A SCOTT FETZER COMPANY801 GLASGOW AVE.

FORT WAYNE, IN 46803

Publication Date: 12/13/2010

MODELS8.J HSG200.".JIIIiI!lN

HSG400GAS BURNERS120V/50-60 HZ 220V/50 HZ

PART NO. 62484-001

WARNING: If the information in these instructionsis not followed exactly, a fire or explosion may resultcausing property damage, personal injury or death.

- Do not store or use gasoline or other flammablevapors and liquids in the vicinity of this or any otherappliance.

- WHAT TO DO IF YOU SMELL GAS

• Do not try to light the appliance.• Do not touch any electrical switch; do not use any

phone in your building.• Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier'sinstructions.

• If you cannot reach your gas supplier, call the firedepartment.

- Installation and service must be performed by aqualified, licensed installer, service agency or the gassupplier. WARRANTY IS VOIDED IF NOTINSTALLED BY QUALIFIED SERVICE PERSON.

fi@C US

MEAMASS.

ANSIZ21.17

APPROVEDFOR USE CITYOF NEW YORK

MEA 49-83-E

NOTICETHESE INSTRUCTIONS SHOULD BE AFFIXED TO THE BURNER

OR ADJACENT TO THE HEATING APPLIANCE.FOR FURTHER INSTRUCTIONS AND WARNINGS,

SEE PAGE 21 OF THIS MANUAL.

SPECIFICATIONS[SEE PAGE #1]

SPECIFICATIONS MODELSHSG2OO, HSG4OO

NATURAL OR PROPANE GAS

NOTE: Dimensions in ( ) are informational only. English values take priority.

HSG2OOMaximum lnput Capacity - 200 MBtu/HR (211000 kJ)Minimum Input Capacity - 60 MBtu/HR (63300 kJ)

HSG4OOMaximum Input Capacity - 400 MBtu/HR (422000 kJ)Minimum Input Capacity - 200 MBtuiHR (211000 kJ)

SUPPLY LINE PRESSURE REQUIRED: Natural or Propane 5.5 W.C. (1370 Pa) Minimum, 14.0 WC. (3487 Pa)Maximum

AIR TUBE DIAMETER: 4 inches (101.6 mm)

AIR TUBE LENGTHS: HSG200 6 inches (152.4 mm)(See Fig. 12C tor HSG400 6.25 inches (158.75 mm)Overall Dimensions) HSG200|4O0 9.00 inches (228.6 mm)

HSG200/400 12.00 inches (304.8 mm)

MOUNTING: Adjustable flange standard (deduct 1 1/8 inch (28.575 mm) from above air tube lengths when usingflange). Optional pedestal mounting.

STANDARDVOLTAGE: 120VAC I60HZl 1 Phase120 VAC | 50 HZ 1 Phase (Special motor installed with max capacity reduced 20%)220VACl50HZl 1 Phase

FLAME SAFETY: 24 VAC Electronic

IGNITION: 7300 VAC Direct Spark

GAS VALVE=314x 3/4 (19.05 mm x 19.05 mm) NPT 3 Function Redundant 24VAC.200 MBtu/HR (211000 kJ) (200,000 BTU [58.62 kW] / HR) or 400 MBtu/HR (42200 kJ) (400,000 BTU [117.24 kW]/ HR) at sea level. Derate input for altitude over 2000 tt. (609.6 m) by 4"/. each 1000 ft. (304.8 m) above sea level.(one gallon (3.79 L) fueloi l = 140 MBtu/HR (14770 kJ)).

CONTENTSPAGE

sEcTtoN I tNSTALLATION ............ . .1

C. HEATING APPLIANCE INSPECTION. ... . . . . . .-. . .-.2

D. CHIMNEY FLUE PIPE AND DRAFT CONTROL ... . . . . . . . . . . .2.3E. COMBUSTTON CHAMBER .... . . . . . . . . .4

G. ELECTRICAL

H. MAIN BURNER ORIFICE SIZING AND INSTALLATION ... . . . . . . . . . . . . . . . . . . . . .5r. CoMBUSTTON GAS VA1VE.... . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

SECTION III OPERATION AND TROUBLESHOOTING.. ...........9.14SECTION IV SERVICE

EXPLODED VIEW

TECHNICAL INFORMATION.,........

SPECIFICATIONS MODELSHSG200, HSG400

NATURAL OR PROPANE GAS

NOTE: Dimensions in ( ) are informational only. English values take priority.

HSG200Maximum Input Capacity - 200 MBtu/HR (211000 kJ)Minimum Input Capacity - 60 MBtu/HR (63300 kJ)

HSG400Maximum Input Capacity - 400 MBtu/HR (422000 kJ)Minimum Input Capacity - 200 MBtu/HR (211000 kJ)

SUPPLY LINE PRESSURE REQUIRED: Natural or Propane 5.5 W.C. (1370 Pa) Minimum, 14.0 W.C. (3487 Pa)Maximum

AIR TUBE DIAMETER: 4 inches (101.6 mm)

AIR TUBE LENGTHS: HSG200(See Fig. 12C for HSG400Overall Dimensions) HSG200/400

HSG200/400

6 inches6.25 inches9.00 inches12.00 inches

(152.4 mm)(158.75 mm)(228.6 mm)(304.8 mm)

MOUNTING: Adjustable flange standard (deduct 1 1/8 inch (28.575 mm) from above air tube lengths when usingflange). Optional pedestal mounting.

STANDARD VOLTAGE: 120 VAC 1 60 HZ/1 Phase120 VAC 150 HZ/1 Phase (Special motor installed with max capacity reduced 20%)220 VAC 150 HZ/1 Phase

FLAME SAFETY: 24 VAC Electronic

IGNITION: 7300 VAC Direct Spark

GAS VALVE: 3/4 x 3/4 (19.05 mm x 19.05 mm) NPT 3 Function Redundant 24 VAC

*200 MBtu/HR (211000 kJ) (200,000 BTU [58.62 kW] 1 HR) or 400 MBtu/HR (42200 kJ) (400,000 BTU [117.24 kW]1HR) at sea level. Derate input for altitude over 2000 ft. (609.6 m) by 4% each 1000 ft. (304.8 m) above sea level.(one gallon (3.79 L) fuel oil =140 MBtu/HR (14770 kJ)).

CONTENTSPAGE

SECTION I INSTALLATION 1

A. GENERAL 2

B. VENTILATION 2

C. HEATING APPLIANCE INSPECTION 2

D. CHIMNEY, FLUE PIPE AND DRAFT CONTROL 2-3

E. COMBUSTION CHAMBER 4

F. GAS PIPING 4

G. ELECTRiCAL 5

H. MAIN BURNER ORIFICE SIZING AND INSTALLATION 5

I. COMBUSTION GAS VALVE 6

SECTION II INITIAL START UP 7-8

SECTION III OPERATION AND TROUBLESHOOTING 9-14

SECTION IV SERVICE 15-16

PARTS LISTS 17

EXPLODED VIEW 18

TECHNICAL INFORMATION 19

WARRANTy 20

CONSUMER INSTRUCTIONS 21

SECTION IINSTALLATION

A. GENERAL

The Wayne HSG200 and HSG400 power gasconversion burners are adaptable to most types ofcentral heating plants previously fired by power oilburners. Typical heating plants are gravity and forcedair circulation furnaces, hot water, steam or vaporboilers. Power burner design makes the HSG200 andHSG400 well suited for "negative draft" firedappliances where an oil burner is being replaced.

lnstallation of these power gas conversion burnermodels must conform to local codes, or in theirabsence, the American National Standard for theInstallation of Domestic Gas Conversion Burners.ANS|Z21.8 - and the National Flue Gas Code,ANSlZ223.1 or current standard year.

NOTICE: ANSI or local installation code compliance isthe sole responsibility of the qualified installer.

VENTILATION

The HSG conversion burner models covered by thismanual shall not be installed in an appliance locatedwhere normal air circulation or infiltration is limited inproviding all the air necessary for proper combustionand draft hood dilution air.

ln ooen basements of homes of normal construction(without basement storm windows or tight stair doors)infiltration of combustion air is usually sufficient toreplace that drawn up the flue, so special provisionsare seldom necessary.

When the heating appliance is installed in a tightly closedroom without ventilation openings to outdoors, or otherrooms, provisions shall be made for supplying air forcombustion through special openings, one near the floorline and the other near the ceiling. Each is to be sizedon the basis of one square inch (645.2mm') or more offree area each 1,000 BTU (.29kW) input per hour.

When the building is of unusually tight construction, haskitchen and/or bathroom ventilation fans which may beused for exhausting air to outdoors, or has a ventedfireplace, it is recommended that combustion air besupplied to the furnace room through intakes extendingto the outside of the building and terminating in downturned fittings, suitably arranged to prevent obstructionfrom snow or rain, and including a protecting screen notsmaller than 1/4 inch (6.35mm) mesh.

HEATING APPLIANCE INSPECTION

Clean the appliance heat exchanger interior,combustion chamber and flue connections. Removeall adhering tars, scale, dirt and soot. lnspect the heat

exchanger for obvious and potential flue gas leaks.Cement all joints around the appliance base andaccess openings to prevent air and/or flue gas leakageinto or out of the combustion chamber.

Warm Air Furnaces* - Make certain the electricalcharacteristics of the fan and limit switch correspond tothose required by this burner and that they are inproper working order.

Hot Water Boilers* - Make certain water temperatureand altitude gauges, pressure relief valves are inproper working order.

Steam Boilers* - Make certain the system is pressuretight, and that the pressure gage and pop off safetyvalve are in proper working order. Existing water sightglass permits clear observation of boiler water level.

*Where applicable, existing temperature of pressurelimit switch or low water cut-off switch operation andelectrical characteristics shall be checked to determinetheir compatibility to the gas control circuitry of thisburner.

D. CHIMNEY, FLUE PIPE AND DRAFT CONTROL

The chimney should be inspected for unsafeconditions such as excessive soot accumulation,deteriorated masonry, blockage or potential blockage.

NOTICE: No manually adjustable flue pipe damper ispermitted on any gas burner installation.

The chimney should be lined with a corrosion resistantmaterial, lf the chimney is unlined, consult your localgas utility for recommendations.

WARNING: Under no circumstances should the fluepipe be connected to the chimney of an open fireplace.

The flue pipe should be sized to carry of the flue gasesas outl ined in Figure 1.

Figure 1

Strict compliance to appropriate codes should be maderegarding flue pipe clearances from combustible materials,

B.

INPUTBTU/HR (kW/HR)

DRAFTHOODFLUE PIPE SIZE

UP to -120 MBH (35.172kW) 5 INCH (127mm) DIAMETER120 MBtu/HR 135172kM - 180 MBH (52.758kW)6 INCH (152.4mm) DIAMETER180 MBtu/HR (52.758kM - 250 MBH (73.275kW)7 INCH {177.8mm) DIAMETER250 MBtu/HR f3.275k$ - 320 MBH {93.792kW)8 INCH (203.2mm) DIAMETER320 MBtu/HR (93 792kW)- 410 MBH (120.171kW)I INCH (228.6mm) DIAMETER

c.

PAGE 2

SECTION IINSTALLATION

A. GENERAL

The Wayne HSG200 and HSG400 power gasconversion burners are adaptable to most types ofcentral heating plants previously fired by power oilburners. Typical heating plants are gravity and forcedair circulation furnaces, hot water, steam or vaporboilers. Power burner design makes the HSG200 andHSG400 well suited for "negative draft" firedappliances where an oil burner is being replaced.

Installation of these power gas conversion burnermodels must conform to local codes, or in theirabsence, the American National Standard for theInstallation of Domestic Gas Conversion Burners,ANSIZ21.8 - and the National Flue Gas Code,ANSIZ223.1 or current standard year.

NOTICE: A1'JSI or local installation code compliance isthe sole responsibility of the qualified installer.

B. VENTILATION

The HSG conversion burner models covered by thismanual shall not be installed in an appliance locatedwhere normal air circulation or infiltration is limited inproviding all the air necessary for proper combustionand draft hood dilution air.

In open basements of homes of normal construction(without basement storm windows or tight stair doors)infiltration of combustion air is usually sufficient toreplace that drawn up the flue, so special provisionsare seldom necessary.

When the heating appliance is installed in a tightly closedroom without ventilation openings to outdoors, or otherrooms, provisions shall be made for supplying air forcombustion through special openings, one near the floorline and the other near the ceiling. Each is to be sizedon the basis of one square inch (645.2mm2

) or more offree area each 1,000 BTU (.29kW) input per hour.

When the building is of unusually tight construction, haskitchen and/or bathroom ventilation fans which may beused for exhausting air to outdoors, or has a ventedfireplace, it is recommended that combustion air besupplied to the furnace room through intakes extendingto the outside of the building and terminating in downturned fittings, suitably arranged to prevent obstructionfrom snow or rain, and including a protecting screen notsmaller than 1/4 inch (6.35mm) mesh.

C. HEATING APPLIANCE INSPECTION

Clean the appliance heat exchanger interior,combustion chamber and flue connections. Removeall adhering tars, scale, dirt and soot. Inspect the heat

exchanger for obvious and potential flue gas leaks.Cement all joints around the appliance base andaccess openings to prevent air and/or flue gas leakageinto or out of the combustion chamber.

Warm Air Furnaces* - Make certain the electricalcharacteristics of the fan and limit switch correspond tothose required by this burner and that they are inproper working order.

Hot Water Boilers* - Make certain water temperatureand altitude gauges, pressure relief valves are inproper working order.

Steam Boilers* - Make certain the system is pressuretight, and that the pressure gage and pop off safetyvalve are in proper working order. Existing water sightglass permits clear observation of boiler water level.

*Where applicable, existing temperature of pressurelimit switch or low water cut-off switch operation andelectrical characteristics shall be checked to determinetheir compatibility to the gas control circuitry of thisburner.

D. CHIMNEY, FLUE PIPE AND DRAFT CONTROL

The chimney should be inspected for unsafeconditions such as excessive soot accumulation,deteriorated masonry, blockage or potential blockage.

NOTICE: No manually adjustable flue pipe damper ispermitted on any gas burner installation.

The chimney should be lined with a corrosion resistantmaterial. If the chimney is unlined, consult your localgas utility for recommendations.

WARNING: Under no circumstances should the fluepipe be connected to the chimney of an open fireplace.

The flue pipe should be sized to carry of the flue gasesas outlined in Figure 1.

INPUT DRAFTHOODBTU/HR (kW/HR) FLUE PIPE SIZE

UP to -120 MBH (35.172kW) 51NCH (127mm) DIAMETER120 MBtu/HR (35172kW) -180 MBH (52.758kW) 6 INCH (152.4mm) DIAMETER180 MBtu/HR (52.758kW) - 250 MBH (73.275kW) 7 INCH (177.8mm) DIAMETER250 MBtu/HR (73.275kW) - 320 MBH (93.792kW) 8INCH (203.2mm) DIAMETER320 MBlu/HR (93.792kW)- 410 MBH (120171 kW) 9 INCH (228.6mm) DIAMETER

Figure 1

Strict compliance to appropriate codes should be maderegarding flue pipe clearances from combustible materials.

