Doc. No: HS-WI-H28-0029-21 1.0 Edition: 01 B315-0510 AA200 BURNER ASSY ELEVATOR ASSEMBLY: 1.1 Mount THREE(3) Standoffs (P/N:N040-1194) onto the Ignitor Support Plate (P/N:N040-1185) with THREE(3) M4X10 Pan Hd Screws (P/N:0991-9207). Ignitor Support Plate (P/N:N0401185) Standoff – Louie Optical Base (P/N:N040-1194) M4X10 Screws (P/N:0991-9207) 1.2 Mount the Solenoid Assy (P/N:N041-0096) onto the Solenoid Support Plate (P/N:N040-1187) with the Solenoid Locking Plate (P/N:N040-1190). Secure with TWO(2) M3 Split SST Lock Washers (P/N:0991-9046) and Nuts supplied with the Solenoid Assy. Finger tighten only pending later adjustment. Louie Solenoid Support Plate (P/N:N040-1187) Louie Solenoid Locking Plate (P/N:N040-1190) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Dewey Ignitor Solenoid Assy (P/N:N041-0096) M3 Split SST Washer (P/N:0991-9046) & Nuts Page 2 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 1.3 Mount the Solenoid Assembly on top of the Standoffs using THREE(3) M4X19 Alum Hex Standoffs (P/N:0994-0819). M4X19 Alum Hex Standoffs (P/N:0994-0819) 1.4 Mount the Glow Plug (P/N:0009-1279) onto the Ignitor PCB Holder (P/N:N040-1188) and secure it with ONE(1) Washer (supplied with Glow Plug) and Hex Nut (P/N:0998-5897). Glow Plug (P/N:0009-1279) Washer & Pot Mtg Hex Nut 1/4-32 (P/N:0998-5897) Louie Ignitor PCB Holder (P/N:N040-1188) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 3 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 1.5 Mount the Interface Board (P/N:N041-9064) onto the Holder (P/N:N040-1188) with FOUR(4) M3X10 Pan Hd Sems Screws (P/N:0991-9201). Insert the Socket from the flying lead on the Board into the Glow Plug. Align the Hex Nut on the Glow Plug with the Hex on the Socket and push both together rotating clockwise to lock them in place. Install one end of the Ground Wire (P/N:0998-3822) to ONE(1) of the M3X10 Pan Hd Sems Screws as shown. Note: ESD Strap to be worn when handling PCBAs. Wire-Hook Up 18AWG Blk (P/N:0998-3822) M3X10 Pan Hd Sems Screws (P/N:0991-9201) Dewey Burner Hd Interface PCBA (P/N:N041-9064) 1.6 Mount the Flame Sensor Board onto the Holder (P/N:N040-1188) with TWO(2) M3X6 Pan Hd Sems Screws (P/N:0991-9200). M3X6 Pan Hd Sems Screws (P/N:0991-9200) Louie Ignitor PCB Holder (P/N:N040-1188) Flame Sensor Board Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 4 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 1.7 Attach the Extension Spring (P/N:0990-2361) onto the Burner Hook Casting (P/N:N040-1215). Louie Burner Hook Casting (P/N:N040-1215) Extension 0.188OD 0.500FL Spring (P/N:0990-2361) 1.8 Insert the Hook Casting (P/N:N040-1215) through the slot on the Holder (P/N:N040-1188) followed by positioning the Holder on top of the M4X19 Hex Standoffs (P/N:0994-0819) of the Ignitor Assembly. Secure the Hook Casting to the Holder using TWO(2) Flat Nylon Washers (P/N:0991-1260) and TWO(2) M3 Slot Hd Shoulder Screws (P/N:0991-9740). Lock the Hook Casting with the Extension Spring (P/N:0990-2361). 