Model No. S2200D - Heat Wagon · Sure Flae Products Maintenance and Oertation Manual PN 974-9247 Re...

Retain these instructions for future reference.

Sure Flame ProductsA Divison of Haul-All Equipment4115 - 18 Avenue NorthLethbridge, Alberta T1H 5G1www.sureflame.ca

P/N 974-9247Rev: 4.32 April 8, 2014

Operation and Maintenance Manual

Model No. S2200DCONSTRUCTION HEATER2,250,000 Btu/h

Failure to comply with the precautions and instructions provided with this heater, can result in death, serious bodily injury and property loss or damage from hazards of fire, explosion, burn, asphyxiation, carbon monoxide poisoning, and/or electrical shock.

Only persons who can understand and follow the instructions should use or service this heater.

If you need assistance or heater information such as an instruction manual, labels, etc. Contact the manufacturer.

GENERAL HAZARD WARNINGFire, burn, inhalation, and explosion hazard. Keep solid combustibles, such as building materials, paper or cardboard, a safe distance away from the heater as recommended by the instructions. Never use the heater in spaces which do or may contain volatile or airborne combustibles, or products such as gasoline, solvents, paint thinner, dust particles or unknown chemicals.

WARNING

Not for home or recreational vehicle use. WARNING

WARNINGRead and follow all installation, and operating instructions before first use of this product.

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Sure Flame Products

Maintenance and Opertation Manual

P/N 974-9247 Rev 4.32. April 2014

FOR YOUR SAFETYDO NOT USE THIS HEATER IN A SPACE WHERE

GASOLINE OR OTHER LIQUIDS HAVING FLAMMABLE VAPOURS ARE STORED OR USED.

Read This Warning First !

The heater is designed and approved for use as a construction heater under ANSI 83.7-2000. The primary purpose of construction heaters is to provide temporary heating of buildings under construction, alteration, or repair and to provide temporary emergency heat. Properly used the heater provides safe economical heating. Products of combustion are vented into the area being heated.

The heater is not designed as an Unvented Gas Fired Room Heater under ANSI-Z21.11.2 and should not be used in the home.

ANSI A119.2(NFPA 501C)-1987 Recreational Vehicle Standard prohibits the installation or storage of LP-Gas containers even temporarily inside any recreational vehicle. The standard also prohibits the use of Unvented Heaters in such vehicles.

Use of the heater must be in accordance with this Standard and in compliance with all govern-ing state and local codes. Storage and handling of propane gas and propane cylinders must be in accordance with NFPA 58 and all local gov-erning codes.

We cannot anticipate every use which may be made for our heaters. CHECK WITH YOUR LOCAL FIRE SAFETY AUTHORITY IF YOU HAVE QUESTIONS ABOUT LOCAL REGU-LATIONS.

Other standards govern the use of fuel gases and heat producing products in specific applications. Your local authority can advise you about these.

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

3

Specifications..........................................4

Heater Installation................................... 5

Heater Operation .................................... 6

Thermostat Operation............................ 6

Blower Operation .................................... 6

Installation for Propane Supply Tank ...... 7

Installation for Natural Gas ..................... 7

Common Installation and OperationalProblems ................................................ 8

Safety Features ...................................... 8

Additional Design-relatedSafety Features ...................................... 9

On-site Safety Problems......................... 10

Preventative Maintenance ...................... 11

Trouble Shooting .................................... 12

Wiring Diagrams ..................................... 20

Replacement Parts ................................ 26

Table of Contents

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Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

Model No.

S2200D Construction Heater

Certification

Gas Fired Construction Heaters,ANSI Z83.7 -2002

Fuel Natural Gas or Propane Vapour

Input Rating

Maximum (Second Stage)2,250,000 Btu/h (659 kW)

Minimum (First Stage)1,950,000 Btu/h (571 kW) Propane1,650,000 Btu/h (484 kW) Natural Gas

Operating Temperature

Minimum -28°F (-30°C)

Burner Orifice Size

40 DMS x 45 holes42 DMS x 33 holes

Electrical Rating

Varies - Rating determined as stated on the Specification Label and the Electric Motor on the heater

Supply Pressure to Regulator

Propane & Natural GasMinimum: 12” WC (3.0 kPa)Maximum: 5 psi (34 kPa) Pressure to Manifold

PropaneMinimum: 0.4” WC (100 Pa)Maximum: 0.7” WC (170 Pa)

Natural GasMinimum: 2” WC (500 Pa)Maximum: 4.6” WC (1.1 kPa)

(Minimum inlet pressure is for purpose of input adjustment)

Weight

860 lbs (390 kg)

Specifications

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P/N 974-9247 Rev 4.32. April 2014

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The Sure Flame Model S2200 is a direct fired gas heater intended to be used primarily for the temporary heating of buildings under construc-tion, alteration, or repair. Since all the products of combustion are released into the area being heated, it is imperative that adequate ventilation is provided. The flow of supply air must not be obstructed in any way. 1. Install the heater in a horizontal position at

least 10 feet (3 m) from any LP-gas contain-er. The front outlet must be at least 20 feet (6 m) from any LP-gas container. Allow the following clearances from any combustible material or fuel containers:

Outlet: 25 feet (7.6 m) Sides: 3 feet (0.9 m) Intake: 3 feet (0.9m) Top: 4 feet (1.2 m) Duct: 1 foot (0.3 m) Floor: Noncombustible

Also make sure that no flammable vapours are present in the space where the heater is being used.

