Wayne Burner P250AF User Manual

MODELS

P250AF

P265

P250AF-EP

P265F

P250AF-DI

P265-EP

WAYNE COMBUSTION SYSTEMS

801 GLASGOW AVE.

GAS BURNER

Publication Date 5/01

NOTE: Dimensions in ( ) are informational only. English values take priority.

Revision B

Manual 101220

FORT WAYNE, IN 46803

FOR YOUR SAFETY

WARNING: If the information in these

instructions is not followed exactly, a fire or

explosion may result causing property

damage, personal injury or death.

IF YOU SMELL GAS:

1. OPEN WINDOWS

2. DON’T TOUCH ELECTRICAL SWITCHES

3. EXTINGUISH ANY OPEN FLAME

4. IMMEDIATELY CALL YOUR GAS

SUPPLIER.

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 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.

CARBON MONOXIDE

POISONING HAZARD

CARBON MONOXIDE IS A COLORLESS, ODORLESS GAS

THAT CAN KILL. FOLLOW THESE RULES TO CONTROL

CARBON MONOXIDE.

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.

L Do not use this burner if in an unvented, enclosed area. Carbon

monoxide may accumulate.

L Do not adjust the pressure regulator. High pressures produce

carbon monoxide.

L Check flue gases for carbon monoxide. This check requires

specialized equipment.

L Allow only qualified burner service persons to adjust the burner.

Special instruments and training are required.

L Read the owner’s manual before using.

ELECTRIC SHOCK HAZARD

HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT.

FOLLOW THESE RULES TO AVOID ELECTRIC SHOCK.

L Use only a properly grounded circuit. A ground fault

interrupter is recommended.

OVERHEATING HAZARD

L Do not spray water directly on burner.

L Turn off power before servicing.

SHOULD OVERHEATING OCCUR:

L Shut off the manual gas valve to the appliance.

L Do not shut off the control switch to the pump or blower.

L Read the owner’s manual before using.

THESE INSTRUCTIONS SHOULD BE AFFIXED TO THE

BURNER OR ADJACENT TO THE HEATING APPLIANCE.

NOTICE

SPECIFICATIONS

BURNER MODELS

MINIMUM INPUT

MAXIMUM INPUT

FUELS

P-250AF & P-250AF-EP & P250AF-DI

P-265 & P-265-EP

50,000 BTU/HR (14.65 kW/Hr)

65,000 BTU/HR (19.05 kW/Hr)

250,000 BTU/Hr (73.27 kW/Hr) Natural & L.P. Gas

200,000 BTU/Hr (58.61 kW/Hr) Natural & L.P. Gas

MOUNTING: Adjustable Flange is Standard

Pedestal Mount is Optional.

P-265-F & P-265F-EP

ELECTRICAL Power Supply - 115V/60HZ 1 Ph.

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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.

NOTE: Ducts used for make-up

air may be connected to the

cold air return of the heat-

Air Inet Opening 1 Sq.

ing system only if they connect

in. (645.2 mm²) for each

directly to outdoor air.

1,000 Btu (.2931 kW)

per hour input.

Attic Ventilation Louvers are

required at each end of attic

with alternate air inlet No. 1.

1, 2, and 3 mark alternate loca-

tions 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.

Ventilating Air Opening

1 Sq. in. (645.2 mm²)

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.

Illustration showing air opening necessary to supply air for combustion

when heating appliance is installed in an enclosed room.

FIGURE 1

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1/2” (12.7 mm)

FIGURE 2

FIGURE 3

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)

FIGURE 4

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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)

Per Hour

Draft Hood and

Flue Pipe Size

Up to --- 120,000 (35.17)

5 inch (127mm)

6 inch (152.4mm)

7 inch (177.8mm)

120,000 (35.17) --- 180,000 (52.75)

180,000 (52.75) --- 250,000 (73.27)

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 A REFACTORY 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.

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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 (.093m²) 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)

INPUT

PER HOUR

NATURAL GAS

3 1/2” (871.8Pa) W.C.P.

Drill Size

PROPANE GAS

10” (2491 Pa) W.C.P.

Drill Size

50,000 (14.65)

75,000 (21.98)

90,000 (26.38)

100,000 (29.31)

125,000 (36.63)

130,000 (38.1)

150,000 (43.96)

160,000 (46.89)

175,000 (51.29)

180,000 (52.75)

200,000 (58.61)

225,000 (65.94)

242,000 (70.92)

250,000 (73.27)

#30 (3.264mm)

5/32 (3.967mm)

#17 (4.394mm)

#14 (4.623mm)

#5 (5.22mm)

#4 (5.309mm)

#1 (5.791mm)

15/64 (5.954mm)

C (6.147mm)

1/4 (6.35mm)

G (6.629mm)

J (7.036mm)

L (7.366mm)

M (7.493mm)

#45 (2.083mm)

#41 (2.438mm)

#37 (2.642mm)

#35 (2.794mm)

1/8 (3.175mm)

#30 (3.264mm)

#29 (3.454mm)

#28 (3.569mm)

#26 (3.734mm)

#25 (3.797mm)

#22 (3.988mm)

#19 (4.216mm)

#17 (4.394mm)

#16 (4.496mm)

FIGURE 6

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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

BTU/Hr.

(kW/Hr.)

Floor Area

Sq. Inches

(mm²)

Preferred

Width and

Length (mm)

Recommended

Minimum

Wall Thickness

Recommended

Minimum

Floor Construction

50,000 (14.65)

85,000 (24.91

100,000(29.31)

120,000(35.17)

140,000(41.03

154,000(45.13)

175,000(51.29)

210,000(61.55)

240,000(70.34)

250,000(76.2)

49 (31610)

56 1/4 (36290)

64 (41290)

7(177.8)x7 (177.8)

7 1/2(190.5)x7 1/2(190.5)

8(203.2) X 8(203.2)

2 1/2” (63.5mm)

insulating firebrick

plus back up of

1 1/2” (38.1mm)

or more loose

insulation.

