Heat Wise SU-3 User manual

1
QHT Manual for:
SU-3 199,000 BTU/H to 400,000 BTU/H
SU-4 300,000 BTU/H to 550,000 BTU/H
The burner shall be used only with NATURAL GAS or LP GAS .
Warning: If the following instructions are not followed exactly, a fire or explosion may result,
causing property damage, personal injury or death.
•Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any
other appliance.
- WHAT TO DO IF YOU SMELL GAS? –
•Do not try to light any appliance.
•Do not touch any electrical appliance.
•Do not use any telephone in your building.
•Immediately call your gas supplier from an outside phone. Follow the gas supplier’s instructions.
•If you cannot reach your gas supplier, call the fire department.
•A qualified installer, service agency or the gas supplier must perform installation and service.
•At least once per year, a qualified service agency needs to contracted for other than routine
maintenance.
•All installations must be made in accordance with all state and local codes, which may differ from
instructions in this manual.
•The installer should inform and demonstrate to the user the correct operation and maintenance of the
appliance.
•The installer shall also inform the user of hazards of flammable liquids and vapors and shall remove
such liquids and vapors from the vicinity of the burner.
•The installation adjustment data trap (or label) supplied shall be filled in and affixed to the burner or
the covered appliance.
These instructions should be affixed to the burner or adjacent to the heating appliance.
Massachusetts Plumbing Board
G3-0904-16
Manufactured by Heat Wise, Inc.
28 Industrial Blvd. Unit I Medford, NY 11763
rev 2007-1

2
The SU-3 and SU-4 comes in many distinct model numbers, which reflect the listing agency, OEM
standard, the fuel, BTU range of the gas train and type of safety control originally supplied with the
burner. Check the model number on the label located on the cover of the control box for the
specifications of the burner.
Note: Gas trains supplied with the SU-3 and SU-4 are for specific firing ranges, as covered by
various codes and listing agencies. Firing this burner above the allowed firing rate will void the
warranty, and may result in a fire or explosion, causing property damage, personal injury or death.
Table 1 : SU-3 & SU-4 Models and Specifications
Model Range
(MBH)
Fuel Listing Gas Train Gas
Conn.
SU-3
U.S. and Canada 199 to 400
Natural Gas
And LP
VR 8305 ¾”
SU-4AN
U.S. and Canada
300 to 500 Natural Gas
Only
VR 8305M ¾”
SU-4N (H or F)*
Canada
300 to 550 Natural Gas
Only
Two VR 8305M
valves in parallel
1”
SU-4P (H or F)*
Canada
300 to 550 LP Only VR 8305M ¾”
SU-4N (H or F)*
U.S.
300 to 500 Natural Gas
Only
VR8305M
ANSI Z 21.17 compliant ¾”
SU-4P (H or F)*
U.S.
300 to 500 LP Only
VR8305M
ANSI Z 21.17 compliant ¾”
SU-4N (H or F)*
U.S.
300 to 550 Natural Gas
Only
U.L. 795** w/ low and high
gas pressure switches ¾”
SU-4P (H or F)*
U.S.
300 to 550 LP Only
U.L. 795** w/ low and high
gas pressure switches ¾”
* H=Honeywell control F= Fenwal control ** Also conforms to NFPA-86
Table 2: SU-3 & SU-4 Electrical Specifications
Primary Electric Input Secondary Electric Input Total Watts Total Amps
120 Volt
60 Hz
1 Ph
24 Volts 150 Max 3 or less

3
•Fuel: The SU-3 and SU-4 Burners will fire natural gas or LP. The maximum inlet pressure at
test port is 11” W.C. for both natural and LP gas.
•Length of Flame Tube: 5 ¼” or 14” (special order)
•Firing System: The burner operates as ON – OFF with a fixed air inlet shutter and proportional
head setting. (See the charts for approximate firing rates. In the field, they may vary)
•Blower Motor: 120 Volt/ 60 Hz/1 Ph, 1/6 HP PSC motor
•Burner Ignition: A separate external high voltage ignition transformer provides interrupted
ignition with 4 second safety timing to establish the flame.
•Air Flow Safety Switch: Diaphragm switch closes when the burner blower develops adequate air
pressure. Loss of air pressure causes the fuel valves to close immediately.
•Pre-Purge: Minimum 30 seconds is standard on burners.
•Gas Train: Below 400,000 BTU low and high gas pressure switches are optional. Above 400,000
BTU they are standard with gas leak shut off valve. (See the setting pressures from the table
given) Dual gas valves in the form of a combination valve or separate with built in pressure
regulator or separate with shut off valves are all part of the factory-assembled system. When
pressure switches are used, the power (120V) passes through each as a part of the limits; they will
trip power to the burner as soon as pressure increases or decreases to the system. See the pictures
below for common configurations of SU-3 and SU-4 gas trains. The same gas valve is used for
both natural gas and propane without any conversion kit.
Picture 2: Below 400 MBH Gas Manifold
Picture 1:U.L. 795
gas pressure switches
Gas Leak Test Cock
Picture 3: Dual Gas Valve – Canadian applications only

