Nu-Way Selectos Instruction Manual

Installation & Maintenance Manual
Series SG fully automatic gas burners
Selectos SG100 & SG170
Gas Burner
11/12
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SG10010603
IMPORTANT - SAFETY
It is essential that the following
instructions and adjustments are
carried out by qualified engineers
that are experienced in forced
draught gas burner commissioning.
In the UK it is a legal requirement
that anyone working on gas
installation, as defined in the “Gas
Safety (Installation & Use)
Regulations 1998”, is CORGI
registered. The manufacturer
cannot be held responsible for any
consequential damage, loss or
personal injury as a result of failure
to follow these instructions, or as a
result of misuse.

SG10020602
COMPONENT IDENTIFICATION
COMPONENTS
1. Reset Button
2. ControlBox
3. Transformer
4. MultiBlock
5. AirDamper
6. Air Pressure Switch
7. FanShield
8. FanWheel
9. AirAdjustment
10. FanMotor
11. ElectricalConnection
12. FlameTube
13. FlameProbe
14. IgnitionElectrode
15. HeadAdjustmentScrew
16. PressureTest Point
17. HeadClampingBolt
18. AdjustmentMarkings
19. Diffuser
15
17
14
13
12
16
19
18
4
8
10
11 9 7 6
5
321

TECHNICAL DATA
MODELSSG100/170
SG10030603
PERFORMANCEENVELOPE
*Calorificvalue:
Naturalgas10.7kW/m3
LPG 26kW/m3
** Dependingongastype and
availablepressure
OUTPUTRANGE
Theabovedimensionsaremaximummeasurements.Dependingonthecomponentsusedthesemayvary.
DIMENSIONS
323
1
9
2
6
0
275
113
139
1
1
4
ELECTRICALDATA
Type Motor Ignition Transformer
SG100 125W, 2800rpm, 230v, 50Hz, 0.65A Electronic 230/11000V
SG170 125W, 2800rpm, 230v, 50Hz, 0.65A Electronic 230/11000V
Type SG100 SG170
Gas Connection ** 1/2" BSP 3/4" BSP
40 60 80 100 120 140 160
180
Burner Output (kW)
C
h
a
m
b
e
r
Resistance (mbar)
SG100 SG170
NG LPG NG LPG NG LPG
SG100 60-110 5.6 2.3 10.3 4.2 20 37
SG170 110-160 10.3 4.2 15.0 6.2 20 37
Type Volume (m³) Min Volume (m³) Max Supply Pressure
(mbar)
Gross Input
(kW) *

SG10040602
Ifthehinged extension/flametubeassembly isnotfitted to
thefancaseassembly,itshouldbefittedbeforemountingto
theapplicationusingthepinsprovided.Ensurethatthegas
inlet connection is at the bottom.
Once the burner is mounted open the hinged extension,
connect the flame probe and ignition cables. The terminal
endsare dissimilarand cannot be wrongly connected.
The gas train can now be fitted to the hinged extension.
•Ensure that the gaskets are seated correctly when
tighteningtheassembly.
•Iftheburneristobefittedtoanewpackagedunit,refer
tothemanufacturersrecommendations.
•If the burner is to be used with an existing appliance
preparethemountingflange.
•Ensurethe jointbetween appliance and burner is
effectivelysealedwiththegasketprovided.
140-190
155-210PCD
120Dia
1
3
.
0
m
m
2PLACES
1
2
.
0
m
m
4
P
L
A
C
E
S
MOUNTING THE BURNER
ELECTRICAL
EXTERNAL WIRING
ADDITIONAL CONNECTIONS FOR
HIGH/LOW VALVES
7 PIN BLACK/BROWN
WIELAND PLUG 4 PIN BROWN WIELAND PLUG
ON/OFF VALVES
ELECTRICALPOWERSUPPLY
Connect a single phase 50Hz electrical supply to the burner observing all applicable IEE Regulations. Refer to the
connection diagram below or the wiring diagram contained in the instruction pack supplied with the burner.
ELECTRICALCONNECTIONS
MOUNTINGFLANGEDETAIL

