User Manual

SmartFlare – Flare 95XX

Single Stage with Pilot

Version 95.13
Table of Contents
1 PREFACE ....................................................................................................................................... 3

2 ABOUT THIS GUIDE ...................................................................................................................... 4

2.1 W HO SHOULD USE IT ................................................................................................................. 4

2.2 TYPOGRAPHICAL CONVENTIONS ................................................................................................. 5

3 WARNINGS..................................................................................................................................... 6

4 INTRODUCTION............................................................................................................................. 7

4.1 PURPOSE .................................................................................................................................. 7

4.2 FLARE MODELS ......................................................................................................................... 7
4.3 F1 KEY SCREENS ...................................................................................................................... 7
4.4 F2 KEY SCREENS ...................................................................................................................... 8
4.5 F3 KEY SCREENS ...................................................................................................................... 9
4.6 F4 KEY SCREEN ........................................................................................................................ 9
4.7 TOP MENU ..............................................................................................................................10
4.8 VOC OPERATION MENU...........................................................................................................10
4.9 SETUP MENU ...........................................................................................................................12
4.10 SYSTEM MENU ........................................................................................................................14
4.11 ABOUT ....................................................................................................................................16
4.12 PASSWORD .............................................................................................................................16
4.13 FAULTS ...................................................................................................................................16

5 I/O WIRING ...................................................................................................................................18

6 MODBUS COMMUNICATIONS ....................................................................................................20

6.1 RJ-45 W IRING .........................................................................................................................20

6.2 MODBUS COMMUNICATION OPTIONS.........................................................................................21
6.3 MODBUS REGISTERS ...............................................................................................................21

7 SYSTEM SETTINGS ....................................................................................................................25

8 LOGGING......................................................................................................................................26

9 APPENDIX A – GLOSSARY OF TERMS .....................................................................................29

Kimark SmartFlare User Manual Page 2 of 29

1 Preface

1.1.1 Version Number log.

Version Description

70.03 Compatible program.

70.24 Compatible program.

95.09 First release that this manual covers

95.12 Second Release

95.13 Third Release

1.1.2 Copyright
All rights reserved. No parts of this work may be reproduced in any form or by any means -
graphic, electronic, or mechanical, including photocopying, recording, taping, or information
storage and retrieval systems - without the written permission of the publisher.

Products that are referred to in this document may be either trademarks and/or registered
trademarks of the respective owners. The publisher and the author make no claim to these
trademarks.

While every precaution has been taken in the preparation of this document, the publisher and
the author assume no responsibility for errors or omissions, or for damages resulting from the
use of information contained in this document or from the use of programs and source code that
may accompany it. In no event shall the publisher and the author be liable for any loss of profit
or any other commercial damage caused or alleged to have been caused directly or indirectly by
this document.

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2 About this guide

This document is divided into the following chapters:

• INTRODUCTION

• SCREENS

• I/O WIRING

• MODBUS COMMUNICATIONS

• SYSTEM SETTINGS

• LOGGING

• APPENDIX A – GLOSSARY OF TERMS

2.1 Who Should Use It

This guide is intended for users of different degrees of knowledge and experience with the
Burner Control:

• Operators: Operators can learn how to configure and operate the Kimark Smart Flare.

• Service Techs: For troubleshooting and maintenance

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2.2 Typographical Conventions
This document uses the following typographical conventions:

• Command and option names appear in bold type in definitions and examples. The
names of directories, files, machines, partitions, and volumes also appear in bold.

• Variable information appears in italic type. This includes user-supplied information on

command lines.

• Screen output and code samples appear in monospace type.

In addition, the following symbols appear in command syntax definitions.

• Square brackets [ ] surround optional items.

• Angle brackets < > surround user-supplied values.

• Percentage sign % represents the regular command shell prompt.

• Pipe symbol | separates mutually exclusive values for an argument.

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3 Warnings

• Never open the Flare Box Door without first turning off power to the flare control panel.
Also ensure the Run Switch is in the off position. The Flares are automated and can
ignite at any time when they are running.

