PF X4-400 User manual

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
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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.
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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”.
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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.
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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.
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Figure 4 Location of Side Orifice
Figure 5 Typical Wiring Diagram for S8680Jwith Proved Pilot Ignition
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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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