Power Flame Incorporated

Series X4
Installation and
Operation Manual

Power Flame Incorporated

The Power to Manage Energy

2001 South 21st Street, Parsons, KS 67357

Telephone: 620-421-0480 FAX: 620-421-0948
Website: http://www.powerflame.com
e-mail: [email protected]

X4OM 07/01
Rev. 04/09

Copyright 2009 Power Flame Incorporated

 X4 Installation and Operation Manual - POWER FLAME INCORPORATED

Table of Contents
1. GENERAL INFORMATION .................................................................................. 4
2. CAPACITIES & SPECIFICATIONS ...................................................................... 4
3. ACCEPTANCE PROCEDURE ............................................................................. 5
4. INSTALLATION .................................................................................................... 5
5. GAS PIPING......................................................................................................... 7
6. WIRING .............................................................................................................. 10
7. START UP.......................................................................................................... 10
8. COMBUSTION ARRANGEMENT REQUIREMENTS......................................... 14
9. SERVICE/MAINTENANCE SUGGESTIONS...................................................... 15
10. BURNER PARTS LIST X4.................................................................................. 16
11. SEQUENCE OF OPERATION FOR X4M BURNER .......................................... 19
12. X4M HTD (High Turn Down)............................................................................... 23

List of figures
Figure 1: Mounting in Heat Exchanger ............................................................................ 5
Figure 2: Mounting in Boiler Base ................................................................................... 6
Figure 3: UL Gas Piping Train (X4) – See Figure 14, page 21, for X4M ......................... 8
Figure 4: Location of Side Orifice .................................................................................... 8
Figure 5: Typical Wiring Diagram for S8680J with Proved Pilot Ignition.......................... 9
Figure 6: Typical Wiring Diagram for S89F with Direct Spark Ignition ............................. 9
Figure 7: Pilot/Gun Assembly – Flame Rod Type – Natural Gas/LP Gas...................... 11
Figure 8: Detail Pilot Assembly ..................................................................................... 11
Figure 9: Detail Direct Spark Gun Assembly ................................................................. 13
Figure 10: X4 general assembly and parts.................................................................... 17
Figure 11: X4M general assembly and parts................................................................. 17
Figure 12: X4 specifications and dimensions ................................................................ 18
Figure 13: Typical Wiring Diagram For X4M with LF-24 Actuator.................................. 20
Figure 14: General Arrangement Diagram for X4M (AMCX-24).................................... 21
Figure 15: Belimo LF24-SR-S Actuator ......................................................................... 21
Figure 16: Belimo AMCX-24 Actuator ........................................................................... 22
Figure 17: X4M Firing Rate vs Manifold Pressure......................................................... 22

List of tables
Table 1: X4 Specifications............................................................................................... 4
Table 2: Combustion Chamber Recommended Dimensions........................................... 6
Table 3: Gas Piping Pressure Drop Data ........................................................................ 7
Table 4: Equivalent length in feet for fittings.................................................................... 7
Table 5: Natural/LP Gas Orifice Pressure Settings/Flow Rate ...................................... 14
Table 6: firing rate and damper opening for X4M-HTD.................................................. 23

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 X4 Installation and Operation Manual - POWER FLAME INCORPORATED

POWER FLAME MODEL X4 BURNER

For use by Qualified Service Personnel Only
Rev. 03/2009

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.

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

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1. GENERAL INFORMATION

1.1 The X4 burner is a new generation of gas power burners designed to fire natural gas and
propane against a positive furnace pressure.

1.2 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.

