Carlin G3B User Manual

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Instruction manual

Contents

PLEASE read this ﬁ rst.......................................................... 2

Codes and standards........................................................... 2

G3B Gas burner at-a-glance .............................................. 3

Prepare site • prepare burner • mount burner ................ 4

Install gas piping .................................................................. 9

Wire burner .........................................................................10

Check system • start-up burner/appliance ....................12

Perform checkout procedure • ﬁ ll out certiﬁ cate ........ 14

Maintenance and service procedures ...........................17

Troubleshooting .................................................................. 19

Dimensions and mounting information .......................... 21

Replacement parts............................................................. 22

™

Ratings

Input: .................................................... 60,000 to 180,000 BTUH

Fuels: .........................................Natural gas or propane gas

Max. supply pressure .............................14 INCHES W.C.

Min. supply pressure ................................5 INCHES W.C.

Manifold pressure .................................3.5 INCHES W.C.

Electrical: Power ...................................120

Motor..................................................1/50 HP, 3450 RPM

Ignition: .................................. Norton hot surface ignitor, 120V

Control: .................................Honeywell S89C primary control

Agencies: ........................CSA certiﬁ ed, U. S.

The G3B burner has been assigned U. S. Patent No. 4397631

V/60HZ/1-PHASE, 8 AMPS

Installer/servicer — Except where speciﬁ -

cally stated otherwise, this manual must be used only by a qualiﬁ ed service technician. In the state of MA, this product must be installed by a licensed plumber or gas ﬁ tter. Failure to comply with this or other requirements in this manual could result in severe personal injury, death or substantial property damage.

Handling — Handle burner (and hot surface ignitor)

carefully to avoid cracking or breaking the ceramic ignitor. Ignitor protrudes slightly beyond burner head. Do not set burner on its end.

User — Refer only to User’s Information manual

for information regarding operation of this burner. The remainder of this manual is intended only for your service technician. The burner and heat exchanger must be inspected and started at least annually by your service technician.

Carlin Combustion Technology, Inc.

70 Maple Street East Longmeadow, MA 01028 Ph 413-525-7700 Fx 413-525-8306

TECH SUPPORT 800-989-2275

carlincombustion.com

Model G3B Gas burner — Instruction manual

PLEASE read this ﬁ rst . . .

Special attention ﬂ ags

Please pay particular attention to the following when you see them throughout this manual.

Notiﬁ es you of hazards that WILL cause severe personal injury,

death or substantial property damage.

Notiﬁ es you of hazards that CAN cause severe personal injury,

death or substantial property damage.

Notiﬁ es you of hazards that WILL or CAN cause minor personal

injury or property damage.

Notiﬁ es you of special instructions on installation, operation or

maintenance that are important, but are not normally related to injury or property damage hazards.

General information

Burner applications

Follow all instructions in this manual and the appliance manual. Where appliance instructions differ from this manual, follow the appliance instructions. Read the label attached to the burner air tube to verify the burner is correct for the appliance being used. See pages 6 and 7 for procedures.

Damage or shortage claims

The consignee of the shipment must ﬁ le damage or shortage claims immediately against the transportation company.

When calling or writing about the burner . . .

Please provide us with the burner serial number and burner model number to assist us in locating information. Enter this information on the Installation Certiﬁ cate in this manual. The certiﬁ cate information can be helpful when troubleshooting or obtaining replacement parts.

Follow the guidelines below to avoid potential severe

personal injury, death or substantial property damage.

Installer/service technician . . .

• Read all instructions before proceeding. Perform all procedures, and in the order given to avoid potential of severe personal injury, death or substantial property damage.

• Before leaving the site after startup or service, review the User’s information manual with the user. Make the user aware of all potential hazards and perform the training outlined below.

Train the user . . .

• To properly operate the burner/appliance per this manual, the appliance instructions and the User’s information manual.

• To keep this manual at or near the burner/appliance for ready access by the user and service technician.

• To contact the service technician, gas supplier or ﬁ re department should the user smell gas.

• To keep the appliance space free of ﬂ ammable liquids or vapors and other combustible materials.

• Do not use laundry products, paints, varnishes or other chemicals in the room occupied by the burner/appliance.

• To contact the service technician at least annually for startup and burner/appliance service.

When servicing the burner . . .

• Disconnect electrical supply to burner before attempting to service to avoid electrical shock or possible injury from moving parts.

• Burner and appliance components can be extremely hot. Allow all parts to cool before attempting to handle or service to avoid potential of severe burns.

• Handle the ceramic ignitor with care to avoid breaking or cracking the ignitor. Do not handle ignitor when it is hot. NEVER touch the surface of the ignitor with bare ﬁ ngers. Body oils can cause damage.

Codes and standards

The installer/servicer is solely responsible for compliance

with all applicable codes and standards.

Burner listings/approvals

Carlin G3B gas burners are CSA certiﬁ ed for use with natural gas or propane gas, United States installations only.

Burners are NYC/MEA approved. MEA-369-89-E.

Installation:

Burner/appliance installations must comply with the latest editions of:

• “Installation of Domestic Gas Conversion Burners,” ANSI Z21.8.

• National Fuel Gas Code, ANSI Z223.1/NFPA 54.

• National Electrical Code, ANSI/NFPA 70.

• All additional applicable national, state and local codes.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

G3B Gas burner at-a-glance

1 Air tube, with powder coat paint ﬁ nish

2 Flameholder

3 Hot surface ignitor

4 Adjustable ﬂ ange

5 Rear ignitor assembly with terminal boots

6 Ignition tube assembly mounting plate

7 Pedestal legs

8 Burner gas inlet connection (see page 8)

9 Combination gas valve (with integral gas pressure regulation — set

for 3½” w.c. outlet pressure)

10 Control panel

11 Terminal strip

Carlin part number MNG3B Gas Rev. 03/17/09

12 Primary control (Honeywell Model S89C primary control, for use with

ﬂ ame rectiﬁ cation)

13 Control transformer, 120

14 Gas valve on indicator light

15 Motor relay

16 High-efﬁ ciency motor

17 Blower housing (cast aluminum), with powder coat paint ﬁ nish

18 Air inlet tube assembly

19 Air throttle indicator — Only a single adjustment required for setting

combustion air; see page 8 for starting setting based on appliance model and input)

VAC / 24 VA C, 40 VA

Model G3B Gas burner — Instruction manual

1. Prepare site • prepare burner • mount burner

Inspect installation site

Inspect, repair and/or replace vent system

Do not install this burner unless you have veriﬁ ed the entire

vent system and the appliance are in good condition and comply with all applicable codes. And . . .

