Enertech Nu-Way NG Series Mode d’emploi

Installation & Maintenance Manual

Series NG fully automatic gas burner

Models NGN40 to NGN100

Gas Burner

11/12

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

Model NGN40-100Page 2

Contents

BURNER & COMPONENT I DENTIFICATION ............................................................................................................ 4

FEATURES ........................................................................................................................................................... 6

Burner Capacity .............................................................................................................................................................................. 6

Air Regulation ................................................................................................................................................................................. 6

Controls .......................................................................................................................................................................................... 6

Operation ........................................................................................................................................................................................ 6

Fuel ................................................................................................................................................................................................. 6

GENERAL ........................................................................................................................................................... 6

Flue And Chimney Requirements.................................................................................................................................................... 6

Plant Room Ventilation .................................................................................................................................................................... 6

Existing Appliances......................................................................................................................................................................... 6

Com ustion Cham er Conditions ................................................................................................................................................... 7

PACKAGING FOR TRANSIT ................................................................................................................................. 7

Mode One: Comprising Two Units ................................................................................................................................................. 7

Mode Two: Comprising Three Units ............................................................................................................................................... 7

Assem ly ........................................................................................................................................................................................ 7

SERVICES & SITE CONDITIONS ........................................................................................................................... 7

Gas Supply ...................................................................................................................................................................................... 7

Gas Boosters ................................................................................................................................................................................... 7

INSTALLATION .................................................................................................................................................... 8

General ............................................................................................................................................................................................ 8

Fitting To The Appliance ................................................................................................................................................................ 8

Electrical Power Supply................................................................................................................................................................... 8

BURNER AIR CONTROLS .................................................................................................................................... 8

Air Diffuser ..................................................................................................................................................................................... 8

Air Pressure Switch......................................................................................................................................................................... 8

BURNER GAS CONTROLS ................................................................................................................................... 8

Gas Nozzle ....................................................................................................................................................................................... 8

High Gas Pressure Switch ............................................................................................................................................................... 8

Low Gas Pressure Switch ................................................................................................................................................................ 8

Gas Valve Train ............................................................................................................................................................................... 8

ELECTRICAL DATA TABLE ................................................................................................................................... 9

TERMINAL CONNECTIONS - HIGH/LOW BURNER ................................................................................................ 9

TERMINAL CONNECTIONS - MODULATING BURNER ........................................................................................... 10

WIELAND PLUG & SOCKET CONNECTIONS ....................................................................................................... 11

Air/Gas Ratio Controller .................................................................................................................................................................12

Valve Proving Systems ..................................................................................................................................................................12

Landis & Staefa LDU11 .................................................................................................................................................................. 12

Dungs VPS 504 ..............................................................................................................................................................................12

CONTROLS ...................................................................................................................................................... 12

FLAME MONITOR ............................................................................................................................................ 12

GAS VALVE TRAIN - LANDIS & STAEFA SKP70 / SKP10 ................................................................................. 13

LANDIS & STAEFA SKP70 VALVE A CTUATOR ................................................................................................... 14

AIR DAMPER MOTORS - H/L ..........................................................................................................................14

CONTROL BOX SEQUENCE AND TIMING CHART ................................................................................................ 1

AIR DAMPER MOTOR - MODULATING ............................................................................................................. 1

MODULATING OPERATION ................................................................................................................................16

Burner Control Panel. ..................................................................................................................................................................... 16

Manual Operation ..........................................................................................................................................................................16

Temperature detector......................................................................................................................................................................16

Pressure detector. ...........................................................................................................................................................................16

Gas controls. ..................................................................................................................................................................................16

SKP70 com ustion cham er impulse connection. .........................................................................................................................16

Installation of the com ustion cham er impulse pipe. ...................................................................................................................17

IMPORTANT - SAFETY ............................................................................................................................ 17

EMERGENCY INSTRUCTIONS .............................................................................................................. 17

BURNER OPERATING SEQUENCE ........................................................................................................................ 17

Initial Burner Setting ...................................................................................................................................................................... 17

Air/Gas Ratio Controller .................................................................................................................................................................17

Start Rate Gas Governor ................................................................................................................................................................. 17

Page 3

Model NGN40-100

IMPORTANT - SAFETY

It is essential that the following instructions and adjustments are carried out by qualified engineers that

are experienced in blown gas burner commissioning. In the U.K. it is a legal requirement that anyone

working on gas installation, as defined in the  as Safety (Installation & Use) Regulations 1994 is

COR I registered. The manufacturer cannot be held responsible for any consequential damage, loss or

personal injury as a result of failure to follow these instructions, or as a result of misuse. Your attention

is drawn to the Emergency Instructions on Page 17.

