Burners - Bid on Equipmentbidonequipment.info/s/Burners.pdf · Stelter & Brinck, Ltd. Standard Duct Style Air Heaters Model AHDX Job Data Sheet Date: S&B Job no. Revision # Customer:

Burners

ITEM QTY DESCRIPTION MFG. PART NO.

BURNER

1 1 BURNER ECLIPSE AH-MA

2 1 SPARK IGNITOR (INCLUDED w/ BURNER) ECLIPSE 13047-1

3 2 FLAME ROD (INCLUDED w/ BURNER) ECLIPSE 13093

MAIN VALVE TRAIN

5 2 1-1/2" NPT GAS COCK w/ HANDLE, KH 01/6-15 DUNGS D240894

6 1 1-2" NPT DUAL SAFETY SHUTOFF VALVE, DMV-DLE 703/624L VLA DUNGS 244-165VP

7 2 1-1/2" NPT FLANGE ADAPTOR DUNGS 222-003

8 1 VISUAL INDICATOR DUNGS 217-665

9 1 PROOF OF CLOSURE SWITCH (INCLUDED w/ SSOV) DUNGS CPI 400

10 1 1-1/2" NPT RED. PORT GAS CONTROL VALVE, 6BV-ARB ECLIPSE 501233

11 1 MODULATING MOTOR HONEYWELL M7284C1083

1 CRANK ARM KIT HONEYWELL 7616BR

1 WEATHER PROOFING KIT FOR MOD. MOTOR HONEYWELL 4074ERU

12 1 MOUNT AND LINKAGE KIT ECLIPSE 100099

13 1 LOW FIRE SWITCH (INCLUDED w/ MOD. MOTOR) HONEYWELL 220736A

*14 1 LOW GAS PRESS. SWITCH, GAO-A2-4-6 (12.0 - 60.0") DUNGS 217-088A

*15 1 HIGH GAS PRESS. SWITCH, GAO-A2-4-8 (40.00 - 200.0") DUNGS 217-089A

16

17 1 1/4" NPT BALL VALVE, KH 01/6-02 DUNGS D240887

18 1 INLET PRESSURE GAUGE (0-15 PSI) ASHCROFT 63-1008AL-02L-15

19 1 1-2" NPT MAIN GAS SUPPLY REGULATOR, FRI 712/6 DUNGS 230-475

1 MAIN GAS REG. SETPOINT SPRING, BLACK (24 - 40") SP=37" DUNGS 229-848

20 1 FRI TO DMV MTG. KIT (INCLUDED w/FRI) DUNGS

21

22 1 3/4" NPT VENT VALVE ECLIPSE 20161

23 1 G1/8" TO 1/4" ADAPTER DUNGS 225-047

24

PILOT VALVE TRAIN

25 1 3/8" NPT PILOT SUPPLY REGULATOR MAXITROL 325-3

1 PILOT REG. SETPOINT SPRING, TAGGED (24-40") MAXITROL R325C10-P12

26 2 3/8" NPT SAFETY SHUTOFF SOLENOID ECLIPSE 20168

27 1 1/4" NPT ADJUSTABLE GAS COCK ECLIPSE 12659

28 1 3/8" NPT STRAINER, STYLE B w/30 MESH SS SCREEN KECKLEY 30 MESH 3/8

AIR FLOW

*30 1 DIFFERENTIAL AIR FLOW SWITCH, AA-A2-6-2 (.16 - 1.2") DUNGS 217-329A

*31 1 EXHAUST AIR FLOW SWITCH, AA-A2-6-2 (.16 - 1.2") DUNGS 217-329A

32 1 EXHAUST SWITCH MOUNTING BRACKET DUNGS D230-289

MISC.

35 4 1/4" NPT TEST COCK ESSEX AC50

36 2 1/4" NPT HOSE BARB ESSEX FT2701414

37 2 2" PEEPSIGHT ECLIPSE 120054

38 2 G1/8" TEST TAP DUNGS 219-008

39 2 REGULATOR VENT PROTECTOR MAXITROL 13A15

TEMPERATURE ELEMENTS

SHIPPED LOOSE 100 1 TEMP. CONTROL (HEATER OUTLET) THERMOCOUPLE (TYPE K) OMEGA NB2CASS14U18DUA

SHIPPED LOOSE 101 1 HIGH LIMIT (HEATER OUTLET) THERMOCOUPLE (TYPE K) OMEGA NB2CASS14U18DUA

SHIPPED LOOSE 102 1 TEMP. CONTROL (PRODUCT OR EXHAUST) THERMOCOUPLE (TYPE K) OMEGA NB2CASS14U18DUA

SHIPPED LOOSE 103 1 HIGH LIMIT (EXHAUST) THERMOCOUPLE (TYPE K) OMEGA NB2CASS14U18DUA

* See Job Data Sheet For Component Setpoint Information.

STELTER & BRINCK, Ltd.STELTER & BRINCK, Ltd.STELTER & BRINCK, Ltd.STELTER & BRINCK, Ltd.

HARRISON, OHIOHARRISON, OHIOHARRISON, OHIOHARRISON, OHIO

REV DATE www.stelterbrinck.comwww.stelterbrinck.comwww.stelterbrinck.comwww.stelterbrinck.com

B.O.M. # Date: REV

01-1633-02 BOM 7/16/2014 -

AHDX STANDARD AIR HEATER / JOB No. 116334

CARRIER VIBRATING EQUIPMENT SN28558

BILL OF MATERIALS

DESCRIPTION

1-1/2" VALVE TRAIN B.O.M., GAP, NEMA 4NOTICE OF PROPRIETARY INFORMATION

This document contains proprietary information which is being disclosed to you in strict confidence. It is not to be copied, given to a third party, or used to furnish any information for making prints, structures or the like embodying subject matter derived from it, without

our express consent. It is to be returned upon demand.STELTER & BRINCK, Ltd.

BILL OF MATERIALSITEM QTY DESCRIPTION MFG. PART NO.

ENCLOSURE

1 1 REMOTE OPERATOR'S PANEL HOFFMAN CSD242410LG

2 1 INNER PANEL FOR OPERATOR'S PANEL HOFFMAN CP2424

RELAYS & CONTROLS

10 1 HEATER OUTLET HIGH TEMPERATURE LIMIT LOVE TSF-4010

11 1 EXHAUST HIGH TEMPERATURE LIMIT LOVE TSF-4010

12 1 MASTER (PRODUCT OR EXHAUST) TEMP. CONTROLLER HONEYWELL DC2500-C0-1A00-100-00000-00

13 1 SLAVE (HEATER OUTLET) TEMP. CONTROLLER HONEYWELL DC2500-C0-1A00-110-00000-00

14 1 PROGRAMMABLE REMOTE KEYBOARD DISPLAY HONEYWELL S7800A1142

15 1 10 AMP CIRCUIT BREAKER (TRIP CLASS C) SQUARE D 60110

16 3 CONTROL RELAY, 3 NO / 1 NC SQUARE D CA2KN31G7

BUTTONS & LIGHTS

20 1 2 POSITION SELECTOR SWITCH, MAINTAINED SQUARE D ZB5AD2

21 1 PUSH BUTTON, TWIN, ILLUMINATED SQUARE D ZB5AW7L3741

22 1 EMERGENCY STOP SQUARE D ZB5AS844

23 1 INDICATOR LIGHT, BLUE SQUARE D ZB5AV06

24 1 E-STOP YELLOW CIRCULAR LEGEND SQUARE D ZBY9330

25 1 LIGHT MODULE w/ MOUNTING COLLAR & INTEGRATED LED (BLUE) SQUARE D ZB5AVBG6

26 1 LIGHT MODULE w/ MOUNTING COLLAR & INTEGRATED LED (GREEN) SQUARE D ZB5AVBG3

27 2 1 N.O. CONTACT BLOCK SQUARE D ZBE101

28 3 1 N.C. CONTACT BLOCK SQUARE D ZBE102

29 2 BODY / MOUNTING COLLAR SQUARE D ZB5AZ009

30 2 LEGEND PLATE HOLDER (SNAP ON TYPE) SQUARE D ZBZ33

MISC.

40 1 ALARM HORN FEDERAL SIGNAL 350-120-30

1 ALARM HORN GASKET FEDERAL SIGNAL 8435666A

41 1 KEYBOARD DISPLAY COVER ASSEMBLY (w/ RESET BUTTON) HONEYWELL 204718C

42 8 SCREWS w/ WASHERS HONEYWELL w/ CONTROLLER

TERMINALS AND TERMINAL ACCESSORIES

50 AS REQ'D FINGER SAFE TERMINAL BLOCK, GREY SQUARE D NSYTRV42

51 AS REQ'D FINGER SAFE TERMINAL BLOCK, BLUE SQUARE D NSYTRV42BL

52 AS REQ'D FINGER SAFE TERMINAL BLOCK, ORANGE SQUARE D NSYTRV42AR

53 AS REQ'D PARTITION PLATE SQUARE D NSYTRAP22

54 AS REQ'D END COVER SQUARE D NSYTRAC22

55 AS REQ'D END STOP SQUARE D NSYTRAABV35

56 AS REQ'D FINGER SAFE BLADE DISCONNECT TERMINAL BLOCK SQUARE D NSYTRV42ST




B.O.M. # Date: REV

01-1633-04A 7/16/2014 -

AHDX Standard Heater Panel w/ Nema 4 Option / Job No. 116334


DESCRIPTION

Dual Loop Control w/ PLC OutputsNOTICE OF PROPRIETARY INFORMATION



HONEYWELL

SP2500

2500

Display

Lower

ALM

Setup

OUT

Function

PV

Reset

M-A

Run

Hold

Select

SP

HONEYWELL

SP2500

2500

Display

Lower

ALM

Setup

OUT

Function

PV

Reset

M-A

Run

Hold

Select

SP

BILL OF MATERIALS

ITEM QTY DESCRIPTION MFG. PART NO.

ENCLOSURE

1 1 LOCAL FLAME RELAY PANEL HOFFMAN CSD20208LG

2 1 INNER PANEL FOR LOCAL FLAME RELAY PANEL HOFFMAN CP2020

3 1 TRANSFORMER ENCLOSURE HOFFMAN LHC151512

4 1 INNER PANEL FOR TRANSFORMER ENCLOSURE HOFFMAN LP1515

RELAYS & CONTROLS

10 1 BURNER FLAME RELAY HONEYWELL RM7897C1000

11 2 UNIVERSAL WIRING SUB-BASE HONEYWELL Q7800A1005

12 1 FLAME SIGNAL AMPLIFIER HONEYWELL R7847A1082

13 1 6 MINUTE PLUG IN PURGE TIMER CARD HONEYWELL ST7800A1096

14 1 EXPANDED ANNUNCIATOR HONEYWELL S7830A1005

15 1 DATA CONTROL BUS MODULE HONEYWELL S7810M1003

16 1 CONTROL RELAY, 3 NO / 1 NC SQUARE D CA2KN31G7

17 1 AUXILIARY CONTACT, 1 N0 / 1 NC SQUARE D LA1KN11

MISC.

30 1 IGNITION TRANSFORMER ECLIPSE 22967

31 1 CONNECTOR ECLIPSE 10002351

32 1 CAP ECLIPSE 10002354

TERMINALS AND TERMINAL ACCESSORIES

40 AS REQ'D FINGER SAFE TERMINAL BLOCK, GREY SQUARE D NSYTRV42

41 AS REQ'D FINGER SAFE TERMINAL BLOCK, BLUE SQUARE D NSYTRV42BL

42 AS REQ'D FINGER SAFE TERMINAL BLOCK, ORANGE SQUARE D NSYTRV42AR

43 AS REQ'D PARTITION PLATE SQUARE D NSYTRAP22

44 AS REQ'D END COVER SQUARE D NSYTRAC22

45 AS REQ'D END STOP SQUARE D NSYTRAABV35

46 AS REQ'D FINGER SAFE BLADE DISCONNECT TERMINAL BLOCK SQUARE D NSYTRV42ST




B.O.M. # Date: REV

01-1633-04B BOM 7/16/2014

AHDX Standard Air Heater B.O.M. Job No. 116334


Flame Relay & Ignition Transformer JIC

DESCRIPTION

NOTICE OF PROPRIETARY INFORMATION



Stelter & Brinck, Ltd. Standard Duct Style Air Heaters Model AHDX

Job Data Sheet

Date: S&B Job no. Revision #

Customer:

Customer P.O. No: Ser. No:

Air Heater Model No. : AHDX040 - I4 - N - R - GR - DC - L2 - 2 0 C 4 - 0

Drawings & BOM's

General Arrangement : 01-1633-01 Flame Relay & Ign. Trans. JIC : 01-1633-04B

P&ID: 01-1633-02 Flame Relay & Ign. Trans. JIC BOM : 01-1633-04B BOM

P&ID BOM: 01-1633-02 BOM Support Leg Option : 01-1633-21

Wiring Diagram : 01-1633-03

Remote Operator Panel : 01-1633-04A

Remote Operator Panel BOM : 01-1633-04A BOM

Heater Specifications & Options Operating Conditions

Burner Size 4 feet Air Flow (SCFM) 2,800-3,624

Valve Train Insurance Rating GAP Air Static Pressure @ Heater ("w.c.) 8

Valve Train NEMA Rating NEMA 4 Min.Inlet Air Temp.-Start Up (oF) 0

Fuel Type Natural Gas Min.Inlet Air Temp.-Operating (oF) 10

Valve Train Location Right Side Max. Air Temp.In (oF) 95

Main Gas Regulator Yes Max. Air Temp. Out (oF) 800

Duct Material Carbon Steel Available Fuel Pressure (PSIG) 3-7

Integral Air Diffuser Yes Min / Max Allowable Fuel Pressure (PSIG) 3-7

Duct Support Legs Yes Elevation (ft. above sea level) 564

Duct Centerline Height - From Floor 54" R1 Summer design max temp.(oF) 95

Control Panel Standard Winter design min temp.(oF) 10

Panel Heater No Cont. Panel Loc. (indoor/outdoor) Indoor

PLC Outputs Yes Heater Location (indoor/outdoor) Indoor

Panel NEMA Rating 4 Heater Area Electrical Class Non-Hazardous

Paint Finish: S&B standard Other: ______________________________________ 850 Charcoal

Setup & Configuration

Process Air ΔP between PTB & PTC. ("wc) 1.0

Air Static Pressure @ Heater ("wc) 8

High Fire Burner Gas ΔP between PTA & PTC ("wc) 19

The above pressure includes burner plus header losses

Press. Drop - Gas Cont. Valve ("wc) 5.0

Press. Drop - S.S.O.V. ("wc) 5.5Job Specials (-S Model No.): Misc. Pipe Loss ("wc) 1

Pressure Out of Main Gas Regulator ("wc) 37

Pressure Out of Pilot Gas Regulator ("wc) 24.4

CFH of Gas Required 4,000

Low Gas Pressure Switch Setpoint ("wc) 22

High Gas Pressure Switch Setpoint ("wc) 53

High Temp. Limit Max. Setpoint(oF) 850

Process Air Press. Switch Setpoint ("wc) 0.5

Exhaust Air Press. Switch Setpoint ("wc) 1.2

Calculated Burner Gap (in.) 1

Number of Flame Rods 2

Total System Volume (cu. Ft.) 2340

Proven Purge Air Flow (SCFM) 2563

Purge Time(Min.) 6.0

REV DATE

R1 7/23/2014

DESCRIPTION

Revised Centerline Height

PTC = Downstream Air Pressure Tap

R17/16/2014 116334

00157542

CARRIER VIBRATING EQUIPMENT

SN28558

@ 4.0 MMBtu/hr

PTB = Upstream Air Pressure Tap

PTA = Main Gas Burner Supply Pressure Tap

PTD = Pilot Gas Burner Supply Pressure Tap

X


This document contains proprietary information which is being disclosed to you in strict confidence. It is not to be copied, given to a third party, or used to furnish any information for making prints, structures or the like embodying

subject matter derived from it, without our express consent. It is to be returned upon demand.STELTER & BRINCK, Ltd.

