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• Oil Burner Repair Manual
• Wayne Oil Burner Troubleshooting

This 115V EHASR Series of Burner Assemblies features Flamelock which assures a positive flame stability, resulting in a clean, uniform high temperature flame. It also boasts:. High static pressure for better air/oil mixture. Clean, smooth ignition and sharp, positive no-drip shutoff prevents carbon soot from forming.

Nozzle operating temperatures remain low. Economy results from high CO2 readings, providing a high combustion efficiency that saves fuel Specifications:. Fan: 6-1/4'. Capacity: 0.75 GPH thru 3.00 GPH, No. 1 or No.2 fuel oil. Fuel Pump: Standard 3450 RPM fuel pump - easy to service. One or two stage.

Controls: Control and cadium cell are optional. Ignition: 10,000 V. Constant duty transformer. TV-Radio interference proof. Positive make or break contact with electrodes. Swing-away design swings open for easy access to gun assembly.

Motor: 3450 RPM. Firing Cap: 0.75 to 3.00 BPH. Air Adjustment: Patented dual adjusting air bands interlock for positive air adjustment. Flame Retention Head: High temperature stainless steel for longer life.

Approximate Weight: 38 lbs. Additional Information.

1 801 GLASGOW AVE. FORT WAYNE, IN MODEL EHA/EH & EHASR OIL BURNERS Publication Date 8/14/2000 Revision 06 Manual U.S. 4,388,064 ELECTRIC SHOCK HAZARD OVERHEATING HAZARD HIGH VOLTAGES ARE PRESENT IN THIS EQUIP- MENT.

Oil Burner Repair Manual

FOLLOW THESE RULES TO AVOID ELEC- TRIC SHOCK. Use only a properly grounded circuit. A ground fault interrupter is recommended. Do not spray water directly on burner. Turn off power before servicing. Read the owner s manual before using.

SPECIFICATIONS SHOULD OVERHEATING OCCUR: Shut off the manual oil valve to the appliance. Do not shut off the control switch to the pump or blower. NEVER ATTEMPT TO USE GASOLINE AS A FUEL FOR THIS BURNER, AS IT IS MORE COMBUSTIBLE AND COULD RESULT IN A SERIOUS EXPLOSION. FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. FUELS Use No. 2 heating oil (ASTM D-396) only.

NEVER attempt to use gasoline as a fuel for your burner, as it is more combustible and could result in a serious explosion. NEVER burn garbage or refuse in the heating unit. NEVER try to ignite oil by tossing burning paper or other material into the heating unit. NEVER burn waste or crankcase oil in the heating unit. FIRING CAPACITIES - MODEL EHA and EHASR 0.75 TO 3.00 GALLONS PER HOUR 105,000 TO 420,000 BTU/HR INPUT FIRING CAPACITIES - MODEL EH 3.00 TO 6.00 GALLONS PER HOUR 420,000 TO 840,000 BTU/HR INPUT FUEL PUMPS Suntec or Danfoss - Single Stage Standard DIMENSIONS (STANDARD) HEIGHT /8 WIDTH /16 DEPTH.8 1/4 CENTER LINE OF TUBE TO FLOOR 8 1/16 MOUNTING Rigid Flange, Adjustable Flange, or Base Mount ELECTRICAL Power Supply.115V / 60HZ / 1 PH Motor RPM, N.E.M.A. Flange, Manual Reset Overload Protection Ignition.10,000V / 23MA secondary, Continuous Duty-Shielded Interrupted INSTALLATION OF BURNER INSTALLATION OF THE BURNER MUST BE DONE BY A QUALIFIED INSTALLER IN ACCORDANCE WITH REGULATIONS OF THE NATION- AL FIRE PROTECTION STANDARD FOR OIL-BURNING EQUIPMENT, 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. THESE INSTRUCTIONS SHOULD BE AFFIXED TO THE BURNER OR ADJACENT TO THE HEATING APPLIANCE. 2 TO THE HOMEOWNER Since 1928, Wayne has supplied the Homeowners of the world with oil burners. You are obtaining a quality burner unsurpassed in engineering design and product development. It will provide you with many years of efficient, troublefree operation, if properly installed and serviced. Please read this manual carefully.

