Nu-Way PO160, PO250, PO310, PO400, PO490 Maintenance Manual

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Page 1

Installation & Maintenance Manual

PO Series Automatic Oil Burner

Fully Modulating

Oil Burner

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

Page 2

PO Series ContentsPage A.2

ONTENTSONTENTS

ONTENTS

IMPORTANT INFORMATION .............................................................................. A.4

SAFETY ................................................................................................................... A.4

EMERGENCY INSTRUCTIONS ........................................................................................ A.4

EUROPEAN BOILER EFFICIENCY DIRECTIVE (B.E.D.) ........................................................ A.4

GENERAL INFORMATION ................................................................................. B.1

INTRODUCTION ....................................................................................................... B.2

FEATURES ............................................................................................................... B.2

Burner Designation .............................................................................................................. B.2

Burner Capacity ...................................................................................................................B.2

Fuel .....................................................................................................................................B.2

Controls...............................................................................................................................B.2

Operating Mode ..................................................................................................................B.2

SITE CONDITIONS AND SERVICES ................................................................................ B.3

Flue and Chimney Requirements ......................................................................................... B.3

Plant Room Ventilation ........................................................................................................B.3

Existing Appliances ..............................................................................................................B.3

Oil Supply ...........................................................................................................................B.3

Electrical Power Supply ........................................................................................................B.4

BURNER PACKAGING, ASSEMBLY AND INSTALLATION ........................................................ B.4

Packaging For Transit ............................................................................................................B.4

Assembly And Installation ....................................................................................................B.4

Fitting To The Appliance.......................................................................................................B.4

Air Supply ............................................................................................................................B.5

Combustion Chamber Conditions ........................................................................................B.5

Electrical Power Supply ........................................................................................................B.5

TECHNICAL SPECIFICATION .............................................................................. C.1

BURNER SPECIFICATION SHEET .................................................................................... C.2

BURNER AND COMPONENT IDENTIFICATION .................................................................. C.3

BURNER OPERATION................................................................................................. C.3

BURNER CONTROLS ................................................................................................. C.3

Modulating Unit .................................................................................................................. C.3

Flame Monitor .....................................................................................................................C.5

BURNER OPERATING SEQUENCE .................................................................................. C.5

Burner Sequence Controller .................................................................................................C.5

RWF40 MODULATING CONTROL............................................................................... C.5

Operation ............................................................................................................................C.5

Basic display ........................................................................................................................ C.5

To change the working set point. ..........................................................................................C.5

To enter a new parameter ....................................................................................................C.6

COMBUSTION HEAD DETAILS ..................................................................................... C.6

COMMISSIONING ......................................................................................... D.1

INDIVIDUAL SETTING RECORD .................................................................................... D.2

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Page A.3

PO Series Contents

SAFETY ................................................................................................................... D.2

MERGENCY INSTRUCTIONS ........................................................................................ D.2

INSPECTION ............................................................................................................ D.2

INITIAL SETTINGS ..................................................................................................... D.3

DRY RUN .............................................................................................................. D.3

LIVE RUN ............................................................................................................... D.3

General .............................................................................................................................. D.3

Oil Supply Temperature And Pressure ................................................................................. D.4

Initial Checks ...................................................................................................................... D.4

MODULATING UNIT ................................................................................................. D.5

COMMISSIONING THE BURNER ................................................................................... D.6

Checking The Flame Signal ................................................................................................. D.6

Setting The Air Pressure Switch ........................................................................................... D.7

Final Checks........................................................................................................................ D.7

RWF40 MODULATION............................................................................................. D.7

On Completing Commissioning ........................................................................................... D.7

COMMISSIONING SHEET : OIL ................................................................................. D.11

E : OPERATION AND MAINTENANCE .................................................................. E.1

NORMAL OPERATION ................................................................................................. E.2

Automatic Modulation......................................................................................................... E.2

ROUTINE SAFETY CHECKS ...........................................................................................E.2

Combustion Air.................................................................................................................... E.2

Flame Detector .................................................................................................................... E.2

Combustion Air Pressure Switch ........................................................................................... E.2

ROUTINE MAINTENANCE ............................................................................................E.2

Combustion Air Fan ............................................................................................................. E.2

Burner Inner Assembly ......................................................................................................... E.3

Oil Filters ............................................................................................................................. E.3

Oil Preheater ....................................................................................................................... E.3

FAULT FINDING .........................................................................................................E.3

Modulating System .............................................................................................................. E.3

Incorrect Rotation of the Fan Motor ..................................................................................... E.3

Fan Motor Fails To Start ........................................................................................................ E.3

Fan Motor Starts And Burner Goes To Lockout ..................................................................... E.4

Start Flame Failure ............................................................................................................... E.4

Main Flame Is Not Established ............................................................................................. E.4

Fan Motor Only Runs Continuously ..................................................................................... E.4

SPARE PARTS ............................................................................................................E.4

BURNER SERVICE RECORD ..........................................................................................E.5

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PO Series ContentsPage A.4

IMPORTANT INFORMATION

AFETYAFETY

AFETY

It is essential that the following instructions and adjustments are carried out by qualified engineers that are experienced in forced draught pressure jet oil burner commissioning. Nu-way cannot be held responsible for any consequential damage, loss or personal injury as a result of customers failing to follow these instructions, or as a result of misuse.

MERGENCYMERGENCY

MERGENCY

I I

NSTRUCTIONSNSTRUCTIONS

NSTRUCTIONS

P Series Burners are designed and constructed to meet all applicable European Directives. When used in accordance with the instructions provided, P Series Burners are unlikely to produce

a hazardous condition. If, however, such a condition should arise in connection with the burner, the appliance or any instrument, machine or service in the vicinity of the burner, the FUEL AND ELECTRICITY SUPPLIES SHALL BE ISOLATED IMMEDIATELY and they shall remain isolated until the fault has been identified and rectified.

UROPEANUROPEAN

UROPEAN

B B

OILEROILER

OILER

E E

FFICIENCYFFICIENCY

FFICIENCY

D D

IRECTIVEIRECTIVE

IRECTIVE

(B.E.D.) (B.E.D.)

(B.E.D.)

All burners and boiler bodies marketed separately within the European Union must comply with EN267 - Oil 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.

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Page B.1

PO Series General Information

GENERAL INFORMATION

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PO Series General Information

Page B.2

NTRODUCTIONNTRODUCTION

NTRODUCTION

This handbook has been produced to enable users to install, commission and use P Series burners safely and efficiently. At each stage the conditions that should be met and the adjustments and other actions which should be carried out are detailed and the locations of the various components and adjustment mechanisms are identified. Where appropriate, this information is supported by tables and graphs.

Literature on the proprietary components used in P Series burner systems is available on request.

EAEA

TURESTURES

TURES

The P Series of fully automatic burner equipment is offered for industrial and air heater applications. This is a versatile range of fully modulating burners with a turndown of 3:1.

P Series burners meet current test authority requirements both in the UK and overseas.

P Series burners are designed for flange mounting to the appliance. All components are pre-wired, input and output circuits being grouped for ease of connection to the power supply and to electrical equipment on the burner head, air damper and oil pumping and heating units.

Larger sizes of PO burners can be supplied with air/steam oil atomisation in place of the usual pressure jet.

This technique, for larger thermal ratings, reduces emissions, increases turndown and prolongs oil pump life because lower oil pressures can be used.

For more information contact Nu-Way.

Burner Designation

Each burner is described by a comprehensive code that defines all the important parameters of each individual burner and is an important point of reference for burners in service. In addition to the burner casing size and maximum power output, the code is composed as shown in the Table on Page B.6.

