Nu-Way GB 535 Instruction Manual

Installation & Maintenance Manual
GB 535 / GB 540
GB 3160 / GB 3500
Gas Booster
11/12
Tel:[phone] Fax: [phone] Email: [email protected] Web: www.nu-way.co.uk

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Contents
Contents
GENERAL............................................................................................................................................... 3
OPERATION........................................................................................................................................... 3
ELECTRICAL.......................................................................................................................................... 3
SPARES & COMPONENTS.................................................................................................................... 3
OPTIONAL EXTRAS............................................................................................................................... 3
BOOSTER / BURNER OPERATING MODES ......................................................................................... 4
Single Booster / Burner Operation ....................................................................................................... 4
Single Booster/Multi Burner Operation................................................................................................. 4
Automatic Twin Duty Standby Operation ............................................................................................. 4
GAS BOOSTER DIMENSIONS............................................................................................................... 5
INSTALLATION INSTRUCTIONS ........................................................................................................... 7
Safety .................................................................................................................................................. 7
Delivery ............................................................................................................................................... 7
Installation ........................................................................................................................................... 7
Gas Booster Anti-Vibration Kit ............................................................................................................. 8
Electrical Installation ............................................................................................................................ 8
GAS PRESSURE SWITCHES ................................................................................................................ 9
Inlet Gas Pressure Switch.................................................................................................................... 9
Outlet Gas Pressure Switch................................................................................................................. 9
MAINTENANCE .................................................................................................................................... 10
Replacement of the Fan Bearing Assembly ....................................................................................... 10
Drive Motor........................................................................................................................................ 10
Drive Belt........................................................................................................................................... 10
Belt and Pulley Replacements ........................................................................................................... 11
OPTIONAL EXTRAS............................................................................................................................. 12
Acoustic Cover .................................................................................................................................. 12
Gas Booster Reservoir....................................................................................................................... 13
SLOW PRESSURE RAMP UP AND SPEED CONTROL OPTIONS ..................................................... 14
INTRODUCTION ............................................................................................................................... 14
GAS BOOSTER INVERTER DRIVE SYSTEM INSTALLATION GUIDELINES .................................. 14
PRESSURE TRANSDUCER INSTALLATION SCHEMATIC ............................................................. 14
GB3160 / GB3500 VSD GENERAL ARRANGEMENT....................................................................... 15
SLOW PRESSURE RAMP UP INVERTER CONTROL AND OPERATION ....................................... 15
SPEED CONTROL INVERTER CONTROL AND OPERATION......................................................... 15
SET UP PROCEDURE FOR DANFOSS VLT MICRO DRIVE............................................................ 16
VSD Booster FC51 VLT Microdrive Parameters ................................................................................ 17
ELECTRICAL DATA.............................................................................................................................. 17
PERFORMANCE GRAPH..................................................................................................................... 18

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GENERAL
A gas booster is required on installations where the required gas burner supply pressure falls below the
minimum required for the appliance to achieve full output.
Only qualified gas operatives holding ACS CBHP1 can carry out work on gas boosters this
includes changing gas booster belts. Anyone not holding ACS CBHP1 MUST NOT work on a gas
booster as this is classed as interfering with a gas supply in accordance with The Gas Safety
(Installations & Use) Regulations 1988.
Nu-way gas boosters are suitable for use with both natural and clean, dry manufactured gases, giving
the performance shown on page 10. The ma imum ambient temperature should not e ceed 40°C.
Boosters are supplied with an Anti-Vibration Kit as standard.
OPERATION
The booster control enables the booster to work automatically. Gas flow through the booster is required
to stop any e cessive increase in operating temperature and we recommend that the booster should
only operate in conjunction with the burner. Prolonged periods of operation without any gas flow will
cause an increase in temperature, shortening the life of the booster and increasing service frequency. If
however the plant is required to work under such conditions, consideration should be given to the use of
a purpose-designed bypass to dissipate the e cess heat and the installation of a twin duty standby
system to allow for regular inspection. Where a standby booster is fitted, it should be operated regularly
or in rotation. If the booster is operating in rotation auto cycling may have been installed as an option.
Model GB 540 may show some degree of instability of gas flow at very low rates of throughput, or, when
this booster serves a long and involved system of pipework. If this situation is anticipated a controlled
bypass will overcome the problem.
ELECTRICAL
All models are designed to operate with a 3-phase 400 Volt 50Hz electrical supply, the GB 3160 is also
available to suit a single-phase 230Volt 50Hz supply.
Earthing
The anti-vibration mountings effectively insulate the booster unit from the floor and a proper earth
connection should be made.
SPARES & COMPONENTS
A full range of spare parts is readily available, should they be needed.
To assist with identification, the full data plate details should be supplied when ordering any spares,
including if the unit is three or single phase (GB 3160 only).
OPTIONAL EXTRAS
• Acoustic Covers
These are available for all boosters should they be required. For dimensional detail see the Optional
E tras section.
• Gas Booster Pressure Reservoir
• Non-Return Valves