PAGE 2

Pitch the horizontal run of the flue pipe upward 1/4 inch(6.35mm) per foot (.305m) or more. Run directly to thechimney, fasten joints securely and support horizontalruns to prevent sagging.

lf the flue pipe must be extra long, it's size should beincreased. The horizontal length of the flue pipe shouldnot exceed the height of the chimney above the flueconnection.

PITCH HOBIZONTALRUN 1/4" (6.35mm) MlN.

PER FOOT (.gosM)

VERTICALDRAFT HOOD

Figure 2

HSG -BURNER

The draft control should be hood type per Figure 2 or,lFAPPROVED BY LOCAL AUTHORITIES, a singlebarometric damper suitable for gas firing per Figure 3.The draft control should be sized the same as the fluepipe per Figure 1, and should be located higher than thehighest part on the appliance flue passage. Refer to thebarometric draft regulator manufacturer's instructions forcomplete detail.

NOTICE: Should the flue pass through a partition,the draft control must be located in thesame room as the heating appliance.

PITCH HORIZONTALBUN 1/4" (6.3smm) MlN.

PEF FOOT (.3osrV) DO NOT EXTENDFLUE PIPE BEYONOINSIDE OF CHIMNEY

SINGLE ACTINGBAROMETRIC

DRAFT CONTROL

BAROMETRIC DRAFTCONTROL POSITION

Figure 3

EXISTINGPREFABRICATEOCOMBUSTIONCHAMBEB LINER

TO PROTECT PROPERLYLOCATE END OF BURNEFTUBE. POSITION TUBE 1/2'(12.7mm) SHORT OF INSIDEOF COMBUSTIONCHAMBEB

FORCED AIR FURNACEFigure 4

EXISTING ORADDED TARGETTO BACK OF COMBUS-TION CHAMBER

TO PROTECT PBOPERLYLOCATE END OF BURNERTUBE. POSITION TUBE 1/2'(12.7mm) SHORT OF INSIDEOF COMBUSTIONCHAI\4BER

EXISTINGPREFABRICATEOCOMBUSTIONCHAIV]BEB LINEFI

TO PROTECT PROPERLYLOCATE END OF BURNEFTUBE. POSITION TUBE 1/2"(12.7mm) SHOBT OF INSIDEOF COMBUSTIONCHAMBEF

HOT WATER OR STEAM BOILER WITHCOMBUSTION CHAMBER TARGET

Figure 5PAGE 3

HOT WATER OR STEAM BOILER WITHCOMBUSTION CHAMBER LINER

COFFOSIONRESISTANT LINING

CLEANOUT

SELECT EITHERHORIZTONAL ORVEFTICAL DBAFT HOOD

DRAFT HOOD POSITONS

Figure 6

Pitch the horizontal run of the flue pipe upward 1/4 inch(6.35mm) per foot (.305m) or more. Run directly to thechimney, fasten joints securely and support horizontalruns to prevent sagging.

If the flue pipe must be extra long, it's size should beincreased. The horizontal length of the flue pipe shouldnot exceed the height of the chimney above the flueconnection.

CHI""NEYCLEANOUT

BULL HEAD TEE

CORROSION -=-+--1------'"RESISTANT LINING

DO NOT EXTENDFLUE PIPE BEYONDINSIDE OF CHIMNEY

SINGLE ACTINGBAROMETRIC

DRAFT CONTROL

The draft control should be hood type per Figure 2 or, IFAPPROVED BY LOCAL AUTHORITIES, a singlebarometric damper suitable for gas firing per Figure 3.The draft control should be sized the same as the fluepipe per Figure 1, and should be located higher than thehighest part on the appliance flue passage. Refer to thebarometric draft regulator manufacturer's instructions forcomplete detail.

NOTICE: Should the flue pass through a partition,the draft control must be located in thesame room as the heating appliance.

PITCH HORIZONTALRUN 1/4" (6.35mm) MIN.

PER FOOT (.305M)

CHIMNEY

CORROSIONRESISTANT LINING

CLEANOUT

DO NOT EXTENDFLUE PIPE BEYONDINSIDE OF CHIMNEY

SELECT EITHERHORIZTONAL ORVERTICAL DRAFT HOOD

DRAFT HOOD POSITONS

REDUCER

VERTICALDRAFT HOOD

PITCH HORIZONTALRUN 1/4" (6.35mm) MIN.

PER FOOT (.305M)

Figure 2 BAROMETRIC DRAFTCONTROL POSITION

Figure 3

EXISTINGPREFABRICATEDCOMBUSTIONCHAMBER LINER

HSGBURNER

TO PROTECT PROPERLYLOCATE END OF BURNERTUBE. POSITION TUBE 112"(12.7mm) SHORT OF INSIDEOF COMBUSTIONCHAMBER

FORCED AIR FURNACE

Figure 4

HOT WATER OR STEAM BOILER WITHCOMBUSTION CHAMBER LINER

Figure 6

EXISTINGPREFABRICATEDCOMBUSTIONCHAMBER LINER

TO PROTECT PROPERLYLOCATE END OF BURNERTUBE. POSITION TUBE 1/2"(12.7mm) SHORT OF INSIDEOF COMBUSTIONCHAMBER

,,_ ... y .. ..l .. .,.. .. .J. ...y

.. __, , ,. , ,, , ,. , ,, , ,, . ,. ,

HSGBURNER

EXISTING ORADDED TARGETTO BACK OF COMBUS·TION CHAMBER

TO PROTECT PROPERLYLOCATE END OF BURNERTUBE. POSITION TUBE 1/2"(12.7mm) SHORT OF INSIDEOF COMBUSTIONCHAMBER

HOT WATER OR STEAM BOILER WITHCOMBUSTION CHAMBER TARGET

Figure 5PAGE 3

E. COMBUSTION CHAMBER

A combustion chamber is normally required toprotect non-heat transfer surfaces, and to provide aradiant bed for rapid heat transfer to the primarysurfaces of the heat exchanger. lf in good condition,the existing combustion chamber can be used.

Afull combustion chamber liner is recommended forwarm air furnaces, (see Figure 4), and a target wallor full combustion chamber liner is recommendedfor wet leg cast iron or steel boilers. (See Figures 5and 6). lf a built-up chamber is necessary, use2300' F (1260"C) minimum insulating fire-brick orfiberfrax.

THE BURNER AIR TUBE MUST NOT BEALLOWED TO EXTEND INTO THE CHAMBERPROPER; lT MUST BE SET 1/2 INCH (12.7mm1SHORT OF THE INSIDE SURFACE.

Before permanently securing the burner to theheating appliance with either the adjustable mountingflange or pedestal or cementing around the air tubein the combustion chamber opening, check that theburner head assembly is free of foreign materials andthat the sensor and electrode probes have not beendamaged or repositioned, see Figure 13.

RECOMMENDED COMBUSTIONCHAMBER SIZES

Figure 7

SUPPLY LINE CONNECTIONTO BURNER

F. GAS PIPINGNOTICE: All piping must comply with state and/orlocal codes. The available gas supply pressureshould be within minimum and maximum pressuresshown in the burner specifications. lf the gas supplypressure exceeds the 14" W.C. (3.5 k Pa) maximum,an intermediate main gas regulator must be installedahead of the main gas manual shut off valve shownin Figure 8.WARNING: Failure to install the intermediate gasregulator will result in gas leakage from burner gasvalve.A drip leg or sediment trap must be installed in thesupply line to the burner. See Figure 8.A pipe union shall be installed in the gas lineadjacent to, and upstream from, the main gasmanual shutoff valve, See Figure 8.The gas supply piping to the burner should branchoff from the main gas supply line as close to the gasmeter as possible. Do not connect to the bottom ofa horizontal section. See Figure 9 for gas supplypipe sizes.Use new black iron pipe and malleable fittings freeof burrs and defects. Use pipe joint compoundresistant to liquefied petroleum gases.A118" (3.175mm) NPT plugged tapping accessiblefor test gauge connection shall be providedimmediately upstream of the gas supply connectionfor determining gas supply pressure to the burner.Test new supply piping for leaks. CAUTION:DURING PRESSURE TEST FOR LEAKS IN GASSUPPLY PIPING, THE BURNER MUST BEDISCONNECTED TO PREVENT EXPOSING THECOMBINATION GAS VALVE TO PRESSURESOVER 112" (3447 PaG) PSIG. POSSIBLYDAMAGING THE VALVE AND VOIDING THEBURNER WARRANTY.

CAPACITIES SHOWN ARE FOR A TOTAL PRESSUREDROP OF 0.3" W.C. (74.73Pa) FOR 0.5" W.C. (12a.55Pa)PRESSURE DROP. MULTIPLY CAPACITY SHOWN BY 1.3.FOR HIGHER PERMISSIBLE PRESSURE DROPS,CONSULT YOUR UTILITY.

SUPPLY PIPE CAPACITIES lN MBtu/HR (kW)

INPUTBTU/HRkWHr

PREFERRED

wlu I H"{mm) x LLNU I H"(mm)ulAM." (mm50 MBtu/HH (.|4.655kW) 7 n77 8\X7 t177 8\ 8 (203.2)

75 MBtu/HR (219.825kW)7 1/2 (190 5) X 7 1/2 (190.5) 9 {228.6)100 MBtu/HR (293.1kW) 12 (304.8) X 12 (304.8) 1 3 (330.2)150 MBtu/HR (439 65kW) 12 (304.8) X 15 (381) 14 (355 6)200 MBtu/HR (586.2kW) 13 (330.2) X 17 (431.8) 15 (381 )250 MBtu/HR fi32.75kW) 13 (330.2) X 18 1457.2) '16 (406.4)300 MBtu/HR f879,3kW) 13 (330.2) X 20 (508) 18 U57.2\350 MBtu/HR (1 025.85kW)14 (355.6) X 21 (533.4) 20 (508)400 MBtu/HR {11i2.4kw) t5 (381) X 22 {558.8) 21 (533.4)

PI PESIZE

TYPEOF GAS

CAPACITY - MBtu/HR (kJ)

LENGTH OF PIPE15 (381mm)l0 (762mm)15 (1143mm)0 (2286mm

3t4t19.05mm)

Propane 400422000k.t.|

250t263750k,

20021 1 000kJ)

1(25.4mm)

l\atu ral

Propane

4UU422000kJ)

z5u(263750kJ

400ta220nok. l

ZUU21 1 000kJ)

350i6q25nk. t)

250'26i750k.t \

1 1t4(31.75mm)

Natural

Propane

400(422000kJ)

400422000kJ)

400422000k.1\

30031 6500kJ)

400422000kJ)

1 1t2l38.1mm)

Natural 400arrnnnk.t\

Figure 8

Figure 9PAGE 4PAGE 4

E. COMBUSTION CHAMBER

A combustion chamber is normally required toprotect non-heat transfer surfaces, and to provide aradiant bed for rapid heat transfer to the primarysurfaces of the heat exchanger. If in good condition,the existing combustion chamber can be used.

A full combustion chamber liner is recommended forwarm air furnaces, (see Figure 4), and a target wallor full combustion chamber liner is recommendedfor wet leg cast iron or steel boilers. (See Figures 5and 6). If a built-up chamber is necessary, use2300° F (1260°C) minimum insulating fire-brick orfiberfrax.

THE BURNER AIR TUBE MUST NOT BEALLOWED TO EXTEND INTO THE CHAMBERPROPER; IT MUST BE SET 1/2 INCH (12.7mm)SHORT OF THE INSIDE SURFACE.

Before permanently securing the burner to theheating appliance with either the adjustable mountingflange or pedestal or cementing around the air tubein the combustion chamber opening, check that theburner head assembly is free of foreign materials andthat the sensor and electrode probes have not beendamaged or repositioned, see Figure 13.

INPUT PREFERREDBTU/HR

kW/Hr WIDTH"(mm) XLENGTH"(mm) DIAM." (mm50 MBtu/HR (14655kW) 7 (177.8) X7 (177.8) 8(203.2)75 MBtu/HR (219825kW) 71/2 (1905) X71/2 (190.5) 9(2286)100 MBtu/HR 293,lkW) 12 304,8 X12 304.8) 13 330.2)150 MBtu/HR 43965kW) 12 304.8 X15 381) 14 3556)200 MBtu/HR 586,2kW) 13 330.2 X17 431.8) 15 381)250 MBtu/HR 73275kW) 13 330.2 X18 457.2) 16 4064)300 MBtu/HR 8793kW) 13 330.2 X20 508) 18 457.2)350 MBtu/HR 102585kW) 14 355.6 X21 5334) 20 508)400 MBtu/HR 11724kW) 15 381) X22 (558.8) 21 5334)

RECOMMENDED COMBUSTIONCHAMBER SIZES

Figure 7

~ANUALSHUTOFFVALVE

I 1/8" (3,175mm) N.P.T.DIRECTION • PLUGGED TAPPINGOF FLOW PRESSURE GAGE PORT

I

'i,--y--+-

PIPE CAP

DRIP LEG

SUPPLY LINE COI\II\IECTIONTO BURNER

Figure 8

F. GAS PIPINGNOTICE: All piping must comply with state andlorlocal codes. The available gas supply pressureshould be within minimum and maximum pressuresshown in the burner specifications. If the gas supplypressure exceeds the 14" W.C. (3.5 k Pa) maximum,an intermediate main gas regulator must be installedahead of the main gas manual shut off valve shownin Figure 8.WARNING: Failure to install the intermediate gasregulator will result in gas leakage from burner gasvalve.A drip leg or sediment trap must be installed in thesupply line to the burner. See Figure 8.A pipe union shall be installed in the gas lineadjacent to, and upstream from, the main gasmanual shutoff valve. See Figure 8.The gas supply piping to the burner should branchoff from the main gas supply line as close to the gasmeter as possible. Do not connect to the bottom ofa horizontal section. See Figure 9 for gas supplypipe sizes.Use new black iron pipe and malleable fittings freeof burrs and defects. Use pipe joint compoundresistant to liquefied petroleum gases.A 1/8" (3.175mm) NPT plugged tapping accessiblefor test gauge connection shall be providedimmediately upstream of the gas supply connectionfor determining gas supply pressure to the burner.Test new supply piping for leaks. CAUTION:DURING PRESSURE TEST FOR LEAKS IN GASSUPPLY PIPING, THE BURNER MUST BEDISCONNECTED TO PREVENT EXPOSING THECOMBINATION GAS VALVE TO PRESSURESOVER 1/2" (3447 PaG) PSIG. POSSIBLYDAMAGING THE VALVE AND VOIDING THEBURNER WARRANTY.

PIPE TYPECAPACITY - MBtu/HR (kJ)

SIZE OF GAS LEI~GTH OF PIPE

15 (381mm) 30 (762mm) 45 (1143mm) 90 (2286mm3/4 Propane 400 250 200

1(19.05mm) 422000kJ) I (263750kJ) 211000kJ)1 Natural 400 250 200

(25.4mm) (422000kJ) (263750kJ) (211000kJ)Propane 400 350 250

I(422000kJ) 369250kJ) '263750kJ)1 1/4 Natural 400 400 300

(31.75mm) (422000kJ) (422000kJ) (316500kJ)Propane 400 400

422000kJ) 422000kJ)1 1/2 Natural 400

(38.1mm) '422000kJ)

CAPACITIES SHOWN ARE FOR A TOTAL PRESSUREDROP OF 0.3" W.C. (74.73Pa) FOR 0.5" W.C. (124.55Pa)PRESSURE DROP, MULTIPLY CAPACITY SHOWN BY 1.3.FOR HIGHER PERMISSIBLE PRESSURE DROPS,CONSULT YOUR UTILITY.