1.3 All Power Flame burners are operationally fire tested at the factory.

1.4 Nomenclature:

Modulating

Burner name X4 M - 700 - HTD High Turn Down

Firing input

2. CAPACITIES & SPECIFICATIONS

BURNER SPECIFICATIONS
X4-400 150,000 – 400,000 Fuel Type Natural or LP Gas

X4-700 200,000 – 725,000 Blast Tube Length 9", 12"

Input Capacity
(Btu/hr)
X4M-400 150,000 – 400,000 Voltage 120V, 60 Hz

X4M-700 90,000 – 725,000 Amp Rating 5.0 Amp

X4-400 3/4" Motor 1/4 Hp 3450 RPM

X4-700 1" Transformer 40VA, 24 VAC

Gas Train Size
X4(M)-400 Honeywell
X4M-400 3/4"
w/direct spark VR8305M
X4(M)-400 Honeywell
X4M-700 1" Gas Valve
w/proved pilot VR8304M
X4(M)-700 Robert Shaw
X4-400 6-1/4" x 2-3/4"
w/proved pilot 7000DERHC-S7A

X4-700 7" x 3" direct spark Honeywell S89F

Blower Wheel Size Primary Control
X4M-400 6-1/4" x 3-3/4" proved pilot Honeywell S8680J

Max Inlet Pressure to Main

X4M-700 7" x 3" 14" W.C.
Shut-off Cock

Table 1: X4 Specifications

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3. ACCEPTANCE PROCEDURE

3.1 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.

3.2 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

4.1 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.

4.2 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.

4.3 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

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Figure 2: Mounting in Boiler Base

4.4 Combustion chamber sizing:

Gas Input Width Length

MBTU/HR Inches Inches
250 13 17
450 15 20
600 16 23
700 17 25
850 18 26
Table 2: Combustion Chamber Recommended Dimensions

4.5 Whichever method of mounting is chosen, the burner blast tube must be recessed into the front
wall surface from 0” to 1/2”.

Serious Damage To The Burner May Result If The Blast Tube Is Extended Into The
Combustion Chamber.

4.6 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.

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5. GAS PIPING

5.1 Contact your 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 3. 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 4).

EQUIVALENT LENGTH OF STRAIGHT PIPE IN FEET

20 30 40 50 60 80 100 150 200
Pipe Size In Inches CFH GAS WITH 0.2” 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

Table 3: Gas Piping Pressure Drop Data

EQUIVALENT LENGTHS OF STANDARD PIPE

IN FEET FOR LISTED FITTINGS
Nominal Pipe Size In Inches 3/4 1 1-1/2 1-1/2 2 2-1/2
Std. Tee 2.4 5.5 7.5 9 12 13.5
Fitting Type
Std. Elbow 4.4 2.7 3.7 4.5 5.5 6.1

Table 4: Equivalent length in feet for fittings

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 drip leg and main gas cock upstream of regulator
or automatic valve(s).

5.6 The pilot line should be piped into the upstream tapped nipple to minimize pilot line piping length.
An optional location is in a tapping located on the main shut-off cock. Refer to Figure 3. For
ease of servicing we recommend the use of a union immediately upstream of the main gas
pressure regulator or combination gas valve/pressure regulator.

5.7 Install vent lines from main gas regulator (if used) and diaphragm gas valve where applicable.
Vent lines should be run to the outside of the building, terminating clear of windows or fresh air
intakes. Outside termination of vent should have a screen to prevent insects from building nests
in vent pipe. The vent should terminate in a manner, which will preclude the possibility of water,
dirt or other foreign matter from entering the line.

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Figure 3: UL Gas Piping Train (X4)

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 orifice size is correct according to burner specification sheet (See Figure 4). To
gain access to orifice, remove Plug A and withdraw spring and orifice. When reinserting or
replacing the orifice, ensure that it seats properly inside the tee and reinstall plug.

Figure 4: Location of Side Orifice

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Figure 5: Typical Wiring Diagram for S8680J with Proved Pilot Ignition

Figure 6: Typical Wiring Diagram for S89F with Direct Spark Ignition

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6. WIRING

6.1 Refer to wiring diagram shipped with burner and typical wiring diagrams Figures 5 and 6. The two
power leads (black and white) are located inside the burner panel.

6.2 Electrical installation must be made in accordance with the NEC NFPA 70 or Canadian Electrical
Code, Part 1 and applicable local codes. If this burner is part of a boiler or furnace package
system, check wiring diagram as supplied by the boiler or furnace manufacturer.

7. START UP

7.1 Before attempting a burner start up, thoroughly study and familiarize yourself with 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 water level (if applicable).

