VHC Iom 2012 0207

INSTALLATION AND
OPERATION MANUAL
Alliance
Horizontal Coil Design
Thermal Fluid Heaters
Serial/ National
Board Number
Model
Volcanic Order
Sold To
Job Name
Date
VHC-IOM-2012-0207
VHC-IOM-2012-0207 TABLE OF CONTENTS
Introduction 1-1 Operation 3-1
Overview .............................................................................................................. 1-2 Start-Up Preparation & Installation Review ........................................................ 3-2
Warnings & Cautions............................................................................................ 1-2 Fill the System ...................................................................................................... 3-2
Disclaimers and Local Codes ................................................................................ 1-2 FILLING PROCEDURE FOR SYSTEMS OPEN TO ATMOSPHERE ....................................................3-3
FILLING PROCEDURE FOR SYSTEMS EQUIPPED WITH INERT BLANKETS .................................3-3
Installation 2-1 CIRCULATING PUMP ....................................................................................................................3-4
PUMP WITH MECHANICAL/AIR COOLED SEAL ...........................................................................3-5
Placement & Rigging ........................................................................................... 2-2
PUMP WITH PACKED SEAL ..........................................................................................................3-6
Clearances & Serviceability .................................................................................. 2-3
Start-Up Service ................................................................................................... 3-6
Environment, Ventilation and Combustion Air Requirements ............................ 2-3
Initial Start-Up ..................................................................................................... 3-6
Utilities ................................................................................................................. 2-6
Filtering the System ............................................................................................. 3-7
THE GAS SUPPLY ..........................................................................................................................2-6
BOILOUT .......................................................................................................................................3-8
THE OIL SUPPLY ...........................................................................................................................2-7
COMBUSTION ...............................................................................................................................3-9
Instrument Air ...................................................................................................... 2-8
Expansion Tank Start-Up.................................................................................... 3-13
Electrical Supply ................................................................................................... 2-8
Flame Programmers .......................................................................................... 3-14
Thermal Fluids...................................................................................................... 2-9
FIREYE LINKAGE MODULATION, YB110/E110 ..........................................................................3-14
THERMAL FLUIDS AT ELEVATED TEMPERATURES ......................................................................2-9
SIEMENS LINKAGELESS MODULATION, LMV 51 ......................................................................3-15
SELECTING A THERMAL FLUID ....................................................................................................2-9
Operating Controls ............................................................................................. 3-20
ROUTINE ANALYSIS OF HEAT TRANSFER FLUID........................................................................2-11
LIQUID LEVEL SWITCH - WHEN COMBINATION TANK IS SUPPLIED ........................................3-20
THERMAL FLUID BREAKDOWN .................................................................................................2-11
AIR SAFETY SWITCH ..................................................................................................................3-20
Piping Specifications .......................................................................................... 2-13
BLOWER MOTOR STARTER.........................................................................................................3-20
Insulation ........................................................................................................... 2-16
PUMP MOTOR STARTER.............................................................................................................3-21
System Interfaces ............................................................................................... 2-16
DIFFERENTIAL PRESSURE SWITCH ...........................................................................................3-21
HEATER CONNECTIONS ..............................................................................................................2-16
HIGH AND LOW FLUID PRESSURE SWITCHES...........................................................................3-22
THERMAL FLUID CIRCULATING PUMP .....................................................................................2-18
GAS PRESSURE SWITCH ............................................................................................................3-22
REQUIREMENTS FOR AIR COOLED PUMPS ..............................................................................2-18
OPERATING TEMPERATURE CONTROLS ....................................................................................3-23
REQUIREMENTS FOR WATER COOLED PUMPS .........................................................................2-19
HIGH TEMPERATURE LIMIT SWITCHES SAFETY ......................................................................3-24
COMBINATION DEAERATOR/THERMAL BUFFER/EXPANSION TANK........................................2-19
OPERATING LIMIT CONTROLLER ...............................................................................................3-24
SIZING THE EXPANSION TANK FOR THE SYSTEM ......................................................................2-20
ON/OFF CONTROLS ....................................................................................................................3-24
HOPKINS EXPANSION TANK ......................................................................................................2-22
MODULATING CONTROLS ..........................................................................................................3-25
LIMIT AND SAFETY CONTROLS .................................................................................................2-23
PRESSURE GAUGES....................................................................................................................3-25
PUMPS AND VALVES ..................................................................................................................2-23
TEST OF IGNITION SAFETY SYSTEM SHUTOFF ..........................................................................3-25
PRESSURIZED SYSTEMS ............................................................................................................2-24
CYCLE TESTING...........................................................................................................................3-26
VENT CONNECTIONS ..................................................................................................................2-25
Required Pressure Drop Across the Heater ......................................................... 3-26
CATCH TANK ...............................................................................................................................2-26
Procedure for First Shutdown ............................................................................ 3-27
DRAIN/FILL CONNECTION .........................................................................................................2-26
Daily Start-Up..................................................................................................... 3-27
PRESSURE GAUGES ...................................................................................................................2-26
Daily Shutdown.................................................................................................. 3-28
THERMOMETERS .......................................................................................................................2-26
Before Leaving the Installation .......................................................................... 3-28
VALVES .......................................................................................................................................2-26
AUTOMATIC FLUID CONTROL VALVES .......................................................................................2-28
BY-PASS VALVES ........................................................................................................................2-28
Maintenance 4-1
Assembly of Volcanic Multi-Skid Engineered Systems ...................................... 2-28 Required Equipment ............................................................................................ 4-2
Stack and Flue .................................................................................................... 2-29 Required Maintenance at First Shutdown ........................................................... 4-2
Testing ................................................................................................................ 2-31 Daily Maintenance Schedule................................................................................ 4-2
Weekly Maintenance Schedule............................................................................ 4-3
Monthly Maintenance Schedule .......................................................................... 4-4
0-1
Questions? Call toll free (866) 378-9263, or visit us online at www.volcanic-heater.com
TABLE OF CONTENTS VHC-IOM-2012-0207
Semi-Annual Maintenance Schedule .................................................................. 4-5

Annual Maintenance Schedule ........................................................................... 4-5
General Maintenance Procedures ....................................................................... 4-6
LUBRICATION ...............................................................................................................................4-6
SOOT CLEANING ..........................................................................................................................4-6
Safety Check Procedures ..................................................................................... 4-6
LIQUID LEVEL SWITCH ................................................................................................................4-6
STACK LIMIT .................................................................................................................................4-6
DIFFERENTIAL PRESSURE SWITCH .............................................................................................4-7
LOW INLET PRESSURE SWITCH ...................................................................................................4-7
HIGH INLET PRESSURE SWITCH ..................................................................................................4-7
HIGH OUTLET PRESSURE SWITCH...............................................................................................4-8
AIR SWITCH ..................................................................................................................................4-8
AIR FILTER BOX SWITCH ..............................................................................................................4-8
TEMPERATURE LIMIT(S)..............................................................................................................4-8
HIGH/LOW GAS PRESSURE SWITCH ...........................................................................................4-8
POWER FLAME #2 OIL BURNERS ................................................................................................4-8
Troubleshooting ................................................................................................... 4-9
FLOW CIRCUIT/ CIRCULATING PUMP(S) .....................................................................................4-9
Warranty & Parts 5-1

Parts ..................................................................................................................... 5-2
Standard Warranty for Volcanic Thermal Fluid Heaters ....................................... 5-3
0-2
© Volcanic Heater, Inc. 2012
INTRODUCTION
INTRODUCTION
1
INSTALLATION
2
OPERATION
3
MAINTENANCE
4
WARRANTY & PARTS
5
1-1
INTRODUCTION VHC-IOM-2012-0207 SECTION 3
Overview Warnings & Cautions

Prior to shipment, the following inspections and tests are WARNINGS and CAUTIONS appear in various chapters of this
made to ensure the highest standards of manufacturing for manual. It is critical that all personnel read and adhere to all
our customers: information contained in WARNINGS and CAUTIONS.
§ Material inspections § WARNINGS must be observed to prevent serious injury

or death to personnel.
§ Manufacturing process inspections
§ CAUTIONS must be observed to prevent damage
§ American Society of Mechanical Engineers (ASME)
or destruction of equipment or loss of operating
welding inspection
effectiveness.
§ ASME hydrostatic test inspection
All Warnings and Cautions are for reference and guidance
§ Electrical components inspection purposes, and do not substitute for required professional
training, conduct, and strict adherence to applicable
§ Operating test
jurisdictional/professional codes or regulations.
§ Final engineering inspection
§ Crating inspection Disclaimers and Local Codes
This manual is provided as a guide to the correct operation
Installation of the equipment shall conform to all the
and maintenance of your Volcanic equipment, and should be
requirements or all national, state and local codes established
read in its entirety and be made permanently available to the
by the authorities having jurisdiction or, in the absence
staff responsible for the operation of the heater. It should not,
of such requirements, in the US to the National Fuel Gas
however, be considered as a complete code of practice, nor
Code ANSI Z2231/NFPA 54 latest edition, and the specific
should it replace existing codes or standards which may be
instructions in this manual. Authorities having jurisdiction
applicable. Volcanic reserves the right to change any part of
should be consulted prior to installation.
this installation, operation and maintenance manual.
The boiler heat exchanger is manufactured and stamped
Installation, start-up, and maintenance of this equipment
in accordance with ASME Boiler and Pressure Vessel Code,
can be hazardous and requires trained, qualified installers
Section I or Section VIII, Div. 1.
and service personnel. Trained personnel are responsible
for the installation, operation, and maintenance of this
product, and for the safety assurance of installation,
operation, and maintenance processes. Do not install,
operate, service or repair any component of this
equipment unless you are qualified and fully understand
all requirements and procedures. Trained personnel refers
to those who have completed Volcanic Service School
training specific to this product.
When working on this equipment, observe all warnings,

cautions, and notes in literature, on stickers and labels, and
any additional safety precautions that apply. Follow all safety
codes and wear appropriate safety protection. Follow all
jurisdictional codes and consult any jursidictional authorities
prior to installation.
1-2
INSTALLATION
INTRODUCTION
1
INSTALLATION
2
OPERATION
3
MAINTENANCE
4
WARRANTY & PARTS
5
2-1
INSTALLATION VHC-IOM-2012-0207 SECTION 2
! WARNING
Placement & Rigging
All information in this manual is for
reference and guidance purposes, Proper placement of your Volcanic Product (see Figures 1 and 2, and Tables 1
and does not substitute for required and 2) is essential. Attention paid to the following points will save a great deal
professional training, conduct, of difficulty in the future. Correct placement is the first step to trouble-free
and strict adherence to applicable installation, operation and maintenance.
jurisdictional/professional codes and
regulations. Adhere to the following for equipment placement and rigging:
1. Consult authorities with jurisdiction over any national or local codes

Unless otherwise noted, this heater is (including but not limited to National Fire Protection Agency (NFPA),
certified for indoor installation only.
American National Standards Institute (ANSI), Underwriters Laboratories
(UL), SCA, and ASME, which might be applicable to heater applications
A competent rigger experienced in before beginning.
handling heavy equipment should
handle rigging your equipment into 2. Make appropriate determinations for placement, based on the following:
position.
§ Check building specifications and Table 3 for permissible floor loading.
The equipment must be installed on a § Ensure the equipment is to be placed on a non-combustible level base
non-combustible surface. with adequate clearances from combustible materials. See Clearances
& Serviceability section.
Ensure all labels on the heater are
legible. All connections and safety § Locate heater as close as possible to the place where the heat will be
devices, both mechanical and used in order to keep pipe work costs to a minimum.
electrical, must be kept clean, with
§ Ensure that there is adequate clearance around the unit to provide
ease of access for inspection, use and
maintenance. access for operators and maintenance personnel to all parts of the
equipment. Ensure also that clearance provides for component removal
for maintenance. See Clearances & Serviceability section. The
Do not store or use gasoline or other equipment should be placed in a suitable heater house or well ventilated
flammable vapors and liquids or
separate room through which personnel do not normally pass. The
corrosive materials in the vicinity of
layout should eliminate traffic in potentially hazardous areas. For
this or any other appliances.
instance, the service engineer or the operator should not have to pass
exposed, hot pipe work to make adjustments to the heater controls.
4 CAUTION § Ensure the equipment is to be placed in such a way that the electrical
components are protected from exposure to water or excessive
Do not allow weight to bear on humidity.
equipment components to prevent
damage. 3. Determine rigging procedure, based on the following:
§ Units are crated for forklift transport. Once uncrated, all units can be
transported with a forklift. All skidded units can be moved with forklifts.
Some stand-alone heaters are supplied with lifting lugs.
§ If means of lifting are not available, place rollers beneath the frame of the
equipment for guidance to the position of where it is to be installed.
§ Under no circumstances allow weight to bear on the jacket, control

panel, burner, fuel train or fan housing of any Volcanic heater.
4. Install a 4 inch (102 mm) curb completely around the unit. In the event of a
large spill, this will help contain the fluid.
2-2
SECTION 2 VHC-IOM-2012-0207 INSTALLATION
Clearances & Serviceability ! WARNING
Adhere to the following for equipment clearances and serviceability: reference and guidance purposes,
and does not substitute for required
1. Ensure appropriate front, back, sides and top clearances are met. This professional training, conduct,
will allow access around the equipment to facilitate maintenance and a and strict adherence to applicable
safe work environment, and ensure technicians will commission the unit. jurisdictional/professional codes and
Technicians will not commence commissioning if hazardous conditions regulations.
exist.
2. Place heater with clearances to unprotected combustible materials, Failure to provide required and
safe access to the equipment
including plaster or combustible supports, not less than the following:
could impede commissioning and
§ Heater Front 36” (1m) maintenance. Service technicians
are instructed not to commence
§ Heater Sides 18” (0.5 m), 36” (1 m) on side where panel located commissioning if hazardous
conditions exist.
§ Heater Rear 18” (0.5 m)
§ Flue Pipe 18” (0.5 m) Failure to provide proper minimum

clearances between equipment and
3. Pipes must not be run within 10” (254 mm) of any control cabinets or combustible materials may result in
combustible material. fire.
4. Verify that all clearances are acceptable with the local ordinances.
Environment, Ventilation and Combustion Air

Requirements
Ventilation must be sufficient to maintain a building temperature of 120°F (49°C)
or less. Consistent proper ventilation of the equipment room is essential for good
combustion.
´ NOTE: When calculating ventilation requirements, heat losses from the Volcanic
equipment (and other equipment) should be considered.
Adhere to the following to meet ventilation and combustion air requirements:
1. Install two fresh air openings, one at a low level, 24” (610 mm) from the
floor, and one at a higher level on the equipment room wall. This will
provide a flow of air to exhaust the hot air from the equipment room.
2. Ensure the burner has an adequate supply of air. Based on NBIC

recommendations, unobstructed air openings must be sized on the basis
of 0.5 square inch of free area per 1,000 BTU/hr input maximum fuel
input of the combined burners in the equipment room or as specified by
applicable codes.
3. Ensure the equipment room air supply openings are kept clear at all times.
4. See Table 4 for minimum make-up air required and the recommended area
of each opening for each model.
2-3
TABLE 1 - SPECIFICATIONS - COIL DESIGN THERMAL FLUID HEATER
Model 0240 0400 0600 0800 1000 1200 1600 2000
Heat Output
1000 BTU/HR 2400 4000 6000 8000 10,000 12,000 16,000 20,000
1000 KCAL/HR 600 1000 1500 2000 2500 3000 4,032 5,040
Thermal Fluid Content
GAL 75 115 190 264 325 508 480 1150
LITERS 284 435 719 998 1230 1921 1817 4353
Recommended Flow Rate
GPM 150 300 400 600 850 1000 1200 1500
M3/HR 35 69 91 137 193 227 273 341
Typical Circulating Pump Motor
HP 15 25 30 50 60 75 100 125
KW 11.2 18.7 22.5 37.3 45 56.3 74.5 93.2
Typical Burner Motor*
HP 2 5 7.5 10 15 15 30 30
KW 1.5 3.7 5.6 7.5 11.2 11.2 22.4 22.4
Fuel Consumption @ Full Output No.2 Oil
GPH 23 39 58 77 96 115 143 179
LITER/HR 88 148 220 292 364 436 542 678
Natural Gas
FT3/HR 3200 5340 8000 10,700 13,340 16,000 20,000 25,000
M3/HR 91 152 227 304 378 454 566 708
* Standard burner, single fuel applicaons.
Notes: Voltage 3 Phase for Burner and Pump - Each unit has an incorporated stepdown transformer. Fuel up to No. 6 Oil Available for Large Units. Eﬃciency up to 75% Minimum Based
on High Heang Value of the Fuel (No. 2 Oil @ 140,000 BTU/GHHV; Natural Gas @ 1000 BTU/"3HHV. Modulaon 3 to 1 Turn Down Rao. Circulang pump motor sizes based on standard
pressure (55 PSIG) and viscosity 1 cs, speciﬁc gravity 0.7, with 25-37 PSID available head for installaon.
TABLE 2 - DIMENSIONS-COIL DESIGN THERMAL FLUID HEATER (SEE FIGURE 2)

Model 0240 0400 0600 0800 1000 1200 1600 2000
Heater Inlet/ Outlet Connections

IN 2.5 3 4 6 6 6 8 8
MM 65 76 100 152 152 152 203 203
(A) Overall Height
IN 64 68 78 107 107 131 114 118
MM 1626 1727 1981 2718 2718 3327 2896 2997
(B) Overall Diameter
IN 62 62 81 95 95 130 118.5 119.5
MM 1575 1575 2057 2413 2413 3302 3010 3035
(C) Overall Depth
IN 134 137 169.9 208.25 182 240 327 351
MM 3404 3480 4315.5 5289.6 4623 6096 8306 8915
(D) Flue Outlet Diameter

IN 12 14 18 22 22 22 36 36
MM 304 356 457 559 559 559 914 914
Approximate Dry Weight

LB 5000 7500 9500 12,500 19,250 21,700 39,000 39,000
KG 2272 3409 5455 5682 8750 9864 17,728 17,728
2-4
TABLE 3- APPROXIMATE FLOOR LOADING 5. If positive forced ventilation is adopted, ensure that
(BASED ON OPERATING WEIGHT) there will be no appreciable pressure variation in the
equipment room.
Model Heater Only*
0240-HC 125 6. Avoid ventilation which creates a negative pressure
0400-HC 200
in the building as it will seriously affect combustion
and proper operation of the stack. Please note that
0600-HC 260
exhaust fans or similar equipment can create a down
0800-HC 200 draft in the chimney or starve the burner’s air supply.
1000-HC 300 Either case may result in poor combustion or nuisance
1200-HC 300 failures. A properly designed make-up air system in the
1600-HC 325 equipment room will preclude these possibilities and is
2000-HC 300 required to maintain proper combustion.
*All weights are lbs/ft2
Notes:
1. The burner fires down the center of the coil.
2. The hot gases return between the coils to the front end plate,
then flow to the back of the heater and exit out the flue.
FIGURE 1 -COMPONENT VIEW OF THE THERMAL FLUID HEATER
2-5
! WARNING TABLE 4- MINIMUM MAKE-UP AIR REQUIREMENTS AND RECOMMENDED AREA OF
OPENING FOR VENTS
A qualified installer, service agency
or the gas supplier must perform Model Minimum Make-Up Opening Area (in2)** Opening Area (in2)
installation and service on the fuel Air (SCFM)* Lower Vent Upper Vent
delivery system. 0240-HC 600 1200 400
0400-HC 1000 2000 670
Do not use matches, candles, flame or
0600-HC 1500 3000 1000
other sources of ignition to check for
gas leaks. 0800-HC 2000 4000 1335
1000-HC 2500 5000 1670
What to do if you smell gas: 1200-HC 3000 6000 2000

