Wayne Hsg200 User manual

ASCOTT FETZER COMPANY

801

GLASGOW

AVE.

FORT WAYNE,

46803

Publication Date: 12/13/2010

MODELS

8.J

HSG200

.".JIIIiI!lN

HSG400

GAS BURNERS

120V/50-60 HZ 220V/50 HZ

PART

NO.

62484-001

WARNING:

the information

these instructions

is not followed exactly, afire or explosion may result

causing property damage, personal injury or death.

-Do not store or use gasoline or other flammable

vapors and liquids in the vicinity

this or any other

appliance.

-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's

instructions.

•

you cannot reach your gas supplier, call the fire

department.

-Installation and service must be performed by a

qualified, licensed installer, service agency or the gas

supplier. WARRANTY IS VOIDED

NOT

INSTALLED

QUALIFIED SERVICE PERSON.

fi@

MEA

MASS.

ANSIZ21.17

APPROVED

FOR

USE CITY

OF NEW YORK

MEA 49-83-E

NOTICE

THESE INSTRUCTIONS SHOULD

AFFIXED TO THE BURNER

OR ADJACENT TO THE HEATING APPLIANCE.

FOR FURTHER INSTRUCTIONS AND WARNINGS,

SEE

PAGE

OF THIS MANUAL.

SPECIFICATIONS

[SEE PAGE #1]

SPECIFICATIONS

MODELS

HSG2OO,HSG4OO

NATURAL

PROPANE

GAS

NOTE:Dimensionsin

( )are

informational

only.

Englishvaluestake

priority.

HSG2OO

Maximumlnput

Capacity

-200

MBtu/HR

(211000

kJ)

MinimumInput

Capacity

-60

MBtu/HR

(63300

kJ)

HSG4OO

MaximumInputCapacity

-400MBtu/HR

(422000

kJ)

MinimumInput

Capacity

-200MBtuiHR

(211000

kJ)

SUPPLYLINEPRESSUREREQUIRED:NaturalorPropane5.5W.C.

(1370

Pa)Minimum,14.0WC.(3487

Pa)

Maximum

AIRTUBEDIAMETER:4inches

(101.6

mm)

AIRTUBELENGTHS: HSG200 6inches (152.4

mm)

(See

Fig.

12C

tor HSG400 6.25

inches (158.75

mm)

OverallDimensions) HSG200|4O0 9.00

inches (228.6

mm)

HSG200/400 12.00

inches (304.8

mm)

MOUNTING:Adjustableflangestandard

(deduct

11/8inch

(28.575

mm)from

aboveairtube

lengthswhenusing

flange).Optional

pedestal

mounting.

STANDARDVOLTAGE:120VACI60HZl1Phase

120

VAC

| 50HZ 1Phase

(Special

motorinstalledwithmax

capacity

reduced20%)

220VACl50HZl1Phase

FLAMESAFETY:24VACElectronic

IGNITION:

7300VACDirect

Spark

GASVALVE=314x

3/4

(19.05

mmx 19.05mm)NPT

3 FunctionRedundant24VAC

.200

MBtu/HR

(211000

kJ)

(200,000

BTU

[58.62

kW]/ HR)or400MBtu/HR

(42200

kJ)

(400,000

BTU

[117.24

kW]

/ HR)

atsea

level.Derateinputforaltitude

over

2000tt.

(609.6

4"/.each1000ft.

(304.8

abovesea

level.

(one

gallon

(3.79

L)fueloil

=140MBtu/HR

(14770

kJ)).

CONTENTS PAGE

sEcTtoNI tNSTALLATION............ ..1

C. HEATINGAPPLIANCEINSPECTION. .........-...-.2

D. CHIMNEY

FLUEPIPEANDDRAFT

CONTROL ..............2.3

E. COMBUSTTONCHAMBER .............4

G. ELECTRICAL

H. MAINBURNER

ORIFICESIZING

ANDINSTALLATION ........................5

r. CoMBUSTTONGASVA1VE........ ........................6

SECTIONIIIOPERATIONAND

TROUBLESHOOTING.. ...........9.14

SECTIONIVSERVICE

EXPLODED

VIEW

TECHNICAL

INFORMATION.,........

SPECIFICATIONS MODELS

HSG200, HSG400

NATURAL

PROPANE GAS

NOTE: Dimensions

( ) are informational only. English values take priority.

HSG200

Maximum Input Capacity -200 MBtu/HR (211000 kJ)

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

HSG400

Maximum 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: 4inches (101.6 mm)

AIR TUBE LENGTHS: HSG200

(See Fig. 12C for HSG400

Overall Dimensions) HSG200/400

HSG200/400

6inches

6.25 inches

9.00 inches

12.00 inches

(152.4 mm)

(158.75 mm)

(228.6 mm)

(304.8 mm)

MOUNTING: Adjustable flange standard (deduct 11/8 inch (28.575 mm) from above air tube lengths when using

flange). Optional pedestal mounting.

STANDARD VOLTAGE: 120 VAC 160

HZ/1

Phase

120 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 x3/4 (19.05 mm x19.05 mm) NPT 3Function Redundant 24 VAC

*200 MBtu/HR (211000 kJ) (200,000 BTU [58.62 kW] 1HR) 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

by 4% each 1000 ft. (304.8

above sea level.

(one gallon (3.79

fuel oil =140 MBtu/HR (14770 kJ)).

CONTENTS PAGE

SECTION IINSTALLATION 1

GENERAL 2

VENTILATION 2

HEATING APPLIANCE INSPECTION 2

CHIMNEY, FLUE PIPE AND DRAFT CONTROL 2-3

COMBUSTION CHAMBER 4

GAS PIPING 4

ELECTRiCAL 5

MAIN BURNER ORIFICE SIZING AND INSTALLATION 5

COMBUSTION GAS VALVE 6

SECTION

INITIAL START UP

7-8

SECTION III OPERATION AND TROUBLESHOOTING 9-14

SECTION IV SERVICE 15-16

PARTS LISTS

EXPLODED VIEW

TECHNICAL INFORMATION 19

WARRANTy

CONSUMER INSTRUCTIONS

SECTIONI

INSTALLATION

A. GENERAL

The WayneHSG200and HSG400

power

gas

conversionburnersareadaptable

to most

typesof

centralheating

plantspreviously

firedby power

oil

burners.Typicalheating

plants

are

gravity

andforced

air circulationfurnaces,hotwater,

steam

or vapor

boilers.

Power

burnerdesignmakesthe

HSG200

and

HSG400well suitedfor "negativedraft"fired

applianceswhereanoilburner

beingreplaced.

lnstallationof these

power

gas conversionburner

modelsmustconformto local

codes,or in their

absence,theAmericanNational

Standard

for the

Installation

of Domestic

Gas Conversion

Burners.

ANS|Z21.8

- andthe NationalFlue

GasCode,

ANSlZ223.1

current

standard

year.

NOTICE:ANSI

localinstallation

codecompliance

the

sole

responsibilityofthe

qualified

installer.

VENTILATION

TheHSGconversionburnermodelscoveredbythis

manualshall

not

beinstalled

inanappliancelocated

where

normal

aircirculationorinfiltrationis

limitedin

providing

alltheairnecessaryfor

proper

combustion

anddrafthooddilutionair.

ooen

basementsofhomesofnormalconstruction

(without

basementstorm

windows

ortightstairdoors)

infiltration

of combustionair is usuallysufficient

replacethatdrawnupthe

flue,

sospecial

provisions

are

seldom

necessary.

When

the

heating

appliance

isinstalledin

tightly

closed

roomwithout

ventilation

openingstooutdoors,orother

rooms,

provisions

shall

bemadefor

supplyingair

for

combustionthroughspecial

openings,

one

nearthefloor

line

andtheother

near

theceiling.Eachistobe

sized

onthebasisofonesquare

inch

(645.2mm')

ormoreof

free

areaeach

1,000BTU

(.29kW)

input

per

hour.

When

thebuilding

ofunusuallytightconstruction,

has

kitchenand/orbathroom

ventilation

fanswhichmaybe

usedforexhaustingair

tooutdoors,orhas

a vented

fireplace,it is recommendedthatcombustionairbe

supplied

tothefurnaceroomthroughintakesextending

tothe

outside

the

buildingandterminating

down

turned

fittings,

suitablyarrangedtoprevent

obstruction

from

snow

rain,

andincludinga

protecting

screen

not

smallerthan

1/4inch

(6.35mm)

mesh.

HEATINGAPPLIANCEINSPECTION

Clean the appliance

heat exchanger

interior,

combustion

chamberand

flue

connections.

Remove

all

adheringtars,scale,dirtand

soot.

lnspecttheheat

exchanger

for

obviousand

potential

flue

gas

leaks.

Cementall joints

aroundthe appliancebaseand

accessopeningsto

prevent

air

and/or

flue

gas

leakage

into

oroutofthecombustionchamber.

WarmAir Furnaces*

- Make

certainthe electrical

characteristicsofthe

fan

and

limit

switchcorrespondto

those

required

bythisburnerandthat

theyare

proper

working

order.

Hot

Water

Boilers*

- Make

certainwatertemperature

andaltitude

gauges,

pressure

relief

valvesare in

proper

working

order.

Steam

Boilers*

- Makecertainthesystemispressure

tight,andthatthe

pressuregage

and

pop

offsafety

valve

arein

proper

working

order.

Existingwater

sight

glass

permits

clearobservationofboilerwaterlevel.

*Where

applicable,

existingtemperature

of pressure

limit

switchorlowwatercut-off

switch

operationand

electricalcharacteristics

shall

becheckedtodetermine

theircompatibilitytothe

gas

controlcircuitryofthis

burner.

D. CHIMNEY,

FLUEPIPEANDDRAFTCONTROL

The chimneyshouldbe inspected

for unsafe

conditionssuchas excessivesootaccumulation,

deteriorated

masonry,

blockageor

potential

blockage.

NOTICE:Nomanuallyadjustableflue

pipe

damperis

permitted

onany

gas

burner

installation.

Thechimney

should

belined

with

acorrosionresistant

material,

lfthechimney

unlined,consult

your

local

gas

utilityforrecommendations.

WARNING:

Under

nocircumstances

should

theflue

pipe

beconnectedto

the

chimneyofanopen

fireplace.

Theflue

pipe

should

sized

tocarryoftheflue

gases

outlinedinFigure1.

Figure1

Strictcompliance

to appropriate

codesshould

be made

regardingflue

pipe

clearances

from

combustible

materials,

INPUT

BTU/HR

(kW/HR) DRAFTHOOD

FLUEPIPE

SIZE

UPto-120MBH

(35.172kW) 5INCH

(127mm)

DIAMETER

120MBtu/HR135172kM

-180MBH

(52.758kW)

6INCH

(152.4mm)

DIAMETER

180

MBtu/HR

(52.758kM

-250

MBH

(73.275kW)

7INCH

{177.8mm)

DIAMETER

250MBtu/HRf3.275k$-320MBH{93.792kW)8INCH

(203.2mm)

DIAMETER

320MBtu/HR

(93

792kW)-410MBH

(120.171kW)

I INCH

(228.6mm)

DIAMETER

PAGE2

SECTION I

INSTALLATION

GENERAL

The Wayne HSG200 and HSG400 power gas

conversion burners are adaptable to most types of

central heating plants previously fired by power oil

burners. Typical heating plants are gravity and forced

air circulation furnaces, hot water, steam or vapor

boilers. Power burner design makes the HSG200 and

HSG400 well suited for "negative draft" fired

appliances where

oil burner

being replaced.

Installation of these power gas conversion burner

models must conform to local codes, or

their

absence, the American National Standard for the

Installation 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

the sole responsibility of the qualified installer.

VENTILATION

The

HSG

conversion burner models covered

this

manual shall not

installed

appliance located

where normal air circulation or infiltration

limited

providing

all

the air necessary for proper combustion

and draft hood dilution

air.

open basements of homes of normal construction

(without basement storm windows or tight stair doors)

infiltration of combustion air

usually sufficient to

replace that drawn

the flue,

special provisions

are seldom necessary.

When the heating appliance

installed

atightly closed

room

without ventilation openings to outdoors, or other

rooms,

provisions shall

made

for

supplying air for

combustion through special openings,

one

near

the

floor

line and the other near

the

ceiling.

Each

sized

the

basis of

one

square

inch

(645.2mm2)or more of

free

area each 1,000

BTU

(.29kW) input per

hour.

When

the

building

of unusually tight construction, has

kitchen and/or bathroom ventilation fans which may

used for exhausting air to outdoors, or has avented

fireplace,

recommended that combustion air

supplied to the furnace room through intakes extending

the outside of

the

building

and

terminating

down

turned fittings, suitably arranged to prevent obstruction

from snow or

rain,

and

including aprotecting screen not

smaller than 1/4 inch (6.35mm) mesh.

HEATING APPLIANCE INSPECTION

Clean the appliance heat exchanger interior,

combustion chamber and flue connections. Remove

all

adhering tars, scale, dirt and soot. Inspect the heat

exchanger for obvious and potential flue gas leaks.

Cement all joints around the appliance base and

access openings

prevent air and/or flue gas leakage

into or out of the combustion chamber.

Warm Air Furnaces* -Make certain the electrical

characteristics of the fan and limit switch correspond to

those required

this burner and that they are

proper working order.

Hot Water Boilers* -Make certain water temperature

and altitude gauges, pressure relief valves are

proper working order.

Steam Boilers* -Make certain the system

pressure

tight, and that the pressure gage and pop off safety

valve are

proper working order. Existing water sight

glass permits clear observation of boiler water level.

*Where applicable, existing temperature of pressure

limit switch or low water cut-off switch operation and

electrical characteristics shall

checked to determine

their compatibility to the gas control circuitry of this

burner.