Wayne warrants its burners specifically to those who have purchased it for resale, including your dealer. If, in any case, you have a problem with your burner, or its installation, you should contact your dealer for assistance. APPROVALS This burner complies with ANSI/UL Standard 296 and is for use with No. 2 fuel oil and is U/L listed for use with Group I or Group II primary safety controls.

State and local approvals are shown on burner rating label. All burners should be installed in accordance with the National Fire Protection Association, and in complete accordance with al local codes and authorities having jurisdiction. Regulation of these authorities take precedent over the general instructions provided in this manual. GENERAL INFORMATION When installing the appliance and/or burner be sure to provide adequate space for easy service and maintenance. Prior to installation of the oil burner, the heating system should be carefully inspected for defects and cleanliness. The flue passages and heat absorbing surfaces must be clean to assure maximum heat transfer, soot acts as an insulator retarding the transfer of heat.

The combustion chamber, flue gas passages, and all doors and openings must be sealed tight to eliminate air infiltration. Excess air, decreases CO2 levels and thus lowers efficiency. Inspect the flue and chimney for leaks and obstructions, be sure the chimney is of adequate size and height. Install a draft regulator the same size as the flue pipe (see paragraph under Draft Regulators). COMBUSTION CHAMBER The purpose of a combustion chamber is to maintain a high flame temperature, by reflecting the heat back into the flame.

A high temperature assures greater combustion efficiency and lower stack losses. An insulating refractory or a Fiber Fax type chamber can be used with this burner. It is important to select and install, if necessary, the correct size chamber on a conversion job (see chart, page 5). On the Flamelock conversion burners the atomized oil burns just off the Flamelock. On all oil burners the atomized oil must not touch the sides or bottom of chamber, or smoke will result. To eliminate the smoke, excess air will be required, resulting in high stack temperature and lower combustion efficiency. Install burner so the face of air cone of burner is set 1/4 behind the inside front wall of the chamber (See Figure 5, page 6).

Caution on installing Flamelock burners in stainless steel chambers should be taken, because of the higher temperature levels produced by high performance flame retention burners. The temperature may exceed the temperature ratings of the stainless steel chamber and can result in chamber burn outs.

When you are replacing a standard burner with a flame retention burner, take the following precautions: (1) use pliable Ceramic Liner to line the inside of chamber, (2) adjust burner (See column under Final Adjustments ). FUEL PUMPS AND OIL LINES Model EHA, EH and EHASR 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. Never exceed 3 PSI pressure to the suction side of fuel pump. A pressure over 3 PSI may cause damage to the shaft seal and allow it to leak oil. When it is necessary to lift the oil to the burner, a return line should be run between fuel pump and oil supply.

(If lift exceeds 10 feet, a two stage fuel pump must be used with a return line.) When a two line installation is made, the by-pass plug must be installed. This is supplied with the burner attached to fuel pump, along with an information pump data sheet in a plastic bag. When oil lines are continuous runs of heavy wall copper tubing is recommended. Be sure that all connections are absolutely air-tight. Check all connections and joints. Flared fittings are recommended.

Do not use compression fittings. Avoid running tubing against the appliance and across ceiling or floor joist; if possible install under floor. Avoid using fittings in inaccessible locations. If possible, avoid running oil lines overhead. Specific information on piping, connections, lift capabilities and tank installations is provided in the instruction sheet of the fuel pump manufacturer. Use an oil filter of adequate size for all installations.

Install inside the building between the tank shutoff valve and the burner. Install shutoff valve in oil supply line in accessible locations, one close to the tank, another close to the oil burner but ahead of the filter. NOTE: If the maximum burner firing rate exceeds the integral fuel pump strainer rating, an external U/L listed filter/strainer must be placed in the fuel line between the fuel tank and burner fuel pump. TANKS AND PIPING Local codes and regulations must be followed regarding tank and burner installation.

Check existing tanks for water and sludge accumulation, clean if necessary. Also clean or replace existing piping. WIRING All wiring must comply with the National Electric Code and local ordinances. Refer to diagram supplied with burner or controls, making sure the burner and controls are wired correctly and that the line switch is properly connected to a 20 amp fused service.

