Wayne SC80 User manual

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BURN
E
SC80
ELECT
R
INSTALLA
T
REGULATI
ALL LOCA
INCORRE
C
AND COU
L
A QUALIF
THE EQUI
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ICAL Powe
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ION OF THE
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PMENT AND
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N
D ORDINAN
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B
URNER I
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Man
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D
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BURNER MU
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ECI
F
U
M INPUT
Btu/hr
(
6 k
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C|Publicat
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B
URNER
I
ED INSTALL
E
.
1/NFPA 54,
A
.
H
IS BURNER
W
OR SUBSTA
N
B
LE FOR THE
U
RNING EQUI
P
D
MAX AI
R
L
NEED AIR
M
G
A
T
IO
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80,000 Btu
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dj
ustable flan
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ructions is
property d
a
ionDate:Jan
y
.Englishval
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
E
R IN ACCO
R
A
ND IN COMP
L
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ILL VOID TH
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TIAL PROPE
INSTALLATI
O
P
MENT IN AC
R
. BURNER
M
ADJUSTME
N
M
O
D
SC
8
A
S BU
N
S
M
INPUT
/hr (23 kW)
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e is standar
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uary31,201
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2
THESE INSTRUCTIONS SHOULD BE AFFIXED TO THE BURNER OR ADJACENT TO THE
HEATING APPLIANCE.
INSTALLATION LOG
BURNER MODEL: SPECIFICATION NUMBER: FUEL (NATURAL OR
PROPANE):
GAS ORIFICE DRILLED
SIZE:
INLET GAS PRESSURE
(in. w.c.):
CO2 (%): O2 (%): CO (PPM):
INSTALLER’S NAME: CONTRACTOR NAME: CONTRACTOR
ADDRESS:
CONTRACTOR PHONE
NUMBER:
CONTRACTOR LICENSE #: DATE OF INSTALLATION:
COMMENTS ABOUT INSTALLATION/START UP:
BURNER/APPLIANCE SERVICE LOG
SERVICE
DATE TECHNICIAN
COMPANY
/ADDRESS
CONTRACTOR
LICENSE#
WORKPERFORMED
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
F
F
OR YO
V
APO
WHAT T
 Ope
n
 Do n
o
 Do n
o
 Exti
n
 Imm
e
sup
p
 If yo
u
spre
a
ELE
C
HIGH V
O
EQUIPMEN
T
 Use o
n
fault i
n
 Do no
t
 Turn
o
 Read
t
C





UR SAF
T
RS AND
L
O DO IF Y
O
n
windows
o
t try to li
g
o
t touch e
n
guish an
y
e
diately c
a
p
lier’s inst
r
u
cannot r
e
a
de
r
adjust
m
C
TRIC S
H
O
LTAGES A
T
. FOLLOW
T
ELECTR
I
n
ly a properl
y
n
terrupter is r
e
t
spray water
o
ff power bef
o
t
he owner’s
m
ARBON MO
N

Do not u
s
accumul
a

Do not m

Check fl
u

A
llow onl
y
training
a

Read the

T
EY: D
O
L
IQUIDS I
N
O
U SMEL
L
.
g
ht any ap
lectrical s
w
y
open fla
m
a
ll your ga
s
r
uctions.
e
ach your
For shipp
i
m
ent is man
d
H
OCK H
A
R
E PRESEN
T
HESE RUL
E
I
C SHOCK.
y
grounded ci
r
e
commende
d
directly on b
u
o
re servicing.
m
anual befor
e
N
OXIDE IS
A
THESE
R
s
e this burne
r
a
te.
isadjust the
p
u
e gases for
c
y
qualified b
u
re required.
owner’s ma
n
O
NOT ST
O
N
THE VIN
C
L
GAS:
p
liances.
w
itches; d
o
m
e.
s
supplier
gas suppl
i
ng purpose
s
d
atory and
a
A
ZARD
T
IN THIS
E
S TO AVOI
D
r
cuit. A grou
n
d
.
u
rner.
e
using.
A
COLORLE
S
R
ULES TO C
O
r
if in an unve
p
ressure regu
c
arbon mono
x
u
rner service
p
n
ual before u
s
3
O
RE OR U
C
INITY OF
o
not use
a
from a nei
ier, call th
e
s
, the flame
a
ffects burn
e
D
n
d
SH
O
C
A
P
O
S
S, ODORL
E
O
NTROL CA
R
nted, enclos
e
lator. High p
r
x
ide. This ch
e
p
ersons to a
d
s
ing.
SE GASO
L
F
THIS OR
A
a
ny phon
e
ghbor’s p
h
e
fire dep
a
spreade
r
, i
f
e
r ignition a
n
OVE
R
O
ULD OVER
H
 Shut off
t
 Do not s
h
A
RBON
M
O
ISONIN
E
SS GAS TH
A
R
BON MON
O
e
d area. Car
b
r
essures pro
d
e
ck requires
s
d
just the burn
L
INE OR
O
A
NY OTH
E
e
in your b
u
h
one. Foll
o
a
rtment.
f
adjustable,
n
d performa
R
HEATI
N
H
EATING O
C
t
he manual g
a
h
ut off the co
n
M
ONO
X
G HAZ
A
A
T CAN KIL
L
O
XIDE.
b
on monoxid
e
d
uce carbon
m
s
pecialized e
q
er. Special i
n
O
THER FL
A
E
R APPLI
A
u
ilding.
o
w the ga
s
is fully retr
a
nce.
N
G HAZA
R
C
CUR:
a
s valve to t
h
ntrol switch t
o
X
IDE
A
RD
L
. FOLLOW
e
may
m
onoxide.
q
uipment.
n
struments a
n
A
MMABLE
A
NCE.
s
a
cted. Flam
e
R
D
h
e appliance.
o
the blower.
n
d
e

4
CONTENTS
SECTION I: INSTALLATION AND SETUP………………………………………………................................……….………......5
A. INSTALLATION OF MOUNTING FLANGE……………………………………………………….….................................5
B. DETERMINE ORIFICE SIZE AND RATE…………………………………………………………….…............................6
C. CHANGING THE ORIFICE………………………………………………………………………….………………..............7
D. INSPECTION AND SIZING OF GAS PIPING…………………………………………………….……………..................9
E. TESTING PIPING FOR LEAKS…………………………………………………………………….……………................11
F. ELECTRICAL WIRING OF BURNER…………………………………………………………….……………..................11
G. INSPECTION OF LIMIT CONTROL SWITCHES……………………………………………….………………..............12
H. LOW/HIGH SC80 MODEL………………………………………………………………………….……...........................13
I. ELECTRICAL WIRING OF LOW/HIGH SC80………………………………………………….………….......................13
SECTION II INITIAL START UP…………………………………………………………………………….…………....................14
A. OPERATION OF BURNER………………………………………………….…………………….....................................14
B. COMBUSTION ADJUSTMENT OF BURNER…………………………………………………….……..........................15
C. FINAL INSTALLATION INSTRUCTIONS………………………………………………………….…………...................15
SECTION III GAS CONVERSION…………………………………………………………………………….…............................16
A. NATURAL GAS AND LP CONVERSION INSTRUCTIONS……………………………………….…………................16
SECTION IV CONSUMER INSTRUCTIONS………..……..…………………………………….…………….............................16
A. GENERAL INSTRUCTIONS FOR SERVICING BURNER……………………………..………...................................16
SECTION V SERVICE AND TROUBLESHOOTING……………………………………………..…………….……...................17
A. NORMAL OPERATION CHECK OF BURNER……………………………………………..………….….......................17
B. TROUBLESHOOTING GUIDE………………………….……………………………………..………….……..................17
C. PRELIMINARY CHECKS, DIAGNOSIS AND SERVICE HINTS……………………………..……….…......................18
D. COMPONENT TROUBLESHOOTING AND DIAGNOSIS……………………………………………...........................19
E. MORE SERVICE HINTS…………………………………………………………………………………….……................20
F. FLAME ROD AND SPARK ELECTRODE SPACING………………………………………………..…….....................21
G. WIRING DIAGRAMS…………………………………………………….………….………………………........................22
SECTION VI PARTS LIST AND EXPLODED VIEWS ………..………………………….…………………………....................23
A. EXPLODED VIEWS………………………………………………………………….……………….…………..................23
B. PARTS LIST…………………………………………………………………………….……………….…..........................25
SECTION VII WARRANTY………………………..…………………………….……………….……………………......................26
A. WARRANTY…………...…..…………………………………………………………….…………………..........................26

