Wayne P250AF-DI, P265, P265F, P250AF-EP, P265-EP User Manual
...
WAYNE COMBUSTION SYSTEMS
801 GLASGOW AVE.
FORT WAYNE, IN 46803
ELECTRIC SHOCK HAZARD
OVERHEATING HAZARD
HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT.
FOLLOW THESE RULES TO AVOID ELECTRIC SHOCK.
Use only a properly grounded circuit. Aground fault
interrupter is recommended.
Do not spray water directly on burner.
Turn off power before servicing.
Read the owner’s manual before using.
SHOULD OVERHEATING OCCUR:
Shut off the manual gas valve to the appliance.
Do not
shut off the control switch to the pump or blower.
SPECIFICATIONS
FOR YOUR SAFETY
IF YOU SMELL GAS:
1. OPEN WINDOWS
2. DON’T TOUCH ELECTRICAL SWITCHES
3. EXTINGUISH ANY OPEN FLAME
4. IMMEDIATELY CALL YOUR GAS
SUPPLIER.
THESE INSTRUCTIONS SHOULD BE AFFIXED TO THE
BURNER OR ADJACENT TO THE HEATING APPLIANCE.
MODELS
P250AF P265
P250AF-EP P265F
P250AF-DI P265-EP
P265-EP
GAS BURNER
Publication Date 5/01 - Revision B - Manual 101220
NOTE: Dimensions in ( ) are informational only. English values take priority.
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.
- WHATTO DO IF YOU SMELL GAS
• Do not try to light the appliance.
• Do not touch any electrical switch; do not use any
phone in your building.
• Immediately call your gas supplier from a neighbor’s
phone. 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. Warranty is
voided if not installed by qualified service person.
CARBON MONOXIDE IS ACOLORLESS, 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.
Do not adjust the pressure regulator. High pressures produce
carbon monoxide.
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 owner’s manual before using.
CARBON MONOXIDE
POISONING HAZARD
NOTICE
BURNER MODELS MINIMUM INPUT MAXIMUM INPUT FUELS
P-250AF & P-250AF-EP & P250AF-DI 50,000 BTU/HR (14.65 kW/Hr) 250,000 BTU/Hr (73.27 kW/Hr) Natural & L.P. Gas
P-265 & P-265-EP 65,000 BTU/HR (19.05 kW/Hr) 200,000 BTU/Hr (58.61 kW/Hr) Natural & L.P. Gas
P-265-F & P-265F-EP 65,000 BTU/HR (19.05 kW/Hr) 200,000 BTU/Hr (58.61 kW/Hr) Natural & L.P. Gas
ELECTRICAL Power Supply - 115V/60HZ 1 Ph. MOUNTING: Adjustable Flange is Standard
Pedestal Mount is Optional.
1
These instructions were prepared for the guidance of those installing this particular gas conversion burner. While thy apply in
principle to all installations, they should not be interpreted as meaning the only safe and economical way to install a conversion
burner. It may be necessary to deviate from these instructions in some instances in order to comply with local gas company
rules or codes in effect in the area in which the installation is made. It is recommended that the installer confer with the local
gas company and with the proper municipal officials regarding any specific code or regulation governing the installation of gas
conversion burners, the installation must conform with local codes or, in the absence of local codes, with the American National
Standard Installation of Domestic Gas Conversion Burners, Z21.8-1984, and the National Fuel Gas Code, ANSI Z223.1-1984.
Safe and Economical operation of the burner throughout its service life is dependent to a large extent upon its proper
installation in the heating appliance. Therefore, we may impress upon the installer that good clean workmanlike installations
mean satisfied customers.
VISUAL INSPECTION OF THE HEATING SYSTEM
A conversion burner shall not be installed in an appliance located in a room or basement where facilities for normal air
circulation or infiltration are so limited so as to interfere with ready obtainment of all air necessary for proper combustion and
draft hood dilution, unless at the time of burner installation special provisions are made for combustion and draft hood dilution
air.
a. In open basements of homes of normal construction (without basement storm windows or tight stair doors) infiltration
of combustion air is usually sufficient to replace that drawn up the flue, so special provisions are seldom necessary.
b. When the heating appliance is installed in a tightly close room without ventilating openings to outdoors or other
rooms, provisions shall be made for suppling air for combustion through special openings, one near the floor line
and the other near the ceiling, each to be sized on the basis of one square inch or more of free area for each 1,000
BTU (.2931 kW) input per hour. See Figure 1.
c. When the house is of unusually tight construction, has a (kitchen) ventilating fan which may be used for exhausting
air to indoors, or has a vented fireplace, it is recommended that combustion air be supplied to the furnace room
through intakes extending to the outside of the building and terminating in down turned fittings, suitably arranged to
prevent obstruction from snow or rain, and including a protecting screen not smaller than 1/4-inch (6.35 mm) mesh.