The vent and chimney must be sized and constructed in

accordance with all applicable codes. If intended for use with an oil burner as well, the vent system must comply with relevant codes for both gas and oil ﬁ ring.

The vent system must not be pressurized unless the vent

piping and vent system are designed accordingly. The vent must provide draft at all times (negative pressure in vent).

Do not install or use an existing manual damper in the vent

connector or vent.

Do not connect the appliance vent connector to a chimney

or vent serving a ﬁ replace, incinerator or solid-fuel-burning apparatus.

In a cold climate, do not vent into a masonry chimney that

has one or more sides exposed to the outside. Install a listed stainless steel liner to vent the ﬂ ue products.

Figure 1 Vent and vent connector installation

A defective vent system could result in severe personal injury,

death or substantial property damage.

Vent/chimney sizing

• Follow all local codes when sizing the vent and chimey

• Refer to the appliance manufacturer’s manual, when available, for venting recommendations

Prepare vent/chimney

• Secure all metal vent joints with screws, following the vent manufacturer’s instructions. Seal all joints in the vent system and chimney. Repair masonry chimney lining and repair all mortar joints as needed.

• Install a double-acting barometric draft regulator in the vent piping. (The damper must be located in the same space as the appliance.) Install a manual reset spill switch in the top of the draft regulator outlet. Wire the switch into the appliance limit circuit to shut off the appliance/burner if sustained downdraft should occur.

• Provide support for the vent piping. Do not rest the weight of any of the vent piping on the appliance ﬂ ue outlet.

Verify clearances

• Verify that clearances required for service/maintenance comply with the appliance manual and applicable codes. Provide at least 6 inches around burner and 24 inches in front of burner panel for service access.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

1. Prepare site • prepare burner • mount burner (continued)

Inspect installation site

Combustion/ventilation air openings

Installing the burner/appliance in a space that does not provide

enough air for combustion and ventilation can result in severe personal injury, death or substantial property damage. Follow all applicable codes and guidelines below to ensure space has sufﬁ cient air openings.

Large spaces

For appliances located in basements, ventilated crawl spaces or other large areas, no additional air openings should be necessary.

Exception: If the building construction is unusually tight (see National Fuel Gas Code or CSA B149.1 or .2 for deﬁ nition), you will need to provide air openings into the building if appliance air comes from inside. Provide one opening within 12 inches of the ceiling, and one opening within 12 inches of the ﬂ oor. Size each opening to provide free area (after deduction for louvers) of 1 square inch per 1,000 Btuh input of all fuel-burning appliances in the building.

Conﬁ ned spaces — air from inside building

If air openings connect to areas inside the building, provide two openings, one within 12 inches of the ceiling, the other within 12 inches of the ﬂ oor. Each opening must have a free area (after deduction for louvers) of 1 square inch per 1,000 Btuh of all appliances in the space. If the building construction is unusually tight (see National Fuel Gas Code or CSA B149.1 or .2 for deﬁ nition), you will need to provide air openings into the building. Provide two openings sized and located as for the openings into the boiler space.

Figure 2 Locating & sizing air openings

Conﬁ ned spaces — air from outside

If air openings connect directly to outside, provide two openings, one within 12 inches of the ceiling, the other within 12 inches of the ﬂ oor. Each opening must have a free area (after louver deduction) of:

• If directly through side wall: 1 square inch for each 4,000 Btuh of all appliances in the space.

• If through vertical ducts: 1 square inch for each 4,000 Btuh of all appliances in the space.

• If through horizontal ducts: 1 square inch for each 2,000 Btuh of all appliances in the space.

Verify openings

When sizing air openings for combustion and ventilation, include

air required for exhaust fans and other appliances, such as clothes driers, that require air for operation.

Check appliance manual and applicable codes for required sizing of combustion and ventilation air openings.

• Verify that openings are unobstructed.

• Verify that appliance space and air source spaces are free of:

– gasoline or other ﬂ ammable liquids or vapors. – combustible materials. – air contaminants, such as laundry products, paint, thinner, varnish, etc.

• Conﬁ rm with user that the area will be kept free of these materials at all times.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

1. Prepare site • prepare burner • mount burner (continued)

Prepare the appliance

Burner input: Install a gas burner sized for the normal input

rating of the appliance. Do not install a burner with a higher ﬁ ring rate than the appliance rating. Do not install a burner with a ﬁ ring rate more than 10% lower than the appliance rating. The appliance and vent system could be damaged due to condensation.

Seal the appliance: Seal all ﬂ ue-gas containing joints. Seal

all connections to the vent piping or breeching.

Clean and check the appliance: Clean the appliance

thoroughly. Test all electrical components and verify the relief valve works (boilers only).

Verify combustion chamber dimensions comply with the

minimum dimensions shown in Figure 3. Install or replace combustion chamber liner if required by the appliance manufacturer. The burner air tube must not extend into the combustion chamber. The end of the burner air tube must be within ¼” of the inside face of the combustion chamber. If the space around the burner air tube is more than ¼”, wrap the burner air tube with minimum 2300-°F-rated ceramic ﬁ ber blanket to seal off the gap. Notice that the ﬂ ameholder may extend slightly into chamber as shown in Figure 3.

Repair or replace damaged appliance components. Inspect

the appliance thoroughly. Follow appliance manufacturer’s guidelines for repair or replacement of any component found defective.

When cleaning the appliance or working with ceramic ﬁ ber

refractories or ﬁ berglass insulation, see WARNING on page

Figure 3 Minimum combustion chamber dimensions

Input Minimum chamber dimensions, Inches

(Note 1)

Btuh

60,000 7 x 7 x 9 8 x 9 70,000 7½ x 7½ x 9 8½ x 9 100,000 8 x 8 x 9 9 x 9 120,000 9 x 9 x 9 10 x 9 140,000 10 x 10 x 9 11 x 9 160,000 11 x 11 x 9 12 x 9 180,000 12 x 12 x 9 13 x 9

Note 1: Rectangular chambers of similar ﬂ oor area are equally acceptable, but the L/W ratio should not

exceed 2 and the width should be at least 5 inches.

