Haul-All Equipment SURE FLAME S400 Installation and user guide

September 2, 2003
SERVICE AND MAINTENANCE MANUAL No. 934-6638
PLEASE RETAIN FOR FUTURE REFERENCE
A DIVISION OF HAUL-ALL EQUIPMENT LTD.
LETHBRIDGE, ALBERTA
S400
&
S400T
CONSTRUCTION HEATERS
PRODUCTS

S400 & S400T
CONSTRUCTION HEATERS
Failure to comply with the precautions and instructions
provided with this heater, can result in death, serious
bodily injury and property loss or damage from hazards
of fire, explosion, burn, asphyxiation, carbon monoxide
poisoning, and/or electrical shock.
Only persons who can understand and follow the
instructions should use or service this heater.
If you need assistance or heater information such as
an instruction manual, labels, etc. Contact the
manufacturer.
Fire, burn, inhalation, and explosion hazard. Keep solid
combustibles, such as building materials, paper or
cardboard, a safe distance away from the heater as
recommended by the instructions. Never use the heater
in spaces which do or may contain volatile or airborne
combustibles, or products such as gasoline, solvents,
paint thinner, dust particles or unknown chemicals.
Not for home or recreational vehicle use
WARNING
WARNING
GENERAL HAZARD WARNING

S400/S400T Manual 934-6638 - Page4
READ THIS
WARNING
FIRST!
Theheaterisdesignedandapprovedforuseasaconstructionheater
under CAN2.14-1972. The primary purpose of construction heaters
is to provide temporary heating of buildings under construction,
alteration, or repair and to provide temporary emergency heat.
Properly used the heater provides safe economical heating. Prod-
ucts of combustion are vented into the area being heated.
The heater is not designed as an Unvented Gas Fired Room Heater
under ANSI-Z21.11.2 and should not be used in the home.
ANSI A119.2(NFPA 501C)-1987 Recreational Vehicle Standard
prohibits the installation or storage of LP-Gas containers even
temporarilyinsideanyrecreationalvehicle.Thestandardalsoprohib-
its the use of Unvented Heaters in such vehicles.
Gas inspection authorities in Canada require that the
installation and maintenance of heaters and accessories be
accomplished by qualified gas fitters.
Installation must comply with CAN/CGA-B149.2 Installation
Code for Propane Burning Equipment.
Installation must comply with CAN/CGA-B149.1 Installation
Code for Natural Gas Burning Equipment.
We cannot anticipate every use which may be made for our heaters.
CHECK WITH YOUR LOCAL FIRE SAFETY AUTHORITY IF YOU
HAVE QUESTIONS ABOUT LOCAL REGULATIONS.
Other standards govern the use of fuel gases and heat producing
productsinspecificapplications.Yourlocalauthoritycanadviseyou
about these.

S400/S400T Manual 934-6638 - Page 5
FOR YOUR SAFETY
DO NOT USE THIS HEATER IN A SPACE WHERE
GASOLINE OR OTHER LIQUIDS HAVING
FLAMMABLE VAPOURS ARE STORED OR USED.
S400 & S400T
CONSTRUCTION HEATERS
CONTENTS
Specifications .......................................................................................... 6
Installation ...............................................................................................7
Installation Using APropane Supply Tank ................................................8
Installation For Natural GasApplications ................................................. 8
Operating Instructions .............................................................................9
Sequence Of Operation......................................................................... 10
Common InstallationAnd Operational Problems ................................... 10
Safety Features ..................................................................................... 11
Design RelatedAdditional Safety Features............................................ 12
On-site Safety Problems........................................................................ 12
PreventiveMaintenance ........................................................................ 13
Trouble Shooting S400/S400T............................................................... 14
S400/S400T Heater Parts......................................................................18
S400 Connection Wiring Diagram ......................................................... 20
S400 Ladder Wiring Diagram ................................................................ 21
S400T Connection Wiring Diagram ....................................................... 22
S400T Ladder Wiring Diagram .............................................................. 23