The heating system (both the heat exchanger and distribution system) shall be of a size to properly heat the building.
Through inquiry it shall be determined that all rooms have been heated adequately without wide variations in temperature,
without objectionable drafts, and without excessive fuel costs in the past. If the heating system is deficient with respect to any of
the above determinations, provisions shall be made to correct the deficiency, replace obsolete parts, or (by storm windows,
insulation, etc.) to reduce the heat loss to a point where the existing system will provide the proper amount of heat.
a. Gravity Warm Air System
The supply and return ducts and registers should be sized and arranged so that the house can be heated without
excessive furnace temperatures. Reference may be made to the American Society of Heating, Refrigerating and
Air-Conditioning Engineers Guide and Data Book series and Handbook of Fundamentals.*
b. Forced Warm Air Systems
Inspection should also show whether the electrical characteristics of the fan and limit switch are satisfactory and
whether the air filters and fan are in condition for continued proper service with the gas burner, reference may be
made to the American Society of Heating, Refrigerating and Air-Conditioning Engineers Guide and Data Book series
and Handbook of Fundamentals.*
c. Hot Water Systems
The boiler thermometer and altitude gauge should be in good order. On a closer system, the feed and pressure
relief valves shall be in proper operating condition. If there is an expansion tank on a closer system, inspection
should show it to be substantially empty of water. When there is an existing water temperature limiting switch, its
operating and electrical characteristics shall be checked to determine its suitability to the gas control circuit. For
common piping systems reference can be made to the American Society of Heating, Refrigerating and AirConditioning Engineers Guide and Data Book series* and to the Hydronic Institute Guides.**
d. Steam or Vapor System
The system shall be pressure tight, with pressure gauge and pop safety valve in good condition and with an existing
water glass which permits clear observation of boiler water level. When there is a pressure limit switch or low-water
cut-off, inspection shall determine whether either device can be utilized in the gas burner control circuit, reference
should be made to the American Society of Heating, Refrigerating and Air-Conditioning Engineers and Institute of
Boiler and Radiator Manufacturers guides. Traps and air vents shall be of adequate capacity, in good condition, and
correctly placed in the system. (Coal firing tends to maintain a slight but continuous steam pressure which prevents
air from being drawn back into the steam system. Intermittent gas burner operation and resultant intermittent steam
supply usually introduces the need for repurging the system of air each time the boiler is steamed if satisfactory heat
distribution is to be achieved.)
*copies may be obtained from the American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc., 345 East
47th Street, New York, NY 10017.
** Copies may be obtained from the Hydronic Institute, 35 Russo Place, Berkeley, NJ 07922.
2
FLUE PIPE AND CHIMNEY
The flue pipe should be carefully inspected and replaced if necessary in connection with installation of a draft hood. All
installations must operate with a negative draft overfire. Refer to your local gas company or codes for assistance or to the
furnace and/or boiler manufacturer for recommendations.
The flue pipe entrance into the chimney should be at least two feet (.610m) above the clean-out opening in the chimney.
The chimney should extend high enough above the dwelling or other neighboring obstructions so that wind from any direction
will not strike the chimney from any angle above horizontal. Unless the obstruction is of greater magnitude, it is the usual
experience that a chimney extending two feet above flat roofs or above fire wall parapets, and peaked roofs within 30 feet
(9.144m) will be reasonably free of downdraft.
Where the chimney is unlined or where local experience indicates that flue gas condensate might be a problem, the local gas
company should be consulted.
The chimney should be examined and thoroughly cleaned, if necessary, before installation is made to make sure it freely
conduct the flue gases to the outside.
