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Wayne P250 Manual

Iheat system
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WAYNE COMBUSTION SYSTEMS
801 GLASGOW AVE.
FORT WAYNE, IN 46803
PHONE: (260) 425-9200
www.waynecombustion.com
Manual 64659-001| Revision A | Publication Date: 07/06/18
NOTE: Dimensions in () are informational only. English values take priority.
Electrical power supply: 120V/60Hz 1 Ph.
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 MANUAL FOR FUTURE
REFERENCE. INSTALLER: LEAVE THIS MANUAL WITH THE END USER.
INSTALLATION OF THE BURNER MUST BE DONE BY A QUALIFIED INSTALLER IN ACCORDANCE WITH REGULATIONS
OF THE NATIONAL FUEL GAS CODE ANSI Z223.1/NFPA54, AND IN COMPLETE ACCORDANCE WITH ALL LOCAL
CODES AND AUTHORITIES HAVING JURISDICTION.
A QUALIFIED INSTALLER IS THE PERSON WHO IS RESPONSIBLE FOR THE INSTALLATION AND ADJUSTMENT OF THE
EQUIPMENT AND WHO IS LICENSED TO INSTALL GAS-BURNING EQUIPMENT IN ACCORDANCE WITH ALL CODES
AND ORDINANCES.
(855) WAYNECS
(800) 443-4625
FAX: (260) 424-0904
Maximum Input
Minimum Input
Turndown
Fuels
Maximum Inlet
Pressure
Minimum Inlet
Pressure
CSA CERTIFICATE NUMBER: 1156769
iHEAT SYSTEM
P250
250,000 Btu/hr (73 kW)
15,000 Btu/hr (4.4 kW)
5:1
Natural & L.P. Gas
14" w.c. Natural
14" w.c. LP
5.5" w.c. Natural
11" w.c. LP
MOUNTING: Adjustable flange is standard.
P265
200,000 Btu/hr (59 kW)
15,000 Btu/hr (4.4 kW)
5:1
Natural & L.P. Gas
14" w.c. Natural
14" w.c. LP
5.5" w.c. Natural
11" w.c. LP

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  • Page 1 WAYNE COMBUSTION SYSTEMS 801 GLASGOW AVE. iHEAT SYSTEM FORT WAYNE, IN 46803 PHONE: (260) 425-9200 (855) WAYNECS (800) 443-4625 FAX: (260) 424-0904 www.waynecombustion.com Manual 64659-001| Revision A | Publication Date: 07/06/18 NOTE: Dimensions in () are informational only. English values take priority.
  • Page 2 INSTALLATION LOG BURNER MODEL: SPECIFICATION NUMBER: FUEL (NATURAL OR GAS ORIFICE DRILLED PROPANE): SIZE: INLET GAS PRESSURE (%): (%): CO (PPM): (in. w.c.): INSTALLER’S NAME: CONTRACTOR NAME: CONTRACTOR ADDRESS: CONTRACTOR PHONE NUMBER: CONTRACTOR LICENSE #: DATE OF INSTALLATION: COMMENTS ABOUT INSTALLATION/START UP: BURNER/APPLIANCE SERVICE LOG SERVICE COMPANY...

  • Page 3: Overview Of Safety Warning System And Your Responsibilities

    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 System or see www.waynecombustion.com.
  • Page 4 Hazard Level Pictogram Type Free Text Fire or Failure to follow safety warnings exactly could result in serious injury, Explosion death or property damage. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
  • Page 5 State of California to cause cancer or birth defects or other reproductive harm. For more information, go to www.p65Warnings.ca.gov. If any instructions in the manual are not clear, contact Wayne Combustion Systems at 1-260-425-9200 for assistance. 64659-001 REV. A 07/06/18...

  • Page 6: Table Of Contents

    CONTENTS OVERVIEW OF SAFETY WARNING SYSTEM AND YOUR RESPONSIBILITIES ..............3 DESCRIPTION OF SYSTEM AND COMPONENTS ......................7 System Description ..............................7 Component Functions ...............................7 BURNER INSTALLATION ..............................8 Mounting the Burner ..............................8 Sizing and Inspection of Gas Piping ........................10 ELECTRICAL WIRING OF BURNER ..........................

