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