Installation of burner installation of the burner must be done by a qualified installer in accordance with regulations of the national fuel gas code ansi z223.1/nfpa 54, and in complete accordance with all local codes and authorities having jurisdiction. Incorrect installation, adjustment, or misuse...
2 installation log burner model: specification number: fuel (natural or propane): gas orifice drilled size: inlet gas pressure (in. W.C.): co 2 (%): o 2 (%): co (ppm): installer’s name: contractor name: contractor address: contractor phone number: contractor license #: date of installation: comments...
3 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 an...
4 contents page section i installation and setup………………………………………………………………………………………. A. Visual inspection of the heating system………………………………………………………………….. B. Inspection of flue pipe and chimney………………………………………………………………………… c. Inspection of heating appliance…………………………………………………………………………….. D. Flue pipe, ...
5 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 w...
6 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 conve rsion bur...
7 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...
8 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 ac cess openin...
9 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 ...
10 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 ...
11 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 sq. Inches (cm 2 ) preferred width and...
12 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 completel...
13 lp gas is heavier than air and will settle in low lying areas such as combustion chambers or heat exchangers. All connections should be checked for leaks using a soapy solution applied to gas connections. Determine orifice size and rate the gas conversion burner needs to be set to deliver the sam...
14 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 cub...
15 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 sid...
16 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 m...
17 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 ch...
18 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.. Maximum capacity of tube size in btu per hour pipe size 1/2” 5/8” 3/4” 7/8” length (feet) maximum capacity in btu/hr 10 110,000 206...
19 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 wi...
20 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 ap...
21 operation of burner (electronic pilot) (p265-ep, p265f-ep, p250af-ep) starting the burner: 1. Depress the gas valve control knob on the combination gas valve and turn to “off” (see figure 14). 2. Set room thermostat above room temperature and let burner run five minutes to purge the appliance. 3....
22 operation of burner (standing pilot) starting the burner: 1. Depress the gas valve control knob on the combination gas valve and turn to “off” (see figure 15). 2. Set room thermostat above room temperature and let burner run five minutes to purge the appliance. 3. Set thermostat below room temper...
23 combustion adjustment of burner all adjustments below must be made with the following equipment: 1. Draft gauge 3. Co tester 2. O 2 or co 2 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. Dependi...
24 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 tha...
25 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 wholes...
26 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...
27 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 certa...
28 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 w...
29 turn gas supply off, turn thermostat (controller) to call for heat power to module (24v nominal) yes spark across igniter/sensor gap turn gas supply on. Pilot burner lights? Yes spark stops when pilot is lit? Yes yes main burner lights yes yes yes system runs until call for heat ends? Call for he...
30 table 8: troubleshooting chart electronic pilot ignition (for burners utilizing fenwal control) preliminary checks, diagnosis and service hints (electronic pilot ignition) although the following tests can be made using standard volt meter, it is quicker and more convenient to use a fenwal model 0...
31 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...
32 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 bur...
33 figure 21 p 2 5 0 dir e ct ig nit io n ig nit o r p o s it io n 7 /1 6 ” (1 1 .1 m m ) + /- 1 /1 6 ” (1 .6 m m ) 1 /4 ” (6 .4 m m ) + /- 1 /1 6 ” (1 .6 m m ) 1 /8 ” (3 .2 m m ) g a p 3 1 /6 4 ” (1 2 .3 m m ) + /- 1 /1 6 ” (1 .6 m m ) 5 /1 6 ” (7 .9 m m ) 1 /8 ” (3 .2 m m ) g a p p 2 6 5 dir e ct ...
34 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 22: wiring diagrams for gas burner with direct ignition-honeywell.
35 figure 23: wiring diagrams for gas burner with direct ignition-fenwal.
36 figure 24: wiring diagrams for gas burner with electronic pilot-honeywell.
37 figure 25: wiring diagrams for gas burner with electronic pilot-no t-stat.
38 figure 26: wiring diagrams for gas burner with electronic pilot-fenwal.
39 section vi: parts list and exploded views figure 27: right side exploded view of p265f parts in exploded view 1. Gas valve 2. Air shutter 3. Motor/blower 4. Transformer 5. Model/specification label 6. Motor relay 7. Ignition control 8. Electrode/sensor/ground rod asm 9. T-t terminal 10. Orifice h...
40 4 figure 28: left side exploded view of p265f parts in exploded view 1. Gas valve 2. Air shutter 3. Motor/blower 4. Transformer 5. Model/specification label 6. Motor relay 7. Ignition control 8. Electrode/sensor/ground rod asm 9. T-t terminal 10. Orifice holder 11. Orifice 12. Flame spreader.
41 p265f parts list qty req’d p2 65 f ep n p2 65 f ep lp p2 65 f di n p2 65 f di lp p2 65 f di n bo il er b u rn er part no. Item description *note: only for firing rate of 160,000 btu/hr or less when finer adjustment at low rate is required. 60172-002 motor/blower asm (w/o control box) 1 61803 cont...
42 figure 29: right side exploded view of p250af parts in exploded view 1. Gas valve 2. Air shutter 3. Motor/blower 4. Transformer 5. Model/specification label 6. Motor relay 7. Ignition control 8. Electrode/sensor/ground rod asm 9. T-t terminal 10. Orifice holder 11. Orifice 12. Flame spreader.
43 figure 30: left side exploded view of p250af parts in exploded view 1. Gas valve 2. Air shutter 3. Motor/blower 4. Transformer 5. Model/specification label 6. Motor relay 7. Ignition control 8. Electrode/sensor/ground rod asm 9. T-t terminal 10. Orifice holder 11. Orifice 12. Flame spreader.
44 p250af parts list qty req’d p2 50 af e pn p2 50 af e pl p p2 50 af d in p2 50 af d il p part no. Item description *note: only for firing rate of 160,000 btu/hr or less when finer adjustment at low rate is required. 60172-002 motor/blower asm (w/o control box) 1 61803 control box asm (incl. Trans....
45 section vii: warranty 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 repa...
46 notes.
