Nu-Way NO Series User manual

Page 1
Models NOL/NOR Modulating Revision 101199B
HH
HH
HANDBOOKANDBOOK
ANDBOOKANDBOOK
ANDBOOK
Series NO fully automatic oil burners
Models NOL/NOR Modulating
Distillate & Residual Fuel Oils
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Models NOL/NOR Modulating Revision 101199BPage 2
CC
CC
CONTENTSONTENTS
ONTENTSONTENTS
ONTENTS
BB
BB
BURNERURNER
URNERURNER
URNER & C& C
& C& C
& COMPONENTOMPONENT
OMPONENTOMPONENT
OMPONENT II
II
I
DENTIFICDENTIFIC
DENTIFICDENTIFIC
DENTIFICAA
AA
ATIONTION
TIONTION
TION FF
FF
F
OROR
OROR
OR NO35-34 TNO35-34 T
NO35-34 TNO35-34 T
NO35-34 TOO
OO
ONO100-38 MNO100-38 M
NO100-38 MNO100-38 M
NO100-38 MODULODUL
ODULODUL
ODULAA
AA
ATINGTING
TINGTING
TING
BB
BB
BURNERSURNERS
URNERSURNERS
URNERS 44
44
4
BB
BB
BURNERURNER
URNERURNER
URNER & C& C
& C& C
& COMPONENTOMPONENT
OMPONENTOMPONENT
OMPONENT II
II
I
DENTIFICDENTIFIC
DENTIFICDENTIFIC
DENTIFICAA
AA
ATIONTION
TIONTION
TION FF
FF
F
OROR
OROR
OR NO100-41 TNO100-41 T
NO100-41 TNO100-41 T
NO100-41 TOO
OO
ONO150-44 MNO150-44 M
NO150-44 MNO150-44 M
NO150-44 MODULODUL
ODULODUL
ODULAA
AA
ATINGTING
TINGTING
TING
BB
BB
BURNERSURNERS
URNERSURNERS
URNERS 66
66
6
II
II
INTRODUCTIONNTRODUCTION
NTRODUCTIONNTRODUCTION
NTRODUCTION 88
88
8
FF
FF
FEAEA
EAEA
EATURESTURES
TURESTURES
TURES 88
88
8
Burner Nominal Capacities 8
Controls and Safety Systems 8
Operating Mode 8
Fuels 8
SS
SS
SITEITE
ITEITE
ITE CC
CC
CONDITIONSONDITIONS
ONDITIONSONDITIONS
ONDITIONS ANDAND
ANDAND
AND SS
SS
S
ERVICESERVICES
ERVICESERVICES
ERVICES 88
88
8
Flue and Chimney Requirements 8
Plant Room Ventilation 8
Existing Appliances 8
Combustion Chamber Conditions 8
Oil System 9
Main Oil Storage Tank 9
Oil Supply to the Burner 9
Single Pipe System 9
Pumped Ring Main System 9
Burner Pump Capacities 9
Filtration 9
Electrical Power Supply 9
UU
UU
UNPNP
NPNP
NPACKINGACKING
ACKINGACKING
ACKING ANDAND
ANDAND
AND AA
AA
A
SSEMBLSSEMBL
SSEMBLSSEMBL
SSEMBLYY
YY
Y99
99
9
TT
TT
TYPICALYPICAL
YPICALYPICAL
YPICAL RR
RR
R
INGMAININGMAIN
INGMAININGMAIN
INGMAIN OO
OO
OILIL
ILIL
IL SS
SS
S
YSTEMYSTEM
YSTEMYSTEM
YSTEM 1010
1010
10
BB
BB
BURNERURNER
URNERURNER
URNER OO
OO
OILIL
ILIL
IL SS
SS
SYSTEMYSTEM
YSTEMYSTEM
YSTEM 1111
1111
11
II
II
INSTNST
NSTNST
NSTALLALL
ALLALL
ALLAA
AA
ATIONTION
TIONTION
TION 1212
1212
12
General 12
Fitting To the Appliance 12
Connections 12
Electrical Power Connection 12
BB
BB
BURNERURNER
URNERURNER
URNER CC
CC
CONTROLONTROL
ONTROLONTROL
ONTROL ANDAND
ANDAND
AND OO
OO
O
PERAPERA
PERAPERA
PERATIONTION
TIONTION
TION 1212
1212
12
Burner Description 12
EE
EE
ELECTRICALLECTRICAL
LECTRICALLECTRICAL
LECTRICAL CC
CC
CONNECTIONONNECTION
ONNECTIONONNECTION
ONNECTION DD
DD
D
IAGRAMIAGRAM
IAGRAMIAGRAM
IAGRAM 1313
1313
13
BB
BB
BURNERURNER
URNERURNER
URNER CC
CC
CONTROLSONTROLS
ONTROLSONTROLS
ONTROLS 1414
1414
14
Oil Pumping / Pumping & Heating Units 14
Modulating Unit 14
Residual Oil Heating Controls 14
Safety Features 14
OO
OO
OILIL
ILIL
IL PP
PP
PUMPINGUMPING
UMPINGUMPING
UMPING / P/ P
/ P/ P
/ PUMPINGUMPING
UMPINGUMPING
UMPING & H& H
& H& H
& HEAEA
EAEA
EATINGTING
TINGTING
TING SS
SS
SETET
ETET
ET 1515
1515
15
CC
CC
COMMISSIONINGOMMISSIONING
OMMISSIONINGOMMISSIONING
OMMISSIONING 1616
1616
16
IMPORTANT - SAFETY 16
EMERGENCY INSTRUCTIONS 16
Inspection 16
Pre-firing Checks 16
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Page 3
Models NOL/NOR Modulating Revision 101199B
II
II
IMPORTMPORT
MPORTMPORT
MPORTANTANT
ANTANT
ANT - S- S
- S- S
- SAFETYAFETY
AFETYAFETY
AFETY
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 16
EE
EE
EUROPEANUROPEAN
UROPEANUROPEAN
UROPEAN BB
BB
B
OILEROILER
OILEROILER
OILER EE
EE
E
FFICIENCYFFICIENCY
FFICIENCYFFICIENCY
FFICIENCY DD
DD
D
IRECTIVEIRECTIVE
IRECTIVEIRECTIVE
IRECTIVE (B.E.D.)(B.E.D.)
