Frost Fighter IDF350-II, IDF500 Installation, Operation And Maintanance Manual

FROSTFROSTFROSTFROST

INDIRECT FIRED SPACE HEATERS

MODEL IDF350-II

MODEL IDF500 (AUGUST 2008-

PRESENT)

Installation - Operation/Maintenance

Instructions and Parts List

READ INSTRUCTIONS PRIOR TO STARTING HEATERS

FROST FIGHTER INC.

100-1500 NOTRE DAME AVE

WINNIPEG, MANITOBA

CANADA R3E 0P9

TEL : (204) 775-8252

FAX: (204) 783-6794

WWW.FROST-FIGHTER.COM

TOLL FREE 1-888-792-0374

FROSTFIGHTER WARRANTY

Frost Fighter Inc. warrants the Frostfighter heater to be free from defects in workmanship and materials for a period of twelve (12) months from date of initial service not to exceed fifteen (15) months from date of shipment.

If during the warranty period, the heat exchanger fails under normal use and service due to a defect in material or workmanship said heat exchanger will be repaired or replace free of charge F.O.B. the Winnipeg Factory..

All mechanical and electrical components are covered by a one (1) year limited warranty. Normal maintenance items are excluded under the warranty. The warranty does NOT include any freight, labor or sales taxes incurred by the purchaser and is subject to the following conditions:

1. The heater shall be operated in accordance with the manufacturer’s operating and maintenance manual.

2. The heater shall be subject to normal use in service and shall not have been misused, neglected, altered or other wise damaged.

3. The unit shall be operated within the rated capacities and with the prescribed fuel.

4. The unit has not been allowed to exceed its proper temperature limits due to control malfunction or inadequate air circulation.

5. There is no evidence that the unit has been subject to tampering or deliberate destruction.

6. The heat exchanger shows no signs of an implosion or explosion.

No representative of Frost Fighter Inc., nor any of its distributors or dealers, is authorized to assume for Frost Fighter Inc. any other obligations or liability in connection with this product, nor alter the terms of the warranty in any way. This warranty is limited to the express provisions contained herein and does not extend to liability for labor costs incurred in replacing defective parts.

Parts can be obtained from Frost Fighter Inc, Winnipeg, Manitoba on the basis that credit will be issued if the defective parts returned qualify for replacement pursuant to the terms and conditions of this warranty. Authorization to return any alleged defective parts must be first obtained from the factory prior to transporting the part. A R.G.A.# must be provided from an Frost Fighter Inc representative. The transportation charges for the alleged defective part must be prepaid by the owner. Frost Fighter Inc. will not accept charges for parts purchased unless the conditions of this warranty have been satisfied and prior authorization to purchase the parts has been received from the factory.

100-1500 NOTRE DAME WINNIPEG, MANITOBA R3E 0P9, (204) 775-8252

SPECIFICATIONS

MODEL

IDF350-II

IDF500

IDF500HS

MAXIMUM INPUT

350,000 BTU/HR

500,000 BTU/HR

NOZZLE

SIZE

2.00 USGPH 45’ B (SOLID)

2.5O USGPH 60’B (SOLID)

PUMP

PRESSURE

125 P.S.I. MAXIMUM

140 P.S.I. MAXIMUM

FUEL

TANK CAP.

35 IMP GALS. 42 US GALS.

ELECTRICAL SUPPLY

115 VOLT 15 AMP

115 VOLT 20 AMP

115 VOLT 25 AMP

HEATED AIR

(W/O DUCT)

2500 CFM

3100 CFM

3500 CFM

APROX.

RUN TIME

13 HOURS

11 HOURS

APPROVAL AGENCY

DRY WEIGHT

510 LBS.

PLEASE REFER TO PAGE 7 IF KEROSENE IS NOT BEING USED.

Flue size-6” on all units

NOTE: -These heaters are intended for use primarily as temporary heating of buildings under construction, alteration or repair

MAXIMUM ALLOWABLE DUCT LENGTHS (IDF 350 & IDF 500 )

DISCHARGE OUTLET

Two 12“ ducts

One 16“ duct

For the IDF500 HS, the maximum allowed ducting is 50' for the 12" X 2 and 100' for the 16".

