Hastings COUNTERFLO CF SERIES Manual

Installation and Service Manual
COUNTERFLO
CF SERIES HEATERS
GAS FIRING
Notice
Read These Instructions Before Installation
ISCF-1
March 2012
Supersedes April 2011
WARNING
FOR YOUR SAFETY
The use and storage of gasoline or other flammable vapors
and liquids in open containers in the vicinity of this appliance
is hazardous.

TABLE OF CONTENTS
Section I. – General Information 1
A. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Equipment Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section II. – Installation Procedure 3
A. Handing the Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Positioning the Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Combustion Air Openings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D. Location of Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
E. Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F. Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
G. Exhaust Duct Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
H. Optional Remote Control Panel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section III. – Pre-Start Inspection 8
A. Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section IV. – Start-up 11
A. Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Section V. – Maintenance Schedule and Lubrication Requirements 20
A. Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
B. Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
C. Testing of Controls & Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Section VI. – Troubleshooting 22
A. Troubleshooting Gas-Fired Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
B. General Troubleshooting Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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SECTION I. – GENERAL INFORMATION
A. PURPOSE
The purpose of this manual is to present a guide for proper installation, maintenance, and
operation of the Counterflo CF Series heaters, and to supplement, but not to replace, the services
of qualified field service personnel to supervise the initial start-up and adjustment of the
Counterflo unit. Persons without previous experience with large commercial and industrial
equipment should not attempt the initial adjustment and checkout procedure which is essential
before such installations may be considered as ready for operation. This manual should be made
readily available to operating personnel as an aid in trouble-shooting and proper maintenance.
B. SHIPPING
Base Counterflo units are shipped with blower and burner sections assembled. Discharge air
nozzles and/or discharge hoods, optional filter and/or damper sections, or other large optional
accessories are assembled and shipped mounted and wired whenever possible within limitations
of shipping and handling. Optional accessories shipped separately are shipped as assembled
sections. Any wired accessories which have been disassembled for separate shipment require
no additional conduit or wire for field reassembly. All wire leads will be tagged for ease of
reconnection in the field.
Shipments are made F.O.B. Hastings, Nebraska, by truck. In either case, the unit is securely
strapped, tied, and blocked to prevent shipping damage. All shipments are checked by an
inspector before they are accepted by the carrier. Parts that are shipped unmounted are noted on
the bill of lading. These parts, where feasible, are packaged and shipped with the units. Upon
receipt of shipment, all units should be checked against the bill of lading to insure all items have
been received. The units should be checked carefully for physical damage in the presence of the
carrier’s representative. If parts are missing or damage has occurred, a claim should be filed
immediately with the carrier.
All Counterflo units are given a complete operations test and control circuit checkout before
shipment. A copy of the flame test report and wiring diagram is included with each unit shipped.
If correspondence with the factory is necessary, please provide the unit model and serial number.
C. STORAGE
If weatherproof equipment is not installed within 5 days after receipt, the equipment must
be stored in a dry environment and free of rodents.
D. EQUIPMENT DESCRIPTION
The Counterflo heater is a rugged industrial grade space heater. Models are available for vertical
upright mounting indoors, or outdoors, and horizontal mounting for indoor floors, ceiling
suspension or rooftops.
1. Cabinet and Frame
Rugged channel iron frame and all aluminized steel cabinet surfaces are painted with heat and
corrosion resistant industrial enamel. Standard unit includes three side return air screens.
Burner end has a closure plate for motor access.
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2. Blowers
Depending on heater size, there are two or three centrifugal, double width, double inlet,
forward curved, class I industrial fans mounted on a one-piece shaft with self-aligning 200,000
hour prelubricated ball bearings. Blower wheels are statically and dynamically balanced.
Fixed drives are standard on all units. A premium energy efficient open dripproof ball bearing
squirrel cage induction T-frame motor is provided as standard for all voltages.
3. Burners
Standard burner is On-Off.
