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Hastings COUNTERFLO CF SERIES, Installation And Service Manual

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Hastings COUNTERFLO CF SERIES Installation And Service Manual Download Page 1

ISCF-1 

April 2003 

Supersedes 

October 2000 

Installation and Service Manual 

COUNTERFLO 

CF SERIES HEATERS 

GAS, OIL, GAS/OIL FIRING 

WARNING 

FOR YOUR SAFETY

 

The use and storage of gasoline or other flammable vapors 
and liquids in open containers in the vicinity of this appliance 
is hazardous. 

Notice 

Read These Instructions Before Installation 

Summary of Contents for COUNTERFLO CF SERIES

Page 1: ...Manual COUNTERFLO CF SERIES HEATERS GAS OIL GAS OIL FIRING WARNING FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous Notice Read These Instructions Before Installation ...

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Page 3: ...ion 13 H Optional Remote Control Panel Installation 13 Section III Pre Start Inspection 13 A Procedure 13 Section IV Start Up 16 A Procedure 16 Section V Maintenance Schedule and Lubrication Requirements 23 A Maintenance Schedule 23 B Lubrication Instructions 24 C Testing of Controls Safety Devices 25 Section VI Troubleshooting 26 A Troubleshooting Gas Fired Units 26 B Troubleshooting Oil Fired Un...

Page 4: ...d by an inspector before they are accepted by the carrier Parts that are shipped unmounted are noted on the bill of material These parts where feasible are packaged and shipped with the units Upon receipt of shipment all units should be checked against the bill of lading to insure all items have been received The units should be checked carefully for physical damage in the presence of the carrier ...

Page 5: ...d burner is On Off Gas G Power type with pilot spark ignition and main burner pilot ignition for use with natural manufactured mixed liquefied petroleum gas or liquefied gas air mixture Included in the manifold are main gas electric shut off valve with linkage to combustion air damper main and pilot gas pressure regulators for maximum inlet pressure of 2 PSIG pilot gas air mixer and pilot solenoid...

Page 6: ...lating control system has an On Off thermostat as described above plus a modulating thermostat to control a modulating butterfly fuel valve Fan operation is intermittent Thermostats are factory furnished for field mounting and wiring 6 Remote Control Panel Optional The optional panel is furnished with a heavy duty toggle switch and three 115 volt signal lights as depicted in Figure 8 The switch co...

Page 7: ... placed on a solid foundation and set exactly as detailed later During transit unloading and setting of the unit bolts and nuts may have become loosened particularly in the pillow block ball bearing assemblies in the fan section It is recommended that all nuts and set screws be tightened Turn fan shaft by hand to make certain that blower does not rub against blower housing and that bearing lock ri...

Page 8: ...and return air ducts running direct to the base of the heater or when the plant is under a high negative pressure condition provisions should be made for an outside source of combustion air A conservative rule of thumb for estimating the inlet area required is 90 square inches per 1 000 000 BTU HR heater output The following table lists the recommended free area of vent opening in the outside wall...

Page 9: ...8 17 3 II 100 125 98 44 70 21 51 2 1 5 16 118 18 17 4 II 150 175 108 55 91 25 53 2 1 5 16 132 22 20 4 II 200 225 250 130 60 100 25 72 1 5 16 153 22 20 4 II 275 300 325 134 67 142 29 88 1 2 11 16 1 1 16 164 11 16 29 5 16 29 4 III 350 400 450 134 80 164 29 88 1 2 11 16 1 1 16 164 11 16 29 5 16 29 5 III Figure 1 Typical Counterflo Heater for Vertical Upright Mounting 6 ...

Page 10: ...ing voltage to the unit The total amperage of the main disconnect switch blower motor and control circuit transformer fusing is affected by the addition of 25 to the full load amps as required by the National Electric Code Check the supply voltage before energizing the unit The maximum voltage variations should not exceed 10 Phase voltage unbalance must not exceed 2 F PIPING CONNECTIONS All gas an...

