OGI TotalArc BMS 460346 SOLAR POWER User manual

A product of:
OPERATOR’S MANUAL
ALL
VERSIONS
OGI# 460346 SOLAR POWER
OGI# 460347 100-240 VAC
OGI# 460348 12-24 VDC
When you purchase a TotalArc BMS you purchase a product of “Quality, integrity, and innovation from concept to
commissioning.” That promise, along with proper maintenance, will ensure that your TotalArc BMS 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. RED STATUS INDICATOR LIGHT
3. IGNITION PUSH BUTTON
4. GREEN STATUS INDICATOR LIGHT
5. TOTALARC ENCLOSURE
6. TOTALARC MAIN GAS VALVE
7. TOTALARC PILOT GAS VALVE
8. TEMPERATURE CONTROL PRESSURE SWITCH
9. CUSTOMER POWER ENTRY
10. IGNITION MODULE
11. MALE M12 RECEPTACLE
12. CLASS 1 DIV 2 CLAM SHELL
13. TOTALARC CABLE ASSEMBLY
14. FEMALE M12 RECEPTACLE

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: MOUNTING HOLE DIMENSIONS
MOUNTING PATTERN FOR
TOTALARC BMS SYSTEM
BACKPLATE

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

V
FIGURE 6: Ignition Rod Installation

VI
FIGURE 6: Ignition Rod Installation
FIGURE 7: ASCO Flow Diagrams

VII
Figure 8: Solar Panel Assembly

VIII
Figure 9: Solar Panel Assembly

VIIII
Figure 10: Tubing Diagram
For more details see P&ID in Operations Section

X
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 BMS 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 BMS.
The TotalArc BMS is a flame controlling system that monitors a call for heat from pneumatic controllers upstream of the
device. When the system receives a call for heat it will attempt to light the pilot, prove the pilot for ten seconds, then ignite
the main burner. The TotalArc BMS system enforces safety shutdowns of the heater when the lighting of either the pilot or
the main burner fails. When these lockout conditions occur the TotalArc BMS forces a 5-minute purge before allowing
another relight attempt.
The operation stages of the TotalArc BMS are indicated by green and red lights installed on the front of the control enclosure.
See operation instructions for light code indication status descriptions.
The TotalArc BMS 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# 460346
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 gel battery.
OGI Part# 460347
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# 460348
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 BMS 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.
◼Checktheworkareabeforeeachuse.
◼ Use Safety Glasses –Always wear eye protection with
sideshieldsmarkedtocomplywithANSIZ87.1.
◼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.
◼Toreducetheriskofelectricshock,thiscontrol 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 ahazard or cause product damage.
◼Maintain TotalArc BMS 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 BMS
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.
◼IfBMS isnotworkingasitshould, 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 BMS.
TOOLS FOR RETROFIT INSTALLATION
**Please note that each retrofit job is a custom job, additional tools may be required given the conditions and installation
of the heater
▪Cordless Drill
▪Drill bit (5/16”)
▪Tape Measurer
▪Hole Saw or Punch –1” Diameter
▪Screw Drivers –Phillips and Flathead
▪Wire cutters and strippers
▪Adjustable Wrench
▪Tubing Cutter
▪Tubing Bender
▪Pliers
DANGER!
Read and understandall instructionsbeforeusingthis
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.

SYMBOLS
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# 460346 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# 460347 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# 460348 VDC Powered Control Panel
Nominal System Voltage: 12-24 VDC
Rated Current Input: 2.3-1.1A
◼OGI PART# 452024 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 alloperating features and safety rules, in this manual.
TWO CONTROL METHODS
The TotalArc BMS is configurable to operate via either
pneumatic actuation or an electronic control system.
SAFETY INPUT OPTIONS
Intelligent design allows the safety line configuration
command to be set up for electronic controls or pneumatic
systems.
REMOTE TROUBLE ALARM
The TotalArc BMS comes complete with a dry contact set
to allow you to monitor the system remotely. The dry
contact set sends a constant “OKAY” signal that ends
when there is trouble with the TotalArc BMS.
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.
◼Donotdiscardthepackingmaterialuntilyouhavecarefully
inspected and satisfactorily operated the product.
PACKING LIST
OGI# 460346 –TotalArc BMS Solar:
▪TotalArc BMS System
▪Solar Panel w/ attached cable
▪3/8” U-bolt x 2” with (2) 5/16” nuts
▪Ignition Module
▪Ignition rod
▪Turck Cordset x2
▪Clam shell locks x4
▪Ignition cable
▪Ground cable
▪Battery Enclosure
460347 / 460348 –TotalArc VAC/VDC:
▪TotalArc BMS System
▪Ignitor box
▪Ignition rod
▪Turck Cordset x2
▪Clam shell locks x4
▪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 BMS:
oSolar Panel with SO Cord cable
terminated at solar panel
o12 VDC 51Ah Gel Battery
•120 VAC / 12-24 VDC TotalArc BMS:
oAll required components for the TotalArc
BMS will be installed on the unit prior to
shipment. No Loose Ship Components
with 120VAC Systems OR 12-24VDC
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 two 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 four stainless steel
washers and four 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
cables provided with the unit (varying lengths
available upon request).
◼Control panel must be installed in the vertical position
and leveled.
◼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 assemblies 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 BMS (p/n 460346):
Solar Panel Wiring:
WARNING –MAINTAIN SOLAR COVER UNTIL
TOTALARC BMS UNIT IS FULLY INSTALLED
AND SOLAR PANEL IS TERMINATED IN
BATTERY ENCLOSURE
1. Run solar panel SO Cord cable through cable
gland on bottom of battery 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 1
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 460347):
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 BMS***
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

