Heat Wise SU-3 Manuale utente

Heat Wise, Inc.

Manual for:

SU-3 199,000 BTU/H to 400,000 BTU/H

SU-4 300,000 BTU/H to 550,000 BTU/H

The burner shall be used only with NATURAL GAS or PROPANE .

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 telephone in your building.

•Immediately call your gas supplier from an outside 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.

•At least once per year, a qualified service agency needs to contracted for other than routine

maintenance.

•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 appliance.

Massachusetts Plumbing Board

G3-0904-16

Manufactured by Heat Wise, Inc.

28 Industrial Blvd. Unit I

Medford, NY 11763

rev 2007-1

The SU-3 and SU-4 comes in many distinct model numbers, which reflect the listing agency, OEM

standard, the fuel, BTU range of the gas train and type of safety control originally supplied with the

burner. Check the model number on the label located on the cover of the control box for the

specifications of the burner.

Note: Gas trains supplied with the SU-3 and SU-4 are for specific firing ranges, as covered by

various codes and listing agencies. Firing this burner above the allowed firing rate will void the

warranty, and may result in a fire or explosion, causing property damage, personal injury or death.

Table 1: SU-3 & SU-4 Models and Specifications

Model Range

(MBH)

Fuel Listing Gas Train Gas

Conn.

SU-3

U.S. and Canada

199 to 400

Natural Gas

And LP

VR 8305

¾”

SU-4AN

Canada

300 to 500

Natural Gas

Only

VR 8305M

¾”

SU-4N (H or F)*

Canada

300 to 550

Natural Gas

Only

Two VR 8305M

valves in parallel

1”

SU-4P (H or F)*

Canada

300 to 550

LP Only

VR 8305M

¾”

SU-4N (H or F)*

U.S.

300 to 400

Natural Gas

Only

VR8305M

ANSI Z 21.17 compliant

¾”

SU-4P (H or F)*

U.S.

300 to 400

LP Only

VR8305M

ANSI Z 21.17 compliant

¾”

SU-4N (H or F)*

U.S.

300 to 550

Natural Gas

Only

U.L. 795** w/ low and high

gas pressure switches

¾”

SU-4P (H or F)*

U.S.

300 to 550

LP Only

U.L. 795** w/ low and high

gas pressure switches

¾”

* H=Honeywell control F= Fenwal control ** Also conforms to NFPA-86

Table 2: SU-3 & SU-4 Electrical Specifications

Primary Electric Input Secondary Electric Input Total Watts Total Amps

120 Volt

60 Hz

1 Ph

24 Volts

150 Max

3 or less

•Fuel: The SU-3 and SU-4 Burners will fire natural gas or LP. The maximum inlet pressure at

test port is 10” W.C. for both natural and LP gas.

•Length of Flame Tube: 5 ¼” or 14” (special order)

•Firing System: The burner operates as ON – OFF with a fixed air inlet shutter and proportional

head setting. (See the charts for approximate firing rates. In the field they may vary)

•Blower Motor: 120 Volt/ 60 Hz/1 Ph, 1/6 HP PSC motor

•Burner Ignition: A separate external high voltage ignition transformer provides interrupted

ignition with 4 second safety timing to establish the flame.

•Air Flow Safety Switch: Diaphragm switch closes when the burner blower develops adequate air

pressure. Loss of air pressure causes the fuel valves to close immediately.

•Pre-Purge: Minimum 30 seconds is standard on burners.

•Gas Train: Below 400,000 BTU low and high gas pressure switches are optional. Above 400,000

BTU they are standard with gas leak shut off valve. (See the setting pressures from the table

given) Dual gas valves in the form of a combination valve or separate with built in pressure

regulator or separate with shut off valves are all part of the factory-assembled system. When

pressure switches are used, the power (120V) passes through each as a part of the limits; they will

trip power to the burner as soon as pressure increases or decreases to the system. See the pictures

below for common configurations of SU-3 and SU-4 gas trains. The same gas valve is used for

both natural gas and propane without any conversion kit.