S400/S400T Manual 934-6638 - Page6
SPECIFICATIONS
Model No. S400 & S400T Construction Heaters
CSA Certified to CSA 2.14-2000 Gas Fired Unvented Construction
Heater
Gases: Natural or Propane
Capacity: 400,000 Btu/h maximum
Orifice Size: 42 DMS (X18)
Blower: 2,000 cfm
Electrical Rating: 115 volts, 60 Hz, 5 amps, single phase
Gas Supply:
Inlet Pressure Manifold Pressure
Max.W.C. Min.W.C. Max.W.C. Min.W.C
(S400T only)
Propane 14 inch 7 inch 1.3 inch 0.6 inch
Natural 14 inch7 inch 4.0 inch 1.8 inch
(Minimum inlet pressure is for purpose of input adjustment)

S400/S400T Manual 934-6638 - Page 7
INSTALLATION
TheSureFlameModelsS400&S400Taredirectfiredgasheatersintended
to be used primarily for the temporary heating of buildings under construc-
tion,alteration,orrepair. Since all the products ofcombustionarereleased
into the area being heated, it is imperative that adequate ventilation is
provided. The flow of supply air and combustion gases must not be
obstructedinanyway. Donotusetheheaterwithductworkasthiswillrestrict
the flow of supply air.
1Install the heater in a horizontal position at least 6 feet from any LP-
gas container, and allow the following clearances from any combusti-
ble materials:
Front Outlet: 12 feet (3.6 M) Sides:2 feet (0.6 M)
Intake: 2 feet (0.6 M) Top:4 feet (1.2 M)
Front Outlet must not be directed at any LP-gas container within 20
feet (6 M).
Also make sure that no flammable vapours are present in the space
where the heater is being used.
The installation of this heater MUST bein accordance with either ofthe
appropriate following Standards:
CAN/CGA B149.1 Natural Gas Installation Code or
CAN/CGA B149.2 Propane Installation Code
2When connecting the heater to a natural gas or propane supply line
ensurethatthepressureattheheaterinlet iswithinthespecifiedrange.
Please refer to Propane and Natural Gas Installation sections on page
8. Excessive pressure (over 1/2" psi) will damage the controls and void
thewarranty.
3Visually inspect the hose assembly and ensure that it is protected from
traffic, building materials, and contact with hot surfaces. If it is evident
that there is excessive abrasion or wear, or the hose is cut, it must be
replaced.
4After installation, check the hose assembly for gas leaks by applying a
water and soap solution to each connection.
5Connecttheheatertoanadequate115voltelectricalsupplyasspecified
ontheratingplate. Forprotectionagainstshockhazardthesupplycord
mustbepluggeddirectlyintoa properlygroundedthree-prongrecepta-
cle.TheelectricalinstallationoftheheaterMUSTbeinaccordancewith
CSA Standard C22.1-1990 Safety Standard for Electrical Installations.
6In all applications, install the heater in such a manner that it is not
directly exposed to water spray, rain and/or dripping water.

S400/S400T Manual 934-6638 - Page8
INSTALLATION USING A
PROPANE SUPPLYTANK
1Wheninstallingtheheaterforusewithpropanegas,setthegasselector
valve to “Propane” and lock in position.
2The supply container must be equipped with a UL listed Gas Pressure
Regulator. This is essential to reduce the gas pressure to a safe
transmittable pressure. This pressure must further be reduced so the
gas pressure does not exceed the maximum input pressure of the
heater. This can be accomplished by placing a suitably sized second
stagegasregulatoronthevalvetrainattheheater.Thisregulatorshould
also be a UL listed LP Gas Pressure Regulator.
3Arrange the propane supply system to provide for vapour withdrawal
from the operating container. Supplying liquid propane to the heater is
dangerous and will damage the components.
4Ensurethatforthesurroundingtemperaturethesizeandcapacityofthe
propanesupplycontainerisadequatetoprovidetheratedBtu/hinputto
the heater.
5Turnoffthepropanesupplyvalveatthecontainerwhentheheaterisnot
in use.
6Theinstallationmustconformwithlocalcodes,orintheabsenceoflocal
codes, with CAN/CGA-B149.2 Propane Installation Code.
7When the heater is to be stored indoors the propane container must be
disconnectedfromtheheaterandthecontainermovedawayandstored
in accordance with the above National Standard.
INSTALLATION FOR
NATURAL GAS APPLICATIONS
1Wheninstalling the heater for usewith natural gas,set the gas selector
valve to the “Natural” position.
2A regulator must be installed on the heater to ensure that the pressure
to the heater does not exceed 1/2 psi inlet pressure.
3Theinstallationofthisheatertoa natural gas supply must conform with
allapplicablelocalcodesor,intheabsenceoflocalcodes,withtheCAN/
CGA-B149.1 Natural Gas Installation Code.