Flue pipe should extend through the chimney wall to inner face of chimney liner but not beyond, and should be firmly
cemented to masonry. A thimble may be used to facilitate removal of flue pipe for cleaning, in which event the thimble should be
permanently cemented in place with mortar or other fireproof material that will not crack or check the flue pipe or thimble,
whichever is used, should be sealed into the chimney liner.
Flue connections from two or more appliances should not enter opposing or adjacent sides of the chimney at the same level.
Under no circumstances should the flue pipe be connected it to a flue of an open fireplace.
INSPECTION OF HEATING APPLIANCE
A careful inspection of furnace or boiler should be made. If cracked heating sections, leaking soft plugs or any other
condition which might make the unit unsatisfactory for gas conversion is found, proper arrangements should be made for
replacement or repair before proceeding with the burner installation. Cracked heating sections should be replaced.
A neutral pressure point adjuster, similar to the one shown in figure 2 may be installed in the flue pipe between the furnace
and a conventional type CSA draft hood. The neutral pressure point adjustment should be left in the fully open position until
after the burner rating has been established. The material used for flue pipe should be resistant to corrosion.
The necessity for installing a neutral pressure point adjuster as outlined above, may be eliminated by reducing the flue pipe
and draft hood to the sizes shown in the table.
NOTE: For oil fired conversions consult boiler or furnace manufacturer. Appliance must maintain negative draft overfire.
FIGURE 1
Air Inet Opening 1 Sq.
in. (645.2 mm2) for each
1,000 Btu (.2931 kW)
per hour input.
Ventilating Air Opening
1 Sq. in. (645.2 mm
2
)
for each 1,000 Btu
(.2931 kW) per hour
input.
Application located in confined spaces. Ventilation air
from inside building - combustion and draft hood
dilution air from outside. Ventilated attic or ventilated
craw space.
NOTE: Ducts used for make-up
air may be connected to the
cold air return of the heating system only if they connect
directly to outdoor air.
Attic Ventilation Louvers are
required at each end of attic
with alternate air inlet No. 1.
1, 2, and 3 mark alternate locations for air from outdoors. Free
area shall be not less than 1 Sq.
in. (645.2 mm2) per 5,000 Btu
(.1.465 kW) per hour of the total
per hour of the total input rating
of all appliances in the
enclosure.
Crawl-space Ventilation Louvers
for unheated crawl space
are required with alternate air
inlet No. 3.
Each Ventilation Air Opening
from inside the building shall
have a free area of not less than
1 Sq. in. (645.2 mm2) per 5,000
Btu (.1.465 kW) per hour of the
total per hour of the total input
rating of all appliances in the
enclosure.
Illustration showing air opening necessary to supply air for combustion
when heating appliance is installed in an enclosed room.
3
FIGURE 2
FIGURE 3
FIGURE 4
1/2” (12.7 mm)
Minimum rise 1/4” (6.35
mm) to the foot (.305 m)
Minimum rise 1/4” (6.35
mm) to the foot (.305 m)
Minimum rise 1/4” (6.35
mm) to the foot (.305 m)
90˚ (1.57 rad) ANGLE TYPE DRAFT HOOD
(Always install in a vertical position)
4
PREPARATION OF FURNACE OR BOILER
Clean combustion chamber thoroughly. Scrape and brush all heating surfaces and flue ways. Soot and fly ash are excellent
insulators and unless removed the efficiency of the heating plant will be impaired. Plugged or restricted flue passages will
prevent burner from operating properly.
Be sure water column and gauge on boiler is clean and water level is visible. In all cases make sure the pigtail to limit control
is clear. Safety pop valves on team boilers and automatic relief valves on closed water systems should be thoroughly checked
to make sure they are in good working condition.
FLUE PIPE AND DRAFT HOOD
A CSA type draft hood or its equivalent shall be placed in and made part of the flue pipe from the appliance. At no time
should the draft hood be located at a point lower than the highest flue passage in the appliance. The draft hood should be
installed in the position for which it was designed and in no case installed in a false ceiling, separate room from the heating
appliance, or in any other manner that will permit a difference in pressure between the draft hood relief opening and the
combustion air supply. On sealed type appliances where all combustion air is taken from the outside, a cap should be installed
on end of flue pipe to prevent back drafts. In such cases no draft hood or diverter should be installed inside. See Figure 4.
