Wayne EHG User manual

"@;' MEA
#: to7-04-E
A SCOTT FETZERCOMPANY
8OI
GLASGOW
AVE.
FORTWAYNE,IN 46803
PublicationDate9I5I06
PARTNO. 63537-001
Rev.
F
MODEL "EHG" GAS BURNERS
WARNING:If theinformation
intheseinstructionsisnotfollowedexactly,
afireorexplosion may
result,causing
property
damage,
personal
injuryor
death.
- Donotstore
oruse
gasoline
orother
flammable
vaporsandliquidsinthe
vicinityofthis orany
other
appliance.
-WHATTODOIFYOUSMELLGAS
. Do
nottrytolighttheappliance.
. Donottouchany
electricalswitch;donotuseany
phone
inyour
building.
. Immediately
call
yourgas
supplier
from
a
neighbor's
phone.
Follow
the
gas
supplier's
instructions.
. If you
cannotreach
yourgas
supplier,call
the
firedepartment.
- Installationand
servicemustbe
performed
byaqualified
installer,
service
agency
orthe
gas
supplier.
Warrantyisvoided if notinstalled
byqualified service
person.
NOTICE
THESE
INSTRUCTIONSSHOULDBEMAINTAINEDIN LEGIBLE
CONDITION.
THESEINSTRUCTIONSSHOULDBEPOSTED,AFFXED TOTHEBURNER,
OR
ADJACENT
TOTHEHEATINGAPPLTANCE.FORFURTHERINSTRUCTIONS
AND WARNINGS,SEETHEBACK OFTHISMANUAL.
G~
C US MEA #: 107-04-E
A SCOTT FETZER COMPANY
801 GLASGOW AYE.
FORT WAYNE, IN 46803
Publication Date 9/5/06
PART NO. 63537-001 Rev. F
MODEL "EHG" GAS BURNERS
WARNING: If the infonnation in these instructions is not followed exactly,
afire 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 the appliance.
•Do not touch any electrical switch; do not use any phone in your building.
•Immediately call your gas supplier from aneighbor's phone. Follow the
gas supplier's instructions.
•
If you cannot reach your gas supplier, call the fire department.
-Installation and service must be perfonned by aqualified installer, service
agency
or the gas supplier.
Warranty is voided
if not installed by qualified service person.
NOTICE
THESE INSTRUCTIONS SHOULD BE MAINT AD'JED IN LEGIBLE CONDITION.
THESE INSTRUCTIONS SHOULD BE POSTED, AFFIXED TO THE BURNER, OR
ADJACENT TO THE HEATING APPLIANCE. FOR FURTHER INSTRUCTIONS
AND WARNINGS, SEE THE BACK OF THIS MANUAL.

SPECIFICATIONSFOR
MODEL 55EHG"
BTJRI\ERS
NATURAL GASOR PROPANE
NOTE:
"S.I."
Dimensions
in() are
informational
only.English
valuestake
priority.
MaximumInputCapacity
* - 700MBTU(738500
kJ)
MinimumInput
Capacity
* - 425MBTU(448400
kJ)
* De-rate
input
foraltitudeover2000ft.(609.6
m)by4Yo
each1000ft.
(304.8
m)
above
sealevel.
SUPPLYLINE PRESSUREREQUIRED:NaturalorPropane
6"W.C.
(1494
Pa)Minimum,14"
W.C.
(3487
Pa)Maximum
AIR TLIBEDIAMETER: 4inches
(101.6
mm)
AIR TUBEINSERTIONS
(STANDARD
BURNERS):
5.00
inches
(127
mm)Maximim
7.00
inches
(177.8
mm)Maximum
10.00inches
(254
mm)Maximum
13.00
inches
(381.0
mm)
Maximum
MOUNTING:Adjustableflangestandard.
STANDARD
VOLTAGE: 120VACI 60HZl I Phase
FLAME SAFETY:24YAC Single-RodGas Primary
IGNITION: 10,000VAC Direct
Spark
Ignition.Optionaltransformers
are
available.
Standardburnersareshipped
withtheignition transformer
mountedtothe
burner.If thetransformeristoberemotely
mounted,the
ignition
wiremustnotexceed
36"
(914.4mm)
per
UL795.
GASPIPETRAIN: The
pipehain
ispre-assembled
and
pre-wired
and
is
IlL795compliant,whichincludesHigh
& Lowgaspressure
safetyswitches,
twomanual
ballvalves,twoI'J.{PT x I"NPT 110VAC
SolenoidShutoff
Valves,aMainGas PressureRegulator,and
gas
test
ports.
Upon
request
the
pipetrain
canbeassembledwithouta
Gas
PressureRegulator,
butthecorrect
GasPressureRegulatormustbeinstalled
beforeoperation.The
pipetrain
is
shippedseparate,andminorfield
plumbing
andwiringarerequired.
The
pipetrain
must
be
located
12'
(3.6m)
orlessfrom theburnerfor
optimal
performance.
SPECIFICATIONS FOR MODEL "EHG" BURNERS
NA TURAL GAS OR PROPANE
NOTE: "S.l." Dimensions in ( ) are informational only. English values take
priority.
Maximum Input Capacity *-700 MBTU (738500 kJ)
Minimum Input Capacity * -425 MBTU (448400 kJ)
*De-rate input for altitude over 2000 ft. (609.6 m) by 4% each 1000 ft.
(304.8 m) above sea level.
SUPPL Y LINE PRESSURE REQUIRED: Natural or Propane 6" W.C.
(1494 Pa) Minimum, 14" W.C. (3487 Pa) Maximum
AIR TUBE DIAMETER: 4inches (101.6 mm)
AIR TUBE INSERTIONS (STANDARD BURNERS):
5.00 inches (127 mm) Maximim
7.00 inches (177.8 mm) Maximum
10.00 inches (254 rum) Maximum
13.00 inches (381.0 mm) Maximum
MOUNTING: Adjustable flange standard.
STANDARD VOLTAGE: 120 VAC /60 HZ/ 1Phase
FLAME SAFETY: 24 VAC Single-Rod Gas Primary
IGNITION: 10,000 VAC Direct Spark Ignition. Optional transformers are
available. Standard burners are shipped with the ignition transformer
mounted to the burner.
If the transformer is to be remotely mounted, the
ignition wire must not exceed 36" (914.4rum) per
UL 795.
GAS
PIPETRAIN: The pipetrain is pre-assembled and pre-wired and is
UL795 compliant, which includes High &Low gas pressure safety switches,
two manual ball valves, two 1''NPT x 1
"NPT 11 OV AC Solenoid Shut-off
Valves, a
Main Gas Pressure Regulator, and gas test ports. Upon request the
pipetrain can
be assembled without aGas Pressure Regulator, but the correct
Gas Pressure Regulator must be installed before operation. The pipetrain is
shipped separate, and minor field plumbing and wiring are required. The
pipetrain must be located 12' (3.6m) or less from the burner for optimal
performance.
2

CONTENTS
SECTION
I INSTALLATION
A. GENERAL
B.VENTILATION
C.HEATTNGAPPLIANCEINSPECTION
PAGE
4
4
4
5-6
6-7
7-9
4-13
9
10
10-lt
l2
13
l5-18
t9
27
D.CHIMNEY,FLUEPIPE
ANDDRAFT
CONTROL
E.
COMBUSTIONCHAMBER
F'.
GASPIPING
G.ELECTRICAL
H.MAIN BURNER
ORIFICESIZINGAND INSTALLATION..
r. llOvAC
soLENorDSHUT-OFFGASVALVE(S)
J.
PRESSURE
REGULATORADJUSTMENT
K. GASPRESSURE
SWITCHES
SECTIONII INITIAL STARTUP
SECTIONIII OPERATION ANDTROUBLESHOOTING....
SECTIONIV SERVICE
DRAWINGS& PARTSLIST 28.38-48
TECHNICAL INFORMATION
WARRANTY
CONSUMER INSTRUCTIONS
31
34
35
CONTENTS
PAGE
SECTION I INSTALLATION 4-13
A. GENERAL 4
B.
VENTILATION 4
C.
HEATING APPLIANCE INSPECTION 4
D.
CHIMNEY, FLUE PIPE AND DRAFT CONTROL 5-6
E.
COMBUSTION CHAMBER 6-7
F. GAS PIPING 7-9
G.
ELECTRlCAL 9
H. MAIN
BURNER ORIFICE SIZING AND INSTALLATION.. 10
I. IIOVAC SOLENOID SHUT-OFF GAS VALVE(S) 10-11
J.
PRESSURE REGULATOR ADJUSTMENT 12
K. GAS PRESSURE SWITCHES................................... 13
SECTION II INITIAL START UP J5-18
SECTION III OPERATION AND TROUBLESHOOTING.... 19
SECTION IV SERVICE
DRA WINGS & PARTS LIST
27
28,38-48
TECHNICAL INFORMATION 31
WARRANTY 34
CONSUMER INSTRUCTIONS 35
3