4
Warning: Should overheating occur, 1) shut off the manual gas shut off valve to control the
appliance; 2) DO NOT shut off the control switch to the blower
This power gas burner is designed to convert oil and/or coal fired boilers and furnaces to a gas-burning
appliance. The conversion must conform to local codes. In the absence of such codes, the American
National Standard Institute (ANSI) for the installation of gas conversion burners, Z21.8A-1990 and the
National Fuel Gas Code ANSI 223.1-1992 or current standards should be applied.
Two electrodes act as a sparker and a flame rod (See Fig. 1). Flame rectification by this flame
rod monitors the continued presence of the burner flame.
Fig. 1 Electrode and Flame Sensor Positioning
1/8” Spark Gap
3/16”
Projection of ceramic past retention plate
0.65”
AIR FOR COMBUSTION
If the boiler or furnace room is unusually tight, or if the house has a ventilation fan, it is
recommended that the combustion air be supplied to the furnace room through intakes from the outside of
the building. The intakes must terminate facing down in order to avoid obstruction from rain, snow,
leaves, etc. Openings must have one square inch of free area per 10,000 BTU input rate (see Example 1).
Refer to the QHT boiler manual for instructions and recommendations for installing louvers, etc.
Example 1: 350,000 BTU/hr firing rate
( )
(
)
2
2
35
/000,10
1
*/000,350 in
hrBTU
in
hrBTU =
1”

5
Chimney Requirements
The chimney should extend at least 3’ above a flat roof or the highest roof ridge (see Fig. 2) and
be free in a radius of 30’ of objects such as tree limbs, other buildings, etc, which may cause a down
draft. The chimney should be lined as required by the local Gas utility or local codes. Some utilities
require new chimney liners for all gas installations. Use a corrosion resistant chimney liner (approved for
gas service) of the same size as the vent pipe.
Fig. 2 Chimney and Fresh Air Dimensions
Installing the Burner
Install the burner on the unit and then tighten the nuts on the flange so that the burner is permanently
secured. Seal off any free openings with high temperature cement.
Picture 5: BODY FLANGE:
First, install the gasket and boiler flange to the boiler. For
heat exchangers with a square stud pattern, one allen screw on the
flange should be on the top, slightly to the right of the 12 o’clock
stud. The second screw should be on the left (slightly above the 9
o’clock position stud). Tighten all the nuts equally. Make sure that
the allen screws are backed out, to allow enough clearance. Then,
insert the SU-3/SU-4 gas burner into the boiler.
Once the burner is inserted and pushed all the way forward,
tighten the allen screw on the top of the flange. This screw MUST
go into the groove that is on the burner housing.
Tighten the second allen screw, located on the right side of
the flange. This screw should be tight.
Seal off any free openings with either high temperature cement or
high temperature silicone.

