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Summary of Contents for Nu-Way NDF 35
- Page 1 Installation & Maintenance Manual NDF 35 - 100 Dual Fuel Burner 11/12 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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Page 2: Table Of Contents
LL BURNERS AND BOILER BODIES MARKETED SEPARATELY SHOULD COMPLY WITH GAS BURNERS ’ ). B EATING OILERS URNER ADJUSTMENTS MUST BE MADE IN ACCORDANCE WITH BOILER MANUFACTURERS INSTRUCTIONS CO 2 AND THESE MUST INCLUDE FLUE GAS TEMPERATURES AVERAGE WATER TEMPERATURE CONCENTRATION Page 2 of 64 NDF 35-180 11/12... -
Page 3: Introduction
The burner’s additional safety systems include for gas pressure monitoring (low and high) whilst gas firing and low oil temperature monitoring (NDFR) whilst firing on fuel oil. Continuous flame supervision is provided by an ultraviolet (UV) cell and automatic programming control unit. Page 3 of 64 NDF 35-180 11/12... -
Page 4: Operating Mode
Comprising two stage NDFL burners NDFL 100-41 and larger All fully modulating NDFL burners All two stage NDFR burners All fully modulating NDFR burners Throughout this handbook the burners are referred to by this grouping. Page 4 of 64 NDF 35-180 11/12... - Page 5 Burner Terminal Panel Flexible Oil Pipe Casing Access Lid Quick Release Oil Couplings High Gas Pressure Switch Pressure Gauges Valve Body Oil Manifold Control Valve Manual Gas Interlock Valve Main Valve 16 17 Page 5 of 64 NDF 35-180 11/12...
- Page 6 FIG 2 13 10 12 BURNER PROJECTION 20 19 Page 6 of 64 NDF 35-180 11/12...
- Page 7 FIG 3: BURNER AND COMPONENT IDENTIFICATION FOR NDF TWO STAGE (H/L) BURNER (MODEL SHOWN NDF 35 SHOWN) Item Description Item Description Burner Casing Connection Box Hinged Extension Valve proving system Flame Tube Pilot Solenoid Valve Fan Motor Pilot Governor Damper Motor...
- Page 8 FIG 4 BURNER PROJ ECTION Page 8 of 64 NDF 35-180 11/12...
- Page 9 1196 NDF 100-44 1240 1196 NDF 125-36 1240 1196 NDF 125-41 1240 1196 NDF 125-44 1240 1196 NDF 150-36 1240 1210 NDF 150-41 1240 1210 NDF 150-44 1240 1210 NDF 180-44 1240 1210 Page 9 of 64 NDF 35-180 11/12...
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Page 10: Site Conditions And Services
Codes and Standards. It shall be of sufficient size to satisfy the pressure and volume requirements of the burner under all firing conditions. Checks should be made to ensure that all meters and other components are appropriately rated for the maximum gas flow rate anticipated. Page 10 of 64 NDF 35-180 11/12... - Page 11 The gas supplier should be asked to recommend the size of the pipework between the meter and the booster to ensure that the required pressure and flow are available. Page 11 of 64 NDF 35-180 11/12...
- Page 12 MUST also be fitted to prevent damage should the shut-off valve be inadvertently left closed during the burner start-up cycle. the relief valve must be set at 0.70 kg/cm (10 psi) above the normal supply pressure. Page 12 of 64 NDF 35-180 11/12...
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Page 13: Unpacking & Assembly
Note: In some circumstances it may be advisable to fit the burner casing to the appliance before attaching the gas control train. It is recommended that lifting gear should be employed if necessary. Page 13 of 64 NDF 35-180 11/12... - Page 14 Note: In some circumstances it may be advisable to fit the burner casing to the appliance before attaching the gas control train. It is recommended that lifting gear should be employed if necessary. Page 14 of 64 NDF 35-180 11/12...
- Page 15 The NDF compact burner, in particular the NDFR series, will be heavier than its standard counterpart. This must be taken into consideration when fitting the burner to the appliance. It is strongly recommended that lifting gear should be employed when carrying out this task. Page 15 of 64 NDF 35-180 11/12...
- Page 16 123.7 50.3 16.0 80.0 12.0 NDF 180-44 1.5/2.0 123.7 50.3 16.0 80.0 12.0 NOTE: Burner fan motors up to and including 7.5 kW are started D.O.L. Above 7.5 kW Star/Delta starters are fitted. Page 16 of 64 NDF 35-180 11/12...
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Page 17: Installation
Air Controls: Air Regulator: NDF 35-25 to NDF 100-38 The flow of combustion air into the burner is controlled by a single adjustable air damper blade located within the air damper casting on the right-hand side (in all cases, such descriptions refer to the system as viewed from the rear) of the burner. -
Page 18: Gas Controls
The pressure switch, which is fitted with an illuminated fault indicator and manual reset button, is factory set to the maximum value. Final adjustment of the setting of this switch is described in the Section on commissioning. Page 18 of 64 NDF 35-180 11/12... - Page 19 4. The position at which the main flame oil valve is activated is controlled by adjusting cams III and IV. A setting should be made to ensure a smooth changeover whilst maintaining good combustion quality. 5. The motor will traverse 90° within a maximum of 6 seconds. Page 19 of 64 NDF 35-180 11/12...
- Page 20 4. Cams 2 and 3 may be adjusted to give the correct related burner firing rates on gas and oil. 5. The cam assembly can be rotated manually by disconnecting it from the drive motor using the disengagement lever. The cams are adjusted with the special ‘C’ spanner provided. Page 20 of 64 NDF 35-180 11/12...
- Page 21 FIG 14: TYPICAL GAS TRAIN Page 21 of 64 NDF 35-180 11/12...
- Page 22 Adjustment and indication of the parallel displacement of the characteristic (low fire setting) Vented to atmosphere Connection to the fuel gas line Connection to the combustion air supply at the burner head Indication of the valve stroke Page 22 of 64 NDF 35-180 11/12...
- Page 23 A program indicator, which stops whenever a fault is signalled, indicates which valve(s) set is leaking. The control unit requires to be reset manually, either on the unit itself or by a remote resetting if this has been fitted. Page 23 of 64 NDF 35-180 11/12...
- Page 24 FIG 16: VALVE PROVING SYSTEM: LDU 11 Page 24 of 64 NDF 35-180 11/12...
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Page 25: Oil Controls - Twin Pressure Jet Oil Burners
The two oil nozzles (high and low fire) are held in a nozzle block located within the flame tube (refer to the Appendix). The nozzles are pre-sized by Nu-way in accordance with the heat inputs required and the available operating pressure. -
Page 26: Oil Controls - Single Spill Back Oil Burners
This nozzle is factory-specified to deliver optimum performance under the specified operating conditions. Any queries regarding the size of the nozzle should be referred to Nu-way. The nozzle is held in position by the inner assembly oil lance, through which the oil flows from the manifold block to the nozzle and is recirculated back through the spill regulating valve. - Page 27 ” Pressure gauge Regulator Shaft Shaft Connection Sizes Item Description Size ” Pressure port Return port & ½” internal bypass plug Suction port or ½“ vacuum gauge ” Pressure gauge Regulator Page 27 of 64 NDF 35-180 11/12...
- Page 28 Connection Sizes Item Description Size ¾” Pressure port ¾” Return port ¾” Suction port Vacuum gauge & ¼“ internal bypass plug ¼” Pressure gauge Regulator cap nut Washer Regulator screw Locknut Shaft Shaft Page 28 of 64 NDF 35-180 11/12...
- Page 29 3. Solenoid valves are shown as either NO (normally open) or NC (normally closed). 4. Pipework connections between the burner oil system and the separate pumping/heating set are not supplied by Nu-way. (N.B: This pipework is not required on the ‘Compact’ burner). Page 29 of 64...
- Page 30 2. Solenoid valves are shown as either NO (normally open) or NC (normally closed). 3. Pipework connections between the burner oil system and the separate pumping/heating set are not supplied by Nu-way. (N.B: This pipework is not required on the ‘Compact’ burner). Page 30 of 64...
- Page 31 273 mm 1295 mm Connection Size Thermostat Settings Item Description (inches) Fuel Temper Control Low Oil Main Inlet Connection Class ature Thermostat Temperature Main Return Connection (Optional) Burner Feed ¾ Burner Return ¾ Page 31 of 64 NDF 35-180 11/12...
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Page 32: Control Panel
A separate free-standing panel contains the programming burner controller, contactors and other items. This enclosure carries an amber light which indicates “BURNER ON” and a red light which is illuminated when the burner stops as a result of “EXCESS TEMPERATURE / PRESSURE” in the appliance. Page 32 of 64 NDF 35-180 11/12... - Page 33 The pre-purge times shown refer to the control box only. the time taken for the air damper to move to the appropriate position will extend the total purge time up to a maximum of 157 seconds depending on the firing rate and air requirements of the appliance. Page 33 of 64 NDF 35-180 11/12...
- Page 34 Lockout caused by the loss of the flame signal during normal operation. Lockout caused by flame signal (either real or due to extraneous light) or flame supervision circuit fault after completion of shutdown. Page 34 of 64 NDF 35-180 11/12...
- Page 35 Red sector fuel valves End of Red / Start of Green Main flame established at low fire End of Green / Start of Black Run position, released to high fire Black sector Post purge Page 35 of 64 NDF 35-180 11/12...
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Page 36: Modulating Controller
5. Press PGM button to enter value and change to next screen (to cancel and enter - press EXIT) Set remaining parameters/settings as recommended by Nu-way. 5. At last screen the PGM button will return the controller to the original operating display. - Page 37 Press PGM key until lower window displays AL (limit comparator) in Green. Scroll through screen using PGM button until you reach SPI. Use to change operating pressure/temperature to desired set point. 4. Wait until display flashes, it has accepted the change, then press EXIT. Page 37 of 64 NDF 35-180 11/12...
- Page 38 The Pressure detector type QBE61 is used in all Steam boiler applications. The detector has a plastic casing to IP42. The detector may be mounted on vibrating surfaces, however in all cases it is necessary to mount the water trap pipe supplied. Page 38 of 64 NDF 35-180 11/12...
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Page 39: Commissioning
(Installation & Use) Regulations 1994", is Gas Safe registered or whatever scheme is in force at the time. Nu-way can accept no responsibility for consequential loss, damage or injury which results from a failure to follow the commissioning instructions provided or from commissioning procedures being undertaken by unqualified personnel. -
Page 40: Oil Commissioning
12. Allow the burner to light momentarily. Switch off the burner and the electrical supply to the burner. 13. The burner safety systems have now been proven on oil firing and commissioning can proceed to the next stage. Page 40 of 64 NDF 35-180 11/12... - Page 41 Fill to the neck of the outlet with clean fuel oil only. 6. Switch on the electricity supply to the burner and check that the pump rotation is correct to the direction arrows shown on the pump face. Page 41 of 64 NDF 35-180 11/12...
- Page 42 9. 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 Figure 30. Page 42 of 64 NDF 35-180 11/12...
- Page 43 Increase Adjustable Plunger Rotation Direction Cam Disk High Fire Profile Band Low Fire View O n ‘B’ : Air Cam Retaining Saddle Cable Adjuster Cam Lever Operating Cable Adjuster Locking Screw Profile Adjuster Page 43 of 64 NDF 35-180 11/12...
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Page 44: Gas Commissioning
14. Switch off the gas booster (if fitted). Remove the temporary link fitted to the low gas pressure switch and replace the cover. 15. The burner's safety systems have now been proven and commissioning can proceed to the next stage. Page 44 of 64 NDF 35-180 11/12... - Page 45 3. Close the manual gas isolation valve at the inlet to the gas train to an opening of approximately 20%. 4. Set the gas inlet pressure switch to its minimum value. 5. With the burner set for low flame hold (hand operation), re-establish the electrical supply and switch on the burner. Page 45 of 64 NDF 35-180 11/12...