When converting oil fire appliances the flue pipe and draft hood or diverter used should be the same size as the furnace flue
collar. It is recommended that a rise as great as possible or at least 1/4 inch (6.35mm) to the foot (.305m) (horizontal length) be
maintained in the flue pipe from the appliance to the chimney. The flue pipe should be relocated where possible to avoid sharp
turns.
DRAFT HOOD & FLUE PIPE SIZES FOR GAS CONVERSION
BURNERS IN UP-DRAFT COAL FURNACES ND BOILERS
Not more than 6,500 BTU (1.905 kW) per inch (645.2 mm2) of the flue area
Input - BTU (kW) Draft Hood and
Per Hour Flue Pipe Size
Up to --- 120,000 (35.17) 5 inch (127mm)
120,000 (35.17) --- 180,000 (52.75) 6 inch (152.4mm)
180,000 (52.75) --- 250,000 (73.27) 7 inch (177.8mm)
NOTE: If the flue pipe exceeds 10 ft. (3.048m) in length, or contains more than two elbows, use next size larger pipe and
draft hood.
NO MOVEABLE FLUE PIPE DAMPER SHOULD BE USED ON ANY INSTALLATION.
NOTE: All installations must operate with negative draft overfire. Refer to your local gas company and codes for assistance.
REVERTIBLE FLUE (DOWN DRAFT OR DIVING FLUE TYPE) FURNACES OR BOILERS
When installing the burner in the above type furnaces or boilers, the draft hood (or draft diverter) should be located at least
one foot higher than the top of the highest point of the appliance flue passage or combustion chamber. It is also recommended
that a vent pipe, not less than one inch in diameter, be provided from the highest point in the flue passage, directly to the flue
pipe. This is not necessary on the appliances with built in up draft bypass. (See Figure 3.) The gas company serving the area
should be consulted in regards to their recommendations for converting this type of furnace or boiler.
The flue pipe should be securely supported and the joints fastened with sheet metal screws or riveted to prevent sagging,
and in no case should be located in a manner that will present a hazard to combustible building material. (Refer to local building
code.)
PREPARATION OF COMBUSTION CHAMBER
THE POWER GAS BURNER IS DESIGNED FOR “INSHOT” FIRING INTO AREFACTORY LINED COMBUSTION
CHAMBER CONSTRUCTED IN THE ASH PIT OF ANY BOILER OR FURNACE ORIGINALLY DESIGNED FOR COAL OR OIL
FIRING. THE SIZE, SHAPE AND CONSTRUCTION OF THE CHAMBER SHOULD BE GIVEN SUCH CONSIDERATION AS
WILL RESULT IN THE MAXIMUM EFFICIENCY OF EACH INSTALLATION.
On smaller inputs precast chambers may be used if the firing door and ash pit are large enough to insert the chambers and
assemble.
When converting oil designed boilers and furnaces, it is recommended that the same combustion chamber be used with the
gas burner. If the blast tube opening into the combustion chamber is larger than the 4” (101.6mm) diameter, high temperature
cement should be used to reduce the opening to 4” (101.6mm) diameter.
IN NO CASE SHOULD THE TUBE BE ALLOWED TO EXTEND INTO THE CHAMBER PROPER. IT MUST BE AT LEAST
1/8” (3.175mm) SHORT OF THE INSIDE SURFACE OF THE COMBUSTION CHAMBER.
5
COMBUSTION CHAMBERS
The combustion chamber sizes given in Figure 5 are based on the maximum rated BTU capacity. If the input is to be
permanently set at a reduced rate, the combustion chamber floor area can be reduced proportionately to the proposed input,
allowing 200,000 BTU (211000kJ) per square foot (.093m
2
) of combustion chamber floor area and proportioning the length about
70% greater than the width.
The height of the walls of the combustion chamber is generally determined by the grate line. The side and front walls should
be built about 2” (50.8mm) above the grate line, covering the grate lugs and covering the bases of the water legs of boilers
about 3” (76.2mm) or 4” (101.6mm) to avoid heating sections that may be filled with sediment. The back wall should be carried
one or two courses higher and overhung to deflect hot gases from direct impingement on the rear heat exchanger surfaces.
Hard firebrick should be used for the overhung section to prevent erosion of the brick at this point by the high velocity gases
m9moving over it.
