Wayne HSG200, HSG400 User Manual
WAYNE COMBUSTION SYSTEMS
801 GLASGOW AVE.
FORT WAYNE, IN 46803
PHONE: (260) 425-9200
(855) WAYNECS
(800) 443-4625
FAX: (260) 424-0904
www.waynecombustion.com
Manual 62484 | Revision D | Publication Date: 4/25/2018
Note: Dimensions in parentheses ( ) are informational only. English values take priority.
HSG200
HSG400
SPECIFICATIONS
BURNER MODELS MINIMUM INPUT MAXIMUM INPUT Air Tube Standard Lengths
HSG200 60,000 Btu/hr (18 kW) 200,000 Btu/hr (59 kW) 6, 9,12 in. (153, 229, 305 mm)
HSG400 200,000 Btu/hr (59 kW) 400,000 Btu/hr (117 kW) 6, 9,12 in. (159, 229, 305 mm)
FUELS: Natural Gas and LP Gas FLAME SAFETY: 24 Vac Electronic IGNITION: 7300 Vac Direct Spark
AVAILABLE VOLTAGES: 120 Vac 60 Hz, 230 Vac 50/60 Hz 1 Phase
AIR TUBE DIAMETER: 4 in (101.6 mm) MOUNTING: Adjustable Flange is standard; Pedestal Mount is Optional
Gas Burners
READ THIS MANUAL BEFORE USING THIS PRODUCT. FAILURE TO FOLLOW THE
INSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN
SERIOUS INJURY OR DEATH. KEEP THIS MANUAL FOR FUTURE REFERENCE.
INSTALLTION OF THE BURNER MUST BE DONE BY A QUALIFIED INSTALLER IN
ACCORDANCE WITH REGULATIONS OF THE NATIONAL FUEL GAS CODE ANSI
Z223.1/NFPA54, AND IN COMPLETE ACCORDANCE WITH ALL LOCAL CODES AND
AUTHORITIES HAVING JURISDICTION.
A QUALIFIED INSTALLER IS THE PERSON WHO IS RESPONSIBLE FOR THE
INSTALLATION AND ADJUSTMENT OF THE EQUIPMENT AND WHO IS LICENSED
TO INSTALL GAS-BURNING EQUIPMENT IN ACCORDANCE WITH ALL CODES AND
ORDINANCES.
CSA CERTIFICATION:
189810-1154925
ANSI Z21.17
MASS G3-0903-67
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. The meaning of this safety alert symbol is as follows: Attention! Become alert!
Your safety may be at risk. The message that appears next to the warning which can be
either written or pictorially presented. NEVER remove or tamper with the warning labels,
safety devices or guards fitted on the unit.
Wayne Combustion System is NOT responsible for any bodily injury and/or property
damage that may result from operation outside of the stated operating conditions for
which this unit was intended.
Indicates a hazardous situation, which, if not avoided, will result in
death or serious bodily injury.
Indicates a hazardous situation, which, if not avoided, could result in
death or serious bodily injury.
Indicates a hazardous situation, which, if not avoided may result in
minor or moderate bodily injury.
Indicates a situation that may result in equipment-related damage.
Overview of Safety Warning System and Your Responsibilities
The safety of you and others depends upon you thoroughly reading and understanding this manual. If you
have questions or do not understand the information presented in this manual, please call Wayne
Combustion System or see www.waynecombustion.com.
Hazard Definitions:
2
Hazard Level
Pictogram
Type
Hazard Explanation
Fire or
Explosion
Failure to follow safety warnings exactly could
result in serious injury, death or property damage.
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
WHAT TO DO IF YOU SMELL GAS:
Open windows.
Do not try to light any appliances.
Do not touch electrical switches; do not use
any phone in your building.
Extinguish any open flame.
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.
Electric shock
or burn
High voltages are present in this equipment. Follow
these rules to avoid electric shock:
Use only a properly grounded circuit. A ground
fault interrupter is recommended.
Do not spray water directly on burner.
Turn off power before servicing.
Read the owner’s manual before using.
Overheating
Should overheating occur:
Shut off the manual gas control to the
appliance.
DO NOT shut off power to the equipment,
allow blower to continue running.