4DX4L M3 Slot Hd Shoulder Screw (P/N:0991-9740) Louie Ignitor PCB Holder (P/N:N040-1188) Louie Burner Hook Casting (P/N:N040-1215) Prepared By: FOO SACK ANN M4X19 Alum 6AF Hex Standoff (P/N:0994-0819) 18 FEBRUARY 2005 Flat 0.171ID 0.375OD Nylon Washers (P/N:0991-1260) Extension 0.188OD 0.500FL Spring (P/N:0990-2361) Page 5 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 1.9 Place the Ignitor Cover (P/N:N040-1189) over the Ignitor PCB Holder(P/N:N040-1188) and secure them with THREE(3) BLACK M4X10 Pan Hd Nylon Screws (P/N:0992-0676). Dewey Ignitor Solenoid Assy (P/N:N041-0096) Louie Ignitor Cover (P/N:N040-1189) Louie Ignitor PCB Holder (P/N:N040-1188) M4X10 Pan Hd Nylon Screws (P/N:0992-0676) 1.10 Attach the Ignitor Tube Holder (P/N:N037-1077) to the Solenoid Assy (P/N:N041-0096) with ONE(1) M3X5 Skt Hd Cup Set Screw (P/N:0991-9009). M3X5 Skt Hd Cup Pt Stl Set Screw (P/N:0991-9009) Igniter Tube Holder (P/N:N037-1077) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 6 of 21 Doc. No: HS-WI-H28-0029-21 2.0 Edition: 01 B315-0510 AA200 BURNER ASSY MIXING CHAMBER (BURNER FINISHING CHAMBER) ASSEMBLY: 2.1 Paste the Caution Burner Label (P/N:N040-1219) onto the Burner Finishing Chamber (P/N:N037-1467). Place the Clamping Ring (P/N:N040-1171) over the Chamber and secure with TWO(2) 4-40X3/8 Cap Screws (P/N:0991-0473). Caution Burner Label (P/N:N040-1219) Burner Finishing Chamber (P/N:N037-1467) Clamp Ring (N0401171) 4-40X3/8 Skt Hd SST CLP Cap Screw (P/N:0991-0473) 2.2 Place the Flow Spoiler (P/N:0057-2561) into the Chamber with ONE(1) Fin of the Spoiler pointing to the 12 O’clock position in line with the Caution Label Arrow. Ensure that the Spoiler fits snugly into the Chamber. Flow Spoiler (P/N:0057-2561) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 7 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 2.3 Very lightly lubricate the BLACK Viton O-Ring (P/N:0990-2219) with Super-O-Lube (P/N:09908439) and install it into the SMALL end of the Chamber (P/N:N037-1467). Hand-tighten and secure with the Burner Chamber Collar (P/N:N040-1197). Viton O-Ring (P/N:0990-22197) Louie Burner Chamber Collar (P/N:N040-1197) 2.4 Install the Burner Cap Assy (End Cap Assy) (P/N:N037-0392) onto the Chamber with the FOUR(4) Captive Screws (P/N:0992-0664). Hand-tighten ALL FOUR(4) Screws evenly. End Cap Assy (P/N:N037-0392) 10-32 1.625LG Knurl Hd SST Captive Screw (P/N:0992-0664) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 8 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 2.5 Insert TWO(2) Thumbscrews (P/N:0992-0675) onto the Burner Chamber Mount (P/N:N0401184). Burner Chamber Mount (P/N:N040-1184) Thumbscrew (P/N:0992-0675) 2.6 Install the Chamber Mount onto the Assembly from 2.4 with TWO(2) 10-32X3/8 Cap Screws (P/N:0991-0495). 10-32X3/8 Skt Hd Cap Screw (P/N:0991-0495) Burner Chamber Mount (P/N:N040-1184) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 9 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 3.0 SLIDE ASSEMBLY: 3.1 Attach ONE(1) Spring (P/N:0992-2001) to the Bracket (P/N:N040-1083). Secure the Slide (P/N:N040-1082) to the Bracket with THREE(3) M4X10 Pan Hd Screws (P/N:0991-9207). Attach the Burner Rot Screw[Left-Right] (P/N:N037-1170) to the Bracket. M4X10 Screws (P/N:0991-9207) Rot Adj Bracket (P/N:N040-1083) Vert Guide Slide (P/N:N040-1082) Molding Burner Rot Screw (P/N:N037-1170) Extension Spring (P/N:0992-2001) 4.0 BURNER [UP-DOWN] KNOB ASSEMBLY: 4.1 Insert Spring Pin (P/N:0991-2085) through the Vertical Adjust Screw (P/N:N040-1079) till Pin protrudes out evenly from both sides. Press the Vertical Adjust Screw firmly into the Burner Knob (P/N:N037-1022). Spring Pin (P/N:0991-2085) Vert Adj Screw (P/N:N040-1079) Burner Knob (P/N:N037-1022) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 10 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 5.0 BASE ASSEMBLY: 5.1 Place Glider Catch (P/N:N315-1055) on the