2. When connecting the heater to a natural gas or propane supply line ensure that the pres-sure at the heater inlet is within the specified range. Excessive pressure (over 5 psig or 34 kPa) will damage the controls and void the warranty.

3. Visually inspect the supply hose assembly and ensure that it is protected from traffic, building materials, and contact with hot sur-faces. If it is evident that there is excessive abrasion or wear, or the hose is cut, it must be replaced.

4. After installation, check the hose assembly for gas leaks by applying a water and soap solution to each connection.

5. Connect the heater to an adequate electric power supply as specified on the Heater Specification label and the Electric Motor plate.

6. For protection against shock hazard the sup-ply cord should be plugged directly into a properly grounded receptacle in compliance with the

National Electrical Code, ANSI/NFPA 70

The appliance area should be kept clear and free from combustible materials, gasoline, and other flammable vapours and liquids.

Ensure that the flow of supply air is not ob-structed.

The installation and operation of the heater shall comply with the code requirements specified by the authorities having jurisdiction.

General criteria for the installation and use of construction heaters may be found in the appli-cable sections of the

ANSI A10.10, Safety Requirements for Temporary and Portable Space Heating Devices and Equipment The installation and maintenance of the heater must be accomplished by a qualified service person.

This heater is approved for use without ductwork, or with up to 40 feet of 24” square ductwork. Only ductwork supplied by the man-ufacturer should be used with this heater.

When using the heater without ductwork, securely fasten the outlet screen in the down position.

Heater Installation

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P/N 974-9247 Rev 4.32. April 2014

1. Set the gas selector valve to the gas being used. The conversion shall only be done by the owner or lessor of the heater.

IMPORTANT: When using propane gas, the selector valve must be locked in posi-tion.

2. Ensure the firing valve (manual valve near-est the burner) is in the ON position.

3. Connect power. Use appropriate electric power supply as specified on the heater specification label and the electric motor plate.

4. Open gas supply.

5. Press and release START HEATER switch. START HEATER light will come on. Set thermostat to desired setting. Blower will start after about 10 seconds. Flame will ig-nite after another 20 seconds. If STOP/RE-SET light comes on, press STOP/RESET switch, then repeat the above sequence.

6. Heater will switch between high flame, low flame, and no flame as required to maintain the desired temperature.

7. To stop, press STOP/RESET switch and turn off gas supply. Blower will stop after about 20 seconds.

Heater OperationThermostat Operation The heater operation is controlled by the

remote thermostat. When the heater is op-erated in heat mode, the power light on the thermostat will come on. If the ambient temperature is significantly lower than the thermostat setting, both the Stage 1 and Stage 2 lights will come on and the heater will operate on high flame. As the tem-perature approaches the thermostat setting, the Stage 2 light will go off and the heater will switch to low flame. Once the desired temperature is reached, the Stage 1 light will go off and the flame and blower will shut off. The flame and blower will come on again automatically once the tempera-ture drops.

Blower Operation1. Press and release START BLOWER

switch. Blower will start immediately.

2. To stop, press STOP/RESET switch.

Note: When switching between heater mode and blower mode, unit must first be stopped by pressing the STOP/RESET switch.

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

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1. When installing the heater for use with pro-pane gas, ensure that the gas selector valve is LOCKED in the propane position.

2. The supply container MUST be equipped with a suitable UL listed gas pressure reg-ulator. This is essential to reduce the gas pressure to a safe transmittable pressure that does not exceed the maximum input pressure of the heater.

3. Arrange the supply system to provide for vapour withdrawal from the operating tank. Supplying liquid propane to the heater is dangerous and will damage the components.

4. Ensure that for the surrounding temperature the size and capacity of the propane supply tank is adequate to provide the rated Btu/h input to the heater.

Installation For Natural Gas Applications

Installation Using A Propane Supply Tank

1. When installing the heater for use with nat-ural gas, ensure that the gas selector valve is set in the natural gas position.

2. Ensure that the supply is equipped with a suitable UL listed gas pressure regulator to limit the gas to a pressure that does not exceed the maximum inlet pressures of the heater.

5. Turn off the propane supply valve at the tank when the heater is not in use.

6. The installation must conform with local codes, or in their absence, with the follow-ing:

Storage and Handling of Liquidied Petroleum Gases, ANSI/NFPA 58 7) When the heater is to be stored indoors the

propane tank must be disconnected from the heater and stored in accordance with the above mentioned National Standard.

3. The installation must conform with local codes, or in their absence, with the follow-ing:

National Fuel Gas Code, ANSI Z223.1/NFPA 54

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Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

Low Voltage

This is one of the most common problems and is usually the result of the supply cord having too small a wire gauge for its length. Low voltage results in the motor overheating, burnt relay contacts, or a relay that will not make contact.

Supply Line Too Small

Insufficient Vaporization At Supply

Normally caused by too small size of supply tank.

Improper Gas Supply Pressure

Usually a result of supply pressure being too high because of improper or lack of regulation.

Common Installation And Operational Problems

Servicing of Sure Flame Construction Heaters normally involves one of several built-in safety features. The Model S2200 incorporates devic-es to detect the following:

Loss Of Flame

Gas supply is shut off if flame is lost to prevent raw gas from leaving the heater.

Overheating

a) Thermal overload protection in the motor.

b) High temperature limit switch in the com-bustion chamber.

c) High temperature limit switch in the blower

housing.

Dirty Gas Supply

Dirty gas can cause strainers to plug or form a build-up in the burner orifice.

Lack Of Preventative Maintenance

Heaters must be cleaned as required, especially when used in a dirty environment.

Improper Supply Of Fresh Air

It is normally recommended that the intake air of the heater be taken from outside the enclosed area. This provides a slight pressurization and prevents any problems associated with recircu-lation.

Safety FeaturesLoss Of Power

Total shutdown with manual reset required. Any one of the safety devices will create a loss of power situation.

Blocked Air Supply

A switch detects the differential pressure in the combustion chamber and shuts down when air flow is insufficient .

Cool Down Period

When thermostat is turned down, blower will continue running for about 20 seconds to cool down the heater and purge any unburned gases from the combustion chamber.

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P/N 974-9247 Rev 4.32. April 2014

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Locking Position For Lpg On Gas Selector Valve

Units used with LPG while the gas selector valve is positioned for Natural Gas will throw significantly more heat than the rated Btu/h. This is definitely a safety hazard.

Additional Design-Related Safety FeaturesDurable Construction

The Model S2200 uses a stainless steel burner for long life and consistent performance.

In order to maintain the highly efficient combus-tion of the Sure Flame Heater, the combustion chamber must remain as manufactured. Any change or distortion could alter the fuel/air mix-ture and create unwanted gases.

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Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

Shorting Out Of Defective Com-ponents

This is a very common problem which saves short term expense at the risk of a large future cost. Any heaters found in this condition should be removed immediately.

Improper Enclosures

When heaters are installed partially to the out-side for fresh air intake, strict adherence must be made to the minimum clearance to combustibles given on the instruction plate. Wood framing around a heater is a request for trouble.

On-site Safety Problems

Supplying Liquid Propane To Heater

This problem has occurred from time to time. To minimize the damage, shut off the gas supply and let the heater run until all of the liquid in the lines has been burnt.

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

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Sure Flame Construction Heaters are built to withstand the rigours of operating on construc-tion sites, for mining applications, and a multi-tude of other locations where heaters are used. To maintain the reliable performance required it is necessary to do a certain amount of regular maintenance.

The heater should be inspected before each use, and at least annually by a qualified service person.

Visual Checks

The following items should be checked for excessive wear or damage:

1. Cords and Connectors

2. Wiring and Conduit

3. Heater Shell (including heat shield), Blow-er Housing and Control Box

4. Blower Drive Belts and Bearings

5. All Screens and Guards

Preventative Maintenance

Burner

Flame Rod and Insulator - Clean with soap and water or solvent on a routine basis. Any build up on burner should also be removed at this time.

U.V. Flame Sensor - Clean the bulb with a soft cloth.

Ground Wire - Ensure that the ground wire is secured to the burner. This is necessary for the flame detection system to operate.

Spark Plug - Clean with solvent and check spark gap.

Flame Safeguard Control

The Flame Safeguard Control should be cleaned using alcohol. Do not use any other liquid or aerosol spray cleaners.

Motor

Motors equipped with oil cups should require only a few drops of clean, light machine oil every year. Motors not equipped with oil cups are fitted with sealed bearings and no oiling is required.

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Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

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Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

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P/N 974-9247 Rev 4.32. April 2014

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Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

15

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circ

uit b

reak

er.

