HHW-40 Heater Operation, Service & Parts Manual · C16-003, CEI HHW-40 Heater Overview 3 Overview...

HHW-40 HeaterOperation, Service & Parts Manual

CEI EnterprisesAn Astec Company

Albuquerque, New Mexico, U.S.A.

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IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE TO THE BURNER CAN CAUSE INJURY OR PROPERTY DAMAGE.

Because of the critical nature of burner operations, CEI recommends that you retain the services of a CEI factory trained and licensed burner technician and/or a local licensed burner/boiler technician to check and, if required, adjust the burner prior to commissioning your equipment.

WARNING!

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C16-003, CEI HHW-40 Heater

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Contents

Section 1: Operations ...................................................... 1Overview ................................................................................... 3Safety ........................................................................................ 3

IF YOU SMELL GAS .....................................................................3WARNING! ....................................................................................3Safety Symbols .............................................................................4

HHW-40 Main Components ...................................................... 4Burner ............................................................................................4Tank ..............................................................................................5Control Panel/Circuitry ..................................................................5

Installation ................................................................................. 5Inspection ......................................................................................5Position ..........................................................................................5Connect Electrical .........................................................................5Connect Natural Gas .....................................................................6Connect Water ..............................................................................7Startup ...........................................................................................7

UT150 Burner Modulation Controller ......................................... 8

Section 2: Maintenance ................................................. 11Gas Train Components ........................................................... 13Burner Back Plate Sight Glass ................................................ 13Thermometer (any) .................................................................. 13Burner Blower Motor ............................................................... 14Burner Air Flow Switch ............................................................ 15Burner Gas Ignition Transformer ............................................. 17Gas Pilot Assembly ................................................................. 19

Ignition Electrode .........................................................................20Ignition Cable ..............................................................................21

UV Scanner ............................................................................. 21UT150 Burner Modulation Controller ....................................... 23Modulating Motor ..................................................................... 26

Workbench ..................................................................................28On Heater ....................................................................................30

Abnormal Shutdowns .............................................................. 32Air Damper, Gas Linkage ........................................................ 32Gas/Air Mixture Adjustments ................................................... 33

Gas Burner Instructions ...............................................................33

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Section 3: Parts .............................................................37Replaceable Parts List by Drawing ..........................................39Burner As Built Information.......................................................41Drawings ..................................................................................49

6690103-01 .................................................................................496690114-06 .................................................................................506690114-07 .................................................................................516690114-08 .................................................................................52HHW4000000 (Schematic) ..........................................................53HHW0000000 ..............................................................................54

Specifications .................................................................55Contact Information .................................................................59

CEI Service (General Contact) ....................................................59Departmental Contacts ................................................................59


Section 1: Operations

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C16-003, CEI HHW-40 Heater Overview

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Overview

The HHW-40 Heater is an on-demand heater meaning the burner is fired to heatonly the water used, as it is used. Your HHW-40 Heater heater provide a constantsupply of hot water flowing at a rate of up to 1200 gpm while raising the water tem-perature up to 185°F. A high thermal efficiency (up to 99%) helps keep the exhauststack temperature near the temperature of the incoming water.

The HHW-40 Heater serial and model number is located on the electrical cabinetdoor.

Note: Please supply the serial number when requesting service support or making reference to the tank for spare parts or operational questions.

Safety

Safety is of prime concern whenever using an electrically operated, hightemperature device. Please use proper safety precautions and follow all com-pany, local, state and federal regulations for operating potentially dangerousequipment. Lock-out/tag-out equipment before performing maintenance.

IF YOU SMELL GAS

1. Open windows.

2. Do not touch electrical switches.

3. Extinguish any open flame.

4. Call your gas supplier immediately.

Do not store or use gasoline or other flammable liquids and vapors in thevicinity of this or any other appliance.

WARNING!

Although your HHW-40 Heater heater provides safe, unattended operation,improper installation, adjustment, alteration, service or maintenance can causeinjury or property damage. For assistance or additional information contact CEI.

HHW-40 Main Components

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This manual gives basic instructions which must be observed during installation,operation and maintenance of your HHW-40 Heater. It is imperative that this man-ual be read by the responsible personnel/operator(s) prior to the commissioning ofany liquid media storage system. It must always be kept available at the site ofinstallation. It is not only the general safety instructions contained in this Safetysection which must be observed, but also the specific information provided in thefollowing sections and other applicable manuals.

Safety Symbols Some symbols shown below may not be used elsewhere in this manual

HHW-40 Main Components

Burner

A fully modulated unit running on natural gas (or propane) the burner fires onlywhen heated water is requested. Because it is modulated, the burner only runs at arate high enough to heat the requested quantity of water thus saving fuel.

Explosion prevention Spray prevention

Fire prevention Lock-Out / Tag-Out

Burn prevention Hot surfaces

Electrocution prevention Environmental protection

Important High pressure

C16-003, CEI HHW-40 Heater Installation

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Tank

Cold water is introduced into the tank top as a spray where it migrates downthrough a bed of stainless steel packing rings. Packing temporarily slows the flow ofwater and provides surface area for heat transfer. Hot gasses rising from the burnerheat the packing and, through contact with the heated packing, heats the water.Low-level switches prevent the burner from firing when there is no flow of waterthrough the heater to ensure the structural walls of the heater are not damaged byoverheating. High-level switches shut off the burner and incoming water. Addition-ally, there is a water overflow and a drain valve.

Control Panel/Circuitry

The control panel, and the circuitry within the cabinet, is where the system parame-ters are set and controlled.

Installation

Inspection

CEI takes great care in the construction and shipping of each HHW-40 Heater sothat it will arrive ready for installation and operation. However sometimes theunforeseen happens and damage occurs during loading, shipment and/or delivery.

We recommend a full inspection of the unit for any signs of damage and/or miss-ing parts before installing the unit. In the unlikely event that damage has occurredor a part (or parts) is missing, please contact your CEI representative before con-tinuing with installation.

Position

The HHW-40 Heater is normally positioned so its heated water can easily be con-nected to the intended connections and where the burner exhaust gasses can safelydissipate.

Connect Electrical

Verify that there is sufficient electrical power for the HHW-40 Heater before pro-ceeding. Power requirements are listed on the Electrical Print located within thecontrol box.