Gas (G) – Power type with pilot spark ignition and main burner pilot ignition for use with
natural, manufactured, mixed, liquefied petroleum gas or liquefied gas/air mixture. Included in
the manifold are main gas electric shut-off valve with linkage to combustion air damper, main
and pilot gas pressure regulators for maximum inlet pressure of 1 PSIG, pilot gas-air mixer and
pilot solenoid valve. Mininum standard entering gas pressure is 4 ounces.
4. Fuel and Electric Controls
Standard components for Counterflo Series heaters include a Nema 1 control box with
electronic flame safeguard system and ignition transformer, motor starter, control transformer,
high temperature limit switch, air flow switch, and gas electrical control system.
5. Control System
The standard On-Off control system is obtained with a single pole, single throw thermostat that
closes upon a temperature drop below setpoint. Fan operation is intermittent. A detailed
sequence of operation for standard gas-fired heaters is provided later in this manual.
Thermostat is factory furnished for field mounting and wiring.
The optional control system for Hi-Lo-Off burner operation is obtained with a two-stage
thermostat that closes in sequence on a temperature drop below setpoint. Fan operation is
intermittent. The thermostat is factory furnished for field mounting and wiring.
The optional modulating control system has an On-Off thermostat as described above plus a
modulating thermostat to control a modulating butterfly fuel valve. Fan operation is
intermittent. Thermostats are factory furnished for field mounting and wiring.
6. Remote Control Panel (Optional)
The optional panel is furnished with a heavy duty toggle switch and three 115 volt signal lights
as depicted in Figure 8. The switch controls the blower and the burner. The signal lights
indicate supply blower operation (white light marked “blower”), burner operation (amber light
marked “heating”), and safety lockout (red light marked “lockout”). Remote control panel lids
are 16 gauge. Wiring box dimensions are 8” x 5” x 3-1/2” deep. All wiring is 14 AWG 16/30
stranded 105°thermoplastic or equivalent, color coded per corresponding wiring diagrams.
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SECTION II. – INSTALLATION PROCEDURE
This equipment shall be installed and wired in accordance with regulations of the National
Board of Fire Underwriters, National Electric Code, Gas Burning Appliance and Equipment,
CGA B.149.1 & 2, applicable Provincial Regulations for the class, and local governing bodies
which should be carefully followed in all cases. The following recommendations are not
intended to supplant any requirements of federal, state, or local codes having jurisdiction.
Authorities having jurisdiction should be consulted before installations are made. Local codes
may require additional safety controls and/or interlocks.
The installer must identify the emergency shut-off devices after completion of the installation.
A. HANDLING THE EQUIPMENT
The Counterflo heater has been designed for rigging and handling through the use of special
lifting lug hooks installed on the sides of the unit. As explained previously, the standard unit is
designed for shipping in one piece. Optional accessories must be field mounted. Figure 1
depicts a typical Counterflo heater for vertical floor mounting.
When unloading and setting the heater, use the lifting lugs provided or move the heater on
rollers. Hooks, jacks, or chains must not be used around the casing, exhaust fan, or main
control panel – DO NOT LIFT UNIT USING COMBUSTION CHAMBER BRACKETS.
To be properly set, the Counterflo heater should be placed on a solid foundation and set
exactly as detailed later.
During transit, unloading, and setting of the unit, bolts and nuts may have become loosened,
particularly in the pillow block ball bearing assemblies in the fan section. It is recommended
that all nuts and set screws be tightened. Turn fan shaft by hand to make certain that blower
does not rub against blower housing, and that bearing lock rings are tight.
Open the cover on the electrical control box located near the middle on the side of the burner
section. Box can be opened by turning main disconnect switch to the “off” position. Inspect all
wire terminals and wiring terminations to ensure that all connections are tight.
B. POSITIONING THE HEATER
Locate the heater exactly level, making certain the minimum clearance is maintained between
the heater, and any unprotected combustible material. The clearances are: 48” from main
control panel located at the burner end, 18” at the rear, both sides and top. The exhaust stack
clearance must be 18”. See page 9 for stack details. Units must be installed on non-
combustible flooring.
For convenient access for maintenance, provide 24” clearance at the right side, as seen when
facing the burner, and 36” at the rear. Position the heater, if practical, with the left hand side
(as seen from burner end) next to any adjacent wall.
