Power Flame HAC3-GO2 User manual

Power Flame Incorporated
HAC INSTALLATION
AND
OPERATION MANUAL
THE POWER TO MANAGE ENERGY
2001 South 21st Street, Parsons, Kansas 67357
Telephone [phone], Fax[phone]
Web Site: www.powerflame.com
E-Mail: [e-mail]
HACOM 985
Rev. 0498
OBSOLETE MODEL

FOR YOUR SAFETY
Ifyou smell gas:Do not store or use gasoline or other
1.Open windows.flammable liquids and vapors in the
2.Do not touch electrical switches/vicinityofthis or anyother appliance.
3. Extinguish anyopen flame.
4. Call your gas supplier immediately.
WARNING
Improper installation, adjustment, alteration,
service or maintenance can cause injuryor
propertydamage. Refer to this manual. For
assistance or additional information consult
a qualified installer, service agencyor gas
supplier.
Copyright © Power Flame Incorporated 1985 Printed USA
OBSOLETE MODEL

TABLE OF CONTENTS
INSTALLATION AND OPERATION HAC MANUAL
PAGE
General Product Information...............................................................................................................................101-2
Air Compressor..........................................................................................................................................................2
Model HAC Receiving Instructions.............................................................................................................................2
(Table 1) Standard Burner Ratings & Component Data............................................................................................3
(Figure 1) Model HAC Dimensional Data...................................................................................................................4
(Figure 2) Model HACR Dimensional Data................................................................................................................5
Installation Information - General...............................................................................................................................6
Combustion Air Supply...............................................................................................................................................7
Combustion Adjustments on Oil & Gas - General.....................................................................................................7
StackTemperature....................................................................................................................................................7
Smoke Measurements...............................................................................................................................................7
Gas Adjustments........................................................................................................................................................7
Fuel Oil Adjustments..................................................................................................................................................7
General Start-up Procedures All Fuels......................................................................................................................8
Fuel Oil Start-up Procedures.................................................................................................................................9-12
Gas Fuel Start-up Procedures............................................................................................................................13-15
(Table 2) Combustion Chamber Dimension Chart...................................................................................................16
(Figure 3) Burner Mounting Detail for Brickset Firebox Boiler.................................................................................17
(Figure 4) Burner Mounting Detail for Scotch Marine Boiler....................................................................................18
(Figure 5) Burner Mounting Detail for Packaged Firebox Boiler..............................................................................19
(Figure 6) No. 2 Fuel Oil Pump Suction Curve........................................................................................................20
(Figure 7) No. 4 Fuel Oil Pump Suction Curve........................................................................................................21
(Figure 8) No. 5 and 6 Fuel Oil Pump Suction Curve..............................................................................................22
(Figure 9) No. 2 Fuel - Oil/Air Piping Schematic......................................................................................................23
(Figure 10) No. 4 Fuel - Oil/Air Piping Schematic....................................................................................................24
(Figure 11) No. 5 and 6 - Oil/Air Piping Schematic.................................................................................................25
(Figure 12) Gas Piping Schematic - U.L. Gas Train................................................................................................26
Compressed Atomizing Air Piping Information........................................................................................................27
(Table 3) Compressed Air Pipe Sizing.....................................................................................................................27
Gas SupplyPiping....................................................................................................................................................27
(Table 4A) CapacityofPipe - Natural Gas...............................................................................................................28
(Table 4B) Correction Factors..................................................................................................................................28
(Table 4C) Equivalent Length ofFittings in Feet......................................................................................................28
Adjusting and Servicing - General............................................................................................................................29
(a)
OBSOLETE MODEL

PAGE
Gas Pilot Ignition......................................................................................................................................................29
Oil Pumps and Piping...............................................................................................................................................30
Oil Nozzles..........................................................................................................................................................30-31
Electric Oil Heater....................................................................................................................................................31
Air Compressor........................................................................................................................................................31
(Figure 13) Internal Gas/Air FlowDrawing...............................................................................................................32
(Figure 14) Linkage Adjustment - Gas/Oil................................................................................................................33
(Figure 15) VaricamFuel Metering System.............................................................................................................34
(Figure 16) Case Type - Gas Pilot Drawing.............................................................................................................35
(Figure 17) Round Type - Gas Pilot Drawing...........................................................................................................36
(Table 5) Oil/Air Pressure Chart...............................................................................................................................37
(Figure 18) CO2- O2Fuel Ratio Curve....................................................................................................................37
(Figure 19) Fuel Oil Viscosity/Temperature Chart...................................................................................................38
Maintenance.............................................................................................................................................................39
Trouble Shooting Suggestions HAC Oil and Gas/Oil Burner...................................................................................40
Gas Operation.....................................................................................................................................................41-42
Oil Operation.......................................................................................................................................................42-44
Burner Start-up Information & Test Data............................................................................................................45-46
Owner Operating Instructions..................................................................................................................................47
Limited Warranty......................................................................................................................................................48
(b)
OBSOLETE MODEL