Installation

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Connect the external electrical power while adhering to any applicable codes.

Power is normally supplied through the bottom of the control box.

Connect Natural Gas

1. Verify that there is a sufficient supply of Natural Gas for the HHW-40 Heaterbefore proceeding.

2. Make sure the heater’s gas inlet supply valve is closed then connect the Gassupply to the inlet on the Heater. Open the source gas supply valve and checkfor leaks. Correct as necessary.

Gas Inlet Valve(shown closed)

Gas Supply Inlet

C16-003, CEI HHW-40 Heater Installation

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Connect Water

There are two primary water connections, incoming cold and outgoing heatedwater. The incoming cold water connection is near the top of the unit while theoutgoing heater water connection is near the bottom adjacent to the pump/notorassembly. A third connection is for a permanent drain. Connect the plumbing,check for leaks and correct as necessary.

Startup

The position of the Water Pump and Burner switches for operation depends onwhether the unit is operated locally or from a remote location.

• When operating locally, both the Water Pump and Burner switches are inthe ON position.

• When operating from a remote location the Water Pump and Burnerswitches are in the AUTO position.

Once all connections are made and verified, set the desired water temperature onthe digital controller, and let the heater do the rest.

Temperature Controller

Water Pump & Burner Switches

Status Lights

Fireye Flame Monitor

UT150 Burner Modulation Controller

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UT150 Burner Modulation ControllerNote: The Burner Modulation Controller is normally pre-programmed to the values listed

in the tables below when ordered from CEI.However, if the display shows that IN is OFF when you first apply power, the controller has not been programmed. Repeatedly press the UP arrow key until the display shows 35 then press the SET/ENT key.

Setup Parameters

1. To enter Setup Parameters press and hold the key for approximately 3seconds until the display shows A/M.

2. Repeatedly press the key until the display shows LOC.

3. Press the key to change the display to –1.

Note: If the LOC display shows 1, press the down key for a display of 0. Press the SET/ENT key, press the down arrow key for a display of –1, then press the SET/ENT again to enter Setup Parameters.

4. Use the and keys to change the displayed value to those in

the following table then press the key to save the value.

5. Press the key again to move to the next item.

6. Repeat steps 4 and 5 for all items in the following table:

Prompt Parameter Type Value

Input type 35

Setpoint range maximum value 200

Setpoint range minimum value 0

Setpoint ramp-up rate OFF

Setpoint ramp-down rate OFF

Setpoint ramp-rate time unit 1

Retransmission maximum value 200

Retransmission minimum value 0

C16-003, CEI HHW-40 Heater UT150 Burner Modulation Controller

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7. When finished entering the Setup Parameters:

Operating Parameters

Note: The controller automatically returns to the Operator mode after 2 minutes if no buttons are pressed.

1. To enter Operating Parameters press and hold the key for approxi-mately 3 seconds until the display shows SP.

2. Use the and to change the displayed value to those in the

following table then press the key to save the value.



Alarm 1 type 5

Alarm 2 type 0

Alarm 1 hysteresis 20


SUPER function OFF

Direct / reverse action 0



Auto / Manual AUT

A1 Value 10

A2 Value 0

Control mode PID

Auto-tuning OFF

Proportional band 24

Integral time 256


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5. When finished entering the Operating Parameters:

6. Press and hold the key until the display returns to normal operations

Derivative time 64

PV input filter OFF

PV input bias 0

Key lock 0



Section 2: Maintenance

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C16-003, CEI HHW-40 Heater Gas Train Components

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Gas Train Components

Because components in the Gas Train should only be replacedand/or adjusted by qualified personnel CEI has not includedreplacement instructions for these components in this manual.

Burner Back Plate Sight Glass

Let the Heater cool before removing or replacing the Sight Glass.

1. Remove the two screws holding the burner back plate in place then slide theplate down and off.

2. From the inside of the plate pop the sight glass ring out of the plate.

3. Reverse the procedure to install the replacement sight glass.

Thermometer (any)

Let the Heater and Heat Transfer Fluid cool before removing or replacing aThermometer.

CAUTION! - Make sure to unscrew the thermometer and NOT the thermowell.

1. Unscrew the thermometer from the thermowell and remove the thermometer.

Thermometer nut

Thermowell nut

Burner Blower Motor

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2. Screw the new thermometer into the thermowell using gas/oil resistant pipethread compound on the threads. Pay attention to the readability of thethermometer.

Burner Blower Motor

CAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Burner Blower Motor.

Let the Heater cool before removing or replacing the Burner Blower Motor.

1. On the blower motor, remove the cover over the electrical junction box, labelthe motor wiring then disconnect the wiring. Release the wiring strain reliefthen remove the wiring cable from the junction box.

CAUTION! - The blower motor/fan assembly is heavy. Use care in removing it.

2. Remove all six flange nuts w/washers holding the motor/fan assembly to theburner and remove the assembly.

Note: When removing the assembly be careful not to damage the rubber coupling between the fan and the fuel oil pump (when equipped).

Flange Nuts (6 total)

Blower Motor

Electrical Connection Access

C16-003, CEI HHW-40 Heater Burner Air Flow Switch

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3. Mark the position of the fan on the motor shaft then remove the fan from themotor shaft. Measure the distance from the motor shaft end to the mark justmade and write it down.

4. Remove the motor from the burner mounting flange.

5. Attach the replacement motor to the burner mounting plate.

6. Measure from the end of the new motor’s shaft the distance written downabove and make a mark on the shaft. Position the fan at the mark on themotor shaft and tighten the fan mounting screws.

7. Place the assembly back onto the burner and reinstall the flange nuts w/washers.

8. Reinstall the cable, reconnect the wiring then tighten the strain relief. Reinstallthe junction box cover.

9. Remove the lockout and restore power.

10. Start the heater and verify the motor is rotating in the direction indicated onthe housing. Correct if necessary.

11. Check for unwanted vibrations when the blower turns on - correct asnecessary.

Burner Air Flow Switch

CAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Burner Air Flow Switch.

Let the Heater cool before removing or replacing the Burner Air FlowSwitch.


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1. Loosen the air line nuts and disconnect both air lines from the switch.