S400/S400T Manual 934-6638 - Page 9
OPERATING INSTRUCTIONS
1SetGASSELECTORVALVEtogasbeingused. Theconversionshall
be done by the owner or lessor of the equipment.
NOTE: WhenusingPropaneGastheSelectorValveMUSTbelocked
in position.
2EnsuretheFIRINGVALVE(ManualValvenearesttheburner)isinthe
“ON” position.
3Connect power - 115 volt supply.
4Open gas supply.
5Push “START” button and hold for 5 seconds.
6Set heat selector switch to desired heating mode. ( S400T only )
7Set thermostat to desired temperature. ( S400T only )
8To stop, turn gas off and push “STOP” button.
The appliance area should be kept clear and free from combustible
materials, gasoline, and other flammable vapours and liquids.
Ensurethatthe flow of supply air and combustiongasesisnotobstructed.
The installation and operation of the heater shall comply with the code
requirements specified by the authorities having jurisdiction. In the ab-
sence of specific Local Codes the installation of this Construction Heater
MUST conform with the following National Standards:
CSAStandardC22.1-1990SafetyStandardforElectricalInstallations
(Canadian Electrical Code Part 1)
CAN/CGA-B149.1 Natural Gas Installation Code
CAN/CGA-B149.2 Propane Installation Code
General criteria for the use of construction heaters may be found in the
applicable sections of either the following Standards:
National Standard of Canada Natural Gas Installation Code CAN/
CGA-B149.1
National Standard of Canada Propane Installation Code CAN/CGA-
B149.2.

S400/S400T Manual 934-6638 - Page10
SEQUENCE OF OPERATION
1Push AND HOLD start button for 5 seconds.
2Control relay closes.
3Motor starting relay closes.
4Fan starts.
5Fan reaches full speed and air switch closes.
6Solenoid valve opens.
7Spark is generated.
8Flame rod senses flame, and then maintains flame.
(The following is for S400T only)
9If selector switch is set on HI-LO, heater will cycle from lo to hi flame
thermostatically.
10 If selector switch is set on ON-OFF, heater will cycle on and off
thermostatically.
COMMON INSTALLATION AND
OPERATIONAL PROBLEMS
1LOW VOLTAGE
Thisisoneofthemostcommonproblemsandisusuallytheresultofthe
supply cord having too small a wire gauge for its length. Low voltage
resultsinthemotoroverheating, burntrelaycontacts,orarelaythat will
not maintain contact.
2SUPPLY LINE TOO SMALL
NOTE: S400 HEATERS WITH SERIAL NUMBER 5984 AND
GREATER AND S400T HEATER WITH SERIAL NUMBER 11271
AND GREATER WILL HAVE A 3.3 SECOND DELAY BEFORE
STARTING.
THE INSTALLATION AND MAINTENANCE OF THE HEATER
MUST BE ACCOMPLISHED BY A QUALIFIED SERVICE PERSON.

