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THESE INSTRUCTIONS SHOULD BE AFFIXED TO THE BURNER OR ADJACENT TO THE

HEATING EQUIPMENT.

Overview of Safety Warning System and Your Responsibilities

The safety of you and others depends upon you thoroughly reading and understanding this manual. If you have questions
or do not understand the information presented in this manual,

please call Wayne Combustion Systems or see

www.waynecombustion.com

.

Hazard Definitions:

Indicates a hazardous situation, which, if not avoided,

will

result in

death or serious bodily injury.

Indicates a hazardous situation, which, if not avoided,

could

result in

death or serious bodily injury.

Indicates a hazardous situation, which, if not avoided

may

result in

minor or moderate bodily injury.

Indicates a situation that

may

result in equipment-related damage.

This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. The meaning of this safety alert symbol is as follows: Attention! Become
alert! Your safety may be at risk. The message that appears next to the warning
describes the hazard, which can be either written or pictorially presented. NEVER
remove or tamper with the warning labels, safety devices or guards fitted on the unit.

Wayne Combustion Systems is NOT responsible for any bodily injury and/or property
damage that may result from operation outside of the stated operating conditions for
which this unit was intended.

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Содержание EHASR-DC

Страница 1: ...uels Use No 1 or No 2 heating oil ASTM D 396 Kerosene Diesel ASTM D975 18 JP8 Dimensions Standard Height 12 1 2 Width 15 1 2 Depth 11 1 2 Center Line of Tube to Floor 8 1 16 Mounting Rigid Flange Adjustable Flange or Pedestal Mount READ THIS MANUAL BEFORE USING THIS PRODUCT FAILURE TO FOLLOW THE INSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH KEEP THIS MANU...

Страница 2: ...l Pressure psi CO2 Smoke Spot CO PPM INSTALLER S NAME CONTRACTOR NAME CONTRACTOR ADDRESS CONTRACTOR PHONE NUMBER CONTRACTOR LICENSE DATE OF INSTALLATION COMMENTS ABOUT INSTALLATION START UP BURNER EQUIPMENT SERVICE LOG SERVICE DATE TECHNICIAN COMPANY ADDRESS CONTRACTOR LICENSE WORK PERFORMED ...

Страница 3: ...or serious bodily injury Indicates a hazardous situation which if not avoided may result in minor or moderate bodily injury Indicates a situation that may result in equipment related damage This is the safety alert symbol It is used to alert you to potential personal injury hazards The meaning of this safety alert symbol is as follows Attention Become alert Your safety may be at risk The message t...

Страница 4: ...quires specialized equipment Allow only qualified burner service persons to adjust the burner Special instruments and training are required Read the burner manual before using CARBON MONOXIDE POISONING Early signs of carbon monoxide poisoning are similar to the flu with headaches dizziness weakness nausea vomiting sleepiness and confusion If you suspect carbon monoxide poisoning get outside to fre...

Страница 5: ... BURNERS WITH WAYNE 12Vdc OIL PRIMARY CONTROL 101382 002 19 SEQUENCE OF OPERATION BURNERS WITH WAYNE 12Vdc OIL PRIMARY CONTROL 101382 003 20 SEQUENCE OF OPERATION BURNER WITH DROP OUT TIMER 20 SEQUENCE OF OPERATION BURNER WITHOUT CONTROL OR DROP OUT TIMER 21 OPERATIONAL CHECK OF BURNER 21 START SYSTEM 21 CHECK SAFETY FEATURES 21 GENERAL INSTALLATION INFORMATION 22 COMBUSTION CHAMBER 22 FUEL PUMPS ...

Страница 6: ...ATION This manual is organized so that the licensed contractor can troubleshoot the burner by working through the GENERAL TROUBLESHOOTING GUIDE on page 7 The GENERAL TROUBLESHOOTING GUIDE is organized by the performance issue or problem requiring attention Each problem will list potential root causes that may result in the problem listed in order from most likely to least likely and the solution t...

