Emerson Process Management 36E86 User's Manual
Contents
1. shahu 36E86 Series Gas Control for Cycle Pilot Systems FOR NATURAL GAS ONLY INSTALLATION AND START UP INSTRUCTIONS FAILURE TO READ AND FOLLOW ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLING OR OPERATING THIS CONTROL COULD CAUSE PERSONAL INJURY AND OR PROPERTY DAMAGE This system is NOT for use with L P Gas and is NOT designed for use on applications requiring step opening two stage or slow opening gas controls The incorrect application could cause fire and or explosion The 36E86 combination gas control is a compact multi function control designed to meet the requirements for use with cycle pilot Along with its compact size all valve adjustments and features as well as the system interface wiring panel have beendesigned onthe top surface ofthe control for simplified application and easy accessibility This control system automatically cycles the pilot flame on demand froma room thermostat or operating control The system eliminates the gas wasted by a standing pilot and pilot outage problems due to drafts The troubleshooting guides and sequence of operation apply only to systems with the components listed in the following table titled REPLACEMENT PARTS 4 REPLACEMENT PARTS E51 or E52 Pilot Burner Electrode Assemb Harness l Length 12 18 24 30 36 3098 MERCURY FLAME SENSOR 5059 PILOT RELIGHT CONTROL E51 15 ELECTRODE ASSEMBLY CYCLE PILOT HARNESSES Avail2. clean mercury flame sensor pins NO NO Is gas present at the pilot Is pilot orifice or tubing blocked Replace 36E86 gas valve YES YES Clean or replace tubing or orifice NO Does pilot gas flash and lift from Check for drafts across pilot pilot burner but not ignite burner and damaged pilot YES Reduce pilot gas pressure by adjusting pilot adjust screw Figure 9 CONDITION SPARK WILL NOT SHUT OFF AFTER PILOT FLAME IS ESTABLISHED Is electrode tip YES Is pilot relight Disconnect Does continuity in pilot flame control YES cable from exist between grounded pilot relight pilot burner and through metal control Does chassis location NO standoffs continuity exist yeg of pilot relight between tip of control A com NO Replace pilot ignition mon ground must relight control electrode and exist between Check for high end of cable pilot burner and drafts or Scrape paint that was pilot relight con damaged pilot from mounting connected to trol mounting burner or surface and pilot relight rings electrode securely control Check for high ground pilot or low pilot relight control NO YES gas pressure Remove corrosion or paint from pilot burner mounting surface If a common ground cannot be established route a separate ground wire from the pilot burner to one of the mounting rings on the pilot relight control Replace pilot burner electrode assembly Figure 10 These troubleshooting cha
3. continuity across pins 2 and 4 replace mercury flame sensor If the gas cock on the valve is in the ON position see fig 2 but the main burners will not come on with a jumper between holes 2 and 4 of gas valve socket see fig 2 replace gas valve If you need further information about this product please write to White Rodgers Division Emerson Electric Co 9797 Reavis Road St Louis MO 63123 Attention Technical Service Department
4. able for Natural Gas Only CONTENTS Description Precautions Specifications System Operation Component Descriptions 36E86 Gas Control 5059 Pilot Relight Control 3098 Mercury Flame Sensor E51 Pilot Burner Electrode Assembly Installation Main Piping Connections Pilot Gas Connection System Wiring Troubleshooting WHITE RODGERS DIVISION EMERSON ELECTRIC CO 9797 REAVIS ROAD EMERSON ST LOUIS MISSOURI 63123 PART NO 37 5034A Printed in U S A 9123 PRECAUTIONS Do not exceed the specification ratings All wiring must conform to local and national electrical codes and ordinances This package contains precision instruments that should be handled carefully Rough handling or distorting com ponents could cause the controls to malfunction Do not use on circuits exceeding specified voltage Higher voltage will damage the control and may cause shock or fire hazard SPECIFICATIONS Voltage 24 volts AC 30 VAC max 60 Hz Current 0 54 amps Power Requirements 15 VA min Timing Specifications 5059 Pilot Relight Control Flame Failure Response Time 0 8 sec Flame Failure Recognition 0 8 sec 36E86 Gas Valve Specifications Capacities at pipe size 1 2 x 3 8 100 000 BTUH 1 2 x 1 2 140 000 BTUH 1 2 x 3 4 140 000 BTUH SYSTEM OPERATION Refer to COMPONENT DESCRIPTIONS for detailed operation of each component 1 When the room thermostat or operating control calls for heat it sim
