Enertech Nu-Way G200 Universal Mode d’emploi

Installation & Maintenance Manual

G200 Universal

Oil Burner

11/12

Tel:+44 (0) 1905 794331 Fax: +44 (0) 1905 794017 Email: [email protected] Web: www.nu-way.co.uk

E.04.2000 • G. 16.11.10

Contents

1. General information ................................................................................................................... 3

2. Checking scope of supply and electrical ratings ........................................................................ 3

3. Operating instructions ................................................................................................................ 3

4. Instruction .................................................................................................................................. 3

5. Maintenance and customer service ........................................................................................... 3

6. Technical specifications ............................................................................................................. 4

7. Functional description ................................................................................................................ 4

8. Air/oil flow schematic.................................................................................................................. 4

9. Installing flange and burner........................................................................................................ 5

10. Connecting to power supply....................................................................................................... 5

11. Compressed air connection ....................................................................................................... 5

12. Oil pump..................................................................................................................................... 6

13. Installing the oil line.................................................................................................................... 6

14. Setting the ignition electrodes.................................................................................................... 6

15. Control unit ................................................................................................................................ 7

16. Table of settings ........................................................................................................................ 8

17. Settings for primary airflow ........................................................................................................ 9

18. Combustion air flow rate ............................................................................................................ 9

19. Flue connection.......................................................................................................................... 10

20. Flue gas thermometer................................................................................................................ 10

21. Maintenance .............................................................................................................................. 10

22. Wiring diagram........................................................................................................................... 11

23. Possible errors .......................................................................................................................... 12

24. Exploded view drawing / parts list.............................................................................................. 13

25. Burner dimensions / boiler connecting dimensions.................................................................... 16

26. Operating range ......................................................................................................................... 16

E. 04.2000 • G. 16.11.10

General information

1. General information

An oil-fired system must be installed in compliance with a number of regulations and requirements. It is

therefore the duty of the installer to be familiar with all applicable regulations and requirements. Installation,

start-up and maintenance must be performed with utmost care.

The burner must not be operated in rooms with high levels of air humidity (laundry rooms), dust or corrosive

vapours.

The universal oil burners are suitable for use with a variety of natural oils and mineral-

based oils. On account of their viscosity, these oils are not in conformity with EN 267 for

oil burners. The burners are, therefore, not licensable. An inspection to determine suita-

bility for the selected fuel type must be performed by the operator prior to acceptance of

the installation.

The design and degree of protection of the burner make it suitable for operation in

enclosed rooms.

2. Checking scope of supply and electrical ratings

Before installing the GIERSCH universal oil burner please check the items supplied for completeness.

Scope of supply:

burner, mounting unit, separate operating instructions, technical information, flange seal.

Near wear-free compressed air atomising nozzles are pre-fitted at the factory.

3. Operating instructions

This technical information should be displayed in a visible position in the boiler room as operating instruc-

tions. It is essential to write the address of the nearest customer service centre in the operating instructions.

Caution !

Improper installation, adjustment, modification, operation or maintenance may result in

physical injury or damage to property/equipment. Read the instructions prior to use.

This product must be installed in accordance with the applicable regulations

(e.g. DIN-VDE).

4. Instruction of operating personnel

Faults are often caused by operator error. The operating personnel must be properly instructed in how the

burner works. In the event of recurring faults, Customer Service should be notified.

5. Maintenance and customer service

The complete system should be checked once a year for proper functioning and leak tightness by an au-

thorised representative of the manufacturer or by another expert. We accept no liability for consequential

damage in cases of incorrect installation or repair, the fitting of non-genuine parts or where the equipment

has been used for purposes for which it was not intended.

E.04.2000 • G. 16.11.10

Technical specifications

6. Technical specifications

7. Functional description

The fuel is pumped out of the supply tank and into the burner tank. A float switch controls the level inside

the burner tank. An additional microswitch serves as a limiter, switching over to fault mode when the tank

is overfilled.

A thermostat regulates the oil temperature in the burner tank and starts the burner when the set tempera-

ture is reached. Thereafter, the automatic oil burner control system controls and monitors the operation of

the burner.

Fuel is aspirated and finely atomised by a special nozzle using the compressed air flowing through the

burner, which is used as primary air for the combustion process.

The burner blower supplies the secondary air which is added to the atomised spray at the baffle plate. This

ensures full combustion and operational reliability.

At the oil temperature in excess of 150° C, the safety switch automatically de-energises the burner.

