SAMUEL JACKSON HG-4-111OC User manual

GAS-FIRED HEATER
I HG-4-111OC I
SAMUEL JACKSON
DRYAIRE HEATER

17400 TEMPERQTURE CONTROL ASSEMBLY
OPERATION NOTES
This assembly incorporates UDC
increasing during the preburn
ro
equipped with the 16910 Modul
point, there
will be two digital contro
used, there will be a single controller
whether they have relay
or micr
This assembly has two indicator I
STATUS LIGHT -- On all heaterswith micropr
in operation and preburn and
conditionsby blinkingas explained belo
ntrollers. To keep control outputs from
from the flame signal.
If the heater is
to control temperature before the mix
d one on the right). If the
16910 is not
e same assemblyis used on all heaters,
. Their operationis as follows:
ustion controls, this light will be
ON while
It will indicate alarm and error
FLAME LIGHT
-- With all heaters, this light will be ON when flame is established.
ALARMSAND ERRORS
ALARMS -- Problemsnot serious enough to shut down operation.
ERRORS
-- Problemswhich require that operations cease.
ALARM PROCEDURE
-- During operation, the STATUS light will blink at the rate of one pulse every
two seconds for
5 minutes then revert to ON. During the 5-minute interval, the ALARM light on the
local panel will be
ON. The counter will display the code number corresponding to the alarm
problem, and will reset to zero at the end of the interval.
ERROR PROCEDURE
-- The burner will shut down and cannot be restartedunless the RESET button
on the local panel is pushed. The counter will display the appropriatecode number and the ALARM
light
will be ON until the RESET button is pushed. The STATUS light will blink at the rate of one
pulse per second for
5 minutes, then go OFF. If an attempt is made to start the burner before
RESET, the STATUS light will blink for
10 secondsthen go OFF.
17400 91 1022

GAS - FIRED
SAMUEL JACKSON COTTON GIN HEATEiRS
Many of the safety features designed into cotton drying heaters can be tampered with
and circumvented
if the operating pers
but hidden, safety feature in all Samuel
performance. Assembly of components in the factory instead of in the field and the
inspection of each installation by a
performance. One design aspect
the achievement
of high flame electr
the flame safeguard relay which can
Specific safety features which are not
below.
el are desperate to dry cotton. An important,
kson heaters is their dependable
entative helps to insure trouble-free
mance, but contributingto safety, is
This prevents nuisance shutdowns by
ors to desperation.
y used on cotton gin heaters will be listed
A purge timer requires that air be flowing through the heater and drying system for
15
seconds before ignition is attempted. This removes any hazardous gas accumulated
during the shut-down period.
A static pressure switch is often used to infer that air is moving through the dryer.
If a
chokeup occurs, static pressure is still present and the burner continues to operate.
This can cause a fire.
All Samuel Jackson heaters use an air flow switch which
measures the difference in pressure sensed by orifices pointing upstream and
downstream. When air flow is reduced, the burner
is turned off.
If the fan motor starter overloads and drops out, ordinary heaters will keep burning until
the fans have slowed down enough for the air flow switch to turn off. In order to give
immediate burner shutoff, and serve as a safety backup for the air flow switch, we
include a fan safety relay which is easily interlockedwith the fan motor starter.
To prevent any debris from jamming a gas valve in the open position or causing it to
leak when closed, we always use
two gas valves in series. We also provide means for
easily checking the valves for leaks.
All Samuel Jackson burners come complete with
microprocessor combustion controls which check for gas leaks automatically each
time the burner is turned off. The combustion control computer also checks for
other safety and performance problems on a daily basis over the
life of the
burner and notifies the operator with a numeric code described with the heater’s
documentation.
When the burner flame goes out during operation,
it is customary for the flame
safeguard relay to fire the sparkplug immediately in an attempt to reignite.
If air flow
has been choked enough to produce an explosive mixture, this can be serious.
If our
burner should flameout, it will first close all gas valves, then wait for air to purge the
drying system. It then proceeds to restart the burner, observing all safety precautions,
including checking for a jammed flame relay.
SAMUEL JACKSON MFG. CO.
P.O. BOX 16587 / LUBBOCK, TX 79490 / U S A
TELEPHONE [phone] FAX 806-7!35-8240
GASSAFET.MAN 911022

