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Cmax Installation & Operation Manual

 - 

POWER FLAME INCORPORATED 

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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

Cmax Installation & Operation Manual

 - 

POWER FLAME INCORPORATED 

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Power  Flame  Incorporated, hereinafter called

the Seller, of 2001  South 21

st

Street,  Parsons, 

Kansas, hereby warrants  its  equipment

manufactured  by it and  bearing  its  nameplate

(hereinafter called Warranted Equipment) in the

respects and exclusively for the benefit of those

users, described  herein.

THIS LIMITED

WARRANTY SHALL EXTEND SOLELY TO

THOSE  PERSONS WHO ARE  OWNERS OF

THE  WARRANTED  EQUIPMENT  DURING

THE WARRANTY PERIOD HEREINAFTER

DEFINED 

AND 

WHO

USE

SUCH

WARRANTED EQUIPMENT IN THE PROJECT

AND  FOR THE  PURPOSES FOR  WHICH 

SUCH WARRANTED EQUIPMENT WAS 

ACQUIRED FROM THE  SELLER. The  Seller

warrants its equipment to be free from defects in

the material and workmanship under normal use

and service for fifteen (15) months from date of

shipment. Burner blast tube is warranted a full

five  (5)  years.  EXCLUDED  FROM ANY

COVERAGE UNDER THIS WARRANTY  ARE 

DEFECTS  IN  WARRANTED EQUIPMENT

FROM DAMAGE IN SHIPMENT, FAULTY

INSTALLATION, 

LACK

OF

PROPER 

MAINTENANCE, CLOGGED OR DAMAGED

FILTERS, MISUSE OR NEGLIGENCE. If any

person becomes  entitled to a  claim under  this

warranty, such  person shall, as  a  condition

precedent to  securing warranty performance,

return the Warranted Equipment  to the Seller’s

plant, 2001 South 21

st

Street, Parsons, Kansas,

transportation  prepaid.

If the  Warranted

Equipment thus returned is found by the Seller

to be  defective  for a  cause  and  within  a  time

covered by this Warranty, such equipment shall

be  repaired or  replaced without charge;  and

returned to  its  owner  or job  site  at the Seller’s

cost for  transportation and handling.

If

inspection of the  Warranted  Equipment

discloses defects not covered by this Warranty,

the Seller  shall notify the  owner.

Said

equipment, at the  owner’s option (to  be

determined  thirty (30) days  from the  date of

notification), may be repaired or replaced at the

expense  of the owner and Seller’s regular

charges  shall  apply. Owner  shall  assume  the

cost

for 

transportation 

and

handling.

Equipment, which is repaired or replaced, shall

carry a warranty equal to the unexpired portion

of the  original  warranty. 

The Seller  will

commence  inspection of any Warranted

Equipment  returned to  it  for  warranty  claim 

within seven (7) working days after the arrival of

such Warranty Equipment at Seller’s plant, and

shall  complete any repairs required under this

warranty within sixty (60) days after such arrival,

unless  Seller  shall sooner  notify said  owner of

reasonable  cause for  delay beyond control of

Seller. Warranty obligations  hereunder  will  be

performed only between the hours of 9:00 a.m.

and  4:00  p.m. Monday through  Friday and

excluding  holidays.

Any person believing

himself entitled  to  warranty performance

hereunder  is required  to  notify the Quality

Assurance or  Service Department of Power

Flame  Incorporated, 2001  South 21

st

Street,

Parsons, Kansas, prior to return  of any

Warranted Equipment for repair hereunder. IN

ALL EVENTS, SELLER WILL NOT BE LIABLE

FOR  AND  WILL NOT REIMBURSE  ANY

LABOR, MATERIAL, OR OTHER  REPAIR

CHARGES INCURRED BY  ANYONE OTHER 

THAN

SELLER

ON  ANY  WARRANTY

EQUIPMENT,  UNLESS SUCH CHARGES 

HAVE BEEN SPECIFICALLY AUTHORIZED IN

ADVANCE IN WRITING BY SELLER. ANY 

WARRANTY

IMPLIED  BY

LAW

WITH 

RESPECT TO THE MERCHANTABILITY  OR 

FITNESS OF THE WARRANTED EQUIPMENT

IS HEREBY LIMITED TO THE DURATION OF

THE  WARRANTY PERIOD  HEREUNDER.

THE SELLER WILL NOT IN ANY  EVENT BE 

LIABLE

FOR

ANY

INCIDENTAL

OR

CONSEQUENTIAL

DAMAGES 

ATTRIBUTABLE  TO

THE  WARRANTED

EQUIPMENT.

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2001 South 21

st

Street, Parsons, KS 67357

Telephone: 620-421-0480  FAX: 620-421-0948

Website:  http://www.powerflame.com 

e-mail: [email protected] 

®

®

POWER FLAME MODEL NOVA PREMIX

POWER FLAME MODEL NOVA PREMIX

POWER FLAME MODEL NOVA PLUS

POWER FLAME MODEL NOVA PLUS

WHAT TO DO IF YOU SMELL GAS

1.        Open windows.

2.        Do not touch electrical switches.

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 

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For use by Qualified Service Personnel Only 

Rev. 03/2009

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 

Cmax Installation & Operation Manual

 - 

POWER FLAME INCORPORATED 

47

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W

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y

Power  Flame  Incorporated,  hereinafter  called

the  Seller,  of 2001  South 21

st

Street,  Parsons, 

Kansas,  hereby  warrants  its  equipment

manufactured  by  it  and  bearing  its  nameplate

(hereinafter called Warranted Equipment) in the 

respects and exclusively for the benefit of those

users,  described  herein. 

