OPERATING AND MAINTENANCE MANUAL NVPOM-0104
TABLE OF CONTENTS Section Page 1 SPECIFICATIONS...1 1.1 Nova Plus Specifications...1-1 1.2 Warranty...1-2 2 GENERAL BURNER DESCRIPTION...2 2.1 Burner...2-1 2.2 Operational Requirements...2-2 3 INSTALLATION...3 3.1 Handling Precautions...3-1 3.2 Burner Installation to Mounting Plate...3-1 3.2 Burner Installation to boiler...3-1 4 GENERAL OPERATION...4 4.1 Pre-Fire Checks...4-1 4.2 Initial Startup...4-1 4.3 Normal Startup and Shutdown...4-1 5 MAINTENANCE AND TROUBLESHOOTING...5 5.1 Maintenance...5-1 5.2 Troubleshooting...5-1 6 APPENDIX...6 6.1 Start-up Data...6-1 NVPOM-0104
SECTION 3 INSTALLATION 3.1 Handling Precautions 3.2 Boiler Preparation 3.3 Burner Installation NVPOM-0104
SECTION 3 INSTALLATION Burner installation is recommendeded by personnel trained by Power Flame or under close supervision of Power Flame personnel. The burner assembly is shipped assembled. This section describes the installation of the burner element into the mounting plate and into the boiler. Prior to installing the burner, inspect all materials upon receipt. Verify that all components on the packing list are accounted for and check for any shipping damage. If any parts are missing or damaged, contact the factory to obtain replacement parts. NOTICE: Although Power Flame is not responsible for shipping damage or missing items, we will gladly assist you in making the appropriate claims with a shipper. 3.1 HANDLING PRECAUTIONS The surface of the burner element is very durable and will last for many years under normal operating conditions. However it is possible to puncture the metal fiber material with a sharp object such as a screwdriver. NEVER install a burner segment which has a damaged surface. Consult the factory immediately. The burner element has an insulation assembly composed of blanket and board insulation. The insulation assembly is fasten to the burner metal work by 2-4 ceramic cups. Caution should be taken in handling the burner element by the rigid metal work and not by the insulation assembly. 3.2 BURNER INSTALLATION TO MOUNTING PLATE Refractory work on the mounting plate must be completed before installing the burner element to the mounting plate. Precaution must be taken not to damage the burner element and its insulation while handling it during this procedure. Installing burner element: The burner/mounting plate gasket, a Fiberfrax gasket, must be installed on the burner element (provided by Power Flame). Lift burner element over mounting plate and align the studs on the burner element with the mount holes on the mounting plate. Lower the burner element to the mounting plate. Fasten burner to mounting plate with 8-3/8 hex nuts, flat washers, and lock washers. Torque hex nuts to ~30 ft-lbs. NVPOM-0104
3.3 BURNER INSTALLATION TO BOILER (TO BE USED AS REFERENCE ONLY) Verify adequate gas supply and electrical power requirements. Familiarize yourself with the burner assembly by studying the Nova Plus General Arrangement Drawing (See Appendix). The Power Flame Nova Plus burner usually ships as a complete assembly comprised of four sub-assemblies; the Burner Mixer Mounting Plate, the Mixing Spool, blower housing assembly, and the Pilot Assembly, therefore some steps in the following assembly procedure may not be necessary: NOVA PLUS-I.072905 Santa Clara, California, USA
Refer to the general arrangement drawing to locate parts and view their orientation. 1. Locate the fuel/air mixing spool and the Fiberfrax gasket used for the mixing spool and burner mixer mounting plate 2. Attach the burner and mounting plate to the front of the boiler. The assembly must be introduced into the boiler carefully and avoid any contact between the burner element and the boiler. Be sure to use the correct gasket and fasteners. 3. Attach the fuel/air mixing spool to the mounting plate with the use of the proper hardware. 4. Attach the blower controls assembly to the fuel/air mixing spool. Place a Neoprene gasket between the two assemblies and fasten with the appropriate hardware. Install the provided support to the blower. The blower needs to be supported at all times. 5. Attach the pilot assembly to the burner mixer mounting plate. The pilot assembly should be mounted to the pilot port located to the side of the burner mixer mounting plate. To attach the pilot use the threaded portion of the assembly and thread it through the coupling at the end of the pilot tube that is attached to the burner mounting plate assembly. For the proper positioning of the pilot, insert the pilot fully, retract the pilot 1. 6. Provide gas to the pilot from the pilot gas train. Air for the pilot is provided from a coupling on motor side of the blower housing; purge air for the UV scanner is provided through this coupling, The ignition transformer is used as the electrical input to the pilot. 7. Connect the remaining utilities. NOVA PLUS-I.072905 Santa Clara, California, USA