(B.E.D.)(B.E.D.)
(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 O2concentration.
Hand Auto Selector Switch 17
Commissioning the Burner 17
MM
MM
MODULODUL
ODULODUL
ODULAA
AA
ATINGTING
TINGTING
TING UU
UU
U
NITNIT
NITNIT
NIT 1818
1818
18
RR
RR
ROUTINEOUTINE
OUTINEOUTINE
OUTINE MM
MM
MAINTENANCEAINTENANCE
AINTENANCEAINTENANCE
AINTENANCE OFOF
OFOF
OF NOL/NOR MNOL/NOR M
NOL/NOR MNOL/NOR M
NOL/NOR MODULODUL
ODULODUL
ODULAA
AA
ATINGTING
TINGTING
TING BB
BB
B
URNERSURNERS
URNERSURNERS
URNERS 1919
1919
19
General 19
Daily Checks 20
Cleaning the Oil Nozzle 20
Photoelectric Cell 20
Cold Oil Filter(s) 20
Replenishing the Fuel Supply 20
Boiler Combustion Surface 20
FF
FF
FAA
AA
AULUL
ULUL
ULTT
TT
TFF
FF
F
INDINGINDING
INDINGINDING
INDING 2020
2020
20
If the Burner Fails to Start 20
If the burner is found at lockout (red lockout lamp illuminated) 20
Flame Occurs Followed by Immediate Lockout 21
The Burner Starts With The Correct Oil Pressure But No Flame Appears 21
Modulating System 21
FF
FF
FUELUEL
UELUEL
UEL PP
PP
P
UMPSUMPS
UMPSUMPS
UMPS 2121
2121
21
Danfoss Series KSA Fuel Pumps 21
Suntec Series TA Fuel Pumps 21
Suntec Series TV Pressure Regulating Valve 21
Oil Pumps - Where Used 23
FF
FF
FLL
LL
LAMEAME
AMEAME
AME FF
FF
F
AILAIL
AILAIL
AILUREURE
UREURE
URE & S& S
& S& S
& SEQUENCEEQUENCE
EQUENCEEQUENCE
EQUENCE CC
CC
CONTROLSONTROLS
ONTROLSONTROLS
ONTROLS 2323
2323
23
Burner Control Program 23
MM
MM
MODULODUL
ODULODUL
ODULAA
AA
ATINGTING
TINGTING
TING CC
CC
C
ONTROLONTROL
ONTROLONTROL
ONTROL 2424
2424
24
Landis & Staefa RWF32 24
RWF32 Recommended Settings 24
BB
BB
BURNERURNER
URNERURNER
URNER OO
OO
OILIL
ILIL
IL NN
NN
N
OZZLEOZZLE
OZZLEOZZLE
OZZLE 2626
2626
26
SS
SS
SERVICEERVICE
ERVICEERVICE
ERVICE & R& R
& R& R
& REPLEPL
EPLEPL
EPLACEMENTACEMENT
ACEMENTACEMENT
ACEMENT 2626
2626
26
AA
AA
APPENDIXPPENDIX
PPENDIXPPENDIX
PPENDIX 2727
2727
27
Burner Performance Graph 27
Burner Head Details & Electrode Settings 28
Electrical Data Table 29
Burner Commissioning Sheet 30
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Models NOL/NOR Modulating Revision 101199BPage 4
BB
BB
BURNERURNER
URNERURNER
URNER & C& C
& C& C
& COMPONENTOMPONENT
OMPONENTOMPONENT
OMPONENT II
II
I
DENTIFICDENTIFIC
DENTIFICDENTIFIC
DENTIFICAA
AA
ATIONTION
TIONTION
TION FF
FF
FOROR
OROR
OR NO35-34 TNO35-34 T
NO35-34 TNO35-34 T
NO35-34 TOO
OO
ONO100-NO100-
NO100-NO100-
NO100-
38 M38 M
38 M38 M
38 MODULODUL
ODULODUL
ODULAA
AA
ATINGTING
TINGTING
TING BB
BB
BURNERSURNERS
URNERSURNERS
URNERS
Standard Burner Arrangement Shown
All dimensions are mm.
A
B
1
2
3
6
4
9
10
11
8
7
Projection 270
E
D
C
G
300
F Dia.
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Page 5
Models NOL/NOR Modulating Revision 101199B
12
5
Hole
H Dia.
