1
PNA Manual for: SU-2A Gas Burner
50,000 BTU/H to 250,000 BTU/H
The burner shall be used only with NATURAL GAS or PROPANE (LPG).
Warning: If the following instructions are not followed exactly, a fire or
explosion may result, causing property damage, personal injury or death.
• Do not store or use gasoline or other flammable vapors and liquids in the vicinity
of this or any other appliance.
-
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical appliance.
• Do not use any phone in your building.
• Immediately call your gas supplier from an outside phone.
• Follow the gas supplier’s instructions.
•
If you cannot reach your gas supplier, call the fire department.
• A qualified installer, service agency or the gas supplier must perform installation and service.
• All installations must be made in accordance with all state and local codes, which may differ
from instructions in this manual.
• The installer should inform and demonstrate to the user the correct operation and maintenance
of the appliance.
• The installer shall also inform the user of hazards of flammable liquids and vapors and shall
remove such liquids and vapors from the vicinity of the burner.
• The installation adjustment data trap, or label supplied, shall be filled in and affixed to the
burner or the covered appliance.
• A combustion analyzer must be used to commission or adjust the burner.
These instructions should be affixed to the burner or adjacent to the heating appliance
Massachusetts Plumbing Board # G3-1107-132
–
New York City Dept. of Buildings MEA # 382-03-E
Manufactured by Heat Wise, Inc.
28 Industrial Blvd. Unit I, Medford NY 11763
2
(
)
Chart 1: Natural Gas and Propane (LPG)
Length
Model
SU-2A
- Control System: Honeywell S89F with 34 second Pre-Purge.
- The system uses a remote ignition system with a separate Ignition Transformer.
- Gas Valve: ½” Honeywell VR8205
of Flame
Tube
4 ¼”
Firing Rate Burner
Min
BTU/H
50,000 250,000
Max
BTU/H
Primary
Electric
Input
120 Volt
60 Hz
1 Ph
Secondary
Electric
Input
24 Volts
Total
Watts
150
Max
Total
Amps
3 or
less
Gas
Conn.
½”
BURNER DESCRIPTION
The SU-2A Gas Burner is a fully automatic, flame retention burner and is suitable for
combustion of natural gas or LPG (propane). Changing orifices alters the firing rate. The gas
pressure may be adjusted on the gas valve and can be used to convert a natural gas unit to LPG (or
vice versa). NOTE: The same gas valve is used for both natural gas and LPG without any
conversion kit.
The combustion air can be adjusted for proper O2 or CO2 by the dial located at the rear of the
burner housing, which allows the air to flow more or flow less within the burner.
Two electrodes act as a sparker and a flame rod (See Fig. 1). Flame rectification by this
flame rod monitors the continued presence of the burner flame.
control the appliance; 2) DO NOT shut off the control switch to the pump or blower
Warning: Should overheating occur, 1) shut off the manual gas shut off valve to
Fig. 1 Electrode and Flame Sensor Dimensions
If the boiler or furnace room is unusually tight, or if the house has a ventilation fan, it is
recommended that the combustion air be supplied to the furnace room through intakes from the
outside of the building. The intakes must terminate facing down in order to avoid obstruction from
rain, snow, leaves, etc. Openings must have one square inch of free area per 10,000 BTU input
rate (see Example 1). Refer to the PNA boiler manual for instructions and recommendations for
installing direct vent kits, installing louvers, etc.
150 000
( )
AIR FOR COMBUSTION
Example 1: 150,000 BTU/hr firing rate
2
1
, / *
BTU hr
10 000
, /
in
BTU hr
15
2
in=
3
CHIMNEY REQUIREMENTS
The chimney should extend
2) and be free in a
radius of 30’
at least 3’
above a flat roof or the highest roof ridge (see Fig.
of objects such as tree limbs, other buildings, etc, which may
cause a down draft. The chimney should be lined as required by the local Gas Company or local
codes.
Some utilities require new chimney liners for all gas installations. Use a corrosion resistant
chimney liner (approved for gas service) of the same size as the vent pipe.
