Carlin 801GAS User manual

™
126 Bailey Road North Haven, CT 06473
Ph 203-680-9401 Fx 203-680-9403
Carlin Combustion Technology
T
ech support
800-989-2275 carlincombustion.com
©Copyright 2020 — Carlin Combustion Technology
 Exceptwherespecicallystatedotherwise,thismanual
mustbeusedonlybyaqualiedservicetechnician.
 In the state of Massachusetts, this product mustbe
installedbyalicensedPlumberorGasFitter.
 Failuretocomplywiththeaboveorotherrequirements
inthismanualcouldresultinseverepersonalinjury,
deathorsubstantialpropertydamage.
USER—ReferonlytoUsercareandmaintenance
onback pagefor informationregarding operationof
thisburner.TheburnerInstructionManualisintended
onlyforyourservicetechnician.Theburnerandheat
exchangermustbeinspectedandstartedatleastan-
nuallybyyourservicetechnician.
 Checkburner cartonscarefully.The Model801GAS
burnerwasassembledandtestedatthefactorybefore
shipment.Iftheburnerwasorderedwithacompleted
assembledgas train,the trainwas pressuretested
andelectricallycheckedforproperoperation.Where
possible,thegastrainorcomponentswereshippedin
thesamecartonastheburner.Checkyourpackingslip
forthenumberofcartonsshippedfromthefactory.
MODEL 801GAS
Advanced Combination
Gas Burners
Low-High-Low Step Modulating
Low Rate (Model 52600A)
1400
to
2100 MBH
High Rate (Model 52600B)
2100 to 2500 MBH
Instruction
Manual

MN801GAS 060520
– 2 –
Contents
PLEASEreadthisrst.................................................................2
Generalinformation.....................................................................3
1.TheCarlinModel801GAScombinationgasburner.............4
2.Preparesite•assembleburner•mountburner...........5
3.Installgaspiping.................................................................11
4.Wiretheburner...................................................................12
5.Checkoutprocedure–beforestartingtheburner...............15
6.Setburnerinitialheadanddamperpositions.....................16
7.Adjusttheburnerusingtestinstruments............................16
8.Maintenanceandserviceprocedures................................20
9.Dimensions.........................................................................22
10.Repairparts........................................................................24
Usercareandmaintenance........................................ Rearcover
PLEASE read this rst . . .
Special attention ags . . .
Pleasepay particular attentionto thefollowing whenyou seethem
throughoutthismanual.
 NotiesyouofhazardsthatWILLcauseseverepersonal
injury,deathorsubstantialpropertydamage.
 NotiesyouofhazardsthatCANcauseseverepersonal
injury,deathorsubstantialpropertydamage.
 Notiesyou of hazardsthat WILL orCAN causeminor
personalinjuryorpropertydamage.
 Notiesyouofspecialinstructionsoninstallation,operation
ormaintenance thatare important,but arenotnormally
relatedtoinjuryorpropertydamagehazards.
Before installing or
servicing:
 Shouldoverheatingoccur:
 (1)Shutoffthegassupplytotheburner.
 (2)DONOTshutoffthecontrolswitchtotheboiler
circulatorortheburner.
 Followtheguidelinesbelowtoavoidpotentialsevere
personalinjury,deathorsubstantialpropertydam-
age.
Installer/service technician . . .
• Readallinstructionsbeforeproceeding.Performallprocedures,
andintheordergiventoavoidpotentialofseverepersonalinjury,
deathorsubstantialpropertydamage.
• Beforeleavingthesiteafterstartuporservice,reviewtheUser
careandmaintenancepagewiththeuser.Maketheuseraware
ofallpotentialhazardsandperformthetrainingoutlinedbelow.
Installer/service technician —
Train the user . . .
• Toproperlyoperatetheburner/applianceperthismanualand
theapplianceinstructions.SeeUsercareandmaintenance.
• Tokeepthismanualatorneartheburner/applianceforready
accessbytheuserandservicetechnician.
• Tocontacttheservicetechnicianifheencountersproblemswith
theburner/appliance.
• Tokeeptheappliancespacefreeofammableliquidsorvapors
andothercombustiblematerials.
• Toneveruselaundryproducts,paints,varnishesorotherchemi-
calsintheroomoccupiedbytheburner/appliance.
• Tocontacttheservicetechnicianatleastannuallyforstartupand
burner/applianceservice.
When servicing the burner . . .
• DISCONNECTELECTRICALSUPPLYandallotherelectrical
connectionsto burnerbeforeattempting toserviceto avoid
electricalshockorpossibleinjuryfrommovingparts.
• CLOSEallmanualgasvalvesbeforedisconnectinganyportion
offuellinesandbeforecleaningorremovinganypartsfromthe
burnerorrelatedequipment.
• Burnerandappliancecomponentscanbeextremelyhot.Allow
allpartstocoolbeforeattemptingtohandleorservicetoavoid
potentialofsevereburns.

MN801GAS 060520
– 3 –
Burner applications
Followallinstructionsinthismanual,theprimarycontroldatasheetand
theappliancemanual.
Verifytheburneriscorrectfortheappliancebeingusedandforallap-
plicablecodes/standards.
Adjustthenozzleselection/ringrateifnecessaryduetopositiveoverre
pressureand/oraltitudesmorethan2,000feetabovesealevel.Seethe
NOTICEundertheRatingsinformationatright.Whereapplianceappli-
cationinformationisavailable,therecommendedringrateandburner
informationwill includeappropriate adjustmentsforpositive overre
pressureandrecommendationsforhighaltitudes.Followtheappliance
manualguidelineswhenavailable.
Damage or shortage claims
Theconsignee ofthe shipmentmust ledamage orshortage claims
immediatelyagainstthetransportationcompany. Seethe NOTICEon
page1forburnercartoninformation.
When calling or writing about the
burner:
PleaseprovideuswiththeULserialnumberandburnermodelnumber
toassistusinlocatinginformation.Thisinformationcanbehelpfulwhen
troubleshootingorobtainingreplacementparts.
Codes and standards
Certification
801GASburnersareU.L.listedfortheU.S.,certiedtocomplywith:
• UL295,forusewithnaturalgasorpropane.
• Burnerlabelslistcompliance,whenrequired,withspeciallocal,state
orprovincialapprovals.
 Installthisburnerinaccordancewithalllocalcodesand
authoritieshavingjurisdiction.Regulationsoftheseauthori-
tiestakeprecedenceoverthegeneralinstructionsprovided
inthismanual.
United States installations
Burner/applianceinstallationsintheUnitedStatesmustcomplywiththe
latesteditionsof:
• InstallationofDomesticGasConversionBurners,ANSIZ21.8.
• NationalFuelGasCode,ANSIZ223.1/NFPA54.
• NationalElectricalCode,ANSI/NFPA70.
• Alladditionalapplicablenational,stateandlocalcodes.
The801GASburner,conguredforMassachusettsCode
compliance,differsfromthestandard801GASin:
1 Lowandhighgaspressureswitchesareaddedtothegas
train.
2 JumperJR2ontheprimarycontrolisclippedandremoved,
causingthecontroltobenon-recycling.
Ratings
(With0.00”w.c.overrepressure,altitude2,000feetmax.;
seeNOTICEbelow)
Gas Input
......................................... Highre(51600A):1,400to2,100MBH
......................................... Lowre(51600B):2,100to2,500MBH
Fuels
....................................................................Naturalgasorpropane
Gastrain:(availableinstraightorangledconguration)
...........................................(2)Maingasvalves&RV-81regulator
............................................ Butterygasvalveforinputregulation
................................. 11⁄2"gastrainstandard;2"gastrainavailable
Electrical
 Power............................................................ 120
vac/
60
hz
/1-
phase
 Limitcircuitinput........................................................ 120
vac
/60
hz
 Controlcircuitload(120vac).............................................
1.2 amps
 Motor...................................................
3/4 hp, 3450 rpm, 56c-frame
..............................
115 / 208-230 vac/60 hz/1-ph, 9.8 / 4.8-4.9 amps
...................... Opt:208-230/460
vac/60
hz
/3-
ph
,3.0-3.2/1.6
amps
 Dampermotor(withendswitch)...........................Siemens sQN71
Ignition & primary control
....................................................... Carlinsolidstate41800ignitor
 Ignitionvoltage.............................................................. 9,000
volts
 Primarycontrol...............................................HoneywellRM7897C
..........................................................................Alt:
fireye mec120
Agencies
................................................................................. ULListed(US)
Reducenozzle/ringrate when required — Maximumburner
capacityisreducedwhenoverrepressureispositiveandfor
altitudesabove2,000 feet.Seebelow,and adjustringrate/
nozzleselectionifnecessary.
801GAS – Maximum ring rate for
positive overre pressure and high altitutde
Altitudes:Foraltitudesmorethan2,000feetabovesealevel,reducethe
abovecapacitiesanadditional4%per1,000feethigherthan2,000
feetabovesealevel.
General information
2520
2380
2240
2100
1960
1820
1680
1540
1400
1260
1120
18
17
16
15
14
13
12
11
10
9
8
0 .1 .2 .3 .4 .5 .6
BACK PRESSURE IN FIREBOX – INS. W.C.
MAXIMUM FIRING RATE – GPH
MAXIMUM FIRING RATE – MBH