201 Sales Ave. Harrison, Ohio 45030 ph: 513/367-9300 Fax: 513/367-1524 Website: WWW.STELTERBRINCK.COM


Job Data Sheet


Customer:



Drawings & BOM's

General Arrangement : 01-1633-01 Flame Relay & Ign. Trans. JIC : 01-1633-04B

P&ID: 01-1633-02 Flame Relay & Ign. Trans. JIC BOM : 01-1633-04B BOM

P&ID BOM: 01-1633-02 BOM Support Leg Option : 01-1633-21

Wiring Diagram : 01-1633-03

Remote Operator Panel : 01-1633-04A

Remote Operator Panel BOM : 01-1633-04A BOM

Heater Specifications & Options Operating Conditions

Burner Size 4 feet Air Flow (SCFM) 2,800-3,624

Valve Train Insurance Rating GAP Air Static Pressure @ Heater ("w.c.) 8

Valve Train NEMA Rating NEMA 4 Min.Inlet Air Temp.-Start Up (oF) 0

Fuel Type Natural Gas Min.Inlet Air Temp.-Operating (oF) 10

Valve Train Location Right Side Max. Air Temp.In (oF) 95

Main Gas Regulator Yes Max. Air Temp. Out (oF) 800

Duct Material Carbon Steel Available Fuel Pressure (PSIG) 3-7

Integral Air Diffuser Yes Min / Max Allowable Fuel Pressure (PSIG) 3-7

Duct Support Legs Yes Elevation (ft. above sea level) 564

Duct Centerline Height - From Floor 54" R1 Summer design max temp.(oF) 95

Control Panel Standard Winter design min temp.(oF) 10

Panel Heater No Cont. Panel Loc. (indoor/outdoor) Indoor

PLC Outputs Yes Heater Location (indoor/outdoor) Indoor


Paint Finish: S&B standard Other: ______________________________________ 850 Charcoal


Process Air ΔP between PTB & PTC. ("wc) 1.0

Air Static Pressure @ Heater ("wc) 8

High Fire Burner Gas ΔP between PTA & PTC ("wc) 19

The above pressure includes burner plus header losses

Press. Drop - Gas Cont. Valve ("wc) 5.0

Press. Drop - S.S.O.V. ("wc) 5.5Job Specials (-S Model No.): Misc. Pipe Loss ("wc) 1

Pressure Out of Main Gas Regulator ("wc) 37

Pressure Out of Pilot Gas Regulator ("wc) 24.4

CFH of Gas Required 4,000

Low Gas Pressure Switch Setpoint ("wc) 22

High Gas Pressure Switch Setpoint ("wc) 53

High Temp. Limit Max. Setpoint(oF) 850

Process Air Press. Switch Setpoint ("wc) 0.5

Exhaust Air Press. Switch Setpoint ("wc) 1.2

Calculated Burner Gap (in.) 1

Number of Flame Rods 2

Total System Volume (cu. Ft.) 2340

Proven Purge Air Flow (SCFM) 2563


@ 4.0 MMBtu/hr

PTB = Upstream Air Pressure Tap

PTA = Main Gas Burner Supply Pressure Tap


R17/16/2014 116334

00157542


SN28558



REV DATE

R1 7/23/2014

DESCRIPTION

X


This document contains proprietary information which is being disclosed to you in strict confidence. It is not to be copied, given to a third party, or used to furnish any information for making prints, structures or the like embodying

subject matter derived from it, without our express consent. It is to be returned upon demand.STELTER & BRINCK, Ltd.


P.O. # 00157542

S.O. # SN28558-101

STELTER & BRINCK JOB # 116334

www.stelterbrinck.com ~ 513-367-9300 ~ [email protected]

201 Sales Avenue

Harrison, Ohio

45030

INSTRUCTION MANUAL

Process Air Heaters

Environmental Systems

Steel & Aluminum Mill Equipment

Integrated Packaged Systems

General Industrial Equipment

In-House Test-Firing

Combustion Equipment Parts

Combustion Field Services


TC-SGF-05/28/03

STELTER & BRINCK, Ltd. 201 SALES AVENUE

HARRISON, OHIO 45030-1484

TELEPHONE: 513-367-9300

FAX: 513-367-1524

TABLE OF CONTENTS

TAB# DESCRIPTION

1 INSTALLATION, HANDLING, & STORAGE

2 SAFETY DATA

3 EQUIPMENT DATA

4 SYSTEM OPERATION

5 TROUBLESHOOTING

6 INSPECTIONS, TESTING AND

MAINTENANCE

COMPONENT LITERATURE

7 BURNER INFORMATION

8 BLOWER INFORMATION

9 SHUT-OFF VALVES

10 CONTROL VALVES

11 ELECTRONIC CONTROLLERS

12 FLAME SAFETY

13 MISC.

14 SPARE PARTS

Page 1 GI–SGF-02/21/07

GENERAL INFORMATION

This manual has been written for people who have a thorough understanding of combustion equipment and associated components. Only such personnel should be allowed to operate, troubleshoot, adjust, and maintain the equipment. Read this entire manual prior to performing any work related to this equipment. For additional information, always refer to individual component literature. If you find any errors, omissions, discrepancies, or need help understanding any of the information, contact our engineering dept. *Authority Having Jurisdiction. The organization, office, or individual responsible for enforcing the requirements of a code or standard, or for approving equipment, materials, an installation, or a procedure. The phrase “authority having jurisdiction” is used in NFPA documents in a broad manner, since jurisdictions and approval agencies vary, as do their responsibilities. Where public safety is primary, the authority having jurisdiction may be a federal, state, local, or other regional department or individual such as a fire chief; fire marshal; chief of a fire prevention bureau, labor department, or health department; building official; electrical inspector; or others having statutory authority. For insurance purposes, an insurance inspection department, rating bureau, or other insurance company representative may be the authority having jurisdiction. In many circumstances, the property owner or his or her designated agent assumes the role of the authority having jurisdiction; at government installations, the commanding officer or departmental official may be the authority having jurisdiction. *Reprinted with permission from NFPA 86 Ovens and Furnaces Copyright © 2007 National Fire Protection Association, Quincy, MA 02269. This reprinted material is not the complete and official position of the National Fire Protection Association, on the referenced subject which is represented only by the standard in its entirety.

Page 1 IH-SGF-022308

INSTALLATION & HANDLING

HANDLING

All equipment must be handled carefully. It must be picked up using spreader bars, hooks, sling, and lifting

eyes as appropriate. Some equipment is top heavy, or can be unstable and must be lifted where indicated.

The unit must be handled by experienced machinery and equipment moving contractors.

- Care must be used when handling the equipment so that the components are not damaged.

- Use spreader bars where required to keep cables, straps, chains, etc. at a safe distance from any

piping, conduit, tubing, etc.

- Avoid mechanical shock

- Adjust straps, cables, or chains to insure load is balanced and stable

- All devices must be rated for the intended use & weight

- Use all lifting ears/lugs provided and lift or handle where indicated.

- Lifting ears/lugs attached to individual components must only be used to lift the component and

must not be used for lifting skid assemblies.

- See component literature for handling instructions on individual components

- Lift evenly on both sides.

- Do not allow skid assembly to twist.

- See lifting examples attached

TRANSPORT

- Insure the unit has been properly packaged and protected for the type of transport selected

- Equipment must be properly secured

- Over hung components that cannot bear the mechanical shock of the selected transport, must be

individually braced or removed and separately packaged for transport.

- Protect components/system from weather, damage, dirt, moisture, and excessive temperatures.

STORAGE

- It is recommended placing equipment in a clean and dry location.

- Insure the system and components are protected from weather, dirt, insects, moisture, and

excessive temperatures.

- All open ducts, electrical, piping, and tubing connections should be sealed.


INSTALLATION

GENERAL

- A thorough inspection should be made to insure components are clean and free of damage. Any

parts that appear to be broken, bent, or damaged must be replaced.

- Disconnect or isolate any utilities to be connected to the equipment

- Equipment must be secured in place by bolting/anchoring with the holes provided or other

appropriate means.

- All ducting, piping, etc connecting to equipment must be independently supported unless approved

otherwise by equipment manufacturer.

� Flex connectors should be considered at locations where thermal expansion or

vibration could cause damage due to stress.

- Clearances around the unit for servicing and distance to combustibles should be maintained

according to applicable codes and the authority having jurisdiction.

o Minimum Recommended

� 24” around equipment for inspection

� 36” in front of valve trains and control panels for servicing

• All access doors and control enclosure doors must be able to swing

open 90 deg.

- The flooring around the equipment should be non-combustible

- A sufficient fresh air supply as required for combustion, ventilation, and dilution of any flue gases

must be provided. Venting systems must comply with the appropriate codes and the authority

having jurisdiction.

- Noise & surface temperature are affected by equipment environment. Be certain to take this into

account when locating the equipment.

PIPING

- Piping must not interfere with maintenance, inspection, & service

- A drip leg and strainer must be installed (if not supplied) at the inlet connection to the unit.

- The supply piping must have the correct size to deliver the correct volume and pressure required

for maximum operating conditions.

- Piping must comply with local codes and the authority having jurisdiction

- Over pressure protection devices shall be provided by the user to prevent the pressure in the piping

system from exceeding valve ratings that would cause unsafe operation of any connected

utilization equipment.

- All components that have vents must be piped to a safe location.

o The vent pipe should be designed per local code and must not create back pressure on any

other items that have a common vent line.

- Shut off main gas supply, leak test valve, and purge supply piping according to code prior to

performing any work.

- Prior to acceptance and initial operation, all piping installations shall be inspected and tested.

WIRING

- See the unit nameplate and wiring diagram for proper electrical supply. Wiring must be

completed according the supplied wiring diagrams. Wiring completed at the factory should not be

disturbed. All wiring notes must be adhered to for proper operation.

- All wiring must comply with local codes and must be acceptable to the authority having

jurisdiction.


DUCT CONNECTIONS

- When designing connecting ductwork, insure the proper size flange, holes, and bolts are sufficient

for the pressures and support of the weight.

- Use suitable gaskets that can handle the max operating temperatures and pressures to insure

against leaks.

- All ductwork must be supported and/or guyed as required by code to resist wind loads or seismic

forces.

- Maintain proper clearances to combustibles according to code for hot exhaust and process ducts.

RELOCATION & DECOMMISSIONING

- Shut off gas supply, leak test isolation valve, and purge gas supply piping prior to disconnecting.

- Disconnect all electrical power and pneumatic service.

- Do not disassemble any bracing, or loosen any fasteners, without first making certain that the

equipment is properly supported, inherently stable and will not topple.

- Lift and/or handle all equipment where indicated.

- Refer to individual component literature for additional information

- Handle and despose of materials as described in the MSD sheets (MSDs applicable to equipment

are provided in the safety data section)

Page 1 SD-SGF-11/12/02

SAFETY DATA

- Only qualified personnel should be allowed to operate, adjust, and maintain equipment.

- Always isolate utilities and follow safety standards set up by the authority

having jurisdiction when performing maintenance.

- Never operate equipment without guards or covers in place over electrical or mechanical hazards.

- Do not operate without access doors securely fastened close.

- The equipment may have hot surfaces. Wear protective clothing when

working on or near the unit.

- Equipment must be well maintained and operated within the design parameters. Improper operation could damage equipment or cause fires and explosions.

- Never bypass any safety feature or limit device.

o Fire or explosion could occur.

- Any modifications to the equipment must be performed by a qualified agency.

o All modification must be properly documented.

- A pre-purge of fresh air is required prior to burner ignition in order to avoid explosions. Do not by-pass or reduce purge timer settings.

- For additional hazards refer to individual component literature.

Material Safety Data Sheet

Material Name: Mineral Wool Insulation

Page 1 of 7 Issue Date: November 16, 2010 Replaces Issue: March 1, 2010

1. Identification:

1.1 Product Generic Name: Mineral Wool Insulation 1.2 Product Use: Commercial, Industrial and Residential Insulation

1.3 Products:

CavityRock®, ConRock, CurtainRock®, Roxul DrainBoard®, Enerwrap®, Flexibatt, ComfortBatt™, RHM, RHT®, AFB®, RoxulPlus, RW®, Roxul Safe®, Roxul Safe’n’Sound, Techton® 1200, Techton® 1200 Marine, SturdiRock®, Roxul FireWall, RockBoard, TopRock®, MonoBoard™, FabRock™

1.4 Company Address: Roxul Inc. 551 Harrop Drive Milton, Ontario Canada L9T 3H3 1.5 Web Site: www.roxul.com 1.6 If further information is required, please call or fax Roxul Inc. Telephone: 1-800-265-6878 or 905-878-8474 Fax: 905-878-8077

2. Information on Ingredients:

Ingredient Name

CAS Number %

Mineral Fiber

RN 65997-17-3 94-99

Cured Urea Extended Phenolic Formaldehyde Binder

25104-55-6 1-6

3. Hazards Identification:

3.1 Appearance and Odor: Grey, green fibrous batt or board. 3.2 Emergency Overview: Acrid smoke may be generated during a fire. Exposure to dust may be irritating to the eyes, nose and throat. 3.3 Potential Health Effects: 3.3.1 Inhalation: Temporary mechanical irritation of the upper respiratory tract (scratchy throat, coughing,

congestion) may result from exposures to dusts and fibers in excess of applicable exposure limits. 3.3.2 Skin Contact: Dusts and fibers may cause temporary mechanical irritation (itching) or redness to the

skin. 3.3.3 Eye Contact: Dusts and fibers may cause temporary mechanical irritation (itching) or redness to the

eyes.

3.3.4 Ingestion: Ingestion of this product is unlikely and not intended under normal conditions of use. Ingestion of this product may cause gastrointestinal irritation.

3.3.5 Existing Medical Conditions: Pre-existing chronic eye, skin and respiratory conditions may temporarily worsen due to exposure to dusts and fibers.




4. First-Aid Measures:

4.1 Inhalation: If irritation occurs, remove the affected person to fresh air. Drink water, and blow nose, to clear

dusts and fibers from throat and nose. If irritation persists, consult a physician. 4.2 Skin: If irritation occurs, do not rub or scratch. Rinse under running water prior to washing with mild soap

and water. Use a washcloth to help remove fibers. If irritation persists, consult a physician. 4.3 Eyes: If irritation occurs, flush eyes with plenty of water for at least 15 minutes. Do not rub the eyes. Consult a

physician if irritation persists. 4.4 Ingestion: Ingestion of this product is unlikely and not intended under normal conditions of use. If it does

occur, rinse mouth with plenty of water to help remove dust and fibers, and drink plenty of water to help reduce potential gastrointestinal irritation. Do not induce vomiting unless directed to do so by a physician.

5. Fire-Fighting Measures:

The products are non-combustible and do not pose a fire hazard. However, packaging material may burn.