Fig. 2 Chimney and Fresh Air Dimensions
4
MOUNTING THE BURNER
Picture 2: Flange
Picture 3: Holding Screw
Picture 4: Mounting the Burner
Picture 1: Parts
Mounting the SU-2A to the Boiler
• Refer to Picture 1 for all the parts required to
mount the burner.
• First, install the gasket and burner flange (see
Picture 2) to the boiler. The flange is marked
“up”. There are two set screws; one slightly to
the right of the 12 o’clock position. The second
screw should be on the left (slightly above the 9
o’clock position). Tighten all the nuts equally.
Make sure that the set screws on the flange are
backed out, to allow enough clearance.
• Install the provided O-ring on the blast tube.
Then, insert the SU-2A gas burner
into the boiler. Once the burner is inserted and
pushed all the way forward, insert the holding
screw with the two split washers (See Picture 3)
into the slot on the top of the housing and attach
the burner to the flange (see Picture 4). Use a 5
mm allen key (or a 3/16 allen key) to tighten the
holding screw. Make sure that both split
washers are installed on the holding screw as
shown in Picture 3.
• Once the holding screw is tight, tighten the two
set screws on the flange. Seal off any free
openings with either high temperature cement or
high temperature silicone.
completely
5
GAS SERVICE & PIPE CAPACITY
Before connecting the burner to the gas supply, insure that the gas pipes and service meter
are large enough to permit the additional load of the gas burner (see Chart 2).
Chart 2: Pipe Capacity Table*( x 1,000 BTU’s)
Nominal diameter of pipe in inches
Pipe Length**
15’
30’
45’
60’
75’
90’
105’
120’
* Using 0.6 Specific Gravity Gas and a Pressure Drop of 0.3” of Water Column
** Each 900 elbow counts as 3’ for the purpose of these calculations
Example 2:
There is 75 feet of 1” pipe from the meter to the burner and there are 5 elbows.
(5 elbows X 3’) + 75’ pipe = 15’ + 75’ = 90’ of effective pipe length
The maximum BTU that can be fired is 141,000 BTU (see chart 2)
It is advisable to run a separate gas line from the meter to the gas burner to avoid pressure
drops. Refer to the above Pipe Capacity table for the correct sizes.
CONFORM TO LOCAL CODES.
cast iron parts
gas leaks using an approved gas leak tester.
Piping should consist of:
1. A shut off valve approximately 6’ away from the unit.
2. A 1/8” plugged NPT tapping for gas pressure measurement preferably on the manual shut off
valve (as shown or anywhere between the gas valve and the shut off valve).
Note: The manual shut-off valve and tapping are NOT part of the SU-2A Gas Burner.
Please make sure you conform to local and state codes.
3. A gas union.
4. A drip pipe.
Caution: The gas valve should not be subjected to more than ½ PSIG. Therefore, the
burner should be isolated during high-pressure gas leak tests.
individual shut off valve must be disconnected from the gas supply piping system during any
pressure testing of that system at test pressures in excess of ½ psig. The appliance must be
isolated from the gas supply piping by closing its individual manual shut off valve during any
pressure testing of the gas supply piping system at test pressures equal to or less than ½ psig.
) with a suitable pipe dope that is resistant to liquefied petroleum gases. Test for
¾” 1” 1 ¼” 1 ½”
172 345 750
120 241 535 850
99 199 435 700
86 173 380 610
77 155 345 545
70 141 310 490
65 131 285 450
120 270 380
ALL PIPING MUST
Use black steel pipe and malleable fittings (
The appliance and its
do not use
6
Fig. 3 Gas Burner Piping*
*The dotted lines represent field installation.
ORIFICE INSTALLATION
All burners are equipped with an orifice set at the appropriate firing rate. It sometimes may
be necessary to drill the orifice. Drilling the orifice increases the firing rate. To drill the orifice,
first open the stainless steel union and then unscrew the orifice from inside the union. Determine
the proper orifice size for the desired firing rate and drill the orifice (see Chart 3 and Chart 4).
