Midco RE4400DS Service Manual

Installation and Service Instructions

RE4400DS & RE4400DSA

Ne touchez à aucun interrupteur. Ne pas vous servir des

Appelez immédiatement votre fournisseur de gaz depuis

Economite

Gas Burner

In the United States, Installation must conform
with local codes or, in the absence of local codes, with
Installation of the National Fuel Gas Code, ANSI Z223.1-
latest edition,from the American National Standard Institute.
Further reference should be made to the recommendation of
your fuel supplier.

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

Codes for Gas Burning Appliances and Equipment, CGA
Standard CAN/CGA 1B-149. Further reference should be

made to the recommendation of your fuel supplier.

WARNING: Additions, changes, conversions, and
service must be performed by an authorized MIDCO
representative, service agency, or the fuel supplier. Use
only MIDCO specified and approved parts.
INSTALLER: Inform and demonstrate to the user the
correct operation and maintenance of the gas utilization
equipment. Inform the user of the hazards of storing
flammable liquids and vapors in the vicinity of this gas
utilization equipment and remove such hazards. Affix
this manual and associated literature adjacent to the
burner. CODE COMPLIANCE IS THE SOLE
RESPONSIBILITY OF THE INSTALLER.
USER: Retain this manual for future reference. If other
than routine service or maintenance as described in this
manual and associated literature is required, contact a
qualified service agency. DO NOT ATTEMPT REPAIRS.
An inadvertent service error could result in a dangerous
condition.

FOR SERVICE CONTACT:

Name
Address

WARNING: If the information in these instructions
is 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 switch;do not use any

phone in your building.

? Immediately phone your gas supplier from another

building. Follow the gas supplier’s instructions. If you

cannot reach your gas supplier call the fire department.
Installation and service must be performed by a
qualified installer, service agency or the gas supplier.

?

AVERTISSEMENT. Assurez-vous de bien suivre
les instructions données dans cette notice pour
réduire au minimum le risque d’incendie ou
d’explosion pouvant entraîner des dommages
matériels, des blessures ou la mort.

Ne pas entreposer ni utiliser d’essence ni d’autres
vapeurs ou liquides inflammables à proximité de cet
appareil ou de tout autre appareil.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer d’appareil.

•
téléphones se trouvant dans le bâtimentoù vous êtes.

•
un voisin. Suivez les instructions du fournisseur.

• Si vous ne pouvez rejoindre le fournisseur de gaz,
appelez le service des incendies.

L’installation et l’entretien doivent être assurés par un
installateur ou un service d’entretien qualifié ou par le
fournisseur de gaz.

Burner Model

Bill of Material #
Phone
Date of Installation

notations and have standard meanings throughout this manual. They are printed in all capital letters using a bold type face
as shown below, and preceded by the exclamation mark symbol. When you see the safety alert symbol and one of the
safety information terms as shown below, be aware of the hazard potential.

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

DANGER: Identifies the most serious hazards which will result in severe personal injury or death.
WARNING: Signifies a hazard that could result in personal injury or death.
CAUTION : Identifies unsafe practices which would result in minor personal injury or product and property damage.

Midco®International Inc.

4140 West Victoria St. - Chicago, Illinois 60646
tel [phone] fax [phone]

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

Quality Designed for Proven Performance

Serial Number

Wiring Diagram

602

8471 25

Printed in U.S.A.

Part 1 Installation

Specifications

The ECONOMITE Model RE 4400DS and RE4400DSA burners with direct spark ignition

1

are adaptable to most gas utilization equipment, including furnaces and boilers. Power
burner design makes them perfectly suited for oil burner replacement, including rooftop and
industrial applications.

AIR DELIVERY (Approximate Air Delivery at Zero Draft)
FIRING RATE (NATURAL OR PROPANE )

GAS SUPPLY PRESSURE REQUIRED

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

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

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

ELECTRICAL SUPPLY......................................120 VAC...........60 Hertz

ELECTRONIC CONTROL VOLTAGE ................ 24 VAC

FLAME SAFETY....Direct Spark Ignition of Main Flame, Electronic Safety

RE4400DS and RE4400DSA ..... 125 SCFM

3

RE4400DS & RE4400DSA
MAXIMUM MBH
MINIMUM MBH

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

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

WIDTH 10"
LENGTH 16.5"

4

4

400
132

RE4400DS & RE4400DSA

2

5

Part 1

Installation

I Ventilation

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

TABLE 1: Burner Specifications

PROPANE gas burners.