SG10050602
GENERAL INSTRUCTIONS
The SG100 & 170 burners are
supplied for On/Off or High/Low
operation and for use with single
phase electrical supply. Where an
instruction or information is
applicable to only one of the burner
types, single or two stage, then this
is indicated in the text.
This manual is structured to enable
theuser toproceed fromthe delivery
of the burner to its commissioning
and use.
The conditions to be fulfilled and the
controlsand adjustments tobe used
are dealt with in the sequence that
should be followed for the correct
assembly installation and use.
Commissioning procedures are
described and the location of
necessarycontrols andadjustments
to undertake these runs are
illustrated and supported by
appropriate tabular matter and
graphs.
Routine Maintenance and Fault
Finding complete the manual;
literatureon proprietarycomponents
isavailable onrequest.
SETTINGCOMBUSTIONHEAD
The venturi flame ring assembly is
adjustable longitudinally so that the
restriction between the air diffuser
and the throat of the flame tube
effectivelymeters the combustionair
and therefore the assembly should
be set to approximately the position
corresponding to the required gas
rate.
Method of Adjustment
Undo the two safety bolts of the
hinged extension.
Remove one hinge pin on the
opposite side to that which it is
required to swing the burner.
Unplug any electrical connections
that are restricting movement.
Swing the burner body away slowly,
at the same time unclipping the
ignitionand flame detector leads.
Undo the lock nut clamping bolt.
Lift out the venturi flame ring
assembly.
Undo the socket set screw.
Adjust the position of the assembly
inthesocket of thesupportingelbow
aligning the required scribed ring
against the end of the socket.
The positon is relative to the firing
rate of the burner, the graph below
showstherelation betweenthehead
setting and burner output.
Securethe assemblyand replacein
reverse order taking care that the
assembly sits squarely on the gas
inlet spigot and is squarely locked
in position by its clamping bolt, and
that the burner is swung back into
position the ignition and flame
detector leads are carefully clipped
back on their respective electrodes
(the terminal ends are dissimilar so
that they cannot be wrongly
connected).
BURNERAIRCONTROLS
The air for combustion is controlled
by an adjustable air flap located
inside the air inlet on the right hand
side of the burner viewed from the
rear.
Itspurpose is toregulate and control
thevolume ofcombustion airflowing
throughthe burner.
Onallburnerstheairadjustmentcan
be made with or without the cover
fitted with the use of an Allen key.
There is a visible scale to assist in
the setting of combustion air, it is
numberedbetween1and22.
Finalfineadjustmentmustbemade
withthecoveron.
Air Diffuser
The air diffuser is fitted to the front
end of the inner assembly and
located within the flame tube.
Itcontrols thevolume ofcombustion
airand creates apressure drop over
theburner head toensure goodfuel/
air mixing and flame stability.
Burner Output (kW)
H
e
a
d
S
e
t
t
i
n
g
HeadSetting
SG100
C
h
a
m
b
e
r
Resistance (mbar)
SG170
VENTURIHEADSETTING

BURNERGASCONTROLS
Low Gas Pressure Switch
The low gas pressure switch is
located on the inlet side of the gas
valve. It is required to monitor inlet
gaspressureduringburneroperation.
Thelow gas pressureswitch iswired
in series with the appliance
controlling instruments and in the
event of gas pressure failure will
cause the burner to effect a safety
shut down.
Isolate the burner and remove the
gas pressure switch cover. Switch
ontheelectricalsupplyandallowthe
burnertoestablishmainflame.Slowly
turn the adjustment dial on the gas
pressure switch clockwise until the
flameisextinguishedandtheburner
shuts down. Turn the dial slowly
anticlockwiseone division ata time
until the burner restarts and
establishesmainflame.Recheckthe
performanceandthenturnthediala
further two divisions anticlockwise.
Switchofftheburnerandreplacethe
gas pressure switch cover.
Gas Valve Multibloc - Single
Stage (On/Off)
Thegasvalveisofthemultibloctype
incorporating start rate, safety and
main valves and pressure governor.
Valveadjustmentsaredetailedinthe
Gas Controls and Adjustments
section.
SG10060602
Two Stage (High/Low)
Thegasvalveisofthemultibloctype
incorporating startrate,safetyandtwo
stage valve and pressure governor.
Valveadjustmentsaredetailedinthe
GasControlsandAdjustmentsection.
FLAMEMONITOR
Probe
Theflame probe (flame rectification
probe)is locatedon theburner head
and is required to supervise the safe
operation of the burner under all
working conditions.
UV
As an option burners can be fitted
with an ultraviolet cell (UV) cell to
detect the presence of the flame.
BURNEROPERATING
SEQUENCE
Single Stage (On/Off) Burners
Theoperating sequence beginswith
apre-purgeon fullair,then startrate
gasflame which whenproved allows
theburnerto operate onmainflame,
then to the “OFF” position after the
heatinput issatisfied. Theoperation
is determined by demand of the
appliance control instruments.
GENERAL INSTRUCTIONS continued......
Two Stage (High/Low) Burners
Thesequencebeginswithanair pre-
purgeonfullair,followedbystart rate
gasflame which whenproved allows
the burner to operate on High/Low/
Off. The operation is determined by
the demand of the appliance control
instruments.
FLUEANDCHIMNEY
REQUIREMENTS
Thetop of theChimney/Flue should
be above all roofs within a radius of
10 metres.
Check that it is suitable for use with
gas fired appliances. Reference
should be made to Local Authority
andother regulations governingsuch
installations.
Ensure that the flue pipe from the
appliancedoes notprotrude intothe
chimney beyond the wall thickness
and is sealed throughout its run.
If more than one appliance is
connected to a common flue/
chimney, ensure that the cross
section of the flue/chimney is
adequatefor thetotal volumeof flue
gases from all the appliances.
PLANT ROOM VENTILATION
An adequate supply of dust free,
fresh air is required for the burner at
bothhighandlowlevelinaccordance
with the appropriate standards.
GAS SUPPLY
The gas supply to the burner must
be constructed and installed to
comply with local conditions and
appropriateCodes and Standards. It
should be of sufficient size to satisfy
thepressure/volumerequirements of
the burner to ensure its operation.
Itisessentialthata90°manual shut-
off is fitted upstream of the burner
gastrainfortheisolationoftheburner
duringservicing andmaintenance.
Thevalvesize mustnotbe lessthan
the burner valve train or create
restriction to gas flow.