Special attention should be given to the exhaust duct connections, electrical power and control
hookup points, and fuel connection points. This information should be cross-checked with the
position of support beams and stand pipes to insure that clearance dimensions coincide with
those of the unit.
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The following recommendations are not intended to supplant requirements of federal, state or
local codes having jurisdiction. All local authorities having jurisdiction should be consulted
before the installation is made. The heater should be installed in accordance with the standard
of the National Board of Fire Underwriters for the class and all wiring connections must
conform to the National Electric Code.
C. COMBUSTION AIR OPENINGS
When the heaters are installed in a separate heater room with fresh air and return air ducts
running direct to the base of the heater, or when the plant is under a high negative pressure
condition, provisions should be made for an outside source of combustion air. A conservative
rule of thumb for estimating the inlet area required is 90 square inches per 1,000,000 BTU/HR
heater output. The following table lists the recommended free area of vent opening in the
outside wall for various heater sizes.
HEATER SIZE AREA OF COMBUSTION AIR CONNECTING DUCT
MODEL INTAKE OPENING – SQ.INCHES DIAMETER – INCHES
20 18 6
25 22 6
40 36 7
50 45 8
75 68 9
100 90 11
125 113 12
150 135 13
175 158 14
200 180 14
225 202 16
250 225 18
275 248 18
300 270 19
325 292 20
350 315 20
400 360 22
450 405 24
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DIMENSIONS IN INCHES
CF
MODEL A B C D E F G H J K L
Qty. of
Nozzles
Type of
Hood/
Nozzle
40/55 88 33 52 22 50¾ 2 1 5/16 104½ 16¾ 15¼ 3 II
60/85 94⅝39 ⅛61⅛22¾ 49⅝1½ 1 5/16 114⅛18 17 3 II
100/125 98⅛44⅝70⅝21⅝51¾ 2 1 5/16 118⅛18 17 4 II
150/175 108 55⅛91⅛25¼ 53 2 1 5/16 132½ 22½ 20 4 II
200/225/250 130¾ 60⅛100 25½ 72½ - 1 5/16 153¼ 22½ 20 4 II
275/300/325 134 67⅝142½ 29⅛88 1⅜2 -11/16 1-1/16 164-11/16 29-5/16 29½ 4 III
350/400/450 134 80 164 29⅛88 1⅜2 -11/16 1-1/16 164-11/16 29-5/16 29½ 5 III
Figure 1 – Typical Counterflo Heater for Vertical Upright Mounting
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D. LOCATION OF ACCESSORIES
Where applicable, standard or optional accessories will be placed inside the fan section of the
unit for shipment, and must be removed and installed by the mechanical or electrical
contractor.
E. ELECTRICAL CONNECTIONS
All wiring must comply with all applicable local, state, provincial, and national electric codes.
Since shipment of unit may require disassembly after factory flame test, reconnection of some
electrical devices will be required in the field. Connect electrical wires (supplied in factory
furnished conduit) to appropriate terminals. All leads are tagged to facilitate rewiring in the field.
See wiring diagram provided with equipment. Complete all wiring to any optional accessories
as shown on the electrical wiring diagram as required before applying voltage to the unit.
The total amperage of the main disconnect switch, blower motor, and control circuit transformer
fusing is affected by the addition of 25% to the full load amps as required by the National
Electric Code.
Check the supply voltage before energizing the unit. The maximum voltage variations should
not exceed ± 10%. Phase voltage unbalance must not exceed 2%.
F. PIPING CONNECTIONS
All gas piping connections are not shown in this manual because of the many manifold
arrangements available due to approval code requirements and different types of modulation.
All piping must comply with “Standards of National Board of Fire Underwriters” and all applicable
local codes. Contact factory if exact piping dimensions are required. Protective pipe caps are
furnished on manifolds for shipment from factory; these caps should be removed for installation.
Run correctly sized piping to unit. Install manual gas hand shut-off valve and gas pressure
regulator. Please note that gas line pressure must be as shown on specification plate when unit
is operating at full input.
