Midco Economite re4850ba Quick guide

Installation and Service Instructions

12 01

8471 24

Printed in U.S.A.

In the United States, Installation must

conform with local codes or, in the absence of local

codes, with Installation of the National Fuel Gas

Code, ANSI Z223.1-latest edition, from the American

National Standard Institute. Further reference should

be made to the recommendation of your fuel supplier.

In Canada,Installation must conform with local

codes or, in the absence of local codes, with

Installation Codes for Gas Burning Appliances and

Equipment, CGA Standard CAN/CGA 1B-149.

Further reference should be made to the

recommendation of your fuel supplier.

WARNING: Additions, changes, conversions,

and service must be performed by an authorized

MIDCO representative, service agency, or the fuel

supplier. Use only MIDCO specified and approved

parts.

INSTALLER: Inform and demonstrate to the user

the correct operation and maintenance of the gas

utilization equipment. Inform the user of the

hazards of storing flammable liquids and vapors in

the vicinity of this gas utilization equipment and

remove such hazards. Affix this manual and

associated literature adjacent to the burner. CODE

COMPLIANCE IS THE SOLE RESPONSIBILITY OF

THE INSTALLER.

USER: Retain this manual for future reference. If

other than routine service or maintenance as

described in this manual and associated literature

is required, contact a qualified service agency. DO

NOT ATTEMPT REPAIRS. An inadvertent service

error could result in a dangerous condition.

Economite

RE4850BA / RE4700BA

RE4400B / RE4400BA

Gas Burners

BURNER MODEL

BILL OF MAT'L

NUMBER

SERIAL CODE #

WIRING DIAGRAM

FOR SERVICE CONTACT:

Name

Address

Phone

Date of Installation

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 switch;do not use any

phone in your building.

?Immediately phone your gas supplier from another

building. Follow the gas supplier’s instructions. If

you cannot reach your gas supplier call the fire

department.

Installation and service must be performed by a

qualified installer, service agency or the gas supplier.

The following terms are used to identify hazards, safety precaution of special

notations and have standard meanings throughout this manual. They are printed in all capital letters using a bold type face

as shown below, and preceded by the exclamation mark symbol. When you see the safety alert symbol and one of the

safety information terms as shown below, be aware of the hazard potential.

DANGER: Identifies the most serious hazards which will result in severe personal injury or death.

WARNING: Signifies a hazard that could result in personal injury or death.

CAUTION: Identifies unsafe practices which would result in minor personal injury or product and property damage.

WARNING: If the information in these instructions

is not followed exactly, a fire or explosion may result,

causing property damage, personal injury or death.

Midco International Inc.

4140 West Victoria St. - Chicago, Illinois 60646

tel 773.604.8700 fax 773.604.4070

web www.midco-intl.com e-mail [email protected]

Quality Designed for Proven Performance

Part 1 Installation

Specifications 1The ECONOMITE Models RE 4850BA, RE4700BA, RE4400B and RE4400BA burners

with intermittent spark ignited pilot are adaptable to most gas utilization equipment, including

gravity and forced circulation furnaces and boilers. They are particularly recommended for

firing horizontal or downdraft equipment since no draft is required to maintain a pilot. Power

burner design makes them perfectly suited for oil burner replacement, including rooftop and

industrial applications.

AIR DELIVERY (Approximate Air Delivery at Zero Draft)

RE 4850BA, RE4700BA, RE4400B AND RE4400BA -125 SCFM2

FIRING RATE (NATURAL OR PROPANE )3

RE 4850BA RE4700BA RE4400B RE4400BA

MAXIMUM MBH4850 700 400 400

MINIMUM MBH 280 230 132 132

GAS SUPPLY PRESSURE REQUIRED

NATURAL ............................................................. 7.0" to 14.0" W.C.

PROPANE ............................................................ 5.0" TO 14.0" W.C.

TUBE DIAMETER.................................................................. 4"

TUBE LENGTH...................................................................... 9"

RECOMMENDED COMBUSTION CHAMBER SIZE (AT MAX. BTU/HR)

RE 4850BA RE4700BA RE4400B RE4400BA

WIDTH 15" 15" 10" 10"

LENGTH 30" 25" 16.5" 16.5"

ELECTRICAL SUPPLY......................................120 VAC...........60 Hertz5

IGNITION CONTROL MODULE VOLTAGE ....... 24 VAC

FLAME SAFETY....Electronic Flame Safety with Spark Ignited Pilot and 100% Shut-Off6

TABLE 1: Burner Specifications

1. Standard burners are shipped as NATURAL gas models. Contact your Midco dealer for

PROPANE gas burners.