Burner Capacity

The burner output (based on the gross calorific value) is shown on the Burner Specification Sheet on Page C.2 Technical Details.

Fuel

The PO is available in two forms, to use distillate or residual fuel oils.

Controls

The control panel, housed in a free-standing or wall-mounted cabinet, is a purpose designed and robustly constructed unit that complies with relevant Standards and Codes of Practice and can be tailored to individual customer requirements.

Depending on the burner specification, the control panel incorporates such components as a burner management sequence controller, a fuel selector switch (for the dual fuel range), modulating control gear, a starter for the combustion air fan, starters for fuel pumps and boiler feed water pump, and safety devices e.g. low and high water cut-out relays.

Air for combustion can be adjusted to give maximum efficiency. An air pressure switch provides safe shutdown if the combustion air supply becomes insufficient for complete combustion.

A photo electric cell and automatic programming control unit provide continuous flame supervision.

Operating Mode

P Series burners are all fully modulating offering a standard turndown of 3 to 1.

To ensure efficient operation of any boiler, two requirements are of paramount importance. The air to fuel ratio must be kept to a minimum whilst being sufficient for complete combustion and the settings for this condition, once arrived at, are accurately repeated. The temperature or pressure of the boiler must be monitored by the control system and the correct amounts of fuel and air fired to achieve the set value, variations from this set point must be minimised even when the load changes.

Modulation By Electro-Mechanical Systems P Series burners can be supplied with a Landis and

Staefa RWF40 modulating controller. This unit is designed specifically for the control of boiler temperature or steam pressure in oil- and gas-fired heating plant.

The system comprises a reversible motor that is coupled directly to the cam shaft of the modulating unit. Two adjustable cams are mounted on this shaft, one of which operates the air linkage and the other, the modulating oil cam.

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Page B.3

PO Series General Information

ITEITE

ITE

C C

ONDITIONSONDITIONS

ONDITIONS

A A

NDND

S S

ERVICESERVICES

ERVICES

Flue and Chimney Requirements

It is important that:

- the flue pipe from the appliance and the joint between this flue and the chimney are sealed to prevent leakage of combustion products

- the flue pipe from the appliance does not protrude into the chimney beyond the inside wall

- the top of the flue or chimney shall be higher than any roof within a radius of 10 metres

- checks are made to ensure that the chimney is suitable for oil-fired appliances and that the proposed installation complies with all Local Authority and other regulations covering such installations

- 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

- it is recommended that each appliance should be exhausted into a separate flue.

Plant Room Ventilation

An adequate dust-free supply of fresh air is required for the burner at both high and low levels in accordance with the appropriate standards.

Existing Appliances

The appliance should be prepared for installation of a P Series burner by thorough cleaning, including the removal of all adhering tar, scale and dirt. An inspection should also be carried out to ensure that the appliance is in good condition. Any doubt about the suitability of the appliance should be referred to the manufacturer.

Oil Supply

In addition to the oil system supplied with the burner, there are some requirements for the main oil storage and supply system that supplies oil to the burner system.

Main Oil Storage Tank Residual fuel oils must be maintained at all times

at the temperature specified by the fuel supplier. The Table on Page B.7 shows the temperatures and pressures for Class D, E, F and G oils.

Oil Deliveries It is good practice to shut down boilers whilst the

delivery of oil is made and allow 30 minutes for oil sediment to settle out before re-starting the burners.

Ring Main System The oil from the tank must be supplied to the

burner from a pumped ring main system. A typical system is shown on Page B.8.

The inlet pressure of the oil will depend upon the type of oil. Oil must be handled and delivered at the temperatures and pressures shown in the Table on the Burner Specification Sheet on Page C.2 Technical Specification.

The ring main pumps and pipe size must be designed to at least 1.25 times the total swept volume of the burner pump(s) it supplies. Oil supply pipes must be constructed and installed to comply with local conditions and appropriate Codes and Standards. All pipework must be supported firmly, and in the case of residual oils, lagged, traced and thermostatically controlled. (The minimum pipe size is 1.5 inch BSP).

Galvanised steel pipe should not be used. 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 flow rate that is anticipated.

The final connection to the oil pump inlet port should be made using the flexible pipe supplied with the burner.

Precautions For Residual Oil If heavy oils are heated to too high a temperature,

then lighter fractions will vaporise and this will cause premature wear to the pump.

It is essential to filter heavy fuel oil before the burner inlet. The filtration system should be selected according to the individual features of the installation but the diagram on Page B.8 gives some basic guidelines. The ring main pressure should be measured at the pump vacuum gauge port to allow for any pressure drop caused by the filters.

For residual oil burners the pipework should be insulated, trace heated and thermostatically controlled.

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PO Series General Information

Page B.4

Electrical Power Supply

A three phase 50 Hz electrical supply is required. Power requirements are listed on the Burner Specification Sheet on Page C.2 Technical Specification. The power supply provided must comply with all relevant Codes and Standards.

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ACKACK

ACK

AGINGAGING

AGING

, A, A

, A

SSEMBLSSEMBL

SSEMBL

NDND

I I

NSTNST

NST

ALLALL

ALL

TIONTION

TION

Packaging For Transit

All PO Series modulating burners are supplied in partly assembled form consisting of the following:

- burner head and air plenum chamber

- damper section with modulating air system

- modulating oil system as appropriate

- combustion air fan

- floor/wall mounted burner control panel

- a pumping and heating unit, or pumping unit only for distillate oil burners, is supplied as a separate component inclusive of flexible pipes to make all necessary oil connections.

Assembly And Installation

P Series burners are supplied in partly assembled form comprising some or all of the units indicated above, depending upon the type(s) of fuel to be fired.

Make sure that the appliance is suitable for the heat input of the burner. If there is any doubt in this area, reference should be made to the appliance manufacturer.

Fitting To The Appliance

If the burner is to be fitted to a new appliance refer to the manufacturer’s recommendations.

If the burner is to be fitted to an existing appliance, the burner front plate and appliance must be prepared; the details of the drilling arrangements are shown on Page B.7.

The chimney, flues, passageways and heat transfer surfaces on the existing appliances must be cleaned. An inspection should be carried out to ensure that the appliance is in good condition. Any doubt about the suitability of the appliance should be referred to the manufacturer.

To assemble the burner: 1 Fit the burner head to the prepared

appliance front plate.

2 Ensure that the joint between the burner and

the mounting flange is sealed effectively using the gasket provided. The flame tube should not generally extend beyond the inner face of the furnace brickwork or the front plate protection, except where extensions have been expressly specified by the appliance manufacturer.

3 Fit the damper section to the burner head

using the fasteners and gasket provided.

4 Position the combustion air fan and connect

the damper section using the fasteners and gasket provided. Depending on the appliance layout it may be necessary for the customer to provide a connecting duct section between the damper and the fan scroll (not supplied by Nu-way).

5 For PO burners, place the pumping and

heating unit (or pumping unit) in the desired position.

6 Connect the flexible oil pipes from the oil

inlet and return to the pumping (and heating) unit, and the main oil supply pipework.

7 Locate the control panel in the desired

position and make the necessary connections between the burner head, pumping (and heating) unit and other auxiliary appliance controls.

Reference must be made to the wiring diagrams that are supplied with the burner (electrical connection diagrams do not form part of this handbook); all electrical wiring must comply with all applicable Codes and Standards.

Air Supply

A floor-mounted fan provides the air supply for the system, although the fan can be suspended for the smaller sizes of burner. The flange on the rectangular outlet is drilled for bolting onto the air damper section of the burner unit. For safety, a wire mesh guards the circular inlet of the fan. The motor unit is enclosed, air-cooled and mounted on a rigid base. The fan orientation/burner mounting positions would have been specified by the customer when the order was placed.

