HEATEC TEC-NOTE

Publication No. 6-04-135

CONTROLS
HC AND HCS SERIES HELICAL COIL HEATERS
Scope the control panel include circuit breakers, auxiliary contacts,
and relays. (See Figs. 3, 4 and 5.) Each of these items is
This document describes functions of controls on heaters discussed below. The words set in capital letters match the
with conventional control panels. It applies to both HC labels on the panel.
heaters (Fig. 1) and HCS heaters. (Note: conventional control
panels have status lights as shown in Fig. 2.) EMERGENCY STOP control (Fig. 2)
Push in this control to immediately shut down the heater. Use
it only in an emergency. The control incorporates a light that
comes on when the control is pushed in. Unlike using the
HEATER CONTROL switch to shut down, the emergency stop
control removes electrical power from all other controls and
shuts down the heater without a post purge.
POWER ON indicator light (Fig. 2)
This indicator light denotes the status of power to the control
panel. The light is on when 120 Vac, single phase, 60 hertz
power from the Heatec control transformer is connected to
the terminal bus within the panel. When there is no power
connected to the terminal bus the light is off. The light
usually has a white lens.
HEAT DEMAND indicator light (Fig. 2)
An indicator light that indicates the status of the burner
control relay during normal operation. When the light is
on the relay contacts are closed, which means that the
relay is energized. When the light is off the relay contacts
are open, which means that its coil is not energized. The
Figure 1. Heatec HCS heater with conventional control panel.
coil is controlled by the Honeywell UDC3300 modulating
controller and the HEATER CONTROL switch. The light has
General a blue lens. The light is on when the controller is calling for
Key operator controls and status lights are on the main heat. It is off when the controller is not calling for heat.
control panel (Fig. 2.). Controls on the front of these panels
LOW MEDIA LEVEL indicator light (Fig. 2)
allow the operator to start and run the heater.
An indicator light that denotes the level of thermal fluid in
A variety of other controls related to safe operation are the expansion tank during normal operation. It is electrically
located at various places on the heater. These devices will connected to the low media level relay, which is controlled
shut down the heater when certain undesirable conditions are by a float switch mounted in the expansion tank (Fig. 8).
present. These devices control an electrical circuit known as
When the light is on, the level of fluid in the expansion tank
a limit circuit. The limit circuit is the key to troubleshooting.
is within normal operating range and the level switch and
relay contacts are closed. When the light is out, the level of
CONTROL PANEL fluid in the expansion tank is abnormally low and the switch
Controls on the outside of the control panel (Fig. 2) consist and relay contacts are open.
of status lights, switches, flame monitor, two controllers, an
alarm horn and operating handle. Controls located inside The float switch in the tank is also part of the limit circuit
and will shut down the heater when opened. Moreover, when
 HIGH MEDIA MODULATING
TEMP. CONTROLLER CONTROLLER

Honeywell Honeywell

AUTO 40 ALM PV ALM

F 345 A %
F
345
OUT DI
FLAME SIGNAL RSP

SCRL RESET MODE

OUT SP 350
FUNCTION LOWER MANUAL SETPOINT
FUNCTION DISPLAY RESET SET UP DISPLAY
LOOP 1/2 AUTO SELECT

ALARM AUTO
TUNE
RUN
HOLD
SET UP
RUN
HOLD OFF

HORN
FLAME-MONITOR

RESET
OPEN

MANUAL
RESET

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POWER ON LIMITS MADE
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HEAT DEMAND GAS OIL
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LOW MEDIA ������������� HEATER ALARM

GAS VALVE ON
LEVEL ����������� OFF ON

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OIL VALVE ON
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Panel varies according to the number of thermal fluid circuits and options

Figure 2. Typical control panel for HC heater.