BURNER GAS CONTROLS & ADJUSTMENTS
SINGLE STAGE (ON/OFF) USING PILOT GAS - MULTIBLOC MB-DLE 405-412 B07
Includesgas pressure governor, safety, main andstartgas valves.
SINGLE STAGE (ON/OFF) MAIN GAS IGNITION - MULTIBLOC MB-DLE 405-412 B01
Containsgaspressure governor, safety,andmain gasvalves.
ADJUSTMENTS
A Governoradjustment (mainand pilot). Turn clockwise to increase
pressure.Range 4-20 mbar.
B Start gas rate (B07 valve only). Turn anticlockwise to increase
and clockwise to decrease rate.
C Mainvalve. Fast initiallift adjuster.
D Main gas adjustment. Slacken cheesehead screw, and turn the
fluted knob anticlockwise to open, clockwise to close.
E Lowgas pressure switch (Optional).
F Upstreamtestpoint.
G Downstreamtestpoint.
TWO STAGE (HIGH/LOW) USING PILOT GAS - MULTBLOC MB-ZRDLE 405-412 B07
Includesgas pressuregovernor, safety,two positionmain andpilot valves.
TWO STAGE (ON/OFF) USING MAIN GAS IGNITION - MULTIBLOC MB-ZRDLE 405-412 B01
Includesgas pressuregovernor, safety,two mainand startgas valves.
ADJUSTMENTS
A Governoradjustment formain flame.Turn clockwiseto increase
pressure.Range 3 -20 mbar.
B Start gas rate (B07 valve only). Turn anticlockwise to increase and
clockwise to decrease rate.
C Main valve - first and second stage - fast initial lift adjuster.
D Highflame throughput adjustment.Slacken offlocking screw, turn
anticlockwise to increase and clockwise to decrease rate.
E Low flame throughput adjustment, as in D.
F Lowpressure gas switch (Optional).
G Upstreamtestpoint.
H Downstreamtestpoint.
GASMULTIBLOCKSCHEMATIC
AD
EFBGC
AEC
B
H
D
G
F
1 3
V1 V2
V3
5
2
4
V1 - Valve 1
V2 - Valve 2 - Single Stage (MB-D) or Two Stage(MB-
Z)
V3 - Pilot Valve (B07 Only)
1 - Pressure Switch (Optional)
2 - Regulator
3 - Restrictor
4 - Filter
5 - Inlet connection
SG10070501