Burner Top Plate (P/N:N315-1051) and secure them together with ONE(1) Extension Spring (P/N:0992-2025). Burner Top Plate (P/N:N315-1051) Glider Catch (P/N:N315-1055) Extension Spring (P/N:0992-2025) 5.2 Place the Burner Catch Arm (P/N:N315-1056) onto the Base and add the Arm Attachment (P/N:N315-1057) to connect the Catch Arm and Glider Catch together. Catch Arm (P/N:N315-1056) Prepared By: FOO SACK ANN Arm Attachment (P/N:N315-1057) 18 FEBRUARY 2005 Page 11 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 5.3 Place FOUR(4) Ball Bearings (P/N:0990-0991) into the slots of the Top Plate. Burner Top Plate (P/N:N315-1051) Ball Bearings (P/N:0990-0991) 5.4 Install the Vertical Guide Rod (P/N:N040-1081) and secure it to the Slide Lower Plate (P/N:N315-1052) with ONE(1) M6X12 Cap Screw (P/N:0991-9236). Install the Vert Adj Post (P/N:N040-1078) to the Lower Plate and secure with ONE(1) Cap Screw (P/N:0991-3452). Vertical Adj Post (P/N:N040-1078) Cap Screw (P/N:0991-3452) M6X12 Screw (P/N:0991-9236) Slide Lower Plate (P/N:N315-1052) Vert Guide Rod (P/N:N040-1081) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 12 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 5.5 Place Slide Lower Plate onto the Base Assy (Burner Top Plate) and put FOUR(4) Ball Bearings (P/N:0990-0991) into the slots of the Slide Lower Plate. Ball Bearings (P/N:0990-0991) Slide Lower Plate (P/N:N315-1052) 5.6 Mount the Slide Upper Plate (P/N:N315-1053) onto the Assembly with TWO(2) M4X12 Pan Hd Screws (P/N:0991-9208). Slide Upper Plate (P/N:N315-1053) M4X12 Screws (P/N:0991-9208) 5.7 Install ONE(1) Ext Ret Ring (P/N:0991-1375) to the Burner Screw[In-Out] (P/N:N315-1155). Install the Burner Screw to the Base Assy (Burner Top Plate). Ext Ret Ring (P/N:0991-1375) Phx Burner Screw (P/N:N315-1155) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 13 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 5.8 Use another Ext Ret Ring (P/N:0991-1375) to secure the Burner Screw to the Base Assy (Burner Top Plate) on the other side. Ext Ret Ring (P/N:0991-1375) 5.9 Insert the THREE(3) pcs of Tubings (P/N:0998-5727) with Wire Markers - AUX (P/N:09987266), NEB (P/N:0998-7267) & FUEL (P/N:0998-7286) approx. 2” from the ends - into THREE(3) Connectors (P/N:0992-0054) and secure them together with THREE(3) ¼” Hose Clamps (P/N:0992-0041). Wire Marker AUX (P/N:0998-7266) Quick Conn Body -1/8 TBG (P/N:0992-0054) 2” Tubing-BEVALINE VHT 0.125ID Clear (P/N:0998-5727) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Hose Clamp ¼” SST (P/N:0992-0041) Page 14 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 5.10 Insert the Tubings into the Base Assy (Burner Top Plate). Secure each Connector onto the Assy with a Spacer (P/N:N315-1199) and C-Clip which is supplied with the Connectors. Phx Quick Conn Body Spacer (P/N:N315-1199) 5.11 Insert the Main Cable Assy (Phx Hsg/Burner Cable Assy) (P/N:N315-0300) through the slot in the Base Assy and secure the Connector with TWO(2) 4-40 Hex Nuts (P/N:0991-1179). Phx Hsg/Burner Cable Assy (P/N:N315-0300) Prepared By: FOO SACK ANN Hex Nut - SM STL 4-40 (P/N:0991-1179) 18 FEBRUARY 2005 Page 15 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 6.0 BURNER MAIN ASSEMBLY: 6.1 Place the Slide Assy onto the Base Assy. The Extension Spring (P/N: 0992-2001) goes over the Vert Adj Post (P/N:N040-1078). Mount the Elevator Assy onto the Slide Assy with THREE(3) M4X10 Pan Hd Screws. Install the other end of