Page 2
it opens it also disables the circulating pump circuit. The opened. The contacts automatically close when power is
switch automatically closes when the fluid level in the tank is restored to the motor.
restored to normal.
Note: only heaters with an external fuel pump have auxiliary
LOW FUEL PILOT PRESS. indicator light (Fig. 2) contacts for the fuel pump. But the panel may still have an
An indicator light that denotes the status of the low fuel pilot indicator light for the contacts. In that case the contacts are
gas pressure switch. When the light is on the fuel pilot gas replaced by a jumper wire. Thus, the light will react the same
pressure is normal and the switch is closed. When the light as auxiliary contacts that are closed.
is out the fuel pilot gas pressure is too low and the switch
LOW FUEL OIL PRESS. indicator light (Fig. 2)
is open. This switch is part of the limit circuit and will shut
An indicator light that denotes the status of the low fuel
down the burner when open. The switch has a manual reset
oil pressure switch when the FUEL SELECTOR switch is set
button.
to OIL. When the light is on the fuel oil pressure is normal
Note: Not all heaters have a low fuel pilot pressure switch. and the switch is closed. When the light is out the fuel oil
But the panel may still have an indicator light for the switch. pressure is too low and the switch is open. This switch is part
In that case the switch is replaced by a jumper wire. Thus, of the limit circuit and will shut down the burner when open.
the light will react the same as it would with a switch in its
Note: Only heaters with an external fuel pump have a low
normal pressure state.
fuel oil pressure switch. But the panel may still have an
HIGH FUEL GAS PRESS. indicator light (Fig. 2) indicator light for the switch. In that case the switch is
An indicator light that denotes the status of the high fuel gas replaced by a jumper wire. Thus, the light will react the same
pressure switch (Fig. 9) when the FUEL SELECTOR switch as it would with a switch in its normal pressure state.
is set to GAS. When the light is on the fuel gas pressure is
HIGH MEDIA TEMP. indicator light (Fig. 2)
normal and the switch is closed. When the light is out the
An indicator light that denotes temperature status of the
fuel gas pressure is too high and the switch is open. This
thermal fluid. It is electrically connected to contacts of the
switch is part of the limit circuit and will shut down the
high media temperature relay (Fig. 5), which is controlled by
burner when open. The switch has a manual reset button.
the high media temperature controller UDC2300.
Note: Not all heaters have a high fuel gas pressure switch.
When the light is on, temperature of the thermal fluid is
But the panel may still have an indicator light for the switch.
within normal operating range. When the light is out, the
In that case the switch is replaced by a jumper wire. Thus,
temperature of the fluid has exceeded the preset limit of the
the light will react the same as it would with a switch in its
controller. The relay contacts are also part of the limit circuit,
normal pressure state.
which shuts down the burner when the contacts are opened.
LOW FUEL GAS PRESS. indicator light (Fig. 2) The controller must be reset after the thermal fluid has
An indicator light that denotes the status of the low fuel gas cooled down to within the operating range.
pressure switch (Fig. 10) when the FUEL SELECTOR switch
HIGH FLUE GAS STACK TEMP. indicator light (Fig. 2)
is set to GAS. When the light is on the fuel gas pressure is
An indicator light that denotes temperature status of gas
normal and the switch is closed. When the light is out the
in the exhaust stack. It is electrically connected to the high
fuel gas pressure is too low and the switch is open. This
flue gas stack temperature switch ( Fig. 11) mounted in the
switch is part of the limit circuit and will shut down the
exhaust stack. The manufacturer of this switch calls it a
burner when open. The switch has a manual reset button.
differential expansion temperature control.
Note: Not all heaters have a low fuel gas pressure switch.
When the light is on, temperature of the gas is within normal
But the panel may still have an indicator light for the switch.
operating range and the switch contacts are closed. When the
In that case the switch is replaced by a jumper wire. Thus,
light is out, gas temperature has exceeded its factory setting
the light will react the same as it would with a switch in its
of 1000 degrees F and the contacts are open.
normal pressure state.
The switch is also part of the limit circuit and will shut
HEATER FUEL OIL PUMP AUX. CONTACTS indicator light
down the heater when the switch is opened. The switch must
(Fig. 2)
be manually reset, which requires removing its cover and
An indicator light that denotes the status of a set of auxiliary
pressing a reset button.
contacts on the motor controller that connects electrical
power to the motor of the fuel pump. When the indicator CIRC. PUMP AUX. CONTACTS indicator light (Fig. 2)
light is on electrical power is connected to the pump motor. An indicator light that denotes the status of a set of auxiliary
When the light is off the contacts are open because electrical contacts (Fig. 4) on the motor controller that connects
power is not connected to the motor. The contacts are also electrical power to the motor of the fluid circulating pump.
part of the limit circuit and will shut down the heater when