Carbon
Monoxide
Poisoning
Carbon monoxide is a colorless, odorless gas that
can kill. Follow these rules to control carbon
monoxide:
Do not use this burner if in an unvented,
enclosed area. Carbon monoxide may
accumulate.
Do not adjust the pressure regulator. High
pressures produce carbon monoxide.
Check flue gases for carbon monoxide. This
check requires specialized equipment.
Allow only qualified burner service persons to
adjust the burner. Special instruments and
training are required.
Read the burner manual before using.
CARBON MONOXIDE POISONING: Early signs of
carbon monoxide poisoning are similar to the flu with
headaches, dizziness, weakness, nausea, vomiting,
sleepiness, and confusion. If you suspect carbon
monoxide poisoning, get outside to fresh air
immediately, and then call 911. Some people are more
affected by carbon monoxide than others. These
include pregnant women, people with heart or lung
disease or anemia, those under the influence of
alcohol, and those at high altitudes. Propane/LP gas
and natural gas are both odorless. An odor-making
agent is added to each of these gases. The odor helps
you detect a gas leak. However, the odor added to
these gases can fade. Gas may be present even
though no odor exists.
3
Hazard Level
Pictogram
Type
Hazard Explanation
Proposition 65
material
This product can expose you to chemicals, including
lead, nickel, carbon monoxide and sulfur dioxide, which
are known to the State of California to cause cancer or
birth defects or other reproductive harm. For more
information, go to www.p65Warnings.ca.gov.
Special
Requirements
When contacting Wayne Combustion Systems for
service information, please have the burner
specification number and model number when calling
or writing. Specification number is at the bottom of the
“T” shape on the back of the burner and model number
is at the top of the “T” shape on the back of the burner.
If any instructions in the manual are not clear, contact Wayne
Combustion Systems at 1-260-425-9200 for assistance.
4
INSTALLATION LOG
BURNER MODEL:
SPECIFICATION
NUMBER:
FUEL (NATURAL OR
LP):
GAS ORIFICE SIZE:
INLET GAS
PRESSURE
(in. w.c.):
CO2 (%):
O2(%):
CO (PPM):
INSTALLER’S NAME:
CONTRACTOR NAME:
CONTRACTOR
ADDRESS:
CONTRACTOR PHONE
NUMBER:
CONTRACTOR
LICENSE #:
DATE OF INSTALLATION:
COMMENTS ABOUT INSTALLATION/START UP:
BURNER/APPLIANCE SERVICE LOG
SERVICE DATE
TECHNICIAN
COMPANY
/ ADDRESS
CONTRACTOR
LICENSE #
WORK PERFORMED
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
/ /
THESE INSTRUCTIONS SHOULD BE AFFIXED TO THE BURNER OR ADJACENT
TO THE HEATING APPLIANCE.
5
Contents
SECTION I: INSTALLATION AND SETUP .......................................................................................................... 7
VISUAL INSPECTION OF THE HEATING SYSTEM .......................................................................................... 7
INSPECTION OF FLUE PIPE AND CHIMNEY .................................................................................................. 8
INSPECTION OF HEATING APPLIANCE ......................................................................................................... 9
FLUE PIPE, DRAFT HOOD, AND BAROMETERIC DAMPER ............................................................................ 9
PREPARATION OF COMBUSTION CHAMBER ............................................................................................. 11
SIZING OF COMBUSTION CHAMBER ......................................................................................................... 12
BURNER INSTALLATION ............................................................................................................................ 12
INSTALLATION OF MOUNTING FLANGE .................................................................................................... 12
DETERMINE ORIFICE SIZE AND RATE ........................................................................................................ 13
CHANGING THE ORIFICE ........................................................................................................................... 15
INSPECTION AND SIZING OF GAS PIPING .................................................................................................. 17
TESTING PIPING FOR LEAKS ...................................................................................................................... 20
ELECTRICAL WIRING OF BURNER .............................................................................................................. 20
INSPECTION OF LIMIT CONTROL SWITCHES ............................................................................................. 21
INSTALLATION OF THERMOSTAT .............................................................................................................. 21
SECTION II: INITIAL START UP ..................................................................................................................... 22
INITIAL BURNER START UP PROCEDURE ................................................................................................... 23
COMBUSTION ADJUSTMENT OF BURNER ................................................................................................. 24
SECTION III: GAS CONVERSION ................................................................................................................... 25
