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

Combustion Chamber: General
2.5
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2. .3 3 C Co om mb bu us st ti io on n A Ai ir r R Re eq qu ui ir re em me en nt ts s
2.3.1Fresh air required tosupport combustion, as wellasto provideadequate location ventilation,must be
supplied.All types offuel require approximately10 cubic feet of standard air (sealevelat 60°F) per 1000
BTU’s firing rate, for theoretical perfect combustion. Inactualpractice, acertainamount ofexcess air is
required toensurecomplete combustion, but this can varysubstantiallywith specific job conditions.
2.3.2Additional air is lost fromthe boiler roomthrough barometric dampers, draftdiverters and similar venting
devices. It is generallyacceptedthat ½square inch of free air opening (for eachgas or oilburner inthe
room)per 1000 BTU/hr firing rate will be adequate. Under nocircumstances should aboiler roombe
under negativepressure. Jurisdictionalauthorityrelating tocombustion air andboiler roomventilation
requirements varywidely.In order tomakecertaincompliance, thecontrollingauthorities shouldbe
consulted.
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2. .4 4 B Bu ur rn ne er r M Mo ou un nt ti in ng g: : G Ge en ne er ra al l
2.4.1Provisions shouldbe made to provideadequate space around theburner and associated equipment to
allowfor ease ofinspection, maintenance and service.
2.4.2Observe codes for the minimumclearances to combustible materials.
2.4.3Provideasuitableburner front plate, consisting ofasteelplateofample thicknessto support the weight
ofthe burner/refractoryandholdthemfirmlyinalignment withthe heatexchanger. The front plate must
be protectedfromheat using hightemperature refractory.Once the burner is mounted to the refractory
insure the burner scanner port is alignedwith the scanner port in the refractory.
2.4.4The burner mountingflangemust be securelyattachedto the refractoryfront platewithsuitable gasket or
non-asbestos, high temperature ropepacking to prevent anyproducts ofcombustion fromescaping from
the combustionchamber throughtheburner-boiler mounting flanges.The burner assembly must be
supportedatthebase ofthe housing to preventundue strain on thefront plate.(Amountingpedestal
maybe furnished for this purpose.)
2.5.1All possible points of air infiltration or ex-filtration must be sealed. If the unit is to be fired under positive
combustion chamber conditions, extreme care must be taken to ensure that a 100% seal is maintained.
The Model UCM burner is designed to provide all the air required for complete and efficient
combustion. Entryor loss of air fromsources other than the firing unit will decrease its overall
combustion and operational efficiency.
Combustion Chamber: General
2.5

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3. .S ST TA AR RT T U UP P P PR RO OC CE ED DU UR RE ES S
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3. .1 1 B Bu ur rn ne er r S St ta ar rt t U Up p a an nd d S Se er rv vi ic ce e T Te es st t E Eq qu ui ip pm me en nt t R Re eq qu ui ir re ed d
3.1.1The followingtestequipment isrequiredtoensureproper start upandadjustment ofburner equipment to
obtain maximumefficiencyand reliabilityofoperation.
3.1.2Equipment required:
For anyfuel:
·O
2
analyzer (Required)
·NOx analyzer (Required)
·Stackthermometer
·Draft gaugeor inclined manometer
·Combination volt/ammeter
·DC Micro-ammeter or DC Voltmeter, as required byFlame Safeguard programmer
For gas:
·CO indicator
·U-Tube manometers 0-16” W.C.
·Calibrated pressure gauges 0-100” W.C. and 0-5 PSIG (Higher pressure ranges maybe
necessarydepending upongas inlet supplypressure)
For Oil:
·Compound vacuum/pressure gauge for pump suction side (-30” to 30” W.C.)