6
Gas Service and Pipe Capacity
Before connecting the burner to the gas supply, insure that the gas pipes and service meter are
large enough to permit the additional load of the gas burner (see Table 3).
Table 3: Pipe Capacity Table*( x 1,000 BTU’s)
Nominal diameter of pipe in inches
Pipe Length** 1” 1 ¼” 1 ½” 2”
15’
345 750
30’
241 535 850
45’
199 435 700
60’
173 380 610
75’
155 345 545
90’
141 310 490
105’
131 285 450 920
120’
120 270 380 850
150’
109 242 300 780
180’
100 225 225 720
* Using 0.6 Specific Gravity Gas and a Pressure Drop of 0.3” of Water Column
** Each 90
0
elbow counts as 3’ for the purpose of these calculations
Gas Piping to the Burner
It is advisable to run a separate gas line from the meter to the gas burner to avoid pressure drops.
Refer to the above Pipe Capacity table for the correct sizes. ALL PIPING MUST CONFORM WITH
LOCAL CODES. Use black steel pipe and malleable fittings (do not use cast iron parts) with a suitable
pipe dope which is resistant to liquefied petroleum gases.
Piping should consist of:
1. A shut off valve approximately 6’ away from the unit.
2. A 1/8” plugged NPT tapping for gas pressure measurement preferably on the manual shut off valve
(as shown or anywhere between the gas valve and the shut off value).
Note: The manual shut off valve and tapping are NOT part of the SU-4 Gas Burner. Please make
sure you conform to local and state codes.
3. A gas union.
4. A drip pipe.
Caution: The gas valve should not be subjected to more than ½” PSIG. Therefore, the burner
should be isolated during high-pressure gas leak tests. The appliance and its individual shut off
valve must be disconnected from the gas supply piping system during any pressure testing of that
system at test pressures in excess of ½ psig. The appliance must be isolated from the gas supply
piping by closing its individual manual shut off valve during any pressure testing of the gas supply
piping system at test pressures equal to or less than ½ psig.
.

7
Fig. 3 Gas Burner Piping*
*The dotted lines represent field installation.
Chimney Liner, Draft Regulator And Vent Pipe
Some utilities require new chimney liners for all gas installations. Use a corrosion
resistant chimney liner (approved for gas service) of the same size as the vent pipe. Use a
double swing draft regulator, listed by CSA or U.L. The vent pipe should extend only to (but
not beyond) the inside wall of the chimney. The draft over fire should always be positive.
Adjusting the Pressure Switches
Figure 4 demonstrates the possible positioning of pressure switches on the SU-4 gas train. Use the
figures in Table 4 to approximate the settings.
Fig. 4 Sample Gas Train #1

8
Table 4: Pressure Switch Settings
Gas Firing
Rate
MBH
Flame
Tube
Inlet Press.
T
P
Manifold Press.
T
M
T
M
> 50% T
M
+
∆P*
LPS
<1.5 x T
M
HPS
Nat. 300 5 ¼” 6.9” 3.3” 1.6+1=2.6” 3.3x1.5=4.9”
Nat 550 5 ¼” 5.5” 4” 2+1=3” 4x1.5=6”
Nat. 300 14” 6.9” 3.3” 1.6+1=2.6” 3.2x1.5=4”
Nat. 550 14” 5.5” 4” 3” 4”
LP 300 5 ¼” 8.6” 3.7” 1.85+1=2.85” 5.6”
LP 550 14” 9.2” 2.3” 2.2” 3.4”
* ∆P= Pressure drop. For this gas valve, ∆P= 1”. Refer to the literature for the gas valve for more
information on pressure drops.
Pressure Switch Settings
The high and low gas pressure switches must be set during installation (refer to Table 3 and Table 4). To
determine the setting of the low pressure gas switch (LPS), measure the manifold pressure (MP), inlet
pressure (IP) and the pressure between the valve (BV):
Initial setting of the High Gas Pressure Switch:
After the firing rate is determined, refer to the charts Table 3 or Table 4 on page 12 of this
manual. Multiply the manifold pressure necessary by 1.5 and set the High Gas Pressure Switch to reflect
that calculation.
Initial setting of the Low Gas Pressure Switch:
Divide the manifold pressure by 2 and add the pressure drop across the valve.
Example: Natural Gas at 340 MBH
Required Manifold Pressure= 2.7”
Pressure drop across Honeywell valve=1.0”
HPS = 1.5*2.7”=4.0”
LPS = (2.7”/2) + 1.0”=2.35”
For other valves, refer to the manual for that specific valve for the pressure drop.
Warning: After the burner has been adjusted so that the burner is operating properly, the pressure
switches must be readjusted.
•Using a monometer, measure the manifold pressure that was necessary to achieve the exact firing
rate necessary. Multiply the manifold pressure by 1.5. With the burner firing, use an analyzer
and slowly increase the gas pressure up to the new calculated high pressure cutoff point. If the
CO level reaches 400 ppm before the newly calculated setting, then at the point just before 400
ppm CO is reached is where the high gas pressure switch must be set.
•Reset the manifold pressure back to the correct setting.
•After the High Gas Pressure Switch is set, the recalculate the low gas pressure switch setting by
dividing the actual manifold pressure by 2 and adding the pressure drop across the valve. With
the burner firing use an analyzer and slowly decrease the gas pressure into the valve to the new
calculated low pressure cutoff point. If the CO reaches 400 ppm before the newly calculated
setting, then at the point just before 400 ppm CO is reached is where the low gas pressure switch
must be set.
•Reset the incoming pressure back to the correct setting.
If the combustion does not reach the 400 ppm mark at the set points, the burner can be left at those
settings. IMPORTANT: Any switch can be adjusted, as long as it meets both sets of criteria: Not
greater than 400 ppm CO and meets the appropriate calculation for the switch.