2 1/2” (63.5mm)

Insulating firebrick

plus 1 1/2” (38.1mm)

asbestos or magnesia

block.

72 1/4 (46610)

81 (52260)

8 1/2(215.9) x * 1/2(215.9)

9(228.6) x 9(228.6)

90 1/4 (58230)

100 (64520)

9 1/2(241.3) x 9 1/2(241.3)

10(254) X 10(254)

122 (78710)

11(279.4) X 11(279.4)

12(304.8) x 12(304.8)

12 1/2(317.5) X 12 1/2(317.5)

144 (92900)

156 1/4 (100800)

FIGURE 5

P265 ONLY

Input

BTU/Hr.

(kW/Hr)

Floor Area

Sq. Inches

(mm²)

Preferred

Width and

Length (mm)

Recommended

Minimum

Wall Thickness

Recommended

Minimum

Floor Construction

65,000 (19.05)

75,000 (21.98)

100,000 (29.31)

150,000 (43.96)

200,000 (58.61)

63 (40650)

71 1/4 (45970)

180 (116100)

200 (129000)

220 (141900)

7 (177.8) x 9 (228.6)

7 1/2 (190.5) x 9 1/2 (241.3)

12 (304.8) X 15 (381)

2 1/2” (63.5mm) insulating

firebrick plus back up

of 1 1/2” (38.1mm) or

more loose insulation.

2 1/2” (63.5mm) insulating

firebrick plus 1 1/2” (38.1mm)

asbestos or magnesia

block.

13 (330.2) x 17 (431.8)

FIGURE 5A

P265F ONLY

Input

BTU/Hr.

(kW/Hr.)

Floor Area

Sq. Inches

(mm²)

Preferred

Width and

Length (mm)

Recommended

Minimum

Wall Thickness

Recommended

Minimum

Floor Construction

65,000 (19.05)

75,000 (21.98)

100,000 (29.31)

150,000 (43.96)

200,000 (58.61)

63 (40650)

63 (40650

7 (177.8) x 9 (228.6)

2 1/2” (63.5mm) insulating

firebrick plus back up

of 1 1/2” (38.1mm) or

more loose insulation.

2 1/2” (63.5mm) insulating

firebrick plus 1 1/2” (38.1mm)

asbestos or magnesia

block.

71 1/4 (45970)

110 (70970)

165 (106500)

7 1/2 (190.5) x 9 1/2 (241.3)

10 (254) x 11 (297.4)

11 (297.4) x 15 (381)

FIGURE 5B

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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. 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 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. A horizontal 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 (.014m³) 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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After the piping and meter have been checked completely, purge the system of air. Do not bleed the air inside the furnace.

Be sure to relight all the gas pilots on other appliances.

PURGING

After the piping has been checked, all piping and appliances receiving gas through the meter shall be fully purged. A

suggested method for purging th gas line to the burner is to disconnect the pilot line at the outlet o the pilot valve. Under no

circumstances shall th line be purged into the combustion chamber.

After th e gad line to the conversion burner has been fully purged and the pilot line reconnected, the gas supply at other pilot

burners located on other gas appliances which were extinguished as the result of interrupted service shall be reignited.

LENGTH OF STANDARD PIPE THREADS inches (mm)

EFFECTIVE

LENGTH

OVERALL

LENGTH

PIPE SIZE

OF THREAD

3/8 (9.525)

1/2 (12.7)

3/4 (19.05)

1 (25.4)

3/8 (9.525)

1/2 (12.7)

1/2 - 9/16 (14.29)

9/16 (14.29)

3/4 (19.05)

13/16 (20.64)

1 (25.4)

PIPE CAPACITY TABLE

Nominal Diameter of Pipe in Inches

3/4 (19.05) 1(25.4) 1-1/4 (31.75) 1-1/2 (38.1) 2 (50.8)

Length

of Pipe

in Feet

Capacity - Cu, Ft. Per Hr. with a 0.6

Sp. Gr. Gas and Press. Drop of 0.3 In. (74.72 Pa) Water Col.

15 (4.572)

30 (9.144)

45 (13.72)

60 (18.29)

75 (22.86)

105 (32)

172

120

345

241

199

173

155

131

120

100

750

535

435

380

345

285

270

225

850

700

610

545

450

420

350

920

860

720

120 (36.58)

180 (54.86)

FIGURE 8

To convert the figures given above to capacities for another

gas of different specific gravity, multiply the tabular values by

the multiplier shown below.

MULTIPLIER FOR VARIOUS

SPECIFIC GRAVITIES

SPECIFIC

GRAVITY

SPECIFIC

GRAVITY

MULTIPLIER

1.31

MULTIPLIER

.775

.35

1.00

.40

1.23

1.10

.740

.45

.50

.55

.60

.65

.70

.75

1.16

1.10

1.04

1.00

.962

.926

.895

1.20

1.30

1.40

1.50

1.60

1.70

1.80

.707

.680

.655

.633

.612

.594

.577

.80

.90

.867

.817

1.90

2.10

.565

.535

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ADJUSTMENT OF BURNER

Starting the burner:

1. Depress the gas valve control knob on the combination gas valve and turn to “OFF”. Figure 9.

2. Set room thermostat above room temperature and let burner run five minutes to purge the unburned gas from the unit.

3. Set thermostat below room temperature.

4. Turn gas valve control to “PILOT”.

5. Depress red button on valve to start pilot gas flow.

6. Push re button down on spark generator until it snaps. Repeat this until the pilot lights. Note: this may take some time until

all the air is “bled: out of the line.

