nuway Nu-Way MOL 200 S1L (B30A) Oil Burner User guide

Installation & Maintenance Manual

MOL 200 S1L (B30A)

Oil Burner

Tel: [phone] Fax: [phone] Email: [e-mail] Web: www.nu-way.co.uk

11/12

DESCRIPTION

COMPONENTS

1. Shrouded disc

2. Nozzle

3. Ignition electrodes

4. Nozzle assembly

5. Ignition cable

6. Ignition transformer

7. Control box

8. Reset button

9. Cover, inspection glass

10. Fan wheel

11. Motor

12. Photo cell

13. Nozzle assembly adjustment

14. Blast tube

15. Air adjustment

16. Air damper

17. Solenoid valve

18. Air intake

19. Pump

171 205 17 97-01

TECHNICAL DATA

Type designation B 30A

DIMENSIONS

ø108

ø108

220

281

ø108 35

303

175

382

B

372

160-190

Burner tube Length of burner tube Measure B
L 150 115

L Standard 222 187

OUTPUT RANGE AND NOZZLES RECOMMENDED

Burner tube Oil capacity Output Recommended nozzle Recommended

kg/h kW Mcal/h Angle Danfoss Monarch Pump pressure

L 6,0-17,0 71-202 61-173 45° - 60° S, B, R, PLP 10-15 bar

The net calorific value of 11,86 kWh/kg for light oil has been used.

RECOMMENDED NOZZLE

Because of different boiler types
existing on the market, with varying
combustion chamber designs, it is not

ELECTRODE ADJUSTMENT

2,5-3,5 1,0-2,0

7,0-9,0

possible to state a definite spray angle
or spray pattern.

Note that the spray angle and the spray
pattern change with the pump pressure.

171 235 02 00-03

GENERAL INSTRUCTIONS

GENERAL RULES

The installation of an oil burner should
be carried out in accordance with local
regulations. The installer of the burner
must therefore be aware of all
regulations relating to oil and combu­stion.
Only oil suitable for the burner should
be used and then in combination with
a suitable oil filter before the oil pump
of the burner.
If the burner is replacing an existing
burner make sure that the oil filter is
replaced or cleaned. The installation
must only be undertaken by experien­ced personnel.

INSTALLATION INSTRUCTIONS

General installation instructions ac­company the burner and should be left
in a prominent place adjacent to the
burner.

ADJUSTMENT OF BURNER

The burner is from the factory pre-set
to an average value that must then be
adjusted to the boiler in question.
All burner adjustments must be made in
accordance with boiler manufacturers
instructions.These must include the
checking of flue gas temperatures,
average water temperature and CO2 or
O2 concentration.
To adjust the combustion device, start
by increasing the air volume and the
nozzle assembly somewhat.When the
burner starts it is burning with excess
air and smoke number 0. Reduce the
nozzle assembly adjustment until soot
occurs, and then increase the
adjustment to make the soot disappear
again. Then the volume of air is reduced
until soot occurs and increased again
to reach a combustion free of soot.
By this procedure an optimum adjust­ment is obtained. If larger nozzles are
used the preadjustment of both the air
volume and the nozzle assembly must
be increased.
A whistling sound may be heard which
can be eliminated or reduced as fol­lows: Increase the nozzle assembly
adjustment somewhat. The CO2-con­tent and consequently the air volume
will then be reduced.

CONDENSATION IN CHIMNEY

A modern burner works with less ex­cess air and often also with smaller
nozzles than older models. This
increases the efficiency but also the

risk of condensation in the chimney.
The risk increases if the area of the
chimney flue is too large. The tempera­ture of the flue gases should exceed
60°C measured 0,5 metres from the
chimney top.
Measures to raise the temperature:
Insulate the chimney in cold attics
Install a tube in the chimney
Install a draught regulator (dilutes the
flue gases during operation and dries
them up during standstill)
Increase the oil quantity
Raise the flue gas temperature by
removing turbulators, if any, in the
boiler.

PUMP ADJUSTMENT

See separate description.

F

G

AIR ADJUSTMENT

Loosen the stop screw B and turn the
knob along the scale to the position
wanted and tighten the screw. Check
the air adjustment by making a flue gas
analysis.

MAINTENANCE

The boiler/burner should be examined
regularly for any signs of malfunction
or oil leakage
.

