SAMUEL JACKSON Vulcain Service Manual Download Page 2

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PAGE 2 of 79 VULCAIN OIL-FIRED HEATER

Table of Contents

WARNING .................................................................................................................................................... 5

SAFETY FEATURES OF OIL-FIRED HEATERS .................................................................................. 7

NEW FEATURES ........................................................................................................................................ 8

HEATER OPERATION .............................................................................................................................. 9

NAVIGATING IMPORTANT MENUS ................................................................................................. 14

ENHANCING FUEL EFFICIENCY ......................................................................................................... 17

MOISTURE MIRROR X OPTION ......................................................................................................... 18

ERROR & ALARM LOGGING SYSTEM .............................................................................................. 20

ERROR & ALARMS EXPLANATION .................................................................................................. 21

TROUBLESHOOTING ............................................................................................................................ 30

TEST PROGRAM ..................................................................................................................................... 31

SETUP WIZARD ...................................................................................................................................... 37

ADDITIONAL SETTINGS ...................................................................................................................... 39

ANALOG FUSE REPLACEMENT.......................................................................................................... 44

ELECTRICAL INSTALLATION NOTES .............................................................................................. 45

ADDITIONAL INSTALLATION NOTES ............................................................................................. 46

INSTALLATION STUB-UPS FOR HO-7-VULCAIN AND HO-4-VULCAIN ................................. 47

EXTERNAL ELECTRICAL CONNECTIONS FOR VULCAIN HEATERS ....................................... 51

ELECTRICAL CONNECTION OF OPTIONS FOR VULCAIN HEATERS ...................................... 52

EXTERNAL WIRING DIAGRAM FOR FAN CURRENT RELAY .................................................... 53

NETWORK ID SETTINGS ..................................................................................................................... 54

ELECTRICAL SCHEMATIC WITH DISCRETE PLC I/O ................................................................. 55

ELECTRICAL SCHEMATIC WITH ANALOG PLC I/O .................................................................... 56

COMPONENT LIST FOR HO-7-VULCAIN & HO-4-VULCAIN ...................................................... 57

OIL BURNER HEAD COMPONENTS FOR HO-7 AND HO-4 VULCAIN ..................................... 63

BURNER HEAD SUB-ASSEMBLY MAINTENANCE ........................................................................ 64

FUEL VALVE LINKAGE ADJUSTMENT FOR HO-7-VULCAIN ..................................................... 66

FUEL VALVE LINKAGE ADJUSTMENT FOR HO-4-VULCAIN ..................................................... 67

DIMENSION SHEET FOR HO-7-VULCAIN W/ VERTICAL DISCHARGE .................................. 68

DIMENSION SHEET FOR HO-7-VULCAIN W/ HORIZONTAL DISCHARGE ........................... 69

INLET AND OUTLET HOLE PATTERN FOR HO-7-VULCAIN ..................................................... 70

Summary of Contents for Vulcain

Page 1: ...Vulcain Oil Fired Heaters...

Page 2: ...NSTALLATION STUB UPS FOR HO 7 VULCAIN AND HO 4 VULCAIN 47 EXTERNAL ELECTRICAL CONNECTIONS FOR VULCAIN HEATERS 51 ELECTRICAL CONNECTION OF OPTIONS FOR VULCAIN HEATERS 52 EXTERNAL WIRING DIAGRAM FOR FAN...

Page 3: ...RN FOR HO 4 VULCAIN 71 DIMENSION SHEET FOR HO 4 VULCAIN 72 DISCHARGE OPTIONS FOR HO 4 VULCAIN 73 ASSEMBLY DETAIL OF INLET SCREEN ASSEMBLY 74 OUTLET HOLE PATTERN FOR INLET SCREEN ASSEMBLY 75 ADJUSTMENT...

Page 4: ...her jobs Heater installation will then go smoothly with no delays waiting or looking for missing parts This manual gives general information on the location of thermocouples and optional moisture sens...

Page 5: ...esult in injury or even death Si usted no entiende llamar a Samuel Jackson en 806 795 5218 antes de proceder La falta de hacer tan pod a dar lugar alesi n o a n a muerte Electrical Most Samuel Jackson...

Page 6: ...ORATED 2018 ALL RIGHTS RESERVED Additional safety information is located throughout this manual and should be read carefully before operating this Samuel Jackson product If you have any questions abou...

Page 7: ...ressure sensed by orifices pointing upstream and downstream In order to give immediate burner shutoff and serve as a safety backup for the airflow switch we include a fan interlock device for each bur...

Page 8: ...ing through the sequence of a test program Touch Screen Temperature Control Earlier Samuel Jackson Heater models used Honeywell UDC 3300 s for temperature control On the model 1500 series Heaters the...

Page 9: ...OFF button If there is a problem detected by the Heater s control system it will notify you on the touch screen with a brief description that includes a diagnostic number This number will be helpful t...

Page 10: ...ower is removed before diagnostics are completed To prevent lightning damage to controls in the off season it is a good idea to turn power off to the control cabinet until it is needed again WHERE DO...

Page 11: ...ore the tower Due to the responsiveness of the temperature controls placing this thermocouple farther down in the tower will cause control instability For Heaters operating with Hot Boxes and module f...

Page 12: ...ture control based on incoming seed cotton moisture is active the after mixpoint temperature is adjusted automatically and the setpoint button will not be shown More details for operation with the opt...

Page 13: ...asier for both the user and Samuel Jackson service personnel This system remembers the last 500 ERRORS and ALARMS thus showing a history of past problems along with the time and date of each one WHAT...

Page 14: ...PAGE 14 of 79 VULCAIN OIL FIRED HEATER LAST UPDATED JAN 22 2019 COPYRIGHT SAMUEL JACKSON INCORPORATED 2018 ALL RIGHTS RESERVED Navigating Important Menus MAGNIFYING GLASS HEATER STATUS...

Page 15: ...VULCAIN OIL FIRED HEATER LAST UPDATED JAN 22 2019 COPYRIGHT SAMUEL JACKSON INCORPORATED 2018 ALL RIGHTS RESERVED WRENCH HEATER SETUP Under heater setup press the button to proceed to the correspondin...

Page 17: ...s are automatically and quickly raised often resulting in no loss of production When dry cotton enters the system the temperatures are automatically reduced saving fuel and possible fiber damage INSUL...

Page 18: ...oller and Super Grid Refer to the Moisture Mirror X manual for more information on features connections and compatible moisture sensors Displayed on the Moisture Mirror X are the START STOP operations...

Page 19: ...neath the temperatures to navigate to a numerical keypad When you have typed in the desired temperature press ENT and then press Set Now underneath the number you just entered When Heater Banks are ac...

Page 20: ...showing a history of past problems To access the log press the magnifying glass on the color touch panel s Home Screen which brings up the STATUS screen Then press VIEW ERROR LOG button Navigate throu...

Page 21: ...d at a time The oldest unacknowledged ALARM condition is shown even if the Heater shuts down due to an ERROR Pressing the OK button will show consecutive ALARM conditions leading up to the shutdown ER...

Page 22: ...the pressure is above the current oil high pressure limit The default high limit is 80 PSI but can be changed in the settings menu Check to see if the Fuel Pressure Relief Valve FPR is jammed shut or...

Page 23: ...INTERLOCK ARE ALL FANS ON This error is caused when an attempt is made to start or operate the burner when no fan interlock signal is present A fan interlock relay is supplied with the unit to provide...

Page 24: ...hows air getting cooler after flame is established indicating reversed thermocouple wiring If this problem persists try the following In the junction head of the red Thermocouple check that RED wire i...

Page 25: ...R BURNOUT The integrity of the thermocouple wiring and thermocouple is checked during the pre ignition checks each time the Heater is started This error occurs when the after mix point thermocouple co...

Page 26: ...put card 2 for the PLC has a jumper in place that needs to be removed Consult the factory for help ERROR 403 REMOVE JUMPER FROM ANALOG CARD 3 The analog input card 3 for the PLC has a jumper in place...

Page 27: ...ansducer First check that all wires are firmly attached in the circuit that there is no broken wire and that fuse 2 4 is not blown ERROR 412 ANALOG INPUT 3 1 ATOMIZING AIR PRESSURE FAILED The analog i...

Page 28: ...The modulating valve on the burner head failed to close in a timely fashion Check that the modulating motor is functioning and that the low fire sensor LFS is operating and adjusted correctly ERROR 4...

Page 29: ...aged or bypassed ERROR 458 COMBUSTION AIR ON TOO LONG This error occurs when the combustion air fan has been on for greater than 20 seconds during the ignition process and may impede the attempt to ig...

Page 30: ...EATERS included in this manual and on the inside door of the cabinet show the input output numbers for the PLC Input lights for X0 through X23 are shown on the PLC Input lights for X100 through X107 a...

Page 31: ...breaker CB off Check that power to terminals 1 and 2 on the electrical panel is between 110 and 125 VAC Check that the thermocouples are connected and hooked to the correct terminals on the electrical...

Page 32: ...osen the adjustment screw to lower the oil pressure It should be noted that the atomizing air pressure should be set at 50 psi for HO 1 and 120 psi for HO 4 and HO 7 The TEST PROGRAM offers a methodic...

Page 33: ...lling a normally closed operator switch Now methodically press each button on the TEST PROGRAM screen to check and make adjustments before attempting to light the unit An alternative method that autom...

Page 34: ...has been adjusted at the factory for correct travel TCV is shown in closed position below It travels 90 degrees for fully open while FVM linkage arm travels 160 degrees Turns 120VAC power on off to F...

Page 35: ...pump oil valve and fuel valve motor FVM are checked here Each component may be tested as follows Atomizing Air Valve Open the Atomizing Air Valve Check that the atomizing air pressure reading is displ...

Page 36: ...Operation of the ignition transformer and spark plug is checked here Electrical interference between the spark plug and flame sensor is also checked The fan must be running at least 20 seconds before...

Page 37: ...mp and combustion air fan are checked here as well as the rotation of the main fan for HO 1 If the rotation is wrong disconnect 3 phase power to the Heater Unit following OSHA lockout tag out procedur...

Page 38: ...r HO 1 and 120 psi for HO 4 and HO 7 Step 8 This screen allows to purge the oil line with the oil pump on and the oil valve opened The fuel pressure is displayed on the top of the screen The oil press...

Page 39: ...ditional adjustments are made from the SETUP screen Access the SETUP screen by pressing the on the color touch panel s home screen then enter the password The SET FACTORY DEFAULTS button returns all c...

Page 40: ...actory before making any changes to the control settings on these screens Pressing the ANALOG SOURCES button brings up the following screen Now press the AFTER MIX TEMPERATURE button Normally the LOCA...

Page 41: ...ttons are used when multiple stages of Heaters are connected and the user wants the temperatures to be different between the stages For example more heat for collision air and less heat for the Hot Bo...

Page 42: ...ime the Heater will automatically shut down and ERROR 131 will be shown COMBUSTION LIMITS The low and high limits involved in the combustion process are set on this page Fuel Low Limit is the minimum...

Page 43: ...ory before adjusting these values TEMP LIMITS UNITS The set point temperature ranges for modulating before and after mix point temperatures are set in this screen The high limit kill point is also set...

Page 44: ...e sure the Thermocouple or other analog transmitter device is wired correctly using the correct hookup wire Type J thermocouple wire cannot be used to connect the 4 20mA transmitter type thermocouples...

Page 45: ...ocouple wire for hookup Never run the shielded sensor wires with the power wiring including 120 VAC control wires You can run several shielded 4 20mA shielded wires together in the same conduit with o...

Page 46: ...he pipe supplying the fuel oil to the gate valve connection as indicated on the side of the control cabinet Make sure that the pipe supplying the unit is free of debris and after running the unit for...

Page 47: ...BINET 2 FAN INTERLOCK SIGNAL FROM GIN CONSOLE OR MOTOR CONTROL CENTER TO BURNER CABINET ONE CONDUIT WITH TWO 16 GA WIRES FOR INTERLOCK SIGNAL 120 VAC 240 VAC OR 24 VDC 3 THERMOCOUPLES FROM BURNER CABI...

Page 48: ...5 COMPRESSED AIR SUPPLY FOR HEATER 3 8 PIPE HO 7 12 SCFM 100 PSI 6 9 BAR HO 4 6 SCFM 100 PSI 6 9 BAR 6 CONNECTION TO MIRROR X OPTIONAL FROM BURNER CABINET TO MIRROR X STEEL CONDUIT WITH ONE CAT5B ETHE...

Page 57: ...COUPLE 20514B KTN F6 F3B108 3 AIR PRESSURE GAUGE 20266 0 100 PSI AIR PRESSURE REGULATOR 13594A R07 200 RNKA UPPER CABINET UPPER CABINET UPPER CABINET UPPER CABINET CAF COMPRESSED AIR FILTER 13593A F07...

Page 58: ...ABINET FPG FUEL PRESSURE GAUGE 12313 0 160 PSI LOWER CABINET FPOL FPR FPT FS FUEL PUMP OVERLOAD 14737A LR2D1305 FUEL PRESSURE RELIEF VALVE 12385 VJ 2W WS FUEL PRESSURE TRANSDUCER 23732 628 10 GH P1 E1...

Page 59: ...ER LOWER CABINET OPMC OIL PUMP MOTOR CONTACTOR 14854A LC1D0910G6 UPPER CABINET PLC PROGRAMMABLE LOGIC CONTROL 21562 DL06 PLC UPPER CABINET PS POWER SUPPLY 120VAC TO 24VDC 21553 PS5R SD24 UPPER CABINET...

Page 60: ...of 79 VULCAIN OIL FIRED HEATER LAST UPDATED JAN 22 2019 COPYRIGHT SAMUEL JACKSON INCORPORATED 2018 ALL RIGHTS RESERVED FLR PLC N S CB PS AIHT AF T CAFMC OPMC CAFOL FPOL AAP AA V CA T CA F AP G FUS E...

Page 69: ...PAGE 69 of 79 VULCAIN OIL FIRED HEATER LAST UPDATED JAN 22 2019 COPYRIGHT SAMUEL JACKSON INCORPORATED 2018 ALL RIGHTS RESERVED Dimension Sheet for HO 7 Vulcain w Horizontal Discharge...

Page 78: ...ifications to meet the particular requirements Implementation of alternative safety devices may incur additional charges No warranty of compliance with a particular standard is made in the absence of...

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