!Nu Way NOL R Modulating

Models NOL/NOR Modulating Revision 101199B

HHHHHANDBOOKANDBOOKANDBOOKANDBOOKANDBOOKSeries NO fully automatic oil burnersModels NOL/NOR Modulating

Distillate & Residual Fuel Oils


CCCCCONTENTSONTENTSONTENTSONTENTSONTENTSBBBBBURNERURNERURNERURNERURNER & C & C & C & C & COMPONENTOMPONENTOMPONENTOMPONENTOMPONENT I I I I IDENTIFICDENTIFICDENTIFICDENTIFICDENTIFICAAAAATIONTIONTIONTIONTION F F F F FOROROROROR NO35-34 T NO35-34 T NO35-34 T NO35-34 T NO35-34 TOOOOO NO100-38 M NO100-38 M NO100-38 M NO100-38 M NO100-38 MODULODULODULODULODULAAAAATINGTINGTINGTINGTING

BBBBBURNERSURNERSURNERSURNERSURNERS 44444

BBBBBURNERURNERURNERURNERURNER & C & C & C & C & COMPONENTOMPONENTOMPONENTOMPONENTOMPONENT I I I I IDENTIFICDENTIFICDENTIFICDENTIFICDENTIFICAAAAATIONTIONTIONTIONTION F F F F FOROROROROR NO100-41 T NO100-41 T NO100-41 T NO100-41 T NO100-41 TOOOOO NO150-44 M NO150-44 M NO150-44 M NO150-44 M NO150-44 MODULODULODULODULODULAAAAATINGTINGTINGTINGTING

BBBBBURNERSURNERSURNERSURNERSURNERS 66666

IIIIINTRODUCTIONNTRODUCTIONNTRODUCTIONNTRODUCTIONNTRODUCTION 88888

FFFFFEAEAEAEAEATURESTURESTURESTURESTURES 88888Burner Nominal Capacities 8Controls and Safety Systems 8Operating Mode 8Fuels 8

SSSSSITEITEITEITEITE C C C C CONDITIONSONDITIONSONDITIONSONDITIONSONDITIONS ANDANDANDANDAND S S S S SERVICESERVICESERVICESERVICESERVICES 88888Flue and Chimney Requirements 8Plant Room Ventilation 8Existing Appliances 8Combustion Chamber Conditions 8Oil System 9Main Oil Storage Tank 9Oil Supply to the Burner 9Single Pipe System 9Pumped Ring Main System 9Burner Pump Capacities 9Filtration 9Electrical Power Supply 9

UUUUUNPNPNPNPNPACKINGACKINGACKINGACKINGACKING ANDANDANDANDAND A A A A ASSEMBLSSEMBLSSEMBLSSEMBLSSEMBLYYYYY 99999

TTTTTYPICALYPICALYPICALYPICALYPICAL R R R R RINGMAININGMAININGMAININGMAININGMAIN O O O O OILILILILIL S S S S SYSTEMYSTEMYSTEMYSTEMYSTEM 1010101010

BBBBBURNERURNERURNERURNERURNER O O O O OILILILILIL S S S S SYSTEMYSTEMYSTEMYSTEMYSTEM 1111111111

IIIIINSTNSTNSTNSTNSTALLALLALLALLALLAAAAATIONTIONTIONTIONTION 1212121212General 12Fitting To the Appliance 12Connections 12Electrical Power Connection 12

BBBBBURNERURNERURNERURNERURNER C C C C CONTROLONTROLONTROLONTROLONTROL ANDANDANDANDAND O O O O OPERAPERAPERAPERAPERATIONTIONTIONTIONTION 1212121212Burner Description 12

EEEEELECTRICALLECTRICALLECTRICALLECTRICALLECTRICAL C C C C CONNECTIONONNECTIONONNECTIONONNECTIONONNECTION D D D D DIAGRAMIAGRAMIAGRAMIAGRAMIAGRAM 1313131313

BBBBBURNERURNERURNERURNERURNER C C C C CONTROLSONTROLSONTROLSONTROLSONTROLS 1414141414Oil Pumping / Pumping & Heating Units 14Modulating Unit 14Residual Oil Heating Controls 14Safety Features 14

OOOOOILILILILIL P P P P PUMPINGUMPINGUMPINGUMPINGUMPING / P / P / P / P / PUMPINGUMPINGUMPINGUMPINGUMPING & H & H & H & H & HEAEAEAEAEATINGTINGTINGTINGTING S S S S SETETETETET 1515151515

CCCCCOMMISSIONINGOMMISSIONINGOMMISSIONINGOMMISSIONINGOMMISSIONING 1616161616IMPORTANT - SAFETY 16EMERGENCY INSTRUCTIONS 16Inspection 16Pre-firing Checks 16


IIIIIMPORTMPORTMPORTMPORTMPORTANTANTANTANTANT - S - S - S - S - SAFETYAFETYAFETYAFETYAFETY

It is essential that the following instructions and adjustments are carried out by qualified engineers thatare experienced in pressure jet oil burner commissioning. The manufacturer cannot be held responsi-ble for any consequential damage, loss or personal injury as a result of customers failing to follow theseinstructions, or as a result of misuse. Your attention is drawn to the Emergency Instructions on page 16

EEEEEUROPEANUROPEANUROPEANUROPEANUROPEAN B B B B BOILEROILEROILEROILEROILER E E E E EFFICIENCYFFICIENCYFFICIENCYFFICIENCYFFICIENCY D D D D DIRECTIVEIRECTIVEIRECTIVEIRECTIVEIRECTIVE (B.E.D.) (B.E.D.) (B.E.D.) (B.E.D.) (B.E.D.)All burners and boiler bodies marketed seperately should comply with EN267 (oil burners) or EN676(gas burners) and EN303-1 (boiler bodies).Burner adjustments must be made in accordance with boiler manufactures� instructions, and thesemust include flue gas temperatures, average water temperature, and CO2or O2 concentration.

Hand Auto Selector Switch 17Commissioning the Burner 17

MMMMMODULODULODULODULODULAAAAATINGTINGTINGTINGTING U U U U UNITNITNITNITNIT 1818181818

RRRRROUTINEOUTINEOUTINEOUTINEOUTINE M M M M MAINTENANCEAINTENANCEAINTENANCEAINTENANCEAINTENANCE OFOFOFOFOF NOL/NOR M NOL/NOR M NOL/NOR M NOL/NOR M NOL/NOR MODULODULODULODULODULAAAAATINGTINGTINGTINGTING B B B B BURNERSURNERSURNERSURNERSURNERS 1919191919General 19Daily Checks 20Cleaning the Oil Nozzle 20Photoelectric Cell 20Cold Oil Filter(s) 20Replenishing the Fuel Supply 20Boiler Combustion Surface 20

FFFFFAAAAAULULULULULTTTTT F F F F FINDINGINDINGINDINGINDINGINDING 2020202020If the Burner Fails to Start 20If the burner is found at lockout (red lockout lamp illuminated) 20Flame Occurs Followed by Immediate Lockout 21The Burner Starts With The Correct Oil Pressure But No Flame Appears 21Modulating System 21

FFFFFUELUELUELUELUEL P P P P PUMPSUMPSUMPSUMPSUMPS 2121212121Danfoss Series KSA Fuel Pumps 21Suntec Series TA Fuel Pumps 21Suntec Series TV Pressure Regulating Valve 21Oil Pumps - Where Used 23

FFFFFLLLLLAMEAMEAMEAMEAME F F F F FAILAILAILAILAILUREUREUREUREURE & S & S & S & S & SEQUENCEEQUENCEEQUENCEEQUENCEEQUENCE C C C C CONTROLSONTROLSONTROLSONTROLSONTROLS 2323232323Burner Control Program 23

MMMMMODULODULODULODULODULAAAAATINGTINGTINGTINGTING C C C C CONTROLONTROLONTROLONTROLONTROL 2424242424Landis & Staefa RWF32 24RWF32 Recommended Settings 24

BBBBBURNERURNERURNERURNERURNER O O O O OILILILILIL N N N N NOZZLEOZZLEOZZLEOZZLEOZZLE 2626262626

SSSSSERVICEERVICEERVICEERVICEERVICE & R & R & R & R & REPLEPLEPLEPLEPLACEMENTACEMENTACEMENTACEMENTACEMENT 2626262626

AAAAAPPENDIXPPENDIXPPENDIXPPENDIXPPENDIX 2727272727Burner Performance Graph 27Burner Head Details & Electrode Settings 28Electrical Data Table 29Burner Commissioning Sheet 30


BBBBBURNERURNERURNERURNERURNER & C & C & C & C & COMPONENTOMPONENTOMPONENTOMPONENTOMPONENT I I I I IDENTIFICDENTIFICDENTIFICDENTIFICDENTIFICAAAAATIONTIONTIONTIONTION F F F F FOROROROROR NO35-34 T NO35-34 T NO35-34 T NO35-34 T NO35-34 TOOOOO NO100- NO100- NO100- NO100- NO100-38 M38 M38 M38 M38 MODULODULODULODULODULAAAAATINGTINGTINGTINGTING B B B B BURNERSURNERSURNERSURNERSURNERS

Standard Burner Arrangement ShownAll dimensions are mm.

