OGI TotalArc BMS 460246 SOLAR POWER User manual

Doc# OGI-OM-TAREV1
A product of:
OPERATOR’S MANUAL
ALL VERSIONS
OGI# 460246 SOLAR POWER
OGI# 460312 100-240 VAC
OGI# 460371 12-24 VDC
When you purchase a TotalArc Relighter you purchase a product of “Quality, integrity, and innovation from concept to
commissioning.” That promise, along with proper maintenance, will ensure that your TotalArc Relighter gives you years of
rugged, trouble-free performance. Thank you for your purchase.
SAVE THIS MANUAL FOR FUTURE REFERENCE
WARNING: To reduce the risk of injury, the user must read and understand the operator’s manual before using
this product.

I
See this section for all the figures referenced in the operator’s manual.
Figure 1:
1. ON/OFF POWER SWITCH
2. STATUS INDICATOR LIGHT
3. IGNITION PUSH BUTTON
4. MAIN GAS SHUTOFF SOLENOID
5. TOTALARC ENCLOSURE
6. CUSTOMER POWER ENTRY
7. M12 RECEPTACLE
8. IGNITION MODULE CABLE ASSEMBLY
9. CLASS 1 DIV 2 CLAM SHELL LOCK
10. IGNITION MODULE

II
FIGURE 2: IGNITION MODULE
Installation in Flame Arrestor
For details see Installation instructions on page 7

III
FIGURE 3A: INSTALLATION
TotalArc kit includes mounting feet for easy installation
For details see Installation instructions on page 6
FIGURE 3B: INSTALLATION
MOUNTING PATTERN
FOR TOTALARC
ENCLOSURE
SEE FIGURE
3B
FOR
DIMENSIONS

IV
FIGURE 4: Clamshell Installation
FIGURE 5: Battery Connection Detail
SOLAR OPTION ONLY

V
FIGURE 6: Ignition Rod Installation
Figure 7: BASO Pilot Safety Valve

VI
Figure 8: Solar Panel Assembly

VII
Figure 9: Solar Panel Assembly

VIII
Introduction ....................................................................................................................................................................1
Important Safety Instructions .......................................................................................................................................2
Symbols ...................................................................................................................................................................... 3-4
Electrical .........................................................................................................................................................................4
Features ..........................................................................................................................................................................5
Assembly .................................................................................................................................................................... 5-7
Operation .................................................................................................................................................................... 8-9
Maintenance..................................................................................................................................................................10
Trouble Shooting ................................................................................................................................................... 11-12
Wiring Diagrams..................................................................................................................................................... 13-14
Warranty........................................................................................................................................................................15
Parts Ordering and Service.......................................................................................................................... Back Page
TABLE OF CONTENTS

1
When you purchase a TotalArc Relighter you purchase a product of “Quality, integrity, and innovation from concept to
commissioning.” Please read through the entire manual to get familiar with installation and operations of the TotalArc
Relighter.
The TotalArc Relighter is a flame monitoring device that monitors flame status and reacts to a flame failure by creating a
spark. The TotalArc system will close the main gas valve supply to the burner to minimize the amount of gas entering the
fire tube while a relight is in process.
The operation stage of the TotalArc is indicated by a green light installed on the front of the control enclosure. See operation
instructions for light code indication status descriptions.
The TotalArc System can be purchased to operate with three different power sources. Confirm power availability at
installation site and select one of the following models:
OGI Part# 460246 / 450592 (Polycarbonate / Stainless Steel)
Solar Powered System
This system is provided with a solar panel and all required installation hardware. The solar panel provided
is sized to 35 Watts, but solar systems can be supplied with a solar panel up to 50 Watts (subject to
availability). The method of energy storage system is a 12 VDC sealed lead battery.
OGI Part# 460312 / 450490 (Polycarbonate / Stainless Steel)
120 VAC Powered System
This model connects to a 120 VAC power source. This model also contains an internal battery back up
system designed to maintain stable and uninterrupted power supply to the TotalArc control system. The
battery back up provided with this system is intendeded to maintain power during short time periods or
power fluctuations periods.
OGI Part# 460371 / 450591 (Polycarbonate / Stainless Steel)
12-24 VDC Powered System
This model connects to a 12-24 VDC power source, no battery back up is included on this model. This
system typically connects to an RTU power source that will typically have a built-in power back up.
**The TotalArc Relighter is a fully customizable productline – other options are available upon request.
Please speak to an OGI Sales Representative to discuss options to fit your needs**
* * *
INTRODUCTION