SECTION IV: CONSUMER INSTRUCTIONS .................................................................................................... 26
GENERAL INSTRUCTIONS FOR SERVICING BURNER .................................................................................. 26
SECTION V: SERVICE AND TROUBLESHOOTING .......................................................................................... 27
HSG SERIES BURNER UTILIZING WAYNE 64420 SERIES IGNITION CONTROLS .......................................... 27
HSG SERIES BURNER UTILIZING HONEYWELL IGNITION CONTROLS ........................................................ 28
FLAME SENSING ON HSG SERIES BURNERS .............................................................................................. 29
TROUBLESHOOTING GUIDE PRIMARY IGNITION CONTROLS .................................................................... 32
SERVICING HSG SERIES BURNER ............................................................................................................... 38
TROUBLESHOOTING GUIDE ...................................................................................................................... 40
HSG WIRING DIAGRAMS ........................................................................................................................... 42
SECTION VI: PARTS LIST AND EXPLODED VIEWS ......................................................................................... 46
HSG200/400 PARTS LIST ........................................................................................................................... 46
HSG EXPLODED VIEWS .............................................................................................................................. 47
SECTION VII: WARRANTY ............................................................................................................................ 51
6
Ventilating Air Opening
1 Sq. in. (645.2 mm2)
for each 1,000 Btu
(.29 kW) per hour
Input, 100 Sq. in. minimum.
Application below located in confined spaces. Ventilation
air from inside building – combustion and draft hood
dilution air from outside with ventilated attic or ventilated
crawl space.
3. CHIMNEY OR GAS
2. ATTIC
VENTILATION
LOUVERS
VENTILATION
AIR OUTLET
1. VENTILATION
AIR INLET
Air Inlet Opening 1 Sq. in.
(645.2 mm2) for each
1,000 Btu (.29 kW)
per hour input, 100 Sq. in.
minimum.
CRAWL SPACE VENTILATION LOUVERS
Illustration above shows air opening
necessary to supply air for combustion
when heating appliance is installed in
an enclosed room.
Figure 1
Figure 2
SECTION I: INSTALLATION AND SETUP
These instructions were prepared for the guidance of those installing this particular gas conversion burner.
While they apply in principle to all installations, they should not be interpreted as meaning the only safe and
economical way to install a conversion burner. It may be necessary to deviate from these instructions in some
instances in order to comply with local gas company rules or codes in effect in the area in which the installation is
made. It is recommended that the installer confer with the local gas company and with the proper municipal officials
regarding any specific code or regulation governing the installation of gas conversion burners.
The installation must conform with local codes or, in the absence of local codes, with the American National Standard
ANSI Z21.8 Installation of Domestic Gas Conversion Burners and ANSI Z223.1 the National Fuel Gas Code, latest
version.
Safe and economical operation of the burner throughout its service life is dependent to a large extent upon its
proper installation in the heating appliance. Therefore, we may impress upon the installer that good clean workmanlike
installations mean satisfied customers.
VISUAL INSPECTION OF THE HEATING SYSTEM
A conversion burner shall not be installed in an appliance located in a room or basement where facilities for normal air
circulation or infiltration are so limited so as to interfere with ready obtainment of all air necessary for proper
combustion and draft hood dilution, unless at the time of burner installation special provisions are made for combustion
and draft hood dilution air.
a. In open basements of homes of normal construction (without basement storm windows or tight stair doors)
infiltration of combustion air is usually sufficient to replace that drawn up the flue, so special provisions are
seldom necessary.
b. When the heating appliance is installed in a tightly closed room without ventilating openings to outdoors or
other rooms, provisions shall be made for supplying air for combustion through special openings, one near
the floor line and the other near the ceiling, each to be sized on the basis of one square inch or more of free
area for each 1,000 Btu/hr (0.2931 kW) input but not less than 100 square inches. (See Figure 1).
c. When the house is of unusually tight construction, has a (kitchen) ventilating fan which may be used for
exhausting air from indoors, or has a vented fireplace, it is recommended that combustion air be supplied to
the furnace room through intakes extending to the outside of the building and terminating in down turned
fittings, suitably arranged to prevent obstruction from snow or rain, and including a protecting screen not
smaller than 1/4-inch (6.35 mm) mesh.
