Power Flame Nova Plus, Installation And Operation Manual

Page 1: ...Copyright 2006 Power Flame Incorporated Printed in U S A Power F 4 DRAFT CONTROL ENTER ESC Power Flame Incorporated Power Flame Incorporated Nova Plus Nova Plus Installation and Operation Manual Installation and Operation Manual ...

Page 2: ...witches 3 Extinguish any open flame 4 Call your gas supplier immediately NOVA PLUS Installation Operation Manual POWER FLAME INCORPORATED DC4 DRAFT CONTROL ENTER ESC NOVA PLUS Installation Operation Manual POWER FLAME INCORPORATED DC4 DRAFT CONTROL ENTER ESC Cmax Installation Operation Manual POWER FLAME INCORPORATED 2 P PO OW WE ER R F FL LA AM ME E M MO OD DE EL L C Cm ma ax x B BU UR RN NE ER R...

Page 3: ...s 6 9 Burner Mounting General 6 10 Combustion Chamber General 7 11 General Start Up Procedures 8 12 Burner Start Up and Service Test Equipment Required 10 13 Burner Start Up Sequence Instructions 10 14 Gas Pilot Ignition Adjustment 15 15 Trouble Shooting Suggestions 16 16 Maintenance 19 17 Burner Startup Information Test Data 22 18 Owner Operating Instructions 26 NOVA PLUS Installation Operation M...

Page 4: ... 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 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 2...

Page 5: ...ervice Department in Parsons Kansas or you may register on line through the Power Flame website www powerflame com 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 into the burner nameplate that is attached to the integral control panel or to the burner when remote control panels ...

Page 6: ...________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ________________...

Page 7: ..._____________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ______________________________________________________...

Page 8: ...______________________ Name of Technician Performing Start Up______________________________________________________________________ Type of Gas Natural LP Other __________________________ Gas Firing Gas Pressure at Train Inlet Flame signal Readings Stack Outlet Test Point Draft Burner in Off Position ________ W C Pilot________________________ Low Fire ____________________ Low Fire ________________...

Page 9: ...ket 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 is furnished for this purpose 21 NOVA PLUS Installation Operation Manual POWER FLAME INCORPORATED D...

Page 10: ...uctions Low draft fan air pressure Monthly Operator Refer to this manual and control manufacturer s and damper instructions High low gas pressure interlocks Monthly Operator Refer to instructions in this manual Fuel valve interlock switch Annually Service Technician Refer to valve manufacturer s instructions Purge switch Annually Service Technician Refer to fuel air control motor manufacturer s in...

Page 11: ...tart Up A thoroughly qualified burner technician must be employed to provide the initial burner start up as well as any subsequent servicing of the burner and related controls A representative of the owner and or the person or persons responsible for operating and maintaining the unit should be present during the initial start up A service representative may also be required by the local utility o...

Page 12: ...or atmospheric vent line obstructed Correct G Defective main gas pressure regulator replace Misadjusted main gas pressure regulator readjust to meet required operational values 5 Carbon Monoxide Readings Too High A Flame impingement on cold heat transfer surfaces caused by excessive firing rate Reduce firing rate to correct input volume B Flame impingement on cold combustion chamber surfaces due t...

Page 13: ... when main flame lights the air flow switch is not so critically set as to allow occasional momentary opening of the air switch contacts 10 NOVA PLUS Installation Operation Manual POWER FLAME INCORPORATED DC4 DRAFT CONTROL ENTER ESC 12 BURNER START UP AND SERVICE TEST EQUIPMENT REQUIRED The following test equipment is required to ensure proper start up and adjustment of burner equipment to obtain ...

Page 14: ...e operating condition Secondary causes lockout Set to actuate at approximately 0 7 w c under normal operating conditions Verify acceptable 02 level Combustion Air Flow Switch 16 NOVA PLUS Installation Operation Manual POWER FLAME INCORPORATED DC4 DRAFT CONTROL ENTER ESC Table 3 Acceptable Stable Pilot and or Main Flame Current Readings Control U V Infrared R7800 1 25 5 0 DC Volts 1 25 5 0 DC Volts...

Page 15: ...e burner on With the wires disconnected the burner should go into a purge cycle although neither the ignition nor the main fuel valve circuits will be energized If they do energize there is a wiring problem Correct as required 10 Turn power off Reconnect the air flow switch wires to the air flow switch terminals Place burner back into normal operation 28 The Owner s Operating Instructions page 26 ...

Page 16: ...ches as follows a Low gas pressure switch With the burner running slowly close the main gas train manual shutoff cock and adjust the switch to open its circuit when the pressure falls to a maximum of 50 below its normal value The burner will shut down Open the 14 NOVA PLUS Installation Operation Manual POWER FLAME INCORPORATED DC4 DRAFT CONTROL ENTER ESC manual gas shutoff cock to the full open po...

Page 17: ...ches as follows a Low gas pressure switch With the burner running slowly close the main gas train manual shutoff cock and adjust the switch to open its circuit when the pressure falls to a maximum of 50 below its normal value The burner will shut down Open the 14 NOVA PLUS Installation Operation Manual POWER FLAME INCORPORATED DC4 DRAFT CONTROL ENTER ESC manual gas shutoff cock to the full open po...

Page 18: ...e burner on With the wires disconnected the burner should go into a purge cycle although neither the ignition nor the main fuel valve circuits will be energized If they do energize there is a wiring problem Correct as required 10 Turn power off Reconnect the air flow switch wires to the air flow switch terminals Place burner back into normal operation 28 The Owner s Operating Instructions page 26 ...

Page 19: ...e operating condition Secondary causes lockout Set to actuate at approximately 0 7 w c under normal operating conditions Verify acceptable 02 level Combustion Air Flow Switch 16 NOVA PLUS Installation Operation Manual POWER FLAME INCORPORATED DC4 DRAFT CONTROL ENTER ESC Table 3 Acceptable Stable Pilot and or Main Flame Current Readings Control U V Infrared R7800 1 25 5 0 DC Volts 1 25 5 0 DC Volts...

Page 20: ... when main flame lights the air flow switch is not so critically set as to allow occasional momentary opening of the air switch contacts 10 NOVA PLUS Installation Operation Manual POWER FLAME INCORPORATED DC4 DRAFT CONTROL ENTER ESC 12 BURNER START UP AND SERVICE TEST EQUIPMENT REQUIRED The following test equipment is required to ensure proper start up and adjustment of burner equipment to obtain ...

Page 21: ...or atmospheric vent line obstructed Correct G Defective main gas pressure regulator replace Misadjusted main gas pressure regulator readjust to meet required operational values 5 Carbon Monoxide Readings Too High A Flame impingement on cold heat transfer surfaces caused by excessive firing rate Reduce firing rate to correct input volume B Flame impingement on cold combustion chamber surfaces due t...

Page 22: ...tart Up A thoroughly qualified burner technician must be employed to provide the initial burner start up as well as any subsequent servicing of the burner and related controls A representative of the owner and or the person or persons responsible for operating and maintaining the unit should be present during the initial start up A service representative may also be required by the local utility o...

Page 23: ...uctions Low draft fan air pressure Monthly Operator Refer to this manual and control manufacturer s and damper instructions High low gas pressure interlocks Monthly Operator Refer to instructions in this manual Fuel valve interlock switch Annually Service Technician Refer to valve manufacturer s instructions Purge switch Annually Service Technician Refer to fuel air control motor manufacturer s in...

Page 24: ...ket 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 is furnished for this purpose 21 NOVA PLUS Installation Operation Manual POWER FLAME INCORPORATED D...

Page 25: ...______________________ Name of Technician Performing Start Up______________________________________________________________________ Type of Gas Natural LP Other __________________________ Gas Firing Gas Pressure at Train Inlet Flame signal Readings Stack Outlet Test Point Draft Burner in Off Position ________ W C Pilot________________________ Low Fire ____________________ Low Fire ________________...

Page 26: ..._____________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ______________________________________________________...

Page 27: ...________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ________________...

Page 28: ...ervice Department in Parsons Kansas or you may register on line through the Power Flame website www powerflame com 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 into the burner nameplate that is attached to the integral control panel or to the burner when remote control panels ...

Page 29: ... 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 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 2...

Page 30: ... 3 Extinguish any open flame 4 Call your gas supplier immediately NOVA PLUS Installation Operation Manual POWER FLAME INCORPORATED DC4 DRAFT CONTROL ENTER ESC NOVA PLUS Installation Operation Manual POWER FLAME INCORPORATED DC4 DRAFT CONTROL ENTER ESC Cmax Installation Operation Manual POWER FLAME INCORPORATED 2 P PO OW WE ER R F FL LA AM ME E M MO OD DE EL L C Cm ma ax x B BU UR RN NE ER R For us...

Page 31: ...er Flame Incorporated Power Flame Incorporated Nova Plus Nova Plus Installation and Operation Manual Installation and Operation Manual Power Flame Incorporated 2001 South 21st Street Parsons KS 67357 Telephone 620 421 0480 FAX 620 421 0948 Product Support 620 820 8301 Website http www powerflame com e mail CSD powerflame com ...