2. Locate and disconnect the wires coming from the air flow switch inside thePowerFlame terminal box.

3. Remove the conduit lock nut and pull the conduit with wires out of theterminal box.

4. Remove the screws holding the air flow switch in place and remove the switch.

5. Position and install the replacement switch using the screws removed abovethen reconnect the air lines.

6. Feed the wiring through the side of the terminal box and reattach the conduit.

7. Close the gas train checking cock. Remove the lockout and restore power.


Air line nuts

PowerFlame Terminal Box

C16-003, CEI HHW-40 Heater Burner Gas Ignition Transformer

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8. Start the blower motor and observe the Comb. Air/All Limits light on thecontrol panel.

a. If necessary, turn the adjustment screw (under the rubber dust cover)clockwise until the light goes off.

b. Turn the adjustment screw counter-clockwise until the light comes on.c. Turn the adjustment screw clockwise approximately ¼ turn.

9. Verify the burner started as expected. Repeat from step 8 as required.

Burner Gas Ignition Transformer

CAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Burner Gas Ignition Trans-former.

Adjusting Screw(under rubber cap)


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Let the Heater cool before removing or replacing the Burner Gas IgnitionTransformer.

1. Open the access cover to the Burner Gas Ignition Transformer. Label thewiring then disconnect the wiring.

2. Disconnect the gas spark ignition wire from the top of the transformer.

3. Remove the transformer mounting screws then remove the transformer.

4. Install the replacement transformer using the mounting screws removedabove.

5. Reconnect the gas spark ignition wire to the top of the transformer.

6. Connect the wires to the transformer terminals disconnected above.

7. Close the cover.


9. Start the heater on gas to confirm proper operation.

Gas Spark Ignition Wire


C16-003, CEI HHW-40 Heater Gas Pilot Assembly

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Gas Pilot Assembly

CAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Gas Pilot Assembly.

CAUTION! Turn the gas supply OFF with the Main Gas Cock valve on thegas train.

Note: Before removing the pilot housing from the blast tube mount make sure that alignment marks are present.

1. Disconnect the ignition wire from the gas pilot transformer and disconnectthe tubing connection from the gas pilot assembly.

2. Mark the position of the Pilot Mounting Plate against the blast tube thenremove the indicated mounting screws.

3. Loosen both the indicated screw and setscrew then remove the assembly fromthe blast tube (the assembly is shown already removed from the blast tube forclarity).

Ignition Wire – Transformer Connection

Gas Pilot Connection and Cable Tie

Mounting Screws

Loosen screw and setscrew

Alignment Marks

Gas Pilot Assembly

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4. Reverse the procedure making sure the clip on goes on the inside of the blasttube to hold the front end of the assembly in place. Make sure to line up thealignment marks before tightening the screws and setscrew.



Ignition Electrode

1. Remove the clamp screw and clamp then remove the electrode.

2. Install the replacement electrode and adjust the electrode distance from theopen end and the spark gap then tighten the clamp screw.The spark gap between the electrode and the outside radius of the gas pilot

Clip - goes on inside of blast tube

Pilot Mounting Plate - goes on outside of blast tube

Clamp screw

Electrode

C16-003, CEI HHW-40 Heater UV Scanner

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assembly should be 1/16" - 3/32". DO NOT set the spark to arc against thepilot head nozzle.

3. Reinstall the assembly following the steps under Gas Pilot Assembly above.

Ignition Cable

1. Unplug the cable from the back of the electrode and pull out through thestrain relief.

2. Reinstall the assembly following the steps under Gas Pilot Assembly above.

UV Scanner

CAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the UV Scanner.

1/16" - 3/32"Spark Gap - Electrode Tip to Pilot Case

2 15/16"Air Hole

Primary Air Holes (2)

Pilot Orifice

Strain relief

Cable

UV Scanner

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Let the Heater cool before removing or replacing the UV Scanner.

1. Note the route of the UV Sensor’s cable then remove the cable ties holding thecable (be sure to note how the excess cable is coiled).

2. Open the PowerFlame terminal box and locate terminals S1 and S2.

3. Note which color of wire is connected to which terminal then disconnect theUV Scanner wires and pull the cable out the conduit connector.

Terminals S1 & S2Scanner connects to RIGHT terminals

Cable enters here


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4. Remove the UV Scanner from the burner.

5. Install the replacement UV Scanner and feed its cable through the conduitconnector.

6. Connect the wires to terminals S1 and S2 in the PowerFlame terminal box.

Note: Newer scanners also include a ground wire - be sure to connect it to the ground connection in the terminal box.

7. Route and cable tie the cable as noted in step 1 and coil the excess cable so itdoesn’t get caught/damaged in moving parts.



UT150 Burner Modulation ControllerNote: The Burner Modulation Controller is normally pre-programmed to the values listed

in the tables below when ordered from CEI.However, if the display shows that IN is OFF when you first apply power, the controller has not been programmed. Repeatedly press the UP arrow key until the display shows 35 then press the SET/ENT key.

UV Scanner


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Setup Parameters

1. To enter Setup Parameters press and hold the key for approximately 3seconds until the display shows A/M.

2. Repeatedly press the key until the display shows LOC.

3. Press the key to change the display to –1.

Note: If the LOC display shows 1, press the down key for a display of 0. Press the SET/ENT key, press the down arrow key for a display of –1, then press the SET/ENT again to enter Setup Parameters.

4. Use the and keys to change the displayed value to those in

the following table then press the key to save the value.




Input type 35

Setpoint range maximum value 200

Setpoint range minimum value 0

Setpoint ramp-up rate OFF

Setpoint ramp-down rate OFF

Setpoint ramp-rate time unit 1

Retransmission maximum value 200

Retransmission minimum value 0

Alarm 1 type 5

Alarm 2 type 0



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7. When finished entering the Setup Parameters:

Operating Parameters

Note: The controller automatically returns to the Operator mode after 2 minutes if no buttons are pressed.

1. To enter Operating Parameters press and hold the key for approxi-mately 3 seconds until the display shows SP.

2. Use the and to change the displayed value to those in the

following table then press the key to save the value.




SUPER function OFF

Direct / reverse action 0



Auto / Manual AUT

A1 Value 10

A2 Value 0

Control mode PID

Auto-tuning OFF

Proportional band 24

Integral time 256

Derivative time 64

Modulating Motor

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5. When finished entering the Operating Parameters:

6. Press and hold the key until the display returns to normal operations

Modulating Motor

Let the Heater cool before removing or replacing the Modulating Motor.