7
NOTE ON FIGURE 2: Ducts used for make-up air may be connected to the cold air return of the heating system only if
they connect directly to outdoor air. Attic Ventilation Louvers are required at each end of attic with alternate air inlet
No. 1.
1, 2, and 3 mark alternate locations for air from outdoors. Free area shall be not less than 1 sq.in. (645.2 mm2) per
5,000 Btu/hr (1.465 kW) of the total input rating of all appliances in the enclosure.
Crawl-space Ventilation Louvers for unheated crawl space are required with alternate air inlet No. 3.
Each Ventilation Air Opening from inside the building shall have a free area of not less than 1 sq. in. (645.2 mm2) per
5,000 Btu per hour (1.465 kW) of the total input rating of all appliances in the enclosure.
The heating system (both the heat exchanger and distribution system) shall be of a size to properly heat the
building. Through inquiry it shall be determined that all rooms have been heated adequately without wide
variations in temperature, without objectionable drafts, and without excessive fuel costs in the past. If the heating
system is deficient with respect to any of the above determinations, provisions shall be made to correct the
deficiency, replace obsolete parts, or (by installing storm windows, insulation, etc.) to reduce the heat loss to a
point where the existing system will provide the proper amount of heat.
a. Gravity Warm Air System
The supply and return ducts and registers should be sized and arranged so that the house can be heated
without excessive furnace temperatures. Reference may be made to the American Society of Heating,
Refrigerating and Air-Conditioning Engineers Guide and Data Book series and Handbook of Fundamentals.*
b. Forced Warm Air Systems
Inspection should also show whether the electrical characteristics of the fan and limit switch are satisfactory
and whether the air filters and fan are in condition for continued proper service with the gas burner.
Reference may be made to the American Society of Heating, Refrigerating and Air-Conditioning Engineers
Guide and Data Book series and Handbook of Fundamentals.*
c. Hot Water Systems
The boiler thermometer and altitude gauge should be in good order. On a closed system, the feed and
pressure relief valves shall be in proper operating condition. If there is an expansion tank on a closed system,
inspection should show it to be substantially empty of water. When there is an existing water temperature
limiting switch, its operating and electrical characteristics shall be checked to determine its suitability to the
gas control circuit. For common piping systems reference can be made to the American Society of Heating,
Refrigerating and Air-Conditioning Engineers Guide and Data Book series* and to the Hydronic Institute
I=B=R Guides.**
d. Steam or Vapor System
The system shall be pressure tight, with pressure gauge and pop safety valve in good condition and with an
existing water glass which permits clear observation of boiler water level. When there is a pressure limit
switch or low-water cut-off, inspection shall determine whether either device can be utilized in the gas burner
control circuit, reference should be made to the American Society of Heating, Refrigerating and Air-
Conditioning Engineers and Institute of Boiler and Radiator Manufacturers guides. Traps and air vents shall
be of adequate capacity, in good condition, and correctly placed in the system.
*Copies may be obtained from the http://www.ashrae.org
**Copies may be obtained from the Hydronic Institute, 35 Russo Place, Berkeley, NJ 07922.
INSPECTION OF FLUE PIPE AND CHIMNEY
The flue pipe should be carefully inspected and replaced if necessary in connection with installation of a draft
hood. A barometric damper may be used per Flue Pipe, Draft Hood, and Barometric Damper section of
manual. All installations must operate with a negative draft overfire. Refer to your local gas company or
codes for assistance or to the furnace and/or boiler manufacturer for recommendations.
The flue pipe entrance into the chimney should be at least two feet (0.610m) above the clean-out opening in
the chimney.
The chimney should extend high enough above the dwelling or other neighboring obstructions so that wind
from any direction will not strike the chimney from any angle above horizontal. Unless the obstruction is of
greater magnitude, it is the usual experience that a chimney extending two feet above flat roofs or above fire
wall parapets, and peaked roofs within 30 feet (9.144m) will be reasonably free of downdraft.
