Nu-Way NOL Handbook

H ANDBOOK
®
Series NOL fully automatic oil burner
Models NOL Compact Modulating
Class D Oil
NOL Compact Modulating
Page 1
CONTENTS
BURNER & COMPONENT IDENTIFICATION .............................................................4
Burner Mounting Details .............................................................................................5
FEATURES ......................................................................................................6
Air Regulation .............................................................................................................6
Controls and Safety Systems ........................................................................................6
Fuels............................................................................................................................6
Fuel System .................................................................................................................6
Construction ................................................................................................................6
GENERAL .......................................................................................................6
SITE CONDITIONS AND SERVICES .......................................................................6
Fuel Storage and Handling ..........................................................................................6
Fuel Supply .................................................................................................................6
Single Pipe system ......................................................................................................6
Two-Pipe System .........................................................................................................6
Flue and Chimney Requirements ................................................................................6
Plant Room Ventilation ................................................................................................6
Existing Appliances .....................................................................................................7
Combustion Chamber Conditions ...............................................................................7
INSTALLATION .................................................................................................7
General .......................................................................................................................7
Fitting to the Appliance ...............................................................................................7
Oil Supply Connections ..............................................................................................7
Electrical Power Connection ........................................................................................7
BURNER AIR CONTROLS ...................................................................................7
Air Diffuser .................................................................................................................7
BURNER OIL CONTROLS ...................................................................................7
Oil Nozzle ..................................................................................................................7
Oil Control Train..........................................................................................................7
Modulating Unit ..........................................................................................................7
BURNER OIL SYSTEM .......................................................................................8
ELECTRICAL CONNECTIONS ...............................................................................9
OPERATION ................................................................................................ 10
COMMISSIONING ......................................................................................... 10
IMPORTANT - SAFETY .................................................................................... 10
EMERGENCY INSTRUCTIONS ............................................................................ 10
Inspection .................................................................................................................10
Pre-firing Checks .......................................................................................................11
Manual Operation ....................................................................................................11
Commissioning the Burner ........................................................................................11
MODULATING UNIT ..................................................................................... 12
Page 2
NOL Compact Modulating
ROUTINE MAINTENANCE
OF
NOL MODULATING BURNERS ................................... 13
General .....................................................................................................................13
Daily Checks .............................................................................................................14
Photoelectric Cell ......................................................................................................14
Replenishing the Fuel Supply ....................................................................................14
Boiler Combustion Surface ........................................................................................14
FAULT FINDING ........................................................................................... 14
If the Burner Fails to Start ...........................................................................................14
If the burner is found at lockout (red lockout lamp illuminated) .................................14
Flame Occurs Followed by Immediate Lockout ........................................................14
The Burner Starts With The Correct Oil Pressure But No Flame Appears...................14
Modulating System ...................................................................................................14
Burner Commissioning Sheet ....................................................................................14
FUEL PUMPS ............................................................................................... 14
FLAME FAILURE & SEQUENCE CONTROL ............................................................ 15
Burner Control Program.............................................................................................15
Control Program Under Fault Conditions And Lockout Indication ..............................16
RWF40 MODULATING CONTROL ................................................................... 16
Basic display .............................................................................................................16
To change the working set point. ...............................................................................16
To enter a new parameter .........................................................................................16
BURNER OIL NOZZLE ................................................................................... 18
FLUIDICS KC2 ATOMISER .............................................................................. 18
SERVICE & REPLACEMENT .............................................................................. 18
BURNER PERFORMANCE CURVES ...................................................................... 18
BURNER COMBUSTION HEAD ......................................................................... 20
ELECTRODE SETTING .................................................................................... 21
ELECTRICAL DATA TABLE ................................................................................ 21
COMMISSIONING SHEET ................................................................................ 22
BURNER SERVICE RECORD ............................................................................. 23
IMPORTANT - SAFETY
It is essential that the following instructions and adjustments are carried out by qualified engineers that
are 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 these
instructions, or as a result of misuse. Your attention is drawn to the Emergency Instructions on page 10
EUROPEAN BOILER EFFICIENCY DIRECTIVE (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 these
must include flue gas temperatures, average water temperature, and CO2or O2 concentration.
NOL Compact Modulating
Page 3
BURNER & COMPONENT IDENTIFICATION
Standard Burner Arrangement Shown
All dimensions are mm.
