C7Rev.106

J. The standard pump normally supplied is 19 GPH for On-Off or Modulating and 40 GPH for Fixed Air Low Fire Start, Low-High-Off and Low-High-Low operation. Optional pumps are available which, depending on model specified, could be as high as 70 GPH. Refer to information shipped with the burner and/or consult the factory for specifics.

K. The standard pump normally supplied is 40 GPH for Low-High-Off and Low-High-Low, 70 GPH for On-Off and modulating operation. Optional pumps are available for Low-High-Off and Low-High-Low which could be as high as 70 GPH. Refer to information shipped with the burner and/or consult the factory for specifics.

Control Panel Information

Figure 6

Total Access Control Panel (Patented) Featuring Alpha System� Circuit Board with Light & Switch Board for a CombinationGas/Oil Modulating Burner. Typical system for units shipped prior to October, 2005.

21

20

1. Main Power Connections (L1 Main) Hot 115 Volt Main Power Connection* (L2 Main) 2. Flame Safeguard Subbase On Circuit Board 3. Replaceable Fuse 4. Light & Switch Board Connection 5. Replaceable Relays 6. Chassis Plate 7. Motor Starter 8. (L2) Neutral 115 Volt* 9. (FL1 Fused) Auxiliary Power Connection* (Factory Use Only) 10. Main Circuit Board 11. Terminals for Field Connection 12. Grounding Lug

1. Power On Indicator2. Control Switch3. Fuel Changeover Switch4. Gas On Indicator5. Oil On Indicator6. Manual Potentiometer7. Manual-Auto Select Switch

8. Automatic Mode Indicator 9. Auxilary Light Circuit Board

Indicators10. Demand Indicator11. Main Fuel Indicator12. FSG Alarm Indicator13. Customer Selected Indicator

14. Main Circuit Board15. Flame Safeguard Control16. Stepdown Control Voltage Transformer17. DIN Rail Mounted Terminal Strips18. Primary & Secondary Fuses

19. Motor Starter20. Light & Switch Circuit Board21. Auxiliary Light Board Indicators22. Motor Overloads

2 3 91

11

6

15 16 17 18

7

10

12

13

4 5

14

8

1922

Figure 6A

Alpha System� Typical Layout Drawing. Typical system for units shipped after October, 2005.

* L1 Main 115 volt hot incoming power terminal is locatedat the top of the circuit board. The FL1 Fused terminallocated at the lower set of terminals is for factory use onlyand should not be used for incoming power connections.

1

11 12

4 5

109

3

6

7

8

2

16

This Total Access Control Panel is typical in generalconstruction and configuration for the fuel and mode ofoperation indicated. Each burner is shipped with a wiringdiagram, as well as specific documentation on specificpanel components. Side view of removable front and top

Figure 6B

Alpha System� Circuit Board Typical Electrical Schematic with Light & Switch Circuit Board

1. Control Switch2. Fuel Changeover Switch3. Manual Potentiometer4. Manual-Auto Select

Switch

5. Power On Indicator6. Main Fuel Indicator7. Auxiliary Functions8. Motor Starter

9. Motor Overloads

10. Stepdown Control VoltageTransformer

11. DIN Rail Mounted TerminalStrips

12. Primary & Secondary Fuses

1. Main Circuit Board 2. (L1 Main) Hot 115 Volt Power Connection* 3. (L2) Neutral 115 Volt Wiring Connection* 4. Control Circuit Fuse 5. Primary Fuses 6. Motor Starter 7. Step-Down Transformer 8. Light & Switch Circuit Board 9. Auxiliary Light Board Connection (Typical)10. Gas Ignition Transformer11. Operating Valve Connections12. Modulation Motor Connections13. Limit Device Connections (Typical)14. Running Interlock Connections15. Motor Starter Coil16. Wiring Terminal Strip Identification (If Used)17. Operating Control Connection18. Flame Detector Connection19. Alarm Buzzer or Bell

panel doors. To remove front panel door, place unlatcheddoor in closed position and lift it up. For total access tocomponents mounted in the top panel, remove the fourholding screws and rotate the top panel upward, aroundthe hinge located at the top rear of the panel box.