SUPPLY PIPE CAPACITIES IN MBtulHR (kW)

Figure 9

G. ELECTRICAL

The installation must be wired and GROUNDED inaccordance with local codes or in their absence,with the National Electric Code ANSI/NFPA No. 70-1987 or latest edition.For the 120 VAC wiring to the burner, use solidcopper conductor wire not lighter than #14 AWG. lfa fused disconnect is used, it should be fused for aminimum of 15 amps.CAUTION: Each installation must include suitablelimit controls. Existing oil burner combination limitand operating controls are normally not suitable forgas burner use.CAUTION: The burner is equipped with it's own 24VAC transformer. Do not add any 24 VAC powerconsuming device in the 24 VAC control circuit ofthe burner, as it could overload the transformer.Set the room thermostat "heat anticipator" for thetotaf current draw of the 24 VAC burner operationcircuit. (HSG200 0.55 amps, HSG400 0.7 amps)GAUTION: Label all wires orior to disconnectionwhen servicing controls. Wiring errors can causeimproper and dangerous operation.Verify proper operation after servicing.NOTE: lf any of the original burner wiring must be

replaced, it must be replaced with #18AWG 105 degrees C wire or equivalent.

Section 3- Operation and Troubleshooting forapplicable burner wiring diagrams.

H. MAIN BURNER ORIFICE SIZINGAND INSTALLATION

The HSG200 and HSG400 power gas conversionburners are approved for use with natural andpropane gas only.The HSG200 and HSG400 burner models areshipped labeled and orificed for natural gas. Toconveft to propane gas and/or increase BTU/HR(kcal/Hr) input on natural or propane gas, an orificekit is supplied with each burner with the orificesshown in Figure 10.When selecting a desired BTU/HR (kcal/Hr) input,figure 140,000 BTU's per gallon of oil input. Forexample: furnace or boiler rating of 0.75gph at 100psig. The 0.75 x 140,000 = 105,000 BTU's inputrate. lt may be possible to reduce the firing rate onnatural or propane gas 15% lo 20o/", as most olderappliances are oversized for the heating load.(2.83875L x 9356 kcal = 26559.35 kcal)To remove or interchange main orifice discs refer toFigure 15 (Page 16).1. Remove slotted orifice cap, ltem #40, making

sure orifice cap gasket, #39, stays attached toorifice cap and is not damaged.

2. Remove orifice spring, ltem #38, to access andremove orifice disc. ltem #42.

3. Install desired orifice from Figure 10, makingsure it is seated flat in the orifice holder, ltem#37.

4. Replace orifice spring and securely tightenorifice cap against orifice cap gasket in orificeholder.

NOTE: For50 cycleapplicationderate inputby 15%

HSG SERIES POWER GAS CONVERSION BURNERSORIFICE CHART

Figure 10

ORIFICESIZE & DRILL

MANIFOLD PRESSURE2.0" (498.2Pa) 3.0" (747.3Pa) 4.0" (996.4Pa)

HSG2OO NATURAL GAS#29 - .136 (3.4544mm) 50.000 BTU (52750kJ) 64.000 BTU {67520kJ) 76.500 BTU (80707.5kJ#8 - .199 (5.0546mm)i4,000 BTU (78070kJ)95.000 BTU (100225kJ)116.000 BTU (122380kJ

J - .277 (7.0358mm)112.000 BTU (118160kJ)138.000 BTU (145590kJ)164.000 BTU (173020kJ

Q - .332 (8.4328mm) 160,000 BTU (168800kJ)206,000 BTU (217330kJ)HSG2OO L.P. GAS

#30 - 128 (3.2512mm) 49.000 BTU (5169skJ) 58.500 BTU (61717.5kJ)68.200 BTU (71951kJ)

#27 - j44 (3.6576mm)66.000 BTU (69630kJ) 78,000 BTU (82290kJ) 92.000 BTU {97060kJ)#15 - .180 (4.572mm)82.000 BTU (86510kJ) '1 12.500 BTU (1 1 8687.5kJ)136.000 BTtl (143480kJ)D - .246 (6.2484mm) 131,000 BTU (138205kJ)1 87.500 BTU (1 9781 2.5kJ)243,000 BTU (256365kJ)

HSG4OO NATURAL GAST - .358 (9.0932mm) 200.000 BTU (211000kJ)248.000 BTU (261640kJ)285000 BTU (300675kJ)

15/32 - .468 (11.8872mm)265,000 BTU (279575kJ)343.000 BTU {361865kJ)400,000 BTU (422000kJ)HSG4OO L.P. GAS

K - .281 (7.1374mm) 190.000 BTU (200450kJ)242.500 BTU (255837.5kJ ) 295.000 BTU {311225kJ)0- .332 (8.4328mm)242,500 BTU (255837kJ)332,500 BTU (350787.5kJ)400,000 BTU (422000kJ)

PAGE 5

G. ELECTRICAL

The installation must be wired and GROUNDED inaccordance with local codes or in their absence,with the National Electric Code ANSI/NFPA No. 70­1987 or latest edition.

For the 120 VAC wiring to the burner, use solidcopper conductor wire not lighter than #14 AWG. Ifa fused disconnect is used, it should be fused for aminimum of 15 amps.

CAUTION: Each installation must include suitablelimit controls. Existing oil burner combination limitand operating controls are normally not suitable forgas burner use.

CAUTION: The burner is equipped with it's own 24VAC transformer. Do not add any 24 VAC powerconsuming device in the 24 VAC control circuit ofthe burner, as it could overload the transformer.

Set the room thermostat "heat anticipator" for thetotal current draw of the 24 VAC burner operationcircuit. (HSG200 0.55 amps, HSG400 0.7 amps)

CAUTION: Label all wires prior to disconnectionwhen servicing controls. Wiring errors can causeimproper and dangerous operation.

Verify proper operation after servicing.

NOTE: If any of the original burner wiring must bereplaced, it must be replaced with #18AWG 105 degrees C wire or equivalent.

Section 3- Operation and Troubleshooting forapplicable burner wiring diagrams.

H. MAIN BURNER ORIFICE SIZINGAND INSTALLATION

The HSG200 and HSG400 power gas conversionburners are approved for use with natural andpropane gas only.

The HSG200 and HSG400 burner models areshipped labeled and orificed for natural gas. Toconvert to propane gas and/or increase BTU/HR(kcal/Hr) input on natural or propane gas, an orificekit is supplied with each burner with the orificesshown in Figure 10.

When selecting a desired BTU/HR (kcal/Hr) input,figure 140,000 BTU's per gallon of oil input. Forexample: furnace or boiler rating of 0.75gph at 100psig. The 0.75 x 140,000 == 105,000 BTU's inputrate. It may be possible to reduce the firing rate onnatural or propane gas 15% to 20%, as most olderappliances are oversized for the heating load.

(2.83875L x 9356 kcal == 26559.35 kcal)

To remove or interchange main orifice discs refer toFigure 15 (Page 16).

1. Remove slotted orifice cap, Item #40, makingsure orifice cap gasket, #39, stays attached toorifice cap and is not damaged.

2. Remove orifice spring, Item #38, to access andremove orifice disc, Item #42.

3. Install desired orifice from Figure 10, makingsure it is seated flat in the orifice holder, Item#37.

4. Replace orifice spring and securely tightenorifice cap against orifice cap gasket in orificeholder.

PAGE 5

ORIFICE MANIFOLD PRESSURESIZE & DRILL 2.0" (498.2Pa) 3.0" (747.3Pa) 4.0" (996.4Pa)

HSG200 NATURAL GAS#29 - .136 (3.4544mm) 50,000 BTU 152750kJl 64,000 BTU 167520kJ) 76 500 BTU 180707.5kJ)#8 - .199 (5.0546mml 74,000 BTU 178070kJ) 95,000 BTU (1 00225kJ) 116,000 BTU (122380kJ)J - .277 (7.0358mm) 112,000 BTU (118160kJ) 138,000 BTU 1145590kJ) 164,000 BTU 1173020kJ)Q - .332 (8.4328mm) 160,000 BTU 1168800kJ) 206,000 BTU (217330kJ)

HSG200 L.P. GAS#30 - .128 13.2512mm) 49,000 BTU 151695kJ) 58,500 BTU 161717.5kJ) 68,200 BTU 171951 kJ)

#27 - .144 (3.6576mm) 66,000 BTU 169630kJ) 78,000 BTU 182290kJ) 92,000 BTU 197060kJ)#15 - .180 14572mm) 82,000 BTU 186510kJ) 112,500 BTU 1118687.5kJ) 136,000 BTU 1143480kJ)D· .246 (6.2484mm) 131,000 BTU 1138205kJ) 187,500 BTU (197812.5kJ) 243,000 BTU 1256365kJ)

HSG400 NATURAL GAST- .358 (9.0932mm) 200,000 BTU (211 OOOkJl 248,000 BTU 1261640kJ) 285000 BTU 1300675kJ)

15/32 - .468 (11.8872mm) 265,000 BTU (279575kJ) 343,000 BTU (361865kJ) 400,000 BTU (422000kJlHSG400 L.P. GAS

K- .281 (7.1374mm) 190,000 BTU (200450kJ) 242,500 BTU (255837.5kJ) 295,000 BTU 1311225kJlQ - .332 (8.4328mm) 242,500 BTU (255837kJ) 332,500 BTU (350787.5kJ) 400,000 BTU (422000kJ)

HSG SERIES POWER GAS CONVERSION BURNERSORIFICE CHART

Figure 10

NOTE: For50 cycleapplicationderate inputby 15%

J.

COMBINATION GAS VALVE

The 24 VAC combination gas valve serves three (3)functions: (1) manual gas shut-off, (2) main gasflame pressure regulator, (3) automatic electricredundant (double seated) gas shut off. (SeeFigure 11)

The correct operating manifold orifice pressure rangefor both natural and propane gas is 2.0" W.C.(498.2Pa) minimum to 4.0" W.C. (996.aPa)maximum. By adjusting the pressure regulatorbetween 2.0" W.C. (498.2Pa) and 4.0' W.C.(996.4Pa) on either natural or propane gas, a wideinput range can be achieved with a single orifice size.lf the desired input rating cannot be obtained withinthe above manifold orifice pressure adjustmentrange, the next size larger or smaller orifice should beused. (Referto orifice chart Fig. 10.)

PRESSURE REGULATOR ADJ USTMENT

The combination gas valve pressure regulator,which has an outlet pressure setting range of

PRESSUREREGUI-ATOR

approximately 2.0" W.C. (498.2Pa) to 4.0" W.C.(996.4Pa) is factory set at 3.5' W.C (871.85Pa).When pressure adjustment is required for settinginput capacity with a selected orifice from Figure 10,remove the regulator cap for access to the slottedadjustment screw. Turning the screw counterclockwise reduces manifold orifice pressure,clockwise increases the pressure.

NOTE: MANIFOLD PRESSURE ADJUSTMENTSCAN ONLY BE MADE WITH THEBURNER RUNNING AND THE GAS ON.

The 1/8" (3.175mm) NPT pressure tap for orificemanifold pressure measurement is located on theoutlet side of the combination gas valve. Use a "u"tube manometer or dial type pressure gauge,scaled from "0" zero lo 15.0' W.C. (3736.5Pa) toread pressure (See Figure 11).

PRESSUREREGULATOR

1/8" (3.175mm) NPTPRESSURE TAP PLUG

HSG 2OOI4OO GAS VALVEHONEYWELL VR83O5

t /ANUAL CONTROLKNOB (SHOWN tNoFF POSmON)

HSG4OO GAS VALVEROBERTSHAW TOOO DERHC

Figure 11

PAGE 6

I. COMBINATION GAS VALVE

The 24 VAC combination gas valve serves three (3)functions: (1) manual gas shut-off, (2) main gasflame pressure regulator, (3) automatic electricredundant (double seated) gas shut off. (SeeFigure 11)

The correct operating manifold orifice pressure rangefor both natural and propane gas is 2.0" WC.(498.2Pa) minimum to 4.0" W.C. (996.4Pa)maximum. By adjusting the pressure regulatorbetween 2.0" WC. (498.2Pa) and 4.0" WC.(996.4Pa) on either natural or propane gas, a wideinput range can be achieved with a single orifice size.If the desired input rating cannot be obtained withinthe above manifold orifice pressure adjustmentrange, the next size larger or smaller orifice should beused. (Refer to orifice chart Fig. 10.)

J. PRESSURE REGULATOR ADJUSTMENT

The combination gas valve pressure regulator,which has an outlet pressure setting range of

approximately 2.0" WC. (498.2Pa) to 4.0" WC.(996.4Pa) is factory set at 3.5" WC (871.85Pa).When pressure adjustment is required for settinginput capacity with a selected orifice from Figure 10,remove the regulator cap for access to the slottedadjustment screw. Turning the screw counterclockwise reduces manifold orifice pressure,clockwise increases the pressure.

NOTE: MANIFOLD PRESSURE ADJUSTMENTSCAN ONLY BE MADE WITH THEBURNER RUNNING AND THE GAS ON.

The 1/8" (3.175mm) NPT pressure tap for orificemanifold pressure measurement is located on theoutlet side of the combination gas valve. Use a "u"tube manometer or dial type pressure gauge,scaled from "0" zero to 15.0" WC. (3736.5Pa) toread pressure (See Figure 11).

PRESSUREREGULATOR

MANUAl CONTROLKNOB (SHOWN INOFF pOSmON)

1/8" (3.175mm) NPTPRESSURE TAPPLUG

INLET

MANUAL CONTROLKNOB (SHO'olN IN

orr POSITION)

118" (3.175mm) NPTPRESSURE TAP PLUG

HSG400 GAS VALVEROBERTSHAW 7000 DERHC

HSG 200/400 GAS VALVEHONEYWELL VR8305

Figure 11

PAGE 6

SECTION IIINITIAL START UP

1. NOTE: Read the applicable sequence ofburner/primary gas control operation inSection 3 Operation and Troubleshootingbefore proceeding.

2. Depress the combination gas valve manual controlknob and turn to "OFF" position.

3. Adjust the primary air and off-cycle damper to thestart up settings shown in Figure 12Aand 128.

4. On new gas line installations, air may be trapped inthe l ine, the burner may experience severallockouts until all the air is purged from the lines.

5. Turn on the main electrical power and set thethermostat or operation control to call for heat.Allow the burner to run a MINIMUM of 5 minutes topurge combustion chamber and appliance heatexchanger.

6. Set the thermostat or operating control below roomtemperature, shutting the burner "OFF" 1 minute toRESET the primary control.

7. Depress the combination gas valve manual controlnow and turn to "ON" position.

8. Set the thermostat or operating control to call forheat. The burner will start and go through theapplicable sequence of burner/primary gas controloperation, refer to step 1.

