SAMUEL JACKSON HG-1-1401A User manual

HG-1-1401A
1-Million Btu/Hr
Gas-Fired Heater
Service and Operation Guide

PAGE -1 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED

PAGE 0 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
TABLE OF CONTENTS
Introduction.................................................................................. 2
Heater Operation.......................................................................... 3
Error & Alarm Logging System................................................... 7
Other Logs - “Flame On Timer” ................................................. 8
Error & Alarm Diagnostic Codes................................................. 9
Error & Alarm Explanations...................................................... 10
TESTS Explanation ................................................................... 17
SETUP Explanation ................................................................... 23
Stub-Ups .................................................................................... 25
External Electrical Connections................................................. 26
Electrical Schematic with PLC inputs/outputs........................... 27
Proper Grounding....................................................................... 28
Gas Piping.................................................................................. 29
Recommended Minimum Pipe Sizes ......................................... 30
LPG Gas Tank Installation......................................................... 31
Component Labels for Electrical Cabinet.................................. 32
Component Labels for Gas Train............................................... 33
Component List.......................................................................... 34
Burner Head Assembly .............................................................. 36
Dimensions for HG-1-1401 Heater............................................ 37
Warranty Information ................................................................ 40
Electrical Controls and Your Safety .......................................... 41
Copyright © 2005 SAMUEL JACKSON, INCORPORATED. All rights reserved.

PAGE 1 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
We appreciate your business and hope you enjoy your
Samuel Jackson Gas-Fired Heater
This manual contains information on the installation, startup, and operation of your heater.
Included is information on:
•Electrical installation.
•Gas piping and supply.
•Heater dimensions.
•Maintenance and troubleshooting.
This manual gives general information on the location of the temperature sensing thermocouple.
If the heater is part of a Samuel Jackson Steamroller System, more detailed information will be
shipped to you under separate cover specifically for your system.
IS STARTUP ASSISTANCE PROVIDED?
Depending upon your location, a startup and inspection service may be provided with your new
heater, free of charge, by Samuel Jackson, Inc. Please contact us to make arrangements or for
questions.
In the future when you require service, technical support or parts, contact us by phone, fax or E-
Mail. Our engineers and service people are available to assist you in obtaining the best
performance from your Samuel Jackson, Inc. products.
Again, thanks for choosing a Samuel Jackson Gas-Fired Heater.
SAMUEL JACKSON, INCORPORATED
MAIL: P.O. BOX 16587 LUBBOCK, TEXAS 79490
COURIER: 3900 UPLAND AVENUE LUBBOCK, TEXAS 79407
TELEPHONE [phone] OR 800-862-9966
TELEFAX 806-795-8240
E-Mail: [e-mail]
Internet: www:samjackson.com

PAGE 2 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
INTRODUCTION
When using a moisture restoration system in cold regions, a source of hot air separate
from the Humidaire Unit is helpful for pre-warming the Steamroller, Moisture
Condenser, or lint slide jacket. The HG-1-1401A heater is built for this purpose. It
includes PLC combustion controls with diagnostics. It has built-in temperature controls
with a 2-HP fan and motor combination capable of delivering up to 3,000 CFM of tightly
controlled, reliable hot air.
HG-1-1401A GAS-FIRED HEATER

PAGE 3 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
HEATER OPERATION
HOW DO I TURN IT ON?
The heater is turned on by momentarily turning the START-STOP (O -I) selector switch to the
right and releasing it. This is done at the LOCAL PANEL (LP) in the heater's upper cabinet. The
wiring electrician may have installed an optional remote START-STOP switch at the console
which can also be used for start/stop.
Local Panel LP 4376
After the START-STOP switch is turned and released, observe the display. The heater’s fan will
start and various operations will be displayed as the self-checks and ignition sequence are
performed. The STATUS light will remain on throughout this process. After approximately 20
seconds, the burner will attempt ignition. If ignition fails, the heater controls will automatically
make two more attempts following appropriate air purge delays.
1401 V1.0 OK
Mode: Off
AIR: 180F
SETUP LOGS TESTS
BLINKS TO INDICATE ERROR OR
ALARM CONDITION
DISPLAYS OPERATION MODE AND
ERRORS OR ALARMS (DMD)
TURN RIGHT MOMENTARILY TO START
TURN LEFT MOMENTARILY TO STOP
USE TO CHANGE
SET POINT AND
OTHER VARIABLES
PRESS TO ENABLE AIR
TEMPERATURE SETPOINT
(SP) ADJUSTMENT
PRESS TO CLEAR
ALARM OR ERROR
AND TO SELECT
VARIABLE TO CHANGE
ACTUAL AIR
TEMPERATURE
SHOWN DURING
OPERATION

