Carlin G3B User manual

Contents
PLEASE read this first.......................................................... 2
Codes and standards........................................................... 2
G3B Gas burner at-a-glance.............................................. 3
Prepare site • prepare burner • mount burner................ 4
Install gas piping.................................................................. 9
Wire burner......................................................................... 10
Check system • start-up burner/appliance.................... 12
Perform checkout procedure • ll out certicate ........ 14
Maintenance and service procedures........................... 17
Troubleshooting.................................................................. 19
Dimensions and mounting information .......................... 21
Replacement parts............................................................. 22
Instruction Manual
Ratings
Input: .................................................... 60,000 to 180,000
btuh
Fuels: .........................................Natural gas or propane gas
Max. supply pressure.............................14
inches w.c.
Min. supply pressure................................5
inches w.c.
Manifold pressure .................................3.5
inches w.c.
Electrical: Power...................................120
v
/60
hz
/1-
phase
, 8
amps
Motor..................................................1/50
hp
, 3450
rpm
Ignition: .................................. Norton hot surface ignitor, 120
v
Control: .................................Honeywell S89C primary control
Agencies: ........................................................CSA certified, U. S.
The G3B burner has been assigned
U. S. Patent No. 4397631
Installer/servicer — Except where specifi-
cally stated otherwise, this manual must be used only by
a qualified service technician. In the state of MA, this
product must be installed by a licensed plumber or gas
fitter. Failure to comply with this or other requirements
in this manual could result in severe personal injury, death
or substantial property damage.
Handling — Handle burner (and hot surface ignitor)
carefully to avoid cracking or breaking the ceramic ignitor.
Ignitor protrudes slightly beyond burner head. Do not set
burner on its end.
User — Refer only to User’s Information manual
for information regarding operation of this burner. The
remainder of this manual is intended only for your
service technician. The burner and heat exchanger must
be inspected and started at least annually by your service
technician.
126 Bailey Road North Haven, CT 06473
Ph 203-680-9401 Fx 203-680-9403
Carlin Combustion Technology, Inc.
T
ech support
800-989-2275 carlincombustion.com
©Copyright 2015 — Carlin Combustion Technology, Inc.

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
2
General information
Burner applications
Follow all instructions in this manual and the appliance manual. Where
appliance instructions differ from this manual, follow the appliance instruc-
tions. Read the label attached to the burner air tube to verify the burner is
correct for the appliance being used. See pages 6 and 7 for procedures.
Damage or shortage claims
The consignee of the shipment must file damage or shortage claims
immediately against the transportation company.
When calling or writing about the burner . . .
Please provide us with the burner serial number and burner model number
to assist us in locating information. Enter this information on the Installation
Certificate in this manual. The certificate information can be helpful when
troubleshooting or obtaining replacement parts.
PLEASE read this first . . .
Special attention flags
Please pay particular attention to the following when you see them through-
out this manual.
Notifies you of hazards that WILL cause severe personal injury,
death or substantial property damage.
Notifies you of hazards that CAN cause severe personal injury,
death or substantial property damage.
Notifies you of hazards that WILL or CAN cause minor personal
injury or property damage.
Notifies you of special instructions on installation, operation or
maintenance that are important, but are not normally related to
injury or property damage hazards.
Follow the guidelines below to avoid potential severe
personal injury, death or substantial property damage.
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’s
information manual with the user. Make the user aware of all
potential hazards and perform the training outlined below.
Train the user . . .
• Toproperlyoperatetheburner/applianceperthismanual,the
appliance instructions and the User’s information manual.
• Tokeepthismanualatorneartheburner/applianceforready
access by the user and service technician.
• Tocontacttheservicetechnician,gassupplierorredepartment
should the user smell gas.
• Tokeeptheappliancespacefree of flammable liquids or vapors
and other combustible materials.
• Donotuselaundryproducts,paints,varnishesorotherchemicals
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 to burner before attempting to
service to avoid electrical shock or possible injury from moving
parts.
• 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.
• Handletheceramicignitorwithcaretoavoidbreakingorcracking
the ignitor. Do not handle ignitor when it is hot. NEVER touch
the surface of the ignitor with bare fingers. Body oils can cause
damage.
Codes and standards
 The installer/servicer is solely responsible for compliance
with all applicable codes and standards.
Burner listings/approvals
Carlin G3B gas burners are CSA certified for use with natural gas or propane
gas, United States installations only.
BurnersareNYC/MEAapproved.MEA-369-89-E.
Installation:
Burner/applianceinstallations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.

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
3
G3B Gas Burner At-a-Glance
1 Air tube, with powder coat paint finish
2 Flameholder
3 Hot surface ignitor
4 Adjustable flange
5 Rear ignitor assembly with terminal boots
6 Ignition tube assembly mounting plate
7 Pedestal legs
8 Burner gas inlet connection (see page 8)
9 Combination gas valve (with integral gas pressure regulation —
set for 3½” w.c. outlet pressure)
10 Control panel
11 Terminal strip
12 Primary control (Honeywell Model S89C primary control, for use with
ame rectication)
13 Control transformer, 120
vac
/ 24
vac
, 40
va
14 Gas valve on indicator light
15 Motor relay
16 High-efciency motor
17 Blower housing (cast aluminum), with powder coat paint nish
18 Air inlet tube assembly
19 Air throttle indicator — Only a single adjustment required for setting
combustion air; see page 8 for starting setting based on appliance
model and input)

