PF NPM15-10-24 User manual

Power Flame Incorporated
NOVAPREMIXINSTALLATION
AND
OPERATIONMANUAL
THEPOWERTOMANAGEENERGY
2001 South21st Street, Parsons, Kansas67357
Telephone: [phone], Fax: [phone]
WebSite: www.powerflame.com
E-mail: [e-mail] NPM–12/04
®

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1.GENERAL INFORMATION
The NPM NOVAPremixfburneremploysafullypremixed high swirlstabilized combustion head
technologytoprovide proven lowNOXemissionsforsub 30 PPM applicationsand superiorflame
retention.NOXemissionslowerthan 30 PPM can be obtained byrunning at slightlyhigher02levels. The
NPM burnerisdesigned tofirenatural gasand propaneagainst apositive, balanced ornegativefurnace
pressure.
The burnerisaself-contained unitcomprised ofablowerassembly,firing head,ignition system,and
flamesafeguardcontrolpanel. Aswithanypremixburnerthe excess 02operating range isnarrowerthan
thoseofaconventionalnozzlemixgasburner. Therefore, during setup careshouldbe exercised in
obtaining an excess 02 reading of notless than 2% ormorethan 7%.
AllPowerFlameburnersareoperationallyfiretested at the factory.
2.CAPACITIES &SPECIFICATIONS
ModelNumber NPM15-10-24 NPM15-10-120 NPM30A-12-120 NPM30-12-120 NPM50-15-120
Natural/LPGasFlow300-720300-850390-1,100480-1,260825-2,200
X1,000 BTU/HR
GasTrainSize1”1”1-1/4”1-1/4”1-1/2”
BlowerWheelSize7”x3”7”x3”7”x3”8-1/4”x1-1/2”9-1/8”x2-1/2”
BlowerMotorHP1/4”1/4”1/2“1/2”1”
MotorVoltage120/60 Hz120/60 Hz120/60 Hz120/60 Hz120/60Hz
ControlVoltage24 V120 V120 V120 V120 V
InletPressure
ToMainShut-off
Cock Inches
W.C.Min. /Max.6.8/14.06.7/14.07.3/14.08.2/14.011.6/14.0
3.ACCEPTANCEPROCEDURE
Uncrateburnercarefullyand check allpartsreceived against yourcomputergenerated Billof Material
thatisenclosed inthe owner’sinformation envelope.
Warranty
The OwnersInformationenvelope packed withthe burnercontainsaWarrantyRegistration Card.The
WarrantyRegistrationCardisalsoarequest formforaSparePartsList. Anon-hand supplyof spare
partsishighlyrecommended incaseofemergency shutdown. Werequest thatyou completeand return
the cardtoPowerFlameinthe enclosed self-addressedenvelope oryou can registeron line at
www.powerflame.com assoon aspossible.
4.INSTALLATION
PriortoInstallation,Carefullyread thisInstallation and Operation Manual,ReviewAll Charts, Drawings
and DiagramsShipped withthe Burner.Installationmust be inaccordancewithalllocaland national
codesincluding CAN1-B149.1orB149.2and CanadianelectricalcodesforCanadian installations.

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4.1Ifthe burneristobe mounted inan existing boilerorfurnace, ensurethat allfireside surfacesareclean
and ingood condition.Alldoors, clean outs, cracksorotheropeningsallowing excess airintothe
combustion chambershouldbe tightlysealed, whetherthe burneristobe fired underpositiveornegative
Combustion Chamberconditions.
4.2The burnercan be mounted through aheat exchangerend wall orinthe baseofthe boiler–see Figures
1and 2. The opening forthe burnerblast tube shouldnot be less than 6¼,8¼, or10 ¼inchesin
diameter(depending on the burnermodel)toalloweasy removal of the burner.The gap between the
boileropening and the blast tube shouldbe sealed withnon-asbestos, high temperaturerope orKa-O-
Wool. Whereaneworreplacementcombustion chamberlining istobe used the chamberistobebuilt
using 2,300 degree F insulating firebrickorceramicfiberblanket.
Figure 1.MountinginHeatExchanger
Figure 2.MountinginBoiler Base

