Nu-Way NG2 Instruction Manual

Installation & Maintenance Manual
Series NG fully automatic gas burner
Model NG2
Gas Burner
11/12
Tel:[phone] Fax: [phone] Email: [email protected] Web: www.nu-way.co.uk

Model NG2 Revision 210798APage 2
CC
CC
CONTENTSONTENTS
ONTENTSONTENTS
ONTENTS
FF
FF
FEAEA
EAEA
EATURESTURES
TURESTURES
TURES 33
33
3
Burner Capacity 3
The NG Series 3
Construction 3
Air Regulation 3
Controls 3
Operation 3
Fuel 3
Approx. Weight 3
GG
GG
GENERALENERAL
ENERALENERAL
ENERAL 33
33
3
Flue and Chimney Requirements 3
Plant Room Ventilation 3
Existing Appliances 3
BB
BB
BURNERURNER
URNERURNER
URNER & C& C
& C& C
& COMPONENTOMPONENT
OMPONENTOMPONENT
OMPONENT II
II
IDENTIFICDENTIFIC
DENTIFICDENTIFIC
DENTIFICAA
AA
ATIONTION
TIONTION
TION 44
44
4
Combustion Chamber Conditions 5
SS
SS
SERVICEERVICE
ERVICEERVICE
ERVICE & S& S
& S& S
& SITEITE
ITEITE
ITE CC
CC
CONDITIONSONDITIONS
ONDITIONSONDITIONS
ONDITIONS 55
55
5
Gas Supply 5
Pressure Required at Burner Governor 5
Electrical Power Supply 5
PP
PP
PACKACK
ACKACK
ACKAGINGAGING
AGINGAGING
AGING FF
FF
FOROR
OROR
OR TT
TT
TRANSITRANSIT
RANSITRANSIT
RANSIT 55
55
5
Assembly 5
II
II
INSTNST
NSTNST
NSTALLALL
ALLALL
ALLAA
AA
ATIONTION
TIONTION
TION 55
55
5
General 5
Fitting To Appliance 5
Connecting The Electrical Supply 5
Connecting The Gas Supply 5
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BURNERURNER
URNERURNER
URNER AA
AA
AIRIR
IRIR
IR CC
CC
CONTROLSONTROLS
ONTROLSONTROLS
ONTROLS & A& A
& A& A
& ADJUSTMENTSDJUSTMENTS
DJUSTMENTSDJUSTMENTS
DJUSTMENTS 66
66
6
Air Controls 6
Air Diffuser 6
Air Proving Switch 6
BB
BB
BURNERURNER
URNERURNER
URNER GG
GG
GASAS
ASAS
AS CC
CC
CONTROLSONTROLS
ONTROLSONTROLS
ONTROLS & A& A
& A& A
& ADJUSTMENTSDJUSTMENTS
DJUSTMENTSDJUSTMENTS
DJUSTMENTS 66
66
6
Gas Nozzle 6
Low Gas Pressure Switch 6
Gas Valve Multibloc 7
EE
EE
EMERGENCYMERGENCY
MERGENCYMERGENCY
MERGENCY II
II
INSTRUCTIONSNSTRUCTIONS
NSTRUCTIONSNSTRUCTIONS
NSTRUCTIONS 77
77
7
CC
CC
COMMISSIONINGOMMISSIONING
OMMISSIONINGOMMISSIONING
OMMISSIONING TT
TT
THEHE
HEHE
HE BB
BB
BURNERURNER
URNERURNER
URNER 77
77
7
Pre-commissioning checks 7
Pre-Commissioning (Dry Run) 8
Air Control 8
Control 8
Switch On Electricity Supply 8
Main Gas Pressure Governor 8
Commissioning - Live Run 8
Check For Valve Closure 8
Testing Main Flame 8
Setting Main Flame Gas Rate 9
Combustion Air Settings 9
Setting The Step Start Facillity 9
Air Pressure Switch Setting 9
Low Gas Pressure Switch Setting 9
Final Check 10
Commissioning Is Now Complete 10
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COMMISSIONINGOMMISSIONING
OMMISSIONINGOMMISSIONING
OMMISSIONING & R& R
& R& R
& ROUTINEOUTINE
OUTINEOUTINE
OUTINE SS
SS
SAFETYAFETY
AFETYAFETY
AFETY CC
CC
CHECKSHECKS
HECKSHECKS
HECKS 1010
1010
10
Flame Detection System 10
Routine Maintenance 10
Combustion Air Fan 10
Inner Assembly 10
Air Diffuser And Gas Nozzle 10
Ignition Electrode and Probe 10
Draught Tube and Swirler 10
FF
FF
FAA
AA
AULUL
ULUL
ULTT
TT
TFF
FF
FINDINGINDING
INDINGINDING
INDING 1010
1010
10
Burner Motor Fails To Start 10
Fan Starts And Burner Goes To Lockout 10
CC
CC
COMMISSIONINGOMMISSIONING
OMMISSIONINGOMMISSIONING
OMMISSIONING SS
SS
SHEETHEET
HEETHEET
HEET 1111
1111
11
BB
BB
BURNERURNER
URNERURNER
URNER MM
MM
MODIFICODIFIC
ODIFICODIFIC
ODIFICAA
AA
ATIONTION
TIONTION
TION RR
RR
RECORDECORD
ECORDECORD
ECORD 1212
1212
12
AA
AA
APPENDIXPPENDIX
PPENDIXPPENDIX
PPENDIX 1313
1313
13
Technical Specifications 13
Combustion Head Details 13
Landis & Gyr Control Wiring Diagram 14
Satronic Control Wiring Diagram 15
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 blown gas burner commissioning. In the U.K. it is a legal requirement
that these engineers should also be CORGI registered. The manufacturer cannot be held
responsible for any consequential damage, loss or personal injury as a result of customers
failing to follow these instructions, or as a result of misuse.
EE
EE
EUROPEANUROPEAN
UROPEANUROPEAN
UROPEAN BB
BB
BOILEROILER
OILEROILER
OILER EE
EE
EFFICIENCYFFICIENCY
FFICIENCYFFICIENCY
FFICIENCY DD
DD
DIRECTIVEIRECTIVE
IRECTIVEIRECTIVE
IRECTIVE (B.E.D.)(B.E.D.)
(B.E.D.)(B.E.D.)
(B.E.D.)
All burners and boiler bodies marked 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 manufacturers instructions, and these
must include flue gas temperaturesm average water temperature, and CO2or O2concentration.