9
Adjusting the Firing Rate
See Fig. 6 below. Position D
1
represents the burner head all the way forward. By rotating the burner
head adjustment screw clockwise, the head can be moved back 0.5” (to position D
3
). Similarly, if the
head adjustment screw is turned counter-clockwise, the head is moved forward. At head position D
3
, the
SU-3/SU-4 gas burner fires at 300,000 BTU when the gas manifold pressure is 3.5” W.C. Adjust the air
shutter and use a combustion analyzer to set the burner to between 8.5% and 10.0% CO
2
for natural gas or
between 10.0% and 11.5% for LP gas. (See page 13 & 14 of this manual for further details on burner
operation). NOTE: The static pressure of the system may be within norm, but the pressure drop
when the system is running can reduce this greatly. Check the running pressure to make sure
there are no fluctuations in the pressure.
By adjusting the manifold pressure, it is possible to adjust the firing rate. Refer to Table 5.
Fig. 5 Adjusting the Firing Rate
Table 5: Various Settings for QHT/Biasi Boilers
Boiler B10/8 B10/9 SG/6 SG/7 B40/6 B40/7 B40/8
Burner SU-3 SU-3 SU-3 SU-3 SU-3 SU-4 SU-4
Firing Rate (Input)
272,000 308,000 279,300 330,000 323,000 426,000 529,000
Insertion
Full Full Full Full Full Full Full
Natural Gas
Manifold Pressure ( " of
W.C.)
1.7" 2.3" 1.7" 2.5" 2.4” 3.4” 3.8”
Head
1 1 4 3 1 7 20
Air
3.25 6.75 3.5 8.5 7.5 17 24.5
Propane/LP
Firing Rate (Input)
272,000 308,000 279,300 330,000 308,000 406,000 504,000
Manifold Pressure ( " of
W.C.)
1.3" 1.7" 1.4" 2.0" 1.9” 2.5” 2.5”
Head
1 2 4 3 1 7 18
Air
3.25 6.5 4.75 9.0 7.5 14.5 19.5

10
Electric Wiring
These gas burners are manufactured for use with 120 volt, 60 cycle, single-phase electric current.
The installation must comply and be grounded in accordance with the National Board of Fire
Underwriters and National Electric Code ANSI/NFPA No. 70-1987 (or the latest addition). All
applicable local codes should be followed as well.
Installation wiring should be wired through each limit control or interlock, while operating
controls (like the thermostat) should be treated as 24-Volt wiring. The burner has its own 24 Volt AC
power supply. Do not add a 24 Volt AC transformer for the burner wiring. Do not use the 24 Volt
transformer found on the burner to power other items in the heating system, such as thermostats, spill
switches, etc. See the sample wiring diagrams provided below:
Wiring Diagrams
Fig. 6 Wiring the SU-4 with a switching relay

11
SEQUENCE OF OPERATIONS
Honeywell S89F
1. Limits close.
2. Blower motor starts as the 24 Volt transformer powers the airflow switch.
3. Power from the airflow switch to the S89F control initiates 34 second pre-purge.
4. At the end of the pre-purge, the spark is energized for 4 seconds. At the same time, the 24 Volt transformer powers the gas valve, allowing the fuel to flow.
5. Within 4 seconds, the flame should be established and proved. The spark will shut off and the control will hold power to the gas valve until the limits open and
the burner stops firing.
6. If the flame is not established, the blower motor continuously runs.
7. To restart, power should be interrupted for five minutes. Then turn on the power to start this sequence again.
FIG. 8 Optional motor-off delay wiring
Note: This wiring diagram is included for reference as an option for field wiring of a
motor –off delay with the S89F control. Burners do not come equipped with this
option and require extra components to be purchased and installed according to code.

