HSG 200, HSG 400 Gas Powered Burners Manual [English]

Publication Date: 12/13/2010
MODELS
HSG200
.".JIIIiI!lN
HSG400
GAS BURNERS
8.J
A SCOTT FETZER COMPANY
801 GLASGOW AVE.
FORT WAYNE, IN 46803
120V/50-60 HZ
220V/50 HZ
PART NO. 62484-001
WARNING: If the information in these instructions
is not followed exactly, a fire or explosion may result
causing property damage, personal injury or death.
fi@
C
- Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of 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.
• If you cannot reach your gas supplier, call the fire
department.
MEA
MASS.
ANSIZ21.17
APPROVED
FOR USE CITY
OF NEW YORK
MEA 49-83-E
- Installation and service must be performed by a
qualified, licensed installer, service agency or the gas
supplier. WARRANTY IS VOIDED IF NOT
INSTALLED BY QUALIFIED SERVICE PERSON.
NOTICE
THESE INSTRUCTIONS SHOULD BE AFFIXED TO THE BURNER
OR ADJACENT TO THE HEATING APPLIANCE.
FOR FURTHER INSTRUCTIONS AND WARNINGS,
SEE PAGE 21 OF THIS MANUAL.
SPECIFICATIONS
[SEE PAGE #1]
US
MODELS
SPECIFICATIONS
MODELS
SPECIFICATIONS
HSG2OO,
HSG4OO
HSG200,
HSG400
NATURALOR
PROPANE
NATURAL
GAS
OR PROPANE
GAS
NOTE:Dimensions
Dimensions
in
informational
Englishvalues
valuestake
takepriority.
NOTE:
in ( )) are
are informational
only. English
priority.
only.
HSG2OO
HSG200
MaximumInput
lnputCapacity
Maximum
200 MBtu/HR
MBtu/HR (211000
(211000 kJ)
kJ)
Capacity
- 200
(63300kJ)
MinimumInput
InputCapacity
MBtu/HR(63300
kJ)
Minimum
- 60
Capacity
60 MBtu/HR
HSG4OO
HSG400
MBtu/HR(422000
kJ)
MaximumInput
InputCapacity
Maximum
Capacity - 400
400 MBtu/HR
(422000 kJ)
Minimum
200 MBtuiHR
Minimum Input
Input Capacity
Capacity - 200
MBtu/HR (211000
(211000 kJ)
kJ)
(3487Pa)
Pa)
SUPPLYLINE
REQUIRED:
Natural
or Propane
5.5W.C.
W.C.(1370
Pa)Minimum,
14.0WC.
SUPPLY
LINE PRESSURE
PRESSURE REQUIRED:
Natural or
Propane 5.5
(1370 Pa)
Minimum, 14.0
W.C. (3487
Maximum
Maximum
(101.6mm)
AIR
DIAMETER:
mm)
AIR TUBE
TUBE DIAMETER:
4 inches
inches (101.6
AIR
TUBELENGTHS:
HSG200
AIR TUBE
LENGTHS:
HSG200
(See
tor
HSG400
12Cfor
(See Fig.
Fig. 12C
HSG400
HSG200|4O0
OverallDimensions)
Overall
Dimensions)
HSG200/400
HSG200/400
HSG200/400
inches
6 inches
6.25inches
6.25
inches
inches
9.00inches
9.00
12.00inches
inches
12.00
(152.4mm)
mm)
(152.4
(158.75
mm)
(158.75 mm)
(228.6
(228.6 mm)
mm)
(304.8
(304.8 mm)
mm)
(28.575mm)
mm)from
lengthswhen
MOUNTING:
Adjustable flange
flange standard
standard (deduct
(deduct 1 1/8
1/8 inch
inch (28.575
from above
above air
air tube
tube lengths
when using
using
MOUNTING:
Adjustable
pedestal
mounting.
flange).
flange). Optional
Optional pedestal
mounting.
STANDARDVOLTAGE:
I60HZl
STANDARD VOLTAGE: 120VAC
120 VAC 1
60 HZ/11 Phase
Phase
50 HZ
HZ/11 Phase
Phase (Special
(Special motor
motor installed
installed with
with max
max capacity
capacity reduced
reduced 20%)
20%)
120 VAC
VAC 1
120
| 50
220VACl50HZl
220
VAC 1 50 HZ/11 Phase
Phase
FLAME
FLAME SAFETY:
SAFETY: 24
24 VAC
VAC Electronic
Electronic
IGNITION:
IGNITION: 7300
7300 VAC
VAC Direct
Direct Spark
Spark
GAS
24VAC
GAS VALVE=314x
VALVE: 3/4 x 3/4
3/4 (19.05
(19.05 mm
mm x 19.05
19.05 mm)
mm) NPT
NPT 3 Function
Function Redundant
Redundant 24
VAC
.200
/ HR)
*200 MBtu/HR
MBtu/HR (211000
(211000 kJ)
kJ) (200,000
(200,000 BTU
BTU [58.62
[58.62 kW]
kW] 1
HR) or
or 400
400 MBtu/HR
MBtu/HR (42200
(42200 kJ)
kJ) (400,000
(400,000 BTU
BTU [117.24
[117.24 kW]
kW]
/1 HR)
HR) at
at sea
sea level.
level. Derate
Derate input
input for
for altitude
altitude over
over 2000
2000 tt.
ft. (609.6
(609.6 m)
m) by
by 4"/.
4% each
each 1000
1000 ft.
ft. (304.8
(304.8 m)
m) above
above sea
sea level.
level.
(one
(one gallon
gallon (3.79
(3.79 L)
L) fueloil
fuel oil =
= 140
140 MBtu/HR
MBtu/HR (14770
(14770 kJ)).
kJ)).
CONTENTS
CONTENTS
SECTION I tNSTALLATION
INSTALLATION ............
sEcTtoN
A. GENERAL
B. VENTILATION
C.
C. HEATING
HEATING APPLIANCE
APPLIANCE INSPECTION.
INSPECTION
D.
D. CHIMNEY
CHIMNEY, FLUE
FLUE PIPE
PIPE AND
AND DRAFT
DRAFT CONTROL
CONTROL
E.
E. COMBUSTTON
COMBUSTION CHAMBER
CHAMBER
PAGE
PAGE
1
..1
2
2
.........-...-.2
2
2-3
..............2.3
4
.............4
F. GAS PIPING
4
G.
G. ELECTRICAL
ELECTRiCAL
5
H.
H. MAIN
MAIN BURNER
BURNER ORIFICE
ORIFICE SIZING
SIZING AND
AND INSTALLATION
INSTALLATION
r.
I. CoMBUSTTON
COMBUSTION GAS
GAS VA1VE........
VALVE
SECTION II INITIAL START UP
SECTION
SECTION III
III OPERATION
OPERATION AND
AND TROUBLESHOOTING..
TROUBLESHOOTING
SECTION
SECTION IV
IV SERVICE
SERVICE
PARTS LISTS
EXPLODED
EXPLODED VIEW
VIEW
5
........................5
........................6
6
7-8
9-14
...........9.14
15-16
17
18
TECHNICAL
INFORMATION.,........
TECHNICAL INFORMATION
19
WARRANTy
20
CONSUMER INSTRUCTIONS
21
SECTION
SECTIONI
INSTALLATION
INSTALLATION
A.
A. GENERAL
GENERAL
power gas
The Wayne
gas
Wayne HSG200
HSG200and
and HSG400
HSG400power
The
conversion
burners
to
conversion
burnersare
are adaptable
adaptable
mosttypes
to most
typesof
of
plantspreviously
previously
poweroil
central
fired
centralheating
heatingplants
fired by
by power
oil
plantsare
gravityand
burners.Typical
Typicalheating
heatingplants
burners.
aregravity
andforced
forced
air
furnaces,
air circulation
circulation
furnaces,hot
hot water,
water,steam
or vapor
vapor
steamor
Powerburner
HSG200
boilers.
design
and
boilers.Power
burner
designmakes
makesthe
theHSG200
and
HSG400 well
well suited
for "negative
"negativedraft"
draft" fired
fired
HSG400
suited for
is being
appliances
where
appliances
wherean
anoil
oilburner
burneris
beingreplaced.
replaced.
powergas
gas conversion
Installation
of
lnstallation
of these
these power
conversionburner
burner
modelsmust
must conform
conformto
to local
localcodes,
in their
their
models
codes,or
or in
AmericanNational
NationalStandard
for the
the
absence,
absence,the
the American
Standardfor
Installation
DomesticGas
Burners.
Installation
of
of Domestic
Gas Conversion
ConversionBurners,
ANS|Z21.8
and the
the National
NationalFlue
Flue Gas
ANSIZ21.8
- and
Gas Code,
Code,
year.
ANSlZ223.1
current
ANSIZ223.1
or
standard
year.
or current
standard
NOTICE:
A1'JSI
code
is
NOTICE:
ANSIor
localinstallation
installation
is
or local
codecompliance
compliance
qualified
the
responsibility
of
the
qualified
installer.
thesole
responsibility
of
the
installer.
sole
B.
B. VENTILATION
VENTILATION
The
burner
by
The HSG
HSGconversion
conversion
burnermodels
modelscovered
covered
by this
this
not be
installed
manual
in
located
manualshall
shallnot
be installed
in an
an appliance
appliance
located
normalair
limitedin
in
is
where
or
wherenormal
aircirculation
circulation
or infiltration
infiltration
is limited
providing
propercombustion
providing
all
for
allthe
theair
air necessary
necessary
for proper
combustion
and
anddraft
drafthood
hooddilution
dilutionair.
air.
In
of
ln open
basements
of homes
homesof
of normal
normalconstruction
construction
ooenbasements
(without
windowsor
(without
basement
storm
basement
stormwindows
or tight
tightstair
stairdoors)
doors)
infiltration
is usually
to
infiltration
of
air
of combustion
combustion
air is
usuallysufficient
sufficientto
provisions
flue,so
replace
that
replace
thatdrawn
drawnup
up the
the flue,
so special
specialprovisions
areseldom
necessary.
are
seldomnecessary.
Whenthe
heating
isinstalled
installed
inaa tightly
tightly
is
in
closed
When
appliance
theheating
appliance
closed
ventilation
room
openings
to
or
roomwithout
withoutventilation
openings
to outdoors,
outdoors,
or other
other
provisions
be made
madefor
for supplying
for
rooms,provisions
rooms,
shall
air
shallbe
supplying
air for
openings,
nearthe
thefloor
floor
one
combustion
through
special
openings,
combustion
through
special
onenear
lineand
nearthe
line
andthe
theother
othernear
theceiling.
ceiling.Each
Eachis
is to
to be
be sized
sized
2
(645.2mm')
inch(645.2mm
on
) or
or more
moreof
of
on the
thebasis
basisof
of one
onesquare
squareinch
(.29kW)
perhour.
freearea
1,000BTU
BTU(.29kW)
inputper
hour.
free
input
areaeach
each1,000
Whenthe
isof
has
When
is
tight
has
thebuilding
building
of unusually
unusually
tightconstruction,
construction,
ventilation
kitchen
ventilation
fans
kitchenand/or
and/orbathroom
bathroom
fanswhich
whichmay
maybe
be
usedfor
for exhausting
to outdoors,
hasaa vented
vented
used
air
or
exhausting
air to
outdoors,
or has
fireplace,
itit is
that
air
fireplace,
is recommended
recommended
that combustion
combustion
air be
be
supplied
to
intakes
extending
to the
thefurnace
furnaceroom
roomthrough
through
intakes
extending
supplied
to the
outsideof
the building
in down
to
and
in
the outside
of the
building
andterminating
terminating
down
prevent
fittings,
turned
suitably
arranged
to
obstruction
turnedfittings,
suitably
arranged
to prevent
obstruction
protecting
fromsnow
rain,and
not
a
screen
from
or rain,
andincluding
including
a protecting
screennot
snowor
(6.35mm)
smaller
than
mesh.
1/4inch
inch(6.35mm)
smaller
than1/4
mesh.
c.
C.
HEATING
APPLIANCE
INSPECTION
HEATING
APPLIANCE
INSPECTION
the appliance
heat exchanger
interior,
Clean
Clean the
applianceheat
exchangerinterior,
combustion
flueconnections.
Remove
combustion
chamber
Remove
chamberand
andflue
connections.
alladhering
all
tars,
the
adhering
tars,scale,
scale,dirt
dirtand
andsoot.
lnspect
theheat
heat
soot. Inspect
potential
for obvious
gas leaks.
exchanger
obviousand
and potential
fluegas
exchanger
for
flue
leaks.
joints around
Cement
base
Cementall
all joints
aroundthe
the appliance
appliancebase and
and
prevent
gasleakage
accessopenings
openings
to prevent
airand/or
fluegas
to
air
access
and/orflue
leakage
intoor
into
chamber.
or out
outof
of the
thecombustion
combustion
chamber.
Warm
WarmAir
Air Furnaces*
Furnaces*- Make
Make certain
certainthe
the electrical
electrical
fanand
limitswitch
characteristics
of
to
characteristics
ofthe
thefan
andlimit
switchcorrespond
correspond
to
required
by
those
thoserequired
by this
this burner
burnerand
and that
that they
in
they are
are in
properworking
proper
workingorder.
order.
WaterBoilers*
Makecertain
Hot
HotWater
Boilers*- Make
certainwater
watertemperature
temperature
pressurerelief
gauges,pressure
reliefvalves
and
and altitude
altitudegauges,
valvesare
are in
in
properworking
proper
workingorder.
order.
pressure
Boilers*
Steam
- Make
Makecertain
certainthe
the system
systemis
is pressure
SteamBoilers*
pressuregage
gageand
pop off
tight,
tight,and
andthat
thatthe
the pressure
and pop
off safety
safety
properworking
valveare
workingorder.
Existing
watersight
water
valve
arein
in proper
order.Existing
sight
permitsclear
glasspermits
glass
of
clearobservation
observation
of boiler
boilerwater
waterlevel.
level.
*Whereapplicable,
pressure
existing
temperature
*Where
existing
temperature
of
applicable,
of pressure
limit
and
limitswitch
lowwater
watercut-off
cut-offswitch
operation
and
switchor
or low
switchoperation
to
electrical
characteristics
shall
electrical
characteristics
bechecked
checked
to determine
determine
shallbe
gas control
their
to
of
theircompatibility
compatibility
to the
the gas
controlcircuitry
circuitry
of this
this
burner.
burner.
D.
FLUE
D. CHIMNEY,
FLUEPIPE
PIPEAND
ANDDRAFT
DRAFTCONTROL
CONTROL
CHIMNEY,
inspectedfor
The
The chimney
chimneyshould
should be
be inspected
for unsafe
unsafe
conditions
such
conditions
such as
as excessive
excessivesoot
soot accumulation,
accumulation,
potential
masonry,
deteriorated
masonry,
blockage
or
blockage.
deteriorated
blockage
or potential
blockage.
pipedamper
NOTICE:
No
adjustable
flue
NOTICE:
Nomanually
manually
adjustable
fluepipe
damperis
is
permitted
gasburner
installation.
on
permitted
on any
anygas
burnerinstallation.
withaa corrosion
The
should
resistant
Thechimney
chimney
belined
linedwith
corrosion
resistant
shouldbe
yourlocal
material,Iflf the
is unlined,
local
is
your
material.
thechimney
chimney
unlined,consult
consult
gasutility
gas
utilityfor
forrecommendations.
recommendations.
WARNING:
should
WARNING:Under
no circumstances
circumstances
theflue
flue
Underno
shouldthe
pipebe
thechimney
fireplace.
to
of
pipe
beconnected
connected
tothe
chimney
ofan
anopen
openfireplace.
gases
pipeshould
The
besized
to carry
carryof
of the
theflue
fluegases
Theflue
fluepipe
shouldbe
sizedto
outlined
in Figure
Figure
1.
as
in
1.
asoutlined
INPUT
INPUT
(kW/HR)
BTU/HR
BTU/HR
(kW/HR)
DRAFTHOOD
DRAFTHOOD
F L UEPIPE
P I P ESIZE
FLUE
SIZE
(35.172kW)
(127mm)
UP
(35.172kW)
51NCH
(127mm)
DIAMETER
UPto
to-120
-120MBH
MBH
5 INCH
DIAMETER
(52.758kW)
(152.4mm)
- 180MBH
120
(35172kW)
-180
(52.758kW)
6 INCH
(152.4mm)
DIAMETER
120MBtu/HR
MBtu/HR
135172kM
MBH
INCH
DIAMETER
(52.758kM
(73.275kW)
180
(52.758kW) - 250
(73.275kW) 7 INCH
(177.8mm)
DIAMETER
INCH
DIAMETER
180MBtu/HR
MBH
MBtu/HR
250MBH
{177.8mm)
(203.2mm)
250
(73.275kW)
(93.792kW)
8INCH
(203.2mm)
DIAMETER
250MBtu/HR
MBtu/HR
f3.275k$- 320
320MBH
MBH
{93.792kW)
8 INCH
DIAMETER
(228.6mm)
(93792kW)(120.171kW)
(228.6mm)
DIAMETER
410MBH
MBH
I INCH
INCH
DIAMETER
320
(93.792kW)410
(120171
kW) 9
320MBlu/HR
MBtu/HR
Figure
Figure1
to appropriate
codes should
be made
made
Strict
Strict compliance
complianceto
appropriatecodes
should be
pipeclearances
regardingflue
flue pipe
fromcombustible
materials,
regarding
clearancesfrom
combustiblematerials.
PAGE
PAGE2
Pitch
Pitch the
the horizontal
horizontal run
run of
of the
the flue
flue pipe
pipe upward
upward 1/4
1/4 inch
inch
(6.35mm)
per
(.305m)
foot
or
more.