%
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Page 4
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NOL Compact Modulating
(
Burner Mounting Details
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
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BURNER
NOL18-34
NOL18-38
NOL30-25
NOL35-25
NOL35-34
NOL35-38
NOL50-28
NOL50-34
NOL50-38
NOL60-28
NOL60-34
NOL60-38
NOL85-38
A
440
465
365
365
440
465
440
440
465
440
440
465
465
B
674
721
544
544
674
721
674
674
721
674
674
721
721
C
430
430
430
430
430
430
430
430
430
430
430
430
430
D
420
457
307
307
420
457
420
457
480
457
480
480
537
E
457
457
457
457
457
480
420
457
480
457
480
480
480
F
387
314
314
387
387
387
387
387
-
DESCRIPTION
Flame Tube
Burner Casing
Modulating Motor
Fan Motor
Air Control Cable
Oil Spill Control Valve
Modulating Cam Unit
Temperature Controller
Control Panel
Photocell
Viewing Window
Oil Pump
G
440
480
360
360
440
480
440
440
480
440
440
480
480
H Dia.
230
230
230
230
230
230
254
254
254
254
254
254
280
J PC D
305
305
254
254
305
305
305
305
305
305
305
305
305
NOL Compact Modulating
Page 5
FEATURES
SITE CONDITIONS
Developed from Worldwide field experience, the
NOL Modulating series sets new standards in
efficient and reliable operation. The burners, which
are designed to meet the requirements of all
International markets, are designed for flange
mounting to the appliance front plate and are
delivered ready to install with a pre wired packaged
control system.
SERVICES
Fuel Storage and Handling
The requirements of BS2869 will ensure that the
fuel is suitable. Under sustained cold and exposed
conditions, class D grade of fuel should be stored
and supplied to the burner at a minimum
temperature of 5°C (41°F).
Fuel Supply
Air Regulation
Air for combustion can be adjusted to give
maximum efficiency.
Controls and Safety Systems
Flame supervision is by photocell with a sequence
controller for automatic start up, running, and
shutdown of the burner.
Fuels
Light distillate oil class D (1.5 5.5 cSt @ 40°C).
Burner outputs are based upon a gross CV of 45.5
MJ/kg.
Fuel System
Suitable for single pipe gravity or two pipe suction
lift systems. The filter supplied with the burner is
of the disposable element type.
Construction
Of monobloc design using fasteners to ISO
standards. and designed for flange mounting.
GENERAL
The burners are supplied for fully modulating
operation only.
This manual is structured to enable the user to
proceed from the delivery of the burner to its
commissioning and use.
The conditions to be fulfilled and the controls and
adjustments to be used are dealt with in the
sequence that should be followed for the correct
installation and use. Pre commissioning and Live
Run are described, and the location of necessary
controls and adjustments to undertake these are
illustrated and supported by appropriate tabular
matter and graphs.
Routine maintenance, Fault Finding and Spare
Parts identification complete the manual. Literature
on proprietary components is available on request.
Page 6
AND
The oil line should consist of metallic tube (NEVER
galvanised steel). The final connection to the pump
inlet port is made with a flexible pipe supplied with
the burner. Joints should be made with compression
fittings.
When gravity feed is used, the maximum head
should not exceed 4m, (35 kPa).
On installations where the fuel tank is situated
below the level of the burner the maximum suction
permitted is 40 kPa (300 mm HG) and a two pipe
(supply and return) fuel supply system MUST be
used.
Single Pipe system
On a single pipe (gravity feed) system, the pump
should be primed under gravity from the tank and
not by running the pump mechanically. To prime
the pump remove the purge plug, connect the
purge port to a suitable container.
Two-Pipe System
The suction line will require priming before
energising the pump mechanically. It is essential
to ensure that the return pipe is not obstructed in
any way. Any obstructions will damage the pump.
The fuel supply line may need priming if the oil
storage is allowed to drain completely.
Flue and Chimney Requirements
The flue and chimney must be constructed and
installed to the appropriate local conditions, Codes
and Standards. It shall be of sufficient size to satisfy
the volume of flue gases at all firing conditions.
Plant Room Ventilation
An adequate dust free supply of fresh air is required
for the burner at both high and low level in
accordance with the appropriate standards.
NOL Compact Modulating
Existing Appliances
In preparing the appliance to receive the NOL oil
burner, a careful inspection should be made of its
condition after it has been cleaned thoroughly to
remove all adhering tars, scale and dirt.