STA

RT

BLO

WER

ST

OP/

R

ESET

ST

AR

T H

EATE

R

STA

RT

BLO

WER

ST

OP/

R

ESET

ST

AR

T H

EATE

R

STA

RT

BLO

WER

ST

OP/

R

ESET

ST

AR

T H

EATE

R

STA

RT

BLO

WER

ST

OP/

R

ESET

ST

AR

T H

EATE

R

STA

RT

BLO

WER

ST

OP/

R

ESET

ST

AR

T H

EATE

R

STA

RT

BLO

WER

ST

OP/

R

ESET

ST

AR

T H

EATE

R

OM

RO

N

ZEN

10

C2A

R-A

O

MR

ON

ZE

N 1

0 C

2AR

-A

OM

RO

N

ZEN

10

C2A

R-A

16

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

Trou

ble

Shoo

ting

SE

QU

ENC

E EX

TER

NA

L EF

ECT

DES

CR

IPTI

ON

C

AU

SE

18

- To

RES

ET p

ush

“STA

RT

HEA

TER

”.

- A

lso,

to R

ESET

, pus

h “S

TOP/

RES

ET” a

nd “

STA

RT

HEA

TER

”.

-

Nat

ural

gas

min

imum

man

ifold

pr

essu

re: 1

.25”

WC

. -

Nat

ural

gas

max

imum

man

ifold

pr

essu

re: 7

.00”

WC

. -

Prop

ane

vapo

rs m

inim

um

man

ifold

pre

ssur

e: 0

.70”

WC

. -

Prop

ane

vapo

rs m

inim

um

man

ifold

pre

ssur

e: 3

.00”

WC

.

- R

ed a

larm

ligh

t and

LF

L C

ontro

ller a

larm

lig

ht o

n:

- Th

e LF

L se

quen

ce

mec

hani

sm lo

ckou

t in

P po

sitio

n:

- Th

e LF

L se

quen

ce

mec

hani

sm lo

ckou

t in

po

sitio

n:

- N

o sp

ark,

and

the

LFL

sequ

ence

m

echa

nism

lock

out i

n 1

or 2

pos

ition

: -

The

LFL

sequ

ence

m

echa

nism

lock

out

in | p

ositi

on:

- Er

ror i

ndic

ator

be

caus

e th

ere

is n

o ai

r pre

ssur

e in

dica

tion

at th

e be

ginn

ing

of a

ir pr

essu

re c

ontro

l. -

Safe

ty lo

ckou

t be

caus

e no

air

flow

s de

tect

ed d

urin

g th

e pr

e-pu

rge.

RES

ET

nece

ssar

y.

- Sa

fety

lock

out d

ue to

a

faul

t in

the

flam

e su

perv

isio

n ci

rcui

t. -

Safe

ty lo

ckou

t be

caus

e no

flam

e si

gnal

is p

rese

nt a

fter

com

plet

ion

of th

e fir

st o

r sec

ond

safe

ty

time.

-

Che

ck th

e m

anifo

ld

pres

sure

or/e

nd th

e D

ungs

val

ve c

oils

in

tegr

ity.

- Fa

ulty

, spa

rk p

lug

conn

ectio

n, ig

nitio

n tra

nsfo

rmer

or

igni

tion

trans

form

er

pow

er su

pplie

s.

- Sa

fety

lock

out

beca

use

the

flam

e si

gnal

has

bee

n lo

st

durin

g bu

rner

op

erat

ion.

-

Che

ck th

e fu

el g

as

supp

ly.

STA

RT

BLO

WER

ST

OP/

R

ESET

ST

AR

T H

EATE

R

THER

MO

STA

T

THER

MO

STA

T

The

sequ

ence

mec

hani

sm is

not

turn

ing,

lo

ckou

t in

P,

, 1, 2

or |

posi

tion.

P

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

17

Trou

ble

Shoo

ting

SE

QU

ENC

E EX

TER

NA

L EF

ECT

DES

CR

IPTI

ON

C

AU

SE

19

- To

RES

ET p

ush

“STA

RT

HEA

TER

”.

- A

lso,

to R

ESET

, pus

h “S

TOP/

RES

ET” a

nd “

STA

RT

HEA

TER

”.

- R

ed a

larm

ligh

t of

and

LFL

Con

trolle

r al

arm

ligh

t on:

-

See

posi

tion

18.

- Fa

ulty

Sto

p bu

tton

LED

. -

See

posi

tion

18.

STA

RT

BLO

WER

ST

OP/

R

ESET

ST

AR

T H

EATE

R

THER

MO

STA

T

THER

MO

STA

T

The

sequ

ence

mec

hani

sm is

not

turn

ing,

lo

ckou

t in

P,

, 1, 2

or |

posi

tion.