Page 3
When the indicator light is on electrical power is connected An open switch disconnects current flowing to solenoids of
to the pump motor. When the light is off the contacts are the fuel control valves. This closes the fuel valves, shutting
open because electrical power is not connected to the motor. off fuel to the burner. Consequently, the flame monitor will
The contacts are also part of the limit circuit and will shut display the message: FLAME FAILURE 3 TO P INTERLOCK
down the heater when opened. The contacts automatically OPEN. The flame monitor must be manually reset after the
close when power is restored to the motor. abnormal condition has been cleared.
LOW MEDIA DIFF. PRESS. indicator light (Fig. 2) A separate indicator light is also provided for each switch in
An indicator light that denotes pressure/flow status of the limit circuit, except for the low combustion air switch,
thermal fluid in the helical coil. It is controlled by a normally which is the last switch in the series. The indicator lights
open switch (Fig. 12) that detects abnormally low differential identify the status of each individual limit switch. All
pressure of thermal fluid across the helical coil. If the indicator lights in the limit circuit have clear lenses, except
indicator light is off the switch senses that the differential for the LIMITS MADE light, which has a green lens.
pressure at the outlet is too low and remains open. When
As already noted, there is no indicator light labeled LOW
the light is on there is enough differential pressure to close
COMBUSTION AIR. However, if the low combustion air
the switch. See Pressure switch herein for additional
switch opens due to low combustion air, the green LIMITS
information.
MADE light will go out, but none of the clear lights will go
Inadequate pressure/flow of thermal fluid is probably the out. Thus, the limits made light in effect functions as a low
most common cause of heater malfunctions. A clogged combustion air light in addition to a limits made light.
strainer is the most common cause of inadequate flow of
PILOT GAS VALVE ON indicator light (Fig. 2)
thermal fluid.
This indicator light denotes the status of two ignition circuits:
HIGH MEDIA DIFF. PRESS. indicator light (Fig. 2) ignition spark transformer and pilot gas solenoid valve (Fig.
An indicator light that denotes pressure/flow status of 13). The light has an amber lens. When the light is on, power
thermal fluid in the helical coil. It is controlled by a is connected to the ignition spark voltage transformer and to
normally closed switch (Fig. 12) that detects abnormally the pilot gas solenoid valve. As a result the pilot valve opens
high differential pressure of thermal fluid across the helical and high voltage is generated in the secondary winding of
coil. When the indicator light is off the switch senses that the spark ignition transformer. The high voltage produces a
the differential pressure at the inlet is too high and opens. spark across the gaps in the points of the igniter to ignite the
When the light is on the differential pressure is low enough pilot gas. When the light is off, power is not connected to the
to close the switch. See Pressure switch herein for additional transformer or solenoid valve. Hence, there is no spark and
information. the pilot gas solenoid is de-energized. Power to the circuit
is controlled by the Fireye flame monitor. This light was
COMB. AIR AUX. CONTACTS indicator light (Fig. 2)
previously labeled IGNITION ON.
An indicator light that denotes the status of a set of auxiliary
contacts (Fig. 4) on the motor controller that connects GAS VALVE ON indicator light (Fig. 2)
electrical power to the burner fan motor. When the indicator This indicator light denotes the status of the main gas shutoff
light is on electrical power is connected to the fan motor. valve, which is an actuator-operated valve. When the light
When the light is off the contacts are open because electrical is on, the valve is open. When the light is off, the valve is
power is not connected to the motor. closed. This light has an amber lens.
The contacts are also part of the limit circuit and will shut OIL VALVE ON indicator light (Fig. 2)
down the heater when opened. The contacts automatically This indicator light denotes the status of the main oil valve
close when power is restored to the motor. and the auxiliary oil valve. Both are solenoid-operated
valves. When the light is on, the valves are open. When the
LIMITS MADE indicator light (Fig. 2)
light is off, the valves are closed. This light has an amber
An indicator light that denotes the status of the limit circuit,
lens.
which has several switches connected in series with each
other. This circuit is also connected to the Fireye flame HEATER ALARM indicator light (Fig. 2)
monitor so that its current flows through the limit circuit of This indicator light denotes the status of the heater alarm
the Flame monitor and to solenoids of the fuel control valves. system. When the indicator light is on the heater is in an
alarm state. The light has a red lens. The alarm is controlled
When this light is on all of the switches in the limit circuit
by the flame monitor, which turns on the alarm when it
are closed and operating conditions are normal.
detects a variety of abnormal conditions. The monitor
When this light is off one or more of the switches in the limit displays one of several messages to report the condition that
circuit is open because of an abnormal operating condition. caused the alarm.