8
Pitch Horizontal Run
1/4” (6.35mm) MIN.
per foot (0.305m)
Do Not Extend Flue
Pipe Beyond Inside
of Chimney
Cleanout
Reducer
Corrosion
Resistant Lining
Bull Head Tee
Single Acting
Control
Do Not Extend Flue
of Chimney
Pitch Horizontal Run
per foot (0.305m)
Vertical Draft Hood
Reducer
Horizontal
Draft Hood
Corrosion
Resistant Lining
Select either
Horizontal or
Vertical Draft Hood
Cleanout
Draft Hood Positions
Figure 3
Barometric Draft Control
Position
Figure 4
Where the chimney is unlined or where local experience indicates that flue gas condensate might be a
problem, the local gas company should be consulted.
The chimney should be examined and thoroughly cleaned, if necessary, before installation is made to make
sure it will freely conduct the flue gases to the outside.
Flue pipe should extend through the chimney wall to the inner face of the chimney liner but not beyond, and
should be firmly cemented to masonry. A thimble may be used to facilitate removal of flue pipe for cleaning, in
which event the thimble should be permanently cemented in place with mortar or other fireproof material that
will not crack or check the flue pipe or thimble, whichever is used, should be sealed into the chimney liner.
Flue connections from two or more appliances should not enter opposing or adjacent sides of the chimney at
the same level.
Under no circumstances should the flue pipe be connected to a flue of an open fireplace.
INSPECTION OF HEATING APPLIANCE
Clean the appliance heat exchanger interior, combustion chamber and flue connections. Remove all adhering
tars, scale, dirt, and soot. Inspect the heat exchanger for obvious and potential flue gas leaks. Cement all joints
around the appliance base and access openings to prevent air and/or flue gas leakage into or out of the
combustion chamber.
Warm Air Furnaces* - Make certain the electrical characteristics of the fan and limit switch correspond to those
required by this burner and that they are in proper working order.
Hot Water Boilers* - Make certain water temperature and altitude gauges, pressure relief valves are in proper
working order.
Steam Boilers* - Make certain the system is pressure tight and that the pressure gage and pop off safety valve are
in proper working order. Verify existing water sight glass permits clear observation of boiler water level.
*Where applicable, existing temperature of pressure limit switch or low water cut-off switch operation and
electrical characteristics shall be checked to determine their compatibility to the gas control circuitry of this burner.
NOTE: For oil fired conversions consult boiler or furnace manufacturer. Appliance must maintain negative draft over
fire.
FLUE PIPE, DRAFT HOOD, AND BAROMETERIC DAMPER
1/4” (6.35mm) MIN.
Pipe Beyond Inside
Barometric Draft
9
Input Btu/hr (kW)
Drafthood Flue Pipe Size
Up to 120,000 Btu/hr (35 kW)
5 Inch (127 mm) Diameter
120,000 Btu/hr (35 kW) – 180,000 Btu/hr (53 kW)
6 Inch (152 mm) Diameter
180,000 Btu/hr (53 kW) – 250,000 Btu/hr (73 kW)
7 Inch (178 mm) Diameter
250,000 Btu/hr (73 kW) – 320,000 Btu/hr (94 kW)
8 Inch (203 mm) Diameter
320,000 Btu/hr (94 kW) – 410,000 Btu/hr (120 kW)
9 Inch (229 mm) Diameter
Strict compliance to appropriate codes should be made regarding flue pipe clearances from combustible
materials. A CSA type draft hood or its equivalent shall be placed in and made part of the flue pipe from
the appliance. A barometric damper may be used in place of the draft hood where permitted by local
building codes. If an oil barometric damper has been previously installed this may be used if it is in good
condition and any and all weights and/or stops are removed. The flapper on a gas barometric damper must
be free swinging in both directions. Check with local building codes and building inspectors. At no time
should the draft hood be located at a point lower than the highest flue passage in the appliance. The draft
hood should be installed in the position for which it was designed and in no case installed in a false ceiling,
separate room from the heating appliance, or in any other manner that will permit a difference in pressure
between the draft hood relief opening and the combustion air supply. On sealed type appliances where all
combustion air is taken from the outside, a cap should be installed on end of flue pipe to prevent back
drafts. In such cases no draft hood or diverter should be installed inside.