Burner Mounting Details
8 Holes M10 Equispaced On
305mm PCD
metI noitpircseD
1gnisaCrenruB
2noisnetxEdegniH
3ebuTemalF
4rotoMnaF
5telnIriA
6rotoMlortnoCgnitaludoM
7lenaPlortnoC
8tinUmaCgnitaludoM
9evlaVlortnoCllipSliO
01 noitcennoCtelnIliO
11 noitcennoCliOnruteR
21 revoCnoitcepsnInaF
ledoMrenruB A B C D E F G H
43-81*ON 769 037 024 754 034 281 783 612
83-81*ON 4101 557 754 084 034 281 084 612
43-53*ON 769 037 024 754 034 322 783 452
83-53*ON 4101 557 754 084 034 322 084 452
82-05*ON 769 037 024 024 034 322 783 452
43-05*ON 769 037 754 754 034 322 783 452
83-05*ON 4101 557 084 084 034 322 084 452
82-06*ON 769 037 754 754 034 322 783 452
43-06*ON 769 037 084 084 034 322 783 452
83-06*ON 4101 557 084 084 034 322 084 452
83-58*ON 4101 557 735 735 034 452 084 082
83-001*ON 4101 557 735 735 034 452 084 082
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Models NOL/NOR Modulating Revision 101199BPage 6
BB
BB
BURNERURNER
URNERURNER
URNER & C& C
& C& C
& COMPONENTOMPONENT
OMPONENTOMPONENT
OMPONENT II
II
I
DENTIFICDENTIFIC
DENTIFICDENTIFIC
DENTIFICAA
AA
ATIONTION
TIONTION
TION FF
FF
F
OROR
OROR
OR NO100-41 TNO100-41 T
NO100-41 TNO100-41 T
NO100-41 TOO
OO
O
NO150-44 MNO150-44 M
NO150-44 MNO150-44 M
NO150-44 MODULODUL
ODULODUL
ODULAA
AA
ATINGTING
TINGTING
TING BB
BB
BURNERSURNERS
URNERSURNERS
URNERS
Compact Burner Arrangement Shown
All dimensions are mm
1210
270
906
Projection
385
545
440
595
345
565
6
14
2
3
1
15 4
9
10
11
16
7
13
8
305 Dia
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Page 7
Models NOL/NOR Modulating Revision 101199B
Burner Mounting Details
4 Holes M20 Equispaced On
454mm PCD
Hole
330mm
Dia.
45°
12
5
metI noitpircseD
1gnisaCrenruB
2noisnetxEdegniH
3ebuTemalF
4rotoMnaF
5telnIriA
6rotoMlortnoCgnitaludoM
7lenaPlortnoC
8tinUmaCgnitaludoM
9evlaVlortnoCllipSliO
01 telnIliOdaeHrenruB
noitcennoCesaeleRkciuQ
11 liOnruteRdaeHrenruB
noitcennoCesaeleRkciuQ
21 revoCnoitcepsnInaF
31 remrofsnarTnoitingI
metI noitpircseD
41 elttoBrotarepeSriA
51 tinUretaeherPliO
61 tinUgnipmuPliO
Items 14 to 16 Refer to
Compact Modulating Burners
Only
Upon request NO Modulating burners
can be supplied in the fully assembled
compact configuration as shown.
On compact models NO*18, 35 & 50
the Oil Pump may be driven by the fan
motor. All other models utlise an
independant pumping set.
Supply oil connections are made to the
Air Seperator Bottle item 14. Refer to
the Pumping Unit connections shown
on page 15 for identification.
Standard burners are supplied with a
floor mounted pumping or pumping &
heating unit. In this configuration, the
system oil connections 10 & 11 on
pages 4 & 5 refer.
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Models NOL/NOR Modulating Revision 101199BPage 8
II
II
INTRODUCTIONNTRODUCTION
NTRODUCTIONNTRODUCTION
NTRODUCTION
This manual has been produced to enable users
to install, commission and use NO Modulating
burners safely and efficiently. The manual covers
two types of burner: Models NOL distillate (Class
D fuel) oil burners and models NOR residual (Class
E, F & G) oil burners. At each stage the conditions
which should be met and the adjustments and
other actions which should be carried out are de-
tailed and the locations of the various components
and adjustment mechanisms are identified. Where
appropriate, this information is supported by ta-
bles and graphs. Literature on the proprietary com-
ponents used in NO Modulating systems is avail-
able on request.
FF
FF
FEAEA
EAEA
EATURESTURES
TURESTURES
TURES
Developed through extensive field experience in
the UK and overseas markets, the NO Fully modu-
lating series meets the current known test author-
ity requirements in these markets and sets new
standards in efficient and reliable operation. NO
Modulating burners are designed for flange mount-
ing to the appliance front plate and they are deliv-
ered ready to install with a pre-wired packaged
control system and oil pumping or pumping & heat-
ing unit.
Burner Nominal Capacities
NO18 (2 Models) 530 kW 42.0 kg/h
NO35 (2 Models) 940 kW 74.0 kg/h
NO50 (3 Models) 1750 kW 138.0 kg/h
NO60 (3 Models) 2100 kW 165.5 kg/h
NO85 (1 Model) 2432 kW 192.0 kg/h
NO100 (2 Models) 2930 kW 231.5 kg/h
NO125 (3 Models) 3668 kW 290.0 kg/h
NO150 (3 Models) 4396 kW 347.0 kg/h
Controls and Safety Systems
NO Modulating burners are fitted with an auto-
matic sequence / flame failure control and photo-
electric cell for continuous flame supervision. A
combustion air flow control coupled to an oil noz-
zle pressure control system ensures smooth start-
ing and optimum operating effeciency.
Operating Mode
In standard form the NO Fully Modulating burner
can provide a turndown range of up to 3:1.
Fuels
NO burners covered in this manual are designed
to fire distillate and residual fuel oils, which com-
ply with the specifications given in the tables on
page 10. NO burners configured for firing other fuel
grades may be available on request.
SS
SS
SITEITE
ITEITE
ITE CC
CC
C
ONDITIONSONDITIONS
ONDITIONSONDITIONS
ONDITIONS ANDAND
ANDAND
AND SS
SS
S
ERVICESERVICES
ERVICESERVICES
ERVICES
Flue and Chimney Requirements
It is important that:
 The flue pipe from the appliance and the
joint between this flue and the chimney are
sealed to prevent leakage of combustion
products.
 The flue pipe from the appliance does not
protrude into the chimney beyond the inside
wall.
 The top of the flue or chimney shall be higher
than any roof within a radius of 10 metres.
 Checks are made to ensure that the chim-
ney is suitable for oil fired appliances and that
the proposed installation complies with all
Local Authority and other regulations cover-
ing such installations.
