SAMUEL JACKSON Vulcain Service Manual

Oil-fired heaters

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Vulcain

Oil-Fired Heaters

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Page 1 Vulcain Oil-Fired Heaters...
Page 2: Table Of Contents
ELECTRICAL SCHEMATIC WITH ANALOG PLC I/O ..............56 COMPONENT LIST FOR HO-7-VULCAIN & HO-4-VULCAIN ............57 OIL BURNER HEAD COMPONENTS FOR HO-7 AND HO-4 VULCAIN ........63 BURNER HEAD SUB-ASSEMBLY MAINTENANCE ................ 64 FUEL VALVE LINKAGE ADJUSTMENT FOR HO-7-VULCAIN ............. 66 FUEL VALVE LINKAGE ADJUSTMENT FOR HO-4-VULCAIN .............
Page 3 INLET AND OUTLET HOLE PATTERN FOR HO-4-VULCAIN ............. 71 DIMENSION SHEET FOR HO-4-VULCAIN ..................72 DISCHARGE OPTIONS FOR HO-4-VULCAIN .................. 73 ASSEMBLY DETAIL OF INLET SCREEN ASSEMBLY ..............74 OUTLET HOLE PATTERN FOR INLET SCREEN ASSEMBLY ............75 ADJUSTMENT OF 12796 AND 14200 SPARK IGNITORS ............76 WARRANTY AND SAFETY NOTICES ....................
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: Warning
Moving Parts. Many Samuel Jackson products have moving or rotating parts. These parts could form pinch points or grab loose clothing or jewelry. Do not reach across or into any product while in operation.
Page 6 Additional safety information is located throughout this manual and should be read carefully before operating this Samuel Jackson product. If you have any questions about how to properly operate a Samuel Jackson product, please call 806-795-5218 before proceeding. PAGE 6 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT ©...
Page 7: Safety Features Of Oil-Fired Heaters
If a choke 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 transducer which measures the difference in pressure sensed by orifices pointing upstream and downstream.
Page 8: New Features
Moisture Mirror 2X, 3X, or 4X. You may simply connect it using a standard Ethernet CAT-5e cable to a Samuel Jackson Moisture Mirror X. A single Mirror will act as a common remote control for a maximum of eight Samuel Jackson 15XX Heaters and four 1600 Series Humidaire Units at the same time.
Page 9: Heater Operation
(for instance a fuel supply valve that is closed) and you may be able to correct it without assistance. PAGE 9 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 10 Angling the thermocouple 45 degrees in the direction of cotton flow will prevent cotton and trash from tagging on the thermocouple. PAGE 10 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 11 Basic Temperature Control In Samuel Jackson drying systems, the after mix-point thermocouple is placed after the dryer’s skimmer in the skimmed air. In some Samuel Jackson drying systems, one after mix-point temperature will be used for controlling the before mix-point temperatures of more than one Heater.
Page 12 Press the magnifying glass on the Home Screen to switch to the STATUS screen. Heater Status Screen PAGE 12 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 13 WHAT IS THE ERROR & ALARM LOGGING SYSTEM? The ERROR & ALARM LOGGING SYSTEM 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 along with the time and date of each one.
Page 14: Navigating Important Menus
Navigating Important Menus MAGNIFYING GLASS → HEATER STATUS PAGE 14 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 15 WRENCH →HEATER SETUP Under heater setup, press the button to proceed to the corresponding menu below. PAGE 15 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 17: Enhancing Fuel Efficiency
Heat guns are available from the factory for rental or purchase. Applying Cotton Koozie Shrink Wrap Film over fiberglass batt insulation. PAGE 17 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 18: Moisture Mirror X Option
The 1500 series Heaters are compatible with the optional Moisture Mirror X offering remote control (normally from ginner’s console) of the unit via a CAT5 ethernet connection. It has the ability to control up to eight Samuel Jackson Heaters and four Samuel Jackson Humidaire Units.
Page 19 By pressing either manual button the heater can then be controlled by manually putting in either a Before-Mix or After-Mix temperature target. These options can be seen in the following two screenshots. PAGE 19 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 20: Error & Alarm Logging System
Error & Alarm Logging System The ERROR and ALARM LOGGING SYSTEM 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 21: Error & Alarms Explanation
ERROR code 144. After ERROR code 144 is cleared, the operator can attempt to restart the burner. PAGE 21 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 22 Heater to shut down once a day at a user defined time. This error will only occur if it is enabled. PAGE 22 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 23 ERROR 141 FAN INTERLOCK BYPASSED: Samuel Jackson Heaters are provided with a fan interlock relay (FIR) to provide immediate shutdown of the Heater when the fan(s) 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 24 (and easily exceeded by normal operating temperatures). It can also occur if Type-K thermocouple wire has not been used PAGE 24 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 25 HOT BOX TRASH GATE OPEN FOR 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 II has remained open for more than 20 seconds allowing outside air to leak into the drying system.
Page 26 4mA DC from the heater body temperature transducer. First check that all wires are firmly attached in the circuit, that there is no broken wire and that fuse 1.3 is not blown. PAGE 26 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 27 • Verify free rotation of motor and pump shaft. • Verify fuel oil high pressure is not set too high. PAGE 27 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 28 FLAME ON TOO LONG: This error occurs when a flame signal has been received for greater than 10 seconds during shutdown mode. PAGE 28 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 29 If this error occurs, check for proper wiring of the combustion fan. PAGE 29 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 30: Troubleshooting
(such as voltage signal showing on/off condition of a switch) have small red lights that are shown on the face of the PLC. The “ELECTRICAL SCHEMATIC WITH PLC INPUTS/OUTPUTS FOR VULCAIN HEATERS”, included in this manual and on the inside door of the cabinet, show the input/output numbers for the PLC.
Page 31: Test Program
777. Oil Burner Head and Purge Line Oil cock at back of burner head (Open to Purge) PAGE 31 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 32 Press the “TESTS” button to access the Test Program Contrast button adjusts the brightness of the screen for easier viewing PAGE 32 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 33 If it is red, then the component may have failed, may not be connected properly, or is out of adjustment. PAGE 33 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 34 It travels 90 degrees for fully open while FVM linkage arm travels 160 degrees. Fuel Valve Motor (FVM) Temperature Control Valve (TCV) PAGE 34 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 35 Close this valve after it has been checked to prevent fuel pooling in the heater. PAGE 35 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 36 See the page ADJUSTMENT OF 12796 AND 14200 SPARK IGNITORS for information on setting the oil spark plug. PAGE 36 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 37: Setup Wizard
The Atomizing Air Valve and Oil Valve are checked here. Pressing the corresponding button will turn the valve on and off. Each valve should be turned off before exiting this page. PAGE 37 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 38 OFF) when the ignition is transformer is on. For safety, the “Transformer Off” button will not be available until both the fan interlock and air flow conditions are satisfied for 20 seconds. PAGE 38 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 39: Additional Settings
Descriptions for the rest of the setups are shown below. Heater Setup Screen ANALOG SETTINGS Analog Settings Screen PAGE 39 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 40 Ethernet port ID number of the Heater that the after mix thermocouple is connected to for some drying systems. PAGE 40 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 41 When more than one Heater is used in a Samuel Jackson drying system, it is common to have one after mix temperature controlling the before mixpoint set points of all the Heaters. The “HEATER 1”, “HEATER 2”, etc. buttons are referring to which Heater is connected to the after mixpoint thermocouple.
Page 42 Combustion Air Low Limit is the minimum atomizing air pressure allowed for the heater to continue running without going into an emergency stop. The default is 0.5 inches water column. PAGE 42 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 43 The default password is 1234. Touch the “PASSWORD” button to go to a screen that allows you to change the default password. The password can be a 1 to 4 digit number. PAGE 43 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 44: Analog Fuse Replacement
Analog Fuse Replacement Your Vulcain Heater is equipped with 32 mA fast blow fuses on analog 4-20 mA DC inputs to prevent damage to the input cards in the event that the analog sensors are wired incorrectly. In the event that a fuse is burned out, two spares are provided.
Page 45: Electrical Installation Notes
If bypassed, the Heater will signal this as an error later in operation. PAGE 45 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 46: Additional Installation Notes
Recommended Fuel and Atomizing Air pressure settings Machine Fuel Atomizing Air HO-1 20 psi 50 psi HO-4 60 psi 120 psi HO-7 60 psi 120 psi PAGE 46 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 47: Installation Stub-Ups For Ho-7-Vulcain And Ho-4-Vulcain
2 CONDUCTOR, 18 GA CABLE. * DO NOT RUN WITH AC VOLTAGE WIRES. OKAY TO RUN WITH OTHER THERMOCOUPLE OR DC VOLTAGE SENSOR WIRES. PAGE 47 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 48 OKAY TO RUN WITH THERMOCOUPLE WIRE OR OTHER DC WIRES. * SHIELDED 2 CONDUCTOR, 18 GA CABLE - 200 FEET PAGE 48 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 51: External Electrical Connections For Vulcain Heaters
External Electrical Connections for Vulcain Heaters PAGE 51 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 52: Electrical Connection Of Options For Vulcain Heaters
Electrical Connection of Options for Vulcain Heaters PAGE 52 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 53: External Wiring Diagram For Fan Current Relay
External Wiring Diagram for Fan Current Relay PAGE 53 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 55: Electrical Schematic With Discrete Plc I/O
Electrical Schematic with Discrete PLC I/O PAGE 55 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 56: Electrical Schematic With Analog Plc I/O
Electrical Schematic with Analog PLC I/O PAGE 56 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 57: Component List For Ho-7-Vulcain & Ho-4-Vulcain
16480A, 500 VA, E500TF DISCONNECT SWITCH IGNITION RELAY UPPER CABINET 17446, RH1B-U 120VAC FUEL FLOW METER BURNER 13319, 2-20 GPH 26989 PAGE 57 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 58 12796, CS 13508, FOR HO-7-VULCAIN IGNITION TRANSFORMER BEHIND CABINET 14200, IP-19 LOW FIRE SWITCH BURNER 16848, BZE6-2RN80 NETWORK SWITCH UPPER CABINET 23702C, IE-SW5-WAVE PAGE 58 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 59 THERMOCOUPLE (RED), BEFORE MIX-POINT PIPING BEFORE 21709, 8”, TYPE ‘J’, 0-777, 4-20mA TRANSMITTER MIXPOINT COLOR TOUCH PANEL UPPER CABINET 22045B, EA9-6IN DOOR PAGE 59 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 63: Oil Burner Head Components For Ho-7 And Ho-4 Vulcain
Oil Burner Head Components for HO-7 and HO-4 Vulcain PAGE 63 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 64: Burner Head Sub-Assembly Maintenance
Burner Head Sub-Assembly Maintenance PAGE 64 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 66: Fuel Valve Linkage Adjustment For Ho-7-Vulcain
Fuel Valve Linkage Adjustment for HO-7-Vulcain PAGE 66 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 67: Fuel Valve Linkage Adjustment For Ho-4-Vulcain
Fuel Valve Linkage Adjustment for HO-4-Vulcain PAGE 67 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 68: Dimension Sheet For Ho-7-Vulcain W/ Vertical Discharge
Dimension Sheet for HO-7-Vulcain w/ Vertical Discharge PAGE 68 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 69: Dimension Sheet For Ho-7-Vulcain W/ Horizontal Discharge
Dimension Sheet for HO-7-Vulcain w/ Horizontal Discharge PAGE 69 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 70: Inlet And Outlet Hole Pattern For Ho-7-Vulcain
Inlet and Outlet Hole Pattern for HO-7-Vulcain PAGE 70 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 71: Inlet And Outlet Hole Pattern For Ho-4-Vulcain
Inlet and Outlet Hole Pattern for HO-4-Vulcain PAGE 71 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 72: Dimension Sheet For Ho-4-Vulcain
Dimension Sheet for HO-4-Vulcain PAGE 72 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 73: Discharge Options For Ho-4-Vulcain
Discharge Options for HO-4-Vulcain PAGE 73 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 74: Assembly Detail Of Inlet Screen Assembly
Assembly Detail of Inlet Screen Assembly PAGE 74 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 75: Outlet Hole Pattern For Inlet Screen Assembly
Outlet Hole Pattern for Inlet Screen Assembly PAGE 75 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 76: Adjustment Of 12796 And 14200 Spark Ignitors
Adjustment of 12796 and 14200 Spark Ignitors PAGE 76 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...
Page 78 The modifier of the controls assumes all liability for these consequences. Samuel Jackson, Incorporated 3900 Upland Avenue Lubbock, Texas 79407 806-795-5218 PAGE 78 of 79 VULCAIN OIL-FIRED HEATER LAST UPDATED: JAN 22-2019 COPYRIGHT © SAMUEL JACKSON, INCORPORATED 2018 ALL RIGHTS RESERVED...

SAMUEL JACKSON Vulcain Service Manual

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