2 3 AIR SUPPLY FOR COMBUSTION A burner shall not be installed in an area where facilities for normal air circulation or infiltration are so limited as to interfere with ready obtainment of all air necessary for proper combustion and venting. When the heating appliance is installed in a confined space, two permanent openings shall be provided. One near the top of the enclosure and one near the bottom. Each opening shall have a free area of not less than one square inch per 1000 BTU per hour (140 square inch per gph) of the total input rating of all the appliances in the enclosure. When the house is out of unusually tight construction, has a kitchen ventilating system, exhaust fans, clothes dryer or vented fireplaces, it is recommended that combustion air be supplied through two permanent openings. The openings shall communicate directly, or by means of ducts, with outdoors or to such spaces (attic or craw) that freely communicate with outdoors. For additional information, refer to ANSI standard NFPA 31.

CHIMNEY Follow the recommendations of the appliance manufacturer. A chimney shall be capable of producing a draft as required by the appliance and as recommended by the appliance manufacturer. It must be properly designed, of adequate size, and should be above the surrounding objects, tile-lined, with no obstructions, and be in good state of repair. The smoke pipe should set flush with the inside of tile and be cemented in place. All cleanout doors should be sealed. A draft inducer may be used to overcome inadequate draft conditions.

If a draft inducer is used, provisions must be made to insure the burner does not operate if the draft inducer fails. DRAFT REGULATORS A draft regulator shall be provided unless otherwise specified by the appliance manufacturer. The draft regulator shall be installed in accordance with local codes and regulations or in the absence of local codes, with the American National Standard NFPA31. Refer to appliance manufacturer s instructions for recommended overfire and stack draft. NOZZLE AND AIR CONE SELECTION The EHA, EH and EHASR oil burners typically fire well with a solid or semi-solid nozzle with a spray angle of 80, 70 or 60 degrees.

In most upgrading or conversion installations, the use of an 80 degree solid nozzle is the best way to start with. Always use the proper nozzle size, spray cone type and spray angle the appliance manufacturer recommends. Should this information not be available, your own good judgement will prevail. Under no circumstances attempt to fire the EHA or EHASR oil burners under their 0.75 gph minimum or over their 3.00 gph maximum.

Under no circumstances attempt to fire the EH oil burner under its 3.00 gph minimum or over its 6.00 gph maximum input ratings. EH Mod Pak Air Tube/gun Assembly Combinations are built with a 3.00 to 4.50 GPH P-4 as standard. To convert to the 5.00 to 6.00 GPH P-7 rating: 1.

Change the 3-1/4 I.D. Cast iron cone (EH 12990) installed to the 3-9/16 I.D. Cast iron air cone (EH 13003) supplied. To change air cones, remove the phillips head counter sunk 8-32 screw securing the existing air cone in the air tube end, remove the air cone.

Install the larger air cone. Adjust flamelock on gun assembly ahead of air cone face: 1/8 ahead for 3.00 to 4.50 GPH (UL rate P-4) rating, 1/4 ahead for 5.00 to 6.00 GPH (UL rate P-7) rating. Once the proper cast air cone has been installed the nozzle can be installed from the air tube end into the Flamelock/nozzle adaptor. Thread the nozzle into the adaptor finger tight then tighten securely with a nozzle wrench.

CAUTION: Do not over tighten. At this time position the Flamelock face forward of the cast iron air cone face as shown in figure 00.

To position the Flamelock gun assembly forward, loosen the gun assembly 3/8-24 hex lock nut and 5/16 hex slotted slot cover screw. Once in the the required position, retighten the hex lock nut and slot cover screw, move and align arrow decal with slot plate cover for Flamelock gun assembly position reference (see Figure 3, page 6). To remove a gun assembly once the burner has been installed on the appliance, remove the copper oil line where it attaches with the gun assembly oil line adaptor fitting and remove the 9/16 hex gun assembly locknut. Next, remove the ignition transformer hold down the clip and 5/16-18 hex slotted screw on the top right of the burner and swing open the ignition transformer to the left. Now grasp the rear of the gun assembly where the oil line fitting adaptor exits thru the housing and pull the oil line adaptor to the right out of the housing slot and slot plate cover.

Gently lift, do not force, the rear of the gun assembly, rotating the oil line fitting adaptor up at 45 degrees pulling the entire gun assembly out of the housing opening. Remove and install finger tight in the regular or Flamelock nozzle adaptor, then securely tighten nozzle with a nozzle wrench. Check electrodes for proper position (see Figure 1, page 6). Reinstall the Flamelock gun assembly into the burner by repeating the above steps for removal in reverse order. Once reinstalled, securely tighten the 3/8-24 hex gun assembly lock nut and the 7/16 hex oil line flare nut to the oil line fitting adaptor. 3 4 CAUTION: Close the ignition transformer and assure there is 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 ignition transformer hold down clip and tighten the 5/16-18 hex slotted screw securely. Care should be taken when closing the transformer not to pinch the lead wires between the housing and cover plate.