9. Once burner is running adjust the orifice manifoldpressure regulator as described in paragraph J -Pressure Regu lator Adjustment.

10. A more accurate BTU (kW) input can be determinedby using the NATURAL gas service meter with theburner only on (all other gas appliances should beoff). The hand on the gas meter dialwith the lowestcubic feet valve (fastest revolving dial), should beclocked for one complete revolution and use thefollowing formula.

3600 x cubic ft. (m3)pre revolution x btu (kW)valve/cub ic fl (m3)= BTU/HR (kWH0seconds oer revolulion

EXAMPLE: 3600 x 1 x 1000 (.2931k$ = 300,000 BTU/HR (87.93 kWHB)12

11. After the desired input has been obtained, re-adjust

the primary air damper open or closed to visuallyobtain a blue flame with well defined orange oryellow tips for natural gas, or well defined yellow tipsfor propane gas.

12. After the burner has been in operation for at least 10minutes, assuring combustion chamber and heatexchanger are fully warmed, take combustionanalysis flue gas samples just ahead of the draftcontrol in the flue pipe.

NOTE: ALWAYS USE RELIABLE COMBUSTIONTEST INSTRUMENTS. BEINGPROFICIENT IN THE USE OF THESEINSTRUMENTS AND INTERPRETINGTHEIR DATA IS NECESSARY FOR SAFE,RELIABLE AND EFFICIENT BURNEROPERATION.

13. Perform the following combustion analysis. Alladjustments below must be made with the followinginstruments: draft gauge, 02 or CO2 analyze andCO tester.

A. Adjust the primary air damper to provide about257o excess combustion air. Confirm this bychecking the flue gas for its FREE OXYGEN(Oz) or CARBON DIOXIDE (COz) PERCEN-TAGES with a test instrument. Free oxygenshould be about 4.5"/o, or carbon dioxide shouldbe about 9.5% for natural gas, 12.1"/" forpropane gas.

B. CARBON MONOXIDE - Should be checked forits presence in the flue gas. This percentageshould not exceed .04/" (or 400 PPM).

C. NOTE: Check overfire draft and adjust toNEGATIVE -.01 (2.491Pa) to -.02 (4.982Pa)inches w/c during burner operation.

PAGE 7

SECTION IIINITIAL START UP

1. NOTE: Read the applicable sequence ofburner/primary gas control operation inSection 3 Operation and Troubleshootingbefore proceeding.

2. Depress the combination gas valve manual controlknob and turn to "OFF" position.

3. Adjust the primary air and off-cycle damper to thestart up settings shown in Figure 12A and 12B.

4. On new gas line installations, air may be trapped inthe line, the burner may experience severallockouts until all the air is purged from the lines.

5. Turn on the main electrical power and set thethermostat or operation control to call for heat.Allow the burner to run a MINIMUM of 5 minutes topurge combustion chamber and appliance heatexchanger.

6. Set the thermostat or operating control below roomtemperature, shutting the burner "OFF" 1 minute toRESET the primary control.

7. Depress the combination gas valve manual controlnow and turn to "ON" position.

8. Set the thermostat or operating control to call forheat. The burner will start and go through theapplicable sequence of burner/primary gas controloperation, refer to step 1.

9. Once burner is running adjust the orifice manifoldpressure regulator as described in paragraph J ­Pressure Regulator Adjustment.

10. A more accurate BTU (kW) input can be determinedby using the NATURAL gas service meter with theburner only on (all other gas appliances should beoff). The hand on the gas meter dial with the lowestcubic feet valve (fastest revolving dial), should beclocked for one complete revolution and use thefollowing formula.

3600 xcubic ft. (m3)pre revolution xbtu (kW) valve/cub ic ft (m3)=BTUIHR (kW/Hr)seconds per revolution

EXAMPLE: 3600 x 1x 1000 1.2931 kW) =300,000 BTU/HR (87.93 kW/HR)12

11. After the desired input has been obtained, re-adjust

PAGE 7

the primary air damper open or closed to visuallyobtain a blue flame with well defined orange oryellow tips for natural gas, or well defined yellow tipsfor propane gas.

12. After the burner has been in operation for at least 10minutes, assuring combustion chamber and heatexchanger are fully warmed, take combustionanalysis flue gas samples just ahead of the draftcontrol in the flue pipe.

NOTE: ALWAYS USE RELIABLE COMBUSTIONTEST INSTRUMENTS. BEINGPROFICIENT IN THE USE OF THESEINSTRUMENTS AND INTERPRETINGTHEIR DATA IS NECESSARY FOR SAFE,RELIABLE AND EFFICIENT BURNEROPERATION.

13. Perform the following combustion analysis. Alladjustments below must be made with the followinginstruments: draft gauge, 02 or C02 analyze and

CO tester.

A. Adjust the primary air damper to provide about25% excess combustion air. Confirm this bychecking the flue gas for its FREE OXYGEN(02) or CARBON DIOXIDE (C02) PERCEN-

TAGES with a test instrument. Free oxygenshould be about 4.5%, or carbon dioxide shouldbe about 9.5% for natural gas, 12.1 % forpropane gas.

B. CARBON MONOXIDE - Should be checked forits presence in the flue gas. This percentageshould not exceed .04% (or 400 PPM).

C. NOTE: Check overfire draft and adjust toNEGATIVE -.01 (2.491 Pa) to -.02 (4.982Pa)inches w/c during burner operation.

D. The flue gas temperature should be between325"F (162.78"C) and 550"F (287.78"C)tordomestic gas conversion burners. Higher fluegas temperatures indicate overf ir ing orexcessive draft through the appliance. Lowerflue gas temperatures may cause excessivecondensation and indicate underfiring. Consultyour local utility or the appliance manufacturerfor acceptable flue gas temperatures.

CAUTION: lF THE BURNER BTU/HR (kWHr)INPUT IS CHANGED. REPEAT STEP 13

3/8" (9.525mm)

HSG2OO SETAT NO. 1HSG4OO SETAT NO. 1 1/2

OFF CYCLE DAMPERSETTING

Figure 12A

14. FILL OUT THE INSTALLATION COMBUSTIONDATA TAG AND AFFIX IT TO THE BURNER ORCONVERTED APPLIANCE.

SUGGESTION: All new installations should bereinspected for proper combustion and burneroperation after one or two weeks of normaloperation.

For subsequent normal starting and shut offprocedure, refer to the "Consumer lnstructions" inthe back of this manual or the instruction plateattached to the burner.

HSG2OO SET AT NO.2HSG4OO SET AT NO.4

PRIMARY AIRSETTING

Figure 128

IMPORTANTTHESE SETTINGS ARE FOR INITIAL STARTUP ONLY AND MUST BE

READJUSTED FOR COMBUSTION EFFICIENCY.

,ssK

Figure 12C

PAGE 8

D. The flue gas temperature should be between325'F (162.78'C) and 550'F (287.78'C)fordomestic gas conversion burners. Higher fluegas temperatures indicate overfiring orexcessive draft through the appliance. Lowerflue gas temperatures may cause excessivecondensation and indicate underfiring. Consultyour local utility or the appliance manufacturerfor acceptable flue gas temperatures.

CAUTION: IF THE BURNER BTU/HR (kWlHr)INPUT IS CHANGED, REPEAT STEP 13

14. FILL OUT THE INSTALLATION COMBUSTIONDATA TAG AND AFFIX IT TO THE BURNER ORCONVERTED APPLIANCE.

SUGGESTION: All new installations should bereinspected for proper combustion and burneroperation after one or two weeks of normaloperation.

For subsequent normal starting and shut offprocedure, refer to the "Consumer Instructions" inthe back of this manual or the instruction plateattached to the burner.

3/8" (9.525mm)

HSG200 SET AT NO.1HSG400 SET AT NO.1 1/2

OFF CYCLE DAMPERSETTING

Figure 12A

HSG200 SET AT NO.2HSG400 SET AT NO.4

PRIMARY AIRSETTING

Figure 12B

IMPORTANTTHESE SETTINGS ARE FOR INITIAL STARTUP ONLY, AND MUST BE

READJUSTED FOR COMBUSTION EFFICIENCY.

r----1J.18(JJ4.77mm) REF..----j

FlANGE NOT SHOWN

7.01(178.05mm) REF.

Figure 12C

7.88('95.07mm) REF.

15.2J(J86.84mm)REF

PAGE 8

SECTION IIIOPERATION AND TROUBLESHOOTING

SEQUENCE OF OPERATION - HSG SERIES POWER GASCONVERSION BURNER UTILIZING HONEYWELL S89F

GAS PRIMARY P/N 62759-002 WBUILT IN 30 SECOND PREPURGE

On a call for heat, voltage (24V) is applied to motor startrelay and air switch. Once the fan motor reachesoperating rpm combustion air pressure is sensed by theair proving switch and closes the switch contactsenergizing the S89F gas primary control.

THE S89F gas primary control has an internal 30second prepurge timer. After the initial 30 secondprepurge, an internal 8 second safe start check of theS89F wil l commence. Once this is successful lycompleted, the S89F simultaneously energizes the gasvalve and ignition transformer. Gas flows and thetransformer produces an approximate 7300 volt sparkend point grounded at the burner head establishingmain burner flame.

At the start of each heat cycle, there is a trial for ignitionperiod of four (4) seconds duration. Normally, burnerflame will be established before the end of this period.Once the flame is established, sparking will cease and

the flame rod will provide flame monitoring to the S89Fgas control primary for the remainder of the heat cycle.lf the flame should be extinguished during the heatcycle, the S89F gas control primary will go into the 30second prepurge and 8 second safe start check, thenre-energize the gas valve and ignition transformer in anattempt to establish the main burner flame. lf this doesnot occur within the 4 second trial for ignition period, theS89F gas primary control will go into lockout de-energizing the gas valve and ignition transformer.

To restart the system, the main power or thermostatmust be de-energized momentarily, then re-energized.lf at any time during the heat cycle, there is aninsufficient supply of combustion air to the burner, theair switch will open, putting the system into lockoutclosing the gas valve.

BURN ERGAS PRIMARY

HSG POWER GASWITH HONEYWELL S89F

24VACTRANS.

N WIRE NUT

BURNER GND 24VACYL-__--1--l

t<lYL--------lJl

REOUNOANTGAS VALVE

IGNITION RODIF ANY OF IHE ORIGIML WIRE.AS SUPPUEO $TH THE APPLINCE,MUST 8E REPLACED. IT VUSI EEREPLACED Y{ITH TYPE AWM ISGAIO5'C WIRE OR EOUIVALENT.

PAGE 9

lScHEMATiel

SECTION IIIOPERATION AND TROUBLESHOOTING

SEQUENCE OF OPERATION - HSG SERIES POWER GASCONVERSION BURNER UTILIZING HONEYWELL S89F

GAS PRIMARY PIN 62759-002 W/BUILT IN 30 SECOND PREPURGE

On a call for heat, voltage (24V) is applied to motor startrelay and air switch. Once the fan motor reachesoperating rpm combustion air pressure is sensed by theair proving switch and closes the switch contactsenergizing the S89F gas primary control.

THE S89F gas primary control has an internal 30second prepurge timer. After the initial 30 secondprepurge, an internal 8 second safe start check of theS89F will commence. Once this is successfullycompleted, the S89F simultaneously energizes the gasvalve and ignition transformer. Gas flows and thetransformer produces an approximate 7300 volt sparkend point grounded at the burner head establishingmain burner flame.

At the start of each heat cycle, there is a trial for ignitionperiod of four (4) seconds duration. Normally, burnerflame will be established before the end of this period.Once the flame is established, sparking will cease and

the flame rod will provide flame monitoring to the S89Fgas control primary for the remainder of the heat cycle.If the flame should be extinguished during the heatcycle, the S89F gas control primary will go into the 30second prepurge and 8 second safe start check, thenre-energize the gas valve and ignition transformer in anattempt to establish the main burner flame. If this doesnot occur within the 4 second trial for ignition period, theS89F gas primary control will go into lockout de­energizing the gas valve and ignition transformer.

To restart the system, the main power or thermostatmust be de-energized momentarily, then re-energized.If at any time during the heat cycle, there is aninsufficient supply of combustion air to the burner, theair switch will open, putting the system into lockoutclosing the gas valve.

HSG POWER GAS BURNERWITH HONEYWELL S89F GAS PRIMARY

~.L1 L2

MOTOR MOTOR

~-:l~9-FIRELAYI INTEGRAL IGN. TRANS.

RELAY ~

I I ~I I

THERMOSTAT ~ 24VAC TRANS.

I COIL IL..::J

AIR

~~ II

~SWITCH 1 G 24 24 V V

N VAC VAG A A= 0 L L

I LADDER I -S V V

EE E REDUNDANT

N GAS VALVE

PART NO. 62488-004 FLAME SENSOR I S-B9-F

24VAC

YL --------r=nYL-------UJ

REDUNDANTGAS VALVE

S-89-F

8w

BURNER GND

~~'TCH VALVE~ VALVEYL~YL----;}-----F1 24VAC SENS

,------'1-BRN 24VAC

GRN GNO(24VAC~8K

FLAME SENSOR

WHT ==S;:"K"====-~BLK BLU IGNITION

1\ WIRE NUT

24VACTRANS.

IGNITION ROO

:e-__---===~8L~K=7(I---'-----"'v::s A;~P~~E6H~?HRI~~~APW~~I~CE,MUST BE REPLACED. IT MUST BEREPLACED WITH TYPE AWM 18CA105" C WIRE OR EQUIVALENT.

ISCHEMATlcl'-----==--- ---.J

PAGE 9

SEQUENCE OF OPERATION - HSG SERIESPOWER GAS CONVERSION BURNER UTILIZING

HONEYWELL S89E GAS PRIMARY P/N 62758.002 W/ EXTERNAL30 SECOND PREPURGE TIMER P/N 62388-001 AND RESISTOR P/N 62530-001

On a call for heat, voltage (24V) is applied to the motorstart relay and air switch. The motor relay pulls in themotor. After the motor reaches speed, the combustionair blower closes the air proving switch contacts,energizing the external30 second prepurge timer. Afterthe 30 second prepurge timing, the S89E is energized.

The S89E gas primary control has an internal 8 secondsafe start check. After the initial 30 second prepurgeprovided by the external timer, the S89E gas primarycontrol is energized, the I second safe start check willcommence. Once this is accomplished, the S89Eactivates the gas valve allowing gas to flow to the burnerhead. Simultaneously, the S89E control energizes theignition transformer, producing an approximate 7300volt spark end point grounded at the burner head,establishing main burner flame.

At the start of each heat cycle, there is a trial for ignitionperiod of four (4) seconds duration. Normally, burnerflame will be established before the end of this period.Once the flame is established, sparking will cease andthe flame rod will provide flame monitoring to the S89Egas primary control for the remainder of the heat cycle.

When utilizing the S89E gas primary control with theeternal 30 second prepurge timer, a 10K ohm resistor iswired in parallel between the outout terminal of the 30

second prepurge timer and the input terminal to theS89E gas primary control. The function of this resistoris to keep a load on the output terminal of the external30 second prepurge timer, after the initial call for heatand 30 second start prepurge and 8 second safe startcheck.

