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Wayne HSG200 User Manual

Other manuals for HSG200: Manual, Instructions Manual
Manual is about: Gas Burners

Summary of HSG200

  • Page 2: Hazard Definitions:

    2 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.Waynecombu...

  • Page 3

    3 hazard level pictogram type hazard explanation fire or explosion 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 ...

  • Page 4

    4 hazard level pictogram type hazard explanation proposition 65 material 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,...

  • Page 5: Installation Log

    5 installation log burner model: specification number: fuel (natural or lp): gas orifice size: inlet gas pressure (in. W.C.): co 2 (%): o 2 (%): co (ppm): installer’s name: contractor name: contractor address: contractor phone number: contractor license #: date of installation: comments about instal...

  • Page 6

    6 contents section i: installation and setup .......................................................................................................... 7 visual inspection of the heating system .......................................................................................... 7 inspection of...

  • Page 7

    7 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 burn...

  • Page 8

    8 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. 1, 2, and 3 mark alternate locations for air from out...

  • Page 9

    9 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 gas...

  • Page 10

    10 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...

  • Page 11

    11 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 ...

  • Page 12

    12 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. Burner installation the hsg200 and hsg400 power gas burners were designed for converting oil fired furnaces and...

  • Page 13

    13 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 ...

  • Page 14

    14 hsg series power gas converion burner orifice chart figure 11: orifice selection guide note: for 50 cycle application de-rate input by 15% note: the btu/hr input values in figure 11 show the approximate hourly input of the burner for the various orifice sizes. To determine the actual input of the...

  • Page 15

    15 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 ha...

  • Page 16

    16 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 gasket orifice cap.

  • Page 17

    17 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 ...

  • Page 18

    18 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. It should be clea...

  • Page 19

    19 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.. Maximum capacity of pipe size in btu/hr length of pipe (ft) 1/2” 3/4” 1” 1 1/4” 1 1/2” 1...

  • Page 20

    20 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.. Maximum capacity of tube size in btu/hr pipe size 1/2” 5/8” 3/4” 7/8” length (feet) maximum capacity in btu/hr 10 110,000 206,000 348,000 536,0...

  • Page 21

    21 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 app...

  • Page 22

    22 section ii: initial start up figure 17: gas valves for hsg series burner hsg400 gas valve robertshaw 7000 derhc hsg400 gas valve robertshaw 7000 derhc hsg200/400 gas valve honeywell vr8305 hsg200/400 gas valve honeywell vr8305.

  • Page 23

    23 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, ref...

  • Page 24

    24 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” ...

  • Page 25

    25 if an o 2 analyzer is used: co airfree = x co ppm if a co 2 analyzer is used: for natural gas: co airfree = x co ppm for lp gas: co airfree = x co ppm stack temperatures for furnaces and boilers are recommended to be between 350 and 400 degrees fahrenheit. Note: check overfire draft and adjust to...

  • Page 26

    26 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 ...

  • Page 27

    27 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 se...

  • Page 28

    28 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 s...

  • Page 29

    29 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. See figur...

  • Page 30

    30 figure 20: flame current measurement, top: wayne control; bottom: honeywell control.

  • Page 31

    31 probe dim “a” ref igniter 1 5/8 in (41.3mm) flame sensor 1 1/4 in (31.8mm) figure 21: igniter and flame sensor probe settings figure 22: burner face and flame sensor probe location.

  • Page 32

    32 troubleshooting guide primary ignition controls motor does not start check voltage input to burner, 120 vac. Check low voltage transformer for 24 volt output. 24 vac should be present across terminals 1 and 3 of the motor start relay. Ok ok check for 120 volts ac between terminal 2 and ground and...

  • Page 33

    33 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 ok check for correct orifi...

  • Page 34

    34 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...

  • Page 35

    35 no ignition – no gas flow wayne control error codes number of flashes error green normal operation 1 no flame during trial 3 gas valve relay fail 4 line voltage error 5 internal control error ok no ok ok no ok no 3. Check for 24vac across the primary control terminals labeled “valve” and “gnd (va...

  • Page 36

    36 loses flame during cycle – control locks out on safety number of flashes error green normal operation 1 no flame during trial 3 gas valve relay fail 4 line voltage error 5 internal control error if using a wayne control, check the diagnostic led for an error code. Consult the table below to troub...

  • Page 37

    37 burner cycles erratically note: when the thermostat wires terminate on the hsg primary control box “t” terminals, the heat anticipator setting value for the hsg burner is determined by adding the primary control current to the gas valve current. The result is the anticipator setting. (example: 0....

  • Page 38

    38 servicing hsg series burner (service technician only) a. Burner head and electrode/sensor assembly the burner head, electrode, sensor probe, combination valve, orifice housing and housing cover are part of the gas train assembly which can be removed as one unit (see figure 23). 1. Disconnect the ...

  • Page 39

    39 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 ...

  • Page 40

    40 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 ...

  • Page 41

    41 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 ...

  • Page 42

    42 hsg wiring diagrams hsg series burner with wayne 64420-001 ignition control figure 25: wiring diagram for burners with wayne 64420-001 control.

  • Page 43

    43 hsg series burner with wayne 64420-002 ignition control figure 26: wiring diagram for burners with wayne 64420-002 control.

  • Page 44

    44 hsg series burner with honeywell s89e gas primary control figure 27: wiring diagram for burners with honeywell s89e control.

  • Page 45

    45 hsg series burner with honeywell s89f gas primary control figure 28: wiring diagram for burners with honeywell s89f control.

  • Page 46

    46 section vi: parts list and exploded views hsg200/400 parts list item part no. Description 1 100934-001 burner housing 2 62576-ser6 air tube - hsg200 6" (152.4mm) 63270-004 air tube - hsg400 6 1/4" (158.75mm) 62576-ser9 air tube - hsg200 9" (228.6mm) 63270-015 air tube - hsg400 9" (228.6mm) 62576-...

  • Page 47

    47 hsg200/400 parts list cont. Item part no. Description 32 62909-001 8" (203.2mm) ignition wire - s89e & s89f controls only; 6", 6 1/4" burner 62909-003 14" (355.6mm) ignition wire- s89e & s89f controls only; 9 ”, 12", 15" burner 64095-001 ignition wire - 500mm cable (230v 50/60hz) use with 64051-0...

  • Page 48

    48 figure 29 continued: junction box assemblies exploded figure 30: motor assembly exploded.

  • Page 49

    49 figure 31: gun assembly exploded figure 32: hsg series burner exploded.

  • Page 50

    50 figure 33: outer dimensions of hsg series burner 13.2 (335 mm) ref. 7.7 in (195mm) 7 in (178 mm) 15.25 in (377 mm).

  • Page 51

    51 section vii: warranty 4. A burner so repaired will then carry the limited warranty equal to the unexpired portion of the original burner limited warranty. 5. If inspection by wayne does not disclose any defect covered by this limited warranty, the burner or burner component(s) will be either repa...

  • Page 52: Notes

    52 notes.