Publication Date: 12/13/2010

MODELS
8.J
.".JIIIiI!lN
HSG200
HSG400
A SCOTT FETZER COMPANY
801 GLASGOW AVE.
FORT WAYNE, IN 46803
GAS BURNERS
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.
C
fi@ US
- Do not store or use gasoline or other flammable MEA
vapors and liquids in the vicinity of this or any other MASS.
appliance. ANSIZ21.17

- WHAT TO DO IF YOU SMELL GAS APPROVED

Do not try to light the appliance. FOR USE CITY
OF NEW YORK
Do not touch any electrical switch; do not use any MEA 49-83-E
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.
- 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]
 SPECIFICATIONS
SPECIFICATIONS MODELS
MODELS
HSG2OO,
HSG200, HSG4OO
HSG400
NATURALOR
NATURAL PROPANE
OR PROPANE GAS
GAS
NOTE:Dimensions
NOTE: Dimensionsin ( )) are
in informational
are informational only. Englishvalues
only. English takepriority.
valuestake priority.
HSG2OO
HSG200
MaximumInput
Maximum lnputCapacity
Capacity - 200 MBtu/HR (211000
200 MBtu/HR (211000 kJ)
kJ)
MinimumInput
Minimum InputCapacity
Capacity 60 MBtu/HR
- 60 (63300kJ)
MBtu/HR(63300 kJ)
HSG4OO
HSG400
MaximumInput
Maximum Capacity - 400
InputCapacity MBtu/HR(422000
400 MBtu/HR kJ)
(422000 kJ)
Minimum
Minimum Input
Input Capacity
Capacity - 200 MBtu/HR (211000
200 MBtuiHR (211000 kJ)
kJ)
SUPPLYLINE
SUPPLY LINE PRESSURE REQUIRED:
PRESSURE REQUIRED: Natural or Propane
Natural or Propane 5.5 W.C.(1370
5.5W.C. Pa)Minimum,
(1370 Pa) 14.0WC.
Minimum, 14.0 (3487Pa)
W.C. (3487 Pa)
Maximum
Maximum
AIR
AIR TUBE DIAMETER:
TUBE DIAMETER: 4 inches (101.6mm)
inches (101.6 mm)
AIR TUBELENGTHS:
AIR TUBE LENGTHS: HSG200
HSG200 inches
6 inches (152.4mm)
(152.4 mm)
(See
(See Fig. tor
12Cfor
Fig. 12C HSG400
HSG400 6.25inches
6.25 inches (158.75 mm)
(158.75 mm)
OverallDimensions)
Overall Dimensions) HSG200|4O0
HSG200/400 inches
9.00inches
9.00 (228.6
(228.6 mm)
mm)
HSG200/400
HSG200/400 12.00inches
12.00 inches (304.8
(304.8 mm)
mm)
MOUNTING:
MOUNTING: Adjustable
Adjustable flange standard (deduct
flange standard (deduct 1 1/8
1/8 inch (28.575mm)
inch (28.575 mm)from
from above
above air
air tube lengthswhen
tube lengths when using
using
flange).
flange). Optional pedestal
Optional pedestal mounting.
mounting.
STANDARDVOLTAGE:
STANDARD VOLTAGE: 120VAC I60HZl
120 VAC 1 60 HZ/11 Phase
Phase
120 VAC
120 | 50
VAC 1 50 HZ Phase (Special
HZ/11 Phase (Special motor
motor installed
installed with
with max capacity reduced
max capacity reduced 20%)
20%)
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
GAS VALVE=314x 3/4 (19.05
VALVE: 3/4 x 3/4 (19.05 mm
mm x 19.05
19.05 mm)
mm) NPT
NPT 3 Function
Function Redundant 24VAC
Redundant 24 VAC
.200 MBtu/HR (211000
*200 MBtu/HR kJ) (200,000
(211000 kJ) (200,000 BTU [58.62 kW]
BTU [58.62 / HR)
kW] 1 HR) oror 400 MBtu/HR (42200
400 MBtu/HR kJ) (400,000
(42200 kJ) (400,000 BTU [117.24 kW]
BTU [117.24 kW]
/1 HR)
HR) at sea level.
at sea level. Derate
Derate input
input for
for altitude over 2000
altitude over ft. (609.6
2000 tt. (609.6 m) by 4"/.
m) by 4% each
each 1000 ft. (304.8
1000 ft. (304.8 m)
m) above sea level.
above sea level.
(one gallon
(one gallon (3.79
(3.79 L)
L) fueloil = 140
fuel oil = MBtu/HR (14770
140 MBtu/HR (14770 kJ)).
kJ)).
CONTENTS
CONTENTS
PAGE
PAGE
sEcTtoN
SECTION I tNSTALLATION
INSTALLATION ............ 1
..1
A. GENERAL 2
B. VENTILATION 2
C.
C. HEATING
HEATING APPLIANCE
APPLIANCE INSPECTION.
INSPECTION .........-...-.2
2
D. CHIMNEY, FLUE
D. CHIMNEY FLUE PIPE
PIPE AND
AND DRAFT
DRAFT CONTROL
CONTROL ..............2.3
2-3
E.
E. COMBUSTTON
COMBUSTION CHAMBER
CHAMBER .............4
4
F. GAS PIPING 4
G.
G. ELECTRICAL
ELECTRiCAL 5
H.
H. MAIN
MAIN BURNER
BURNER ORIFICE SIZING AND
ORIFICE SIZING AND INSTALLATION
INSTALLATION ........................5
5
r.
I. CoMBUSTTON
COMBUSTION GAS
GAS VA1VE........
VALVE ........................6
6
SECTION II INITIAL START UP 7-8
SECTION
SECTION III
III OPERATION AND TROUBLESHOOTING..
OPERATION AND TROUBLESHOOTING ...........9.14
9-14
SECTION
SECTION IV
IV SERVICE
SERVICE 15-16
PARTS LISTS 17
EXPLODED
EXPLODED VIEW
VIEW 18
TECHNICAL INFORMATION.,........
TECHNICAL INFORMATION 19
WARRANTy 20
CONSUMER INSTRUCTIONS 21
 SECTIONI
SECTION
INSTALLATION
INSTALLATION

A. GENERAL
A. GENERAL exchanger
exchanger for obvious
for obviousand potential
and potential gas leaks.
fluegas
flue leaks.
Cementall
Cement joints around
all joints aroundthe
the appliance
appliancebase and
base and
The Wayne
The Wayne HSG200
HSG200and and HSG400
HSG400power power gasgas accessopenings
access openings prevent
to prevent
to airand/or
air gasleakage
fluegas
and/orflue leakage
conversion
conversion burnersare
burners are adaptable
adaptable to mosttypes
to most typesof of intoor
into or out
outof
of the
thecombustion
combustion chamber.
chamber.
centralheating
central plantspreviously
heatingplants previously fired by
fired poweroil
by power oil
burners.Typical
burners. Typicalheating plantsare
heatingplants gravityand
aregravity andforced
forced WarmAir
Warm Air Furnaces*
Furnaces*- MakeMake certain
certainthe
the electrical
electrical
air circulation
air circulation furnaces,hot
furnaces, hot water,
water,steam
steamoror vapor
vapor characteristics
characteristics ofthe
of fanand
thefan limitswitch
andlimit switchcorrespond
correspond to
to
boilers. Powerburner
boilers.Power burnerdesignmakes
design makesthe HSG200
theHSG200 and
and those required
thoserequired by this
by this burner
burnerand
and that
that they
they are in
are in
HSG400 well
HSG400 well suited for "negative
suited for "negativedraft"
draft" fired
fired properworking
proper workingorder.
order.
appliances
appliances wherean
where anoil
oilburner is being
burneris beingreplaced.
replaced.
Hot WaterBoilers*
HotWater Makecertain
Boilers*- Make certainwater
watertemperature
temperature
lnstallation
Installation of these
of powergas
these power gas conversion
conversionburner
burner and altitude
and altitudegauges, pressurerelief
gauges,pressure reliefvalves
valvesare
are in
in
modelsmust
models must conform
conformto to local
localcodes,
codes,or in their
or in their properworking
proper workingorder.
order.
absence,the
absence, AmericanNational
the American NationalStandard for the
Standardfor the
Installation
Installation DomesticGas
of Domestic
of Gas Conversion Burners.
ConversionBurners, Boilers*
SteamBoilers*
Steam Makecertain
- Make certainthe
the system
systemis pressure
is pressure
ANS|Z21.8
ANSIZ21.8 and the
- and the National
NationalFlue
Flue Gas
Gas Code,
Code, tight,and
tight, andthat
thatthe pressuregage
the pressure gageand pop off
and pop off safety
safety
ANSlZ223.1
ANSIZ223.1 or current
or current standard
standard year.
year. valveare
valve arein properworking
in proper workingorder. Existing
order.Existing watersight
water sight
glass permitsclear
glasspermits clearobservation
observation of boiler
of boilerwater
waterlevel.
level.
NOTICE:
NOTICE: ANSIor
A1'JSI localinstallation
or local installationcodecompliance
code is
compliance
is *Whereapplicable,
thesole
the soleresponsibility
responsibility of
of the
the qualified
qualified installer.
installer. *Where applicable, existing
existing temperature
temperature of pressure
of pressure
limitswitch
limit switchor lowwater
or low watercut-off
cut-offswitch operation
switchoperation and
and
B. VENTILATION
B. VENTILATION electrical
electrical characteristics
characteristics shallbe
shall bechecked
checked to determine
to determine
theircompatibility
their compatibility to the
to gas control
the gas controlcircuitry
circuitry of this
of this
The HSG
The HSGconversion
conversion burnermodels
burner modelscovered
covered by this
by this burner.
burner.
manualshall
manual not be
shallnot installed
be installed in an
in an appliance
appliance located
located
normalair
wherenormal
where aircirculation
circulation or infiltration
or infiltration limitedin
is limited
is in D. CHIMNEY,
D. CHIMNEY, FLUEPIPE
FLUE PIPEAND
ANDDRAFT
DRAFTCONTROL
CONTROL
providing
providing allthe
all theair
air necessary
necessary propercombustion
for proper
for combustion
anddraft
and drafthood
hooddilution
dilutionair.
air. The chimney
The chimneyshould
should be inspectedfor
be inspected for unsafe
unsafe
conditions
conditions such as
such as excessive
excessivesoot
soot accumulation,
accumulation,
ln open
In basements
ooenbasements of homes
of homesof of normal
normalconstruction
construction deteriorated
deteriorated masonry,
masonry, blockage
blockage potential
or potential
or blockage.
blockage.
(without
(without basement
basement storm windowsor
stormwindows or tight
tightstair
stairdoors)
doors)
infiltration
infiltration of combustion
of combustion is usually
air is
air usuallysufficient to
sufficientto NOTICE:
NOTICE: Nomanually
No manuallyadjustable
adjustable pipedamper
fluepipe
flue damperis
is
replace
replace thatdrawn
that drawnup
up the flue,so
the flue, so special provisions
specialprovisions permitted
permitted on any
on gasburner
anygas installation.
burnerinstallation.
areseldom
are necessary.
seldomnecessary.
Thechimney
The chimney belined
shouldbe
should withaa corrosion
linedwith corrosion resistant
resistant
Whenthe
When heating
theheating appliance
appliance isinstalled
is installed inaa tightly
in tightly closed
closed material,Iflf the
material. thechimney
chimney is unlined,
is unlined,consult
consult yourlocal
your local
roomwithout
room ventilation
withoutventilation openings
openings to outdoors,
to outdoors, or other
or other gasutility
gas utilityfor
forrecommendations.
recommendations.
rooms, provisions
rooms,provisions shallbe
shall be made
madefor for supplying
supplying for
air for
air
WARNING:Under
WARNING: Undernono circumstances
circumstances theflue
shouldthe
should flue
combustion
combustion through
through special
special openings,
openings, nearthe
onenear
one thefloor
floor pipebe
pipe beconnected
connected to thechimney
tothe chimney ofan
of anopen fireplace.
openfireplace.
lineand
line andthe
theother nearthe
othernear theceiling.
ceiling.Each
Eachisis to
to be
be sized
sized
on the
on thebasis
basisof
of one
onesquare
squareinch (645.2mm')
inch(645.2mm 2
or more
) or moreof of Theflue
The pipeshould
fluepipe besized
shouldbe to carry
sizedto carryof
of the
theflue gases
fluegases
freearea
free areaeach 1,000BTU
each1,000 (.29kW)
BTU(.29kW) input perhour.
inputper hour. outlined
asoutlined
as in Figure
in Figure 1.
1.
Whenthe
When thebuilding
building isof
is of unusually
unusually tightconstruction,
tight construction, has
has
kitchenand/or
kitchen and/orbathroom
bathroom ventilation
ventilation fanswhich
fans whichmaymaybe be INPUT
INPUT DRAFTHOOD
DRAFTHOOD
usedfor
used for exhausting
exhausting air to outdoors,
air to outdoors, or hasaa vented
or has vented BTU/HR
BTU/HR (kW/HR)
(kW/HR) F L UEPIPE
FLUE P I P ESIZE
SIZE
fireplace,
fireplace, itit is
is recommended
recommended that combustion
that combustion air be
air be
UPto
UP to-120
-120MBH
MBH (35.172kW)
(35.172kW) 5 INCH
51NCH (127mm)
(127mm) DIAMETER
DIAMETER
supplied
supplied to the
to thefurnace
furnaceroomroomthrough
through intakes
intakes extending
extending
120MBtu/HR
120 MBtu/HR 135172kM
(35172kW) - 180MBH
-180 MBH (52.758kW)
(52.758kW) INCH
6 INCH (152.4mm)
(152.4mm) DIAMETER
DIAMETER
to the
to outsideof
the outside the building
of the building andterminating
and terminating in down
in down
turned fittings,
turnedfittings, suitably
suitably arranged
arranged prevent
to prevent
to obstruction
obstruction 180MBtu/HR
180 MBtu/HR (52.758kM
(52.758kW) - 250 MBH
250MBH (73.275kW)
(73.275kW) 7 INCH
INCH (177.8mm)
{177.8mm) DIAMETER
DIAMETER
fromsnow
from snowor rain,and
or rain, andincluding
including protecting
a protecting
a screennot
screen not 250MBtu/HR
250 MBtu/HR f3.275k$- 320
(73.275kW) 320MBH
MBH {93.792kW)
(93.792kW) 8 INCH
8INCH (203.2mm)
(203.2mm) DIAMETER
DIAMETER
smaller
smaller than1/4
than 1/4inch (6.35mm)
inch(6.35mm) mesh.
mesh. 320MBlu/HR
320 MBtu/HR (93792kW)-
(93.792kW)- 410MBH
410 MBH (120.171kW)
(120171 kW) 9
I INCH
INCH (228.6mm)
(228.6mm) DIAMETER
DIAMETER

c.
C. HEATING
HEATING APPLIANCE
APPLIANCE INSPECTION
INSPECTION
Figure1
Figure
the appliance
Clean the
Clean applianceheatheat exchanger interior,
exchangerinterior,
combustion
combustion chamberand
chamber flueconnections.
andflue connections. Remove
Remove Strict compliance
Strict complianceto to appropriate codes should
appropriatecodes be made
should be made
alladhering
all adheringtars,scale,
tars, scale,dirt
dirtand
andsoot. lnspect
soot. Inspect theheat
the heat regardingflue
regarding pipeclearances
flue pipe fromcombustible
clearancesfrom materials,
combustiblematerials.
PAGE2
PAGE
Pitch
Pitch the
the horizontal
horizontal run
run of
of the flue pipe
the flue pipe upward
upward 1/4
1/4 inch
inch The
The draft
draft control
control should be hood
should be type per
hood type per Figure
Figure 2 or,lF
or, IF
(6.35mm) per foot(.305m) or more. Run directly
(6.35mm) per foot (.305m) or more. Run directly to the
to the APPROVED
APPROVED BY BY LOCAL
LOCAL AUTHORITIES,
AUTHORITIES, a single single
chimney, fasten joints
chimney, fasten joints securely
securely and
and support
support horizontal
horizontal barometric
barometric damper for gas
suitable for
damper suitable firing per
gas firing per Figure
Figure 3. 3.
runs to prevent
runs to prevent sagging.
sagging. The draft control should be sized the
The draft control should be sized the same same as the flue
as the flue
pipe
pipe per
per Figure
Figure 1,1, and
and should
should be
be located
located higher
higher than
than the
the
lfIf the flue pipe
the flue pipe must
must be extra long,
be extra long, it's
it's size
size should
should bebe highest part
highest part on
on the
the appliance flue passage.
appliance flue passage. Refer
Refer to
to the
the
increased.
increased. The The horizontal
horizontal length
length of
of the flue pipe
the flue pipe should
should barometric
barometric draft
draft regulator
regulator manufacturer's
manufacturer's instructions
instructions for
for
not
not exceed
exceed the
the height
height of
of the
the chimney
chimney above
above the
the flue
flue complete
complete detail.
detail.
connection.
connection.
NOTICE:
NOTICE: Should
Should the flue pass
the flue through a partition,
pass through partition,
PITCH
PITCH HOBIZONTAL
HORIZONTAL the
the draft
draft control
control must
must be located
located in the
the
RUN 1/4" (6.35mm)
RUN 1/4" (6.35mm) MlN.
MIN. DO NOT EXTEND
PER FOOT (.gosM)
PER FOOT (.305M) FLUE PIPE BEYOND same room
same room as the
the heating
heating appliance.
appliance.
INSIDE OF CHIMNEY
PITCH
PITCH HORIZONTAL
HORIZONTAL
BUN 1/4" (6.3smm)
RUN 1/4" (6.35mm) MlN.
MIN.
DO
DO NOT
NOT EXTEND
EXTEND
PER FOOT (.3osrV)
PEF FOOT (.305M)
FLUE
FLUE PIPE
PIPE BEYONO
BEYOND
VERTICAL
VERTICAL INSIDE
INSIDE OF
OF CHIMNEY
CHIMNEY
DRAFT
DRAFT HOOD
HOOD SINGLE ACTING
SINGLE ACTING
BAROMETRIC
BAROMETRIC
DRAFT
DRAFT CONTROL
CONTROL