Combustion Chamber Conditions
When the burner is fitted to an appliance designed
to work under balanced or negative combustion
chamber conditions, the over fire draught must not
exceed 0.25 mbar.
Should the over fire draught exceed this figure, then
steps should be taken to reduce it to this level.
INSTALLATION
General
Check that the burner is appropriate for the
appliance rating. Detailed burner performance
data is given on page 19.
Fitting to the Appliance
If the burner is to be fitted to a new packaged unit,
refer to the manufacturers recommendations.
If the burner is being fitted to an existing appliance,
prepare the mounting flange as detailed on page
5.
Ensure the joint between appliance and burner is
effectively sealed with the gasket provided.
Unless the appliance manufacturer specifies
extensions, the flame tube should be flush with
the inner face of the appliance combustion
chamber.
Oil Supply Connections
Connect the oil supply to the burner oil pump
using the flexible pipes supplied. Refer to the
burner oil system diagram on page 8.
Electrical Power Connection
Connect a three phase, 50 Hz electrical supply to
the burner, observing all applicable Codes and
Standards. The electrical connections required are
shown on page 9 and in the wiring diagram
contained in the instruction pack attached to the
burner. These diagrams also show the auxiliary
control connections, which must be made.
If the burner is supplied as part of a packaged
appliance/burner unit refer to the appliance
manufacturers instructions.
BURNER AIR CONTROLS
A motorised, cable driven air flap controls the air
for combustion. It is located inside the air inlet.
Air Diffuser
The air diffuser creates a pressure drop to ensure
good fuel/air mixing and flame stability.
BURNER OIL CONTROLS
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.
The nozzle should be sized to match the rating
and turndown requirements of the appliance.
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.
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
connected to a flexible cable operating the burner
air inlet control damper and is of the variable
contour type (see fig. 2 on page 12). The second
cam is the modulating oil cam and is illustrated in
fig. 1. The Burner Oil System Drawing on page 8
shows 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.
There is a well defined relationship between the
delivery of fuel through the nozzle and pressure
behind the nozzle, therefore movement of the oil
cam ‘modulates’ the nozzle output and hence the
output of the burner.
NOL Compact Modulating
Page 7
BURNER OIL SYSTEM
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DESCRIPTION
Pressure Switch
Spill Control Valve
Non-Return check valve
Feed Pressure Gauge
Spill Pressure Gauge
Gauge Shut- Off Valve
Burner Manifold Block
N/C Safety Valve (Feed)
N/C Safety Valve (Return)
Oil Pump
Spill-Back Nozzle
Flex ible Oil Pipe
Manual Shut- Off Valve
Oil Filter
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Page 8
NOL Compact Modulating
ELECTRICAL CONNECTIONS
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DESCRIPTION
Appliance Limit Instrument
B urner Fault Signal
B urner Operating Signal
Appliance On/Off Instrument
B urner Operating Hours Run
Counter
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NOL Compact Modulating
Page 9
The volume of air required for combustion must
also be varied as the nozzle output varies, and this
is done by the air control damper operated by a
flexible steel cable connected to a lever system
bearing against the air control cam.
Once the oil cam has been adjusted as described
in the commissioning section of this handbook, the
profile of the air cam must be adjusted to give the
required combustion conditions. This is achieved
by turning the thumbscrews under the cam in or
out as the burner is ‘inched’ through its firing range.
The air control damper is spring loaded ‘open’ for
safety in the event of cable failure.
EMERGENCY INSTRUCTIONS
OPERATION
Inspection
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 pre
determined 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.
COMMISSIONING
IMPORTANT - SAFETY
It is essential that commissioning shall be
undertaken only by suitably qualified and
experienced personnel. In the case of NOL
Modulating burners, commissioning engineers
should be experienced in pressure jet oil burner
commissioning . Nu way can accept no
responsibility for consequential loss, damage or
personal injury which results from a failure to follow
the commissioning instructions provided or from
commissioning procedures being undertaken by
unqualified personnel.
Page 10
NOL Modulating burners are designed and
constructed to meet current legislation. When used
in accordance with the instructions provided, NOL
Modulating burners are unlikely to produce a
hazardous condition. If, however such a condition
should arise in connection with the burner, the
appliance or of any instrument, machine or service
in the vicinity of the burner, the OIL AND
ELECTRICITY SUPPLIES SHALL BE ISOLATED
IMMEDIATELY and they shall remain isolated until
the fault has been identified and rectified.