5.1. Suitable extinguishing media: Water, foam, carbon dioxide or dry powder

5.2 Extinguishing media which must not be used for safety reasons: None 5.3 Combustion products: Carbon dioxide, carbon monoxide and trace gases 5.4 Special protective equipment for fire-fighters: Observe normal fire fighting procedures 5.5 Flash point: None Flash Point Method Used: Not Applicable Upper Flammable Lower Flammable Limit (UFL): Not Applicable Limit: Not Applicable Autoignition: Not Applicable Explosive Properties: Not Applicable

6. Accidental Release Measures:

6.1 Containment Procedures: Pick up large pieces and scoop up dusts and fibers after they have settled out of air.

These materials will disperse and settle along the bottom of waterways and ponds. It cannot easily be removed once it is waterborne, but is considered non-hazardous in water.

6.2 Cleanup Procedures: Use OSHA-recommended work practices and protective equipment as described in

Section 8 of this Material Safety Data Sheet. Avoid generating airborne dusts and fibers during cleanup. Do not use compressed air. Vacuum dusts and fibers. Place material in an appropriate container for disposal as non-hazardous waste.

6.3 Response Procedures: Isolate area. Keep unnecessary personnel away. If dry methods or compressed air are

used to collect dusts and fibers, all personnel in the area should wear OSHA-approved protective equipment (see Section 8 of this Material Safety Data Sheet).




7. Handling and Storage:

7.1 General Precautions:

- Utilize OSHA-recommended work practices and protective equipment when using the products (see Section 8 of this Material Safety Data Sheet).

7.2 Handling:

- Unpack material at application site to avoid unnecessary handling of product. - Keep work areas clean. Avoid unnecessary handling of scrap material and debris by placing such materials

in suitable containers, which should be kept as close to the work area as possible. - Ensure good ventilation. Local exhaust ventilation may be required if the method of use produces dust

levels which exceed applicable exposure limits (see Section 8 of this Material Safety Data Sheet). - Avoid excessive eye and skin contact with dusts and fibers. - Use recommended cleanup procedures to avoid buildup of dusts and fibers in the work area.

7.3 Storage: - Keep material in original packaging until it is to be used. - Store material to protect against adverse conditions including precipitation.

8. Exposure Controls/Personal Protection: 8.1 Exposure Guidelines: 8.1.1 General Product Information: Follow all applicable exposure limits. Local regulations may apply. Roxul

recommends that users of the products adhere to the OSHA-recommended PEL of 1 f/cc TWA (fibers longer than 5 m with diameters less than 3 m). This recommended PEL, together with recommended work practices and personal protective equipment, were adopted in a Health and Safety Partnership Program (HSPP) agreement in 1999 between OSHA and the North American Insulation Manufacturers Association (NAIMA), of which Roxul is a member. Adherence to the OSHA-recommended PEL, work practices and protective equipment in the HSPP is expected to provide appropriate protection against all inhalation-related health risks that may be associated with exposures to mineral wool fibers (ACGIH 1997; NAIMA 1999; OSHA 1999; National Research Council 2000, IARC 2001), and to minimize eye and skin irritation.

8.1.2 Component Exposure Limits:

Source Legal or Recommended Exposure Limit Exposure

OSHA 1 f/cc TWA (recommended) Synthetic Vitreous Fibers, > 5 m length, < 3 m diameter

ACGIH 1 f/cc TWA (threshold limit value – TLV) Synthetic Vitreous Fibers, > 5 m length, < 3 m diameter

OSHA 15 mg/m3 TWA-PEL (total particulate) 5 mg/m3 TWA-PEL (respirable particulate)

Inert dust and particulates not otherwise regulated

ACGIH 10 mg/m3 TWA-TLV (inhalable particulate) 3 mg/m3 TWA-TLV (respirable particulate)

Particulates not otherwise classified, containing no asbestos and <1% crystalline silica




8.2 Equipment and Work Practices: Follow OSHA-recommended equipment and work practices. A complete copy of these practices can be obtained from Roxul Inc. (see Section 1 of this Material Safety Data Sheet), and is available on the OSHA website (http://www.osha.gov/SLTC/syntheticmineralfibers). 8.2.1 Follow OSHA-recommended safe handling practices listed in Section 7.2 above. 8.2.2 Where feasible, general dilution ventilation or local exhaust ventilation should be used as necessary to

maintain exposures below applicable exposure limits. Dust collection systems should be used in cutting or machining operations and may be needed when using power tools.

8.2.3 Follow OSHA-recommended work practices when fabricating, installing or removing product. 8.3 Personal Protective Equipment:: 8.3.1 Respiratory:

8.3.1.1 General: In poorly ventilated areas when dusty conditions exist and/or dust levels exceed applicable exposure

limits, wear a NIOSH certified dust respirator with an efficiency rating of N95 or higher. Use disposable face masks complying with NIOSH respirator standards, such as a 3M Model 8210 (or 8710) (3M Model 9900 in high humidity environments) or equivalent. For exposures up to five times the established exposure limits use a quarter-mask respirator, rated N95 or higher; and for exposures up to ten times the established exposure limits use a half-mask respirator (e.g. MSA’s DM-11, Racal’s Delta N95, 3M’s 8210), rated N95 or higher. For exposures up to 50 times the established exposure limits use a full-face respirator, rated N99 or higher.

8.3.1.2 Specific Operations: In poorly ventilated areas when dusty conditions exist and/or dust levels exceed applicable exposure

limits, wear a NIOSH certified dust respirator with an efficiency rating of N95 or higher, such as a 3M Model 8210 (or 8710) (3M Model 9900 in high humidity environments) or equivalent, when fabricating, installing or removing product.

8.3.2 Skin:

Wear loose fitting, long sleeved and long-legged clothing to prevent irritation. A head cover is also recommended, especially when working with material overhead. The use of suitable gloves is also recommended. Skin irritation cannot occur if there is no contact with the skin. Do not tape sleeves or pants at wrists or ankles. Remove fibers from the work clothes, before leaving work to reduce potential skin irritation. If working in a very dusty environment it is advisable to shower and change clothes

8.3.3 Eyes/Face:

Wear safety goggles or safety glasses with side shields. 9. Physical and Chemical Properties: 9.1 Appearance: Grey, green fibrous batt or board

9.2 State: Solid

9.3 Odor: May have slight resin odour

9.4 Boiling point:: n.a.

9.5 Melting point: Approximately 2150 F (1177 C)

9.6 Vapour pressure: n.a.

9.7 Vapour Density: n.a.

9.8 Specific Gravity: n.a.

9.9 Evaporation Rate: n.a.

9.10 Freezing Point: n.a.

9.11 Viscosity: n.a.

9.12 Solubility: Insoluble (H2O)

9.13 Partition coefficient: n.a.

n.a. = not applicable




10. Stability and Reactivity: 10.1 Stability: Stable 10.2 Reactivity: Not reactive 10.3 Thermal decomposition products: Primary combustion products of the cured urea extended phenolic formaldehyde binder, when heated above

390 F (200 C), are carbon monoxide, carbon dioxide, ammonia, water and trace amounts of formaldehyde. Other undetermined compounds could be released in trace quantities. Emission usually only occurs during the first heating. The released gases may be irritating to the eyes, nose and throat during initial heat-up. Use appropriate respirators (air supplied) particularly in tightly confined or poorly ventilated areas during initial heat-up.

10.4 Hazardous Polymerization: Will not occur 10.5 Incompatible Materials: This product reacts with hydrofluoric acid.

11. Toxicological Information: 11.1 Acute Toxicity:

Coarse fibers and dust from mineral wool products can cause temporary mechanical irritation (itching, redness) of the skin, and of the mucous membranes in the eyes and in the upper respiratory tract (nose and throat). The itching and possible inflammation are a mechanical reaction to dust and coarse fibers (of more than about 5 µm in diameter), and are not damaging in the way chemical irritants may be. They generally abate within a short time after the end of exposure. When products are handled continually, the skin itching generally diminishes.

11.2 Chronic Toxicity:

11.2.1 Summary: In October 2001, IARC completed a re-evaluation of respirable mineral wool fibers and classified them in Group 3 (not classifiable as to their carcinogenicity to humans). A summary of the most important scientific studies appears below:

11.2.2 Human Data:

11.2.2.1 The possible carcinogenic effects of exposure to mineral wool fibers has been evaluated in a number of

epidemiological (human) studies. Most of this research, including large long-tem studies of mineral wool production workers in the U.S. and Europe, has been sponsored or supported by the North American and International thermal insulation industries, including Roxul Inc. Published reports of the early results of these studies identified significantly elevated rates of respiratory cancer in several subcohorts of the worker populations under evaluation (e.g., Simonato et al. 1987; Enterline et al. 1987). However, the studies had several methodological limitations, including failure to control for confounding exposures to other possible causes of the elevated cancer risk, including tobacco use and occupational exposures to recognized carcinogens such as asbestos. For these reasons, the authors of these reports did not interpret the results as establishing an association between exposure to mineral wool fibers and an increased risk of cancer. Several of these earlier reports formed part of the basis for IARC’s previous classification of mineral wool fibers in Group 2B (possibly carcinogenic to humans) (IARC 1987).

11.2.2.2 Follow-up studies, including case-control studies designed to exclude the contribution of confounding

exposures to the cancer experience of the study populations, found no evidence that mineral wool fibers are associated with an increased cancer risk (Marsh et al. 1996; Wong, et al. 1991; Kjaerheim et al. 2001). In announcing the new Group 3 classification for mineral wool fibers, IARC stated: “Epidemiologic studies published during the 15 years since the previous IARC Monographs review of these fibers in 1988 provide no evidence of increased risks of lung cancer or of mesothelioma (cancer of the lining of the body cavities) from occupational exposures during manufacture of these materials” (IARC 2001).

11.2.3 Animal Data:

11.2.3.1 Several studies of intraperitoneal injection of high doses of mineral wool fibers have produced

significant increases in the incidence of mesothelioma (IARC 2002). The intraperitoneal injection studies formed part of the basis for IARC’s previous (IARC 1987) Group 2B classification for mineral wool fibers. Leading scientists agree that intraperitoneal injection studies (i.e., surgical implantation or injection into the chest or abdomen) are the least relevant type of animal study for evaluating




potential human risk for fiber exposures, because such studies bypass the animals’ natural defense mechanisms and involve a type and pattern of exposure (implantation of a high dose early in life) that does not mimic human patterns of exposure (inhalation of much lower doses over a lifetime) (National Research Council 2000).

11.2.3.2 A well-designed long-term inhalation study in rats exposed to mineral wool fibers found no significant

increase in lung tumor incidence, and no mesotheliomas (IARC 2002). Likewise, in two intratracheal instillation studies of mineral wool fibers, no significant increase in the incidence of lung tumors or mesotheliomas was found (IARC 2002). Inhalation studies are regarded as the most relevant type of animal data for evaluating potential human risk, and intratracheal instillation studies, while less relevant, are considered valuable for the initial screening of fibrous compounds (National Research Council 2000). Thus, evaluating all the available animal studies in conjunction with the human data, IARC’s most recent review finds “inadequate evidence overall for any cancer risk” from mineral wool fibers (IARC 2001).

11.3 Evaluations of Potential Carcinogenicity:

Source Classification Description

IARC Group 3 Not Classifiable as a Human Carcinogen

ACGIH Group A3 Confirmed Animal Carcinogen with Unknown Relevance to Humans

12. Ecological Information:

12.1 Ecotoxicity: No data available for the products. The products are stable, are not expected to cause harm to

animals, plants or fish, and have no other known adverse environmental effects. 12.2 Environmental Fate: No data available for the products.

13. Disposal Considerations: 13.1 US EPA Waste Number & Descriptions:

13.1.1 General Product Information: The products, as supplied, are not expected to be a characteristic hazardous waste under RCRA if discarded.

13.1.2 EPA Waste Numbers: No EPA Waste Numbers are applicable for this product's components. 13.2 Disposal Instructions: Product is not considered a hazardous waste. Dispose of waste material according to

Federal, State, Provincial, and Local environmental regulations.

14. Transport Information: 14.1 General: No special precautions.

14.2 US DOT Information: This product is not classified as a hazardous material for transport.

15. Regulatory Information: 15.1 U.S. Regulations: 15.1.1 Toxic Substances Control Act (TSCA): All components in this product are listed, as required, on the US

EPA TSCA inventory, or are not required to be listed

15.1.2 CERCLA: Includes mineral fiber emissions from facilities manufacturing or processing glass rock or slag fibers (or other mineral derived fibers) of average diameter 1 micrometer or less; Statutory RQ = 1 pound (.454 kg); no final RQ is being assigned to the generic or broad class (related to Fine mineral fibers).




15.1.3 Clean Air Act: Mineral wool fiber appears on the Clean Air Act-1990 Hazardous Air Pollutants List. 15.2 State and Local Regulations: State, Provincial, and Local regulations not identified in this Material Safety Data

Sheet may apply. 15.3 WHMIS: The products have been classified in accordance with the hazard criteria of the Controlled Product

Regulations and this Material Safety Data Sheet contains all the information required by the Controlled Product Regulations

15.3.1: WHMIS IDL: No components are listed on the IDL 15.3.2: WHMIS Classification: No components are classified as controlled products.

16. Further Information: 16.1 Potential Health Effects:

IARC Monograph Man-made Vitreous Fibres, press release October 2001 Safety in the Use of Mineral and Synthetic Fibers, Occupational Safety and Health Series. International Labor Office (ILO).

Information about “Health and Safety Research on Rock- and Slag-wool” can be obtained from the North American Insulation Manufacturers Association (NAIMA), 44 Canal Center Plaza, Suite 310, Alexandria, VA 22314, USA). Home-page: http://www.naima.org

16.2 Key/Legend:

ACGIH = American Conference of Governmental Industrial Hygienists; CAA = Clean Air Act; CAS = Chemical Abstracts Service; CERCLA = Comprehensive Environmental Response, Compensation and Liability Act; DOT = Department of Transportation; EPA = Environmental Protection Agency; HMIS = Hazardous Material Identification System; HSPP = Health and Safety Partnership Program; IARC = International Agency for Research on Cancer; MSDS = Material Safety Data Sheet; NAIMA = North American Insulation Manufacturers Association; NFPA = National Fire Protection Association; NIOSH = National Institute for Occupational Safety and Health; OSHA = Occupational Safety and Health Administration; PEL = Permissible Exposure Limit; RCRA = Resource Conservation and Recovery Act; RQ = Reportable Quantity; SVF = synthetic vitreous fibers; TSCA = Toxic Substances Control Act; TWA = time-weighted average; WHMIS = Workplace Hazardous Materials Information System.

16.3 References: Complete citations, or copies, of all references cited in this Material Safety Data Sheet can be

obtained from Roxul Inc. (see Section 1). 16.4 Accuracy: The information contained herein is based upon data considered to be accurate. However, no

warranty is expressed or implied regarding the accuracy of these data, the results to be obtained from the use thereof, or that any such use will not infringe upon any patent. This information is furnished as a guide only and upon the condition that the person receiving it shall make tests to determine the accuracy and suitability for his or her own purpose.

http://www.naima.org/

ED-SGF-05/22/03

EQUIPMENT DATA

- Refer to job data sheets, P&ID, and/or wiring diagrams for set points of control &

limit devices, design conditions, and minimum/maximum operating parameters.

- For burner set-up pressures & methodology refer to job data sheets, general

arrangement drawings, P&ID drawings, burner literature, and control component

literature.

