. To learn more about FLARE
mode, please see the INTRODUCTION section.
IGNITION DELAY
Ignition Delay Wait: 30s
Off
PILOT SOLENOID*
Pilot Solenoid On Off
IGNITION
Igniting Off
FLAME DETECTION
Flame Detect: 3s Flame:
75% Off
MAIN DELAY*
Main Delay: 30s Flame:
87% Off
MAIN SOLENOID*
Main Solenoid: On Flame:
100% Off
TECHNICAL TRAINING
203
RUNNING
IGNITER running Bat:
13.8V Off
TECHNICAL TRAINING
204
TECHNICAL TRAINING
205
RATINGS
POWER SUPPLY
SOLAR / BATTERY
MODE
Solar Input
LINE IN MODE
Power Control
MPPT
Battery Output
Charging Current
2 A output max
Line In
17-28 VDC
Battery Output
Charging Current
2 A output max
Line In
12-28 VDC
MODE
INDICATORS
SOLENOID
CONFIGURATION
POWER
(TYPICAL)
IGNITER
3 x No valves
selected
0.48 W @ 24 V
IGNITER
3 x No valves
selected
0.14 W @ 24 V
IGNITER
3 x latch
0.52 W @ 13.8 V
IGNITER
3 x latch
0.19 W @ 13.8 V
FLARE
0.41 W @ 13.8 V
FLARE
0.08 W @ 13.8 V
FUSE
CERAMIC 250 V FAST 3AB 3A
CLOCK BACKUP BATTERY
CR2032
ESD OUTPUT RELAY
Max. switching voltage 220 VDC, 250 VAC rated current 2A
TECHNICAL TRAINING
206
TROUBLESHOOTING
ESD SCREEN MESSAGES
If the PLATINUM-500 detects a problem that does not require a restart, it will shut down any ongoing
operation and display the cause(s) of the problem. The time/date and reason for shutdown will also be
stored into the event log and can be viewed later.
For the following table, xx.xV, indicated the voltage reading at the time of the problem.
For example:
REMEDIES/SOLUTION
TECHNICAL TRAINING
207
The driver for the ESD solenoid has detected a high internal
temperature; This may indicate a short in the ESD wiring, ESD
solenoid or a problem with the Main Board.
There is a problem with the power supply for the ESD solenoid
coil; This may indicate a problem with the Main Board.
A short has been detected between the flame rod and ground;
Check the flame rod and wiring and retry.
The line power input voltage is lower than allowable for proper
operation; Verify the supply is at its correct voltage.
TECHNICAL TRAINING
208
The driver for the main solenoid has detected a high internal
temperature; This may indicate a short in the main wiring,
main solenoid or a problem with the Main Board.
During the pilot delay, the pilot solenoid type was detected as
corrupted; Use Setup to select the correct solenoid type.
TECHNICAL TRAINING
209
The driver for the pilot solenoid has detected a high internal
temperature; This may indicate a short in the pilot wiring, pilot
solenoid or a problem with the Main Board.
There is a problem with the power supply for the pilot solenoid
coil; This may indicate a problem with the Main Board.
There is a problem with the power supply for the pilot or main
solenoid coils; This may indicate a problem with the Main
Board.
Power supply
The solenoid power supply voltage is too low; This may indicate
a problem with the Main Board.
The ESD solenoid power supply voltage is too high; This may
indicate a problem with the Main Board;This may also be seen
if the solenoid voltage was set to 24V, then changed to 12V;
wait a few minutes for this to clear.
The ESD solenoid power supply voltage is too low; This may
indicate a problem with the Main Board.
TECHNICAL TRAINING
210
The main solenoid power supply voltage is too high; This may
indicate a problem with the Main Board. This may also be seen
if the solenoid voltage was set to 24V, then changed to 12V;
wait a few minutes for this to clear.
The main solenoid power supply voltage is too low; This may
indicate a problem with the Main Board.
The pilot solenoid power supply voltage is too high; This may
indicate a problem with the Main Board. This may also be seen
if the solenoid voltage was set to 24V, then changed to 12V;
wait a few minutes for this to clear.
The pilot solenoid power supply voltage is too low; This may
indicate a problem with the Main Board.
MESSAGE
REMEDIES/SOLUTION
TECHNICAL TRAINING
211
MISCELLANEOUS MESSAGES
The PLATINUM-500 may show messages to show the user a temporary condition. These messages are
not stored into the log.
MESSAGE
REMEDIES/SOLUTION
Not charging
TECHNICAL TRAINING
212
ISSUE
REMEDIES/SOLUTION
TECHNICAL TRAINING
213
TECHNICAL TRAINING
214
TITLE
DESCRIPTION
Document
Document
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Document
Video
Video Segment
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CONCLUSION
The Platinum Burner and Ignition Management Systems are simple and safe to use, and provides
extensive operator feedback. For technical assistance, contact Platinum Control Technologies, or your
local authorized distributor.
