Nu-Way G100 Universal User manual

G100
Universal
Oil Burner
Installation & Maintenance
Manual

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Contents
1. General information ................................................................................................................... 3
2. Checking scope of supply and electrical ratings ........................................................................ 3
3. Operating instructions ................................................................................................................ 3
4. Instruction .................................................................................................................................. 3
5. Maintenance and customer service ........................................................................................... 3
6. Technical specifications ............................................................................................................. 4
7. Functional description ................................................................................................................ 4
8. Air/oil flow schematic.................................................................................................................. 4
9. Installing flange and burner........................................................................................................ 5
10. Connecting to power supply....................................................................................................... 5
11. Compressed air connection ....................................................................................................... 5
12. Oil pump..................................................................................................................................... 6
13. Installing the oil line.................................................................................................................... 6
14. Setting the ignition electrodes.................................................................................................... 6
15. Control unit ................................................................................................................................ 7
16. Table of settings ........................................................................................................................ 8
17. Settings for primary airflow ........................................................................................................ 9
18. Combustion air flow rate ............................................................................................................ 9
19. Flue connection.......................................................................................................................... 10
20. Flue gas thermometer................................................................................................................ 10
21. Maintenance .............................................................................................................................. 10
22. Wiring diagram........................................................................................................................... 11
23. Possible errors .......................................................................................................................... 12
24. Exploded view drawing / parts list.............................................................................................. 13
25. Burner dimensions / boiler connecting dimensions.................................................................... 16
26. Operating range ......................................................................................................................... 16

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General information
1. General information
An oil-fired system must be installed in compliance with a number of regulations and requirements. It is
therefore the duty of the installer to be familiar with all applicable regulations and requirements. Installation,
start-up and maintenance must be performed with utmost care.
The burner must not be operated in rooms with high levels of air humidity (laundry rooms), dust or corrosive
vapours.
The universal oil burners are suitable for use with a variety of natural oils and mineral-
based oils. On account of their viscosity, these oils are not in conformity with EN 267 for
oil burners. The burners are, therefore, not licensable. An inspection to determine suita-
bility for the selected fuel type must be performed by the operator prior to acceptance of
the installation.
The design and degree of protection of the burner make it suitable for operation in
enclosed rooms.
2. Checking scope of supply and electrical ratings
Before installing the GIERSCH universal oil burner please check the items supplied for completeness.
Scope of supply:
burner, mounting unit, separate operating instructions, technical information, flange seal.
Near wear-free compressed air atomising nozzles are pre-fitted at the factory.
3. Operating instructions
This technical information should be displayed in a visible position in the boiler room as operating instruc-
tions. It is essential to write the address of the nearest customer service centre in the operating instructions.
Caution !
Improper installation, adjustment, modification, operation or maintenance may result in
physical injury or damage to property/equipment. Read the instructions prior to use.
This product must be installed in accordance with the applicable regulations
(e.g. DIN-VDE).
4. Instruction of operating personnel
Faults are often caused by operator error. The operating personnel must be properly instructed in how the
burner works. In the event of recurring faults, Customer Service should be notified.
5. Maintenance and customer service
The complete system should be checked once a year for proper functioning and leak tightness by an au-
thorised representative of the manufacturer or by another expert. We accept no liability for consequential
damage in cases of incorrect installation or repair, the fitting of non-genuine parts or where the equipment
has been used for purposes for which it was not intended.