(Using 2300ûF or higher refractories)

Square

L x W x H

Vertical cylinder

Diameter x H

Failure to comply with the above could result in severe

personal injury, death or substantial property damage.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

1. Prepare site • prepare burner • mount burner (continued)

Inspect burner and components

Do not install or operate the burner if any component is

damaged or if burner does not comply with the speciﬁ cations and guidelines in this manual and the appliance manual.

Air tube insertion length (UTL)

• Usable air tube length (UTL) is the distance from mounting ﬂ ange to end of air tube.

• Verify that the end of the air tube will be ﬂ ush with, or no more than ¼ inch short of, the inside of the appliance combustion chamber front wall when the burner is mounted. See Figure 3, page 6.

• Minimum UTL is 1¾ inches. Maximum UTL is tube length less 1¾ inches. Tubes are available in 6-inch, 9-inch and 12-inch lengths.

• Notice that the ﬂ ameholder may extend slightly into chamber as shown.

Prepare appliance for burner mounting

The universal ﬂ ange supplied with G3B Gas burners is

intended only for ﬁ ring chambers with negative overﬁ re pressure. The G3B burner must not be installed on a product that operates with a pressurized combustion chamber. Failure to comply could result in severe personal injury, death or substantial property damage.

Ceramic ﬁ ber or Fiberglass insulation

Ceramic ﬁ ber materials, such as chamber liners, may

contain carcinogenic particles (chrystobalites) after exposure to heat. Airborne particles from ﬁ berglass or ceramic ﬁ ber components have been listed as potentially carcinogenic by the State of California. Take the following precautions when removing, replacing and handling these items.

Avoid breathing dust and avoid contact with skin

or eyes. Wear long-sleeved, loose-ﬁ tting clothing, gloves and eye protection. Use a NIOSH N95 certiﬁ ed respirator. This respirator meets requirements for protection from chrystobalites. Actual job requirements or NIOSH regulations may require other or additional protection. For information, refer to the NIOSH website, http://www.cdc.gov/niosh/homepage.html.

Ceramic ﬁ ber removal: To prevent airborne dust, thor-

oughly wet ceramic ﬁ ber with water before handling. Place ceramic ﬁ ber materials in a plastic bag and seal to dispose.

• See page 21 for required dimensions and bolt locations.

Avoid blowing, tearing, sawing or spraying ﬁ ber-

glass or ceramic ﬁ ber materials. If such operations are necessary, wear extra protection to prevent breathing dust.

Wash work clothes separately from other laundry.

Rinse clothes washer thoroughly afterwards to prevent contamination of other clothing.

NIOSH First aid procedures:

Eye exposure — irrigate immediately

Breathing — fresh air.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

1. Prepare site • prepare burner • mount burner (continued)

Inspect burner and components

Drill or ream gas oriﬁ ce to size (initial installation)

You must disconnect power to burner and close main manual

gas valve before proceeding. Failure to do so could result in severe personal injury, death or substantial property damage.

You must drill or ream the burner oriﬁ ce to the size given in

Figure 4. The oriﬁ ce is shipped with a pilot hole only. Firing the burner with the oriﬁ ce as shipped can result in damage to the burner. Never ﬁ re the G3B burner below 60,000 Btuh input. The ﬂ ameholder can overheat, resulting in potential severe personal injury, death or substantial property damage.

1. After drilling or reaming oriﬁ ce to correct size, thread oriﬁ ce ﬁ tting into oriﬁ ce nipple as shown in Figure 4.

Install gas valve on burner

1. Read WARNING’s on page 9 before installing gas valve.

2. Apply a small amount of pipe dope (suitable for propane gas) to gas valve outlet connection, gas line elbow and oriﬁ ce nipple. Assemble elbow and oriﬁ ce nipple to gas valve.

To avoid damage to gas valve, do not hold valve with a pipe

wrench or over-tighten. Use only a crescent wrench or other means. Failure to comply could result in severe personal injury, death or substantial property damage.

3. Insert oriﬁ ce nipple into burner gas connection and secure in place using the two Allen screws.

4. Connect gas valve wires to gas valve.

Inspect/redrill gas oriﬁ ce when required

1. Turn off power to the burner/appliance before proceeding.

2. Close main manual gas valve in gas line to burner. Then disconnect the ground joint union to allow rotating burner combination gas valve.

You must disconnect power to burner and close main manual

gas valve before proceeding. Failure to do so could result in severe personal injury, death or substantial property damage.

3. Loosen Allen screws securing gas line to burner gas connection.

4. Remove combination gas valve (item 9, page 3) and gas piping to burner gas connection (item 8, page 3) on burner air tube.

5. Read correct oriﬁ ce drill size from Figure 4. Then check actual oriﬁ ce size using that size twist drill bit.

• If gas oriﬁ ce is smaller than required, redrill oriﬁ ce to correct size,

if necessary. Replace gas valve and piping, using only pipe dope listed for use with liqueﬁ ed petroleum gases.

• If gas oriﬁ ce is larger than required, obtain a replacement gas oriﬁ ce

ﬁ tting. Drill oriﬁ ce hole in replacement oriﬁ ce ﬁ tting.

Figure 4 Oriﬁ ce and gas valve installation

Input

Btuh

Note 1 Natural Gas Propane Gas

60,000 #28 (0.141) #33 (0.113) 0 70,000 #24 (0.152) ¹⁄₈ (0.125) ½ 80,000 #20 (0.161) #30 (0.129) ¾ 90,000 #17 (0.173) #28 (0.141) 1 100,000 #14 (0.182) #25 (0.150) 1½ 110,000 #11 (0.191) #22 (0.157) 1¾ 120,000 #7 (0.201) #20 (0.161) 2¼ 140,000 #3 (0.213) #16 (0.177) 3 160,000 A (0.234) #12 (0.189) 4¼ 180,000 D (0.246) #7 (0.201) 9

Note 1: High altitude applications: The maximum burner input at sea level is 180,000 Btuh.

Note 2: Use this as the starting setting only. Adjust air throttle, if necessary, after performing

Burner oriﬁ ce drill size

Diameter, inches

Reduce this capacity by 4% per 1,000 feet above sea level. Example — max. capacity at 5,000 feet is 144,000 Btuh (20% reduction).

combustion testing (see page 14).

Air throttle turns (appr.)

Notes 1 & 2

Hot surface ignitor

• Inspect the burner from air tube end. The hot surface ignitor must extend slightly past the end of the burner.

• Carefully inspect the ignitor, ensuring it is intact, with no cracks or visual signs of degradation.

• Do not touch the ignitor with bare hands. Body oils can cause deterioration of the silicon carbide.