This
natu
r
maki
burn
e
NOT
adju
s
Posi
t
appli
Note
the fl
Inse
r

manual is a
g
r
al gas or LP
ng the SC80
e
r is supplied
E: The burn
e
s
tment and r
e
t
ion the mou
n
ance allows
t
the orientati
o
ange. Tighte
n
r
t the burner
t
g
uide for the i
fired burner
c
as simple an
as a comple
e
r must be in
s
e
pairs.
n
ting flange o
n
t
he flange to
s
o
n of the flan
g
n
the flange t
o
t
ube into the
f
SECTI
O
nstallation a
n
c
apable of firi
d easy to ins
t
tely assembl
e
s
talled in suc
h
INS
T
n
the applian
c
s
it flush. (Se
e
g
e and remo
v
o
the applian
c
f
lange and p
o
Figure 1:
O
N I: INS
T
n
d operation
o
ng in the ran
g
t
all and servi
c
e
d package
u
h
a manner th
T
ALLATION
c
e wall, adju
s
e
Figure 1 for
v
e it so that t
h
c
e wall.
o
sition the bu
r
Adjustable
5
T
ALLATIO
N
o
f the Wayne
g
e of 20,000
–
c
e as possibl
e
u
nit.
at all control
s
OF MOUNTI
s
ting orientati
o
flange dime
n
h
e flange gas
r
ner in the ap
Mounting Fl
a
N
AND SE
T
Combustion
–
80,000 Btu
/
e
without we
a
s
will be read
i
NG FLANG
E
o
n as neces
s
n
sions.)
ket may be p
p
pliance. Tigh
a
nge Dimen
s
T
UP
Systems SC
/
hr. Due con
s
a
kening its d
u
i
ly accessibl
e
E
s
ary until the
b
laced betwe
e
ten the flang
e
s
ions
80 burner. T
h
s
ideration wa
s
u
rability or eff
i
e
for inspecti
o
b
olt pattern o
f
e
n the applia
n
e
onto the bu
r
h
e SC80 is a
s
given to
i
ciency. The
o
n, cleaning,
f the
n
ce wall and
rner tube.

as co
m
for lea
k
Once the
burners c
o
burners o
orifices si
z
To deter
m
the prope
drilled wit
NOTE: N
u
been pro
bit size.
The corr
e
should b
e
mbar) an
d
should b
e
range.
The corr
e
be made
maximu
m
pressure
a
Btu/hr
(
20,
0
25,
0
30,
0
35,0
0
40,0
0
45,0
0
50,0
0
55,0
0
60,0
0
65,0
0
70,0
0
75,0
0
80,0
0
m
bustion c
h
k
s using a
s
desired heat
o
me with an
o
r .071” diam
e
z
ed per cust
o
m
ine the prop
e
r column bas
h
a #19 drill
b
u
mbered dri
v
ided in Ta
b
e
ct manifold p
e
made by ad
j
d
the maximu
e
used if the
d
e
ct manifold p
by adjusting
t
m
pressure 10
a
nd adjustm
e
(
kW) Input
00 (5.9)
00 (7.3)
00 (8.8)
0
0 (10.3)
0
0 (11.7)
0
0 (13.2)
0
0 (14.7)
0
0 (16.1)
0
0 (17.6)
0
0 (19.0)
0
0 (20.5)
0
0 (22.0)
0
0 (23.4)
LP gas is
h
h
ambers or
s
oapy solu
t
DE
output of the
o
rifice near t
h
e
ter for propa
n
o
mer specific
a
e
r orifice siz
e
ed on the ga
s
b
it (0.166”).
l
l bit sizes a
r
b
le 1 as assi
s
ressure for n
a
j
usting the pr
e
m pressure
s
d
esired input
r
ressure for L
.
t
he pressure
.0” w.c. (25
m
e
nt range the
n
Ta
b
Natura
l
Num
b
Letter/F
r
#4
5
3/3
2
#3
8
7/6
4
#3
2
1/8
#3
0
#2
9
9/6
4
#2
5
5/3
2
#2
0
#1
9
h
eavier tha
n
heat excha
t
ion applie
d
TERMINE O
R
burner has
b
h
e low end of
n
e fired burn
e
a
tions.
e
for the appli
c
s
to be used.
r
e valid bit s
i
s
tance in de
t
a
tural gas is
3
e
ssure regul
a
s
hould be 3.5
”
r
ating cannot
.
P. gas is 10”
r
egulator. Th
e
m
bar). If the d
e
n
the next siz
b
le 1: Orific
e
l
Gas: 3.5” w
b
er/
r
action
5
2
”
8
4
”
2
”
0
9
4
”
5
2
”
0
9
6
n
air and wi
ngers. All
c
d
to gas co
n
R
IFICE SIZE