Page 4
BLOWER ON indicator light (Fig. 2) MANUAL RESET switch (Fig. 2)
This indicator light denotes the status of the combustion air A switch for resetting the flame monitor is on the outside
blower. When the indicator light is on electrical power is of the control panel. It duplicates the function of the switch
connected to the blower motor controller. When the light is actually on the flame monitor, which is mounted inside the
off, no power is connected to the controller. The light has a control panel. The external switch eliminates the need to
blue lens. Power to the controller is controlled by the flame open the control panel to reset the monitor.
monitor.
FIREYE FLAME MONITOR (Fig. 2)
CIRC. PUMP OFF-ON switch (Fig. 2) The flame monitor normally used is a Fireye Flame
This is a manually controlled switch for applying/removing Monitor E110 with Programmer Module EP160. It is a
power to/from the circulating pump motor. This switch must microprocessor based burner management control system.
be on for the heater to operate. The switch is in series with The unit provides the proper burner sequencing, ignition
the low media level relay and the motor controller breaker and flame monitoring protection. In conjunction with limit
auxiliary switch, both of which must be closed for power to and operating controls it sequences the burner/blower motor,
reach the motor. ignition and fuel valves to provide for proper and safe burner
operation.
HEATER CONTROL OFF-ON switch (Fig. 2)
This is a manually controlled switch for turning the heater on The unit will deenergize all fuel valve circuits within four
and off. It must be on for the heater to operate. seconds (maximum) following a flame failure or at the end of
the pilot trial for ignition period if no flame is detected. An
GAS-OIL switch (Fig. 2)
alarm circuit will be energized following a safety lockout.
This is a manually controlled switch for selecting either
gas or oil as a fuel source to operate the heater. Setting the The flame monitor must be manually reset after the abnormal
switch to OIL allows the flame monitor to energize and open condition has been cleared.
the two solenoid valves (main and auxiliary) in the fuel oil
The unit incorporates a display panel that shows up to 42
supply line. This setting prevents the main gas valve from
different messages related to the safe operation state of the
energizing.
heater. A logic flow diagram of the unit is shown in a Fig. 14.
Setting the switch to GAS allows the flame monitor to
MODULATING CONTROLLER (Fig. 2)
energize and open the automatic gas valve. This setting
The modulating controller normally used is a Honeywell
prevents the two fuel oil shutoff valves from energizing.
UDC3300. It provides three functions:
HEATER ALARM OFF-ON switch (Fig. 2)
• Burner modulation control
This switch is provided in the horn circuit so that the horn
• Burner low-fire hold control
can be switched off until the problem that set off the alarm
• Burner on/off control
can be cleared. It should be turned back on after the problem
is cleared. Burner modulation control. This function of the controller
controls heating of the thermal fluid to maintain a
AUX. PUMP OFF-ON switch (Fig. 2)
temperature setting (known as set point or SP) that has been
This is a manually controlled switch for applying/removing
preset by the operator. It senses fluid temperature (known as
power to/from an auxiliary pump motor. This switch must
a process variable or PV) from a thermocouple. It processes
be on to pump thermal fluid through the piping circuit
the output voltage of the thermocouple and sends control
connected to the pump. The switch is in series with the motor
signals to Honeywell modulating actuator M9174C1025
controller breaker auxiliary switch, which must be closed for
(Fig. 7), which either increases or decreases the firing rate
power to reach the motor.
as required to maintain fluid temperature at set point. The
Note: there may be more than one of these switches on the difference between set point and PV is known as error or
control panel, depending upon the number of independent deviation (DEV).
thermal fluid circuits used. When there is more than
The controller maintains the temperature within one or two
one, the switches are marked #1, #2, #3, etc. to identify
degrees of set point when the heating system is in a steady
different independent circuits. Only heaters with manifolds
state or maintenance mode. However, when starting up a
have auxiliary pumps to circulate thermal fluid through
cold system the burner fires at its maximum rate until the
independent piping circuits, each with its own pump. These
temperature of the thermal fluid (PV) reaches the preset
circuits operate independently of the thermal fluid circuit
proportional band (PB) of the modulating controller. The
that circulates thermal fluid through the coil of the heater.
proportional band is the modulating range of the controller.
(The thermal fluid of heaters without manifolds is circulated
While thermal fluid temperatures are within the proportional
through all piping circuits by the same pump that circulates
band, the controller causes small incremental changes in
the fluid through the heater.)
the burner firing rate (in proportion to the error) allowing its
temperature to reach set point.