- Maximum conditions are those at which limit device settings should not exceed.

The control set point/operating points must be within these conditions.

- Prior to any work being performed, insure the drawings used are the latest

revisions.



Job Data Sheet


Customer:



Drawings & BOM'sGeneral Arrangement : 01-1633-01 Flame Relay & Ign. Trans. JIC : 01-1633-04B

P&ID: 01-1633-02 Flame Relay & Ign. Trans. JIC BOM : 01-1633-04B BOMP&ID BOM: 01-1633-02 BOM Support Leg Option : 01-1633-21

Wiring Diagram : 01-1633-03Remote Operator Panel : 01-1633-04A

Remote Operator Panel BOM : 01-1633-04A BOMHeater Specifications & Options Operating Conditions

Burner Size 4 feet Air Flow (SCFM) 2,800-3,624Valve Train Insurance Rating GAP Air Static Pressure @ Heater ("w.c.) 8

Valve Train NEMA Rating NEMA 4 Min.Inlet Air Temp.-Start Up ( o F) 0Fuel Type Natural Gas Min.Inlet Air Temp.-Operating ( o F) 10

Valve Train Location Right Side Max. Air Temp.In ( o F) 95Main Gas Regulator Yes Max. Air Temp. Out ( o F) 800

Duct Material Carbon Steel Available Fuel Pressure (PSIG) 3-7Integral Air Diffuser Yes Min / Max Allowable Fuel Pressure (PSIG) 3-7Duct Support Legs Yes Elevation (ft. above sea level) 564

Duct Centerline Height - From Floor 54" R1 Summer design max temp.( o F) 95Control Panel Standard Winter design min temp.( o F) 10Panel Heater No Cont. Panel Loc. (indoor/outdoor) IndoorPLC Outputs Yes Heater Location (indoor/outdoor) Indoor


Paint Finish: S&B standard Other: 850 Charcoal


Process Air ΔP between PTB & PTC. ("wc) 1.0Air Static Pressure @ Heater ("wc) 8

High Fire Burner Gas ΔP between PTA & PTC ("wc) 19The above pressure includes burner plus header losses

Press. Drop - Gas Cont. Valve ("wc) 5.0Press. Drop - S.S.O.V. ("wc) 5.5

Job Specials (-S Model No.): Misc. Pipe Loss ("wc) 1Pressure Out of Main Gas Regulator ("wc) 37Pressure Out of Pilot Gas Regulator ("wc) 24.4

CFH of Gas Required 4,000Low Gas Pressure Switch Setpoint ("wc) 22High Gas Pressure Switch Setpoint ("wc) 53

High Temp. Limit Max. Setpoint( o F) 850Process Air Press. Switch Setpoint ("wc) 0.5Exhaust Air Press. Switch Setpoint ("wc) 1.2

Calculated Burner Gap (in.) 1Number of Flame Rods 2

Total System Volume (cu. Ft.) 2340Proven Purge Air Flow (SCFM) 2563


@ 4.0 MMBtu/hr

PTB = Upstream Air Pressure TapPTA = Main Gas Burner Supply Pressure Tap


R17/16/2014 116334

00157542


SN28558



REV DATER1 7/23/2014

DESCRIPTION

X


This document contains proprietary information which is being disclosed to you in strict confidence. It is not to be copied, given to a third party, or used to furnish any information for making prints, structures or the like embodying subject matter derived from it, without our express consent. It is to be returned upon demand.

STELTER & BRINCK, Ltd.

1 of 2

Device Type and Version UDC2500 v3.00

Groups Functions Units Actual Values Range

SetPoints SetPoint 1 F 0 0 .. 300 SetPoint 2 F 120 (TBD) 0 .. 300

Tuning Prop. Band % 15 (TBD) 0 .. 1000 Rate in Minutes Min 0.25 (TBD) 0.00 .. 10.00 Reset in RPM RPM 1.4 (TBD) 0.02 .. 50.00 Security Code 0 0 .. 9999 Lockout VIEW

Auto/Manual Key DISRun/Hold Key DISSP Select Key DIS

SetPoint Ramp SetPoint Ramp DIS SetPoint Rate ENAB Rate Up Value Hrs 500 (TBD) 0 .. 9999 Rate Down Value Hrs 0 0 .. 9999

Accutune III Fuzzy Logic DIS Accutune Enable DIS

Algorithm Control Algorthm PIDA Timer DIS

Output Algorithm Output Algorithm CUR Current Range 4-20

Input 1 Input 1 Type K M Input 1 High Rng F 1200 -20 .. 1200 Input 1 Low Rng F -20 -20 .. 1200 Input 1 Ratio 1 -20.00 .. 20.00 Input 1 Bias F 0 -999.0 .. 9999.0 Input 1 Filter Sec 1 0 .. 120 Input 1 Burnout UP

Input 2 Input 2 Type DIS Transmitter 2 Input 2 High Rng F -999 .. 9999 Input 2 Low Rng F -999 .. 9999 Input 2 Ratio -20.00 .. 20.00 Input 2 Bias F -999.0 .. 9999.0 Input 2 Filter Sec 0 .. 120

116334 MASTER CONTROLLER CONFIGURATION SHEET

2 of 2


Control Num. of PID Sets ONE Local SetPoints TWO Remote SP Source NONE SP Tracking Enab NONE Power Up Mode ALSP SetPoint Hi Val. F 300 (TBD) -20 .. 1200 SetPoint Low Val F -20 -20 .. 1200 Control Action REV Output Hi Limit % 99 -5.0 .. 105.0 Output Low Limit % 1 -5.0 .. 105.0 FailSafe Output % 0 0.0 .. 100.0 FailSafe Mode NO L Prop Band / Gain PB Minutes or RPM RPM

Options Auxiliary Output PROC 0 PCT -20 -20 .. 1200 100 PCT 1200 -20 .. 1200 Current Range 4 - 20 Dig Inp 1 Type SP2

Digital In1Combo DIS

Communications Comm Address 3 1 .. 99 Comm State DIS IR Enable DIS Baud Rate 19.2K Response Delay 1 1 .. 500

Alarms Alarm1 SP1 Type NONE Alarm1 SP2 Type NONE Alarm2 SP1 Type NONE Alarm2 SP2 Type NONE Alarm Hysteresis % 0.1 0.0 .. 100.0 Alarm Blocking DIS Diagnostic Alarm DIS

Display Decimal Points NONE Temperature Unit F Power Freq (Hz) 60 LWRDSP ENAB Language ENGL TCDIAG ENAB

CONFIGURATION SHEET (CONTINUED)116334 MASTER CONTROLLER

1 of 2

Device Type and Version UDC2500 v3.00


SetPoints SetPoint 1 F 0 0 .. 750 SetPoint 2 F 0 0 .. 750

Tuning Prop. Band % 15 (TBD) 0 .. 1000 Rate in Minutes Min 0.15 (TBD) 0.00 .. 10.00 Reset in RPM RPM 1 (TBD) 0.02 .. 50.00 Security Code 0 0 .. 9999 Lockout VIEW

Auto/Manual Key DISRun/Hold Key DISSP Select Key DIS

SetPoint Ramp SetPoint Ramp DIS SetPoint Rate DIS

Accutune III Fuzzy Logic DIS Accutune Enable DIS

Algorithm Control Algorthm PIDA Timer DIS

Output Algorithm Output Algorithm CUR Current Range 4-20

Input 1 Input 1 Type K M Input 1 High Rng F 1200 -20 .. 1200 Input 1 Low Rng F -20 -20 .. 1200 Input 1 Ratio 1 -20.00 .. 20.00 Input 1 Bias F 0 -999.0 .. 9999.0 Input 1 Filter Sec 1 0 .. 120 Input 1 Burnout UP

Input 2 Input 2 Type 4-20 Transmitter 2 LIN Input 2 High Rng F 700 -999 .. 9999 Input 2 Low Rng F 0 -999 .. 9999 Input 2 Ratio 1 -20.00 .. 20.00 Input 2 Bias F 0 -999.0 .. 9999.0 Input 2 Filter Sec 1 0 .. 120

116334SLAVE (HEATER) CONTROLLER CONFIGURATION SHEET

2 of 2


Control Num. of PID Sets ONE Local SetPoints ONE Remote SP Source INP2 SP Tracking Enab NONE Power Up Mode ARSP SetPoint Hi Val. F 850 -20 .. 1200 SetPoint Low Val F 0 -20 .. 1200 Control Action REV Output Hi Limit % 100 -5.0 .. 105.0 Output Low Limit % 0 -5.0 .. 105.0 FailSafe Output % 0 0.0 .. 100.0 FailSafe Mode NO L Prop Band / Gain PB Minutes or RPM RPM

Options Auxiliary Output PROC 0 PCT -20 -20.0 .. 1200.0 100 PCT 1200 -20.0 .. 1200.0 Current Range 4 - 20 Dig Inp 1 Type NONE

Communications Comm Address 3 1 .. 99 Comm State DIS IR Enable DIS Baud Rate 19.2K Response Delay 1 1 .. 500

Alarms Alarm1 SP1 Type NONE Alarm1 SP2 Type NONE Alarm2 SP1 Type NONE Alarm2 SP2 Type NONE Alarm Hysteresis % 0.1 0.0 .. 100.0 Alarm Blocking DIS Diagnostic Alarm DIS

Display Decimal Points NONE Temperature Unit F Power Freq (Hz) 60 LWRDSP ENAB Language ENGL TCDIAG ENAB

116334 SLAVE (HEATER) CONTROLLER CONFIGURATION SHEET (Continued)

SO-SGF-07/09/04

TYPICAL SAFETY LIMITS & INTERLOCK DESCRIPTION

A. RUNNING INTERLOCKS Running interlocks are those safe operating conditions that must be proven prior to the purge sequence and ignition of the burner and/or throughout the operation of burner. Safety control interlocks with the burner operation consist of but are not limited to the following: High Fuel Pressure Switch – Used to detect high and unsafe fuel pressures. Low Fuel Pressure Switch – Used to detect low and unsafe fuel pressures Temperature Limit Switch – Used to detect high or low operating temperatures. Air Flow/Pressure Switch – Used to prove that sufficient airflow or pressure is present. Motor Starter Contacts – Used to electrically interlock blowers providing air flow essential to the system operation. Customer Limits – Used to interlock all other required process conditions associated with the operation of the system. B. PRE-IGNITION INTERLOCKS Pre-ignition interlocks are those safe operating conditions that must be proven prior to the ignition of the burner. Pre-ignition interlocks consist of but are not limited to the following: Low Fire Switch – Used to prove that the fuel or combustion air-modulating valve is properly positioned prior to each ignition attempt to assure a reduced firing rate for safe and reliable ignition. C. PRE- PURGE INTERLOCKS Pre-purge interlocks are those safe operating conditions that must be proven prior to and during the purge sequence. Pre-purge interlocks consist of but are not limited to the following: Purge Air Flow Switch – Used to prove that the minimum purge airflow is maintained throughout the purge cycle. High Fire Switch – On systems which use the combustion air as a source of purge air and also control the burner firing rate by controlling the combustion air; this switch proves the control valve is properly positioned to provide the required purge air flow. Proof of Closure Switches – These switches prove that the fuel safety shut-off valves are closed. (pre-purge & pre-ignition)

NOTE: VALUES FOLLOWED BY (TBD) ARE PRELIMINARY SETTINGS. FINAL SETTINGS ARE TO BE DETERMINED AT START-UP!

Description Units Range Setting

SP Set Point Degrees r1 to r2 200 Deg. F (TBD)

r0 Differential or hysteresis Degrees 1 to 99 1 Deg. F

r1 Lower value for SP Degrees 0 to r2 0 Deg. F. (TBD)

r2 Higher value for SP Degrees r1 to 999 250 Deg F. (TBD)

r3 Reset of control Range Aut/hoL/PuP hoL

d0 High or low limit temperature Option Hi/Lo Hi

c0 Minimum stopping time Seconds 0 to 999 1 sec.

c2 Output status with probe error Range Off/On Off

c3 Energize on limit condition Range No/Yes No

P1 Ambient probe adjustment Degrees -30 to 30 0 Deg. F.

P5 Ambient probe type Range tcJ,tch,tcS tch

P6* Probe Response Numeric 0 to 3 3

H1* Display Reading Range PU/SP PU

H5 Access code to parameters Numeric 0 to 255 0*= Parameter not available in models earlier than v2.4

Job 116334 Exhaust High Temperature LimitTSF Series v2.4

Configuration Record Sheet

NOTE: VALUES FOLLOWED BY (TBD) ARE PRELIMINARY SETTINGS. FINAL SETTINGS ARE TO BE DETERMINED AT START-UP!

Description Units Range Setting

SP Set Point Degrees r1 to r2 850 Deg. F (TBD)

r0 Differential or hysteresis Degrees 1 to 99 1 Deg. F

r1 Lower value for SP Degrees 0 to r2 0 Deg. F. (TBD)

r2 Higher value for SP Degrees r1 to 999 900 Deg F. (TBD)

r3 Reset of control Range Aut/hoL/PuP hoL

d0 High or low limit temperature Option Hi/Lo Hi

c0 Minimum stopping time Seconds 0 to 999 1 sec.

c2 Output status with probe error Range Off/On Off

c3 Energize on limit condition Range No/Yes No

P1 Ambient probe adjustment Degrees -30 to 30 0 Deg. F.

P5 Ambient probe type Range tcJ,tch,tcS tch

P6* Probe Response Numeric 0 to 3 3

H1* Display Reading Range PU/SP PU

H5 Access code to parameters Numeric 0 to 255 0*= Parameter not available in models earlier than v2.4

Job 116334 Heater High Temperature LimitTSF Series v2.4

Configuration Record Sheet

SO-AHDX-HON-080213

STANDARD AHDX STYLE AIR HEATER

START-UP/SHUT-DOWN SEQUENCE

WARNING: Prior to every start up, ensure that no personnel are inside unit and all access doors

are firmly in place.

WARNING: initial adjustment and light-off should be undertaken only by trained and experienced

personnel familiar with combustion systems. If fuel is allowed to enter the combustion chamber

for longer than a few seconds without ignition, an explosive mixture could result.

WARNING: Never operate the burner system without the exhaust and other system blowers in

operation and verification of proper exhaust flow.

CAUTION: Shut down or loss of fans/process flow at elevated temperatures without a cool down

cycle can be adverse to some system components. It is recommended to restore system flow as soon

as possible when this occurs.

NOTICE: During extended shut downs, close main manual fuel valve and disconnect main power

from equipment.

A. PRELIMINARY CHECKS

CAUTION: ensure that all pipe work is free of debris, welding slag, etc. Before the equipment is

put into service after initial commissioning, maintenance or long periods of shutdown. NOTE: Start any additional equipment according to system supplier instructions.

1. Open all gas cocks.

2. Check for proper fuel supply and pressure.

3. Switch “ON” the 10 amp circuit breaker in the burner control panel and pull the “EMERGENCY STOP”

pushbutton to the “ON” position.

B. NORMAL START-UP 1. Start any additional system equipment according to manufacturer’s instructions.

2. Turn the power selector switch to the “ON” position.

3. Initiate the burner start sequence.

When all the limits in the circuit are satisfied and the low fire switch on the gas modulating valve is made, purging

of the air heater will begin. “LIMITS” shall include all running interlocks, pre-ignition interlocks and purge

interlocks as described below.