 If more than one appliance is connected to
a common flue or chimney the cross-section
of this flue or chimney should be adequate
for the total volume of combustion products
from the appliances. It is recommended that
each appliance should be exhausted into a
separate flue.
Plant Room Ventilation
The burner must be supplied with dust free air at
sufficient rates for all firing conditions, in accord-
ance with the appropriate standards.
Existing Appliances
The appliance should be prepared for installation
of the NO burner by thorough cleaning, including
the removal of all adhering tar, scale and dirt. An
inspection should also be carried out to ensure
that the appliance is in good condition. Any doubt
about the appliances suitability for oil firing shall
be referred to the appliance manufacturer.
Combustion Chamber Conditions
The combustion chamber conditions should not
exceed those shown on page 27 of this manual.
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Page 9
Models NOL/NOR Modulating Revision 101199B
Burners working with zero rated combustion
chamber conditions can be subjected to a maxi-
mum negative chamber condition of 0.05 kPa (0.5
mb)
Oil System
Refer to the drawings on page 11 for details of the
burner oil system.
Main Oil Storage Tank
Residual oils must be maintained at all times to a
temperature specified by the supplier.
Oil Supply to the Burner
The oil supply from the storage tank to the burner
may be provided by:
(a) Single pipe gravity feed system. Class D only.
(b) Pumped ring main system. Class E, F and G
fuels.
Single Pipe System
The height of the main storage tank above the
burner and the sizing of the pipe to the burner must
be designed so that the oil pressure at the burner
oil pump inlet is not less than 35 kPa (0.35 bar).
The maximum oil pressure at the burner pump inlet
must not exceed 500 kPa (5.0 bars) under any op-
erating conditions.
The pipe must be sized to the full swept volume of
the burner oil pump and not the capacity of the
burner nozzles.
Pumped Ring Main System
The pumped ring main is the preferred system of
oil supply and is essential for multiple burner in-
stallations and where heavy residual fuel oils are
to be used.
The ring main pumps and supply pipe work must
be designed to cater for 1.25 times the total swept
volume of the burner oil pumps connected to the
supply system.
All oil supply pipes must be constructed and in-
stalled to comply with local conditions and appro-
priate codes of practice and standards. All pipe
work must be firmly supported and in the case of
residual fuel oils, lagged, traced and thermostati-
cally controlled. A Pressure Reducing Valve (PRV)
should be fitted to control the supply pressure.
Further details are shown in the typical ring main
diagram on page 10
Burner Pump Capacities
The oil pumps used on Nu-Way modulating oil
burners are listed in the table on page 23. It is es-
sential that the full swept volume of the pump be
considered when oil supply lines or ring main sys-
tems are calculated.
The minimum recommended size of the supply
pipe or ring main is 2 BSP when residual oil is
used.
Lagging and tracing is considered essential for re-
sidual fuel. The table on page 10 gives the recom-
mended storage and oil supply temperature re-
quired at the burner pump.
Filtration
When using fuel oils and in particular residual
grades, filtration of the oil is essential. The filtra-
tion system should be chosen according to the in-
dividual features of the installation. The ring main
system diagram on page 10 gives guidelines. When
the ring main pressure is checked then this should
be measured at the burner pump vacuum gauge
port to allow for any pressure drop across the fil-
ters.
Failure to provide a good clean oil supply will al-
most certainly lead to premature wear and rapid
failure of the oil pump unit.
Electrical Power Supply
A three phase 50 Hz supply is required (60 Hz
burners are available on request). Power require-
ments are tabulated in the Appendix of this hand-
book. The power supply provided must comply
with all relevant Codes and Standards.
UU
UU
UNPNP
NPNP
NPACKINGACKING
ACKINGACKING
ACKING ANDAND
ANDAND
AND AA
AA
A
SSEMBLSSEMBL
SSEMBLSSEMBL
SSEMBLYY
YY
Y
To safeguard against damage in transit, NO Modu-
lating burners may be supplied in partly assembled
form in one of three alternative modes:
Mode 1:
The complete burner unit fully assembled.
Mode 2:
Burner body complete with control panel. Com-
bustion head hinged extension and flame tube
assembly
To assemble the burner:
Assembly of the burner can be completed after fit-
ting the hinged extension/flame tube assembly to
the appliance.
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Models NOL/NOR Modulating Revision 101199BPage 10
Alternatively, fit the extension/flame tube assem-
bly to the burner body using the eight nuts and
washers provided.
A pumping and heating unit, or pumping unit in
the case of distillate burners is supplied as a sepa-
rate component to modes 1 and 2 and is inclusive
of flexible pipes to make all the necessary oil con-
nections.
Mode 3:
Upon request NO Modulating burners can be sup-
plied in a fully assembled compact configuration.
These burners include the oil pumping and condi-
tioning unit mounted beneath the burner body
and are pre-piped, requiring only the connection
of fuel and electrical supplies to complete the in-
stallation. The suitability for installation of com-
pact modulating burners should be referred to the
appliance manufacturer as the addition of the oil
pumping or pumping & heating unit adds extra
weight to the appliance frontplate.
TT
TT
TYPICYPIC
YPICYPIC
YPICALAL
ALAL
AL RR
RR
R
INGMAININGMAIN
INGMAININGMAIN
INGMAIN OO
OO
O
ILIL
ILIL
IL SS
SS
SYSTEMYSTEM
YSTEMYSTEM
YSTEM
Oil Storage
Tank
Tank Heater
Outflow Heater
Pressure
Regulator
Return From Burner
(If Fitted)
Feed To Burner
Pressure
Relief Valve
Sludge Valve Non Return
Valve
Non Return
Valve
40 Mesh
Filter
80 Mesh
Filter
Oil
Pumps
Line
Heaters
Drain
Valve
P
P
T
T
T
T
P
Temperature Switch
Pressure Switch
Manual Shut Off Valve
Duplex Pumping &
Heating Sets
The fitting of duplex Oil Pumping &
Heating sets is recommended for sys-
tem continuity and serviceability.