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4 Introduction

4.1 Purpose
This document covers the operation and configuration of the Kimark SmartFlare. For
maintenance and installation information see the Kimark Installation Manual 95XX.

4.2 Flare Models

• This document covers the following SmartFlare Models:

70.03 through 70.24 and 95.00 through 95.12 SmartFlare

4.3 F1 Key Screens

The screens can be scrolled through by pressing the F1 Key or the </> buttons on the title.

Overview Screen
Ign – Igniter
Ctr – Control Line
Sys – System Line
LEL – Dark is Activated/Triggered
HKO – (High Knockdown) Dark is Activated/Triggered
Fuel Gas Disabled – Fuel gas is not being used, Flare
will ignite using VOC Gas.

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4.4 F2 Key Screens

Runtime
Runtime is displayed in minutes. Runtime indicates the
amount of time the main valve is open.
Start
The Start Count, keeps count of how often the main
valve is opened.

Flame Loss
The Flame Loss Count shows how many time the flame
is lost and the system has to relight.

VOC Trend
Trend of the pressure for the past 136 minutes.

Temperature Trend
Trend of the temperature for the past 136 minutes.

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4.5 F3 Key Screens

Gas Flow
Displays the current gas flow and totals for both VOC
and Fuel.

Burner Info
This page shows configured information for the
SmartFlare.

4.6 F4 Key Screen

Info and Configuration Access
This screen serves two purposes, version info and
access to the configuration screens. To access the
configuration screens, enter the password.
Note: This screen is only displayed if the password is
set.

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4.7 Top Menu

Top Menu
This is the top menu.

Note: This screen is displayed if the password is not set

or after the correct password is entered.

4.8 VOC Operation Menu

VOC Operation
This is the VOC Operation menu.

Start/Stop Setpoints
Enter the start and stop pressures for the VOC.

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 Gas Measurement
Enter Specific Gravity for VOC and Fuel.

The “Manual Fuel (PSI) is for entering the pressure that

the fuel is delivered at.

Fuel/Pilot Operations
This flare is designed to allow for fuel gas or not.
If Fuel is turned off, the flare will be set to “Pilot on
Demand”.

Warning: The default setting for a new flare is:

-Use Fuel Gas
-Pilot Always On

Warning: If the factory reset is pushed, the pilot

operations will revert back to:
-Use Fuel Gas
-Pilot Always On

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4.9 Setup Menu
Setup Menu
The operations menu configures Analog scaling, Igniter
Sequencing, Flame Detector and Retries and Restarts.

Pressure
Configure the VOC Analog pressure scaling.

Temperature
Configure the Temperature Analog temperature scaling.

You can also set the High Temperature Shutdown.

When the high temperature is reached, the burner will
turn off for the preset time “ResartMin”

Flame
The settings on this screen rarely, if ever, need to be
changed. These setting affect the flame detection.

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 Retries/Restarts
“Restart After Flame On Fail” by default is off,
meaning that the controller will go into fault if a
flame is detected before lighting off. Set to yes, and
the controller will ignite when the flame goes away.
Igniter Retries-Number of attempts to ignite before
faulting.
Restart Delay-Number of minutes to wait before re-
attempting to ignite.
Restart Attempts-The number of restart attempts
before hard faulting.

Startup Sequence
The settings on this screen rarely, if ever, need to be
changed. These setting affect the ignition sequence.

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4.10 System Menu

System Menu
The System Configuration Menu

*Some versions may not have the Maint/Test Option.

Media
This button allows you to format or delete files on the
removable media.

Communications - Modbus
Modbus communications can be configured for either
RS-232 or RS-485. Other protocols, baud rates can be
configured, please contact the factory for this.

Date Time
Date and time are only needed for Logging and possibly
Modbus communications if you read the time/date
registers.
Press “Get” first.
The Data and Time can also be changed from “System
Settings”

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 Resets
Factory Defaults will load the factory default values for
startup times, scaling, etc.
Reset will clear all timers and counters.
Note: Neither Factory Defaults or Reset will clear the
user password.

Input Data
Various pieces of information can be entered. This info
can be read by Modbus or viewed in the log.