USING THE 17400 DIGVAL TEMPERATURE CONTROL
(WITH THE 16910 MOD
TEMPERATURE LIMIT)
The 17400 Temperature Control
ModulatingHigh Temperature Limit to preve
cases, cause fires. These instru
all Samuel Jackson Dryaire Heaters.
eaters can be used with the 16910
s which can harm cottonquality and, in extreme
delines for use of this control arrangementwith
The 17400 control assembly uses two H ure controllers. The controller on
the k& as you face the control ntroller. The controller on the
.t$&j is
designatedthe "HIGH LIMIT" controller. ts thermocouple temperature sensor
mountedDOWNSTREAM of th LIMIT controller has its thermocouple
mountedupstream of the mixpoint. The P atches the temperature after cotton has mixed
with the air.
If wet cotton is fed into the system, the air is cooled and the PRIMARY controller signals the HIGH
LIMIT controller that more heat is needed to compensate for this cooling. The HIGH LIMIT controller operates
the burner's gas valve to supply this heat, but
in no case will the temperature be permitted to exceed the limit
which the ginner
has previouslyspecified. If dry cotton isfed into the system the reverse occurs. In the case of
achoke or large air leak, the HIGH LIMIT controller may not be able to contain the temperature within the
specified limits and
it will then shut down the burner to prevent a fire (with an appropriate ERROR code on
burnerswith microprocessorcombustioncontrols).
NORMAL OPERATION PROCEDURE
There is a spring return selector switch located below the PRIMARY controller with a "1" on the right and a "0" on
the left. These are symbols for START-STOPoperations. Turn the switchto "1" and release it to start the burner.
Turn the switch to
"0" to shut down the burner. After turning the switch to "l", please notethat there is a preset
time delay to allow the burner head and piping to be purged with air. Following this delay, ignition is tried and
should occur immediately. If ignition is not successful and your model has microprocessor combustion
controls, observe the STATUS light to see if
it isflashing. If it is, go to the burner's control cabinet and note the
ERROR/ALARM code displayed on the local panel. There is a decal at the control cabinet and a page in each
service manual explaining the numbers.
It will be necessary to press the RESET button on the burner's local
panel in order to clear the
ERROR and rest r. In the case of failure in ignitionor failure in operation,
the burner will automatically attempt to
r
itself for a maximum of three attempts. Neither digital
temperaturecontroller
will come on until flame has been established in the burner. This is to prevent the highly
responsivecontrolsfrom "winding up" during
t ir purge delay time and causingthe burner to come on with a
roar. When they do energize, the controllers take 12 seconds to perform self-check operations and then
display
the temperatures.
There are four temperatures displayed at all times du g burner operation. The PRIMARY control on the left
shows two and the HIGH LIMIT control on the right shows
two as well. The lower display on the PRIMARY is the
temperaturewhich the ginner sets and is the only one he will adjust under normal circumstances. It is the
temperaturedesired after the mixpoint.
It is raised and lowered with the orange buttons below it. The upper
displayshows the actual temperature being by th thermocouple. On the HIGH
LIMIT
controller, the lower display is the tempera ntrol is feeding it (See "Principle of
Operation"Section). The upper display on the right is the actualtemperature beforethe mixpoint. By observing
the upper display on both controllers,
it is possible to estimate the wetness of the incoming cotton as they will
move farther apart as the cotton gets wetter.
h the
Page 1

17400 CONTROL WITH 16910 HIGH LIMIT 11
/90
17600 CONTROL INTERFACE OPTION
When the 17400 control is used with the 17600 Control InterfaceOption, it is not necessaryfor the ginner to use
the arrow buttons on the PRIMARY controllerto he desired temperature downstream. The PRIMARY
will
obtainthis value from the 17600 (which is comi erry Series
800 Moisture Monitor). If the ginner
disagreeswith the suggested temperature co 600, he should use the arrow buttons on the
17604to adjust
it to his preference. Pressing the DOWN ARROW button on the 17600 tells the control that he
desiresa lower cotton moisture content at the feeder a d
it will turn UP the temperature on the 17400
controlto achieve
it. Pressingthe UP ARROW bu
If it is ever desired to bypass the Series 800 and 600 Control Interface, operating the burner with manual
setpointentry by the ginner can be done easily. the button cover on the upper left button on the
PRIMARY control. This is the FUNC button. Pressi button will tell the PRIMARY controller to ignorethe
incomingsignal from the 17600 (designated
"RSP ower display) and take its temperature commands
from the ginner. The new lower display will be desi
"SP. "RSP stands for Remote Set Point and "SP"
stands for Set Point.
ADJUSTING THE MODULATING LIMIT
The modulating limit is the temperature before the mixpoint which the control is programed not to exceed.
Please note that the burner will not be killed,
it will simply not be allowed to go over this setting. This setting is
factory preset at
350 F (176 C) as there is general agreement in the industry that temperatures in excess of this
level permanentlydamage cottonfibers. The procedurefor changingthis setting follows.
The programming is done on the HIGH LIMIT controller. Remove the button covers on the lefthand top and
bottom buttons. These are labelled FUNC and SETUP. First, unlock the controller by pressing SETUP 1time
and FUNC 4 times. LOCKOUT should be displayed in the lower display. Press either ARROW button untilthe
upper display says NONE. Press LOWR DlSP one time to unlock the control.
Now press SETUP
5 times until INPUT 2 is displayed in the lower display area. Press FUNC 2 times until IN2 HI
is in the lower display. This is your modulatinghigh limit value. Use the ARROW buttonsto set
it at the desired
level. Please note that the controller will not operate correctly if this value is set higher than 400 F
(204 C) or
lower than
200 F (93 C). Press LOWR DlSP to set the new value.
Relock the control by repeating the above procedure but pressingthe ARROW buttons until MAX LOCKOUT is
displayed. Replace the buttoncoversto discourage use by unauthorizedpersonnel.
ADJUSTING THE CUTOFF SAF'LIMIT
This limit is set on the HIGH LIMIT controller in a similar fashion to the modulating limit. Remove the button
coverson the lefthand top and bottom buttons. These are labelled FUNC and SETUP. First, unlock the
controller by pressingSETUP one $me and FUNC 4 times. LOCKOUT should be displayed in the lower display.
Press either ARROW button until the upper display says NONE. Press LOWR DlSP one time to unlock the
control.
Now press SETUP
8 times until ALARMS is displayed in the lower display area. Press FUNC 1 time untilAlSl
VAL is in the lower display. This is your cutoff high limit value. Use the ARROW buttonsto set
it at the desired
level. We recommend setting this value approximately 25-50 degrees F above the modulating limit. Press
LOW DlSP to set the new value.
Relock the control by repeating the above procedure but pressingthe ARROW buttons until LOCKOUT MAX is
displayed. Replace the button coversto discourage use by unauthorizedpersonnel.
1 7400-H 1
Page 2