SO-AHDX-HON-080213

LIMITS

PROOF OF CLOSURE SWITCHES IN MAIN SHUT OFF VALVES

BURNER START CONTACT

AUX. SYSTEM INTERLOCKS (BY OTHERS)

PROCESS BLOWER MOTOR STARTER/RUNNING CONTACTS

HEATER OUTLET HIGH TEMPERATURE LIMIT

EXHAUST AIR HIGH TEMPERATURE LIMIT

HIGH GAS PRESSURE SWITCH

LOW GAS PRESSURE SWITCH

PROCESS DIFFERENTIAL AIR FLOW SWITCH

LOW FIRE SWITCH

Once the unit has purged, the Trial for Ignition period will begin and run for the amount of time as designated

by the flame relay. The ignition transformer will be energized and the pilot safety shut off valves will open

during the trial for ignition.

Once pilot flame is established, the main safety shutoff valves will be energized to open. If the heater gas train

is equipped with a vent valve, the vent valve will be energized to close at this time. After the main flame

establishing period (approx. 10 seconds), the pilot valves will close and the gas modulating valve will be

energized. The temperature control signal supplied to the gas modulating valve will then control the temperature

of the air heater.

If the burner does not light on the first attempt, the flame relay will lockout. The alarm contact on the flame

relay will be energized. To reset, push the red “RESET” button on the keyboard display module.

On larger heaters equipped with dual flame sensors, it is required to prove flame at the far end of the burner after

the main flame-establishing period. If for some reason the flame does not reach the flame sensor in the time

period allowed, the burner will shutdown and lockout. Check flame propagation and increase low fire if

required.

For a more detailed description of the flame relay operation, see the flame relay literature.

3. If at any time during operation a limit should drop out, the burner will trip and the flame relay will lockout.

Push the “RESET” button on the keyboard display module to reset the flame relay.

The burner cannot be re-lit until all limits are satisfied. Once all limits are made, a new purge cycle will begin.

C. NORMAL SHUTDOWN

NOTE: Follow any additional equipment shutdown procedure according to system supplier instructions in

conjunction with this procedure.

1. Depress the “BURNER STOP” button. The burner will shut down.

2. Allow the system fans to run until system has cooled below 150o F.

3.Turn power selector switch to “POWER OFF”

SO-AHDX-HON-080213

D. EMERGENCY SHUTDOWN The “EMERGENCY STOP” button should only be used in the event of an emergency situation where

conditions warrant an immediate system shut down.

In case of an emergency shut down, close main manual gas valve and remove all electrical power from the

system.

E. LOSS OF POWER

1. Loss of power will de-energize all relays and valves and will cause all components to fail to their normal fail-safe

positions. Upon power loss, switch power off to the controls until main power has been restored.

SO-AHD-ADJ 090505

AHD BURNER ADJUSTMENT Refer to drawings and burner set-up information for pressures and tap locations. Different system operating conditions could cause a change in the set-up pressures. Check pressures at all operating conditions. A. BURNER AIR DIFF. PRESSURE Use adjustable profile plates inside of duct. Adjust inward for a higher and out for a lower pressure drop. B. PILOT GAS Use adjustment screw inside of pilot adjustable gas cock (CW decreases gas, CCW increases gas). If backing screw out does not increase pilot, then increase pressure out of pilot regulator. C. HIGH FIRE MAIN GAS Refer to Info 720 With actuator at high fire and butterfly valve at or near full open position (Linkage limited to 50% opening when firing on propane or butane), adjust main gas regulator outlet pressure. Low fire adjustment should be checked after making any adjustments to high fire D. LOW FIRE MAIN GAS Refer to Info 720 With actuator at low fire position, adjust degree opening of butterfly valve. Note: When making adjustments to the linkage, crank arms, or valve position, always drive actuator back to the minimum/low fire position prior to making the adjustment. This will help insure the new set-up will not bind up.

Page 1 TS-SGF-04/21/03

TROUBLE SHOOTING GUIDE

This list contains typical combustion system limits. Refer to P&ID, Electrical diagrams, and

annunciator faults to determine which limits apply. For specific component problems, refer to

component literature.

LIMIT NOT MADE REASON FOR FAILURE HOW TO CORRECT PROBLEM

“CUSTOMER THIS INDICATES ONE OF THE AUXILARY SYSTEM

INTERLOCKS” INTERLOCKS IS NOT MADE. SEE SYSTEM SUPPLIER

INFORMATION

“BLOWER THIS INDICATES THAT THE FAN

MOTOR STARTER MOTOR STARTER CONTACT IS NOT

CONTACTS” MADE. THIS WILL HAPPEN IF:

1. THE MOTOR IS NOT STARTED 1. START THE MOTOR

2. MOTOR THERMAL OVERLOADS 2. RESET AND CHECK

ON STARTER HAVE TRIPPED FOR EXCESSIVE AMP

DRAW

3. MOTOR STARTER IS BAD 3. INSPECT MOTOR

STARTER, REPLACE IF

BAD

“AIRFLOW SWITCH” THIS INDICATES AIRFLOW SWITCH IS NOT MADE. THIS WILL

HAPPEN IF:

1. BLOWER IS NOT

RUNNING 1. START THE BLOWER

2. SENSING LINES TO THE SWITCH ARE 2. VERIFY TUBING IS

LOOSE OR BLOCKED CLEAR AND TIGHT

3. INLET OR OUTLET TO BLOWER IS 3. VERIFY BLOWER INLET

BLOCKED. AND OUTLET ARE CLEAR

4. SWITCH / WIRING IS BAD 4. INSPECT SWITCH / WIRING

REPLACE IF BAD

5. PROPER AIRFLOW HAS NOT BEEN SET 5. SET PROPER AIRFLOW



“LOW FUEL PRESSURE THIS INDICATES THE LOW FUEL PRESSURE

SWITCH” SWITCH IS NOT MADE. THIS WILL HAPPEN

IF:

1. FUEL PRESSURE IS TOO LOW 1. REGULATOR PRESSURE IS

TOO LOW- INCREASE

REGULATOR PRESSURE, OR

FUEL IS SHUT OFF. OPEN

ALL FUEL VALVES.

2. SENSING LINES ARE LOOSE OR 2. VERIFY TUBING CLEAR

BLOCKED AND TIGHT

3. SWITCH / WIRING IS BAD 3. VERIFY SWITCH / WIRING.

REPLACE IF BAD.

“HIGH FUEL THIS INDICATES THE HIGH FUEL PRESSURE

PRESSURE SWITCH” SWITCH IS NOT MADE. THIS WILL HAPPEN

IF:

1. THERE IS TOO HIGH OF FUEL PRESSURE 1. LOWER REGULATOR.

OUTLET PRESSURE OR

FOREIGN MATTER IN

VALVE. CLEAN SEAT.

2. SWITCH /WIRING IS BAD 2. INSPECT SWITCH /.

WIRING. REPLACE IF

BAD

“ PROOF OF LOW THIS INDICATES THE MODULATING

OR HIGH VALVE LOW / HIGH FIRE SWITCH IS NOT MADE

FIRE SWITCH” THIS WILL HAPPEN IF:

1. THE MODULATING VALVE DID NOT 1. MAKE SURE VALVE IS

GO TO LOW / HIGH FIRE FULLY CLOSED / OPEN.

CHECK FOR MECH

BINDING

2. LIMIT SWITCH IS NOT MADE 2. CHECK ADJUSTMENT

ON LIMIT SWITCH TO

ENSURE SWITCH IS

PROPERLY ALIGNED

3. LIMIT SWITCH/ RELAY IS BAD 3. CHECK LIMIT SWITCH

AND RELAY FOR

PROPER OPERATION

AND WIRING



“SSOV THIS INDICATES THE SAFETY

PROOF OF CLOSURE SHUTOFF VALVE SWITCH IS NOT

SWITCH” MADE. THIS WILL HAPPEN IF:

1. THE SAFETY SHUTOFF VALVE IS 1. VERIFY VALVE IS FULLY

NOT FULLY CLOSED CLOSED. CHECK FOR

MECHANICAL BINDING

2. THE SWITCH IS MISALIGNED OR BAD 2. CHECK ALIGNMENT /

OPERATION. REPLACE IF

BAD

“TEMP LIMIT SWITCH” THIS INDICATES THE TEMPERATURE HAS RISEN ABOVE OR DROPPED BELOW

THE SETPOINT LIMIT. THIS WILL HAPPEN IF:

1. THE SETPOINT HAS BEEN INADVERTENTLY 1. SET CORRECT TEMP ON

CHANGED ON THE LIMIT CONTROLLER. LIMIT CONTROLLER

2. THERE IS NO BURNER TEMP CONTROL 2. CHECK LINKAGE

(RUNAWAY BURNER) OPERATION OF

MODULATING

VALVE

( LINKAGE MAY HAVE

COME LOOSE.)

3. THERMOCOUPLE IS BAD 3. CHECK THERMOCOUPLE

AND WIRING FOR

PROPER POLARITY AND

OPERATION

“BURNER FLAME” THIS INDICATES THE BURNER FLAME RELAY

HAS DETECTED A LOSS OF BURNER FLAME.

THIS WILL HAPPEN IF:

1. FUEL SUPPLY TO BURNER IS CUT OFF 1. MAKE SURE ALL FUEL

VALVES ARE OPEN AND

MAIN REGULATOR IS

OPERATING PROPERLY

2. TOO MUCH COMBUSTION AIR 2. ENSURE COMBUSTION

(BLOWING OUT FLAME) AIR IS NOT EXCESSIVE

3. ADJUSTABLE PILOT FLAME TOO BIG 3. SET PILOT ADJUSTING

OR TOO SMALL VALVE FOR PROPER

PILOT

NOTE: FOR ADDITIONAL PROBLEMS RELATED TO BURNER, REFER TO BURNER LITERATURE.

ITM-SGF-072214

- 1 -

INSPECTION, TESTING, & MAINTENANCE

- It is the responsibility of the user to ensure the equipment is in proper working order. An

established maintenance program is essential. Documented safety inspections and testing

shall be performed at least annually (check with the authority having jurisdiction)

- All personnel associated with the equipment must be thoroughly trained by a qualified

person and be required to demonstrate such knowledge for safe operation. Regular

retraining and testing is required to maintain a high level of proficiency.

- Modifications must be evaluated, performed, and tested by a qualified entity familiar with

the equipment. All modifications should have prior approval by the authority having

jurisdiction and be well documented.

- Never reduce purge timer settings or bypass any limit. Explosions could result.

- Prior to any maintenance being performed, make sure the following are turned off and

locked out as required for personnel safety.

o Electrical Power o Mechanical Equipment

o Fuel Lines

o Process Lines

o Other Utilities

Important: It is required for the user to follow tag out/lock out, confined space, and

any other programs established by the authority having jurisdiction when performing

maintenance on the equipment.

- Cool down equipment as required for personnel safety.

- For additional requirements refer to individual component literature and MSD sheets

prior to performing any maintenance.

*Procedures. The user’s operational and maintenance program shall include procedures that

apply to entry into equipment in accordance with all applicable regulations.

*Inspection, Testing, and Maintenance. It shall be the responsibility of the user to establish,

schedule, and enforce, the frequency and extent of the inspection, testing, and maintenance

program, as well as the corrective action to be taken.

NOTE: THE USER SHOULD REVIEW RECOMMENDATIONS

FROM THE INSURANCE UNDERWRITER AND THE

EQUIPMENT SUPPLIER AND WHERE APPLICABLE,

INCLUDE THESE RECOMMENDATIONS IN THE

MAINTENANCE PROGRAM.

Cleaning. Foreign material, parts, and residue shall be removed from recirculation blowers,

exhaust blowers, heat exchangers, burner and pilot ports, combustion blowers, ductwork, and

equipment interiors. Ductwork shall be checked for obstructions. Cleaning frequency shall be

determined by process requirements.

ITM-SGF-072214

- 2 -

Tension and Wear. Recirculation and exhaust system blowers that are driven by V-belts shall be

checked for belt slippage and excessive belt wear. If slippage is detected, belts shall be adjusted

or replaced.

Flammable Loading. It shall be the user’s responsibility to prevent the flammable loading from

exceeding the safety ventilation design capacity.

*Continuous vapor alarms shall be calibrated and maintained in accordance with the following:

(1) The sensor and the sample system shall be maintained at a temperature that prevents

condensation, and sampling lines shall be clean and airtight

(2) The system shall be secured against unauthorized adjustment

(3) Maintenance shall be performed in accordance with manufacturer’s instructions.

(4) Calibration shall be performed in accordance with manufacturer’s instructions and shall

be performed at least once per month.

OPERATIONAL AND MAINTENANCE CHECKLIST

Prior To Initial Operation:

- Check tightness of all electrical terminal connections.

- Check utilities for proper supply.

- Verify and test all electrical wiring according to codes established by the authority having

jurisdiction.

- Check tightness of all bolted connections and re-torque after first initial heating cycle.

o Periodic check of these connections is required until a routine maintenance

schedule can be determined.

Initial Start-up: A dry run shall be carried out with all manual gas valves closed to determine

that all controls are in a safe operating condition.

- Check movement or position of air dampers.

- Simulate failure of air flow and all other limits to ensure that ignition does not occur.

- Check to ensure there is no flame signal during ignition cycle.

- Check purge flow and purge cycle to ensure minimum required fresh air flow changes.

- Leak test valve train.

*Visual Operational Checklist. The following operational checks should be performed:

(1) Check burners for ignition and combustion characteristics.

(2) Check pilots or igniters, or both, for main burner ignition.

(3) Check air-fuel ratios.

(4) Check operating temperatures.

(5) Check sight drains or gauges, or both, for cooling water flow and water temperature.

(6) Check that burners or pilots, or both, have adequate combustion air.

(7) Check the operation of ventilating equipment.

*Regular Shift Checklist. The following operational checks should be performed at the start of

every shift:

(1) Check the setpoint of control instrumentation.

(2) Check positions of hand valves, manual dampers, secondary air openings, and adjustable

bypasses.

(3) Check blowers, fans, compressors, and pumps for unusual bearing noise and shaft

vibration; if V-belt driven, check belt tension and belt fatigue.

ITM-SGF-072214

- 3 -

(4) Perform lubrication in accordance with manufacturer’s requirements.

*Periodic Checklist. The following maintenance checklist should be completed at intervals

based on the recommendations of the manufacturer and the requirements of the process:

(1) Inspect flame-sensing devices for condition, location, and cleanliness.

(2) Inspect thermocouples and lead wires for shorts and loose connections. A regular

replacement program should be established for all control and safety

thermocouples. The effective life of thermocouples varies, depending on the

environment and temperature, and these factors should be considered in setting

up a replacement schedule.

(3) Check setting and operation of low and high temperature limit devices.

(4) Test visual or audible alarm systems, or both, for proper signals.

(5) Check igniters and verify proper gap.

(6) Check all pressure switches for proper pressure settings.

(7) Check control valves, dampers and actuators for free, smooth action and

adjustment.

(8) Test the interlock sequence of all safety equipment. If possible, the interlock

should be made to fail manually, verifying that the related equipment operates as

specified by the manufacturer.

(9) Test the safety shutoff valves for operation and tightness of closure as specified

by the manufacturer.

(10) Test the main fuel manual valves for operation and tightness of closure as

specified by the manufacturer.

(11) Test the pressure switches for proper operation at set point.

(12) Visually inspect electrical switches, contacts, or controls for signs of arcing or

contamination.

(13) Test instruments for proper response to thermocouple failure.