SG10080501
CONTROL BOX
DMG970
INTRODUCTION
TheburnercontrolboxDMG970controlsandsupervisesforceddraughtburnersforgasanddualfuel.
Themicroprocessorprogrammingsequenceensuresextremelystabletimingsindependentofvoltagevariations,
ambient temperature and/or switch-on cycles. The built-in information system not only provides a continuous
monitoring of the actual state of the box (including monitoring of the start-up phase) but also informs about the
possible cause of a lockout. The lockout cause is stored in such a way that it can be retrieved even after a power
failure.
The control box is designed for maximum safety in case of fluctuations in the voltage supply. If the mains voltage
drops below the permitted level, operation is interrupted and the control box automatically prevents the start
sequencefrombeingrepeated.Inthisway,thesafetyofthesystemisnotputatriskbyadropinthemainsvoltage.
Thislow-voltageprotectionworksnotonlyduringstart-upbutalsopermanentlyduringoperation.
LOCK-OUTIDENTIFICATION
InthecaseofafailuretheLEDispermanentlyilluminated.Every10secondstheilluminationisinterruptedbyaflash
codewhichindicatesthe cause oftheerror.The following sequenceisperformedand is thenrepeatedaslongas
the unit is not reset.
FLASHCODES
ERROR MESSAGE POSSIBLE FAULT
within lock out safety time no
flame establishment
stray light during startup
detector may be faulty
loss of flame
stray light
air pressure switch opened
during operation
loss of flame during operation
air pressure switch contact
welded
air pressure switch timeout air pressure switch does not
close within specified time
FLASH CODE
air pressure switch opened
lock out safety time
air pressure switch closed
illuminated phase dark phase Flash-Code dark phase
for 10 sec for 0.6 sec for 1.2 sec
SEQUENCETIMINGS
tlw Max. reaction time for air
proving switch 60
tv1 Supervised pre-purge time 40
tvz Pre-ignition time 3
tz Ignition time total 5.5
ts Safety time 3
tv2 Delay 2nd-stage 12.5
SEGMENT OPERATION DURATION (S)
tlw
tv1
tvz
tz ts
tv2

ThecapacityofSelectosSG burners
using natural gas has been
determined at a minimum supply
pressureof17.8mbar(max40mbar).
ForLPG the supplypressure should
bebetween 25mbar and40mbar.
These burners will operate
satisfactorily on gas supply
pressures lower than those quoted
above, but burner capacity will be
reduced accordingly.
Any LPG high pressure regulator
fitted must be equiped with over
pressureshut offprotection.
Turnoffthegas supplyatthemanual
shut off valve upstream of the gas
valveinlet.
Fitan approved pressuremeasuring
instrument at the pressure test point
ontheinletof thegasMultiBloc.Turn
on the gas supply. Check gas
pressure, this will record static
pressure which will be higher than
running pressure, which should not
beless than17.8mbar whenrunning
on main flame.
INNERASSEMBLY
Ensure that the ignition electrode
and ionisation probe are correctly
adjusted. Correct positioning is
shown on the Component
Identification page.
Ensure that the head has been
positionedaccordingtothegasrate.
GASTYPE
Ensurethattheburnerheadiscorrect
forthetypeofgastobeused.Check
theburnerdataplate.
PURGING
The gas line is purged by loosening
the screw on the inlet pressure test
nipple. Connect a plastic hose and
conduct the gas into atmosphere.
Afterpurgingthe gaslinere-tighten
the screw.
LEAKAGETESTING
When making a leak test of the gas
supplysystemthegasvalveshould
beclosed.Connectapressuregauge
to the test nipple on the gas valve.
The test pressure in the system
should be 1.5 x maximum inlet
pressure or minimum 150 mbar. If
there is any leakage, locate the
sourcebymeansofsoapywaterora
leakdetectionspray.Aftertightening
repeat the test
DRYRUN
Turn off the electricity supply to the
burner. Close the manual gas shut-
offvalve.
Topreventthegaspressure(iffitted)
switchfromlockingout,removethe
coverandfitatemporarylink.
Adjust the thermostats to call for
heat and switch on the electrical
supplytotheburner,thepre-purging
periodwillbegin(24-40seconds).At
theendofthisperiodthepre-ignition
period starts (3 seconds).
Thegasvalveisenergizedandopens
andtheflamewouldbeestablished.
At the end of the safety time (3 to 5
seconds) the control box will go to
lockout. The gas valve will be de-
energised and the motor will stop
running.Thedryrunis complete.
Ensure to remove the link from the
gas pressure switch after the test is
finished.
PRE-COMMISSIONING CHECKS
IMPORTANT
Aftereachadjustment, the gasflow rate andfluegas analysis shouldbe checked.
ALWAYS
Useapprovedtest equipment(Continuallymonitoringelectronic equipmentisrecommended).
NEVER
Relyona visualinspection oftheflame asa guide tocombustion quality.
SG10090501