ss
GPSH
COMPONENT LABELS
FOR HG-4-111OC
PLC CB7
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COMPONENT LIST -1- HG4-111OC
NAME
PART NUMBER. MFR'S TYPE
SYMBOL
AFS
LOCATION
AIR FLOW SWITCH
16188, PC-301
UPPER CABINET
AS AIR SCREEN SWITCH (OPTIONAL)
16188, PC-301
UPPER CABINET
CB CIRCUIT BREAKER
17427, NRAS1100F5AAA
UPPER CABINET
DTC DIGITAL TEMPERATURE CONTROLLER
16401, DC3001-0-000-1-00
REMOTE
DTCH
ED
FE
FL
GPG
GPR
GPSH
16910 DIGITAL HIGH TEMP OPTION
17090, DC3002-0-010-1-00
REMOTE
ELECTRONIC DRIVE FOR
MM, 4-20MA LOWER CABINET
14845, CP-8391-716
FLAME ELECTRODE
12399, FRS-2-6
BURNER
FLAME RELAY
16235, R7023B1003
UPPER CABINET
GAS PRESSURE GAGE
(2)
11278, 9851933
LOWER CABINET
GAS PRESSURE REGULATOR, 2 inch
14055, 243-8
LOWER CABINET
GAS PRESSURE SWITCH (HIGH PRESS) LOWER CABINET
17595, SWITCH UNIT, PB-21A
17596, PRESSURE TRANSDUCER, RD20A11
GAS PRESSURE SWITCH (LOW PRESS) LOWER CABINET
16643, SWITCH UNIT, PB-41A
16645, PRESSURE TRANSDUCER, RD4OA11
GPSL
GLTS GAS LOW TEMPERATURE SWITCH LOWER CABINET
16647, SWITCH UNIT, PB-11A
16561, TEMPERATURE TRANSDUCER, KBlOAl
(USED ONLY WITH PROPANE UNITS)
IGP
IGT
IGNITER PLUG
12398, 1-64-1
BURNER
UPPER CABINET
IGNITION TRANSFORMER
11172, 612-6A7

MM
PLC
PV1
PV2
SP
ss
SSOVl
ssov2
TCV
COMPONENT LIST -- HG-4-111 OC
PG 2
MODULATING MOTOR FOR TCV LOWER CABINET
14824, MP-2150-500-0-02 (FOR 60 HZ)
16614, MP5-2150-500-2-2 (FOR 50 HZ)
PROGRAMMABLE LOGIC CONTROLLER UPPER CABINET
16708, C28K
GAS PILOT VALVE (2)
17218, 804068
SEQUENCE PANEL COMPLETE
17735
SURGE SUPPRESSOR
16191
, ZX-5000
LOWER CABINET
UPPER CABINET
UPPER CABINET
SAFETY SHUT-OFF GAS VALVE, 1-1/2 LOWER CABINET
17271, VALVE, VGG10.14040
17270, ACTUATOR, SKP1O.lllO1
TEMPERATURE CONTROL VALVE, 1-1/4
U LOWER CABINET
13946
, 63-23882
111OCCOM 911018

31 74
4-94
HG-4-111OC & D GAS-FIRED HEATER, (-MILLION BTU/HR
STUB-UPS
NO. DESCRIPTION ROUTING AND NOTES
1 BURNER POWER FROM POWER CENTER TO BURNER
120 V,
15 A SUPPLY
1/2" COND,
2 - 14 GA WIRES
2 BURNER TEMPERATURE CONTROL FROM BURNER CABINET
TO CONSOLE OR TEMP CONTROL
3/4" COND, 9 - 16 GA WIRES
3 BURNER SPARK PLUG WIRES FROM BURNER CABINET
RUN OVERHEAD TO THE BURNER BODY
1 - 1" COND WITH 1 SPK PLUG
WIRE AND
1 - 1/4 PLASTIC
AIR FLOW TUBE.
4 BURNER FLAME ROD WIRES FROM BURNER CABINET
RUN OVERHEAD TO THE BURNER BODY
1 - 1" COND WITH 2 - 14 GA
WIRES AND
1 - AIR FLOW TUBE
5 THERMOCOUPLES FROM CONSOLE TO:
PRIMARY ENTRANCE OF TOWER OR SECOND-
STAGE SKIMMER AIR OUTLET OF
FOUNTAIN DRYING SYSTEM.
USE BLUE-MARKED THERMOCOUPLE
HIGH
LIMIT HOT AIR BEFORE MIX POINT.
USE RED-MARKED THERMOCOUPLE.
1/2" COND WITH 2 PAIR TYPE-J
THERMOCOUPLE WIRE.
DO
NOT RUN WITH A-C WIRES.
0 K WITH T/C OR DC WIRES.
6 GAS SUPPLY FOR BURNER 1 1/4" GAS SUPPLY LINE.
NATURAL GAS OR PROPANE
5 TO 20 PSI, .3 TO 1.4 BARS
CAT3174 4-94

