HSG200 HSG400 WAYNE COMBUSTION SYSTEMS 801 GLASGOW AVE. FORT WAYNE, IN 46803 PHONE: (260) 425-9200 (855) WAYNECS (800) 443-4625 FAX: (260) 424-0904 www.waynecombustion.com Gas Burners Manual 62484 | Revision D | Publication Date: 8/17/2018 Note: Dimensions in parentheses ( ) are informational only. English values take priority. CSA CERTIFICATION: 189810-1154925 ANSI Z21.
Overview of Safety Warning System and Your Responsibilities The safety of you and others depends upon you thoroughly reading and understanding this manual. If you have questions or do not understand the information presented in this manual, please call Wayne Combustion System or see www.waynecombustion.com. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. The meaning of this safety alert symbol is as follows: Attention! Become alert! Your safety may be at risk.
Hazard Level Pictogram Type Fire or Explosion Electric shock or burn Overheating Carbon Monoxide Poisoning 62484 REV. D 8/17/18 Hazard Explanation Failure to follow safety warnings exactly could result in serious injury, death or property damage. 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: Open windows. Do not try to light any appliances.
Hazard Level Pictogram Type Proposition 65 material Hazard Explanation This product can expose you to chemicals, including lead, nickel, carbon monoxide and sulfur dioxide, which are known to the State of California to cause cancer or birth defects or other reproductive harm. For more information, go to www.p65Warnings.ca.gov. Special Requirements When contacting Wayne Combustion Systems for service information, please have the burner specification number and model number when calling or writing.
INSTALLATION LOG BURNER MODEL: SPECIFICATION NUMBER: FUEL (NATURAL OR LP): GAS ORIFICE SIZE: INLET GAS PRESSURE (in. w.c.
Contents SECTION I: INSTALLATION AND SETUP.......................................................................................................... 7 VISUAL INSPECTION OF THE HEATING SYSTEM ..........................................................................................7 INSPECTION OF FLUE PIPE AND CHIMNEY ..................................................................................................8 INSPECTION OF HEATING APPLIANCE .............................................................
SECTION I: INSTALLATION AND SETUP These instructions were prepared for the guidance of those installing this particular gas conversion burner. While they apply in principle to all installations, they should not be interpreted as meaning the only safe and economical way to install a conversion burner. It may be necessary to deviate from these instructions in some instances in order to comply with local gas company rules or codes in effect in the area in which the installation is made.
NOTE ON FIGURE 2: Ducts used for make-up air may be connected to the cold air return of the heating system only if they connect directly to outdoor air. Attic Ventilation Louvers are required at each end of attic with alternate air inlet No. 1. 2 1, 2, and 3 mark alternate locations for air from outdoors. Free area shall be not less than 1 sq.in. (645.2 mm ) per 5,000 Btu/hr (1.465 kW) of the total input rating of all appliances in the enclosure.
Where the chimney is unlined or where local experience indicates that flue gas condensate might be a problem, the local gas company should be consulted. The chimney should be examined and thoroughly cleaned, if necessary, before installation is made to make sure it will freely conduct the flue gases to the outside. Flue pipe should extend through the chimney wall to the inner face of the chimney liner but not beyond, and should be firmly cemented to masonry.
Strict compliance to appropriate codes should be made regarding flue pipe clearances from combustible materials. A CSA type draft hood or its equivalent shall be placed in and made part of the flue pipe from the appliance. A barometric damper may be used in place of the draft hood where permitted by local building codes. If an oil barometric damper has been previously installed this may be used if it is in good condition and any and all weights and/or stops are removed.
PREPARATION OF COMBUSTION CHAMBER Clean the combustion chamber thoroughly. Scrape and brush all heating surfaces and flue ways. Soot and fly ash are excellent insulators and unless removed, the efficiency of the heating appliance will be impaired. Plugged or restricted flue passages will prevent burner from operating properly. Be sure water column and gauge on boiler are clean and water level is visible. In all cases make sure the pigtail to limit control is clear.
SIZING OF COMBUSTION CHAMBER The following table is provided as a guideline for determining combustion chamber size and corresponding firing rate when appliance rates are not available. Input Btu/hr (kW) 50,000 (14.7) 75,000 (22.0) 100,000 (29.3) 150,000 (44.0) 200,000 (58.6) 250,000 (73.3) 300,000 (88.0) 350,000 (102.6) 400,000 (117.2) Preferred Width Inches (mm) x Length Inches (mm) 7 (177.8) x 7 (177.8) 7.5 (190.5) x 7.5 (190.5) 12 (304.8) x 12 (304.8) 12 (304.8) x 15 (381) 13 (330.2) x 17 (431.