Run
directly
to
(6.35mm) per foot (.305m) or more. Run directly to the
the
chimney,
chimney, fasten
fasten joints
joints securely
securely and
and support
support horizontal
horizontal
runs
runs to
to prevent
prevent sagging.
sagging.
lfIf the
the flue
flue pipe
pipe must
must be
be extra
extra long,
long, it's
it's size
size should
should be
be
increased.
increased. The
The horizontal
horizontal length
length of
of the
the flue
flue pipe
pipe should
should
not
not exceed
exceed the
the height
height of
of the
the chimney
chimney above
above the
the flue
flue
connection.
connection.
PITCH
PITCH HOBIZONTAL
HORIZONTAL
RUN
RUN 1/4"
1/4" (6.35mm)
(6.35mm) MlN.
MIN.
PER
PER FOOT
FOOT (.gosM)
(.305M)
The
The draft
draft control
control should
should be
be hood
hood type
type per
per Figure
Figure 2 or,lF
or, IF
APPROVED
APPROVED BY
BY LOCAL
LOCAL AUTHORITIES,
AUTHORITIES, a single
single
barometric
barometric damper
damper suitable
suitable for
for gas
gas firing
firing per
per Figure
Figure 3.
3.
The
draft
control
should
be
sized
the
The draft control should be sized the same
same as
as the
the flue
flue
pipe
pipe per
per Figure
Figure 1,
1, and
and should
should be
be located
located higher
higher than
than the
the
part
highest
highest part on
on the
the appliance
appliance flue
flue passage.
passage. Refer
Refer to
to the
the
barometric
barometric draft
draft regulator
regulator manufacturer's
manufacturer's instructions
instructions for
for
complete
complete detail.
detail.
NOTICE:
NOTICE: Should
Should the
the flue
flue pass
pass through
through a partition,
partition,
the
the draft
draft control
control must
must be located
located in the
the
same
same room
room as the
the heating
heating appliance.
appliance.
DO NOT EXTEND
FLUE PIPE BEYOND
INSIDE OF CHIMNEY
PITCH
PITCH HORIZONTAL
HORIZONTAL
BUN
RUN 1/4"
1/4" (6.3smm)
(6.35mm) MlN.
MIN.
PEF
FOOT
PER FOOT (.3osrV)
(.305M)
VERTICAL
VERTICAL
DRAFT
DRAFT HOOD
HOOD
DO
DO NOT
NOT EXTEND
EXTEND
FLUE
FLUE PIPE
PIPE BEYONO
BEYOND
INSIDE
INSIDE OF
OF CHIMNEY
CHIMNEY
SINGLE
SINGLE ACTING
ACTING
BAROMETRIC
BAROMETRIC
DRAFT
DRAFT CONTROL
CONTROL
BULL HEAD TEE
REDUCER
COFFOSION
CORROSION
RESISTANT
RESISTANT LINING
LINING
-=-+--1------'"
CORROSION
RESISTANT LINING
CLEANOUT
CLEANOUT
SELECT
SELECT EITHER
EITHER
HORIZTONAL
HORIZTONAL OR
OR
VEFTICAL
VERTICAL DBAFT
DRAFT HOOD
HOOD
CHIMNEY
CLEANOUT
CHI""NEY
DRAFT
DRAFT HOOD
HOOD POSITONS
POSITONS
Figure
Figure 22
BAROMETRIC
BAROMETRIC DRAFT
DRAFT
CONTROL
CONTROL POSITION
POSITION
Figure
Figure 33
EXISTING
EXISTING
PREFABRICATEO
PREFABRICATED
COMBUSTION
COMBUSTION
CHAMBEB
CHAMBER LINER
LINER
TO
TO PROTECT
PROTECT PROPERLY
PROPERLY
LOCATE
LOCATE END
END OF
OFBURNEF
BURNER
TUBE.
112"
TUBE. POSITION
POSITIONTUBE
TUBE 1/2'
((12.7mm)
12.7m m SH
)SHORT
OR TOF
SID E
OF IN
INSIDE
OF
OF COMBUSTION
COMBUSTION
CHAMBEB
CHAMBER
HSG
HSG BURNER
BURNER
FORCED
FORCED AIR
AIR FURNACE
FURNACE
Figure
Figure 44
..,,, ,,,,,
, .
, , _ ... y .. ..l .. .,.. .. .J. ...
EXISTING
EXISTINGOR
OR
ADDED
ADDEDTARGET
TARGET
TO
TO BACK
BACKOF
OFCOMBUSCOMBUS·
TION
TIONCHAMBER
CHAMBER
TO
TOPROTECT
PROTECTPBOPERLY
PROPERLY
LOCATE
LOCATEEND
ENDOF
OFBURNER
BURNER
TUBE.
POSITION
TUBE. POSITIONTUBE
TUBE 1/2'
1/2"
(12.7mm)
SHORT
OF
(12.7mm) SHORT OFINSIDE
INSIDE
OF
OFCOMBUSTION
COMBUSTION
CHAI\4BER
CHAMBER
HOT
HOT WATER
WATER OR
OR STEAM
STEAM BOILER
BOILER WITH
WITH
COMBUSTION
COMBUSTION CHAMBER
CHAMBER TARGET
TARGET
Figure
Figure 55
PAGE
PAGE 33
,,
,,
,,
,
y
.. __
EXISTING
EXISTING
PREFABRICATEO
PREFABRICATED
COMBUSTION
COMBUSTION
CHAIV]BEB
CHAMBERLINEFI
LINER
TO
TOPROTECT
PROTECTPROPERLY
PROPERLY
LOCATE
LOCATE END
ENDOF
OFBURNEF
BURNER
TUBE.
TUBE. POSITION
POSITIONTUBE
TUBE 1/2"
1/2"
(12.7mm)
(12.7mm)SHOBT
SHORTOF
OFINSIDE
INSIDE
OF
OFCOMBUSTION
COMBUSTION
CHAMBEF
CHAMBER
HSG
BURNER
HOT
HOT WATER
WATER OR
OR STEAM
STEAM BOILER
BOILER WITH
WITH
COMBUSTION
COMBUSTION CHAMBER
CHAMBER LINER
LINER
Figure
Figure 66
E.
CHAMBER
E. COMBUSTION
CHAMBER
COMBUSTION
is normally
normallyrequired
A
A combustion
combustionchamber
chamberis
requiredto
to
provideaa
protectnon-heat
non-heattransfer
protect
transfersurfaces,
surfaces,and
andto
to provide
primary
radiantbed
for rapid
rapid heat
heat transfer
transferto
radiant
bed for
to the
the primary
goodcondition,
heatexchanger.
in good
Iflf in
surfaces
of
condition,
surfaces
of the
theheat
exchanger.
the
chamber
the existing
existingcombustion
combustion
chambercan
canbe
be used.
used.
Afull
lineris
is recommended
recommended
for
A
full combustion
chamber
for
combustion
chamberliner
(seeFigure
furnaces,
Figure4),
4),and
wall
warm
(see
warmair
airfurnaces,
andaa target
targetwall
full combustion
or
chamber
or full
combustion
chamberliner
lineris
is recommended
recommended
(See
ironor
for
for wet
wet leg
legcast
castiron
or steel
steelboilers.
boilers.(See Figures
Figures55
and
use
and 6).
6). Iflf aa built-up
built-upchamber
chamberis
is necessary,
necessary,
use
(1260"C)minimum
2300°
fire-brick
or
minimuminsulating
insulating
fire-brick
or
2300' FF (1260°C)
fiberfrax.
fiberfrax.
A IR TUBE
TUB E MUST
MUS T NOT
THE
THE BURNER
BURNE R AIR
N O T BE
BE
ALLOWED
ALLOWEDTO
TO EXTEND
EXTENDINTO
INTO THE
THE CHAMBER
CHAMBER
(12.7mm1
PROPER;IT
lT MUST
MUSTBE
BE SET
1/2 INCH
INCH(12.7mm)
PROPER;
SET 1/2
SHORT
SHORTOF
THEINSIDE
INSIDESURFACE.
SURFACE.
OF THE
permanently
Before
securing
Beforepermanently
securingthe
the burner
burnerto
to the
the
witheither
heating
appliance
with
mounting
heating
appliance
eitherthe
theadjustable
adjustable
mounting
pedestal
or
around
flange
flangeor
or pedestal
or cementing
cementing
aroundthe
theair
airtube
tube
in
chamber
in the
the combustion
combustion
chamberopening,
opening,check
thatthe
the
checkthat
headassembly
isfree
freeof
foreignmaterials
burner
is
and
burnerhead
assembly
of foreign
materials
and
probeshave
that
thatthe
the sensor
andelectrode
electrodeprobes
havenot
not been
been
sensorand
repositioned,
Figure13.
13.
damaged
or
see
damaged
or repositioned,
seeFigure
INPUT
PREFERRED
INPUT
PREFERRED
BTU/HR
BTU/HR
(mm
WIDTH"(mm)
XLENGTH"(mm)
(mm
kWHr
wluIH"{mm)
x LLNU
IH"(mm)DIAM."
u lAM."
kW/Hr
(.|4.655kW) 7 (177.8)
X7 (177.8)
50MBtu/HR
MBtu/HH
n778\X7
t177
8\
8 (203.2)
50
(14655kW)
8(203.2)
(219.825kW)71/2
(190
(190.5) 9(2286)
75
(219825kW)
75MBtu/HR
MBtu/HR
7 1/2(1905)
5)X71/2
X7 1/2(190.5)
9 {228.6)
(293.1kW)
293,lkW)
12
304,8 X12
304.8)
13
330.2)
12(304.8)
X12(304.8)
13 (330.2)
100
100MBtu/HR
MBtu/HR
(439
(304.8)
(381)
14(355
6)
14
3556)
12304.8 X15
X15381)
150
43965kW)
150MBtu/HR
MBtu/HR
65kW) 12
(586.2kW)
586,2kW)
431.8)
381))
200MBtu/HR
MBtu/HR
13(330.2)
X17(431.8)
15(381
200
13
330.2 X17
15
'16(406.4)
457.2)
13(330.2)
250
73275kW)
13
330.2 X18
16
4064)
250MBtu/HR
MBtu/HR
fi32.75kW)
X181457.2)
8793kW)
508)
457.2)
300
13
330.2 X20
18
300MBtu/HR
MBtu/HR
f879,3kW)
13(330.2)
X20(508)
18U57.2\
(1
102585kW)
5334)
508)
X21(533.4)
350
14 (355.6)
355.6 X21
350MBtu/HR
MBtu/HR
025.85kW)14
20(508)
20
11724kW)
400
15
381) X22
21
5334)
400MBtu/HR
MBtu/HR
{11i2.4kw)
t5 (381)
X22(558.8)
{558.8)
21(533.4)
RECOMMENDED
RECOMMENDED
COMBUSTION
COMBUSTION
CHAMBER
SIZES
CHAMBER
SIZES
Figure
Figure77
I
DIRECTION
OF FLOW
I
~
•
ANUALSHUTOFFVALVE
1/8" (3,175mm) N.P.T.
PLUGGED TAPPING
PRESSURE GAGE PORT
'i,--y--+-
PIPE CAP
DRIP LEG
LINECOI\II\IECTION
SUPPLY
LINE
SUPPLY
CONNECTION
TO BURNER
TO
BURNER
Figure 8
Figure
F. GAS
PIPING
F.
GAS PIPING
pipingmust
NOTICE:All
withstate
NOTICE:
All piping
mustcomply
complywith
and/or
stateandlor
pressure
gas supply
local codes.
The available
local
codes. The
availablegas
supply pressure
pressures
should
be within
withinminimum
minimumand
andmaximum
maximumpressures
shouldbe
gassupply
inthe
Iflf the
shown
shownin
theburner
burnerspecifications.
specifications.
thegas
supply
(3.5kk Pa)
pressure
W.C.(3.5
Pa)maximum,
pressure
exceeds
the
exceeds
the14"
14"W.C.
maximum,
gasregulator
intermediate
maingas
regulator
mustbe
an
main
must
an intermediate
be installed
installed
gas manual
ahead
aheadof
of the
the main
maingas
manualshut
off valve
valveshown
shutoff
shown
in
in Figure
Figure8.
8.
gas
WARNING:
Failureto
installthe
intermediate
WARNING:
Failure
gas
to install
the intermediate
gas leakage
gas
regulator
regulatorwill
will result
resultin
in gas
leakagefrom
from burner
burnergas
valve.
valve.
trap
in
A drip
dripleg
legor
trapmust
mustbe
be installed
installed
in the
the
or sediment
sediment
lineto
Figure8.
supply
supplyline
to the
the burner.
burner.See
SeeFigure
8.
pipe union
gas line
A
A pipe
union shall
installedin
in the
the gas
line
shall be
be installed
gas
adjacent
adjacentto,
to, and
and upstream
upstreamfrom,
from, the
the main
main gas
manualshutoff
valve,See
Figure8.
manual
shutoffvalve.
SeeFigure
8.
pipingto
gas supply
to the
the burner
burnershould
branch
The gas
The
supplypiping
shouldbranch
gassupply
gas
lineas
the main
maingas
off
from the
to the
supplyline
as close
closeto
the gas
offfrom
possible.Do
Do not
notconnect
meter
meteras
as possible.
connectto
to the
the bottom
bottomof
of
gas supply
horizontal
Figure99 for
for gas
a
section.
supply
a horizontal
section.See
See Figure
pipesizes.
pipe
sizes.
pipeand
Use
fittings free
free
new black
blackiron
ironpipe
and malleable
malleable
fittings
Usenew
joint compound
pipe joint
of
of burrs
burrsand
and defects.
defects. Use
Use pipe
compound
petroleum
gases.
resistant
to liquefied
liquefied
resistant
to
petroleum
gases.
(3.175mm)
plugged
AA118"
1/8" (3.175mm)
NPT
tapping
NPTplugged
tappingaccessible
accessible
provided
gauge connection
for test
for
test gauge
connectionshall
shall be
be provided
gassupply
immediately
upstream
of
immediately
upstream
of the
thegas
supplyconnection
connection
pressure
gassupply
for
to
the burner.
burner.
for determining
gas
to the
determining
supplypressure
piping
Test
Test new
new supply
for leaks.
leaks. CAUTION:
CAUTION:
supply piping for
DURING
TEST
DURINGPRESSURE
PRESSURE
TESTFOR
FORLEAKS
LEAKSIN
IN GAS
GAS
SUPPLY
P I P I NG ,THE
T HE BURNER
B URNE R MUST
M U S T BE
BE
S UP P L YPIPING,
TO PREVENT
EXPOSING
THE
DISCONNECTED
TO
THE
DISCONNECTED
PREVENTEXPOSING
GAS VALVE
VALVE TO
TO PRESSURES
PRESSURES
COMBINATION
GAS
COMBINATION
(3447 PaG)
PSIG. POSSIBLY
POSSIBLY
OVER
OVER 1/2"
112" (3447
PaG) PSIG.
DAMAGING
AND VOIDING
DAMAGINGTHE
THE VALVE
VALVE AND
VOIDINGTHE
THE
BURNER
WARRANTY.
BURNERWARRANTY.
PIPE
PIPE
SIZE
SIZE
TYPE
TYPE
OF
OFGAS
GAS
(kJ)
CAPACITY
- MBtu/HR
MBtu/HR(kJ)
CAPACITY
LEI~GTH
OF
LENGTH
OFPIPE
PIPE
(381mm)
(762mm)
(1143mm
(2286mm
15
30
45
15(381mm)
l0 (762mm)
15(1143mm)
)0(2286mm
90
Propane
400
3/4
Propane
400
250
200
3t4
250
200
422000k.t.|
t263750k, 211000kJ)
1(19.05mm)
422000kJ)
I (263750kJ)
211000kJ)
t19.05mm)
Natural
l\atural
4UU
z5u
ZUU
1
400
250
200
(25.4mm)
(263750kJ
(263750kJ)
422000kJ)
211000kJ)
(25.4mm)
(422000kJ)
(211000kJ)
Propane
250
400
Propane
400
350
250
350
ta220nok.l 369250kJ)
i6q25nk.t) '263750kJ)
' 26i 750k .t\
I (422000kJ)
400
1 1/4
Natural
400
400
300
1t4
Natural
400
300
(422000kJ)
(31.75mm)
(31.75mm)
(422000kJ)
(422000kJ)
(316500kJ)
316500kJ)
422000kJ)
400
Propane
400
Propane
400
400
422000k.1\
422000kJ)
422000kJ)
422000kJ)
400
Natural
400
1t2
Natural
1 1/2
arrnnnk.t\
l 38.1mm)
(38.1mm)
'422000kJ)
CAPACITIES
CAPACITIESSHOWN
ARE FOR
FOR A TOTAL
TOTAL PRESSURE
PRESSURE
SHOWN ARE
(74.73Pa)FOR
(12a.55Pa)
FOR 0.5"
W.C. (124.55Pa)
DROP
DROP OF
OF 0.3"
0.3" W.C.
W.C. (74.73Pa)
0.5" W.C.
BY 1.3.
1.3.
PRESSURE
PRESSUREDROP,
DROP.MULTIPLY
MULTIPLYCAPACITY
CAPACITYSHOWN
SHOWN BY
P R E S S URE DROPS,
DRO PS,
FOR
FOR HIGHER
H IGH E R PERMISSIBLE
P E R MIS S IB LE PRESSURE
YOUR UTILITY.
CONSULT
CONSULTYOUR
UTILITY.