• Replace ignitor if there are any signs of damage.

You must allow ignitor to cool before attempting to handle.

Failure to do so could result in severe personal injury or damage to the ignitor.

Inspect components and wiring

• Visually inspect all burner components and wiring.

• Verify that wiring is intact and leads are securely connected.

• Verify that all burner components are in good condition.

Mount burner in appliance

• Verify appliance burner front plate dimensions per page 21.

• Slide gasket supplied with burner over end of air tube.

• Insert burner into appliance opening and bolt in place.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

2. Install gas piping from meter to combination gas valve

Code compliance

The burner/appliance installation must comply with codes listed on page 2 and any other locally applicable codes.

Piping from meter to burner

Connect from the gas supply to the burner combination gas valve

inlet using new, clean black iron pipe and malleable iron ﬁ ttings only. Do not use copper, brass, cast iron or galvanized pipe or ﬁ ttings.

Provide support for gas piping. Do not rest weight of piping on burner

gas valve.

Apply pipe dope sparingly at all joints. Use only pipe dope listed for

use with propane gas. Do not use pipe sealing tape.

Do not hold gas valve with pipe wrench. Use crescent wrench or

other smooth-jawed device. Do not over-tighten.

Failure to comply with above could result in severe personal injury,

death or substantial property damage.

1. If possible, install a new gas line directly from the gas meter. If you are using an existing gas line, verify it is clean and in good condition, and verify it is large enough to handle the load of all connected appliances.

2. When branching from a common gas line, do not tap off from the bottom of horizontal sections — only from the side or top.

3. Install a main manual shutoff valve, sediment trap and ground joint union near the burner combination gas valve connection as shown in Figure 5.

4. If the burner is installed inside the appliance jacket, install the main manual gas valve and sediment trap external to the jacket.

5. Size piping (or verify size) using Table 2. You will ﬁ nd additional information on gas line sizing in the National Fuel Gas Code, ANSI Z223.1.

Gas supply pressure — natural or propane

• Maximum supply pressure: 14 inches w.c.

• Minimum supply pressure: 5 inches w.c.

Do not expose the combination gas valve to gas pressure in

excess of 14 inches water column. Higher pressure could damage the valve seat, resulting in potentially hazardous condition. When pressure testing piping at higher pressures, disconnect burner from gas line before testing.

If the gas supply pressure can exceed 14 inches water

column at any time, you must install a lockup type gas pressure regulator in the gas supply piping, ahead of the main manual gas valve installed at the burner.

Test and purge gas line

Read WARNING above.

Pressure test and purge the line. Pressure testing should be done by the gas supplier or utility, following all applicable codes.

Table 2 Capacities of black iron pipe, cubic feet gas/hour

Figure 5 Connecting gas supply piping to burner

1 Pipe to meter or branch 2 Main manual gas shutoff valve (must

be ‘T’ handle in state of MA)

3 Use clean, burr-free black iron pipe

and malleable iron ﬁ ttings

4 Ground joint union

Carlin part number MNG3B Gas Rev. 03/17/09

5 Sediment leg 6 Burner combination gas valve 7 Upstream pressure tap, 1/8” 8 Outlet pressure tap, 1/8” NPT 9 Gas pressure regulator access screw 10 Gas valve wire terminal strip

NPT

Model G3B Gas burner — Instruction manual

3. Wire burner

Code compliance

The burner/appliance installation must comply with codes listed on page 2 and any other locally applicable codes.

General wiring requirements

Read and follow the guidelines in this manual. Failure to

comply could result in severe personal injury, death or substantial property damage.

Electrical shock hazard — Disconnect electrical supply to the

burner before attempting to service. Failure to comply could result in severe personal injuiry, death or substantial property damage.

Figure 6 Ladder wiring diagram

Electrically ground burner — The burner must be grounded

in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 (in Canada, the Canadian Electrical Code Part 1, C.S.A. Standard C22.1.)

Label all wires before removing for servicing. Wiring errors

could result in unsafe appliance/burner operation.

Read appliance manufacturer’s instructions completely before

wiring burner.

Check polarity carefully. If hot and neutral wires are reversed

at appliance power source, the control will not operate.

If replacing any of the wire supplied with the burner, use

minimum #14 AWG 125°C or better.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

3. Wire burner (continued)

Verify power supply

1. The burner requires a 120VAC/60HZ/single-phase power supply. The current draw will be aproximately 8.0 amps. Protect line with a 10-amp or 15-amp fuse or breaker.

Figure 7 Wiring diagram — wire routing

Control panel enclosure

Yel

BlueBk

Yel

Honeywell S89C control

GND (BURNER)

24V (GND)

24V

VALVE (GND)

VALVE

Gray

Blue

HSI

Yel

Red

Transformer

2. The 120 shown in Figure 7. The control is polarity-sensitive, and will not work if the hot and neutral lines are reversed.

3. Verify that the power supply to the burner is no less than 102 more than 132 VAC.

VAC power connections to the burner must be connected as

Supplied by installer

Line switch **

Thermostat **

Spill switch (if used) (may also be wiring in

the 120-v limit circuit)

Yel

Red

Pur

Gnd

Valve on light

NOTICE: Line voltage polarity

The hot and neutral power wires must connect as shown for correct operation of the burner controls.

120-v limit

circuit

120 VAC

VAC nor

GND

Hot

Neu

Hot surface

ignitor

BkBk

MV MV

G3B01

Carlin part number MNG3B Gas Rev. 03/17/09

TH/TR

Red

Motor

end switch

Combination gas valve

Motor

relay

Red

Wire color coding

Bk = black Blue = blue

Terminal

strip

120 factory wiringVAC 24 factory wiringVAC 120 field wiringVAC 24 field wiringVAC Wire connector

Connect ground wires

Motor 120

VAC

Or = orange Br = brown Gr = green

Pur = purple

Gray = gray

to green terminal strip screws when replacing a Fenwal control with a Honeywell S89C.

Red = red Wh = white Yel = yellow

Model G3B Gas burner — Instruction manual

4. Check system • start-up burner/appliance

Inspect/check system

Before starting the burner and appliance, verify the system has been installed as directed by this manual and the appliance instructions.

Check gas piping for leaks

Disconnect the burner from the gas supply line if gas line

test pressure will exceed 14 inches w.c. Exposing the burner combination gas valve to pressure higher than 14 inches w.c. can damage the valve seat, resulting in potentially unsafe operation.