CHIMNEY, FLUE PIPE AND DRAFT CONTROL

The chimney should be inspected for unsafe

conditions such as excessive soot accumulation,

deteriorated masonry, blockage or potential blockage.

NOTICE:

manually adjustable flue pipe damper is

permitted

any gas burner installation.

The chimney should

lined with acorrosion resistant

material.

the chimney

unlined, consult your local

gas utility for recommendations.

WARNING: Under

circumstances should the flue

pipe

connected to the chimney of

open fireplace.

The flue pipe should

sized

carry of the flue gases

outlined

Figure

INPUT DRAFTHOOD

BTU/HR (kW/HR) FLUE PIPE SIZE

-120

MBH

(35.172kW)

51NCH

(127mm)

DIAMETER

120

MBtu/HR

(35172kW)

-180

MBH

(52.758kW)

INCH

(152.4mm)

DIAMETER

180

MBtu/HR

(52.758kW)

250

MBH

(73.275kW)

INCH

(177.8mm)

DIAMETER

250

MBtu/HR

(73.275kW)

320

MBH

(93.792kW)

INCH

(203.2mm)

DIAMETER

320

MBlu/HR

(93.792kW)-

410

MBH

(120171

kW)

INCH

(228.6mm)

DIAMETER

Figure 1

Strict compliance to appropriate codes should

made

regarding flue pipe clearances from combustible materials.

PAGE 2

Pitch

thehorizontalrun

ofthe

flue

pipe

upward1/4inch

(6.35mm)per

foot

(.305m)

ormore.Rundirectly

tothe

chimney,fasten

joints

securelyand

supporthorizontal

runs

prevent

sagging.

lfthe

flue

pipe

mustbe

extra

long,

it's

sizeshouldbe

increased.The

horizontallength

oftheflue

pipe

should

notexceedtheheight

of thechimney

abovetheflue

connection.

PITCHHOBIZONTAL

RUN 1/4"

(6.35mm)

MlN.

PER FOOT(.gosM)

VERTICAL

DRAFTHOOD

Figure

HSG

BURNER

The

draftcontrol

shouldbe

hood

type

per

Figure

2 or,lF

APPROVED

BY LOCALAUTHORITIES,

a single

barometricdamper

suitable

for

gas

firing

per

Figure

The

draftcontrol

shouldbesizedthe

sameasthe

flue

pipe

per

Figure1,andshouldbelocatedhigher

thanthe

highest

part

ontheapplianceflue

passage.

Refer

tothe

barometricdraftregulatormanufacturer's

instructionsfor

completedetail.

NOTICE:

Shouldtheflue

pass

throughapartition,

thedraftcontrolmust

belocated

inthe

same

room

the

heating

appliance.

PITCHHORIZONTAL

BUN1/4"

(6.3smm)

MlN.

PEFFOOT

(.3osrV) DONOTEXTEND

FLUEPIPE

BEYONO

INSIDE

OFCHIMNEY

SINGLE

ACTING

BAROMETRIC

DRAFTCONTROL

BAROMETRIC

DRAFT

CONTROLPOSITION

Figure

EXISTING

PREFABRICATEO

COMBUSTION

CHAMBEB

LINER

TO PROTECTPROPERLY

LOCATEENDOFBURNEF

TUBE.POSITIONTUBE

1/2'

(12.7mm)

SHORTOFINSIDE

OFCOMBUSTION

CHAMBEB

FORCED

AIRFURNACE

Figure

EXISTING

ADDEDTARGET

TO BACKOF COMBUS-

TION

CHAMBER

TOPROTECT

PBOPERLY

LOCATEEND

OFBURNER

TUBE.POSITION

TUBE 1/2'

(12.7mm)

SHORTOF INSIDE

OFCOMBUSTION

CHAI\4BER

EXISTING

PREFABRICATEO

COMBUSTION

CHAIV]BEBLINEFI

TOPROTECTPROPERLY

LOCATEENDOF BURNEF

TUBE. POSITIONTUBE 1/2"

(12.7mm)

SHOBTOFINSIDE

OFCOMBUSTION

CHAMBEF

HOT

WATER

ORSTEAMBOILER

WITH

COMBUSTION

CHAMBER

TARGET

Figure

PAGE

HOTWATER

ORSTEAMBOILER

WITH

COMBUSTION

CHAMBERLINER

COFFOSION

RESISTANT

LINING

CLEANOUT

SELECTEITHER

HORIZTONAL

VEFTICAL

DBAFTHOOD

DRAFT

HOODPOSITONS

Figure6

Pitch

the

horizontal

run

the

flue

pipe

upward

1/4

inch

(6.35mm) per foot (.305m)

more.

Run

directly

the

chimney, fasten joints securely

and

support horizontal

runs

prevent sagging.

the flue pipe must

extra

long,

it's size should

increased. The horizontal length of the flue

pipe

should

not exceed

the

height of

the

chimney above

the

flue

connection.

CHI""NEY

CLEANOUT

BULL HEAD

TEE

CORROSION -=-+--1------'"

RESISTANT LINING

NOT EXTEND

FLUE PIPE BEYOND

INSIDE OF CHIMNEY

SINGLE ACTING

BAROMETRIC

DRAFT CONTROL

The draft control should

hood type per Figure 2

or,

APPROVED

LOCAL AUTHORITIES, asingle

barometric damper suitable for gas firing per Figure

The

draft control should

sized the same

the flue

pipe

per Figure

and

should

located higher than

the

highest part

the

appliance flue passage. Refer

the

barometric draft regulator manufacturer's instructions for

complete detail.

NOTICE: Should the flue pass through apartition,

the draft control must be located

the

same room as the heating appliance.

PITCH HORIZONTAL

RUN 1/4" (6.35mm) MIN.

PER FOOT (.305M)

CHIMNEY

CORROSION

RESISTANT LINING

CLEANOUT

DO NOT EXTEND

FLUE PIPE BEYOND

INSIDE

CHIMNEY

SELECT EITHER

HORIZTONAL OR

VERTICAL DRAFT HOOD

DRAFT HOOD POSITONS

REDUCER

VERTICAL

DRAFT HOOD

PITCH HORIZONTAL

RUN 1/4" (6.35mm) MIN.

PER FOOT (.305M)

Figure 2BAROMETRIC DRAFT

CONTROL POSITION

Figure 3

EXISTING

PREFABRICATED

COMBUSTION

CHAMBER LINER

HSG

BURNER

TO PROTECT PROPERLY

LOCATE END OF BURNER

TUBE. POSITION TUBE

112"

(12.7mm) SHORT OF INSIDE

OF COMBUSTION

CHAMBER

FORCED AIR FURNACE

Figure 4

HOT WATER

STEAM BOILER WITH

COMBUSTION CHAMBER LINER

Figure 6

EXISTING

PREFABRICATED

COMBUSTION

CHAMBER LINER

TO PROTECT PROPERLY

LOCATE END OF BURNER

TUBE. POSITION TUBE 1/2"

(12.7mm) SHORT OF INSIDE

COMBUSTION

CHAMBER

,,_

...

..l

.,.. .. .J.

...

, , ,

.,,

,, ,

., ,

,,,

,.,

HSG

BURNER

EXISTING OR

ADDED TARGET

TO BACK OF COMBUS·

TION CHAMBER

TO PROTECT PROPERLY

LOCATE END OF BURNER

TUBE. POSITION TUBE 1/2"

(12.7mm) SHORT OF INSIDE

OF COMBUSTION

CHAMBER

HOT WATER OR STEAM BOILER WITH

COMBUSTION CHAMBER TARGET

Figure 5

PAGE 3

E. COMBUSTION

CHAMBER

A combustionchamber

is normally

requiredto

protect

non-heat

transfersurfaces,andtoprovide

radiant

bedfor rapidheattransfer

to the primary

surfacesofthe

heat

exchanger.

lfin

good

condition,

theexistingcombustionchambercanbeused.

Afull

combustionchamber

linerisrecommendedfor

warmair

furnaces,

(see

Figure4),

andatarget

wall

orfull

combustionchamberlineris recommended

forwetlegcast

iron

orsteelboilers.

(See

Figures5

and6). lf a built-upchamberis necessary,use

2300'

F (1260"C)

minimuminsulatingfire-brickor

fiberfrax.

THE BURNER

AIR TUBE MUST NOT BE

ALLOWEDTO EXTENDINTOTHECHAMBER

PROPER;lT MUSTBE

SET

1/2INCH

(12.7mm1

SHORT

THEINSIDESURFACE.

Before

permanently

securingthe burnerto the

heatingappliance

with

eithertheadjustablemounting

flangeorpedestal

orcementingaroundtheairtube

inthecombustionchamberopening,

check

thatthe

burner

head

assembly

isfree

foreign

materialsand

thatthe

sensor

andelectrode

probes

havenotbeen

damagedor

repositioned,

see

Figure13.

RECOMMENDED

COMBUSTION

CHAMBERSIZES

Figure7

SUPPLY

LINE

CONNECTION

BURNER

F. GAS

PIPING

NOTICE:

All

piping

mustcomply

with

state

and/or

localcodes.

The available

gas supply

pressure

should

bewithinminimumandmaximum

pressures

shown

theburnerspecifications.

the

gas

supply

pressure

exceedsthe14"

W.C.

(3.5

kPa)

maximum,

intermediatemain

gas

regulatormust

beinstalled

aheadofthemain

gas

manual

shut

offvalve

shown

inFigure8.

WARNING:Failure

to install

theintermediate

gas

regulatorwillresultingas

leakagefromburner

gas

valve.

Adripleg

orsediment

trapmustbeinstalledinthe

supply

line

totheburner.See

Figure

A pipeunion

shallbe installedin the gas line

adjacentto, and upstreamfrom, the main gas

manual

shutoff

valve,

See

Figure

The

gas

supply

piping

totheburner

should

branch

off

fromthemain

gas

supply

line

asclosetothe

gas

meteras

possible.

Donot

connecttothebottomof

a horizontal

section.See

Figure

9 for

gas

supply

pipe

sizes.

Use

newblackiron

pipe

andmalleablefittingsfree

of burrsanddefects. Usepipe

joint

compound

resistanttoliquefied

petroleumgases.

A118"

(3.175mm)

NPT

plugged

tappingaccessible

for test gauge connectionshall be provided

immediatelyupstreamofthe

gas

supplyconnection

for

determining

gas

supply

pressure

totheburner.

Testnew supply

piping

for leaks. CAUTION:

DURINGPRESSURETESTFORLEAKSINGAS

SUPPLY

PIPING,THE BURNERMUST BE

DISCONNECTED

TOPREVENT

EXPOSINGTHE

COMBINATION

GAS VALVETO PRESSURES

OVER 112" (3447 PaG) PSIG. POSSIBLY

DAMAGINGTHE VALVEAND VOIDINGTHE

BURNERWARRANTY.

CAPACITIES

SHOWN ARE FOR A TOTAL PRESSURE

DROPOF 0.3"W.C.(74.73Pa)

FOR0.5"W.C.(12a.55Pa)

PRESSUREDROP.MULTIPLYCAPACITYSHOWN

BY 1.3.

FOR HIGHER PERMISSIBLE PRESSURE DROPS,

CONSULT

YOUR

UTILITY.

SUPPLY PIPE CAPACITIES lN MBtu/HR (kW)

INPUT

BTU/HR

kWHr

PREFERRED

wluIH"{mm)xLLNUIH"(mm)ulAM."

(mm

50MBtu/HH

(.|4.655kW) 7n778\X7t1778\ 8

(203.2)

75MBtu/HR

(219.825kW)71/2

(190

5)X71/2

(190.5) 9{228.6)

100MBtu/HR

(293.1kW) 12

(304.8)

X12

(304.8) 1

(330.2)

150MBtu/HR

(439

65kW) 12

(304.8)

X15

(381) 14

(355

200MBtu/HR

(586.2kW) 13

(330.2)

X17

(431.8) 15

(381

)

250MBtu/HRfi32.75kW) 13

(330.2)

1457.2) '16

(406.4)

300MBtu/HRf879,3kW) 13

(330.2)

X20

(508) 18

U57.2\

350MBtu/HR

025.85kW)14

(355.6)

X21

(533.4) 20

(508)

400MBtu/HR{11i2.4kw) t5(381)

X22{558.8) 21

(533.4)

PIPE

SIZE TYPE

OFGAS

CAPACITY- MBtu/HR

(kJ)

LENGTHOFPIPE

(381mm)

l0(762mm)

(1143mm

(2286mm

3t4

t19.05mm)

Propane 400

422000k.t.| 250

t263750k, 200

211

000kJ)

(25.4mm) l\atural

Propane

4UU

422000kJ) z5u

(263750kJ

400

ta220nok.l

ZUU

211

000kJ)

350

i6q25nk.t) 250

'26i750k.t\

11t4

(31.75mm)

Natural

Propane

400

(422000kJ)400

422000kJ)

400

422000k.1\

300

316500kJ)

400

422000kJ)

11t2

l38.1mm)Natural 400

arrnnnk.t\

Figure

8Figure

9PAGE4

PAGE 4

COMBUSTION CHAMBER

Acombustion chamber is normally required to

protect non-heat transfer surfaces, and to provide a

radiant bed for rapid heat transfer to the primary

surfaces of the heat exchanger. If

good condition,

the existing combustion chamber can be used.

Afull combustion chamber liner is recommended for

warm air furnaces, (see Figure 4), and atarget wall

full combustion chamber liner is recommended

for wet leg cast iron

steel boilers. (See Figures 5

and 6). If abuilt-up chamber is necessary, use

2300° F(1260°C) minimum insulating fire-brick

fiberfrax.

THE BURNER AIR TUBE MUST NOT

ALLOWED TO EXTEND INTO THE CHAMBER

PROPER; IT MUST

SET 1/2 INCH (12.7mm)

SHORT OF THE INSIDE SURFACE.

