Enertech Nu-way MULTIPLEX ENERGYSTREAM ES Series Guide

Installation, Commissioning & Maintenance
MULTIPLEX
ENERGYSTREAM nozzle-mix gas burner
GAS SUPPLY
Ensure that the gas pressure is the correct type and is available at a suitable pressure. Standard valve trains
will accept gas at pressures up to 70 mbar (28 in wg). For higher pressures, please consult Nu-way.
The burner assembly should not be used to support the gas supply pipework, suitable brackets or hangers
should be used for this purpose. Care should be taken to ensure that the supply pipework is large enough to
prevent excessive pressure drops and that connections are gas-tight. The gas line should be purged and
pressure-tested in accordance with any local legislation or gas authority requirements.
ELECTRICAL SUPPLY
The electrical supply must be provided with an isolator adjacent to the burner; if a separate control panel has
been supplied by NU-WAY LIMITED the isolator included in this is acceptable.
Wiring of the burner should be in accordance with the appropriate wiring standards, and the final electrical
connections to the burner should be in flexible conduits. It is vital that the live and neutral wires are connected
to their appropriate terminals as reversal could present a hazard; also the earth bonding must be checked to
ensure a good connection (poor earth connections are often the cause of faulty burner operation when using
flame probe detection). GAS PIPING MUST NOT BE USED FOR EARTHING.
All electrical interlocks should have been installed and tested for correct operation before commissioning.
COMMISSIONING
The procedure below is given as a guide to commissioning, which must be undertaken by a trained and
experienced combustion engineer. This procedure should be followed not only on first lighting the burner, but
also when any repairs have been carried out, or it has been out of commission for any length of time.
INSPECTION
1. Ensure that all mechanical and electrical drawings relating to the plant are available.
2. Check that all gas and electrical supplies to the burner are turned off.
3. Check the whole of the plant in which the burner is operating to ensure it is safe to light the burner and
that any safety interlocks are in the ‘safe’ position.
4. Check that no moving part of the plant will damage any part of the burner or its gas or electrical
supplies, and that no passing traffic will come into contact with it.
5. Check that gas is available at the burner stop valve.
page 1
SERIES
ES

ACTIVATION
Before gas is admitted to the burner, at least two faultless ‘dry runs’ must have taken place. No interlock may
be by-passed during these runs.
Dry Run
1. By means of pressure test nipples and with both manual isolating valves closed, using air or inert gas, test
the burner valvetrains for leaks, and the safety shut-off valves for pressure tightness.
2. Start the main duct fan.
3. Adjust the pressure switch to 1.9 mbar (0.7in wg).
4. Make electricity available to the system.
5. Check by manipulation of the control instrument that the modulating motor and butterfly valve operate
correctly. Remove the link between motor and valve, and close the valve by hand.
6. Operate the ‘Burner Run’ button. The combustion air fan (if fitted) should start, and following the purge
period a spark should appear at the burner. About 10 seconds after the spark is initiated the spark should
stop, and because no gas is available the control should go to ‘lockout’.
If the spark fails to appear:-
a. Check the spark gap. It should be 2-3 mm.
b. Check the electrical circuit.
c. Check the settings of the pressure switches.
d. Check all interlocks.
Repeat the test.
Live Run
7. Make certain the ball valve between the motorised butterfly valve and the burner is closed.
Adjust the valve train governor to give the minimum possible gas pressure.
Open the ball valve at the inlet to the valve train.
8. Operate the ‘Burner Start’ button, the pilot should light. If it does not light after three attempts:
a. Check that the pilot gas valve is operating.
b. Adjust the adjustable port pilot cock as follows, starting with the cock two turns open:
Remove the top hexagon screw cap c/w washer. The slotted head adjusting screw now exposed is
turned clockwise for less gas and counter-clockwise for more gas.
For flame rod system the proper amount of pilot gas is the minimum that will reliably ignite each time
the spark electrode is energised. A scanner system will require a slightly larger pilot than a flame rod
system.
Repeat the test.
9. Run the motor to its lowest position and try to start the burner. if a stable low flame is not obtained, or if the
flame is too large, it may be necessary to adjust the butterfly valve slightly against the clutch. When this
has been done, screw in the ‘bottom’ adjusting screw until it just touches the stop, and tighten the locknut.
10. If any adjustment has subsequently to be made to the high fire rate, it must be done by adjusting the gas
pressure and not by adjusting the butterfly valve. If the high fire rate is altered it may be necessary to
adjust the low fire rate by following the above procedure from 1. above. If this method is not followed the
control characteristics of the valve and motor will be spoilt.
MAINTENANCE
To ensure the continuing fault-free operation of the burner, the following operations should be undertaken every
six months:
1. Clean the working faces of the burner with a stiff brush.
2. Clean the fan impeller (a dirty impeller will cause a dirty flame).
3. Check all safety circuits.
4. Check pressure, etc, against the values recorded when the burner was commissioned.
Page 2