2. SCFM = Standard Cubic Feet / Minute.

3. All Ratings Based on 1000 BTU/Cu. Ft. NATURAL and 2500 BTU/cu.ft PROPANE. Derate
burner for altitude over 2,000 feet by 4% for each 1,000 feet above sea level.

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

5. For 50 Hertz applications the RE4400DS and RE4400DSA will be derated by 20%. Contact the
factory for details. NOTE: Burners rated for 50Hertz are not UL Listed.

____________________________

CAUTION: The ECONOMITE Model RE4400DS and RE4400DSA Burners are
not intended for outdoor installation and must be protected from excessive moisture.
Provide adequate clearance for service and proper operation.

If the former automatic oil burner gave trouble-free operation, it is probable that the heating
plant area has sufficient infiltration of air for combustion and dilution of flue gases.

Nevertheless, the area must be checked.

? Open basement or utility areas of normal construction, without storm windows or tight
doors, will generally allow sufficient air infiltration. However, if the heating plant is located in
a tight or separate room, ventilation to an open area as described above will be required.
Install two permanently open grills, each sized on the basis of one square inch free area per
1,000 BTU (but not less than 100 square inches) of the total input rating of all gas utilization
equipment in the combined space. One grille should be located within 12 inches of the
ceiling, the other within 12 inches of the floor.
?? If the heating plant is located in an area of unusually tight construction, or if an exhaust
fan, kitchen ventilation system, clothes dryer and/or fireplace is installed in the building,
provisions must be made for an outside air supply near the heating appliance area. Install
permanently open grills sized at not less than one square inch free area per 4,000 BTU of
burner input. When ventilating through horizontal ducts, grills should be sized at not less
than one square inch free area per 2,000 BTU of burner input. In any case, the minimum
dimension of rectangular air ducts shall not be less than 3 inches.
? In Canada, for detailed ventilation requirements, refer to standard CAN 1-B149.1 or .2
and/or local codes.

____________________________

II Preparation of

the Gas Utilization

Equipment

2

? Clean the gas utilization equipment combustion chamber, heat exchanger interior, and flue
connections. Remove all adhering tars, scale, dirt and soot. Inspect for actual or potential
leaks.
? Cement all joints, including those in the heating appliance base and around the door
frames, to prevent leakage into, or out of the combustion chamber.
? The access or firing door should open easily to relieve pressure. If positive latches exist,
they should be modified to permit easy opening; a spring loaded door holder is
recommended.
? On all boilers, make certain the pressure relief safety valve is in good operating condition.

3

Part 1

Part 1 Installation

Installation Continued

III Combustion

Chamber

____________________________

A combustion chamber liner is normally required to protect non-heat transfer surfaces and to
provide a radiant bed for rapid heat transfer to the primary surfaces of the heat exchanger.
In most cases the existing chamber liner can be used, if in good condition.
? In the case of wet base boilers, where the entire firing chamber is comprised of heat
exchange surfaces and no chamber liner was provided for oil firing, a liner is usually not
required for the ECONOMITE. However, a liner or target wall may be necessary if the firing
chamber is unusually short, in order to avoid excess flame contact on the heat exchanger
walls or flueways.

? If a built up chamber liner is required, use 2,300°F minimum insulating material.
? The burner tube, or the stainless steel sleeve that is included with the burner, must be

sealed air tight into the combustion chamber opening with refractory material. The sleeve is
preferred as it is designed to properly locate the end of the tube relative to the inside wall of
the combustion chamber, and to permit burner removal without breaking the seal.

CAUTION: In no case should the burner tube be allowed to extend into the
chamber proper; it must be set at least 1" short of the inside surface because high
combustion chamber temperatures will cause premature pilot, electrode, burner tube
and sleeve deterioration.