You can usually test the gas piping by allowing the line to ﬁ ll with gas to main regulator outlet pressure.

1. Shut off gas ﬂ ow to all appliances connected to the meter.

2. If test pressure will be less than 14 inches w.c., turn the burner combi-

nation gas valve knob to OFF. If test pressure will be higher than 14 inches, disconnect the burner from the gas line by shutting off the main manual gas valve installed near the burner (per Figure 5, page 9) and disconnecting the ground joint union. See warning above.

3. Watch the gas meter dial. For a one half cubic foot per revolution dial, there should be no movement of the dial for at least 5 minutes. For larger volumes per revolution, increase this time proportionately.

Figure 8 Air throttle adjustment

6. The Figure 4 setting will probably be satisfactory without change. If the combustion test indicates a need for more or less air, however, you will have to adjust the throttle accordingly.

Check burner and Honeywell S89C control

Inspect burner thoroughly. Verify all components are secure and burner is in good condition. Verify all wiring is in place and all components are secure and in position.

Verify ﬂ ame failure lockout of Honeywell control

4. If you detect a gas leak, locate the leak with a soap suds mixture and repair it. Then test the system for leaks again.

Do not test for leaks with an open ﬂ ame. And do not use

oxygen as a test gas. Either of these could cause an explosion, resulting in severe personal injury, death or substantial property damage.

Bleed gas line

Purge all air from the gas line. Purge to outside of the building, NEVER into the appliance or burner.

Leak test near-burner gas piping

If piping near burner has not already been pressure tested, open main manual gas valve on supply to burner and smell around area for any signs of gas. Apply a soap suds mixture to all gas piping joints near burner and check for any leaks. If any leaks appear, repair before proceeding and retest.

Set air throttle

1. See Figure 8. Loosen air throttle locking nut.

2. Rotate the air throttle plate clockwise to the closed position.

3. Check the air throttle indicator. The “0” position of the indicator should be even with the end of the air inlet tube. If not, bend the arm slightly until the indicator reads zero.

4. Rotate air throttle until indicator points to setting given in Figure 4, page 8.

5. Tighten air throttle locking nut.

1. Install a hose barb ﬁ tting in the combination gas valve outlet pressure tap and connect with a hose to a U-tube manometer.

2. Close the main manual gas valve and turn the combination gas valve knob to ON.

3. Turn on power to appliance and set appliance limit(s) to call for heat.

4. Burner motor will start. The Honeywell S89C control will run the blower for 34 seconds (pre-purge and ignitor warm-up). Then the combination gas valve will open and the “Valve on” light will light. (The manometer should show almost no pressure, because the main manual gas valve is closed.)

5. After 6 seconds, the S89C will lockout. The ignitor will shut off and the gas valve will close. Turn off power or interrupt thermostat circuit for 45 seconds. The control should reset. Turn off power and set controls to stop call for heat.

6. If lockout does not occur, replace the S89C control.

Do not start the burner if you smell gas or if there may be gas

present in the appliance combustion chamber, heat exchanger or the vent system. An explosion could occur, causing severe personal injury, death or substantial property damage.

During initial start-up, you must be constantly alert for

emergency conditions such as fuel leaks, electrical malfunctions, etc. Familiarize yourself with the location of manual shutoff valves and switches so you can quickly use them if needed.

If the burner fails to ignite, NEVER attempt to manually bypass

the normal sequence of the control, which provides purging of the combustion chamber.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

4. Check system • start-up burner/appliance (continued)

Installer/servicer

Should overheating or an emergency occur, immediately:

• Shut off main manual gas valve.

• Shut off power to burner.

NOTICE: Under some circumstances power should remain

on for water pumps or circulating blowers. Determine proper response before attempting start-up.

If burner fails ignition on several attempts, close gas valve

and use burner blower to purge appliance before restart.

Before starting burner, verify:

❏ Burner/appliance installed per appliance instruction manual? ❏ Burner oriﬁ ce size and air throttle veriﬁ ed against Figure 4, page 8? ❏ Burner/appliance installed per all applicable codes? ❏ Installation site has adequate ventilation openings and vent

system?

❏ Gas supply line in good condition and sized correctly? ❏ All gas line joints sealed with pipe dope listed for use with liqueﬁ ed

petroleum gases?

❏ Gas supply pressure to combination gas valve checked? ❏ Regulator installed if pressure can exceed 14 inches w.c.? ❏ Air purged from gas line? ❏ Gas piping checked for leaks? ❏ Wiring installed per burner and appliance instruction manuals?

Ignition and ﬂ ame sensing

Ignition The G3B burner uses a silicon carbide hot surface ignitor

for ignition. The Honeywell S89C primary control feeds 120

VAC power to the ignitor and allows time for the ignitor to

warm up to ignition temperature during the burner pre-purge period.

Sensing The S89C primary control uses ﬂ ame rectiﬁ cation to detect

ﬂ ame, with the hot surface ignitor acting as the “ﬂ ame rod.”

Start-up & operation

Do not start the burner if the combustion chamber contains

residual gas. Allow gas to disperse. Failure to comply could result in severe personal injury, death or substantial property damage.

Power ON Open all manual gas line valves. Turn burner combination gas

valve knob to “ON.” Close the line switch. (If burner does not follow sequence below, see troubleshooting suggestions on pages 19 and 20.)

Stand-by (No call for heat) Control waits for heat call.

Call for heat Set operating control and all limit controls to call for heat.

The thermostat circuit must be closed and power coming to control panel L1 and L2 terminals

Burner on The motor starts. The hot surface ignitor starts. The motor

centrifugal switch makes.

Pre-purge The primary control allows 34 seconds for pre-purge and

ignitor warm-up.

Gas valve on After the pre-purge/ignitor warm-up period, the primary

control activates the gas valve (if motor centrifugal switch is closed). The green “Gas valve on” light turns on.

TFI The primary control turns off the ignitor within 2 to 6 seconds

after gas valve activation. When the control deactivates the ignitor, it begins checking for ﬂ ame signal. If ﬂ ame is not detected within 6 seconds after gas valve activation, the primary control will lockout with continuous purge (see following).

Run period The burner continues ﬁ ring during call for heat if the ﬂ ame

rod (hot surface ignitor) senses ﬂ ame. The green “Gas valve on” light remains on during normal running, indicating gas valve is energized.

Shutdown When the call for heat ends, the primary control immediately

deactivates the gas valve and blower. The burner returns to stand-by.