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4.3COMBUSTIONCHAMBERSIZING
Table1.Combustion Chamber RecommendedDimensions
Gas InputWidthLength Gas InputWidthLength
MBTU/HRInchesInchesMBTU/HRInchesInches
45015 20 126023 33
60016 23 150025 38
70017 25 180026 40
85018 26 220028 42
4.4Whichevermethod ofmounting ischosen, the burnerblast tube must be recessedintothefrontwall
surfacefrom0”to1/2”.
NOTE:SeriousDamageToTheBurnerMayResultIfTheBlastTubeis
ExtendedIntoTheCombustionChamber.
4.5 Securethe burnertothe heat exchangerorboiler,using the burner-mountingflange. Atight seal
betweenthe mounting flange and the frontplateshouldbe made using the factory-furnished gasket or
ceramicnon-asbestosfiberrope.
5GASPIPING
5.1 Contact you local gasservicecompanytoensurethatadequategasserviceisavailableand toreview
applicableinstallation codesforyourarea.Allgaspiping installationsmust be inaccordancewithNFPA
54, NationalFuelGasCode, Definitionsand General FieldRecommendations, CGA3.0, Canadian
NaturalGasInstallation Code CAN/CGAB149.1orPropane Installation Code, CGAB149.2.
5.2Sizethe maingasline inaccordancewithTable2.Thefiguresshown areforstraightlengthsofpipe at
0.2”W.C.pressuredrop, whichisconsidered normal forlow-pressuresystems. Notethatfittingssuchas
elbowsand teeswilladd tothe pipe pressuredrop.
Table2-Gas PipingPressureDrop Data
EQUIVALENTLENGTHOFSTRAIGHTPIPE INFEET
20 30 40 50 60 80 100 150 200
Pipe SizeInInchesCFHGASWITH.2” PRESSUREDROP
1” 300 250 210 190 180 150 135 110 75
1-1/4” 520 425 360 325 300 260 230 190 165
1-1/2” 800 690 560 500 480 410 370 300 260
2” 1700 1400 1200 1100 1000 850 750 600 540
2-1/2” 3000 2500 2100 1900 1800 1550 1375 1100 950
EQUIVALENTLENGTHSOFSTANDARD PIPE INFEETFORLISTEDFITTINGS
FittingType1” 1-1/4” 1½” 2” 2-1/2” NominalPipe SizeInInches
Std. Tee 5.57.59.012.013.5
Std. Elbow2.73.74.55.56.1
5.3 RefertoFigure3fordetailsofstandardgaspiping.(Alsorefertoanyadditionalpiping diagramssupplied
forthisspecificunit.)
5.4Mount leakage test and maingascocks,mainautomaticgasvalveorcombination gasvalve/pressure
regulator, and auxiliaryvalves(if required and notfactory mounted)perpiping diagramorFigure3on
page 4.

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Figure 3.Typical ULGas Piping Train(Modulating Burner)
5.5Installpressureregulator(not used withcombination gasvalve/pressureregulator) directlyupstreamof
mainautomaticgasvalve(s)and fitdriplegand maingascock upstreamof regulatororautomatic
valve(s).
5.6The pilotline shouldbe piped intothe upstreamtappednippletominimizepilotline piping length.An
optionallocation isinatapping located on the mainshut-offcock.RefertoFigure3.Foreaseof
servicing theuseofaunion immediatelyupstreamof themaingaspressureregulatororcombination gas
valve/pressureregulatorisrecommended.
5.7Installventlinesfrommaingasregulator(if used)and diaphragmgasvalvewhereapplicable.Ventlines
shouldbe run tothe outside of the building,terminatingclearofwindowsorfreshairintakes. Outside
termination ofventshouldhaveascreen topreventinsectsfrombuilding nestsinvent pipe.The vent
shouldterminateinamanner, whichwillpreclude the possibilityof water, dirt orotherforeign matterfrom
entering the line. Refertostateorlocal codesforproperventing requirements.
5.8Test gaslinesforleaksusing asoap solution. Yourlocalgasservicecompanymaywishtoexecuteor
witnessthistest. CAUTION–gaspressureabove14”W.C.maydamage the standarddiaphragmgas
shut-offvalve.Do not exceed thisvalue when pressuretesting lineswithoutfirstcapping off line
upstreamofmaingascock and pilottake-off.
5.9Check that side orificesize(if used)matcheswiththe burnerspecification sheet See Figure4on page 5.
Togainaccess toorifice,removeorificetee plug and withdrawspring and orifice.When reinserting or
replacing the orifice,ensurethat it seatsproperlyinside the tee and reinstallplug.