Before permanently securing the burner to the

heating appliance with either the adjustable mounting

flange

pedestal or cementing around the air tube

the combustion chamber opening, check that the

burner head assembly is free of foreign materials and

that the sensor and electrode probes have not been

damaged

repositioned, see Figure 13.

INPUT

PREFERRED

BTU/HR

kW/Hr

WIDTH"(mm)

LENGTH"(mm)

DIAM."

(mm

MBtu/HR

(14655kW)

(177.8)

(203.2)

MBtu/HR

(219825kW)

71/2

(1905)

71/2

(190.5)

(2286)

100

MBtu/HR

293,lkW)

304,8

304.8)

330.2)

150

MBtu/HR

43965kW)

304.8

381)

3556)

200

MBtu/HR

586,2kW)

330.2

X17

431.8)

381)

250

MBtu/HR

73275kW)

330.2

457.2)

4064)

300

MBtu/HR

8793kW)

330.2

508)

457.2)

350

MBtu/HR

102585kW)

355.6

5334)

508)

400

MBtu/HR

11724kW)

381)

(558.8)

5334)

RECOMMENDED COMBUSTION

CHAMBER SIZES

Figure 7

ANUALSHUTOFFVALVE

I1/8" (3,175mm)

N.P.T.

DIRECTION •PLUGGED TAPPING

OF FLOW PRESSURE GAGE PORT

'i,--y--+-

PIPE CAP

DRIP LEG

SUPPLY LINE COI\II\IECTION

TO BURNER

Figure 8

GAS PIPING

NOTICE: All piping must comply with state

andlor

local codes. The available gas supply pressure

should be within minimum and maximum pressures

shown

the burner specifications. If the

gas

supply

pressure exceeds the 14" W.C. (3.5 kPa) maximum,

intermediate main gas regulator must be installed

ahead of the main gas manual shut off valve shown

Figure

WARNING: Failure to install the intermediate

gas

regulator will result

gas leakage from burner gas

valve.

Adrip leg or sediment trap must be installed in the

supply line to the burner. See Figure

Apipe union shall be installed

the gas line

adjacent to, and upstream from, the main gas

manual shutoff valve. See Figure

The gas supply piping to the burner should branch

off from the main gas supply line as close to the gas

meter as possible. Do not connect to the bottom

ahorizontal section. See Figure 9for gas supply

pipe sizes.

Use new black iron pipe and malleable fittings free

of burrs and defects. Use pipe joint compound

resistant to liquefied petroleum gases.

A1/8" (3.175mm) NPT plugged tapping accessible

for

test

gauge

connection

shall be

provided

immediately upstream of the gas supply connection

for determining gas supply pressure to the burner.

Test new supply piping for leaks. CAUTION:

DURING PRESSURE TEST FOR LEAKS

GAS

SUPPLY PIPING, THE BURNER

MUST

DISCONNECTED TO PREVENT EXPOSING THE

COMBINATION GAS VALVE TO PRESSURES

OVER

1/2"

(3447

PaG) PSIG. POSSIBLY

DAMAGING THE VALVE AND VOIDING THE

BURNER WARRANTY.

PIPE

TYPE

CAPACITY

-MBtu/HR

(kJ)

SIZE

GAS

LEI~GTH

PIPE

(381mm)

(762mm)

(1143mm)

(2286mm

3/4

Propane

400

250 200

1(19.05mm)

422000kJ)

(263750kJ)

211000kJ)

Natural

400

250

200

(25.4mm)

(

422000kJ)

(263750kJ)

(211000kJ)

Propane

400

350

250

(422000kJ)

369250kJ)

'263750kJ)

1/4

Natural

400 400

300

(31.75mm)

(422000kJ)

(316500kJ)

Propane

400 400

422000kJ) 422000kJ)

1/2

Natural

400

(38.1mm)

'422000kJ)

CAPACITIES SHOWN ARE FOR ATOTAL

PRESSURE

DROP

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

MBtulHR (kW)

Figure 9

G. ELECTRICAL

Theinstallationmust

wired

andGROUNDED

accordance

withlocal

codesor in their

absence,

with

the

National

ElectricCodeANSI/NFPANo.70-

1987

latest

edition.

For

the 120VACwiring

to theburner,

usesolid

copperconductorwirenotlighterthan#14AWG.lf

afused

disconnect

used,itshouldbe

fused

fora

minimum

of15

amps.

CAUTION:

Eachinstallationmustinclude

suitable

limitcontrols.Existingoilburner

combinationlimit

andoperatingcontrolsarenormally

not

suitable

for

gas

burneruse.

CAUTION:

Theburneris

equipped

withit'sown24

VAC

transformer.Donotaddany24VAC

power

consumingdevicein the24VACcontrol

circuitof

theburner,asitcouldoverloadthetransformer.

Setthe roomthermostat

"heat

anticipator"forthe

totafcurrentdrawofthe24VAC

burneroperation

circuit.

(HSG200

0.55amps,

HSG400

0.7amps)

GAUTION:

Label

allwires

orior

to disconnection

whenservicingcontrols.Wiringerrorscancause

improperanddangerousoperation.

Verify

proper

operationafter

servicing.

NOTE:lfanyof

the

originalburner

wiringmust

replaced,it mustbe replacedwith#18

AWG105degrees

wireorequivalent.

Section3- Operationand Troubleshootingfor

applicableburnerwiringdiagrams.

H. MAIN

BURNER

ORIFICESIZING

ANDINSTALLATION

TheHSG200andHSG400

powergasconversion

burnersare approvedfor use with natural

and

propane

gas

only.

The HSG200and HSG400

burner

models

are

shipped

labeled

andorificedfor natural

gas. To

conveftto propanegas and/orincreaseBTU/HR

(kcal/Hr)

inputonnaturalorpropane

gas,

orifice

kit is supplied

witheachburner

withthe orifices

shown

inFigure

10.

Whenselectinga desiredBTU/HR

(kcal/Hr)

input,

figure140,000BTU's

per

gallon

of oilinput. For

example:

furnaceorboiler

rating

of0.75gphat100

psig.The

0.75x 140,000

= 105,000

BTU'sinput

rate.ltmaybe

possible

toreducethefiringrateon

natural

propanegas

15%

lo20o/",

most

older

appliancesareoversizedfortheheatingload.

(2.83875L

x9356kcal

=26559.35kcal)

remove

interchangemain

orificediscs

refer

Figure15

(Page

16).

1. Removeslottedorificecap,ltem#40,making

sureorifice

capgasket,

#39,

stays

attachedto

orificecapand

isnot

damaged.

2. Removeorifice

spring,

ltem#38,to access

and

removeorificedisc.ltem#42.

3. InstalldesiredorificefromFigure10,making

sure

it is seated

flatin theorifice

holder,

ltem

#37.

4. Replaceorifice

springand securelytighten

orificecapagainstorificecapgasket

in orifice

holder.

NOTE:For

50cycle

application

derateinput

by15%

HSG

SERIES

POWER

GAS

CONVERSIONBURNERS

ORIFICECHART

Figure

ORIFICE

SIZE& DRILL MANIFOLDPRESSURE

2.0"

(498.2Pa) 3.0"

(747.3Pa) 4.0"

(996.4Pa)

HSG2OONATURAL

GAS

#29-.136

(3.4544mm) 50.000BTU

(52750kJ) 64.000BTU{67520kJ) 76.500BTU

(80707.5kJ

#8-.199

(5.0546mm)i4,000

BTU

(78070kJ)95.000BTU

(100225kJ)116.000BTU

(122380kJ

.277

(7.0358mm)

112.000BTU

(118160kJ)138.000BTU

(145590kJ)164.000

BTU

(173020kJ

-.332

(8.4328mm) 160,000BTU

(168800kJ)

206,000

BTU

(217330kJ)

HSG2OOL.P.

GAS

#30-128

(3.2512mm) 49.000BTU

(5169skJ) 58.500BTU

(61717.5kJ)

68.200BTU

(71951kJ)

#27-

j44

(3.6576mm)

66.000BTU

(69630kJ) 78,000

BTU

(82290kJ) 92.000BTU

{97060kJ)

#15

-.180

(4.572mm)82.000BTU

(86510kJ)'1

12.500BTU

18687.5kJ)136.000BTtl

(143480kJ)

-.246

(6.2484mm) 131,000BTU

(138205kJ)

187.500BTU

9781

2.5kJ)243,000BTU

(256365kJ)

HSG4OONATURAL

GAS

-.358

(9.0932mm) 200.000BTU

(211000kJ)248.000BTU

(261640kJ)

285000BTU

(300675kJ)

15/32-

.468

(11.8872mm)

265,000

BTU

(279575kJ)343.000BTU

{361865kJ)400,000BTU

(422000kJ)

HSG4OOL.P.

GAS

K-.281

(7.1374mm)190.000

BTU

(200450kJ)

242.500BTU

(255837.5kJ

)295.000

BTU{311225kJ)

0- .332

(8.4328mm)242,500BTU

(255837kJ)

332,500BTU

(350787.5kJ)

400,000

BTU

(422000kJ)

PAGE

ELECTRICAL

The installation must be wired and GROUNDED

accordance with local codes or

their absence,

with the National Electric Code ANSI/NFPA

No.

70-

1987 or latest edition.

For the 120

VAC

wiring

the burner, use solid

copper conductor wire not lighter than #14 AWG.

afused disconnect is used, it should

fused for a

minimum of 15 amps.

CAUTION: Each installation must include suitable

limit controls. Existing oil burner combination limit

and operating controls are normally not suitable for

gas burner use.

CAUTION: The burner is equipped with it's own 24

VAC

transformer.

not add any 24

VAC

power

consuming device

the 24

VAC

control circuit of

the burner, as

could overload the transformer.

Set the room thermostat "heat anticipator" for the

total current draw of the 24

VAC

burner operation

circuit. (HSG200 0.55 amps, HSG400 0.7 amps)

CAUTION: Label

all

wires prior to disconnection

when servicing controls. Wiring errors can cause

improper and dangerous operation.

Verify proper operation after servicing.

NOTE: If any of the original burner wiring must

replaced, it must

replaced with #18

AWG 105 degrees Cwire or equivalent.

Section 3- Operation and Troubleshooting for

applicable burner wiring diagrams.

MAIN BURNER ORIFICE SIZING

AND INSTALLATION

The HSG200 and HSG400 power gas conversion

burners are approved for use with natural and

propane gas only.

The HSG200 and HSG400 burner models are

shipped labeled and orificed for natural gas.

convert to propane gas and/or increase BTU/HR

(kcal/Hr) input

natural or propane gas,

orifice

kit

supplied with each burner with the orifices

shown

Figure 10.

When selecting adesired BTU/HR (kcal/Hr) input,

figure 140,000 BTU's per gallon of oil input. For

example: furnace or boiler rating of 0.75gph at 100

psig. The 0.75 x140,000

105,000 BTU's input

rate.

may

possible to reduce the firing rate

natural or propane gas 15%

20%, as most older

appliances are oversized for the heating load.

(2.83875L x9356 kcal

26559.35 kcal)

remove or interchange main orifice discs refer

Figure 15 (Page 16).

Remove slotted orifice cap, Item #40, making

sure orifice cap gasket, #39, stays attached to

orifice cap and is not damaged.

Remove orifice spring, Item #38,

access and

remove orifice disc, Item #42.

Install desired orifice from Figure 10, making

sure

seated flat

the orifice holder, Item

#37.

Replace orifice spring and securely tighten

orifice cap against orifice cap gasket

orifice

holder.

PAGE 5

ORIFICE MANIFOLD PRESSURE

SIZE &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)

500

BTU

180707.5kJ)

.199

(5.0546mml

74,000

BTU

178070kJ)

95,000

BTU

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

GAS

T-

.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

(422000kJl

HSG400

L.P.

GAS

K-

.281

(7.1374mm)

190,000

BTU

(200450kJ)

242,500

BTU

(255837.5kJ)

295,000

BTU

1311225kJl

Q -

.332

(8.4328mm)

242,500

BTU

(255837kJ)

332,500

BTU

(350787.5kJ)

400,000

BTU

(422000kJ)

HSG SERIES POWER GAS CONVERSION BURNERS

ORIFICE CHART

Figure

NOTE: For

50 cycle

application

derate input

by 15%

COMBINATIONGASVALVE

The24VAC

combination

gas

valve

serves

three

(3)

functions:

(1)

manual

gas

shut-off,

(2)

main

gas

flamepressure

regulator,

(3) automatic

electric

redundant

(double

seated)

gas shutoff. (See

Figure11)

Thecorrectoperatingmanifold

orifice

pressure

range

for both natural

and propane

gas is 2.0" W.C.

(498.2Pa)

minimumto 4.0" W.C. (996.aPa)

maximum. By adjusting

the pressure

regulator

between2.0" W.C. (498.2Pa)

and 4.0' W.C.

(996.4Pa)

oneithernatural

orpropanegas,

a wide

inputrangecanbeachievedwithasingle

orifice

size.

lfthedesired

input

ratingcannotbeobtainedwithin

the abovemanifoldorifice

pressure

adjustment

range,thenext

size

larger

orsmallerorificeshould

used.

(Referto

orifice

chartFig.

10.)

PRESSUREREGULATOR

ADJUSTMENT

The combination

gas valve pressure

regulator,

whichhas an outlet

pressure

setting

range

PRESSURE

REGUI-ATOR

approximately2.0"W.C.(498.2Pa)

to 4.0" W.C.

(996.4Pa)

is factory

setat 3.5' W.C

(871.85Pa).

When

pressure

adjustment

is required

for setting

inputcapacitywithaselectedorifice

from

Figure10,

removetheregulatorcapforaccess

totheslotted

adjustmentscrew. Turningthe screwcounter

clockwise

reducesmanifoldorifice pressure,

clockwise

increases

the

pressure.

