SAMUEL JACKSON HG-1-1401A, Service Manual

Page 1: ...HG 1 1401A 1 Million Btu Hr Gas Fired Heater Service and Operation Guide ...

Page 2: ...PAGE 1 of 41 HG 1 1401A GAS FIRED HEATER SAMUEL JACKSON INCORPORATED 2005 ALL RIGHTS RESERVED ...

Page 3: ...P Explanation 23 Stub Ups 25 External Electrical Connections 26 Electrical Schematic with PLC inputs outputs 27 Proper Grounding 28 Gas Piping 29 Recommended Minimum Pipe Sizes 30 LPG Gas Tank Installation 31 Component Labels for Electrical Cabinet 32 Component Labels for Gas Train 33 Component List 34 Burner Head Assembly 36 Dimensions for HG 1 1401 Heater 37 Warranty Information 40 Electrical Co...

Page 4: ...der separate cover specifically for your system IS STARTUP ASSISTANCE PROVIDED Depending upon your location a startup and inspection service may be provided with your new heater free of charge by Samuel Jackson Inc Please contact us to make arrangements or for questions In the future when you require service technical support or parts contact us by phone fax or E Mail Our engineers and service peo...

Page 5: ...ate from the Humidaire Unit is helpful for pre warming the Steamroller Moisture Condenser or lint slide jacket The HG 1 1401A heater is built for this purpose It includes PLC combustion controls with diagnostics It has built in temperature controls with a 2 HP fan and motor combination capable of delivering up to 3 000 CFM of tightly controlled reliable hot air HG 1 1401A GAS FIRED HEATER ...

Page 6: ...l start and various operations will be displayed as the self checks and ignition sequence are performed The STATUS light will remain on throughout this process After approximately 20 seconds the burner will attempt ignition If ignition fails the heater controls will automatically make two more attempts following appropriate air purge delays 1401 V1 0 OK Mode Off AIR 180F SETUP LOGS TESTS BLINKS TO...

Page 7: ...error number are displayed ALARMS will warn the operator of an impending problem and ERRORS will cause an immediate shutdown WHAT ARE THE TESTS AND SETUP PROGRAMS The TESTS and SETUP programs can be activated by a qualified service man or trained user to test the heater and make custom settings They are always performed in the Samuel Jackson factory before shipment of a new heater and occasionally...

Page 8: ...on and the selector switch on the Local Panel See below To change the air temperature set point press and hold the AIR SP button while using the selector switch to raise or lower the desired set point temperature Release the AIR SP button when the desired set point is shown Changing the SP can be done with the heater on or off The range that the set point can be adjusted to depends on the minimum ...

Page 9: ... I ADJUST THE AIR VOLUME OUTPUT OF THE FAN A variable pitch sheave on the fan motor can be adjusted to fine tune the output of the fan The maximum fan RPM for the 2 HP motor is about 1980 RPM The fan s speed was set at the factory to about 1650 RPM The fan will deliver between 750 and 3000 CFM of air depending on the fan s speed and the total resistance to air flow for the duct system TIPS It is b...

Page 10: ...ntries are in a first in first out stack therefore Error Log 500 is replaced when another log event occurs A typical Error Log display is shown below Error Log 002 is shown with a code of 121 that occurred on 08 19 August 19 at 16 49 4 49 PM Referring to the DIAGNOSTIC CODES decal located on the heater cabinet door Code 121 is an ALARM that air flow went off for a moment A more detailed descriptio...

Page 11: ...an be used to determine regular maintenance intervals Access to this step is easy and can be done when the burner is on or off Turn the switch until the blinking cursor is over LOGS Press the SELECT button once Then use the switch to scroll through until FLAME ON TIMER is shown Press SELECT again The switch is now used to scroll from month to month When you are finished viewing the times press SEL...

Page 12: ...K UPSTREAM CHECK SSOV1 137 E GAS VALVE LEAK DOWNSTREAM CHECK SSOV2 PV 140 E RESTART NOT PERMITTED NO LEAK TEST PERFORMED FOR PAST SIX SHUTDOWNS 141 E FAN RELAY FAILED TO OPEN WHEN AIR FLOW WAS ABSENT HAS THIS RELAY BEEN JUMPERED 142 E AIR FLOW SWITCH IS ON WITHOUT FAN INTERLOCK RELAY CHECK OPERATION OF AIR FLOW SWITCH 143 E NO FAN INTERLOCK SIGNAL IS THE FAN ON 144 E EXCESSIVE FLAME FAILURES THREE...

Page 13: ...wn even if the burner shuts down due to an ERROR Pressing the SELECT button will show consecutive ALARM conditions leading up to the shutdown ERROR EXAMPLE The flame electrode is fouled This prevents the burner from having a flame signal ALARM code 146 Burner failed to ignite is displayed and the status light flashes While this is occurring the burner is automatically restarting itself three times...