Before commissioning is begun 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 rating.
•
Check electrical earthing.
•
Verify that the oil supply system is correctly
designed and that the supply pipework is
correctly sized and free from leaks.
•
Ensure that all manual fuel isolation valves
are operable, fully closed and leak tight.
•
Make all personnel involved in the
commissioning aware of the location of the
emergency fuel and electricity isolation
points.
•
Check that fittings for bleed and pressure
testing are fitted.
•
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.
•
Check the appliance’s ventilation and flueing
arrangements.
•
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.
NOL Compact Modulating
•
•
Check that all relevant documentation is
available including, where appropriate:
•
The agreed plant performance
specifications.
•
Plant drawings and pipework layouts.
•
Electrical logic and wiring diagrams.
•
Certificates confirming satisfactory
completion of procedures such as
soundness testing and electrical safety
tests.
•
Commissioning , operating and
maintenance instructions for the plant.
Establish that the operation of plant other
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 and 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.
Pre-firing Checks
With the oil and power switched off, carry out the
following checks.
•
Check the nozzle size and position relative
to the diffuser plate. (The burner head
dimensional details are given on page 20).
•
Check that the electrode positions and H.T.
leads are correct.
•
Check the fan motor overload settings.
•
If the appliance is a boiler, check that the
water level is correct, the controlling valves
are open and that the water pumps are in
working order.
•
If a flue damper is fitted, check that it is
correctly interlocked to the burner or fixed
in the fully open position.
•
Ensure that there is a good oil supply to the
burner pump. Bleed one or two gallons from
the flexible to eliminate any pipe scale and
air from the system.
•
Check that the oil supply is of the
recommended temperature and pressure.
•
Bleed the burner pump manually by
removing the right hand ¼” BSP plug in the
top of the pump until air free oil flows.
•
Switch on the electricity supply to the burner.
•
Remove the access lid on the modulating
cam box unit.
•
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 pre
purge phase.
•
Allow the fan motor to run up to speed,
switch off the burner and check the fan
rotation (Anti clockwise as viewed from the
motor side) as the fan slows down.
•
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).
THE BURNER IS NOW READY TO BE
COMMISSIONED.
Manual Operation
Check that the RWF40 controller is configured
correctly (refer to page 17). Press and hold the ‘EXIT’
key until the ‘manual operation’ indicator
illuminates. The modulating motor can now be
inched using the ‘increase’ & ‘reduce’ buttons on
the controller face. Press and hold the ‘EXIT’ key
until the ‘manual operation’ indicator extinguishes
to return to automatic mode
Commissioning the Burner
New burners are generally supplied against the
firing specification of the appliance. In this case the
system and spill pressures may be pre set and
require checking and minor adjustments only. The
following section describes how to set up the
modulating cam box unit from a ‘scratch’ situation.
The modulating cam layshaft can be rotated by
hand by using the gearbox disengagement lever in
the drive servomotor.
•
Ensuring that the modulating cam
arrangement is in the low flame position,
adjust the oil cam (see fig. 1 on page 12) so
that it gives approximately 1.5mm throw
(3mm stroke) and lock in position.
•
Check to ensure that the spill valve push rod
bears lightly against the oil cam.
NOL Compact Modulating
Page 11
MODULATING UNIT
Oil Cam Adjusting
Screw
Oil Cam Hub
(Cams shown in the Low
Flame Position)
Oil Cam A
Air Cam B
Oil Spill Back
Regulating Vlave
Lever
Servomotor
Camstack
Motor Unit
View of Servomotor from underside
(cover removed) showing position of
disengagement lever
Throw
Cam Follower
Oil Cam View On A
Fig. 1.
Locking
Screws
Spill Pressure
Reduce
Increase
Adjustable
Plunger
Cam Disk
Rotation for High
Flame position
Profile Band
Retaining
Saddle
Air Cam View On B
Cable Adjuster
Fig. 2.
Operating
Cable
Cam Lever
Adjuster Locking
Screws
Page 12
Profile Adjuster
NOL Compact Modulating
•
Turning to the air cam (fig. 2 opposite), rotate
the thumbscrews in or out so that they give
a reasonable amount of adjustment in each
direction. Adjust the flexible cable (at either
end if necessary) until the air inlet damper is
fully closed (i.e. until all the slack is taken up
on the cable).
•
Now adjust the thumbscrews to give a small
opening of the air damper at low flame.
