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G~
"@;' US MEA#:
MEA to7-04-E
#: 107-04-E
A SCOTT FETZER COMPANY
SCOTT FETZER COMPANY
8OIGLASGOW
801 GLASGOWAYE. AVE.
FORTWAYNE,
FORT WAYNE, IN 46803
46803
PublicationDate
Publication Date9/5/06
9I 5I 06
PARTNO.
PART 63537-001
NO. 63537-001 Rev.F
Rev. F

MODEL "EHG"
"EHG" GAS BURNERS
GAS BURNERS
WARNING: If
WARNING: If the
the infonnation
informationin theseinstructions
in these instructionsis is not
not followed
followedexactly,
exactly,
aa fire
fire or
or explosion
explosionmay mayresult,
result,causing propertydamage,
causingproperty damage, personalinjury
personal injury or
or
death.
death.
Do not
- Do not store
storeor gasolineor
usegasoline
or use or other flammablevapors
otherflammable vaporsand
andliquids
liquidsin the
the
vicinityof this
vicinity thisor
or any
anyother appliance.
otherappliance.
WHAT TO
- WHAT TO DO
DO IF IF YOU
YOU SMELL
SMELLGAS GAS
.• Do
Do notnot try
try to
to light
light the
theappliance.
appliance.
.• Do
Do notnot touch
touchanyany electrical
electricalswitch;
switch;dodo not
not use
useany phonein your
anyphone your building.
building.
•. Immediately
Immediatelycall yourgas
call your gassupplier neighbor'sphone.
fromaa neighbor's
supplierfrom the
Followthe
phone. Follow
gassupplier's
gas supplier'sinstructions.
instructions.
.• If you cannot
If you cannotreach your gas
reachyour gassupplier,
supplier,call the fire
call the fire department.
department.
Installationand
- Installation andservice
servicemust
mustbe be performed
perfonned by qualifiedinstaller,
by aa qualified installer,service
service
agencyor the
agency gassupplier.
the gas supplier.
Warrantyis
Warranty is voided
voidedif if not installedby
not installed qualifiedservice
by qualified person.
serviceperson.
NOTICE
THESEINSTRUCTIONS
THESE INSTRUCTIONSSHOULD
SHOULDBE
BE MAINTAD'JED
MAINTAINED IN LEGIBLE
LEGIBLE CONDITION.
CONDITION.
THESEINSTRUCTIONS
THESE SHOULDBE
INSTRUCTIONS SHOULD BE POSTED,
POSTED,AFFIXED
AFFXED TO
TO THE
THE BURNER,
BURNER,OR
OR
ADJACENTTO
ADJACENT TO THE
THE HEATING
HEATING APPLIANCE.
APPLTANCE.FOR
FORFURTHER
FURTHERINSTRUCTIONS
INSTRUCTIONS
WARNINGS, SEE
AND WARNINGS, SEETHE
THE BACK OF
OF THIS
THIS MANUAL.
SPECIFICATIONS 55EHG"BTJRI\ERS
SPECIFICATIONSFOR MODEL "EHG" BURNERS
NATURAL GAS
GAS OR PROPANE
PROPANE

NOTE: "S.I." Dimensions


NOTE: "S.l." Dimensions in ( ) are
are informational
informational only.
only. English
English values
values take
take
priority.
priority.
Maximum
Maximum Input Capacity** -- 700
Input Capacity 700MBTU (738500(738500 kJ)
kJ)
Minimum
Minimum Input
Input Capacity *
Capacity * -- 425
425MBTU (448400
(448400 kJ)
kJ)
** De-rate
De-rate input
input for altitude
altitude over
over 2000 ft. (609.6
2000ft. (609.6 m)
m) by 4Yo each1000
4% each 1000 ft.
ft.
(304.8
(304.8 m)m) above
above sea
sea level.
level.

SUPPLY
SUPPLY LINELINE PRESSURE
PRESSURE REQUIRED:
REQUIRED: Natural
Natural or Propane
Propane 6" W.C.
W.C.
(1494
(1494 Pa)
Pa) Minimum,14" W.C. (3487
Minimum, 14" W.C. (3487 Pa)
Pa) Maximum
Maximum
AIR TLIBE
TUBE DIAMETER: 4 inches inches (101.6
(101.6 mm)
mm)
AIR INSERTIONS (STANDARD
AIR TUBE INSERTIONS (STANDARD BURNERS):
BURNERS):
5.00 inches (127
5.00 inches (127 mm)
mm) Maximim
Maximim
7.00 inches (177.8
7.00 inches (177.8 mm)
mm) Maximum
Maximum
10.00 inches (254
10.00 inches mm)Maximum
(254 rum) Maximum
13.00 inches (381.0
13.00 inches mm) Maximum
(381.0 mm) Maximum
MOUNTING: Adjustable
Adjustable flange
flange standard.
standard.
STANDARD VOLTAGE: 120
STANDARD 120 VAC I/ 60HZl
60 HZ/ I1 Phase
Phase
FLAME SAFETY:24YAC
SAFETY: 24 VAC Single-Rod Gas Primary
Single-Rod Gas Primary
IGNITION:
IGNITION: 10,000
10,000 VAC Direct Spark Ignition.
Direct Spark Ignition. Optional
Optional transformers
transformers are
are
available.
available. Standard
Standard burners
burners are
are shipped
shipped with the
the ignition
ignition transformer
transformer
mounted
mounted to the
the burner.
burner. If
If the
the transformer
transformer is to be
be remotely
remotely mounted,
mounted, the
the
ignition
ignition wire
wire must
must not
not exceed 36" (914.4mm)
exceed 36" (914.4rum) per
per UL795.
UL795.

GAS
GAS PIPETRAIN: The The pipehain
pipetrain is pre-assembled
pre-assembled andand pre-wired
pre-wired and
and is
IlL795
UL795 compliant,
compliant, which
which includes
includes High
High && Low gas
gas pressure
pressure safety
safety switches,
switches,
two
two manual
manual ball
ball valves, two I'J.{PT
valves, two 1''NPT x I"NPT
1"NPT 110VAC
11 OV AC Solenoid
Solenoid Shutoff
Shut-off
Valves,
Valves, a Main Gas
Gas Pressure
Pressure Regulator,
Regulator, and gas test ports.
and gas test Upon request
ports. Upon request the
the
pipetrain
pipetrain can
can be
be assembled
assembled without
without a Gas
Gas Pressure
Pressure Regulator,
Regulator, but
but the
the correct
correct
Gas
Gas Pressure
Pressure Regulator
Regulator must
must be
be installed
installed before
before operation. The pipetrain
operation. The pipetrain is
shipped
shipped separate,
separate, and
and minor field plumbing
minor field plumbing and
and wiring arerequired.
wiring are required. The
The
pipetrain
pipetrain must be located
must be 12' (3.6m)
located 12' (3.6m) or less
less from
from the
the burner
burner for optimal
optimal
performance.
performance.

2
CONTENTS
CONTENTS
PAGE
SECTION I INSTALLATION
SECTION 4-13
4-13
A. GENERAL
GENERAL 4
B.
B. VENTILATION
VENTILATION 4
C.
C. HEATTNG
HEATING APPLIANCE
APPLIANCE INSPECTION
INSPECTION 4
D. CHIMNEY,
D. CHIMNEY, FLUE
FLUE PIPE
PIPE AND DRAFT
DRAFT CONTROL
CONTROL 5-6
5-6
E. COMBUSTION
E. COMBUSTION CHAMBER
CHAMBER 6-7
6-7
F'.
F. GAS PIPING
PIPING 7-9
7-9
G. ELECTRICAL
G. ELECTRlCAL 9
H.
H. MAIN BURNER
BURNER ORIFICE SIZING AND INSTALLATION
ORIFICE SIZING INSTALLATION.... 1100
r.
I. lIIOVAC
lOvAC soLENorD
SOLENOID SHUT-OFF
SHUT-OFF GAS
GAS VALVE(S)
VALVE(S) 110-11
0 -l t
J. PRESSURE
J. PRESSURE REGULATOR
REGULATOR ADJUSTMENT
ADJUSTMENT l2
12
K. GAS
GAS PRESSURE
PRESSURE SWITCHES
SWITCHES................................... 1
133

SECTION
SECTION II
II INITIAL
INITIAL START
START UP
UP l5 - 18
J 5-18

SECTION
SECTION III OPERATION AND TROUBLESHOOTING....
III OPERATION TROUBLESHOOTING.... t9
19

SECTION
SECTION IV
IV SERVICE
SERVICE 27
27

DRAWINGS
DRAWINGS & PARTS
PARTS LIST 28.38-48
28,38-48

TECHNICAL
TECHNICAL INFORMATION
INFORMATION 3311
WARRANTY
WARRANTY 3344
CONSUMER
CONSUMER INSTRUCTIONS
INSTRUCTIONS 3355

3
SECTION II
TNSTALLATION
INSTALLATION
A. GENERAL
A.GENERAL
Installation these power
of these
Installation of power gas
gas burners
burners must
must conform
conform to local codes,
codes, or in
their absence, the National Fuel Gas
their absence, the National Fuel Gas Code,
Code, ANSI Z223.IAIFPA
Z223.1/NFPA 54.54.

In CANADA,
CANADA, "The equipment
equipment shall
shall be
be installed
installed in accordance
accordance with the
the
Provincial Installation
Provincial Installation Requirements,
Requirements, or in their absence,
absence, the
the CGA 8149.1
B 149.1
and Bl49.2Installation
and B 149.2 Installation Codes
Codes shall prevail."
shall prevail." Authorities
Authorities having jurisdiction
having jurisdiction
should
should be
be consulted
consulted before
before installations are made.
installations are made.

NOTICE:
NOTICE: ANSI or local local installation
installation code compliance is the
code compliance the sole
sole
responsibility
responsibility of the qualified
of the qualified installer.
installer.

B. VENTILATION
VENTILATION
The EHG burner
burner models
models covered
covered byby this
this manual shall not
manual shall be installed
not be installed in an
an
appliance
appliance located
located where
where normal
normal air circulation
circulation or infiltration
infiltration is
is limited
limited in
providing
providing all the necessary for proper
the air necessary combustion and
proper combustion draft hood
and draft hood dilution
dilution
air.
alr.

When the heating


When the heating appliance
appliance is installed
installed in a tightly
tightly closed
closed room
room without
without
ventilation
ventilation openings
openings to
to outdoors,
outdoors, or other rooms, provisions
other rooms, provisions shall be made
shall be made
for supplying
supplying air for combustion
combustion through
through special openings, one
special openings, one near
near the
the floor
line
line and
and the other near
the other near the
the ceiling.
ceiling. Each
Each isis to
to be
be sized
sized on the
the basis
basis of
of one
one
2
square inch (645.2mm') or more of free area
square inch (645.2mm ) or more of free area each (.29kW)
each 1,000 BTU (.29kW) input
1,000 BTU input
per hour.
per hour.

C. HEATING
HEATING APPLIANCE
APPLIANCE INSPECTION
INSPECTION
Clean the
Clean the appliance
appliance heat
heat exchanger
exchanger interior,
interior, combustion
combustion chamber
chamber and and flue
connections.
connections. Remove
Remove all
all adhering
adhering tars,
tars, scale,
scale, dirt
dirt and soot. Inspect
and soot. Inspect thethe heat
heat
exchanger
exchanger for for obvious and potential
obvious and flue gas
potential flue gas leaks. Cement all
leaks. Cement all joints
joints around
around
the
the appliance base and
appliance base and access
access openings
openings to to prevent
prevent air
air and/or flue gas
and/or flue gas leakage
leakage
into
into or
or out
out of
of the
the combustion
combustion chamber.
chamber.

Warm
Warm Air Fumaces* -- Make
Air Furnacesx Make certain
certain the
the electrical
electrical characteristics of the
characteristics of the fan
fan
and
and limit
limit switch
switch correspond
correspond to those required
to those required by
by this burner and
this burner and are
are in
in
proper
proper working
working order.
order.

Hot
Hot Water
Water Boilers*
Boilers* -- Make
Make certain
certain water
water temperature
temperature and altitude gauges,
and altifude gauges,
pressure relief valves are in proper
pressure relief valves are in proper working
working order.
order.

4
SteamBoilers* - Make certainthe systemis pressuretight,
Steam Boilers* - Make certain the system is pressure tight, with
withpressure
pressure
g?geand pop off safetyvalve in proper working
order.Insure
gage and pop off safety valve in proper working order. inrur. Existing
Existingwater
water
sight glasspermits clear observationof boil"r riutrr level.
sight glass permits clear observation of boiler water level.
*Where applicable,
*Where applicable, existingtemperature
existing temperature of pressure
ofpressure limitswitch
limit switchororlow
low
watercut-off switch operationand electricaicharacteristics
water cut-off switch operation and electrical characteristics shall be checked
shall be checked
to determinetheir compatibility to the gas control circuitry
to determine their compatibility to the gas control circuitry of
ofthis
thisburner.
burner.
D. CHIMNEY, FLUE PIPE AND DRAFT CONTROL
D. CHIMNEY, FLUE PIPE AND DRAFT CONTROL
The chimney shouldbe inspectedfor unsafeconditions
suchas
The chimney should be inspected for unsafe conditions such asexcessive
excessive
soot accumulation,deterioratedmasonry,blockageor potential
soot accumulation, deteriorated masonry, blockage or potential blockage.
blockage.
NOTICE: No manuallyadjustableflue pipe damperis permitted
NOTICE: No manually adjustable flue pipe damper is permitted on on any
anygas
gas
burnerinstallation.The chimneyshouldbe lined with a
corrosionresistant
burner installation. The chimney should be lined with a corrosion resistant
material.If the chimneyis unlined,consultyour local gas
material. If the chimney is unlined, consult your local gas utility
utility for
for
recommendations.
recommendations.
WARNING: Under no circumstances shouldthe
the flue
flue pipe
pipe be
WARNING: Under no circumstances should be connected
connectedto
to
the chimneyof an openfireplace.
the chimney of an open fireplace.
strict compliance to appropriate codesshould be made
Strict compliance to appropriate codes be made regardingflue
regarding flue pipe
pipe
clearances,fro* combustiblematerials.
clearances from combustible materials.
Pitch the horizontal run of the flue pipe upward r/4 inch(6.35mm)
Pitch the horizontal run of the flue pipe upward 1/4 inch (6.35mm) per
per foot
(.305m) or more. Run directly to ttre ctrimney,fastenjoinis
(.305m) or more. Run directly to the chimney, fasten joints secure'ly
securely and
and
supporthorizontal runs to prevent sagging.
support horizontal runs to prevent sagging.
If the flue pipe must be extralong, its diametershould
I f the flue pipe must be extra long, its diameter should be
be increased.
increased. The
The
horizontal length of_theflue pipe should not exceedthe
horizontal length of the flue pipe should not exceed the height
height of
ofthe
the
chimneyabovethe flue conneCtion.
chimney above the flue connection.

5
PITCH
PITCH HOBIZONTAL
HORIZONTAL
RUN 1/4'(6.35mm)
RUN 1/4' (6.35mm) MlN.
MIN. DO NOT EXTENO
EXTEND
PER FOOT (.30sM)
PER FOOT (.305M) FLUE
FLUE PIPE
PIPE BEYOND
INSIDE
INSIDE OF CHIMNEY
CHIMNEY

VERTICAL
VERTICAL
DBAFT
DRAFT HOOD

REDUCER CORBOSION
CORROSION
RESISTANT
RESISTANT LINING
LINING

CLEANOUT

SELECT
SELECT EITHER
EITHER
HORIZTONAL
HORIZTONAL OR
VEBTICAL
VERTICAL DRAFT
DRAFT HOOD

DRAFT
DRAFT HOOD
HOOD POSITONS
POSITONS
FIGURE I1

The
The draft control
control should
should be
be hood type per Figure
hood type Figure Ilor,
or, IF APPROVED BY BY
LOCAL
LOCAL AUTHORITIES,
AUTHORITIES, a barometric
barometric damper suitable for gas
damper suitable gas firing per
Figure
Figure 2.
2. The draft control
control should
should be sized the
be sized the same
same as the flue pipe
as the pipe and
and
should
should be
be located
located higher
higher than highest part on the
the highest
than the flue passage.
appliance flue
the appliance passage.
Refer
Refer to the barometric draft regulator
the barometric manufacturer's instructions
regulator manufacturer's instructions for
complete
complete detail.
detail.

NOTICE: Should
Should the flue pass
the flue through a partition,
pass through partition, the
the draft
draft control
control must
must be
be
located
located in the
the same
same room as the heating
as the heating appliance.
appliance.

PITCH
PITCH HORIZONTAL
HORIZONTAL
RUN 114" (6.35mm)
RUN 1/4" (6.35mm) MlN.
MIN.
PER FOOT (.305M)
(.305M)
DO
DO NOT
NOT EXTENO
EXTEND
FLUE PIPE
PIP£ BEYOI'IO
BEYOND
INSIOE
INSIDE OF CHIMNEY
OOUBLEACTING
DOUBLE ACTING
BAROMETFIC
BAROMETRIC
DRAFTCONTROL
DRAFT CONTROl

BUll HEAD TEE


BAROMETRIC
BAROMETRIC DRAFT
DRAFT
REDUCER
CONTROL
CONTROL POSITION
POSITION
CORROSION ..c=:-F1---f"i
RESISTANT LINING
FIGURE
FIGURE 2

CLEANOUT

E. COMBUSTION
COMBUSTION CHAMBER
A combustion
combustion chamber
chamber is normally required to protect
normally required protect non-heat
non-heat transfer
transfer
surfaces, and provide
surfaces, and to provide a radiant bed for rapid
radiant bed rapid heat
heat transfer the primary
transfer to the primary
surfaces
surfaces of the heat
of the heat exchanger.
exchanger. If good
If in good condition,
condition, the
the existing
existing combustion
combustion
chamber
chamber can
can be
be used.
used.