12
Commissioning the Burner
Once installed, a higher or lower firing rate can be achieved by raising or lowering the manifold
pressure by +/- 0.3”. Pressure changes can only be made when the burner is running. The typical
working manifold pressure for natural gas is 1.5 to 3.5 Inches of Water Column (“W.C.), or 1.0 to 3.0
“W.C. for propane. The maximum inlet pressure at the gas valve is 11 “W.C.; the minimum is 5 “W.C.
Refer to Chart 5 on page 9. NOTE: The static pressure of the system may be within norm, but the
pressure drop when the system is running can reduce this greatly. Check the running pressure
to make sure there are no fluctuations in the pressure.
Clock the meter to determine the firing rate. The firing rate should be +/- 3% of the heat
exchanger manufacturers’ specifications. Check the heat exchanger manual for further details.
The head is pre-set at the factory for OEM applications. Check your OEM manual for the proper
head setting for that oven. Using a combustion analyzer, check the CO
2
(or O
2
) and carbon monoxide
levels. Adjust the air as necessary (See below :)
Picture 6
Turning the Air Adjustment dial clockwise opens the air shutter and increases the air; turning the air
adjustment dial counter-clockwise closes the air shutter and reduces the air.
Adjusting the Burner
Using a combustion analyzer, check the following readings:
If CO
2
is greater than 9.5% (O
2
<3.5%); Open Air Shutter
If CO
2
is less than 8.8% (O
2
> 5%); Close Air Shutter
Carbon monoxide levels should be below 400 ppm; 100 ppm or less is ideal. Check local codes for
emissions requirements.
Note: if any adjustments are made, it is important to recheck the firing rate and combustion analysis.
LIGHTING INSTRUCTIONS
To light the SU-3/SU-4 Gas
Burner
1. Set the thermostat to the lowest
temperature
2. The control knob on the gas valve
should be in the “OFF” position for
at least five minutes.
3. Rotate the control knob counter-
clockwise to the “ON” position and
set the thermostat to the desired
temperature settings
Reset, if Flame Lockout Occurs
1. Turn the thermostat off, or turn the main power off
2. Wait five minutes
3. Turn the main power on
To shut the burner off
1. Rotate the control knob on the gas valve to the “OFF”
position
2. Set the thermostat to the lowest temperature
Head
Adjustment
Air
Adjustment

13
Burner Operation
Before turning the burner on, check for gas supply leaks. Check the wiring diagrams; install
manometers before and after the gas valve. Keep the observation port of the boiler or furnace open.
Follow the instructions on the nameplate of the burner to turn it on. Follow the sequence of operations
for the control (see pages 10 and 11). Record the readings below.
COMMISSIONING/TROUBLESHOOTING CHECKLIST
There are four factors that are needed to operate the gas burner:
____ 1. Combustion Air
____ 2. Electricity
____ 3. Gas Flow
____ 4. Combustion Analysis
1. Combustion Air
Check the air coming into the area where the burner is located.
____ 1. If the burner is in a large area that air can come into freely (i.e. an open basement for home heating
systems), then the air supply should be sufficient for the burner.
____ 2. If the burner is in an enclosed area (i.e. small room or closet) then fresh air must be supplied to the
burner. The intakes to the area must terminate facing down in order to avoid obstructions. The
total open free area must be 1 in
2
per 10,000 BTU input
Example 350,000 Btu/hr firing Rate
( )
(
)
2
2
35
/000,10
1
*/000,350 in
hrBTU
in
hrBTU =
When commissioning the burner, make sure the gas control knob is in the ”ON” position. Install
monometers at the inlet pressure tap and outlet pressure tap. Record the static incoming gas pressure.
Note: When checking manifold pressure, do not subtract burner housing pressure during valve-on delay .
When the burner lights off, record the running incoming gas pressure; the running incoming gas pressure
should never be below 5”. Note: this pressure drop should not be greater than 1”.
Check the manifold pressure from the outlet pressure tap. Refer to Table 5 on page 9 to make sure the gas
pressure is set for the appropriate fuel and pressure. If adjustments need to be made, remove the cap screw
and adjust the pressure regulator. Screwing the regulator clockwise will increase the manifold pressure and
counter
-
clockwise will decrease the manifold pressure.
Fig. 10 Side View of Front of Burner
Optimal place for manifold
readings. Loosen Screw and
attach manometer.
Lo