CEI suggests that the Modulation Motor and its internal Resistor Board bereplaced together.

1. If not already present, mark both the low and high fire positions for the airdamper openings, both right and left linkages and the modulating fuel oil valvepointer.

CAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Modulating Motor.

PV input filter OFF

PV input bias 0

Key lock 0


C16-003, CEI HHW-40 Heater Modulating Motor

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2. Remove the electrical connection cover, label all the wiring then disconnectthe wiring. Remove the conduit nuts then remove the wiring cable from themotor enclosure.

3. DO NOT loosen any linkage bolts or screws. Loosen the 2 hex head bolts onthe modulating motor shaft extensions just enough to allow the extensions toslide then slide each shaft extension off the motor shafts.

Electrical connection cover

Loosen these hex head bolts

Modulating Motor

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4. Remove the 4 mounting bolts/nuts/washers holding the modulating motorthen remove the motor.

If possible, replace the resistor board and adjust the cams on a workbench.• See Workbench on page 28 for workbench instructions.• See On Heater on page 30 for on heater instructions.

Workbench

1. When installing a new resistor board, set its DIP switches to match those ofthe removed motor’s resistor board.

Note: To verify the DIP switches are correctly set measure the resistance from W+ to R and R+ and B. Resistance should be 66.5Ω and 237Ω respectively.

2. Remove the new modulating motor cover and install the resistor board.

3. When the resistor board is installed, connect the brown wires from the trans-former to T1 & T2 on the resistor board then set the board switches the sameas those on the removed motor.

If the resistor board is not installed at this time connect the brown wires fromthe transformer to the T1 & T2 lugs.

CAUTION! Possibility of electrical shock - all connections may and alltransformer leads will be live. Use proper precautions for steps 4 through 8.

Resistor Board Installed No Resistor Board

Old Style Dip Switches New Style Dip Switches

Switch positions are the same - numbering differs

T1 & T2 connections

DIP switches

T1 lug

T2 lug


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4. Connect 110VAC to the motor’s transformer input leads then apply power.When power is applied the motor will drive to the low fire position (if notalready there).

5. With the motor at the Low Fire position, adjust the outer cam so that theindicated high point of the cam is actuating the low fire switch.

6. Remove power, place a jumper between R– and B. Reapply power to drive themotor to the High Fire position.

7. With the motor at the High Fire position, adjust the inner cam so that theindicated high point of the cam is actuating the high fire switch.

8. Remove power and remove the jumper.

9. Repeat steps 4 through 8 to verify the cams actuate their switches at the properpositions. Disconnect the external power.

Resistor Board Installed No Resistor Board

Transformer Input Leads

Outer Cam

Inner Cam

Switch forLOW

fire signal

Switch forHIGHfire signal

Outer cam High point

Inner cam High point

R- B

R- lug

B lug

Modulating Motor

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10. Using the bolts/nuts/washers removed earlier, install the new modulatingmotor.

11. See Air Damper, Gas Linkage on page 32 to complete the modulating motorreplacement.

On Heater

1. Note the removed motor’s resistor board switch settings and wire connections:• When installing a new resistor board, set its DIP switches to match those

of the removed motor’s resistor board

Note: To verify the DIP switches are correctly set measure the resistance from W+ to R and R+ and B. Resistance should be 66.5Ω and 237Ω respectively.

• If the existing resistor board is being reused, disconnect the wiring andremove it from the defective motor.

2. Install the resistor board in the new motor and connect all the wires except thewire to the W+ terminal.

3. Using the bolts/nuts/washers removed earlier, install the new modulatingmotor.

Old Style Dip Switches New Style Dip Switches

Switch positions are the same - numbering differs

Resistor Board Switches

Brown wires from transformer to T1 & T2

Leave the W+ wire disconnected


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CAUTION! Possibility of electrical shock - all terminal connections mayand all transformer leads will be live. Use proper precautions for steps 4through 11.

4. Route the wiring cable into the new motor and secure the conduit with theconduit nuts removed earlier.

5. Verify that the main fuel valves are closed then apply power to the burner –the burner will go through a prepurge cycle and stop (locked out) in a low fireposition.

6. With the motor at the Low Fire position, adjust the outer cam so that theindicated high point of the cam is actuating the low fire switch.

7. Remove power, place a jumper between R– and B. Reapply power to drive themotor to the High Fire position.

8. With the motor at the High Fire position, adjust the inner cam so that theindicated high point of the cam is actuating the high fire switch.

9. Remove power and remove the jumper.

10. Repeat steps 5 through 9 to verify the cams actuate their switches at the properpositions.

11. Connect the W+ wire to the W+ terminal then install the motor cover.

12. Continue to Air Damper, Gas Linkage.

Outer Cam

Inner Cam

Switch forLOW

fire signal

Switch forHIGH

fire signal

Outer cam High point

Inner cam High point

R- B

Abnormal Shutdowns

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Abnormal Shutdowns

If the heater encounters an abnormal operating condition it shuts down and the redlight on top of the panel flashes. The problem must be located and correctedbefore the heater can restart.

In addition to the flashing red light, a LOCKOUT message displays on the Fireyeflame monitor.

The first line of the lockout message indicates the operating condition when thelockout happened. The second line indicates what abnormal condition triggeredthe lockout. However, even though the triggering condition is indicated, the opera-tor must still pinpoint the source of the problem.

• A lockout message of 3-P INTLCK OPEN indicates that one of the limitdevices in the 3-P interlock circuit triggered the shutdown. In that case thefirst status light out provides a clue as to which device caused the shut-down. The label on that light denotes the device that needs to be checked.

• Lockout messages on the flame monitor may indicate that a shutdown wascaused by abnormal conditions not related to the 3-P circuit. A message ofD-8 LIMIT OPEN is usually caused by a problem with the burner modu-lation motor.

• A message of LOCKOUT STANDBY FALSE FLAME indicates afaulty flame scanner (when there is really not a flame in the burner).

• A message of LOCKOUT PTFI FLAME FAIL is usually caused by aproblem with the flame scanner, or with fuel, or with ignition.

• A message of LOCKOUT AUT FLAME FAIL is usually caused by aproblem with fuel or combustion air.

