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WAYNE COMBUSTION SYSTEMS
801 GLASGOW AVE.
FORT WAYNE, IN 46803
FOR YOUR SAFETY
IF YOU SMELL GAS:
1. OPEN WINDOWS
2. DON'T TOUCH ELECTRICAL SWITCHES
3. EXTINGUISH ANY OPEN FLAME
4. IMMEDIATELY CALL YOUR GAS
SUPPLIER.
CARBON MONOXIDE
POISONING HAZARD
CARBON MONOXIDE IS A COLORLESS, ODORLESS GAS
THAT CAN KILL. FOLLOW THESE RULES TO CONTROL
CARBON MONOXIDE.
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.
OVERHEATING HAZARD
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.
FOR SHIPPING PURPOSES, THE FLAME
SPREADER IS FULLY RETRACTED.
FLAME SPREADER ADJUSTMENT IS
MANDATORY AND EFFECTS BURNER
IGNITION AND PERFORMANCE.
BURNER MODELS
P250AF & P250AF-EP & P250AFDI
P265 & P265EP
P265F & P265FEP
ELECTRICAL Power Supply - 115V/60HZ 1 Ph.
MODELS
P250AF
P250AFEP P265F
P250AFDI
GAS BURNER
Publication Date 5/01 - Revision B - Manual 101220
NOTE: Dimensions in ( ) are informational only. English values take priority.
WARNING: If the information in these
instructions is not followed exactly, a fire or
explosion may result causing property
damage, personal injury or death.
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HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT.
FOLLOW THESE RULES TO AVOID ELECTRIC SHOCK.
L Use only a properly grounded circuit. A ground fault
L Do not spray water directly on burner.
L Turn off power before servicing.
L Read the owner's manual before using.
SPECIFICATIONS
MINIMUM INPUT
50,000 BTU/Hr (14.65 kW/Hr)
65,000 BTU/Hr (19.05 kW/Hr)
65,000 BTU/Hr (19.05 kW/Hr)
P265
P265FEP
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 any 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.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
ELECTRIC SHOCK HAZARD
interrupter is recommended.
THESE INSTRUCTIONS SHOULD BE
NOTICE
AFFIXED TO THE BURNER OR
ADJACENT TO THE HEATING
APPLIANCE.
MAXIMUM INPUT
250,000 BTU/Hr (73.27 kW/Hr) Natural & L.P. Gas
200,000 BTU/Hr (58.61 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.
P265EP
P265DI
FUELS
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Summary of Contents for Wayne P265DI
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Page 1: Specifications
WAYNE COMBUSTION SYSTEMS 801 GLASGOW AVE. Publication Date 5/01 - Revision B - Manual 101220 FORT WAYNE, IN 46803 NOTE: Dimensions in ( ) are informational only. English values take priority. FOR YOUR SAFETY WARNING: If the information in these... -
Page 2: Visual Inspection Of The Heating System
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 conversion burner. It may be necessary to deviate from these instructions in some instances in order to comply with local gas company rules or codes in effect in the area in which the installation is made. - Page 3 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.
- Page 4 If there is a by-pass as indicated in Fig. 1, crack bypass and lock. Otherwise install pipe as suggested in Fig. 2. Suggested form of neutral pressure point adjuster. Insert in slot cut in flue pipe. When adjustment is completed, scribe a line on adjuster so it can be relocated.
- Page 5 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.
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Page 6: Natural Gas
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 (.093m ) of combustion chamber floor area and proportioning the length about 70% greater than the width. - Page 7 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, 2, or 5 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.
- Page 8 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.
- Page 9 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 the gas line to the burner is to disconnect the pilot line at the outlet of the pilot valve.
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Page 10: Standing Pilot
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. - Page 11 P265DI JUNCTION BOX ROTATED JUNCTION BOX NOT ROTATED P265DI COMBINATION GAS VALVE...
- Page 12 CO 2 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.
- Page 13 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.
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Page 14: First Stage -- Trial For Pilot Ignition
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. -
Page 15: Sequence Of Operation
IMPORTANT: The electronic S8600 control Module cannot be repaired. If troubleshooting procedure indicates a malfunction in the S8600, the 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... - Page 16 S8600, S8610 TROUBLESHOOTING GUIDE START NOTE: Before troubleshooting, familiarize yourself with the start up and checkout procedure. TURN GAS SUPPLY OFF, TURN THERMOSTAT Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and (CONTROLLER) TO CALL wiring. Also, check air proving switch on combustion air blower system (if used) and that vent FOR HEAT damper (if used) is open and end switch is made.
- Page 17 (1.587 mm) (6.35 mm) 1/8” (3.175 mm) GAP 31/64” 1/16” (12.3 mm) (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.
- Page 18 7. OPEN END WRENCHS 8. TAPE MEASURE The Wayne Burner that you are attempting to troubleshoot has the following electrical 115 Volt Single phase components: 1. 115 volt Combustion Fan Motor w/End Switch 2. Fan Relay-24 volt coil side and 110 volt fan side 3.
- Page 19 NORMAL BURNER SEQUENCE OF OPERATION 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 side of the fan relay which are the bottom terminals. 3.
- Page 20 FASCO COMBUSTION FAN ENDSWITCH 1. The Fasco 115 volt motor is equipped with a centrifugal endswitch. The purpose of the endswitch is to ensure that the combustion fan motor has reached the proper operating RPM which is generally about 3400 rpm. If the endswitch fails to close then the 24 volt circuit to the gas primary is interrupted and the gas valve will not open.
- Page 22 To measure flame current, first shut off the power to the system and then remove the flame sensing lead wire from 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”...
- Page 23 PARTS LIST - P265/P265F SERIES GAS BURNERS Part No. Description Req’d 62903-001 Control Box/Strap Assembly • • • • • • • • • 60182-002 Power Cord Assembly • • • 60186-004 Transformer - 24V • • • • • •...
- Page 24 PARTS LIST - P250AF SERIES GAS BURNERS Part No. Description Req’d P250AF P250AF EP P250AF DI 62903-001 Control Box/Strap Assembly • • • 60182-002 Power Cord Assembly • 60186-004 Transformer-24V • • • 100986-002 Relay • • • 62899 Control Box Cover •...
- Page 25 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.
- Page 26 Notes...
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