Page 3
Model NG2 Revision 210798A
FF
FF
FEAEA
EAEA
EATURESTURES
TURESTURES
TURES
Burner Capacity
NGN2
14kW to 62 kW
(Based on the following gross C. V.
Natural Gas 38.56 MJ/M3
Liquid Petroleum Gas 92.60 MJ/M3)
The NG Series
Developed from field experiences in the UK and
overseas markets, the NG series sets new stand-
ards in efficient and reliable operation, developed
to current and future test authority requirements
in UK and overseas markets, and delivered ready
to install with prepared packaged control system
and simple plug in gas train arrangements.
Construction
A monobloc metric design, using fastenings to ISO
standards. Suitable for flange mounting. The burner
can be easily removed for servicing, the fan and
inner assembly are accessible by removing the
cover plate.
Air Regulation
Air for combustion can be adjusted to give maxi-
mum efficiency. A patented air control device pro-
duces smooth start conditions.
Controls
Flame supervision is by ionisation probe and au-
tomatic sequence control.
Operation
Single stage (On/Off) operation only.
Fuel
Natural Gas at 17.5 mbar.
Liquid Petroleum Gas at 20.0 mbar.
Approx. Weight
9 kg.
GG
GG
GENERALENERAL
ENERALENERAL
ENERAL
This manual is structured to enable the user to pro-
ceed from the delivery of the burner to its com-
missioning and use. The conditions to be fulfilled
and the controls and adjustments to be used are
dealt with in the sequence that should be followed
for the correct assembly installation and use. Pre-
commissioning (Dry Run) and Live Run are de-
scribed and the location of necessary controls and
adjustments to undertake these runs are illustrated
and supported by appropriate tabular matter and
graphs. Routine Maintenance, Fault Finding, Spares
Parts identification and Wiring Diagrams complete
the manual; literature on proprietary components
is available on request.
Check and identify that the burner type is appro-
priate for the appliance rating and fuel type. De-
tailed burner performance data is given in the tech-
nical specifications section at the back of this hand-
book. Under no circumstances attempt to install
or commission a burner of the incorrect fuel type.
If in doubt please contact the manufacturer for as-
sistance.
Flue and Chimney Requirements
The top of the chimney/flue should be above all
roofs within a radius of 10 metres. Check that it is
suitable for use with gas fired appliances. Refer-
ence should be made to Local Authority and other
regulations governing such installations. Ensure that
the flue pipe from the appliance does not protrude
into the chimney beyond the wall thickness. If more
than one appliance is connected to a common flue/
chimney, ensure that the cross section of the flue/
chimney is adequate for the total volume of flue
gases from all the appliances.
Plant Room Ventilation
An adequate dust free supply of fresh air is required
for the burner at both high and low level in ac-
cordance with the appropriate standards.
Existing Appliances
In preparing the appliance to receive the NG gas
burner a careful inspection should be made of its
condition. If in doubt as to its suitability for gas
firing refer to the appliance manufacturer. In pre-
paring the appliance for gas firing it should be
cleaned thoroughly removing all adhering tars, scale
and dirt.