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SUPPLEMENT TO HANDBOOKS

SPECIFICATION CHANGES

In accordance with the Requirements for Electrical Installations BS 7671:2001 Amendment No 2 (the IEE wiring regulations), wiring colour coding has been amended to Brown (L) and Blue (N) for single phase power circuits and Brown (L1) Black (L2) and Grey (L3) and Blue (N) in three phase power circuits from 1 June 2006.

Full details of the changes can be found in Amendment No 2 (AMD 14905) to BS 7671:2001 - which is a free download from the IEE website (www.iee.org/cablecolours). They are also within the new version of BS7671:2001 (Incorporating Amds 1& 2) published on 31st March; this new version of the Wiring Regulations can be identified by its brown cover.

Supplement Wiring.PMD

Revision 120606A

NEW WIRING COLOURS

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Page B.5

PO Series General Information

Electrical Power Supply

Connect the power supply to the burner observing all applicable Codes and Standards. Reference should be made to the wiring diagrams provided in the instruction pack that is supplied with all P Series burners and to those wiring diagrams in the appliance manufacturer’s instructions.

All external auxiliary control circuits should be connected with reference to the appropriate wiring diagram. All systems and circuits should be checked to ensure that correctly rated fuses are used.

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PO Series General Information

Page B.6

URNERURNER

URNER

D D

ESIGNAESIGNA

ESIGNA

TIONTION

TION

C C

ODEODE

ODE

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Page B.7

PO Series General Information

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OUNTINGOUNTING

OUNTING

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ETET

AILAIL

AIL

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ANDLINGANDLING

ANDLING

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EMPERA

TURESTURES

TURES

A A

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P P

RESSURESRESSURES

RESSURES

Fuel

Class

Viscosity

(Seconds)

Minimum

From Tank

Burner

Inlet

Atomising

kg/cm

psi

D 35 0.35 to 0.70 5 to 10

E 200 16 16 82

960 30 43 110 1500 36 65 118 3500 50 82 132 4200 55 86 140

Fuel Handling Temperatures (°C)

Fuel Delivery Pressures

Minimum 5 Recommended

4 to 5 57 to 71

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PO Series General Information

Page B.8

YPICYPIC

YPIC

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P P

UMPEDUMPED

UMPED

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INGING

ING

M M

AINAIN

AIN

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Page B.9

PO Series General Information

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PO Series General Information

Page B.10

AAD \PFinal\B_Gen\PO\B_Gen.pmd 250504A

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Page C.1

PO Series Technical Specification

TECHNICAL SPECIFICATION

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PO Series Technical SpecificationPage C.2

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S S

PECIFICPECIFIC

PECIFIC

TIONTION

TION

S S

HEETHEET

HEET

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Page C.3

PO Series Technical Specification

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OMPONENTOMPONENT

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The general arrangement of a PO burner employing RWF40 Controller is shown in the diagram Burner and Component Identification on Page C.7. An enlarged view of the burner head casing is shown in the diagram on Page C.8.

These diagrams are for illustrative purposes only and actual components supplied may vary from those shown.

All personnel concerned with commissioning and/ or operation of P Series burners should familiarise themselves particularly with the information presented in this section.

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PERAPERA

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TIONTION

TION

When the boiler control calls for heat, the burner modulating unit will travel to the ‘high flame’ position and interlock the control circuit. An air pre-purge will take place at this position for a predetermined period, at the end of which the burner sequence controller will stop until the modulating unit has travelled to the ‘low flame’ position and interlocked the control circuit again. The sequence control will now recommence its operational cycle and the burner will light and remain at low flame until the high flame release signal is given by the sequence control.

Under the instruction of the modulating controller, the modulating unit will now move to high flame and remain at this position until the desired boiler temperature/pressure is attained. From this stage, the modulating controller will drive the burner towards the low flame position, but, depending on the temperature/pressure, will stop in any intermediate position between low and high flame.

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ONTROLSONTROLS

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Modulating Unit

The Nu-way modulating unit consists of a reversible servomotor, which is directly coupled to the camshaft of the modulating unit. Two adjustable cams are mounted on this shaft, one of which is operating the burner air inlet control damper and is of the variable contour type, the second cam is the modulating oil cam (see illustrations on Page C.18).

Oil System The Burner Oil Control System Drawings on pages

C.10 & .11 show the burner hydraulic circuit. Oil for combustion is drawn from the supply through a fixed displacement pump and supplied direct to the burner nozzle. A return line from the back of the nozzle is connected to a ‘spill regulating valve’ which regulates the oil pressure at the nozzle according to the position of an internal piston which is actuated by the oil control cam in the modulating unit.

Air Damper To control the air for combustion, PO burners have

an adjustable multi-blade damper located in a rectangular section attached directly to the burner casing (diagrams on Pages C.7 and C.8). This damper is driven directly by a servo-motor and must be set during commissioning.

Air Diffuser An air diffuser (shown in the diagram Burner Head

on Page C.15) is fitted to the front end of the inner assembly and is located within the flame tube. It directs the combustion air flow and creates a pressure drop across the burner head, promoting good air/fuel mixing and flame stability.

Air Pressure Switch The air pressure switch is located on the rear of

the burner casing. Its function is to ensure that the combustion air flow is adequate under all operating conditions.

An air flow failure at any stage beyond the first few seconds of the pre-purge period will result in a safe burner shutdown.

Oil Controls The components vary according to whether

distillate or residual oil is fired. In all cases a twopipe system is essential to ensure that the oil pump remains primed. The oil must be supplied and maintained at the temperature and pressure given in the Table on Page B.8.

PO burners are supplied with an oil system where specified, (see diagrams on Page C.10 Distillate Oil Control Train Schematic and on Page C.11 Residual Oil Control Train Schematic) consisting of :

- pumping/heating set

- oil manifold block

- oil valve (normally-closed; for distillate fuel oil)

- inner gun assembly housing the oil nozzle

- oil solenoid valve (tip shut-off)

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PO Series Technical SpecificationPage C.4

- motorised spill control valve

- non-return valve Pumping Set For Class D Fuel The pump unit is free standing and comprises :

- oil pump

- motor

- oil filter(s)

- air bottle The unit is assembled for floor mounting (see

diagrams Distillate Oil Pumping Set on Page C.12 and Oil Pumps on Page C.9). This unit is designed to deliver the oil volume and pressure for the required burner output.

Filter(s) are an integral part of the burner oil supply system. The filter(s) should be checked regularly as failure to do so may result in a drop in oil pressure to the system.

Pumping/Heating Set For Class E, F and G Fuels The pump unit is free standing and comprises :

- oil pump

- motor

- hot oil filter

- cold oil filter(s)

- air bottle

- isolation valve (for residual fuel oil)

- return thermostat

- oil pre-heater tank with thermometer to record the temperature of the oil at the outlet. The pre-heater contains three thermostats:

- High limit thermostat

- Control thermostat

- Low limit thermostat (reverse acting)

The return thermostat is fitted in the return oil line and will override the burner firing controls and start the burner oil pump in order to maintain the correct oil temperature in the nozzle and burner pipework.

The thermostats should be set to the temperatures specified in the Table forming part of diagram Residual Oil Pumping Set on Page C.13.

The unit is pre-assembled on a base plate for floor mounting (see diagrams Residual Oil Pumping Set on Page C.13 and Oil Pumps on Page C.9). This unit is designed to deliver the oil volume at temperature and pressure for the required burner output.

The pump should not be started when the oil is cold as this can lead to damage to the pump and couplings. The oil must be supplied and maintained at the temperature and pressure given in the Table on Page B.8.