A

B

123

6

4

9

1011

8

7

Projection 270

EDC

G30

0

F D

ia.


12

5

Hole�H� Dia.

Burner Mounting Details

8 Holes M10 Equispaced On305mm PCD

metI noitpircseD

1 gnisaCrenruB

2 noisnetxEdegniH

3 ebuTemalF

4 rotoMnaF

5 telnIriA

6 rotoMlortnoCgnitaludoM

7 lenaPlortnoC

8 tinUmaCgnitaludoM

9 evlaVlortnoCllipSliO

01 noitcennoCtelnIliO

11 noitcennoCliOnruteR

21 revoCnoitcepsnInaF

ledoMrenruB A B C D E F G H

43-81*ON 769 037 024 754 034 281 783 612

83-81*ON 4101 557 754 084 034 281 084 612

43-53*ON 769 037 024 754 034 322 783 452

83-53*ON 4101 557 754 084 034 322 084 452

82-05*ON 769 037 024 024 034 322 783 452

43-05*ON 769 037 754 754 034 322 783 452

83-05*ON 4101 557 084 084 034 322 084 452

82-06*ON 769 037 754 754 034 322 783 452

43-06*ON 769 037 084 084 034 322 783 452

83-06*ON 4101 557 084 084 034 322 084 452

83-58*ON 4101 557 735 735 034 452 084 082

83-001*ON 4101 557 735 735 034 452 084 082


BBBBBURNERURNERURNERURNERURNER & C & C & C & C & COMPONENTOMPONENTOMPONENTOMPONENTOMPONENT I I I I IDENTIFICDENTIFICDENTIFICDENTIFICDENTIFICAAAAATIONTIONTIONTIONTION F F F F FOROROROROR NO100-41 T NO100-41 T NO100-41 T NO100-41 T NO100-41 TOOOOO

NO150-44 MNO150-44 MNO150-44 MNO150-44 MNO150-44 MODULODULODULODULODULAAAAATINGTINGTINGTINGTING B B B B BURNERSURNERSURNERSURNERSURNERS

Compact Burner Arrangement ShownAll dimensions are mm

1210

270

906

Projection

385

545

440

595

345

565

614

23

1

15 4

9

10

11

16

7

13

8

305

Dia


Burner Mounting Details

4 Holes M20 Equispaced On454mm PCD

Hole330mmDia.

45°

12

5

metI noitpircseD

1 gnisaCrenruB

2 noisnetxEdegniH

3 ebuTemalF

4 rotoMnaF

5 telnIriA

6 rotoMlortnoCgnitaludoM

7 lenaPlortnoC

8 tinUmaCgnitaludoM

9 evlaVlortnoCllipSliO

01 telnIliOdaeHrenruBnoitcennoCesaeleRkciuQ

11 liOnruteRdaeHrenruBnoitcennoCesaeleRkciuQ

21 revoCnoitcepsnInaF

31 remrofsnarTnoitingI

metI noitpircseD

41 elttoBrotarepeSriA

51 tinUretaeherPliO

61 tinUgnipmuPliO

Items 14 to 16 Refer toCompact Modulating Burners

Only

Upon request NO Modulating burnerscan be supplied in the fully assembled�compact� configuration as shown.On �compact� models NO*18, 35 & 50the Oil Pump may be driven by the fanmotor. All other models utlise anindependant pumping set.Supply oil connections are made to theAir Seperator Bottle item 14. Refer tothe Pumping Unit connections shownon page 15 for identification.

Standard burners are supplied with afloor mounted pumping or pumping &heating unit. In this configuration, thesystem oil connections 10 & 11 onpages 4 & 5 refer.


IIIIINTRODUCTIONNTRODUCTIONNTRODUCTIONNTRODUCTIONNTRODUCTION

This manual has been produced to enable usersto install, commission and use NO Modulatingburners safely and efficiently. The manual coverstwo types of burner: Models NOL distillate (ClassD fuel) oil burners and models NOR residual (ClassE, F & G) oil burners. At each stage the conditionswhich should be met and the adjustments andother actions which should be carried out are de-tailed and the locations of the various componentsand adjustment mechanisms are identified. Whereappropriate, this information is supported by ta-bles and graphs. Literature on the proprietary com-ponents used in NO Modulating systems is avail-able on request.

FFFFFEAEAEAEAEATURESTURESTURESTURESTURES

Developed through extensive field experience inthe UK and overseas markets, the NO Fully modu-lating series meets the current known test author-ity requirements in these markets and sets newstandards in efficient and reliable operation. NOModulating burners are designed for flange mount-ing to the appliance front plate and they are deliv-ered ready to install with a pre-wired packagedcontrol system and oil pumping or pumping & heat-ing unit.

Burner Nominal CapacitiesNO18 (2 Models) 530 kW 42.0 kg/hNO35 (2 Models) 940 kW 74.0 kg/hNO50 (3 Models) 1750 kW 138.0 kg/hNO60 (3 Models) 2100 kW 165.5 kg/hNO85 (1 Model) 2432 kW 192.0 kg/hNO100 (2 Models) 2930 kW 231.5 kg/hNO125 (3 Models) 3668 kW 290.0 kg/hNO150 (3 Models) 4396 kW 347.0 kg/h

Controls and Safety SystemsNO Modulating burners are fitted with an auto-matic sequence / flame failure control and photo-electric cell for continuous flame supervision. Acombustion air flow control coupled to an oil noz-zle pressure control system ensures smooth start-ing and optimum operating effeciency.

Operating ModeIn standard form the NO Fully Modulating burnercan provide a turndown range of up to 3:1.

FuelsNO burners covered in this manual are designedto fire distillate and residual fuel oils, which com-ply with the specifications given in the tables onpage 10. NO burners configured for firing other fuelgrades may be available on request.

SSSSSITEITEITEITEITE C C C C CONDITIONSONDITIONSONDITIONSONDITIONSONDITIONS ANDANDANDANDAND S S S S SERVICESERVICESERVICESERVICESERVICES

Flue and Chimney RequirementsIt is important that:� The flue pipe from the appliance and the

joint between this flue and the chimney aresealed to prevent leakage of combustionproducts.

� The flue pipe from the appliance does notprotrude into the chimney beyond the insidewall.

� The top of the flue or chimney shall be higherthan any roof within a radius of 10 metres.

� Checks are made to ensure that the chim-ney is suitable for oil fired appliances and thatthe proposed installation complies with allLocal Authority and other regulations cover-ing such installations.

� If more than one appliance is connected toa common flue or chimney the cross-sectionof this flue or chimney should be adequatefor the total volume of combustion productsfrom the appliances. It is recommended thateach appliance should be exhausted into aseparate flue.

Plant Room VentilationThe burner must be supplied with dust free air atsufficient rates for all firing conditions, in accord-ance with the appropriate standards.

Existing AppliancesThe appliance should be prepared for installationof the NO burner by thorough cleaning, includingthe removal of all adhering tar, scale and dirt. Aninspection should also be carried out to ensurethat the appliance is in good condition. Any doubtabout the appliances suitability for oil firing shallbe referred to the appliance manufacturer.

Combustion Chamber ConditionsThe combustion chamber conditions should notexceed those shown on page 27 of this manual.


Burners working with zero rated combustionchamber conditions can be subjected to a maxi-mum negative chamber condition of 0.05 kPa (0.5mb)

Oil SystemRefer to the drawings on page 11 for details of theburner oil system.

Main Oil Storage TankResidual oils must be maintained at all times to atemperature specified by the supplier.

Oil Supply to the BurnerThe oil supply from the storage tank to the burnermay be provided by:(a) Single pipe gravity feed system. Class D only.(b) Pumped ring main system. Class E, F and G

fuels.

Single Pipe SystemThe height of the main storage tank above theburner and the sizing of the pipe to the burner mustbe designed so that the oil pressure at the burneroil pump inlet is not less than 35 kPa (0.35 bar).The maximum oil pressure at the burner pump inletmust not exceed 500 kPa (5.0 bars) under any op-erating conditions.The pipe must be sized to the full swept volume ofthe burner oil pump and not the capacity of theburner nozzles.

Pumped Ring Main SystemThe pumped ring main is the preferred system ofoil supply and is essential for multiple burner in-stallations and where heavy residual fuel oils areto be used.The ring main pumps and supply pipe work mustbe designed to cater for 1.25 times the total sweptvolume of the burner oil pumps connected to thesupply system.All oil supply pipes must be constructed and in-stalled to comply with local conditions and appro-priate codes of practice and standards. All pipework must be firmly supported and in the case ofresidual fuel oils, lagged, traced and thermostati-cally controlled. A Pressure Reducing Valve (PRV)should be fitted to control the supply pressure.Further details are shown in the typical ring maindiagram on page 10

Burner Pump CapacitiesThe oil pumps used on Nu-Way modulating oilburners are listed in the table on page 23. It is es-sential that the full swept volume of the pump beconsidered when oil supply lines or ring main sys-tems are calculated.The minimum recommended size of the supplypipe or ring main is 2� BSP when residual oil isused.Lagging and tracing is considered essential for re-sidual fuel. The table on page 10 gives the recom-mended storage and oil supply temperature re-quired at the burner pump.