S400/S400T Manual 934-6638 - Page 11
3INSUFFICIENT VAPORIZATION AT SUPPLY
Normally caused by too small size of supply tank.
4IMPROPER GAS SUPPLY PRESSURE
Usually a result of supply pressure being too high because of improper
or lack of regulation.
5DIRTY GAS SUPPLY
Dirty gas can cause strainers to plug or form a build-up in the burner
orifice.
6LACK OF PREVENTATIVE MAINTENANCE
Heaters must be cleaned as required, especially when used in a dirty
environment.
7IMPROPER SUPPLY OF FRESH AIR
Itisnormallyrecommendedthattheintakeairoftheheaterbetakenfrom
outside the enclosed area. This provides a slight pressurization and
prevents any problems associated with recirculation.
SAFETY FEATURES
Servicing of Sure Flame Construction Heaters normally involves one of
several built-in safety features. The Models S400 & S400T incorporate
devices to detect the following:
1LOSS OF FLAME Gas supply is shut off if flame is lost to
prevent raw gas from leaving the heater.
2OVERHEATING (a) Thermal overload protection in the mo-
tor.
(b) High temperature limit switch in the
combustion chamber.
3LOSS OF POWER Totalshutdown with manual resetrequired.
Any one of the safety devices will create a
loss of power situation.
4BLOCKED AIR SUPPLY A switch detects the differential pressure in
the combustion chamber and shuts down
when insufficient .

S400/S400T Manual 934-6638 - Page12
DESIGN RELATED ADDITIONAL
SAFETY FEATURES
1LOCKING POSITION FOR LPG ON GAS SELECTOR LEVER
UnitsusedwithLPGwhilethegasselectorvalveispositionedforNatural
Gas will throw significantly more heat than the rated Btu/h. This is
definitely a safety hazard.
2LOW SKIN TEMPERATURE
SureFlame Heaters are designed to have a lowskin temperature. This
provides added safety in the workplace.
3DURABLE CONSTRUCTION
TheModelsS400 & S400T use astainlesssteelburner for long life and
consistent performance.
In order to maintain the highly efficient combustion of the Sure Flame
Heater, the combustion chamber must remain as manufactured. Any
changeordistortioncouldalterthefuel/airmixtureandcreateunwanted
gases.
ON-SITE SAFETY PROBLEMS
1SHORTING OUT OF DEFECTIVE COMPONENTS
This common problem saves short term expense at the risk of a large
future cost. Any heaters found in this condition should be removed
immediately.
2IMPROPER ENCLOSURES
When heaters are installed partially to the outside for fresh air intake,
strictadherencemustbemadetotheminimumclearancetocombustibles
givenontheinstructionplate.Woodframingaroundaheaterisarequest
for trouble.
3SUPPLYING LIQUID PROPANE TO HEATER
Thisproblemhasoccurredfrom timetotime. Tominimizethedamage,
and possible personal injury, shut off the gas supply and let the heater
run until all of the liquid in the lines has been vaporized..

S400/S400T Manual 934-6638 - Page 13
PREVENTIVE MAINTENANCE
Sure Flame Construction Heaters are built to withstand the rigours of
operating on construction sites, for mining applications, and a multitude of
other locations where heaters are used. To maintain the reliable perform-
ancerequireditisnecessarytodoacertainamountofregularmaintenance.
AVISUAL CHECKS
The following items should be checked for excessive wear or damage:
1) Wheels (if installed)
2) Cords and Connectors
3) Wiring and Conduit
4) Heater Shell (including heat shield) and Control Box
It is recommended that units purchased as spares be rotated periodi-
cally,sothateachunitwillbeplacedinoperationatleast onceevery90
days.
BBURNER
Flame Rod and Insulator - Clean with soap and water or solvent on a
routinebasis. Anybuilduponburnershouldalsoberemovedatthistime.
Spark Plug - Clean with solvent and check spark gap.
CCONTROL BOX
The inside of the control box should be cleaned using a dry cloth or by
blowingcompressedair. Donotuseanyliquidoraerosolspraycleaners.
Also check that all electrical connections are snug and tight.
DMOTOR
The electric motor on the S400 & S400T Heaters is fitted with sealed
bearings and no oiling is required. Keep the motor clean by blowing or
wiping off dust or dirt in order to prevent it from over heating.
EFAN
Checkfordustordirtbuildup on fan blades. Check the tightness of the
set screw and run the heater to check for fan vibration.

S400/S400T Manual 934-6638 - Page14
TROUBLE SHOOTING S400/S400T
An AC Voltmeter is required to perform these checks. The control circuit is
24V,themotorpoweris115V.Useextremecautionwhencheckingvoltage.
1Push start button and release
2Control relay should close. If not, check the following:
a) Check for 115V between terminals A & B of the control relay, if no
power proceed to hi-limit switch terminals.
b) If115Vispresent atbothterminalsoflimitswitchthencontrolrelayis
faulty, or there are poor connections.
c) If there is 115V at only one terminal of the hi-limit switch, the limit
switch is faulty.
d) If115Visnotpresentateitherterminalofthehi-limitswitch,checkthe
stop switch terminals.
e) If there is 115V present at only one terminal of the stop switch, while
start switch is depressed, then check dual wire assembly on control
relay.
f) If there is no power at either terminal of stop switch then check start
switch.
g) If there is 115V present at only one terminal of the start switch, while
start switch is depressed, then replace start switch.
h) If there is no power at either terminal of the start switch, then check
red wire leading from start switch to the motor starting relay.
3Motor starting relay should close. If not, check the following:
a) Remove the 6 pin connector assembly from the side of the Fenwall
module and clean both sides with electrical contact cleaner.
b) If there is 24V across the coil terminals of the motor relay then relay
is faulty.
c) Ifthereisnopowerbetweenthecoilterminalsofthemotorrelaythen
check for 24V at terminal P of the Fenwall module.
d) If 24V is present at terminal P then the Fenwall module is faulty.
For S400 proceed to j), steps e to i apply to S400T only.
e) Ifthere isnopowerpresent atterminalPofthe Fenwallmodule,then
turnthermostatclockwisetomaximumsetting.Thencheckforpower
at terminal 1 of the thermostat.
f) Ifthereis24Vpresentatterminal1ofthethermostatthentheselector
switch is faulty.
g) If there is no power present at terminal 1 of thermostat, check for
power on the output side of the secondary transformer, if there is

S400/S400T Manual 934-6638 - Page 15
power present then check wire.
h) Turn thermostat knob to the extreme clockwise position, if 115V is
detected between the input terminals of the secondary transformer,
then transformer is faulty.
i) Ifthereisnot 24Vontheoutputside,andnot115V ontheoutputside
of the transformer then check the black wire on the input side of
transformer
j) If120Vispresentattheblackwireontheinputsideofthetransformer
then the transformer is faulty.
4Fan starts. If motor does not run check the following:
a) Check to see if the fan blade is turning freely.
b) If there is 115V between T1 & T2 on the motor starting relay then
there is a bad connection or broken wire between motor and relay.
c) If there is no power at T1 & T2 the contact points are dirty or the
relay is faulty.
d) Remove back plate on motor, if there is 115V between the incom-
ing white and black wires, then the connection to the motor is
incorrect or the motor is faulty.
5Fan reaches full speed and air switch closes, if air switch does not
close check:
a) If there is 24V on only one of the airswitch terminals while motor is
running, then airswitch is staying open, first check the airtubes.
b) If either upstream or downstream air tubes are plugged.
c) If both are free then check alignment ( tubes should be positioned
parallel to the air flow direction).
d) If above procedures do not correct problem, then the adjusting
screw located on the side of the airswitch can be rotated counter
clockwise, just enough so that fan stays running.
e) If this does not help then bypass the airswitch by joining the two
wires together, if heater now runs then the airswitch is faulty.
6Solenoid valve opens, if valve fails to open check:
a) If there is 24V between the wires of the solenoid valve and a sharp
click is not heard, then the coil of the solenoid valve is faulty.
b) If a sharp click is heard, then the valve body is faulty.
7Spark is generated, if no spark is present, check:
a) If the ignition wire is burnt, or cracked it may be shorting out to the