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Technical specifications
6. Technical specifications
7. Functional description
The fuel is pumped out of the supply tank and into the burner tank. A float switch controls the level inside
the burner tank. An additional microswitch serves as a limiter, switching over to fault mode when the tank
is overfilled.
A thermostat regulates the oil temperature in the burner tank and starts the burner when the set tempera-
ture is reached. Thereafter, the automatic oil burner control system controls and monitors the operation of
the burner.
Fuel is aspirated and finely atomised by a special nozzle using the compressed air flowing through the
burner, which is used as primary air for the combustion process.
The burner blower supplies the secondary air which is added to the atomised spray at the baffle plate. This
ensures full combustion and operational reliability.
At the oil temperature in excess of 150° C, the safety switch automatically de-energises the burner.
8. Air/oil flow schematic
Burner type
Technical specifications G100
Output, fuel oil KW 70 - 132
Output, rapeseed oil KW 65 - 101
Oil throughput kg/h 8.6
Compressor output m
3
/h 11.5
Primary air connection bar 0.4 - 1.5
Motor output W 180
Heating element W 1100
Voltage 1/N/PE ~50 Hz 220 - 240 V
Weight kg 21
Feed line
Contact switch
Heating cartridge
E1 + E2
Overflow tank
Burner tank
Thermostat
F1
Safety valve Pressure gauge
Solenoid valve
Y1
Primary air actuator
Pressure controller
Connecting line
baffle plate
Burner pipe
Nozzle
Nozzle assembly
Oil line
Fan wheel
M1
Micro-switch,
overflow protection
S1
Micro-switch,
level control
S2

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Install flange and burner
9.Install flange and burner
Attach the burner flange and the seal to the heat
generator.
10. Connect to power supply
• Connect the burner to the power supply using the
supplied connector unit as indicated in the wiring
diagram.
• HEED LOCAL REGULATIONS !
• Use flexible wiring.
Overcurrent protection configuration
The overcurrent protection devices must be rated for
the electrical current range indicated in the technical
specifications and to provide protection against electri-
cal shock according to DIN IEC 60364-4-41
(VDE 0100-410).
11. Compressed air connection
Connect a compressed air line to the pressure regula-
tor (1).
7-pin
1

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Oil pump
12. Oil pump
The oil pumps serve as delivery units, pumping oil into the burner tank. The atomisation of the oil is not
dependent on the oil pressure.
Suntec oil pump:
 = feed
 = return
 = pressure pipe connection
 = pressure measuring connection
 = vacuum measuring connection
 = pressure adjustment
13. Installing the oil line
Install oil lines, filters and floating suction unit from the supply pump to the supply tank.
For installation in the open air or on outside walls, the lines must be specially insulated or fitted with addi-
tional pipe heaters, as otherwise the water contained in the oil will freeze causing the oil to become highly
viscous.
14. Setting the ignition electrodes
The ignition electrodes are preset. The specified dimensions (Fig.) are for checking purposes.
12
3
4
6
5
4

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Function testing the control unit
15. Function testing the control unit
Carry out the following checks after start-up and after the burner has been serviced:
• Restarting with a covered flame detector:
the control unit must go into fault mode on expiration of the safety period.
• Burner start-up with flame detector exposed to external light, e.g. fluorescent lamp, lighter, light bulb
(daylight is not enough):
The control device must switch over to fault mode during the pre-aeration period as a consequence of
the external light.
• Normal start-up - if the burner is in operation, darken the flame detector during the post-ignition
period (e.g. unplug and cover flame detector)
TF 834: the ignition must switch on and upon expiration of the safety period the device must switch
over to fault mode.
• Post-aeration after flame cut-off.
Safety and switching functions
If a flame failure occurs during operation, the fuel feed shuts off immediately and the system tries a restart,
with pre-aeration and retarded ignition. If no flame results, the control box indicates a fault after the safety
interval expires. In any case, the control unit is restarted following a mains power failure. The control unit
indicates a fault if an external light source is detected during the pre-aeration cycle after expiration of the
safety cycle.
The control unit may only be plugged in or unplugged if the master switch is in the "OFF" position
or if the 7-pin plug connector is disconnected, because the bottom part of the control unit
carries 230 V.
Incidence of external light on the photoresistor or flame detector must be prevented (e.g. through
a sight glass or red-hot fireclay lining). Only then is fault-free operation of the system assured.
Honeywell: TF 834.3
t
v1
= pre-ignition cycle + pre-aeration 12 secs.
t
s
= safety interval 10 secs.
t
n
= post-ignition time 20 sec.
Post-aeration after flame cut-out. -
Delay after switching-off fault approx. 60 sec.
Photoresistor (flame detector) MZ770
Ölvorwärmung
Ventilator
Zündung
Magnetventil
Flammenwächter
Störlampe
Anlauf mit Flammenbildung (Normalbetrieb)
Betrieb
Störung
Ölvorwärmung
Ventilator
Zündung
Magnetventil
Flammenwächter
Störlampe
Anlauf ohne Flammenbildung (Störbetrieb)
Sicherheit
Sicherheit
ts
tv1
tv1
ts
tn
Ventilator
Magnetic valve
Ignition
Fault indicating lamp
Flame detector
Oil preheater
Operation
Fault
Start without flame formation
Start with flame formation
safety period
safety period
Ventilator
Magnetic valve
Ignition
Fault indicating lamp
Flame detector
Oil preheater