7.3 Lay out combustion test equipment (see Section 8.3).

7.4 Attach gas pressure gauge or manometer to upstream side of main gas cock (0-35” w.c.) and to
orifice pressure tap (0-10” w.c.) as well as to pilot gas pressure test tee tapping (0-10” w.c.).

7.5 Check the voltage at the disconnect switch to make certain that it matches that indicated on the
burner label.

7.6 Ensure that all dampers in the flue or stack are fully open.

7.7 Install stack thermometer and Flue Gas Analyzer sample line into breeching and connect the draft
gauge to combustion chamber test point.

7.8 Connect a microammeter to the Primary Safety Control as directed in the PSG control
manufacturer’s instruction bulletin to determine flame detection system values. The meter is
normally connected in series with the (SENSE) terminal on the S8600 or S89F series control.

7.9 With the main and leak test cocks and pilot cock in OFF position, turn on the gas cock at meter.
Check to make certain that pressure upstream of main and pilot cocks does not exceed 14” w.c.
(1/2 PSIG) – unless special valve train components suitably rated have been 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.

7.10.1 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 application.
Refer to Fig. 7 and 8.

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7.10.2 To prepare the pilot for proper operation, it is essential that appropriate adjustments be
made to the burner air inlet damper and the pilot gas pressure. See Table 5 for the
approximate air damper setting at the various firing rates. Typical pilot test pressures are
3” to 4” w.c. for natural and propane gas. Normally, lower pressures are required for air
damper openings of 50% or less.

7.10.3 Frequently the cause for pilot problems relates to gas pressures that are too high and/or
air dampers that are closed too far. Both conditions can cause a fuel rich mixture in the
pilot chamber which can substantially delay or totally prevent pilot ignition.

Figure 7: Pilot/Gun Assembly – Flame Rod Type – Natural Gas/LP Gas

Figure 8: Detail Pilot Assembly

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7.11 With the leak gas cock closed and pilot gas cock opened (if provided); turn the burner switch ON.
The blower motor will purge the heat exchanger of any accumulated combustibles. At the end
of the purge cycle, the pilot solenoid valve will energize and spark will be initiated. The pilot will
attempt to light for 15 seconds. Adjust the pilot pressure at this time. If the pilot fails to light,
power must be removed from the control for 60 seconds to allow it to reset. Note: If the leak test
cock is not provided, remove the main gas valve wire (MV) from the control to prevent the main
valve from energizing during the pilot adjustment period.

7.12 Pilot Adjustment and Main Flame Light Off Procedure

7.12.1 Set the air flow (see Table 5) and pilot gas pressure in order to provide instant pilot
ignition, good flame stability and a strong/steady signal reading. This can be
accomplished as follows: Start with the pilot pressure at the minimum adjustment on the
regulator. When the pilot valve energizes 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.

7.12.2 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 relight the pilot at this pressure. If relight occurs this is the upper limit of the pilot
pressure. Now set the pilot pressure between the minimum and maximum pressure.
This range is typically 1” w.c..

7.12.3 After attaining the proper pilot flame signal values, cycle the pilot off and on several times
in order to ensure reliability (with the gas leak test cock still closed). Turn Burner
Switch Off.

7.12.4 Having established pilot reliability, open gas leak test cock.

7.12.5 After burner has completed pre-purge and established a good pilot flame signal reading,
the main automatic fuel valve will be energized. The main flame should light
immediately. If light off does not occur, it is possible that air will need to be purged from
the main gas line. Adjust main gas pressure regulator (if used) or combination valve
regulator to obtain the desired firing rate pressure.

7.12.6 Adjust burner as necessary to provide smooth ignition of main flame. If pilot flame signal
drops significantly when main fuel valve opens, increase pilot gas pressure slightly to
obtain a reasonably stable flame signal value.

7.12.7 Select and install the main orifice that corresponds to the desired firing rate. Make
certain that the airflow setting provides the correct CO2 or O2 levels and other combustion
values at the proper firing input rates.

