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19 40 SERIES GAS BURNER CONTROLLER TROUBLESHOOTING Before a new controller is installed in gas burner the following tests must be performed. If not damage to controller may occur and void warranty! Step 1. Remove Controller, connect 120 volts to burner making sure the (hot) wire is connected to the (L) terminal and the (neutral) wire to the (N) terminal. Using a volt meter confirm the following voltages at each of the terminals. L to 1 (120 Volts) L to 3 (120 Volts) L to 8 (120 Volts) L to 9 (120 Volts) L to 12 (120 Volts) Step 2. Check air damper (controller removed) With power to burner as in step 1 (allow air damper to open) use a volt meter and measure voltage at terminals 5 & N. If 120 volts is not present replace air damper. Remove power to burner at terminal strip, use an ohm meter and measure resistance between terminals L & N. If 575 (±30 ohms) is not present replace air damper. Step 3. Check air switch (controller removed) and no power to burner. Using ohm meter check for continuity between terminals 8 & 12 (closed contacts) if not replace air switch. Using ohm meter check for absence of continuity between terminals 7 & 12 (open contacts) if not replace air switch. 19

20 Step 4. Check Blower motor (controller removed) With no power to burner, Using ohm meter, check for continuity between terminals 1&3, 3&8, 9&1, 9&3. If any of the connections are open replace blower motor. Jump terminal 5 & 8, apply power to burner, verify that blower motor runs smooth and without excessive noise. Verify voltage readings with blower motor running, Terminal 9 to 3 (156 volts) Terminal 1 to 3 (72 volts) Terminal 8 to 3 (120 volts) If there is a ±5% discrepancy in any of the voltage readings replace blower motor. Step 5. Check gas train valves (Remove Power) Using ohm meter verify resistance of (Asco) gas solenoid valve coil. Resistance should be about 102 ohms. If coil is open, replace solenoid valve. Using ohm meter verify resistance of (Karl Dunges) gas shut off valve coil. Resistance should be about 3.40 ohms. If coil is open, replace shut off valve. Remove gas valve wires from terminals V1 & V2. Using ohm meter verify resistance of solenoid valve & shutoff valve together. Resistance should be about 114 ohms. Step 6. Check gas train valve (amp draw) Turn off main gas valve to burner. Remove gas valve wires from V1 & V2 on terminal strip; apply 120 volts to gas train valves. Using amp meter check amperage draw. Reading is about 0.2 amps. After all steps are confirmed, new controller can be installed on burner. Please proceed to the start up directions in the burner manual. NOTE: Please refer to step 1 when making electrical connections as burner will not operate with the Phase/Neutral wires reversed and damage to the controller will occur! 20

21 INSTALLATION DATA Note: This label is supplied in the package with the burner and should be filled out and affixed to the inside of the electrical panel door on a StingRay Parts Washer when the conversion burner is installed. ADJUSTMENT DATA TAG ANSI Z21-17b-1994 INPUT C.F.H. MANIFOLD PRES. AIR DAMPER AiR/GAS RATIO No. FLUE GAS TEMP. 02 LEVEL % C02 LEVEL % CO LEVEL P.P.M DATE: COMPLETED BY INSTALLATION CONTRACTOR For Technical help call, fax, or arcus Corporation dba: StingRay Tech Services 2450 Adie Road Suite 100 Maryland Heights, MO Tele: Fax: lahey@ stingwash.com Website:

22 GAS BURNER SYSTEM RIELLO 40 N200 REVISED: 09/01 NO MTS PARTS NUMBER DESCRIPTION NO MTS PARTS NUMBER DESCRIPTION 1 CALL Burner back cover 21 CALL Short combustion head (27ST1) 2 CALL Air switch 22 CALL Drawer assembly elbow Primary control box 525 SE/A Electrode assembly 4 CALL Primary control sub-base 24 CALL Electrode and ionization clamp 5 N/A 120/24 volt transformer Ionization assembly 6 CALL Air switch tube and connector Natural gas orifice 7 CALL Ionization lead 27 CALL Distributor head and mixing plate 8 CALL Air tube cover 28 CALL Manifold 9 CALL Chassis mounting collar 29 CALL End cone 10 CALL Chassis front plate 30 CALL Gas test point 11 CALL Air damper motor 31 CALL Hinge assembly Motorized air damper 13 CALL Manual air shutter(air gate) 14 CALL Air intake housing 15 CALL Fan Capacitor 10uF Burner motor Mounting gasket 19 CALL Universal mounting flange 20 CALL Ground lead and connector CALL Gas Valve (Honeywell)

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24 To be filled out by the customer. Services and Connections Electrical: Incoming voltage, Master Disconnect Installed. Yes No NEW BURNER STARTUP FORM Model No. Serial No. Customer Contact Address State ZIP Ph. FAX. Water makeup: Supply pipe dia., Length from next size feeder ft. Water supply turned on. Yes No To be performed by qualified gas burner/boiler technician! Gas supply Line (If applicable) Type, Natural Gas Propane Oil. Diameter of supply pipe Approximate distance to next larger size line or fuel tank, ft. Other devices on same main trunk total BTU s Gas flue pipe (customer installed): Material, Diameter, Number and type of elbows Vertical length ft. Horizontal length ft. Is rain cap installed. Yes No Is flue exhaust above highest point of roof line, Yes No If no, Explain, Gas Burner Information Measure and record incoming gas pressure (burner unfired) w.c.i. Measure and record incoming gas pressure (burner fired) w.c.i. Measure and record manifold gas pressure (burner fired) w.c.i. Measure and record exhaust stack temperature with burner fired and water at or near desired temperature. deg. F. Measure and record exhaust emissions, CO, Oxygen, Co2 Test measurements taken by Company Temperature Control: Does water heat system function properly, Yes No If no, Explain, Record time required for machine to heat from ambient temperature to approx deg. F. min s. Please refer to to the operating manual for recommended operating temperatures for your machine. Please write the altitude above sea level in feet for your machine Tested Burner Operation, Good Fair Poor Comments: Thank you for taking time to complete the above. Should you have any questions on your StingRay Parts Washer during this test, or anytime in the future, we at the StingRay Tech Services (800) are here to assist you in resolving any questions or problems. To begin your StingRay Warranty, please sign and return to StingRay Tech Services by mail or fax. Authorized Signature Title Date

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26 RUN GAS TRAIN WIRES THRU BLACK STRAIN RELIEF FITTING INSTALL GRAY CONDUIT,CONNECTOR,1/2",45 DEG THIS DRAWING/PRINT IS THE PROPERTY OF THE MART CORPORATION ANY REPRODUCTION OR USE OF THIS DRAWING/PRINT, WITHOUT THE EXPRESS WRITTEN CONSENT OF THE MART CORPORATION IS PROHIBITED IF REQUIRED REPIPE GAS TRAIN AS SHOWN USE PIPE DOPE ONLY FOR THREAD SEALANT NO TEFLON SEALING TAPE THE CORPORATION ST.LOUIS MO. DECIMAL `.010 FRACTIONAL ` 1/16 ANGULAR ` 1 TITLE ASSY,BURNER,MODIFIED,30 AND 40 SIZE DWG NO REV B DRAWN BY steves 12/21/2005 SHEET 1 OF 1