BULL HEAD TEE

REDUCER COFFOSION
CORROSION
RESISTANT
RESISTANT LINING
LINING

CORROSION -=-+--1------'"
RESISTANT LINING
CLEANOUT
CLEANOUT

SELECT
SELECT EITHER
EITHER CHIMNEY
HORIZTONAL
HORIZTONAL OR
OR CLEANOUT
VEFTICAL
VERTICAL DBAFT
DRAFT HOOD
HOOD 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
CHAMBER LINER
CHAMBEB LINER

TO
TO PROTECT
PROTECT PROPERLY
PROPERLY
LOCATE
LOCATE END
END OF
OFBURNEF
BURNER
HSG
HSG - TUBE.
TUBE. POSITION
POSITIONTUBE
TUBE 1/2'
112"
BURNER
BURNER ((12.7mm)
12.7m m SH
)SHORT
OR TOF
OF IN SID E
INSIDE
OF
OF COMBUSTION
COMBUSTION
CHAMBEB
CHAMBER

FORCED
FORCED AIR
AIR FURNACE
FURNACE
Figure
Figure 44

..,,, ,,,,,
, , _ ... y .. ..l .. .,.. .. .J. ...
,,
y

,,
.. __

, . ,,
EXISTING
EXISTINGOR
OR
ADDED
ADDEDTARGET
TARGET ,
TO
TO BACK
BACKOF
OFCOMBUS-
COMBUS EXISTING
EXISTING
TION
TIONCHAMBER
CHAMBER PREFABRICATEO
PREFABRICATED
COMBUSTION
COMBUSTION
CHAIV]BEB
CHAMBERLINEFI
LINER
TO
TOPROTECT
PROTECTPBOPERLY
PROPERLY TO
TOPROTECT
PROTECTPROPERLY
PROPERLY
LOCATE
LOCATEEND
ENDOF
OFBURNER
BURNER LOCATE
LOCATE END
ENDOFOFBURNEF
BURNER
TUBE. POSITION
TUBE. POSITIONTUBE
TUBE 1/2'
1/2" HSG TUBE.
TUBE. POSITION
POSITIONTUBE
TUBE 1/2"
1/2"
(12.7mm)
(12.7mm) SHORT OFINSIDE
SHORT OF BURNER (12.7mm)
INSIDE (12.7mm)SHOBT
SHORTOFOFINSIDE
INSIDE
OF
OFCOMBUSTION
COMBUSTION OF
OFCOMBUSTION
COMBUSTION
CHAI\4BER
CHAMBER CHAMBEF
CHAMBER

HOT
HOT WATER
WATER OR
OR STEAM
STEAM BOILER
BOILER WITH
WITH HOT
HOT WATER
WATER OR
OR STEAM
STEAM BOILER
BOILER WITH
WITH
COMBUSTION
COMBUSTION CHAMBER
CHAMBER TARGET
TARGET COMBUSTION
COMBUSTION CHAMBER
CHAMBER LINER
LINER
Figure
Figure 55 Figure
Figure 66
PAGE
PAGE 33
E. COMBUSTION
E. COMBUSTION CHAMBER
CHAMBER F. GAS
F. PIPING
GAS PIPING
A combustion
A combustionchamber
chamberis is normally
normallyrequired
requiredto to NOTICE:All
NOTICE: pipingmust
All piping mustcomply withstate
complywith and/or
stateandlor
local codes.
local codes. The The available
availablegas gas supply pressure
supply pressure
protectnon-heat
protect non-heattransfer
transfersurfaces,
surfaces,and andto provideaa
to provide
shouldbe
should be within
withinminimum
minimumand andmaximum
maximumpressures pressures
radiantbed
radiant for rapid
bed for rapid heat
heat transfer
transferto to the primary
the primary gassupply
shownin
shown inthe
theburner
burnerspecifications.
specifications. Iflf the
thegas supply
surfaces
surfaces of the
of heatexchanger.
theheat exchanger. Iflf in goodcondition,
in good condition, pressure
pressure exceeds
exceeds the14"
the 14"W.C. (3.5kk Pa)
W.C.(3.5 Pa)maximum,
maximum,
the existing
the existingcombustion
combustion chambercan
chamber canbebe used.
used. an intermediate
an intermediate gasregulator
maingas
main regulator mustbe
must be installed
installed
Afull
A combustion
full combustion lineris
chamberliner
chamber is recommended
recommended for
for aheadof
ahead of the
the main gas manual
maingas manualshut shutoff off valve
valveshown
shown
warmair
warm furnaces,
airfurnaces, (seeFigure
(see Figure4),
4),and
andaa target wall
targetwall in Figure
in Figure8. 8.
or full combustion
or full combustion chamberliner
chamber linerisis recommended
recommended WARNING:
WARNING: Failureto
Failure installthe
to install intermediate
the intermediate gas
gas
for wet
for wet leg
legcast ironor
castiron or steel
steelboilers. (See
boilers.(See Figures
Figures55 regulatorwill
regulator will result
resultin gas leakage
in gas leakagefrom
from burner
burnergas gas
and 6).
and 6). Iflf aa built-up
built-upchamber
chamberis is necessary,
necessary, use
use valve.
valve.
2300 (1260"C)minimum
2300' FF (1260C) minimuminsulating
insulating fire-brick
fire-brick or
or A drip
dripleg
legor or sediment
sediment trapmust
trap mustbe be installed
installed in the
in the
fiberfrax.
fiberfrax. supplyline
supply linetoto the
the burner.
burner.See Figure8.
SeeFigure 8.
A pipe union
A pipe union shall
shall be installedin
be installed in thethe gas gas line
line
THE BURNER
THE A IR TUBE
BURNE R AIR TUB E MUST
MUS T NOT
N O T BE
BE adjacentto,
adjacent to, and
and upstream
upstreamfrom, from, the the main
main gas gas
ALLOWEDTO
ALLOWED TO EXTEND
EXTENDINTO
INTO THE
THE CHAMBER
CHAMBER manualshutoff
manual valve,See
shutoffvalve. Figure8.
SeeFigure 8.
PROPER;IT
PROPER; lT MUST
MUSTBEBE SET 1/2 INCH
SET 1/2 (12.7mm1
INCH(12.7mm) The gas
The gas supply pipingto
supplypiping to the
the burner
burnershould branch
shouldbranch
SHORTOF
SHORT THEINSIDE
OF THE INSIDESURFACE.
SURFACE. offfrom
off the main
from the maingasgassupply lineas
supplyline as close
closeto gas
the gas
to the
Before permanently
Beforepermanently securingthe
securing the burner
burnerto
to the
the meteras
meter possible.Do
as possible. Do not
notconnect
connectto to the
the bottom
bottomof of
heating
heating appliance
appliance witheither
with eitherthe
theadjustable
adjustablemounting
mounting horizontal
a horizontal
a section.See
section. Figure99 for
See Figure gas supply
for gas supply
flangeor
flange pedestal
or pedestal or cementing
or cementing aroundthe
around theair
airtube
tube pipesizes.
pipe sizes.
in the
in the combustion
combustion chamberopening,
chamber opening,check thatthe
checkthat the Usenew
Use new black
blackiron pipeand
ironpipe and malleable
malleable fittings
fittings free
free
headassembly isfree
freeof foreignmaterials of burrs
of burrsandand defects.
defects. UseUse pipe joint compound
pipe joint compound
burnerhead
burner assembly is of foreign materials and
and
thatthe
the sensor andelectrode probeshave
electrodeprobes havenot
not been
been resistant
resistant to liquefied
to liquefied petroleum
petroleum gases.
gases.
that sensorand
damaged
damaged repositioned,
or repositioned,
or Figure13.
seeFigure
see 13. AA118" (3.175mm)
1/8" (3.175mm) NPT plugged
NPTplugged tappingaccessible
tapping accessible
for
for test gauge connection
test gauge connectionshall shall be provided
be provided
INPUT
INPUT PREFERRED
PREFERRED immediately
immediately upstream
upstream of the
of gassupply
thegas supplyconnection
connection
BTU/HR
BTU/HR for determining
for determining gassupply
gas pressure
supplypressure to the burner.
to the burner.
kWHr
kW/Hr wluIH"{mm)
WIDTH"(mm) x LLNU u lAM."
IH"(mm)DIAM."
XLENGTH"(mm) (mm
(mm Test new
Test new supply piping
supply piping for for leaks.
leaks. CAUTION:
CAUTION:
50
50MBtu/HR (.|4.655kW) 7 (177.8)
(14655kW)
MBtu/HH n778\X7 t177 8\
X7 (177.8) 8 (203.2)
8(203.2) DURINGPRESSURE
DURING PRESSURE TESTFOR
TEST FORLEAKS
LEAKSIN IN GAS
GAS
75MBtu/HR
75 (219.825kW)71/2
MBtu/HR
(219825kW) (190
7 1/2(1905)5)X71/2 (190.5) 9(2286)
X7 1/2(190.5) 9 {228.6) SUPPLY P I P I NG ,THE
S UP P L YPIPING, T HE BURNER
B URNE R MUST M U S T BE BE
100MBtu/HR
100 (293.1kW)
MBtu/HR293,lkW) 12(304.8)
12 X12(304.8)
304,8 X12 304.8) 13 (330.2)
13 330.2) DISCONNECTED
DISCONNECTED TO PREVENT
TO PREVENTEXPOSINGEXPOSING THE
THE
150MBtu/HR
150 (439
MBtu/HR 65kW) 12
43965kW) (304.8)
12304.8 X15 (381)
X15381) 14(355
14 3556) 6) COMBINATION
COMBINATION GAS VALVE
GAS VALVE TO TO PRESSURES
PRESSURES
200MBtu/HR
200 (586.2kW)
MBtu/HR586,2kW) 13(330.2)
13 X17(431.8)
330.2 X17 431.8) 15(381
15 381)) OVER 1/2"
OVER (3447 PaG)
112" (3447 PaG) PSIG.PSIG. POSSIBLYPOSSIBLY
250MBtu/HR
250 MBtu/HR
fi32.75kW)
73275kW) 13(330.2)
13 X181457.2)
330.2 X18 457.2) '16(406.4)
16 4064) DAMAGINGTHE
DAMAGING THE VALVE
VALVE AND VOIDINGTHE
AND VOIDING THE
300MBtu/HR
300 MBtu/HR
f879,3kW)
8793kW) 13(330.2)
13 X20(508)
330.2 X20 508) 18U57.2\
18 457.2) BURNERWARRANTY.
BURNER WARRANTY.
350MBtu/HR
350 (1
MBtu/HR 14 (355.6)
025.85kW)14
102585kW) X21(533.4)
355.6 X21 5334) 20(508)
20 508)
400MBtu/HR
400 MBtu/HR
{11i2.4kw)
11724kW) t5 (381)
15 X22(558.8)
381) X22 {558.8) 21(533.4)
21 5334)
CAPACITY
CAPACITY - MBtu/HR (kJ)
MBtu/HR(kJ)
RECOMMENDED
RECOMMENDED COMBUSTION
COMBUSTION
PIPE
PIPE TYPE
TYPE
SIZE
SIZE OFGAS
OF GAS LENGTH
LEI~GTH OFPIPE
OF PIPE
CHAMBER
CHAMBER SIZES
SIZES (381mm)
15(381mm)
15 (762mm)
l0 (762mm)
30 (1143mm
15(1143mm)
45 (2286mm
)0(2286mm
90
Figure77
Figure 3t4
3/4 Propane
Propane 400
400 250
250 200
200
1(19.05mm)
t19.05mm) 422000k.t.|
422000kJ) t263750k, 211000kJ)
I (263750kJ) 211000kJ)
1 Natural
l\atural 400
4UU z5u
250 ZUU
200

