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AGCO AP Cumberland VariFlame VF-16-ENG, Owner'S Manual

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AGCO AP Cumberland VariFlame VF-16-ENG Owner'S Manual Download Page 17

3

System Overview

Topics Covered in this Chapter

▪

User Interface

▪

Typical Controller Connections

▪

Heater component functions

▪

Burner control module and sequence of operation

▪

Operation modes

Pneg-2092

VariFlame Heater with Edge Connect

17

Summary of Contents for AP Cumberland VariFlame VF-16-ENG

Page 1: ...VariFlame Heater with EDGE Connect Patent Pending Models VF 16 EPS VF 16 EPP VF 16 EPG VF 16 ENG VF 16 ENS VF 16 ENP Owner s Manual PNEG 2092 Version 1 0 Date 09 14 16 PNEG 2092...

Page 2: ...d out and kept on record Equipment Information Model Number Serial Number Date Purchased Dealer Name and Phone Number All information illustrations photos and specifications in this manual are based o...

Page 3: ...e parameters for a Variable Input Mode 43 Setting the parameters for Standalone Mode 46 Setting the parameters for Legacy Mode 47 Enabling a second probe 49 Testing the LED probes with blink mode 51 C...

Page 4: ...er 9 Parts List 75 VariFlame EDGE Controller Parts 75 Switch and Probe Parts 76 Gas Parts 77 Motor and Blower Wheel Parts 78 GSI Group LLC Limited Warranty 79 4 Pneg 2092 VariFlame Heater with Edge Co...

Page 5: ...s required Unqualified persons must stay out of the work area at all times Alterations must not be made to the equipment Alterations can produce dangerous situations resulting in SERIOUS INJURY or DEA...

Page 6: ...l indicates an imminently hazardous situation which if not avoided will result in serious injury or death This symbol indicates a potentially hazardous situation which if not avoided can result in ser...

Page 7: ...ate personal protective equipment Eye Protection Respiratory Protection Foot Protection Hearing Protection Head Protection Fall Protection Hand Protection Wear clothing appropriate to the job Remove a...

Page 8: ...stand any part of this manual or need assistance contact your dealer Retain these instructions for future reference ST 0025 3 For Your Safety If you smell gas 1 Open windows 2 Don t touch electrical s...

Page 9: ...ay start without warning Do not service the heater without first disconnecting and locking out power Keep area clean and dry Keep hands feet and clothing away from moving parts Keep the heater in prop...

Page 10: ...regulations which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made For the United States The equipment shall be installed in...

Page 11: ...ified electrician Lock out power source before making adjustments cleaning or maintaining equipment ST 0069 1 Improper Use Warning The intended use of this appliance is the heating of agricul tural an...

Page 12: ...personnel involved in the installation operation service and maintenance of the equipment Location Decal No Decal Description Inside door panel DC 2426 Warning Electrical Hazard Instructions Wiring D...

Page 13: ...tion On Door DC 2429 Caution On Door DC 2430 Warning Hot Surface To replace a damaged or missing decal contact us to receive a free replacement GSI Decals 1004 E Illinois St Assumption IL 62510 Tel 1...

Page 14: ...heet that can be used to verify that all personnel have read and understood the safety instructions This sign off sheet is provided for your convenience and personal record keeping Date Employee Name...

Page 15: ...12 0 in W C Burner manifold pressure maximum 10 0 in W C Burner manifold pressure minimum 0 4 in W C Fuel consumption per hour maximum 11 58 lbs Fuel consumption per hour minimum 2 32 lbs Motor charac...

Page 16: ...W C Burner manifold pressure minimum 0 4 in W C Fuel consumption per hour maximum 238 cu ft Fuel consumption per hour minimum 47 6 cu ft Motor characteristics 1 3 H P 1100 RPM Electrical supply Volts...

Page 17: ...Topics Covered in this Chapter User Interface Typical Controller Connections Heater component functions Burner control module and sequence of operation Operation modes Pneg 2092 VariFlame Heater with...

Page 18: ...value B Press to go down in the menu or to decrease a parameter value C Enter function in a menu or to edit a parameter D 24Vdc supply state E Lock mode activation state F EDGE Automation network stat...