Line heaters are recommended for
Class F & G fuels. They are generally
not necessary for Class E fuel.
Pre-heating of Class D fuel is not re-
quired, however fuel companies rec-
ommend a minimum fuel temp of 5°C
and that all exposed pipework should
be lagged.
T
leuF
ssalC sceS muminiM knaTmorF
ottelnI
renruB
gnisimotA
erutarepmeT
D 53 - - -
E 002 C°61 C°61 C°28
F 069 C°03 C°34 C°011
0051 C°63 C°56 C°811
G 0053 C°05 C°28 C°231
0024 C°55 C°68 C°041
Fuel Handling Temperatures
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Page 11
Models NOL/NOR Modulating Revision 101199B
BB
BB
BURNERURNER
URNERURNER
URNER OO
OO
OILIL
ILIL
IL SS
SS
SYSTEMYSTEM
YSTEMYSTEM
YSTEM
Hyd
Retn
Feed
Fluidics Atomiser Burnerlance
Inner Manifold
Outer Manifold
Oil Pressure Gauge
Spill Valve
Filter Oil
Pump Oil Preheater (Residual Fuel
Only)
Hot Oil
Filter
Thermometer
Pressure Relief Valve
Non Return Valve
NO/NC = Normally Open/Closed
Oil Solenoid Valve
Manual Shut Off Valve
Air Seperator
Bottle
NO NC
All inter-connecting pipework to be mini-
mum 19mm bore and pressure rated for
42kg/cm2 (600 psi).
On Residual fuel burners this pipework must
be maintained at the burner atomising tem-
perature and In the case of Class F and G
fuels, must also be traced.
Distillate oil burners require a pump inlet
pressure of 0.35 to 0.70 kg/cm2(5 to 10 psi).
For Residual fuel, the oil inlet temperature
must be maintained as recommended in the
table on page 10, and the pump inlet pres-
sure set between 4&5 bar.
If a shut off valve is fitted in the inlet line, a
pressure relief valve set at 0.7 kg/cm2(10 psi)
above the supply pressure must be fitted
to prevent damage should the valve be left
shut during burner/heater start-up.
Pumped Systems - All Burners
Pumped Supply From Ringmain. Minimum Bore
25mm Class D / 50mm Class E, F & G
Not Supplied By Nu-way
Pipework Shown In Chain Dot Not Supplied
By Nu-way. (Not Required On Compact
Burner Arrangement)
Flex Oil
Pipes
NO
Return
Tstat
Notes.
The Oil Preheater, Return Oil Thermo-
stat and Spill Valve NO bypass Solenoid
Valve are not fitted on Distillate fuel
systems.
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Models NOL/NOR Modulating Revision 101199BPage 12
II
II
INSTNST
NSTNST
NSTALLALL
ALLALL
ALLAA
AA
ATIONTION
TIONTION
TION
General
Ensure that the appliance is suitable for the heat
input of the burner. If there is any doubt in this
area, reference shall be made to the appliance
manufacturer. Detailed burner performance data
are presented in the appendix of this handbook.
Fitting To the Appliance
If the burner is to be fitted to a new appliance re-
fer to the appliance manufacturers recommenda-
tions.
If the burner is to be fitted to an existing appliance
a mounting flange must be provided as detailed in
the section on Burner & Components Identifica-
tion. Ensure that the joint between the burner and
the mounting flange is sealed effectively using the
gasket provided.
The flame tube should not extend beyond the in-
ner face of the appliance combustion chamber
unless the appliance manufacturer specifies exten-
sions, for example in the case of reverse flame boil-
ers.
Connections
Once the burner is mounted to the appliance, open
the hinged extension by removing the two nuts
and washers, connect the HT leads to the ignition
electrodes and close and fasten the extension.
Connect the flexible oil pipes between the burner
and the pumping or pumping and heating unit by
referring to the burner component and pumping
or pumping & heating unit drawings on pages
4,5&15.
Connect the oil supply to the burner pumping unit
with reference to the oil system diagrams and
pumping unit drawings on pages 10,11&15.
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 opposite and in the wiring diagram con-
tained 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 ap-
pliance/burner unit refer to the appliance manu-
facturers instructions.
BB
BB
BURNERURNER
URNERURNER
URNER CC
CC
C
ONTROLONTROL
ONTROLONTROL
ONTROL ANDAND
ANDAND
AND OO
OO
OPERAPERA
PERAPERA
PERATIONTION
TIONTION
TION
All personnel concerned with commissioning and/
or operation of NO modulating burners shall fa-
miliarise themselves with the information pre-
sented in this section.
Burner Description
Nu-way NOL/NOR modulating series fully auto-
matic oil burner units are of packaged design and
meet relevant National and International stand-
ards based on the ISO system of measurement and
fastening.
A system of pressure atomisation employing a sin-
gle spill back nozzle is used throughout the range.
If the burner is equiped with the Nu-way Electronic
Cam Modulation (ECM) system, then reference
should also be made to the supplementary docu-
mentation supplied with this handbook. In this case
references to the RWF32 Universal Controller and
Modulating Unit within this handbook can be ig-
nored.
The standard method of operation is based on the
Landis & Staefa RWF32 Universal Controller, which
has been designed for use in oil and gas fired in-
stallation, where it provides temperature or pres-
sure control of modulating burners with continu-
ously adjustable fuel throughput.
The control output of the RWF32 is a potential
free 3-position switch, which is used for the con-
trol of reversible motors. The control signals for the
open (Y1) and closed (Y2) are indicated on the
controller face by light emitting diodes.
Replaceable range insert PCBs which are used in
conjunction with passive detectors of type QAE21
(Temperature) and QBE61 (Pressure) achieve
configuration of the unit to a control value and
setting range. For further information on the
RWF32 and its associated components please re-
fer to the data provided on page 25 of this hand-
book.