FiltrationWhen using fuel oils and in particular residualgrades, filtration of the oil is essential. The filtra-tion system should be chosen according to the in-dividual features of the installation. The ring mainsystem diagram on page 10 gives guidelines. Whenthe ring main pressure is checked then this shouldbe measured at the burner pump vacuum gaugeport to allow for any pressure drop across the fil-ters.Failure to provide a good clean oil supply will al-most certainly lead to premature wear and rapidfailure of the oil pump unit.

Electrical Power SupplyA three phase 50 Hz supply is required (60 Hzburners are available on request). Power require-ments are tabulated in the Appendix of this hand-book. The power supply provided must complywith all relevant Codes and Standards.

UUUUUNPNPNPNPNPACKINGACKINGACKINGACKINGACKING ANDANDANDANDAND A A A A ASSEMBLSSEMBLSSEMBLSSEMBLSSEMBLYYYYY

To safeguard against damage in transit, NO Modu-lating burners may be supplied in partly assembledform in one of three alternative modes:

Mode 1:The complete burner unit fully assembled.

Mode 2:Burner body complete with control panel. Com-bustion head hinged extension and flame tubeassemblyTo assemble the burner:Assembly of the burner can be completed after fit-ting the hinged extension/flame tube assembly tothe appliance.


Alternatively, fit the extension/flame tube assem-bly to the burner body using the eight nuts andwashers provided.

A pumping and heating unit, or pumping unit inthe case of distillate burners is supplied as a sepa-rate component to modes 1 and 2 and is inclusiveof flexible pipes to make all the necessary oil con-nections.

Mode 3:Upon request NO Modulating burners can be sup-plied in a fully assembled compact configuration.These burners include the oil pumping and condi-tioning unit mounted beneath the burner bodyand are pre-piped, requiring only the connectionof fuel and electrical supplies to complete the in-stallation. The suitability for installation of com-pact modulating burners should be referred to theappliance manufacturer as the addition of the oilpumping or pumping & heating unit adds extraweight to the appliance frontplate.

TTTTTYPICYPICYPICYPICYPICALALALALAL R R R R RINGMAININGMAININGMAININGMAININGMAIN O O O O OILILILILIL S S S S SYSTEMYSTEMYSTEMYSTEMYSTEM

Oil StorageTank

Tank Heater

Outflow Heater

PressureRegulator

Return From Burner(If Fitted)

Feed To Burner

PressureRelief Valve

Sludge Valve Non ReturnValve

Non ReturnValve

40 MeshFilter

80 MeshFilter

OilPumps

LineHeaters

DrainValve

P

PT

T

T

T

P

Temperature Switch

Pressure Switch

Manual Shut Off Valve

Duplex Pumping &Heating Sets

The fitting of duplex Oil Pumping &Heating sets is recommended for sys-tem continuity and serviceability.Line heaters are recommended forClass F & G fuels. They are generallynot necessary for Class E fuel.

Pre-heating of Class D fuel is not re-quired, however fuel companies rec-ommend a minimum fuel temp of 5°Cand that all exposed pipework shouldbe lagged.

T

leuFssalC sceS muminiM

knaTmorFottelnIrenruB

gnisimotAerutarepmeT

D 53 - - -

E 002 C°61 C°61 C°28

F 069 C°03 C°34 C°011

0051 C°63 C°56 C°811

G 0053 C°05 C°28 C°231

0024 C°55 C°68 C°041

Fuel Handling Temperatures


BBBBBURNERURNERURNERURNERURNER O O O O OILILILILIL S S S S SYSTEMYSTEMYSTEMYSTEMYSTEM

Hyd

Ret

�n

Feed

Fluidics Atomiser Burnerlance

Inner Manifold

Outer Manifold

Oil Pressure Gauge

Spill Valve

Filter OilPump

Oil Preheater(Residual Fuel

Only)

Hot OilFilter

Thermometer

Pressure Relief Valve

Non Return Valve

NO/NC = Normally Open/ClosedOil Solenoid Valve

Manual Shut Off Valve

Air SeperatorBottle

NO NC

All inter-connecting pipework to be mini-mum 19mm bore and pressure rated for42kg/cm2 (600 psi).

On Residual fuel burners this pipework mustbe maintained at the burner atomising tem-perature and In the case of Class �F� and �G�fuels, must also be traced.

Distillate oil burners require a pump inletpressure of 0.35 to 0.70 kg/cm2 (5 to 10 psi).For Residual fuel, the oil inlet temperaturemust be maintained as recommended in thetable on page 10, and the pump inlet pres-sure set between 4&5 bar.

If a shut off valve is fitted in the inlet line, apressure relief valve set at 0.7 kg/cm2 (10 psi)above the supply pressure must be fittedto prevent damage should the valve be leftshut during burner/heater start-up.

Pumped Systems - All Burners

Pumped Supply From Ringmain. Minimum Bore25mm Class D / 50mm Class E, F & G

Not Supplied By Nu-way

Pipework Shown In Chain Dot Not SuppliedBy Nu-way. (Not Required On Compact

Burner Arrangement)

Flex OilPipes

NO

ReturnT�stat

Notes.The Oil Preheater, Return Oil Thermo-stat and Spill Valve NO bypass SolenoidValve are not fitted on Distillate fuelsystems.


IIIIINSTNSTNSTNSTNSTALLALLALLALLALLAAAAATIONTIONTIONTIONTION

GeneralEnsure that the appliance is suitable for the heatinput of the burner. If there is any doubt in thisarea, reference shall be made to the appliancemanufacturer. Detailed burner performance dataare presented in the appendix of this handbook.

Fitting To the ApplianceIf the burner is to be fitted to a new appliance re-fer to the appliance manufacturers recommenda-tions.If the burner is to be fitted to an existing appliancea mounting flange must be provided as detailed inthe section on Burner & Components Identifica-tion. Ensure that the joint between the burner andthe mounting flange is sealed effectively using thegasket provided.The flame tube should not extend beyond the in-ner face of the appliance combustion chamberunless the appliance manufacturer specifies exten-sions, for example in the case of reverse flame boil-ers.

ConnectionsOnce the burner is mounted to the appliance, openthe hinged extension by removing the two nutsand washers, connect the HT leads to the ignitionelectrodes and close and fasten the extension.Connect the flexible oil pipes between the burnerand the pumping or pumping and heating unit byreferring to the burner component and pumpingor pumping & heating unit drawings on pages4,5&15.Connect the oil supply to the burner pumping unitwith reference to the oil system diagrams andpumping unit drawings on pages 10,11&15.

Electrical Power ConnectionConnect a three-phase, 50 Hz electrical supply tothe burner, observing all applicable Codes andStandards. The electrical connections required areshown opposite and in the wiring diagram con-tained in the instruction pack attached to theburner. These diagrams also show the auxiliarycontrol connections, which must be made.If the burner is supplied as part of a packaged ap-pliance/burner unit refer to the appliance manu-facturers instructions.

BBBBBURNERURNERURNERURNERURNER C C C C CONTROLONTROLONTROLONTROLONTROL ANDANDANDANDAND O O O O OPERAPERAPERAPERAPERATIONTIONTIONTIONTION

All personnel concerned with commissioning and/or operation of NO modulating burners shall fa-miliarise themselves with the information pre-sented in this section.

Burner DescriptionNu-way NOL/NOR modulating series fully auto-matic oil burner units are of packaged design andmeet relevant National and International stand-ards based on the ISO system of measurement andfastening.A system of pressure atomisation employing a sin-gle spill back nozzle is used throughout the range.If the burner is equiped with the Nu-way ElectronicCam Modulation (ECM) system, then referenceshould also be made to the supplementary docu-mentation supplied with this handbook. In this casereferences to the RWF32 Universal Controller andModulating Unit within this handbook can be ig-nored.The standard method of operation is based on theLandis & Staefa RWF32 Universal Controller, whichhas been designed for use in oil and gas fired in-stallation, where it provides temperature or pres-sure control of modulating burners with continu-ously adjustable fuel throughput.The control output of the RWF32 is a potentialfree 3-position switch, which is used for the con-trol of reversible motors. The control signals for theopen (Y1) and closed (Y2) are indicated on thecontroller face by light emitting diodes.Replaceable range insert PCB�s which are used inconjunction with passive detectors of type QAE21(Temperature) and QBE61 (Pressure) achieveconfiguration of the unit to a control value andsetting range. For further information on theRWF32 and its associated components please re-fer to the data provided on page 25 of this hand-book.When the boiler control calls for heat, the burnermodulating unit will travel to the �high flame� po-sition and interlock the control circuit. An air pre-purge will take place at this position for a pre-de-termined period, at the end of which the burnersequence controller will stop until the modulatingunit has travelled to the �low flame� position andinterlocked the control circuit again. The sequencecontrol will now recommence its operational cy-cle and the burner will light and remain at low flameuntil the high flame release signal is given by thesequence control.