(kW)
PIPE CAPACITIES
lN MBtulHR
MBtu/HR (kW)
SUPPLY
CAPACITIES IN
SUPPLY PIPE
Figure 9
Figure
PAGE4
PAGE
G
ELECTRICAL
G.. ELECTRICAL
The
installation
must
The installation
must be
be wired
wired and
and GROUNDED
GROUNDED in
in
accordance
accordance with
with local
local codes
codes or
or in
in their
their absence,
absence,
with
with the
the National
National Electric
Electric Code
Code ANSI/NFPA
ANSI/NFPA No.
No. 70701987or
1987
or latest
latest edition.
edition.
For
VAC wiring
wiring to
to the
the burner,
burner, use
use solid
solid
For the
the 120
120 VAC
copper
If
copper conductor
conductor wire
wire not
not lighter
lighter than
than #14
#14 AWG.
AWG. lf
a fused
fused disconnect
disconnect is
is used,
used, it
it should
should be
be fused
fused for
for a
minimum
15 amps.
minimum of
of 15
amps.
Each
CAUTION:
CAUTION: Each installation
installation must
must include
include suitable
suitable
limit
limit controls.
controls. Existing
Existing oil
oil burner
burner combination
combination limit
limit
and
and operating
operating controls
controls are
are normally
normally not
not suitable
suitable for
for
gas
gas burner
burner use.
use.
own24
CAUTION:
CAUTION: The
The burner
burner is
is equipped
equipped with
with it's
it's own
24
VAC
VAC transformer.
transformer. Do
Do not
not add
add any
any 24
24 VAC
VAC power
power
consuming
consuming device
device in
in the
the 24
24 VAC
VAC control
control circuit
circuit of
of
the
it could
could overload
overload the
the transformer.
transformer.
the burner,
burner, as
as it
Set
Set the
the room
room thermostat
thermostat "heat
"heat anticipator"
anticipator" for
for the
the
totaf
total current
current draw
draw of
of the
the 24
24 VAC
VAC burner
burner operation
operation
circuit.
circuit. (HSG200
(HSG200 0.55
0.55 amps,
amps, HSG400
HSG400 0.7
0.7 amps)
amps)
GAUTION:
CAUTION: Label
Label all
all wires
wires orior
prior to
to disconnection
disconnection
when
when servicing
servicing controls.
controls. Wiring
Wiring errors
errors can
can cause
cause
improper
improper and
and dangerous
dangerous operation.
operation.
Verify
Verify proper
proper operation
operation after
after servicing.
servicing.
NOTE:
NOTE: lf
If any
any of
of the
the original
original burner
burner wiring
wiring must
must be
be
replaced,
replaced, it
it must
must be
be replaced
replaced with
with #18
#18
AWG
AWG 105
105 degrees
degrees C wire
wire or
or equivalent.
equivalent.
Section
Section 33- Operation
Operation and
and Troubleshooting
Troubleshooting for
for
applicable
applicable burner
burner wiring
wiring diagrams.
diagrams.
ORIFICE
ORIFICE
SIZE
DRILL
SIZE & DRILL
H.
H. MAIN
MAIN BURNER
BURNER ORIFICE
ORIFICE SIZING
SIZING
AND
AND INSTALLATION
INSTALLATION
The
The HSG200
HSG200 and
and HSG400
HSG400 power
power gas
gas conversion
conversion
burners
burners are
are approved
approved for
for use
use with
with natural
natural and
and
propane
propane gas
gas only.
only.
The
The HSG200
HSG200 and
and HSG400
HSG400 burner
burner models
models are
are
shipped labeled
labeled and
and orificed
orificed for
for natural
natural gas.
gas. To
To
shipped
convert to
to propane
propane gas
gas and/or
and/or increase
increase BTU/HR
BTU/HR
conveft
(kcal/Hr)
on natural
natural or
or propane
propane gas,
gas, an
an orifice
orifice
(kcal/Hr) input
input on
kit
kit is
is supplied
supplied with
with each
each burner
burner with
with the
the orifices
orifices
10.
in Figure
Figure 10.
shown in
shown
When
When selecting
selecting a desired
desired BTU/HR
BTU/HR (kcal/Hr)
(kcal/Hr) input,
input,
per
gallon
figure
140,000BTU's
figure 140,000
BTU's per gallon of
of oil
oil input.
input. For
For
100
example: furnace
furnace or
or boiler
boiler rating
rating of
of 0.75gph
0.75gph at
at 100
example:
psig.
140,000=
psig. The
The 0.75
0.75 x 140,000
== 105,000
105,000 BTU's
BTU's input
input
possible
rate.
rate. lt
It may
may be
be possible to
to reduce
reduce the
the firing
firing rate
rate on
on
natural
natural or
or propane
propane gas
gas 15%
15% lo
to 20o/",
20%, as
as most
most older
older
appliances
appliances are
are oversized
oversized for
for the
the heating
heating load.
load.
(2.83875L
(2.83875L x 9356
9356 kcal
kcal =
== 26559.35
26559.35 kcal)
kcal)
To remove
remove or
or interchange
interchange main
main orifice
orifice discs
discs refer
refer to
to
To
Figure
Figure 15
15 (Page
(Page 16).
16).
1. Remove
Remove slotted
slotted orifice
orifice cap,
cap, ltem
Item #40,
#40, making
making
1.
sure orifice
orifice cap
cap gasket,
gasket, #39,
#39, stays
stays attached
attached to
to
sure
orifice
orifice cap
cap and
and is
is not
not damaged.
damaged.
2.
2. Remove
Remove orifice
orifice spring,
spring, ltem
Item #38,
#38, to
to access
access and
and
remove
remove orifice
orifice disc.
disc, ltem
Item #42.
#42.
3. Install
Install desired
desired orifice
orifice from
from Figure
Figure 10,
10, making
making
3.
sure it is
is seated
seated flat
flat in
in the
the orifice
orifice holder,
holder, ltem
Item
sure
#37.
#37.
4.
4. Replace
Replace orifice
orifice spring
spring and
and securely
securely tighten
tighten
orifice
orifice cap
cap against
against orifice
orifice cap
cap gasket
gasket in
in orifice
orifice
holder.
holder.
MANIFOLD
MANIFOLD PRESSURE
PRESSURE
2.0"
4.0"
2.0" (498.2Pa)
(498.2Pa)
3.0" (747.3Pa)
(747.3Pa)
3.0"
4.0" (996.4Pa)
(996.4Pa)
HSG2OO
HSG200 NATURAL
NATURAL GAS
GAS
(52750kJ)
(3.4544mm)
#29
50.000
64.000
76.500
#29 - .136
.136 (3.4544mm)
50,000 BTU
BTU 152750kJl
64,000 BTU
BTU {67520kJ)
167520kJ)
76 500 BTU
BTU (80707.5kJ
180707.5kJ)
(5.0546mm)
(100225kJ)
(78070kJ)
i4,000
#8
95.000
116.000
BTU
#8 - .199
.199 (5.0546mml
74,000 BTU
BTU 178070kJ)
95,000 BTU
BTU (1 00225kJ)
116,000
BTU (122380kJ
(122380kJ)
112,000 BTU
BTU (118160kJ)
(118160kJ) 138.000
J - .277
112.000
.277 (7.0358mm)
(7.0358mm)
138,000 BTU
BTU (145590kJ)
1145590kJ) 164.000
164,000 BTU
BTU (173020kJ
1173020kJ)
160,000
Q - .332
.332 (8.4328mm)
(8.4328mm)
160,000 BTU
BTU (168800kJ)
1168800kJ) 206,000
206,000 BTU
BTU (217330kJ)
(217330kJ)
Q
HSG2OO
L.P.
GAS
HSG200 L.P. GAS
#30
49.000
58.500
TU(61717.5kJ)
68.200
TU(71951kJ)
49,000 BTU
BTU (5169skJ)
151695kJ)
58,500 B
BTU
161717.5kJ)
68,200 B
BTU
171951 kJ)
#30 - 128
.128 (3.2512mm)
13.2512mm)
j44
(3.6576mm)
(69630kJ)
(82290kJ)
#27
78,000
666,000
6.000
BTU
92.000
#27 - .144 (3.6576mm)
BTU 169630kJ)
78,000 BTU
BTU 182290kJ)
92,000 BTU
BTU {97060kJ)
197060kJ)
#15
82.000
12.500
BTU
18687.5kJ)1
36.000
BTtl
82,000 BTU
BTU (86510kJ)
186510kJ) '1
112,500
BTU (1
1118687.5kJ)
136,000
BTU (143480kJ)
1143480kJ)
#15 -.180
- .180 (4.572mm)
14572mm)
D
131,000
87.500
BTU
2.5kJ) 243,000
D·- .246
.246 (6.2484mm)
(6.2484mm)
131,000 BTU
BTU (138205kJ)
1138205kJ) 1
187,500
BTU (1
(197812.5kJ)
243,000 BTU
BTU (256365kJ)
1256365kJ)
9781
HSG4OO
HSG400 NATURAL
NATURAL GAS
GAS
T - .358
200.000
85000
BTU
.358 (9.0932mm)
(9.0932mm)
200,000 BTU
BTU (211000kJ)
(211 OOOkJl 248.000
248,000 BTU
BTU (261640kJ)
1261640kJ) 2
285000
BTU (300675kJ)
1300675kJ)
NOTE:
NOTE: For
For
(11.8872mm)
15/32
15/32 - .468
.468 (11.8872mm) 265,000
265,000 BTU
BTU (279575kJ)
(279575kJ) 343.000
343,000 BTU
BTU {361865kJ)
(361865kJ) 400,000
400,000 BTU
BTU (422000kJ)
(422000kJl
50
50 cycle
cycle
HSG4OO
HSG400 L.P.
L.P. GAS
GAS
application
application
.1 3 7 4 m m ) 190.000
K
42.500
BTU
K-- .2
.2818 1(7
(7.1374mm)
190,000 BTU
BTU (200450kJ)
(200450kJ) 2
242,500
BTU (255837.5kJ
(255837.5kJ)) 295.000
295,000 BTU
BTU {311225kJ)
1311225kJl
derate
derate input
input
0242,500
Q - .332
.332 (8.4328mm)
(8.4328mm)
242,500 BTU
BTU (255837kJ)
(255837kJ) 3
32,500
BTU
332,500
BTU (350787.5kJ)
(350787.5kJ) 400,000
400,000 BTU
BTU (422000kJ)
(422000kJ)
by
by 15%
15%
PAGE
PAGE 55
HSG
HSG SERIES
SERIES POWER
POWER GAS
GAS CONVERSION
CONVERSION BURNERS
BURNERS
ORIFICE
ORIFICE CHART
CHART
Figure
Figure 10
I.
W.C. (498.2Pa)
approximately 2.0"
2.0" WC.
(498.2Pa) to
WC.
to 4.0"
4.0" W.C.
approximately
(996.4Pa)
is factory
W.C (871.85Pa).
(996.4Pa) is
factory set
set at
at 3.5'
3.5" WC
(871.85Pa).
pressureadjustment
is required
When
When pressure
required for
adjustmentis
for setting
setting
input capacity
capacity with
with a selected
orifice from
from Figure
input
selectedorifice
Figure10,
10,
remove
the
regulator
cap
for
access
remove the regulator cap for access to
the slotted
to the
slotted
the screw
adjustment screw.
Turning the
screw counter
adjustment
screw. Turning
counter
reduces manifold
clockwise
manifold orifice
orifice pressure,
pressure,
clockwise reduces
pressure.
increases
clockwise
the pressure.
clockwise
increases
the
COMBINATION
GAS
COMBINATION
GAS VALVE
VALVE
gasvalve
The 24
24 VAC
VACcombination
valveserves
three(3)
combination gas
serves three
(3)
The
(1) manual
functions:(1)
manualgas
functions:
gas shut-off,
shut-off, (2)
(2) main
main gas
gas
pressureregulator,
(3) automatic
flame
regulator,(3)
flame pressure
automatic electric
electric
(doubleseated)
gas shut
(See
redundant(double
off. (See
redundant
seated) gas
shut off.
Figur e11)
11)
Figure
pressure
Thecorrect
correctoperating
operating
manifold
range
orificepressure
The
manifold orifice
range
for
naturaland
is 2.0"
2.0" W.C.
for both
both natural
and propane
propane gas
gas is
WC.
(498.2Pa)minimum
(996.aPa)
to 4.0"
(498.2Pa)
minimum to
4.0" W.C.
W.C. (996.4Pa)
maximum. By
By adjusting
adjustingthe
regulator
maximum.
pressure regulator
the pressure
W.C. (498.2Pa)
between 2.0"
(498.2Pa) and
and 4.0'
4.0" W.C.
WC.
between
2.0" WC.
(996.4Pa)on
propanegas,
gas,a wide
on either
or propane
(996.4Pa)
either natural
natural or
wide
inputrange
beachieved
input
range can
can be
achieved with
with a single
single orifice
orifice size.
size.
lf the
If
the desired
desired input
input rating
rating cannot
cannot be
be obtained
obtained within
within
the
the above
above manifold
manifold orifice
orifice pressure
pressure adjustment
adjustment
range,the
nextsize
range,
the next
size larger
larger or
or smaller
smaller orifice
orifice should
should be
be
10.)
used.
used. (Referto
(Refer to orifice
orifice chart
chart Fig.
Fig. 10.)
NOTE:
MANIFOLD PRESSURE
ADJUSTMENTS
NOTE: MANIFOLD
PRESSURE
ADJUSTMENTS
BE MADE
MADE WITH
CAN
ONLY BE
WITH THE
CAN ONLY
THE
BURNER
BURNER RUNNING
RUNNING AND
AND THE
THE GAS
GAS ON.
ON.
pressuretap
The
1/8" (3.175mm)
NPT pressure
The 1/8"
(3.175mm) NPT
tap for
for orifice
orifice
locatedon
manifold pressure
pressure measurement
measurement is
is located
on the
the
manifold
outlet side
side of
of the
the combination
combination gas
gas valve.
valve. Use
Use a "u"
"u"
outlet
manometeror
tube manometer
or dial
dial type
type pressure
pressure gauge,
gauge,
tube
15.0' W.C.
scaled from
from "0"
"0" zero
zero lo
to 15.0"
WC. (3736.5Pa)
(3736.5Pa) to
to
scaled
11).
read
read pressure
pressure (See
(See Figure
Figure 11).
J. PRESSURE
USTMENT
PRESSURE REGULATOR
REGULATOR ADJ
ADJUSTMENT
The
The combination
combination gas
gas valve
valve pressure
pressure regulator,
regulator,
which
an outlet
outlet pressure
pressure setting
setting range
range of
of
which has
has an
1/8" (3.175mm) NPT
PRESSURE TAP
PLUG
PRESSURE
PRESSURE
REGUI-ATOR
REGULATOR
PRESSURE
REGULATOR
MANUAL CONTROL
KNOB (SHO'olN IN
orr POSITION)
tMANUAl
/ANUALCONTROL
CONTROL
KNOB
KNOB (SHOWN
(SHOWN tN
IN
oFF
OFF POSmON)
pOSmON)
1/8"
118" (3.175mm)
(3.175mm) NPT
NPT
PRESSURE TAP
TAP PLUG
PLUG
PRESSURE
INLET
HSG4OO
HSG400 GAS
GAS VALVE
VALVE
ROBERTSHAW
ROBERTSHAW TOOO
7000 DERHC
DERHC
HSG
HSG 2OOI4OO
200/400 GAS VALVE
VALVE
HONEYWELL
HONEYWELL VR83O5
VR8305
Figure
Figure 11
11
PAGE
PAGE 6
SECTION
SECTION
IIII
INITIALSTART
UP
INITIAL
START UP
1. NOTE:
NOTE:Read
the applicable
sequence of
of
1.
Read the
applicable sequence
gas
burner/primary
controloperation
operationin
in
burner/primary gas control
Troubleshooting
Section3 Operation
and Troubleshooting
Section
Operationand
before
before proceeding.
proceeding.
2.
Depressthe
2. Depress
the combination
combination gas
gas valve
valve manual
manual control
control
knob
knob and
and turn
turn to
to "OFF"
"OFF" position.
position.
3.
3. Adjust
Adjust the
the primary
primary air
air and
and off-cycle
off-cycle damper
damper to
to the
the
start
12Aand
128.
start up
up settings
settings shown
shown in
in Figure
Figure 12A
and 12B.
4.
4. On
On new
new gas
gas line
line installations,
installations, air
air may
may be
be trapped
trapped in
in
the
the line,
line, the
the burner
burner may
may experience
experience several
several
lockouts
lockouts until
until all
all the
the air
air is
is purged
purged from
from the
the lines.
lines.
5.
5. Turn
Turn on
on the
the main
main electrical
electrical power
power and
and set
set the
the
thermostat
thermostat or
or operation
operation control
control to
to call
call for
for heat.
heat.
Allow
to run
run a MINIMUM
MINIMUM of
of 5 minutes
minutes to
to
Allow the
the burner
burner to
purge
purge combustion
combustion chamber
chamber and
and appliance
appliance heat
heat
exchanger.
exchanger.
6.
6. Set
Set the
the thermostat
thermostat or
or operating
operating control
control below
below room
room
temperature,
temperature, shutting
shutting the
the burner
burner "OFF"
"OFF" 1 minute
minute to
to
RESET
RESET the
the primary
primary control.
control.
7.
7. Depress
Depress the
the combination
combination gas
gas valve
valve manual
manual control
control
now
now and
and turn
turn to
to "ON"
"ON" position.
position.
8.
8. Set
Set the
the thermostat
thermostat or
or operating
operating control
control to
to call
call for
for
go
heat.
The
burner
will
start
and
through
heat. The burner will start and go through the
the
applicable
applicable sequence
sequence of
of burner/primary
burner/primary gas
gas control
control
operation,
operation, refer
refer to
to step
step 1.
1.
9.
