SAMUEL JACKSON HO-7-1237 Service Manual

Oil-fired heaters

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SERVICE MANUAL

HO-7-1237

HO-4-1234

OIL-FIRED HEATERS

SAMUEL JACKSON

DRYAIRE HEATER

PAGE -2 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS

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Page 1 SERVICE MANUAL HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS SAMUEL JACKSON DRYAIRE HEATER PAGE -2 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 3: Table Of Contents
Assembly Detail for 80080 Inlet Screen Stand......59 Outlet Bolt Hole Pattern for 80080 Inlet Screen Stand..... 60 Copyright © 2003 SAMUEL JACKSON, INCORPORATED. All rights reserved. PAGE 0 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 4 This manual gives general information on the location of thermocouples and optional moisture sensing equipment and the temperature control logic. If the heater is part of a Samuel Jackson Drying System, more detailed information will be shipped to you under separate cover specifically for your system.
Page 5 If a chokeup occurs, static pressure is still present and the burner continues to operate. This can cause a fire. All Samuel Jackson heaters use an air flow switch which measures the difference in pressure sensed by orifices pointing upstream and downstream.
Page 6: Heater Operation
If ignition fails, the heater controls will automatically make two more attempts following appropriate air purge delays. PAGE 3 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 7 The “Test Program” can be activated by a qualified service man or trained user to test the heater. It is always performed in the Samuel Jackson factory before shipment of a new heater and occasionally in the field when necessary for troubleshooting. This program allows the service man to proceed step-by-step, through a series of tests where individual components of the heater can be tested, calibrated, and adjusted.
Page 8 Figure 2 – Basic Temperature Control 14-3567.3 In Samuel Jackson drying systems, the blue primary thermocouple is placed after the dryer’s skimmer in the skimmed air. For tower drying systems, this thermocouple should be placed in the top of the tower or in the transition immediately before the tower. Due to the responsiveness of the temperature controls, placing this thermocouple farther down in the tower will cause control instability.
Page 9 Pressing SETPOINT SELECT button again will put the controller back into RSP mode. A bright rectangle will appear on the left of the control display indicating when the PAGE 6 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 10 Figure 4 shows the feed- forward control with a moisture sensor in the storage bin of a feed control. The moisture control is adjusting the temperature of one heater that may be part of either a Samuel Jackson drying system or tower drying system. Figure 4 – Basic Feed-Forward Moisture Control 14-3567.4...
Page 11 Use this arrangement for tower drying systems where both first and second stage heater temperatures are adjusted automatically with the moisture control. This arrange ment is used for Samuel Jackson drying systems using more than one heater. One PRIMARY TEMP CONTROLLER is used for measuring the temperature after a dryer.
Page 12 The ALARM and ERROR history can also be viewed at the console. See the section on ERROR and ALARM LOGGING SYSTEM for information on using this special feature. PAGE 9 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 13: Error And Alarm Logging System
The ERROR and ALARM LOGGING SYSTEM is a new feature for the Oil-Fired Heaters and is designed to make troubleshooting easier for both the user and Samuel Jackson service personnel. This system remembers the last 500 ERRORS and ALARMS, thus showing a history of past problems.
Page 14: Error And Alarm Diagnostic Codes
GAS VALVE LEAK, UPSTREAM (DUAL-FUEL MODEL) 459 * GAS VALVE LEAK, DOWNSTREAM (DUAL-FUEL MODEL) 460 * GAS LOW PRESSURE SWITCH NOT WORKING (DUAL- FUEL MODEL) PAGE 11 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 15 POWER FAULT DURING OPERATION STAGE USER SPECIFIED TIME FOR SHUTDOWN E320 TIME OUT E042 NO CPU BATTERY † ALERTS ARE NOT LOGGED * DUAL-FUEL OPTION ONLY PAGE 12 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 16: Error And Alarm Explanations