IV Chimney, Vent

Connector and

Draft Control

Figure 1: Dry Base Boiler with Combustion

Chamber Liner (Warm Air Furnace

Construction is Similar)

WARNING: BURNER MUST BE MOUNTED IN ORIENTATION SHOWN IN
FIGURES 1 AND 2. ANY OTHER MOUNTINGS MAY CAUSE A DANGEROUS
CONDITION, AND WILL VOID BURNER WARRANTY AND AGENCY APPROVALS. NON­STANDARD ARRANGEMENTS MAY BE AVAILABLE FOR SOME MODELS. CONSULT
FACTORY FOR DETAILS IF REQUIRED.

? Before permanently setting the burner in place, check that the main burner ports are free
of foreign materials, and also that the spark electrode assembly has not been damaged or
displaced. See Figures 7A and 7B.

Figure 2: Wet Base Boiler with Unlined

Combustion Chamber

____________________________

deteriorated masonry and excessive soot or other blockage or potential blockage.
Installation must conform with local codes or in the absence of local codes with NFPA,
ANSI Z223.1 latest edition.

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

? The Vent Connector shall be made of non-combustible, corrosion resistant material
capable of withstanding the vent gas temperature produced by the gas utilization equipment
and of sufficient thickness to withstand physical damage.
? The Vent Connector shall be as short as possible. The entire length shall be readily
accessible for inspection, cleaning, and replacement.
? The length of horizontal uninsulated Vent Connector between the chimney and a single
gas utilization equipment shall not exceed 75% of the height of the chimney above the
connector, or 100% if the Vent Connector is insulated.
? The Vent Connector shall be installed so as to avoid turns or other construction features
which create excessive resistance to flow of vent gas. It shall be installed without any dips or
sags and shall slope upward at least 1/4" per foot.
? A manually operated damper shall not be placed in the Vent Connector or chimney of
any gas utilization equipment.
? The Vent Connector shall be firmly attached to draft hood outlets and flue collars. Joints
between sections of connector piping shall be fastened by sheet-metal screws or other
approved means. The Vent Connector shall be supported for the design and weight of the
material employed to maintain clearance and prevent physical damage and separation of
joints.

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

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

Part 1

Part 1 Installation

Installation Continued

IV Chimney, Vent

Connector and

Draft Control

Continued

? A draft hood or a barometric draft regulator shall be installed in the same room or
enclosure as the equipment in such a manner as to prevent any difference in the pressure
between the hood or regulator and the combustion air supply (see Figures 3 and 4). In no
case shall the relief opening of the draft hood or barometric draft regulator be located at a
point lower than the top of the highest flue passage in the equipment.

Figure 3: Recommended Locations for Draft Hoods

Note: Figure 3 and 4 :

Copyright by American Gas

Association.

Used by permission of the

copyright holder.

Figure 4: Location for Barometric

Draft Regulators

? Gas utilization equipment requiring controlled draft may be equipped with a listed double
acting barometric draft regulator, if approved by local codes (see Figure 4).
? If a device which will automatically shut off the gas to the burner in the event of sustained
backdraft is required. It shall be of the listed manual reset type and installed and adjusted by
a qualified service technician in accordance with the manufacturer’s instructions.
? Refer to gas utilization equipment manufacturer for recommended vent connection
requirements.

____________________________

V Electrical

4

burner housing cover.

CAUTION:Refer to wiring diagram in Figure 5 or located on the inside of the

Installation wiring and grounding to the burner must conform to local codes, or, in their
absence in the United States to National Electric Code, ANSI/NFPA No. 70 latest edition;
in Canada, to Canadian Electrical Code Part 1, CSA Standard C22.1
? Use copper wire not less than 14 gage for line voltage wiring. Hook up to a dedicated line
with an on-off disconnect switch and a minimum 10 Amp breaker.
? The frame of the burner should be well grounded. Normally the piping and/or electric

5

Part 1

Part 1 Installation

Installation Continued

V Electrical

Continued

Figure 5: Wiring Diagram

conduit will provide sufficient grounding. However, a ground lug is located in control box for
positive grounding where insulated pipe couplings are used or where any doubt exists
regarding grounding sufficiency.
? Confirm that the polarity is correct—hot wire to strip terminal L1, neutral L2—and that the
neutral line is not subject to induced low voltage (check L2 to earth ground) from other
equipment, as that can cause the Electronic Control to malfunction.
? Each installation must include suitable limit control(s). Existing oil burner combination
operating and limit controls are normally NOT SUITABLE for gas burner use.
? Connect motors used on forced air furnace fans or boiler pumps to a combination limit
control and switch.
? Set the thermostat heat anticipator for the total current draw handled by the thermostat.
The current draw of the ECONOMITE 24V operating circuit is 0.9 amps.