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Adjustment table
Measuring the photocurrent (MZ 770S only)
To measure the photocurrent, disconnect the plug unit
from the flame failure controller and install the pair of
measuring cables* between the plug and socket unit.
Both measuring connections should be connected to
the measuring instrument. If there is a negative deflec-
tion of the measuring instrument, reverse the plug on
the measuring instrument lead ! Set the measuring in-
strument to ampere metering for DC, measuring range
up to approx. 200 µ mA !
Recommended measuring accessories
Digital measuring instrument Art. No. 59-20-50263
* Pair of measuring cables
for photocurrent Art. No. 59-20-50408
16. Adjustment table
The values given in the table are only setting values for start-up. The system settings required
in each case must be redefined if values such as boiler output, calorific value and altitude deviate.
Adjustment is required in any case (due to the system design).
• For initial start-up, fill the burner tank up to the oil mark by hand.
Caution !
If the oil level is too high, the float switch will switch off the burner.
If the oil level is too low, the heating cartridge will become encrusted or damaged.
Adjustment table for rapeseed oil
Adjustment table for fuel oil
The thermostat on the burner tank must be set to between "min." for heating oil EL and 140°C
for rapeseed oil, depending on the viscosity of the oil.
Burner type G100
Output in kW 65 70 78 82 90 96 102
Oil throughput in kg/h 6.4 7.0 7.7 8.1 8.9 9.5 10.1
Primary air in bar 0.5 0.6 0.7 0.8 1.0 1.2 1.5
Secondary air
(scale on air damper)
3.0 3.5 3.8 4.0 4.5 5.0 6.0
Thermostat setting in °C 140
Burner type G100
Output in kW 71 82 91 100 117 123 133
Oil throughput in kg/h 5.9 6.9 7.6 8.4 9.8 10.3 11.1
Primary air in bar 0.4 0.5 0.6 0.8 1.0 1.2 1.5
Secondary air
(scale on air damper)
3.2 3.8 4.0 4.8 6.2 6.5 7.0
Thermostat setting in °C 0° do not heat
Flame failure controller
Control unit
bottom part
500µA
or
200µA

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Settings for primary airflow
17. Settings for primary airflow
The primary airflow should be set using the pressure
regulator (1) according to the required burner output.
The information given in the diagram can be used as
guide values.
Higher-viscosity fuels require higher air pressures.
18. Combustion air flow rate
Setting the combustion air flow rate (2).
Ideal values:
- Soot index according to Bacharach <1
- O
2
= 4 - 5%
The CO
2
values of a commercially available measuring in-
strument can only be used for processing the combustion
process for heating oil EL.
Flue gas temperature according to the operating instructions
of the heat generator.
1
2

