HP SU-2A User's Manual
Contents
1. T T terminals are closed 24 volt power carrying lines do not power this Sometimes T T terminals are jumped with a wire nut for burners not set for post purge Burner motor starts and pre purge begins Burner housing pressurizes and proves air flow contacts closed Note if the contacts are closed before the motor starts blower motor runs continuously Diagnostic light flashes once every 3 seconds At the end of pre purge ignition spark starts audible sound and the redundant gas valve opens for 4 seconds Trial for ignition Within 4 seconds gas flame is established and the flame rod carries current to prove the flame Note a minimum of 0 7 micro amps are required 5 micro amps is not uncommon Flame remains till operating limit is open If T T is used to fire the burner field wired for post purge the burner will go into post purge once the thermostat is satisfied T T open These burners have 60 seconds post purge If the flame is not established the control will attempt ignition two more times before locking out for 60 minutes The control will then attempt to re establish the flame every 60 minutes To reset the control interrupt power for five minutes to start the sequence again ae Lag Fig 5 Wiring Diagram for Honeywell S89F Honeywell SBOF Combustion Air Blower PA site Limite Gas LowHiehFr Sur Ne Pes St Burner Onli 1207 0Hs1Ph ME ng oe He L2 Green Lala Flame Rod Eli bt so 120 V Ig2. i Ends 1 FT t Above Floor NLET AIR Ventilation Louvers For unheated crawl space VENT PIPE AND DRAFT HOOD SIZES Refer to Chart 3 to properly size the flue pipe If the flue pipe exceeds 10 in length including elbows use the next larger diameter flue pipe and draft hood If a draft regulator is required any Canadian Standards Association CSA or Underwriter s Laboratory UL listed double swing draft regulator must be used A movable internal damper is not permitted on gas installations When the burner is used as a conversion burner draft over fire should be maintained as 0 02 W C by adjusting the regulator when the burner is fired The installer should follow the barometric draft regulator manufacturer s instructions for complete details for installations and adjustments The vent pipe should extend only to but not beyond the inside wall of the chimney The sizing below does not apply on any factory listed packaged units Chart 3 Vent Pipe Sizing Input per Hour Draft Hood and Flue Pipe Sizes Up to 120 000 BTU 120 000 to 160 000 BTU 160 000 to 250 000 BTU INSTALLING THE BURNER If the burner being installed is a conversion burner use a prefabricated chamber or build a firing chamber that can withstand 2000 F See Chart 2 on page 3 Measure the boiler or furnace mounting plate to determine the flame tube insertion required Deduct 4 from the total length and tighten the flange on the flame tube wi
3. Tran TonitionElect L Factory Wiring E Field Wiring Use Copper Conductors Oriy SEQUENCE OF OPERATIONS Honeywell S89F Limits close Blower motor starts as the 24 Volt transformer powers the airflow switch Power from the airflow switch to the S89F control initiates 34 second pre purge At the end of the pre purge the spark is energized for 4 seconds At the same time the 24 Volt transformer powers the gas valve allowing the fuel to flow Within 4 seconds the flame should be established and proved The spark will shut off and the control will hold power to the gas valve until the limits open and the burner stops firing If the flame is not established the blower motor continuously runs To restart power should be interrupted for five minutes Then turn on the power to start this sequence again To light the SU 2A Gas Burner Reset if Flame Lockout Occurs 1 Set the thermostat to the lowest Turn the thermostat off or turn the main power off temperature 2 Wait five minutes 2 The control knob on the gas Turn the main power on valve should be in the OFF position for at least five minutes To shut the burner off Rotate the control knob counter Rotate the control knob on the gas valve to the clockwise to the ON position OFF position and set the thermostat to the Set the thermostat to the lowest temperature desired temperature settings Turn Main Power Off BURNER OPERATION Befor