CAUTION: Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation. Verify proper operation
after servicing.

____________________________

VI Piping

CAUTION: The available gas pressure should be within the limits shown in
Table 1 - SPECIFICATIONS section. Excessive pressure may damage electric valves,
regulators and manual valves. If the supply pressure exceeds the 14.0"W.C. maximum,
a suitable high pressure regulator must be installed between the Main Manual Shut­Off Valve and burner combination valve as shown in Figure 6.

? The burner gas supply piping should branch off from the main line as close to the gas
meter as possible. Do not connect to the bottom of a horizontal section. Use new black pipe
and malleable fittings free of cutting and threading burrs or defects.
? Provide a sediment trap, union and 1/8" pressure tap in piping close to burner as shown
in Figure 6.

? Use pipe joint compound approved for use with Liquid Petroleum Gases.
? Piping must also comply with your local codes.
? To obtain the maximum firing rate of the burner, the gas supply piping must be sized to

provide a minimum pressure of 7.0"W.C. (Natural) and 5.0”W.C. (Propane) to the inlet of the
combination redundant valve when the burner and all other gas utilization equipment are on.
The main regulator, if equipped, should be mounted upright and in a horizontal run of pipe.

CAUTION: Because it is difficult to accurately control pressure during supply
pipe leak testing, it is recommended that all low pressure (14.0"W.C. max.)
components be disconnected during testing. Exposing low pressure regulators and
valves, including manual valves, to pressures over 1/2 PSIG (14.0"W.C.) will cause
damage and void all warranties.

DANGER: Explosion hazard.

Do not use oxygen for pressure testing.

An explosion could occur during initial start up.

??If the burner piping must be rearranged because of space limitation, be sure to carry out
the general arrangement shown in Figure 6. Install the combination valve in any position
except up-side down.

Part 1

Part 1 Installation

Installation Continued

VI Piping

Continued

Figure 6: Piping Diagram

? When the burner is installed in the vestibule of jacketed equipment, it is recommended
that the Automatic Safety Shut-Off Valves be left adjacent to the burner within the vestibule
and the Main Manual Shut-Off Valve be installed outside.
? Run full size pipe or tubing from regulator vent openings to outside of building. Provide no
traps in the vent lines and terminate away from all doors and windows; also make provisions
for keeping rain and foreign objects from entering the vent piping.
? When high supply gas pressure is encountered, as in the case in many industrial plants,
the gas line size can be reduced to allow for a greater pressure drop; however, the size must
be sufficient to deliver burner rating pressure.

Natural Gas capacities

Pipe
Size

3/4
3/4

1

1
1 1/4
1 1/4
1 1/2

reducing regulators. Install a high pressure regulator of the Tight Shut-Off type, sized
for main gas input, upstream of the low pressure regulators.

? The high pressure regulators must be adjustable to 14" W.C. outlet pressure.
? When the gas supply line is about to be put into service it must be tested to insure that it

is gas tight. Use air or inert gas under pressure and test with soap and water to locate leaks.
? Before gas is turned onto the system, a check must be made to see that there are no open
fittings and to make sure the burner main valve is closed.
? After checking for leaks, purge the gas line up to the burner inlet. Purging the air from the
gas supply line at this step will expedite the first light-off.

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

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

Type

of Gas

Natural

Propane

Natural

Propane

Natural

Propane

Natural

CAUTION: High gas pressure supply lines require the proper pressure

Approximate Capacity -MBH

Pipe Length

10
200
590
400

20
150
400
275

40

275
200
500
450

650

75

190
150
360
325

475

100

160

300
275
630
400

shown are for a total
pressure drop of 0.3"W.C.
For 0.5"W.C. pressure drop,
multiply capacity shown by

1.3. Propane capacities
shown are for a total
pressure drop of 0.5”W.C.
For higher permissible
pressure drops, consult
your gas supplier.

