PVI Industries Universal Remote PV500 9 User Manual

PVI FIREPOWERâ GAS BURNER  
TYPICAL CONSTRUCTION  
Figure 9-1  
1. Burner housing  
2. Air intake  
15. Air switch  
16. Door assembly *  
17. Flame sensing electrode  
18. Ignition electrode  
19. Ignition transformer  
20. On-off switch *  
21. 1/4” NPT pressure port plug  
22. Motor mounting plate *  
23. Motor relay or starter *  
24. Pressure plate  
25. Primary gas ports  
26. Secondary gas ports (gas spider)  
29. Orifice location *  
30. Electrode retaining bracket  
31. Burner cover  
32. Burner sight glass  
33. Air shutter  
34. Union  
35. Flame safeguard control  
36. Flame cone  
37. Manual gas valve  
38. Lifting eye bolt  
39. Power connector  
40. Manifold test port  
3. Oil pump opening plug  
4. Mounting flange  
5. Mounting flange gasket  
6. Blast tube screw  
7. Blast tube  
8. Nozzle assembly  
9. Nozzle mount bolt  
10. Air inlet cone  
11. Air screen  
12. Fan wheel  
13. Motor, 3450 rpm CWSE rotation  
14. Air nipple  
27. Gas regulator  
28. Gas valve  
* On some models  
PV500-9 04-2000  
(1)  
Section 9  
 
POWER GAS BURNER START-UP (Con’t)  
flame safeguard reset button. The burner should pre-  
clearance). Ensure plate is seated firmly against the  
gas spider and tighten the plate retaining screws.  
Recheck electrode setting as to gap and position.  
purge for not longer than thirty seconds. The TFM  
series control will have either an MT30-4, MT30-10  
or MT12-5 time card. The “30 indicated a 30-second  
purge time and the “4”, “5” or “10” indicated a 4-  
second, 5-second, or 10-second trial for ignition  
period, commonly called TFI.  
15. Replace nozzle assembly; be sure to connect the flame  
and spark rod wires before installing nozzle assembly  
fully into blast tube. Check to be sure connectors on  
the ends of the flame and spark rod wires have a good  
contact. Look for properly stripped wire ends. Be sure  
connectors are firmly attached to the flame and ignition  
rod ends. Insulating boots can give a false feeling of  
proper seating. BE CAREFUL NOT TO MOVE  
ELECTRODES. Be careful not to bump electrodes  
Check fan wheel for free rotation.  
When the blower motor starts, the air switch which  
proves air flow should close and terminal 6 will be  
powered. This starts the pre-purge timing sequence.  
After purging is complete, terminal 3 or 4 on the  
TFM control are energized. Terminal 3 energizes  
the pilot valve and terminal 4 energizes the ignition  
transformer. At this time, the pilot is established.  
The VDC reading on thermometer should read a  
steady 14-17 VDC for a TFM control. Each different  
control will have the required flame response signal  
stamped on it. This is the minimum for it to properly  
operate. If the pilot fails to light during the initial  
ignition period, it is probably due to air in the line.  
The control will lock out. Wait one minute and push  
the flame safeguard reset button to restart burner  
and begin the purge cycle again.  
16. Reinstall orifices in unions (if required). Reinstall burner  
cover.  
17. Connect a test meter to the control for reading the  
flame response signal.  
NOTE: Some controls read the flame signal in micro  
amps and some in volts DC. The TFM series control has  
two terminals marked for reading volts DC. The S89  
control uses a micro amp signal for measuring flame  
strength. For this control, a meter must be hooked in  
series with the flame rod wire. Disconnect the leadwire  
at the S89 sensor terminal. Connect the positive lead of  
the meter to the quick-connect sensor terminal on the  
S89 and the negative lead to the free end of the sensor  
leadwire.  
Now, set the pilot pressure (measured downstream  
of gas valve) at the pressure shown on the tag  
attached to the gas train. Next, open the main gas  
valve slowly. Set manifold pressure at the pressure  
shown on the tag attached to the gas train. Do not  
screw the adjusting nut of the regulator in past the  
point where no further increase in manifold pressure  
is noted. Check the incoming pressure with the  
burner running. This is recorded as inlet flow  
pressure.  
18. Be sure the tank is filled with water. Once the burner is  
reassembled, two devices to read pressure, preferable  
U-tube manometers, will be needed to read gas  
pressures. Connect one to read the inlet pressure of  
the burner. This is the pressure measured before all  
components in the gas train. The manometer must stay  
connected throughout the testing, as the inlet pressure  
must be monitored during the firing of the burner.  
Record static pressure. It must not exceed 14” W.C. for  
burners with inputs through 3,200,000 Btu/h. For inputs  
above 3,200,000 Btu/h, refer to the appliance date  
plate for the correct maximum inlet pressure Pressures  
above this could cause damage to the diaphragm in the  
gas valve or pressure regulator.  
Our standard flow pressure requirements are:  
a. 5” W.C. with 8” W.C. flow on burners with inputs  
through 1,600,000 Btu/h.  
b. 8” W.C. with 11” W.C. flow on burners with inputs  
from 2,000,000 Btu/h through 3,200,000 But/h.  
c. For inputs above 3,200,000 Btu/h, refer to the tag  
attached to the gas train for the correct inlet  
pressures.  
C. If the required manifold cannot be reached, check  
the inlet pressure. It should be a minimum of that  
shown above with the burner running on full input. It  
is important that the incoming pressure does not fall  
below these minimums or nuisance control lockouts  
could occur.  
19. Burners with pilot:  
A. Connect the manometer to the manifold test port at  
the shutoff valve closest to the burner. Turn the main  
gas shutoff valve off. Set the air shutter as shown on  
the tag attached to the gas train, (see Figure 9-4 and  
9-5). This may not be the exact setting you end with,  
but it is a good starting point. Turn the unit on using  
the rocker switch on the side of the control enclosure  
assembly and the toggle switch on the burner. If the  
operating control switches are closed, the burner  
should come on and pre-purge begin.  
NOTE: Where low gas pressure is a problem, special  
arrangements may have been made to fire the burner  
with reduced pressure. The appliance data decal will  
reflect this information.  
B. If nothing happens, check the control to be sure it is  
not in the tripped position and reset it by pushing  
PV500-9 04-2000  
(3)  
 