Page 14: ...ion Note For most HG 1 heater installations the fan is an integral part of the heater system so this ERROR will not occur unless the air flow switch AFS is out of adjustment ALARM 121 AIR FLOW WENT OFF FOR A MOMENT This ALARM is an indication that a choke of the air flow is occurring It is displayed when the air flow switch goes off and comes back on in less than 3 seconds The air flow switch AFS ...

Page 15: ...pressure gauge should read 0 PSI ERROR 131 USER SPECIFIED TIME FOR SHUTDOWN Some countries require that gas fired combustion products turn off once every 24 hours as a safety measure To accommodate operators that need to comply with this regulation ERROR 131 will force the heater to shut down once a day at a user defined time This error will only occur if the 24 Hour Shutdown routine is enabled in...

Page 16: ...interlock with no air flow present effectively bypassing this important safety feature ERROR 142 AIR FLOW SWITCH IS ON WITHOUT FAN INTERLOCK RELAY ON This error indicates that an electrical signal is being received from the air flow switch with no fan interlock signal present 10 minutes after burner shutdown effectively bypassing this important safety feature Check the adjustment of the Air Flow S...

Page 17: ...it Incorrectly spliced spark plug wires splayed wires on the high voltage connectors or a defective high voltage insulator terminal can cause troublesome ignition Running a clean spark plug wire from the ignition transformer directly to the burner head can help to isolate this problem ERROR 153 FLAME SIGNAL BEFORE FUEL AND SPARK This ERROR means a flame signal is observed before spark and fuel are...

Page 18: ...lve 1 upstream SSOV valve is opening and closing in a timely manner If this problem persists try the following Check that SSOV opens and closes Check for gas leaks Check operation of SSOV s proof of closure switch POC Replace SSOV valve actuator and or its proof of closure switch If the operator is aware of the safety issues involved in bypassing the function of the Proof of Closure switch POC a t...

Page 19: ...continue to operate with a dead battery ALERTS are not entered into the error logging system ALARM 271 PLC BATTERY BACKUP DISABLED Replace PLC battery Indicates an ERROR condition that can be temporarily bypassed To bypass the ERROR perform the following steps These steps will have to be performed in order to bypass the ERROR each time the heater is started until the condition is fixed Some proble...

Page 20: ...rt pipe debris trap nipple under the regulator and quickly open close the gas supply valve several times Debris in the pipe will blast out Keep doing this until gas is noticeable Make sure good ventilation is present and no one is smoking Check that power on terminals 1 and 2 on the electrical panel is between 103 and 125 VAC TO ENTER TESTS PROGRAM The TESTS program is run from the diagnostic modu...

Page 21: ...ress the SELECT button Killing the supply power will also exit the test program Following are the TESTS selections that are available with descriptions of each BACK Pressing SELECT button when BACK is displayed exits the TESTS program INPUTS Observe the condition of PLC inputs The alphanumeric displays ON and OFF status of inputs If input status is not correct the input number will flash on the di...

Page 22: ... the vanes closer together to increase velocity pressure VP or farther apart to reduce it Make the adjustment the same on all vanes 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 or may be difficult to light On higher air volume systems where the velocity cannot be reduced to 0 4 with the shu...

Page 23: ...the valve and checks the operation of the valve The AIR SP set point temperature needs to be adjusted to at least 150F for this test to work well since the PLC will generate a full 20mA signal for full valve travel at higher set points The fan is on during this test The Gas Valve Motor GVM has been adjusted at the factory for correct travel If replacement of GVM is necessary in the future refer to...

Page 24: ...o to energize PV This will evacuate the gas cavity Leave the valves closed several minutes to see that the pressure does not build up This tells us that the upstream valve first SSOV is not leaking The operating program will perform similar tests every time the heater is shut down This is one reason electrical power must be supplied to the heater continuously or at least for 10 minutes after each ...

Page 25: ...cal interference occurs TRY IGNITE The fan will run for 20 seconds before the burner attempts to ignite During the first 5 seconds of this period the first SSOV and PV gas valves open for 5 seconds to purge gas out of the piping system to the burner head After the 20 seconds trial for ignition occurs and only lasts 10 seconds During this time adjust the gas low fire valve shown on next page Start ...

Page 26: ...tch to for YES To disable this feature turn the switch to Once the desired option is selected press the SELECT button to continue If the disable option has been chosen the test program will advance back to the 24 HR SHUTDOWN prompt If the enable option is chosen a prompt will appear which allows you to set the time you want the Heater to automatically shutdown Once the shutdown time has been set p...

Page 27: ...ater from excessive temperatures The default temperature is set to 140 degrees F The adjustable range is from 0 to 200 degrees F PID SETUP GAIN The temperature control system has been pre tuned at the factory for best operation of the heater in most situations If the tuning has been corrupted or changed and a return to the original factory setting is desired set GAIN to 075 PID SETUP RESET The tem...