Filter(s) are an integral part of the burner oil supply system. The filter(s) should be checked regularly as failure to do so may result in a drop in oil pressure to the system.

Oil Control Train The oil control train consists of a high pressure fuel

pump driven by the burner fan motor. The oil nozzle throughput is controlled by a

variable orifice regulator situated in the return supply oil line, and actuated by the Modulating Unit described below. Solenoid operated normally closed valves in the feed and return lines act as the safety shut off for the nozzle.

Oil Manifold The oil manifold block is located on the burner

casing and incorporates pressure gauges to measure pump and spill pressures.

Solenoid Valve For burners designed for distillate oil firing there is

a solenoid valve which is ‘normally-closed’ and is located between the manifold block and the oil lance (see diagram on Page C.10).

There is no solenoid valve fitted when the system is designed to fire residual oil (see diagram on Page C.11).

Inner Assembly Gun The oil inner assembly gun is located in the middle

of the head casing assembly of the burner. Its primary function is to carry oil from the oil pump to the nozzle and to recirculate the oil back through the spill regulating valve.

The spill-back atomiser utilises a spring loaded orifice shut-off needle that is closed by the spring of the actuating piston of the burner lance. This guarantees a reliable shut-off under any condition. This piston is driven by the supply pressure, via a branch pipe, and controlled by a solenoid valve. The needle opens by means of a spring and moves to the correct position governed by a fixed stop on the needle itself.

During the pre-purge period the needle holds the orifice closed and the fuel oil circulates through the lance and the atomiser under the set supply and return pressure. When the solenoid is actuated, immediate oil atomisation and ignition are achieved.

Page 20

Page C.5

PO Series Technical Specification

Oil Nozzle The oil nozzle is of the spill-back type and is fitted

to the front end of the inner assembly and located in the flame tube. Page C.6.

The primary function of the nozzle is to spray oil in a suitable pattern into the combustion air stream at a rate appropriate to the appliance’s thermal rating.

Oil Solenoid Valve (tip shut-off) This valve operates the needle that releases oil to

the burner tip. Non-return Valve This valve allows flow in one direction only. Control Panel The control panel is a separate unit, free-standing

or wall-mounted, that is positioned adjacent to the burner unit. The panel design depends upon whether the boiler is for water heating or steam raising. The sequence controller, relays, indicating lamps, panel isolating switch etc. are contained within this unit.

The burner is also fitted with an ignitor/terminal box on the side of the burner casing. This is a junction for all electrical components that are held in the free standing control panel.

Connections must be made between the control panel and the terminal box.

Flame Monitor

All P Series burners are fitted with continuous flame supervision systems employing a photo electric cell to detect the presence of a flame.

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EQUENCEEQUENCE

EQUENCE

The operating sequence of P Series Burners begins with checks on external interlocks and a check for no flame, a pre-purge period on full air is then initiated.

On completion of the pre-purge period the appropriate oil valve or valves open, ignition is initiated and low fire is established then the burner modulates to high fire.

The burner sequence controller will then continue to its normal operating position (i.e. it continues to supervise the control functions and is therefore able to shutdown the burner safely should this be necessary), after driving to high fire, the modulating controller will drive the burner towards the low flame position, but, depending on the temperature/ pressure, will stop in any intermediate position between low and high flame.the burner will be controlled by the modulation controller.

Burner Sequence Controller

The burner sequence controller, together with the flame monitoring system, provide a safe light-up sequence for the burner.

A Landis & Staefa burner controller of the type LAL2.25 (see the diagram Burner Sequence Controller : Landis & Staefa LAL2.25 on Page C.14) is fitted as standard.

RWF40 MRWF40 M

RWF40 M

ODULODUL

ODUL

TINGTING

TING

C C

ONTROLONTROL

ONTROL

Operation

The burner employs a modulation system using a Landis & Staefa RWF40 Universal Controller (shown on Page C.17). The modulating unit drives a reversible motor that is coupled directly to the combustion air damper linkage. When the RWF40 determines that a change to the burner output is required, the air damper and the oil spill back regulating valve are adjusted accordinly.

Basic display

The diagram on Page C.17 shows the RWF40 after switching on the supply voltage. This condition is called the basic display. The actual operating value and the currently active set-point will be shown. Manual operation, self-optimization, the operating parameter and the configuration levels can be activated from this display.

To change the working set point.

The basic display shows the actual pressure/ temperature of the boiler in red and the required set point pressure/temperature beneath in smaller green digits.

One quick press of the PGM button, the display changes to show the set point as the larger red digits and the SPI in the lower small green digits.

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PO Series Technical SpecificationPage C.6

LUIDICSLUIDICS

LUIDICS

O O

ILIL

N N

OZZLEOZZLE

OZZLE

Alter the red display using the up/down buttons to show the new required set point, press exit or let the unit time out to return to the basic display which should be the new set point figure.

To enter a new parameter

The parameters dictate the way in which the burner firing rate alters in response to changes in the pressure/temperature of the boiler.

A major factor that determines the need to change the parameters is if the burner is fitted to a steam or hot water boiler. The table on Page C.18 indicates the parameter and its setting for steam and hot water boilers. It must be emphasised that it is only an indication and any departure from these settings should be made in small increments, with time given to see how the burner is reacting to the changed parameter.

Press and hold the PGM button down until the green set point figure changes to an AL, the larger upper figures show the value. Use the up/down buttons to set the new value, press the PGM button to enter the value and change to the next screen. To cancel an entry press exit. Scroll through the screens, (PGM button) modifying any value found to be in error (up/down buttons). At the last screen the PGM button will return the controller to the original operating display.

At any point in the procedure the original operating display can be obtained by letting the unit time out, the value in the display at the time out will be accepted.

A value can only be altered within the permitted range of that parameter. All other parametrs must remain as supplied.

Note: The detector range parameters SCL & SCH are given as °C for Hot Water (temperature) and bar for Steam (pressure).

OMBUSTIONOMBUSTION

OMBUSTION

H H

EADEAD

EAD

D D

ETET

AILSAILS

AILS

The combustion Head and Inner assembly are shown in the diagram Burner Head on Page C.15.

Page 22

Page C.7

PO Series Technical Specification

URNERURNER

URNER

A A

NDND

C C

OMPONENTOMPONENT

OMPONENT

I I

DENTIFICDENTIFIC

DENTIFIC

TIONTION

TION

Combustion Air

Control Damper

Ignitor/Terminal

Box Assembly

Oil Valve

Assembly

Burner

Head Casing

Transition

Ductwork

Combustion

Air Fan

Modulating Cam Uni

Oil Lance

Flame Tube

Inner Assembly

Access Plate

Combustion Air Fan

This diagram is for illustrative purposes only.

Actual components supplied may vary from those shown.

Please refer to the Burner Specification Sheet and the drawings elsewhere in this manual for details of the components supplied.

Oil spill control valve

Page 23

PO Series Technical SpecificationPage C.8

metItnenopmoC

1)'a'x3(tekcoSdoRediuG

2etalpkcaBylbmessArennI

3ssalGthgiS

4gniRrotpadAetalpkcaB

5redloHlleC.V.U 6kcolBpmalCecnaLrenruB 7egauGerusserPliOtelnI 8egauGerusserPliOkcaBllipS 9evlaVlipS

01eniLdeelBffo-tuhSpiTelzzoN

11tinUmaCdnarotoMgnitaludoM

21)'b'x4(stuNgniniateRetalpkcaB 31enaVlortnocriA 41tinUrepmadriA 51ylbmessAkcolBlanimreTdnarotingI 61seldnaHlawardhtiWetalpkcaB 71gnisaCdaeHrenruB 81dioneloSffo-tuhSpiTelzzoN 91ecnaLliOkcaBllipS

URNERURNER

URNER

ANDAND

AND

C C

OMPONENTOMPONENT

OMPONENT

I I

DENTIFICDENTIFIC

DENTIFIC

TIONTION

TION

D D

ETET

AILAIL

AIL

1 23 4 5

Oil Inlet from

Pump Unit

Page 24

Page C.9

PO Series Technical Specification

ILIL

P P

UMPSUMPS

UMPS

Page 25

PO Series Technical SpecificationPage C.10

ISTILLISTILL

ISTILL

TETE

O O

ILIL

C C

ONTROLONTROL

ONTROL

T T

RAINRAIN

RAIN

S S

CHEMACHEMA

CHEMA

TICTIC

TIC

Notes:

1 All interconnecting pipework must have a minimum bore of 19mm (3/4") and must be pressure

rated for 42kg/cm².