The remaining open spaces between the combustion chamber and ash pit walls should be filled with loose insulation. Since
this insulation may not stand combustion chamber temperatures, the top course of the combustion chamber walls be laid flat,
extending to, and fitting the contour of the firebox and covering the loose insulation.
Always use cement furnished by the brick manufacturer for cementing insulating firebrick. It should be thinned to the
consistency of a very thick cream so that the brick can be dipped into it and set in place. The use of other cement or mortar
may impair the insulating and radiating qualities of the brick.
Magnesia block insulation, common brick, hard fire brick, dry sand and/or expanded mica products such a “Vermiculite” or
“Zonolite” can be used to back up the insulating firebrick. High temperature furnace cement can be used to seal the openings
around the burner and furnace.
Approved insulating bricks are: Babcock & Wilcox No. K-23 and No. K-26, A. P. Grenn No. G-23 and No. G-26, Armstrong
Cork No. A-23 and No. A-26 an Johns Manville No. JM-23 and No. JM-26.
INSTALLATION OF BURNER AND CONTROLS
The inshot power gas burner was designed especially for converting gun fired oil designed furnaces and boilers. Due
consideration was given to making it as simple and easy to install and service as possible without weakening its durability or
efficiency. The burner is supplied as a completely assembled package unit.
NOTE: The burner must be installed in such a manner that they unit and all controls will be readily accessible for inspection,
cleaning, adjustment and repairs.
SIZING OF INPUT IN RELATION TO FURNACE
FIGURE 140,000 BTUs (147700KJ) per gal. of oil input. For example: Furnace rating 0.60 G.P.H. then 0.60 x 140,000 =
72,000 BTUs input rate
The orifice spud supplied with all burners is the size for the minimum BTU input of the burner for the type gas shown on the
rating plate. Figure 6 shows the correct drill size for various inputs.
The correct manifold pressure for natural gas is 3.5” w.c(871.8 Pa). Only minor adjustments in the input rate should be made
by adjusting the pressure regulator. The minimum manifold pressure should be 3.0” w.c. (747.2Pa) and the maximum pressure
should be 3.5 w.c. (871.8 Pa) the next size larger or smaller orifice size should be used if the desired input rating cannot be
obtained within the above manifold pressure adjustment range.
The correct manifold pressure for L.P. gas is 10” w.c. (2491Pa), only minor adjustments in the input rate should be made by
adjusting the pressure regulator. The minimum manifold pressure should be 9.5” w.c. (2366 Pa), the maximum pressure 10.0”
w.c. (2491 Pa). If the desired input rating cannot be obtained within the above manifold pressure and adjustment range then the
next size larger or smaller drill should be used.
B.T.U. (kW) NATURALGAS PROPANE GAS
INPUT 3 1/2” (871.8Pa) W.C.P. 10” (2491 Pa) W.C.P.
PER HOUR Drill Size Drill Size
50,000 (14.65) #30 (3.264mm) #45 (2.083mm)
75,000 (21.98) 5/32 (3.967mm) #41 (2.438mm)
90,000 (26.38) #17 (4.394mm) #37 (2.642mm)
100,000 (29.31) #14 (4.623mm) #35 (2.794mm)
125,000 (36.63) #5 (5.22mm) 1/8 (3.175mm)
130,000 (38.1) #4 (5.309mm) #30 (3.264mm)
150,000 (43.96) #1 (5.791mm) #29 (3.454mm)
160,000 (46.89) 15/64 (5.954mm) #28 (3.569mm)
175,000 (51.29) C (6.147mm) #26 (3.734mm)
180,000 (52.75) 1/4 (6.35mm) #25 (3.797mm)
200,000 (58.61) G (6.629mm) #22 (3.988mm)
225,000 (65.94) J (7.036mm) #19 (4.216mm)
242,000 (70.92) L (7.366mm) #17 (4.394mm)
250,000 (73.27) M (7.493mm) #16 (4.496mm)
FIGURE 6
6
NOTE: The BTU input valves on the preceding page show the approximate hourly input of the burner for the various drill
sizes shown. To determine the actual input of the burner:
1) Turn off all other gas appliances.
2) The hand on the dial with the lowest cubic feet value (fastest revolving dial) should be clocked for one complete revolution.
