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 MODELS ALL P250 AND P265 SERIES GAS BURNERS Manual 101220 | Revision C | Publication Date: 7/11/14 NOTE: Dimensions in () are informational only. English values take priority.
INSTALLATION LOG BURNER MODEL: SPECIFICATION NUMBER: FUEL (NATURAL OR PROPANE): GAS ORIFICE DRILLED SIZE: INLET GAS PRESSURE (in. w.c.
FOR YOUR SAFTEY: DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VINCINITY OF THIS OR ANY OTHER APPLIANCE. WHAT TO DO IF YOU SMELL GAS: Open Windows. Do not try to light any appliances. Do not touch electrical switches; do not use any phone in your building. Extinguish any open flame. 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.
CONTENTS PAGE SECTION I INSTALLATION AND SETUP……………………………………………………………………………………….6 6 A. VISUAL INSPECTION OF THE HEATING SYSTEM………………………………………………………………….. B. INSPECTION OF FLUE PIPE AND CHIMNEY…………………………………………………………………………7 C. INSPECTION OF HEATING APPLIANCE…………………………………………………………………………….. 8 D. FLUE PIPE, DRAFT HOOD, AND BAROMETRIC DAMPER………………………………………………………..8 E. PREPARATION OF COMBUSTION CHAMBER………………………………………………………………………10 F. SIZING OF COMBUSTION CHAMBER…………………………………………………………………………………11 G.
E. PRELIMINARY CHECK, DIAGNOSIS AND SERVICE HINTS(ELECTRONIC PILOT IGNITION)…………… 30 F. COMPONENT TROUBLESHOOTING AND DIAGNOSIS………………………………………………………… 31 G. MORE SERVICE HINTS……………………………………………………………………………………………… 32 H. P250AF/P265F IGNITOR POSITION………………………………………………………………………………. 33 I. P250AF/P265F WIRING DIAGRAMS………………………………………………………………………………. 34 SECTION VI PARTS LIST AND EXPLODED VIEWS ………..……………………………………………………………. 39 A. P265F EXPLODED VIEWS………………………………………………………………………………………….. 39 B.
SECTION I: INSTALLATION AND SETUP These instructions were prepared for the guidance of those installing this particular gas conversion burner. While they 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.
The heating system (both the heat exchanger and distribution system) shall be of a size to properly heat the building. Throug h 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.
INSPECTION OF HEATING APPLIANCE Clean the appliance heat exchanger interior, combustion chamber and flue connections. Remove all adhering tars, scale, dirt, and soot. Inspect the heat exchanger for obvious and potential flue gas leaks. Cement all joints around the appliance base and access openings to prevent air and/or flue gas leakage into or out of the combustion chamber.
When converting oil fired 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 (0.305m) (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 – When installing Wayne power gas burners in oil fired boilers a minimum negative draft of .02” (5 Pa) w.c.
PREPARATION OF COMBUSTION CHAMBER Clean the 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 appliance will be impaired. Plugged or restricted flue passages will prevent burner from operating properly. Be sure water column and gauge on boiler are clean and water level is visible. In all cases make sure the pigtail to limit control is clear.
SIZING OF COMBUSTION CHAMBER The following tables are provided as a guideline for determining combustion chamber size and corresponding firing rate when appliance rates are not available. Table 1: Combustion Chamber for P250 Only Input Btu/hr (kW) Floor Area 2 Sq. Inches (cm ) Preferred Width and Length Inches (cm) 50,000 (15) 49 (316) 7 (17.8) x 7 (17.8) 85,000 (25) 56 ¼ (363) 7 ½ (19.1) x 7 ½ (19.1) 100,000 (29) 120,000 (35) 64 (413) 72 ¼ (466) 8 (20.3) x 8 (20.3) 8 ½ (21.6) x 8 ½ (21.
BURNER INSTALLATION The P250 and P265 power gas burners were designed for converting oil fired 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 all controls will be readily accessible for inspection, cleaning, adjustment and repairs.
DETERMINE ORIFICE SIZE AND RATE The gas conversion burner needs to be set to deliver the same amount of heat to the appliance as the oil burner it is replaci ng. Determine the Btu/hr heat input rate for the appliance by locating the rating plate of the appliance and determine the firing rate of the oil burner. Typically the nozzle in the oil burner is stamped with the gallon per hour rate. Use the lesser of these t wo rates as the firing rate of the gas burner.
NOTE: The Btu/hr input values in Table 4 show the approximate hourly input of the burner for the various drill bit sizes shown. To determine the actual input of the burner by using the gas meter, follow these steps: 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 revoluti on.
