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Wayne EHASR-DC Manual

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WAYNE COMBUSTION SYSTEMS
801 GLASGOW AVE.
FORT WAYNE, IN 46803
TOLL FREE: (800) 443-4625
www.waynecombustion.com
Manual 101441-001 | Revision A | Publication Date: 12/4/2020
Firing Capacities:
Model EHASR-DC
0.75 – 3.00 gal/hr
105,000 – 420,000 Btu/hr Input
Model EH-DC
3.00 – 6.00 gal/hr
420,000 – 840,000 Btu/hr Input
Fuel Pumps
Single Stage Standard
Electrical
Power Supply ..........13.5Vdc, Operating Load w/igniter on: 30 A, w/igniter off: 25A
Motor .....................13.5Vdc, 3850 rpm, 25 Amps
Ignition ...................20,000V secondary, Continuous Duty or Interrupted Duty
Note- The electrical specifications shown are maximum current draw; blower wheel and other
components will affect current draw.
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 FIRE PROTECTION AGENCY,
NFPA NO. 31, 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 OIL-
BURNING EQUIPMENT IN ACCORDANCE WITH ALL CODES AND ORDINANCES.
PHONE: (260) 425-9200
FAX: (260) 345-0341
SPECIFICATIONS
MODEL
EHASR-DC &
EH-DC
OIL BURNERS
Fuels:
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
1
UL File Number: MP98
):

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  • Page 1 MODEL WAYNE COMBUSTION SYSTEMS 801 GLASGOW AVE. FORT WAYNE, IN 46803 EHASR-DC & PHONE: (260) 425-9200 EH-DC TOLL FREE: (800) 443-4625 FAX: (260) 345-0341 OIL BURNERS www.waynecombustion.com Manual 101441-001 | Revision A | Publication Date: 12/4/2020 UL File Number: MP98...
  • Page 2 INSTALLATION LOG BURNER MODEL: SPECIFICATION NUMBER: FUEL: Nozzle Size and Pattern: Pump Fuel Pressure (psi): (%): Smoke Spot: CO (PPM): INSTALLER’S NAME: CONTRACTOR NAME: CONTRACTOR CONTRACTOR PHONE ADDRESS: NUMBER: CONTRACTOR LICENSE #: DATE OF INSTALLATION: COMMENTS ABOUT INSTALLATION/START UP: BURNER/EQUIPMENT SERVICE LOG SERVICE COMPANY CONTRACTOR...
  • Page 3 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.
  • Page 4 State of California to cause cancer or birth defects or other reproductive harm. For more information, go to www.p65Warnings.ca.gov. Special When contacting Wayne Combustion Systems for Requirements service information, please have the burner specification and model number when calling or writing.

  • Page 5: Table Of Contents

    TROUBLESHOOTING ................................7 GENERAL TROUBLESHOOTING GUIDE ......................... 7 BURNER DOES NOT LIGHT, 12Vdc WAYNE OIL PRIMARY CONTROL REMAINS ON STANDBY ......10 BURNER WILL LIGHT, BUT 12Vdc WAYNE OIL PRIMARY CONTROL GOES INTO LOCKOUT ........ 11 BURNER COMPONENTS DIAGRAM ……………………………………………………………………………………………...13 BURNER REPLACEMENT PART NUMBERS &...

  • Page 6: General Information

    MODEL VARIATIONS The EHASR-DC burner utilizes unique air cones and oil gun assemblies to optimize burner performance in its rated firing rate range. The air cone is a single piece construction and is fixed to the air tube. The oil gun depth is set in reference to the fixed air cone.

  • Page 7: Troubleshooting

    This may cause smoking and possible detonation that will damage the equipment if the burner does light. Wayne Combustion Systems produces EHASR-DC and EH-DC burners in different variations for multiple OEM manufacturers. When troubleshooting a burner on a piece of equipment, consult your equipment manual for specific troubleshooting information.
  • Page 8 If burner mode (Applicable only if burner comes remains on standby see Burner does not light, Wayne with oil primary control). control remains on standby, on page 10.
  • Page 9 PROBLEM POSSIBLE CAUSE SOLUTION BURNER SMOKES Low fuel pressure Increase fuel pressure to manufacturer's specifications. See (continued) Figure 25 on page 36 for pump features. Air bubble in fuel lines Check fuel lines for leaks or air bubbles. Tighten or replace as needed.