IMPORTANT SAFETY INSTRUCTIONS
2
READ ALL INSTRUCTIONS
For safe operation, read, and understand all
instructions before using this product. Follow all safety
instructions. Failure to follow all safety instructions
listed below can result in serious personal injury.
Do not allow untrained individuals to use this unit.
Check the work area before each use.
 Use Safety Glasses – Always wear eye protection with
side shields marked to comply with ANSI Z87.1.
Stay alert – Do not operate this unit when you are tired,
ill, upset, or under the influence of alcohol, drugs, or
medication.
Do not install or operate in explosive atmospheres,
such as in the presence of flammable liquids, gases, or
dust. Area of classification at time of installation must
be General location.
Toreduce therisk of electric shock, this control system has
polarized connection points. Check installation
instructions.
Disconnect Power source before opening control
enclosure, servicing, or performing maintenance tasks.
Use only identical manufacturer’s replacement
parts and accessories. Use of any other parts may
create a hazard or cause product damage.
Maintain TotalArc Relighter with care – Follow
instructions for changing components. Inspect control
cable periodically and if damaged have it replaced by
an authorized service facility.
Make sure all control cable clam shell guards are
properly and securely attached prior to power up
stage.
Use only the manufacturer’s replacement clam shells,
cables, and battery.
Keep the area around the enclosure clear and free of
debris to allow proper air flow around the enclosure.
If a solar unit is not operated during a prolonged
period of time, the unit’s power switch should be
placed in the OFF position, but power to the unit
should be maintained ON to allow the internal
batteries to be charged.
Keep solar panel covered until after full TotalArc
Relighter installation. Solar panel voltage will be live
and unregulated if uncovered before installation
It is recommended that units with battery back up
storage have the batteries replaced at the beginning
of each heating season to guarantee operation of the
unit during the critical operation season.
If relighter is not working as it should, call OGI service
department, available 24/7 to assist you with
installation, operation, and troubelshooting.
Save these instructions. Refer to them frequently and
use them to instruct others who may use this relighter.
DANGER!
Read and understand all instructions before using this
product. Failure to follow all instructions listed below may
result in electric shock, fire, serious personal injury, and/or
death.

SYMBOLS
3
The following signal words and meanings are intended to explain the levels of risk associated with this product.
SYMBOL SIGNAL MEANING
DANGER:
Indicates a hazardous situation, which, if not avoided, will result in death or
serious injury.
NOTICE:
(Without Safety Alert Symbol) Indicates information considered important, but
not related to a potential injury (e.g. messages relating to property damage).
Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper inter-
pretation of these symbols will allow you to operate the product better and safer.
SYMBOL
NAME
DESIGNATION/EXPLANATION
Safety Alert Indicates a potential personal injury hazard.
Read Operator’s Manual To reduce the risk of injury, user must read and understand
operator’s manual before using this product.
Eye Protection
Always wear eye protection with side shields marked to comply
with
ANSI Z87.1. Hearing and/or head protection may also be required.
Electrical Shock Hazard
Risk of electrical shock – use proper lock out tag out procedures
and wear appropriate PPE.

4
Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper inter-
pretation of these symbols will allow you to operate the product better and safer.
SYMBOL NAME DESIGNATION/EXPLANATION
VAC Voltage Alternating Current Voltage
VDC Voltage Direct Current Voltage
A Amperes Current
Hz Hertz Frequency (cycles per second)
W
Watt Power
min Minutes Time
ELECTRICAL
OGI PART# 460246 Solar Powered Control Panel
Nominal System Voltage: 12 VDC
Rated Solar Input: 6A
Max. Solar Voltage: 30 VDC
Regulation Voltage: 14.1 VDC at 25°C
OGI PART# 460312 VAC Powered Control Panel
Nominal System Voltage: 85 - 264 VAC
Rated Current Input: 1.35A at 120 VAC/0.65A at 230 VAC
OGI PART# 460371 VDC Powered Control Panel
Nominal System Voltage: 12-24 VDC
Rated Current Input: 2.3-1.1A
OGI PART# 461557 Ignition Module
Flame Sensing Method: Flame Ionization
Ignition Module Input Voltage: 11.5 – 13.5 VDC
Max Current Draw: 220 mA
Stand-By Current Draw: 63 mA (Flame On monitoring)
Stand-By Current Draw: 26 mA (System is On waiting on start signal)
Current Draw values dependent on solenoid valve selection (11.6 W MAX ALLOWED)
Ignition Wire Properties:
Maximum Length: 20 ft
Operating Temperature Rating: -40°F to 175°F
Read installation instructions for important information on ignition Wire installation details.