4. the numbered dials to the appropriate head setting please refer to Chart 5 on page 8 These recommended settings are only approximate settings Actual field conditions will vary and require a certified technician to adjust the burner OEM settings may differ When to adjust the Air The air shutter 1s a mechanical shutter Do NOT over crank the air shutter General rule if the CO Carbon Dioxide is too low then close the air shutter If the CO is too high then open the air shutter Note Do NOT set the CO higher than 9 8 for Natural Gas or 11 5 for LP Gas If the CO Carbon Monoxide is above 100 ppm there is either too much air or too little air Check the CO level and adjust the burner When to adjust the Head The retention head is 1 8 inside the tube when the marking reads 22 There is a full 2 movement for the retention disk to move backward to increase secondary air or forwards to decrease secondary air NOTE the head physically moves within the blast tube Do not over crank the head dial This movement can also be used to compensate for backpressure in the combustion area up to 0 3 W C Caution If this is the case the flange and the combustion chamber should be completely sealed This pressure firing decreases as the firing rate increases See Graph 1 Note the burner Should be adjusted while it ts firing Graph 1 Chamber Pressure versus Firing Rate BTU Inches of Water 50 000 100 000 15
5. 0 000 200 000 250 000 300 000 BTU s Trouble shooting There are three factors to operate the gas burner properly 1 Electricity main Power 120V 60 Hz 1 Ph secondary 24V 2 Gas flow Incoming pressure should be 10 w c with proper gas line without pressure drop during burner operation 3 Combustion air Check these three items properly before proceeding in detail for other problems 1 Burner motor runs and No flame after pre purge amp no fuel indicator where applicable Check 24V feed to airflow switch amp after airflow switch to control Fix or replace the airflow switch If there is no secondary power then replace the 24V transformer No flame fuel indicator on where applicable Check ignition transformer electrode cracked faulty ignition transformer or spark separately electrode or gap Fix or replace Fenwal control defective after above tests 2 Burner locks out after 4 seconds First check ionization electrode ionization cable for cracks and boot Fix as needed Polarity reversed Check power feed for broken polarity Bad earth grounding Fix the ground wire Gas pressure is too low Check the gas pressure and adjust to proper pressure 3 Pulsation at start SL in te ame ibe Ads ac mesa o the end of the flame tube Adjust as necessary 4 Pulsation during operation Burner is not correctly adjusted Readjust with combustion analyzer The burner is dirty Clean the burner Defective chi
6. 0 volt 60 cycle single phase electric current The installation must comply and be grounded in accordance with the National Board of Fire Underwriters and National Electric Code ANSI NFPA No 70 1987 or the latest addition All applicable local codes should be followed as well Installation wiring should be wired through each limit control or interlock while operating controls like the thermostat should be treated as 24 Volt wiring The burner has its own 24 Volt AC power supply Do not add a 24 Volt AC transformer for the burner wiring Do not use the 24 Volt transformer found on the burner to power other items in the heating system such spill switches etc Follow the wiring diagrams provided below Fig 4 Wiring Diagram for Fenwal 2466H Fenwal 2466H 1 8 x1 16 IGNITOR TRANSFORMER Agan CURRENT TEST PINS F1 191 an 120V 60HZ 1 PH NEUTRAL FROM FUSE NEUTRAL DISCONNECT F2 BLOWER MOTOR SENSOR S2 R PRESSURE SWITC 2466H036 111 GRD NOTE 1 HOT amp NEUTRAL CAN NOT BE CHANGED FACTORY WIRING 2 1F ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS CONVERSION FIELD WIRING BURNER MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C USE COPPER CONDUCTORS WIRE OR IT S EQUIVALENT ONLY X 3 OPERATING LIMIT FOR POST PURGE SEQUENCE OF OPERATIONS Fenwal 2466H 036 111 All limits are closed and 120 volt power is on for the burner
7. Wea Ideas in Heating Manual for SU 2A Gas Burner 50 000 BTU H to 250 000 BTU H The burner shall be used only with NATURAL GAS or LP GAS as specified on the nameplate Warning If the following instructions are not followed exactly a fire or explosion may result causing property damage personal injury or death 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 appliance 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 A qualified installer service agency or the gas supplier must perform installation and service All installations must be made in accordance with all state and local codes which may differ from instructions in this manual The installer should inform and demonstrate to the user the correct operation and maintenance of the appliance The installer shall also inform the user of hazards of flammable liquids and vapors and shall remove such liquids and vapors from the vicinity of the burner The installation adjustment data trap or label supplied shall be filled in and affixed to the burner or the covered appliance These instructions should be affixed to the burner or adjacent to the heating appli
8. ance NYC MEA 382 03 E Massachusetts Plumbing Board G1 0903 40 09 03 2004 Manufactured by Heat Wise Inc 1528 Rocky Point Road Middle Island NY 11953 rev 2004 2 Chart 1 Natural Gas and LP Length Firing Rate Primary Secondary Total Total Gas of Flame Electric Electric Watts Amps Conn Tube Min Max Input Input 120 Volt SU 2A 4 4 50 000 250 000 60 Hz 24 Volts 150 3 or 1 9 1 Ph Max less Control System Fenwal Model 2466H936 111 with 15 Second Pre Purge and 60 Second Post Purge OR Honeywell S89F with 34 second Pre Purge The system uses a remote ignition system with a separate Ignition Transformer Gas Valve VR8205A 2008 or VR 8305 P with step opening special applications BURNER DESCRIPTION The SU 2A Gas Burner is a fully automatic flame retention burner and is suitable for combustion of natural gas or LP Changing orifices alters the firing rate The combustion air can be adjusted for proper O or CO by the dial located on top of the burner housing which allows the air to flow more or flow less within the burner Two electrodes act as a sparker and a flame rod See Fig 1 Flame rectification by this flame rod monitors the continued presence of the burner flame With three trials for ignition consistency with Fenwal control trouble free safe operation is achieved Warning Should overheating occur 1 shut off the manual gas shut off valve to control the appliance 2 DO NOT shut off
9. e turning the burner on check for gas supply leaks Check the wiring diagrams install manometers before and after the gas valve Keep the observation port of the boiler or furnace open Follow the instructions on the nameplate of the burner to turn it on Follow the sequence of operations for the control see pages 9 and 10 Use a combustion analyzer and record the readings below BURNER OPERATION Record the Readings at Steady State Draft over fire at steady state should be 0 02 W C or zero Nan NOTE This may vary for OEM applications Natural Gas CO 9 0 to 9 8 or O 5 0 to 3 5 pe LP Gas CO 10 5 to 11 5 or O 5 0 to 3 5 Stack Temperature 300 F minimum 550 F maximum Percentage of Carbon Monoxide CO in PPM Natural Gas manifold gas pressure W C 3 5 required 0 3 NOTE This may vary for OEM applications LP Gas manifold gas pressure W C 2 3 required 0 3 Carbon Monoxide in flue less than 100 PPM ideal should not exceed 400 PPM Oxygen free Incoming Gas LP pressure W C minimum 5 pe PICTURE 4 HEAD AND AIR ADJUSTMENT To access the head and air adjustment remove the plastic cover from the rear of the housing using the supplied 4 mm allen key The left dial is the head adjustment dial the right dial is the air adjustment dial These dials can spin 360 22 times for the head and 32 times for the air Using the same 4 mm allen key turn
10. eep the area around the conversion burner clear and free from combustible materials gasoline and other flammable vapors and liguids No obstruction for the flow of combustion and ventilating air ref Page 4 GL uae FL Mala apis wog pang xog 01U0J 3 0H wal Gb SNOISN3WIO sawung SB YZNS BIP jesuy2e
11. iance must be isolated from the gas supply piping by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 2 psig Fig 3 Gas Burner Piping MANUAL SHUT OFF VALVE rs kas ie 1 8 N P T PLUGGED TAPPING i I 4 DIRECTION OF FLOW UNION FLOOR LEVEL 1 ee ee ORIP FF PIPE CAP PIPE N THIS IS NOT A PART OF SU 2A BURNER The dotted lines represent field installation To determine the firing rate of the burner multiply the heating capacity of the appliance by 1 2 or multiply the flow rate in GPH by 140 000 BTU gal Example 2 if the boiler or furnace is rated for 0 75 GPH of No 2 oil then 0 75 GPH x 140 000 105 000 BTU input rate Use the calculated input rate to fire the boiler or furnace ORIFICE INSTALLATION All burners are eguipped with an orifice set at the minimum firing rate except for OEM packaged units Drilling the orifice increases the firing rate To drill the orifice first open the union and then unscrew the orifice from inside the union Determine the proper orifice size for the desired firing rate and drill the orifice see Chart 5 Replace the orifice in the union and tighten the union so that it is gas tight Once installed a higher or lower firing rate can be achieved by raising or lowering the manifold pressure by 0 3 Pressure changes can only be made when the burner is ru