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6WIRING
6.1Refertowiring diagramshipped withburner.
6.2Electricalinstallation must be made inaccordancewiththe NEC, NFPA70 orCanadian Electrical Code,
Part 1and applicablelocal codes. Ifthisburnerispart of aboilerorfurnacepackage system, check-
wiring diagramassupplied bythe boilerorfurnacemanufacturer.
7START UP
7.1Beforeattemptingaburnerstart up,thoroughlystudyand familiarizeyourself withthe exact sequenceof
operation and allotherdetailson the specificPrimarySafetyControlSystembeing used. This
information maybe found inbulletinssupplied withthe burner, aswell asintechnicalbulletinscovering
othercomponents. Allof thesematerialsshouldbe used asreferenceinburnerstart up and service.
7.2Check boilerwaterlevel(if applicable)and allsafetyinterlocks.
7.3Layout combustion test equipment (see Section 8.4).
7.4Attachgaspressuregauge ormanometertoupstreamside ofmaingascock (0-35”W.C.)and toorifice
pressuretap (0-10”W.C.)aswell astopilot gaspressuretest tee tapping (0-10”W.C.).Note:On
burnersusing the combination gasvalvesuchasthe RobertShaw7000DERHC the manifoldpressureis
taken atthe 1/8”downstreampressuretapping located on the valve.RefertoFigure4.
Figure 4. Typical24 VoltGas PipingTrain(On-Off)
7.5Check the voltage atthe disconnect switchtomakecertainthatit matchesthe voltage indicated on the
burnerlabel.
7.6Ensurethat alldampersinthe flue orstack arefullyopen.
7.7Installstack thermometerand Flue GasAnalyzersample line tobreaching and draft gauge tocombustion
chambertest point.

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7.8Connect amicroampmeterorvoltmetertothe Primary SafetyControlasdirected inthe PSC
manufacturer’sinstruction bulletintodetermine flamedetectionsystemvalues. The meterisnormally
connected inserieswiththe (SENSE)terminalon the S8680 seriescontrol.
7.9Withthe mainand leaktest cocksand pilotcockin OFF position,turnon the gascock atmeter.Check to
makecertainthatthe pressureupstreamofmainand pilotcocksdoesnot exceed 14”W.C.(1/2PSIG)–
unless specialvalvetraincomponentssuitablyrated havebeen furnished (RefertoBurnerSpecification
Sheet).If pressureisacceptable, proceed tonext step.
7.10 PilotIgnition
Nextcheck theoperationofthegas pilotsystem.Thisisavery importantpartofthestartup
procedure.
A.Beforeattemptingburnerstart up makecertainthat youarefamiliarwiththe operation of the
PrimarySafetyControland othercomponentsbeing used on thisspecificapplication. Referto
Fig. 5and 5Aforpilot spark gap dimensions.
B.Topreparethe pilotforproperoperation,itisessentialthat appropriateadjustmentsbe made on
the burnerairinletdamperand tothe pilot gaspressure. Initialairdamperopening shouldbe
approximately1/8inchopen forlowhigh lowormodulating type models.Onfixed rateburners
the airdampermayhavebeen factoryset toapredetermined opening.The pilotpressure
needed willbe affected bythe damperposition.Typicalpilot pressureis0.5”W.C.higherthan
the staticairpressuremeasured on the pilot duringpre-purge fornatural and propane gas.
C. In manyinstances,pilotproblems relatetogas pressures thatare toohighortoolow,
causing thepilotgas mixture tobejustoutsideoftheignitionrange.Theoptimumpilot
pressure shouldbedeterminedbyadjusting thepilotregulatorand finding theminimum
and maximumpressure thatthepilotlights. Then, setthepilotregulatorwhere the
pressure isinthemiddleofthese twopressures.
Figure 5.PilotAssembly–Flame Rod Type–Natural Gas/LPGas -NPM15 –24 Volt