Страница 7: ...POSSIBLE CAUSE SOLUTION BURNER WILL NOT LIGHT Little or no fuel Fill tank with fuel Improper fuel or water in fuel Drain fuel tank and fill with proper fuel Limit switch open Close flow switch or thermostat switch and check flow switch for proper cycling operation Improper electrode spacing gap too small or too large Clean and position electrode tips according to Figure 15 on page 27 or Figure 16 ...

Страница 8: ... for proper arc between contacts Replace as needed See Figure 1 on page 13 for replacement part Disconnected or short in electrical wiring All wire contacts should be clean and tight No breaks in wire insulation replace as needed See page 23 for wire size recommendations Oil primary control sees light during safety check and remains in standby mode Applicable only if burner comes with oil primary ...

Страница 9: ...er s specifications See Figure 25 on page 36 for pump features Replace pump if needed Soot build up on heat exchanger Clean heat exchanger with soot remover Improper burner nozzle installed nozzle size too small Contact equipment manufacturer for proper nozzle size and replace See page 23 for instructions BURNER RUNS BUT EQUIPMENT IS OVERHEATING Fuel pump pressure too high Readjust fuel pressure t...

Страница 10: ... There should be 14 volts or higher at the battery and investigate equipment wiring for any crack or tears in the wire insulation 3 Check LED light on 101382 control 101382 red LED flashes for 2 seconds followed by one short 0 5 second flash Sees external light during safety check or connections are shorted 4 Shield cad cell from external light Identify control model number Energize white thermost...

Страница 11: ...ound connector on battery and energize burner If burner does not stay running replace control 4 Check that nozzle size is per equipment manufacturer s recommendation Burner nozzle incorrect Change nozzle and fuel pressure to factory settings and retest if burner doesn t stay lit go to step 5 Burner nozzle correct Go to step 5 5 Check that burner air band setting is set up per manufacturer recommen...

Страница 12: ...r view of flame Place cad cell back in socket Re energize burner Burner locks out Go to step 7 Burner keeps running until call for heat is satisfied System is okay 7 Check Control Cad cell Remove cad cell wires from connectors on the oil primary control and leave lead wires unconnected Energize burner Place jumper across cad cell terminals after burner motor turns on Burner doesn t run Replace pri...

Страница 13: ...13 Figure 1 Burner Components Models EH DC and EHASR DC ...

Страница 14: ...21B1 Stainless SR 3A 14159 11 Air Band Inner 8 Sot 2669 002 2669 002 Stainless SR 4A 14160 12 Air Band Outer 8 Slot 2668 002 2668 002 22 Gasket 12484 12484 13 Coupling MOD E 101320 001 101320 001 23 Junction Box See NOTE Below 14 Oil Line Assembly 14452 14452 Not Shown Pedestal 2794 011 2794 011 15A 3 Pump A2VA 7116 13495 Pump A2YA 7916 14375 15B 2 Pump A2VA 3006 12Vdc SOL 101128 011 NOTE STATE SP...

Страница 15: ...n Replacement Parts No Part Description EH DC EHASR DC 1 Nozzle Adaptor Flame lock Tripod Assembly 100427 SER 12988 002 2A Stamped Stabilizer Support Kit 21923 001 21923 001 2B Cast Stabilizer Support Kit 21408 SER 21408 SER 3 Stem Insulator Kit 13286 13286 4 Oil Pipe Fitting 14295 002 14295 002 1 3 2B 4 1 2A 3 4 ...

Страница 16: ...ING DIAGRAMS Figure 3 Wiring Diagram for EH DC and EHASR DC burner with Wayne 12Vdc Oil Primary Control Figure 4 Wiring Diagram for 12Vdc EH DC EHASR DC burner with Igniter Drop Out Timer Interrupted Ignition ...