1. Fuel piping – Gas Models
Figure 2 presents a table of gas piping sizes for varying flow rates. A typical On-Off gas
piping manifold is shown in Figure 3. Gas burner connection will vary between 1”
and 3” depending on the Counterflo model and type of gas.
On gas systems, vent pressure regulator(s) and vent valve (if included with unit) to outside of
building. With vent pipe outside, install a proper vent cap and/or screen to prevent entrance
of foreign material and plugging.
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Furnished and Installed by Others
Furnished By Factory, Installed By Others
Factory Furnished And Installed
ITEM DESCRIPTION
1 Drip Leg X
2 Main Gas High Pressure Hand Shut-Off Valve (If Required) X
3 Main Gas High Pressure Regulator (If Required) X
4 Vent Line Thru Roof To Outside Atmosphere X
5 Main Gas Hand Shut-Off Valve X
6 Main Gas Pressure Regulator X
7 Safety Shut-Off Valve X
8 Manual Leak Test Hand Valve X
9 Main Gas Burner X
10 Leak Test Petcock W/ Plugged Test Connection X
11 Pilot Gas Supply Line X
12 Pilot Gas Hand Valve X
13 Pilot Gas Pressure Regulator X
14 Pilot Gas Solenoid Valve X
15 Needle Valve (If Required) X
16 Pilot Gas Burner X
1 To Natural Gas Or Propane Fuel Supply.
Figure 3 – Typical On-Off Gas Piping
For Counterflo Heaters (1/2# Inlet Pressure)
GAS FLOW CAPACITY (CFH)
Iron Pipe Size (IPS) Inches
Length of
Pipe
(Equiv. Ft.) 1 1-1/4 1-1/2 2 3 4 6 8
50 244 537 832 1680 5018 8464 22472 41518
100 173 380 588 1188 3549 5986 15894 29364
150 141 310 480 970 2896 4885 12972 23965
200 122 268 416 840 2509 4232 11238 20760
250 109 240 372 751 2244 3785 10050 18567
300 99 219 339 685 2047 3454 8170 16943
400 86 189 294 594 1774 2992 7945 14679
500 77 169 263 531 1587 2677 7108 13132
1000 54 119 185 375 1121 1891 5022 9279
1500 44 97 151 306 915 1544 4101 7577
2000 38 84 131 265 793 1338 3554 6567
Figure 2 – Gas Flow Capacity for Piping of
Different Sizes and Lengths
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G. EXHAUST DUCT CONNECTION
Installation of exhaust stack must comply with regulations of the National Board of Fire
Underwriters and local governing bodies.
The exhaust stack, exhaust stack connector, exhaust stack support and miscellaneous items
related to the exhaust stack are to be supplied and installed by others. Exhaust stack located
inside the building must be positive pressure vent.
Connect the exhaust stack to the heater breeching box and run stack through roof as shown in
Figure 7. Avoid use of long horizontal exhaust pipe runs; the exhauster fan has ample capacity
for venting the heater, but cannot perform satisfactorily against strong back drafts or excessive
stack resistance.
Heaters are not approved for use with Type L Vent in Canada.
H. OPTIONAL REMOTE CONTROL PANEL INSTALLATION
1. Refer to Figure 8 for guidelines.
2. All wiring must comply with applicable electric codes.
3. Align box with spirit level.
4. If box is to be surface mounted, three (3) mounting holes in back of box are recommended,
one in each top corner and one at bottom center. If mounting holes are to be located in side
of box as shown, four (4) holes are recommended, two at top and two at bottom.
5. If wiring box is to be recessed, install so that open edge of box will be flush with finish wall.
Install optional flush mounting wall plate. Examine wiring box and control panel for
clearance before providing conduit hole(s).
6. Control panel is furnished with components wired to coded terminal strip. Installer to
connect numbered terminal blocks on remote control panel to corresponding terminal
block(s) in master control panel on unit.
7. Use proper wire sizing practices when running wires for the remote control panel.
SECTION III. – PRE-START INSPECTION
A pre-start inspection is extremely important and should be completed with greatest attention given to
detail. This will insure against possible unit damage on start-up and will save valuable analysis time in
the event malfunctions occur on start-up and check-out.