7.12.8 See Section 8 and Table 5 for firing rate information. Generally accepted values for
natural gas are 8½ to 10% CO2 or 5½ to 3% O2. Equivalent CO2 readings on propane
gas are 10 to 11½% CO2 or 5½ to 3½% O2. It is important that the CO (carbon
monoxide) level is checked and held at 0% or minimum (typically under 100 ppm or
0.01%). Check with local utility and any other authorities having jurisdiction before
making final burner adjustments.

7.13 Direct Spark Ignition (S89F control)

7.13.1 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 application.
Refer to Figure 9 to verify the correct position of the ignition electrode placement since
shipment may have altered the placement.

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7.13.2 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.

7.13.3 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 any accumulated
combustibles. At the end of the purge cycle, typically 35 seconds, the combination valve
will be energized and a spark will be initiated. The trial for ignition will be approximately
three seconds.

7.13.4 Complete setup in accordance with item 7.12.7 and 7.12.8 above.

7.13.5 If ignition failure occurs the main power must be switched off for at least one minute to
allow the control to reset. Refer to the Service/Maintenance section for further
information on Direct Spark Ignition.

Figure 9: Detail Direct Spark Gun Assembly

7.14 Conduct all applicable test procedures shown in control manufacturer’s bulletins included with
burners. Set and check operation of low and high gas pressure switches (if applicable), all burner
and heat exchanger controls, and operating devices. Check blower airflow switch by first closing
main gas cock and disconnecting motor lead wire. A properly adjusted air switch should open
within 3 to 4 seconds when the power is removed from the motor.
7.15 Clean up area around the burner and instruct owner and/or operator.

7.16 Post Operating Instructions card (inside back cover) close to the burner in clearly visible position.

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8. COMBUSTION ARRANGEMENT REQUIREMENTS

8.1 The X4 burner has been designed to fire with high combustion efficiency into combustion
chambers with positive, balanced or negative pressures using natural or LP gas only.

8.2 In order to fire efficiently, the burner requires an adequate supply of combustion air. Ventilation to
any enclosed area should be provided on the basis of ½ square inch of opening for each 1000
BTU/HR input. This excludes the requirement for any other fired equipment in the area. The
enclosed area should not become excessively hot and under no circumstances should be under a
negative pressure.

8.3 The burner should be initially set up and serviced at regular intervals (preferably at the beginning
of and mid way through high use periods) by a trained serviceman using the proper test
instruments. Failure to maintain the correct burner settings may result in inefficient gas
consumption, premature wear of burner components or explosion hazard.

8.4 Approximate gas flows and pressures are shown in Table 5 for natural gas and LP gas. Actual
firing rates should be verified by clocking the gas meter and applying the appropriate correction
factor.

X4-400
MBH Natural Gas MBH LP Gas
Approx. Damper Position
Main Orifice 1000 BTU/CF 2500 BTU/CF
Diameter/I.D.#
2" w.c. 3" w.c. 4" w.c. 2" w.c. 3" w.c. 4" w.c. MBH Indicator #

0.203 / 1 133 180 198 150 1

0.234 / 2 158 196 227 200 2
0.265 / 3 150 183 210 213 250 287 300 3
0.281 / 4 175 215 248 219 264 292 400 4
0.343 / 5 200 245 280 298 351 389
0.406 / 6 225 274 316 370 431
Note: Pilot pressure is different
0.468 / 7 275 338 390 410
at each damper position and
0.500 / 8 295 360 415 must be set at each position.
None 400

X4-700
MBH Natural Gas MBH LP Gas
Approx. Damper Position
Main Orifice 1000 BTU/CF 2500 BTU/CF
Diameter/I.D.#
2" w.c. 3" w.c. 4" w.c. 2" w.c. 3" w.c. 4" w.c. MBH Indicator #

0.203 / 1 174 201 200 1

0.234 / 2 162 198 239 300 1 3/4
0.265 / 3 120 148 171 194 227 272 400 2
0.281 / 4 131 163 189 201 250 285 500 3
0.343 / 5 186 230 269 273 335 387 600 4
0.406 / 6 246 302 394 383 470 541 700 6
0.468 / 7 306 372 433 472 578 667 725 9
0.500 / 8 326 394 454 497 609 725 Note: Pilot pressure is different
None 451 563 652 At each damper position and
725 @ 4.8" w.c. Must be set at each position.