Replace the orifice in the union and tighten the union so that it is gas tight. Once installed, a
higher or lower firing rate can be achieved by raising or lowering the manifold pressure by +/-
0.3”. Pressure changes can only be made when the burner is running. A manometer must be used
to check and adjust the pressure. The typical working manifold pressure for natural gas is
W.C
. (2.3” W.C. for LPG). The maximum inlet pressure at the gas valve is
minimum is
pressure is 5” W.C. NOTE: The static pressure of the system may be within norm, but the
pressure drop when the system is running can reduce this greatly. Check the running pressure to
make sure there are no fluctuations in the pressure.
5” W.C.
(for the purpose of input adjustment). Note: the minimum running input
11” W.C
3.5”
.; the
INSTALLING THE CHIMNEY LINER, DRAFT REGULATOR AND
VENT PIPE
Some utilities require new chimney liners for all gas installations. Use a corrosion resistant
chimney liner (approved for gas service) of the same size as the vent pipe. Use a double swing
draft regulator, listed by CSA or U.L. The vent pipe should extend only to (but not beyond) the
inside wall of the chimney. The draft over fire should always be positive.
7
BURNER SETTINGS
Refer to the below charts for the proper settings for the SU-2A burner and PNA boiler. Note: a
pressure change at the valve, and, in some cases, an orifice change, is all that is required to
convert a natural gas burner to a LPG (propane) unit and vice-versa.
Chart 3: Heat Wise Burner Settings for
PNA DK-2 Series Boilers (Gas & LPG)
Boiler Model Burner Fuel Input Orifice Head Air
DK2-3 SU-2A
DK2-4 SU-2A
DK2-5 SU-2A
DK2-6 SU-2A
DK2-7 SU-2A
DK2-8 SU-2A
Nat. Gas 98,000 7/32" 21 0.5 3.5
Propane 98,000 7/32" 20 0.5 2.3
Nat. Gas 140,000 1/4" 16 5 3.5
Propane 140,000 1/4" 16 5 1.8
Nat. Gas 175,000 19/64" 15 11 3.5
Propane 175,000 19/64" 15 11 2.2
Nat. Gas 194,000 21/64" 13 13.25
Propane 194,000 21/64" 13 13.75
Nat. Gas 224,000 27/64" 11 16 3.5
Propane 224,000 27/64" 11 16.25
Nat. Gas 250,000 none 3 15 3.5
Propane 250,000 none 3 15 2.3
Manifold
Pressure ("W.C.)
3.5
2.3
2.3
8
ELECTRIC WIRING
These gas burners are manufactured for use with 120 volt, 60 cycle, single-phase electric current. The installation must comply and be grounded in accordance with
the National Board of Fire Underwriters and National Electric Code ANSI/NFPA No. 70-1987 (or the latest addition). All applicable local codes should be followed
as well.
Installation wiring should be wired through each limit control or interlock, while operating controls (like the thermostat) should be treated as 24-Volt wiring. The
burner has its own 24 Volt AC power supply. Do not add a 24 Volt AC transformer for the burner wiring. Do not use the 24 Volt transformer found on the burner to
power other items in the heating system, such spill switches, etc. The power supply must have a 15-amp circuit breaker or fuse with a service switch located not more
than 3 feet from the burner. Follow the wiring diagram provided below:
Fig. 4 Wiring Diagram for Honeywell S89F Fig. 5 Wiring Diagram for Optional Motor-Off Delay
SEQUENCE OF OPERATIONS: Honeywell S89F
1. Limits close.
2. Blower motor starts as the 24 Volt transformer powers the airflow switch.
3. Power from the airflow switch to the S89F control initiates 34 second pre-purge.
4. At the end of the pre-purge, the spark is energized for 4 seconds. At the same time, the 24 Volt transformer powers the gas valve, allowing the fuel to flow.
5. Within 4 seconds, the flame should be established and proved. The spark will shut off and the control will hold power to the gas valve until the limits
open and the burner stops firing.