b
een determi
n
the burner’s
e
rs). Burners
c
ation, refer t
o
Example: To
i
zes. They a
r
t
ermining cl
o
3
.5” w.c (8.7
m
a
tor. The mini
”
w.c. (8.7 m
b
be obtained
w
w.c. (25 mb
a
e
minimum
m
e
sired input r
e larger or s
m
e
Size and D
r
.c. (8.7 mbar
)
Decimal (i
n
0.082
0.094
0.101
0.109
0.116
0.125
0.129
0.136
0.144
0.150
0.154
0.161
0.166
i
ll settle in
l
c
onnection
s
n
nections.
AND RATE
n
ed, the gas
o
firing range (
produced fo
r
o Table 1 bel
fire 80,000
B
r
e machinis
t
o
sest fractio
n
m
bar). Only
m
i
mum manifo
l
b
ar). The nex
t
w
ithin the ab
o
a
r). Only min
o
m
anifold pres
s
r
ating cannot
m
aller orifice
s
r
ill Bit Chart
)
P
r
n
) Nu
m
l
ow lying a
r
s
should b
e
o
rifice must
b
.0846” diam
e
r
OEM applic
a
ow. Locate t
h
B
tu/hr on nat
u
t
’s drill bits.
D
nal drill bit
s
m
inor adjust
m
l
d pressure s
h
t
size larger
o
o
ve manifold
o
r adjustmen
t
s
ure should b
be obtained
w
s
ize should b
r
opane Gas:
m
ber/Fraction
3/64”
#55
#53
1/16”
#50
#48
5/64”
#45
#43
3/32”
#41
#39
#37
r
eas such
e
checked
b
e properly si
z
e
ter for natur
a
a
tions will ha
v
h
e drill size b
y
u
ral gas requi
D
ecimal val
u
s
ize to the n
u
m
ents in the i
n
h
ould be 3.0”
o
r smaller ori
f
pressure adj
u
t
s in the inpu
t
e 9.5” w.c. (2
w
ithin the ab
o
e used.
10” w.c. (25
m
Deci
m
0.
0
0.
0
0.
0
0.
0
0.
0
0.
0
0.
0
0.
0
0.
0
0.
0
0.
0
0.1
0.1
z
ed. Stock
a
l gas fired
v
e their
y
selecting
res an orifice
u
es have
u
mbered dril
n
put rate
w.c. (7.5
f
ice size
u
stment
t
rate should
4 mbar), the
o
ve manifold
m
bar)
m
al (in)
0
47
0
52
0
60
0
63
0
70
0
76
0
78
0
82
0
89
0
94
0
96
00
04
l

NOT
sho
w
1) T
u
2) T
h
3) Di
dep
e
4) M
u
EXA
M
ther
e
of 1
0
IMP
O
Whe
To i
n
size.
Befo
nuts
E: The Btu/h
r
w
n. To deter
m
u
rn off all oth
e
h
e hand with
t
vide 3,600 b
y
e
nding on siz
e
u
ltiply the nu
m
M
PLE: Time
e
fore 50 x 2 i
s
0
7,500 Btu/hr
O
RTANT: Th
e
Th
e
V
alve
n leaving the
n
crease the B
To determin
e
re replacing
t
that hold the
r
input value
s
m
ine the actu
a
e
r gas applia
n
t
he lowest cu
y
the time in
s
e
of meter.)
m
ber from st
e
in seconds f
o
s
100. Multipl
y
(31.5 kW). U
e
minimum s
u
e
maximum
s
is rated for
0
factory, eac
h
tu/hr rating (i
n
e
drill bit size
he orifice, ga
orifice holde
r
s
in Table 1 s
h
a
l input of the
n
ces.
bic feet valu
e
s
econds for o
e
p (3) by the
h
o
r one compl
e
y
100 by hea
t
se a heating
u
pply pressu
r
s
upply press
u
0
.5 PSI or 14
h
stock burne
r
n
crease the
h
for required
r
s supply and
r
and gas pip
e
Figure 2: O
h
ow the appr
o
burner by us
e
(fastest rev
o
ne complete
h
eating valu
e
e
te revolution
t
ing value of
g
value of 250
0
r
e is 4.5” w.c.
u
re is 14” w.c.
” w.c. Over
p
CHANGI
N
r
is sent out f
i
h
eating outpu
r
ate, see Tab
power must
b
e
train to the
rifice Holde
r
7
o
ximate hour
l
ing the gas
m
o
lving dial) sh
revolution an
d
e
of the gas t
o
of dial is 72.
g
as which is
1
0
for LP gas.
(11 mbar) fo
(35 mbar) f
o
p
ressurizing
N
G THE ORI
i
ring close to
t) the orifice
m
le 1.
b
e shut off. T
back of the b
r/
Gas Pipe T
r
l
y input of th
e
m
eter, follow t
h
ould be cloc
k
d multiply by
o
obtain the i
n
3,600 divide
d
1
,075 for nat
u
r natural gas
o
r natural gas
valve may
c
FICE
the minimu
m
m
ust either b
e
T
o replace th
e
urner (Figur
e
r
ain Screw
L
e
burner for t
h
t
hese steps:
k
ed for one c
o
the dial valu
e
n
put rate in B
t
d
by 72 is 50,
u
ral gas; and
and 11” w.c.
and 14” w.c.
c
ause dama
g
m
Btu/hr ratin
g
e
changed o
r
e
orifice, loca
t
e
2).
L
ocation
h
e various dri
l
o
mplete revo
l
e
(1, 2, or 5 c
u
t
u per hour.
2 cubic foot
w
this will give
y
(27 mbar) fo
r
(35 mbar) fo
g
e to the val
v
g
.
r
drilled out t
o
t
e and remov
e
ll bit sizes
l
ution.
ubic feet
w
as timed
you an input
r
L.P. gas.
r L.P. gas.
v
e.
o
the correct
e
the four

Pull
t
the
o
To d
r
linin
g
and
s
man
NOT
The
b
t
he gas train
o
o
rifice with a
9
r
ill the orifice,
g
up the drill
b
s
ecure the g
a
ual.
E: Numbere
d
b
urner is no
w
o
ut of the bu
r
9
/16” wrench
place it face
b
it easier. De
b
a
s pipe train t
o
d
and lettered
w
ready to be
r
ner. The orifi
c
(Figure 3).
down in a vi
c
b
urr the orific
e
o
the back of
drill sizes ar
e
connected to
c
e is located
Figure 3
:
c
e and drill th
e
and mark n
the burner u
s
e
valid bit siz
e
the gas sup
p
8
on the end o
f
:
Orifice Loc
a
rough the ba
c
ew size on o
r
s
ing the nuts.
e
s. They are

p
ly piping; se
e
f
the gas trai
n
ation
c
k side. The
b
r
ifice with pe
r
.
Record dril
machinist’s d
e
instruction
s
n
and looks li
k
b
ack side is t
r
manent mar
k
led orifice s
i
d
rill bits.
s
in next secti
o
k
e a brass pl
u
apered and
w
k
er. Reinstall
i
ze in install
a
o
n.
u
g. Remove
w
ill make
the orifice
a
tion log in

A
ll pi
sedi
m
upst
r
plug
g
conn
in th
e
The
g
and l
be d
u
Alu
m
mal
e
It is
r
build
othe
r
be b
e
The
g
free
z
not
b
from
mba
r
valv
e
gau
g
2imp
e
thre
a
ping must co
m
ent trap or
d
r
eam from th
e
g
ed tapping
p
ection for th
e
e
gas supply
g
as line shou
ocated so th
a
u
rable, subst
a
m
inum tubing
s
e
threads onl
y
r
ecommende
d
ing structure
r
piping, but
s
e
nt. Note: E
a
g
as piping s
h
z
ing.
A
horiz
o
b
e run throug
h
the gas sup
p
r
gauge). Th
e
e
during any
p
g
e).
Figure 4:
M
Man
u
e
rfect
a
ds
mply with loc
d
rip leg must
e
control ma
n
p
ort accessibl
e
purpose of
d
line external
t
ld be a sepa
r
a
t a minimu
m
a
ntial, and g
a
s
hould not b
e
y
and be appr
o
d
that tables
2
should not b
e
s
hould be fir
m
a
ch elbow, u
n
ould be so in
o
ntal pipe sh
o
h
or in an air
d
p
ly piping sys
t
e
appliance
m
p
ressure testi
1/
8
Plugg
e
Pressur
e
M
anual Shut
Pressure T
a
u
al Shutoff Val
v
INS
P
al codes and
be installed i
n
ifold and do
w
e
for test gau
d
etermining t
h
t
o the applia
n
r
ate supply di
amount of
w
a
s tight. It sh
o
e
used for the
o
ved for all g
a
2
, 3, and 4 b
e
e
weakened
b
m
ly supported
n
ion, and te
e
stalled so as
o
uld be pitch
e
d
uct or cloth
e
t
em during a
n
ust be isolat
e
ng of the ga
s
8
” NPT
e
d Tapping
e
Gauge Port
off Valve an
d
a
p
v
e
Leave2end
threadsbare
P
ECTION AN
D
ordinances
o
n
the supply l
w
nstream fro
m
ge connectio
h
e gas suppl
y
n
ce (See Fig
u
rect from the
w
ork will be re
q
o
uld be clear
a
main gas su
a
ses.
Figure 6: Pr
o
e
used to det
e
b
y installation
with pipe ho
o
e
adds appr
o
to prevent a
n
e
d so that it g
r
e
s chute. The
n
y pressure t
e
e
d from the g
a
s
supply pipin
g
d