Picture 1: U.L. 795

gas pressure switches

Gas Leak Test Cock Picture 2: Below 400 MBH Gas Manifold

Picture 3: Dual Gas Valve – Canadian applications only

Warning: Should overheating occur, 1) shut off the manual gas shut off valve to control the

appliance; 2) DO NOT shut off the control switch to the 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 Institute (ANSI) for the installation of gas conversion burners, Z21.8A-1990 and the

National Fuel Gas Code ANSI 223.1-1992 or current standards should be applied.

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.

Fig. 1 Electrode and Flame Sensor Positioning

1/8” Spark Gap

3/16”

Projection of ceramic past retention plate

0.65”

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. Measure the boiler or furnace mounting plate to determine

the flame tube insertion required. Deduct ¼” from the total length and tighten the flange on the

flame tube with the deducted insertion depth. The ¼” 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.

1”

Picture 4: STANDARD FLANGE:

Measure your insertion depth and mark the blast tube. Deduct ¼”

from the total length; the ¼” deduction will prevent the tip of the

flame tube from burning off. Remove the blast tube by loosening

the two 3 mm allen screws located on the housing near the base of

the blast tube. Install the flange and gasket from the rear of the blast

tube and tighten the four ¼”-20 setscrews on the flange. Reinstall

the blast tube (with flange to the housing). Make sure that the blast

tube is firmly fixed to the burner. Mount the burner to the heat

exchanger and tighten the bolts. Seal off any free openings with

either high temperature cement or high temperature silicone

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 utility 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

Picture 5: BODY FLANGE:

First, install the gasket and boiler flange to the boiler. 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-4 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 groove that is on the burner housing. Tighten the second allen screw,

located on the right side of the flange. This screw should be tight. Seal

off any free openings with either high temperature cement or high

temperature silicone.

Gas Service and Pipe Capacity

Before connecting the burner to the gas supply, insure that the gas pipes and service

meter are large enough to permit the additional load of the gas burner (see Table 3).

Table 3: Pipe Capacity Table*( x 1,000 BTU’s)

Nominal diameter of pipe in inches

Pipe Length** 1” 1 ¼” 1 ½” 2”

15’

345 750

30’

241 535 850

45’

199 435 700

60’

173 380 610

75’

155 345 545

90’

141 310 490

105’

131 285 450 920

120’

120 270 380 850

150’

109 242 300 780

180’

100 225 225 720

* 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

Example 1:

There is 75 feet of 1 ¼” pipe from the meter to the burner and there are 5 elbows.

(5 elbows X 3’) + 75’ pipe = 15’ + 75’ = 90’ of effective pipe length

The maximum BTU that can be fired is 310,000 BTU (see Table 3)

Gas Piping to the Burner

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 WITH LOCAL CODES.

Use black steel pipe and malleable

fittings (do not use cast iron parts) with a suitable pipe dope which is resistant to liquefied

petroleum gases.

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-4 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 ½” 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 ½ psig. The appliance

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 ½ psig.

Fig. 3 Gas Burner Piping*

*The dotted lines represent field installation.

Adjusting the Pressure Switches

Figure 4 demonstrates the possible positioning of pressure switches on the SU-4 gas train. Use the

figures in Table 4 to approximate the settings.

Fig. 4 Sample Gas Train #1

The high and low gas pressure switches must be set during installation (refer to Table 3 and Table 4). To

determine the setting of the low pressure gas switch (LPS), measure the manifold pressure (MP), inlet

pressure (IP) and the pressure between the valve (BV):

Initial setting of the High Gas Pressure Switch:

After the firing rate is determined, refer to the charts Table 3 or Table 4 on page 12 of this

manual. Multiply the manifold pressure necessary by 1.5 and set the High Gas Pressure Switch to reflect

that calculation.

Initial setting of the Low Gas Pressure Switch:

Divide the manifold pressure by 2 and add the pressure drop across the valve.