Pull the gas train out of the burner. The orifice is located on the end of the gas train and looks like a brass plug. Remove the orifice with a 11/16 inch wrench (Figure 8). FIGURE 8: ORIFICE LOCATION To drill the orifice, place it face down in a vice and drill through the back side. The back side is tapered and will make lining up the drill bit easier. Deburr the orifice and mark new size on orifice with permanent marker.
INSPECTION AND SIZING OF GAS PIPING All piping must comply with local codes and ordinances or the National Fuel Gas Code ANSI Z223.1/NFPA No. 54. A sediment trap or drip leg must be installed in the supply line to the burner. A union shall be installed in the gas line upstream from the con trol manifold and downstream from the sediment trap or drip leg (See Figure 10).
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 psig (3447 PaG). Table 5: Pipe Sizing Chart for Natural Gas (0-0.5 psi) with Straight Schedule 40 Metal Pipe The following chart is based on 0-0.5 psi inlet pressure, specific gravity of 0.6, and a pressure loss of 0.5” w.c..
Table 7: Pipe Sizing Chart for Liquid Propane (11” w.c.) with Copper Tubing The following chart is based on 11” w.c. inlet pressure and a pressure drop of 0.5” w.c..
INSPECTION OF 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.
SECTION II: INITIAL START UP OPERATION OF BURNER (DIRECT SPARK IGNITION) Starting the Burner: 1. Depress the gas valve control knob on the combination gas valve and turn to “OFF” (See Figure 13). 2. Set the room thermostat above room temperature and let the burner run five minutes to purge the appliance. 3. Set thermostat below room temperature. 4. Turn gas control valve knob to “ON”. 5. Set room thermostat higher than room temperature so that the burner will start. To put burner out of operation 1.
OPERATION OF BURNER (ELECTRONIC PILOT) (P265-EP, P265F-EP, P250AF-EP) Starting the Burner: 1. 2. 3. 4. 5. Depress the gas valve control knob on the combination gas valve and turn to “OFF” (See Figure 14). Set room thermostat above room temperature and let burner run five minutes to purge the appliance. Set thermostat below room temperature. Turn gas valve control to “ON”. Set room thermostat higher than room temperature so that the burner will start. To put burner out of operation 1.
OPERATION OF BURNER (STANDING PILOT) Starting the Burner: 1. 2. 3. 4. 5. 6. Depress the gas valve control knob on the combination gas valve and turn to “OFF” (See Figure 15). Set room thermostat above room temperature and let burner run five minutes to purge the appliance. Set thermostat below room temperature. Turn gas valve control to “PILOT”. Depress red button on valve to start pilot gas flow. Push red button down on spark igniter until it snaps. Repeat this until the pilot lights.
COMBUSTION ADJUSTMENT OF BURNER All adjustments below must be made with the following equipment: 1. Draft Gauge 3. CO Tester 2. O2 or CO2 Analyzer 4. Water Column Gauge Flame Spreader Adjustment (P250AF Only) The flame spreader is used to shape the flame to best suit the firing chamber. Depending on the firing chamber, the flame spreader can be used to produce a long narrow flame or a short bushy flame.
With the flame spreader pulled all the way back, the flame spreader adjustment rod should measure approximately 3 1/4 inches from the back plate. With the flame spreader adjustment rod pushed all the way in it should measure approximately 1 inch from the burner back plate. Adjust the flame so that it will fill the firebox without impinging on the back wall. Once the flame is adjusted properly, retighten the set screw.
In addition to the necessary parts to complete the gas conversion, each kit contains detailed instructions for the conversion. To order the appropriate gas conversion kit, please contact a local wholesaler. The Wayne Combustion Customer Service Department can assist in locating the nearest wholesaler.
SECTION V: SERVICE AND TROUBLESHOOTING NORMAL OPERATION CHECK OF BURNER (DIRECT IGNITION) 1. APPLIANCE CALLS FOR HEAT BY RAISING THE THERMOSTAT TO THE DESIRED SETTING: Note the transformer is always energized with 110 volts. 2. When the thermostat circuit is complete, this allows 24 volts to coil side of the fan relay which are the bottom terminals. 3.
NORMAL OPERATION CHECK OF BURNER (ELECTRONIC PILOT) PRELIMINARY CHECK The following visual checks should be made before troubleshooting an after installation or maintenance. 1. Check the power to the appliance and S8600. 2. Manual shutoff cocks in gas line to appliance must be open. 3. Make certain all wiring connections are clean and tight. 4. S86G, H module must not be in safety lockout. First de-energize the system and wait at least one (1) minute.