SECTION I
TNSTALLATION
A. GENERAL
Installation
of these
powergas
burnersmustconform
to localcodes,or in
theirabsence,theNationalFuel
Gas
Code,
ANSI Z223.IAIFPA54.
In CANADA, "Theequipment
shallbeinstalledin accordance
with the
Provincial
Installation
Requirements,
orintheirabsence,the
CGA 8149.1
andBl49.2Installation
Codesshall
prevail." Authoritieshaving
jurisdiction
shouldbeconsulted
beforeinstallations
are
made.
NOTICE: ANSI or localinstallation
codecompliance
isthe
sole
responsibility
of the
qualified
installer.
B. VENTILATION
The
EHGburnermodels
covered
bythismanual shall
not
beinstalledin an
appliancelocatedwhere
normalaircirculationor infiltration
islimitedin
providing
alltheairnecessaryforproper
combustion
and
draft
hood
dilution
air.
Whenthe
heating
applianceisinstalledin atightlyclosedroomwithout
ventilationopeningstooutdoors,
orotherrooms,
provisions
shall
be
made
for supplyingairforcombustion
through
specialopenings,
onenearthefloor
lineandthe
other
near
theceiling.Eachistobesized
on
thebasisof one
squareinch(645
.2mm')ormore
of free area
each
1,000BTU (.29kW) input
per
hour.
C.HEATING APPLIANCE INSPECTION
Clean
theappliance
heat
exchangerinterior,
combustionchamberandflue
connections.
Removeall adhering
tars,
scale,dirt and
soot.
Inspecttheheat
exchangerforobviousand potential
fluegas leaks.
Cement
all
jointsaround
theappliance
base
and
access
openingstoprevent
airand/orfluegas leakage
intooroutof thecombustion
chamber.
WarmAir Furnacesx - Makecertain
theelectricalcharacteristics
of thefan
andlimit switchcorrespond
tothose required
by thisburner and
arein
proper
working order.
Hot WaterBoilers* - Makecertain
watertemperatureandaltifude
gauges,
pressure
relief valvesarein proper
working order.
SECTION I
INSTALLATION
A.GENERAL
Installation of these power gas burners must conform to local codes, or in
their absence, the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
In
CANADA, "The equipment shall be installed in accordance with the
Provincial Installation Requirements,
or in their absence, the CGA B149.1
and B149.2 Installation Codes shall prevail." Authorities having jurisdiction
should be consulted before installations are made.
NOTICE: ANSI or local installation code compliance is the sole
responsibility
of the qualified installer.
B. VENTILATION
The EHG burner models covered by this manual shall not be installed in an
appliance located where normal air circulation
or infiltration is limited in
providing all the air necessary for proper combustion and draft hood dilution
alr.
When the heating appliance is installed in atightly closed room without
ventilation openings
to outdoors, or other rooms, provisions shall be made
for supplying air for combustion through special openings,
one near the floor
line and the other near the ceiling. Each
is to be sized on the basis of one
square inch (645.2mm2)
or more of free area each 1,000 BTU (.29kW) input
per hour.
C. HEATING APPLIANCE INSPECTION
Clean the appliance heat exchanger interior, combustion chamber and flue
connections.
Remove all adhering tars, scale, dirt and soot. Inspect the heat
exchanger for obvious and potential flue gas leaks. Cement all joints around
the appliance base and access openings to prevent air and/or flue gas leakage
into
or out of the combustion chamber.
Warm Air Fumaces* - Make certain the electrical characteristics of the fan
and limit switch correspond to those required
by this burner and are in
proper working order.
Hot Water Boilers* - Make certain water temperature and altitude gauges,
pressure
relief valves are in proper working order.
4

Steam
Boilers* - Makecertain
thesystem
ispressure
tight,with pressure
g?ge
and
pop off safety
valvein proper
working order.
inrur. Existingwater
sight
glass
permitsclear
observation
of boil"r riutrr level.
*Where
applicable,
existing
temperature
ofpressure
limit switch
orlow
water
cut-offswitch
operation
and
electricai
characteristics
shall
be
checked
to determine
theircompatibility
to thegas
control
circuitryof thisburner.
D. CHIMNEY, FLUE PIPE AND DRAFT CONTROL
The
chimney
should
beinspected
forunsafe
conditions
such
as
excessive
soot
accumulation,
deteriorated
masonry,
blockage
orpotential
blockage.
NOTICE: No manually
adjustable
fluepipe
damper
ispermitted
onanygas
burner
installation.
The
chimney
should
belined
with acorrosion
resistant
material.
If thechimney
isunlined,
consult
yourlocal
gas
utility for
recommendations.
WARNING: Under
nocircumstances
should
the
fluepipe
be
connected
to
the
chimney
of anopen
fireplace.
strict complianceto appropriatecodes
shouldbemade
regardingflue pipe
clearances,fro* combustible
materials.
Pitchthehorizontal
runof thefluepipeupward r/4 inch(6.35mm)
perfoot
(.305m)
or more.
Run directly
to ttre
ctrimney,
fasten
joinis secure'ly
and
support
horizontal
runs
toprevent
sagging.
If the
fluepipemust
be
extra
long,
itsdiameter
should
beincreased.
The
horizontal
length
of_the
fluepipeshould
notexceed
theheight
of the
chimney
above
the
flueconneCtion.
Steam Boilers* -Make certain the system is pressure tight, with pressure
gage and
pop off safety valve in proper working order. Insure Existing water
sight glass permits clear observation
of boiler water level.
*Where applicable, existing temperature
of pressure limit switch or low
water
cut-off switch operation and electrical characteristics shall be checked
to determine their compatibility to the gas control circuitry
of this burner.
D. CHIMNEY, FLUE PIPE AND DRAFT CONTROL
The chimney should be inspected for unsafe conditions such as excessive
soot accumulation, deteriorated masonry, blockage
or potential blockage.
NOTICE: No manually adjustable flue pipe damper is permitted on any gas
burner installation.
The chimney should be lined with acorrosion resistant
material.
If the chimney is unlined, consult your local gas utility for
recommendations.
WARNING: Under no circumstances should the flue pipe be connected to
the
chimney of an open fireplace.
Strict compliance to appropriate codes should be made regarding flue pipe
clearances
from combustible materials.
Pitch the horizontal run of the flue pipe upward 1/4 inch (6.35mm) per foot
(.305m)
or more. Run directly to the chimney, fasten joints securely and
support horizontal runs to prevent sagging.
Ifthe flue pipe must be extra long, its diameter should be increased. The
horizontal length of the flue pipe should not exceed the height of the
chimney
above the flue connection.
5

VERTICAL
DBAFTHOOD
DRAFTHOODPOSITONS
FIGURE I
Thedraftcontrolshouldbehood
type
perFigureI or,IF APPROVEDBY
LOCAL AUTHORITIES, abarometricdampersuitable
for gas firing per
Figure2.Thedraftcontrolshouldbesized
thesameasthefluepipeand
shouldbelocatedhigherthan
thehighest
partontheappliance
fluepassage.
Refer
to thebarometricdraftregulator manufacturer's
instructionsfor
complete
detail.
NOTICE: Should thefluepass
throughapartition, thedraftcontrolmustbe
locatedin thesameroomasthe
heating
appliance.
PITCHHOBIZONTAL
RUN1/4'(6.35mm) MlN.
PER FOOT(.30sM)
PITCHHORIZONTAL
RUN1/4"
(6.35mm)
MlN.
PER FOOT(.305M)
OOUBLEACTING
BAROMETFIC
DRAFTCONTROL
DO NOT EXTENO
FLUE PIPE BEYOND
INSIDE
OFCHIMNEY
DONOT
EXTENO
FLUE PIPE BEYOI'IO
INSIOE
OF CHIMNEY
BAROMETRIC
DRAFT
CONTROLPOSITION
FIGURE2
E.COMBUSTIONCHAMBER
A combustionchamberisnormally
requiredtoprotect
non-heat
transfer
surfaces,and
toprovide aradiant
bed
forrapidheattransfertothe
primary
surfacesof the heat
exchanger.If ingood condition,theexistingcombustion
chambercanbeused.
CORBOSION
RESISTANTLINING
CLEANOUT
SELECTEITHER
HORIZTONALOR
VEBTICALDRAFTHOOD
SELECT EITHER
HORIZTONAL OR
VERTICAL DRAFT HOOD
PITCH HORIZONTAL
RUN 1/4' (6.35mm) MIN.
PER FOOT (.305M)
VERTICAL
DRAFT HOOD
REDUCER
DO NOT EXTEND
FLUE PIPE BEYOND
INSIDE OF CHIMNEY
CORROSION
RESISTANT LINING
CLEANOUT
DRAFT HOOD POSITONS
FIGURE 1
The draft control should be hood type
per Figure lor, IF APPROVED BY
LOCAL AUTHORITIES, abarometric damper suitable for gas firing per
Figure 2. The draft control should be sized the same as the flue pipe and
should be located higher than the highest part on the appliance flue passage.
Refer to the barometric draft regulator manufacturer's instructions for
complete detail.
NOTICE: Should the flue pass through apartition, the draft control must be
located in the same room as the heating appliance.
PITCH HORIZONTAL
RUN 114" (6.35mm) MIN.
PER FOOT (.305M)
DOUBLE ACTING
BAROMETRIC
DRAFT CONTROl
REDUCER
DO NOT EXTEND
FLUE PIP£ BEYOND
INSIDE OF CHIMNEY
BUll HEAD TEE
CORROSION ..c=:-F1---f"i
RESISTANT LINING
CLEANOUT
BAROMETRIC DRAFT
CONTROL POSITION
FIGURE 2
E. COMBUSTION CHAMBER
Acombustion chamber is normally required to protect non-heat transfer
surfaces, and to provide aradiant bed for rapid heat transfer to the primary
surfaces
of the heat exchanger. If in good condition, the existing combustion
chamber can be used.
6

