TECHNICAL
INFORMATION
"Troubleshooting
Guide"
NUISANCE
LOCKOUTS/FLAME
SENSING
PROBLEMS. HSG2OO
&
HSG4OO
GAS
BURNERS
Wayne's HSG series direct spark
ignition
(DSl) gas
burners
prove
flame
through the
process
of
flame
rectification. Flame
rectification is
achieved by
placing
a
small
voltage on the flame sensing
probe.
When the
probe
is
surrounded
by flame, the voltage on the
probe
"leaks"
to
ground
through the flame,
resulting in
an
electrical current.
This current is interpreted by the
ignition control as the
presence
of
flame.
One of
the most common
problems
with
gas
appliances
utilizing this type of electronic
flame
sensing system
is
the
"nuisance lockout". Lockouts are not
generally
due
to the burner failing to ignite, but rather
simply
the
failure
of the system to sense the establishment of
flame.
Should
this
situation
exist for a
period
of time longer
than the ignition control's state lockout timing, the
control will
shut
down or
go
into
permanent
lockout. The
only
way
to
get
the
burner
to recycle is
to break, and
then
reinstate
power
to the burner.
The following
situations can
lead
to
flame
sensing
problems
and can be checked
without
disassembling
the burner:
.
The
burner
is not
properly grounded
to
"earth
ground"
on the
line voltage.
.
The ignition control is not
properly
grounded
to the
burner
itself.
Using an ohmmeter, check the wire
attached to both
parts
for
good
contact and
continuity.
.
The
burner
ignition control is
polarity
sensitive.
The
polarity
of
the incoming line voltage may
be
reversed. Verify that
black and
white wires
are
hot
and
neutral respectively,
and that they are
connected to the
corresponding black and
white
wires
on the burner.
The remaining checks andlor
adjustments
require
removal of the
gas
train:
.
The
connections
from the'SENSE'terminal
of the
ignition
control
to the end
of the
flamerod
may be
broken at some
point.
Check all
quick
connect
terminations and connections.
Check
the
continuity
with
an ohmmeter
while
flexing wires to
assure
no
hidden
conductor breakage exists. lf replaced,
wiring must
be of equal, or heavier
gauge
and
equal, or better temperature rating.
.
The flamerod
probe
may
be
grounded
out.
Assure
that the
flamerod
probe
is not touching the
burner
head. The
probe
should be
positioned
in the center
of the clearance
groove
on the outer
edge of the
burner
head with
approximately
1116"
(1.5875mm)
clearance
from
the
head. The
probe
must not be
positioned
to
far
away
from the head as this may
result in
grounding
out of the
probe
against the
inside
surface of the air tube.
.
The flamerod
probe
should
be free of soot and
creosote. Deposits may
insulate
the
probe,
leading
it not to
pass
the electrical charge to the flame. The
probe
can be cleaned with
steel
wool, emery
paper
or
fine
sandpaper.
NOTE: This is
the
leading cause
of nuisance lockouts in dual-fuel
wood/oas fired
appliances.
.
The flamerod
probe
may be burned away. Check it
against dimensions on the ELECTRODE AND
FLAMEROD PROBE
SETTINGS
drawing.
.
The dimensional location
of
the flamerod
probe
may
be incorrect,
or the
probe
may be bent out of
shape.
Check it against dimensions on the ELECTRODE
AND FLAMEROD PROBE
SETTINGS
drawing and
adjust
if necessary.
.
The
spark electrode
gap
may be incorrect, resulting
in no
spark or an
inadequate
spark that
will not
ignite the
gas
properly.
Check the electrode
gap
against
the ELECTRODE AND FLAMEROD
PROBE
SETTINGS drawing and adjust if
required.
.
The high
tension
lead
conductor from the ignition
transformer to the tip of the
spark
electrode may be
broken,
preventing
the high
voltage
current
from
getting
to the electrode tip. Check all connections
thoroughly and/or check to continuity of the lead
wire
assembly with an ohmmeter.
Once all of the
items listed
previously
have
been
carefully
checked
and corrected
if necessary, reinsert
the
gas
train assembly into the burner. NOTE: Be
careful not to
bend
the
air
proving
switch sail arm
(if
so
equipped) or accidentally
reposition
either the
flamerod
probe
or electrode during reinstallation of the
gas
train
assembly.
lf,
after all of the above
listed
items have been carefully
checked, the burner
still
fails to work, it is due to one
or
more
of
the following
problems:
1.