PAGE 4 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
WHY IS THERE A DELAY AFTER I TURN IT ON?
When the STATUS light comes on, the combustion control computer begins opening and closing
valves to test the integrity of various safety switches located in the heater's control cabinet. If it
finds a problem with one of these devices, it alerts the operator on the display with a description
of the problem.
These diagnostics are performed every time the heater is started and continue during operation
until approximately 10 minutes after the heater is turned off. The status of post-burn testing is
shown on the display with the time remaining.
TIPS
Always leave power on the heater during gin season. There is a permanent memory in the
combustion control computer that remembers when you turned off the power and did not permit
the computer to check the gas valves. It will result in ERROR 140 after 6 shutdowns with no leak
check.
To prevent lightning damage to the surge protector and controls in the off season, it is a good
idea to turn 3 phase power off to the control cabinet until it is needed again.
ALARMS and ERRORS are fully described later in this manual. They may also be found on a
decal in the burner cabinet. The decal will be helpful when reviewing error history of the heater
as only time, date, and error number are displayed. ALARMS will warn the operator of an
impending problem and ERRORS will cause an immediate shutdown.
WHAT ARE THE TESTS AND SETUP PROGRAMS?
The TESTS and SETUP programs can be activated by a qualified service man or trained user to
test the heater and make custom settings. They are always performed in the Samuel Jackson
factory before shipment of a new heater and occasionally in the field, when necessary, for
troubleshooting. The TESTS program allows the service man to proceed through a set of tests
where individual components of the heater can be tested, calibrated, and adjusted.
The TESTS program is described fully in the TESTS EXPLANATION section of the manual. The
SETUP program is explained in the SETUP EXPLANATION section of the manual.
WHAT ARE THE GAS LEAK TESTS?
Every time the heater is turned off, one of two gas leak tests will be performed automatically. The
heater will alternate between the two tests after each normal shut down. The test takes about 10
minutes to perform and the status of the tests is shown on the Diagnostic Module Display DMD
in the control cabinet. Leak Test 1 checks the integrity of the safety shut off valve SSOV. With
gas evacuated from between the valves in the gas train, if gas builds up pressure and closes the
gas low pressure switch GLPS, then gas is leaking past the “upstream” SSOV. For Leak Test 2,
the gas train is charged with gas at the start of the test so the gas low pressure switch GLPS is
closed. If gas leaks out of the gas train through the Pilot Valve PV, “downstream” SSOV or

PAGE 5 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
fittings, then the GLPS will open and a downstream leak exists. An ERROR will be displayed if
one of these two tests fail. See the ERROR & ALARM EXPLANATION section for ERRORS 136
and 137. Power must be left on to the heater for at least 10 minutes after shutdown for these tests
to be performed. The heater can be restarted at any point during the test.
HOW DO I SET THE TEMPERATURE?
The set point (SP) for the air temperature is set using the AIR SP button and the +/- selector
switch on the Local Panel (See below). To change the air temperature set point, press and hold
the AIR SP button while using the +/- selector switch to raise or lower the desired set point
temperature. Release the AIR SP button when the desired set point is shown. Changing the SP
can be done with the heater on or off. The range that the set point can be adjusted to depends on
the minimum and maximum set point settings that have been made in the SETUP steps. See
SETUP EXPLANATION section of the manual for more details on setting the ranges.
Setting Air Temperature Set Point (SP) 4376
SETUP LOGS
1401 V1.0 OK..
Mode: OPERATION
AIR: 185F
TO ADJUST TEMPERATURE SET POINT
(SP) PRESS IN AIR SP BUTTON AND
TURN +/- SELECTOR SWITCH
AIR SETPOINT (SP)