2. SCFM = Standard Cubic Feet / Minute.

3. All Ratings Based on 1000 BTU/Cu. Ft. NATURAL. Derate burner for altitude over 2,000

feet by 4% for each 1,000 feet above sea level.

4. 1 MBH = 1,000 BTU/hr.

5. For 50 Hertz applications the RE4850BA, RE4700BA, RE4400B and RE4400BA will be derated

by 20%. Contact the factory for details. NOTE: Burners rated for 50Hertz are not UL Listed.

6. See Section XII of Operational Sequence

CAUTION: The ECONOMITE Models RE4850BA, RE4700BA, RE4400B and

RE4400BA Burners are not intended for outdoor installation and must be protected

from excessive moisture. Provide adequate clearance for service and proper

operation.

If the former automatic oil burner gave trouble-free operation, it is probable that the heating

plant area has sufficient infiltration of air for combustion and dilution of flue gases.

Nevertheless, the area must be checked.

?Open basement or utility areas of normal construction, without storm windows or tight

doors, will generally allow sufficient air infiltration. However, if the heating plant is located in

a tight or separate room, ventilation to an open area as described above will be required.

Install two permanently open grills, each sized on the basis of one square inch free area per

1,000 BTU (but not less than 100 square inches) of the total input rating of all gas utilization

equipment in the combined space. One grille should be located within 12 inches of the

ceiling, the other within 12 inches of the floor.

?If the heating plant is located in an area of unusually tight construction, or if an exhaust

fan, kitchen ventilation system, clothes dryer and/or fireplace is installed in the building,

provisions must be made for an outside air supply near the heating appliance area. Install

permanently open grills sized at not less than one square inch free area per 4,000 BTU of

burner input. When ventilating through horizontal ducts, grills should be sized at not less

than one square inch free area per 2,000 BTU of burner input. In any case, the minimum

dimension of rectangular air ducts shall not be less than 3 inches.

?In Canada, for detailed ventilation requirements, refer to standard CAN 1-B149.1 or .2

and/or local codes.

Part 1

Installation

IVentilation

?Clean the gas utilization equipment combustion chamber, heat exchanger interior, and flue

connections. Remove all adhering tars, scale, dirt and soot. Inspect for actual or potential

leaks.

?Cement all joints, including those in the heating appliance base and around the door

frames, to prevent leakage into, or out of the combustion chamber.

?The access or firing door should open easily to relieve pressure. If positive latches exist,

they should be modified to permit easy opening; a spring loaded door holder is

recommended.

?On all boilers, make certain the pressure relief safety valve is in good operating condition.

A combustion chamber liner is normally required to protect non-heat transfer surfaces and to

provide a radiant bed for rapid heat transfer to the primary surfaces of the heat exchanger.

In most cases the existing chamber liner can be used, if in good condition.

?In the case of wet base boilers, where the entire firing chamber is comprised of heat

exchange surfaces and no chamber liner was provided for oil firing, a liner is usually not

required for the ECONOMITE. However, a liner or target wall may be necessary if the firing

chamber is unusually short, in order to avoid excess flame contact on the heat exchanger

walls or flueways.

?If a built up chamber liner is required, use 2,300°F minimum insulating material.

?The burner tube, or the stainless steel sleeve that is included with the burner, must be

sealed air tight into the combustion chamber opening with refractory material. The sleeve is

preferred as it is designed to properly locate the end of the tube relative to the inside wall of

the combustion chamber, and to permit burner removal without breaking the seal.

CAUTION: In no case should the burner tube be allowed to extend into the

chamber proper; it must be set at least 1" short of the inside surface because high

combustion chamber temperatures will cause premature pilot, electrode, burner tube

and sleeve deterioration.

WARNING: BURNER MUST BE MOUNTED IN ORIENTATION SHOWN IN

FIGURES 1 AND 2. ANY OTHER MOUNTINGS MAY CAUSE A DANGEROUS

CONDITION, AND WILL VOID BURNER WARRANTY AND AGENCY APPROVALS. NON-

STANDARD ARRANGEMENTS MAY BE AVAILABLE FOR SOME MODELS. CONSULT

FACTORY FOR DETAILS IF REQUIRED.

?Before permanently setting the burner in place, check that the main burner and pilot ports

are free of foreign materials, and also that the spark electrode assembly has not been

damaged or displaced. See Figures 7A and 7B.

WARNING: The chimney shall be inspected for unsafe conditions such as

deteriorated masonry and excessive soot or other blockage or potential blockage.

Installation must conform with local codes or in the absence of local codes with NFPA,

ANSI Z223.1 latest edition.

WARNING: The vent connector shall not be connected to a chimney already

venting solid fuel burning equipment, an incinerator or an open fireplace.