Table 5: Natural/LP Gas Orifice Pressure Settings/Flow Rate. NOTE: Pressure taken at
Combination Valve Pressure Tap Upstream of Orifice

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8.5 The correct test instruments are:

1) O2 analyzer (electronic or Fyrite absorption system)
2) CO indicator (Monoxor or similar)
3) Stack thermometer
4) Draft gauge or inclined manometer
5) U-tube manometer or calibrated 0-10” and 0-35” w.c. pressure gauge
6) Combination volt/ammeter
7) D.C. Micro-Ammeter

9. SERVICE/MAINTENANCE SUGGESTIONS

9.1 Burner fails to start:

1) Bad fuse or switch open on in-coming power source, or motor overload out.
2) Control circuit has an open control such as operating, limit or low water cut-off.
3) Push the reset button on the motor or open the power circuit to the primary safety control.
4) Loose or faulty wiring. Tighten all terminal screws. Check wiring, against wiring diagram
furnished with burner.
9.2 Burner motor runs, but pilot does not light:
1) Be sure gas is turned on at meter and pilot cock is open.
2) Place hand on pilot valve to “feel” it open. Check gauge at tee in pilot line for gas
pressure and prompt opening of pilot valve.
3) Check visually or by sound for spark arcing.
4) Refer to section 7.10 on pilot checking procedures.
5) Check air switch and be sure its circuit closes during start.
9.3 Burner motor runs, pilot lights, but main gas valve does not open:
1) Check flame signal. If signal is low, adjust pilot 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 micro-amp 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 porcelain for damage or breaks, which could cause
short.
3) Check for loose or broken wires.
9.5 Burner will not start, even though burner had never failed before or had been running on normal
cycling without failure:
1) Operating Control circuit open.
2) Defective control or loose wiring.
3) Limit circuit open.

9.6 The burner must be periodically inspected to insure safety and performance. All maintenance
must be performed with the main electrical power off and the main gas shutoff valve off:
1) Inspect blower inlet screen and clean any buildup of lint.
2) Inspect blower wheel blades and clean any buildup of dirt.
3) Inspect ignition electrodes and wiring for any cracks that may cause shorting.
4) Oil the blower motor at the manufacturer’s recommended intervals.

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5) Verify that the pilot and or direct spark electrodes are still within specifications (set per
drawing 7, 8 and 9 in this manual).
6) Verify the proper operation of the Primary Safety Control, airflow switch, and operating
controls.
7) Check safety gas shutoff valves for gas tightness.
9.7 In the event of extended shutdown, the main power should be turned off and the main manual
gas shutoff valve should be closed.

EMERGENCY SHUTDOWN: Should over-heating occur, (1) shut off the manual
gas valve to the appliance, (2) do not shut off the control switch to the feed water
pump or blower.

9.8 An additional source of information relative to trouble shooting can be found in the Flame Safeguard
Control Manual supplied with the burner.

10. BURNER PARTS LIST X4

1 Burner Housing 24 Pilot Tubing

2 Inlet Ring 25 Pilot Assembly
3 Blast tube (6”, 9”, 12”) 26 Ignition Electrode
4 Gun Assembly 27 Flame Rod
5 Flange Gasket 28 Back Plate
6 Mounting Flange 29 Inner Damper
7 Blower Wheel 30 Middle Damper
8 Motor Plate 31 Outer Damper
9 Blower Motor 32 Air Sensing Tube
10 Air Switch 33 Orifice Kit
11 24 Volt Transformer 34 Direct Spark Transformer
12 Panel & Door 35 Gas Piping Support Bracket
13 Flame Monitor 36 Damper Axle
14 Grounding Lug 37 Relay
15 Nipple Tapped 38 5/16” Ball Joint Swivel
16 Gun Head 39 Mod Motor
17 Side Orifice tee 40 Butterfly Valve
18 Side Orifice Spring 41 5/16” Linkage Rod
19 Pilot Regulator 42 Light
20 Pilot Solenoid Valve 43 Axle Bushing
21 Combination Gas Valve 44 1/2” Damper Arm
22 Main Gas Cock 45 Pie DPR Retainer Washers
23 Pilot Gas Cock

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Figure 10: X4 general assembly and parts

Figure 11: X4M general assembly and parts

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Figure 12: X4 specifications and dimensions

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11. SEQUENCE OF OPERATION FOR X4M BURNER

LF-24 BELIMO ACTUATOR

11.1 Refer to typical wiring diagram for X4M burner (Figure 13). Upon a call for heat, the blower motor
starts, closing the combustion air switch. Power is supplied to the 24-vac transformer. Initially
power to the actuator is held out through one set of normally open contacts on the 24-vac relay.