6
A full cornbustion
combustion chamber liner is
chamber liner recommended for warm
is recommended furnaces, see
warm air fumaces, see
Figure
Figure 3,
3, and
and aatargetwall chamber liner
combustion chamber
target wall or full combustion liner is
is recommended
recommended
for
for wet leg
wet leg cast
cast iron
iron or steel boilers. See Figures and S. If a built up
or steel boilers. See Figures4 and 5. If a built up
chamber is
chamber is necessary,
necessary, use 2300'F
use 2300° (1260'C)
F (1260°C) minimum insulating firebrick
minimum insulating firebrick
or FiberFraxrM.
FiberFrax™.

EXISTING
EXISTING
PFEFABBICATED
PREFABRICATED
:COMBUSTION
COMBUSTION
CHAMBER LINER
LINER

PROTECT PFOPERLY
TO PROTECT PROPERLY
LOCATE
LOCATE END BURNER
OF BURNER
END OF
EHG TUBE. POSITION
TUBE. POSITIONTUBE 1/2"
TUBE 112"
BURNER (l2.7mm)
(12.7mm) SHORT INSIDE
OF INSIDE
SHORT OF
BURNER
OF COMBUSTION
COMBUSTION
CHAMBER
CHAMBER

FORCEDAIR
FORCED FURNACE
AIR FURNACE
FIGURE
FIGURE 33

EXISTINGOR
EXISTING OB
ADDED TARGET
ADDED TARGET
TO BACK OF
TO BACK OF COMBUS,
COMEU$ EXISTING
EXISTING
TION CHAMBER
TlON CHAMBER PREFABRICATED
PREFABRICATED
COMBUSTION
COMBUSTION
CHAMBER UNER
CHAMBER
TO PROTECT
TO PFOTECT PROPERLY
PBOPERLY .TO PROTECT PROPERLY
TO PROTECT PROPERLY
LOCATEEND
LOCATE END OF
OF BURNER
BUFNEB LOCATE END
LOCATE ENO OF BURNER
OF BURNER
EHG
EHG TUBE. POSITION
TUBE. POSITIONTUBE
TUAE 1/2'
1/2" EHG TUBE. POSITION TUBE 1/2"
TUBE. POSITION TUBE 1I2"
(l2.7mm) SHORT
SHORTOF INSIDE (12.7mm)SHORT
BTJRNER
BURNER (12.7mm)
OF COMBUSTION
COMBUSTION
OF INSIDE BURN ER ~4ii:1tl1""""'fl (l2.7mm) SHORTOF INSIDE
OF INSIDE
OF COMAUSTION
OF COMBUSTION
CHAMBER
CHAMBER CHAMBER
CHAMBER

HOT WATER
HOT WATEROR
OR STEAM
STEAM BOILER
BOILERWITH
WITH HOT WATER
HOT WATEROR
OR STEAM
STEAMBOILER
BOILERWITH
WITH
COMBUSTION
COMBUSTION CHAMBERTARGET
CHAMBER TARGET COMBUSTION
COMBUSTION CHAMBERLINER
CHAMBER LINER
FIGURE 4
FIGURE FIGURE 5
FIGURE

BURIIER AIR
THE BURNER AIR TUBE MUST NOT BE ALLOWED EXTEND
ALLOWED TO EXTEND
INTO THE CHAMBER
INTO PROPER; IT
CHAMBER PROPER; SET 1/2"
IT MUST BE SET (12.7mm)
ll2" (12.7mm)
THE INSIDE SURFACE.
SHORT OF THE SURFACE.

pernanently securing
Before permanently
Before the burner
securingthe burnerto
to the heatingappliance
the heating either
appliancewith either
the adjustable
the mounting flange
adjustablemounting flangeor pedestal,cementing
or pedestal, cementingaround air tube
the air
aroundthe in
tube in
the combustionchamber
the combustion chamberopening, that the
checkthat
opening,check the burner headassembly
burnerhead assemblyis is
free of foreign
free foreign materials
materialsand
andthat
that the
the sensor and electrode
sensorand probeshave
electrodeprobes havenotnot
beendamaged
been repositioned,see
damagedor repositioned, seeFigure
Figure6.
6.

7
PROBE DIM
PROBE D IM REF (20,3?mn)
,80 (20,32MM) REF,
REF,
IGNITER1,06
IGNITER 1.06 2 6 .9 2 m m ) *l F_.7s
--,75
SENSOR.84
SENSOR ,84 21.34mm) <le'osmn)
C19,OSrvH')
il |
1

o
o
(?,67nn)
C2,67MM) I
CD
n
'"
0
<0
n
.125(3.'l75mm)
,125(3,175mm) '"
@
CD

FIGURE
FIGURE 66
F. GAS
F. PIPING
GAS PIPING
NOTICE:
NOTICE: All All piping
piping must local codes.
comply with local
must comply The available
codes.The gas
availablegas
supply pressureshould
supplypressure shouldbebe within minimum and maximum pressures
and maximum shown
pressures shown
the burner
in the specifications.
burner specifications. If the
If gassupply
the gas supplypressure 14" w.e.
exceeds14"
pressure exceeds W.C.
(3487.4Pa)maximum,
(3487.4Pa) maximum, an an intermediate
intermediate main gas gas regulator
regulator must
must be
be
installedahead
installed aheadof the main
of the gas manual
main gas shut off
manual shut off valve shown in Figure
valve shown Figure 7.
7.

WARNING: Failure inrtu"tlthe


Failur. to install the intermediate
intennediate gasgas regulator will result
regulator will result in
gas leakage
gas leakagefrom
from the
the main burner regulator.
main burner Consult local
regu lator. Consult codesto install
local codes install
vent
vent lines from regulators,
lines from regulators, if used. Vent
ifused. shouldterminate outside the
lines should
Vent lines terminate outside the
building, away from windows,
building, away doors,and
windows, doors, fresh air intakes.
and fresh should
intakes. Vent should
terminatein aa way to prevent
tenninate prevent water, foreign matter,
dirt, foreign
water, dirt, insectsfrom
matter, or insects from
entering the line.
enteringthe line.

~
ANUAL SHUTOFF VALVE

I
DIRECTION •
1/8' (3. 175mm) N.P.T.
PLUGGED TAPPING
OF FLOW PRESSURE GAGE PORT

CONTROL MANIFOLD

SUPPLYLINE
SUPPLY LINE CONNECTION
CONNECTION
TO BURNER
TO BURNER

FTGURE
FIGURE 7

8
pipeunion
A pipe unionshall
shallbe installedin
be installed in the gasline
thegas line adjacent
adjacentto
to and
andupstream from
upstream from
the main
the gasmanual
maingas manual shutoff valve.A drip
shutoffvalve. leg or
drip leg or sediment
sedimenttrap/strainer
trap/strainermust
must
be installedin the
be installed the supply line to
supplyline to the
theburner. Figure7.
SeeFigure
burner. See 7.

The gassupply
The gas supplypiping
piping to the burner
to the shouldbranch
burner should from the
branch off from the main gas
main gas
line as
supplyline
supply asclose to the
closeto gasmeter
thegas aspossible.
meter as Do not
possible. Do connectto
not connect to the
the
bottom of aahoizontal
bottom section.
horizontal section.

CANADA, the
In CANADA, theinstaller
installermust identifythe
must identify Main Electrical
the Main ElectricalPower
Power
disconnect,
disconnect, andthe
and themanual shut-offvalve
manual shut-off on the
valve on GasSupply
the Gas drop-lineto
Supplydrop-line to the
the
burner.
burner.

Use new
Use ironpipe
blackiron
new black pipe and malleable
andmalleable fittingsfree
fittings freeof burrs anddefects.
burrs and defects.Use
Use
pipejoint
pipe compoundresistant
joint compound resistant to liquefiedpetroleum
to liquefied gases.
petroleum gases. A 1/8"
l/8"
(3.175mm)NPT
(3.175mm) NPT plugged acces.sible
tapacces,sible
plugged tap for gairgetest
for gauge testconnection
connection is
is
provided for determining
provided for determining gassupply
gas supplypressure
pressure toto the
theburner. Testnew
burner. Test newsupply
supply
pipingfor
piping for leaks.
leaks.

CAUTION:
DURING PRESSURE
DURING PRESSURETEST
TEST FOR
FOR LEAKS IN GAS
GAS SUPPLY
SUPPLYPIPING,
PIPING.
BURNER MUST BE DISCONNECTED
THE BURNER DISCONNECTEDTO PREVENT
PREVENT
EXPOSING THE REGULATOR
EXPOSING TO PRESSURES
REGULATOR TO PRESSURESOVER 1i2'' PSIG
OVER 1/2" PSIG
(3447PaG),
(3447 PaG),POSSIBLY
POSSIBLYDAMAGING THE UNIT AND
AND VOIDING
BURJ\ER WARRANTY.
THE BURNER WARRANTY.

G. ELECTRICAL
G.
The installation
The installation mustbe
must wiredand
be wired andGROUNDED
GROLfNDEDin in accordance
accordance with local
with local
codesor
codes or in
in their absence,
their absence, with the
with the National ElectricCode
National Electric CodeANSIAIFPA
ANSIfNFP A No.
No.
70-1987or
70-1987 or latest edition.
latest edition.

CANADA, all
In CANADA, all wiring shallbe
wiring shall donein
be done in accordance
accordance with the
with theCanadian
Canadian
Electrical Code.
Electrical Code.

For the
For the 120
120VAC wiring
wiring to theburner,
to the burner, use solidcopper
use solid copperconductor
conductor wire
wire not
not
lighterthan
lighter than#14
# 14 AWG. If aa fused
AWG. If fuseddisconnect
disconnect is used,
is shouldbe
used, it should fusedfor
be fused for aa
minimumof 15
minimum 15amps.
amps.

9
'.,
CAUTION: EachEach installation
installation must
must include
include suitable
suitable limit controls.
controls. Existing
Existing
oil burner
burner combination
combination limit and
and operating
operating controls
controls are
are normally
normally not
not suitable
suitable
for gas
gas burner
burner use.
use.

CAUTION: The
CAUTION: The burner
burner is equipped
equipped with it's own
own 24VAC
24VAC transformer.
transformer. Do
not
not add any24
add any 24 VAC power
power consuming
consuming device
device in the
the 24
24 V AC control
VAC control circuit
circuit
of
of the burner, as
the burner, as it could
could overload
overload the
the transfonner.
transformer.

CAUTION: LabelLabel all wires prior


all wires prior to
to disconnection
disconnection when
when servicing
servicing controls.
controls.
Wiring errorscan cause improper and dangerous
Wiring errors can cause improper and dangerous operation.
operation. Verify proper
proper
operation after servicing
operation after servicing.

NOTE:
NOTE: IfIf any
any of
of the
the original
original burner
burner wiring
wiring must
must be
be replaced,
replaced, it must
must be
be
replaced # 18 AWG
replaced with #18 AWG 105105 degrees
degrees C wire
wire or equivalent.
equivalent. See
See Section
Section 3-
Operation and Troubleshooting
Operation and Troubleshooting for applicable
applicable burner
burner wiring diagrams.
diagrams.

H.
H. MAIN
MAIN BURIIER
BURNER ORIFICE
ORIFICE SIZING
SIZING ANDAND INSTALLATION
INSTALLATION
The EHG power
The power gas burners are
gas burners are approved
approved for useuse with natural and propane
with natural propane
gas only. The
gas only. The EHG
EHG burner
burner models
models are shipped labeled
are shipped labeled and
and orificed
orificed for
for
natural gas.
natural gas. To
To convert
convert to propane gas
to propane gas and/or
and/or increase BTU/HR (kWHr)
increase BTUiHR (kW/Hr)
input on natural
input on or propane
natural or propane gas,
gas, an orifice kit
an orifice kit is
is supplied
supplied with
with each
each burner
burner
with the orifices shown in Figure
with the orifices shown in Figure 8.

To
To remove
remove or or interchange
interchange main
main orifice
orifice discs
discs refer
refer to
to the exploded parts
the exploded parts view
view
drawing
drawing in in this manual (Figure
this manual (Figure 17).
17).
1.
1. Remove
Remove l'NPT orifice plug,
1"NPT orifice plug, Item
Item #5.
#5.
2.
2. Remove
Remove orifice spring, Item#4,
orifice spring, Item #4, to
to access
access and
and remove
remove orifice disc, Item
orifice disc, Item
#3.
#3.
3. Install
3. Install desired orifice from
desired orifice from Figure
Figure 8,8, making
making sure
sure itit is
is seated
seated flat
flat in
in the
the
orifice holder,
orifice holder, ltem#2.
Item #2.
4. Replace
4. Replace orifice spring and
orifice spring securely tighten
and securely tighten I'NPT orifice plug
I"NPT orifice plug (using
(using
proper
proper pipe dope) into
pipe dope) orifice holder.
into orifice holder.

l0
10
'.\
BTU/hr LP,Gas Orifice Manifold
lnput Drill Decimal Part No. AP "w.e.
.LlP "w.c.
425,000(124.6kW) 3680"(9.35mm) 62438-031
425,000(124.6kW) tr. "tI" .3680"(9.35mm) 12438-031 3.7(921.6Pa)
3.7(921.6Pa\
450.000(
450,000( l3 l.9kw) J/g"
131.9kW) 3750"(9.53mm) 62438-036
.3750"(9.53mm) i2438-036 3.5( 871.8Pa)
3.5(871.8Pa)
500,000( 146.5kW) z7/64', .4219"(10.72mm)
500,000(146.5kw) 4219"(10.12mm) 62438-037
i2438-037 3.5( 811.8Pa)
3.5(871.8Pa)
ss0,000(
550,000( l61.2kw) 29164" .4531
161.2kW) 4531"( l.5lm
l mm)
"(11.51 m) i2438-038
62438-038 3.5( 871.8P a)
3.5(871.8Pa)
600,000(l75.8kw) \t64',
600,000(175.8kW) 4844"( l2.3m m ) 62438-039
.4844"(12.3mm) 52438-039 3.5(871.8Pa)
3.5( 871.8Pa)
650,000(
650,000( 190.5kW) t/2"
l90.5kw) 1/2" 5000"( 12.7m m ) 62438-040
.5000"(12.7mm) 52438-040 3.5(871.8Pa)
3.5( 871.8P a)
700,000(205.2kw)
700,000(205.2kW) J7164', .5781
37/64" 5781"(14.68mm)
"(14.68mm) 52438-041 3.5(871.8Pa)
62438-041 3.5( 811.8P a)
(LP)
Propane(LP)
Propane

-'
')~i~' :
...
.• J
'. .;. " ~r
~ '; •-. ":~s.1,,·';:f -::~~y;ii~!JIr.~~~~~~(;~~~ ;,!~~- ~1'H~'~~r' "~.~1f."~-
"EHG 0f:!fiY~£.Jz~o<~lic!t1 i...,!_~A:;~i..'1 . '"".~-
~ ·.-~*"~-.f ;'" h:L,,, ...
• ~ ,
J,,-.,;.i

BTU/hr Gas
Natural Gas Orifice
Orifice Manifold
Input Drill Decimal
Drill Decimal Part No.
Part No. AP "w.e.
.LlP "ry.c.
42s.000(
425,000( l24.6kw)15132"
124.6kW) 52438-042
4 68 8 " (ll. 9 1 mm)62438-042
15/32" .4688"(11.91mm) 3.8(946.5Pa)
3.8(946.5Pa)
4 5 0,0 0 0l 3l
( .9kw ) 31/64"
450,000(131.9kW) \t/64',.4844"(12.3mm)
4844"(l2.3mm)62438-039
52438-039 3.5( 871.8Pa)
3.5(871.8Pa)
5 0 0,0 0 0146.5kW)
500,000( l 4( 6 .5 kw ))3/64" 12438-043
5 I 5 6 " (1 3 .I mm) 62438-043
33/64" .5156"(13.1mm) 3.5( 871.SPa)
3.5(871.8Pa)
550,000(I 6l .2kw) 35/64"
550,000(161.2kW) \5/64".5469"(13.89mm)
5469"( 13.89m62438-044
m
i2438-044
) 33.5( 871.8Pa)
.5(871.8Pa)
6 0 0 ,0 0 0l 775.8kW)
600,000(1 ( 5 .8 kw )19132" 5 938"( 15.08m62438-045
19/32" .5938"(15.08mm) m
52438-045
) 3.5( 871.8Pa)
3.5(871.8Pa)
650,000(
650,000( l90.5kw)5/8"
190.5kW) i/8" 6 250"(
.6250"( 15.88m62438-046
15.88mm) m
52438-046
) 3.5( 871.8Pa)
3.5(871.8Pa)
700,000(205.2kw)
700,000(205.2kW) z3/32"
23/32" 7 188"( 18.26mno
.7188"(18.26mm) m
ro )orifice
orifice 3.5( 871.SPa)
3.5(871.8Pa)
Natural

Figure 8

I. 120VAC
12OVAC SOLENOID SHUT-OFF VALVES
SHUT.OFF GAS VALVES
The gassolenoid
The gas solenoidshut-off
shut-offvalves are pre-plumbed
valvesare the pipetrain.
onto the
pre-plumbed onto The
pipetrain. The
pipetrainis
pipetrain pre-wiredfor
is pre-wired for convenience,
convenience, the electrical
but the
but electricalwiring from
from the
the
burnermust
burner must be the field.
connectedin the
be connected field.