?The Vent Connector shall be made of non-combustible, corrosion resistant material

capable of withstanding the vent gas temperature produced by the gas utilization equipment

and of sufficient thickness to withstand physical damage.

?The Vent Connector shall be as short as possible. The entire length shall be readily

accessible for inspection, cleaning, and replacement.

?The length of horizontal uninsulated Vent Connector between the chimney and a single

gas utilization equipment shall not exceed 75% of the the height of the chimney above the

connector, or 100% if the Vent Connector is insulated.

Part 1

Installation

Continued

Part 1 Installation

II Preparation of

the Gas Utilization

Equipment

III Combustion

Chamber

IV Chimney, Vent

Connector and

Draft Control

Figure 1: Dry Base Boiler with Combustion

Chamber Liner (Warm Air Furnace

Construction is Similar)

Figure 2: Wet Base Boiler with Unlined

Combustion Chamber

?The Vent Connector shall be installed so as to avoid turns or other construction features

which create excessive resistance to flow of vent gas. It shall be installed without any dips or

sags and shall slope upward at least 1/4" per foot.

?A manually operated damper shall not be placed in the Vent Connector or chimney of

any gas utilization equipment.

?The Vent Connector shall be

firmly attached to draft hood outlets

and flue collars. Joints between

sections of connector piping shall

be fastened by sheet-metal screws

or other approved means. The Vent

Connector shall be supported for

the design and weight of the

material employed to maintain

clearance and prevent physical

damage and separation of joints.

?A draft hood or a barometric

draft regulator shall be installed in

the same room or enclosure as the

equipment in such a manner as to

prevent any difference in the

pressure between the hood or

regulator and the combustion air

supply (see Figures 3 and 4). In no

case shall the relief opening of the

draft hood or barometric draft

regulator be located at a point lower

than the top of the highest flue

passage in the equipment.

?Gas utilization equipment requiring controlled draft may be equipped with a listed double

acting barometric draft regulator, if approved by local codes (see Figure 4).

?A device which will automatically shut off gas to the burner in the event of sustained

backdraft is required. It shall be of the listed manual reset type and installed and adjusted by

a qualified service technician in accordance with the manufacturer’s instructions.

?Refer to gas utilization equipment manufacturer for recommended vent connection

requirements.

Part 1

Installation

Continued

Part 1 Installation

Figure 3: Recommended Locations for Draft Hoods

Figure 4: Location for Barometric Draft Regulators

Note: Figure 3 and 4 :

Used by permission of the copyright holder.

IV Chimney, Vent

Connector and

Draft Control

Continued

CAUTION:Refer to wiring diagram located on the inside of the burner housing

cover or above wiring diagram.

Installation wiring and grounding to the burner must conform to local codes, or, in their

absence in the United States to National Electric Code, ANSI/NFPA No. 70 latest edition;

in Canada, to Canadian Electrical Code Part 1, CSA Standard C22.1

?Use copper wire not less than 14 gage for line voltage wiring. Hook up to a dedicated line

with an on-off disconnect switch and a minimum 10 Amp breaker.

?The frame of the burner should be well grounded. Normally the piping and/or electric

conduit will provide sufficient grounding. However, a ground lug is located in control box for

positive grounding where insulated pipe couplings are used or where any doubt exists

regarding grounding sufficiency.

?Confirm that the polarity is correct—hot wire to strip terminal L1, neutral L2—and that the

neutral line is not subject to induced low voltage (check L2 to earth ground) from other

equipment, as that can cause the Ignition Control Module to malfunction.

?Each installation must include suitable limit control(s). Existing oil burner combination

operating and limit controls are normally NOT SUITABLE for gas burner use.

?Connect motors used on forced air furnace fans or boiler pumps to a combination limit

control and switch.

?Set the thermostat heat anticipator for the total current draw handled by the thermostat.

The current draw of the ECONOMITE 24V operating circuit is 0.9 amps.

CAUTION: Label all wires prior to disconnection when servicing controls.

Wiring errors can cause improper and dangerous operation. Verify proper operation

after servicing.

CAUTION: The available gas pressure should be within the limits shown in

SPECIFICATIONS section. Excessive pressure may damage electric valves, regulators

and manual valves. If the supply pressure exceeds the 14.0"W.C. maximum, a suitable

high pressure regulator must be installed between the Main Manual Shut-Off Valve and

burner shut-off valve as shown in Figure 5.

Part 1

Installation

Continued

Part 1 Installation

VElectrical

VI Piping

Wiring Diagram

Capacities shown are for a

total pressure drop of

0.3"W.C. For 0.5"W.C.

pressure drop, multiply

capacity shown by 1.3 .

