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Summary of Contents for Power Flame X4
- Page 1 X4 & X4M Installation and Operation Manual...
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Page 2: For Your Safety
FOR YOUR SAFETY If you smell gas: Do not store or use gasoline or other 1. Open windows. flammable liquids and 2. Do not touch electrical switches. vapors in the vicinity of this or 3. Extinguish any open flame. any other appliance. 4. -
Page 3: Table Of Contents
Figure 1: Mounting in Heat Exchanger ................2 Figure 2: Mounting in Boiler Base ................... 3 Figure 3: UL Gas Piping Train (X4) – See Figure 14, page 18, for X4M ......5 Figure 4: Location of Side Orifice ..................5 Figure 5: Typical Wiring Diagram for S8680J with Proved Pilot Ignition...... -
Page 4: General Information
The X4 burner is a new generation of gas power burner designed to fire natural gas and propane against a positive furnace pressure. The burner is a self-contained unit comprised of a blower assembly, firing head, ignition system, combination gas valve, flame safeguard and control panel. It only requires connection of 115V electrical supply, minor gas train piping, connection to gas service, and operating controls. -
Page 5: Acceptance Procedure
Registration Card. The Warranty Registration Card is also a request form for a Spare Parts List. An on-hand supply of spare parts is highly recommended in case of emergency shutdown. We request that you complete and return the card to Power Flame in the enclosed self-addressed envelope as soon as possible. -
Page 6: Figure 2: Mounting In Boiler Base
Figure 2: Mounting in Boiler Base Combustion chamber sizing: Gas Input Width Length MBTU/HR Inches Inches Table 2: Combustion Chamber Recommended Dimensions Whichever method of mounting is chosen, the burner blast tube must be recessed into the front wall surface from 0” to 1/2”. Serious Damage To The Burner May Result If The Blast Tube Is Extended Into The Combustion Chamber. -
Page 7: Gas Piping
Contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area. All gas piping installations must be in accordance with NFPA 54, National Fuel Gas Code, Definitions and General Field Recommendations, CGA 3.0, Canadian Natural Gas Installation Code CAN/CGA B149.1 or Propane Installation Code, CGA B 149.2. -
Page 8: Figure 3: Ul Gas Piping Train (X4) - See Figure 14, Page 18, For X4M
Figure 3: UL Gas Piping Train (X4) Test gas lines for leaks using a soap solution. Your local gas service company may wish to execute or witness this test. CAUTION – gas pressure above 14” w.c. may damage the standard diaphragm gas shut-off valve. -
Page 9: Figure 5: Typical Wiring Diagram For S8680J With Proved Pilot Ignition
Figure 5: Typical Wiring Diagram for S8680J with Proved Pilot Ignition Figure 6: Typical Wiring Diagram for S89F with Direct Spark Ignition... -
Page 10: Wiring
Refer to wiring diagram shipped with burner and typical wiring diagrams Figures 5 and 6. The two power leads (black and white) are located inside the burner panel. Electrical installation must be made in accordance with the NEC NFPA 70 or Canadian Electrical Code, Part 1 and applicable local codes. -
Page 11: Figure 7: Pilot/Gun Assembly - Flame Rod Type - Natural Gas/Lp Gas
7.10.2 To prepare the pilot for proper operation, it is essential that appropriate adjustments be made to the burner air inlet damper and the pilot gas pressure. See Table 5 for the approximate air damper setting at the various firing rates. Typical pilot test pressures are 3”... - Page 12 Pilot Adjustment and Main Flame Light Off Procedure Select and install the main orifice that corresponds to the desired firing rate. Note: X4 Burners light off at the high fire position. Set the air flow (see Table 5) and pilot 7.12.