Section 9  
POWER GAS BURNER START-UP (Con’t)  
20. Direct Spark Ignition – (DSI) Burners – No pilot:  
STACK TEMPERATURES  
MAX. GROSS  
1. Connect a manometer to the manifold test port. Set  
the air shutter as shown on the tag attached to the  
gas train. This may not be the exact setting you end  
up with, but it is a good starting point. Turn the unit  
on using the rocker switch on the side of the control  
enclosure assembly. The burner should come on  
and ignition occur. If the burner fails to ignite, there  
may have been air in the line. To reset the control,  
turn the switch off for 60 seconds (S89 controls only)  
and it should automatically reset or push the reset  
button on the control. Once the burner fires, set the  
manifold pressure at the valve shown on the tag  
attached to the gas train. There will a tap on the  
downstream side of the valve to measure pressure.  
The manifold pressure must be taken downstream of  
the gas valve. Check the incoming pressure with the  
burner running. This is recorded as flow pressure  
and must be a minimum of 8” W.C.  
*MIN. NET  
STACK  
SERIES  
STACK  
PG  
(Vertical Tube)  
TP  
550°F  
300°F  
TPO  
TPGO  
375°F  
300°F  
TABLE 9-1  
* Net temperature is the total stack temperature, less room temperature.  
22. On burners with pilots, recheck pilot to make sure its  
operation has not deteriorated if adjustments are made  
to the air shutter. To do this, shut off the main valve,  
check the flame response signal by cycling the burner  
through several lightoffs.  
23. Check each operating and limit control to be sure they  
function properly by lowering and raising the  
temperature setting on each control, causing the burner  
to cycle on and off.  
21. Make final settings of the air shutter by checking the  
flue gas analyzer.  
NOTE: During the initial firing of the burner, smoke that  
is not related to the burner will be emitted from the  
heater. This is normal during “burn in” and could  
possibly continue for several days.  
A. The readings need to be taken from a hole in the  
vent several inches above the heater vent  
connection, but before draft regulator.  
B. Insert draft gauge into the 1/4” test opening in the  
stack. Draft in stack should read -.02 to -.06 W.C.  
Adjust draft regulator, if installed.  
24. Record the following information for future use:  
C. When water in the tank is above 120°F°, insert CO2  
tester in 1/4” test opening and take CO2 reading in  
percentage. CO2 reading at this time will probably be  
below optimum.  
D. Gradually close the air shutter, taking CO2 reading at  
each adjustment of air shutter until optimum CO2  
percentage (8-10%) is reached. If CO2 percentage  
decreases, open air shutter to last reading where the  
greatest reading was achieved.  
A. Air shutter position__________________________  
B. Manifold gas pressure____________________"W.C.  
C. Stack draft_____________________________"W.C.  
D. CO2 reading______________________% (8%-10%)  
E. CO reading__________________% (less than .03%)  
F. Stack temperature:  
Gross_____________________________°F  
Less ambient_______________________°F  
Net_______________________________°F  
E. Insert CO tester in 1/4” test opening and take CO  
reading. CO should not exceed .03%. A reading  
greater then .03% indicates lack of air. Open air  
shutter slightly and take readings until CO is within  
proper range. Optimum reading is no CO.  
G. Thermal efficiency_________________________%  
F. If air shutter has been changed during CO test, take  
a final CO2 reading.  
G. Insert stack temperature gauge in 1/4” test opening  
and read gross stack temperature. Temperature  
should be as shown in Table 9-1. If an excessively  
high gross stack temperature is recorded, check the  
flue tubes for baffles. All tubes should have at least  
one baffle for TURBOPOWERâ modules. Record the  
length of the baffles on TURBOPOWERâ models for  
future use.  
H. Make sure the air shutter is locked securely in place.  
PV500-9 04-2000  
(4)  
 
