Power Flame Ultra CMax User manual

P
PO OW WE ER R F FL LA AM ME E M MO OD DE EL L U UC CM M B BU UR RN NE ER R
For use by Qualified Service Personnel Only
Rev. 10/2016
WARNING
The improperinstallation, adjustment, alteration, serviceor maintenance
of thisequipmentcan resultinfire,explosion,serious injury, or death.
Refer to thismanual.For assistance or additional information consulta
qualifiedinstaller, service agencyor the gassupplier.
Do not storeoruse gasolineor anyother flammable liquids in the vicinity
of thisor anyother appliance.
ATTENTION!
All Personnel involved withthe startup,maintenance, oradjustment of thisburnermustread
and understandtheentire contentsofthis manual priortoanystartup or adjustmentmadeto
the burner andrelated components.Installation and servicemust beperformedbya qualified
installer,service agencyor the gas supplier.
WHATTO DO IF YOU SMELL GAS
1. Do not tryto light anyappliance
2. Do not touch anyelectrical switch
3. Do not use anyphoneinyour building
4. Immediatelycall your gas supplier froma neighbor’s phone
5. Followthe gas supplier’s instructions
6. If you cannot reach your gas supplier, call the fire department
Rev. 5/2017

1.GENERALPRODUCTINFORMATION1
1.1Principle ofOperation1
1.2Unpacking and Handling1
1.3Warrantyand Spare Parts Information2
1.4GeneralComponents Information 2
2.INSTALLATION3
2.1Gas SupplyPiping 3
2.2Oil SupplyPiping 5
2.3Combustion Air Requirements 8
2.4Burner Mounting: General 8
2.5Combustion Chamber: General8
3.STARTUP PROCEDURES 9
3.1Burner Start Up and Service Test Equipment Required 9
3.2GeneralStart-Up All Fuels9
3.3Fuel Change-Over Procedure 10
3.4Burner Start-Up Sequence Instructions: Gas 12
3.5Burner Start-Up Sequence Instructions: Oil14
4.IFGR: Induced Flue GasRecirculation17
4.1Introduction17
4.2Principle ofOperation18
4.3Installation18
4.4Start up: IFGR18
4.5Determining Percentage of IFGR 19
5. TROUBLESHOOTING21
5.1Oil Pump or Oil FlowProblems and TypicalSolutions21
5.2Gas Pilot Ignition Adjustment22
5.3Gas Pilot Flood Test 22
5.4Trouble Shooting Suggestions Gas, Oil or Gas/OilBurner: general 23
5.5Trouble Shooting Suggestions: Gas24
5.6Trouble Shooting Suggestions: Oil 25
6.MAINTENANCE 27
6.1GeneralInformation27
6.2Periodic CheckList 28
7.BURNER STARTUPINFORMATION & TESTDATA29