NOTE:MANIFOLDPRESSUREADJUSTMENTS

CAN ONLY BE MADE WITH THE

BURNERRUNNINGANDTHE

GASON.

The1/8"

(3.175mm)

NPT

pressure

tapfororifice

manifold

pressure

measurementis located

onthe

outlet

side

ofthecombination

gas

valve.Usea"u"

tube manometeror dial type pressure

gauge,

scaled

from

"0"

zerolo 15.0'W.C.

(3736.5Pa)

read

pressure(See

Figure11).

PRESSURE

REGULATOR

1/8"

(3.175mm)

NPT

PRESSURETAPPLUG

HSG2OOI4OOGAS VALVE

HONEYWELLVR83O5

t /ANUAL

CONTROL

KNOB

(SHOWN

oFF POSmON)

HSG4OO

GASVALVE

ROBERTSHAW

TOOO

DERHC

Figure11

PAGE6

COMBINATION GAS VALVE

The 24

VAC

combination gas valve serves three

(3)

functions:

(1)

manual gas shut-off,

(2)

main gas

flame pressure regulator,

(3)

automatic electric

redundant (double seated) gas shut off. (See

Figure

11)

The correct operating manifold orifice pressure range

for both natural

and

propane gas

2.0"

WC.

(498.2Pa) minimum to 4.0" W.C. (996.4Pa)

maximum.

adjusting the pressure regulator

between 2.0"

WC.

(498.2Pa) and 4.0"

WC.

(996.4Pa)

either natural or propane gas, awide

input range can

achieved with asingle orifice size.

If the desired input rating cannot

obtained within

the above manifold orifice pressure adjustment

range, the next size larger or smaller orifice should

used. (Refer to orifice chart

Fig.

10.)

J. PRESSURE REGULATOR ADJUSTMENT

The combination gas valve pressure regulator,

which has

outlet pressure setting range of

approximately 2.0"

WC.

(498.2Pa) to 4.0"

WC.

(996.4Pa) is factory set at 3.5"

(871.85Pa).

When pressure adjustment

required for setting

input capacity with aselected orifice from Figure 10,

remove the regulator cap for access to the slotted

adjustment screw. Turning the screw counter

clockwise reduces manifold orifice pressure,

clockwise increases the pressure.

NOTE: MANIFOLD PRESSURE ADJUSTMENTS

CAN ONLY

MADE

WITH

THE

BURNER RUNNING AND THE GAS ON.

The 1/8" (3.175mm) NPT pressure tap for orifice

manifold pressure measurement is located

the

outlet 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) to

read pressure (See Figure

11).

PRESSURE

REGULATOR

MANUAl CONTROL

KNOB

(SHOWN

OFF

pOSmON)

1/8" (3.175mm) NPT

PRESSURE TAP

PLUG

INLET

MANUAL CONTROL

KNOB

(SHO'olN IN

orr POSITION)

118"

(3.175mm) NPT

PRESSURE TAP PLUG

HSG400 GAS

VALVE

ROBERTSHAW 7000 DERHC HSG

200/400

GAS VALVE

HONEYWELL VR8305

Figure

PAGE 6

SECTIONII

INITIAL

STARTUP

1. NOTE:Read the applicablesequence of

burner/primary

gas controloperationin

Section3 Operation

and

Troubleshooting

before

proceeding.

2. Depressthe

combination

gas

valvemanual

control

knob

andturnto"OFF"

position.

3. Adjusttheprimary

airand

off-cycle

damper

to the

startup

settingsshown

inFigure12Aand128.

4. On

new

gas

lineinstallations,

air

may

betrapped

the line,the burnermay experienceseveral

lockouts

untilalltheair

ispurged

fromthelines.

5. Turn on the mainelectrical

power

and set the

thermostator operationcontrolto call for heat.

AllowtheburnertorunaMINIMUM

of5minutes

purgecombustion

chamberand appliance

heat

exchanger.

6. Setthethermostatoroperatingcontrolbelowroom

temperature,

shutting

the

burner

"OFF"

1minute

RESETthe

primary

control.

7. Depressthe

combination

gas

valvemanual

control

now

andturnto"ON"

position.

8. Setthethermostat

or operating

controlto call

for

heat. The burnerwillstartandgo throughthe

applicablesequenceofburner/primary

gas

control

operation,

refer

tostep1.

9. Onceburneris running

adjusttheorificemanifold

pressure

regulator

asdescribed

in paragraph

J -

PressureRegulator

Adjustment.

10.Amore

accurateBTU

(kW)

input

canbedetermined

byusingtheNATURAL

gas

servicemeterwiththe

burner

onlyon(all

other

gas

appliancesshouldbe

off).Thehand

the

gas

meter

dialwiththe

lowest

cubicfeetvalve

(fastest

revolving

dial),

should

clockedforonecompleterevolution

andusethe

followingformula.

3600xcubicft.

(m3)pre

revolutionx

btu

(kW)valve/cub

fl(m3)=

BTU/HR

(kWH0

seconds

oer

revolulion

EXAMPLE:3600x1x1000

(.2931k$

300,000BTU/HR

(87.93

kWHB)

11. After

thedesiredinputhasbeenobtained,

re-adjust

theprimary

airdamperopenor closedto visually

obtain

a blue

flamewithwell

definedorangeor

yellow

tipsfornatural

gas,

orwelldefined

yellow

tips

for

propanegas.

12.After

theburner

has

been

operation

for

least

minutes,

assuring

combustion

chamberandheat

exchangerare fully warmed,take combustion

analysisfluegassamples

justaheadof thedraft

controlinthe

flue

pipe.

NOTE:

ALWAYSUSE

RELIABLE

COMBUSTION

TEST INSTRUMENTS. BEING

PROFICIENTIN THE USE OF THESE

INSTRUMENTSAND INTERPRETING

THEIRDATAISNECESSARYFOR

SAFE,

RELIABLEAND EFFICIENTBURNER

OPERATION.

13.Perform

the following

combustion

analysis.All

adjustments

below

must

madewith

the

following

instruments:draft

gauge,

02 or CO2analyzeand

COtester.

A. Adjustthe

primary

airdamper

toprovide

about

257oexcesscombustionair. Confirm

thisby

checkingtheflue

gasfor its FREE

OXYGEN

(Oz)

or CARBONDIOXIDE

(COz)

PERCEN-

TAGESwith

a testinstrument.Free

oxygen

should

beabout4.5"/o,

orcarbondioxideshould

be about9.5%for natural

gas, 12.1"/"for

propanegas.

B. CARBON

MONOXIDE

- Should

becheckedfor

itspresence

intheflue

gas. This

percentage

should

not

exceed

.04/"

(or

400

PPM).

C. NOTE: Checkoverfiredraft and adjust

NEGATIVE

-.01(2.491Pa)

to -.02(4.982Pa)

inchesw/cduring

burneroperation.

PAGE

SECTION

INITIAL START

NOTE: Read the applicable sequence of

burner/primary gas control operation in

Section 3Operation and Troubleshooting

before proceeding.

Depress the combination gas valve manual control

knob and turn to "OFF" position.

Adjust the primary air and off-cycle damper to the

start

settings shown

Figure 12A and 12B.

On new gas line installations, air may

trapped

the line, the burner may experience several

lockouts until

all

the air

purged from the lines.

Turn

the main electrical power and set the

thermostat or operation control

call for heat.

Allow the burner

run

aMINIMUM of 5minutes

purge combustion chamber and appliance heat

exchanger.

Set the thermostat or operating control below room

temperature, shutting the burner "OFF" 1minute to

RESET the primary control.

Depress the combination gas valve manual control

now and turn to "ON" position.

8. Set the thermostat or operating control to call for

heat. The burner will start and go through the

applicable sequence of burner/primary gas control

operation, refer

step

Once burner is running adjust the orifice manifold

pressure regulator as described

paragraph J -

Pressure Regulator Adjustment.

10. Amore accurate

BTU

(kW) input can

determined

by using the NATURAL gas service meter with the

burner only

(all other gas appliances should

off). The hand

the gas meter dial with the lowest

cubic feet valve (fastest revolving dial), should

clocked for one complete revolution and use the

following formula.

3600

cubic

ft.

)pre

revolution

btu

(kW)

valve/cub

3)=

BTUIHR

(kW/Hr)

seconds

per

revolution

EXAMPLE:

3600

x1x

1000

1.2931

kW)

300,000

BTU/HR

(87.93

kW/HR)

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

PAGE 7

the primary air damper open or closed to visually

obtain ablue flame with well defined orange or

yellow tips for natural gas, or well defined yellow tips

for propane gas.

12. After the burner has been

operation for at least 10

minutes, assuring combustion chamber and heat

exchanger are fully warmed, take combustion

analysis flue gas samples just ahead of the draft

control

the flue pipe.

NOTE: ALWAYS USE RELIABLE COMBUSTION

TEST

INSTRUMENTS. BEING

PROFICIENT

THE USE OF THESE

INSTRUMENTS AND INTERPRETING

THEIR DATA IS NECESSARY FOR SAFE,

RELIABLE

AND EFFICIENT BURNER

OPERATION.

13. Perform the following combustion analysis. All

adjustments below must

made with the following

instruments: draft gauge,

C02

analyze and

tester.

Adjust the primary air damper

provide about

25% excess combustion air. Confirm this by

checking the flue gas for its FREE OXYGEN

2)or CARBON DIOXIDE (C02) PERCEN-

TAGES with atest instrument. Free oxygen

should

about 4.5%, or carbon dioxide should

about 9.5% for natural gas,

12.1

%for

propane gas.

CARBON MONOXIDE -Should

checked for

its presence

the flue gas. This percentage

should not exceed .04% (or 400 PPM).

NOTE: Check overfire draft and adjust to

NEGATIVE

-.01

(2.491

Pa)

to -.02 (4.982Pa)

inches w/c during burner operation.

D. The

flue

gas

temperature

shouldbebetween

325"F(162.78"C)

and 550"F(287.78"C)tor

domestic

gas

conversionburners.

Higherflue

gas temperatures

indicate

overfiringor

excessivedraftthroughtheappliance.

Lower

flue gas temperaturesmay causeexcessive

condensationand

indicate

underfiring.Consult

your

localutilityortheappliancemanufacturer

for

acceptable

flue

gas

temperatures.

CAUTION:

lF THE BURNERBTU/HR

(kWHr)

INPUTIS

CHANGED.

REPEATSTEP13

3/8"

(9.525mm)

HSG2OOSETAT

NO.1

HSG4OO

SETAT

NO.11/2

OFFCYCLE

DAMPER

SETTING

Figure12A

14.FILL OUTTHE INSTALLATION

COMBUSTION

DATA

TAGAND

AFFIXITTOTHEBURNER

CONVERTED

APPLIANCE.

SUGGESTION:All newinstallationsshould

reinspectedfor proper

combustionand burner

operationafter one or two weeks of normal

operation.

For subsequentnormalstartingand shut off

procedure,

refertothe

"Consumer

lnstructions"in

the backof thismanualor the instruction

plate

attached

totheburner.

HSG2OOSET AT NO.2

HSG4OOSET AT NO.4

PRIMARYAIR

SETTING

Figure

128

IMPORTANT

THESE

SETTINGS

ARE

FOR

INITIAL

STARTUPONLY

ANDMUSTBE

READJUSTEDFOR

COMBUSTION

EFFICIENCY.

,ssK

Figure12C

PAGE

The flue gas temperature should

between

325'F

(162.78'C) and

550'F

(287.78'C)for

domestic gas conversion burners. Higher flue

gas temperatures indicate overfiring or

excessive draft through the appliance. Lower

flue gas temperatures may cause excessive

condensation and indicate underfiring. Consult

your local utility or the appliance manufacturer

for acceptable flue gas temperatures.

CAUTION: IF THE BURNER BTU/HR (kWlHr)

INPUT

CHANGED, REPEAT STEP 13

14. FILL OUT THE INSTALLATION COMBUSTION

DATA TAG AND AFFIX IT

THE BURNER

CONVERTED APPLIANCE.

SUGGESTION: All new installations should

reinspected for proper combustion and burner

operation after one or two weeks of normal

operation.

For subsequent normal starting and shut off

procedure, refer to the "Consumer Instructions"

the back of this manual or the instruction plate

attached

the burner.

3/8" (9.525mm)

HSG200 SET

NO.1

HSG400 SET

NO.1 1/2

OFF

CYCLE DAMPER

SETTING

Figure

12A

HSG200 SET

NO.2

HSG400 SET

NO.4

PRIMARY AIR

SETTING

Figure

12B

IMPORTANT

THESE 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

III

OPERATION

ANDTROUBLESHOOTING

SEQUENCEOFOPERATION

-HSG

SERIES

POWERGAS

CONVERSION

BURNER

UTILIZING

HONEYWELL

S89F

GAS

PRIMARYP/N

62759-002

WBUILTIN

30SECONDPREPURGE

acall

for

heat,

voltage

(24V)

isappliedtomotorstart

relayand air switch. Oncethe fan motorreaches

operating

rpm

combustionair

pressure

sensed

bythe

air proving

switchand closesthe switchcontacts

energizingtheS89F

gasprimary

control.

THE S89F gas primary

control

has an internal

second

prepurge

timer. Afterthe initial

30 second

prepurge,

aninternal8 secondsafestart

checkofthe

S89Fwill commence. Once

this is successfully

completed,the

S89Fsimultaneouslyenergizesthe

gas

valve and ignition

transformer.Gas flowsand the

transformer

produces

an approximate7300voltspark

endpoint

grounded

at the burnerheadestablishing

mainburnerflame.

Atthe

startofeach

heat

cycle,there

atrial

forignition

period

of four(4)secondsduration.Normally,burner

flamewillbeestablished

beforetheendofthis

period.