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
4
1. Prepare Site • Prepare Burner • Mount Burner
Inspect installation site
Inspect, repair and/or replace vent system
Do not install this burner unless you have verified 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 constructed in ac-
cordance with all applicable codes. If intended for use with an
oil burner as well, the vent system must comply with relevant
codes for both gas and oil firing.
The vent system must not be pressurized unless the vent
piping and vent system are designed accordingly. 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 fireplace, 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 flue products.
A defective vent system could result in severe personal injury,
death or substantial property damage.
Vent/chimney sizing
• Followalllocalcodeswhensizingtheventandchimey
• Refer to the appliance manufacturer’s manual, when available, for
venting recommendations
Prepare vent/chimney
• Secureallmetalventjointswithscrews,followingtheventmanufactur-
er’s instructions. Seal all joints in the vent system and chimney. Repair
masonry chimney lining and repair all mortar joints as needed.
• 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 in the top of the draft regulator outlet.Wire the
switchintotheappliancelimitcircuittoshutofftheappliance/burnerif
sustained downdraft should occur.
• Providesupportfortheventpiping.Donotresttheweightofanyofthe
vent piping on the appliance flue outlet.
Figure 1 Vent and vent connector installation
Verify clearances
• Verifythatclearancesrequiredforservice/maintenancecomplywith
the appliance manual and applicable codes. Provide at least 6 inches
aroundburnerand24inchesinfrontofburnerpanelforservice
access.

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
5
1. Prepare Site • Prepare Burner • Mount Burner (continued)
Inspect installation site
Combustion/ventilation air openings
 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
sufficient air openings.
Large spaces
For appliances located in basements, ventilated crawl spaces or other large
areas, no additional air openings should be necessary.
Exception:Ifthebuildingconstructionisunusuallytight(seeNationalFuel
GasCodeorCSAB149.1or.2fordenition),youwillneedtoprovideair
openings into the building if appliance air comes from inside. Provide one
openingwithin12inchesoftheceiling,andoneopeningwithin12
inches of the floor. Size each opening to provide free area (after deduction
forlouvers)of1squareinchper1,000Btuhinputofallfuel-burning
appliances in the building.
Confined spaces — air from inside building
If air openings connect to areas inside the building, 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 deduction for louvers) of 1 square
inchper1,000Btuhofallappliancesinthespace.Ifthebuildingconstruc-
tionisunusuallytight(seeNationalFuelGasCodeorCSAB149.1or.2for
definition), you will need to provide air openings into the building. Provide
two openings sized and located as for the openings into the boiler space.
Confined spaces — air from outside
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.
Verify openings
When sizing air openings for combustion and ventilation, include
air required for exhaust fans and other appliances, such as
clothes driers, that require air for operation.
Check appliance manual and applicable codes for required sizing of
combustion and ventilation air openings.
• Verifythatopeningsareunobstructed.
• Verifythatappliancespaceandairsourcespacesarefreeof:
– gasoline or other flammable 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 & sizing air openings

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
6
Prepare the appliance
 Burnerinput:Installagasburnersizedforthenormalinput
rating of the appliance. Do not install a burner with a higher
firing rate than the appliance rating. Do not install a burner
witharingratemorethan10%lowerthantheappliance
rating. The appliance and vent system could be damaged
due to condensation.
 Sealtheappliance:Sealallue-gascontainingjoints.Seal
all connections to the vent piping or breeching.
 Clean  and  check  the appliance:  Clean the appliance
thoroughly. Test all electrical components and verify the
relief valve works (boilers only).
Verify combustion chamber dimensions comply with the
minimum dimensions shown in Figure 3. Install or replace
combustion chamber liner if required by the appliance
manufacturer. The burner air tube must not extend into the
combustion chamber. The end of the burner air tube must be
within¼”oftheinsidefaceofthecombustion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. Notice that the flameholder may
extend slightly into chamber as shown in Figure 3.
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 fiber
refractories or fiberglass insulation, see WARNING on page 7.
Failure to comply with the above could result in severe
personal injury, death or substantial property damage.
1. Prepare Site • Prepare Burner • Mount Burner (continued)
Input Minimum chamber dimensions, Inches
(Note 1)
(Using 2300ûF or higher refractories)
Btuh Square
L x W x H
Vertical cylinder
Diameter x H
60,000 7 x 7 x 9 8 x 9
70,000 7½ x 7½ x 9 8½ x 9
100,000 8 x 8 x 9 9 x 9
120,000 9 x 9 x 9 10 x 9
140,000 10 x 10 x 9 11 x 9
160,000 11 x 11 x 9 12 x 9
180,000 12 x 12 x 9 13 x 9
Note 1: Rectangular chambers of similar floor area are equally acceptable, but the L/W ratio should not
exceed 2 and the width should be at least 5 inches.
Figure 3 Minimum combustion chamber dimensions

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
7
1. Prepare Site • Prepare Burner • Mount Burner (continued)
Inspect burner and components
Do not install or operate the burner if any component is
damaged or if burner does not comply with the specifications
and guidelines in this manual and the appliance manual.
Air tube insertion length (UTL)
• Usableairtubelength(UTL) is the distance from mounting flange 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 appliance combustion chamber front
wall when the burner is mounted. See Figure 3, page 6.
• MinimumUTL is1¾ inches.Maximum UTL istube length less1¾
inches.Tubesareavailablein6-inch,9-inchand12-inchlengths.
• Notice that the ameholder may extend slightly into chamber as
shown.
Ceramic fiber or
Fiberglass insulation
Ceramic fiber materials, such as chamber liners, may
contain carcinogenic particles (chrystobalites) after
exposure to heat. Airborne particles from fiberglass or
ceramic fiber components have been listed as poten-
tially 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-fitting clothing,
glovesandeyeprotection.UseaNIOSHN95certied
respirator. This respirator meets requirements for
protection from chrystobalites. Actual job requirements
or NIOSH regulations may require other or additional
protection. For information, refer to the NIOSH website,
http://www.cdc.gov/niosh/homepage.html.
Ceramic fiber removal:Topreventairbornedust,thor-
oughly wet ceramic fiber with water before handling.
Place ceramic fiber materials in a plastic bag and seal
to dispose.
Avoid blowing, tearing, sawing or spraying fiber-
glass or ceramic fiber 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.
Prepare appliance for burner mounting
The universal flange supplied with G3B Gas burners is
intended only for firing chambers with negative overfire
pressure. The G3B burner must not be installed on a
product that operates with a pressurized combustion
chamber. Failure to comply could result in severe per-
sonal injury, death or substantial property damage.
• Seepage21forrequireddimensionsandboltlocations.