·0-100 PSIG oil pressure gauge (two required for atomizing pressure andoil pressure)
·0-400 PSIG gaugefor pump pressure
·Smoke tester
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3. .2 2 G Ge en ne er ra al l S St ta ar rt t- -U Up p A Al ll l F Fu ue el ls s
3.2.1Athoroughlyqualified burner technician must be employedto provide the initial burner start up, as wellas
anysubsequentservicingof the burner andrelatedcontrols.
3.2.2Arepresentative ofthe owner and/or the person or persons responsible for operating and maintaining the
unit shouldbe present during the initial start up. Aservice representativemayalso be required bythe
local utilityongas-fired equipment. Instructions regarding the proper care and maintenance ofthe unit
should beoutlinedwith these peoplepresent.
3.2.3Before initiating start up,thestart up technicianshouldthoroughlystudyand becomecompletelyfamiliar
withtheexact sequence ofoperation andallother details ofthe specific flamesafeguard control system
being used. This information will befound in bulletins printedandsupplied bythe control manufacturer. A
copyofthis bulletin is supplied with the burner.
3.2.4Makeageneral inspectionofthe equipment roomto ensure that theinstallationis complete. Check
piping, controls, wiring andetc.
3.2.5Close main and checking gas cocks. Open suction linemanual oil valves and others as appropriate.
3.2.6Tighten all screws on terminal blocks in control cabinet in casesomemayhave loosenedinshipment.
3.2.7Checkfuses in main panel(ifsupplied) and inburner control cabinet.Checkwiring totheburner control
cabinet for compliance with the wiringdiagramand local codes. Determine that voltage supplyis correct
to motor starter lineconnections andto controlcircuit lineconnections. Ifacontrol circuittransformer is
supplied, make certain its primaryvoltagematches the line voltage being supplied.

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3.2.8Checkbreachingand stack to ensure that theyare open and unobstructed.
3.2.9Checkblower (and oil pumpmotor, as applicable) rotationbymomentarilymaking contact ofthe motor
starters. Proper rotation isimprinted onthe fan housing and (ifsupplied) theremote oil pumpset
assembly.
3.2.10 Check operating controls, limit controls, lowwater cut-off, flamesafeguard control reset, highand lowgas
pressure switches (ifused), lowfire interlockswitch (ifused) and all other applicableinterlocks. All
contacts shouldbe closed(an exception willbe foundon jobs using the lowgas pressure switch; this
switch should be openuntil the main gas cockis opened). Ifalowoilpressure switch is used, its
contacts will remain open until the oil pump is running and the lowoil pressure cut-in pointis reached.
3.2.11 Do not repeatedlyrecycle the burner, as toallowanyunburned fuel in thecombustion chamber to collect.
Allow5 minutes between recycles.
3.2.12 Specific instructions relative to component sequencingare provided in the flamesafeguard
manufacturer’s bulletin which is included with the documentation shipped withthe burner.
3.2.13 Proper test equipment mustbe usedinorder to achievemaximumsystemoperational reliabilityandfuel
efficiencies. See previous pagefor a list ofrequired equipment.
3.2.14 Allfuel/air adjustments shouldbe made to achieverequiredinput rate, satisfactorycombustion test
values, flame stabilityand appearance.
3.2.15 Before firing gas, confirmthe expectedhigh fire manifold pressure as listedontheburner data plate. The
manifold pressure shownwillbetheapproximate manifold pressure at highfire.Specific adjustments to
the burner such as changing orifice sizeor re-positioning the center gas ringwill affect the ultimate
manifold pressure.
3.2.16 Everynewburner startupshould employthe use of theBurner Start-Up Information and Test Datasheets
on pages 32, 33 and 34.
3.2.17 The gas systemuses twomotorized gas shutoff valves to control the on/off flowofthe gas. The oil
systememploystwooil solenoid valves to controlthe on/off flowofoilto the oil nozzle. The gas flowis
controlled byabutterflytype Gas ProportioningValve while aV-ported meteringoil valve provides the
proportioning function in theoilnozzle line. These fuel valves are controlledbyindividual servomotors.
The IFGR damper and combustion air dampers are also controlled byindividual servomotors, through
appropriatesequencing – providing lowfuel/air input for asmooth lowfire start anda near infinite number
offuel/air positions between full lowandhigh fire.
3.3Fuel Change-Over Procedure
3.3.1The change-over fromone fuel to the other requires amanual change-out of the gas or oil gun
assembly.This operationwillrequire approximatelyfifteen minutes for completionwhen switching from
either fuel. This procedure is assuming that the burner is presentlyset up on gas and is to be changed to
oilfiring. To begin the change-out, shutdown the burner and disconnect power.
3.3.2Removethe 9/16” hex bolts securing the side access cover and movethe cover out of the wayfor access
to the insideofthe blast tube.
3.3.3Loosenthetwocompression nuts on the 3/8” aluminumpilot tubinglocated inside the blast tubeand
remove the tubing.
3.3.4Disconnect the ignitionwirefromthe electrode bypulling thewire fromthe end of the electrode.
3.3.5Loosenand remove the two 9/16” hex bolts fromthe center gas flange.
3.3.6Grab hold ofthe center gassupplypipe and liftslightlytoseparate the flanges while rotating the flange
toward you.

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3.3.7It shouldnowbe possibleto angle the gun assemblytoward the access openingandpull the entire
assemblyout.
3.3.8Once the gas gunassemblyis out verifythat the centergas o-ring is still in place, then install the blanking
flange and bolts. Tighten the bolts.
3.3.9Loosen and removethe one9/16” boltandoil supplyblanking flange frominside.Verifythat the two o-
rings are still in place on the flange.
3.3.10 Installthe oilgunassemblyinto theblast tube.Insure thatthe two o-rings are stillinplacebefore
securing the flange. Pinsare locatedon the gun assemblyflange which willalignthetwoflanges.
Tighten the 9/16” bolt.
3.3.11 Using thepilottubingsuppliedwiththeoil gunassembly,connect the supplyto the pilot andtightenthe
two compression nuts.
3.3.12 Insert theignition cable into the ignition electrode.
3.3.13 Remove anytools frominside the blast tube andinstall the access cover and bolts.
3.3.14 Switchthefuel selector switch to (Oil). The burner is nowreadyto fire on oil.
Figure 5:UCMGas and Oil Gun Assemblies

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3. .4 4 B Bu ur rn ne er r S St ta ar rt t- -U Up p S Se eq qu ue en nc ce e I In ns st tr ru uc ct ti io on ns s: : G Ga as s
3.4.1Prior to burner start up –contact thelocalgas companyto determine ifanycorrection factors have to be
appliedto their indicatedmeter flowrates. This informationis important as itrelates to achieving specific
heat exchanger BTU/HR inputs.
3.4.2Refer to the gas pipingdiagramfurnished with theburner. Checkgas piping,controls andvalves for
leaks and compliance withcodes.
3.4.3Close main checking andpilotgas cocks. Install onegas pressure gauge (0-100”W.C.) to gas manifold
pressure port.SeeFigure2for pressure sensinglocations.Installasecondgas pressure gaugetoread
gas supplypressure between the main gas cockand the inlet to themain gas pressure regulator (use a
0-5 PSI gauge or as appropriate). If thereis no tappingin this location, install atee at the point where the
pilot gas supplyis connected tothemain gas line.Slowlyopenthemain gas cockin order to determine
that the incoming gas pressure is withinthe specifiedlimits of the main and pilot gas pressure regulators,
automatic fuel valves andgas pressure switches.
3.4.4Disconnectpilotlineatinlet tothepilot gas pressureregulator and purgeair fromthe pilot gas line.
Purging ofgas lines mustbe donein accordancewithNFPA54 ofthe NationalFire Protection
Association’s NationalFuelGas Code.After theair is purged from the gas supplysystem,close thepilot
cockand reconnect the pilot line. Leave the pilot cockclosed.