7. Hold the red button on the valve for seconds, then release.

8. Observe pilot - if not lit, SHUT OFF BURNER COMPLETELY AND WAIT 5 MINUTES. Repeat steps 1 through 7.

9. Turn gas control valves to “ON”.

10. Set room thermostat higher than room temperature so that the burner will start.

To put burner out of operation

1. Depress the gas valve control knob on the combination gas valve and turn to “OFF”.

2. Turn off electrical supply.

STANDING PILOT

COMBINATION GAS VALVE

FIGURE 9

ELECTRONIC PILOT

FIGURE 11

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P265DI - JUNCTION BOX ROTATED

P265DI

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All adjustments below must be made with the following instructions:

1. Draft Gauge

3. CO Tester

2. O or CO Analyzer

4. Water Column Gauge

After the burner has been in operation for 10 minutes and if a neutral pressure point adjuster was installed, proceed as

follows. Start from the wide open position and gradually close the neutral pressure point adjustment. Crack observation door

about 1/8 inch (3.175mm). Then by holding match flame along opening, the neutral pressure point can be determined. The

flame should be drawn in below the center of the door and it should be blown outward above the center. In other words, the

pressure inside the combustion chamber should be above atmospheric pressure above the burner flame and below atmospheric

pressure below the burner flame. The pressure should be neutral at the center. Closing the adjuster lowers the neutral

pressure point and opening the adjuster raises the neutral pressure point.

Once the neutral pressure point has been adjusted, the combination air shutter should be adjusted so that the percent CO

test must be made at the inlet side of the draft hood. If the CO reading is not within the recommended limits, then the

combustion air shutter should be re-adjusted and then the neutral pressure point be rechecked and reset if necessary.

IT IS ESSENTIAL TO MAKE CERTAIN THAT THE PRODUCTS OF COMBUSTION DO NOT CONTAIN CARBON

MONOXIDE, CO. It is possible to have flame impingement on cold surfaces with resultant CO even if CO and O are within

acceptable limits. The flue gas sample is taken through the same hole used for the CO test. CO test instrument must be used

for this test.

The most common causes of CO are flame impingement on cool surface and insufficient primary air, both of which could be

caused by over firing. The only answer is to reduce the firing rate or increase the primary air.

Combustion efficiency is determined by the percent CO and the temperature of the flue gases. These two measurements

are taken on the inlet side of the draft hood. Combustion efficiency and stack loss calculators provide slide rule convenience for

correlating CO and stack temperature readings. These calculators are available from several manufactures of combustion test

equipment.

IMPORTANT

DRAFT - When installing Wayne power gas burners in oil fired boilers a minimum negative draft of .02” (4.982 Pa) w.c. over

fire must be maintained.

Refer to your local gas company and codes for assistance.

For gad fired equipment requiring a double acting barometric the preferred location of the barometric draft control is part of

the bullhead tee shown in figures A, B OR C. During normal operation, flue gases make a right angle turn behind the control,

but do not infringe upon it. Should a downdraft occur, air flowing n the opposite direction strikes the control directly, causing it to

open outwardly and vents the air into the room with a minimum of resistance. Entrained products of combustion are thus

provided grater relief.

BEST LOCATIONS FOR GAS

WIRING DIAGRAM LADDER FORM

FIG. A

FIG. B

FIG. C

WIRING DIAGRAM FOR GAS BURNER WITH STANDING PILOT

FIGURE 12

WIRING DIAGRAM LADDER FORM

FIGURE 13

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GENERAL INSTRUCTION

Gas burners require the services of an experienced technician for proper setting and adjustment. If the burner does not

appear to be operating properly, DO NOT ATTEMPT TO ADJUST THE BURNER YOURSELF, but call in a competent

serviceman.

A homeowner should be able to check several possible causes of shutdown before calling in a serviceman. The following

check list may eliminate the need for a service call or at least provide information for the serviceman.

1. Check thermostat. Make sure that it is set at the desired room temperature. If the thermostat is damaged or loose on the

wall, have it replaced or repaired.

2. Check fuses in service box for the burner circuit. Replaceable type fuses should not be loose in the socket. If a fuse is

blown out or if in doubt, replace with the same size and type. If circuit breaker are in the service box, check position of

indicator. If tripped, reset.

3. Check on-off switch for the burner circuit, it may have been accidentally turned off.

4. With the thermostat set 10 degrees above room temperature, the burner should start automatically. If it does not start,

check pilot. If no flame is visible, relight pilot following lighting instructions.

It is advisable, periodically, to visually inspect the burner. Check air inlet blower to make sure it is not clogged or

blocked. Check air shutter to make sure that it has not been tampered with, make sure that it is in the same position as

when final adjustments were made. Check blower wheel to see if it is dirty or full of lint. Open observation door and

check pilot flame. If the flame does not appear normal or if in doubt, call a serviceman.

The areas around the conversion burner should be kept clear and free of combustible materials, gasoline and other

flammable vapors and liquids.

The flow of combustion and ventilating air to the burner must not be blocked or obstructed in any manner.

CLEANING OF BURNERS: Remove the burner from the appliance and visually inspect the blast tube for any deterioration.

On burners equipped with standing pilot or intermittent ignition, inspect pilot burner for dust or corrosion and clean if necessary.

Check pilots, thermo-couples, electrodes, etc. with illustrations in the owner’s manual for proper locations.

Check flame spreaders if applicable for any deterioration and replace if necessary.

Remove corrugated flame ring from the end of the venturi and clean. Visually inspect the inside of the venturi for any

excessive rust or corrosion and clean if necessary. Replace corrugated flame ring and reinstall burner.