GENERAL PRODUCT INFORMATION
Power Flame Model HAC and HACR (inverted) burners incorporate the principles of air atomization for all fuel oils,
and multiple-orifice, high velocityvortex mix operation for gas. The total package utilizes the forced-draft, flame-
retention concept. All air forcombustion iscompletelyfurnished bythe burner fan. The burnercan be operated under
positive or negative furnace pressures with clean efficient combustion of fuels. Forced draftpressurized operation
permitsstacks of smaller diameter and height. The oil pressure required for airatomization variesfrom20 to 70 psig.
Oil flowis controlled bya metering valve in the nozzle supplyline.
The Power Flameair-atomizing burner consists ofatotallypackaged and tested system(with unit responsibility)
capable ofdelivering to the combustion area properlyatomized fuel with aspraypattern to match the air pattern.
Accurate control of atomized fueland air results in properflamepatternsandcleancombustion formaximumefficiency
throughout the firing range. A proven gas pilot ignites the main fuel.
An electric trimheater is supplied as an integral partofthe burner assemblywhen supplied for #4 or heavier grades
offuel oil.On burners for#4, #5and#6gradefueloil,oilfroma continuouslyoperatingoilpump ispumpedthrough
an auxiliaryheater(steamofhot watermaybe the auxiliaryheating medium)underaccurate temperature control then
through a thermostaticallycontrolled electric heater. Theseauxiliaryheaters arenota partofthe standardHACburner
package.
The electrictrimheaterisprimarilyfortrimheating and maybe used forcold starting. The thermostat isset at a value
slightlyhigherthan thatofthe steamorhot waterheater. The auxiliaryheatertakes overafterthe steamor hot water
isgenerated and maintainsconstant temperature ofthe oilto theburner, to provide viscositycontrol, which isessential
to good atomization.
Theoil pumpsupplies oilto thesysteminexcess of burnerrequirements. Anoil-regulating valvemaintains relatively
constant oil supplypressure. The oil in excess ofburner firing requirements is returned to the storage tank.
Frequently,on multiple burner installations asingle, separate, remote pumpand heater set is used to preheat and
transfer the fuel to the burner assemblies. These pump and heater sets are not apart of the standard HAC burner
package.
A matchedandpretestedair compressor,drivenbyaseparatemotor,suppliestheairforatomizationandpurgingof
the oil line and nozzle at the end ofeach firing cycle (#4, #5 and #6 oil only). The compressor is equipped with a
pressure reliefvalve, intakefilter and air receiver tank.An orifice bleed valve permits selection ofthe proper air
pressure to suit various grade offuel oil.
On anormal limit shutdown, the safetyoil valve is de-energized and oil flowto the nozzle is interrupted. On #4, #5
and #6 oil the air purge valve is energized to permit compressor air to flowthrough the burner piping and nozzle,
leaving it clean for next firing cycle.
Combustionair isprovidedbyaforwardcurvedbladefan,drivenbyan integralmotor,and controlledbyadual blade
inlet damper operated bya modulating motor actuator.
The modulating motor provides modulated positioning ofthe oil metering valve, the gas metering valve (on gas-oil
burners only)and the dual blade inlet air damper throughout the firing range. It is controlled byapressure or
temperature activated potentiometric control thatmatchesfiring rate with load demand.The fuel-airratio is established
at the timeofstart up bylinkage adjustment and set with combustion test equipment to provide the highestpractical
CO2with a clean flame.
A flamesafeguard programmer,availableinnumerouscontrol sequences,programs thefiring cycles fromprepurge
through post purge. Thecycle is sequenced to provide normal and safe conditions before fuel can beintroduced into
the combustion area. The complete firing cycle is supervised. Ignition and main flame failure protection is fast and
reliable to render the burner inoperable in the event ofpilot for main flame failure and to provide an alarmsignal.
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OBSOLETE MODEL

The limit circuit must include, asa minimum, an operating control, to maintain set boilerpressure ortemperature; high
limit control, to guard against excessive pressure or temperature; and lowwater control, to guard against operation
with inadequatewater level inthe boiler. Devices as recommended bythe heat exchanger manufacturer should be
used.
Interlock switches protect against anattempttofire byholding the limitcircuit open if the oil temperatureis too low for
proper atomization, ifcombustion air pressure is inadequate, ifatomizing air is belowapreset value, or ifthe
modulating motor is not in the lowfire position.
The control circuit is 120volts A.C.. The power supplyfor motors and heaters is polyphase208 volts or higher. An
auxiliarycontact onthecombustion airfanmotorstarter isinterlockedwiththecontrolcircuittoshutdown theburner
ifthis fan starter is not pulled in.
Power FlameHAC burners are offered in models to meet oil or gas/oil dual fuel requirements. Fuel changeover is
accomplished bymanual operation of asingle fuel transfer switch. Automatic fuel changeover is available at extra
cost. In some instances manual starting ofthe circulating pumps mayalso be required.
The prewired control panel, mounted and wired as an integral part ofthe burner, is in accordance with the
requirements ofUnderwriters Laboratories, Inc.and the NationalElectricalCode.Components arewired to numbered
terminal strips. Panels and burners arefire testedbefore shipment.Comprehensive wiring diagrams are furnished
with each burner. Special panels for wall mounting or free standing applications are available at extra cost.
The fuel oil pump is remote on all burners for #4, #5 and #6 fuel oil and for HAC5 and HAC6 burners on #2 fuel oil.
Theintegral pump systems employtwostagefuelunits and are designed and testedfortwo pipesystemoperation.
When remote pumps are used on #2 fuel oil, the pumping systemistotallypackagedand generallyconsistsofpump,
motor, direct coupling, bell housingand systembase. Remote pumps for #4, #5 and #6 fuel oilare generallysingle
stage, lowrpm, belt driven pumps.
AIR COMPRESSOR
The air compressor should be located as close as possible to the burner with minimumpipe and fittings, to ensure
minimumpressure drop.Excess pipe length and too manyfittings will cause excessive line pressure dropresulting
in poor atomization, higher oil temperature requirements, and high maintenance. Consult table 3, page 27, for line
sizing information.
Atomizing air fromthe air receiver on the remote compressor is routed through a checkvalve on the burner then to
the nozzle. Anormallyclosed air purge valve, with an adjustable orifice, provides purge ofthe oil remaining in the
nozzle line after the safetyoil valve is closed, (Standard on #4, #5 and #6 fueloil units, extra cost option on #2 fuel
oil units).
MODEL HAC RECEIVING INSTRUCTIONS
Upon receipt, the burner and accessoryequipment should be carefullyunpacked and checked against the packing
slip. Claims for shortage or damage must be immediatelyfiled with the carrier.
Care shouldbe taken to prevent damage to burner, control panel and accessoryequipment. Usethe furnished lifting
lugswhenlifting the burnerforease ofhandling and mounting and toprevent damage to theburnerorburner mounted
components.
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OBSOLETE MODEL