•
Uncover and replace the photocell. Reset the
sequence control and allow the burner to
start. Immediately the burner starts, switch
the hand/auto selector switch to the ‘hand’
position and hold low flame until the
appliance is ready to accept high flame.
During this period, check and adjust the low
flame oil throughput.
•
Check the flame visually. If the flame is dirty,
adjust the air cam thumbscrews until the
flame becomes clean.
•
After a suitable delay, inch the camshaft to
the high flame position (i.e. through 180°) by
using the RWF40 control in manual mode
(see page 11). Adjust the air cam profile by
means of the thumbscrews until the air
damper is sufficiently open to give clean
combustion. At this stage it will be found that
all of the thumbscrews between low and high
position will require adjusting so as to avoid
over stressing the cam profile band.
Once this has been done, there should be a fairly
smooth profile between low and high positions.
Ensure that the flame is visually clean throughout
the modulation range at all times.
Check the oil consumption. If this is not correct for
the full burner rating, the oil cam must be adjusted
as 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
compensate 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 flame
oil rate is correct.
When a satisfactory flame is achieved, again check
the line and spill pressures.
•
Inch the camshaft back to the low flame
position. The oil consumption rate should
now be between 35 and 50% of the rated
maximum.
•
Measure the flue gas composition and adjust
the combustion air volume as necessary.
•
Check the burner performance throughout
the range adjusting the air cam profile as
necessary to give a clean and efficient flame.
When a satisfactory setting has been achieved, lock
the air cam thumbscrews with the grubscrews fitted
in the side face of the cam body. Refit the
Modulating unit access cover.
If the burner control panel is inclusive of Low
Excess low and High Water interlocks and alarms,
test that these function correctly. Ensure that the
boiler feed pump switchgear provided in the panel
is operating satisfactorily.
Adjust the modulating control to the required
pressure/temperature.
Allow the boiler to attain the correct working
pressure/temperature and adjust the on/off and
limit instruments to the desired values.
Return the RWF40 to automatic mode. The plant
is now under the control of the pressure/
temperature controllers for modulation and the on/
off and high limit instruments for control.
Finally check all ancillary controls and equipment
such as damper interlocks etc.
ROUTINE MAINTENANCE
MODULATING BURNERS
OF
NOL
General
It is vitally important that personnel responsible for
the day to day operation and maintenance of the
plant are instructed by the commissioning engineer
on the basic function of the burner as well as the
need for routine maintenance and daily checking
of burner operations.
Final adjustments, which will have been made
during the commissioning, must be recorded on
the Commissioning Sheet at the back of this manual
and in the appliance logbook. A copy of the
commissioning data must be sent to the appliance
manufacturer.
The burner should be kept clean inside and out. It
will be more reliable, and if an oil leak occurs it
will be spotted more readily.
NOL Compact Modulating
Page 13
Daily Checks
Inspect the burner daily to check if there is any
variation from the correct operating sequence, as
follows:
Check the oil pressure on the nozzle line gauge.
This should be 27.8 bar (400 psi).
Check the spill pressures. If these are low it may
indicate that the oil nozzle filter is clogged.
If there is an inspectIon window on the appliance
through which the ignition spark and flame can
be observed, ignition and flame should be
inspected and any irregularities that are observed
should be rectified i.e. nozzle/electrodes cleaned
and any deposits removed from the inside of the
flame tube and diffuser.
Photoelectric Cell
Remove the photoelectric cell and clean with a
soft lint free cloth if necessary. Be carefull not to
touch the glass buld of the cell as this can lead to
premature failure of the unit.
Replenishing the Fuel Supply
It is usual practice to shut boiler(s) off whilst delivery
of fuel is being made and allow approximately 30
minutes for any sediment to settle before restarting
the burners.
Boiler Combustion Surface
Keep the boiler combustion surfaces and flueways
clean. Any accumulation of soot will decrease the
efficiency of the boiler and increase the flue gas
exit temperature. Always cover up the burner
during boiler cleaning operations.
FAULT FINDING
If the Burner Fails to Start
Make sure that all the thermostats and switches in
the control circuit are in the ‘made’ position. Check
that the oil pressure switch is not registering an
excess oil pressure in the burner spill return system
(switch contact broken).
Check that the electricity supply to the burner is
‘live’ and that the control and main circuit fuses
are intact. If a fuse is found to be ‘blown’ then the
cause should be investigated and rectified before
proceeding further.