TROUBLESHOOTING GUIDE DIRECT IGNITION NOTE 1: BURNERS ARE NOT PRESET FROM THE FACTORY AND MUST BE ADJUSTED AT THE SITE. NOTE 2: NEW GAS LINE INSTALLATIONS WILL HAVE AIR IN THE LINES AND REQUIRE SEVERAL IGNITION ATTEMPTS TO PURGE ALL THE AIR FROME THE LINES. NOTE 3: DO NOT ATTEMPT TO PERFORM ANY WORK ON THIS BURNER UNLESS THE FOLLOWING TOOLS ARE AVAILABLE AND YOU ARE A CERTIFIED INSTALLER: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
START TURN GAS SUPPLY OFF, TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT POWER TO MODULE (24V NOMINAL) NO Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring. Also check end switch on combustion air blower system. YES SPARK ACROSS IGNITER/SENSOR GAP NO - Check ignition cable, ceramic insulator and gap, and replace part if necessary. - Check boot of the ignition cable for signs or melting or buckling.
Table 8: Troubleshooting Chart Electronic Pilot Ignition (For Burners Utilizing Fenwal Control) Symptoms 1. PILOT DOES NOT LIGHT. 2. MOTOR DOES NOT RUN. 3. MOTOR RUNNING BUT NO FLAME. Possible Causes a. Air in gas line. b. High or low gas pressure. c. Blocked pilot orifice. d. Broken or damaged ignition cable. a. Thermostat or limit defective or improperly set. b. Relay or transformer defective. c. Motor burned out. d. Improper wiring. a. Very low or no gas pressure to pilot. b.
voltage, it should be replaced. If the voltage is not present at Terminals PV1 and ground (or across valve), the control should be replaced. 5. Electrode Placement a. Electrode should be placed so optimum flame current is achieved for proper application. b. Flame should not impinge on any portion of ceramic insulator. 6. Flame Current The flame detector circuit uses the ionized gas flame to conduct the flame signal.
IGNITER ROD The igniter rod is responsible for conveying the spark to a grounding rod in an appropriate location to ignite the gas and air mix. The igniter rod gap should be 1/8”, larger gaps will create ignition problems. If the igniter rod is cracked, sparking sound will be heard inside the burner air tube but ignition will not occur and lockout will occur. MORE SERVICE HINTS THERMOSTAT CALLS FOR HEAT AND THE FOLLOWING CONDITIONS OCCUR: 1. PROBLEM: The combustion fan motor is not operating.
+/- P250 DIRECT IGNITION IGNITOR POSITION 7/16” (11.1 mm) +/- 1/16” (1.6 mm) P265 DIRECT IGNITION IGNITOR POSITION 5/16” (7.9 mm) 1/8” (3.2 mm) Gap 31/64” (12.3 mm) +/1/16” (1.6 mm) 33 1/4” (6.4 mm) 1/16” (1.6 mm) 1/8” (3.
WIRING DIAGRAMS CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
FIGURE 23: WIRING DIAGRAMS FOR GAS BURNER WITH DIRECT IGNITION-FENWAL 35
FIGURE 24: WIRING DIAGRAMS FOR GAS BURNER WITH ELECTRONIC PILOT-HONEYWELL 36
FIGURE 25: WIRING DIAGRAMS FOR GAS BURNER WITH ELECTRONIC PILOT-NO T-STAT 37
FIGURE 26: WIRING DIAGRAMS FOR GAS BURNER WITH ELECTRONIC PILOT-FENWAL 38
SECTION VI: PARTS LIST AND EXPLODED VIEWS Parts in Exploded View 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Parts in Exploded View 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
60172-002 61803 61875 62406-002 60186-004 60178-002 62510-SER 60353-SER 62715-001 62715-002 62715-004 62715-006 62715-007 21724-011 100428-002 21760-011 62246-004 62256-004 62374-004 62374-PRO 62898-001 60249 60250 Varies Varies 60533 60944 61403 61637-004 Motor/Blower Asm (w/o Control Box) Control Box Asm (Incl. Trans. & Relay) Motor/Blower & Control Box Pkg.
Parts in Exploded View 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Parts in Exploded View 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
60172-002 61803 61875 62406-002 60186-004 60178-002 62510-SER 63566-SER 62715-003 21724-011 100428-002 21760-011 62246-004 62256-004 62374-004 62374-PRO 62898-001 Varies Varies 60533 61817 60748 61818 63062-001 64008-SER 60375-002 62261 62947-003 61455 80274-SER 101243-001 62245-007 63375-001 63103-001 Motor/Blower Asm (w/o Control Box) Control Box Asm (Incl. Trans. & Relay) Motor/Blower & Control Box Pkg.
SECTION VII: WARRANTY LIMITED WARRANTIES FOR OIL AND GAS BURNERS, MADE BY WAYNE AND USED IN RESIDENTIAL INSTALLATIONS WAYNE COMBUSTION SYSTEMS (“WAYNE”) warrants to those who purchase its Oil Burner Models for resale or for incorporation into a product of resale, that its burner is free from defects in material and workmanship under normal use and service for thirty-six (36) months from the date of manufacture.
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