MN801GAS 060520
– 4 –
801GAS overview
TheModel801GASburnerisalow-high-low(stepmodulating)burnerthat
utilizesadampermotortocontrolair(andgasfuelrate).Theburneroperates
ongas(naturalorpropane).
Gas mode operation
Ignitionformainameisaccomplishedbyaprovedgaspilotofapproximately
75,000Btuh.Pilotgasisintroducedatthesideofburnerairtubeassembly
andisignitedbyaCarlin9,000-voltelectronicignitorwiredtotheelectrode.
Afterthepilotameisproven,thetwomaingassafetyvalvesopen.Thepilot
gasvalveclosesafteratimedelaytoallowmainametoestablish.Flame
ismonitoredbothforpilotameandmainamewithaUVscannermounted
tothesideoftheburnerairtubeassembly.Theburnermainamebegins
atlowre.Ifadditionalinputisrequired,thedampermotoropensthegas
butteryvalveandairdampertotheirhighrepositions.
Gasisintroducedintotheburnerthroughamanifoldaroundtheairtube.The
gasthencirculatesthroughasetoffouroricespudsintotheairstream,
upstreamoftheretentionring.Thespinoftheairowattheretentionring
thoroughlymixesthegas/airbeforeitreachesthecombustionzone.
Firing rate adjustment
• Gasowisadjustedtomatchtheairowatlowandhighrerates.High
remustbesetbeforelowre.
• Seethe“Startingandoperating”sectionofthismanualforthecomplete
descriptionoftheadjustmentprocess.Thefollowingisabriefsummary
only.
• High-reairissetbyadjustingthecombustionheadposition(tocontrol
airowthroughandaroundtheretentionring).
• Low-reairisthenadjustedbyne-tuningthepositionofthelowre
damperadjustingscrew.
• Pilotgasowissetforasmoothlight-off.Thengasinputsareadjusted
forgoodcombustionatlowandhigh-reairsettings.
1. The Carlin Model 801GAS burner
Gas pressure requirements
The801G/Oburnerrequires 3.4" w.c.minimum pressureat thebuttery
valveduringhighre.Selectagastrainthathasapressuredropnomore
thantheavailablepressureatthegastraininletminusthe3.4"neededat
thebutteryvalve.Seepage12forgastrainpressuredropinformation.The
burnerisequippedwitha11⁄2"gastrainunlessalargergastrainisordered.
Example: A boilerhas aninputrating of2,500,000 Btuh.Gas pressure
availableatthegastrainentranceis6.0"w.c.Subtract3.4"fromtheavail-
able6.0"w.c.Thegastrainpressuredropmustbe2.6"orless.A11⁄2"a
2"RV-61regulatorgastrain,whichhasapressuredropof1.19"w.c.

MN801GAS 060520
– 5 –
2. Prepare site • assemble burner • mount burner
Vent system
Vent/chimney sizing
1. Followalllocalcodeswhensizingtheventandchimney.
2. Refertotheappliancemanufacturer’smanual,whenavailable,forventing
recommendations.
Prepare vent/chimney (Figure 1)
1. Secureallmetalventjointswithscrews,followingtheventmanufacturer’s
instructions.Sealalljointsintheventsystemandchimney.Repairma-
sonrychimneyliningandrepairallmortarjointsasneeded.
2. Wheredraftuctuationsarelikely,installadouble-actingbarometricdraft
regulatorintheventpiping.(Thedampermustbelocatedinthesame
spaceastheappliance.)Installamanualresetspillswitchpermanu-
factuer’sinstructions.Wiretheswitchintotheappliancelimitcircuitto
shutofftheappliance/burnerifsustaineddowndraftshouldoccur.Refer
totheappliancemanufacturer’sinstructionmanualforrecommendations
regardingtheneedforabarometricdraftregulator.
3. Providesupportfortheventpiping.Donotresttheweightofanyofthe
ventpipingontheapplianceueoutlet.
Clearances
Check codes, standards and the equipment
manual
• Verifythattheburner/appliancewillmaintainallclearancestocombustible
wallsor oorandall clearances requiredforservice/maintenance as
requiredintheappliancemanualandapplicablecodes.
Inspect, repair and/or replace vent
system
 Donotinstallthisburnerunlessyouhaveveried
theentireventsystemandtheapplianceareingood
conditionand complywith allapplicable codes.
And...
 Thevent and chimneymust besized andcon-
structedinaccordancewithallapplicablecodes.
Theventsystemmustcomplywithrelevantcodes
forgasring.
 Theventsystemmustnotbepressurizedunless
theventpipingandventsystemaredesignedac-
cordingly.Theventmustprovidedraftatalltimes
(negativepressureinvent).
 Donotinstalloruseanexistingmanualdamperin
theventconnectororvent.
 Donotconnecttheapplianceventconnectortoa
chimneyorventservingareplace,incineratoror
solid-fuel-burningapparatus.
 Inacoldclimate,donotventintoamasonrychimney
thathasoneormoresidesexposedtotheoutside.
Installalistedstainlesssteellinertoventtheue
products.
 Adefectiveventsystemcouldresultinsevereper-
sonalinjury,deathorsubstantialpropertydamage.
Figure 1 Vent and vent connector installations, typical