P

18

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

Trou

ble

Shoo

ting

SE

QU

ENC

E EX

TER

NA

L EF

ECT

DES

CR

IPTI

ON

C

AU

SE

20

FUN

CTI

ON

WIT

HO

UT

ERR

OR

S

Poor

flam

e

- H

eate

r mod

e on

: -

Stag

e I a

nd/o

r II o

n:

- Ex

haus

t tem

pera

ture

lo

w, f

lam

e in

firin

g st

age:

-

Stag

e II

on:

- N

o er

rors

. -

No

erro

rs.

- C

heck

the

firin

g va

lve

coil.

-

Che

ck a

lso

the

ZEN

con

trolle

r Q3

rela

ys –

pos

sibl

e m

echa

nica

l err

or.

- C

heck

stag

e II

knob

. It i

s pos

sibl

e cl

osed

. -

Che

ck st

age

II el

ectri

c bo

x,

- C

heck

als

o th

e ZE

N c

ontro

ller Q

2 re

lays

– p

ossi

ble

mec

hani

cal e

rror

.

21

H

igh

flam

e on

ly.

- St

age

II of

f: -

Che

ck st

age

II kn

ob. I

t is p

ossi

ble

full

open

.

The

sequ

ence

mec

hani

sm is

not

turn

ing,

lo

ckou

t in

| pos

ition

.

Dun

gs D

MV

-ZR

D d

oubl

e so

leno

id v

alve

syst

em

Stag

e I k

nob

Stag

e I

knob

Stag

e II

el

ectri

c bo

x St

age

I el

ectri

c pl

ug

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

19

20

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

Wiring Diagrams (1 Phase)