(14) Clean or replace the air blower filters.

(15) Clean the water, fuel, gas compressor, and pump strainers.

(16) Clean the fire-check screens and valve seats and test for freedom of valve

movement.

(17) Inspect burners and pilots for proper operation, air-fuel ratio, plugging, and

deterioration. Burner refractory parts should be examined to ensure good

condition.

(18) Check all orifice plates, air-gas mixers, flow indicators, meters, gauges, and

pressure indicators; if necessary, clean or repair them.

(19) Check the ignition cables and transformers.

(20) Check the operation of modulating motors.

(21) Check the integrity of and the interior of the equipment, ductwork, and

ventilation systems for cleanliness and flow restrictions.

(22) Test pressure-relief valves, if necessary, repair or replace.

(23) Inspect air, water, fuel, and impulse piping for leaks.

(24) Inspect radiant tubes and heat exchanger tubes for leakage and repair if

necessary.

(25) Lubricate the instrumentation, valve motors, valves, blowers, compressors,

pumps, and other components.

(26) Test and recalibrate instrumentation in accordance with manufacturer’s

recommendations.

*Periodic Checklist (Cont.)

(27) Test flame safeguard units. A complete shutdown and restart should be made to

check the components for proper operation.

ITM-SGF-072214

- 4 -

(28) Check electric heating elements for contamination, distortion, cracked or broken

refractory element supports, and proper positioning. Repair or replace if

grounding or shorting can occur.

(29) Check electric heating element terminals for tightness.

*Maintenance of Gas Equipment.

General. These recommendations are prepared for maintenance of gas equipment. Special

types of equipment command special attention. A preventive maintenance program that includes

adherence to manufacturer’s recommendations should be established and followed. This program

should establish a minimum maintenance schedule that includes inspection and action on the

recommendations provided in the following paragraphs (G.5.2 through G.5.5). An adequate

supply of spare parts should be maintained.

Burners and Pilots. Burners and pilots should be kept clean and in proper operating

condition. Burner refractory parts should be examined at frequent, regular intervals to ensure

good condition.

Flame Safeguard Equipment. Where automatic flame safeguards are used, a complete

shutdown and restart should be made at frequent intervals to check the components for proper

operation.

Other Safeguard Equipment. Accessory safeguard equipment - such as manual reset

valves, automatic safety shutoff valves, pressure or vacuum switches, high temperature limit

switches, draft control, manual shutoff valves, airflow switches, door switches, and gas valves -

should be operated at frequent, regular intervals to ensure proper functioning. If inoperative, they

should be repaired or replaced promptly.

Where fire checks are installed in air-gas mixture piping, the pressure loss across the fire

checks should be measured at regular intervals. Where excessive pressure loss is found, screens

should be removed and cleaned. Water-type backfire checks should be inspected at frequent

intervals, and the liquid level should be maintained.

Safety Shutoff Valves. All safety shutoff valves should be checked for leakage and proper

operation at frequent, regular intervals. An example procedure for testing gas safety shutoff

valves is outlined in A.7.4.9.

*Reproduced with permission from NFPA 86-2011, Ovens and Furnaces Copyright © 2010 National Fire Protection Association. This reprinted 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.

ITM-SGF-072214

- 5 -

Safety Shutoff Valves

All safety shutoff valves should be checked for leakage and proper operations at initial

start-up, weekly for the first month, monthly for the first quarter, quarterly for the first year,

and then if all test are satisfactory, frequency can be reduced to annually.

A procedure for making tests of gas safety valve is outlined as follows:

LEAK TEST PROCEDURE FOR SAFETY SHUT-OFF VALVES

READ ALL INSTUCTIONS FIRST.

DANGER…. THIS PROCEDURE MAY RELEASE COMBUSTIBLES INTO THE ATMOSPHERE.

KEEP ANY IGNITION SOURCES AWAY FROM THIS AREA DURING PROCEDURE. REFER TO

LEAK TEST DIAGRAM. TURN BURNER OFF PRIOR TO PERFORMING THE PROCEDURE

BELOW.

NOTE: SOME SYSTEMS ALREADY HAVE TEST VALVES INSTALLED. VALVE MAY BE A 90

DEGREE PET COCK STYLE VALVE OR MAY BE A PRESSURE TEST TAP WITH INTERNAL

NEEDLE VALVE. TEST TAPS WITH NEEDLE VALVE WILL REQUIRE A SMALL FLAT

BLADED SCREW DRIVER INSERTED INTO THE TAP AND 3-4 TURNS CCW TO OPEN THE

TAP FOR TESTING.

Open/disconnect all terminal disconnect switches that are located in the power feed from

the flame relay and directly upstream of the Main & Pilot SSOV No. 1 and Vent Valve(s)

if vent valves are installed.

1. Safety Shutoff Valve (SSOV) No. 2 Check:

(a) Verify burner(s) shutoff,

(b) Close manual shutoff valve downstream of SSOV No. 2 (just prior to burner) on

both main and pilot. Verify the main inlet manual valve and all other upstream

valves are open and piping upstream of first SSOV is pressurized.

(c) Remove plug and place test cock (closed position) and hose barb with tube on

both main and pilot SSOV No. 2 at downstream test connection located on valve.

(d) Add jumper from an energized main power supply terminal (same voltage as

valve) to the outlet side of the disconnect terminal feeding the Vent valve(s), if

applicable. NOTE: If Vent valves exist, you want to energize these prior to

energizing the SSOV in order not to release gas to the atmosphere. (Vent valve

will close. If vent valve is a solenoid, check that the valve is functioning properly;

coil becomes magnetic). Add jumper from the an energized main power supply

terminal (same voltage as valve) to the outlet side of the disconnect terminal

feeding the Main or Pilot SSOV No. 1, depending on which one you are testing at

the time (SSOV No. 1 will open. If valve is a solenoid, check that the valve is

functioning properly; coil becomes magnetic).

ITM-SGF-072214

- 6 -

(e) Open test cock and immerse the tube just below the surface of a container of

water. Wait one minute and if bubbles appear after initial relief of pressure, valve

is leaking. Also refer to valve manufacturer’s instructions for leak testing and

corrective actions. Close test cock. Repeat for other SSOV No. 2.

(f) Remove jumper(s) supplying power to SSOV(s) No. 1. Verify that SSOV No. 1

valves have de-energized and are closed. Remove test cocks and place plugs back

into valves test tap (or close needle valve). Leave jumper on that is supplying

power to vent valve(s), if applicable.

2. Safety Shutoff Valve No. 1 Check:

To be completed after verifying safety shutoff valve No. 2 is tight.

(a) If jumpers are not still in place on the Vent valve(s) then add jumper from an

energized power supply terminal (same voltage as valve) to the outlet side of the

disconnect terminal feeding the Vent valve(s), if applicable. NOTE: If Vent valves

exist, you want to energize these prior to energizing SSOV in order not to release

gas to the atmosphere. (Vent valve will close. If vent valve is a solenoid, check

that the valve is functioning properly; coil becomes magnetic).

(b) Remove plug and place test cock (closed position) and hose barb with tube on

both main and pilot SSOV No. 1 at downstream test connection located on valve.

(c) Open test cock and immerse the tube just below the surface of a container of

water. If bubbles appear after initial relief of pressure, valve is leaking. Refer to

manufacturer’s instructions for corrective actions. Close test cock. Repeat for

other SSOV No. 1.

ITM-SGF-072214

- 7 -

(d) Remove all jumpers and test cocks. Place plugs back into valves (or close needle

valve). Close all disconnect terminal switches.

3. After repairing/replacing and retesting of any failed components, burner system can

be returned to service. Open downstream manual shutoff valve (prior to burner) on

both main and pilot.

1 For use with Natural Gas only.2 When using UV scanners, Eclipse recommends a flame monitoring system that terminates the ignition spark at the

end of the trial for ignition period not when it "sees" flame. Eclipse recommends that flame supervision is fitted at bothends of the burner when the flame travels more than 10 ft.

3 Direct spark ignition can be used on burners up to 18 inches (460 mm) long and up to 60% capacity.4 See Design Guide 160 for more information about typical fuel composition and properties.• All information is based on laboratory testing. Different chamber conditions may affect the data.• All inputs based upon gross calorific values and standard conditions; 1 atmosphere, 70°F

(21°C). Contact Eclipse, Inc. for performance data above ambient temperature.• Eclipse reserves the right to change the construction and/or configuration of our

products at any time without being obliged to adjust earlier supplies accordingly.

Parameter DescriptionMaximum Input, Btu/h/ft (kW/ft) 1,200,000 (351.7)Combustion Air Pressure Drop, "w.c. (mbar) 0.2 to 1.4 (0.5 to 3.5)Pilot Interruptible pilot for natural gas, propane or butaneIntegral Pilot Capacities, Btu/h (kW) 20,000 (5.9)Burner Bodies Standard Aluminum

Low Pressure Aluminum1

Stadard Cast IronCorrosion Resistant, EN Plated Cast IronLow Pressure Cast Iron1

Burner Section Sizes 6" (150mm) straight section12" (300mm) straight section12" (300mm) straight section with back inlet12" (300mm) straight section with pilot6" (150mm) by 12" (300mm) tee section6" (150mm) by 12" (300mm) tee section with pilot12" (300mm) by 12" (300mm) cross section

Maximum Upstream Air Temperature, °F (°C) 450 (232)Maximum Downstream Air Temperature, °F (°C) 850 (454)Maximum Temperature Rise, °F (°C) 750 (400)Pipe Threads NPT or BSPFlame Detection2 Flame rod or UV scannerIgnition (6kVAC transformer)3 Direct Spark Ignition

Spark Ignited PilotMinimum Inlet Air Oxygen 18%FuelsFor any other mixed gas, contact Eclipse, Inc.

Natural Gas, Propane, Butane4

Approvals

Eclipse AirHeatBurners

AH-MA Series

Datasheet 160

Version 2

11/15/2013

2 Eclipse AirHeat Burners, AH-MA Series, V2, Datasheet 160, 11/15/2013

Operating Range and Duct Pressure Measurement

Inlet Air Temperature Correction

Air Velocity Calculation

1,000,000

900,000

800,000

700,000

600,000

500,000

400,000

300,000

30,000

25,000

20,000

15,000

10,000

5,000

0

1,100,000

1,200,000

1,300,000

Natural GasPropane/Butane

Hea

t Inp

ut (B

tu/h

/ft)

Hea

t Inp

ut (k

W/ft

)

0.2 0.4 0.6 0.8 1.0 1.2 1.4

0.5 1.0 1.5 2.0 2.5 3.0 3.5

Air Pressure Drop ("w.c.) @ 70°F Air Inlet

Air Pressure Drop (mbar) @ 21°C Air Inlet

Maxim

um Heat Input

Minimum Heat Input

300

250

200

150

100

9.0

7.5

6.0

4.5

3.0

1.5

0

350

400

Air Pressure Drop @ Air Temp. = Air Pressure Drop from "Operating Range" Chart x Correction FactorAir Inlet Temp., °F(°C) 0

(-18)30(-1)

70(21)

150 (66)

200 (93)

250 (121)

300 (149)

350 (177)

400 (204)

450 (232)

Correction Factor 0.87 0.92 1.00 1.15 1.25 1.34 1.43 1.53 1.62 1.72

Air Velocity (fpm) = 1096.2Air Pressure Drop (”w.c.)

Air Density (lbs/ft3)√ Air Velocity (m/s) = 4.43

Imperial units: Metric units:

Air Pressure Drop (mm w.c.)

Air Density (kg/m2)√

3Eclipse AirHeat Burners, AH-MA Series, V2, Datasheet 160, 11/15/2013

Differential Pressure Measurement and Gas Pressure Drops

Flame Lengths

Emissions Data

“D”10-20"(254-508mm)

30

25

20

15

10

5

00 200 400 600 800 1000 1200

0 60 120 180 240 300 360

("w

.c.)

75

60

45

30

15

0

Gas

Pre

ssur

e D

rop,

Bur

ner I

nlet

to D

uct

(mab

r)

Heat Input (1000 x Btu/h/ft)

Heat Input (kW/ft)

Main gas differential pressure measured between “A” and “D”

Natural Gas*Propane*Butane*Natural Gas (Low Press.)**

* 0.08” (2mm) gas ports.** 0.09” (2.4mm) gas ports

"A"Tap On

Inlet GasPiping

•

Datasheet 160, 11/15/2013

Eclipse AirHeatBurners

160 Installation Guide8/13/2010

Version 2AH-MA Series

2

CopyrightCopyright 2007 by Eclipse, Inc. All rights reservedworldwide. This publication is protected by federalregulation and shall not be copied, distributed,transmitted, transcribed or translated into any human orcomputer language, in any form or by any means, to anythird parties, without the express written consent ofEclipse, Inc.

Disclaimer NoticeIn accordance with the manufacture’s policy of continualproduct improvement, the product presented in thisbrochure is subject to change without notice or obligation.

The material in this manual is believed adequate for theintended use of the product. If the product is used forpurposes other than those specified herein, confirmationof validity and suitability must be obtained. Eclipsewarrants that the product itself does not infringe upon anyUnited States patents. No further warranty is expressed orimplied.

Liability & WarrantyWe have made every effort to make this manual asaccurate and complete as possible. Should you find errorsor omissions, please bring them to our attention so that wemay correct them. In this way we hope to improve ourproduct documentation for the benefit of our customers.Please send your corrections and comments to ourMarketing Communications Manager.

It must be understood that Eclipse’s liability for its product,whether due to breach of warranty, negligence, strictliability, or otherwise is limited to the furnishing ofreplacement parts and Eclipse will not be liable for any

other injury, loss, damage or expenses, whether direct orconsequential, including but not limited to loss of use,income, or damage to material arising in connection withthe sale, installation, use of, inability to use, or the repairor replacement of Eclipse’s products.

Any operation expressly prohibited in this manual, anyadjustment, or assembly procedures not recommended or authorized in these instructions shall void the warranty.

Document ConventionsThere are several special symbols in this document. Youmust know their meaning and importance.

The explanation of these symbols follows below. Pleaseread it thoroughly.

How To Get HelpIf you need help, contact your local Eclipse representative.You can also contact Eclipse at:

1665 Elmwood Rd.Rockford, Illinois 61103 U.S.A.Phone: 815-877-3031Fax: 815-877-3336http://www.eclipsenet.com

Please have the information on the product label availablewhen contacting the factory so we may better serve you.

www.eclipsenet.comProduct NameItem #S/N DD MMM YYYY

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Is used to address practices not related to personal injury.