3.4.5Installrequired systemmeasuringdevices: a) appropriateflamesignal meterto the flamesafeguard
control;b) manometer (or 0-10” W.C. gauge) in thepilot test teeport; c) stack thermometer and O
2
sample line to the breaching; and d) draft gauge tothecombustion chamber test point.
3.4.6It is stronglyrecommendedthat an automatic gas valve bubble leaktest be performed in accordance with
the gas valvemanufacturer’s instructions oneverynewinstallation and periodicallyafterwards in order to
ensure that the valve is functioningaccording tothemanufacturer’s specifications. It is also suggested
that the test be conducted duringanormal pre-purge burner operation. This test will revealanyproblems
that relate to incorrect wiring ofthe automatic gas valvethat could cause premature energizing ofthe
valve.
3.4.7Verifythepositionofeachservo.After theinitialspanningoftheservos thefuelvalveshouldbeator
near zero withtheair dampers closed to1/8” open. With both pilot and leaktest gas cocksclosed, open
the main gas cock(to allowthe lowgas pressure switch, ifsupplied, tomakeits circuit). With the control
switch in the OFF position, applypower to the burner throughthe main burner disconnect switch. Switch
the burner panelOn/Off switch totheON positionmomentarilyto determine that theblower rotationis
correct.
3.4.8Re-start the burner. With the pilot gas cockclosed, the burner will gothrough ablower pre-purgeperiod,
after whichthe gas pilot ignition transformer will beenergized, although nopilotwill beestablished. (At
no timeshould there be anyflamesignalreading,nor shouldthe main gas valveattempt to open.) At the
end ofthe pilot trialfor ignition andblower purgeperiod,theflamesafeguard controlshould shut the
systemdowninasafetylockout mode, requiringmanual reset ofthe flamesafeguard control to restart
the burner.
3.4.9Wait three minutes, reset the flamesafeguard controlsafetyswitch (restarting theburner) and open the
pilot gas cock.When the blower pre-purgeperiod ends andthe burner is energized–ifthe flame
safeguard controlhas atest/run switch –fliptheswitchtothetestpositionwhilethe pilotis onandmake
adjustments as required. The typical pilotpressure is 2.5” to 4.0” W.C. See page 25 for pilot ignition
adjustments. Recycle the burner severaltimes to make certain pilot operationis reliable.
3.4.10 With pilot adjustments completed, reset the switch tothe Runposition, which willallowthe sequence to
proceed to the automatic gas valve energizingposition.
3.4.11 When the main automatic gas valvebegins toopen, slowlyopenthechecking gas cockto lightoff the
main flame. The main flame should light immediately.Ifnot, itmaybe necessaryto eliminate air fromthe
main gas line and/or adjust main gas pressure regulator flowrates.

13
3.4.12 Adjust theburner as necessarytoprovide smooth ignition ofthe main flame. Ifthe flamesignal drops
significantlywhen the mainautomatic gas valveopens, slightlyincrease thepilot gas pressure to attain a
stableflame signal value.
3.4.13 Refer to paragraph3.4.20 and 3.4.21 carefullyfor recommended limit control andother controldevices
operationalcheckout.
3.4.14 Initial adjustments should be made at the lowfire position.
3.4.15 With the burner in thelowfire position, adjust air and fuel servos to good fuel/air ratio lowfire settings (5 –
6% O2and little or noCO). Operate theburner at lowfire until the flue gas temperature is at least 200°F
and the water is warmin the boiler. Slowlyopenthe IFGR valveservotoobtain the desired NOx
reduction. The O2 percent willdrop approximately2% –3% whenthe desiredNOx reduction is achieved.
Allowsufficienttimefor theflue gas piping towarmupbefore movingontothenext point, typically200-
250 °F.
3.4.16 At anypointduringcommissioning, ifthe NOx levelcan not beachievedit maybe necessarytoremove
somegas fromthe center gas can. This is done bythe shutting downthe burner and closing thecenter
gas can orifice ring. However, as long as the burner maintains stabilityitis recommended that the
commissioning continue since the regulator mayneedadjusted at high fire. Anyflameinstabilitymaybe
due to too much FGR or insufficient gas to the center gas can.
3.4.17 Slowlyincreasethefiringrate byadjustingeachservoto obtainthedesiredemissions levelwhile
maintaining stable combustion values (3 - 5% O2andlittle or no CO).
3.4.18 Continueto slowlyincreasethe rateto highfire position. It will benecessaryto reach thehigh fire
positionto determine the final gas regulator setting. Results should range in the area of3% to 5%O2with
little or no CO. The servosettings should benotedtoobtainhighfire reference points. The high fire gas
manifold pressure will be approximately55” to 65” W.C. for each burner model.
3.4.19 Determine that the requiredgas input rateis being achieved byclocking the gasflowat thegas meter.
The gas utilityshould beconsultedto determine ifanycorrection factors have to be applied to the
indicated meter flowrates.
3.4.20 Limit control checkshould be made as follows:
1) Permit the burner to run until the limit control settings havebeen reached.
2) The burner should turnoffwhen the set temperature or pressure has been reached. Set the
controls so that the burnerwill goto the lowfire position before the operatinglimit control turns
the burner off.
3) After a differential pressureor temperature drop, the burner should re-start automatically.
4) With the unit running normally,opentheblowdownvalveand removewater to the point below
the LowWater Cut Offsetting.The burner should turn off and re-start automaticallywhen the
proper water level is re-established.(If amanual reset typeLowWater Cut Offis used, it will
have tobe reset).
3.4.21 Set and checkoperation ofLowandHigh Gas Pressure Switches. Seegas pressure switch
manufacturer’s instructionsfor detailedprocedures.For initialstart up, once the burner’s normal
operationalgas pressure has been set, adjust the lowand high gas pressure switches as follows:
1) LowGas Pressure Switch:with theburner running, slowlyclose the main gas train manual shutoff
cock and adjust theswitch to open its circuit whenthepressure falls approximately25% belowits
normal value.The burnerwillshut down.Openthemanual gas shutoff cockto thefullopen
position andmanuallyreset the LowGas Pressure Switch. The burner will re-start.
2) HighGas Pressure Switch:withtheburner running, adjust the switch to apointwhere the switch
opens its circuit. The burner willshut down. Manuallyreset the switch andreadjust the cutout
point to bemade at the normal operatingpressure, but to open as the pressure increases to
approximately25% abovenormal.

14
3.4.22 Checkall burner and heat exchanger controls andoperating devices.
3.4.23 CheckBlower Combustion Air FlowSwitch:
1) Shutburner power off.
2) Disconnect both wires at the air flowswitch andtemporarilyclip themtogether.Makesure that
theycannot ground against anything,since theywill be poweredwith 110volts during the test.
3) Put a continuitymeter across the common and normallyopen terminals on the airswitch.
4) Close the gas train checking cock.
5) Start the blower motor. The meter should read electrical continuityas soon as the blower starts.
6) Disconnect thewire which energizes the coilofthe motor relay(starter), or openthe main power
disconnect switch to the burner. Within 3to 4seconds after the blower motor is de-energized,
the meter should indicate an open air flowswitch circuit (no continuity).
7) Ifthe switch does not openin 3to4seconds, readjust accordingly.Turn the air flowswitch
adjustment screwclockwiseto shorten cut-off response timeand counter-clock-wise tolengthen
cut-off response time.
8) Turn the burner power off.Removethe shorting clipfromthe twodisconnectedwires andcap
themwithawire nut, let themhang loose (theywillbepowered with 110volts, so don’t let them
ground out).
9) Open the gas train checking cock.Turnthe burner on. With the wires disconnected, the burner
shouldgo into apurgecycle, although neither the ignition nor the main fuel valvecircuits will be
energized. Iftheydo energize, there is awiringproblem. Correct as required.
10) Turn power off.Reconnect the air flowswitchwires tothe air flowswitch terminals. Place burner
backinto normal operation.
3.4.24 The Owner’s OperatingInstructions, attheend ofthis manual, should be posted inaclearlyvisible
location close to the burner.
3.4.25 Ifthe burner operationisabnormal, refer to Section5, Troubleshooting,as wellas troubleshooting
information included in theflamesafeguard manufacturer’s bulletinshippedwiththe burner. It is also
stronglysuggested that alltest procedures outlined in the flamesafeguard controlmanufacturer’s bulletin
be conducted.
3.4.26 Complete the Burner Start-up Information and Test Data sheets on pages 32, 33 and 34.
3
3. .5 5 B Bu ur rn ne er r S St ta ar rt t- -U Up p S Se eq qu ue en nc ce e I In ns st tr ru uc ct ti io on ns s: : O Oi il l
3.5.1Power Flame Model UCM oilburners are oftheair atomizing forced draft type.
3.5.2Checkoil andgas piping (ifapplicable) for leaksand checkall controls for compliance with codes and
insurancerequirements.
3.5.3Installoilpressure andvacuumgauges. See Figure 4for mechanical operationand oilandair pressure
gaugelocationfor the system.Check suction lineto be sure manual valve is open andthat anycheck
valves are opening in theproper directionofoilflow.Checkoil filter for tightness. There shouldbeno
manual valveinthereturnline frompumpto tank.Refer to Figure 6for theapproximate nozzleoil
pressures for aspecific firingrate.The corresponding atomizingair pressures will typicallybe5to10PSI
lower than theoilpressure at highfire. NOTE:During pre-purge makean initialatomizing air adjustment
ofapproximately20 to 30PSI bysetting the bleed valve onthecompressor. At lowfire the atomizingair
pressure will typicallybe5to 10 PSIhigher thanthe oil pressure. The atomizingair linefromthe
compressor to theburner shallbeaminimumof¾” NPTfor the UCM-200through theUCM-600,for a
maximumequivalent lengthof300 ft. Larger UCMmodels shall have aminimumof1” NPTfor the
atomizing air line.
3.5.4Gas PilotOil Ignition. Install amanometer or 0-10” W.C. gas pressure gauge inthe pilot gas pressure
test port. See pages 15 fordetails on gas pilotadjustments. Disconnect the pilotgas line at theinlet to
the pilot gas pressure regulator andbleedair outofthepilotline.Makecertain that the gas pressure to

15
the pilotregulator does not exceed the regulator or pilot solenoid valve rating. When bleedingairfromthe
pilot line system, do not allowthe ventingofgas into the room.
3.5.5Install required systemmeasuring devices:
1Appropriate flame signal meter to the flame safeguard control
2Stackthermometer, O2, andSmoke Test sample lineinthe breaching
3Draft gaugeto the combustion chamber test point
3.5.6With the burnerpanelcontrol switch in theOFF position, applypower to theburner throughthe main
burner disconnect switch. Switch theburner panelOn/Offswitch totheON position momentarilyto
determine that theblower motor, compressor motor and oilpumpset motors are running in the correct
rotation.
0100 200 300 400 500
0
20
40
60
80
100
120
150
300
360
PF Y-TYPENOZZLE
(30psiprepurgeAir)
GPH#2OIL
PSI OIL
Figure 6:Pressure/FlowCurve for PF Y-Type Nozzles
3.5.7Appropriate steps must be taken to transfer the oilfromthe tankto theburner.It is imperativethatthe
systembe primed prior tooperation.The systempriming maybe achieved byclosing themanual valvein
the oil suction line and priming the oilpumpthrough the pumpgauge pressure port. Priming can also be
accomplishedthroughtheoilfilter on the suctionline,ifit is ofthe removabletoptype. When replacing
the oil filter cap,besure to attain avacuum tight seal. Start the burner withthesuctionline manualvalve
closed. Lettheburner rununtilthevacuumgauge indicates ahighvacuum,thenquicklyopen the
manual valvein the suctionline. This combination ofpriming and highsuction should pullthe oilfrom the
tankto the burner, providedthat there are no leaksand the lineis properlysized (see Figure 3for proper
line size).
3.5.8Refer to the burner wiringdiagramand flamesafeguard control information supplied with theburner to
determine the specific firingsequence relating to limit and interlockcircuits.
3.5.9The air servo should be ator near zero withthe air damper closed to 1/8” open. The ignition circuit will be
energized after theblower pre-purgeperiodhas been completed and alllimit andother interlockcircuits
have been closed. Allowtimefor the pilot to light, andadjust it for proper ignitionand flamesignal. For
flamesafeguard controls having aTest/Run test switch, place the switch in theTest position, causing the

16
ignition timing sequence tostop while air and gas pressure adjustments are beingmade. See page25
for details on gas pilot ignition adjustments.
3.5.10 Cycle the burner several timesto makecertain the pilot is operating reliably.Shut thepilot gas cockand
cycle the burner through pre-purge. With the gas shut off,the pilot valveandignitiontransformer will
energize, but there will be no pilotand the unit will shutdownon safetylockout.
3.5.11 There shouldbeno evidence of aflamesignal reading, nor should themain oil solenoidvalves attempt to
open.
3.5.12 When a Gas Pilot is used to ignite the main oil, there will be aperiodoftimewhen onlythe pilot will be on.
The flamescanner must first detect thepilotandthen, inagivennumber of seconds, themain oil
solenoidvalves will be energized.
3.5.13 When the compressor is running, a pressure will be indicated on both the air and oilpressure gauges.
3.5.14 Verifythe positionofthebleed valve ontheatomizing air compressor. The bleedvalveis usedto setthe
nozzlepre-purge pressure (20 to 30PSI). Normallyunder reduced firingrate conditions the bleed valve
is used tobleedoff excessatomizingair fromthe nozzle. Itmayalso be necessarytobleedoff excess
atomizing air to obtain rate/goodcombustion atthehigher rates.
3.5.15 Once themain solenoidoilvalves are energized, the oil flameshouldbeestablished immediately.Ifnot,
shut the systemdown andmakecorrections as required. Donot repeatedlyrecycle the burner, such as
to allow anyaccumulation ofunburned fuelinthecombustion chamber.
3.5.16 See paragraph 3.5.22and3.5.23in this section for recommended limit controland other control device
settings.
3.5.17 Afuel metering valvecontrols the fuel input fromlowtohigh fire. Initial adjustments shouldbe made at
the lowfireposition(lowfuel/air flow).Todetermine thatthemeteringvalveis, in fact, in the lowfire
position, observe thepointer on themetering valveshaft. The pointer must be near theclosed position
pointing toward the#1 or #2on thedial of the Hauck valve. As the burner runs fromlowto highfire, it will
proceed fromthe lowfire setting toward the open positionon the dial.
3.5.18 With the burner in the factorysetlowfire position, adjust the servos toagood fuel/air ratio lowfire setting
(6 -7% O
2
and #0 to #2 smokereading). At each point slowlyopen the IFGRservoto achievethe
desired NOx reduction. TheO2will drop 2% -3% whenthe IFGR valveis opened.It willbe necessaryto
adjust theIFGR valvepercent opening throughout the firing range.
3.5.19 Intermittentlyoperatetheburner untilthewater is warmin the boiler, or followspecific initial firing
recommendations providedbythe heat exchanger manufacturer.
3.5.20 Slowlyincrease thefiring rate to establish anewpointalong the firing rate curve.Adjust each servoto
set the fuel/air ratios to achievegood combustion values (4 - 6% O2and #0 to #2 smoke reading).
