Power Flame UCM-1000, Installation And Operation Manual

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Page 2: ...ty of this or any other appliance ATTENTION All Personnel involved with the startup maintenance or adjustment of this burner must read and understand the entire contents of this manual prior to any st...

Page 3: ...0 3 4 Burner Start Up Sequence Instructions Gas 12 3 5 Burner Start Up Sequence Instructions Oil 14 4 IFGR Induced Flue Gas Recirculation 17 4 1 Introduction 17 4 2 Principle of Operation 18 4 3 Insta...

Page 4: ...ignition of main flame is properly established and maintained Flame monitoring is provided by either a lead sulfide or ultraviolet type optical scanner 1 1 7 The limit circuit includes the operating l...

Page 5: ...of emergency shutdown All communications with the factory will be handled more efficiently if the burner is identified by the burner model serial and job numbers This information is stamped into the b...

Page 6: ...to provide the required pressure at the burner train inlet manual shutoff cock when operating at the maximum desired fuel input 2 1 3 All gas piping should be appropriately pressure tested to ensure l...

Page 7: ...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...

Page 8: ...ck to the tank in the event the manual valve is inadvertently left in the closed position 2 2 4 Use copper tubing with flare fittings or iron pipe on all installations All units must utilize the prope...

Page 9: ...raph below based on the pipe size Read up from horizontal line Total Feet of Iron pipe to Suction Capacity in GPH 4 Read left to the vertical line Inches of Vacuum at Fuel Unit This is the vacuum requ...

Page 10: ...gth of 1 1 4 NPS Pipe Inches of Vacuum of Fuel Unit Suction Capacity GPH 50 150 200 250 300 350 400 450 500 100 1 2 3 6 7 8 9 10 4 5 100 200 250 Total Length of 1 NPS Pipe Inches of Vacuum of Fuel Uni...

Page 11: ...allow for ease of inspection maintenance and service 2 4 2 Observe codes for the minimum clearances to combustible materials 2 4 3 Provide a suitable burner front plate consisting of a steel plate of...

Page 12: ...e of the owner and or the person or persons responsible for operating and maintaining the unit should be present during the initial start up A service representative may also be required by the local...

Page 13: ...ging orifice size or re positioning the center gas ring will affect the ultimate manifold pressure 3 2 16 Every new burner startup should employ the use of the Burner Start Up Information and Test Dat...

Page 14: ...tall the oil gun assembly into the blast tube Insure that the two o rings are still in place before securing the flange Pins are located on the gun assembly flange which will align the two flanges Tig...

Page 15: ...according to the manufacturer s specifications It is also suggested that the test be conducted during a normal pre purge burner operation This test will reveal any problems that relate to incorrect wi...

Page 16: ...be noted to obtain high fire reference points The high fire gas manifold pressure will be approximately 55 to 65 W C for each burner model 3 4 19 Determine that the required gas input rate is being ac...

Page 17: ...oting as well as troubleshooting information included in the flame safeguard manufacturer s bulletin shipped with the burner It is also strongly suggested that all test procedures outlined in the flam...

Page 18: ...e manual valve in the oil suction line and priming the oil pump through the pump gauge pressure port Priming can also be accomplished through the oil filter on the suction line if it is of the removab...

Page 19: ...e metering valve is in fact in the low fire position observe the pointer on the metering valve shaft The pointer must be near the closed position pointing toward the 1 or 2 on the dial of the Hauck va...

Page 20: ...re 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 disconn...

Page 21: ...iping is not provided by Power Flame 4 3 2 Install the IFGR pipe from the stack or last pass smoke box to the burner IFGR connecting flange If the takeoff is from the stack it should be upstream of an...

Page 22: ...ly above 0 1 W C a reducing orifice may be required in the IFGR piping to restrict excessive flow Consult Power Flame if this circumstance is encountered 4 4 5 Typical IFGR percentages range from 20 t...

Page 23: ...r calculating the temperature ratio and locating that value on the X Axis move vertically to the plotted curve then read the IFGR value across the graph on the Y Axis Excess air O2 in the stack or fue...

Page 24: ...boiler or heat exchanger 5 5 T TR RO OU UB BL LE ES SH HO OO OT TI IN NG G 5 5 1 1 O Oi il l P Pu um mp p o or r O Oi il l F Fl lo ow w P Pr ro ob bl le em ms s a an nd d T Ty yp pi ic ca al l S So ol...

Page 25: ...e pilot gas pressure to a point where the signal is erratic or reduced substantially from initial reading 3 Raise the pilot gas pressure to the point where the signal is again stable Remove scanner an...

Page 26: ...r on and verify that the pilot lights and proves instantly providing good smooth ignition of the main gas flame 7 If Gas Pilot Flood Test is successful it is not always a guarantee of correct pilot ai...

Page 27: ...gh or too low at pilot Readjust as required 5 Defective ignition transformer replace Incorrect ignition electrode settings refer to gas pilot adjustments for correct settings 6 Defective flame safegua...

Page 28: ...off pressure 3 Defective oil pump Replace 4 Defective oil solenoid valve Replace 5 Oil pump coupling loose or defective Replace or tighten as required 6 Low oil pressure switch defective or incorrectl...

Page 29: ...rrow the flame as required 2 Defective or dirty oil nozzle Replace or clean nozzle 3 Incorrect oil air ratios Readjust burner to correct O2 and smoke levels 4 Atomizing air pressure too low resulting...

Page 30: ...e for routine maintenance 6 1 5 Make sure that combustion and ventilation fresh air sources to the burner room remain clean and open 6 1 6 Periodically check all electrical connections and make sure t...

Page 31: ...ctions Pilot turndown tests As required annually Service Technician Required after any adjustments to flame scanner mount or pilot burner Refer to flame safeguard manufacturer s instruction Pilot sign...

Page 32: ...______________ Phone_______________________________________ Start Up Date_______________________________________ Type of Gas Natural Gas_____ LP_____ Other _____________________________ Fuel Oil Grade...

Page 33: ...essure Net Stack Temperature Stack Outlet Test Point Draft Over Fire Draft Power Supply Remote Oil Pump Motor Amps at High Fire CO ppm NOx ppm Inpu Rate GPH Combustion Efficiency Flame signal Bacharac...

Page 34: ...____________________________________________________________________________________ ______________________________________________________________ Notes ______________________________________________...

Page 35: ...rning gas on a combination gas oil unit that has a blower motor driven oil pump open all oil line valves Oil must circulate through the oil pump even when burning gas Start Up Oil Burner 1 Open all va...

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Page 39: ...Said equipment at the owner s option to be determined thirty 30 days from the date of notification may be repaired or replaced at the expense of the owner and Seller s regular charges shall apply Own...

Page 40: ...09 Power Flame Incorporated Printed in the U S A Power Flame Incorporated 2001 South 21st Street Parsons KS 67357 Telephone 620 421 0480 FAX 620 421 0948 Product Support 620 820 8301 Website http www...