11.2 Since power is not supplied to the actuator it will spring return clockwise to the open damper
position if not already there. When the actuator reaches the full clockwise position (full open
damper) the internal auxiliary end switch closes (S1 to S3).

11.3 24-vac power will be supplied through the S1 – S3 contacts and the combustion air switch to the
S8680 control.

11.4 The control will begin its pre-purge time period of approximately 30 seconds.

11.5 At the end of the pre-purge period, a trial for ignition will 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 interlocks the high fire auxiliary end switch.
Another set of relay contacts closes and completes the modulation circuit.

11.8 Modulation of the burner is now accomplished by the control signal. Depending on the setting of
the Direction Control Switch located on the actuator (Figure 15), a low or high input signal can
drive the actuator clockwise or counterclockwise (low fire or high fire).

11.9 An adjustable stop located on the actuator (Figure 15), can be used to limit the high fire or low fire
position. If the high fire damper position is changed due to a lower than maximum firing rate, the
pilot should be rechecked at this new damper position.

AMCX-24 BELIMO ACTUATOR

11.10 The AMCX actuator is available with control signal inputs of 2-10 vdc, 4-20 mA or 0-135 ohm.
Therefore, refer to the specific wiring diagram supplied with the burner.

11.11 Upon a call for heat, the blower motor starts, closing the combustion air switch. Power is
supplied to the 24-vac transformer which powers the AMCX actuator causing it to drive to the
open damper position.

11.12 When the damper opens to the high fire position the high fire end switch (purge switch) closes
which provides power to the ignition control (S8670).

11.13 The control will begin its pre-purge time period of approximately 30 seconds.

11.14 At the end of the pre-purge period, a trial for ignition will 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.

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11.15 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.

11.16 One set of normally open relay contacts close which interlocks the high fire auxiliary end switch.
Another set of relay contacts closes and completes the modulation circuit.

11.17 Modulation of the burner is now accomplished by the control signal. Depending on the setting of
the Direction Control Switch located on the actuator (Figure 15), a low or high input signal can
drive the actuator clockwise or counterclockwise (low fire or high fire).

11.18 An adjustable stop located on the actuator (Figure 15), can be used to limit the high fire or low fire
position. If the high fire damper position is changed due to a lower than maximum firing rate, the
pilot should be rechecked at this new damper position.

Figure 13: Typical Wiring Diagram For X4M with LF-24 Actuator

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X4 Installation and Operation Manual - POWER FLAME INCORPORATED

Figure 14: General Arrangement Diagram for X4M (AMCX-24)

Figure 15: Belimo LF24-SR-S Actuator

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Figure 16: Belimo AMCX-24 Actuator

Manifold Pressure vs. Firing Rate

4
X4M-700
Manifold Pressure "w.c. (net)

3.5
3
X4M-400
2.5
2
1.5
1
0.5
0
0 100 200 300 400 500 600 700 800
Firing Rate (MBH)

Figure 17: X4M Firing Rate vs Manifold Pressure

11.19 The manifold pressures shown are the gas pressures taken at the 1” tee and represent a zero
furnace pressure (net manifold pressure). Therefore, the actual furnace pressure 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 17 shows 2.5” w.c. net manifold pressure is
equal to 400,000 BTUH.

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12. X4M HTD (High Turn Down)

12.1 The main difference between the X4M and X4M-HTD is the use of the 1/3 hp ODP motor on the
HTD model to prevent air infiltration at the low end of the firing rate.