TROUBLE CHART

SYMPTOMS

CAUSE

a. Air in Gas Line.

b. High or low gas pressure.

c. Blocked pilot orifice.

1. PILOT DOES NOT LIGHT

a. Restriction in the pilot gas line.

b. Low gas pressure.

c. Blocked pilot orifice.

2. PILOT GOES OUT FREQUENTLY

DURING STANDBY.

d. Loose thermocouple connection on 100% shut off.

e. Defective thermocouple or pilot safety switch.

f. Poor draft condition.

3. PILOT GOES OUT WHEN MOTOR STARTS.

4. MOTOR DOES NOT RUN.

g. Draft tube set into or flush with inner wall of combustion chamber.

a. Restriction in pilot gas line.

b. High or low gas pressure.

c. Excessive pressure drop when the main gas valve opens.

a. Burned out fuse or current off.

b. Thermostat or limit defective or improperly set.

c. Relay or transformer defective.

d. Motor burned out.

5. MOTOR RUNNING BUT NO FLAME.

6. SHORT NOISY BURNER FLAME.

7. LONG YELLOW FLAME.

e. Improper wiring.

a. Pilot out.

b. Thermocouple not generating sufficient voltage.

c. Very low or no gas pressure.

d. Vent in regulator plugged.

e. Defective regulator.

8. MAIN GAS VALVE DOES NOT

CLOSE WHEN BLOWER STOPS.

a. Air shutter not open enough.

b. Air openings or blower wheel clogged.

c. Too much input.

9. REGULATOR VENT LEAKING GAS.

a. Hole in diaphragm.

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P 265-EP, P265F-EP, P250AF-EP

INTERMITTENT PILOT INSTRUCTION

FOR HONEYWELL SYSTEM

STARTING BURNER

1. Depress the gas valve control knob on the combination gas valve and turn to “OFF”. See Figure 9.

2. Set the room thermostat above room temperature and wait five (5) minutes.

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.

SHUTTING DOWN THE BURNER

1. Depress the gas valve control knob on the combination gas valve and turn to “OFF”.

2. Turn off electrical supply.

OPERATION

FIRST STAGE -- TRIAL FOR PILOT IGNITION

On every call for heat (system start), the S8600 performs an internal safe-start check. A system start is prevented if the

check shows that a flame-simulating condition is present..

During a normal start, the S8600 opens the first operator in the gas control. This allows gas to flow to the pilot burner.

Simultaneously, the electronic spark generator in the S8600 produces a 15,000 volt spark pulse output. This voltage produces a

spark at the pilot burner ignitor-sensor rod, igniting the gas flowing around the electrode. If the pilot flame is not detected during

the trial for pilot ignition, the S86E an F will continue trying for pilot ignition until a flame is established. The S86G and H contain

a safety locknut timer to limit the trial for pilot ignition period.

SECOND STAGE -- MAIN BURNER OPERATION

When the pilot flame is established, a flame rectification circuit is completed to the burner ground. The S8600 flame sensing

circuit detects the flame current and shuts the spark generator off. At the same time the second operator (main) is opened in

the gas control, allowing gas flow to the main burner. The pilot flame ignites the main burner conventionally. On the S86G and

H the flame current also holds the safety lockout timer in the reset, or normal, operating condition.

SAFETY LOCKOUT TIME (S8600 only)

The safety lockout timer circuit starts timing the moment the trial for pilot ignition starts. When the timing period runs out, the

trial for ignition ends, and the control module goes into lockout. Before another attempt to start can be made, the S8600 must

be reset. Reset by adjusting the thermostat or controller below room temperature, or to its “OFF” position. An alternate method

is to shut the system power “OFF”. Wait at least one (1) minute, then turn the system “ON”. If normal ignition does not occur,

use the troubleshooting table to determine the problem.

SERVICE

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. This resets

the module, allowing a return to start condition.

5. Review the S8600 system normal sequence of operation.

SYSTEM TROUBLESHOOTING

Start the system by setting the thermostat or controller above required temperature. Observe system response. Establish

type of malfunction or deviation from normal operation. Use the S8600 Intermittent Pilot System Troubleshooting Table (Page

13) to check for normal system operation.

Use table by following instruction question in box. If the condition is true or okay (answers yes), go down to next box

underneath. If the condition is not true or not okay (answers no), go right to the next box alongside. Continue checking and

answering conditions in each box encountered, until a problem and/or the repair are explained. After any maintenance or repair,

the troubleshooting sequence should be repeated until the troubleshooting procedure ends with normal system operation.

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IMPORTANT: The electronic S8600 Control Module cannot be repaired. If troubleshooting procedure indicates a malfunction in

the S8600 the S8600 Control Module must be replaced. Intermittent pilot systems should be serviced only by

trained and experienced personnel.

SEQUENCE OF OPERATION

THERMOSTAT (CONTROLLER)

CALLS FOR HEAT

START

SPARK GENERATOR

STAGE 1

TRIAL FOR

IGNITION

PILOT BURNER OPERATION

Pilot burner lights.

Module senses

flame current.

Pilot burner does not light

Module

Response

S8600A,F

S8610A, F

Ignition spark continues, pilot valve remains

open until system is reset

S8600B, H

S8610B, H

After 15 or 90 sec. a system

lock outs; must be manually reset

S8600M

After on sec. a system shuts off; after 5 minutes

min. (6 minutes nom.), module restarts trial for

ignition; ignition trial, shutoff, wait sequence

repeats until pilot lights or call for heat ends.

a Shutoff/lockout timing is stamped on module

FLAME CURRENT SENSED

• Spark generator off

• Second valve operator (main) opens.

POWER INTERRUPTION

System shuts off, restarts when power is

restored.

STAGE 2

MAIN BURNER

OPERATION

MAIN BURNER OPERATION

Module monitors pilot flame current.

