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- Page 1 Power Flame Incorporated HAC INSTALLATION OPERATION MANUAL THE POWER TO MANAGE ENERGY 2001 South 21 Street, Parsons, Kansas 67357 Telephone 620-421-0480, Fax 620-421-0948 Web Site: www.powerflame.com E-Mail: csd@powerflame.com HACOM 985 Rev. 0498...
- Page 2 WARNING Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency or gas supplier. Copyright © Power Flame Incorporated 1985 Printed USA...
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Page 3: Table Of Contents
TABLE OF CONTENTS INSTALLATION AND OPERATION HAC MANUAL PAGE General Product Information..........................101-2 Air Compressor ................................2 Model HAC Receiving Instructions..........................2 (Table 1) Standard Burner Ratings & Component Data .................... 3 (Figure 1) Model HAC Dimensional Data........................4 (Figure 2) Model HACR Dimensional Data ........................ 5 Installation Information - General.......................... - Page 4 PAGE Gas Pilot Ignition ..............................29 Oil Pumps and Piping............................... 30 Oil Nozzles ................................30-31 Electric Oil Heater ..............................31 Air Compressor ................................ 31 (Figure 13) Internal Gas/Air Flow Drawing....................... 32 (Figure 14) Linkage Adjustment - Gas/Oil........................ 33 (Figure 15) Varicam Fuel Metering System ......................34 (Figure 16) Case Type - Gas Pilot Drawing ......................
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Page 5: General Product Information
GENERAL PRODUCT INFORMATION Power Flame Model HAC and HACR (inverted) burners incorporate the principles of air atomization for all fuel oils, and multiple-orifice, high velocity vortex mix operation for gas. The total package utilizes the forced-draft, flame- retention concept. All air for combustion is completely furnished by the burner fan. The burner can be operated under positive or negative furnace pressures with clean efficient combustion of fuels. -
Page 6: Air Compressor
Power Flame HAC burners are offered in models to meet oil or gas/oil dual fuel requirements. Fuel changeover is accomplished by manual operation of a single fuel transfer switch. Automatic fuel changeover is available at extra cost. -
Page 7: (Table 1) Standard Burner Ratings & Component Data
POWER FLAME MODEL HAC & HACR BURNERS STANDARD BURNER RATINGS & COMPONENT DATA Table 1 MAXIMUM POWER FLAME CERTIFIED CAPACITY (2) BLOWER -0.5” W.C. +0.5” W.C. BURNER MOTOR REMOTE ELECTRIC MODEL COMPRESSOR FREE PUMP PUMP HEATER PRESSURE MBTU MBTU 3450 RPM... -
Page 10: Installation Information General
INSTALLATION INFORMATION GENERAL Existing boilers must be thoroughly cleaned to obtain maximum operating efficiency. All fireside surfaces must be free of soot, carbon deposits and scale. Water side surfaces and mud legs must be free of scale and deposits of any kind. Provisions should be made for adequate space around the burner and associated equipment to allow ease of inspection, maintenance and service. -
Page 11: Combustion Air Supply
COMBUSTION AIR SUPPLY Fresh air required to support combustion as well as to provide adequate equipment ventilation must be supplied. It is generally accepted that ½ square inch of free air opening per 1000 BTU/hr firing rate (for each combustion device in the room) will be adequate. -
Page 12: General Start-Up Procedures All Fuels
GENERAL START-UP PROCEDURES ALL FUELS A representative of the owner and/or the persons responsible for operating and maintaining the unit should be present during the initial start-up. Instructions on the proper care and maintenance of the unit can be covered at this time. Consult your local utility to determine if they require their service representative’s presence at the initial start-up of a gas-fired boiler. -
Page 13: Fuel Oil Start-Up Procedures
FUEL OIL START-UP PROCEDURES Power Flame model HAC oil burners are of the air atomizing, forced draft type. The input is controlled by a modulating metering valve connected with appropriate linkage to a modulating motor. Determine that the oil and gas piping has been installed, pressure tested for leakage and gas lines purged in accordance with the instructions previously given in section entitled “Installation”. - Page 14 Let the burner run (for 30 seconds at a time – then reprime as necessary) until the vacuum gauge indicates a 15”Hg vacuum, then quickly open the manual oil valve in the suction line. This combination of priming and high suction should pull the oil from the tank to the burner provided there are no air leaks and the line is properly sized.