3) Divide 3,600 by the time in seconds for one complete revolution and multiply by the dial value (1 (.028), 2 (.057), or 5
(.142) cubic feet depending on size of meter.)
4) Multiply this by the heating value of the gas to obtain the input to the burner in BTU per hour.
EXAMPLE: Time in seconds for one complete revolution of dial is 72. 3,600 divided by 72 is 50, a 2 cubic foot dial was timed
therefore 50 x 2 is 100. Multiply 100 by heating value of gas which is 1,000 and this will give you an input of
100,000 BTU (29.31 kW) per hour.
IMPORTANT: The minimum gas supply pressure is 4.5” w.c. (1121Pa) for natural gas and 11.0” w.c. (2740Pa) for L.P. gas;
the maximum gas supply pressure is 10.5: w.c. (2615Pa) for natural gas and 13” w.c. (3238Pa) for L.P. gas.
P250 ONLY
Input Floor Area Preferred Recommended Recommended
BTU/Hr. Sq. Inches Width and Minimum Minimum
(kW/Hr.) (mm
2
) Length (mm) Wall Thickness Floor Construction
50,000 (14.65) 49 (31610) 7(177.8)x7 (177.8) 2 1/2” (63.5mm) 2 1/2” (63.5mm)
85,000 (24.91 56 1/4 (36290) 7 1/2(190.5)x7 1/2(190.5) insulating firebrick Insulating firebrick
100,000(29.31) 64 (41290) 8(203.2) X 8(203.2) plus back up of plus 1 1/2” (38.1mm)
120,000(35.17) 72 1/4 (46610) 8 1/2(215.9) x * 1/2(215.9) 1 1/2” (38.1mm) asbestos or magnesia
140,000(41.03 81 (52260) 9(228.6) x 9(228.6) or more loose block.
154,000(45.13) 90 1/4 (58230) 9 1/2(241.3) x 9 1/2(241.3) insulation.
175,000(51.29) 100 (64520) 10(254) X 10(254)
210,000(61.55) 122 (78710) 11(279.4) X 11(279.4)
240,000(70.34) 144 (92900) 12(304.8) x 12(304.8)
250,000(76.2) 156 1/4 (100800) 12 1/2(317.5) X 12 1/2(317.5)
FIGURE 5
P265 ONLY
Input Floor Area Preferred Recommended Recommended
BTU/Hr. Sq. Inches Width and Minimum Minimum
(kW/Hr) (mm
2
) Length (mm) Wall Thickness Floor Construction
65,000 (19.05) 63 (40650) 7 (177.8) x 9 (228.6) 2 1/2” (63.5mm) insulating 2 1/2” (63.5mm) insulating
75,000 (21.98) 71 1/4 (45970) 7 1/2 (190.5) x 9 1/2 (241.3) firebrick plus back up firebrick plus 1 1/2” (38.1mm)
100,000 (29.31) 180 (116100) 7 1/2 (190.5) x 9 1/2 (241.3) of 1 1/2” (38.1mm) or asbestos or magnesia
150,000 (43.96) 200 (129000) 12 (304.8) X 15 (381) more loose insulation. block.
200,000 (58.61) 220 (141900) 13 (330.2) x 17 (431.8)
FIGURE 5A
P265F ONLY
Input Floor Area Preferred Recommended Recommended
BTU/Hr. Sq. Inches Width and Minimum Minimum
(kW/Hr.) (mm
2
) Length (mm) Wall Thickness Floor Construction
65,000 (19.05) 63 (40650) 7 (177.8) x 9 (228.6) 2 1/2” (63.5mm) insulating 2 1/2” (63.5mm) insulating
75,000 (21.98) 63 (40650 7 (177.8) x 9 (228.6) firebrick plus back up firebrick plus 1 1/2” (38.1mm)
100,000 (29.31) 71 1/4 (45970) 7 1/2 (190.5) x 9 1/2 (241.3) of 1 1/2” (38.1mm) or asbestos or magnesia
150,000 (43.96) 110 (70970) 10 (254) x 11 (297.4) more loose insulation. block.
200,000 (58.61) 165 (106500) 11 (297.4) x 15 (381)
FIGURE 5B
7
ELECTRICAL WIRING
The power burner is shipped completely wired. It is only necessary to supply the 115 volt circuit, thermostat and limit circuit.