9. Once
Once burner
burner is
is running
running adjust
adjust the
the orifice
orifice manifold
manifold
pressure
pressure regulator
regulator as
as described
described in
in paragraph
paragraph J Pressure
latorAdjustment.
Pressure Regu
Regulator
Adjustment.
10.
10. A more
more accurate
accurate BTU
BTU (kW)
(kW) input
input can
can be
be determined
determined
by
by using
using the
the NATURAL
NATURAL gas
gas service
service meter
meter with
with the
the
burner
burner only
only on
on (all
(all other
other gas
gas appliances
appliances should
should be
be
off).
off). The
The hand
hand on
on the
the gas
gas meter
meter dialwith
dial with the
the lowest
lowest
cubic
cubic feet
feet valve
valve (fastest
(fastest revolving
revolving dial),
dial), should
should be
be
clocked
clocked for
for one
one complete
complete revolution
revolution and
and use
use the
the
following
following formula.
formula.
3600
3600 x cubic
cubic ft.
ft. (m3)pre
(m 3)pre revolution
revolution x btu
btu (kW)valve/cub
(kW) valve/cub ic
ic fl
ft (m3)=
(m 3) = BTU/HR
BTUIHR (kWH0
(kW/Hr)
seconds
seconds oer
per revolulion
revolution
EXAMPLE:
EXAMPLE: 3600
3600 x 1x 1000
1000 (.2931k$
1.2931 kW) =
=300,000
300,000 BTU/HR
BTU/HR (87.93
(87.93 kWHB)
kW/HR)
12
12
11.
11. After
After the desired
desired input
input has
has been
been obtained,
obtained, re-adjust
re-adjust
PAGE
PAGE 7
the primary
primary air
air damper
damper open
open or
or closed
closed to
to visually
visually
the
obtaina blue
obtain
blue flame
flame with
with well
well defined
defined orange
orange or
or
yellow
naturalgas,
yellow tips
tips for
for natural
gas, or
or well
well defined
defined yellow
yellow tips
tips
for
for propane
propane gas.
gas.
12. After
in operation
operation for
for at
at least
least 10
10
12.
After the
the burner
burner has
has been
been in
minutes,
minutes, assuring
assuring combustion
combustion chamber
chamber and
and heat
heat
exchanger are
are fully
fully warmed,
warmed, take
take combustion
combustion
exchanger
analysis
analysis flue
flue gas
gas samples
samples just
just ahead
ahead of
of the
the draft
draft
control
control in
in the
the flue
flue pipe.
pipe.
NOTE:
NOTE: ALWAYS
ALWAYS USE
USE RELIABLE
RELIABLE COMBUSTION
COMBUSTION
INSTRUMENTS.
TEST
INSTRUMENTS.
BEING
TEST
B
EING
PROFICIENT IN
IN THE
THE USE
USE OF
OF THESE
THESE
PROFICIENT
INSTRUMENTS
AND
INTERPRETING
INSTRUMENTS
AND INTERPRETING
THEIR
THEIR DATA
DATA IS
IS NECESSARY
NECESSARY FOR
FOR SAFE,
SAFE,
RELIABLE
AND
EFFICIENT
BURNER
RE
L I A B L EA
ND E
F F I CI EN TB
URNER
OPERATION.
OPERATION.
13. Perform
13.
Perform the
the following
following combustion
combustion analysis.
analysis. All
All
adjustments
adjustments below
below must
must be
be made
made with
with the
the following
following
instruments:
CO2 analyze
analyzeand
instruments: draft
draft gauge,
gauge, 02 or
or C02
and
CO
CO tester.
tester.
A.
A. Adjust
Adjust the
the primary
primary air
air damper
damper to
to provide
provide about
about
257o
25% excess
excess combustion
combustion air.
air. Confirm
Confirm this
this by
by
checking the
the flue
flue gas
gas for
for its
its FREE
FREE OXYGEN
OXYGEN
checking
(Oz)
or CARBON
CARBON DIOXIDE
DIOXIDE (COz)
(C02) PERCENPERCEN(0 2) or
TAGES
TAGES with
with a test
test instrument.
instrument. Free
Free oxygen
oxygen
should be
be about
about 4.5"/o,
4.5%, or carbon
carbon dioxide
dioxide should
should
should
be
12.1"/"
be about
about 9.5%
9.5% for
for natural
natural gas,
gas, 12.1
% for
for
propane
propane gas.
gas.
B.
B. CARBON
CARBON MONOXIDE
MONOXIDE - Should
Should be
be checked
checked for
for
its
its presence
presence in
in the
the flue
flue gas.
gas. This
This percentage
percentage
should not
not exceed
exceed .04/"
.04% (or
(or 400
400 PPM).
PPM).
should
C.
C. NOTE:
NOTE: Check
Check overfire
overfire draft
draft and
and adjust
adjust to
to
NEGATIVE
NEGATIVE -.01
-.01 (2.491Pa)
(2.491 Pa) to
to -.02
-.02 (4.982Pa)
(4.982Pa)
inches
inches w/c
w/c during
during burner
burner operation.
operation.
gas temperature
flue gas
temperature
D.
should
D. The
The flue
shouldbe
be between
between
(287.78"C)tor
(162.78"C)and
325'F
and 550'F
550"F (287.78'C)for
325"F (162.78'C)
gas conversion
Higherflue
flue
domestic
burners.
conversion
burners.Higher
domesticgas
gas temperatures
indicate overfiring
gas
temperaturesindicate
overfiringor
or
Lower
excessive
excessivedraft
draftthrough
throughthe
the appliance.
appliance.Lower
gas temperatures
flue
flue gas
temperaturesmay
may cause
cause excessive
excessive
indicate
condensation
and
Consult
condensation
andindicate underfiring.
underfiring.
Consult
yourlocal
your
manufacturer
localutility
utilityor
or the
the appliance
appliance
manufacturer
gastemperatures.
for acceptable
fluegas
temperatures.
for
flue
acceptable
14. FILL
FILL OUT
THE INSTALLATION
INSTALLATION
14.
COMBUSTION
OUT THE
COMBUSTION
TAG AND
AND AFFIX
DATA
DATATAG
AFFIXIT
IT TO
TO THE
THE BURNER
BURNEROR
OR
CONVERTED
APPLIANCE.
APPLIANCE.
CONVERTED
(kWHr)
CAUTION:
IF
lF THE
THE BURNER
BURNER BTU/HR
BTU/HR (kWlHr)
CAUTION:
INPUT
REPEAT
STEP
INPUTIS
ISCHANGED,
REPEAT
STEP13
13
CHANGED.
new installations
SUGGESTION:
should
SUGGESTION:All
All new
installations
shouldbe
be
proper combustion
reinspected
reinspectedfor
for proper
combustionand
and burner
burner
operation
operationafter
after one
one or
or two
two weeks
weeks of
of normal
normal
operation.
operation.
For subsequent
For
subsequentnormal
normal starting
starting and
and shut
shut off
off
procedure,
"Consumer
procedure,
refer
Instructions"
in
referto
to the
the "Consumer
lnstructions"
in
plate
the
plate
the back
back of
of this
this manual
manualor
or the
the instruction
instruction
to the
the burner.
burner.
attached
attachedto
,ssK
(9.525mm)
3/8"
3/8" (9.525mm)
NO.1
HSG200
SET
AT NO.1
HSG2OO
SETAT
HSG4OO
NO. 1 1/2
1/2
HSG400
SET
AT NO.1
SETAT
AT NO.2
HSG200
HSG2OOSET
SET AT
HSG400
AT NO.4
HSG4OOSET
SET AT
P RI MA RY
AIR
PRIMARY
AIR
SETTING
SETTING
OFF
DAMPER
OFF CYCLE
CYCLEDAMPER
SETTING
SETTING
128
Figure
Figure12B
Figure12A
12A
Figure
IMPORTANT
IMPORTANT
AREFOR
INITIAL
ANDMUST
MUSTBE
BE
THESE
ARE
STARTUP
ONLY,
FORINITIAL
STARTUP
ONLYAND
THESESETTINGS
SETTINGS
READJUSTED
FOR
EFFICIENCY.
READJUSTED
FORCOMBUSTION
EFFICIENCY.
COMBUSTION
r----1J.18(JJ4.77mm) REF..- - - - j
7.88('95.07mm) REF.
FlANGE NOT SHOWN
15.2J(J86.84mm)
REF
7.01(178.05mm) REF.
Figure
Figure 12C
12C
PAGE8
PAGE
III
SECTION
III
SECTION
AND
TROUBLESHOOTING
OPERATION
AND TROUBLESHOOTING
OPERATION
SEQUENCE
OF
- HSG
HSGSERIES
POWERGAS
GAS
SEQUENCE
OF OPERATION
OPERATION
SERIESPOWER
CONVERSION
BURNER
UTILIZING
HONEYWELL
S89F
BURNER
HONEYWELL
CONVERSION
UTILIZING
S89F
PRIMARY
P/N62759-002
WBUILTIN
IN 30
GAS
PIN
W/BUILT
GASPRIMARY
62759-002
30 SECOND
SECONDPREPURGE
PREPURGE
(24V)is
for heat,
voltage(24V)
On
is applied
appliedto
to motor
motorstart
start
callfor
heat,voltage
On a call
relay
relay and
and air
air switch.
the fan
fan motor
motor reaches
reaches
switch. Once
Once the
pressureis
rpmcombustion
operating
air
operatingrpm
combustion
air pressure
is sensed
by the
the
sensedby
proving switch
air
air proving
and closes
closes the
the switch
contacts
switch and
switch contacts
gasprimary
primarycontrol.
energizing
the
energizing
the S89F
S89Fgas
control.
provideflame
willprovide
the
flame rod
to
flamemonitoring
monitoring
to the
the S89F
theflame
rodwill
S89F
gas control
primaryfor
for the
remainderof
heatcycle.
gas
controlprimary
the remainder
of the
the heat
cycle.
Iflf the
during
the flame
flame should
shouldbe
be extinguished
extinguished
duringthe
the heat
heat
gas control
primarywill
go into
willgo
intothe
cycle,
cycle,the
the S89F
S89Fgas
controlprimary
the 30
30
prepurgeand
second
secondprepurge
and 88 second
safestart
startcheck,
check,then
then
secondsafe
gasvalve
re-energize
the
in
re-energize
the gas
valveand
and ignition
ignitiontransformer
transformer
in an
an
attempt
attemptto
to establish
establishthe
the main
mainburner
burnerflame.
flame. Iflf this
thisdoes
does
period,the
not
notoccur
occurwithin
withinthe
the 4 second
trialfor
for ignition
ignitionperiod,
the
secondtrial
primarycontrol
go into
gas primary
will go
S89F
controlwill
into lockout
lockoutdedeS89F gas
gasvalve
energizing
the
transformer.
energizing
thegas
valveand
andignition
ignition
transformer.
primarycontrol
gas primary
THE
has an
internal30
THE S89F
S89F gas
control has
an internal
30
prepurge
timer.
initial
second
second prepurge timer. After
After the
the initial 30
30 second
second
prepurge,an
prepurge,
an internal
internal88 second
checkof
of the
the
secondsafe
safestart
startcheck
S89F
will commence.
commence. Once
this is
is successfully
S89F will
Once this
successfully
gas
completed,
the S89F
completed,
the
energizes
the
S89Fsimultaneously
simultaneously
energizes
the gas
power or
valve and
ignitiontransformer.
To restart
restartthe
valve
To
and ignition
transformer. Gas
Gas flows
flows and
and the
the
the system,
system,the
the main
main power
or thermostat
thermostat
produces
transformer
must
7300
momentarily,
then
transformerproduces an
an approximate
approximate
7300 volt
volt spark
spark
mustbe
be de-energized
de-energized
momentarily,
then re-energized.
re-energized.
point grounded
groundedat
end
end point
during the
heat cycle,
at the
the burner
burnerhead
head establishing
establishing Iflf at
at any
any time
time during
the heat
cycle, there
there is
is an
an
main
insufficient
mainburner
burnerflame.
flame.
insufficient
supply
air
of combustion
combustion
to the
supplyof
air to
the burner,
burner,the
the
puttingthe
will open,
air
air switch
switchwill
open, putting
the system
into lockout
lockout
systeminto
At
thestart
heatcycle,
is aa trial
forignition
ignition closing
At the
startof
of each
eachheat
cycle,there
thereis
trialfor
gas
closingthe
the gas valve.
valve.
periodof
(4) seconds
of four
four (4)
period
secondsduration.
duration. Normally,
Normally,burner
burner
period.
flame
before
flamewill
will be
be established
established
beforethe
the end
end of
of this
this period.
Once
sparking
will cease
Oncethe
the flame
flameis
is established,
established,
ceaseand
and
sparkingwill
HSG
HSGPOWER
POWERGAS
GASBURNER
B URNE R
WITHHONEYWELL
HONEYWELL
WITH
S89F
S89FGAS
GASPRIMARY
PRIMARY
BURNER
BURNER GND
GND
24VAC
--------r=n
24VAC
YL-__--1--l
YL
t<l
YL--------lJl
YL-------UJ
REDUNDANT
REOUNOANT
VALVE
GAS
GAS VALVE
WIRE NUT
1\
N WIRE
NUT
S-89-F
~~'TCH
24VAC
24VAC
TRANS.
TRANS.
,------'1-BRN
24VAC
MOTOR
I
RELAYI
SENS
24VAC
GNO(24VAC~8
K
GRN
FLAME SENSOR
WHT
MOTOR
~-:l
VALVE
VALVE
~
YL~YL----;}-----F1
L2
~.L1
==S;:"K"====-~
BLK
BLU
I
I
I
I
~9-F
INTEGRAL
RELAY
IGN. TRANS.
~
~
IGNITION
8w
AIR
1~~
SWITCH
IGNITIONROO
ROD
IGNITION
IF ANY OF IHE ORIGIML WIRE.
AS SUPPUEO $TH THE APPLINCE,
MUSTBE
REPLACED.
IT MUST
VUSI BE
MUST
IT
8E REPLACED.
EE
REPLACEDWITH
Y{ITHTYPE
TYPE AWM
AWM 18CA
ISGA
REPLACED
IO5'C
WIREOR
105"
C WIRE
OR EQUIVALENT.
EOUIVALENT.
I
:e-__---===~8L~K=7(I---'-----"'v::s A;~P~~E6H~?HRI~~~APW~~I~CE,
'-----==---
PAGE
PAGE99
---.J
ISCHEMATlcl
lScHEMATiel
~
THERMOSTAT
24VAC TRANS.
I COIL I
L..::J
PART NO. 62488-004
II
G 24 24 V V
N VAC VAG A A
=0
L L
V V
S
LADDER
E E
E
N
FLAME SENSOR
S-B9-F
I
I
~
REDUNDANT
GAS VALVE
HSGSERIES
OPERATION
SEQUENCE
OF
- HSG
SERIES
SEQUENCE
OF OPERATION
BURNER
POWER
GAS
CONVERSION
UTILIZING
POWER GAS CONVERSION BURNER UTILIZING
W/
EXTERNAL
PRIMARYPIN
P/N62758-002
62758.002
HONEYWELL
S89E GAS
WI EXTERNAL
HONEYWELL
S89E
GAS PRIMARY
P/N62388-001
AND
RESISTOR
P/N62530-001
PREPURGE
TIMER
62388-001
30
TIMER PIN
AND RESISTOR
PIN
62530-001
30 SECOND
SECONDPREPURGE
(24V)is
for heat,
heat,voltage
voltage(24V)
to the
the motor
motor
On
call for
is applied
applied to
On a call
pullsin
The motor
relaypulls
in the
and air
the
start
relay and
air switch.
motor relay
startrelay
switch.The
motor.After
the motor
speed,the
the combustion
motor.
After the
motor reaches
reaches speed,
combustion
contacts,
the air
air proving
air
blower closes
proving switch
switch contacts,
air blower
closes the
energizing
theexternal
external30
secondprepurge
timer.After
energizing
the
30 second
prepurge timer.
After
prepurge
timing,the
the S89E
S89Eis
is energized.
energized.
the
30 second
timing,
the30
secondprepurge
prepurgetimer
timerand
the input
inputterminal
terminalto
the
secondprepurge
second
and the
to the
gas primary
resistor
control.The
The function
of this
this resistor
S89E
S89E gas
primary control.
function of
is to
loadon
on the
the output
outputterminal
terminalof
of the
the external
external
to keep
is
keep a load
prepurge
the initial
initialcall
30
timer,
callfor
secondprepurge
30 second
timer, after
after the
for heat
heat
and 30
startprepurge
and 8 second
secondsafe
safe start
30 second
secondstart
start
and
prepurge and
check.
check.