Do not try to light the appliance. 1600-HC 4000 8000 2664
Do not touch any electrical switch. 2000-HC 5000 10,000 3330
Do not use any phone in the building.
Leave building and contact gas * Minimum make-up air requirements are based on 25% excess air at high fire.
supplier from neighbor’s phone. If you ** Opening areas are calculated based input of a single heater and do not account for the ventilation
cannot reach gas supplier, phone the needs of the equipment room. These measurements are subject to state and local regulations.
fire department.
´ NOTE: A properly designed make-up air system in the equipment room will
When making gas piping joints, preclude these possibilities and is required to maintain proper combustion.
maintain proper ventilation to reduce
breathing hazards. 7. Eliminate potential for high risk situations for particulate matter to
be in the combustion air supply (e.g., as a result of construction and
An exhaust fan may draw products maintenance activities).
of combustion into the work
environment creating a possible
hazard to personnel. Utilities
Assure all electrical connections are ¡ The Gas Supply
powered down prior to attempting
replacement or service of electrical Adhere to the following for gas supply installation:
components or connections of the
equipment. 1. Install gas piping in accordance with all applicable codes.
2. Ensure pipe and fittings used are new and free of dirt or other deposits.
4 CAUTION 3. Ensure piping is of the proper size for adequate gas supply to the gas head
assembly. Consult your gas company for specific recommendations.
It is essential that only fresh air be
allowed to enter the combustion air 4. When making gas piping joints, use a sealing compound resistant to the
system. Foreign substances, such action of liquefied petroleum gases. Do not use Teflon tape on gas line
as combustible volatiles and lint in heads.
the combustion system can create
hazardous conditions. If foreign 5. Ensure no piping stresses are transmitted to the equipment. The
substances can enter the air stream, equipment shall not be used as a pipe anchor.
the combustion air inlet must be piped
to an outside location. Failure to do so 6. Ensure all vent connections on diaphragms, gas valves, pressure regulators,
will void the warranty. and pressure switches (gas-fired units) are vented per local code.
7. On gas-fired units with NFPA valve trains, ensure the vent valve is piped to
To avoid failures due to poor
atmosphere per local code.
combustion, ensure make-up air
system is properly designed.
2-6
8. During any pressure testing of the system at pressures 12. After gas piping is completed and before wiring
in excess of 1/2 psig (14 inch W.C.)., disconnect the installation is started, carefully check all piping
heater at the heater manual shutoff valve (located at connections, (factory and field), for gas leaks. Use a soap
the end of the supplied gas train) from the gas supply and water solution.
piping system.
9. Ensure the supply pressure is regulated by a non- ¡ The Oil Supply

stacking, tight, shut-off regulator.
Fuel Oil Viscosity Specific Gravity Sulfur Content
10. Arrange gas piping so that it does not interfere with #2 Less than 0.824 to 0.852 at less than 0.40%
any cover or burner, inhibit service or maintenance, 31.9 Seconds 59 C (15°C) by weight
or prevent access between unit and walls or another Redwood #1 at
unit.The burner assembly and gas controls terminate 100°F (38°C)
at a manual stop valve to which the gas supply should #4 Less than 0.90 to 0.93 at 59 less than 0.1.6%
be connected. Piping must be sized for a gas flow 81 Seconds C (15°C) by weight
consistent with the required BTU/Hr input. Large Redwood #1 at
pressure drops must be avoided. Volcanic recommends 100°F (38°C)
that the supply piping between the pressure regulator #6 Less than 3000 0.95 to 0.98 at less than 2.12%
and the inlet to the heater be kept to a minimum. The Seconds Red- 59°F (15°C) by weight
wood #1 at 100°F
minimum required gas pressure at the stop valve varies
(38°C)
with the model of heater.
Adhere to the following for installation:
´ NOTE: Even when the unit is shut down, the gas supply
pressure must never exceed these values. 1. Fuel pipes must be of approved materials and of a
diameter suitable for the quantity of oil being delivered to
the burner and the static head available. See .
´ NOTE: When operating, the supply pressure must not drop
below these limits: Not less than 11 “ w.c. where 14” w.c is 2. Make fuel connection in accordance with the details on
required. Not less than 50” w.c. where 60” w.c. is required. the enclosed fuel pump cut sheet.
Not less than 100” w.c. where 120” w.c. is required.
3. Ensure fuel oil piping is in accordance with local and/or
national requirements. In addition, if a two pipe system
11. Some fuel train configurations are require a safety relief
is employed, a check valve must be fitted into the return
valve which must be piped to a safe area in accordance
pipe.
with local codes.
B C
FIGURE 2 - DIMENSIONS (REFER TO TABLE 2)
2-7
4. Do not exceed the maximum pressure allowed at the
fuel oil pump inlet per the National Fire Protection
Electrical Supply
Association (NFPA).
Adhere to the following for electrical supply installation:
´ NOTE: If for some reason the pressure of the fuel supply will 1. Install wiring and ground in equipment in accordance
exceed NFPA maximum, fitting a regulator to the fuel line with authority having jurisdiction or in absence of such
must be considered, e.g. when there is a tank situated with an requirements the National Electrical Code, ANSI/NFPA 70.
oil level eight feet (2.4 m) or more above the pump.
2. Provide a wall-mounted, fused disconnect sized for
5. On units fitted with NFPA controls, ignition is obtained by the unit. This must be fitted by the client/contractor if
means of a gas pilot. A natural gas or LP supply is required disconnect is not supplied on the panel.
for these units. The required gas supply pressure is 7” w.c.
If a guaranteed supply of natural gas is not available, then 3. Size fuses according to motor name plates and local
a supply of bottled gas at 11“w.c. is required. For details electrical codes.
contact a local liquid propane dealer. 4. Connect power to the terminal strip as supplied on the
inside of the panel box.
Instrument Air
´ NOTE: Single skid systems are generally shipped completely
Instrument air provision for pneumatically actuated control prewired.
devices should meet the minimum and maximum flow rate
and delivery pressures specified by the individual equipment. ´ NOTE: The liquid level switch on the expansion tank, when
Additionally, it should be a dry, dust free supply with a dew supplied, will be shipped in the parts box and must be
point of -40°F (-40°C). installed in the field.
2” NPT Gas Connection

Pilot Gas Valve
Pilot Gas Valve
Manual Gas Valve
HI/LOW Gas Pressure Switch

Main Gas Regulator
Gas Safety Shutoff Valve
Manual Gas Valve

FIGURE 3 - TYPICAL GAS-FIRED FUEL TRAIN
2-8
5. Determine multiple skid systems wiring requirements (between the ! WARNING
skids). Volcanic will run conduit and wire the devices on each skid. For the
devices that have to come down for shipping, the wire will be left at the All information in this manual is for
end Locate electrical schematic diagram, a copy of which is inside of the reference and guidance purposes,
panel box. Ensure the information on the electrical drawing corresponds to and does not substitute for required
professional training, conduct,
your voltage and frequency. Check the supply voltage and make sure that
and strict adherence to applicable
there is no over-or under-voltage exceeding 10% of the nominal value.
regulations.
´ NOTE: Normal supply will be 460 volts, 3 phase, 60 Hz, AC unless otherwise
specified.
The vent line connection on the
gas pressure regulator must be
Thermal Fluids piped to outdoor air by the installer
in accordance with National Fuel
Gas Code, ANSI Z223-1-1991 or
latest addenda. In Canada, gas
¡ Thermal Fluids at Elevated Temperatures installations must be in accordance
Personnel must be familiar with the nature of potential hazards when working with the current CAN/CGA B149.1 and
with thermal fluids at operating temperatures. Unlike steam or high-pressure 2 and/or local codes.
water systems, thermal fluid attains extremely high temperatures without a
corresponding increase in pressure. If a fire does occur, extinguish using
CO2 foam or dry chemical. Do not use
Adhere to the following: water.
1. Be aware that certain types of thermal fluid may have operating

temperatures reaching 650°F (345°C) and above, so all exposed pipework is
hazardous and should be insulated. 4 CAUTION
2. Check that flanged joints are tight during and after the first warming up of Proper selection of thermal fluid is
critical to system performance.
the system. Turn burner and pump off before fittings are tightened. After
these checks, exposed hot flanges, pumps, valves and fittings should be
fitted with some sort of shield.
3. Remember that there is pressure generated in the system by the circulating

pump. Care should be exercised when opening any drain or vent valves in
the system. This is especially important during commissioning, when any
air trapped in the system is vented at high points, and when water, which
will flash into steam, is either expelled from the deaerator vent or drained
off at low points.
¡ Selecting a Thermal Fluid

The selection of the thermal fluid most suited to your application is very
important. Factors to be considered include efficiency, thermal stability,
adaptability to various systems, and physical properties, including vapor
pressure, freezing point, and flash and fire points.
Heat transfer fluids of both mineral and synthetic origin have been specially
developed to give thermal stability over a very wide range of temperature.
A wide variety of thermal fluids have been used successfully in Volcanic
Thermal Fluid Heater systems, however, your final selection should be made in
conjunction with recommendations from Volcanic or the fluid manufacturer.
Consider the following for thermal fluid selection:
2-9
! WARNING 1. The Volcanic coil design heater is a fired heat exchanger and the safe
control and monitoring of the thermal fluid temperature is of paramount
All information in this manual is for importance.
reference and guidance purposes,
and does not substitute for required 2. The safe maximum bulk temperature of the fluid must be strictly adhered
professional training, conduct, to. The safe maximum temperature of the fluid varies.
jurisdictional/professional codes and 3. Special care must be taken when consulting fluid manufacturers’ literature,
regulations. as maximum fluid temperatures quoted are the actual limit to which any
of the fluids may be subjected. It is important to remember that in any
fired heater there exists a “film temperature” which is higher than the
4 CAUTION temperature of the “bulk” of the fluid. It is the BULK fluid temperature and
NOT the FILM temperature that is indicated by the instruments.
Some soap used for leak testing is
corrosive to certain types of metals. 4. As a general guide, the following list of fluids that have given satisfactory
Clean all piping thoroughly after service over many years is provided. This is by no means a complete list.
completing the leak check. Any fluid specifically designed for heat transfer use may be considered;
multipurpose oils are not acceptable.
Some plastics can be dissolved by § AMOCO Transfer Oil 4199
thermal fluid.
§ CHEVRON
If excessive amounts of thermal fluid § DOW G
are vented from the system, additional § EXXON 43
thermal fluid may be required in the
system. Contact Volcanic for further
§ MOBIL
assistance. § MONSANTO
§ MULTITHERM
§ PARATHERM
§ PETROCANADA T
§ SHELL
§ TEXACO
5. Any fluid specifically designed for heat transfer use must also exhibit these
characteristics:
§ Be a stable and homogenous liquid to a temperature of at least 100°F

(38°C) over and above the maximum intended temperature of utilization,
compatible with metals used in the installation, and tolerating contact
with atmospheric air.
§ No solid matter in suspension.
§ Non-toxic in the case of leakage.
§ Sufficient lubricity, i.e. not likely to cause seizure.
6. The thermal fluid manufacturer must guarantee the characteristics of the

product, and verify that the fluid bulk temperature limitation exceeds the
expected operating temperature
2-10
7. After a fluid is selected, refer to the manufacturer’s recommendations, ! WARNING
published in compliance with the Occupational Safety and Health
Administration (OSHA). All information in this manual is for
8. If the fluid expansion volume from 50°F to 600°F (10°C to 316°C) exceeds and does not substitute for required
20% of the initial fluid volume, consult Volcanic. professional training, conduct,
¡ Routine Analysis of Heat Transfer Fluid regulations.
Nearly all leading manufacturers of heat transfer fluids provide an after
sales service to monitor the condition of the fluid in operation and make Volcanic is not responsible for any
recommendations when replacement becomes necessary. injury or damage caused by the use of
inadequate fluid.
Each fluid manufacturer has procedures for regular testing and analysis of the
fluid. These usually allow for a sample to be taken and analyzed at least once a Non-Volcanic product information
year, although actual frequency will depend on operating temperature, number is for reference purposes only. No
of hours operated weekly, and the results of tests made during the first weeks of Volcanic document may substitute
system operation. for full review of documentation
available from the component
Volcanic recommends that the thermal fluid in your system be analyzed within manufacturer.
the first two months after startup and annually thereafter.
During the first few months of operation, sampling may be carried out at
frequent intervals to confirm that system performance has been predicted
correctly.
If the supplier of your thermal fluid does not contact you within four weeks of
commissioning, contact the supplier and make certain that the “fill” is registered
for routine analysis.
¡ Thermal Fluid Breakdown

The possibilities of thermal fluid breakdown are very slim in a typical closed loop
thermal fluid system. Volcanic’s combination expansion/deaerator/thermal buffer
tank creates a “cold seal” of fluid that is slightly above ambient temperature. This
prevents oxidation that will otherwise happen when high temperature fluid
contacts air.
Oxidation of the fluid will also occur when hot thermal fluid contacts air at a leak
in the system piping. Oxidized thermal fluid becomes acidic and will damage the
thermal fluid system. Thermal fluid breakdown can occur in sections of piping
where there is a low flow condition. A low flow rate through the heater will result
in high film temperatures leading to breakdown of the thermal fluid.
2-11
INSTALLATION FTHC-IOM-2011-0804 SECTION 2
! WARNING } THERMAL FLUID BREAKDOWN PREVENTION
All information in this manual is for § Multiple pressure switches and a differential pressure switch are used to
reference and guidance purposes, prevent this condition from occurring. See Figure 4. These safeties must
and does not substitute for required not be bypassed at any time.
and strict adherence to applicable § Exceeding the maximum operating temperature of the thermal fluid will
jurisdictional/professional codes and also result in thermal fluid breakdown. Volcanic heaters are equipped
regulations. with a temperature limit switch (located on the front of the panel box) to
prevent this from occurring.
If a fire does occur, extinguish using § A high temperature limit switch is an over temperature safety device.
CO2, foam or dry chemical. DO NOT
If the high temperature limit shuts down the unit, the manual reset
USE WATER.
button on the limit switch must be pressed. The reset button on the
flame programmer must also be pressed to reset the unit before it can be
restarted. See Figure 5. Refer to Maintenance section of this manual for
4 CAUTION troubleshooting activities.
Some plastics may be dissolved by
thermal fluid.
FIGURE 4 - PRESSURE SWITCHES
FIGURE 5 - TEMPERATURE LIMIT DISPLAY
2-12
Piping Specifications ! WARNING
For piping, the basic considerations are: the design temperature, the pressure reference and guidance purposes,
retained by the pipe, the fluid in the pipe, the load resulting from thermal and does not substitute for required
expansion or contraction, impact or shock loads imparted such as water hammer, professional training, conduct,
external loads, wind loads and vibration from equipment. and strict adherence to applicable
Adhere to the following for piping installation (see Figures 6 and 7): regulations.
1. Ensure the arrangement of the piping and its appurtenances takes into
consideration the location of other structures and equipment adjacent to Volcanic is not responsible for any
injury or damage caused by the use of
the piping, which may result in freezing interference and/or damage as a
inadequate fluid.
result of expansion, contraction, vibration, or other movements.
2. Consider the appropriate location and orientation of valves necessary

for safe operation and isolation of the piping. Valves are used in piping 4 CAUTION
systems to stop and start the flow of fluids, to regulate flow, to prevent the
back flow, and to relieve excessive pressure build up in the piping. The weight of all piping must be
properly supported. Failure to support
3. Ensure all piping and piping components are suitable for the design piping may result in equipment
temperatures, pressure and fluid used in the system. damage and/or system leakage.
4. Ensure all components exposed to thermal fluid flow, including pipe,

Piping must take into consideration
valves, and screens, are not copper, copper alloys, bronze, brass, potential for freezing interference and/
aluminum, or cast iron. Cast iron is porous to thermal fluids, and copper or damage as a result of expansion,
and aluminum act as catalysts in the degradation of some thermal fluids. contraction, vibration, or other
Carbon or stainless steel, or ductile iron, are recommended. movements.
5. Ensure all pipework is constructed from seamless mild steel pipe,

conforming to ASME SA 106B or SA 53B, Schedule 40 or Schedule 80 or Dirt, water, and/or other debris in the
equal, as required based on the design temperature and pressure of the piping system after welding may result
in equipment failure.
system.
6. If an isolating valve is completely closed, the pressure in the system will

rise to the deadhead pressure of the pump. Suitably sized pipe will enable
the system to withstand the total head generated by the circulating
pump, should this occur. In applications where it is desirable to design
to pressures lower than 100 psig, an alternative safeguard is to install
appropriately sized safety valves.
7. Where secondary circulating pumps are installed, ensure the system is

suitable for the aggregate head, against a closed valve, of both pumps.
8. During construction of the installation, ensure that no dirt, water, or

residue from welding is left in the system.
9. Consider expansion joints or pipe loops to accommodate thermal

expansion. Design should be per latest edition of ASHRAE Systems and
Equipment Handbook to prevent detrimental forces and stresses at
connected equipment. Thermal expansion should be calculated using the
maximum possible utilization fluid temperature, regardless of whether the
pipe considered is in the feed or return circuit. Steel pipe will grow axially
and can be expected to expand approximately 1” over 100ft @ 100dg°F
temperature rise (1mm per meter over 100 C rise).
2-13
! WARNING 10. Provide properly designed supports and anchors for all piping where
necessary to prevent undue stress from being imparted on equipment
All information in this manual is for such as pumps, valves and the heater. Care should be taken as end
reference and guidance purposes, reactions transmitted to rotating equipment, such as pumps, may deform
and does not substitute for required the equipment. Therefore equipment manufacturers’ recommendations
on allowable forces and movements should be followed. Ensure all pipe
joints are of either welded or flanged construction. Screwed joints must be
regulations.
avoided where possible. In no instance should screwed joints be used in
the flow circuit. All flanges should be welded to the pipe and not screwed.
Depending on the size, flanges should be 150# or 300# raised face flanges,
Non-Volcanic product information SA105.
is for reference purposes only. No
Volcanic document may substitute 11. Ensure heaters that are skid mounted with pumps and tanks are equipped
for full review of documentation with a y-strainer, a flex connector and a valve in the inlet run between the
available from the component pump and the combination tank. Piping between the discharge of the
manufacturer.
pump and the inlet of the heater will include a flex connector and a valve.
12. If screwed connections have to be made, e.g., to items of control

equipment, use a thread sealant suitable for use with fluids at elevated
temperature. Teflon tape, standard pipe sealant, or hemp and paste are not
acceptable.
13. Cut screw threads carefully and accurately. If possible, new tools should
be used. Threaded connections larger than 1” are not to be used. It is
recommended that GR5 or higher tensile steel bolts be used for all flanged
joints.
14. Use gaskets to make all flanged connections. Gasketing material must be
suitable for use with the pressure, temperatures and fluids in the system.
Flexible graphite gaskets are suited for most applications. Recommended
gasket thickness is 1/10 - 1/8 inch. Ensure that all bolts are tightened
evenly and to the torque recommended values provided by the gasket
manufacturer. Refer to Tables 5 - 8 and Figure 8 for guidelines.
´ NOTE: Typical gaskets used by Volcanic include JM Clipper Elastograph

gaskets and Flexitallic gaskets. Adhere to installation instructions and torque
requirements for these gaskets.
15. Install high point bleeds at all high points in the system piping. 1/2” x 12”
nipples welded in the top of the piping with ball valves and plugs attached
are to be used.
´ NOTE: It will save a considerable amount of time during the cold filtration if the
system piping is cleaned prior to assembly. The mill scale (the results of oxidation)
on the inside of the piping as well as construction debris can foul the fluid and
cause the need for the filters (strainers) to be cleaned more than need be. This can
range from simply using a rag to ordering pickled pipe. (“Pickling” is a process
where the piping is first soaked in an acid bath, then soaked in a neutralizing bath,
then given a protective oil coating.)
16. Install all pipes with a pitch to facilitate draining and venting.
2-14
TABLE 5 - RECOMMENDED GASKET LOADS FOR FLEXITALLIC SPIRAL WOUND CLASS 150# ! WARNING
GASKETS SAE GRADE 5 BOLTS OR EQUAL
Nominal Flange Number of Bolts Diameter of Bolts Preferred Torque reference and guidance purposes,
Size (in.) (in.) Req. Per Bolt (ft-lb) and does not substitute for required
1/2 4 1/2 45 professional training, conduct,
3/4 4 1/2 45
1 4 1/2 45 regulations.
1 1/4 4 1/2 45
1 1/2 4 1/2 45 Non-Volcanic product information
2 4 5/8 90 is for reference purposes only. No
2 1/2 4 5/8 90 Volcanic document may substitute
for full review of documentation
3 4 5/8 90
3 1/2 8 5/8 90 manufacturer.
4 8 5/8 90
5 8 3/4 150 To maintain a reasonable
6 8 3/4 150 temperature in the equipment area
8 8 3/4 150 and ensure safety to personnel, the
10 12 7/8 240 section of the chimney duct within
the building should be insulated.
Due to extremely high operating

TABLE 6 - RECOMMENDED LOADS FOR FLEXITALLIC SPIRAL WOUND CLASS 300# GASKETS
temperatures of the thermal fluid,
SAE GRADE 5 BOLTS OR EQUAL all exposed pipework should be
insulated, and exposed hot flanges,
Nominal Flange Number of Bolts Diameter of Bolts Preferred Torque pump, valve, and fittings should be
Size (in.) (in.) Req. Per Bolt (ft-lb) shielded. Refer to Insulation section of
1/2 4 1/2 45 this manual for details.
3/4 4 5/8 90
1 4 5/8 90
1 1/4 4 5/8 90
1 1/2 4 3/4 150
2 8 5/8 90
2 1/2 8 3/4 150
3 8 3/4 150
3 1/2 8 3/4 150
4 8 3/4 150
5 8 3/4 150
6 12 3/4 150
8 12 7/8 240
10 16 1 368
2-15
TABLE 7 - RECOMMENDED LOADS FOR JM CLIPPER ELASTOGRAPH
150# GASKETS SAE GRADE 5 BOLTS OR EQUAL
Insulation
Nominal Number of Diameter of Preferred After the appropriate system tests have been satisfactorily
Flange Size Bolts Bolts (in.) Torque Req. completed (see Testing section of this manual), all hot
(in.) Per Bolt (ft-lb) pipework and vessels must be adequately insulated with
1/2 4 1/2 30 material suited to the temperature and application to prevent
both heat loss and personnel injury.
3/4 4 1/2 30
1 4 1/2 30 Adhere to the following for insulation installation:
1 1/4 4 1/2 30
1. For inspection and maintenance purposes, leave
1 1/2 4 1/2 30
pumps, flanges, valves and fittings uninsulated but
2 4 5/8 60
suitably shielded for safety.
2 1/2 4 5/8 60
3 4 5/8 60 2. Insulate the deaerator section of the combination tank.
4 8 5/8 60
3. Do not insulate the thermal buffer and expansion
5 8 3/4 100 sections of the combination tank. On units operated
6 8 3/4 100 with inert gas blankets above the fluid in the expansion
8 8 3/4 100 tank, the entire combination tank, including the
10 12 7/8 160 expansion and thermal buffer sections, may be
insulated but it is not necessary.
4. Ensure hot oil pipe insulation is a minimum of 2” (51

TABLE 8 - RECOMMENDED LOADS FOR JM CLIPPER ELASTOGRAPH mm) thick, high temperature, laminated, foamglass
300# GASKETS SAE GRADE 5 BOLTS OR EQUAL cellular glass insulation as manufactured by Pittsburgh
Corning Corporation or equal.
Nominal Number of Diameter of Preferred
Flange Size Bolts Bolts (in.) Torque Req.
(in.) Per Bolt (ft-lb) System Interfaces
1/2 4 1/2 30
3/4 4 5/8 60
Proper selection and installation of the components in the hot
oil system will ensure proper and safe operation of the heater.
1 4 5/8 60
1 1/4 4 5/8 60
1 1/2 4 3/4 100 ¡ Heater Connections
2 8 5/8 60 Adhere to the following for heater connections:
2 1/2 8 3/4 100
3 8 3/4 100
1. Connect the outlet of the pump directly to the inlet of
the heater via an isolating valve (preferably a throttling
4 8 3/4 100
valve) and pump flexible connector.
5 8 3/4 100
6 12 3/4 160 2. Pipe heater outlets directly to the system via an isolating
8 12 7/8 245 valve.
10 16 1 160 3. A safety relief valve may be shipped in the parts box
accompanying the fuel-fired heater, and must be installed
in the outlet manifold. On all units, the outlet must be
piped to a safe discharge area. The piping from the outlet
of the safety valve must be piped to a catch tank. The
discharge flow must not be restricted, i.e. no valve should
be installed. The weight of the piping must be properly
supported in order to prevent damage to the safety valve.
If the valve body becomes warped, leakage may result.
2-16
1. Thermal Fluid Heater
2. Thermal Fluid Circulating Pump
3. Safety Relief Valve 11
4. Thermometer
5. Pressure Gauge
10
6. Thermal Fluid Heated Equipment 13
14
7. Bypass Valve to maintain full flow to heater
12
8. Expansion Joints as required
9. Anchor and Pipe Guides
10. Expansion Tank
11. Vent Piping (should be full size of expansion tank vent) 9
12. Deaerator Tank 8
13. Deaerator Tank Inlet (must be highest point of piping)