EUROPEAN BOILER EFFICIENCY DIRECTIVE (B.E.D.)

All burners and boiler bodies marketed seperately should comply with EN676 (gas burners) and EN303

(Heating Boilers). Burner adjustments must be made in accordance with boiler manufacturers

instructions, and these must include flue gas temperatures, average water temperature, and CO2 or O2

concentration.

BURNER PRE-COMMISSIONING ......................................................................................................................... 17

BURNER COMMISSIONING ................................................................................................................................18

Check For Valve Closure (Burners Without Valve Proving System) ..............................................................................................18

Gas Supply Pressure ......................................................................................................................................................................18

ESTABLISHING MAIN FLAME ............................................................................................................................ 18

General Notes.................................................................................................................................................................................18

Landis & Staefa SKP70 ..................................................................................................................................................................19

BURNER START G AS RATE ................................................................................................................................19

Check Flame Signal ........................................................................................................................................................................19

Air Pressure Switch Setting ...........................................................................................................................................................20

High Gas Pressure Switch Setting ..................................................................................................................................................20

Low Gas Pressure Switch Setting ...................................................................................................................................................20

FINAL CHECK .................................................................................................................................................. 20

RWF40 MODULATING CONTROL .................................................................................................................... 20

Basic display ..................................................................................................................................................................................20

To change the working set point....................................................................................................................................................20

To enter a new parameter ...............................................................................................................................................................21

ROUTINE SAFETY CHECKS ................................................................................................................................22

Com ustion Air ..............................................................................................................................................................................22

Flame Detector ...............................................................................................................................................................................22

Valve Proving System ....................................................................................................................................................................22

ROUTINE MAINTENANCE .................................................................................................................................. 22

Com ustion Air Fan .......................................................................................................................................................................22

Inner Assem ly ..............................................................................................................................................................................22

Air Diffuser And Gas Nozzle ..........................................................................................................................................................22

Ignition Electrode...........................................................................................................................................................................22

FAULT F INDING ................................................................................................................................................ 22

Burner Motor Fails To Start ...........................................................................................................................................................22

Starting Flame Failure Without Ignition .........................................................................................................................................23

Starting Flame Failure Without Flame ............................................................................................................................................23

Burner Fails To Esta lish Main Flame ............................................................................................................................................23

Burner Motor Only Runs Continuously ........................................................................................................................................23

Replacement Of Air/Gas Ratio Controller .......................................................................................................................................23

Incorrect Rotation Of Burner Motor ..............................................................................................................................................23

Motor & Fan - Removal .................................................................................................................................................................23

SERVICE & REPLACEMENT ............................................................................................................................... 23

BURNER HEAD DETAILS .................................................................................................................................... 24

BURNER PERFORMANCE CURVES ...................................................................................................................... 2

BURNER SERVICE RECORD .............................................................................................................................. 31

Model NGN40-100Page 4

BURNER & COMPONENT IDENTIFICATION

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Model NGN40-100

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Model NGN40-100Page 6

GENERAL

The N 40-N 100 burner is supplied for two stage

(High/Low) or fully modulating operation and for

use with a three phase electrical supply.

This manual is structured to enable the user to

proceed from the delivery of the burner to its

commissioning and use.

The conditions to be fulfilled and the controls and

adjustments to be used are dealt with in the

sequence that should be followed for the correct

assembly installation and use. Pre-commissioning

and commissioning are described and the location

of necessary controls and adjustments to

undertake these runs are illustrated and supported

by appropriate tabular matter and graphs.

Routine Maintenance, Fault Finding and Spare Parts

Identification complete the manual; literature on

proprietary components is available on request.

