Sun Peaks Propane Plant Evaporator #3 - Manual Part I

Transcription

Energy Efficiency Engineering Ltd.
Client: TERASEN ENERGY SERVICES
Project: BS&B 1000 IHPV PROPANE VAPOURIZER
Location: SUN PEAKS, B.C.
PO Number:
AFE:
Description: New Liquid Propane Vapourizer
INSTALLATION OPERATION AND MAINTENANCE
MANUAL
November 2008
TABLE OF CONTENT
1. PROJECT INFORMATION
1.1. ENEFEN Project Information Sheet
1.2. ENEFEN Design Evaluation
1.3. ENEFEN Design Approval In Principle
1.4. ENEFEN Field Inspection
1.5. ENEFEN Final Approval
2. BS&B’s P&ID and Bill Of Materials
3. CSA B149.3 Compliant Rating Plate Layout
4. Job Specific Setpoints
5. Job Specific Wiring Diagrams
6. Liquid Propane & Vapourizer Parts Manuals
6.1. SOR Level Switch Manual
6.2. UE Series 120 TEMPERATURE SWITCH Manual
6.3. Type “K” Thermocouple Data Sheet
7.Burner Management System & Burner Parts Manuals
7.1. Profire 1100 Ignition Flame Safety Controller Manual
7.2. Profire Bath Temperature Control Module
8. Fuel train Parts Manual
8.1. Fisher 627 Pressure Regulator Manual
8.2. Wika Type 233.53 Pressure Gauge Data Sheet
8.3. UE Spectra Pressure Switch Manual
8.4. ASCO solenoid valve Model Manual
8.5. Fisher 67CFR Pressure Regulator Manual
8.6. NEO Manual Valves
1. PROJECT INFORMATION
1.1. ENEFEN Project Information Sheet
Jozef Jachniak, P.Eng.
jjachniak@enefen.com
www.enefen.com
T:780-940-3464 / 604-808-1974
ENEFEN
82-52A St, Delta BC, V4M 2Z5
F:866-583-0520
GAS FIRED EQUIPMENT / APPLIANCE DATABASE V.1.0.1
Installation ID
IR0810001
Created Date
PROJECT INFORMATION
Rev 0
19-Sep-2008
Reviewer
PI0810001
1
PROJECT INFORMATION DETAILS
Project Description
Propane Vaporizer Addition
Confirmed
Project References
Sun Peas Vaporizer
Confirmed
Client / Consultant
Terasen Energy Services Inc.
Confirmed
Jarek Bekesza, P.Eng., Manager, Operations & Project Assessment
Confirmed
jarek.bekesza@terasen.com
Confirmed
Client / Consultant Telephone
(250) 380-5738
Confirmed
Client / Consultant Cell
(250) 889-5782
Confirmed
Client / Consultant Fax
(250) 388-6876
Confirmed
320 Garbally Road, Victoria, BC. V8T 2K1
Confirmed
Confirmed
Plant
Sun Peaks Propane Plant
Confirmed
Area
Sun Peaks, BC (50 km driving distance northeast of Kamloops)
Confirmed
Vaporizer Building, Sun Peaks Propane Plant
Confirmed
1,255 m (4,117')T
Confirmed
F081017
Confirmed
Terasen Energy Services Purchase Order 704988 September 2, 2008
Confirmed
Propane storage and vaporization for Sun Peaks Utilities propane gas utility distribution system
Confirmed
Liquid Propane Vaporization
Confirmed
Indirect Water Bath Heater
Confirmed
Black, Sivalls & Bryson (Canada) Limited (BS&B)
Confirmed
Location Built In
Nisku, AB
Confirmed
Built Month [MM]
10
Confirmed
Built Year [YYYY]
2008
Confirmed
Model No.
1000 IH PV with propane vapour burner and electric controls
Confirmed
Serial No.
F081017
Confirmed
Inside prefricated building with natural ventilation at flloor and roof level with explosion relief panels
Confirmed
Indoor - Design Suitable for Outdoor Operation
Confirmed
Indoor
Confirmed
Non-classified - Burner has BS&B Std. Flame Arrestolr
Confirmed
Class I Div 2
Confirmed
Client / Consultant Contact
Client / Consultant Email
Client / Consultant Mailing Address
Owner / Operator
Appliance Location LSD
Appliance Elevation A.S.L. [m]
Appliance Tag No.
Project Number (to show on rating plate):
Process (for ex. Wellsite)
Appliance Function (for ex. Raw Gas Heating)
Appliance Type (for ex. Line Heater)
Manufacturer
Burner Location (indoor or outdoor)
Fuel Train Location (indoor or outdoor)
Control Panel Location (indoor or outdoor)
Electrical Area Classification At Burner
Electrical Area Classification At Fuel Train
PROJECT INFORMATION
Page 1 of 2
www.enefen.com
T:780-940-3464 / 604-808-1974
ENEFEN
F:866-583-0520
Class I Div 2 at Vaporizer location - Electrical Building Not Classified
Confirmed
Design Minimum Ambient Temp. [Deg C]
-40
Confirmed
Design Maximum Ambient Temp. [Deg C]
40
Confirmed
Propane
Confirmed
2500 BTU/scf
Confirmed
As required
Confirmed
Additional Main Fuel(s) Type
N/A
N/A
Additional Main Fuel(s) Higher Heating Value
N/A
N/A
Additional Main Fuel(s) Inlet Pressure [psig]
N/A
N/A
Process Duty [MM BTU/Hr]
N/A
N/A
Fuel Maximum Input HHV [MM BTU/Hr]
1.1
Confirmed
Electrical Area Classification At Control Panel
Main Fuel Type
Main Fuel Type Higher Heating Value
Main Fuel Inlet Pressure [psig]
Propane
Confirmed
2500 BTU/scf
Confirmed
3 psig
Confirmed
Instrument Gas Type
Not Applicable
Confirmed
Instrument Gas Pressure [psig]
Not Applicable
Confirmed
120 VAC
Confirmed
24VDC power suply
Confirmed
T8653.21 Coil / U6704.21 Propane pot
Confirmed
Pilot Fuel Type
Pilot Fuel Higher Heating Value
Pilot Gas Pressure [psig]
Main Power [V/Ph/Hz/A]
Control Power [V/Ph/Hz/A]
Appliance CRN Number
Other Comments:
Techno-Commercial Offer dated August 7, 2008 was for lump sum supply of BS&B Model 1000-IHPV c/w intrumentation, piping, supports and skid assembly as depicted in the Tehno-Commercial Offer. The
combustion safety controller was not specified. The burner was stated as BS&B std. On 11 Septembert 2008 an Instrument List and P&ID Drrawing was submitted for approval that indicated that a Zirco
Safety-Light Model ACL-5500-P Combustion Safety Controller was being used with CSA 149.3 compatible valve train.
Assist Barry Cavens, Cavens & Associates, as instucted to provide comment and education as appropriate to assist BS&B to deliver a unit according to industry standards and fit for the application.
PROJECT INFORMATION
Page 2 of 2
1.2. ENEFEN Design Evaluation
www.enefen.com
T:780-940-3464 / 604-808-1974
ENEFEN
F:866-583-0520
Installation ID
IR810001
Client/Consultant
Tel
(250) 380-5738
Comment:
Owner/Operator
LSD
DESIGN EVALUATION
Created Date
Appliance Tag
F081017
Reviewer
Jarek Bekesza, P.Eng., Manager, Operations &
Email
Project Assessment
Contact
Cel
Plant
DE0810001
(250) 889-5782
Fax
(250) 388-6876
Area
1255
Jurisdiction
British Columbia
Appliance
Indirect Water Bath Evap.
Elevation A.S.L. [m]
Propane storage and vaporization for Sun Peaks Utilities
Function
propane gas utility distribution system
Process
20-Nov-2008
Rev 0
Comment:
4. APPLIANCE DESIGN EVALUATION DETAILS
EVALUATION TOPIC / QUESTION
RESPONSE
Response Ref.
EVALUATION COMMENTS
STATUS
DETERMINATION OF THE APPLICABILITY OF THE SPECIAL FIELD APPROVAL OF GAS FIRED APPLIANCE AND EQUIPMENT FOR OIL AND GAS PROCESS APPLICATION IN ALBERTA TO THIS INSTALLATION
Is the installation site located in the Province of Alberta?
PI
No
Documentation prepared on behalf of client for
review by BC Safety Authority
Noted
Does the function of this installation qualify it for Field Evaluation Program?
PI
Yes
Yes in Alberta under Province Wide Variance
Accepted
Does this combustion system fall under the category of gas-fired equipment used to
produce energy for and oil and gas process?
PI
Yes
Yes, energy for gas evaporation
Accepted
Is this installation being used in a building heating and ventilation application?
PI
No
Enclosure around unit is ventilated
Accepted
Does this installation qualify for Special Field Approval of Gas Fired Appliance and
Equipment For Oil and Gas Process Application in Alberta under the Alberta
Municipal Affairs File Number 16570-G01, Variance VAR-GAS-05-05 [rev 1],
Engineered Designs For
PI
Yes
Yes in Alberta under Province Wide Variance
Accepted
Operational specification submitted?
Pi
Standard Design and Application
Accepted based on standard design
Accepted
Does it provide sufficient explanation of equipment function?
PI
Accepted
Standard Design
Yes
Accepted
No
Accepted
REVIEW OF OPERATIONAL SPECIFICATIONS
Does it address the gas safety design?
Does it raise any concerns regarding gas safety?
Standard Design
REVIEW OF COMPLIANCE WITH PROJECT SPECIFICATIONS AS RELATED TO OVERALL SYSTEM ACCEPTANCE BY OWNER
DESIGN EVALUATION
Page 1 of 8
ENEFEN
F:866-583-0520
www.enefen.com
T:780-940-3464 / 604-808-1974
Statement of compliance with project specifications submitted?
N/A
Is the design fully compliant with project/owner specifications?
Standard Design
Approved by client
Accepted
Are there any non-compliant items affecting gas safety?
Standard Design
No
Accepted
Have all outstanding specification items been resolved?
Standard Design
Approved by client
Accepted
Yes
Approved by client
Accepted
Has the design been approved/accepted by the owner and/or his consultant?
N/A
REVIEW OF SYSTEM RATING
Process Duty in MM BTU/hr
PI
0.75
Accepted
Maximum Fuel Input MM BTU/hr HHV
PI
1.10
Accepted
Minimum Fuel Input MM BTU/hr HHV
Calculated
0.26
Accepted
Design Ambient Temperature Rating
PI
-28 to 40 deg C
Accepted
REVIEW OF FUEL SPECIFICATIONS AND FUEL SAFETY
Fuel Type
PI
Propane
Accepted
Sweet or Sour?
PI
Sweet
Accepted
Dry or Wet?
PI
Dry
Accepted
Fuel Composition
PI
100% Propane
Accepted
Fuel Specific Gravity
PI
1.56
Accepted
Fuel Higher Heating Value (HHV)
PI
2500 BTU/scf
Standard Design
-20 to +40 deg C
Fuel Temperature
Accepted
Accepted
Fuel Supply Pressure[psig]
PI
1.1
Accepted
Fuel Flow Max [SCFH]
PI
440
Accepted
Fuel Flow Min [SCFH]
PI
104
Accepted
Moisture Removal Present?
N/A
N/A
Accepted
Inspection
Yes
Accepted
Is Fuel Odorized?
Standard Design
Yes
Standard practice with personal LEL monitors
required
Accepted
Does Fuel Pressure Inside Building Exceed 66 psig?
Standard Design
No
Propane from storage tank
Accepted
Is H2S Detector Installed?
Standard Design
No
N/A
Accepted
Is LEL Detector Installed?
Standard Design
Yes
LEL monitors will be installed
Accepted
Any Other Sources Of Fuel In The Building?
Standard Design
Yes
Liquid propane piping and vents to outside
Accepted
No
Standard practice with personal 4-head
monitors required
Accepted
Open building
Fuel Preheat Present?
Is Mechanical Ventilation Present?
Standard Design
Size Of Building Air Intake?
N/A
N/A
Upstream Fuel Supply Overpressure Protection PSV Present [SP In psig]?
AS
250
DESIGN EVALUATION
N/A
Accepted
Page 2 of 8
ENEFEN
F:866-583-0520
Direct Fired Or Catalythic Heaters In The Building?
Standard Design
www.enefen.com
T:780-940-3464 / 604-808-1974
No
Open building
Accepted
REVIEW OF BURNER SPECIFICATION
Number Of Main Burners
AS
1
per firetube
Accepted
Are Multiple Burners Installed In A Common Firebox?
N/A
N/A
N/A
N/A
Are Multiple Burners Installed In A Common Windbox?
N/A
N/A
N/A
Forced Or Natural Draft?
AS
Natural draft
Accepted
Accepted
Make
AS
Maxon
Model
AS
Ventive with Sticktite nozzle and secondary air plate
Each Main Burner Input Rating [MM BTU/Hr]
AR
1.10
Burner Fuel Pressure at Max Fire [psig]
AR
18
Burner Fuel Pressure at Min Fire [psig]
Standard Design
1
Burner Fuel Maximum Turndown
Burner Materials
Primary Air Adjustment
Secondary Air Adjustment
Pilot Type
N/A
Accepted
#24 orifice
Accepted
Accepted
Accepted
Calculated
4.2
Standard Design
Cast Iron & Steel
Design
Mixer
Accepted
AS
Secondary Air Plate:
Accepted
Accepted
Accepted
Design
1/2" Natco
Pilot Rating [BTU/Hr]
Standard Design
12,500
#72 orifice
Accepted
Pilot pressure [psig]
Accepted
Accepted
Standard Design
3
Flame Arrestor Installed?
Design
Yes
Accepted
Ignition Type
Design
Electronic
Accepted
Design
Flame Rod
Accepted
Electrical Area Classification
PI
Class I, Zone 2 Gr. C,D
at burner outside windbox
PI
at fuel train
Accepted
PI
at control panel
Accepted
inside windbox
Accepted
Type Of Flame Detectors
REVIEW OF ELECTRICAL DESIGN
Accepted
PI
Non-classified
Power Source ( For Example: Grid, Teg, Solar, Plant, Engine, None Etc)?
Design
Grid
Accepted
Main Power [V/Ph/Hz/A]
Design
120/1/60/8
Accepted
Control Power [V/Ph/Hz/A]
Design
24/-/DC/5
Accepted
Local Disconnect installed?
N/A
N/A
N/A
Multiple Power Sources Present?
Design
Yes
Accepted
Is There A Local ESD Connected To This System?
Design
Yes
DESIGN EVALUATION
From panel in electric room
Accepted
Page 3 of 8
ENEFEN
F:866-583-0520
www.enefen.com
T:780-940-3464 / 604-808-1974
Are All Electric Components CSA Approved?
Design
Yes
Accepted
Is The Control Panel Inspected And Approved?
Design
Yes
Accepted
Are All Electric Components And Panel Rating Appropriate For The Area
Classification?