Pitch the horizontal run of the flue pipe upward 1/4 inch (6.35 mm) per foot (0.305 m) or more. Run directly
to the chimney, fasten joints securely and support horizontal runs to prevent snagging. If the flue pipe must
be extra-long, it’s size should be increased. The horizontal length of the flue pipe should not exceed the
height of the chimney above the flue connection.
The draft control should be hood type per Figure 3 or, IF APPROVED BY LOCAL AUTHORITIES, a single
barometric damper suitable for gas firing per Figure 4. The draft control should be sized the same as the
flue pipe per Figure 5. Refer to the barometric draft regulator manufacturer’s instructions for complete
detail.
NOTICE: Should the flue pass through a partition the draft control must be located in the same room as
the heating appliance.
DRAFT HOOD & FLUE PIPE SIZES FOR GAS CONVERSION BURNERS IN FURNACES AND BOILERS
Figure 5
NOTE: If the flue pipe exceeds 10 ft. (3 m) in length, or contains more than two elbows, use next size larger
pipe and draft hood.
NOTE: All installations must operate with negative draft over fire. Refer to your local gas company and codes
for assistance.
When installing the burner in revertible flue (down draft or diving flue type) furnaces or boilers, the draft hood (or
draft diverter) should be located at least one foot higher than the top of the highest point of the appliance flue
passage or combustion chamber. It is also recommended that a vent pipe, not less than one inch in diameter, be
provided from the highest point in the flue passage, directly to the flue pipe. This is not necessary on the
appliances with built in up draft bypass. The gas company serving the area should be consulted in regards to their
recommendations for converting this type of furnace or boiler.
The flue pipe should be securely supported and the joints fastened with sheet metal screws or riveted to prevent
sagging, and in no case should be located in a manner that will present a hazard to combustible building material.
(Refer to local building code).
10
Forced Air Furnace
Figure 6
Hot Water or Steam Boiler
with Combustion Chamber
Target
Figure 7
Hot Water or Steam Boiler
with Combustion Chamber
Liner
Figure 8
HSG
Burner
HSG
Burner
HSG
Burner
Mounting
Flange
Mounting Flange
Mounting Flange
To Protect Properly
Locate End of Burner Tube. Position Tube
1/8” (3.2 mm) Short of Inside of
Combustion Chamber
To Protect Properly
Locate End of
Burner Tube.
Position Tube 1/8”
(3.2 mm) Short of
Inside of
Combustion
Chamber
To Protect Properly
Locate End of
Burner Tube.
Position Tube 1/8”
(3.2 mm) Short of
Inside of
Combustion
Chamber
Existing
Prefabricated
Combustion
Chamber
Liner
Existing
Prefabricated
Combustion
Chamber
Liner
Existing
Prefabricated
Combustion
Chamber
Liner
PREPARATION OF COMBUSTION CHAMBER
Clean the combustion chamber thoroughly. Scrape and brush all heating surfaces and flue ways. Soot and fly ash are
excellent insulators and unless removed, the efficiency of the heating appliance will be impaired. Plugged or restricted
flue passages will prevent burner from operating properly.
Be sure water column and gauge on boiler are clean and water level is visible. In all cases make sure the pigtail to limit
control is clear. Safety pop valves on steam boilers and automatic relief valves on closed water systems should be
thoroughly checked to make sure they are in good working condition.
When converting oil designed boilers and furnaces, it is recommended that the existing combustion chamber be used
with the gas burner, provided it is in good condition. If the blast tube opening into the combustion chamber is larger
than the 4” (102 mm) diameter, high temperature cement should be used to reduce the opening to 4” (102 mm)
diameter.
IN NO CASE SHOULD THE TUBE BE ALLOWED TO EXTEND INTO THE CHAMBER PROPER. IT MUST BE AT
LEAST 1/8” (3.2mm) SHORT OF THE INSIDE SURFACE OF THE COMBUSTION CHAMBER. (SEE FIGURES 6, 7,
8)
11
Input
Btu/hr (kW)
Preferred
Width Inches (mm) x
Length Inches (mm)
Diameter
Inches (mm)
50,000 (14.7)
7 (177.8) x 7 (177.8)
8 (203)
75,000 (22.0)
7.5 (190.5) x 7.5 (190.5)
9 (229)
100,000 (29.3)
12 (304.8) x 12 (304.8)
13 (330)
150,000 (44.0)
12 (304.8) x 15 (381)
14 (356)
200,000 (58.6)
13 (330.2) x 17 (431.8)
15 (381)
250,000 (73.3)
13 (330.2) x 18 (457.2)
16 (406)
300,000 (88.0)
13 (330.2) x 20 (508)
18 (457)
350,000 (102.6)
14 (355.6) x 21 (533.4)
20 (508)
400,000 (117.2)
15 (381) x 22 (558.8)
21 (533)
Recommended Combustion Chamber Sizes
Figure 9
SIZING OF COMBUSTION CHAMBER
The following table is provided as a guideline for determining combustion chamber size and corresponding
firing rate when appliance rates are not available.
BURNER INSTALLATION
The HSG200 and HSG400 power gas burners were designed for converting oil fired furnaces and boilers. Due
consideration was given to making it as simple and easy to install and service as possible without weakening its
durability or efficiency. The burner is supplied as a completely assembled package unit.
NOTE: The burner must be installed in such a manner that all controls will be readily accessible for inspection,
cleaning, adjustment and repairs.
INSTALLATION OF MOUNTING FLANGE
Position the mounting flange on the furnace wall, adjusting orientation as necessary until the bolt pattern of the furnace
allows the flange to sit flush. (See Figure 10 for flange dimensions.)
Note the orientation of the flange and remove it so that the flange gasket may be placed between the furnace wall and
the flange. Tighten the flange to the furnace wall.
Insert the burner tube into the flange and position it per Figures 6, 7, 8. Tighten the flange onto the burner tube.
12
FIGURE 10: Adjustable Mounting Flange Dimensions
DETERMINE ORIFICE SIZE AND RATE
The gas conversion burner needs to be set to deliver the same amount of heat to the appliance as the oil burner it is
replacing. Determine the Btu/hr heat input rate for the appliance by locating the rating plate of the appliance and
determine the firing rate of the oil burner. Typically the nozzle in the oil burner is stamped with the gallon per hour rate.
Use the lesser of these two rates as the firing rate of the gas burner.
For calculating from gallon/hour of oil to Btu/hour of gas, one gallon of oil produces 140,000 Btu/gal (147700 kJ/L) of
heat. For example: A furnace rating of 0.60 G.P.H. would be 0.60 x 140,000 = 84,000 Btu/hr. This is the input rate
needed from the gas burner.
Once the desired heat output of the burner has been determined, the gas orifice must be properly sized. The HSG200
and HSG400 power gas conversion burners are approved for use with natural and LP gas only. The HSG200 and
HSG400 burner models are shipped labeled and orificed for natural gas. To convert to LP gas and/or increase Btu/hr
(kW) input on natural or LP gas, an orifice kit is supplied with each burner with the orifices shown in Figure 11. Use
Figure 11 to select orifice size and manifold pressure to achieve desired rate on burner. If the desired input rating
cannot be obtained within the Figure 11 manifold orifice pressure adjustment range, the next size larger or smaller
orifice should be used (Refer to orifice chart Figure 11).
HSG200 is shipped from factory with a #8 - 0.199” orifice installed and HSG400 is shipped from the factory with a T -
0.358” orifice. The combination gas valve pressure regulator, which has an outlet pressure setting range of
approximately 2.0” w.c. (498.2 Pa) to 4.0” w.c (996.4 Pa) and is factory set at 3.5” w.c. (872 Pa).
13
Orifice Size and Drill
Manifold Pressure
2.0” (498 Pa)
3.0” (747 Pa)
4.0” (996 Pa)
HSG200 Natural Gas
#29 -.136 (3.5 mm)
50,000 (15)
64,000 (19)
76,500 (22)
#8 - .199 (5.1mm)
74,000 (22)
95,000 (28)
116,000 (34)
J - .277 (7.0 mm)
112,000 (33)
138,000 (40)
164,000 (48)
Q - .332 (8.4 mm)
160,000 (47)
206,000 (60)
-
HSG200 LP Gas
#30 - .128 (3.3 mm)
49,000 (14)
58,500 (17)
68,200 (20)
#27 - .144 (3.7 mm)
66,000 (19)
78,000 (23)
92,000 (27)
#15 - .180 (4.6 mm)
82,000 (24)
112,500 (33)
136,000 (40)
D - .246 (6.2 mm)
131,000 (38)
187,500 (55)
243,000 (71)
HSG400 Natural Gas
T - .358 (9.1 mm)
200,000 (59)
248,000 (73)
285,000 (84)
15/32 - .468 (11.9 mm)
265,000 (78)
343,000 (101)
400,000 (117)
HSG400 LP Gas
K - .281 (7.1 mm)
190,000 (56)
242,500 (71)
295,000 (86)
Q - .332 (8.4 mm)
242,500 (71)
332,500 (97)
400,000 (117)
GAS LEAK HAZARD
Liquefied petroleum gas is heavier than air. All connections should be checked for
leaks using a soapy solution applied to gas connections. Leaking gas will settle in
low lying areas such as basements and trenches. This can lead to asphyxiation and
explosion.
Valve is rated for 0.5 PSI or 14 inch w.c. Over pressurizing valve
may cause damage to the valve.
HSG SERIES POWER GAS CONVERION BURNER ORIFICE CHART
Figure 11: Orifice Selection Guide
NOTE: For 50 cycle application de-rate input by 15%
NOTE: The Btu/hr input values in Figure 11 show the approximate hourly input of the burner for the various orifice
sizes. To determine the actual input of the burner by using the gas meter, follow these steps:
1) Turn off all other gas appliances.
2) The hand on the dial with the lowest cubic feet value (fastest revolving dial) should be clocked for one complete
revolution.
3) Divide 3,600 by the time in seconds for one complete revolution and multiply by the dial value (1, 2, or 5 cubic feet
depending on size of meter.)
4) Multiply this by the heating value of the gas to obtain the input to the burner in Btu per hour.
EXAMPLE: Time in seconds for one complete revolution of dial is 72. 3,600 divided by 72 is 50, 2 cubic foot was timed
therefore 50 x 2 is 100. Multiply 100 by heating value of gas which is 1,075 for natural gas; and this will give you an
input of 107,500 Btu/hr (31.51 kW). Use a heating value of 2500 for LP gas.
Running Pressure Required: Natural or LP 5.5” w.c. (1400 Pa) Minimum, 14” w.c. (3500 Pa) Maximum.
De-rate input for altitude over 2000 ft. (609.6 m) by 4% each 1000 ft. (304.8 m) above sea level.
IMPORTANT: MANIFOLD PRESSURE ADJUSTMENTS CAN ONLY BE MADE WITH THE BURNER
RUNNING AND THE GAS ON.
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CHANGING THE ORIFICE
Before replacing the orifice, the gas supply and power must be shut off. The HSG200 is shipped from
factory with a #8 - 0.199” orifice installed and HSG400 is shipped from the factory with a T - 0.358” orifice
installed. The combination gas valve pressure regulator, which has an outlet pressure setting range of
approximately 2.0” w.c. (498.2 Pa) to 4.0” w.c (996.4 Pa) is factory set at 3.5” w.c. (871.85 Pa). The HSG
Series burners come with an orifice kit that contains all the size orifices listed in Figure 11.
To remove the orifice, locate the HSG manifold (Figure 12).
Figure 12: HSG Manifold
Once the HSG manifold is located, remove the slotted orifice cap, making sure the orifice cap gasket stays
attached to the orifice cap and is not damaged (Figure 13).
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GASKET
ORIFICE
CAP
Figure 13: HSG Cap with Gasket on Manifold
Remove orifice spring to access and remove orifice (Figure 14). Orifice will be stamped with its size
(Figure 15).
Figure 14: HSG Cap with Gasket Removed and Spring Removed
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