On steam boilers, check that the ‘water level
interlocks’ are in the ‘made’ position.
Page 14
If the burner is found at lockout (red lockout
lamp illuminated)
Reset the burner and observe the starting
sequence. (Make reference to the Sequence
Diagram and Timing Charts for the Flame Failure
controls on page 15 for further information).
Check the fan motor overload and reset if necessary.
Flame Occurs Followed by Immediate
Lockout
Check the PE cell and the air regulator for correct
operation. Check that the oil pressures are correct.
Ensure that there is sufficient oil in the storage tank,
bleed the oil pump in case it is partially air locked.
Check to ensure that all stop/fire valves in the
supply line are fully open.
The Burner Starts With The Correct Oil
Pressure But No Flame Appears
Check the ignition system, HT lead connections,
electrode gap and the condition of the electrode
insulators. Check that the air damper cable is not
broken or disconnected (the air regulator will be
fully open). It is important to note that continued
resetting of the burner should be avoided as this
can lead to a dangerous situation.
Modulating System
If malfunction of the modulating controller (RWF
40) is suspected, check that only a compatible
pressure/temperature detector has been used. If
problems persist then replacement of the unit
should be considered.
Burner Commissioning Sheet
This manual contains a record of the essential
information and will have been completed by the
commissioning engineer with individual details of
the burner. These details should be verified
periodically and adjusted if variations are noted.
Commissioning details must also be recorded in
the appliance logbook.
FUEL PUMPS
On spill back oil systems, the fuel pump is sized to
deliver oil volume at 2.5 times the maximum
burner throughput at a pressure of 28 bars (400
psi). Suntec models ‘E’ and ‘TA’ are supplied as
standard fittment. Pump details are shown in the
drawings and table on page 15.
NOL Compact Modulating
6
6
3
5
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6
3
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All pumps are set for 2 pipe (suction & return) system.
Refer to pages 6&8 for single pipe (gravity feed) connection.
ITEM
PORT
S
Suction Port
P
Pressure Port
R
Return Port
Pn
Vacuum Gauge
BURNER MODEL
NOL18-34,38
NOL30 & 35-25
NOL35 & 50-28,34,38
NOL60 & 85
ITEM
PORT
Ps
Pressure Gauge
1
Regulator Capnut
2
Regulator Screw
PUMP UNIT
Suntec E7
Suntec TA2
Suntec TA2
Suntec TA3
MAX FLOW
190 lt/h
380 lt/h
380 lt/h
600 lt/h
If a lockout situation occurs, the burner will not
start until it is manually reset by pressing the
lockout window on the control. (The control can
also be reset by the off/on/reset switch situated on
the control panel facia)
If the burner fails to fire and persists in locking out,
no more than three attempts should be made. To
do so may create a dangerous situation.
If a burner becomes troublesome then the
assistance of a qualified commissioning engineer
should be obtained. To assist in his diagnosis, notes
should be made detailing the events leading up to
the lockout situation. The symbol appearing in the
lockout window should also be noted prior to
resetting the burner. (Refer to theSequence Diagram
and Timing Chart below).
PLEASE NOTE. When the control box goes to
lockout it is generally performing the function it is
designed for.
Burner Control Program
Burner operational sequence based on the Landis
& staefa LAL1.25 Control box. Note. Timings are
for operation on a 50 hz electrical supply only.
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FLAME FAILURE & SEQUENCE
CONTROL
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The standard control box fitted to the NOL
Modulating series of burners is the Landis & Staefa
type LAL1.
The unit is designed to provide control and
supervision for atomising oil burners of medium
to large capacity. They are suitable for use on multi
stage and modulating burners.
For safety reasons, at least one controlled
shutdown must be provided within each 24 hour
period of continuous operation.
When a burner failure is encountered the box goes
into lockout mode. This is indicated by an orange
neon, which displays within the lockout window
of the control and is repeated at the lockout lamp
on the panel facia.
PERIOD
t1
t2
t3
t4
t5
t6
t7
t8
Ts
Tp
T
NOL Compact Modulating
TIME
(secs)
2.5
5
54
22.5
54
54
5
15
155.5
15
170.5
7S
DESCRIPTION
Start up time for fan motor
Start up to 'open' signal
Modulating servo to 'High flame'
Full air pre-purge
Modulating servo to 'Low flame'
Pre-ignition
Safety period
Release to RWF40 controller
Total start up time
Post purge time
Control re-cycle time
Page 15
Control Program Under Fault Conditions
And Lockout Indication
In the event of fault conditions the sequence
switch stops and simultaneously the lockout indi
cator. The symbol appearing above the reading
mark indicates the kind of fault encountered.