9
D
SIZING O
F
o
r the Nation
a
ine to the bu
r
m
the sedime
n
n shall be in
s
y
pressure to
u
re 4).
meter to the
q
uired in futu
a
nd free from
pply. Joint c
o
Pipe
S
Inch (
m
3/8 (
9
1/2 (1
2
3/4 (1
9
1 (25
o
per Piping
e
rmine the si
z
for the gas
p
o
ks, straps, b
o
ximately 2.
5
n
accumulati
o
r
ades toward
appliance a
n
e
sting of the
s
a
s supply pip
g
system at t
e
3” minim
u
(76 mm
)
F
GAS PIPIN
G
a
l Fuel Gas
C
r
ner. A union
n
t trap or dri
p
s
talled imme
d
the burner.
A
burner. It is
r
re servicing.
cutting burr
s
o
mpounds (pi
p
S
ize
m
m)
Ef
f
9
.5)
2
.7)
9
.1)
1
.4)
Practice
z
e pipe to us
e
p
iping. The pi
ands or han
g
5
feet of pip
e
o
n of conden
s
the meter a
n
n
d its individu
s
ystem at tes
ing system b
y
e
st pressure
s
D
i
Pi
u
m
)
Location of
u
conver
s
Figure 5:
P
G
C
ode ANSI Z
2
shall be inst
a
p
leg (See Fi
g
d
iately upstre
a
A
manual shu
t
r
ecommende
d
The piping s
h
s
and defects
p
e dope) sho
f
ective Leng
Thread
Inch (mm
)
3/8 (9.5)
1/2 (12.7)
1/2 – 9/16 (1
4
9/16 (14.3
)
e
from the m
e
ping should
n
g
ers. Butt or l
a
e
.
s
ation and it
m
n
d is free fro
m
al shutoff val
v
t pressure in
y
closing its i
n
s
equal to or l
i
rection of Flo
w
Tee
Control
M
pe Cap
u
nion and dri
p
s
ion burner t
o
P
ipe Union a
n
Floor
L
2
23.1/NFPA
N
a
lled in the g
a
g
ure 5). A 1/8
”
a
m of the ga
s
t
off valve sha
d
that new pi
p
h
ould be so i
n
in structure
o
uld be used
s
th of
)
Ov
o
I
9
4
.3) 1
)
e
ter to the bu
r
n
ot be suppo
r
a
p welded pi
p
m
ust be prot
e
m
sags. The p
v
e must be d
i
excess of 1/
2
n
dividual ma
n
ess than 1/2
w
Union
M
anifold
p
leg for con
n
o
house pipin
g
n
d Fittings
L
evel
N
o. 54. A
a
s line
”
NPT
s
supply
ll be installe
d
p
e be used
n
stalled as to
o
r threading.
s
paringly on
erall Length
o
f Thread
I
nch (mm)
9
/16 (14.3)
3/4 (19.1)
3/16 (20.6)
1 (25.4)
r
ner. The
r
ted by the
p
e should no
t
e
cted against
p
ipe should
i
sconnected
2
psig (34
n
ual shutoff
psig (34 mb
a
n
ecting
g
.
r

10
Table 2: Pipe Sizing Chart for Natural Gas (0-0.5 psi) with Straight Schedule 40 Metal Pipe
The following chart is based on 0-0.5 psi inlet pressure, specific gravity of 0.6, and a pressure loss of 0.5” w.c..
Maximum Capacity of Pipe Size in Btu per Hour
Length of
Pipe (ft) 1/2” 3/4” 1” 1 1/4” 1 1/2”
10 175,000 360,000 680,000 1,400,000 2,100,000
20 120,000 250,000 465,000 950,000 1,460,000
30 97,000 200,000 375,000 770,000 1,180,000
40 82,000 170,000 320,000 660,000 990,000
50 73,000 151,000 285,000 580,000 900,000
60 66,000 138,000 260,000 530,000 810,000
70 61,000 125,000 240,000 490,000 750,000
80 57,000 118,000 220,000 460,000 690,000
90 53,000 110,000 205,000 430,000 650,000
100 50,000 103,000 195,000 400,000 620,000
150 40,000 84,000 160,000 325,000 500,000
200 35,000 72,000 135,000 280,000 430,000
Table 3: Pipe Sizing Chart for Liquid Propane (11” w.c.) with Straight Schedule 40 Metal Pipe
The following chart is based on 11” w.c. inlet pressure and a pressure drop of 0.5” w.c.
Special use:Piping sizing between single or second stage (low pressure regulator) and appliance.
Maximum Capacity of Pipe Size in Btu per Hour
Pipe
Size 1/2” 3/4” 1” 1 1/4” 1 1/2” 2” 3”
Actual ID 0.622 0.824 1.049 1.38 1.61 2.067 3.068
Length
of Pipe
(feet)
Maximum Capacity in Btu/hr
10 291,000 608,000 1,145,000 2,352,000 3,523,000 6,786,000 19,119,000
20 200,000 418,000 787,000 1,616,000 2,422,000 4,664,000 13,141,000
30 160,000 336,000 632,000 1,298,000 1,945,000 3,745,000 10,552,000
40 137,000 287,000 541,000 1,111,000 1,664,000 3,205,000 9,031,000
50 122,000 255,000 480,000 984,000 1,475,000 2,841,000 8,004,000
60 110,000 231,000 434,000 892,000 1,337,000 2,574,000 7,253,000
80 94,000 197,000 372,000 763,000 1,144,000 2,203,000 6,207,000
100 84,000 175,000 330,000 677,000 1,014,000 1,952,000 5,501,000
125 74,000 155,000 292,000 600,000 899,000 1,730,000 4,876,000
150 67,000 140,000 265,000 543,000 814,000 1,568,000 4,418,000
200 58,000 120,000 227,000 465,000 697,000 1,342,000 3,781,000
250 51,000 107,000 201,000 412,000 618,000 1,189,000 3,351,000
300 46,000 97,000 182,000 373,000 560,000 1,078,000 3,036,000
350 42,000 89,000 167,000 344,000 515,000 991,000 2,793,000
400 40,000 83,000 136,000 320,000 479,000 922,000 2,599,000