Page 19: ...Chapter 3 System Overview Figure 3 1 User Interface Flow Chart Pneg 2092 VariFlame Heater with Edge Connect 19...

Page 20: ...Chapter 3 System Overview Figure 3 2 User Interface Flow Chart 20 Pneg 2092 VariFlame Heater with Edge Connect...

Page 21: ...ariFlame heaters with EDGE Connect can be installed to existing controllers or to an EDGE controller Figure 3 3 Controller connections using existing control Figure 3 4 Controller connections with EDG...

Page 22: ...ch that limits the outlet temperature of the heater If the outlet temperature of the heater ever reaches the temperature limit of the high limit switch the switch opens and the heater will go into loc...

Page 23: ...heater The control board controls all of the heater com ponents and is responsible for making all safety related decisions Any time the heater goes into lockout mode power to the control board must be...

Page 24: ...Chapter 3 System Overview Burner control module and sequence of operation Figure 3 6 VariFlame Sequence of Operation 24 Pneg 2092 VariFlame Heater with Edge Connect...

Page 25: ...fies the stability of the flame for 6 seconds If the flame is stable at 80 of conduction the burner is considered on If at anytime during this process the gas valve is not found to be energized or the...

Page 26: ...d of the recovery period VariFlame will stop and wait for a signal from the main controller If no signal is received before reaching the failsafe start temperature another period will occur Standalone...

Page 27: ...re cleared and a new Learning cycle is triggered In this mode the temperature is continuously monitored such that if the temperature drops below the Fail safe Temperature Setpoint parameter defined by...

Page 28: ...The period starts as soon as the failsafe mode is entered At the end of the recovery period VariFlame will stop and wait for a signal from the main controller If no signal is received before reaching...

Page 29: ...ir as it exits the heater 1 Bend the diverter flaps 1 to the desired angle 2 Bend the top and bottom sides down making sure the tabs of the diverter flaps align with the holes in the top and bottom si...

Page 30: ...tom air intake is not restricted in any manner What You Should Know 1 Install the j hooks with the lock nuts into the four corners of the heater NOTE Adjust the length of the j hooks using the lock nu...

Page 31: ...ce 8 Install a sediment trap and a manual shut off valve to the heater s gas inlet 9 Install a low pressure gauge tester to the gas valve to verify that the gas pressure is within the range specified...

Page 32: ...our for each section of pipe HVR number heaters supplied by pipe section X heat output per heater Determine the Equivalent Length Of Pipe ELOP required for sufficient gas service ELOP length from mete...

Page 33: ...ft 13 m 160 ft 51 m Tabulated ELOP 200ft 60 m Round up to the nearest table value In the appropriate table NG Table 2 or LP Table 3 select the column showing the ELOP or the next longer length if the...

Page 34: ...72 000 21 in 19 1 c g 72 000 21 in 19 1 IMPORTANT The following tables are based on values given in the Gas Engineers Handbook and are intended as a guide only Consult your gas supplier for gas capaci...

Page 35: ...Pipe Size Internal Dia IPS Maximum Capacity Of Pipe In Thousands Of BTU per Hour Liquid Propane LP Pressure Drop Of 0 5 in w c Values listed are for 1 6 sp gr based on Heat Of Combustion of 2500 BTU...

Page 36: ...s and schematics to connect components to the VariFlame Edge controller DANGER Make sure all power sources are disconnected and locked out before performing any maintenance to the equipment Figure 4 6...

Page 37: ...Chapter 4 Installation Figure 4 7 VariFlame EDGE wiring diagram Pneg 2092 VariFlame Heater with Edge Connect 37...

Page 38: ...Chapter 4 Installation Figure 4 8 VariFlame EDGE schematic 38 Pneg 2092 VariFlame Heater with Edge Connect...

Page 39: ...Chapter 4 Installation Figure 4 9 VariFlame EDGE mode wiring Pneg 2092 VariFlame Heater with Edge Connect 39...

Page 40: ...Chapter 4 Installation Figure 4 10 Dipswitches 40 Pneg 2092 VariFlame Heater with Edge Connect...