Flame failure If the primary control loses ﬂ ame signal during a run period,

it deactivates the gas valve within 2 seconds. The control restarts the heating cycle, beginning with a 34-second pre-purge/ignitor warm-up period, then a 6-second trial for ignition. If ignition/ﬂ ame sensing is successful, the burner returns to normal operation. If the attempt is not successful, the primary control will lockout.

Lockout If the primary control does not sense ﬂ ame within the TFI

time limit after gas valve activation (6 seconds), lockout occurs. The control deactivates the gas valve. The blower motor continues to run, providing a post-purge of the burner and appliance.

Reset To reset after a lockout, turn off power to burner or interrupt

the thermostat circuit for at least 45 seconds. Then restore power (or thermostat circuit). Burner should restart.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

5. Perform checkout procedures • ﬁ ll out certiﬁ cate

Make ﬁ nal burner adjustments

Check for leaks in gas piping

❏ Smell around burner to make sure there is no gas leak in near-burner

piping. Verify integrity of gas line joints between combination gas valve and burner gas inlet tapping using soap suds mixture. Verify gas piping is fully supported, independently of burner.

Check for leaks from burner components

❏ Smell around burner to make sure there is no leakage from the burner

inlet air tube, blower housing or air tube. Verify burner is properly supported and ﬂ ange is securely tightened.

If you detect leakage from any burner component, immediately

close the main manual gas valve. Use a soap suds mixture to determine leakage location. Replace burner if leakage cannot be corrected by properly securing components. You may have to restart the burner several times during leakage testing since the control will lockout when ﬂ ame is not detected. Failure to correct leakage problems could result in severe personal injury, death or substantial property damage.

Make ﬁ nal burner adjustments (continued)

Check/adjust gas valve outlet pressure

❏ With burner running, check manometer reading for combination gas

valve outlet pressure. Adjust valve regulator if necessary so the reading is 3.5 inches w.c. for either natural gas or propane gas.

Inspect ﬂ ame

❏ Look at ﬂ ame through appliance observation port. The ﬂ ame should

be a soft blue with well-deﬁ ned orange and yellow tips for natural gas, or well-deﬁ ned yellow tips for propane gas. (If you make air or gas pressure changes later, inspect the ﬂ ame again.)

Check the ﬁ ring rate

❏ Natural gas only — Turn off all other gas appliances connected to

the gas meter. Use a stopwatch to time the number of seconds for a ﬂ ow of one cubic foot of gas (two revolutions for a one half cubic foot per revolution dial, for example). You will also need to know the gas heat content in Btu per cubic foot. Determine the actual input from: INPUT = (3600 x Btu per cubic foot) ÷ (number of seconds for one cubic foot), for ﬁ ring rate in Btuh. For example, for 1050 Btu per cubic foot natural gas, with meter timed at 30.2 seconds for one cubic foot of gas: INPUT example = (3600 x 1050) ÷ (30.2) = 125,200 Btuh. Firing rate should be within ± 5% of rated input for the appliance. Adjust the combination gas valve pressure regulator if necessary to obtain the correct ﬁ ring rate. Valve outlet pressure must not be lower than

3.2 inches w.c. nor higher than 3.8 inches w.c.

❏ For propane gas, contact your propane supply for procedure to verify

ﬁ ring rate.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

5. Perform checkout procedures • ﬁ ll out certiﬁ cate (continued)

Make ﬁ nal burner adjustments (continued)

Check combustion using instruments

You must use combustion test instruments. Failure to properly

verify/adjust combustion could allow unsafe operation of the burner, resulting in severe personal injury, death or substantial property damage.

Fuel

Natural Gas 9.6% 10.8% 4.0% 2.0%

Propane Gas 11.0% 12.5% 4.0% 2.0%

Minimum Maximum Maximum Minimum

❏ Insert test probe into vent above appliance to sample ﬂ ue products.

The results should show CO2 or O2 as follows:

❏ If the combustion results are outside the range above, and the ﬁ ring

rate of the burner is within 5% of rated input, open or close the air throttle until the CO

After CO2 (O2) tests are completed satisfactorily, measure

ﬂ ue products for carbon monoxide (CO) concentration. The CO must not exceed 50 ppm adjust to “air free”, or other if speciﬁ ed by local codes.

(or O2) are acceptable.

Make ﬁ nal burner adjustments (continued)

Check ﬂ ame signal

Electrical shock hazard — Turn off power to burner before

proceeding with setup for ﬂ ame signal measurement.

❏ (See Figure 9.) The HSI is powered with 120 VAC during pre-purge

so a microammeter with a shunt switch must be used to test ﬂ ame signal or the meter will be destroyed. USE ONLY needle movementtype meters, not digital meters.

❏ Remove the ignitor lead wire from HSI terminal of the S89C primary

control. Connect a shunt switch and HSI terminal and the ignitor lead wire. Make sure shunt switch is closed. Then turn on power to the burner. After the burner ﬂ ame starts, wait at least 15 seconds, then open shunt switch and read DC amps (must be at least 0.8 microamps DC).

DO NOT start the burner or adjust the air throttle with the

shunt switch open. The 120 V supply to the HSI will destroy the microammeter.

Figure 9 Flame signal measurement connections

DC microammeter between

❏ Adjust the draft in the appliance so the draft overﬁ re is about –0.01

inch w.c. and take a ﬂ ue gas sample from the combustion chamber. If CO

is noticeably lower overﬁ re than in the vent, the appliance has

leaks that must be repaired.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

5. Perform checkout procedures • ﬁ ll out certiﬁ cate (continued)

Verify burner/appliance operation

Check burner/appliance/controls operation

❏ Test operating and limit controls on appliance as speciﬁ ed in appliance

instruction manual.

❏ Check operation of the S89C primary control, forcing lockout by

closing the main manual gas cock and cycling the burner. See page 13 for procedure to reset the control.

Verify burner operation

❏ Start and stop the burner several times, allowing the primary control

to sequence through normal operation. Verify correct operation of burner and control throughout. See page 13 for burner sequence of operation.

Verify vent system operation

❏ Verify vent is operating correctly and ﬂ ue products are properly

exhausted from building.

❏ Check operation of barometric damper and spill switch. ❏ If the building contains any exhaust fans or conditions that could

affect vent performance, check burner/appliance/vent operation with exhaust fans (or other conditions) operating.

Prepare burner for normal operation

❏ Cycle burner off with appliance controls. Then turn off power to the

appliance.