PAGE 6 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
WHERE DO I INSTALL THE AIR TEMPERATURE SENSING
THERMOCOUPLE?
A thermocouple with blue paint on the pipe threads (Part Number 16900C) is supplied for
installation in the hot air duct after the heater. Place it at least 10 feet away from the outlet of the
heater.
HOW DO I ADJUST THE AIR VOLUME OUTPUT OF THE FAN?
A variable pitch sheave on the fan motor can be adjusted to fine tune the output of the fan. The
maximum fan RPM for the 2 HP motor is about 1980 RPM. The fan’s speed was set at the
factory to about 1650 RPM. The fan will deliver between 750 and 3000 CFM of air depending
on the fan’s speed and the total resistance to air flow for the duct system.
TIPS
It is better to change the speed of the fan to get close to the desired air volume than
severely gating down the air flow from an over sped fan.
Variable pitch pulley

PAGE 7 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
ERROR & ALARM LOGGING SYSTEM
The ERROR and ALARM LOGGING SYSTEM is designed to make troubleshooting easier for
both the user and Samuel Jackson service personnel. This system remembers the last 500
ERRORS and ALARMS, thus showing a history of past problems. The Alphanumeric
display DMD located in the LOCAL PANEL (See below) shows the code number for the
ERROR or ALARM along with the month, day and time of occurrence.
Access to the system is easy and can be done when the burner is on or off. Turn the +/-
switch until the blinking cursor is over LOGS. Press the SELECT button once. Then use the
+/- switch to scroll through until ERRORS/ALARMS is shown. Press SELECT again. Error
Log #001 will be shown first. Use the +/- switch to increment (+) to earlier logs or decrement
(-) to the latest. Log entries are in a first-in first-out stack, therefore Error Log #500 is
replaced when another log event occurs.
A typical Error Log display is shown below. Error Log #002 is shown with a code of 121 that
occurred on 08/19 (August 19) at 16:49 (4:49 PM). Referring to the DIAGNOSTIC CODES
decal located on the heater cabinet door, Code 121 is an ALARM that air flow went off for a
moment. A more detailed description of the codes are given in the ERROR AND ALARMS
EXPLANATIONS section of the Service Manual. For the Error Log, no distinction is made
between ALARMS or ERRORS.
Error Log Display 3567
To quickly advance through earlier logs, press the SELECT button while in the logging
system. Each press of the SELECT button will increment the log number to the next 50th
entry.
There are two ways to exit the logging system. Turn the +/- switch to the left (-) and hold for
5 seconds. Then use the same switch to choose BACK and press SELECT once. Also, the
display will change back to the normal operation mode screen after two minutes of inactivity
Error Log #002
Code: 221
M/D: 08/19
Time: 16:49

PAGE 8 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
OTHER LOGS -
“FLAME ON TIMER”
The LOGS system does more than just monitor and display problems. It also displays the
heater run time for each month the heater is operated during a year. These times can be
used to determine regular maintenance intervals.
Access to this step is easy and can be done when the burner is on or off. Turn the +/- switch until
the blinking cursor is over LOGS. Press the SELECT button once. Then use the +/- switch to
scroll through until FLAME ON TIMER is shown. Press SELECT again.
The +/- switch is now used to scroll from month to month. When you are finished
viewing the times, press SELECT to quit the FLAME ON TIMER step, then use +/-
to select BACK. Press SETUP to exit the LOGS.

