Wayne EH, EHA, EHASR User Manual
UL File Number: MP-98
SPECIFICATIONS
Firing Capacities:
Model EHA & EHASR
0.75 – 3.00 gal/hr
105,000 – 420,000 Btu/hr Input
Model EH
3.00 – 6.00 gal/hr
420,000 – 840,000 Btu/hr Input
Fuel Pumps
Single Stage Standard
Electrical
Power Supply ……….120 Vac 60Hz, 230 Vac 60 Hz 1 Phase; optional 230 Vac 50 Hz 1 Phase
Motor ………………...3450 rpm, Automatic Reset Overload Protection
Ignition ……………….14,000 V secondary, Continuous Duty or Interrupted Duty
WAYNE COMBUSTION SYSTEMS
801 GLASGOW AVE.
FORT WAYNE, IN 46803
PHONE: (260) 425-9200
(855) WAYNECS
(800) 443-4625
FAX: (260) 424-0904
www.waynecombustion.com
MODEL
EH, EHA &
EHASR
OIL BURNERS
Fuels: Use No.1 or No.2 heating oil (ASTM D-396),
Kerosene, Diesel (ASTM D975-18), JP8
Dimensions (Standard):
Height ……………………….…..…..12 1/2”
Width ……………………….…..……15 1/2”
Depth ………………………….…….. 8 1/4”
Center Line of Tube to Floor ......... 8 1/16”
Mounting:
Rigid Flange, Adjustable Flange, or Pedestal
Mount
READ THIS MANUAL BEFORE USING THIS PRODUCT. FAILURE TO FOLLOW THE
INSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN
SERIOUS INJURY OR DEATH. KEEP THIS MANUAL FOR FUTURE REFERENCE.
INSTALLER: LEAVE THIS MANUAL WITH THE END USER.
INSTALLATION OF THE BURNER MUST BE DONE BY A QUALIFIED INSTALLER IN
ACCORDANCE WITH REGULATIONS OF THE NATIONAL FIRE PROTECTION
AGENCY, NFPA NO. 31, AND IN COMPLETE ACCORDANCE WITH ALL LOCAL
CODES AND AUTHORITIES HAVING JURISDICTION.
A QUALIFIED INSTALLER IS THE PERSON WHO IS RESPONSIBLE FOR THE
INSTALLATION AND ADJUSTMENT OF THE EQUIPMENT AND WHO IS LICENSED TO
INSTALL OIL-BURNING EQUIPMENT IN ACCORDANCE WITH ALL CODES AND
ORDINANCES.
Manual 21530 | Revision 10 | Publication Date: 9/14/18
1
INSTALLATION LOG
BURNER MODEL:
SPECIFICATION NUMBER:
FUEL:
Nozzle Size and Pattern:
Pump Fuel Pressure (psi):
CO2 (%):
Smoke Spot:
CO (PPM):
INSTALLER’S NAME:
CONTRACTOR NAME:
CONTRACTOR
ADDRESS:
CONTRACTOR PHONE
NUMBER:
CONTRACTOR LICENSE #:
DATE OF INSTALLATION:
COMMENTS ABOUT INSTALLATION/START UP:
BURNER/APPLIANCE SERVICE LOG
SERVICE
DATE
TECHNICIAN
COMPANY
/ ADDRESS
CONTRACTOR
LICENSE #
WORK PERFORMED
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
THESE INSTRUCTIONS SHOULD BE AFFIXED TO THE BURNER OR ADJACENT TO THE
HEATING APPLIANCE.
2
Overview of Safety Warning System and Your Responsibilities
Indicates a hazardous situation, which, if not avoided, will result in
death or serious bodily injury.
Indicates a hazardous situation, which, if not avoided, could result in
death or serious bodily injury.
Indicates a hazardous situation, which, if not avoided may result in
minor or moderate bodily injury.
Indicates a situation that may result in equipment-related damage.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. The meaning of this safety alert symbol is as follows: Attention! Become
alert! Your safety may be at risk. The message that appears next to the warning
describes the hazard, which can be either written or pictorially presented. NEVER
remove or tamper with the warning labels, safety devices or guards fitted on the unit.