  • Page 7: Description Of System And Components

    DESCRIPTION OF SYSTEM AND COMPONENTS System Description iHEAT is an electronically controlled gas/air modulation system that can be utilized by P250 or P265 burners to provide a variable heat source for an appliance. The components of the system include: a fan-assisted gas burner, a modulating gas valve, and an electronic control module that varies the speed of the burner fan and the gas flow rate through the gas valve.

  • Page 8: Burner Installation

    BURNER INSTALLATION Mounting the Burner The burner ships with a mounting flange which grips the burner tube and has holes to bolt to the appliance. Dimensions for the flange are shown below. Burners with iHEAT are also available with all burner parts contained in an enclosure.
  • Page 9 An alternate flange with a smaller profile is used on some models per OEM specifications. The dimensions for the alternate flange are shown below. Figure 2 - Alternate Flange Dimensions 64659-001 REV. A 07/06/18...

  • Page 10: Sizing And Inspection Of Gas Piping

    Sizing and Inspection of Gas Piping GAS LEAK HAZARD Liquefied petroleum gas is heavier than air. All connections should be checked for leaks using a soapy solution applied to gas connections. Leaking gas will settle in low lying areas such as basements and trenches.
  • Page 11 Effective Length of Overall Length 2 imperfect Thread of Thread Pipe Size Inch (mm) Inch (mm) threads Inch (mm) 3/8 (9.5) 3/8 (9.525) 9/16 (14.29) 1/2 (12.7) 1/2 (12.7) 3/4 (19.05) 3/4 (19.0) 1/2 – 9/16 (14.29) 13/16 (20.64) Leave 2 end 1 (25.4) 9/16 (14.29) 1 (25.4)
  • Page 12 Pipe Sizing Chart for Liquid Propane (11” w.c.) with Straight Schedule 40 Metal Pipe The following chart is based on 11” w.c. inlet pressure and a pressure drop of 0.5” w.c.. Special use: Piping sizing between single or second stage (low pressure regulator) and appliance. Maximum Capacity of Pipe Size in Btu per Hour Pipe Size 1/2”...

  • Page 13: Electrical Wiring Of Burner

    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 test dial and allowing 5 minutes to show any movement, or by soaping each pipe connection and watching for bubbles.

  • Page 14: Setup

    SETUP Proper setup of the burner system requires: 1. Installing the proper orifice 2. Setting the air shutter 3. Calibrating the blower 4. Setting the dip switches on the control board 5. Adjusting the modulating valve The orifice, air shutter, and dip switches may all be set before installation. Adjusting the modulating valve and calibrating the blower require that power be connected to the burner system and gas be connected to the inlet pipe.
  • Page 15 Table 5 - Orifice Sizes and Approximate Air Shutter Settings to Achieve a Given Firing Rate Natural gas Propane gas Letter/ Letter/ Decimal Decimal (in.) shutter (in.) shutter Btu/hr Number Btu/hr Number 0.50 0.25 50,000 0.1250 50,000 0.0820 0.50 0.50 60,000 0.1285 60,000...

  • Page 16: Calibrating The Blower

    Air Shutter Use Table 5 to determine the general air shutter setting based on the orifice size. Use a ¼” wrench to loosen the screw on the shutter’s numerical scale. Position the shutter so that the center of the screw lines up with the desired number on the scale, then re-tighten the screw.

  • Page 17: Dip Switches

    Dip Switches Note: When power is first applied to the iHEAT control system, a 30 second delay will occur before the system will initiate an attempt to light the burner. No gas will flow during this wait time. The dip switches at the bottom right corner of the iHEAT board allow changes to the board’s configuration to be made in the field without reprograming, including switching from natural gas to propane.
  • Page 18 To measure the pressure:  Locate the appropriate pressure tap: The pressure taps are on top of the valve near the modulating coil (see illustration). The manifold pressure is measured from the tap nearest to the valve outlet. The other tap can be used to check inlet pressure.

  • Page 19: Final Steps Of Setup

    To set the low pressure setting:  Determine the recommended manifold gas Natural gas Propane gas pressure setting based on the table at right. Low pressure setting 0.2" w.c. 0.8" w.c.  Locate the 5mm low pressure adjustment Table 10 - Recommended Manifold Pressure Settings nut.