A full cornbustionchamberliner
isrecommended
forwarmairfumaces,
see
Figure3,andatargetwallorfull combustion
chamber
linerisrecommended
for
wet
leg
castironorsteel
boilers.See
Figures
4 and5.
If abuiltup
chamber
isnecessary,use2300'F
(1260'C)
minimum
insulating
firebrick
orFiberFraxrM.
EXISTING
PFEFABBICATED
:COMBUSTION
CHAMBER LINER
EHG
TO PROTECTPFOPERLY
LOCATEEND
OFBURNER
TUBE. POSITIONTUBE 1/2"
(l2.7mm) SHORTOF INSIDE
OFCOMBUSTION
CHAMBER
BURNER
EHG
BTJRNER
EXISTINGOB
ADDEDTARGET
TO BACKOF COMEU$
TIONCHAMBER
TOPFOTECTPBOPERLY
LOCATE
ENDOF BUFNEB
TUBE.POSITIONTUAE 1/2"
(l2.7mm)
SHORTOFINSIDE
EXISTING
PREFABRICATED
COMBUSTION
CHAMBER UNER
.TOPROTECT PROPERLY
LOCATEENOOF BURNER
TUBE. POSITIONTUBE 1I2"
(12.7mm)
SHORTOF INSIDE
OF COMAUSTION
CHAMBER
OFCOMBUSTION
CHAMBER
HOTWATER
OR
STEAM
BOILER
WITH
COMBUSTION
CHAMBER
TARGET HOTWATERORSTEAM
BOILER
WITH
COMBUSTIONCHAMBER
LINER
FIGURE 4FIGURE 5
THE BURIIER AIR TUBE MUST NOT BE ALLOWED TO EXTEND
INTO THE CHAMBER PROPER;IT MUST BE SET ll2" (12.7mm)
SHORT OF THE INSIDE SURFACE.
Before
pernanently securing
theburnerto theheating
appliancewith either
theadjustable
mountingflange
orpedestal,
cementing
around
theairtube
in
thecombustion chamberopening,
check
thattheburner
headassembly
is
freeof foreignmaterialsandthatthesensor
andelectrode
probes
have
not
been
damagedorrepositioned,seeFigure6.
FORCED
AIRFURNACE
FIGURE3
Afull combustion chamber liner is recommended for warm air furnaces, see
Figure 3, and atarget wall or full combustion
chamber liner is recommended
for wet leg cast iron or steel boilers. See Figures 4and S. If abuilt up
chamber
is necessary, use 2300° F(1260°C) minimum insulating firebrick
or FiberFrax™.
EXISTING
PREFABRICATED
COMBUSTION
CHAMBER LINER
EHG
BURNER
TO PROTECT PROPERLY
LOCATE END OF BURNER
TUBE. POSITION TUBE 112"
(12.7mm) SHORT OF INSIDE
OF COMBUSTION
CHAMBER
EXISTING
PREFABRICATED
COMBUSTION
CHAMBER
UNER
TO PROTECT PROPERLY
LOCATE END OF BURNER
TUBE. POSITION TUBE 1/2"
(l2.7mm) SHORT OF INSIDE
OF COMBUSTION
CHAMBER
EHG
BURN ER ~4ii:1tl1""""'fl
FORCED AIR FURNACE
FIGURE 3
EXISTING OR
ADDED TARGET
TO BACK OF COMBUS,
TlON CHAMBER
TO PROTECT PROPERLY
LOCATE END
OF BURNER
TUBE. POSITION TUBE 1/2'
(12.7mm) SHORT OF INSIDE
OF COMBUSTION
CHAMBER
EHG
BURNER
HOT WATER OR STEAM BOILER WITH
COMBUSTION
CHAMBER TARGET
FIGURE 4
HOT WATER OR STEAM BOILER WITH
COMBUSTION CHAMBER LINER
FIGURE 5
THE BURNER AIR TUBE MUST NOT BE ALLOWED TO EXTEND
INTO
THE CHAMBER PROPER; IT MUST BE SET 1/2" (12.7mm)
SHORT OF THE INSIDE SURFACE.
Before permanently securing the burner to the heating appliance with either
the adjustable
mounting flange or pedestal, cementing around the air tube in
the combustion
chamber opening, check that the burner head assembly is
free
of foreign materials and that the sensor and electrode probes have not
been
damaged or repositioned, see Figure 6.
7

PROBE DIM REF
IGNITER1.0626.92mm)
SENSOR.84 21.34mm)
(20,3?mn)
REF,
*l F_.7s
il | <le'osmn)
(?,67nn)
.125(3.'l75mm)
I
n
0
n
@
FIGURE6
F. GASPIPING
NOTICE: All piping
must
complywith local codes.
Theavailable
gas
supply
pressure
shouldbewithin minimum and
maximum
pressures
shown
in the
burnerspecifications.
If the
gas
supply
pressure
exceeds
14"W.C.
(3487.4Pa)
maximum,anintermediate
main gas regulatormustbe
installedahead
of themaingas
manualshutoff valveshown
in Figure7.
WARNING: Failur. to inrtu"tltheintermediate
gas
regulatorwill resultin
gas
leakagefrom themainburner regulator.Consult
localcodesto install
ventlinesfromregulators,if used.Ventlinesshould
terminateoutsidethe
building, away
from windows,doors,and freshair intakes.Vent should
terminatein away toprevent
water,dirt, foreignmatter,
or insectsfrom
entering
theline.
SUPPLY
LINECONNECTION
TOBURNER
FTGURE
7
CONTROL MANIFOLD
PROBE DIM
IGNITER 1,06
SENSOR
,84
,80 (20,32MM) REF,
1
--,75
C19,OSrvH')
C2,67MM)
,125(3,175mm)
FIGURE 6
o
oI
CD
'"
<0
'"
CD
F. GAS PIPING
NOTICE: All piping must comply with local codes. The available gas
supply pressure should be within minimum and maximum pressures shown
in the burner specifications.
If the gas supply pressure exceeds 14" w.e.
(3487.4Pa) maximum, an intermediate main gas regulator must be
installed ahead
of the main gas manual shut off valve shown in Figure 7.
WARNING: Failure to install the intennediate gas regulator will result in
gas leakage from the main burner regulator. Consult local codes to install
vent lines from regulators,
ifused. Vent lines should terminate outside the
building,
away from windows, doors, and fresh air intakes. Vent should
tenninate in away to prevent water, dirt, foreign matter, or insects from
entering the line.
~
ANUAL SHUTOFF VALVE
I1/8' (3. 175mm) N.P.T.
DIRECTION •PLUGGED TAPPING
OF FLOW PRESSURE GAGE PORT
I
SUPPLY LINE CONNECTION
TO
BURNER
FIGURE 7
8