This promotes simultaneous re-ignition of the mainburner flame after the S89E's 8 second safe start check,overriding the 30 second prepurge. This is desirable inoven or similar applications where temperatures cannotvary drastically.

Should the flame be extinguished during the heat cycle,the S89E primary ignition control will go into the Isecond safe staft check after which time it will re-energize the gas valve and ignition transformer in anattemot to re-establish the main burner flame. lf thisdoes not occur within the 4 second trial for ignitionperiod, the S89E gas primary control will go into lockoutde-energizing the gas valve and ignition transformer. Torestart the system, the main power or thermostat mustbe de-energized momentarily, then re-energized. lf atany time during the heat cycle, there is insufficientsupply of combustion air to the burner, the air switchcontacts will open, putting the system into lockoutclosing the gas valve.

AIR PREPURGESWITCH TIMER

N WIRE NUT BURNER CNO

HSG POWER GAS BURNERWITH HONEYWELL S89E GAS PRIMARY

24VACYL---_-F-l

t { lYL------lJl

REDUNOANTGAS VALVE

s-E9-E

IF ANY OF THE ORIGINAL WIRE,AS SUPPL]ED W]TH THE APPLIANCE.MUST AE REPUCED, IT VUST BEREPLACEO WITH TYPE AWM 1AGA1O5'C WIRE OR EOUIVAL€NT.

ze

LIMIT/ @

I i THERMOSTAT :24VAC TRANS.

lScHEMATIcl

PAGE 10

SEQUENCE OF OPERATION - HSG SERIESPOWER GAS CONVERSION BURNER UTILIZING

HONEYWELL S89E GAS PRIMARY PIN 62758-002 WI EXTERNAL30 SECOND PREPURGE TIMER PIN 62388-001 AND RESISTOR PIN 62530-001

On a call for heat, voltage (24V) is applied to the motorstart relay and air switch. The motor relay pulls in themotor. After the motor reaches speed, the combustionair blower closes the air proving switch contacts,energizing the external 30 second prepurge timer. Afterthe 30 second prepurge timing, the S89E is energized.

The S89E gas primary control has an internal 8 secondsafe start check. After the initial 30 second prepurgeprovided by the external timer, the S89E gas primarycontrol is energized, the 8 second safe start check willcommence. Once this is accomplished, the S89Eactivates the gas valve allowing gas to flow to the burnerhead. Simultaneously, the S89E control energizes theignition transformer, producing an approximate 7300volt spark end point grounded at the burner head,establishing main burner flame.

At the start of each heat cycle, there is a trial for ignitionperiod of four (4) seconds duration. Normally, burnerflame will be established before the end of this period.Once the flame is established, sparking will cease andthe flame rod will provide flame monitoring to the S89Egas primary control for the remainder of the heat cycle.

When utilizing the S89E gas primary control with theeternal 30 second prepurge timer, a 10K ohm resistor iswired in parallel between the output terminal of the 30

second prepurge timer and the input terminal to theS89E gas primary control. The function of this resistoris to keep a load on the output terminal of the external30 second prepurge timer, after the initial call for heatand 30 second start prepurge and 8 second safe startcheck.

This promotes simultaneous re-ignition of the mainburner flame after the S89E's 8 second safe start check,overriding the 30 second prepurge. This is desirable inoven or similar applications where temperatures cannotvary drastically.

Should the flame be extinguished during the heat cycle,the S89E primary ignition control will go into the 8second safe start check after which time it will re­energize the gas valve and ignition transformer in anattempt to re-establish the main burner flame. If thisdoes not occur within the 4 second trial for ignitionperiod, the S89E gas primary control will go into lockoutde-energizing the gas valve and ignition transformer. Torestart the system, the main power or thermostat mustbe de-energized momentarily, then re-energized. If atany time during the heat cycle, there is insufficientsupply of combustion air to the burner, the air switchcontacts will open, putting the system into lockoutclosing the gas valve.

HSG POWER GAS BURNERWITH HONEYWELL S89E GAS PRIMARY

24VACREDUNDANTGAS VALVE

24VAC TRANS.

L2

IGN. TRANS.

S-89-E

SE

MOTOR

NFLAME SENSOR

I LADDER I

RESISTOR

THERMOSTAT

L1

MOTOR,..----.: H'----,---=--=--=-----{: RELAY:I II II II I

I II., .J

LIMIT

AIR PRf,~~~GE ,..-__,/1/'1/1, -----, -1

SWITch liMIY/CONTROLLER

I COIL,

f--f-{' )-;'------------------i

PART NO. 62488-003

S-89-E

24VAC

YL------r=nYL---UJ

REDUNDANTGAS VALVE

BLU

BRN

GRN

MOTO

VALVE

'---~VALVE

r-:7---+--~ 24VAC SENS

24VACGND(24VAC) 8LK

~LAME S~RWHT==i~====~BlK BLU ICNlT10N

BURNER GND

IGNITiON ROOL-~~~==.!8!l..!!\K,-=~-"'------':~ IF ANY OF THE ORIGINAl WIRE.

AS SuPPLIED WITH THE APPUANCE.MUST BE REPLACED, IT t.4UST BEREPLACED WITH TYPE AWM 18GAlOS" C WIRE OR EQUIVAlENT.

/\ WIRE NUT

AIR PREPURGESWITCH TIMER

~RESISTOR

YL.-."" I \I \ I \ ~r-'

YL

24VACTRANS.

ISCHEMATlcl'----'==-- ....J

PAGE 10

FLAME SENSING

The Honeywell S89 series primary ignition controlsutilize the flame current rectification principal for mainburner flame sensing.

The flame rectification phenomenon occurs as follows.The ignited gas flame causes the immediateatmosphere around the flame to become ionized (gasatoms become electrically charged). The ionizationcauses the atmosphere around the flame to becomeelectrically conductive. An AC voltage output from thecontrol sensing circuit is routed through the flamesensor probe. When the sensor probe and the burnerhead are both in contact with a properly adjusted flame,the burner head with its larger surface attracts more freeelectrons, thus becoming negatively charged. Thesensor probe with its small surface area gives up freeelectrons, thus becoming positively charged. The freeelectrons from the AC voltage in the sensor probe flow

PROBE DIM

IGNITER't 5/8 41.2EmmSENSOR1 1/4 J1.75mm)

through the ionized gas flame to the grounded burnerhead. As the AC current passes through the gas flame,it is rectified into a DC current flowing back to thegrounded side of the sensing circuit. The flame inactuality is a switch. When the flame is present, theswitch is closed allowing current to flow through thesensing circuit of the control. When no flame is present,the switch is open with no current flowing through thesensing circuit of the control.

The DC current flow is measured in units called DCmicroamperers. A steady DC microamp current of .8minimum (and steady) or higher through the sensingcircuit of the primary ignition control is sufficient to keepthe burner running without a safety lockout. See Figure13 for sensor probe and electrode dimensional settings,Figure 14 for flame current measurement.

13/16 Q0,64nn) REF,F-3t+

| { ls.0smm)

(2,381mn)

1 / 16 (1.588mm)

Figure 13

S89 FLAME CURRENT MEASUREMENTFigure 14

FLAME SENSOR CURRENT CHECK-USE pA SCALE

TOSENSOR

MULTIPURPOSE METER

DISCONNECTWIRE FFOMSENSETEBMINAL

RED(+

BLACK(-)

0.8 uA DC MINMUM(AND STEADY)

O\'C

PAGE 11

FLAME SENSING

The Honeywell S89 series primary ignition controlsutilize the flame current rectification principal for mainburner flame sensing.

The flame rectification phenomenon occurs as follows.The ignited gas flame causes the immediateatmosphere around the flame to become ionized (gasatoms become electrically charged). The ionizationcauses the atmosphere around the flame to becomeelectrically conductive. An AC voltage output from thecontrol sensing circuit is routed through the flamesensor probe. When the sensor probe and the burnerhead are both in contact with a properly adjusted flame,the burner head with its larger surface attracts more freeelectrons, thus becoming negatively charged. Thesensor probe with its small surface area gives up freeelectrons, thus becoming positively charged. The freeelectrons from the AC voltage in the sensor probe flow

through the ionized gas flame to the grounded burnerhead. As the AC current passes through the gas flame,it is rectified into a DC current flowing back to thegrounded side of the sensing circuit. The flame inactuality is a switch. When the flame is present, theswitch is closed allowing current to flow through thesensing circuit of the control. When no flame is present,the switch is open with no current flowing through thesensing circuit of the control.

The DC current flow is measured in units called DCmicroamperers. A steady DC microamp current of .8minimum (and steady) or higher through the sensingcircuit of the primary ignition control is sufficient to keepthe burner running without a safety lockout. See Figure13 for sensor probe and electrode dimensional settings,Figure 14 for flame current measurement.

"A"

13/16 (20,64MM) REF.~3/4I <l9,05MM)

-,

Figure 13

FLAME SENSOR CURRENT CHECK-USE jJA SCALE

@_ VAlVE

- 24V

- (~)_ GHO

@

@

@

TOSENSOR

BLACK(-)

0.8 ~A DC MINMUM(AND STEADY)

S89 FLAME CURRENT MEASUREMENTFigure 14

PAGE 11

HSG SERIES WITH A HONEYWELL S89E, S89F PRIMARY IGNITION CONTROLSTROUBLE SHOOTING GUIDE

MOTOR DOES NOT START

Replace 24 volt AC20 VA Transformer

2. Check tor 24 volts AC between terminals 1 and 3on motor start relay.

3. Check for 120 volts AC between terminal 2 onmotorstart relay and neutral line.

4. Check electrical wiring and connections.

1. Check for blower clearance.2. Lubricate motor bearings.5. Does motor shaft turn freely?

Check the low voltage transformer tor 24 volt outputbetween terminal 3 on the motor start relay eitherof the'T'terminals on the control box.

IGNITION ARC ESTABLISHED - NO FLAME

l.

Reset Control - Motor starts - Completes 30 second prepurge cycle, 8 second safe start check and trial forignition, 4 seconds Honeywell series. NOTE: The burner motor will continue tooperate during the lock out mode when the thermostat circuit is called for burner operation.

2. Check for correct orifice/air setting relationship (see figures 10, 12A, 128, and 12C).

In order for the following functional test to be made,the control must be reset and the tests monitored dur-ing the 4 second Honeywell series trial for ignition peri-od that occurs at the END of the 30 second prepurgeand I second safe start check cycle.

3. Check tor 24 volts AC at gas valve terminals. Check electrical wiring andconnections. Be sure leadsare on correct gas valve ter-minals

4. Make sure leads are on the correct gas valveterminals

pressure

PAGE 12

HSG SERIES WITH A HONEYWELL S89E, S89F PRIMARY IGNITION CONTROLSTROUBLE SHOOTING GUIDE

MOTOR DOES NOT START

I. Check the low voltage transformer for 24 volt outputbetween terminal 3 on the motor start relay eitherof the "T' terminals on the control box.

2. Check for 24 volts AC between terminals 1 and 3on motor start relay.

3. Check for 120 volts AC between terminal 2 onmotorstart relay and neutral line.

4. Check electrical wiring and connections.

Check electrical wiring andconnections.

Check electrical wiring andconnections.

Check electrical wiring andconnections.

Replace 24 volt AC20 VA Transformer

Replace motorstart relay.

Replace motorstart relay.

5. Does motor shaft turn freely?

6.

IGNITION ARC ESTABLISHED - NO FLAME

OK

1. Check for blower clearance.2. Lubricate motor bearings.

Reset Control - Motor starts - Completes 30 second prepurge cycle, 8 second safe start check and trial forignition, 4 seconds Honeywell series. NOTE: The burner motor will continue tooperate during the lock out mode when the thermostat circuit is called for burner operation.

2. Check for correct orifice/air setting relationship (see figures 10, 12A, 12B, and 12C).

In order for the following functional test to be made,the control must be reset and the tests monitored dur­ing the 4 second Honeywell series trial for ignition peri­od that occurs at the END of the 30 second prepurgeand 8 second safe start check cycle.

3. Check for 24 volts AC at gas valve terminals.

4. Make sure leads are on the correct gas valveterminals

Check for correct manifold regulated pressure(see figure 10).

Check electrical wiring andconnections. Be sure leadsare on correct gas valve ter­minals

Replace primaryignition control.

6.PAGE 12

NO IGNITION ARC ESTABLISHED

Control . Motor starts - Completes 30 second prepurge start check series.. Gas valve opens, regulating adequate gas pressure.. No flame established - Primary control locks out after 4 secondHoneywell series trial for

In order for the following functional test to be made,the control must be reset and the tests monitored dur-ing the 4 second Honeywell series trial for ignition thatoccurs at the end of the 30 second prepurge cycle,and I second safe start check.

Check tor 12O volts AC between the neutral lineand the function of the blue primary control leadand the black ignition transformer lead.

Gheck electrical wiring and connections.

Check the flame sensing circuit for (1) groundedflamerod. (2) Damage to flamerod lead insula-tion. NOTE: Make sure that the flamerod circuitand/or primary control is moisture-free.

3. Check electrical wiring and connections.

4. Check high voltage lead and connection to ignitionelectrode rod.

Inspect ignition electrode for cracked insulator andcorrect spark gap (Fig. 13).

NO IGNITION - NO GAS VALVE

1. Reset Control - Motor starts - After 30 second prepurge cycle and 8 second safe start check. Motor continuesto run but flame is not established.

In order to perform the following functional tests, theprimary control must be reset and the tests monitoredduring the 4 second Honeywellseries trialfor ignitionthat occurs at the end of the 30 second prepurge cycleand 8 second safe start check.

2. Check tor 24 volts AC atthe 24 volt primary controlinput terminals labeled yellow and brown.

Replace primary ignition control.

3. Check air proving switch for:a. Any impairment that would keep it from

closing or opening.b. Electrical continuity; switch is normally open.c. Replace switch as necessary.

4. Check (when applicable) external 30 secondprepurge timer (jumper around timer from airswitch). Should primary ignition controlbecome energized, replace timer.

PAGE 13

NO IGNITION ARC ESTABLISHED

1. Reset Control • Motor starts - Completes 30 second prepurge cycle, 8 second safe start check series.• Gas valve opens, regulating adequate gas pressure.• No flame established - Primary control locks out after 4 second Honeywell series trial for

ignition periods.

0In order for the following functional test to be made,the control must be reset and the tests monitored dur-ing the 4 second Honeywell series trial for ignition thatoccurs at the end of the 30 second prepurge cycle,and 8 second safe start check.

~ h..2. Check for 120 volts AC between the neutral line ~ Check electrical wiring and connections.

and the junction of the blue primary control leadand the black ignition transformer lead. ~~ Check the flame sensing circuit for (1) grounded

3. Check electrical wiring and connections.flamerod. (2) Damage to flamerod lead insula-tion. NOTE: Make sure that the flamerod circuit

~ and/or primary control is moisture-free.

4. Check high voltage lead and connection to ignition ~electrode rod. Replace primary ignition control. I~

5. Inspect ignition electrode for cracked insulator andcorrect spark gap (Fig. 13).

-

W6. Replace ignition transformer.