Design
Yes
Accepted
Are All Electric Components And Panel Rating Appropriate For The Temperature?
Design
Yes
Accepted
Type of instrument gas
PI
N/A
N/A
Instrument Gas Pressure [Psig]
PI
N/A
N/A
Is Instrument Gas Clean And Dry?
Shop Inspection
N/A
N/A
Instrument Gas Dew Point [Deg C]
Shop Inspection
N/A
N/A
Instrument Gas Filter, Coalescer, Drip Dot, Scrubber, Etc, Installed?
Shop Inspection
N/A
N/A
N/A
N/A
N/A
Shop Inspection
N/A
N/A
Design
Triple setpoint in Profire BMS add on card
Accepted
Standard Design
Yes, part of BMS
Accepted
Low Level Protection Interlocked With The BMS?
Design
Yes
Level switch in expansion tank
Accepted
Fuel Gas PSHH / PSLL
Design
Yes
Accepted
Furnace Pressure PSHH
N/A
N/A
N/A
Instrument Gas PSLL
N/A
N/A
Are Any Other Permissives Incorporated?
Design
Yes
Burner Management System Type?
Design
Certified Packaged system
Accepted
BMS Make And Model?
Design
Profire 1100
Accepted
Are Isolation Valves Installed On Safety Pressure Switches Lockable In Open
Position?
Design
Yes
Accepted
Are Pressure Gauges Of Appropriate Ranges?
Design
Yes
Accepted
Are Pressure Gauges Protected From Overpressure?
Design
Yes
Accepted
Is low fire stop incorporated?
Is Low Fire Start Incorporated For System In Excess Of 1 MM BTU/Hr HHV Fuel
Input?
Is Overtravel Proof Of Closure Switch Incorporated For Single ESD Valve System In
Design
HI/LO Fire design with delay timer
Accepted
Standard Design
Yes
N/A
Double solenoid valves
N/A
N/A
REVIEW OF INSTRUMENT GAS SYSTEM
Instrument Gas Consumption [SCFH]
Instrument Gas Heat Tracing?
REVIEW OF CONTROLS
HIHI temperature switch
High Temperature Protection Separate From Temperature Control And Interlocked
With The BMS?
Excess Of 400 000 BTU/Hr HHV Fuel Input?
Is Proof Of Closure Switch Incorporated On Other Valves?
DESIGN EVALUATION
N/A
Liquid propane controls
Accepted
Accepted
N/A
N/A
Page 4 of 8
ENEFEN
F:866-583-0520
www.enefen.com
T:780-940-3464 / 604-808-1974
Method Of Temperature Control?
Design
Temperature Switch
Accepted
Ignition type
Design
Electronic
Accepted
N/A
N/A
Design
Delay timer
Is Fuel Measurement Method Incorporated?
Is slow valve opening incorporated?
Is Fuel to Air Ratio Controller (FARC) Incorporated?
N/A
Accepted
N/A
N/A
N/A
Are All Controls CSA Approved?
Design
Yes
Accepted
Are All Components Rated For The Specified Ambient Temperature Range?
Design
Yes
Accepted
N/A
N/A
N/A
Main Fuel Inlet Connection
Design
1" fuel inlet line
Valve, regulator and meter installed in the field
Accepted
Fuel Train Overpressure Protection Method?
Design
Inlet from tank at 30 psig
Accepted
Is Manual Inlet Valve To Fuel Train Accessible / Certified?
Design
Neo2500 valve certified
One valve upstream of regulator and meter,
second valve inside furl train box
Accepted
Fuel Strainer / Drip Pot?
Design
Y-strainer
Appliance Main Pressure Regulation Method?
Design
627 Fisher regulator
Does main regulator(s) have an internal relief
Standard Design
No
PRV rated for downstream pressure
Accepted
External Pressure Relief
Standard Design
No
Not required for downstream components
Accepted
Design
UE 12 Series
Approved component list
Accepted
Standard Design
ASCO certiied valves to CSA 6.5 C/I
Accepted
PLC BASED BMS REVIEW
Processor(s)?
REVIEW OF MAIN FUEL TRAIN DESIGN
Low Gas Pressure Switch?
Are Main Safety Shutoff ESD Valve(S) Certified To CSA 6.5 C/I?
Overtravel Proof of Closure Switch Certified to ANSI Z21.21-2002?
Accepted
Accepted
N/A
N/A
Temperature Control Valve TCV?
Design
HI/LO Fire bypass with third solenoid nad regulator
Accepted
High Gas Pressure Switch?
Design
UE 12 Series
Accepted
Is Main Burner Test Firing Valve Certified?
Design
Accepted
Are All Main Fuel Train Components Suitable For Fuel Used
Standard Design
Yes
Accepted
Are All Main Fuel Train Components Suitable For Design Ambient Temperature
Range?
Standard Design
Yes
Accepted
Sufficient pressure test points?
Design
Yes
Accepted
Sufficient unions / flanges for maintenance?
Design
Yes
Accepted
Is Manual Inlet Valve To Pilot Train Certified?
Design
Pilot Train Pressure Regulation Method?
Design
Fisher 67 regulator
Accepted
Pilot Fuel train Overpressure Protection
Standard Design
No
Not required for downstream components
Accepted
N/A
REVIEW OF PILOT FUEL TRAIN DESIGN
DESIGN EVALUATION
Accepted
Page 5 of 8
ENEFEN
F:866-583-0520
www.enefen.com
T:780-940-3464 / 604-808-1974
Is Pilot Safety Shutoff ESD Valve Certified To CSA 6.5 C/I?
Design
ASCO certiied valves to CSA 6.5
Is Pilot Test Firing Valve Certified?
Design
Accepted
Accepted
Does Pilot train have sufficient pressure test points?
Accepted
Design
Yes
Are All Pilot Fuel Train Components Suitable For Fuel Used?
Standard Design
Yes
Accepted
Are All Pilot Fuel Train Components Suitable For Design Ambient Temperature
Range?
Standard Design
Yes
Accepted
Piping Material Used?
Standard Design
Piping: ASTM A333 GR.6, Sch.80 SMLS,
Pipe fittings: ASTM A350 GR. LF2, 3000 lbs.,
Tubing: 316SS, min 3/8" O.D. ASTM A269 SMLS Tubing
Accepted
Fabrication Method (welded, screwed, tubing, etc)
Standard Design
Screwed Piping, Swagelok or equivalent compression fittings.
Accepted
Are There Any Low Point Traps In The Piping / Tubing?
Shop Inspection
No
Accepted
Are There Sufficient Pressure Test Points In The Piping?
Shop Inspection
Yes
Accepted
Are There Sufficient Unions In The Piping?
Shop Inspection
Yes
Accepted
N/A
N/A
N/A
Is Piping / Tubing Material Suitable For Fuel Used?
Standard Design
Yes
Accepted
Is Piping / Tubing Material Suitable For Design Ambient Temperature Range?
Accepted
REVIEW OF FUEL TRAIN PIPING
Is Heat Tracing/Insulation Of Piping And / Or Tubing Required?
Standard Design
Yes
Are there means to drain the pipe?
Shop Inspection
Yes
Drip leg
Accepted
Is piping properly supported and anchored?
Shop Inspection
Yes
Piping supported off heater
Accepted
Are there any mechanical stresses on piping?
Shop Inspection
No
Piping supported off heater
Accepted
Is Sour Gas Vented?
N/A
N/A
Do Vents Have To Be Connected To Flare?
N/A
No
N/A
Shop Inspection
Yes
Accepted
Are Instrument Gas (Flammable) Vents Installed?
N/A
N/A
N/A
Are PSV's Vented Separately?
N/A
N/A
N/A
Are vent connections to devices reduced?
Shop Inspection
No
Accepted
Are Any Of The Vent Lines Combined?
Accepted
REVIEW OF VENTING ON PREPACKAGED SYSTEMS
Are All Flammable Gas Vents Piped To Safe Location?
N/A
Shop Inspection
No
Are There Any Vent Lines Under The Building?
Shop Inspection
No
Are Vent Terminations Away From Building Openings?
Shop Inspection
Yes
Are There Any Vent Terminations Close To Operating Personnel?
Shop Inspection
No
Accepted
Are Vent Terminations Equipped With Screens?
Shop Inspection
Yes
Accepted
Vent Piping Materials
Shop Inspection
Steel
Accepted
Is Vent Line Sizing And Installation Compliant With CSA B149.1- 05 Requirements?
Shop Inspection
Yes
Accepted
DESIGN EVALUATION
Accepted
Open building design
Accepted
Page 6 of 8
ENEFEN
F:866-583-0520
www.enefen.com
T:780-940-3464 / 604-808-1974
REVIEW OF MARKING AND ALARMS
Rating Plate Design Submitted?
Standard Design
Yes
Accepted
Manufacturer's or Vendor's Name On Rating Plate?
Standard Design
Yes
Accepted
Location and Date Of Manufacture On Rating Plate?
Standard Design
Yes
Accepted
Appliance Type On Rating Plate?
Standard Design
Yes
Accepted
Appliance Identification (Model, Serial Number) On Rating Plate?
Standard Design
Yes
Accepted
Electrical Specifications On Rating Plate?
Standard Design
Yes
Accepted
Type of Fuel, BTU/SCF HHV On Rating Plate?
Standard Design
Yes
Accepted
Maximum Fuel Input Rating BTU/hr HHV on Rating Plate?
Standard Design
Yes
Accepted
Design Altitude ft A.S.L. on Rating Plate?
Standard Design
Yes
Accepted
Fuel Inlet Pressure At The Point Of Connection PSIG on Rating Plate?
Standard Design
Yes
Accepted
Maximum Burner Manifold Fuel Pressure On Rating Plate?
Standard Design
Yes
Accepted
Minimum Burner Manifold Fuel Pressure On Rating Plate?
Standard Design
Yes
Accepted
Place for Approval Sticker provided?
Standard Design
Yes
Accepted
Electrical Approval/Inspection Sticker Present?
Shop Inspection
Yes
Multiple Sources Of Voltage Sign Present?
Shop Inspection
Yes
H2S warning sign installed?
N/A
N/A
N/A
Non-Odorized Fuel Warning Sign installed?
N/A
N/A
N/A
Fuel Train Pressure Tested In The Shop?
Shop Inspection
Yes
Bubble testng
Accepted
Wiring Continuity / Loop Check Done In The Shop?
Shop Inspection
Yes
Except remote panel
Field Inspection
Functional Test Performed In The Shop?
Shop Inspection
Yes
Burner fired
Accepted
Electrical Inspection Conducted In The Shop?
Shop Inspection
Yes
Instruments Calibrated In The Shop?
Shop Inspection
Yes
Except liquid propane TSL
Field Inspection
Operating And Maintenance Manual Available?
Shop Inspection
Yes
Accepted
Installation Instruction Included?
Shop Inspection
Yes
Accepted
Operating Instructions Included?
Shop Inspection
Yes
Accepted
Maintenance And Troubleshooting Instructions Included?
Shop Inspection
Yes
Accepted
P&ID Included?
Shop Inspection
Yes
Accepted
BOM Included?
Shop Inspection
Yes
Accepted
Electrical Drawings Included?
Shop Inspection
Yes
Accepted
N/A
N/A
N/A
Shop Inspection
Yes
Accepted
Accepted
Sign attached
Accepted
REVIEW OF SHOP TESTING CERTIFICATES
Accepted
REVIEW OF SYSTEM DOCUMENTATION
Shutdown Key Included?
List Of Setpoints Included?
DESIGN EVALUATION
Page 7 of 8
ENEFEN
F:866-583-0520
www.enefen.com
T:780-940-3464 / 604-808-1974
Test Reports Included?
Shop Inspection
Yes
Accepted
Maintenance And Troubleshooting Instructions Included?
Shop Inspection
Yes
Accepted
Component Manuals Included?
Shop Inspection
Yes
Accepted
Room For Copy Of Approval Report Provided?
Shop Inspection
Yes
Accepted
Other Comments:
Evaluation topics marked with Status: "Field Inspection" could not be addressed during the Design Evaluation because they were undetermined or incomplete at this stage of the project.
The Design Approval in Principle is subject to field inspection.
DESIGN EVALUATION
Page 8 of 8
1.3. ENEFEN Design Approval in Principle
www.enefen.com
T:780-940-3464 / 604-808-1974
ENEFEN
F:866-583-0520
Installation ID
Client/Consultant
Tel
IR810001
(250) 380-5738
Comment:
Owner/Operator
LSD
DESIGN APPROVAL
Created Date
Contact
20-Nov-2008
Cel
Plant
F081017
(250) 889-5782
Fax
(250) 388-6876
Area
1255
Jurisdiction
British Columbia
Appliance
0
Comment:
1. REQUIREMENTS USED AS BASIS FOR EVALUATION:
Alberta Safety Code Act, Chapter S-1 section 38(1), Gas Code Regulation AR113/2005
Alberta Municipal Affairs File Number 16570-G01, Variance VAR-GAS-05-05[rev 2]
CAN/CSA B149.1-05(07) - Natural Gas and Propane Installation Code
CAN/CSA B149.3-05(07) - Code For the Field Approval Of Fuel-Related Components On Appliances And
Equipment
CSA Std C22.1-06 - Canadian Electric Code Part I
CSA Standard C22.2 No. 0-M91 General Requirements - Canadian Electrical Code, Part II
Approved By:
P.Eng. Stamp
Appliance Tag
Reviewer
Jarek Bekesza, P.Eng., Manager, Operations & Project
Email
Assessment
Function
Process
DA0810001
Rev 0
Signature:
Date:
20-Nov-08
Permit to Practice:
P-8977
2. SCOPE:
Our evaluation is limited only to the safety aspects of the combustion system as required by the above regulations and does not include other design aspects, such as detailed compliance APPROVAL IN PRINCIPLE ISSUED UNDER THE AUTHORITY OF
with the project or owner specifications, and the suitability of the equipment for any specific purpose, process conditions or performance requirements. We base our acceptance in this
:
regard on a general statement of compliance with project specifications, and on documentation received for evaluation.
Alberta Safety Codes Act, Chapter S-1 section 38(1), Gas Code
Regulation AR113/2005 and Alberta Municipal Affairs File 16570G01 Province Wide Varinace VAR-GAS-05-05(rev 2) Engineered
3. APPROVAL VALIDITY:
Designs For Site-Specific Gas-Fired Process Equipment
This approval is valid for operation of the subject equipment in oil and gas industry process application in the province of Alberta only and is void if this appliance is altered or relocated.