CIRUCITBREAKER

2 1

Q0

Q1

Q2

Q3

I5I4

I3I2

I1I0

NC

LN

PO

WE

RR

UN

ER

RO

R

Nan

oP

rogr

amab

leC

ontro

ller

ZEN

20C

2AR

-A-V

2

IbIa

I9I8

I7I6

NC

Q4

Q5

Q6

Q7

CO

IL

NO

NOLF

LR

ELA

Y

0

1

24

68

CO

IL

NO

NO

STA

GE

IIR

ELA

Y

0

1

24

68

BU

RN

ER

SU

RG

ES

UP

RE

SS

OR

A2

A1

T1T3

L1L2

L3

OV

ER

LOA

DR

ELA

Y

T2

9697

9895

H1

H2

H3

H4

H5

X1

X2

STE

PD

OW

NTR

AN

SFO

RM

ER

1 NC

2 NO

PC

OM

AIR

SW

ITC

H

FLA

ME

CO

NTR

OLL

ER

654321 7 108 9 11 1213

1514

1617

1819

2021

2223

24

NIG

NIT

ION

TRA

NS

FOR

ME

R

N L

ENDBRACKET

ENDPLATEBR

N

BLU S

PA

RK

PLU

G

M

4

STA

RT

BU

TTO

N

X1

X2

34

STO

P/

RE

SE

TB

UTT

ON

X1

X2

34

BLO

WE

RB

UTT

ON

X1

X2

3

CO

NTA

CTO

R

L3L2

L1

T3T2

T1

ENDBRACKET

BLU

BLU

BLK

BLK

BLK

U.V

.SE

NS

OR

+-

BLU

BLK

FLA

ME

RO

D

CO

NTR

OL

BO

XC

ON

TRO

LB

OX

CO

NTR

OL

BO

X

FIE

LDIN

STA

LLE

D

FAC

TOR

YIN

STA

LLE

D

WIR

ES

YM

BO

LLE

GE

ND

LOW

VO

LTA

GE

HIG

HV

OLT

AG

E

THE

RM

OS

TAT

RE

CE

PTA

CLE

HIG

HTE

MP

.LI

MIT

SW

ITC

HR

EC

EP

TAC

LE

GA

SV

ALV

ES

TAG

EII

RE

CE

PTA

CLE

1P

HA

SE

MO

TOR

GA

SV

ALV

ES

TAG

EI

PLU

G

GA

SV

ALV

ES

TAG

EI

1

3

2

BLK

BR

N

WH

T

BLU

FEM

ALE

FAC

EV

IEW

Q Z Y B K A

23

1

CD

5

G

61

23

4

GL1

L2L3

HV

Te

rmin

al

Blo

cks

GR

NR

ED

BLK

BLK

ORG

BLU

BLK

WHT

BLK

BLU

BLK

BLU

WH

T

OP

TIO

NA

L

WH

T

WHT

L47

BLK

BLU

GRN

10G

a

RED

RED

10G

a

RED

BLK

BLK

BLK

BLK

BLK

BLK

10Ga

10Ga

BLK

RED

RED

RED

HIV

OLT

BLK

WHT

RE

DG

RN

RE

D

GR

N

GR

N

7B

LU

GR

Y 4B

LU 5G

RN 6

WH

T

BLK

BLK

BLK

WHT

BLK

RE

D

GRN

GR

N

BLK

BLK

BLK

BLK

BLK

WH

TB

RN

RED

BLK

BLK

BLK

GR

N

BLK

RED

RED

BLK

BLK

BR

N

10Ga10Ga

10Ga

10Ga

BLK

WH

T

RED

WH

T

BLK

BLK

BLK

BLK

WH

T

Con

nect

topr

imar

ysi

deof

trans

form

erac

cord

ing

tora

ted

volta

gean

dm

arki

ngs

ontra

nsfo

rmer

BR

NB

RN

BR

NB

RN

BR

NB

RN

BR

NB

RN

BR

NB

RN

BR

NB

RN

WHT

BLK

RE

DW

HT

BLK

BLK

BLK

WHT

BLK

+

Rev

4.32

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

21

Ladder Diagram (1 Phase)

M

1

3

4

5

6

7

8

2

12

24

18

15

16

21

13

14Air Switch

19

StepdownTransformer

110 V

230

V

460

V

575

V

HeaterLimit Switch

23

Flame Rod

I5

Start Light

Blower Light

First Stage Valve 1 First Stage Valve 2

Second Stage Valve

Ignition Transformer

Stop/Reset Light

Second Stage Thermostat Switch

First Stage Thermostat Switch

Overload Contact (a) (NC)

OverloadContact (a)

Motor contactor Coil

Surge Suppressor

BlowerLimit Switch

to

N

I1

I0

I8

I7

I5

I4

I3

I2

I9

L

I6

L

N

22

U.V. Sensor

Flame Controller

Q

Out

Key

Input: Programmable ControllerCPU and Expansion Unit

Output: Programmable ControllerCPU Unit

Output: Programmable ControllerExpansion Unit

Braker Breaker

Q4

Q5

Q1

Q7

Q6

Q3

Q2Start Button

Stop/Reset Button

Blower Button

208

V

L

(NO)

to

Rev 4.3

Stage II Relay Coil

LFL Relay Coil

NMotor Contactor

ContactMotor Contactor

Contact

22

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

CIRUCITBREAKER

2 1

Q0

Q1

Q2

Q3

I5I4

I3I2

I1I0

NC

LN

PO

WE

RR

UN

ER

RO

R

Nan

oP

rogr

amab

leC

ontro

ller

ZEN

20C

2AR

-A-V

2

IbIa

I9I8

I7I6

NC

Q4

Q5

Q6

Q7

CO

IL

NO

NOLF

LR

ELA

Y

0

1

24

68

CO

IL

NO

NO

STA

GE

IIR

ELA

Y

0

1

24

68

BU

RN

ER

SU

RG

ES

UP

RE

SS

OR

A2

A1

T1T3

L1L2

L3

OV

ER

LOA

DR

ELA

Y

T2

9697

9895

H1

H2

H3

H4

H5

X1

X2

STE

PD

OW

NTR

AN

SFO

RM

ER

1 NC

2 NO

PC

OM

AIR

SW

ITC

H

FLA

ME

CO

NTR

OLL

ER

654321 7 108 9 11 12 1315

1416

1718

1920

2122

2324

NIG

NIT

ION

TRA

NS

FOR

ME

R

N L

ENDBRACKET

ENDPLATEBR

N

BLU S

PA

RK

PLU

G

M

4

STA

RT

BU

TTO

N

X1

X2

34

STO

P/

RE

SE

TB

UTT

ON

X1

X2

34

BLO

WE

RB

UTT

ON

X1

X2

3

CO

NTA

CTO

R

L3L2

L1

T3T2

T1

ENDBRACKET

BLU

BLU

BLK

BLK

BLK

U.V

.SE

NS

OR

+-

BLU

BLK

FLA

ME

RO

D

CO

NTR

OL

BO

X

CO

NTR

OL

BO

X

FIE

LDIN

STA

LLE

D

FAC

TOR

YIN

STA

LLE

D

WIR

ES

YM

BO

LLE

GE

ND

LOW

VO

LTA

GE

HIG

HV

OLT

AG

E

THE

RM

OS

TAT

RE

CE

PTA

CLE

HIG

HTE

MP

.LI

MIT

SW

ITC

HR

EC

EP

TAC

LE

GA

SV

ALV

ES

TAG

EII

RE

CE

PTA

CLE

(WR

S-1

51)

3P

HA

SE

MO

TOR

GA

SV

ALV

ES

TAG

EI

PLU

G

GA

SV

ALV

ES

TAG

EI

1

3

2

BLK

BR

N

WH

T

BLU

FEM

ALE

FAC

EV

IEW

Q Z Y B K A

23

1

CD

5

G

61

23

4

GL1

L2L3

HV

Te

rmin

al

Blo

cks

GR

NR

ED

BLK

BLK

ORG

BLU

BLK

WHT

BLK

BLU

BLK

BLU

WH

T

OP

TIO

NA

L

WH

T

WHT

L47

BLK

BLU

GRN

10G

a

RED

RED

10G

a

RED

RED

BLK

BLK

BLK

BLK

BLK

BLK

10G

a

10G

a

10G

a

BLK

RED

RED

RED

HIV

OLT

BLK

WHT

RE

DG

RN

RE

D

GR

N

GR

N

7B

LU

GR

Y 4B

LU 5G

RN 6

WH

T

BLK

BLK

BLK

WHT

BLK

RE

D

10G

a

GRN

GR

N

BLK

BLK

BLK

BLK

BLK

WH

TB

RN

RED

BLK

BLK

BLK

GR

N

BLK

RED

RED

RED

BLK

BLK

BR

N

10Ga

10Ga

10Ga

10Ga

BLK

WH

T

RED

WH

T

BLK

BLK

BLK

BLK

WH

T

Con

nect

topr

imar

ysi

deof

trans

form

erac

cord

ing

tora

ted

volta

gean

dm

arki

ngs

ontra

nsfo

rmer

BR

NB

RN

BR

NB

RN

BR

NB

RN

BR

NB

RN

BR

NB

RN

BR

NB

RN

WHT

BLK

RE

DW

HT

BLK

BLK

BLK

WHT

BLK

Rev

4.32

Wiring Diagrams (3 Phase)

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

23

Ladder Diagram (3 Phase)

M

1

3

4

5

6

7

8

2

12

24

18

15

16

21

13

14Air Switch

19

StepdownTransformer

110 V

230

V

460

V

575

V

HeaterLimit Switch

23

Flame Rod

I5

Start Light

Blower Light

First Stage Valve 1 First Stage Valve 2

Second Stage Valve

Ignition Transformer

Stop/Reset Light

Second Stage Thermostat Switch

First Stage Thermostat Switch

Overload Contact (a) (NC)

OverloadContact (a)

Motor contactor Coil

Surge Suppressor

BlowerLimit Switch

to

N

I1

I0

I8

I7

I5

I4

I3

I2

I9

L

I6

LN

22

U.V. Sensor

Flame Controller

Q

Out

Key

Input: Programmable ControllerCPU and Expansion Unit

Output: Programmable ControllerCPU Unit

Output: Programmable ControllerExpansion Unit

Braker Breaker

Q4

Q5

Q1

Q7

Q6

Q3

Q2Start Button

Stop/Reset Button

Blower Button

Motor ContactorContacts

OverloadRelay (A)

208

V

L1L2

L3

(NO)

to

Rev 4.3

Stage II Relay Coil

LFL Relay Coil

24

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

Two-Stage Thermostat Wiring Diagram (S1500-714)

RED

ST2ST1

GRN

BLK

BRN

BLK

RED

PNK

WH

T

LAMP(STAGE I & II)

STAG

E II

LOHI

STAG

E I

LOHI

1- BLACK120VAC

2 - WHITENEUTRAL

3 - REDSTAGE I

4 - GREENSTAGE I I

�

PLUG PINS

WH

T

RED

PRL VIL

GRN

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

25

Connection Diagram High Temperature Limit Switches

Connection Diagram Gas Valve Stage II

GAS VALVESTAGE II

NMp

LP

BLU16 Ga.

GRN16 Ga.

BRN16 Ga.

PLUG

BRN BLU

GRN

MALE FACEVIEW

BLO

WER

SWIT

CHH

EATE

RSW

ITCH

WHT16 Ga.

RED16 Ga.

BLK16 Ga.

PLUG

WHT

RED

BLK

PLUGPINS

ORG 16 Ga.

GRN

ORGGRN

WHT

WHT

26

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

Heater Parts Diagram

4

126 3 8

9

10

11

2 5 1

Ref # Part # Description Qty1 6032 Inlet Screen 12 2143 Spark Plug 13 2441 Flame Rod 14 9161 Limit Switch 15 BV14-506 2.25 Million Btu/h Burner 16 FN12-157 Limit Switch Box 18 S2200-740 Air Tube Bracket Assy. 19 S2200-235 Valve Train Cover Bracket 1

10 S2200-236 Gas Valve Cover 111 S2200-512 Heater Body 112 9005 U.V. Sensor 1

Ref # Part # Description Qty- 2849 Natural Gas/Propane Label 1- 4504 Electrical Warning Label 1- 4505 Valve On/Off Label 1- 4506 Rotation Label 1- 4802 Sure Flame Decal 2- 6503 Gas Inlet Warning Label 1- 7362 General Warning Label, En. 1- 8821 General Warning Label, Fr. 1- 9137 S2200D Spec. Label 1- 9249 Outlet Screen Warning Label 1- 9252 Inlet Pressure Warning Label 1- 9253 Electrical Grnd. Warning Label 1