2 Pipework connections between the burner oil system and the separate pumping set are not

supplied by Nu-Way. 3 Connections to the ring main on the air separator bottle air 1" BSP. .

Spill Back Nozzle

Tip Shut Off Solenoid Valve

Solenoid Valve

Pressure Guages

Manifold Block

Quick Release Couplings

Flexible Connections

Spill Control Valve

Non Return Valve

Feed To Burner

Return from Burner

Feed

Return

Pump

Cold Filter

Air Separator

Return to Ring Main (Optional)

Inlet from Ring Main

Pressure Switch

Burner Mounted Components

Pumping Set Components

Page 26

Page C.11

PO Series Technical Specification

ESIDUESIDU

ESIDU

ALAL

O O

ILIL

C C

ONTROLONTROL

ONTROL

T T

RAINRAIN

RAIN

S S

CHEMACHEMA

CHEMA

TICTIC

TIC

Spill Back Nozzle

Tip Shut Off Solenoid Valve

Pressure Guages

Manifold Block

Quick Release Couplings

Flexible Connection

Spill Control Valve

Non Return Valve

Feed To Burner

Return from Burner

Feed

Return

Pump

Cold Filter

Air Separator

Return to Ring Main (Optional)

Inlet from Ring Main

Pressure Switch

Lockshield Isolation Valve

Hot Filter

Thermometer

Burner Mounted Components

Pumping/Heating Set Components

Notes:

1 All interconnecting pipework must have a minimum bore of 19mm (3/4") and must be

pressure rated for 42kg/cm².

2 Pipework connections between the burner oil system and the separate pumping set are

not supplied by Nu-Way. 3 Connections to the ring main on the air separator bottle air 1" BSP. 4 On residual fuel oil burners this pipework must be maintained at the burner atomising

temperature and in the case of class F and class G fuels must also be trace heated.

Page 27

PO Series Technical SpecificationPage C.12

ISTILLISTILL

ISTILL

TETE

O O

ILIL

P P

UMPINGUMPING

UMPING

S S

ETET

Page 28

Page C.13

PO Series Technical Specification

ESIDUESIDU

ESIDU

ALAL

O O

ILIL

P P

UMPINGUMPING

UMPING

/H/H

EAEA

TINGTING

TING

S S

ETET

Page 29

PO Series Technical SpecificationPage C.14

URNERURNER

URNER

S S

EQUENCEEQUENCE

EQUENCE

C C

ONTROLLERONTROLLER

ONTROLLER

: L : L

: L

ANDISANDIS

ANDIS

& S & S

& S

AEFAEF

AEF

L L

AL2.25AL2.25

AL2.25

Enlarged Detail Of Sequence Indicator

Sequence Indicator

In the event of a fault condition the sequence disc stops rotating, with the symbol appearing above the indicator mark indicating the nature of the fault. If the fault leads to a lockout condition the orange lockout indicator will be illuminated.

Symbol Lockout Fault

Yes

None Yes

Yes

Failure of one or more of the pre-start checks. Before allowing the sequence to begin the unit carries out the following checks:

Burner Controller not in lockout position.

ir Damper Closed (proved by limit switch supplying voltage from terminal

11 to terminal 8).

Fuel Valves closed (

roved by limit switch supplying voltage to terminal 12)

Fuel pressure switch, Limit Thermostat or Limit Pressure Switch all closed (proved by continuity between terminals 4 and 5)

Interru

tion to sequence whilst controller waits for the air damper to drive to

open position (proved by servo motor limit switch).

Lockout caused by the failure of the air pressure switch to changeover from the 'no air' position shortly after the pre-purge. Lockout caused by a fault in the flame supervision circuit.

Interruption to sequence whilst controller waits for the air damper to drive to start position (proved by servo motor limit switch). Lockout during the pre-ignition period not marked by a symbol is usually caused by premature flame signal.

Lockout caused by the absence of a flame signal at the end of the first safety period (time for start flame establishment).

Lockout caused by the loss of the flame signal during normal operation.

Page 30

Page C.15

PO Series Technical Specification

URNERURNER

URNER

H H

EADEAD

EAD

Page 31

PO Series Technical SpecificationPage C.16

LECTRODELECTRODE

LECTRODE

S S

ETTINGETTING

ETTING

D D

ETET

AILAIL

AIL

Page 32

Page C.17

PO Series Technical Specification

ODULODUL

ODUL

TIONTION

TION

C C

ONTROLLERONTROLLER

ONTROLLER

: L : L

: L

ANDISANDIS

ANDIS

ANDAND

AND

S S

AEFAEF

AEF

RWF40 RWF40

RWF40

Page 33

PO Series Technical SpecificationPage C.18

ODULODUL

ODUL

TINGTING

TING

U U

NITNIT

NIT

(Cams shown in the Low Flame Position)

Motor Unit

Camstack

Lever

Servomotor

Oil Spill Back

Regulating Valve

Oil Cam -

Air Cam -

Oil Cam Adjusting Screw

Oil Cam Hub

Rotation for High Flame Position

Locking Screws

Spill Pressure

Reduce Increase

Cam Disk

Roller

Adjustable Plunger

Cam Follower

Throw

Oil Cam View On -

Adjuster Locking Screws

Profile Adjuster

Profile Band

Damper Drive Arm

Cam Lever

Roller

Retaining Saddl

Return Spring

ir Cam View On -

Page 34

Page C.19

PO Series Technical Specification

Page 35

PO Series Technical SpecificationPage C.20

AAD PFinal\C_Tech\Po\RWF40\C_Tech.pmd 250504A

Page 36

Page D.1P Series Commissioning

COMMISSIONING

Page 37

P Series CommissioningPage D.2

NDIVIDUALNDIVIDUAL

NDIVIDUAL

S S

ETTINGETTING

ETTING

R R

ECORDECORD

ECORD

This manual contains commissioning sheets (Page D.11) of essential information that should be completed by the commissioning engineer with individual details of the burner. These details should be verified periodically and changed as adjustments occur.

AFETYAFETY

AFETY

IIt is essential that commissioning be undertaken only by suitably qualified and experienced personnel. In the case of P Series Burners, commissioning engineers should be experienced in commissioning forced draught, fully modulating oil burners.

Nu-way can accept no responsibility for consequential loss, damage or injury, which results from a failure to follow the commissioning instructions provided or from commissioning procedures being undertaken by unqualified personnel.

It is the commissioning engineer’s responsibility to ensure that all settings are in accordance with the appropriate local standards and applicable codes of practice.

MERGENCYMERGENCY

MERGENCY

I I

NSTRUCTIONSNSTRUCTIONS

NSTRUCTIONS

P Series Burners are designed and constructed to meet all applicable European Directives.