Table 2: Schedule 40 NPT

Pipe-Capacity Chart

____________________________

6

7

Part 1

Part 1 Installation

Installation Continued

VII Main Gas

Input Selection

Burners are approved for use with NATURAL gas or PROPANE gas and should be used only
with the gas specified on the rating plate. If the supplied burner is designed to run on natural
gas and needs to be changed to run on propane, a conversion kit is available from Midco®.
? The gas input should be set at the heating rate determined by the building heat loss and/or
heating plant survey, but not exceeding the rated maximum input of the gas utilization
equipment or Economite burner.

____________________________

VIII Initial Start-

up /Adjustment

chamber only with Main Manual Shut-Off Valves closed. Confirm that gas utilization
equipment does not contain any accumulated gases. Purge as described in step 3
below.

at all times except during maintenance and service.

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

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

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

WARNING: Ignition is automatic. Make spark observations into combustion

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

solution to unions and joints with the gas supply on. Leakage will be indicated by the
appearance of soap bubbles. Locate and correct all gas leaks before proceeding.

WARNING: DO NOT USE OPEN FLAME.

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

main Manual Gas Cock OFF, turn burner power on, and set operating control to ON or
thermostat to call for heat. Let the blower run long enough to accomplish four
combustion chamber volume air changes, but not less than five minutes.

Natural Gas / Propane Gas Orifice Size and Pressure Settings

Input
MBH

Natural Gas

Orifice

Size

(Inches)

Letter

Stamp

Manifold

Pressure

("W.C)

1

Propane Gas

Orifice

Size

(Inches)

Letter

Stamp

Manifold

Pressure

("W.C)

RE4400DSA

400
350
300

250

200
132

No Orifice
No Orifice
No Orifice

*

0.358

0.290

No Orifice

-

-

-

J

B

-

4.7

3.6

2.7

3.3

3.5

0.6

0.358

0.290

0.261

0.219

0.219

0.358

J

3.5
B
C
E
E

4.7

4.2

4.8

2.8

0.45

J

RE4400DS

400
350
300
250

*

200
132

1.

Adjust the main regulator to vary the manifold gas pressure and burner input within the range
shown. Do not exceed pressure as listed in Table 3, under any circumstances. Use combustion
readings (CO and O2) and a flow meter to determine exact inputs.

* Spud Size and approximate manifold gas pressure setting: as shipped. Air shutter set full open.
NOTE: For LP Conversion kit contact the factory

and the preliminary combustion air shutter setting are suitable for capacity rating of
the gas utilization equipment. Refer to Section VIII and Table 3.

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

No Orifice
No Orifice
No Orifice

0.358

0.290

No Orifice

Table 3: Capacity and Preliminary Gas Settings

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

-

-

-

J

B

-

4.3

3.3

2.4

2.9

2.8

0.6

0.358

0.290

0.261

0.219

0.219

0.358

J

2.8
B
C
E
E

3.6

3.1

3.2

2.1

0.3

J

Part 1

Part 1 Installation

Installation Continued

VIII Initial Start-

up /Adjustment

Continued

4. RESET the Electronic Control by setting the operating control to OFF or the thermostat
below room temperature for at least 30 seconds. See Section XII.

5. Confirm that Main Manual Shut-Off Valves are open. Turn main Manual Gas Cock ON.

6. Turn operating control to ON or set thermostat above room temperature. Main flame
should come on after the 30 second pre purge period. Whenever the burner fails to light
during the 6-second ignition trial, or if the flame is lost during the burner run and is not
re-established within 36 seconds, the Electronic Control will shut off the Combination
Valve and LOCK OUT. To RESET the Electronic Control for restart, de-energize the
Electronic Control by setting the operating control to OFF or thermostat below room
temperature for at least 30 seconds. If burner still fails to light, turn it off and repeat from
step 5 above. Then, if necessary, refer to the TROUBLE CHART to isolate the problem.

WARNING: Repeated unsuccessful attempts to light will result in accumulated

gases in gas utilization equipment and chimney. To prevent these gases from
reaching an explosive level, periodically purge the gas utilization equipment and
chimney as described in step 3 above.