The following labels and decal are not shown

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

27

Blower Parts Diagram

3

5

7

8

210 1 16 11

14

18

19

4

21

22

12920

13

17

15 6 23

Ref # Part # Description Qty1 2408 Impeller Bushing 12 6162 Motor 5hp, 3Ph, 208/230/460V 12 6422 Motor 5hp, 1Ph, 208/230V 12 7713 Motor 5hp, 3Ph, 575V 13 6292 Motor Bushing 14 6293 Flex Conduit 15 6978 Sheave Bushing 16 9688 Belt 17 9133 Motor Sheave 18 9134 Impeller Sheave 19 9136 Bearing 2

10 9162 Blower Limit Switch 1

Ref # Part # Description Qty11 FN12-148 Limit Switch Plate 112 FN12-509 Heat Slinger 113 FN12-510 Inlet Cone 114 FN12-512 Blower Housing 115 FN12-514 Belt Tensioner Bracket 116 FN12-517 Limit Switch Box 117 FN12-707 Impeller 118 FN12-708 Belt Tensioner 119 FN12-709 Belt Guard 120 FN12-903 Impeller Shaft 121 S2200-240 Outlet Screen 122 S2200-241 Outlet Screen Hinge 2

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Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

Control Box Parts

1

2

3

4

5

6 7

8

9

11

12

13

14 15

16

17 18 23

24

25 26

27

28 29

32

33

34

35 36 10

30

Ref # Part # Description Qty1 8624 Terminal Block End Plate 32 8629 3 Pole AC Operated Contactor 13 8635 Protective Cover 14 9937 DIN Rail Adapter 1

5 9402 Nano Programable Controller 1

6 4703 Circuit Breaker 17 8651 DIN Rail End Bracket 18 S2200-253 Monting Rail 19 8713 Cross Connector 3

10 8631 Overload Relay 3.7 - 12 Amp 111 8634 Surge Suppressor 112 8623 Feed-Through Terminal Block 5

Ref # Part # Description Qty13 8693 Marker 614 8626 Protective Earth Terminal Block 115 8628 Terminal Block Cover 616 8654 Distributuin Element, Brown 1317 8655 Distribution Element, Blue 518 8652 Basic Element 619 8660 End Plate 120 8658 Marking Tag 2021 8653 Basic Element Grounded 122 8656 Distribution Element, Green 223 8657 Distribution Element, Gray 1

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

29

Control Box Parts

12

13

11

14

15 16

10

17

1

2

6

78

9

34 5

Ref # Part # Description Qty1 S2200-207 Control Box Lid 12 S2200-511 Control Box Weldment 1

3a 9612 Start Pushbutton 13b IX-5726 Start Contact Block 14a 9613 Blower Pushbutton 14b IX-5727 Blower Contact Block 15a 9611 Stop Pushbutton 15b IX-5725 Stop Contact Block 16 WRS-145 Thermostat Plug Assembly 17 WRS-150 Limit Switch Plug Assembly 18 WRS-151 Stage II Plug Assembly 1

Ref # Part # Description Qty9 WRS-152 Stage I Cord Assembly 1

10 3976 ½” Strain Relief 111 6283 ½” 90° Connector 112 7723 Flexible Trim 113 S1500-713 Thermostat Jumper Plug 114 8687 Cable Gland Membrane 215 8691 Cable Gland Metric 316 8734 Hexagonal Jam Nut 317 9219 ½” Sealing O-Ring 4

- S2200-714 Thermostat Assembly 1Not shown

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Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

Control Box Parts Diagram

1

2

3

4

5678

9

10

Ref # Part # Description Qty1 9264 Omron Relay 120V 22 9826 Omron Relay Mounting Clip 23 S2200-739 Differential Pressure Switch 14 5509 ½” Snap Bushing 3

5 8678 Flame Controller Base Plate 1

Ref # Part # Description Qty6 8677 Flame Controller 17 S2200-727 Ignition Transformer 18 2502 Stepdown Transformer 19 S2200-205 Control Box Mounting Panel 1

10 S2200-253 Mounting Rail 1

Sure Flame Products


P/N 974-9247 Rev 4.32. April 2014

31

Valve Train Parts Diagram

1 2 6 4 5 3

Ref # Part # Description Qty1 8685 Gas Regulator 12 8648 2 Stage Valve 13 S2200-712 Changeover Valve 1

Ref # Part # Description Qty4 8708 G1/8” Test Port 15 S2200-132 Test Nipple 16 2539 1.5” Ball Valve 1

Model No. S2200D - Heat Wagon · Sure Flae Products Maintenance and Oertation Manual PN 974-9247 Re...

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Transcript of Model No. S2200D - Heat Wagon · Sure Flae Products Maintenance and Oertation Manual PN 974-9247 Re...