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BOOSTER / BURNER OPERATING MODES
Single Booster / Burner Operation
The unit is supplied with all controls fitted and pre-wired, they include a motor starter, inlet gas pressure
switch, outlet gas pressure switch, and all necessary burner interlocks needed for a single booster/burner
operation.
However, a manual isolating valve (not supplied by Nu-way) must be fitted immediately before the
fle ible inlet coupling.
Single Booster/Multi Burner Operation
The unit is supplied with all the controls pre-wired and fitted, they include a motor starter, inlet gas
pressure switch, outlet gas pressure switch, and all necessary burner interlocks needed for a single
booster with up to four burners in operation.
However, a manual isolating valve, not supplied by Nu-way, must be fitted immediately before the
fle ible inlet coupling.
Automatic Twin Duty Standby Operation
This system comprises of two gas boosters and a separate control panel.
One hand reset inlet gas pressure switch and one gas pressure switch are fitted to each booster.
The pressure switches are to be wired to the control panel in accordance with the wiring diagram
supplied with the booster.
All necessary electrical equipment needed for the operation of two boosters with up to four burners in
operation is contained within the control panel. Changeover to the standby booster in the event of a
failure of the booster is automatic.
Manual isolating valves and non-return valves (not supplied by Nu-way) must be fitted to comply with
IGE/UP/2.
Note: Non-return valves are available from Nu-way.
Single Booster / Multi Burner Automatic Twin Booster Duty & Standby

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GAS BOOSTER DIMENSIONS
GB 3160 & GB 3500 (Single Booster with Panel)
Dimensions (mm)
Approximate Dimensions (mm) for separate panels
Operation Height Width Depth
Automatic twin duty standby 500 500 500

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GB 540/1
-
3 (Single Booster with Panel)
Dimensions (mm)

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INSTALLATION INSTRUCTIONS
Safety
Boosters are tested for gas tightness during manufacture using air pressure and should be protected
from any hydraulic pressure when testing on site. Hydraulic pressure applied to the fan chamber will
result in damage to the bearing assembly.
This unit is specially designed for ease and speed of on-site installation. It has been run and is pressure
tested ready to fit. Note that all usual safety precautions must be taken when fitting this appliance. In
the UK it must be installed and maintained by a Gas Safe registered engineer. In e port markets it must
be installed by qualified personnel according to local legal requirements and regulations.
The fact that gas boosters have been installed and operated for many years does not guarantee a
safe and adequate installation. As with all engineering units regular maintenance and checks are
essential.
Delivery
Check the booster and ancillary equipment to ensure that damage has not occurred during transit.
Installation
Boosters and all ancillary equipment should be installed to meet the requirements of all relevant
standards and practices, including the Institute of Gas Engineers Publication IGE/UP/2.
It is recommended that Nu-way gas boosters are positioned as close to the combustion equipment as is
reasonably possible, in non-hazardous atmospheres where the ambient temperature will not e ceed
40°C, but must not be installed in governor or meter rooms.
The installation site must be well ventilated but free of e cessive dust and have sufficient free area
around the booster for servicing. The booster should be placed on a firm, flat and horizontal surface
using anti-vibration mountings, and all connecting pipework should be well supported and accurately
positioned to prevent strain on the casing.
Fle ible inlet and outlet connectors must be fitted between the booster ports and the pipework, these
will serve to eliminate strain on the case and reduce noise during operation. Stress should not be put
onto the gas booster casing by using fi ed pipework to the inlet and outlet connections.
Anti-vibration mountings must be used.
Abrasive particles and dust from building operations are particularly harmful to this equipment and
under such conditions the unit should be regularly cleaned, particularly the belt and pulleys.
The pipework and fittings adjacent to the booster should be sized to give minimum pressure loss.
(Details of pressure loss through fle ible connectors can be found on page 10).
Pressure switches and test points should not be sited in areas of e cessive turbulence.
Electrical connections to the motor terminal bo should terminate in a short length of fle ible conduit to
ensure free movement of the motor platform.