Propane capacities shown

are for a total pressure drop

of 0.5” W.C. For higher

permissible pressure drops,

consult your gas supplier.

Table 2: Schedule 40 NPT

Pipe-Capacity Chart

200

590

400

1075

900

275

200

500

450

1040

650

190

150

360

325

750

475

150

400

275

730

600

900

Pipe

Size

3/4

1 1/4

1 1/2

Natural

Propane

Natural

Propane

Natural

Propane

Natural

Propane

100

160

300

275

630

400

975

Approximate Capacity -MBH

Pipe Length

Type

of Gas

?The burner gas supply piping should branch off from the main line as close to the gas

meter as possible. Do not connect to the bottom of a horizontal section. Use new black pipe

and malleable fittings free of cutting and threading burrs or defects.

?Provide a sediment trap, union and 1/8" pressure tap in piping close to burner as shown

in Figure 5.

?Use pipe joint compound approved for use with Liquid Petroleum Gases.

?Piping must also comply with your local codes.

?To obtain the maximum firing rate of the burner, the gas supply piping must be sized to

provide a minimum of 7.0"W.C. pressure to the inlet of the upstream automatic safety shut-

off valve when the burner and all other gas utilization equipment are on. The pilot regulator

can be mounted in any position, the main regulator, if equipped, should be mounted upright

and in a horizontal run of pipe.

CAUTION: Because it is difficult to accurately control pressure during supply

pipe leak testing, it is recommended that all low pressure (14.0"W.C. max.)

components, both main and pilot, be disconnected during testing. Exposing low

pressure regulators and valves, including manual valves, to pressures over 1/2 PSIG

(14.0"W.C.) will cause damage and void all warranties.

DANGER: Explosion hazard.

Do not use oxygen for pressure testing.

An explosion could occur during initial start up.

??If the burner piping must be rearranged because of space limitation, be sure to carry out

the general arrangement shown in Figure 5. Install the combination valve (RE4700BA,

RE4400B & RE4400BA only ) in any position except up-side down.

Part 1

Installation

Continued

Part 1 Installation

RE4400B and RE4400BA

UL, Valve Train Assembly 24VAC

VI Piping

Continued

Figure 5: Piping Diagram

Part 1

Installation

Continued

Part 1 Installation

RE4850BA UL, Valve Train

Assembly 24VAC

Figure 5: Piping Diagram (Continued)

?When the burner is installed in the vestibule of jacketed equipment, it is recommended that

the Automatic Safety Shut-Off Valves be left adjacent to the burner within the vestibule and the

Main Manual Shut-Off Valve be installed outside.

?Run full size pipe or tubing from regulator vent openings to outside of building. Provide no

traps in the vent lines and terminate away from all doors and windows; also make provisions

for keeping rain and foreign objects from entering the vent piping.

?When high supply gas pressure is encountered, as in the case in many industrial plants, the

gas line size can be reduced to allow for a greater pressure drop; however, the size must be

sufficient to deliver burner rating pressure.

CAUTION: High gas pressure supply lines require the proper pressure reducing

regulators. Install a high pressure regulator of the Tight Shut-Off type upstream of the

low pressure regulator. Sized for main gas input, and suitable for the minimum flow

regulating capacity of the pilot.

?The high pressure regulator must be adjustable to 14" W.C. outlet pressure.

?When the gas supply line is about to be put into service it must be tested to insure that it is

gas tight. Use air or inert gas under pressure and test with soap and water to locate leaks.

?Before gas is turned onto the system, a check must be made to see that there are no open

fittings and to make sure the burner main and pilot manual valves are closed.

?After checking for leaks, purge the gas line up to the burner inlet. Purging the air from the

gas supply line at this step will expedite the first light-off.

NOTE: If there is more than 1.0" W.C. differential in the inlet pressure to the burner compared

to when all other gas utilization equipment are off, refer to Section VI.

Burners are approved for use with NATURAL gas or PROPANE gas and should be used only

with the gas specified on the rating plate.

?The gas input should be set at the heating rate determined by the building heat loss and/or

heating plant survey, but not exceeding the rated maximum input of the gas utilization

equipment or Economite burner.

WARNING: Ignition is automatic. Make spark observations into combustion

chamber only with Main and Pilot Manual Shut-Off Valves closed. Confirm that gas

utilization equipment does not contain any accumulated gases. Purge as described in

step 3 below.

CAUTION: Cover plates, guards, and enclosures must be maintained in place at

all times except during maintenance and service.

1. Check the burner piping and valves for gas leaks by applying a weak liquid soap

solution to unions and joints with the gas supply on. Leakage will be indicated by the

appearance of soap bubbles. Locate and correct all gas leaks before proceeding.