Page 5
The proportional band (for an asphalt plant) is usually The preset temperature limit (SP) should always be set to
from 7-1/2 degrees below set point to 7-1/2 degrees a value higher than the modulating range of the burner.
above set point. Thus, when the set point is 320 degrees Otherwise, normal modulation of the burner may cause the
F, the controller causes the burner to modulate or vary burner to shut off prematurely.
proportionally while thermal fluid temperatures vary from
The maximum limit for a single line heater is not the same as
312.5 to 327.5 degrees F. Thermal fluid temperatures above
the limit for a heater with a manifold. On single line heaters
327.5 cause the controller to go to zero output, which sets
set the maximum limit to at least 50 degrees F above setpoint
the burner to its low-fire position. Thermal fluid temperatures
of the modulating controller. On heaters with manifolds set
below 312.5 cause the controller to fire the burner at its
the limit to at least 80 degrees F above the setpoint of the
maximum rate.
modulating controller. Remember, the temperature settings in
Burner low-fire control. This function of the Modulating this example are typical and may need to be reset to different
Controller causes the burner to change from low-fire to values in the field for actual operating conditions.
high-fire when the temperature of the thermal fluid reaches
HEATER ALARM horn (Fig. 2)
a predetermined value. It is normally set manually at 200
This horn denotes the status of the heater alarm system.
degrees F. Thus, the burner will remain at low-fire until the
When the horn is sounding the heater is in an alarm state.
thermal fluid temperature reaches about 230 degrees F. At
A switch is provided in the horn circuit so that the horn
that point it goes to high fire and remains there until the
can be switched off. The alarm is controlled by the flame
temperature reaches the modulating range.
monitor, which turns on the alarm when it detects a variety
Burner on-off control. This function of the Modulating of abnormal conditions. The monitor displays one of several
Controller shuts off the burner completely by shutting off messages to report the condition that caused the alarm.
its main fuel valve. This happens if system heat demand
Door handle
decreases, allowing thermal fluid temperature to reach a limit
Use this handle (Fig. 2) to open the control panel. Do not
equal to the set point plus a predetermined value. This value
open the door unless you are a qualified technician familiar
is normally set manually at 20. It is known as a floating value
with the hazards of electricity.
since it creates the limit based on the set point. Thus, if its
value is 20 and the set point is 320 degrees F, the limit is 340 As a safety feature the handle shuts off electric power
degrees F (the sum of 320 plus 20). After the thermal fluid inside the control panel when the panel is opened. A keyed
cools down about 30 degrees the controller initiates a new rod from the main circuit breaker (Fig. 3) inside the panel
burner cycle. engages a slot on the back of the handle. The rod switches
the breaker on and off as the handle is rotated. The handle is
Please see separate Tec-Note on programming and re-tuning
marked to indicate its functions.
the Honeywell UDC3300 for additional explanation of how
the controller works.
HIGH MEDIA TEMP CONTROLLER (Fig. 2)
Note: the term media means thermal fluid. Thermal fluid is
commonly called hot oil.
The temperature controller normally used is a Honeywell
UDC2300. It limits maximum temperature of thermal fluid
to a set point (SP) value that the operator presets in the
controller. (Do not confuse the set point of this controller
with the set point of the Modulating Controller.)
The high media temperature controller senses fluid
temperature from a thermocouple (Fig. 6) in the outlet side
of the helical coil. If the temperature of the thermal fluid
exceeds preset limits (SP) the controller de-energizes the Figure 3. Main disconnect circuit breaker with keyed rod.
high media temperature relay, opening its contacts and
shutting off the burner. The controller must be manually reset Be aware that certain heater control panels have electrical
in order to restart the burner. The controller cannot be reset circuits that are not shut off by the rotary door-mounted
until the temperature of the thermal fluid has fallen below the handle. Panels that combine heater controls and plant
set point value.