~
ANUALSHUTOFFVALVE (25.4mm)
(25.4mm) 422000kJ)
(422000kJ) (263750kJ
(263750kJ) 211000kJ)
(211000kJ)
Propane
Propane 400
400 350
350 250
250
I (422000kJ)
ta220nok.l 369250kJ)
i6q25nk.t) '263750kJ)
' 26i 750k .t\
I 1/8" (3,175mm) N.P.T.
400
DIRECTION PLUGGED TAPPING
1t4
1 1/4 Natural
Natural 400 400
400 300
300
OF FLOW PRESSURE GAGE PORT (31.75mm)
(31.75mm) (422000kJ)
(422000kJ) 422000kJ)
(422000kJ) 316500kJ)
(316500kJ)
I Propane
Propane 400
400 400
400
422000k.1\
422000kJ) 422000kJ)
422000kJ)
1t2
1 1/2 Natural
Natural 400
400
'i,--y--+- l 38.1mm)
(38.1mm) arrnnnk.t\
'422000kJ)
CAPACITIESSHOWN
CAPACITIES SHOWN ARE ARE FORFOR A TOTAL
TOTAL PRESSURE
PRESSURE
PIPE CAP
DROP OF
DROP OF 0.3"
0.3" W.C. (74.73Pa)FOR
W.C. (74.73Pa) FOR 0.5"
0.5" W.C. (12a.55Pa)
W.C. (124.55Pa)
PRESSUREDROP,
PRESSURE DROP.MULTIPLY
MULTIPLYCAPACITY
CAPACITYSHOWN
SHOWN BYBY 1.3.
1.3.
DRIP LEG P R E S S URE DROPS,
DRO PS,
FOR HIGHER
FOR H IGH E R PERMISSIBLE
P E R MIS S IB LE PRESSURE
SUPPLY
SUPPLY LINECOI\II\IECTION
LINE CONNECTION CONSULT YOUR UTILITY.
CONSULTYOUR UTILITY.
TO BURNER
TO BURNER
Figure 8
Figure SUPPLY
SUPPLY PIPE
PIPE CAPACITIES
CAPACITIES IN
lN MBtulHR (kW)
MBtu/HR (kW)
Figure 9
Figure
PAGE4
PAGE
G
G.. ELECTRICAL
ELECTRICAL H. MAIN BURNER
H. MAIN BURNER ORIFICE
ORIFICE SIZING
SIZING
AND
AND INSTALLATION
INSTALLATION
The installation
The installation must
must be be wired
wired and GROUNDED in
and GROUNDED in
accordance with
accordance with local
local codes
codes or or inin their
their absence,
absence, The
The HSG200
HSG200 and HSG400 power
and HSG400 power gas gas conversion
conversion
with the National
with the National Electric
Electric CodeCode ANSI/NFPA
ANSI/NFPA No. No. 70-
70- burners
burners are are approved
approved for for useuse withwith natural
natural and and
1987or
1987 or latest
latest edition.
edition. propane
propane gas gas only.
only.
For
For the
the 120
120 VAC
VAC wiring
wiring to to the
the burner,
burner, use use solid
solid The
The HSG200
HSG200 and and HSG400
HSG400 burner burner models
models are are
copper
copper conductor
conductor wirewire notnot lighter
lighter than
than #14#14 AWG.
AWG. lf If shipped labeled
shipped labeled and and orificed
orificed for natural gas.
for natural gas. To To
a fused disconnect is
fused disconnect is used,
used, it it should
should be be fused
fused forfor a conveft
convert to to propane
propane gas gas and/or
and/or increase
increase BTU/HRBTU/HR
minimum
minimum of 15 amps.
of 15 amps. (kcal/Hr)
(kcal/Hr) input
input on on natural
natural or or propane
propane gas, gas, an an orifice
orifice
CAUTION: Each installation
CAUTION: Each installation must must include
include suitable
suitable kit
kit is supplied with
is supplied with each
each burnerburner with with thethe orifices
orifices
limit
limit controls.
controls. Existing
Existing oil burner combination
oil burner combination limit limit shown in
shown in Figure
Figure 10.10.
and
and operating
operating controls
controls are normally not
are normally suitable for
not suitable for When
When selecting
selecting a desired
desired BTU/HRBTU/HR (kcal/Hr)
(kcal/Hr) input,
input,
gas
gas burner
burner use.
use. figure 140,000BTU's
figure 140,000 per gallon
BTU's per gallon of of oil
oil input.
input. For For
CAUTION: The
CAUTION: The burner
burner is equipped with
is equipped with it's own24
it's own 24 example: furnace
example: furnace or boiler rating
or boiler rating of of 0.75gph
0.75gph at 100
at 100
VAC
VAC transformer.
transformer. Do Do notnot add any 24
add any VAC power
24 VAC power psig.
psig. TheThe 0.75 140,000=
0.75 x 140,000 == 105,000
105,000 BTU'sBTU's input
input
consuming
consuming device
device in the 24
in the 24 VACVAC control
control circuit
circuit of of rate.
rate. ltIt may
may be possible
be possible to to reduce
reduce the the firing
firing rate
rate onon
the
the burner,
burner, asas it
it could
could overload
overload the the transformer.
transformer. 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.
Set the
Set the room thermostat "heat
room thermostat "heat anticipator"
anticipator" for for the
the
totaf
total current
current draw
draw of of the
the 24 24 VACVAC burner
burner operation
operation (2.83875L
(2.83875L x 9356 kcal =
9356 kcal == 26559.35
26559.35 kcal) kcal)
circuit. (HSG200
circuit. (HSG200 0.55 amps, HSG400
0.55 amps, HSG400 0.7 0.7 amps)
amps) To remove
To remove or or interchange
interchange main main orifice discs refer
orifice discs refer toto
CAUTION: Label
GAUTION: Label all all wires prior to
wires orior to disconnection
disconnection Figure
Figure 15 15 (Page
(Page 16).
16).
when
when servicing
servicing controls.
controls. Wiring
Wiring errors
errors can can cause
cause 1.
1. Remove
Remove slotted slotted orifice
orifice cap, cap, ltem
Item #40,
#40, making
making
improper
improper and and dangerous
dangerous operation.
operation. sure orifice cap
sure orifice cap gasket,
gasket, #39, stays attached
#39, stays attached to to
Verify proper
Verify proper operation
operation after after servicing.
servicing. orifice
orifice cap
cap andand is
is not
not damaged.
damaged.
NOTE:
NOTE: lf If any of the
any of the original burner wiring
original burner wiring must
must be be 2.
2. Remove
Remove orifice spring, ltem
orifice spring, Item #38,#38, toto access
access and and
replaced,
replaced, it it must
must be be replaced
replaced with with #18
#18 remove
remove orifice
orifice disc.
disc, ltem
Item #42.#42.
AWG
AWG 105105 degrees
degrees C wire wire oror equivalent.
equivalent. 3. Install
3. Install desired
desired orifice
orifice fromfrom Figure
Figure 10, 10, making
making
Section
Section 3- 3- Operation
Operation and and Troubleshooting
Troubleshooting for for sure it is
sure seated flat
is seated flat inin the orifice holder,
the orifice holder, ltem
Item
applicable
applicable burner
burner wiring
wiring diagrams.
diagrams. #37.
#37.
4.
4. Replace
Replace orificeorifice spring
spring and and securely
securely tighten
tighten
orifice
orifice capcap against
against orifice
orifice cap cap gasket
gasket in in orifice
orifice
holder.
holder.

ORIFICE
ORIFICE MANIFOLD
MANIFOLD PRESSURE
PRESSURE
SIZE
SIZE & DRILL
DRILL 2.0" (498.2Pa)
2.0" (498.2Pa) 3.0" (747.3Pa)
3.0" (747.3Pa) 4.0" (996.4Pa)
4.0" (996.4Pa)
HSG2OO
HSG200 NATURAL
NATURAL GAS GAS
#29
#29 - .136 (3.4544mm)
.136 (3.4544mm) 50.000
50,000 BTU (52750kJ)
BTU 152750kJl 64.000
64,000 BTU
BTU {67520kJ)
167520kJ) 76.500 BTU (80707.5kJ
76 500 BTU 180707.5kJ)
#8
#8 - .199 (5.0546mm)
.199 (5.0546mml i4,000
74,000 BTU (78070kJ)
BTU 178070kJ) 95.000
95,000 BTU (100225kJ)
BTU (1 00225kJ) 116.000
116,000 BTU (122380kJ
BTU (122380kJ)
.277 (7.0358mm)
J - .277 (7.0358mm) 112.000 BTU (118160kJ)
112,000 BTU (118160kJ) 138.000 BTU (145590kJ)
138,000 BTU 1145590kJ) 164.000 BTU (173020kJ
164,000 BTU 1173020kJ)
Q .332 (8.4328mm)
Q - .332 (8.4328mm) 160,000 BTU (168800kJ)
160,000 BTU 1168800kJ) 206,000 BTU (217330kJ)
206,000 BTU (217330kJ)
HSG2OO L.P.
HSG200 L.P. GASGAS
#30 .128 (3.2512mm)
#30 - 128 13.2512mm) 49.000 BTU (5169skJ)
49,000 BTU 151695kJ) 58.500
58,500 B TU(61717.5kJ)
BTU 161717.5kJ) 68.200
68,200 B TU(71951kJ)
BTU 171951 kJ)
#27 j44 (3.6576mm)
#27 - .144 (3.6576mm) 666,000
6.000 BTU (69630kJ)
BTU 169630kJ) 78,000
78,000 BTU (82290kJ)
BTU 182290kJ) 92.000
92,000 BTU
BTU {97060kJ)
197060kJ)
- .180 (4.572mm)
#15 -.180
#15 14572mm) 82.000
82,000 BTU 186510kJ) '1
BTU (86510kJ) 12.500
112,500 BTU (1
BTU 18687.5kJ)1
1118687.5kJ) 36.000
136,000 BTU (143480kJ)
BTtl1143480kJ)
D .246 (6.2484mm)
D- .246 (6.2484mm) 131,000 BTU (138205kJ)
131,000 BTU 1138205kJ) 1 87.500
187,500 BTU (1
BTU 9781 2.5kJ) 243,000
(197812.5kJ) BTU (256365kJ)
243,000 BTU 1256365kJ)
HSG4OO
HSG400 NATURAL
NATURAL GAS GAS
.358 (9.0932mm)
T - .358 (9.0932mm) 200.000 BTU (211000kJ)
200,000 BTU (211 OOOkJl 248.000 BTU (261640kJ)
248,000 BTU 1261640kJ) 2 85000
285000 BTU (300675kJ)
BTU 1300675kJ) NOTE:
NOTE: For
For
15/32
15/32 - .468 (11.8872mm)
.468 (11.8872mm) 265,000 BTU (279575kJ)
265,000 BTU (279575kJ) 343.000
343,000 BTU (361865kJ) 400,000
BTU {361865kJ) BTU (422000kJ)
400,000 BTU (422000kJl 50
50 cycle
cycle
HSG4OO
HSG400 L.P.
L.P. GAS
GAS application
application
K .2818 1(7
K-- .2 .1 3 7 4 m m ) 190.000
(7.1374mm) BTU (200450kJ)
190,000 BTU (200450kJ) 2 42.500
242,500 BTU (255837.5kJ
BTU (255837.5kJ)) 295.000
295,000 BTU
BTU {311225kJ)
1311225kJl derate
derate input
input
0- .332 (8.4328mm)
Q - .332 (8.4328mm) 242,500 BTU (255837kJ)
242,500 BTU (255837kJ) 3 32,500
332,500 BTU (350787.5kJ)
BTU (350787.5kJ) 400,000 BTU (422000kJ)
400,000 BTU (422000kJ) by 15%
by 15%

HSG SERIES POWER

HSG SERIES POWER GAS
GAS CONVERSION
CONVERSION BURNERS
BURNERS
ORIFICE
ORIFICE CHART
CHART
Figure
Figure 10
PAGE
PAGE 55
I. COMBINATION
COMBINATION GAS
GAS VALVE
VALVE approximately
approximately 2.0" W.C. (498.2Pa)
2.0" WC. (498.2Pa) to to 4.0"
4.0" W.C.
WC.
(996.4Pa) is factory
(996.4Pa) is set at
factory set at 3.5'
3.5" WC W.C (871.85Pa).
(871.85Pa).
The 24
The 24 VAC
VACcombination gasvalve
combination gas valveserves three(3)
serves three (3) When pressureadjustment
When pressure adjustmentis is required
required forfor setting
setting
(1) manual
functions:(1)
functions: manualgas shut-off, (2)
gas shut-off, main gas
(2) main gas input
input capacity
capacity with orifice from
selectedorifice
with a selected Figure10,
from Figure 10,
flame pressureregulator,
flame pressure (3) automatic
regulator,(3) automatic electric
electric remove the regulator cap for access
remove the regulator cap for access to to the slotted
the slotted
(doubleseated)
redundant(double
redundant gas shut
seated) gas (See
off. (See
shut off. adjustment screw. Turning
adjustment screw. Turning thethe screw counter
screw counter
Figur e11)
Figure 11) clockwise reduces manifold
clockwise reduces orifice pressure,
manifold orifice pressure,
clockwise
clockwise increases
increases pressure.
the pressure.
the
Thecorrect
The correctoperating
operating manifold pressure
orificepressure
manifold orifice range
range
for
for both naturaland
both natural and propane
propane gas gas is is 2.0"
2.0" W.C.
WC. NOTE: MANIFOLD
NOTE: PRESSURE
MANIFOLD PRESSURE ADJUSTMENTS
ADJUSTMENTS
(498.2Pa)minimum
(498.2Pa) minimum to to 4.0"
4.0" W.C. (996.aPa)
W.C. (996.4Pa) CAN ONLY
CAN BE MADE
ONLY BE MADE WITH THE
WITH THE
maximum. By
maximum. By adjusting
adjustingthe the pressure regulator
pressure regulator BURNER
BURNER RUNNING
RUNNING AND
AND THE
THE GAS
GAS ON.
ON.
between 2.0"
between W.C. (498.2Pa)
2.0" WC. (498.2Pa) and and 4.0'4.0" W.C.
WC.
(996.4Pa)on
(996.4Pa) on either
either natural
natural or propanegas,
or propane gas,a wide
wide The 1/8" (3.175mm)
The 1/8" (3.175mm) NPT pressuretap
NPT pressure tap for
for orifice
orifice
inputrange
input range can beachieved
can be achieved withwith a single
single orifice
orifice size.
size. manifold pressure
manifold pressure measurement
measurement is locatedon
is located on the
the
lf the
If desired input
the desired input rating
rating cannot
cannot be
be obtained
obtained within
within outlet side of
outlet side of the combination gas
the combination gas valve. Use a "u"
valve. Use "u"
the
the above
above manifold orifice pressure
manifold orifice pressure adjustment
adjustment tube manometeror
tube manometer or dial type pressure
dial type pressure gauge,
gauge,
range,the
range, nextsize
the next size larger
larger or
or smaller
smaller orifice should be
orifice should be scaled from "0"
scaled from "0" zero
zero lo
to 15.0" WC. (3736.5Pa)
15.0' W.C. (3736.5Pa) to to
used. (Referto
used. (Refer to orifice
orifice chart
chart Fig. 10.)
Fig. 10.) read pressure
read pressure (See
(See Figure 11).
Figure 11).

J. PRESSURE
PRESSURE REGULATOR
REGULATOR ADJUSTMENT
ADJUSTMENT

The combination gas

The combination valve pressure
gas valve pressure regulator,
regulator,
which
which has
has an outlet pressure
an outlet setting range
pressure setting range ofof

1/8" (3.175mm) NPT

PRESSURE TAP
PLUG
PRESSURE
REGULATOR

PRESSURE
PRESSURE
REGUI-ATOR
REGULATOR
MANUAL CONTROL
KNOB (SHO'olN IN
orr POSITION)

tMANUAl
/ANUALCONTROL
CONTROL
KNOB (SHOWN
KNOB (SHOWN tN
IN
OFF POSmON)
oFF pOSmON)

118" (3.175mm)
1/8" (3.175mm) NPT
NPT
PRESSURE
PRESSURE TAPTAP PLUG
PLUG

INLET

HSG4OO
HSG400 GAS
GAS VALVE
VALVE HSG 200/400 GAS VALVE
HSG 2OOI4OO VALVE
ROBERTSHAW
ROBERTSHAW TOOO
7000 DERHC
DERHC HONEYWELL
HONEYWELL VR83O5
VR8305

Figure
Figure 11
11

PAGE
PAGE 6
 SECTION
SECTION IIII
INITIALSTART
INITIAL START UP UP
1. NOTE:
1. NOTE:Read
Read thethe applicable sequence of
applicable sequence of the primary
the primary air
air damper
damper open
open or
or closed to visually
closed to visually
burner/primary gas controloperation
burner/primary gas control operationinin obtaina blue
obtain blue flame
flame with
with well
well defined
defined orange
orange oror
Section3 Operation
Section Troubleshooting
and Troubleshooting
Operationand yellow
yellow tips
tips for naturalgas,
for natural gas, or
or well defined yellow
well defined yellow tips
tips
before proceeding.
before proceeding. for propane
for propane gas.
gas.

2. Depressthe
2. Depress combination gas
the combination gas valve
valve manual
manual control
control 12. After
12. After the burner has
the burner been in
has been operation for
in operation at least
for at least 10
10
knob
knob and
and turn
turn to "OFF" position.
to "OFF" position. minutes, assuring combustion
minutes, assuring combustion chamber and heat
chamber and heat
exchanger
exchanger are are fully
fully warmed,
warmed, take
take combustion
combustion
3.
3. Adjust the primary
Adjust the air and
primary air off-cycle damper
and off-cycle to the
damper to the analysis flue gas
analysis flue samples just
gas samples just ahead
ahead of
of the
the draft
draft
start
start up
up settings shown in
settings shown in Figure 12Aand
Figure 12A 128.
and 12B. control
control in
in the flue pipe.
the flue pipe.
4.
4. On new gas
On new gas line
line installations, air may
installations, air may be trapped in
be trapped in NOTE:
NOTE: ALWAYS
ALWAYS USEUSE RELIABLE
RELIABLE COMBUSTION
COMBUSTION
the
the line,
line, the
the burner
burner may may experience
experience several
several TEST
TEST INSTRUMENTS.
INSTRUMENTS. B EING
BEING
lockouts
lockouts until
until all
all the
the air is purged
air is purged from
from the
the lines.
lines. PROFICIENT
PROFICIENT IN IN THE
THE USE
USE OF OF THESE
THESE
INSTRUMENTS
INSTRUMENTS AND INTERPRETING
AND INTERPRETING
5. Turn
5. Turn on
on the
the main electrical power
main electrical power and set the
and set the
THEIR
THEIR DATA
DATA IS
IS NECESSARY
NECESSARY FOR FOR SAFE,
SAFE,
thermostat
thermostat or
or operation
operation control
control to
to call
call for
for heat.
heat.
RE L I A B L EA
RELIABLE ND E
AND F F I CI EN TB
EFFICIENT URNER
BURNER
Allow
Allow the
the burner
burner to
to run
run a MINIMUM
MINIMUM of of 5 minutes
minutes toto
purge OPERATION.
OPERATION.
purge combustion
combustion chamber
chamber and appliance heat
and appliance heat
exchanger.
exchanger. 13. Perform
13. the following
Perform the combustion analysis.
following combustion analysis. AllAll
adjustments below must
adjustments below be made
must be made with the following
with the following
6.
6. Set
Set the
the thermostat
thermostat or
or operating
operating control
control below
below room
room
instruments: draft gauge,
instruments: draft gauge, 02 or CO2 analyze
or C02 analyzeandand
temperature, shutting the
temperature, shutting burner "OFF"
the burner "OFF" 1 minute
minute to
to
RESET the primary
RESET the primary control.
control. CO
CO tester.
tester.