PAGE 9 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
HG-1-1401A DIAGNOSTIC CODES
(ERRORS SHUT DOWN BURNER, ALARMS WARN UNTIL ACKNOWLEDGED)
CODE
ERR/ALM
DESCRIPTION
101
E
FAN MOTOR OVERLOAD.
120
E
RESTART NOT PERMITTED BECAUSE AIR FLOW SWITCH
HAS NOT BEEN OFF IN 24 HOURS. STOP FANS MOMENTARILY
OR CHECK OPERATION OF AIR FLOW SWITCH.
121
A
MOMENTARY LOW AIR FLOW. ADVANCE WARNING OF
POSSIBLE CHOKE-UP.
122
E
AIR FLOW WENT OFF FOR MORE THAN 3 SECONDS. LOOK FOR CHOKE-UP.
125
E
GAS LOW PRESSURE. CHECK FOR CLOSED VALVE OR VAPORIZER
MALFUNCTION.
126
E
GAS HIGH PRESSURE. CHECK FOR GAS REGULATOR MALFUNCTION.
130
E
GAS LOW PRESSURE SWITCH FAILED TO OPEN WHEN NO GAS WAS
PRESENT. CHECK OPERATION OF GLPS AND SSOV.
131
E
USER SPECIFIED TIME FOR SHUTDOWN.
134
E
CHECK GAS SUPPLY AND OPERATION OF SSOV1.
136
E
GAS VALVE LEAK, UPSTREAM. CHECK SSOV1.
137
E
GAS VALVE LEAK, DOWNSTREAM. CHECK SSOV2 & PV.
140
E
RESTART NOT PERMITTED. NO LEAK TEST PERFORMED FOR
PAST SIX SHUTDOWNS.
141
E
FAN RELAY FAILED TO OPEN WHEN AIR FLOW WAS ABSENT. HAS THIS
RELAY BEEN JUMPERED?
142
E
AIR FLOW SWITCH IS ON WITHOUT FAN INTERLOCK RELAY. CHECK
OPERATION OF AIR FLOW SWITCH.
143
E
NO FAN INTERLOCK SIGNAL. IS THE FAN ON?
144
E
EXCESSIVE FLAME FAILURES. THREE OCCURRENCES OF 146 OR 151.
146
A
BURNER FAILED TO IGNITE.
151
A
BURNER FAILED IN OPERATION.
153
E
FLAME SIGNAL BEFORE FUEL AND BEFORE SPARK.
155
E
FLAME SIGNAL BEFORE FUEL DURING SPARK. LOOK FOR
ELECTRICAL INTERFERENCE BETWEEN SPARK AND FLAME WIRES.
164
E
AIR THERMOCOUPLE BURNOUT.
163
E
HIGH TEMPERATURE AT BURNER HEAD.
166
E
SSOV1 FAILED POC SWITCH NOT SATISFIED.
171
E
HIGH TEMPERATURE DOWNSTREAM.
172
A
FLAME SIGNAL CONTINUES TOO LONG AFTER SHUTDOWN.
174
E
CONSTANT AIR TEMP > 5 MINUTES. CHECK THERMOCOUPLE WIRING AND
THERMOCOUPLE INPUT CARD.
177
E
POWER FAULT DURING OPERATION.
270
A
LOW PLC BATTERY.
271
A
PLC BATTERY BACKUP DISABLED. REPLACE BATTERY!

PAGE 10 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
ERROR & ALARM EXPLANATIONS
HG-1-1401A
(FOR SOFTWARE VERSIONS 3.0 AND LATER)
PRELIMINARIES -- As explained in the Heater Operation section, ERRORS will cause the
burner to automatically shut down. ALARMS will permit the burner to continue operation but
warn of conditions which may cause a shutdown if left unattended. In each case, the
DIAGNOSTIC CODE with a brief description of the ERROR or ALARM will be shown on the
display screen located on the LOCAL PANEL in the heater cabinet.
ERROR and ALARM Condition Display 3567
The display will continue to show the ALARM or ERROR until the SELECT button is
pressed. Only one ALARM or ERROR condition is displayed at a time. The oldest
unacknowledged ALARM condition is shown even if the burner shuts down due to an
ERROR. Pressing the SELECT button will show consecutive ALARM conditions
leading up to the shutdown ERROR.
EXAMPLE: The flame electrode is fouled. This prevents the burner from having a
flame signal. ALARM code 146 (Burner failed to ignite) is displayed and the status light
flashes. While this is occurring, the burner is automatically restarting itself (three times
max) attempting to light. The burner shuts itself down on ERROR code 144 (Excessive
flame failures) after 3 unsuccessful tries. The display continues to show ALARM code
146 although the status light is still flashing and the burner is shut down due to an
ERROR. Press SELECT to clear each ALARM code and then to clear ERROR code 144.
After ERROR code 144 is cleared, the operator can attempt to restart the burner.
Note: Errors that have an * in front of them can be temporarily bypassed. See the bypass
routine explanation at the end of this section for more details.
ERROR 222 - Low
Than 3 Seconds
AirFlow For More