Страница 17: ...th one of three different timings and features The 101382 001 is the standard control the 101382 002 is designed for quick starts when used on a pressure washer and the 101382 003 is equipped with a post purge feature see sequence of operation for details on each one All oil primary controls are potted and sealed to protect against harsh operating environments The oil primary control has built in ...

Страница 18: ... wire the burner solenoid is de energized and the motor will perform a 30 second post purge before shutdown If the presence of a flame is not detected during the trial for ignition the oil primary control will go into a lock out condition If this occurs proceed to the section titled SAFETY LOCK OUT TIME SAFETY LOCK OUT TIME Ignition failure occurs during the first trial for ignition period The cad...

Страница 19: ... the presence of a flame is not detected the oil primary control will go into a lockout condition When the oil primary control goes into lockout it will de energize the burner and the control s red LED light on the bottom of the control will flash for 2 seconds followed by five short 0 5 second flashes The red LED will repeat this sequence until the control is reset Remove power from the white com...

Страница 20: ...owed by five short 0 5 second flashes The red LED will repeat this sequence until the control is reset Remove power from the white command wire for 2 seconds to reset the control If normal ignition does not occur see GENERAL TROUBLESHOOTING GUIDE on page 7 Intermittent flame failure occurs during a call for heat If the oil primary control stops sensing the presence of a flame after the signal has ...

Страница 21: ... FEATURES Simulate flame failure Follow starting procedures to turn on burner Close hand valve on supply line stopping fuel delivery to the burner The oil primary control should lockout after control s trial for ignition timer expires The burner blower motor and ignition device should stop and the solenoid valve should close Simulate ignition failure Close hand valve on supply line stopping fuel d...

Страница 22: ...o high gas exhaust temperatures and lower combustion efficiency Install the burner according to the equipment manufacturer s guidelines FUEL PUMPS Model EHASR DC and EH DC oil burners are provided with single stage 3450 RPM fuel pumps with the by pass plug removed for a single pipe installation This is satisfactory where the fuel supply is on the same level or above burner permitting gravity flow ...

Страница 23: ...spray angle of 80 70 or 60 degrees Generally the use of an 80 degree solid nozzle is a good starting point Always use the proper nozzle size spray cone type and spray angle the equipment manufacturer recommends Should this information not be available your own good judgment will prevail Under no circumstances attempt to fire the EHASR DC oil burners under their 0 75 gal hr minimum input rating or ...

Страница 24: ...e way Figure 8 on page 24 Note For pumps with combination solenoid valves disconnect the oil line from the brass elbow fitting installed in the nozzle port of the pump Figure 8 Oil Line Assembly Fitting 2 Loosen and disconnect the brass nut of the copper oil line assembly from the oil gun assembly fitting and rotate the oil line out of the way Figure 9 Figure 9 Oil Line Removal ...

Страница 25: ...ing plate this will allow the igniter device assembly to swing open to the left Leave the plate in the closed position Figure 10 Figure 10 Ignitor mounting plate screw removal 4 Using a 9 16 inch wrench loosen and remove the oil gun assembly locknut Figure 11 Figure 11 Oil Gun Lock Nut Removal Hold down clip Motor Flange Hold down clip ...

Страница 26: ...d pull the oil gun to the right out of the housing slot and the slot plate cover Figure 12 Figure 12 Oil Gun Removal 6 While rotating the oil line fitting adapter up at a 45 degree angle gently lift but do not force the entire gun assembly out of the housing opening Figure 13 Figure 13 Oil Gun Removal Continued ...

Страница 27: ...ed up Figure 14 Figure 14 Oil Gun Nozzle Installation Flamelock and electrodes removed for clarity 8 Identify which burner model you have then measure and verify that the electrode spacing is per Figure 15 or Figure 16 on pages 27 28 if not correct to factory settings Figure 15 EH DC Electrode Positions Factory settings DO NOT touch the new nozzle s filter or touch the face of the nozzle Oil from ...

Страница 28: ...ectrodes gap after installing gun assembly in burner to verify that the position has not shifted SETTING GUN DEPTH For the oil burner to function properly the distance between the nozzle and the air cone needs to be maintained as shown in Figure 17 Figure 18 on pages 28 29 Suggested startup setting EH DC Flamelock 1 8 ahead of cast iron cone face for 3 00 to 4 50 gal hr or ahead for 4 50 to 6 00 g...

Страница 29: ...Oil Gun Depth Adjustment 3 Once in the required position per Figure 17 and Figure 18 retighten the hex lock nut and slot cover screw move and align arrow decal with slot plate cover Close the ignition transformer and assure there is a positive spring contact with the brass buss bars Take care not to pinch the ignition transformer lead wires between the housing and cover plate Reinstall the igniter...

Страница 30: ... the air band until black smoke is eliminated on start up see Figure 20 Figure 20 Air Band Adjustment Screw Location Once black smoke is eliminated measure the air band open according to Figure 21 with a ruler and mark it down in the notes of this manual for the next service Figure 21 Air Band Opening Open the ignition device mounting plate and turn on the burner switch if one is present Next blee...

Страница 31: ...pump is set up in two pipe operation with the by pass plug installed bleeding the pump is not necessary 1 Slide a 1 8 Vinyl hose on the bleeder valve as shown in Figure 23 and route the hose into a small container Figure 23 Bleeder hose location Bleeder Valve ...

Страница 32: ...ween 10 12 for most applications and CO should be minimized with a goal of 250 ppm or less In no case should CO be above 400 ppm The burner should be started and stopped several times to assure good operation Open ignition device mounting plate unplug solenoid valve lead and check the oil primary control if equipped for normal operation see Check operation of flow switch and thermostat Check for o...

Страница 33: ...this manual Replace electrodes if worn excessively or if electrode insulator is oil soaked or cracked Fan and Blower Housing This must be kept clean free of dirt and lint open transformer to check fan blades from above Be sure the electric power is off on burner when the transformer is opened up for this inspection Components If replacement of a burner component becomes necessary always use parts ...

Страница 34: ...5 73 0 7 5 70 0 68 5 10 5 85 5 84 0 82 5 81 0 79 5 78 0 76 5 75 0 73 8 72 0 70 5 69 0 67 5 10 85 0 83 5 82 0 80 5 78 8 77 3 75 8 74 3 72 8 71 0 69 5 68 0 66 3 9 5 84 5 83 0 81 5 79 8 78 0 76 5 75 0 73 3 71 8 70 0 68 3 66 8 65 0 9 84 0 82 3 80 8 79 0 77 3 75 8 74 0 72 3 70 8 68 8 67 0 65 3 63 5 8 5 83 5 81 8 80 0 78 3 76 5 74 8 73 0 71 3 69 3 67 5 65 5 63 8 62 0 8 83 0 81 0 79 3 77 5 75 5 73 8 71 8...

Страница 35: ...2 2 50 17 14 x 16 14 5 1 2 3 00 15 1 2 x 15 1 2 17 1 2 13 x 18 1 2 14 7 EH Only Cast iron air cone P N 13003 3 00 15 1 2 x 15 1 2 17 1 2 13 x 18 1 2 14 7 3 50 17 3 4 x 17 3 4 20 15 x 23 15 7 1 2 4 00 19 x 19 23 1 2 16 x 22 1 2 16 8 4 50 20 x 20 17 x 23 1 2 17 8 1 2 Cast iron air cone P N 101366 001 5 00 23 1 4 x 23 1 4 18 x 25 18 9 6 00 24 x 1 2 x 24 1 2 23 x 28 1 2 20 10 Chamber size not recommen...

Страница 36: ...36 REFERENCE FIGURES Figure 25 Pump Feature Identification Figure 26 Blower Wheel Spacing ...

Страница 37: ...ants 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 manufactur...

Страница 38: ...38 NOTES ...

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