Power Flame EVO User manual

EVO MANUAL

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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.
Do not store or use gasoline or any other flammable liquids in the vicinity
of this or any other appliance.
ATTENTION!
All Personnel involved with the startup, maintenance, or adjustment of this burner must read
and understand the entire contents of this manual prior to any startup or adjustment made to
the burner and related components. Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
WHAT TO DO IF YOU SMELL GAS
1. Do not try to light any appliance
2. Do not touch any electrical switch
3. Do not use any phone in your building
4. Immediately call your gas supplier from a neighbor’s phone
5. Follow the gas supplier’s instructions
6. If you cannot reach your gas supplier, call the fire department
EVO®Installation and Operation Manual

EVO®Installation and Operation Manual
1. GENERAL PRODUCT INFORMATION 1
1.1 Principle of Operation 1
1.2 Unpacking and Handling 1
1.3 Warranty and Spare Parts Information 1
1.4 General Components Information 2
2. INSTALLATION 6
2.1 Gas Supply Piping 6
2.2 Combustion Air Requirements 7
2.3 Burner Mounting: General 7
2.4 Combustion Chamber: General 9
2.5 Extreme Temperature Operation: General 9
3. START UP PROCEDURES 10
3.1 Burner Start Up and Service Test Equipment Required 10
3.2 General Start-Up All Fuels 10
3.3 Burner Start-Up Sequence Instructions: Gas 11
4. TROUBLESHOOTING 15
4.1 Gas Pilot Ignition Adjustment 15
4.2 Gas Pilot Flood Test 15
4.3 Trouble Shooting Suggestions: general 16
4.4 Trouble Shooting Suggestions: Gas 16
5. MAINTENANCE 18
5.1 General Information 18
5.2 Periodic Check List 19
6. BURNER START UP INFORMATION & TEST DATA 20