Model NG2 Revision 210798APage 4
Item Description
1Burner Body
2Draught Tube
3Fan Motor
4Mounting Flange
5Air Pressure Switch
6Sequence
Control Box
7Gas Multibloc Valve
8Adjustable Air Inlet
9Air Sensing Probe
10 Ignition Unit
11 Gas Inlet
Pressure Switch
BB BB
BURNERURNER
URNERURNER
URNER & C& C
& C& C
& COMPONENTOMPONENT
OMPONENTOMPONENT
OMPONENT II
II
IDENTIFICDENTIFIC
DENTIFICDENTIFIC
DENTIFICAA
AA
ATIONTION
TIONTION
TION

Page 5
Model NG2 Revision 210798A
Combustion Chamber Conditions
When the burner is fitted to an appliance designed
to work under balanced or negative combustion
chamber conditions, the over fire draught must not
exceed 0.25 mbar.
Should the over fire draught exceed this figure,
then steps should be taken to reduce it to this level.
SS
SS
SERVICEERVICE
ERVICEERVICE
ERVICE & S& S
& S& S
& SITEITE
ITEITE
ITE CC
CC
CONDITIONSONDITIONS
ONDITIONSONDITIONS
ONDITIONS
Gas Supply
The piped gas supply to the burner must be con-
structed and installed to comply with local condi-
tions and appropriate codes and standards. All
pipework must be firmly supported. It should be
of sufficient size to satisfy the pressure/volume re-
quirements of the burner to ensure its operation.
It is essential that a 90° manual shut-off is fitted
upstream of the burner connection for the isola-
tion of the burner during servicing and maintenance.
The valve size must not be less than the NG burner
valve train or create restriction to gas flow.
Pressure Required at Burner Governor
Natural Gas 17.5 mb
Liquid Petroleum Gas 20.0 mb
Max. allowable inlet pressure 34.8 mb
Electrical Power Supply
A single phase electrical supply to all applicable
codes and standards is required for the burner.
PP
PP
PACKACK
ACKACK
ACKAGINGAGING
AGINGAGING
AGING FF
FF
FOROR
OROR
OR TT
TT
TRANSITRANSIT
RANSITRANSIT
RANSIT
To safeguard against transit damage and for Export
shipment, the NG2 burner is despatched in a car-
ton.
Assembly
Remove the burner from the carton, it is necessary
to turn the double magnetic valve and governor
unit so that the magnetic coils are in the vertical
position, then tighten the pipe coupling at the end
of the valve. Two spanners should be used to avoid
straining the pipework. The burner is now com-
pletely assembled and ready for fitting to the ap-
pliance.
II
II
INSTNST
NSTNST
NSTALLALL
ALLALL
ALLAA
AA
ATIONTION
TIONTION
TION
General
Check and identify the burner type is appropriate
for the appliance rating. Detailed burner perform-
ance data is given in the Technical Specifications
section at the back of this handbook.
Fitting To Appliance
If the burner is to be fitted to a new packaged unit,
refer to the manufacturers recommendations. The
appliance should be prepared for mounting the
burner, using the flange provided (refer to the
Burner Fixing Details in the Burner & Component
Identification section on page 4). The draught tube
should be flush with the inner combustion cham-
ber wall face, or in accordance with the appliance
manufacturers requirements. If the burner is to be
used with an existing appliance, prepare the burner
mounting plate. Ensure that the joint between the
appliance and the burner is effectively sealed by
using the gasket provided.
Connecting The Electrical Supply
NG2 burners are currently available for use with
a 220V (-10%) 240V (+15%) / 1ph / 50Hz or
110-120V / 1ph / 50Hz supply.
Connect the electrical supply to the burner ob-
serving all applicable IEE Regulations. The incom-
ing live supply must be fused, not exceeding 5
amps.
Connect L, N, E and external auxiliary control cir-
cuits with reference to the connection diagram on
page 6.
Connecting The Gas Supply
Connect the gas supply to the gas valve inlet, ob-
serving all relevant regulations and standards.
The connection for NG2 is ½ BSP female.