A pipe union
shallbe
installedinthe
gas
lineadjacent
toand
upstream
from
the
main
gas
manualshutoff
valve.A drip legorsedimenttrap/strainermust
be
installedinthe
supply
linetotheburner.
See
Figure
7.
The
gas
supply
piping
totheburnershould
branchoff from themain
gas
supply
lineas
close
tothe
gas
meter
as
possible.
Donotconnect
tothe
bottomof ahoizontal section.
InCANADA, theinstallermustidentifytheMainElectricalPower
disconnect,
andthemanual
shut-off
valve
on
the
Gas
Supply
drop-linetothe
burner.
Use
new
black
iron
pipe
and
malleablefittingsfree
ofburrsanddefects.
Use
pipe
jointcompound
resistant
toliquefied
petroleumgases.
A l/8"
(3.175mm)
NPT
plugged
tap
acces.siblefor
gairge
testconnectionis
provided
for
determining
gas
supply
pressure
totheburner.Testnewsupply
piping
forleaks.
CAUTION:
DURINGPRESSURETESTFORLEAKSIN GASSUPPLYPIPING.
THE BURNERMUST BEDISCONNECTEDTO PREVENT
EXPOSINGTHE REGULATORTO PRESSURES
OVER1i2''PSIG
(3447
PaG),
POSSIBLY
DAMAGING THE UNIT ANDVOIDING
THE BURJ\ERWARRANTY.
G.ELECTRICAL
Theinstallation
must
be
wiredand
GROLfNDED
inaccordancewithlocal
codesorintheirabsence,with
theNationalElectric
CodeANSIAIFPANo.
70-1987orlatestedition.
InCANADA, allwiringshallbedoneinaccordance
withtheCanadian
Electrical
Code.
Forthe120VACwiringtotheburner,use solidcopperconductor
wirenot
lighterthan#14AWG.If afuseddisconnectisused,
itshouldbe fusedfora
minimum
of 15amps.
Apipe union shall be installed in the gas line adjacent to and upstream from
the main gas manual
shutoff valve. Adrip leg or sediment trap/strainer must
be installed in the supply line to the burner. See Figure 7.
The gas supply piping to the burner should branch
off from the main gas
supply line as close to the gas meter as possible. Do not connect to the
bottom
of ahorizontal section.
In
CANADA, the installer must identify the Main Electrical Power
disconnect, and the manual shut-offvalve on the Gas Supply drop-line to the
burner.
Use new black iron pipe and malleable fittings free
of burrs and defects. Use
pipe joint compound resistant to liquefied petroleum gases. A1/8"
(3.175mm)
NPT plugged tap acces,sible for gauge test connection is
provided for determining gas supply pressure to the burner. Test new supply
piping for leaks.
CAUTION:
DURING PRESSURE TEST FOR LEAKS IN GAS SUPPLY PIPING,
THE BURNER MUST BE DISCONNECTED TO PREVENT
EXPOSING THE REGULATOR TO PRESSURES OVER 1/2" PSIG
(3447 PaG), POSSIBLY DAMAGING THE UNIT AND VOIDING
THE BURNER WARRANTY.
G. ELECTRICAL
The installation must be wired and GROUNDED in accordance with local
codes
or in their absence, with the National Electric Code ANSIfNFPANo.
70-1987
or latest edition.
In CANADA, all wiring shall be done in accordance with the Canadian
Electrical Code.
For the 120 V AC wiring to the burner, use solid copper conductor wire not
lighter than #
14 AWG. If afused disconnect is used, it should be fused for a
minimum of 15 amps.
9
'.,

CAUTION: Each installationmust
include
suitable
limit controls.Existing
oilburnercombination
limitandoperating
controls
arenormally
notsuitable
forgas burner
use.
CAUTION: The burnerisequipped
withit's own24VAC
transformer.
Do
notaddany24VAC power
consumingdeviceinthe24VAC controlcircuit
ofthe
burner,
asit couldoverloadthetransfonner.
CAUTION: Label allwires
prior
todisconnection
when
servicing
controls.
Wiringerrorscancauseimproperand
dangerous
operation.
Verifyproper
operationafterservicing
NOTE: If anyof the
originalburnerwiringmust
bereplaced,
it must
be
replaced
with#18
AWG105degrees
Cwire orequivalent.
SeeSection3-
Operationand
Troubleshooting
forapplicable
burnerwiringdiagrams.
H. MAIN BURIIER ORIFICE SIZING AND INSTALLATION
TheEHG powergas
burners
areapprovedfor usewith naturaland
propane
gas
only. TheEHG burnermodelsare shipped
labeled
and
orificedfor
natural
gas.
To converttopropane
gas
and/or
increase
BTUiHR (kWHr)
inputonnatural
or propanegas,
anorificekit is supplied
with each
burner
with theorificesshownin Figure8.
Toremove
or interchangemainorificediscsrefertotheexploded
parts
view
drawingin thismanual
(Figure17).
1.Removel'NPT orifice
plug,
Item
#5.
2.Remove
orificespring,
Item#4,toaccessand
remove
orifice
disc,
Item
#3.
3.
Install
desiredorifice
fromFigure
8,
making
sureitis
seatedflat
inthe
orifice
holder,ltem#2.
4.
Replace
orificespring
and
securely
tighten
I'NPT orifice
plug(using
properpipe
dope)
into
orifice
holder.
l0
CAUTION: Each installation must include suitable limit controls. Existing
oil burner combination limit and operating controls are normally not suitable
for gas
burner use.
CAUTION: The burner is equipped with it's own 24VAC transformer. Do
not add any 24 VAC power consuming device in the 24 VAC control circuit
of the burner, as it could overload the transformer.
CAUTION: Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation. Verify proper
operation after servicing.
NOTE: If any of the original burner wiring must be replaced, it must be
replaced with #
18 A WG 105 degrees Cwire or equivalent. See Section 3-
Operation and Troubleshooting for applicable burner wiring diagrams.
H. MAIN BURNER ORIFICE SIZING AND INSTALLATION
The EHG power gas burners are approved for use with natural and propane
gas only.
The EHG burner models are shipped labeled and orificed for
natural gas.
To convert to propane gas and/or increase BTU/HR (kW/Hr)
input
on natural or propane gas, an orifice kit is supplied with each burner
with the orifices shown in Figure
8.
To remove or interchange main orifice discs refer to the exploded parts view
drawing in this manual (Figure 17).
1. Remove 1 "NPT orifice plug, Item #5.
2. Remove orifice spring, Item #4, to access and remove orifice disc, Item
#3.
3. Install desired orifice from Figure 8, making sure it is seated flat in the
orifice holder, Item #2.
4. Replace orifice spring and securely tighten I
"NPT orifice plug (using
proper pipe dope) into orifice holder.
10
'.\

