Wayne HSG200, User Manual

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SECTION V: SERVICE AND TROUBLESHOOTING
HSG SERIES BURNER UTILIZING WAYNE 64420 SERIES IGNITION CONTROLS
HSG burners with a spec number that contains a “D,” for example, 62377D, use Wayne ignition controls.
Older burners that have a spec number containing a “C” use a Honeywell control. See next sections for
information on these controls. Spec numbers can be found on HSG burners on a small label located below
the T-shaped label on the back of the burner.
WIRING BURNERS USING WAYNE IGNITION CONTROLS
These burners ship with black, white, and green wires exiting the junction box via its conduit connection
point. The black and white wires are used for testing at the factory and should be removed and discarded.
After that, connect incoming L1 to the connector where the black wire was and L2 where the white wire
was. Use a wire nut to connect earth ground to the green wire.
Failure to connect earth ground to the
green ground wire will cause the ignition control to lock out with a “LINE Voltage Error” fault.
WAYNE IGNITION CONTROL ERROR CODES
NUMBER OF FLASHES ERROR
GREEN NORMAL OPERATION
1 NO FLAME DURING TRIAL
3 GAS VALVE RELAY FAIL
4 LINE VOLTAGE ERROR
5 INTERNAL CONTROL ERROR
Table 4: Error Codes for Wayne Control
SEQUENCE OF OPERATION
– HSG SERIES POWER GAS CONVERSION BURNER
UTILIZING WAYNE 64420-001 IGNITION CONTROL WITH EXTERNAL
30 SECOND PRE-PURGE TIMER P/N 62388-001 AND RESISTOR P/N 62530-001
On a call for heat,120 Vac goes to the motor, and 24Vac goes to the air switch. Once the motor reaches
operating rpm, combustion air pressure closes the air proving switch, energizing the external 30 second
pre-purge timer. After the 30 second pre-purge timing, the ignition control is energized.
After the initial 30 second pre-purge provided by the external timer, the Wayne control is energized, and it
will activate the gas valve allowing gas to flow to the burner head. Simultaneously, the ignition control
energizes the ignition transformer, producing a spark at the electrode, establishing main burner flame.
This trial for ignition period lasts four (4) seconds and occurs at the beginning of every heat cycle.
Normally, burner flame will be established before the end of this period. Once the flame is established and
the trial for ignition ends, sparking will cease and the flame rod will provide flame monitoring to the ignition
control for the remainder of the heat cycle.
When utilizing the Wayne 64420-001 control with the eternal 30 second pre-purge timer, a 10K ohm
resistor is wired in parallel between the output terminals of the 30 second pre-purge timer and the input
terminal to the ignition control. The function of this resistor is to keep a load on the output terminal of the
external 30 second pre-purge timer, after the initial call for heat and 30 second start pre-purge.
This promotes immediate re-ignition of the main burner flame after initial 30 second pre-purge provided by
the external timer, overriding the need for a separate pre-purge for each heat cycle. This control scheme is
used in oven or similar applications where process temperatures must remain constant.
If the flame is extinguished during the heat cycle, the ignition control will attempt to re-establish the main
burner flame. If this does not occur within the trial for ignition period, the ignition control will go into lockout,
de-energizing the gas valve and ignition transformer. Then, the LED on the ignition control will flash an
error code
. These error codes are listed on the ignition control’s label near the LED and in Table 4 above.
To restart the system, the main power or thermostat must be de-energized momentarily, then re-
energized. If at any time during the heat cycle, there is an insufficient supply of combustion air to the
burner, the air switch will open, putting the system into lockout and closing the gas valve.
See Figure 25 for the wiring diagram for burners with the Wayne 64420-001 control.