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
8
1. Prepare Site • Prepare Burner • Mount Burner (continued)
Mount burner in appliance
• Verifyapplianceburnerfrontplatedimensionsperpage21.
• Slidegasketsuppliedwithburneroverendofairtube.
• Insertburnerintoapplianceopeningandboltinplace.
Inspect burner and components
Drill or ream gas orifice to size (initial installation)
You must disconnect power to burner and close main manual
gas valve before proceeding. Failure to do so could result
in severe personal injury, death or substantial property
damage.
You must drill or ream the burner orifice to the size given in
Figure 4.The orifice is shipped with a pilot hole only. Firing the
burner with the orifice as shipped can result in damage to the
burner.NeverretheG3Bburnerbelow60,000Btuhinput.
The flameholder can overheat, resulting in potential severe
personal injury, death or substantial property damage.
1. After drilling or reaming orifice to correct size, thread orifice fitting into
orifice nipple as shown in Figure 4.
Install gas valve on burner
1. Read WARNING’s on page 9 before installing gas valve.
2. Applyasmallamountofpipedope(suitableforpropanegas)togas
valve outlet connection, gas line elbow and orifice nipple. Assemble
elbow and orifice nipple to gas valve.
To avoid damage to gas valve, do not hold valve with a pipe
wrench or over-tighten. Use only a crescent wrench or other
means. Failure to comply could result in severe personal
injury, death or substantial property damage.
3. Insert orifice nipple into burner gas connection and secure in place
using the two Allen screws.
4. Connect gas valve wires to gas valve.
Inspect/redrill gas orifice when required
1. Turnoffpowertotheburner/appliancebeforeproceeding.
2. Closemainmanualgasvalveingaslinetoburner.Thendisconnectthe
ground joint union to allow rotating burner combination gas valve.
You must disconnect power to burner and close main manual
gas valve before proceeding. Failure to do so could result
in severe personal injury, death or substantial property
damage.
3. LoosenAllenscrewssecuringgaslinetoburnergasconnection.
4. Remove combination gas valve (item 9, page 3) and gas piping to burner
gasconnection(item8,page3)onburnerairtube.
5. ReadcorrectoricedrillsizefromFigure4.Thencheckactualorice
size using that size twist drill bit.
• If gas orifice is smaller than required, redrill orifice to correct size,
ifnecessary.Replacegasvalveandpiping,usingonlypipedopelisted
forusewithliqueedpetroleumgases.
• If gas orifice is larger than required, obtain a replacement gas orifice
fitting. Drill orifice hole in replacement orifice fitting.
Hot surface ignitor
• Inspecttheburnerfromairtubeend.Thehotsurfaceignitormustextend
slightlypasttheendoftheburner.
• Carefullyinspecttheignitor,ensuringitisintact,withnocracksorvisual
signsofdegradation.
• Donottouchtheignitorwithbarehands.Bodyoilscancausedeterioration
ofthesiliconcarbide.
• Replaceignitorifthereareanysignsofdamage.
You must allow ignitor to cool before attempting to handle.
Failure to do so could result in severe personal injury or
damage to the ignitor.
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.
Figure 4 Orifice and gas valve installation
Input
Btuh
Burner orifice drill size
Diameter, inches
Air throttle
turns (appr.)
Notes 1 & 2
Note 1 Natural Gas Propane Gas
60,000 #28 (0.141) #33 (0.113) 0
70,000 #24 (0.152) Z\, (0.125) ½
80,000 #20 (0.161) #30 (0.129) ¾
90,000 #17 (0.173) #28 (0.141) 1
100,000 #14 (0.182) #25 (0.150) 1½
110,000 #11 (0.191) #22 (0.157) 1¾
120,000 #7 (0.201) #20 (0.161) 2¼
140,000 #3 (0.213) #16 (0.177) 3
160,000 A (0.234) #12 (0.189) 4¼
180,000 D (0.246) #7 (0.201) 9
Note 1: High altitude applications: The maximum burner input at sea level is 180,000 Btuh.
Reduce this capacity by 4% per 1,000 feet above sea level. Example — max.
capacity at 5,000 feet is 144,000 Btuh (20% reduction).
Note2: Usethisasthestartingsettingonly.Adjustairthrottle,ifnecessary,afterperforming
combustion testing (see page 14).

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
9
2. Install Gas Piping from Meter to Combination Gas Valve
Code compliance
Theburner/applianceinstallationmustcomplywithcodeslistedonpage2and
any other locally applicable codes.
Piping from meter to burner
Connect from the gas supply to the burner combination gas valve
inlet using new, clean black iron pipe and malleable iron fittings only.
Do not use copper, brass, cast iron or galvanized pipe or fittings.
Provide support for gas piping. Do not rest weight of piping on burner
gas valve.
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 gas valve with pipe wrench. Use crescent wrench or
other smooth-jawed device. Do not over-tighten.
Failure to comply with above could result in severe personal injury,
death or substantial property damage.
1. 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.
2. Whenbranchingfromacommongasline,donottapofffromthebottom
of horizontal sections — only from the side or top.
3. Install a main manual shutoff valve, sediment trap and ground joint
union near the burner combination gas valve connection as shown in
Figure5.
4. If the burner is installed inside the appliance jacket, install the main
manual gas valve and sediment trap external to the jacket.
5. Sizepiping(orverifysize)usingTable2.Youwillndadditionalinforma-
tionongaslinesizingintheNationalFuelGasCode,ANSIZ223.1.
Gas supply pressure — natural or propane
• Maximumsupplypressure:14inchesw.c.
• Minimumsupplypressure:5inchesw.c.
Do not expose the combination gas valve 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.
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.
Table 2 Capacities of black iron pipe, cubic feet gas/
hour
Figure 5 Connecting gas supply piping to burner
1 Pipe to meter or branch
2Mainmanualgasshutoffvalve(must
be ‘T’ handle in state of MA)
3 Use clean, burr-free black iron pipe
and malleable iron fittings
4 Ground joint union
5Sedimentleg
6 Burner combination gas valve
7Upstreampressuretap,1/8”
npt
8Outletpressuretap,1/8”
npt
9 Gas pressure regulator access screw
10Gasvalvewireterminalstrip