BTU/hr LP,Gas Orifice Manifold
lnput Drill Decimal Part No. AP"w.c.
425,000(124.6kW) tr."tI" 3680"(9.35mm) 12438-031 3.7(921.6Pa\
450.000(
l3l.9kw) J/g" 3750"(9.53mm) i2438-036 3.5(871.8Pa)
500,000(146.5kw)
z7/64', 4219"(10.12mm) i2438-037 3.5(811.8Pa)
ss0,000(
l61.2kw)29164" 4531"(ll.5lmm) i2438-038 3.5(871.8Pa)
600,000(l75.8kw) \t64', 4844"(l2.3mm) 52438-039 3.5(871.8Pa)
650,000(l90.5kw) t/2" 5000"(12.7mm) 52438-040 3.5(871.8Pa)
700,000(205.2kw)J7164', 5781"(14.68mm) 52438-041 3.5(811.8Pa)
Propane
(LP)
BTU/hr Natural Gas Orifice Manifold
Input Drill Decimal Part
No. AP "ry.c.
42s.000(l24.6kw)15132"
4688"(ll.91mm)52438-042 3.8(946.5Pa)
450,000(
l3l.9kw)\t/64',4844"(l2.3mm)52438-039 3.5(871.8Pa)
500,000(l46.5kw))3/64"5I56"(13.Imm) 12438-043 3.5(871.SPa)
550,000(I
6l.2kw)\5/64"5469"(13.89mm)i2438-044 3.5(871.8Pa)
600,000(
l75.8kw)19132"5938"(15.08mm)52438-045 3.5(871.8Pa)
650,000(l90.5kw)i/8" 6250"(15.88mm)52438-046 3.5(871.8Pa)
700,000(205.2kw)z3/32"7188"(18.26mm)
ro orifice 3.5(871.SPa)
Natural
Figure 8
I. 12OVAC
SOLENOID SHUT.OFF GASVALVES
The
gas
solenoid
shut-off
valves
are
pre-plumbed
onto
the
pipetrain.
The
pipetrain
ispre-wiredforconvenience,buttheelectrical
wiring fromthe
burnermust
beconnected
inthefield.
Theinstallation
must
bewired
andGROTINDED
in accordance
with local
codes
or in their
absence,withtheNationalElectric Code
ANSIAIFPANo.
70-1987or latest
edition.
ll
425,000(124.6kW)
450,000( 131.9kW)
500,000( 146.5kW)
550,000( 161.2kW)
600,000(175.8kW)
650,000(190.5kW) 1/2"
700,000(205.2kW) 37/64"
. 3680"(9.35mm)
.3750"(9.53mm)
.4219"(10.72mm)
.4531 "(11.51 mm)
.4844"(12.3mm)
.5000"(12.7mm)
.5781 "(14.68mm)
Propane (LP)
62438-031
62438-036
62438-037
62438-038
62438-039
62438-040
62438-041
.LlP "w.e .
3.7(921.6Pa)
3.5(871.8Pa)
3.5(871.8Pa)
3.5(871.8Pa)
3.5(871.8Pa)
3.5(871.8Pa)
3.5(871.8Pa)
')~i~'
...
~
'; • -. ":~s.1,,·';:f -::~~y;ii~!JIr.~~~~~~(;~~~
;,!~~- ~1'H~'~~r' "~.~1f."~-
:• J
'. .;. " ~r
"EH G 0f:!fiY~£.Jz~o<~lic!t1
i... ,!_~A:;~i..'1 . '"".~- • ~ ,
-'
..
~ ·.-~*"~-.f ;'" h:L,,, ... J,,-.,;.i
BTU/hr
Natural Gas
Orifice Manifold
Input Drill
Decimal
Part No. .LlP "w.e.
425,000(124.6kW) 15/32" .4688"(11.91mm) 62438-042 3.8(946.5Pa)
450,000(131.9kW)
31/64" .4844"(12.3mm) 62438-039 3.5(871.8Pa)
500,000( 146.5kW) 33/64" .5156"(13.1mm) 62438-043 3.5(871.8Pa)
550,000(161.2kW)
35/64" .5469"(13.89mm) 62438-044
3.5(871.8Pa)
600,000(1
75.8kW)
19/32" .5938"(15.08mm) 62438-045 3.5(871.8Pa)
650,000(190.5kW) 5/8" .6250"(15.88mm)
62438-046 3.5(871.8Pa)
700,000(205.2kW)
23/32" .7188"(18.26mm) no orifice 3.5(871.8Pa)
Natural
Figure 8
I. 120V
AC SOLENOID SHUT-OFF GAS VALVES
The gas solenoid shut-offvalves are pre-plumbed onto the pipetrain. The
pipetrain is pre-wired for convenience, but the electrical wiring from the
burner must be connected in the field.
The installation must be wired and
GROUNDED in accordance with local
codes
or in their absence, with the National Electric Code ANSIINFPA No.
70-1987
or latest edition.
11

?.+2
67/8" KN0CKoUT
FOR1/2" CONDUTT
CONNECTION
(2 HOLESrN L|NE)
1,/8',NPT
DOWNSTREAM
PPESSURE
TAP
@
I&
s"
.@
Fig.9
Fig.10
Note:The
gas
pipetrain,
andall
its
safety
components,
should
beleaktested
afterinstallation.l/8"NPTfittingshave
been
provided
toisolate
and
testthe
solenoid
valves.The
pipetrain,
and
all
safety
components,
should
be
tested
forleaks
andfunctionalityat
regularintervals.
J.PRESSUREREGULATOR ADJUSTMENT
The
gas
pressure
regulatorisNOTfactory
preset,
andmust
befield-adjusted
whilethe
burnerisin operation.
Refer
toFigure
8forpressure
requirements.
t2
1--- D SQ -~-l
r~1.671
A
~7 /8" KNOCKOUT
FOR 1/2." CONDUIT
CONNECTION
(2 HOLES IN LINE)
·1 0 ~ • /"i/a"NPT UPSTREAM \
1/8"NPT DOWNSTREAM ~ PRESSURE TAP
PPESSURE TAP
1---- C --+-----l
.Fig.9
®
<F?
M
@.
.e Fig.tO
Note: The gas pipetrain, and all its safety components, should be leak tested
after installation. 1/8"NPT fittings have been provided to isolate and test the
solenoid valves. The pipetrain, and all safety components, should be tested
for leaks and functionality at regular intervals.
J. PRESSURE REGULATOR ADJUSTMENT
The gas pressure regulator is NOT factory preset, and must be field-adjusted
while the burner is in operation. Refer to Figure 8for pressure requirements.
12

J.PRESSURE REGULATORADJUSTMENT
The
gaspressure
regulatorisNOTfactory
preset,
and
must
befield-adjusted
while
the
burnerisinoperation.
RefertoFigure
8forpressure
requirements.
When
pressure
adjustment
isrequiredforsetting input
capacitywitha
selectedorifice
fromFigure
8,
removetheregulator
capforaccesstothe
slottedadjustmentscrew.Turningthescrewcounter
clockwisereduces
manifold
orifice
pressure,
clockwise
increases
the
pressure.
A wideinput
range
can
be
achievedwitha singleorificesize.If the
desiredinputrating
cannotbeobtainedwithinthe
abovemanifold
orifice
pressure
adjustment
range,thenext
size
largerorsmallerorificeshould
beused.
(Refer
toorifice
chartFig.
8)
NOTE:MANIFOLD PRESSURE
ADJUSTMENTS
CANONLY BE
MADE WITH THE BURNERRUNNINGANDTHE GASON.
The1/8"
(3.175mm)
NPT
pressure
tapfororificemanifold pressure
measurementislocatedonthesideofthe
orifice
holder.
Use
a
"u"-tube
manometer
ordial
type
pressuregauge,
scaledfrom
0"W.C.to 15.0"W.C.
(3736.5Pa)
toread
pressure.
Fig.11
l3
J. PRESSURE REGULATOR ADJUSTMENT
The gas pressure regulator is NOT factory preset, and must be field-adjusted
while the burner is in operation. Refer to Figure 8for pressure requirements.
When pressure adjustment
is required for setting input capacity with a
selected orifice from Figure 8, remove the regulator cap for access to the
slotted adjustment screw. Turning the screw counter clockwise reduces
manifold orifice pressure, clockwise increases the pressure. Awide input
range can be achieved with asingle orifice size.
If the desired input rating
cannot be obtained within the above manifold orifice pressure adjustment
range, the next size larger or smaller orifice should be used. (Refer to orifice
chart Fig. 8)
NOTE: MANIFOLD PRESSURE ADJUSTMENTS CAN ONLY BE
MADE
WITH THE BURNER RUNNING AND THE GAS ON.
The 1/8" (3.175mm) NPT pressure tap for orifice manifold pressure
measurement
is located on the side of the orifice holder. Use a"u"-tube
manometer or dial type pressure gauge, scaled from O"W.C. to 15.0" W.C.
(3736.5Pa) to read pressure.
Fig.II
13
'.\

K. GASPRESSURE
SWITCHES
MOUNTING
All switches
canbe
mounted
ineitherhorizontal
orvertical
position.
Switches
shouldbereasonablylevel
butdonotrequireaccurateleveling.
Switcheshavebeenfactory
calibratedandtestedforleaks.However,
itis
recorunended
thattheswitch,
gaspipe
inletsand
connections
besoap
bubbletested
forleaksafterinstallation.
OPERATION
LowGasPressure
Models
Lowgaspressure
switchesbreakthe
electricalcircuit
on
pressure
dropatthe
point
when
gaspressure
becomeslower
thantheindicated
set
pressure.
Before
the
manualreset
button
canbe
properly
latched,
gas
pressure
inthe
chambermust
behigherthantheindicated
setting.
High
GasPressureModels
Highgas pressure
switchesbreak
theelectrical
circuitwhen
pressure
rises
abovetheindicatedpresetpressure.
Range
Adjustment
-All Models
Toadjust gas
pressure
cut-offsetting,remove
the
cover.
Turn
therange
scale
adjustable
knob
toincrease
pressure
setting
ordecrease
pressure
setting.Install
cover
and
tighten
the
coverscrewstoprevent
tampering.
FIGURE12
l4
K. GAS PRESSURE SWITCHES
FIGURE 12
MOUNTING
All switches can be mounted in either horizontal or vertical position.
Switches should be reasonably level but do not require accurate leveling.
Switches have been factory calibrated and tested for leaks. However, it is
recommended that the switch, gas pipe inlets and connections be soap
bubble tested for leaks after installation.
OPERATION
Low Gas Pressure Models
Low gas pressure switches break the electrical circuit on pressure drop at the
point when gas pressure becomes lower than the indicated set pressure.
Before the manual reset button can be properly latched, gas pressure
in the
chamber must be higher than the indicated setting.
High Gas Pressure Models
High gas pressure switches break the electrical circuit when pressure rises
above the indicated preset pressure.
Range Adjustment -All Models
To adjust gas pressure cut-offsetting, remove the cover. Tum the range
scale adjustable knob to increase pressure setting or decrease pressure
setting. Install cover and tighten the
cover screws to prevent tampering.
14