Example: Natural Gas at 340 MBH

Required Manifold Pressure= 2.7”

Pressure drop across Honeywell valve=1.0”

HPS = 1.5*2.7”=4.0”

LPS = (2.7”/2) + 1.0”=2.35”

For other valves, refer to the manual for that specific valve for the pressure drop.

Warning: After the burner has been adjusted so that the burner is operating properly, the pressure

switches must be readjusted.

•Using a monometer, measure the manifold pressure that was necessary to achieve the exact firing

rate necessary. Multiply the manifold pressure by 1.5. With the burner firing, use an analyzer

and slowly increase the gas pressure up to the new calculated high pressure cutoff point. If the

CO level reaches 400 ppm before the newly calculated setting, then at the point just before 400

ppm CO is reached is where the high gas pressure switch must be set.

•Reset the manifold pressure back to the correct setting.

•After the High Gas Pressure Switch is set, the recalculate the low gas pressure switch setting by

dividing the actual manifold pressure by 2 and adding the pressure drop across the valve. With

the burner firing use an analyzer and slowly decrease the gas pressure into the valve to the new

calculated low pressure cutoff point. If the CO reaches 400 ppm before the newly calculated

setting, then at the point just before 400 ppm CO is reached is where the low gas pressure switch

must be set.

•Reset the incoming pressure back to the correct setting.

If the combustion does not reach the 400 ppm mark at the set points, the burner can be left at those

settings. IMPORTANT: Any switch can be adjusted, as long as it meets both sets of criteria: Not

greater than 400 ppm CO and meets the appropriate calculation for the switch.

Table 4: Sample Pressure Switch Settings

Gas

Firing

Rate

MBH

Flame

Tube

Inlet Press.

Manifold Press.

> 50% T

+ ∆P*

LPS

<1.5 x T

HPS

Nat. 300 5 ¼” 6.9” 3.3” 1.6+1=2.6” 3.3x1.5=4.9”

Nat 550 5 ¼” 5.5” 4” 2+1=3” 4x1.5=6”

Nat. 300 14” 6.9” 3.3” 1.6+1=2.6” 3.2x1.5=4”

Nat. 550 14” 5.5” 4” 3” 4”

LP 300 5 ¼” 8.6” 3.7” 1.85+1=2.85” 5.6”

LP 550 14” 9.2” 2.3” 2.2” 3.4”

* ∆P= Pressure drop. For this gas valve, ∆P= 1”. Refer to the literature for the gas valve for more

information on pressure drops.

Chimney Liner, Draft Regulator 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 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 between –0.02 and +0.01 “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.

Adjusting the Firing Rate

See Fig. 6 below. Position D

represents the burner head all the way forward. By rotating the

burner head adjustment screw clockwise, the head can be moved back 0.5” (to position D

Similarly, if the head adjustment screw is turned counter-clockwise, the head is moved forward.

At head position D

, the SU-4 gas burner fires at 300,000 BTU when the gas manifold pressure

is 3.5” W.C. Adjust the air shutter and use a combustion analyzer to set the burner to between

8% and 9.5% CO

for natural gas or between 10.0% and 11.5% for LP gas. (See page 13 & 14 of this

manual for further details on burner operation).

By adjusting the manifold pressure, it is possible to adjust the firing rate. Refer to Tables 5 and 6.

Note: The pressure and head setting may vary for OEM packaged units.

When commissioning the burner, make sure the gas control knob is in the ”ON” position. Install monometers

at the inlet pressure tap and manifold pressure tap on the burner. Record the static incoming gas pressure.

When the burner lights off, record the running incoming gas pressure; the running incoming gas pressure

should never be below 5”. Note: this pressure drop should not be greater than 1”. Check the manifold

pressure from the outlet pressure tap. Note: When checking manifold pressure, do not subtract burner

housing pressure during valve-on delay. Refer to Charts 5, 6, 7 and 8 on pages 10 and 11

to make sure the gas

essure is set for the appropriate fuel and pressure. If adjustments need to be made, remove the cap screw and

adjust the pressure regulator. Screwing the regulator clockwise will increase the manifold pressure and

counter-clockwise will decrease the manifold pressure.