7. To make a preliminary setting of the burner input, determine the manifold gas pressure
required from Table 3 and adjust the Main Gas Pressure Regulator accordingly. See
Section XI.

8. To determine the firing rate for NATURAL gas, accurately time test dial for the number
of seconds for one revolution and use the following formula. All other gas utilization
equipment must be off.

Then divide by 1,000 for MBH value.
Example: 3600 x 1 x 1000

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

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

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

3600 x test dial size x BTU value

No. of seconds for one rev. test dial

10

= 360,000 BTU/HR = 360 MBH

= BTU/Hr.

8

Figure 7A: General Assembly for the RE4400DS

9

Part 2 Service

Part 1

Installation Continued

VIII Initial Start-

up /Adjustment

Continued

flue gas samples and temperature immediately ahead of the draft control.
A. The flue gas temperature should be above 325°F but not exceeding 550°F.

Excessive flue gas temperatures will result in low efficiencies. Low flue gas
temperature may cause excessive condensation. Reset gas input, if necessary, to
adjust stack temperature.

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

with an ORSAT or similar combustion testing instrument. The carbon monoxide
content should conform to local codes, or in their absence, to the level specified
in the United States or Canadian Standard referenced on the front cover of this
manual; and the carbon dioxide content should be approximately 9.5% for
NATURAL or 12% for propane , or within the limits prescribed by local codes.

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

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

NOTE: For subsequent normal starting and shut off procedure, refer to CONSUMER
INSTRUCTIONS, located in part 3 of this manual, or to the instruction plate mounted

on the burner.

____________________________

Part 2

Service

IX Electrodes

DANGER: Do not tamper with the unit or controls. If trouble occurs contact

the installing contractor, service agency, or fuel supplier. See front cover.

DANGER: Be sure that the main Shut-Off Valve is closed and the burner

power supply is turned off before removing any parts for service.

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

place at all times except during maintenance and service.

____________________________

? The flame sensing rod must be positioned as shown in Figures 7A and 7B so that the
Electronic Control will detect a proper flame.
? Both the spark and flame rods are current carrying conductors and, along with their
connecting wires, must be kept free of contact with conductive metal parts of the burner. Rod
insulators and wire insulators should be clean, dry and free of cracks.

Figure 7B: General Assembly for the RE4400DSA

Part 2

Part 2 Service

Service Continued

IX Electrodes

Continued

? Both the spark and flame rods are made from heat resistant alloys and can be expected
to have a long service life. They should be routinely inspected, however, for corrosion or loss
of metal.

Figure 8: Motor / Blower Assembly

____________________________

X Motor Blower

Interlock

XI Valve Train

CAUTION: BEFORE SERVICING, mark with a scribe line or measure opening
of air controlling shutter, so that it can be reset to its original position following
servicing.

? Cleaning of the blower wheel is usually the only service required. Need for cleaning is
indicated if the character of the flame indicates a deficiency of air. Motor cooling air vents (if
present) should also be cleaned at this time.
? The motor and wheel are removed as an assembly. Disconnect the motor conduit from
the motor and remove the mounting bolts.
? The burner is equipped with a diaphragm type air pressure switch so as to prevent the
burner from firing if the blower wheel is not running at its operating speed. When the motor is
off there is no air pressure present to activate the pressure switch and in turn there is no
power flow to the Electronic Control.
? To make a specific test of the interlock circuit:

1. Turn burner power OFF.

2. Turn Manual Gas Cock OFF.

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

4. Turn burner power ON and set the operating control to ON or thermostat to call for
heat. Verify there is 120VAC line voltage by using a multimeter. Check for 24V
between the Electronic Control 25V and 25V GND terminals.
A. No voltage: Interlock circuit OK.
B. Voltage present: check that the switch is wired properly or check switch

operation. Replace if switch tests bad.

____________________________

? Should replacement or service be required, valve manufacturer's instructions must be
followed as outlined in their information sheet.