❏ Close the main manual gas valve. ❏ Remove the U-tube manometer line from the combination gas valve

outlet pressure tap hose barb. Remove hose barb and replace 1/8" NPT pipe plug in tapping.

❏ Verify all components and wires are in place and burner is ready for

operation.

Train the user

❏ Train the user to operate the burner and appliance under normal

conditions. Explain procedure to shut down burner/appliance when required.

❏ Review the user information section of this manual (and the appliance

manual) with the user.

❏ Verify the user is aware of all procedures speciﬁ ed in the manual. ❏ Verify user will not store or use combustible liquids or materials or

contaminants in the vicinity of the burner/appliance.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

6. Maintenance and service procedures

Annual start-up & service

This burner should be started and serviced at least annually

by a qualiﬁ ed service technician. Failure to properly maintain and service the burner could result in severe personal injury, death or substantial property damage.

Turn off power to appliance and close main manual gas

valve when servicing burner. See WARNINGS on page 2 and elsewhere in this manual regarding correct procedures. Failure to comply could result in severe personal injury, death or substantial property damage.

❏ Discuss burner/appliance operation with user to determine any prob-

lems that may have occurred during the previous season and to verify user is aware of proper operation and care of the burner/appliance.

❏ Turn off power to appliance and close main manual gas valve.

❏ Remove burner from appliance and inspect ﬂ ame holder, hot surface

ignitor and burner components.

❏ Inspect ignitor and ignition tube assembly.

1. The hot surface ignitor (HSI) is a silicon carbide element that performs dual functions of ignition and ﬂ ame detection. On a call for heat, the ignitor is powered with 120 vac and is electrically heated to about 2600°F. This ignites the gas/air mixture when the primary control energizes the gas valve.

2. The primary control then switches the HSI to the ﬂ ame detector circuit, using ﬂ ame rectiﬁ cation to monitor the ﬂ ame.

3. The ignitor is positioned in the ignition tube assembly against a factoryset non-adjustable stop ring for proper ignition and ﬂ ame sensing.

4. To inspect the HSI, ﬁ rst be sure the 120 vac power supply to burner is disconnected. Then slide the two silicone insulating boots off of the insulators.

5. Pull off the quick-disconnect terminals.

6. Remove the four #8-32 screws securing the air tube back plate.

Annual start-up & service (continued)

7. Swing the hold-on bracket away and carefully pull out the ignition tube assembly.

As the white ceramic is exposed, support it using a rag. It

could be HOT. Do not let the hot surface ignitor element bump into anything. Do not drop the assembly or ignitor element. The element is very fragile. Even a small hairline fracture will destroy the HSI.

8. If the ignitor element is damaged in any way, replace it with a new one.

9. If replacing the ignition tube assembly in the burner, replace the back plate gasket with a new one. Replace the hold-on bracket and screws. Ensure the back plate gasket is sealed gas-tight to the burner air tube.

❏ Inspect and clean ﬂ ameholder.

1. Remove the ignition tube assembly from the burner as described in the steps for inspecting the hot surface ignitor.

2. Reach in and, with one ﬁ nger through the center hole of the ﬂ ameholder, pull the ﬂ ameholder out of the burner air tube.

3. Use a small brush to remove dirt and lint from the inside surface of the ﬂ ameholder. All holes must be clean and unobstructed.

4. If the ﬂ ameholder is damaged, dented or defective in any way, replace it with a new one.

5. Replace the ﬂ ameholder in the air tube.

6. Replace the ignition tube assembly as described in the steps for inspecting the hot surface ignitor. Be sure to install a new back plate gasket and seal assembly to air tube gas-tight.

7. Follow the instructions on page 8 to inspect the hot surface ignitor.

If the inside surface of the air tube needs to be cleaned,

clean with a vacuum cleaner with brush attachment while the ignition tube assembly is out of the burner.

❏ Check the burner ﬂ ange gasket. It must be in good condition. Replace

gasket on burner ﬂ ange and mount burner in appliance, securing to mounting studs.

Carlin part number MNG3B Gas Rev. 03/17/09

❏ Perform the complete checkout procedures of pages 12 through 17,

including system inspection and checks.

Model G3B Gas burner — Instruction manual

6. Maintenance and service procedures (continued)

Maintenance/service procedures

Cleaning blower wheel

❏ Periodically inspect and clean the blower housing and wheel.

1. The best time to clean the blower housing and blower wheel is while the ignition tube assembly is out of the air tube (see “Inspect ignitor and ignition tube assembly”).

2. Remove the four #8-32 slotted screws in the motor mounting plate.

3. By pulling about 1 “ of slack in the motor wires from the control box, the motor blower/wheel assembly can be pulled out and rotated to a good position for cleaning the blower wheel.

4. With a small brush or pipe cleaner, remove all dirt from the blades in the wheel.

5. With a clean rag, wipe out all the dirt from inside the blower housing.

6. Dirt that drops into the burner tube must be removed while the ignition tube is out.

7. Replace the motor plate gasket with a new one.

8. Replace the motor blower wheel assembly, being very careful that the gasket on the motor mounting plate makes a gas-tight seal against the blower housing cover.

Maintenance/service procedures (continued)

Replacing blower motor or wheel

Follow this procedure to replace motor or wheel.

1. Remove the four #8-32 screws in the motor mounting plate.

2. Pull about 1” of slack in the motor wires from the control box. Then pull out and rotate the motor/blower wheel assembly.

3. Loosen Allen set screw in blower wheel hub and take the wheel off the motor shaft.

4. Remove four #8-32 nuts holding motor to mounting plate. Be sure to take the four nylon washer seals from the motor studs and save for the new motor. Also remove the nylon motor bushing. Save the motor bushing for use with the new motor.

5. Disconnect the motor wires from their wire nuts in the control panel, keeping track of their locations.

6. Connect the new motor wires to their proper terminals.

7. Place the four nylon washer seals on the new motor studs and assemble the motor plate to the motor using the four nuts.

8. Replace the blower wheel with about 1/16” of shaft protruding beyond the hub.

9. Replace the motor plate gasket with a new one.

10. Replace the entire assembly, making sure that the gasket on the motor plate makes a gas-tight seal against the blower housing cover.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

7. Troubleshooting

Problem Possible

cause

WARNING

Burner motor will not start

Burner prepurges for 34 seconds but does not light

(continued on next page)

120 V power Check 120 V at terminal strip. L1 - L2

24 V circuit Check that 24 V thermostat/circuit is calling for heat.

Incorrect wiring Check all ﬁ eld and factory wiring.

