PVI Industries FIREPOWER B40 User Manual

INSTALLATION & MAINTENANCE MANUAL FOR



PVI FIREPOWER

B40 OIL BURNER

1.0 thru 10.0 gph

CARBON MONOXIDE WARNING:

CAUTION: IMPROPER COMBUSTION MAY CAUSE SERIOUS INJURY.

PVI recommends a seasonal or annual combustion check-out be performed by a

qualified service agency to ensure safe and efficient operation.

Typical Construction

Figure 22A-1

1. Burner housing 12. Pump coupling

2. Mounting flange 13. Fan wheel

3. Flange gasket 14. Fan motor

4. Blast tube 15. Flame safeguard

5. Oil nozzle assembly 16. Ignition transformer

6. Ignition electrodes 17. Damper assembly

7. Housing plug 18. Housing cover

8. Connecting pipe 19. Locating block

9. Electric oil valve 20. Scanner or photocell

10. Oil pump 21. Control enclosure

11. Oil strainer

PV500-22A 08-98 1 Section 22A

PVI FIREPOWER

B40 OIL BURNER

1. Wiring to the unit should conform to the
National Electrical Code or the code legally
authorized to your locality. A fused disconnect
switch should be used for water heater
control. Service wiring connections of 115V, 1
phase, 60 Hz. are located in the enclosure on
the water heater. (See Figure 22-10, pg. 14.)

FOR YOUR SAFETY

DO NOT store or use gasoline or other

flammable vapors and liquids in the

vicinity of this or any other appliance.

FOR YOUR SAFETY

WARNING: Improper installation,
adjustment, alteration, service or

maintenance can cause injury or

property damage. Refer to this manual

for assistance, or consult a qualified

service agency.

ELECTRICAL

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NOTE: Use only copper wire of proper sizing
for incoming service. Damage resulting from
use of aluminum wiring will be excluded from
coverage under the warranty of this unit.

PV500-22A 08-98 2 Section 22A

PVI FIREPOWER

B40 OIL BURNER START-UP

(Refer to Figure 22-1 to identify burner parts)

1. Remove the enclosure panel cover on the water
heater or boiler to expose the control circuit. The
wiring diagram, located on the backside of the
cover, will show the controls used in our circuitry.

2. Visually check that all components are intact and
no damage has occurred during transit.

3. Check all connections in control cabinet. A loose
connection could cause intermittent shutdowns.

4. Check oil supply lines to insure proper practices
have been followed and installation complies with
local codes. Use only a two-pipe system. Check
for adequate burner intake air supply.

NOTE: Do not tamper with or readjust program
dipswitch settings. This will cause the control
to become inoperable. Damage resulting from
tampering will be excluded from coverage
under the warranty of this unit.

5. Remove the flame safeguard control from its
base. Check the connections in control mounting
base; loose connections can cause nuisance
shutdowns. When applicable, check the time card
or programmer, for good connection.

6. With electrodes exposed, check them for the
proper settings as in Figure 22-4 & 7, pages 7 & 8.
Check for any hairline cracks in the insulators.
Should replacement of burner electrodes be
required, certain procedures must be followed. In
all cases, removal of electrodes is accomplished
by loosening the electrode mounting clamps.
Draw electrodes out of the nozzle assembly
through the holes in the pressure plate.

7. Open manual oil valve(s). Make certain check
valves are positioned for the correct oil flow. There
should not be a manual shut-off valve in the return
line from the pump to the tank.

8. Pull the nozzle assembly to check the ignition
electrodes. See Figure 22-3 & 6, pages 7 & 8.

9. Inspect the electrodes for cracked ceramic or
loose retaining studs that hold the wire within the
ceramic. Select the proper pressure plate hole to
place each electrode and insert the electrode
through the hole, retaining stud end first.

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10. Tighten the electrode mounting clamp slightly until
electrode ceramics are seated firmly and
completely in the mounting bracket without gaps
between ceramics and mounting bracket at the
bearing faces.

11. Measure and set electrodes according to Figure
22-4 & 7, pages 7 & 8. After gaps and setting are
complete, fully tighten electrode mounting clamp.

Do not overtighten or insulation may crack.

12. Replace nozzle assembly; be sure to connect the
spark rod wires before installing nozzle assembly
fully into blast tube. Check connections on the
ends of the flame and spark rod wires for good
contact. Look for properly stripped wire ends. Be
sure connectors are firmly attached to the ignition
rod ends. Insulating boots can give a false feeling
of proper seating. DO NOT MOVE
ELECTRODES. Be careful not to bump
electrodes. Check fan wheel for free rotation.