? Outlet pressure settings must be checked while the gas is flowing.
? To adjust outlet pressure, remove the seal cap for access to the adjusting screw. Turning

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

____________________________

XII Sequence of

XIII Electronic

10

Operation

Control

? The RE4400DS and RE4400DSA operate when power is applied to L1 and L2 through a
safety and or operating control. With power applied to L1 and L2 the blower motor starts.
Once the diaphragm air flow switch proves blower operation power is applied to the S87
Electronic Control. The S87 Electronic Control provides the switching of the gas valve and
ignition sequence. If the flame signal is above 2DC micro amps the RE4400DS and
RE4400DSA will remain in operation until a safety or operating control opens the circuit to
L1 and L2. For a more thorough explanation of the Honeywell electronic control refer to the
literature provided with the power burner. For startup information see section VIII.

____________________________

? The S87 is a low voltage, solid state, direct spark ignition control module for gas-fired
furnaces, boilers and heating appliances. UL Listed models are only available with a pre­purge timer. The S87 controls the gas valve, monitors the main burner flame and
generates a high voltage for spark ignition.
? The S87K uses separate electrodes for spark ignition and flame sensing. Use with any
gas control designed for DSI application that is rated at 2.0 A or less. Includes a 30 second

Part 3 Maintenance and Trouble Chart

Part 2

11

Service Continued

XIII Electronic

Control Continued

XIV Special

Equipment

(OEM Versions)

(minimum) delay for use with system pre-purge.
? For operation characteristics, maintenance, and service procedures, refer to

manufacturer's literature provided with burner, or contact your Honeywell dealer.

____________________________

Special equipment, either factory or contractor installed, may cause variation in the procedures
and descriptions given in this manual.

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

____________________________

Part 3

Maintenance and

Trouble Chart

Maintenance

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

CONSUMER INSTRUCTIONS

flammable liquids or vapors. Do not obstruct burner air openings or ventilation grills for
combustion air.
? After 3 years of normal service, the motor bearings need to be reoiled annually with 10 drops
of 5W30 oil.

WARNING: If any flame is observed when the burner is on standby, or if the ignition
spark or valve operator is heard to come on before the motor reaches operating speed,
immediately turn off the manual gas control and burner power. A dangerous condition
has developed and must be corrected. CONTACT A QUALIFIED SERVICE TECHNICIAN
FOR CLEANING, READJUSTMENT OR REPAIR.

? Check that the ignition spark does not come on before the motor reaches operating speed.
If it does, the air switch is defective and must be replaced. (See Section X, Motor / Blower
Interlock).

LIGHTING INSTRUCTIONS

1. SET OPERATING CONTROL TO OFF OR THERMOSTAT BELOW ROOM

TEMPERATURE.

2. TURN MANUAL GAS COCK ON.

3. TURN BURNER POWER ON.

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

5. WAIT 36 SECONDS. IF BURNER HAS FAILED TO LIGHT, OR IF BURNER

LIGHTS THEN GOES OUT AND SYSTEM GOES INTO SAFETY LOCKOUT,

DE-ENERGIZE THE SYSTEM BY SETTING OPERATING CONTROL TO OFF

OR THERMOSTAT BELOW ROOM TEMPERATURE FOR AT LEAST 30

SECONDS TO RESET THE SYSTEM.

6. REPEAT STEP 4 FOR RESTART.

TO SHUT OFF

1. TURN MANUAL GAS COCK OFF.

2. TURN BURNER POWER OFF.

SHOULD OVERHEATING OF THE APPLIANCE OCCUR

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

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

Make sure the thermostat and operating controls are calling for heat. Defective wiring or loose

Trouble Chart

connections can simulate the component defects outlined below. Check associated wiring before

ELECTRICAL AND FLAME CHECKS MUST BE MADE IN ORDER LISTED.

I Motor Will

Not Run or Motor
Runs in Repeated

Cycles

II Motor Runs

Continuously, But

No Flame

I Confirm 120V between strip terminals 1and 2and verify the circuit polarity and electrical

ground, between strip terminal 1and burner chassis metal.
II A. Confirm that both Main Manual Shut-Off Valve and Manual Gas Cock Knob on

Combination Gas Valve are in the ON position.