When used in accordance with the instructions provided, P Series Burners are unlikely to produce a hazardous condition. If, however, such a condition should arise in connection with the burner, the appliance or any instrument, machine or service in the vicinity of the burner, the FUEL

AND ELECTRICITY SUPPLIES SHALL BE ISOLATED IMMEDIATELY and they shall remain

isolated until the fault has been identified and rectified.

NSPECTIONNSPECTION

NSPECTION

Before commissioning is started it is important to:

- Check that the electrical wiring is complete and complies with all applicable Codes and Standards.

- Ensure that the fuses are fitted and are of the correct ratings.

- Check electrical earthing.

- Verify that the oil pipework is correctly sized and that it has been checked for leakage.

- Check that the appropriate modulating detector which is supplied loose with each burner, is fitted correctly to the appliance. (Technical Specification Pages C.2).

- Make all personnel involved in the commissioning aware of the location of the emergency oil and electricity isolation points.

- Check that the appliance's ventilation and flueing arrangements are adequate.

- Ensure that any warning notices appropriate to the commissioning procedure are in position.

- Ensure that all necessary tools and test equipment are available and ready for use. Essential items include temperature measuring instruments for measuring flue gas and appliance water temperatures, and a means of analysing the flue products for carbon dioxide (CO2), oxygen (O2), carbon monoxide (CO) and smoke.

- Check that all relevant documentation is available, including, where appropriate:

- The agreed plant performance

specification.

- Plant drawings and pipework layouts.

- Electrical logic and wiring diagrams.

- Certificates confirming satisfactory

completion of procedures such as soundness testing, purging and electrical safety tests.

- Commissioning, operating, emergency

shutdown and maintenance instructions for the plant.

- Establish that the operation of plant other than that being commissioned will not have an adverse effect on the operation of the plant to be commissioned, and similarly, that the operation of the plant to be commissioned will not have an adverse effect on other plant.

- Confirm that the operation of adjacent plant and machinery will not constitute a hazard to the personnel involved in commissioning.

- Establish that the appliance is in an appropriate and safe condition to be fired; for example, that there is water in the boiler.

- Set the appliance controls to call for heat.

Page 38

Page D.3P Series Commissioning

NITIALNITIAL

NITIAL

S S

ETTINGSETTINGS

ETTINGS

To prepare the burner for commissioning:

1. Check that the electrical power to the control panel and to the burner is off.

2. Remove the cover from the Landis & Staefa SQM10 air damper servo-motor and check the cam positions. Adjust if necessary.

3. Check and if necessary re-set the ignition electrode gaps. The burner head arrangement is shown on Page C.16 and access instructions are provided in Operation and Maintenance on Page E.3.

4. When the inner assembly is out and whilst the back cover is off, check that the air damper is in the closed position. If not in the closed position put power on to the control panel. DO NOT SWITCH ON THE BURNER. The damper servomotor should run to the closed position and stop. After the motor has stopped the damper blades should be fully closed, if not adjust the blades on their spindles.

Warning - In some applications the fan may be

running so care must be exercised.

5. Set the air pressure switch to minimum. (This must be re-set to the desired level during commissioning).

RYRY

R R

UNUN

The following procedure should be followed. It is important that a complete and flawless dry run be completed before fuel is supplied to the system.

1. Check that the electrical supply to the control panel and burner are turned off.

2. Switch the burner On/Off switch to ‘OFF’ position.

3. Check that the oil pipework and ringmain are ready for operation.

4. Set the Hand/Auto switch on the control panel to the ‘Hand’ position.

5. Establish the electrical supply to the control panel. Press the sequence controller re-set button if necessary. If the sequence controller is not at its start position it will motor round to its start position and wait.

6. Ensure that the flame detection system detects the presence of a simulated flame or, where permissible an independent flame source.

Remove the flame detector from the burner, expose the detector to a flame or simulated flame. This should cause a lockout indicated by illumination of the corresponding indicator light on the control panel.

7. Replace the flame detector in its housing in the burner. Reset the sequence controller using the ‘Reset’ button on the control panel.

8. Switch off the electrical power supply to the control panel and to the burner.

IVEIVE

IVE

R R

UNUN

General

The instructions in this section are presented as a sequence. No separate set of actions (for example, checking the flame signal) should be followed in isolation without paying particular attention to any safety precautions such as isolating the electrical supply to the burner which must precede such actions. At all stages, the operation of the burner should be checked against the programming sequence controller diagram (Technical Specification Page C.14).

Before proceeding check again that :

· The electrical wiring is complete and complies with all relevant Codes and Standards.

· All fuses are fitted, and are of the correct ratings.

· The oil supply pipework is correctly installed and has been leak tested. If, at any time during commissioning, there is a fuel leak,

FUEL AND ELECTRICITY SUPPLIES SHALL BE ISOLATED IMMEDIATELY and the leak

sealed before proceeding.

· The appliance is in an appropriate and safe condition to be fired.

· The appliance controls are set to call for heat.

Oil Supply Temperature And Pressure

Check that the temperature and pressure of the oil delivered to the burner are as stated in General Information Page B.8. If residual fuel is used check that the oil supply is at the correct temperature. For residual oil ensure that pressure inlet to the pump is correct, for distillate oil pressure set to 1bar.

Page 39

P Series CommissioningPage D.4

Initial Checks

1. Remove the access lid on the modulating cam box unit.

2. Establish electrical supply to the control panel and switch the burner on. If the burner sequence controller is at lockout press the re-set button.

3. Switch on the burner at the control panel. The modulating unit camshaft should now rotate to the high flame setting, and the combustion air motor will start the air prepurge phase.

4. Observe that the rotation of the combustion air fan is in the direction of the arrow on the fan casing. If the fan rotation is incorrect, switch off the electricity supply and take action to remedy this.

5. Check motor rotation is correct for the pump.

6. The burner will proceed through its ignition sequence. Check that an ignition spark is present. (If there is no spark and the burner goes to lockout the air pressure switch may require adjustment - refer to Operation and Maintenance Page E.2).

7. Remove and cover the photoelectric cell with a clean lint free cloth, switch on the burner, and allow it to run through to lockout. During this run check that the ignition spark is occurring, and note the spill and line oil pressures at the moment of ignition. Reset the sequence control and repeat the run if necessary to check these functions. If necessary, adjust the spill pressure to the correct figure according to the nozzle specification and the line pressure at the burner pump to 27.8 bar (400 psi).

8. The ignition spark will cease and the system will go to lockout.

9. Uncover and replace the photocell.

10. Switch off the burner and the electrical power supply to the control panel.

THE BURNER IS NOW READY TO BE COMMISSIONED.

OMMISSIONINGOMMISSIONING

OMMISSIONING

THETHE

THE

B B

URNERURNER

URNER

Establish fuel supply to the burner. Establish electrical supply to the control panel and switch the burner on. If the burner sequence controller is at lockout press the re-set button.

Warning - From this point onwards the ignition sequence will be initiated and fuel will be admitted to the burner. Care must be exercised.

NOTE: HAND/AUTO Selector switch. This switch must always be in the ‘auto’ position

when the burner is required to start. The ‘hand’ selection can be made immediately the burner has stated to fire. Should the burner stop in the ‘hand’ position it will restart but will not modulate until ’auto’ has been selected.

1. With the ‘hand/auto’ switch set to ‘hand, ‘inch’ the camshaft round until the back of the oil cam is in line with the spill valve push rod. This is the low flame position. Adjust the oil cam to about 1.5mm (3mm stroke) and lock in that position.

2. Check to ensure the spill valve push rod bears lightly against the cam.

3. Turning now to the air cam, adjust the thumbscrews out to a reasonable maximum and adjust the linkage until the air damper is fully closed. Note the position of the operating lever against the air damper position scale in the cam box.