14
2. Electricity
Check burner wiring
____ 1. Check that 120VAC is coming into the burner
____ 2. Check that the burner is properly grounded using a ground wire
____ 3. Check the polarity to the burner is correct.
(To check polarity: Set a multimeter to VAC. Touch L1 to one of the probe tips and ground to the
other. If a voltage between 110 and 125 is shown then it has the correct polarity; if any other
reading is shown, then check the L2 wire. If the L2 wire shows a voltage between 110 and 125 is
shown then the polarity to the burner is reversed.)
3. Gas Flow
____ 1. Check that the capacity of the meter can meet the demand of the burner and all
other appliances
running off the meter.
____ 2. Check that the burner is on a direct pipe from the meter.
____ 3. Measure the total length of all the pipe and count the number of elbows (1 90
o
elbow=3 ft. of
pipe). Compare the total feet of pipe and the BTU demand using the chart on Page 5 to determine
the size of the pipe required.
____ 4. Check that the proper orifice is installed if needed.
____ 5. Check the gas pressure at the gas valve (line pressure). This pressure should be between 5” wc and
10” wc when the burner is not firing. Note: When checking manifold pressure, do not subtract burner
housing pressure during valve-on delay.
____ 6. With the burner firing the pressure drop on the supply side should not exceed 2” wc. If the
pressure drops and then surges back up, double check the piping because it means the pipes are
undersized.
4. Commissioning the Burner
____ 1. Check the head and air settings and start the burner.
____ 2. Use a combustion analyzer to check CO
2
and CO. CO
2
should be between 9% and 9.8% and CO
must be less than 400 ppm but we suggest less than 100ppm. If the CO
2
is greater than 9.8% then the air
should be opened to reduce the CO
2
; if the CO
2
is below 8%, then the air should be closed to increase CO
2
.
____ 3. Check the manifold pressure to verify that it is at the specified pressure.
____ 4. Clock the gas meter and check that the correct firing rate is achieved. If the firing rate is low, the
gas pressure should be increased slightly. If the firing rate is too high then the gas pressure should
be decreased. (Usually if the stack temperature is below 300F the firing rate is too low. If the
stack temperature is over 600F then the firing rate is usually too high or on rare occasions the heat
exchanger is blocked up)
Gas Input to Burner in ft
3
/hr *
Seconds 1/2 ft
3
1 ft
3
2 ft
3
5 ft
3
Seconds
2 ft
3
5 ft
3
10 180 360 720 1800 50 144 360
12 150 300 600 1500 55 131 327
14 129 257 514 1286 60 120 300
16 113 225 450 1125 65 111 277
18 100 200 400 1000 70 103 257
20 180 360 900 75 240
22 164 327 818 80 225
24 150 300 750 90 200
26 138 277 692 100 180
30 120 240 600 110 164
35 103 206 514 120 150
40 180 450 130 138
45 160 400
* For BTU/hr Natural gas multiply by 1000
For BTU/hr Propane multiply by 2500
____ 5. If the firing manifold has been readjusted, redo steps 2 and 4
____ 6.Check that the draft over-fire is positive