FIGURE 10: Adjustable Mounting Flange Dimensions DETERMINE ORIFICE SIZE AND RATE The gas conversion burner needs to be set to deliver the same amount of heat to the appliance as the oil burner it is replacing. Determine the Btu/hr heat input rate for the appliance by locating the rating plate of the appliance and determine the firing rate of the oil burner. Typically the nozzle in the oil burner is stamped with the gallon per hour rate. Use the lesser of these two rates as the firing rate of the gas burner.
GAS LEAK HAZARD Liquefied petroleum gas is heavier than air. All connections should be checked for leaks using a soapy solution applied to gas connections. Leaking gas will settle in low lying areas such as basements and trenches. This can lead to asphyxiation and explosion. HSG SERIES POWER GAS CONVERION BURNER ORIFICE CHART Manifold Pressure Orifice Size and Drill 2.0” (498 Pa) 3.0” (747 Pa) 4.0” (996 Pa) HSG200 Natural Gas #29 -.136 (3.5 mm) #8 - .199 (5.1mm) J - .277 (7.0 mm) Q - .332 (8.
CHANGING THE ORIFICE Before replacing the orifice, the gas supply and power must be shut off. The HSG200 is shipped from factory with a #8 - 0.199” orifice installed and HSG400 is shipped from the factory with a T - 0.358” orifice installed. The combination gas valve pressure regulator, which has an outlet pressure setting range of approximately 2.0” w.c. (498.2 Pa) to 4.0” w.c (996.4 Pa) is factory set at 3.5” w.c. (871.85 Pa).
ORIFICE CAP GASKET Figure 13: HSG Cap with Gasket on Manifold Remove orifice spring to access and remove orifice (Figure 14). Orifice will be stamped with its size (Figure 15). Figure 14: HSG Cap with Gasket Removed and Spring Removed 62484 REV.
Figure 15: HSG Orifice Install the new orifice in manifold, reinstall spring and cap with gasket in the manifold. The orifice kit included with conversion burners also contains gas identification labels. When changing from one gas to another, locate the gas identification label on the burner and if necessary, place the proper label from the kit over the label on the burner. The burner is now ready to be connected to the gas supply piping; see instructions in next section.
Manual Shutoff Valve 1/8” (3.175mm) N.P.T. Plugged Tapping Pressure Gage Port Direction of Flow Tee 3’’ MIN (76.2 mm) Union Control Manifold Pipe Cap Drip Leg Supply Line Connection to Burner Figure 16 The gas line should be a separate supply direct from the meter to the burner. It is recommended that new pipe be used and located so that a minimum amount of work will be required in future servicing. The piping should be so installed as to be durable, substantial and gas tight.
Table 1: Pipe Sizing Chart for Natural Gas (0-0.5 psi) with Straight Schedule 40 Metal Pipe The following chart is based on 0-0.5 psi inlet pressure, specific gravity of 0.6, and a pressure loss of 0.5” w.c..
Table 3: Pipe Sizing Chart for LP (11” w.c.) with Copper Tubing The following chart is based on 11” w.c. inlet pressure and a pressure drop of 0.5” w.c..
and controlling when voltage is sent to the burner. Make sure the jumper wire or the thermostat wires if used do not come in contact with any metal. This may cause the burner to ground out. The burner is controlled by the appliance. Once wiring is complete between burner and appliance, verify appliance is controlling the burner’s on/off operation. When connecting the burner to the line voltage electrical supply, utilize the knockout provided on the burner’s junction box.
SECTION II: INITIAL START UP HSG400 Gas Valve Robertshaw 7000 DERHC HSG200/400 Gas Valve Honeywell VR8305 Figure 17: Gas Valves for HSG Series Burner HSG200/400 Gas Valve HSG400 Gas Valve Honeywell VR8305 Robertshaw 7000 DERHC 62484 REV.
INITIAL BURNER START UP PROCEDURE READ THE APPLICATICABLE SEQUENCE OF BURNER/PRIMARY GAS CONTROL OPERATION IN SECTION V SERVICE AND TROUBLESHOOTING BEFORE PROCEEDING. 1. Depress the combination gas valve manual control knob and turn to “OFF” position. (For location of the manual control knob, refer to Figure 17). Remove the 1/8” NPT pressure tap plug from the gas valve and install a hose barb fitting. Connect a manometer to the hose barb fitting. 2.
3. Turn on the main electrical power and set the thermostat or operation control to call for heat. Allow the burner to run a MINIMUM of 5 minutes to purge combustion chamber and appliance heat exchanger. 4. Set the thermostat or operating control below room temperature, shutting the burner “OFF” for 1 minute. This is will reset the primary control. 5. Depress the combination gas valve manual control now and turn to “ON” position. 6. Set the thermostat or operating control to call for heat.