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Flue connection
19. Flue connection
The prerequisite for perfect operation of the furnace is a correctly dimensioned flue.
Dimensioning is effected in accordance with DIN 4705 in consideration of DIN 18160 and based on the
boiler and burner outputs.
For operation on a sliding basis, provide flues as per DIN 18160 part, group 1. The flue gas mass flow
of the total rated heat output must be factored into the calculation. The effective flue height is counted from
burner level. Furthermore, we refer you to the statutory building regulations of the individual German fed-
eral states.
Select a flue design which minimises the danger of condensation or of a cold flue inner wall.
For exact adjustment and stabilisation of the flue draught we recommend the installation
of a draught limiter.
Thus:
• any draught fluctuations are equalised
• moisture in the flue is largely excluded
• stoppage losses are reduced.
Connection pieces should be introduced into the flue with a gradient of 30° or 45° viewed in flow direction.
It is best to provide flue gas pipes with thermal insulation.
20. Flue gas thermometer
For flue gas temperature monitoring the heating system should be equipped with a flue gas thermometer.
The higher the flue gas temperature, the greater the flue gas loss.
Rising flue gas temperatures indicate increasing deposits that will reduce the degree of combustion effi-
ciency. In the event of an increasing flue gas temperature have the heating installation cleaned and read-
justed by a skilled person.
21. Maintenance
Depending on the quality of the oil used, we recommend the following maintenance intervals:
After more than 3 days downtime:
• drain off residual water and sludge through the water drain cock in the burner tank,
Monthly:
• Clean the filter in the supply tank or the unit tank and strainer on the floating suction unit
• Remove and clean the feed pump filter
• Remove sludge and residual water from the supply tank or unit tank
• The quantity can be determined by using water indication paste and a gauging rod
• Clean the photocell
• Clean the ignition electrode and baffle plate and blow out the nozzle with compressed air, check the
spacing between the ignition electrodes (refer to checking dimensions for ignition electrodes)
Annually (before or after the heating period):
• Carry out monthly maintenance as described
• Clean the heating cartridges in the burner tank
• Clean the ignition electrodes and baffle plate, blow out the nozzle with compressed air and check the
spacing between the ignition electrodes
• Clean the burner tank, supply tank and unit tank thoroughly.

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Circuit diagram
22. Circuit diagram
SP_1-579
Boiler controller
B1 Flame detector MZ770
E1 Heating coil 1100 W
F Ext. fuse
F1 Control thermostat
F21 Ext. temperature control
F3 Ext. safety temperature limiter
F6 Safety thermostat (STB)
H11 Ext. status lamp
H13 Ext. fault indication lamp
K1 Relay
M1 Burner motor
P11 Ext. operating hours counter
Q1 Heater power switch
S1 Micro-switch, overflow protection
S2 Level micro-switch (pump SV)
T1 Ignition transformer
X11 Boiler control connector unit
X12 Burner socket unit
Y1 Compressed air solenoid valve
Y2 Pump solenoid valve
PE Grounded conductor
bl = blue
br = brown
ge = yellow
gr = grey
grü = green
sw = black
rt = red
ws = white

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Troubleshooting
23. Troubleshooting
Observation Cause Remedy
Burner does not start
up
Oil not combustible due to sludge and / or water
Oil tank empty
Oil level in burner tank too high
Filter dirty, oil or air lines leaky
Faulty feed pump solenoid valve
Nozzle dirty or faulty
Feed pump blocked
No current
Motor faulty
Thermostat faulty
Photocell dirty or not correctly inserted
Control unit faulty
No ignition
No compressed air
Solenoid valve faulty
Compressor or air line faulty
Open the water drain cock on the burner tank,
drain off sludge and water or
use a higher-grade heating oil
Refill tank with oil
Correct the oil level by draining off oil by means
of the water cock (readjust the level control
float switch, if necessary)
Clean the filter, feed pump filter and lines
Check the feed pump solenoid valve and
replace if necessary
Replace nozzle
Strip the feed pump and clean the gear
Switch on the heater switch
Replace
Replace
Clean the photocell, replace it or connect it
properly
Replace
Adjust the ignition electrode, replace the igni-
tion transformer if necessary and check the
ignition cable
Connect and/or open the compressed air and
set the pressure
Replace
Replace
Burner starts very late Heating cartridge and thermocouple in burner
tank encrusted or faulty
Clean or replace the heating cartridge and
thermocouple in the burner tank
Burner starts without
pre-ventilating
Solenoid valve sticking in open position Replace
No oil feed Solenoid valve faulty Replace
Flame is interrupted or
extinguishes
Oil not combustible due to sludge and / or water
Oil supply used up
Clogged nozzle
Dirty feed pump filter
Oil line to tank frozen
Supply tank to far away from burner
Filter or oil lines dirty
Solenoid valve faulty
Too much or not enough compressed air
Safety temperature limiter is in the safety posi-
tion because the heater has overheated
Micro-switch in burner tank cuts out
Open the water drain cock on the burner tank,
drain off sludge and water or use higher-grade
oil
Refill tank with oil
Replace nozzle
Clean feed pump filter
Clean oil lines, and insulate tank and oil line
Install an additional feed pump
Replace filter and clean oil lines
Replace
Check compressed air and gauge pressure
using primary airflow control
Troubleshoot the heater and unlock the safety
temperature limiter
Adjust the level control float
Nozzle and baffle plate
are heavily soiled with
oil or soot
Incorrect baffle plate setting
Combustion airflow rate too high or too low
Boiler room is not sufficiently ventilated
Correct the baffle plate setting dimensions
Set the primary airflow rate
Set the secondary airflow rate at the air control
flap
Pay attention to sufficiently large ventilation
ports