Page 6
controls may include live circuits controlled by circuit the fluid circulating pump. The auxiliary contacts open a
breakers elsewhere in the plant. Consequently, shutting off limit circuit if the circuit breaker for the circulating pump
the main breaker inside the panel does not remove all power motor is tripped.
to components within the panel. The contacts are part of a limit circuit and shut down the
A screw on the left side of the handle allows you to open heater when opened. The heater cannot be restarted until the
the panel without shutting off the main circuit breaker. To flame monitor and the circulating pump circuit breaker is
do so, use a screwdriver to turn the screw about 1/4 turn manually reset. The auxiliary contacts automatically close
counter-clockwise and then pull the handle to open the door. when power is restored to the motor.
The purpose of this feature is to allow you to open the panel
High media temperature relay
without shutting down the heater. Use extra caution when
This relay is located inside the control panel. It is a relay
working inside the panel while the power is on. Always use a
(Fig. 5) that opens a limit circuit if temperature of the
voltage tester to make sure there is no voltage on terminals or
media (thermal fluid) exceeds the preset limit of high media
bare wires you may touch.
temperature controller (Fig. 2), which controls the relay.
Combustion air auxiliary contacts When the limit circuit opens, it shuts down the burner. The
The auxiliary contacts are located inside the control panel. controller must be reset after the thermal fluid has cooled
This is a set of auxiliary contacts on the motor starter (Fig. down to within the operating range.
4) that connects electrical power to the burner fan motor. The
auxiliary contacts open a limit circuit if the circuit breaker
for the burner fan motor is tripped. When the limit circuit
opens it shuts down the burner in a lockout state. The display
of the Fireye flame monitor (Fig. 2) will indicate LOCKOUT
3-P INTLK OPEN.

Figure 5. Relays: HMT1, BC 1, LML 1

OTHER CONTROLS
Thermocouples
Heaters without manifolds have one duplex thermocouple
installed near the outlet of the helical coil. The thermocouple
has two pairs of leads. One pair is connected to the
UDC3300 controller for temperature regulation. The other
is connected to the UDC2300 controller, which prevents
temperature of the thermal fluid from exceeding its limits.
On heaters with manifolds, (Fig. 6) two duplex
Figure 4. Auxiliary contacts for combustion air and circulating thermocouples are installed. Only one pair of leads from
pump motor controllers. each thermocouple is used, leaving a spare set of leads.
The burner cannot be restarted until the flame monitor and One of the two thermocouple is installed near the outlet of
the burner circuit breaker is manually reset. The auxiliary the helical coil and is connected to the UDC2300 controller
contacts automatically close when power is restored to the which prevents the temperature of the thermal fluid from
motor. exceeding its limits.
Circulating pump auxiliary contacts The other is installed in the manifold and is connected to the
The circulating pump has a set of auxiliary contacts located UDC3300 controller for temperature regulation. Note: fluid
inside the control panel (Fig. 4). The contacts are on the temperature at the thermocouple in the manifold could be as
motor starter that connects electrical power to the motor of