Page 41: ...for Legacy Mode Enabling a second probe Testing the LED probes with blink mode Checking the System Status The Main Screen The main screen will vary depending on the operating mode and will alternate...

Page 42: ...y changes at the end of the cycle The Set tings Menu contains the following parameters Unit The unit of measure the heater should operate in Celsius C or Fahrenheit F Critical high limit temperature T...

Page 43: ...variable rate heater What You Should Know You have to cycle through all of the parameters and confirm any changes at the end of the cycle The Var iable 0 10V and 4 20mA Menus contain the following par...

Page 44: ...ush the Up or Down button to change the Failsafe Offset to the desired negative offset from the last input start and push Enter NOTE The default offset is 10 and pushing the up and down buttons modifi...

Page 45: ...Chapter 5 Controller Settings Figure 5 4 Variable Operations 0 10V or 4 20mA Pneg 2092 VariFlame Heater with Edge Connect 45...

Page 46: ...controller push either the Up or Down button until the Operation Modes Menu appears then push the Enter button 2 Push either the Up or Down button to scroll through the operation modes until Standalon...

Page 47: ...It is defined as a duration in minutes for which the heater may run continuously without reaching the stop temperature if the loop reaches the Maximum Runtime before reaching the Stop Temperature it s...

Page 48: ...s Pushing the up and down buttons modifies the time in 15 minute increments The range can be set from 0 to 900 minutes 4 Push the Up or Down button to change the Failsafe Offset to the desired negativ...

Page 49: ...ntains the following parameters Second probe status You can choose to enable or disable a second probe Probe discard offset The probe discard offset will be the negative offset from the first temperat...

Page 50: ...4 Push the Up or Down button to enter the Probe Discard Offset NOTE The default offset is 5 0 Pushing the up and down buttons modifies the offset in 0 1 incre ments The range can be set from 0 1 to 20...

Page 51: ...il Blink Mode Submenu appears hen push the Enter button 3 Push the Up or Down button to select Probe 1 or Probe 2 then push Enter to select the probe you want to test NOTE Probe 2 will only blink if i...

Page 52: ...To check the System Status 1 On the controller push either the Up or Down button until the System Status Menu appears then push the Enter button 2 Push either the Up or Down button to scroll through t...

Page 53: ...ator if applicable has been vented to the outside of the building Look at the gas hose for excessive abrasion wear or cuts Make sure that all external accessories have been installed and secured Look...

Page 54: ...e the selector switch to the OFF position 6 Repeat steps 3 through 5 several times to ensure proper ignition and burner operation 7 Depending on when the heater will be used follow the lighting and sh...

Page 55: ...rectly adjusted CAUTION Turn off all power sources before performing any adjustments to equipment Follow all safety procedures at all times To adjust the heater output 1 Open the heater door 2 Turn th...

Page 56: ...NOTES 56 Pneg 2092 VariFlame Heater with Edge Connect...

Page 57: ...outside of the heater 1 Spray the heater down with water only do not use cleaning solution 2 Wait at least one hour for the heater to completely dry before reconnecting the power cord to the electrica...

Page 58: ...emove the gauges and reconnect the hoses 8 Close both pressure tap screws by turning clockwise and check for gas leaks After You Finish Once the inlet and burner manifold pressures match close the fue...

Page 59: ...to the motor 4 Remove the five screws 3 attaching the motor mounting bracket 4 to the fan housing 2 5 Remove the motor and blower wheel assembly 4 from the heater enclosure To reinstall the motor and...

Page 60: ...Maintenance Figure 7 1 Control mounting bracket 1 Control mounting bracket 2 Fan housing 3 Screw Figure 7 2 Motor and fan wheel 2 Fan housing 3 Screw 4 Motor and fan assembly 60 Pneg 2092 VariFlame He...

Page 61: ...Slide the air proving switch 3 through the opening in the mounting plate 2 to remove To install the air proving switch 6 Slide the air proving switch 3 through the opening in the mounting plate 2 7 In...

Page 62: ...the mounting plate 2 to the fan housing 3 Slide the mounting plate 2 off of the screws through the keyholes in the bracket 4 Remove the two screws 1 securing the temperature high limit switch 5 from t...