  • Page 10: Burner Does Not Light, 12Vdc Wayne Oil Primary Control Remains On Standby

    NOTE: This section refers to Wayne 101382 series controls. BURNER DOES NOT LIGHT, 12Vdc WAYNE OIL PRIMARY CONTROL REMAINS ON STANDBY Procedure Corrective Actions...

  • Page 11: Burner Will Light, But 12Vdc Wayne Oil Primary Control Goes Into Lockout

    BURNER WILL LIGHT, BUT 12Vdc WAYNE OIL PRIMARY CONTROL GOES INTO LOCKOUT Procedure Status Corrective Actions Check for DC voltage at the oil primary control If voltage is good Go to step 2 (13.5 volts) 101382 red LED light flashes for ...
  • Page 12 BURNER WILL LIGHT, BUT 12Vdc WAYNE OIL PRIMARY CONTROL GOES INTO LOCKOUT (CONT) Procedure Status Corrective Actions Check cad cell sighting for view of flame. De-energize burner.  Burner locks out. Go to step 7 Unplug cad cell and clean face with soft cloth.

  • Page 13: Burner Components Diagram

    Figure 1- Burner Components – Models EH-DC and EHASR-DC...

  • Page 14: Burner Replacement Part Numbers & Descriptions

    Table 1- EH-DC and EHASR-DC Replacement Parts Description EHASR Description EHASR 12Vdc Solenoid 13.5Vdc Motor (See NOTE Below) 100610-005 100610-005 Valve Motor Mounting 12Vdc Solenoid 100891-001 100891-001 100885-003 100885-003 Flange Valve Coil Cad Cell 5” Wire 15002 15002 Cad Cell - Up to...

  • Page 15: Oil Gun Assembly Diagram & Replacement Part Numbers

    EH-DC OR EHASR-DC EHASR-DC Figure 2– Oil Gun Assembly Detail View (Parts not necessarily as shown) Table 2- Oil Gun Replacement Parts Part Description EH-DC EHASR-DC Nozzle Adaptor/Flame lock/Tripod Assembly 100427-SER 12988-002 Stamped Stabilizer Support Kit 21923-001 21923-001 Cast Stabilizer Support Kit...

  • Page 16: Wiring Diagrams

    WIRING 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)

  • Page 17: Wayne 12Vdc Oil Primary Control

    OIL PRIMARY CONTROL FEATURES The 12Vdc Wayne 101382 series oil primary control is an option used on 12Vdc oil burners. The 12Vdc oil primary control is used with a cad cell flame sensor to control the oil burner’s sequence of operation. The 101382 series control is equipped with one of three different timings and features.

  • Page 18: Sequence Of Operation: Burners With Wayne 12Vdc Oil Primary Control 101382-001

    Note- Long flash is 2 second long and short flashes are ½ second long. Fault codes will flash on/off continuously until voltage is removed from the white command wire. SEQUENCE OF OPERATION: BURNERS WITH WAYNE 12Vdc OIL PRIMARY CONTROL 101382-001 BURNER OPERATION On every call for heat the oil primary control performs an internal safety check;...

  • Page 19: Sequence Of Operation: Burners With Wayne 12Vdc Oil Primary Control 101382-002

    SEQUENCE OF OPERATION: BURNERS WITH WAYNE 12Vdc OIL PRIMARY CONTROL 101382-002 BURNER OPERATION On every call for heat the oil primary control performs an internal safety check; verifying the cad cell is not registering a false flame signal. Completing a successful check, the burner’s blower motor is energized; after 1 second the ignition device and fuel solenoid are energized which begins the 15 second trial for ignition.

  • Page 20: Sequence Of Operation: Burners With Wayne 12Vdc Oil Primary Control 101382-003

    SEQUENCE OF OPERATION: BURNERS WITH WAYNE 12Vdc OIL PRIMARY CONTROL 101382-003 BURNER OPERATION On every call for heat the oil primary control performs an internal safety check; verifying the cad cell is not registering a false flame signal. Completing a successful check, the burner’s blower motor is energized, after 10 seconds the ignition device is energized and in another 3 seconds the fuel solenoid is energized which begins the 15 second trial for ignition.

  • Page 21: Sequence Of Operation: Burner Without Control Or Drop-Out Timer

    SEQUENCE OF OPERATION: BURNER WITHOUT CONTROL OR DROP-OUT TIMER BURNER OPERATION If the burner is controlled by a flow switch on the incoming power line to the burner, the operation of the burner is a simple ON/OFF mechanism, where all the burner components will be energized to fire the burner. If any problems arise during ignition or continued operation of the burner see the GENERAL TROUBLESHOOTING GUIDE on page 7.