- Page 15 D. Turn the control switch on. Provided the cold oil lockout switch (heavy oil only) is made, the burner fan motor should start. After prepurge the pilot should be ignited and proven, and after “pilot trial for ignition” period, the safety oil valve should open to ignite the oil burner at low fire. Low fire flame should now be established.
- Page 16 Mark the linkage setting previously arrived at for low fire warm up prior to proceeding with modulation linkage adjustments at higher firing rates. Using the manual potentiometer manually increase the firing rate to the midway point by small increments, watching linkage to assure free movement at each position. Set the air/fuel ratios to obtain a clean appearing flame.
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Page 17: Gas Fuel Start-Up Procedures
GAS FUEL START-UP PROCEDURE Power Flame model HAC gas burners are of the multiple orifice, high velocity vortex mix, forced draft type. The input is controlled by a modulating butterfly gas valve connected with appropriate linkage to a modulating motor. - Page 18 Reset the flame safeguard. Place the manual-auto switch in the manual position and the potentiometer in the closed position. Place the fuel transfer switch in the gas position. Open the main manual gas valve leaving the checking cock closed. Open the pilot gas cock. Reset the high and low gas pressure switches.
- Page 19 Set the low gas pressure switch to trip at 20% less than the sensed gas pressure with the burner firing at the high fire rate. Proceed to warm up the boiler following the recommended procedure as provided by the boiler manufacturer.
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Page 20: (Table 2) Combustion Chamber Dimension Chart
Table 2 COMBUSTION CHAMBER DIMENSION CHART FOR FIGURE 3, PAGE 17 AND FIGURE 4, PAGE 18 (ALL DIMENSIONS IN INCHES) FIREBOX TYPE BOILERS SCOTCH MARINE TYPE FIRING RECOMMENDED CHAMBER BOILERS RECOMMENDED RATE DIMENSIONS CHAMBER DIMENSIONS DIAMETER LENGTH -16-... -
Page 21: (Figure 3) Burner Mounting Detail For Brickset Firebox Boiler
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Page 22: (Figure 4) Burner Mounting Detail For Scotch Marine Boiler
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Page 23: (Figure 5) Burner Mounting Detail For Packaged Firebox Boiler
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Page 24: (Figure 6) No. 2 Fuel Oil Pump Suction Curve
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Page 25: (Figure 7) No. 4 Fuel Oil Pump Suction Curve
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Page 26: (Figure 8) No. 5 And 6 Fuel Oil Pump Suction Curve
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Page 27: (Figure 9) No. 2 Fuel - Oil/Air Piping Schematic
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Page 28: (Figure 10) No. 4 Fuel - Oil/Air Piping Schematic
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Page 29: (Figure 11) No. 5 And 6 - Oil/Air Piping Schematic
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Page 30: (Figure 12) Gas Piping Schematic - U.l. Gas Train
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Page 31: Compressed Atomizing Air Piping Information
COMPRESSED ATOMIZING AIR PIPING INFORMATION SUGGESTED AIR PIPE SIZES FOR VARIOUS PIPE RUNS - COMPRESSOR TO HAC BURNERS PREFERRED MOUNTING Set compressor as close as practical to the burner and use shortest run possible with minimum number of fittings. NOTE: Steel flexible hose (where provided) must be fitted directly to compressor. -
Page 32: (Table 4A) Capacity Of Pipe - Natural Gas
CAPACITY OF PIPE - NATURAL GAS (CFH) With Pressure Drop of 0.3” W.C. and Specific Gravity of 0.60 Table 4A Pipe Size -Inches (IPS) Pipe Length 1-1/4 1-1/2 2-1/2 In Feet 1050 1600 3050 4800 8500 17500 1100 2100 3300 5900 12000 1650... -
Page 33: Adjusting And Servicing - General
Call your authorized service representative for dependable service assistance. Service instructions on controls and components not manufactured by Power Flame are included as part of the burner shipping literature. Copies of these manufacturers bulletins are available on request. -
Page 34: Oil Pumps And Piping
ACCEPTABLE STABLE FLAME CURRENT READINGS CONTROL ULTRAVIOLET LEAD SULPHIDE 7800 series 1.25 - 5.0 volts dc 1.25 – 5.0 volts dc R4140M(G)(L) OR 3-1/2 to 7-1/2 2-5 microamps R7248A red amp BC7000 microamps 3-1/2 microamps R7248B red amp D series 15-25 volts dc 15-25 volts dc E series... -
Page 35: Electric Oil Heater
The nozzle should be seated firmly on the oil gun to prevent leaks. If nozzle is damaged or burned, replace it. The air-atomizing nozzle is designed to handle No. 2, 4, 5 and 6 fuels. Air is supplied from the air compressor at relatively low pressure to provide the energy for atomization. -
Page 36: (Figure 13) Internal Gas/Air Flow Drawing
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Page 37: (Figure 14) Linkage Adjustment - Gas/Oil
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Page 38: (Figure 15) Varicam Fuel Metering System
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Page 39: (Figure 16) Case Type - Gas Pilot Drawing
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Page 40: (Figure 17) Round Type - Gas Pilot Drawing
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Page 41: (Table 5) Oil/Air Pressure Chart
TYPICAL OIL AND AIR PRESSURE FOR VARIOUS Table 5 INPUTS USING #2 OIL IN MODEL HAC BURNERS (1) LOW FIRE HIGH FIRE BURNER OIL PSIG AIR PSIG OIL PSIG AIR PSIG MODEL AT GUN AT GUN AT GUN AT GUN HAC3-O2 HAC4A-O2 HAC4B-O2... -
Page 42: (Figure 19) Fuel Oil Viscosity/Temperature Chart
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Page 43: Maintenance
MAINTENANCE General Only qualified service technicians should make mechanical or electrical adjustments to the burner and/or associated control equipment. Preventative maintenance can usually be performed by building maintenance personnel. Always follow the information provided in the “Owner Operating Instructions” on page 47. These should be conspicuously posted in the boiler room at the time of the initial burner installation and start-up. -
Page 44: Trouble Shooting Suggestions Hac Oil And Gas/Oil Burner
TROUBLE SHOOTING SUGGESTIONS HAC OIL OR GAS/OIL BURNER GENERAL Burner Fails to Start Defective On/Off or fuel transfer switch. Replace switch. Control circuit has an open control contact. Check limits, low water cutoff, proof of closure switch and others as applicable. Bad fuse or switch open on in-coming power source. -
Page 45: Gas Operation
GAS OPERATION Burner Motor Runs, but Pilot Does Not Light Gas supply to burner shutoff - make sure all manual gas supply valves are open. Automatic high pressure valve at meter such as “Sentry” type tripped shut due to high gas pressure - reset valve and correct cause for trip out. -
Page 46: Oil Operation
Gas High Fire Input Rate Cannot Be Achieved Gas company pressure regulator or meter operating incorrectly, not allowing required gas pressure at burner train inlet. Have gas company correct. Gas cock upstream of train inlet not fully open. Check and correct Gas line obstructed. - Page 47 Oil Flame Ignites, but then Flame Safeguard Control Locks Out on Safety. Dirty oil nozzle causing unstable flame and scanning problems. Clean oil nozzle. Fuel/air ratios incorrect, resulting in unstable or smoky flame causing scanner flame sighting problem. Readjust ratios for clean stable flame. Defective flame safeguard amplifier or control.
- Page 48 Defective or dirty oil nozzle. Replace or clean nozzle. Incorrect oil/air ratios. Readjust burner to correct CO and smoke levels. Air pressure too low resulting in poor atomization. Readjust. Check compressor air filter as required. Impingement of raw oil spray on the blast tube. Position the oil gun assembly fore or aft in the blast tube to correct.
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Page 52: Owner Operating Instructions
2001 South 21 St., Parsons, KS 67357, 620-421-0480, Fax 620-421-0948 POWER FLAME INCORPORATED OWNER OPERATION INSTRUCTIONS FOR YOUR SAFETY WARNING If you smell gas: Open windows Improper installation, adjustment, alteration, service Do not touch electrical switches or maintenance can cause injury or property damage. Refer to Extinguish any open flame the Burner manual. -
Page 53: Limited Warranty
POWER FLAME INCORPORATED LIMITED WARRANTY Power Flame Incorporated, hereinafter called the Seller, expense of the owner and Seller’s regular charges shall of 2001 South 21 Street, Parsons, Kansas, hereby apply. Owner shall assume the cost for transportation warrants its equipment manufactured by it and bearing and handling.
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