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
10
3. Wire Burner
Code compliance
Theburner/applianceinstallationmustcomplywithcodeslistedonpage
2andanyotherlocallyapplicablecodes.
General wiring requirements
Read and follow the guidelines in this manual. Failure to
comply could result in severe personal injury, death or
substantial property damage.
Electrical shock hazard — Disconnect electrical supply to the
burner before attempting to service. Failure to comply could
result in severe personal injuiry, death or substantial property
damage.
Figure 6 Ladder wiring diagram
Electrically ground burner — The burner must be grounded
in accordance with local codes or, in the absence of local
codes,withtheNationalElectricalCode,ANSI/NFPA70(in
Canada, the Canadian Electrical Code Part 1, C.S.A. Standard
C22.1.)
Label all wires before removing for servicing. Wiring errors
couldresultinunsafeappliance/burneroperation.
Read appliance manufacturer’s instructions completely before
wiring burner.
Check polarity carefully. If hot and neutral wires are reversed
at appliance power source, the control will not operate.
If replacing any of the wire supplied with the burner, use
minimum#14AWG125°Corbetter.

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
11
3. Wire Burner (continued)
Figure 7 Wiring diagram — wire routing
M
L1
L2
T
T
Red
Gray
Bk
Wh
Blue
Br
Or
Yel
24V
HSI
L1
L2
HSI
VALVE
VALVE (GND)
Red
Pur
Yel
BlueBk
Wh
Pur
MV MV
TH/TR
Red
Bk
Bk
Bk
Wh
Bk
Gn
Yel
Bk
Red
Red
BkBk
Motor
120 VAC
Motor
relay
Honeywell S89C
control
Hot surface
ignitor
40
Transformer
VA
Valve on
light
Te rminal
strip
Motor
end switch
Thermostat **
Spill switch (if used)
(may also be wiri
ng in
the 120-v limit circuit)
**
120-v limit
circuit 120 VAC
GND
Hot
Neu
Control panel enclosure
Combination
gas valve
NOTICE:Line voltage polarity
The hot and neutral power wires
must connect as shown for correct
operation of the burner controls.
Br = brown
Gr = green
Bk = black
Blue = blue
Or = orange
Pur = purple
Gray = gray
Wire color coding
120 factory wiringVAC
24 factory wiring
VAC
120 field wiringVAC
24 field wiringVAC
Wire connector
G3B01
Line switch **
** Supplied by installer
Red = red
Wh = white
Yel = yellow
Bk
GND (BURNER)
Gn
Yel
24V (GND)
Yel
Gnd
Connect ground wires
to green terminal strip
screws when replacing
a Fenwal control with a
Honeywell S89C.
Verify power supply
1. The burner requires a 120
vac
/60
hz
/single-phase power supply. The
currentdrawwillbeaproximately8.0amps.Protectlinewitha10-amp
or15-ampfuseorbreaker.
2. The120
vac
power connections to the burner must be connected as
shown in Figure 7. The control is polarity-sensitive, and will not work if
the hot and neutral lines are reversed.
3. Verifythatthepowersupplytotheburnerisnolessthan102
vac
nor
morethan132
vac
.