*Maintenance Mode
Press “Enable Maintenance Mode” to turn to ON, Panel
must be off. Then press next to go to maintenance
screens.

*Some versions may not have a maintenance mode.

Maintenance Mode (cont.)

Here you can test fire the Ignitor, open/close the Fuel
Valve/Solenoid, open/close the Stage 1 VOC valve as
well as read it’s open and closed status, read the Fire
eye’s flame value, and see the unit’s system and
controller status.

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4.11 About

About
When contacting the factory, please have version
number available.

4.12 Password
Change Password
You can set a password that must be used to enter any
configuration data. If set to zero, no password is
required.
The password is active for 60 seconds. However, as
long as you stay in the configuration screens you will not
need to re-enter it.

4.13 Faults
Fault - Paused
When this screen is displayed, a fault has occurred but
the system will restart after a time delay.

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 Failed
When this screen is displayed the system must be
cycled on and off to restart.

Valve Not Closed

This screen is displayed when the VOC valve is not
reading closed before the unit tries to startup operation.

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5 I/O Wiring

5.1.1 I/O Wiring

Digital In Name Type

1 System On Switch NO

2 Control Line NO

3 Fuel Valve Open SW NO

4 Fuel Valve Close SW NO

5 VOC Valve Open SW NO

6 VOC Valve Close SW NO

7 Spare NO

8 Spare NO

9(h1) Flame Detect NA

10 (h2) SD1 (LEL) - NC NC

11(h3) SD2 (High Knockout) - NC NC

12(h4) Spare NO

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Digital Out Name Type
1 Pilot Valve/Solenoid

2 VOC Main Valve

3 Igniter

4 Spare

Analog In Name Type

1 Analog 1 In - VOC Pressure - Ounces 4-20ma

2 Analog 2 In - Temperature 4-20ma

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6 Modbus Communications

*Use MJ1 for communications.

6.1 RJ-45 Wiring

You can use a standard Ethernet cable with the following wire colors:

For RS-232

Pin (RJ-45) RS-232 Connection

8 (Brown) TXD

7 (White/Brown) RXD

6 (Green) Ground

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For RS-485

Pin (RJ-45) RS-485 Connection

1 (White/Orange) RX/TX+

2 (Orange) RX/TX-

6.2 Modbus Communication Options

Modbus RTU is used for all communication settings.
1. No Communications
2. RS-232 9600/8/N/1
3. RS-232 19200/8/N/1
4. RS-485 9600/8/N/1
5. RS-485 19200/8/N/1

6.3 Modbus Registers

Register Description Format

4xxxx

3001 Date Float / YYMMDD

3003 Time Float / HHMMSS

3005 System ID/Modbus Address Float

3007 Status Register Float

3009 Current Hour Runtime Float

3011 15 Minute Average Pressure Float

3013 Analog 1 Scaled - Pressure Float

3015 Current Hour Flame Loss Count Float

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 3017 Flame Intensity Level Float

3019 Version Float

3021 Current Day Flame Loss Count Float

3023 Daily Runtime Count Float

3025 Inputs Int

3026 Outputs Int

3027 Spare Float

3029 Analog 2 Scaled - Temperature Float

3031 Previous Day Runtime Float

3033 VOC Start Pressure Float

3035 VOC Stop Pressure Float

3037 VOC Flow MCF Float

3039 Fuel Flow MCF Float

3041 VOC Previous Day MCF Float

3043 Fuel Previous Day MCF Float

3045 VOC Current Day MCF Float

3047 Fuel Current Day MCF Float

3049 Status Bits Float

3051 Name – 2 Letters ASCII

3052 Name – 2 Letters ASCII

3053 Name – 2 Letters ASCII

3054 Name – 2 Letters ASCII

3055 Name – 2 Letters ASCII

3056 Name – 2 Letters ASCII

3057 Name – 2 Letters ASCII

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 3058 Serial Number – 2 Letters ASCII