When the boiler control calls for heat, the burner
modulating unit will travel to the high flame po-
sition and interlock the control circuit. An air pre-
purge will take place at this position for a pre-de-
termined 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 cy-
cle and the burner will light and remain at low flame
until the high flame release signal is given by the
sequence control.
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Page 13
Models NOL/NOR Modulating Revision 101199B
EE
EE
ELECTRICLECTRIC
LECTRICLECTRIC
LECTRICALAL
ALAL
AL CC
CC
C
ONNECTIONONNECTION
ONNECTIONONNECTION
ONNECTION DD
DD
DIAGRAMIAGRAM
IAGRAMIAGRAM
IAGRAM
Standard Terminal Connections For Burner
Mounted Control Panels
(Please refer to the Wiring Diagrams packaged with
the burner if a separate Control Panel is supplied)
L1
Limit Instrument
Control Instrument
Modulating Control In-
strument Type QBE 61
3-Wire (Pressure)or
QAE 22 2-Wire (Tem-
perature)
Oil Pumping and Heating Unit
QAE
22
L2
L3
N
L*
Terminals 1 to 22
refer to all Stand-
ard and Compact
Burners
LO
BR
Burner or Boiler Hinge
Microswitch (If fitted, re-
move link 21-22)
Terminals 23 to
37 refer to Stand-
ard Residual Oil
Burners (Pre-
wired on Compact
series Burners)
Terminals
30,31 and
32 refer to
Standard
Distillate
Oil Burners
(Pre-wired
on Compact
series
Burners)
Heater Limit
and Control
Stats
Low Oil Temp
Stat
Circulation
Stat
Oil Pump
Motor
Oil Preheater
Elements
Oil Pump Car-
tridge Heater (If
Fitted)
1. For temperature control use Landis & Staefa detector type QAE 22 and for pressure control type
QBE 61.
2. Any interlock designed to switch or control the burner such as a time switch, damper or I.D.
fan interlock etc. is to be wired in series with the control and limit thermostats.
3. If the burner is used on a steam boiler, the water level interlocks must be wired between
terminals 13 & 17 and the link removed.
4. A remote Run indication (BR) can be wired from terminal 9.
5. A remote Excess Temerature or Pressure alarm can be wired from terminal 10.
6. A remote Lockout alarm (LO) can be wired from terminal 11.
7. A remote Oil Heater Tripped alarm can be wired from terminal 24.
Notes:
For specifications and sizing of the
electrical supply and interconnecting
wiring please refer to the Electrical
Data Table in the Appendix of this
Handbook
L* =(If fitted) for connection of
an independant control circuit
supply. If not required fit a
0.75mm (24/.20) between L1
and L
Burner Mounted Control Panel
7
M
B
GG
8
M
B
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Models NOL/NOR Modulating Revision 101199BPage 14
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 unit will commence to move to-
wards the low flame position, but, depending on
the temperature/pressure, will stop in any inter-
mediate position between low and high flame.
BB
BB
BURNERURNER
URNERURNER
URNER CC
CC
C
ONTROLSONTROLS
ONTROLSONTROLS
ONTROLS
Burners are supplied with an integral control panel
containing a sequencing control unit and the
burner switchgear. On steam boiler applications
an auxiliary control panel containing boiler feed
pump controls, water level interlocks and alarms
is available.
Oil Pumping / Pumping & Heating Units
Standard burners are supplied with a floor
mounted pumping (Distillate fuel) or pumping and
heating unit (Residual fuel) for conditioning of the
supply oil prior to entering the burner hydraulic
circuit. Details of each unit are shown on page 15
opposite.
On burners supplied in compact configuration,
the pumping and heating equipment is mounted
on the burner.
Modulating Unit
The Nu-way modulating unit consists of a revers-
ible 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 con-
tour type (see fig. 2 on page 18). The second cam
is the modulating oil cam and is illustrated in fig.
1.
The Burner Oil System Drawing on page 11 shows
the hydraulic circuits for residual and distillate fuel
burners. Oil for combustion is drawn from the sup-
ply through a fixed displacement pump and sup-
plied direct to the burner nozzle. A return line from
the back of the nozzle is connected to a spill regu-
lating valve which regulates the oil pressure at the
nozzle according to the position of an internal pis-
ton 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.
leuF
ssalC
timiLhgiH
tatsomrehT
lortnoC
tatsomrehT
timiLwoL
tatsomrehT
noitalucriceR
tatsomrehT
EC°011C°58C°56C°04
FC°031C°001C°08C°05
GC°051C°041C°001C°07
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 procedure section of this
handbook, the profile of the air cam is adjusted to
give the desired combustion conditions 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.
Residual Oil Heating Controls
A preheater and recirculation thermostat is fitted
to the residual oil burner range (NOR).
The preheater contains three thermostats:
(a) High limit thermostat
(b) Control thermostat
(c) Low limit thermostat (reverse acting)
The recirculation thermostat is fitted in the return
oil line and will override the burner firing controls
and start the burner oil pump in order to maintain
the correct oil temperature in the nozzles and
burner pipework.
The thermostats should be set to the temperatures
specified in the following table.