SECTION 4 GENERAL OPERATIONS 4.1 Pre-Fire Checks 4.2 Initial Startup 4.3 Normal Startup and Shutdown NOVA PLUS-I.072905 Santa Clara, California, USA
SECTION 4 GENERAL OPERATION 4.1 PRE-FIRE CHECKS 1. Leak check all fuel gas connections and pilot gas connections 2. Check for proper rotation of the combustion air blower. 3. Approximately set air damper linkage 4. Start the combustion air fan and note the burner pressure drops at the low and high fire positions with air flow only. At low fire, the burner pressure drop should be 0.3 inches of water column. At high fire the burner pressure drop should be about 3.0-4.0 inches of water column. Re-adjust the low and high fire damper positions until you match these pressures. Fine tuning of the air damper will be made after the burner is fired. 5. Set fuel gas valve to match air valve. 4.2 INITIAL START UP The initial Nova Plus burner startup should be performed with an authorized Power Flame representative present. After the initial tuning of the system is completed, start up can be performed by the user. 1. Start the combustion air blower 2. Satisfy all operating interlocks* 3. Set the air damper to the low fire position 4. Establish the pilot 5. Light the main burner 6. A Power Flame representative will tune the fuel/air ratio to meet the NO x emissions and performance guarantees. The over-temperature detection interlock uses a temperature switch which fails safe when power to the control panel is cycled. Therefore, when the control panel looses power, one needs to reset the temperature switch. The interlock string will not be satisfied without resetting the temperature switch.
4.3 NORMAL STARTUP AND SHUTDOWN Once the system has been tuned initially by a Power Flame representative, startup and shutdown become routine. Proper gas pressure must be delivered to the burner system at all times. The system can be operated in Auto or Manual modes with the on/off switch located on the main control panel. When the burner is shut down and the heater is at its operating temperature the following procedures MUST be followed: 1. Shut off main burner fuel gas 2. Operate the combustion air fan with sufficient combustion air so that the burner overtemperature thermocouples do not exceed 400 F. Continue to operate the combustion air fan until the internal heater temperature drops below 350 F. This procedure is extremely important and it serves to protect the burner structure from over heating. 3. Once the internal heater temperature drops below 350 F, it is safe to shut down the combustion air fan. WARNING IF HARD STARTS ARE EXPERIENCED, THE BURNER SHUTS DOWN ON BURNER OVERTEMPERATURE LIMIT, OR OTHER UNUSUAL CONDITIONS EXIST, SUCH AS A VISIBLY DAMAGED METAL FIBER ELEMENT, DO NOT ATTEMPT TO OPERATE THE BURNER FURTHER. ATTEMPTS TO OPERATE UNDER THESE CONDITIONS MAY DAMAGE THE BURNER, AND/OR THE BOILER AND/OR RESULT IN PERSONAL INJURY. CONTACT POWER FLAME INCORPORATED FOR FURTHER INSTRUCTIONS. SECTION 5
MAINTENANCE AND TROUBLESHOOTING 5.1 Maintenance 5.2 Troubleshooting
SECTION 5 MAINTENANCE & TROUBLESHOOTING 5.1 MAINTENANCE The Power Flame Nova Plus burner itself is relatively maintenance-free. With proper maintenance long term service of the burner can be expected. However, it is the responsibility of maintenance personnel in charge to determine the precise maintenance interval required to maintain the specifications of Section 1.1. As part of the maintenance program for the Power Flame Nova Plus burner, and to assist in troubleshooting, burner performance data should be measured at various firing rates and furnace stoichiometric conditions. The data should be collected during the initial start-up and on an annual basis during routine maintenance. This data should include: 1. The burner pressure drop at minimum, intermediate, and maximum firing rates and standard excess air levels. 2. The burner pressure drop at minimum and maximum air flows with no fuel flowing. 3. Fuel pressure data and O 2 levels at the above conditions should be recorded. The form in Section 6.5 (Startup Data) can be used to record the data and provide a quick reference for troubleshooting. Burner pressure should be measured using the upstream static pressure tap located on the gas injection spool and referenced to the firebox pressure. This data can be used to generate a burner performance data curve of pressure drop versus firing rate. The pressure drop across the air filter should also be recorded to assist in monitoring the cleanliness of the filter element. WARNING: IF HARD STARTS ARE EXPERIENCED, OR OTHER UNUSUAL CONDITIONS EXIST, SUCH AS A VISIBLY DAMAGED METAL FIBER ELEMENT, DO NOT ATTEMPT TO OPERATE THE BURNER FURTHER. ATTEMPTS TO OPERATE UNDER THESE CONDITIONS MAY DAMAGE THE BURNER. CONTACT POWER FLAME INCORPORATED FOR FURTHER INSTRUCTIONS. 4. Service/removal of the main burner should not be necessary under normal conditions. Should service become necessary, contact Power Flame Incorporated. 