15
Use a combustion analyzer and record the readings below.
BURNER OPERATION: Record the Readings at Steady State
Draft over fire at steady state (should be Positive – refer to boiler manual)
Natural Gas CO
2
% = (8.5% to 10.0%) or O
2
% = (5.0% to 3.5%)
LP Gas CO
2
% = (10.5% to 11.5%) or O
2
% = (5.0% to 3.5%)
Gross Stack Temperature (350
o
F minimum, 450
o
F maximum)
NOx (If required)
Carbon Monoxide (CO) in PPM (less than 100 PPM ideal; should not
exceed 400 PPM Oxygen free)
Incoming Gas/LP pressure = “W.C. (minimum 5”, maximum 11”)
Manifold Pressure = “W.C.
Head Setting
Air Setting
Maintenance Instructions: TO BE FIXED/ATTACHED NEAR BURNER
At least once a year, a qualified service agency needs to be contracted for other than routine
maintenance.
1. The blower motor is the only moving part. It does not require lubrication, since the ball bearings
have been permanently lubricated.
2. The user should do periodic visual checks of the burner and the flame.
3. Laundry lint or dog and/or cat hairs should not go inside the blower. If they are seen, they
should be removed after disconnecting the power to the burner and cover parts should be
installed before starting the burner.
4. Keep the area around the conversion burner clear and free from combustible materials, gasoline,
and other flammable vapors and liquids.
5. No obstruction for the flow of combustion and ventilating air.
Trouble shooting:
There are three factors to operate the gas burner properly:
1. Electricity {(main Power 120V/60 Hz /1 Ph) ( secondary 24V)}
2. Gas flow (Incoming pressure should be 10” w.c. with proper gas line without pressure drop
during burner operation).
3. Combustion air.
Check these three items properly before proceeding in detail for other problems.
Condition Solutions
1. Burner motor runs and:
No flame after pre-purge & no fuel indicator (where
applicable)
Check 24V feed to airflow switch & after airflow switch to
control. Fix or replace the airflow switch. If there is no
secondary power, then replace the 24Vtransformer.
No flame, fuel indicator on (where applicable),
faulty ignition transformer or spark separately
Check ignition transformer, electrode, cracked electrode or
gap. Fix or replace.
Fenwal control defective after above tests. Replace
Burner locks out after 4 seconds
First, check ionization electrode, ionization cable (for
cracks) and boot. Fix as needed.
Polarity reversed Check power feed for broken polarity
Bad earth grounding Fix the ground wire
Gas pressure is too low Check the gas pressure and adjust to proper pressure
2. Pulsation at start
First, check the burner head location with respect to the end

16
of the flame tube. Adjust as necessary.
Gas pressure is too high. Use manometer and readjust the pressures.
Blocked Flue Check draft and clear flue of foreign materials.
3. Pulsation during operation
Burner is not correctly adjusted. Readjust with combustion analyzer.
The burner is dirty. Clean the burner.
Defective chimney Check and change if necessary with liners.
4. Burner locks out
Ionization current is too low. Check current. Minimum 0.8 micro amps. Check position of
ionization electrode and the condition of the cable.
5. The CO content is too high
Excess air is too high or too low. Adjust air shutter.
The gas holes are clogged. Clean them.
The fresh air intakes are too small. Check and readjust.
The burner head is out of position. Check and readjust.
6. Condensation in the heat exchanger
Firing Rate is too low. Increase the firing rate so that the stack temperature is 350
o
F
or HIGHER. Insulate the chimney.
ITEM PART PART # ITEM PART PART #
1 Blast Tube 1175-1701 17 Scale - Nozzle Line 1188-8501
2 Flange Gasket 10195-1 17A Scale - Air Regulation 1188-7801
3 Adjustable Flange 10195 18 24 Volt Transformer 2440VA
4 Front piece - Housing 19 Safety Control S89F
5 Rear piece – Housing 20 Plastic Cover Plate 11850001
6 Fan Wheel - 146 mm 1187-2601 21 Screw (Long Special) 1175-0702
7 1/6 HP PSC Blower motor D82132 22 Airflow Switch 6041A
8 Shielding Plate Housing 23 Ignition Electrode 1153-4704
9 Outside Air Boot (optional) 83296 24 Flame Rod 1153-4703
9A Silencer (optional) 11909-
60105
25 Retention head 1193-8501
10 Air Regulation Plate 1186-7401 26 Union 113-9101
11 Air Damper 1186-7501 27 Gas Valve VR 8305
12 Air Regulation Adjustment screw 1184-8401 Power On light 115-2001
13 Adjustment Screw – Nozzle Line 1191-2901 Fuel On Light 124-2001
14 Ionization Cable 1186-5805 Air light 124-2001
15 Ignition Transformer 2260-TW Adjustable Flange Ring 11726701
16 Cover Plate - Air Regulation 1188-7401
Low Pressure Gas Switch C6097B or
GML- A4-4-4
16A Cover Plate - Nozzle Line 1188-7302 High Pressure Gas Switch C6097A or
(GMH-A4-4-4