CAT 31498
EXTERNAL ELECTRICAL CONNECTIONS
HG-4-1110D
4 MBTU/HR GAS-FIRED HEATER
REMOTE STOP 521
REMOTE START 531
STATUS LIGHT 3
FLAME LIGHT 58
-
-
-
4-20 rnA (+)
4-20 mA (-)
I--
WITH 17400 REMOTE CONTROL
I1
II
I1
II
II
II
II
II
II
II
It
I1
II
t
II
/\
I1
I I In
120 VAC HOT
50/60 Hz SUPPLY
1 I1 I
II
II
FLAME SIGNAL /FJ II
120 VAC TO REMOTE n-- 50
HIGH TEMP ALARM
120 VAC NUETRAL
BEFORE -MIX T/C (RED)
(HOT AIR ONLY PIPE)
..
I I RED
11-94
>
r----lH
FAN START
BUTTON
a:& (SEE NOTE A)
a
-El
-Dl
-a
33
-El
--Dl
REMOTE CONTROL
REMOTE CONTROL REQUIRES A RECTANGULAR
MOUNTING CUTOUT 10 1/8 WIDE X 7 1/8
HIGH.
FOR
BLUE UDC--3ooo CONTROLS MAKE THE
FOLLOWING TERMINAL SUBSTITUTIONS:
10 FOR 23, 11 FOR
24, 18 FOR 27, AND
1 FOR
3.
INSTALLING ELECTRICIAN IS
RESPONSIBLE FOR CONNECTION OF A
NORMALLY OPEN INTERLOCK (FURNISHED
TO THE HEATER FAN.
AFTER MIX T/C (BLUE)
(HOT AIR AND COTTON' PIPE)

HG-4-111OC 4-MILLION BTU/HR GAS-FIRED HEATER
(ERRORS SHUT DOWN BURNER.
ALARMS WARN FOR FIVE MINUTES.)
ERROR
GODEALARM DESCRZPTION
20
21
22
23
24
25
26
27
28
29
30
31
32
34
36
38
39
40
42
43
44
50
E
RESTART NOT PERMITTED BECAUSE AIR FLOW SWITCH
HAS NOT BEEN OFF
IN 24 HOURS. STOP FANS MOMEN-
TARILY OR CHECK OPERATION OFAIR FLOW SWITCH.
A AIR FLOW
WENT OFF FOR MOMENT. ADVANCE WARNING
OFPOSSIBLE CHOKJX,.JP.
AIR FLOW
WENT OFF FOR MORE THAN 3 SECONDS. LOOK
FOR CHOKE-UPOR LARGE AIR LEAK
IN SYSTEM.
AIR MLET SCREEN CLOGGED. PLEASE CLEAN IT.
GAS LOW TEMPERATURE. LIQUID PROPANE IN LINE.
VAPORIZER NOT WORKING OR HIGH PRESSURE
REGULATOR LEAKING DURING LONG SHUTDOWN
PERIOD.
GAS LOW PRESSURE. CHECK FOR CLOSED VALVE.
GAS HIGH PRESSURE. CHECK GAS REGULATOR BELOW.
GPS VALVE LEAK, UP!3TREAM. CHECK P1 AND SSOVl.
GAS VALVE LEAK, DOWNSTEAM. CHECK P2 AND SSOV2.
RESTART NOT PERMITTED.
NO LEAK TEST PERFORMED FOR
PASTSIX SHUTDOWNS. LEA= ELECTRICAL POWER ON
BURNER FOR
15 MINUTES AFTER SHUTDOWN.
GAS LOW PRESSURE SWITCH FAILED TO OPEN WHEN NO GAS
PRESENT. CHECK OPERATION OF GLP.
FAN RELAY AT REMOTE CONTROL STATION FAIL.ED TO
OPEN
WHEN AIR FLOW WAS ABSENT. HAS THIS RELAY
BEEN JUMPERED?
EXCESSIVE FLAME FAILURES.
THREE OCCURRENCES OF
ALARMS 34 AND 36 SINCE BURNER STARTED. ONE OF
THOSE ALARM CODES MAY BE SHOWN FOR THIS
ERROR.
BUFNER FAILED TO IGNITE. SEE 32.
BURNER FAILED
M OPERATION. SEE 32.
FLAME SIGNAL BEFORE FUEL AND BEFORE SPARK.
LOOK FOR TAMPERING AT FWERELAY CONTACTS.
FLAME SIGNAL BEFORE FUEL DURING SPARK. LOOK FOR
ELECTRICALINTERFERENCE BEWENSPARK AND
FLAME
WIRES. THEY SHOULD BE IN SEPARATE
CONDUITS.
FLAME CONTINUESTOO LONG AFTER SHUTDOWN.
CHECK FOR CHOKE-UP OR AIR LEAK INTO SYSTEM.
HAS THE FAN INTERLOCK RELAY BEEN CONNECTED?
E
E
E
E
E
E
E
E
E
E
E
A
A
E
E
E
E HIGH TEMPERATURE LIMIT EXCEEDED.
E
E
AIR FLOW SWITCH IS ON WITHOUT FAN INTERLOCK RELAY
FOLLOWING SHUTDOWN. CHECK OPERATION
OF AIR
FLOW SWITCH.
E CA,LLFALTORY.
111OCAJ.M 921125