FEATURES
5
KNOW YOUR PRODUCT
See Figure 1 (pg. I)
The safe use of this product requires an understanding of
the information on the tool and in this operator’s manual as
well as a knowledge of the heater the product is being
installed on. Before use of this product, familiarize yourself
with all operating features and safety rules, in this manual.
AUTOMATED SOLENOID VALVE
Prevents fuel from entering the fire tubes of a heater via
the main burner when the pilot light is not on or otherwise
lit.
PILOT LIGHT IGNITION PROCESS
Intelligent design allows pilot ignition when predetermined
conditions are met and shuts down both the pilot and main
gas fuel systems when conditions are not met.
NON-FAILURE POINT SYSTEM
If the TotalArc loses power or suffers a fatal error, it will not
affect or interrupt heater operations.
ASSEMBLY
UNPACKING
This product requires assembly.
Inspect the product carefully to make sure no
breakage or damage occurred during shipping.
Carefully remove the product and any accessories from
the box. Make sure that all items listed in the packing list
are included.
Do not discard the packing material until you have carefully
inspected and satisfactorily operated the product.
PACKING LIST
OGI# 460246 – TotalArc Solar:
TotalArc enclosure
Solar Panel w/ attached cable
Mounting bracket
3/8” U-bolt x 2” with (2) 5/16” nuts
Ignition Module
Ignition rod
Turck Cordset
Clam shell locks x2
Ignition cable
Ground cable
Battery
460312 / 460371 – TotalArc VAC/VDC:
TotalArc enclosure
Ignitor box
Ignition rod
Turck Cordset (P-RKG-8T-1250-3-RSG-8T-
M12)
Clam shell locks
Ignition cable
Ground cable
SHIP LOOSE ITEMS
If the TotalArc system is shipped with an OGI Heater the
following components will be shipped separately as loose
items:
•Solar TotalArc:
o12 V C 18 Ah Battery (Batteries are fully
charged prior to shipment)
oSolar Panel with SO Cord cable
terminated at solar panel
•120 VAC TotalArc
oAll required components for the TotalArc
will be installed on the unit prior to
shipment. No Loose Ship Components
with 120VAC Systems
•Loose shipped items MUST be stored indoors and
in a dry location

ASSEMBLY
6
IGNITION MODULE INSTALLATION
This product requires assembly.
Ignition module must be installed inside the
flame arrestor via a 1 ¼” diameter hole in the
flame arrestor wall. Ignition module MUST be
installed on a flat surface.
Perform an initial inspection of the interior of the
flame arrestor to confirm there is proper installation
room inside the flame arrestor.
Ignition module is provided with two stainless steel
washers and two rubber washers. Install washers
according to Figure 2 (pg.II) to provide a water tight
connection between flame arrestor and the ignition
module.
CONTROL PANEL INSTALLATION
This product requires assembly.
Install the control enclosure within reach of the
cable provided with the unit (varying lengths
available upon request).
Control panel must be installed in the vertical position
and leveled, allowing the battery to sit flat in the
bottom of the enclosure when applicable.
Control panel includes mounting feet for easy
installation on a flat surface. See Figure 3A & 3B (pg.
III)
CABLE AND CLAM SHELL ASSEMBLY
WARNING - BEFORE BEGINNING THIS STEP
CONFIRM THAT THE POWER SWITCH IS IN
THE OFF POSITION.
Cable assembly between control panel and
ignition module is a polarized cable.
Line up keyway between connector and the
receptacle, insert connector into receptacle, and
carefully turn connector clockwise to thread
connector.
Once the connection is made, install clam shell
around the connectors (See Figure 4 pg IV). These
shells are required to maintain Class 1 Division 2
rating. Failure to apply clam shells could lead to a
hazardous work environment.
Do NOT connect or disconnect cable assembly while
power is on.
POWER CONNECTIONS
The TotalArc system is shipped full factory wired
except for the power system. See wiring instructions
for all power options:
Solar Power TotalArc (p/n 460246):
Solar Panel Wiring:
WARNING – MAINTAIN SOLAR PANEL
COVER UNTIL TOTALARC UNIT IS FULLY
INSTALLED AND SOLAR PANEL
IS TERMINATED IN ENCLOSURE
1. Run solar panel SO Cord cable through cable
gland on bottom of enclosure
2. Insert enough length of wire to reach the
terminal blocks.
3. Tighten cable gland.
4. Terminate Solar Panel Wires:
•Black Wire to Terminal Block 2
•White Wire to Terminal Block 9
Battery Connection:
1. Install battery inside enclosure; Make sure it
sits flat in bottom of enclosure.
2. Connect Red wire to Red battery terminal
3. Connect Black wire to Black battery
terminal
4. Install battery terminal connectors
according to Figure 5 (pg. IV)
120VAC Power TotalArc (p/n 460246):
Grid Power Wiring:
**All field wiring and conduit to be sized
by an electrical contractor**
1. Run conduit connection into plugged Myers Hub
on bottom of enclosure panel
***WARNING: PROPER HAZARDOUS
LOCATION WIRING METHODS MUST BE USED
WHEN INSTALLING AND TERMINATING THE
TOTALARC RELIGHTER***
2. Insert enough length of wire to reach the terminal
blocks.
3. Terminate wires to terminal blocks:
•Black wire to Terminal Block L
•White wire to Terminal Block N
•Green wire to ground lug on back panel