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
12
4. Check System • Start-up Burner/Appliance
Inspect/check system
Before starting the burner and appliance, verify the system has been installed
as directed by this manual and the appliance instructions.
Check gas piping for leaks
Disconnect the burner from the gas supply line if gas line
test pressure will exceed 14 inches w.c. Exposing the burner
combination gas valve to pressure higher than 14 inches w.c.
can damage the valve seat, resulting in potentially unsafe
operation.
You can usually test the gas piping by allowing the line to fill with gas to
main regulator outlet pressure.
1. Shut off gas flow to all appliances connected to the meter.
2. Iftestpressurewillbelessthan14inchesw.c.,turntheburnercombi-
nation gas valve knob to OFF. If test pressure will be higher than 14
inches, disconnect the burner from the gas line by shutting off the
mainmanualgasvalveinstalledneartheburner(perFigure5,page9)
and disconnecting the ground joint union. See warning above.
3. Watch the gas meter dial. For a one half cubic foot per revolution dial,
thereshouldbenomovementofthedialforatleast5minutes.For
larger volumes per revolution, increase this time proportionately.
4. If you detect a gas leak, locate the leak with a soap suds mixture and
repair it. Then test the system for leaks again.
Do not test for leaks with an open flame. And do not use
oxygen as a test gas. Either of these could cause an
explosion, resulting in severe personal injury, death or
substantial property damage.
Bleed gas line
Purge all air from the gas line. Purge to outside of the building, NEVER into
the appliance or burner.
Leak test near-burner gas piping
If piping near burner has not already been pressure tested, open main
manual gas valve on supply to burner and smell around area for any signs of
gas.Apply a soap suds mixture to all gas piping joints near burner and check
for any leaks. If any leaks appear, repair before proceeding and retest.
Set air throttle
1. SeeFigure8.Loosenairthrottlelockingnut.
2. Rotatetheairthrottleplateclockwisetotheclosedposition.
3. Checktheairthrottleindicator.The“0”positionoftheindicatorshould
be even with the end of the air inlet tube. If not, bend the arm slightly
until the indicator reads zero.
4. Rotate air throttle until indicator points to setting given in Figure 4,
page8.
5. Tightenairthrottlelockingnut.
Figure 8 Air throttle adjustment
Do not start the burner if you smell gas or if there may be gas
present in the appliance combustion chamber, heat exchanger
or the vent system.An explosion could occur, causing severe
personal injury, death or substantial property damage.
During initial start-up, you must be constantly alert for
emergency conditions such as fuel leaks, electrical malfunc-
tions, etc. Familiarize yourself with the location of manual
shutoff valves and switches so you can quickly use them if
needed.
If the burner fails to ignite, NEVER attempt to manually bypass
the normal sequence of the control, which provides purging
of the combustion chamber.
6. The Figure 4 setting will probably be satisfactory without change. If the
combustion test indicates a need for more or less air, however, you will
have to adjust the throttle accordingly.
Check burner and Honeywell S89C control
Inspect burner thoroughly. Verify all components are secure and burner
is in good condition. Verify all wiring is in place and all components are
secure and in position.
Verify flame failure lockout of Honeywell control
1. Install a hose barb fitting in the combination gas valve outlet pressure tap
and connect with a hose to a U-tube manometer.
2. Closethemainmanualgasvalveandturnthecombinationgasvalveknob
to ON.
3. Turn on power to appliance and set appliance limit(s) to call for heat.
4. Burnermotorwillstart.TheHoneywellS89Ccontrolwillruntheblowerfor
34 seconds (pre-purge and ignitor warm-up). Then the combination gas
valvewillopenandthe“Valveon”lightwilllight.(Themanometershould
show almost no pressure, because the main manual gas valve is closed.)
5. After6seconds,theS89Cwilllockout.Theignitorwillshutoffandthegas
valvewillclose.Turnoffpowerorinterruptthermostatcircuitfor45seconds.
The control should reset. Turn off power and set controls to stop call for
heat.
6. Iflockoutdoesnotoccur,replacetheS89Ccontrol.

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
13
4. Check System • Start-up Burner/Appliance (continued)
Installer/servicer
 Shouldoverheatingoranemergencyoccur,immediately:
 •Shutoffmainmanualgasvalve.
 •Shutoffpowertoburner.
 NOTICE:Undersomecircumstancespowershouldremain
onforwaterpumpsorcirculatingblowers.Determineproper
responsebeforeattemptingstart-up.
 Ifburnerfailsignitiononseveralattempts,closegasvalve
anduseburnerblowertopurgeappliancebeforerestart.
Start-up & operation
 Donotstarttheburnerifthecombustionchambercontains
residualgas.Allowgastodisperse.Failuretocomplycould
result in severe personal injury, death or substantial property
damage.
Power ON Openallmanualgaslinevalves.Turnburnercombinationgas
valveknobto“ON.”Closethelineswitch.(Ifburnerdoesnot
followsequencebelow,seetroubleshootingsuggestionson
pages19and20.)
Stand-by (Nocallforheat)Controlwaitsforheatcall.
Call for heat Setoperatingcontrolandalllimitcontrolstocallforheat.
Thethermostatcircuitmustbeclosedandpowercomingto
controlpanelL1andL2terminals
Burner on Themotorstarts.Thehotsurfaceignitorstarts.Themotor
centrifugalswitchmakes.
Pre-purge Theprimarycontrol allows34secondsforpre-purgeand
ignitorwarm-up.
Gas valve on Afterthe pre-purge/ignitor warm-upperiod, the primary
control activates the gas valve(ifmotorcentrifugalswitch
isclosed).Thegreen“Gasvalveon”lightturnson.
TFI Theprimarycontrolturnsofftheignitorwithin2to6seconds
aftergasvalveactivation.Whenthecontroldeactivatesthe
ignitor,itbeginscheckingforamesignal.Ifameisnot
detectedwithin6secondsaftergasvalveactivation,the
primarycontrol will lockout with continuous purge (see
following).
Run period Theburnercontinuesringduringcallforheatiftheame
rod(hotsurfaceignitor)sensesame.Thegreen“Gasvalve
on”lightremainsonduringnormalrunning,indicatinggas
valve is energized.
Shutdown Whenthecallforheatends,theprimarycontrolimmediately
deactivatesthegasvalveandblower.Theburnerreturnsto
stand-by.
Flame failure Iftheprimarycontrollosesamesignalduringarunperiod,
itdeactivatesthegasvalvewithin2seconds.Thecontrol
restartsthe heating cycle, beginningwith a 34-second
pre-purge/ignitorwarm-upperiod,thena6-secondtrialfor
ignition.Ifignition/amesensingissuccessful,theburner
returnstonormaloperation.Iftheattemptisnotsuccessful,
theprimarycontrolwilllockout.
Lockout IftheprimarycontroldoesnotsenseamewithintheTFI
timelimitaftergasvalveactivation(6seconds),lockout
occurs.Thecontroldeactivatesthegasvalve.Theblower
motorcontinuestorun,providingapost-purgeoftheburner
and appliance.
Reset Toresetafteralockout,turnoffpowertoburnerorinterrupt
thethermostatcircuitforatleast45seconds.Thenrestore
power(orthermostatcircuit).Burnershouldrestart.
Ignition and flame sensing
Ignition TheG3Bburnerusesasiliconcarbidehotsurfaceignitor
forignition.TheHoneywellS89Cprimarycontrolfeeds120
vac
powertotheignitorandallowstimefortheignitorto
warmuptoignitiontemperatureduringtheburnerpre-purge
period.
Sensing TheS89Cprimarycontrolusesamerecticationtodetect
ame,withthehotsurfaceignitoractingasthe“amerod.”
Before starting burner, verify:
❏Burner/applianceinstalledperapplianceinstructionmanual?
❏BurneroricesizeandairthrottleveriedagainstFigure4,page8?
❏Burner/applianceinstalledperallapplicablecodes?
❏Installationsitehasadequateventilationopeningsandvent
system?
❏Gassupplylineingoodconditionandsizedcorrectly?
❏Allgaslinejointssealedwithpipedopelistedforusewithliqueed
petroleumgases?
❏Gassupplypressuretocombinationgasvalvechecked?
❏Regulatorinstalledifpressurecanexceed14inchesw.c.?
❏Airpurgedfromgasline?
❏Gaspipingcheckedforleaks?
❏Wiringinstalledperburnerandapplianceinstructionmanuals?