MN801GAS 060520
– 6 –
2. Prepare site • assemble burner • mount burner (continued)
Combustion air/ventilation openings
Sizing air openings
Followall applicablecodes and theappliance instruction manual(when
available)tosizecombustionairopenings.Usethefollowingguidelineswhen
applianceinstructionsarenotavailable.
• Allairfrominsidebuilding(buildingmustbewell-ventilated):
 Sizeairopeningsforafreearea(afterlouverdeduction)ofatleast1
squareinchper1,000Btuhinputofallappliancesinthespace.
• Allairthroughopeningsdirectlyfrom outside the buildingthrough an
adjacentoutsidewall:
 Ifairopeningsconnectdirectlytooutside,providetwoopenings,one
within12inchesoftheceiling,theotherwithin12inchesoftheoor.Each
openingmusthaveafreearea(afterlouverdeduction)of:
• Ifdirectlythroughsidewall:1squareinchforeach4,000Btuhofall
appliancesinthespace.
• Ifthroughverticalducts:1squareinchforeach4,000Btuhofall
appliancesinthespace.
• Ifthroughhorizontalducts:1squareinchforeach2,000Btuhofall
appliancesinthespace.
Locating air openings
Followall applicablecodes and theappliance instruction manual(when
available)tosizecombustionairopenings.RefertoFigure2whenappliance
instructionsarenotavailable.
Estimating free area
Whenspecicinformationonthefreeareaoflouversisnotavailable,estimate
freeareaasfollows:
1. Woodlouvers—freearea=areatimes0.25.
2. Metallouversorgrilles—freearea=areatimes0.60.
3. Screens,whenusedmustbenosmallerthan¼inchmesh.
Motorized vent dampers
Wiretheventdamperendswitchtopreventoperationoftheburneruntilthe
airopeninglouversarefullyopen.
Combustion air/ventilation opening checklist
• Verifythatairopeningsareunobstructed.
• Verifythatappliancespaceandairsourcespacesarefreeof:
• Gasolineorotherammableliquidsorvapors.
• Combustiblematerials.
• Aircontaminants,suchaslaundryproducts,paint,thinner,varnish,
etc.
• Conrmwithuserthattheareawillbekeptfreeofthesematerialsat
alltimes.
Figure 2 Locating combustion air/ventilation openings
Appliance
Minimum
24 inches above
grade or snow line
Air opening
Where air opening is high on the wall,
duct to within 12 inches of the floor
Installingtheburner/applianceinaspacethatdoesnot
provideenoughairforcombustionandventilationcan
resultinseverepersonalinjury,deathorsubstantial
propertydamage. Followallapplicable codes and
guidelinesbelowtoensure space hassufcientair
openings.
 Exhaustfans andnegativepressure conditions—
Isolatetheboilerroomfromareassubjecttonegative
pressure.Size combustionairopenings to ensure
neutralairpressureintheboilerroomwheneverthe
burneroperates.
 Makesure thespaceprovides enoughventilation
topreventoverheatingoftheappliance,burnerand
controls.Ifthereisriskofoverheating,youmustinstall
ventilationairopeningssizedlargeenoughtoprovide
airforcoolingtheequipment.Failuretoprovideven-
tilationcanresultinseverepersonalinjury,deathor
substantialpropertydamage.
 Thespaceandcombustionairsupplymustnotcontain
corrosive contaminants, such as laundry products,
paints,varnishesorotherchemicals.

MN801GAS 060520
– 7 –
Prepare the appliance
 Burnerinput:Installaburnersizedforthenormalinputrating
oftheappliance.Donotinstallaburnerwithahigherringrate
thantheappliancerating.Donotinstallaburnerwitharing
ratemorethan10%lowerthantheappliancerating.Theappli-
anceandventsystemcouldbedamagedduetocondensation.
 Cleantheappliance:Cleantheappliancethoroughly.Testall
electricalcomponentsandverifythereliefvalveworks(boilers
only).
 Sealtheappliance:Sealallue-gascontainingjoints.Sealall
connectionstotheventpipingorbreeching.
 Verifycombustionchamberdimensionscomplywiththemini-
mumdimensionsrecommendedonpage8.Installorreplace
chamberlinerifrequiredbytheappliancemanufacturer.The
burnermustnotextendintothecombustionchamber.Theend
oftheburnerairtubemustbewithin¼"oftheinsidefaceof
thechamber.Ifthespacearoundtheburnerairtubeismore
than¼",wraptheburnerairtubewithminimum2300-°F-rated
ceramicberblankettosealoffthegap.
 Repairorreplacedamagedappliancecomponents.Inspect
theappliance thoroughly.Follow appliancemanufacturer’s
guidelinesforrepairorreplacementofanycomponentfound
defective.
 Whencleaning theappliance or workingwith ceramic ber
refractories or berglass insulation, see WARNING on this
page.
 Failuretocomplywiththeabovecouldresultinseverepersonal
injury,deathorsubstantialpropertydamage.
Prepare appliance for burner mounting
 Positiveoverrepressureapplications:Whenringwithpositive
overrepressure,donotexceedthepressurespeciedinthe
appliancemanual.
 Positiveoverrepressurereducesmaximumburnercapacity.
SeePage3forestimatedreductionin burner capacity with
pressurizedringandhighaltitudeapplications.
 Failuretocomplycouldresultinseverepersonalinjury,death
orsubstantialpropertydamage.
Prepare burner and components
 Donotinstalloroperatetheburnerifanycomponentisdam-
agedorifburnerdoesnotcomplywiththespecicationsof
Table2andotherguidelinesinthismanual.
Combustion chamber minimum dimensions
1. Forapplicationsthathavenotbeenspecicallytested(OEMapplications),
verifythatthecombustionchamberprovidestheminimumdimensions
showninTable2A.ForspecicOEMapplications,theappliance
testingensuressuitabilityofthechamber.
2. ChamberdimensionsmaybelargerthanlistedinTable2B,butshould
notbeexcessivelylarge.
Ceramic ber or
Fiberglass insulation
Ceramicbermaterials,suchaschamberliners,may
containcarcinogenic particles (chrystobalites)after
exposuretoheat.Airborneparticlesfromberglass
orceramicbercomponentshavebeenlistedaspo-
tentiallycarcinogenicbytheStateofCalifornia.Take
thefollowingprecautionswhenremoving,replacing
andhandlingtheseitems.
Avoid breathing dust and avoid contact with skin or
eyes.Wearlong-sleeved,loose-ttingclothing,gloves
andeyeprotection.UseaNIOSHN95certiedrespira-
tor.Thisrespiratormeetsrequirementsforprotection
fromchrystobalites.ActualjobrequirementsorNIOSH
regulationsmay requireotheror additional protec-
tion.For information,referto theNIOSHwebsite,
http://www.cdc.gov/niosh/homepage.html.
Ceramic ber removal:To preventairborne dust,
thoroughlywetceramicberwithwaterbeforehan-
dling.Placeceramicbermaterialsinaplasticbag
andsealtodispose.
Avoid blowing, tearing, sawing or sprayingber-
glassorceramicbermaterials.Ifsuchoperationsare
necessary,wearextraprotectiontopreventbreathing
dust.
Wash work clothes separately from other laundry.
Rinseclotheswasherthoroughlyafterwardstoprevent
contaminationofotherclothing.
NIOSH First aid procedures:
 Eyeexposure—irrigateimmediately
 Breathing—freshair.
2. Prepare site • assemble burner • mount burner (continued)

