FLARE IGNITORS & RENTALS, LLC.
Phone: 210-656-7115
13506 Topper Circle Fax:210-656-6728
San Antonio, TX 78233 sales@flareignitors.com
SOLAR CS 308 FLARE IGNITION SYSTEM
HORIZONTAL PROPANE PILOT
INSTALLATION & MAINTENANCE MANUAL
MLN Production Engineer
Sonatrach-Conoco Phillips Association
Algeria
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INITIAL INSTALLATION
1. The CS 3081gnition Box and Solar Panel will come complete, mounted to a
desktop stand. This stand will sit atop of the portable stand you will place
approximately 350 ft. from the end of your flare line tip. You will need to assemble
this stand by attaching the legs to the mounting brackets with the provided bolts
and nuts.
2. The Surefire propane pilot will also come completely assembled and the spark
gap pre-set to 1/16". The Pilot Stand will need to be assembled by attaching the
legs, bases, and top brackets with the provided bolts and nuts. After assembly,
you may want to weld these pieces together for better stability, if you prefer. Place
this stand over top of flare line tip.
Bolt these stands together
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0 RIG UP DIRECTIONS
1. Place Pilot and stand over flare line tip.
2. Attach one end of 1/8,. SS aircraft cable to electrode with
Yz"cable clamp.
3. Connect one end of 1/4" SS tubing to propane jet with SS
compression fitting.
4 Drive the insulator poles into ground (WITHOUT
INSULATORS!!) EVERY 20FT. Place 3" Porcelain insulators
onto insulator poles and tighten with %"nuts and washers.
Run cable around eache insulator careful not to short it out on
the poles.
5. Use tie wraps to secure onto insulators and at the hi-volt
Coil Box, attach to red wire as shown below.
6. Reel out 1/4" SS tubing down flare line past Coil Box Stand.
7. Attach to adapter with compression fitting and then attach to
0 1/4" X 200ft. Propane hose that will run to Propane Bottle
Rack and special hi pressure regulator.
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1. HI VOLT COIL BOX
2. (250') 1213 SOWA EXTENSION CORD
3. (6') RED HI VOLT WIRE
4. BOX STAND
1. SET CS 308 ON QUAD-LEGGED STAND.
2. DRIVE GROUND ROD INTO DIRT AS FAR AS POSSIBLE.
3. CONNECT GREEN GROUND WIRE TO GROUND ROD WITH CLAMP.
4. PLUG EXTENTION CORD INTO PIGTAIL AND RUN OUT TO HI VOLT COIL BOX. PLUG
INTO PIGTAIL.
5. SET PILOT AND INSULATOR POLES AS DESCRIBED.
0 6. TURN ON SWITCH AND CHECK FOR SPARKING. GAP SHOULD BE 1/16".
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HI VOLT TRANSFORMER
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1. PULSE GENERATOR
KIMRAY, HIGH PRESSURE
2. SOLAR CHARGE CONTROLLER REGULATOR USED FOR LOCAL
BUTANE PRESSURES. CONNECT
3. 7AH BATTERRY POL FITTING ONTO BUTANE BOTTLE
AND THE 1/4" PROPANE HOSE TO
4. ON/OFF SWITCH HOSE BARB FITTING WITH HOSE
CLAMP PROVIDED.
5. 2AMPFUSE
6.10 WATT SOLAR PANEL, 12V.
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Ignitor Stand
Assembly of the SureFire... Propane Ignitor stand
1. Match like numbers to each other and fasten to stand using W'xl-1/2" bolts, washers and nuts provided;
tighten accordingly.
2. Using provided hardware, mount the Sure Fire"' Propane Ignitor to top of stand matching like numbers to
one another.
3. Place at the end of the flare line with the end of the Sure Fire"' Propane Ignitor right over the top of the
flare line and secure to the mounting surface or ground.
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0 CS 308 Stand
Assembly of the CS 308 Stand
1. Assemble the legs to the main stand, matching like numbers to one another using 14'' x 1" bolts &
hardware, tighten acco~rdingly. Place 308 stand approximately 90 feet away from the Sure Fire,.,. Propane
Ignitor assembly adjacent to the flare line. (Back towards the rig). Place the CS 308 Continuous Spark
Model Ignition Box with the attached Solar Panel, pointed in a Westerly direction.
