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 heaters with micropr
in operation and preburn and
conditions by blinking as 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 assembly is used on all heaters,
.
Their operation is 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
--
Problems not serious enough to shut down operation.
ERRORS
--
Problems which 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 restarted unless the RESET button
on the local panel is pushed. The counter will display the appropriate code 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
seconds then 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 contributing to 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 interlocked with 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
806-795-521
8
FAX
806-7!35-8240
GASSAFET.MAN
911022
USING
THE
17400
DIGVAL
TEMPERATURE
CONTROL
(WITH THE
16910
MOD
TEMPERATURE LIMIT)
The 17400 Temperature Control
Modulating High 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 cotton quality and,
in
extreme
delines for use of this control arrangement with
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
designated the "HIGH LIMIT" controller. ts thermocouple temperature sensor
mounted DOWNSTREAM of th LIMIT controller has its thermocouple
mounted upstream 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
previously specified.
If
dry cotton is fed 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
burners with microprocessor combustion controls).
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-STOP operations. Turn the switch to "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 note that 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
is flashing.
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 ignition or failure
in
operation,
the burner will automatically attempt to
r
itself for a maximum of three attempts. Neither digital
temperature controller
will
come on until flame has been established
in
the burner. This is to prevent the highly
responsive controls from "winding up" during
t
ir
purge delay time and causing the 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
temperature which the ginner sets and is the only one he will adjust under normal circumstances. It is the
temperature desired after the mixpoint.
It
is raised and lowered with the orange buttons below
it.
The upper
display shows 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 actual temperature before the 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 Interface Option,
it
is not necessary for the ginner to use
the arrow buttons on the PRIMARY controller to he desired temperature downstream. The PRIMARY
will
obtain this value from the 17600 (which is comi erry Series
800
Moisture Monitor).
If
the ginner
disagrees with the suggested temperature co 600, he should use the arrow buttons on the
17604 to adjust
it
to his preference. Pressing the DOWN ARROW button on the 17600 tells the control that he
desires a lower cotton moisture content at the feeder a d
it
will
turn UP the temperature on the 17400
control to achieve
it.
Pressing the UP ARROW bu
If
it
is ever desired to bypass the Series
800
and 600 Control Interface, operating the burner with manual
setpoint entry 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 ignore the
incoming signal 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 permanently damage cotton fibers. The procedure for changing this 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 1 time
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
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 modulating high limit value. Use the ARROW buttons to 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 pressing the ARROW buttons until MAX LOCKOUT is
displayed. Replace the button covers to discourage use by unauthorized personnel.
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 pressing SETUP 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 until AlSl
VAL is in the lower display. This is your cutoff high limit value. Use the ARROW buttons to 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 pressing the ARROW buttons until LOCKOUT MAX is
displayed. Replace the button covers to discourage use by unauthorized personnel.
1
7400-H
1
Page 2
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 OF AIR FLOW SWITCH.
A AIR FLOW
WENT
OFF
FOR MOMENT. ADVANCE WARNING
OF POSSIBLE CHOKJX,.JP.
AIR FLOW
WENT
OFF
FOR MORE
THAN
3
SECONDS. LOOK
FOR CHOKE-UP OR 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 FWE RELAY CONTACTS.
FLAME
SIGNAL BEFORE FUEL DURING SPARK. LOOK FOR
ELECTRICAL INTERFERENCE BEWEN SPARK AND
FLAME
WIRES.
THEY SHOULD BE
IN
SEPARATE
CONDUITS.
FLAME CONTINUES TOO 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,
control cabinet. This number will refer
to
either
ALARM
or ERROR to occur
in
a five m
the burner may have shut down due to
ORS
will
cause the burner to automatically shut
ation
but
warn of conditions which may cause a
displayed on the local panel inside the burner's
an ERROR. The number displayed
will
be the FIRST
is could mean that an
ALARM
code is displayed yet
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 is flashing 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
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 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 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.
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 bypass this can result in "hot streaking" of the burner,
a
major cause of cotton fires.
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 regulator is
leaking during a 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 ball valve
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 interrupted by simply turning off the power or restarting the burner
before the 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
adjustment the 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 adjustment or it's wiring.
ERROR
31
The external electrical connection diagram indicates that a fan interlock contact be installed between terminals
50
and 5OA on the 17400 (or 16400) remote control. The purpose of this is to interlock the power to the heater's
control station with the motor starter@) which drive the
pull
and/or push fans. (Sometimes the installing
electrician substitutes 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 low fire
gas.
ERROR
38
This ERROR is normally caused by tampering with
the
Flame Relay (FIR). Check to see
if
the contacts of FIR are
bridged or the relay jammed.
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 along the
BOTTOM
of the control cabinet and not the top where
it
can interfere with 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 indication of a gas leak
in
the system. Consult the fadtory for service recommendations for this problem.
ERROR
42
This
ERROR
will shut the burner down due to excessively high temperatures occurring before the mixpoint which
the modulating control
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
interlock relay is supplied with the
17400
remote control to provide instant shutdown of the burner when the fans
are stopped. The installing electrician is responsible for wiring the coil of this relay to the fan circuits.
ERROR
44
This error indicates that 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 condition that can be temporarily bypassed. To bypass the
ERROR,
perform the following
d in order to bypass the
ERROR
each time the heater is started until steps. 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 local START-STOP switch to the left
(STOP)
3
times.
-
Press the RESET button to clear the
ERROR
and attempt to restart the 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 debris from 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
pressing RESET button, turn selector This puts you in Step
0
of the test
sequence. The STATUS light
will
confi per second.
The
presence of 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
digital display on the sequence panel SP.
STEP
0
--
After releasing RESET 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 adjustment may 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 bring them closer together to increase velocity pressure VP 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-through systems 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, press and
hold the RESET button for
3
seconds to ad
STEP2
--
Observe the condition of inputs in TEST SEQUENCE.
The
operation of the
remote and
local
start-stop switches and 0th can be tested
while
observing the 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, verii that the jumper
betweenterminal
3
and terminal 12 is remove High Temperature Limit option is
installed and 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,
advancing to Step
3
will
be prohibited.
If
problem is understood and bypass is desired, press and
hold RESET button for
3
seconds to advance.)
2.)
TEST SEQUENCE EPLANATION
-2-
STEP
3
--
The digital temperature controlle
this opportunity to check its configuration
configuration and 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 increased to
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
pilot valve P1, admitting gas pressur
Input 6 should turn on at about
1
psi.
valvesclosed several minutes to
see
downstream valves, P2 a
pressure from the cavity.
build
up.
This tells us that the upstream
The operating program will perform simi
reason electrical power must be sup
each shutdown.
r presence of gas, adjust its pressure, test
,
if
necessary. The START position opens
P1 and P2. Slowly pressurize the 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 minutes to 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 press RESET to proceed to 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 automatically step to
6.
STEP
6
--
This step requires the fan to run for
15
seconds to purge the burner of any combustible
gas. It then automatically steps to
7.
STEP
7
--
The local start-stop switch is now used to test the ignition transformers. Turning the switch to
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
seconds while 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 before each ignition, the burner will not operate until this 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
program steps 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
modulating motor. 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
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.
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