NO IGNITION - NO GAS VALVE

1. Reset Control - Motor starts - After 30 second prepurge cycle and 8 second safe start check. Motor continues Ito run but flame is not established.

VIn order to perform the follOWing functional tests, theprimary control must be reset and the tests monitoredduring the 4 second Honeywell series trial for ignitionthat occurs at the end of the 30 second prepurge cycleand 8 second safe start check.

~ h..2. Check for 24 volts AC at the 24 volt primary control ~l Replace primary ignition control. Iinput terminals labeled yellow and brown.

~3. Check air proving switch for: h.. 4. Check (when applicable) external 30 second

a. Any impairment that would keep it from OK) prepurge timer Oumper around timer from airclosing or opening. ,. switCh). Should primary ignition control

b. Electrical continuity; switch is normally open. become energized, replace timer.c. Replace switch as necessary.

PAGE 13

LOSES FLAME DURING CYCLE _ CONTROL LOCKS OUT ON SAFEW

1 Reset contror ti#fi,":',lT*h" H.:*"J",-"

-;",::;T::.ffi "ircuit is satisried

2. Disconnect flamerod lead from primary control. Connect(+) positive lead (DC) Microampere Meter to the primarycontrolterminal. Connect the (-) negative microamperemeter lead to the flamerod lead terminal. See Fig. 14:Flame Current Measurement.

Probable cause of erratic lockout:1. Flame proving circuit grounded by moisture.2. Damaged insulation on flamerod lead.3. Flamerod improperly positioned in flame (see

Fig. 13).4. Poor ground path to primary control.5. Defective primary control.6. Read manual section "Flame Sensing".7. Applicable only to Honeywell S89 series

primary ignition controls: Connect L1 to theblack lead and 12 to the white lead exiting theS89 otherwise the S89 will not detect theflame and will lock out.

3. Reset control, after prepurge cycle, flame is established.A stable microampere current of .8 or more is requiredfor dependable operation.

Probable causes:1. Extremely poor combustion level.2. Flamerod improperly positioned in flame.3. Defective primary control.

4. Microampere reading is less than .8 or unstable.

BURNER CYCLES ERRATICALLY

for proper thermostat installation and location.

2. Check thermostat heat anticipator for correct setting. Set anticipator to correct value if adjustable type.lf proper setting cannot be made, replace withcompatible thermostat.

3. Check low voltage circuit for bad wiring, electricalconnections and/or switches.

4. Check line voltage circuit for bad wiring, electricalconnection and/or switches.

NOTE: When the thermostat wires terminate on theHSG primary control box'T" terminals, the heat anticipa-tor setting value for the HSG burner is determined byadding the primary control current to the gas valve cur-rent. The result is the anticipator setting.(Exampfe: .2 + .6 =.8 amps.)

lf the thermostat wires ARE NOT terminated on thebumer control box "7" terminals, and these terminals areJUMPERED, you must then determine what the correctanticipator setting is by inspecting the controlling deviceat the point where the thermostat wires terminate.Typically, this information can be found on the body orcover of the controlling device.

When determining the cunent draw of the dual head gasvalve, be sure to consider the separate ampere valuesfor each valve. These usually are stenciled on the valvebody, and must be added together to obtain the correctsum. (Example: .4 + .2 = .6 amps).

When the current draw cannot be determined accuratelyby the above method, measure the current with anampere meter using the 1 AMP scale. Connect themeter leads in series with one of the thermostat leadsfor the accurate reading.

PAGE 14

lOSES FLAME DURING CYCLE - CONTROL lOCKS OUT ON SAFETY

1. Reset Control • Completes 30 second prepurge cycle, and 8 second safe start check.• Flame is established.• Sometimes the control locks out before the thermostat or controlling circuit is satisfied.

~2. Disconnect flamerod lead from primary control. Connect

Probable cause of erratic lockout:(+) positive lead (DC) Microampere Meter to the primarycontrol terminal. Connect the (-) negative microampere 1. Flame proving circuit grounded by moisture.

meter lead to the flamerod lead terminal. See Fig. 14: 2. Damaged insulation on flamerod lead.

Flame Current Measurement. 3. Flamerod improperly positioned in flame (seeFig. 13).

~ 4. Poor ground path to primary control.

~5. Defective primary control.

3. Reset control, after prepurge cycle, flame is established. 6. Read manual section "Flame Sensing".A stable microampere current of .8 or more is required 7. Applicable only to Honeywell S89 seriesfor dependable operation. primary ignition controls: Connect L1 to the

black lead and L2 to the white lead exiting theNO S89 otherwise the S89 will not detect the

flame and will lock out.

""to~ h.

4. Microampere reading is less than .8 or unstable. ) Probable causes:,. 1. Extremely poor combustion level.2. Flamerod improperly positioned in flame.3. Defective primary control.

BURNER CYCLES ERRATICALLY

I 1. Check for proper thermostat installation and location.

~ h.

2. Check thermostat heat anticipator for correct setting. .!o) Set anticipator to correct value if adjustable type.

~,. If proper setting cannot be made, replace with

compatible thermostat.

3. Check low voltage circuit for bad wiring, electricalconnections and/or switches. NOTE: When the thennostat wires tenninate on the

HSG primary control box "1"" tenninals, the heat anticipa-

~ tor setting value for the HSG burner is detennined byadding the primary control current to the gas valve cur-

4. Check line voltage circuit for bad wiring, electrical rent. The result is the anticipator setting.connection and/or switches. (Example: .2 + .6 = .8 amps.)

If the thennostat wires ARE NOT tenninated on thebumer control box "T" tenninals, and these tenninals areJUMPERED, you must then detennine what the correctanticipator setting is by inspecting the controlling deviceat the point where the thennostat wires tenninate.Typically, this infonnation can be found on the body orcover of the controlling device.

When detennining the current draw of the dual head gasvalve, be sure to consider the separate ampere valuesfor each valve. These usually are stenciled on the valvebody, and must be added together to obtain the correctsum. (Example: .4 + .2 = .6 amps).

When the current draw cannot be detennined accuratelyby the above method, measure the current with anampere meter using the 1 AMP scale. Connect themeter leads in series with one of the thennostat leadsfor the accurate reading.

PAGE 14

SECTION IVSERVICE

Caution: Make sure the main manual, combinationvalves and main power switch are turnedoff before opening burner or removing anyparts for service.

A. BURNER HEADANDELECTRODE/S EN SOR ASS EMBLY

The burner head, electrode, sensor probe,combination valve, orifice housing and housingcover are part of the gas train assembly which canbe removed as one unit. (See Figure 15)

1. Disconnect gas line from combustion gas valveinlet, flame sensor lead wire from gas primarygas valve lead wires lrom gas valve operatorand (orange) ignition lead wire from ignitiontransformer ignition lead wire.

2. Remove the two 1/4" (6.35mm) hex slottedscrews on the top front of the housing cover andthe two 5/16" (7.9375mm) hex slotted screwson the left and right side back of the housingcover.

3. To remove gas train assembly, gently lift up rearof housing cover pulling rearward slightly on thedrawer assembly gradually positioning the rearof the drawer assembly upward 90 degrees(1.57RAD). Gently extract burner head andelectrode/sensor assembly out opening inhousing taking extreme care to not dislocate ordamage electrode or sensor probe

4. When servicing, clean burner head ports,electrodes and sensor probe. Inspect thesensor probe and electrode wires and porcelaininsulators carefully for hairline cracks whichmight provide an electrical leak path that couldshort out the ignition spark, or flame signal.

5. Examine the electrode and sensor probe forany serious corrosion or deterioration of metalat the tips. Check for proper dimensionalsettings of the sensor probe and electrode (seeFigure 13). Adjust and/or replace theseassemblies as necessary. Make sure that theignition and sensor probe wires go to thecorrect electrodes and the ignition wire boot isin place over the electrode porcelain.

6. Make sure that the burner tube end is properlypositioned in the combustion chamber entry. ltmust be set '112" (12.7mm) short of the insideface of the combustion chamber as shown infigures 4, 5 or 6.

B. AIR PROVING SWITCH

The air proving switch is mounted to the housingcover with (2) #6 self tapping screws under the gasvalve. A clear plastic tube, protected by a springcover, is connected to the barbed fitting on thepressure switch while the other end is connected toa brass barbed fitting. The plastice tube allowspressurized air from the blower housing to travel to

PAGE 15

the pressure switch causing the diaphragm contactsto close thus completing the circuit.

The function of the air proving switch is to ensuresufficient combustion air is being developed by theblower motor and blower wheel. Should the blowermotor fail or the blower wheel malfunction. theburner gas valve will shut off.

1. The air proving switch should never requiremaintenance. However. should nuisancelockouts occur, the pressure switch can bechecked. This is done by disconnecting theyellow and white leads from the Air Provingswitch and jumpering the leads together. lf theburner functions correctly, the switch needs tobe replaced.

WARNING: lf a jumper is used to check the switch itmust be removed or an unsafe conditioncan occur resulting in death or propertydamage.

2. As mentioned above, the switch should neverrequire maintenance. However a pinched tubewill shut off the flow of pressurized air to thediaphragm creating a failure made similar tobad Air Proving switch. Always check to ensurethat the clear tubing is not pinched. Make surethe spring cover is reinstalled over tube.

3. Switch is mounted in the horizontalposition withterminals up from factory. Final burner mountingshould maintain horizontal switch position.

WARNING: Damage to internalcomponents ofburner may result, if burner is mounted in otherthan horizontal position.

C. COMBUSTION AIR BLOWER AND MOTOR

1. Cleaning of the combustion air blower isindicated if the blades show an accumulation ofdust and lint, or if the character of the flameindicates a deficiency of combustion air.

2. The side plate, motor and blower wheel areremoved as one assembly. Disconnect themotor wire inside the junction box beneath theignition transformer. Remove the four (4) 5116"(7.9375mm) hex slotted screws securingsideplate to fan housing.

CAUTION: Do not remove blower wheel from motorshaft during periodic cleaning.

3. Should removal of the blower wheel benecessary for cleaning or replacement of it orthe motor, the blower wheel must be positionedcorrectly on the motor shaft. (Figure 16)

HSG200 blower wheel pln 21664 is positioned21/16" (52.3875mm) measured from the blowerwheel inlet ring face to the side plate face.

HSG400 blower wheel pln 21642 is positioned23116" (55.5625mm) measured from the blowerwheel inlet ring face to the side plate face.

SECTION IVSERVICE

Caution: Make sure the main manual, combinationvalves and main power switch are turnedoff before opening burner or removing anyparts for service.

A. BURNER HEAD ANDELECTRODE/SENSOR ASSEMBLY

The burner head, electrode, sensor probe,combination valve, orifice housing and housingcover are part of the gas train assembly which canbe removed as one unit. (See Figure 15)

1. Disconnect gas line from combustion gas valveinlet, flame sensor lead wire from gas primary,gas valve lead wires from gas valve operatorand (orange) ignition lead wire from ignitiontransformer ignition lead wire.

2. Remove the two 1/4" (6.35mm) hex slottedscrews on the top front of the housing cover andthe two 5/16" (7.9375mm) hex slotted screwson the left and right side back of the housingcover.

3. To remove gas train assembly, gently lift up rearof housing cover pulling rearward slightly on thedrawer assembly gradually positioning the rearof the drawer assembly upward 90 degrees(1.57RAD). Gently extract burner head andelectrode/sensor assembly out opening inhousing taking extreme care to not dislocate ordamage electrode or sensor probe.

4. When servicing, clean burner head ports,electrodes and sensor probe. Inspect thesensor probe and electrode wires and porcelaininsulators carefully for hairline cracks whichmight provide an electrical leak path that couldshort out the ignition spark, or flame signal.

5. Examine the electrode and sensor probe forany serious corrosion or deterioration of metalat the tips. Check for proper dimensionalsettings of the sensor probe and electrode (seeFigure 13). Adjust and/or replace theseassemblies as necessary. Make sure that theignition and sensor probe wires go to thecorrect electrodes and the ignition wire boot isin place over the electrode porcelain.

6. Make sure that the burner tube end is properlypositioned in the combustion chamber entry. Itmust be set 1/2" (12.7mm) short of the insideface of the combustion chamber as shown infigures 4, 5 or 6.

B. AIR PROVING SWITCH

The air proving switch is mounted to the housingcover with (2) #6 self tapping screws under the gasvalve. A clear plastic tube, protected by a springcover, is connected to the barbed fitting on thepressure switch while the other end is connected toa brass barbed fitting. The plastice tube allowspressurized air from the blower housing to travel to

PAGE 15

the pressure switch causing the diaphragm contactsto close thus completing the circuit.

The function of the air proving switch is to ensuresufficient combustion air is being developed by theblower motor and blower wheel. Should the blowermotor fail or the blower wheel malfunction, theburner gas valve will shut off.

1. The air proving switch should never requiremaintenance. However, should nuisancelockouts occur, the pressure switch can bechecked. This is done by disconnecting theyellow and white leads from the Air Provingswitch and jumpering the leads together. If theburner functions correctly, the switch needs tobe replaced.

WARNING: If a jumper is used to check the switch itmust be removed or an unsafe conditioncan occur resulting in death or propertydamage.

2. As mentioned above, the switch should neverrequire maintenance. However a pinched tubewill shut off the flow of pressurized air to thediaphragm creating a failure made similar tobad Air Proving switch. Always check to ensurethat the clear tUbing is not pinched. Make surethe spring cover is reinstalled over tube.

3. Switch is mounted in the horizontal position withterminals up from factory. Final burner mountingshould maintain horizontal switch position.

WARNING: Damage to internal components ofburner may result, if burner is mounted in otherthan horizontal position.

C. COMBUSTION AIR BLOWER AND MOTOR

1. Cleaning of the combustion air blower isindicated if the blades show an accumulation ofdust and lint, or if the character of the flameindicates a deficiency of combustion air.

2. The side plate, motor and blower wheel areremoved as one assembly. Disconnect themotor wire inside the junction box beneath theignition transformer. Remove the four (4) 5/16"(7.9375mm) hex slotted screws securingsideplate to fan housing.

CAUTION: Do not remove blower wheel from motorshaft during periodic cleaning.

3. Should removal of the blower wheel benecessary for cleaning or replacement of it orthe motor, the blower wheel must be positionedcorrectly on the motor shaft. (Figure 16)

HSG200 blower wheel pIn 21664 is positioned2 1/16" (52.3875mm) measured from the blowerwheel inlet ring face to the side plate face.

HSG400 blower wheel pIn 21642 is positioned23/16" (55.5625mm) measured from the blowerwheel inlet ring face to the side plate face.

DRAWER ASSEMBLYFigure 15

PAFIT NII ] \ 'FI t rFI

21664HSG2OO

51t4 0.D.(133.35mm)

21/16"(52.3875mm)

21642HSG4OO

5 1t2 0.D.(139.7mm)

2 3t16"(55.5625mm)

MOTOR/BLOWER ASSEMBLYFigure 16

PAGE 16

33

DRAWER ASSEMBLY

Figure 15

MOTOR SIDEPLATE"AUPIN 21658

r'I

Il-

i-

\

b... " -r

r2 1/16"

(52.3875mm)

23/16"(55.5625mm)

21642HSG400

5112 G.D.(139.7mm)

21664HSG200

5114 G.D.(133.35mm)

MOTOR/BLOWER ASSEMBLY

Figure 16

PAGE 16

PARTS LIST - MODEL HSG 2OOI4OO SEE FIG. 15 & FIG. 17

Item Part No. Description

3.4.

o.