THIS LIMITED

WARRANTY  SHALL  EXTEND  SOLELY  TO 

THOSE  PERSONS  WHO ARE  OWNERS OF

THE  WARRANTED  EQUIPMENT  DURING 

THE  WARRANTY  PERIOD  HEREINAFTER 

DEFINED 

AND 

WHO 

USE 

SUCH

WARRANTED EQUIPMENT IN THE PROJECT 

AND  FOR THE  PURPOSES  FOR  WHICH 

SUCH WARRANTED EQUIPMENT  WAS 

ACQUIRED FROM THE  SELLER.  The  Seller 

warrants its equipment to be free from defects in 

the material and workmanship under normal use 

and service for fifteen (15) months from date of 

shipment. Burner blast tube is warranted a full 

five  (5)  years.  EXCLUDED  FROM ANY 

COVERAGE UNDER  THIS  WARRANTY  ARE 

DEFECTS  IN  WARRANTED  EQUIPMENT

FROM DAMAGE IN SHIPMENT,  FAULTY 

INSTALLATION, 

LACK  OF

PROPER 

MAINTENANCE,  CLOGGED  OR DAMAGED 

FILTERS,  MISUSE  OR  NEGLIGENCE.  If  any 

person  becomes  entitled  to a  claim under  this 

warranty,  such  person  shall,  as  a  condition 

precedent  to  securing warranty performance,

return the Warranted Equipment  to  the  Seller’s 

plant, 2001 South 21

st

Street, Parsons, Kansas, 

transportation  prepaid. 

If the  Warranted

Equipment thus returned is found by the Seller 

to be  defective  for  a  cause  and  within  a  time 

covered by this Warranty, such equipment shall 

be  repaired  or  replaced without  charge;  and

returned  to  its  owner  or  job  site  at  the Seller’s 

cost  for  transportation  and  handling. 

If

inspection of the  Warranted  Equipment 

discloses defects not covered by this Warranty, 

the  Seller  shall  notify  the  owner. 

Said

equipment,  at  the  owner’s  option  (to  be

determined  thirty  (30)  days  from the  date of

notification), may be repaired or replaced at the

expense  of the  owner  and  Seller’s  regular

charges  shall  apply.  Owner  shall  assume  the 

cost 

for 

transportation 

and

handling.

Equipment, which is repaired or replaced, shall 

carry a warranty equal to the unexpired portion

of  the  original  warranty. 

The  Seller  will 

commence  inspection  of  any  Warranted 

Equipment  returned to  it  for  warranty  claim 

within seven (7) working days after the arrival of

such Warranty Equipment at Seller’s plant, and

shall  complete  any  repairs required under  this 

warranty within sixty (60) days after such arrival, 

unless  Seller  shall  sooner  notify  said  owner  of

reasonable  cause  for  delay  beyond control of

Seller.  Warranty  obligations  hereunder  will  be 

performed only between the hours of 9:00 a.m. 

and  4:00  p.m.  Monday  through  Friday and

excluding  holidays. 

Any  person believing

himself entitled  to  warranty performance 

hereunder  is required  to  notify  the Quality 

Assurance  or  Service Department of Power

Flame  Incorporated,  2001  South 21

st

Street, 

Parsons,  Kansas, prior to return  of  any 

Warranted Equipment for repair hereunder.  IN

ALL EVENTS, SELLER WILL NOT BE LIABLE

FOR  AND  WILL  NOT REIMBURSE  ANY 

LABOR, MATERIAL,  OR OTHER  REPAIR

CHARGES  INCURRED  BY  ANYONE  OTHER 

THAN

SELLER  ON  ANY  WARRANTY 

EQUIPMENT,  UNLESS  SUCH  CHARGES 

HAVE BEEN SPECIFICALLY AUTHORIZED IN

ADVANCE  IN WRITING  BY  SELLER.  ANY 

WARRANTY  IMPLIED  BY  LAW  WITH 

RESPECT  TO  THE  MERCHANTABILITY  OR 

FITNESS OF THE WARRANTED EQUIPMENT

IS HEREBY LIMITED TO THE DURATION OF 

THE  WARRANTY PERIOD  HEREUNDER. 

THE SELLER WILL NOT  IN  ANY  EVENT  BE 

LIABLE  FOR

ANY  INCIDENTAL

OR

CONSEQUENTIAL 

DAMAGES 

ATTRIBUTABLE  TO  THE  WARRANTED 

EQUIPMENT.

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2001 South 21

st

Street, Parsons, KS  67357

Telephone: 620-421-0480  FAX: 620-421-0948 

Website:  http://www.powerflame.com 

e-mail: [email protected] 

®

®

DC4 DRAFT CONTROL

ENTER

ESC

®

Power Flame Incorporated

Power 

Flame

 Incorporated

DC4 DRAFT CONTROL

ENTER

ESC

®

Rev. 08/2017

Summary of Contents for Nova Plus

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 ...

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