The
an internal
internal8 second
The S89E
gas primary
primary control
control has
has an
second
S89Egas
prepurge
the initial
initial30
30 second
secondprepurge
safe
check. After
After the
safe start
start check.
primary
providedby
gas primary
the external
timer,the
the S89E
provided
by the
externaltimer,
S89Egas
is energized,
the 8I second
startcheck
checkwill
control is
the
second safe
safe start
will
control
energized,
this is
is accomplished,
commence.
accomplished, the
the S89E
S89E
commence. Once
Once this
gasvalve
gasto
valveallowing
flowto
the burner
burner
activates
the
activates
thegas
allowinggas
to flow
to the
the
head.
the
the
head. Simultaneously,
the S89E
S89Econtrol
controlenergizes
energizes
Simultaneously,
producingan
7300
ignitiontransformer,
an approximate
approximate
ignition
producing
7300
transformer,
point grounded
groundedat
volt spark
the burner
head,
volt
end point
at the
burnerhead,
spark end
mainburner
flame.
establishing
main
establishing
burnerflame.
re-ignition
main
of the
the main
This
simultaneous
This promotes
promotes simultaneous
re-ignition of
flameafter
afterthe
theS89E's
S89E's8 second
secondsafe
safestart
check,
burnerflame
burner
start check,
is desirable
in
Thisis
overriding
the 30
30 second
secondprepurge.
overriding the
prepurge. This
desirable in
wheretemperatures
temperatures
cannot
oven
or similar
similarapplications
oven or
applications where
cannot
vary
drastically.
vary drastically.
heatcycle,
thereis
is a trial
trialfor
for ignition
ignition
At
At the
thestart
startof
of each
eachheat
cycle,there
periodof
(4) seconds
Normally,
of four
four (4)
secondsduration.
duration.Normally,
burner
period
burner
period.
thisperiod.
flame
before
flamewill
willbe
be established
established
beforethe
the end
end of
of this
flameis
is established,
willcease
ceaseand
and
Once
sparking
Oncethe
the flame
established,
sparkingwill
provideflame
theflame
flamerod
rodwill
willprovide
flamemonitoring
monitoring
to the
the S89E
S89E
the
to
gasprimary
primarycontrol
forthe
remainder
heatcycle.
cycle.
controlfor
the remainder
of the
the heat
gas
of
primarycontrol
gas primary
with the
the
When
controlwith
When utilizing
utilizingthe
the S89E
S89Egas
prepurge
resistor
is
eternal30
timer,a 10K
10Kohm
ohmresistor
eternal
timer,
is
30 second
secondprepurge
parallelbetween
wiredin
in parallel
betweenthe
the output
outoutterminal
terminalof
of the
the 30
30
wired
heatcycle,
flamebe
be extinguished
extinguished
duringthe
the heat
Shouldthe
Should
the flame
during
cycle,
primaryignition
go into
ignitioncontrol
will go
into the
the 8I
the S89E
controlwill
S89E primary
the
will rerecheck after
after which
which time
time itit will
second safe
safe start
staft check
second
gas valve
ignitiontransformer
in an
the gas
valveand
and ignition
transformer
an
energizethe
energize
in
re-establish
mainburner
burnerflame.
this
attemotto
to re-establish
the main
attempt
the
flame. Iflf this
ignition
not occur
withinthe
the 4 second
trial for
for ignition
does not
occurwithin
secondtrial
does
go into
period,the
gasprimary
primarycontrol
willgo
intolockout
lockout
theS89E
S89Egas
controlwill
period,
gasvalve
valveand
ignition
transformer.
To
de-energizing
thegas
andignition
de-energizing
the
transformer.
To
poweror
mainpower
or thermostat
thermostatmust
must
restartthe
the system,
system,the
the main
restart
re-energized.
momentarily,
thenre-energized.
at
be de-energized
de-energized
be
momentarily,
then
Iflf at
the heat
heat cycle,
cycle, there
there is
is insufficient
insufficient
any time
time during
duringthe
any
air to
to the
the burner,
burner,the
the air
air switch
switch
supplyof
of combustion
combustion
supply
air
puttingthe
into lockout
lockout
will open,
open, putting
the system
systeminto
contactswill
contacts
gasvalve.
valve.
closingthe
the gas
closing
HSGPOWER
POWERGAS
GASBURNER
BURNER
HSG
WITHHONEYWELL
HONEYWELL
PRIMARY
S89EGAS
GASPRIMARY
WITH
S89E
BURNERGND
CNO
BURNER
/\
WIRENUT
NUT
N WIRE
24VAC
------r=n
24VAC
YL---_-F-l
YL
AIR PREPURGE
PREPURGE
AIR
TIMER
SWITCH
SWITCH TIMER
~
YL------lJl
Y
L---UJ
REDUNOANT
REDUNDANT
VALVE
GASVALVE
GAS
RESISTOR
YL.-."" I
LIMIT/
z
e
@
GRN
: RELAY:
WHT
SENS
24VAC
GND(24VAC)
==i~====~
BlK
BLU
MOTOR
H'----,---=--=--=-----{
:
I
r-:7---+--~ 24VAC
L2
MOTOR
,..----.
'---~VALVE
BRN
L1
LIMIT
S-89-E
s- E9- E
VALVE
\ I \ I \ ~r-'
YL
24VAC
TRANS.
t{ l
8LK
~LAME S~R
ICNlT10N
BLU
IGN. TRANS.
I
I
I
I
I
I
I
I
i
I
COIL,
f--f-{'
II.,
)-;'------------------i
.JI
RESISTOR
AIR PRf,~~~GE ,..-_ _,/1/'1/1,
SWITch
-----,
-1
liMIY/
CONTROLLER
I
MOTO
IGNITiON ROO
IF ANY
ANY OF
L-~~~==.!8!l..!!\ K,-=~-"'------':~ IF
OF THE
THE ORIGINAl
ORIGINALWIRE.
WIRE,
AS SuPPLIED
SUPPL]EDWITH
W]TH THE
THE APPUANCE.
APPLIANCE.
AS
MUSTBE
AE REPLACED,
REPUCED,IT
VUST BE
IT t.4UST
MUST
BE
ISCHEMATlcl
lScHEMATIcl
REPLACEOWITH
WITH TYPE
TYPE AWM
AWM 18GA
1AGA
REPLACED
....J
1O5'C
WIREOR
OR EQUIVAlENT.
EOUIVAL€NT.
lOS"
C WIRE
:24VAC24VAC TRANS.
TRANS.
THERMOSTAT
THERMOSTAT
LADDER
I
S
E
24VAC
REDUNDANT
GAS VALVE
N
PART NO. 62488-003
FLAME SENSOR
S-89-E
'----'==--
PAGE10
10
PAGE
FLAMESENSING
SENSING
FLAME
The Honeywell
HoneywellS89
ignitioncontrols
controls
The
series primary
primary ignition
S89 series
principalfor
for main
main
utilize the
the flame
flame current
current rectification
principal
utilize
rectification
burner flame
flame sensing.
burner
sensing.
The flame
The
rectification phenomenon
phenomenon occurs
occurs as
as follows.
follows.
flamerectification
gas
immediate
The
ignited
flame
causes
the
The ignited gas flame causes the immediate
(gas
atmosphere
aroundthe
the flame
flameto
to become
becomeionized
atmosphere
around
ionized (gas
ionization
atoms become
becomeelectrically
electrically
charged). The
The ionization
atoms
charged).
to become
causesthe
atmospherearound
aroundthe
causes
the atmosphere
the flame
flame to
become
voltageoutput
electrically
conductive.
An
the
electrically conductive.
An AC
AC voltage
output from
from the
circuit is
routed through
control sensing
sensing circuit
is routed
through the
the flame
flame
control
probeand
the sensor
sensor probe.
probe. When
When the
the burner
burner
sensor
sensorprobe
and the
headare
bothin
in contact
contactwith
witha properly
flame,
head
properly adjusted
flame,
areboth
adjusted
its larger
morefree
the burner
largersurface
surfaceattracts
attractsmore
the
burner head
head with
with its
free
The
electrons,thus
thus becoming
becomingnegatively
negativelycharged.
charged.The
electrons,
probewith
free
sensor probe
with its
its small
area gives
gives up
up free
sensor
smallsurface
surfacearea
positivelycharged.
The free
free
electrons,thus
becomingpositively
electrons,
thus becoming
charged.The
probeflow
fromthe
AC voltage
voltagein
flow
electronsfrom
the AC
in the
the sensor
electrons
sensorprobe
ionizedgas
the grounded
burner
throughthe
the ionized
through
gas flame
flame to
to the
grounded burner
passesthrough
gasflame,
head.
currentpasses
head. As
As the
the AC
AC current
through the
the gas
flame,
is rectified
rectifiedinto
into a DC
currentflowing
flowingback
itit is
DC current
back to
to the
the
grounded
in
of the
sensingcircuit.
circuit.The
side of
grounded side
the sensing
The flame
flame in
When the
actuality
the flame
is a switch.
switch. When
flame is
is present,
present, the
the
actuality is
allowingcurrent
flow through
throughthe
the
switchis
closedallowing
switch
is closed
current to
to flow
present,
flameis
is present,
circuitof
of the
thecontrol.
control.When
no flame
sensingcircuit
sensing
When no
flowingthrough
the
with no
currentflowing
throughthe
the
switchis
openwith
the switch
is open
no current
the control.
sensing
circuitof
control.
sensing circuit
of the
DC
The DC
DC current
is measured
measuredin
unitscalled
The
current flow
flow is
in units
called DC
.8
microamperers.
steadyDC
DC microamp
currentof
of .8
microamperers. A steady
microamp current
(and steady)
minimum(and
steady)or
or higher
higherthrough
throughthe
the sensing
sensing
minimum
primaryignition
ignitioncontrol
controlis
is sufficient
to keep
keep
circuitof
of the
theprimary
sufficient
circuit
to
runningwithout
withouta safety
lockout.See
Figure
the burner
burnerrunning
safetylockout.
SeeFigure
the
probeand
13for
electrode
dimensional
settings,
sensorprobe
13
for sensor
and electrode
dimensional settings,
Figure14
14 for
flamecurrent
measurement.
Figure
for flame
current measurement.
REF,
13/16
13/16(20,64MM)
Q0,64nn)REF.
~3/4
F -3 t +
{ls.0smm)
<l9,05MM)
PR OBE DIM
IGN IT ER't 5/8 4 1 .2 Emm
S EN SOR1 1 /4 J 1 .7 5 m m )
I
|
-,
"A"
(2,381mn)
1/ 16 (1.588mm)
Figure13
13
Figure
pA SCALE
SCALE
CHECK-USE jJA
CURRENT
FLAME
CHECK-USE
FLAMESENSOR
SENSORCURRENT
TO
TO
SENSOR
SENSOR
MULTIPURPOSEMETER
@
@
_
VAlVE
-
24V
_
DISCONNECT
WIRE FFOM
SENSE
TEBMINAL
(~)
GHO
O
\'C
RED(+
BLACK(-)
BLACK(-)
@
@
MINMUM
0.8 ~A
DC MINMUM
0.8
uA DC
(AND STEADY)
STEADY)
(AND
MEASUREMENT
S89
MEASUREMENT
FLAMECURRENT
CURRENT
S89FLAME
Figure14
14
Figure
PAGE11
11
PAGE
HSG SERIES
HONEYWELLS89E,
SERIESWITH
PRIMARYIGNITION
HSG
WITH A HONEYWELL
S89E,S89F
S89FPRIMARY
IGNITIONCONTROLS
CONTROLS
TROUBLESHOOTING
SHOOTINGGUIDE
TROUBLE
GUIDE
NOT START
START
MOTOR
MOTORDOES
DOES NOT
Check electrical wiring and
connections.
Replace
Replace 24 volt
volt AC
AC
VA Transformer
Transformer
20 VA
tor 24
voltsAC
AC between
betweenterminals
1 and
24 volts
2.
terminals 1
and 3
2. Check
Checkfor
motorstart
relay.
on motor
start relay.
on
Check electrical wiring and
connections.
Replace motor
start relay.
120 volts
3. Check
for 120
volts AC
AC between
between terminal
terminal 2 on
on
3.
Checkfor
relay
neutral
line.
motorstart
motorstart relay and
and neutral line.
Check electrical wiring and
connections.
Replace motor
start relay.
low voltage
tor 24 volt
I.l. Check
Check the
the low
voltage transformer
transformer for
volt output
output
relayeither
terminal3 on
on the
the motor
start relay
either
between terminal
motor start
between
the control
controlbox.
box.
of
"T' terminals on
on the
of the
the'T'terminals
4.
4. Check
Check electrical
electrical wiring
wiring and connections.
connections.
1.
1. Check
Check for
for blower
blower clearance.
clearance.
2.
2. Lubricate
Lubricate motor
motor bearings.
bearings.
5. Does
Does motor
motor shaft
shaft turn
turn freely?
freely?
5.
OK
6.
IGNITION
IGNITION ARC ESTABLISHED
ESTABLISHED -
NO FLAME
Reset
Reset Control
Control - Motor
Motor starts
starts - Completes
Completes 30
30 second
second prepurge
prepurge cycle,
cycle, 8 second
second safe
safe start
start check
check and
and trial
trial for
for
ignition,
to
ignition, 4 seconds
seconds Honeywell
Honeywell series.
series. NOTE:
NOTE: The
The burner
burner motor
motor will
will continue
continue to
operate
operate during
during the
the lock
lock out
out mode
mode when
when the
the thermostat
thermostat circuit
circuit is
is called
called for
for burner
burner operation.
operation.
128, and
2.
2. Check
Check for correct
correct orifice/air
orifice/air setting
setting relationship
relationship (see
(see figures
figures 10,
10, 12A,
12A, 12B,
and 12C).
12C).
In
In order
order for
for the
the following
following functional
functional test
test to be
be made,
made,
the
the control
control must
must be
be reset
reset and
and the
the tests
tests monitored
monitored durduring
ing the
the 4 second
second Honeywell
Honeywell series
series trial
trial for
for ignition
ignition periperiod
od that
that occurs
occurs at
at the
the END
END of
of the
the 30
30 second
second prepurge
prepurge
and
and I8 second
second safe
safe start
start check
check cycle.
cycle.
3.
tor 24 volts
3. Check
Check for
volts AC
AC at
at gas
gas valve
valve terminals.
terminals.
Check
Check electrical
electrical wiring
wiring and
and
connections.
connections. Be
Be sure
sure leads
leads
are
are on
on correct
correct gas
gas valve
valve terterminals
minals
Replace primary
ignition control.
4.
4. Make
Make sure leads
leads are on the correct
correct gas valve
valve
terminals
terminals
Check for correct manifold regulated pressure
pressure
(see figure 10).
6.
PAGE
PAGE 12
NO
NO IGNITION
IGNITION ARC ESTABLISHED
ESTABLISHED
1. Reset Control
Control
.• Motor
Motor starts
starts - Completes
Completes 30
30 second
second prepurge
prepurge cycle, 8 second safe start
start check
check series.
series.
.• Gas
Gas valve
valve opens,
opens, regulating
regulating adequate
adequate gas
gas pressure.
pressure.
.• No
after4 secondHoneywell
No flame
flame established
established - Primary
Primary control
control locks
locks out after
second Honeywell series
series trial
trial for
for
ignition periods.
0
In order
order for
for the
the following
following functional
functional test
test to be made,
made,
the control
control must
must be reset
reset and
and the
the tests
tests monitored
monitored durduring
ing the
the 4 second
second Honeywell
Honeywell series
series trial
trial for ignition
ignition that
that
occurs
occurs at the
the end
end of the
the 30 second
second prepurge
prepurge cycle,
cycle,
and
and I8 second
second safe start
start check.
check.
~
2. Check
Check tor
for 12O
120 volts
volts AC
AC between
between the
the neutral
neutral line
line
and
and the
the function
junction of the
the blue
blue primary
primary control
control lead
lead
and
and the
the black
black ignition
ignition transformer
transformer lead.
lead.
h..
~ Gheck
Check electrical
electrical wiring
wiring and
and connections.
connections.
~
~
Check
Check the
the flame
flame sensing
sensing circuit
circuit for
for (1)
(1) grounded
grounded
flamerod.
(2) Damage
Damage to flamerod
flamerod lead
lead insulainsulaflamerod. (2)
tion.
tion. NOTE:
NOTE: Make
Make sure
sure that
that the
the flamerod
flamerod circuit
circuit
and/or
and/or primary
primary control
control is moisture-free.
moisture-free.
3. Check
Check electrical
electrical wiring
wiring and
and connections.
connections.
~
~
4.
4. Check
Check high
high voltage
voltage lead
lead and
and connection
connection to ignition
ignition
electrode
electrode rod.
rod.
Replace primary ignition control.
~
I
5. Inspect
Inspect ignition
ignition electrode
electrode for
for cracked
cracked insulator
insulator and
and
correct
correct spark
spark gap
gap (Fig.
(Fig. 13).
13).
-
W
6. Replace ignition transformer.
NO IGNITION
IGNITION - NO GAS
GAS VALVE
VALVE
1.
Reset Control
Control - Motor
Motor starts
starts -- After
After 30 second
second prepurge
prepurge cycle
cycle and
and 88 second
second safe
safe start
start check.
check. Motor
Motor continues
continues
1. Reset
flame
to
to run
run but
but flame is not
not established.
established.
V
In
In order
order to
to perform
perform the
the following
follOWing functional
functional tests,
tests, the
the
primary
primary control
control must
must be
be reset
reset and
and the
the tests
tests monitored
monitored
during
during the
the 44 second
second Honeywellseries
Honeywell series trialfor
trial for ignition
ignition
that
that occurs
occurs at
at the
the end
end of
of the
the 30
30 second
second prepurge
prepurge cycle
cycle
and
and 88 second
second safe
safe start
start check.
check.
~
2.
24 volts
volts AC
AC atthe
at the 24
24 volt
volt primary
primary control
control
Check tor
for 24
2. Check
input
input terminals
terminals labeled
labeled yellow
yellow and
and brown.
brown.
~
3.
3. Check
Check air
air proving
proving switch
switch for:
for:
a.
Any
impairment
a. Any impairment that
that would
would keep
keep itit from
from
closing
closing or
or opening.
opening.
b.
b. Electrical
Electrical continuity;
continuity; switch
switch is
is normally
normally open.
open.
Replace
c.
as
necessary.
c. Replace switch
switch as necessary.
PAGE
PAGE 13
13
h..
~l Replace
Replace primary
primary ignition
ignition control.
control.
h..
OK)
,.
4.