STARTING PROCEDURE STARTING BURNER Be sure main switch is in OFF position, thermostat is substantially above room temperature, 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 partially. Open the inspection door and turn on switch. Prime pump according to the pump manufacturer s recommendations and check pressure. If safety lockout occurs, reset after one or two minutes. Do not run fuel unit dry for more than five minutes or damage to the pump may result. When flame is established make a temporary air adjustment for a clean combustion flame, reduce air supply until flame tips appear slightly smoky, then readjust so flame tips are clean looking.

Leave inspection door open until chamber is dry. When normal temperature are reached, close inspection door. (See paragraph under Draft Regulators ).

FINAL ADJUSTMENTS At this point a final adjustment should be made by the use of a COMBUSTION TEST KIT. After operating ten minutes to warm up unit, a smoke tester should be used to take a smoke reading. Smoke test should read no greater than #1 (Shell Bacarach scale), and less than a #1 smoke is desired.

At times, a new heating unit requires more time than this to burn clean due to the oil film on the new heater unit surfaces. Recheck draft and take a CO2 reading over the fire and in the stack.

If a large differential between CO2 readings is noted, air leakage is the most common cause. CO2 readings must be taken ahead of draft control, if used.the CO2 measured in the stack should be at least 9% for oil rates 1.00GPH or below, and be at least 10% for oil rates over 1.00GPH. Units should be started and stopped several times to assure good operation. Open inspection door, turn off valve, and check out safety timing of combustion control. Check operation of limit controls and thermostat.

Check for oil leaks. NOTE: ALL NEW INSTALLATIONS SHOULD BE REINSPECTED AFTER ONE OR TWO WEEKS OF NORMAL OPERATION. SETTING COMBUSTION EFFICIENCY (A) Selecting firing rate desired.

(B) Install proper nozzle for appliance (see paragraph under Nozzle and Air Cone Selection page 3). (C) For model EHA and EH burners make gun adjustments per firing rate (see Figure 5, page 6). Note: the EHASR guns are permanently set and not adjusted with changing rates (see Figure 6, Page 6). (D) Fire burner, adjust interlocking air bands for yellow tips above combustion chamber.

(E) Record CO2 and smoke. If CO2 is low, adjust gun setting back 1/32 and repeat CO2 and smoke test. Continue this adjustment until desired CO2 and smoke is obtained. Record stack temperature.

(F) Check lighting with cold and hot chamber. (G) Lock all adjustment screws. FINAL CHECKS Be sure all screws are locked, and the controls on heating unit are adjusted in accordance with the heater and control manufacturer s instruction sheets. MAINTENANCE OILING MOTOR Proper lubrication of the motor will prolong its service life. Oil sleeve bearing motors with 6 drops of SAE 20 oil once a year. DO NOT OVER OIL. Ball-bearing motors do not require oiling under normal service conditions.

The bearing type is printed on the motor nameplate. FILTER The oil filter cartridge should be replaced once a year so the fuel oil will not become contaminated and plug up fuel pump and nozzle of oil burner. NOZZLE The nozzle should be changed at least once a year before the start-up of the heating season.

Wayne Oil Burner Troubleshooting

Ma 2a hoisting license study guide. Replace with proper nozzle. COMPONENTS If for any reason any of the burner parts have to be replaced, always use parts recommended by the manufacturer. Specify part numbers and description when ordering. (IN ALL COMMUNICATIONS STATE BURN- ER MODEL, SERIAL NUMBERS AND APPLIANCE MANUFACTURERS AND APPLIANCE MODEL DESIGNATION). ELECTRODE SETTINGS This is very important for reliable ignition of the oil; check these once a year in accordance with the instructions provided in this manual. Replace electrodes if worn excessively or if porcelain insulator is oil soaked or cracked. FAN & BLOWER HOUSING This must be kept clean, free of dirt and lint; open transformer to check fan blades from above.

CAUTION: Be sure the electric power is off on burner when the transformer is opened up for this inspection. 4 5 EFFICIENCY CHART FOR NO.