11
Table 4: Pipe Sizing Chart for Liquid Propane (11” w.c.) with Copper Tubing
The following chart is based on 11” w.c. inlet pressure and a pressure drop of 0.5” w.c.
Maximum Capacity of Tube Size in Btu per Hour
Pipe Size 1/2” 5/8” 3/4” 7/8”
Length (feet)Maximum Capacity in Btu/hr
10 110,000 206,000 348,000 536,000
20 76,000 141,000 239,000 368,000
30 61,000 114,000 192,000 296,000
40 52,000 97,000 164,000 253,000
50 46,000 86,000 146,000 224,000
60 42,000 78,000 132,000 203,000
70 38,000 71,000 120,000 185,000
80 36,000 67,000 113,000 174,000
90 33,000 62,000 105,000 161,000
100 32,000 59,000 100,000 154,000
NOTE: Copper tubing shall comply with standard type K or L of ASTM B 88 or ASTM B 280.
TESTING PIPING FOR LEAKS
Before turning gas under pressure into piping, all openings from which gas can escape should be closed. Immediately
after turning on gas, the system should be checked for leaks. This can be done by watching the 1/2 cubic feet test dial
and allowing 5 minutes to show any movement, or by soaping each pipe connection and watching for bubbles. If a leak is
found, make the necessary repairs and repeat the above test. Defective pipes or fittings should be replaced and not
repaired. Never use a flame or fire in any form to locate gas leaks, use a soap solution.
After the piping and meter have been checked completely, purge the system of air. Do not bleed the air inside the furnace.
Be sure to relight all the gas pilots on other appliances.
ELECTRICAL WIRING OF BURNER
The SC80 burner is shipped completely wired. It is only necessary to supply the 120 volt circuit, thermostat and limit
circuit. All wiring must conform with the National Electric Code or the code legally authorized in the locality where the
installation is being made. The burner, when installed, must be electrically grounded in accordance with local codes or, in
the absence of local codes, with the latest edition of the National Electrical Code, ANSI/NFPA No. 70. See wiring
diagrams in the Section V: Service and Troubleshooting for reference on wiring, thermostat connection, and limit circuit. If
an external electrical source is utilized, the conversion burner, when installed, must be electrically grounded in
accordance with local codes or, in the absence of local codes, with the latest edition of the National Electrical Code
ANSI/NFPA No. 70.
The burner ships with a jumper wire on the thermostat (T-T) terminals. The jumper needs to be removed for remote
thermostat control and the thermostat needs to be connected per wiring diagrams. T-T terminal is an open/close switch for
the burner and no voltage should be connected to it. For boilers it may be necessary to leave the T-T terminal jumped as
the aquastat may be providing the voltage to the burner and controlling when voltage is sent to the burner. The burner is
controlled by the appliance. Once wiring is complete between burner and appliance, verify appliance is controlling the
burner’s on/off operation. When connecting the burner to the 120 volt electrical supply, utilize the knockout provided on
the burner’s junction box.

T‐
T
JUMP
E
Warm air
Hot wate
r
or vapor
b
dangerou
T
TERMINAL
E
RWIRE
furnaces (gr
a
r
boilers (forc
e
b
oilers shoul
d
sly low.
INSPE
a
vity and forc
e
e
d or gravity)
d
be provided
CTION OF L
e
d air) shoul
d
should be e
q
with means
t
Figure 7: T-
T
CONNECT
LINE
VOLTAGE
12
IMIT CONT
R
d
be equippe
d
q
uipped with
a
t
o guard agai
T
Terminal
L
R
OL SWITCH
d
with an aut
o
a
n automatic
nst firing a d
r
L
ocation
ES
o
matic temp
e
temperature
r
y boiler or o
n
e
rature limit c
o
limit control
s
n
e in which th
o
ntrol switch.
s
witch. Stea
m
e water is
m

The
S
gas
v
SC8
0
natu
r
mod
e
pres
s
the
h

The
L
sam
e
requ
i
sep
a
ener
g
conn
be c
o
S
C80 Low/Hi
v
alve marked
0
Low/High
m
r
al and propa
e
. Low fire m
o
s
ure required
h
igh rate requ
L
ow/High SC
e
as the stan
d
i
res a separa
t
a
rate thermos
t
g
ized which i
s
ected to the
h
o
nnected to t
h
gh model op
e
“LO HI” nea
r
m
odel contain
s
ne gas. The
t
o
de utilizes t
h
to achieve a
ired for the a
p
Btu/hr(kW)
Input
30,000(8.8
)
40,000(11.
7
50,000(14.
7
60,000(17.
6
70,000(20.
5
80,000(23.
4
80 is wired s
i
d
ard SC80 a
n
t
e 24VAC th
e
t
at controls
w
s
controlled
b
h
igh terminal
h
e separate
2
e
rates at diff
e
r
the solenoid
s
a low firing
t
able below li
s
h
e same orifi
c
desired low
m
p
plication.
Table 5: Hi
g
Natur
a
Numbe
r
)

#
7
)
#
7
)
#
6
)
#
5
)
#
4
)
#
E
milar to the
s
n
d utilizes th
e
e
rmostat to p
o
w
hen high fire
b
y the SC80’
s
and the bro
w
2
4VAC therm
o
Figur
e
Low/Hi
e
rent gas pre
s
and has fou
r
rate and a hi
g
s
ts orifice siz
e
c
e as high fir
e
m
ode firing r
a
g
h Fire Mod
e
a
l Gas: 3.5” w.
r
/Fraction
#
38
#
32
#
30
#
27
#
23
#
19
E
lectrical Wi
r
s
tandard SC8
0
e
same (T-T)
t
o
wer the high
mode is ene
r
s
ignition cont
w
n wire is con
o
stat and req
e
8: Wiring
D
13
gh SC80 M
o
s
sures than t
h
r
terminals c
o
g
h firing rate.
e
s based on
t
e
mode but u
s
a
te is depend
e
e
Orifice Siz
e
c. (8.7 mbar)
Decimal (in)
0.101
0.116
0.129
0.144
0.154
0.166
r
ing of Low/
H
0
, but utilize
s
t
erminals me
n
fire side of t
h
r
gized, but hi
g
rol. A wiring
d
nected to th
e
uire 24VAC.
D
iagram for
L
o
del 
h
e standard
S
o
nnected to t
h
The Low/Hi
g
t
he manifold
s
es a reduce
d
ent on the or
i
e
and Drill B
Propane
G
Number/
F
2.15
m
#4
1
#3
6
3.00
m
3.20
m
#2
9
H
igh SC80
s
a different v
a
n
tioned for th
h
e gas valve
a
g
h fire mode
d
iagram is sh
e
common wi
r
L
ow/High SC
S
C80 model.
T
h
e gas valve
i
g
h SC80 ope
r
pressure of
3
d
pressure to
i
fice selected
it Chart
G
as: 3.5” w.c.
F
raction D
e
m
m
1
6
m
m
m
m
9
a
lve. The lo
w
e standard S
a
nd low fire
m
will not oper
a
own below.
T
r
e. The yello
w
80
This model h
i
nstead of ju
s
r
ates at 3.5 i
n
3
.5 in. w.c. fo
r
achieve its l
o
so it can var
y
(8.7 mbar)
e
cimal (in)
0.085
0.096
0.107
0.118
0.126
0.136
w
fire mode o
p
C80. High fir
e
m
ode to be e
n
a
te unless lo
w
T
he yellow wi
r
w
and brown
w
as a special
s
t two. The
n
. w.c. on bot
h
r
the high fire
o
wer rate. Th
e
y
depending
p
erates the
e
mode
n
ergized. Th
e
w
fire mode i
s
r
e is
w
ires are to
h
e
e