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1. .G GE EN NE ER RA AL L P PR RO OD DU UC CT T I IN NF FO OR RM MA AT TI IO ON N
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1. .1 1 P Pr ri in nc ci ip pl le e o of f O Op pe er ra at ti io on n
1.1.1The Power FlameModelUCM Burneris aforced draft, highswirl, partial premix/nozzle mix gas burner
which incorporates fluegasrecirculation on bothgasand oilto achieve ultra lowNOx reduction.The
combustionairis furnishedbyanintegrallymountedcombustion air fan.The Power Flamepackaged
combustion systemcan be operated under positiveor negativefurnace pressures with clean,efficient
combustion in awide range ofcombustion chamber conditions.
1.1.2Power FlameModelUCMburner’s highswirl design enables greater flameturbulence at areducedflame
size. As aresult, these burners require less combustion chamber volumeforcomplete combustion and
can be easilyfired under positive furnacepressure conditions.
1.1.3The Power FlameModelUCM burner is atotallypackaged andfactorytestedcombustion systemoffering
singleunit responsibility.The package incorporates accurate control ofthe fuel-air ratiothroughout the
firing range with the resultant controlled flame patterns and clean combustion for maximumefficiency.
1.1.4Combustion air flowis controlledbyamulti-louvered damper assembly.Combustion air is suppliedbyan
integral motor-driven blower, which discharges into the burner blast tube assembly.
1.1.5The air-fuel ratio is established at the timeofstart-upand proven with combustion test equipment to
provide the lowest practicaloxygen and lowest NOx with a cleanflame.
1.1.6AFlameSafeguard Controller programsthe firing cycle. The operatingcycle issequencedto ensure
normal and safeconditions before fuel can be introduced into thecombustion chamber area. The
complete firing cycle is supervised toensure that ignitionofmain flameis properlyestablished and
maintained. Flamemonitoring is provided byeither a lead sulfide or ultraviolet type optical scanner.
1.1.7The limit circuit includes theoperating limit controlto maintain set operating pressure or temperature, as
wellas ahigh limit controlto guard against excessive pressure or temperature.Lowwater and other
similar safetycontrols can be interlocked into theburner control system to satisfyspecific job and/or code
requirements.
1.1.8The control circuit is normally120volts. Acontrolcircuit transformer maybefurnished to provide the 120
volts control circuitfor polyphase motor voltage applications.
1.1.9Power Flame Model UCM burners are capable offiring single or multi-fuel applications. A manual change-
over ofthe particular fuel’s gun assemblyis required.
1.1.10 The pre-wiredControlPanel is mounted and wired asan integralpart ofthe burner in accordance with
recommendations ofUnderwriters Laboratories, Inc. and The NationalElectrical Code.Components are
wired tonumbered terminal strips. Panel and burners are factoryfire tested before shipment.
Comprehensive wiringandgas and/or oilpipingdiagramsare furnishedwitheachburner in accordance
withindividual jobor applicationrequirements. Wall mounted or free standingcontrolpanels are also
available.
1.1.11 PowerFlameModelUCMburners areavailablewithcontrolsystemsto complywiththerequirements of
FactoryMutual, IndustrialRiskInsurers and anyspecialstate,municipal, local and utilitycompanycodes,
including NewYorkCityDepartment ofBuildings (MEA), NYCDepartment ofEnvironmental Protection,
Commonwealth ofMassachusetts, State ofConnecticut Fire Marshall,Illinois School Code and others.
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1. .2 2 U Un np pa ac ck ki in ng g a an nd d H Ha an nd dl li in ng g
1.2.1Power FlameModelUCMburners are usuallyshipped as aunit with anintegrallymounted, pre-wired
control panel. Aremote fuel oilpump-set is shipped separatelyonthe oil andcombinationoil/gas units.

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Acompletelypackaged compressor set is also shippedseparatelywithoil and combinationgas/oil
systems. Gas train components maybe pre-piped as an option or shipped loose for field mounting.
1.2.2Uncrate the burner carefullyandcheckallparts receivedagainstthecomputer generatedBurner
SpecificationSheets supplied byPower Flame. Components not mountedontheburner (shippedloose)
are designatedwithanLin theright hand columnonthe sheets. Claimson shortages or damage must
be immediatelyfilled withthe carrier.
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1. .3 3 W Wa ar rr ra an nt ty y a an nd d S Sp pa ar re e P Pa ar rt ts s I In nf fo or rm ma at ti io on n
1.3.1Power Flameoffersa15 month Limited Warrantyonall components fromthe date ofshipment (see
inside ofbackcover for details).
1.3.2The Owners Information envelope packed withthe burner contains aQualityControl Questionnaire.
Please fill this out ifyou haveanyqualityissues. The questionnaire is pre-addressed and postage paid.
Please visit our web site (www.powerflame.com)for warrantyregistration. The serial number is located on
the burner nameplate or on thespecificationsheetand is required for online registration.Acomputer
generated Spare Parts Listis included inthe informationpacket. Wehighlyrecommend an on-hand
supplyof spare parts in case of emergencyshutdown. Allcommunications with thefactorywillbe handled
more efficientlyifthe burneris identified bythe burner model, serial and job numbers. This information is
stamped into the burner nameplate that is attached tothe integralcontrol panel,or to the burner when
remote control panels are supplied. Youcan list thembelowfor quickreference.
M
Mo od de el l: : _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _
S
S/ /N N: : _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _
J
Jo ob b n nu um mb be er r: : _ __ __ __ __ __ __ __ __ __ __ __ __ _
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1. .4 4 G Ge en ne er ra al l C Co om mp po on ne en nt ts s I In nf fo or rm ma at ti io on n
1.4.1The contents ofthis manual aregeneralinnature due to the widevarietyofequipment specifications,
insurancerequirements, and state, local and other applicable codes.
1.4.2The computer generated Burner Specification Sheets, shippedwiththe burner,represent theAs-Built
versionofyour specific Power Flamecombustion system.Part numbers and component descriptions will
match those components supplied.Aduplicate set ofBurner SpecificationSheets is available through
Power Flame’s Customer Service Department or through the securedarea ofour website.
1.4.3 The components and arrangements shownare typical foraModel UCM-GOcombination gas/oil
burner. In somecases, the type of componentsand/or theirarrangement mayvaryfrom this
depiction. For specifics on you system, refer to the technicalinformation suppliedwith the burner.