LENGTH

24 Feet

45 Feet

Dimensions of IDF350-II and of the IDF500 Heaters

FROST

MODEL

IDF350

IDF500

Heater Only

51"

76 1/2"

27"

WEIGHT (LBS)

510

83"

With Packaging

38"

52 1/2"

38"

52 1/2"

WEIGHT (LBS)

562

Heater Only

MODEL

IDF350

IDF500

29 1/2"

65 1/2"

WEIGHT (LBS)

25"

325

70 1/2"

With Packaging

32"

35 1/4"

WEIGHT (LBS)

375

INSTALLATION INSTRUCTIONS

1. The recommendations of local authorities having jurisdiction must be followed. For recommended Installation practices refer to C.S.A. Standard B139 (CANADA) or NFPA 54 (US)

2. When firing the unit in an enclosed area 3 square feet must be provided to allow the free entry of the air required for operation.

3. For electrical supply, use 3 wire receptacle with “U” ground.

4. Do not operate the unit in partly ventilated areas without a flue pipe or in close proximity to combustible surfaces or materials.

NOTE: Installation clearances are as follows:

Top - 3 inches Discharge End - 10 feet Sides - 6 inches Vent Connector - 18 inches Burner End - 2 feet Floor - Combustible

FLUE PIPE CONNECTIONS

When the heater is connected to a flue pipe the flue pipe shall terminate in a vertical section at least two feet long. Horizontal runs should have rise ratio of 1 in 10 away from the heater. The chimney should have .02” W.C. draft to ensure safe operation of the unit. Where down drafts are liable to occur a vent cap should be used. All venting Should correspond with the CSA B149 (CANADA), NFPA 54 (US) standard or local codes.

INSTALLATION CLEARANCES

FLUE WITH VERTICAL RUN

2 FT. MIN.

FLUE WITH HORIZONTAL RUN

FROST

2 FT. MIN.

RISE RATIO 1 IN 10

OPERATING INSTRUCTIONS

TO START HEAT WITH HONEYWELL CONTROL

1. Ensure unit is on flat, level ground before starting, canopy and fan guards must be closed.

2. Flip switch to “OFF” position 3 Check fuel level ( 2-4 gallons to start)

4. Plug in supply cord to 115 volt outlet.

5. Flip switch to “MANUAL” position.

6. For thermostat operation flip switch to “THERM” position. 7 There will be a 5 second safe start check, a 15 second pre purge then the burner will fire.

TO START HEATER WITH GENISYS CONTROL 1-6 same as above

7. There will be a 5 second safe start, 45 second pre purge then the burner will fire. On shutdown there is a 2 minute post purge.

IF HEATER FAILS TO START

1. Press manual reset button on burner relay.

2. Check for low voltage condition and 115 volt supply.

3. Check fuel filter, suction tubing and nozzle assembly

NOTE: If unit has been reset a number of times without ignition there will be an

accumulation of oil in the combustion chamber! Do the Following:

1. Make sure unit is sitting on level ground to ensure excess oil drain out of secondary exchanger (via small drain hole located on outer shell of heat exchanger by burner end).

2. Allow unit to drain for 15-20 minutes or until all oil has drained out.

3. Upon ignition excessive amounts of smoke will be present until all excess oil has been burnt from the heat exchanger.

4. When the unit has stabilized and the burner set up to operate properly, shut off the switch. Let the fan cool down the chamber and stop.

IF UNIT STILL DOES NOT START REFER TO THE TROUBLE SHOOTING GUIDE PAGE 12

CAUTION

1. Do not start heater when excess oil has accumulated in chamber.

2. Do not fill tank while unit is operating.

3. Do not shut off by disconnecting supply cord. The heat exchanger should be properly cooled before power shutdown.

4. In no case should extension cords be smaller than 12 A.W.G. If cord is longer than 50’ use 10 A.W.G. minimum.

5. Do not use gasoline, crankcase oil or heavier than No. 2 furnace oil.

6. Always maintain adequate fuel supply.

ELECTRICAL REQUIREMENTS:

15 amp circuit IDF 350-II 20 amp circuit IDF 500 25 amp circuit IDF 500HS

TO STOP HEATER

Flip switch to “OFF” position. The supply fan will continue to operate until the heat exchanger has sufficiently cooled. Do not disconnect main power until supply fan has stopped running.