6. If the flame is not established, the blower motor continuously runs.
7. To restart, power should be interrupted for five minutes. Turn on the power to start this sequence again.
9
LIGHTING INSTRUCTIONS
To light the SU-2A Gas Burner
1. Set the thermostat to the lowest
temperature
2. The control knob on the gas
valve should be in the “OFF”
position for at least five minutes.
3. Rotate the control knob counterclockwise to the “ON” position
and set the thermostat to the
desired temperature settings
1. Turn the thermostat off, or turn the main power off
2. Wait five minutes
3. Turn the main power on
1. Rotate the control knob on the gas valve to the
“OFF” position
2. Set the thermostat to the lowest temperature
3. Turn Main Power Off.
Reset, if Flame Lockout Occurs
To shut the burner off
BURNER OPERATION
Before turning the burner on, make sure the proper orifice is installed. Check for gas supply leaks.
Check the wiring diagrams. Install manometers before and after the gas valve;
manifold pressure corresponds with the proper orifice and fuel (refer to the charts 3 and 4 on
page 7)
the burner to turn it on. Follow the sequence of operations for the control (see page 8).
. Keep the observation port of the boiler open. Follow the instructions on the nameplate of
HEAD AND AIR ADJUSTMENT
Head Air
make sure that the
To access the head and air adjustment, remove the
black plastic cover
using the supplied 4 mm allen key. The left dial is
the head adjustment dial; the right dial is the air
adjustment dial. These dials can spin 360o; 22
times for the head and 32 times for the air.
from the rear of the housing,
When to adjust the Air
The air shutter is a mechanical shutter. Do NOT over crank the air shutter. You must use an
analyzer to measure the CO2 (Carbon Dioxide). General rule: if the CO2 is too low, then close the
air shutter. If the CO2 is too high, then open the air shutter.
than 9.8% for Natural Gas or 11.5% for LPG.
If the CO (Carbon Monoxide) is above 100 ppm, there is either too much air or too little air.
Check the CO2 level and adjust the burner.
Note: Do NOT set the CO2 higher
When to adjust the Retention Head
The retention head is set at the factory. The retention head is 1/8” inside the tube when the
marking reads ‘22’. There is a full ½” movement for the retention disk to move backward (to
increase secondary air) or forwards (to decrease secondary air).
moves within the blast tube. Do not over crank the head dial.
to compensate for backpressure in the combustion area, up to 0.3” W.C.
NOTE: the head physically
This movement can also be used
10
When commissioning the burner, make sure the gas control
knob is in the ”ON” position. Install monometers at the
inlet pressure tap and outlet pressure tap. Note: When
checking manifold pressure, do not subtract burner
housing pressure during valve-on delay. Record the static
incoming gas pressure. When the burner lights off, record
the running incoming gas pressure; the running incoming
gas pressure should never be below 5”. Note: this pressure
drop should not be greater than 1”.
Check the manifold pressure from the outlet pressure tap.
Refer to Charts 3 and 4 on page 7 to make sure the gas
pressure is set for the appropriate fuel and pressure. If
adjustments need to be made, remove the cap screw and
adjust the pressure regulator. Screwing the regulator
clockwise will increase the manifold pressure and
counter-clockwise will decrease the manifold pressure.
Trouble shooting:
There are three factors to operate the gas burner properly:
1. Electricity {(main Power 120V/60 Hz /1 Ph)( secondary 24V)}
2. Gas flow (Incoming pressure should be 10” w.c. with proper gas line without pressure drop
during burner operation).
3. Combustion air.
Check these three items properly before proceeding in detail for other problems.
Condition Solutions
Burner motor runs and:
No flame after pre-purge & no fuel indicator (where
applicable)
No flame, fuel indicator on (where applicable),
faulty ignition transformer or spark separately
Fenwal control defective after above tests. Replace
Burner locks out after 4 seconds
First, check ionization electrode, ionization cable (for cracks)
Polarity reversed Check power feed for broken polarity
Bad earth grounding Fix the ground wire
Gas pressure is too low Check the gas pressure and adjust to proper pressure
Pulsation at start
First, check the burner head location with respect to the end of
Gas pressure is too high. Use manometer and readjust the pressures.