WARNING: DO NOT USE OPEN FLAME.

2. Purging the air from the gas supply line at this step will expedite first light-off.

IMPORTANT: Purge outside the building. Do not purge into the gas utilization

equipment.

3. To purge the gas utilization equipment and chimney of any accumulated gases, turn

main Manual Gas Cock OFF, close Pilot Manual Shut-Off Valve, turn burner power on,

and set operating control to ON or thermostat to call for heat. Let the blower run long

enough to accomplish four combustion chamber volume air changes, but not less than

five minutes.

CAUTION:Make sure that the capacity range of the burner, manifold pressure,

and the combustion air shutter setting are suitable for capacity rating of the gas

utilization equipment. Refer to Section VIII and Table 3.

4. RESET the Ignition Control Module by setting the operating control to OFF or the

thermostat below room temperature for at least 30 seconds. See Section XII.

5. Confirm that Main and Pilot Manual Shut-Off Valves are open. Turn main Manual Gas

Cock ON.

6. Turn operating control to ON or set thermostat above room temperature. After the pre-

purge is complete, the pilot should ignite. Whenever the burner pilot fails to light during

the ignition trial, or if the flame is lost during the burner run and is not reestablished

within 15 seconds after the pre-purge, the Ignition Control Module will shut off the

Automatic Safety Shut-off Valves and LOCK OUT.To RESET the Ignition Control Module

Control for restart, de-energize the Ignition Control Module by setting the operating

control to OFF or thermostat below room temperature for at least 30 seconds. If burner

still fails to light, turn it off and repeat from step 4 above. Then if necessary, refer to the

TROUBLE CHART to isolate the problem.

WARNING: Repeated unsuccessful attempts to light will result in accumulated

gases in gas utilization equipment and chimney. To prevent these gases from

reaching an explosive level, periodically purge the gas utilization equipment and

chimney as described in step 3 above.

Part 1

Installation

Continued

Part 1 Installation

VII Main Gas

Input Selection

VIII Initial Start-

up /Adjustment

VI Piping

Continued

Part 1 Installation

VIII Initial Start-

up /Adjustment

Continued

RE4850BA

RE4700BA

2.8

2.5

4.1

3.4

2.8

2.3

3.4

0.3

0.422

0.358

0.290

0.422

3.5

3.0

3.3

3.2

2.7

2.9

2.3

0.4

0.688

0.563

0.500

0.422

0.688

700

650

600

550

500

450

400*

233

RE4400BA

Table 3: Capacity and Preliminary Gas Settings

1. Adjust the main regulator to vary the manifold gas pressure and burner input within the range shown.

Do not exceed pressure as listed in Table 3, under any circumstances. Use combustion readings (CO

or O2) and a flow meter to determine exact inputs.

*Orifice Size and approximate manifold gas pressure setting: as shipped. Air shutters are set at full

open (Note: RE4400B and BA full open is at the stop on mark 3.2).

NOTE: For LP Conversion kit contact the factory

DATA FOR TABLES IS APPROXIMATE AND BASED ON “0" OVERFIRE PRESSURE AT SEA LEVEL

2.4

2.5

2.7

2.8

2.4

3.9

3.3

2.7

2.2

3.3

0.15

0.688

0.563

0.500

0.422

0.358

0.290

0.688

3.5

3.1

2.7

2.8

2.4

2.8

3.15

2.4

2.6

4.3

0.4

No Orifice

0.688

0.563

0.500

0.422

0.358

No Orifice

Input

MBTU/HR1

Orifice

Size

(Inches)

Natural Gas

Natural Gas / Propane Gas Orifice Size and Pressure Settings

Manifold

Pressure

("W.C)

Orifice

Size

(Inches)

850

800

750

700

650

600

550

500

450*

400

280

Propane Gas

Manifold

Pressure

("W.C)

3.5

4.65

4.15

4.75

2.8

0.45

0.358

0.290

0.261

0.219

0.358

4.7

3.6

2.7

3.3

3.5

0.6

No Orifice

0.358

0.290

No Orifice

400

350

300

250*

200

133

Letter

Stamp

Letter

Stamp

RE4400B

2.8

3.6

3.1

3.2

2.1

0.3

0.358

0.290

0.261

0.219

0.358

4.3

3.3

2.4

2.9

2.8

0.6

No Orifice

0.358

0.290

No Orifice

400

350

300

250*

200

132

Part 1

Installation

Continued

7. To make a preliminary setting of the burner input, determine the manifold gas pressure

required from Table 3 and adjust the Main Gas Pressure Regulator accordingly. See

Section XI.