5. b is vaporized transmit ting a pressure increase to the diaphragm through the capillary The increase in pressure causes the snap switch to break to connection between the common and cold contacts pins 4 and 3 and make the common and hot contacts pins 4 and 2 The cold contact controls the pilot solenoid while the hot contact controls the main valve E51 PILOT BURNER ELECTRODE ASSEMBLY This component consists of a non aerated lintless pilot with an integral electrode and cable assembly A slip on orifice is held inthe burner flame with a spring clip and can easily be removed for inspection cleaning or replace ment The electrode is factory installed and positioned for proper operation It is equipped with a high voltage cable female quick connect 1 4 terminal and an insulating boot INSTALLATION 3 The contro must be installed in an upright position or at an angle 90 from upright The arrow on the valve indicates the direction of gas flow through the control 4 You should use new pipe that is properly chamfered reamed and free of burrs and chips If you are using old pipe be sure it is clean and free of rust scale burrs chips and old pipe joint compound 5 Apply pipe joint compound pipe dope or teflon tape that is approved for all gases only to the male threads of the pipe joints DO NOT apply com pound or teflon tape to the first two threads see fig 1 for typical piping connections When install
6. ce Manometer to measure inlet and outlet gas pres sures 6 jumper wire for testing circuits stripped at both ends 18 jumper wire and alligator clips e Assorted hand tools l ae PIN 3 SMALL SMALL 7 4 PIN 4 Ds farce 2 Oj 4 FLAME SENSOR ACTION Pins 4 and 3 6 Continuity when Coid Pins 4 and 2 Continuity when Hot 3098 MERCURY FLAME SENSOR PLUG Figure 6 Mercury Flame Sensor Plug TROUBLESHOOTING Figures 8 through 11 are troubleshooting guides that provide a systematic method for isolating equipment problems To effectively use the guides each step must be completed in the proper sequence performing what ever tests are suggested After completion of each test the guides will direct the service technician to the next troubleshooting step based on the results of the previous check Components should be replaced only when sug gested by the troubleshooting guide and only after com pleting each check in the proper sequence 5 These troubleshooting charts are for natural gas systems ONLY Figure 7 Testing Pilot Solenoid Coil CONDITION NO SPARK Is 24 VAC available across terminals of pilot relight control see fig 4 YES Turn main gas supply OFF and disconnect power from system at main fuse or circuit breaker Disconnect ignition cable from pilot relight control Attach an alligator clip with insulated lead to high voltage terminal on pilot
7. ing gas control to supply piping grip the control by the inlet boss only DO NOT overtighten see table below for maximum torque Maximum torque to apply to inlet boss Inlet Boss Inch Lbs N M 1 2 NPT 42 38 7 See SYSTEM WIRING when making electrical con nections After all gas and electrical connections are completed turn gas on and check for gas leaks with leak detection solution or soap suds Bubbles form ing indicate a leak SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY INSTALLATION cont PIPED GAS SUPPLY DRIP LEG DIRT LEG __ OR SEDIMENT TRAP 3 IN MINIMUM Figure 1 Piping Connections PILOT GAS CONNECTION Install fitting into pilot gas outlet see fig 3 turning until finger tight Insert clean deburred tubing all the way through the fitting While holding the tubing securely slowly tighten fitting until you feel a slight give Tighten the fitting an additional 1 1 2 turns SYSTEM WIRING To prevent electrical shock and or equipment dam age disconnect electrical power to system at main fuse or circuit breaker box until installation is com plete NOTE The wiring and schematic diagrams on the following page show only terminal identification and typical wiring hookup Always refer to the equipment manufacturer s wiring instructions for system hookup operations Allwiring should be installed in accordance with local and national electrical codes and ordinances Alwa
