HG-1-1142 1-Million Btu/Hr Gas-Fired Heater
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Table of Contents Warnings... 1-2 Specifications... 3 Preliminary Checks Prior to Initial Operation... 4 Adjusting the Gas Pressure Regulator... 4 Installation of Thermocouple to Sense Temperature... 5 Adjusting Air Volume from Heater Fan... 5 Starting the Heater... 6 Adjusting the Air Flow Switch... 7 Primary Burner Control... 8 Settings for the Gas and Combustion Air Pressure Switches... 9 Adjustment of Air Shutter & Band on Burner... 10 Adjusting the Heater Output Temperature... 11 Adjusting Fuel Flow for Heat Output from Burner... 12 Troubleshooting Guide... 13-15 External Electrical Connections... 16 Electrical Schematic... 17 Gas Piping... 18 Recommended Minimum Pipe Sizes... 19 Liquefied Petroleum Gas Tank Installation... 20 Burner Components... 21 Heater Control Cabinet Components... 22-23 Gas Train Components... 24 Most Common Replacement Parts for Heater Body... 25 Heater Fan Components... 26 Temperature Sensing Thermocouple... 26 Basic Dimensions of Heater... 27 PAGE -1 of 30 HG-1-1142 GAS-FIRED HEATER
We appreciate your business and hope you enjoy your Samuel Jackson HG-1-1142 Gas-Fired Heater This manual contains information on the installation, wiring and use of your HG-1-1142 Gas- Fired Heater. Included are sections on: Safety information Operation of the heater Basic electrical installation Most common replacement components In the future when you require service, technical support, or parts please contact us by phone, fax, or the internet. Our engineers and service people are available to assist you in obtaining the best performance from your Samuel Jackson, Inc. products. Again, thanks for choosing a Samuel Jackson Gas-Fired Heater SAMUEL JACKSON, INCORPORATED MAIL: P.O. BOX 16587 LUBBOCK, TEXAS 79490 COURIER: 3900 UPLAND AVENUE LUBBOCK, TEXAS 79407 TELEPHONE 806-795-5218 OR 800-862-9966 TELEFAX 806-795-8240 E-Mail: engineering@samjackson.com Internet: www.samjackson.com Copyright 2008 SAMUEL JACKSON, INCORPORATED. All rights reserved. PAGE 0 of 30 HG-1-1142 GAS-FIRED HEATER
READ THIS CAREFULLY BEFORE OPERATING THIS SAMUEL JACKSON PRODUCT! The Samuel Jackson product line consists of sophisticated technology capable of greatly enhancing a gin s productivity and efficiency. Improper use of these products could adversely affect those very same factors and potentially cause injury to gin personnel. For this reason, we include an extensive manual with every product. These manuals outline the proper and safe operating procedure for their respective product. Do not operate any Samuel Jackson product without first reading the entire manual and all accompanying information. Sometimes there are updates added at the customer s discretion to products already in the field. We always refer customers to our website, www.samjackson.com for the latest product information. The latest manual can be downloaded or printed from the website free of charge. In addition to printed literature, the website includes training videos on several popular products. When available, these videos are highly recommended for viewing before operating a respective product. If you do not have internet access, give us a call and we will gladly send you the latest product information. DANGER: Please read and understand all the warnings below before operating or maintaining a Samuel Jackson product. If you do not understand, call Samuel Jackson at 806-795-5218 before proceeding. Failure to do so could result in injury or even death. (Si usted no entiende, llamar a Samuel Jackson en 806-795-5218 antes de proceder. La falta de hacer tan podía dar lugar alesión o aún a muerte.) Electrical. Most Samuel Jackson products use supply voltage between 110 and 480 volts AC. These levels are considered high voltage and are extremely dangerous. The ignition transformer voltage output is much higher than this. Fire. Samuel Jackson Humidaire Units and Heaters are combustion-based products. They ignite and burn fuel during operation. These products can reach very high temperatures inside and out. Allow combustion based products 15 minutes to cool before attempting any work. Automatic Flame Ignition. Some Samuel Jackson Humidaire Units and Heaters use technology to ignite automatically. If you do not see a flame, it does not mean that respective product is not in operation. Access Doors. Samuel Jackson products have access doors for added convenience of product maintenance. Access doors must not be opened while the equipment is in operation. Access doors should also remain closed while any connected equipment such as a fan or conveyor is in operation. PAGE 1 of 30 HG-1-1142 GAS-FIRED HEATER
CONTINUED Moving Parts. Many Samuel Jackson products have moving or rotating parts. These parts could form pinch points or grab loose clothing or jewelry. Do not reach across or into any product while in operation. Do not work on any Samuel Jackson product without first following OSHA Lockout/Tagout procedures. Confirmation by a licensed electrician that there is no electricity present is highly recommended. We recommend using a Samuel Jackson Authorized Technician for all work Samuel Jackson products. Additional safety information is located throughout this manual and should be read carefully before operating this Samuel Jackson product. If you have any questions about how to properly operate a Samuel Jackson product, please call 806-795-5218 before proceeding. PAGE 2 of 30 HG-1-1142 GAS-FIRED HEATER
Specifications HG-1-1142 Gas-Fired Heater Fuel: Heater Capacity: Control: Air Volume: Electrical: Natural Gas or Vaporized Propane Gas 300,000 to 1 million BTU/hr Temperature set-point with on/off firing mode Up to 4,000 cubic feet/minute depending on static pressure at heater discharge 230 VAC 50/60 HZ 3 phase, 20 amp AND 230 VAC 50/60 HZ 1 phase, 10 amp PAGE 3 of 30 HG-1-1142 GAS-FIRED HEATER
Preliminary Checks Prior to Initial Operation To test a new installation, first check that all necessary connections for electrical and gas are made. Standard electrical power supply for the heater is 3-phase 230 VAC 50/60 HZ and single-phase 230 VAC 50/60 HZ. The gas supply inlet is 1 inch NPT (national pipe thread) for natural gas or vaporized propane fuel. Inlet pressure of 6 to 20 PSI (0.4 to 1.7 bars) is sufficient. See Drawing 14-1899 in this manual for nominal recommended pipe sizes and Drawing 14-3566 for Liquefied Petroleum Gas (LPG) systems. With electrical power off, prepare to purge the gas line of debris and air by closing off the gas supply valve before the Gas Pressure Regulator and having the main gas supply on. Open the pipe cap on the end of the short pipe debris trap nipple under the regulator and quickly open and close the gas supply valve several times. Debris in the pipe will blast out. Keep doing this until gas is noticeable. Make sure good ventilation is present and no one is smoking. After purging air and debris from the gas line, reinstall the pipe cap on the debris trap nipple. Turn on the gas supply and check for gas leaks with a mixture of soapy water. Adjusting the Gas Pressure Regulator 5 ½ inches water column pressure on this upstream gage Remove spring cover cap and adjust regulator for 5 ½ inches water column 1 inch NPT pipe gas supply inlet Cap on debris trap nipple PAGE 4 of 30 HG-1-1142 GAS-FIRED HEATER
Installation of Thermocouple to Sense Temperature A thermocouple with blue paint on the pipe threads (Part Number 16900C) is supplied for installation in the hot air duct after the heater or in the dryer. Place the thermocouple at least 10 feet away from the outlet of the heater. In some drying applications, this thermocouple will actually be placed after the dryer in the exhaust air. Consult the factory for thermocouple placement suggestions. 10 FEET Adjusting Air Volume from Heater Fan A variable pitch sheave on the fan motor can be adjusted to fine tune the output of the fan. The maximum fan RPM for the 3 HP motor is about 1670 RPM. The fan will deliver up to 4000 CFM of air depending on the fan s speed and the total resistance to air flow for the duct system. TIPS It is better to change the speed of the fan to get close to the desired air volume than severely gating down the air flow from an over sped fan. Variable pitch sheave PAGE 5 of 30 HG-1-1142 GAS-FIRED HEATER
Starting the Heater Start the heater by turning the two position maintained switch on the face of the control cabinet to the I position. The fan motor and burner motor combustion air fan will both start. After a few seconds of self checks by the primary burner control, the burner should light provided that the air flow switch, gas high pressure switch, gas low pressure switch, combustion air proving switch are all satisfied and the target temperature (SP) on the Universal Digital Controller is lower than the measured temperature. If any one of the safety switches is not satisfied, the trial for ignition will not commence. See Troubleshooting Guide section for additional help. Heater ON/OFF control switch O - OFF I - ON PAGE 6 of 30 HG-1-1142 GAS-FIRED HEATER
Adjusting the Air Flow Switch Before attempting to operate the heater, the air flow switch should be adjusted for the actual air flow through the heater for safety. The air flow switch is connected to a pitot tube mounted in the air inlet duct to the blower fan so the velocity pressure of the air flow through the heater is monitored. To adjust the air flow switch, remove the aluminum electrical cover on the front of the switch. Turn the heater control switch to I (ON). The blower fan should start. Check if the motor on the Beckett burner is on. If the burner motor is off, slowly adjust the air flow switch adjusting screw counterclockwise until the motor comes on then continue turning the screw another ½ round out. If the burner motor is on, slowly adjust the air flow switch adjusting screw clockwise until the motor turns off. Next, adjust the screw counter-clockwise until the motor comes on then continue turning the screw another ½ round out. After operating the heater at target temperature, it may be necessary to adjust the screw out (counter-clockwise) a little more to prevent nuisance trips of the air flow switch. Adjustment screw on air flow switch. Turning the screw counter-clockwise makes the switch less sensitive to air flow changes. PAGE 7 of 30 HG-1-1142 GAS-FIRED HEATER
Primary Burner Control The Primary Burner Control provides automatic burner sequencing, flame supervision, and system status indication. Five LED s provide sequence and status information. When the heater on/off switch is in the ON I position and electrical power is on to the control cabinet, the green LED next to POWER will be illuminated. In the event of failure to establish flame within the short flame establishing period, the burner control will go into lockout and the red LED next to ALARM will be illuminated. To clear the lockout, press the RESET button. If ALARM lockout occurs without an obvious reason, consult the factory. An optional Keyboard Display Module (Samuel Jackson Part No. 23229) is available to show a fault code and facilitate troubleshooting. The Keyboard Display Module attaches to the Burner Control. Press RESET to clear the ALARM lockout. PAGE 8 of 30 HG-1-1142 GAS-FIRED HEATER
Settings for the Gas and Combustion Air Pressure Switches There are three pressure switches to monitor burner combustion air and gas pressures for safety. The contacts in these switches are connected in series with one another to shut down the burner if the gas pressure or combustion air pressures are outside of the acceptable ranges. These switches are preset at the factory. Consult the factory before making any changes to the settings. Combustion Air Proving Switch will automatically reset once the set pressure is maintained. It is set to 1.5 inches water column. Gas Low Pressure Switch is set to 3 inches water column. The switch trips upon pressure falling below the setting. When the switch is tripped, the orange LED will be lit and the switch requires manual resetting. Press the red button in the center of the adjustment dial to reset the switch. The button can be pressed without removing the switch cover. Gas High Pressure Switch is set to 7 inches water column. The switch trips upon pressure rising above the setting. The orange LED will be lit indicating a tripped switch which requires manual resetting. Press the red button in the center of the adjustment dial to reset the switch. PAGE 9 of 30 HG-1-1142 GAS-FIRED HEATER
Adjustment of Air Shutter & Band on Burner The shutter and band both control the amount of air flow area available for air inlet to the burner for good combustion. These have been pre-set at the factory for the anticipated firing rates and will seldom need to be adjusted further. Consult the factory before making any changes to these settings. Band is adjusted to the 1 setting Shutter is adjusted to the 9 setting PAGE 10 of 30 HG-1-1142 GAS-FIRED HEATER
Adjusting the Heater Output Temperature Adjust the target temperature using the digital temperature controller on the control cabinet door. The target temperaure is also called the SP (set point). The actual temperature is the PV (process variable). The normal range for the target temperature is pre-set at the factory for 100 to 350 degrees fahrenheit. If desired, the controller can be set to display the temperature in degrees celsius. Consult the factory for changing these settings in the digital temperature controller. Use the up and down arrow keys on the controller s keypad to increase or decrease the target (SP) temperature. The thermocouple will quickly respond to heater output changes if the thermocouple is placed in the air pipe just after the heater s outlet. In this case, adjust the target temperature a little above the actual desired temperature and adjust the fuel flow to keep the actual temperature below the set target. Refer to the Adjusting Fuel Flow for Heat Output from Burner section in this manual for fine tuning the fuel flow to the burner to minimize on/off burner cycling. The digital temperature control can switch between two target temperatures with an optional remote switch connected to two pre-wired terminals in the heater control cabinet. Refer to the external electrical connetion diagram for specific terminal numbers. Measured temperature of the heated air - process variable (PV) Target set point (SP) temperature PAGE 11 of 30 HG-1-1142 GAS-FIRED HEATER
Adjusting Fuel Flow for Heat Output from Burner After the burner is on, adjust the fuel flow to the burner to give the desired temperature without too much on/off burner cycling as the temperature goes above and falls under the desired target temperature (set point) on the temperature controller. A change in air volume through the heater or a change in ambient temperature conditions may require fine tuning the fuel flow after startup. Too high of fuel flow will increase cycling. Too little fuel flow will make achieving the target temperature take longer or imposssible. Fuel Flow Knob MORE FUEL + Do not loosen the screw with the blue painted top on the fuel flow knob! Adjust fuel flow knob to obtain a pressure between 1 to 4 ½ inches water column on the down stream gage. Higher pressure means more fuel flow and higher heat output. PAGE 12 of 30 HG-1-1142 GAS-FIRED HEATER
Troubleshooting Guide If the heater does not light, follow through the guide below for help. If the heater fan is not running: 1. Check 230 VAC 3 phase power supply to the fan motor contactor. 2. Check that the fan motor overload relay is not tripped. If the heater fan is running but the burner motor is not running: 1. Check and adjust the air flow switch. See Adjusting the Air Flow Switch section. 2. Check 230 VAC single phase power to the burner motor contactor. 3. Check that the burner motor overload relay is not tripped. 4. The burner motor has an internal overload protection circuit. The reset button is near the nameplate decal on the motor case. Press button on motor case to reset. If both fans are running but the burner will not ignite and only the green POWER light is lit on the Primary Burner Control: 1. Check that gas supply is turned on and that adequate gas pressure registers on the gage upstream of the safety shut off valves. Gas pressure should be 5 ½ inches water column. 2. Check if the Gas Low Pressure Switch is tripped. The orange LED will be lit if the switch is tripped. If the gas pressure falls below 3 inches water column, this switch will trip. Adjust gas pressure regulator if necessary for at least 5 ½ inches water column on the gage upstream of the safety shut off valves. See Adjusting the Gas Pressure Regulator section. Press red button on switch cover to reset. 3. Check if the Gas High Pressure Switch is tripped. The orange LED will be lit if the switch is tripped. If the gas pressure goes above 7 inches water column after the safety shut off valves, this switch will trip. Adjust gas pressure regulator to lower the pressure. If pressure rises again, check operation of gas regulator. 4. The Combustion Air Proving Switch will automatically reset once the air pressure from the combustion air fan is maintained at or above 1.5 inches water column. If it does not reset, check that the tube connected to the switch from the fan intake is securely in place. Check that the air shutter and band are adjusted as shown in the Adjustment of Air Shutter & Band on Burner section. PAGE 13 of 30 HG-1-1142 GAS-FIRED HEATER
Troubleshooting Guide (continued) 5. Check that the target temperature (SP) displayed on the digital temperature controller is above the actual measured temperature PV (process variable). The controller will only call for heat and start when the process variable is lower than the target. If both fans are running, the green POWER light is lit on the Primary Burner Control, PILOT comes on mometarily but FLAME light does not come on or remain on: 1. Access the Gas Gun Assembly by removing the screws on the cover under the ignition transformer. Loosen the jacking screw (1) shown below. Disconnect the ignition wire from the ignition transformer (2). Gently pull the gas gun assembly out of the burner tube being careful not to damage the UV flame detector (7). Check that the gap between the ignition electrodes is 1/8 inch as shown below. Note that the burner uses a UV sensor to detect flame, not the flame rod shown in the lower picture. PAGE 14 of 30 HG-1-1142 GAS-FIRED HEATER