No start, because, e.g., the CLOSE signal has
not been supplied to control box terminal 8
by the servo motor limit or auxillary switch,
or a contact has not been closed between
control box terminals 12 and 4 or 4 and 5.
Shut down of start up sequence, because
the OPEN signal has not been supplied to
control box terminal 8 by the servo motor
limit switch. Terminals 6,7 and 15 remain
under voltage until the fault is corrected.
Lockout due to a fault in the flame supervi
sion circuit.
Shut down of start up sequence, because
the signal for the low flame position has not
been supplied to control box terminal 8 by
the servo motor auxillary switch. Terminals
6,7 and 15 remain under voltage until the
fault is corrected.
1 Lockout, because no flame signal has been
received on completion of the safety time.
Lockout, because the flame signal has been
lost during burner operation or an air pres
sure failure has occured.
Lockout on completion or after completion
of the control program sequence due to ex
traneous light (e.g. flame not extinguished,
leaking fuel valves) or due to a faulty flame
signal (e.g. fault in the flame supervision cir
cuit or similar).
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Page 16
RWF40 MODULATING CONTROL
Basic display
The diagram below opposite 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.
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
a
Landis & Staefa
LAL1. Program
Sequence Disk.
When lockout occurs, the control can be reset
immediately. After the resetting (and also after the
correction of a fault which resulted in a controlled
shut down, or after each mains failure) the se
quence switch always runs through to the start
position, whereby only terminals 7,9,10 and 11
receive voltage in accordance with the control pro
gram. It is only then that the control unit programs
a fresh burner start up.
Note: Do not press the lockout reset button (or
remote reset switch) for more than 10 seconds.
Start up sequence.
idle steps up to the self shut down of
the sequence switch.
Post purge sequence.
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 below 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.
NOL Compact Modulating
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).
RWF40 RECOMMENDED SETTINGS
Display
Hot
Water
Steam
Proportional
ba nd
Pb1
10
1
Derivative
time
Dt
10
5
Reset time
Rt
50
20
Parameter
Set to the Air
Damper running
time between low
& high flame
Actuator
time
Tt
Switch on
threshold
Hys 1
0
0
Upper off
threshold
Hyst 3
999.9
999.9
Detector:
range start
SCL
0
0
Detector:
range end
SCH
100
25
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NOL Compact Modulating
Page 17
BURNER OIL NOZZLE
SERVICE & REPLACEMENT
The Burnerlance is designed to operate spill back
atomisers of the non tip shut off variety, and having
a 9/16” x 24 unef fixing thread.
The Fluidics KC2 series atomiser is the prefered type
and this will have been sized at the point of order
to suit the burner rating and application.
When the nozzle has completed 3000 hours of
operation, it should be replaced with the same
Make, Type and Size as fitted. Failure to do so will
alter the characteristics of the burner and may
impair the performance and efficiency of the plant.
The nozzle identification code is stamped onto the
face of the hexagonal nut section of the nozzle
body as shown below.
Should any doubts arise concerning the suitability
or performance of the burner nozzle, please
contact the Nu way Technical dept. who will be
pleased to assist.
Nu way Ltd Parts & Components Division carry a
comprehensive stock making up the burner systems
described in this handbook. Should it become
necessary to order replacement parts, it is
important to quote the burner model, specification
and serial numbers to ensure correct expedition
of your order.
Nu way Ltd is able to offer ‘on site’ Commissioning,
Service and Repair through its wordwide network
of authorised distributors and sales offices. Please
contact the Nu way Service Department for further
information.
FLUIDICS KC2 ATOMISER
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BURNER PERFORMANCE CURVES
The Performance Graph shown on page 19 plots
burner input against the appliance running
resistance. The appliance starting resistance is
derived from a combination of the combustion
chamber shape, volume, start rate and flue
conditions. It may be necessary to select a burner
with a higher fan static pressure than would
normaly be chosen, if the appliance has a high
starting resistance.
Similarly, when firing a reverse pass boiler up to 2
MW, with a combustion intensity of 2 MW/M3 and
an operating resistance between 40 and 90 mm
wg. it is recommended that a burner with a higher
fan static pressure is selected, ie. if the graph selects
a burner with a 28 cm fan then use the 34 cm fan
model for correct combustion.