AL,ARMS/ERRORS EXPLANATION
HG-4-1110C
(FOR SOlWVARE VERSIONS 2.7 AND LATER)
PRELIMINARIES -- As explained in the Operation
down where
ALARMS will permit the burner
shutdown
if left unattended. In each case,
controlcabinet. This number will refer
to either
ALARM or ERROR to occur in a five m
the burner may haveshut down due to
ORS will cause the burner to automaticallyshut
ation
but warn of conditions which may cause a
displayed on the local panel inside the burner's
an ERROR. The number displayed
will bethe FIRST
is could mean that an
ALARM code is displayedyet
EXAMPLE: The flame electrode is dirty.
ignite) is displayed for five minutes on
this is occurring, the burner is automatical
burner shuts itself down on ERROR num
occurs within a five minute period, the
light isflashing once every second and the burner is
sh
* ERROR 20
from starting. ALARM code 34 (Burner failed to
s light flashes once every 2 seconds. while
times max) attempting to light the burner. The
e failures) after
3 unsuccessful tries. This all
o show ALARM code 36 although the status
due to
an ERROR.
The air flow switch must be exercised periodically to insure its proper operation.
If the burner and fans have run
continuouslyfor over
24 hours, the burner will NOT shut down due to this ERROR, however if the burner isturned
off and an attempt is made to restart it without turning off the fans, it will not start and will display ERROR 20. The
RESET button will NOT allow restart. The fans MUST be turned
off and then back on to allow the burner to start
again.
ALARM 21
This ALARM is an indicationthat a choke of the air flow is occurring. It is displayedwhen the air flow switch goes
off and comes back on in lessthan 3 seconds.
ERROR 22
This ERROR occurs when the air flow is interrupted for more than 3 seconds. Verify proper air flow and adjust
switch if necessary.
ERROR 23
This ERROR applies ONLY to pull through systems. The air inlet screen is choked. It requires cleaning. Failure
to do
so or bypassthis can result in "hot streaking"of the burner, a major cause of cottonfires.
ERROR 24
This ERROR occurs when liquid propane is sensed in the line by the low temperature switch in the burner's gas
pipe.
It is an indication that there are problems with the vaporizer or possibly the high pressure regulatoris
leaking duringa long shutdown period.
ERROR 25
The gas pressure is constantly monitored by the pressure switch in the lower cabinet. This ERROR is triggered
when the pressure is below
1-1 /2 psi when the gas valves are open. Check for a closed gas cock or ballvalve in
the gas line to the heater.

HG-4-111 OC ALARMSIERRORS D(PLANATKIN ----- PAGE 2
ERROR 26
This ERROR occurs when the gas pressure is excessively high. Check the reading on the gas gauge in the lower
cabinet to see if the pressure is between 3-1/2 and
5 psi and adjust the gas regulator on the burner if required.
ERROR 27
1
This is a serious ERROR caused by a leaking valve upstream in the burner. The two upstream valves are the
Safety Shutoff Valve (SSOVl) and the P1 pilot valve. Run the Test Program (see attached test program
instructions)and observe the gas gauge dur step
4 to determine the severity of the leak and consult the
factory for service.
ERROR 28
This ERROR is caused by a downstream gas leak in the burner. The downstream gas valves are the SSOV2 and
P2. After running the Test Program to determine the severity of the leak, consult the factory for service
recommendations.
ERROR 29
Each time the burner is turned off, the PLC spends the next 15 minutes performing an automatic leak check on
the gas train
and valves. These tests can be interruptedby simply turning off the power or restartingthe burner
beforethe 15 minutes is ended. The PLC demands however, 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
RESET button is pressed(ERROR 29 will be displayed).
ERROR 30
The PLC performs an automatic check of most of the heater's switches and safety devices each time the burner is
started. One of these checks is
the Gas Low Pressure switch (GLP). If this switch has been bridged, or is out of
adjustmentthe PLC will not permit the burner to start until
it is fixed. To check the GLP, run the Test Program to
step 2 and then turn the local START-STOP selector switch to "1". This opens P2 valve. This evacuates the gas
pressure cavity in the gas train and the gas pressure gauge should read
0 psi. Observe input light 6 on the PLC.
This should be off.
If not, check the switch's adjustmentor it's wiring.
ERROR 31
The external electricalconnectiondiagram indicatesthat a fan interlock contact be installedbetween terminals 50
and 5OA on the 17400 (or 16400) remote control. The purpose of this is to interlock the power to the heater's
controlstation with the motor starter@) which drive the
pull and/or push fans. (Sometimes the installing
electriciansubstitutes an electrical interlock on the motor starter to accomplish the same purpose. This is
OK.)
As part of its routine checkout procedures, the PLC occasionally checks for this interlock to make sure that it has
not been bridged or otherwise tampered with. If
it has, it will not permit the burner to start and displays ERROR
31. Press RESET to clear this.
ERROR 32
While the burner is running, 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 32. If ALARM codes 34 or 36 are shown for this, it
means that the failures took place within a
5 minute interval and the first failure is the one displayed (ie: "Burner
failed to ignite"might mean the spark plug needs to be cleaned on the burner.) Press RESET to clear this ERROR.