Page 28: ...ITH AC VOLTAGE WIRES OKAY TO RUN WITH OTHER THERMOCOUPLE OR DC VOLTAGE WIRES 3 BURNER SPARK PLUG WIRE IN ONE CONDUIT IN SEPARATE CONDUIT BURNER FLAME ROD WIRE WITH GROUND WIRE FROM BURNER CABINET TO THE BURNER BODY CONDUITS AND WIRE SUPPLIED WITH HEATER RUN WITH ONE INCH PLASTIC AIR FLOW TUBE IN EACH CONDUIT TUBES SUPPLIED WITH HEATER 4 OPTIONAL HEATER CONTROL AC WIRES TO REMOTE LOCATION FOR REMOT...

Page 29: ...PAGE 26 of 41 HG 1 1401A GAS FIRED HEATER SAMUEL JACKSON INCORPORATED 2005 ALL RIGHTS RESERVED TYPE J THERMOCOUPLE WIRE 50 FEET ...

Page 30: ...PAGE 27 of 41 HG 1 1401A GAS FIRED HEATER SAMUEL JACKSON INCORPORATED 2005 ALL RIGHTS RESERVED ...

Page 31: ...PAGE 28 of 41 HG 1 1401A GAS FIRED HEATER SAMUEL JACKSON INCORPORATED 2005 ALL RIGHTS RESERVED ...

Page 32: ...Y4 Y6 C 2 Y16 Y14 Y13 Y11 N C Y0 Y2 C 1 Y5 Y7 Y17 Y15 Y10 Y12 C 3 G LG N C C 1 X5 X7 X10 X12 C 3 X22 X20 X17 X15 X0 X2 N C X4 X6 C 2 X11 X13 X14 X23 X21 C 4 X16 X1 X3 C 0 PORT1 PORT2 RUN STOP TERM PWR RUN C PU TX1 RX1 TX2 RX2 0 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 20 21 22 23 Direct LOGIC 06 Koyo D 0 06D R D Y X ...

Page 33: ...s PLC can loose its program if not properly grounded rendering the Heater inoperable For this reason it is recommended that you follow these grounding tips Always run the ground wire directly to a 6 foot or longer earth ground rod Always use AWG8 aluminum ground wire or better The earth ground rod should be within 25 of the heater control cabinet Do not connect Heater ground to the gin s common gr...

Page 34: ... 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...

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Page 37: ...6 Y14 Y13 Y11 N C Y0 Y2 C 1 Y5 Y7 Y17 Y15 Y10 Y12 C 3 G LG N C C 1 X5 X7 X10 X12 C 3 X22 X20 X17 X15 X0 X2 N C X4 X6 C 2 X11 X13 X14 X23 X21 C 4 X16 X1 X3 C 0 PORT1 PORT2 RUN STOP TERM PWR RUN C PU TX1 RX1 TX2 RX2 0 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 20 21 22 23 Direct LOGIC 06 Koyo D 0 06D R D Y X OUTPUT 6 240V INPUT 12 24V 50 60Hz 3 15mA 2 0A 2 0A 6 27V PWR 12 24V 20W ...

Page 38: ...PAGE 35 of 41 HG 1 1401A GAS FIRED HEATER SAMUEL JACKSON INCORPORATED 2005 ALL RIGHTS RESERVED Heater Gas Train Component Labels GPR ...

Page 39: ... FAN 20897 7H165 2 HP MOTOR FE FLAME ELECTRODE BURNER 12399A CA390 FL FLAME RELAY UPPER CABINET 20107 LFE10 GHPS GAS PRESSURE SWITCH HIGH PRESS LOWER CABINET 21332 D217089 GAO A2 4 8 GLPS GAS PRESSURE SWITCH LOW PRESS LOWER CABINET 21332 D217089 GAO A2 4 8 GPG1 GAS PRESSURE GAGE 0 5 PSI 1 LOWER CABINET 19188 BCM DIAPHRAGM GPG2 GAS PRESSURE GAGE 0 5 PSI 1 LOWER CABINET 19188 BCM DIAPHRAGM GPG3 GAS ...

Page 40: ...R MOTOR OVERLOAD 21677 TK E02 340 UPPER CABINET PLC PROGRAMMABLE LOGIC CONTROLLER UPPER CABINET 21562 DL06 PLC COMPRISED OF 19857 21563 21564 21565 21566 POC PROOF OF CLOSURE SWITCH LOWER CABINET 21328 D224253 CPI 400 PS POWER SUPPLY 120VAC TO 24VDC UPPER CABINET 21553 IDEC PS5R SD24 PV GAS PILOT VALVE LOWER CABINET 21352 8040H7 SSOV DOUBLE SAFETY SHUT OFF GAS VALVES LOWER CABINET 21326 D224843 DM...

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Page 44: ...eet 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 pos...