8. Air/oil flow schematic

Burner type

Technical specifications G200

Output, fuel oil KW 149 - 208

Output, rapeseed oil KW 100 - 149

Oil throughput kg/h 16.5

Compressor output m

/h 25

Primary air connection bar 0.5 - 1.4

Motor output W 250

Heating element W 1100

Voltage 1/N/PE ~50 Hz 220 - 240 V

Weight kg 22

Feed line

Contact switch

Heating cartridge

E1 + E2

Overflow tank

Burner tank

Thermostat

Safety valve Pressure gauge

Solenoid valve

Primary air actuator

Pressure controller

Connecting line

baffle plate

Burner pipe

Nozzle

Nozzle assembly

Oil line

Fan wheel

Micro-switch,

overflow protection

Micro-switch,

level control

E. 04.2000 • G. 16.11.10

Install flange and burner

9.Install flange and burner

Attach the burner flange and the seal to the heat

generator.

10.Connect to power supply

• Connect the burner to the power supply using the

supplied connector unit as indicated in the wiring

diagram.

• HEED LOCAL REGULATIONS !

• Use flexible wiring.

Overcurrent protection configuration

The overcurrent protection devices must be rated for

the electrical current range indicated in the technical

specifications and to provide protection against electri-

cal shock according to DIN IEC 60364-4-41

(VDE 0100-410).

11. Compressed air connection

Connect a compressed air line to the pressure regula-

tor (1).

7-pin

E.04.2000 • G. 16.11.10

Oil pump

12. Oil pump

The oil pumps serve as delivery units, pumping oil into the burner tank. The atomisation of the oil is not

dependent on the oil pressure.

Suntec oil pump:



= feed



= return



= pressure pipe connection



= pressure measuring connection



= vacuum measuring connection



= pressure adjustment

13.Installing the oil line

Install oil lines, filters and floating suction unit from the supply pump to the supply tank.

For installation in the open air or on outside walls, the lines must be specially insulated or fitted with addi-

tional pipe heaters, as otherwise the water contained in the oil will freeze causing the oil to become highly

viscous.

14.Setting the ignition electrodes

The ignition electrodes are preset. The specified dimensions (Fig.) are for checking purposes.

E. 04.2000 • G. 16.11.10

Function testing the control unit

15. Function testing the control unit

Carry out the following checks after start-up and after the burner has been serviced:

• Warm restart with covered flame failure controller:

The control box must indicate a fault once the safety time has elapsed.

• Burner start-up with flame detector exposed to external light, e.g. fluorescent lamp, lighter, light bulb

(daylight is not enough):

Due to the flame simulation, the control box must indicate a fault during the pre-aeration time.

• Normal start-up - if the burner is in operation, darken the flame detector during the post-ignition

period (e.g. unplug and cover flame detector)

TF 834: the ignition must switch on and upon expiration of the safety period the device must switch

over to fault mode.

• Post-aeration after flame cut-off.

Safety and switching functions

If a flame failure occurs during operation, the fuel feed shuts off immediately and the system tries a restart,

with pre-aeration and retarded ignition. If no flame results, the control box indicates a fault after the safety

interval expires. In any case, the control unit is restarted following a mains power failure. The control unit

indicates a

fault if an external light source is detected during the pre-aeration cycle after expiration of the safety cycle.

The control unit may only be plugged in or unplugged if the master switch is in the "OFF" position

or if the 7-pin plug connector is disconnected, because the bottom part of the control unit

carries 230 V.

Flame simulation must not be permitted on the photoresistor or on the flame failure controller

(e.g. via an inspection glass or glowing chamotte). Only then is fault-free operation of the system

assured.

Honeywell: TF 834.3

= pre-ignition cycle + pre-aeration 12 secs.

= safety interval 10 secs.

= post-ignition time 20 sec.

Post-aeration after flame cut-out. -

Delay after switching-off fault approx. 60 sec.

Photoresistor (flame detector) MZ770

Ölvorwärmung

Ventilator

Zündung

Magnetventil

Flammenwächter

Störlampe

Anlauf mit Flammenbildung (Normalbetrieb)

Betrieb

Störung

Ölvorwärmung

Ventilator

Zündung

Magnetventil

Flammenwächter

Störlampe

Anlauf ohne Flammenbildung (Störbetrieb)

Sicherheit

tv1

Ventilator

Magnetic valve

Ignition

Fault indicating lamp

Flame detector

Oil preheater

Operation

Fault

Start without flame formation

Start with flame formation

safety period

Ventilator

Magnetic valve

Ignition

Fault indicating lamp

Flame detector

Oil preheater

E.04.2000 • G. 16.11.10

Adjustment table

Measuring the photocurrent (MZ 770S only)

To measure the photocurrent, disconnect the plug unit

from the flame failure controller and install the pair of

measuring cables* between the plug and socket unit.

Both measuring connections should be connected to

the measuring instrument. If there is a negative deflec-

tion of the measuring instrument, reverse the plug on

the measuring instrument lead ! Set the measuring in-

strument to ampere metering for DC, measuring range

up to approx. 200

mA !

Recommended measuring accessories

Digital measuring instrument Art. No. 59-20-50263

* Pair of measuring cables

for photocurrent Art. No. 59-20-50408

16.Adjustment table

The values given in the table are only setting values for start-up. The system settings required

in each case must be redefined if values such as boiler output, calorific value and altitude deviate.

Adjustment is required in any case (due to the system design).

• For initial start-up, fill the burner tank up to the oil mark by hand.

Caution !

If the oil level is too high, the float switch will switch off the burner.

If the oil level is too low, the heating cartridge will become encrusted or damaged.

Adjustment table for rapeseed oil

Adjustment table for fuel oil

The thermostat on the burner tank must be set to between "min." for heating oil EL and 140°C

for rapeseed oil, depending on the viscosity of the oil.

Burner type G200

Output in kW 100 111 131 140 149

Oil throughput in kg/h 9.42 10.5 12.3 13.2 14

Primary air in bar 0.5 0.7 0.8 1.0 1.2

Secondary air

(scale on air damper)

2.8 3.0 3.3 4.2 1.7

Thermostat setting in °C 140

Burner type G200

Output in kW 149 159 179 192 208

Oil throughput in kg/h 12.5 13.3 15.0 16.1 17.4

Primary air in bar 0.6 0.7 0.9 1.1 1.4

Secondary air

(scale on air damper)

5.0 5.2 6.0 6.8 7.5

Thermostat setting in °C 0° do not heat

Flame failure controller

Control unit

bottom part

500µA

200µA

E. 04.2000 • G. 16.11.10

Settings for primary airflow

17. Settings for primary airflow

The primary airflow should be set using the pressure

regulator (1) according to the required burner output.

The information given in the diagram can be used as

guide values.

Higher-viscosity fuels require higher air pressures.

18. Combustion air flow rate

Setting the combustion air flow rate (2).

Ideal values:

- Soot index according to Bacharach <1

- O

= 4 - 5%

The CO

values of a commercially available measuring in-

strument can only be used for processing the combustion

process for heating oil EL.

Flue gas temperature according to the operating instructions

of the heat generator.

E.04.2000 • G. 16.11.10

Flue connection

19. Flue connection

The prerequisite for perfect operation of the furnace is a correctly dimensioned flue.

Dimensioning is effected in accordance with DIN 4705 in consideration of DIN 18160 and based on the

boiler and burner outputs.

For operation on a sliding basis, provide flues as per DIN 18160 part, group 1. The flue gas mass flow

of the total rated heat output must be factored into the calculation. The effective flue height is counted from

burner level. Furthermore, we refer you to the statutory building regulations of the individual German fed-

eral states.

Select a flue design which minimises the danger of condensation or of a cold flue inner wall.

For exact adjustment and stabilisation of the flue draught we recommend the installation

of a draught limiter.

Thus:

• any draught fluctuations are equalised

• moisture in the flue is largely excluded

• stoppage losses are reduced.

Connection pieces should be introduced into the flue with a gradient of 30° or 45° viewed in flow direction.

It is best to provide flue gas pipes with thermal insulation.

20. Flue gas thermometer

For flue gas temperature monitoring the heating system should be equipped with a flue gas thermometer.

The higher the flue gas temperature, the greater the flue gas loss.

Rising flue gas temperatures indicate increasing deposits that will reduce the degree of combustion effi-

ciency. In the event of an increasing flue gas temperature have the heating installation cleaned and read-

justed by a skilled person.

21. Maintenance

Depending on the quality of the oil used, we recommend the following maintenance intervals:

After more than 3 days downtime:

• drain off residual water and sludge through the water drain cock in the burner tank,

Monthly:

• Clean the filter in the supply tank or the unit tank and strainer on the floating suction unit

• Remove and clean the feed pump filter

• Remove sludge and residual water from the supply tank or unit tank

• The quantity can be determined by using water indication paste and a gauging rod

• Clean the photocell

• Clean the ignition electrode and baffle plate and blow out the nozzle with compressed air, check the

spacing between the ignition electrodes (refer to checking dimensions for ignition electrodes)

Annually (before or after the heating period):

• Carry out monthly maintenance as described

• Clean the heating cartridges in the burner tank

• Clean the ignition electrodes and baffle plate, blow out the nozzle with compressed air and check the

spacing between the ignition electrodes

• Clean the burner tank, supply tank and unit tank thoroughly.

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