Oncetheflameisestablished,

sparking

willceaseand

theflamerod

will

provide

flamemonitoringtothe

S89F

gas

control

primary

for

theremainder

oftheheat

cycle.

lf theflameshouldbe extinguishedduringthe heat

cycle,theS89F

gas

control

primary

will

gointo

the30

second

prepurge

and

8 second

safestartcheck,then

re-energizethe

gas

valveandignitiontransformerinan

attempttoestablishthemainburnerflame.lfthis

does

notoccurwithinthe4second

trialforignition

period,

the

S89Fgas primary

control

will go into lockoutde-

energizingthe

gas

valveandignitiontransformer.

Torestart

the system,the main

power

or thermostat

mustbede-energizedmomentarily,thenre-energized.

lf at any time duringthe heat cycle,there is an

insufficient

supply

ofcombustion

air

totheburner,the

air switch

willopen,

putting

the system

intolockout

closingthe

gas

valve.

BURNER

GASPRIMARY

HSGPOWERGAS

WITHHONEYWELL

S89F

24VAC

TRANS.

N WIRE NUT

BURNERGND 24VAC

YL-__--1--l t<l

YL--------lJl

REOUNOANT

GAS VALVE

IGNITIONROD

IF ANY OF IHE ORIGIML WIRE.

AS SUPPUEO$TH THE APPLINCE,

MUST

8E REPLACED.IT VUSI EE

REPLACEDY{ITHTYPEAWM ISGA

IO5'C WIRE

OR EOUIVALENT.

PAGE9

lScHEMATiel

SECTION III

OPERATION AND TROUBLESHOOTING

SEQUENCE OF OPERATION -HSG SERIES POWER GAS

CONVERSION BURNER UTILIZING HONEYWELL S89F

GAS PRIMARY

62759-002 W/BUILT

30 SECOND PREPURGE

On acall for heat, voltage (24V) is applied

motor start

relay and air switch. Once the

fan

motor reaches

operating rpm combustion air pressure is sensed by the

air proving switch and closes the switch contacts

energizing the S89F gas primary control.

THE S89F gas primary control has

internal 30

second prepurge timer. After the initial 30 second

prepurge,

internal 8second safe start check of the

S89F will commence. Once this is successfully

completed, the S89F simultaneously energizes the gas

valve and ignition transformer. Gas flows and the

transformer produces

approximate 7300 volt spark

end point grounded at the burner head establishing

main burner flame.

the start of each heat cycle, there

atrial for ignition

period of four

(4)

seconds duration. Normally, burner

flame will

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 S89F

gas control primary for the remainder of the heat cycle.

the flame should be extinguished during the heat

cycle, the S89F gas control primary will go into the 30

second prepurge and 8second safe start check, then

re-energize the gas valve and ignition transformer

attempt

establish the main burner flame.

this does

not occur within the 4second trial for ignition period, the

S89F gas primary control will go into lockout de-

energizing the gas valve and ignition transformer.

restart the system, the main power or thermostat

must

de-energized momentarily, then re-energized.

any time during the heat cycle, there is

insufficient supply of combustion air to the burner, the

air switch will open, putting the system into lockout

closing the gas valve.

HSG POWER GAS BURNER

WITH HONEYWELL S89F GAS PRIMARY

~.L1

MOTOR

~-:l

~9-F

RELAYI

INTEGRAL

IGN.

TRANS.

RELAY

THERMOSTAT

24VAC

TRANS.

COIL

L..::J

AIR

SWITCH

1G24

V V

VAC

VAG

A A

=0L L

LADDER

I-SVV

EE E

REDUNDANT

GAS

VALVE

PART

NO.

62488-004

FLAME

SENSOR

S-B9-F

24VAC

--------r=n

YL-------UJ

REDUNDANT

GAS

VALVE

S-89-F

BURNER

GND

~~'TCH

VALVE

YL~YL----;}-----F1

24VAC SENS

,------'1-BRN

24VAC

GRN

GNO(24VAC~8

FLAME

SENSOR

WHT

==S;:"K"====-~

BLK

BLU

IGNITION

WIRE

NUT

24VAC

TRANS.

IGNITION

ROO

:e-

---===~8L~K

=7(I---'-----"'v::s

A;~P~~E6H~?HRI~~~

APW~~I~CE,

MUST

REPLACED.

MUST

REPLACED

WITH

TYPE

AWM

18CA

105"

WIRE

EQUIVALENT.

ISCHEMATlcl

'-----==---

---.J

PAGE 9

SEQUENCEOF

OPERATION

-HSG

SERIES

POWERGASCONVERSION

BURNER

UTILIZING

HONEYWELLS89EGAS

PRIMARYP/N62758.002

W/EXTERNAL

30SECOND

PREPURGETIMER

P/N

62388-001

ANDRESISTORP/N62530-001

acall

forheat,voltage

(24V)

isappliedtothemotor

start

relayandair

switch.

The

motor

relay

pulls

the

motor.Afterthemotorreachesspeed,thecombustion

air blowercloses

the air proving

switch

contacts,

energizingtheexternal30second

prepurge

timer.

After

the30second

prepurge

timing,theS89Eisenergized.

The

S89E

gasprimary

controlhasaninternal8second

safestartcheck. Aftertheinitial30 second

prepurge

provided

bythe

external

timer,theS89E

gas

primary

control

energized,

the

I secondsafe

startcheck

will

commence.Once

this is accomplished,the S89E

activatesthe

gas

valve

allowing

gas

flow

theburner

head.Simultaneously,

theS89Econtrolenergizes

the

ignition

transformer,

producing

an approximate

7300

voltspark

end pointgrounded

at the burner

head,

establishing

main

burner

flame.

Atthestartofeach

heat

cycle,

thereisatrialforignition

period

offour

(4)

secondsduration.

Normally,

burner

flamewillbeestablishedbeforetheendof

this

period.

Oncethe

flameis

established,sparking

willceaseand

theflamerodwill

provide

flamemonitoringtotheS89E

gasprimary

control

for

the

remainder

ofthe

heatcycle.

WhenutilizingtheS89E

gas

primary

control

withthe

eternal

30second

prepurge

timer,a 10Kohm

resistoris

wiredinparallel

betweentheoutoutterminalofthe30

second

prepurge

timer

andthe inputterminalto the

S89E

gasprimary

control.The

function

ofthis

resistor

tokeepa loadontheoutputterminaloftheexternal

30second

prepurge

timer,after

theinitial

call

forheat

and

30second

start

prepurge

and8 secondsafe

start

check.

Thispromotes

simultaneous

re-ignition

of the main

burner

flameaftertheS89E's8secondsafestartcheck,

overridingthe30second

prepurge.

This

desirable

ovenorsimilar

applicationswheretemperaturescannot

vary

drastically.

Should

theflamebeextinguishedduringthe

heat

cycle,

the S89E

primary

ignition

control

willgo intothe I

secondsafe staft checkafterwhichtime it will re-

energize

the

gas

valveand

ignition

transformer

in an

attemotto re-establish

themainburnerflame. lf this

does

notoccur

withinthe 4 second

trialfor ignition

period,

theS89E

gasprimary

control

will

intolockout

de-energizingthe

gas

valve

and

ignitiontransformer.To

restartthesystem,the

main

power

orthermostatmust

bede-energized

momentarily,then

re-energized.lf at

anytimeduring

theheatcycle, thereis insufficient

supplyof combustion

airto theburner,theairswitch

contacts

will open,

putting

the system

into lockout

closingthe

gas

valve.

AIR PREPURGE

SWITCHTIMER

N WIRENUT BURNER

CNO

HSGPOWERGASBURNER

WITHHONEYWELL

S89EGAS

PRIMARY

24VAC

YL---_-F-l t{l

YL------lJl REDUNOANT

GAS

VALVE

s-E9-E

IF ANY OF THE ORIGINALWIRE,

AS SUPPL]EDW]THTHE APPLIANCE.

MUST

AE REPUCED,

IT VUST

REPLACEOWITHTYPE AWM 1AGA

1O5'C WIRE

OR EOUIVAL€NT.

LIMIT/ @

I i THERMOSTAT :24VAC TRANS.

lScHEMATIcl

PAGE10

SEQUENCE OF OPERATION -HSG SERIES

POWER GAS CONVERSION BURNER UTILIZING

HONEYWELL S89E GAS PRIMARY

62758-002 WI EXTERNAL

30 SECOND PREPURGE TIMER

62388-001 AND RESISTOR PIN 62530-001

On acall for heat, voltage (24V)

applied

the motor

start relay and air switch. The motor relay pulls

the

motor. After the motor reaches speed, the combustion

air blower closes the air proving switch contacts,

energizing the external 30 second prepurge timer. After

the 30 second prepurge timing, the S89E is energized.

The S89E gas primary control has

internal 8second

safe start check. After the initial 30 second prepurge

provided by the external timer, the S89E gas primary

control is energized, the 8second safe start check will

commence. Once this

accomplished, the S89E

activates the gas valve allowing gas to flow to the burner

head. Simultaneously, the S89E control energizes the

ignition transformer, producing an approximate 7300

volt spark end point grounded at the burner head,

establishing main burner flame.

the start of each heat cycle, there is atrial for ignition

period of four

(4)

seconds duration. Normally, burner

flame will be established before the end of this period.

Once the flame

established, sparking will cease and

the flame

rod

will provide flame monitoring

the S89E

gas primary control for the remainder of the heat cycle.

When utilizing the S89E gas primary control with the

eternal 30 second prepurge timer, a10K ohm resistor is

wired

parallel between the output terminal of the 30

second prepurge timer and the input terminal to the

S89E gas primary control. The function of this resistor

to keep aload

the output terminal of the external

30 second prepurge timer, after the initial call for heat

and 30 second start prepurge and 8second safe start

check.

This promotes simultaneous re-ignition of the main

burner flame after the S89E's 8second safe start check,

overriding the 30 second prepurge. This is desirable

oven or similar applications where temperatures cannot

vary drastically.

Should the flame

extinguished during the heat cycle,

the S89E primary ignition control will go into the 8

second safe start check after which time it will re-

energize the gas valve and ignition transformer in

attempt

re-establish the main burner flame.

this

does not occur within the 4second trial for ignition

period, the S89E gas primary control will go into lockout

de-energizing the gas valve and ignition transformer.

restart the system, the main power or thermostat must

de-energized momentarily, then re-energized. If at

any time during the heat cycle, there

insufficient

supply of combustion air

the burner, the air switch

contacts will open, putting the system into lockout

closing the gas valve.

HSG POWER GAS BURNER

WITH HONEYWELL S89E GAS PRIMARY

24VAC

REDUNDANT

GAS VALVE

24VAC TRANS.

IGN.

TRANS.

S-89-E

MOTOR

FLAME

SENSOR

LADDER

RESISTOR

THERMOSTAT

MOTOR

,..----.

: H'----,---=--=--=-----{

RELAY:

I I

I.,

LIMIT

AIR

PRf,~~~GE

,..-

,/1/'1/1,

-----,

-1

SWITch

liMIY/

CONTROLLER

COIL,

f--f-{'

)-;'------------------i

PART

NO.

62488-003

S-89-E

24VAC

------r=n

YL---UJ

REDUNDANT

GAS

VALVE

BLU

BRN

GRN

MOTO

VALVE

'---~VALVE

r-:7---+--~

24VAC SENS

24VAC

GND(24VAC) 8LK

~LAME

S~R

WHT

==i~====~

BlK

BLU

ICNlT10N

BURNER

GND

IGNITiON

ROO

L-~~~==.!8!l..!!\

K,-=~-"'------':~

ANY

THE

ORIGINAl

WIRE.

SuPPLIED

WITH

THE

APPUANCE.

MUST

REPLACED,

t.4UST

REPLACED

WITH

TYPE

AWM

18GA

lOS"

WIRE

EQUIVAlENT.

WIRE

NUT

AIR

PREPURGE

SWITCH

TIMER

RESISTOR

YL.-.""

\I\

~r-'

24VAC

TRANS.

ISCHEMATlcl

'----'==--

....J

PAGE 10

FLAME

SENSING

The Honeywell

S89 series

primary

ignitioncontrols

utilizethe

flame

currentrectification

principal

formain

burner

flame

sensing.

The

flame

rectification

phenomenon

occurs

asfollows.

The ignited gas flame causes the immediate

atmospherearoundtheflameto become

ionized

(gas

atomsbecomeelectricallycharged).The ionization

causesthe atmospherearoundtheflameto become

electricallyconductive.AnACvoltage

output

from

the

controlsensing

circuitis routedthroughthe flame

sensor

probe.

Whenthe

sensor

probe

and

theburner

head

are

bothincontactwith

aproperly

adjusted

flame,

theburner

headwithits

largersurfaceattracts

morefree

electrons,thus becomingnegativelycharged.

The

sensor

probe

withitssmallsurfacearea

gives

upfree

electrons,thusbecoming

positively

charged.

Thefree

electrons

from

the

ACvoltage

inthe

sensor

probe

flow

PROBE DIM

IGNITER

't 5/8 41.2Emm

SENSOR1 1/4J1.75mm)

throughthe

ionized

gas

flametothe

grounded

burner

head.AstheACcurrent

passes

throughthe

gas

flame,

it is rectifiedintoa DC currentflowingbackto the

grounded

side of the sensingcircuit.

The flame in

actualityis a switch.

When

theflameis present,

the

switch

is closed

allowingcurrentto flowthroughthe

sensing

circuitofthecontrol.

When

flameis

present,

the

switch

isopen

withnocurrent

flowing

throughthe

sensingcircuitof

the

control.

TheDCcurrent

flowis measuredin unitscalled

microamperers.A steadyDCmicroamp

currentof .8

minimum

(and

steady)or higherthroughthesensing

circuitofthe

primary

ignitioncontrolis

sufficient

tokeep

theburner

runningwithout

asafety

lockout.