S400/S400T Manual 934-6638 - Page16
heater.
b) Spark plug, clean and gap to approximately 1/8".
c) If there is 24V at terminal P of the Fenwall module, check ignition
wire, if good then spark plug or ignition module is defective.
8Flame rod senses and maintains flame, if not check:
a) If flame rod wire is connected to flame rod and not grounding out to
the heater.
b) If flame rod wire is inserted into the correct position of the Fenwall
module.
c) The flame rod should be screwed into the burner securely. The
probe part should not be touching the burner in any way thus
grounding out.
S400T Heaters Only
9Selector switch set on HI-LO position.
a) If flame stays on low when thermostat is turned to the extreme
clockwise position check for 24V at the 2 stage regulator terminals
if 24V is present, then unit is wired wrong (refer to wiring diagram)
b) If it is wired correctly then 2-Stage regulator is faulty.
c) If flame stays on high when thermostat is turned to the extreme
counter clockwise position check for 24V between the two termi-
nals of the 2-Stage regulator if power is present then the regulator
is adjusted wrong or faulty.
d) If there is no power between the terminals of the 2-stage regulator
check for power at the top terminal (black wire) of the selector
switch.
e) If no power at the top terminal (black wire) of the selector switch
then thermostat is faulty.
10 Selector switch set to ON-OFF position.
a) Firstly make sure that the white light is on signifying that unit is on.
b) If the heater does not start, check for power at terminal 3 of ther-
mostat if power is present then the selector switch is faulty.
c) If there is no power present at terminal 3 of the thermostat then the
transformer is faulty.
d) Turn thermostat to high setting, if no power is present at terminal
#2 of the thermostat then the thermostat is faulty.

S400/S400T Manual 934-6638 - Page 17

S400/S400T Manual 934-6638 - Page18
S400/S400T HEATER PARTS
12
6
7
8
9
10
23
25
26
28
29
30
31
24
REVISED: JULY 25, 1996
1
2
3
3
2A
4
511
13
14
15
16
17
1921
32
S400T
VALVE TRAIN
S400
VALVE TRAIN
22 20A
20
18
27

S400/S400T Manual 934-6638 - Page 19
S400/S400T HEATER PARTS
September 13, 2002
Ref. Part No Description
1S400-80 Strainer
22524 3/4" Appliance Regulator (S400 only)
2A 4517 2-Stage Regulator (S400T only)
34514 Solenoid Shut-Off Valve 24V
4S400-73 Gas Selector Valve
55869 Manual Shut-Off Valve
62430 Motor 1/4 HP
72420 Fan Blade
8BV45-50 Burner
92143 Spark Plug
10 S400-86 Flame Rod
11 4512 Control Relay with Clip 120V
12 6440 RelayClip
13 4510 Transformer 24V
14 8264 Direct Spark Ignition Control
15 5124 Air Switch (0.2" W.C.)
16 4519 Motor Relay 24V
17 2446 HI Limit Thermoswitch
18 4518 Indicator Light 24V
19 2453 Thermostat (S400T only)
20 3337/8 OFF Switch (Red)
20A 3337/9 ON Switch (Green)
21 5545 Toggle Selector Switch (S400T only)
22 5768 Terminal Block
23 S400-16 Heat Shield
24 S400-57 Front Leg Assembly
25 S400-47 Rear Leg Assembly (less Motor Mount & Screen)
26 S400-7 Control Box Lid
27 S400-103 Valve Train Cover
28 S400-53 Heater Body includes: 23, 24 & 30
29 S400-502 Motor Mount (with Screen & Rear Legs)
30 S400-3 Nose Cone
31 S400-81 Wheel Kit (optional)
32 2527 3/4” Regulator (optional)

S400/S400T Manual 934-6638 - Page20
S400 CONNECTION WIRING
DIAGRAM
FENWALL
#05-296426
S
G
NC
SP
5
M
AB
7
AIR SWITCH
HI LIMIT
SWITCH
POWER RELAY
P V
N
L

S400/S400T Manual 934-6638 - Page 21
S400 LADDER WIRING DIAGRAM
S1
START BUTTON STOP BUTTON
M
AIR SWITCH
HI LIMIT
SWITCH
RELAY
FLAME ROD
110V-24V
STEPDOWN
TRANSFORMER
FENWALL
#2460D-XXX-XXX
V1
NC
GND
TH
HV
SOLENOID VALVE
L
N
POWER RELAY