Operation & Maintenance Manual · 2019. 11. 25. · CEI Enterprises, Inc. | 245 Woodward Rd SE |...

CEI Enterprises, Inc. | 245 Woodward Rd SE | Albuquerque, NM 87102 | 800.545.4034 | ceienterprises.com

Ecoheat Direct-Contact Water Heater

Operation & Maintenance Manual

WARNING!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.

CEI Service & Parts: 800.545.4034

For worldwide parts & service support, call CEI Enterprises: 800.545.4034

For Service & Parts Support

Service

Parts

Training

CEI maintains a fully-staffed service department, with factory-trained service technicians based across the United States for the fastest possible response to your service needs. For service work, including installation, startup, preventive maintenance and retrofits, contact the CEI Service Dept at 800.545.4034.

CEI Enterprises has one of the largest spare parts warehouses in the asphalt industry, stocked with parts for not only CEI products, but parts for competitors products as well. Moreover, our parts representatives have a more comprehensive knowledge of the parts and components used on your CEI equipment than anyone... anywhere. Based near interstates I-40 and I-25, as well as the nearby Albuquerque International Airport, we are convenientlylocated to rapidly ship parts nationwide and internationally. For your parts needs, contactthe CEI Parts Dept at 800.545.4034.

CEI offers annual service training at our facility in Albuquerque, New Mexico. Hands-on instruction is provided by our factory-trained service technicians, merely steps away from where your CEI equipment was designed and built. Sessions are typically held in January and February, during the winter off season. Our Service Training Seminars provide the highest quality training available on maintaining your CEI equipment in top working order. For owners and operators of asphalt plants large and small, this is an invaluable investment in the knowledge & experience of your crew. For more information, please visit our website at ceienterprises.com.

CEI Service & Parts: 800.545.4034

Table of Contents

Section 1: Introduction Safety ..................................................................................... 1 Main Components ............................................................. 4 Installation ............................................................................ 4 Startup ................................................................................... 4

Section 2: Operation UT150 Burner Modulation Controller ........................ 7

Section 3: MaintenanceMaintenance ....................................................................... 10

Gas Train Components .................................................... 10 Burner Back Plate Sight Glass .......................................... 10 Thermometer (any) ......................................................... 10 Burner Blower Motor ....................................................... 11 Burner Air Flow Switch .................................................... 12 Burner Gas Ignition Transfer ............................................ 14 Gas Pilot Assembly ......................................................... 16 Ignition Electrode ............................................................ 17 Ignition Cable .................................................................. 18 UV Scanner ..................................................................... 18 UT150 Burner Modulation Controller ............................... 20 Modulating Motor ............................................................. 23

Troubleshooting ............................................................... 29 Abnormal Shutdowns ..................................................... 29 Air Damper, Gas Linkage ................................................. 29 Gas/Air Mixture Adjustments ........................................... 30

Contact Information ............................................................... 33

i

Safety

Warning!

Important Precautions

If You Smell Gas

Safety Symbols (some symbols shown may not be used in this manual)

Safety is of prime concern whenever using an electrically operated, fuel driven high temperature device. Please use proper safety precautions and follow all company, local, state and federal regulations for operating potentially dangerous equipment. Lock-out/tag-out equipment before performing maintenance.

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. For assistance or additional information consult CEI, a qualified installer, gas supplier or a service agency.

This manual gives basic instructions which must be observed during installation, operation and maintenance of your CEI tank. It is imperative that this manual be read by the responsible personnel/operator(s) prior to assembly and commissioning of any heat transfer fluid system. It must always be kept available at the site of tank installation. It is not only the general safety instructions in this Safety section which must be observed, but also the specific information provided in the following sections and other applicable manuals.

1. Never attempt to light burner with paper or other materials.2. Never experiment with the burner.3. Never change the fuel or air adjustments without consulting with CEI or a qualified

burner technician.4. Never attempt to light the burner if combustion chamber contains any unburned fuel

or gases.5. Never throw waste paper, rags, garbage, or other waste materials into the combustion

chamber.6. Never wash out heating equipment room without first covering the burner with

waterproof material.

1. Open windows.2. Do not touch electrical switches.3. Extinguish any open flame.4. Call your gas supplier immediately.

Section 1: Introduction

Safety

Caution, Potential for Explosion

Caution, Potential for Electrocution

Caution, Confined Space

Caution, Moving Parts

Caution, Moving Belt(s)

Caution, High Pressure

Caution and/or Important Information

Potential Environmental Hazard

Caution, Potential for Spray

Caution, Potential for Fire

Caution, Potential for Burn(s)

Caution, Hot Surface(s)

Lock-Out / Tag-Out

1


Safety

This Product May Contain A Chemical Known To The State Of California To Cause Cancer, Or Birth Defects Or Other Reproductive Harm.

WARNING!

This Product Can Expose You To Chemicals Including Diesel Engine Exhaust, Which Is Known To The State Of California To Cause Cancer.