A. PROCEDURE
1. Check to see that all factory installed pipe plugs have been removed.
2. Check supply voltage against unit voltage.
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MODEL A B C D
D1E E1H J K R S
40/55 4” 8” 8” 13” 13” 18” 18” 6-1/2” 3-3/4” 69 –1/4” 16”
7-3/8”
60/85 5” 10” 10” 16” 18” 22” 26” 7 5/8” 4-3/8” 72-1/16” 20”
8-5/16”
100/125 5”/6” 10”/12” 10”/12” 16”/18” 18”/20” 22”/24” 26”/28” 9-1/4” 5-1/4” 73-1/16” 20”/24” 9-1/2”
150/175 6” 12” 12” 18” 20” 24” 28” 9-11/16” 5” 80-1/4” 24”
13-9/16”
200/250 6” 12” 12” 18” 20” 24” 28” 9-11/16” 5” 23-1/8” 24”
9-5/8”
275/325 10-1/2” 16” 16” 22” 24” 28” 32’ 11-5/16” 5-5/8” 33” 37-1/4” 6-3/8”
350/450 14” 18” 18” 24” 26” 30” 34” 11-5/16” 5-5/8” 33” 48”
9-1/4”
Note: Use D1and E1for orders with FM approval.
Note: Interior flue vent must be suited for positive pressure venting.
Note: Avoid 90° elbows or sweeping elbows if at all possible by using two 45° elbows.
Figure 7 – Exhaust Details for Counterflo Heaters
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-10-

3. Check all electrical connections in the main control panel.
4. Check that all fuses are installed and that fuse sizing agrees with the fuse chart affixed on
the inside of the main control panel door.
5. Check to see if all gas connections are tight and that all joints have been properly sealed.
6. Check positioning of flame rod, and spark rod. Make sure the combustion air fan is
fastened securely to motor shaft.
7. Check for cracks in refractory around the blast tube. This inspection requires close
observation with the aid of a good flashlight. Even a tiny crack can cause a positive
pressure within the combustion chamber and result in faulty burner operation.
8. Check fan supply area to insure freedom of shaft rotation and proper belt tension. Check to
see that blowers are tight on shaft and turn freely without rubbing the blower housing. The
motor and shaft should turn readily by hand pull of the belts. Properly adjusted belts can be
easily depressed about one inch. Make sure the fan shaft pillow block bearing locking
collars are tight and main fan bearings have been lubricated.
9. Lubricate main fan bearing with a high grade lithium base grease. Perform at least every
quarter (three months) or schedule according to equipment use.
10. Check fan motor to insure that pulleys are secure and drive belts are tight.
NOTE: Do not start the burner unless the main blower access plate or screen is secured ion place.
Deflection ForceBelt Cross Section
(marked on belt)
Motor Pulley Pitch
Diameter Minimum Maximum
3.0” – 3.6” 2.62 lbs. 3.25 lbs.
3.8” – 4.8” 3 lbs. 4 lbs.
A
5.0” – 7.0” 3.25 lbs. 5 lbs.
3.4” – 4.2” 3 lbs. 5 lbs.
4.4” – 5.6” 4 lbs. 5.87 lbs.
B
5.8” – 8.6” 5.25 lbs 7.87 lbs.
11. Check all areas for cleanliness.
SECTION IV. – START-UP
All safety and operating controls have been checked during the factory test period; however, it is
advisable to complete a similar check when first operating the unit. Before attempting any service
work, make sure all electrical switches are open and manual valves are closed.
A. PROCEDURE – Caution: Always wear proper protective gear with face shield while opera-
ting these units.
1. Precheck:
a. The high limit should be set for 200°F. The fan control should be set at 120°F on
high and 90°F on low. Note that fan operation is intermittent.