HG-4-111 OC ALARMSIERRORS E."ATlON ----- PAGE 3
ALARM 34
This ALARM means that the burner failed to light. Check for a dirty spark plug and/or flame electrode. If these
are
OK check for sufficient low fire gas.
ALARM 36
This ALARM means that the burner failed while burning. Check for a dirty flame electrode.
If it is OK check for
sufficient lowfire
gas.
ERROR 38
This ERROR is normally caused by tamperingwith the Flame Relay (FIR). Check to see if the contacts of FIRare
bridged or the relayjammed.
ERROR 39
This ERROR is caused by electrical interference between the spark plug wires and the flame electrode wires.
They should
be run in separate conduits. (As the spark plug wire carries in excess of 6000 Volts, also check to
make sure that
it is routed alongthe BOTTOM of the control cabinet and not the top where it can interferewith the
operation of the PLC, counter, etc.).
ERROR 40
This ERROR means that the burner does not turn off in the time it is allowed to turn off in (12 seconds).
It is a
possible indicationof a gas leak
in the system. Consult the fadtory for service recommendationsfor this problem.
ERROR 42
This ERROR will shut the burner down due to excessively high temperaturesoccurring beforethe mixpoint which
the modulatingcontrol
is unable to constrain.
ERROR 43
This ERROR is caused when an attempt is made to start the burner when no fan interlock relay is present. A fan
interlockrelay is supplied with the
17400 remote control to provide instant shutdown of the burner when the fans
are stopped. The installingelectrician is responsiblefor wiring the coil of this relay to the fan circuits.
ERROR 44
This error indicatesthat the air flow switch is ON while the fan interlock relay is OFF 10 minutes after shutdown.
Thisnormally means that the air flow switch is not functioning properly or has been jammed
in the closed
position.
* Indicates an ERROR conditionthat can be temporarily bypassed. To bypassthe ERROR, performthe following
d in order to bypassthe
ERROR each time the heater is started untilsteps. These steps will have to be perf0
the condition
is fixed. While the ALARM light is ON and the STATUS light is flashing:
- Turn the localSTART-STOP switch to the left (STOP) 3 times.
- Press the RESET buttonto clear the ERROR and attempt to restartthe heater.
111OCOO1 921210

TEST SEQUENCE
BG-4-1110 C
STEP ACTION TAKING PLACE NDITION FOR NEXT STEP
0 NONE -- START TEST PROGRAM RESET
1 CHECK FAN RELAY OPERATION RESET & 3 OFF, 5 OFF
AND ADJUST AIR FLOW SWITCH. OR HOLD RESET
ADJUST AIR VANES, VP
= .4"
ADJUST AIR SCREEN SWITCH.
FAN ON AND OFF THIS STEP.
2 OBSERVE CONDITION OF INPUTS:
0002 RESET OFF
0003 HOLD ON TEST (IF FAN IS ON)
0004 START OFF TEST (IF FAN IS ON)
0005 AIR FLO SW OFF (ON IF FAN IS ON)
0006 GAS LP SW OFF LOCAL START SW WILL RELIEVE
0007 GAS HP SW ON (JUMPERED IF NOT APPLICABLE)
0008 GAS L TEMP ON (JUMPERED IF NOT APPLICABLE)
0009 HI TEMP LIM ON (JUMPERED IF NOT APPLICABLE)
0010 LOCAL HOLD ON
0011 LOCAL START OFF USE TO OPEN VALVE P2
0012 AIR SCR SW OFF OPTIONAL FOR PULL-THROUGH
0014 FLAME OFF. RESET & 4,6,7,8,9,10,12, 14
AS SHOWN OR HOLD RESET
3 TEST UDC AND MOD MOTOR
START
: TO OPEN 0106 ON IN THIS STEP
CENTER: TO HOLD
STOP
: TO CLOSE RESET
4 VALVE LEAK TEST
ADJUST GAS
LOW PRESS SWITCH
START: OPENS P1
STOP: OPENS P2
START FAN RESET AND AIR FLOW ON
5 GAS PURGE, P1 P2 OPEN TIM 3 (5 SEC)
6 AIR PURGE TIM 4 (15 SEC)
7 TEST IGN TRANS AND IGN LTS
START: TURNS ON IGT
FLAME LT MUST STAY OFF
, RESET AND NO FLAME SIGNAL
8 TRIAL FOR IGNITION TIM 5 (10 SEC)
ADJUST
SMALL COCK FOR
10 SEC WITHOUT FLAME
LOW FIRE AND GOOD START
RESETS STEP
& DISPLAY FLAME STEPS TO 9
9 OPERATE BURNER NOT (FLAME)
OR STOP
OR RESET STEPS TO 10
10 RESET STEP & DISPLAY
111OCTS2 VERSION 2.0 920831