4. Check
Check (when
(when applicable)
applicable) external
external 30
30 second
second
prepurge
prepurge timer
timer (jumper
Oumper around
around timer
timer from
from air
air
switch).
switCh). Should
Should primary
primary ignition
ignition control
control
become
become energized,
energized, replace
replace timer.
timer.
I
I
LOSESFLAME
DURINGCYCLE
LOCKSOUT
lOSES
FLAME DURING
CYCLE -_ CONTROL
CONTROL lOCKS
OUT ON
ON SAFETY
SAFEW
1 Reset
contror
• Completes 30 second prepurge cycle, and 8 second safe start check.
• Flame is established.
•ti#fi,":',lT*h"
Sometimes the control H.:*"J",-"
locks out before the thermostat or controlling circuit is
satisfied.
issatisried
"ircuit
-;",::;T::.ffi
~
1. Reset Control
primarycontrol.
2. Disconnect
Connect
Disconnect flamerod
flamerod lead
lead from
from primary
control.Connect
2.
positive
(DC)
(+)
MicroampereMeter
(+) positive lead
lead (DC) Microampere
Meter to
to the
the primary
primary
microampere
controlterminal.
control terminal. Connect
Connect the
the (-)
(-) negative
negative microampere
14:
meter
meter lead
lead to the
the flamerod
flamerod lead
lead terminal.
terminal. See
See Fig.
Fig. 14:
Flame
Flame Current
Current Measurement.
Measurement.
~
~
3.
Reset control,
control, after
after prepurge
prepurge cycle,
cycle, flame
flame is
is established.
established.
3. Reset
A stable
stable microampere
microampere current
current of .8
.8 or more
more is
is required
required
for
for dependable
dependable operation.
operation.
NO
""to~
4.
4. Microampere
Microampere reading
reading is
is less
less than
than .8
.8 or unstable.
unstable.
Probable
Probable cause
cause of erratic
erratic lockout:
lockout:
1.
1. Flame
Flame proving
proving circuit
circuit grounded
grounded by
by moisture.
moisture.
2.
2. Damaged
Damaged insulation
insulation on flamerod
flamerod lead.
lead.
3. Flamerod
Flamerod improperly
improperly positioned
positioned in
in flame
flame (see
(see
3.
Fig.
13).
Fig. 13).
4.
4. Poor
Poor ground
ground path
path to primary
primary control.
control.
primary
Defective primary control.
control.
5.
5. Defective
6. Read
Read manual
manual section
section "Flame
"Flame Sensing".
Sensing".
6.
7.
Applicable
only to Honeywell
Honeywell S89
S89 series
series
7. Applicable only
primary
primary ignition
ignition controls:
controls: Connect
Connect L1
L 1 to the
the
black lead
lead and
and 12
L2 to the
the white
white lead
lead exiting
exiting the
the
black
S89
S89 otherwise
otherwise the
the S89
S89 will
will not
not detect
detect the
the
flame
flame and
and will
will lock
lock out.
out.
h.
,.)
Probable causes:
causes:
Probable
1.
1. Extremely
Extremely poor
poor combustion
combustion level.
level.
2. Flamerod
Flamerod improperly
improperly positioned
positioned in
in flame.
flame.
2.
primary
Defective
control.
3. Defective primary control.
3.
BURNER
BURNER CYCLES
CYCLES ERRATICALLY
ERRATICALLY
I 1. Check for
for proper
proper thermostat
thermostat installation
installation and
and location.
location.
~
2.
correct setting.
setting.
Check thermostat
thermostat heat
heat anticipator
anticipator for correct
2. Check
~
3.
Check low voltage
voltage circuit
circuit for bad wiring,
wiring, electrical
electrical
3. Check
connections
connections and/or switches.
switches.
~
4.
Check line
line voltage
voltage circuit
circuit for bad wiring,
wiring, electrical
electrical
4. Check
connection
connection and/or switches.
switches.
h.
.!o)
,.
Set anticipator
anticipator to correct
correct value
value if
if adjustable
adjustable type.
type.
Set
lf proper
If
proper setting
setting cannot
cannot be
be made,
made, replace
replace with
with
compatible
compatible thermostat.
thermostat.
NOTE:
NOTE: When
When the thermostat
thennostat wires terminate
tenninate on the
HSG
HSG primary
primary control
control box'T"
box "1"" terminals,
tenninals, the heat anticipaanticipator setting
setting value
value for the HSG burner
burner is determined
detennined by
adding the primary
primary control current
current to the gas valve curadding
rent.
rent. The result
result is the anticipator setting.
setting.
(Exampfe:
(Example: .2
.2 + .6
.6 =.8
= .8 amps.)
amps.)
lfIf the thermostat
thennostat wires ARE NOT terminated
tenninated on the
bumer control
control box "7"
"T" terminals,
tenninals, and these
these terminals
tenninals are
JUMPERED,
JUMPERED, you
you must then determine
detennine what
what the correct
correct
anticipator setting
setting is by inspecting
inspecting the controlling
controlling device
anticipator
at the point
point where
where the thermostat
thennostat wires
wires terminate.
tenninate.
Typically,
Typically, this information
infonnation can be found
found on the body or
cover of the controlling
controlling device.
When
When determining
detennining the cunent
current draw of the dual head gas
valve,
valve, be sure
sure to consider the separate
separate ampere values
for each valve.
valve. These usually are stenciled
stenciled on the valve
body, and must
must be added together to obtain
obtain the correct
body,
sum.
sum. (Example:
(Example: .4 + .2 == .6 amps).
amps).
When
When the current
current draw cannot be determined
detennined accurately
accurately
by the above
above method,
method, measure the current
current with an
ampere meter
meter using
using the 1 AMP scale.
scale. Connect
Connect the
ampere
meter leads
leads in series
series with one of the thermostat
thennostat leads
for the accurate
accurate reading.
reading.
PAGE
PAGE 14
14
SECTION IV
IV
SECTION
SERVICE
SERVICE
Caution:
Caution: Make
Make sure
sure the
the main
main manual,
manual, combination
combination
valves
valves and
and main
main power
power switch
switch are
are turned
turned
off before
before opening
opening burner
burner or removing
removing any
any
parts
parts for service.
service.
A.
R N ER
H
EA DA
ND
A. BU
BURNER
HEAD
AND
ELECTRODE/S
ENSORASS
EMBLY
ELECTRODE/SENSOR
ASSEMBLY
The
The burner
burner head,
head, electrode,
electrode, sensor
sensor probe,
probe,
combination
combination valve,
valve, orifice
orifice housing
housing and
and housing
housing
cover
cover are
are part
part of
of the
the gas
gas train
train assembly
assembly which
which can
can
15)
be
be removed
removed as
as one
one unit.
unit. (See
(See Figure
Figure 15)
1. Disconnect
1.
Disconnect gas
gas line
line from
from combustion
combustion gas
gas valve
valve
inlet,
inlet, flame
flame sensor
sensor lead
lead wire
wire from
from gas
gas primary
primary,
gas
gas valve
valve lead
lead wires
wires lrom
from gas
gas valve
valve operator
operator
and
and (orange)
(orange) ignition
ignition lead
lead wire
wire from
from ignition
ignition
transformer
transformer ignition
ignition lead
lead wire.
wire.
2.
2. Remove
Remove the
the two
two 1/4"
1/4" (6.35mm)
(6.35mm) hex
hex slotted
slotted
screws
screws on
on the
the top
top front
front of
of the
the housing
housing cover
cover and
and
the
the two
two 5/16"
5/16" (7.9375mm)
(7.9375mm) hex
hex slotted
slotted screws
screws
on
on the
the left
left and
and right
right side
side back
back of
of the
the housing
housing
cover.
cover.
3.
3. To
To remove
remove gas
gas train
train assembly,
assembly, gently
gently lift
lift up
up rear
rear
of
of housing
housing cover
cover pulling
pulling rearward
rearward slightly
slightly on
on the
the
drawer
drawer assembly
assembly gradually
gradually positioning
positioning the
the rear
rear
of
of the
the drawer
drawer assembly
assembly upward
upward 90
90 degrees
degrees
(1.57RAD).
(1.57RAD). Gently
Gently extract
extract burner
burner head
head and
and
electrode/sensor
electrode/sensor assembly
assembly out
out opening
opening in
in
housing
housing taking
taking extreme
extreme care
care to
to not
not dislocate
dislocate or
damage
damage electrode
electrode or sensor
sensor probe
probe.
4.
4. When
When servicing,
servicing, clean
clean burner
burner head
head ports,
ports,
electrodes
Inspect
electrodes and
and sensor
sensor probe.
probe.
Inspect the
the
sensor
sensor probe
probe and
and electrode
electrode wires
wires and
and porcelain
porcelain
insulators
insulators carefully
carefully for
for hairline
hairline cracks
cracks which
which
might
might provide
provide an
an electrical
electrical leak
leak path
path that
that could
could
short
short out
out the
the ignition
ignition spark,
spark, or flame
flame signal.
signal.
5.
5. Examine
Examine the
the electrode
electrode and
and sensor
sensor probe
probe for
for
any
any serious
serious corrosion
corrosion or
or deterioration
deterioration of metal
metal
at
at the
the tips.
tips. Check
Check for
for proper
proper dimensional
dimensional
settings
settings of the
the sensor
sensor probe
probe and
and electrode
electrode (see
(see
Figure
Figure 13).
13). Adjust
Adjust and/or
and/or replace
replace these
these
assemblies
assemblies as
as necessary.
necessary. Make
Make sure
sure that
that the
the
ignition
ignition and
and sensor
sensor probe
probe wires
wires go
go to
to the
the
correct
correct electrodes
electrodes and
and the
the ignition
ignition wire
wire boot
boot is
is
in
in place
place over
over the
the electrode
electrode porcelain.
porcelain.
6.
6. Make
Make sure
sure that
that the
the burner
burner tube
tube end
end is
is properly
properly
positioned
in the
the combustion
combustion chamber
chamber entry.
entry. lt
It
positioned in
must
must be
be set
set '112"
1/2" (12.7mm)
(12.7mm) short
short of
of the
the inside
inside
face
face of
of the
the combustion
combustion chamber
chamber as
as shown
shown in
in
figures
figures 4,
4, 5 or
or 6.
6.
B.
B. AIR
AIR PROVING
PROVING SWITCH
SWITCH
The
The air
air proving
proving switch
switch is
is mounted
mounted to
to the
the housing
housing
cover
(2) #6
#6 self
self tapping
tapping screws
screws under
under the
the gas
gas
cover with
with (2)
valve.
valve. A clear
clear plastic
plastic tube,
tube, protected
protected by
by a spring
spring
cover,
cover, is
is connected
connected to the
the barbed
barbed fitting
fitting on
on the
the
pressure
pressure switch
switch while
while the
the other
other end
end is
is connected
connected to
to
a brass
brass barbed
barbed fitting.
fitting. The
The plastice
plastice tube
tube allows
allows
pressurized
pressurized air
air from
from the
the blower
blower housing
housing to
to travel
travel to
to
PAGE
PAGE 15
the
the pressure
pressure switch
switch causing
causing the
the diaphragm
diaphragm contacts
contacts
to
to close
close thus
thus completing
completing the
the circuit.
circuit.
The
The function
function of
of the
the air
air proving
proving switch
switch is
is to
to ensure
ensure
sufficient combustion
combustion air
air is
is being
being developed
developed by
by the
the
sufficient
blower motor
motor and
and blower
blower wheel.
wheel. Should
Should the
the blower
blower
blower
motor
motor fail
fail or
or the
the blower
blower wheel
wheel malfunction.
malfunction, the
the
burner
burner gas
gas valve
valve will
will shut
shut off.
off.
1. The
1.
The air
air proving
proving switch
switch should
should never
never require
require
maintenance.
However. should
maintenance. However,
should nuisance
nuisance
lockouts
lockouts occur,
occur, the
the pressure
pressure switch
switch can
can be
be
checked.
checked. This
This is
is done
done by
by disconnecting
disconnecting the
the
yellow
yellow and
and white
white leads
leads from
from the
the Air
Air Proving
Proving
switch and
and jumpering
jumpering the
the leads
leads together.
together. If
the
switch
lf the
burner functions
functions correctly,
correctly, the
the switch
switch needs
needs to
to
burner
be
be replaced.
replaced.
WARNING:
WARNING: lf
If a jumper
jumper is
is used
used to
to check
check the
the switch
switch it
it
must
be removed
removed or an
an unsafe
unsafe condition
condition
must be
can
can occur
occur resulting
resulting in
in death
death or
or property
property
damage.
damage.
2.
2. As
As mentioned
mentioned above,
above, the
the switch
switch should
should never
never
require
require maintenance.
maintenance. However
However a pinched
pinched tube
tube
will
will shut
shut off
off the
the flow
flow of
of pressurized
pressurized air
air to
to the
the
diaphragm creating
creating a failure
failure made
made similar
similar to
to
diaphragm
bad Air
Air Proving
Proving switch.
switch. Always
Always check
check to
to ensure
ensure
bad
that the
the clear
clear tubing
tUbing is
is not
not pinched.
pinched. Make
Make sure
sure
that
is reinstalled
reinstalled over
over tube.
tube.
the spring
spring cover
cover is
the
3. Switch
Switch is
is mounted
mounted in
in the
the horizontalposition
horizontal position with
with
3.
terminals
terminals up
up from
from factory.
factory. Final
Final burner
burner mounting
mounting
should maintain
maintain horizontal
horizontal switch
switch position.
position.
should
WARNING:
WARNING: Damage
Damage to
to internalcomponents
internal components of
of
burner may
may result,
result, if burner
burner is
is mounted
mounted in
in other
other
burner
than
than horizontal
horizontal position.
position.
C.
C. COMBUSTION
COMBUSTION AIR
AIR BLOWER
BLOWER AND
AND MOTOR
MOTOR
1.
1. Cleaning
Cleaning of
of the
the combustion
combustion air
air blower
blower is
is
indicated
if the
the blades
blades show
show an
an accumulation
accumulation of
of
indicated if
dust
dust and
and lint,
lint, or
or if
if the
the character
character of
of the
the flame
flame
indicates
indicates a deficiency
deficiency of
of combustion
combustion air.
air.
2.
2. The
The side
side plate,
plate, motor
motor and
and blower
blower wheel
wheel are
are
removed
removed as
as one
one assembly.
assembly. Disconnect
Disconnect the
the
motor
motor wire
wire inside
inside the
the junction
junction box
box beneath
beneath the
the
ignition
ignition transformer.
transformer. Remove
Remove the
the four
four (4)
(4) 5116"
5/16"
(7.9375mm)
(7.9375mm) hex
hex slotted
slotted screws
screws securing
securing
sideplate
sideplate to
to fan
fan housing.
housing.
CAUTION: Do
Do not
not remove
remove blower
blower wheel
wheel from
from motor
motor
CAUTION:
shaft
shaft during
during periodic
periodic cleaning.
cleaning.
3.
3. Should
Should removal
removal of
of the
the blower
blower wheel
wheel be
be
necessary
it or
necessary for
for cleaning
cleaning or
or replacement
replacement of it
the
be positioned
positioned
the motor,
motor, the
the blower
blower wheel
wheel must
must be
correctly
correctly on
on the
the motor
motor shaft.
shaft. (Figure
(Figure 16)
16)
HSG200
HSG200 blower
blower wheel
wheel pln
pIn 21664
21664 is
is positioned
positioned
21/16"
2 1/16" (52.3875mm)
(52.3875mm) measured
measured from
from the
the blower
blower
wheel
wheel inlet
inlet ring
ring face
face to
to the
the side
side plate
plate face.
face.
HSG400
HSG400 blower
blower wheel
wheel pln
pIn 21642
21642 is
is positioned
positioned
23116"
23/16" (55.5625mm)
(55.5625mm) measured
measured from
from the
the blower
blower
wheel
wheel inlet
inlet ring
ring face
face to the
the side
side plate
plate face.
face.
33
DRAWER
ASSEMBLY
DRAWER
ASSEMBLY
Figure15
15
Figure
r
"AU
MOTOR SIDEPLATE
PIN 21658
r'I
P A F I T N I I ] \ ' F I t r FI
21664
21664
HSG2OO
HSG200
51t 4 0.
D.
5114
G.D.
((133.35mm)
133. 35m m )
2 11/16"
/1 6 "
(52.3875mm)
(52.3875mm)
21642
21642
HSG4OO
HSG400
1t 2 0.
55112
D.
G.D.
((139.7mm)
139. 7m m )
223/16"
3t16"
(55.5625mm)
(55.5625mm)
I
l-
i-
\
b
...
"
-r
MOTOR/BLOWER
MOTOR/BLOWER ASSEMBLY
ASSEMBLY
Figure
Figure 16
16
PAGE 116
PAGE
6
FIG.17
17
2OOI4OO
SEEFIG.
FIG.15
15&
& FIG.
PARTS
SEE
PARTSLIST
LIST-- MODEL
MODELHSG
HSG200/400
Item
Item
1.
1.
z.
2.
3.
3.
4.
4.
5.
o.
6.
7.
7.
8.
8.
9.
9.
10.
10.
11.
11.
12.
12.
13.
13.
14.
14.
15.
15.
16.
16.
17.
17.
18.
18.
19.
19.
22.
22.
23.
23.
24.
24.
25.
25.
26.
26.
27.
27.
28.
28.
29.
29.
30.
30.
31.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
PAGE
PAGE 17
PartNo.
No.