Air Damper, Gas Linkage1. With the burner locked out and the modulating motor at the low fire position

slide the motor shaft extensions onto the motor shafts paying attention to thelinkage marks made earlier. Because the motor shafts are square the shaftextensions will properly align onto the motor shafts (when the shaft extensionbolts were only loosened). Tighten the shaft extension bolts.

2. Turn the burner on and let it advance to the main flame light off position.

3. With the burner in the low fire position, check for a fuel/air ratio low firesettings of 7 - 9% CO2 and little or no1 CO.

Note: If an adjustment is necessary, make the adjustment and mark the linkage at the new settings.

1. Although Underwriters Laboratories permits higher readings of CO (Carbon Monoxide), it is desirable to obtain readings between 0 and 100 PPM, depending on local codes and burner manu-facturer’s recommendations

C16-003, CEI HHW-40 Heater Gas/Air Mixture Adjustments

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4. Increase the firing rate to the midway point. Again check for a fuel/air ratio of7 - 9% CO2 and little or no CO.


5. Increase the firing rate to high fire position and repeat the test done for themid point adjustment. Check for fuel/air ratio of 8½ - 10% CO2 and little orno CO.


Gas/Air Mixture Adjustments

CAUTION! The following procedures should only be performed by individ-uals qualified and trained to perform the adjustments.

The adjustments that follow are condensed. For complete instructions consult themanufacturer’s manual.

Gas Burner Instructions

1. Check all linkages

2. Close the main, checking and pilot gas cocks.

3. Install required system measuring devices:• Appropriate flame signal meter to the flame safeguard control.• U-Tube Manometer or 0-10" W.C. gauge in the pilot test tee port.• Stack thermometer and CO2 or O2 analyzer sample line to the breaching.

• Draft gauge or inclined manometer to the combustion chamber test point.• 0-35" W.C. gauge main gas pressure regulator inlet.

4. Slowly open the main gas cock in order to determine that the incoming gaspressure is within the specified limits of the main and pilot gas pressureregulators, automatic fuel valves and gas pressure switches.

5. Disconnect the pilot line at the inlet to the pilot gas pressure regulator andpurge air from the pilot gas line. After the air is purged from the gas supplysystem, close the pilot cock and reconnect the pilot line. Leave the pilot cockclosed.

Note: It is strongly recommended that an automatic gas valve bubble leak test be performed in accordance with the gas valve manufacturer’s instructions periodically in order to ensure that the valve is functioning according to the manufacturer’s specifications. It is also suggested that the test be conducted during a normal prepurge burner operation.


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6. If necessary, set the air dampers approximately ⅛" to x" open. With bothpilot and leak test gas cocks closed, open the main gas cock to allow the lowgas pressure switch to make its circuit. With the control switch in the OFFposition, apply power to the burner through the main burner disconnectswitch. Switch the burner panel ON/OFF switch to the ON position momen-tarily to determine that the blower rotation is correct.

7. Restart the burner. With the pilot gas cock closed, the burner goes through ablower prepurge period. After the prepurge the gas pilot ignition transformeris energized although no pilot will be established. At no time should there beany flame signal reading nor should the main gas valve attempt to open. At theend of the pilot trial for ignition and blower purge period the flame safeguardcontrol should shut the system down in a safety lock-out mode. The safetylock-out mode requires a manual reset to the flame safeguard control to restartthe burner.

8. Wait three minutes, reset the flame safeguard control safety switch and openthe pilot gas cock. When the blower prepurge period ends and the burner isenergized, set the flame safeguard timer Stop/Run switch to Stop. While thepilot is on make adjustments as required. Recycle the burner several times tomake certain pilot operation is reliable.

9. Initial Spark Pickup Test. With the pilot gas cock closed, the burner goesthrough a blower prepurge period. After the prepurge the gas pilot ignitiontransformer will be energized although no pilot will be established. At no timeshould there be any flame signal reading nor should the main gas valve attemptto open. At the end of the pilot trial for ignition and blower purge period theflame safeguard control should shut the system down in a safety lock-outmode. The safety lock-out mode requires a manual reset to the flamesafeguard control to restart the burner.

10. Once the pilot adjustments are complete set the timer switch to the Runposition to allow the start-up sequence to proceed to the automatic gas valveenergizing position.

11. When the main automatic gas valve begins to open, slowly open the checkinggas cock to light off the main flame. The main flame should light immediately.

12. Adjust the burner as necessary to provide smooth ignition of the main flame.If the flame signal drops significantly when the main automatic gas valveopens, slightly increase the pilot gas pressure to attain a stable flame signalvalue.

13. Verify that the butterfly valve is in the low fire position. To verify observe theend of the metering valve shaft, the slot in the end of the shaft indicates theposition of the valve. If low fire the valve should be nearly closed.

14. Turn the burner on and let it advance to the main flame light off position.Take action as necessary to hold the linkage at the low fire position by electri-cally disconnecting the modulating motor.

Note: It is suggested that the factory settings be noted and marked on the linkage prior to proceeding with final adjustment.

C16-003, CEI HHW-40 Heater Gas/Air Mixture Adjustments

35

15. With the burner in the factory set low fire position, adjust air and fuel linkageto good fuel/air ratio low fire settings (7 - 9% CO2, little or no CO). If thelinkage position is different from the factory settings, mark the linkage at thenew settings.

16. Increase the firing rate to the midway point. Set the fuel/air ratios to achievegood combustion values (7-9% CO2, little or no CO). Again, if the linkageposition is different from the factory settings, mark the linkage at the new midfire position.

17. Increase the rate to high fire position and repeat the test done for the midpoint adjustment. Results should range in the area of 8½ to 10% CO2, withlittle or no CO. The metering device setting and air damper openings shouldbe marked and noted to obtain high fire reference points if different from thefactory settings.

18. Operate the modulating lever arm on the modulating motor through the threepreviously referenced points. Minor setting modifications may be required toensure that the reference points are acquired.

19. Tighten (finger tight) the hex bolt to the linkage rod at the swivel on themodulating motor driver arms and run the motor through its full travel toensure that the linkage is free and that limits on the metering device and airdampers are not exceeded.