All outputs quoted are based on gross C.V.
2 5,1*
5(785125
63,//6,'(
.
Page 18
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NOL Compact Modulating
200
150
100
50
0
500
0
0
5
10
15
20
BURNER OUTPUT (Kg/h)
2000
1500
NOL30-25
1000
BURNER OUTPUT (kW)
NOL50-28
NOL35-25
NOL60
-28
NOL18-34
NOL18-38
NOL35-34
NOL35-38
NOL50-38
NOL50-34
NOL60-38
NOL60-34
NOL85-38
2500
NOL100-38
3000
240
Burner Performance Curves
TOTAL RESISTANCE (mbar)
Burner outputs are based on a gross calorific value of class D fuel of 12.66 kW/Kg.
Graphs produced in accordance with BS EN 267.
NOL Compact Modulating
Page 19
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2
3
4
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10
11
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BURNER
NOL18-34
NOL18-38
NOL30-25
NOL35-25
NOL35-34
NOL35-38
Page 20
DESCRIPTION
Diffuser
Inner Assembly Disc
Inner Draught Tube
Ignition Electrodes
Oil Lance
Inner Assembly Union
Draught Tube Adaptor
Draught Tube
Flame Tube
Restrictor Ring
Oil Nozzle
ØA
178
178
178
178
178
178
ØB
165
165
165
165
165
165
ØC
152
152
152
140
152
152
ØD
165
165
NONE
NONE
NONE
NONE
BURNER
NOL50-28
NOL50-34
NOL50-38
NOL60-28
NOL60-34
NOL60-38
NOL85-38
NOL Compact Modulating
ØA
220
220
220
220
220
220
254
ØB
197
197
197
197
197
197
234
ØC
178
178
178
178
178
178
204
ØD
206
206
206
NONE
NONE
NONE
NONE
ELECTRICAL DATA TABLE -
Supply 400 3 50
Burner
Model
Motor
(kW/rpm)
Start
Current (A)
Full Load
Current (A)
Main
Fuse (A)
Cable
Size (mm2)
NOL18-34
2.2/2800
25
5.0
16
1.5
NOL18-38
3.0/2800
35
6.6
20
1.5
NOL30-25
1.5/2800
17
3.6
16
1.5
NOL35-25
1.5/2800
17
3.6
16
1.5
NOL35-34
3.0/2800
35
6.6
20
2.5
NOL35-38
4.0/2800
45
8.5
25
2.5
NOL50-28
3.0/2800
35
6.6
20
2.5
NOL50-34
4.0/2800
45
8.5
25
2.5
NOL50-38
5.5/2800
57
11.3
32
2.5
NOL60-28
4.0/2800
45
8.5
25
2.5
NOL60-34
4.0/2800
45
8.5
25
2.5
NOL60-38
5.5/2800
57
11.3
32
2.5
NOL85-38
7.5/2800
76
15.2
40
4.0
ELECTRODE SETTING
NOL Compact Modulating
Page 21
COMMISSIONING SHEET
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 : ____________________________
Combustion Details
Low
Flame
Point
2
Point
3
Point
4
Point
5
High
Flame
CO2 %
Smoke NO.
Ambient Temp. °C
Flue G as Temp. °C
Efficiency. %
C.C.P. mm/wg
Flue Draught. mm/wg
Fan Static. mm/wg
Oil Pressure. bar
Spill Pressure. bar
Oil Temperature. °C
Oil Consumption. us/gph
Air Control. % Open
Motor FLC. Amps
Engineers Name : _________________________________________
Signature : _______________________________________________ Date : ____________________
Page 22
NOL Compact Modulating
BURNER SERVICE RECORD
The details below are to be completed by the Servicing Engineer
This sheet to be compl eted and signed fol l owing each service / adj ustment
Date
Details Of Service
NOL Compact Modulating
Signature
Page 23
NOL Modulating.PM65
Revision 101201B
®
BS EN ISO 9001
CERT No. FM00921
Page 2
NU WAY LIMITED, P.O.Box 1, Vines Lane
Droitwich, Worc, WR9 8NA, England
Telephone: (01905) 794331
e mail: info@nu way.co.uk
Fax: Office (01905) 794017
Parts & Components (01905) 795829
NOL Compact Modulating