TEST SE ON
(FOR SOFlWm VERSIONS 2.5 AND LATER)
PRELIMINARIES -- To test a new installation, first pu gas supply pipe to fill it with gas and
blow debrisfrom it. Check the voltage of the electric
TO ENTER TEST SEQUENCE
-- Press RESET button while turning local selector switch to "0"
(STOP). Hold both in for 5 seconds. Watch the STATUS light for seconds count.
while still
pressingRESET button, turn selector This puts you in Step
0 of the test
sequence. The STATUS light
will confi per second.
The presenceof various
inputscan
be verified by observing the
s at the right end of the heater's PLC.
INPUTS are at the bottom. OUTPUTS are
P NUMBER will be shown on the LCD
digitaldisplay on the sequence panel SP.
STEP
0 -- After releasingRESET button, press it once to go to Step 1.
STEP 1 -- Fan must be OFF at this step. Confirm
5 are OFF. If 3 is ON, it means
that the fan interlock relay is not working or has n
. This must be corrected. (The
operation should be the same
if a central PLC is used instead of a mechanical relay.) If input 5 is
ON, it means that the air flow switch AF needs adjusting. Remove its cover and rotate
the adjusting
screw clockwise until input
5 goes OFF. To adjust it more precisely, disconnect the black tube from
its low pressure port, and attach a sensitive manometer to
the port with a T-fitting so you can suck
on it and measure the vacuum applied. Adjust AF
so it turns ON input 5 at about 0.3" (.75 cm) of
water and turns OFF at
0.2 (.50 cm). Further adjustmentmay be necessary in actual operation if the
conveyance of cotton slows down
the air flow.
Nowconnect the manometer to the white and blac
it will measure the air velocity
should be at about
inside
the two access doors. The ends of their adjusting links can be bolted in a series of holes
which bringthem closer together to increase velocity pressureVP or farther apart to reduce it. Make
the adjustment
the same on both sides. If VP is too low, the flame might be yellowish, and the air
flow switch not
so responsive. If VP is too high, the flame will burn with a roar at high outputs. On
high air volume, pull-throughsystems where
the velocity cann reduced to .4" with the shutters,
burner operation
will not be adverseiy affected.
The air screen switch AS is an option used to d logging of the air inlet screen where the heater
isused on a pull-through drying system. It is to the left of air flow switch
AF. Using the
manometer
as on AF, adjust AS to operate at about 2" (5 cm) of vacuum.
Turn fan OFF, and press RESET button to is inconvenient to turn fan OFF, pressand
holdthe RESET button for
3 seconds to ad
STEP2
-- Observe the condition of inputs in TEST SEQUENCE.
The operation of the
remote and
local start-stopswitches and 0th can be tested while observingthe input LED'S.
If input 6 (gas low pressure switch) is on, t al switch to START. This will open valve P2 to
relieve
the pressure between the valves. Be ing to
the next step, veriithat the jumper
betweenterminal
3 and terminal 12 is remove High Temperature Limit option is
installedand that the jumper between terminal
3 and terminal 10 is removed if the LPG Low
Temperatureswitch option is installed. Press RESET to proceed. (If lights are not correct,
advancingto Step
3 will be prohibited. If problem is understood and bypass is desired, press and
hold RESET buttonfor
3 seconds to advance.)
2.)