S
T
BU
R
On
e
purg
e
Sim
u
spar
k
for i
g
dete
c
secti
o
SAF
E
The
t
expi
r
cont
r
be r
e
“ON
”
If no
r
Gas
v
S
tarting the b
u
 Ensu
r
 Have
sequ
e
T
o put burner
 Turn
o
Figure 9:
R
NER OPER
A
e
very call for
h
e
, the ignitio
n
u
ltaneously, t
h
k
at the burn
e
g
nition, the b
u
c
ted after the
o
n titled SAF
E
TY LOCK-
O
t
rial for igniti
o
r
es prior to th
e
r
ol will go int
o
e
set by remo
v
”
.
r
mal ignition
d
valve
Motor
/
asse
m
u
rner:
r
e power and
the applianc
e
e
nce describ
e
out of opera
t
o
ff electrical
s
Burner Co
m
A
TION
h
eat (system
n
control ope
n
h
e electronic
e
r spark elect
u
rner will try t
o
third trial for
ETY LOCK-
O
O
UT TIME
o
n timer circu
i
e
detection o
f
o
a “lock-out”
c
v
ing the call f
o
d
oes not occ
u
/
blower
m
bly
S
E
gas are bein
e
thermostat
c
e
d in the sect
i
t
ion:
s
upply.
m
ponent Loc
start), the ig
n
n
s the gas val
spark gener
a
rode, igniting
o
light two m
o
ignition, the i
g
O
UT TIME.
t starts timin
g
f
a flame, the
c
ondition. B
e
o
r heat or po
w
u
r, use Secti
o
E
CTION II:
OPERA
T
g supplied to
c
all for heat.
i
on below.
ations
n
ition control
p
ve operator i
n
a
tor in the co
n
the gas flowi
o
re times, ea
c
g
nition contr
o
g
the momen
t
ignition cont
r
e
fore another
w
ering off the
o
n V: Servicin
Igniti
o
contr
o
Junc
t
box
14
INITIAL S
T
T
ION OF BU
R
the burner.
Burner shoul
d
p
erforms a 3
0
n
the gas co
n
n
trol produce
s
ng around th
e
c
h preceded
b
o
l will go into
a
t
the trial for i
g
r
ol will attem
p
attempt to s
t
appliance.
W
g and Troubl
e
Outle
pres
s
tap
o
n
o
l
t
ion
T
ART UP
R
NER
d
start after
p
Figure 1
0
0
second pre
-
n
trol. This all
o
s
a spark pul
s
e electrode. I
b
y another 3
0
a “lock-out”
c
g
nition starts
.
p
t to light aga
t
art the burne
W
ait at least
o
e
shooting to
d
V
e
t
s
ure
Gas outl
e
p
rogressing t
h
0
: Detailed
V
-
purge. Upo
n
o
ws gas to flo
s
e output. Th
i
f flame is no
t
0
second pre
-
c
ondition. If t
h
. If the desig
n
in. After faili
n
r can be ma
d
o
ne (1) minut
e
d
etermine th
e
V
alve on/off s
w
e
t
h
rough the st
a
V
iew of Gas
V
n
completion
o
w to the bur
n
i
s voltage pr
o
t
detected du
r
-
purge. If fla
m
h
is occurs, p
r
n
ated trial for
n
g to light thr
e
d
e, the ignitio
n
e
and then tu
r
e
problem.
w
itch
Wi
r
a
rtup
V
alve
o
f the pre-
n
er.
o
duces a
r
ing the trial
m
e is not
r
oceed to the
ignition time
e
e times, the
n
control mu
s
r
n the syste
m
r
ing terminal
s
s
t
s

A
ir
S
To a
d
ope
n
shut
t
For
n
CO
s
For
p
and
C
Stac
k
the l
o
up in
Onc
e
duri
n
cont
a
A
ll adjust
m
1. Draft
G
2. O
2
or
C
S
hutter
A
djust
d
just the air
s
n
ings. Increa
s
t
er adjustme
n
n
atural gas a
p
s
hould be mi
n
p
ropane gas
a
C
O should b
e
k
temperatur
e
o
ck nut to se
c
formation an
d
e
adjustment
s
n
g setup, bur
n
a
ct informati
o
m
ents below
G
auge
C
O
2
A
nalyzer
ment
s
hutter, loose
n
s
ing the air s
h
n
t a combusti
o
p
plications, b
e
n
imized with
a
a
pplications,
b
e
minimized
w
e
s for furnac
e
c
ure the air s
h
d
leave it wit
h
s
to the burn
e
n
er model nu
m
o
n in the Inst
a
COM
must be mad
3. CO Test
e
4. Water C
o
n
the indicat
e
utter openin
g
o
n analyzer c
Fig
u
e
st performa
n
a
goal of 100
b
est perform
a
w
ith a goal of
e
s and boiler
s
h
utter.
A
fter t
h
h
the burner.
FI
N
e
r are comple
t
m
ber, model
s
a
llation Log. L
BUSTION A
D
e with the fol
l
e
r
o
lumn Gaug
e
e
d nut and th
e
g
will usually l
apable of m
e
u
re 11:
A
ir S
h
n
ce will be ac
ppm or less.
a
nce will be
a
100 ppm or l
e
s
are recomm
h
e air is adju
s
N
AL INSTAL
L
t
e and burne
r
s
pecification
eave the ma
n
15
D
JUSTMEN
T
l
owing equip
m
e
e
n spin the di
s
ower the CO
2
e
asuring CO
2
h
utter Lock
N
hieved with
a
In no case s
a
chieved with
e
ss. In no ca
ended to be
b
s
ted and the
b
L
ATION INS
T
r
is set up pe
r
number, inle
t
n
ual with app
T
OF BURNE
m
ent:
s
c to either i
n
2
and CO rea
(or O
2
) and
C
N
ut Locatio
n
a
CO
2
setting
hould CO b
e
a CO
2
settin
g
a
se should C
b
etween 350
b
urner is run
n
T
RUCTIONS
r
the manual,
t
gas pressur
e
liance.
R
n
crease or de
a
dings. To de
t
C
O must be u
s
n
of 8% to 10
%
e
above 400
g
of 9.5% to
1
O be above
4
and 400 deg
n
ing properly
,
record com
b
e
, date of ins
t
crease the si
t
ermine the c
o
s
ed.
%
(3% to 6.5
%
ppm.
1
1.8% (3% t
o
4
00 ppm.
rees Fahren
h
,
be sure to r
e
b
ustion numb
e
t
allation, and
ze of the
o
rrect air
%
O
2
) and
o
6.5% O
2
)
h
eit. Tighten
e
cord all set
e
rs measure
d
contractor
d