WARNING!: BEFORE MOVING ANY GUARDS OR SAFETIES DISCONNECT

THE MAIN POWER AS THE SUPPLY FAN WILL CYCLE AUTOMATICALLY.

IDF MAINTENANCE INSTRUCTIONS

!WARNING!: Heaters should be fully serviced annually to ensure proper

Performance. Maintenance should be performed by trained personnel only. Incorrect maintenance may result in improper operation and serious injury.

HIGH LIMIT SWITCH

The limit switch should be checked every heating season to ensure the burner will

shutdown if temperature exceeds 220 F. (This can be done by restricting the air

flow through the unit. After tests are complete, remove restricters as both 12” ducts

must be open for proper operation).

FAN SWITCH

The fan switch has been selected to allow for preheating of the heat exchanger to ensure that

only heated air is allowed to enter the space. Upon satisfying the need for heat, the fan switch will

continue to run the supply fan until the heat exchanger has cooled sufficiently. This feature will

help prolong the life of your heat exchanger.

FUEL FILTER

Replace cartridge (48164 or 48164A)once every week of normal usage or sooner, depending

upon fuel quality.

FLAME DETECTOR

When doing maintenance, turn on machine. After having run the machine run for over 10

seconds, press red button on primary control. Hold for one second and then release. If light

flashes once or twice, cad cell is functioning properly. If flashes three times, check alignment and

proper flame. If correct a cleaning of the face of the cad cell with a soft non abrasive cloth is

recommended. If light flashes four times, follow above steps. If flashing four times persists,

replace cad cell.

LED FLASHES CAD CELL RESISTANCE

1 0-400 Ohms

2 400-800 Ohms

3 800-1600 Ohms 4 >= 1600 Ohms BURNER

The electrode spacing must be checked and adjusted, if necessary after every nozzle

change. Nozzle should be replaced annually or sooner if burner cannot be set up to

operate properly. Nozzle size and type are marked on the rating plate.

ELECTRICAL Ensure all conduit (BX) connectors are tight. Check inside connections in control box to ensure

good connections. Check marrettes.

FAN Check for dust or dirt build up on blades. Check for tightness of the set screw. Run heater to

check for fan vibration. Replace fan blade if vibration is noticeable.

MOTORS

No lubrication is necessary since the bearings are the sealed type. Clean motor of existing dust or dirt.

FUEL SYSTEM Periodically remove fuel tank drain plug and clean tank. Do not store unit containing furnace oil for long periods. The quality of fuel oil will affect light off at low ambient

temperatures, #1 fuel oil or kerosene are recommended for temperatures below -10 C /

8 F. (see page 7 for recommended settings if using #2 fuel oil in cold temperature) FUEL PUMP Check fuel pump pressure on a regular basis. This should be checked at the bleeder screw. WITH THE CLEAN CUT PUMP ADD 10 LBS TO THIS READING TO GET THE TRUE PRESSURE.

There is a pressure loss when fuel passes through solenoid valve. Example: IDF350 pressure should be read on the guage at 135 PSI, reading at nozzle line will then be 125. Units with the Suntec A2YA7916, pressure reading can be checked at the guage port. This will provide a true reading.

HEAT EXCHANGER

If a smokey condition continues even after adjusting the air band assembly, the heat exchanger should be thoroughly cleaned as per next page.

CLEANING PROCEDURE

1. Remove front cap. (48205, 48205A or 20205)

2. Remove cover panel (jacket to front). (48119 or 20119)

3. Remove fan thermostat cover on outer jacket (the one nearest the burner). (48112A) Loosen thermostat and remove from the jacket. Remove high limit thermostat

cover.(48112). Remove the two screws that are on jacket, at the 3’o’clock & 9 o’clock position 8 inches from front of unit.