Flue And Chimney Requirements

It is important that:

a) the flue pipe from the appliance and the joint

between this flue and the chimney are sealed

to prevent leakage of combustion products.

b) the flue pipe from the appliance does not

protrude into the chimney beyond the inside

wall.

c) the top of the flue or chimney shall be higher

than any roof within a radius of 10 metres.

d) checks are made to ensure that the chimney

is suitable for gas fired appliances and that

the proposed installation complies with all

Local Authority and other regulations

covering such installations.

e) if more than one appliance is connected to

a common flue or chimney the cross-section

of this flue or chimney should be adequate

for the total volume of combustion products

from the appliances.

Plant Room Ventilation

An adequate dust free supply of fresh air is required

for the burner at both high and low level in

accordance with the appropriate standards.

Existing Appliances

In preparing the appliance to receive the N gas

burner a careful inspection should be made of its

condition. If in doubt as to its suitability for gas

firing refer to the appliance manufacturer.

FEATURES

Burner Capacity

Developed from field experiences in the UK and

overseas markets, the N series sets new standards

in efficient and reliable operation, having been

developed to current test authority requirements

in UK and overseas markets. It is delivered ready

to install with pre-wired packaged control system

and simple plug in gas train arrangements.

Air Regulation

Air for combustion can be adjusted to give

maximum efficiency. A air control device produces

smooth start conditions. A fully closing air control

is fitted as standard.

Controls

Flame supervision is by UV cell, and automatic

sequence control.

Operation

Two stage (high/low) and fully modulating

operation.

Fuel

Natural as. Special requirements on request - i.e.

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Page 7

Model NGN40-100

In preparing the appliance for gas firing it should

be cleaned thoroughly removing all adhering tars,

scale and dirt.

Com ustion Cham er Conditions

When the burner is fitted to an appliance designed

to work under balanced or negative combustion

chamber conditions, the over-fire draught must not

exceed 0.25 mBar.

Should the over-fire draught exceed this figure, then

steps should be taken to reduce it to this level.

PACKAGING FOR TRANSIT

To safeguard against transit damage and for Export

shipment, the burner may be despatched in partly

assembled form in one of two modes.

Mode One: Comprising Two Units

a) Burner Body, complete with Control Package,

Hinged Extension and Flame Tube Assembly.

b) as train complete.

Mode Two: Comprising Three Units

a) Burner Body complete with Control Package.

b) as Train Complete.

c) Hinged Extension and Flame Tube Assembly.

Assem ly

Mode One

Fit the gas valve train to the burner body using the

gasket provided. Ensure that the gasket is fitted

correctly with all holes corresponding with those

on the burner flange. Connect the combustion air

impulse pipe from SKP70 gas valve to left hand

side of the hinged extension.

Mode Two

Fit the hinged extension and flame tube assembly

to the burner body with the eight studs provided.

Ensure the gas inlet flange is at the bottom. Fit the

gas valve train to the burner body, with the four

studs and using the gasket provided. Ensure that

the gasket is fitted correctly with all holes

corresponding with those on the burner flange.

Connect the combustion air impulse pipe from

SKP70 gas valve to left hand side of the hinged

extension.

Modes One & Two

Open the hinged extension and connect the

Ignition cable to the electrode. Close hinged

extension.

Connect the multi-pin plug from the gas valve train

to the socket located on the rear of the control

package on the left of the burner body.

SERVICES & SITE CONDITIONS

Gas Supply

The gas supply pipework to the burner must be

appropriate to local conditions and must be

constructed and installed in compliance with

appropriate Codes and Standards. It shall be of

sufficient size to satisfy the pressure and volume

flow requirements of the burner under all firing

conditions. Checks should be made to ensure that

all meters and other components are appropriately

rated for the maximum gas flow rate anticipated.

It is essential that a 90° manual isolation valve is

fitted upstream of the gas control train to allow

the burner to be isolated for maintenance The size

of this valve should not be less than that of the

burner control train in order to avoid any restriction

in gas flow

Gas Boosters

When a gas booster is used the gas pressure at the

booster inlet must not fall below 10 mbar under

any conditions. A low gas pressure switch must be

fitted on the upstream side of the booster to

prevent it starting if the supply pressure is

insufficient. An additional pressure switch can be

used to monitor the pressure downstream of the

booster to prevent the burner operating if the

pressure is insufficient.

The booster should be installed as near to the

burner as possible. It should be positioned on a

firm, flat, horizontal surface using anti-vibration

mountings. All connecting pipework should be well

supported and accurately positioned in order to

avoid stressing the booster casing. The use of

flexible connectors, which reduce both pipework

stresses and transmitted noise, is strongly

recommended. The gas supplier should be asked

to recommend the size of pipework between the

meter and the booster to ensure that the required

pressure and flow are available.

Model NGN40-100Page 8

INSTALLATION

General

Check that the burner is appropriate for appliance

rating. Detailed burner performance data is given

at the back of this handbook.

Fitting To The Appliance

If the burner is to be fitted to a new packaged unit,

refer to the manufacturers recommendations.

If the burner is to be used with an existing

appliance prepare the mounting flange as detailed

in the Burner And Components Identification

section. Ensure the joint between appliance and

burner is effectively sealed with the gasket

provided. The flame tube should be flush with the

inner face of the appliance combustion chamber

except where extensions are specified by the

appliance manufacturer (i.e. reverse flame boilers).

Electrical Power Supply

Connect a three phase 50 Hz electrical supply to

the burner observing all applicable IEE Regulations.

Refer to the connection diagrams on pages 9-11

or the wiring diagram contained in the instruction

pack attached to the burners. If supplied as a

packaged appliance/burner unit refer to the

manufacturers instructions.

Connect the external auxiliary controls by

reference to the appropriate connection/wiring

diagram.

BURNER AIR CONTROLS

The air for combustion is controlled by an

adjustable air flap located inside the air inlet on

the right hand side of the burner viewed from the

rear. Its purpose is to regulate and control the

volume of combustion air flowing through the

burner. Combustion air is controlled by a three

position servo motor. Positions for high and low

flame air are adjustable. A fully closed position is

incorporated for when the appliance temperature/

pressure is satisfied.

Air Diffuser

The air diffuser is fitted to the front end of the inner

assembly and located within the flame tube.

Its function is to control the volume of combustion

air and create a pressure drop over the burner head

to ensure good fuel/air mixing and flame stability.

Air Pressure Switch

The air pressure switch is located on the right side

of the burner casing viewed from the rear. It is

required to prove adequate air flow throughout

the burner operating cycle. Air flow failure at any

stage will result in burner lockout.

BURNER GAS CONTROLS

Gas Nozzle

The gas nozzle is fitted to the front end of the inner

assembly and located in the flame tube. The holes

in the gas nozzle are designed to suit the output of

the particular burner model and gas type being

used.

High Gas Pressure Switch

A high gas pressure switch is fitted and pre-wired

to the gas train to ensure that if the gas pressure at

the burner head increases above the gas pressure

at maximum continuous running, then the burner

will shut down to a safe condition, thus indicating

a fault on the governing valve (air/gas ratio valve).

The switch is factory set to the maximum position.

Final adjustment of this switch is described in the

Commissioning section on page 20.

Low Gas Pressure Switch

The low gas pressure switch is located on the inlet

side of the gas valve block on the left of the burner,

viewed from the rear. It is required to monitor inlet

gas pressure during the burner operating cycle. as

pressure failure will result in safe shutdown of the

burner. Final adjustment of this switch is described

in the Commissioning section on page 20.

Gas Valve Train

The gas valve train system includes an air/gas ratio

controller, safety shut-off valve, and gas regulator

in the start rate line. Three impulse pipes are

connected to the air/gas ratio controller. All are

factory supplied. One pipe is connected to the

burner hinged extension and supplies combustion

air pressure to the ratio controller. A second pipe

is connected downstream of the valve set and

supplies gas pressure to the ratio controller. The

third pipe is vented to atmosphere. Valve

adjustments are detailed in Valve Adjustment

Diagram on page 14.

Page 9

Model NGN40-100

TERMINAL CONNECTIONS - HIGH/LOW BURNER

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ELECTRICAL DATA TABLE

L*=(If fitted) for connection of independent

control circuit supply If not required fit 0 75mm

(24/ 20) link between L1 & L

BR=Burner run

LO=Lockout

NB: For details of booster connections, refer to

the instruction pack provided with the booster

Wiring diagram for connection of burner to power supply for

NG40-100 with DOL fan motor starter

Model NGN40-100Page 10

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TERMINAL CONNECTIONS - MODULATING BURNER

Ce manuel convient aux modèles suivants

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