Safety Features
Flame supervision is effected by photoelectric cell
and sequence control box. An air pressure switch
is fitted to prove that combustion air is available
to the burner head before allowing the oil pump
to start. (The oil pump is driven by a separate mo-
tor in all cases except for the smaller compact
design of burner)
All manuals and user guides at all-guides.com

Page 15
Models NOL/NOR Modulating Revision 101199B
OO
OO
OILIL
ILIL
IL PP
PP
P
UMPINGUMPING
UMPINGUMPING
UMPING / P/ P
/ P/ P
/ PUMPINGUMPING
UMPINGUMPING
UMPING & H& H
& H& H
& HEAEA
EAEA
EATINGTING
TINGTING
TING SS
SS
SETET
ETET
ET
3
4
2
1
3
4
2
1
1
2
3
4
3
2
4
1
B
273
1295
A
Distillate Oil
Pumping Set
Residual Oil
Pumping &
Heating Set
Pump/Motor
Coupling Pump Motor
Air Bleed Valve
Oil Filter
Oil Pump
Air Seperator
4 x M10
Foundation Bolts
Air Bleed Valve Cold Oil Filter
Return Oil
Thermostat
Preheater Tank
Thermometer
Pump/Motor
Coupling
Pump Motor
Hot Oil Filter Heater Element
Cover
Electrical
Connection Box
Isolation Valve
Oil Pump
4 x M12
Foundation Bolts
Air Seperator
Foundation
Detail
Foundation
Detail
Electrical
Connection Box
metI noitpircseD "R
1noitcennoCtelnIliO 1
2noitcennoCnruteRliO 1
3deeFliOrenruB 4/3
4nruteRliOrenruB 4/3
Pipework Connections
ledoMrenruB A B
05LONotpU 322 251
051ot06LON 022 491
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Models NOL/NOR Modulating Revision 101199BPage 16
IMPORTIMPORT
IMPORTIMPORT
IMPORTANT - SAFETYANT - SAFETY
ANT - SAFETYANT - SAFETY
ANT - SAFETY
It is essential that commissioning shall be under-
taken only by suitably qualified and experienced
personnel. In the case of NO 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 fail-
ure to follow the commissioning instructions pro-
vided or from commissioning procedures being
undertaken by unqualified personnel.
EMERGENCY INSTRUCTIONSEMERGENCY INSTRUCTIONS
EMERGENCY INSTRUCTIONSEMERGENCY INSTRUCTIONS
EMERGENCY INSTRUCTIONS
NO Modulating burners are designed and con-
structed to meet current legislation. When used in
accordance with the instructions provided, NO
Modulating burners are unlikely to produce a haz-
ardous condition. If, however such a condition
should arise in connection with the burner, the ap-
pliance or of any instrument, machine or service
in the vicinity of the burner, the OIL AND ELEC-
TRICITY SUPPLIES SHALL BE ISOLATED IMME-
DIATELY and they shall remain isolated until the
fault has been identified and rectified.
CC
CC
COMMISSIONINGOMMISSIONING
OMMISSIONINGOMMISSIONING
OMMISSIONING
Inspection
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 cor-
rectly 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 commis-
sioning aware of the location of the emer-
gency fuel and electricity isolation points.
•Check that fittings for bleed and pressure test-
ing are fitted.
•Establish that the appliance is in an appro-
priate and safe condition to be fired; for ex-
ample, 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 posi-
tion.
•Ensure that all necessary tools and test equip-
ment are available and ready for use. Essen-
tial items include temperature measuring in-
struments for measuring flue gas and appli-
ance water temperatures, and a means of
analysing the flue products for carbon diox-
ide (CO2), oxygen (O2), carbon monoxide
(CO) and smoke.
•Check that all relevant documentation is
available including, where appropriate:
•The agreed plant performance specifi-
cations.
•Plant drawings and pipework layouts.
•Electrical logic and wiring diagrams.
•Certificates confirming satisfactory com-
pletion of procedures such as sound-
ness testing and electrical safety tests.
•Commissioning, operating and mainte-
nance 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 di-
mensional details are given in the appendix
of this handbook).
•Check that the electrode positions and H.T.
leads are correct.
•Check all the 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 cor-
rectly interlocked to the burner or fixed in
the fully open position.
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Page 17
Models NOL/NOR Modulating Revision 101199B
•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 recom-
mended temperature and pressure.
•Bleed the burner pump manually by remov-
ing the right hand ¼ BSP plug in the top of
the pump until air-free oil flows.
•Fill the oil pre-heater tank, if fitted, by remov-
ing the hot oil filter retaining flange in the
outlet pocket on the top of the tank. Fill to
the neck of the tank outlet with clean fuel
oil only.
•Switch on the electricity supply to the burner
and check that the pump motor rotation is
correct to the direction arrows shown on the
pump face.
•Remove the access lid on the modulating
cam box unit.
•Switch on the burner at the control panel. (If
an oil pre-heater is fitted, then a delay may
be experienced whilst the system attains
temperature). 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 rota-
tion (Anti-clockwise as viewed from the mo-
tor 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. Dur-
ing this run check that the ignition spark is
occurring, and note the spill and line oil pres-
sures at the moment of ignition. Reset the
sequence control and repeat the run if nec-
essary 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 COMMIS-
SIONED.
Hand Auto Selector Switch
This switch must always be in the Auto position
when the burner is required to start. The Hand
selection can be made immediately the burner has
started to fire.
Should the burner be left in the Hand position it
will NOT modulate until the Auto position is se-
lected.
Commissioning the Burner
New NO Modulating burners are generally sup-
plied against the firing specification of the appli-
ance. 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 arrange-
ment is in the low flame position, adjust the
oil cam (see fig. 1 on page 18) 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.
•Turning to the air cam (fig. 2 on page 18),
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 appli-
ance 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
means of the inching switch on the control
panel. Adjust the air cam profile by means of
the thumbscrews until the air damper is now
fully open. 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.
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Models NOL/NOR Modulating Revision 101199BPage 18
MM
MM
MODULODUL
ODULODUL
ODULAA
AA
ATINGTING
TINGTING
TING UU
UU
U
NITNIT
NITNIT
NIT
Oil Cam Hub
Servomotor
Camstack
Motor Unit
Oil Spill Back
Regulating Vlave
Oil Cam Adjusting
Screw
Lever
Throw
Cam Follower
Cam Disk
Adjustable
Plunger
Locking
Screws
Profile Band
Cam Lever Operating
Cable
Adjuster Locking
Screws Profile Adjuster
Retaining
Saddle
Cable Adjuster
Oil Cam - A
Air Cam - B
Oil Cam View On - A
Air Cam View On - B
View of Servomotor from underside
(cover removed) showing position of
disengagement lever
Rotation for High
Flame position
(Cams shown in the Low
Flame Position)
Fig. 1.