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Figure 1:Gun Assemblies View
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2. .I IN NS ST TA AL LL LA AT TI IO ON N
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2. .1 1 G Ga as s S Su up pp pl ly y P Pi ip pi in ng g
2.1.1The installer should contact the localgas utilityfor information relatedtoavailable supplypressures,
limitations onallowablepressures inthebuilding,generalpipingrequirements andapplicablecodes,
restrictions andregulations. Considerations of these types, as wellas writtenpermitsand other state, city
and local codes should bediscussed with and approved bythe appropriate governing bodies.
2.1.2Gas pipingshould be sized to provide the required pressure at theburner traininlet manual shutoff cock,
when operating at the maximumdesired fuel input.
2.1.3Allgas pipingshould be appropriatelypressure testedto ensure leakfree operation. It is recommended
that adirt pocket or trap be piped into thegas supplysystemjust ahead ofthe burner traininlet manual
shutoff cock.
2.1.4When testingwithpressureshigher thanthemaximumpressure ratings ofthegas traincomponents, be
sure to isolate these components and test their pipingfor gas leaks with correct pressures only.
2.1.5Refer to Table1and 2for information relatingtothesizing ofgas supplypiping.These charts are based
on the general flowcharacteristics ofcommerciallyproduced blackcarbon steel pipe. Ifin doubt

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regarding flowcapabilities ofachosenlinesize, thenext largest sizeis recommended. Use correction
factors (multiplier) at right for other specific gravities and pressure drops.
2.1.6Refer to Figure 2for thetypicalgas pipingschematic to meet U.L. requirements inthe UCM burner firing
ranges.
1 1-1/4 1-1/2 2 2-1/2 3 4
10 520 1050 1600 3050 4800 8500 17500
20 350 730 1100 2100 3300 5900 12000
30 285 590 890 1650 2700 4700 9700 0.5 1.1 0.1 0.577
40 245 500 760 1450 2300 4100 8300 0.6 1 0.2 0.815
50 215 440 670 1270 2000 3600 7400 0.7 0.926 0.3 1
60 195 400 610 1150 1850 3250 6800 0.8 0.867 0.4 1.16
70 180 370 560 1050 1700 3000 6200 0.9 0.817 0.6 1.42
80 170 350 530 990 1600 2800 5800 1 0.775 0.8 1.64
90 160 320 490 930 1500 2600 5400 1 1.83
100 150 305 460 870 1400 2500 5100 1.1 0.74 2 2.58
125 130 275 410 780 1250 2200 4500 3 3.16
150 120 250 380 710 1130 2000 4100 1.55 0.662 4 3.65
175 110 225 350 650 1050 1850 3800 6 4.47
200 100 210 320 610 980 1700 3500 2 0.547 8 5.15
Propane
Butane
PipeSize –Inches(IPS)
Pipe Length
(Feet)
Specific Gravity
other than0.60
Specific
Gravity Multiplier
Propane -Air
Specific Drop
other than 0.3" w.c.
Pressure
drop
(" w.c.)
Multiplier
Capacityof Pipes –Natural Gas (CFH)
With Pressure Drop of 0.3” w.c.and Specific Gravityof 0.60
Note: Use multiplierat right for other specificgravitiesandpressure drops
CorrectionFactors
Table 1:Capacityof pipes and correction factors
11-1/4 1-1/2 2 2-1/2 3 4
Std teethrough side 5.5 7.5 9 12 14 17 22
Std. E11 2.7 3.7 4.3 5.5 6.5 8 12
45°E11 1.2 1.6 2 2.5 3 3.7 5
Plug Cock 3 4 5.5 7.5 9 12 16
PipeSize(IPS)
Table 2:Equivalent Length of Fittingsin Feet