8. lot burner ground ignition sparks stop lf the pilot flame is extinguished during the heat cycle the pilot relight control will begin to generate sparks the instant the flame is not detected The control delivers very low current sparks at approximately 10 000 voits 3098 MERCURY FLAME SENSOR This control is a mechanical device that proves the existence of an adequate pilot flame It converts pilot flame heat to motion through hydraulic action to operate a set of electrical contacts that control power to the main valve The flame sensor consists of a sensing bulb NEVER USE FLAME OR ANY KIND OF SPARKS TO CHECK FOR GAS LEAKS COULD CAUSE FIRE AND OR EXPLOSION Allpiping must comply with local codes ordinances and or national fuel gas codes DO NOT REMOVE plastic dust covers from the gas valve until ready for installation MAIN PIPING CONNECTIONS Failure to turn off electric or main gas supply to heating system could cause personal injury and or property damage by shock gas suffocation fire and or explosion 1 Tum off electrical power to the system at the fuse box or circuit breaker Also turn off the main gas supply 2 If replacing an existing control disconnect all plumb ing and electrical connections from the old control COMPONENT DESCRIPTIONS cont capillary diaphragm and snap switch assembly and a mercury fill When the sensing bulb is heated by the pilot flame the mercury within the bul
9. mercury flame sensor bulb 3 After approximately 45 seconds sufficient heat is sensed causing the flame sensor to energize the main gas valve Main burner gas is ignited by the pilot flame The system will operate in this mode until the thermostat is satisfied or electrical power or gas pressure are interrupted valve is the first in the two valve series It controls gas flow to the pilot and main burner outlets The pilot solenoid is controlled by the room thermostat or operating control and opens on each cali for heat When the pilot solenoid opens gas pressure enters the valve body and passes through to the pilot outlet Gas pressure within the valve body causes the contacts on the pressure switch to close creating a holding circuit for the pilot valve The pilot valve will remain energized as long as the thermostat and pressure switch contacts are closed The main valve is the second in the two valve series and is controlled by the mercury flame sensor Itwillopen only after a pilot flame has been proven by the flame sensor The integral pressure regulator maintains a constant outlet pressure with varying inlet pressures from 5 to 14 W C 5059 PILOT RELIGHT CONTROL This control is energized by the thermostat or operating control on each call for heat It generates ignition sparks that are routed to the pilot burner via the electrode cable assembly Once a pilot flame is detected between the ignition electrode and pi
10. relight control Route stripped end of lead approximately 1 8 from ground or appliance chassis Do not grasp end of wire especially when system is energized Energize system Does sparking from wire to ground occur YES Check the ignition electrode and pilot burner for damage or dirt scale across electrode and Replace pilot pilot burner burner electrode assembly if damaged NO NO Figure 8 Check thermostat and operating control circuits On a heat call 24 vAC must be available across terminal of pilot relight control Replace pilot relight control CONDITION SPARK IS PRESENT PILOT WILL NOT LIGHT Make sure mercury flame sensor is plugged into gas valve and that gas cock is in the ON position see fig 2 Lay a steel rule or small screwdriver blade across the top of the pilot solenoid coil see fig 7 A magnetic pull indicates that the coil is energized Is the pilot solenoid coil energized NO Unplug mercury flame sensor from gas valve Use a wire to jumper holes 3 and 4 on gas valve socket see fig 2 Does pilot solenoid coil energize YES NO Replace 36E86 gas valve Does continuity exist between NO pins 3 and 4 of mercury flame sensor see fig 6 If no continuity when mercury flame sensor bulb is cold replace mercury flame sensor YES YES Problem is connections between flame sensor plug and gas valve Use emery cloth to socket