4. ‘Inch’ the camshaft back to the ‘high flame’ position, i.e. through 180°, and adjust the band by means of the thumbscrews until the air inlet damper is open to suit the desired high flame position. Again note the operating lever position on the scale. At this stage it will have been found that nearly all the thumbscrews have been adjusted to avoid straining the band, which will now have a fairly smooth contour between low and high flame positions.

5. ‘Inch’ the camshaft back to the low flame position, and adjust the thumbscrews to give a small opening at the air damper, using the scale as a guide.

6. Check all fuel and electrical supply connections to the burners. Set HAND/ AUTO switch to “AUTO”.

Page 40

Page D.5P Series Commissioning

7. Reset the sequence controller and allow the burner to start pump. Immediately the burner starts, switch the ‘hand/auto’” selector to the ‘hand’ position and hold the low flame until the appliance is ready to accept high flame. During this period check and adjust the low flame oil throughput.

8. Check flame visually. If flame is not clean, adjust the air cam. When a satisfactory flame is achieved, again check line and spill pressures. The oil consumption rate should now be between 40 and 50% of the rated maximum.

9. Measure flue gas composition and adjust air as necessary.

10. Use the ‘inching’ switch to modulate to high flame and adjust the air cam to give a reasonable flame.

11. Check the oil consumption. If this is not correct for the full burner rating the oil cam must be adjusted as follows:-

12. ‘Inch’ burner to low flame, and carefully note spill pressure. To increase the minimum rate adjust as shown in the diagram. Adjust to give more eccentricity for more oil at high flame, and vice versa.

13. Return to minimum setting and compensate for any changes.

14. ‘Inch’ the burner to high flame and again check oil flow.

15. Continue to repeat the above procedure until the high flame oil rate is correct.

16. ‘Inch’ the burner to two or three intermediate positions between low and high flame, and adjust the air cam at each position to give the desired flue gas analysis.

17. Check burner performance through the range, adjust air can as necessary and secure the thumbscrews by means of the grub screws.

Checking The Flame Signal

1. Check that electrical power is off.

2. Open the ‘Terminal/Ignitor Box Unit’ panel and disconnect the wire from terminal 20.

3. Connect a DC micro-ammeter between terminal 20 and the wire that has been taken from terminal 20.

4. Establish the electrical supply and switch on the burner. Allow the burner to light and operate normally.

5. Observe the reading on the micro-ammeter at all firing levels. A steady reading in excess of 7 microamps is satisfactory. Lower readings may cause intermittent burner lock-out and indicate a need for adjustment of the burner settings - refer to Section E, Operation and Maintenance.

6. Switch off the burner and the electrical power supply to the burner. Disconnect the microammeter and replace the wire in terminal 20.

7. Close the ‘Terminal/Ignitor Box Unit’ panel.

Setting The Air Pressure Switch

1. Check that the electrical supply to the control panel off and that the burner is off.

2. Remove the air pressure switch cover.

3. Fit a manometer or other approved pressure measuring instrument to the pressure switch so that the actual measured air pressure can be compared to the pressure switch dial setting.

4. Check that the Hand/Auto switch is set to Hand operation.

5. Switch on electrical supply to the control panel. Switch on the burner, allow the burner to proceed through its sequence until it is operating at low flame.

6. Slowly turn the adjusting dial on the air pressure switch clockwise until the flame is extinguished.

7. The burner will go to lock-out.

8. Turn the dial one division anti-clockwise and re-set burner lock-out. The burner will then continue through its cycle until either the start rate flame is established or burner goes to its lock-out position.

If the burner goes to lock-out, repeat the procedure (turning the dial one division) once per burner cycle until start rate flame is established.

9. Allow the burner to cycle to low flame and then turn the adjusting dial a further two divisions anti-clockwise.

10. Switch off electrical supply to the control panel and to the burner.

11. Replace the air pressure switch cover.

Page 41

P Series CommissioningPage D.6

12. Remove the pressure measuring equipment.Final Checks

Final Checks

1. Check that all covers have been replaced and that all locking devices are secure.

2. Check the operation of the appliance control instruments and safety interlocks.

3. Ensure that the appliance safety controls and any other interlocks are set to safe limits.

4. COMMISSIONING OF THE BURNER IS

NOW COMPLETE.

RWF40 MRWF40 M

RWF40 M

ODULODUL

ODUL

TIONTION

TION

A description of the operation of the RWF40 is

provided in the Technical Specification Section on Pages C5 and C.6.

1. On the RWF40 check the parameter settings and configuration values (Technical Specification Page C.2)

2. Dial in the required Set Point.

3. Establish the electrical supply to the control panel and switch on the burner.

4. Switch the Hand/Auto switch to Auto operation.

The burner modulation is now under the control

of the RWF40.

5. Allow the burner to proceed through its operating sequence and check that it is responding appropriately.

The burner will now operate normally until:

(a) It is switched off by the appliance

controls. (b) It is switched off manually. (c) There is an electrical power failure. In

this event the burner will restart and

run normally when power is restored.

No manual intervention is required. (d) A failure in any of the safety functions

monitored by the sequence controller.

On Completing Commissioning

When commissioning has been completed satisfactorily the commissioning engineer shall prepare a report, which shall contain the following:

1. Details of any modifications made to the system, together with revised drawings if necessary.

2. Customer and plant details, including any serial numbers.

3. Operating levels and settings, including flue gas analysis information.

This report shall be passed to the person responsible for the plant. This responsible person shall ensure that:

1. All personnel concerned with operating, supervising and maintaining the plant receive instruction covering:

- The way in which the plant operates

and the locations and functions of the plant's safety systems.

- The correct light-up and shutdown

procedures.

- Adjustment of operating variables.

- Checking of plant interlocks.

- The plant's maintenance requirements.

- The actions to be taken in the event of

a fault condition.

2. Clear light-up and shutdown procedures are displayed on the plant and that the pipes, valves and switches involved are clearly marked.

3. CLEAR AND CONCISE EMERGENCY

SHUTDOWN PROCEDURES ARE DISPLAYED.

Page 42

Page D.7P Series Commissioning

Page 43

P Series CommissioningPage D.8

OMMISSIONINGOMMISSIONING

OMMISSIONING

S S

HEETHEET

HEET

: O : O

: O

ILIL

Appliance

Serial No.

Burner

Serial No.

High

Fire

Low

Fire

Units

Oil

bar or

Air

mbar or

ins w.

kg/h or

lb/h

MW or

MJ/h or

Btu/h

% Dry

Basis

% Dry

Basis

ppm Dry

Basis °C or

°F

°C or

°F

°C or

°F %

Note : Where a choice of measurement units is shown, delete those not applicable

Flue Temp.

Ambient Temp.

Temp. Difference

Efficiency

Heat input

Firing Rate Intermediate Positions

Pressure at burner

Oil rate

Standing

bar or

Running

bar or psi

Commissioning Date : Guarantee Expiry Date : Fuel Oil Type : Oil pressure upstream of pump :

Type : Size :

Site Address :

The details below are to to be completed by the Commissioning Engineer. The completed sheet must then be

hotocopied and a copy forwarded to the appliance manufacturer.

Installer's Name :

Address :

Page 44

Page D.9P Series Commissioning

AAD PFinal\C_Tech\Po\RWF40\D_Comm.pmd 250504A

Page 45

P SeriesPage 10

Page 46

Page E.1

PO Series Operation And Maintenance

E : OPERATION AND MAINTENANCE

Page 47

PO Series Operation And MaintenancePage E.2

ORMALORMAL

ORMAL

O O

PERAPERA

PERA

TIONTION

TION

Automatic Modulation

1. Establish the electrical power supply to the control panel.

2 Ensure that the oil supply is operational at

the correct temperature and pressure

3. Switch on the burner. The burner will go through the ignition sequence and be released to modulation under the control of the RWF40

The burner will now operate normally until :

- It is switched off by the appliance

controls

- It is switched off manually

- There is an elevtrical power failure. In

this event the burner will restart and run normally whuen power is restored. No manual intervention is required.

- A failure in any of the safety functions

monitored by the sequence controller.

OUTINEOUTINE

OUTINE

S S

AFETYAFETY

AFETY

C C

HECKSHECKS

HECKS

THESE CHECKS SHOULD BE CARRIED OUT ONLY BY APPROPRIATELY QUALIFIED AND EXPERIENCED PERSONNEL

Combustion Air

Check that the plant room is well ventilated at all times and inspect the burner air inlet frequently to ensure that there is no obstruction to the air flow.

Flame Detector

1. Switch off the burner and the electrical supply to the control panel

2. Remove the PE cell from the burner casing and cover the quartz glass envelope to exclude light. Care should be taken not to touch the glass.

3. Establish the electrical supply to the control panel and switch on the burner. The burner should go to lockout at the end of the ignition cycle.

4. Switch off the burner and the electrical power supply to the burner. Replace the PE cell. Establish the electrical supply to the burner and switch on the burner. Reset the lockout.

Combustion Air Pressure Switch

1. Check that the electrical supply to the control panel off and that the burner is off.

2. Remove the air pressure switch cover.

3. Fit a manometer or other approved pressure measuring instrument to the pressure switch so that the actual measured air pressure can be compared to the pressure switch dial setting.

4. Switch on electrical supply to the control panel. Switch on the burner, allow the burner to proceed through its sequence until it is operating at low flame.

5. Slowly turn the adjusting dial on the air pressure switch clockwise until the flame is extinguished.

6. The burner will go to lock-out.

7. Turn the dial one division anti-clockwise and re-set burner lock-out. The burner will then continue through its cycle until either the start rate flame is established or burner goes to its lock-out position.

If the burner goes to lock-out, repeat the procedure (turning the dial one division) once per burner cycle until start rate flame is established.

8. Allow the burner to cycle to low flame and then turn the adjusting dial a further two divisions anti-clockwise.

9. Switch off electrical supply to the control panel and to the burner

10. Replace the air pressure switch cover.

11. Remove the pressure measuring equipment.

OUTINEOUTINE

OUTINE

M M

AINTENANCEAINTENANCE

AINTENANCE

ALWAYS SWITCH OFF THE ELECTRICAL POWER AND FUEL SUPPLIES TO THE BURNER BEFORE CARRYING OUT MAINTENANCE.

Combustion Air Fan

Access the fan blades as follows:

1. Remove the ring of nuts on the air inlet side of the fan unit

2. Remove the plate containing the air inlet.

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Page E.3

PO Series Operation And Maintenance

Clean the fan blades with a stiff brush, taking care not to damage them. Inspect the burner air inlet and ensure that there is no obstruction to the air flow.

Replace the plate and retaining nuts.

Burner Inner Assembly

Air Diffuser Remove the burner air diffuser plate for inspection

and cleaning as follows: -

1. Remove the PE cell from its holder and secure to a safe place.

2. Fit the three guide rods through the sockets on the front plate.

3. Loosen and remove the 4 nuts and washers securing the backplate to the burner casing.

4. Pull the backplate assembly rearwards, guiding the inner tube until the diffuser is clear of the burner head casing

5. Clean the diffuser of any deposits using a stiff brush.

Ignition Electrodes Clean and check the electrodes are not cracked or

worn. Renew if necessary. Check the settings of the ignition electrodes and

reset if necessary, details are shown on Page C.16. Oil Nozzle Remove the oil nozzle, dismantle it and wash the

internal filter and other components in a suitable solvent. Remove any remaining deposits with a clean, lint-free cloth. The oil nozzle should be replaced after 2000 hours operation.

Re-assemble the inner assemblies in reverse order. Replace all covers and secure all fittings. The burner is now ready for operation and remove the guide rods. Switch on the electrical and fuel supplies to the burner.

Oil Filters

The oil filter located on top of the preheater should be removed and cleaned in paraffin or another suitable solvent.

SAFETY WARNING : CLASS ‘G’ OIL BURNERS OPERATE WITH OIL AT 140°C FOR ATOMISATION. THE BURNER SYSTEM SHOULD BE TAKEN OFF LINE AND ALLOWED TO COOL BEFORE ATTEMPTING THESE TASKS.

In the case of the cold oil filter, remove the plug from the sump and drain off any sludge and/or water present at six-weekly intervals. The cleaning knob on this filter should be rotated daily. If the filter fitted in the oil supply line has a disposable element this should be replaced at least once a year, more frequently if this is dictated by the condition of the fuel or other local conditions. If the filter element is re-usable it should be cleaned at appropriate intervals. After filter cleaning operations it will be necessary to remove air from the system by bleeding the pump.

Oil Preheater

Regular checks should be made to ensure that the oil temperature is maintained at the correct level (refer to the table on Page B.8).

ULUL

F F

INDINGINDING

INDING

Any changes made in control settings as a result of identifying and remedying fault conditions as described below may necessitate partial or complete recommissioning. Recommissioning shall be undertaken only by appropriately qualified and experienced personnel.

Modulating System

If malfunction of the modulating controller (RWF40) is suspected, check that only a compatible pressure/temperature detector has been used. If problems persist then replacement of the unit should be considered.

Incorrect Rotation of the Fan Motor

The fan motor rotates in the direction of the arrow printed on the Nu-way nameplate mounted on the fan casing. If the direction of rotation is incorrect, interchange any two phases.

Fan Motor Fails To Start

Check that :

- The electricity supply is available

- The burner is correctly wired

- The fuses are correctly sized and not blown

- The motor overload is not tripped

- The burner controller is not locked out

- The appliance controls are calling for heat

- The oil preheater thermostats and oil temperature

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PO Series Operation And MaintenancePage E.4

Fan Motor Starts And Burner Goes To Lockout

If there is no ignition spark check that:

- The combustion air pressure sensor setting is correct

- The ignition electrodes are in good condition and correctly set

- The HT lead is not disconnected or damaged

- The ignition transformer is not faulty

- The burner controller is not faulty

If there is an ignition spark but no start flame check

- The oil supply to the burner

- The oil pump

- The pump

- The pump coupling

- The pump drive motor

- The oil presssure and temperature are in accordance with the values in the Table on Page B.8

- The oil valve(s) have opened at the appropriate time in the sequence

- The filters are clear

- The nozzle is clear

- There is no carbon on the diffuser

Start Flame Failure

Failure of the start flame during the start flame proving period will cause the sequence controller to go to lockout. If this occurs check that:

- The glass envelope on the PE Cell is clean and correctly orientated (it must face towards the flame)

- The PE Cell and wiring are not faulty

- There is no carbon on the diffuser

- The nozzle is clear

- The flame detector current is adequate and stable.

- The burner sequence controller is not faulty

- There is sufficient fuel under ignition conditions to enable the flame to be detected adequately.

Main Flame Is Not Established

Check that:

- The fuel pressure and flow rate are adequate

- The fuel valves are open at the appropriate time in the sequence

- The manual isolation valves are open fully and there are no partial blockages in the control train

Fan Motor Only Runs Continuously

Check that:

- The air valve positioning motor is correctly wired and working

AREARE

ARE

P P

ARTSARTS

ARTS

For spare parts contact Nu-way's Parts And Components Division at the address and telephone number listed on the rear cover of this manual. To avoid delays, please provide the burner model and serial numbers.

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