4. Slide heat exchanger out of jacket and place front face down on floor.

5. Access for combustion chamber and heat exchanger cleaning is obtained through the burner head opening and by removing the heat exchanger cap ring(s) (48115 or

50115).

6. To reassemble, reverse procedure. If you need assistance, please contact the factory.

Close canopy and ensure fan guards are in proper position before trying to restart the unit..

COMBUSTION AIR ADJUSTMENTS

****For proper combustion air adjustment a calibrated gas analyzer and smoke tester should be used to ensure complete combustion. Air adjustment should be made at the correct input and be adjusted to achieve 10% CO2. For optimum combustion efficiency the combustion air control should be

set to provide no more than a No. 1 smoke (Bacharach Scale). The Beckett burner has a calibrated air band, which will assist in adjusting the primary air for a good oil/air mixture. Adjust air band supply by loosening lock screws and moving air shutter (B48254) and if necessary the bulk air band. Begin by reducing the air until the unit begins to produce smoke. Increase air until no smoke is produced. Check for excessive heat build up in the heat exchanger. Insufficient air will cause flame impingement and reduced heat exchanger life. Increase air until heat build up has been eliminated. Check for proper ignition. Once satisfied re- tighten all screws and locking mechanisms.

This adjustment is to be carried out while the unit is operating and after 5 minutes of firing. Rotating the air bands on the burner housing makes the adjustment.

AIR SETTINGS

OHV200

IDF 350

IDF 350-II

IDF 500

SHUTTERUNIT MODEL

4.0

BAND

BURNER MODEL

CF 375

CF 500

CF 800

***Note: The above settings are approximations based upon clean equipment in proper working order. Combustion air adjustments will vary with location, altitude and type of fuel used.

Due to the increased density of #2 oil at colder temperatures, kerosene fuel must be used or the oil nozzle change as follows at temperatures below 8'F/-10'C.

Model Nozzle (USGPH) OHV350 1.5 x 60' R Monarch IDF350/IDF350-II 1.75 X 45'B Delevan OHV500 2.25 x 60' R Monarch IDF500 2.25 X 60'B Delevan

TEMPERATURE FEELER ADJUSTMENT: (Attached to fan switch)

ALWAYS MAKE SURE THAT THE TEMPERATURE FEELER IS TOUCHING THE HEAT EXCHANGER!!

The temperature feeler provides air flow over the fan switch, which regulates the cycling of the fan. The temperature feeler can be adjusted for different outside temperatures, by rotating the location of the temperature feeler holes. This will provide optimum performance of the unit in different applications, and will reduce or eliminate unnecessary fan cycling.

IF SURROUNDING AIR IS WARM (EG., -5 C or 23 F, indoor application):

TURN THE TEMPERATURE FEELER SO THAT THE HOLES ARE PARALLEL WITH THE HEAT EXCHANGER, AND ENSURE THAT NOTHING IS BLOCKING THE AIR FLOW (EG., SCREWS). BY DOING THIS THE FAN SWITCH WILL REMAIN COOL AND NOT OVERHEAT. (SEE FOLLOWING) The fan switch is located under the high limit/fan cover which is mounted on the jacket close to front of unit. The switch can be adjusted by using a flat-headed screw driver and turning it clockwise or counter clock wise to desired temperature.

IF SURROUNDING AIR IS COLD (EG., under -5 C or 23 F)

TURN THE TEMPERATURE FEELER SO THAT THE HOLES ARE CLOSED OFF AS THE AIR GOES OVER THE HEAT EXCHANGER, THIS WILL REDUCE FAN CYCLING, UNIT SHUTDOWN, ETC. (SEE FOLLOWING)

Indoor and outdoor settings of fan switch

Indoors & if surrounding air is warm i.e. -5C/23F-Fan switch should be set to 115’ or higher so as to shut down unit when heat exchanger is properly cooled, also keeps fan motor

from excessive running on when discharging cooler air.

Outdoor-Fan switch should be set between 100’-90’. The colder the temperature the lower the setting.

+ 18 hidden pages

Frost Fighter IDF350-II, IDF500 Installation, Operation And Maintanance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual