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Nu-Way PO160, Installation & Maintenance Manual

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Nu-Way PO160 Installation & Maintenance Manual Download Page 3

Page A.3

PO Series Contents

S

AFETY

................................................................................................................... D.2

E

MERGENCY

  I

NSTRUCTIONS

........................................................................................ D.2

I

NSPECTION

............................................................................................................ D.2

I

NITIAL

 S

ETTINGS

..................................................................................................... D.3

D

RY

 R

UN

.............................................................................................................. D.3

L

IVE

 R

UN

............................................................................................................... D.3

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

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

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

M

ODULATING

 U

NIT

................................................................................................. D.5

C

OMMISSIONING

 

THE

 B

URNER

................................................................................... D.6

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

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

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

RWF40 M

ODULATION

............................................................................................. D.7

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

C

OMMISSIONING

 S

HEET

 : O

IL

................................................................................. D.11

E : O

PERATION

 A

ND

 M

AINTENANCE

.................................................................. E.1

N

ORMAL

 O

PERATION

.................................................................................................E.2

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

R

OUTINE

 S

AFETY

 C

HECKS

...........................................................................................E.2

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

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

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

R

OUTINE

  M

AINTENANCE

............................................................................................E.2

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

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

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

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

F

AULT

 F

INDING

.........................................................................................................E.3

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

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

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

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

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

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

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

S

PARE

 P

ARTS

............................................................................................................E.4

B

URNER

 S

ERVICE

 R

ECORD

..........................................................................................E.5

Summary of Contents for PO160

Page 1: ...Installation Maintenance Manual PO Series Automatic Oil Burner Fully Modulating Oil Burner Tel 44 0 1905 794331 Fax 44 0 1905 794017 Email info nu way co uk Web www nu way co uk ...

Page 2: ...al Power Supply B 4 BURNER PACKAGING ASSEMBLY AND INSTALLATION B 4 Packaging For Transit B 4 Assembly And Installation B 4 Fitting To The Appliance B 4 Air Supply B 5 Combustion Chamber Conditions B 5 Electrical Power Supply B 5 TECHNICAL SPECIFICATION C 1 BURNER SPECIFICATION SHEET C 2 BURNER AND COMPONENT IDENTIFICATION C 3 BURNER OPERATION C 3 BURNER CONTROLS C 3 Modulating Unit C 3 Flame Monit...

Page 3: ...NG SHEET OIL D 11 E OPERATION AND MAINTENANCE E 1 NORMAL OPERATION E 2 Automatic Modulation E 2 ROUTINE SAFETY CHECKS E 2 Combustion Air E 2 Flame Detector E 2 Combustion Air Pressure Switch E 2 ROUTINE MAINTENANCE E 2 Combustion Air Fan E 2 Burner Inner Assembly E 3 Oil Filters E 3 Oil Preheater E 3 FAULT FINDING E 3 Modulating System E 3 Incorrect Rotation of the Fan Motor E 3 Fan Motor Fails To...

Page 4: ...P Series Burners are unlikely to produce a hazardous condition If however such a condition should arise in connection with the burner the appliance or any instrument machine or service in the vicinity of the burner the FUEL AND ELECTRICITY SUPPLIES SHALL BE ISOLATED IMMEDIATELY and they shall remain isolated until the fault has been identified and rectified E E E E EUROPEAN UROPEAN UROPEAN UROPEAN...

Page 5: ...Page B 1 PO Series General Information GENERAL INFORMATION ...

Page 6: ...wn on the Burner Specification Sheet on Page C 2 Technical Details Fuel The PO is available in two forms to use distillate or residual fuel oils Controls The control panel housed in a free standing or wall mounted cabinet is a purpose designed and robustly constructed unit that complies with relevant Standards and Codes of Practice and can be tailored to individual customer requirements Depending ...

Page 7: ...The Table on Page B 7 shows the temperatures and pressures for Class D E F and G oils Oil Deliveries It is good practice to shut down boilers whilst the delivery of oil is made and allow 30 minutes for oil sediment to settle out before re starting the burners Ring Main System The oil from the tank must be supplied to the burner from a pumped ring main system A typical system is shown on Page B 8 T...

Page 8: ...nsure that the appliance is in good condition Any doubt about the suitability of the appliance should be referred to the manufacturer To assemble the burner 1 Fit the burner head to the prepared appliance front plate 2 Ensure that the joint between the burner and the mounting flange is sealed effectively using the gasket provided The flame tube should not generally extend beyond the inner face of ...

Page 9: ... Black L2 and Grey L3 and Blue N in three phase power circuits from 1 June 2006 Full details of the changes can be found in Amendment No 2 AMD 14905 to BS 7671 2001 which is a free download from the IEE website www iee org cablecolours They are also within the new version of BS7671 2001 Incorporating Amds 1 2 published on 31st March this new version of the Wiring Regulations can be identified by i...

Page 10: ...e to the wiring diagrams provided in the instruction pack that is supplied with all P Series burners and to those wiring diagrams in the appliance manufacturer s instructions All external auxiliary control circuits should be connected with reference to the appropriate wiring diagram All systems and circuits should be checked to ensure that correctly rated fuses are used ...

Page 11: ...PO Series General Information Page B 6 B B B B BURNER URNER URNER URNER URNER D D D D DESIGNA ESIGNA ESIGNA ESIGNA ESIGNATION TION TION TION TION C C C C CODE ODE ODE ODE ODE ...

Page 12: ... ANDLING T T T T TEMPERA EMPERA EMPERA EMPERA EMPERATURES TURES TURES TURES TURES A A A A AND ND ND ND ND P P P P PRESSURES RESSURES RESSURES RESSURES RESSURES Fuel Class Viscosity Seconds Minimum From Tank Burner Inlet Atomising kg cm 2 psi D 35 0 35 to 0 70 5 to 10 E 200 16 16 82 960 30 43 110 1500 36 65 118 3500 50 82 132 4200 55 86 140 Fuel Handling Temperatures C Fuel Delivery Pressures Minim...

Page 13: ...Series General Information Page B 8 T T T T TYPIC YPIC YPIC YPIC YPICAL AL AL AL AL P P P P PUMPED UMPED UMPED UMPED UMPED O O O O OIL IL IL IL IL R R R R RING ING ING ING ING M M M M MAIN AIN AIN AIN AIN ...

Page 14: ...Page B 9 PO Series General Information ...

Page 15: ...PO Series General Information Page B 10 AAD PFinal B_Gen PO B_Gen pmd 250504A ...

Page 16: ...Page C 1 PO Series Technical Specification TECHNICAL SPECIFICATION ...

Page 17: ...PO Series Technical Specification Page C 2 B B B B BURNER URNER URNER URNER URNER S S S S SPECIFIC PECIFIC PECIFIC PECIFIC PECIFICA A A A ATION TION TION TION TION S S S S SHEET HEET HEET HEET HEET ...

Page 18: ...ulating unit Two adjustable cams are mounted on this shaft one of which is operating the burner air inlet control damper and is of the variable contour type the second cam is the modulating oil cam see illustrations on Page C 18 Oil System The Burner Oil Control System Drawings on pages C 10 11 show the burner hydraulic circuit Oil for combustion is drawn from the supply through a fixed displaceme...

Page 19: ...and pressure given in the Table on Page B 8 Filter s are an integral part of the burner oil supply system The filter s should be checked regularly as failure to do so may result in a drop in oil pressure to the system Oil Control Train The oil control train consists of a high pressure fuel pump driven by the burner fan motor The oil nozzle throughput is controlled by a variable orifice regulator s...

Page 20: ...r will then continue to its normal operating position i e it continues to supervise the control functions and is therefore able to shutdown the burner safely should this be necessary after driving to high fire the modulating controller will drive the burner towards the low flame position but depending on the temperature pressure will stop in any intermediate position between low and high flame the...

Page 21: ...to the changed parameter Press and hold the PGM button down until the green set point figure changes to an AL the larger upper figures show the value Use the up down buttons to set the new value press the PGM button to enter the value and change to the next screen To cancel an entry press exit Scroll through the screens PGM button modifying any value found to be in error up down buttons At the las...

Page 22: ... Control Damper Ignitor Terminal Box Assembly Oil Valve Assembly Burner Head Casing Transition Ductwork Combustion Air Fan Modulating Cam Unit Oil Lance Flame Tube Inner Assembly Access Plate Combustion Air Fan This diagram is for illustrative purposes only Actual components supplied may vary from those shown Please refer to the Burner Specification Sheet and the drawings elsewhere in this manual ...