SECTION
II
INITIAL START UP
1. NOTB: Readtheapplicablesequenceofburner/primary
gas
control
operation,
gqspressure
switches,
etc. in Section3 Operation
and
Tr
oubI
es
hooting befo
r
e
pro
c
eeding.
2.Lay outcombustion
testequipment,manometers,stopwatch,
DC micro-
ampmeter,
andother
miscellaneoustoolsasneeded.
3.Adjust the
primaryairshuttersetting per
thedimensionsshown
in the
chartbelow. Removeblanking
platefrom thesideof theburner IF thefiring
rateisover650,000(190.5kW) BTU'son
LP ONLY. Seechart below.
Note: Air Shutter
Opening
Dimensionsand
Gas
ManifoldPressuresareapproximate
andmustbe
properly
adjustedwithcalibratedemissions
equipment.
FIGURE
13
4.NOTE: Initial activation
oftheburnershouldbegin
withchecking
the
function of theautomatic
controlsbymeansof a "dry ntn" before
gasis
supplied
to themainburnernozzle
- througha complete
mainburner
firing
cycleanda complete checkof all automaticsqfety
controlswith thetest
fi,ring valvein theclosed
positionthen
throughanactivated
firing cycle.
5.Temporarily removethecovers
from
the
High andLow gas
pressure
switchesand
set
theswitchesusingthedials.Thehighgaspressure
switch
should
besetatthe
highest
"w.c.setting,
as
an
initialstarting
point. Thelow
gaspressure
switchshouldbesetat
thelowest
"'w.c.
setting,
as
astarting
point. Push
the
manualresetbuttonsonthe
gas
pressure
switches.
Note:Thesesettingsmustbere-adjustedafter
theburner
isignited.
',: l;
.: '.-l'
:iir
,.il: I
:..,r
-
1
,'
-' i;Y:]t1o';,!t
t:;t
BTU/hr
Input Air shutter Manifold
AP o'w.c. Air shutter Manifold
AP t'w.c.
Opening BlankPlatr Onenins BlankPlatr
+25,000(24.6kW 3/8"(9.53mm) yes \.7(921.6Pa5116"(l.94mm) yes ).8(946.5Pa
150,000(3l.9kw l/2"(l2.7mm) yes \,5(87I.8Pa l12"(12.7mm\ yes t.5(871.SPa
500,000(46.5kW13116"(20.64mm yes ].5(871.8Pa13l16"Q0.64mm yes t.5(811.SPa
550,000(6l.2kw l-l18"(28.58mm yes ].5(871.8Pa l"(25.4mm\ yes 1.5(81I
.8Pal
500,000(75.8kW l-3/8"04.92mm yes \.s(871.SPal-112"(38.1mm) yes 3.5(871.8Pal
550.000(l
90.5kwl-314"(l9.05mrn removed ].5(871.8Pal-314"(44.45mm yes 1.5(871.8Pa
/00.000(205.2kw
l-7/8"(47.63mm) removed ].5(871.8Pa2-118"(53.97mm) yes 1.5(871.8Pa
l5
SECTION II
INITIAL START UP
1. NOTE: Read the applicable sequence of burner/primary gas control
operation, gas pressure switches, etc. in Section 3Operation and
Troubleshooting beforeproceeding.
2. Layout combustion test equipment, manometers, stopwatch, DC micro-
amp meter, and
other miscellaneous tools as needed.
3. Adjust the primary air shutter setting per the dimensions shown in the
chart below. Remove blankingplatefrom the side
of the burner IF thefiring
rate is over 650,OOO(l90.5kW) BTU's on LP ONLY. See chart below.
Air shutter
olank Plate 0
3/8"(9.53mm) es 3.7(921.6Pa) 5/l6"(7.94mm) 3.8(946.5Pa)
50,OOO(131.9kW)
l/2"(12.7mm) yes 3.5(871.8Pa) l/2"(12.7mm) 3.5(871.8Pa)
500,OOO( l46.5kW) l3/16"(20.64mm) yes 3.5(871.8Pa) 13/16"(20.64mm) yes 3.5(871.8Pa)
550,OOO( 16] .2kW) 1-1/8"(28.58mm) yes 3.5(871.8Pa) I "(25.4mm) es 3.5(871.8Pa)
600,OOO(l75.8kW) 1-3/8"(34.92mm) es 3.5(871.8Pa) 1-1/2"(38.1mm) yes 3.5(871.8Pa)
650,OOO(l90.5kW) 1-3/4"(
19.05mm) removed 3.5(871.8Pa) 1-3/4"( 44.45mm) es 3.5(871.8Pa)
700,OOO(205.2kW) 1-7/8"(
47.63mm) removed 3.5(871.8Pa) 2-1/8"(53.97mm) yes 3.5(871.8Pa)
Note:
Air Shutter Opening Dimensions and Gas Manifold Pressures are approximate
and
must be properly adjusted with calibrated emissions equipment.
FIGURE 13
4. NOTE: Initial activation of the burner should begin with checking the
function
of the automatic controls by means of a"dry run" before gas is
supplied to the main burner nozzle -through acomplete main burnerfiring
cycle and acomplete check
of all automatic safety controls with the test
firing valve
in the closedposition then through an activatedfiring cycle.
5. Temporarily remove the covers from the High and Low gas pressure
switches and set the switches using the dials.
The high gas pressure switch
should be set at the highest "w.c. setting, as an initial starting point. The low
gas pressure switch should be set at the lowest "w.c. setting, as astarting
point. Push the manual reset buttons on the gas pressure switches.
Note: These settings must be re-adjusted after the burner
is ignited.
15

6.Open
theball valveto theinletof the
gas
pipetrain. Makesure
theball
valvenearest
theburner(the
outlet
of thegas
pipetrain)
remains
closed.
Test
allnewpipingfor leaks
withasoapy
soluti,on,
orleak
detector.
Do not
use
anopen
flameto test
for gas
leaks.
7.Turnonthemainelectrical
power
and
set
thethermostat
or operation
control
to callfor heat.
Turn
the
burner
on-off
switch
tothe
onposition.
Allow thecombustion
fantorunaMINIMUM of 5minutes
to purge
the
combustion
chamber
and
appliance
heat
exchanger.
Theambei
indicator
lightshows
that
the
burner
is
powered
and
the
switch
isinthe
onposition.
8.Turntheburner
on-off switch
totheoff positionor set
thethermostat
or
operating
control
below
room
temperature,
shutting
the
burner.,oFF,'at
least
I minute
toRESET
theprimary
control.
9.Open
the
ballvalve
onthe
outlet
ofthepipetrain
(nearest
the
burner).
10.
Power
theburner,
turn
the
burner
on-off
switch
tothe
on
position
and
set
thethermostat
or operating
control
to callfor heat.
Theburneiwill start
and
gothrough
theapplicable
sequence
of burnerlprimary
gas
controloperation,
refer
tostep
l. Thegreen
indicator
lightshows
that
the
solenoid
shut-off
valves
are
powered.
Note:
on new gas
line
installations,
air
may
be
trapped
in the gas
line,
the
burner
mayexperience
several
lockouts
until all theair isprrg-.4fromthe
lines.
11.
Once
burner
isrunning,
adjust
thegas
pressure
regulator
as
described
in
section
l, paragraph
J- pressure
Regulator
Adjustment,
based
onthe
pressure
described
inFigure
8.
12.
A moreaccurate
BTU (kw) inputcan
bedetermined
by using
thegas
service
meter
with theburner
operating(all othergas
applian..rihorld be
off). Thehand
onthegas
meter
dialwith theloweit cubicfeet
valve(fastest
revolving
dial),
should
beclocked(timed)
for one
complete
revolution
and
use
the
followingformula.
t6
6. Open the ball valve to the inlet of the gas pipetrain. Make sure the ball
valve nearest the burner (the outlet
of the gas pipetrain) remains closed.
Test all new piping for leaks with asoapy solution, or leak detector.
Do not
use an open flame to test for gas leaks.
7.
Tum on the main electrical power and set the thermostat or operation
control to call for heat.
Tum the burner on-off switch to the on position.
Allow the combustion fan to run a
MINIMUM of 5minutes to purge the
combustion
chamber and appliance heat exchanger. The amber indicator
light shows that the burner
is powered and the switch is in the on position.
8. Turn the burner
on-off switch to the off position or set the thermostat or
operating control below room temperature, shutting the burner
"OFF" at
least 1minute to
RESET the primary control.
9. Open the ball valve on the outlet
of the pipetrain (nearest the burner).
10. Power the burner, turn the burner on-off switch to the on position and set
the thermostat
or operating control to call for heat. The burner will start and
go through the applicable sequence of burner/primary gas control operation,
refer to step
1. The green indicator light shows that the solenoid shut-off
valves are powered.
Note: On new gas line installations, air may
be trapped in the gas line, the
burner may experience several lockouts until all the air is purged from the
lines.
11. Once burner is running, adjust the gas pressure regulator as described in
Section
I, paragraph J - Pressure Regulator Adjustment, based on the
pressure described in Figure
8.
12. Amore accurate BTU (kW) input can be determined by using the gas
service meter with the burner operating (all other gas appliances should be
off). The hand on the gas meter dial with the lowest cubic feet valve (fastest
revolving dial), should be clocked (timed) for one complete revolution and
use the following formula.
16