Wayne Combustion Systems is NOT responsible for any bodily injury and/or property
damage that may result from operation outside of the stated operating conditions for
which this unit was intended.
The safety of you and others depends upon you thoroughly reading and understanding this manual. If you have questions
or do not understand the information presented in this manual, please call Wayne Combustion Systems or see
www.waynecombustion.com.
Hazard Definitions:
3
Hazard Level
Pictogram
Type
Hazard Explanation
Fire or
Explosion
Failure to follow safety warnings exactly could result in
serious injury, death or property damage.
Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
Never attempt to use gasoline as a fuel for this burner,
as it is more combustible and could result in a serious
explosion.
Electric Shock
or Burn
High voltages are present in this equipment. Follow
these rules to avoid electric shock:
Use only a properly grounded circuit. A ground
fault interrupter is recommended.
Do not spray water directly on burner.
Turn off power before servicing.
Read the owner’s manual before using.
Overheating
Should overheating occur:
Shut off the manual oil valve to the appliance.
Do not shut off the control switch to the pump
or blower.
Carbon
Monoxide
Poisoning
Carbon monoxide is a colorless, odorless gas that
can kill. Follow these rules to control carbon
monoxide:
Do not use this burner if in an unvented,
enclosed area. Carbon monoxide may
accumulate.
Check flue gases for carbon monoxide. This
check requires specialized equipment.
Allow only qualified burner service persons to
adjust the burner. Special instruments and
training are required.
Read the burner manual before using.
CARBON MONOXIDE POISONING: Early signs of
carbon monoxide poisoning are similar to the flu with
headaches, dizziness, weakness, nausea, vomiting,
sleepiness, and confusion. If you suspect carbon
monoxide poisoning, get outside to fresh air
immediately, and then call 911. Some people are more
affected by carbon monoxide than others. These
include pregnant women, people with heart or lung
disease or anemia, those under the influence of
alcohol, and those at high altitudes.
Proposition 65
material
This product can expose you to chemicals, including
lead, nickel, carbon monoxide and sulfur dioxide, which
are known to the State of California to cause cancer or
birth defects or other reproductive harm. For more
information, go to www.p65Warnings.ca.gov.
Special
Requirements
When contacting Wayne Combustion Systems for
service information, please have the burner
specification and model number when calling or writing.
Specification number will be located on a 1” X 2”
rectangular sticker on the back of the burner and model
number is on the big square sticker that has the
manufacturer’s logo and contact information. This
sticker will be above the specification label.
4
Contents
GENERAL INFORMATION ............................................................................................................................... 6
TROUBLESHOOTING....................................................................................................................................... 7
GENERAL TROUBLESHOOTING GUIDE ..................................................................................................... 7
BURNER DOES NOT LIGHT, HONEYWELL CONTROL REMAINS ON STANDBY .................................... 10
BURNER WILL LIGHT, BUT WILL NOT STAY LIT DURING “CALL FOR HEAT” ........................................ 11
WIRING DIAGRAMS ....................................................................................................................................... 16
SEQUENCE OF OPERATION: BURNERS WITH R7284G AND R8184G CONTROLS .................................. 17
SEQUENCE OF OPERATION: BURNER WITH R7284P CONTROL .............................................................. 18
SEQUENCE OF OPERATION: BURNER WITHOUT CONTROL .................................................................... 19
OPERATIONAL CHECK OF BURNER ............................................................................................................ 19
START SYSTEM ......................................................................................................................................... 19
CHECK SAFETY FEATURES ...................................................................................................................... 19
GENERAL INSTALLATION INFORMATION ................................................................................................... 20
COMBUSTION CHAMBER .......................................................................................................................... 20
FUEL PUMPS .............................................................................................................................................. 20
FUEL LINES ................................................................................................................................................ 20
FUEL TANKS ............................................................................................................................................... 21
ELECTRICAL WIRING OF BURNER ........................................................................................................... 21
CHIMNEY INSTALLATION .......................................................................................................................... 21
DRAFT REGULATORS ............................................................................................................................... 21
AIR SUPPLY FOR COMBUSTION .............................................................................................................. 22
NOZZLE AND AIR CONE SELECTION ....................................................................................................... 22
NOZZLE INSTALLATION ............................................................................................................................ 22
SETTING GUN DEPTH ............................................................................................................................... 27
STARTING PROCEDURE ............................................................................................................................... 30
STARTING BURNER ................................................................................................................................ ... 30
FINAL ADJUSTMENTS ............................................................................................................................... 32
SETTING COMBUSTION EFFICIENCY ...................................................................................................... 32
FINAL CHECKS ........................................................................................................................................... 33
MAINTENANCE .............................................................................................................................................. 33
REFERENCE INFORMATION ......................................................................................................................... 34
REFERENCE FIGURES .............................................................................................................................. 36
OIL PIPE SIZING INFORMATION ............................................................................................................... 37
WARRANTY .................................................................................................................................................... 39
5
GENERAL INFORMATION
Read this manual carefully and in it’s entirety prior to performing any maintenance or service on
the burner.