11. rts are for natural gas systems ONLY CONDITION PILOT IS LIT OR CYCLES ON AND OFF NO MAIN BURNER IGNITION De energize the system for 2 minutes to allow flame sensor to cool Make sure gas cock is in the ON position see fig 2 Energize system and observe pilot flame and sensing bulb Is sensing bulb in pilot flame Upper 3 4 of flame sensor bulb must be engulfed by pilot flame YES With a pilot flame established unplug flame sensor from gas valve Does pilot flame remain on with sensor unplugged from valve YES After a pilot has been established for 45 seconds or more check for continuity across pins 2 and 4 of the mercury flame sensor plug see fig 6 Does continuity exist YES Use a short wire to jumper holes 2 and 4 on the gas valve socket see fig 2 CAUTION This should energize the main valve Does the main valve come on YES Problem is connections between pins on flame sensor plug and gas valve socket Use emery cloth to clean flame sensor pins NO NO NO NO Figure 11 Reposition bulb in pilot burner Bulb should slide into burner so that upper portion of bulb is in pilot flame Check for low incoming gas pressure Incoming pressure must be at least 1 5 W C above the regulator pressure stamped on the side of the valve If incoming pressure is okay replace gas valve If flame sensor bulb is engulfed by pilot flame but sensor does not show
12. ultaneously energized the 5059 pilot relight control and the pilot redundant solenoid in the gas valve Sparks from the pilot relight control ignite the pilot gas establishing a pilot flame COMPONENT DESCRIPTIONS 36E86 GAS CONTROL The 36E86 series gas control incorporates the following features Pilot redundant solenoid line valve Integral pressure switch to sense incoming gas pres sure e Main valve relay and operator Integral pressure regulator e Socket to accept plug in mercury flame sensor The 36E86 series control is composed of two indepen dently operated gas valves The pilot redundant solenoid 2 To prevent electrical shock and or equipment dam age disconnect electrical power to the system at the main fuse or circuit box until Installation is complete Do not short out terminals on gas valve or primary control to test Short or incorrect wiring can cause equipment damage property damage and or per sonal injury This control is not intended for use in locations where it may come in direct contact with water Suitable protection must be provided to shield the control from exposure to water dripping spraying rain etc Pressures Inlet 5to 14 W C 14 W C 1 2 PSI Max Outlet stamped on side of valve Ambient Operating Temperatures 40 to 175 F 2 Sparking stops once the flame is detected by the pilot relight control The pilot flame begins to heat the 3098
13. ys check that the electrical power supply used agrees with the voltage and frequency shown on the gas control HARNESS ASSEMBLY OPTIONAL SURE TART f NOTE HARNESS WILL GO ON ONLY ONE WAY NOTCH O HARNESS ASSEMBLY MUST F4 MATCH UP WITH SLOT ON CONTROL PILOT REDUNDANT TERMINAL COIL TOP VIEW OF 36E GAS VALVE Figure 2 Flame Sensor and Harness Cable Connections to 36E Gas Control MAIN REGULATOR ADJUSTMENT ee ee PILOT ADJUSTMENT SCREW PILOT GAS OUTLET OUTLET PRESSURE TAP GAS OUTLET Figure 3 36E Gas Control Side View af HARNESS ASSEMBLY SPARK mn MAIN GAS SUPPLY yi ROOM THERMOSTAT LIMIT ifi LINE TRANSFORMER OAL FLAME SENSOR 5059 PILOT RELIGHT CONTROL MAIN BURNER Figure 4 Schematic Diagram 24v AC Control Circuit S____ 36 E 86 3 MIN GAS CONTROL DRIP LEG aaa ele T 7 3666SERIES 7 7 T 3098 SENSOR GAS CONTROL ne lt O HOT MAIN COIL i 2 A COLD P 3 000 PILOT K REDUNDANT Bien b COIL as 4 5 3 e eo tee Ty WIRING Mee sep eee ae ee ee 7 HARNESS TO ELECTRODE THRU MOUNTING HOLES 40VA TRANSFORMER THERMOSTAT LIMIT LINE Figure 5 Internal Wiring of 36E86 Gas Control and 3098 Flame Sensor The following test equipment is required to troubleshoot this system with a minimum of time and effort Volt ohmmeter for measuring voltage and resistan
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