If the operator is aware of the safety reasons for this air flow switch check and desires to not turn the fans off, a passcode to bypass this ERROR is described in the footnote for this section. PAGE 13 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 17 The pressure shown on the air pressure gage in the cabinet should be equal to the oil pressure, normally about 60 psi. PAGE 14 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 18 ERROR 441 FAN INTERLOCK HAS BEEN BYPASSED: Samuel Jackson Heaters are provided with a fan interlock to provide immediate shutdown of the heater when the fans are turned off. This error indicates that an electrical signal is being received through the fan interlock with no airflow present, effectively bypassing this important safety feature.
Page 19 See maintenance tips below. The Heater will not attempt to restart if ERROR 456 NO SAFETY SWITCH TEST PERFORMED LAST SIX SHUTDOWNS occurs and is reset without allowing time for test. PAGE 16 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 20 6 shutdowns have had the tests interrupted, the PLC will not start until the RESET button is pressed (ERROR 456 will be displayed). PAGE 17 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 21 3 and 5 PSI. Contamination in the gas pressure regulator (or a failed gas pressure regulator) can cause this error. PAGE 18 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 22 HOT BOX TRASH GATE OPEN MORE THAN 20 SECONDS: This ALARM is optional for users of the Samuel Jackson Hot Box II. The pivoting trash gate on the Hot Box has remained open for more than 20 seconds allowing outside air to leak into the drying system.
Page 23 POWER FAULT DURING OPERATION STAGE: This ERROR means that electrical power was disconnected while the burner was on. Check for faulty supply wiring connections. PAGE 20 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 24 20000 remote control to the left (STOP) 3 times. - Press the RESET button to clear the ERROR and attempt to restart the heater. PAGE 21 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 25: Test Sequence Explanation
When finished, confirm the new time and date by pressing RESET to proceed to step 2. PAGE 22 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 26 The digital air temperature c ontrollers are energized during this step. These digital controllers have been pre-tuned by the factory for best operation with the Oil-Fired Heater. PAGE 23 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 27 45 psi (3.1 bars). Adjust OLP if necessary. The Oil High Pressure Switch OHP (right) is factory set to turn OFF Input No. 21 at about 90 psi (6.2 bars). Press RESET to proceed. PAGE 24 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 28 The STATUS light should stop blinking when the test program is terminated. To operate the burner normally, turn either START (l) switch and release. PAGE 25 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 29: Test Sequence
ADJUST LOW FIRE SWITCH AND LINKAGE (+) RIGHT: OPENS VALVE CENTER TO HOLD POSITION (-) LEFT: CLOSES VALVE RESET AND AIR FLOW ON PAGE 26 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 30 * 10 SEC WITHOUT FLAME RESETS TO STEP 0 FLAME STEPS TO 16 10 MINUTE NORMAL OPERATION NOT FLAME OR STOP OR 10 MINUTES EXITS TEST PROGRAM PAGE 27 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 31: Installation Stub-Ups
NATURAL GAS OR PROPANE (DUAL-FUEL ONLY) 5 TO 20 PSI, 0.3 TO 1.4 BARS (HO-7) 2 INCH PIPE (HO-4) 1 ½ INCH PIPE PAGE 28 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 32 TYPE-J THERMOCOUPLE WIRE: 400 FEET CABLE WITH 2 SHIELDED TWISTED PAIRS AND GROUND WIRE: 200 FEET (WHEN SHIPPED WITH OPTIONAL 20050 DIAGNOSTIC MODULE) PAGE 29 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 43: Component List
ELECTRONIC DRIVE, 4-20 UPPER CABINET 14845A, CP-9302 WATER TRAIN FUEL FLOW METER BURNER 16690, 26991, 2-60 GPH (HO-7) 14501, 26990, 2-40 GPH (HO-4) PAGE 40 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 44 16645, PRESSURE TRANSDUCER, RD40A11 *GPG GAS PRESSURE GAGE GAS TRAIN 11278, 9851933, 0-5 PSI CABINET *GPR GAS PRESSURE REGULATOR, 1-1/4 LOWER CABINET 16595A, 121-8HP PAGE 41 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 45 14856A, LR2D1312 MOL2 FUEL PUMP OVERLOAD UPPER CABINET 14737A, LR2D1305 OIL HIGH PRESSURE SWITCH LOWER CABINET 16647, PB-11B TRANSDUCER FOR OHP 16668, RF10A42 PAGE 42 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...
Page 46 GAS SAFETY SHUT-OFF VALVE, 1 –1/2 GAS TRAIN *SSOV2 17271, VALVE, VGG 10.404U 1-1/2 CABINET 17270, ACTUATOR, SKP10.110U17 * GAS TRAIN COMPONENTS USED ONLY ON DUAL-FUEL UNITS PAGE 43 of 61 HO-7-1237 & HO-4-1234 OIL-FIRED HEATERS © SAMUEL JACKSON, INCORPORATED 2003 ALL RIGHTS RESERVED...

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Ho-4-1234

SAMUEL JACKSON HO-7-1237 Service Manual

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