WARRANTY
Wayne Combustion Systems warrants its burner’s specifically to organizations that have purchased it for resale, including
your dealer. If you have a problem with your burner, or its installation, you should contact your dealer for assistance, for a
full description of the warranty see page 39.
MAINTENANCE
Wayne Combustion Systems recommends yearly inspection/service of your oil heating system by a qualified service
agency or individual.
A qualified service agency or individual must be:
Licensed or certified to install and provide technical service to oil heating systems.
Experienced with all applicable codes, standards and ordinances.
Responsible for the correct installation and commission of the equipment.
Skilled in the adjustment of oil burners using combustion test instruments
APPROVALS
This burner complies with ANSI/UL Standard 296 and is for use with No. 1 fuel oil or No. 2 fuel oil and is UL listed for use
with Group I or Group II primary safety controls. The states of Massuchusetts, New York and local approvals are shown
on the burner’s nameplate label. All burners must be installed in accordance with the National Fire Protection Association,
and in complete accordance with all local codes and authorities having jurisdiction. Regulation of these authorities takes
precedence over the general instructions provided in this manual.
MANUAL ORGANIZATION
This manual is organized so that the licensed contractor can troubleshoot the service issue with the burner by working
through the GENERAL TROUBLESHOOTING GUIDE on page 7. The GENERAL TROUBLESHOOTING GUIDE is
organized by the performance issue or “problem” requiring attention. Each problem will list potential root causes that may
result in the problem listed in order from most likely to least likely, and the solution to correct each root cause that may be
affecting burner performance. The solution listed for each root cause will reference supplemental information regarding
normal burner/component operation and service instructions depending on the problem and root-cause. If this is a new
installation see GENERAL INSTALLATION INFORMATION on page 20.
MODEL DIFFERENCES
The EHASR burner utilizes unique air cones and oil gun assemblies to optimize burner performance in its rated firing
range. The air cone is a single piece construction and is fixed to the air tube. The oil gun depth is set in reference to the
fixed air cone The EH and EHA have the flamelock attached to the nozzle adaptor on the oil gun, this allows the burner to
have a variable gun depth setting based on the firing rate needed. An EHA burner is different from a EH because the EHA
uses an oil pump that is rated up to 3 gal/hr, while the EH model will use a larger pump that is rated up to 7 gal/hr to attain
the higher firing rates.
BURNER COMPONENTS
The EHASR, EHA, and EH model burners are constructed with components of varying design. For example, the ignition
device may be an iron core transformer or a solid state igniter. Both devices perform the same function, and they use the
same troubleshooting methodology. There are also two distinct types of motors utilized by these burners. The “Permanent
Split Capacitor” or PSC motors (silver in color) utilize a thermal protection device that automatically resets when the motor
cools down. The “Split-Phase” motors (black jacket) utilize a manual reset thermal protector. Appliance or equipment
manufacturers may specify one type of component over another. Please contact Wayne Combustion Systems for
assistance with replacement component selection.
6
TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
SOLUTION
BURNER WILL NOT
LIGHT
Little or no fuel
Fill tank with fuel.
Improper fuel or water in fuel
Drain fuel tank and fill with proper fuel.
Limit switch open
Close limit or thermostat switch, and check limit switch for
proper cycling operation.