Page 11: ...opposite end from fill line Vents must have weatherproof hoods and sufficient height to prevent obstruction by snow or ice Vents for tanks installed above ground must have flame arrestors All piping should be wrought iron steel or copper with standard fittings not less than iron pipe size All fittings must be absolutely airtight All screwed fittings should be coated with acid resisting pipe cement...

Page 12: ...d Valve l 15 Needle Valve If Required l 16 Pilot Gas Burner l 1 To Natural Gas Or Propane Fuel Supply Figure 3 Typical On Off Gas Piping For Counterflo Heaters 1 2 Inlet Pressure GAS FLOW CAPACITY CFH Iron Pipe Size IPS Inches Length of Pipe Equiv Ft 1 1 1 4 1 1 2 2 3 4 6 8 50 100 150 200 244 537 173 380 141 310 122 268 832 1680 588 1188 480 970 416 840 5018 8464 3549 5986 2896 4885 2509 4232 2247...

Page 13: ...ystems Remove Oil Safety Valve and Pipe As Shown Above Burner Pump By Pass Plug Installed By Unit Manufacturer 4 Oil Supply Pressure Must Not Exceed 3 PSI Or Pump Seals May Be Damaged 5 100 125 PSI At Low Fire 200 300 PSI At High Fire 6 Two Pipe Systems Only Oil Return To Supply Tank Burner Pump By Pass Plug Installed By Unit Manufacturer On One Pipe Systems Burner Pump By Pass Plug Removed By Uni...

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Page 15: ...Figure 6 Typical Light Oil Piping Suction System Two Pipe Method 12 ...

Page 16: ... are recommended one in each top corner and one at bottom center If mounting holes are to be located in side of box as shown four 4 holes are recommended two at top and two at bottom 5 If wiring box is to be recessed install so that open edge of box will be flush with finish wall Install optional flush mounting wall plate Examine wiring box and control panel for clearance before providing conduit ...

Page 17: ...6 20 24 9 1 2 150 175 6 12 12 18 20 24 28 9 11 16 5 80 1 4 24 13 9 16 200 250 6 12 12 18 20 24 28 9 11 16 5 23 1 8 24 9 5 8 275 325 10 1 2 16 16 22 24 28 32 11 5 16 5 5 8 33 37 1 4 6 3 8 350 450 14 18 18 24 26 30 34 11 5 16 5 5 8 33 48 9 1 4 Note Use D1 and E1 for orders with FM approval Note Interior flue vent must be suited for positive pressure venting Figure 7 Exhaust Details for Counterflo He...

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Page 19: ...lower housing The motor and shaft should turn readily by hand pull of the belts Properly adjusted belts can be easily depressed about one inch Make sure the fan shaft pillow block bearings are tight 9 Check fan motor to insure that pulleys are secure and drive belts are tight 10 Check all areas for cleanliness SECTION IV START UP All safety and operating controls have been checked during the facto...

Page 20: ...out clatter If they do not operate quietly check immediately for proper line voltage Even temporary low voltage at start up will cause constant operating trouble and must be corrected before the Counterflo heater is placed in service 9 Recheck all set screws on motor sheave and fan sheave Check alignment of belt s and pulley s Run blower for a few minutes and adjust motor take up if necessary Moto...

Page 21: ...lustrates a flame that is much too long and will cause over heating of the rear wall A correct flame should be fairly vigorous free of smoky haze and should barely impinge on the rear wall of the chamber Figure 10C illustrates proper flame travel This long steady flame provides adequate time for complete combustion and balanced heat release to all surfaces of the chamber Typical draft conditions a...

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Page 23: ... 20 45 50 70 55 70 40 55 75 90 1 10 1 25 1 00 1 10 1 10 1 10 200 225 250 275 2000 2250 2500 2750 1800 2000 2000 1635 1750 1850 1850 1675 55 60 65 60 1 00 1 00 1 00 1 00 1 40 1 48 1 50 2 00 1 50 1 55 1 60 2 90 300 325 350 400 450 3000 3250 3500 4000 4500 1635 1635 1850 1850 1850 1675 1675 1850 1850 1850 65 60 50 50 30 1 30 1 00 1 00 1 00 1 00 2 00 2 00 2 00 2 00 2 00 2 70 2 80 2 90 2 70 2 80 Note V...