  • Page 20: Sequence Of Operation

    SEQUENCE OF OPERATION On a call for heat, the ignition control’s diagnostic LED will flash rapidly while the ignition control begins sparking. After successful ignition, the LED will light green and remain lit as long as a flame is detected. If the burner fails to light, the control will wait for the interpurge time, then spark again.

  • Page 21: Diagnostic Lights

    Diagnostic Lights The iHEAT control provides 5 diagnostic lights that display the status of the iHEAT system and aid in diagnosing possible system component problems during the repair process. The lights and their functions are: Flash – Flashing light indicates the control is functioning properly. T-input –...

  • Page 22: Troubleshooting Guide

    TROUBLESHOOTING GUIDE Lights Possible Symptom Corrections Flash T-Input Valve Blower 24V/Cal 1. Check to make sure burner switch is on. 2. With burner switch on, check for 120 volts across L1 and Neutral terminals; repair if necessary. 3. With burner switch on, check for 24 volts across 24Vac terminals;...
  • Page 23 Lights Possible Symptom Corrections Flash T-Input Valve Blower 24V/Cal 1. Check wiring connections at RELAY COM and RELAY N.O. terminals. 2. Check wiring connections on ignition control. Verify 24 Vac input to ignition control and 24 Vac at valve terminals on ignition control during call for heat.

  • Page 24: Service Information

    Lights Possible Symptom Corrections Flash T-Input Valve Blower 24V/Cal Appliance runs, oven 1. Verify proper gas orifice size for temperature at or desired firing rate and type of gas. near t-stat set point, Flash 2. Check low pressure setting of slowly increases modulating gas valve;...

  • Page 25: Electrode Position - Factory Setting

    Electrode Position – Factory Setting 1/4” ± 1/16” 6.4 ± 1.6 mm 1/8” (3.2 mm) Figure 11 – P250 Electrode Positions, Factory Setting 64659-001 REV. A 07/06/18...
  • Page 26 5/16” ± 1/16” 6.4 ± 1.6 mm 1/8” (3.2 mm) Figure 12 - P265 Electrode Positions, Factory Setting 64659-001 REV. A 07/06/18...

  • Page 27: Wiring Diagram

    Wiring Diagram. Figure 13 - Wiring Diagram 64659-001 REV. A 07/06/18...

  • Page 28: Exploded Views

    62371-033 ORIFICE 62049-002 PLATE, BACK HOUSING P250/265 64503-001 MOTOR/BLOWER 63566-001 SHUTTER, AIR ASM-(PIE STYLE) Figure 14 - Exploded View of P250 Burner 62556-002 BRACKET, ELECTRODE MOUNT-DI 63916-001 WIRE, IGNITOR LEAD-5MM 27”L 62411-080 WIRE, SENSOR-24" BLUE 64050-006 GAS TRAIN, GAS/AIR MOD 21756-011 FLANGE ASM., ADJ-BLACK...
  • Page 29 PART NUMBER DESCRIPTION 61637-008 VENTURI ASM.-P265 NAT DI 62261-002 ELECTRODE, ASM-DI P265 63402-001 BRACKET, ELECTRODE MOUNT-DI 62715-001 TUBE/HOUS-5" 63256-002 PLATE, BACK HOUSING P250/265 61828 ORIFICE 64503-001 MOTOR/BLOWER 63566-001 SHUTTER, AIR ASM-(PIE STYLE) 21756-011 FLANGE ASM., ADJ-BLACK 63916-001 WIRE, IGNITOR LEAD-5MM 27”L 62411-080 WIRE, SENSOR—24”...
  • Page 30 Figure 16 - Mounting Plate View PARTS LIST ITEM PART NUMBER DESCRIPTION 64528-001 CONTROL, IGN -WAYNE-0 PREPURGE 64054-006 IHEAT, CONTROL BOARD GAS/AIR 60186-004 TRANSFORMER 120V/24V/30VA 63592-003 TERMINAL BLOCK, 3 POLE LC 64659-001 REV. A 07/06/18...

  • Page 31: Warranty

    WAYNE neither assumes or authorizes covered under this LIMITED WARRANTY by any person to assume for WAYNE any other liability or WAYNE shall be repaired or replaced at WAYNE’s obligation in connection with the sale of these products.
  • Page 32 NOTES 64659-001 REV. A 07/06/18...

This manual is also suitable for:

P265

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