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
14
5. Perform Checkout Procedures • Fill Out Certicate
Make final burner adjustments
Check for leaks in gas piping
❏Smellaroundburnertomakesurethereisnogasleakinnear-burner
piping.Verifyintegrityofgaslinejointsbetweencombinationgas
valveandburnergasinlettappingusingsoapsudsmixture.Verify
gaspipingisfullysupported,independentlyofburner.
Check for leaks from burner components
❏Smellaroundburnertomakesurethereisnoleakagefromtheburner
inletairtube,blowerhousingorairtube.Verifyburnerisproperly
supported and flange is securely tightened.
If you detect leakage from any burner component, immediately
close the main manual gas valve. Use a soap suds mixture to
determine leakage location. Replace burner if leakage cannot
be corrected by properly securing components.You may have
to restart the burner several times during leakage testing
since the control will lockout when flame is not detected.
Failure to correct leakage problems could result in severe
personal injury, death or substantial property damage.
Check/adjust gas valve outlet pressure
❏Withburnerrunning,checkmanometerreadingforcombinationgas
valveoutletpressure.Adjustvalveregulatorifnecessarysothe
readingis3.5inchesw.c.foreithernaturalgasorpropanegas.
Inspect flame
❏Lookatamethroughapplianceobservationport.Theameshould
beasoftbluewithwell-denedorangeandyellowtipsfornatural
gas,orwell-denedyellowtipsforpropanegas.(Ifyoumakeairor
gaspressurechangeslater,inspecttheameagain.)
Check the firing rate
❏Naturalgasonly—Turnoffallothergasappliancesconnectedto
thegasmeter.Useastopwatchtotimethenumberofsecondsfora
owofonecubicfootofgas(tworevolutionsforaonehalfcubicfoot
perrevolutiondial,forexample).Youwillalsoneedtoknowthegas
heatcontentinBtupercubicfoot.Determinetheactualinputfrom:
INPUT=(3600xBtupercubicfoot)÷(numberofsecondsforonecubic
foot),forringrateinBtuh.Forexample,for1050Btupercubicfoot
naturalgas,withmetertimedat30.2secondsforonecubicfootof
gas:INPUTexample=(3600x1050)÷(30.2)=125,200Btuh.Firing
rateshouldbewithin±5%ofratedinputfortheappliance.Adjust
thecombinationgasvalvepressureregulatorifnecessarytoobtain
thecorrectringrate.Valveoutletpressuremustnotbelowerthan
3.2inchesw.c.norhigherthan3.8inchesw.c.
❏Forpropanegas,contactyourpropanesupplyforproceduretoverify
firing rate.
Make final burner adjustments (continued)

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
15
Make final burner adjustments (continued)
Check combustion using instruments
You must use combustion test instruments. Failure to properly
verify/adjustcombustioncouldallowunsafeoperationofthe
burner, resulting in severe personal injury, death or substantial
property damage.
Figure 9 Flame signal measurement connections
❏Inserttestprobeintoventaboveappliancetosampleueproducts.
TheresultsshouldshowCO2or O2asfollows:
❏Ifthecombustionresultsareoutsidetherangeabove,andthering
rateoftheburneriswithin5%ofratedinput,openorclosetheair
throttleuntiltheCO2(orO2)areacceptable.
After CO2(O2) tests are completed satisfactorily, measure
flue products for carbon monoxide (CO) concentration. The
COmustnotexceed50ppmadjustto“airfree”,orotherif
specified by local codes.
❏Adjustthedraftintheappliancesothedraftoverreisabout–0.01
inchw.c.andtakeauegassamplefromthecombustionchamber.
IfCO2isnoticeablyloweroverrethaninthevent,theappliancehas
leaksthatmustberepaired.
5. Perform Checkout Procedures • Fill Out Certicate (continued)
Check flame signal
Electrical shock hazard — Turn off power to burner before
proceeding with setup for flame signal measurement.
❏(SeeFigure9.)TheHSIispoweredwith120VACduringpre-purge
soamicroammeterwithashuntswitchmustbeusedtotestame
signalorthemeterwillbedestroyed.USEONLYneedlemovement-
type meters, not digital meters.
❏RemovetheignitorleadwirefromHSIterminaloftheS89Cprimary
control.Connectashuntswitchand
dc
microammeterbetween
HSIterminalandtheignitorleadwire.Makesureshuntswitchis
closed.Thenturnonpowertotheburner.Aftertheburnerame
starts,waitatleast15seconds,thenopenshuntswitchandreadDC
amps(mustbeatleast0.8microampsDC).
DO NOT start the burner or adjust the air throttle with the
shuntswitchopen.The120VsupplytotheHSIwilldestroy
the microammeter.
Make final burner adjustments (continued)
Fuel CO2O2
Minimum Maximum Maximum Minimum
Natural Gas 9.6% 10.8% 4.0% 2.0%
Propane Gas 11.0% 12.5% 4.0% 2.0%