3600
x cubicft.
per
revolutionx BTUvaiue/cubic
ft: BTUiHR
seconds
per
revolution
NATURALGAS EXAMPLE:Timingone
revolutionofthe
1ft3dialat6
secondson
natural
gas(roughly
1000BTU's/ft'heatingvalue).
3600x
I x 1000:600,000BTU/HR
6
PROPANE
GAS
EXAMPLE:
Timingone
revolutionofthe
tft3aialat15
secondson
propanegas
(roughly
2515BTU's/
ft'heatingvalue).
3600x 1x 2515
: 603,600
BTUAIR
t5
13.Afterthe
desired
input
has
beenobtained,
re-adjustthe
primaryair
damper
openorclosed
to
visually
obtain
a
blue
flamewithwelldefined
orange
or
yellow
tipsfornatural
gas,
orwelldefined
yellow
tips
for
propane
gas.
14.After
theburner
has
been
inoperation foratleast
10minutes,
assuring
combustion
chamber
andheatexchangerare
fully warmed,takecombustion
analysisflue
gas
samples
just
ahead
ofthedraftcontrol
inthe flue
pipe.
A
combustion
gas
analyzershouldbeused
tofine-tunetheburner.
NOTE:ALWAYS USERELIABLE COMBUSTION TEST
INSTRUMENTS.BEINGPROFICIENTIN THE USEOFTHESE
INSTRUMENTS
ANDINTERPRETINGTHEIR DATA IS
NECESSARY
FORSAFE.RELIABLE ANDEFFICIENT BURNER
OPERATION.
15.Performthe
followingcombustion
analysis.A11adjustmentsbelow
must
be
made
withthefollowinginstruments:draft
gauge,
02or CO2
analyzer
and
COtester.
A. Adjust
the
primary
airdampertoprovide about
25%
excess
combustion
air.Confirm
this
bycheckingtheflue
gas
foritsFREE
OXYGEN(Oz)
orCARBON
DIOXIDE(COz)
PERCENTAGESwith
atestinstrument.
Free
oxygenshouldbe
about4.5yo,orcarbon
dioxide
should
beabout9.5%
fornatural
gas,
12.1%for
propane
gas.
B. CARBONMONOXIDE
(CO)-
Shouldbe
checkedforits
presencein
theflue
gas.
This
percentage
should
notexceed.04%
(or
400
PPMair
free).
l7
3600 xcubic ft. per revolution xBTU value/cubic ft = BTU/HR
seconds per revolution
NATURAL GAS EXAMPLE: Timing one revolution of the 1 fe dial at 6
seconds on natural gas (roughly 1000
BTU's/ ft3 heating value).
3600 x 1 x 1000 =600,000
BTU/HR
6
PROPANE GAS EXAMPLE: Timing one revolution of the Ift
3dial at
15
seconds on propane gas (roughly 2515 BTU's/ ft3 heating value).
3600 x 1 x 2515 =603,600
BTU/HR
15
13. After the desired input has been obtained, re-adjust the primary air
damper
open or closed to visually obtain ablue flame with well defined
orange
or yellow tips for natural gas, or well defined yellow tips for propane
gas.
14. After the burner has been in operation for at least 10 minutes, assuring
combustion
chamber and heat exchanger are fully warmed, take combustion
analysis flue gas samples
just ahead of the draft control in the flue pipe. A
combustion gas analyzer should be used to fine-tune the burner.
NOTE: ALWAYS USE RELIABLE COMBUSTION TEST
INSTRUMENTS. BEING PROFICIENT IN THE USE OF THESE
INSTRUMENTS
AND INTERPRETING THEIR DATA IS
NECESSARY
FOR SAFE, RELIABLE AND EFFICIENT BURNER
OPERATION.
15. Perform the following combustion analysis. All adjustments below must
be
made with the following instruments: draft gauge, O2 or CO
2analyzer
and
CO tester.
A. Adjust the primary air damper to provide
about 25% excess
combustion air. Confirm this by checking the flue gas for its FREE
OXYGEN (0
2)
or CARBON DIOXIDE (C0
2)
PERCENTAGES with
atest instrument. Free oxygen should be about 4.5%,
or carbon
dioxide should be about 9.5% for natural gas, 12.1%for propane gas.
B.
CARBON MONOXIDE (CO)- Should be checked for its presence in
the flue gas. This percentage should not
exceed .04% (or 400 PPM air
free).
17

20.g
COanrnrs
: (ZO.g-O) X COppr'a
t2.2
ForNatural Gas:COanrnsp
: ( CO,) X COppv
t4
ForPropane
Gas:CO
enrnrB
: (CO,
) X COppla
C.NOTE:TheEHG
wasdesignedto
fireinto
slightly
positive,
balanced,or
slightly
negative
combustionchambers.
For
optimal
performance,
check
overfiredraftandadjust
toNEGATIVE-.01
(2.491Pa)
to-.02
(4.982Pa)
inches
w/cduringburneroperation.
D.Theflue
gas
temperatureshouldbebetween325"F
(162.78"C)
and550oF
(287.78"C)
forgas burners.Higherflue
gas
temperatures
indicateoverfiring
orexcessivedraftthroughtheappliance.Lowerfluegas temperaturesmay
causeexcessivecondensationandindicateunderfiring.
Consult
your
local
utilityorthe
appliancemanufacturerforacceptableflue
gas
temperatures.
CAUTION: IFTHEBURNERBTU/I{R
(KWAIT)
INPUTISCHANGED,
REPEATSTEP13
16.AdjusttheHigh& Lowgaspressure switchesaccordingtoactualfiring
conditions.
TheHighgaspressure switchshould
beset
atapproximately
4"w.c.
andtheLowgaspressure
switch
should
beset
atapproximately
2"w.e.forcloseburnercontrol.Nuisance lockouts
will occur
if the
switch
settingsaretooclosetothe
gas
manifold
setting,and
fluctuationsingas
pressures
occur.Reattachswitch covers.
L7.Record
the
installation
data,thecombustionreadings,
etc.,
andaffix
to
thismanual,ortheburnerand/orappliance.
Space
has
been
provided
atthe
backofthis
manualforstart-up notes,
dealer's
name,
address,telephone
number,
aswellas
the
dateofinstallation.
SUGGESTION:
All newinstallations
shouldbe
re-inspected
for
proper
combustionandburneroperation
after
oneortwoweeks
ofnormal
operation.
For
subsequent
normal
startingandshutoffprocedure, refertothe
"ConsumerInstructions"inthe
backofthismanual
orthe
instruction
plate
attachedtothe burner.
18
20.9
COAIRFREE = ( 20.9-0
2)XCOPPM
12.2
For Natural Gas: COAIRFREE = (C0
2)X
CO
PPM
14
For Propane Gas: CO AIRFREE = ( CO2)X CO
PPM
C. NOTE: The EHG was designed to fire into slightly positive, balanced, or
slightly negative combustion chambers. For optimal performance, check
overfire draft and adjust to NEGATIVE -.01 (2.491Pa) to -.02 (4.982Pa)
inches w/c during burner operation.
D.
The flue gas temperature should be between 325°F (1 62.78°C) and 550°F
(287.78°C) for gas burners. Higher flue gas temperatures indicate overfiring
or excessive draft through the appliance.
Lower flue gas temperatures may
cause excessive condensation and indicate underfiring. Consult your local
utility
or the appliance manufacturer for acceptable flue gas temperatures.
CAUTION: IF THE BURNER BTUIHR (kW/Hr) INPUT IS CHANGED,
REPEAT STEP 13
16. Adjust the High & Low gas pressure switches according to actual firing
conditions. The High gas pressure switch should be set at approximately
4"w.c. and the
Low gas pressure switch should be set at approximately
2"w.c. for close burner control. Nuisance lockouts will occur
if the switch
settings are too close to the gas manifold setting, and fluctuations in gas
pressures occur. Reattach switch covers.
17. Record the installation data, the combustion readings, etc., and affix to
this manual,
or the burner and/or appliance. Space has been provided at the
back
of this manual for start-up notes, dealer's name, address, telephone
number, as well as the date
of installation.
SUGGESTION: All new installations should be re-inspected for proper
combustion and burner operation after one
or two weeks of normal
operation.
For subsequent normal starting and shut off procedure, refer to the
"Consumer Instructions" in the back of this manual or the instruction plate
attached to the burner.
18