See

Figure

13for

sensor

probe

andelectrodedimensionalsettings,

Figure14forflamecurrentmeasurement.

13/16Q0,64nn)

REF,

F-3t+

| {ls.0smm)

(2,381mn)

/ 16 (1.588mm)

Figure13

S89

FLAMECURRENT

MEASUREMENT

Figure14

FLAMESENSOR

CURRENT

CHECK-USE

SCALE

SENSOR

MULTIPURPOSE

METER

DISCONNECT

WIREFFOM

SENSE

TEBMINAL

RED(+

BLACK(-)

0.8uADCMINMUM

(ANDSTEADY)

\'C

PAGE11

FLAME SENSING

The Honeywell S89 series primary ignition controls

utilize the flame current rectification principal for main

burner flame sensing.

The flame rectification phenomenon occurs as follows.

The ignited gas flame causes the immediate

atmosphere around the flame to become ionized (gas

atoms become electrically charged). The ionization

causes the atmosphere around the flame to become

electrically conductive.

voltage output from the

control sensing circuit is routed through the flame

sensor probe. When the sensor probe and the burner

head are both

contact with aproperly adjusted flame,

the burner head with its larger surface attracts more free

electrons, thus becoming negatively charged. The

sensor probe with its small surface area gives

free

electrons, thus becoming positively charged. The free

electrons from the

voltage

the sensor probe flow

through the ionized gas flame to the grounded burner

head.

the

current passes through the gas flame,

rectified into a

current flowing back

the

grounded side of the sensing circuit. The flame in

actuality

aswitch. When the flame

present, the

switch

closed allowing current

flow through the

sensing circuit of the control. When no flame is present,

the switch

open with

current flowing through the

sensing circuit of the control.

The

current flow is measured

units called

microamperers. Asteady

microamp current of

minimum (and steady) or higher through the sensing

circuit of the primary ignition control

sufficient to keep

the burner running without asafety lockout. See Figure

13 for sensor probe and electrode dimensional settings,

Figure 14 for flame current measurement.

"A"

13/16

(20,64MM)

REF.

~3/4

I<l9,05MM)

Figure 13

FLAME SENSOR CURRENT

CHECK-USE

jJA

SCALE

_VAlVE

-24V

(~)

GHO

SENSOR

BLACK(-)

0.8

MINMUM

(AND STEADY)

S89 FLAME CURRENT MEASUREMENT

Figure 14

PAGE

HSG

SERIES

WITHA HONEYWELL

S89E,S89F

PRIMARY

IGNITION

CONTROLS

TROUBLE

SHOOTINGGUIDE

MOTORDOES

NOT

START

Replace

24volt

20VA

Transformer

2. Check

tor

24voltsACbetween

terminals

1and

onmotor

startrelay.

3. Check

for120

volts

ACbetweenterminal2on

motorstart

relay

and

neutralline.

4. Checkelectrical

wiring

andconnections.

Check

for

blower

clearance.

2.Lubricatemotor

bearings.

5. Doesmotor

shaft

turn

freely?

Check

thelowvoltagetransformertor24voltoutput

between

terminal

3onthemotorstart

relay

either

ofthe'T'terminals

onthecontrolbox.

IGNITION

ARC ESTABLISHED

- NO FLAME

Reset

Control

- Motorstarts

- Completes30second

prepurge

cycle,8 second

safestartcheck

and

trialfor

ignition,

4 secondsHoneywellseries.

NOTE:

Theburnermotor

will

continue

operate

during

thelock

out

modewhen

thethermostatcircuit

calledforburneroperation.

2. Check

forcorrectorifice/airsetting

relationship

(see

figures10,

12A,

128,

and12C).

orderforthefollowingfunctionaltestto bemade,

thecontrol

must

beresetand

the

tests

monitored

dur-

ing

the

4 second

Honeywell

seriestrial

forignition

peri-

that

occurs

theENDofthe30second

prepurge

and

I secondsafe

start

check

cycle.

3. Checktor24voltsACatgas

valve

terminals. Check

electrical

wiring

and

connections.

Besureleads

areon

correct

gas

valveter-

minals

4. Makesure leadsare on the correct gas valve

terminals

pressure

PAGE

HSG SERIES WITH AHONEYWELL S89E, S89F PRIMARY IGNITION CONTROLS

TROUBLE SHOOTING GUIDE

MOTOR DOES

NOT

START

Check the low voltage transformer for

volt output

between terminal 3on the motor start relay either

the

"T'

terminals

the control box.

Check for

volts AC between terminals 1and 3

motor start relay.

Check for 120 volts AC between terminal 2on

motorstart relay and neutral line.

Check electrical wiring and connections.

Check electrical wiring and

connections.

Check electrical wiring and

connections.

Check electrical wiring and

connections.

Replace

volt

Transformer

Replace motor

start relay.

Replace motor

start relay.

Does motor shaft turn freely?

IGNITION ARC ESTABLISHED -

FLAME

Check for blower clearance.

Lubricate motor bearings.

Reset Control -Motor starts -Completes 30 second prepurge cycle, 8second safe start check and trial for

ignition, 4seconds Honeywell series. NOTE: The burner motor will continue

operate during the lock out mode when the thermostat circuit

called for burner operation.

Check for correct orifice/air setting relationship (see figures

10,

12A, 12B, and 12C).

order for the following functional test to be made,

the control

must

be reset and the tests monitored dur-

ing

the 4second Honeywell series trial for ignition peri-

that occurs at the END of the 30 second prepurge

and

8second safe start check cycle.

Check for

volts AC at gas valve terminals.

Make sure leads are on the correct gas valve

terminals

Check for correct manifold regulated pressure

(see figure 10).

Check electrical wiring and

connections.

sure leads

are

correct gas valve ter-

minals

Replace primary

ignition control.

PAGE 12

NOIGNITION

ARC ESTABLISHED

Control . Motorstarts

- Completes30second

prepurge start

check

series.

. Gas

valveopens,regulating

adequate

gas

pressure.

. Noflame

established

- Primary

control

locks

out after4 secondHoneywell

series

trial

for

Inorder

for

thefollowingfunctional

test

tobemade,

thecontrolmustbe reset

andthetestsmonitored

dur-

ingthe4second

Honeywell

series

trialforignition

that

occursat

theendofthe30second

prepurge

cycle,

andI second

safestartcheck.

Check

tor12O

voltsACbetweentheneutralline

and

the

function

oftheblue

primary

control

lead

andthe

blackignitiontransformer

lead.

Gheckelectrical

wiring

and

connections.

Checkthe

flame

sensing

circuitfor

(1)grounded

flamerod.

(2)

Damage

toflamerod

lead

insula-

tion.NOTE:Make

surethat

the

flamerod

circuit

and/or

primary

controlismoisture-free.

3. Checkelectricalwiring

and

connections.

4. Checkhighvoltage

leadandconnectiontoignition

electroderod.

Inspectignition

electrode

for

cracked

insulator

and

correctspark

gap(Fig.

13).

IGNITION

- NOGAS

VALVE

1. Reset

Control

- Motorstarts

- After

30second

prepurge

cycleand8secondsafe

start

check.Motor

continues

to runbut

flame

isnot

established.

Inordertoperform

thefollowing

functionaltests,the

primary

controlmustbereset

andthetestsmonitored

duringthe4second

Honeywellseriestrialfor

ignition

thatoccurs

attheend

ofthe

second

prepurge

cycle

and8 second

safestartcheck.

2. Check

tor24voltsAC atthe

24volt

primary

control

inputterminalslabeled

yellow

andbrown. Replace

primary

ignition

control.

3. Check

airproving

switch

for:

a.Anyimpairment

thatwouldkeepitfrom

closing

oropening.

b.Electrical

continuity;switchisnormallyopen.

c. Replace

switch

asnecessary.

4. Check

(when

applicable)

external

30second

prepurge

timer

(jumper

around

timerfrom

air

switch).Should

primary

ignition

control

become

energized,replace

timer.

PAGE13

NO IGNITION

ARC

ESTABLISHED

Reset Control •Motor starts -Completes

second prepurge cycle, 8second safe start check series.

•Gas valve opens, regulating adequate gas pressure.

•No flame established -Primary control locks out after 4second Honeywell series trial for

ignition periods.

order for the following functional test to be made,

the control must

reset and the tests monitored dur-

ing the 4second Honeywell series trial for ignition that

occurs at the

end

the 30 second prepurge cycle,

and 8second 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 lead

and 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.

Check high voltage lead and connection to ignition

electrode rod. Replace primary ignition control. I

5. Inspect ignition electrode for cracked insulator and

correct spark gap (Fig. 13). -

6. Replace ignition transformer.

NO IGNITION -NO GAS

VALVE

Reset Control -Motor starts -After 30 second prepurge cycle and 8second safe start check. Motor continues I

to run but flame is not established.

In order to perform the

follOWing

functional tests, the

primary control must

reset and the tests monitored

during the 4second Honeywell series trial for ignition

that occurs at the end of the

second prepurge cycle

and 8second safe start check.

h..

2. Check for

volts AC at the 24 volt primary control

Replace primary ignition control. I

input terminals labeled yellow and brown.

Check air proving switch for:

h..

Check (when applicable) external 30 second

a. Any impairment that would keep

from

OK)

prepurge timer Oumper around timer from air

closing

opening.

switCh). Should primary ignition control

b. Electrical continuity; switch is normally open. become energized, replace timer.

Replace switch as necessary.

PAGE 13

LOSESFLAMEDURING

CYCLE

_ CONTROLLOCKS

OUTONSAFEW

1Resetcontror

ti#fi,":',lT*h"

H.:*"J",-"

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

issatisried

2. Disconnect

flamerod

leadfrom

primary

control.Connect

(+)

positive

lead

(DC)

MicroampereMetertothe

primary

controlterminal.

Connectthe(-)negativemicroampere

meter

leadtotheflamerodlead

terminal.

See

Fig.

14:

FlameCurrentMeasurement.

Probable

cause

of erratic

lockout:

1. Flame

proving

circuit

grounded

moisture.

2. Damagedinsulation

onflamerodlead.

3. Flamerodimproperly

positioned

inflame

(see

Fig.13).

4. Poor

groundpath

to primary

control.

5. Defective

primary

control.

6. Readmanual

section

"Flame

Sensing".

7. Applicable

onlyto Honeywell

S89

series

primary

ignitioncontrols:

Connect

L1tothe

blackleadand12tothewhitelead

exiting

the

S89otherwisetheS89

will

not

detectthe

flameandwilllockout.

3. Reset

control,after

prepurge

cycle,flameisestablished.

Astable

microampere

current

of .8ormore

required

for

dependableoperation.

Probablecauses:

1. Extremely

poor

combustion

level.

2. Flamerodimproperly

positioned

flame.

3. Defective

primary

control.

4. Microampere

readingislessthan.8or unstable.

BURNERCYCLESERRATICALLY

for

proper

thermostat

installation

and

location.

2. Check

thermostat

heatanticipator

for correctsetting. Set

anticipatortocorrect

valueifadjustable

type.

lfproper

setting

cannot

bemade,replacewith

compatiblethermostat.

3. Checklowvoltagecircuit

for bad wiring,electrical

connectionsand/orswitches.

4. Checklinevoltage

circuit

for bad wiring,electrical

connectionand/orswitches.

NOTE:Whenthethermostat wiresterminate

on the

HSGprimary

controlbox'T" terminals,

the heat anticipa-

torsettingvaluefor the HSG burneris determinedby

addingtheprimarycontrol currentto the gas valve cur-

rent.

The result

isthe anticipatorsetting.

(Exampfe:

.2+ .6

=.8 amps.)

lf thethermostatwires ARE NOT terminatedon the

bumercontrol

box "7" terminals,andtheseterminalsare

JUMPERED,

youmustthen determinewhat

thecorrect

anticipatorsetting

is by inspectingthecontrollingdevice

atthe pointwherethe thermostat wiresterminate.

Typically,

thisinformationcan be foundon the body or

coverof thecontrollingdevice.

Whendeterminingthe cunent drawof the dual head gas

valve,be sureto consider the separateampere values

for eachvalve.

These usually are stenciled

on the valve

body,

and mustbe added togetherto obtainthe correct

sum.(Example:

.4+ .2= .6amps).

Whenthecurrent

draw cannot be determined

accurately

bythe abovemethod,measure the currentwith an

amperemeterusingthe 1AMP scale.Connectthe

meterleadsin serieswith one of the thermostatleads

forthe accuratereading. PAGE14

lOSES

FLAME DURING CYCLE -CONTROL

lOCKS

OUT

SAFETY

Reset Control •Completes

second prepurge cycle, and 8second 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 primary

control terminal. Connect the (-) negative microampere

Flame proving circuit grounded by moisture.

meter lead to the flamerod lead terminal. See Fig. 14:

Damaged insulation

flamerod lead.

Flame Current Measurement.

Flamerod improperly positioned in flame (see

Fig. 13).

4. Poor ground path to primary control.

Defective primary control.

Reset control, after prepurge cycle, flame is established.

Read manual section "Flame Sensing".

Astable microampere current

required 7. Applicable only to Honeywell S89 series

for dependable operation. primary ignition controls: Connect L1to the

black lead and L2 to the white lead exiting the

NO S89 otherwise the

S89

will not detect the

flame and will lock out.

""to~

4. Microampere reading is less than .8

unstable. )Probable causes:

Extremely poor combustion level.

Flamerod improperly positioned

flame.

Defective primary control.

BURNER CYCLES ERRATICALLY

I1. Check for proper thermostat installation and location.

2. Check thermostat heat anticipator

for

correct setting.