7.
7. Depress
Depress the combination gas
the combination gas valve
valve manual
manual control
control A.
A. Adjust the primary
Adjust the primary airair damper
damper to to provide
provide about
about
now
now and
and turn
turn to "ON" position.
to "ON" position. 257o
25% excess
excess combustion
combustion air. Confirm this
air. Confirm this by
by
checking
checking the flue gas
the flue gas for
for its
its FREE
FREE OXYGEN
OXYGEN
8.
8. Set
Set the
the thermostat
thermostat oror operating
operating control
control to call for
to call for (Oz)
(0 2) or
or CARBON DIOXIDE (COz)
CARBON DIOXIDE (C02) PERCEN-
PERCEN-
heat. The burner will go
heat. The burner will start and go through the
start and through the TAGES
TAGES with
with a test
test instrument.
instrument. FreeFree oxygen
oxygen
applicable
applicable sequence
sequence of burner/primary gas
of burner/primary gas control
control should be
should be about
about 4.5"/o,
4.5%, or carbon
carbon dioxide
dioxide should
should
operation, refer
operation, refer to
to step
step 1.
1. be
be about 9.5% for
about 9.5% natural gas,
for natural 12.1"/"
gas, 12.1 % for
for
propane
propane gas.
gas.
9.
9. Once
Once burner is running
burner is running adjust
adjust the
the orifice
orifice manifold
manifold
pressure
pressure regulator
regulator as described in
as described in paragraph
paragraph J - B. CARBON MONOXIDE
B. CARBON Should be
MONOXIDE - Should be checked
checked for
for
Pressure
Pressure Regu latorAdjustment.
Regulator Adjustment. its presence
its presence in
in the flue gas.
the flue This percentage
gas. This percentage
should not
should not exceed .04% (or
exceed .04/" (or 400
400 PPM).
PPM).
10.
10. A more
more accurate BTU (kW)
accurate BTU (kW) input
input can
can bebe determined
determined
by
by using
using the NATURAL gas
the NATURAL gas service
service meter
meter with
with the
the C.
C. NOTE:
NOTE: Check
Check overfire
overfire draft
draft and
and adjust
adjust to
to
burner
burner only on (all
only on other gas
(all other gas appliances
appliances should
should be
be NEGATIVE -.01 (2.491Pa)
NEGATIVE -.01 (2.491 Pa) to -.02 (4.982Pa)
to -.02 (4.982Pa)
off).
off). The
The hand the gas
on the
hand on gas meter
meter dialwith the lowest
dial with the lowest inches
inches w/c
w/c during
during burner
burner operation.
operation.
cubic
cubic feet valve (fastest
feet valve (fastest revolving
revolving dial), should be
dial), should 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. (m 3)pre revolution
ft. (m3)pre btu (kW)valve/cub
revolution x btu (kW) valve/cub ic
ic fl (m 3) = BTU/HR
ft (m3)= BTUIHR (kWH0
(kW/Hr)
seconds
seconds oerper revolulion
revolution

EXAMPLE:
EXAMPLE: 3600 1000 (.2931k$
3600 x 1x 1000 =300,000
1.2931 kW) = BTU/HR (87.93
300,000 BTU/HR (87.93 kWHB)
kW/HR)
12
12

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

PAGE
PAGE 7
D. The
D. The flue gas temperature
flue gas temperature shouldbe
should be between
between 14. FILL
14. FILL OUT THE INSTALLATION
OUT THE INSTALLATION COMBUSTION
COMBUSTION
(162.78"C)and
325"F (162.78'C)
325'F and 550'F (287.78"C)tor
550"F (287.78'C)for DATA TAG AND
DATATAG AND AFFIX
AFFIXIT
IT TO
TO THE
THE BURNER
BURNEROR
OR
gas conversion
domesticgas
domestic conversion Higherflue
burners.Higher
burners. flue CONVERTED
CONVERTED APPLIANCE.
APPLIANCE.
gas temperatures
gas temperaturesindicate indicate overfiring
overfiringor or
excessivedraft
excessive draftthrough
throughthethe appliance. Lower
appliance.Lower SUGGESTION:All
SUGGESTION: new installations
All new installationsshouldbe
should be
flue gas temperatures
flue gas temperaturesmay may cause
cause excessive
excessive reinspectedfor
reinspected proper combustion
for proper combustionand and burner
burner
condensation
condensation and indicate
andindicate underfiring.
underfiring. Consult
Consult operationafter
operation after one
one oror two
two weeks
weeks of of normal
normal
yourlocal
your localutility
utilityor or the
the appliance
appliance manufacturer
manufacturer operation.
operation.
for acceptable
for acceptable flue gastemperatures.
fluegas temperatures.
For subsequent
For subsequentnormal
normal starting
starting and
and shut
shut off
off
CAUTION:
CAUTION: lF THE
IF THE BURNER
BURNER BTU/HR (kWHr)
BTU/HR (kWlHr) procedure,
procedure, referto
refer to the "Consumer
the "Consumer lnstructions"
Instructions" in
in
INPUTIS
INPUT ISCHANGED,
CHANGED. REPEAT
REPEAT STEP13
STEP 13 the back
the back of
of this
this manual
manualoror the
the instruction
instruction plate
plate
to the
attachedto
attached the burner.
burner.

3/8" (9.525mm)
3/8" (9.525mm)
,ssK
HSG2OO
HSG200 SETAT
SET NO.1
AT NO.1 HSG2OOSET
HSG200 AT NO.2
SET AT
HSG4OO
HSG400 SETAT
SET NO. 1 1/2
AT NO.1 1/2 HSG400 SET AT
HSG4OOSET AT NO.4

OFF CYCLE
OFF DAMPER
CYCLEDAMPER P RI MA RY
PRIMARY AIR
AIR
SETTING
SETTING SETTING
SETTING
Figure12A
Figure 12A 128
Figure12B
Figure

IMPORTANT
IMPORTANT
THESESETTINGS
THESE SETTINGSAREFOR
ARE INITIAL
FORINITIAL STARTUP
STARTUP ANDMUST
ONLYAND
ONLY, MUSTBE
BE
READJUSTED
READJUSTED FORCOMBUSTION
FOR COMBUSTION EFFICIENCY.
EFFICIENCY.
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 12C
Figure 12C

PAGE8
PAGE
 SECTION
SECTION III
III
OPERATION
OPERATION AND TROUBLESHOOTING
AND TROUBLESHOOTING
SEQUENCE
SEQUENCE OF OPERATION
OF OPERATION HSGSERIES
- HSG POWERGAS
SERIESPOWER GAS
CONVERSION
CONVERSION BURNER
BURNER UTILIZING
UTILIZING HONEYWELL
HONEYWELL S89F
S89F
GAS PRIMARY
GASPRIMARY P/N62759-002
PIN 62759-002WBUILTIN
W/BUILT IN 30
30 SECOND
SECONDPREPURGE
PREPURGE
for heat,
callfor
On a call
On heat,voltage (24V)is
voltage(24V) is applied
appliedtoto motor
motorstart
start theflame
the rodwill
flame rod provideflame
willprovide flamemonitoring
monitoring to the
to the S89F
S89F
relay and
relay and air
air switch.
switch. Once
Once the the fan
fan motor
motor reaches
reaches gas control
gas primaryfor
controlprimary for the remainderof
the remainder of the heatcycle.
the heat cycle.
operating rpmcombustion
operatingrpm combustion air pressureis
air pressure is sensed
sensedbyby the
the Iflf the
the flame
flame should
shouldbe be extinguished
extinguished duringthe
during the heat
heat
air proving switch
air proving and closes
switch and closes the the switch contacts
switch contacts cycle,the
cycle, the S89F gas control
S89Fgas primarywill
controlprimary willgogo into
intothe
the 3030
energizing
energizing the S89F
the gasprimary
S89Fgas primarycontrol.
control. second prepurgeand
secondprepurge and 88 second safestart
secondsafe startcheck,
check,then
then
re-energize
re-energize the gasvalve
the gas valveand
and ignition
ignitiontransformer
transformer in an
in an
THE S89F
THE S89F gas primarycontrol
gas primary has an
control has internal30
an internal 30 attemptto
attempt to establish
establishthe
the main
mainburner
burnerflame.
flame. Iflf this
thisdoes
does
second prepurge timer.
second prepurge timer. After After the initial
the initial 30 30 second
second notoccur
not occurwithin
withinthe
the 4 second trialfor
secondtrial for ignition period,the
ignitionperiod, the
prepurge,an
prepurge, an internal
internal88 second
secondsafe
safestart checkof
startcheck of the
the S89F gas
S89F primarycontrol
gas primary go into
will go
controlwill into lockout
lockoutde- de-
will commence.
S89F will
S89F commence. Once this is
Once this is successfully
successfully energizing
energizing gasvalve
thegas
the valveand
andignition
ignition transformer.
transformer.
completed,
completed, the S89F
the S89Fsimultaneously
simultaneously energizes
energizes gas
the gas
the
valve and
valve ignitiontransformer.
and ignition transformer. GasGas flows
flows andand the
the To restart
To restartthe
the system,
system,the
the main power or
main power or thermostat
thermostat
transformer produces
transformerproduces an an approximate
approximate 7300 volt
7300 volt spark
spark mustbe
must be de-energized
de-energized momentarily,
momentarily, then re-energized.
then re-energized.
end point grounded
end point groundedat at the
the burner
burnerhead establishing Iflf at
head establishing at any
any time during the
time during heat cycle,
the heat cycle, there
there isis an
an
mainburner
main burnerflame.
flame. insufficient
insufficient supply of combustion
supplyof combustion to the
air to
air the burner,
burner,the
the
air switch
air will open,
switchwill puttingthe
open, putting the system
systeminto into lockout
lockout
At thestart
At the startof
of each heatcycle,
eachheat cycle,there is aa trial
thereis forignition
trialfor ignition closing
closingthe gas
the gas valve.
valve.
periodof
period of four (4) seconds
four (4) secondsduration.
duration. Normally,
Normally,burner burner
flamewill
flame will be
be established
established beforethe
before the end
end of of this period.
this period.
Oncethe
Once the flame
flameis is established,
established, sparkingwill
sparking ceaseand
will cease and

HSGPOWER
HSG POWERGAS
GASBURNER
B URNE R
WITHHONEYWELL
WITH HONEYWELLS89FGAS
S89F GASPRIMARY
PRIMARY

BURNER
BURNER GND
GND
24VAC
24VAC

N WIRE
1\ WIRE NUT
NUT
YL --------r=n
YL-__--1--l
t<l
YL--------lJl
YL-------UJ
REOUNOANT
REDUNDANT
GAS
GAS VALVE
VALVE
L2
S-89-F
~.L1
MOTOR MOTOR
~~'TCH VALVE ~-:l
24VAC
24VAC
~
YL~YL----;}-----F1
VALVE
24VAC SENS I RELAYI
~9-F
INTEGRAL IGN. TRANS.
~
TRANS.
TRANS. ,------'1-BRN 24VAC RELAY
GRN GNO(24VAC~8
K I I ~
THERMOSTAT ~ 24VAC TRANS.
I I
FLAME SENSOR
WHT ==S;:"K"====-~
I COIL I
BLK BLU IGNITION
8w L..::J
AIR

1~~
~
SWITCH II
G 24 24 V V
N VAC VAG A A
=- 0 L L
IGNITION
IGNITIONROO
:e-__---===~8L~K=7(I---'-----"'v::s A;~P~~E6H~?HRI~~~APW~~I~CE,
ROD
IF ANY OF IHE ORIGIML WIRE.
I LADDER I S
E
V V
E E REDUNDANT
AS SUPPUEO $TH THE APPLINCE, N GAS VALVE

'-----==--- ---.J lScHEMATiel

ISCHEMATlcl
MUSTBE
MUST REPLACED.
8E REPLACED.
REPLACEDWITH
REPLACED Y{ITHTYPE
IT MUST
IT
TYPE AWM
VUSI BE
EE
AWM 18CA
ISGA PART NO. 62488-004 FLAME SENSOR I S-B9-F
IO5'C
105" WIREOR
C WIRE OR EQUIVALENT.
EOUIVALENT.

PAGE99
PAGE
 SEQUENCE
SEQUENCE OF OPERATION
OF OPERATION HSGSERIES
- HSG SERIES
POWER GAS CONVERSION BURNER UTILIZING
POWER GAS CONVERSION BURNER UTILIZING
HONEYWELL
HONEYWELL S89E PRIMARYPIN
GAS PRIMARY
S89E GAS P/N62758-002
62758.002 W/ EXTERNAL
WI EXTERNAL
30 SECOND
30 PREPURGE
SECONDPREPURGE TIMER P/N62388-001
TIMER PIN 62388-001 AND RESISTOR
AND RESISTOR P/N62530-001
PIN 62530-001

On a call
On for heat,
call for heat,voltage (24V)is
voltage(24V) is applied to the
applied to the motor
motor prepurgetimer
secondprepurge
second timerand the input
and the inputterminal
terminalto the
to the
startrelay
start and air
relay and The motor
switch.The
air switch. motor relay pullsin
relaypulls in the
the S89E gas primary
S89E gas primary control. The function
control.The of this
function of resistor
this resistor
motor.After
motor. the motor
After the motor reaches speed,the
reaches speed, the combustion
combustion is to
is to keep loadon
keep a load on the
the output
outputterminal
terminalof of the
the external
external
air blower
air closes the
blower closes air proving
the air contacts,
switch contacts,
proving switch 30 prepurge
secondprepurge
30 second timer,
timer, after the initial
after the initialcall
callfor
for heat
heat
energizing
energizing theexternal
the external30 secondprepurge
30 second timer.After
prepurge timer. After and 30
and 30 second startprepurge
secondstart and 8 second
prepurge and secondsafesafe start
start
the30
the prepurge
secondprepurge
30 second timing,the
timing, the S89E
S89Eis is energized.
energized. check.
check.