7.8.

9.10.11.

12.

18.19.

22.23.24.

25.26.27.28.

1.z.

13.14.

15.16.17.

29.30.31.

1 00934-00162576-00363270-00462576-01 563270-01 562576-02763270-02763270-02862393-00121724-011100428-002216642164221 6582062720627-0041 00373-00262408-00162388-00162530-001601 86-00463005-0021 00450-00162406-00262759-00262758-002

100377-00210042963263-00563272-00563935-001601 78-00210037220-21.2'131961 84362407-O0164051 -00162391 -00262390-00262387-00162575-00262575-00162575-01462575-01262575-02662575-02462575-0316241 9-00161951-00162411-0286241 1 -0306241 1 -06864096-00162909-00162909-003

64095-00162404-OO26230462402-00162410-00162401 -00162385-00162374-004624s9-00162459-00221760-001

Burner HousingAir Tube - HSG200 6" (152.4mm)Air Tube - HSG4OO 6 1/4" (158.75 mm)Air Tube - HSG200 9" (228.6mm)Air Tube - HSG400 9" (228.6mm)Air Tube - HSG200 '12" (304.8mm)Air Tube - HSG400 12" (304.8mm)Air Tube - HSG400 15" (381 mm)Air Cone - (HSG200 only)Adjustable Flange Assembly (includes gasket)(not shown)Flange Gasket (not shown)Blower Wheel HSG200 5114 OD (133.35mm)Blower Wheel HSG400 5112'OD (139,7mm)Side Plate (Used with 20627 and 20627-004 Motors Only)Motor, Split Phase 117 (.107kW) or 1/8 (.093kW) HP 3450 RPM 115V/60Motor, Split Phase 117 (.107kW) HP 2850 RPM 230V/50H2 (220Y150H2)Combustion Air Inlet DamperControl Box (S89E & S89F) Used with Primary safety Control

P/N 62758-002(Special limit applications only)

30 Sec. Prepurge TimeResistor Wire Assy.24 Volt Transformer 1 20V24 Volt Transformer 220VBushingMotor RelayPrimary Safety Control H'Well S89F w/30 Sec Prepurge (220Y150H2)Primary Safety Control H'Well S89E w/o 30 Sec Prepurge(Special Limit Applications Only)Damper Indicator PointerDamper DecalPressure SwitchPressure Switch Conversion KitPressure Switch (220Vl50H2)Thermostat Terminal StripAdjustment Arm Off-Cycle Damper100371-KlT Off-Cycle Damper KitJunction Box (under lgnition Transformer)Lighting Platelgnition Transformer 7500Vlgnition Transformer 220Y l50Hz DanfossElectrode AssemblySensor Probe AssemblyInsulator Bushing (not shown)Chamber/Manifold - HSG200 6" ('152.4mm)Chamber/Ivlanifold - HSG400 6 1/4. (158.75 mm)Chamber/Manifold - HSG200 9" (228.6mm)Chamber/Ivlanifold - HSG400 9" (228.6mm)Chamber/Manifold - HSG200 12" (304.8mm)Chamber/Manifold - HSG400 12" (304.8mm)Chamber/Manifold - HSG400 15" (381 mm)Clip, Electrode Bracketlgnitor Support Parts Kit11 " (279.4mm) Sensor Wire - 6" (1 52.4mm), 6 1/4" (1 58.75mm) Burner14" (355,6mm), Sensor Wire - 9" (228.6mm), 12" (304.8mm) Burner17" (431,8mm), Sensor Wire - 15" (228.6mm) BurnerSense Wire - 330mm Cable (220Vl50H2)8" (203.2mm) lgnition Wire - 6" (152.4mm), 6 1/4" (158.75mm) Burner14" (355.6mm) lgnition Wire - 9" (228.6mm), 12" (304.8mm) Burner,15" (228.6mm) Burnerlgnition Wire - 500mm Cable (220Vl50H2)Top Plate/Housing CoverStrain Relief Bushing/lgnition WireOrifice HousingOrifice SpringOrifice GasketOrifice CaoGas Valve Honeywell VR8305M 4801Orifice Package - HSG200 (not shown)Orifice Package - HSG400 (not shown)Ootional Pedestal Mountinq (not shown)

PAGE 17

PARTS LIST - MODEL HSG 200/400 SEE FIG. 15 & FIG. 17

Item Part No. Description1. 100934-001 Burner Housing2. 62576-003 Air Tube - HSG200 6" (152.4mm)

63270-004 Air Tube - HSG400 6 1/4" (158.75 mm)62576-015 Air Tube - HSG200 9" (228.6mm)63270-015 Air Tube - HSG400 9" (228.6mm)62576-027 Air Tube - HSG200 12" (304.8mm)63270-027 Air Tube - HSG400 12" (304.8mm)63270-028 Air Tube - HSG400 15" (381 mm)

3. 62393-001 Air Cone - (HSG200 only)4. 21724-011 Adjustable Flange Assembly (includes gasket)(not shown)5. 100428-002 Flange Gasket (not shown)6. 21664 Blower Wheel HSG200 5 1/4" OD (133.35mm)

21642 Blower Wheel HSG400 51/2" OD (139.7mm)7. 21658 Side Plate (Used with 20627 and 20627-004 Motors Only)8. 20627 Motor, Split Phase 1/7 (.107kW) or 1/8 (.093kW) HP 3450 RPM 115V/60

20627-004 Motor, Split Phase 1/7 (.107kW) HP 2850 RPM 230V/50Hz (220V/50Hz)9. 100373-002 Combustion Air Inlet Damper

10. 62408-001 Control Box (S89E & S89F) Used with Primary safety Control11. 62388-001 30 Sec. Prepurge Time .. PIN 62758-002

62530-001 Resistor Wire Assy. (Special limit applications only)12. 60186-004 24 Volt Transformer 120V

63005-002 24 Volt Transformer 220V100450-001 Bushing

13. 62406-002 Motor Relay14. 62759-002 Primary Safety Control H'Well S89F w/30 Sec Prepurge (220V/50Hz)

62758-002 Primary Safety Control H'Well S89E w/o 30 Sec Prepurge(Special Limit Applications Only)

15. 100377-002 Damper Indicator Pointer16. 100429 Damper Decal17. 63263-005 Pressure Switch

63272-005 Pressure Switch Conversion Kit63935-001 Pressure Switch (220V/50Hz)

18. 60178-002 Thermostat Terminal Strip19. 100372 Adjustment Arm Off-Cycle Damper

20-21. 100371-KIT Off-Cycle Damper Kit22. 21319 Junction Box (under Ignition Transformer)23. 61843 Lighting Plate24. 62407-001 Ignition Transformer 7500V

64051-001 Ignition Transformer 220V/50Hz Danfoss25. 62391-002 Electrode Assembly26. 62390-002 Sensor Probe Assembly27. 62387-001 Insulator Bushing (not shown)28. 62575-002 Chamber/Manifold - HSG200 6" (152.4mm)

62575-001 Chamber/Manifold - HSG400 6 1/4" (158.75 mm)62575-014 Chamber/Manifold - HSG200 9" (228.6mm)62575-012 Chamber/Manifold - HSG400 9" (228.6mm)62575-026 Chamber/Manifold - HSG200 12" (304.8mm)62575-024 Chamber/Manifold - HSG400 12" (304.8mm)62575-031 Chamber/Manifold - HSG400 15" (381 mm)

29. 62419-001 Clip, Electrode Bracket30. 61951-001 Ignitor Support Parts Kit31. 62411-028 11" (279.4mm) Sensor Wire - 6" (152.4mm), 6 1/4" (158.75mm) Burner

62411-030 14" (355,6mm), Sensor Wire - 9" (228.6mm), 12" (304.8mm) Burner62411-068 17" (431 ,8mm), Sensor Wire - 15" (228.6mm) Burner64096-001 Sense Wire - 330mm Cable (220V/50Hz)

32. 62909-001 8" (203.2mm) Ignition Wire - 6" (152.4mm). 6 1/4" (158. 75mm) Burner62909-003 14" (355.6mm) Ignition Wire - 9" (228.6mm), 12" (304.8mm) Burner,

15" (228.6mm) Burner64095-001 Ignition Wire - 500mm Cable (220V/50Hz)

33. 62404-002 Top Plate/Housing Cover34. 62304 Strain Relief Bushing/Ignition Wire35. 62402-001 Orifice Housing36. 62410-001 Orifice Spring37. 62401-001 Orifice Gasket38. 62385-001 Orifice Cap39. 62374-004 Gas Valve Honeywell VR8305M 480140. 62459-001 Orifice Package - HSG200 (not shown)

62459-002 Orifice Package - HSG400 (not shown)41. 21760-001 Optional Pedestal Mountina (not shown)

PAGE 17

TECHNICAL INFORMATION"Troubleshooting Guide"

NUISANCE LOCKOUTS/FLAME SENSING PROBLEMS. HSG2OO & HSG4OO GAS BURNERS

Wayne's HSG series direct spark ignition (DSl) gasburners prove flame through the process of flamerectification. Flame rectification is achieved by placing asmall voltage on the flame sensing probe. When theprobe is surrounded by flame, the voltage on the probe"leaks" to ground through the flame, resulting in anelectrical current. This current is interpreted by theignition control as the presence of flame.

One of the most common problems with gas appliancesutilizing this type of electronic flame sensing system isthe "nuisance lockout". Lockouts are not generally dueto the burner failing to ignite, but rather simply the failureof the system to sense the establishment of flame.Should this situation exist for a period of time longerthan the ignition control's state lockout timing, thecontrol will shut down or go into permanent lockout. Theonly way to get the burner to recycle is to break, andthen reinstate power to the burner.

The following situations can lead to flame sensingproblems and can be checked withoutdisassembling the burner:. The burner is not properly grounded to "earth

ground" on the line voltage.. The ignition control is not properly grounded to the

burner itself. Using an ohmmeter, check the wireattached to both parts for good contact andcontinuity.

. The burner ignition control is polarity sensitive. Thepolarity of the incoming line voltage may bereversed. Verify that black and white wires are hotand neutral respectively, and that they areconnected to the corresponding black and whitewires on the burner.

The remaining checks andlor adjustments requireremoval of the gas train:. The connections from the'SENSE'terminal of the

ignition control to the end of the flamerod may bebroken at some point. Check all quick connectterminations and connections. Check the continuitywith an ohmmeter while flexing wires to assure nohidden conductor breakage exists. lf replaced,wiring must be of equal, or heavier gauge andequal, or better temperature rating.

. The flamerod probe may be grounded out. Assurethat the flamerod probe is not touching the burnerhead. The probe should be positioned in the centerof the clearance groove on the outer edge of the

burner head with approximately 1116" (1.5875mm)clearance from the head. The probe must not bepositioned to far away from the head as this mayresult in grounding out of the probe against theinside surface of the air tube.

. The flamerod probe should be free of soot andcreosote. Deposits may insulate the probe, leadingit not to pass the electrical charge to the flame. Theprobe can be cleaned with steel wool, emery paperor fine sandpaper. NOTE: This is the leading causeof nuisance lockouts in dual-fuel wood/oas firedappliances.

. The flamerod probe may be burned away. Check itagainst dimensions on the ELECTRODE ANDFLAMEROD PROBE SETTINGS drawing.

. The dimensional location of the flamerod probe maybe incorrect, or the probe may be bent out of shape.Check it against dimensions on the ELECTRODEAND FLAMEROD PROBE SETTINGS drawing andadjust if necessary.

. The spark electrode gap may be incorrect, resultingin no spark or an inadequate spark that will notignite the gas properly. Check the electrode gapagainst the ELECTRODE AND FLAMERODPROBE SETTINGS drawing and adjust if required.

. The high tension lead conductor from the ignitiontransformer to the tip of the spark electrode may bebroken, preventing the high voltage current fromgetting to the electrode tip. Check all connectionsthoroughly and/or check to continuity of the leadwire assembly with an ohmmeter.

Once all of the items listed previously have beencarefully checked and corrected if necessary, reinsertthe gas train assembly into the burner. NOTE: Becareful not to bend the air proving switch sail arm (if soequipped) or accidentally reposition either the flamerodprobe or electrode during reinstallation of the gas trainassembly.

lf, after all of the above listed items have been carefullychecked, the burner still fails to work, it is due to one ormore of the following problems:

1. Unit sparks and fires but will not stay lit. lgnitioncontrol module is malfunctioning and must bereplaced.

2. Unit does not spark. lgnition transformer is bad andmust be replaced.

PAGE 19

TECHNICAL INFORMATION"Troubleshooting Guide"

NUISANCE LOCKOUTS/FLAME SENSING PROBLEMS - HSG200 & HSG400 GAS BURNERS

Wayne's HSG series direct spark ignition (DSI) gasburners prove flame through the process of flamerectification. Flame rectification is achieved by placing asmall voltage on the flame sensing probe. When theprobe is surrounded by flame, the voltage on the probe"leaks" to ground through the flame, resulting in anelectrical current. This current is interpreted by theignition control as the presence of flame.

One of the most common problems with gas appliancesutilizing this type of electronic flame sensing system isthe "nuisance lockout". Lockouts are not generally dueto the burner failing to ignite, but rather simply the failureof the system to sense the establishment of flame.Should this situation exist for a period of time longerthan the ignition control's state lockout timing, thecontrol will shut down or go into permanent lockout. Theonly way to get the burner to recycle is to break, andthen reinstate power to the burner.

The following situations can lead to flame sensingproblems and can be checked withoutdisassembling the burner:

The burner is not properly grounded to "earthground" on the line voltage.

The ignition control is not properly grounded to theburner itself. Using an ohmmeter, check the wireattached to both parts for good contact andcontinuity.

The burner ignition control is polarity sensitive. Thepolarity of the incoming line voltage may bereversed. Verify that black and white wires are hotand neutral respectively, and that they areconnected to the corresponding black and whitewires on the burner.

The remaining checks and/or adjustments requireremoval of the gas train:

The connections from the "SENSE" terminal of theignition control to the end of the f1amerod may bebroken at some point. Check all quick connectterminations and connections. Check the continuitywith an ohmmeter while flexing wires to assure nohidden conductor breakage exists. If replaced,wiring must be of equal, or heavier gauge andequal, or better temperature rating.

The flamerod probe may be grounded out. Assurethat the flamerod probe is not touching the burnerhead. The probe should be positioned in the centerof the clearance groove on the outer edge of the

PAGE 19

burner head with approximately 1/16" (1.5875mm)clearance from the head. The probe must not bepositioned to far away from the head as this mayresult in grounding out of the probe against theinside surface of the air tube.

The flamerod probe should be free of soot andcreosote. Deposits may insulate the probe, leadingit not to pass the electrical charge to the flame. Theprobe can be cleaned with steel wool, emery paperor fine sandpaper. NOTE: This is the leading causeof nuisance lockouts in dual-fuel wood/gas firedappliances.