Improper electrode spacing, gap to
small
Clean and position electrode tips according to Figure 14 or
Figure 15 on pages 26-27.
Plugged fuel filter
Replace as needed.
Misadjusted burner air bands
Re-adjust air bands for clean burn.
Little or no fuel pressure from fuel pump
Increase fuel pressure to manufacturer's specifications. See
Figure 25 on page 36 for pump features. Check that plastic
coupler (see Figure 1 on page 13, item 10) is not slipping on
pump shaft, replace as needed and/or replace pump.
Before troubleshooting, familiarize yourself with the startup procedures and
sequence of operation. Check the burner, ignitor or transformer, oil primary
control (if equipped), and cad cell (if equipped) for proper operation and condition.
The Honeywell R7284 oil primary control’s reset button is the “i” button, the R7184, R8184 and
Wayne control is the big red button. Pressing the reset button and restarting the burner more
than once with the burner not lighting could cause oil buildup in the firing chamber. This will
cause smoking and possible detonation that could damage the equipment if the burner does light
Preliminary Steps
Check the following common causes of issues:
Wiring connections, fuses, power supply to the burner blower motor, controls, and ignition device.
Limit control is closed.
Thermostat (controller) is calling for heat.
Contacts between ignition device and electrodes.
Electrode gap is properly set at nozzle.
Oil piping to burner and tank is properly sized and is in good condition (see Oil Pipe Sizing Information on
page 37 ).
Oil pump pressure.
Oil nozzle is correctly sized for application.
Check cad cell location and photo eye cleanliness.
GENERAL TROUBLESHOOTING GUIDE
7
PROBLEM
POSSIBLE CAUSE
SOLUTION
BURNER WILL NOT
LIGHT
(continued)
Air bubble sucked and trapped in pump
Bleed pump (see page 31 for instructions) and check all fuel
lines for air leaks, replace lines as needed. See Figure 25 on
page 36 for pump features.
Burner motor thermal protector actuated
If tripped, check voltage, connections, and extensions for
cause. Check fuel pump shaft rotation for binding causing
motor to overheat.
Flex-coupling slipping on fuel pump
shaft or burner motor shaft
Replace as needed. See Figure 1 on page 13, Item 10.
Fuel not reaching combustion chamber
Check fuel system for proper flow going through the burner.
Clogged burner nozzle
Replace. See page 22 for instructions.
Low voltage at burner wire leads
Check for proper 120/230 Vac going to the burner
Fuel solenoid malfunction
Replace as needed. See Figure 1 on page 13 for
replacement part.
Faulty burner ignition device
Test ignition device for proper arc between contacts. Replace
as needed. See Figure 1 on page 13 for replacement part.
Disconnected or short in electrical wiring
All wire contacts should be clean and tight. No breaks in wire
insulation, replace as needed. See page 21 for wire size
recommendations.
Oil primary control sees light during
safety check and remains in standby
mode (Applicable only if burner comes
with oil primary control).
Press and hold the reset button for 2 seconds on a Honeywell
control, (push and hold for 3 seconds if it is an older style
Wayne control), observe burner sequence of operations. If
burner remains on standby see Burner does not light,
Honeywell controls remains on standby, on page 10.
Oil gun depth spaced too far ahead
causing electrodes too short to ground
through air cone.
Identify burner model and position oil gun depth according to
Figure 16 and Figure 17. See page 27 for instructions.
Heavy sooting on burner electrodes,
and air cone causing a weak arc
between the electrodes.
Clean as required. Check ceramic for any chips and cracks
that could affect arc between the electrodes, replace as
required. See Table 2 on page 15 for replacement parts.
BURNER WILL LIGHT,
BUT NOT STAY LIT
DURING CALL FOR HEAT
Oil primary control goes into nuisance
lockout (Applicable only if burner comes
with oil primary control).
Press and hold the reset button for 2 seconds on a Honeywell
control, (push and hold for 3 seconds if it is an older style
Wayne control), observe burner sequence of operations. If
burner locks out again see Burner Will Light, But Will Not
Stay Lit During “Call For Heat”, on page 11.