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2. Approximately every 20-25 feet between the CS 308 Continuous Spark Model Ignition box and the Sure
Fireno Propane Ignitor, place one 5 foot insulator pole and drive the insulator into the ground, until the pole
is secure. (Approx; 6-8" minimum)
3. Place one 3 inch porcelain insulator on each pole and secure with one washer and~" nut as provided.
4. Uncoil the supplied Stainless Steel aircraft cable.
5. Attach one end of the cable to the threaded rod on the Sure Fireno Propane Ignitor using the supplied #10 x
1 inch Stainless Steel hardware.
6. Utilizing the supplied hose clamp, further secure the cable to the threaded rod.
7. Stretch the cable out, looping once around the 3 inch porcelain insulator, ensuring the cable is taught
between insulators.
8. Connect the red wire protruding from the CS 308 Continuous Spark Model Ignition box to the cable using the
supplied W' x W' stainless hardware. Tighten to 5-10 inch Lbs minimum.
9. Attach the green wire protruding from the CS 308 Continuous Spark Model Ignition box to a flange bolt
connected to the Flare line. Torque to 10-15 inch lbs. (extra ground wire is supplied to bridge the distance if
required)
c PROPANE HOOKUP
Connecting the supplied copper tubing
1. Supplied with your package is a 100 foot coil of X" copper tubing. Remove the tubing from your kit, and
carefully uncoil the tubing, taking caution to prevent kinks in the line.
2. Install (1) compression nut and ferule to the jet orifice located on the back of the Sure FireTN Propane Ignitor.
3. Tighten the compression nut on the Sure Fireno Propane Ignitor to prevent gas leakage. DO NOT OVER-
TIGHTEN.
4. Locate the opposite end of the copper tubing. Install one X" compression nut and ferule on the supplied
male brass connector of the supplied %" LP rubber hose.
5. Roll out the supplied X" LP rubber hose to the propane supply.
6. Connect the supplied manifold & regulator assy to the propane supply.
7. Attach the supplied X" LP rubber hose to the X" hose barb located on the manifold assy.
8. Secure the supplied W' LP rubber hose with the supplied hose clamp.
9. Tighten the manifold assy on the propane supply adequately to prevent gas leakage.
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c IGNITION FLARE SYSTEM
Powering the flare ignition system
1. Open the CS 308 Continuous Spark Model Ignition box and ensure the battery is connected.
2. Turn the power switch located on the side of the CS 308 Continuous Spark Model Ignition box to the "ON"
position.
A clkking sound can be heard at the SureFire"• Propane Ignitor.
WARNING: DO NOT TOUCH STAINLESS CABLE OR IGNITOR WHEN THE SYSTEM IS ON!
ELECTRICAL SHOCK HAZARD IS PRESENT!
A h
l£l.l~
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c Turn on propane supply, and open the YEllOW HANDLE ball valve to allow pressure to flow. Pressure
should be within 15-18 lbs as indicated. Adjustments are possible by turning the BlACK knob on the RED
regulator valve on the manifold.
NOTE: When the Sure Fire- Propane Ignitor is lit, a BLUE flame will be seen exiting from the end,
and a sound similar to a small turbine {jet) engine will be heard.
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TROUBLESHOOTING GUIDE
SYMPTOM 1. Ensure battery is connected, and power is "ON".
2. Ensure the ignitor gap spacing is 1/16" and is free
Not sparking
of debris.
3. Check the supplied battery. Voltage should be
between 12-13 Volts indicated.
4. Ensure insulators are not damaged & remain clean.
5. Check all connections for proper torque and
cleanliness.
6. Check entire unit, cables, and insulators for
improper grounding.
0 PILOT WON'T LIGHT 1. Ensure propane supply is adequate, that fuel is
flowing and the propane regulator indicates 15-18
lbs.
2. Ensure the jet and the pilot are clean, and free
from debris. (with no fuel or ignition powered on
during inspection)
3. Verify electrode is receiving spark.
WARNING: MONTHLY VISUAL INSPECTIONS ARE REQUIRED. TURN OFF OR REMOVE
ALL POWER & GAS/FUEL SUPPLIES PRIOR TO ANY EXPOSURE, VISUAL INSPECTION OR
OTHER INSPECTION OF APPARATUS, EQUIPMENT OR COMPONENTS. EYE
PROTECTION IS REQUIRED DURING ALL INSPECTION(S).
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