PILOT FLAME FAILURE

Mail valve closes.

Module starts trial for ignition.

THERMOSTAT (CONTROLLED)

SATISFIED

Valves close, pilot and main burners are off.

END

WIRING DIAGRAM HONEYWELL EP SYSTEM

WIRING DIAGRAM LADDER FORM

S86

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S8600, S8610 TROUBLESHOOTING GUIDE

START

NOTE: Before troubleshooting, familiarize yourself with the start up and checkout procedure.

TURN GAS SUPPLY OFF,

TURN THERMOSTAT

(CONTROLLER) TO CALL

FOR HEAT

Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and

wiring. Also, check air proving switch on combustion air blower system (if used) and that vent

damper (if used) is open and end switch is made.

POWER TO MODULE

(24V NOMINAL)

Pull ignition lead and

check spark at module

•

On modules with vent damper plug, make sure

vent damper has not been installed, then

removed. Replace vent damper if necessary.

YES

SPARK ACROSS

IGNITER/SENSOR GAP

Spark okay?

On other models, replace module.

YES

• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.

• Check boot of the ignition cable for signs of melting or buckling. Take protective

action to shield cable and boot from excessive temperatures.

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

• Check that all manual gas valves ar open, supply tubing and pressures are good, and pilot

burner orifice is not blocked.

YES

• Check electrical connections between module and pilot operator on gas control.

• Check for 24 Vac across PV-Mv/PV terminals on module. If voltage if okay, replace gas

control; if not, replace module.

NOTE: If S8600B, H; S8610B, H goes into lockout, reset system. For S8600M, wait 6 min.

norm. for retry or reset system.

• Check continuity of ignition cable and ground wire.

• Clean flame rod.

SPARKS STOP WHEN

PILOT IS LIT?

• Check electrical connections between flame rod and module.

• Check for cracked ceramic flame rod insulator.

• Check that pilot flame covers flame rod and is steady and blue.

• Adjust pilot flame.

YES

• If problem persists, replace the module.

• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.

MAIN BURNER LIGHTS?

• Check electrical connections between module and gas control. If okay, replace gas control

or gas control operator.

YES

NOTE: If S8600B, H; S8610B, H goes into lockout, reset system. For S8600M, wait 6 min.

norm. for retry or reset system.

• Check continuity of ignition cable and ground wire.

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS?

NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though operation

is normal at the time of checkout.

YES

• Check that pilot flame covers flame rod and is steady and blue.

• If checks are okay, replace the module.

CALL FOR HEAT END

SYSTEM SHUTS OFF?

• Check for proper thermostat (controller) operation.

• Remove MV lead at module; if valve closes, recheck temperature controller and wiring; if

not, replace gas control.

YES

TROUBLESHOOTING

ENDS

Repeat procedure until trouble

free operation is obtained.

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P250AF DIRECT SPAR ELECTRODE LOCATION

7/16”

1/16”

+/- _{(1.587 mm)}

1/4”

(6.35 mm)

_{(11.11 mm)}+/- _{(1.587 mm)}

1/8” (3.175 mm) GAP

31/64”

(12.3 mm)

1/16”

+/- _{(1.587 mm)}

P265DI

DIRECT SPARK IGNITION

HONEYWELL S87K SYSTEM

P250AF/P265-DI

DIRECT SPARK IGNITION

HONEYWELL SYSTEM

Starting the burner:

1) Turn the gas valve control knob to “OFF”, wait five minutes.

2) Turn gas valve control knob to “ON”.

3) Set room thermostat above room temperature.

4) If burner does not light, SHUT OFF BURNER COMPLETELY AND WAIT FIVE MINUTES, then repeat steps 1 through 3

above.

To shut off burner:

1) Turn the gas valve control knob to “OFF”.

2) Turn off electrical supply.

DESCRIPTION

The Honeywell S87K (24VAC) Direct Spark Ignition Systems operate through a thermostat to provide a means of ignition for

the main burner on gas-fired equipment. This is accomplished by generating a spark between high voltage electrode and

ground. Once the flame is established a flame rod monitors the main burner flame.

SEQUENCE OF OPERATION

On a call for heat, voltage is applied to the ignitor across Terminals 1 (power) and ^ (ground) of the input connector. A high

voltage spark is then generated from the spark electrode to ground. Simultaneously, the gas valve is energized.

At the start of each heat cycle, there is a “Trial for ignition period” of three seconds duration. Normally main burner flame will

be established before the end of this period. Once the flame is established, sparking will cease and the “flame rod” will provide

flame monitoring for the remainder of heat cycle. If the flame is extinguished during this cycle, the ignitor will start sparking

automatically in an attempt to re-establish the flame. If this does not occur within the “Trial for ignition period,” the system will go

into lockout, closing the gas valve.

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TROUBLESHOOTING

Although the following tests can be made using standard volt meter, it is quicker and more convenient to use a Fenwal

Model 05-125539-001 Test Adapters.

PRELIMINARY CHECKS

1. Input Polarity

If a spark is present and the gas valve opens for the flame establishing period but then locks out

to ten seconds, check the input voltage at Terminals 1 and 6 for the proper polarity. Terminal 1 should be “hot”; 14AVC

(05-16) with respect to ground. Terminal 6 is neutral, or zero voltage, with respect to ground.

at the end of other

2. Improper Grounding

If a flame is present during the Trial for Ignition period but th system shuts down, insure that the burner is properly

grounded. If the burner is not grounded, the flame monitoring signal will not function and the system will go into lockout.

Check for loose or corroded terminals and replace if necessary. Insure good electric connection by scraping paint or any

other foreign matter off the area where ground connection is made.