The flamerod probe may be burned away. Check itagainst dimensions on the ELECTRODE A1'JDFLAMEROD PROBE SETTINGS drawing.

The dimensional location of the flamerod probe maybe incorrect, or the probe may be bent out of shape.Check it against dimensions on the ELECTRODEAND FLAMEROD PROBE SETTINGS drawing andadjust if necessary.

The spark electrode gap may be incorrect, resultingin no spark or an inadequate spark that will notignite the gas properly. Check the electrode gapagainst the ELECTRODE AND FLAMERODPROBE SEn-INGS drawing and adjust if required.

The high tension lead conductor from the ignitiontransformer to the tip of the spark electrode may bebroken, preventing the high voltage current fromgetting to the electrode tip. Check all connectionsthoroughly and/or check to continuity of the leadwire assembly with an ohmmeter.

Once all of the items listed previously have beencarefully checked and corrected if necessary, reinsertthe gas train assembly into the burner. NOTE: Becareful not to bend the air proving switch sail arm (if soequipped) or accidentally reposition either the flamerodprobe or electrode during reinstallation of the gas trainassembly.

If, after all of the above listed items have been carefullychecked, the burner still fails to work, it is due to one ormore of the following problems:

1. Unit sparks and fires but will not stay lit. Ignitioncontrol module is malfunctioning and must bereplaced.

2. Unit does not spark. Ignition transformer is bad andmust be replaced.

LIMITED WARRANTIES FOR OIL ANDGAS BURNERS, MADE BY WAYNE ANDUSED IN RESIDENTIAL INSTALLATIONS

WAYNE COMBUSTION SYSTEMS ("WAYNE") warrantsto those who purchase its Oil Burner Models for resale orfor incorporation into a product of resale, that its burner isfree from defects in material and workmanship undernormal use and service for thirty-six (36) months from thedate of manufacture, ALL GAS BURNERS manufacturedby "WAYNE" will be similarly warranted for eighteen(18)months from date of manufacture except where originalmanufacture offers a greater warranty. (Reference #6below) THESE LIMITED WARRANTIES DO NOT APPLYUNLESS THE BURNER COVERED BY IT IS PROPERLYINSTALLED BY A OUALIFIED, COMPETENTTECHNICIAN, WHO IS LICENSED WHERE STATEAND/OR LOCAL CODES PREVAIL. AND WHO ISEXPERIENCED IN MAKING SUCH INSTALLATIONS, INACCORDANCE WITH NFPA #31 OF THE NATIONALFIRE PROTECTION ASSOCIATION AND INACCORDANCE WITH ALL LOCAL. STATE ANDNATIONAL CODES.

Any lN-WARRANTY burner component which is defectivein material or workmanship will be either repaired orreplaced as follows:1. Fuel units, motors, transformers, gas valves, and

controls should be returned to an authorized servicestation or distributor of WAYNE for determination ofapplicability of this LIMITED WARRANTY as to eitherrepair or replacement, where said service station ordistributor is reasonably available in the customer'slocality. The manufacturers of burner componentsregularly publish and distribute listings showing thelocations of their network of service stations. Wheresuch local service is NOT available for the burnercomoonents described above or other burner oarts areinvolved, these items should be returned, freightprepaid, to WAYNE Service Department, 801 GlasgowAve, Fort Wayne, Indiana 46803.

2. Burners and/or component(s) determined to becovered under this LIMITED WARRANTY by WAYNEshall be repaired or replaced at WAYNE's sole option.

3. WAYNE is not responsible for any labor cost for theremoval and replacement of said burner or burnercomponents and equipment associated therewith.

4. A burner so repaired will then carry the LIMITEDWARRANTY equal to the unexpired portion of the

original burner LIMITED WARRANTY.5. lf inspection by WAYNE does NOT disclose any defect

covered by this LIMITED WARRANry, the burner orburner component(s) wil l be either repaired orreplaced at the expense of the customer and WAYNE'sregular charges will apply.

6. lf the original manufacturer of a burner componentoffers a warranty greater than either of our LIMITEDWARRANTIES described above, then this portion willbe added to our LIMITED WARRANTY.

This LIMITED WARRANTY does NOT cover oroductswhich have been damaged as the result of accident,abuse, misuse, neglect, improper installations, impropermaintenance or failure to operate in accordance withWAYNE's written instructions.These LIMITED WARRANTIES do not extend to anyoneexcept the first purchaser at retail and only when theburner is in the original installation site,IMPLIED WARRANTIES OF MERCHANTABILITY ANDFITNESS FOR A PARTICULAR PURPOSE SHALL BELIMITED TO THE DURATION OF THE LIMITEDEXPRESS WARRANTIES CONTAINED HEREIN. WAYNEEXPRESSLY DISCLAIMS AND EXCLUDES ANYLIABILITY FOR CONSEQUENTIAL OR INCIDENTALDAMAGES OF ANY NATURE FOR BREACH OF ANYEXPRESS OR IMPLIED WARRANTY.Some states do not allow limitation on how long an impliedwarranty lasts, so the above limitation may not apply toyou. Also, some states do not allow the exclusion orlimitation of incidental or consequential damages, so theabove limitation or exclusion may not apply to you.WAYNE neither assumes or authorizes any person toassume for WAYNE any other liability or obligation inconnection with the sale of these products. This warrantygives you specific legal rights, and you may also haveother rights which vary from state to state.

PAGE 20

LIMITED WARRANTIES FOR OIL ANDGAS BURNERS, MADE BY WAYNE ANDUSED IN RESIDENTIAL INSTALLATIONS

WAYNE COMBUSTION SYSTEMS ("WAYNE") warrantsto those who purchase its Oil Burner Models for resale orfor incorporation into a product of resale, that its burner isfree from defects in material and workmanship undernormal use and service for thirty-six (36) months from thedate of manufacture. ALL GAS BURNERS manufacturedby "WAYNE" will be similarly warranted for eighteen(18)months from date of manufacture except where originalmanufacture offers a greater warranty. (Reference #6below) THESE LIMITED WARRAI\lTIES DO NOT APPLYUNLESS THE BURNER COVERED BY IT IS PROPERLYINSTALLED BY A QUALIFIED, COMPETENTTECHNICIAN, WHO IS LICENSED WHERE STATEAND/OR LOCAL CODES PREVAIL, AND WHO ISEXPERIENCED IN MAKING SUCH INSTALLATIONS, INACCORDANCE WITH I\lFPA #31 OF THE NATIONALFIRE PROTECTION ASSOCIATION AND INACCORDANCE WITH ALL LOCAL, STATE ANDNATIONAL CODES.

Any IN-WARRANTY burner component which is defectivein material or workmanship will be either repaired orreplaced as follows:

1. Fuel units, motors, transformers, gas valves, andcontrols should be returned to an authorized servicestation or distributor of WAYNE for determination ofapplicability of this LIMITED WARRANTY as to eitherrepair or replacement, where said service station ordistributor is reasonably available in the customer'slocality. The manufacturers of burner componentsregularly publish and distribute listings showing thelocations of their network of service stations. Wheresuch local service is NOT available for the burnercomponents described above or other burner parts areinvolved, these items should be returned, freightprepaid, to WAYNE Service Department, 801 GlasgowAve, Fort Wayne, Indiana 46803.

2. Burners and/or component(s) determined to becovered under this LIMITED WARRANTY by WAYNEshall be repaired or replaced at WAYNE's sole option.

3. WAYNE is not responsible for any labor cost for theremoval and replacement of said burner or burnercomponents and equipment associated therewith.

4. A burner so repaired will then carry the LIMITEDWARRANTY equal to the unexpired portion of the

original burner LIMITED WARRANTY.

5. If inspection by WAYNE does NOT disclose any defectcovered by this LIMITED WARRANTY, the burner orburner component(s) will be either repaired orreplaced at the expense of the customer and WAYNE'sregular charges will apply.

6. If the original manufacturer of a burner componentoffers a warranty greater than either of our LIMITEDWARRANTIES described above, then this portion willbe added to our LIMITED WARRANTY.

This LIMITED WARRANTY does NOT cover productswhich have been damaged as the result of accident,abuse, misuse, neglect, improper installations, impropermaintenance or failure to operate in accordance withWAYf\IE's written instructions.

These LIMITED WARRANTIES do not extend to anyoneexcept the first purchaser at retail and only when theburner is in the original installation site.

IMPLIED WARRANTIES OF MERCHANTABILITY ANDFITNESS FOR A PARTICULAR PURPOSE SHALL BELIMITED TO THE DURATION OF THE LIMITEDEXPRESS WARRANTIES CONTAINED HEREIN. WAYNEEXPRESSLY DISCLAIMS AND EXCLUDES ANYLIABILITY FOR CONSEQUENTIAL OR INCIDENTALDAMAGES OF ANY NATURE FOR BREACH OF ANYEXPRESS OR IMPLIED WARRANTY.

Some states do not allow limitation on how long an impliedwarranty lasts, so the above limitation may not apply toyou. Also, some states do not allow the exclusion orlimitation of incidental or consequential damages, so theabove limitation or exclusion may not apply to you.WAYNE neither assumes or authorizes any person toassume for WAYNE any other liability or obligation inconnection with the sale of these products. This warrantygives you specific legal rights, and you may also haveother rights which vary from state to state.

PAGE 20

CONSUMER INSTRUCTIONSMAINTENANCE:tr Keep the area around the burner clear and free of com-bustible materials, gasoline or other flammable liquids orvapors. Do not obstruct burner air openings or ventilationgrilles for combustion air.

CAUTION: Check the burner flame periodically. A properNATURAL gas flame will appear blue at the burner face withorange and yellow tips. A proper PROPANE gas flame willappear blue at the burner face with yellow tips. lf the flameis too rich, it will appear billowy and yellow with hazy tips,if too lean, it will appear short and all blue. Burner cleaningand/or readjustment is indicated by flames that are too richor too lean.

WARNING: lf any flame is observed when the burner is onstandby, or if the ignition spark or valve operator is heard tocome on before the motor reaches operating speed, im-mediately turn otf the manual gas control and main power.

A dangerous condition has developed and must be corrected.CONTACT A QUALIFIED SERVICE TECHNICIAN FORCLEANING, READJUSTMENT OR REPAIR.LIGHTING INSTRUCTIONS:See Section ll InitialStart Uo1. TURN (DEPRESS) VALVE DIALTO ON.2. TURN MAIN POWER ON.3. SET THERMOSTAT OR OPERATING CONTROL TO CALL

FOR HEAT.4. WAIT 30 SECONDS. IF BURNER HAS FAILED TO LIGHT

OR IF BURNER LIGHTS THEN GOES OUI TURNBURNER OFF FOR 30 SECONDS AND THEN BACK ONFOR RESTART.

TO SHUT OFF:1. TURN (DEPRESS) VALVE D]ALTO OFF.2. TURN MAIN POWER OFF.

EXPLOSION HAZARDlf PROPANE gas is used and the burner is located in a areas or confined spaces. This would create a DANGERbasement, crawlspace or confined space, contact your OF EXPLOSION OR FIRE. lf you suspect a gas leak,gas supplier about installing a "gas leak" warning device. follow instructions on front cover of this manual.PROPANE gas is heavier than air and can settle in low

CARBON MONOXIDEPOISONING HAZARD

CARBON MONOXIDE ISACOLORLESS, ODOBLESS GASTHAT CAN KILL. FOLLOW THESE RULES TO CONTROLCARBON MONOXIDE.

A Do not use this burner if in an unvented, enclosed area.Carbon monoxide may accumulate.

A Do not adjust the pressure regulator. High pressuresproduce carbon monoxide.

)uELECTRIC SHOCK HAZARD

HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENTFOLLOW THESE RULES TO AVOID ELECTRICAL SHOCK.

A Use only a properly grounded circuit. A ground faultinterrupter is recommended

A Do not spray water directly on burner,

A Turn off power before servicing.

l' Read the owner's manual before using.

- vrr996 t tug Yq99D I

requires specialized equipment.

A Allow only qualified burner service persons to adjustthe burner. Special instruments and training arerequired.

A Read the owner's manual before using.-

OVERHEATING HAZARD

SHOULD OVERHEATING OCCUR:

Shut off the manual gas control to the appliance

Do not shut off the control switch to the pump or blower.

PAGE 21

CONSUMER II\ISTRUCTIONS

MAINTENANCE:o Keep the area around the burner clear and free of com­bustible materials, gasoline or other flammable liquids orvapors. Do not obstruct burner air openings or ventilationgrilles for combustion air.

CAUTION: Check the burner flame periodically. A properNATURAL gas flame will appear blue at the burner face withorange and yellow tips. A proper PROPANE gas flame willappear blue at the burner face with yellow tips. If the flameis too rich, it will appear billowy and yellow with hazy tips,if too lean, it will appear short and all blue. Burner cleaningand/or readjustment is indicated by flames that are too richor too lean.

WARNING: If any flame is observed when the burner is onstandby, or if the ignition spark or valve operator is heard tocome on before the motor reaches operating speed, im­mediately turn off the manual gas control and main power.

A dangerous condition has developed and must be corrected.CONTACT A QUALIFIED SERVICE TECHNICIAN FORCLEANING, READJUSTMENT OR REPAIR.LIGHTING INSTRUCTIONS:See Section II Initial Start Up1. TURN (DEPRESS) VALVE DIAL TO ON.2. TURN MAIN POWER ON.3. SET THERMOSTAT OR OPERATING CONTROL TO CALL

FOR HEAT.4. WAIT 30 SECONDS. IF BURNER HAS FAILED TO LIGHT,

OR IF BURNER LIGHTS THEN GOES OUT, TURNBURNER OFF FOR 30 SECONDS AND THEN BACK ONFOR RESTART.

TO SHUT OFF:1. TURN (DEPRESS) VALVE DIAL TO OFF.2. TURN MAIN POWER OFF.

If PROPANE gas is used and the burner is located in abasement, crawlspace or confined space, contact yourgas supplier about installing a "gas leak" warning device.PROPANE gas is heavier than air and can settle in low

areas or confined spaces. This would create a DANGEROF EXPLOSION OR FIRE. If you suspect a gas leak,follow instructions on front cover of this manual.

CARBON MONOXIDEPOISONING HAZARD

ELECTRIC SHOCK HAZARD

HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENTFOLLOW THESE RULES TO AVOID ELECTRICAL SHOCK.

CARBON MONOXIDE IS A COLORLESS, ODORLESS GASTHAT CAN KILL. FOLLOW THESE RULES TO CONTROLCARBON MONOXIDE.

... Use only a properly grounded circuit. A ground faultinterrupter is recommended

... Do not use this burner if in an unvented, enclosed area.Carbon monoxide may accumulate.

... Do not spray water directly on burner.

... Turn off power before servicing.... Do not adjust the pressure regulator. High pressures

produce carbon monoxide. ... Read the owner's manual before using.

OVERHEATING HAZARD

... Allow only qualified burner service persons to adjustthe burner. Special instruments and training arerequired.

... Check flue gases for carbon monoxide. This check ....----------------------1requires specialized equipment.

... Read the owner's manual before using. SHOULD OVERHEATING OCCUR:

Shut off the manual gas control to the appliance

Do not shut off the control switch to the pump or blower.

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