MN801GAS 060520
– 8 –
2. Prepare site • assemble burner • mount burner (continued)
Table 2 Minimum combustion chamber dimensions
 Combustionchambersshouldbesizedasrecommendedin
Table2A and2B.They should beconstructed of refractory
materialswiththecapacitytowithstand2600°Forhigher.
 Itisdifculttoincludeallpossiblechamberconstructionsinthis
manual.Therefore,youshouldusetheinformationpresented
inthismanualcombinedwithcommonlypracticedtechniques
whendeterminingchamberdesign.Ifcertainconditionsarein
question,consultthefactory.
Using chamber linings
1. When using refractoryliners orlightweight chambers, useinsulating-
typerefractoryrated2600°Fminimum,orasspeciedbytheappliance
manufacturer.
2. Youmustinstallatargetwalllinerifamelengthisclosetothelength
ofthechamber.
3. Useaoorlinerwhenpossible.Theoorlinerwillimproveringinmost
applications.Extendoorliner3to4inchesupthesidewalls.
4. Targetwallliners—Extendtargetwalllinersatleast3to4inchesabove
thecenteroftheamecorbelthetop1½to2½inchesdeep.
5. Usepreformedchamberlinerswhenavailable.Liningtheoorandtar-
getwallwater-backedcombustionchamberswithlightweightinsulating
refractorywillaccomplishthesame.
6. Whenconvertingcoal-redunits,installacombustionchamberinthe
ashpitarea,orlltheashpitwithsandupto2inchesabovethe“mud
ring”oftheboiler(ringthroughthedoor).Installalightweightrefractory
lineronthetargetwall.
Air tube insertion length (UTL)
1. Insertionair tubelength(UTL) is thedistance from mounting
angeto endof air tube.Verify thatthe end ofthe air tubewill be
ushwith, orno more than¼ inchshort of, theinside ofthe appli-
ance combustion chamber front wall when the burner is mounted.
NOTE:MountingangespacerisavailableforapplianceswithaUTL<4"
(consultfactoryforpart#).
TABLE 2A 801GAS
MINIMUM DIMENSIONS RECOMMENDED IN REFRACTORY
COMBUSTION CHAMBERS–(Inches)
1
Gas
MBH
2
Length
L
3
Width
W
4
Dimens.
C
5
Suggested
Height
H
6
Minimum
Dia.
Vertical
Cyl.
11.4
12.0
12.6
13.2
13.2
14.4
15.0
15.6
16.2
16.8
17.4
33
34
35
36
38
39
40
41
43
44
46
15
16
16
17
17
18
18
19
19
20
20
7.5
8.0
8.0
8.5
8.5
9.0
9.0
9.5
9.5
10.0
10.0
15
16
16
17
17
18
18
19
19
20
20
31
32
33
34
36
37
38
39
41
42
44
TABLE 2B 801GAS
MINIMUM DIMENSIONS RECOMMENDED BOILERS FIRED
WITHOUT COMBUSTION CHAMBERS–(Inches)
1
Gaz
MBH
2
L
With
Target
3
L
Withou
Target
4
Width
W
5
Dimens.
C
6
Dimens.
D
11.4
12.0
12.6
13.2
13.8
14.4
15.0
15.6
16.2
16.8
17.4
33
34
35
36
38
39
40
41
43
44
46
38
39
40
41
43
44
46
47
49
50
52
17
18
18
19
19
20
20
21
21
22
22
7.5
8.0
8.0
8.5
8.5
9.0
9.0
9.5
9.5
10.0
10.0
9.5
10.0
10.0
10.5
10.5
11.0
11.0
11.5
11.5
12.0
12.0

MN801GAS 060520
– 9 –
Inspect burner and components
• Checktheairtubelength.VerifytheinsertionlengthofthetubeUTLwill
belongenough(see“Mountburnerinappliance”).
• Visuallyinspectallburnercomponentsandwiring.
• Verifythatwiringisintactandleadsaresecurelyconnected.
• Verifythatallburnercomponentsareingoodcondition.
Donotinstalloroperatetheburnerifanycomponentisdam-
agedorifburnerdoesnotcomplywithotherguidelinesofthis
manualandtheappliancemanual.
Mount burner in appliance
Welded-flange burners
1. Verifythe boltpatternon theappliance chamber matchesthe ange
pattern.
2. Verifytheinsertiondepth(UTL),includingspacers,matchesthedepthof
theapplianceopening(sotheendoftheairtubeisushwith,orslightly
shortof,theinsidesurfaceofthecombustionchamber).
3. Placegasketontoboilerfrontplate.
4. Slidetheendoftheairtubeintotheopeningandsecuretheangeto
theboilerfrontplate.
Install the burner pedestal (optional)
1. Adjustthepedestalsothattheheightoftheairtubematchesthelocation
oftheburneropening.
2. Thepedestalhasapproximately3"ofadjustment.Iftheburneropening
istoohighforthepedestaltorestontheoor,thenconstructabase.
Twosolidcementblocks,sidebyside,isrecommended.Alternatethe
directionaslayersareputdown.
3. Placeaspiritlevelontheairtube.Adjustthepedestalsotheairtube
slopesdownslightlytowardtheappliance.Theslopeshouldbeabout
2degrees.
4. Tightenthepedestalboltsecurely.
2. Prepare site • assemble burner • mount burner (continued)
Figure 3 Fire assembly spacing

MN801GAS 060520
– 10 –
Inspect components and wiring
• Visuallyinspectallburnercomponentsandwiring.
• Verifythatwiringisintactandleadsaresecurelyconnected.
• Verifythatallburnercomponentsareingoodcondition.
Install gas train on burner
1. Thestandardburnergastrainisshippedfullyassembled,withthepiping
disconnectedatthegastrainunions.Seeseparateinstructionsifinstalling
anoptionalknockeddowngastrain.Thegastrainisavailableineither
anangled(standard)orstraight(optional)conguration.
2. Connectthemainandpilotgastrainsattheunions(Figure4).
 Toavoiddamagetogastraincomponents,donotholdcompo-
nentswithapipewrenchorovertighten.Useonlyacrescent
wrenchorothermeans.Failuretocomplycouldresultinsevere
personalinjury,deathorsubstantialpropertydamage.
3. Connecttheexibleconduit,pre-attachedtotheburnerJ-box,tothegas
trainJ-box,andattachthewirestotheterminalstripinsidethegastrain
J-box.
a. Matchwirecolorsoftheincomingwirestothosepre-wiredtotheterminal
stripinsidethegastrainJ-box.
b. Seethelabelintheburnerjunctionboxorthewiringdiagramsonpages
13-14.
 Gasvalveventopening—TheV48diaphragmgasvalveis
NOTttedwithaventlimitingoriceintheventconnection.
Iflocalcodesrequire,installpipingfromtheventconnection
tooutside,sizedandinstalledasrequiredbycodes.Because
thisisadiaphragm-assistedsolenoidvalve,asmallamountof
gaswillexitfromtheventoriceeachtimethevalveopens.
Figure 4 Gas train installation (shown with angled gas train)
2. Prepare site • assemble burner • mount burner (continued)
 Connectfromthegassupplytotheburnergastraininletusingnew,cleanblackironpipeandmalleableironttingsonly.Donotuse
copper,brass,castironorgalvanizedpipeorttings.
 Providesupportforgaspiping.Donotresttheweightofthegaspipingonburnergastrain.
 Provideasupportfortheburnergastrain.
 Applypipedopesparinglyatalljoints.Useonlypipedopelistedforusewithpropanegas.Donotusepipesealingtape.
 Donotholdthegasvalvewithpipewrench.Usecrescentwrenchorothersmooth-jaweddevice.Donotovertighten.
 Failuretocomplywithabovecouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.
 Donotexposethegastraintogaspressureinexcessof14incheswatercolumn.Higherpressurecoulddamagethevalveseat,
resultinginpotentiallyhazardouscondition.Whenpressuretestingpipingathigherpressures,disconnectburnerfromgaslinebefore
testing.
 Ifthegassupplypressurecanexceed14incheswatercolumnatanytime,youmustinstallalockuptypegaspressureregulatorin
thegassupplypiping,aheadofthemainmanualgasvalveinstalledattheburner.
Connect pilot gas
train at union
Connect main gas
train at union