If an O2 analyzer is used: COAIRFREE = 20.9 x COPPM (20.9 – %O2) If a CO2 analyzer is used: For Natural Gas: COAIRFREE = 11.7 x COPPM % CO2 For LP Gas: COAIRFREE = 13.8 x COPPM % CO2 Stack temperatures for furnaces and boilers are recommended to be between 350 and 400 degrees Fahrenheit. NOTE: Check overfire draft and adjust to NEGATIVE -0.01 (2.491 Pa) to -0.02 (4.982 Pa) inches w.c. during burner operation.
Orifice kits for the HSG200 and HSG400 burners are available from Wayne Combustion Systems. Some HSG burner models are sold to Original Equipment Manufacturers and are pre-set with the proper orifice for the firing rate and gas utilization for the specific equipment. Before attempting to convert this equipment from one gas to another, consult the equipment manual or contact the equipment manufacturer for the procedure on gas conversion.
SECTION V: SERVICE AND TROUBLESHOOTING HSG SERIES BURNER UTILIZING WAYNE 64420 SERIES IGNITION CONTROLS HSG burners with a spec number that contains a “D,” for example, 62377D, use Wayne ignition controls. Older burners that have a spec number containing a “C” use a Honeywell control. See next sections for information on these controls. Spec numbers can be found on HSG burners on a small label located below the T-shaped label on the back of the burner.
SEQUENCE OF OPERATION – HSG SERIES POWER GAS CONVERSION BURNER UTILIZING WAYNE P/N 64420-002 IGNITION CONTROL W/BUILT IN 30 SECOND PRE-PURGE On a call for heat, 24V goes to the motor start relay and air switch. Once the motor reaches operating rpm, combustion air pressure closes the air proving switch, energizing the ignition control. This Wayne ignition control has an internal 30 second pre-purge timer.
attempt to re-establish the main burner. If this does not occur within the 4 second trial for ignition period, S89E gas primary control will go into lockout de-energizing the gas valve and ignition transformer. To restart the system, the main power or thermostat must be de-energized momentarily, then re-energized. If at any time during the heat cycle, there is insufficient supply of combustion air to the burner, the air switch contacts will open, putting the system into lockout closing gas valve.
Figure 20: Flame Current Measurement, Top: Wayne control; Bottom: Honeywell control 62484 REV.
PROBE IGNITER FLAME SENSOR DIM “A” REF 1 5/8 in (41.3mm) 1 1/4 in (31.8mm) Figure 21: Igniter and Flame Sensor Probe Settings Figure 22: Burner Face and Flame Sensor Probe Location 62484 REV.
TROUBLESHOOTING GUIDE PRIMARY IGNITION CONTROLS MOTOR DOES NOT START Check voltage input to burner, 120 VAC. NO Diagnose reason for absence of voltage. NO Repair T-STAT or add jumper as necessary. OK Check continuity though 24 volt T-STAT if used, or if burner is cycled on-off through 120V circuit, T-T terminals must have jumper wire. OK Check low voltage transformer for 24 volt output. 24 VAC should be present across terminals 1 and 3 of the motor start relay.
IGNITION ARC ESTABLISHED – NO FLAME Reset Control – Motor starts – Completes 30 second pre-purge cycle and 4 second trial for ignition. NOTE: the burner motor will continue to operate during the lockout mode when the thermostat circuit is called for burner operation. OK Check for correct orifice/air setting relationship (Figures 11, 18, 19).
NO IGNITION ARC ESTABLISHED 1. Reset Control Motor starts – Completes 30 second pre-purge cycle. Gas valve opens, regulating adequate gas pressure. No flame established – Primary control locks out after 4 second trial for ignition period. In order for the functional test described in Step 2 to be made, the control must reset and the voltage measured during the 4 second trial for ignition period that occurs at the end of the 30 second prepurge. 2.
NO IGNITION – NO GAS FLOW Reset Control – Motor starts- After 30 second pre-purge cycle, motor continues to run but flame is not established. If using a Wayne control, check the diagnostic LED for an error code. If a “LINE VOLTAGE ERROR,” is indicated check the connection between earth ground and the burner chassis.
LOSES FLAME DURING CYCLE – CONTROL LOCKS OUT ON SAFETY Reset Control Completes 30 second pre-purge cycle. Flame is established. Sometimes the control locks out before thermostat or controlling circuit is satisfied If using a Wayne control, check the diagnostic LED for an error code. Consult the table below to troubleshoot the issue. Disconnect flame sensor lead from primary control. Connect (+) positive lead (dc) microampere meter to the primary control terminal.