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Gas Booster Anti Vibration Kit
General
The Nu-way gas booster anti-vibration kit is standard supply. For a twin duty standby unit, two kits will
be required.
Installation
Fle ible connections and anti-vibration mountings should be installed in accordance with Codes of
Practice.
Note: Fle ible connections are NOT designed to take up large amounts of misalignment; they are being
supplied in this instance as anti-vibration devices only.
Kit Contents
1 off Inlet Fle ible Connector
1 off Outlet Fle ible Connector
2 off Inlet Gasket
2 off Outlet Gasket
4 off Anti-Vibration Mountings
4 off M8 Set Pin and Washer
4 off M12 Set Pin and Nut
8 off M8 30 Rawl Plug Thrubolt
Electrical Installation
Always ensure that the motor data plate details coincide with the electricity supply.
Electric cables should terminate in short lengths of fle ible conduit before entering the booster terminal
bo .
A correctly sized fuse must be fitted.
Check the rotation of the motor. This should be clockwise when viewed from the rear of the motor, do
not however run the booster with inlet and outlet in free air as this may overload the motor. Check that
the movement of the motor platform is not restricted.
Check the wiring scheme allows the booster to operate as recommended in the Operation section of this
manual on page 1.

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GAS PRESSURE SWITCHES
The booster is supplied with gas pressure switches (as required), they are either fitted to the rear of the
control panel, or in the case of duty standby systems mounted on a bracket above the booster.
The purpose of the switches is to monitor the inlet and outlet pressures. Adjustment of the switches is
achieved by removal of the clear plastic cover and turning the dial to the required setting. They should
be adjusted as follows:-
Inlet Gas Pressure Switch
This hand reset type switch is a mandatory requirement and MUST NOT be set below the statutory
(UK) minimum of 10 mbar.
In use, this switch will stop the booster should the inlet gas supply pressure fall below 10 mbar. An
indication of failure is given both within the switch and on top of the electrical panel, also a facility for
remote indication is provided.
Manual resetting of this switch is required when the gas pressure is restored; this is achieved by pressing
the red button via the small soft plastic panel in the lid.
If problems are e perienced due to a momentary low pressure when the plant starts up, a booster inlet
reservoir may be required, see detail on page 8.
Outlet Gas Pressure Switch
This switch is not a mandatory requirement but it is provided on duty & standby units to initiate the
changeover if the lead booster fails.
On stand-alone boosters the outlet pressure switch can be added as an e tra should indication of low
outlet pressure be required.
To adjust this switch fit a manometer to register the outlet pressure being boosted when the burners are
all at high fire, the switch should then be adjusted to between 80% and 90% of this pressure.
An indication of a failure is given at the top of the electrical panel, also a facility for remote indication is
provided. Reset is automatic when the outlet pressure is restored.
Note: When used within twin booster standby systems the switches must be fitted between the
booster outlet and the non-return valve.

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MAINTENANCE
Experience has shown that maintenance of booster units can be overlooked or undertaken in an
inadequate manner. Such practice can lead to the failure of the bearing and fan units.
It is essential that a regular inspection is completed, that the booster is kept in a safe working order and
maintained in accordance with good engineering practice.
Particular attention should be paid to the bearings, fan seals, and drive elements.
Replacement of the Fan Bearing Assembly
It is not possible to e tract the fan, bearings or other parts of the fan assembly without causing damage
and seriously impairing the safety of this high speed unit. The fan bearings and gas seals are of
particular importance and have an estimated life of three to five years. The bearings are lubricated for
this life e pectancy and must not have further lubrication applied.
Normally, the first sign of bearing failure is an increase of operational noise or vibration. Further
e amination can be made of the radial and a ial movement of the impeller shaft, however this requires
the removal of the guard and belt. The relevant instructions given on page 7 should be consulted.
When the fan assembly requires replacement the complete Nu-way unit must be substituted and fitted
in accordance with the instructions supplied with the kit. Care must be taken not to over-tighten the
bearing securing nuts as this can damage the fan chamber.
For replacement, we recommend the use of the Nu-way kits:-
Model Part Number
GB 3160 / GB 3500 U90993N
GB 540 G10016Y
The kits comprise of a sealed and pre-tested fan unit with drive pulley, inlet and outlet gaskets, together
with pressure switch pipework to convert older models of booster.
Drive Motor
Life sealed bearings are fitted and no maintenance is required until they need replacing.
Drive Belt
The drive belt and pulleys should be kept clean, free from grease or dirt, and replaced on an annual basis
or immediately if wear or damage is found.
Do not apply a belt dressing under any circumstances.
The motor mounting assembly ensures correct belt tension, the spring supporting the motor platform is
factory set and must not be tampered with.
If the drive belt is thrown from its pulley this could indicate possible bearing wear or other malfunction
in the booster drive system which must be investigated and corrected. The flat belt drive is a safety
feature and therefore alternative types or sizes of pulley must not be fitted under any circumstances. To
obtain replacement belts quote the booster model number.