Table of Contents
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1-800-836-7432
Heating
Cooling
Dehumidifying
Ventilating
This manual is the property of the
owner. Leave with the unit when
set-up and start-up are complete.
For your safety,
do not use this heater in a
space where gasoline or
other liquids having
flammable vapors are
stored or used.
THP-400A, THP-500A and THP-550
Gas, Direct-Fired Process Heater
Installation and Service Manual
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Rating Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Fuel Supply System - Bulk-Tank System . . . . . . . . . . . . . . . . . . . . . . . . . .7
Natural-Gas Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Preliminary Start-Up Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Control Vestibule Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Start-Up Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Shut-Down Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Short-Term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Long-Term or Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Wiring Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Airflow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Setting Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
To Check Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
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Table of Contents
Summary of Contents for Temp-Heat THP-400A
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Page 1: Table Of Contents
THP-400A, THP-500A and THP-550 Gas, Direct-Fired Process Heater Installation and Service Manual 1-800-836-7432 Warning ............3 Introduction . - Page 2 THP-400A, THP-500A and THP-550 Installation and Service Manual...
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Page 3: Warning
TEMP-HEAT ® Warning We cannot anticipate every use which may be made of our heaters. Check with your local fire safety authority if you have questions about applications. Other standards govern the use of fuel gases and heat-producing products in specific applications. -
Page 4: Introduction
This instruction booklet contains the necessary information, instructions, and guidelines to achieve maximum efficiency and safety from the TEMP-HEAT process heater. Please read all instructions before attempting the set-up and operation of this heater. -
Page 5: Rating Information
TEMP-HEAT ® Rating Information For indoor or outdoor installation Unit Specifications THP-400A THP-500A THP-550 2,500 3,000 3,000 BTU/Hour minimum 200,000 44,500 40,500 maximum 400,000 500,000 550,000 Inlet Pressure minimum psig Natural Gas maximum psig Inlet Pressure maximum psig Propane Gas... -
Page 6: Control Functions
Second-Stage Regulator Reduces the outlet pressure from first-stage levels to burner pressure. Starter Interlock Proves motor-starter is engaged in the normally closed position. Thermostat Automatically cycles the heater from low- to high-fire to maintain desired room temperature. THP-400A , THP-500A and THP-550 Installation and Service Manual... -
Page 7: Fuel Supply System - Bulk-Tank System
TEMP-HEAT ® Fuel Supply System — Bulk-Tank System • Installation must comply with all state and local codes or, in the absence of local codes, with the standard for the Storage and Handling of Liquified Petroleum Gases, ANSI/NFPA 58. •... -
Page 8: Natural-Gas Installations
Do not move, handle, or service heater while hot, running, or connected to power supply. • Check for gas leaks and proper functioning during installation, periodically, or when relocating. Typical Heater Installation THP-400A, THP-500A and THP-550 Installation and Service Manual... -
Page 9: Preliminary Start-Up Steps
Reset flame-safety control by pressing reset button on control. • Reset motor overload. • Check control settings: high-temperature limit switch: 270° F low-temperature limit switch: 40° F THP-400A Switch Panel THP-550 Switch Panel Note: Other switch panel layouts may be used depending on application. THP-500A Switch Panel... -
Page 10: Control Vestibule Layouts
Control Vestibule Layout THP-400A Vestibule Layout THP-500A Vestibule Layout THP-400A, THP-500A and THP-550 Installation and Service Manual... - Page 11 TEMP-HEAT ® Control Vestibule Layout THP-550 Vestibule Layout...
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Page 12: Start-Up Steps
To reset: turn blower and burner switches OFF. Reset the Flame-Safety Control and turn switches back to ON. Do not attempt to light the pilot manually. 8. Set discharge air temperature. 9. Set room air temperature. THP-400A, THP-500A and THP-550 Installation and Service Manual... -
Page 13: Shut-Down Steps
TEMP-HEAT ® Shut-Down Steps Short-Term Shut Down • Turn burner switch to OFF position. • Wait 30-sec. • Turn blower switch to OFF position. • Look to see that flame is extinguished. Extended Shut-down or Disconnection of Unit • With unit running, close vapor-fuel supply valve at vaporizer. (Propane installation only.) Caution: Do not close liquid supply valve while vaporizer is ON. -
Page 14: Wiring Sequence Of Operation
SW-07 blower switch VA-02 2nd main-gas valve PS-01 air flow switch TR-02 low-voltage transformer VA-03 pilot-gas valve RE-07 flame-safety relay TR-03 ignition transformer VA-05 modulating gas valve RF-01 rectifier TS-01 discharge-air sensor THP-400A, THP-500A and THP-550 Installation and Service Manual... - Page 15 TEMP-HEAT ® THP-400A Sequence of Operation When the main safety switch, SW-01 is turned ON, power is supplied: — to the line side of the motor starter, ST-01, — to the primary side of the power transformer, TR-01, and — from the secondary side of the power transformer to the FU-02 control fuse, located on the transformer.
- Page 16 2nd high temp limit switch VA-04 modulating gas valve MT-01 supply blower motor SW-07 blower starting switch TS-07 low temp stat/timer PS-01 low air flow switch SW-09 unit tip over switch TS-08 remote disch. temp. setpoint THP-400A, THP-500A and THP-550 Installation and Service Manual...
- Page 17 TEMP-HEAT ® THP-500A Sequence of Operation When the main safety switch, SW-01 is turned ON, power is supplied: — to the line side of the motor starter, ST-01, — to the primary side of the power transformer, TR-01, and — from the secondary side of the power transformer to the FU-02 control fuse, located on the transformer.
- Page 18 MT-01 supply-blower motor TR-02 low-voltage transformer VA-02 2nd main-gas valve PS-01 air flow switch TS-01 discharge-air sensor VA-03 pilot-gas valve RE-07 flame-safety relay TS-04 high-temperature limit switch VA-05 modulating gas valve THP-400A, THP-500A and THP-550 Installation and Service Manual...
- Page 19 TEMP-HEAT ® THP-550 Sequence of Operation When the main safety switch, SW-01 is turned ON, power is supplied: — to the line side of the motor starter, ST-01, — to the primary side of the power transformer, TR-01, and — from the secondary side of the power transformer to the FU-02 control fuse, located on the transformer.
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Page 20: Troubleshooting
Adjustable high- Set at 240° F. If unit continues to shut down, the unit is temperature limit switch either overfired or the limit switch is defective. Contact not at proper setting TEMP-HEAT. THP-400A, THP-500A and THP-550 Installation and Service Manual... - Page 21 TEMP-HEAT ® Problem Probable Cause Remedy Blower runs, burner Flame safety control Press reset button on the control. If resetting does not does not ignite lockout correct problem, the flame safety control must be replaced. Gas valve defective Check wiring connections and condition to and from gas valves.
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Page 22: Control Adjustments
1/2 turn at a time until burner re-ignites. To check setting 1. Set remote thermostat on highest setting. 2. Observe that when operating on high-fire, Airflow Control the switch does not break contact. THP-400A, THP-500A and THP-550 Installation and Service Manual... - Page 24 Boston, MA 800-666-8133 fax 508-624-0036 Chicago, IL 800-283-2843 fax 847-931-7704 Cleveland, OH 800-443-3301 fax 330-721-7742 Columbus, OH 800-444-3481 fax 614-471-1933 Denver, CO 800-577-7053 fax 303-783-8579 Detroit, MI 800-678-1488 fax 248-526-9527 Kansas City, MO 800-430-0523 fax 816-471-7774 Minneapolis, MN 800-836-7432 fax 952-707-5104 Newark, DE 800-656-6000 fax 302-369-8022...