the Ground Wire to one end of the D-Type Connector as shown. Secure the Plate onto the Burner Knob (P/N:N037-1022) with the Ring Ext Ret (P/N:0991-1372), Flat Washer (P/N:0991-1688), Spring (P/N:0990-2426) and UST Washer (P/N:0991-1246). Elevator Assy M4X10 Screws (P/N:0991-9207) Vertical Adj Post (P/N:N040-1078) Extension Spring (P/N:0992-2001) UST Washer (P/N:0991-1246) Ring Ext Ret (P/N:0991-1372) Flat Washer (P/N:0991-1688) Spring (P/N:0990-2426) Delrin Washer (P/N:0992-0575) Wire-Hook Up 18AWG Blk (P/N:0998-3822) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 16 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 6.2 Install the Plunger onto the Base Assembly. Caps Tubing (P/N:0990-6430) Plunger (P/N:N315-1234) 6.3 Mount the Mixing Chamber Assy onto the Igniter Support Plate using the TWO(2) Snap-Top Standoffs as guides. Secure the mixing chamber onto the assembly with TWO(2) Thumbscrews (P/N:0992-0675). Snap-Top Standoff (P/N:0994-0774) Thumbscrew (P/N:0992-0675) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 17 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 6.4 Insert the TWO(2) SST Inserts (P/N:0990-3989) into the FUEL & AUX Tubings and attach them to their respective fittings on the End Cap Assy (P/N:N037-0392). Paste the other set of Wire Markers - AUX (P/N:0998-7266), NEB (P/N:0998-7267) & FUEL (P/N:0998-7286) onto the respective Tubings approx. 2” from the ends. NEB AUX FUEL SST Insert (P/N:0990-3989) 6.5 Insert the Nebulizer Sensor Assy (P/N:N041-0095) into Neb Housing Molding (P/N:N040-1218) and secure with ONE(1) M3X5 Skt Hd Cup Set Screw (P/N:0991-9009). M3X5 Skt Hd Cup Pt Stl Set Screw (P/N:0991-9009) NEB Sensor Assy (P/N:N041-0095) NEB Hsg Molding (P/N:N040-1218) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 18 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 6.6 Mount the Neb Sensor Molding Assy to the Main Assy with TWO(2) M3X20 Pan Hd Sems Screws (P/N:0991-9204). Also, insert the Hsg Connector from the Main Cable Assy (P/N:N3150300) into the Neb Housing Molding. Secure both Cables with a Cable Tie as shown. M3X20 Pan Hd Sems Screw (P/N:0991-9204) Cable Tie Phx Hsg/Burner Cable Assy (P/N:N315-0300) 6.7 Install the Phx Ground Wire (P/N:N315-0342) – One end to the Elevator Assy and the other end to the D-Type Connector on the Main Cable Assy(P/N:N315-0300) - as shown. Phx Ground Wire (P/N:N315-0342) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 19 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 6.8 Install the Magnet Strip (P/N:0992-3322) onto the 4” Titanium Burner Head (P/N:N040-1104) with TWO(2) 4-40X0.25 Screws (P/N:0991-0132) and TWO(2) Magnet Clamps (P/N:N0401153). Place the Burner Head Assy (P/N:N040-0102) onto the Mixing Chamber Assy. Magnet 3.9LG (P/N:0992-3322) Louie Burner Magnet Clamp (P/N:N040-1153) 4-40X0.250LG BDG HD SST CLP Screw (P/N:0991-0132) 6.9 Ensure that ALL the Connectors - Solenoid Assy, Main Cable Assy, Neb Sensor Assy - and the Grounding Wire are properly secured onto the Interface Board (P/N:N041-9064). Dewey Burner Hd Interface PCBA (P/N:N041-9064) Wire-Hook Up 18AWG Blk (P/N:0998-3822) NEB Sensor Assy (P/N:N041-0095) Phx Hsg/Burner Cable Assy (P/N:N315-0300) Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 20 of 21 Doc. No: HS-WI-H28-0029-21 Edition: 01 B315-0510 AA200 BURNER ASSY 6.10 Ensure that ALL Cable Ties are properly secured. Cable Tie Prepared By: FOO SACK ANN 18 FEBRUARY 2005 Page 21 of 21