Section 9  
REMOVAL OF THE NOZZLE ASSEMBLY  
(EXCEPT “L” SERIES BURNERS)  
Figure 9-2  
ELECTRODE POSITIONS  
“L,P,Q,R,S,T” SERIES BURNER  
Figure 9-3  
PV500-9 04-2000  
(5)  
Section 9  
 
AIR ADJUSTMENT  
FIXED AIR BURNERS  
Loosen the locking screw and move the arm (B) along  
the scale (C) to the position wanted and tighten the  
screw. Check the air adjustment by making a flue gas  
analysis.  
Figure 9-4  
AIR ADJUSTMENT  
VARIABLE AIR BURNERS  
Adjust first air shutter by loosening locking screw  
and move arm (B) along scale (C) to give best  
flame signal strength and most consistent light-off  
with pilot pressures set. Set second shutter linkage  
by installing linkage rod into ball joints of  
modulating motor and air damper shaft arm. With  
damper closed and modulating motor in full down  
position, set ball joints secured. Observe  
combustion reading through full range of  
modulation. Adjust as needed to obtain proper  
combustion efficiencies with carbon monoxide-free  
combustion. Make all adjustments with linkage in  
the low fire position. CAUTION: Do not allow the  
modulating motor to push the air damper past  
the full open or full closed position while  
making adjustments. Damage will occur. Record  
damper positions from indicator dials and hold  
linkage rod in ball joint with fingers as motor  
actuates to eliminate this risk. After correct damper  
movement is determined, tighten ball joint screws.  
Figure 9-5  
BURNER MOTORS  
No routine service is necessary on the blower system other than cleaning the blower wheel or oiling the motor when  
necessary. Blowers using three-phase motors will run in either direction depending on the connection of the power supply.  
On new installations, motor replacement or power supply disturbance, the rotation must be checked. Corrections can be  
made by interchanging any 2 wires of the three-phase power supply.  
NOMOGRAPH FOR DETERMINING FLUE LOSSES FROM CO2 AND FLUE TEMPERATURE FOR NATURAL GAS  
(STEADY STATE EFFICIENCY CAN BE DETERMINED FROM THE FLUE LOSS)  
PV500-9 04-2000  
(6)  
Section 9  
 