3059 Serial Number – 2 Letters ASCII

3060 Serial Number – 2 Letters ASCII

3061 Serial Number – 2 Letters ASCII

3062 Serial Number – 2 Letters ASCII

3063 Serial Number – 2 Letters ASCII

3064 Serial Number – 2 Letters ASCII

3065 Latitude Float

3067 Longitude Float

3069 Spare

3071 Previous Hour VOC MCF Float

3073 Main Open Count Previous Hour Float

3075 Main Open Count Current Hour Float

3077 Main Open Count Current Day Float

3079 Main Open Count Previous Day Float

3081 Previous Day Flame Loss Float

3083 Current Day Flame Loss Float

3085 Previous Hour Flame Loss Float

3087 Previous Hour Runtime Float

3089 Current Hour VOC MCF Float

3091 Spare

3093 Spare

3095 Spare

3097 Spare

3099 Spare

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6.3.1 Status Register Codes
Status Code Status

0 Stop

1 Running

2 Restart

3 System Off

4 Control Off

5 1: Open Valve

6 2: Igniter

7 3: Test

8 Restart Fail
Flame On, Can’t Start
9
Factory Reset
10
Not Used
11
Not Used
12
System Idle
13
Spare
14
LEL Active - Fault
15
High Knockout - Fault
16
High Temp Shutdown
17

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7 System Settings
The system menu is accessed by pressing System key.
WARNING: Do no change any settings in the System
Menu. You risk “breaking” your controller’s operational
capability by changing settings in these sub-menus.
These screens are for trained technicians, to be used for
advanced troubleshooting.

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8 Logging

The controller supports logging with a Micro SD Card. We recommend a 2 gig SanDisk.

Column 15 Minute Log Description Format

1 Date Float / YYMMDD

2 Time Float / HHMMSS

3 System ID/Modbus Address Float

4 Analog 1 - Pressure Float

5 Analog 2 - Temperature Float

6 Analog 3 - Spare Float

7 Analog 4 - Spare Float

8 Flame Intensity Level Float

9 Version Float

10 Retry Counter Float

11 15 Min Prev Avg Pressure Float

12 Status Codes Float

13 Inputs Int

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 14 Outputs Int

15 Status Bits Float

16 VOC Flow MCF Float

17 Fuel Flow MCF Float

18 VOC Previous Day MCF Float

19 VOC Current Day MCF Float

20 VOC Previous Hour MCF Float

21 VOC Current Hour MCF Float

22 VOC Previous Day MCF Float

23 Runtime Previous Day Float

24 Runtime Current Day

25 Runtime Previous Hour

26 Runtime Current Hour

27 Main Open Count Previous Day

28 Main Open Count Current Day

29 Main Open Count Previous Hour

30 Main Open Count Current Hour

31 Flame Loss Count Previous Day

32 Flame Loss Count Current Day

33 Flame Loss Count Previous Hour

34 Flame Loss Count Current Hour

35 Purge Time Left

36 Fuel Previous Day MCF

37 Fuel Current Day MCF

38 Fuel Previous Hour MCF

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 39 Fuel Current Hour MCF

40 Fuel Previous Day MCF

8.1.1 Status Register Codes

Status Code Status

0 Stop

1 Running

2 Restart

3 System Off

4 Control Off

5 1: Open Valve

6 2: Igniter

7 3: Test

8 Restart Fail

9 Flame On, Can’t Start

10 Factory Reset

11 Not Used

12 Not Used

13 System Idle

14 Spare

15 LEL Active - Fault

16 High Knockout - Fault

17 High Temp Shutdown

18 Maintenance Mode

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9 Appendix A – Glossary of Terms

Terms used in this document.

Term Meaning

LEL lower explosive limit

BTEX benzene, toluene, ethylbenzene, and xylenes

Igniter Retries The number of attempts when igniting.

If the igniter fails to light, (Max Igniter Retries) the system will wait a
Restarts
specified amount of time and try to re-light.

Pilot On
In this mode, the flare will ignite only when the flare is needed.
Demand

Pilot Always In this mode, there will always be a pilot flame. If the pilot goes out,
On the Flare will relight the pilot.

Gas from a separate source, used to assist in burning. The Smart

Fuel Gas
Flare can be used with or without Fuel Gas.

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