The S89Egas
The S89E gas primary
primary control
control has
has anan internal
internal8 second
second This promotes
This simultaneous
promotes simultaneous re-ignition of the
re-ignition of main
the main
safe start
safe check. After
start check. the initial
After the initial30
30 second prepurge
secondprepurge flameafter
burnerflame
burner afterthe
theS89E's
S89E's8 second
secondsafesafestart check,
start check,
providedby
provided the external
by the timer,the
externaltimer, the S89E
S89Egas primary
gas primary overriding the 30
overriding the secondprepurge.
30 second Thisis
prepurge. This is desirable in
desirable in
control is energized,
control is energized, the 8I second
the second safe
safe start checkwill
startcheck will oven
oven or similarapplications
or similar wheretemperatures
applications where temperatures cannot
cannot
commence. Once
commence. this is
Once this is accomplished,
accomplished, the the S89E
S89E vary drastically.
vary drastically.
activates
activates gasvalve
thegas
the valveallowing
allowinggasgasto flowto
to flow the burner
to the burner
head. Simultaneously,
head. Simultaneously, the S89E
the S89Econtrol
controlenergizes
energizes the
the Shouldthe
Should flamebe
the flame be extinguished
extinguished duringthe
during heatcycle,
the heat cycle,
ignitiontransformer,
ignition transformer, producingan
producing an approximate
approximate 7300
7300 the S89E
the primaryignition
S89E primary ignitioncontrol will go
controlwill go into
into the
the 8I
volt spark
volt point grounded
end point
spark end groundedat the burner
at the head,
burnerhead, second safe
second safe start check after
staft check after which time itit will
which time will re- re-
establishing
establishing mainburner
main flame.
burnerflame. energizethe
energize gas valve
the gas valveand ignitiontransformer
and ignition transformer in an
in an
attemotto
attempt re-establish
to re-establish mainburner
the main
the burnerflame.
flame. Iflf thisthis
At the
At thestart
startof
of each heatcycle,
eachheat thereis
cycle,there is a trial
trialfor
for ignition
ignition does not
does not occur withinthe
occurwithin the 4 second
secondtrialtrial for ignition
for ignition
periodof
period of four (4) seconds
four (4) secondsduration. Normally,
duration.Normally, burner
burner period,the
period, theS89E
S89Egasgasprimary
primarycontrol willgo
controlwill go into
intolockout
lockout
flamewill
flame willbebe established
established beforethe
before the end
end ofof this period.
thisperiod. de-energizing
de-energizing the gasvalve
thegas valveand ignition
andignition transformer.
transformer. To
To
Oncethe
Once flameis
the flame is established,
established, willcease
sparkingwill
sparking ceaseandand restartthe
restart the system,
system,the
the main poweror
mainpower or thermostat
thermostatmust must
theflame
the flamerodrodwill provideflame
willprovide flamemonitoring
monitoring to the
to the S89E
S89E be de-energized
be de-energized momentarily,
momentarily, then re-energized.
thenre-energized. Iflf at
at
gasprimary
gas primarycontrol forthe
controlfor remainder
the remainder of the
of heatcycle.
the heat cycle. any time
any time during the heat
duringthe heat cycle,
cycle, there
there is is insufficient
insufficient
supplyof
supply of combustion
combustion air to
air to the
the burner,
burner,the the air
air switch
switch
When utilizing
When utilizingthe
the S89E
S89Egas primarycontrol
gas primary with the
controlwith the contactswill
contacts will open, puttingthe
open, putting the system
systeminto into lockout
lockout
eternal30
eternal 30 second prepurge
secondprepurge timer,a 10K
timer, 10Kohm resistor
ohmresistor is
is closingthe
closing gasvalve.
the gas valve.
wiredin
wired parallelbetween
in parallel betweenthe
the output
outoutterminal
terminalof
of the
the 30
30

HSGPOWER
HSG POWERGAS
GASBURNER
BURNER
WITHHONEYWELL
WITH HONEYWELLS89EGAS
S89E PRIMARY
GASPRIMARY

WIRENUT
N WIRE
/\ NUT BURNERGND
BURNER CNO
24VAC
24VAC
YL ------r=n
YL---_-F-l
t{ l
AIR PREPURGE
AIR PREPURGE YL------lJl
Y L---UJ
SWITCH TIMER
SWITCH TIMER REDUNOANT
REDUNDANT LIMIT L1 L2

~
VALVE
GASVALVE
GAS
RESISTOR
,..----.
MOTOR MOTOR
s- E9- E
S-89-E
: H'----,---=--=--=-----{
YL.-."" I \ I \ I \ ~r-' VALVE
: RELAY:
YL '---~VALVE IGN. TRANS.
I I
z I I
e r-:7---+--~ 24VAC SENS I I
24VAC LIMIT/ @
BRN 24VAC I I
TRANS.
GRN GND(24VAC) 8LK
I i THERMOSTAT
THERMOSTAT :24VAC24VAC TRANS.
TRANS.

WHT ==i~====~
~LAME S~R f--f-{'
I

II.,
COIL,
)-;'------------------i
.JI
BlK BLU ICNlT10N
RESISTOR
BLU AIR PRf,~~~GE ,..-_ _,/1/'1/1, -----, -1

SWITch liMIY/
CONTROLLER

I LADDER I S 24VAC
MOTO E REDUNDANT
IGNITiON ROO GAS VALVE
N
L-~~~==.!8!l..!!\ K,-=~-"'------':~ IF IF ANY
ANY OF
OF THE
THE ORIGINAl
ORIGINALWIRE.
WIRE,
FLAME SENSOR
AS SuPPLIED
AS SUPPL]EDWITH
W]TH THE
THE APPUANCE.
APPLIANCE. PART NO. 62488-003 S-89-E
MUSTBE
MUST AE REPLACED,
REPUCED,IT VUST BE
IT t.4UST BE
'----'==-- ....J lScHEMATIcl
ISCHEMATlcl REPLACEOWITH
REPLACED
1O5'C
lOS"
WITH TYPE
WIREOR
C WIRE
TYPE AWM
AWM 18GA
OR EQUIVAlENT.
EOUIVALNT.
1AGA

PAGE10
PAGE 10
 FLAMESENSING
FLAME SENSING
The Honeywell
The HoneywellS89 series primary
S89 series ignitioncontrols
primary ignition controls throughthe
through ionizedgas
the ionized gas flame
flame to the grounded
to the burner
grounded burner
utilize the flame
utilize the flame current rectification
current rectification principalfor
principal for main
main head.
head. As As the
the AC
AC current passesthrough
currentpasses through the gasflame,
the gas flame,
burner flame
burner sensing.
flame sensing. itit is
is rectified
rectifiedinto
into a DC currentflowing
DC current flowingbackback to to the
the
grounded
grounded side of the
side of circuit.The
sensingcircuit.
the sensing The flame
flame inin
The flame
The rectification phenomenon
flamerectification occurs as
phenomenon occurs as follows.
follows. actuality
actuality is is a switch. When the
switch. When the flame
flame is is present,
present, the
the
The ignited gas flame causes
The ignited gas flame causes the immediate the immediate switchis
switch allowingcurrent
closedallowing
is closed current to flow through
to flow throughthethe
atmosphere
atmosphere aroundthe
around the flame
flameto becomeionized
to become ionized (gas (gas circuitof
sensingcircuit
sensing of the control.When
thecontrol. When no flameis
no flame present,
is present,
atoms become
atoms becomeelectrically
electrically charged). The
charged). ionization
The ionization the switchis
the switch with no
openwith
is open flowingthrough
currentflowing
no current throughthethe
causesthe
causes atmospherearound
the atmosphere the flame
aroundthe flame toto become
become sensing circuitof
sensing circuit the control.
of the control.
electrically conductive.
electrically conductive. An
An AC voltageoutput
AC voltage output from
from thethe
control
control sensing circuit is
sensing circuit routed through
is routed through the the flame
flame The DC
The DC current
current flow
flow isis measured
measuredin unitscalled
in units DC
called DC
sensor probe.
sensor probe. When
When the the sensor probeand
sensorprobe and the
the burner
burner microamperers.
microamperers. A steady steadyDC DC microamp currentof
microamp current .8
of .8
headare
head bothin
areboth in contact
contactwithwitha properly adjusted
properly adjusted flame,
flame, minimum(and
minimum (and steady)
steady)or or higher
higherthrough
throughthe the sensing
sensing
the burner head
the burner head with its larger
with its largersurface
surfaceattracts morefree
attractsmore free circuitof
circuit of the primaryignition
theprimary ignitioncontrol
controlisis sufficient
sufficient to keep
to keep
electrons,thus
electrons, thus becoming
becomingnegatively
negativelycharged.
charged.The The the burner
the runningwithout
burnerrunning withouta safety lockout.See
safetylockout. Figure
SeeFigure
sensor probewith
sensor probe with its smallsurface
its small area gives
surfacearea gives up free
up free 13for
13 probeand
sensorprobe
for sensor electrode
and electrode dimensional settings,
dimensional settings,
electrons,thus
electrons, thus becoming positivelycharged.
becomingpositively charged.The The free
free Figure14
Figure 14 for flamecurrent
for flame measurement.
current measurement.
fromthe
electronsfrom
electrons AC voltage
the AC voltageinin the
the sensor probeflow
sensorprobe flow

PR OBE DIM 13/16

13/16(20,64MM) REF,
Q0,64nn)REF.
~3/4
F -3 t +
IGN IT ER't 5/8 4 1 .2 Emm
I {ls.0smm)
<l9,05MM)
S EN SOR1 1 /4 J 1 .7 5 m m )
|
-,
"A"
(2,381mn)
1/ 16 (1.588mm)

Figure13
Figure 13

FLAMESENSOR
FLAME CURRENT
SENSORCURRENT CHECK-USE pA SCALE
CHECK-USE jJA SCALE
TO
TO
SENSOR
SENSOR

MULTIPURPOSEMETER

@
_ VAlVE
@
DISCONNECT
WIRE FFOM
O
- 24V
SENSE
TEBMINAL \'C
-
_ (~)
GHO
RED(+

BLACK(-)
BLACK(-)
@ @ 0.8 ~A
0.8 MINMUM
DC MINMUM
uA DC
(AND STEADY)
(AND STEADY)

FLAMECURRENT
S89FLAME
S89 CURRENT MEASUREMENT
MEASUREMENT
Figure14
Figure 14
PAGE11
PAGE 11
 HSG SERIES
HSG SERIESWITH
WITH A HONEYWELL
HONEYWELLS89E,
S89E,S89F PRIMARYIGNITION
S89FPRIMARY IGNITIONCONTROLS
CONTROLS
TROUBLESHOOTING
TROUBLE SHOOTINGGUIDE
GUIDE
MOTORDOES
MOTOR NOT START
DOES NOT START

Check the
I.l. Check low voltage
the low voltage transformer tor 24 volt
transformer for volt output
output Check electrical wiring and Replace
Replace 24 volt
volt AC
AC
between terminal3 on
between terminal on the
the motor relayeither
start relay
motor start either connections. 20 VA
VA Transformer
Transformer
of the
of "T' terminals on
the'T'terminals the control
on the controlbox.
box.

2. Check
2. tor 24
Checkfor voltsAC
24 volts AC between
betweenterminals 1 and
terminals 1 and 3 Check electrical wiring and Replace motor
on motorstart
on motor relay.
start relay. connections. start relay.

3. Checkfor
3. Check 120 volts
for 120 volts AC
AC between
between terminal
terminal 2 on
on Check electrical wiring and Replace motor
motorstart relay
motorstart relay and neutralline.
and neutral line. connections. start relay.

4.
4. Check electrical wiring
Check electrical wiring and connections.
connections.

1. Check for
1. Check blower clearance.
for blower clearance.
5. Does
5. Does motor turn freely?
shaft turn
motor shaft freely?
2.
2. Lubricate
Lubricate motor
motor bearings.
bearings.

6. OK

IGNITION
IGNITION ARC ESTABLISHED
ESTABLISHED - NO FLAME

Reset Control - Motor

Reset Control Motor starts
starts - Completes
Completes 30 second prepurge
30 second prepurge cycle,
cycle, 8 second
second safe
safe start
start check and trial
check and trial for
for
ignition,
ignition, 4 seconds
seconds Honeywell series. NOTE:
Honeywell series. NOTE: The
The burner motor will
burner motor continue to
will continue to
operate during the
operate during the lock out mode
lock out mode when
when the
the thermostat circuit is
thermostat circuit is called
called for
for burner
burner operation.
operation.

2. Check for correct

2. Check correct orifice/air
orifice/air setting relationship (see
setting relationship (see figures
figures 10,
10, 12A, 128, and
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 control must
the control must bebe reset and the
reset and tests monitored
the tests monitored dur-
dur-
ing the 4 second
ing the second Honeywell
Honeywell series trial for
series trial ignition peri-
for ignition peri-
od that
od that occurs
occurs atat the
the END
END ofof the
the 30 second prepurge
30 second prepurge
and
and I8 second
second safe start check
safe start check cycle.
cycle.

3.
3. Check tor 24 volts
Check for volts AC at gas
AC at gas valve
valve terminals.
terminals. Check electrical wiring
Check electrical wiring and
and Replace primary
connections.
connections. Be
Be sure
sure leads
leads ignition control.
are
are on correct gas
on correct gas valve
valve ter-
ter-
minals
minals
4.
4. Make
Make sure leads correct gas valve
leads are on the correct 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 second prepurge
30 second prepurge cycle, 8 second safe start
start check
check series.
series.
. Gas
Gas valve
valve opens,
opens, regulating
regulating adequate gas pressure.
adequate gas pressure.
. No
No flame
flame established
established - Primary control locks
Primary control locks out after
after4 secondHoneywell
second Honeywell series trial for
series trial for
ignition periods.

0
order for
In order the following
for the following functional test to be made,
functional test made,
the control
control must
must be reset
reset and
and the
the tests
tests monitored
monitored dur-
dur-
ing
ing the
the 4 second Honeywell series
second Honeywell series trial
trial for ignition
ignition that
that
occurs
occurs at the
the end
end of the second prepurge
the 30 second prepurge cycle,
cycle,
and
and I8 second
second safe start
start check.
check.

~ h..
Check tor
2. Check for 12O
120 volts
volts AC
AC between the neutral
between the neutral line
line ~ Gheck electrical wiring
Check electrical wiring and
and connections.
connections.
and the
and junction of the
the function blue primary
the blue control lead
primary control lead
and
and the
the black
black ignition
ignition transformer
transformer lead.
lead.
~
~ Check the flame
Check the flame sensing
flamerod. (2)
flamerod.
sensing circuit
(2) Damage
for (1)
circuit for
Damage to flamerod
(1) grounded
flamerod lead
grounded
lead insula-
insula-
3. Check
Check electrical
electrical wiring and connections.
wiring and connections.
tion.
tion. NOTE:
NOTE: Make
Make sure
sure that the flamerod
that the flamerod circuit
circuit

~ and/or primary
and/or primary control
control is moisture-free.
moisture-free.

4.
4. Check
Check high
high voltage
voltage lead
lead and connection to ignition
and connection ignition ~
electrode
electrode rod.
rod. Replace primary ignition control.
I
~
5. Inspect
Inspect ignition electrode for
ignition electrode cracked insulator
for cracked insulator and
and
-
correct spark gap
correct spark gap (Fig.
(Fig. 13).
13).

W
6. Replace ignition transformer.

NO IGNITION
IGNITION - NO GAS
GAS VALVE
VALVE

1.
1. Reset second prepurge
Reset Control
to
to run
Control - Motor
run but flame
Motor starts
but flame is not
starts -- After
After 30 second
not established.
established.
prepurge cycle
cycle and
and 88 second
second safe
safe start
start check.
check. Motor
Motor continues
continues
I
V
In
In order to perform
order to perform the follOWing functional
the following functional tests,
tests, the
the
primary
primary control
control must be reset
must be reset and
and the
the tests
tests monitored
monitored
during
during the
the 44 second
second Honeywellseries trial for ignition
Honeywell series trialfor ignition
that
that occurs
occurs at
at the
the end of the
end of second prepurge
30 second
the 30 prepurge cycle
cycle
and
and 88 second
second safe
safe start
start check.
check.

~ h..
2. Check tor
2. Check for 24
24 volts
volts AC at the 24
AC atthe volt primary
24 volt primary control
control ~l Replace
Replace primary
primary ignition
ignition control.
control.
I
input
input terminals labeled yellow
terminals labeled yellow and
and brown.
brown.

~
3.
3. Check air proving
Check air switch for:
proving switch for: h.. 4. Check (when
4. Check (when applicable)
applicable) external
external 30
30 second
second
a. Any impairment
a. Any impairment that
that would keep itit from
would keep OK) prepurge timer (jumper
prepurge timer Oumper around
around timer
timer from
closing
closing or
or opening.
opening.
from
,. switch). Should primary
switCh). Should primary ignition
from air
ignition control
control
air

b.
b. Electrical
Electrical continuity;
continuity; switch
switch is
is normally
normally open.
open. become
become energized,
energized, replace
replace timer.
timer.
c. Replace
c. Replace switch as necessary.
switch as necessary.