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Figure 5A. PilotAssembly–Flame Rod Type–NaturalGas/LPGas–NPM15 –NPM50 –120 Volt
7.11 Withthe leakgascock closed and pilotgascock open;turnthe burnerswitchON.The blowermotorwill
purge the heat exchangerof anyaccumulatedcombustibles.Atthe end ofthe purge cycle,the pilot
solenoidvalvewillenergizeand spark willbe initiated. The pilotwillattempttolightfor10 seconds(15
secondswithS8680 control).Adjust the pilot pressureat thistime.Ifthe pilot failstolight,lockoutwill
occur. Note: If using the S8680 control powermust beremoved for60 secondstoallowittoreset.
7.12 PilotAdjustmentand MainFlameLightOff Procedure
A.Set the airdamperand adjust the pilotregulatorgaspressureinordertoprovide instant pilot
ignition,good flamestability, and astrong/steadysignal reading.Connect aDC voltmeteror
microampmetertothe flamesafeguardcontrolasappropriatetodetermine flamedetection
systemsignalvalues. RefertoTable3.
B.Adjust the pilot regulatortoobtainapproximately0.5”to1.0”W.C. pressureat the pilottest port.
Note: Thispressurevariesdepending on the damperopening/burnermodel.The actualpilot gas
pressureswilltypicallybe 0.5”to0.1”W.C. abovethe staticairpressureasseen on the gage
beforethe pilot valveopens. Furtherpressureadjustmentsmaybe necessary toobtainthe best
pilot operating point.
C.Afterattaining the properpilot flamesignalvalues, cycle the piloton and off severaltimesinorder
toensurereliability(withthe gasleaktest cock still closed). Turn Burner SwitchOff.
D.Having established pilotreliability, open gasleaktest cock.
Table3.AcceptablePilotand/orMainFlame CurrentReadings
CONTROL FLAME ROD
RM78XXseries1.25-5VDC
FireyeEseries10 min/20 normal
S8680J1.5Microamps

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E.Afterthe burnerhascompleted pre-purge and established agood pilotflamesignalreading,the
mainautomaticfuelvalvewillbe energized.Aswhen settingup the pilot,staticairpressurewill
alsobe evident on the gasmanifold.Thispressurewillincreaseasthe maingasvalvesopen.
The mainflameshouldlightimmediately.Ifimmediatelight off doesnot occur,itispossiblethat
airwillneed tobe purged fromthemaingasline.Adjust maingaspressureregulator(ifused)or
combination valveregulatortoobtainthe desired firing ratepressure.
F.Adjust burnerasnecessary toprovide smoothignition ofmainflame.Ifflamesignal drops
significantlywhen mainfuelvalveopens, decreasepilot gaspressureslightlytoobtaina
reasonablystableflamesignalvalue.
G.Ifrequired, selectand installthe mainorificethatcorrespondstothe desired firing rate, see table
4on page 9. Ensurethatthe airflowsetting providesthecorrect CO2orO2levelsand other
combustion valuesat theproperfiring inputrates.Generallyaccepted valuesfornaturalgasare
8-1/2to10% CO2or5-1/2to3% O2.EquivalentCO2 readingson propane gasare10 to11-1/2%
CO2 or5-1/2to3-1/2%O2.It isimportantthatthe CO (carbon monoxide)level ischecked and
heldat 0%orminimum(typicallyunder100ppmor0.01%). Checkwiththelocalgasutilityand
anyotherauthoritieshaving jurisdiction beforemaking final burneradjustments.
7.13 Conduct allapplicabletest proceduresshowninthe PrimarySafetyControlmanufacturer’sbulletins
included withthe burner.Setand check operation of low and high gaspressureswitches(if applicable),
allburnerand heat exchangercontrols, and operating devices. Check blowerairflowproving switchby
first closing maingascock and disconnecting motorleadwire. Aproperlyadjusted airswitchshouldopen
within3to4secondswhen the powerisremoved fromthe motor.
7.14 Clean up arearound the burnerand reviewoperating proceduresand instructionswithownerand/or
operator.
7.15 Post Installation and Operating Instructionsclosetotheburnerinclearlyvisibleposition forfuturereference.

