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PF X4-400, Installation And Operation Manual

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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-

Summary of Contents for X4-400

Page 1: ...X4 AND X4M INSTALLATION AND OPERATION MANUAL ...

Page 2: ...on 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 ...

Page 3: ... 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 neighbor s phone Follow the gas X4M 400 150 000 400 000 supplier s 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 Ga...

Page 4: ......

Page 5: ... 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 owner s information envelope Warranty The Owners Information envelope packed with the burner contains a War...

Page 6: ...than 4 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 ...

Page 7: ...able 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 11...

Page 8: ...Piping Train X4 See Figure 11B page 17 for X4M 5 8 Test gas lines for leaks using a soap solution Your local gas service company may wish to execute or witness this test CAUTION gas pressure above 14 w c may damage the standard diaphragm gas shut off valve Do not exceed this value when pressure testing lines unless you cap off line upstream of main gas cock and pilot take off 5 9 Check that side o...

Page 9: ...Figure 4 Location of Side Orifice Figure 5 Typical Wiring Diagram for S8680J with Proved Pilot Ignition 6 ...

Page 10: ...requirements Also this manual will provide information about the exact sequence of operation and all other details on the specific Primary Safety Control System being used This information will be found in bulletins supplied with the burner as well as technical bulletins covering other components All of these materials should be used as reference in burner start up and service 7 2 Check boiler wat...

Page 11: ...een furnished Refer to Burner Specification Sheet If pressure is acceptable proceed to next step 7 10 Pilot Ignition Next check the operation of the gas pilot system This is a very important part of the start up procedure A Before attempting burner start up make certain that you are familiar with the operation of the Primary Safety Control and other components being used on this specific applicati...

Page 12: ...izes begin increasing the pilot pressure Note the pressure where a signal is obtained or the main valve energizes This will be the minimum pilot pressure Acceptable pilot and or main flame current reading is 1 5 microamp B Raise the pilot gas pressure to the point where the signal and or main valve drops out noting this pressure Reduce the pressure slightly and recycle the burner for an attempt to...

Page 13: ...since shipment may have altered the placement B Set the burner s combustion air inlet damper to the approximate setting as shown in this manual for the desired firing rate Also verify that the correct main orifice is installed in the main orifice tee C Open the main manual gas valve and turn the combination gas valve to ON Turn the burner power on The blower motor will purge the heat exchanger of ...

Page 14: ...intain the correct burner settings may result in inefficient gas consumption premature wear of burner components or explosion hazard 8 3 Approximate gas flows and pressures are shown in Table 3 for natural gas and LP gas Actual firing rates should be verified by clocking the gas meter and applying the appropriate correction factor Table 3 Natural LP Gas Orifice Pressure Settings Flow Rate NOTE Pre...

Page 15: ... gas pressure and air settings for improved readings 2 Check gas valve circuit 3 Shut off cock or test cock not open 4 Defective main valve 9 4 Occasional Lockouts For No Apparent Reason 1 Re check micoamp readings If insufficient check gas pressure and air damper setting Check electrode setting If flame signal is low flame rod may have to be re positioned 2 Check ignition cable and electrode porc...

Page 16: ...Side Orifice tee 32 Air Sensing Tube 3 Side Orifice Spring 18 Side Orifice Spring 33 Orifice Kit 4 Gun Assembly 19 Pilot Regulator 34 Direct Spark Transformer 5 Flange Gasket 20 Pilot Solenoid Valve 35 Gas Piping Support Bracket 6 Mounting Flange 21 Combination Gas Valve 36 Damper Axle 7 Blower Wheel 22 Main Gas Cock 37 Relay 8 Motor Plate 23 Pilot Gas Cock 38 5 16 Ball Joint Swivel 9 Blower Motor...

Page 17: ...X4M 14 ...

Page 18: ...15 ...

Page 19: ...ll be attempted On pilot ignited burners the pilot pressure would be set here to achieve the best pilot performance Refer to Pilot Adjustment Procedure earlier in section 7 10 of this manual 11 6 When the main gas valve is energized after a proven pilot or during direct spark ignition on DSI burners the 24 vac relay will also be energized 11 7 One set of normally open relay contacts close which in...

Page 20: ...Figure 11A Typical Wiring Diagram For X4M Figure 11B General Arrangement Diagram for X4M 17 ...

Page 21: ...must be subtracted from these pressures to obtain the correct firing rate Example While firing an X4M 400 the Manifold pressure is 3 0 w c The furnace pressure from the manometer reads 0 5 w c Therefore 3 0 5 2 5 w c The chart in Figure 11D shows 2 5 w c net manifold pressure is equal to 400 000 BTUH 18 Manifold Pressure vs Firing Rate 0 0 5 1 1 5 2 2 5 3 3 5 4 0 100 200 300 400 500 600 700 800 Fi...

Page 22: ... available 2 Set the burner control panel switch to the OFF position 3 Turn the thermostat or operating control down to its lowest setting 4 Check fuses and replace as necessary 5 Depress the flame safeguard programming control reset button Start Up 1 Manually open and close the main gas shut off cock leak test cock and pilot cock to determine that they operate freely Open all three cocks Reset lo...

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