PF X4-400 Bedienungsanleitung

X4 AND X4M INSTALLATION

AND

OPERATION MANUAL

Table of Contents

General Information............................................................................................................................2

Capacities & Specifications.................................................................................................................2

Acceptance Procedures......................................................................................................................2

Installation........................................................................................................................................2-4

Gas Piping.......................................................................................................................................4-6

Wiring.................................................................................................................................................7

Start Up.........................................................................................................................................7-11

Combustion Arrangement Requirements.....................................................................................11-12

Service/Maintenance Suggestions...............................................................................................12-13

Burner PartsList..........................................................................................................................13-14

Sequenceof Operationfor X4MBurners..........................................................................................16

X4M Wiring Diagram.........................................................................................................................17

X4MGeneral Arrangement Drawing.................................................................................................17

X4MActuator....................................................................................................................................18

X4MFiringRate vs. Manifold Pressure.............................................................................................18

-A-

POWER FLAME MODEL X4 BURNERS Rev.10/04

For use byQualified Service Personnel Only

U.S. Patent No. 6,508,645

WARNING: If the information in these

instructions is not followed exactly,a fire or

explosion mayresult causingproperty

damage, personal injury, or death.

Do not store or use gasoline or anyother

flammable liquids in the vicinityof this or

anyother appliance.

WHAT TO DO IFYOU SMELL GAS BURNER SPECIFICATIONS

1. Do not tryto light anyappliance.

2. Do not touch anyelectrical switch; do Input Capacity

BTU/Hr

not use anyphone in your building. X4-400150,000 – 400,000

3. Immediatelycall your gas supplier from X4-700200,000 – 725,000

a neighbor’s phone. Follow the gas X4M-400150,000 – 400,000

supplier’s instructions. X4M-70090,000 –725,000

4. Ifyou cannot reach your gas supplier, Fuel Type Natural or LP Gas

call the fire department. Blast Tube Length 9”, 12”

Inlet Gas Pressure

X4-4005.0 –14” w.c.

X4M-4005.5 –14” w.c.

INSTALLATION AND SERVICE X4-7005.0 –14” w.c.

MUST BE PERFORMED BY A X4M-7005.5 –14” w.c.

QUALIFIED INSTALLER, SERVICE Voltage 120V, 60 Hz

AGENCY, OR THE GAS SUPPLIER AmpRating 5.0 Amp

Motor ¼ Hp,3450 RPM

Transformer 40VA, 24 VAC

Rev.10/04

1. GENERAL INFORMATION

The X4 burner is a new generation ofgas power burners designed to fire natural gas andpropaneagainst

a positive furnace pressure.

The burner is a self-contained unit comprised ofa blowerassembly, firing head,ignition system,

combinationgas valve, flame safeguard and control panel. It onlyrequires connectionof115V electrical

supply, minor gas trainpiping, connectionto gas service, and operating controls.

All Power Flame burners are operationallyfire tested at the factory.

2. CAPACITIES & SPECIFICATIONS

Burner NumberX4-400X4-700X4M-400X4M-700

Natural/LP Gas Flowx 1,000BTU/HR150-400200-725150-40090-725

Gas Train Size3/4”1”3/4”1”

Blower Wheel Size6-1/4” x 2-3/4”7” x 3”6-1/4” x 3-3/4”7” x 3”

Blower Motor HP1/41/41/41/4

Voltage120/60 hz120/60 hz120/60 hz120/60 hz

MaximumInlet Pressure to Main Shut-

off CockInches W.C. 14.014.014.014.0

3.ACCEPTANCE PROCEDURE

Open the box and carefullyremove the top cardboard packaging. Lift the burner fromthe box and ensure

all shippedloose items are removed before discarding the box. Checkall parts received against your

computer generated Bill ofMaterial that is enclosed in the owner’s information envelope.

Warranty

The Owners Information envelopepacked with the burner contains a WarrantyRegistration Card. The

WarrantyRegistration Card is also a request formfor a Spare Parts List. An on-hand supplyofspare

parts is highlyrecommended incase ofemergencyshutdown. We request that you complete andreturn

the card toPower Flame in the enclosed self-addressedenvelope as soon as possible.

4.INSTALLATION

Prior to Installation,please review the MART Operator's Manuel for recommend setting

and flue requirements. Additional charts, drawings and

diagrams shipped with the burner are provided in this manual.

Installationmust be in accordance withall local and national codes includingCAN1-B149.1 or B149.2and

Canadian electrical codes for Canadian installations.

4.1Ifthe burner is tobe mounted in an existing boiler or furnace, ensure that all fireside surfaces are clean

and in good condition. All doors, cleanouts, cracks or other openings allowing excess air into the

combustion chamber should be tightlysealed, whether the burner is to befired under positive or negative

combustion chamber conditions.

4.2The burner can be mountedthrough a heat exchanger endwall or in the base ofthe boiler – see Figures

1 and 2. The opening for the burner blast tube should not be less than 4 ¼ inches indiameter to allow

easyremoval ofthe burner. The gapbetween the burner opening and the blast tube should be sealed

with non-asbestos, high temperature rope or Ka-O-Wool. Where a newor replacement combustion

chamber lining is to be usedthe chamber is to be built using2300 degree F insulating firebrickor ceramic

fiber blanket.

Figure 1 Mounting in Heat Exchanger

Figure 2 Mounting in Boiler Base

4.3 COMBUSTION CHAMBER SIZING

Table 1 Combustion Chamber Recommended Dimensions

Gas InputWidthLength

MBTU/HRInches Inches

2501317

4501520

6001623

7001725

8501826

4.4 Whichever method ofmountingis chosen, the burner blast tubemust be recessed into the front wall

surface from0” to 1/2”.