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1. GENERAL PRODUCT INFORMATION
1.1 Principle of Operation
1.1.1 The Power Flame Model EVO®Burner, U.S. Patent #11,585,528, is a forced draft, partial premix/nozzle
mix, staged gas burner designed for Sub 30 PPM NOx emissions without the use of Flue Gas Recirculation,
while maintaining 3% O2, when firing with typical Natural Gas fuel. The Model EVO®burner is listed and
labeled by Underwriters Laboratories, Inc. up to EVO800. The combustion air is furnished by an integrally
mounted combustion air fan. The Power Flame packaged combustion system can be operated under
positive or negative furnace pressures with clean, efficient combustion in a wide range of combustion
chamber conditions.
1.1.2 The Power Flame Model EVO®burner is a totally packaged and factory tested combustion system offering
single unit responsibility. The package incorporates accurate control of the fuel-air ratio throughout the firing
range with the resultant controlled flame patterns and clean combustion for maximum efficiency.
1.1.3 Combustion air flow is controlled by a multi-louvered damper assembly. Combustion air is supplied by an
integral motor-driven blower, which discharges into the burner blast tube assembly.
1.1.4 The air-fuel ratio is established at the time of start-up and proven with combustion test equipment to provide
the lowest practical oxygen and lowest NOx with a clean flame. Firetube applications typically have bent
lean extensions as depicted in Figures 1a-1c while watertube applications typically have straight lean
extensions.
1.1.5 A Flame Safeguard Controller programs the firing cycle. The operating cycle is sequenced to ensure normal
and safe conditions before fuel can be introduced into the combustion chamber area. The complete firing
cycle is supervised to ensure that ignition of main flame is properly established and maintained. Flame
monitoring is provided by a scanner as required by code.
1.1.6 The limit circuit includes the operating limit control to maintain set operating pressure or temperature, as
well as a high limit control to guard against excessive pressure or temperature. Low water and other similar
safety controls can be interlocked into the burner control system to satisfy specific job and/or code
requirements.
1.1.7 The control circuit is normally 120 volts. A control circuit transformer may be furnished to provide the 120
volts control circuit for polyphase motor voltage applications.
1.1.8 The pre-wired Control Panel is mounted and wired as an integral part of the burner in accordance with
recommendations of Underwriters Laboratories, Inc. and The National Electrical Code. Components are
wired to numbered terminal strips. Panel and burners are factory fire tested before shipment.
Comprehensive wiring and gas and/or oil piping diagrams are furnished with each burner in accordance
with individual job or application requirements. Wall mounted or free standing control panels are also
available.
1.1.9 Power Flame Model EVO®burners are available with control systems to comply with the requirements of
Factory Mutual, Industrial Risk Insurers and any special state, municipal, local and utility company codes,
including New York City Department of Buildings (MEA), NYC Department of Environmental Protection,
Commonwealth of Massachusetts, State of Connecticut Fire Marshall, Illinois School Code and others.
1.2 Unpacking and Handling
1.2.1 Power Flame Model EVO®burners are usually shipped as a unit with an integrally mounted, pre-wired
control panel. Gas train components may be pre-piped as an option or shipped loose for field mounting.
1.2.2 Uncrate the burner carefully and check all parts received against the computer generated Burner
Specification Sheets supplied by Power Flame. Components not mounted on the burner (shipped loose)
are designated with an L in the right hand column on the sheets. Claims on shortages or damage must be
immediately filled with the carrier.
1.3 Warranty and Spare Parts Information
1.3.1 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
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Material, wiring and piping diagrams, and a Recommended Spare Parts List. An on-hand supply of spare
parts is highly recommended. All communications with the factory will be handled more efficiently if the
burner is identified by the burner model, serial and job numbers. This information is stamped onto the burner
nameplate that is attached to the integral control panel (or to the burner, when remote control panels are
supplied).
1.4 General Components Information
1.4.1 The contents of this manual are general in nature due to the wide variety of equipment specifications,
insurance requirements, and state, local and other applicable codes.
1.4.2 The computer generated Burner Specification Sheets, shipped with the burner, represent the As-Built
version of your specific Power Flame combustion system. Part numbers and component descriptions will
match those components supplied. A duplicate set of Burner Specification Sheets is available through
Power Flame’s Customer Service Department or through the secured area of our website.
1.4.3 The components and arrangements shown are typical for a Model EVO®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.
1.4.4 Any part of the burner and associated equipment including gas trains and control panels shall not
be used as a step to climb on during service work. Warranty will be void if evidence is found.
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Figure 1a: Model EVO®Dimensions, size 40-150
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Figure 1b: Model EVO®Dimensions, size 200-400
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Figure 1c: Model EVO®Dimensions, size 500-1000
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2. INSTALLATION
2.1 Gas Supply Piping
2.1.1 The installer should contact the local gas utility for information related to available supply pressures,
limitations on allowable pressures in the building, general piping requirements and applicable codes,
restrictions and regulations. Considerations of these types, as well as written permits and other state, city
and local codes should be discussed with and approved by the appropriate governing bodies.
2.1.2 Gas piping should be sized to provide the required pressure at the burner train inlet manual shutoff cock,
when operating at the maximum desired fuel input.
2.1.3 All gas piping should be appropriately pressure tested to ensure leak free operation. It is recommended
that a dirt pocket or trap be piped into the gas supply system just ahead of the burner train inlet manual
shutoff cock.
2.1.4 When testing with pressures higher than the maximum pressure ratings of the gas train components, be
sure to isolate these components and test their piping for gas leaks with correct pressures only.
2.1.5 Refer to Table 1 and 2 for information relating to the sizing of gas supply piping. These charts are based
on the general flow characteristics of commercially produced black carbon steel pipe. If in doubt regarding
flow capabilities of a chosen line size, the next largest size is recommended. Use correction factors
(multiplier) at right for other specific gravities and pressure drops.
2.1.6 Refer to Figure 2 for the typical gas piping schematic to meet U.L. requirements in the EVO®burner firing
ranges.
Table 1: Capacity of pipes and correction factors
Table 2: Equivalent Length of Fittings in Feet
11-1/4 1-1/2 22-1/2 3 4
10 520 1050 1600 3050 4800 8500 17500
20 350 730 1100 2100 3300 5900 12000
30 285 590 890 1650 2700 4700 9700 0.5 1.1 0.1 0.577
40 245 500 760 1450 2300 4100 8300 0.6 10.2 0.815
50 215 440 670 1270 2000 3600 7400 0.7 0.926 0.3 1
60 195 400 610 1150 1850 3250 6800 0.8 0.867 0.4 1.16
70 180 370 560 1050 1700 3000 6200 0.9 0.817 0.6 1.42
80 170 350 530 990 1600 2800 5800 10.775 0.8 1.64
90 160 320 490 930 1500 2600 5400 11.83
100 150 305 460 870 1400 2500 5100 1.1 0.74 22.58
125 130 275 410 780 1250 2200 4500 33.16
150 120 250 380 710 1130 2000 4100 1.55 0.662 43.65
175 110 225 350 650 1050 1850 3800 64.47
200 100 210 320 610 980 1700 3500 20.547 85.15
Propane
Butane
Pipe Size – Inches (IPS)
Pipe Length
(Feet)
Specific Gravity
other than 0.60
Specific
Gravity Multiplier
Propane - Air
Specific Drop
other than 0.3" w.c.
Pressure
drop
(" w.c.)
Multiplier
Capacity of Pipes – Natural Gas (CFH)
With Pressure Drop of 0.3” w.c. and Specific Gravity of 0.60
Note: Use multiplier at right for other specific gravities and pressure drops
Correction Factors
11-1/4 1-1/2 22-1/2 34
Std tee through side 5.5 7.5 912 14 17 22
Std. E11 2.7 3.7 4.3 5.5 6.5 812
45qE11 1.2 1.6 22.5 33.7 5
Plug Cock 345.5 7.5 912 16
Pipe Size (IPS)
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Figure 2: Typical Gas Piping Schematic for Model EVO®Burner
2.2 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 60qF) per 1000
BTU’s firing rate, for theoretical perfect combustion. In actual practice, a certain amount of excess air is
required to ensure complete combustion, but this can vary substantially with specific job conditions.
2.2.2 Additional air is lost from the boiler room through barometric dampers, draft diverters, and similar venting
devices. It is generally accepted that ½ square inch of free air opening (for each gas or oil burner in the
room) per 1000 BTU/hr firing rate will be adequate. Under no circumstances should a boiler room be under
negative pressure. Jurisdictional authority relating to combustion air and boiler room ventilation
requirements vary widely. In order to achieve compliance, the controlling authorities should be consulted.
2.3 Burner Mounting: General
2.3.1 Provisions should be made to provide adequate space around the burner and associated equipment to
allow for ease of inspection, maintenance, and service.
2.3.2 Observe codes for the minimum clearances to combustible materials.
2.3.3 Provide a suitable burner front plate, consisting of a steel plate of ample thickness to support the weight of
the burner to hold it firmly in alignment with the heat exchanger.
2.3.4 The burner mounting flange must be securely attached to the heat exchanger front plate with suitable
gasket or non-asbestos, high temperature rope packing to prevent any products of combustion from
escaping from the combustion chamber through the burner-boiler mounting flanges. The burner assembly
must be supported at the base of the housing to prevent undue strain on the front plate. (A mounting
pedestal may be furnished for this purpose.)
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