MN801GAS 060520
– 11 –
3. Install gas piping
Piping from gas meter to burner
1. Verifythegastrainontheburneriscorrectlysized.Thegastrainpres-
suredropmustnotbemorethanthegaspressureattheburnergas
trainentranceminus3.4"w.c.(pressurerequiredatentrancetobuttery
valve).SeeFigure6forgastrainpressuredropinformation.Thestandard
gastrainis11⁄2inch.
2. Ifpossible,installanewgaslinedirectlyfromthegasmeter.Ifyouare
usinganexistinggasline,verifyitiscleanandingoodcondition,and
verifyitislargeenoughtohandletheloadofallconnectedappliances.
3. Whenbranchingfromacommongasline,donottapofffromthebottom
ofhorizontalsections—onlyfromthesideortop.
4. Installamainmanualshutoffvalve,sedimenttrapandgroundjointunion
neartheburnergastrainconnectionasshowninFigure5.
5. Iftheburnerisinstalledinsideanappliancejacket,installthemainmanual
gasvalveandsedimenttrapexternaltothejacket.
6. Sizepiping(orverifysize)usingpage12.Youwillndadditionalinfor-
mationongaslinesizingintheNationalFuelGasCode,ANSIZ223.1.
7. Gassupplypressure—naturalgasorpropane
• Maximumsupplypressure: 14inchesw.c.
• Minimumsupplypressure: 5inchesw.c.
Test and purge gas line
ReadWARNINGabove.
Pressuretestandpurgetheline.Pressuretestingshouldbedonebythegas
supplierorutility,followingallapplicablecodes.
Figure 5 Connecting gas supply piping to burner
(shown with angled gas train)
Figure 5A Gas piping schematic
GAS FUEL TRAIN
Gas Input
F A
A
A
M
Test
To Main Burner
To Pilot Burner
J
R1 B S
R2 S C
S
Sediment Trap
A Manual Valve
B Firing Rate Valve
C Orifice
D Manual Reset Low Gas Pressure Switch (optional)
E Manual Reset High Gas Pressure Switch (optional)
F Gas Filter or Strainer (if required)
J Leakage Test Valve
M Pipe Cap
R1 Main Gas Pressure Regulator
R2 Pilot Gas Pressure Regulator
S Safety Shutoff Valve
D E
1Pipetometerorbranch
2 T-handlemainmanualgasvalve
3 Useclean,burr-freeblackiron
pipeandmalleableironttings
4 Groundjointunion
5 Sedimentleg
6Pressuretap,1/4"(upstream
shown,outletnotshown)
7 Gasregulatoraccessscrew
(theregulatorspringislocated
undertheadjustingscrew)
8 Gastrainwirejunctionbox

MN801GAS 060520
– 12 –
NATURAL GAS
Capacities in Cubic feet per hour
for Schedule 40 metal pipe
Pipe size
(inches)
Total length of gas piping,
from meter to burner connection (feet)
20 40 60 80 100
Natural gas @ .60 specific gravity, pressure drop 0.3 in. w.c. (note 1)
1¼ 730 500 400 350 305
1½ 1,100 760 610 530 460
22,100 1,450 1,150 990 870
2½ 3,300 2,300 1,850 1,600 1,400
Natural gas @ .60 specific gravity, pressure drop 0.5 in. w.c. (note 1)
1¼ 950 660 530 460 400
1½ 1,460 990 810 690 620
22,750 1,900 1,520 1,300 1,150
2½ 4,350 3,000 2,400 2,050 1,850
Note 1 For natural gas with specific gravity other than 0.60,
consult National Fuel Gas Code for correction factor.
PROPANE GAS
Capacities in Btuh for
Schedule 40 metal pipe
Propane gas @ 1.5 specific gravity, pressure drop 1 psi
½1,839 1,264 1,015 869 770
¾3,845 2,643 2,122 1,816 1,610
17, 2 4 3 4.978 3,998 3,422 3,033
Propane gas @ 1.5 specific gravity, pressure drop 0.5 in. w.c.
1787 541 434 372 330
1¼ 1,616 1 , 111 892 677 543
1½ 2,422 1.664 1,337 1 , 11 4 1,014
Table 3 Capacities of black iron pipe, cubic feet gas/hour Figure 6 Gas train pressure drop
3. Install gas piping (continued)
Regulator spring:
 Thestandardmaingaspressureregulatorspring1½"RV81isplated.Therangeis
from3.0to6.0incheswatercolumn(oravioletspring,witharangeof4.0to12.0
incheswatercolumn).
4. Wire the burner — RM7897C primary control
Wire the burner (RM7895CorRM7897Cprimarycontrolonly)
1. Allwiringmustcomplywith:
• IntheU.S.–theNationalElectricalCode,ANSIZ223.1/NFPA54.
• InCanada–theCanadianElectricalCodePart1,CSAstandardC22.1.
• Allapplicablelocalcodes/standards.
2. ConnecttheburnerfollowingFigure8andanyspecialinstructionsor
wiringdiagramsprovidedwiththeappliance,burnerorothercomponents.
3. Theburnerrequiresa120VAC/60hz/single-phasecontrolpowersupply,
witha10-ampfuse.Thecontrolcircuitcurrentdrawisapproximately1.2
amps.Anadditionalpowersourceisrequiredforthemotor(120VACor
208-220VAC,60hz),withfusesizedaccordingly.SeeFigure9foreld
wiringconnections.
4. ReadtheHoneywellRM7897Cinstructionsforinformationonsettinga
roomthermostat,ifused.
5. Makesuretheburnerandappliancearecorrectlywiredandthelineswitch
isproperlyfusedfortheload.