It is equally important to be certain that the electrode bracket assembly is properly grounded. The bracket should be

common with the ground lead on the input connector (ground terminal 6). If the bracket is not properly grounded,

damage to the ignitor can result.

3. Inoperative High Voltage

If there is no spark or sparking is intermittent, check the following after disconnecting voltage to the system.

a. Check spark gap. Gap should be 1/8 (3.175mm)+/- 1/32”(.7937mm) form H.V. to ground.

CAUTION: NEVER REPLACE THE COMPONENT BOARD WITHOUT FIRST CHECKING TO INSURE THAT THE

ELECTRODE HAS THE PROPER GAP. IF THE GAP IS TOO WIDE, DAMAGE TO THE IGNITOR CAN RESULT.

b. Check electrode leads and determine there is no corrosion at the terminals. If there is corrosion, clean it off.

c. Check ceramic insulators for cracks, foreign matter, and carbon. If there are cracks, replace electrodes. If there is

carbon or foreign matter, clean it off.

d. Check high voltage lead wire for cracks or breaks. If there are cracks, breaks or chaffing, replace high voltage wire.

e. Check that the high voltage lead wire is not too close to a metal surface to insure that arcing will not occur at any

point other than across the H.V. electrode. Also, insure that the high voltage lead wire is not taped or connected to a

metal frame along its length, sharp metal edges, or crossing, do not bundle with other wires. Always leave one inch

spacing between the high voltage lead wire and any other metal or wires.

f. For best operation, the high voltage wire should be short as possible and should not exceed 23 inches (584.2 mm) in

length.

g. Check to insure that the high voltage terminal is clear of dust, moisture or any foreign matter that could create high

voltage leakage to ground.

4. Valve Malfunction

With power applied to the ignitor, sparking should occur and the solenoid valve should open simultaneously. If sparking

occurs but the valve does not open, place a volt meter between Terminal 4 on the input connector and ground (or across

valve). (terminals 4 (valve) and 6 (ground) in Figure 1). If voltage is present and the valve does not open, remove wires

from the valve terminals and retest the valve on a known voltage source. If valve still does not function, it should be

replaced. If the voltage is not present at Terminals 4 and 6, the ignitor should be replaced. Check p.c. connection area.

(clean with soft rubber eraser only). Also, check the terminals in the plastic connector for good contact.

The valve relay is rated for 24VAC on th 05-16, at .5 amps. If a valve is used with a higher current rating than that

specified, damage can result to the relay contacts.

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. This signal is a small DC current

which can be measured directly with a 0 to 50 microamp meter.

Although the minimum flame current necessary to keep the 05-16 ignitor from going into lockout is 2.5 ,microamps, the

lowest recommended is 5.0 microamps. These ignitors can stand flame currents as high as 30 to 40 microamps.

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To measure flame current, first shut off the power to the system and then remove the flame sensing lead wire form the

electrode terminal and insert a 0-50 DC microamp meter in series with the sensor electrode and the sensor lead wire. “Plus”

terminal of meter to component board and “negative”: terminal to sense electrode. Energize the ignitor. If the meter reads

below zero, shut the system off and reverse meter leads.

Once the flame is established, assure that the flame current is above the minimum specified. If not, assure that the system

has the proper input voltage, and ten relocate the sensor electrode in the flame pattern until flame current is increased.

Once the flame has been established and the system is in its heat cycle, occasional sparking may occur. This is common in

some installations and is not significant. Sparking will not damage the ignitor.

7. Ambient Temperatures

The 05-16 is designed to operate over the temperature range of -40 to 150 F (-40 to 65.56 C). Care should be taken to

insure that it operates within this range. If these limits are exceeded, the ignitor should be relocated to an area that is

within this temperature range.

8. Relative Humidity

The 05-16 is coated for moisture resistance to 90 percent relative humidity. Caution should be taken to protect the

component board against direct exposure to water.

SERVICE HINT, DIAGNOSIS AND CORRECTIVE MEASURES

WHAT’S WRONG

WHY

WHAT TO DO

1. Lockout Occurs 3-10

seconds after ignition.

1. Reverse polarity.

Para. 1.

Para. 2.

Check to ensure input pressure

as specified on manufacturer’s

data plate.

2. System improperly grounded

3. Gas pressure too high, causing

flame to lift off burner.

4. Sensor probe incorrectly

positioned in flame pattern.

Spark gap too small.

Spark too large.

Corroded connector.

1. Cracked or dirty insulator.

Para. 6.

2. Flame not established.

Arching to ground.

3. No spark.

Para. 3a

Para. 3a.

Para. 3b.

Para. 3c.

4. Arching other than across gap.

2. Broken high voltage lead.

High voltage lead too close to

metal surface.

Para. 3c.

Para. 3e.

Weak Spark.

No flame.

Valve malfunction.

Electrode improperly placed.

Para. 4.

Para. 5.

Low flame current and/or

nuisance lockouts.

Nuisance lockouts.

1. Flame current falls below 2.5 uA

2. Low gas pressure.

Para. 6.

Check to ensure that manifold

pressure meets manufacturer’s

specifications.

WIRING DIAGRAM

HONEYWELL S87KDI SYSTEM

WIRING DIAGRAM

LADDER FORM

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No.

Req’d

Part

No.