Figure 9-6  
NOTE: Nomograph is limited for use with Natural Gases with the following characteristics:  
Heating Value (gross) Btu/SCF - 970-1100; Specific Gravity - 0.57-0.70; Ultimate CO2 - 11.7-12.2.  
PV500-9 04-2000  
(7)  
Section 9  
 
NOMOGRAPH FOR DETERMINING FLUE LOSSES FROM CO2 AND FLUE TEMPERATURE FOR L.P. GAS  
(STEADY STATE EFFICIENCY CAN BE DETERMINED FROM THE FLUE LOSS)  
Figure 9-7  
NOTE: Nomograph is limited for use with L.P. Gas with the following characteristics:  
Heating Value (gross) Btu/SCF – 2466-2542; Specific Gravity – 1.522-1.574; Ultimate CO2 – 13.73-13.82.  
PV500-9 04-2000  
(8)  
Section 9  
 
TROUBLESHOOTING SUGGESTIONS  
GAS BURNER  
1. BURNERS FAILS TO START  
A. Defective On/Off or fuel transfer switch. Replace switch.  
B. Control circuit has an open control contact. Check limits, low water cutoff, proof of closure switch and  
others as applicable.  
C. Bad fuse or switch open on incoming power source. Correct as required.  
D. Motor overloads tripped. Reset and correct cause for trip out.  
E. Flame safeguard control safety switch tripped out. Reset and determine cause for apparent flame  
failure.  
F. Loose connections or faulty wiring. Tighten all terminal screws and consult wiring diagram furnished  
with the burner.  
G. Flame safeguard control starting circuit blocked due to flame relay being energized. Possible defective  
scanner or flame rod – replace. Possible defective amplifier – replace. Scanner actually sighting flame  
due to leaking fuel valve – correct unwanted flame cause. Defective flame safeguard control – replace.  
H. Defective blower motor. Repair or replace.  
2. OCCASIONAL LOCKOUTS FOR NO APPARENT REASON  
A. Gas pilot ignition failure. Check to see that ignition is instant and that flame signal readings are stable  
and above minimum values. Use a manometer or 0 to 10" W.C. gas pressure gauge to make certain that  
pressure is as recommended.  
B. Loose or broken wires. Check all wire nut connections and tighten all terminal screw connections in  
panel and elsewhere as appropriate.  
C. With flame safeguard controls that incorporate the air flow switch in the non-recycling circuit, ensure  
that when main flame lights, the air flow switch is not so critically set as to allow occasional momentary  
opening of the air switch contacts.  
D. Occasional low voltage supply. Have local utility correct. Make certain that the burner control circuit  
transformer (if supplied) is correct for the voltage and power (VAC) being supplied.  
E. Occasional low gas supply pressure. Have local utility correct.  
3. BURNER MOTOR RUNS, BUT PILOT DOES NOT LIGHT  
A. Gas supply to burner shut off – make sure all manual gas supply valves are open. Automatic high  
pressure valve at meter such as "Sentry" type tripped shut due to high gas pressure – reset valve and  
correct cause for trip out.  
B. Pilot solenoid valve not opening – listen and feel for valve actuation. Solenoid valve not being powered  
– check electrical circuitry. Replace coil or entire valve if coil is burned out.  
C. Defective gas pilot regulator – replace.  
D. Gas pressure too high or too low at pilot orifice (if supplied). Check orifice size in gas pilot assembly.  
Replace if incorrect. Readjust pressure as required.  
E. Defective ignition transformer – replace. Incorrect ignition electrode settings – readjust as required.  
F. Defective flame safeguard control or plug in purge timing card. Replace as required.  
G. Air flow switch not making circuit – check out electrically. Defective air flow switch – replace. Air switch  
negative pressure sensing tube out of position – reposition if necessary.  
4. BURNER MOTOR RUNS & PILOT LIGHTS, BUT MAIN GAS FLAME IS NOT ESTABLISHED  
A. Main shut off or test cock closed. Check to make certain fully open.  
B. Pilot flame signal reading too low to pull in flame safeguard relay. Readjust as required.  
C. Defective automatic main or auxiliary gas shut off valves. Check electrical circuitry to valves. Replace  
valves or correct circuitry as required.  
D. Main diaphragm shut off valve opening too slowly. Adjust bleed on valve.  
E. Defective flame safeguard control or plug in amplifier. Check and replace as required.  
F. Butterfly valve set incorrectly on modulating burner. Readjust as required.  
G. Main gas pressure regulator atmospheric vent line obstructed. Correct.  
H. Defective main gas pressure regulator – replace. Misadjusted main gas pressure regulator – readjust to  
meet required operational values.  
PV500-9 04-2000  
(9)  
Section 9  
 
TROUBLESHOOTING SUGGESTIONS  
GAS BURNER (Con't)  
5. CARBON MONOXIDE READINGS ON GAS FIRING  
A. Flame impingement on "cold" heat transfer surfaces caused by excessive firing rate. Reduce firing rate  
to correct input volume.  
B. Incorrect gas/air ratios. Readjust burner to correct CO2/O2 levels, eliminating all CO formation.  
6. GAS HIGH FIRE INPUT CANNOT BE ACHIEVED  
A. Gas company pressure regulator or meter operating incorrectly, not allowing required gas pressure at  
burner train inlet. Have gas company correct.  
B. Gas cock upstream of train inlet not fully open. Check and correct.  
C. Gas line obstructed. Check and correct.  
D. Gas train main and/or leak test cocks not fully open. Check and correct.  
E. Gas supply line between gas company regulator and burner inlet too small. Check supply pressure at  
meter, determine pressure drop and increase line size as required, or raise supply pressure to  
compensate for small line. Do not raise pressure so high that under static (no flow) condition the  
pressure exceeds the maximum allowable pressure to the gas train components on the burner.  
F. Burner gas train components sized too small for supply pressure. Increase component size as  
appropriate or consult factory.  
G. Automatic gas valve not opening fully due to defective operation. Replace gas valve.  
H. Orifice (if supplied) too small. Replace with correct size.  
I.  
On modulating burner, butterfly valve not fully opened. Readjust.  
J. Defective main gas pressure regulator. Replace.  
K. Incorrect spring in main gas pressure regulator. Replace as required.  
L. Main gas pressure regulator vent line obstructed. Check and correct.  
M. Normally open vent valve (if supplied) not closing when automatic gas valves open. Check to see if  
valve is fully closed when automatic valves are open. Replace vent valve, if not closing fully.  
Additional troubleshooting information can be found in the Flame Safeguard Control bulletin supplied with the burner.  
PV500-9 04-2000  
(10)  
Section 9  
 

Pelco Home Security System PT7800 User Manual
Pelco Pacemaker TW3004AR User Manual
Philips Cell Phone Accessories SCM7880 27 User Manual
Philips DVD Player MDV450 User Manual
Philips Flat Panel Television M2239CLE1T User Manual
Philips Indoor Furnishings 232835 User Manual
Poulan Trimmer 530087525 User Manual
Powermate Portable Generator PM0545006 User Manual
Precor Elliptical Trainer EFX 835 User Manual
PYLE Audio DJ Equipment PWMA 840 User Manual