Fig. 2.
Spill Pressure
Reduce Increase
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Page 19
Models NOL/NOR Modulating Revision 101199B
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 compen-
sate 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. Check the pre-heater
temperature (if fitted) and adjust if necessary.
•Inch the camshaft back to the low flame po-
sition. The oil consumption rate should now
be between 35 and 50% of the rated maxi-
mum.
•Measure the flue gas composition and ad-
just the combustion air volume as necessary.
•Check the burner performance throughout
the range adjusting the air cam profile as nec-
essary to give a clean and efficient flame.
When a satisfactory setting has been achieved, lock
the air cam thumbscrews with the grubscrews fit-
ted in the side face of the cam body. Refit the
Modulating unit access cover.
Check the function of the air pressure switch.
•Switch off the electrical supply to the burner.
•Remove the air pressure switch cover. Fit a
manometer to the pressure switch to check
the actual air pressure against the pressure
switch dial setting.
•Switch on the electrical supply and allow the
burner to establish low flame.
•Select Hand control and ensure that the
burner is at low flame by using the inching
switch.
•Slowly turn the air pressure switch adjusting
dial clockwise until the flame is extinguished.
The burner will go to lockout.
•Turn the dial one division anticlockwise and
reset the burner lockout. The burner will now
continue through its cycle until flame is es-
tablished or the burner goes to its lockout
position. If the burner goes to lockout repeat
the procedure one division per burner cycle
until flame is established. Once successful,
turn the dial a further two divisions anticlock-
wise.
•Switch off the burner electrical supply, re-
place the air pressure switch cover and re-
move the manometer.
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 pres-
sure/temperature.
Allow the boiler to attain the correct working pres-
sure/temperature and adjust the on/off and limit
instruments to the desired values.
Switch the Hand/Auto selector switch to Auto.
The plant is now under the control of the pres-
sure/temperature controllers for modulation and
the on/off and high limit instruments for control.
On residual oil burners, check the operation of the
three oil temperature thermostats fitted in the end
of the preheater tank element, and the re-circula-
tion thermostat (class G fuel only).
Finally check all ancillary controls and equipment
such as damper interlocks etc.
RR
RR
ROUTINEOUTINE
OUTINEOUTINE
OUTINE MM
MM
M
AINTENANCEAINTENANCE
AINTENANCEAINTENANCE
AINTENANCE OFOF
OFOF
OF NOL/NOL/
NOL/NOL/
NOL/
NOR MNOR M
NOR MNOR M
NOR MODULODUL
ODULODUL
ODULAA
AA
ATINGTING
TINGTING
TING BB
BB
BURNERSURNERS
URNERSURNERS
URNERS
General
It is vitally important that personnel responsible
for the day to day operation and maintenance of
the plant are instructed by the commissioning en-
gineer 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 com-
missioning data must be sent to the appliance
manufacturer.
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Models NOL/NOR Modulating Revision 101199BPage 20
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.
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). On heavy fuel
burners a drop in line pressure may indicate clog-
ging of the hot oil filter which is situated in the
outlet pocket of the pre-heater tank. Remove the
filter by removing the four bolts from the outlet
pocket flange and disconnecting the pipework. Lift
the filter out and wash in kerosene. If the oil pres-
sure remains low, then check the oil supply sys-
tem, stop/fire valves, ring main pumps etc and also
the cold oil filter(s).
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 in-
spected 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.
Cleaning the Oil Nozzle
To clean the oil nozzle, switch off the electricity
supply to the burner and disconnect the flexible
oil lines at the burner head quick release couplings.
Remove the hinge plate retaining nuts and swing
open the burner. Disconnect the H.T. leads and
remove the two long cap head screws retaining the
inner assembly, from the face of the oil manifold
block on the side of the hinged extension. The in-
ner assembly lance can now be removed complete
with the diffuser and electrode assembly by with-
drawing from the flame tube/hinge assembly. It is
important that the nozzle is cleaned using non-
abrasive materials, never use anything which may
scratch the finely finished surfaces of the nozzle.
Nozzle life is approximately 5000 hours opera-
tion, after which wear will affect atomisation and
plant efficiency will drop.
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.
Cold Oil Filter(s)
On residual oil burners, rotate the cleaning knob
of the cold oil filter daily.
The plug in the bottom of the filter housing should
be removed and sludge water drained off at inter-
vals not exceeding six weeks. If a duplex cold oil
filter set is fitted, the filters can be alternated and
isolated for cleaning operations as necessary.
On distillate oil burners, the filter bowl should be
removed and the filter element cleaned in kero-
sene every six months. If the filter has a disposable
element renewal should be considered.
Replenishing the Fuel Supply
It is usual practice to shut boiler(s) off whilst deliv-
ery of fuel is being made and allow approximately
30 minutes for any sediment to settle before re-
starting 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 dur-
ing boiler cleaning operations.
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If the Burner Fails to Start
Make sure that all the thermostats and switches in
the control circuit are in the made position and
that the oil pre-heater excess limit thermostat has
not tripped. Reset if required. Check that the low
oil temperature thermostat is set correctly for the
appropriate fuel.
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 in-
terlocks are in the made position.
If the burner is found at lockout (red lockout
lamp illuminated)
Reset the burner and observe the starting se-
quence. (Make reference to the Sequence Diagram
and Timing Charts for the Flame Failure controls
on page 23 for further information).
Check the fan and oil pump motor overloads and
reset if necessary.
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