MN801GAS 060520
– 13 –
Figure 8 801GAS burner wiring using Honeywell RM7897C
primary control (see appliance manual or separate
wiring information for burner equipped with a primary
control not covered in this manual); see Figure 7 for a
legend to callouts.
4. Wire the burner — RM7897C primary control (continued)
Turnoffpowertoappliancewhenservicingburner.Failure
tocomplycouldresultinsevere personal injury,deathor
substantialpropertydamage.
Figure 7 Legend for Figure 8

MN801GAS 060520
– 14 –
Low-High-Low step modulation
1. Totakeadvantageoftheenergy-savingpotentialoftheModel801GAS
burner,itshouldbewiredtooperateatlow-high-lowcycles.Thering
cyclecanbemuchlongerusinglow-high-lowring,becausetheburner
cancycletolowreasdemanddecreases.Thiskeepstheburneron
longer,reducingcycliclosses.
2. Theappliancemustbeequippedwithahighrecontrol.Thiswouldbea
make-on-fallcontrol,eithertemperature(waterboiler)orpressure(steam
boiler)activated.Readtheappliancemanualforthelocationofthehigh
recontrol,whenused.
3. SeeFigures8and9Atoconnectthehighrecontroltotheburnerring
ratecircuit.
4. Theburnerincludesapre-wiredmanualhigh-reswitch.Closethisswitch
toholdtheburnerinhighremode.Opentheswitchtoholdtheburner
inlowremode.
4. Wire the burner — RM7897C primary control (continued)
Figure 9A
801GAS Mass Code
wiring diagram (burners
with RM7897C primary
only); see Figure 9 for a
legend to callouts
Turnoffpowertoappliancewhenservicingburner.Failure
tocomplycouldresultinsevere personal injury,deathor
substantialpropertydamage.
Figure 9 Legend for Figure 9A

MN801GAS 060520
– 15 –
5. Checkout procedure – before starting the burner
Before firing the burner . . .
 Shouldoverheatingoranemergencyoccur,immediately
dothefollowing:
 • Shutoffgassupplyvalves.
 • Undersomecircumstancespowershouldremainonfor
waterpumpsorblowers.Determineproperresponse
beforeattemptingstart-up.
 • Ifburnerfailsignitiononseveralattempts,useburner
blowertopurgeappliancechamberbeforerestart.
Checklist before firing . . .
❏Burnerand applianceinstalledper thismanual and appliance
instructionmanual?
❏Burner/applianceinstalledperallapplicablecodes?
❏Installationsitehasadequatecombustion/ventilationairopenings
andventsystem?
❏Arevoltagescorrect?Burner,applianceandmotorcorrectlywired
perburnerandappliancemanualsandwiringdiagrams?
❏Gasmanifoldspudoricessealedwithpipedopeandtight?
❏Burnernozzleveriedperappliancemanufacturer’sinstructions,
❏Gaslinesingoodcondition,sizedanddesignedcorrectly?
❏Gasconnectionsandttingstight?
❏Burner, appliance and all components inspected and in good
condition?
❏Appliancelimitandoperatingcontrolsproperlyinstalled,wiredand
adjusted?
❏Boilerwatersupply,feedpumps,automaticfeeders,andlowwater
cut-offsproperlypipedandwired?
❏Breeching,draft regulator, draftinducer(if required)properlyin-
stalledandoperational?
❏Gastrain pipingand components correctly installed, testedand
veriedgastight?
❏Ventlinesinstalledwhenrequired?
❏Gaslinespurged?
❏Sufcientgaslinepressurepresent?

MN801GAS 060520
– 16 –
Before firing the burner . . .
Set combustion head (Dimension “A”)
1. Thecombustionheadadjustingscrewisusedtosetthespacingbetween
theretentionringandthrottlering(oraircone),regulatinghowmuchair
passesaroundtheretentionring.
2. SeeFigure10.Loosenthetwohousingcoverscrews.Thenrotatethe
headadjustingscrewuntilthedistancefromthehousingdetenttothe
beginningofthescaleorscribedlinoncombustionheadequalsthevalue
giveninTable5(Dimension“A”).Tightenthehousingcoverscrews.
Set air damper (low fire position)
1. SeeFigure11.Loosentheairdamperadjustingscrewandlocknut.Rotate
theadjustingscrewuntiltheairopeningbetweenthedamperandthe
damperhousingequalstheinitiallow-reopeninginTable5.Leavescrew
andlocknutlooseuntilnaladjustment.
Followtheproceduresgivenhereandonthefollowing
pagestoensuretheburneriscorrectlyadjusted.Take
yourtimeandtheburnershouldoperateproperlyand
youwillavoidreturnservicecalls.
 Youmustperformtheadjustmentsinthesequence
giveninthismanual.
 Failuretofollowthecorrectprocedurescouldresultin
severepersonalinjury,deathorsubstantialproperty
damage.
Figure 11 Set initial low re air damper setting Figure 11A Setting air damper linkage
Figure 10 Set initial combustion head position
6. Set burner initial head and damper positions
Determining final adjustments
1. Theburnerisnowadjustedtotheapproximateairsettingsforthering
rateused. Follow theprocedureson the followingpagesto use test
instrumentsandmakenalburneradjustments.
Set the air damper linkage
1. MakesureAirDamperLinkageissetat1/2"fromthetopoftheDamper
Motorandthecenterofthelinkagescrew(seegure11A).Ifyourset-
tingsareoff,loosenthetwohexheadscrewsfoundonthelinkagearm
bossesatthetopandbottomoftheAirDamperLinkage(seegure11
forbottom example).Adjustthelinkageaccordingly,thentightenscrews
tosetposition.
Low-Fire adjusting
screw and locknut

MN801GAS 060520
– 17 –
Adjustment procedure, summary
Step 1: Setgaspilotoperation.Seedetailsfollowing.
Step 2: Sethigh-regasowtomatchhigh-reair.Seedetailsfollowing.
Step 3: Adjustthebutteryvalvelinkagetomatchlow-regastolow-re
air.Seedetailsfollowing.
Step 4: Verifyoperationofburner,appliance,andcontrols.
Use test instruments
1. Usecombustion test equipmentandan accurate manometerordraft
gaugetocorrectlysettheburnerasrequired.
2. Overrepressuremustnotexceedtheappliancemanufacturer’srecom-
mendations.Theburnermustneverberedatanoverrepressuremore
than0.60inchesw.c.
 Whentheoverrepressureispositive,themaximumburner
ringrate isreduced.The ringrateis alsoreduced for
altitudeshigherthan2000feetabovesealevel.
3. Adjusttheburnerfuelandairsettingsusingthefollowingprocedures.
Whenadjustmenthasbeencompleted,theCO2(orO2)shouldbewithin
therangesinTable6,atbothlowreandhighre.
Table 6 Allowable values of CO2and O2
Fuel
CO 2 O 2
Minimum Maximum Maximum Minimum
Natural Gas 8.5 % 10.0 % 6.2 % 3.6 %
Propane 9.5 % 11.2 % 6.0 % 3.5 %
7. Adjust the burner using test instruments
 ThesettingsgiveninSection6areinitialsettings
only. You must use test instrumentsto check
combustion,andadjusttheburnerasnecessary,fol-
lowingtheproceduresgiveninthefollowingpagesof
thismanual.Failuretoproperlyadjusttheburnercan
resultinseverepersonalinjury,deathorsubstantial
propertydamage.
Step 1
Check gas pilot operation
 TheModel801GASusesagaspilotforignitionofthegas
mainame.Thegaspilotisignitedbythepilotelectrode.
1. Makesurethegaslinehasbeencompletelybled.Thenturntheservice
switchtoON.
2. Thepilotwillusuallylightthersttimeoncethepilotgastrainhasbeen
completelypurgedofair.
3. Thepilot ameisapproximately 75MBH,and is largeenoughto be
heardwhenlit.Ifthepilotfailstolight,besurethegaslinehasbeenbled
properly.Ifitstillfailstolight,increasethepilotgaspressureto4inches
w.c.Iftheprimarycontrolisequippedwithapilottestholdswitch,itcan
beusedtoholdthepilot“on”whileadjustingpilotgaspressure.
4. Followtheinstructionsintheprimarycontrolinstructionmanualtocheck
amesignal.Makesuretheamesignalissteady,andgreaterthanthe
requiredminimumfortheUVsensor.
5. Check and ensurethat the bentignitor (Figure12)is approximately
centeredinpilotassembly.Ifnot,loosenelectrodelockingnut,rotate
assemblyandtightennut.
 Thelinkage between the damper motor arm and the
air damper crankissetatthefactory,andshouldONLY
needadjustmentifthedampermotororthedamper
rodisreplaced.Withtheburnerinhigh-reposition,
thereshouldbeminimalplayintheconnectingrod.
DONOTchangethislinkagesetting.
 Smellaroundthegastrainandcheckalljointswith
asoapsudsmixturetoensurethegastrainandall
componentsaretight and leak-free.Shutdownthe
burnerandcorrectanyleakimmediately.Failureto
complycouldresultinseverepersonalinjury,death
orsubstantialpropertydamage.
Figure 12 Pilot Spark Gap Figure 12A Pilot Test Port
3/32"-1/8"

MN801GAS 060520
– 18 –
7 Adjust the burner using test instruments (continued)
Step 3
Set butterfly gas valve linkage
1. Switchthelow-reholdswitchtolowre.
2. CheckCO2andCO.TheCO2shouldbebetween9.0%and10.0%(natural
gas)orbetween10.0%and11.2%(propane);withCOlessthan100PPM.
3. Toadjustthelow-reair(changeCO2),movetheburnerfuelselector
switchto OFF.Adjust thebuttery gas valvelinkage asdescribed in
thefollowingtochangethelow-regasowtotheburnerhead.Donot
changethemaingaspressureregulatorsetting.
4. DO NOT ADJUST THE LOW-FIRE AIR DAMPER SETTING.
5. SeeFigure13forlocationoflinkagecomponents.
Figure 13 Buttery gas valve linkage
Toadjustthelinkage,loosensetscrewintheadjustablelinkin
smallincrements.A1/8-inchmovecancauseCO2tochange
asmuchas1.5%.
• Ifmoregasisneeded(toincreaseCO2),slidelinkageUP.
• Iflessgasisneeded(todecreaseCO2,),slidelinkageDOWN.
6. Tightenthesetscrewintheadjustablelink.
7. The buttery valve indicator must be at 90°.IFNOT,turntheburner
off.Loosenthetwohex-headscrewssecuringthevalvelinkagearm.
Rotatethebutteryvalveindicatoruntilitisat90°.Disengageactuator
motor.Rotatelinkagetohighre.Tightenthetwohexheadscrewswhile
stillholdingthemotorlinkagearminhighre.Rotatelinkagetolowre.
Re-engagepin.
8. Tightenthetwohexheadscrewsonthebutteryvalvelinkagearmboss.
9. RestartandrepeatasnecessaryuntilCO2andCOareacceptable.
IF EQUIPPED WITH LOW-HIGH GAS PRESSURE SWITCH,
PROCEED TO STEP 3A.
OTHERWISE PROCEED TO STEP 4
FOR MASS CODE, PROCEED TO STEP 3A,
OTHERWISE PROCEED TO STEP 4.
Step 2
Set main gas pressure regulator
Thebutterygasvalveisfactorysettoapreliminarysettingof
30%openforlowre,and100%openforhighre.Thepilot
regulatorissetfor3.0inchesw.c.Usemanometerinthepilot
testport(Figure12A)providedtoconrmsettings.
1. Leavethelow-reswitchinlowre.
2. Withthegaspilotoperatingcorrectly,andtheUVsensoramesignal
aboveminimum required,the primarycontrol will cyclethe burnerto
maingas.
3. Checktheamesignalafterthepilothasshutdowntoensurethesignal
isstillstrongwithmainameon.
4. MovetheburnerfuelselectorswitchtoOFF.Theburnerwillshutdown.
5. TemporarilyinstalltwoU-tubemanometerconnectionstocheckgaspres-
sures.Installconnectionsattheinletpressuretapofthemainmanual
gasvalveandatthedownstreampressuretapofthemanualgasvalve
nexttothebutteryvalve.
6. The gas pressureat the inletto thegastrain mustneverexceed
14inchesw.c.,eitherwhentheburnerisofforringongas.
7. MovetheburnerfuelselectorswitchtoGAS.Theburnershouldstart.
8. Withtheburnerringinlowre,checkthegaspressureatthedownstream
manualgasvalvetapping.Adjustthemaingaspressureregulatorifneces-
saryuntilthegaspressurereads3.4inchesw.c.asastartingpressure.
9. Switchthelow-reswitchtohighre.CAUTION:Bepreparedtoturnthe
burneroffimmediatelyifitbeginstopulsateasitattemptstomoveto
highre.
10. Iftheamepulsates,itisprobablytoorich.Switchthelow-reswitchto
lowreandreducethegaspressurebyadjustingthemaingaspressure
regulator.Thenreturnto9,above.
11. Ifthereistoolean,itwillappearsmallandcanevenblowoutduringthe
swingtohighre.Ifitblowsout,shutofftheburnerimmediately.Switch
thelow-reswitchtolowreandstarttheburneragain.Adjustthemain
gaspressureregulatortoincreasethegaspressure.Returnto9,above.
Withtheburnerrunninginhighre,inspectthebutteyvalve
shaftslot(Figure13).Theslotmustbehorizontal.IFNOT,turn
theburneroff.Loosenthetwohex-headscrewssecuringthe
valvelinkagearm.Withthedampermotorlinkagearmpulled
up,useascrewdrivertorotatethebutteryvalveslotuntilitis
horizontal.Tightenthetwohexheadscrewswhilestillholding
thedampermotorlinkagearmup.Returntostep9,above.DO
NOTproceedwithcombustionadjustmentunlessthebuttery
valvepositionhasbeenveried,andcorrectedifnecessary.
12. Withtheburnerrunninginhighre,adjustthemaingaspressureregulator
toachievethevaluesinTable6.MeasuretheCOcontent.Itshouldbe
nogreaterthan100PPM.
HighCOreadingsmayindicatethecombustionisonthewrong
sideoftheCO2curve.Youwillknowthisifadecreaseingas
pressurecausesanincreaseinCO2.
13. Thegaspressuremayhavetobesetaslowasabout2.0inchesw.c.toas
highasabout4.0inchesw.c.,dependingontheringrateoftheburner.
Hex
Nuts
Set
Screw
Butterfly
Valve
Indicator
(red needle)