Indicates an important part of text. Read thoroughly.NOTENOTICE

CAUTION

WARNING

3Eclipse AH-MA AirHeat Burner, V2, Installation Guide 160, 8/13/2010

Table of Contents1 Introduction............................................................................................................................ 4

Product Description .............................................................................................................. 4Audience .............................................................................................................................. 4Purpose................................................................................................................................ 4Related Documents.............................................................................................................. 4

2 Safety...................................................................................................................................... 5Introduction .......................................................................................................................... 5Safety Warnings................................................................................................................... 5Capabilities........................................................................................................................... 5Operator Training ................................................................................................................. 5Replacement Parts............................................................................................................... 5

3 Installation.............................................................................................................................. 6Introduction .......................................................................................................................... 6Handling & Storage .............................................................................................................. 6Position of Components ....................................................................................................... 6Approval of Components...................................................................................................... 6Checklist Before Installation ................................................................................................. 7Duct Configuration................................................................................................................ 7Suspending the Burner......................................................................................................... 7Prepare the Burner............................................................................................................... 8Piping ................................................................................................................................... 9Checklist After Installation .................................................................................................... 10

4 Adjustment, Start & Stop ...................................................................................................... 11Introduction .......................................................................................................................... 11Adjustment Procedure.......................................................................................................... 11Step 1: Reset the System..................................................................................................... 11Step 2: Set Air Pressure Drop.............................................................................................. 11Step 3: Verify the Air Setting ................................................................................................ 11Step 4: Ignite Pilot ................................................................................................................ 11Step 5: Ignite the Burner ...................................................................................................... 12Step 6: Adjust Low Fire Gas................................................................................................. 12Step 7: Adjust High Fire Gas................................................................................................ 12Step 8: Verify Gas Settings .................................................................................................. 12Start Procedure .................................................................................................................... 12Stop Procedure .................................................................................................................... 13

5 Maintenance & Troubleshooting.......................................................................................... 14Introduction .......................................................................................................................... 14Maintenance......................................................................................................................... 14Monthly Checklist ................................................................................................................. 14Yearly Checklist.................................................................................................................... 14Troubleshooting Guide......................................................................................................... 15Parts Lists............................................................................................................................. 17

Appendix ................................................................................................................................... iConversion Factors .............................................................................................................. iSystem Summary ................................................................................................................. ii

4 Eclipse AH-MA AirHeat Burner, V2, Installation Guide 160, 8/13/2010

IntroductionProduct DescriptionEclipse AH-MA Air Heat burners produce a uniform,odorless, and smokeless flame ideal for heating fresh airin make-up and process air heating applications. The AH-MA design provides stable operation over a wide range ofvelocities, inputs, and fuels.

AH-MA burners are line type burners constructed of castiron or aluminum burner bodies and diverging stainlesssteel air wings. The burner bodies supply fuel to the centerof the air wings to control the air and fuel mixture insidethe burner and to optimize emissions and efficiency.Completely corrosion resistant design options areavailable using aluminum burner bodies or electrolessnickel plated cast iron burner bodies.

The AH-MA Air Heat burner is assembled from straightsections, tees, and crosses to produce nearly anyconfiguration required. Large burners can be built as acombination of staged, individually controlled sections toincrease turndown.

Figure 1.1. AH-MA AirHeat Burner

AudienceThis manual has been written for personnel alreadyfamiliar with all aspects of an air heat burner and it’s add-on components, also referred to as the burner package.

These aspects are:

• Installation• Use• Maintenance• Safety

The audience is expected to be qualified and haveexperience with this type of equipment and its workingenvironment.

PurposeThe purpose of this manual is to make sure that you carryout the installation of a safe, effective and trouble-freesystem.

AH-MA DocumentsInstallation Guide No. 160

• This documentDatasheet Series No. 160

• Required to complete installationDesign Guide No. 210

• Used with Datasheet to complete design calculations

Related Documents• EFE 825 (Combustion Engineering Guide)• Eclipse Bulletins and Information Guides: 818, 820,

826, 832, 852, 854, 856

AdjustableProfile Plate

AdjustableProfile Plate

Heated Air

Air WingUniformAir Flow

UniformAir Flow

GasFeed Pipe

Burner Body

FlameLength

1


SafetyIntroductionImportant notices for safe operation of the burner systemwill be found in this section. To avoid personal injury,damage to property or the facility, the following warningsmust be observed. Read this entire manual beforeattempting to start the system. If any part of theinformation in this manual is not understood, contactEclipse before continuing.

Safety Warnings

■ The burners covered by this guide are designed tomix gas with air and burn the resulting mixture. Allgas burning devices are capable of producing firesand explosions if improperly applied, installed,adjusted, controlled or maintained.

■ Do not bypass any safety feature; fire or explosioncould result.

■ Never try to light a burner if it shows signs ofdamage or malfunction.

■ The burner and duct sections are likely to haveHOT surfaces. Always wear protective clothingwhen approaching the burner.

■ Eclipse products are designed to minimize the useof materials that contain crystalline silica.Examples of these chemicals are: respirablecrystalline silica from bricks, cement or othermasonry products and respirable refractoryceramic fibers from insulating blankets, boards, orgaskets. Despite these efforts, dust created bysanding, sawing, grinding, cutting and otherconstruction activities could release crystallinesilica. Crystalline silica is known to cause cancer,and health risks from the exposure to thesechemicals vary depending on the frequency andlength of exposure to these chemicals. To reducethe risk, limit exposure to these chemicals, work ina well-ventilated area and wear approved personalprotective safety equipment for these chemicals.

■ This manual provides information in the use of theburner for its specific design purpose. Do notdeviate from any instructions or application limitsdescribed herein without written advice fromEclipse.

CapabilitiesOnly qualified personnel, with good mechanical aptitudeand experience with combustion equipment, shouldadjust, maintain or troubleshoot any mechanical orelectrical part of this system.

Operator TrainingThe best safety precaution is an alert and trainedoperator. Train new operators thoroughly and have themdemonstrate an adequate understanding of theequipment and its operation. A regular retraining scheduleshould be administered to ensure operators maintain ahigh degree of proficiency.

Replacement PartsOrder replacement parts from Eclipse only. Any customersupplied valves or switches should carry UL, FM, CSA,CGA and/or CE approvals where applicable.

DANGER

WARNING

NOTICE

2


InstallationIntroductionIn this section you will find the information and instructionsneeded to install the burner and system components.

NOTE: Information in Datasheet 160 is necessary tocomplete some of the procedures.

■ Only qualified competent personnel withexperience of combustion systems are allowed toinstall, adjust or maintain the burner.

■ All installation work must be carried out incompliance with current legislated standards.

Handling & StorageHandling

• Make sure the area is clean.• Inspect the burner, ensure that all components are

clean and free from damage.• Use appropriate support and handling equipment

when lifting the burner.• Protect the burner from weather, damage, dirt and

moisture.• Protect the burner and components from excessive

temperatures and humidity.

Storage• Make sure the components are clean and free of

damage.• Store the components in a cool, clean, dry room.• After making sure everything is present and in good

condition, keep the components in original packages as long as possible.

Position of ComponentsThe position and amount of components are determinedby three factors: burner design, system design, and thecontrol method that you choose. All three factors areconsidered in the “System Design” chapter of the AH-MAAirHeat Burner Design Guide No. 160. Use theinformation in that chapter to build your system.

Approval of ComponentsLimit Controls & Safety Equipment

All limit controls and safety equipment must comply withall applicable local codes and/or standards and must belisted for combustion safety by an independent testingagency. Typical application examples include:

• American: NFPA 86 with listing marks from UL, FM, CSA

• European: EN 746-2 with CE mark from TuV, Gastec, Advantica

Electrical Wiring

All the electrical wiring must comply with all applicablelocal codes and/or standards such as:

• NFPA Standard 70• IEC60364• CSA C22• BS7671

Gas Piping

All the gas piping must comply with all applicable localcodes and/or standards such as:

• NFPA Standard 54• ANSI Z223• EN 746-2

Where to Get the Standards:The NFPA Standards are available from: National Fire Protection Agency Batterymarch ParkQuincy, MA 02269www.nfpa.org

The ANSI Standards are available from: American National Standard Institute 1430 BroadwayNew York, NY 10018www.ansi.org

The UL Standards are available from: 333 Pfingsten RoadNorthbrook, IL 60062www.ul.com

NOTICE

3


The FM Standards are available from: 1151 Boston-Providence TurnpikePO Box 9102Norwood, MA 02062www.fmglobal.com/approvals

Information on the EN standards and where to getthem is available from: Comité Européen de Normalisation Stassartstraat 36B-1050 BrusselsPhone: +32-25196811Fax: +32-25196819www.cen.eu

Comité Européen de Normalisation Electronique Stassartstraat 36B-1050 BrusselsPhone: +32-25196871Fax: +32-25196919 www.cenelec.org

Checklist Before InstallationAccessMake sure that you install the system in such a way thatyou can get easy access to the burner for inspection andmaintenance.

EnvironmentMake sure that the local environment matches the originaloperating specifications. Check the following items:

• Voltage, frequency and stability of the electricalpower

• Fuel type and supply pressure of the fuel• Availability of enough fresh, clean combustion air• Humidity, altitude and temperature of air

• Presence of damaging corrosive gases in the airDuct ConfigurationWhen laying out the duct, allow enough lengthdownstream of the burner to avoid flame impingement;see page 3 of the Data Sheet No. 160 for flame lengths.To improve temperature uniformity, this distance shouldbe increased or a flow distribution plate used, as shown inFigure 3.1.

NOTE: Use the following distances between the burnerand transition duct when temperature uniformity isessential. For rectangular ducts: either the width or heightof one duct section (whichever is greater), or for circularducts: the diameter of one duct section.

Suspending the BurnerEclipse AH-MA AirHeat burners must be securelysupported to avoid misalignment of the burner in the duct;see Figure 3.2 for support examples.

■ Supports should allow for thermal expansion ofthe burner and duct as the temperature of thecomponents increase. Piping expansion jointsshould be used outside of the duct toaccommodate movement of the duct section whenheated.

■ Avoid large obstructions in the air flow fromsupport causing uneven air flow into the burner.Use low profile supports such as flat iron tominimize flow disturbances.

NOTE: On pipe or manifold support examples, locate themain support as close as possible to the burnerassembly’s center of gravity to minimize the load.

Figure 3.1 Duct Configuration

CAUTION

Air Flow

AH-MABurner

Flow DistributionPlate (as required)

7.5° Max.for Transition

Reduction (Transition) Duct

Duct Section


Figure 3.2 Burner and Pipe Support Examples

Prepare the BurnerThere are several components that must be installed to aburner system before it can operate. Instructions to dothat follow below:

Adjust the Profile PlatesProfile plates should be adjusted to their initial position;see Figure 3.3.

■ Profile plates should be positioned upstream ofthe firing end of the burner. If necessary, the platescan be located up to 1" back from the firing end,but under no circumstances should they be infront of the burner. Figure 3.3 Profile Plate Position

GasManifold

BurnerFeedPipes

U-Bolt

Strap, Angle or ChannelIron Frame to Top and

Bottom of Duct

Air Flow

Air Flow

Angle, Strap orChannel Iron Frame to

Top and Bottom of Duct

Angle, Strap orChannel Iron Frame

to Bottom of Duct

Gas Manifold Pipe(Two are needed)

U-Bolt

U-Bolt

Air Flow

305mm (12")

U-Bolt

BurnerPipe Feeds

GasManifold

Gas Manifold Support

Burner Feed Pipe Support

Vertical Burner Run Support

181

40

7xØ13

38

3871142

Mounting Bracket for Hanger Rods #21509 (can be ordered as a separate line item.)

CAUTION AH-MABurner

ProfilePlate

ProfilePlate

¼ to 1"


Figure 3.4 End Plate Examples (Shown with Optional UV, Flamerod, and Spark Plug Installed)

Install the Flame Sensor1. Depending on the chosen flame sensor, locate and

install it into the corresponding opening located in theend plate as shown in Figure 3.4.

2. Make sure that you connect the flame sensor of aburner to the electrical circuit of the burner.

■ If you connect the flame sensor of a burner to theelectrical circuit of the wrong burner, then you cancause fires and explosions.

There are two different types of flame sensors:

UV Scanner:

For detailed information on how to install and connect aUV scanner, refer to:

• Bulletin/Instruction Manual 854 for straight UV scanners

• Bulletin/Instruction Manual 852 for 90° UV scanners• Bulletin/Instruction Manual 956 for self-check UV

scannersFlamerod:

For detailed information on how to install and connect aflamerod, refer to Bulletin/Info Guide 832.

Install the Spark PlugInstall the spark (ignition) plug into the appropriateopening of the end plate as shown in Figure 3.4.

NOTE: DO NOT apply any grease to the threads of thespark plug. You can cause bad grounding of the sparkplug if you apply grease to it. Bad grounding of the sparkplug results in a weak spark.

PipingPiping LayoutInstall all piping as shown in Figure 3.5.

Support the PipingUse brackets or hangers to support the piping. If you havequestions, consult your local gas company.

Piping Connections1. Install a pipe union in the line to each burner. This

simplifies removal of the burner.

2. The use of flexible pipe nipples in gas lines to theburner is optional. Flexible nipples can absorbstresses due to heat expansion.

3. Flexible pipe nipples may cause higher pressuredrops than equivalent standard pipes. Consider thatwhen you size the air lines.

4. Install pressure taps in the main and pilot gas lines asshown.

Avoid Large Pressure Drops

NOTE: The pressure drop of the gas in the piping is acritical parameter. Make sure that the size of all the pipingis large enough to prevent excessive pressure losses.

Plug

Flame Rod

Plug

Flame Monitoring Endwith

Flame Rod

Pilot Endwith

Flame Rod

Pilot Endwith

UV Scanner

IgnitionPlug

FlameRod

UV Scanner

UV ScannerAdaptor

Main GasConnection

IgnitionPlug

Main GasConnection

1/4" nptPilot Gas

Connection

DANGER


Figure 3.5 Gas Piping and Layout

Checklist After Installation1. Make sure that there are no leaks in the gas lines.

2. Make sure that the blower rotates in the correctdirection. If incorrect, then have a qualified electricianrewire the blower to reverse its rotation.

3. Set the air proving switch.

4. Set the low gas pressure switch at 4" w.c. below thegas pressure that you measure at the inlet to the maingas valve train.

5. Set the high gas pressure switch at 4" w.c. above thegas pressure that you measure at the inlet to the maingas valve train.

6. Close all the burner gas cocks.

7. Trip out pressure switches and other limit interlocks.Make sure that the main gas valves close.

■ If simulated limits or simulated flame failures donot shut down the fuel system within the requiredfailure response time, then immediately correct theproblem.

MainGas

Gas Manifold

BurnerFeed Pipe

PilotGas

SparkIgnitor

FlameRod

Burner Body

Pilot End Plate

PlainEnd Plate

PipeUnion

PipeUnion

PipeUnion

DANGER


Adjustment, Start &Stop

IntroductionIn this chapter you will find instructions on how to adjust asystem and how to start and stop a system.

■ Do not bypass any safety features. You can causefires and explosions.

■ Obey the safety precautions in the Safety chapter.

Adjustment ProcedureNOTE: Adjustment requires two manuals: this InstallationGuide and Datasheet No. 160. This chapter refers tocomponent information which is found in Datasheet 160.

Read all of this chapter before starting your system.

Step 1: Reset the SystemIf you are adjusting the burner system for the first time,then you must follow these steps:

1. Reset the system

2. Set air pressure drop

3. Verify the air setting

4. Ignite the pilot

5. Ignite the burner

6. Set low fire gas

7. Set high fire gas

8. Verify the gas settings

Close the automatic gas valves and the gas cocks.

Step 2: Set Air Pressure Drop1. Start the main fan on the make-up or process air unit.

2. Set the fan inlet damper or profile plates to producethe desired pressure drop across the burner. Airpressure drop can be read as a differential pressureacross the burner using a U-Tube manometer asshown.

Figure 4.1

Step 3: Verify the Air SettingsMake sure that all the settings are still the same after youcycle the system several times between high fire and lowfire. Check air proving switch and adjust if necessary.

NOTE: Test spark ignitor with a visual or audible checkbefore attempting ignition.