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Figure 2:Typical Gas PipingSchematic for Model UCMBurner
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2. .2 2 O Oi il l S Su up pp pl ly y P Pi ip pi in ng g
2.2.1The UCM burner is designed for use with commercial standard grade No. 2 fuel oil.
2.2.2It is recommended thatprior to installation, NFPA85 and allother national,state, localandother
applicable codes be reviewed to ensure total compliance withtheir requirements including, butnot
necessarilylimited to, theuse ofanti-siphonvalve(s), oil safetyvalve(s) (OSV), or other acceptable
means to prevent siphoningofthe oil when the tankis above burner level. Evenifsuch devices are not
requiredbycode, theyshould beconsidered goodinstallation practice and mandatorywhenthe tankis
aboveburner level.
2.2.3Do not installmanual valves in the return line between the pumpand the tankunless required bya
specific code. If a manual valve is required, an automatic relief valvemust be installed across the manual
valve to ensure that oilwill bypass directlybackto the tankin the event the manual valveis inadvertently
left in the closed position.
2.2.4Use copper tubingwithflare fittings or ironpipe on allinstallations. Allunits must utilizethe proper size
and type ofsuction lineoil filters (see Table 3for sizingoil filters).
2.2.5Ifthe oil storage systemhas been used withfuel heavier than No.2fuel oil, theentire systemshould be
thoroughlycleaned andflushed before starting up thenewsystem.Utilizefusible linkand/or overhead
anti-siphonvalves as appropriate.
2.2.6Ifiron pipeoillines are used on undergroundtanks, swing joints utilizing nipplesand elbowsmust be
used andjoinedtogether, making certain the piping connections are tightened asthe tanksettles. Keep
swing joints in the suction and return lines as close to the tank as possible. Undergroundtanksshould be
pitchedawayfromthe suction lineend ofthe tankto prevent sediment fromaccumulating at the suction
line entrance.The suctionline should be a minimumof 3” fromthe tankbottom.
2.2.7Before startingup the system,all appropriateair andoil leaktests should be performed. Makecertain
that the tankatmospheric vent line is unobstructed.

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Refer to Figure 4for fuel pumpoil pipingconnectioninformation. Further informationrelating to burner oilpiping
can be found in Table 3.
Burner
Model Pump Suction Compressor Flow
Capacity (GPH) Rate (CFM) @
145 psi
UCM-200 130 10.8
UCM-250 130 10.8
UCM-300 130 10.8
UCM-350 220 20.5
UCM-400 220 20.5
UCM-500 220 20.5
UCM-600 220 20.5
UCM-700 292 28.8
UCM-800 292 28.8
UCM-900 480 28.8
UCM-1000 480 28.8
UCM-1100 480 28.8
UCM-1200 480 28.8
UCM-1300 510 46.4
Table 3:Oil Pump Suction/Compressor CFMCapacityChart
2.2.10 It is veryimportant to properlysizethe oilsuctionline and oil filter, toprovidefuel flowtotheburner
without exceeding10” suctionpressure (vacuum)at the oilpumpsuctionport. The method toproperly
sizethe fuel pump supplyline is outlined below.
1) Checkoil pumpGPH Suction Capacityshownin Table3to pipe sizeshown inFigure 3,Oil Line
Sizing.
2) Measuretotal pipinglength(horizontaland vertical) fromthe end ofthe line in the tank,to the
connection at the oil pump.
3) Choose the appropriate graph belowbasedon thepipe size. Readup fromhorizontalline Total
Feet ofIron pipe to Suction CapacityinGPH.
4) Read leftto theverticalline Inches ofVacuum at Fuel-Unit. (This is thevacuum required todraw
oilthrough the lengthofpipe selected.)
5) Ifinstallationhas lift(Liftis definedas thevertical distance thefuel unit(pump) is above thetop of
the tank) add 1” ofvacuumfor everyfootoflift.
6) Add the vacuumdetermined fromitems 4 and 5 together to determine total inches ofvacuum.
7) Iftotal is over 10”,move to next larger pipesize chart and re-calculate total inches ofvacuum.
8) The instructions above donot allowfor anyaddedrestrictions, suchas linefilter, elbows, sharp
bends,checkvalves,etc.Suctionline vacuumvalues for such componentsvaryfromone
manufacturer to another.
9) It is alwayssafeto sizethereturn line fromthe pumptothe tankat the samesizeas the selected
suction line.
10) A RuleofThumbto determine totalvacuumfor suctionlinesizingis toadd10% tovacuum
determined fromFigure 3 calculations.
11) Ifapressure feed (FloodedLoop, Remote Feed Pump, etc) is used to supplyoil tothe burner oil
pump, pressure at the pump inletmust be kept below3 PSI tocomplywith NFPA85.

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50 150 200 250 300 350 400 450 500100
1
2
3
6
7
8
9
10
4
5
300
400
500
Total Length of 11/4" NPS Pipe
Inchesof Vacuumof Fuel Unit
Suction CapacityGPH
50 150 200 250 300 350 400 450 500100
1
2
3
6
7
8
9
10
4
5
100
200
250
Total Lengthof 1" NPSPipe
Inches ofVacuumof Fuel Unit
SuctionCapacityGPH
400
600
Figure 3:Oil LineSizing
Figure 4:Oil PipingDetails