NOTE:Serious DamageTo The Burner MayResult IfThe Blast

Tube Is Extended Into TheCombustion Chamber.

4.5 Secure the burner to the heat exchanger or boiler, using the burner-mounting flange. The burner-

mounting flange must be secured to the blast tube at the selected location for proper insertion

intotheend or front wall ofthe firedunit. A tight seal between the mounting flange andthefront

plate shouldbe accomplished usingthefactory-furnished gasket or a ceramic or other non-

asbestos fiber rope.

5GAS PIPING

5.1Contact you local gas service companyto ensure that adequate gas serviceis available and to

reviewapplicable 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, CGAB 149.2. This product must be installed onlybya Licensed

Plumber or Gasfitter, when installed in the Commonwealth ofMassachusetts.

5.2Size the main gas line inaccordance with Table2. The figures shownare for straight lengths of

pipe at 0.2” w.c. pressure drop, which is considered normal for low-pressure systems. Note that

fittings such as elbows and tees will add tothepipe pressure drop.

Table 2 - Gas Piping PressureDrop Data

EQUIVALENTLENGTH OF STRAIGHTPIPE IN FEET

203040506080100150200

PipeSize In InchesCFH GAS WITH .2” PRESSURE DROP

3/4”152120105938473665445

1”30025021019018015013511075

1-1/4”520425360325300260230190165

1-1/2”800690560500480410370300260

2”17001400120011001000850750600540

2-1/2”30002500210019001800155013751100950

EQUIVALENTLENGTHS OF STANDARD PIPE IN FEETFOR LISTED FITTINGS

Fitting Type3/411-1/2 1-1/222-1/2Nominal Pipe Size In Inches

Std. Tee2.45.57.59.012.013.5

Std. Elbow4.42.73.74.55.56.1

5.3Refer to Figure 3 for details ofgas piping. (Also refer to anyadditional piping diagrams supplied for this

specific unit.)

5.4Mount leakage test andmain gas cocks, main automatic gas valve or combination gas

valve/pressure regulator, andauxiliaryvalves (ifrequired and not factorymounted) per piping

diagramor Figure 3.

5.5Install pressure regulator (not usedwith combination gas valve/pressure regulator) directly

upstreamofmain automatic gas valve(s) and fit drip leg and main gas cockupstreamofregulator

or automatic valve(s).

5.6 The pilot line should be pipedinto the upstreamtapped nipple to minimizepilot linepiping length.

An optional locationis in a tapping located on the main shut-off cock. Refer to Figure 3. For

ease ofservicing we recommend the use ofa union immediatelyupstreamofthe main gas

pressure regulator or combination gas valve/pressure regulator.

5.7 Install ventlines frommain gas regulator (ifused) and diaphragmgas valve where applicable.

Ventlines should be run to the outside ofthebuilding, terminatingclear ofwindows or fresh air

intakes. Outside termination ofventshould have a screen to prevent insects frombuilding nests

in vent pipe.The vent should terminate in a manner, which will preclude the possibilityofwater,

dirt or other foreign matter fromentering the line.

Figure 3 UL GasPiping Train (X4) – See Figure 11B,page 17, for X4M

5.8Test gas lines for leaks using a soap solution. Your local gas service companymaywish to execute or

witness this test.CAUTION – gas pressure above14” w.c. maydamage the standard diaphragmgas

shut-off valve. Do not exceed this valuewhen pressure testing lines unless youcap off line upstreamof

main gas cockand pilot take-off.

5.9 Checkthat sideorifice size is correct according to burner specificationsheet(See Figure 4). To gain

access to orifice, remove Plug A andwithdraw spring and orifice. When reinserting or replacingthe

orifice, ensurethat itseats properlyinside the tee and reinstall plug.

Figure 4 Location of Side Orifice

Figure 5 Typical Wiring Diagram for S8680Jwith Proved Pilot Ignition

Figure 5ATypical Wiring Diagram for S89F with Direct SparkIgnition

6WIRING

6.1 Refer to wiring diagramshippedwith burner and typicalwiringdiagrams Figures 5 and 5A.The

two power leads (blackand white) are locatedinside theburner panel.

6.2Electrical installation must be made in accordance with the NEC NFPA 70 or Canadian Electrical

Code,Part1 and applicablelocal codes. Ifthis burner is part ofa boiler or furnace package

system, checkwiring diagramas supplied bythe boiler or furnacemanufacturer.

7START UP

7.1Before attempting aburner start up, please review the MART Operator's Manuel for recommend setting

and flue requirements.Also this manual will provide information about theexact sequence of

operation and all other details on the specific PrimarySafetyControl Systembeing used. This

information will be found in bulletins supplied with the burner, as well as technical bulletins covering other

components. All ofthese materials should be usedas reference in burner start up and service.

7.2Checkboiler water level (ifapplicable).

7.3Layoutcombustion test equipment (see Section 8.3).

7.4Attach gas pressure gauge ormanometer to upstreamside ofmain gas cock(0-35” w.c.) andto orifice

pressure tap (0-10” w.c.) as well as to pilot gas pressure test tee tapping (0-10” w.c.).

7.5 Checkthe voltage at the disconnect switch to make certain that it matches that indicated on the burner

label.

7.6Ensure that all dampers in the flue or stackare fullyopen.

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