8. To determine the firing rate for NATURAL gas, accurately time test dial for the number

of seconds for one revolution and use the following formula. All other gas utilization

equipment must be off. 3600 x test dial size x BTU value = BTU/Hr.

No. of seconds for one rev. test dial

Then divide by 1,000 for MBH value.

Example: 3600 x 1 x 1000 = 360,000 BTU/HR = 360 MBH

9. Check the operation of the burner; start and stop it several times with the thermostat

or operating control.

10. With the burner running, check the operation of all limit and associated controls.

11. Perform the following final adjustments for combustion and flue gas temperature. Take the

flue gas samples and temperature immediately ahead of the draft control.

A. The flue gas temperature should be above 325°F but not exceeding 550°F.

Excessive flue gas temperatures will result in low efficiencies. Low flue gas

temperature may cause excessive condensation. Reset gas input, if necessary, to

adjust stack temperature.

B. Make the final setting of the combustion air shutter by checking the flue gases

with an ORSAT or similar combustion testing instrument. The carbon monoxide

content should conform to local codes, or in their absence, to the level specified

in the United States or Canadian Standard referenced on the front cover of this

Part 1

Installation

Continued

Part 1 Installation

VIII Initial Start-

up /Adjustment

Continued

Figure 7A: General Assembly for RE4850BA, RE4700BA and RE4400BA

manual; and the carbon dioxide content should be approximately 9.5% for

NATURAL or 12% for propane , or within the limits prescribed by local codes.

12. Check the draft control to make sure there is no spillage of flue products into the room.

13. FILL OUT THE INSTALLATION ADJUSTMENT DATA TAG and affix to the burner or

gas utilization equipment.

NOTE: For subsequent normal starting and shut off procedure, refer to CONSUMER

INSTRUCTIONS, located in part 3 of this manual,or to the instruction plate mounted

on the burner.

PART 2 SERVICE

DANGER: Do not tamper

with the unit or controls. If trouble

occurs contact the installing

contractor, service agency, or fuel

supplier. See front cover.

DANGER: Be sure that the

main and pilot manual Shut-Off

Valves are closed and the burner

power supply is turned off before

removing any parts for service.

CAUTION: Cover plates,

guards, and enclosures must be

maintained in place at all times

except during maintenance and

service.

Figure 7B: General Assembly for RE4400B

Part 1

Installation

Continued

Part 2

Service

6000

3.0”

4.5”

W.C.

Model

RE 4850BA

RE 4700BA

RE 4400B

RE 4400BA

0.055”

Table 4: Pilot Specifications

Gas

Orifice

Diameter

#54

Wire Drill

Approx.

Capacity

BTU/Hr.

Pilot Gas Pressure

2.5”

3.5”

W.C.

Natural Propane

Part 1 Installation

VIII Initial Start-

up /Adjustment

Continued

Part 2 Service

The pilot is of the premix, blast type. The full force of blower air is brought into the mixing tube

where the proper amount of gas is added through the pilot orifice. This mixture is discharged

through the pilot. The mixture provides the flame that contacts the flame sensing rod and also

ignites the main gas.

CAUTION: Do not indiscriminately increase pilot orifice size. Pilot troubles are rarely

cured in this manner and new troubles may be created.

?Under normal conditions, with a slight negative pressure in the combustion chamber, pilot

operating pressures should be set as indicated in Table 4.

?Some conditions which may require a change from the normal setting include: extremely long

tubing connections between the regulator and pilot solenoid, high negative or positive

combustion chamber pressure, actual air shutter setting and altitude extremes.

?Do not subject the pilot to an inlet pressure over 14.0"W.C. See Section VI PIPING for high

pressure gas.

?To adjust outlet pressure, remove the seal cap for access to the adjusting screw. Turning the

screw clockwise will increase outlet pressure, counter clockwise will decrease outlet pressure.

?The spark rod for a natural gas burner is welded to a round 1/2” perforated retention plate.

(The spark rod for a propane gas burner is welded to a round 1/2” solid retention plate.)

CAUTION: Make sure that the natural gas burner has the correct spark rod

retention plate before operating the burner. See “Replacement Parts Lists” if replacement

is needed. The 1/2” retention plate is centered in the 3/8” Tee pilot and is positioned so the high

tension voltage will arc to the inside of the 3/8” Tee pilot.(See Figure 7A and 7B).

?The flame sensing rod must be positioned as shown in Figures 7A and 7B so that the Ignition

Control Module will detect a proper flame.

?Both the spark and flame rods are current carrying conductors and, along with their

connecting wires, must be kept free of contact with conductive metal parts of the burner. Rod

insulators and wire insulators should be clean, dry and free of cracks.