Description

Air Tube & Housing Assy. 5” (127mm) Burner

Air Tube & Housing Assy. 8” (203.2mm) Burner

Air Tube & Housing Assy. 11” (279.4mm) Burner

Air Tube & Housing (F) 5” (127mm) Burner

Air Tube & Housing (F) 8” (203.2mm) Burner

Air Tube & Housing (F) 11” (279.4mm) Burner

Adjustable Flange

62715-001

62715-003

62715-005

62715-002

62715-004

62715-006

21756-011

60214

•

Mounting Pedestal

Pedestal Mounting Bracket

Motor/Blower Assembly

60215

60172-002

60944

Venturi w/o Flame Spreader

Venturi with Flame Spreader

Control Box/Strap Assembly

Control Box Cover

61403

•

62903-001

62899-001

62653-001

63228-001

63062-001

62249-002

60195

•

Pilot Shield

Pilot Burner

•

Ignition Cable

Pilot Tube 5” (127mm) Burner

Pilot Tube 5” (127mm) Burner EP

Pilot Tube 8” (203.2mm) Burner

Pilot Tube 8” (203.2mm) Burner EP

Pilot Tube 11” (279.4mm) Burner

Pilot Tube 11” (279.4mm) Burner EP

Spark Generator Bracket

•

62320-002

62320-003

63212-001

62901-001

61770-002

60187

•

Air Shutter Body (Stationary Part)

Air Shutter Disk (Moveable Part)

Motor relay

•

Transformer 120/24V

60186-003

61455

Bulkhead Union

Thermocouple 5” (127mm) Burner

Thermocouple 8” (203.2mm) Burner

Thermocouple 11” (279.4mm) Burner

Venturi Spacer 8” (203.2mm) Burner`

Venturi Spacer 11” (279.4mm) Burner

Venturi Mounting Bolt 5” (127mm) Burner

Venturi Mounting Bolt 8” (203.2mm) Burner

Venturi Mounting Bolt 11” (279.4mm) Burner

Orifice - Natural Gas

60154

•

60987

60280

60252

•

61054

60072

60083

60085

see chart

Pg. 15

Orifice - L.P. Gas

Orifice Holder Assy. 5” (127mm) Burner

Orifice Holder Assy. 8” (203.2mm) Burner

Orifice Holder Assy. 11” (279.4mm) Burner

Elbow - 1/2” (12.7mm) Pipe - Black Iron

Valve Spring Kit

60155

•

60249

60250

60001

62672-004

60013

Nipple - 1/2” (12.7mm) Pipe - Special

Piezo Ignitor

•

63213-001

63217-001

63217-002

63217-003

60182

•

Ignitor Wire 5” (127mm) Burner

Ignitor Wire 8” (203.2mm) Burner

Ignitor Wire 11” (279.4mm) Burner

Gas Valve Cord Assy.

•

Pilot Orifice - (Natural Gas) .024 (.610mm)

Pilot Orifice - (L.P. Gas) .018 (.457mm)

Gas Valve - (Standing Pilot)

Gas Valve - (Electronic Pilot)

Ignition Control - S8600

60680-002

60680

•

60270-002

62246-004

62243-003

62947-001

63646-002

60645

•

Ignition Wire

Pilot Bracket

•

Feeder Tube

Electronic

63210-001

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No.

Req’d

Part

No.

Description

Control Box Assembly

Power Cord Assembly

Transformer

62296

60182-002

60186-003

60187

•

Relay

Control Box Cover

Motor and Blower Assembly

Air Shutter Stationary Part

Air Shutter Disc

62899-001

60172-002

61874

61770-002

62715-003

63228-001

63062-001

See Chart

Pg. 15

Air Tube and Housing Assembly

Pilot Burner

Pilot Burner with Ignitor/Sensor

Orifice - Natural Gas

•

Orifice - L.P. Gas

Pilot Orifice (Natural Gas) .024 (.610mm)

Pilot Orifice (L.P. Gas) .018 (.457mm)

Thermocouple

60680-002

60680

•

60987

Flame Spreader Assembly

Piezo Ignitor

61818

•

63213-001

60270-002

60246-004

62243-003

63212-001

62672-004

63220

Gas Valve - (Standing Pilot)

Gas Valve - ( Electronic Pilot)

Ignition Control

•

Spark Generator Bracket

Valve Spring Kit

•

Valve Spring Kit

•

Lead Wire Assembly - Ignitor

Ignitor Wire

62947-001

63217-004

62261

Electrode Assembly UL

Gas Valve (Direct Ignition)

Ignition Cable - High Voltage

Ignition Cable - DI

•

62374-002

61987

61990

Wire Assembly - Low Voltage

61986

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PARTS LIST - P265/P265F SERIES GAS BURNERS

Qty

Part No.

Description

Req’d

62903-001

60182-002

60186-004

100986-002

62899

Control Box/Strap Assembly

•

Power Cord Assembly

•

Transformer - 24V

•

Relay

•

Control Box Cover

•

60172-002

620901-001

61770-002

62715-001

62715-003

62715-005

62715-002

62715-004

62715-006

62715-007

21724-011

100428-002

21760-011

60270-002

62246-004

62374-004

62898-001

60249

Motor/Blower (inch end switch)

Air Shutter - Stationary Position

Air Shutter - Disc

•

Air Tube/Housing Assembly

Adjustable Flange w/Gasket

Flange Gasket

5” (127mm)

8” (203.0mm)

11”(279.4mm)

5”(127mm)

8” (203.0mm)

11”(279.4mm)

5”(127mm)

8” (203.0mm)

11”(279.4mm

5” (127mm)

8” (203.0mm)

11”(279.4mm)

5” (127mm)

8” (203.0mm)

11”(279.4mm)

5” (127mm)

8” (203.0mm)

11”(279.4mm)

•

Base Assembly

Gas Valve - Standing Pilot

Gas Valve - EP Pilot

•

Gas Valve - Direct Spark (DI)