Page 7
much as 50 degrees (or more) lower than its temperature at Low media level switch
the thermocouple in the outlet. This is a float switch mounted in the expansion tank (Fig.
8). It opens a limit circuit if media (thermal fluid) in the tank
falls below a certain level. Moreover, when the circuit opens
it also disables the circulating pump circuit. The switch
automatically closes when fluid level in the tank is restored
to normal. The switch is connected to the low media level
relay.

Figure 6. Thermocouples in manifold and outlet of HC heater.

Modulating actuator
The modulating actuator normally used is a Honeywell
M9174C1025 (Fig. 7). It controls the firing rate of the
burner in response to signals it receives from the modulating
controller. It controls the firing rate by moving mechanical Figure 8. Low medial level switch.
linkage connected to the gas butterfly metering valve, the
fuel oil metering valve and the air damper to either increase High fuel gas pressure switch
or decrease the firing rate. If linkage becomes loosened from This is a pressure switch (Fig. 9) that opens a limit circuit if
operation it will lose its adjustment and the burner will not gas pressure is too high when operating on gas. When the
operate properly. This is a common problem. limit circuit opens it shuts down the burner. The switch has a
manual reset button.
The actuator has two cams that are activated when the heater
is started up by the Fireye flame monitor. When startup is
initiated the actuator goes to high fire purge, causing one
cam to close a switch inside the actuator thereby confirming
that the system is in high fire purge. Then, after a preset time,
the actuator automatically goes to low fire purge and the
other cam closes another switch inside the actuator thereby
confirming that purge is complete and that the system is
ready to light in low fire.

Figure 9. High fuel gas pressure switch.

Figure 7. Modulating actuator.

Page 8
Low fuel gas pressure switch reset for this switch. It automatically resets when adequate
This is a pressure switch (Fig. 10) that opens a limit circuit pressure/flow is restored.
if gas pressure is too low when operating on gas. When the
HCS heaters have a time delay relay in the pressure switch
limit circuit opens it shuts down the burner. The switch has a
circuit to prevent unintended shutdown of the heater when
manual reset button.
flow is briefly interrupted when temperature control valves in
the system open and close.
Note: Excessive buildup of trash in the strainer will reduce
flow of thermal fluid through the helical coil and may cause
the pressure switch to shutdown the burner.
A separate Tec-Note provides information on setting
Barksdale pressure switches. Another Tec-Note covers
pressure switches used prior to the Barksdale switch.

Figure 10. Low fuel gas pressure switch.

High flue gas stack temperature switch

This is a temperature sensing switch (Fig. 11) that opens a
limit circuit if flue gas temperature exceeds its factory setting
of 1000 degrees F. When the limit circuit opens, it shuts
down the burner. The switch must be manually reset, which
requires removing its cover and pressing a reset button. (The
manufacturer of this switch calls it a differential expansion
temperature control.)
Figure 12. Center: Barksdale pressure differential switch. Left:
Outlet pressure gauge. Right: Inlet pressure gauge.

Low combustion air switch

This is a switch (Fig. 13) that opens a limit circuit if
combustion air pressure differential is too low. When the
limit circuit opens it shuts down the burner in a lockout state.
The display of the Fireye flame monitor (Fig. 2) will indicate
LOCKOUT 3-P INTLK OPEN.
The burner cannot be restarted until the flame monitor is
manually reset. The air pressure switch automatically closes
when adequate air pressure is restored.

LOW
LOW
LOW COMBUSTION
COMBUSTION
COMBUSTION AIR
AIR
AIR SWITCH
SWITCH
SWITCH
Figure 11. High flue gas temperature switch.