PAGE 11 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
ERROR 101
FAN MOTOR OVERLOAD: This ERROR means that the overload relay for the fan
motor starter MOL is tripped. The following should be checked before continuing
operation with this error:
•Verify setting of overload relay MOL at 3.1 amperes for 480VAC, 3.6 amperes for
380VAC.
•Verify voltage as 380VAC, 415VAC or 480VAC. Check for low voltage condition.
•Verify free rotation of fan and motor.
•Verify that fan speed is not faster than 1980 RPM.
* ERROR 120
RESTART NOT PERMITTED BECAUSE AIR FLOW SWITCH HAS NOT BEEN OFF IN
24 HOURS: The air flow switch (AFS) must be exercised periodically to insure its proper
operation. If the burner and fan have run continuously for over 24 hours, the burner will
NOT shut down due to this ERROR, however if the burner is turned off and an attempt is
made to restart it without turning off the fan (see note below), it will not start and will
display ERROR 120. The SELECT button will NOT allow restart. The fan MUST be
turned off and then back on to allow the burner to start again. If the operator is aware of
the safety reasons for this air flow switch check and desires to not turn the fan off, a
passcode to bypass this ERROR is described in the footnote for this section.
Note: For most HG-1 heater installations, the fan is an integral part of the heater system
so this ERROR will not occur unless the air flow switch (AFS) is out of adjustment.
ALARM 121
AIR FLOW WENT OFF FOR A MOMENT: This ALARM is an indication that a choke of
the air flow is occurring. It is displayed when the air flow switch goes off and comes
back on in less than 3 seconds. The air flow switch (AFS) may be set too sensitive.
ERROR 122
AIR FLOW WENT OFF FOR MORE THAN 3 SECONDS: This ERROR occurs when the
air flow is interrupted for more than 3 seconds. Verify proper air flow and adjust switch
if necessary.
ERROR 125
GAS LOW PRESSURE: The gas pressure is constantly monitored by the gas low pressure
switch (GLPS) in the lower cabinet. This ERROR is triggered when the pressure is
below 1.5 PSI when the gas valves are open. Check for a closed gas cock or ball valve in
the gas line to the heater. For propane systems, check for malfunction of vaporizer. The
GLPS is set to 45 inches water column (about 1.5 PSI).
In rare cases, the screen on the inlet to the SSOV valve block may be clogged. Refer to
the TESTS EXPLANATION section for GAS LOW PRESSURE for a picture of the
location of this screen.
ERROR 126
GAS HIGH PRESSURE: The gas pressure is constantly monitored by the gas high
pressure switch (GHPS) in the lower cabinet. This ERROR is triggered when the
pressure is above 4.5 PSI. Check for malfunction of the gas pressure regulator (GPR).
The GHPS is set to 120 inches water column (about 4.5 PSI).