EEEEELECTRICLECTRICLECTRICLECTRICLECTRICALALALALAL C C C C CONNECTIONONNECTIONONNECTIONONNECTIONONNECTION D D D D DIAGRAMIAGRAMIAGRAMIAGRAMIAGRAM

Standard Terminal Connections For BurnerMounted Control Panels(Please refer to the Wiring Diagrams packaged withthe burner if a separate Control Panel is supplied)

L1

Limit Instrument

Control Instrument

Modulating Control In-strument Type QBE 613-Wire (Pressure)orQAE 22 2-Wire (Tem-perature)

Oil Pumping and Heating Unit

QAE22

L2L3NL*

Terminals 1 to 22refer to all Stand-ard and CompactBurners

LO

BR

Burner or Boiler HingeMicroswitch (If fitted, re-move link 21-22)

Terminals 23 to37 refer to Stand-ard Residual Oil

Burners (Pre-wired on Compact

series Burners)

Terminals30,31 and32 refer toStandardDistillate

Oil Burners(Pre-wired

on Compactseries

Burners)

Heater Limitand Control

Stats

Low Oil TempStat

CirculationStat

Oil PumpMotor

Oil PreheaterElements

Oil Pump Car-tridge Heater (If

Fitted)

1. For temperature control use Landis & Staefa detector type QAE 22 and for pressure control typeQBE 61.

2. Any interlock designed to switch or control the burner such as a time switch, damper or I.D.fan interlock etc. is to be wired in series with the control and limit thermostats.

3. If the burner is used on a steam boiler, the water level interlocks must be wired betweenterminals 13 & 17 and the link removed.

4. A remote �Run� indication (BR) can be wired from terminal 9.5. A remote �Excess Temerature or Pressure� alarm can be wired from terminal 10.6. A remote �Lockout� alarm (LO) can be wired from terminal 11.7. A remote �Oil Heater Tripped� alarm can be wired from terminal 24.

Notes:

For specifications and sizing of theelectrical supply and interconnectingwiring please refer to the ElectricalData Table in the Appendix of thisHandbook

L* =(If fitted) for connection ofan independant control circuitsupply. If not required fit a0.75mm (24/.20) between L1and L

Burner Mounted Control Panel

7MBG G

8MB


The modulating unit will now move to high flameand remain at this position until the desired boilertemperature/pressure is attained. From this stagethe modulating unit will commence to move to-wards the low flame position, but, depending onthe temperature/pressure, will stop in any inter-mediate position between low and high flame.

BBBBBURNERURNERURNERURNERURNER C C C C CONTROLSONTROLSONTROLSONTROLSONTROLS

Burners are supplied with an integral control panelcontaining a sequencing control unit and theburner switchgear. On steam boiler applicationsan auxiliary control panel containing boiler feedpump controls, water level interlocks and alarmsis available.

Oil Pumping / Pumping & Heating UnitsStandard burners are supplied with a floormounted pumping (Distillate fuel) or pumping andheating unit (Residual fuel) for conditioning of thesupply oil prior to entering the burner hydrauliccircuit. Details of each unit are shown on page 15opposite.On burners supplied in �compact� configuration,the pumping and heating equipment is mountedon the burner.

Modulating UnitThe Nu-way modulating unit consists of a revers-ible servomotor, which is directly coupled to thecamshaft of the modulating unit. Two adjustablecams are mounted on this shaft, one of which isconnected to a flexible cable operating the burnerair inlet control damper and is of the variable con-tour type (see fig. 2 on page 18). The second camis the modulating oil cam and is illustrated in fig.1.The Burner Oil System Drawing on page 11 showsthe hydraulic circuits for residual and distillate fuelburners. Oil for combustion is drawn from the sup-ply through a fixed displacement pump and sup-plied direct to the burner nozzle. A return line fromthe back of the nozzle is connected to a �spill regu-lating valve� which regulates the oil pressure at thenozzle according to the position of an internal pis-ton which is actuated by the oil control cam in themodulating unit.There is a well defined relationship between thedelivery of fuel through the nozzle and pressurebehind the nozzle, therefore movement of the oilcam �modulates� the nozzle output and hence theoutput of the burner.

leuFssalC

timiLhgiHtatsomrehT

lortnoCtatsomrehT

timiLwoLtatsomrehT

noitalucriceRtatsomrehT

E C°011 C°58 C°56 C°04

F C°031 C°001 C°08 C°05

G C°051 C°041 C°001 C°07

The volume of air required for combustion mustalso be varied as the nozzle output varies, and thisis done by the air control damper operated by aflexible steel cable connected to a lever systembearing against the air control cam.Once the oil cam has been adjusted as describedin the commissioning procedure section of thishandbook, the profile of the air cam is adjusted togive the desired combustion conditions by turningthe thumbscrews under the cam in or out as theburner is �inched� through its firing range.The air control damper is spring loaded �open� forsafety in the event of cable failure.

Residual Oil Heating ControlsA preheater and recirculation thermostat is fittedto the residual oil burner range (NOR).The preheater contains three thermostats:(a) High limit thermostat(b) Control thermostat(c) Low limit thermostat (reverse acting)The recirculation thermostat is fitted in the returnoil line and will override the burner firing controlsand start the burner oil pump in order to maintainthe correct oil temperature in the nozzles andburner pipework.The thermostats should be set to the temperaturesspecified in the following table.

Safety FeaturesFlame supervision is effected by photoelectric celland sequence control box. An air pressure switchis fitted to prove that combustion air is availableto the burner head before allowing the oil pumpto start. (The oil pump is driven by a separate mo-tor in all cases except for the smaller �compact�design of burner)


OOOOOILILILILIL P P P P PUMPINGUMPINGUMPINGUMPINGUMPING / P / P / P / P / PUMPINGUMPINGUMPINGUMPINGUMPING & H & H & H & H & HEAEAEAEAEATINGTINGTINGTINGTING S S S S SETETETETET

34

21

3

42

1

12

3

4

3

2

4

1

B27

3

1295

A

Distillate OilPumping Set

Residual OilPumping &Heating Set

Pump/MotorCoupling

Pump Motor

Air Bleed Valve

Oil Filter

Oil Pump

Air Seperator

4 x M10Foundation Bolts

Air Bleed ValveCold Oil Filter

Return OilThermostat

Preheater Tank

ThermometerPump/MotorCoupling

Pump Motor

Hot Oil FilterHeater Element

Cover

ElectricalConnection Box

Isolation ValveOil Pump

4 x M12Foundation Bolts

Air Seperator

FoundationDetail

FoundationDetail

ElectricalConnection Box

metI noitpircseD "R

1 noitcennoCtelnIliO 1

2 noitcennoCnruteRliO 1

3 deeFliOrenruB 4/3

4 nruteRliOrenruB 4/3

Pipework Connections

ledoMrenruB A B

05LONotpU 322 251

051ot06LON 022 491


IMPORTIMPORTIMPORTIMPORTIMPORTANT - SAFETYANT - SAFETYANT - SAFETYANT - SAFETYANT - SAFETYIt is essential that commissioning shall be under-taken only by suitably qualified and experiencedpersonnel. In the case of NO Modulating burners,commissioning engineers should be experiencedin pressure jet oil burner commissioning. Nu-waycan accept no responsibility for consequential loss,damage or personal injury which results from a fail-ure to follow the commissioning instructions pro-vided or from commissioning procedures beingundertaken by unqualified personnel.

EMERGENCY INSTRUCTIONSEMERGENCY INSTRUCTIONSEMERGENCY INSTRUCTIONSEMERGENCY INSTRUCTIONSEMERGENCY INSTRUCTIONSNO Modulating burners are designed and con-structed to meet current legislation. When used inaccordance with the instructions provided, NOModulating burners are unlikely to produce a haz-ardous condition. If, however such a conditionshould arise in connection with the burner, the ap-pliance or of any instrument, machine or servicein the vicinity of the burner, the OIL AND ELEC-TRICITY SUPPLIES SHALL BE ISOLATED IMME-DIATELY and they shall remain isolated until thefault has been identified and rectified.

CCCCCOMMISSIONINGOMMISSIONINGOMMISSIONINGOMMISSIONINGOMMISSIONING

InspectionBefore commissioning is begun it is important to:• Check that the electrical wiring is complete

and complies with all applicable Codes andStandards.

• Ensure that the fuses are fitted and are of thecorrect rating.

• Check electrical earthing.• Verify that the oil supply system is correctly

designed and that the supply pipework is cor-rectly sized and free from leaks.

• Ensure that all manual fuel isolation valvesare operable, fully closed and leak tight.

• Make all personnel involved in the commis-sioning aware of the location of the emer-gency fuel and electricity isolation points.

• Check that fittings for bleed and pressure test-ing are fitted.

• Establish that the appliance is in an appro-priate and safe condition to be fired; for ex-ample, that there is water in the boiler.

• Set the appliance controls to call for heat.• Check the appliance�s ventilation and flueing

arrangements.