TECHNICAL TRAINING
215
ADDENDUM DRAWINGS
PLATINUM-500 ELECTRIC
TECHNICAL TRAINING
216
PLATINUM-500 PNEUMATIC
TECHNICAL TRAINING
217
TECHNICAL TRAINING
218
Glossary
TECHNICAL TRAINING
219
TERM
DEFINITION
ALARM SETPOINT
This temperature setting will be a little bit higher than your Main Off setpoint. If for any
reason the bath temperature overheats, once this Alarm Setpoint is reached the BMS will
ESD and shut in all the gas.
AMINE UNIT
API
American Petroleum Institute represents all aspects of the United States petroleum and
natural gas industry.
BAFFLE
Partician plates inside a vessel that reduce turbulence, change the direction of the flow,
and aid in the separation process.
BRITISH THERMAL
UNIT (BTU)
The measure of heat created by burning any material. The amount of heat required to
raise the temperature of 1 pound of water one degree.
BURNER
The component inside the combustion chamber where fuel gas is burned to heat a
process stream or media.
BURNER
MANAGEMENT
SYSTEM (BMS)
A system to provide remote access, automatic ignition, temperature control, and data
collection capability that improves safe operations for production equipment with fired
components.
BURNER MIXER
Component in the combustion chamber used to adjust the mixture of the oxygen and fuel
gas supply to the main burner for optimum combustion.
BURNER NOZZLE
The last component in the burner train. This nozzle allows for dispersion and burning of
the supplied fuel gas.
CLASS I HAZARDOUS
LOCATION
An area in which flammable gases or vapors may be present in the air in sufficient
quantities to be explosive or ignitable.
CO2
COILS
The piping that carries the well stream through a heated media. This is for the purpose of
heat exchange to aid in separation or the prevention of hydrates. These coils have the
same pressure rating as the flow line.
COMBINATION UNIT
These units may be the combination of a gas production unit and a dehydration system
combined on the same skid and enclosed.
COMBUSTION
The process of burning, any process in which a substance reacts with oxygen to produce a
significant rise in temperature and the emission of light.
COMBUSTION
CHAMBER
The front portion of the firetube adjoined with the flame arrestor. Housed in this area is
where oxygen and fuel gas are combined and ignited to produce heat within the firetube.
COMBUSTOR
A device used to incinerate waste gas emissions VOCs (Volatile Organic Compounds), and
BTEX (Benzene, Toluene, Ethyl Benzene, Xylenes) resulting from the production process.
It eliminates and vaporizes these hazardous emissions by maintaining a certain
temperature at the flash point. Maximum destruction efficiency is paramount.
TECHNICAL TRAINING
220
TERM
DEFINITION
CSA
DEFLAGRATION
Combustion that propagates through a gas or along the surface of an explosive at a rapid
rate driven by the transfer of heat.
DIRECT FIRED
A production equipment component in which the heat energy from the combustion
chamber radiates directly from the process stream. Example: Heat Treater.
DIVISION I
Gas, vapor or mist will be present or expected to be present for long periods of time
under normal operating conditions.
DIVISION II
A zone that has been defined as an area in which an explosive atmosphere is only present
under abnormal conditions.
DRAIN
ELECTROSTATIC
TREATER
A vessel that receives emulsion flows and resolves the emulsion to oil, water, and usually
gas by using heat, chemicals, and a high-voltage electric field.
EMERGENCY
SHUTDOWN DEVICE
(ESD)
EMULSION
ENERGY
This connection will receive ESD alerts from other pieces of equipment, signaling the BMS
to shut down the burners. This contact looks for a normally closed condition.
EXTERNAL INPUTS
Any device with a normally closed dry contact can be tied into the BMS. If one of these is
tripped, the BMS will ESD and shut in all gas.
FLAME
FLAME ARRESTOR
A device utilized to insure that combustion stays in the combustion chamber. This item
allows cool air to be drafted into the firetube for the purpose of ignition, but minimizes
possible combustion outside of the flame arrestor and firetube combustion chamber area.
FLAME CELL
Mounted in the flame arrestor, and is a tortuous path of passages that serves as a heat
exchanger. This device is usually made of aluminum.
FLAME IONIZATION
This is the technique we use to recognize a pilot being present. This is done by passing a
current through the flame and measuring change in the conductivity with our kanthol
igniter rod. This process will also measure the flame quality in Meg Ohms. This flame
quality will read out on the front display panel.