The
The installation
installationmust
mustbebe wired and GROUNDED
wired and accordancewith local
GROTINDEDin accordance local
codes
codesor in their absence,
their absence, with the National
with the National Electric
ElectricCode ANSIAIFPA No.
CodeANSIINFPA No.
70-1987or latest
70-1987 edition.
latestedition.

ll
11
?.+2 1--- D SQ -~-l
r~1.671

A
67/8"
~7 /8" KN0CKoUT
KNOCKOUT
FOR
FOR 1/2"
1/2." CONDUTT
CONDUIT
CONNECTION
CONNECTION
(2 HOLES
HOLES rN
IN L|NE)
LINE)

1---- C --+-----l ·1 0
DOWNSTREAM ~
1/8"NPT DOWNSTREAM
1,/8',NPT
~ • /"i/a"NPT UPSTREAM\
PRESSURE TAP
PPESSURE TAP
PPESSURE TAP

. Fig.9
Fig.9

®
@
I<F?
&
M
s"
@.

.e
.@
Fig.10
Fig.tO

Note: The gas


Note: The gas pipetrain, and all its
pipetrain, and its safety
safety components,
components, should
should be
be leak
leak tested
tested
after
after installation.
installation. l/8"NPT
1/8"NPT fittings
fittings have been provided
have been provided to isolate
isolate and
and test
test the
the
solenoid
solenoid valves. The pipetrain,
valves. The and all
pipetrain, and all safety
safety components,
components, should be tested
should be tested
for leaks
leaks and functionality at regular
and functionality regular intervals.
intervals.

J.
J. PRESSURE
PRESSURE REGULATOR
REGULATOR ADJUSTMENT

The gas
The gas pressure
pressure regulator
regulator is
is NOT factory preset,
NOT factory preset, and
and must
must be
be field-adjusted
field-adjusted
while
while the
the burner is in
burner is operation. Refer
in operation. to Figure
Refer to Figure 88 for
for pressure
pressure requirements.
requirements.

t2
12
PRESSUREREGULATOR ADJUSTMENT
J. PRESSURE

The gas
The gas pressure
pressure regulator
regulator is
is NOT factory preset,
NOT factory preset, and
and must
must be
be field-adjusted
field-adjusted
while the
while the burner is in operation.
burner is operation. Refer
Refer to Figure for pressure
Figure 8 for pressure requirements.
requirements.

When pressure
When adjustment is
pressure adjustment is required
required for setting
setting input
input capacity
capacity with aa
selected orifice from
selected orifice from Figure 8, remove
Figure 8, remove the
the regulator
regulator cap
cap for
for access to the
access to the
slotted
slotted adjustment
adjustment screw.
screw. Turning
Turning the screwcounter
the screw counter clockwise
clockwise reduces
reduces
manifold orifice pressure,
manifold orifice clockwise increases
pressure, clockwise the pressure.
increases the pressure. A wide
wide input
input
range
range can be achieved
can be with a
achieved with a single
single orifice
orifice size.
size. If
If the
the desired
desired input
input rating
rating
cannot
cannot bebe obtained
obtained within the above
within the above manifold orifice pressure
manifold orifice pressure adjustment
adjustment
range,
range, the
the next size larger
next size larger or
or smaller
smaller orifice
orifice should
should be
be used. (Refer
used. (Refer to
to orifice
orifice
chart
chart Fig. 8)
Fig. 8)

NOTE:
NOTE: MANIFOLD PRESSURE ADJUSTMENTS
MANIFOLD PRESSURE ADJUSTMENTS CAN ONLY BE
MADE WITH
WITH THE BURNER BURNER RUNNING
RUNNING AND THE GAS GAS ON.
ON.
The 1/8" (3.175mm)
The 1/8" (3.175mm) NPTNPT pressure
pressure tap
tap for orifice manifold pressure
orifice manifold pressure
measurement
measurement isis located
located on
on the
the side
side of the orifice holder.
the orifice Use a
holder. Use "u"-tube
a "u"-tube
manometer
manometer or dial type pressure
dial type pressure gauge,
gauge, scaled
scaled from
from 0"W.C.
O"W.C. to
to 15.0"
15.0" W.C.
W.C.
(3736.5Pa) read pressure.
to read
(3736.5Pa) to pressure.

Fig.11
Fig.II

l3
13
'.\
K. GAS
GAS PRESSURE
PRESSURE SWITCHES
SWITCHES

FIGURE
FIGURE 12
12

MOUNTING
MOUNTING
All
All switches
switches can be mounted
can be mounted in in either
either horizontal
horizontal or vertical position.
or vertical position.
Switches
Switches should
should bebe reasonably
reasonably levellevel but
but do
do not
not require
require accurate
accurate leveling.
leveling.
Switches
Switches have
have been
been factory
factory calibrated
calibrated andand tested
tested for
for leaks.
leaks. However,
However, itit isis
recorunended
recommended that that the switch, gas
the switch, gas pipe
pipe inlets
inlets and
and connections
connections be be soap
soap
bubble
bubble tested
tested for
for leaks
leaks after
after installation.
installation.
OPERATION
OPERATION
Low
Low Gas
Gas Pressure
Pressure Models
Models
Low gas pressure
Low gas pressure switches break
switches break the
the electrical
electrical circuit on pressure
circuit on pressure drop
drop at
at the
the
point when gas pressure becomes
point when gas pressure becomes lower than lower than the
the indicated
indicated set pressure.
set pressure.
Before the manual reset
Before the manual reset button button cancan be properly gas
latched, gas pressure
be properly latched, pressure inin the
the
chamber
chamber mustmust be
be higher
higher than
than the
the indicated
indicated setting.
setting.
High
High Gas
Gas Pressure
Pressure Models
Models
High gas
High gas pressure
pressure switches
switches break
break thethe electrical
electrical circuit when pressure
circuit when pressure rises
rises
above
above the
the indicated
indicated preset
preset pressure.
pressure.
Range
Range Adjustment
Adjustment -- All All Models
Models
To adjust gas
To adjust gas pressure
pressure cut-off
cut-offsetting,
setting, remove
remove the cover. Turn
the cover. Tum thethe range
range
scale
scale adjustable
adjustable knob
knob to increase pressure
to increase pressure setting
setting or decrease pressure
or decrease pressure
setting.
setting. Install
Install cover and tighten
cover and tighten the
the cover
cover screws
screws to to prevent
prevent tampering.
tampering.

l4
14
II
SECTION II
SECTION
INITIAL START
INITIAL START UP

1.
1. NOTB: Read
NOTE: the applicable
Read the applicablesequence
sequence of burner/primarygas
ofburner/primary control
gas control
operation,gqs
operation, gas pressure etc. in Section
switches, etc.
pressure switches, Section3 Operation
Operation and
Troubleshooting befor e pr
TroubI eshooting before oceeding.
proceeding.
2.Lay
2. combustiontest
out combustion
Layout equipment,manometers,
test equipment, stopwatch,DC micro-
manometers, stopwatch, micro-
amp meter,
amp other miscellaneous
and other
meter, and miscellaneous tools as needed.
tools as needed.
3. Adjust the primary
Adjust the air shutter
primary air settingper
shuttersetting per the
the dimensions shownin the
dimensionsshown the
chart below.
chart below. Remove blankingplatefrom
Remove blanking the side
plate from the side ofthe burner IF
of the burner thefiring
IF thefiring
rate is over
rate is over 650,OOO(l90.5kW)
650,000(190.5kW) BTU's
BTU's on on LP ONLY.
ONLY. See
Seechart below.
chart below.

:iir
',: l; ,.il:
.: I
'.-l'
t:;t
:..,r- 1 ,' -' i;Y:]t1o';,!t

BTU/hr Air shutter


shutter Manifold Air shutter Manifold
Input o
Opening Blank Platr AP
lank Plate o'w.c. 0Onenins Blank Platr AP t'w.c.
+25,000( 24.6kW 3/8"(9.53mm)
3/8"(9.53mm) yes
es \.7(921.6Pa 5/l6"(7.94mm)
3.7(921.6Pa) 5116"(l.94mm) yes ).8 ( 9 4 6 . 5 P a
3.8(946.5Pa)
150,000( 3 l . 9 kw l/2"(12.7mm)
50,OOO(131.9kW) l/2"(l2.7mm) yes
yes l12"( 12.7m m \ yes
\ , 5 (8 7I . 8 P a l/2"(12.7mm)
3.5(871.8Pa) t .5 ( 8 7 1. S P a
3.5(871.8Pa)
500,000(
500,OOO( 4 6.5kW l3/16"(20.64mm)
l46.5kW) 13116"(20.64mm yes
yes ] . 5 (8 7 1 . 8 P a
3.5(871.8Pa) 1 3l16"Q0.64mm
13/16"(20.64mm) yes
yes t .5 ( 8 1 1 . S P a
3.5(871.8Pa)
550,000
550,OOO( 6( l ..2kW)
16] 2 k w 1-1/8"(28.58mm)
l-l1 8 "(28.5 8 mm yes
yes ] . 5 (8 7 1
3.5(871.8Pa) l"(25.4mm\
. 8 P a I"(25.4mm) yes
es 1. 5 ( 8 1.I8 P a l
3.5(871.8Pa)
500,000(7 5.8k W 1-3/8"(34.92mm)
600,OOO(l75.8kW) l-3/8"04.92mm yes
es \.s( 871
3.5(871.8Pa).SPa 1-1/2"(38.1
l-1 1 2 " (3 8 .mm) yes
1 mm) yes 3 . 5 ( 8 7.18 P a l
3.5(871.8Pa)
5 5 0. 0 0 09( 0
l . 5 k w 1-3/4"(
650,OOO(l90.5kW) l-314"(19.05mm)
l9.05mrn removed ] . 5 (8 7 1
removed 3.5(871.8Pa) . 8 P a 1-3/4"(
l-314"(44.45mm
44.45mm) yes
es 1.5(871.8Pa
3.5(871.8Pa)
/00.000(205.2kw
700,OOO(205.2kW) l-7/8"(47.63mm)
1-7/8"( 47.63mm) removed ] . 5 (8 7 1 . 8 P a2-1/8"(53.97mm)
removed 3.5(871.8Pa) 2-118"(53.97mm) yes yes 1.5(871.8Pa
3.5(871.8Pa)
Note: Dimensionsand
OpeningDimensions
ShutterOpening
Note: Air Shutter andGas Manifold Pressures
GasManifold Pressures areapproximate
are approximate
and must
and be properly
must be adjustedwith
properly adjusted with calibrated
calibratedemissions equipment.
emissionsequipment.
13
FIGURE 13
FIGURE

4. NOTE: Initial activation


4. of the burner
activationofthe burnershould
shouldbegin with checking
begin with the
checkingthe
function ofthe
function of the automatic controls by
automatic controls by means
meansofa "dry
of a "dry run"
ntn" before gas is
beforegas is
suppliedto
supplied to the
the main
main burner
burner nozzle -
nozzle through
through a complete main burner
completemain burnerfiring
firing
cycle and
cycle and a complete checkofall
completecheck of all automatic
automaticsafety controls with
sqfetycontrols the test
with the test
valve in the
firing valve
fi,ring closedposition
the closed through an
thenthrough
position then an activatedfiring cycle.
activatedfiring cycle.

Temporarilyremove
5. Temporarily
5. removethethe covers from the
coversfrom High and
the High and Low gasgaspressure
pressure
switchesand
switches and set the switches
setthe switchesusing
usingthe
the dials. The high
dials. The gaspressure
high gas pressureswitch
switch
shouldbe
should be set
setatat the
the highest "w.c. setting,
highest"w.c. asan
setting,as initial starting
an initial point. The
startingpoint. The low
gaspressure
gas pressureswitch
switch should
shouldbebe set
setat the lowest
at the "'w.c.setting,
lowest"w.c. setting,asas aa starting
starting
point. Push
point. Pushthe manualreset
the manual resetbuttons
buttonson on the
the gas pressureswitches.
gaspressure switches.
Note: These
Note: Thesesettings
settingsmust
mustbe
be re-adjusted
re-adjusted the burner
afterthe
after burneris is ignited.
ignited.

l5
15
6. Open the ball valve to the inlet of the gaspipetrain. Make sure the ball
6. Open the ball valve to the inlet of the gas pipetrain. Make sure the ball
valve nearestthe burner (the outlet of the gaspipetrain) remainsclosed.
valve nearest the burner (the outlet of the gas pipetrain) remains closed.
Test all new piping for leakswith a soapysoluti,on,or leak detector.Do not
Test all new piping for leaks with a soapy solution, or leak detector. Do not
use an open flame to test for gas leaks.
use an open flame to test for gas leaks.

7. Turn on the main electricalpower and set the thermostator operation


7. Tum on the main electrical power and set the thermostat or operation
controlto call for heat.Turn the burneron-off switch to the on position.
control to call for heat. Tum the burner on-off switch to the on position.
Allow the combustionfan to run a MINIMUM of 5 minutesto purge the
Allow the combustion fan to run a MINIMUM of 5 minutes to purge the
combustionchamberand applianceheatexchanger. The ambei indicator
combustion chamber and appliance heat exchanger. The amber indicator
light showsthat the burneris poweredand the switch is in the on position.
light shows that the burner is powered and the switch is in the on position.

8. Turn the burner on-off switch to the off position or set the thermostator
8. Turn the burner on-off switch to the off position or set the thermostat or
operatingcontrol below room temperature, shuttingthe
the burner
burner.,oFF,'at
operating control below room temperature, shutting "OFF" at
least I minute to RESET the primarycontrol.
least 1 minute to RESET the primary control.
9. Openthe ball valve on the outletof the pipetrain(nearestthe burner).
9. Open the ball valve on the outlet of the pipetrain (nearest the burner).
10. Power
10. Power the
the burner, turn the
burner, turn the burner on-off switch
burner on-off switch to
to the on position
the on and set
position and set
the thermostator operatingcontrol to call for heat. The burnei will start and
the thermostat or operating control to call for heat. The burner will start and
go through the applicablesequenceof burnerlprimarygas control operation,
go through the applicable sequence of burner/primary gas control operation,
refer to step l. The greenindicatorlight showsthat the solenoidshut-off
refer to step 1. The green indicator light shows that the solenoid shut-off
valvesarepowered.
valves are powered.
Note: on new gas line installations,air may be trappedin the gas line, the
Note: On new gas line installations, air may be trapped in the gas line, the
burner may experienceseverallockoutsuntil all the air is prrg-.4 from the
burner may experience several lockouts until all the air is purged from the
lines.
lines.
11. Onceburneris running,adjustthe gaspressureregulatoras describedin
11. Once burner is running, adjust the gas pressure regulator as described in
section l, paragraphJ - pressureRegulatorAdjustment, basedon the
Section I, paragraph J - Pressure Regulator Adjustment, based on the
pressuredescribedin Figure 8.
pressure described in Figure 8.
12. A more accurateBTU (kw) input can be determinedby using the gas
12. A more accurate BTU (kW) input can be determined by using the gas
servicemeter with the burner operating(all other gas applian..rihorld be
service meter with the burner operating (all other gas appliances should be
off). The hand on the gas meterdial with the loweit cubic feet valve (fastest
off). The hand on the gas meter dial with the lowest cubic feet valve (fastest
revolving dial), shouldbe clocked(timed)for one completerevolutionand
revolving dial), should be clocked (timed) for one complete revolution and
usethe following formula.
use the following formula.

t6
16
3600 cubicft.
3600 x cubic ft. per
per revolution
revolution x BTU value/cubic ft := BTUiHR
BTU vaiue/cubic BTU/HR
seconds
seconds per
per revolution
revolution
NATURAL
NATURAL GAS GAS EXAMPLE:
EXAMPLE: Timing onerevolution
Timingone revolution of the 1ft3dial
the 1fe dial at
at 66
seconds
seconds on natural
on natural gasgas(roughly
(roughly1000
1000BTU's/ ft'heating
BTU's/ ft3 heating value).
value).
360 0xx1I x 1000
3600 1 0 0 0=: 6 0 0 , 0 0BTU/HR
600,000 0 BT U/HR
6
PROPANE
PROPANE GAS GAS EXAMPLE:
EXAMPLE: Timing onerevolution
Timingone revolution of the Ift 3 aial
the tft3 dial at 15
at 15
seconds on propane
seconds on propane gas (roughly2515
gas(roughly BTU's/ ft'heating
2515BTU's/ value).
ft3 heating value).
3600x 11 x 2515
3600 :
2515= 603,600
603,600 BTUAIR
BTU/HR
t5
15
13.After
13. After the
thedesired
desiredinput hasbeen
input has obtained,
been obtained, re-adjust the primary
re-adjust the primary airair
damperopen
damper openor closedto
or closed obtainaa blue
visuallyobtain
to visually flamewith
blue flame with well defined
well defined
orangeor
orange yellowtips
or yellow tipsfor
for natural gas,or
naturalgas, or well
well defined yellowtips
definedyellow for propane
tips for propane
gas.
gas.

14.After
14. After the
theburner hasbeen
burner has in operation
been in operation for at
for at least 10minutes,
least10 assuring
minutes,assuring
combustionchamber
combustion andheat
chamberand heatexchanger
exchanger warmed,take
arefully warmed,
are takecombustion
combustion
analysisflue
analysis gassamples
flue gas samples just aheadof the
just ahead thedraft
draftcontrol in the
controlin theflue pipe. A
fluepipe.
combustiongas
combustion gasanalyzer
analyzershould
shouldbe be used
usedtoto fine-tune
fine-tunethe
the burner.
burner.

NOTE:
NOTE: ALWAYS USE TEST
COMBUSTION TEST
USE RELIABLE COMBUSTION
INSTRUMENTS.BEING
INSTRUMENTS. BEING PROFICIENT
PROFICIENTIN THE USE
USE OF THESE
THESE
INSTRUMENTSAND
INSTRUMENTS AND INTERPRETING
INTERPRETINGTHEIR DATA IS
NECESSARYFOR
NECESSARY FOR SAFE, BURNER
SAFE.RELIABLE AND EFFICIENT BURNER
OPERATION.
OPERATION.