  • Page 22: General Installation Information

    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 of oil.

  • Page 23: Electrical Wiring Of Burner

    NOZZLE AND AIR CONE SELECTION The EHASR-DC and EH-DC oil burners typically fire well with a solid or semi-solid nozzle with a 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.
  • Page 24 1. Locate the slot plate cover, loosen the brass oil assembly nut with a 7/16 inch wrench at the connection with the brass fitting on the solenoid valve, but do not remove all the 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.
  • Page 25 3. Next loosen the ignition device mounting plate clip screw by using a flat head screwdriver, move the hold down clip off of the mounting plate, this will allow the igniter device assembly to swing open to the left. Leave the plate in the closed position (Figure 10).
  • Page 26 Now grasp the rear of the oil gun assembly where the oil line fitting adapter exits through the housing and 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.
  • Page 27 7. Thread the nozzle into the nozzle adaptor finger tight, then tighten the nozzle securely with a 5/8” wrench, while using a 3/4" backing wrench to hold the nozzle adapter. Do not over tighten. There is a brass stamp that reads “TOP” on the nozzle adapter that should be orientated up (Figure 14).

  • Page 28: Setting Gun Depth

    Figure 16–EHASR-DC Electrode Positions, Factory settings 9. At this time position the gun assembly back into the housing in reverse sequence that gun assembly was removed in, while taking care not to disrupt the electrode spacing. Note: Re-measure electrodes gap after installing gun assembly in burner to verify that the position has not shifted...
  • Page 29 3/8-24 Decal Hex lock nut 5/16 inch Hex slotted screw Figure 19– EH-DC/EHASR-DC Oil Gun Depth Adjustment Figure 17 Figure 18 3. Once in the required position per , retighten the hex lock nut and slot cover screw, move and align arrow decal with slot plate cover.

  • Page 30: Starting Procedure

    STARTING PROCEDURE STARTING BURNER Be sure that the starter switch on the equipment is in the “OFF” position, set the thermostat to a temperature substantially above room temperature, and ensure the oil tank is filled, all valves are open, and controls set for operation. Adjust air supply on burner by loosening screw on interlocking air bands, and open the air band until black smoke is eliminated on start-up (see Figure 20).
  • Page 31 Bleeder Valve Figure 22– Fuel Pump Bleeder Valve Location Note: If the 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–...

  • Page 32: Final Adjustments

    2. With the burner running, use a 3/8 inch wrench to open the bleeder valve about one-half turn (Figure 24). Allow oil to drain into the container until a steady, clear bubble free oil stream is noticed. Close the bleeder plug. Figure 24–...

  • Page 33: Maintenance

    MAINTENANCE Before beginning any maintenance work on the burner, be sure that all oil valves from the tank are closed and electrical power to the burner is disconnected. The following routine maintenance operations should be performed on the burner once a year: Filter/strainer: The oil filter cartridge should be replaced once a year so the fuel oil will not become contaminated and plug up the fuel pump and fuel nozzle in the oil burner.

  • Page 34: Reference Information

    REFERENCE INFORMATION Table 4- Efficiency Chart for No. 2 Fuel Oil Net Stack Temperature (°F) 300° 350° 400° 450° 500° 550° 600° 650° 700° 750° 800° 850° 900° 87.5 86.5 85.3 84.3 83.3 82.0 81.0 79.8 78.8 77.5 76.3 75.5 74.3 14.5 87.5...
  • Page 35 Table 5– Max Suggested Firing rate for a Given Combustion Chamber Size Firing Diameter Rect. Nozzle Square Rectangular Air Cone Size Rate Round Chamber Distance Chamber Chamber (gal/hr) Chamber Height to Floor 0.75 10" 8" x 9" 9" 4" 1.00 11"...

  • Page 36: Reference Figures

    REFERENCE FIGURES Figure 25- Pump Feature Identification Figure 26– Blower Wheel Spacing...

  • Page 37: Warranty

    WAYNE neither assumes or authorizes WAYNE is not responsible for any labor cost for the any person to assume for WAYNE any other liability or removal and replacement of said burner or burner obligation in connection with the sale of these products.
  • Page 38 NOTES...

This manual is also suitable for:

Eh-dc

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