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Exploded view drawing / spare parts list
24. Exploded view drawing / spare parts list
ZBZ_2-278

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Exploded view drawing / spare parts list
Position Designation Pack qty. Art. No.
1 Burner pipe 1 47-90-27900
2 Diaphragm plate compl. with holder 1 47-90-27885
3 Nozzle assembly compl. 1 37-90-11304
4 Delavan HV1.5 nozzle 1 59-10-50448
5 Ignition electrodes (left + right) 1 47-90-26037
6 Ignition cable G55 1 47-90-27621
7 Air control handwheel 1 47-90-12100
8 Air damper flange 1 47-90-12099
9 Air damper compl. 1 47-90-12096
10 Housing cover 5 47-90-12095
11 Sight glass 5 47-50-12105
12 Sight glass cover 5 47-50-12106
13 7-pin socket with cable 1 47-90-11839
14 Control unit bottom part S98 9-pin. compl. 1 31-90-22664
15 Satronic TF 834.3 control unit 1 37-90-11285
16 Fan wheel 146 x 52 1 47-90-12104
17 Motor 180 W 1 47-90-12113
18 Motor with fan impeller compl. 1 47-90-27249
19 Coupling 10 37-50-10110
20 Suntec D45B pump with connections 1 47-90-26160
21 Conical nipple AL 13 x 18 x 2 50 38-50-11293
22 Hose nipple R 1/4“ x 8LL 10 37-50-11348
23 Metal hose, nom. size 6 1 47-90-11347
24 Pump - solenoid valve connecting tube 1 37-90-10780
25 Banjo screw R1/8“ 10 37-50-10736
26 Conical nipple AL 14 x 10 x 2 50 37-50-10788
27 Solenoid valve R1/4“ SV04 1 36-90-11583
27 Solenoid valve coil 1 47-90-24686
28 Thread reducing adaptor 1/4“ - 1/8“ 1 47-90-11303
29 Solenoid valve - oil tank connecting tube 1 47-90-26171
30 Oil tank connection compl. 1 47-90-27627
31 Seal 24 x 16 x 2 10 47-50-10516
32 Drain valve 1 47-90-10472
33 Intake tube compl. 1 47-90-24514
34 Heating coil 1100 W 1 47-90-24505
35 Oil tank G100 compl. 1 47-90-26177
36 Oil tank cover 1 47-90-24520
37a Oil tank - nozzle assembly connecting tube part 1 1 37-90-10370
37b Oil tank - nozzle assembly connecting tube part 2 1 37-90-10371
38 Control housing shroud, compl. preassembled 1 47-90-27351
39 Safety thermostat 1 47-90-27327
40 Flush-type thermostat 1 47-90-22805-01
41 Twin microswitch 1 47-90-10601
42 Float 1 47-90-22420
43 Control housing cover 1 47-90-24525
44 Electronic ignition unit Mod. 26/48 1 47-90-26930
45 Flame detector MZ770 compl. with cable 1 47-90-22816
46 Swivel flange compl. 1 47-90-26181
47 Mounting flange seal 5 47-50-24429
48 Air distributor connecting tube 1 47-30-27631
49 Air distributor, compl. preassembled 1 47-90-24568
50 Safety valve 1 47-90-26640
51 Pressure gauge 0-2.5 bar 1 47-90-12121
52 Solenoid valve coil 1 59-90-50368
53 Double reduction nipple 1/4“ - 1/8“ 1 44-90-23075
54 Replacement pressure regulator 1 47-90-24594

G100 Universal Oil Burner 07/11
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