PAGE
PAGE 13
13
LOSESFLAME
lOSES FLAME DURING CYCLE -_ CONTROL
DURINGCYCLE LOCKSOUT
CONTROL lOCKS OUT ON
ON SAFETY
SAFEW

1 Reset
contror
1. Reset Control
Completes 30 second prepurge cycle, and 8 second safe start check.
Flame is established.
ti#fi,":',lT*h"
Sometimes the control H.:*"J",-" issatisried
locks out before the thermostat or controlling circuit is satisfied.
-;",::;T::.ffi "ircuit
~
2. Disconnect flamerod
2. Disconnect flamerod lead
lead from primarycontrol.
from primary control.Connect
Connect
(+) positive
(+) positive lead (DC) MicroampereMeter
lead (DC) Microampere Meter to the primary
to the primary
Probable cause of erratic
Probable cause erratic lockout:
lockout:
1. Flame proving
1. Flame circuit grounded
proving circuit grounded by by moisture.
moisture.
control terminal. Connect
controlterminal. the (-)
Connect the (-) negative microampere
negative microampere
meter lead
meter lead to the
the flamerod
flamerod lead
lead terminal. See Fig.
terminal. See 14:
Fig. 14:
2.
2. Damaged
Damaged insulation
insulation on flamerod
flamerod lead.
lead.
3. Flamerod
3. improperly positioned
Flamerod improperly positioned in flame (see
in flame (see
Flame
Flame Current
Current Measurement.
Measurement.
Fig. 13).
Fig. 13).
~ 4.
5.
Poor ground
4. Poor ground path
5. Defective
path to primary
primary
Defective primary control.
primary control.
control.
control.

~
3. Reset
3. Reset control, after prepurge
control, after prepurge cycle,
cycle, flame
flame is
is established.
established. 6. Read
6. Read manual section "Flame
manual section "Flame Sensing".
Sensing".
stable microampere
A stable microampere current
current of .8 more is
.8 or more is required
required 7. Applicable only to Honeywell
7. Applicable only Honeywell S89 S89 series
series
for
for dependable
dependable operation.
operation. primary
primary ignition
ignition controls: Connect L1
controls: Connect L 1 to the
the
black
black lead
lead and
and 12 L2 to the
the white
white lead exiting the
lead exiting the
NO S89
S89 otherwise
otherwise the the S89 will not
S89 will not detect
detect the
the
flame
flame and
and will
will lock
lock out.
out.
""to~ h.
4. Microampere reading
4. Microampere reading is
is less
less than
than .8
.8 or unstable.
unstable.
,.) Probable
Probable causes:
1.
2.
causes:
Extremely poor
1. Extremely
2. Flamerod
combustion level.
poor combustion level.
improperly positioned
Flamerod improperly in flame.
positioned in flame.
3. Defective primary control.
3. Defective primary control.

BURNER
BURNER CYCLES
CYCLES ERRATICALLY
ERRATICALLY

I 1. Check for
for proper thermostat installation
proper thermostat and location.
installation and location.

~ h.
2. Check thermostat
2. Check thermostat heat anticipator for correct
heat anticipator correct setting.
setting. .!o)
,. Set anticipator
Set anticipator to correct
lf proper
correct value
value if adjustable type.
if adjustable type.
If setting cannot
proper setting be made,
cannot be made, replace
replace with
with
~ compatible
compatible thermostat.
thermostat.
3. Check low voltage
3. Check circuit for bad wiring,
voltage circuit wiring, electrical
electrical
connections
connections and/or switches.
switches. NOTE: When
NOTE: When the thermostat
thennostat wires terminate
tenninate on the
HSG primary
HSG primary control
control box'T"
box "1"" terminals,
tenninals, the heat anticipa-
anticipa-
~ setting value
tor setting value for the HSG burner
adding the primary
adding
burner is determined
primary control current
detennined by
current to the gas valve cur-
4. Check line
4. Check line voltage circuit for bad wiring,
voltage circuit wiring, electrical
electrical rent. The result
rent. result is the anticipator setting.
setting.
connection
connection and/or switches.
switches. (Exampfe:
(Example: .2 .6 =.8
.2 + .6 = .8 amps.)
amps.)
lfIf the thermostat
thennostat wires ARE NOT terminated
tenninated on the
control box "7"
bumer control tenninals, and these
"T" terminals, these terminals
tenninals are
JUMPERED, you
JUMPERED, you must then determine
detennine what
what the correct
correct
anticipator setting
anticipator setting is by inspecting
inspecting the controlling
controlling device
at the point
point where
where the thermostat
thennostat wires
wires terminate.
tenninate.
Typically, this information
Typically, infonnation can be found
found on the body or
controlling device.
cover of the controlling

When determining
When current draw of the dual head gas
detennining the cunent
valve, be sure
valve, sure to consider the separate
separate ampere values
valve. These usually are stenciled
for each valve. stenciled on the valve
body, and must
body, must be added together to obtain
obtain the correct
sum. (Example: .4 + .2 == .6 amps).
sum. (Example: amps).
When the current
When current draw cannot be determined
detennined accurately
accurately
above method,
by the above method, measure the current
current with an
ampere meter
ampere meter using
using the 1 AMP scale.
scale. Connect
Connect the
leads in series
meter leads series with one of the thermostat
thennostat leads
accurate reading.
for the accurate reading.
PAGE
PAGE 14
14
 SECTION IV
SECTION IV
SERVICE
SERVICE
Caution: Make
Caution: Make sure the main
sure the main manual,
manual, combination
combination the pressure
the switch causing
pressure switch causing the
the diaphragm
diaphragm contacts
contacts
valves
valves and main power
and main power switch
switch are
are turned
turned to close thus
to close thus completing
completing the
the circuit.
circuit.
off before
before opening
opening burner
burner or removing
removing any
any
parts The
The function
function ofof the air proving
the air proving switchswitch is
is to
to ensure
ensure
parts for service.
service.
sufficient
sufficient combustion
combustion air air is
is being
being developed
developed by by the
the
A.
A. BU R N ER
BURNER H EA DA
HEAD ND
AND blower motor
blower motor and blower wheel.
and blower wheel. Should
Should the
the blower
blower
ELECTRODE/S ENSORASS
ELECTRODE/SENSOR EMBLY
ASSEMBLY motor
motor fail
fail or
or the blower wheel
the blower wheel malfunction.
malfunction, the the
burner gas
burner gas valve
valve will shut off.
will shut off.
The burner head,
The burner head, electrode, sensor probe,
electrode, sensor probe,
combination valve,
combination valve, orifice
orifice housing and housing
housing and housing 1. The
1. air proving
The air proving switch should never
switch should never require
require
cover are part
cover are part of the gas
of the gas train
train assembly
assembly which
which can
can maintenance. However. should
maintenance. However, should nuisance
nuisance
be removed
be removed as
as one unit. (See
one unit. (See Figure 15)
Figure 15) lockouts
lockouts occur, the pressure
occur, the pressure switch switch can
can be be
checked.
checked. ThisThis is done by
is done by disconnecting
disconnecting the the
1. Disconnect gas
1. Disconnect gas line
line from combustion gas
from combustion gas valve
valve yellow
yellow and
and white leads from
white leads from thethe Air
Air Proving
Proving
inlet,
inlet, flame sensor lead
flame sensor lead wire from gas
wire from gas primary
primary, switch and jumpering
switch and jumpering the the leads
leads together.
together. If lf the
the
gas
gas valve
valve lead
lead wires from gas
wires lrom gas valve
valve operator
operator burner functions
burner functions correctly,
correctly, the switch needs
the switch needs to to
and (orange)
and (orange) ignition
ignition lead
lead wire
wire from
from ignition
ignition be
be replaced.
replaced.
transformer ignition
transformer ignition lead
lead wire.
wire.
WARNING:
WARNING: lf If a jumper
jumper is used to
is used to check
check the switch it
the switch it
2.
2. Remove
Remove the the two two 1/4" 1/4" (6.35mm)
(6.35mm) hex hex slotted
slotted must
must bebe removed
removed or an an unsafe
unsafe condition
condition
screws on
screws on thethe toptop front
front ofof the
the housing
housing cover cover and and can occur resulting
can occur resulting in in death
death oror property
property
the
the two 5/16" (7.9375mm)
two 5/16" (7.9375mm) hex hex slotted
slotted screwsscrews damage.
damage.
on the left
on the left andand right side back
right side back of the housing
of the housing
cover.
cover. 2.
2. As
As mentioned above, the
mentioned above, the switch should never
switch should never
require
require maintenance. However a pinched
maintenance. However pinched tube
tube
3. To
3. remove gas
To remove gas train assembly, gently
train assembly, gently lift up rear
lift up rear will
will shut
shut off the flow
off the flow ofof pressurized
pressurized air
air to
to the
the
of
of housing
housing cover cover pulling
pulling rearward
rearward slightly
slightly on on the
the diaphragm creating a failure
diaphragm creating failure made
made similar
similar toto
drawer assembly gradually
drawer assembly gradually positioning
positioning the the rear
rear bad
bad Air
Air Proving switch. Always
Proving switch. Always check
check to
to ensure
ensure
of
of the
the drawer
drawer assembly assembly upward upward 90 90 degrees
degrees that
that the
the clear tUbing is
clear tubing not pinched.
is not pinched. Make
Make sure
sure
(1.57RAD).
(1.57RAD). Gently Gently extractextract burnerburner head head and and the
the spring
spring cover
cover is
is reinstalled
reinstalled over
over tube.
tube.
electrode/sensor
electrode/sensor assembly assembly out opening in
out opening in
housing
housing takingtaking extreme
extreme care care to to not
not dislocate
dislocate or 3.
3. Switch
Switch is
is mounted
mounted in
in the
the horizontalposition
horizontal position with
with
damage
damage electrode
electrode or sensor sensor probeprobe. terminals
terminals up
up from
from factory.
factory. Final
Final burner
burner mounting
mounting
should maintain
should maintain horizontal switch position.
horizontal switch position.
4.
4. When
When servicing,
servicing, clean clean burnerburner head head ports, ports,
electrodes
electrodes and and sensorsensor probe. probe. Inspect
Inspect the the WARNING:
WARNING: Damage
Damage to to internalcomponents
internal components of
of
sensor probe
sensor probe and and electrode
electrode wires wires andand porcelain
porcelain burner may
burner may result,
result, if burner
burner is
is mounted
mounted in
in other
other
insulators
insulators carefully
carefully for for hairline
hairline crackscracks which which than horizontal position.
than horizontal position.
might provide
might provide an an electrical
electrical leak leak path
path that
that could
could
short
short outout thethe ignition
ignition spark,
spark, or flame flame signal.
signal.
C.
C. COMBUSTION
COMBUSTION AIR
AIR BLOWER
BLOWER AND
AND MOTOR
MOTOR

5.
5. Examine
Examine the the electrode
electrode and sensor probe
and sensor probe for for
1.
1. Cleaning
Cleaning of of the
the combustion
combustion air air blower
blower is is
any
any serious
serious corrosion
corrosion or or deterioration
deterioration of metal metal
indicated
indicated if
if the
the blades
blades showshow an
an accumulation
accumulation of of
at
at the
the tips.tips. Check Check for for proper
proper dimensional
dimensional dust and lint,
dust and lint, or
or if
if the
the character
character of
of the
the flame
flame
settings of the
settings sensor probe
the sensor probe and electrode (see
and electrode (see
indicates
indicates a deficiency
deficiency of of combustion
combustion air.
air.
Figure
Figure 13). 13). Adjust Adjust and/or and/or replace
replace these these 2.
2. The side plate,
The side plate, motor
motor andand blower
blower wheel
wheel areare
assemblies
assemblies as as necessary.
necessary. Make Make sure sure thatthat thethe removed
removed as as one assembly. Disconnect
one assembly. Disconnect the the
ignition
ignition and and sensor sensor probe probe wires wires go go to to the
the motor
motor wire
wire inside the junction
inside the junction box
box beneath
beneath thethe
correct electrodes
correct electrodes and and thethe ignition
ignition wirewire boot boot is is ignition transformer. Remove
ignition transformer. Remove the four (4)
the four (4) 5116"
5/16"
in place
in place over over the electrode porcelain.
the electrode porcelain. (7.9375mm)
(7.9375mm) hex hex slotted
slotted screws
screws securing
securing
6.
6. Make
Make sure sure that that thethe burner
burner tube tube end end is is properly
properly
sideplate
sideplate to
to fan
fan housing.
housing.
positioned
positioned in in the
the combustion
combustion chamber chamber entry. entry. lt It CAUTION: Do
CAUTION: Do not
not remove blower wheel
remove blower wheel from
from motor
motor
must
must be be setset '112"
1/2" (12.7mm)
(12.7mm) short short of of the
the inside
inside shaft during periodic
shaft during periodic cleaning.
cleaning.
face
face of of the
the combustion
combustion chamber chamber as shown in
as shown in
figures
figures 4, 4, 5 or or 6.6. 3. Should removal
3. Should removal of of the
the blower
blower wheel
wheel be be
necessary
necessary for cleaning or
for cleaning or replacement
replacement of it it or
B.
B. AIR
AIR PROVING
PROVING SWITCH SWITCH the
the motor,
motor, the blower wheel
the blower wheel must
must bebe positioned
positioned
The air proving
The air proving switch switch is is mounted
mounted to the housing
to the housing correctly
correctly on
on the
the motor shaft. (Figure
motor shaft. (Figure 16)
16)
cover with (2)
cover with (2) #6 #6 self
self tapping
tapping screwsscrews under under the the gas
gas HSG200 wheel pln
blower wheel
HSG200 blower pIn 21664
21664 is is positioned
positioned
valve.
valve. A clearclear plastic
plastic tube,tube, protected
protected by by a spring
spring 2 1/16" (52.3875mm)
21/16" (52.3875mm) measured
measured fromfrom the
the blower
blower
cover,
cover, isis connected
connected to the the barbed
barbed fittingfitting on on the
the wheel
wheel inlet
inlet ring
ring face
face to
to the side plate
the side plate face.
face.
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 allowsallows HSG400
HSG400 blower wheel pln
blower wheel pIn 21642
21642 is is positioned
positioned
pressurized
pressurized air air from
from the the blower
blower housing
housing to to travel
travel to to 23/16" (55.5625mm)
23116" (55.5625mm) measured
measured fromfrom the
the blower
blower
wheel
wheel inlet
inlet ring
ring face
face to the side plate
the side plate face.
face.
PAGE
PAGE 15
 33

DRAWER
DRAWER ASSEMBLY
ASSEMBLY
Figure15
Figure 15

"AU MOTOR SIDEPLATE

r
PIN 21658

r'I

P A F I T N I I ] \ ' F I t r FI
21664
21664
HSG2OO
HSG200 2 11/16"
/1 6 "
51t 4 0.
5114 D.
G.D. (52.3875mm)
(52.3875mm) I
l-
((133.35mm)
133. 35m m )
21642 i-
21642
HSG4OO
HSG400 223/16"
3t16" \
(55.5625mm)
b
1t 2 0.
55112 D.
G.D. (55.5625mm)
((139.7mm)
139. 7m m )