PAGE 12 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
* ERROR 130
GAS LOW PRESSURE SWITCH FAILED TO OPEN: The gas low pressure switch is not
responding as it should in normal operation. The PLC performs an automatic check of
the heater's switches and safety devices each time the burner is started. One of these
checks is the Gas Low Pressure Switch (GLPS). If this switch is closed when it should
be open, the PLC will not permit the burner to start.
Possible causes of this abnormal operation of GLPS are:
(1) SSOV is malfunctioning and is open, maintaining gas pressure on GLPS at all times.
(2) the GLPS switch is out of adjustment. GLPS should close above 1.5 PSI.
(3) GLPS has been tampered with or bypassed electrically.
(4) Excessively high static pressure within the combustion chamber.
(5) The low fire gas valve is closed off too far to allow gas to bleed off when gas is
evacuated from the gas train by the Pilot Valve (PV) during the startup tests.
If the operator is aware of the safety issues involved in bypassing the function of this
switch, a software bypass is available for emergency operation. The passcode for this
bypass is described in the footnote for this section.
To check GLPS, run the TESTS program step for Gas Low Pressure and then turn the
local START-STOP selector switch to "-". This opens the Pilot Valve (PV). This
evacuates the gas pressure cavity in the gas train and the gas pressure gauge should read 0
PSI.
ERROR 131
USER SPECIFIED TIME FOR SHUTDOWN: Some countries require that gas-fired
combustion products turn off once every 24 hours as a safety measure. To accommodate
operators that need to comply with this regulation, ERROR 131 will force the heater to
shut down once a day at a user defined time. This error will only occur if the 24 Hour
Shutdown routine is enabled in the SETUP program. This error can be disabled in the
SETUP program at any time. See the SETUP EXPLANATION section for more
information.
ERROR 134
CHECK GAS SUPPLY AND OPERATION OF SSOV: Gas pressure is tested when the
heater is started. ERROR 134 occurs when the GLPS switch does not close with this gas
pressure. Possible causes are low gas pressure, a defective SSOV valve actuator that
prevents gas from reaching the GLPS switch, or a maladjusted GLPS switch. If upstream
gas pressure gauges indicate that gas pressure is sufficient (6 PSI before the regulator
should be minimum), suspect the SSOV valve actuator. GLPS switches are normally not
a problem and should not be adjusted unless suggested by the factory.
ERROR 136
GAS VALVE LEAK, UPSTREAM: This is a serious ERROR caused by a leak in the first
SSOV valve. This is the "upstream" gas valve. The test program may be run to determine
the severity of the leak. See the TESTS program for Gas Low Pressure. A leak in the
first SSOV valve is usually caused by dirt or other contaminants on the rubber seat of the
valve. This can be easily cleaned by removal of the lower housing of the valve (with the
gas supply turned off). Contact the factory for technical assistance if required.

PAGE 13 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
ERROR 137
GAS VALVE LEAK, DOWNSTREAM: This ERROR is caused by a leak in either the pilot
valve (PV) or the second SSOV valve. These are both "downstream" gas valves. The test
program may be run to determine the severity of the leak. See the Gas Low Pressure
TESTS for details. Contact the factory for technical assistance.
ERROR 140
RESTART NOT PERMITTED. NO LEAK TEST PERFORMED FOR PAST SIX
SHUTDOWNS: Automatic gas leak testing has been interrupted for the past 6 shutdowns.
Each time the burner is turned off, the PLC attempts to spend about 10 minutes
performing an automatic leak check on the gas valve assembly. These tests can be
interrupted by simply turning off the power or restarting the burner before the 10 minutes
has ended. The PLC demands that a leak test be performed at least once every 7
shutdowns. If each of the past 6 shutdowns have had the leak test interrupted, the PLC
will not start until the SELECT button is pressed to clear ERROR 140.
ERROR 141
FAN RELAY FAILED TO OPEN WHEN AIR FLOW WAS ABSENT: Samuel Jackson
heaters are provided with a fan interlock to provide immediate shutdown of the heater if
the fan turns off. This error indicates that an electrical signal is being received through
the fan interlock with no air flow present, effectively bypassing this important safety
feature.
ERROR 142
AIR FLOW SWITCH IS ON WITHOUT FAN INTERLOCK RELAY ON: This error
indicates that an electrical signal is being received from the air flow switch with no fan
interlock signal present 10 minutes after burner shutdown, effectively bypassing this
important safety feature. Check the adjustment of the Air Flow Switch (AFS) and verify
its operation.
ERROR 143
NO FAN INTERLOCK SIGNAL. IS THE FAN ON?: This ERROR is caused when an
attempt is made to start the burner when no fan interlock signal is present. A fan
interlock signal is supplied on the heater control panel through a set of auxiliary contacts
on the blower fan’s motor contactor (MC) to provide instant shutdown of the burner if the
fan stops. If the heater is operated in a pull through arrangement, then the installing
electrician is responsible for wiring a fan interlock contact between terminals 30 and 10
on the heater control panel. Contact the factory for technical assistance if an external fan
is used.
ERROR 144
EXCESSIVE FLAME FAILURES: While the burner is operating, it counts the number of
times the flame fails (either igniting or while running). When the total comes to 3, it
shuts the burner down on ERROR 144. If either of the ALARM codes 146 or 151 are
shown for this, it means that the first failure is the one displayed (i.e.: "Burner failed to
ignite" might mean the spark plug needs to be cleaned). Press SELECT as required to
clear all ALARMS and this ERROR.