Page 23: ... u d o M 2 1 b x 4 s t u N g n i n i a t e R e t a l p k c a B 3 1 e n a V l o r t n o c r i A 4 1 t i n U r e p m a d r i A 5 1 y l b m e s s A k c o l B l a n i m r e T d n a r o t i n g I 6 1 s e l d n a H l a w a r d h t i W e t a l p k c a B 7 1 g n i s a C d a e H r e n r u B 8 1 d i o n e l o S f f o t u h S p i T e l z z o N 9 1 e c n a L l i O k c a B l l i p S 18 20 19 B B B B BURNER URN...

Page 24: ...Page C 9 PO Series Technical Specification O O O O OIL IL IL IL IL P P P P PUMPS UMPS UMPS UMPS UMPS ...

Page 25: ...re rated for 42kg cm 2 Pipework connections between the burner oil system and the separate pumping set are not supplied by Nu Way 3 Connections to the ring main on the air separator bottle air 1 BSP Spill Back Nozzle Tip Shut Off Solenoid Valve Solenoid Valve Pressure Guages Manifold Block Quick Release Couplings Flexible Connections Spill Control Valve Non Return Valve Feed To Burner Return from ...

Page 26: ...ump Cold Filter Air Separator Return to Ring Main Optional Inlet from Ring Main Pressure Switch Lockshield Isolation Valve Hot Filter Thermo meter Burner Mounted Components Pumping Heating Set Components Notes 1 All interconnecting pipework must have a minimum bore of 19mm 3 4 and must be pressure rated for 42kg cm 2 Pipework connections between the burner oil system and the separate pumping set a...

Page 27: ...PO Series Technical Specification Page C 12 D D D D DISTILL ISTILL ISTILL ISTILL ISTILLA A A A ATE TE TE TE TE O O O O OIL IL IL IL IL P P P P PUMPING UMPING UMPING UMPING UMPING S S S S SET ET ET ET ET ...

Page 28: ...es Technical Specification R R R R RESIDU ESIDU ESIDU ESIDU ESIDUAL AL AL AL AL O O O O OIL IL IL IL IL P P P P PUMPING UMPING UMPING UMPING UMPING H H H H HEA EA EA EA EATING TING TING TING TING S S S S SET ET ET ET ET ...

Page 29: ...ckout position Air Damper Closed proved by limit switch supplying voltage from terminal 11 to terminal 8 Fuel Valves closed proved by limit switch supplying voltage to terminal 12 Fuel pressure switch Limit Thermostat or Limit Pressure Switch all closed proved by continuity between terminals 4 and 5 Interruption to sequence whilst controller waits for the air damper to drive to open position prove...

Page 30: ...Page C 15 PO Series Technical Specification B B B B BURNER URNER URNER URNER URNER H H H H HEAD EAD EAD EAD EAD ...

Page 31: ...PO Series Technical Specification Page C 16 E E E E ELECTRODE LECTRODE LECTRODE LECTRODE LECTRODE S S S S SETTING ETTING ETTING ETTING ETTING D D D D DET ET ET ET ETAIL AIL AIL AIL AIL ...

Page 32: ...MODUL ODUL ODUL ODUL ODULA A A A ATION TION TION TION TION C C C C CONTROLLER ONTROLLER ONTROLLER ONTROLLER ONTROLLER L L L L LANDIS ANDIS ANDIS ANDIS ANDIS AND AND AND AND AND S S S S ST T T T TAEF AEF AEF AEF AEFA A A A A RWF40 RWF40 RWF40 RWF40 RWF40 ...

Page 33: ...ck Lever Servomotor Oil Spill Back Regulating Valve Oil Cam A Air Cam B Oil Cam Adjusting Screw Oil Cam Hub Rotation for High Flame Position Locking Screws Spill Pressure Reduce Increase Cam Disk Roller Adjustable Plunger Cam Follower Throw Oil Cam View On A Adjuster Locking Screws Profile Adjuster Profile Band Damper Drive Arm Cam Lever Roller Retaining Saddle Return Spring Air Cam View On B ...

Page 34: ...Page C 19 PO Series Technical Specification ...

Page 35: ...PO Series Technical Specification Page C 20 AAD PFinal C_Tech Po RWF40 C_Tech pmd 250504A ...

Page 36: ...Page D 1 P Series Commissioning COMMISSIONING ...