BURNER CYCLES ERRATICALLY Check for proper thermostat installation and location. If thermostat is used, remove wires at T-T terminals and replace with jumper wire. If burner runs properly, check thermostat for proper operation. OK Check thermostat heat anticipator for correct setting. OK OK Set the anticipator to the correct value if adjustable type. If proper setting cannot be made, replace with compatible thermostat. OK Check low voltage circuit for bad wiring, electrical connections and/or switches.
SERVICING HSG SERIES BURNER (SERVICE TECHNICIAN ONLY) ELECTRICAL SHOCK HAZARD Make sure the main manual gas valve, manual control knob on the combination valve and electrical supply are turned off before opening burner or removing any parts for service. BURN HAZARD, HOT SURFACE Burner flange and air tube are hot when burner is in operation. Do not service this area during or immediately after operation. Allow area to cool. A.
Electrical Hazard If a jumper is used to check the pressure switch it must be removed or an unsafe operating condition can occur resulting in personal injury or death. 2. As mentioned above, the switch should never require maintenance. However a pinched tube will shut off the flow of pressurized air to the diaphragm creating a failure made similar to bad air proving switch. Always check to ensure that the clear tubing is not pinched. Make sure the spring cover is reinstalled over the tube. 3.
Figure 23: HSG Gas Train Assembly (INDIVIDUAL PARTS ONLY SOLD SEPARATELY. REFERENCE SECTION VI FOR PART NUMBERS) Figure 24: MOTOR/BLOWER ASSEMBLY TROUBLESHOOTING GUIDE Nuisance Lockouts/Flame Sensing Problems –HSG200 & HSG400 Gas Burners Wayne’s HSG series direct spark ignition (DSI) gas burners prove flame through the process of flame rectification. Flame rectification is achieved by the ignition control as it places a small voltage on the flame sensor.
simply the failure of the system to sense the establishment of the flame. Should this situation exist for a period of time longer than the ignition control’s stated lockout timing, the control will shut down or go into permanent lockout. The only way to get the burner to recycle is to break, and then reinstate power to the burner.
HSG WIRING DIAGRAMS HSG SERIES BURNER WITH WAYNE 64420-001 IGNITION CONTROL Figure 25: Wiring Diagram for Burners with Wayne 64420-001 Control 62484 REV.
HSG SERIES BURNER WITH WAYNE 64420-002 IGNITION CONTROL Figure 26: Wiring Diagram for Burners with Wayne 64420-002 Control 62484 REV.
HSG SERIES BURNER WITH HONEYWELL S89E GAS PRIMARY CONTROL Figure 27: Wiring Diagram for Burners with Honeywell S89E Control 62484 REV.
HSG SERIES BURNER WITH HONEYWELL S89F GAS PRIMARY CONTROL Figure 28: Wiring Diagram for Burners with Honeywell S89F Control 62484 REV.
SECTION VI: PARTS LIST AND EXPLODED VIEWS HSG200/400 PARTS LIST Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 15-16 17 18 19 20-21 22 23 24 25 26 27 28 29 30 31 Part No.
HSG200/400 PARTS LIST CONT. Item 32 33 34 35 36 37 38 39 40 41 42 43 Part No. 62909-001 62909-003 64095-001 63995-001 64460-001 64460-002 62404-002 62304 62402-KIT 62402-001 62410-001 62401-001 62385-001 ---------------62374-004 62459-001 62459-002 21760-011 64635-001 Description 8" (203.2mm) Ignition Wire - S89E & S89F controls only; 6", 6 1/4" Burner 14" (355.
Figure 29 continued: Junction Box Assemblies Exploded 62484 REV.
Figure 30: Motor Assembly Exploded Figure 31: Gun Assembly Exploded 62484 REV.
Figure 32: HSG Series Burner Exploded 13.2 (335 mm) REF. 7.7 in (195mm) 15.25 in (377 mm) 7 in (178 mm) Figure 33: Outer Dimensions of HSG Series Burner 62484 REV.
SECTION VII: WARRANTY LIMITED WARRANTIES FOR OIL AND GAS BURNERS, MADE BY WAYNE AND USED IN RESIDENTIAL INSTALLATIONS WAYNE COMBUSTION SYSTEMS (“WAYNE”) warrants to those who purchase its Oil Burner Models for resale or for incorporation into a product of resale, that its burner is free from defects in material and workmanship under normal use and service for thirty-six (36) months from the date of manufacture.
NOTES 62484 REV.