All wiring must conform with the National electric Code or the code legally authorized in the locality where the installation is
being made. The burner, when installed, must be electrically grounded in accordance with local codes or, in the absence of
local codes, with the National Electrical Code, ANSI/NFPA No. 70-1987. See wiring diagrams, Figures 12&13.
If an external electrical source is utilized, the conversion burner, when installed, must be electrically grounded in accordance
with local codes or, in the absence of local codes, with the National Electrical Code ANSI/NFPA No. 70-1987.
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous
operation. Verify proper operation after servicing.
LIMIT CONTROL SWITCHES
Warm air furnaces (gravity and forced air) should be equipped with an automatic temperature limit control switch. Hot water
boilers (forced or gravity) should be equipped with an automatic temperature limit control switch.
Steam or vapor boilers be provided with means to guard against firing a dry boiler or one in which the water is dangerously low.
IMPORTANT: On installations where an oil burner replaced with a gas burner, the controls on the boiler or furnace will have
to be checked for compatibility with the gas burner. All controls should be checked to insure that they operate
properly and that they are in good condition. In no case should any limit or safety control be bypassed or
wired in such a manner that it will result in unsafe operation of the burner or appliance. If the controls on the
appliance are not compatible with the burner operation they should be replaced with the proper controls.
THERMOSTAT
The thermostat should be installed on an inside wall and should be located in the natural circulating path of room air.
Locations which would expose the thermostat to cold air, or drafts from windows, door, or openings leading to the outside, or to
air currents from cold or warm air registers, or where the natural circulation of air is shut off such as behind doors, above or
below mantels, shelves or in corners, should be avoided. The thermostat should not be exposed to heat from nearby radiators,
lamps, rays of the sun or mounted on a wall near pipes, warm air ducts or chimney flue. Any hole in the plaster or panel
through which the thermostat wires pass should be sealed to prevent drafts.
The maximum comfort to be obtained from any automatic heating installation is dependent to a great extent upon the proper
installation and adjustment of the room thermostat.
GAS PIPING
All piping must comply with local codes and ordinances or the National Fuel Gas Code ANSI Z223. 1-1984 and NFPA No.
54. Asediment trap or drip leg must be installed in the supply line to the burner.
A union shall be installed in the gas line adjacent to the upstream from the control manifold and downstream from the manual
main shutoff trap or drip leg must be installed in the supply line to the burner.
A 1/8” N.P.T. (3.175mm) plugged tapping accessible fro test gauge connection shall be installed immediately upstream of the
gas supply connection for the purpose of determining the gas supply pressure to the burner.
A manual shutoff valve shall be installed in the gas supply line external to the appliance, see Figure 7.
The gas line should be a separate supply direct from the meter to the burner. It is recommended that new pipe; be used and
located so that a minimum amount of work will be required in future servicing. The piping should be so installed as to be
durable, substantial and gas tight. It should be clear and free from cutting burrs and defects in structure or threading. Cast iron
fittings or aluminum tubing should not be used for the main gas circuit. Joint compounds (pipe dope) should be used sparingly
on male threads only and be approved for all gases.
It is recommended that table 8 be used to determine the size pipe to use from the meter to the burner.
The building structure should not be weak ended by installation for the gas piping. The piping should not be supported by the
other piping, but should be firmly supported with pipe hooks, straps, bands or hangers. Butt or lap welded pipe should not be
bent.
The gas piping should be so installed so as to prevent an accumulation of condensation and it must be protected against
freezing. Ahorizontal pipe should be pitched so that it grades toward the meter and is free from sags. The pipe should not be
run through or in an air duct or clothes chute.
The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure
testing of the system at test pressure in excess of 1/2 (3447 PaG) psig.
The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 (3447 PaG) psig.
TESTING PIPING FOR LEAKS
Before turning gas under pressure into piping, all openings from which gas can escape should be closed. Immediately after
turning on gas, the system should be checked for leaks. This can be done by watching the 1/2 cubic feet (.014m
3
) test dial and
allowing 5 minutes to show any movement, or by soaping each pipe connection and watching for bubbles. If a leak is found,
make the necessary repairs and repeat the above test.
Defective pipes or fittings should be replaced and not repaired. Never use a flame or fire in any form to locate gas leaks, use
a soap solution.
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