?Both the spark and flame rods are made from heat resistant alloys and can be expected to

have a long service life. They should be routinely inspected, however, for corrosion or loss of

metal.

?The pilot air tubing must be kept free of kinks or inside obstructions and must be positioned

per Figures 7A & 7B, otherwise air flow could be reduced and adversely affect the pilot flame.

CAUTION: BEFORE SERVICING, mark with a scribe line or measure opening of

air controlling shutter, so that it can be reset to its original position following servicing.

?Cleaning of the blower wheel is usually the only service required. Need for cleaning is

indicated if the character of the flame indicates a deficiency of air. Motor cooling air vents (if

present) should also be cleaned at this time.

?The motor and wheel are removed as an assembly. Disconnect the motor wires from the

motor terminal strip. Disconnect the motor conduit from the motor and remove the mounting

bolts.

?The burner is equipped with a diaphragm type air pressure switch so as to prevent the burner

from firing if the blower wheel is not running at its operating speed. When the motor is off there

is no air pressure present to activate the pressure switch and in turn there is no power flow to

the Ignition Control Module.

Figure 6: Motor / Blower Assembly

Part 2

Service Continued

XMotor Blower

Interlock

IX Pilot

Part 2 Service

?To make a specific test of the interlock circuit:

1. Turn burner power OFF.

2. Turn Manual Gas Cock OFF.

3. Disconnect the motor wire from the terminal strip to keep the motor off.

4. Turn burner power ON and set the operating control to ON or thermostat to call for

heat. Verify there is 120VAC line voltage by using a multimeter. Check for 24V

between the Ignition Control Module 24V and 24V GND terminals.

A. No voltage: Interlock circuit OK.

B. Voltage present: check that the switch is wired properly or check switch

operation. Replace if switch tests bad.

?Should replacement or service be required, valve manufacturer's instructions must be

followed as outlined in their information sheet.

?Outlet pressure settings must be checked while the gas is flowing.

?To adjust outlet pressure, remove the seal cap for access to the adjusting screw. Turning the

screw clockwise will increase outlet pressure, counter clockwise will decrease outlet pressure.

?The RE4400B / RE4400BA / RE4700BA / RE4850BA operate when power is applied to L1

and L2 through a safety or operating control. With power applied to L1 and L2 the blower

motor starts. Once the diaphragm airflow switch proves blower operation, power is applied to

the S8680J Ignition Module. The S8680J Ignition Module provides prepurge of 30 seconds,

ignition sequence timing, flame sensing and the switching of the gas valves. If the flame

signal is above 2 DC micro amps the gas burner will remain in operation until a safety or

operating control opens the circuit to L1 and L2. For a more thorough explanation of the

Honeywell control refer to the literature provided with the power burner. For startup

information see section VIII.

?For operation characteristics, maintenance, and service procedures, refer to manufacturer's

literature provided with burner.

?To check the flame signal on the gas burner you will need a DC micro amp meter. Install

the meter probes in series with the flame rod wire and the sense terminal on the control

board. Turn on the gas burner and observe the reading on the micro amp meter. If the flame

signal is above 2 DC micro amps the gas burner will continue to operate. If the flame signal

is below 2DC micro amps increase or decrease the pilot gas pressure by adjusting the pilot

gas pressure regulator as shown in Figure 5 clockwise to increase gas pressure and

counterclockwise to decrease gas pressure. See Table 4 for the correct pilot gas pressure

settings. Gas burner flame signal will vary for all applications and adjustments should be

made to the pilot gas pressure regulator and pilot flame signal before the main gas valve is

energized. To de-energize the main gas valve remove the wire connected to the MV terminal

on the S8680J Ignition Control Module.

Special equipment, either factory or contractor installed, may cause variation in the procedures

and descriptions given in this manual.

Consult the OEM's manual to identify the differences in the information.

The major difference for the CUL version of the RE4850BA, RE4700BA, RE4400BA and

RE4400B is the French / English specification plate, French / English manual and the firing

valve for the pilot line.

XI Valve Train

XII Sequence of

Operation

XIII S8680J

Ignition

Control Module

Part 2

Service Continued

XV Special

Equipment

(OEM Versions)

XIV Ignition

Control Module

XVI Canadian

Specifications

XMotor Blower

Interlock

Continued

Part 3 Maintenance

CONSUMER INSTRUCTIONS

?Keep the area around the burner clear and free of combustible material, gasoline or other

flammable liquids or vapors. Do not obstruct burner air openings or ventilation grills for

combustion air.

?The motor features permanently lubricated ball bearings and requires no maintenance.