12.2 Each of the HTD model’s maximum firing rate may be reduced by either lowering the combination
valve regulator outlet pressure or by placing an orifice in the orifice tee (see Fig. 4, page 8 for the
orifice location). It is not necessary to use a main gas orifice except when it is desired to further
reduce the burner’s maximum firing rate. See table 5 for orifice sizes and approximate pressures.

12.3 When no orifice is used, refer to the pressure/rate on figure 17, page 22 for the approximate
manifold pressure (taken on orifice tee) for a given firing rate.

Burner Firing Rate Orifice Tee Damper Opening

Model Min/Max (BTUH) Pressure (no orifice) @ High Fire
X4M-400-HTD 35,000/400,000 Wide Open
X4M-400-HTD 35,000/350,000 2” (approximate)
See page 22
X4M-400-HTD 35,000/250,000 1-1/8” (approximate)
X4M-700-HTD 60,000/725,000 Wide Open
Table 6: firing rate and damper opening for X4M-HTD

12.4 The setting up of the X4M-XXX-HTD is identical to that of the standard X4M burner. Follow the
same procedures as listed in this I&O manual.

12.5 When properly setup the burner will operate between 6% and 11% excess 02 at the low fire rate
while maintaining less than the maximum allowable air free CO of 400 ppm.

12.6 As with the standard modulating X4M burner the HTD version is designed to light off at the high
fire (open damper) position. At this position the pilot performance is improved and a full open
damper air purge is accomplished.

12.7 When the burner is set up to fire at a reduced maximum firing rate and the damper opening is set
accordingly, the high fire switch located on the Belimo actuator must be set to close at this
position. Power will not be provided to the flame control module until the switch closes.

12.8 For specific wiring connections, refer to the wiring diagram provided with each burner as listed in
the burner’s As Built Sheet.

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OWNER OPERATING INSTRUCTIONS

WARNING
Improper installation, adjustment, alteration, service or maintenance can cause injury or property
damage. Refer to the burner manual for assistance or additional information consult a qualified
installer, service agency or the gas supplier.

Do not store or use gasoline or other flammable liquids and vapors in the vicinity of this or any
other appliance.

START UP FOR YOUR SAFETY

Preparation for Start Up If you smell gas:
1) Ensure that the system is in working order. If 1) Open windows
heat exchanger is a boiler, ensure that 2) Do not touch electrical switches
proper water level is available. 3) Extinguish any open flame
2) Set the burner control panel switch to the 4) Call you gas supplier immediately
OFF position.
3) Turn the thermostat or operating control
down to its lowest setting. IMPORTANT PRECAUTIONS
4) Check fuses and replace as necessary. 1) Never attempt to light burner with paper or
5) Depress the flame safeguard programming other materials.
control reset button 2) Never experiment with the burner.
Start Up 3) Never change the fuel or air adjustments
1) Manually open and close the main gas shut without consulting with the burner service
off cock, leak test cock and pilot cock to company.
determine that they operate freely. Open all 4) Never attempt to light the burner if
three cocks. (Reset low gas pressure switch combustion chamber contains any unburned
if supplied). fuel or gases.
2) Set the main power switch and burner panel 5) Never throw waster paper, rags, garbage or
control switch to the ON position. Wait 30 other waster materials into the combustion
seconds and turn up thermostat or operating chamber.
control to the desired setting. 6) Never wash out heating equipment room
3) The burner blower motor will start and after a without first covering the burner with
suitable pre-purge period (this will vary with waterproof material.
the type of flame safeguard control supplied
– but will usually be minimum of 30 seconds
to a maximum of 90 seconds) the burner pilot
will light, after which the main flame will be MAINTENANCE
established. Burner should be maintained and serviced by a
4) If the system does not respond properly, qualified service agent. See service and
contact your qualified burner service maintenance section of the manual for
company. suggestions on periodic maintenance and
service.

EXTENDED SHUT DOWN

1) Place main power switch and burner control
panel switch in the OFF position.
2) Close all valves in gas lines. POWER FLAME INCORPORATED
3) Cover burner to protect it from dust and 2001 South 21 St. Street, Parsons, KS 67357
dampness. 620-421-0480, FAX 620-421-0948

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