Figure 6C

Total Access Control Panel (Patented) For Combination Gas/Oil Modulation Burners

8

9

13121110

1 3 42 75 6

* L1 Main 115 volt hot incoming power terminal is located atthe top of the circuit board. The FL1 Fused terminal located atthe lower set of terminals is for factory use only and shouldnot be used for incoming power connections.

17151413 18 19

L2 MAIN

L1 MAIN

P 2

CS_Y

CS_B

WHT

RED

BLU

CL1

X-ALARM

CL2

OL1

OL2

GL1

GL2

A 1

A 2

O11

O12

L 2

BM 96 95 A1A2

NO NO1MS

1MS

3PS

BURNER MOTORSTARTER

1 , 1 7

COMB.AIR SW.

PRESS. SW.HIGH GAS

1PS

2PS

LOW GASPRESS. SW.

1CBL

OFF

POWER

DEMAND

MAINFUEL FSG

ALARM

GASON

OFF

FUEL SELECT MODULATION

MANUAL

AUTO

MAXMINLOW

WATER

1MBQ7800C1027

FUSE & HOLDER

2FU STEPDOWN TRANSFORMER

PRIMARY FUSES1FU

1 T

L1

L2

L3

T1

T2

T3

1MS 1M

BURNERMOTOR

1ALB

AUX. LIGHTBOARD

LIGHT & SW.CIRCUIT BOARD

L2 4

IGNITION

OPERATINGCONTROL

10C1HL

HIGHLIMITCUTOFF

LOW WATER

1 L L S

2

A

W

R

B

W

R

B

1MMC

MODULATINGCONTROLLER

BLUE

(UV SCAN ONLY)

WHITE

1FD

SCANNER1ABG

F

ALARM

B

R

W

1MM

WH BK

3

14

2LS

MODULATINGMOTOR

PURGE INTERLOCK(IN MOD. MOTOR)

LOW FIRE STARTINTERLOCK(IN MOD. MOTOR)

1LS

R Y

18

5

19

1FSGRM7800L OR RM7840L

6VLV

5VLV

4VLV

3VLV

2VLVMF

L 2

GV1

L 2

L 2

PV1

T 2 0

AUX. GAS VALVE

MAIN GAS VALVE

SAFETY RETURN

AUX. OIL VALVE

MAIN OIL VALVE

PILOT VALVE

1VLVSPARK ELECTRODE

A

2 T

GAS IGN.TRANS.

65 7432 8 91 10 11 12

13. Flame Safeguard Control

TO FUSED DISCONNECTSW. BY OTHERS

P 1

ON

GND

ON

ON

E 5

E 4

E 3

E 2

E 1

WHT

TERMINAL STRIP ARRANGEMENT

1LSB

PV2

13

12

L2

F L 1

F L 1

OIL VALVE

BK-R BK-BL

CAUTION: THROW ALL DISCONNECTS TO OFFBEFORE SERVICING.

�USE COPPER CONDUCTORS ONLY.�

EQUIPMENT SHOWN ON DIAGRAM IS ONLYPROVIDED AND MOUNTED BY POWER FLAME IFSPECIFICALLY CALLED FOR ON BURNER SPEC.SHEET.

ADD GREEN GROUND WIRE TO GROUNDING LUGFOR PILOT VALVES WITH GROUND WIRE.

CAUTION: ALL FIEL WIRING MUST BE WIRED AS SHOWN ON WIRING DIAGRAM.

NEUTRAL WIRING MAY NOT BE CONNECTED ASSHOWN, BUT MAY BE WIRED TO TERMINATE ATNEUTRAL TERMINALS SUCH AS 2, 2A, T2, or L2.