- Page 46 4. Turn the adjusting dial approximately 20% clockwise. 5. Refit the cover and reset the pressure switch by pressing the button on the cover. The burner will restart. Page 46 of 64 NDF 35-180 11/12...
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Page 47: Final Commissioning Stages - Oil & Gas
(a) It is switched off by the appliance controls. (b) It is switched off manually. (c) There is an electrical power failure. In this event the burner will restart and run normally when power is restored. No manual intervention is required. Page 47 of 64 NDF 35-180 11/12... -
Page 48: Fuel Changeover Procedure
If the burner has been operating on oil for a prolonged period it may be necessary to purge the gas line of air. Page 48 of 64 NDF 35-180 11/12... -
Page 49: Routine Safety Checks
2. Switch on the electrical supply to the burner and the burner itself. The valve proving system should lock out through failing gas pressure as the burner runs through its start cycle. 3. Re-tighten the screw in the pressure test point and reset the lockout button on the valve proving system. Page 49 of 64 NDF 35-180 11/12... -
Page 50: Routine Maintenance
Oil Preheater - NDFR Only Regular checks should be made to ensure that the oil temperature is maintained at the correct level (refer to the table on in Figure 8). Page 50 of 64 NDF 35-180 11/12... -
Page 51: Fault Finding
Air flow incorrect for gas flow Check and adjust as necessary Valves fail to open Check wiring and replace valves if necessary Manual isolation valve closed Open valve Carbon deposits on diffuser Clean Page 51 of 64 NDF 35-180 11/12... - Page 52 Burner Motor Only Runs Continuously Possible Reason Remedy Air control damper motor failed Replace Air control damper cam loose Tighten Microswitch failes to changeover Replace Damper motor incorrectly wired Check and correct wiring Page 52 of 64 NDF 35-180 11/12...
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Page 53: Spare Parts
Spare Parts For spare parts contact Nu-way's Parts And Components Division at the address and telephone number listed on the rear cover of this manual. To avoid delays, please provide the burner model and serial numbers. Page 53 of 64... -
Page 54: Appendix
NDF 85-38 NDF 100-38 NDF 100-41 12.7 NDF 100-44 12.7 NDF 125-36 12.7 NDF 125-41 12.7 NDF 125-44 12.7 NDF 150-36 12.7 NDF 150-41 12.7 NDF 150-44 12.7 NDF 170-44 12.7 NDF 180-44 12.7 Page 54 of 64 NDF 35-180 11/12... - Page 55 FIG 31: Burner Head Details: Twin Pressure Oil Jet Models Page 55 of 64 NDF 35-180 11/12...
- Page 56 FIG 32: Burner Head Details: Single Spill-back Oil Nozzle Models Page 56 of 64 NDF 35-180 11/12...
- Page 57 FIG 33: Electrode Setting Detail Twin Pressure J et Single Spill Back Oil Nozzle Models Oil Nozzle Models All dimensions are mm Page 57 of 64 NDF 35-180 11/12...
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Page 58: Oil Commissioning Sheet
WG Kg/h / Oil Rate Heat Input % dry % dry ppm dry Flue Temp Ambient Temp Temp Difference Efficiency Note: Where a choice of measurement units is shown, delete if not applicable. Page 58 of 64 NDF 35-180 11/12... -
Page 59: Gas Commissioning Sheet
/ Oil Rate ft3/h Heat Input % dry % dry ppm dry Flue Temp Ambient Temp Temp Difference Efficiency Note: Where a choice of measurement units is shown, delete if not applicable. Page 59 of 64 NDF 35-180 11/12... -
Page 60: Performance Envelopes
Performance Envelopes FIG 34: Performance Envelopes: NDF 35, 50 & 60 Page 60 of 64 NDF 35-180 11/12... - Page 61 FIG 35: Performance Envelopes: NDF 85, 100, 125 & 150 Page 61 of 64 NDF 35-180 11/12...
- Page 62 FIG 36: Performance Envelope: NDF 180 Page 62 of 64 NDF 35-180 11/12...
- Page 63 Page 63 of 64 NDF 35-180 11/12...
- Page 64 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 NDF 35-180 11/12...
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