13. 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 MC120
series control has two terminals marked for
reading volts DC.

14. Be sure tank is filled with water. Once the burner
is reassembled, a gauge to read pressure,
preferably a 300 psi gauge, will be needed to read
oil pressures. Connect gauge to the pressure side
of the oil pump. Connect vacuum gauge to supply
side of oil pump (15”HG maximum allowed).

15. Single stage oil burners. Before turning the unit
on, make sure all valves in the oil supply and
return lines are on. Check the air damper setting
against the setup tag attached to the burner.
Turn the unit on using the rocker switch on the
side of the control cabinet. If the operating
control switches are closed, the burner blower
should come on and prepurge begins.

If nothing happens, check the control to be sure it
is not in the tripped position and reset it by
pushing the flame safeguard reset button. Burner
should prepurge for no more than thirty seconds.

PV500-22A 08-98 3 Section 22A

PVI FIREPOWER

B40 OIL BURNER START-UP (con't)

After purging is complete, terminal 3 energizes
the oil valve and terminal 4 energizes the ignition
transformer. The flame is then established and
the VDC reading on the meter should read a
steady 14-18 VDC for photocell or 4-6 VDC for
UV amplifiers. Each different control will have the
required flame response signal stamped on it.
This is the minimum for it to properly operate. If
the burner fails to light during the initial period, it
is probably due to air in the line. The control will
lock out. Push the flame safeguard reset button
to restart burner and begin the purge cycle again.

Once the flame is established, set the oil
pressure (measured at the oil pump) at the
pressure shown on the tag attached to the
burner. Oil pressure should be adjusted while
firing on the second stage. Do not exceed the oil
supply pressure specified on the setup tag.

16. Two stage oil burners. Before turning the unit
on, make sure all valves in the oil supply and
return lines are on. Check the first stage air
damper setting against the setup tag attached to
the burner. The second stage air setting must be
adjusted while the burner is operating. Turn the
unit on using the rocker switch on the side of the
control cabinet. If the operating control switches
are closed, the burner blower should come on
and prepurge begin.

If nothing happens, check the control to be sure it
is not in the tripped position and reset it by
pushing the flame safeguard reset button. The
burner should prepurge for no longer than thirty
seconds.

After purging is complete, terminal 3 energizes
the oil valve and terminal 4 energizes the ignition
transformer. The flame is then established and
terminal 5 energizes the main oil valve after a
short delay. This will simultaneously supply oil to
the second stage oil nozzle and the damper
actuator, driving the damper open. The burner
can be temporarily locked in the first or second
stage by adjusting the low-fire hold switch. The
VDC reading on the meter should read a steady
14-18 VDC for photocell or 4-6 VDC for UV
amplifiers. Each different control will have the
required (minimum) flame response signal
stamped on it. If the burner fails to light during the
initial period, check for air in the line. The control
will lock out. Push flame safeguard reset button
to restart burner and begin purge cycle again.

Once the flame is established, set the oil pressure
(measured at the oil pump) at pressure shown on
the tag attached to the burner. Oil pressure should
be adjusted while firing on the second stage. Do
not exceed the oil supply pressure specified on
the setup tag.

17. Check flue gases with a flue analyzer and smoke
spot pump to make final settings of the air
damper.

a. Readings need to be taken from a hole in the

vent several inches from flue outlet
connection.

b. Insert draft gauge into the test opening in the

stack. Draft in stack should read -.02" to -.06"
W.C. Adjust draft regulator, if installed.

c. Insert analyzer in test opening and determine

O2 content in percentage.

d. Gradually close air damper to decrease O2

reading or open air damper to increase O2
reading until optimum O2 % (4-5%) is reached.
Refer to Figure 22-2 & 5, pages 7 & 8 for
damper adjustment details.

e. Once the O2 reading is in the specified range,

check smoke content in the flue gas by
pumping ten times through a new smoke spot
sample paper. Smoke spot should not exceed
a #2. If the smoke spot exceeds a #2, it may
be necessary to increase the O2 %.

f. Once combustion is set, take note of the gross

stack temperature; maximum gross stack is to
be 400°F, minimum net stack is to be 300°F.

(NOTE: net temperature is the total stack
temperature, less room temperature.) If an

excessively high gross stack temperature is
recorded, consult the factory.

g. Make sure air shutter is locked securely in

place.

18. On two-stage oil burners, the preceding analysis
must be done for the first and second stage.

19. Check each operating and limit control to be sure
they function properly by lowering and raising the
temperature setting on each of the controls,
causing the burner to cycle on and off.

PV500-22A 08-98 4 Section 22A