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Power Flame C Series Installation & Operation Manual

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C MANUAL

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  • Page 1 C MANUAL...
  • Page 2 Rev.202 FOR YOUR SAFETY Do not store or use gasoline or other If you smell gas: flammable liquids and vapors in the 1. Open windows. vicinity of this or any other appliance. 2. Do not touch electrical switches. 3. Extinguish any open flame. 4.

  • Page 3: Table Of Contents

    GENERAL PRODUCT INFORMATION Principal of Operation Power Flame Type C Burners incorporate the principles of The Power Flame C Burner is a totally packaged and factory tested combustion system offering single unit pressure atomization for oil and multiple orifice, venturi operation for gas.

  • Page 4: Model Identification

    New York City Department of Buildings (MEA), NYC interruption of the motor current. Department of Environmental Protection, Commonwealth Power Flame Type C burners are capable of firing single or of Massachusetts, State of Connecticut Fire Marshall, multi-fuel applications. (See model selection, page 6, Table 2.) Illinois School Code and others.

  • Page 5: Burner Component Identification

    Power Flame combustion system. Part codes. numbers and component descriptions will match those components supplied.

  • Page 6: Burner Component Identification

    Rev.703 Figure 2 Burner Component Identification Typical for Model C-GO with Low-High-Off or Low-High-Low Fuel/Air Control Modes of Operation.* 1. Blower Motor 2. Blast Tube 3. Air Inlet Housing 4. Air Flow Switch 5. Air Diffuser 6. Flame Retention Ring 7.

  • Page 7: Standard Burner Dimensional Data

    Rev.304 Oil Pump Oil Nozzle Modulating Oil Valve Oil Nozzle Bypass Pressure Test Tee Nozzle Return Line Check Valve Control Panel On-Off Switch Fuel Selector Switch Hinged (Total Access) Top Section Light and Switch Circuit Board Removable Total Access Door Motorized Gas Valve Test Port Optional Board for Sequence...

  • Page 8: Standard Burner Ratings And Component Data

    Rev.304 Table 2 Standard Burner Ratings and Component Data Power Flame Certified Capacity 0.2” W.C. Positive Pressure (D) Burner Standard 3450RPM MBTU/HR. Nominal Standard Burner Pump Suction Capacity Model Flame Blower Maximum Natural Gas Boiler Pressure Gas Train Burner Separate Driven...

  • Page 9: Control Panel Information

    Rev.304 J. The standard pump normally supplied is 19 GPH for On-Off or Modulating The standard pump normally supplied is 40 GPH for Low-High-Off and and 40 GPH for Fixed Air Low Fire Start, Low-High-Off and Low-High-Low Low-High-Low, 70 GPH for On-Off and modulating operation. Optional operation.
  • Page 10 FACTORY WRNG EQUIPMENT SHOWN ON DIAGRAM IS ONLY 2 4 V “USE COPPER CONDUCTORS ONLY.” FIELD WIRING PROVIDED AND MOUNTED BY POWER FLAME IF 1 1 5 V CL1 CL2 GL1 GL2 17. Operating Control Connection CAUTION: THROW ALL DISCONNECTS TO OFF 2 0 0 - “SEE SPEC.

  • Page 11: Installation

    Rev.304 Figure 7 The Director ® Annunciation System The Director ® Annunciation System Mounted on removable Total Access front panel door, complete with quick disconnect electrical connection. The Director can be removed from the panel box (see above) and kept in operating mode by using the extended length umbilical cord between the Director and panel box connections.

  • Page 12: Gas Train Components Supplied For Standard Ul Burner Requirements

    Rev.304 Table 4 Equivalent Length of Fittings in Feet Pipe Size (IPS) 1.25 Std. Tee through Side 12.0 14.0 17.0 22.0 Std. E11 12.0 Plug Cock 12.0 16.0 Table 5 Gas Train Components Supplied for Standard U.L. Burner Requirements See Gas Flow Schematics this page, Figure 8 and 9 for additional information Fuel Air Control Modes of Operation On/Off Low/High/Off...

  • Page 13: Oil Pump Suction Capacity And

    The method to properly size copper tubing is outlined code. If a manual valve is required, an automatic relief on page 12 (Figure 10). Consult Power Flame Customer valve must be installed across the manual valve to Services Department for sizing assistance regarding ensure that oil will bypass directly back to the tank in the iron pipe.

  • Page 14: Oil Pump Detail

    Rev.304 Figure 10 Oil Line Sizing Suction Capacity in G.P .H. Total Feet of " O.D. Total Feet of " O.D. Total Feet of " O.D. Total Feet of " O.D. Copper Tube #2 Fuel Oil Copper Tube #2 Fuel Oil Copper Tube #2 Fuel Oil Copper Tube #2 Fuel Oil 6.