16
SECTION III: GAS CONVERSION
NATURAL GAS AND LP CONVERSION INSTRUCTIONS
In order to allow SC80 burners to be converted from natural gas to LP gas operation, or from LP to natural gas
operation, Wayne Combustion Systems has created gas conversion kits that contain all the parts necessary for any
burner model The part numbers for these kits are as follows:
64520-001 Kit for converting natural gas burners to LP gas.
64521-001 Kit for converting LP gas burners to natural gas.
In addition to the necessary parts to complete the gas conversion, each kit contains detailed instructions for the
conversion. To order the appropriate gas conversion kit, please contact a local wholesaler. The Wayne Combustion
Customer Service Department can assist in locating the nearest wholesaler.
The conversion will require drilling a new gas orifice, changing the regulator spring in the gas valve, properly adjusting
the gas pressure, and applying new labels to the burner. In order to assist with the planning of a conversion from
natural to LP gas, or LP gas to natural, a list of necessary tools/equipment is shown below:










To complete the conversion, follow the directions provided with the kit.
SECTION IV: CONSUMER INSTRUCTIONS
GENERAL INSTRUCTIONS FOR SERVICING BURNER
Gas burners require the services of an experienced technician for proper setting and adjustment. If the burner does
not appear to be operating properly, DO NOT ATTEMPT TO ADJUST THE BURNER YOURSELF, but call in a
competent serviceman. An OEM should be able to check several possible causes of shutdown before calling in a
serviceman. The following check list may eliminate the need for a service call or at least provide information for the
serviceman.
1. Check thermostat. Make sure that it is set at the desired temperature.
2. Check fuses in service box for the burner circuit. Replaceable type fuses should not be loose in the socket. If a
fuse is blown out or if in doubt, replace with the same size and type. If circuit breaker is in the service box, check
position of indicator. If tripped, reset.
3. Check on-off switch for the burner circuit, it may have been accidentally turned off.
4. With the thermostat set 10 degrees above room temperature, the burner should start automatically.
It is advisable, periodically, to visually inspect the burner. Check air inlet blower to make sure it is not
clogged or blocked. Check air shutter to make sure that it has not been tampered with, make sure that it is in
the same position as when final adjustments were made. Check blower wheel to see if it is dirty or full of lint.
If the flame does not appear normal or if in doubt, call a serviceman. The areas around the burner should be kept
clear and free of combustible materials, gasoline and other flammable vapors and liquids. The flow of combustion and
ventilating air to the burner must not be blocked or obstructed in any manner.
CLEANING OF BURNERS (BY SERVICEMAN ONLY): Remove the burner from the appliance and visually inspect
the blast tube for any deterioration. Check thermo-couples, electrodes, etc. with illustrations in the owner’s manual for
proper locations. Check flame spreader for any deterioration and replace if necessary. Visually inspect the inside of
the venturi for any excessive rust or corrosion and clean if necessary.
Equipment (Both Kits):
1. Slack tube manometer
2. Flat head screw driver
3. 3/16” Allen wrench
4. 1/2” Open end wrench
5. 9/16” Open end wrench
6. 1/8” NPT brass barbed fitting
7. 1/8” Diameter clear or rubber tubing
8. An Instrument to measure CO2-%
9. An Instrument to measure CO-ppm
10. Orifice chart
11. Stop watch
12. Burner manual
13. Drill Index (drill bits)
14. Drill
15. Conversion kit
16. Soapy water bottle
17. Two 10” pipe wrenches

17
SECTION V: SERVICE AND TROUBLESHOOTING
NORMAL OPERATION CHECK OF BURNER
1. Appliance calls for heat by raising the thermostat to the desired setting. Note the transformer is always energized with
120 volts.
2. When the thermostat circuit is complete, this allows 24 volts to coil side of the fan relay which are the bottom
terminals.
3. Now that 24 volts (yellow wires) are applied to the coil, this in turn allows the 120 volt contacts to close thus allowing
120 volts to flow to the fan across terminals #2 and #4 which are in series with the fan motor.
4. The combustion fan motor should now be energized.
5. With the fan energized, there will be a 30 second pre-purge.
6. The fan motor will develop 3400 rpm quickly causing the centrifugal endswitch to close. The endswitch can be
identified by the two red wires coming from the end cap of the fan motor.
7. After the endswitch makes, this allows 24 volts to the direct ignition control.
8. Now the ignition process will follow.
9. The direct ignition control will generate a high frequency spark at the same time the gas valve opens. The ignition
control has a 4 second trial for ignition period. If after four seconds the control does not sense a minimum flame signal
of 0.1 microamps then the control will enter into another 30 second pre-purge period followed by a second trial for
ignition. This process will be repeated a third time if necessary. If after three tries for ignition, the control does not
sense a flame, it will go into lockout. To reset the control simply cycle the thermostat off and then set it to the desired
temperature.
10. After the burner is operational, the control shifts into a rectification mode constantly monitoring the flame signal.
11. The burner will now cycle off and on based on the thermostat setting.
TROUBLESHOOTING GUIDE
NOTE 1: BURNERS ARE NOT PRESET FROM THE FACTORY AND MUST BE ADJUSTED AT THE SITE.
NOTE 2: NEW GAS LINE INSTALLATIONS WILL HAVE AIR IN THE LINES AND REQUIRE SEVERAL IGNITION
ATTEMPTS TO PURGE ALL THE AIR FROM THE LINES.
NOTE 3: DO NOT ATTEMPT TO PERFORM ANY WORK ON THIS BURNER UNLESS THE FOLLOWING TOOLS ARE
AVAILABLE AND YOU ARE A CERTIFIED INSTALLER:
1. Volt meter-volts, ohms, continuity
2. Amp meter-clamp type
3. Burner manual
4. Manometer
5. O2 or CO2 analyzer
6. CO tester
7. Blade screw drivers
8. Nut drivers
9. Open end wrenches
10. Tape measure
The Wayne burner that you are troubleshooting has the following electrical single phase components:
1. 120 Volt Combustion Fan Motor with End Switch
2. Fan Relay-24 volt coil side and 120 volt fan side
3. Ignition Control (24 volt)
4. Honeywell Gas Valve (24 volt)
5. Transformer- 120 volt side and 24 volt side
6. Ignition Rod/Sensing Rod
7. Ignition Lead
8. T-T (24 volt) terminal