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b. Combustion air and exhaust air proving switches are factory set for 0.2” to 0.4” W.C.
c. Recheck all set screws on motor sheave and fan sheave. Check alignment of belt(s) and
pulley(s). Run blower for a few minutes and adjust motor take-up if necessary. Motor is
mounted on an adjustable base shown on Figure 9. Do not over-tighten belt(s) since
excessive tension will reduce belt life and cause excessive load on bearings. After initial
start, allow the belts a few days’ running time to become seated in pulley grooves , then
readjust as necessary. Do not roll belts over grooves or sheaves as this will result in per-
manent belt damage.
2. With the unit main control panel under lock out tag out procedure applied and with the (first-
supply) manual gas valve being closed, remove the plug from the (first) electrical safety
shutoff valve on the inlet side (in some cases a plugged tee is installed). Open the (first-
supply) manual valve to purge air from the gas line. Caution: use an electronic combustible
gas indicator as air is purged. Do not depend on sensing the odor of gas to determine if the
gas line is purged. Refer to NFPA-54 (2012 edition or later) on procedures for proper gas
purging.
3. Close main disconnect switch.
4. Push reset button on unit programming controller while power is on.
5. The On-Off burner switch on the master control panel will operate the burner and exhauster
blowers.
6. All three phase motors were properly phased during factory testing. If rotation is reversed,
interrupt main power supply and interchange any two of the incoming power leads.
Reestablish power and recheck fan operation.
7. On three phase units, the starter contacts should pull in and hold quietly without “clatter”. If
they do not operate quietly, check immediately for proper line voltage. Even temporary low
voltage at start-up will cause constant operating trouble and must be corrected before the
Counterflo heater is placed in service.
8. Open manual hand valves. After manual valves have been opened, burner should ignite
automatically if thermostat is in control circuit.
9. The burner assembly for gas Counterflo heaters generally requires readjustment of the flame
test settings for proper operation under actual field conditions. The most accurate guides to
proper burner adjustment are:
WARNING: Never be within the swing radius of the access door when making flame
observations through the peephole. Always wear proper protective gear with face
shield while operating these units.
a. Proper flame travel within the stainless steel combustion chamber differs from the pattern
usually desired for a refractory lined furnace. Never adjust the burner to produce a short
“bushy” flame concentrated in the front end of chamber as shown in Figure 10A. Such a
flame concentrates heat release in the front end of the chamber and creates a short circuit
between the burner and economizer tube section which results in high stack temperature.
Figure 10B illustrates a flame that is much too long and will cause over-heating of the rear
wall. A correct flame should be fairly vigorous, free of smoky haze, and should barely
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impinge on the rear wall of the chamber. Figure 10C illustrates proper flame travel. This
long steady flame provides adequate time for complete combustion and balanced heat
release to all surfaces of the chamber. Typical draft conditions are noted in Figure 11 for
firing at full rate capacity. Adjust to field conditions when necessary.
b. Stack temperature, CO2, O2, CO and percentage of excess air percentage content of the
flue gasses.
c. Proper flame signal from the flame rod sensor, (4-10VDC).
10. Burner Start-UP
Open the air louver on the air inlet to approximately the one-quarter open position. Open the
manual gas valve slowly, burner will ignite. Allow motorized safety shut-off valve to open valve
until gas pressure on the gauge is approximately 4 ounces w.c. (See spec plate for factory dif-
ferential pressure setting. Use “U” tube manometer). Observe flame conditions and com-
bustion readings from combustion analyzer. If gas flame has yellow or yellow tip appearance,
open combustion air louver wider until flame appears short and hard.
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Adjust gas pressure regulator on burner to the unit name plate operating pressure rating while
firing with the manual gas cock in the wide open position. Read gas meter serving burner,
input should be approximately that stated on the burner name plate. If not, readjust regulator
to obtain rated input. NOTE: Check to see if other appliances are on before reading meter.
When the gas input rate is established, air adjustments may be made. The final air setting
should produce a flue gas analysis of between 8½% and 9½ % CO2., and 5.5% to 6.5% O2
with 0 ppm to 10 ppm of CO and 23% to 30% excess air.
Your local gas utility may aid you in making burner adjustments if you do not have the proper
instruments.
Start and stop burner several times to insure proper operation. Check for proper functioning of
high limit and operating control. Burner is now ready for normal operation.