POWER FLAME MODEL HAC & HACR BURNERS
STANDARD BURNER RATINGS & COMPONENTDATA
Table 1
MAXIMUMPOWER FLAME
CERTIFIED CAPACITY (2)
-0.5” W.C.+0.5” W.C.
BURNER
MODEL
(1)GPHMBTUGPHMBTU
BLOWER
MOTOR
HP
3450 RPM
3 PHASE
AIR
COMPRESSOR
MOTOR HP
3 PHASE
CFM
FREE
AIR @
40 PSIG
REMOTE
PUMP
MOTOR HP
3 PHASE
OIL
PUMP
RATE
GPH
ELECTRIC
HEATER
KW
3 PHASE
GAS
TRAIN
SIZE
GAS
PRESSURE
REQUIRED
“w.c. (3)
HAC3-GO230.0420028.5399031-1/2-7LDE4.5INTEGRAL45N/A2”7
HAC4A-GO239.0546037.5525031-1/2-7LDE4.5INTEGRAL55N/A2-1/2”5.5
HAC4B-GO245.0630043.5609051-1/2-7LDE4.5INTEGRAL75N/A2-1/2”7
HAC4C-GO252.5735051.0714051-1/2-7LDE8.2INTEGRAL75N/A3”8
HAC5-GO260.0840058.5819052-C508.21/2-V056C130N/A3”15
HAC6-GO282.51160081.0113407.52-C5012.01/2-V056C130N/A3”17
HAC3-GO429.0420027.5399031-1/2-7LDE8.21/3-H4PA4532”7
HAC4A-GO437.7546036.2525031-1/2-7LDE8.21/3-H5PB5532-1/2”5.5
HAC4B-GO443.4630042.0609051-1/2-7LDE8.21/3-H6PA7542-1/2”7
HAC4C-GO450.7735049.2714051-1/2-7LDE8.21/3-H6PA7543”8
HAC5-GO457.9840056.5819053-D8020.91/2-V056C13053”15
HAC6-GO479.71155078.2113407.53-D8020.91/2-V056C13063”17
HAC3-GO5(6)28.0420026.6399032-C5012.01/3-18B17822”7
HAC4A-GO5(6)36.4546035.0525032-C5012.01/3-18B17832-1/2”5.5
HAC4B-GO5(6)42.0630040.6609053-D8020.91/3-18B17832-1/2”7
HAC4C-GO5(6)49.0735047.6714053-D8020.91/3-18B19543”8
HAC5-GO5(6)56.0840054.6819053-D8020.91/3-37B112043”15
HAC6-GO5(6)77.01155075.6113407.53-D8020.91/3-37B112053”17
HAC3-O230.0N/A28.5N/A31-1/2-7LDE4.5INTEGRAL45N/AN/AN/A
HAC4A-O239.0N/A37.5N/A31-1/2-7LDE4.5INTEGRAL55N/AN/AN/A
HAC4B-O245.0N/A43.5N/A51-1/2-7LDE4.5INTEGRAL75N/AN/AN/A
HAC4C-O252.5N/A51.0N/A51-1/2-7LDE8.2INTEGRAL75N/AN/AN/A
HAC5-O260.0N/A58.5N/A52-C508.21/2-V056C130N/AN/AN/A
HAC6-O282.5N/A81.0N/A7.52-C5012.01/2-V056C130N/AN/AN/A
HAC3-O429.0N/A27.5N/A31-1/2-7LDE8.21/3-H4PA453N/AN/A
HAC4A-O437.7N/A36.2N/A31-1/2-7LDE8.21/3-H5PB553N/AN/A
HAC4B-O443.4N/A42.0N/A51-1/2-7LDE8.21/3-H6PA754N/AN/A
HAC4C-O450.7N/A49.2N/A51-1/2-7LDE8.21/3-H6PA754N/AN/A
HAC5-O457.9N/A56.5N/A53-D8020.91/2-V056C1305N/AN/A
HAC6-O479.7N/A78.2N/A7.53-D8020.91/2-V056C1306N/AN/A
HAC3-O5(6)28.0N/A26.6N/A32-C5012.01/3-18B1782N/AN/A
HAC4A-O5(6)36.4N/A35.0N/A32-C5012.01/3-18B1783N/AN/A
HAC4B-O5(6)42.0N/A40.6N/A53-D8020.91/3-18B1783N/AN/A
HAC4C-O5(6)49.0N/A47.6N/A53-D8020.91/3-18B1954N/AN/A
HAC5-O5(6)56.0N/A54.6N/A53-D8020.91/3-37B11204N/AN/A
HAC6-O5(6)77.0N/A75.6N/A7.53-D8020.91/3-37B11205N/AN/A
(1) Model HACR (inverted configuration) carries the same firing rates and other data as the Model HAC.
(2) Burner capacities are based on using 1000 BTU/CU Ft., 0.6 specific gravity natural gas, 150,000 BTU/GAL #6 fuel
oil, 145,000 BTU/GAL #4 fuel oil, and 140,000 BTU/GAL #2 fuel oil at 2,000ft. elevation.
(3) At inlet to main (manual) shutoff cock to obtain PFI certified rating at +0.5” w.c.
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OBSOLETE MODEL