Page 24: ... gas Turn on burner control switch Oil will ignite when oil solenoid valve opens observe flame conditions Normally gas air setting will be correct for oil If too little air oil flame is dark in appearance and smokey With too much air oil flame is bright and ragged in appearance and tends to be hard to ignite Before making final air adjustments loosen lock screw by oil line connection on side of fa...

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Page 26: ...nternal lockout switch will trip and lockout the protectorelay SECTION V MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS A MAINTENANCE SCHEDULE Weekly 1 Check that fan belts are tight and sheaves are lined up 2 Turn cleaning handle of fuel oil filter 3 Inspect oil pump and burner for oil leakage 4 Remove burner drawer assembly inspect nozzle and electrode tips and remove any carbon deposits 5 Ch...

Page 27: ...file sandpaper or other abrasives to clean contacts clean with notebook or heavy wrapping paper not newspaper NOTE Keep screened air intakes clear of obstructions at all times B LUBRICATION INSTRUCTIONS ITEM All 3 phase fan motors 1 HP to 100 HP ODP or TEFC Fractional HP exhauster motors single phase ODP or TEFC Fractional HP burner motors and oil pump motors single phase ODP or TEFC Fan shaft bea...

Page 28: ...etween flame absence and shutting of safety shut off valve It should be less than 2 3 seconds 4 The unit should go into a safety shutdown 5 Reset Flame Safety and open manual shut off valves 6 Refer to the Flame Safety Manufacturers Installation and Maintenance Manual for further information Safety Shut Off Valves 1 Close the Manual Leak Test Hand Valve located down stream from the Second Safety s...

Page 29: ... starter g There are any loose wires or connections in blower circuit at either terminal block or control components h Bonnet fan switch is in electrical circuit burner must be operative Also check the following optional controls if used to see if a Main gas cock is open units equipped with manual reset low gas pressure switch must have gas at switch for proper switch operation b Low gas pressure ...

Page 30: ...pe plug from regular or optional inlet as preferred Connect inlet line using PT fittings b Tighten pipe plugs in unused inlet and two return line ports c Start burner and bleed all air from system by removing gage port plug Allow oil to flow until it is clear then replace plug and tighten securely 2 Procedure for two pipe installation a Remove pipe plug from optional inlet Insert bypass plug furni...

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Page 32: ...iner at least once each heating season Remove the eight screws cover and cover gasket and lift out strainer Clean with fuel oil or very hot water under pressure from the faucet b When replacing strainer make sure that the strainer gasket is properly positioned If there is evidence of rust inside the pump be sure to remove water from the supply tank E GENERAL TROUBLESHOOTING TIPS 1 If blower operat...

Page 33: ... 30 1 Rota Roll Gears 2 Cutoff Valve 3 Positive Strainer 4 Leakproof Diaphragm Type Shaft Seal 5 Anti hum Device 6 Large Shaft Bearing 7 Body 8 Bleed Valve ...

Page 34: ...rted in the normal manner In case of emergency which requires the furnace to be shutdown disconnect main electrical power supply and close all manual valves If unit has filters they must be replaced at regular intervals with filters of the same type number and size The installer must identify the emergency shutoff devices after completion of the installation The equipment shall be installed in acc...

Page 35: ...SECURED IN PLACE DO NOT TAMPER WITH THE UNIT OR CONTROLS CALL YOUR SERVICEMAN NEVER BURN GARBAGE OR PAPER IN THE HEATING SYSTEM AND NEVER LEAVE PAPER OR RAGS AROUND THE UNIT THE INSTALLATION OF THE UNIT SHALL BE IN ACCORDANCE WITH THE REGULATIONS OF THE AUTHORITIES HAVING JURISDICTION REFER TO CSA STANDARD B139 FOR RECOMMENDED INSTALLATION PRACTICE OIL FIRED APPLIANCES SHALL BE CONNECTED TO FLUES ...

Page 36: ...PO Box 669 O 3606 Yost Avenue O Hastings NE 68902 0669 Phone 402 463 9821 O Fax 402 462 8006 www hastingshvac com O sales hastingshvac com ...

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