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COUNTERFLO / AFX FLAME TEST REPORT
Model No._________________ Configuration No.___________________ Ser. No.___________
Date: _______________ Assembled By _______________ Tested By_____________
Approvals and/or Label No. ____________________________
MOTOR OPERATING DATA
Blower Exhauster Burner
Nameplate As Read Nameplate As read Nameplate As Read
MFG.
MODEL/CAT NO.
HP
RPM
VOLT
AMP
PHASE
FAN OPERATION
Main Fan
Design Speed ____________ RPM Drive Fixed_________ Variable________
As Read____________ RPM
Exhauster
Design Speed ____________ RPM Drive Fixed_________ Variable________
As Read____________ RPM
BURNER OPERATION
MFG. HASTINGS MAXON OTHER _______________
MODEL ____________________ ________________ _______________
FUEL TYPE NG or LP
DESIGN INLET PRESSURE _______________ “ W.C./PSI AS TESTED ____________ : W.C./PSI
BURNER (High Fire) OPERATING DIFF. PRESSURE (7” W.C. MAX) AS TESTED _________” W.C.
FLAME SAFETY D.C. Volt Reading (High Fire) _____________ (Low Fire) ______________
STACK TEMPERATURE _____________°F COMBUSTION TEST __(Attach Comb Text Printout)_
DRAFT IN COMB CHAMBER (Hot) _______________” W.C. STACK _______________” W.C.
DIELECTRIC TEST
1-30V @ 600V for 1 Sec.
31-120V @ 1500V for 1 Sec.
121-250V @ 1800V for 1 Sec.
215-600V @ 2400V for 1 Sec.
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Control Set Point
HIGH LIMIT (HL) OVERRIDING TIMER (OT)
AUXILIARY HIGH LIMIIT (AX) AIR PROVING SWITCH (AP)
BONNET FAN SWITCH (BF) CLOGGED FILTER/BLOCKED INTAKE (CS)
LOW LIMIT (LL) COMBUSTION AIR SWITCH (CA)
OUTSIDE AIR CONTROL (AT) DRAFT SWITCH (DS)
MODULATING DISCHARGE CONTROL (MD) LOW GAS PRESSURE SWITCH (LG)
MODULATING LO LIMIT CONTROL (ML) HIGH GAS PRESSURE SWITCH (HG)
DELAY TIMER (DT) ROOM STAT (RT)
Modulating Damper Wired to Unit/Adjusted
Yes No Yes No
Fresh Air Discharge Air
Return air Other
Operation and Inspection
This unit has been tested and inspected to insure that: (1) Fabrication, wiring, quality and location of
all materials agree with Hastings HVAC Standard. (2) Bearings, sheaves, belts, and motors have
proper alignment, lubrication and adjustment. (3) Controls, valves and programmers have proper
sequence of operation and setting. (Limit, pressure and fan switches, thermostats, regulators, timers,
microampere generation, pre and post purge, etc.)
________________________________________________________________________________
COMMENTS
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HASTINGS COUNTERFLO
OPERATING PRESSURE SETTING
PROCEDURE FOR THE MAXON BURNER
1-1/4” Gas
Test Conn.
(not for pilot)
3/8” Pilot
Adj. Orif.
Cock
Flame Rod
w /Rubber Cover
(or UV Scanner) (DETAIL)
ATTACH ONE SIDE OF THE FLUID MANOMETER TO THE “1/4 IN. GAS
CONN.” ON THE MAXON BURNER. ATTACH THE OTHER SIDE OF THE
MANOMETER TO A 1/4” X 7” TUBING WHICH IS INSERTED THROUGH
THE SMALL OBSERVATION PORT OF THE COMBUSTION CHAMBER.
THIS WILL YIELD A DIFFERENTIAL PRESSURE.
AFTER THE BURNER HAS BEEN RUNNING FOR 15 TO 20 MINUTES SET
THE OPERATING PRESSURE TO HASTINGS SPECIFIED PRESSURE
LISTED ON THE NAME PLATE OF THE HASTINGS UNIT WHILE IN THE
HIGH FIRE MODE.
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