MN801GAS 060520
– 19 –
Step 3a
Verify operation
Perform all of the checkout procedures given in Step 6 of the
burner manual. In addition, verify operation of the gas pressure
switches as described below.
Verify high gas pressure switch operation
❏Cycle the burner off with the appliance controls and turn off power to the
appliance/burner.
❏Attach a manometer to the manifold-side manual gas valve test port.
❏Turn on power and cycle the burner on with the appliance controls.
❏Measure the manifold gas pressure with the manometer.
❏Set the high gas pressure switch to a pressure less than actual manifold
pressure. The high gas pressure switch should shut the burner down.
Replace the switch if necessary.
❏Turn off power to the appliance/burner; remove the manometer and replace
the plug in the gas valve test port. Reset switch.
Verify low gas pressure switch operation
❏Cycle the burner off with the appliance controls and turn off power to the
appliance/burner.
❏Close the main manual gas valve.
❏Cycle the burner on.
❏The low gas pressure switch should shut the burner down. Replace the
switch if necessary.
❏Turn off power to the appliance/burner.
❏Open the main manual gas valve.
❏Reset low gas pressure switch.
7. Adjust the burner using test instruments (continued)
Step 4
Verify operation
Burner/appliance/controls operation
❏Testoperatingandlimitcontrolsonapplianceasspeciedinappliance
instructions.
❏Checkoperationoftheprimarycontrolbyforcinglockouttooccur.For
primarycontrolsthatenterlatch-upaftermultiplelockouts,forcelatch-up
tooccuraswell.Resetprimarycontrolpercontroldatasheetinstructions
aftereachtest.
❏Startandstoptheburnerseveraltimes,allowingtheprimarycontrolto
sequencethroughnormaloperation.Verifycorrectoperationofburner
andprimarycontrolthroughout.
❏Conrmand/or adjustoverrecombustion pressure.Referto boiler/
furnacemanufacturer’srecommendations.
Verify vent system operation
❏Verifyventisoperatingcorrectlyandueproductsareproperlyexhausted
frombuilding.Ifthebuildingcontainsanyexhaustfansorconditionsthat
couldaffectventperformance,checkburner/appliance/ventoperation
withexhaustfans(orotherconditions)operating.
Combustion/ventilation air
❏Verifycombustion/ventilationairopeningsarenot,andwillnotbeob-
structed.
❏Verifyairopeninglouversarefullyopen.
❏Iflouversaremotor-operated,verifymotorandendswitchareinterlocked
withappliance/burnerwiringtopreventoperationoftheburneriftheair
louversarenotfullyopened.
Prepare burner for normal operation
❏Cycleburneroffwithappliancecontrols.
❏Turnoffpowertotheappliance.
❏Sealtheapplianceuetestopening.
❏Verifyallcomponents andwiresarein place andburnerisready for
operation.
❏Restorepowertotheappliance.
Train the user
❏Traintheusertooperatetheburnerandapplianceundernormalcondi-
tions.
❏Explaintheproceduretoshutdowntheburner/appliancewhenrequired.
❏Reviewthebackcoverofthismanual(andtheappliancemanual)with
theuser.
❏Verifytheuserisawareofallproceduresspeciedinthemanuals.
❏Verifythattheuserwillnotstoreorusecombustibleliquidsormaterials
orcontaminantsinthevicinityoftheburner/appliance.

MN801GAS 060520
– 20 –
Removing the combustion head assembly
1. Tochecktheelectrodesettingsorchangethenozzle,youmustremove
thecombustionheadassemblyfromtheairtube.Followthestepsbelow,
andreversethesequencetoreassemble.
2. Shutofftheburner.
3. Removethetwohousingcoverlockingscrewsandswingthehousing
open.
4. Partiallyremovethecombustionheadassembly,anddisconnectthetwo
ignitioncablesfromtheelectrodesandthermalfusewire.
5. Removethecombustionheadassemblyfromthetube.
Thermal fuse
1. Whentheburnerisinahigh-overredraftcondition,andnotproperly
adjusted,itispossiblethattheamecouldashbackinsidetheairtube.
Ifthisoccurs,thethermalfusewillopeninlessthantwoseconds.The
fusemustbereplaced.(Theburnerissuppliedwithsparefuses.)
Annual start-up and service
Thisburnermustbestartedandservicedatleastannuallyby
aqualiedservicetechnician.Failuretoproperlymaintainand
servicetheburnercouldresultinseverepersonalinjury,death
orsubstantialpropertydamage.
❏Discussburner/applianceoperationwithusertodetermineanyproblems
thatmayhaveoccurredduringthepreviousseasonandtoverifyuseris
awareofproperoperationandcareoftheburner/appliance.
❏Reviewproperoperationoftheappliance/burnerunitwiththeuser.
❏Turnoffpowertoappliance.
❏Removecombustionheadassemblytocleanandadjustifnecessary.
(Seeabove.)
❏Ifthe insidesurfaceof theairtube and/orretentionring needtobe
cleaned,cleanthemwithavacuumcleanerwithbrushattachmentwhile
thecombustionheadassemblyisoutoftheburner.
❏Inspectandadjusttheignitionelectrodesandinsulatorsperinstructions
onpage9,Figure3ofthismanual.Replaceifproperspacingcannotbe
achievedorifcomponentsaredamaged.
❏Closethehousingcoverplateandsecureinplace.
❏Performthecompletecheckoutproceduresofpage15,includingsystem
inspectionandchecks.
❏Informtheuserofanyproblemsfound.
8. Maintenance and service procedures
Turnoffpowertoappliancewhenservicingburner.Afterservicing,
alwaysoperateburner/appliancetoverifyallcomponentsare
functioningcorrectlyandthattheburnerisproperlyadjusted.
Failuretocomplycouldresultinseverepersonalinjury,death
orsubstantialpropertydamage.
General maintenance
Cleaning blower wheel
1. Theblowerwheelaccumulatesdustanddebrisfromnormaloperation.
Youwillneedtocleanthewheelbladesperiodicallytopreventreduction
inairow.Inspecttheblowerwheelregularlyby opening the housing
cover.
2. Tocleanblades,whennecessary,removetheboltssecuringthemotor
totheblowerhousing.
a. Slidethemotoroutandrotatetoremoveandaccessblowerwheel.
b. Useabrushandvacuumtocleaneachbladeandtheblowerhousing
interior.
c. Installmotor/wheelinblowerhousingandsecurewiththetwobolts.
d. Pushwireslackbackintojunctionbox.
Replacing blower motor or wheel
1. Ifeithertheblowerwheelormotormustbereplaced,removethebolts
securingthemotortohousing.
2. Disconnectthemotorwiresintheburnerjunctionbox(comingfromthe
motorcontactor).
3. LoosentheAllenscrewsecuringtheblowertothemotorshaftandremove
thewheel.
4. Whenassemblingthereplacementassembly,slidethewheelontothe
motorshaftandusefeelergaugestosetspacebetweentheblowerwheel
andthemotorface.Thisspacemustbe3/64inch.
5. Installthemotor/wheelassemblyinthehousing,wirethemotorleads
andsecurethemotorwiththetwobolts.
Motor maintenance
• Refertomotormanufacturer’sinstructionsforoilingthemotorasneeded.
Checking ignitor
Nevertestanignitorbyplacingascrewdriver(orothermetallic
object)acrossthehighvoltageclips.Thiscouldcauseignitor
damageorseverepersonalinjury.
1.Turnoffthepowertotheburner/appliance.
2.Shutoffgassupplytotheburner.
3.Removeignitorfrombackofpanel.
4.Attachthesparkplugclamptotheunpaintedareaoftheignitorplateusing
thescrewfromstep3.Thisgroundsthesparkplug.
5.Connecttheignitorleadtothesparkplug.
6.Reapplypower to theburner and, afterthe pre-purge timing,observe
thespark.
7.Ifthereisaspark,verifythattheignitorelectrodeisinthecorrectposi-
tionandnotgroundedtothediffuserplate.Removethesparktesterand
replacethescrewandignitorlead.
8.Ifthereisnospark,verifythatthereis120voltsbeingsuppliedtothe
ignitor.Ifthereisnot120voltssupplied,thenreplacetheignitor.