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
16
5. Perform Checkout Procedures • Fill Out Certicate (continued)
Verify burner/appliance operation
Check burner/appliance/controls operation
❏ Testoperatingandlimitcontrolsonapplianceasspeciedinappliance
instruction manual.
❏CheckoperationoftheS89Cprimarycontrol,forcinglockoutby
closingthemainmanualgascockandcyclingtheburner.Seepage
13forproceduretoresetthecontrol.
Verify burner operation
❏Startandstoptheburnerseveraltimes,allowingtheprimarycontrol
tosequence through normal operation.Verify correct operationof
burnerandcontrolthroughout.Seepage13forburnersequenceof
operation.
Verify vent system operation
❏Verifyventisoperatingcorrectlyandueproductsareproperly
exhaustedfrombuilding.
❏Checkoperationofbarometricdamperandspillswitch.
❏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.
Prepare burner for normal operation
❏Cycleburneroffwithappliancecontrols.Thenturnoffpowertothe
appliance.
❏Closethemainmanualgasvalve.
❏RemovetheU-tubemanometerlinefromthecombinationgasvalve
outletpressuretaphosebarb.Removehosebarbandreplace1/8"
NPTpipeplugintapping.
❏Verifyallcomponentsandwiresareinplaceandburnerisreadyfor
operation.
Train the user
❏Traintheuser to operate the burner and applianceundernormal
conditions.Explainproceduretoshutdownburner/appliancewhen
required.
❏Reviewtheuserinformationsectionofthismanual(andtheappliance
manual)withtheuser.
❏Verifytheuserisawareofallproceduresspeciedinthemanual.
❏Verifyuserwillnotstoreorusecombustibleliquidsormaterialsor
contaminantsinthevicinityoftheburner/appliance.

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
17
Annual start-up & service
This burner should be started and serviced at least annually
by a qualified service technician. Failure to properly maintain
and service the burner could result in severe personal injury,
death or substantial property damage.
Turn off power to appliance and close main manual gas
valve when servicing burner. See WARNINGS on page 2
and elsewhere in this manual regarding correct procedures.
Failure to comply could result in severe personal injury, death
or substantial property damage.
❏ Discussburner/applianceoperationwithusertodetermineanyprob-
lemsthatmayhaveoccurredduringthepreviousseasonandtoverify
userisawareofproperoperationandcareoftheburner/appliance.
❏ Turnoffpowertoapplianceandclosemainmanualgasvalve.
❏ Removeburnerfromapplianceandinspectameholder,hotsurface
ignitor and burner components.
❏ Inspectignitorandignitiontubeassembly.
1. Thehotsurfaceignitor(HSI)isasiliconcarbideelementthatperformsdual
functionsofignitionandamedetection.Onacallforheat,theignitor
ispoweredwith120vacandiselectricallyheatedtoabout2600°F.This
ignitesthegas/airmixturewhentheprimarycontrolenergizesthegas
valve.
2. TheprimarycontrolthenswitchestheHSItotheamedetectorcircuit,
using flame rectification to monitor the flame.
3. Theignitorispositionedintheignitiontubeassemblyagainstafactory-
setnon-adjustablestopringforproperignitionandamesensing.
4. ToinspecttheHSI,rstbesurethe120vacpowersupplytoburneris
disconnected.Then slide the two silicone insulating bootsoff ofthe
insulators.
5. Pulloffthequick-disconnectterminals.
6. Removethefour#8-32screwssecuringtheairtubebackplate.
6. Maintenance and Service Procedures
7. Swingthehold-onbracketawayandcarefullypullouttheignitiontube
assembly.
As the white ceramic is exposed, support it using a rag. It
could be HOT. Do not let the hot surface ignitor element bump
into anything. Do not drop the assembly or ignitor element.
The element is very fragile. Even a small hairline fracture will
destroy the HSI.
8. Ifthe ignitor element is damagedin anyway,replace it with a new
one.
9. Ifreplacingtheignitiontubeassemblyintheburner,replacetheback
plategasketwithanewone.Replacethehold-onbracketandscrews.
Ensurethebackplategasketissealedgas-tighttotheburnerairtube.
❏ Inspectandcleanameholder.
1. Removetheignitiontubeassemblyfromtheburnerasdescribedinthe
stepsforinspectingthehotsurfaceignitor.
2. Reachinand,withonengerthroughthecenterholeoftheameholder,
pulltheameholderoutoftheburnerairtube.
3. Useasmallbrushtoremovedirtandlintfromtheinsidesurfaceofthe
flameholder. All holes must be clean and unobstructed.
4. Iftheameholderisdamaged,dentedordefectiveinanyway,replace
itwithanewone.
5. Replacetheameholderintheairtube.
6. Replacetheignitiontubeassemblyasdescribedinthestepsforinspecting
thehotsurfaceignitor.Besuretoinstallanewbackplategasketand
sealassemblytoairtubegas-tight.
7. Followtheinstructionsonpage8toinspectthehotsurfaceignitor.
If the inside surface of the air tube needs to be cleaned,
clean with a vacuum cleaner with brush attachment while
the ignition tube assembly is out of the burner.
❏Checktheburnerangegasket.Itmustbeingoodcondition.Replace
gasketonburnerangeandmountburnerinappliance,securingto
mounting studs.
❏Performthecompletecheckoutproceduresofpages12through17,
includingsysteminspectionandchecks.
Annual start-up & service (continued)