  • Page 15: Multiple Burner System Oil Piping Schematic

    Rev.304 Figure 12 Multiple Burner System Oil Piping Schematic (Flooded Suction) Vent Fill Tee with Plug To Tank Return Vent (Highest Point) Vacuum Vacuum Breaker Breaker Standby Equipment From Same as Shown Below Supply Pump 12” Min. Connection Return Return Line Press Gauge with Compound To Burner...

  • Page 16: Combustion Chamber Data

    Rev.304 Figure 13 Conventional Firebox Boiler #1 Firebrick Insulation 6-8” ” Recess or Loose Insulation Flush Model CR See Table 7 #1 Firebrick for Dimensions Magnesia Block or Equivalent Insulating Firebrick (2600 Figure 14 Figure 15 Typical Firedoor Installation - Cast Iron Boiler Packaged Firebox Boiler NOTE: On oil and gas/oil burners...

  • Page 17: Mechanical Operation Of

    Rev.304 MECHANICAL OPERATION OF FUEL/AIR CONTROL MODES Figure 17 Typical Gas Burner with On-Off Fuel/Air Control Mode (Model CR-G) MECHANICAL OPERATION: This system uses a combina- at the " Plugged Gauge Test Port (8) in the Side tion Diaphragm Gas Valve and Integral Pressure Orifice Tee.
  • Page 18 Rev.304 Low Fire Operating Position Adjustment in addition to the increase the travel of the Air Damper Arm (13) as the light off and high fire operating positions. (See manufacturer’s Linkage Rod ball joint (11) is moved away from the Gas bulletin included with the burner.) Valve Crank Shaft (12).
  • Page 19 Rev.304 require a spark ignited gas pilot* to provide ignition for the main oil flame. The nozzle oil flow rate is set by adjusting the Oil Pump Pressure Regulating Valve (3). Turn clock- wise to increase the pressure and counter-clockwise to decrease the pressure to the Nozzle.
  • Page 20 Rev.304 Note 2 Component operational sequencing will vary with the specific Flame Safeguard Control bulletin supplied with the burner for complete information. Flame Safeguard Control being used. Refer to the specific Figure 22 Typical Oil or Gas/Oil Burner with Reduced Air, Low Fire Start RALFS #72 Drill Orifice High Fire Oil Hydraulic Cylinder...
  • Page 21 Rev.304 Figure 23 Typical Oil Burner with Low-High-Off or Low-High-Low Fuel/Air Control Mode Using Webster 22R Oil Pump 3 Way Oil By Others Unless Specified CAUTION: Valve 10 on Order. All field piped components must be Pressure 9 Damper Cylinder mounted in the proper location ** Burners with Remote Pressure and proper direction of oil flow.
  • Page 22 Rev.304 of operation and the oil components would be identical to the Note 2 Webster 22R system. For additional information on your specific Component operational sequencing will vary with the specific system refer to the oil piping diagram and the oil pump Flame Safeguard Control being used.
  • Page 23 Rev.304 and that there is no binding of the Linkage or Dampers. Make Note 1 Component operational sequencing will vary with the specific Flame certain the cast iron Linkage Return Weight (15) is secure on Safeguard Control being used. Refer to the specific Flame Safeguard its Linkage Arm (17).
  • Page 24 Rev.304 Figure 26 Gas or Gas/Oil Burner Fuel/Air Premix Adjustment - Gas, Oil or Gas/Oil Burner Diffuser Adjustment Gas/Air Premix Adjustment Knob Blast Tube Diffuser Position Adjustment moving it forward decreases the premix air. Generally, the best (quietest/smoothest) operation is in the full forward position with minimum premix air.

  • Page 25: Gas - On-Off

    Rev.304 GENERAL START UP PROCEDURES-ALL FUELS All Fuels - General Start Up A thoroughly qualified burner technician should be Close main and checking gas cocks. Open suction employed to provide the initial burner start up, as well as line manual oil valves and others as appropriate. any subsequent servicing.

  • Page 26: Burner Start Up And Service Test Equipment Required

    Rev.304 product bulletin supplied with the burner for specific details. for specific adjustment details (pages 15 and 17). Gas On/Off System with Oil Reduced Air, Low Fire Start For the Low/High/Low system oil side operation, the additional temperature or pressure control will also cause RALFS See page 18.