Differential pressure switch

The differential pressure switch currently used on all Heatec
helical coil heaters is shown in Fig. 12. It is Barksdale
Dialmatic pressure switch CDPD2H-A8OSS. It shuts down
the burner if it senses abnormal differential pressures at
either of its two switches. Abnormal differential pressure is
a symptom of inadequate flow of thermal fluid through the
coil. PILOT GAS SOLENOID

This protects the coil from overheating and prevents

breakdown of thermal fluid. The burner cannot be restarted
until adequate pressure/flow is restored. There is no manual Figure 13. Low combustion air switch and pilot gas solenoid.

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As previously explained, there is no indicator light labeled IDENTIFYING CAUSE OF SHUTDOWN
LOW COMBUSTION AIR. However, if the low combustion air
switch opens due to low combustion air, the green LIMITS All devices in the limit circuit sense different operating
MADE light will go out, but none of the clear lights will conditions. If one device opens in response to an abnormal
go out. Thus, the limits light in effect functions as a low operating condition it will open the limit circuit and shut
combustion air light in addition to a limits made light. down the burner. When the device that initiated the shutdown
opens it may cause another safety device to open also.
LIMIT CIRCUIT But you need to identify the device that first responded to the
Certain control devices on the heater open and close a limit condition that caused the shutdown. That condition is most
circuit. If any of these devices opens the limit circuit, the likely the root of the problem.
burner will shut down. If you are watching the clear status lights on the control
The limit circuit is designated 3-to-P or 3-P. It is a circuit that panel when the shutdown occurs, the first one that goes out
starts with terminal 3 on the Fireye flame monitor (Fig. 2) indicates the cause. Unfortunately, if you are not watching
and ends with terminal P on the flame monitor. The devices the lights when the shutdown ocurs you may not be able to
listed below are in the 3-P circuit and are wired in the same tell which one went out first, because you may find several
sequence they are listed. lights out soon after the shutdown. Even so, you should
check the lights for the devices listed for the 3-P circuit in
When one of the devices opens it will open limit circuit 3-P.
same sequence they are listed. The first one you find out
This will cause the heater alarm indicator light to come on
likely indicates the cause.
and the burner will shut down in a lockout state. Moreover,
the display of the flame monitor will show LOCKOUT 3-P Once you suspect a particular device in the limit circuit,
INTLK OPEN. you can use a voltmeter to confirm that it is actually open.
A device is open when voltage is present on the terminal
1. Low media level relay contacts (Fig. 5)
connection on one side of the device, but not present on the
2. Low fuel pilot pressure switch* terminal connection on its other side.
3. High fuel gas pressure switch* (Fig. 9) Terminals for these devices are inside the heater control
panel. They are marked for easy identification. Use the
4. Low fuel gas pressure switch* (Fig. 10)
wiring diagram furnished with your heater to identify the
5. Heater fuel oil pump auxiliary contacts*) appropriate terminals for the devices.
6. Low fuel oil pressure switch* To check for voltage, connect one voltmeter lead to one
terminal on the device and connect the other lead to neutral
7. High media temperature relay (Fig. 5)
(a blue terminal). To check for voltage on its other terminal,
8. High flue gas stack temperature switch (Fig. 11) connect one lead to the other terminal and connect the
other lead to neutral (a blue terminal). Do not connect
9. Circulating pump auxiliary contacts (Fig. 4)
voltmeter leads across both terminals on a device because
10. Low media differential pressure switch (Fig. 12) your voltmeter will not show presence of voltage when its
contacts are closed.
11. High media differential pressure switch (Fig. 12)
Note that some of the limit devices automatically reset
12. Combustion air auxiliary contacts (Fig. 4)
themselves after an abnormal condition has cleared.
13. Low combustion air switch (Fig.13)
*On some heaters this switch (or contacts) is not used. A
jumper wire is used instead. In such cases, the flame monitor
will never show this switch (or contacts) as the cause of a
shutdown.
In case of an abnormal shutdown, you need to identify which
device initiated the shutdown (next topic).

Page 10
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Heatec, Inc. 5200 Wilson Road Chattanooga, Tennessee 37410 www.heatec.com (423) 821-5200 (800) 235-5200 Fax (423) 821-7673
© 2004 Heatec, Inc.

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