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OBSOLETE MODEL

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OBSOLETE MODEL

INSTALLATION INFORMATION
GENERAL
Existing boilers must be thoroughlycleaned to obtain maximumoperating efficiency. Allfireside surfacesmust be free
ofsoot, carbon deposits and scale. Waterside surfacesand mud legsmust be freeofscale and depositsofanykind.
Provisions should be made for adequate space around the burner and associated equipment to allowease of
inspection, maintenance and service. Observe all applicable codesforminimumclearancesto combustible materials.
Install the burnerusing asa guide, a typical installation drawing selected fromthoseprovided asa part ofthismanual.
See Figure 3, 4 and 5, pages 17, 18 and 19 respectively.
Provide asuitableburner steel front plate ofamplethickness tosupport theweightof the burner,andto hold itfirmly
in alignmentwiththeboiler. The front plateshallbe protected byheatinsulation, and high temperaturerefractoryon
the firebox side.
To installthe burner, a circular opening sized in accordance with Figure1, page 4and Figure 2,page5 must becut
in the steel front plate and surrounded bysuitable bolts or studs. The burner mounting flange must be securely
attachedtothefront plate usingtheseboltsor studsand gas tightsealedwith asuitable gasket or fiberrope packing.
The burner assemblyshould be furthersupportedatthe baseofthehousing to prevent unduestrain on the front plate,
the burner housing and blast tube. A mounting pedestal is furnished for this purpose.
Combustion chambers shall be provided as recommended in “chamber dimension charts”, Table 2, page 16. They
should be constructed of high temperature refractoriesin the formoffirebrick orrammed plasticrefractoryandbacked
bysuitable heat insulating material.
Note:It is the installers responsibilityto supplyand properlyinstall refractorymaterials suitable for the application
and temperature duty, provide expansion joints, refractorysupports, wall ties, etc. as maybe required for a
proper installation. Consult yourrefractorysupplier for construction detailsand requirements forthese items.
Where boilers are ofthe mud-ring type, refractoryshould extend 6” to 8” above the bottomofmud-ring.
All possible points ofcombustion chamber air infiltration or air loss must be sealed. Ifthe unit is to be fired under
positive combustion chamber conditions, extreme care must be taken to ensure that a 100% seal is developed and
maintained as hightemperature gas leakage willoccur at anyleakagepoint possiblyallowing flame and/or products
ofcombustion into the boilerroom. The model HAC burneris designed to provide all the airrequired forcomplete and
efficientcombustion.Entryof air intotheheat exchanger fromsourcesother thantheburnerwilldecrease its overall
combustion and operational efficiency.
Gas train components and gas piping must be installed and sized in strict accordance with the piping schematic
drawing supplied with the burner, Gas Companyand/or local codes and regulations and applicable portions ofthe
current revision ofNational Fuel GasCodeANSI Z223.1. Also see Tables4A, B, andC, page 28and Figure 12, page
26. Afterinstallation the gaspipingmust be tested and purged in accordance with part4 of the current revision ofthe
“National Gas Fuel Gas Code” ANSI Z223.1.
Oiltraincomponents andoilpipingmust beinstalled,sized andtestedinstrictaccordancewiththepiping schematic
drawings supplied with the burner, local codes and regulations and applicable portions ofthe current revisions of
“Installation ofOil Burning Equipment” NFPA No. 31.
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OBSOLETE MODEL

COMBUSTION AIR SUPPLY
Fresh air required to support combustion as well as to provide adequate equipment ventilation must be supplied. It
is generallyaccepted that ½square inch offree air openingper 1000 BTU/hr firingrate (foreach combustion device
in the room)will be adequate. Under no circumstances should the boiler roombe under anegative pressure.
Jurisdictional authorityrelating tocombustion air and boilerroomventilation requirementsvarywidely.Check with the
controlling authorities to make certain ofcompliance.
COMBUSTION ADJUSTMENTS ON
OIL AND GAS - GENERAL
Efficient combustion cannot be properlyjudged byflameappearance, although it mayhelp in making preliminary
settings.
The proper settings ofair-fuelratiosmustbe determinedbyflue gas analysis. Combustion gasanalysis indicatesthe
airtofuelratioandthedegreeof completecombustion.Instruments are available tomeasurecarbondioxide(CO2),
oxygen (O2), carbon monoxide (CO), and smoke levels.
STACK TEMPERATURE
Net stacktemperature is obtained bysubtracting the ambient temperature fromthe flue gas temperature. Ahigh stack
temperature indicates wasted heat. Stacktemperature should be as lowas possible without causing flue gas
condensation.
Stack heat loss canbe reduced bydecreasingeither the temperatureorthevolumeofthe fluegas,orboth. Flue gas
temperature isreduced byimproving heat transferorbyreducing excess combustion air. A certainamount of excess
air is necessaryto complete combustion. More efficient burners require minimumexcess air.
SMOKE MEASUREMENTS
Smokemeasurementscanbemadeusing avarietyof differentmethods. Thestandards will varysomewhataccording
to the equipment used, and instructions accompanying the instrument should be followed.
Smokeycombustion can result from:Improper airdelivery,insufficient draft, improperfuelviscosity,improperfuel-air
ratio, excessive air leaks in the combustion chamber, or improper fuel oil temperature.
GAS ADJUSTMENTS
Low fire combustion analysistypicallyis7 to 9 percent CO2and less than .04 percent CO(400ppm). High fire reading
typicallyis 9 to 10.5 percent CO2and less than .04 percent CO. See Figure 18, page 37.
FUEL OIL ADJUSTMENTS
Adjust fora “clean fire”. TypicallyforNo. 2 through 4oil, CO2is8to 11 percentat lowfire and 10 to 13 percent at high
fire. No. 5 and 6 oil, CO2is 8 to 13 percent at lowfire and 11 to 14 percent at high fire. See Figure 18, page 37.
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OBSOLETE MODEL

GENERAL START-UP
PROCEDURES ALL FUELS
A representative ofthe ownerand/orthe personsresponsible foroperating and maintaining the unit should be present
during the initial start-up. Instructions on the proper care and maintenance ofthe unit can be covered at this time.
Consult your local utilitytodetermine iftheyrequire their service representative’s presence at theinitial start-upofa
gas-fired boiler.
Before beginning start-up, the start-up technician should thoroughlystudyand becomecompletelyfamiliar with the
exact sequence ofoperation and all other details ofthe specific flamesafeguard control systembeing used. This
information will be found in bulletins printed and supplied byHoneywell or Fireye, Inc.. Acopyofthis bulletin was
supplied with the burner.
After the burner is mounted on the boiler and all the field piping and wiring have been completed and tested, it is
recommended that the following procedure be followed.
1.Makea general inspectiontour around the boileror furnaceto ensure that the installationis complete. Check
piping, controls, wiring, etc.
2. Checkcontrol transformer (ifsupplied) connections and motor wiring to confirmthatproper connections are
made for the supplyvoltage to be used.
3. Checkfuses in the main panel and in the burner control cabinet. Checkwiring totheburner control cabinet
for compliance with the wiring diagramand local codes.
4.Tighten all screwson the terminalblocks in the control cabinet in case some mayhave loosened in shipment.
5. Close all main fuel valves.
6. Checkboiler breeching and stackto be sure theyare open and unobstructed.
7. Check operating controls, limit controls, low watercutoff, flame safeguard reset, high gaspressure switch and
lowfire interlockswitch. All contacts should be closed.
8. Withthe controlswitch “off”, allmanualgasvalvesclosed, oilsuction linemanualvalveclosedandoilreturn
line open,close thefused disconnect switches supplying power totheblowermotor,aircompressor,and oil
pump(ifapplicable) motor. Checkrotation ofthese motors bymomentarilymaking contact ofthe motor
starters. Properrotation isimprinted on the burnerblowerhousing, remote pumpand compressorassembly.
9.If the burnerissupplied with aburner mounted oilpump,driven bydirect coupling to the blower motor wheel,
oilfor circulation must beprovidedandpumpmust beprimedbefore operationof thefanmotor which drives
the oil pump. Operation ofthe pumpwithoutpriming and oil circulation mayresult in pump damage orseizure
not covered byguarantee ifrun “dry”.
10. For thereasons given in the proceeding paragraph the procedure for start-up on oil should be followedfirst,
followed bythe procedure given for gas fuel.
11. On dual fuel unitswhere the pumpisdriven bya blowerwheel couplingthe pump blowerwheel coupling must
be disconnected ifthe burner is to operate on gas fuel without full oil circulation in the oil pumping system.
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OBSOLETE MODEL

FUEL OIL START-UP
PROCEDURES
Power Flame model HAC oil burners are ofthe air atomizing, forced drafttype. The input iscontrolled bya modulating
metering valve connected with appropriate linkage to a modulating motor.
1. Determine that the oil and gas piping has been installed, pressure tested for leakage and gas lines
purged in accordance with the instructions previouslygiven in section entitled “Installation”.
2. Checkall controls for compliance with codes and insurance requirements.
3. Checkall fuel/air drive linkage. The linkage has been roughlyadjusted whenfactoryfire tested; but it
should be checked to make sure it was not damaged or loosened in shipment. The linkage will have
to be reset to suit the job conditions. See Figures 14 and 15, pages 33 and 34.
4.Install oilpressure andvacuumgauges. Check the suction linesto be sure the check valveisinstalled
so that it will open in the proper direction. Checkoil filter for tightness. Checkreturn lines to be sure
theyare free ofobstructions and will allowfree circulation to the tanksystem.
NOTE: There should be no shutoff valve installed in the return line.
5. Keep the fused disconnect switch to the electric oil preheater (ifsupplied) in the “off” position untilthe
heater elements are completelyimmersed in oil.
6. Checkthe pilot burner for proper setting ofthe ignition electrode sparkgap. See Figure 16 ,page 35
and Figure 17, page 36. Open the gas pilot cock.
7. Set the air damper approximately¼” open.
8. Disconnect the wire tothesafetyoil valve toprevent opening during the following procedure.(Donot
allowto ground or short to other power sources).
9.Appropriatestepsmust betaken to transfer theoilfromthe tank to theburner. Itis imperative that the
systembe primed priorto pumpoperation.The systempriming maybe achieved byclosing the manual
valve in the suction line and priming the oil pump through the fitting in which the oil pressure gauge was
installed. Priming can also be accomplished through the oil filter on the suction line, ifit is the
removable top type. When replacing the oil strainer cap, be careful to assure avacuumtight seal.
Close the manual oilvalve inthesuction line and start the oil pump orthe burneriftheoil pumpisdriven
bythe blower motor.
To start burner-
A. Ifheavyoil - temporarilyset the cold oil lockout switch in the burner mounted trimpreheater to
the “made” position.
B. Reset the flame safeguard control.
C. Place manual-auto switch in the manual position and the potentiometer in the closed position.
D. With the control switch off, close the main disconnect switch supplying control cabinet power.
E. On gas/oil units place the transfer switch in the oil position.
F. Turn the control switch on. Burner fan and pump motor will start to prime pump and oil lines.
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OBSOLETE MODEL

10. Let the burner run (for 30 seconds at atime–then reprimeas necessary)until the vacuumgauge
indicatesa 15”Hg vacuum, then quicklyopen the manual oil valve in the suction line. This combination
ofpriming and high suction should pull the oil fromthe tankto the burnerprovidedthereare no airleaks
and the line is properlysized. (See figures 6, 7 and 8, pages 20, 21 and 22 respectivelyfor sizing oil
lines.)Continuepump operation untillinesare full and oil isflowing freely. Examine the burner mounted
electric oil trimheater to assure that the procedure filled the oil heater with oil. Ifnot, continue
circulation ofthe oil until the heater is filled.
11. Whenit has beendetermined thatoil isflowingfreelythrough the trimoil heater(when supplied), close
the fused disconnect switch supplying powerto the trimheater. Reset the cold oil lockoutswitch tothe
desired temperature settings.
12. The next step is to light the pilot and adjust it for proper ignition and signal. The procedure is
accomplished with the safetyoil valve still disconnected.
A. Install a manometer or 0-10” w.c. gas pressure gauge on the pilot test tee.
B. On flamesafeguard controls having acamtimer arrangement and/or controls having atest
switch,meansis providedtoholdapilotatthe“on”positionfor aslongasnecessary(once pilot
is proven) toadjust gas pressureand/or primaryairsetting for thebestsignal strength. Set this
switch to hold pilot at the “on” position. Refer to the flamesafeguard manual for complete
procedure and operation.
C. Open pilot manual gas valve leaving main gas cockclosed.
D. Close control switch. Burner should start and after pre-purge the pilot should light and flame
safeguard programmer should stop and hold at the “trial for ignition” point. (See 12.B above)
E. See page 29 for specific pilot adjustments. Measure pilot gas pressure and re-adjust pilot gas
pressure regulator as required.
F. Using appropriate meter measure the flamesafeguard control signal with the pilot operating.
Refer to the flamesafeguard instruction manual for type ofmeter and proper level ofsignal.
Follow procedure listedintheflamesafeguardmanualand/or pages29and30in thismanualif
the proper signal is not obtained.
G.When pilotadjustments arefinished and correctpilotsignal level obtained, switch thetest switch
(oritsequivalent)backto the runposition. The flamesafeguard will advanceto the “trial formain
flameignition” point as indicated bythe “main fuel” light. Since the safetyoil valve is still
disconnected, after a shortdelaythe flame safeguardshould “lockout”and go intothepost purge
cycle.
13. After the fan motor stops, disconnect cabinet power, and reconnect the safetyoil valve.
14. For heavyoil systemsset the oil trim heater thermostat at the oil temperature required to provide oil
viscosityequalto 100-150 SSUviscositywiththe fuel beingused. See viscositychart, Figure 19, page
38.
15. For heavyoil systems set the cold oil lockout switch approximately20 degreesF. below the trimheater
thermostat setting.
16. Set the high oil temperature switch (ifsupplied) approximately20 degrees F. above the trimheater
thermostat setting.
17. The next procedure will light the main oil flame.
A. Throwall fused disconnect switches to the “on” position.
B. Open all manual oil valves required for normal oil flowto and fromthe tank.
C. Place in operation anymanual start pumprequired to supplyoil to the burner and circulating
system. -10-
OBSOLETE MODEL

D. Turn the control switch on. Provided the cold oil lockout switch (heavyoil only)is made, the
burner fan motor should start. After prepurge the pilot should be ignited and proven, and after
“pilot trial for ignition” period, the safetyoil valve should open to ignite the oil burner at lowfire.
Lowfire flameshould nowbe established. Ifnot, shut the systemdownand correct failure
cause.
18. Test the operation ofthe oil temperature switches, all oil pressure switches, atomizing air switch, fan
air flowswitch, all limit switches and lowwater cutoffs to assure these switch actions close the safety
oil valve and properlyshut downthe burner. Refer to the respective control specification sheets, the
burner wiring diagramand oil pipingschematics forthe correct procedures and theresultantshutdown
sequence that should occur.
CAUTION:Do not proceed with furtherstart-up procedure for eitherfuel ifthe propershutdown sequence foreach
ofthese safetydevices cannot be demonstrated at this time.
19. Measure and adjust asrequired the oil gun pressure and atomizing airgun pressure forthe desired low
fire rate using data supplied on the factoryfiretest sheetsupplied with the burnerasaguide. Also, refer
to Table 5, page37. Fuel and air pressures will require job site readjustment to assurethedesired firing
rates for the fuel to be used. Set the burner air damper to obtain 9-10% CO2for warmup purposes.
20.Set thelow oilpressureswitch(if supplied) totripat20%belowthesensedoil pressurefor thelow fire
rate.
21.Setthelowatomizingairpressureswitchtotripat20%belowthesensedairpressure requiredfor the
lowfire rate.
22. Set the high oilpressure switch (if supplied) to trip at 20% above the sensed oil pressure required for
the full firing rate.
23. Proceed to warmup the boiler following the recommended procedure as provided bythe boiler
manufacturer. Intheabsenceofthese boiler manufacturers instructions, warmup the boilerat low fire
onlyfollowing a cycle of5 minutes on and 5 minutes off for 5 cycles then continuous lowfire until the
boiler reaches the desired operating pressure or temperature.
Note: It maybe necessaryto limit the boiler load in order obtain operation pressure or temperature at the
lowfire rate.
24. For HeavyOil Systems-When boiler operating temperature or pressure is achieved the auxiliaryoil
system steam or hot water oil heaters maybe brought into operation. When these heaters are fully
operationalandthecompleteoilcirculatingsystemuptodesiredoperatingtemperature,thesystemis
readyto fire the burner above the lowfire rate.
25. All HAC burners aredesignedfor modulation. The modulating motoris connected bylinkageto the air
inletdampers andfuelmeteringdevices.Eachcontrolpointhas its own multi-positionarmsothatthe
proper air-fuel ratiocan beobtainedthroughout themodulating range.After preliminarysafetychecks
and start-upprocedures have been accomplished, proceed to the modulating operation adjustments.
See Figure 14, page 33 for linkage operation.
Note:Ifthe burnerhasbeen supplied with the “Varicam®”characterized fuel metering system, referto Figure
15, page34 thismanual andBulletin No. VA1588“Varicam®”Adjustment Instructions” includedin the
information shipped with the burner.
A. In order for you to determine that the metering valve is in the lowfire position, observe the
metering valve pointer. The “deep end”ofthe slot mustbe pointing toward the number3 position
or less. This position islocatedtowardthe closedposition on the meteringvalvedialand will be
determined bythe lowfire required at start-up.
B.Settingsmust be noted and marked on the linkage priorto proceeding with yourfinal adjustment.
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OBSOLETE MODEL

C. Markthe linkage setting previouslyarrived at for lowfire warmup prior to proceeding with
modulation linkage adjustments at higher firing rates.
D. Using the manual potentiometer manuallyincrease the firing rate to the midwaypoint bysmall
increments, watching linkage to assure free movement at each position. Set the air/fuel ratios
to obtain a cleanappearing flame. Lockthe settings and record CO2and smoke readings. 12-
1/2 to 13-1/2% CO2with #2 Bacharach smokespot or less on 140,000 Btu/gas oil or 13.2 to
14.1% CO2on150,000 Btu/gal oil with #4Bachrach smoke spot or less shouldbe obtainable by
fuel/air ratio adjustments from50% full firing rate to 100% fullfiringrate. Readjust the settings,
ifnecessaryto obtain optimumfiring conditions. Mark and note the settingsfor the midpoint firing
position.
E. Againbysmallincrements,usethemanualpotentiometertomanuallymovetheratetothehigh
fire position and repeat the tests done for the midpoint adjustments. The oil metering valve
setting and air damper openings being used to obtain your high fire reference points should be
marked and noted.
F.Move the modulating leverarmon the modulating motorthrough the three previouslydetermined
reference points. Check to determine that the samefuel/air ratio %CO2)are obtained. Minor
setting modifications maybe required to ensure that your reference points are acquired.Reset
fuel/air linkage at lowfire to obtain the highest possible CO2(but not exceeding high fire CO2
recommendations) at acceptable smoke levels.
G. Tighten all the linkages and permanentlymarksettings.
26.Byadjustmentof theneedlevalvelocatedinthepurgevalvebody(notsuppliedon#2oilburners), set
the gun purge oil flowrate so that there is no appreciable change in fire sizewhen the purge valve
opens to purge the oil gun.
27. Final checks:Aftertheburner hasbeen adjusted properly, proceed with the checkout of the low firestart
switch,purgepositionswitch, starting interlocks, running interlocks, limit controls,outsideair dampers
interlocks and anyother interlocks and limits that are used.
28. The “Owner’s Operating Instructions,” page 48 ofthis manual, should be posted in aclearlyvisible
location close to the burner.
29. The oil burner start-up is nowcomplete. Proceed to the Gas Fuel Start-up Procedure.
-12-
OBSOLETE MODEL

GAS FUEL START-UP
PROCEDURE
Power Flamemodel HAC gas burners are ofthemultiple orifice, highvelocityvortexmix, forceddraft type.The input
is controlled bya modulating butterflygas valve connected with appropriate linkage to a modulating motor.
This procedure is written as ifthe oil fuel start-up has not been completed. Ifall phases ofthe oil fuel start-up have
been satisfactorilycompleted then referencesto proceduresand testsin the gasstart-up alreadyaccomplished in the
oil start-up need not be duplicated.
As a safetyprecaution: Ifthe oil start-upprocedure has not been completed, the oil pump coupling must be
disconnected for the gas start-up on those units supplied with burner mounted oil pumps direct driven by
coupling to the blower motor. Similarlyseparate motor driven oil pumps must be prevented fromoperating
during gas start-up ifthe oil start up procedure has not been completed.
1. Close all manual gas valves.
2. Determine that all gas piping has been installed, pressure tested for leakage, gas lines purged in
accordance with the instructions previouslygiven in the section entitled “Installation”.
3. Checkall gas piping, safetyand automatic gas valves, and controls for compliance with codes and
insurance requirements.
4. Checkall safetygas valves, normallyopen vent valves and automatic gas valves for leakage. Refer
to the valve manufacturers installation instructions for the proper procedure.
5. Checkall linkage. The linkage has been roughlyadjusted when factoryfire tested; but it should be
checked tomakesureitwas not damagedor loosenedin shipment. The linkagewillhavetobe reset
to suit the job conditions.
6. Install gas pressure gauges. One gaugeupstreamofthe maingas pressure regulator to monitor gas
supplypressure, one gauge immediatelydownstreamofthe main gas pressure regulator to read the
regulator outlet pressure and determine the proper set pointfor the lowgas pressure switch, andone
gauge to read the burner manifold or orifice pressure. Amanometer or 0-10” w.c. gauge should be
installed in the pilot test tee.
7. Keep the fused disconnect switch to the electric oil preheater(ifsupplied)inthe “off” position during gas
fuel start-up.
8. Checkthepilotburnerforpropersettingoftheignitionelectrodesparkgap.Seepage 29,also Figure
16, page 35 and Figure 17, page 36.
9. Set the air damper approximately¼” open or leave as adjusted during oil start-up.
10. The next step is to light the pilot and adjust it for proper ignition and signal.
A. On combustion safetycontrolshaving a test switch, a meansisprovided to hold a pilot at the “on”
positionforas long asnecessary(once the pilot is proven) to adjust gaspressure and/or primary
airsettingfor thebest signalstrength.Set theswitchto holdthepilot atthe “on” position. Refer
to the flame safeguard manual for complete procedure and operation.
B. Withtheburnercontrolswitch offthrow thefuseddisconnectswitches for thefanmotor andthe
control circuit to the “on” position. Leave the oil heater fused disconnect and all pumpfused
disconnect switches off.
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OBSOLETE MODEL

C. Reset the flame safeguard.
D. Place the manual-auto switch in the manual position and the potentiometerin the closed position.
E. Place the fuel transfer switch in the gas position.
F. Open the main manual gas valve leaving the checking cockclosed.
G. Open the pilot gas cock.
H. Reset the high and lowgas pressure switches. It maybe necessaryto adjust the lowgas
pressure switch operating point to assure the switch is made with the available gas pressure.
I. Closethe controlswitch.Theburnershould startandafter aprepurgethe pilot should lightand
flamesafeguard programmer should stop and hold at the “trial for ignition” point. (See 10.A
above).
J. See pages 29 and 30 for specific pilot adjustments. Measure pilot gas pressure and re-adjust
pilot gas pressure regulator as required.
K.Using the appropriate meter, measure the flamesafeguard control signal with the pilot operating.
Refer to the flamesafeguard instruction manual for type ofmeter and proper level ofsignal.
Follow procedure listedintheflamesafeguardmanualand/or pages29and30in thismanualif
the proper level or type ofsignal is not obtained.
L.When pilotadjustments arefinished and correctpilotsignal level obtained, switch thetest switch
(oritsequivalent)backto the runposition. The flamesafeguard will advanceto the “trial formain
flameignition” point as indicated bythe “main fuel” light. Since the checking gas cockis still
closed, aftera short delaythe flame safeguard should “lock out”and go into the post purge cycle.
11. Turn the control switch off and reset the flame safeguard.
12. Turn the control switch on to restart the burner using ameter to monitor the flamesignal during pilot
and main flameoperation. After prepurge and trial for pilot ignition, when the safetygas valve is
energizedto open,slowlyopenthemaincheckinggascocktolightoffthe main burner at lowfire rate.
Low firegas flameshouldnow beestablished. Ifnotshutthesystemdown and correct failurecause.
13. Recycle the burner on and off several times at lowfire rate to determine that safetygas valves and
normallyopen gas valves (ifused) are closing properlyand that flame signal is adequate and steady.
14. Test the operation ofall limit controls, lowwater cutoffs, operating controls, fan air flowswitch, gas
pressure switches, outside combustion air damper interlocks(ifused) or anyother existing limit or
safetycontrols to demonstrate closure ofthe safetygas valve(s) and proper shut down ofthe burner.
Refer to the respective manufacturers control specification and installation sheets, the burner wiring
diagramandgas pipingschematics for the correct procedures and the resultant shutdown sequence
that should occur.
15. Test the operation ofalllinkage position switches,valve position switches, airflow and all otherlimit and
control devices. Referto the respective manufacturers control specificationand installation sheetsand
theburner-wiring diagramtodeterminethe properprocedure and theexpectedresults fromoperation
ofthese devices.
16.Read thegas meter todeterminethelowfirerateand re-adjustgas flowrateasrequired.Contact the
local gas utilityto determine applicable correction factors.
17. Adjust the lowfire fuel/air ratio to 6-8% CO2with less than 0.4% CO. See Figure 18, page 37.
-14-
OBSOLETE MODEL

18.Set thelow gas pressureswitchto tripat20%less thanthe sensed gas pressure with theburnerfiring
at the high fire rate.
19. Proceed to warmup the boiler following the recommended procedure as provided bythe boiler
manufacturer. Intheabsenceofthese boiler manufacturers instructions, warmup the boilerat low fire
onlyfollowing a cycle of5 minutes on and 5 minutes off for 5 cycles then continuous lowfire until the
boiler reaches the desired operating pressure or temperature.Note: It maybenecessaryto limit the
boiler load inordertoobtain operating pressureortemperature atthe low firerate. Onlyafter reaching
the boiler operating pressure or temperature should the boiler be fired at full firing rate.
20. All HAC burners aredesignedfor modulation. The modulating motoris connected bylinkageto the air
inlet dampers and fuel metering devices. Each control point has its ownmulti-position armso that
proper air to fuel ratio can be obtained throughout the modulating range. After preliminarysafety
checks and start-up procedures have been accomplished, then proceed to the modulating operation
adjustments. See Figure 14, page 33 for linkage operation.
NOTE:Ifthe burner has been supplied with the Varicam® characterized fuel metering system,refer to
Figure15,page 34ofthis manualandbulletin No. VA1588“Varicam®Adjustment Instructions”
included in the information supplied with the burner.
A.Inorderforyoutodeterminethatthebutterflygas valveisinthelowfire position,observe
the slot in the end ofthe butterflyvalve shaft. The slot position is parallel to the valve
butterflyand thus indicates butterflyposition.
B. Settings must be noted and marked on the linkage prior to proceeding with your final
adjustment.
C. Mark thelinkagesetting previouslyarrivedatforlowfire warmupprior toproceedingwith
modulation linkage adjustments at higher firing rates.
D. Using the manual potentiometer manuallyincrease the firing rate to the midwaypoint by
small increments, watching linkage to assure free movement at each position. When
midpointis reached takefluegasreadingsandadjustthefuel/air ratio. 9.5to10.5% CO2
with CO less than 0.04$ CO should be obtainable from50% to 100% full firing rate. The
metering device settingsand airdamperopening should be noted and marked on linkages
before proceeding to full firing rate.
E.Againbysmall increments, use the manual potentiometer tomanuallymove the firing rate
to the high fire position. The high fire rate is set approximatelyto the manifold gas
pressuregiven ontheburnerspecificationsheet.Readthe gasmetertodetermineexact
firingrate.Check withthelocalgasutilitytodeterminemetercorrectionfactor applicable.
Repeatthetestsandadjustfuel/airratiothesameasdonefor themidpointadjustment.If
desired high fire input rate cannot be achieved with the butterflyvalve wide open (do not
go beyond fullopen) increase the gaspressure at the burnermain gaspressure regulator,
asrequired. The metering device setting and airdamper openingsused to obtainyour high
fire reference points should be marked and noted.
F. Move the modulating lever armon the modulating motor through the three previously
determined reference points. Check todetermine that the same fuel/airratios(%CO2)are
obtained. Minorsetting modificationsmaybe requiredtoensurethat your referencepoints
are acquired. Reset fuel/air linkage at lowfire to obtain the highest possible CO2
recommendations) with less than 0.04% CO.
G.Adjustthe high gaspressure switchto trip at 20%above thesensed gaspressure present
at full burner firing rate.
H. Tighten all linkages and permanentlymarksettings.
21. The “Owner” Operating Instructions,” page 48 ofthis manual, should be posted in aclearlyvisible
location close to the burner.
22. The gas burner start-up procedure is nowcomplete.
-15-
OBSOLETE MODEL

Table 2
COMBUSTION CHAMBER DIMENSION CHARTFOR
FIGURE 3, PAGE 17 AND FIGURE 4, PAGE 18
(ALL DIMENSIONS IN INCHES)
FIREBOX TYPE BOILERS
RECOMMENDED CHAMBER
DIMENSIONS
SCOTCH MARINE TYPE
BOILERS RECOMMENDED
CHAMBER DIMENSIONS
FIRING
RATE
GPH CLWDIAMETERLENGTH
181450281890
231454312095
2815593420100
3317643722110
3717683922120
4218734324130
4719774526130
5120814726140
5620864928145
6021905128150
6521945330150
7022965532160
7723985732160
-16-
OBSOLETE MODEL