Unit sparks and
fires
but
will not
stay
lit. lgnition
control module is malfunctioning
and must be
replaced.
2. Unit does not
spark.
lgnition transformer is bad and
must be replaced.
PAGE
19
TECHNICAL INFORMATION
"Troubleshooting Guide"
NUISANCE LOCKOUTS/FLAME SENSING PROBLEMS - HSG200 & HSG400 GAS BURNERS
Wayne's HSG series direct spark ignition (DSI) gas
burners prove flame through the process of flame
rectification. Flame rectification
is
achieved
by
placing a
small voltage
on
the flame sensing probe. When the
probe
is
surrounded by flame, the voltage
on
the probe
"leaks" to ground through the flame, resulting
in
an
electrical current. This current is interpreted by the
ignition control as the presence of flame.
One of the most common problems with gas appliances
utilizing this type of electronic flame sensing system is
the "nuisance lockout". Lockouts are not generally due
to
the burner failing
to
ignite, but rather simply the failure
of the system
to
sense the establishment of flame.
Should this situation exist for a period of time longer
than the ignition control's state lockout timing, the
control will shut down or go into permanent lockout. The
only way
to
get the burner to recycle
is
to
break, and
then reinstate power to the burner.
The following situations can lead to flame sensing
problems and can be checked without
disassembling the burner:
The burner
is
not properly grounded
to
"earth
ground"
on
the line voltage.
The ignition control
is
not properly grounded
to
the
burner itself. Using
an
ohmmeter, check the wire
attached to both parts for good contact and
continuity.
The burner ignition control
is
polarity sensitive. The
polarity of the incoming line voltage may
be
reversed. Verify that black and white wires are hot
and neutral respectively, and that they are
connected to the corresponding black and white
wires
on
the burner.
The remaining checks and/or adjustments require
removal of the gas train:
The connections from the "SENSE" terminal of the
ignition control to the end of the
f1amerod
may be
broken at some point. Check all quick connect
terminations and connections. Check the continuity
with
an
ohmmeter while flexing wires
to
assure
no
hidden conductor breakage exists.
If
replaced,
wiring must be of equal, or heavier gauge and
equal, or better temperature rating.
The flamerod probe may
be
grounded out. Assure
that the flamerod probe
is
not touching the burner
head. The probe should
be
positioned
in
the center
of the clearance groove
on
the outer edge of the
PAGE 19
burner head with approximately 1/16" (1.5875mm)
clearance from the head. The probe must not be
positioned
to
far away from the head as this may
result
in
grounding out of the probe against the
inside surface of the air tube.
The flamerod probe should
be
free of soot and
creosote. Deposits may insulate the probe, leading
it
not
to
pass the electrical charge to the flame. The
probe can
be
cleaned with steel wool, emery paper
or fine sandpaper. NOTE: This is the leading cause
of nuisance lockouts in dual-fuel wood/gas fired
appliances.
The flame
rod
probe may
be
burned away. Check
it
against dimensions
on
the ELECTRODE
A1'JD
FLAMEROD PROBE SETTINGS drawing.
The dimensional location of the flame
rod
probe may
be
incorrect, or the probe may
be
bent out of shape.
Check
it
against dimensions
on
the ELECTRODE
AND FLAMEROD PROBE SETTINGS drawing and
adjust if necessary.
The spark electrode gap may
be
incorrect, resulting
in
no spark or
an
inadequate spark that will not
ignite the gas properly. Check the electrode gap
against the ELECTRODE AND FLAMEROD
PROBE
SEn-INGS
drawing and adjust if required.
The high tension lead conductor from the ignition
transformer
to
the tip of the spark electrode may
be
broken, preventing the high voltage current from
getting
to
the electrode tip. Check all connections
thoroughly and/or check
to
continuity of the lead
wire assembly with
an
ohmmeter.
Once all of the items listed previously have been
carefully checked and corrected if necessary, reinsert
the gas train assembly into the burner.
NOTE:
Be
careful not to bend the air proving switch sail arm (if so
equipped) or accidentally reposition either the flamerod
probe or electrode during reinstallation of the gas train
assembly.
If,
after
all
of the above listed items have been carefully
checked, the burner still fails to work,
it
is due
to
one or
more of the following problems:
1.
Unit sparks and fires but will not stay lit. Ignition
control module is malfunctioning and must be
replaced.
2.
Unit does not spark. Ignition transformer is bad and
must
be
replaced.
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