Page 63: ...h limit switch bracket 1 Loosen screw 2 Mounting plate 3 Air proving switch 4 Air proving mounting bracket 5 High limit switch Figure 7 6 Temperature high limit switch 1 Screw 2 Mounting plate 8 High...

Page 64: ...Slide the igniter flame probe mounting bracket 1 off of the screws to remove the probe assembly 4 Remove the flame probe 4 from the igniter flame probe mounting bracket 1 by removing the screw 2 To i...

Page 65: ...Chapter 7 Service and Maintenance Figure 7 8 Flame probe 1 Probe mounting bracket 2 Screw 3 Ignitor 4 Flame probe Pneg 2092 VariFlame Heater with Edge Connect 65...

Page 66: ...3 Slide the igniter flame probe mounting bracket 1 off of the screws to remove the probe assembly 4 Remove the the igniter 3 from the igniter flame probe mounting bracket 1 by removing the screw 2 To...

Page 67: ...ld wired connections from the board 3 Disconnect all heater electrical components from the board 4 Remove all screws connecting the board to the control box 5 Remove the control board To install the c...

Page 68: ...ice and Maintenance Figure 7 11 Control Board Cover 7 Screw 8 Control cover Figure 7 12 Control Board 7 Screw 8 Control board Replacing the gas valve Before You Begin 68 Pneg 2092 VariFlame Heater wit...

Page 69: ...r pipe dope or thread tape approved for use with gaseous fuels install and tighten the gas valve to the burner pipe train The valve should be vertical when done 7 Turn the pipetrain 90 degrees away fr...

Page 70: ...Chapter 7 Service and Maintenance Figure 7 13 Remove supply valve 3 Supply line 6 Gas valve Figure 7 14 Gas valve removal 6 Gas valve 70 Pneg 2092 VariFlame Heater with Edge Connect...

Page 71: ...work link length is below 4000 feet 1200m with the recommended wire gage The VariFlame controller does not power up Verify if the LED 3 3V or 5V is activated on the PCB 443 Verify if the wires are ins...

Page 72: ...n detected Solution Power cycle the VariFlame Faulty Air Switch Cause sail switch has been seen close when fan is off Solution Verify that sail switch is in open position and that nothing can push on...

Page 73: ...flame sensor wiring Verify igniter condition and wiring Verify flame sensor rod for contact with metal housing Verify earth wire connection Too Many Retries After Flame Loss Cause BCM was not able to...

Page 74: ...activity DBG1 Debug LEDs DBG2 FAN ON Led active when the fan relay is running BURNER ON Led active when the burner is running LOCKOUT Led active when the controller goes to the lockout mode for a BCM...

Page 75: ...eel Parts VariFlame EDGE Controller Parts Figure 9 1 VariFlame EDGE Controller Parts Item Part Description 4 VF3 1055 VariFlame Variable Rate Replacement Display 5 VF3 1054 VariFlame Variable Rate Rep...

Page 76: ...m Part Description 1 3001 1740 Switch Micro with Sail Lever V3l 2 3005 0111 TSTAT TDISC 60T15 310D Airstream 3 VF3 1025 VariFlame Variable Rate Heater Control 13 VF1 3004 Hot Surface Igniter Assembly...

Page 77: ...iFlame Variable Rate LP VF3 1023 NG Gas Valve VariFlame Variable Rate NG 10 VF3 1013 Ball Valve 1 4 Mnpt x 1 4 Fnpt Compact 11 VF2 3009 LP VariFlame Orifice Propane VF2 3010 NG X VariFlame Orifice Nat...

Page 78: ...tor and Blower Wheel Parts Figure 9 4 Motor and Blower Wheel Parts Item Part Description 7 20 5099D Motor 1 3HP 1 Ph 120V 60 Hz C225m 8 20 5011X Wheel Blower Large C225m 50 Hz 78 Pneg 2092 VariFlame H...

Page 79: ...the date of purchase extended warranty period During the extended warranty period GSI will replace the frame or basket components that prove to be defective under normal conditions of use without char...

Page 80: ...llowed in all cases Authorities having jurisdiction should be consulted before installations are made 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 www gsiag com...

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