.!o)

Set anticipator to

correct

value if adjustable type.

proper setting

cannot

be made, replace with

compatible thermostat.

3. Check low voltage circuit for

bad

wiring, electrical

connections

and/or

switches.

NOTE:

When

the

thennostat

wires

tenninate

the

HSG

primary

control

box

"1""

tenninals,

the

heat anticipa-

tor

setting

value

for

the

HSG

burner

detennined

adding

the

primary

control current

the

gas

valve

cur-

4. Check line voltage circuit

for

bad wiring, electrical

rent.

The

result

the

anticipator

setting.

connection and/or switches.

(Example:

amps.)

the

thennostat wires

ARE

NOT

tenninated

the

bumer

control

box

"T" tenninals,

and

these

tenninals

are

JUMPERED,

you

must then detennine

what

the correct

anticipator

setting

by inspecting

the

controlling device

the

point

where

the

thennostat

wires

tenninate.

Typically,

this

infonnation can

found

the

body

cover

the

controlling device.

When

detennining

the

current

draw

the

dual

head

gas

valve,

sure

consider the

separate

ampere

values

for

each

valve.

These

usually

are

stenciled

the

valve

body,

and

must

added together

obtain

the

correct

sum.

(Example:

.4 +

amps).

When

the

current

draw cannot

detennined accurately

the

above

method,

measure

the

current

with

ampere

meter

using

the

AMP

scale.

Connect

the

meter

leads

series

with

one

the

thennostat

leads

for

the

accurate

reading.

PAGE 14

SECTION

SERVICE

Caution:

Make

surethemainmanual,

combination

valvesandmainpower

switchareturned

offbeforeopeningburner

orremovingany

parts

for service.

A. BURNERHEADAND

ELECTRODE/S

ENSOR

ASS

EMBLY

The burnerhead, electrode,sensor probe,

combination

valve,orificehousing

and housing

cover

are

part

ofthe

gas

trainassemblywhichcan

removed

asoneunit.

(See

Figure15)

1. Disconnect

gas

linefrom

combustion

gas

valve

inlet,flame

sensor

lead

wirefrom

gasprimary

gasvalveleadwires

lromgasvalve

operator

and (orange)

ignitionleadwire

fromignition

transformer

ignition

leadwire.

2. Remove

the two 1/4"

(6.35mm)

hex slotted

screws

thetop

front

ofthehousingcoverand

thetwo5/16"

(7.9375mm)

hexslotted

screws

ontheleft

and

right

side

back

ofthehousing

cover.

3. Toremove

gas

trainassembly,

gently

lift

rear

ofhousingcover

pulling

rearward

slightlyon

the

drawerassembly

graduallypositioning

the

rear

of the drawerassemblyupward

90 degrees

(1.57RAD).

Gently

extractburnerhead

and

electrode/sensor

assemblyout opening

housingtakingextremecaretonot

dislocateor

damageelectrodeorsensor

probe

4. When servicing,clean burnerhead ports,

electrodesand sensorprobe. Inspectthe

sensor

probe

andelectrodewires

and

porcelain

insulatorscarefullyfor hairline

cracks

which

might

provide

anelectricalleak

path

thatcould

shortout

theignition

spark,orflamesignal.

5. Examinethe electrode

andsensor

probe

for

anyseriouscorrosionordeterioration

of metal

at the tips. Checkfor proper

dimensional

settings

ofthe

sensor

probe

andelectrode

(see

Figure13). Adjust

and/or

replace

these

assembliesas necessary.

Make

sure

thatthe

ignitionand sensor

probe

wiresgo to the

correct

electrodes

andthe

ignition

wirebootis

place

over

theelectrode

porcelain.

6. Makesurethattheburner

tubeend

properly

positioned

inthe

combustionchamberentry.lt

mustbe

set

'112"

(12.7mm)

shortoftheinside

faceof the

combustionchamberasshown

figures4,

5or6.

B. AIRPROVING

SWITCH

The

airproving

switchis mountedto thehousing

coverwith

(2)

selftappingscrewsunderthe

gas

valve.A clear

plastic

tube,

protected

bya spring

cover,is connectedto the barbedfitting

on the

pressure

switchwhilethe

otherendis

connectedto

a brassbarbedfitting.Theplastice

tubeallows

pressurized

air

from

theblowerhousing

totravelto

PAGE15

the

pressure

switch

causingthediaphragmcontacts

thuscompletingthecircuit.

Thefunctionoftheair

proving

switch

istoensure

sufficientcombustionair

beingdevelopedbythe

blower

motor

andblower

wheel.

Shouldtheblower

motorfail or the blower

wheelmalfunction.

the

burner

gas

valvewill

shut

off.

1. The air proving

switchshould

neverrequire

maintenance.However.

should nuisance

lockouts

occur,the pressure

switchcan be

checked.Thisis doneby disconnectingthe

yellow

andwhiteleads

from

theAir Proving

switchand

jumpering

the

leads

together.lfthe

burner

functions

correctly,theswitch

needs

bereplaced.

WARNING:lf ajumper

isused

tochecktheswitch

must

be removedor an unsafecondition

canoccur

resultingin deathor property

damage.

2. Asmentioned

above,

the

switchshould

never

requiremaintenance.Howevera pinched

tube

willshutofftheflowof pressurized

airto the

diaphragmcreatinga failuremade

similarto

badAirProving

switch.

Always

checktoensure

thatthecleartubing

isnot

pinched.

Make

sure

thespringcoverisreinstalledovertube.

3. Switchismountedinthehorizontalpositionwith

terminalsupfromfactory.Finalburnermounting

should

maintainhorizontal

switch

position.

WARNING:

Damageto

internalcomponents

burner

mayresult,ifburner

ismountedinother

than

horizontal

position.

C. COMBUSTIONAIRBLOWERANDMOTOR

1. Cleaningof the combustionair bloweris

indicatedif

thebladesshowanaccumulationof

dustand

lint,

or if thecharacterof theflame

indicates

adeficiencyofcombustionair.

2. Theside

plate,

motor

andblowerwheelare

removed

as one assembly.

Disconnect

the

motorwireinsidethe

junction

boxbeneaththe

ignition

transformer.

Remove

the

four

(4)

5116"

(7.9375mm)

hex slottedscrewssecuring

sideplatetofanhousing.

CAUTION:

Do notremove

blower

wheelfrommotor

shaftduring

periodic

cleaning.

3. Should

removal

of the blowerwheel be

necessaryfor

cleaning

orreplacement

of itor

themotor,the

blower

wheelmust

positioned

correctlyonthemotor

shaft.

(Figure

16)

HSG200

blower

wheel

pln

21664ispositioned

21/16"

(52.3875mm)

measuredfrom

theblower

wheelinletring

facetothe

side

plate

face.

HSG400

blower

wheel

pln

21642is

positioned

23116"

(55.5625mm)

measuredfrom

theblower

wheelinlet

ringfacetothe

side

plate

face.

SECTION IV

SERVICE

Caution: Make sure the main manual, combination

valves and main power switch are turned

off before opening burner or removing any

parts for service.

A. BURNER HEAD AND

ELECTRODE/SENSOR ASSEMBLY

The burner head, electrode, sensor probe,

combination valve, orifice housing and housing

cover are part of the gas train assembly which can

removed as one unit. (See Figure 15)

Disconnect gas line from combustion gas valve

inlet, flame sensor lead wire from gas primary,

gas valve lead wires from gas valve operator

and (orange) ignition lead wire from ignition

transformer ignition lead wire.

Remove the two 1/4" (6.35mm) hex slotted

screws

the top front of the housing cover and

the two 5/16" (7.9375mm) hex slotted screws

on the left and right side back of the housing

cover.

remove gas train assembly, gently lift up rear

of housing cover pulling rearward slightly on the

drawer assembly gradually positioning the rear

of the drawer assembly upward 90 degrees

(1.57RAD). Gently extract burner head and

electrode/sensor assembly out opening in

housing taking extreme care to not dislocate or

damage electrode or sensor probe.

When servicing, clean burner head ports,

electrodes and sensor probe. Inspect the

sensor probe and electrode wires and porcelain

insulators carefully for hairline cracks which

might provide

electrical leak path that could

short out the ignition spark, or flame signal.

Examine the electrode and sensor probe for

any serious corrosion or deterioration of metal

at the tips. Check for proper dimensional

settings of the sensor probe and electrode (see

Figure 13). Adjust and/or replace these

assemblies as necessary. Make sure that the

ignition and sensor probe wires go to the

correct electrodes and the ignition wire boot is

place over the electrode porcelain.

Make sure that the burner tube end is properly

positioned

the combustion chamber entry.

must

set 1/2" (12.7mm) short of the inside

face of the combustion chamber as shown

figures

5or

B. AIR PROVING SWITCH

The air proving switch is mounted to the housing

cover with

(2)

#6 self tapping screws under the gas

valve. Aclear plastic tube, protected by aspring

cover,

connected to the barbed fitting on the

pressure switch while the other end is connected to

abrass barbed fitting. The plastice tube allows

pressurized air from the blower housing to travel to

PAGE 15

the pressure switch causing the diaphragm contacts

to close thus completing the circuit.

The function of the air proving switch

to ensure

sufficient combustion air

being developed by the

blower motor and blower wheel. Should the blower

motor fail or the blower wheel malfunction, the

burner gas valve will shut off.

The air proving switch should never require

maintenance. However, should nuisance

lockouts occur, the pressure switch can

checked. This

done by disconnecting the

yellow and white leads from the Air Proving

switch and jumpering the leads together. If the

burner functions correctly, the switch needs to

replaced.

WARNING: If ajumper is used to check the switch it

must

removed or

unsafe condition

can occur resulting

death or property

damage.

As mentioned above, the switch should never

require maintenance. However apinched tube

will shut off the flow of pressurized air to the

diaphragm creating afailure made similar to

bad Air Proving switch. Always check to ensure

that the clear tUbing

not pinched. Make sure

the spring cover

reinstalled over tube.

Switch

mounted

the horizontal position with

terminals up from factory. Final burner mounting

should maintain horizontal switch position.

WARNING: Damage to internal components of

burner may result,

burner

mounted

other

than horizontal position.

COMBUSTION AIR BLOWER AND MOTOR

Cleaning of the combustion air blower is

indicated

the blades show

accumulation of

dust and lint, or if the character of the flame

indicates adeficiency of combustion air.

The side plate, motor and blower wheel are

removed as one assembly. Disconnect the

motor wire inside the junction box beneath the

ignition transformer. Remove the four

(4)

5/16"

(7.9375mm) hex slotted screws securing

sideplate to fan housing.

CAUTION: Do not remove blower wheel from motor

shaft during periodic cleaning.

Should removal of the blower wheel be

necessary for cleaning or replacement of

the motor, the blower wheel must

positioned

correctly

the motor shaft. (Figure 16)

HSG200 blower wheel pIn 21664

positioned

21/16" (52.3875mm) measured from the blower

wheel inlet ring face to the side plate face.

HSG400 blower wheel pIn 21642

positioned

23/16"

(55.5625mm) measured from the blower

wheel inlet ring face to the side plate face.

DRAWER

ASSEMBLY

Figure

PAFIT NII]\'FItrFI

21664

HSG2OO

51t40.D.

(133.35mm)

21/16"

(52.3875mm)

21642

HSG4OO

5 1t2

0.D.

(139.7mm)

3t16"

(55.5625mm)

MOTOR/BLOWER

ASSEMBLY

Figure16

PAGE

DRAWER ASSEMBLY

Figure 15

MOTOR SIDEPLATE

"AU PIN 21658

r'I

...

-r

21/16"

(52.3875mm)

23/16"

(55.5625mm)

21642

HSG400

5112

G.D.

(139.7mm)

21664

HSG200

5114

G.D.

(133.35mm)

MOTOR/BLOWER ASSEMBLY

Figure 16

PAGE 16

PARTSLIST

- MODELHSG

2OOI4OOSEEFIG.15& FIG.17

Item PartNo. Description

10.

11.

12.

18.

19.

22.

23.

24.

25.

26.

27.

28.

13.

14.

15.

16.

17.

29.

30.

31.

00934-001

62576-003

63270-004

62576-015

63270-015

62576-027

63270-027

63270-028

62393-001

21724-011

100428-002

21664

21642

21658

20627

20627-004

00373-002

62408-001

62388-001

62530-001

60186-004

63005-002

00450-001

62406-002

62759-002

62758-002

100377-002

100429

63263-005

63272-005

63935-001

601

78-002

100372

20-21.

2'1319

61843

62407-O01

64051

-001

62391

-002

62390-002

62387-001

62575-002

62575-001

62575-014

62575-012

62575-026

62575-024

62575-031

62419-001

61951-001

62411-028

62411

-030

6241

-068

64096-001

62909-001

62909-003

64095-001

62404-OO2

62304

62402-001

62410-001

62401

-001

62385-001

62374-004

624s9-001

62459-002

21760-001

BurnerHousing

AirTube

-HSG2006"

(152.4mm)

AirTube

-HSG4OO

61/4"

(158.75

mm)

AirTube

-HSG2009"

(228.6mm)

AirTube

-HSG4009"

(228.6mm)

AirTube

-HSG200

'12"

(304.8mm)

Air

Tube

-HSG40012"

(304.8mm)

AirTube

-HSG400

15"

(381

mm)

Air

Cone

-(HSG200

only)

AdjustableFlange

Assembly

(includesgasket)(not

shown)

FlangeGasket

(not

shown)

BlowerWheelHSG2005114OD

(133.35mm)

BlowerWheelHSG4005112'OD

(139,7mm)

SidePlate

(Used

with

20627and

20627-004Motors

Only)

Motor,SplitPhase

117

(.107kW)

or1/8

(.093kW)

HP3450RPM

115V/60

Motor,

Split

Phase117

(.107kW)

HP2850RPM230V/50H2

(220Y150H2)

CombustionAir

InletDamper

Control

Box

(S89E

& S89F) Used

withPrimary

safetyControl

P/N62758-002

(Special

limit

applications

only)

30Sec.