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8.COMBUSTIONARRANGEMENT REQUIREMENTS
8.1The NPM burnerhasbeen designed tofirewithhigh combustion efficiency intocombustion chamberswith
positive,balanced ornegativepressuresusing naturalorPROPANEgasonly.
8.2Inordertofireefficiently,the burnerrequiresan adequatesupplyofcombustionair.Ventilation toany
enclosed area shouldbe provided on the basisof 1/2squareinchof opening foreach1,000 BTU/HR
input.Thisexcludesthe requirementforanyotherfiredequipmentinthe area.Consult NFPA 54 for
combustion airrequirement. The enclosed area should not becomeexcessivelyhot and underno
circumstancesshouldbe underanegativepressure.
The burnershouldbe initiallyset up and serviced atregularintervals(preferablyat thebeginning of and
midwaythrough high useperiods)byatrained serviceman using the propertestinstruments. Failureto
maintainthe correctburnersettingsmayresultininefficient gasconsumption, prematurewearof burner
and heat exchangercomponents, uncontrolled combustion.
8.3Approximategasflowratesand corresponding pressuresareshowninTable4fornaturalgasand
propane gas. Theserates/pressuresrepresent approximately5% excess 02at 0.0”W.C.furnace
pressure. Sincethe amount of excess airwill affect theactual manifoldpressure/rate,verification of the
exact firing rateshouldbe confirmed byclocking the gasmeterand applying the appropriatecorrection
factor.
8.4The necessary test instrumentation are:
a.O
2
analyzer(electronicorFyriteabsorption system)
b.COindicator(Monoxororsimilar)
c.Stack thermometer
d.Draft gauge orinclined manometer
e.U-tube manometerorcalibrated 0-10”and 0-35”W.C.pressuregauge
f.Combinationvolt/ammeter
g.D.C. Micro-Ammeter
Table4.ManifoldPressure Chart. The pressuresshownrepresent azerofurnacepressure. Actual
furnacepressuremust be added tothesepressurestoobtainthe totalpressureneededat agivenfiring
rate.
ManifoldPressurevs. FiringRate
0
2
4
6
8
10
0500 1000 1500 2000 2500
FiringRate(MBH)
Manifold Pressure ("w.c.)
NPM15
NPM30(A)
NPM50