Part
100934-001
100934-001
62576-003
62576-003
63270-004
63270-004
62576-01
5
62576-015
63270-01
5
63270-015
62576-027
62576-027
63270-027
63270-027
63270-028
63270-028
62393-001
62393-001
21724-011
21724-011
100428-002
100428-002
21664
21664
21642
21642
21658
21658
20627
20627
20627-004
20627-004
100373-002
100373-002
62408-001
62408-001
62388-001
62388-001
62530-001
62530-001
60186-004
60186-004
63005-002
63005-002
100450-001
100450-001
62406-002
62406-002
62759-002
62759-002
62758-002
62758-002
100377-002
100377-002
100429
100429
63263-005
63263-005
63272-005
63272-005
63935-001
63935-001
60178-002
60178-002
100372
100372
20-21.
20-21.
2'1319
21319
61
843
61843
62407-O01
62407-001
64051
64051-001
-001
62391
-002
62391-002
62390-002
62390-002
62387-001
62387-001
62575-002
62575-002
62575-001
62575-001
62575-014
62575-014
62575-012
62575-012
62575-026
62575-026
62575-024
62575-024
62575-031
62575-031
6241
9-001
62419-001
61951-001
61951-001
62411-028
62411-028
6241
1-030
62411-030
1-068
6241
62411-068
64096-001
64096-001
62909-001
62909-001
62909-003
62909-003
64095-001
64095-001
62404-OO2
62404-002
62304
62304
62402-001
62402-001
62410-001
62410-001
62401
62401-001
-001
62385-001
62385-001
62374-004
62374-004
624s9-001
62459-001
62459-002
62459-002
21760-001
21760-001
Description
Description
Burner
Housing
Burner
Housing
(152.4mm)
AirTube
Tube-- HSG200
HSG200
6"(152.4mm)
Air
6"
(158.75
AirTube
Tube-- HSG400
HSG4OO
1/4"(158.75
mm)
Air
66 1/4"
mm)
(228.6mm)
AirTube
Tube-- HSG200
HSG200
9"(228.6mm)
Air
9"
(228.6mm)
AirTube
Tube-- HSG400
HSG400
9"(228.6mm)
Air
9"
'12"(304.8mm)
(304.8mm)
AirTube
Tube-- HSG200
HSG200
Air
12"
(304.8mm)
Tube-- HSG400
HSG400
12"(304.8mm)
Air
12"
AirTube
(381mm)
15"(381
mm)
AirTube
Tube-- HSG400
Air
15"
HSG400
(HSG200
AirCone
only)
Air
only)
Cone-- (HSG200
(includes
gasket)(not
Assembly
shown)
Adjustable
Flange
Assembly
(includes
gasket)(not
shown)
Adjustable
Flange
(notshown)
Flange
Gasket(not
shown)
Flange
Gasket
(133.35mm)
Blower
WheelHSG200
HSG200
OD(133.35mm)
Blower
Wheel
55114
1/4" OD
(139,7mm)
Blower
Wheel
HSG400
5112'OD
Blower
Wheel
HSG400
51/2"
OD (139.7mm)
(Usedwith
with20627
20627-004
MotorsOnly)
Side
Motors
SidePlate
Plate(Used
20627and
and20627-004
Only)
(.107kW)
(.093kW)
115V/60
Motor,
Split
or
HP
117(.107kW)
or 1/8
1/8(.093kW)
HP3450
3450RPM
RPM115V/60
Motor,
SplitPhase
Phase1/7
(.107kW)
(220Y150H2)
Motor,
Split
HP
(220V/50Hz)
Motor,
Phase1/7
117(.107kW)
HP2850
2850RPM
RPM230V/50Hz
230V/50H2
SplitPhase
InletDamper
Damper
Combustion
Air
Combustion
Air Inlet
(S89E&
Used
safety
withPrimary
Primary
Box (S89E
Usedwith
safetyControl
Control
Control
ControlBox
& S89F)
S89F)
PIN
Prepurge
Time
P/N62758-002
62758-002
30Sec.
Sec.Prepurge
30
Time
(Special
(Special
limit
only)
limitapplications
only)
Resistor
WireAssy.
Assy.
applications
Resistor
Wire
24 Volt
VoltTransformer
Transformer
120V
24
120V
Transformer
24 Volt
VoltTransformer
220V
24
220V
Bushing
Bushing
MotorRelay
Relay
Motor
(220Y150H2)
w/30Sec
Prepurge(220V/50Hz)
Primary
PrimarySafety
SafetyControl
ControlH'Well
H'WellS89F
S89Fw/30
Sec Prepurge
w/o 30
Prepurge
Primary
PrimarySafety
ControlH'Well
H'WellS89E
S89Ew/o
30 Sec
Sec Prepurge
SafetyControl
(SpecialLimit
LimitApplications
Applications
Only)
(Special
Only)
Pointer
DamperIndicator
IndicatorPointer
Damper
DamperDecal
Decal
Damper
PressureSwitch
Pressure
Switch
PressureSwitch
Kit
Pressure
SwitchConversion
ConversionKit
(220Vl50H2)
PressureSwitch
Pressure
Switch(220V/50Hz)
ThermostatTerminal
TerminalStrip
Strip
Thermostat
AdjustmentArm
Damper
Adjustment
Arm Off-Cycle
Off-CycleDamper
100371-KlTOff-Cycle
DamperKit
Kit
100371-KIT
Off-CycleDamper
(underIgnition
Box (under
lgnitionTransformer)
Transformer)
Junction
JunctionBox
LightingPlate
Plate
Lighting
lgnitionTransformer
Transformer
7500V
Ignition
7500V
Danfoss
lgnitionTransformer
220Yl50HzDanfoss
Ignition
Transformer 220V/50Hz
Electrode
Electrode Assembly
Assembly
SensorProbe
Sensor
Probe Assembly
Assembly
Insulator
Insulator Bushing
Bushing (not
(not shown)
shown)
Chamber/Manifold
Chamber/Manifold - HSG200
HSG200 6"
6" ('152.4mm)
(152.4mm)
Chamber/Ivlanifold
1/4. (158.75
mm)
Chamber/Manifold - HSG400
HSG400 6 1/4"
(158.75 mm)
Chamber/Manifold - HSG200
HSG200 9"
9" (228.6mm)
(228.6mm)
Chamber/Manifold
(228.6mm)
9" (228.6mm)
Chamber/Ivlanifold
Chamber/Manifold - HSG400
HSG400 9"
Chamber/Manifold
12"(304.8mm)
Chamber/Manifold - HSG200
HSG200 12"
(304.8mm)
(304.8mm)
12" (304.8mm)
Chamber/Manifold - HSG400
HSG400 12"
Chamber/Manifold
(381mm)
HSG40015"
15" (381
mm)
Chamber/Manifold
- HSG400
Chamber/Manifold
Clip,Electrode
Bracket
Clip,
Electrode Bracket
lgnitor
SupportParts
PartsKit
Kit
Ignitor Support
(152.4mm),6 1/4"
(158.75mm)Burner
11"" (279.4mm)
(279.4mm) Sensor
Sensor Wire
Wire - 6"
6" (152.4mm),
Burner
11
1/4"(158.75mm)
(355,6mm),
14"
14" (355,6mm),
Sensor Wire
Wire - 9"
9" (228.6mm),
(228.6mm), 12"
12" (304.8mm)
(304.8mm) Burner
Burner
Sensor
(431 ,8mm), Sensor
Sensor Wire
Wire - 15"
15" (228.6mm)
(228.6mm) Burner
Burner
17" (431,8mm),
17"
Sense Wire
Wire - 330mm
330mm Cable
Cable (220Vl50H2)
(220V/50Hz)
Sense
8" (203.2mm)
(203.2mm) lgnition
Ignition Wire
Wire - 6"
6" (152.4mm),
(152.4mm). 6 1/4"
1/4" (158.75mm)
(158. 75mm) Burner
Burner
8"
14"
14" (355.6mm)
(355.6mm) lgnition
Ignition Wire
Wire - 9"
9" (228.6mm),
(228.6mm), 12"
12" (304.8mm)
(304.8mm) Burner,
Burner,
15"
15" (228.6mm)
(228.6mm) Burner
Burner
lgnition
Ignition Wire
Wire - 500mm
500mm Cable
Cable (220Vl50H2)
(220V/50Hz)
Top
Top Plate/Housing
Plate/Housing Cover
Cover
Strain
Strain Relief
Relief Bushing/lgnition
Bushing/Ignition Wire
Wire
Orifice
Orifice Housing
Housing
Orifice
Orifice Spring
Spring
Orifice
Orifice Gasket
Gasket
Orifice
Orifice Cao
Cap
Gas
Gas Valve
Valve Honeywell
Honeywell VR8305M
VR8305M 4801
4801
Orifice
Orifice Package
Package - HSG200
HSG200 (not
(not shown)
shown)
Orifice
Orifice Package
Package - HSG400
HSG400 (not
(not shown)
shown)
Optional Pedestal
Pedestal Mountinq
Mountina (not
(not shown)
shown)
Ootional
..
INFORMATION
TECHNICAL
INFORMATION
TECHNICAL
"Troubleshooting
Guide"
"Troubleshooting Guide"
LOCKOUTS/FLAME
BURNERS
NUISANCE
NUISANCE
LOCKOUTS/FLAME SENSING
SENSING PROBLEMS.
PROBLEMS - HSG2OO
HSG200 & HSG4OO
HSG400 GAS
GAS BURNERS
Wayne's
direct spark
spark ignition
Wayne's HSG
HSG series
series direct
ignition (DSl)
(DSI) gas
gas
flame through
burners prove
through the
the process
of flame
burners
prove flame
process of
flame
rectification.
by placing
is achieved
achieved by
placing a
rectification. Flame
Flame rectification
rectification is
probe.When
on the
the flame
Whenthe
flame sensing
sensing probe.
the
small
voltage on
smallvoltage
probeis
is surrounded
by flame,
thevoltage
on the
the probe
surrounded by
flame, the
voltage on
probe
probe
"leaks"to
resultingin
to ground
the flame,
an
"leaks"
ground through
through the
flame, resulting
in an
This current
current is
interpretedby
by the
the
electrical
current.This
electrical current.
is interpreted
ignition
controlas
as the
of flame.
ignition control
the presence
presence of
flame.
mostcommon
One
of the
the most
common problems
problems with
with gas
gas appliances
appliances
Oneof
is
utilizing
utilizing this
this type
type of
of electronic
electronic flame
flame sensing
sensing system
system is
lockout".Lockouts
Lockouts
are
notgenerally
the "nuisance
"nuisance lockout".
are not
generally due
due
the
to
to the
the burner
burner failing
failing to
to ignite,
ignite, but
but rather
rather simply
simply the
the failure
failure
of
to sense
sense the
the establishment
establishment of
of flame.
flame.
of the
the system
system to
Should this
this situation
situation exist
exist for
for a period
period of
of time
time longer
longer
Should
than
than the
the ignition
ignition control's
control's state
state lockout
lockout timing,
timing, the
the
control
control will
will shut
shut down
down or
or go
go into
into permanent
permanent lockout.
lockout. The
The
only
to get
get the
the burner
burner to
to recycle
recycle is
is to
to break,
break, and
and
only way
way to
then
then reinstate
reinstate power
power to
to the
the burner.
burner.
The
The following
following situations
situations can
can lead
lead to flame
flame sensing
sensing
problems
without
and
can
be checked
problems
and
can
checked
without
disassembling
disassembling the
the burner:
burner:
. The
The burner
burner is
is not
not properly
properly grounded
grounded to
to "earth
"earth
ground"
ground" on
on the
the line
line voltage.
voltage.
. The
is not
not properly
properly grounded
grounded to
to the
the
The ignition
ignition control
control is
itself.
burner
Using
an
ohmmeter,
check the
the wire
wire
burner itself. Using an ohmmeter, check
attached
attached to
to both
both parts
parts for
for good
good contact
contact and
and
continuity.
continuity.
. The
is polarity
polarity sensitive.
sensitive. The
The
The burner
burner ignition
ignition control
control is
polarity
polarity of
of the
the incoming
incoming line
line voltage
voltage may
may be
be
reversed.
reversed. Verify
Verify that
that black
black and
and white
white wires
wires are
are hot
hot
and
are
and neutral
neutral respectively,
respectively, and
and that
that they
they are
connected
connected to
to the
the corresponding
corresponding black
black and
and white
white
wires
on the
the burner.
burner.
wires on
The
andlor adjustments
The remaining
remaining checks
checks and/or
adjustments require
require
removal
removal of the
the gas
gas train:
train:
. The
The connections
connections from
from the'SENSE'terminal
the "SENSE" terminal of
of the
the
ignition
f1amerod may
may be
be
ignition control
control to
to the
the end
end of
of the
the flamerod
broken
broken at
at some
some point.
point. Check
Check all
all quick
quick connect
connect
terminations
terminations and
and connections.
connections. Check
Check the
the continuity
continuity
with
an ohmmeter
ohmmeter while
while flexing
flexing wires
wires to
to assure
assure no
no
with an
hidden
hidden conductor
conductor breakage
breakage exists.
exists. lf
If replaced,
replaced,
wiring
wiring must
must be
be of
of equal,
equal, or
or heavier
heavier gauge
gauge and
and
equal,
equal, or
or better
better temperature
temperature rating.
rating.
. The
be grounded
grounded out.
out. Assure
Assure
The flamerod
flamerod probe
probe may
may be
that
that the
the flamerod
flamerod probe
probe is
is not
not touching
touching the
the burner
burner
head.
be positioned
positioned in
in the
the center
center
head. The
The probe
probe should
should be
of
of the
the clearance
clearance groove
groove on
on the
the outer
outer edge
edge of
of the
the
PAGE
PAGE 19
(1.5875mm)
1116"(1.5875mm)
burner
head with
with approximately
1/16"
burnerhead
approximately
The probe
not be
be
clearance from
from the
head. The
probe must
must not
clearance
the head.
positionedto
far away
away from
from the
the head
head as
as this
this may
may
positioned
to far
result
againstthe
result in
in grounding
grounding out
out of
of the
the probe
probe against
the
insidesurface
of the
tube.
inside
surface of
the air
air tube.
.
The flamerod
be free
free of
of soot
soot and
and
The
flamerod probe
probe should
should be
creosote. Deposits
Deposits may
may insulate
insulate the
the probe,
probe, leading
leading
creosote.
it
it not
not to
to pass
pass the
the electrical
electrical charge
charge to
to the
the flame.
flame. The
The
probecan
probe
can be
be cleaned
cleaned with
with steel
steel wool,
wool, emery
emery paper
paper
NOTE:This
is the
leadingcause
or fine
fine sandpaper.
sandpaper. NOTE:
This is
the leading
cause
or
of nuisance
lockouts in
dual-fuel wood/oas
wood/gas fired
fired
of
nuisancelockouts
in dual-fuel
appliances.
appliances.
.
The
probe may
may be
be burned
burned away.
away. Check
Check it
it
The flamerod
flame rod probe
against
against dimensions
dimensions on
on the
the ELECTRODE
ELECTRODE AND
A1'JD
FLAMEROD
PROBE
SETTINGS drawing.
drawing.
FLAMEROD
PROBESETTINGS
.
The
The dimensional
dimensional location
location of
of the
the flamerod
flame rod probe
probe may
may
be
be incorrect,
incorrect, or
or the
the probe
probe may
may be
be bent
bent out
out of
of shape.
shape.
Check it
it against
against dimensions
dimensions on
on the
the ELECTRODE
ELECTRODE
Check
AND
FLAMEROD
PROBE
AND FLAMEROD
PROBE SETTINGS
SETTINGS drawing
drawing and
and
adjust
adjust if
if necessary.
necessary.
.
The
be incorrect,
incorrect, resulting
resulting
The spark
spark electrode
electrode gap
gap may
may be
in
in no
no spark
spark or
or an
an inadequate
inadequate spark
spark that
that will
will not
not
ignite
ignite the
the gas
gas properly.
properly. Check
Check the
the electrode
electrode gap
gap
against the
the ELECTRODE
ELECTRODE AND
AND FLAMEROD
FLAMEROD
against
PROBE
SEn-INGS drawing
drawing and
and adjust
adjust if
if required.
required.
PROBE SETTINGS
.
The
The high
high tension
tension lead
lead conductor
conductor from
from the
the ignition
ignition
transformer
transformer to
to the
the tip
tip of
of the
the spark
spark electrode
electrode may
may be
be
broken, preventing
preventing the
the high
high voltage
voltage current
current from
from
broken,
getting
to the
the electrode
electrode tip.
tip. Check
Check all
all connections
connections
getting to
thoroughly and/or
and/or check
check to
to continuity
continuity of
of the
the lead
lead
thoroughly
wire
wire assembly
assembly with
with an
an ohmmeter.
ohmmeter.
Once all
all of
of the
the items
items listed
listed previously
previously have
have been
been
Once
carefully checked
checked and
and corrected
corrected if
if necessary,
necessary, reinsert
reinsert
carefully
the
NOTE: Be
Be
the gas
gas train
train assembly
assembly into
into the
the burner.
burner. NOTE:
careful
careful not
not to
to bend
bend the
the air
air proving
proving switch
switch sail
sail arm
arm (if
(if so
so
equipped)
equipped) or
or accidentally
accidentally reposition
reposition either
either the
the flamerod
flamerod
probe
probe or
or electrode
electrode during
during reinstallation
reinstallation of
of the
the gas
gas train
train
assembly.
assembly.
lf,
If, after
after all
all of
of the
the above
above listed
listed items
items have
have been
been carefully
carefully
checked,
it is
is due
due to
to one
one or
or
checked, the
the burner
burner still
still fails
fails to
to work,
work, it
more
more of
of the
the following
following problems:
problems:
1.
1. Unit
Unit sparks
sparks and
and fires
fires but
but will
will not
not stay
stay lit.
lit. lgnition
Ignition
control
control module
module is
is malfunctioning
malfunctioning and
and must
must be
be
replaced.
replaced.
2.