PrepurgeTime

ResistorWireAssy.

24VoltTransformer120V

24Volt

Transformer

220V

Bushing

MotorRelay

PrimarySafetyControlH'WellS89F

w/30

Sec

Prepurge

(220Y150H2)

Primary

Safety

ControlH'WellS89E

w/o

30Sec

Prepurge

(Special

LimitApplicationsOnly)

DamperIndicator

Pointer

DamperDecal

Pressure

Switch

Pressure

SwitchConversion

Kit

Pressure

Switch

(220Vl50H2)

ThermostatTerminalStrip

AdjustmentArm

Off-Cycle

Damper

100371-KlT

Off-Cycle

DamperKit

Junction

Box

(under

lgnitionTransformer)

LightingPlate

lgnitionTransformer7500V

lgnitionTransformer220Y

l50HzDanfoss

ElectrodeAssembly

Sensor

ProbeAssembly

InsulatorBushing

(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

- HSG20012"

(304.8mm)

Chamber/Manifold

- HSG400

12"

(304.8mm)

Chamber/Manifold

- HSG40015"

(381

mm)

Clip,ElectrodeBracket

lgnitorSupportPartsKit

"(279.4mm)

SensorWire

-6"

52.4mm),6 1/4"

58.75mm)Burner

14"

(355,6mm),

Sensor

Wire

- 9"

(228.6mm),

12"

(304.8mm)

Burner

17"

(431,8mm),

Sensor

Wire

- 15"

(228.6mm)

Burner

Sense

Wire

- 330mmCable

(220Vl50H2)

(203.2mm)

lgnition

Wire

-6"

(152.4mm),

6 1/4"

(158.75mm)

Burner

14"

(355.6mm)

lgnitionWire

-9"

(228.6mm),

12"

(304.8mm)

Burner,

15"

(228.6mm)

Burner

lgnitionWire

- 500mmCable

(220Vl50H2)

TopPlate/Housing

Cover

Strain

Relief

Bushing/lgnition

Wire

Orifice

Housing

OrificeSpring

OrificeGasket

OrificeCao

Gas

Valve

HoneywellVR8305M4801

OrificePackage

- HSG200

(not

shown)

OrificePackage

- HSG400

(not

shown)

OotionalPedestalMountinq

(not

shown)

PAGE17

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

Item Part No. Description

1. 100934-001 Burner Housing

62576-003 Air Tube -HSG200 6" (152.4mm)

63270-004 Air Tube -HSG400 61/4" (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)

100428-002 Flange Gasket (not shown)

21664 Blower Wheel HSG200 51/4" OD (133.35mm)

21642 Blower Wheel HSG400

51/2"

OD (139.7mm)

21658 Side Plate (Used with 20627 and 20627-004 Motors Only)

20627 Motor, Split Phase 1/7 (.107kW)

1/8 (.093kW) HP 3450 RPM 115V/60

20627-004 Motor, Split Phase 1/7 (.107kW) HP 2850 RPM 230V/50Hz (220V/50Hz)

100373-002 Combustion Air Inlet Damper

10. 62408-001 Control Box (S89E &S89F) Used with Primary safety Control

11.

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 220V

100450-001 Bushing

13. 62406-002 Motor Relay

14. 62759-002 Primary Safety Control H'Well S89F w/30 Sec Prepurge (220V/50Hz)

62758-002 Primary Safety Control H'Well S89E w/o

Sec Prepurge

(Special Limit Applications Only)

15. 100377-002 Damper Indicator Pointer

16. 100429 Damper Decal

17. 63263-005 Pressure Switch

63272-005 Pressure Switch Conversion Kit

63935-001 Pressure Switch (220V/50Hz)

18. 60178-002 Thermostat Terminal Strip

19. 100372 Adjustment Arm Off-Cycle Damper

20-21. 100371-KIT Off-Cycle Damper Kit

22. 21319 Junction Box (under Ignition Transformer)

23. 61843 Lighting Plate

24. 62407-001 Ignition Transformer 7500V

64051-001 Ignition Transformer 220V/50Hz Danfoss

25. 62391-002 Electrode Assembly

26. 62390-002 Sensor Probe Assembly

27. 62387-001 Insulator Bushing (not shown)

28. 62575-002 Chamber/Manifold -HSG200 6" (152.4mm)

62575-001 Chamber/Manifold -HSG400 61/4" (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 Bracket

30. 61951-001 Ignitor Support Parts Kit

31. 62411-028 11" (279.4mm) Sensor Wire -6" (152.4mm), 61/4" (158.75mm) Burner

62411-030 14" (355,6mm), Sensor Wire -9" (228.6mm), 12" (304.8mm) Burner

62411-068 17"

(431

,8mm), Sensor Wire -15" (228.6mm) Burner

64096-001 Sense Wire -330mm Cable (220V/50Hz)

32. 62909-001 8" (203.2mm) Ignition Wire -6" (152.4mm). 61/4" (158.75mm) Burner

62909-003 14" (355.6mm) Ignition Wire -9" (228.6mm), 12" (304.8mm) Burner,

15" (228.6mm) Burner

64095-001 Ignition Wire -500mm Cable (220V/50Hz)

33. 62404-002 Top Plate/Housing Cover

34. 62304 Strain Relief Bushing/Ignition Wire

35. 62402-001 Orifice Housing

36. 62410-001 Orifice Spring

37. 62401-001 Orifice Gasket

38. 62385-001 Orifice Cap

39. 62374-004 Gas Valve Honeywell VR8305M 4801

40. 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'sHSGseriesdirectspark

ignition

(DSl)gas

burners

proveflamethroughthe process

of flame

rectification.Flame

rectificationis

achievedby

placing

small

voltageon theflamesensing

probe.

Whenthe

probe

surrounded

byflame,thevoltageonthe

probe

"leaks"

to ground

throughtheflame,

resultingin an

electricalcurrent.

This currentis interpretedby the

ignitioncontrolasthe

presence

flame.

Oneof

themostcommon

problems

with

gas

appliances

utilizingthistypeofelectronic

flame

sensingsystem

the

"nuisancelockout".Lockoutsarenot

generally

due

totheburnerfailingtoignite,butrather

simply

the

failure

of the systemto sensethe establishmentof flame.

Should

this

situation

existfora period

of timelonger

than the ignitioncontrol'sstatelockouttiming,the

controlwill

shut

downor

into

permanent

lockout.The

only

way

toget

the

burner

to recycleistobreak,and

then

reinstate

power

totheburner.

Thefollowing

situationscanlead

to flame

sensing

problems and can be checked without

disassembling

theburner:

. The burneris not properlygrounded

to "earth

ground"

onthe

linevoltage.

. Theignitioncontrolisnot

properly

grounded

tothe

burner

itself.

Usingan ohmmeter,checkthewire

attachedto both parts for good contactand

continuity.

. The

burner

ignitioncontrolis

polarity

sensitive.

The

polarity

of the incomingline voltagemay be

reversed.Verifythat

blackand

whitewires

are

hot

and neutral respectively,

and that they are

connectedto thecorrespondingblackandwhite

wires

ontheburner.

The remainingchecks andlor

adjustments

require

removalofthe

gas

train:

. The

connections

fromthe'SENSE'terminal

ofthe

ignition

control

totheend

ofthe

flamerod

maybe

brokenat some

point.

Checkall quick

connect

terminationsandconnections.

Check

the

continuity

with

anohmmeter

while

flexingwirestoassure

hidden

conductorbreakageexists.lf replaced,

wiringmust

be of equal,or heavier

gauge

and

equal,orbettertemperaturerating.

. Theflamerod

probe

may

grounded

out.

Assure

thatthe

flamerod

probe

isnottouchingthe

burner

head.The

probe

shouldbe

positioned

inthecenter

of theclearance

groove

ontheouter

edgeof the

burner

headwith

approximately

1116"

(1.5875mm)

clearance

from

the head.Theprobe

mustnotbe

positioned

to faraway

fromtheheadas thismay

resultin grounding

out of the probe

againstthe

inside

surfaceoftheairtube.

. The flamerod

probe

should

be free of soot and

creosote.Depositsmay

insulate

the

probe,

leading

itnottopass

theelectricalchargetotheflame.The

probe

canbecleanedwith

steel

wool,emery

paper

fine

sandpaper.

NOTE:Thisis

the

leadingcause

of nuisancelockoutsin dual-fuel

wood/oasfired

appliances.

. Theflamerod

probe

maybeburnedaway.Checkit

againstdimensionson the ELECTRODEAND

FLAMERODPROBE

SETTINGS

drawing.

. Thedimensionallocation

theflamerod

probe

may

beincorrect,

orthe

probe

maybebentoutof

shape.

CheckitagainstdimensionsontheELECTRODE

ANDFLAMERODPROBE

SETTINGS

drawingand

adjust

ifnecessary.

. The

sparkelectrode

gap

maybeincorrect,resulting

in no sparkor an inadequate

sparkthatwill not

ignitethe gas properly.

Checkthe electrode

gap

against

the ELECTRODEAND FLAMEROD

PROBE

SETTINGSdrawingandadjustif

required.

. Thehigh

tension

lead

conductorfromthe ignition

transformertothetipofthe

spark

electrodemaybe

broken,

preventing

the highvoltage

current

from

getting

to theelectrodetip.Checkallconnections

thoroughlyand/orcheckto continuityof the lead

wire

assemblywithanohmmeter.

Onceall of the itemslisted

previously

havebeen

carefully

checked

andcorrected

if necessary,reinsert

the gas trainassemblyintothe burner.NOTE:Be

carefulnottobend

the

air

proving

switchsailarm

(if

equipped)oraccidentally

reposition

eitherthe

flamerod

probe

orelectrodeduringreinstallationofthe

gas

train

assembly.

lf,

afteralloftheabove

listed

itemshavebeencarefully

checked,theburner

still

failstowork,itisduetoone

thefollowing

problems:

1. Unitsparksand

fires

but

willnot

stay

lit.lgnition

controlmoduleis malfunctioning

and mustbe

replaced.

2. Unitdoesnot

spark.

lgnitiontransformerisbadand

mustbereplaced.

PAGE

TECHNICAL INFORMATION

"Troubleshooting Guide"

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

Wayne's HSG series direct spark ignition (DSI) gas

burners prove flame through the process of flame

rectification. Flame rectification

achieved

placing a

small voltage

the flame sensing probe. When the

probe

surrounded by flame, the voltage

the probe

"leaks" to ground through the flame, resulting

electrical current. This current is interpreted by the

ignition control as the presence of flame.

One of the most common problems with gas appliances

utilizing this type of electronic flame sensing system is

the "nuisance lockout". Lockouts are not generally due

the burner failing

ignite, but rather simply the failure

of the system

sense the establishment of flame.

Should this situation exist for aperiod of time longer

than the ignition control's state lockout timing, the

control will shut down or go into permanent lockout. The

only way

get the burner to recycle

break, and

then reinstate power to the burner.

The following situations can lead to flame sensing

problems and can be checked without

disassembling the burner:

The burner

not properly grounded

"earth

ground"

the line voltage.

The ignition control

not properly grounded

the

burner itself. Using

ohmmeter, check the wire

attached to both parts for good contact and

continuity.

The burner ignition control

polarity sensitive. The

polarity of the incoming line voltage may

reversed. Verify that black and white wires are hot

and neutral respectively, and that they are

connected to the corresponding black and white

wires

the burner.

The remaining checks and/or adjustments require

removal of the gas train:

The connections from the "SENSE" terminal of the

ignition control to the end of the

f1amerod

may be

broken at some point. Check all quick connect

terminations and connections. Check the continuity

with

ohmmeter while flexing wires

assure

hidden conductor breakage exists.

replaced,

wiring must be of equal, or heavier gauge and

equal, or better temperature rating.

The flamerod probe may

grounded out. Assure

that the flamerod probe

not touching the burner

head. The probe should

positioned

the center

of the clearance groove

the outer edge of the

PAGE 19

burner head with approximately 1/16" (1.5875mm)

clearance from the head. The probe must not be

positioned

far away from the head as this may

result

grounding out of the probe against the

inside surface of the air tube.

The flamerod probe should

free of soot and

creosote. Deposits may insulate the probe, leading

not

pass the electrical charge to the flame. The

probe can

cleaned with steel wool, emery paper

or fine sandpaper. NOTE: This is the leading cause

of nuisance lockouts in dual-fuel wood/gas fired

appliances.

The flame

rod

probe may

burned away. Check

against dimensions

the ELECTRODE

A1'JD

FLAMEROD PROBE SETTINGS drawing.

The dimensional location of the flame

rod

probe may

incorrect, or the probe may

bent out of shape.

Check

against dimensions

the ELECTRODE

AND FLAMEROD PROBE SETTINGS drawing and

adjust if necessary.

The spark electrode gap may

incorrect, resulting

no spark or

inadequate spark that will not

ignite the gas properly. Check the electrode gap

against the ELECTRODE AND FLAMEROD

PROBE

SEn-INGS

drawing and adjust if required.

The high tension lead conductor from the ignition

transformer

the tip of the spark electrode may

broken, preventing the high voltage current from

getting

the electrode tip. Check all connections

thoroughly and/or check

continuity of the lead

wire assembly with

ohmmeter.

Once all of the items listed previously have been

carefully checked and corrected if necessary, reinsert

the gas train assembly into the burner. NOTE:

careful not to bend the air proving switch sail arm (if so

equipped) or accidentally reposition either the flamerod

probe or electrode during reinstallation of the gas train

assembly.

If,

after

all

of the above listed items have been carefully

checked, the burner still fails to work,

is due

one or

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