Sure Flame S2200D User manual

Retain these instructions for future
reference.
Sure Flame Products
A Divison of Haul-All Equipment
4115 - 18 Avenue North
Lethbridge, Alberta T1H 5G1
www.sureflame.ca
P/N 974-9246
Rev: 4.22 September 22, 2010
Operation and Maintenance Manual
Model No. S2200D
CONSTRUCTION HEATER
2,250,000 Btu/h
Failure to comply with the precautions and
instructions provided with this heater, can
result in death, serious bodily injury and
property loss or damage from hazards of
fire, explosion, burn, asphyxiation, carbon
monoxide poisoning, and/or electrical
shock.
Only persons who can understand and
follow the instructions should use or service
this heater.
If you need assistance or heater
information such as an instruction
manual, labels, etc. Contact the
manufacturer.
GENERAL HAZARD WARNING
Fire, burn, inhalation, and explosion
hazard. Keep solid combustibles, such as
building materials, paper or cardboard, a
safe distance away from the heater as
recommended by the instructions. Never
use the heater in spaces which do or may
contain volatile or airborne combustibles,
or products such as gasoline, solvents, paint
thinner, dust particles or unknown
chemicals.
WARNING
Not for home or recreational vehicle use.
WARNING
WARNING
Read and follow all installation, and operating
instructions before first use of this product.
S/N:311

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Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22 September 2010
The heater is designed and approved for use as a
construction heater under CSA 2.14-2000. The
primary purpose of construction heaters is to pro-
vide temporary heating of buildings under con-
struction, alteration, or repair and to provide tem-
porary emergency heat. Properly used the heater
provides safe economical heating. Products of
combustion are vented into the area being heated.
The heater is not designed as an Unvented Gas
Fired Room Heater under ANSI-Z21.11.2 and
should not be used in the home.
ANSI A119.2(NFPA 501C)-1987 Recreational
VehicleStandardprohibitstheinstallationorstor-
age of LP-Gas containers even temporarily inside
any recreational vehicle. The standard also pro-
hibits the use of Unvented Heaters in such vehi-
cles.
Gas inspection authorities in Canada require
that the installation and maintenance of heat-
ers and accessories be accomplished by quali-
fied gas fitters.
FOR YOUR SAFETY
DO NOT USE THIS HEATER IN A SPACE WHERE
GASOLINE OR OTHER LIQUIDS HAVING
FLAMMABLE VAPOURS ARE STORED OR USED.
Read This Warning First !
Installation must comply with CAN/CGA-
B149.1 Natural Gas and Propane Installation
Code.
We cannot anticipate every use which may be
made for our heaters. CHECK WITH YOUR
LOCAL FIRE SAFETY AUTHORITY IF YOU
HAVE QUESTIONS ABOUT LOCAL REGU-
LATIONS.
Other standards govern the use of fuel gases and
heat producing products in specific applications.
Your local authority can advise you about these.

Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22. September 2010
3
Specifications .......................................... 4
Heater Installation ..................................5
Heater Operation....................................6
Thermostat Operation ...........................6
Blower Operation....................................6
Installation for Propane Supply Tank ......7
Installation for Natural Gas.....................7
Common Installation and Operational
Problems ................................................8
Safety Features......................................8
Additional Design-related
Safety Features......................................9
On-site Safety Problems ........................10
Preventative Maintenance......................11
Trouble Shooting ....................................12
Wiring Diagrams.....................................20
Replacement Parts................................26
Table of Contents

4
Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22 September 2010
Model No.
S2200D Construction Heater
Certification
Gas Fired Construction Heaters, CSA 2.14-2000
Fuel
Natural Gas or Propane Vapour
Input Rating
Maximum (Second Stage)
2,250,000 Btu/h (659 kW)
Minimum (First Stage)
1,950,000 Btu/h (571 kW) Propane
1,650,000 Btu/h (484 kW) Natural Gas
Operating Temperature
Minimum -30°C (-28°F)
Burner Orifice Size
40 DMS x 45 holes
42 DMS x 33 holes
Electrical Rating
Varies - Rating determined as stated on the
Specification Label and the Electric Motor on
the heater
Supply Pressure to Regulator
Propane & Natural Gas
Minimum: 12" WC (3.0 kPa)
Maximum: 5 psi (34 kPa)
Pressure to Manifold
Propane
Minimum: 0.4" WC (100 Pa)
Maximum: 0.7" WC (170 Pa)
Natural Gas
Minimum: 2" WC (500 Pa)
Maximum: 4.6" WC (1.1 kPa)
(Minimum inlet pressure is for purpose of input
adjustment)
Weight
860 lbs (390 kg)
Specifications

Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22. September 2010
5
The Sure Flame Model S2200 is a direct fired
gas heater intended to be used primarily for the
temporary heating of buildings under construc-
tion, alteration, or repair. Since all the products
of combustion are released into the area being
heated, it is imperative that adequate ventilation
is provided. The flow of supply air must not be
obstructed in any way.
1. Install the heater in a horizontal position at
least 10 feet (3 m) from any LP-gas
container. The front outlet must be at least
20 feet (6 m) from any LP-gas container.
Allow the following clearances from any
combustible material or fuel containers:
Outlet: 25 feet (7.6 m)
Sides: 3 feet (0.9 m)
Intake: 3 feet (0.9m)
Top: 4 feet (1.2 m)
Duct: 1 foot (0.3 m)
Floor: Noncombustible
Also make sure that no flammable vapours
are present in the space where the heater is
being used.
2. When connecting the heater to a natural gas
or propane supply line ensure that the
pressure at the heater inlet is within the
specified range. Excessive pressure (over 5
psig or 34 kPa) will damage the controls and
void the warranty.
3. Visually inspect the supply hose assembly
and ensure that it is protected from traffic,
building materials, and contact with hot
surfaces. If it is evident that there is
excessive abrasion or wear, or the hose is
cut, it must be replaced.
4. After installation, check the hose assembly
for gas leaks by applying a water and soap
solution to each connection.
5. Connect the heater to an adequate electric
power supply as specified on the Heater
Specification label and the Electric Motor
plate.
6. For protection against shock hazard the
supply cord should be plugged directly into
a properly grounded receptacle in compli-
ance with the
Canadian Electrical Code,
CSA C22.1, Part 1.
The appliance area should be kept clear and free
from combustible materials, gasoline, and other
flammable vapours and liquids.
Ensure that the flow of supply air is not
obstructed.
The installation and operation of the heater shall
comply with the code requirements specified by
the authorities having jurisdiction.
General criteria for the installation and use of
construction heaters may be found in the
applicable sections of the
Natural Gas and Propane Installation
Code,CSA B149.1
The installation and maintenance of the heater
must be accomplished by a qualified service
person.
This heater is approved for use without
ductwork, or with up to 40 feet of 24” square
ductwork. Only ductwork supplied by the
manufacturer should be used with this heater.
When using the heater without ductwork,
securely fasten the outlet screen in the down
position.
Heater Installation

6
Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22 September 2010
1. Set the gas selector valve to the gas being
used. The conversion shall only be done by
the owner or lessor of the heater.
IMPORTANT: When using propane gas,
the selector valve must be locked in
position.
2. Ensure the firing valve (manual valve
nearest the burner) is in the ON position.
3. Connect power. Use appropriate electric
power supply as specified on the heater
specification label and the electric motor
plate.
4. Open gas supply.
5. Press and release START HEATER
switch. START HEATER light will come
on. Set thermostat to desired setting.
Blower will start after about 10 seconds.
Flame will ignite after another 20 seconds.
If STOP/RESET light comes on, press
STOP/RESET switch, then repeat the
above sequence.
6. Heater will switch between high flame, low
flame, and no flame as required to maintain
the desired temperature.
7. To stop, press STOP/RESET switch and
turn off gas supply. Blower will stop after
about 20 seconds.
Heater Operation Thermostat Operation
The heater operation is controlled by the
remote thermostat. When the heater is
operated in heat mode, the power light on
the thermostat will come on. If the
ambient temperature is significantly lower
than the thermostat setting, both the Stage
1 and Stage 2 lights will come on and the
heater will operate on high flame. As the
temperature approaches the thermostat
setting, the Stage 2 light will go off and
the heater will switch to low flame. Once
the desired temperature is reached, the
Stage 1 light will go off and the flame and
blower will shut off. The flame and
blower will come on again automatically
once the temperature drops.
Blower Operation
1. Press and release START BLOWER
switch. Blower will start immediately.
2. To stop, press STOP/RESET switch.
Note: When switching between heater mode
and blower mode, unit must first be stopped by
pressing the STOP/RESET switch.

Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22. September 2010
7
1. When installing the heater for use with
propane gas, ensure that the gas selector
valve is LOCKED in the propane position.
2. The supply container MUST be equipped
with a suitable UL listed gas pressure
regulator. This is essential to reduce the gas
pressure to a safe transmittable pressure that
does not exceed the maximum input pressure
of the heater.
3. Arrange the supply system to provide for
vapour withdrawal from the operating tank.
Supplying liquid propane to the heater is
dangerous and will damage the components.
4. Ensure that for the surrounding temperature
the size and capacity of the propane supply
tank is adequate to provide the rated Btu/h
input to the heater.
Installation For Natural Gas Applications
Installation Using A Propane Supply Tank
1. When installing the heater for use with
natural gas, ensure that the gas selector
valve is set in the natural gas position.
2. Ensure that the supply is equipped with a
suitable UL listed gas pressure regulator to
limit the gas to a pressure that does not
exceed the maximum inlet pressures of the
heater.
5. Turn off the propane supply valve at the
tank when the heater is not in use.
6. The installation must conform with local
codes, or in their absence, with the follow-
ing:
CAN/CGA - B149.1 Natural Gas and
Propane Installation Code
7) When the heater is to be stored indoors
the propane tank must be disconnected
from the heater and stored in accord-
ance with the above mentioned National
Standard.
3. The installation must conform with local
codes, or in their absence, with the follow-
ing:
CAN/CGA - B149.1 Natural Gas and
Propane Installation Code

8
Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22 September 2010
Low Voltage
This is one of the most common problems and is
usually the result of the supply cord having too
small a wire gauge for its length. Low voltage
results in the motor overheating, burnt relay
contacts, or a relay that will not make contact.
Supply Line Too Small
Insufficient Vaporization At Supply
Normally caused by too small size of supply
tank.
Improper Gas Supply Pressure
Usually a result of supply pressure being too
high because of improper or lack of regulation.
Common Installation And Operational Problems
Locking Position For Lpg On Gas
Selector Valve
Units used with LPG while the gas selector
valve is positioned for Natural Gas will throw
significantly more heat than the rated Btu/h.
This is definitely a safety hazard.
Dirty Gas Supply
Dirty gas can cause strainers to plug or form a
build-up in the burner orifice.
Lack Of Preventative Maintenance
Heaters must be cleaned as required, especially
when used in a dirty environment.
Improper Supply Of Fresh Air
It is normally recommended that the intake air
of the heater be taken from outside the enclosed
area. This provides a slight pressurization and
prevents any problems associated with
recirculation.
Additional Design-Related Safety Features
Durable Construction
The Model S2200 uses a stainless steel burner
for long life and consistent performance.
In order to maintain the highly efficient
combustion of the Sure Flame Heater, the
combustion chamber must remain as manufac-
tured. Any change or distortion could alter the
fuel/air mixture and create unwanted gases.

Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22. September 2010
9
Servicing of Sure Flame Construction Heaters
normally involves one of several built-in safety
features. The Model S2200 incorporates
devices to detect the following:
Loss Of Flame
Gas supply is shut off if flame is lost to prevent
raw gas from leaving the heater.
Overheating
a) Thermal overload protection in the motor.
b) High temperature limit switch in the
combustion chamber.
c) High temperature limit switch in the blower
housing.
Safety Features
Loss Of Power
Total shutdown with manual reset required.
Any one of the safety devices will create a loss
of power situation.
Blocked Air Supply
A switch detects the differential pressure in the
combustion chamber and shuts down when air
flow is insufficient .
Cool Down Period
When thermostat is turned down, blower will
continue running for about 20 seconds to cool
down the heater and purge any unburned gases
from the combustion chamber.

10
Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22 September 2010
Shorting Out Of Defective Compo-
nents
This is a very common problem which saves
short term expense at the risk of a large future
cost. Any heaters found in this condition should
be removed immediately.
Improper Enclosures
When heaters are installed partially to the
outside for fresh air intake, strict adherence
must be made to the minimum clearance to
combustibles given on the instruction plate.
Wood framing around a heater is a request for
trouble.
On-site Safety Problems
Supplying Liquid Propane To
Heater
This problem has occurred from time to time.
To minimize the damage, shut off the gas
supply and let the heater run until all of the
liquid in the lines has been burnt.

Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22. September 2010
11
Sure Flame Construction Heaters are built to
withstand the rigours of operating on construc-
tion sites, for mining applications, and a
multitude of other locations where heaters are
used. To maintain the reliable performance
required it is necessary to do a certain amount
of regular maintenance.
The heater should be inspected before each use,
and at least annually by a qualified service
person.
Visual Checks
The following items should be checked for
excessive wear or damage:
1. Cords and Connectors
2. Wiring and Conduit
3. Heater Shell (including heat shield),
Blower Housing and Control Box
4. Blower Drive Belts and Bearings
5. All Screens and Guards
Preventative Maintenance
Burner
Flame Rod and Insulator - Clean with soap
and water or solvent on a routine basis. Any
build up on burner should also be removed at
this time.
U.V. Flame Sensor - Clean the bulb with a soft
cloth.
Ground Wire - Ensure that the ground wire is
secured to the burner. This is necessary for the
flame detection system to operate.
Spark Plug - Clean with solvent and check
spark gap.
Flame Safeguard Control
The Flame Safeguard Control should be cleaned
using alcohol. Do not use any other liquid or
aerosol spray cleaners.
Motor
Motors equipped with oil cups should require
only a few drops of clean, light machine oil
every year. Motors not equipped with oil cups
are fitted with sealed bearings and no oiling is
required.

12
Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22 September 2010
Trouble Shooting

Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22. September 2010
13
Trouble Shooting
SEQUENCE EXTERNAL EFECT DESCRIPTION CAUSE
6
-Heater mode on: -Stage I and/or II on: -Blower doesn’t start:
-No errors. -No errors. -Non-extinguished
flame,
-Defects in the
flame supervision circuit
-Check the air
switch integrity, mechanical and electrical
-Check also the
LFL controller fuse.
7
Flashing ones every 3 seconds.
-Blower function off: -Appears in Heater
and Blower mode.
-For one phase motor
this error will never appear.
-Blower motor
overload relay off, automatic reset in 2min. 30 sec.
8
TO START THE BLOWER PUSH
Solid light.
-Blower function on: -No error.
THERMOSTAT
THERMOSTAT
The sequence mechanism is not turning.
START
BLOWER STOP/
RESET START
HEATE
R
START
BLOWE
R
STOP/
RESET START
HEATER START
BLOWER STOP/
RESET START
HEATE
R

14
Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22 September 2010
Trouble Shooting

Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22. September 2010
15
Trouble Shooting
SEQUENCE EXTERNAL EFECT DESCRIPTION CAUSE
14
Solid blue or green light. To stop the blower or the heater press STOP/RESET button.
-Heater or blower
stops:
-Short stop only
when the heater is in stand-by – no flame.
-No errors.
15
When pressing , STOP when the heater is on end also the flame.
Flashing four times every 3 seconds.
-Heater stops after
LFL controller returns to START position:
-Long stop only
when the flame is on when pressing the STOP button.
-No errors. -If pushing the Start
Heater button the stop sequence will be canceled and is followed by a long pre-purge.
16
-Heater stops after
LFL controller returns to START position:
-Long stop only
when the flame is on when pressing the STOP button.
-No errors. -If pushing the Start
Heater button the stop sequence will be canceled and is followed by a long pre-purge.
17
A B
C
-ZEN controller
related errors.
-A. No power, faulty step
down transformer or circuit breaker.
-B. ZEN controller is not in
“RUN” mode.
-C. ZEN controller is not in
“ERROR” mode, reset by cutting the power from the circuit breaker.
START
BLOWER STOP/
RESET START
HEATER
START
BLOWE
R
STOP/
RESET START
HEATE
R
START
BLOWE
R
STOP/
RESET START
HEATE
R
START
BLOWER STOP/
RESET START
HEATE
R
START
BLOWER STOP/
RESET START
HEATE
R
START
BLOWER STOP/
RESET START
HEATE
R
OMRON ZEN 10 C2AR-A OMRON
ZEN 10 C2AR-A OMRON
ZEN 10 C2AR-A

16
Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22 September 2010
Trouble Shooting
SEQUENCE EXTERNAL EFECT DESCRIPTION CAUSE
18 - To RESET push “START
HEATER”.
-Also, to RESET, push
“STOP/RESET” and “START
HEATER”.
-Natural gas minimum manifold
pressure: 1.25” WC.
-Natural gas maximum manifold
pressure: 7.00” WC.
-Propane vapors minimum
manifold pressure: 0.70” WC.
-Propane vapors minimum
manifold pressure: 3.00” WC.
-Red alarm light and
LFL Controller alarm light on:
-The LFL sequence
mechanism lockout in P position:
-The LFL sequence
mechanism lockout in position:
-No spark, and the
LFL sequence mechanism lockout in 1 or 2 position:
-The LFL sequence
mechanism lockout in |position:
-Error indicator
because there is no air pressure indication at the beginning of air pressure control.
-Safety lockout
because no air flows detected during the pre-purge. RESET necessary.
-Safety lockout due to
a fault in the flame supervision circuit.
-Safety lockout
because no flame signal is present after completion of the first or second safety time.
-Check the manifold
pressure or/end the Dungs valve coils integrity.
-Faulty, spark plug
connection, ignition transformer or ignition transformer power supplies.
-Safety lockout
because the flame signal has been lost during burner operation.
-Check the fuel gas
supply.
START
BLOWER STOP/
RESET START
HEATER
THERMOSTAT THERMOSTAT
The sequence mechanism is not turning, lockout in P, , 1, 2 or |position.
P

Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22. September 2010
17
Trouble Shooting
SEQUENCE EXTERNAL EFECT DESCRIPTION CAUSE 19 - To RESET push “START
HEATER”.
-Also, to RESET, push
“STOP/RESET” and “START
HEATER”.
-Red alarm light of
and LFL Controller alarm light on:
-See position 18.
-Faulty Stop button
LED.
-See position 18.
START
BLOWE
R
STOP/
RESET START
HEATE
R
THERMOSTAT THERMOSTAT
The sequence mechanism is not turning, lockout in P, , 1, 2 or |position.
P

18
Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22 September 2010
Trouble Shooting
SEQUENCE EXTERNAL EFECT DESCRIPTION CAUSE
20
FUNCTION WITHOUT ERRORS
Poor flame
-Heater mode on:
-Stage I and/or II on:
-Exhaust temperature
low, flame in firing stage:
-Stage II on:
-No errors. -No errors. -Check the firing
valve coil.
-Check also the
ZEN controller Q3 relays – possible mechanical error.
-Check stage II
knob. It is possible closed.
-Check stage II
electric box,
-Check also the
ZEN controller Q2 relays – possible mechanical error.
21 High flame only. - Stage II off: - Check stage II
knob. It is possible full open.
The sequence mechanism is not turning, lockout in |position.
Dungs DMV-ZRD double solenoid valve system
Sta
g
e I knob
Stage I knob Stage II electric box
Stage I electric plug

Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22. September 2010
19

20
Sure Flame Products
Maintenance and Opertation Manual
P/N 974-9246 Rev 4.22 September 2010
Wiring Diagrams (1 Phase)
BR BR
B
BR BR
B
M
BR
B
BR BR
M
BR BR
B B
BR BR
234
156
7
GROUNND
G
BR BR
Q0 Q1 Q2 Q3
I5I4I3I2I1I0NCLN
POWER RUN ERROR
Nano Programable Controller
ZEN20C2AR-A-V2
IbIaI9I8I7I6NC
Q4 Q5 Q6 Q7
END BRACKET
BURNER
SURGE
SUPRESSOR
A2 A1 T1 T3
L1 L2 L3
OVERLOAD
RELAY
T2
96 97 9895
H1H2H3H4H5
X1 X2
STEP DOWN
TRANSFORMER
1
NC
2
NO
P
COM AIR
SWITCH
FLAME CONTROLLER
6 5 4 3 2 1 7
10
8 9
11 12
1315 14161718192021222324
31
32
N
IGNITION
TRANSFORMER
N
L
END BRACKET
END PLATE
CIRCUIT
BREAKER
3 4
21
UTILITY
BOX
SPARK
PLUG
M
4
START
BUTTON
X1 X2
3 4
STOP/
RESET
BUTTON
X1 X2
3 4
BLOWER
BUTTON
X1 X2
3
CONTACTOR
L3 L2 L1
T3 T2 T1
END BRACKET
U.V. SENSOR +
-
10Ga
575V
460V
230V
208V
10Ga
10Ga
VOLTAGE SETTING
JUMPERS
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
FIELD INSTALLED
FACTORY INSTALLED
WIRE SYMBOL LEGEND
LOW VOLTAGE
HIGH VOLTAGE
THERMOSTAT RECEPTACLE
HIGH TEMP.
LIMIT SWITCH
RECEPTACLE
GAS VALVE
STAGE II
RECEPTACL
3 PHASE
GAS VALVE
STAGE I
PLUG
GAS VALVE
STAGE I
1
3
2
GRN
BRN
BLK
BLU
FEMALE FACE VIEW
Q
Z
Y
B K A
E
L F1562
C3 D
574
G
6
1234
GL1 N
VS Terminal Blocks
HV Terminal Blocks
ST
BLUE
REDGREEN
10Ga
10Ga10Ga
10Ga
10Ga
16Ga GTF
FLAME ROD
8