WARNING: If any flame is observed when the burner is on standby, or if the

ignition spark or valve operator is heard to come on before the motor reaches

operating speed, immediately turn off the manual gas control and burner power. A

dangerous condition has developed and must be corrected. CONTACT A QUALIFIED

SERVICE TECHNICIAN FOR CLEANING, READJUSTMENT OR REPAIR.

?Check that the pilot ignition spark does not come on before the motor reaches operating

speed. If it does, the air switch is defective and must be replaced. (See Section X, Motor /

Blower Interlock).

LIGHTING INSTRUCTIONS

1. SET OPERATING CONTROL TO OFF OR THERMOSTAT BELOW ROOM

TEMPERATURE.

2. TURN MANUAL GAS COCK ON.

3. TURN BURNER POWER ON.

4. SET OPERATING CONTROL TO ON OR THERMOSTAT TO CALL FOR

HEAT.

5. IF THE PILOT FLAME IS NOT PROVEN WITHIN 15 SECONDS, AFTER THE

PRE-PURGE, THE IGNITION CONTROL MODULE WILL SHUT OFF THE

AUTOMATIC SAFETY SHUT-OFF VALVES AND LOCK OUT. IF THE PROOF

OF FLAME IS LOST DURING BURNER RUN AND THE PILOT IS NOT RE-

ESTABLISHED WITHIN15 SECONDS AFTER THE PRE-PURGE, THE

PRIMARY SAFETY CONTROL WILL SHUT OFF THE AUTOMATIC SAFETY

SHUT-OFF VALVES AND LOCKOUT. TO RESET FOR RESTART, DE-

ENERGIZE THE CONTROL BY SETTING THE OPERATING CONTROL TO

OFF OR THERMOSTAT BELOW ROOM TEMPERATURE FOR AT LEAST 60

SECONDS.

6. REPEAT STEP 4 FOR RESTART.

TO SHUT OFF

1. TURN MANUAL GAS COCK OFF.

2. TURN BURNER POWER OFF.

SHOULD OVERHEATING OF THE APPLIANCE OCCUR

1. Shut off the manual gas control to the appliance.

2. Do not shut off the electrical supply power to the blower.

Part 3

Maintenance

Lighting Instructions

Part 3 Trouble Chart

TROUBLE CHART

Make sure the thermostat and operating controls are calling for heat.

CAUTION: If a test indicates an electrical component may be defective,

before replacing it, make sure that its associated wiring is not at fault.

ELECTRICAL AND FLAME CHECKS MUST BE MADE IN THE ORDER LISTED BELOW.

I. MOTOR WILL NOT RUN

A. Confirm 120V between strip terminals L1 and L2 and verify the circuit polarity and

electrical ground between strip terminal L1 and burner Ground.

B. Check for 120V between strip terminals L1 and L2.

1. No voltage, open circuit in operating controls.

2. Voltage present, motor is defective.

II. MOTOR RUNS CONTINUOUSLY, PILOT WILL NOT LIGHT

A. Confirm that ALL Main Manual Shut-Off Valves are in the ON position.

B. After the pre-purge, if the pilot flame is not proven within the pilot flame re-

re-establishing period, or if the proof of flame is lost during the burner run and the

pilot is not re-established after the pre-purge, the Ignition Control Module will lock

out. To reset the control for restart, de-energize the Ignition Control Module by

setting the operating control to OFF or thermostat below room temperature for at

least 60 seconds.

C. Clogged pilot orifice.

D. Pilot regulator mis-adjusted

or defective.

E. Defective spark electrode or

Ignition Control Module.

F. Defective high tension wire.

G. Wrong pilot orifice.

H. Defective pilot valve.

I. Pilot air tube clogged.

J. Incorrect spark gap.

K. Pilot regulator vent clogged.

L. Defective blower air switch.

M. Slow motor.

N. Step down transformer is defective.

III PILOT LIGHTS, NO MAIN FLAME

A. Poor pilot flame adjustment.

B. Clogged pilot air tube.

C. Defective flame sensing rod or wire.

D. Flame sensing rod mis-located.

E. Pilot regulator vent clogged.

F. Defective Ignition Control Module.

G. Defective main gas valve.

H. Low gas pressure.

I. Grossly mis-adjusted main gas and air.

Part 3

Continued

Trouble Chart

IMotor Will

Not Run or Motor

Runs in Repeated

Cycles

II Motor Runs

Continuously, But

No Flame

III Pilot Lights,

No Main Flame

Midco International Inc.

4140 West Victoria Street * Chicago, Illinois 60646 1201

tel 773.604.8700 fax 773.604.4070 web www.midco-intl.com email [email protected]

8471 24

Printed in USA

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Midco economite RE4850BA Quick guide