OIL SUPPLY

The oil line should be dimensioned in
accordance with the pump manu­facturer´s instruction. In the suction
line to the burner a filter should be
mounted to prevent any particles in the
oil from reaching the burner. If the
installation consists of several burners
each one should have its own suction
line from the tank or a circulation
system should be used.
The temperature in the oil line should
be kept as constant as possible. Avoid
exposing the line to excessive cold
which may cause blockages of paraf­fin deposits.
The oil pipe and electric cable should
be fitted so that the burner can be
placed on the floor for inspection of the
combustion device.

ADJUSTMENT OF NOZZLE
ASSEMBLY

Loosen the screw G and adjust the
nozzle assembly by turning the screw
F.

Max. capacity - Front position
Medium capacity - Middle position
Min. capacity - Rear position

B

171 305 46 97-02

MAINTENANCE

Warning: Before doing any service switch off power at the main switch and cut off the oil supply.

SERVICE OF BURNER HEAD

Open the cover and disconnect the
connecting pipes by loosening screw
A.

A

1. Loosen or swing out the burner
from the boiler.

2. Turn the blast tube to the left and
withdraw it.

171 305 74 95-01

ELECTRIC EQUIPMENT

OIL BURNER CONTROL: LOA21.173A27/LOA24.173A27/BHO61.A/B

FUNCTION

1. Switch on operating switch and twin thermostat
The burner motor starts, an ignition spark is formed, the prepurge goes
on till the prepurge period expires and the solenoid valve opens (2).

2. Solenoid valve opens
Oil mist is formed and ignited. The photocell indicates a flame. The
ignition spark goes out 2 s. after flame indication when the ignition
transformer is connected to terminal 7.

3. The safety time expires
a. If no flame is established before this time limit the control cuts out.
b. If for some reasons the flame disappears after this time limit, the

burner will make an attempt to re-start.

3-4. Operating position

If the burner operation is interrupted by means of the main switch or the
thermostat, a new start takes place when the conditions in accordance
with point 1 are fulfilled.

The oil burner control cuts out
A red lamp in the control is lit. Press the reset button and the burner
re-starts.

Post-ignition
If a post-igniton of 15 s. is wanted, move the ignition transformer from
terminal 7 to terminal 6.

WIRING DIAGRAM

*

LIST OF COMPONENTS

A1 Oil burner control R 1 Photoresistor
A2 Twin thermostat S3 Main switch
F1 Fuse, max. 10A T1 Ignition transformer
H 1 Alarm lamp Y1 Solenoid valve
H 2 Signal lamp (optional) X 1 Plug-in contact, burner
M1 Burner motor X 2 Plug-in contact, boiler
P1 Time meter (optional)

Mains connection and fuses in accordance with local regulations.

TECHNICAL DATA

Pre-ignition time: 13 s
Pre-purge time: 13 s
Post-ignition time: 2 s
Safety lock-out time: 10 s
Reset time after lockout: min. 50 s
Reaction time on flame failure: max. 1 s
Ambient temperature: from - 20 to +60°C
Min. current with flame established: 65 A
Max. photo current at start: 5 A
Enclosure: IP 40
(Under voltage proof only LOA24.173A27)

* If there is no plug-in contact (X2) on the boiler,

connect to the contact enclosed. In case the
twin thermostat is in series on incoming phase
L1, a loop between the terminals T1 and T2 is
necessary.

OUTER ELECTRICAL CONNECTION

X1

X2

CONTROL OF PHOTO CURRENT

Current through photo unit is measured with a d.c. ammeter (a moving coil
instrument connected in series with the photo unit).

