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Power Flame Incorporated Power Flame Incorporated
X4 AND X4M INSTALLATION
AND
OPERATION MANUAL
THE POWER TO MANAGE ENERGY
2001 South 21
st
Street, Parsons, Kansas 67357
Telephone: 620-421-0480, Fax: 620-421-0948
Web Site: www.powerflame.com
E-mail: CSD@powerflame.com
X4OM 07/01
Rev.1005
Copyright 2005 Power Flame Incorporated 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 Parts List .......................................................................................................................... 13-14
Sequence of Operation for X4M Burners .......................................................................................... 16
X4M Wiring Diagram......................................................................................................................... 17
X4M General Arrangement Drawing ................................................................................................. 17
X4M Actuator .................................................................................................................................... 18
X4M Firing Rate vs. Manifold Pressure ............................................................................................. 18
-A- POWER FLAME MODEL X4 BURNERS
Rev. 10/04
For use by Qualified 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 may result causing property
damage, personal injury, or death.
Do not store or use gasoline or any other
flammable liquids in the vicinity of this or
any other appliance.
WHAT TO DO IF YOU SMELL GAS
BURNER SPECIFICATIONS
1. Do not try to light any appliance.
2. Do not touch any electrical switch; do
Input Capacity
BTU/Hr
not use any phone in your building.
X4-400
150,000 400,000
3. Immediately call your gas supplier from
X4-700
200,000 725,000
a neighbors phone. Follow the gas
X4M-400
150,000 400,000
suppliers instructions.
X4M-700
90,000 725,000
4. If you cannot reach your gas supplier,
Fuel Type
Natural or LP Gas
call the fire department.
Blast Tube Length
9, 12
Inlet Gas Pressure
X4-400
5.0 14 w.c.
X4M-400
5.5 14 w.c.
INSTALLATION AND SERVICE
X4-700
5.0 14 w.c.
MUST BE PERFORMED BY A
X4M-700
5.5 14 w.c.
QUALIFIED INSTALLER, SERVICE
Voltage
120V, 60 Hz
AGENCY, OR THE GAS SUPPLIER
Amp Rating
5.0 Amp
Motor
¼ Hp, 3450 RPM
Transformer
40VA, 24 VAC
Gas Valve
Honeywell
X4(M)-400
w/direct spark
VR8305M
w/proved pilot
VR8304M
X4(M)-700
w/proved pilot
Robert Shaw
7000DERHC-S7A
Primary Control
Honeywell
direct spark
S89F
proved pilot
S8680J
1
Rev. 10/04
1. GENERAL INFORMATION
The X4 burner is a new generation of gas power burners designed to fire natural gas and propane against
a positive furnace pressure.
The burner is a self-contained unit comprised of a blower assembly, firing head, ignition system,
combination gas valve, flame safeguard and control panel. It only requires connection of 115V electrical
supply, minor gas train piping, connection to gas service, and operating controls.
All Power Flame burners are operationally fire tested at the factory.
2. CAPACITIES & SPECIFICATIONS
Burner Number
X4-400
X4-700
X4M-400
X4M-700
Natural/LP Gas Flow x 1,000 BTU/HR
150-400
200-725
150-400
90-725
Gas Train Size
3/4
1
3/4
1
Blower Wheel Size
6-1/4 x 2-3/4
7 x 3
6-1/4 x 3-3/4
7 x 3
Blower Motor HP
1/4
1/4
1/4
1/4
Voltage
120/60 hz
120/60 hz
120/60 hz
120/60 hz
Maximum Inlet Pressure to Main Shut-
off Cock Inches W.C.
14.0
14.0
14.0
14.0
3.
ACCEPTANCE PROCEDURE
Open the box and carefully remove the top cardboard packaging. Lift the burner from the box and ensure
all shipped loose items are removed before discarding the box. Check all parts received against your
computer generated Bill of Material that is enclosed in the owners information envelope.
Warranty
The Owners Information envelope packed with the burner contains a Warranty Registration Card. The
Warranty Registration Card is also a request form for a Spare Parts List. An on-hand supply of spare
parts is highly recommended in case of emergency shutdown. We request that you complete and return
the card to Power Flame in the enclosed self-addressed envelope as soon as possible.
4.
INSTALLATION
Prior to Installation, carefully study these instructions, all charts, drawings and diagrams
shipped with the burner.
Installation must be in accordance with all local and national codes including CAN1-B149.1 or B149.2 and
Canadian electrical codes for Canadian installations.
2 4.1
If the burner is to be 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 tightly sealed, whether the burner is to be fired under positive or negative
combustion chamber conditions.
4.2
The burner can be mounted through a heat exchanger end wall or in the base of the boiler see Figures
1 and 2. The opening for the burner blast tube should not be less than 4 ¼ inches in diameter to allow
easy removal of the burner. The gap between the burner opening and the blast tube should be sealed
with non-asbestos, high temperature rope or Ka-O-Wool. Where a new or replacement combustion
chamber lining is to be used the chamber is to be built using 2300 degree F insulating firebrick or 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 Input
Width
Length
MBTU/HR
Inches
Inches
250
13
17
450
15
20
600
16
23
700
17
25
850
18
26
4.4
Whichever method of mounting is chosen, the burner blast tube must be recessed into the front wall
surface from 0 to 1/2.
3 NOTE: Serious Damage To The Burner May Result If The Blast
Tube Is Extended Into The Combustion 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
into the end or front wall of the fired unit. A tight seal between the mounting flange and the front
plate should be accomplished using the factory-furnished gasket or a ceramic or other non-
asbestos fiber rope.
5
GAS PIPING
5.1
Contact you local gas service company to ensure that adequate gas service is available and to
review applicable 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, CGA B 149.2. This product must be installed only by a Licensed
Plumber or Gasfitter, when installed in the Commonwealth of Massachusetts.
5.2
Size the main gas line in accordance with Table 2. The figures shown are 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 to the pipe pressure drop.
Table 2 - Gas Piping Pressure Drop Data
EQUIVALENT LENGTH OF STRAIGHT PIPE IN FEET
20
30
40
50
60
80
100
150
200
Pipe Size In Inches
CFH GAS WITH .2 PRESSURE DROP
3/4
152
120
105
93
84
73
66
54
45
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
EQUIVALENT LENGTHS OF STANDARD PIPE IN FEET FOR LISTED FITTINGS
Fitting Type
3/4
1
1-1/2 1-1/2
2
2-1/2
Nominal Pipe Size In Inches
Std. Tee
2.4
5.5
7.5
9.0
12.0
13.5
Std. Elbow
4.4
2.7
3.7
4.5
5.5
6.1
5.3
Refer to Figure 3 for details of gas piping. (Also refer to any additional piping diagrams supplied for this
specific unit.)
5.4
Mount leakage test and main gas cocks, main automatic gas valve or combination gas
valve/pressure regulator, and auxiliary valves (if required and not factory mounted) per piping
diagram or Figure 3.
5.5
Install pressure regulator (not used with combination gas valve/pressure regulator) directly
upstream of main automatic gas valve(s) and fit dr