18
PRELIMINARY CHECKS, DIAGNOSIS AND SERVICE HINTS
Although the following tests can be made using standard volt meter, it is quicker and more convenient to use a Fenwal
Model 05-125539-001 Test Adapters.
1. Input Polarity
If a spark is present and the gas valve opens for the flame establishing period but the control locks without sensing
flame, check the input voltage at terminals 1 and 6 for the proper polarity. Terminal TH or 24V should be “hot”; 24VAC
(05-16) with respect to ground. Terminal GND is neutral, or zero voltage, with respect to ground.
2. Improper Grounding
If a flame is present during the Trial for Ignition period but the system shuts down, ensure that the burner is properly
grounded. If the burner is not grounded, the flame monitoring signal will not function and the system will go into
lockout. Check for loose or corroded terminals and replace if necessary. Ensure good electric connection by scraping
paint or any other foreign matter off the area where ground connection is made.
It is equally important to be certain that the electrode bracket assembly is properly grounded. The bracket should be
common with the ground lead on the input connector (ground terminal 6). If the bracket is not properly grounded,
damage to the ignitor can result.
3. Inoperative High Voltage
If there is no spark or sparking is intermittent, check the following after disconnecting voltage to the system.
a. Check spark gap. Reference Flame Rod and Spark Electrode drawings later in this section and ensure the gaps
are correct.
CAUTION: NEVER REPLACE THE COMPONENT BOARD WITHOUT FIRST CHECKING TO ENSURE THAT THE
ELECTRODE HAS THE PROPER GAP. IF THE GAP IS TOO WIDE, DAMAGE TO THE IGNITOR CAN RESULT.
b. Check electrode leads and determine there is no corrosion at the terminals. If there is corrosion, clean it off. DO
NOT USE LIQUIDS TO CLEAN TERMINALS. Use steel wool or emery cloth to clean.
c. Check ceramic insulators for cracks, foreign matter, and carbon. If there are cracks, replace electrodes. If there is
carbon or foreign matter, clean it off. DO NOT USE LIQUIDS TO CLEAN. Use steel wool or emery cloth to clean.
d. Check high voltage lead wire for cracks or breaks. If there are cracks, breaks or chafing, replace high voltage
wire.
e. Check to ensure that the high voltage terminal is clear of dust, moisture or any foreign matter that could create
high voltage leakage to ground.
4. Valve Malfunction
With power applied to the ignitor, sparking should occur and the gas valve should open simultaneously. If sparking
occurs but the valve does not open, place a volt meter between the Valve terminal on the ignition control and ground
(or across valve). If valve does not function with voltage, it should be replaced. If the voltage is not present across
Valve terminal and ground (or across valve), the control should be replaced.
5. Electrode Placement
a. Electrode should be placed so optimum flame current is achieved for proper application.
b. Flame should not impinge on any portion of ceramic insulator.
6. Flame Current
The flame detector circuit uses the ionized gas flame to conduct the flame signal. This signal is a small DC current
which can be measured directly with a 0 to 50 microamp meter.
Typical flame current readings with the Wayne control range from .4-.8 µA. Although this control is able to sense
flame with a signal as low as .1 µA, we recommend replacing the electrode assembly if the signal is .1 µA or less in
order to avoid future nuisance lockouts.
To measure flame current, first shut off the power to the system and then connect a DC micro amp meter between the
blue flame sense wire and the terminal marked “SENSE” on the ignition control. Light the burner. If the meter reads
below zero, shut the system off and reverse the meter leads.

19
Once the flame is established, assure that the flame current is above the minimum specified. If not, assure that the
system has the proper input voltage. During service, a scale may build up on the flame sensing rod, which may also
reduce flame current readings. DO NOT USE LIQUIDS TO CLEAN. Use steel wool or emery cloth to clean.
Once the flame is has been established and the system is in its heat cycle, occasional sparking may occur. This is
common in some installations and is not significant. Sparking will not damage the ignitor.
Table 6: Service Hints
What’s Wrong Why What To Do
 Lockout occurs 3-10 seconds
after ignition.
 Reverse polarity.
 System improperly grounded.
 Gas pressure too high, causing
flame to lift off burner.

See Input Polarity (See 1)
 See Improperly Grounding (See 2)
 Check to ensure input pressure as
specified on manufacturer’s data
plate.
 See Flame Current (See 6)

Flame not established. Arcing to
ground.

No spark.

Arcing other than across gap.
 Sensor probe incorrectly
positioned in flame pattern. Spark
gap too small. Spark too large.
Corroded connector.
 Cracked or dirty insulator.
 See Inoperative High Voltage
(See 3a)

Weak spark.
 Broken high voltage lead. High
voltage lead too close to metal
surface. Valve malfunction.
Electrode improperly placed.
 See Valve Malfunction (See 4)
 See Electrode Placement (See 5)
 See Flame Current (See 6)
 Check to ensure that manifold
pressure meets manufacturer’s
specifications

No flame.

Low flame current and/or
nuisance lockouts.
 Flame current falls below 0.1 µA.
 Low gas pressure.
COMPONENT TROUBLESHOOTING AND DIAGNOSIS
24 VOLT TRANSFORMER MALFUNCTION
The 24 volt transformer has a 120 volt primary side with a 24 volt secondary circuit. To check the transformer,
simply apply 120 volts to the black and white leads. If the transformer is working correctly, 24 volts will be present
across the two yellow leads. If the multimeter does not register 24 volts then the transformer needs to be
replaced. The transformer will not function unless 120 volts are present across L1 and neutral.
COMBUSTION FAN ENDSWITCH
The 120 volt motor is equipped with a centrifugal endswitch. The purpose of the endswitch is to ensure that the
combustion fan motor has reached the proper operating rpm which is generally about 3400 rpm. If the endswitch
fails to close then the 24 volt circuit to the gas primary is interrupted and the gas valve will not open. If the blower
motor has 120 volts applied but is not rotating then the motor assembly must be replaced. Lastly if the motor is
not rotating, the centrifugal switch will not make and 24 volts will not be present at the gas primary control.
IGNITER ROD
The igniter rod is responsible for conveying the spark to a grounding rod in an appropriate location to ignite the
gas and air mix. The igniter rod gap should be 1/8”, larger gaps will create ignition problems. If the igniter rod is
cracked, sparking sound will be heard inside the burner air tube but ignition will not occur and lockout will occur.

20
MORE SERVICE HINTS
THERMOSTAT CALLS FOR HEAT AND THE FOLLOWING CONDITIONS OCCUR:
1. PROBLEM: The combustion fan motor is not operating.
Possible Reasons:
a. Power is not on.
b. Circuit breaker tripped.
c. Thermostat in the off position.
d. Thermostat connections to T-T terminals on junction box have shorted to the junction box.
e. Bad thermostat.
f. Blower wheel jammed
g. Debris stuck in blower wheel blades.
h. 24 volt transformer is not functioning properly.
i. Thermostat leads not connected to the T-T terminals.
j. Motor shorted out due to overvoltage.
k. Motor start relay not functioning properly.
2. PROBLEM: Combustion fan motor runs but ignition sequence does not occur.
Possible Reasons:
a. Blower motor endswitch not closed which completes the 24 volt circuit to the gas primary.
b. The blower motor is not reaching full rpm due to debris on wheel.
c. Low voltage to the blower motor.
d. Loose connections on the 24 volt circuit after the endswitch or between fan relay and the 24 volt side of the
gas primary.
e. The gas ignition control is defective and must be replaced.
3. PROBLEM: Combustion fan motor runs and ignition sequence initiated but goes into lockout.
Possible Reasons:
a. Spark electrode rod is cracked shorting spark to ground.
b. Loose connection on spark electrode rod.
c. Gas primary control not allowing 24 volts to gas valve.
d. Gas valve shorted out or defective.
e. No ground between burner and appliance.
f. Spark electrode location shifted.
g. Ignition control not generating spark.
h. Ignition wire insulation melted and is grounding out on burner.
i. Gas supply is not turned on.
j. Gas manifold pressure is too high.
k. Gas manifold pressure is too low.
l. High negative draft conditions.
m. Gas supply line is undersized.
n. Multiple appliances operating on undersized line.
o. Insufficient combustion air flow.
p. Incorrect air shutter adjustment allowing too much combustion air to enter burner.