7
Battery Connection:
1. The 120VAC TotalArc model has a din rail
mounted battery pack that is pre-wired at
the factory.
2. Locate the battery pack inside the
enclosure
3. Locate fuse hanging off the battery pack
case in a plastic bag
4. Insert blade fuse.
12-24VDC Power TotalArc (p/n 460246):
12-24VDC Power Wiring:
1. Run conduit connection into plugged Myers
Hub on bottom of enclosure panel
***WARNING: PROPER HAZARDOUS
LOCATION WIRING METHODS MUST
BE USED WHEN INSTALLING AND
TERMINATING THE TOTALARC
RELIGHTER***
2. Insert enough length of wire to reach the
terminal blocks.
3. Terminate wires to terminal blocks:
•Black wire to Terminal Block V+
•White wire to Terminal Block V-
•Green wire to Terninal Block G
TROUBLE RELAY CONNECTIONS
The TotalArc includes a set of contacts for
remote trouble reporting for Customers.
•Heater Trouble Customer Connections:
•TB11 and TB12
•“0” = OKAY
•“1” = TROUBLE
For details on Dry Contact Ratings please see
label inside of TotalArc Enclosure
IGNITION ROD INSTALLATION
This product requires assembly.
Ignition rod must be installed towards the top of
the pilot assembly with the hook oriented
downwards into the pilot nozzle.
Before setting the ignition rod’s final position –
check the spark gap. A standard spark gap is
between 1/8” and 3/16” – anything smaller
might not ignite a flame, anything larger might
not create a spark. See Figure 6 (pg V) for
details.
The ignition rod’s position can be adjusted by
using a 7/64” allen wrench and loosening a set
screw on the rod’s clamp. Once the position is
set, tighten the set screw.
Ground connection – remove one side of the
metal clamp holding the ceramic insulator and
install provided #12AWG THHN green ground
wire with terminal connector and replace screw.
Install opposite end of ground wire to the ground
lug on the ignition module – remove the wing nut
and re-install with ground wire.
SOLAR PANEL
This product requires assembly. See Figures 8, pg
VI and Figure 9, pg VII.
1. Install 2” pipe cap to top of solar mounting
pole.
2. Install 2” solar mounting pole on heater
support base and secure with u-bolt and
hardware to upper support on side of
heater.
3. Install solar panel to solar mounting pole
with (2) u-bolts and hardware so that the
bottom of the solar panel is about 7 feet
from grade (see Figure 8, pg. VI).
4. Loosen solar panel angel adjustment bolts
to adjust angel of solar panel from vertical
based on the table in Figure 9, pg. VII.
5. Loosen the heater mounting u-bolt and
rotate the solar panel to due-South to
capture the maximum sunlight. Adjust panel
per Figure 9, pg VII.
6. Install SO-Cord from solar panel through
cord grip located in the bottom of the
TotalArc Control Panel.
7. Terminate solar panel power leads as
shown in previous “Solar Panel Wiring”
section. Area must be nonhazardous during
installation.
8. Confirm panel fuses are installed by
opening each fuse holder, inspecting the
fuse, and reinstalling. FU1 should be 4A,
FU2 should be 1A.
9. Place battery in bottom of control panel.
10. Terminate battery as shown in Figure 5.
11. Ensure heater is properly grounded.
12. Ensure TotalArc cable assembly is properly
secured at both the TotalArc and Ignition
Module
13. Install Clamshell lock out device around
connectors as shown in Figure 4