LISTED GROUNDING BAR AND/

EARTH GROUND LABELEDIN PANEL AND WIRED TOOR GREEN SCREW MOUNTED

�EQUIPMENT GROUND�

-G- EQUIPMENT GND. CONDUCTOR

CONDUIT OR SHIELDED CABLE-F- FLAME CIRCUIT: RUN IN SEPERATE

FACTORY WRNG24V1 1 5 V2 0 0 -5 7 5 V

}X

O

FIELD WIRING�SEE SPEC. SHEETFOR VOLTAGE�

C8Rev.106

1 5 62 37 84

Table 3A

Correction Factors

Table 3

Capacity of Pipe - Natural Gas (CFH)With Pressure Drop of 0.3� w.c. and Specific Gravity of 0.60

Pipe Length Pipe Size - Inches (IPS)In Feet 1 11/4 11/2 2 21/2 3 4

10 520 1050 1600 3050 4800 8500 17500

20 350 730 1100 2100 3300 5900 12000

30 285 590 890 1650 2700 4700 9700

40 245 500 760 1450 2300 4100 8300

50 215 440 670 1270 2000 3600 7400

60 195 400 610 1150 1850 3250 6800

70 180 370 560 1050 1700 3000 6200

80 170 350 530 990 1600 2800 5800

90 160 320 490 930 1500 2600 5400

100 150 305 460 870 1400 2500 5100

125 130 275 410 780 1250 2200 4500

150 120 250 380 710 1130 2000 4100

175 110 225 350 650 1050 1850 3800

200 100 210 320 610 980 1700 3500

Note: Use multiplier at right for other specific gravities and pressure drops.

Specific GravityOther Than 0.60

Specific Multiplier

Gravity

0.50 1.10

0.60 1.00

0.70 0.926

0.80 0.867

0.90 0.817

1.00 0.775

Propane - Air

1.10 0.740

Propane

1.55 0.662

Butane

2.00 0.547

Specific DropOther Than 0.3

Pressure Multiplier

Drop

0.1 0.577

0.2 0.815

0.3 1.00

0.4 1.16

0.6 1.42

0.8 1.64

1.0 1.83

2.0 2.58

3.0 3.16

4.0 3.65

6.0 4.47

8.0 5.15

Figure 7

The Director® Annunciation System

The Director® Annunciation System Mounted onremovable Total Access front panel door, complete withquick disconnect electrical connection. The Director canbe removed from the panel box (see above) and kept inoperating mode by using the extended length umbilicalcord between the Director and panel box connections.

Annunciation Legend for Gas/Oil Burner with Low-High-Low Operating Mode

1. Power On2. Limit Circuit Closed3. Flame Failure (Flame Safeguard Lockout)4. Main Gas Valve - Low Position5. Main Gas Valve - High Position6. Main Oil Valve7. High Fire Oil System8. High Fire Air System

INSTALLATIONThe installer should contact the local gas utility relativeto available supply pressures, limitations on allowablepressures in the building, general piping requirementsand applicable codes, restrictions and regulations.

Considerations of these types, as well as writtenpermits and other state, city and local codes, should bediscussed with and approved by the appropriategoverning bodies.

GAS SUPPLY PIPINGGas piping should be sized to provide required pressureat the burner train inlet manual shutoff cock, whenoperating at the maximum desired fuel input.

All gas piping should be appropriately pressure tested toensure leak free operation. It is recommended that a dirtpocket or trap be piped into the gas supply system justahead of the burner train inlet manual shutoff cock.

When testing with pressures higher than the maximumpressure ratings of the gas train components, be sure toisolate these components and test their piping for gasleaks with correct pressures only. On some burners, the

maximum main gas train and/or pilot gas train compo-nents pressure is 1/2 psig. (14" W.C.).

Refer to Table 3 for information relating to the sizing ofgas supply piping. These charts are based on thegeneral flow characteristics of commercially producedblack wrought iron pipe. If in doubt regarding flowcapabilities of a chosen line size, the next largest sizeis recommended.

Refer to page 10, Figures 8 and 9 for typical gas pipingschematics to meet U.L. requirements in the C burnerfiring ranges.

C9Rev.304