BURNER SMOKES
Improper fuel or water in fuel
Drain tank and replace contaminated fuel.
Improper air adjustment
Re-adjust air bands on burner assembly for clean burn.
Low fuel pressure
Increase fuel pressure to manufacturer's specifications. See
Figure 25 on page 36 for pump features.
Air leaks in fuel lines
Check fuel lines for leaks or air bubbles. Tighten or replace
as needed.
Plugged or dirty burner nozzle
Replace burner nozzle. See page 22 for instructions.
Improper nozzle size installed, nozzle
size too big
Contact appliance manufacturer for proper nozzle size, and
replace. See page 22 for instructions.
8
PROBLEM
POSSIBLE CAUSE
SOLUTION
BURNER SMOKES
(continued)
Heavy accumulation of soot on heat
exchanger and burner assembly
Remove burner assembly from heat exchanger. Clean
thoroughly.
Faulty burner nozzle spray pattern
Replace. See page 22 for instructions.
Misaligned or damaged electrode
Realign electrodes according to Figure 14 or Figure 15 on
pages 26-27, and the oil gun depth according to Figure 16 or
Figure 17 on pages 27-28.
Obstruction in smoke stack
Check for blockage or other foreign objects.
BURNER RUNS
CONTINOUSLY WITHOUT
SATISFYING CALL FOR
HEAT
Improper fuel or water in fuel
Drain fuel tank and fill with proper fuel.
Reduced fuel pressure
Check fuel pump pressure. Check that fuel filter isn’t partially
clogged, replace as necessary. Increase fuel pressure to
manufacturer's specifications. See Figure 25 on page 36 for
pump features. Replace pump if needed.
Soot build-up on heat exchanger.
Clean heat exchanger with soot remover.
Improper burner nozzle installed, nozzle
size too small.
Contact appliance manufacturer for proper nozzle size, and
replace. See page 22 for instructions.
BURNER RUNS BUT
APPLIANCE IS
OVERHEATING
Fuel pump pressure too high
Readjust fuel pressure to appliance manufacturer's specs.
See Figure 25 on page 36 for pump features.
Oil primary control keeps energizing
burner past “call for heat”. (Applicable
only if burner comes with oil primary
control).
Identify control model. Replace Control, and wire accordingly
to Figure 3 or Figure 4 on page 16.
Faulty fuel pump shut-off valve
Replace fuel pump shut-off valve.
Defective high limit switch or
Thermostat
Replace.
Incorrect fuel nozzle size, nozzle size
too big
Contact appliance manufacturer for proper nozzle size, and
replace. See page 22 for instructions.
BURNER MOTOR WILL
NOT RUN
Overload protector activated
Wait 20 minutes for motor to cool down, will restart
automatically.
Faulty oil primary control. (Applicable
only if burner comes with oil primary
control).
Observe burner sequence of operations. Check voltage going
to the burner motor if it does not run during the 15 second
trial for ignition, replace control.
Fuel pump seized
Replace fuel pump. See Figure 1 on page 13 for replacement
parts
Burner fan loose or misaligned
Identify fan part number by measuring O.D of fan then
reference Table 1 on page 14 and position the fan spacing
according to Figure 26 on page 36 and tighten set screw.
Defective control switch
Replace switch.
Loose wire
Check and replace or tighten wiring.
Defective burner motor
Replace motor.
BURNER STAYS ON
WHEN NO CALL FOR
HEAT
Faulty oil primary control. (Applicable
only if burner comes with ignition
control).
Observe burner sequence of operations. Replace control if
necessary
Thermostat defective
Check for proper operation, replace if necessary.
Fuel solenoid defective
Replace fuel solenoid.
9
Procedure
Status
Corrective Actions
1. Make sure limit
switches are closed
---------------------
---------------------
2. Check for line voltage
power at primary
Control. 120 vac.
---------------------
Check breaker and investigate appliance wiring
3. Check R7284G or
R8184G indicator light,
(LED Screen if R7284P
control) with burner off,
no call for heat. No
Flame.