Bad motor relay Check 24 V at motor relay. Relay should click (pull-in) on call for heat.

Bad motor If motor relay is good (see above) and wiring is correct, disconnect the

Bad primary control

Incorrect air setting

Wrong oriﬁ ce size

Manual gas shutoff valve closed

Manifold pressure

Gas valve not opening

Motor end switch not making

Hot surface ignition element damaged

Corrective action

These procedures must only be performed by a qualiﬁ ed service technician. Use care when performing tests on electrically or mechanically live parts. Disconnect power to burner/appliance and close main manual gas valve when removing components for service. Failure to comply could result in severe personal injury, death or substantial property damage.

Check limit/operative circuit.

Check transformer output. Each “T” on terminal strip should read approx. 24 volts to “G” ground.

Check continuity across contacts (N.O.) or each side of contact to L2 on terminal strip should read 120 volts.

motor leads and power the motor directly with 120 V to check motor operation.

If all above tests prove negative replace control.

For initial light-off set air throttle according to desired input.

Check oriﬁ ce drill size.

Check supply line gas cock and manual shut-off valve on combination gas valve.

Adjust regulator to 3.5 W.C. for natural gas and propane.

Check for 24 V valve coil during TFI. Indicator light should also be on.

Line pressure in excess of 14.0 W.C. can damage valve.

Check motor end switch.

Disconnect the two red leads in the panel coming from the motor end bell. Check continuity during pre-purge. End switch will not activate if motor is not running up to speed.

Element normally glows red within 20 seconds during pre-purge. Use ﬂ ame mirror to visually inspect.

Check for 120 V at rear of ignitor assembly during pre-purge.

If visual inspection cannot be done, remove element and power directly with 120 V. Replace element if it does not glow red within 45 seconds.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

7. Troubleshooting (continued)

Problem Possible

cause

WARNING

Burner prepurges for 34 seconds but does not light

(continued)

Burner lights but primary control locks out after TFI

Bad primary control

Incorrect air setting

Wrong oriﬁ ce size

Manifold pressure

Inadequate gas supply

Insufﬁ cient ﬂ ame signal

Improper draft Improperly adjusted air throttle setting for the fuel input.

Polarity Check 120 V at L1 on terminal strip.

Corrective action

Check for 24 V on valve lead on control during TFI.

Check for 120 V on HSI lead on control during pre-purge.

Replace primary control if either above tests show negative.

For initial light-off, set air throttle according to desired input.

Check oriﬁ ce drill size.

Adjust regulator to 3.5 W.C. for natural gas or propane.

Line pressure requirements are: 5.0 W.C. for both natural and propane fuels.

Line pressure in excess of 14.0 W.C. could damage combination gas valve.

Watch line pressure gauge during TFI. If pressure drops below minimum required when gas valve is energized look for partially closed gas cocks in line, other appliances using the same supply or improperly adjusted intermediate regulators.

If other appliances are on the same supply line and piping will not sustain adequate pressure for all units on that piping, then it is undersized. Check with gas utility.

Check ﬂ ame signal. Minimum signal 0.8 DC microamps.

Over-ﬁ re draft is normally -0.01 W.C. Refer to boiler/furnace manufacturer’s recommendations for specially packaged units.

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

8. Dimensions and mounting information

Figure 10 Dimensional data

Mounting burner to appliance

The universal ﬂ ange supplied with G3B Gas burners is

Prepare the burner opening on the front of the appliance as shown in Figure 11. See page 6 to determine the location of the ﬂ ange on the burner air tube. Tighten the ﬂ ange locking screws ﬁ rmly.

Figure 11 Universal ﬂ ange mounting

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

9. Replacement parts

Item

Description Part

number

1 Air Inlet Tube Assembly 50823

2 Air Throttle 50757

3 G3B Oriﬁ ce, No. 33 drill (.113 dia.), Propane 60,000 BTUH, drill open for other rates 60582

4 Oriﬁ ce Nipple 61663

5 Gas Valve, dual, 24-volt (1/2” X 1/2” LH-outlet) 41053

6 Gasket, mounting ﬂ ange 40287

7 Air Tube/Flange Assembly, 3-3/4 ID Flame Ring G3B 6”, overall length approx. 9-7/8”

G3B 9”, overall length approx. 12-7/8” G3B 12”,overall length approx. 157/8”

8 Air Tube Housing Clamp (2 required) 50807

9 Flameholder 57117

10 Ignition Tube Assembly with gasket 6”, overall length approx. 10-9/16”

9”, overall length approx. 13-9/16” 12”, overall length approx. 16-9/16”

11 Gasket, motor mounting ring & air tube back plate (2 required) 40402

12 Electrode Hold-in 54858

13 Insulator Tube (2 required) 74617

number

50070

50112

50021

97875 97876 97877

14 Hot Surface Ignitor, NORTON 120-volt, 5-3/8” OAL 87197S

15 Gasket, ignitor assembly 40360

16 Rear Ignitor Assembly 6”, overall length 7-1/2”

9”, overall length 10-1 /2” 12”, overall length 13-1 /2”

17 Ignition Terminal boot (2 required) 9788401

18 Housing and cover plate (with liquid gasket) 45856

19 Blower Wheel, 4” OD x 1” wide, 5/16” bore, CCW rotation facing open end 28613

20 Motor Mounting Ring 51060

21 Bushing, motor shaft, nylon 34686

22 Washer, motor stud, nylon (4 required) 30577

23 Burner Motor, 1/50 hp, 3300 rpm, 115-volt, 60-hz, permanent split capacitor with centrifugal

switch, CCW rotation facing shaft

24 Control Panel Base 61028

25 Indicator Light, 24-volt 33936

26 Pedestal Legs, 3/8” OD x 12” long (2 required) 61036

27 Control, Honeywell No. S89C hot surface ignition primary control, with 6 sec. TFI 99564

28 Transformer, 40-VA rating, 115-volt primary, 24-volt secondary 24315S

29 Terminal Block 33944

46631 46656 46615

27789S

30 Motor Relay, 24-volt coil, SPST 35782

31 Control Panel Cover less nameplate 61150

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

9. Replacement parts (continued)

Carlin part number MNG3B Gas Rev. 03/17/09

Model G3B Gas burner — Instruction manual

Carlin part number MNG3B Gas Rev. 03/17/09

Carlin G3B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual