How to Select Control Panel Components for Riello Press1G Burners & Single Thermocouple

Hi,
I have a project which consists of designing a control panel for a Biomedical Waste Incenrator.
The incenrator consists of 3 burners and a thermocouple sensor. 2 burners are located at the top of the chamber and 1 at the bottom.  When inceneration reaches  800 degrees celcius, the two top burners are shutoff while the bottom one is still in operation....Sort of a low burn....When High Burn is required, all if the burners are switched on.I would like to know how does one determine the specification for the components of a control panel that should successfully carry out proper incenration....
What could be the simplest approach?....Note there is only one thermocouple. And the burner in use is the Riello Press1G series 3474520 model.
Thanks.

On the face of it, it seems simple enough - start - activate all 3 burners - monitor temperature via thermocouple - when it is above 800 degrees switch off burners 1/2 and leave no 3 on - presumably then run for a certain time, then shut down, maybe have a time or temperature interlock to ensure chamber can't be opened till cool.  You'd also need some emergency stop facility and maybe some other safety checks.You could build your own controller to do this (an Arduino could do this in theory, with the right interfacing components) but whether you'd get any off-the-shelf hardware to do this for you I am not sure.Aubrey - you do more of this sort of thing - any ideas?

There are so many questions...1. What is your level of expertise?2. What do you want to get out of this project- do you want to learn to program microcontrollers, do you want to learn PLCs (programmable logic controllers) or do you simply want to get the job done?3. Is this an existing installation, is it a project you are shipping to a customer? Are you going to make several or many of them.4. Are you going to be maintaining this for the rest of your working career, do youi have a service department or is a 3rd party going to handle the maintenance?5. Firstly remember there are many "types" of thermocouples. It makes no difference to the approach, but you need to know what type you are using. Does the equipment only have the bare thermocouple or is there signal conditioning to some standard like 4-20mA or 0-10V (proportional to the temperature)..6. I am currently too lazy (weekend) to start digging for data on the burners, but I will presume that they simply turn on with a 24VDC signal.7. If you don't have a power supply, you are going to need one (probably 24VDC) for any combination I can think of.8. Will you want any visual indicators- burners on, temperature measured etc?9. What is you budget?10. Standard packaging and mounting?Enough questions. You asked for the simplest approach and I am presuming you just want a reliable system. I would get a thermocouple signal conditioner (sometimes called a transmitter) with a limit detector something like the microBlox uBTA Series. There are many more manufacturers. Two relays- relay A powered directly from the power so when it's on, the lower burner is on. Relay B controls the top burners. The power through relay B's coil is controller by the limit switch of the signal conditioner. When it is below 800deg, the relay is active, powering the upper two burners. Depending on how you want to set this up in reality, relay A may not be necessary at all.So: power supply, signal conditioner, and a relay (and I guess a power switch) and no programming. Simple enough?You could work around this- the integrated signal conditioner could be 2 devices. You can get them with built in display (for the temperature) and adding 

Just one comment on Aubrey's answer (I knew he would think of more than I did! - A PLC is an ideal device to control something like this - you'd only have a couple of inputs and 2 or 3 outputs, so a small PLC would suffice.  But if you don't know or don't want to learn PLC programming then I'd say contract this out.  Aubrey's simple approach would work fine, but I'd say you'd need more safeguards - a timer to switch it off if left unattended, etc.  There's a huge fire risk here which you want to mitigate as much as possible.  You COULD do this with discrete timers and relays, but again you'd need to have some knowledge of wiring a control board circuit.As Aubrey points out, a lot depends on your level of expertise.

I don't know if it is because it is the weekend or because of an aging brain, but I should have started with the following warning. Fortunately David jogged my memory.Natural gas and Propane are DANGEROUS. Not only can a explosion kill you, it can kill many people in the vicinity And the hazard continues into the future.It seems to me that UL and CSA (Canadian Standards Authority) regulations are more numerous and way stricter than the electricity regulations. In the 3 projects I have worked with that involve gas, not only did the equipment need to be inspected, but the customers found it much easier for that certification to use already certified component parts. They found it far easier to design around the quirks of the certified igniters than to redesign and re-certify. On top of it, the complete installation had to be inspected as well. I was the designer of the circuitry around the heaters and igniter and we still had to add additional precautions.
2 of the 3 projects had air circulation fans (as do all North America home forced air heating systems). The third had the burners out in the open air. The startup sequence required to fans be operating for several minutes before ignition and to continue for several minutes after  the burners were turned off.You have not mentioned any igniters for the burners or if there are circulation fans, so those are some more questions for you as well as what certification you are going to need.All this seems to make your project a little more complex.

Thanks Aubrey and David for your responses.

I am a trainee engineer and have just started my career. 

Aubrey - these are oil burners - datasheet here.However, although they say they have a microprocessor controlled safety control box, the data sheet is a bit short on connection info.But I also found an installation manual with electrical diagrams on Page 26 here. The key is on Page 27.  It does already seem to have some safety features built in and easy shutdown via contacts.

To answer your remaining questions:
2. Simply get it done....However, I am open to suggestion should other control methods prove superior. 

3. It is an existing installation.
4. A service department will be maintaining it.
5. The thermocouple is my proposal as the current thermostat is no longer working.6. The burner is an industrial one (Uses 3phase phase 400V); uses an ignition transformer for ignition (230V -8kV @ 1.8A - 30mA respectively ) 

7.And as for the power supply, can I just feed from a single phase that feeds the burners???....Or Would a bus bar be considered? 

8. Yep...Visual indicators if preferred. 

9. Budget is yet to be determined.But should not compromise safety and risks.

10. Yep standard Packaging.

Your simple approach will be addressed. But I have yet to do an onsite inspection....And what my superiors have decided 

Once Again, thank you very much for your recommendations. Thanks....

Oil burners, huh? Seems the only exercise I get is jumping to conclusions.
The O/P must obviously satisfy the relevant regulatory authorities, but the basic solution could still hold. Let’s wait to hear what Nacanieli has to say.

I don't know if it is because it is the weekend or because of an aging brain, but I should have started with the following warning. Fortunately David jogged my memory.
Natural gas and Propane are DANGEROUS. Not only can a explosion kill you, it can kill many people in the vicinity And the hazard continues into the future.
It seems to me that UL and CSA (Canadian Standards Authority) regulations are more numerous and way stricter than the electricity regulations. In the 3 projects I have worked with that involve gas, not only did the equipment need to be inspected, but the customers found it much easier for that certification to use already certified component parts. They found it far easier to design around the quirks of the certified igniters than to redesign and re-certify. On top of it, the complete installation had to be inspected as well.
 I was the designer of the circuitry around the heaters and igniter and we still had to add additional precautions.
2 of the 3 projects had air circulation fans (as do all North America home forced air heating systems). The third had the burners out in the open air. The startup sequence required to fans be operating for several minutes before ignition and to continue for several minutes after  the burners were turned off.
You have not mentioned any igniters for the burners or if there are circulation fans, so those are some more questions for you as well as what certification you are going to need.
All this seems to make your project a little more complex.
It seems to me that UL and CSA (Canadian Standards Authority) regulations are more numerous and way stricter than the electricity regulations. In the 3 projects I have worked with that involve gas, not only did the equipment need to be inspected, but the customers found it much easier for that certification to use already certified component parts. They found it far easier to design around the quirks of the certified igniters than to redesign and re-certify. On top of it, the complete installation had to be inspected as well. I was the designer of the circuitry around the heaters and igniter and we still had to add additional precautions.2 of the 3 projects had air circulation fans (as do all North America home forced air heating systems). The third had the burners out in the open air. The startup sequence required to fans be operating for several minutes before ignition and to continue for several minutes after  the burners were turned off.

It seems to me that UL and CSA (Canadian Standards Authority) regulations are more numerous and way stricter than the electricity regulations. In the 3 projects I have worked with that involve gas, not only did the equipment need to be inspected, but the customers found it much easier for that certification to use already certified component parts. They found it far easier to design around the quirks of the certified igniters than to redesign and re-certify. On top of it, the complete installation had to be inspected as well.
 I was the designer of the circuitry around the heaters and igniter and we still had to add additional precautions.
2 of the 3 projects had air circulation fans (as do all North America home forced air heating systems). The third had the burners out in the open air. The startup sequence required to fans be operating for several minutes before ignition and to continue for several minutes after  the burners were turned off.Any suggetion ??

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