15.Perform
15. Performthe thefollowing
followingcombustion
combustion analysis.
analysis. A11adjustments
All adjustments below must
below must
be madewith
be made with the
the following
followinginstruments:
instruments: gauge,O
draftgauge,
draft 022 or
or CO
CO2 analyzer
2 analyzer
andCO
and CO tester.
tester.
A. Adjust
A. Adjust the
theprimary airdamper
primary air damperto provideabout
to provide 25% excess
about25% excess
combustionair.
combustion air. Confirm this by
Confirmthis checkingthe
by checking the flue gasfor
flue gas for its
its FREE
FREE
(Oz)
OXYGEN (0 2) or
OXYGEN or CARBON (COz) PERCENTAGESwith
DIOXIDE (C0 2 ) PERCENTAGES
CARBONDIOXIDE with
aa test
testinstrument.
instrument. Freeoxygen
Free oxygenshould
shouldbe about4.5%,
be about 4.5yo,oror carbon
carbon
dioxideshould
dioxide shouldbe about9.5%
be about for natural
9.5%for gas,12.1
naturalgas, 12.1% for propane
% for gas.
propanegas.
B. CARBON
B. CARBONMONOXIDEMONOXIDE(CO)- (CO)- Should
Shouldbe checkedfor
be checked for its presence
its presence in
in
theflue
the gas.This
flue gas. percentage
Thispercentage shouldnot
should not exceed
exceed.04%.04%(or(or 400
400PPMPPMair
air
free).
free).

l7
17
20.g
20.9
COanrnrs =:
COAIRFREE ((ZO.g-O) X CO
20.9-0 2 ) X COppr'a
PPM
t2.2
12.2
For Natural
Natural Gas: COanrnsp=:
Gas: COAIRFREE ( CO,2 )) X
(C0 X COCOppv
PPM
t4
14
For Propane
For PropaneGas:
Gas:CO enrnrB=:
COAIRFREE (( CO X CO
CO,2 )) X COppla
PPM
C. NOTE:
C. NOTE: TheThe EHG
EHG waswasdesigned
designed fire into
to fire
to slightlypositive,
into slightly balanced,
positive, balanced, or
or
slightly negativecombustion
slightlynegative combustionchambers.
chambers.For For optimal performance,
optimalperformance, check
check
overfiredraft
overfire draftand
andadjust
adjustto
to NEGATIVE
NEGATIVE -.01 (2.491Pa)
-.01(2.491Pa) to -.02
to (4.982Pa)
-.02(4.982Pa)
inchesw/c
inches w/c during
duringburner
burneroperation.
operation.
D. The
D. The flue gastemperature
flue gas temperature shouldbe
should be between
between325"F (162.78"C)
325°F (1 and550°F
62.78°C) and 550oF
(287.78"C)for
(287.78°C) gasburners.
for gas burners.Higher
Higherflue gastemperatures
flue gas temperatures indicateoverfiring
indicate overfiring
or excessive
or excessivedraft
draft through
throughthe
the appliance.
appliance. Lower flue
Lower gas
flue gas temperatures
temperatures may
may
causeexcessive
cause excessivecondensation
condensation andindicate
and indicateunderfiring.
underfiring.Consult your local
Consultyour local
appliancemanufacturer
the appliance
utility or the manufacturer for acceptable
for acceptable gastemperatures.
flue gas
flue temperatures.

BURNERBTUIHR
THE BURNER
CAUTION: IF THE (KWAIT)INPUT
BTU/I{R (kW/Hr) INPUT IS
IS CHANGED,
CHANGED,
REPEATSTEP
REPEAT STEP13
13

16.Adjust
16. Adjust the
the High gaspressure
High & Low gas pressureswitchesaccording
switches accordingto actualfiring
to actual firing
conditions.The
conditions. The High gaspressure
High gas switchshould
pressure switch shouldbebe set at approximately
setat approximately
4"w.c. and
4"w.c. andthe
the Low gaspressure
Low gas pressureswitch shouldbe
switchshould be set at approximately
setat approximately
2"w.e.for
2"w.c. for close
closeburner
burnercontrol.
control.Nuisance
Nuisance lockoutswill occur
lockouts if the
occurif theswitch
switch
settingsare
settings aretoo
too close
closeto
to the gasmanifold
thegas manifoldsetting,
setting,and fluctuationsin
andfluctuations gas
in gas
pressures
pressures Reattachswitch
occur. Reattach
occur. switchcovers.
covers.

L7.Record
17. Recordthe installation
theinstallation data,the
data, thecombustion
combustion readings,
readings, etc., andaffix
etc.,and to
affix to
this manual,
this manual,or the
the burner
burnerand/or
and/orappliance.
appliance.Space hasbeen
Spacehas providedat
beenprovided at the
the
backof this
back manualfor
this manual for start-up notes,dealer's
start-upnotes, name,address,
dealer'sname, address, telephone
telephone
number,as
number, aswell
well as thedate
asthe installation.
dateof installation.

SUGGESTION:All new
SUGGESTION: newinstallations
installationsshouldbe
should re-inspected
be re-inspected proper
for proper
for
combustionand
combustion andburner
burneroperation afterone
operationafter oneor two
two weeks
weeksof normal
normal
operation.
operation.
For subsequent
For subsequent normalstarting
normal startingand
andshut procedure,refer
shutoff procedure, referto
to the
the
"ConsumerInstructions"
"Consumer Instructions"in
in the
the back
backof this
this manual
manualoror the plate
instructionplate
the instruction
attachedto
attached the burner.
to the burner.

18
18
TO RESTART
RESTART TITE THE BURNER AFTER AFTER A FLAME FLAlVIE FAILT]RE,
FAILURE, Temoveremove
power
power from thethe burner
burner for I1 minute
minute to reset
reset the
the primary controller. Push
primary controller. Push the
the
manual
manual reset on the
reset on the Low Gas
Gas pressure
pressure switch.
switch. fne
The burner
burner should
should relight
after power
after power is restored
restored and
and the
the' unit has
has a call
call for heat.
heat. If problems persist,
If problems persist,
refer to the troubleshooting section
refer the troublesho01ing section of of this
this manual.
manual.

To stop
stop the burner in the
the burner the event of an
event of an emergency, remove power
emergency, remove power from the
the
main
main electrical
electrical disconnect,
disconnect, shut
shut off
off any manual gas
any manual gas ball valve,
valve, or turn
tum the
the
burner
burner on-off switch
switch to the off position.
the off position.

SECTION
SECTION III
III
OPERATION AND TROUBLESIIO OTING
TROUBLESHOOTING
SEQUENCE
SEQUENCE OF
OF OPERATION _
OPERATION - EHG
EHG POWER GAS BURNER
POWER GAS
UTILIZING
UTILIZING HONEYWELL
HONEYWELL S89F
S89F GAS
GAS PRIMARY PlN 62759-002
PIN 62759-002
WBUILT
WfBUILT IN
IN 30
30 SECOND
SECOND PREPURGE
PREPURGE

On a call
call for heat, voltage (24V)
heat, voltage (24V) is applied
applied to
to motor start relay
motor start and air
relay and
switch.
switch. Once
Once the
the fan
fan motor
motor reaches
reaches operating
operating rpm combustion air pressure
rpm combustion pressure is
sensed
sensed by the
the air-proving
air-proving switch
switch and closes the
and closes the switch
switch contacts energizing
contacts energizing
the S89F gas
the S89F gas primary
primary control.
control.

The S89F gas


The S89F gas primary
primary control
control has
has an
an internal 30-second pre-purge
internal 3O-second pre-purge timer.
timer.
After the
the initial
initial 30 second pre-purge,
30 second pre-purge, anan internal 8-second safe
internal 8-second check of
start check
safe start of
the
the S89F
S89F will
will commence. Once this
commence. Once this is successfully completed, the
successfully completed, the S89F
S89F
simultaneously
simultaneously energizes the gas
energizes the gas valves
valves and
and ignition Gas flows
transformer. Gas
ignition transfonner. flows
and
and the transformer produce
the transformer produce an
an approximate
approximate 10,000
10,000 volt end point
spark end
volt spark point
grounded
grounded at the
the burner
burner head
head establishing
establishing main
main burner
burner flame.
flame.

At
At the
the start
start of
of each
ea'ch heat
heat cycle,
cycle, there
there isis a trial
trial for ignition period
for ignition period of four (4)
of four
seconds
seconds duration.
duration. Normally,
Normally, burner
burner flame
flame willwill be before the
establisqed before
be established the end
end
of this period.
of this Once the
period. Once the flame
flame isis established,
established, sparking
sparking will'cease and the
will'cease and the
flame
flame rod will provide
rod will provide flame
flame monitoring
monitoring to to the S89F gas
the S89F control primary
gas control primary forfor
the
the remainder
remainder ofof the
the heat
heat cycle.
cycle. IfIf the
the flame
flame should
should be extinguished during
be extinguished during
the
the heat
heat cycle,
cycle, the S89F gas
the S89F control primary
gas control primary willwill go into the
go into second pre-
30 second
the 30 pre-
purge
purge and
and 88 second
second safe start check,
safe start check, then
then re-energize
re-energize thethe gas valve and
gas valve and
ignition
ignition transformer
transformer inin an
an attempt
attempt toto establish
establish the the main
main burner flame. IfIfthis
burner flame. this
does not
does not occur
occur within
within the
the 4-second
4-second trial
trial for
for ignition period, the
ignition period, the S89F gas
S89F gas
primary
primary control will go
control will into lockout
go into de-energizing the gas
lockout de-energizingthe valves and
gas valves and
ignition
ignition transformer.
transformer.

t19
9
restart the
To restart system, the
the system, main power
the main power oror: thermostat
thermostat must be de-energizsd
must be de-energiZed
momentarily, then
momentarily, re-energized. If
then re-energized. [f at a~ time
at any time during
during the heatcygle,
the ?eat there is
cysle, there is
an insufficient supply
an insufficient of combustion
supply of combustion air
air io
to the
the burner,
burner, the'air
the air switbh
switch will
open, putting
open, putting the system inio'lockout
the system into/lockout closing
closing the gas
the gas valves.
f
valves.
{

EHG POWERGAS BURNER


EHGPOWCRGASBURNER
WITH HONEYWELL S89F
S89F GAS
GAS PRIMARY

BLACK -- '''''~.
GREEN LIGHT ~ ~ r0-- s;'"
BLACK
SIJITCH
63469-001
BLACK _

T
BLACK

MOTOR 63470-0 2 ~ ~ YELLOIJ ~ "I VELLO'"


SENSOR 20383 >< >< LIGHT r-----l
PROBE ~ t>6J47O-00!rIV" 1
62390-003 VELLO'"

ll--;~B' l'
RELAY
0
:0
1>
z
Cl
f'l
S89F
S89FPRIMARY
PRIHARY
62759-002
6?759-00?
CONTROL
CONTROL
>C
;!;
-t

24V 3 r l OVAC
:
24VAC

3 [
E·v" 62406-002

T-T
T- TERMINAL
T TERMINAL
60178-004
60178-002

f~
c=J VELLO'" RELAY
62406-002
BLACK
62406-002~ ~ AIR SENSING
AIR SENSING SVITCH
SIJITCH
63263-005
1 rvf\-- c::(
=
T

GND (BURNER) r=r /..J tvlV~ GREEN


VELLO'" ~ ~I\-ft-.
,.,~
I
"'~SENSE
(GND)c=r /..J tvlV
~rb t'-~
-=-
/~
24V /f\.- T

= tvl\....! /IL-
~ I
YELLO'"
= 24V r=> I ~~

l-t ~~LLO'" T~~gb~ffttl.fR


2 I
=
=
VAL VE (GND> r=>
VALVE~
c NO
Y LLO'"
~3 "----/ ~ IIHITE YEllOII

IGNITION
I6NITION
TRANSFORHER
TRANSFORMER BLACK
••LLE:

.1
>C"''''
:x: r r
::;l'i~
f'l >< -' "J"
/"\..f

-fro..
20
YELLO'"
/" J
/" 1"\ ~
'\
lOV~ 11~24VAC
BLACK YEllOII 1 I

I ..- \..

~ ~'\
~
-Ll BLACK

0
:0
1>
z
Cl
I
'"rn
1>
I
'\
/"'\

I BLACK -
T "'HITE
.,.- (HOn
L2 IJHITE
(NEUn
f'l
><
I I
I[Z) I ~lV\ 10 II ~lV\ GASSHUTOFF
GAS SHUTOFF
V VALVES
VALVES
IGNITER
IGNITER
ELECTRODE
ELECTRODE
62391-003
62391-003 - A
I BLACK
1.
-""'" BLACK
BLACK

VIRINGDIAGRAM
\.fIRING ,EHG'
"EHG"
DIAGRAM oNo
BLACK
I "NO I
HIGH PRESSURE COM 6'?NC
HI6HPRESSURE I COM 6 yNC LOV PRESSURE
LOIJ PRESSURE
SVITCH
S'w'ITCH
53495-0
63495 0 1 REV
001 C
REV C SVITCH
SIJITCH

14
FIGURE14
FIGURE
SEQUENCE
SEQUENCE OFOPERATION
OF OPERATION _
- EHG SERIES
ERG SERIES
POWERGAS
POWER GAS BTIR]'TENIIIILIZING
BuR1rnR UTILIZING .
HONEY\MELL S89EGAS
HONEYWELL S89E PRIMARYPIN
GAS PRIMARY PlN 62758-002
62758-002 WI EXTERNAL
w/ EXTERNAL
30 SECONDPREPI/RGE
30 SECOND TIMERPN
PREPURGE TIMER
/
62388-001
PIN 62388-001 AI.{DRESISTORPN
AND RESISTOR PIN
.
/ 62530-001
62530-001

On a
On a call
call for heat,
heat, voltage (24V) is
voltage(24V) is applied to the
applied to the motor
motor start
start relay and air
relay and
switch.The
switch. The motor relay pulls
motor relay pulls in the
the motor.
motor. After the motor
After the motor reaches speed,
reachesspeed,
the combustionair
the combustion air blower closesthe
blower closes air proving
the air switchcontacts,
proving switch energizing
contacts,energizing
the external3D-second
the external 3O-second pre-purge
pre-purge timer.
timer. After the30
After the secondpre-purge
30 second pre-purge
timing,the
timing, the S89E.
S89Eisis energized.
energized.

The S89E
The S89Egasgasprimary
primarycontrol
controlhas
hasan
aninternal
intemal8-second
8-s.conasafe startche~k.
safestart check.
the initial
After the initial 30-second
3O-second pre-purge providedby
pre-purge provided theexternal
by the timer, the
externaltimer, the
S89E gasprimary
S89Egas primarycontrol
controlisis energized,
energized, the8-second
the 8-second safestart
safe checkwill
startcheck
commence.
commence. this is
Oncethis
Once is accomplished,
accomplished, theS89E
the activates
S89Eactivates the gasvalves
the gas valves
allowing gasto
allowinggas to flow to the
flow to theburner head.Simultaneously,
burner head. Simultaneously, the S89E
the control
S89Econtrol
energizes
energizes theignition
the transformer,
ignitiontransformer, producing
producing anapproximate
an approximate 10,000volt
10,000
endpoint
sparkend
spark groundedat
point grounded at the
theburner
burnerhead, establishing
head, establishing main burner
main flame.
burner flame.

the start
At the eachheat
startof each cycle,there
heat cycle, thereisis aa trial
trialfor
for ignition
ignitionperiod (4)
four (4)
periodof four
secondsduration.
seconds Normally, burner
duration.Normally, flamervill
burner flame will be established
be established before the end
beforethe end
of this
of period. Once
this period. the flame
Oncethe flameis established,
is established, ceaseand
rvill cease
sparkingwill
sparking the
andthe
rod will provide
flamerod
flame flamemonitoring
provide flame monitoring to
to the S89Egas
the S89E gasprimary
primary control for
controlfor
the remainderof the
the remainder the heat cycle.
heat cycle.

When'utilizingthe
When-utilizing gasprimary
S89Egas
the S89E primarycontrol
controlwith
with the 3O-second
eternal30-second
the eternal pre-
pre-
purgetimer,
purge timer,aa 10K resistoris
ohmresistor
10Kohm is wired
wiredin parallelbetween
in parallel betrveenthe output
theoutput
terminalof the
terminal the30 pre-purge
secondpre-purge
30 second timerand
timer andthe
theinput
inputterminal
terminaltoto the S89E
the S89E
gasprimary
gas primarycontrol. The function
control.The functionof this
thisresistor
resistoris keepaa load
is to keep loadon the
on the
outputterminal
output terminalof the external3D-second
theexternal 30-second pre-purgetimer,
pre-purge timer, after the initial
afterthe
call for
call for heat and30
heatand 30 second
secondstart pre-purge
startpre-purge and8-second
and 8-second safestart
safe check.
startcheck.

promotessimultaneous
This promotes
This simultaneous re-ignitionof the
re-ignition themain burnerflame
main burner the
after the
flame after
S89E's8-second
S89E's 8-secondsafestart
safe check,oveniding
startcheck, the3D-second
ovdnidingthe 3O-second pre-purge. This
pre-purge.This
is desirable
is desirablein oven or similar
ovenor applications
similarapplications wheretemperatures
where temperatures cannot vary
cannotvary
drastically.
drastically.