14. Thermal Buffer Tank
15. Catch Tank for drain of pressure relief valve, cold seal,
expansion tank, and vent. Locate in safe area. 3 16
16. Gate valve
17. Strainer
17
18. 3/4” System Fill Connection 19
7
19. Flexible Connection as necessary 15
20. Isolating Valve as necessary

21. Manual Low Level Test Line
22. Manual High Level Test Line
18
23. Buffer Drain 4
1
2
6 5
FIGURE 6 - TYPICAL THERMAL PIPING SCHEMATIC
From Outlet of Deaerator

Pipe Must Be
Diameter of
Pump Intake
1
5 8
Pump
3 4
First
Fitting
Pipe Support Must Be 7 6

Provided (Not To Be
Welded On Both Ends) 2
6 - 10 Pipe Diameters
FIGURE 7 - TYPICAL PUMP PIPING FIGURE 8 - BOLTING SEQUENCE FOR 4 AND 8 BOLT FLANGES
2-17
¡ Thermal Fluid Circulating Pump § The coupling alignment of the pump and driver must
be carefully checked for angular and axial alignment.
Installing the pump in accordance with the manufacturer’s Check pump manufacturers instructions for these
specifications and these instructions will prolong the life specifications. The use of a dial indicator to check the
of the pump and contribute significantly to the successful axial and angular alignment is recommended.
operation of your Volcanic heater system. The pump
manufacturer’s installation and operation instructions can be § An air cooled pump does not have an oiler. This type
obtained from the manufacturer. of pump has a sleeve bearing which is, like the seals,
lubricated by thermal fluid. An air cooled pump
Adhere to the following for pump installation: has a grease nipple located at the drive end of the
pump near the coupling connection. This comes
1. Locate pump adjacent to the heater. Its base must be
pre-greased, and should be greased at intervals as
firm, level (preferably concrete), and free from vibration.
recommended by the manufacturer.
2. Route pump per the manufacturer’s requirements. It
§ An oiler is shipped with each water cooled pump and
should be equipped with flexible connections at the
it should be filled with a lubricating oil recommended
suction and discharge sides. The primary function of
by the manufacturer. The suggested lubricant is
these connections are to prevent stresses due to pipe
usually SAE-30 non-detergent oil.
expansion from being placed on the pump and to
isolate pump vibrations from the pipe work and the § Thermal fluid is not sufficient lubrication for bearings.
heater. They also allow for expansion and deflection of
the pipe work. These connections should be rated for § All seals on air cooled pumps are lubricated by
high temperature since they are considered part of the thermal fluid, therefore the pump must never be run
piping system. dry, i.e., without thermal fluid in it.
3. Connect suction pipe work directly to the deaerator § Filling a pump equipped with either a Grafoil packed
section via a vertical run with as few elbows as possible. or mechanical seal with thermal fluid will ensure
It should contain the strainer and an isolating valve. lubrication. However, in order to be certain that all
The discharge pipe work must be connected directly to seals on an air cooled pump are coated with thermal
the heater inlet, and should contain an isolating valve. fluid, the pump must be bled.
See that pipe work connections match up accurately
§ Grafoil packings require a run-in procedure. Typically,
with pump flanges. Refer to the pump manufacturer’s
pumps with these seals are shipped with four or five
recommendations for the specific pump inlet piping
rings installed and several rings loose. These extra
requirements. Typically these requirements are that:
rings must be on hand for the initial run-in procedure.
§ It be a straight run of pipe. See manufacturer’s instruction manual for this
procedure.
§ The straight run from the pump inlet to the first
fitting, valve, or flex connector be a minimum of 6-10
pipe diameters in length. ¡ Requirements for Air Cooled Pumps
Adhere to the following for air cooled pumps (See Figure 9):
§ The pipe used should be the same size as the inlet of
the pump. 1. Allow for free air flow around the entire pump casing at
all times.
§ The piping in the immediate vicinity of the pump
must not be supported by the pump. The pump is 2. Maximum room temperature should be 100°F (38°C).
not designed to bear the weight of the piping, and
weight on any part of the pump will throw it out of 3. In no case should any part of the drive side of the pump
alignment. be insulated.
§ Proper alignment directly affects bearing, coupling, 4. Maximum operating temperature for air cooled pumps
and seal life expectancy. The pump is properly aligned varies by manufacturer. Consult instruction manual to
before it leaves the factory. Because the system verify.
expands in operation, pump must be realigned when
the system is at operating temperature.
2-18
3/8” NPT BARRIER OIL
FILL-MECH. SEAL ONLY
DISCHARGE
! WARNING
1/8” NPT
GREASE FITTING
1/8” NPT VENT
1/2” NPT DISCHARGE
GAUGE CONNECTION reference and guidance purposes,
WHEN SPECIFIED
regulations.
1/4” X 1/8”
PUMPAGE
KEYWAY
LEAK DETECTION
MECH. SEAL ONLY Non-Volcanic product information
SUCTION
3/8” NPT BEARING GREASE 1/2” NPT CASING DRAIN is for reference purposes only. No
RELIEF AND LIP SEAL WHEN SPECIFIED
FAILURE DETECTION Volcanic document may substitute
FIGURE 9 - TYPICAL AIR COOLED PUMP for full review of documentation
manufacturer.
FIGURE 10 - TYPICAL WATER COOLED PUMP
¡ Requirements for Water Cooled Pumps

Adhere to the following for water cooled pumps (See Figure 10):
1. Requirements for water cooled pumps will vary with manufacturer.

Consult manufacturer’s instructions for flow rate and temperature
requirements.
2. Check local codes regarding disposal of hot water.
¡ Combination Deaerator/Thermal Buffer/Expansion Tank

Volcanic’s efficient design combines the operation of the expansion, deaerator,
and thermal buffer tanks. Installation is considerably simplified by virtue of this
arrangement.
The expansion section is vital to the thermal fluid system. From ambient to
operating temperature, the thermal fluid in the system will typically expand
in the range of 25% to 50%, and a vessel capable of handling this expansion is
mandatory. The customer should confirm the expansion rate of the chosen fluid
and system volume.
At start up, the primary purpose of the deaerator section is to remove all volatiles
from the system to avoid pump cavitation. The deaerator section also allows
2-19
air to be vented from the system on a continuous basis ¡ Sizing The Expansion Tank For The System
during operation to avoid oxidation of the thermal fluid, and
removes other volatile particles generated by the fluid itself Expansion tank capacity is the total volume of the tank (see
during system operation. This section of the tank must be Figures 11 and 12). It is necessary to have some air space
insulated. available at the top of the tank to avoid spillage or overflow.
At initial fill (for system volume calculations) the deaerator
A system of interconnecting pipe work in the thermal buffer and cold seal sections must be filled completely and the
tank section prevents the movement of any oil that has not expansion section must be filled to a level of 4 inches (102
cooled sufficiently into the expansion section. This avoids mm) to “make” the liquid level switch.
contact of very high thermal fluid temperature with oxygen
contained in the atmosphere, which causes fluid breakdown. The volume between the initial fill level and the safe “full” level
DO NOT insulate this section. is the amount available for expansion. That volume is used to
decide which tank is suitable for the system expansion.
Vent for Piping Expansion

to Safe Catchment Volume
Expansion
Tank
Liquid Fluid In Thermal

Level Buffer
Switch Section
Deaerator
Section Hot Fluid
Medium Fluid
Cool Fluid
Gases (Steam)
Fluid Out Drain
Model Capacity (gallons) Initial Fill (gallons) Available for Max System
Expansion (gallons) Volume
FT-200-L 52 25 46 184
FT-500-L 132 40 121 525
FT-1000-L 264 80 232 1000
FT-1500-L 397 90 380 1400
FT-2000-L 528 145 444 1700
FT-3000-L 793 215 717 2600
FT-5000-L 1310 300 1168 4600
FIGURE 11 - EXPANSION TANK DETAILS
2-20
C
1/2C
3
VENT
(76)
N2 REGULATOR
K 1/2 2
(TYP.) (13) R (50.8)
F
P
SAFETY RELIEF
A VALVE CONN. LIQUID
LEVEL
MANUAL
LIQUID LEVEL TEST
SWITCH D CONNECTION
COUPLING
M L
EXPANSION TANK
DEAERATOR
THERMAL 1/2 E
INLET
BUFFER
(13)
B B J
DRAIN & LIQUID LEVEL
DRAIN
N
R
G H
OUTLET
FT-0200-L FT-0500-L FT-1000-L FT-1500-L FT-2000-L FT-3000-L FT-5000-L

A 20 (510) 26 (660) 36 (915) 36 (915) 42 (1070) 42 (1070) 60 (1524)
B 12 3/4 (325) 16 (405) 20 (510) 20 (510) 22 (560) 26 (660) 26 (660)
C 54 (1370) 74 (1880) 76 (1930) 106 (2690) 106 (2690) 140 (3556) 130 3/8 (3312)
D 60 5/8 (1540) 66 5/8 (1692) 87 5/8 (2226) 87 (2210) 107 5/8 (2734) 115 1/8 (2924) 132 1/8 (3356)
E 34 (865) 37 (940) 49 (1245) 49 (1245) 62 1/2 (1590) 70 (1778) 77 1/2 (1969)
F 26 5/8 (676) 29 5/8 (752) 38 5/8 (981) 38 5/8 (981) 45 1/8 (1146) 45 1/8 (1146) 54 5/8 (1387)
G 16 11/16 (424) 19 3/4 (502) 22 1/4 (565) 24 3/4 (629) 31 3/16 (792) 33 3/16 (843) 32 3/16 (818)
H 12 (305) 14 (355) 15 (380) 17 1/2 (445) 24 (610) 24 (610) 24 (610)
J 4 1/2 (115) 6 (150) 7 11/16 (202) 8 (203) 8 1/2 (216) 9 15/16 (252) 9 3/8 (238)
K 4 1/4 (108) 11 1/2 (290) 14 (355) 14 (355) 15 1/2 (394) 15 1/2 (394) 20 5/8 (524)
L 15 (380) 18 (460) 24 (610) 24 (610) 28 (710) 28 (710) 37 (940)
M 12 15/16 (329) 14 15/16 (379) 14 15/16 (379) 14 15/16 (379) 14 15/16 (379) 18 15/16 (481) 18 15/16 (481)
N 3/4 (20) 3/4 (20) 1 (25) 1 (25) 1 (25) 1 (25) 1 (25)
P 3/4 (20) 3/4 (20) 1 (25) 1 1/4 (32) 1 1/2(38) 1 1/2 (38) 1 1/2 (38)
Dry Wt. 636 (289) 970 (440) 1350 (612) 1710 (776) 2550 (1134) 3200 (1451) 5300 (1637)
Max Full Wt. 1314 (596) 2450 (1111) 4380 (1987) 5875 (2667) 8230 (3733) 11,610 (5265) 17,370 (7895)
Inlet and outlet dimensions vary with installation. All dimensions are approximate. Specifications are subject to change without notice.
Dimensions are in inches (mm). Capacities are in gallons (liters). Weights are in pounds (kg).
FIGURE 12 - COMBINATION/EXPANSION/DEAERATOR THERMAL BUFFER TANK
2-21
! WARNING } SIZING EXAMPLE
All information in this manual is for A system contains 175 gallons, including the heater, but not the tank. You select
reference and guidance purposes, the FT-200-L, so you add 25 gallons to 175 for a total of 200 gallons.
professional training, conduct, You look up the expansion rate for the thermal fluid. (Assuming it is 25%), 200
and strict adherence to applicable gal. x 1.25 = 250 gallons, 250-200 = 50 gallon expansion.
regulations. The FT-200-L has only 46 gallons available for expansion, so the correct selection
is the FT-500-L.
Non-Volcanic product information Adhere to the following for installation:

Volcanic document may substitute 1. Install tank in accordance with Volcanic’s specifications.
available from the component 2. Unless the system is pressurized, the inlet to the deaerator section must be
manufacturer. higher than or equal to the highest point in the system to prevent pockets
of air from collecting in system piping.
3. Take into account the head required at the circulation pump suction inlet to
avoid the possibility of pump cavitation.
4. In systems operating close to maximum fluid temperature, ensure the tank

is elevated enough, possibly well above the highest point in the system, to
prevent pump cavitation by increasing the static head. An inert pressurizing
blanket may be considered as an alternative. See Pressurized Systems
section of this manual.
5. Provide supports for tank mounting. These should be suited for supporting
the tank by the side rails. The eyelets fitted to the tank are for lifting only.
¡ Hopkins Expansion Tank

Hopkins expansion tanks are mounted to the heater as one unit (see Figure 13).
This unique arrangement allows for simplicity of the system, low maintenance,
and unattended operation. The Expansion Tank is required for all closed-loop
liquid circuits. When heated, thermal fluid expands approximately 4% by volume
for every 100° F temperature increase.
The expansion tank is necessary to account for the fluid expansion and allows for
a place to store excess fluid. Upon initial heater startup, tanks typically are filled
to 25% capacity and operate at 75% capacity. When the system is shut down and
the liquid cools, liquid is withdrawn from the expansion tank and maintains a
filled circulating loop.
} SURGE TANK
Characteristics for the surge tank are as follows:
§ Thermal fluid returns from heating the customer’s product and is

deposited into the surge tank.
§ Primary function of the surge tank is to decrease the velocity of the fluid.
§ Any steam or air left in the fluid will travel to the expansion tank.
2-22
§ Fluid in the surge tank flows into the main circulating
pump where it is then transported to the heating coil
and the process is repeated.
} COLD SEAL TANK

Characteristics for the cold seal tank are as follows:
§ Can either be vented to the atmosphere directly or

could be run from a pipe to a catch bin for venting.
This permits air or steam in expansion tank to travel
to cold seal tank and escape.
§ On a barge, fluid level in the expansion tank can FIGURE 13- STANDARD HOPKINS EXPANSION TANK UNIT
rise and fall due to the ocean, and the cold seal tank
provides a place for the fluid to leak into if necessary.
Draining is required after system is shutdown. ¡ Pumps and Valves
§ Figure 13 shows the cold seal tank and the surge tank } MAIN CIRCULATING PUMP
connected to the expansion tank. The cold seal tank
The main circulating centrifugal pump is specifically sized to
is separate from the expansion tank and the surge
provide the proper capacity and pressure head to circulate
tank occupies 8-10 inches inside the expansion tank.
the heat transfer fluid through the heater and heating system.
Characteristics of the main circulating pump are as follows:
¡ Limit and Safety Controls
§ Piping connects the outlet of the surge tank to the
} LOW LEVEL CONTROLLLC inlet of the pump and is the main source of fluid
circulation throughout the system.
Characteristics of the LLC are as follows:
§ The system should be designed such that there is
§ Mounted on surge tank sufficient net positive suction head available for the
pump.
§ Float cage switch will shut down the burner if the
fluid level in the surge tank is too low. § Positive displacement pumping systems should
incorporate features to ensure that minimum flow
§ Normally open contact that closes when the system is
through the heater is maintained at all times.
full and operating. This guarantees that the pump is
supplied with liquid while the heater is operating. § A strainer is inserted before the fluid reaches the
pump.
§ A manual reset is installed and must be reset after
every shutdown. If low level is not corrected, the § Customer has choice for strainer to be placed before
reset will not restart the burner. entering expansion tank or right before pump. A
minimum 60 mesh stainless steel strainer element
} HIGH LEVEL CONTROLHLC should be used. A means should be provided to drain
the strainer prior to cleaning.
An optional high fluid level control can be installed and serves
the same purpose as the LLC but is placed near the top of the
expansion tank. In the event that the fluid in the expansion } VALVES
tank gets too high, the high level control switch is tripped and Valve characteristics are as follows:
the burner will shut down.
§ Gate valves should be used for isolation purposes
§ ¾’’ ball and gate valves are used in Volcanic’s

applications. From Figure 13, valves “A”, “B”, “C”, and “D”
are gate valves. Gate valves are needed to withstand
the temperatures of the thermal fluid. Ball valves
2-23
! WARNING are present in valves “E” and “F”. Ball valves are associated with lower
temperatures such as the cold seal tank.
reference and guidance purposes, § Nitrogen Relief Valve’s main function is to prevent oxidation of fluid due
and does not substitute for required to exposure to air at high fluid temperatures.
and strict adherence to applicable § The expansion tank is pressurized with nitrogen due to any of the
jurisdictional/professional codes and following conditions: The tank is not the highest point in the system;
regulations. tank contents can be at temperatures such that exposure to air would
cause degradation of the fluid; the fluid manufacturer recommends use
Once the system has been filled, of an inert blanket; the fluid is operated above its atmospheric boiling
any modification to the tank or point.
connected piping requires purging
of the work area to prevent ignition
§ Nitrogen relief valves are typically used on land based heaters and rarely
of potentially flammable vapors. used on marine heaters.
Consult factory prior to beginning
work. Consult Material Safety Data
Sheet (MSDS) for your thermal fluid
¡ Pressurized Systems
for flammability limits. Nitrogen pressurization may be used if the total system content is very large, or
in a system operating near or above the vapor pressure of the fluid employed, or
if the inlet of the DA tank is not the highest point in the piping system, or at any
4 CAUTION time to further protect the fluid from oxidation.
Non-code tanks cannot be pressurized In conjunction with this system, adhere to the following:
over 15 psig.
1. An automatic venting device must be fitted to the system expansion tank.
Consult Volcanic for further details.
If the deaerator/thermal buffer/
expansion tank is located outdoors, a 2. The location for the liquid level switch (Figure 14) is a 2-1/2” NPT connection
nitrogen blanket is required. on the same end of the tank as the inlet. The liquid level switch is supplied
and shipped with the unit, and must be installed by the customer and then
wired to the control panel.
3. If the tank is located outdoors, nitrogen is required.
FIGURE 14 - LIQUID LEVEL SWITCH LOCATION

2-24
¡ Vent Connections ! WARNING
Adhere to the following for vent connections: All information in this manual is for
1. Make vent connection in a manner that will prevent penetration of water and does not substitute for required
or foreign bodies into the tank. This connection must always terminate professional training, conduct,
in a safe, well ventilated area and has to be free of obstruction, open to and strict adherence to applicable
atmosphere, and arranged in such a manner that, in the event of discharge jurisdictional/professional codes and
from the system, thermal fluid could drain into a catch tank without regulations.
danger to personnel or property.
Cements for plastic pipe should
2. Make the vent run the same size as the tank outlet. It should run pitch be kept away from all sources of
down from the outlet of the tank to the catch tank. ignition. Proper ventilation should
be maintained to reduce the hazard
3. If nitrogen is used on the system, the vent can be reduced to 2” (51 mm)
and to minimize breathing of cement
and should be piped with a positive closing valve at the catch tank. vapors.
4. Ensure the connection between the tank outlet and the horizontal pump
inlet is as close to a vertical drop as possible. It should have the minimum No shutoff of any kind may be
bends and length of pipe. placed between the safety relief
valve and the equipment, or in the
5. Ensure the inlet to the deaerator is higher than or equal to the highest discharge pipe between such valve
point in the system, or a pressurized system must be used. and the atmosphere. Doing so may
cause accidental explosion from
6. Field-install the liquid level switch (supplied and shipped with the unit). overpressure.
This must be wired to the control panel.
7. Ensure test connections are accurate. The high and low level test Discharge from safety relief valve
connections are 1/2” NPT, and are located on the end of the tank opposite must be configured so that there
is no danger of scalding personnel
the inlet. The low level is on the center line of the expansion tank, the high
or causing equipment damage.
level is next to it, slightly off center. The high level rises up from the bottom
Provisions must be made to properly
of the tank and ends 4” (102 mm) below the top; the low level rises 2” (51 drain safety relief valve discharge
mm) from the bottom of the tank. piping.
8. Both the high and low level connections should be piped to a safe
catchment. Valves should be installed in these lines at the catch tank.
Installation of the valves should be accomplished in such a manner that
any flow will be visible when the valves are open.
9. Flow from the high level test connection indicates a tank that is too full; no
flow from the low level test connection indicates too little fluid.
10. There is a 300 #, raised face, flanged drain on the bottom of the thermal
buffer section, for the purpose of draining the tank when necessary. This
should be piped with a valve in the line, to a safe catchment. The valve
specifications outlined above apply to this valve as well.
11. An inspection opening is located at the highest point on the tank. Access
to this port is recommended but not required.
12. Refer to the maintenance schedule for recommendations on draining the

buffer tank. For positioning of all connections on tank, see Figure 12.
2-25
! WARNING ¡ Catch Tank
All information in this manual is for Adhere to the following for the catch tank:
and does not substitute for required 1. Ensure the heater safety relief valve outlet and connections on the DA tank
professional training, conduct, are piped to a safe catch tank. The catch tank must be appropriately sized
and strict adherence to applicable based on the system volume and configuration.
regulations. 2. Under normal operating conditions, the catch tank should be empty. Fluid
that is expelled into the tank should not be reintroduced into the system.
Failure to properly locate and 3. Ensure the vent from the catch tank is located and installed in such a
install vent connections may cause manner as to protect personnel and property from discharge of steam,
personnel and property damage. water, and thermal fluid. Vent outlet should be positioned in a safe location
outside the heater room.
¡ Drain/Fill Connection
The system is usually filled from the lowest point, with the aid of a pump. On skid-
mounted units, a drain and fill connection is provided in the inlet piping to the
pump. See Figure 15.
¡ Pressure Gauges
The range in which readings are expected to fall should comprise mid-scale on
the pressure gauge chosen (See Figure 16). Pressure gauges must be able to
withstand overpressure equal to the rating of the safety relief valves, normally
100 psig.
¡ Thermometers
Thermometers should read up to 650°F (343°C). For systems with higher
operating temperatures, select thermometers accordingly.
FIGURE 15 - DRAIN AND FILL CONNECTION
¡ Valves
Adhere to the following for valve installation:
1. Use vent and drain valves that normally are 1/2” or 3/4” with internal seals
2-26
made from materials suited to use with thermal fluids. They may be of the ! WARNING
screw type if installed on stalks not less than 12” (30.5 cm) long.
2. Use gasketing material specifically suited to the task. reference and guidance purposes,
3. Fit drain valves at all low points in the pipework system and ventilating professional training, conduct,
valves at all high points in the installation. Valves must be fitted with either and strict adherence to applicable
the conventional packed stuffing box seal or a bellows seal as required. jurisdictional/professional codes and
regulations.
4. Where the stuffing box is specified, it should be as deep as possible and
packed with Grafoil packing or equal. The valves should have a backseating
Do not attempt to start the
to allow re-packing without draining the system.
equipment for any testing prior
5. In all units, install a “Y” type strainer in the fluid return line, between the to filling and purging the vessel.
deaerator tank and the circulating pump. This strainer is provided on A dry fire will seriously damage
the equipment and may result in
all skid-mounted units. Valves must be provided (unless the heater has
property damage or personnel injury
been skid-mounted with the tank) so that the strainer can be isolated for
and is not covered by warranty. In
cleaning of the element. The strainer element should be 60 mesh and must case of a dry firing event, shut off
remain in place during normal operation of the system. the fuel supply and allow the vessel
to cool to room temperature before
6. Check the pump suction pressure periodically, under similar operating
fluid is reintroduced to the pressure
conditions. A vacuum reading on the suction gauge indicates that the vessel.
screen must be cleaned. For isolating purposes, globe, wedge, gate, ball, or
other shut-off valves should be used. When there is a likelihood that some
manual balancing will be required, a ball or globe valve should be used.
4 CAUTION
7. Ensure manual control and isolating valves are of the flanged or weld type,
Avoid flue corrosion and other negative
manufactured from cast or forged steel or ductile iron, with internals and
impacts ensuring properly-sized stack
gland seals made from materials suitable for use with high temperature
and flue.
fluids.
8. When ordering valves, obtain the maximum possible service temperature For reasons of safety, the hot exhaust
and type of fluid. A partial list of manufacturers known to market valves of gas duct and chimney must be
acceptable quality follows: insulated or shielded within the
locality of the heater in compliance
§ Stockham Valves and Fittings Company
with local codes and regulations.
§ Velan
§ Vogt Machine Company The stack arrangement and draft