Step 4: Ignite Pilot

Figure 4.2 Pilot Adjusting Valve

1. Set system to operate on pilot only. See the literatureincluded with the flame monitoring relay.

2. Set pilot regulator to 6" w.c. outlet pressure.

3. Open the pilot adjusting valve 3 to 4 turns. (PN 12659ordered separately.)

4. Initiate start sequence and ignite the pilot.

NOTE: Initially it may be necessary to repeat step 4 twoor three times to purge air out of the gas pipework.

DANGER

AirFlow

Profile Plate

U-TubeManometer

10"Min.

10"Min.

Top Screw

Handle(Shown in

Open Position)

Adjusting Screw(Clockwise for less pilot gas,

Counterclockwise for more pilot gas)

4


5. Trim pilot with adjustable gas cock to obtain flame justinside air wings.

NOTE: The pilot flame should be a bushy, blue flameinside the first one-fourth of the air wings. This flameshould provide a stable pilot with good flame signalreadings sufficient to energize the main gas valve.

Step 5: Ignite the BurnerNOTE: This procedure assumes that automatic flamesafety is installed and is serviceable.

1. Make sure the supply air fan is running.

2. Adjust the main gas regulator to supply the minimumpressure required; see Datasheet No. 160 for gaspressure drop and measurement information.

3. Verify that the main gas control valve is at its minimumopen position (5°).

4. Light the pilot.

5. Open all manual fuel shut-off valves.

6. Initiate the ignition sequence through the flame safety.

7. Check that the pilot and then burner flames haveignited.

NOTE: The input required to ignite the main burner will bemore than the minimum input capability of the burnergiven in Datasheet No. 160. Nominally, an input of 50,000BTU/hr/ft is required for ignition of the main burner.

Step 6: Adjust Low Fire GasIf necessary, adjust the main gas control valve’s minimumopen position until the low fire flame is tight against thebase of the burner body and is uniform along the length ofthe burner.

Step 7: Adjust High Fire Gas

Figure 4.3

1. Drive the main gas control valve to high fire.

2. Measure the gas pressure drop at high fire andcompare to the appropriate chart in Datasheet No.160. If the maximum input is not achieved or is toohigh while the main gas control valve is fully open, twoadjustments can be made:

a.The manual butterfly valve in the gas line can beadjusted open or closed, or

b.The main gas pressure regulator can be adjustedhigher or lower.

■ Make sure that you close all the pressure taps afteryou remove the manometer. Gas that leaks fromthe pressure taps can cause fires and explosions.

Step 8: Verify Gas Settings1. Once the high and low fire conditions have been set,

cycle the burner from high to low fire several times tocheck repeatability of settings.

2. Shut down the burner and relight to ensure automatedpilot and main flame ignition operates correctly.

3. Check all safety interlocks and limits to ensure properoperation.

4. Make sure that all the settings are still the same afteryou cycle the system several times between high fireand low fire.

5. When all settings have been completed, mark theposition of the position indicator on each butterflyvalve to indicate valve position. This will save timelater.

Start Procedure1. Start the air supply fan.

2. Open all the gas cocks.

3. Start the automatic ignition sequence.

■ If a burner does not light, and the system does notshut down automatically then you must close themain gas cock. An uncontrolled flow of gas cancause fires and explosions.

■ Do not touch the ignition plug or the ignition wirewhen the ignition is on. You will get a shock.

“D”10-20"(254-508mm)

Main gas differential pressure measured between “A” and “D”

"A"Tap On

Inlet GasPiping

•

DANGER

DANGER


4. Make sure that you can see the flame in the burnersystem.

If the burner system does not light and does not shutdown automatically, close the main gas cock manually.DO NOT operate the system. Go to "Checklist AfterInstallation" and verify the steps. After that, repeat thestart procedure.

If the burner system does not light and shut downsautomatically, see the troubleshooting section in the nextchapter.

Stop ProcedureTo stop, close the following valves:

• the manual gas cock for the burner• the manual gas cock at the main control valve• all of the manual shut-off valves in the gas line

upstream of the burner gas cock


Maintenance &Troubleshooting

IntroductionThis section is divided into two parts:

• the first part describes the maintenance procedures• the second part helps you to identify problems that

may occur, and gives advice on how to solve these problem

MaintenancePreventative maintenance is the key to a reliable, safeand efficient system. The following are suggestedguidelines for periodic maintenance. Burners in severeenvironments or operational conditions should bechecked more frequently.

NOTE: The monthly and yearly lists are an averageinterval. If your environment is dirty, then the intervals maybe shorter. Check with local authorities having jurisdictionon their recommended maintenance schedules.

■ Turn off power to burner and controls beforeproceeding with burner inspection.

Monthly Checklist1. Inspect flame sensing devices for good condition and

cleanliness.

2. Test all alarms for proper signals.

3. Check ignition spark electrode operation and checkproper gap.

4. Check all valve motors and control valves for free,smooth action and adjustment.

5. Test interlock sequence of all safety equipment andmanually make each interlock fail, noting that relatedequipment closes and stops as specified by themanufacturer. Test flame safeguard by manuallyshutting off gas to burner.

6. Test all manual fuel valves for operation.

7. Check filters on main air fan for cleanliness.

8. Check gas filter or strainers.

Yearly Checklist1. Test (leak test) safety shut-off valves for tightness of

closure.

2. Test pressure switch settings by checking switchmovements against pressure settings.

3. Visually check ignition cable and connectors.

4. Inspect gas injection holes and burner mountingstructure.

5. Check profile plate position against final position frominitial setup.

6. Check all screws and bolts holding air wings to eachother and to the burner bodies.

7. Inspect both sides to ensure no air holes are blockedand that there is no build up of foreign material on thewings.

8. Inspect air wings for distortion and bending.Excessive distress may indicate a non-uniformpressure drop/velocity or operation outside of therecommended limits on input and velocity. Replace airwings as necessary.

CAUTION

5


Problem Possible Cause SolutionCannot initiate start-up sequence Air pressure switch has not made contact;

Air flow too lowCheck air flow and investigate any changes.

Air pressure switch has not made contact;Air pressure switch incorrectly set

Check air pressure switch adjustment.

Air pressure switch has not made contact;Air pressure drop measured incorrectly

Move pressure taps on duct to a better location.

Cannot initiate start-up sequence High gas pressure switch has tripped; Gaspressure too high

Check incoming gas pressure against initialsetting; adjust as required.

High gas pressure switch has tripped; Gaspressure switch set too low

Adjust setting to be approximately 4" w.c. abovegas pressure.

Low gas pressure switch has tripped; Gaspressure too low.

Check incoming gas pressure against initialsettings; adjust as required

Low gas pressure switch has tripped; Gaspressure switch set too high

Adjust setting to be approximately 4" w.c. belowgas pressure.

Purge cycle not completed Check flame safeguard system or purge timer.Main power is off Make sure power is on to control system.No power to control unit Call qualified electrician to investigate.Malfunction of flame safeguard system;Flame sensor shorted out

Ensure flame rod element is not touching burner;check UV sensor and wiring.

Malfunction of flame safeguard system;Electrical noise in sensor line

Shield or separate sensor lines from high voltage.

Malfunction of flame safeguard system;Unit is broken

Call qualified electrician to investigate.

Start-up sequence runs but pilotdoes not light

No spark; No power to ignition transformer Have electrician investigate.No spark; Open circuit between the ignitiontransformer and the spark plug

Repair or replace wiring to spark plug.

No spark; Spark plug has carbon build-up Clean or replace spark plug.No spark; Spark plug not correctlygrounded

Clean spark plug threads. Do not apply grease orpipe compound to pipe threads.

No spark; Spark plug gap is incorrect Set gap to specifications.Not enough pilot gas; Pilot gas regulator settoo low

Check incoming gas pressure against initialsettings; increase as necessary.

Not enough pilot gas; Gas pressure intopilot regulator too low

Check outgoing gas pressure of main regulator;increase as necessary.

Not enough pilot gas; Pilot gas cock closed Open pilot gas cock.Not enough pilot gas; Pilot solenoid valvedoes not open

Have qualified electrician check power supply tosolenoid.

Not enough pilot gas; Gas adjusting valveset too low

Adjust gas flows

Not enough pilot gas; Air in the gas line Repeat start-up several times to purge air out ofgas lines.

Not enough pilot gas; Gas is leaking frompilot end plate

Check bolts and tighten as necessary.

Too much gas Trim pilot gas adjusting valve.Start-up sequence runs, pilot lightsbut main burner does not light

No flamerod or UV signal Check wiring and control logic.Not enough main gas; Main gas regulatorset too low

Check outgoing gas pressure of main regulator;increase as necessary

Not enough main gas; Gas pressure intomain regulator to low

Check incoming gas pressure against initialsettings; increase as necessary


Start-up sequence runs, pilot lightsbut main burner does not light

Not enough main gas; Main gas cockclosed

Open all gas cocks.

Not enough main gas; Main safety shut-offvalve does not open

Have qualified electrician check power supply andsafety circuitry.

Not enough main gas; Gas adjusting valveset too low.

Adjust gas flows.

Not enough main gas; Air in the gas line Repeat start-up several times.Too much gas Trim pilot gas adjusting valve.

Pilot ignites but flame safeguardshuts down burner

No flamerod or UV signal Check wiring and control logic.

Burner kicks out shortly after start-up

Low gas pressure switch is set too high Check and reset low pressure switch setting.

The low fire flame is weak andunstable

Not enough gas Check startup settings and adjust to increase gasflow.

Too much air Check air pressure drops / velocities across theburner and adjust.

Poor distribution of main gas Ensure proper number of gas feeds are used.Ensure manifold is sized properly. Refer to DesignGuide No. 160 for recommendations.

Poor air distribution Check profiling and duct configuration.Burner does not go to high fire Not enough gas pressure into main gas

regulatorAdjust pressure regulator so pressure is providedat burner as specified in this manual.

Gas pressure drops as input is increased Check for clogging of valves and regulators in gasline.

Main gas control valve is not functioning Check actuator and linkage.Main flame is uneven along thelength of the burner

Air pressure drop / velocity is too low Increase air pressure drop.Poor air distribution Check profiling and duct obstructions.Air wings are dirty, holes are clogged Inspect and clean the air wings if necessary,Poor distribution of main gas Ensure proper number of gas feeds are used.

Ensure manifold is sized properly; refer to DesignGuide No. 160 for recommendations.

Main flame is too large at high fire Gas pressure too high at burner inlet Check gas pressure against design. Adjust maingas pressure regulator, or adjust manual adjustingvalve.

Air pressure drop/velocity is too high Open air damper on main air blower or adjustprofile plates.

Main flame does not achievecapacity

Air pressure drop/velocity is too high Check pressure drop or velocity. Check airdamper on main air blower.

Burner is firing below rated input Check gas pressure differential. Adjust main gaspressure regulator as necessary.

Burner gas holes are plugged Inspect gas holes for dirt or lint; clean as needed.Main flame is yellow and long Air pressure drop/velocity is lower than

designCheck pressure drop or velocity. Open air damperon main air blower.

Air wings are dirty, holes are clogged Inspect and clean the air wings if necessary.

Problem Possible Cause Solution


Straight Section Parts List

A

A

B

B

C

C

10

13

17

185

11

8111215

111215 3

11121515

1211

11

12

15

111215

11

7

1

2

1

6

13

14

16

13

16

14

6

4

13

101

2

1

9113

11

9

9

11

11

8

19


Tee Section Parts List

A

A

B

B

C

C

121316

12

8

12

13

16 4

121316

1613

12

121316

11

3

17

15

14

14

15

17

12

10

2

2

12

10

4

11

147

5

9

12

6

12

9

19

18

11

14

7

121316

20


Straight Section Parts List Tee Section Parts List

Recommended Spare Parts SectionTo make sure that the downtime of the system is as short as possible in case of a failure, you should keep a stock ofspare parts.

Recommended spare parts:

• Spark Plug• Flame Rod• UV Scanner (if used)• End Plate Gasket

Ref No. Qty Description Part No.1 4 Straight Air Wing 765012 2 Air Wing Joint Bracket 765073 2 Air Wing Reinforcement Plate 765054 1 Plain End Plate 765045 1 Pilot End Plate 765036 2 End Plate Gasket 765107 8 Screw, M4 x 12, Hex Head 203948 8 Screw, M4 x 20, Hex Head 203959 8 Screw, M4 x 25, Hex Head 2033510 4 Screw, M10 x 40, Hex Head 2033611 48 Washer, M4, Flat 9078712 24 Washer, M4, Lock 2024413 8 Washer, M10, Flat 9076814 4 Washer, M10, Lock 1589015 24 Nut, M4 9078616 4 Nut, M10 1588917 1 Spark Plug 13047-118 1 Flame Rod 1309319 1 UV Adapter, 1/2" 20201019 1 UV Adapter, 3/4" 20201120* 1 Gas Cock, Adjustable 1/4" 12659

* Not shown

Ref No. Qty Description Part No.1 2 Straight Air Wing 765012 2 Air Wing Joint 765023 1 Air Wing Joint Bracket 765074 1 Air Wing Reinforcement Plate 765055 1 Plain End Plate 765046 1 Pilot End Plate 765037 2 End Plate Gasket 765108 8 Screw, M4 x 12, Hex Head 203949 8 Screw, M4 x 20, Hex Head 20395

10 12 Screw, M4 x 25, Hex Head 2033511 4 Screw, M10 x 40, Hex Head 2033612 56 Washer, M4, Flat 9078713 28 Washer, M4, Lock 2024414 8 Washer, M10, Flat 9076815 4 Washer, M10, Lock 1589016 28 Nut, M4 9078617 4 Nut, M10 1588918 1 Spark Plug 13047-119 1 Flame Rod 1309320 1 UV Adapter, 1/2" 20201020 1 UV Adapter, 3/4" 20201121* 1 Gas Cock, Adjustable 1/4" 12659

* Not shown

i

Conversion Factors

Metric to English

Metric to Metric

English to Metric

From To Multiply Byactual cubic meter/hr (am³/h) actual cubic foot/hr (acfh) 35.31

normal cubic meter/hr (Nm³/h) standard cubic foot /hr (scfh) 38.04degrees Celsius (°C) degrees Fahrenheit (°F) (°C x 9/5) + 32

kilogram (kg) pound (lb) 2.205kilowatt (kW) BTU/hr 3415

meter (m) foot (ft) 3.281millibar (mbar) inches water column ("w.c.) 0.402millibar (mbar) pounds/sq in (psi) 14.5 x 10-3

millimeter (mm) inch (in) 3.94 x 10-2

MJ/Nm³ BTU/ft³ (standard) 26.86

From To Multiply BykiloPascals (kPa) millibar (mbar) 10

meter (m) millimeter (mm) 1000millibar (mbar) kiloPascals (kPa) 0.1millimeter (mm) meter (m) 0.001

From To Multiply By

actual cubic foot/hr (acfh) actual cubic meter/hr (am³/h) 2.832 x 10-2

standard cubic foot /hr (scfh) normal cubic meter/hr (Nm³/h) 2.629 x 10-2

degrees Fahrenheit (°F) degrees Celsius (°C) (°F - 32) x 5/9pound (lb) kilogram (kg) 0.454

BTU/hr kilowatt (kW) 0.293 x 10-3

foot (ft) meter (m) 0.3048inches water column ("w.c.) millibar (mbar) 2.489

pounds/sq in (psi) millibar (mbar) 68.95inch (in) millimeter (mm) 25.4

BTU/ft³ (standard) MJ/Nm³ 37.2 x 10-3

Appendix