R7284G & R8184G indicator
light is pulsing (1/4 sec. ON, 4
sec. OFF), R7284P display
would say “STANDBY”
Sees external light during safety check or
connections are shorted,
4. Shield cad cell from
external light
R7284G & R8184G indicator
light starts pulsing (1/4 sec. ON,
4 sec. OFF), R7284P display
will read “STANDBY”
Energize thermostat to verify that burner goes
through proper sequence of operations.
If burner does not light go to step 5
5. Jumper oil primary T-T
terminals
Burner starts
Trouble in thermostat or limit circuit. Check wiring
connections
Burner does not start
Disconnect line voltage and open thermostat or
limit switch.
If burner does not start, replace primary control.
NOTE: This section refers to Honeywell R7284 and R8184 series controls. The R7284G and
R8184G control use a LED light to display the troubleshooting status, and the R7284P
control comes with a display screen that will output the current operating state of the
burner or any troubleshooting errors that might arise in normal burner operation.
Troubleshooting tables on pages 10-11 are specific to burners that
come equipped with an oil primary control, and these sections only
apply if the general troubleshooting guide tells the licensed
contractor to consult these sections while servicing the burner.
BURNER DOES NOT LIGHT, HONEYWELL CONTROL REMAINS ON STANDBY
10
BURNER WILL LIGHT, BUT WILL NOT STAY LIT DURING “CALL FOR HEAT”
Procedure
Status
Corrective Actions
1. Check limit switches
---------------------
---------------------
2. Check for line voltage at
the oil primary control
(120 volts)
---------------------
---------------------
3. Check R7284G or
R8184G indicator light,
(LED Screen if R7284P
control) with burner on,
call for heat.
R7284 or R8184 control is in
lockout. The R7284G &
R8184G control LED flashes for
½ seconds ON, ½ seconds
OFF. The R7284P control reads
“Lockout Mode”
Control is sensing bad flame signal, cad cell or
controller is defective, sees external light or
connections are shorted. Go to step 5.
The R7284P display reads
“Valve on Delay”
Go to step 4.
4. Applications with “valve
on delay”, verify that oil
valve is closed during
the “valve on delay”
period by opening view
port and verifying that
no flame is present
during 15 second “valve
on delay”
R7284P display still reads
“Valve on Delay”
If flame is present, replace valve.
5. Jumper oil primary T-T
terminals
Burner starts, and stays
running.
Trouble is in thermostat or limit circuit.
Burner starts, but doesn’t stay
running.
Disconnect line voltage and open thermostat or
limit switch.
Check all wiring connections
If burner does not stay running, go to step 6
6. Check that nozzle size
is per appliance
manufacturer
recommendation
Burner nozzle incorrect.
Change nozzle and fuel pressure to factory settings
and retest, if burner doesn’t stay lit go to step 7
Burner nozzle correct
Go to step 7
7. Check burner air band
setting is set up per
manufacturer
recommendation
Burner air band setting too low.
Could cause black puff of smoke on ignition if the
fuel-air mixture is too rich.
Use a combustion test kit to measure the CO2 %
and smoke spot in the exhaust.
Adjust air band opening until CO2 % measures
between 10-12 %, and smoke spot is a 1 or less.
If problem persists go to step 8
Burner air band setting too high
Could cause delayed ignition on start-up if the fuel-
air mixture is too lean.
Use a combustion test kit to measure the CO2 %
and smoke spot in the exhaust.
Adjust air band opening until CO2 % measures
between 10-12 %, and smoke spot is a 1 or less.
If problem persists go to step 8
Burner air band set at
manufacturers
recommendations
Go to step 8
11
8. Check cad cell sighting
for view of flame.
- Disconnect line
voltage power and
open line switch.
- Unplug cad cell and
clean face with soft
cloth. Check
sighting for view of
flame. Place cad
cell back in socket.
- Reconnect line
voltage and close
line switch.
- Start burner,
Burner locks out.
Go to step 9
Burner keeps running, until “call
for heat” is satisfied.
System is okay.
9. Check Control & Cad
cell.
- Remove cad cell
wires from
connectors on
primary and leave
lead wires open.
- Apply power to
device
- Place jumper
across cad cell
terminals after
burner motor turns
on.
Burner doesn’t run.
Replace primary control.
Burner runs.
Control is okay, replace cad cell.
12
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