20. Determine that the required gas input rate is being achieved by clocking thegas flow at the gas meter.

21. Intermittently operate the burner until the heat transfer fluid indicates anincrease in temperature.

22. Tighten all linkages and permanently mark the settings.

23. Check the limit control as follows: a. Run the burner until the limit control settings have been reached.b. Set the controls so that the burner goes to the low fire position before the

operating limit control turns the burner off (the burner should turn offwhen the set temperature is reached).

c. After a temperature drop the burner should restart automatically.

24. Set and check operation of:• Low and high gas pressure switches.• All burner and heat exchanger controls and operating devices.• Blower Combustion Air Flow Switch.


36


Section 3: Parts

38

C16-003, CEI HHW-40 Heater Replaceable Parts List by Drawing

39

Replaceable Parts List by DrawingNote: Part #’s and descriptions proceeded with • or – exist on the drawing above the

entry. Drawings immediately follow list.

Assembly, HHW-40 Firestorm Final Drawing – Dwg # 6690103-01

Part Number Description

010301001072020403054080309008030912001003470001056010213202048-5010

JJ20RL ThermocoupleLevel Liquid SwitchGauge Valve Set 20-150-0342" x ¾" Blue Aircraft Flex Hose24" x ¾" Blue Aircraft Flex Hose3/8" x 5/8" OD Clear Vinyl TubingMIST Pad EliminatorStack SwitchElectrical, HHW-40 Control - (Replaced by HHW4000000 Below)

Assembly, Water Pump and Piping – Dwg # 6690114-06


02021080401089040302213010101302081130212113030551304062150215625150582515056

Snubber Pressure 25-1112B-E AshcroftThermometer Bimetallic 3" Dial x 2½" STGauge Pressure 0-60 PSI 2½"Valve Gate Brass Screwed 2"Valve ¼" NPT Bronze 70-101-01Valve 2" Air Actuated Ball SRValve Swing Check 1" BronzeValve Solenoid Single Coil TVCSPump Scot Model #15 S/F 10HPGasket 3" Spiral Stainless SteelGasket 2" Spiral

Assembly, HHW-40 Water Train – Dwg # 6690114-07


0202152040108904030240403026120403613020811302082130212113040622515056

Switch Pressure J400-S146B 0-30 PSIThermometer Bimetallic 3" Dial x 2½" STGauge Pressure 25-1112B-E AshcroftValve Pressure Reducing 2" NPTStrainer Y Mueller 2" 351M 125#Valve ¼" NPT Bronze 70-101-01Valve Ball 2" Bronze Apollo 70-108-01Valve 2" Air Actuated Ball SRValve Solenoid Single Coil TVCSGasket 2" Spiral

Replaceable Parts List by Drawing

40

Assembly, HHW-40 Gas Train – Dwg # 6690114-08


130205504030270102102010210326010190202108

¼" Bronze Ball Valve0-15" H2O Pressure Gauge2½" x ⅞" OrificeSpring for 0102102CR3-G-25B BurnerSnubber Pressure 25-1112B-E Ashcroft

The following parts numbers/parts are from an outside vendor and may require extra time to ship

P1P2P3P4P5P6P7

2½" Leak Test Cock Ball Valve2½" Main Gas Shutoff Cock Ball ValveModulating Gas Butterfly Metering Valve2½" Main Gas Pressure RegulatorHigh Gas Pressure SwitchLow Gas Pressure Switch2½" Main Gas Valve w/Proof of Closure

Electrical Control Box for UL/CSA Echoheat Heaters – Dwg # HHW4000000


0101022010805401080700108073010850801085890108918021500702150544507060HHW0000000

4 Amp 1 Pole Breaker 40 Amp Panel Mount BreakerThru Door Operator ED FrameVariable Depth Breaker Shaft11.0-16.0 Amp Panel Mount Combination Starter3.5-5.0 Amp Panel Mount Combination StarterAxillary Contact Block w/1 N.O. & 1 N.CControl TransformerTransformer Terminal CoverDL-105 Series PLC ModuleElectrical Control Box for UL/CSA Echoheat Heaters See Dwg #HHW0000000 below

Electrical, Ecoheat 40 Control (Schematic) – Dwg # HHW0000000


01011700101188010405301040540106259010626001062610106262010626401082750108348010834901083520108364010737420013084507063

3 Amp Class CC Rejection Type Fuse5 Amp Class CC Rejection Type FuseModular Fuse Holder - SingleModular Fuse Holder - DoubleFireye YB-110UV Chassis w/AmplifierFireye BLL-510 DisplayFireye YP-138 ProgrammerFireye 60-2812-1 Wiring BaseFireye 129-178-4 Remote Mounting Kit2 C-Form Contacts DIN Rail RelayRed Pilot Light/BaseGreen Pilot Light/BaseWhite LED Pilot Lamp - 110-130 VAC3 Position Maintained SwitchPushbutton, Illuminated GreenRed Warning Strobe LightTemperature Controller - Yokogawa

41

AS BUILT BURNER SPECIFICATION SHEETContact EM/KAS 03/04/2016

Number J092936Customer C.E.I. ENTERPRISES

Quantity 2Purchase Order 0068928

Name

Order Number B067134 - 1JOB DETAILS

Model CR3-G-25BMode Of Operation MODODP

Serial Number(s) 031659874-75 UL LabelCode NONE

BURNER DETAILS

HEAT EXCHANGER AND SITE DETAILSC.E.I.

Type HOT OILModel Unknown

Site Altitude 2000Combustion Chamber Press. 0.5Make

High Fire Rate 4800 MBHHigh Fire ManifoldPress.

5.0 Side Orifice Size None

Min. Supply Press. 7.8Gas Reg. Outlet Press. 7.4 Site Press. 8.0 - 14.0

GAS DETAILS ( ALL PRESSURES ARE IN INCHES WC )

Max. Design Press. 14.0 UL Gas GroupNaturalType Pilot Natural

Remote Panel

Wiring G-J092936 General Arrangement

Oil PipingGas Piping PDG-J092936 Additional 1

DIAGRAMS

Additional 3Additional 2

Compressor

Control FLA

Remote PumpBlower Motor 460V/3PH/60HZ FLA 3.8

ELECTRICAL CHARACTERISTICS

FLAFLA

Clipped Circuit Board Part Number Min. Circuit Ampacity

High Fire Rate GPHPump PressureGrade

UL Oil GroupOIL DETAILS ( ALL PRESSURES ARE IN PSI )

Compressor Pressure

Flange Setting 4"

Gas Ignition System GAS PILOT

Diffuser Blade Setting 3/8"Gas Inlet Location SIDE

BURNER SETTINGS AND MISC.