• Ensure that any warning notices appropriateto the commissioning procedure are in posi-tion.

• Ensure that all necessary tools and test equip-ment are available and ready for use. Essen-tial items include temperature measuring in-struments for measuring flue gas and appli-ance water temperatures, and a means ofanalysing the flue products for carbon diox-ide (CO2), oxygen (O2), carbon monoxide(CO) and smoke.

• Check that all relevant documentation isavailable including, where appropriate:• The agreed plant performance specifi-

cations.• Plant drawings and pipework layouts.• Electrical logic and wiring diagrams.• Certificates confirming satisfactory com-

pletion of procedures such as sound-ness testing and electrical safety tests.

• Commissioning, operating and mainte-nance instructions for the plant.

• Establish that the operation of plant otherthat being commissioned will not have anadverse effect on the operation of the plantto be commissioned and similarly, that theoperation of the plant to be commissionedwill not have and adverse effect on otherplant.Confirm that the operation of adjacent plantand machinery will not constitute a hazardto the personnel involved in commissioning.

Pre-firing ChecksWith the oil and power switched off, carry out thefollowing checks.• Check the nozzle size and position relative

to the diffuser plate. (The burner head di-mensional details are given in the appendixof this handbook).

• Check that the electrode positions and H.T.leads are correct.

• Check all the motor overload settings.• If the appliance is a boiler, check that the

water level is correct, the controlling valvesare open and that the water pumps are inworking order.

• If a flue damper is fitted, check that it is cor-rectly interlocked to the burner or fixed inthe fully open position.


• Ensure that there is a good oil supply to theburner pump. Bleed one or two gallons fromthe flexible to eliminate any pipe scale andair from the system.

• Check that the oil supply is of the recom-mended temperature and pressure.

• Bleed the burner pump manually by remov-ing the right hand ¼� BSP plug in the top ofthe pump until air-free oil flows.

• Fill the oil pre-heater tank, if fitted, by remov-ing the hot oil filter retaining flange in theoutlet pocket on the top of the tank. Fill tothe neck of the tank outlet with clean fueloil only.

• Switch on the electricity supply to the burnerand check that the pump motor rotation iscorrect to the direction arrows shown on thepump face.

• Remove the access lid on the modulatingcam box unit.

• Switch on the burner at the control panel. (Ifan oil pre-heater is fitted, then a delay maybe experienced whilst the system attainstemperature). The modulating unit camshaftshould now rotate to the high flame setting,and the combustion air motor will start theair pre-purge phase.

• Allow the fan motor to run up to speed,switch off the burner and check the fan rota-tion (Anti-clockwise as viewed from the mo-tor side) as the fan slows down.

• Remove and cover the photoelectric cell witha clean lint free cloth, switch on the burner,and allow it to run through to lockout. Dur-ing this run check that the ignition spark isoccurring, and note the spill and line oil pres-sures at the moment of ignition. Reset thesequence control and repeat the run if nec-essary to check these functions. If necessary,adjust the spill pressure to the correct figureaccording to the nozzle specification and theline pressure at the burner pump to 27.8 bar(400 psi).

THE BURNER IS NOW READY TO BE COMMIS-SIONED.

Hand Auto Selector SwitchThis switch must always be in the �Auto� positionwhen the burner is required to start. The �Hand�selection can be made immediately the burner hasstarted to fire.

Should the burner be left in the �Hand� position itwill NOT modulate until the �Auto� position is se-lected.

Commissioning the BurnerNew NO Modulating burners are generally sup-plied against the firing specification of the appli-ance. In this case the system and spill pressuresmay be pre-set and require checking and minoradjustments only. The following section describeshow to set up the modulating cam box unit from a�scratch� situation.The modulating cam layshaft can be rotated byhand by using the gearbox disengagement lever inthe drive servomotor.• Ensuring that the modulating cam arrange-

ment is in the low flame position, adjust theoil cam (see fig. 1 on page 18) so that it givesapproximately 1.5mm throw (3mm stroke)and lock in position.

• Check to ensure that the spill valve push rodbears lightly against the oil cam.

• Turning to the air cam (fig. 2 on page 18),rotate the thumbscrews in or out so that theygive a reasonable amount of adjustment ineach direction. Adjust the flexible cable (ateither end if necessary) until the air inletdamper is fully closed (i.e. until all the slackis taken up on the cable).

• Now adjust the thumbscrews to give a smallopening of the air damper at low flame.

• Uncover and replace the photocell. Reset thesequence control and allow the burner tostart. Immediately the burner starts, switchthe hand/auto selector switch to the �hand�position and hold low flame until the appli-ance is ready to accept high flame. Duringthis period, check and adjust the low flameoil throughput.

• Check the flame visually. If the flame is dirty,adjust the air cam thumbscrews until theflame becomes clean.

• After a suitable delay, inch the camshaft tothe high flame position (i.e. through 180) bymeans of the inching switch on the controlpanel. Adjust the air cam profile by means ofthe thumbscrews until the air damper is nowfully open. At this stage it will be found thatall of the thumbscrews between low and highposition will require adjusting so as to avoidover stressing the cam profile band.


MMMMMODULODULODULODULODULAAAAATINGTINGTINGTINGTING U U U U UNITNITNITNITNIT

Oil Cam Hub

Servomotor

CamstackMotor Unit

Oil Spill BackRegulating Vlave

Oil Cam AdjustingScrew

Lever

ThrowCam Follower

Cam Disk

AdjustablePlunger

LockingScrews

Profile Band

Cam Lever OperatingCable

Adjuster LockingScrews

Profile Adjuster

RetainingSaddle

Cable Adjuster

Oil Cam - A

Air Cam - B

Oil Cam View On - A

Air Cam View On - B

View of Servomotor from underside(cover removed) showing position ofdisengagement lever

Rotation for HighFlame position

(Cams shown in the LowFlame Position)

Fig. 1.

Fig. 2.

Spill Pressure

Reduce Increase


Once this has been done, there should be a fairlysmooth profile between low and high positions.Ensure that the flame is visually clean throughoutthe modulation range at all times.Check the oil consumption. If this is not correct forthe full burner rating, the oil cam must be adjustedas follows.(a) Inch the burner to low flame and note the

spill pressure.(b) To increase the minimum rate, adjust as

shown in fig. 1.(c) Adjust the cam to give more eccentricity for

more oil at high flame, and visa-versa.(d) Return to the minimum setting and compen-

sate for any changes.(e) Inch the burner to high flame and again check

the oil flow.Continue to repeat (a) to (d) until the high flameoil rate is correct.When a satisfactory flame is achieved, again checkthe line and spill pressures. Check the pre-heatertemperature (if fitted) and adjust if necessary.• Inch the camshaft back to the low flame po-

sition. The oil consumption rate should nowbe between 35 and 50% of the rated maxi-mum.

• Measure the flue gas composition and ad-just the combustion air volume as necessary.

• Check the burner performance throughoutthe range adjusting the air cam profile as nec-essary to give a clean and efficient flame.

When a satisfactory setting has been achieved, lockthe air cam thumbscrews with the grubscrews fit-ted in the side face of the cam body. Refit theModulating unit access cover.Check the function of the air pressure switch.• Switch off the electrical supply to the burner.• Remove the air pressure switch cover. Fit a

manometer to the pressure switch to checkthe actual air pressure against the pressureswitch dial setting.

• Switch on the electrical supply and allow theburner to establish low flame.

• Select �Hand� control and ensure that theburner is at low flame by using the inchingswitch.

• Slowly turn the air pressure switch adjustingdial clockwise until the flame is extinguished.The burner will go to lockout.

• Turn the dial one division anticlockwise andreset the burner lockout. The burner will nowcontinue through its cycle until flame is es-tablished or the burner goes to its lockoutposition. If the burner goes to lockout repeatthe procedure one division per burner cycleuntil flame is established. Once successful,turn the dial a further two divisions anticlock-wise.

• Switch off the burner electrical supply, re-place the air pressure switch cover and re-move the manometer.

If the burner control panel is inclusive of Low �Excess low and High Water interlocks and alarms,test that these function correctly. Ensure that theboiler feed pump switchgear provided in the panelis operating satisfactorily.Adjust the modulating control to the required pres-sure/temperature.Allow the boiler to attain the correct working pres-sure/temperature and adjust the on/off and limitinstruments to the desired values.Switch the Hand/Auto selector switch to �Auto�.The plant is now under the control of the pres-sure/temperature controllers for modulation andthe on/off and high limit instruments for control.On residual oil burners, check the operation of thethree oil temperature thermostats fitted in the endof the preheater tank element, and the re-circula-tion thermostat (class G fuel only).Finally check all ancillary controls and equipmentsuch as damper interlocks etc.