2. Unit
Unit does
does not
not spark.
spark. lgnition
Ignition transformer
transformer is
is bad
bad and
and
must
must be
be replaced.
replaced.
LIMITED
AND
LIMITEDWARRANTIES
WARRANTIESFOR
FOR OIL
OIL AND
MADE BY
BY WAYNE
GAS
WAYNE AND
AND
GAS BURNERS,
BURNERS,MADE
RESIDENTIALINSTALLATIONS
USED
USED IN
IN RESIDENTIAL
INSTALLATIONS
("WAYNE")
WAYNECOMBUSTION
COMBUSTION
warrants
WAYNE
SYSTEMS
("WAYNE")
warrants
SYSTEMS
purchase
whopurchase
to
its
to those
thosewho
itsOil
BurnerModels
Modelsfor
forresale
resaleor
Oil Burner
or
productof
for
into
for incorporation
incorporation
intoaa product
of resale,
resale,that
its burner
is
thatits
burneris
free from
from defects
in material
materialand
free
under
defectsin
and workmanship
workmanship
under
(36)months
normal
(36)
normaluse
useand
andservice
forthirty-six
thirty-six
monthsfrom
fromthe
the
servicefor
manufacture,
date
ALL
manufactured
dateof
of manufacture.
ALLGAS
GASBURNERS
BURNERS
manufactured
by
warranted
for
by "WAYNE"
"WAYNE"will
willbe
be similarly
warranted
for eighteen(18)
similarly
eighteen(18)
months
except
monthsfrom
fromdate
dateof
of manufacture
manufacture
exceptwhere
whereoriginal
original
greaterwarranty.
(Reference
manufacture
offers
#6
manufacture
offersa greater
warranty.(Reference
#6
below)
WARRAI\lTIES
DO
below)THESE
THESELIMITED
LIMITED
WARRANTIES
DO NOT
NOTAPPLY
APPLY
THE BURNER
BURNERCOVERED
BY IT
IT IS
IS PROPERLY
UNLESS
UNLESSTHE
COVEREDBY
PROPERLY
INSTALLED
INSTALLED BY
BY A QUALIFIED,
OUALIFIED,COMPETENT
COMPETENT
TECHNICIAN,
WHO IS
IS LICENSED
WHO
WHERE
TECHNICIAN,
LICENSED
WHERESTATE
STATE
AND/ORLOCAL
LOCALCODES
AND/OR
AND
PREVAIL.
AND WHO
WHO IS
IS
CODESPREVAIL,
EXPERIENCED
IN
IN
EXPERIENCED
IN MAKING
MAKINGSUCH
INSTALLATIONS,
IN
SUCHINSTALLATIONS,
ACCORDANCE
WITHI\lFPA
NFPA#31
#31 OF
THE NATIONAL
NATIONAL
ACCORDANCE
WITH
OF THE
FIRE PROTECTION
PROTECTIONASSOCIATION
ASSOCIATIONAND
IN
FIRE
AND IN
ACCORDANCE
ACCORDANCE
WITH
WITH ALL
ALL LOCAL,
LOCAL. STATE
AND
STATEAND
NATIONAL
CODES.
NATIONAL
CODES.
lN-WARRANTY
burner
which
Any
AnyIN-WARRANTY
burnercomponent
component
whichis
is defective
defective
in
will
in material
materialor
or workmanship
workmanship
will be
repairedor
be either
eitherrepaired
or
replaced
as
replaced
as follows:
follows:
gas valves,
1. Fuel
Fuel units,
units, motors,
motors,transformers,
valves,and
1.
gas
transformers,
and
returned
controls
to
service
controlsshould
shouldbe
be returned
to an
an authorized
authorized
service
WAYNEfor
for determination
of
station
of
stationor
or distributor
distributor
of WAYNE
determination
of
LIMITED
WARRANTY
applicability
of
WARRANTY
as
applicability
of this
thisLIMITED
asto
to either
either
repairor
or replacement,
replacement,
wheresaid
repair
where
saidservice
servicestation
stationor
or
is reasonably
reasonably
distributor
is
available
distributor
availablein
in the
the customer's
customer's
locality.The
The manufacturers
locality.
of
manufacturers
of burner
burnercomponents
components
publishand
regularly
regularly
publish
listings
and distribute
distribute
listingsshowing
the
showingthe
locations
of their
theirnetwork
networkof
Where
locations
of
of service
servicestations.
stations.Where
localservice
is NOT
NOTavailable
for the
burner
such
for
suchlocal
serviceis
available
the burner
components
described
above
parts
comoonents
described
aboveor
orother
otherburner
burner
oartsare
are
involved,
involved,these
these items
itemsshould
returned,freight
freight
shouldbe
be returned,
prepaid,
prepaid,
to
Service
801
to WAYNE
WAYNE
Department,
Glasgow
ServiceDepartment,
801Glasgow
Ave,
Ave,Fort
FortWayne,
Wayne,Indiana
Indiana46803.
46803.
2. Burners
Burnersand/or
2.
determined
and/or component(s)
component(s)
determinedto
to be
be
covered
under
WARRANTY
by
covered
underthis
thisLIMITED
LIMITED
WARRANTY
by WAYNE
WAYNE
berepaired
repaired
replaced
shall
or
at
sole
shallbe
or replaced
at WAYNE's
WAYNE's
option.
soleoption.
original
burner
WARRANTY.
original
burnerLIMITED
LIMITED
WARRANTY.
5. Iflf inspection
inspection
byWAYNE
WAYNE
doesNOT
NOTdisclose
5.
by
does
any
disclose
anydefect
defect
coveredby
LIMITEDWARRANTY,
WARRANry,the
covered
by this
this LIMITED
the burner
burneror
or
burner
will
burnercomponent(s)
component(s)
will be
be either
either repaired
repairedor
or
replaced
theexpense
ofthe
thecustomer
WAYNE's
replaced
at
of
and
atthe
expense
customer
andWAYNE's
regular
charges
will
regular
charges
willapply.
apply.
6.
of
6. Iflf the
the original
originalmanufacturer
manufacturer
of aa burner
burnercomponent
component
greaterthan
thaneither
eitherof
LIMITED
offers
warranty greater
offersa warranty
of our
our LIMITED
portionwill
WARRANTIES
described
above,
WARRANTIES
described
above,then
thenthis
thisportion
will
WARRANTY.
be
WARRANTY.
beadded
addedto
to our
ourLIMITED
LIMITED
This
does
This LIMITED
LIMITEDWARRANTY
WARRANTY
does NOT
NOTcover
cover products
oroducts
whichhave
havebeen
as
the
result
which
damaged
as
the
result
of
beendamaged
of accident,
accident,
abuse,
improper
installations,
improper
abuse,misuse,
misuse,neglect,
neglect,
improper
installations,
improper
maintenance
or
failure
to
operate
in
accordance
with
maintenance
failure
to
operate
in
accordance
with
or
WAYf\IE's
written
WAYNE's
writteninstructions.
instructions.
LIMITEDWARRANTIES
WARRANTIES
not extend
These
do
TheseLIMITED
do not
extendto
to anyone
anyone
purchaserat
retailand
except
exceptthe
the first
first purchaser
at retail
and only
only when
when the
the
installation
site.
burner
is in
inthe
theoriginal
installation
burneris
original
site,
IMPLIED
OF
AND
IMPLIEDWARRANTIES
WARRANTIES
OF MERCHANTABILITY
MERCHANTABILITY
AND
FITNESS
FOR
PURPOSE
SHALL
FITNESS
FORA PARTICULAR
PARTICULAR
PURPOSE
SHALLBE
BE
LIMITED
LIMITEDTO
TO THE
THE DURATION
DURATIONOF
OF THE
THE LIMITED
LIMITED
EXPRESSWARRANTIES
WARRANTIES
HEREIN.WAYNE
WAYNE
EXPRESS
CONTAINED
HEREIN.
CONTAINED
EXPRESSLY
EXPRESSLYDISCLAIMS
DISCLAIMSAND
AND EXCLUDES
EXCLUDESANY
ANY
LIABILITY
OR
LIABILITYFOR
FOR CONSEQUENTIAL
OR INCIDENTAL
INCIDENTAL
CONSEQUENTIAL
ANY NATURE
FORBREACH
BREACHOF
DAMAGES
OF
DAMAGES
OF ANY
NATUREFOR
OF ANY
ANY
OR
WARRANTY.
EXPRESS
EXPRESS
IMPLIED
WARRANTY.
ORIMPLIED
Some
on
notallow
limitation
onhow
howlong
longan
an implied
implied
Somestates
statesdo
donot
allowlimitation
warrantylasts,
lasts,so
limitation
may not
not apply
warranty
may
so the
the above
abovelimitation
applyto
to
you. Also,
Also,some
do not
not allow
allowthe
the exclusion
exclusionor
you.
somestates
statesdo
or
incidental
so
limitation
of
or
damages,
limitation
of incidental
or consequential
consequential
damages,
so the
the
you.
above
or
abovelimitation
limitation
or exclusion
exclusionmay
may not
not apply
applyto
to you.
personto
WAYNE
any
WAYNEneither
neitherassumes
assumesor
or authorizes
authorizes
any person
to
for WAYNE
WAYNEany
otherliability
liabilityor
or obligation
obligation
in
assume
in
assumefor
any other
products.
withthe
theseproducts.
Thiswarranty
warranty
connection
with
This
connection
the sale
saleof
of these
you may
givesyou
you specific
rights,and
may also
gives
specificlegal
legalrights,
and you
also have
have
rightswhich
whichvary
varyfrom
fromstate
to state.
other
otherrights
stateto
state.
3. WAYNE
WAYNEis
is not
not responsible
responsible
for any
laborcost
for the
3.
for
any labor
costfor
the
removaland
and replacement
replacement
removal
of
of said
said burner
burneror
or burner
burner
and
associated
therewith.
components
components
andequipment
equipment
associated
therewith.
4. A
A burner
repairedwill
will then
4.
burnerso
so repaired
then carry
the LIMITED
LIMITED
carrythe
portionof
WARRANTY
WARRANTY
equal
portion
equalto
to the
the unexpired
unexpired
of the
the
PAGE20
20
PAGE
CONSUMER
II\ISTRUCTIONS
CONSUMER
INSTRUCTIONS
A
condition
and
A dangerous
hasdeveloped
developed
andmust
mustbe
becorrected.
corrected.
dangerous
conditionhas
TECHNICIAN
FOR
FOR
CONTACT
SERVICE
CONTACTA QUALIFIED
QUALIFIED
SERVICETECHNICIAN
CLEANING,
READJUSTMENT
OR
gasolineor
READJUSTMENT
ORREPAIR.
REPAIR.
CLEANING,
bustible
gasoline
liquids
bustiblematerials,
materials,
or other
otherflammable
flammable
liquidsor
or
INSTRUCTIONS:
LIGHTING
INSTRUCTIONS:
vapors.Do
vapors.
or
Do not
not obstruct
obstructburner
burnerair
air openings
openings
or ventilation
ventilation LIGHTING
InitialStart
See
IIll Initial
Start Up
grillesfor
Section
Uo
SeeSection
grilles
air.
forcombustion
combustion
air.
(DEPRESS)
1.
VALVE
DIAL
TO ON.
1.TURN
TURN(DEPRESS)
VALVE
DIALTO
ON.
periodically.
proper 2. TURN MAIN POWER ON.
CAUTION:
A proper
CAUTION:Check
the burner
burnerflame
flameperiodically.
Checkthe
2.TURNMAINPOWER
ON.
gasflame
NATURAL
facewith
with 3.
NATURAL
gas
flamewill
willappear
appearblue
blueat
atthe
theburner
burnerface
OR
CONTROL
THERMOSTAT
OR OPERATING
OPERATING
CONTROLTO
TO CALL
CALL
3. SET
SETTHERMOSTAT
yellowtips.
properPROPANE
gasflame
A proper
PROPANE
flamewill
will
gas
orange
orangeand
and yellow
tips.A
HEAT.
FOR
FORHEAT.
yellowtips.
with yellow
flame 4.
appear
appearblue
blueat
at the
the burner
burnerface
facewith
tips. Iflf the
the flame
IF
IF BURNER
BURNERHAS
HAS FAILED
FAILEDTO
TO LIGHT,
LIGHT
4. WAIT
WAIT30
30 SECONDS.
SECONDS.
yellowwith
is too
too rich,
will appear
with hazy
hazytips,
tips,
is
rich,it will
appearbillowy
billowyand
andyellow
OR
IF BURNER
BURNERLIGHTS
LIGHTSTHEN
THEN GOES
GOES OUT,
OUI TURN
TURN
OR IF
lean,itit will
Burnercleaning
if too
too lean,
will appear
appearshort
shortand
andall
all blue.
blue.Burner
cleaning
BURNER
OFF
AND
BURNER
OFFFOR
FOR30
30 SECONDS
SECONDS
ANDTHEN
THENBACK
BACKON
ON
readjustmentis
is indicated
flamesthat
rich
and/or
and/orreadjustment
indicatedby
by flames
thatare
aretoo
too rich
RESTART.
FOR
FORRESTART.
or
or too
too lean.
lean.
TO
TOSHUT
SHUTOFF:
OFF:
WARNING:
If
WARNING:
lf any
anyflame
flameis
is observed
observedwhen
whenthe
the burner
burneris
is on
on
(DEPRESS)
VALVE
D]ALTO
1.
VALVE
DIAL
TO OFF.
1.TURN
TURN(DEPRESS)
OFF.
ignitionspark
valveoperator
is heard
heardto
standby,
standby,or
or if the
the ignition
sparkor
or valve
operatoris
to
POWER
2.
OFF.
2.TURN
TURNMAIN
MAINPOWER
OFF.
reachesoperating
come
come on
on before
beforethe
the motor
motor reaches
operatingspeed,
speed,imimgascontrol
power.
mediately
mediately
turn
turn off
otf the
the manual
manualgas
controland
andmain
mainpower.
MAINTENANCE:
MAINTENANCE:
otr Keep
Keepthe
the area
areaaround
aroundthe
the burner
burnerclear
clearand
andfree
freeof
of comcom-
EXPLOSIONHAZARD
gas is
lf PROPANE
PROPANEgas
This would
would create
DANGER
If
is used
used and
and the
the burner
burner is
is located
locatedin
in aa areas
areasor confined
confinedspaces.
spaces.This
createa DANGER
your OF
you suspect
gas leak,
FIRE. Iflf you
leak,
basement,
basement,crawlspace
crawlspaceor confined
confined space,
space,contact
contact your
OF EXPLOSION
EXPLOSIONOR
OR FIRE.
suspect aa gas
gas supplier
"gas leak"
gas
supplierabout
aboutinstalling
installingaa "gas
leak"warning
warningdevice.
device. follow
follow instructions
instructionson
on front
front cover
cover of
of this
this manual.
manual.
gas is heavier
PROPANEgas
heavierthan
PROPANE
than air
air and
and can
can settle
settle in
in low
low
)u
MONOXIDE
CARBON
CARBON MONOXIDE
POISONINGHAZARD
HAZARD
POISONING
ELECTRICSHOCK
HAZARD
ELECTRIC
SHOCK HAZARD
HIGH
ARE
IN
HIGHVOLTAGES
VOLTAGES
AREPRESENT
PRESENT
INTHIS
THISEQUIPMENT
EQUIPMENT
FOLLOW
THESERULES
RULESTO
TOAVOID
ELECTRICAL
AVOID ELECTRICAL
SHOCK.
FOLLOW
THESE
SHOCK.
MONOXIDE
CARBON
MONOXIDE
IS
A COLORLESS, ODORLESS
GAS
CARBON
ISACOLORLESS,
ODOBLESS
GAS
properlygrounded
groundedcircuit.
groundfault
THAT
THATCAN
CAN KILL.
KILL.FOLLOW
FOLLOWTHESE
THESERULES
RULESTO
TO CONTROL
CONTROL ...
A Use
Use only
only aa properly
circuit.A ground
fault
is recommended
recommended
interrupter
interrupteris
CARBON
CARBONMONOXIDE.
MONOXIDE.
waterdirectly
A Do
Do not
not spray
spraywater
directlyon
on burner.
burner,
A Do
Do not
not use
this burner
in an
an unvented,
...
usethis
burnerif in
unvented,enclosed
enclosedarea.
area. ...
Carbon
Carbonmonoxide
monoxidemay
mayaccumulate.
accumulate.
powerbefore
...
A Turn
Turnoff
off power
beforeservicing.
servicing.
pressureregulator.
pressures
A Do
Do not
not adjust
...
adjust the
the pressure
regulator.High
High pressures
producecarbon
carbonmonoxide.
monoxide.
l' Read
Readthe
the owner's
manualbefore
produce
...
owner'smanual
beforeusing.
using.
... Check
flue
gases
for
carbon monoxide. This check ....- - - - - - - - - - - - - - - - - - - - - - 1
vrr996
ttug
I
Yq99D
requires
requiresspecialized
specializedequipment.
equipment.
qualifiedburner
personsto adjust
A Allow
...
Allow only
only qualified
burner service
servicepersons
adjust
the burner.
the
burner. Special
Special instruments
instruments and
and training
training are
are
required.
required
.
A Read
Readthe
...
the owner's
owner'smanual
manualbefore
beforeusing.
using.
-
HAZARD
OVERHEATING
HAZARD
OVERHEATING
SHOULD
SHOULDOVERHEATING
OVERHEATINGOCCUR:
OCCUR:
gas control
Shut off the manual
manual gas
Shut
control to the
the appliance
appliance
Do not shut off the control switch to the pump or blower.
Do
blower.
PAGE 21
PAGE
21
Notes
Notes
PAGE22
PAGE
22
Notes
Notes
PAGE22
PAGE
22