conditions should be in accordance
§ Worcester Valve Company with the information in this manual for
proper performance of the equipment.
FIGURE 16 - GAUGES
2-27
! WARNING ¡ Automatic Fluid Control Valves
All information in this manual is for Because of the widely varied processes in which Volcanic Thermal Fluid Heaters
reference and guidance purposes, are used, it is not possible to provide specific rules for the selection of automatic
and does not substitute for required fluid control valves. Generally, these valves must satisfy the specific materials and
professional training, conduct, construction requirements.
jurisdictional/professional codes and The type of operation and design of porting are governed by the degree of
regulations. control required as well as the particular application.
Failure to ensure vent connections

terminate into a well-ventilated
¡ By-Pass Valves
area with catch tank may create an When process flow requirements do not match heater flow requirements, a by-
environmental hazard. pass valve must be installed. If the process flow will vary with the system load, a
suitable bypass system can be recommended by Volcanic.
High temperature thermal fluid,
steam, and combustible vapors
may be vented through the vent
Assembly of Volcanic Multi-Skid Engineered Systems
connection on the combination
deaerator/thermal buffer/expansion Adhere to the following for multi-skid engineered systems:
tank.
1. Refer to the Volcanic mechanical/electrical drawings during assembly.
In order to meet warranty conditions, 2. Ensure that the equipment orientation allows for operation interface and
ensure appropriate tests and maintenance.
operational safety activities are
performed. 3. Align skids as shown in the drawings, ensuring that the skid fasteners are
matched.
Unless specially filtered, compressed air 4. Ensure the skids are leveled and fasten the skids together using the
will introduce moisture to the system. supplied bolts. The skids should be leveled front to back, side to side and
Dry air or nitrogen is recommended.
corner to corner. Failure to properly level the skids will result in piping
misalignment. A level or laser level should be used to verify skid alignment
(when a standard level is used, the length should be appropriate for the
skid) If assembling multi-component support stands, attach sections using
the supplied bolts through the tank frame mounting plates. These should
be hand tight until all piping has been assembled and tightened.
5. Connect the piping between skids by matching the union connections

and/or flange stamps and tightening. Refer to the appropriate instructions
to tighten the flanges and required torque specifications. Support pipe
runs as required.
6. Ensure that a low point drain is installed in the piping.
7. Connect the conduit runs between skids and tighten the conduit
connectors.
8. Locate the supplied wiring for the equipment and pull wiring through
the appropriate conduit runs. Electrical wires are labeled for easy landing.
Connect all wiring per the Volcanic supplied electrical drawing. If a header
is supplied, mount the header as shown in the mechanical drawing.
2-28
´ NOTE: For piping supplied in sections it should be made up 6. Ensure the stack and chimney material complies with all
and connected hand tight until all sections are in place to applicable codes.
ensure sections align properly. Sections are match marked for
reassembly. 7. Make adequate provisions for the support of the
weight of the chimney and stack to avoid having a load
9. Tighten all connections. imparted to the outlet connection of the equipment.
10. Pneumatically test the piping (at 15 psig maximum) 8. Ensure the draft, when firing, is negative and constant.
prior to filling the system. A reading of -0.02 to -0.04”wc when the unit and stack
are cold usually indicates sufficient draft. When the unit
11. Check bolts and connections for tightness after the first is running and the stack is hot, the draft should read 0.04
heat up cycle. Retorquing may be required. to 0.08 “wc negative.
9. The installation of a draft regulator by the client/

Stack and Flue contractor is recommended at all installations. This will
help to maintain the required draft. The placement of
An appropriately sized stack should be connected to the flue the draft regulator should be as shown in Figure 16 and
gas outlet at the heater. The proper flue size and draft control Figure 18.
is most important for proper burner operation. The flue must
be as large or larger than the outlet on the vessel. Avoid flue 10. Insulate the section of the chimney duct within the
piping and elbows by placing the equipment as close as building.
possible to the chimney. 11. Concentration levels of only a few ppm of chlorine
Adhere to the following for stack and flue installation (see containing compounds in combustion air can produce
Figure 17): serious corrosion of the flue over long periods of time.
High chlorine containing compounds such as carbon
1. Ensure the stack is the same diameter as the flue gas tetrachloride or perchloroethylene would be prime
outlet. suspects.
2. Ensure the stack rises continuously to the connection at

the chimney and contains no more than two bends at
45 degree angles or less. If required, as a result of space
limitations, one 90 degree elbow (or tee) can be fitted at
the back of the vessel.
3. Ensure 2 feet (0.6 m) of straight, horizontal flue before

any change in direction, fitting or draft regulator. This is
to prevent potential pilot or main flame failures due to
back pressure build up during ignition. Any alternative
stack arrangement must supply negative 0.02 to
0.04”wc.
4. Ensure the run in the total distance of stack ducting, as

measured in a straight line from the outlet of the heater
to the outlet of the stack, does not exceed 70% of the
rise. With the exception of the duct run previously
described, horizontal sections of ducting must be
avoided and should not exceed 4 feet (1.2 m) total. See
Figure 17.
5. Ensure the stack, chimney, and any components

associated with the stack, such as heat reclaimers or
assist fans, are constructed from material that is rated for
a 1200°F (649°C) operating temperature.
2-29
FIGURE 17 - TYPICAL STACK AND FLUE INSTALLATION
FIGURE 18 - BAROMETRIC DAMPER INSTALLATION
2-30
Testing
Upon completion of the installation, perform the following
testing:
1. A pneumatic test of thermal fluid piping not exceeding

15 psig.
2. Soap tests at all welds and joints to ensure that the

system is free from leaks.
´ NOTE: Under no circumstances should the system be filled

with water. Make sure that the air supply is as free from
moisture as possible.
3. Boil-out. The time needed for adequate boilout directly

corresponds to the volume of the system and the
amount of moisture and debris in the system. Boilout
typically takes anywhere from one to three days to
complete. Pressure testing on the system should be
done by means of an inert gas such as nitrogen or by an
air compressor producing dry air (air with a dewpoint of
50°F [10 C] or less). Never perform a hydrostatic test on
the system. The boilout procedure is described in the
Operation section of this manual.
4. The most satisfactory method of testing is to introduce

bottled nitrogen through a pressure control valve.
Check pressure ratings on all equipment in the system
to ensure that it is capable of withstanding the pressure
involved.
2-31
2-32
OPERATION
INTRODUCTION
1
INSTALLATION
2
OPERATION
3
MAINTENANCE
4
WARRANTY & PARTS
5
3-1
OPERATION VHC-IOM-2012-0207 SECTION 3
! WARNING
Start-Up Preparation & Installation Review
reference and guidance purposes, Review the installation section of this manual carefully. Confirm accordance with
and does not substitute for required the Installation guidelines, including:
and strict adherence to applicable 1. You have read and followed all safety information.
regulations. 2. The equipment area is in conformance with established boiler room
requirements. Review national and local codes.
Do not operate, or allow others 3. There is total absence of water in pipework and fluid. To help the system,
to operate, service or repair this
open all drains; blow dry air or nitrogen if available into a high point bleed
equipment unless you (they) fully
understand all applicable sections through a pressure regulating valve.
of this manual and are qualified to
operate/maintain the equipment.
4. There are no obstructions left in the fluid circuit from pressure leak testing
such as blanking plates in flanged joints.
Defective or improperly installed 5. Pipework is free to expand naturally when hot. Open all valves to user
equipment is hazardous. Do not circuits including air bleed valves at high points and drains at low points in
operate equipment which is defective the piping system, and the liquid level test connections in the expansion
or improperly installed.
section of the combination tank.
Never leave an opened manual air 6. Heater is located with the proper clearances as shown in Installation
vent unattended. In the event an section of this manual.
opened vent is left unattended, water
or fluid damage could occur. The 7. Relief valves have been properly piped to a safe catchment.
exception to this warning is a feed
water deaerator manual vent cracked 8. Flue gas from the heater is properly vented.
open may be left unattended.
9. Combustion air openings are not obstructed in any way and have
adequate capacity.
Defective equipment can injure you
or others. Do not operate equipment 10. There are no flammable liquids, materials or hazardous fumes present in
which is defective or has missing parts. the environment.
Make sure all repairs or maintenance
procedures are completed before 11. Nothing was damaged or knocked loose during shipment and installation.
using the equipment. Do not attempt Inspect the main gas train and trim assembly to be sure they were not
repairs or any other maintenance
damaged during shipment or installation.
work you do not understand.
12. Local authorities where approval for start-up is required have been
notified. In some localities, final inspection of services may be required.
4 CAUTION
13. Installation checklist is complete.
Installation in accordance with the
guidelines within the manual should
be fully completed before performing Fill the System
the initial start-up; and start-up must
be complete prior to putting the unit The viscosity of thermal fluid is generally very high (500 cS) at ambient
into service. Starting a unit without temperature. Below 50°F (10°C) some fluids become very thick. Fluid should be
the proper piping, venting or electrical in a pumpable liquid form prior to filling the system. Refer to the thermal fluid
systems can be dangerous and may
manufacturer’s recommendations.
void the product warranty.
Adhere to the following when filling the system:
1. Refer to Figure 12 for the drain and fill connection.
3-2
SECTION 3 VHC-IOM-2012-0207 OPERATION
2. Filling must be carried out from the lowest point in the system in order to ! WARNING
prevent air pockets from forming.
Pressurizing a drum to force fluid into
3. A drain and fill point (generally a 3/4” threaded coupling) is provided on the system is not recommended. The
the inlet to the pump suction on skid-mounted units. drum may explode, creating a hazard
to personnel and equipment.
4. Typically a portable, high velocity pump, such as the type used for
chemical transfer, is appropriate for filling the system. Where only one or
During operation, any leaks are
two drums of fluid are required, a handheld pump may be practical.
usually detected by a small amount
of vapor. Leaks should be attended
¡ Filling Procedure for Systems Open to Atmosphere to as soon as possible because under
certain circumstances, such as
Adhere to the following: saturated insulation, thermal fluid
can ignite when exposed to air and
1. Follow the instructions in Fill The System section of this manual. heat.
2. Check to see that the liquid level switch operates freely. To confirm
operation of the liquid level switch, manually trip the liquid level switch.
Unit should shut down; pump will stop. 4 CAUTION
3. Fill the system slowly, closing all opened bleed and drain valves as fluid Do not use this equipment if any part
reaches them. has been under water (or subjected to
heavy rains/water if the equipment
4. When the fluid reaches and flows from the expansion tank low level does not have NEMA 4 wiring, controls
manual test connection, begin slowing down the filling process. and instrumentation). Immediately
call a qualified service technician to
5. Close the low level connection and continue to fill until the liquid level inspect the equipment and to replace
switch closes. After fluid appears in the low level connection, only a small any part of the control system and/or
amount of additional fluid should be required. gas control(s) which have been under
water.
6. If fluid is observed coming from the expansion section high level manual
test connection, drain fluid from the tank until the level is between the Commissioning/Start up by a non-
liquid level switch and the high level connection. Volcanic authorized person will void
the product warranty.
7. Filling is complete when the fluid has reached the lowest level in the
expansion tank required to actuate the liquid level switch.
Please read these instructions and
8. As oil reaches a vent, close it. After all vents have been closed, and you post in an appropriate place near the
believe the system to be full, stop filling. Start the circulating pump as equipment. Maintain in good legible
described in Initial Start-Up: Cold Circulation section of this manual. condition.
Leave the fill equipment connected as cleaning the strainer may create the
need for more oil in the system. The system pump is not to be used to fill
the system.
9. Verify to see that the liquid level switch operates freely. To confirm
operation of the liquid level switch, manually trip the liquid level switch.
Unit should shut down; pump will stop. A pump that has been used for water
or a different thermal fluid should not
be used prior to extensive cleaning.
¡ Filling Procedure for Systems Equipped with Inert Blankets Thermal fluid can be damaged by
contact with moisture or other fluids.
Adhere to the following:
1. Follow the instructions in Fill The System section of this manual.
2. Inspect the system to be sure all valves are open and all drains are closed.
3. Open all high point air vents.
3-3
! WARNING 4. Do not pressurize the system with nitrogen at this point.
All information in this manual is for 5. Inspect the liquid level switch (Figure 14) and be sure the switch is
reference and guidance purposes, functioning properly.
professional training, conduct, 6. Begin filling the system.
7. Fill the system until the liquid level switch indicates there is oil in the
regulations. expansion tank.
8. Pressurize the system slightly with nitrogen. Leave the high point vent
Wear eye and hand protection for connections open, as the nitrogen should be isolated from the vents by the
your safety. oil in the system. The pressure required in the system at this point is only
2-3 psi. If too much pressure is applied, the nitrogen will bubble through
Use extreme caution when opening the oil and vent to atmosphere. If this happens, reduce the pressure.
circulating pump plug if system
temperature is elevated. 9. Continue filling the system. If liquid level switch is made, be sure to
observe the high point vents as oil is now entering the elevated portion
of the pipe work. As oil reaches the vent, close it. After all vents have
Non-Volcanic product information
been closed, and you believe the system to be full, stop filling. Start the
circulating pump as described in Initial Start-Up: Cold Circulation
Volcanic document may substitute
section of this manual. Leave the fill equipment connected as cleaning the
available from the component strainer may create the need for more oil in the system.
manufacturer.
10. Determine the final nitrogen pressure by measuring the difference
between the D.A. Tank inlet and the highest point in the system. Divide
If a fire does occur, extinguish using CO2 that number by 2.31 (this will indicate the nitrogen pressure the system
foam or dry chemical. Do not use water. should be set for).
11. If the tank is located outdoors and the inlet to the tank is the highest point
in the system, then 1-2 psig of nitrogen is sufficient.
12. Adjustment can be made via the regulator mounted on top of the D.A.
tank.
´ NOTE: If you are using a fluid above its boiling point, the system must be
pressurized to overcome the vapor pressure of the fluid. Consult the factory for
assistance.
¡ Circulating Pump
1. Read manufacturer’s instruction manual thoroughly. If the pump is

supplied by Volcanic, manufacturer’s literature is included with this
manual.
2. Never run the pump without fluid in the casing. For pumps equipped
with mechanical or air-cooled seals, air must be bled out of the stuffing
box area to ensure that thermal fluid has lubricated all seal and bearing
areas. Operation of the pump even a short time without bleeding first will
damage the pump.
3. Use the thermal fluid as a barrier fluid. Remove the 3/8” plug at the barrier
fluid fill port. Fill the cavity with thermal fluid until it comes out of the
3-4
overflow tube. Replace the 3/8” plug. ! WARNING
¡ Pump With Mechanical/Air Cooled Seal reference and guidance purposes,
1. Open the air bleed connection located directly over the pump shaft. and strict adherence to applicable
Replace plug when a steady stream of thermal fluid, free of entrained air, jurisdictional/professional codes and
regulations.
flows from the port.
2. If flow has not started after two to five minutes, remove the coupling
guard and rotate the pump shaft by hand in the proper direction. This 4 CAUTION
should help move the cold viscous fluid through close tolerance seal areas.
Replace plug when flow is steady. Operation of the circulating pump
for any amount of time without first
3. If this fails to induce flow, introduce fluid through the bleed port and rotate bleeding will result in equipment
the shaft by hand to work the fluid around the seal area. Continue to add damage.
fluid and rotate the shaft until no more fluid can be added.
If fluid temperature exceeds 150 F
4. Replace the plug and run pump for five to ten seconds. Stop the pump,
during start-up and no flow has been
remove the plug and wait for flow to start. If after two minutes flow has established, discontinue start-up and
not started, add more fluid as described above and run the pump for five contact Volcanic Service Department.
minutes. Failure to do so may cause equipment
damage.
5. Constantly check the bearing area (located immediately behind the casing)
for overheating. Remove the plug and check for flow.
6. If flow has not started at this point, the fluid may be too viscous to move
through the seal area. Start the system normally by selecting heat on the
control panel, and raise the temperature 50°F. Continue to raise the system
temperature by 50°F increments. Keep checking the pump until flow starts.
´ NOTE: If at 150°F there is no fluid flow, discontinue Start-up procedures and

contact the Volcanic Service department immediately.
7. The pump should not be subjected to thermal or pressure shock. The thermal
fluid should, therefore, be allowed to flow into the casing slowly.
8. Check field work and make sure that all connections have been made in the
proper places. Check electrical connections to the motor.
9. Rotate the pump shaft by hand to be sure there is no binding or rubbing

within the pump or driver. Correct any problems immediately.
10. Check to see that pump is properly aligned while cold. The pump is properly
aligned before it leaves the factory. Because the system expands in operation,
the pump must be realigned when the system is at operating temperature.
11. Carefully check the coupling alignment of the pump and driver for angular
and axial alignment. Check pump manufacturers instructions for these
specifications. The use of a dial indicator to check the axial and angular
alignment is recommended.
12. Realign at operating temperature, if necessary.
3-5
! WARNING 13. Make sure that the pump is properly greased or oiled.

reference and guidance purposes, ¡ Pump with Packed Seal
Make sure that the gland is finger tight before filling the system.
jurisdictional/professional codes and Start-Up Service
regulations.
If start-up service has been included in the order, the factory should be contacted
Never attempt to operate equipment after the installation has been successfully completed and approved by the client’s
that has failed to pass all safety representative or engineers. Where possible, contact the factory at least three
checks. weeks before a Volcanic service engineer is required on site.
Consider the following in preparation for your on-site visit:

This heater is equipped with an
ignition device which automatically 1. All procedures covered in manual sections Start-Up Preparation and Fill the
lights the burner. Do not try to light
System, including installation review, air testing of piping, pump alignment
burner by hand.
(where applicable), and filling the system must be completed before the
service person’s arrival.
Operating this equipment beyond
its design limits can damage the 2. Depending on the size of the system and the amount of service time
equipment and can be dangerous. contracted, start-up service includes firing the heater, checking, verifying and
Do not operate the equipment adjusting all safety settings.
outside of its limits. Do not try to
upgrade the equipment performance 3. Careful preparation can expedite the commissioning of your heater. Most
through unapproved modifications. delays can be avoided by following the instructions in this manual. Failure
Unapproved modifications may to complete required procedures properly can result in the need for further
cause injury, equipment damage, and service time, at extra cost to the customer.
will void the warranty.
4. Service people will not commence start-up if there are obvious system
Before commissioning the unit, verify deficiencies. However, start-up service in no way constitutes a system design
with proper authorities that gas lines check or approval of the installation.
have been purged.
5. In addition to commissioning the heater, the service person will also
familiarize heater room personnel with the operation of all Volcanic
Check daily that the equipment area equipment. Personnel must be qualified to understand the basic operation
is free and clear of any combustible and function of controls.
materials, including flammable
vapors and liquids.
Initial Start-Up
These instructions are for use when the unit is being started up for the first
time, or after prolonged shutdown. They are to be used in conjunction with the
specific procedure information in manual section Routine Operation.
Cold Circulation
1. Turn on the main power switches.
2. Check for proper fluid level in the expansion section of tank. See Figures
11 - 13.
3. A centrifugal pump cannot be operated with the discharge valve closed

without heating up dangerously.
3-6
4. The pump should be started with the suction valve full open and the ! WARNING
discharge valve open a slight amount.
5. Check pump rotation. Operating the pump in reverse rotation may cause reference and guidance purposes,
extensive damage. and does not substitute for required
6. Turn the three position switch located on the front of the panel box door and strict adherence to applicable
to “Pump”. jurisdictional/professional codes and
regulations.
7. Jog the green pump motor starting button and observe the direction of
rotation. Rotation should be in the direction of the arrow shown on pump
casing. If the rotation direction is incorrect, turn the three position switch
back to “Off ” immediately. Change the wiring connections and recheck.
4 CAUTION
Do not use this equipment if any part
8. Check for proper alignment. Realign, at temperature.
has been under water (or subjected to
9. With the control switch set to “Pump” push and hold the pump start heavy rains/water if the equipment
does not have NEMA 4 wiring, controls
button, check all manual resets on pressuretrols. The circulating pump will
and instrumentation). Immediately
run, but the burner will not fire.
call a qualified service technician to
10. If the pump stops when the button is released, check for proper flow in the inspect the equipment and to replace
any part of the control system and/or
system, and review settings of high and low fluid pressure switches and
gas control(s) which have been under
differential pressure switch. Check liquid level switch.
water.
11. Check that all pressure gauge readings remain stable. Refer to Figure
16. Pressure exceeding 100 PSIG or identical readings at inlet and outlet A temperature exceeding 120°F** in
gauges indicate a closed valve. the boiler room may cause premature
failure of electrical components.
12. If an extremely high vacuum (i.e.15” Hg or more) is indicated on the Provisions should be made to maintain
compound gauge, the valve between the circulating pump and the an ambient temperature of 120°F**
combination tank may have been left closed. In this case, little or no or less (the panel box interior should
pressure will be indicated by other gauges. not exceed 125°F**). **Pumps, PLC or
ModSync panels may require lower
13. Check all piping, connections and users for leaks. Repair any leaks ambient temperatures or additional
immediately. cooling.
Filtering the System

1. Initially, readings on the gauge will indicate zero or slightly positive
pressure. During the first few moments of flow, this reading will go towards
vacuum, indicating that the strainer is becoming plugged.
2. Typically, a reading of 3” Hg or greater vacuum on the pump suction gauge

indicates that the strainer must be cleaned. The strainer screen should be
back flushed or pulled, cleaned and replaced.
3. In some cases, a positive pressure can be measured at the pump suction

gauge (due to the use of a nitrogen blanket or large positive head). This
should be noted and if the reading decreases by several inches or pressure,
check the strainer to ensure it clean.
4. Strainers should be cleaned by means of compressed air. A rag will merely

force the smaller particles into the mesh of the strainer. It is recommended
to place a lint free rag in the center of the strainer and blow air from the
outside, trapping the debris in the rag.
3-7
! WARNING 5. Allow the pump to run again for several minutes and repeat the filtering
process until pump suction pressure remains steady after cleaning. The
Before commissioning the equipment, amount of time which must be allotted for filtering varies with the system.
verify with authorized personnel that
the gas lines have been purged. 6. When the system is initially brought up to temperature, additional pipe
scale and welding slag will loosen and enter the fluid stream. This will be
Never attempt to operate a heater that trapped in the strainer causing vacuum at the pump suction.
has failed to pass all the safety checks.
¡ Boilout
After checking controls by manual
adjustment, make sure they are 1. Check for correct fuel feed. All air must be eliminated from fuel lines, gas
always reset to their proper settings. piping, preheaters, etc. by proper, approved methods.
Contact your Volcanic dealer before
modifying the equipment. 2. Open all manual valves in the fuel oil supply line. Do not run the fuel pump
dry or without fuel lines connected to fuel source. Do not allow the fuel oil
If any “Manual Reset” limit device trips pump to pull a vacuum.
DO NOT reset without determining
3. Check safeties.
and correcting the cause. (Manual
Reset Limits may include: flame
4. Disable N2 blanket if equipped and open vent line on DA tank.
safeguard, high or low gas pressure,
high temperature limit, high pressure 5. Set burner switch to “ON”. The burner will begin the call for heat if oil
limit)
temperature is below setpoint.
Never tamper with low water (liquid 6. With burner firing and pump running, keep checking the gauges
level) cutoff sensors or circuitry. indicating pump and circuit pressures. Make sure they remain stable.
7. In case of pressure fluctuations, stop the burner, but allow the pump to
WHAT TO DO IF YOU SMELL GAS :
continue to circulate fluid.
Do not use matches, candles, flame
or other sources of ignition to check 8. When pressures have stabilized, start burner again.
for gas leaks. Do not try to light the
appliance. Do not touch any electrical 9. Continue in this manner up to the maximum operating temperature.
switch; do not use any phone in your Throughout the initial warm-up, the expansion tank and its overflow pipe
building. Immediately call your gas
must be watched to detect the formation of steam, indicating the presence
supplier from a neighbor’s phone.
Follow the gas supplier’s instructions. of water. If this occurs, burner should be shut down.
If you cannot reach your gas supplier,
call the fire department.
10. If steam is forcing thermal fluid out of the expansion tank vent, turn
the heater off, but leave the pump on. This is to circulate the hot fluid
through the piping without flushing the steam too quickly. Once steam
If excessive amounts of thermal fluid and thermal fluid stop leaving the expansion tank unit, the heater can
are to be vented from the system,
be turned on. Increase the temperature very slowly to prevent fluid from
additional thermal fluid may be
being forced out of the tank.
required in the system. Contact
Volcanic for further information. 11. Continue bringing unit up to temperature slowly, with a temperature rise
not exceeding 100°F (38°C) per hour. Do not exceed specified maximum
Flash steam may be generated at any outlet temperature. In the absence of specific information, consult the
point up to the operating temperature. factory before proceeding.
Watch for gauge fluctuations.
12. Once up to temperature, check the fluid level in the expansion section by
If fluid or piping is added to the opening the high level manual test connection. If a permanent flow of fluid
system, the boilout procedure must results when this valve is opened, and if all previous precautions have been
be followed as water may have been followed, the expansion tank is too small for the capacity of the fluid in the
introduced to the system. installation. A larger tank must be installed.
13. After fifty hours of operation at operating temperature, check all flanges
3-8
and connections for tightness. ! WARNING
¡ Combustion reference and guidance purposes,
Before firing the heater familiarize yourself on the use of the controls, lighting,
and shutdown procedures.
} SEQUENCE OF OPERATION FOR GAS FIRED BURNERS regulations.
The burner is of forced design. The sequence of operation is as follows:
A qualified installer, service agency
1. The flame programmer opens the main gas valve once stable pilot flame is or the gas supplier must perform
established. installation and service on the fuel
delivery system.
2. Pressure regulators on both the pilot and main gas supply, supply pressure to
the proper level.
During system boilout, it is imperative
that all system legs or paths are open
´ NOTE: Note the maximum inlet pressure rating of each fuel train and supply a
to ensure flow throughout the system.
step-down regulator if required. Consult the Volcanic Companies if uncertain of the Never open a cool or unheated user
maximum inlet pressure requirements. leg of a system when the rest of the
system is above 210 F ( 99 C).
3. Combustion air is delivered by a centrifugal blower fan. An air switch monitors
the pressure and is part of the flame programmer safety interlock circuit.
Do not attempt to start the
4. The flame programmer monitors the safe operation of the burner. Functions equipment for any testing prior
to filling and purging the vessel.
include pre-purge of the combustion chamber, provision of ignition via the
A dry fire will seriously damage
ignition transformer and electrode, opening the pilot gas valve, monitoring
the equipment and may result in
the pilot flame signal via the flame sensor, opening main gas valves and property damage or personnel injury
providing post-purge of the combustion chamber. and is not covered by warranty. In
case of a dry firing event, shut off
5. The flame is monitored by a flame sensor. In the event of insufficient,
the fuel supply and allow the vessel
unstable, or non existent pilot or main flame, the flame sensor will cause a to cool to room temperature before
safety lockout of the flame programmer. Safety lockout can also be caused if fluid is reintroduced to the pressure
the flame sensor is improperly positioned or grounded. After fault has been vessel.
corrected, reset by pressing the reset button on the casing of the burner
control box.
When opening any drains on the
equipment or piping system, steps
} SEQUENCE OF OPERATION FOR ON/OFF BURNER should be taken to avoid scalding/
burning of personnel due to hot
The sequence of operation for the on/off burner is as follows:
fluids. Whenever possible, the system
1. Beginning with power on, limit switch closed, fuel valves closed, and should be cooled prior to opening any
temperature controller calling for heat, the flame programmer starts the drains.
cycle and the blower motor starts prepurge.
Use only your hand to turn valve
2. The air proving switch must be closed now. Air dampers remain in handles. Never use tools. If the
maximum position. handle will not turn by hand, don’t try
to repair. Forced or attempted repair
3. (Gas Pilot) Provided all safety interlocks are proven, ignition and pilot are may result in fire or explosion.
energized and a timed trial for pilot ignition begins. After the pilot flame is
proven, the main fuel valve is energized. Ignition is turned off when flame
is registered and the main gas valves open.
4. (Spark Ignition) Provided all safety interlocks are proven, the spark is on
and oil valves are opened. When the flame is proven, the spark is shut off.
3-9
! WARNING 5. When the fluid temperature reaches the off setting (typically the setpoint
plus 2 to 5 degrees) of the operating temperature controller, all fuel valves
All information in this manual is for are closed.
and does not substitute for required The burner motor stops and the entire system is ready for restart on demand.
and strict adherence to applicable } MODULATING BURNER
regulations. The function of the flame programmer must be greatly extended in a modulated
system. Along with limit controls, operating controls and interlock devices, the
Should overheating occur or the gas programmer automatically controls the operation of the burner, blower motor,
supply fails to shut off, manually shut ignition, main fuel valves and modulating motor (or servo motors).
off the gas supply external to the
equipment .
The sequence of operation is as follows:
1. Beginning with power on, limit switch closed, fuel valves closed, and
modulating limit controller closed and calling for heat, the flame
programmer begins its cycle and the blower motor starts prepurge.
The modulating circuit closes, driving the air dampers to maximum for
prepurge.
2. The air flow proving switch must be closed now. After timed prepurge,
the modulating motor (servo motor) drives the air damper to its low fire
position. All start interlocks must be proven or the flame programmer will
lockout.
3. (Units with Gas Pilot) Ignition and pilot are energized and a timed trial for
pilot ignition begins. After the pilot flame is proven, ignition turns off and
the main fuel valve is energized. Pilot fuel is turned off and the modulating
motor (servo motor) is released to automatic.
4. (Units with Spark Ignition) The spark and oil valves are energized and a
timed trial for ignition begins. With the flame proven, the control advances
through its main light off sequence, and the ignition shuts off. At this time,
with the flame proven, the modulating motor (servo motor) is released to
automatic.
5. When the modulating motor (servo motor) is released to automatic,

it receives its signal from the modulating temperature controller. The
modulating motor (servo motor) then drives the modulating fuel valve and
air damper in proportion to the heat demand.
6. During the initial call for heat, the modulating fuel valve and air damper will
drive to their full-fire position. As the temperature set point is approached,
the modulating motor (servo motor) will continue to reduce the input until
low-fire position is reached. Input automatically increases and decreases
according to load demand.
7. When the fluid temperature reaches the set point of the temperature
controller or of the optional operating limit controller, all fuel valves will
close and the flame programmer will advance to the post purge cycle.
When the postpurge cycle begins, the modulating motor will be in the low
fire position. At the end of postpurge, the burner motor stops and the entire
system is ready for restart on demand.
3-10
} OIL FIRED BURNER ! WARNING
The following refers to the design and operation of the on/off burner utilizing All information in this manual is for
fuel oil which requires no preheating. This burner is of high pressure, mechanical reference and guidance purposes,
atomization design. and does not substitute for required
The sequence of operation is as follows: and strict adherence to applicable
1. An oil pump is used to obtain necessary atomizing pressure before the fuel regulations.
oil reaches the nozzle. The fuel oil is divided into fine particles in the nozzle
and imparted with a rotating motion before escaping from the nozzle as a
cone of finely atomized oil. Non-Volcanic product information
2. Combustion air is supplied by a centrifugal fan. A damper provides Volcanic document may substitute
throttling of the inlet opening. The air from the fan reaches the burner for full review of documentation
head after going through a turbulator, accomplishing correct distribution available from the component
manufacturer.
and mixture of air and atomized fuel oil.
3. An electric spark between two electrodes provides ignition of the

atomized mixture, except where code requires a gas pilot. This spark is 4 CAUTION
produced by a high voltage transformer.
Unburned oil, unlike gas, does not leave
4. The flame programmer circuit controls normal operation of the burner. the combustion chamber during purge.
The sequence includes purging of the combustion area for a set period,
ignition and opening of magnetic valves on the oil circuit; post-purge of
combustion area and return to re-start position.
5. A scanner mounted on the burner casing and facing the light of the flame
monitors the flame.
6. Safety lock out occurs within a preset minimum time in the event of
insufficient, unstable or non-existent flame. After fault has been corrected,
reset programmer by depressing the reset button on the casing of the
burner control box.
7. Proper fuel pressure at the burner nozzle is essential. The correct firing rate
is obtained by setting the fuel oil pump to give the design pressure for
each unit. This is done at the factory. Pressure is measured by connecting
a 0-400 PSI (0-25 bar) test pressure gauge to the gauge connection on the
fuel pump. The fuel pressure gauge indicates the pressure of the fuel at the
burner nozzle.
8. Typical pressures range between 160-350 PSI (12-22 bar). Note the correct
setting upon commissioning. Modulating units should have a second
pressure gauge monitoring the pressure in the return pipe from the burner.
This gauge will indicate the variation of oil flow caused by modulation of
the burner. Gauge readings should be recorded at start-up and checked
periodically.
} POWER FLAME GAS BURNER

Adhere to the following for safe starting:
1. Check gas piping, controls and valves for leaks and compliance with code.
2. Check all linkages.
3-11
4 WARNING 3. Close main gas cocks and pilot cocks. Disconnect pilot line at inlet to the
pilot pressure regulator and purge air from gas pilot line. After purge, close
All information in this manual is for pilot clock and reinstall line. Open pilot cock. Refer to flow and instrument
reference and guidance purposes, drawing for proper gas pressure and CFM required.
professional training, conduct, 4. Check electrode spark gap (see burner manual)
jurisdictional/professional codes and 5. Install gas pressure gauges (if not installed), one at manifold and one
regulations. upstream of burner gas train.
6. With main gas cock closed and control power off, turn main power supply
on.
Volcanic document may substitute 7. Switch control power to “on” position.
available from the component 8. Check blower motor rotation.
manufacturer.
9. Start burner and check pilot. Adjust pressure regulator if necessary.
10. After adjusting pilot with main gas cock still closed, check the combustion
safety controls.
11. With interrupted pilot, the burner should go into safety after trial because
main cock is closed.
12. Also check by closing pilot cock after pilot is established. The burner should
complete its sequence without attempting to open main gas valve.
13. Reset combustion control and start burner on normal sequence using
meter to observe the signal strength to pilot. When main gas valve opens,
slowly open main shut-off cock.
14. Proceed with adjustments that will give 9 to 9 1/2 % CO2 at low fire and no
CO2 at high fire.
15. Advance control to start position; recycle the burner several times to full
automatic.
16. Check the gas meter for firing rate. Adjust the gas pressure regulator to
proper firing rate.
} ON “FULL MODULATION” BURNERS

1. With fuel selector on “gas” (if combination burner) the heater should be
started in the low fire position.
2. Manually increase fire rate to midway point. Take CO2 reading and readjust
if necessary.
´ NOTE: Linkage may be manually set by loosening and hand tightening set screws
on linkage rod.
3. Control checks: Allow burner to run until limit control setting has been
reached; the burner should shut down when maximum temperature is
reached.
3-12
} POWER FLAME #2 OIL BURNER 4 WARNING
Checklist for safe starting All information in this manual is for
1. Check all oil piping for leaks. and does not substitute for required
2. Check all linkages, especially for damage incurred in shipment.
3. If not installed, mount oil pressure and temperature gauges. jurisdictional/professional codes and
regulations.
4. There should be NO shut off valve installed in fuel return line.
5. Check electrode spark gap as specified in burner manual.
6. Once properly authorized service personnel have set burner linkage, it is Volcanic document may substitute
advisable to permanently mark the linkage settings for future reference. for full review of documentation
manufacturer.
} DUAL FUEL BURNER  CHANGING FUEL
The following instructions apply only to units supplied with dual fuel burners.
These procedures should be performed only when the fluid is cold, unless
sufficient safeguards are provided to prevent contact with hot fluid piping in the
vicinity of the burner.
1. Set the fuel switch to “Off ” and the heat selector switch to either “Pump” or
“Off.”
Gas to Oil
1. Turn off the manual gas cocks in the gas train.
2. Remove the gas nozzle orifice assembly from the burner.
3. Install the oil nozzle assembly and attach the oil whips to the assembly.
4. Open all oil manual shutoff valves.
5. Set the fuel selector switch to the proper fuel. Restart unit normally
Oil to Gas
1. Turn off all oil manual shutoff valves.
2. Detach the oil whips and remove the oil nozzle assembly.
3. Install the gas nozzle orifice assembly and open the gas cocks in the gas
train.
4. Reset the hi/low gas pressure switch.
5. Set the fuel selector switch to the proper fuel. Restart unit normally.
Expansion Tank Start-Up

Refer to Figure 13 for expansion tank start up and proceed as follows:
1. Load system by attaching hose to valve”C”. Valves “A” and “B” are to be
closed.
3-13
! WARNING 2. Start auxiliary rotary gear pump (provided by customer). Then start main
All information in this manual is for circulating pump.
3. Load system with heat transfer fluid until surge tank overflows into
expansion tank with at least three inches of fluid (viewed through sight
and strict adherence to applicable glass).
4. Shut off auxiliary pump and turn off valve “C”.
regulations.
5. Open valve “A”. The system is now filled.
is for reference purposes only. No 6. The fluid level in the expansion tank is to be adjusted by opening valve
Volcanic document may substitute “D” and “F”. When the liquid level in the cold seal and expansion tank are
for full review of documentation equal, close valve “D” and “F”.
manufacturer. 7. If draining of the fluid is desired, open valves “D”, “E”, and “F”. The surge tank
is drained by opening valve “C”.
8. Upon initial start up, the fluid levels should be as follows:
§ Cold Seal Tank-4-6’’ full from bottom of sight glass
§ Expansion Tank-1/4 full
§ Surge Tank-Completely full
9. Surge tank must remain full for operation; if fluid levels drop after starting
pump, add oil from outside source.
10. Valves “B”, “C”, “D”, “E”, and “F” are to remain closed during normal operation.
Flame Programmers
¡ Fireye Linkage Modulation, YB110/E110
The Fireye Linkage Controls come complete and wired from the factory, with
no programming necessary. Please refer to the Fireye cut sheet for specific
programmer information.
} GASFIRED/DUAL FUEL UNITS

Gas-fired/dual fuel units come with a UV Scanner and amplifier module as
standard. Self-checking scanners are offered as an option by request.
} OILFIRED UNITS
Oil-fired units come with an IR Scanner and amplifier module as standard.
} YZ300/E300 ANNUNCIATOR
Most Volcanic units come with the YZ300/E300 expansion module with panel-
mounted display. This display will read first out annunciation of any recycled or
safety limits wired into the Fireye module.
Both annunciators come pre-programmed from Volcanic with application
3-14
specific display messages. Please refer to Fireye cut sheet or contact Volcanic for ! WARNING
assistance with annunciator programming.
¡ Siemens Linkageless Modulation, LMV 51 Volcanic document may substitute
} SETTING PILOT available from the component
manufacturer.
1. Verify the main burner switch is in the OFF position.
2. Supply power to the heater. The AZL will display “system test” and then
move to the main menu. 4 CAUTION
3. Select PWLogin, press Enter. Select AccessServ. Press Enter. (This type Do NOT leave unit unattended in
of step will be shown as PWLogin > AccessServ for the remainder of this Manual Operation, in this mode the
section. Enter the service passwords using the arrow key. The password is LMV51 will ignore its internal Set Point.
case sensitive. The case of a letter can be changed by pressing the other
arrow key. (For example, if you used the right arrow key to get to the letter
A, press the left arrow key to get a). After you have pressed Enter on the last
character of the password, press Enter once more to accept the password.
If you do not have the password, contact your Volcanic Authorized
Representative to perform the changes. Service=NB# or OEM=AAAA (Enter
after each A).
4. Select Params&Display. Press Enter. Select Ratio Control. Press Enter.

Select ProgramStop. Press Enter. Change the Program Stop to 44
Interv1 by using the arrow keys. Confirm the change by pressing Enter.
This will set the burner management system to a ‘pilot hold’ setting.
5. Verify that the current value “curr” changes to 44 Interv 1.
6. The full listing of program stops are:
» 24: Air damper in the prepurge position

» 32: Traveling to the FGR position
» 36: Ignition position (before pilot ignition)
» 44: Ignition position (after pilot ignition)
» 52: Ignition position (after main burner ignition)
» 72: Air damper in the postpurge position
» 76: Traveling to the FGR position
7. Press Escape 4 times to get back to the main menu.
8. Under ManualOperation > Setload, change the load to 0% by using the

arrow keys. Press Enter and verify the 0% has been acknowledged in the
“curr” field.
9. Press Escape once to get back to the ManualOperation menu.
10. Under Auto/Manual/Off, change the operation to Burner On by using the

arrow keys. Press enter and verify that “Burner On” is acknowledged in the
current field.
3-15
4 WARNING 11. Press Escape twice to get back to the main menu.
Non-Volcanic product information 12. Turn the main burner switch Local or On position.
Volcanic document may substitute 13. Increase the set point. Under operation-Heater set point go to setpoint
for full review of documentation W1 using the arrow key then press Enter. Change the set point under new,
available from the component using the arrows and press Enter. The new set point should appear under
manufacturer. actual and displayed in degrees.
14. After several seconds the burner control will start its pre-ignition phase
and the blower will start.
15. You can observe the status of the burner by going to the main menu (by
pressing Escape) then selecting Operational Stat > Normal Operation.
16. The unit will purge then drive to the ignition position and the pilot should
light.
17. The burner control will stay at this pilot hold stage so you can inspect and
adjust the pilot as needed.
18. The pilot gas pressure should match the test fire sheet.
19. The flame signal should be greater than 90% when viewed from the top
menu of the Siemens AZL display.
20. Once the pilot is adjusted properly and you are ready to light the main
burner, press Escape to the main menu.
} SETTING MAIN BURNER IGNITION

1. Under Params&Display >RatioControl >ProgramStop, change the
Program Stop to 52 Interv2. This is the main burner ignition position.
Press Enter and confirm that 52 Interv2 is acknowledged in the current
field. This change moves the control to the main burner ignition point in
the burner sequence.
2. This will allow the main burner to ignite. Should the burner not light, the
gas and air servo motors are not synchronized to produce a combustible
mix.
3. Turn the ON/OFF switch on the panel box to OFF.
4. To reset the alarm: Press Escape on the AZL once. Press Enter on the AZL
to reset the control. The red light should go out.
5. To change the setting, return to the front menu by pressing Escape until
you are to the main menu. Then select Params&Display >RatioControl
>GasSettings >SpecialPositions > IgnitionPos, adjust the gas servo
position by using the arrow key to move down to Gas servo if needed.
Press Enter to select the servo. Move the gas servo to its new position with
the arrow keys. Press Enter to confirm the new value. Use the down arrow
to move to the air servo setting if needed. Press Enter to select the servo,
use the arrow keys to set the new value. Press Enter to confirm this.
6. Switch the ON/OFF switch back to ON. The heater will re-start.
3-16
7. The light off point for main flame can be set at a higher input than low 4 WARNING
fire.
8. Press Escape 6 times to get back to the main menu. is for reference purposes only. No
9. You can observe the status of the burner by going to OperationalStat > for full review of documentation
NormalOperation. available from the component
manufacturer.
10. Verify that the flame signal on the display is great than 90% and check
combustion. Adjust the burner to match the test fire sheet for main burner
ignition. The procedure described in Setting Main Burner Ignition is used.
11. Once the ignition position has been adjusted properly, you are ready to
check the burner throughout its modulation range. Press Escape twice to
get back to the main menu.
} SETTING MAIN RUN MODULATION

1. Upon releasing the heater to main run modulation, the heater will drive to
low fire.
2. It is necessary to set/check combustion through the entire range of

modulation first to enable high fire to be reached. Once high fire is
achieved, the incoming gas pressure can be set (if required). Fine-tuning
of the servo setting throughout the range should be performed only once
high fire settings are confirmed.
3. Note: If the burner loses flame while driving to a point then:
» Turn the main ON/OFF switch to OFF.

» Reset the loss of flame fault.
» Press Escape on the AZL once.
» Press Enter on the AZL to reset the control. The red light on the
panel box door should go out. Adjust the air and gas servos for
that point while the burner is off.
» Follow steps below.
» Turn the main ON/OFF switch to ON.
4. Under Params&Display >RatioControl >GasSettings >ProgramStop,
change the program stop to deactivated by using the arrow keys. Confirm
that ‘deactivated’ is acknowledged in the current field.
5. This change will allow the burner to modulate. The burner will now drive
to low fire. Remember, it is only important at this stage to set low fire to be
stable and with clean combustion. Exact setting is to be performed once
high fire is confirmed.
6. Press Escape 5 times to get back to the main menu.
7. You can observe the status of the burner By going to OperationalStat/

NormalOperation.
8. Verify the flame signal on the display, measure input if gas meter is
3-17
! WARNING available. If not, match last elbow pressures and combustion for test fire
sheet. Adjust the burner as needed.
Do not operate, or allow others
} SETTING LOW FIRE
understand all applicable sections
´ NOTE: As soon as a servo position is altered, the servo will move to that position.
Only change servo settings by a maximum of 0.5° at a time before verifying
combustion.
Non-Volcanic product information 1. Go to Params&Display >RatioControl >GasSettings>CurveParams.

Volcanic document may substitute 2. Wait for the spinning line on the left to disappear. Press Enter. The number
for full review of documentation 1 should appear to the right of the cursor, this is the Point Number.
manufacturer. 3. Press Enter once. Select ChangePoint by pressing the arrow keys to
highlight and then press Enter to select. This will cause the servo motors to
move to this low fire point.
4. Check combustion and adjust the servo motors as required. To adjust

a servo motor, arrow to it and press Enter. Then adjust the setting as
required and press Enter. You can now adjust another servo motor if
needed.
5. When combustion is properly set for that point, press Escape. If it asks you
to store the point, press Enter. Note the AZL will only ask to save if either
servo value has been altered.
6. Low fire is now set and stored.
} SETTING THE COMPLETE RANGE

1. Remember it is only necessary to approximate the setting through the
modulation range until high fire conditions are established.
2. Press Enter once more to have access to the point number field. Increase
the point number by one and press Enter. Select ChangePoint and press
Enter. The servos will now move to that point.
3. Verify combustion is satisfactory.
4. Measure input or monitor last elbow pressure. Verify that these points are
in general correspondence with the test fire sheet. Repeat step 2 until the
point position has a load value of 100%.
5. You are now at high fire. Verify combustion is per test fire sheet.
6. Once at high fire, adjust the incoming gas pressure at the main gas
regulator to match the test fire report. Adjust the gas servo motor to
change the last elbow pressure to match the test fire report.
7. Adjust the air servo motor to adjust the emissions as needed.
8. Repeat step 2 but start at the high fire point number. Continually decrease
the point number after combustion has been verified at each point.
9. Once all the points have been verified, press Escape until you are back to
3-18
the main menu. ! WARNING
10. You can observe the status of the burner by going to OperationalStat Do not operate, or allow others
>NormalOperation. to operate, service or repair this
11. Turn the main ON/OFF switch to OFF. The control will now postpurge. understand all applicable sections
Verify ignition using steps from Setting Main Burner Ignition with the new of this manual and are qualified to
gas pressures. operate/maintain the equipment.
12. Turn the main burner switch to OFF. The control will now post purge.
13. Under Manual Operation > Auto/Manual/Off, change the operation is for reference purposes only. No
to Automatic and press Enter and confirm Automatic is entered in the Volcanic document may substitute
current field. for full review of documentation
14. Press Escape twice to get back to the main menu. manufacturer.
15. Under Updating >ParamBackup, select LMV51 – AZL. This will store all
of the adjustments that have been made in the LMV base module to the
display. If the base module fails in the future, the display can be used to
download all of the parameters into a new base module.
16. The heater is now ready to run. Adjust your setpoint on the temperature
control to the desired temperature and turn the main ON/OFF switch to
ON for the burner to operate.
} CHANGING SET POINT ON THE AZL

1. Hit Escape to Select Operation than hit Enter and scroll to Heater Set
point, hit Enter to Set point W1 hit Enter and enter new set point with
Select buttons.
2. When accomplished hit Enter than Escape 3 times to Operational Stats

hit Enter to Normal Operation, hit Enter to get to the main screen.
} FOR MANUAL OPERATION

1. Hit Escape and scroll to Manual, hit Enter to Auto / Manual / Off, change
to Manual and hit Escape to Set Load, change to 0 or desired load range
with the select buttons.
2. When in Manual it will allow you to go to any load range to verify

combustion.
3. When done hit Escape and scroll to Operational Stats, hit Enter to
Normal Operation, hit Enter to main screen.
4. To return back to Auto operation repeat step 1 & 2.
5. Please refer to this manual’s addendum for information on specific LMV 51

control parameters.
´ NOTE: Do NOT leave unit unattended in Manual Operation, in this mode the LMV
51 will ignore its internal Set Point.
3-19
! WARNING
Operating Controls
is for reference purposes only. No The following specifications, data, equipment and operating descriptions apply
Volcanic document may substitute to typical heaters. These sections are provided for general information purposes
for full review of documentation only, and do not necessarily reflect the specific details of individual systems.
manufacturer. At commissioning, the operation of all safeties and interlocks should be verified.
Setpoints of all pressure and temperature switches as well as the programs for
all programmable controls (temperature controls, temperature limits, operating
to operate, service or repair this controls, servo motors etc.) should be recorded for future reference. Contact the
equipment unless you (they) fully Volcanic Service Department with any questions regarding the proper operation,
understand all applicable sections set points and verification procedures for these controls.
¡ Liquid Level Switch - When Combination Tank is Supplied
1. Locate the liquid level switch (ships in the parts box, see Figure 14) and
install prior to operation of the equipment. The liquid level switch is wired
to the main heater panel. Failure to “make” this switch will result in lack of
power at the panel.
2. In the event of system fluid loss, the level in the expansion section of the
combination tank will drop, and the liquid level switch will shut the unit
down. Control power will be lost to the panel.
3. To confirm operation, manually trip the liquid level switch. Unit should
shut down; pump will stop. Refer to Figure 14.
¡ Air Safety Switch

1. The air safety switch is installed in the heater panel and is connected
by tubing to the blower outlet. This switch requires that the blower fan
deliver combustion air before energizing any fuel valves.
2. While firing, disconnect the copper line from the fitting in the top cover of
the air switch. The burner should shut down. Attempt to restart the unit by
resetting the flame programmer.
3. Blower motor will start, but firing sequence should not begin.
4. Lockout of LMV will occur.
¡ Blower Motor Starter

´ NOTE: For units equipped with manual trip test button or motor starter.
1. While firing, actuate the manual trip button on blower motor starter. Unit
should lock out. Attempt re-start by resetting the flame programmer.
Purge cycle will not begin.
2. Reset motor starter; blower should start and purge cycle will begin.
3-20
3. Lockout of LMV will occur. ! WARNING
¡ Pump Motor Starter to operate, service or repair this
If a pump starter is supplied the pump motor starter will be located in the heater
panel or pump skid. When the pump start button is pushed, the pump motor
starter will engage the pump. operate/maintain the equipment.
1. While firing, actuate the manual trip button on the pump motor starter.
2. Pump and burner will shut down. is for reference purposes only. No
3. The blower should continue to run for approximately 30 seconds. for full review of documentation
4. Attempt to restart pump by depressing the pump start push button.
manufacturer.
5. The pump should not start. Reset starter and start pump.
¡ Differential Pressure Switch

The differential pressure switch (Figure 19) is mounted to the heater panel.
Sensing lines connect this switch to both the inlet and outlet manifold of the
heater. This switch is critical and ensures proper flow through the heater at all
times.
1. Proper setpoint is 2 psi below the published differential pressure of the

heater.
´ NOTE: The differential pressure will vary with heater model.
2. The heater is dependent on proper flow for operation; therefore, a

differential pressure switch is used to sense the pressure drop across the
heater. The differential pressure switch will shut the unit down in the event
of loss of flow.
3. The differential pressure switch can be tested while only the pump is
running. Remove the metal cover on top of the switch and increase the
FIGURE 19 - DIFFERENTIAL PRESSURE SWITCH
3-21
! WARNING setpoint until the pump shuts down. Next, decrease the setpoint back to
its initial value and depress the pump start button to verify the pump will
Do not operate, or allow others re-start.
understand all applicable sections ¡ High and Low Fluid Pressure Switches
The heater is equipped with a low inlet, high inlet and high outlet pressure switch.
The switches are located on the side of heater panel with tubing connections
to the respective heater inlet and outlet manifolds. The switches are used to
Non-Volcanic product information ensure proper flow through the heater (no restrictions in the piping system). The
switches must be set at startup and the setpoints are based on the system design/
performance.
available from the component 1. The only pressure required in the thermal fluid system is the pressure required
manufacturer.
to maintain the proper flow. Pressure changes are monitored with these
switches, which will shut the unit down in case of a change in the fluid flow.
2. With three position switch set to “Pump”, remove the cover from the pressure
switch and manually activate. Pump should shut down.
3. Repeat for each switch; replace covers. Note, if the burner was on, it would
also stop.
4. To set the low fluid pressure cutout switch, raise the setpoint with the fluid at
operating temperature and pump running, until the pump shuts down. Note
the setpoint and lower by 10 PSI, then re-start pump. The setpoint at cutout
should correspond to the reading on the output pressure gauge.
5. With the unit cold and pump running, lower the high fluid pressure cutout
switch until the pump shuts down. Note the setpoint and raise by 10 PSI, then
re-start pump. The setpoint at cutout should correspond to the inlet gauge
reading.
¡ Gas Pressure Switch

´ NOTE: Gas Fired Units Only
The high and low gas pressure switches are located on the gas train. See Figure
20. The switches are used to ensure that the incoming gas pressure and gas
pressure to the burner are within the appropriate range.
1. While firing, shut the main gas ball valve.
2. Unit will lock out on high gas pressure.

3. Attempt restart by resetting flame programmer.
4. Unit will start purge and lock out.
5. Open the gas valve closest to the burner and reset flame programmer.
6. Reset high side of switch, unit will start purge and fire.
7. To test the low gas pressure switch, close the incoming manual valve.
8. Allow the control to sequence.
3-22
! WARNING

FIGURE 20 - HIGH/LOW GAS PRESSURE SWITCH available from the component
manufacturer.
9. When the gas valves energize, the heater should lock out.
10. Reset the low side of the switch and open the upstream manual valve.
11. The unit will start purge and fire.
¡ Operating Temperature Controls

The operating temperature control (Siemens, Fireye, Honeywell) are located
in the heater panel and regulate the cycling of the heater. On systems with
linkageless modulation, the operating temperature control and operating control
(flame programmer) are the same device.
1. The Coil Design unit is a fired heat exchanger and the safe control and
monitoring of the thermal fluid temperature is of vital importance. The safe
maximum temperature of the fluid must be strictly adhered to.
2. When consulting fluid manufacturer’s literature for the safe maximum fluid
temperature, note that the temperatures quoted are the actual limit to
which any of the fluids may be subjected. It is important to remember that
in any fired heater there exists a “film” temperature which is higher than the
temperature of the bulk of the fluid. Temperature controllers measure the
bulk temperature and not the film temperature. This must be taken into
consideration when setting the temperature controls.
3. Approximate guidelines for temperature settings are not to override the

system design parameters.
4. These instructions should be used in conjunction with information from

the system designer. Consult manufacturer’s literature.
5. Standard primary temperature control sensing point location for On/Off

and Modulating heaters is on the heater outlet. For systems with multiple
heaters manifolded together, the sensing point is on the heater inlet.
6. When optional inlet location of the primary controls is specified, the

following instructions may still be used with some modification. For
instance when primary controls are located on the inlet, the dead band
range will be much narrower than on heaters with outlet control. In
addition, temperature changes will not be as immediately apparent.
3-23
! WARNING 7. An indicating temperature controller is used to regulate the thermal fluid
temperature. Typically the indicating control is a thermocouple.
To ensure that your Volcanic
equipment is kept operating 8. The thermocouple is directly immersed in the thermal fluid in the heater
safely and efficiently, follow the manifold. The setpoint of the controller is regulated by the keypad.
maintenance procedures set forth in
this manual.
¡ High Temperature Limit Switches Safety
The end user of the heater must All units are fitted with high temperature limit controllers which monitor the fluid
maintain all labels on the heater temperature at the heater outlet. This limit controller provides over temperature
in clean, legible condition. All protection. A high temperature limit switch acts as an over temperature safety
connections and safety devices, both device.
mechanical and electrical, must be
kept clean, with ease of access for 1. If the high temperature limit shuts down the unit, the manual reset button
inspection, use and maintenance. on the limit switch must be pressed after determining and resolving issue.
The red button on the flame programmer (or door reset) must also be
pressed to reset the unit before it can be restarted.
2. The high temperature limit controller is factory set to 0 F. This must be set
to the lowest of the following:
» Maximum operating temperature of the fluid.

» Maximum operating temperature of the equipment.
» 15°F (9°C) over maximum system operating temperature.
3. Do not set this controller too close to the normal outlet temperature in
order to avoid nuisance lockouts due to small transient over temperatures.
4. Several consecutive lockouts caused by the high temperature limit

controller indicate the need for immediate installation review.
¡ Operating Limit Controller

The limit controller is mounted in the panel box door. This limit controller senses
temperature in the outlet manifold. The temperature setpoint in the controller
may be adjusted per manufacturer’s instructions.
¡ On/Off Controls
Typically one controller is provided to sense the temperature on the heater
outlet. This controls the operation of the heater by switching it on and off.
1. An adjustable two point differential between shut off and start up is

built into the controller. This prevents frequent cycling of the burner. The
controller is set to provide the desired outlet fluid temperature. Due to the
temperature rise through the unit, this may be considerably higher than
the inlet temperature.
2. If the unit is equipped with an on/off controller, it will be located on the

face of the electrical cabinet. The temperature setpoint in the controller
can be adjusted following the manufacturer’s instructions.
3-24
¡ Modulating Controls ! WARNING
All coil models are standard-equipped with modulating controls. Do not operate, or allow others
1. The modulating temperature controller continuously regulates the outlet equipment unless you (they) fully
fluid temperature between the minimum firing rate and high fire. When understand all applicable sections
the unit is on low fire and the temperature continues to climb past the of this manual and are qualified to
setpoint, the heater will shut down. It will typically re-start when the operate/maintain the equipment.
process temperature drops 7°F below setpoint.
2. Minimum load depends on the degree of modulation provided. Typically

3:1 or 5:1 modulation is provided. In this case minimum load is one third of
full firing rate.
3. The modulating temperature controller is set to maintain the desired fluid

outlet temperature. Due to the temperature rise across the heater, this may
be considerably higher than the inlet temperature.
4. If the unit is equipped with a modulating controller, it will be located on

the face of the electrical cabinet. The temperature setpoint in the controller
can be adjusted following the instructions in the component data sheet
section of this manual.
¡ Pressure Gauges
All units have two pressure gauges measuring the thermal fluid pressure at the
inlet of the heater and at the outlet of the heater. A third gauge measures the
pump suction pressure.
1. The difference between the readings of the two gauges indicates the
pressure loss across the heater. The difference must not fall below the
recommended value. Recommendations are based on heater size and are
listed in manual and on the product data submittals on www.volcanic-
heater.com.
2. The gauge indicating the pressure of the fluid at the inlet is labeled “Inlet“.
The “Outlet” gauge indicates the pressure at the outlet, and in effect
indicates the resistance of the external pipework circuit. The pressure
gauge indicating pressure at the inlet of the pump is labeled “Suction.”
¡ Test of Ignition Safety System Shutoff

Test the ignition system safety shutoff as follows:
1. Shut the pilot valve.
2. Close the last gas valve between the inlet to the burner and the butterfly
valve.
3. With the main gas cock (inlet manual gas valve) open, the burner should
be cycled on. After all the safety limits such as gas pressure, water flow and
temperature are satisfied, the blower will run and pre-purge the heater.
4. Once the purge is complete (30 seconds), the ignition transformer will be
energized. There will be a 4 second trial for ignition period. During this
3-25
! WARNING period, indicator lights on the flame safeguard (pilot and main).
All information in this manual is for 5. With no flame established, the flame safeguard will not receive a flame
reference and guidance purposes, signal from the scanner.
professional training, conduct, 6. After 4 seconds, the flame safeguard programmer will assume a “Flame
and strict adherence to applicable Failure” condition and go to a “lockout” mode. Lockout will require manual
jurisdictional/professional codes and reset of the flame safeguard.
regulations.
7. After completing this test, open the gas valve.
¡ Cycle Testing
The heater should be cycled tested and automatically allowed to go through
its normal starting sequence several times to verify that all components are
functioning properly. This will also verify that combustion is set properly so that
heater light off has a smooth transition from ignition to main flame.
A minimum of 10 cycles should be met without any flame failures, with

combustion readings comparable to the factory test fire sheet and no interlocks
causing the heater to shutdown.
Required Pressure Drop Across the Heater

The thermal fluid pressure drop across your heater is critical. This should be
recorded at the completion of start-up, as follows:
1. The pressure drop value is obtained by subtracting the heater outlet

pressure from the heater inlet pressure when the thermal fluid is at normal
operating temperature.
2. At the recommended standard flow rates, and .7 sp gr, the pressure drop
cross the heater should be as shown in Table 9.
3. In the event of an abnormal reading, contact Volcanic Service immediately.

Failure to take immediate action in the event of reduced fluid flow may
result in rapid and serious degradation of the fluid, with possible damage
to the heater.
TABLE 9 - REQUIRED PRESSURE DROP ACROSS THE HEATER
Model Recommended GPM (schedule 40) Pressure Drop PSI

0240-HC 150 30
0400-HC 300 25
0600-HC 400 26
0800-HC 600 26
1000-HC 850 30
1200-HC 1000 27
1600-HC 1200 11
2000-HC 1500 11
3-26
Procedure for First Shutdown ! WARNING
The heater system should be shut down after no more than 24 hours of reference and guidance purposes,
operation at full operating temperature. At this time, the following maintenance and does not substitute for required
items will need to be completed to meet warranty conditions. professional training, conduct,
1. While pump is still at operating temperature, align circulating pump(s) to jurisdictional/professional codes and
pump manufacturer’s specifications. This should be done by means of a regulations.
dial indicator.
2. Isolate Y-strainer(s) in system and clean regardless of pump suction

pressure. Make sure that the temperature is low enough to handle safely
or provision has been made to handle materials at high temperature.
Generally, temperatures below 150°F (65.5°C) are acceptable to perform
operation with regular work gloves.
3. With piping system cooled to ambient temperature, torque all bolts on

skid and throughout system to gasket manufacturer’s specifications using
proper flange torquing practices such as incremental torque increases, star
pattern, etc. Refer to torque specifications in Tables 5 - 8.
4. Visually inspect all thread fittings and valve packings. Repair leaks and
tighten valve packings to the point of stopping leak.
5. Upon putting unit back into operation, check all gauge readings. Note any
discrepancies and contact Volcanic.
Daily Start-Up
1. Check positioning of all system valves to ensure flow is not dead-headed.
2. Visually check relative position of minimum level float switch in the

combination tank.
3. Turn on power supply switches.
4. Where applicable, open water cooling valve and check that water flows
correctly. (For water cooled pumps only.)
5. Set three position switch to “Pump”. Push and hold manual pump start
button, monitoring pressure gauges on heater.
6. When ready to begin heating, move three position switch from “Pump” to
“Heat”. After a short delay resulting from the purge period, the burner will
ignite. Make sure that the temperature setpoint is as desired.
7. On gas units, pilot valve activation will be indicated after pre-purge cycle
has completed, followed by main flame activation. Check the presence of
the flame by observing flame signal strength from flame programmer or
testing device. Operator attendance during warm-up is a recommended
precaution.
8. Start-up is considered complete when the unit begins to throttle back or

shutdown on target temperature.
3-27
Daily Shutdown
1. Set control switch to “Pump” pump running, burner off.
2. Allow the fluid to circulate for approximately 20-30

minutes and then set the control switch to the “Off ”
position.
3. When using fluid cooled pump, continue to circulate

cooling water to pumps for 30 minutes after stopping
circulation.
4. Open power supply switches.
5. Units switched off by an automatic time switch should

have an extra relay fitted to allow 20-30 minutes of fluid
circulation after stoppage in order to prevent localized
over heating of fluid.
6. Close fuel valves if required. Closing of system valves

is not generally necessary unless maintenance of
components requires a partial draining of the system.
7. Because of the high temperatures usually applied, leaks

are not expected to occur when cool down is achieved,
provided pipework is free to contract naturally when
cold.
Before Leaving the Installation

1. Check all controls to insure they are operating properly.
Cycle the heater several times by raising and lowering
operating temperature on the thermostat.
2. Make sure the installation complies with all applicable

codes.
3-28
MAINTENANCE
INTRODUCTION
1
INSTALLATION
2
OPERATION
3
MAINTENANCE
4
WARRANTY & PARTS
5
4-1
MAINTENANCE VHC-IOM-2012-0207 SECTION 4
! WARNING
Required Equipment
reference and guidance purposes, The following minimum equipment is necessary to start and maintain fuel-fired
and does not substitute for required thermal fluid heaters:
and strict adherence to applicable § Digital Multimeter
regulations. § Combustion Analysis Equipment
§ Draft Gauge
Prior to any maintenance concerning
electrical components of this
equipment, ensure eletrical supply Required Maintenance at First Shutdown
to the equipment is disconnected.
Label all wires prior to disconnection; The thermal fluid system should be shut down after no more than 24 hours of
wiring errors may cause improper operation at operating temperature. At this time, the following maintenance
and hazardous operation. items will need to be completed to meet the condition of warranty.
1. While pump is still at operating temperature, align circulating pump(s) to

Follow all proper lockout/tagout
procedures for service.
pump manufacturer specifications. This should be done by means of a dial
indicator.
Before beginning any maintenance, 2. Isolate Y-strainer(s) in system and clean regardless of pump suction
ensure area is free of any combustible pressure. Make sure that the temperature is low enough to handle safely
materials and other dangers. or provision has been made to handle materials at high temperature.
Generally, temperatures below 150 F (65.5 C) are acceptable to perform
What to do if you smell gas: operation with regular work gloves.
Do not try to light the appliance.
Do not touch any electrical switch. 3. With piping system at ambient temperature, torque all bolts on skid and
Do not use any phone in the building. throughout system to gasket manufacturer specification using proper
Leave building and contact gas flange torquing practices (incremental torque increases, star-pattern, etc).
supplier from neighbor’s phone. If you These values are available in the installation section of the manual..
cannot reach gas supplier, phone the
fire department. 4. Visually inspect all thread fittings and valve packings. Repair leaks and
tighten valve packings to the point of stopping leak.
After initial start-up by qualified 5. Upon putting unit back in operation, check all gauge readings and
personnel, linkage, control settings, compare to values given to you by the start up technician. Note any
and fuel pressures should not be discrepancies and contact manufacturer.
readjusted.
Daily Maintenance Schedule

4 CAUTION
1. Complete the log sheet at least once per day as a minimum. It is
All maintenance procedures should recommended that the log sheet be filled out twice per shift of operation.
be completed by trained personnel. The log sheet is available from the Volcanic Service Department and at the
Appropriate training and instructions end of this section of this manual.
are available from the Volcanic Service
Department or your local Volcanic 2. Make visual inspection of the entire system for leaks. Make repairs as soon
Representative. as possible.
3. Ensure there is always a fresh air supply to the heater.