RRRRROUTINEOUTINEOUTINEOUTINEOUTINE M M M M MAINTENANCEAINTENANCEAINTENANCEAINTENANCEAINTENANCE OFOFOFOFOF NOL/ NOL/ NOL/ NOL/ NOL/NOR MNOR MNOR MNOR MNOR MODULODULODULODULODULAAAAATINGTINGTINGTINGTING B B B B BURNERSURNERSURNERSURNERSURNERS

GeneralIt is vitally important that personnel responsiblefor the day to day operation and maintenance ofthe plant are instructed by the commissioning en-gineer on the basic function of the burner as wellas the need for routine maintenance and dailychecking of burner operations.Final adjustments, which will have been madeduring the commissioning, must be recorded onthe Commissioning Sheet at the back of this manualand in the appliance logbook. A copy of the com-missioning data must be sent to the appliancemanufacturer.


The burner should be kept clean inside and out. Itwill be more reliable, and if an oil leak occurs itwill be spotted more readily.

Daily ChecksInspect the burner daily to check if there is anyvariation from the correct operating sequence, asfollows:Check the oil pressure on the nozzle line gauge.This should be 27.8 bar (400 psi). On heavy fuelburners a drop in line pressure may indicate clog-ging of the hot oil filter which is situated in theoutlet pocket of the pre-heater tank. Remove thefilter by removing the four bolts from the outletpocket flange and disconnecting the pipework. Liftthe filter out and wash in kerosene. If the oil pres-sure remains low, then check the oil supply sys-tem, stop/fire valves, ring main pumps etc and alsothe cold oil filter(s).Check the spill pressures. If these are low it mayindicate that the oil nozzle filter is clogged.If there is an inspectIon window on the appliancethrough which the ignition spark and flame canbe observed, ignition and flame should be in-spected and any irregularities that are observedshould be rectified i.e. nozzle/electrodes cleanedand any deposits removed from the inside of theflame tube and diffuser.

Cleaning the Oil NozzleTo clean the oil nozzle, switch off the electricitysupply to the burner and disconnect the flexibleoil lines at the burner head quick release couplings.Remove the hinge plate retaining nuts and swingopen the burner. Disconnect the H.T. leads andremove the two long cap head screws retaining theinner assembly, from the face of the oil manifoldblock on the side of the hinged extension. The in-ner assembly lance can now be removed completewith the diffuser and electrode assembly by with-drawing from the flame tube/hinge assembly. It isimportant that the nozzle is cleaned using non-abrasive materials, never use anything which mayscratch the finely finished surfaces of the nozzle.Nozzle life is approximately 5000 hours opera-tion, after which wear will affect atomisation andplant efficiency will drop.

Photoelectric CellRemove the photoelectric cell and clean with asoft lint free cloth if necessary. Be carefull not totouch the glass buld of the cell as this can lead topremature failure of the unit.

Cold Oil Filter(s)On residual oil burners, rotate the cleaning knobof the cold oil filter daily.The plug in the bottom of the filter housing shouldbe removed and sludge water drained off at inter-vals not exceeding six weeks. If a duplex cold oilfilter set is fitted, the filters can be alternated andisolated for cleaning operations as necessary.On distillate oil burners, the filter bowl should beremoved and the filter element cleaned in kero-sene every six months. If the filter has a disposableelement renewal should be considered.

Replenishing the Fuel SupplyIt is usual practice to shut boiler(s) off whilst deliv-ery of fuel is being made and allow approximately30 minutes for any sediment to settle before re-starting the burners.

Boiler Combustion SurfaceKeep the boiler combustion surfaces and fluewaysclean. Any accumulation of soot will decrease theefficiency of the boiler and increase the flue gasexit temperature. Always cover up the burner dur-ing boiler cleaning operations.

FFFFFAAAAAULULULULULTTTTT F F F F FINDINGINDINGINDINGINDINGINDING

If the Burner Fails to StartMake sure that all the thermostats and switches inthe control circuit are in the �made� position andthat the oil pre-heater �excess limit� thermostat hasnot tripped. Reset if required. Check that the lowoil temperature thermostat is set correctly for theappropriate fuel.Check that the electricity supply to the burner is�live� and that the control and main circuit fusesare intact. If a fuse is found to be �blown� then thecause should be investigated and rectified beforeproceeding further.On steam boilers, check that the �water level in-terlocks� are in the �made� position.

If the burner is found at lockout (red lockoutlamp illuminated)Reset the burner and observe the starting se-quence. (Make reference to the Sequence Diagramand Timing Charts for the Flame Failure controlson page 23 for further information).Check the fan and oil pump motor overloads andreset if necessary.


Check the operation of the air pressure switch,Failure of the switch to operate prevents the oilpump from starting.

Flame Occurs Followed by ImmediateLockoutCheck the PE cell and the air regulator for correctoperation. Check that the oil pressures are correct.If necessary, check and clean the preheater hot oilfilter, ensure that there is sufficient oil in the stor-age tank, bleed the oil pump in case it is partiallyair-locked. Check to ensure that all stop/fire valvesin the supply line are fully open. Check residualfuel oil temperature � check the ring main for cor-rect operation in respect of temperature and pres-sure.

The Burner Starts With The Correct OilPressure But No Flame AppearsCheck the ignition system, HT lead connections,electrode gap and the condition of the electrodeinsulators. Check that the nozzle cut off is func-tioning and that the air damper cable is not bro-ken or disconnected (the air regulator will be fullyopen). It is important to note that continued re-setting of the burner should be avoided as thiscan lead to a dangerous situation.

Modulating SystemIf malfunction of the modulating controller (RWF32) is suspected, check that only compatible com-ponents such as the range insert and pressure/tem-perature detector have been used. If problemspersist then replacement of the unit should beconsidered.

Burner Commissioning SheetThis manual contains a record of the essential in-formation and will have been completed by thecommissioning engineer with individual details ofthe burner. These details should be verified peri-odically and adjusted if variations are noted. Com-missioning details must also be recorded in theappliance logbook.

FFFFFUELUELUELUELUEL P P P P PUMPSUMPSUMPSUMPSUMPS

Danfoss Series KSA Fuel PumpsThe pump dataplate gives direction of rotation andconnection port details.P = nozzle line connection.

S = suction line connection.R = return line connection.The pump is also fitted with two measuring ports,Pn for nozzle pressure and Ps for suction/feed pres-sure.Ports P, Pn and S, Ps become opposite hand whenpump rotation is reversed.Fig. 3. on page 22 shows the respective connec-tions for counter-clockwise pumps, as viewed fromthe shaft side.A hydraulic pressure-regulating valve is built intothe pump to maintain constant pump pressure,however the valve has no cut-off function.All KSA pumps are designed for 2-pipe operationand therefore should always be connected to thereturn line on the fuel supply system. When usinga positive pressure single pipe system, as on distil-late fuel, the return port is connected to the sup-ply in the form of an external bypass.

Suntec Series TA Fuel PumpsRefer to fig. 4. on page 22 for the respective con-nection details.A hydraulic pressure-regulating valve is built intothe pump to maintain constant pump pressure. Onthe TA pump the valve has a cut-off function.Suntec TA pumps can be used on one and twopipe systems dependant on the fitting of an inter-nal bypass plug. The is removed for single pipe sys-tems.

Suntec Series TV Pressure Regulating ValveThe TV valve is designed for use with the Suntecseries �T� fuel pumps. (Refer to fig. 5. on page 22).This separate pressure-regulating valve, which isinstalled in the nozzle line, is designed to keepconstant pressure even if the output capacity ischanged. A built in dampening device absorbs vi-brations in the valve, effectively eliminating pulsa-tions in the nozzle line.

Pressure adjustment for both TA and TV units isthe same.Remove the cap nut (1), washer (2) and loosen thelocknut (4). Turning the screw (3) counter-clock-wise will decrease the nozzle line pressure and visa-versa. After adjustment, tighten the locknut andrefasten the washer and cap nut.

Note: the maximum allowable pressure for modelTA5 is 30 bar.


OOOOOILILILILIL P P P P PUMPUMPUMPUMPUMP D D D D DETETETETETAILSAILSAILSAILSAILS

S

T

R

P

S P

21

R

1 2

R

4

3

Pn Ps

Pn Ps

I/O

I/O

Fig. 3.Danfoss Series KSAFuel Pump

Fig. 4.Suntec Series TAFuel Pump

Fig. 5.Suntec Series TVPressure Regulating Valve

Refer to the section FuelPumps on page 21.Pump rotation is quoted bythe direction of the pumpshaft as viewed from theshaft side. The direction ar-row embossed on the face ofthe pump or pump name-plate is therefore the reverseof the quoted rotation.The Oil Pump is completelypre-piped as part of thepumping or pumping andheating set.Should the Oil Pump per-formance become suspectthen a replacement unitshould be obtained and theOil Pump returned to deter-mine its serviceability.Upon replacement refer tothe pump bleeding instruc-tions in the section Pre-fir-ing checks on page 17.Further details regarding theOil Pump unit can be sup-plied on request.

General Notes:

(The porting arrangement issimilar for Suntec series �T�pumps, The �T� pump how-ever, must be used in con-junction with the TV regu-lating valve)

metI noitpircseD

S troPnoitcuS

P troPerusserP

R troPnruteR

nP eguaGmuucaV

sP eguaGerusserP

T rotalugeR

O/I teltuO/telnI

1 tunpaCrotalugeR

2 rehsaW

3 wercSrotalugeR

4 tunkcoL

Ports S, P, R & I/O are R.3/4�Ports Pn & Ps are R,1/4�

(For use with Suntec series �T�pumps).