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
18
Maintenance/service procedures
Cleaning blower wheel
❏ Periodicallyinspectandcleantheblowerhousingandwheel.
1. Thebesttimetocleantheblowerhousingandblowerwheeliswhile
theignitiontubeassemblyisoutoftheairtube(see“Inspectignitorand
ignitiontubeassembly”).
2. Removethefour#8-32slottedscrewsinthemotormountingplate.
3. Bypullingabout1“ofslackinthemotorwiresfromthecontrolbox,the
motorblower/wheelassemblycanbepulledoutandrotatedtoagood
positionforcleaningtheblowerwheel.
4. Withasmallbrushorpipecleaner,removealldirtfromthebladesinthe
wheel.
5. Withacleanrag,wipeoutallthedirtfrominsidetheblowerhousing.
6. Dirtthatdropsintotheburnertubemustberemovedwhiletheignition
tube is out.
7. Replacethemotorplategasketwithanewone.
8. Replacethemotorblowerwheelassembly,beingverycarefulthatthe
gasketonthemotormountingplatemakesagas-tightsealagainstthe
blowerhousingcover.
6. Maintenance and Service Procedures (continued)
Replacing blower motor or wheel
Followthisproceduretoreplacemotororwheel.
1. Removethefour#8-32screwsinthemotormountingplate.
2. Pullabout1”ofslackinthemotorwiresfromthecontrolbox.Thenpull
outandrotatethemotor/blowerwheelassembly.
3. LoosenAllensetscrewinblowerwheelhubandtakethewheeloffthe
motorshaft.
4. Removefour#8-32nutsholdingmotortomountingplate.Besuretotake
thefournylonwashersealsfromthemotorstudsandsaveforthenew
motor.Alsoremovethenylonmotorbushing.Savethemotorbushingfor
usewiththenewmotor.
5. Disconnectthemotorwiresfromtheirwirenutsinthecontrolpanel,
keepingtrackoftheirlocations.
6. Connectthenewmotorwirestotheirproperterminals.
7. Placethefournylonwashersealsonthenewmotorstudsandassemble
themotorplatetothemotorusingthefournuts.
8. Replacetheblowerwheelwithabout1/16”ofshaftprotrudingbeyond
the hub.
9. Replacethemotorplategasketwithanewone.
10. Replacetheentireassembly,makingsurethatthegasketonthemotor
platemakesagas-tightsealagainsttheblowerhousingcover.
Maintenance/service procedures (continued)

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
19
7. Troubleshooting
Problem Possible
cause
Corrective action
WARNING
These procedures must only be performed by a qualified service
technician. Use care when performing tests on electrically or
mechanically live parts. Disconnect power to burner/appliance and close
main manual gas valve when removing components for service. Failure
to comply could result in severe personal injury, death or substantial
property damage.
Burner motor will
not start
120 V power Check 120 V at terminal strip. L1 - L2
Check limit/operative circuit.
24 V circuit Check that 24 V thermostat/circuit is calling for heat.
Check transformer output. Each “T” on terminal strip should read
approx. 24 volts to “G” ground.
Incorrect wiring Check all field and factory wiring.
Bad motor relay Check 24 V at motor relay. Relay should click (pull-in) on call for heat.
Check continuity across contacts (N.O.) or each side of contact to L2 on
terminal strip should read 120 volts.
Bad motor If motor relay is good (see above) and wiring is correct, disconnect the
motor leads and power the motor directly with 120 V to check motor
operation.
Bad primary
control
If all above tests prove negative replace control.
Burner pre-
purges for 34
seconds but
does not light
(continued on
next page)
Incorrect air
setting
For initial light-off set air throttle according to desired input.
Wrong orifice
size
Check orifice drill size.
Manual gas shut-
off valve closed
Check supply line gas cock and manual shut-off valve on combination
gas valve.
Manifold
pressure
Adjust regulator to 3.5 W.C. for natural gas and propane.
Gas valve not
opening
Check for 24 V valve coil during TFI. Indicator light should also be on.
Line pressure in excess of 14.0 W.C. can damage valve.
Motor end switch
not making
Check motor end switch.
Disconnect the two red leads in the panel coming from the motor end
bell. Check continuity during pre-purge. End switch will not activate if
motor is not running up to speed.
Hot surface
ignition element
damaged
Element normally glows red within 20 seconds during pre-purge. Use
flame mirror to visually inspect.
Check for 120 V at rear of ignitor assembly during pre-purge.
If visual inspection cannot be done, remove element and power directly
with 120 V. Replace element if it does not glow red within 45 seconds.

Model G3B Gas burner — Instruction manual
MNG3B Gas 041015
20
7. Troubleshooting (continued)
Problem Possible
cause
Corrective action
WARNING
These procedures must only be performed by a qualified service
technician. Use care when performing tests on electrically or
mechanically live parts. Disconnect power to burner/appliance and close
main manual gas valve when removing components for service. Failure
to comply could result in severe personal injury, death or substantial
property damage.
Burner pre-
purges for 34
seconds but
does not light
(continued)
Bad primary
control
Check for 24 V on valve lead on control during TFI.
Check for 120 V on HSI lead on control during pre-purge.
Replace primary control if either above tests show negative.
Burner lights but
primary control
locks out after
TFI
Incorrect air
setting
For initial light-off, set air throttle according to desired input.
Wrong orifice
size
Check orifice drill size.
Manifold
pressure
Adjust regulator to 3.5 W.C. for natural gas or propane.
Inadequate gas
supply
Line pressure requirements are: 5.0 W.C. for both natural and propane
fuels.
Line pressure in excess of 14.0 W.C. could damage combination gas
valve.
Watch line pressure gauge during TFI. If pressure drops below minimum
required when gas valve is energized look for partially closed gas cocks
in line, other appliances using the same supply or improperly adjusted
intermediate regulators.
If other appliances are on the same supply line and piping will not
sustain adequate pressure for all units on that piping, then it is
undersized. Check with gas utility.
Insufficient flame
signal
Check flame signal. Minimum signal 0.8 DC microamps.
Improper draft Improperly adjusted air throttle setting for the fuel input.
Over-fire draft is normally -0.01 W.C. Refer to boiler/furnace
manufacturer’s recommendations for specially packaged units.
Polarity Check 120 V at L1 on terminal strip.