OPERATION
8
The TotalArc Relighter is used to provide initial pilot ignition, monitoring of the pilot flame, and relighting of
the pilot flame if the pilot flame is lost.
BASIC BASO PILOT SAFEGUARD OPERATION WITH TOTALARC(See Figure 7, pg V)
The pilot assemblies for natural draft burners with a TotalArc Relighter consists of a gas pressure
regulator, a BASO Pilot Safeguard Valve, a thermocouple, a pilot nozzle and mixer, and a TotalArc ignitor /
flame sensing rod.
The burner pilot is equipped with a BASO Pilot Safeguard valve and thermocouple. This traditional pilot
monitoring and safety valve requires that the pilot be manually lit by pressing and holding the BASO’s fuel
gas plunger while pressing the “Pilot Ignition” button on the TotalArc enclosure. After the pilot is lit for
approximately 30-45 seconds, the plunger will be held in place by the BASO’s thermocouple sensing the
pilot flame and allow pneumatic control pressure to flow to the remainder of the burner specific safeties. If
the pilot flame is lost and not relit, the BASO will trip, isolating and shutting down the burner pilot and
venting off the downstream pneumatic control pressure.
PILOT RELIGHTER CONTROL AND INDICATION
The TotalArc Relighter augments the BASO Pilot Safeguard valve by monitoring the pilot flame and
relighting the pilot if flame loss is detected. The BASO uses a thermocouple that is immersed in the pilot
flame. The heat from the pilot flame holds the BASO Valve OPEN, allowing pneumatic control pressure to
be supplied to the remainder of the heater’s pneumatic safety and temperature control loops. When the
pilot flame is lost, the BASO’s thermocouple must cool to trip the safety valve which takes approximately
30 seconds. Since the electronic sensing of the TotalArc system is quicker at detecting pilot flame loss, it
is able to re-light the pilot before the BASO’s thermocouple can cool off, keeping the heater online.
Pilot Relighter control and status indication is provided through the TotalArc Relighter control panel

9
TYPICAL HEATER WITH
TOTALARC RELIGHTER P&ID
ARRANGEMENT

MAINTENANCE
10
STANDARD SYSTEM MAINTENANCE CHECKS:
a) Visual inspection of the entire System.
b) If the odor of natural gas is detected, carefully leak test the associated equipment and piping.
Repair leaks as necessary.
c) Inspect and clean burner and pilot assembly.
d) Inspect and clean ground connection at pilot assembly.
e) Visually check the Control Panel and instrumentation for moisture, condensation, connections,
etc.
f) In Northern locations where snow accumulation could be a problem, clear snow from Solar
panel.
g) Check Battery Voltage.
REPAIRS
ALL REPAIRS MUST BE MADE BY A QUALIFED TECHNICIAN.
OGI ACCEPTS NO RESPONSIBILITY FOR REPAIRS MADE BY NON-FACTORY AUTHORIZED
PERSONNEL.
NATURAL GAS IS A DANGEROUS SUBSTANCE - APPROPRIATE PRECAUTIONS MUST BE TAKEN
TO AVOID ACCIDENTS.

TROUBLESHOOTING
11
ISSUE SIGNAL MEANING REACTION POTENTIAL CAUSES
Pilot
Relighter
Lockout
DOUBLE FLASH LOCKOUT - with
burner TCV
DISABLED
Two-minute burner
shutdown condition to
allow BASO to cool
down.
•BASO Pilot Guard Valve or
Thermocouple issues.
Confirm BASO gas supply
and operation.
•Improper positioning of
ignitor/flame rod to Pilot
Head (See figure 6 Page
IV)
•Poor ground between
Relighter Ignition Module (in
flame arrestor) and Pilot
Head
Low Battery Voltage (11.50
Volt minimum required)
•Pilot ignition / sensing cable
connection
•Poor termination of pilot
ignition / sensing cable
•Confirm electrical insulating
rubber boot is installed.
SINGLE FLASH LOCKOUT - with
burner TCV
RELEASED: the
system has
maintained the main
gas closed for a
period of two-
minutes and has
now been released.
TotalArc main gas
valve released to
OPEN; BASO Pilot
Guard should cool
down and close main
gas valve
No Pilot
Flame Ignited
FAST BLINK –
Right after
START/RELIGHT
BURNER push
button is pressed
Ignition process Spark present at
ignition rod
•Confirm Spark Gap (See
Figure 6 Ignition Rod
Installation Page IV)
•BASO Pilot Guard Valve or
Thermocouple issues.
Confirm BASO gas supply
and operation.
•Improper positioning of
ignitor/flame rod to Pilot
Head (See figure 6 Page
IV)
•Poor ground between
Relighter Ignition Module (in
flame arrestor) and Pilot
Head
•Low Battery Voltage (11.50
Volt minimum required)
•Pilot ignition / sensing cable
connection
•Poor termination of pilot
ignition / sensing cable
•Confirm electrical insulating
rubber boot is installed.