B. Whenever the burner fails to light during the 6-second trial for ignition, or if the flame is lost

during the burner run and not re-established within 36 seconds the Electronic Control will
shut off the Combination Valve and LOCK OUT. To RESET the Control for restart, set
the operating control to OFF or thermostat below room temperature for at least 30
seconds.

1. Check for 24V* between strip terminal GNDand Electronic Control 25V terminal. No
voltage, blower interlock circuit is defective.

2. If Electronic Control has a fuse, test for 24V from each end of fuse to strip terminal
GND.

C. For each of the following tests, reset the Electronic Control per step II.B. TESTS ARE

VALID ONLY DURING THE 6 SECOND TRIAL FOR IGNITION.

1. Turn Manual Gas Cock Knob to Off. Check for 24V between the Electronic Control

TROUBLE CHART

replacing a component.

Part 3

Part 3 Trouble Chart Continued

602

8471 25

Printed in USA

Maintenance Continued

Trouble Chart

Continued

VALVE terminal and the other Electronic ControlVALVE . No voltage,
defective Electronic control.

2. Check for 24V* between valve MV terminal and valve body: With voltage, RESET
Electronic Control and listen for audible CLICK as valve operators open. No CLICK,
replace valve.

3. Check for ignition spark (spark length approximately 1/8"). Since this is a capacitor
discharge system, observe closely when visually checking the spark as it is faint and
thread-like and may be overlooked in bright light.

a. Between Electronic Control high voltage terminal and strip terminal GND. No spark,

defective Electronic Control.

b. Between Electronic Control high voltage terminal and Spark Electrode Wire (insert

head of #8 x 3/4" or longer round head screw into snap terminal inside right angle
rubber boot). No spark, broken wire, cracked insulator, or "spark gap" too wide, see
Figures 7A and 7B.

c. Between spark electrode tip and top of ground rod, see Figures 7A and 7B. If spark

is not visible and/or can not be heard, remove nozzle assembly (see Section IX
Electrodes) and ground it solidly to burner metal. No spark, cracked insulator and
spark traveling to ground along crack.

4. Turn Manual Gas Cock Knob to ON. Connect manometer to the manifold gas
pressure tap and during trial for ignition, check the gas pressure:

a. Pressure should be between 2.0" and 4.0" W.C. for NATURAL and PROPANE and

steady. Verify per Section VII (Main Gas Input Selection) and Table 3 (Capacity and
Preliminary Gas Settings ) that the orifice size and manifold pressure are correct.

b. Zero, erratic low or high pressure: confirm that the inlet pressure to the Combination

Valve is between 5" and 14" W.C. for NATURAL and PROPANE during standby and
during trial for ignition.

c. If manifold pressure is zero, below 2.0" or above 4.0" W.C. for NATURAL and

PROPANE or erratic,the regulator section of the Combination Valve is defective and
the entire valve must be replaced.

III Flame on

Only During

6-Second Trial

for Ignition

IV Short

Flame**

V Long Hazy

Flame**

VI Gas Fails to

Shut Off

III A. With motor running check burner line voltage terminals for 120V as follows:

1. Between strip terminals L1 and L2-120V; voltage OK.

2. Between strip terminals L1 and GND-120V: ground OK.

3. Between strip terminals L2 and L2-"0"V: no back-feed, OK

B. Follow RESET procedure as specified in step II.B.

1. Check sense electrode position per Figure 7A or 7B

2. Check sense wire for continuity.

3. Connect DC microameter in series with Electronic Control SENSE terminal and sensor
wire. With flame on, flame signal should be at least 2 microamps.

C. IMPORTANT: If Changes are made in the Main Orifice size, Manifold Gas Pressure or

Primary Air Adjustment, change the installation data tag accordingly.

IV A. Low manifold gas pressure.

B. Main gas orifice too small.

V A. High manifold gas pressure.

B. Main gas orifice too large.
C. Primary air adjustment closed too far.
D. Dirty blower wheel.

VI A. Wutomatic electric (redundant) valve section of Combination Valve is defective and

entire valve must be replaced.

* Normal low voltage:

Motor running-24V minimum.
Combination Valve energized-21V minimum.

** CAUTION: If changes are made in the Main Gas Orifice size, Manifold Gas

Pressure or Primary Air Adjustment, change the installation data tag accordingly.

12

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