Oil Ignition SystemSCANNERFlame Detection

COMMENTS ( MAY CONTINUE ON NEXT PAGE )

RUN CONDUIT FROM BOTTOM OF THE JUNCTION BOX W/45 DEG ELBOWS TO THE BOTTOM OF THEMOD MOTOR W/90 DEG ELBOWSUSE SEALTITE CONDUIT AND CONNECTORS - RUN GROUND WIRES TO ALL ELECTRICAL DEVICES8 X 10 NEMA4 JUNCTION BOXUV COOLING LINE REQUIRED

¹Approximate operating pressure at the manifold inlet for initial start-up. Final pressure should be determined afterchecking actual flow with gas meter. Stack temperature, CO, CO2, O2, and furnace pressure will help in determiningactual input when gas meter is not available for this unit.

²All components are rated for the maximum design pressure specified. That pressure must not be exceeded.

42

PFI Part No. U\M Qty. Material Description Ship Loose058660 EA 1.00 3 HP 3450 RPM 208/230/460/3 TEFC 56C FR. VM3559

BALDOR MOTOR OR P56H1445 RELIANCE060250 EA 1.00 M9174C-1025/P 120V. HONEYWELL MODUTROL

MOTOR SERIES II.WITH LOW FIRE START & PURGE INTERLOCKSEXCPT TYPE 1 UL

060700 EA 1.00 220738A/B HONEYWELL BRACKET WITHHARDWARE FOR MOD IV MODUTROL MOTORS

061540 EA 1.00 221508A-2/U HONEYWELL MOD IV RESISTORBOARD

082510 EA 1.00 9-1/8 X 4 X 5/8 S-HUB R912-400S 3450 CW REVCORWHEEL SPEC. 1-4501

161000 EA 1.00 LGP-G 1-20 INCH ANTUNES LOW GAS PRESSURESWITCH MANUAL RESET (VENTLESS)8103116202

L

161100 EA 1.00 HGP-G 2-20 INCH ANTUNES HIGH GAS PRESSURESWITCH, MANUAL RESET (VENTLESS)8101111202

L

163961 EA 1.00 1950-10-2F 3.0 TO 11.0 IN. W.C. DWYER EXPLOSION-PROOF DIFFERENTIAL SWITCH

190900 EA 1.00 V4055D-1019 13 SECONDS ON-OFF SPST PROOFOF CLOSURE SWITCH 120V. HONEYWELLOPERATOR

L

194300 EA 1.00 V5055C-1018 2-1/2 INCH PROOF OF CLHONEYWELL VALVE BODY

L

202450 EA 1.00 8040H007 1/4 INCH 120 VOLT 50/60 HZ. OR U-28-45-21-18 GAS PILOT VALVE

281200 EA 1.00 S261SG02N3KK4 2-1/2 INCH 25PSI 120/605,700,000 BTU 1" PD 17.5 WATT ASCO G.C.VALVE

L

300900 EA 1.00 RV-91 2-1/2 INCH MAXITROL REGULATOR (AGA3275 CFH MAX) W/ R9110-38 PINK 3-8" SPRING

L

310490 EA 1.00 R9110-412 VIOLET 4-12 INCH SPRING FORMAXITROL RV-91 & 210E REGULATOR

L

320001 EA 1.00 1092-PF-G 6000 VOLT 50/60 HZ. ALLANSON GASIGNITION TRANSFORMER WITH GROUND WIRE

610400 EA 1.00 SLU-35 ILSCO GROUNDING LUG

612200 EA 14.00 11511811 ENTRELEC M6/8 8MM TERMINAL BLOCK 50AMP 8-22 GA. SCREW

612202 EA 1.00 040018621 M6/8 ENTRELEC RED TERMINAL BLOCK

849640 EA 1.00 CMC6-4N-S316 3/8 X 1/4 TUBE TO MP STRAIGHTSTAINLESS STEEL COMPRESSION FITTING

L

879060 EA 1.00 1/4 INCH STANDARD BLACK SQUARE HEAD PIPEPLUG

L

910120 FT 6.00 3/8 INCH X .035 CARBON STEEL TUBING9220K33 (6' LENGTH)

L

3/4/2016 2:11:36 PMReport Number 4 Page 1

BILL OF MATERIALRe-Submittal 1

Customer: C.E.I. ENTERPRISES - 12203

Job Number: J000092936 - 0 Item: CR3-G-25B Order Number: B000067134 - 1

Purchase Order: 0068928

Qty: 2

43

PFI Part No. U\M Qty. Material Description Ship Loose980400 EA 2.00 2-1/2 INCH MODEL 740 FULL BORE BALL VALVE

WITH LONG HANDLE 55090L

C10134 EA 1.00 C3 HOUSING AIR DEFLECTOR

C10190 EA 1.00 C1/2/3 PEDESTAL PLATE

C10202 EA 2.00 CR1/2/3 PEDESTAL PLATE FILLER

C10560 EA 2.00 C3 DAMPER BLADE

C10651 EA 1.00 2 INCH SNAP IN SIGHT GLASS

C10750 EA 1.00 C3 56C FRAME MOTOR PLATE

C11272 EA 1.00 C3 BOILER FLANGE REDUCED MINIMUM SETTING

C11360 EA 1.00 C3 FILLER BAND

C13233 EA 1.00 DWYER NEMA 7 PRESSURE SWITCH BRACKET

C13448 EA 2.00 C(R)3 LIFTING LUG

C20050 EA 1.00 C3 AIR HOUSING ASSEMBLY 1.5" EXTENSION

C21112 EA 1.00 C3 G TUBE AP 8.5 BAFFLE 50-#10 SGI

C22111 EA 1.00 C3 8" CHOKE ASSEMBLY

C24030 EA 1.00 C3 BACK PLATE ASSEMBLY PC

C24110 EA 1.00 C3 PILOT MOUNTING PLATE ASSEMBLY

C80432 EA 2.00 C3 DAMPER SCREEN (RAW FINISH)