Blocked Flue Check draft and clear flue of foreign materials.
Pulsation during operation
Burner is not correctly adjusted. Readjust with combustion analyzer.
The burner is dirty. Clean the burner.
Defective chimney Check and change if necessary with liners.
Burner locks out
Ionization current is too low. Check current. Minimum 0.8 micro amps. Check position of
The CO content is too high
Excess air is too high or too low. Adjust air shutter.
The gas holes are clogged. Clean them.
The fresh air intakes are too small. Check and readjust.
The burner head is out of position. Check and readjust.
Condensation in the heat exchanger
Firing Rate is too low. Increase the firing rate so that the stack temperature is 350o F
Check 24V feed to airflow switch & after airflow switch to
control. Fix or replace the airflow switch. If there is no
secondary power, then replace the 24Vtransformer.
Check ignition transformer, electrode, cracked electrode or
gap. Fix or replace.
and boot. Fix as needed.
the flame tube. Adjust as necessary.
ionization electrode and the condition of the cable.
or HIGHER. Insulate the chimney.
11
(
)
____ 1. Check that the capacity of the meter can meet the demand of the burner and all other appliances
COMMISSIONING/TROUBLESHOOTING CHECKLIST
There are four factors that are needed to operate the gas burner:
____ 1. Combustion Air
____ 2. Electricity
____ 3. Gas Flow
____ 4. Combustion Analysis
1. Combustion Air
Check the air coming into the area where the burner is located.
____ 1. If the burner is in a large area that air can come into freely (i.e. an open
basement for home heating systems), then the air supply should be
sufficient for the burner.
____ 2. If the burner is in an enclosed area (i.e. small room or closet) then
fresh air must be supplied to the burner. The intakes to the area must
terminate facing down in order to avoid obstructions. The total open free
area must be 1 in2 per 10,000 BTU input
Example 150,000 Btu/hr firing Rate
2
1
( )
hrBTU =
*/000,150 in
in
/000,10
2. Electricity
Check burner wiring
____ 1. Check that 120VAC is coming into the burner
____ 2. Check that the burner is properly grounded using a ground wire
____ 3. Check the polarity to the burner is correct.
(To check polarity: Set a multimeter to VAC. Touch L1 to one of the probe tips and ground to
the other. If a voltage between 110 and 125 is shown then it has the correct polarity; if any
other reading is shown, then check the L2 wire. If the L2 wire shows a voltage between 110 and
125 is shown then the polarity to the burner is reversed.)
3. Gas Flow
2
15
hrBTU
running off the meter.
____ 2. Check that the burner is on a direct pipe from the meter.
____ 3. Measure the total length of all the pipe and count the number of elbows (1 90o elbow=3 ft. of pipe).
Compare the total feet of pipe and the BTU demand using the chart on Page 5 to determine the size of
the pipe required.
____ 4. Check that the proper orifice is installed if needed.
____ 5. Check the gas pressure at the gas valve (line pressure). This pressure should be between 5” wc and
10” wc when the burner is not firing. Note: When checking manifold pressure, do not subtract
burner pressure during valve-on delay.
____ 6. With the burner firing the pressure drop on the supply side should not exceed 2” wc. If the pressure
drops and then surges back up double check the piping because it means the pipes are undersized.
4. Commissioning the Burner
____ 1. Check the head and air settings and start the burner.
____ 2. Use a combustion analyzer to check CO2 and CO. CO2 should be between 9% and 9.8% and CO
must be less than 400 ppm but we suggest less than 100ppm. If the CO2 is greater than 9.8% then the air
should be opened to reduce the CO2; if the CO2 is below 8%, then the air should be closed to increase CO2.