WARNING!

2

Basic Safety Instructions• Lockout power to the equipment before working on it.• All drive guards and hand rails must be in place.• Check that the plant components are in good working condition prior to plant

start up.• Never remove, disable, defeat or bypass any safety device on the plant.• Make no modifications to your plant without recommendation or approval of a

representative of CEI Engineering or Service department.• Account for all personnel on the job site before starting the plant.• Avoid wearing loose clothing, necklaces, neckties or anything that could become

entangled in rotating machinery.• Avoid or tie up long hair.• Never leave the controls unattended while the plant is in operation.• Never walk on the material stockpiles or in the cold feed bins, to avoid engulfment by

loose feed stock.• Relieve internal pressure before disconnecting any high-pressure line. Thoroughly

tighten all fittings before reapplying pressure.• Keep away from power driven parts, even if they are not moving, unless they are

locked out.• Use extreme caution if you must approach running equipment.

• A written confined space plan, including recognizing and marking all confined spaceson site;

• Procedures to test and monitor the air inside confined spaces before and during allemployee entries;

• Procedures to prevent unauthorized entries and to have an attendant outside the spaceat all times;

• Effective controls of all existing atmospheric or safety hazards inside the confinedspace;

• Employee and supervisor training on safe work procedures, hazard controls, and rescueprocedures; and

• Effective rescue procedures which are immediately available on site.


Safety

Employees should never enter a tank until all the safety precautions are in place and they have been authorized to enter. Emergency procedures must be in place and ready before any employee enters a confined space.In many jurisdictions, confined space regulations require all employers to have:

3

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

Installation

Inspection

Position

CEI takes great care in the construction and shipping of each HHW-40 Heater so that it will arrive ready for installation and operation. However sometimes the unforeseen 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 occurred or a part (or parts) is missing, please contact your CEI representative before con-tinuing with installation.

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 safely dissipate.

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.


Main Components & Installation

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.

Main Components

4

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

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

Connect Natural Gas1. Verify that there is a sufficient supply of Natural Gas for the HHW-40 Heater

before 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


Installation

5

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


Installation & Startup

6

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

Section 2: Operation

UT150 Burner Modulation Controller

7

7. When finished entering the Setup Parameters:

Operating ParametersNote: 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



8

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




9

Gas Train ComponentsBecause 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 GlassLet 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

Section 3: Maintenance

Maintenance

10

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 MotorCAUTION! - 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 betweenthe fan and the fuel oil pump (when equipped).

Flange Nuts (6 total)

Blower Motor

Electrical Connection Access


Maintenance

11

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 SwitchCAUTION! - 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.


Maintenance

12

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.

Burner Air Flow Switch

Air line nuts

PowerFlame Terminal Box


Maintenance

13

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

Adjusting Screw(under rubber cap)


Maintenance

14

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

Burner Gas Ignition Transformer


Maintenance

15

Gas Pilot AssemblyCAUTION! - 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


Maintenance

16

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 Electrode1. 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


Maintenance

17

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 Cable1. Unplug the cable from the back of the electrode and pull out through the

strain relief.

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

UV ScannerCAUTION! - 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


Maintenance

18

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


Maintenance

19

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 groundconnection 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


Maintenance

20

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



Maintenance

21

7. When finished entering the Setup Parameters:

Operating ParametersNote: 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


Maintenance

22

5. When finished entering the Operating Parameters:

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

Modulating MotorLet 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



Maintenance

23

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


Maintenance

24

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.

Workbench1. 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.

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


Maintenance

25

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


Maintenance

26

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 Heater1. Note the removed motor’s resistor board switch settings and wire connections:

• When installing a new resistor board, set its DIP switches to match thoseof 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


Maintenance

27

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


Maintenance

28

Abnormal ShutdownsIf 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 newsettings.

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


Troubleshooting

29

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 AdjustmentsCAUTION! 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 Instructions1. 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.


Troubleshooting

30

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.


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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.


Troubleshooting

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Contact Information

Office & Manufacturing Facility

CEI Service Department (General Contact)

Departmental Contacts

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

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

Shanon Heath Service Manager Cell: (505) 908-8794

Sam D. Morgan Engineering Director Cell: (505) 400-8958

Johnny Romero Parts Representative Cell: (505) 235-2789

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CEI ENTERPRISES, INC.245 Woodward Road, SE

Albuquerque, New Mexico, U.S.A. 87102

800.545.4034www.ceienterprises.com

© 2019 CEI Enterprises, Inc Publication # 19-11-064

Ecoheat™ Direct-Contact Water Heater

Operation & Maintenance Manual · 2019. 11. 25. · CEI Enterprises, Inc. | 245 Woodward Rd SE |...

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Transcript of Operation & Maintenance Manual · 2019. 11. 25. · CEI Enterprises, Inc. | 245 Woodward Rd SE |...