Shouldthe
Should theflame
flamebe extinguished
be extinguished during theheat
duringthe the S89E
cycle,the
heatcycle, primary
S89Eprimary
ignitioncontrol
ignition go into
controlwill go second
the88 second
into the startcheck
safestart
safe afterwhich
checkafter it
time it
which time
', t.
:..
will reenergize thegasvalve andignitiontransfonner
forme r in anattem
in an attempt to re-
pt to re-
will reenergize the gas valve and ignition trans
establishthe mainburnerflame
establish the main burner
flame.
. ¥this ~es not
Iy'this(oes occurwit~i
notoccur within n the~- second
the 4-second
trial for ignitionperiod,the.s8gdgasprilnary conkor w1i'!o
ol will go into lockout
into-lockout
trial for ignition period, the S89E gas prima ry contr
de-energizingthe gasValveb'and ignitiontransformer. ,
de-energizing the gas ~alves and ignition transf ormer. ToTo restar
restart thesystem
t the system,
the mainpoweror therinostatmustbe de-energized,momentarily,
ergized momentarily, and andthen
then
the main powe r or thermostat must be de-en
re-energized. If at anytime during theheatcycle
cycle, thereis
, there is insufficie"nt suppl
insufficient supply y
re-energized. If at any time during the heat
of combustionair to theburner,the air switch contacts
h conta open,puttin
cts will open, putting g the
the
of combustion air to the burner, the air switc
system into lockout closing
system into lockout closing the gasvalve
thegas valves.
s.
\-
EHG PO~
EHG POWER GAS
RGA RNER
BURNER
SBU
WITH HON
WITH HONEYWELL.S89E GAS PRIM
EYW ELL S89E GAS PRIMARY
ARY

BLACK -- ~j rC2-·
BLACK ~
SIJITCH
BLACK _

~
BLACK

~s~s~ MOTOR
'"''
GREEN LIGHT
63470-0 2
~ ~
~ ~ YELLOII
~
R
63469-0 01
YELLOIJ
SENSOR 20383 " " LIGHT

;<V~ !1~OVA(
PROBE ~63470-001( ~r--.
PROBE
62390-003
62390-003
YELLOIJ ~ RELAY
j~ ~

B: F~
62406-002
.:
x
:; T TERHINAL
I'-T
T- TERMINAL
0
CONTROL
S89EPRIHARY -< -< 3 9 9 4
'"Z
l>
PRIMARY CONTROL
S89E62758-002
M
M
r
r
M
r
r
60r78-00e
60178-002
Cl
M
62758-002 o 0
.: .: BLACK

r=:J
YELLOIJ RELA Y
62405-002
BLACK
62406-002 j ~ AIR SENSING SIJITCH
63263-005
1 tv !'---- <:
;5
T

GND (BURNER )E:> ~ rv- rv~ YELLOIJ ~ ~~ ,.,....


L-
f-c=3SENS E
(GND)<=J-~ rv-
V ..... -=- - J0---
~rt ~ T

/~I N~
24V
RESrSTOR-r-
62530-001
c:::J ?1V f\....=
c:::J 24V <=J-~
VALVE (GND) tv: t\..J"
E:l-p- lVlC-
YElLO\! - -
-r- ~ T~~g[~~.fR
c:::J VAL VEV (GND)
AL VE

IQ
'--
VALVE <=J- YELLO\!
c:::J 1?
60 SEC. PRE- ~3 ~ ~ f\.-
IIHITE YELLO\!

'"'~~IIF 1/
PURGE TIMER 20
I.L~ ~I~~

IGNITION I_
_I~ l>
1M R
62388-002
- YELLOIJ

/tL- - BLACK YELLO\!


IGNITION fl\-..f
TRANSFOR}.IER /"-
TRANSFORMER BLACK L.f
" '" / ~
I\-
BLACK
BLACK
'--1I GOT)
I
I j ~ ~~ ~
1'\
I .....

I
-
T
LE
(HOT>
L2 VHITE
IJHITE
(NEUT)
(NEUT>
ct
T0
>
'"l>
r I BLACK -~ IJHITE
IL

z
'"
6ll>
z
0

" I GAS
GAS SHUTOFF
FICl
M
10 I I ~! ~ 10 I TlV\ SHUTOFF
VALVES
VALVES

-..
-V
IGNITER
I ELECTRODE
IGNITER
ELECTRODE
62391-003
62391-003
- I BLACK
! BLACK
BLACK

~ VIRING ,EHG' I
BLACK
oNo I "NO
DIAGRAM
\JIRING 5DIAG RAM "EHG" HI6H
HIGH PRESSURI 1 I COM ~ fNC LOll PRESSURE
LOV PRESSURE
34 9 5 -00 2 R E V B 63495 002 REV B
PRESSURE
SVITCH
S'w'ITCH
CoM6 NC I I SVITCH
SIJITCH

FIGURE
FIGURE 15
15
FLAME
FLAME SENSING
SENSING

The
The Honeywell S89 series primary
S89 series primary ignition
ignition controls fiilize the
controls utilize the flame
flame current
current
rectlfication principal
rectification principal for main
main burner
burner flame
flame sensing.
sensing.

The
The flame rectification phenomenon
flame rectification phenomenon occurs occurs asas follows:
follows: The ignited gas
The ignited gas
flame
flame causes
causes the
the immediate
immediate atmosphere
atmosphere around the flame
around the flame to become
become ionized
ionized
(gas
(gas atoms
atoms become
become electrically
electrically charged).
charged). TheThe ionization causes the
ionization causes the
atmosphere
atmosphere around
around thethe flame
flame to become electrically conductive.
become electrically conductive. An AC
voltage
voltage output
output from the the control sensing circuit is routed
control sensing routed through
through thethe flame
flame
sensor probe.
sensor probe. When
When the sensor probe
the sensor probe and
and the burner head
the burner head are both in contact
are both contact
with a properly adjusted flame, the burner
adjusted flame, the burner head head with its larger surface
larger surface
attracts more free electrons, thus
attracts more free electrons, thus becoming negatively charged. The
becoming negatively charged. The sensor
sensor
probe
probe with its
its small
small surface
surface area gives
area gives up freefree electrons, thus becoming
electrons, thus becoming
positively
positively charged.
charged. TheThe free
free electrons
electrons from
from the voltage in the
the AC voltage the sensor
sensor
probe
probe flow through
through the ionized gas
the ionized gas flame the grounded
flame to the burner head.
grounded burner head. As
the
the AC current
current passes
passes through
through thethe gas flame, it is rectified
gas flame, rectified into a DC current
current
flowing back the grounded
back to the grounded side
side ofof the
the sensing circuit. The
sensing circuit. The flame
flame in
actuality
actuality is a switch.
switch. When
When the flame is present,
the flame present, the
the switch
switch is closed
closed
allowing
allowing current
current to flow through
through thethe sensing
sensing circuit
circuit of
of the control. When
the control. When no
flame is present,
flame present, the
the switch
switch is open
open with no current through the
current flowing through the
sensing
sensing circuit ofof the
the control.
control.

The DC current
current flow is measured
measured in units called DC microamperes.
units called microamperes. A A steady
steady
DC microampere
microampere current
current of 0.8 minimum (and
of 0.8 steady) or higher
(and steady) higher through
through the
the
sensing
sensing circuit of the primary
of the primary ignition control sufficient to keep
control is sufficient keep the
the burner
burner
running
running without a safety
safety lockout. See Figure
lockout. See sensor probe
Figure 6 for sensor probe and
and
electrode
electrode dimensional
dimensional settings,
settings, Figure
Figure 16
16 for flame current measurement.
flame current measurement.
FLAME
F SENSE
LA M T ST CURRENT
N SE C U R R E N TC H ICK -- U
CHECK USE SCALE
~A S
S E 4A C A LE

MULTIPURPOSE
M METER
UL T IPURPOSEM ET ER

st:NSffi
PROm:
,8 pA D
.8~A DCC MIN
MIN. ,
AND
A STEADY
N D ST E AD Y
S89
S FLAME
89 FLA SENSE
ME S TN S E
SCALE
).LA SCALE S89 PRIMARY CONTROL CURRENT
C MEASUREMENT
U R R IN T ME A S U R E ME N T
lA
"'"
RED(+)
RED( +) ^_.,^_
oo
GND cn}{x)E
ClIlRt£R>~
SENSE
JLNJL aav
l4V cilDE

~
(00) e:;J
DISCONNECT
\.lIRE fROM E
SENSE TERMINAL E =
= 24V€
2"v~
BLACK(-) =
F
=
E
V'[VE
VIltV'( ME
(GNl»1:E:l
Vf,Vf€
VIltV(~

Figure
Figure 16
16

23
23
EHG SERIES
SERIES WITH
WITH A HONEYWELL
HONEYWELL S89E, PRIMARY IGNITION
Sa9F PRIMARY
Sa9E, S89F IGNITION CONTROLS
CONTROLS
TROUBLE SHOOTING GUIDE
TROUBLE SHOOTING GUIDE
DOES NOT START
MOTOR DOES
MOTOR

Checkthe
1. Check
1. low voltage
the low voltage transformer tor 24 volt
transformer for volt output
output Check electrical wiring and Replace 24 volt
Replace volt AC
AC
between terminal 3 on the
between terminal the motor start relay
motor start relay either
either connections. 20 VATransformer
2O VA Transformer
of the
of "T" terminals
the "r on the
terminalson controlbox.
the control box.

tor 24
Checkfor
2. Check volts AC
24 volts AC between
between terminals 1 and
terminals 1 and 3 Check electrical wiring and Replace motor
on motor
on start relaY.
motor start relay. connections. start relay.

3.
3. Check
Check for 12Ovolts
tor 120 volts AC
AC between
between terminal
terminal 2 on
on Check electrical wiring and Replace motor
motorstart relayand
motorstart relay and neutral
neutral line.
line. connections. start relay.

4. Check
4. Checkelectrical wiring and
electricalwiring connections.
and connections.

1. Check
1. Checkfor blower clearance.
for blower clearance.
motor shaft
Doesmotor
5. Does
5. shaft turn treely?
turn freely?
2. Lubricate
2. Lubricatemotor bearings.
motorbearings.

6. OK

TGNITION
IGNITION ARC ESTABLISHED-
ARC ESTABLISHED NO FLAME
NO FLAME

ResetControl
,. Reset starts- Completes
Motor starts
Control- Motor Completes30 prepurgecycle,
secondprepurge
3Osecond secondsafe
cycle,a8 second startcheck
safestart checkand
and trial for
trial for
ignition,4 seconds
ignition, Honeywellseries.
secondsHoneywell NOTE:The
series.NOTE: The burner
bumermotor will continue
motorwill to
continueto
the lock
duringthe
operateduring
operate lock out
out mode
mode when
when the thermostat
the thermostat is called
circuitis
circuit calledfor burneroperation.
for burner operation.

2. Check
2. for correct
Checkfor orifice/airsetting
correctorifice/air settingrelationship. (see figures
relationship(see figures 8 & 13)

In order
In orderforfor the followingfunctional
the following functionaltest
test to
to be
be made,
made,
thecontrol
the must be
controlmust resetand
be reset and the
the tests
tests monitored
monitoreddur-dur-
the 44 second
ingthe
ing Honeywellseries
secondHoneywell seriestrial
trial for
for ignition peri-
ignitionperi-
occursat
thatoccurs
od that
od at the
the END
END ofof the
the 30
3Osecond prepurge
secondprepurge
secondsafe
andaB second
and startcheck
safe start checkcycle.
cycle.

3. Check
3. Check for
for 120
120 volts
volts AC at gasvalve
at gas valve terminals.
terminals. Check wiringand
electricalwiring
Checkelectrical and Replace primary
connections.
connections. Be sure
Be leads
sureleads ignition control.
areon
are gasvalve
correctgas
on correct valveter-
ter-
minals
minals
Makesure
4, Make
4. leadsare
sure leads are on
on the
the correct gas valve
correctgas valve
terminals
terminals

regulatedpressure
5. CheckJor correct manifold regulated pressur€
(se efigures
(see f i g u r e8s&8 &13
13)

6. Replacegas valve.
6.
24
NO IGNITION
IGNITION ARC ESTABUSHED
ESTABUSHEO

1. Reset
1. Reset Control
Control • Motor starts - Completes 3O second prepurge
30 second prepurge cycle, 8 second
second safe start
start chock series.
.• Gas
Gas valve
valve opens,
opens, regulating
regulating adequate gas pressure.
adequate gas pressure.
.• No ffame
flame established Primarycontrol
established - Primary control locks
locks out after4 second
out after second Honepvellseries trial for
Honeywell series trial
ignition periods.
ignition periods.

V
ln order for
In order for the
the following
following functionaltest
functional test to
to be
be made,
made.
th€
the control must
control must be reset
reset and the tests
and the monitored dur-
tests monitored dur-
ing the 4 second
ing the Honeyrell series
second Honeywell series trial
trial for
for ignition
ignition that
that
occurs at
occurs the end of the
at the second prepurge
the 30 second prepurge rycle,
cycle,
and
and 8I second safe start
second safe stad check.
check.

~ ~
2. Chec'k
2. lor 120
Checkfor 12Ovolts
vottsAC
AC between
betweenthe line
neutralline
the neutral ~ Check
Checkelectrical wiringand
electrical wiring and connections.
connections.
and the
and junction of the
the junction of the blue primary lead
controllead
blue primary control
and the
and black ignition
the black ignitiontransformer lead.
transformerlead.
~
~ the flame
Checkthe
Check sensingcircuit
flame sensing
(2)
circuitfor
Damageto flamerod
flamerod-(2) Damage
flamerod.
(1) grounded
for (1)
flamerodlead
grounded
lead insula-
insula-
3. Check electrical
3. Check wiringand
electrical wiring and connections.
connections. Makesure
surethat
that the
tion. NOTE:Make
tion. NOTE: the flamerod circuit
flamerod circuit

~ and/or primary
primary control
control is
is moisture-free.
and/or moisture-free.

high voltage
4. Check high
4. voltage lead
lead and connection ignition
connection to ignition ~
rod.
electrode rod.
electrode Replace primary ignition control.
I
~
Inspect ignition
5. Inspect
5. ignition electrode insulatorand
cracked insulator
electrode for cracked and
correct spark gap (Fig. 6)
correct

~
6. Replace
6. ignitiontransformer.
Fleplaceignition lransformer. I
IGNITION -_ NO GAS VALVE
NO IGNITION VALVE

prepurgecycle and 88 second


cycleand safestart
secondsafe startcheck.
check.Motor continues
Motorcontinues
ResetControl
l. Reset
1.
to
to run
run
Control-- Motor
but
but flame
flame is
is
starts-- After
Motorstarts After30
not established.
not established.
secondprepurge
30 second
I
V
ln order
In orderto performthe
to perform the following functionaltests,
followingfunctional the
tests. the
primarycontrol
primary controlmust
must be resetand
be reset the tests
and the monitored
testsmonitored
the 44 second
duringthe
during secondHoneywell
Honeywellseries
seriestrial
trialfor ignition
for ignition
occursat
that occurs
that at the
the end
end of the 30
of the 30 second prepurgecycle
secondprepurge cycle
and 88 second
and secondsafesafe start check.
startcheck.

~ ~
control ~I Replace primary ignition control.
2. Check
2. Checkfortor 24
inputterminals
input
voltsAC
24 volts AC at
terminalslabeled
the 24
at the 24volt
yellowand
labeledyellow
primarycontrol
volt primary
and brown.
brown. I
~
proving switch
Check air proving
3 Check for:
switch for: .... 4. Check
4. (whenapplicable)
Check(when applicable) external 3Osecond
external30 second
1 .
a. Any
a. impairmentthat
Any impairment that would keep itit from
would keep lrom OK) prepurgetimer
prepurge (jumperaround
timeruumper aroundtimer fromair
timer from air
-;- opening
closingor opening. r' switch).Should
switCh). primaryignition
Shouldprimary ignitioncontrol
control
; closing
b- Electrical
b. continuity; switch
Electrical continuity; normallyopen.
is normally
switch is open. energized,replace
becomeenergized,
become replacetimer.
timer.
I c. switch as
Replace switch
c. Replace necessary.
as necessary.

25
25
FLAME DURING CYCLE
LOSES FLAME CYCLE - CONTROL LOCKS OUT ON SAFETY

1. Reset Control
ResetControl •. Completes
Completes30 prepurgecycle,
secondprepurge
30 second cycle,and secondsafe
and 88 second startcheck.
safe start check.
1.
•, Flame is established.
Flameis established. I
•, Sometimes
Sometimesthethe control
controllocks
locksout
out before the thermostat
beforethe or controlling
thermostator controllingcircuit is satisfied.
circuit is satisfied.

V"
2. Disconnect
2. flamerod
Disconnectflame leadfrom
rod lead primarycontrol.
from primary control.Connect
Connect
positivelead
(+) positive (DC)Microampere
lead (DC) MicroampereMeter to the primary
the primary Probablecause
Probable of erratic
causeof lockout:
erraticlockout:
(+) M€lerto
1. Flame
1. provingcircuit
Flameproving groundedby
circuitgrounded by moisture.
moisture-
control terminal.Connect
controlterminal. Connectthethe (-)
O negative
negative microampere
microampere
leadtoto the
the flamerod
flamerodlead
lead terminal.
terminal-See 2. Damaged
2. insulationon
Damagedinsulation on flamerod lead.
flamerodlead.
meterlead
meter SeeFig.
Fig. 16
l6
3. Flamerod
3. Flamerodimproperly positionedin
improperlypositioned in flame (see
flame (see
FlameCurrent
Rame Measurement.
CurrentMeasurement. (Fie 6)
(Fig. 6)
V" 4. Poor
4. Poorground
5. Defective
5.
path to
groundpath primarycontrol.
to primary
primarycontrol.
Detectiveprimary control.
control.

~
Resetcontrol,
3. Reset
3. control,after prepurgecycle,
after prepurge cycle,flame
flameis
is established.
established- 6. Read
6. manualsection
Readmanual "FlameSensing".
section "Flame Sensing"-
A stable microamperecurrent
stablemicroampere currentof .8 or
of .8 or more is required
moreis required 7. Applicable
7. only to
Applicableonly Honeyruell
to Honeywell series
S89 series
S89
for dependable
for operation.
dependableoperation. primaryignition
primary ignitioncontrols:
controls:Connect
Connectl1 to the
Ll to the
leadand
blacklead
black and L2 L2 to
to the whitelead
the white lead exiting the
exitingthe
NO othenryise
SB9otherwise
S89 the S89
the S89 will not detect
will not the
detectthe
and will
flameand
flame will lock
lock out.
out.
"""".............r ~
4. Microampere
4. Microampere readingis
reading less than
is less than .8
.8 or
or unstable.
unstable. ) Probablecauses:
Probable causes:
1- Extremely
1. poorcombustion
Extremelypoor level.
combustionlevel.
y
2. Flamerod
2. positionedin
improperlypositioned
Flamerodimproperly in flame.
flame.
primarycontrol.
Defectiveprimary
3. Defective
3. control.