12. mney Check and change if necessary with liners 5 Burner locks out Ionization current is too low Check current Minimum 0 8 micro amps Check position of ionization electrode and the condition of the cable 6 The CO content is too high 7 Condensation in the heat exchanger Firing Rate is too low Increase the firing rate so that the stack temperature is 350 F or HIGHER Insulate the chimney PART PART PART PART Regulation Line 16 6A 17 18 19 20 21 22 23 10195 1 1 11417601 Safety Control 2466H or S89F i Plastic Cover Plate 11850001 maa Screw Long Special 11750702 Airflow Switch 6041A Honeywell Tridelta 1 D82132 11859107 7 24 Volt Transformer 2440VA 21 Gas Valve 2008 or VR 8305 P lonization Cable 11865805 Ignition Transformer cable included 2709 or 12299 5SAY Maintenance Instructions TO BE FIXED ATTACHED NEAR BURNER Once a year a gualified service agency needs to be contracted for other than routine maintenance 1 The blower motor is the only moving part It does not require lubrication since the ball bearings have been permanently lubricated 2 The user should do periodic visual checks of the burner and the flame 3 Laundry lint or dog and or cat hairs should not go inside the blower If they are seen they should be removed after disconnecting the power to the burner and cover parts should be installed before starting the burner 4 K
13. ning off Slide the blast tube into the boiler to the proper depth and tighten the two setscrews using a4mm allen key Seal off any free openings with either high temperature cement or high temperature silicone Picture 2 BODY FLANGE picture to the left First install the gasket and boiler flange to the boiler e For heat exchangers with a diamond stud pattern one allen screw on the flange should be on the top slightly to the left of the 12 o clock stud The second screw should be on the right slightly above the 3 o clock position stud Tighten all the nuts equally Make sure that the allen screws are backed out to allow enough clearance Then insert the SU 2A gas burner into the boiler Once the burner is inserted and pushed all the way forward tighten the allen screw on the top of the flange This screw MUST go into the grove that is on the burner housing Tighten the second allen screw located on the right side of the flange This screw should be tight e For heat exchangers with a square stud pattern move one of the allen screws so that both are under the top two boiler studs Tighten the bolts and install the burner Make sure the burner is straight and tighten the allen screws e Seal off any free openings with either high temperature cement or high temperature silicone GAS SERVICE amp PIPE CAPACITY Before connecting the burner to the gas supply insure that the gas pipes and service meter are large enough to permit
14. nning The typical working manifold pressure for natural gas is 3 5 W C 2 3 W C for LP The maximum inlet pressure at the gas valve is 11 W C the minimum is 5 W C for the purpose of input adjustment Note The manifold pressure may vary for OEM packaged units Chart 5 Burner Orifice Sizing For Natural Gas And LP inches Size W C for Nat Gas BTU W C for L P BTU Head Setting Air Setting 532 0156 50 000 50000 No 0 3 16 0 188 80 000 80 000 1 32 0 219 90 000 90 000 Pe 0 Lo oo 5 i no 250 000 250 000 1 20 orifice Assumes 0 to 0 02 Draft over fire INSTALLING THE CHIMNEY LINER DRAFT DIVERTER AND VENT PIPE Some utilities require new chimney liners for all gas installations Use a corrosion resistant chimney liner approved for gas service of the same size as the vent pipe Use an CSA or U L listed draft diverter only if you can maintain draft over fire Otherwise it is better to use a double swing draft regulator listed by CSA or U L When the burner is used as a conversion burner draft over fire should be maintained as 0 02 W C by adjusting the regulator when the burner is fired The installer should follow the barometric draft regulator manufacturer s instructions for complete details for installations and adjustments The vent pipe should extend only to but not beyond the inside wall of the chimney ph ELECTRIC WIRING These gas burners are manufactured for use with 12
15. rnace room is unusually tight or if the house has a ventilation fan it is recommended that the combustion air be supplied to the furnace room through intakes from the outside of the building The intakes must terminate facing down in order to avoid obstruction from rain snow leaves etc Openings must have one square inch of free area per 10 000 BTU input rate see Example 1 Follow the heat exchanger manufacturer s recommendations for installing louvers etc Example 1 150 000 BTU hr firing rate 1 150 000BTU hr a 15in 10 000BTU hr CHIMNEY REQUIREMENTS The chimney should extend at least 3 above a flat roof or the highest roof ridge see Fig 2 and be free in a radius of 30 of objects such as tree limbs other buildings etc which may cause a down draft The chimney should be lined as required by the local Gas Company or local codes Some utilities require new chimney liners for all gas installations Use a corrosion resistant chimney liner approved for gas service of the same size as the vent pipe Fig 2 Chimney and Fresh Air Dimensions CHIMNEY NA E CHIMNEY MINIMUM oi 5 El z Ha MIMIMUM su as Furnace y as i E i na Aa Eo pe ok 3 FT CHIMNEY MINIMUM num f T e CHIMNEY VENTILATION LOUVER5 Inimum ie on l 2 EACH END OF ATTIC T Pi VENTILATION LOUVERS yg EACH ENG OF ATTIC rura an ewan x EEA 4 E i i i i 5 Inlet Air Duct
16. th the deducted insertion depth The 4 deduction will prevent the tip of the flame tube from burning off Install the burner on the unit and then tighten the nuts on the flange so that the burner is permanently secured Seal off any free openings with high temperature cement Refer to the pictures below to determine which flange 1s installed on the SU 2A Picture 1 STANDARD FLANGE Install the gasket and the Standard flange to the boiler Tighten the bolts Measure the boiler or furnace mounting plate to determine the flame tube insertion depth required and make a mark on the tube with a marker or screwdriver Deduct 4 from the total length and tighten the flange on the flame tube with the deducted insertion depth The 4 deduction will prevent the tip of the flame tube from burning off Slide the blast tube into the boiler to the proper depth and tighten the four 4 20 setscrews Seal off any free openings with either high temperature cement or high temperature silicone Picture 2 DIE CAST FLANGE picture to the left Install the gasket and Die Cast flange to the boiler Tighten the bolts Measure the boiler or furnace mounting plate to determine the flame tube insertion depth required and make a mark on the tube with a marker or screwdriver Deduct 14 from the total length and tighten the flange on the flame tube with the deducted insertion depth The 4 deduction will prevent the tip of the flame tube from bur
17. the additional load of the gas burner see Chart 4 Chart 4 Pipe Capacity Table x 1 000 BTU s Nominal diameter of pipe in inches T Using 0 6 Specific Gravity Gas and a Pressure Drop of 0 3 of Water Column Each 90 elbow counts as 3 for the purpose of these calculations It is advisable to run a separate gas line from the meter to the gas burner to avoid pressure drops Refer to the above Pipe Capacity table for the correct sizes ALL PIPING MUST CONFORM TO LOCAL CODES Use black steel pipe and malleable fittings do not use cast iron parts with a suitable pipe dope that is resistant to liquefied petroleum gases Test for gas leaks using an approved gas leak tester Piping should consist of 1 A shut off valve approximately 6 away from the unit 2 A 1 8 plugged NPT tapping for gas pressure measurement preferably on the manual shut off valve as shown or anywhere between the gas valve and the shut off value Note The manual shut off valve and tapping are NOT part of the SU 2A Gas Burner Please make sure you conform to local and state codes 3 A gas union 4 A drip pipe Caution The gas valve should not be subjected to more than 2 PSIG Therefore the burner should be isolated during high pressure gas leak tests The appliance and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 2 psig The appl
18. the control switch to the pump or blower This power gas burner is designed to convert oil and or coal fired boilers and furnaces to a gas burning appliance The conversion must conform to local codes In the absence of such codes the American National Standard for the Installations of gas conversion burners ANSI Z21 17 1984 Z21 8A 1990 and the National Fuel Gas Code ANSI 223 1 1992 or current standards should be applied Fig 1 Electrode and Flame Sensor Dimensions CONVERTING OIL TO GAS Before attempting the gas conversion check to insure the heating system is properly sized for the total heating demand and the entire system is in good operating condition including the fire chamber and flue passages It is important to allow adequate clearance around the appliance for servicing and proper operation of the burner CONVERTING COAL TO GAS When converting a coal appliance to gas the coal firing chamber or the ash pit chamber may be used as a gas firing chamber provided the flame does not impinge on the walls of the appliance see Chart 2 It is important to allow adequate clearance around the appliance for servicing and proper operation of the burner Chart 2 Minimum Firing Chamber Dimensions Rectangular Round Input Rate BTU Length Width Diameter Minimum per hour Height 50 000 to oe oS 80 000 to 150 000 150 000 to 180 000 11 180 000 to 200 000 200 000 to 250 000 AIR FOR COMBUSTION If the boiler or fu
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