Troubleshooting Guide (continued) If the red ALARM light is lit on the Primary Burner Control: 1. Press the blue button next to RESET to clear the ALARM lockout. If the burner does not light and ALARM lockout continues to occur without an obvious reason, consult the factory. An optional Keyboard Display Module (Samuel Jackson Part No. 23229) is available to show a fault code to facilitate troubleshooting. The display module attaches to the front of the Primary Burner Control. Optional 23229 Keyboard Display Module PAGE 15 of 30 HG-1-1142 GAS-FIRED HEATER
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Gas Piping The size of the pipe supplying gas to heaters and other appliances should be large enough to prevent excessive pressure losses when all of them are in use. See following Table of RECOMMENDED MINIMUM PIPE SIZES (Drawing 14-1899) for heater capacities, pipe lengths, and pressures. Where LPG (Liquefied Petroleum Gas, Propane, Butane) is used as fuel, see the following Drawing 14-3566 LIQUEFIED PETROLEUM GAS TANK INSTALLATION FOR HUMIDAIRE UNITS AND DRYING HEATERS for 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 are accessible in an emergency situation. IRI (Industrial Risk Insurers) and some state and local authorities require venting the gas regulator and normally open vent valve. NFPA (National Fire Protection Association) 86* states: 3-3.4.3.2 Regulators shall be vented to a safe location, where vented gas cannot re-enter the building without extreme 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 be 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 lines provided that switch or regulator diaphragm failure will not backload the regulator. * Reprinted with permission from NFPA 86-1985, Standard for Ovens and Furnaces, copyright 1985, National Fire Protection Association, Quincy, Mass. 02269. This reprint of material is not the complete and official position of the NFPA on the referenced subject which is represented only by the standard in its entirety. PAGE 18 of 30 HG-1-1142 GAS-FIRED HEATER
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Burner Components (Contact factory for CG10 Burner parts not individually labeled below) 23224 CG10 Beckett Gas-Fired Burner with CG10.6S Gas Gun 21711 ON-OFF Primary Burner Control 23225 Flame Signal Amplifier (mounted on Primary Burner Control) PAGE 21 of 30 HG-1-1142 GAS-FIRED HEATER
Heater Control Cabinet Components 22175 Double Pole Circuit Breaker 5 Amp 22174 Single Pole Circuit Breaker 5 Amp 19181 Burner Enable Relay 17250 Air Flow Switch Assembly 21679 Contactor & 21677 Overload Relay for Burner Motor 21679 Contactor & 21680 Overload Relay for Heater Fan PAGE 22 of 30 HG-1-1142 GAS-FIRED HEATER
Heater Control Cabinet Components (continued) 23189 UDC2500 Universal Digital Controller 16480A Transformer, 500 VA (do not operate with cover removed) PAGE 23 of 30 HG-1-1142 GAS-FIRED HEATER
Gas Train Components 23190 Gas Pressure Gages (0-10 inch water column) 23226 Gas Pressure Regulator 23228 Gas High Pressure Switch 23227 Gas Low Pressure Switch 21326 Double Safety Shut Off Valves PAGE 24 of 30 HG-1-1142 GAS-FIRED HEATER
Most Common Replacement Parts for Heater Body 13530A Air Intake Screen 17064 Tempered Glass Window (4 X 12 inch) 23131 Heat Shield Weldment PAGE 25 of 30 HG-1-1142 GAS-FIRED HEATER
Heater Fan Components 23149 Fan with 3 HP motor 23230 B42 V-Belt Temperature Sensing Thermocouple 16900C Exposed Tip, Type J, Shrouded Thermocouple 18770 Thermocouple Fitting Assembly PAGE 26 of 30 HG-1-1142 GAS-FIRED HEATER
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IMPORTANT! The following notice affects your warranty. Electrical Controls and Your Safety Your new Sam Jackson product may be equipped with electrical controls, or designed to interact with controls on a related Sam Jackson product. In the event that local, state, federal or other specified safety compliance is required, we will consider modifications to meet the particular requirements. Implementation of alternative safety devices may incur additional charges. No warranty of compliance with a particular standard is made in the absence of specific reference to it in our quotation. If you modify, or permit others to modify, these controls without specific written permission from Sam Jackson, Inc. the warranty on your product will be void and there is a possibility of serious damage to machinery, damage to product, serious injury to personnel, or death. The modifier of the controls assumes all liability for these consequences. Samuel Jackson, Incorporated 3900 Upland Avenue Lubbock, Texas 79407 806-795-5218 PAGE 29 of 30 HG-1-1142 GAS-FIRED HEATER
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