TEST SEQUENCE EPLANATION -2-
STEP 3 -- The digital temperature controlle
this opportunity to check its configuration
configurationand tuning is standard). In a fe
full ouput, the local start-stop switch can be
drive the motor to the open position. Center
it closed. Press RESET to proceed.
trol station is now energized. Take
as not yet been configured (factory
r the digital controller has increasedto
modulating motor. Turn to START to
it
in position. Turn to STOP to drive
STEP
4 -- The local start-stop switch is now used t
for valve leakage and adjust the ga
pilotvalve P1, admitting gas pressur
Input 6 should turn on at about
1 psi.
valvesclosed several minutes to
see
downstreamvalves, P2 a
pressurefrom the cavity.
build
up. This tells us that the upstream
The operating program will perform simi
reasonelectrical power must be sup
each shutdown.
r presence of gas, adjust its pressure, test
, if necessary. The START position opens
P1 and P2. Slowly pressurizethe cavity.
should be between 3 and 4 psi. Leave the
does not leak off. This tells us that the
urn switch to the STOP position to bleed
ral minutesto see that the pressure does not
safety shut-off valve SSOVl, are not leaking.
s every time the heater is shut down. This is one
tinuously, or at least for 15 minutes after
START FAN and pressRESET to proceedto Step 5.
STEP 5 -- The heater's PLC will open valves P1 and P2 for 5 seconds to fill the pipe to the burner
with gas.
It will then automaticallystep to 6.
STEP 6 -- This step requiresthe fan to run for 15 seconds to purge the burner of any combustible
gas. It then automaticallysteps to
7.
STEP 7 -- The local start-stop switch is now used to test the ignition transformers. Turning the switchto
STARTturns on the ignition transformer IGT.
If the gin is quiet, you can hear the spark. If there is
difficulty, check the spark plug electrode gap at 1/16 to 1/8 (1.5 to
3 mm). Hold the IGT on for two
secondswhile observing the flame light on the sequence panel. If the flame light turns on, it means that
there is electrical interference between the spark plug wire and the flame electrode wire. They should be
run to the burner
in separate conduits to avoid such interference. Since the operating program makes a
similar test beforeeach ignition, the burner will not operate untilthis problem is corrected.
Press RESET to proceed.
STEP
8 -- This step is the trial for ignition and only lasts 10 seconds. During this time, adjust the small
gas cock between P1 and P2. Start with it closed, and slowly open
it until the burner ignites. Adjust it for
the lowest flame possible, yet high enough for dependable ignition.
As soon as the burner ignites, the
programsteps to
9.
STEP 9 -- The burner should now operate normally, with TCV free to modulate the flame up to high
output. Make sure that the temperature controller gives the proper 4-20 mA signal to control the
modulatingmotor. The burner will stop when either STOP is operated, air flow fails, RESET is pressed, or
on flame failure. To exit the test program, kill power or press RESET and turn the local STOP switch left
momentarily. The STATUS light should stop blinking. To operate the burner normally, operate either
START switch.
IIIOCTEX VERSION 2.0 911017

3133
4-92
r
t
34 [86.4]
DO NOT PIERCE TOP
FOR CONDUITS
<
1 1/4* FlPT
f
3 -GAS IN
1 1/4" PIPE
I I
SPARK AND
FLAME WIRE
CONDUITS
1
I) I
20 1/2
--TI 12
[ 30.51
ELECTRIC STUB-UPS HERE
TO ENTER CABINET FROM FLOOR.
NOT INCLUDED
-7 1/2
~91
DIMENSIONS IN INCHES AND [CENTIMETERS]
SCALE:
3/4" = 1' 0"

LIQUEFIED
1
t I
PRESSURE
RELIEF VALVE
PETROLEUM GAS
UNITS AND
PRESSURE REGULATOR
15 PSI
TANK INSTALLATION FOR HUMIDAIRE
DRYING
MINIMUM DISTANCE = 25 FEET FOR 2000 GAL OR SMALLER
(I , MINIMUM DISTANCE = 50 FEET FOR 2001 GAL TO 30,000 GAL
For LPG installations, the tank should be at least 1200 Gals. (US) to provide adequate surface area to absorb heat of
vaporization from the atmosphere so that a vaporizer will not be necessary. To be compatible with the quantity of LPG
received in each delivery, a larger tank may be necessary. A battery of small tanks of the desired total capacity has
more heat-absorbing area than one large tank.
Whether
or not a vaporizer is'used, make sure that a regulator reduces the pressure to 15 psi (1 bar) BEFORE the pipe
goes underground. Otherwise, reliquefication will take place in the cool earth and cause MUCH trouble. If the gas
line
in your building feels extremely cold during operation, liquid is in the line and the situation should be cor-
rected IWEDIATELY.

\
GAS
PIPING
Size of pipe supplying gas to heaters and other appliances should
be large enough to prevent excessive pressure losses when all
of
them are in use.
losses.
See following Table of sizes,
flows and pressure
Where
LPG (Liquefied Petroleum Gas, Propane, Butane) is used as
the fuel, see following drawing which shows recommended practices.
Emergency shut-off valves should be provided to permit turning
off the fuel in an emergency. They should be located
so that they
emergency situation.
are accessible in an
IRI (Industrial Risk
require venting the
NFPA 86* states:
Insurers) and some state and local authorities
gas regulator and normally-open vent valve.
3-3.4.3.2 Regulators shall be vented to a safe location,
where vented gas cannot re-enter the building without ex-
treme dilution. The terminating end shall be protected
against water entry and bug-screened. Vent pipe shall be
of adequate size so as to not lengthen response time.
3-3.4.3.3 Vent lines from multiple regulators, where
manifolded together, shall he piped in such
a manner
that diaphragm rupture of one
will not backload the
others.
3-3.4.3.4 Vents from gas pressure switches, but from no
other devices, may be vented into the regulator vent lines
provided that
sw.itch or regulator diaphragm failure will
not hackload the regulator.
*Reprinted with permission from NFPA 86-1985, Standard for Ovens -and
Furnaces, copyright
Q
Quincy, Mass.
and official position
of the NFPA on the referenced subject which
is represented only by the standard in its entirety.
1985, National Fire Protection Association,
This reprint
of material is not the complete
02269.