In order to meet warranty conditions,
ensure all appropriate maintenance 4. Note any failures on the flame programmer noting fault number, fault
activities are performed.
code, fault annunciation, fault hour, fault cycle and fault time.
4-2
SECTION 4 VHC-IOM-2012-0207 MAINTENANCE
5. Check the exhaust for the presence of smoke. If smoke is present, contact ! WARNING
Volcanic Heater, Inc.
6. In systems utilizing linkage, check all linkage components for tightness. reference and guidance purposes,
See Figure 21. and does not substitute for required
7. In systems utilizing a water cooled thermal fluid circulating pump, check and strict adherence to applicable
level of lubricating oil in self-leveling reservoir and check cooling water jurisdictional/professional codes and
circulation loop for proper operation. Refer to Figure 10. regulations.
Fluids under pressure are hazardous

and may cause injury to personnel, or
equipment damage, when released.
Shut off all incoming and outgoing
fluid shutoff valves and carefully
decrease all trapped pressures to zero
before performing any maintenance.
Never use open flame or other sources

of ignition to check for gas leaks.
4 CAUTION
All maintenance procedures should
be completed by trained personnel.
Appropriate training and instructions
Department.

FIGURE 21 - LINKAGE COMPONENTS ensure all appropriate maintenance
Weekly Maintenance Schedule Use caution when using any cleaning

solutions. Refer to local regulations for
proper cleaning solution disposal.
1. Check inlet gas pressure at the beginning of the gas train. This should be
accomplished by the installation of an appropriately scaled gauge. See
Figure 22. Do not allow oil leaks, dust, or dirt to
accumulate around the heater.
2. Check manifold gas pressure at high and low fire and compare to Thermal
Combustion Checklist filled out by start up technician. This should be
accomplished by the installation of an appropriately scaled gauge.
Readings should be with .02” w.c. of Thermal Combustion Checklist.
3. Check heater temperature and pressure readings.
4. Check burner linkage and tighten as needed.
5. Check condition of the oil pump, if used.
6. Report any excessive noise or part wear.
4-3
4 CAUTION
Monthly Maintenance Schedule
reference and guidance purposes, 1. Clean fuel filters.
professional training, conduct, 2. Check burner blower. Clean if necessary.
3. Clean or change air filter if applicable.
regulations. 4. Manually check fluid level in the expansion tank. Drain ½ gallon of thermal
fluid from the expansion tank. If water is present, continue to drain ½
All maintenance procedures should gallon until no water is present.
Appropriate training and instructions 5. Check operation of all safeties. Refer to the instructions at the end of
are available from the Volcanic Service this section. With the burner running, remove or disconnect the flame
Department. detection device. The flame programmer should lockout within 3 seconds.
6. Review daily log sheets noting any deviations from the norm.
ensure all appropriate maintenance 7. Lubricate motors if required.
FIGURE 22- GAS TRAIN
8. Check, clean and adjust and/or replace electrodes if required.
9. Check scanner cell for cleanliness if required.
10. Clean oil nozzle (never use a sharp object) and clean oil fuel strainer if
required. Replace if damaged.
11. Check power flame #2 oil burner for carbon build-up, if installed. Report
any findings immediately.
12. Check the tightness of all couplings, including the fuel oil pump drive (oil-
fired units), fan impeller, circulating pump, etc. See Figure 23.
4-4
Semi-Annual Maintenance Schedule 4 CAUTION
1. Pull burner and inspect for heat stress or soot. Clean or replace as reference and guidance purposes,
necessary. and does not substitute for required
2. Inspect pilot tube assembly and ignition electrode. Clean or replace if and strict adherence to applicable
necessary. Reset ignition settings to manual specifications. jurisdictional/professional codes and
regulations.
3. Inspect internal surfaces of the heater. Inspect refractory for cracks. Cracks
larger than ¼” wide will require repair or replacement of the refractory.
Inspect coil for sooting. If soot is present, it can be removed by utilizing a All maintenance procedures should
brush or compressed air for light sooting. See Soot Cleaning section of this
manual.
4. Have combustion checked for efficiency. Department.
5. Review daily log sheets noting any deviations from the norm. In order to meet warranty conditions,
ensure all appropriate maintenance
Use extreme caution when using

any cleaning solution. Refer to local
regulations for disposal requirements.
FIGURE 23 - PUMP COUPLING
Annual Maintenance Schedule

1. Replace the ignition electrode(s).
2. If the unit utilizes a flame rod, replace.
3. If the unit utilizes power flame #2 oil burners, replace scanner cell as
necessary.
4. Check for loose screws, bolts, and terminals.
5. Clean heater thoroughly. If paint touch-up is required, be sure not to paint

over wires, controls, terminals, gauges, etc.
6. Clean all strainers in the thermal fluid system.
7. Take a one quart sample of thermal fluid and return to the thermal fluid
4-5
! WARNING manufacturer for analysis.
All information in this manual is for 8. Schedule local Volcanic representative or factory service technician to
reference and guidance purposes, perform an annual preventative maintenance.
and strict adherence to applicable General Maintenance Procedures
regulations.
¡ Lubrication
Different motor manufacturers recommend various intervals for lubrication
4 CAUTION schedules. Load variations will dictate the frequency and amount of lubrication
required.
be completed by trained personnel. 1. When developing your lubrication schedule, consider the thermal fluid
Appropriate training and instructions pump and all system pumps.
Department. 2. If you have a thermal fluid circulating pump with a packed seal, the
condition of the pump packing should be checked regularly. If fluid
leakage increases, tighten the packing ¼ turn daily.
¡ Soot Cleaning
If your coil inspection indicates severe sooting, the follow the procedure below:
1. Drain fluid from the coil (using a pump).

2. Remove the burner and lower access doors.
3. Wire brush coils and use compressed air where accessible.
4. Vacuum loose soot where accessible.
5. Reinstall the burner and lower access doors.
6. Fire the heater to roughly 300 F (149 C).
7. Remove the burner again and fill the heater with a water/detergent or
water/caustic mix to the flue outlet.
8. Pump out. Rinse heater thoroughly when finished before reassembling
heater.
Safety Check Procedures

Perform the following safety checks as needed:
¡ Liquid Level Switch

Manually turn liquid level switch cam counterclockwise. See Figure 13. Micro-
switch will open contacts and control voltage will be lost. Release cam and
micro-switch will make and control voltage will be restored.
¡ Stack Limit
The limit manufacturer presets the stack limit. Testing can be performed by
removing switch from stack and applying heat over that of the switch set point
4-6
for several seconds. The switch can then be reset and re-installed. See Figure 24.
! WARNING
¡ Differential Pressure Switch All information in this manual is for
With the circulating pump running, observe the difference in pressure between and does not substitute for required
the heater outlet gauge and the heater inlet gauge. Remove the top cover of professional training, conduct,
the differential pressure switch. Note the original setting of the switch and turn and strict adherence to applicable
adjustment knob clockwise until switch trips. The pointer on the switch should jurisdictional/professional codes and
be within 2 psi of the observed pressure difference. Reset switch to the original regulations.
set point. See Figure 25.
¡ Low Inlet Pressure Switch 4 CAUTION
Slowly close the valve on outlet of main circulating pump observing heater inlet All maintenance procedures should
pressure gauge. Note the pressure at which the switch trips. This pressure should be completed by trained personnel.
be roughly the set point of the switch minus any differential that is set. Appropriate training and instructions
Department.
FIGURE 24 - STACK LIMIT SWITCH
¡ High Inlet Pressure Switch

Note the original setting of the switch and turn adjustment screw
counterclockwise while observing heater inlet pressure gauge until switch trips.
The pointer on the switch should be within 2 psi of the observed pressure. Reset
switch to the original set point.
FIGURE 25 - DIFFERENTIAL PRESSURE SWITCH
4-7
! WARNING ¡ High Outlet Pressure Switch
All information in this manual is for Note the original setting of the switch and turn adjustment screw
reference and guidance purposes, counterclockwise while observing heater outlet pressure gauge until switch trips.
and does not substitute for required The pointer on the switch should be within 2 psi of the observed pressure. Reset
professional training, conduct, switch to the original set point.
regulations. ¡ Air Switch
Remove the ¼” copper tubing from the bottom of the air switch with the fan
4 CAUTION
running. Air switch should trip the interlock circuit. Re-attach copper tubing and
reset flame programmer.
be completed by trained personnel. ¡ Air Filter Box Switch
are available from the Volcanic Service With heater running at high fire, block opening to air filter box by 50%. Slowly
Department. close off further until switch trips. Air switch should trip at just over 50%
blockage.
¡ Temperature Limit(s)
Adjust set point(s) of temperature limit(s) down to a point lower than the process
variable (PV). PV is typically the current fluid temperature at the heater outlet.
Solid-state controls will deactivate a control relay powering a set of n.c. contacts
in the interlock circuit. Analog controls will open their contacts in the interlock
circuit. Trip temperature should be within 5 degrees of PV temperature. Reset
temperature limit if reset exists and reset flame programmer.
¡ High/Low Gas Pressure Switch

Shut off the main gas valve prior to the gas train and attempt to light the unit.
After the gas valves open during the ignition trial, the low gas pressure switch will
trip. Reset the low gas pressure switch and flame programmer. Open main gas
valve prior to gas train and close gas valve between last actuated gas valve and
burner. Attempt to light the unit. After the gas valves open, the high gas pressure
switch will trip. Reset the high gas pressure switch and the flame programmer.
¡ Power Flame #2 Oil Burners

On units equipped with power flame #2 oil burners, the following is required for
the igniter and the nozzle:
1. The igniter should be removed and cleaned regularly.
2. Porcelain insulators should be kept clean and replaced if cracked.
3. The electrode spark gap should be set at 1/8 in. to 3/16 in. tip point type or
1/16 in. Jacob’s ladder type.
4. Tension wires and clips between transformer and electrodes should be

checked for deterioration.
5. When removing or replacing oil nozzle and electrode assembly, take care
4-8
to prevent damage. Refer to Table 10-B for a tripped High Outlet Pressure Switch,
which will require the manual reset button on the switch to
6. Remove nozzle with properly-sized wrench; do not be pushed.
force.
7. Clean with a non-flammable solvent liquid and a brush. } HIGH INLET PRESSURE SWITCH
8. Set nozzle firmly when replaced to prevent leaks. This is a normally closed switch that opens with improper
Replace damaged nozzle immediately. Never heater inlet pressure. This switch is generally a mercury bulb
interchange nozzle parts; replace entire nozzle. type switch. Mercury will rest towards the green cap in a
“made” condition. The purpose of the High Inlet Pressure
Switch is to protect the heater from building too high of a
Troubleshooting pressure.
Typical coil model heaters have a maximum working

¡ Flow Circuit/ Circulating Pump(s) pressure of 150 psi with 100 psi safety valve(s) on the heater
outlet manifold. The High Outlet Pressure Switch should
The flow circuit is the electrical circuit that enables the be set at 5 psi over the heater outlet pressure as read at
circulating pump(s). Your thermal fluid pump(s) will remain on ambient temperature assuming that none of the conditions
until the flow circuit opens to disable the pump starter or the mentioned in Table 10-D are true.
Off / Pump / Heat switch is turned to the “Off ” position. Items
in the flow circuit may include paddle type flow switches, a
} DIFFERENTIAL PRESSURE SWITCH
high inlet pressure switch, a low inlet pressure switch, a high
outlet pressure switch and a differential pressure switch. This is a normally open diaphragm switch that closes with a
proper heater differential pressure between the heater inlet
} LOW INLET PRESSURE SWITCH and outlet.
This is a normally open switch that closes with proper The purpose of the Differential Pressure Switch is to protect
heater inlet pressure. This switch is generally a mercury bulb the heater coil from too high of a temperature and to
type switch. Mercury will rest towards the green cap of the protect the thermal fluid from exceeding its maximum film
mercury bulb in a “made” condition. temperature. Each heater model number has a specific
minimum differential pressure.
The purpose of the Low Inlet Pressure Switch is primarily to
protect the heater from a low flow condition. The Low Inlet This pressure is the difference in pressure between the heater
Pressure Switch should be set at 5 psi below normal heater inlet pressure gauge and the heater outlet pressure gauge.
inlet pressure as read at operating temperature assuming that See Table 10-E for troubleshooting.
none of the conditions indicated in Table 10-A are true. Refer
to Table 10-A for a tripped Low Inlet Pressure Switch. } CALL FOR HEAT/BURNER INTERLOCK
The call for heat circuit is the circuit that enables burner
} HIGH OUTLET PRESSURE SWITCH
operation. Volcanic has used a variety of Temperature
This is a normally closed switch that opens with excessive Controllers to act as the Call for Heat. Generally these
heater outlet pressure. This switch is generally a mercury controls work in combination with a control relay. When
bulb type switch. Mercury will rest towards the green cap in a the Temperature Controller calls for heat, a signal is sent to
“made” condition. the coil of a control relay that closes a normally open set of
contacts in series with the burner circuit.
The purpose of the High Outlet Pressure Switch is primarily to
protect the heater from building too much pressure. Typical When the call for heat is met, the signal is removed and
coil model heaters have a maximum working pressure of 150 the contacts return to their open state. Situations that may
psi with 100 psi safety valve(s) on the heater outlet manifold. interfere with the Call for Heat circuit are in Table 10-F. The
burner interlock is the electrical circuit that enables the flame
The High Outlet Pressure Switch should be set at 5 psi over programmer. Your thermal heater needs to have the items in
the heater outlet pressure as read at ambient temperature the burner interlock ‘made’ before ignition can occur. Items in
assuming that none of the conditions mentioned in Table the burner interlock may include an air switch, air filter switch,
10-B are true. auxiliary blower motor starter contacts, high temperature
4-9
limit(s), high gas pressure switch, low gas pressure switch, and from excessively high temperatures.
/ or low oil pressure switch.
Solid-state high temperature limits will have a manual reset.
Bulb and capillary type limits will not have a manual reset.
} AIR SWITCH
If this/these switch(es) trips, it is generally one of the issues
All C-model heaters have an Air Switch. This is a normally indicated in Table 10-J.
open switch that closes with proper burner fan outlet
pressure. This switch is generally a diaphragm type switch. } HIGH GAS PRESSURE SWITCH
The Air Switch is a safety device that proves that there is an All gas-fired modulating or NFPA rated thermal fluid heaters
adequate pressure and volume of make up air for proper have a High Gas Pressure Switch. This is a normally closed
combustion and mixing. There is no manual reset on the air diaphragm switch that opens on a pressure increase over
switch itself to indicate a trip. The most likely time of an air set point. The High Gas Pressure Switch is a safety device
switch trip is at low fire purge or low fire. If this switch trips, it that protects the burner from receiving too high of a gas
is generally one of the issues indicated in Table 10-G. pressure. The switch senses this pressure downstream of the
last gas valve, upstream of the modulation valve on units that
} AIR FILTER SWITCH modulate.
C-model heaters with an air filter box or ducted supply air This switch is most likely to trip at low fire. If this switch trips, it
have an Air Filter Switch. This is a normally closed switch that is generally one of the issues indicated in Table 10-K.
opens on too high of a suction pressure at the burner fan
inlet. This switch is generally a diaphragm type switch. } LOW GAS PRESSURE SWITCH
The Air Filter Switch is a safety device that proves that there is All gas-fired modulating or NFPA rated thermal fluid heaters
not too negative of a pressure at the combustion blower inlet. have a Low Gas Pressure Switch. This is a normally closed
This switch is only used on units that have a built in air box for diaphragm switch that opens on a pressure decrease below
use as a duct connection or air filtering device. set point.
There is no manual reset on the air filter switch itself to The Low Gas Pressure Switch is a safety device that protects
indicate a trip. The most likely time of an air filter switch trip is the burner from receiving too low of a gas pressure. The switch
at high fire purge or high fire. If this switch trips, it is generally senses this pressure just downstream of the gas regulator. This
one of the issues indicated in Table 10-H. switch will most likely trip at high fire. If this switch trips, it is
generally one of the issues indicated in Table 10-L.
} AUX. BLOWER MOTOR STARTER
} LOW OIL PRESSURE SWITCH
All C-model heaters use an auxiliary set of contacts on their
blower motor starter to prove that the burner motor is All oil fired modulating thermal fluid heaters have a Low Oil
latched on. This is a normally open set of contacts mounted Pressure Switch. This is a normally closed diaphragm switch
on or built in to the blower motor starter. The Auxiliary Blower that opens on a pressure decrease below set point. The Low
Motor Contacts are a safety device that proves that the blower Oil Pressure Switch is a safety device that protects the burner
motor starter is latched in. These contacts work in redundancy from receiving too low of an oil pressure. The switch senses
to the air switch to prove that there is proper makeup air. this pressure just downstream of the gas pump. If this switch
There is no manual reset on the auxiliary contacts themselves trips, it is generally one of the issues indicated in Table 10-M.
to indicate a trip. If the contacts do not make, it is generally
one of the issues indicated in Table 10-I. } PILOT FLAME FAILURE
A Pilot Flame Failure is a flame failure that occurs when the
} HIGH TEMP. LIMIT
unit is trying to establish an adequate flame signal. Solid-state
All thermal fluid heaters have at least one High Temperature controllers indicate a Pilot Flame Failure by showing as a fault
Limit. The high temperature limit(s) is/are normally closed code either Fault 28 for Honeywell 7800 series controllers.
switch(es) that break on a temperature rise over set point. Flame Failure PTFI on Fireye E110 series controllers or Fault
The switch may be either a solid state controller or a bulb and 9 on Fireye Nexus controls. For electro-mechanical controls,
capillary type switch. The High Temperature Limit is a safety you need to witness when the failure occurs. A Pilot Flame
device that protects the thermal fluid and heat transfer coil Failure indicates that either a strong enough pilot flame
4-10
was not generated or the means of sensing the pilot flame
strength has failed. All gas fired units have a gas pilot. Oil fired
units may be 2-stage, in which the 1st stage to light would be
considered the pilot, or may have a gas pilot. In either case,
during the pilot proving period, the flame programmer must
sense a strong enough flame to initiate the opening of the
main valves. See Table 10-N.
} MAIN FLAME FAILURE

Main Flame Failure is a flame failure that occurs while the
unit is trying to establish an adequate flame signal during the
Main Flame Trial for Ignition.
Solid state controllers indicate a Main Flame Failure by

showing as a fault code of either Fault 19 for Honeywell 7800
series controllers, Flame Failure MTFI on Fireye YB110/E110
series controllers, or a Fault 09 for Fireye Nexus controls. For
electro-mechanical controls, you need to witness when the
failure occurs.
A Main Flame Failure indicates that either a strong enough

main flame was not generated or the means of sensing
the main flame strength has failed. During the main flame
proving period, the flame programmer must sense a strong
enough flame to hold the main valves open. If you are
experiencing Main Flame Failures, check the items indicated
in Table 10-O.
4-11
TABLE 10-A - LOW INLET PRESSURE SWITCH TROUBLESHOOTING

Problem Potential Remedy
Plugged circulation pump A plugged strainer will result in a decrease of flow through the heater. High vacuums developed from plugged strainers can also
strainer basket stress the seals of the pump causing the pump to fail.
A “Pump Suction” gauge is provided on Thermal skids to help determine when a strainer needs cleaning. Generally this point is
between 0 and -5” Hg.
If the strainer is plugged, isolate the strainer and drain that section of piping being mindful of the temperature of the thermal fluid.
Remove the strainer and clean with compressed air, high-pressure water or a cleaning solution. Replace and observe new pump
suction pressure.
Failed Circulation Pump A failed coupling will result in a decreased or no flow condition through the heater. The coupling can be checked by removing the
Coupling coupling guard between the pump and pump motor.
The coupling should not be torn or misshapen. If the coupling needs to be replaced, it is recommended to re-align the circulating
pump first at ambient temperature and again when it’s at operating temperature. Alignment should be within pump manufacturers’
specifications
Cavitation of the circulating Cavitation occurs when a pump experiences a loss of head or if any low heater flashes to gas at the impeller. During this time, the
pump pump impeller spins without actually circulating any thermal fluid.
If Volcanic provided the heater skid, loss of head to the pump is extremely unlikely with proper fluid level in the combination tank.
The most common low heater in a thermal piping system is water, which needs to be boiled out at startup or anytime new piping or
fluid is added to the thermal oil system.
Once the system has been brought up to full operating temperature, assuming that the entire system has seen flow, there should be
no further occurrence of low heater contamination apart from possible heat exchanger failure.
System is open Lack of back-pressure. If control valving is improper or pressure drop across the system is too low, the resulting minimal back-
pressure may not provide enough resistance for the flow to make the pressure switch. Check the thermal fluid system for proper
operation of control valves.
Blocked Sensing Line on A blocked sensing line will give an inaccurate pressure reading to the pressure switch. A blocked line will need to be replaced or
Pressure Switch cleaned. Most installations have block valves at the heater to facilitate safe isolation and cleaning of the sensing line. Do not attempt
when system is hot.
Improper Switch Setting Low Inlet Pressure Switch should be set at 5 psi less than the pressure read on the heater inlet pressure gauge at full operating
temperature of the system.
Switch is faulty If pressure is verified and reads correctly above set point on switch and the sensing line to the pressure switch is open, the pressure
switch is faulty. Replace switch, set for desired set point and test for proper operation.
TABLE 10-B - HIGH OUTLET PRESSURE SWITCH TROUBLESHOOTING