C80590 EA 2.00 C2/3 DAMPER AXLE

C95073 EA 1.00 C3 STRAIGHT GAS GUN ASSEMBLY

C95301 EA 1.00 C2/3 DAMPER CROSS LINKAGE ASSEMBLY

E10039 EA 1.00 8 X 10 HOFFMAN PREPUNCH CEI

E10610 EA 2.00 PANEL BOX MOUNTING BRACKET (BURNER)

E12012 EA 1.00 A-10P8 8 X 10 HOFFMAN CHASSIS

F20020 EA 1.00 C3/4 SCANNER PILOT ASSEMBLY #30 NATINCLUDES X04210 ELECTRODE

M20110 EA 1.00 SHIPPING PEDESTAL ASSEMBLY

M90030 EA 1.00 PF-FP 2 INCH BUTTERFLY 8100 @ 1"

X02338 EA 1.00 2-1/2 X 3-1/2 STD BLK NIPPLE L

X09101 EA 1.00 90L203C-1 MOD MOTOR EXTENSION SHAFT

X09341 EA 2.00 10-32X3/8 PHILLIPS PAN HEAD MACHINE SCREW,ZINC PLATED


BILL OF MATERIALRe-Submittal 1

Customer: C.E.I. ENTERPRISES - 12203

Job Number: J000092936 - 0 Item: CR3-G-25B Order Number: B000067134 - 1

Purchase Order: 0068928

Qty: 2

44

45

46

47

Spare Parts List and Order Form

Power Flame Incorporated2001 S 21st StreetParsons, Ks 67357Ph: (620) 421-0480Fx: (620) [email protected]

03/04/2016

J000092936-0

B000067134-1

CR3-G-25B

C.E.I. ENTERPRISESSold to:

Serial Number:

Burner Model:

Order Number:

Job Number:

Date Generated:

---------------Send Orders To:---------------

Please visit www.powerflame.com for yourlocal representative.

Please enter my purchase order for the above spare parts on out P.O. # ___________________

Part#

Req'dQty. PerBurner Part Description Net Each

Qty.Ordered

058660 1 EA 3 HP 3450 RPM 208/230/460/3 TEFC 56C FR.060250 1 EA M9174C-1025/P 120V. HONEYWELL MODUTROL082510 1 EA 9-1/8 X 4 X 5/8 S-HUB R912-400S 3450 CW161000 1 EA LGP-G 1-20 INCH ANTUNES LOW GAS PRESSURE190900 1 EA V4055D-1019 13 SECONDS ON-OFF SPST PROOF194300 1 EA V5055C-1018 2-1/2 INCH PROOF OF CL202450 1 EA 8040H007 1/4 INCH 120 VOLT 50/60 HZ. OR281200 1 EA S261SG02N3KK4 2-1/2 INCH 25PSI 120/60300900 1 EA RV-91 2-1/2 INCH MAXITROL REGULATOR (AGA320001 1 EA 1092-PF-G 6000 VOLT 50/60 HZ. ALLANSONF20020 1 EA C3/4 SCANNER PILOT ASSEMBLY #30 NAT

THIS QUOTATION IS VALID FOR 30 DAYS FROM THE DATE GENERATED AND IS SUBJECT TO THE PFI CONDITIONS OF SALE.

------------------------------------Ship To------------------------------------_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


48

49

C16-003, CEI HHW-40 Heater Dwg # 6690103-01

Drawings6690103-01

Item 5 Replaced by HHW4000000 - Electrical Control Box for UL/CSA Echoheat Heaters


50

6690114-06

51


6690114-07


52

6690114-08

53

C16-003, CEI HHW-40 Heater Dwg # HHW4000000 (Schematic)

HHW4000000 (Schematic)

C16-003, CEI HHW-40 Heater Dwg # HHW0000000

54

HHW0000000


Specifications

56


57

6070

8090

100

110

120

HH

W-0

70.

7525

2119

1715

1413

7236

111

750

163

HH

W-1

01

3329

2522

2018

1779

5211

710

0021

7

HH

W-1

61.

653

4640

3632

2927

8854

117

1600

347

HH

W-2

32.

377

6658

5146

4238

9654

117

2300

498

HH

W-4

04

133

114

100

8980

7367

115

5411

740

0086

7

HH

W-6

06

200

171

150

133

120

109

100

136

6112

860

0013

00

HH

W-8

08

267

229

200

178

160

145

133

158

7814

480

0017

33

HH

W-1

1011

367

314

275

244

220

200

183

180

8415

211

000

2383

HH

W-1

4014

467

400

350

311

280

255

233

202

9616

014

000

3033

HH

W-1

7017

567

486

425

378

340

309

283

225

104

168

1700

036

83

HH

W-2

0020

666

571

500

444

400

364

333

243

108

176

2000

043

33

HH

W-2

4024

800

685

600

533

480

436

400

261

114

184

2400

052

00

HH

W-2

8028

933

800

700

622

560

509

466

279

120

192

2800

060

67

HH

W-3

6036

1200

1028

900

800

720

654

600

297

126

200

3600

078

00

Nat

ural

Gas

(c

fh)

Com

bust

ion

Air

(cfm

)

Spe

cific

atio

ns

Wat

er F

low

Rat

e (g

pm)

App

roxi

mat

eD

imen

sion

s (in

ches

)B

urne

r Req

uire

men

ts

Tem

pera

ture

Ris

e (D

egre

es F

)L

WH

Btu

/hr

(mill

ion)

Mod

el

58

C16-003, CEI HHW-40 Heater Contact Information

59

Contact Information

CEI ENTERPRISES, INC.An Astec CompanyP.O. Box 9156Albuquerque, New Mexico, U.S.A. 87119

CEI Service (General Contact)

Phone: (800) 545-4034 or (505) 842-5556Fax: (505) 243-1422www.ceienterprises.com

Departmental Contacts

Stuart BakerPost Production ManagerCell: (505) 359-1500

Scott CloningerEngineering ManagerCell: (505) 238-0323

Johnny RomeroParts RepresentativeCell: (505) 235-2789

CEI ENTERPRISES, INC.An Astec Company

245 Woodward Road, SEAlbuquerque, New Mexico, U.S.A. 87102

C16-003, CEI HHW-40 Heater v 3.2.0815

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