FAULT FINDING
Fault Possible Cause Remedy
1. Combustion air fan does not
start.
a. No air pressure in duct (positive
or negative).
b. Combustion air switch set too
low.
c. Duct air pressure switch
incorrectly set.
d. If low gas pressure switch fitted
gas pressure too low or switch
set too high.
e. If high gas pressure switch fitted
gas pressure too high or switch
set too low.
a. Switch on main duct fan.
b. Reset switch
c. Reset switch.
d. Increase gas pressure or reset
switch.
e. Decrease gas pressure or reset
switch.
2. Combustion air fan starts, but
burner goes to lockout.
a.Combustion air switch set too
high.
b.Incorrect fan rotation.
c. Fan blades dirty.
a. Reset switch.
b. Correct.
c. Clean fan.
3. No spark. Burner goes to
‘lockout’.
a. High tension lead not properly
tightened at terminations.
b. Spark plug nor properly adjusted.
c. Transformer failed.
a. Tighten lead ends.
b. Adjust as necessary.
c. Change transformer.
4. Pilot does not light. a. No gas
b. Too much gas
c. Pilot valve not opened
a. Find cause and rectify.
b. Adjust gas pilot cock.
c. Change valve or find open
circuit.
5. Pilot lights but burner goes to
‘lockout’.
Flame not detected because:
a. UV cell not looking at flame.
b. UV cell faulty.
c. Flame probe not in flame.
d. Bad earth.
a. Re-align cell
b. Check output. change cell.
c. Rectify.
d. Check output of probe. Make
good earth connection.
6. Pilot alight, no main flame,
burner goes to ‘lockout’.
a. Main valves not opening. a. Check main valves.
Page 3

FAULT FINDING (cont…)
Fault Possible Cause Remedy
7. Main flame goes out after
lighting.
a. Low gas pressure switch (if
fitted) set too high.
b. High gas pressure switch (if
fitted) set too low.
c. Pilot too high.
d. Flame not detected.
a. Reset Pressure switch.
b. Reset pressure switch.
c. Re-adjust pilot.
d. Adjust flame detector to see
main flame.
8. Main flame goes out on
reaching high fire.
See “Main flame goes out after
lighting”.
See “Main flame goes out after
lighting”.
9. Flame goes out. No lockout. a. High or low gas pressure switch
(if fitted) faulty.
b. Duct pressure switch faulty.
c. Loss of duct air pressure.
d. Interlock operated.
a. Rectify switch.
b. Rectify switch.
c. Check main duct fan.
d. e-make interlock.
10. Flame goes out. Burner goes
to lockout.
a. Loss of gas.
b. Loss of combustion air.
c. Failure of flame detector.
a. Turn off gas and investigate.
b. Check combustion air fan.
c. Change detector.
11. Burner goes to lockout when it
is turned off.
a. Main gas valves not shutting
completely.
a. Check main valves at once.
turn gas off at ball valves.
12. Heat output not maintained. a. Gas pressure failing.
b. Burner faces need cleaning.
a. Investigate.
b. Clean burner (see under
‘Maintenance’)

Enertech Limited,
P O Box 1,
Vines Lane
Droitwich,
Worcestershire,
WR9 8NA
Tel: [phone] Fax: [phone]
Email: [email protected] Web: www.nu-way.co.uk