...
" -r

MOTOR/BLOWER
MOTOR/BLOWER ASSEMBLY
ASSEMBLY
Figure
Figure 16
16

PAGE 116
PAGE 6
 PARTSLIST
PARTS LIST-- MODEL
MODELHSG 2OOI4OO
HSG200/400 SEEFIG.
SEE FIG.15
15& FIG.17
& FIG. 17
Item
Item PartNo.
Part No. Description
Description
1.
1. 100934-001
100934-001 Burner
Burner Housing
Housing
2.
z. 62576-003
62576-003 AirTube
Air Tube-- HSG200
HSG200 6" (152.4mm)
6"(152.4mm)
63270-004
63270-004 AirTube
Air Tube-- HSG400
HSG4OO 66 1/4" (158.75
1/4"(158.75 mm)
mm)
62576-01
62576-0155 AirTube
Air Tube-- HSG200
HSG200 (228.6mm)
9"(228.6mm)
9"
63270-01
63270-0155 AirTube
Air Tube-- HSG400
HSG400 9" (228.6mm)
9"(228.6mm)
62576-027
62576-027 AirTube
Air Tube-- HSG200
HSG200 '12"(304.8mm)
12" (304.8mm)
63270-027
63270-027 Tube-- HSG400
AirTube
Air HSG400 12" (304.8mm)
12"(304.8mm)
63270-028
63270-028 AirTube
Air Tube-- HSG400
HSG400 15" (381mm)
15"(381 mm)
3.
3. 62393-001
62393-001 AirCone
Air (HSG200
Cone-- (HSG200 only)
only)
4.
4. 21724-011
21724-011 Adjustable
Adjustable Flange
Flange Assembly
Assembly (includes
(includes gasket)(not
gasket)(not shown)
shown)
5. 100428-002
100428-002 Flange
Flange Gasket(not
Gasket (notshown)
shown)
6.
o. 21664
21664 Blower
Blower WheelHSG200
Wheel HSG200 55114 (133.35mm)
OD(133.35mm)
1/4" OD
21642
21642 Blower
Blower Wheel
Wheel HSG400
HSG400 5112'OD
51/2" (139,7mm)
OD (139.7mm)
7.
7. 21658
21658 SidePlate
Side (Usedwith
Plate(Used with20627
20627and 20627-004
and20627-004 MotorsOnly)
Motors Only)
8.
8. 20627
20627 Motor,
Motor, SplitPhase
Split Phase1/7 (.107kW)
117(.107kW) or 1/8
or (.093kW)
1/8(.093kW) HP3450
HP 3450RPM 115V/60
RPM115V/60
20627-004
20627-004 Motor,
Motor, Phase1/7
SplitPhase
Split (.107kW)
117(.107kW) HP2850
HP 2850RPM
RPM230V/50Hz
230V/50H2 (220Y150H2)
(220V/50Hz)
9.
9. 100373-002
100373-002 Combustion
Combustion InletDamper
Air Inlet
Air Damper
(S89E&
10.
10.
11.
11.
62408-001
62408-001
62388-001
62388-001
62530-001
62530-001
ControlBox
Control
30Sec.
30
Box (S89E
Prepurge
Sec.Prepurge
Resistor
Resistor WireAssy.
Wire Assy.
& S89F)
Time
Time
S89F)
.. Used withPrimary
Usedwith
(Special
(Special
PIN
Primary safetyControl
safety
P/N62758-002
62758-002
limitapplications
limit applications
Control
only)
only)
12.
12. 60186-004
60186-004 24 Volt
24 VoltTransformer
Transformer 120V
120V
63005-002
63005-002 24 Volt
24 Transformer
VoltTransformer 220V
220V
100450-001
100450-001 Bushing
Bushing
13.
13. 62406-002
62406-002 MotorRelay
Motor Relay
14.
14. 62759-002
62759-002 PrimarySafety
Primary SafetyControl
ControlH'Well
H'WellS89F
S89Fw/30 w/30Sec
Sec Prepurge (220Y150H2)
Prepurge(220V/50Hz)
62758-002
62758-002 PrimarySafety
Primary ControlH'Well
SafetyControl H'WellS89E
S89Ew/o w/o 30
30 Sec Prepurge
Sec Prepurge
(SpecialLimit
(Special LimitApplications
Applications Only)
Only)
15.
15. 100377-002
100377-002 DamperIndicator
Damper Pointer
IndicatorPointer
16.
16. 100429
100429 DamperDecal
Damper Decal
17.
17. 63263-005
63263-005 PressureSwitch
Pressure Switch
63272-005
63272-005 PressureSwitch
Pressure SwitchConversion
ConversionKit Kit
63935-001
63935-001 PressureSwitch
Pressure (220Vl50H2)
Switch(220V/50Hz)
18.
18. 60178-002
60178-002 ThermostatTerminal
Thermostat TerminalStripStrip
19.
19. 100372
100372 AdjustmentArm
Adjustment Damper
Off-CycleDamper
Arm Off-Cycle
20-21.
20-21. 100371-KlTOff-Cycle
100371-KIT DamperKit
Off-CycleDamper Kit
22.
22. 2'1319
21319 JunctionBox
Junction (underIgnition
Box (under lgnitionTransformer)
Transformer)
23.
23. 61843
61843 LightingPlate
Lighting Plate
24.
24. 62407-O01
62407-001 lgnitionTransformer
Ignition Transformer 7500V
7500V
64051 -001
64051-001 lgnitionTransformer
Ignition 220Yl50HzDanfoss
Transformer 220V/50Hz Danfoss
25.
25. 62391 -002
62391-002 Electrode
Electrode Assembly
Assembly
26.
26. 62390-002
62390-002 SensorProbe
Sensor Probe Assembly
Assembly
27.
27. 62387-001
62387-001 Insulator Bushing (not
Insulator Bushing (not shown)
shown)
28.
28. 62575-002
62575-002 Chamber/Manifold - HSG200
Chamber/Manifold HSG200 6" 6" ('152.4mm)
(152.4mm)
62575-001
62575-001 Chamber/Manifold - HSG400
Chamber/Ivlanifold HSG400 6 1/4" 1/4. (158.75 mm)
(158.75 mm)
62575-014
62575-014 Chamber/Manifold - HSG200
Chamber/Manifold HSG200 9" 9" (228.6mm)
(228.6mm)
62575-012
62575-012 Chamber/Ivlanifold
Chamber/Manifold - HSG400 HSG400 9" (228.6mm)
9" (228.6mm)
62575-026
62575-026 Chamber/Manifold
Chamber/Manifold - HSG200 HSG200 12" 12"(304.8mm)
(304.8mm)
62575-024
62575-024 Chamber/Manifold
Chamber/Manifold - HSG400 HSG400 12" (304.8mm)
12" (304.8mm)
62575-031
62575-031 Chamber/Manifold
Chamber/Manifold HSG40015"
- HSG400 (381mm)
15" (381 mm)
29.
29. 6241 9-001
62419-001 Clip,Electrode
Clip, Bracket
Electrode Bracket
30.
30. 61951-001
61951-001 lgnitor SupportParts
Ignitor Support PartsKit Kit
31.
31. 62411-028
62411-028 11"" (279.4mm)
11 (279.4mm) Sensor
Sensor WireWire - 6" (152.4mm),6 1/4"
6" (152.4mm), (158.75mm)Burner
1/4"(158.75mm) Burner
62411-030
62411-030 14" (355,6mm),
14" (355,6mm), Sensor Wire
Sensor 9" (228.6mm),
Wire - 9" 12" (304.8mm)
(228.6mm), 12" (304.8mm) Burner
Burner
62411-068
62411-068 17" (431,8mm),
17" Sensor Wire
(431 ,8mm), Sensor 15" (228.6mm)
Wire - 15" (228.6mm) Burner
Burner
64096-001
64096-001 Sense Wire
Sense Wire - 330mm
330mm CableCable (220Vl50H2)
(220V/50Hz)
32. 62909-001
62909-001 8" (203.2mm)
8" Ignition Wire
(203.2mm) lgnition 6" (152.4mm),
Wire - 6" 1/4" (158.75mm)
(152.4mm). 6 1/4" (158. 75mm) Burner
Burner
62909-003
62909-003 14" (355.6mm)
14" (355.6mm) lgnition
Ignition Wire
Wire - 9"9" (228.6mm), 12" (304.8mm)
(228.6mm), 12" (304.8mm) Burner,
Burner,
15" (228.6mm)
15" (228.6mm) Burner
Burner
64095-001
64095-001 lgnition
Ignition Wire
Wire - 500mm
500mm CableCable (220Vl50H2)
(220V/50Hz)
33. 62404-OO2
62404-002 Top
Top Plate/Housing
Plate/Housing Cover
Cover
34. 62304
62304 Strain Relief
Strain Bushing/Ignition Wire
Relief Bushing/lgnition Wire
35. 62402-001
62402-001 Orifice Housing
Orifice Housing
36. 62410-001
62410-001 Orifice
Orifice Spring
Spring
37. 62401 -001
62401-001 Orifice
Orifice Gasket
Gasket
38. 62385-001
62385-001 Orifice
Orifice Cao
Cap
39. 62374-004
62374-004 Gas Valve
Gas Valve Honeywell
Honeywell VR8305M
VR8305M 4801 4801
40. 624s9-001
62459-001 Orifice
Orifice Package HSG200 (not
Package - HSG200 (not shown)
shown)
62459-002
62459-002 Orifice
Orifice Package HSG400 (not
Package - HSG400 (not shown)
shown)
41. 21760-001
21760-001 Ootional
Optional Pedestal Mountina (not
Pedestal Mountinq (not shown)
shown)
PAGE
PAGE 17
 TECHNICAL
TECHNICAL INFORMATION
INFORMATION
"Troubleshooting Guide"
"Troubleshooting Guide"
NUISANCE
NUISANCE LOCKOUTS/FLAME SENSING PROBLEMS.
LOCKOUTS/FLAME SENSING PROBLEMS - HSG2OO
HSG200 & HSG4OO
HSG400 GAS BURNERS
GAS BURNERS

Wayne's
Wayne's HSG HSG series direct spark
series direct ignition (DSl)
spark ignition (DSI) gasgas burnerhead
burner head with approximately
with approximately 1/16" (1.5875mm)
1116"(1.5875mm)
burners prove
burners flame through
prove flame through the the process
process ofof flame
flame clearance from
clearance the head.
from the The probe
head. The probe must not be
must not be
rectification. Flame rectification
rectification. Flame rectification is
is achieved
achieved by by placing
placing a positionedto
positioned to far away from
far away from the
the head
head as
as this
this may
may
smallvoltage
small on the
voltage on the flame
flame sensing
sensing probe.probe.When
Whenthe the result in grounding
result in grounding outout of the probe
of the againstthe
probe against the
probeis
probe is surrounded
surrounded byby flame, thevoltage
flame, the voltage on the probe
on the probe insidesurface
inside of the
surface of the air tube.
air tube.
"leaks"to
"leaks" to ground
ground through
through the the flame, resultingin
flame, resulting an
in an . flamerod probe
The flamerod
The should be
probe should be free
free ofof soot
soot and
and
electrical This current
current.This
electrical current. current is interpretedby
is interpreted by the
the
creosote.
creosote. Deposits may insulate
Deposits may the probe,
insulate the probe, leading
leading
ignition controlas
ignition control the presence
as the presence of of flame.
flame.
it
it not to pass
not to pass the
the electrical
electrical charge
charge toto the
the flame.
flame. The
The
Oneof
One of the common problems
mostcommon
the most with gas
problems with gas appliances
appliances probecan
probe can be
be cleaned
cleaned with steel wool,
with steel emery paper
wool, emery paper
utilizing
utilizing this
this type
type of electronic flame
of electronic flame sensing
sensing system
system is is or fine
or fine sandpaper. NOTE:This
sandpaper. NOTE: is the
This is leadingcause
the leading cause
the "nuisance
the lockout".Lockouts
"nuisance lockout". Lockouts are notgenerally
are not generally duedue of nuisancelockouts
of nuisance lockouts in dual-fuel wood/oas
in dual-fuel wood/gas fired
fired
to
to the
the burner
burner failing
failing to
to ignite,
ignite, but
but rather simply the
rather simply the failure
failure appliances.
appliances.
of
of the
the system
system to to sense
sense the
the establishment
establishment of of flame.
flame. . The flame rod probe
The flamerod probe may
may be
be burned
burned away.
away. Check
Check it
it
Should this
Should situation exist
this situation for a period
exist for period of
of time
time longer
longer
against
against dimensions
dimensions onon the
the ELECTRODE
ELECTRODE AND A1'JD
than
than thethe ignition
ignition control's
control's state
state lockout
lockout timing,
timing, thethe
FLAMEROD
FLAMEROD PROBESETTINGS
PROBE SETTINGS drawing.
drawing.
control
control will shut down
will shut down oror go into permanent
go into permanent lockout.
lockout. The
The
only way
only way toto get
get the burner to
the burner to recycle
recycle isis to
to break,
break, and
and . The
The dimensional
dimensional location of the
location of flame rod probe
the flamerod probe may
may
reinstate power
then reinstate
then power toto the
the burner.
burner. be
be incorrect,
incorrect, or the probe
or the probe may
may bebe bent
bent out
out of
of shape.
shape.
The Check
Check itit against
against dimensions
dimensions onon the
the ELECTRODE
ELECTRODE
The following
following situations
situations can can lead
lead to flame
flame sensing
sensing
problems AND FLAMEROD
AND FLAMEROD PROBE SETTINGS drawing
PROBE SETTINGS drawing and
and
problems and
and can
can be checked
checked without
without
adjust if
adjust if necessary.
necessary.
disassembling the
disassembling the burner:
burner:
. The
The spark electrode gap
spark electrode gap may
may be
be incorrect,
incorrect, resulting
resulting
. The burner is
The burner is notnot properly
properly grounded
grounded to to "earth
"earth
ground" in
in no
no spark
spark or an inadequate
or an inadequate spark that will
spark that will not
not
ground" on the line
on the line voltage.
voltage.
ignite
ignite the gas properly.
the gas properly. Check
Check the electrode gap
the electrode gap
. The
The ignition
ignition control
control is not properly
is not properly grounded
grounded to to the
the against the
against the ELECTRODE
ELECTRODE AND AND FLAMEROD
FLAMEROD
burner itself.
burner itself. Using an ohmmeter, check
Using an ohmmeter, check thethe wire
wire PROBE
PROBE SETTINGS
SEn-INGS drawing
drawing and
and adjust if required.
adjust if required.
attached
attached to both parts
to both for good
parts for good contact
contact andand . The
The high tension lead
high tension lead conductor
conductor from
from the
the ignition
ignition
continuity.
continuity.
transformer
transformer to to the
the tip
tip of
of the spark electrode
the spark electrode maymay bebe
. The burner ignition
The burner ignition control is polarity
control is sensitive. The
polarity sensitive. The broken, preventing
broken, preventing the high voltage
the high current from
voltage current from
polarity
polarity ofof the
the incoming
incoming lineline voltage
voltage may may be be getting
getting to
to the
the electrode
electrode tip.tip. Check
Check all
all connections
connections
reversed.
reversed. Verify
Verify that that black and white
black and white wires are hot
wires are hot thoroughly
thoroughly and/or
and/or check
check to to continuity
continuity of
of the
the lead
lead
and neutral
and neutral respectively,
respectively, and and that
that they
they areare wire
wire assembly
assembly withwith an
an ohmmeter.
ohmmeter.
connected
connected to to thethe corresponding
corresponding black and white
black and white
Once
Once all
all of the items
of the listed previously
items listed previously have have been
been
wires
wires on
on the
the burner.
burner.
carefully checked
carefully checked and corrected if
and corrected if necessary,
necessary, reinsert
reinsert
The
The remaining
remaining checks andlor adjustments
checks and/or adjustments requirerequire the gas
the gas train
train assembly
assembly intointo the
the burner.
burner. NOTE:
NOTE: Be Be
removal the gas
removal of the gas train:
train: careful
careful not
not to bend the
to bend air proving
the air proving switch
switch sail arm (if
sail arm (if so
so
. The equipped)
equipped) or accidentally reposition
or accidentally reposition either the flamerod
either the flamerod
connections from
The connections from the'SENSE'terminal
the "SENSE" terminal of of the
the probe
probe or
or electrode
electrode during
during reinstallation
reinstallation of the gas
of the gas train
train
ignition control to
ignition control to the
the end
end of the flamerod
of the f1amerod may may bebe
assembly.
assembly.
broken
broken at some point.
at some point. Check
Check allall quick
quick connect
connect
terminations
terminations and and connections. Check the
connections. Check the continuity
continuity lf,
If, after
after all
all of
of the above listed
the above listed items
items have
have been
been carefully
carefully
with
with an ohmmeter while
an ohmmeter while flexing
flexing wires
wires to assure no
to assure no checked,
checked, the the burner still fails
burner still fails to
to work,
work, it
it is
is due
due to
to one
one or
or
hidden
hidden conductor
conductor breakage
breakage exists.
exists. lfIf replaced,
replaced, more
more of of the following problems:
the following problems:
wiring
wiring must
must be be ofof equal,
equal, or heavier gauge
or heavier gauge and and
1.
1. Unit
Unit sparks and fires
sparks and but will
fires but will not stay lit.
not stay lit. lgnition
Ignition
equal,
equal, oror better
better temperature
temperature rating.
rating.
control
control module
module is
is malfunctioning
malfunctioning and
and must
must be be
. The flamerod probe
The flamerod probe maymay bebe grounded
grounded out.out. Assure
Assure replaced.
replaced.
that
that the flamerod probe
the flamerod probe isis not
not touching
touching the the burner
burner
2.
2. Unit
Unit does
does not spark. lgnition
not spark. Ignition transformer
transformer is
is bad
bad and
and
head. The probe
head. The probe should
should bebe positioned
positioned inin the
the center
center
must
must be
be replaced.
replaced.
of
of the clearance groove
the clearance groove on on the
the outer
outer edge
edge of of the
the