PAGE 14 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
ALARM 146
BURNER FAILED TO IGNITE: This ALARM means that the burner failed to light. It is
an indication that there may be air in the gas line, insufficient low fire gas, or turbulent
air flow. If the burner is being operated above a push fan, air turbulence can prevent the
burner from lighting. Verify that the shutters installed between the fan and burner head
are not closed down too far. Gas pressure may be increased to provide more low fire gas
to the burner heads if required. See the following maintenance tips.
ALARM 151
BURNER FAILED IN OPERATION: This ALARM means that the burner failed while
burning. See the following maintenance tips.
TIPS
THE FOLLOWING MAINTENANCE TIPS WILL HELP TO MINIMIZE FLAME
FAILURE ALARMS:
- Clean the spark plug if it appears fouled.
- Scrape off the flame electrode and wipe the ceramic insulator with a clean cloth.
- Increase the gas pressure if low fire setting appears to be extinguished from
air turbulence.
- Increase the gas low fire valve opening a little.
- Check for a grounded ignition circuit.
Incorrectly spliced spark plug wires, splayed wires on the high voltage connectors, or a
defective high voltage insulator terminal can cause troublesome ignition. Running a
clean spark plug wire from the ignition transformer directly to the burner head can help to
isolate this problem.
ERROR 153
FLAME SIGNAL BEFORE FUEL AND SPARK: This ERROR means a flame signal is
observed before spark and fuel are supplied to the burner head. This ERROR is normally
caused by a malfunction or tampering with the flame relay (FL). In some cases, a loose
nut or bolt from overhead piping has fallen into the burner head assembly forming a short
circuit between the flame electrode and the burner head. If the flame relay appears to be
good, check for a loose metallic object in the burner head assembly. Also check for
carbon build-up in the burner head causing a short to the flame rod.
ERROR 155
FLAME SIGNAL BEFORE FUEL DURING SPARK: This ERROR is caused by electrical
interference between the spark plug wire and the flame electrode wire. Run these wires in
separate conduits. As the spark plug wire carries in excess of 6000 volts, make sure that it
is routed along the BOTTOM of the control cabinet. A spark plug wire routed incorrectly
in the control cabinet can interfere with the operation of the PLC and other electronic
components.