FLAME IONIZATION
ROD
Rod used for ignition that also has the capability to sense electrical current through the
burner flame. The appearance or lack of appearance of flame resistance triggers reactions
at the burner management system. In Platinum BMS units this rod is made of a superior
metal alloy known as Kanthol.
TECHNICAL TRAINING
221
TERM
DEFINITION
This feature allows the pilot to reestablish itself in the event of a high gust of wind blowing
the pilot off the tip briefly, or the main burner snuffing the pilot flame out for a short
period of time. Allowing the pilot time to reestablish prevents the system from shutting
down and having to go through a relight sequence.
FLARE
A device designed to ignite vent gas and other emissions. The flare does not have the
destruction efficiency of an incinerator.
FLASH ARRESTOR
FILL HATCH
A covered opening for the purpose of adding fluid media to the bath, such as in a line
heater.
FIRETUBE
A U-shaped tube inserted in the heating section of a process vessel. These tubes may be
as small as 6 in diameter and exceed 24 in diameter, with lengths from 3 to over 20.
FLUID INLET
FUEL
A component of the fire triangle that when combined with heat and oxygen allows for
combustion. For the purposes of our training, fuel would be natural gas or propane.
GAS OUTLET
A connection allowing and directing the desired exit of the gas stream from the vessel.
GAS PRODUCTION
UNIT
A unit that is a combination of a line heater and a separator together on one skid or
possibly enclosed housing. These units can also be referred to as stack packs and Tpacks. More elaborate units can have multiple combinations housed together and may
include dehydration equipment as well.
GLYCOL
DEHYDRATOR
A unit used to remove minute water particles from natural gas if dehydration has not
been attained using separators. A glycol dehydrator unit is composed of an absorber,
reboiler, and supporting components.
H2S
A colorless, poisonous gas that smells like rotten eggs. It is formed naturally by decaying
organic matter and is the smelly component of intestinal gas. It is also emitted by
volcanoes and fumaroles. Hydrogen sulfide is used in the petroleum, rubber, and mining
industries and may be found in the natural gas stream.
HEAT
The third component of the Fire Triangle. Heat as an ignition source combined with fuel
and oxygen allows for sustained combustion.
HEATED SEPARATOR
An item of production equipment used to separate liquid components of the well stream
from the gaseous elements.
HEATER TREATER
A vessel that heats an emulsion and removes water and gas from the oil to raise it to a
quality acceptable for a pipeline or other means of transport. A heater treater is a
combination of a heater, free-water knockout, and oil and gas separator.
IGNITER ROD
The rod used to electronically convey a spark to the pilot head for the ignition of the pilot
burner.
IGNITION DELAY
The ignition delay is the amount of time given between attempts to light the pilot. This is
especially important when the system is going through a relight. This delay allows a
natural draft to push any excess gas that may be in the fire tube out of the stack before
the pilot sparks and tries to ignite. The delay can be set anywhere from 15-300 seconds.
TECHNICAL TRAINING
222
TERM
IGNITION MODULE
INCINERATION
DEFINITION
The ignition module for the BMS contains the ignition board and the 30,000 volt ignition
coil. There are connections on the board for the sparker cable, the ground cable, and the
10 conductor cable.
The act of burning something completely.
INDIRECT FIRED
A production equipment component in which the heat energy is now conveyed to heat a
media fluid, which in turn transmits the heat energy to the process stream. Example: Line
Heater
INTERFACE
The fluid level in a vessel where distinct differences in the gravities of fluid can be
observed. Example the area where oil and water can noticeably be distinguished from the
inlet emulsion.
A gas steam with minimal ethane, propane, butane, pentane, hexane, heptane,
condensates, benzene, or toluene.
Instrumentation to monitor the level of the liquid being heated by the firetube. This
protects against excess temperature of the firetube caused by a low liquid level. This
situation can be potentially dangerous if fluid level drops below firetube.
LINE HEATER
LIQUID LEVEL
CONTROLLER
A pneumatic, mechanical, or electrical device that senses liquid height inside a vessel, and
triggers a valve to open or close as desired.
LIQUID OUTLET
A connection that allows for and directs fluid out of the vessel.
A control valve that opens or closes to maintain the desired liquid level in the vessel.
LOCKOUT
The main valve delay is the amount of time allowed after the pilot has been established,
before the main burner is signaled to come on. This can be set 1-300 seconds. The delay
time should be determined by the size of the burner and the climate at the location. The
larger the burner and/or colder the climate, the more time you will want to give the pilot
to establish flame quality and good natural draft through the fire tube.
MIST EXTRACTOR
A device placed in the gas outlet stream of a production vessel. This component is
typically made of mesh or steel plates to remove fine liquid mist from the gas stream as it
exits the vessel.