171 415 20 96-02

INSTRUCTIONS PUMP TYPE SUNTEC AS47C

TECHNICAL DATA

Viscosity range: 1-12 mm2/s
Pressure range: 7-12 bar
Oil temperature: max 60°C

COMPONENTS

1. Pressure adjustment

2. By-pass plug

3. Nozzle outlet G 1/8"

4. Pressure gauge port G 1/8"

5. Vacuum gauge port G 1/8"

6. Return line G 1/4"

and internal by-pass plug

7. Suction line G 1/4"

8. Pressure gauge port G 1/8"

SUCTION LINE TABLES

The suction line tables consist of
theoretically calculated values where
the pipe dimensions and oil velocity
have been matched so that turbulences
will not occur. Such turbulences will
result in increased pressure losses
and in acoustic noise in the pipe system.
In addition to drawn copper piping a
pipe system usually comprises 4
elbows, a non-return valve, a cut-off
valve and an external oil filter.
The sum of these individual resistances
is so insignificant that they can be
disregarded. The tables do not include
any lengths exceeding 100 m as
experience shows that longer lengths
are not needed.
The tables apply to a standard fuel oil
of normal commercial quality according
to current standards. On commis­sioning with an empty tube system the
oil pump should not be run without oil
for more than 5 min. (a condition is that
the pump is being lubricated during
operation).
The tables state the total suction line
length in metres at a nozzle capacity of
2,1 kg/h. Max. permissible pressure at
the suction and pressure side is 2,0
bar. For two-pipe system Q

max

46 l/h

pump capacity at 0 bar.

H

H

1-pipe system 1-pipe system
Height Pipe diameter

H ø4 mm

mm

Height Pipe diameter

H ø4 mm

mm
4,0 100
3,0 100
2,0 100
1,0 91
0,5 82

With an underlying tank a 1-pipe­system is not recommended

0,0 74

Two-pipe system
Height Pipe diameter

H ø6 mm

mm
4,0 29
3,0 25
2,0 22
1,0 18
0,5 16
0,0 14

Two-pipe system
Height Pipe diameter

H ø6 mm

mm

0,0 14

-0,5 12

-1,0 10

-2,0 7

-3,0 3

-4,0 0

171 505 03 96-01

APPLICATIONS FOR
SUNTEC AS47C

- Light fuel oil and kerosine.

- Nozzle flow up to 46 l/h (approx.
395 000 kcal/h - 470 kW).

- One or two-pipe system.

PUMP OPERATING PRINCIPLE

The SUNTEC AS oil pump has a built
in solenoid valve which controls the
regulator cut-off valve giving fast cut-off
and cut-on function independent of the
rotational speed.
The gear-set draws oil from the tank
through the built-in filter and transfers
it to the valve that regulates the oil
pressure to the nozzle line.
All oil which does not go through the
nozzle line will be dumped through the
valve back to the return line or, if it is a
one-pipe installation, back to the
suction port in the gear-set.

- TWO-PIPE OPERATION

When the solenoid valve is non­activated, the by-pass channel
between the pressure and return sides
of the valve is open.
No pressure will then be built up to
open the valve. It does not matter
which speed the gear set has.
When the solenoid is activated, this
by-pass channel will be closed and
because of the full speed of the gear­set, the pressure necessary to open
the valve will be built up very rapidly
which gives a very sharp cut-on function.

Solenoid valve open

Pressure
adjustment

Shaft seal

Back to suction

Oil under
suction
Oil under
pressure
By-passed oil
returned to
tank, or to
suction

One pipe installation

Return plugged

- ONE-PIPE OPERATION

Bleeding on one-pipe is not automatic,
and a pressure port must be opened to
bleed the system.

CUT-OFF

When the burner stops, the solenoid
opens the by-pass at the same
moment which drains all the oil down
to the return and the nozzle valve
closes immediately. This gives a very
sharp cut-off function.
The cut-on and off can be regulated
regardless of motor speed and has an
extremely fast response.

Solenoid valve closed

To nozzle

Side

pressure

By-pass
plug
inserted

By-pass
plug
removed

port

Gear-set

Return

Inlet

Two pipe installation

Pressure
gauge
ports

Vacuum
gauge port

When the solenoid is non activated, the
torque requirement is low up to full motor
speed.

Shaft rotation and nozzle location
C: Anti-clock. rotation/

Left hand nozzle (seen from
Shaft end)

Gear set capacity
(see pump capacity curves)

