Wayne HSG200, User Manual

Page 1: ...120 Vac 60 Hz 230 Vac 50 60 Hz 1 Phase AIR TUBE DIAMETER 4 in 101 6 mm MOUNTING Adjustable Flange is standard Pedestal Mount is Optional Gas Burners CSA CERTIFICATION 189810 1154925 ANSI Z21 17 MASS G...

Page 2: ...that appears next to the warning which can be either written or pictorially presented NEVER remove or tamper with the warning labels safety devices or guards fitted on the unit Wayne Combustion System...

Page 3: ...w blower to continue running Carbon Monoxide Poisoning Carbon monoxide is a colorless odorless gas that can kill Follow these rules to control carbon monoxide Do not use this burner if in an unvented...

Page 4: ...re 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 call...

Page 5: ...ER S NAME CONTRACTOR NAME CONTRACTOR ADDRESS CONTRACTOR PHONE NUMBER CONTRACTOR LICENSE DATE OF INSTALLATION COMMENTS ABOUT INSTALLATION START UP THESE INSTRUCTIONS SHOULD BE AFFIXED TO THE BURNER OR...

Page 6: ...TROL SWITCHES 21 INSTALLATION OF THERMOSTAT 21 SECTION II INITIAL START UP 22 INITIAL BURNER START UP PROCEDURE 23 COMBUSTION ADJUSTMENT OF BURNER 24 SECTION III GAS CONVERSION 25 SECTION IV CONSUMER...

Page 7: ...d draft hood dilution air a In open basements of homes of normal construction without basement storm windows or tight stair doors infiltration of combustion air is usually sufficient to replace that d...

Page 8: ...gauge should be in good order On a closed system the feed and pressure relief valves shall be in proper operating condition If there is an expansion tank on a closed system inspection should show it t...

Page 9: ...or flue gas leakage into or out of the combustion chamber Warm Air Furnaces Make certain the electrical characteristics of the fan and limit switch correspond to those required by this burner and tha...

Page 10: ...ric damper suitable for gas firing per Figure 4 The draft control should be sized the same as the flue pipe per Figure 5 Refer to the barometric draft regulator manufacturer s instructions for complet...

Page 11: ...the combustion chamber is larger than the 4 102 mm diameter high temperature cement should be used to reduce the opening to 4 102 mm diameter IN NO CASE SHOULD THE TUBE BE ALLOWED TO EXTEND INTO THE C...

Page 12: ...n the furnace wall adjusting orientation as necessary until the bolt pattern of the furnace allows the flange to sit flush See Figure 10 for flange dimensions Note the orientation of the flange and re...

Page 13: ...rner has been determined the gas orifice must be properly sized The HSG200 and HSG400 power gas conversion burners are approved for use with natural and LP gas only The HSG200 and HSG400 burner models...

Page 14: ...or LP 5 5 w c 1400 Pa Minimum 14 w c 3500 Pa Maximum De rate input for altitude over 2000 ft 609 6 m by 4 each 1000 ft 304 8 m above sea level IMPORTANT MANIFOLD PRESSURE ADJUSTMENTS CAN ONLY BE MADE...

Page 15: ...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 The HSG Series burners come with an orifice kit that contains all...

Page 16: ...G 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 GASK...

Page 17: ...pply line to the burner A union shall be installed in the gas line upstream from the control manifold and downstream from the sediment trap or drip leg See Figure 16 A 1 8 NPT plugged tapping port acc...

Page 18: ...s or hangers Butt or lap welded pipe should not be bent Note Each elbow union and tee adds approximately 2 5 feet of pipe The gas piping should be so installed so as to prevent an accumulation of cond...

Page 19: ...ngle or second stage low pressure regulator and appliance Maximum Capacity of Pipe Size in Btu hr Pipe Size 1 2 3 4 1 1 1 4 1 1 2 2 3 Actual ID 0 622 0 824 1 049 1 38 1 61 2 067 3 068 Length of Pipe f...

Page 20: ...ir Do not bleed the air into the appliance Be sure to relight all the gas pilots on other appliances ELECTRICAL WIRING OF BURNER The conversion burner is shipped completely wired It is only necessary...