  • Page 27: Gas Start Up

    Rev.304 monoxide) in the flue gases. Therefore, when firing gas, test for Note: When firing gas fuels, it is possible to attain CO readings that CO to make certain that the burner is adjusted so that it has an appear to be acceptable (i.e., 8%, 9%, 10%, etc.) while actually excess, rather than a deficiency, of air.

  • Page 28: Tm Characterized

    Power Flame burners are tested at the factory and 22. Initial adjustments should be made at the low fire position. All Power Flame burners are factory linkage adjustments for modulation are made at that time.
  • Page 29 Rev.304 running, slowly close the main gas train (7 - 9% CO , little or no* CO). Mark the linkage at the new manual shutoff cock and adjust the switch settings. to open its circuit when the pressure falls 25. Increase the firing rate to the midway point. Set the fuel/air below its normal value.
  • Page 30 Combination Gas/Oil systems should also refer to page 23, Information on Fuel/Air Modes of Operation for Combination Gas/Oil Units. General Information Power Flame Type C oil burners are of the pressure This may be accomplished by removing cross connecting linkage between dampers and locking the unused atomizing forced draft type, using a single simplex or damper in a fixed position.
  • Page 31 (low or is leaking. fuel/air flow). All Power Flame burners are factory tested and adjusted. However, to determine that the metering 16. Restart the burner and allow normal sequencing to bring valve is, in fact, in the low fire position, observe the on gas pilot ignition or the direct spark ignition.
  • Page 32 D) With the unit running normally, open the potentiometer or electrically disconnecting the blowdown valve and remove water to the point modulating motor. Power Flame burners are test fired below the low water cutoff setting. The burner at the factory, and linkage adjustments for modulation should turn off and restart automatically when are made at that time.

  • Page 33: Servicing And Component Adjustments

    Rev.304 facturer’s bulletin shipped with the burner. It is also stron- 37. Complete the Burner Start Up Information and gly suggested that all test procedures outlined in the flame Test Data sheets on pages 46 and 47. safeguard control manufacturer’s bulletin be conducted. SERVICING AND COMPONENT ADJUSTMENTS General Information on Internal Bypass Oil Nozzle Systems head.
  • Page 34 Rev.304 HAGO Supply Pressure to Nozzle 300 PSIG at All Rates* Nozzle Size 100 PSIG Approx. High Approx. High Reduced Firing Rates Nominal Fire Rate Fire By-Pass Rating GPH (Return) Approx. Approx. Approx. Approx. Approx. Approx. #2 Fuel Oil 300 PSIG Pressure By-Pass Firing Rate...
  • Page 35 Rev.304 DELAVAN VARI-FLO 33769 Supply Pressure to Nozzle 300 PSIG at All Rates* Nozzle Size Reduced Firing Rates 100 PSIG Approx. High Approx. High Nominal Fire Rate Fire By-Pass Rating GPH (Return) Approx. Approx. Approx. Approx. Approx. Approx. #2 Fuel Oil 300 PSIG Pressure By-Pass...

  • Page 36: Oil Nozzle Flow Rates

    19.2 19.8 Oil Nozzle Servicing 1. Nozzles used on Power Flame Type C burners are of two objects to clean nozzles. Damage to orifices or spray types: simplex and internal bypass. The simplex nozzle slots result in off-center or sparky fires.

  • Page 37: Direct Spark Oil Ignition Adjustments

    Rev.304 PUMP LEAKS CAPACITY TOO LOW 1. Cover bolts need tightening; gasket broken or 1. Suction lift too high (see page 12, Figure 10) defective 2. Air leak in suction line 2. Mechanical seal (used on certain models) may be 3.

  • Page 38: Gas/Oil Burner Firing Head

    Rev.304 Figure 32 Gas/Oil Burner Firing Head Cutaway View Showing Direct Spark Ignition On Oil, Gas Pilot Main Gas Flame Ignition - Using A Common Scanner For Both Fuels Electrode Support Choke 1 ” Boiler Flange Oil Nozzle Assembly Ignition Electrode Blast Tube Stainless...
  • Page 39 Rev.304 Figure 36 C7/C8 Gas and Gas/Oil Gun Assembly .875 [ ] From Front of Nozzle As Shown Fig. 37 Pilot Extends Thru Diffuser 0.125 [ Adpt. to Back of Diffuser ] O.D. Top View 9.026 [9 ” Blade Setting* ”...
  • Page 40 Rev.304 Table 10 (Continued) Gas Burner Orifice Sizing Information (See page 37, Figure 38 for side orifice detail.) ORIFICE (A) LIMITING ORIFICE (B) APPROXIMATE ORIFICE PRESSURE IDENTIFICATION INSIDE DIAMETER INCHES (INCHES W.C.) OR TEE PRESSURE I.P .S.SHOULDER IF NO ORIFICE SIZE IS SHOWN BURNER MBTU NOMINAL O.D.

  • Page 41: Gas Pilot Ignition Adjustment

    Rev.304 Gas Pilot Ignition Adjustment Excessive gas pressure and insufficient air may be proper CO setting. The following steps should be taken: the most common causes of pilot ignition failure. 1. Remove pilot assembly and check for proper orifice Burners with automatic air dampers linked to the gas size (the orifice size is stamped into the hex brass valve or damper motor should have pilot gas pressures fitting connected to the pilot head nozzle assembly)

  • Page 42: Gas Pilot Flood Test

    Rev.304 Figure 40 C1 & C2 Ignition Electrode Adjustment ” - ” Spark Gap between Electrode Tip and Pilot Case (Housing) Primary Air Holes (2) ” Air Hole Pilot Orifice Figure 41 C3, C4 & C5 Ignition Electrode Adjustment ” - ”...

  • Page 43: Flame Safeguard Control Flame

    Rev.304 Flame Safeguard Control Flame Signal Values This curve correlates the relative values of O and CO for the to 9 % CO for Natural Gas. fuels listed, as well as the percentage of excess air at given Again following the 4% O vertical axis fo fuel line E (#2 Fuel and CO values.

  • Page 44: Trouble Shooting Suggestions

    Rev.304 TROUBLE SHOOTING SUGGESTIONS GAS, OIL OR GAS/OIL BURNER GENERAL that ignition is instant and that flame signal 1. Burner Fails to Start readings are stable and above minimum values. A. Defective On/Off or fuel transfer switch. Replace. Use a manometer or 0 to 10" W.C. gas pressure B.
  • Page 45 Rev.304 4. Gas High Fire Input Cannot Be Achieved F. Burner gas train components sized too small for supply pressure. Increase component size as A. Gas company pressure regulator or meter appropriate. operating incorrectly, not allowing required gas G. Automatic gas valve not opening fully due to pressure at burner train inlet.

  • Page 46: Maintenance

    Rev.304 6. White Smoke Formation on Oil Firing B. Nozzle defective—replace. Nozzle mesh filter dirty—clean or replace. A. Oil/Air ratios incorrect due to excess air, or oil C. Oil supply pressure to nozzle too low. Readjust. flow is too low. Readjust for proper fuel input, CO and smoke reading.

  • Page 47: Periodic Check List

    Rev.304 PERIODIC CHECK LIST Item Frequency Checked By Remarks Gages, monitors, and indicators Daily Operator Make visual inspection and record readings in log Instrument and equipment Daily Operator Make visual check against heat exchanger settings manufacturer’s recommended specifications Firing rate control Weekly Operator Verify heat exchanger manufacturer’s settings...

  • Page 48: Burner Start Up Information And Test Data

    Rev.304 BURNER START UP INFORMATION & TEST DATA The following information shall be recorded for each burner start up: Power Flame Model No. Invoice No. Serial No. Installation Name Start Up Date Start Up Contractors Name Phone Name of Technician Performing Start Up...

  • Page 49: Control Settings

    Rev.304 Control Settings General Operating control cut out setting Low gas pressure switch Low oil pressure switch lbs. Operating control cut in setting High gas pressure switch High oil pressure switch lbs. Limit control cut out setting Limit control cut in setting Operation Checklist Checked For Proper Operation of: Low water cut off...
  • Page 50 Rev.304...
  • Page 51 Rev.304...
  • Page 52 Rev.304...
  • Page 53 2001 South 21st St., Parsons, KS 67357, 620-421-0480, 620-421-0948 FAX ® Rev.304 POWER FLAME INCORPORATED 10. OWNER OPERATING INSTRUCTIONS FOR YOUR SAFETY WARNING Improper installation, adjustment, alteration, service or If you smell gas: maintenance can cause injury or property damage.
  • Page 54 Rev.304 POWER FLAME INCORPORATED LIMITED WARRANTY TYPE C BURNERS Power Flame Incorporated, hereinafter called the expense of the owner and Seller’s regular charges Seller, of 2001 South 21st Street, Parsons, Kansas, shall apply. Owner shall assume the cost for hereby warrants its equipment manufactured by it transportation and handling.
  • Page 55 Manual C888 Rev. 304 Copyright Power Flame Incorporated 2004 Printed U.S.A. ® ® 2001 South 21st Street Phone 620-421-0480 Parsons, KS 67357 FAX 620-421-0948 Web Site: http://www.powerflame.com E-Mail: CSD@powerflame.com...

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