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Page 13: Figure 9: Detail Direct Spark Gun Assembly
Set the burner’s combustion air inlet damper to the approximate setting as shown in this 7.13.2 manual for the desired firing rate (Table 5). Also, verify that the correct main orifice is installed in the main orifice tee. 7.13.3 Open the main manual gas valve and turn the combination gas valve to ON. Turn the burner power on. -
Page 14: Combustion Arrangement Requirements
The X4 burner has been designed to fire with high combustion efficiency into combustion chambers with positive, balanced or negative pressures using natural or LP gas only. Caution: In order to fire efficiently, the burner requires an adequate supply of combustion air. -
Page 15: Service/Maintenance Suggestions
The correct test instruments are: analyzer (electronic or Fyrite absorption system) CO indicator (Monoxor or similar) Stack thermometer Draft gauge or inclined manometer U-tube manometer or calibrated 0-10” and 0-35” w.c. pressure gauge Combination volt/ammeter D.C. Micro-Ammeter Burner fails to start: Bad fuse or switch open on in-coming power source, or motor overload out. -
Page 16: Burner Parts List X4
Verify that the pilot and or direct spark electrodes are still within specifications (set per drawing 7, 8 and 9 in this manual). Verify the proper operation of the Primary Safety Control, airflow switch, and operating controls. Check safety gas shutoff valves for gas tightness. In the event of extended shutdown, the main power should be turned off and the main manual gas shutoff valve should be closed. -
Page 17: Figure 10: X4 General Assembly And Parts
Figure 10: X4 general assembly and parts Figure 11: X4M general assembly and parts... -
Page 18: Figure 12: X4 Specifications And Dimensions
Figure 12: X4 specifications and dimensions... -
Page 19: Sequence Of Operation For X4M Burner
LF-24 BELIMO ACTUATOR 11.1 Refer to typical wiring diagram for X4M burner (Figure 13). Upon a call for heat, the blower motor starts, closing the combustion air switch. Power is supplied to the 24-vac transformer. Initially, power to the actuator is held out through one set of normally open contacts on the 24-vac relay. 11.2 Since power is not supplied to the actuator, it will spring return clockwise to the open damper position if not already there. -
Page 20: Figure 13: Typical Wiring Diagram For X4M With Lf-24 Actuator
11.15 When the main gas valve is energized, after a proven pilot or during direct spark ignition on DSI burners, the 24-vac relay will also be energized. 11.16 One set of normally open relay contacts close which interlocks the high fire auxiliary end switch. Another set of relay contacts closes and completes the modulation circuit. -
Page 21: Figure 14: General Arrangement Diagram For X4M (Amcx-24)
Figure 14: General Arrangement Diagram for X4M (AMCX-24) Figure 15: Belimo LF24-SR-S Actuator... -
Page 22: Figure 16: Belimo Amcx-24 Actuator
Figure 16: Belimo AMCX-24 Actuator Manifold Pressure vs. Firing Rate X4M-700 X4M-400 Firing Rate (MBH) Figure 17: X4M Firing Rate vs Manifold Pressure 11.19 The manifold pressures shown are the gas pressures taken at the 1” tee and represent a zero furnace pressure (net manifold pressure). -
Page 23: X4M Htd (High Turn Down)
12.1 The main difference between the X4M and X4M-HTD is the use of the 1/3 hp ODP motor on the HTD model to prevent air infiltration at the low end of the firing rate. 12.2 Each of the HTD model’s maximum firing rate may be reduced by either lowering the combination valve regulator outlet pressure or by placing an orifice in the orifice tee (see Fig. - Page 24 NOTES: ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________...
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Page 25: 13. Owner Operating Instructions
13. OWNER OPERATING INSTRUCTIONS FOR YOUR SAFETY If you smell gas: Open windows Extinguish any open flame Do not touch electrical switches Call your gas supplier immediately Do not store or use gasoline or other flammable liquids and vapors in the vicinity of this or any other appliance. - Page 27 DC4 DRAFT CONTROL ® Cmax Installation & Operation Manual POWER FLAME INCORPO R AT ED Power Flame Incorporated, hereinafter called Equipment, which is repaired or replaced, shall the Seller, of 2001 South 21 Street, Parsons, carry a warranty equal to the unexpired portion...
- Page 28 MANUAL X40M 7/01, REP. 09/19 Copyright 2009 Power Flame Incorporated Printed in U.S.A. Power Flame Incorporated 2001 South 21 Street, Parsons, KS 67357 Telephone: 620-421-0480 FAX: 620-421-0948 Product Support: 620-820-8301 Website: Power Flame Inc. AN ASTEC INC. COMPANY...
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