These units are essentially two or more gas production units on the same skid and usually
enclosed, which are designed for use on multiple well pad locations.
NATURAL DRAFT
BURNER
A burner that uses oxygen supplied by the draft, created due to the heat inside the
firetube.
NFPA
TECHNICAL TRAINING
223
TERM
DEFINITION
ORIFACE
An opening that can be adjustable or non-adjustable allowing a specific amount of the fuel
oxygen mixture to the burner or pilot for combustion.
OSHA
Occupational Safety and Health Administration under the Department of Labor is the
federal department responsible for promoting safe working conditions of wage earners in
the United States.
OXYGEN
A component of our atmosphere that when combined with fuel and heat allows for
combustion.
PILOT ASSEMBLY
The pilot assembly comes with the pilot mixer, pilot tip, and the kanthol igniter rod.
PILOT MIXER
Component in the combustion chamber that combines the oxygen and fuel gas, then
mixes and supplies this combined stream to the pilot burner for ignition.
Operators have the ability to have this feature enabled or have it set to pilot always on.
The default setting is pilot always on. However, in some cases having an intermittent pilot
is necessary. For example, some states such as New Mexico will award carbon credits to
companies if they only have a pilot on when the main burner is on.
PRESSURE GAUGE
PRESSURE RELIEF
VALVE or PRESSURE
SAFETY VALVE (PRV
or PSV)
A device used to allow excessive pressure to be relieved from a production vessel and
associated piping. This is designed to prevent a potentially dangerous over-pressurization
of the production equipment.
PRESSURE SWITCH
Pressure switches can tie into the High Pressure and Low Pressure connectors on the
external inputs. If pressures reach a level that is too high or low, the BMS will ESD and
indicate whether it was due to a High Pressure or a Low Pressure.
PROOF OF CLOSURES
On the external inputs connector there is another port for Proof of Closures. With some
valves, an electronic signal can be sent back to prove that a valve is open or shut.
PROPANE
REMOTE ON/OFF
INPUTS
This signal will direct the microcomputer to enter the off state. The burner is on when the
switch is closed. Open the switch only in the normal burning state. If the contacts are
closed, the burner will start. If the contacts are open, the burner will stop. A remote
system should be used to control the burner.
Rich gas stream usually means a significant amount of components other than methane in
the gas. These would typically be ethane, propane, butane, pentane, hexane, heptane,
and some heavier paraffin molecules known as natural gasoline or condensate, depending
on the composition. There can also be some non-paraffin hydrocarbons such as benzene,
toluene, etc
RTD
Resistance Temperature Device. This is a type of probe that can be used in the thermowell
to monitor and control process temperature. (Any RTD used with the Platinum BMS must
be 1,000 ohm.)
SIGHT GLASS
A component used to present a visual indication of the liquid level inside a production
vessel.
TECHNICAL TRAINING
224
TERM
DEFINITION
SOLENOIDS
These are electromechanical valves that will control the opening and closing of pilot,
main, and ESD control valves.
STACK ARRESTOR
A device designed to be mounted to the top of the firetube to prevent sparks, flashes, or
burning materials, such as carbon, from escaping the stack and potentially igniting
combustible material in the area.
TAGOUT
TANK HEATER
Firetubes designed to be mounted in the door of storage tanks along with burner
instrumentation. The units are found primarily in colder climates.
TEMPERATURE
SAFETY HIGH (TSH)
TEMPERATURE
SAFETY LOW (TSL)
Instrumentation device to monitor for low temperature. When sensed, the burner is
activated to increase the temperature.
TEMPERATURE
SETPOINTS
The temperature setpoints are where the Main On/Off temperatures will be set. The main
burner will cycle between these set points. The burner will shut off when Main Off
temperature is reached, and turn on when temperature has dropped to Main On
temperature. Setpoints can be as close as 5 degrees Fahrenheit.
THERMOCOUPLE
A thermocouple is a type of temperature probe that can be used to monitor and control
process temperatures. A thermocouple will need to be used when measuring
temperatures up above 450 degrees Fahrenheit. (Any thermocouple used with the
Platinum BMS must be Type K.)
TIME LOG
Run times of the pilot and the main will display on the front panel screen during
operation. This data is cleared when the internal reference date is changed. Make sure to
record log time values before changing date.
TURBULATOR
A device installed in the second leg of the firetube and designed to increase heat transfer
by directing heated flue gas towards the firetube wall.
UL
VENTURI
A tube in the main or pilot gas stream with a tapering constriction in the middle that
causes a gas velocity increase with a pressure decrease, creating suction and draft for
drawing fuel gas to the burner.
TECHNICAL TRAINING
225