An obstruction downstream of Any obstruction downstream of the heater will increase the pressure that the heater outlet sees. This obstruction will generally result
the heater from an improper valve setting.
Observe heater outlet pressure at temperature with all users / heat exchangers calling for heat (100% user). Observe heater outlet
pressure at temperature with all users / heat exchangers not calling for heat (100% bypass). Bypass regulating valve(s) should be
adjusted to equal flow condition through users.
Call or e-mail Volcanic for further details. It may be possible that an automatic control valve has failed. If this is the case, the valve
actuator should be inspected and possibly replaced.
Improper Switch Setting The High Outlet Pressure Switch should be set at 5 psi over than the maximum pressure read on the heater outlet pressure gauge
during proper operation at the coldest ambient temperature expected.
Faulty Switch If pressure is verified and reads correctly below set point on switch and the sensing line to the pressure switch is open, the pressure
switch is faulty. Replace switch, set for desired set point and test for proper operation.
4-12
TABLE 10-D - HIGH INLET PRESSURE SWITCH TROUBLESHOOTING

An obstruction downstream of Any obstruction downstream of the heater will increase the pressure that the heater outlet sees. This obstruction will generally result
the heater from an improper valve setting.
pressure at temperature with all users / heat exchangers not calling for heat (100% bypass).
Bypass regulating valve(s) should be adjusted to equal flow condition through users. Call or e-mail Volcanic for further details.
It may be possible that an automatic control valve has failed. If this is the case, the valve should be replaced.
Plugged Coil Pipes If too low of a flow condition has occurred for too long a period of time or if the maximum operating temperature of the oil has been
exceeded, it is possible, however unlikely, that a pipe or pipes in the coil could plug with solids. If this occurs, it will be necessary to
shut down the system and clean the coil. Volcanic should be consulted in this matter.
Improper Switch Setting The High Inlet Pressure Switch should be set at ambient temperature. The setting should be 5 psi over than the maximum pressure
read on the heater outlet pressure gauge during proper operation.
TABLE 10-E - DIFFERENTIAL PRESSURE SWITCH BREAK TROUBLESHOOTING

An obstruction downstream of Any obstruction downstream of the flow switch(es) will increase the pressure that the heater outlet sees. Any increase in outlet
the heater outlet pressure will result in diminished flow. This obstruction will generally result from an improper valve setting.
pressure at temperature with all users / heat exchangers not calling for heat (100% bypass).
Bypass regulating valve(s) should be adjusted to equal flow condition through users. Call or e-mail Volcanic for further details.
It may be possible that an automatic control valve has failed. If this is the case, the valve should be replaced.
TABLE 10-F - CALL FOR HEAT CIRCUIT TROUBLESHOOTING

Programming Problem Volcanic has a general program for each of the temperature controllers we have used over the years. Compare your current
temperature controller program to Volcanic’s general program.
See the back of this section for general programming sheets for standard Volcanic heaters.
Make changes as necessary. Contact Volcanic service department with any questions.
Temperature Controller If the temperature controller is calling for heat but is not putting power on the output to the control relay, the relay will not close the
Failure normally open contacts and the heater will remain disabled. If this is the case, some controllers have separate sets of contacts that
may be utilized in replacement of the damaged contacts. Some rewiring and/or reprogramming will be needed. Contact Volcanic
service department if necessary.
Temperature Sensor Failure Different temperature controllers use different types of temperature sensors. These may be Type J thermocouples, mercury bulbs,
RTDs or another type of sensor. It is possible for these sensors to malfunction. To verify proper sensor operation, use an alternate
source of temperature detection such as an infra-red temperature sensor to sense temperature at the same point.
Control Relay May Have Failed Many temperature controllers energize a relay with a call for heat that in turn closes a normally open set of contacts to energize the
burner circuit.
If your temperature controller is sending an output signal to the control relay but the burner is not initiated, check resistance across
coil of the relay. An open reading indicates that the relay needs to be replaced. If the coil shows resistance, energize coil and check
contacts. With coil energized, normally open contacts should close resulting in a reading of control voltage on both the common
and normally open contact.
If voltage exists on common but not on normally open contact either switch contacts if another set of normally open contacts are
available or replace relay.
4-13
TABLE 10-G - AIR SWITCH TROUBLESHOOTING

Combustion Blower Fan is If the cups of the squirrel cage type fan become dirty, less air will be moved by the fan. If the fans are dirty enough, there will not be
Dirty enough air flow for the air switch to prove. You should assure that the combustion blower fan is clean, reset the flame programmer
and try to light unit again
The sensing line is plugged, If the sensing line to the air switch is crimped or blocked, the switch will not sense the proper pressure. Ensure that the sensing line
crimped or pointing in the is clear and not crimped by removing both sides of the sensing line and using compressed air to blow through the line. Also ensure
wrong area that the elbow acting as an air scoop is pointing directly into the air stream. Reset the flame programmer and try to light the unit
again.
The Switch setting is improper The adjustment screw for the air switch is located opposite the electrical connections. A gray cap covers the screw. Turn the screw
clockwise to increase setting, counter-clockwise to decrease setting. To set switch, run unit at low fire. Increase setting 1/2 turn every
5 seconds until unit trips on interlock. Decrease setting by 2 full turns. Reset unit.
TABLE 10-H - AIR FILTER SWITCH TROUBLESHOOTING

The air filter is dirty If the air filter becomes dirty, the fan will generate greater suction. Too much suction will result in not enough airflow for proper
combustion and mixing and will cause air switch to trip. You should regularly change filters on a schedule dependent on how dirty the
makeup air is. After checking or changing air filter, reset the flame programmer and try to light unit again.
There is an obstruction in the Units that have make-up air ducting need to assure that blockage to the ducting does not occur. Check outside termination and any
make-up air ducting bends in the ducting for blockage. Clear blockage, reset flame programmer and try to light unit again.
The sensing line is pointing in The sensing line for the air filter switch is supposed to provide the static pressure of the air box. The termination of the sensing line
the wrong direction should be pointing in the direction that limits its contact with moving air. If the sensing line is pointed perpendicularly to enetering air
stream, the switch will not sense the proper pressure and could give a false indication of air box suction. Reset the flame programmer
and try to light the unit again.
Switch setting is improper The adjustment screw for the air switch is located opposite the electrical connections. A gray cap covers the screw. Turn the screw
clockwise to increase setting, counter-clockwise to decrease setting. The switch setting should be set in such a way that with 50 % of
the the air box opening blocked, the switch will trip. Reset switch setting, reset the flame programmer, and try to light the unit again.
TABLE 10-I - AUXILIARY BLOWER MOTOR STARTER TROUBLESHOOTING

The blower motor starter coil If this is the case, the blower starter will not latch in. Check for voltage to the coil. If proper voltage is present and the starter does not
is bad pull in, that proves the coil is bad. Replace the starter, reset the flame programmer and try to light unit again.
The auxiliary contacts are Visibly inspect contacts. With power off, attempt to clean or replace starter if damaged. Reset flame programmer and try to light unit
burned or pitted again.
TABLE 10-J - HIGH TEMPERATURE LIMIT TROUBLESHOOTING

Flow rate is too low Too low of a flow rate will result in a higher rate of heat transfer to the thermal fluid and heat transfer coils. This will result in a
higher temperature difference between inlet temperature and outlet temperature.
It is important to make sure that the minimum flow rate as specified by Volcanic for that specific model is maintained Check inlet
and outlet pressures of the heater to determine differential pressure and flow rate. Ensure that this flow rate meets or exceeds
minimums specified by Volcanic (see chart). Also check differential pressure switch for proper operation and setting.
Heater is over-fired If the heater has more fuel input than design, it is probable that the heat transfer rate will increase beyond design. Check input to
heater at high fire for modulated heaters or at the standard rate for on / off units. This can be done by either using a corrected gas
meter reading or measuring gas pressure supplied to the burner compared to factory test-fire settings.
If input is improper, inspect burner as described below. If burner is not damaged or have improper components, adjust fuel input
and combustion to specification.
Gas-fired burner is damaged Pull and inspect the burner. Primary areas of concern for gas-fired units are the orifice plate, pilot assembly seating and orifice plate
gap.
If the orifice plate is warped or burned through, pilot assembly is not seated or gap between orifice plate and gas tube is improper,
more fuel than designed for will enter the furnace.
This will cause the heater to have more fuel input than designed for. The design flow rate will then be too low causing the fluid to
heat up higher than it should.
4-14
TABLE 10-K - HIGH GAS PRESSURE SWITCH TROUBLESHOOTING
Gas pressure setting on the With unit running at high fire, make sure that the modulated gas valve is at full open.
main regulator is too high Since unit lights at low fire, it may be necessary to increase high gas pressure setting or jumper contacts to allow unit to modulate to
where modulation gas valve back pressure is lessened.
Check net last elbow gas pressure and compare to factory test fire sheet. Net gas pressure is running gas pressure minus p urge
pressure. Make sure net pressure reading is within .2” w.c. of factory reading. If there is a difference, adjust main regulator. Adjust for
proper combustion throughout range.
Low fire gas valve setting is Because the sensing point of the High Gas Pressure Switch is upstream of the modulating gas valve, the highest pressure read will
too low occur during low fire.
Check net last elbow gas pressure and compare to factory test fire sheet. Net gas pressure is running gas pressure minus purge
pressure. Make sure net pressure reading is within .1” w.c. of factory reading. If there is a difference, adjust modulating gas valve
linkage. Adjust for proper combustion throughout range.
Gas pressure switch setting is If above two items are proper, check the pressure that the high gas pressure switch is sensing by way of a tee installed in the line.
improper Hold unit at low fire and check pressure. Setting on switch should be 10% over pressure read. Call Volcanic if you have any questions.
Gas regulator has failed open This is highly unlikely. Regulators will usually fail safe in the closed position. The gas regulator can be checked by checking upstream
pressure and comparing to downstream pressure. Make sure that the upstream pressure is not above the rating of the regulator.
Make sure that the downstream pressure does not exceed the range of the spring. If regulator has failed, replace, reset input and
adjust input throughout the range.
TABLE 10-L- LOW GAS PRESSURE SWITCH TROUBLESHOOTING

Gas pressure setting on the At high fire, the modulating gas valve is full open resulting in the least amount of back pressure in the gas train. With unit running
main regulator is too low at high fire, check net last elbow gas pressure and compare to factory test fire sheet. Net gas pressure is running gas pressure minus
purge pressure. Make sure net pressure reading is within .2” w.c. of factory reading. If there is a difference, adjust main regulator.
Adjust for proper combustion throughout range.
Gas orifice plate is damaged If the orifice plate is damaged, it may be holding back less gas creating a lower pressure on the sensing switch. Pull burner and
inspect gas orifice plate. Plate should in no way be warped or degraded. If it is, replace. After reinstallation, recheck input and adjust
combustion throughout range.
Gas regulator has failed closed Regulators will usually fail safe in the closed position. The gas regulator can be checked by checking upstream pressure and
comparing to downstream pressure. Make sure that the upstream pressure is not above the rating of the regulator. If regulator has
failed, replace, reset input and adjust input throughout the range.
TABLE 10-M - LOW OIL PRESSURE SWITCH TROUBLESHOOTING

Oil pressure setting on the At low fire, the modulating oil valve is at its most open position resulting in the least amount of back pressure in the fuel train. With
back pressure valve is too low unit running at low fire, check oil pressure and compare to factory test fire sheet. Make sure oil pressure reading is within 10 psi of
factory reading. If there is a difference, adjust back pressure regulator. Adjust for proper combustion throughout range.
Fuel oil pump may have lost An air bubble in the pump will result in a momentary loss of prime that will be enough to cause the Low Oil Pressure Switch to trip.
its prime Ensure that oil pump is primed properly and all connections are tight. Check the pump seal. A blown seal will allow air in the pump
housing.
Fuel oil pump motor may have Check the pump motor for proper voltage. If voltage is proper but motor does not turn, replace or rebuild motor. If there is no
failed voltage, check motor starter for input signal and incoming 3-phase power.
Fuel oil pump coupling may A failed coupling will result in the pump not turning. Check coupling. Replace if necessary..
have failed
TABLE 10-N - PILOT FLAME FAILURE TROUBLESHOOTING

Pilot flame strength is Cycle the unit. During the pilot trial for ignition, carefully observe the pilot flame strength.
inadequate On Honeywell controllers, the pilot flame strength must be between 1.25 to 5.0 VDC. On Fireye controllers, the pilot flame strength
must be greater than 10 VDC.
Current controls are supplied with a test switch that can hold the programmer in the pilot trial for ignition stage. If a pilot signal
greater that 0.0 but less than the minimum required is detected, look through the sight hole provided on the burner plate of the
heater to visibly detect flame. If flame is seen, make small adjustments to increase pilot gas and air to provide larger flame.
4-15
TABLE 10-N - PILOT FLAME FAILURE TROUBLESHOOTING

Pilot sensing device does not Cycle the unit. If a pilot signal of 0.0 is detected, look through the sight hole provided on the burner plate of the heater to visibly
work properly detect flame.
If flame is seen, your flame detection device or amplifier may be faulty. If the unit has a flame rod, lockout and tag heater’s electrical
circuit and fuel supply. Pull pilot assembly out of unit. Inspect the flame rod. If the flame rod is corroded, shows isgns of heat
impingement, has been burdned off or has cracks in the porcelain, replace with a new flame rod.
Reinstall and cycle unit. If the unit has a U.V. scanner, lockout and tag heater’s fuel supply. Remove U.V. scanner from U.V. sight tube.
Make sure that the lens of the scanner is clean. Use a lighter or match and make a flame in front of the scanner eye. Lens should
flicker. If unti does not flicker, change U.V. scanner. If this change does not work, change U.V. amplifier. Reinstall and cycle unit.
Room air pressure is different Check room air pressure relative to outside air pressure. Heater room pressure should equal outside air pressure. Significant
from outside air pressure differences in pressure will result in an erratic flame, which will not deliver a strong flame signal.
TABLE 10-O - MAIN FLAME FAILURE TROUBLESHOOTING

Main flame strength is Cycle the unit. During the main flame proving period , carefully observe the pilot flame strength. Current controls are supplied with a
inadequate test switch that can hold the programmer in the main flame proving period.
If a main signal is greater than 0.0 but less than the minimum required is detected, look through the observation port to try to visibly
see flame. A combustion change may be necessary to establish main.
If observed flame is blue, slightly decrease the air damper setting and recycle. If flame is red or orange, slightly increase air damper
setting and recycle. Once adequate flame signal is established, reset input and combustion throughout range of modulation.
Flame sensing device does not Cycle the unit. If a signal of 0.0 is detected, look through the sight hole provided on the burner plate of the heater to visibly detect
work properly flame. If flame is seen, your flame detection device or amplifier may be faulty.
If the unit has a flame rod, lockout and tag heater’s electrical circuit and fuel supply. Pull pilot assembly out of unit. Inspect the flame
rod. If the flame rod is corroded, shows signs of heat impingement, has been burned off or has cracks in the porcelain, replace with a
new flame rod. Reinstall and cycle unit.
If the unit has a U.V. scanner, lockout and tag heater’s fuel supply. Remove U.V. scanner from U.V. sight tube Make sure that the lens
of the scanner is clean. Use a lighter or match and make a flame in front of the scanner eye. Lens should flicker. If unit does not flicker,
change U.V. scanner. If this change does not work, change U.V. amplifier. Reinstall and cycle unit.
Room air pressure is different Check room air pressure relative to outside air pressure. Heater room pressure should equal outside air pressure. Significant
from outside air pressure differences in pressure will result in an erratic flame, which will not deliver a strong flame signal.
Unit is experiencing too great At the breaching of the heater, take a draft reading. Draft should read between -.02” w.c. and -.04” w.c. with the heater off and
of a restriction between -.04” w.c. and -.08” w.c. with the unit on. A restrictive draft would be a draft that was positive. A restrictive draft is usually
the result a stack that is undersized, a stack with too many elbows or a stack whose cap or piping is warped and damaged. Another
source of restriction results from broken refractory. If the unit’s refractory breaks, large enough pieces could block the flue passes.
The burner should be pulled for refractory inspection. A broken refractory should be cleaned out and replaced.
4-16
4-17
4-18
WARRANTY & PARTS
INTRODUCTION
1
INSTALLATION
2
OPERATION
3
MAINTENANCE
4
WARRANTY & PARTS
5
5-1
PARTS & WARRANTY VHC-IOM-2012-0207 SECTION 5
! WARNING
Parts
Use of non-factory authorized
replacement parts is not Spare and replacement parts may be ordered from your local representative or
recommended for this equipment. through Volcanic Heater, Inc. When ordering replacement parts, please have the
Use of non-factory authorized parts model number and serial number of your Volcanic boiler ready. Factory-direct
may jeopardize safety and system replacement parts must be used to ensure proper equipment operation and
performance, and voids the product adherance with warranty requirements. Contact Volcanic at (866) 378-9263 for
warranty. further information.
5-2
© The Fulton Companies 2012
SECTION 5 VHC-IOM-2012-0207 WARRANTY & PARTS
Standard Warranty for Volcanic Thermal Fluid Heaters
ONE (1) YEAR (12 MONTH) MATERIAL AND WORKMANSHIP WARRANTY
The pressure vessel is covered against defective material or workmanship for a period of one (1) year from the date of
shipment from the factory. Volcanic will repair or replace F.O.B. factory any part of the equipment, as defined above, provided
this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and
recommendations made by Volcanic. The commissioning agency must also successfully complete and return the equipment
Installation and Operation Checklists to Volcanic’s Quality Assurance department. This warranty covers any failure caused
defective material or workmanship.
The thermal fluid system piping and valves are painted at the factory to protect them from corrosion prior to installation and
operation. These painted surfaces are not covered under warranty.
PARTS WARRANTY
Volcanic will repair or replace F.O.B. factory any part of the equipment of our manufacture that is found to be defective in
workmanship or material within one (1) year of shipment from the factory provided this equipment has been installed, operated
and maintained by the buyer in accordance with approved practices and recommendations made by both Volcanic and the
component manufacturers and the commissioning agency has successfully completed and returned the equipment Installation
and Operation Checklists to Volcanic’s Quality Assurance department.
GENERAL
Volcanic shall be notified in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or
labor charges of any kind.
These warranties are contingent upon the proper sizing, installation, operation and maintenance of the boiler and peripheral
components and equipment. Warranties valid only if installed, operated, and maintained as outlined in the Volcanic Installation
and Operation Manual.
No Sales Manager or other representative of Volcanic other than the Quality Manager or an officer of the company has warranty
authority. Volcanic will not pay any charges unless they were pre-approved, in writing, by the Volcanic Quality Manager.
This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited to the implied
warranties of merchantability and fitness for a particular purpose. Volcanic shall in no event be liable for any consequential or
incidental damages arising in any way, including but not limited to any loss of profits or business, even if Volcanic has been
advised of the possibility of such damages. Volcanic’s liability shall never exceed the amount paid for the original equipment
found to be defective.
To activate the warranty for this product, the appropriate commissioning sheets must be completed and returned to the
Volcanic Quality Assurance department for review and approval.
Effective: 08.04.2011
5-3
WARRANTY & PARTS VHC-IOM-2012-0207 SECTION 5
THIS PAGE INTENTIONALLY LEFT BLANK
5-4
SECTION 5 VHC-IOM-2012-0207 WARRANTY & PARTS
5-5
WARRANTY & PARTS VHC-IOM-2012-0207 SECTION 5
5-6
No part of this Installation, Operation, and Maintenance manual
may be reproduced in any form or by any means without
permission in writing from Volcanic Heater, Inc.
www.volcanic-heater.com
VHC-IOM-2012-0207

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INSTALLATION AND

Semi-Annual Maintenance Schedule .................................................................. 4-5

Warranty & Parts 5-1

Overview Warnings & Cautions

§ Material inspections § WARNINGS must be observed to prevent serious injury

When working on this equipment, observe all warnings,

1. Consult authorities with jurisdiction over any national or local codes

§ Under no circumstances allow weight to bear on the jacket, control

§ Flue Pipe 18” (0.5 m) Failure to provide proper minimum

Environment, Ventilation and Combustion Air

Adhere to the following to meet ventilation and combustion air requirements:

2. Ensure the burner has an adequate supply of air. Based on NBIC

* Standard burner, single fuel applicaons.

TABLE 2 - DIMENSIONS-COIL DESIGN THERMAL FLUID HEATER (SEE FIGURE 2)

Heater Inlet/ Outlet Connections

(D) Flue Outlet Diameter

Approximate Dry Weight

*All weights are lbs/ft2

FIGURE 1 -COMPONENT VIEW OF THE THERMAL FLUID HEATER

What to do if you smell gas: 1200-HC 3000 6000 2000

9. Ensure the supply pressure is regulated by a non- ¡ The Oil Supply

2” NPT Gas Connection

Pilot Gas Valve

Manual Gas Valve

HI/LOW Gas Pressure Switch

Gas Safety Shutoff Valve

Manual Gas Valve

1. Be aware that certain types of thermal fluid may have operating

3. Remember that there is pressure generated in the system by the circulating

¡ Selecting a Thermal Fluid

Consider the following for thermal fluid selection:

§ Be a stable and homogenous liquid to a temperature of at least 100°F

§ No solid matter in suspension.

§ Non-toxic in the case of leakage.

§ Sufficient lubricity, i.e. not likely to cause seizure.

6. The thermal fluid manufacturer must guarantee the characteristics of the

¡ Thermal Fluid Breakdown

FIGURE 4 - PRESSURE SWITCHES

FIGURE 5 - TEMPERATURE LIMIT DISPLAY

2. Consider the appropriate location and orientation of valves necessary

4. Ensure all components exposed to thermal fluid flow, including pipe,

5. Ensure all pipework is constructed from seamless mild steel pipe,

6. If an isolating valve is completely closed, the pressure in the system will

7. Where secondary circulating pumps are installed, ensure the system is

8. During construction of the installation, ensure that no dirt, water, or

9. Consider expansion joints or pipe loops to accommodate thermal

12. If screwed connections have to be made, e.g., to items of control

´ NOTE: Typical gaskets used by Volcanic include JM Clipper Elastograph

Due to extremely high operating

4. Ensure hot oil pipe insulation is a minimum of 2” (51

13. Deaerator Tank Inlet (must be highest point of piping)

20. Isolating Valve as necessary

FIGURE 6 - TYPICAL THERMAL PIPING SCHEMATIC

From Outlet of Deaerator

Pipe Support Must Be 7 6

FIGURE 10 - TYPICAL WATER COOLED PUMP

¡ Requirements for Water Cooled Pumps

* Standard burner, single fuel applicaons.