Orifice Holder - 5” (127mm) Units

Orifice Holder - 8” (203.2mm) Units

Orifice Holder - 11” (279.4mm) Units

Orifices - Natural gas

•

60250

See Chart

61455

•

Orifices - LP gas

Bulkhead Union

63432-001

60944

Venturi - Less Fixed Flamespreader

Venturi - With Fixed Flamespreader

Thermocouple-5” (127mm) & 8” (203.2mm) Units

Thermocouple - 11” (279.4) Units

Pilot Burner

61403

•

61637-003

60987

•

60280

63228-001

63062-001

60680-002

60680

Pilot Burner

•

Pilot Orifice - Natural gas

Pilot Orifice - LP gas

•

63210-001

63212-001

62261-002

61818

Electrode Assembly - Piezo System

Electrode Bracket - Piezo

Electrode Assembly - DI

Flamespreader

•

62243-003

101243-001

63213-001

63217-003

62947-003

63375-001

62955-001

62956-001

Control - EP Pilot

Control - Direct Spark (DI)

Spark Generator - Pushbutton Piezo

Ignitor Wire - Piezo Electrode

Ignition Wire Assembly

•

Wire Set

Burner Conversion Kit - Nat to LP

Burner Conversion Kit - LP to Nat

•

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PARTS LIST - P250AF SERIES GAS BURNERS

No.

P250AF

P250AF EP

P250AF DI

Part No.

Description

Req’d

62903-001

60182-002

60186-004

100986-002

62899

Control Box/Strap Assembly

•

Power Cord Assembly

Transformer-24V

•

Relay

Control Box Cover

60172-002

62901-001

61770-002

62715-003

63228-001

63062-001

62261

Motor/Blower (inch end switch)

Air Shutter - Stationary Portion

Air Shutter - Disc

Air Tube/Housing Assembly

Pilot Burner

•

Electrode Assembly - DI

Orifices - Natural gas

Orifices - LP gas

•

62261-002

See Chart

60680-002

60680

•

Pilot Orifice - Natural gas

Pilot Orifice - LP gas

Thermocouple

•

60987

61818

Flamespreader

•

63213-001

60270-002

62246-004

62374-004

62243-003

101243-001

63212-001

62955-001

62956-001

63217-004

62947-003

63375-001

Piezo Spark Generator

Gas Valve - Standing Pilot

Gas Valve - EP Pilot

Gas Valve - Direct Spark (DI)

Control - EP Pilot

•

Control - Direct Spark (DI)

Spark generator

•

Burner Conversion Kit - Nat to LP

Burner Conversion Kit - LP to Nat

Ignitor Wire - Piezo Electrode

Ignition Wire Assembly

Wire Set

•

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Notes

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WAYNE COMBUSTION SYSTEMS

801 GLASGOW AVE.

FORT WAYNE, IN 48803

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. ALL GAS BURNERS manufactured by

“WAYNE” will be similarly warranted for eighteen(18) months from date of manufacture except where original

manufacture offers a greater warranty. (Reference #6 below) THESE LIMITED WARRANTIES DO NOT APPLY

UNLESS THE BURNER COVERED BY IT IS PROPERLY INSTALLED BY A QUALIFIED, COMPETENT

TECHNICIAN, WHO IS LICENSED WHERE STATE AND/OR LOCAL CODES PREVAIL, AND WHO IS

EXPERIENCED IN MAKING SUCH INSTALLATIONS, IN ACCORDANCE WITH NFPA #31 OF THE NATIONAL FIRE

PROTECTION ASSOCIATION AND IN ACCORDANCE WITH ALL LOCAL, STATE AND NATIONAL CODES.

Any IN-WARRANTY burner component which is defective in material or workmanship will be either repaired or

replaced as follows:

1. Fuel units, motors, transformers, gas valves, and controls should be returned to an authorized service station or

distributor of WAYNE for determination of applicability of this LIMITED WARRANTY as to either repair or

replacement, where said service station or distributor is reasonably available in the customer’s locality. The

manufacturers of burner components regularly publish and distribute listings showing the locations of their network

of service stations. Where such local service is NOT available for the burner components described above or other

burner parts are involved, these items should be returned, freight prepaid, to WAYNE Service Department, 801

Glasgow Ave, Fort Wayne, Indiana 46803.

2. Burners and/or component(s) determined to be covered under this LIMITED WARRANTY by WAYNE shall be

repaired or replaced at WAYNE’s sole option.

3. WAYNE is not responsible for any labor cost for the removal and replacement of said burner or burner components

and equipment associated therewith.

4. A burner so repaired will then carry the LIMITED WARRANTY equal to the unexpired portion of the original

burner LIMITED WARRANTY.

5. If inspection by WAYNE does NOT disclose any defect covered by this LIMITED WARRANTY, the burner or

burner component(s) will be either repaired or replaced at the expense of the customer and WAYNE’s regular

charges will apply.

6. If the original manufacturer of a burner component offers a warranty greater than either of our LIMITED

WARRANTIES described above, then this portion will be added to our LIMITED WARRANTY.

This LIMITED WARRANTY does NOT cover products which have been damaged as the result of accident, abuse,

misuse, neglect, improper installations, improper maintenance or failure to operate in accordance with WAYNE’s

written instructions.

These LIMITED WARRANTIES do not extend to anyone except the first purchaser at retail and only when the burner

is in the original installation site.

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE SHALL BE

LIMITED TO THE DURATION OF THE LIMITED EXPRESS WARRANTIES CONTAINED HEREIN. WAYNE

EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES

OF ANY NATURE FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY.

Some states do not allow limitation on how long an implied warranty lasts, so the above limitation may not apply to you.

Also, some states do not allow the exclusion or limitation of incidental or consequential damages, so the above

limitation or exclusion may not apply to you. WAYNE neither assumes or authorizes any person to assume for WAYNE

any other liability or obligation in connection with the sale of these products. This warranty gives you specific legal

rights, and you may also have other rights which vary from state to state.

MSR & MSR-DC 22019-003 Rev. C 08/15/00

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