PAGE
PAGE 19
 LIMITEDWARRANTIES
LIMITED WARRANTIESFOR
FOR OIL
OIL AND
AND
GAS BURNERS,
GAS MADE BY
BURNERS,MADE BY WAYNE
WAYNE AND
AND
USED IN
USED RESIDENTIALINSTALLATIONS
IN RESIDENTIAL INSTALLATIONS

WAYNECOMBUSTION
WAYNE COMBUSTION SYSTEMS
SYSTEMS ("WAYNE")
("WAYNE") warrants
warrants original
original burnerLIMITED
burner LIMITEDWARRANTY.
WARRANTY.
to those
to thosewho purchase
whopurchase itsOil
its BurnerModels
Oil Burner Modelsfor forresale
resaleor
or 5. Iflf inspection
5. inspection byWAYNE
by WAYNE doesNOT
does NOTdisclose
disclose anydefect
any defect
for incorporation
for incorporation into productof
intoaa product of resale,
resale,that
thatitsits burner
burnerisis coveredby
covered by this LIMITEDWARRANTY,
this LIMITED WARRANry,the the burner
burneror
or
free from
free from defects
defectsin in material
materialandand workmanship
workmanship under
under burnercomponent(s)
burner component(s) will be
will be either
either repaired
repairedoror
normaluse
normal useand
andservice
serviceforforthirty-six
thirty-six (36)months
(36) monthsfrom fromthe
the replaced
replaced at theexpense
atthe expense ofthe
of thecustomer
customer WAYNE's
andWAYNE's
and
dateof
date manufacture,
of manufacture. ALLGAS
ALL GASBURNERS
BURNERS manufactured
manufactured regular
regular charges
charges willapply.
will apply.
by "WAYNE"
by "WAYNE"willwillbe
be similarly
similarly warranted
warranted for eighteen(18)
for eighteen(18)
6. Iflf the
6. the original
originalmanufacturer
manufacturer of aa burner
of burnercomponent
component
monthsfrom
months fromdate
dateof of manufacture
manufacture exceptwhere
except whereoriginal
original
offersa warranty
offers greaterthan
warranty greater thaneither
eitherof
of our LIMITED
our LIMITED
manufacture
manufacture offers greaterwarranty.
offersa greater (Reference
warranty.(Reference #6
#6
WARRANTIES
WARRANTIES described
described above,then
above, thenthis portionwill
thisportion will
below)THESE
below) THESELIMITED
LIMITED WARRANTIES
WARRAI\lTIES DO NOT
DO NOTAPPLY
APPLY
beadded
be addedtoto our
ourLIMITED
LIMITED WARRANTY.
WARRANTY.
UNLESSTHE
UNLESS THE BURNER
BURNERCOVEREDCOVEREDBY BY IT
IT IS
IS PROPERLY
PROPERLY
INSTALLED BY
INSTALLED BY A QUALIFIED,
OUALIFIED,COMPETENT COMPETENT This LIMITED
This LIMITEDWARRANTY
WARRANTY does NOT
does NOTcover
cover products
oroducts
TECHNICIAN,
TECHNICIAN, WHO IS
WHO IS LICENSED
LICENSED WHERESTATE
WHERE STATE whichhave
which havebeen
beendamaged
damaged as
as the
the result
result of accident,
of accident,
AND/ORLOCAL
AND/OR LOCALCODES PREVAIL.
CODESPREVAIL, AND WHO
AND WHO IS IS abuse,misuse,
abuse, misuse,neglect,
neglect, improper
improper installations,
installations, improper
improper
EXPERIENCED
EXPERIENCED IN MAKING
IN MAKINGSUCH INSTALLATIONS,
SUCHINSTALLATIONS, IN
IN maintenance
maintenance or
or failure
failure to
to operate
operate in
in accordance
accordance with
with
ACCORDANCE
ACCORDANCE WITHI\lFPA
WITH NFPA#31 #31 OFOF THETHE NATIONAL
NATIONAL WAYNE's
WAYf\IE's writteninstructions.
written instructions.
FIRE PROTECTION
FIRE PROTECTIONASSOCIATION
ASSOCIATIONAND AND IN IN LIMITEDWARRANTIES
TheseLIMITED
These WARRANTIES not extend
do not
do extendto
to anyone
anyone
ACCORDANCE
ACCORDANCE WITH ALL
WITH ALL LOCAL,
LOCAL. STATE STATEAND AND exceptthe
except the first purchaserat
first purchaser retailand
at retail and only
only when
when the
the
NATIONAL
NATIONAL CODES.
CODES. burner is in
burneris inthe
theoriginal
originalinstallation
installation site,
site.
lN-WARRANTY
AnyIN-WARRANTY
Any burnercomponent
burner component whichis
which is defective
defective IMPLIEDWARRANTIES
IMPLIED WARRANTIES OF MERCHANTABILITY
OF MERCHANTABILITY AND
AND
in material
in materialoror workmanship
workmanship will be
will be either repairedor
eitherrepaired or FITNESS
FITNESS FORA PARTICULAR
FOR PARTICULARPURPOSE
PURPOSE SHALLBE
SHALL BE
replaced
replaced as follows:
as follows: LIMITEDTO
LIMITED TO THE
THE DURATION
DURATIONOFOF THE
THE LIMITED
LIMITED
gas valves, EXPRESSWARRANTIES
EXPRESS WARRANTIES CONTAINED
CONTAINED HEREIN.WAYNE
HEREIN. WAYNE
1. Fuel
1. Fuel units,
units, motors,
motors,transformers,
transformers, gas valves,andand
EXPRESSLYDISCLAIMS
EXPRESSLY DISCLAIMSAND
AND EXCLUDES
EXCLUDESANY ANY
controlsshould
controls shouldbe returned
be returned to an
to an authorized
authorized service
service
LIABILITYFOR
LIABILITY FOR CONSEQUENTIAL
CONSEQUENTIAL OR INCIDENTAL
OR INCIDENTAL
stationor
station or distributor
distributor WAYNEfor
of WAYNE
of for determination
determination of
of
DAMAGES
DAMAGES OF ANY NATURE
OF ANY FORBREACH
NATUREFOR BREACHOF OF ANY
ANY
applicability
applicability of this
of LIMITED
thisLIMITED WARRANTY
WARRANTY asto
as to either
either
EXPRESS
EXPRESS IMPLIED
ORIMPLIED
OR WARRANTY.
WARRANTY.
repairor
repair or replacement,
replacement, wheresaid
where saidservice
servicestation
stationor
or
distributor
distributor is reasonably
is reasonably availablein
available in the
the customer's
customer's Somestates
Some statesdo notallow
donot limitation
allowlimitation onhow
on howlong
longan
an implied
implied
locality.The
locality. The manufacturers
manufacturers of burner
of burnercomponents
components warrantylasts,
warranty lasts,soso the
the above limitation
abovelimitation may not
may not apply
applytoto
regularly
regularly publishand
publish and distribute
distribute listingsshowing
listings showingthe the you. Also,
you. Also,some
somestates do not
statesdo not allow
allowthe
the exclusion
exclusionor or
locations
locations of their
of theirnetwork
networkofof service
servicestations. Where
stations.Where limitation
limitation of incidental
of incidental or consequential
or consequential damages,
damages, so the
so the
localservice
suchlocal
such serviceis is NOT
NOTavailable
available for the
for burner
the burner abovelimitation
above limitation or exclusion
or exclusionmaymay notnot apply
applyto you.
to you.
comoonents
components described
described aboveor
above orother
otherburner
burner oartsare
parts are WAYNEneither
WAYNE neitherassumes
assumesor or authorizes
authorizes personto
any person
any to
involved,these
involved, these items
itemsshould
shouldbe returned,freight
be returned, freight assumefor
assume for WAYNE
WAYNEany otherliability
any other liabilityor
or obligation
obligation in
in
prepaid,
prepaid, to WAYNE
to WAYNE Department,
ServiceDepartment,
Service Glasgow
801Glasgow
801 connection
connection withthe
with the sale
saleof
of these products.
theseproducts. Thiswarranty
This warranty
Ave,Fort
Ave, FortWayne,
Wayne,Indiana
Indiana46803.
46803. givesyou
gives you specific
specificlegal rights,and
legalrights, you may
and you may also
also have
have
rightswhich
otherrights
other whichvary
varyfrom
fromstate to state.
stateto state.
2. Burners
2. Burnersand/or
and/or component(s)
component(s) determinedto
determined to be
be
covered
covered underthis
under thisLIMITED
LIMITED WARRANTY
WARRANTY by WAYNE
by WAYNE
shall berepaired
shallbe repaired or replaced
or replaced at WAYNE's
at WAYNE's sole option.
soleoption.
3. WAYNE
3. WAYNEis is not
not responsible
responsible for any
for laborcost
any labor for the
costfor the
removaland
removal and replacement
replacement of said
of said burner
burneror
or burner
burner
components
components andequipment
and equipment associated
associated therewith.
therewith.
4. A
4. A burner
burnerso repairedwill
so repaired will then
then carry the LIMITED
carrythe LIMITED
WARRANTY
WARRANTY equalto
equal to the
the unexpired
unexpired portionof
portion of the
the

PAGE20
PAGE 20
 CONSUMER
CONSUMER INSTRUCTIONS
II\ISTRUCTIONS
MAINTENANCE:
MAINTENANCE: A dangerous
A dangerous conditionhas
condition hasdeveloped
developed andmust
and mustbe
becorrected.
corrected.
otr Keep
Keepthe
the area
areaaround
aroundthe
the burner
burnerclear
clearand
andfree
freeof
of com-
com- CONTACTA QUALIFIED
CONTACT QUALIFIED SERVICE TECHNICIAN
SERVICETECHNICIAN FOR
FOR
bustiblematerials,
bustible materials, gasolineor
gasoline or other
otherflammable
flammable liquidsor
liquids or CLEANING,
CLEANING, READJUSTMENT
READJUSTMENT ORREPAIR.
OR REPAIR.
vapors.Do
vapors. Do not
not obstruct
obstructburner
burnerair
air openings
openings or ventilation
or LIGHTING
ventilation LIGHTING INSTRUCTIONS:
INSTRUCTIONS:
grillesfor
grilles forcombustion
combustion air.
air. See Section
SeeSection InitialStart
IIll Initial Uo
Start Up
1.TURN
1. (DEPRESS)
TURN(DEPRESS) VALVE
VALVE DIALTO
DIAL ON.
TO ON.
CAUTION:Check
CAUTION: Checkthe the burner
burnerflame periodically.
flameperiodically. proper 2. TURN MAIN POWER ON.
A proper
2.TURNMAINPOWER ON.
NATURAL
NATURAL gasflame
gas flamewillwillappear
appearblue
blueatatthe
theburner
burnerface facewith
with 3.
3. SET THERMOSTAT
SETTHERMOSTAT OR OPERATING
OR OPERATING CONTROLTO
CONTROL TO CALL
CALL
orangeand
orange yellowtips.
and yellow tips.A properPROPANE
A proper PROPANE gasflame
gas flamewillwill HEAT.
FORHEAT.
FOR
appearblue
appear blueatat the
the burner
burnerface
facewith yellowtips.
with yellow tips. Iflf the flame 4.
the flame 4. WAIT
WAIT30
30 SECONDS.
SECONDS. IF BURNER
IF BURNERHASHAS FAILED
FAILEDTO
TO LIGHT,
LIGHT
is too
is too rich, will appear
rich,it will appearbillowy
billowyand yellowwith
andyellow with hazyhazytips,
tips, IF BURNER
OR IF
OR BURNERLIGHTS LIGHTSTHENTHEN GOES
GOES OUT,
OUI TURN
TURN
if too lean,itit will
too lean, will appear
appearshort
shortand
andallall blue. Burnercleaning
blue.Burner cleaning BURNER
BURNER OFFFOR
OFF FOR30 30 SECONDS
SECONDS ANDTHEN
AND THENBACK
BACKONON
and/or readjustmentis
and/orreadjustment is indicated
indicatedby flamesthat
by flames thatare
aretoo rich
too rich RESTART.
FORRESTART.
FOR
or too
or too lean.
lean.
TOSHUT
TO SHUTOFF:
OFF:
WARNING:
WARNING: lf any
If anyflame
flameis is observed
observedwhen
whenthe the burner
burneris is on
on 1.TURN
1. (DEPRESS)
TURN(DEPRESS) VALVE
VALVE D]ALTO
DIAL OFF.
TO OFF.
standby,or
standby, or if the ignitionspark
the ignition sparkor valveoperator
or valve operatoris is heard
heardto to 2.TURN
2. TURNMAIN
MAINPOWER POWER OFF.
OFF.
come on
come on before
beforethe the motor reachesoperating
motor reaches operatingspeed,
speed,im- im-
mediately
mediately turn off
turn otf the
the manual
manualgasgascontrol
controlandandmain
mainpower.power.

EXPLOSIONHAZARD
lf PROPANE
If PROPANEgasgas is
is used
used and
and the
the burner
burner is
is located
locatedin in aa areas
areasor confined
confinedspaces. This would
spaces.This would create DANGER
createa DANGER
basement,crawlspace
basement, crawlspaceor confined
confined space,
space,contact your OF
contact your OF EXPLOSION
EXPLOSIONOR OR FIRE. you suspect
FIRE. Iflf you gas leak,
suspect aa gas leak,
gas supplier
gas supplierabout
aboutinstalling "gas leak"
installingaa "gas leak"warning
warningdevice.
device. follow
follow instructions
instructionsonon front
front cover
cover of
of this
this manual.
manual.
PROPANEgas
PROPANE gas is heavier
heavierthan
than air
air and
and can
can settle
settle in
in low
low

MONOXIDE
CARBON MONOXIDE
CARBON
)u ELECTRICSHOCK
ELECTRIC HAZARD
SHOCK HAZARD

POISONINGHAZARD
POISONING HAZARD HIGHVOLTAGES
HIGH VOLTAGESAREPRESENT
ARE PRESENT INTHIS
IN THISEQUIPMENT
EQUIPMENT
FOLLOW
FOLLOW THESERULES
THESE RULESTO
TOAVOID ELECTRICAL
AVOID ELECTRICAL SHOCK.
SHOCK.
CARBON
CARBON MONOXIDE
MONOXIDE ISACOLORLESS,
IS ODOBLESS
A COLORLESS, ODORLESS GAS
GAS
THATCAN
THAT CAN KILL.
KILL.FOLLOW
FOLLOWTHESE
THESERULES
RULESTOTO CONTROL
CONTROL ...
A Use
Use only properlygrounded
only aa properly groundedcircuit. groundfault
circuit.A ground fault
CARBONMONOXIDE.
CARBON MONOXIDE. interrupter is recommended
interrupteris recommended

A Do
... Do not
not use this burner
usethis in an
burnerif in an unvented,
unvented,enclosed
enclosedarea. A Do
area. ... Do not
not spray waterdirectly
spraywater directlyon
on burner.
burner,
Carbonmonoxide
Carbon monoxidemaymayaccumulate.
accumulate.
A Turn
... Turnoff powerbefore
off power beforeservicing.
servicing.
A Do
... Do not
not adjust
adjust the pressureregulator.
the pressure regulator.High pressures
High pressures
producecarbon
produce carbonmonoxide.
monoxide. l' Read
... Readthe
the owner's manualbefore
owner'smanual beforeusing.
using.

... Check
vrr996 flue
ttug gases
Yq99D for
I carbon monoxide. This check ....- - - - - - - - - - - - - - - - - - - - - - 1
-
requiresspecialized
requires specializedequipment.
equipment.

A Allow
... Allow only qualifiedburner
only qualified burner service personsto adjust
servicepersons adjust
the burner.
the burner. Special
Special instruments
instruments and
and training
training are
are
required.
required . OVERHEATING
OVERHEATING HAZARD
HAZARD
-
A Read
... Readthe
the owner's
owner'smanual
manualbefore
beforeusing.
using. SHOULDOVERHEATING
SHOULD OVERHEATINGOCCUR:
OCCUR:

Shut off the manual

Shut gas control
manual gas 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

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Notes
Notes

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