FFFFFLLLLLAMEAMEAMEAMEAME F F F F FAILAILAILAILAILUREUREUREUREURE & S & S & S & S & SEQUENCEEQUENCEEQUENCEEQUENCEEQUENCE

CCCCCONTROLSONTROLSONTROLSONTROLSONTROLS

The standard control box fitted to the NO Modu-lating series of burners is the Landis & Staefa typeLAL1.The unit is designed to provide control and super-vision for atomising oil burners of medium to largecapacity. They are suitable for use on multi-stageand modulating burners.For safety reasons, at least one controlled shut-down must be provided within each 24-hour pe-riod of continuous operation.When a burner failure is encountered the box goesinto lockout mode. This is indicated by an orangeneon, which displays within the lockout windowof the control and is repeated at the lockout lampon the panel facia.

If a lockout situation occurs, the burner will notstart until it is manually reset by pressing the lock-out window on the control. (The control can alsobe reset by the off/on/reset switch situated on thecontrol panel facia)If the burner fails to fire and persists in locking out,no more than three attempts should be made. Todo so will almost certainly create a dangerous situ-ation.If a burner becomes troublesome then the assist-ance of a qualified commissioning engineer shouldbe obtained. To assist in his diagnosis, notes shouldbe made detailing the events leading up to thelockout situation. The symbol appearing in thelockout window should also be noted prior to re-setting the burner. (Refer to theSequence Diagramand Timing Chart below).PLEASE NOTE. When the control box goes to lock-out it is generally performing the function it is de-signed for.

Burner Control ProgramBurner operational sequence based on the Landis& staefa LAL1.25 Control box. Note. Timings arefor operation on a 50 hz electrical supply only.

RENRUBLEDOM

ETALLITSIDPMUPTINU

LAUDISERPMUPTINU

83-81ON

43-53ON

SSOFNAD0001ASKMPR5241RH/L053

SSOFNAD0001ASKMPR5241RH/L005

83-53ON

82-05ON

43-05ON

83-05ON

82-06ON

5ATCETNUSMPR5241RH/L086

43-06ON

83-06ON

83-58ON

5ATCETNUSMPR5241RH/L086

83-001ON3TCETNUS

MPR5241RH/L027

14-001ON

44-001ON

63-521ON5ATCETNUS

MPR0582RH/L0511 3TCETNUS

MPR5241RH/L059

14-521ON

44-521ON

63-051ON2TCETNUS

MPR0582RH/L0041

14-051ON

44-051ON

Burner Motor

Air Damper

Ignition

Main Oil Valves

Flame On

Ts Run Tp

T

t7

t8t6

t5t4t3

t1

t2

Oil Pumps - Where Used

doireP emiT)sces( noitpircseD

1t 5.2 rotomnafrofemitputratS

2t 5 langis'nepo'otputratS

3t 45 'emalfhgiH'otovresgnitaludoM

4t 5.22 egrup-erprialluF

5t 45 'emalfwoL'otovresgnitaludoM

6t 45 noitingi-erP

7t 5 doirepytefaS

8t 51 rellortnoC23FWRotesaeleR

sT 5.551 emitputratslatoT

pT 51 emitegruptsoP

T 5.071 emitelcyc-erlortnoC


MMMMMODULODULODULODULODULAAAAATINGTINGTINGTINGTING C C C C CONTROLONTROLONTROLONTROLONTROL

Landis & Staefa RWF32

The RWF32 controller has been specifically de-signed for the control of boiler temperature orsteam pressure in Oil and Gas fired plant.The unit is normally mounted in the side face ofthe burner panel and is protected by a clear plas-tic cover which can be swung downwards.By using the appropriate Setting Range Insert, thecontroller is configured for a controlling value andrequired setting range. This setting range insertforms part of the measuring bridge on the detectorside and also carries the setting scale. The settingunit itself is an integral part of the controller.

Control Program Under Fault ConditionsAnd Lockout IndicationIn the event of fault conditions the sequenceswitch stops and simultaneously the lockout indi-cator. The symbol appearing above the readingmark indicates the kind of fault ebcountered.

No start, because, e.g., the CLOSE signal hasnot been supplied to control box terminal 8by the servo motor limit or auxillary switch,or a contact has not been closed betweencontrol box terminals 12 and 4 or 4 and 5.Shut down of start up sequence, becausethe OPEN signal has not been supplied tocontrol box terminal 8 by the servo motorlimit switch. Terminals 6,7 and 15 remainunder voltage until the fault is corrected.Lockout due to a fault in the flame supervi-sion circuit.Shut down of start up sequence, becausethe signal for the low flame position has notbeen supplied to control box terminal 8 bythe servo motor auxillary switch. Terminals6,7 and 15 remain under voltage until thefault is corrected.Lockout, because no flame signal has beenreceived on completion of the safety time.Lockout, because the flame signal has beenlost during burner operation or an air pres-sure failure has occured.Lockout on completion or after completionof the control program sequence due to ex-traneous light (e.g. flame not extinguished,leaking fuel valves) or due to a faulty flamesignal (e.g. fault in the flame supervision cir-cuit or similar).

a - b Start up sequence.b - b� idle steps up to the self shut down of

the sequence switch.b(b�) - a Post purge sequence.

When lockout occurs, the control can be resetimmediately. After the resetting (and also after thecorrectionof a fault which resulted in a controlledshut-down, or after each mains failure) the se-quence switch always runs through to the startposition, whereby only terminals 7,9,10 and 11receive voltage in accordance with the control pro-gram. It is only then that the control unit programsa fresh burner start up.Note: Do not press the lockout reset button (orremote reset switch) for more than 10 seconds.

1

a

b�

b

1

Landis & StaefaLAL1. ProgramSequence Disk.

I


In addition to the setpoint setting slider, furthersetting controls are located beneath the silver fa-cia plate situated above the digital display unit.All the settings can be adjusted whilst the burneris in operation.Three LED�s indicate the following operational sta-tus:-• Control ON / OFF (0-1)• Control Pulse OPEN (II) / CLOSED (I)The digital display below the LED�s gives the setvalue / actual value deviation as a percentage ofthe inserts setting range up to +/- 19%. Measuringand display take place at 2 second intervals and in1% steps.

SettingThe setting slider should be adjusted to the setpointtemperature or pressure.before further adjustments are made: -

-EMARAPRET

TOHRETAWRELIOBGNITTES

MAETSRELIOBGNITTES

pX %02 %5

nT sces05 sces02

vT 1 3

dS %9 %9

H 5.1 5.1

Q 01 5

RWF32 Recommended Settings

Fig. 6.

• Write down the setting values found on thecontrol units supplied.

• Alter only one parameter at a time (i.e. donot alter Xp, Tv and Tn at the same time) !

• Make corrections in small steps only.• Make further adjustments only after the pre-

vious adjustment has produced a clear reac-tion.

• An Increase in the parameter Xp producesgreater control stability but slows down thesystem response to load or setpoint changes.

• A decrease in the parameter Xp improves thesystems response to load changes, but thecontrol stability may suffer, i.e. control oscil-lations may occur.

Commissioning of the plant will be considerablysimpified and accelerated when, during the set-ting operations, the load conditions can be keptfairly constant, thus making it easier to clearly rec-ognise the contol system�s response to load or set-point changes.For most general applications we recommend thesettings listed in the table in fig. 6. However shouldthese settings not prove to be sufficient then thefollowing procedures can be carried out.

Adjustments in the case of a slow correctingresponse.Reduce the set values in a step wise fashion, al-lowing the system time to settle before making fur-ther adjustments. Firstly reduce only Xp (down to5%). If this is not satisfactory then reduce Tv (downto 0) and finally Tn.

Adjustments in the case of an excessively fastcorrecting response.Usually in connection with control oscillations, theselected set values should be increased in a stepwise fashion, again allowing the system to stabi-lise before proceeding further. Firstly increase Xp,then Tv (up to approx. 3) and finally Tn until sta-bility is reached.

A data sheet containing in depth information onthe RWF 32 ands its operation is available uponrequest.


FFFFFLUIDICSLUIDICSLUIDICSLUIDICSLUIDICS W1 A W1 A W1 A W1 A W1 ATOMISERTOMISERTOMISERTOMISERTOMISER

Nozzle Body

Filter(Feed Side)

�O� Ring

�Shut-off� Plunger(Return or Spill

Side)

Nozzle Marking

Fig. 7.

BBBBBURNERURNERURNERURNERURNER O O O O OILILILILIL N N N N NOZZLEOZZLEOZZLEOZZLEOZZLE

The Burnerlance is designed to operate spill-backatomisers having a spring loaded orifice shut-offneedle and a 7/8� x 20 unef fixing thread.The Fluidics W1 series atomiser is the prefered typeand this will have been sized at the point of orderto suit the burner rating and application.When the nozzle has completed 5000 hours ofoperation, it should be replaced with the sameMake, Type and Size as fitted. Failure to do so willalter the characteristics of the burner and may im-pair the performance and efficiency of the plant.The nozzle identification code is stamped onto theface of the hexagonal nut section of the nozzlebody as shown in fig. 7. above.Should any doubts arise concerning the suitabilityor performance of the burner nozzle, please con-tact the Nu-way Technical dept. who will bepleased to assist.