BURNERCYCLES
BURNER ERRATICALLY
CYCLESERRATICAllY

1. Check
1. Check for proper thermostat
for proper thermostat installation
installationand
and location.
location.

~
!0u ....
2. Check
2. thermoslatheat
Checkthermostat heatanticipator
anticipatorfor
for correct
correctsetting.
setting. NO)
t0, Set
Set anticipator to correct
anticipalorto valueifif adjustable
correctvalue type.
adlustabletype.
y propersetting
lf proper
If cannotbe
settingcannot made,replace
be made, with
replacewith
~
l0rt th€rmostat.
compatiblethermostat.
compatible
3. Check low voltage circuit for bad wiring, electrical
connections and/or switches. NOTE:
NOTE: When the thermostat
thermoslat wires
wires terminate
terminate on the
primary control
HSG primary "T" terminals,
control box 'T' terminals, the heat anticipa-
anticipa-

~ tor setting
setting value
adding
value for
for the
th€ HSG burner
burner is determined
primary control current
adding the primary cunent to the
determined by
lhe gas valve cur-
cr:r-
4. Check
4. line voltage
Check line voltage circuit
circuit for bad wiring,
wiring, electrical
electrical rent.
renl. The result
result is the anticipator
anticipator setting.
setting.
and/or switches.
connection and/or
connection switches. (Example:.2
(Example: .2 + .6
.6 ==.8
.8 amps.)
amps.)

Iflf the
lhe thermostat
thermostat wires ARE NOT terminated
terminated on the
burner control box 'T'
bumer control T" terminals,
terminals, and
and these terminals
terminals are
are
JUMPERED,
JUMPERED,you you must
must then
then determine
determinewhat
what the
the correct
conect
anticipator
anticipator setting is by inspecting
setting is inspecting the
the controlling
controfling device
device
point where
at the point where the thermostat
thermostat wires
wires terminate.
terminate.
Typically,
Typically,this information can be found
this information found on the body or
cover of thethe controlling
conlrolling device.
device.

When determining cunent draw of the dual head gas


determining the current
valve,
valve, be sure
sure to consider the separate
separate ampere values
for each valve.
valve. These usually are stenciled
stenciled on the valve
valve
body,
body, and must
must be added together
together to obtain
obtain the correct
conect
sum. (Example:.4
sum. (Example: .2 =
.4 ++ .2 = .6
.6 amps).
amps).

When
When thethe current
cunent draw
draw cannot
cannot be determined
determinedaccurately
accurately
by the
lhe above method, measure the
above method, the current
current with an
ampere
amp€re meter
meler using
using the
lhe 1 AMP scale.
scale. Connect
Connect the
leads in series
meter leads series with one of the
the thermostat
thermostat leads
26
26 for the
for reading.
accurate reading.
the accurate
SECTIONIV
SECTION Iv
SBRYICE
SERVICE

Caution:Make
Caution: Make sure
surethat
that the
themain
mainmanual
manualgas gasvalves
valvesand
andmain
main
electrical power disconnect
electrical power disconnect areturned
are turnedoff
off before
beforeopening
openingburner
burneroror
removingany
removing partsfor
any parts for service.
service.All
AII cover plates,enclosures,
coverplates, enclosures, and guards
andguards
mustbe
must be in placeat
in place at all
all times,
times,except
exceptduring
during maintenance
maintenance andservicing.
and servicing.

A. BURNER
A. BURNER HEAD
HEAD AND
AND
ELECTRODE/SENSORASSEMBLY
ELECTRODE/SENSOR ASSEMBLY

Theburner
The burnerhead,
head,electrodes,
electrodes, orificeholder
orifice holderand
andhousing
housingcover
coverare partof the
arepart the
gashain assembly, whichcan
gas- train assembly, which canbe
beremoved
removedasasone
oneunit.
unit.
(See Figure
(See Figure 17)17)

1.Disconnect
1. Disconnect1"l" NPT gasline
NPT gas linefrom
fromburner
burneriQlet.
iqlet. Also,
Also,disconnect
disconnecttheflame
the flame
sensorlead
sensor leadwire,
wire, ignition
ignitiontransfonner
transformerwire,
wire, and
andthe
the clear
cleartubing
tubinglocated
locatedon
on
the brass hose barb on the top of the housing.
the brass hose barb on the top of the housing.
'2.
Removethe
. 2. Remove the four
four 5/16"-18
5/16"-18hex headscrews
hex head screwsthat
thatattach
attachthe
thecover/manifold
cover/manifold
assembly to the burner.
assembly to the burner.

3.
3. To
To remove
remove gas
gas train assembly, gently
train assembly, gently lift
lift up
up rear
rear of
of housing cover pulling
housing cover pulling
backward
backward slightly
slightly on
on the
the drawer assembly gradually
drawer assembly gradually positioning
positioning the
the rear
rear of
of
the
the drawer
drawer assembly
assembly upward
upward 90
90 degrees.
degrees. Gently
Gently extract
extract burner
burner head
head and
and
electrode/sensor assembly out opening in housing top taking extreme
electrode/sensor assembly out opening in housing top taking extreme care care as
as
to not dislocate or damage electrodeor sensor probe.
to not dislocate or damage electrode or sensor probe.

4.
4. When
When servicing,
servicing, clean
clean burner head ports,
burner head ports, electrodes
electrodes and sensor probe.
and sensor probe.
Inspect the sensor probe and electrode wires
Inspect the sensor probe and electrode wires and and porcelain
porcelain insulators
insulators
carefully for
carefully for hairline
hairline cracks,
cracks, which might provide
which might provide anan electrical leak path
electrical leak path that
that
could short
could short out
out the
the ignition spark, or
ignition spark, or flame
flame signal.
signal.

5. Examine
5. Examine the
the electrode
electrode and sensor probe
and sensor probe for
for any
any serious
serious corrosion
corrosion or
deterioration
deterioration of
ofmetal
metal at
at the
the tips.
tips. Check for proper
Check for proper dimensional
dimensional settings
settings of
of
the sensor probe and electrode (see Figure 6). Adjust and/or replace
the sensor probe and electrode (see Figure 6). Adjust and/or replace these these
assemblies
assemblies as
as necessary.
necessary. Make sure that
Make sure that the
the ignition
ignition and
and sensor
sensor probe
probe wires
wires
go to the correct electrodes and the ignition wire boot is in place
go to the correct electrodes and the ignition wire boot is in place overover the
the
electrode porcelain.
electrode porcelain.

27
27
6.
6. Make sure
sure that the
the burner
burner tube end is properly positioned
tube end positioned in the
combustion
combustion chamber
chamber entry.
entry. It
It must
must be 1/2" (I2.7mm)
set I/2"
be set short of
(l2.7mm) short of the
the inside
inside
face
face of
of the
the combustion
combustion chamber
chamber as shown in figures
as shown figures 3, 4 or 55..

21 It526-0Ol
21 ~2B-ool PECAl. G
PECjI- S tNlEr
GAS INL£T t1
covER/MANIFOLD/OR|F|CEASSEM
COVER/MANIFOLD/ORIFICE BLY
ASSEMBLY
fr20 6irfi-
01275-001 LUG HD(
PLUG, HEX HFJAO
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1/8 ERASS
BRASS T1
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3026 USHING SIMJN
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RElJEF 562
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117 x
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SENSOR EIfCTRODE
ElECTRODE sMU
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(SEE BOI
BOIol I1
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2JO.4 IUSHING
USHING SIRAIN
STRAIN REUEF
RElJEF 7/
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14 lx HAl.lBERIMANIFOlD ASS£t.lBLY SEE BOIol t1
13 2693-002 cREW.
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12 t2+19-
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UP, SPRING
SPRING E-ECTROOE
ElECTRODE I1
t11
l
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269J
2693
i2J90-X
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REW, SEI
SET 10-24
10--24 X
X 25.25 I4
5
2390--XXX IECTRODE. SENSOR (SEE
LECTRODE. SS|SOR SEE E80M I 1
I9 i?Jg1-
2391-XXX I.EC]RODE rcilITB
LECTRODE. IGNITER I1
8 2387-001 }I.'SHI}.IG.
USHING, ELECTROOE
ElECTRODE INSUI.ATOR
INSULATOR z2
7 ;2,+71-{XrJ
2471 OOJ PORT,nELECTRODE
UPPORT, FCIROOEtlw,cH.CH. I1
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ASS£t.lBLY 1
fTElo4 t{AttE
NAME DESCRIPTION
DESCRIPTlON OlY
Portt
Port. Urt
Ust
Fo(
xxx -- PARI
PART NUUBER
NUIolBER Wltl
WIll. C}I NGE ffIll
ClWlGE WTni zuRNER
BURNER t-O{Gm
L£NGnt OR FIRING RATE
OR RRING RATE.
RfrER
REFUl nTO IHE
THE SP€CFE
SPEClF1CATlON NUIIB£R gtl
ION MI/8€R BILL 0f
Of ll/wXuLs
IMTERWS FoR
FOR PART
pm M,u6€Rs
NUIolB£RS

ASSEMBLED
ASSEMBLED VIEW
VIEW

FIGURE
FIGURE 17
17

28
28
B. AIR PROVING SWITCH

The air-proving
The air-proving switch has aa black
switch has plastic top
black plastic top and grey bottom
and grey bottom and is
and is
mounted
mounted inside the junction box
inside the box on the right side
on the side of
of the
the burner housing. A
burner housing.
clear plastic tube
clear plastic is connected
tube is connectedto thethe barbed
barbed fitting onon the pressureswitch
the pressure switch
while the
while the other
other end
end isis connected
connectedto to aa brass
brassbarbed fitting on
barbed fitting the
on the
cover/manifold assembly.
cover/manifold assembly. The plastic tube
The plastic tube allows pressurizedair
allows pressurized air from
from the
the
housing to travel
blower housing travel to the pressureswitch
the pressure switch causing
causingthethe diaphragm
diaphragmto to
closeaa set
close setof micro-switch
micro-switchcontacts, thuscompleting
contacts,thus completingthe the circuit.
circuit.
The function
The function of
of the
the air proving switch
air proving switch isis to ensure
ensurethat
that sufficient
sufficient combustion
combustion
air is
air is being developedby the
being developed the blower motor and
blower motor and blower
blower wheel.
wheel.Should
Shouldthethe
blower motor fail or the the blower malfunction, the
wheel malfunction,
blower wheel the burner gasvalves
burner gas valves
shutoff.
will shut off.

1. The
1. The Air Proving switch
Air Proving shouldnever
switch should requiremaintenance.
never require However,
maintenance. However,
shouldnuisance
should nuisancelockouts
lockoutsoccur, the pressure
occur,the can be
switch can
pressure switch checked.
be checked.
Disconnectingthe
Disconnecting the 24V
24Y leads from the
leads from the air switch
switch and 'Jumpering" the
and "jumpering" the leads
leads
togetherwill bypass
together the switch's
bypass the function.If
switch'sfunction. If the
the burner functionscorrectly
burner functions correctly
then the
then the switch
switch is
is malfunctioning.
malfunctioning.

WAR|IING: If
WARNING: If aa jumper
jumper is to check
usedto
is used the switch
checkthe switch it must be removed
must be removed or
an unsafe
an conditioncan
unsafe condition can occur resultingin death
occurresulting damage.
death or property damage.

2. As mentioned
2. mentionedabove,
above,the
the switch neverrequire
shouldnever
switchshould requiremaintenance.
maintenance.
Howeveraa pinched
However tubewill shut
blockedtube
pinched or blocked off the
shutoff pressurizedair
the flow of pressurized air
to the
to the diaphragm
diaphragmcreating
creatingaa failure
failure similar to aa bad
similar to Provingswitch.
bad Air Proving switch.
Always check
Always checkto ensure
ensurethat
that the
the clear
cleartubing is not
tubing is pinched.
not pinched.

C. COMBUSTION AIR BLOWER AND MOTOR


C.

1. Cleaning
1. Cleaningof the combustion
of the combustionairair blower is required
blower is required if the blades
if the show an
blades show an
accumulationof
accumulation of dust
dust and
and lint, or if
if the
the character
characterof
of the flame indicates
the flame indicates aa
deficiencyof
deficiency of combustion
combustionair.
air.

2. The
2. The motor
motor and
and blower wheel are
blower wheel areremoved as one
removed as one assembly. Disconnect
assembly.Disconnect
the motor
the motor wire under
underthe
the cover/manifold assembly.Remove
cover/manifoldassembly. Removethe
the two (2)
two (2)
5116"-18hex
5/16"-18 hex head
headscrews
screwssecuring the motor
securingthe motor to
to the
the burner housing.
burner housing.

CAUTION: Do not
CAUTION: removeblower
not remove wheel from motor shaft
blower wheel during periodic
shaft during periodic
cleaning.
cleaning.

29
29
3. Should removal
3. Should removal of the blower
ofthe wheel be
blower wheel necessary for
be necessary cleaning or
for cleaning or
replacement of
replacement of either motor, the
the motor,
or the
either itit or wheel must
blower wheel
the blower be positioned
must be positioned
correctly the motor
on the
correctly on shaft. (Figure
motor shaft. (Figure l8)
18)

MOTOR
MOTOR ~

BLOWERWHEEL
BLOWER W Httl

~-.09
F A N SPACING
FAN SPAC I NG
D. GAS
D. PRESSURE
GASPRESSURE SWITCHES
SWITCHES

gaspressure
Thegas
1.l. The pressure switches
switches shouldnever
should maintenance.
requiremaintenance.
neverrequire If nuisance
If nuisance
persist,the
problemspersist,
problems theswitches betemporarily
canbe
switchescan jumperedout
temporarilyjumpered to bypass
outto the
bypassthe
function.If
switchesfunction.
switches If the burnerfunctions
theburner thenthe
correctlythen
functionscorrectly switchisis
theswitch
malfuctioning.
malfuctioning.

WARNING: If
WARNING: jumperisisused
If aajumper checkthe
tocheck
usedto mustbe
switchitit must
theswitch removed
beremoved or
or
anunsafe
an unsafecondition occurresulting
canoccur
conditioncan in death
resultingin deathor propertydamage.
or property damage.

30
TECHNICAL INFORMATION
TECHNICAL INFORMATION
ooTroubleshooting
Guideo'
"Troubleshooting Guide"
NUISANCE LOCKOUTS/FLAME SENSING PROBLEMS - EHG
NUISANCE LOCKOUTS/FLAME SENSING PROBLEMS - EHG GAS GAS
BURNERS
BURNERS
Wayne's EHG seriesdirect sparkignition (DSI) gasburnersprove flame
Wayne's EHG series direct spark ignition (DSI) gas burners prove flame
through the processof flame rectification.Flame rectification i, achieved
through the process of flame rectification. Flame rectification is achieved by by
placing a small voltageon the flame-sensing probe.When
when thetheprobe
probeisis
placing a small voltage on the flame-sensing probe.
surroundedby flame, the voltageon the probe "leaks" to ground
throughthe
surrounded by flame, the voltage on the probe "leaks" to ground through the
resulting in an electricalcurrent.This current is interpretedby the
flame,resulting in an electrical current. This current is interpreted by the
flame,
ignition control as the presenceof flame.
ignition control as the presence of flame.
One of the most colnmonproblemswith gas appliancesutilizing this
One of the most common problems with typeof
gas appliances utilizing this type of
electronicflame sensingsystemis the "nuirunr. lockout".Lockouts
electronic flame sensing system is the "nuisance lockout". Lockouts are arenot
not
generally due to the burner failing to ignite, but rathersimply the failure
generally due to the burner failing to ignite, but rather simply the failure
of the systemto sensethe establishment of flame.
flame.Should
Shouldthis
this situation
situationexist
of the system to sense the establishment of exist
for a period of time longerthanthe ignition control's statedlockout
timing,
for a period of time longer than the ignition control's stated lockout timing,
the control will shutdown or go into permanentlockout.The only
the control will shut down or go into permanent lockout. The only way way to get
to get
the burner to recycle is to break,and then reinstatepower to the burner.
the burner to recycle is to break, and then reinstate power to the burner.
The following situationscan lead to flame sensingproblems and
The following situations can lead to flame sensing problems and can
checkedwithout disassemblingthe main burner:
can be
be
checked without disassembling the main burner:
' The burner is not properly groundedto "earth ground" on the line voltage.
• The burner is not properly grounded to "earth ground" on the line voltage.
' The ignition control is not properly groundedto ttr" burner itself. Using an
• The ignition control is not properly grounded to the burner itself. Using an
ohmmeter,check the wire attachedto both parts for good contactand
ohmmeter, check the wire attached to both parts for good contact and
continuity.
continuity.
' The burnerignition controlis polarity sensitive.The polarity of the
• The burner ignition control is polarity sensitive. The polarity of the
incoming line voltagemay be reversed.Verify that black and white wires are
incoming line voltage may be reversed. Verify that black and white wires are
hot and neutral respectively,
hot and neutral respectively, and
and that
that they
they arqconnected
are connected to
to the
the
correspondingblack and white wires on the burner.
corresponding black and white wires on the burner.
The remaining checksand/or adjustments require removal of the
The remaining checks and/or adjustments require removal of the gas
train: gas
train:
'The connectionsfrom the "SENSE" terminalof the ignition controlto the
• The connections from the "SENSE" terminal of the ignition control to the
end of the flamerod may be broken at somepoint. Chect<all quick-connect
end of the flamerod may be broken at some point. Check all quick-connect
terminations and connections.Check the continuity with un oior-eter while
terminations
flexing wires toand connections. Check the continuity with an ohmmeter while
assureno hidden conductorbreakige exists.If replaced,
wiring must be ofassure
flexing wires to no hidden conductor breakage exists. If replaced,
equal,or heaviergaugeand equaf or bettertemperafure
wiring must be of equal, or heavier gauge and equal, or better temperature
rating.
rating.

3l31
•. The flamerod probe
The flamerod may be
probe may groundedout.
be grounded out. Assure
Assurethat
that the flamerodprobe
the flamerod probe
is not
is not touching
touching the
the burner
burner head. The probe
head.The probe should
shouldbe be positioned
positioned in the
the center
center
of the
of the clearance groove on
clearancegroove on the
the outer edgeof
outer edge of the burner head
the burner head with
approximately.125"
approximately (3.175mm)clearance
.125" (3.175mm) clearancefrom
from the
the head. The probe
head.The must
probe must
not be positioned
not be far away
positioned to far away from
from the
the head
head as
as this
this may
may result grounding
result in grounding
out of
out the probe
of the againstthe
probe against the inside
inside surface
surfaceof the air
of the air tube.
tube.

•. The flamerodprobe
The flamerod shouldbe
probe should freeof soot
be free soot and
and creosote. Depositsmay
creosote.Deposits may
insulatethe
insulate probe, leading
the probe, leadingit not to pass
not to the electrical
pass the electricalcharge
chargeto the flame.
the flame.
The probecan
The probe can bebe cleaned
cleanedwith steel
steelwool,
wool, emery paperor fine
emerypaper fine sandpaper.
sandpaper.
NOTE:
NOTE: ThisThis is
is the leadingcause
the leading causeof nuisance lockoutsin dual-fuel
nuisancelockouts dual-fuelwood/gas
wood/gas
fired appliances.
fired appliances.

•. The flamerod probe


The flamerod probe may be burned
may be burnedaway.
away. Check
Check it against dimensionson
againstdimensions on
the ELECTRODE
the ELECTRODE,AND AND FLAMEROD PROBEPROBE SETTTI\JGS
SETTINGS drawing.
drawing.

•. The
The dimensional location of the
dimensionallocation the flamerod probe may
flamerodprobe may be
be incorrect,
incorrect,or the
the
probe may be
probe may bent out
be bent out of shape.
shape.Check againstdimensions
Checkit against dimensionson
on the
the
ELECTRODE AND AND FLAMEROD PROBE PROBE SETTINGS drawing and
SETTINGS drawing adjust
and adjust
if necessary.
if necessary.

•. The
The spark
spark electrode
electrodegapgapmay
may be
be incorrect,
incorrect,resulting no spark
resulting in no sparkor an
an
inadequatespark
inadequate sparkthat not ignite
that will not ignitethe gasproperly.
the gas the electrode
Checkthe
properly. Check electrode
gapagainst
gap againstthe ELECTRODE AND FLAMEROD
the ELECTRODE FLAMEROD PROBE PROBE SETTINGS
SETTINGS
drawing and
drawing and adjust
adjust if
if required.
required.

•. The
The high tension lead
high tension lead conductor
conductorfrom
from the ignition transforrner
the ignition transformer to the
the tip ofof
the spark
the spark electrode
electrodemay may be broken, preventing
be broken, high voltage
the high
preventing the current from
voltage current from
getting to the
getting the electrode tip. Check
electrodetip. all connections
Check all connectionsthoroughly and/or check
thoroughly and/or check
to continuity
continuity ofof the lead wire assembly
the lead assemblywith an an ohmmeter. Once all of
ohmmeter.Once of the
the
items listedpreviously
items listed havebeen
previously have carefullychecked
been carefully checkedandand corrected if
correctedif
necessary,reinsert
necessary, reinsert the gas train
the gas train assembly
assemblyinto thethe burner. NOTE: Be careful
burner. NOTE: careful
not to
not to accidentally repositioneither
accidentallyreposition eitherthe flamerodprobe
the flamerod during
electrodeduring
probe or electrode
reinstallationof the
reinstallation the gas
gastrain
train assembly.
assembly.

32
32
after all of the
If, after abovelisted
the above itemshave
listed items havebeen carefullychecked,
been carefully checked,the
the burner
burner
still fails
still fails to
to work, is due
work, it is dueto oneor
to one or more followingproblems:
the following
more of the problems:

1. Unit sparks
1. sparksand
andfires but will not
firesbut lit. Ignition
staylit.
not stay Ignitioncontrol
controlmodule
module is
is
malfunctioningand
malfunctioning andmust be replaced.
must be replaced.

2. Unit does
2. doesnot
not spark. Ignitiontransformer
spark.Ignition transformer is
is bad andmust
bad and be replaced.
must be replaced.

33
33
LIMITED WARRANTIES
LIMITED FOR OIL
WARRANTIES FOR OIL AND
AND
GAS BURNERS,
GAS BURNERS, MADE
MADE BY WAYNE
WAYNE AND
USED IN
USED TN RESIDENTIAL
RESIDENTIAL INSTALLATIONS
INSTALLATTONS

WAYNE COMBUSTION
WAYNECOMBUSTION SYSTEMS
SYSTEMS ('WAYNE")warrants
("WAYNE") wanants A burner
4. A
4. burnerso repaired
so repaired will then
will then carry
carry the
the LIMITED
LIMITED
to those
to thosewho purchase
whopurchase its Oil Burner
itsOil BurnerModels
Modelsforfor resale
resaleor
or WARRANWequal
WARRANTY equaltoto the
the unexpired portionof
unexpiredportion of the
the
for incorporation
for incorporation into productof
intoaa product of resale,
resale,that
thatits
its burner
burnerisis originalburner
original LIMITED
burnerLIMITED WARRANTY.
WARRANTY.
free from
free defectsin
from defects in material
materialand and workmanship under
workmanship under 5. inspection
5. Iflf inspection by WAYNE
by WAYNE doesNOT
does NOTdisclose
discloseany defect
anydefect
normaluse
normal useand servicefor
andservice for thirty-six (36)months
thir$-six(36) monthsfrom the
from the covered
covered by this
by LIMITED
thisLIMITED WARRANTY,
WARRANTY, the burner
the burneror
or
dateof
date of manufacture.
manufacture. ALLGAS
ALL GASBURNERS
BURNERS manufactured
manufactured burner component(s)
burnercomponent(s) will be
will be either
either repaired
repairedoror
by "WAYNE"will
by "WAYNE" be similarly
will be similarly warranted
warranted for eighteen(18)
for eighteen(18) replaced
replaced at the
at theexpense
expense of the
of thecustomer
customerand
andWAYNE's
WAYNE's
monthsfrom
months from date
date of manufacture
of manufacture exceptwhere
except original
where original regularcharges
regular charges willapply.
will apply.
manufacture
manufacture oHers greaterwarranty.
offers aa greater (Reference#6
warrang.(Reference #6
6. Iflf the
6. the original manufacturer
originalmanufacturer of aa burner
of burnercomponent
component
below) LIMITED
THESELIMITED
below)THESE WARRANTIES
WARRANTIES DO NOT
DO NOTAPPLY
APPLY
oHers warranty
offersaa warranty greaterthan
greater thaneither
eitherof our LIMITED
of our LIMITED
UNLESS
UNLESS THE BURNER
THEBURNER COVERED
COVERED BYIT
BY IT IS
IS PROPERLY
PROPERLY
WARRANTIES
WARRANTIES described
described above,then
above, thenthis portion
thisportion will
will
INSTALLED BY
INSTALLED BY A QUALIFIED,OUALIFIED,COMPETENT COMPETENT
be addedto
be added to our
ourLIMITED
LIMITED WARRANTY.
WARRANTY.
TECHNICIAN,
TECHNICIAN, WHO
WHO IS IS LICENSED
LICENSED WHEHESTATE
WHERE STATE
AND/OR LOCAL CODES PREVAIL,
AND/OR LOCAL CODES PREVAIL, AND WHO IS AND WHO IS This LIMITED
This WARRANTY
LIMITEDWARRANTY does NOT
does NOTcover products
cover products
EXPERIENCED IN MAKING SUCH
EXPERIENCED IN MAKING SUCH INSTALLATIONS, IN INSTALLATIONS, IN which have been
whichhave damagedas
been damaged as the resultof
the result of accident,
accident,
ACCORDANCE
ACCORDANCE WITH NFPA
WITH NFPA#31 #31 OFOF THE
THE NATIONAL
NATIONAL abuse,misuse,
abuse, neglect,
misuse,neglect, improperinstallations,
improper installations,improper
improper
PROTECTION
FIRE PROTECTION ASSOCIATION
FIRE ASSOCIATION AND IN
AND IN maintenance
maintenance or failureto
or failure to operate
operatein
in accordance
accordance with
with
ACCORDANCE
ACCORDANCE WITH WITH ALL LOCAL, STATE
ALL LOCAL, STATE AND AND WAYNE's
WAYNE's written instructions.
writteninstructions.
NATIONAL
NATIONAL CODES,
CODES. LIMITED
TheseLIMITED
These WARRANTIES
WARRANTIES do not
do not ex1end
extendto anyone
to anyone
first purchaser
the first purchaser at
exceptthe
except retail
at retail and
and only
only when the
whenthe
Any lN-WARRANTY
Any IN-WARRANTY burnercomponent
burner component whichis
which is defective
defective
is in
burneris
burner in the original
theoriginal installation
installation site.
site.
materialor
in material
in workmanship
or workmanship will be either
will be eitherrepaired
repairedor or
replaced
replaced as follows:
as follows: WARRANTIES
IMPLIEDWARRANTIES
IMPLIED OF MERCHANTABILITY
OF MERCHANTABILITY AND
AND
FITNESS
FITNESS FORA
FOR A PARTICULAR
PARTICULAR PURPOSE
PURPOSE SHALLBE
SHALL BE
Fuel units,
1. Fuel
1. motors,transformers,
units,motors, transformers, gas valves,
gas valves,andand
L I MI T E DTO
LIMITED T HE DURATION
T O THE DURA T I O N T H E LIMITED
O F THE
OF LIMITED
controls
controls shouldbe
should returned
be returned to an authorized
to an authorized service
service
WARRANTIES
EXPRESSWARRANTIES
EXPRESS CONTAINEDHEREIN.
CONTAINED WAYNE
HEREIN.WAYNE
stationor
station or distributor
distributor of WAYNE
of WAYNEfor determination
for determination of
of DISCLAIMS
EXPRESSLY AND EXCLUDES
EXPRESSLY DISCLAIMS AND EXCLUDES ANY ANY
applicability
applicability of this
of thisLIMITED
LIMITED WARRANry
WARRANTY as as to
to either
either CONSEOUENTIAL
FOR OR INCIDENTAL
LIABILITYFOR CONSEQUENTIAL OR INCIDENTAL
LIABILITY
repairor
repair or replacement,
replacement, where saidservice
where said servicestation
stationor
or
DAMAGES
DAMAGES OF ANY
OF ANYNATURE
NATUBE FOB BREACH
FOR BREACHOFOF ANY
ANY
distributor
distributor is reasonably
is reasonably available
available in the
in the customer's.
customer's
EXPRESS
EXPRESS ORIMPLIED
OR IMPLIEDWARRANTY.
WARRANTY.
locality. The manufacturers
locality.The manufacturers of burner
ot burnercomponents
components
regularly
regularly publishand
publish distribute
and distribute listingsshowing
listings showingthe the Somestates
Some statesdo notallow
donot allowlimitation
limitation on howlong
on how longan
animplied
implied
locationsof
locations of their networkof
their network of service
servicestations.
stations.Where
Where warranty lasts, so the above limitation may
warrantylasts, so the above limitation may not apply not applytoto
localservice
suchlocal
such serviceis is NOT
NOTavailable
available for the
for the burner
burner you. Also,some
you. Also, states do not
somestates do not allow allowthe exclusion
the exclusion or
or
components
components described above or other burner
described above or other burner parts are parts are limitation
limitation of incidental
of incidental or consequential
or consequential damages,
damages, so the
so the
involved,these
involved, items should
these items should be returned,
be returned, freightfreight above limitationor
abovelimitation or exclusion
exclusionmaymay notnot apply you.
to you.
apply to
prepaid,
prepaid, to WAYNE
to WAYNE Service Department,
ServiceDepartment, 801Glasgow
801 Glasgow WAYNEneither
WAYNE neitherassumes
assumesor authorizesany
or authorizes person
any person to to
Ave, FortWayne,
Ave, Fort 46803.
lndiana46803.
Wayne, Indiana assumefor
assume WAYNEany
for WAYNE any other
other liability
liabilityor
or obligation in
obligationin
connection
connection withthe
with saleof
the sale of these products.This
these products. Thiswarranty
warranty
Burnersand/or
2. Burners
2. and/orcomponent(s)
component(s) determinedto
determined be
to be givesyou legalrights,
speciliclegal rights,and you may
may also have
alsohave
gives you specific and you
covered
covered under this LIMITED WARRANTY
under this LIMITED WARRANTY by WAYNE by WAYNE rightswhich varyfrom stateto state.
otherrights
other which vary from state to state.
shallbe
shall be repaired
repaired or or replaced
replaced at at WAYNE's
WAYNE's sole soleoption.
option.
3. WAYNE
3. WAYNE is is not responsible
not responsible for any labor
for any cost for
labor cost for the
the
removaland
removal and replacement
replacement of of said
said burner
burner or or burner
burner
components
components and andequipment associated
equipment associated therewith.
therewith.

34
J+
INSTRUCTIONS
CONSLMER INSTRUCTIONS
CONSUMER

Keep the area


Keep the aroundthe
areaaround the burner and free
clearand
burner clear free of combustible
combustiblematerials,
materials,
gasolineor other
gasoline other flammable
flammableliquids vapors.Do not
liquids or vapors. not obstruct
obstructburner
burner air
openingsor ventilation
openings grillesfor
ventilationgrilles for combustion air. If
combustionair. If the
the burner is to
burneris to be shut
be shut
down for an
down an extended time. the
extendedtime, main manual
the main gas valve should
manual gas valve shouldbebe closed
closedasas aa
precaution.
precaution.

CAUTION: Check
Checkthe
the burner flameperiodically.
burnerflame periodically. A proper
proper
NATURAL gas
NATURAL gas flame
flame will appear
appearblue at the
blue at the burner face with orange
burner face orangeandand
yellow tips.
yellow tips. A proper PROPANEgas
proper PROPANE gasflame
flame will appear
appearblue
blue atat the
the burner
burner
facewith yellow
face yellow tips.
tips. If flameis
the flame
If the is too
too rich,
rich, it will appear
appearbillowy and and
yellow with
yellow withhazy tips, if
hazy tips, if too lean,it will appear
too lean, appearshort
shortand
and all
all blue. Burner
blue. Burner
cleaningand/or
cleaning and/orreadjustment
readjustment is indicated
is indicatedby flames
flamesthat
that are
aretoo rich or too
too rich too
lean.
lean.

WARNING:
WARIYING.'If any flame
If any is observed
flame is observedwhen the burner
when the is on
burner is on standby, if
standby,or if
the ignition spark
the ignition sparkor valve
valve operator is heard
operatoris to come
heard to comeon
on before the motor
before the motor
reachesoperating
reaches operatingspeed,
speed,immediately turn off
immediately turn the manual
off the gascontrol
manualgas control and
and
main power.
main dangerouscondition
power. A dangerous hasdeveloped
conditionhas and must
developedand must be
be corrected.
corrected.

CONTACT
CONTACT A QUALIFIED
QUALIFIED SERVICE
SBRVICE TECHNICIAN
TBCHNICIAN FOR
CLEANING, READJUSTMENT
CLEANING, READJUSTMENT OR REPAIR.

LIGH TING INSTRUCTIONS:


LIGHTING INS TR UC TIO NS :
See Section II
See II Initiql
Initial Start Up
Up
1. TURN
1. TURN MAIN
MAIN ELECTRICAL DISCONNECT POWBR
ELECTRICAL DISCONNECT POWER SWITCH
SWITCH
oN.
ON.
2. OPEN
2. OPEN ALL
ALL MANUAL GAS VALVES.
GAS VALVES.
3. SET
3. SET THERMOSTAT OR OR OPERATING
OPERATING CONTROL
CONTROL TO CALL FORFOR
HEAT.
4. TURN
4. TURN BURNER
BURNER ON-OFF
ON-OFFSWITCH
SWTTCHTO THE ON POSITION.
ON POSITION.
WAIT 30
WAIT 30 SECONDS.
SECONDS.IF BURNER
BURNERHAS
HAS FAILED
FATLEDTO LIGHT,
OR IF BURNER
OR BURNER LIGHTS THEN GOES OUT, TURN
GOES OUT, TURN BURNER
BURNER OFF
OFF
FOR 30
FOR 30 SECONDS
SECONDSAND
AND THEN BACK ON FOR RESTART.
ON FOR RESTART.

35
35
TO SHUT
SHUT OFF:
OFF:
1. TURN MAIN
1. TURI\ MAIN POWER SWITCH
SWITCH OFF OR TURN BURNER
BURNER
SWITCH OFF.
SWITCH
2. SHUT
2. SHUT ALL
ALL MANUAL
MANUAL GAS VALVES.
VALVES.

EXPLOSION
EXPLOSION HAZARD:
HAZARD: If If PROPANE gas gas is used
used and the burner is
Iocated
located in a basement,
basement, crawlspace
crawlspace or confined
confined space, contact your gas
space, contact gas
supplier about installing
installing a "gas device. PROPANE gas
"gas leak" warning device. gas is
heavier
heavier than air and
and can settle in low areas
can settle areas or confined
confined spaces.
spaces. This
create a DANGER
would create DANGER OF EXPLOSION
EXPLOSION OR FIRE. If If you suspect
suspect a
gas
gas lealq
leak, follow instructions
instructions on front coyer of this manual.
cover of manual.

HIGH
HIGH VOLTAGES ARE PRESENT PRESENT IN THIS EQUIPMENT
EQUIPMENT
FOLLOW
FOLLOW THESE
THESE RULES
RULES TO AVOID ELECTRICAL SHOCK. SHOCK.
_ Use only a properly
Use only properly grounded circuit. A ground
grounded circuit. ground fault
fault interrupter
interrupter is
is
recommended
recommended
_ Do
Do not spray
spray water
water directly
directly on
on burner.
burner.
_ Turn off power
power before
before servicing.
servicing.
_ Read
Read the owner's manual
the owner's manual before
before using.
using.

CARBON
CARBON MONOXIDE IS A COLORLESS, ODORLESS
A COLORLESS, ODORLESS GAS GAS
THAT
THAT CAN KILL.KILL. FOLLOW THESE THESE RULES
RULES TO CONTROL
CARBON
CARBON MONOXIDE.
_ Do
Do not
not use
use this
this burner
burner if
if in an
an un-yentedo
un-vented, enclosed
enclosed area,
area. Carbon
Carbon
monoxide
monoxide may
may accumulate.
accumulate.
_Adequate venting
_Adequate venting and
and combustion
combustion air is is required
required at all
alJ times.
times.
Only qualified
_ Only qualified personnel
personnel should
should adjust the pressure
adjust the pressure regulator.
regulator. High
High
pressures
pressures produce
produce carbon
carbon monoxide.
monoxide.
_ Check flue gases
Check flue gases for carbon
carbon monoxide.
monoxide. This check requires
This check requires specialized
specialized
equipment.
equipment.
_ Allow only qualified
qualified burner service persons
burner service persons to adjust
adjust the
the burner.
burner.
Special instruments
Special instruments and
and training
training are
are required.
required.
_ Read
Read the
the owner's
owner's manual
manual before
before using.
using.

SHOULD
SHOULD OVERHEATING OCCUR: OCCUR:
Shut
Shut off the manual gas
the manual gas control
control to the
the appliance
appliance
Do
Do not shut off the
not shut the control
control switch the pump
switch to the pump or blower.
blower.

36
36
START-UP& SERVICE
START-UP SERVICE NOTES
NOTES

Recordthe
Record installationdata,
the installation thecombustion
data,the combustionreadings, andaffix
etc.,and
readings, etc., affix to
to this
this
manual, or the
manual, or the burner and/orappliance.
burnerand/or appliance.Space
Spacehas
has been providedfor
been provided for start-
start-
up notes,dealer's
up notes, dealer'sname, address,
name, address, servicetelephone
service telephone numbers, emergency
numbers, emergency
telephonenumbers,
telephone numbers,as aswell asthe
well as dateof installation.
the date installation.

37
37
24 00s75-002 )ECAI. SPEC NUMEER
2423100575-002
5J2J )oNNECTOR,
CoNDUr J/8', 9C
232215323
222 114429
+429
| 00196-01 5
)ONNECTOR,DUPLE( CONDUIT
)oNpun,
G A STRAIN
GAS T RA I NWIT HREGULATOR
WITH R EGU L AT OR
E-ExJ/E'X 19.5'
2120100196-016
r00196-ol 9
2019 100196-019
ool 96-OO3
)oNDUtr,FLE( 3/6'X 12. P / N 63527-001
PIN 6 3 s2 7 - 0 0 1
;oNupun,4q cuT 5'
19I E100196-003
I 3660 JUSHING, ASB-1
6
1817 136605801 6
17 13801
ilNNG. CONDUT' J/8
4
T
o1275-OO',t
'LUC, Hg HF}D 1/8 BR'SS 2
16 101275-001
rJ51J-O014 ;wncH, cAS pRESSURELow (&mJNES-LpG:ct- 2
1511 63513-001A
tJsl 5-OO1
T
;WfTCH, GAS PRESSURE LOW THONMFT I
14 1 J 63513-001 'ANO?I
rJ51J-O02A ;wncH, cAs pBEssuRELow (ANnNESHGp_c)
13 63513-oo2A H, G,.!SPRESSURE 1
12 1l 63513-002 e, HD< 1/+' X 1, T
11t o63526-001 2
10 T 63521-002
1,/E. BLK PIPE T
2
9T 100462-00 1
E, P|PE-1/6' X 1 T
2
8 13385
SIREET I/E'NP T
.', GAS INLET T
7?o 63528-001
6T- 63262-003
T
54 63504-001
T
2L
41 550014-002
rJ5ZB-OO2 4
rJs23-001
3 63528-002
'LUG, P-66H 1'PtASnC 2 5
2 63523-001
tJ50J-OO1 /ALVL, MANUAL BqLL 1- 2
1 63503-001
IE[ PARTNO. DESCRIP,IION 2
E PART NO. rqrc OTY
uat 18
Ports U.t

21
(/J
oo

=____.-_____-_*

12
WHEN ANTUNES
WHEN ANTUNES PRESSURE
PRESSURE
SWITCH IS
SWITCH IS USED
USED

EXPLODED
EXPLODED VIEWS
VIEWS

FFIGURE
I G URE119
9
GAS
GAS TRAIN
TRAIN WITH RIGULATOR
WITH REGULATOR

14

ASSEM B L EV
ASSEMBLED DI EW
VIEW

12
FTG 19 ((CONT)
URE
FIGURE 1e c oNr )
(7.eo)
(7.90)

u.J u.J

(2e)
'------------(29 )--------------J

Frcu
FIGURERE
19e (coNT)
1 (CO NT)

A
----ltcA-
tJ-F65t3-02
23 100575-002 sPEc NUMBER
22 5f,2J
22 ~23 :f)NNFCrOR- CONOUT 3/8' 9d
21I 1129
4-429 DUPTD( CONOUIT I
20 oo196-0t6
00196-016 rdNilfif n_d.s/a- x l9-! I

TRAIN W ITH OU T
R EGU LAT OR
I
GAS TRAIN
19 @ts6-ot9
t8 00196-019
18 00t06-005
t6 00196-003
:oNilfiT nFY
:ONUOUTT.ftD( CUT !
f/a'Y 12'
t GAS WITHOUT REGULATOR
tt17 3660 AS8-l I6
16 J80l NOUfr J/8 a P,/N
PIN 63527-O02
63527-002
22
115 5 n Ol01275-001
27 5 -O O r 'LUC. HA HFrD r/6 0R SS
1+
H 1655lJ-oOrA
513-001" X{, G^S PRESSUREU'TI (ANruNES
ANTUNES t.PC{
LPC-C I
r5I., l8J5t3-001
13-001 rr,flnH. cls pREssuRELow ftoNElaEl!
HONEYWEU.. c6097i
C6097A
l12
2 5l.,-002A iWrICH. OtS PRESSURELdI (A{ruNES HCP-( I
-@2
l11
t 51"-002 t. G S PRESSURE HIGH (HONelWAr C6O97B) I
-q)z
to
10 6:t520-OOl
526-001 LHEXl ' x' t/8 , 2
I9 6:t521-00:
21-002 IFF, IIa. BLK PIPE 22
68 1100462-001
100462-001 JrPflr. PrPE-t/E'x | 1/2' 2
7 .,.,85 ir Bow- srREEr 1 /a'NPT
6 6:t52E-001
528-001 lL crs tNtEr
55 i0J5o.+-0ol
4-001 /AL\€. GAS SHIJIOFF 1' 12o'r' 2
,t4 55001 +-q)z
50014-002 rtPPtE. SCH .tO X J.5' J
3
53 lO552E-002
.3528-002 Al- G.\s oLrn.Er I

.3523-001
22 l6J52J-ml 'LUG-
P-8aH t' Pt/LtIlC
I, t{L1505-ool
503-001 ,AL\tr. TANUAL &ILL I. 22
PAFa NO.
PN(T DESCRIPnON
O£SCRIP110N OlY
Portr u.t
Port. Ll.t

17

5 20

11

EXPLODED VIEWS WHENANTUNES


ANTUNES PRESSURE
EXPLODED VIEWS WHEN
S!TTCHISIS USED
USED
PRESSURE
SWITCH

F T G URE
FIGURE 19 ( c o NT )
1 e (CONT)
GASTRAIN
GAS TRAINWITHOUT
WITHOUT REGULATOR
REGULATOR

A
t\)

ASSEMBLTD
ASSEM BLED VIEW
VI EW

F T GURE
FIGURE 119e ((CONT)
Co r u r )
(7)

(22)
~---------(22)----------.I
F I G U R T1e (coNT)
FIGURE 19 (CONT)
A
(,
11 2689
11 12689 )LUG, HOLE
PLUG, HOLE .E75
.875 DIA.
DIA. 1 P
10 t,+015-004
10 64015-004 ]OX,CONTROL-THERMO
BOX,CONTROL-THERMO 1
1 M
00451-003
9 100451-003 ;CREW.FLSL
SCREW,FLSL 5/16-18
5/16-18 X 1.00'
1.00" 4 P
i2205-002
8 62205-002 I.ANGE,MOUNTING_COUNTERSINK
FLANGE, MOUNTING-COUNTERSINK I
1 M
M
00895-001
7 100893-001 ;PACER.TUBE-.I,/4.BRASS
SPACER,TUBE-1/4" BRASS 44 P
t5477-001
b6 63477-001 ruBE,/FI-ANGE-6,EHG
TUBE/FLANGE-6" EHG 11
2697
55 12697 SCREW, HXSLT 23 ',l0-24
;CREW,HXSLT 10-24 X .5 1 P
2909
4 12909 .IIPPLE,CONDUIT
NIPPLE, CONDUIT 1I P
P
P
TUBE/ HO US I NA
TUBE/HOUSING GS S E M B L Y
ASSEMBLY
2910
3 12910 LOCKNUT, CONDUT
CONDUIT
-OCKNI,JT, I
1 P
316 7
2 13167 ryASHER.
WASHER, REDUCING 3/4 X 1/2
REDUCING 3/4 1/2 1 P
20372-005
1 20372-005 {OUSING,
HOUSING, MACHINED
MACHINED I
1 M
ITEM
lLIr PART
PART NO.
NO. DESCRIPTION
DESCRIPTION QTY TYPE
TYPE
Ports
Parts List
List
xX == PART NUMBER WILL
PART NUMBER CHANGE WITH
WILL CHANGE WITH AIR
AIR TUBE
TUBE T.ENGTH,
LENGTH, REFER TO THE
REFER TO THE
SPECIFICATION NUMBER
SPECIRCATION BILL 0F
NUMBER BltI OF IvIATERIALS
MATERIALS FOR
FOR PART
PART NUMBER
NUMBER

EXPLODED
EXPLODED VIEW
VIEW ASSEMBLED
ASSEMBLED VIEW
VIEW
F] G U
RE 20
FIGURE 20
,,8"
MOD EL
MODEL D IM. ''A
DIM. "A",, DIM.
D IM. "B"
~-----( 18.4
1 8 4))------I....-j 6 11q
\(15.3)
| v.v/,
?\ (t
(1 + .t)
4.7)
q
9 ((17.3)
17.3) (r o.
(1 6.7)z )
12
12 (20.3)
(20.3) ((19.7)
1e . 7 )
1q
15 (23.3)
(23.3) (22.7)
(22.7)

l (B 0)
(8.0)

1 1)~
((1.1 )

(DrM "B")---II~
~---(DIM
FIGURE 20
FIGURE 20

(ntv
~---(0 IM "A'~)------a--J
54
34 ,J+CJ-UU
5349 -00' l ECAL, WIRING DIAGRAM I
jJJ
j )JZOU-UUZ COVER,
OVER CONTROL CONTROLBOX (M
BOXOUF63280- 1I
JZ NtJr- 1ZT7o
28 32 JJl J
1331 UT 1/4 X 20 Xx:Eil .50 +
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ASHER 1
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26
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24
24 )J5;l6-(JUJ
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IRE CONTROL SENSE10 10- I
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tVZZ?i }USHING,
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HOLEADAPTER
ADAFTER T
l6 tz + t t-u1-017/ IRE :, ASSEMBY ASSEMRYWHITE WHITE33' I
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ROUNDBODY
BODY +
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22 'U | 60-UU+
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5 o.>46B-002
'*oO-UUZ KA\.-I\t,I, UUMF(JNLNI MOUNIING
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IILM FAr(l NU, DEsCRIPTION
ITEM PART NO. l:JT
Ports List
Parts Ust

'4

EXPLODED VIEW
EXPLODED VIEW

23

ASSEMBLED VIEW
FIGURE
FIGURE 21
21
FINALASSEMBLY
FINAL ASSEMBLY

(2) scREws
(2) suPPuEo
SCREWS SUPPUED
wnH rEM 1
WITH ITEM 1

ASSEMBLED
ASSEMBLED VIEW

/ru
+U Ib')--}\}(X ECAL,)AL. NEW NEUIYORK APPROVAL(SEE
YORK APPROVAL (SEE BOM)
BOM) I

39 IX SCRtW
EUA )UKt Vr ,CRtCW, FURNISI-IEDWIIH IYIIH J··t:!OX
J-AOX 2
38
J6 108
iJJUd IRE IGNITIONIGNITION 3" J- RIGHT
RIGHT ANGLE
ANGLE I

31 | | /':>O-'OOL
co-uuz AG,
AG, WIRINGWIRING SUPPLY
SUPPLY 10:>"C IO5-C I
36
J O li005· IUT, HEX
rvr, nq^ 10,-32
rv-J4
'UU5+
30 100~ -UUL
tt6J5-(J(J2 YASHER,FLAT
ASHER FLAT 118 #8 z
~4
Jil )I17:>:
/JJ CREWV-RDPLMC RDPTM C10-32 r O- 32 X 1.25 1_25-
,3
JJ 5238; -XXX
tzJd6-xxx MER 30
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JU OR 60 OU SEC.SLU. 24VAC
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tJ5J6-(J(J1 i,;A, PKLSsUKL KLGULAIUK
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oor C;A , WAYNt
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'z9bu-uu
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z l 1601
21 OZU I )tCAl,. UAlt DAlt CUUt
coDt 1
26
26 10 1575-XXX ECAL AL. SPEC. NUMBERMASTER
SPEC.NUMBER MASTER(SEE (SEE BOM)
BOM)
25
LO bJ ,34"XXX }ECAL.
ECAL RATING RAT]NG (SEE (SEE BOM BOM) 1
24
z1 lU U U1010
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23
2J li.IJJZY-UU
529-001I AN INLET INLET BLANK
BIINK 1
22
LL JO /J
13 :UVt.K, JUNUIIUN tJUX
;OVLH. UUX 20
z l uu+ud
21 )4011 UT LOCK lo cK 55 /116-18
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20 /5b -U l I LANGE
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18
l5 Uubt'g-UU I
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t5
10 1/9' ;ONIf(9L tlUX
C;UNIKOl UUX A5SEMULY 1I EXPLODED
EXPLODED VIEW
VIEW
t+
14 tJZ++-tJU2.
~44' 102 ,CREW, rtLLE5tLK 10' 'L4 X A .2:>01 1I
FIGURE
1I J 123- 101 ULK VINYL TUBING TUBING1/4
tU-Z+
1./41010
.ZCUI
1
FIGURE 22
22
1t z 'J9ZJ-UUI
iJz6J-OO5
~03- 10:;' ;wilcH,
;WII I,.;H, AIR
At( StNSING
5LNS|NG SP.L 5P.2 I
Il t ,034
JUJ+ IUSHING,SNAP· ·HEYCO st:!· -B/:>··8 1I
110 J0/+5
'V4:> CREW W. 5/16
5/16-16 18 X X .50
.5O THREAD
THRFAOCunlNG
CUTIING 2z
9I :091t
zov ,CRtW,
;CREW. HXSll HXSL| 23 ZJ 10--L4
r0-Z+ X X .:>
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I tb65-uuz UT{
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A 4.14W 1I
2 IOJ6J toToR.
OTOR 11,/4HP 4HP 120V 120V
1I ,IR
IR TUBETUBE/HOUSING
HOUSING ASSEMBLYASSEMBLY 1I
:ITEM
tEn PART
PAT( I NO.
NU. DESCRIPIION IUIY
JI

Ports Us!
Ports Ust
X == PART
X PARTNUMBER
NUMBERWILL
WILLCHANGE
CHAI.IGEWtTFlAIR
WITH AIR TUBE
TUBE LENGTH, REFERTO
LENGTH,REFER IHE
TO THE
SPECIRCATION
SPECIFICATION NUMBERBILL
NUMBER MATERIALS
OF MATERIALS
BILL OF FOR PART
FOR NUMBERS
PIRT NUMBERS
DECAL & TAG
DECAL TAG
LOCATION
LOCATION

ASSEMBLED
ASSEMBLED VIEWS
VIEWS

PACKED
FLANGEDPACKED)
FLANGED
SEPARATELY
SEPARATELY WITH BURNER
WITH BURNER

FrcuRE22
FIGURE (CONT)
22 (CONT)
52
,2 rJz6u-o0r COVER,
63280·:00-1 JOVLIi. UONIKOLCUNIROL BOX T
CONTROL BOX
CONTROL BOX ASSEMBLY
ASSEMBLY )z+t141 I -uuz-OOZ IRE E LA C K 15-
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14

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Ports list
Ports List

XX =: PART
PARTNUMBER WILLCHANGE
NUMBERWILL WITHAIR
CHANGEWITH TUBELENGTH,
AIRTUBE REFERTO
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THE
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SPECIFICATION NUMBER
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FLANGED
FLANGED PACKED I
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25

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