5. Air filter elements should be changed when the pressure drop reaches 2 wc or when insufficient air flow results in low stack O 2 readings. Furthermore, a red service light located on the control panel indicates that the filters are plugged and new ones are needed. Always replace the filter elements to match the specifications on the filter housing. 6. Check the air damper linkage for free travel, and check linkage fasteners for tightness. 7. Refer to Section 6 for maintenance items on other components supplied with the burner. 5.2 TROUBLE SHOOTING This section outlines the steps to help diagnose and correct any problems or abnormal situations that may occur. Abnormal operating conditions should be corrected to prevent any unusual situations from becoming hazardous. IMPORTANT: The over-temperature detection interlock uses a temperature switch which fails safe when power to the control panel is cycled. If the control
panel looses power the temperature switch needs to be reset otherwise the Pilot Assembly interlock string will not be satisfied. Typical problems with the pilot assembly operation include poor ignition, flame sensing and flame stability. If operation of the pilot is unsatisfactory, identify the problem in Table 5-1 and take corrective actions. TABLE 5-1. PILOT TROUBLESHOOTING Poor Pilot Ignition PROBLEM Poor Pilot Flame Sensing SOLUTIONS 1.1 Verify spark voltage and duration. Check for loose electrical connections. 1.2 Verify integrity of spark electrode. If there is no ignition spark at the pilot nozzle tip, inspect for evidence of electrical arcing along the length of the ignition rod. Reposition the spark tip or replace the electrical feedthrough, electrode assembly, or electrode insulators as appropriate. 1.3 Verify the pilot fuel gas manifold pressure. If the pressure is not correct, check the pilot gas train for proper operation. 2.1 Check for proper line-of-sight between the UV flame scanner and the pilot flame. 2.2 Check for proper ignition and stable operation of the pilot flame. See Weak Flame/Yellow Tipping. 2.3 Check for condensation in the lens of the UV flame scanner. If condensation continues to block signal, increase flow of instrument air to scanner port. 2.4 Check wiring and performance of the UV flame scanner and flame amplifier. Weak Flame/ Yellow Tipping 3.1 Examine the gas and air orifices for clogging. Clean if necessary. 3.2 Verify the adjustment of the pilot gas pressure. Adjust the pressure for the proper fuel-air ratio and stable pilot flame. 3.2 Verify the pilot fuel gas manifold pressure. If the pressure is not correct, check the pilot valve train for proper operation. 5-6
Main Burner Element Typical performance problems associated the Nova Plus burner may include poor performance from damage to the burner surface material or operation with the incorrect fuel air ratio. Table 5-2 will help identify and correct the problem. TABLE 5-2. PROBLEM Yellow Tipping or Flame Spikes SOLUTIONS 1.1 During normal operation blue flame spikes should be visible along the length of the burner. At very high turndown rates (greater than 4:1) the blue flames may not be visible. This is normal. 1.2 Yellow tipping or a yellow halo around the burner is normal during startup. As soon as dust particles that have accumulated in the ducting have burned out the yellow will disappear. 1.3 Flame spikes in-between burner segments could indicate a leak in the gasket. Inspect gasket and replace as required. Check that the segment fasteners are torqued to the specification given in Section 3.3. 1.4 Large yellow luminous flames indicate that the burner is not operating at the correct fuel/air ratio. Check the specifications given in Section 1.1 and correct as necessary. 1.5 A large hole or other damage to the metal fiber pad would cause flame spikes. Replace the damaged segment immediately and return it to the factory for refurbishment. Poor NO x or CO performance 2.1 The NO x and CO performance are a function of the fuel and air ratio. Check that the fuel and airflows are within the specified limits of Section 1.1. 2.2 Check that the air filter elements are not plugged, which will reduce the airflow. A filter pressure drop greater than 2 inches of water column indicates the elements need replacing. 5-7
SECTION 6 START-UP DATA Fill out the attached table upon start-up and return a copy to Power Flame for warranty validation. Date: User Name: Boiler Type: Boiler Capacity: Burner Style/ Size: Fuel Gas Type: Sheet: Total Sheets: START-UP DATA Time hh:mm P Valve Position Controller Output (%) Flame Signal Gas Volume (Cu ft) Time (sec) Gas Reg. P (psi) Firing rate (MMBtu/hr) Windbox/Mixing Spool P (in. w.c.) Furnace P (in. w.c.) Burner Diff. P (in. w.c.) Gas Nozzle P (in Psi) Stack O 2 Dry [%] NOx (ppm) CO (ppm) CO 2 Percent (%) Steam P. /Water T. (psi/ 0 F) Stack Temp ( F) Ambient Temp ( F) 6-1
Make Notes on Back Side 6-2