Page 37: ...t is important to Check that the electrical wiring is complete and complies with all applicable Codes and Standards Ensure that the fuses are fitted and are of the correct ratings Check electrical earthing Verify that the oil pipework is correctly sized and that it has been checked for leakage Check that the appropriate modulating detector which is supplied loose with each burner is fitted correct...

Page 38: ...motor round to its start position and wait 6 Ensure that the flame detection system detects the presence of a simulated flame or where permissible an independent flame source Remove the flame detector from the burner expose the detector to a flame or simulated flame This should cause a lockout indicated by illumination of the corresponding indicator light on the control panel 7 Replace the flame d...

Page 39: ...SSIONING THE THE THE THE THE B B B B BURNER URNER URNER URNER URNER Establish fuel supply to the burner Establish electrical supply to the control panel and switch the burner on If the burner sequence controller is at lockout press the re set button Warning From this point onwards the ignition sequence will be initiated and fuel will be admitted to the burner Care must be exercised NOTE HAND AUTO ...

Page 40: ...terminal 20 and the wire that has been taken from terminal 20 4 Establish the electrical supply and switch on the burner Allow the burner to light and operate normally 5 Observe the reading on the micro ammeter at all firing levels A steady reading in excess of 7 microamps is satisfactory Lower readings may cause intermittent burner lock out and indicate a need for adjustment of the burner setting...

Page 41: ... off manually c There is an electrical power failure In this event the burner will restart and run normally when power is restored No manual intervention is required d A failure in any of the safety functions monitored by the sequence controller On Completing Commissioning When commissioning has been completed satisfactorily the commissioning engineer shall prepare a report which shall contain the...

Page 42: ...Page D 7 P Series Commissioning ...

Page 43: ...e Where a choice of measurement units is shown delete those not applicable Flue Temp Ambient Temp Temp Difference Efficiency Heat input O2 CO2 CO Firing Rate Intermediate Positions Pressure at burner Oil rate Standing bar or psi Running bar or psi Commissioning Date Guarantee Expiry Date Fuel Oil Type Oil pressure upstream of pump Type Size Type Size Site Address The details below are to to be com...

Page 44: ...Page D 9 P Series Commissioning AAD PFinal C_Tech Po RWF40 D_Comm pmd 250504A ...

Page 45: ...P Series Page 10 ...

Page 46: ...Page E 1 PO Series Operation And Maintenance E OPERATION AND MAINTENANCE ...

Page 47: ...the electrical power supply to the burner Replace the PE cell Establish the electrical supply to the burner and switch on the burner Reset the lockout Combustion Air Pressure Switch 1 Check that the electrical supply to the control panel off and that the burner is off 2 Remove the air pressure switch cover 3 Fit a manometer or other approved pressure measuring instrument to the pressure switch so ...

Page 48: ...OL BEFORE ATTEMPTING THESE TASKS In the case of the cold oil filter remove the plug from the sump and drain off any sludge and or water present at six weekly intervals The cleaning knob on this filter should be rotated daily If the filter fitted in the oil supply line has a disposable element this should be replaced at least once a year more frequently if this is dictated by the condition of the f...

Page 49: ...ller to go to lockout If this occurs check that The glass envelope on the PE Cell is clean and correctly orientated it must face towards the flame The PE Cell and wiring are not faulty There is no carbon on the diffuser The nozzle is clear The flame detector current is adequate and stable The burner sequence controller is not faulty There is sufficient fuel under ignition conditions to enable the ...

Page 50: ...Page E 5 PO Series Operation And Maintenance B B B B BURNER URNER URNER URNER URNER S S S S SERVICE ERVICE ERVICE ERVICE ERVICE R R R R RECORD ECORD ECORD ECORD ECORD ...

Page 51: ...PO Series Operation And Maintenance Page E 6 ...

Page 52: ...Page E 7 PO Series Operation And Maintenance ...

Page 53: ...PO Series Operation And Maintenance Page E 8 N N N N NOTES OTES OTES OTES OTES ...

Page 54: ...Page E 9 PO Series Operation And Maintenance N N N N NOTES OTES OTES OTES OTES ...

Page 55: ...PO Series Operation And Maintenance Page E 10 N N N N NOTES OTES OTES OTES OTES ...

Page 56: ...Enertech Limited P O Box 1 Vines Lane Droitwich Worcestershire WR9 8NA Tel 44 0 1905 794331 Fax 44 0 1905 794017 Email info nu way co uk Web www nu way co uk ...

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