PAGE 15 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
ERROR 164
AIR TEMPERATURE THERMOCOUPLE BURNOUT: This ERROR normally means
that the thermocouple mounted in the duct sensing air temperature has burned out or the
thermocouple sensor wire connections are loose. If the air temperature remains at 000 F a
few seconds after the heater lights, this ERROR occurs. The thermocouple wires are
polarity sensitive so reversing the wire hookups could also cause this condition. For type
‘J’ thermocouples, the white wire is positive, red is negative. Reversing the wires will
cause the PLC to think the temperature is falling when it is actually rising. If the
temperature is dropping as the gas valve is opening, this ERROR will occur.
ERROR 163
HIGH TEMPERATURE AT BURNER HEAD: This ERROR will shut the burner down
due to a high temperature condition sensed in the burner duct with the factory installed
burner high temperature thermocouple. Operating the heater at very low air flows (under
750 CFM) or with the shutters before the burner head too far open can result in a high
temperature condition.
*ERROR 166
SSOV1 FAILED POC SWITCH NOT SATISFIED: The PLC was not able to verify that
Saftey Shut-Off Valve 1 (upstream SSOV valve) is opening and closing in a timely
manner. If this problem persists, try the following: Check that SSOV opens and closes.
Check for gas leaks. Check operation of SSOV's proof of closure switch (POC). Replace
SSOV valve actuator and/or its proof of closure switch.
If the operator is aware of the safety issues involved in bypassing the function of the
Proof of Closure switch (POC), a temporary software bypass is available by pressing the
BYPASS button on the error screen.
ERROR 171
HIGH TEMPERATURE DOWNSTREAM: This ERROR will shut the burner down if the
heated air temperature is more than 50 degrees above the air temperature setpoint.
ERROR 172
FLAME CONTINUES TOO LONG AFTER SHUTDOWN: This ERROR means that
flame is detected for more than 12 seconds following closure of all gas valves. This
indicates a probable gas leak in the system. Run the TESTS program and perform the
Gas Low Pressure test to determine the severity of the leak. Consult the factory for
service recommendations. In rare cases, very low quality LPG fuel can cause this.
ERROR 174
CONSTANT AIR TEMPERATURE > 5 MINUTES: The heated air temperature is
constantly monitored. Very small fluctuations in temperature are expected and indicate
that the thermocouple wiring and thermocouple input card on the PLC are in working
order. Check for disconnected thermocouple, thermocouple wiring problem and
connections to the thermocouple input card on the PLC.

PAGE 16 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
ERROR 177
POWER FAULT DURING OPERATION: This ERROR means that electrical power was
disconnected while the burner was on. Check for faulty supply wiring connections.
ALERT 270
LOW PLC BATTERY: This ALERT means that the PLC battery needs to be replaced
soon. A dead PLC battery will prevent the display from working (except to display E042
NO CPU BATT) and the ERROR LOGGING SYSTEM will lose the log history. The
burner can continue to operate with a dead battery. ALERTS are not entered into the error
logging system.
ALARM 271
PLC BATTERY BACKUP DISABLED. Replace PLC battery.
* Indicates an ERROR condition that can be temporarily bypassed. To bypass the
ERROR, perform the following steps. These steps will have to be performed in order
to bypass the ERROR each time the heater is started
until the condition is fixed. Some problems will require the bypass of
multiple errors before operation can occur. Before
the SELECT button is pressed to clear the ERROR, do the following:
- Use the START/STOP switch at the LOCAL PANEL in the heater. Turn it to
the left (O) 3 times.
- Press the SELECT button to clear the ERROR and attempt to restart the heater.

PAGE 17 of 41 HG-1-1401A GAS-FIRED HEATER
© SAMUEL JACKSON, INCORPORATED 2005 ALL RIGHTS RESERVED
TESTS EXPLANATION
HG-1-1401A
(For software version 3.0 and later)
PRELIMINARY:
To test a new installation, first check that all necessary connections for electrical,
water, gas and drain are made. Standard 3-phase electrical power supplies are
480VAC 60 HZ, 415VAC 50 HZ, or 380VAC 50 HZ.
With electrical power off, prepare to purge the gas line of debris and air by closing
off the gas supply valve before the Gas Pressure Regulator (GPR) and having the
main gas supply on. Open the pipe cap on the end of the short pipe debris trap nipple
under the regulator and quickly open/close the gas supply valve several times. Debris
in the pipe will blast out. Keep doing this until gas is noticeable. Make sure good
ventilation is present and no one is smoking.
Check that power on terminals 1 and 2 on the electrical panel is between 103 and 125
VAC.
TO ENTER TESTS PROGRAM -- The TESTS program is run from the diagnostic
module display DMD at the local panel. TESTS is used at the factory on the test stand,
used at commissioning time, and used to help troubleshoot the heater in the future.
TESTS can only be accessed when the heater is off and not during the heater’s normal
gas leak test. To access TESTS when the heater is doing its leak test, power cycle the
panel.
Gas Pressure
Regulator (GPR)
Pipe cap on debris
trap nipple