Fig. 6 Adjusting the Firing Rate

Manifold Pressure Tap

Table 7: Firing Rates at Various Head Settings, Natural Gas for SU-4

Manifold Pressure = 2.2” W.C. Manifold Pressure = 2.75” W.C. Manifold Pressure = 3.5” W.C.

Head Setting #

Air Shutter # MBH Head Setting #

Air Shutter # MBH

Head Setting

# Air Shutter # MBH

1 6.04 306 1 10.01 344 1 10.01 395

2 6.18 306 2 10.19 343 2 10.19 393

3 6.32 308 3 10.37 346 3 10.37 396

4 6.47 313 4 10.55 351 4 10.55 403

5 6.61 319 5 10.72 359 5 10.72 412

6 6.76 326 6 10.90 367 6 10.90 422

7 6.90 334 7 11.08 376 7 11.08 433

8 7.04 341 8 11.26 384 8 11.26 443

9 7.19 347 9 11.44 392 9 11.44 452

10 7.33 353 10 11.61 399 10 11.61 460

11 7.48 358 11 11.79 404 11 11.79 467

12 7.62 362 12 11.97 408 12 11.97 471

13 7.76 365 13 12.15 411 13 12.15 475

14 7.91 367 14 12.32 413 14 12.32 477

15 8.05 368 15 12.50 415 15 12.50 478

16 8.20 370 16 12.68 416 16 12.68 479

17 8.34 372 17 12.86 418 17 12.86 480

18 8.48 375 18 13.03 421 18 13.03 484

19 8.63 379 19 13.21 426 19 13.21 489

20 8.77 386 20 13.39 434 20 13.39 499

21 8.92 397 21 13.57 447 21 13.57 514

22 9.06 412 22 13.75 465 22 13.75 537

Table 5: Firing Rates at Various Settings, Natural Gas for SU-3

Manifold Pressure = 1.0” Manifold Pressure = 1.7” Manifold Pressure = 2.7”

Head Setting # Air Shutter # MBH Head Setting # Air Shutter # MBH Head Setting # Air Shutter # MBH

1 0.18 224 1 3.13 272 1 9.62 340

2 0.25 225 2 3.24 272 2 9.79 339

3 0.32 227 3 3.35 274 3 9.97 342

4 0.39 230 4 3.47 278 4 10.14 348

5 0.46 234 5 3.58 284 5 10.32 355

6 0.53 238 6 3.69 290 6 10.49 363

7 0.60 242 7 3.81 296 7 10.67 372

8 0.67 247 8 3.92 302 8 10.84 380

9 0.74 251 9 4.03 307 9 11.02 388

10 0.81 254 10 4.15 312 10 11.19 394

11 0.88 258 11 4.26 316 11 11.37 400

12 0.95 260 12 4.37 320

13 1.02 263 13 4.49 322

14 1.09 265 14 4.60 324

Table 6: Firing Rates at Various Settings, Propane (LP) for SU-3

Manifold Pressure = 1.0” Manifold Pressure = 1.75” Manifold Pressure = 2.1”

Head Setting # Air Shutter # MBH Head Setting # Air Shutter#

MBH Head Setting # Air Shutter # MBH

1 1.04 229 1 4.60 274 1 8.88 328

2 1.25 234 2 4.90 279 2 9.27 333

3 1.45 239 3 5.19 284 3 9.67 339

4 1.66 244 4 5.48 290 4 10.07 345

5 1.87 248 5 5.77 295 5 10.47 351

6 2.07 253 6 6.07 301 6 10.86 358

7 2.28 258 7 6.36 307 7 11.26 365

8 2.49 263 8 6.65 313 8 11.66 373

9 2.69 267 9 6.95 318 9 12.05 380

10 2.90 272 10 7.24 324 10 12.45 388

11 3.11 276 11 7.53 330 11 12.85 396

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