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9.SERVICE/MAINTENANCESUGGESTIONS
9.1Burner failsto start:
1.Bad fuseorswitchopen on in-coming powersource, ormotoroverload tripped out.
2.Controlcircuithasan open controlsuchasoperating,limitorlowwatercut-off.
3.Pushthe reset button on the motororopen thepowercircuittothe primary safetycontrol.
4.Looseorfaultywiring.Tighten allterminalscrews. Check wiring,against wiring diagramfurnished
withburner.
9.2 Burner motorruns,butpilotdoes notlight
1.Besuregasisturned on atmeterand pilotcock isopen.
2.Placehand on pilotvalvetophysicallyconfirmitisopening.Check gauge attee inpilotline forgas
pressureand prompt opening of pilot valve.Thetypicalpilot pressurewillbe 0.5”w.c.abovethe
staticairpressure.
3.Check visuallyorbysound forspark arcing.Verifythatelectrode isnot cracked orshorted.
4.Refertosection 7.10 on pilot checking procedures.
5.Check airswitchand be sureitscircuit closesduring start.
6.Check continuitythrough “Thermal Cutoff Fuse”locatedbetween flamerod and flamerod wire.
7.Verifythe spark gap iscorrect.RefertoFigure6.
8.Check forcarbon fiberbuild-up between electrode tipand pilot body.
9.Check inlet gaspressure. Onburnersusing alowgaspressureswitchthe inletgaspressuremust
be atleast 6.5”W.C.
9.3Burner motorruns,pilotlights,butmain gasvalve does notopen
1.Check flamesignal.If signalislow, adjust pilot gaspressureand airsettingsforimproved readings.
2.Check maingasvalveelectricalcircuit.
3.Shut-off cock orleaktest cocksnot open.
4.Shut-off knob on combination valvenotturned “On”.
5.Defectivemainvalve.
9.4Occasionallockoutsfornoapparentreason
1.Re-check micoampreadings. If insufficient,check gaspressureand airdampersetting.Check
electrode setting.Ifflamesignalislow,flamerod mayhavetobe re-positioned.
2.Check ignition cableand electrode porcelainfordamage orbreaks, whichcouldcauseshort.
3.Check forlooseorbroken wires.
9.5Burner willnotstart–eventhoughburner hadneverfailedbefore orhadbeen runningonnormal
cyclingwithoutfailure.
1.Operating Control circuit open.
2.Defectivecontrolorloosewiring.
3.Limitcircuit open.
9.6Burner isoperatingwith roughcombustionnoise.
1. Excess 02istoo high.Verifythat damperisnot open too far.
9.7Theburner mustbeperiodicallyinspectedtoensuresafetyandperformance.All maintenance
mustbeperformedwith themain electricalpower off and themaingas shutoff valve setinitsoff
position.
1.Inspect blowerinletscreen and clean anybuildup oflint.
2.Inspect blowerwheelbladesand clean anybuildup of dirt.
3.Inspect ignitionelectrodesand wiring foranycracksthatmaycauseshorting.
4.Oil the blowermotoratthe manufacturer’srecommended intervals.
5.Verifythatthe pilot electrode isstillwithinspecifications(set perdrawing inthismanual).
6.Verifythe properoperation of the Primary SafetyControl, airflowswitch, and operating controls.
7.Check safetyshutoff gasvalvesforgastightness.
9.8 In theeventofextendedshutdown,themainpower shouldbeturnedoff andthemainmanualgas
shutoff valve shouldbeclosed. (Off position)
Anadditional sourceof information relativetotroubleshooting can be found inthe PrimarySafetyControl
Manualsupplied withthe burner.

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BURNER STARTUPINFORMATION & TESTDATA
Thefollowinginformationshall berecordedforeachburnerstartup:
PowerFlameModel JobNo. Serial No.
InstallationName StartUpDate
StartUpContractorsName Phone
NameofTechniciandoingStartUp
TypeofGas: Nat. LPOther
GasFiring
Gas Pressure atTrainInlet CombustionEfficiency
BurnerinOff Position “W.C. LowFire %
LowFire “W.C. HighFire %
HighFire “W.C.
Gas Pressure atFiringHead
LowFire “W.C.
HighFire “W.C.
Gas Pressure atPilotTest
Tee “W.C.
Flame Signal ReadingsD.C.Volts
Micro Amps
Pilot
LowFire
HighFire
CO2orO2(Specify)
LowFire %
HighFire %
CO
LowFire PPM
HighFire PPM
InputRate
LowFire BTU/HR
HighFire BTU/HR
Overfire Draft
LowFire “W.C.
HighFire “W.C.
NOx(Correctedto3%O2)
LowFire PPM
HighFire PPM
Stack OutletTestPointDraft
LowFire “W.C.
HighFire “W.C.
NetStack Temperature
LowFire ° F
HighFire ° F

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BURNER STARTUPINFORMATION & TESTDATA
Control Settings
Gas
Operatingcontrolcutoutsetting Lowgaspressureswitch “W.C.
Operatingcontrolcutinsetting Highgaspressureswitch “W.C.
Limit controlcutoutsetting Other
Limit controlcut insetting
Powersupply: Volts Ph Hz
Controlcircuit: Volts
Blowermotorampsathighfire
Other
OperationChecklist
CheckedForProperOperationOf: Yes No Yes No
Lowwatercut off Barometricdamper
Highwatercutoff Boilerroomcombustionair&
Flamesafeguardcontrol ignitionfailure ventilationprovisioncorrect
Flamesafeguardcontrolmainflamefailure Oil tankventsystemcorrect
Burnerairflowswitch Alloil linescheckedforleaks
Induceddraftfancontrols Allgaslinescheckedforleaks
Overfiredraft controls Gaslines&controlsproperlyvented
Freshairdamperendswitch Othersystemcomponents(specify)
Notified ofthefollowingsystemdeficiencies: