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Power Flame EVO Manual

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EVO MANUAL

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  • Page 1 EVO MANUAL...
  • Page 2 Installation and Operation Manual ® ® POWER FLAME MODEL EVO BURNER For use by Qualified Service Personnel Only WARNING The improper installation, adjustment, alteration, service, or maintenance of this equipment can result in fire, explosion, serious injury, or death. Refer to this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier.

  • Page 3: Table Of Contents

    Installation and Operation Manual ® GENERAL PRODUCT INFORMATION Principle of Operation Unpacking and Handling Warranty and Spare Parts Information General Components Information INSTALLATION Gas Supply Piping Combustion Air Requirements Burner Mounting: General Combustion Chamber: General Extreme Temperature Operation: General START UP PROCEDURES Burner Start Up and Service Test Equipment Required General Start-Up All Fuels Burner Start-Up Sequence Instructions: Gas...

  • Page 4: General Product Information

    Please refer to the Power Flame Terms and Conditions for our warranty policy. 1.3.2 Should a component fail, contact Power Flame Inc. or our Representative in your area and advise them of the Serial Number of your burner. The burner as-built included with the installers packet includes a Bill of...

  • Page 5: General Components Information

    ® natural gas burner. In some cases, the type of components and/or their arrangement may vary from this depiction. Power Flame practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice. For specifics on your system, refer to the technical information supplied with the burner.
  • Page 6 Installation and Operation Manual ® Figure 1a: Model EVO ® Dimensions, size 40-150...
  • Page 7 Installation and Operation Manual ® Figure 1b: Model EVO ® Dimensions, size 200-400...
  • Page 8 Installation and Operation Manual ® Figure 1c: Model EVO ® Dimensions, size 500-1000...

  • Page 9: Installation

    Use correction factors (multiplier) at right for other specific gravities and pressure drops. burner firing 2.1.6 Refer to Figure 2 for the typical gas piping schematic to meet U.L. requirements in the EVO ® ranges. Capacity of Pipes – Natural Gas (CFH) Correction Factors With Pressure Drop of 0.3”...

  • Page 10: Combustion Air Requirements

    Installation and Operation Manual ® Figure 2: Typical Gas Piping Schematic for Model EVO ® Burner Combustion Air Requirements 2.2.1 Fresh air required to support combustion, as well as to provide adequate location ventilation, must be supplied. All types of fuel require approximately 10 cubic feet of standard air (sea level at 60 F) per 1000 BTU’s firing rate, for theoretical perfect combustion.
  • Page 11 2.3.6 All burners are set through refractory with sleeve to allow field removal. The unlined space between sleeve and burner blast tube shall be filled in with non-asbestos high-temperature rope or KA-O-Wool. Figure 3. EVO ® Mounting Position Figure 3. EVO Mounting Position ®...

  • Page 12: Combustion Chamber: General

    ® Entry or loss of air from sources other than the firing unit will decrease its’ overall combustion and operational efficiency. 2.4.2 Table 3 below lists the minimum recommended firetube dimensions for the EVO burner. ® Min. Inside Diameter 16”...

  • Page 13: Start Up Procedures

    Installation and Operation Manual ® START UP PROCEDURES Burner Start Up and Service Test Equipment Required 3.1.1 The following test equipment is required to ensure proper start up and adjustment of burner equipment to obtain maximum efficiency and reliability of operation. 3.1.2 Equipment required: For any fuel:...

  • Page 14: Burner Start-Up Sequence Instructions: Gas

    Installation and Operation Manual ®...
  • Page 15 The typical pilot pressure is 2” to 6” W.C. but can be higher depending on site conditions. See page 19 for pilot ignition adjustments, and Figure 4 below for pilot position. Recycle the burner several times to make certain pilot operation is reliable. Figure 4. EVO Pilot Position Figure 4. EVO ®...
  • Page 16 Installation and Operation Manual ® 3.3.10 With pilot adjustments completed, reset the switch to the Run position, which will allow the sequence to proceed to the automatic gas valve energizing position. 3.3.11 When the main automatic gas valve begins to open, slowly open the checking gas cock to light off the main flame.
  • Page 17 Installation and Operation Manual ®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

  • Page 18: Gas Pilot Ignition Adjustment

    Installation and Operation Manual ® !"# $%&'()*+,&&$-./# !"#$ %&'$()*+,$-./),)+/$0123',45/,$ ^MC$**)($&F"*&7%$**5%$&"4.&)4*522)C)$4#&")%&3"6&,$&#-$&39*#&C93394&C"5*$*&92&7)'9#&)F4)#)94&2")'5%$/&G"*& 7%$**5%$&*-95'.&,$&%$".&"#&#-$&#$*#&#$$&94&#-$&7)'9#&F"*&*577'6&7)7$&!)#-&"&3"493$#$%&9%&U&_&AW`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a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

  • Page 19: Trouble Shooting Suggestions: General

    Installation and Operation Manual ® Turn the burner off. Re-connect the ignition leadwire to the ignition transformer secondary terminal. Set the check switch in the flame safeguard control for automatic operation. Re-connect any wires that have been disconnected to hold the motorized gas valve in the pilot position. Open the checking gas cock, turn the burner on and verify that the pilot lights and proves instantly, providing good, smooth ignition of the main gas flame.
  • Page 20 Installation and Operation Manual ® Defective ignition transformer – replace. Incorrect ignition electrode settings – refer to gas pilot adjustments for correct settings. Defective flame safeguard control or plug in purge timing card. Replace as required. Air flow switch not making circuit – check out electrically and correct pressure adjustment on switch, if required.

  • Page 21: Maintenance

    Installation and Operation Manual ® MAINTENANCE General Information 5.1.1 Only qualified service technicians should make mechanical or electrical adjustments to the burner and/or associated control equipment. 5.1.2 Preventive maintenance can usually be performed by building maintenance personnel. 5.1.3 Always follow the information provided in the Owner Operating Instructions at the end of this manual. These should be conspicuously posted in the burner room at the time of the initial burner installation and startup.

  • Page 22: Periodic Check List

    Installation and Operation Manual ® Periodic Check List Item Frequency Checked By Remarks Gages, monitors and indicators Daily Operator Make visual inspection and record readings in log Weekly Operator Verify heat exchanger manufacture’s settings Firing rate control Semiannually Service Technician Verify heat exchanger manufacture’s settings Annually Service Technician...

  • Page 23: Burner Start Up Information & Test Data

    Installation and Operation Manual ® BURNER START UP INFORMATION & TEST DATA The following information shall be recorded for each burner start up Power Flame model No.____________________ Job No.___________________ Serial No.____________________ Installation Name________________________________________________________________________________ Start Up Contractors Name________________________________________________________________________ Name of Technician Performing Start Up_____________________________________________________________...
  • Page 24 Installation and Operation Manual ® Operation Checklist Checked for Proper Operation Fresh air damper Low water cut off switch Barometric High water cut off Damper Boiler room combustion air Flame safeguard control and ventilation Ignition failure provisions Flame safeguard control main All gas lines flame failure checked for leaks...
  • Page 25 Installation and Operation Manual ® NOTES:...
  • Page 26 Installation and Operation Manual ® OWNER OPERATING INSTRUCTIONS WARNING Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to the burner manual for assistance or additional information consult a qualified installer, service agency or the gas supplier. Do not store or use gasoline or other flammable liquids and vapors in the vicinity of this or any other appliance.
  • Page 28 EVO 05/23 Copyright 2023 Power Flame Incorporated Printed in U.S.A.

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