AS:Solenoid valve
with cut-off

AS

47

C

EXCHANGE OF FILTER

MOUNTING/DISMOUNTING
RETURN PLUG

One pipe system

Two pipe system

171 505 04 96-02

NOZZLE TABLE

Gph 8 9 10 11 12 13 14 15

kg/h kW Mcal/h kg/h kW Mcal/h kg/h kW Mcal/h kg/h kW Mcal/h kg/h kW Mcal/h kg/h kW Mcal/h kg/h kW Mcal/h kg/h kW Mcal/h
0,40 1,33 16 13 1,41 17 14 1,49 18 1 5 1,56 18 16 1,63 19 1 7 1,70 20 17 1,76 21 18 1,82 21 18
0,50 1,66 20 17 1,76 21 18 1,86 22 1 9 1,95 23 20 2,04 24 2 1 2,12 25 22 2,20 26 22 2,28 27 23
0,60 2,00 24 20 2,12 25 22 2,23 26 2 3 2,34 28 24 2,45 29 2 5 2,55 30 26 2,64 31 27 2,73 32 28
0,65 2,16 26 22 2,29 27 23 2,42 29 2 5 2,54 30 26 2,65 31 2 7 2,75 33 28 2,86 34 29 2,96 35 30
0,75 2,49 29 25 2,65 31 27 2,79 33 2 8 2,93 35 30 3,08 36 3 1 3,18 38 32 3,30 39 34 3,42 40 35
0,85 2,83 33 29 3,00 36 31 3,16 37 3 2 3,32 39 34 3,47 41 3 5 3,61 43 37 3,74 44 38 3,87 46 39
1,00 3,33 39 34 3,53 42 36 3,72 44 3 8 3,90 46 40 4,08 48 4 2 4,24 50 43 4,40 52 45 4,56 54 46
1,10 3,66 43 37 3,88 46 39 4,09 48 4 2 4,29 51 44 4,48 53 4 6 4,67 55 48 4,84 57 49 5,01 59 51
1,20 3,99 47 41 4,24 50 43 4,47 53 4 6 4,68 55 48 4,89 58 5 0 5,09 60 52 5,29 63 54 5,47 65 56
1,25 4,16 49 42 4,40 52 45 4,65 55 4 7 4,88 58 50 5,10 60 5 2 5,30 63 54 5,51 65 56 5,70 68 58
1,35 4,49 53 46 4,76 56 48 5,02 59 5 1 5,27 62 54 5,50 65 5 6 5,73 68 58 5,95 70 61 6,15 73 63
1,50 4,98 59 51 5,29 63 54 5,58 66 5 7 5,85 69 60 6,11 72 6 2 6,36 75 65 6,60 78 67 6,83 81 70
1,65 5,49 65 56 5,82 69 59 6,14 73 6 3 6,44 76 66 6,73 80 6 9 7,00 83 71 7,27 86 74 7,52 89 77
1,75 5,82 69 59 6,18 73 63 6,51 77 6 6 6,83 81 70 7,14 85 7 3 7,42 88 76 7,71 91 79 7,97 94 81
2,00 6,65 79 68 7,06 84 72 7,45 88 7 6 7,81 93 80 8,18 97 8 3 8,49 101 86 8,81 104 9 0 9,12 108 93
2,25 7,49 89 76 7,94 94 81 8,38 99 8 5 8,78 104 8 9 9,18 109 94 9,55 113 97 9,91 117 101 10,26 122 105
2,50 8,32 99 85 8,82 105 90 9,31 110 9 5 9,76 116 99 10,19 1 21 104 10,61 1 26 108 11,01 13 0 1 12 11,39 135 116
2,75 9,15 108 93 9,71 115 99 10,24 1 21 10 4 10,73 127 1 09 11,21 1 33 114 11,67 138 119 12,11 144 1 23 12,53 148 128
3,00 9,98 118 102 10,59 126 1 08 11,16 1 32 11 4 11,71 139 119 12,23 14 5 125 12,73 15 1 130 13,21 157 1 35 13,67 162 139
3,50 11,65 138 119 12,35 14 6 12 6 13,03 15 4 13 3 13,66 162 1 39 14,27 1 69 145 14,85 176 151 15,42 183 1 57 15,95 189 163
4,00 13,31 158 136 14,12 16 7 14 4 14,89 17 6 15 2 15,62 185 1 59 16,31 1 93 166 16,97 201 173 17,62 209 1 80 18,23 216 186
4,50 14,97 177 153 15,88 18 8 16 2 16,75 19 8 17 1 17,57 208 1 79 18,35 2 17 187 19,10 226 195 19,82 235 2 02 20,51 243 209
5,00 16,64 197 170 17,65 20 9 18 0 18,62 22 1 19 0 19,52 231 1 99 20,39 2 42 208 21,22 251 216 22,03 261 2 25 22,79 270 232
5,50 18,30 217 187 19,42 23 0 19 8 20,48 24 3 20 9 21,47 255 2 19 22,43 2 66 229 23,34 277 238 24,23 287 2 47 25,07 297 256
6,00 19,97 237 204 21,18 25 1 21 6 22,34 26 5 22 8 23,42 278 2 39 24,47 2 90 249 25,46 302 260 26,43 313 2 69 27,49 326 280
6,50 21,63 256 220 22,94 27 2 23 4 24,20 28 7 24 7 25,37 301 2 59 26,51 3 14 270 27,58 327 281 28,63 339 2 92 29,63 351 302
7,00 23,29 276 237 24,71 29 3 25 2 26,06 30 9 26 6 27,33 324 2 79 28,55 3 38 291 29,70 352 303 30,84 366 3 14 31,91 378 325
7,50 24,96 296 254 26,47 31 4 27 0 27,92 33 1 28 5 29,28 347 2 98 30,59 3 63 312 31,83 377 324 33,04 392 3 37 34,19 405 349
8,00 26,62 316 271 28,24 33 5 28 8 29,79 35 3 30 4 31,23 370 3 18 32,63 3 87 333 33,95 403 346 35,25 418 3 59 36,47 432 372
8,50 28,28 335 288 30,00 35 6 30 6 31,65 37 5 32 3 33,18 393 3 38 34,66 4 11 353 36,07 428 368 37,45 444 3 82 38,74 459 395
9,00 29,95 355 305 31,77 37 7 32 4 33,59 39 8 34 2 35,14 417 3 58 36,71 4 35 374 38,19 453 389 39,65 470 4 04 41,02 486 418

The table applies to oil with a viscosity of 4,4 mm2/s (cSt) with density 830 kg/m3.

Pump pressure bar

BURNER WITH PREHEATER

Consider that on preheating the oil quantity is reduced by 5-20% depending on.

- Rise in temperature at the nozzle

- Design of nozzle

- Capacity (high capacity - small difference)

171 505 44 00-01

FAULT LOCATION

BURNER FAILS TO START

Situation

Motor runs Flame instabillity

Burner pre-purges

Flame occurs

Burner locks out

Motor runs

Burner pre-purges

No flame occurs

Burner locks out

Possible causes

Incorrect head settings

Low oil pressure

Excess air

Photo cell not seeing light

Photo cell failed

Control faulty

False light

No spark

No oil

BURNER FAILS TO START AFTER NORMAL OPERATION

Burner fails to start

Fuse has blown

Remedies

Check nozzle to burner head dimension and

elektrode position
Check oil pressure

Adjust air damper

Check that photo cell is clean and unobstructed

Confirm with new photo cell

Confirm with new control. (NB. it is advisable to

change the photo cell if also changing control)

Check that photo cell is not seeing ambient light

Check that H.T. leads are sound and are not

arcing other than at electrode gap

Check oil supply to burner - check that pump

is not airlocked

Check operation of magnetic valve

Check or replace fuse if necessary. Check

reason for failure

Lamp not lit

Motor runs

Burner runs to lockout

Burner pulsates on start-up

only with hot flue

Burner pulsates-on start-up

Appliance thermostat has not reset

Appliance overheat device has operated

Control relay or Photo cell defective

No oil being delivered

Excessive flue draught is preventing

flame establishment

No spark

Reset overheat device. Find reason for its

Check that tank, oil lines, fire valve, pump and

Check ignition transformer. Check electrode

Adjust thermostat

operation and rectify

Check by replacement

nozzle are all in good order

Rectify condition

gap and porecelains

DELAYED IGNITION, BURNERS STARTS VIOLENTLY

Excessive draught

Nozzle partly blocked

Oil pressure too low

Flue blocked or damaged

Fan slipping on shaft

Recommission burner

Replace nozzle

Check and recommission

Check and rectify

Check and retighten

Burner starts violently

171 915 01 91-06

Pump coupling loose or worn

Delayed ignition

Check and replace

Check the electrode adjustment, see diagram

Check electrodes for damage

Check H.T. leads for damage and disconnection

Enertech Limited,
P O Box 1,
Vines Lane
Droitwich,
Worcestershire,
WR9 8NA

Tel: [phone] Fax: [phone]
Email: [e-mail] Web: www.nu-way.co.uk