Page 21: ...tors lamps rays of the sun or mounted on a wall near pipes warm air ducts or chimney flue Any hole in the plaster or panel through which the thermostat wires pass should be sealed to prevent drafts Th...

Page 22: ...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 Hon...

Page 23: ...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 fit...

Page 24: ...er or smaller orifice should be used Refer to orifice chart Figure 11 9 A more accurate Btu hr kW input can be determined by using the natural gas service meter with only the burner on all other gas a...

Page 25: ...mall amount of thread sealant to the plug before replacing SECTION III GAS CONVERSION The HSG200 and HSG400 can operate on either natural gas or LP gas To convert an HSG burner from one gas to another...

Page 26: ...same size and type If circuit breaker is in the service box check position of indicator If tripped reset 3 Check on off switch for the burner circuit it may have been accidentally turned off It is ad...

Page 27: ...flow to the burner head Simultaneously the ignition control energizes the ignition transformer producing a spark at the electrode establishing main burner flame This trial for ignition period lasts fo...

Page 28: ...N 62530 001 On a call for heat voltage 24V is applied to the motor start relay and air switch Once the blower motor reaches operating rpm combustion air pressure causes the air proving switch to clos...

Page 29: ...me during the heat cycle there is an insufficient supply of combustion air to the burner the air switch will open putting the system into lockout closing the gas valve See Figure 28 for the wiring dia...

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: ...OK Check electrical wiring and connections Does motor shaft turn freely OK OK Replace motor Diagnose reason for absence of voltage NO NO OK Replace 24VAC Transformer Check electrical wiring and conne...

Page 33: ...ing functional test to be made the control must be reset and the tests monitored during the 4 second trial for ignition period that occurs at the END of the 30 second pre purge Check for 24 volts AC a...

Page 34: ...unction of the blue primary control lead and black ignition transformer lead 3 Check electrical wiring and connections at ignition transformer 4 Check high voltage lead and connection to igniter elect...

Page 35: ...or opening b Electrical continuity switch is normally open c Replace switch as necessary Check when applicable external 30 second pre purge timer jumper around timer from air switch Should primary ig...

Page 36: ...ed for dependable operation Flame sensor microampere reading is too weak or unstable Probable causes of erratic lockout 1 Flame proving circuit grounded by moisture 2 Damaged insulation on flame senso...

Page 37: ...e usually are stenciled on the valve body and must be added together to obtain the correct sum Example 0 4 0 2 0 6 amps When the current draw cannot be determined accurately by the above method measur...

Page 38: ...essary Make sure that the ignition and sensor probe wires go to the correct electrodes and the ignition wire boot is in place over the electrode porcelain 6 Make sure that the burner tube end is prope...

Page 39: ...e flame indicates a deficiency of combustion air 2 The side plate motor and blower wheel are removed as one assembly Disconnect the motor wire inside the junction box beneath the ignition transformers...

Page 40: ...ation Flame rectification is achieved by the ignition control as it places a small voltage on the flame sensor When the flame sensor is surrounded by flame the voltage on the flame sensor leaks to gro...

Page 41: ...nding out of the flame sensor against the inside surface of the air tube The flame sensor probe should be free of soot and creosote Deposits may insulate the probe leading it not to pass the electrica...

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: ...ations Only 64420 002 Ignition Control Wayne with 30 sec Pre purge 15 100377 002 Damper Indicator Pointer 16 100429 Damper Decal 15 16 100373 KIT Includes 100373 002 100429 100377 002 and 100410 17 63...

Page 47: ...Ignition Wire Use with Wayne control 9 12 15 Burner 33 62404 002 Top Plate Housing Cover 34 62304 Strain Relief Bushing Ignition Wire 62402 KIT Includes items 35 38 35 62402 001 Orifice Housing 36 624...

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: ...D GAS BURNERS MADE BY WAYNE AND USED IN RESIDENTIAL INSTALLATIONS LIMITED WARRANTIES FOR OIL AND GAS BURNERS MADE BY WAYNE AND USED IN RESIDENTIAL INSTALLATIONS WAYNE COMBUSTION SYSTEMS WAYNE warrants...

Page 52: ...52 NOTES...