____ 3. Check the manifold pressure to verify that it is at the specified pressure.
12
____ 4. Clock the gas meter and check that the correct firing rate is achieved. If the firing rate is low, the
gas pressure should be increased slightly. If the firing rate is too high then the gas pressure should
be decreased. (Usually if the stack temperature is below 300F the firing rate is too low. If the stack
temperature is over 600F then the firing rate is usually too high or on rare occasions the heat
exchanger is blocked up)
Gas Input to Burner in ft3/hr *
10 180 360 720 1800 50 144 360
12 150 300 600 1500 55 131 327
14 129 257 514 1286 60 120 300
16 113 225 450 1125 65 111 277
18 100 200 400 1000 70 103 257
20 180 360 900 75 240
22 164 327 818 80 225
24 150 300 750 90 200
26 138 277 692 100 180
30 120 240 600 110 164
35 103 206 514 120 150
40 180 450 130 138
45 160 400
* For BTU/hr Natural gas multiply by 1000
For BTU/hr LPG multiply by 2500
____ 5. If the firing manifold has been readjusted, redo steps 2 and 4
____ 6.Check that the draft over-fire is positive
1/2 ft3 1 ft3 2 ft3 5 ft
3
2 ft3 5 ft
3
Use a combustion analyzer and record the readings below.
BURNER OPERATION: Record the Readings at Steady State
Draft over fire at steady state (should be Positive – refer to boiler manual)
Natural Gas CO2 % = (9.0% to 9.8%) or O2 % = (5.0% to 3.5%)
LPG CO2 % = (10.5% to 11.5%) or O2 % = (5.0% to 3.5%)
Gross Stack Temperature (350o F minimum, 450oF maximum)
NOx (If required)
Carbon Monoxide (CO) in PPM (less than 100 PPM ideal; should not
exceed 400 PPM Oxygen free)
Incoming Gas/LPG pressure = “W.C. (minimum 5”, maximum 11”)
Manifold Pressure = “W.C.
Head Setting
Air Setting
13
ITEM
PART PART #
1 Blast Tube
11728410 16 Cover Plate - Air
2 Flange Gasket
10195-1 16A Cover Plate - Nozzle
3 Adjustable Flange 10195 17 Scale - Nozzle Line
ITEM
PART PART #
11887001
Regulation
11887301
Line
11888101
4 Front piece - Housing 17A Scale - Air Regulation 11887801
5 Rear piece – Housing
6 Fan Wheel
7 1/6 HP PSC Blower motor
8 Shielding Plate Housing
9 Outside Air Boot
9A Silencer
10 Air Regulation Plate
11 Air Damper
12 Air Regulation Adjustment screw
13 Adjustment Screw – Nozzle Line
14 Ionization Cable
15 Ignition Transformer
18 24 Volt Transformer 2440VA
11417601 19 Safety Control 2466H or
S89F
D82132 20 Plastic Cover Plate 11850001
21 Screw (Long Special) 11750702
11859107 22 Airflow Switch
6041A
Honeywell
11879302 23 Ignition Electrode 115 34708
11851001 24 Flame Rod 115 34707
11852201 25 Retention head 119 39701
11848501 26 Union 1139101
11912901
27 Gas Valve
VR 8205A
11865805
2260-TWG
28 Brass orifice 12299
Ignition Cable for 2260-TWG 2260-GTO
14
Maintenance Instructions:
TO BE FIXED/ATTACHED NEAR BURNER
Once a year, a qualified service agency needs to be contracted for other than routine
maintenance.
1. The blower motor is the only moving part. It does not require lubrication, since the ball
bearings have been permanently lubricated.
2. The user should do periodic visual checks of the burner and the flame.
3. Laundry lint or dog and/or cat hairs should not go inside the blower. If they are seen, they
should be removed after disconnecting the power to the burner and cover parts should be
installed before starting the burner.
4.
Keep the area around the conversion burner clear and free from combustible materials,
gasoline, and other flammable vapors and liquids.
5.
No obstruction for the flow of combustion and ventilating air (ref. Page 4).
15
This Page Intentionally Left Blank
16
This Page Intentionally Left Blank
Loading...