4. APPROVAL DETAILS AS FOUND IN THE DESIGN EVALUATION DOCUMENT:
APPROVAL IN PRINCIPLE
DE0810001
Design Approved in Principle
Page 1 of 1
1.4. ENEFEN Field Inspection
1.5. ENEFEN Final Approval
2. BS&B’s P&ID and Bill Of Materials
Jozef Jachniak
14 Nov 2008
P08977
3. CSA B149.3 Compliant Rating Plate Layout
www.enefen.com
T:780-940-3464 / 604-808-1974
ENEFEN
F:866-583-0520
IR810001
Installation ID
Client/Consultant
Tel
Owner/Operator
LSD
Contact
Plant
Propane storage and vaporization for Sun
Peaks Utilities propane gas utility distribution Function
system
Process
Appliance Tag
F081017
Rev 0
RP0810001
Reviewer
14-Nov-2008
Jarek Bekesza, P.Eng., Manager, Email
Cel
(250) 380-5738
Comment:
RATING PLATE
Created Date
(250) 889-5782
Fax
(250) 388-6876
Area
Sun Peaks, BC (50 km driving distance
northeast of Kamloops)
1255
Jurisdiction
British Columbia
Appliance
Comment:
GAS FIRED EQUIPMENT / APPLIANCE RATING PLATE
Manufacturer
Black Sivalls & Bryson BS&B
Built in
Nisku, AB
Model No.
1000 IH PV
Serial No.
F081017
Equipment Type
1255
Elevation A.S.L. [m].
Maximum Fuel Input HHV [MM BTU/hr]
1.10
F081017
Tag No.
Maximum Ambient [deg C]
40
Fuel Inlet Pressure [kPaG]
207
Process Duty [MM BTU/hr]
0.75
Maximum Burner Pressure [kPaG]
124
Minimum Burner Pressure [kPaG]
7
Propane
Pressure [kPaG]
21
Electrical Area
Classification
Main Power
[V/Ph/Hz/A]
120
RATING PLATE
2008
-28
Pilot Gas
Provide Room for Approval Sticker 2-1/2” (W) x 3-1/4” (H)
10
Minimum Ambient [deg C]
Propane
Fuel Type
Built [MM/YY]
Sun Peaks Propane
Location
704988-2SEP08
Project No.
Not Applicable
Instrument Gas
1
60
8
Control Power
[V/Ph/Hz/A]
24
-
Pressure
[kPaG]
N/A
DC
5
Provide Room for Tune-Up Label, Avery 5524 Weather Proof 3-1/3” (W) x 4” (H)
Page 1 of 1
4.
Job Specific Setpoints
www.enefen.com
T:780-940-3464 / 604-808-1974
ENEFEN
F:866-583-0520
Installation ID
IR810001
Client/Consultant
Tel
Comment:
(250) 380-5738
4-Jul-2008
Rev 0
Reviewer
Jarek Bekesza, P.Eng., Manager, Operations & Project
Email
Assessment
Contact
Cel
SP0810001
Jozef Jachniak
(250) 889-5782
Fax
(250) 388-6876
Area
Sun Peaks, BC (50 km driving distance northeast of
Kamloops)
-
Owner/Operator
LSD
Process
SETPOINTS
Created Date
Vaporizer Building, Sun Peaks Propane Plant
Plant
Function
Appliance Tag
F081017
1,255 m (4,117')
Jurisdiction
British Columbia
Appliance
Indirect Water Bath Heater
0
Comment:
INSTALLATION SPECIFIC SETPOINTS AND MEASUREMENTS
SETPOINT OR MEASUREMENT
English Unit
English Unit Value
Metric Unit
Metric Unit Value
Fuel Supply Pressure to Fuel Train
psig
30.00
kPag
689.47
PRV102C – Main Appliance Pressure Regulator
psig
18.00
kPag
124.10
TSL101C (Profire) – Burner runs but alarms below SP
deg F
100.00
deg C
37.78
TSH101C (Separate) – Low fire above SP
deg F
180.00
deg C
82.22
sec
30.00
sec
30.00
TSHH101C (Profire) – Pilot only above SP
deg F
185.00
deg C
85.00
TSHH102C (Profire) – Burner off above SP
deg F
190.00
deg C
87.78
TSHH103C (Profire) – Alarm above SP (reset required)
deg F
195.00
deg C
90.56
PSLL201C – Gas Pressure Switch Low Trip
psig
3.00
kPag
20.68
LFT101C (Timer) – Delay switching to High fire
PSHH201C – Gas Pressure Switch High Trip
psig
25.00
kPag
172.37
PRV205C – Low Fire Pressure Regulator
psig
4.00
kPag
27.58
PRV302C – Pilot Pressure Regulator
psig
4.00
kPag
27.58
Burner Orifice Size
drill
#23
drill
#23
Pilot Oriifce Size
drill
#54
drill
#54
Stack Reading Date
Burner Pressure
Stack Temperature
Stack Oxygen
dd-mmm-yy
dd-mmm-yy
psig
kPag
deg F
deg C
%
%
Stack CO
ppm
ppm
Stack NOx (corrected to 3% O2)
ppm
ppm
Thermal Efficiency HHV
%
%
Fuel Input HHV
MM Btuh
GJ/h
Absorbed Energy
MM Btuh
GJ/h
Other Comments:
SETPOINTS AND MEASUREMENTS
Page 1 of 1
5. Job Specific Wiring Diagrams
CABLE SCHEDULE
cable schedule c/w wire numbers
REV 3
core #
from
terminal #
wire tag
to
1
2
3
4
5
6
7
8
9
10
11
12
13
14
bare
CBC
CBC
CBC
CBC
CBC
CBC
CBC
CBC
CBC
CBC
CBC
CBC
CBC
CBC
CBC
1
2
4
6
7
8
9
10
12
14
16
18
19
20
3
CBC-1-VJBC-1
CBC-2-VJBC-2
CBC-4-VJBC-5
CBC-6-VJBC-6
CBC-7-VJBC-7
CBC-8-VJBC-8
CBC-9-VJBC-9
CBC-10-VJBC-15
CBC-12-VJBC-17
CBC-14-VJBC-23
CBC-16-VJBC-32
CBC-18-VJBC-20
CBC-19-VJBC-21
CBC-20-VJBC-22
ground
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
1
2
5
6
7
8
9
15
17
23
32
20
21
22
3
field contractor
field contractor
field contractor
field contractor
field contractor
field contractor
field contractor
field contractor
field contractor
field contractor
field contractor
field contractor
field contractor
field contractor
field contractor
1
2
3
bare
CBC
CBC
CBC
CBC
50
53
55
46
CBC-50-VJBC-43
CBC-53-VJBC-46
CBC-55-VJBC-50
ground
VJBC
VJBC
VJBC
VJBC
43
46
50
41
field contractor
field contractor
field contractor
field contractor
1
2
3
CBC
CBC
CBC
21
58
47
CBC-21-ACP-10
CBC-58-ACP-10A
CBC-47-ACP-1171
ACP
ACP
ACP
10
10A
1171
field contractor
field contractor
field contractor
1
2
3
4
CBC
CBC
CBC
CBC
25
28
59
60
CBC-25-ODJB-9
CBC-28-ODJB-9A
CBC-59-ODJB-11
CBC-60-ODJB-11A
ODJB
ODJB
ODJB
ODJB
9
9A
11
11A
field contractor
field contractor
field contractor
field contractor
1
2
CBC
CBC
1
2
CBC-1-DPE-CCT #4A
CBC-2-DPE-CCT #4A
DPE
DPE
CCT #4A field contractor
CCT #4A field contractor
1
2
3
4
5
6
7
8
9
10
11
12
13
14
bare
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
VJBC
1
2
4
6
7
8
12
13
16
18
23
24
29
30
3
VJBC-1-BMS-24VDC+
VJBC-2-BMS-COMMON
VJBC-4-BMS-STATUS+
VJBC-6-BMS-STATUSVJBC-7-BMS-START+
VJBC-8-BMS-STARTVJBC-12-BMS-ESD+
VJBC-13-BMS-ESDVJBC-16-BMS-MAIN+
VJBC-18-BMS-MAINVJBC-23-BMS-PILOT+
VJBC-24-BMS-PILOTVJBC-29-BMS-PR.SW+
VJBC-30-BMS-PR.SWground
BMS
BMS
BMS
BMS
BMS
BMS
BMS
BMS
BMS
BMS
BMS
BMS
BMS
BMS
BMS
24VDC+
COMMON
STATUS+
STATUSSTART+
STARTESD+
ESDMAIN+
MAINPILOT+
PILOTPR.SW+
PR.SWGROUND
1
2
VJBC
VJBC
9
10
VJBC-9-LSLL101C
VJBC-10-LSLL101C
LSLL101C
LSLL101C
10/27/2008
terminal # wired by
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
PAGE 1 of 2
CABLE SCHEDULE
core #
from
terminal #
wire tag
to
1
2
VJBC
VJBC
16
18
VJBC-16-SSV202C
VJBC-18-SSV202C
SSV202C
SSV202C
BS&B contractor
BS&B contractor
1
2
VJBC
VJBC
18
20
VJBC-18-TSH101C
VJBC-20-TSH101C
TSH101C
TSH101C
BS&B contractor
BS&B contractor
1
2
VJBC
VJBC
19
21
VJBC-19-SSV203C
VJBC-21-SSV203C
SSV203C
SSV203C
BS&B contractor
BS&B contractor
1
2
VJBC
VJBC
19
22
VJBC-19-SSV205C
VJBC-22-SSV205C
SSV205C
SSV205C
BS&B contractor
BS&B contractor
1
2
VJBC
VJBC
23
24
VJBC-23-SSV305C
VJBC-24-SSV305C
SSV305C
SSV305C
BS&B contractor
BS&B contractor
1
2
VJBC
VJBC
25
26
VJBC-25-PSHH206C
VJBC-26-PSHH206C
PSHH206C
PSHH206C
BS&B contractor
BS&B contractor
1
2
VJBC
VJBC
26
27
VJBC-26-PSLL104C
VJBC-27-PSLL104C
PSLL104C
PSLL104C
BS&B contractor
BS&B contractor
1
2
VJBC
VJBC
43
44
VJBC-43-LSHH401C
VJBC-44-LSHH401C
LSHH401C
LSHH401C
BS&B contractor
BS&B contractor
1
2
VJBC
VJBC
45
46
VJBC-45-TSL401C
VJBC-46-TSL401C
TSL401C
TSL401C
BS&B contractor
BS&B contractor
1
2
VJBC
VJBC
47
48
VJBC-47-SSV401C
VJBC-48-SSV401C
SSV401C
SSV401C
BS&B contractor
BS&B contractor
1
2
VJBC
VJBC
49
50
VJBC-49-ZSO401C
VJBC-50-ZSO401C
ZSO401C
ZSO401C
BS&B contractor
BS&B contractor
1
2
BMS-PI
BMS-PI
TC+
TC-
BMS-PI-TC+-TE102C
BMS-PI-TC--TE102C
TE102C
TE102C
BS&B contractor
BS&B contractor
1
2
BMS
BMS
TC+
TC-
BMS-TC+-TE306C
BMS-TC--TE306C
TE306C
TE306C
BS&B contractor
BS&B contractor
1
2
3
4
BMS
BMS
BMS
BMS
COIL+
COILCOIL-1
COIL-G
BMS-COIL+-IX306C
BMS-COIL--IX306C
BMS-COIL-1-IX306C
BMS-COIL-G-IX306C
IX306C
IX306C
IX306C
IX306C
BS&B contractor
BS&B contractor
BS&B contractor
BS&B contractor
10/27/2008
terminal # wired by
PAGE 2 of 2
6. Liquid Propane & Vapourizer Parts Manuals
6.1. SOR Level Switch Manual
Type 1510
Electric Level Switch
Form 498
Type 1510 is a horizontally mounted,
float-operated level switch suitable for plant
and OEM applications where open or closed
contacts are required to signal presence or
absence of liquid at a discrete level. The float
extension arm moves a magnet which actuates
(deactuates) a hermetically sealed reed switch.
Actuation (deactuation) can be reversed by
rotating the unit 180 degrees.
Dimensions
Float
Body
14.2
0.56
1/2” NPT(F)
Electrical
Connection
1-1/2” NPT(M)
Process Connection
144.3
5.68
Linear = mm
in.
78.5
3.09
(Reference)
Product Specifications
Mounting (Half coupling only)
Orientation
Horizontal mount only
Connection Size
1-1/2” NPT(M) Standard
For
Change
To
2” NPT(M)
G5A
G2A
Flanged Mounting
G5A
*
*See flange table on page 2 for option designator
(316SS construction only)
Maximum Process Pressure
1500 psi (100 bar)
Electrical
Switch Type
Hermetically sealed reed switch
with 18” 20 AWG wire leads
Switch Rating (resistive)
1 amp at 110 VAC
3 amps at 28 VDC
Housing Class I, Groups A, B, C & D; Divisions 1 & 2
Relay Housing Class I, Groups C & D; Divisions 1 & 2
Connection Size
1/2” NPT(F)
Contact Form
SPST
(For SPDT change W9 to W1 in the model number.)
Minimum Specific Gravity
0.45
Design Code
ANSI B31.3
Shipping Weight
Approximately 6 lbs. (3 kg)
Agency Listing
CSA Certified (optional). See Page 2.
Design and specifications are subject to change
without notice. For latest revision, see
www.sorinc.com.
How to Order
Select model number from table below. Accessory designator(s) may be added after ES if required.
See page 2.
Body Material
303SS*
Standard
316SS
Float Material
Process Rating
Model Number
316SS (Standard)
1500 psi - 40 to 400ºF
100 bar
1510B - G5A - C - W9 - ES
Monel
900 psi - 40 to 400ºF
62 bar
1510B - G5A - M - W9 - ES
Polypropylene
5000 psi - 40 to 150ºF
345 bar
1510B - G5A - S - W9 - ES
316SS
1500 psi - 40 to 400ºF
100 bar
1510C - G5A - C - W9 - ES
Monel
900 psi - 40 to 400ºF
62 bar
1510C - G5A - M - W9 - ES
Polypropylene
5000 psi - 40 to 150ºF
345 bar
1510C - G5A - S - W9 - ES
*Also known as ASME SA 320 Grade B8F.
Registered Quality System to ISO 9001
Type 1510
Electronic Level Switch
Optional Flanges
Optional Flanges (316SS) construction only
Designator
Raised Face Flange
G7C
G7D
2-1/2”
G7E
G3C
G3D
3”
G3E
Designator
150#
G4C
300#
G4D
600#
G6C
150#
G6D
300#
4”
150#
300#
6”
150#
300#
On flanged units, the float will be detached from the
unit during shipping.
600#
Optional Accessories
Raised Face Flange
Add option designator(s) to end of model number.
Description
Designator
Wetted parts are cleaned for industrial oxygen service.
BB
3/4” NPT(F) conduit connection.
CR
CSA Certified. Class I, Group A, B, C, D; Divisions 1 & 2.
For relay option; Class I, Group C & D, Divisions 1 & 2.
CS*
Canadian Registration Number (CRN). Maximum allowable pressure rating is 1500 psi. Consult the
factory for details.
CV
Manual check accessory (uses Viton GLT o-rings).
MC**
NACE construction - MR-01-75. Available only with 316SS materials of construction.
NC
Tag, fiber. Attached with plastic wire to housing. Stamped with customer-specified tagging information.
PP
24 VDC powered DPDT relay in explosion proof terminal box. Contact
rating: 10 amps @ 115 VAC. Class I, Group C, D; Divisions 1 & 2.
RB
120 VAC powered DPDT relay in explosion proof terminal box. Contact
rating: 10 amps @ 115 VAC. Class I, Group C, D; Divisions 1 & 2.
RC
Tag, stainless steel. Attached with stainless steel wire to housing. Stamped with customer-specified
tagging information.
RR
Stainless steel nameplate permanently attached to housing. Stamped with customer specified tagging
information.
TT
Fungicidal varnish. Covers exterior except working parts.
VV
Epoxy coating. Exterior only. Polyamide epoxy with 316SS pigment.
YY
ANSI B31.3 certificate of conformance.
CZ
*CS option is required on all flange mounted units.
**Manufacturer limits on Viton GLT are -40 to 400°F.
Replacement Parts
Part Number
Description
3130-091
SPST Hermetically Sealed Reed Switch Capsule
3130-242
SPDT Hermetically Sealed Reed Switch Capsule
3130-106
SPST Hermetically Sealed Reed Switch Capsule for CSA Certified units
3130-243
SPDT Hermetically Sealed Reed Switch Capsule for CSA Certified units
3130-052
316SS Float Assembly
Limited Warranty
SOR® agrees to repair or replace any switch found to be defective in material or workmanship within five years from date of shipment. The
limited warranty is valid only if the switch was installed in accordance with published factory installation instructions, operated within the
design limitations stated on the nameplate, and returned to the factory for inspection, freight prepaid, within the warranty period. Contact the
factory for return authorization. No claim for labor or consequential damages will be allowed.
Form 498 (11.05) © 2005 SOR Inc.
14685 West 105th Street, Lenexa, Kansas 66215
913-888-2630
Toll Free 800-676-6794
www.sorinc.com
Type 1510 Side-Mount
Electric Level Switch
General Instructions
Linear = mm
in.
Body
Float
14.2
0.56
1/2” NPT(F)
Electrical
Connection
1-1/2” NPT(M)
Process Connection
144.3
5.68
78.5 (REF)
3.09
Installation
General
The SOR Type 1510 Electric Level Switch mounts into
the side of a vessel.
Electric switching action is provided by the float
moving a magnet into the field of a hermetically
sealed reed switch capsule.
The unit may be mounted for either high or low liquid
level alarm by rotating the switch body to the proper
position. The body wrench flats provide for ease of
rotation and proper positioning. See decal on
housing.
Design and specifications are subject to change
without notice.
Before Installation of the Level Switch
1. Inspect the unit for any shipment damage.
2. Check for mechanical clearance of the float. Float
must move freely without binding throughout its
stroke.
3. Use an acceptable thread compound when installing unit to ensure a leak-free fit and avoid thread
galling.
4. To achieve required function, install unit according
to the nameplate instructions shown here.
The unit may be mounted in any of the following
installation arrangements.
a. 1-1/2” NPT half coupling (No full coupling).
b. 2” NPT full coupling. (Use in conjunction with
2 x 1-1/2” NPT bushing as required.)
c. 2” NPT pipe tee. (Use in conjunction with 2 x 1-1/2”
NPT bushing as required.)
d. Optional flanged mounting.
e. Optional chamber mounting.
Electrical Connection
Ensure that wiring conforms to all applicable local and
national electrical codes and install unit(s) according
to relevant national and local safety codes.
Electrical connection is free wire leads with a 1/2”
NPT(F) conduit connection. Use two wrenches — one
to hold hex conduit connection, the other to tighten
conduit fitting. Switching element is a hermetically
sealed reed switch.
SPST
Reed Switch
Capsule
Normally Open White Lead
Common Black Lead
SPDT
Reed Switch
Capsule
THIS SIDE UP
N.C. @ HIGH LEVEL
THIS SIDE UP
N.C. @ LOW LEVEL
THIS SIDE UP
N.C. @ LOW LEVEL
THIS SIDE UP
N.C. @ HIGH LEVEL
Nameplate Position
for Low Level Alarm
Normally Closed White Lead
Nameplate Position
for High Level Alarm
NOTE: NC - indicates circuit is closed
For latest revision, see www.sorinc.com
SOR Form 451 (06.01) Printed in USA
Common Black Lead
Normally Open Blue Lead
Wiring schematic for DPDT relay option shown on
reverse.
CAUTION: Do not exceed 1 amp @ 110 VAC or 3
amps @ 28 VDC (resistive). High current input to
switch will cause permanent damage to contacts.
Page 1 of 2
Wiring for DPDT Relay
For Type 1510 Level Switches equipped with DPDT relays, a wiring schematic and pin position schematic is
shown below. When the 1510 is actuated, the coil will energize and “make” both NO1 and NO2 while it will
“break” NC1 and NC2. This provides a DPDT circuit.
Switch Capsule
Black
Lead
White
Lead
8
C2
NC 2
NO 2
5
6
C1
NC 1
NO 1
4
3
2
1
1
8
C1
7
C2
2
Power
Supply
Relay Coil
7
3
NO 1
4
NC 1
5
NC 2
6
NO 2
Troubleshooting
Symptom
Probable Cause
1. Float in actuated position but no output signal.
a. No power supply.
b. Switch damaged. (Replace.)
2. Float in de-actuated position but still receiving an
output signal.
a. Switch damaged. (Replace.)
3. Control will not function when installed but operates
when removed from process connection.
a. Inadequate float travel. Float travel restricted by
mounting nozzle. See Mounting Requirements.
4. Liquid in vessel at the actuation level but unit does
not respond.
a. Leaky or collapsed float. (Replace.)
b. Liquid specific gravity too low.
c. Float stem bound up or dirty. (Clean.)
Replacement Parts
Part Number
Description
3130-091
SPST Hermetically Sealed Reed Switch Capsule
3130-242
SPDT Hermetically Sealed Reed Switch Capsule
3130-106
SPST Hermetically Sealed Reed Switch Capsule for CSA Certified units
3130-243
SPDT Hermetically Sealed Reed Switch Capsule for CSA Certified units
3130-052
316SS Float Assembly
All information and specifications in this bulletin are current at the time of printing. Changes in product design
and specifications may occur without notice. Contact the SOR representative in your area or the factory for the
current revision of this bulletin.
14685 West 105th Street, Lenexa, Kansas 66215
Page 2 of 2
913-888-2630
Fax 913-888-0767
www.sorinc.com
SOR Form 451 (06.01) Printed in USA
6.2. United Electric TEMPERATURE SWITCH Manual
IMT120-06
120 Series Explosion Proof
Temperature and Indicating
Temperature Switches and Controls
Local Mount Types B121, B122, C120
Remote Mount Types E121, E122, E122P, F120;
820E, 822E
UNITED ELECTRIC
CONTROLS
Installation and Maintenance
Instructions
Please read all instructional literature carefully and thoroughly before starting. Refer to the final page for the listing of
Recommended Practices, Liabilities and Warranties.
GENERAL
Misuse of this product may cause explosion and personal injury. These instructions must be thoroughly
read and understood before unit is installed.
This equipment is suitable for use in Class I, Divisions 1
& 2, Groups B, C and D; Class II, Divisions 1 & 2, Groups E,
f and G; class III; or non-hazardous locations only.
This equipment is atex certified for equipment category 2. Suitable for appropriate use in gas zone 1 & dust
zone 21 applications.
0539 DEMKO 03 ATEX 0305048
II 2 G EEx d IIC T6
II 2 D T+ 85 °C
-40 °C ≤ Tamb. ≤ + 71°C, IP66
a sensing element may be occasionally operated without
adversely affecting set point calibration and repeatability. Maximum temperature stated in literature and on
nameplate must never be exceeded, even by surges in
the system. Occasional operation of unit up to max.
temperature is acceptable (e.g., start-up, testing). Continuous
operation should be restricted to the designated adjustable
range.
Part I - Installation
TOOLS NEEDED
Screwdriver
Adjustable Wrench to 1 1/2”
MOUNTING
These products do not have any field replaceable
parts. Any substitution of components may impair suitability for Class I, Division 1.
To prevent ignition of hazardous atmospheres, disconnect supply circuits before opening. keep cover tight
while circuits alive.
Local Mount Types B121, B122, C120 (Immersion Stem)
The 120 Series temperature switch utilizes a liquid filled sensing stem
which expands or contracts against a bellows to detect a temperature
change. The response at a pre-determined set point(s), actuates or
deactuates a SPDT, dual SPDT, or DPDT snap-acting microswitch(es),
converting the temperature signal into an electronic signal. Control set
point(s) may be varied by turning the adjustment hex (C120) or the external knob(s) and pointer(s) (B121, B122) according to the procedures
outlined (see Part II– Adjustments).
Remote Mount Types E121, E122, F120 (Bulb & Capillary)
Remote Mount & Indicating Temperature Types 820E, 822E (Bulb
& Capillary)
The 120 Series temperature switch and control utilizes a liquid filled sensing bulb which hydraulically transmits temperature change to a bellows.
The response at a pre-determined set point(s), actuates or deactuates
a SPDT, dual SPDT or DPDT snap-acting microswitch(es), converting the
temperature signal into an electronic signal. Control set point(s) may be
varied by turning the adjustment hex (F120) or the external knob(s) and
pointer(s) (E121, E122, 820E, 822E) according to the procedures outlined
(see Part II– Adjustments).
MAXIMUM TEMPERATURE: The highest temperature to which
The connection of the device shall be made by cable
entries or a stopping box of a flameproof type, certified eex d iiC. these accessories shall be threaded into
the relevant opening(s) of the device, with at least
5 threads engaged and with at least 8 mm length of thread
engagement. these accessories are not included within this
associated hazardous locations/zone 1 atmospheres approval.
to prevent ignition, seal all conduit runs within 18
inches of enclosure.
Always hold a wrench on the temperature housing hex
when mounting unit. Do not tighten by turning enclosure. This will damage sensor and weaken solder or
welded joints.
Install units where shock, vibration and temperature
fluctuations are minimal. Mount unit to prevent moisture from entering the enclosure. It is imperative to
use properly rated explosion-proof sealing fittings for electrical wire entry. Do not mount unit in ambient temperatures
lower than -40°F (-40°C) or higher than 160°F (71°C).
*Do not knockout any plugs on Explosion-proof types
820E or 822E
C120, F120 and 820E, 822E Enclosures are provided with two 3/4” NPT
electrical conduit openings, one of which is provided with a 3/4” explosion proof plug. Either of the two electrical conduits could be used during
installation, as long as the unused one is properly sealed. The explosion
proof plug must be properly sealed during product installation.
Remote mount types E121, E122, F120 temperature controls should be
IMT120-06
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mounted vertically (temperature assembly facing down) or horizontally
(vent holes facing down). The conduit connection must be properly sealed
(potted) for horizontal installation. Controls may be surface mounted via
the four 1/4” screw clearance holes on the enclosure or through the use
of a mounting bracket (See Mounting Dimensions).
Disconnect all supply circuits before wiring unit.
Wire units according to national and local electrical codes. Maximum recommended wire size is 14
AWG. The recommended tightening torque for field wiring
terminals is 7 to 17 IN-lbS.
Breather Drain Option M450: Types C120, F120
Mount with breather drain facing down (See Figure 1). The conduit connection must be properly sealed (potted) for this type of installation.
Electrical ratings stated in literature and on nameplates must not be exceeded—overload on a switch
can cause failure on the first cycle.
Breather Drain Option M450: Types B121, B122, E121 & E122
Mount in vertical position with temperature assembly and breather drain
facing down (See Figure 2).
To prevent seizure of enclosure cover, DO NOT remove
lubricant. Threads should also be free of dirt, etc.
The external grounding terminal is not to be used
as the primary equipment grounding terminal. The
internal grounding terminal shall be used as the
primary equipment grounding means and the external grounding terminal is only for a supplemental (secondary) grounding
connection where local authorities permit or require such a
connection.
Remove cover and wire control according to product configuration (See
Figure 4). Wire directly to the terminal block. An internal grounding terminal is located near the right-hand conduit opening inside the enclosure.
Replace cover and hand tighten to fully engage cover O-ring.
Figure 1: Types C120, F120
Figure 2: Types B121, B122, E121, E122
TYPES B121, C120, E121, F120 , 820E
N.O.
820E and 822E type units must be surface mounted. Drill mounting
holes per Figure 3.
BLU
COM.
VLT
TYPES B122, E122, E122P
N.C.
N.O.
COM.
N.C.
HIGH
TERMINAL
BLOCK
BLK
ORN
YEL
RED
HIGH SET
(BACK)
N.C.
If a seal fitting is required, install the nipple and the seal fitting prior to
surface mounting the controller.
COM.
N.C.
N.O.
N.O.
COM.
N.C.
N.O.
NOTE REVERSE WIRING
OF LOW SWITCH
COM.
BLK
N.C.
VLT
COM.
LOW SET
(FRONT)
BLU
N.O.
LOW
TERMINAL
BLOCK
OPTION 1010, 1190, 1195
TYPE type
B121, B121,
C120,C120,
E121,E121,
F120 F120 only.)
(For
Clearance for 1/4 screw (4) places
Figure 3: 820E, 822E Mounting
Mounting Bulb and Capillary
Fully immerse the bulb and 6” of capillary in the control zone. For best
control it is generally desirable to place the bulb close to the heating or
cooling source in order to sense temperature fluctuations quickly. Be sure
to locate the bulb so it will not be exposed to temperature beyond the
instruments range limits.
Use 75°C copper conductors only.
Recommended tightening torque for
field wiring terminals is 7-17 in-lbs.
Figure 4
Avoid bending or coiling the capillary tube tighter than 1/2” radius.
Exercise caution when making bends near the capillary ends.
If a separable well or union connector is used follow separate instructions
included with them.
Part II - Adjustments
WIRING
supply leadwires must be rated 75°C miniimum copper
conductor only.
IMT120-06
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TOOLS NEEDED
3/16” Open End Wrench (2)
1/4” Open End Wrench
5/64” Allen Wrench
5/16” Open End Wrench (2 required for 822E only)
AFTER COMPLETING ADJUSTMENTS ON ALL 120 SERIES
TEMPERATURE CONTROLS, BE SURE TO RE-INSTALL
ADJUSTMENT COVER. DO NOT OVER TIGHTEN COVER SCREWS.
NOTE: For set point adjustments and recalibration, connect control to a
calibrated temperature source and stabilize unit.
NOTE: Type 822E has a single knob and pointer for both switches. Both
switches are standardly, factory set together within 5% of the dial range.
Turning the knob positions both switches simultaneously, maintaining a
constant separation between them.
Replace cover and adjustment knob if removed during installation.
Controller is ready for operation. Turn setting pointer to desired
control temperature and star t up the process. To suit particular process conditions or for greater controller accuracy it may be desirable to make slight alterations to the set point or
indicator reading. Procedures for making these adjustments are described
below.
by an amount greater than the difference between the switch settings by
moving the actuating lever upward with a finger or a tool simulating thermal assembly movement. Connect test lights to indicate switch operation
or listen for the individual switch clicks.
The set point of switch #1 is determined by the red Adjustment Pointer.
The set point of switch #2 may be adjusted by up to 25% of the range
span below the switch #1 set point by turning adjustment “D” in (clockwise). See Figure 4. The set point of switch #2 should not be above that
of switch #1.
To align switch #1 to the Adjustment Pointer, loosen adjustment “A” and
set the Adjustment Pointer to the scale, then re-tighten adjustment “A”.
Types C120, F120
Note: Indicating Pointer Deflection (820E, 822E): The indicating pointers
will read slightly low when the bulb temperature is 15° above the controller setting. This deflection is normal and repeatable (approximately 0.5%
of scale range on single switch models) and is due to the transference of
the switching mechanism load to the thermal system. It can be measured
by moving the setting pointer from the high to the low end of the scale
and observing the resultant indicating pointer deflection.
Note: Adjust set point by holding plunger with 3/16” open end wrench
and turning the calibrating screw with another 3/16” open end wrench
(see figure 5). Turn clockwise (in) to increase or counter-clockwise (out)
to decrease setting.
Note: Indicating Pointer Adjustment (820E, 822E): Use an accurate test
thermometer such as a thermocouple with its probe mounted directly to
the center of the sensing bulb. Before making any adjustments, allow process temperature to stabilize; i.e., successive on-off cycles repeated.
Adjustment Procedure
for C120/F120
Correct any difference between the Indicating Pointer and the test thermometer by holding the compensator with a 5/16” wrench while turning
the zero adjustment “C” on the thermal assembly with a second 5/16”
wrench, per Figure 6 until the brown Indicating Pointer reads the same
as the test thermometer. Turning clockwise lowers indicated reading.
Compare the process temperature with the set point Adjustment Pointer.
Loosen adjustment screw “A” to align set point Adjustment Pointer with the
Indicating Pointer. Re-tighten screw “A”.
Figure 5
Type B121 and E121
Adjust set point by turning external knob and pointer to desired setting on
scale.
Type B122 and E122
Individual switches may be set together or apart up to 100% of range.
When not set together, the front (low) switch cannot be set higher than the
rear (high) switch. Turning external knobs will increase or decrease each
switch setting independently.
Type E122P
Individual switches may be set together or apart by up to 60% of range.
The front switch is set by turning the internal calibrating screw to the right
for lower set point and turning to the left for higher set point. When not
set together, the front switch cannot be set higher than the rear switch.
Turning the external knob will increase or decrease each switch setting
simultaneously without disturbing their relationship.
NOTE: Prior to making any controller adjustments, the cover and adjustment knobs should be removed. When adjustments are completed, all
applicable parts should be replaced.
NOTE: The adjustment knob slides off adjustment shaft for the 820E &
822E. Be sure to replace gasket when re-assembling.
Type 820E
Move the set point Adjustment Pointer up scale beyond the brown Indicating
Pointer. This permits checking the set point by moving the lever arm upward
with a finger or tool simulating thermal assembly movement. Connect test
lights to indicate switch operation or listen for the switch to click. Loosen
adjustment “A” and move the Adjustment Pointer until it agrees with the
Indicating Pointer. When the switch clicks re-tighten the screw.
Type 822E
Remove the explosion-proof die-cast cover to permit access to the switches. Move the Adjustment Pointer up scale beyond the Indicating Pointer
Figure 6: Indicating
Enclosure Internals
Correction of Capillary
If the length of capillary immersed in the process differs from the amount
immersed (6”, see Mounting Bulb & Capillary in Part I - Installation) at
the factory calibration bath, a calibration shift will occur. The error may be
corrected as follows:
Move set pointer to the highest temperature setting. Note indicating scale
reading with the head and sensor at room temperature. Loosen the two
thermal assembly mounting screws. Re-position the housing index against
the calibration on the instrument case (or skeleton casting) at a rate of 1
division line per capillary length listed in the following column. Move to the
left if capillary is to be added to the process, or to the right if capillary is
to be removed from process.
IMT120-06
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Type E121, E122, F120
Models 1BS-8BS
Type B121, B122, C120
Models 120-121
Remote Mount
Temperature Assembly
Direct Mount
Temperature Assembly
Internal Set Point Adjustment, Types C120, F120
RECOMMENDED PRACTICES AND WARNINGS
United Electric Controls Company recommends careful consideration of
the following factors when specifying and installing UE pressure and temperature units. Before installing a unit, the Installation and Maintenance
instructions provided with unit must be read and understood.
• To avoid damaging unit, proof pressure and maximum temperature
limits stated in literature and on nameplates must never be exceeded,
even by surges in the system. Operation of the unit up to maximum
pressure or temperature is acceptable on a limited basis (e.g., start-up,
testing) but continuous operation must be restricted to the designated
adjustable range. Excessive cycling at maximum pressure or temperature limits could reduce sensor life.
• A back-up unit is necessary for applications where damage to a
primary unit could endanger life, limb or property. A high or low
limit switch is necessary for applications where a dangerous runaway
condition could result.
• The adjustable range must be selected so that incorrect, inadvertent
or malicious setting at any range point cannot result in an unsafe
system condition.
• Install unit where shock, vibration and ambient temperature fluctuations will not damage unit or affect operation. Orient unit so that
moisture does not enter the enclosure via the electrical connection.
When appropriate, this entry point should be sealed to prevent moisture entry.
• Unit must not be altered or modified after shipment. Consult UE if
modification is necessary.
• Monitor operation to observe warning signs of possible damage to
unit, such as drift in set point or faulty display. Check unit immediately.
• Preventative maintenance and periodic testing is necessary for critical applications where damage could endanger property or personnel.
• For all applications, a factory set unit should be tested before use.
• Electrical ratings stated in literature and on nameplate must not be
exceeded. Overload on a switch can cause damage, even on the first
cycle. Wire unit according to local and national electrical codes,
using wire size recommended in installation sheet.
• Do not mount unit in ambient temp. exceeding published limits.
Dimension A
ModelInches mmNPT
120,121
9.12
231,4Immersion stem
1BS-8BS
8.47
214,8Bulb & capillary External Set Point Adjustment, Types B121, B122, E121, E122
Dimension A
ModelInches mmNPT
120,121
10
254,0Immersion stem
2BS-8BS
9.3
237,0Bulb & capillary
13272, 13322 10
254,0
Immersion stem (Freeze Protection)
13273, 13321 9.3
237,0Bulb & capillary (Heat Tracing)
LIMITED WARRANTY
Type 820E single switch
Dimension A
ModelInches mm
1BS
2BS
3BS
4BS
5BS
6BS
7BS
8BS
Type 822E dual switch
7" [177.8mm]
GROUND
SCREW
3-3/4
2-7/16
2-1/8
6-3/4
5
4-1/2
3
3-1/4
95,3
62,0
54,0
171,5
127,0
114,3
76,2
82,6
4-11/16 [119.3mm]
3-1/2 [88.9mm]
1-11/16
[43.2mm]
6-3/8 [161.9mm]
3-3/16 [81.0mm]
2-1/4
[57.5mm]
O
R
N
YE
L
1-3/16
[30.2mm]
ED
.O
SW .
C
T OM
#1 .
R
Seller’s liability to Buyer for any loss or claim, including liability incurred
in connection with (i) breach of any warranty whatsoever, expressed or
implied, (ii) a breach of contract, (iii) a negligent act or acts (or negligent
failure to act) committed by Seller, or (iv) an act for which strict liability will
be inputted to seller, is limited to the “limited warranty” of repair and/or
replacement as so stated in our warranty of product. In no event shall the
Seller be liable for any special, indirect, consequential or other damages
of a like general nature, including, without limitation, loss of profits or
production, or loss or expenses of any nature incurred by the buyer or any
third party.
UE specifications subject to change without notice.
N
VLT
Limitation OF Seller’s Liability
C
O
M
.
BLK
N
.C
.
BLU
3/4 NPT E/C
PLUGGED
N
.C
.
SW
N
T .O
#2 .
7/8
[22.2mm]
Seller warrants that the product hereby purchased is, upon delivery, free
from defects in material and workmanship and that any such product
which is found to be defective in such workmanship or material will be
repaired or replaced by Seller (Ex-works, Factory, Watertown, Massachusetts.
INCOTERMS); provided, however, that this warranty applies only to equipment found to be so defective within a period of 24 months from the
date of manufacture by the Seller. Seller shall not be obligated under this
warranty for alleged defects which examination discloses are due to tampering, misuse, neglect, improper storage, and in any case where products
are disassembled by anyone other than authorized Seller’s representatives.
EXCEPT FOR THE LIMITED WARRANTY OF REPAIR AND REPLACEMENT
STATED ABOVE, SELLER DISCLAIMS ALL WARRANTIES WHATSOEVER
WITH RESPECT TO THE PRODUCT, INCLUDING ALL IMPLIED WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
5/64 (2mm)
SOCKET
COVER-LOCK
SCREW
3/4 NPT E/C
BOTH SIDES
14-11/16
[373.1mm]
UNITED ELECTRIC
CONTROLS
TEMPERATURE
INDICATING
POINTER
(BLACK)
9" [228.6mm]
CLEARANCE
FOR 1/4 SCREW
4 MT'G HOLES
180 Dexter Avenue, P.O. Box 9143
Watertown, MA 02471-9143 USA
Telephone: 617 926-1000 Fax: 617 926-2568
http://www.ueonline.com
3/8
[9.5mm]
SET POINT
INDICATING
POINTER
(RED)
SET POINT
ADJUSTMENT
KNOB
"A"
BULB
1-17/32
[38.9mm]
IMT120-06
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SP07065000
6.3. Type “K” Thermocouple Data Sheet
Thermocouple - Wikipedia, the free encyclopedia
Page 1 of 7
Thermocouple
From Wikipedia, the free encyclopedia
In electrical engineering and industry, thermocouples are a widely used type of
temperature sensor[1] and can also be used as a means to convert thermal potential
difference into electric potential difference.[2] They are cheap[3] and interchangeable,
have standard connectors, and can measure a wide range of temperatures. The main
limitation is accuracy; System errors of less than one degree Celsius (°C) can be
difficult to achieve.
Contents

1 Principle of operations
1.1 Attachment
1.2 Voltage–temperature relationship
2 Types
2.1 K
2.2 E
2.3 J
2.4 N
2.5 B, R, and S
2.6 T
2.7 C
2.8 M
2.9 Chromel-gold/iron
3 Thermocouple comparison
4 Applications
4.1 Steel industry
4.2 Heating appliance safety
4.3 Thermopile radiation sensors
4.4 Manufacturing
4.5 Radioisotope thermoelectric generators
5 See also
6 References
7 External links
Thermocouple plugged to a
multimeter displaying room
temperature in °C.
Principle of operations
In 1821, the German–Estonian physicist Thomas Johann Seebeck discovered that when any conductor (such as a metal)
is subjected to a thermal gradient, it will generate a voltage. This is now known as the thermoelectric effect or Seebeck
effect. Any attempt to measure this voltage necessarily involves connecting another conductor to the "hot" end. This
additional conductor will then also experience the temperature gradient, and develop a voltage of its own which will
oppose the original. Fortunately, the magnitude of the effect depends on the metal in use. Using a dissimilar metal to
complete the circuit creates a circuit in which the two legs generate different voltages, leaving a small difference in
voltage available for measurement. That difference increases with temperature, and can typically be between 1 and 70
microvolts per degree Celsius (µV/°C) for the modern range of available metal combinations. Certain combinations
have become popular as industry standards, driven by cost, availability, convenience, melting point, chemical
properties, stability, and output. This coupling of two metals gives the thermocouple its name.
http://en.wikipedia.org/wiki/Thermocouple
11/17/2008
Page 2 of 7
Thermocouples measure the temperature difference between two points, not absolute temperature. In traditional
applications, one of the junctions—the cold junction—was maintained at a known (reference) temperature, while the
other end was attached to a probe.
Having available a known temperature cold junction, while useful for laboratory calibrations, is simply not convenient
for most directly connected indicating and control instruments. They incorporate into their circuits an artificial cold
junction using some other thermally sensitive device, such as a thermistor or diode, to measure the temperature of the
input connections at the instrument, with special care being taken to minimize any temperature gradient between
terminals. Hence, the voltage from a known cold junction can be simulated, and the appropriate correction applied.
This is known as cold junction compensation.
Additionally, a device can perform cold junction compensation by computation. It can translate device voltages to
temperatures by either of two methods. It can use values from look-up tables[4] or approximate using polynomial
interpolation.
A thermocouple can produce current, which means it can be used to drive some processes directly, without the need for
extra circuitry and power sources. For example, the power from a thermocouple can activate a valve when a
temperature difference arises. The electric power generated by a thermocouple is a conversion of the heat energy that
one must continuously supply to the hot side of the thermocouple to maintain the electric potential. The flow of heat is
necessary because the current flowing through the thermocouple tends to cause the hot side to cool down and the cold
side to heat up (the Peltier effect).
Thermocouples can be connected in series with each other to form a thermopile, where all the hot junctions are exposed
to the higher temperature and all the cold junctions to a lower temperature. The voltages of the individual
thermocouples add up, allowing for a larger voltage and increased power output, thus increasing the sensitivity of the
instrumentation. With the radioactive decay of transuranic elements providing a heat source this arrangement has been
used to power spacecraft on missions too far from the Sun to utilize solar power.
Attachment
Thermocouple materials are available in several different metallurgical formulations per type, such as: (listed in
decreasing levels of accuracy and cost) Special limits of error, Standard, and Extension grades. Extension grade wire is
less costly than dedicated thermocouple junction wire and it's usually specified for accuracy over a more restricted
temperature range. Extension grade wire is used when the point of measurement is farther from the measuring
instrument than would be financially viable for standard or special limits materials, and has a very similar thermal
coefficient of EMF for a narrow range (usually encompassing ambient). In this case, a standard or special limits wire
junction is tied to the extension grade wire outside of the area of temperature measurement for transit to the instrument.
Since most modern temperature measuring instruments that utilize thermocouples are electronically buffered to prevent
any significant current draw from the thermocouple, the length of the thermocouple or extension wire is irrelevant.
Changes in metallurgy along the length of the thermocouple (such as termination strips or changes in thermocouple
type wire) will introduce another thermocouple junction which affects measurement accuracy. Also, in the United
States, industry standards are that the thermocouple color code is used for the insulation of the positive lead, and red is
the negative lead.
Voltage–temperature relationship
The relationship between the temperature difference and the output voltage of a thermocouple is nonlinear and is
approximated by polynomial:
11/17/2008
Page 3 of 7
The coefficients an are given for N from zero to between five and nine.
To achieve accurate measurements the equation is usually implemented in a digital controller or stored in a look-up
table.[4] Some older devices use analog filters.
Types
A variety of thermocouples are available, suitable for different measuring applications. They are usually selected based
on the temperature range and sensitivity needed. Thermocouples with low sensitivities (B, R, and S types) have
correspondingly lower resolutions. Other selection criteria include the inertness of the thermocouple material, and
whether or not it is magnetic. The thermocouple types are listed below with the positive electrode first, followed by the
negative electrode.
K
Type K (chromel–alumel) is the most commonly used for general purpose
thermocouple. It is inexpensive and, owing to its popularity, available in a wide
variety of probes. They are available in the −200 °C to +1350 °C range. The type K
was specified at a time when metallurgy was less advanced than it is today and,
consequently, characteristics vary considerably between examples. Another potential
problem arises in some situations since one of the constituent metals, nickel, is
magnetic. One characteristic of thermocouples made with magnetic material is that
they undergo a step change when the magnetic material reaches its Curie point. This
occurs for this thermocouple at 354°C. Sensitivity is approximately 41 µV/°C.
K type thermocouple.
E
Type E (chromel–constantan)[4] has a high output (68 µV/°C) which makes it well
suited to cryogenic use. Additionally, it is non-magnetic.
J
Type J (iron–constantan) is less popular than type K due to its limited range (−40 to
+750 °C). The main application is with old equipment that cannot accept modern
thermocouples. The Curie point of the iron (770 °C) causes an abrupt change to the
characteristic and it is this that provides the upper temperature limit. Type J
thermocouples have a sensitivity of about 50 µV/°C.[3]
S and K type thermocouples,
the S one is partially sheathed
with an alundum tube.
N
Type N (nicrosil–nisil) thermocouples are suitable for use at high temperatures, exceeding 1200 °C, due to their
stability and ability to resist high temperature oxidation. Sensitivity is about 39 µV/°C at 900°C, slightly lower than
type K. Designed to be an improved type K, it is becoming more popular.
B, R, and S
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Page 4 of 7
Types B, R, and S thermocouples use platinum or a platinum–rhodium alloy for each conductor. These are among the
most stable thermocouples, but have lower sensitivity, approximately 10 µV/°C, than other types. The high cost of
these makes them unsuitable for general use. Generally, type B, R, and S thermocouples are used only for high
temperature measurements.
Type B thermocouples use a platinum–rhodium alloy for each conductor. One conductor contains 30% rhodium while
the other conductor contains 6% rhodium. These thermocouples are suited for use at up to 1800 °C. Type B
thermocouples produce the same output at 0 °C and 42 °C, limiting their use below about 50 °C.
Type R thermocouples use a platinum–rhodium alloy containing 13% rhodium for one conductor and pure platinum for
the other conductor. Type R thermocouples are used up to 1600 °C.
Type S thermocouples use a platinum–rhodium alloy containing 10% rhodium for one conductor and pure platinum for
the other conductor. Like type R, type S thermocouples are used up to 1600 °C. In particular, type S is used as the
standard of calibration for the melting point of gold (1064.43 °C).
T
Type T (copper–constantan) thermocouples are suited for measurements in the −200 to 350 °C range. Often used as a
differential measurement since only copper wire touches the probes. Since both conductors are non magneteic, there is
no Curie point and thus no abrupt change in characteristics. Type T thermocouples have a sensitivity of about 43 µV/°
C.
C
Type C (tungsten 5% rhenium – tungsten 26% rhenium) thermocouples are suited for measurements in the 0 °C to
2320 °C range. This thermocouple is well-suited for vacuum furnaces at extremely high temperatures and must never
be used in the presence of oxygen at temperatures above 260 °C.
M
Type M thermocouples use a nickel alloy for each wire. The positive wire contains 18% molybdenum while the
negative wire contains 0.8% cobalt.[5] These thermocouples are used in the vacuum furnaces for the same reasons as
with type C. Upper temperature is limited to 1400 °C. Though it is a less common type of thermocouple, look-up tables
to correlate temperature to EMF (milli-volt output) are available.
Chromel-gold/iron
In chromel-gold/iron thermocouples, the positive wire is chromel and the negative wire is gold with a small fraction
(0.03–0.15 atom percent) of iron. It can be used for cryogenic applications (1.2–300 K and even up to 600 K). Both the
sensitivity and the temperature range depends on the iron concentration. The sensitivity is typically around 15 µV/K at
low temperatures and the lowest usable temperature varies between 1.2 and 4.2 K.[6][7][8].
Thermocouple comparison
The table below describes properties of several different thermocouple types. Within the tolerance columns, T
represents the temperature of the hot junction, in degrees Celsius. For example, a thermocouple with a tolerance of
±0.0025×T would have a tolerance of ±2.5 °C at 1000 °C.
11/17/2008
Type
Temperature Temperature
range °C
range °C
(continuous) (short term)
Page 5 of 7
Tolerance class one (°C)
Toleran
K
0 to +1100
−180 to
+1300
±1.5 between −40 °C and 375 °C
±0.004×T between 375 °C and 1000 °C
±2.5 between −4
±0.0075×T betw
J
0 to +700
−180 to +800
±0.004×T between 375 °C and 750 °C
±2.5 between −4
±0.0075×T betw
N
0 to +1100
−270 to
+1300
±0.004×T between 375 °C and 1000 °C
±2.5 between −4
±0.0075×T betw
R
0 to +1600
−50 to +1700
±1.0 between 0 °C and 1100 °C
±1.5 between 0
±[1 + 0.003×(T − 1100)] between 1100 °C and 1600 °C ±0.0025×T betw
S
0 to 1600
−50 to +1750
±1.0 between 0 °C and 1100 °C
±1.5 between 0
±[1 + 0.003×(T − 1100)] between 1100 °C and 1600 °C ±0.0025×T betw
B
+200 to
+1700
0 to +1820
Not Available
±0.0025×T betw
T
−185 to +300 −250 to +400
±0.004×T between 125 °C and 350 °C
±1.0 between −4
±0.0075×T betw
E
0 to +800
±0.004×T between 375 °C and 800 °C
±2.5 between −4
±0.0075×T betw
−40 to +900
Chromel/AuFe −272 to +300 n/a
Reproducibility 0.2% of the voltage; each sensor needs individual calibra
Applications
Thermocouples are most suitable for measuring over a large temperature range, up to 1800 °C. They are less suitable
for applications where smaller temperature differences need to be measured with high accuracy, for example the range
0–100 °C with 0.1 °C accuracy. For such applications, thermistors and resistance temperature detectors are more
suitable.
Steel industry
Type B, S, R and K thermocouples are used extensively in the steel and iron industries to monitor temperatures and
chemistry throughout the steel making process. Disposable, immersible, type S thermocouples are regularly used in the
electric arc furnace process to accurately measure the steel's temperature before tapping. The cooling curve of a small
steel sample can be analyzed and used to estimate the carbon content of molten steel.
Heating appliance safety
Many gas-fed heating appliances such as ovens and water heaters make use of a pilot light to ignite the main gas burner
as required. If the pilot light becomes extinguished for any reason, there is the potential for un-combusted gas to be
released into the surrounding area, thereby creating both risk of fire and a health hazard. To prevent such a danger,
some appliances use a thermocouple as a fail-safe control to sense when the pilot light is burning. The tip of the
11/17/2008
Page 6 of 7
thermocouple is placed in the pilot flame. The resultant voltage, typically around 20 mV, operates the gas supply valve
responsible for feeding the pilot. So long as the pilot flame remains lit, the thermocouple remains hot and holds the
pilot gas valve open. If the pilot light goes out, the temperature will fall along with a corresponding drop in voltage
across the thermocouple leads, removing power from the valve. The valve closes, shutting off the gas and halting this
unsafe condition.
Some systems, known as millivolt control systems, extend this concept to the main gas valve as well. Not only does the
voltage created by the pilot thermocouple activate the pilot gas valve, it is also routed through a thermostat to power the
main gas valve as well. Here, a larger voltage is needed than in a pilot flame safety system described above, and a
thermopile is used rather than a single thermocouple. Such a system requires no external source of electricity for its
operation and so can operate during a power failure, provided all the related system components allow for this. Note
that this excludes common forced air furnaces because external power is required to operate the blower motor, but this
feature is especially useful for un-powered convection heaters.
A similar gas shut-off safety mechanism using a thermocouple is sometimes employed to ensure that the main burner
ignites within a certain time period, shutting off the main burner gas supply valve should that not happen.
Out of concern for energy wasted by the standing pilot, designers of many newer appliances have switched to an
electronically controlled pilot-less ignition, also called intermittent ignition. With no standing pilot flame, there is no
risk of gas buildup should the flame go out, so these appliances do not need thermocouple-based safety pilot safety
switches. As these designs lose the benefit of operation without a continuous source of electricity, standing pilots are
still used in some appliances.
Thermopile radiation sensors
Thermopiles are used for measuring the intensity of incident radiation, typically visible or infrared light, which heats
the hot junctions, while the cold junctions are on a heat sink. It is possible to measure radiative intensities of only a few
µW/cm2 with commercially available thermopile sensors. For example, some laser power meters are based on such
sensors.
Manufacturing
Thermocouples can generally be used in the testing of prototype electrical and mechanical apparatus. For example,
switchgear under test for its current carrying capacity may have thermocouples installed and monitored during a heat
run test, to confirm that the temperature rise at rated current does not exceed designed limits.
Radioisotope thermoelectric generators
Thermopiles can also be applied to generate electricity in radioisotope thermoelectric generators.
See also

Bolometer
Giuseppe Domenico Botto
Resistance thermometer
Thermistor
Thermopile
Thermostat
List of sensors
11/17/2008
Page 7 of 7
References
1. ^ "Thermocouple temperature sensors (http://www.temperatures.com/tcs.html)". Temperatures.com. Retrieved
on 2007-11-04.
2. ^ "Thermocouples - An Introduction (http://www.omega.com/thermocouples.html)". Omega Engineering.
Retrieved on 2007-11-04.
3. ^ a b Ramsden, Ed (September 1, 2000). "Temperature measurement
(http://www.sensorsmag.com/sensors/Technologies+In+Depth/Sensors/Temperature/TemperatureMeasurement/ArticleStandard/Article/detail/358202)". Sensors,
http://www.sensorsmag.com/sensors/Technologies+In+Depth%2FSensors%2FTemperature/TemperatureMeasurement/ArticleStandard/Article/detail/358202. Retrieved on 4 November 2007.
4. ^ a b c Baker, Bonnie C. (September 1, 2000). "Designing the embedded temperature circuit to meet the system's
requirements (http://www.sensorsmag.com/sensors/Technologies+In+Depth/Sensors/Temperature/Designingthe-Embedded-Temperature-Circuit-to-Meet/ArticleStandard/Article/detail/361649)". Sensors,
http://www.sensorsmag.com/sensors/Technologies+In+Depth%2FSensors%2FTemperature/Designing-theEmbedded-Temperature-Circuit-to-Meet/ArticleStandard/Article/detail/361649. Retrieved on 4 November 2007.
5. ^ "Readouts with tungsten–rhenium and other TC's (http://www.tempsensor.net/modules.php?
op=modload&name=News&file=article&sid=685)". Retrieved on 2007-10-31.
6. ^ Lake Shore sensor temperature response data tables
(http://www.lakeshore.com/pdf_files/sensors/LSTC_Thermocouple_l.pdf)
7. ^ Lakeshore Cryotronics thermocouple wire product description
(http://www.lakeshore.com/temp/sen/therm.html)
8. ^ a b Johnson Matthey thermocouple wire brochure (http://www.noble.matthey.com/Library/Thermocouple%
20Wire_brochure_English_119.pdf)
External links

NIST ITS-90 Thermocouple Database (http://srdata.nist.gov/its90/main/)
Thermocouple design guide (http://www.peaksensors.co.uk/design-guide.html)
Notes from a cold junction (http://www.maxim-ic.com/appnotes.cfm/appnote_number/430)
Mineral-Insulated Thermocouple Know-How (http://www.isomil.de/en/mineral-insulated-cable.htm)
Thermocouple Color Code Chart and Specifications (http://www.thermalcorp.com/documents/TCCHART.pdf)
Thermocouple Reference Information (http://www.smartsensors.com/ref.htm)
Retrieved from "http://en.wikipedia.org/wiki/Thermocouple"
Categories: Heating, ventilating, and air conditioning | Thermometers | Sensors
Hidden categories: All articles with unsourced statements | Articles with unsourced statements since July 2008

This page was last modified on 11 November 2008, at 19:44.
All text is available under the terms of the GNU Free Documentation License. (See Copyrights for details.)
Wikipedia® is a registered trademark of the Wikimedia Foundation, Inc., a U.S. registered 501(c)(3) taxdeductible nonprofit charity.
11/17/2008
Type "K" thermocouple
60
50
mV / deg C
40
30
mV
20
10
0
-270
-70
130
330
530
730
930
1130
1330
-10
deg C
7.Burner Management System & Burner Parts Manuals
7.1. Profire 1100 Ignition Flame Safety Controller Manual
PROFIRE 1100
IGNITION
FLAME
SAFETY
CONTROLLER
REV 3
Cautions
WARNING:
EXPLOSION HAZARD -
-DO NOT SERVICE UNLESS AREA IS KNOWN TO BE NONHAZARDOUS
-DO NOT OPEN WHEN ENERGIZED
EXPLOSION HAZARD -
-SUBSTITUTION OF COMPONENTS MAY IMPAIR THE
SUITABILITY FOR ZONE 2 (Class 1 Division 2)
-REPLACEMENT FUSES MUST BE SAND-FILLED
INSTALLATION WARNING
Terminal Connections:
Connections must conform to the directions in this manual.
The unit must be properly connected to earth-ground for effective
ionization operation.
Electrical devises connected to the controller must meet electrical
standards and be within voltage limits.
Contact Number
For any questions call:
780-960-5278
Table of Contents
Introduction
1
Features
2
Specification
3
Installation
4
Hook-up drawing
5
Terminal Connection
6
Coil
7
Pilot hook-up
8
Key-pad
9
Menu
10
Menu functions
11
Set-up
12
Operation
13
Operation
14
Thermocouple
15
Message Codes
16
Error Codes
17
P R O F I R E
C O M B U S T I O N
I N C .
Profire 1100 O peration
Overview
The Profire 1100 is a burner ignition system for atmospheric natural-draft burners. The unit
monitors and controls a pilot valve, main burner valve, uses high-voltage spark ignition and
has inputs to shutdown the burner or prevent startup if there is a fault condition. The
method of flame detection is ionization, with thermocouple being used as a flame detection
backup. The thermocouple is also used to control the main valve opening.
With ionization flame detection, the flame ionization effect is monitored between the
sparker rod and the pilot assembly. With thermocouple, the flame is detected with a ‘K’ type
thermocouple and there are two temperature set-points, one for pilot flame detected and the
other set-point to check for a high temperature pilot (pilot quality) before the main valve is
opened.
The front panel on the unit has LED lamps to display the state of the pilot valve, the main
valve, the sparker, the mode, the flame along with a three digit display to indicate the state
of the unit, purge times, and thermocouple temperature, depending on the sequence the
burner is currently executing. The front panel also has a keypad for entering pilot
temperature set-points, for controlling the operation mode, and has a prominent
“emergency shutdown” button.
A purge timer allows time for natural gas to dissipate from the natural-draft burner between
ignition attempts or after a flame failure. The purge timer is configurable to allow the purge
time to be set to allow proper purging of the burner. The target setting of the purge timer is
to allow three air exchanges before ignition. The purge time is set in 5 second increments
up to 600 seconds (10 minutes).
There is a Lockout Input which can be connected to external devices. The Profire 1100 is
programmed so the Lockout Input must be closed (normal state) before a start sequence is
initiated. The Lockout Input can be connected to valve position sensors or other devices
that give a closed contact when in a “safe-to-start” mode. After the unit has started the
ignition sequence, the Lockout Input is allowed to open.
The PRS Input (pressure input) must be closed for the unit to start, as well as while the unit
is in normal running mode. This input can be wired into high and low pressure switches in
a loop so if any device opens its contacts, the controller will shut down the burner, initiate
alarm mode, and wait for operator intervention.
The Emergency Shutdown input must be closed for the unit to start, as well as while the
unit is in normal running mode. This input can be wired into various alarms such as “High
Glycol Temperature”, “Low Glycol Level”, etc., in a loop, so if any device opens its
contacts, the controller will shut down the burner, initiate the alarm mode and wait for
operator intervention.
An alarm output on the unit can be connected to monitoring equipment which indicates
whether the unit is operating normally or has a fault.
1
P R O F I R E
C O M B U S T I O N
I N C .
Features
CSA:
•
•
•
Zone 2 (Class 1, Division 2) locations approval (CSA 213-92).
Burner Safety approval (CSA 22.2-199).
Industrial Process Equipment approval (CSA 14 -95).
Input Power +10 to +28 VDC.
Dual Flame-sensing for safety:
•
•
Flame Rod (ionization circuit)
Thermocouple (type K thermocouple).
Rapid 1.8 second shut-down on flame-out.
DC Voltage spark generator.
Low-power design to incorporate solar panels or TEG applications.
Auto relight or manual operation, push button selectable.
Remote Start/Stop control.
Remote ESD contact
Pressure Switch monitoring
Large, easily-accessible terminal connections.
Equipped with AVD (Advanced Visual Display) for improved operating functions and
signals.
Programmed purge times, auto restart, and restart tries.
START-LOCKOUT input for connections to safety interlock devices.
All circuits are transient protected and are fail-safe.
Alarm contact output.
2
P R O F I R E
C O M B U S T I O N
I N C .
Specifications
E N C L O S U R E
Fiberglass 8" x 6” x 4"
CSA and UL compliant for Zone 2 (Class 1, Division 2) locations
Enclosure type 4, 4X, 12, 13
C I R C U I T
B O A R D S
All solid state
CSA compliant for Zone 2 (Class 1, Division 2) locations
I G N I T I O N
B A S E
A N D
C OI L
For non -hazardous area only
P O W E R
R E Q U I R E M E N T S
+10 to + 28 volts DC
S U P P L Y
C U R R E N T
2.0 amps surge (limited), 0.015 - 2 amps run
P O W E R
C O N S U M P T I O N
1100 only:
12 volts - Display on - 106 ma or 1.3 watts
12 volts - Display off - 43 ma or 0.6 watts
24 volts - Display on - 66 ma or 1.6 watts
24 volts - Display off - 35 ma or 0.9 watts
* Constant current solenoids add power required by s olenoid manufacture r.
* Power output to solenoids, Max = 30 Watts/solenoid.
Operating Conditions:
–40°C to +55°C
3
P R O F I R E
C O M B U S T I O N
I N C .
Installation
Site Selection
The Profire 1100 system enclosure is CSA compliant for a Zone 2 (Class 1,
Division 2) (C&D) area classification. This means the system enclosure must
be mounted outside any Zone 1 (Class 1, Division 1) area. The system can be
mounted on the unit skid or on a building wall as long as it does not infringe
on a Zone 1 (Class 1, Division 1) area.
The Profire 1100 system enclosure is a fiberglass box, 8" x 6" x 4", complete
with mounting tabs. The enclosure weighs less than 5 pounds, so heavy-duty
supports are not required, but the unit should be firmly mounted, as the push
buttons on the front panel have to be operated. The enclosure should be
mounted in a location that faces away from the burner housing so that the
operator is facing both the enclosure and the burner housing while operating
the unit. Other considerations are panel access, traffic, wire-runs, and
visibility. The enclosure should be mounted about 5 1/2 feet above ground
level.
The spark generator (coil), however, must be mounted in a non-hazardous
area, as there is a potential of a spark arcing across the output terminals of the
coil or along the insulated high-voltage leads. The ideal location for the spark
generator is inside the burner housing.
4
P R O F I R E
C O M B U S T I O N
I NC.
Hook-Up drawing
Terminal Board Profire 1100
Junction box
Power
12 or 24 VDC
STATUS
+
STATUS-
12/24v
dc+
commo
n
Status
START+
Start/Stop
START-
ESD
ground
LCK+
ESD+
LCK-
ESD-
TC+
MAIN+
TC-
Thermocouple to burner
does not require TC wire
MAIN-
TCS
PILOT+
COIL+
PILOT-
COIL-
PR.SW+
COIL-I
PR.SW-
COIL-G
Teck cable
Pilot solenoid
Main solenoid
Proofofclosure switch
Fuelpressure switches
Teck cable to burner housing
Temperature controller
Main
Solenoid
Fuel Gas Supply
PRV 101
R
P.I.
Low gas
P.I.
P.I.
High gas
Manual
Safety valve
5
Union
Main
Test valve
PVC 100
Safety valve
Fast-acting
slow opening
Union
PRV 102
Pilot
Solenoid
P.I.
Manual
Safety valve
Union
Main Burner
Pilot Burner
Burner Housing
High temp/ESD
P R O F I R E
C O M B U S T I O N
I N C .
Terminal board connection for the Profire 1100
For good connections, spade connector should be used and wires should be clearly marked.
Terminal Board Connections
Alarm Signal
Dry contact out
Normally open
Open on flame
out
Dry contact in
Closed to start
Open to initiate
remote stop
Dry contact in
Closed to Run
Open to ESD
unit
STATUS+
12/24vdc+
STATUS-
common
START+
ground
START-
LCK+
ESD+
LCK-
ESD-
TC+
DC Power Supply
Input
+10 VDC
or
+28 VDC
Proof of closure switch
Switch from main valve
Closed to start ignition
sequence
Dry contact in
Thermocouple
connection to
type 'k' probe for
pilot flame
(shield not used)
Main fuel solenoids
up to two in parallel
MAIN+
TC-
2 Amp output
MAIN-
TCS
PILOT+
COIL+
PILOT-
COIL-
Voltage output to
coil with Ionization
return to unit
PR.SW+
COIL-I
Grounding is
required
PR.SW-
COIL-G
Pilot solenoid
2 Amp output
High & Low fuel
switches in series
Dry contact in
Closed to run
Rev 3.B
Version
6
P R O F I R E
C O M B U S T I O N
I NC.
* Coil must be mounted in a NON-HAZARDOUS location.
Coil requires solid ground from Profire 1100 to ensure ionization operates properly.
90 mm
45 mm C/C
Mounting hole
size 8 mm
(1/4" bolt)
130 mm
115 mm
C/C
Coil
Spark lead to
pilot electrode
/ Flame Rod
Coil Power
Ion
Coil ground
from panel
to housing
Ionization
output to
panel
+
-
Coil power
contact
7
Coil height
110 MM
Top view
P R O F I R E
C O M B U S T I O N
I NC.
Pilot bracket assembly
Pilot mounting bracket.
Standard size for 1/2" pipe.
Comes with electrode bushing
and probe fitting.
Type "K" thermocouple probe
2" past pilot nozzle with a 30°
bend
Ignition cable. Five foot carbon lead
with end connections for electrode
and coil.
Kanthol electrode, ignitor and
flame rod. Bend in a fashion
that the gas will ignite.
Pilot bracket assembly can be mounted on existing pilot. Brackets can be ordered to fit pilots 1/2" and up.
Slip-stream applications are also acceptable, but may require custom length probe and ignition electrode.
Pilot burner is not included with standard system
Available as option
8
P R O F I R E
C O M B U S T I O N
I NC.
Key-pad function
Flame light indicates
presence of flame
1
ESD
push-button
3
Display window
4
Keypad for parameter
adjustments and
field settings
Switches between auto
and manual modes
2
5
6
Manual buttons.
Also used for testing on start-ups.
1
Flame light indication: Allows operator to see that the pilot is lit.
2
3
Key-pad: Allows operator to select adjustable field parameters on the unit. Pressing the PROG button scrolls
through the menu. UP and DOWN button adjusts the value or selects parameters. OK button accepts and
stores the change. OK button is also used to exit the field parameter menu.
ESD: Allows operator to manually shut unit down and alarm.
4
Display window: Allows operator to read pilot flame temperature, menu, and errors that have occurred.
5
Mode: Allows operator to switch unit into a manual mode to check pilot ignitor and pilot solenoid, providing all
safety interlocks have been met. LED's indicate the state the unit is in.
6
PILOT button: Allows operator to open pilot solenoid for a period of time (45 sec) in Manual mode.
IGNITE button: Allows operator to activate ignition providing all safety parameters are met.
MAIN button: Allows operator to open Main only when pilot has been proved and stable.
9
P R O F I R E
C O M B U S T I O N
I NC.
Program Mode
On
Screen
Description
Function
AU
Enables unit to
automatically
start on power-up
ON= Auto start enabled
OFF = Auto start disabled
PU
Purge time cycle
Time in seconds set for purge
LED
Allows unit to
turn display off
ON=display always on
OFF=display off after 10 min
Press OK to turn on for 10 min
HI
High set point
Signal setting for a fail point
LO
Low set point
Signal setting for a prove point
RE
Restart attempts
Number of times the unit will
try to relight before alarming
Alarm type
1 : Unit will not alarm if remote
stopped
2 : Unit will alarm if remote stop
3 : Alarm follows main solenoid
AL
10
Default
setting
Off
10
ON
600
200
3
1
P R O F I R E
C O M B U S T I O N
I NC.
Program Menu
ON
PROGRAM
AU
OFF
PU
Purge
time
HI
Hi set
point
LO
Low set
point
Retry
attempts
RE
ON
LED
OFF
1
AL
2
3
11
OK
P R O F I R E
C O M B U S T I O N
I NC.
Changing settings
Changing settings can only be done when unit is in Manual mode.
Using the front keypad buttons, press PRG to enter program mode. Repeated
pressing of the PRG button scrolls through the menu items. Pressing the UP
or DOWN buttons will modify the item selected. Press OK to save and exit
program mode.
Flame mode
The Profire 1100 use two methods of flame detection, using an Ionization
circuit, in conjunction with a type K
thermocouple probe. This is a safe and reliable method. The thermocouple
probe provides a low and high set
point that ensures a stable pilot. Running the Ionization circuit in conjunction
with the probe, detects a flame-out within 1.8 seconds.
Hi and Low set points
Setting the high set points can be done once the lowest running temperature of
the flame has been established. This is done on the initial start-up of the unit.
Typically the pilot temperature can be used, but on occasion the main burner can
cool the flame temperature of the pilot. If that is the case, one should use the lower
of the two flame temperatures as a guideline to setting the Hi set point. The unit
must then be shut down to adjust and accept the new value. Only under special
circumstances will the low set point need adjustment. This will occur if the
operating temperature of the vessel is higher than the low set point, or if the probe
will not cool to a point for re-ignition. One must keep in mind that on a cold start,
there is a time-frame to reach this set point.
12
P R O F I R E
C O M B U S T I O N
I NC.
Operation
Start sequence: In Auto mode
Step #1
-
Check is done to verify unit is in a safe mode to start
- Pilot Closed
- Main Closed
- No Flame detected
- Lockout input closed
- PRS input closed
- ESD input is closed
Step #2
-
-
Sparker starts sparking and Pilot opens
- Sparker sparks 20 times per second for a total of 5 seconds.
- After 5 seconds of Spark, the Pilot remains open for 10 seconds for flame detection.
- If no flame is detected, the Pilot is closed and the system goes into a purge delay.
After the purge delay and if the retry count has not been exceeded, the unit will again try
to light the burner.
The unit is only allowed a set number of retries. If the retry count has been exceeded,
the unit goes into Idle mode and the alarm output indicates an alarm condition. In idle
mode, no additional relight attempts will be made unless there is operator
intervention.
Step #3
-
Pilot flame verification and Main valve opening
- After ignition, if the pilot is verified for 10 seconds, the Main valve is allowed to open.
- The pilot temperature has to reach the high setpoint before the Main will open.
- If flame fails anytime during this sequence, the unit will go into a purge sequence. If
the retry counter allows, it will attempt a relight; otherwise it will go into idle mode,
alarm and wait for operator intervention.
13
P R O F I R E
C O M B U S T I O N
I NC.
Step #4
-
-
Burner running
If flame is lost for 1.8 seconds, the main and pilot valves will close and the burner will go
into a purge sequence. If the retry counter allows, it will attempt a relight; otherwise it
will go into idle mode, alarm and wait for operator intervention.
If the thermocouple temperature drops below the high setpoint, the main and pilot
valves will close and the burner will go into a purge sequence. If the retry counter allows,
it will attempt a relight; otherwise it will go into idle mode, alarm and wait for operator
intervention.
Notes:
- On unit power up, the unit will first go into a purge cycle, then if in Manual mode the
unit will wait for operator input or if in Auto mode, the unit will attempt an ignition
sequence.
-
During an Emergency Shutdown (ESD), the LED display digits show “ESD”, the unit
will shut down, and the unit will switch to Manual mode. To clear ESD, the operator
must press the OK button. If the unit will not clear, the ESD contact is still open. In this
case, check plant condition.
-
If the Lockout Input opens during the start sequence, the unit will display LCK, prevent
startup, and wait for the operator to press OK. If the LCK does not clear, then the
contact is still open and the operator should check the valve or limit-switch position.
-
If the PRS Input opens at any time, the unit will shutdown, display PRS, and wait for the
operator to press OK. If the unit does not clear, check pressure switches.
-
During the purge time, the unit is prevented from ignition or valve operation until the
timer reaches zero. The LED display digits will display “PU” alternating with the time
left on the purge timer.
-
In normal operation, the display will show the thermocouple temperature. There is a
configuration option to turn off the display and indicator LEDs after a time, to save
power.
-
If the thermocouple is disconnected, the unit will flash 999 and prevent startup.
-
When the burner is operating normally the display will show “RUN”.
14
P R O F I R E
C O M B U S T I O N
I NC.
* During anytime, if the ESD button is pressed or the ESD input opens, the
unit shuts down the burner, goes into Alarm mode, and will not attempt any
relights.
Function Diagram 1
Run
High-set point
Main enable
Purge
Low-set point
Re-lights / or Alarms
? Pilot Flame Temperature
Time?
Type ‘K’ Thermocouple Output Chart
TEMP
°C
40
60
100
140
160
200
240
260
300
340
360
400
440
460
500
540
TYPE
K
MV
1.611
2.436
4.095
5.733
6.539
8.137
9.745
10.560
12.207
13.874
14.712
16.395
18.088
18.938
20.640
22.346
TC
OUTPUT
TEMP.
°C
.401
.605
1.015
1.420
1.620
2.015
2.413
2.614
3.022
3.434
3.641
4.057
4.476
4.686
5.107
5.529
560
600
640
660
700
740
760
800
840
860
900
940
960
1000
1060
1100
Default settings are bolded.
15
TYPE
K
MV
23.198
24.902
26.599
27.445
29.128
30.799
31.629
33.277
34.909
35.718
37.325
38.915
39.703
41.269
43.585
45.108
TC
OUTPUT
5.740
6.161
6.581
6.790
7.206
7.619
7.825
8.232
8.636
8.836
9.233
9.626
9.821
10.209
10.781
11.158
P R O F I R E
C O M B U S T I O N
I NC.
Message Codes
Always ensure proper voltage is applied; +10 to + 28 VDC. Earth ground is required.
Display Message
Cause
Action
Unit is in auto mode
No action
required
LCO
Limit switch is open when ignition
sequence initiated.
Ensure valve is
closed and switch
in proper
position.
P-C
Pilot in cool down, thermocouple
must cool to low set point
No action
required
PRS
Fuel pressure switches open.
Ensure proper
fuel pressures.
999
Check probe connections. Check
probe
PU
Purging
No action
required
ESD
ESD contact open or manual push
button depressed
To clear, push
OK
RDY
Unit is in ready state
No action
required
RUN
Unit is running
Press OK to read
pilot temperature
FAL
Unit has failed to start
Check pilot gas
AU
16
Replace
thermocouple
probe.
P R O F I R E
C O M B U S T I O N
I NC.
Display Message
Cause
Action
Check pilot for
flame. Reset
system
Err 1
Start sequence initiated while
FLAME is detected.
Err 2
Configuration memory failure.
Replace door
card.
Err 3
PILOT button pressed for more
than 30 seconds.
Clear and restart
sequence.
Err 5
Thermocouple connection
disconnected.
Check Probe.
Err 6
Pilot or Main solenoid detected ON
when should be OFF
Check solenoids.
Replace bottom
card.
Err 20
Internal self-check fault.
Replace door.
Note: If all the LED’s are off, the unit may be configured for power-saving mode. Press OK
button to turn on LED’s
17
7.1. Profire plug –in temperature control module
INSTALLATION AND OPERATING INSTRUCTIONS
for Bath I Control Card in Profire 1100 Burner Management System
Rev. 1 – 20 November 2008
Function
The Bath I Control Card for the Profire 1100 adds a three-stage high temperature shutdown functionality.
Setpoints can be configured and saved in the Profire 1100 for each temperature trip limit. Bath I Control
Card should not be used directly for temperature control but only as a backup in case primary temperature
control fails. In addition, Bath I Card protects system from overheating in case process heat demand is
lower than the burner low fire, i.e. beyond burner maximum turndown.
Primary Process Temperature Control
Primary process temperature control must be provided by a temperature controller (TC101) external to
this BMS and using a separate temperature element (TE101). A temperature switch, I/P controller, or a
pneumatic temperature controller may be connected to a temperature control valve (TCV205).
Alternately for heaters with fuel inputs not exceeding 1 MM Btuh, a temperature switch (TSH101) can be
wired in series with the BMS output to the automatic safety shutoff valve(s) (SSV202 & SSV 203). To
meet the intent of the CSA B149.3 Code, a controller (TC101), which is not connected to a certified
safety shutoff valve(s) (SSV202 & SSV203) can operate the burner between its maximum and minimum
fire only, but it cannot shut the burner off entirely. This means that the TCV205 must have either a
mechanical or an electronic low fire stop (STP205). In addition, heaters with fuel input in excess of 1
MM BTU/hr must have a low fire start (SOV205) and slow opening valves (SPV205) (10-30 seconds
opening time recommended).
K-type Thermocouple to Bath I Card Connection
K-type thermocouple (TE102) inserted into a thermowell immersed in the bath liquid, must be wired
using a K-type 20 Ga thermocouple wire (yellow (+), red (-), shield) to the optional Bath I card mounted
on the inside of the Profire 1100 door. Shield connection should be done only on the controller side.
Thermocouple sheath tip must be in contact with the bottom of the thermowell. Spring loaded
thermocouple and/or use of heat conductive high temperature compound is recommended to avoid
erroneous temperature readings. Standard wire should not be used for thermocouple connection to the
Bath I card, as it may introduce a significant error in temperature readings.
Fuel Train Design
The most common P&ID is shown in the diagram below. It is based on the use of two CSA 6.5 C/I
certified shutoff valves (SSV202 & SSV203) and one pneumatic TCV205 with EQ% trim, minimum fire
stop (STP205), minimum fire bypass solenoid valve (SOV205) and a speed control valve (SPV205). Bath
temperature is controlled by an external pneumatic controller (TC101), such as a Kimray HT12.
Other standard or customized designs are available from ENEFEN Engineering Ltd. All designs are fully
compliant with the CSA B149.3 Code and can be Field Approved under the Alberta Municipal Affairs
Accepted ENEFEN Fired Appliance Field Approval Program in Alberta or by applicable Authority
Having Jurisdiction in other Canadian provinces.
Three-Stage High Temperature Shutdown (TSHH101, TSHH102, TSHH103)
Profire 1100 BMS displays the current bath temperature value (PV) read from the temperature element
TE102 as “PU”
The three temperature shutdown setpoint values are displayed as:
TSHH1 = “SP” (default value 50 deg C)
TSHH2 = “HH1” (default value 60 deg C)
TSHH3 = “HH2” (default value 65 deg C)
In addition, Profire 1100 displays:
Bath temperature low alarm as “bLo” (default value 0 deg C), and
Temperature setpoint deadband as “dEd” (default value 4 deg C).
Each of the above setpoint values can be viewed by repetitive pressing of the PROG button and when the
desired label is displayed, its associated value can be adjusted by pressing UP and DOWN buttons then
saving it to the memory by pressing the OK button. By holding down the UP or DOWN buttons, the value
will change in increments of 10.
Since the TSHH1, TSHH2 and TSHH3 values are interrelated and the controller expects the TSHH1 to be
the lowest and the TSHH3 the highest value, it is recommended that when decreasing these three values
the adjustment should be started with TSHH1 followed by TSHH2 and then TSHH3. When increasing the
three values the adjustment should be done in the reverse order.
When changing the setpoints, the “SP” will not increase above “HH2” minus 2 deg C, and “HH2” will not
decrease below “SP” plus 2 deg C. If attempting to increment beyond these limits Profire 1100 will
momentarily display “ERR”.
If the password is enabled, pressing the PROG button will only allow the operator to change the TSHH1
(“SP”) value. The operator must press OK and then enter the password to change any other settings
including the TSHH2 (“HH1”) and TSHH3 (“HH2”) setpoints.
While the unit is idle or running and not in program mode, the operator can press the UP or DOWN
button to scroll through the following values:
“PU” = current bath temperature reading from bath thermocouple
TSHH1 (“SP”) = main burner shutdown setpoint
TSHH2 (“HH1”) = pilot shutdown setpoint
TSHH3 (“HH2”) = heater high temperature trip setpoint
“PLc” = Pilot temperature reading from pilot thermocouple
At any time while displaying these values, the operator can press the OK button to return to the
respective idle or running display.
Deadband (“dEd”) Value
The deadband is set by pressing the PROG button until the “dEd” is displayed. The deadband can be
adjusted from 0 to 10 degrees C and applies to the THH1 (“SP”) and the THH2 (“HH1”) setpoints. The
deadband adjusts the difference between the point at which either main burner or pilot, or both are turned
odd, then turned back on.. For example, if the TSHH1 (“SP”) is set to 60 deg C and the dead band
(“dEd”) is set to 5 deg C, the main burner will be turn off when the bath temperature exceeds 60 deg C
and will be turned back on when the bath temperature decreases to 60 deg C – 5 deg C = 55 deg C.
TSHH1 (“SP”) High Temperature Shutdown
The lowest high temperature shutdown setpoint TSHH1 (displayed as “SP”) is used as a backup to the
primary temperature control loop (TC101). In the event of the loss of control by TC101, or an overtemperature condition at low fire, Profire 1100 BMS will remove power to main safety shutoff valve(s)
without causing a system trip or alarm. When the burner is running normally, the display is cycling first
through “SP” label, followed by its setpoint value, then the “PU” label followed by the actual bath
temperature. If the “PU” exceeds the “SP” for a period longer than 10 seconds, the MAIN burner valve(s)
is closed until the bath temperature decreases for a period longer than 60 seconds below the “SP” value
minus the deadband (“dEd”) value. Then the MAIN burner valve(s) reopen. When the MAIN burner
valve is closed due to exceeded “SP”, the MAIN LED on the front panel will flash.
For example: if TSHH1 (“SP”) = 50 deg C and “dEd” = 2 deg C the main valve(s) will close if the bath
temperature (“PU”) exceeds 50 deg C for more than 10 seconds, then will reopen once the bath
temperature decreases to 48 deg C for more than 60 seconds.
Warning: During the TSHH1 (“SP) shutdown, the main valves can automatically restart at any
time. To prevent main valves from reopening, press the MODE button to switch to MANUAL mode. All
alarms and conditions, which automatically switch the unit to MANUAL, will also cancel the temporary
main burner shutdown.
TSHH2 (“HH1”) High Temperature Shutdown
The middle high temperature shutdown setpoint TSHH2 (displayed as “HH1”) is used as a backup in case
the pilot flame alone overheats the system (zero process demand and low heat loss). Profire will remove
power to the pilot safety shutoff valve without causing trip or alarm.
When “HH1” setpoint is exceeded for a period longer than 10 seconds, Profire 1100 will shut down the
pilot until the bath temperature (“PU”) decreases for a period longer than 60 seconds below the “SP”
value minus the deadband (“dEd”) value. Then the ignition is turned on and both pilot and main flame
restarted. During the pilot shutdown due to exceeded “HH1”, both the PILOT and MAIN LEDs on the
front panel will flash indicating the temporary burner shutdown. Also the display will show “H-1”
alternating with the current “HH1” value.
For example: if TSHH1(“SP) = 50 deg C, TSHH2 (“HH1”) = 60 deg C and “dEd” = 2 deg C the pilot
valve will close if the bath temperature (“PU”) exceeds 60 deg C for more than 10 seconds, then the pilot
and main flame will be restarted once the bath temperature decreases to 48 deg C for more than 60
seconds.
Warning: During the TSHH2 (“HH1”) shutdown, the burner can automatically restart at any
time. To cancel the temporary shutdown and prevent automatic restart, press the MODE button to switch
to MANUAL mode. All alarms and conditions, which automatically switch the unit to MANUAL, will
also cancel the temporary shutdown and prevent automatic restart.
Intermittent and Continuous Pilot Mode
There are two “special cases” of TSHH2 (“HH1”) setup:
1) If TSHH2 (“HH1”) is set to the same value as “SP”, Profire 1100 BMS will turn the pilot off at the
same time as the main burner. Then, once the bath temperature (“PU”) decreases below the “SP”
value minus the “dEd” value for a period longer than 60 seconds, Profire will automatically restart
the pilot and the main burner. This mode is recommended as a fuel savings measure, especially on
systems using propane for pilot flame.
2) If TSHH2 (“HH2”) is set to zero (0), Profire 1100 BMS will maintain the pilot operation until the
bath temperature exceeds TSHH3 (“HH2”) and the heater trips. This is a traditional operating
method of fire-tube heaters resulting in higher fuel consumption. Once set to zero display of the
“HH1” setpoint value will display “OFF” indicating that a separate pilot trip point is disabled.
TSHH3 (“HH2”) High Temperature Shutdown
The highest high temperature shutdown setpoint TSHH3 (displayed as “HH2”) is the final heater trip
point. If bath temperature (“PU”) exceeds TSHH3 (“HH2”) setpoint for a period longer than 10 seconds
the Profire 1100 will ESD and alarm. The display will show “H-2” alternating with an “ESD” display.
The operator must press the OK button to acknowledge the alarm before the unit can be restarted.
Bath Temperature Low (“bLo”) Alarm
An additional temperature setpoint in the Profire 1100 BMS is the bath low temperature alarm (“bLo”). If
bath temperature (“PU”) decreases below “bLo” setpoint the Profire 1100 will alarm but will maintain
normal burner firing. The display will show “bLo” alternating with the current bath temperature value.
The alarm will be automatically reset once the bath temperature increases above the “bLo” setpoint. This
function of the Profire 1100 BMS is strictly for the annunciation purposes for the operator in case of an
excessive process load or problems with reduced burner firing rate.
Pilot Thermocouple Display
If the Profire 1100 is set to either dual flame rod/flame thermocouple flame supervision mode or an
emergency flame thermocouple only mode, the pilot thermocouple temperature is displayed during heater
startup until the main safety shutoff valve(s) (SSV2023 & SSV203) open. During this time, the display
will alternate between “PLc” and the pilot temperature. The pilot temperature can also be displayed by
pressing the UP or DOWN buttons while the unit is in idle or running.
Bath Thermocouple Failure
If the process temperature thermocouple becomes disconnected or fails, the unit will
immediately shut down and display “ERR” then “31”.
Thermocouple Calibration
The bath thermocouple reading can be adjusted by +/- 10 deg C using a calibration feature in the menu. If
bath temperature can be accurately confirmed using a temperature calibrator or an accurate temperature
gauge press PROG button until “CPU” is displayed followed by the “CPU” value. The “CPU” value can
be adjusted by pressing the UP or DOWN buttons. Once the correct temperature is displayed, press OK to
save the calibration factor.
The calibration feature is for fine-tuning only and should not be used to compensate for non-linear
temperature reading errors due to improper wiring used, grounding, or thermocouple problems. Typically,
a new Profire 1100 BMS controller should show bath temperature within +/- 1 deg C. If error exceeds +/5C, the problem should be investigated and rectified.
Common thermocouple problems
1) Thermocouple reads ambient temperature but the actual temperature is known to be higher - Check
for shorted thermocouple positive and negative wires
2) Thermocouple shows a large temperature error or the temperature changes erratically - Check that
the thermocouple is isolated from ground. A short to power supply or earth ground on either lead
from the thermocouple will create an offset.
8. Fuel train Parts Manual
8.1. Fisher 627 Pressure Regulator Manual