TO RESTART TITEBURNERAFTER A FLAME FAILT]RE, Temove
power
fromthe
burner
for I minute
toresettheprimary
controller.
Pushthe
manual
reset
on
the
LowGaspressure
switch.fne burnershouldrelight
after
power
isrestoredand
the
unit
hasa
call
forheat.If problems
persist,
refer
tothetroubleshooting
section
ofthismanual.
Tostop the
burnerinthe event
ofan
emergency,
remove
power
fromthe
mainelectrical
disconnect,
shut
off any
manual
gas
ballvalve, orturnthe
burneron-off
switch
tothe
offposition.
SECTION
III
OPERATIONAND TROUBLESIIO
OTING
SEQUENCE
OFOPERATION
_EHG
POWER
GAS
BURNER
UTILIZING HONEYWELL
S89F
GASPRIMARYPlN 62759-002
WBUILT IN 30SECOND
PREPURGE
Onacallforheat, voltage
(24V)
isapplied
tomotor
start
relay
and
air
switch.
Oncethefanmotorreaches
operating
rpmcombustion
air
pressure
is
sensed
bytheair-proving
switchand
closes
the
switchcontacts
energizing
the
S89F
gasprimary
control.
The
S89F
gas
primary
controlhas
aninternal
3O-second
pre-purgetimer.
After
theinitial
30second
pre-purge,
aninternal
8-second
safestart
check
of
the
S89Fwill commence.
Once
thisis
successfully
completed,
theS89F
simultaneouslyenergizes
the
gas
valvesand
ignitiontransfonner.
Gas
flows
and
thetransformer
produce
anapproximate
10,000voltspark
end
point
grounded
atthe
burnerheadestablishing
main
burnerflame.
At the
startof eachheatcycle,there
isatrialforignition
period
of four(4)
seconds
duration.Normally,burner
flamewill beestablished before
theend
ofthis
period.
Once
theflameisestablished,
sparkingwill'cease
and
the
flame
rodwill provide flamemonitoring
tothe
S89F
gas
control
primaryfor
theremainder
ofthe heatcycle.If the
flameshould
be
extinguished
during
theheat
cycle,the
S89F
gas
control
primary
will gointo
the
30second
pre-
purge
and
8secondsafe
start
check,
thenre-energizethe
gas
valve
and
ignition
transformerin anattempttoestablishthemainburner
flame.
If this
doesnot
occurwithinthe
4-secondtrialforignitionperiod,
theS89F
gas
primary
controlwill go
intolockout de-energizingthe
gas
valves
and
ignition
transformer.
t9
TO RESTART THE BURNER AFTER AFLAlVIE FAILURE, remove
power from the burner for 1minute to reset the primary controller. Push the
manual reset on the Low Gas pressure switch. The burner should relight
after
power is restored and the' unit has acall for heat. If problems persist,
refer to the troublesho01ing section of this manual.
To stop the burner in the event
of an emergency, remove power from the
main electrical disconnect, shut
off any manual gas ball valve, or tum the
burner on-off switch to the off position.
SECTION III
OPERATION AND TROUBLESHOOTING
SEQUENCE OF OPERATION -EHG POWER GAS BURNER
UTILIZING HONEYWELL S89F GAS PRIMARY PIN 62759-002
WfBUILT IN 30 SECOND PREPURGE
On acall for heat, voltage (24V) is applied to motor start relay and air
switch. Once the
fan motor reaches operating rpm combustion air pressure is
sensed by the air-proving switch and closes the switch contacts energizing
the S89F gas primary control.
The S89F gas primary control has an internal 30-second pre-purge timer.
After the initial 30 second pre-purge, an internal 8-second safe start check
of
the S89F will commence. Once this is successfully completed, the S89F
simultaneously energizes the gas valves and ignition transformer. Gas flows
and the transformer produce an approximate 10,000 volt spark end point
grounded at the burner head establishing main burner flame.
At the start
of ea'ch heat cycle, there is atrial for ignition period of four (4)
seconds duration. Normally, burner flame will be establisqed before the
end
of this period. Once the flame is established, sparking will'cease and the
flame rod will provide flame monitoring
to the S89F gas control primary for
the remainder
of the heat cycle. If the flame should be extinguished during
the heat cycle, the S89F gas control primary will go into the 30 second pre-
purge and 8second safe start check, then re-energize the gas valve and
ignition transformer in an attempt to establish the main burner flame.
If this
does not occur within the 4-second trial for ignition period, the
S89F gas
primary control will go into lockout de-energizing the gas valves and
ignition transformer.
19

Torestart
thesystem,
themain
power
orthermostat
mustbe
de-energizsd
momentarily,
thenre-energized.
[f atanytimeduringtheheat
cygle,
there
is
aninsufficient
supply
ofcombustion airiotheburner,the'airswitbh
will
open,
putting
thesystem
inio'lockoutclosing
the
gas
valves.
EHGPOWER
GASBURNER
WITH HONEYWELL S89F
GASPRIMARY
S89FPRIHARYCONTROL
6?759-00?
I6NITION
TRANSFORHER
IGNITER
ELECTRODE
62391-003
VIRINGDIAGRAM
53495-001
,EHG'
REV
CHI6HPRESSURE
SVITCH
AIR
SENSINGSVITCH
62406-002
GREEN
T-T TERMINAL
60178-004
T
(
=
I
T
GASSHUTOFF
VALVES
BLACK
LOVPRESSURE
SVITCH
FIGURE
14
To restart the system, the main power or: thermostat must be de-energiZed
momentarily, then re-energized. Ifat
a~ time during the ?eat cysle, there is
an insufficient supply of combustion air to the burner, the air switch will
open, putting the system into/lockout closing the gas valves.
f{
EHGPOWCRGASBURNER
WITH HONEYWELL S89F GAS PRIMARY
-
BLACK
-
BLACK BLACK
_
BLACK
'''''~. r0--
SIJITCH
T
'"
GREEN LIGHT ~ ~ s; 63469-001
MOTOR
63470-0 2 ~ ~ YELLOIJ ~ "I VELLO'"
SENSOR
20383
>< >< LIGHT r-----l
PROBE
~ t>6J47O-00!rIV"
1
E·v"
62390-003
VELLO'"
ll--;~B' l'
RELAY
>C
24VAC
62406-002
0
:0
;!;
1>
-t
24V 3rl
:
OVAC
z
S89F PRIMARY CONTROL
3 [ T-T TERMINAL
Cl
60178-002
f'l
62759-002
VELLO'" RELAY
BLACK
f~ c=J
62406-002 ~
~ AIR SENSING SIJITCH 1T
63263-005
rvf\--
c::
GND (BURNER) r=r /..J
tvlV~
VELLO'" ~
~I\-ft-.
~
"'~SENSE
/..J
tvlV -=-
~rb
~
,.,
24V (GND)c=r
/~
/f\.-
T
t'-
=
~
tvl\....! YELLO'"
/IL-
=
24V r=>
~~LLO'"
III
~~
T~~gb~ffttl.fR
=
VAL VE (GND> r=> 2
l-t
c
NO
=
VALVE~
YLLO'"
~3
J
"----/ ~ IIHITE YEllOII
•• LLE:
>C"'''' 20
lOV~ 11~24VAC
I
:x:
rr
::;l'i~
-'
"J"
YELLO'"
f'l
><
/"\..f /"
IGNITION .1 '\ BLACK YEllOII 1
TRANSFORMER
BLACK
-fro..
/" 1"\ ~
\..
II..-
~
~'\
~
-Ll
BLACK
I
'\
(HOn
/"'\
-
L2 IJHITE
0
.,.
:0
'"
-
(NEUn
1>
r
z
1>
I
BLACK
T"'HITE Cl
n
f'l
><
II
VI
[Z) I
~lV\
10 II ~lV\
GAS SHUTOFF
VALVES
IGNITER
A
1.
ELECTRODE
-
62391-003
I
BLACK
""'"
BLACK
-
oNo
BLACK
I"NO I
\.fIRING DIAGRAM
"EHG"
HIGH PRESSURE
COM 6'?NC
I COM 6 yNC
LOIJ PRESSURE
63495 001 REV C
SIJITCH
S'w'ITCH
FIGURE 14