3.5.21 Continueto slowlyincrease the rate to the high fire position. It maybenecessaryto adjust the oilpump
regulator pressure to reach full rate. The meteringdevice setting, air damper openings andservo
positions should be noted to obtain the high fire reference points.
3.5.22 Limit control checkshould be made as follows:
1
2
3
4
Permit the burner to run until the limit control settings have been reached.
The burner should turn off when the set temperature or pressure has been reached.
Set the controls so that the burner will go to the low fire position before the operating limit control
turns the burner off.
After the differential pressure or temperature drop, the burner should start automatically.
With the unit running normally, open the blow-down valve and remove water to the point below the
low water cutoff setting. The burner should turn off and re-start automatically when the proper water level
is re-established. (If manual reset type low water cutoff is used, it will have to be reset.)

17
3.5.23 Set andcheckoperation oflowOil Pressure Switch. Set at approximately80% oflowfire oilpressure.
Checkvisually, or test electricallyto confirmthat circuitopens at the proper oilpressure.
3.5.24 CheckAtomizing Air Switch. Set just belowthe minimumoperatingpressure during pre-purge.Check
visually,or test electricallyto confirmthat circuit opens on a loss ofatomizing air pressure.
3.5.25 CheckBlower Combustion Air FlowSwitch.
1
2
3
4
5
6
7
8
9
10
Shut burner power off.
Disconnect both wires at the air flowswitch and temporarilyclip them together. Make sure that they
cannot ground against anything, since theywill bepowered with 110 volts during the test.
Put a continuity meter across the common and normally open terminals on the air switch.
Disconnect the wire to the main automatic oil valve.
Start the blower motor. The meter should read electrical continuityas soon as the blower starts.
Disconnect the wire which energizes the coil of the motor relay(starter) or open the main power
disconnect switch to the burner. Within 3 to 4 seconds after the blower motor is de-energized, the
meter should indicate an open air flowswitch circuit (no continuity).
If the switch does not open in 3 to 4 seconds, readjust accordingly. Turn the air flowswitch
adjustment screw clockwise to shorten cut-off response time and counter-clockwise to lengthen cut-off
response time8)
Turn the burner power off. Remove the shorting clip from the two disconnected wires and cap them with
a wire nut, let them hang loose (they will be powered with 110 volts, so don’t let them ground out).
Reconnect the wire to the main automatic oil valve. Turn the burner on. With the air flow switch wires
disconnected, the burner should go into a purge cycle, but neither the ignition nor the main fuel valve
circuits will be energized. If they do energize, there is a wiring problem. Correct as required.
Turn power off. Reconnect the air flow switch wires to the air flow switch terminals. Place burner back
into normal operation.
3.5.26 Checkall burner and heat exchanger controls andoperating devices.
3.5.27 The Owner’s OperatingInstructions, attheend ofthis manual, should be posted inaclearlyvisible
location close to the burner.
3.5.28 Ifthe burner operationisabnormal, refer to Section5, Troubleshooting,as wellas troubleshooting
information intheflamesafeguard manufacturer’s bulletinshippedwiththe burner. Itisalsostrongly
suggestedthat alltest procedures outlined intheflamesafeguard controlmanufacturer’s bulletinbe
conducted.
3.5.29 Complete the Burner Start-Up Information and Test Data sheets onpages 33, 34and 35.
4
4. .I IF FG GR R: : I In nd du uc ce ed d F Fl lu ue e G Ga as s R Re ec ci ir rc cu ul la at ti io on n
4
4. .1 1 I In nt tr ro od du uc ct ti io on n
4.1.1The UCM is equippedwithan InducedFlueGas Recirculation(IFGR) systemwhich must be operational
duringburner operation. TheIFGR utilizes theflue gasto lower theoverallNOXemissions to complywith
the NOXemission regulations.
4.1.2This systemhas beensuccessfullyproveninfieldapplications onfiretube applications. Testingandfield
operations havebeen performed using natural gas andlight oil.