SSSSSERVICEERVICEERVICEERVICEERVICE & R & R & R & R & REPLEPLEPLEPLEPLACEMENTACEMENTACEMENTACEMENTACEMENT

Nu-way Ltd Parts & Components Division carry acomprehensive stock making up the burner sys-tems described in this handbook. Should it be-come necessary to order replacement parts, it isimportant to quote the burner model, specifica-tion and serial numbers to ensure correct expedi-tion of your order.Nu-way Ltd is able to offer �on site� Commission-ing, Service and Repair through its wordwide net-work of authorised distributors and sales offices.Please contact the Nu-way Service Department forfurther information.

M

odels NO

L/NO

R Modulating Revision 101199B

AA AAAPPEN

DIX

PPEND

IXPPEN

DIX

PPEND

IXPPEN

DIX

Burner Performance G

raph

BURNER OUTPUT MW

0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

0

BURNER OUTPUT K CALS/HR x 106

0.5 1.0 1.5 2.0 2.5 3.0 3.5 3.87

BURNER OUTPUT BTU/HR x 10

0

6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

0

50

100

150

200

0

TO

TA

L R

ESIS

TA

NC

E M

M W

G.

@ 1

2%

CO

2

1

2

3

4

5

6

7

TO

TA

L R

ESIS

TA

NC

E I

NC

HES W

G.

@ 1

2%

CO

2

NO 100-44

NO 125-44

NO 125-41

NO 125-36

NO 150-44

NO 150-41

NO 150

NO 50-38

NO 50-28

NO 50-34NO 60

-34

-28NO 60-34

NO 35-34

NO 18

NO 35-38

NO 18-38

-41

NO 100

-38NO 85 NO 100

-38

-36

All O

utputs Quoted Are Based on G

ross C.V.


Burner Performance Graph

The Performance Graph shown on page 24 plotsburner input against the appliance running resist-ance. The appliance starting resistance is derivedfrom a combination of the combustion chambershape, volume, start rate and flue conditions. It maybe necessary to select a burner with a higher fanstatic pressure than would normaly be chosen, ifthe appliance has a high starting resistance.

Similarly, when firing a reverse pass boiler up to 2MW, with a combustion intensity of 2 MW/M3 andan operating resistance between 40 and 90 mmwg. it is recommended that a burner with a higherfan static pressure is selected, ie. if the graph se-lects a burner with a 28 cm fan then use the 34 cmfan model for correct combustion.All outputs quoted are based on gross C.V.

BBBBBURNERURNERURNERURNERURNER H H H H HEADEADEADEADEAD D D D D DETETETETETAILSAILSAILSAILSAILS & E & E & E & E & ELECTRODELECTRODELECTRODELECTRODELECTRODE S S S S SETTINGSETTINGSETTINGSETTINGSETTINGS

6

3

12

8

13

Shown in Plan Section Through Centreline

Electrode Setting

Section on Elevation Section on Plan

A

Flame Tube

Diffuser InnerManifold

Block

BurnerLance

FeedReturn

TipShut-off

InnerDraught

Tube

ElectrodeBush

ElectrodeDisc Ignition

Electrodes

ledoMrenruB noisnemiDA

ot43-81*ON83-001*ON 46

ot14-001*ON44-051*ON 09

M

odels NO

L/NO

R Modulating Revision 101199B

RENRUBLEDOM

NAFROTOM

RETAEH-ERPTUOHTIWRENRUB RETAEH-ERPHTIWRENRUB

PMUPROTOM

tratStnerrucesahp/A

nuRtnerrucesahp/A

elbaCezis

mm( 2)

CRHesuf)A(

PMUPROTOM

tratStnerrucesahp/A

nuRtnerrucesahp/A

elbaCezis

mm( 2)

CRHesuf)A(

-erPretaeh

Wk

elbaCezis

mm( 2)Wk ph Wk ph Wk ph

83-81ON 5.2

43-53ON 0.3 0.4 73.0 5.0 5.2 73.0 5.0 5.7 5.1

83-53ON 0.4 5.5 73.0 5.0 5.2 73.0 5.0 5.7 5.1

82-05ON 2.2 0.3 73.0 5.0 0.23 6.5 5.2 02 73.0 5.0 0.24 0.61 0.4 .03 5.7 5.1

43-05ON 0.3 0.4 73.0 5.0 0.24 0.7 5.2 52 73.0 5.0 0.25 4.71 0.4 04 5.7 5.1

83-05ON 0.4 5.5 73.0 5.0 0.25 8.8 5.2 03 73.0 5.0 0.26 2.91 0.4 05 5.7 5.1

82-06ON 0.3 0.4 57.0 0.1 0.64 9.7 5.2 03 73.0 5.0 0.25 4.71 0.4 04 5.7 5.1

43-06ON 0.4 5.5 57.0 0.1 0.65 7.9 5.2 03 73.0 5.0 0.26 2.91 0.4 05 5.7 5.1

83-06ON 0.4 5.5 57.0 0.1 0.65 7.9 5.2 03 73.0 5.0 0.26 2.91 0.4 05 5.7 5.1

83-58ON 5.5 5.7 57.0 0.1 0.04 6.31 5.2 03 57.0 0.1 0.05 0.42 0.4 05 5.7 5.1

83-001ON 5.7 0.01 5.1 0.2 0.05 8.71 0.4 04 57.0 0.1 0.06 9.62 0.6 05 5.7 5.1

14-001ON 5.7 0.01 5.1 0.2 0.05 8.71 0.4 04 5.1 0.2 0.26 3.03 0.6 06 5.7 5.1

44-001ON 0.11 0.51 5.1 0.2 0.56 0.52 0.6 05 5.1 0.2 0.28 7.14 0.01 08 5.7 5.1

63-521ON 0.11 0.51 5.1 0.2 0.56 0.52 0.6 05 57.0 0.1 0.57 5.53 0.01 06 0.9 5.2

14-521ON 0.11 0.51 5.1 0.2 0.56 0.52 0.6 05 5.1 0.2 0.77 5.73 0.01 06 0.9 5.2

44-521ON 0.11 0.51 5.1 0.2 0.56 0.52 0.6 05 5.1 0.2 0.28 7.14 0.01 08 0.9 5.2

63-051ON 0.11 0.51 5.1 0.2 0.56 0.52 0.6 05 57.0 0.1 0.57 1.43 0.01 06 0.21 0.4

14-051ON 0.11 0.51 5.1 0.2 0.56 0.52 0.6 05 5.1 0.2 0.77 5.73 0.01 06 0.21 0.4

44-051ON 0.51 0.02 5.1 0.2 0.58 0.23 0.01 05 5.1 0.2 0.59 0.44 0.61 08 0.21 0.4

Electrical Data Table


CCCCCOMMISSIONINGOMMISSIONINGOMMISSIONINGOMMISSIONINGOMMISSIONING S S S S SHEETHEETHEETHEETHEET

The details below are to be completed by the Commissioning Engineer

Installer�s Name : ___________________________________________________________________

Address : __________________________________________________________________________

_________________________________________________________________________________

Site Address : ______________________________________________________________________

_________________________________________________________________________________

Appliance : Type :____________________ Rating : ________________ Serial No. :_____________

Burner : Type :____________________ Rating : ________________ Spec No. : _____________

Serial No.: ________________ Nozzles : _______________ Oil Pump : _____________

Commissioning date : __________________ Guarantee Expiry Date : _______________________

Oil type : ____________________________

sliateDnoitsubmoC woLemalF

tnioP2

tnioP3

tnioP4

tnioP5

hgiHemalF

OC 2 %

NekomS O.

C°.pmeTtneibmA

C°.pmeTsaGeulF

%.ycneiciffE

gw/mm.P.C.C

gw/mm.thguarDeulF

gw/mm.citatSnaF

rab.erusserPliO

rab.erusserPllipS

C°.erutarepmeTliO

hpg/su.noitpmusnoCliO

nepO%.lortnoCriA

spmA.CLFrotoM

Engineers Name :_________________________________________

Signature : ______________________________________________ Date : ___________________


BBBBBURNERURNERURNERURNERURNER M M M M MODIFICODIFICODIFICODIFICODIFICAAAAATIONTIONTIONTIONTION R R R R RECORDECORDECORDECORDECORD

Date Details of Modification


P.O.Box 1, Vines Lane, Droitwich, Worcestershire, WR9 8NA, EnglandTelephone: (01905) 794242 (Direct Dial), (01905) 794331

Facsimile: (01905) 794017 & Spares (01905) 795829email: [email protected]

NOL/R MODULATING MANUAL.P65

!Nu Way NOL R Modulating

Documents

Transcript of !Nu Way NOL R Modulating