ASSEMBLY
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 460348):
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 BMS***
2. Insert enough length of wire to reach the
terminal blocks.
3. Terminate wires to terminal blocks:
•+24 VDC wire to Terminal Block V+
•-24 VDC wire to Terminal Block V-
•Green wire to Terninal Block G
TROUBLE RELAY CONNECTIONS
The TotalArc BMS includes a set of contacts for
remote trouble reporting for Customers.
•Heater Trouble Customer Connections:
•TB19 and TB20
•“1” = OKAY
•“0” = 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
6. Install SO-Cord from solar panel through
cord grip located in the bottom of the
TotalArc battery enclosure.
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 4A, FU3 should be 1A.
9. Place battery in bottom of battery enclosure.
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 BMS is a flame controlling system that monitors a call for heat from pneumatic controllers upstream of the
device. When the system receives a call for heat it will attempt to light the pilot, prove the pilot for ten seconds, then ignite
the main burner. The TotalArc BMS system enforces safety shutdowns of the heater when the lighting of either the pilot or
the main burner fails. When these lockout conditions occur the TotalArc BMS forces a 5-minute purge before allowing
another relight attempt.
SEQUENCE OF OPERATIONS
1. Turn down the temperature setpoint of the pneumatic controller upstream of the TotalArc pressure switch.
2. Turn the Power switch to “On” position.
a. The Red Status indicator will start blinking a one blink code.
3. Press the Reset/Relight button.
a. The Red Status indicator will turn off.
b. The Green Status indicator will start a Double-blink sequence. This indicates that it is waiting for a “Call For
Heat”
4. Turn up the temperature setpoint of the pneumatic controller upstream of the TotalArc pressure switch.
a. The TotalArc will start sparking the igniter rod.
b. The TotalArc’s Pilot valve is engaged.
c. The Green Status indicator will blink at a high rate of speed.
d. If the pilot is not lit, a flame failure event will shut down the BMS and the system will begin a 5-minute purge
period. At the end of the purge period, the TotalArc will attempt to relight the pilot one time.
i. If the pilot does not light, then the TotalArc goes into a Lockout condition where the Red Status
indicator will be lit with a steady light.
5. Once the burner’s pilot is lit, a 10 second timer starts.
a. During the 10 second timer, the Green Status indicator will fade on and off, indicating that the TotalArc BMS is
proving the pilot.
b. If the pilot is not proven, a flame failure event will shut down the BMS and the TotalArc immediately goes into a
Lockout condition where the Red Status indicator will be lit with a steady light.
6. After the 10 second timer has expired and the pilot is lit, the TotalArc engages the Main Gas valve.
a. The Green Status indicator is lit with a steady light.
b. The TotalArc BMS will prove the flame for 20 seconds.
i. If the flame is lost during those 20 seconds, the TotalArc immediately goes into a Lockout condition
where the Red Status indicator will be lit with a steady Light.
7. After the flame is proven, the unit enters the run mode until the flame is lost or the Call For Heat is removed.
a. If the flame is lost, a flame failure event will shut down the BMS and the system will begin a 5-minute purge
period. At the end of the purge period, the TotalArc will attempt to relight the pilot one time.
i. If the Pilot does not light, then the TotalArc goes into a Lockout condition where the Red Status
indicator will be lit with a steady light.
8. When the Call For Heat is removed, the TotalArc will shut down the BMS and the system will begin a 5 minute purge
period. At the end of the purge period, the Green Status indicator will start a Double-blink sequence. This indicates
that the system is waiting for another “Call For Heat”.
9. If, at any time during operation, one or more safeties are faulted, the BMS will immediately be shutdown and the Red
Status indicator will be lit with a steady light.
a. Once the faulted safety is corrected, the Red Status indicator will start blinking, indicating that the system is
waiting for the Reset/Relight button to be depressed.

OPERATION
9
TOTALARC BMS LIGHT CODES
SYMBOL
DESCRIPTION
MEANING
POSSIBLE CAUSES
RED LIGHT: SINGLE FLASH
WAITING FOR RESET
INITIAL POWER ON; AFTER
CORRECTED SAFETY FAULT
RED LIGHT: SOLID
LOCKOUT
CONDITION
FAILURE TO LIGHT PILOT; FAILURE TO
LIGHT MAIN GAS; SAFETY FAILURE
EVENT
GREEN LIGHT: DOUBLE
FLASH
WAITING FOR CALL
FOR HEAT
OCCURS WHEN UNIT IS WAITING FOR
A CALL FOR HEAT EITHER AFTER
REACHING TEMPERATURE OR ON
INITIAL START UP
GREEN LIGHT: RAPID FLASH
IGNITION IN
PROGRESS
PILOT VALVE ENGAGED; IGNITION
ROD ASSEMBLY SPARKING IS IN
PROGRESS
GREEN LIGHT: FADE
ON/OFF (10 SECONDS)
PROVING FLAME
PILOT HAS BEEN LIT AND MUST STAY
LIT FOR 10 SECONDS BEFORE
ATTEMPTING TO LIGHT MAIN
BURNER
GREEN LIGHT: FADE
ON/OFF (5 MINUTES)
SYSTEM PURGE
AFTER ANY LOCKOUT CONDITION THE
SYSTEM FORCES A 5 MINUTE PURGE
PERIOD BEFORE ATTEMPTING
ANOTHER RELIGHT