Model NG2 Revision 210798APage 6
BB
BB
BURNERURNER
URNERURNER
URNER AA
AA
AIRIR
IRIR
IR CC
CC
CONTROLSONTROLS
ONTROLSONTROLS
ONTROLS & A& A
& A& A
& ADJUSTMENTSDJUSTMENTS
DJUSTMENTSDJUSTMENTS
DJUSTMENTS
Air Controls
The air control is by means of a rotary air strap
located on the right hand side of the burner viewed
from the rear. Its purpose is to regulate the volume
of combustion air flowing through the burner. To
increase the flow of combustion air turn the rotary
strap anticlockwise, viewed from the right hand
side of the burner. To decrease the flow of com-
bustion air, turn the rotary air strap clockwise
viewed from the same side.
Air Diffuser
The air diffuser is fitted to the front end of the in-
ner assembly and located within the flame tube.
The function of the air diffuser is to control the
volume of combustion air and create a pressure
drop over the burner head to ensure good fuel/air
mixing.
Air Proving Switch
The air pressure switch is located on the air inlet
box on the right hand side of the burner casing,
viewed from the rear. It is required to prove ad-
equate air flow throughout the burner operating
cycle. Air flow failure at any stage will result in safety
shutdown of the burner. Final adjustment of this
switch is described in the section Commissioning
The Burner.
BB
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BURNERURNER
URNERURNER
URNER GG
GG
GASAS
ASAS
AS CC
CC
CONTROLSONTROLS
ONTROLSONTROLS
ONTROLS &&
&&
&
AA
AA
ADJUSTMENTSDJUSTMENTS
DJUSTMENTSDJUSTMENTS
DJUSTMENTS
Gas Nozzle
The eight hole gas nozzle is fitted to the front end
of the inner assembly and located in the flame tube.
The holes in the gas nozzle are of a size to suit the
output of the particular burner model and gas type
being used.
Low Gas Pressure Switch
The low gas pressure switch is located on the inlet
side of the gas valve block on the left hand side of
the burner, viewed from the rear.It is required to
monitor inlet gas pressure during the burner oper-
ating cycle. Gas pressure failure at any stage will
result in safety shutdown of the burner. Final ad-
justment of this switch is described in the section
Commissioning The Burner.
Connection Diagram

Page 7
Model NG2 Revision 210798A
Gas Valve Multibloc
The gas valve is of the multibloc type incorporat-
ing safety and main valves and pressure governor.
Valve adjustments are detailed in the diagram Valve
Adjustment Diagram.
CC
CC
COMMISSIONINGOMMISSIONING
OMMISSIONINGOMMISSIONING
OMMISSIONING TT
TT
THEHE
HEHE
HE BB
BB
BURNERURNER
URNERURNER
URNER
Pre-commissioning checks
Before proceeding further, check that the appli-
ance is in a proper state to be fired, e.g. is there
water in the boiler?. Re-check that both gas and
electrical supplies to the burner are turned off.
Model kW MJ Kcal/h BTU/h Strap
Setting
A27 97 23000 92000 5
B31 111 26000 105000 5
C41 147 35000 139000 5
E54 194 46000 184000 5
F62 223 53000 211000 5
Initial Setting Table
Valve Adjustment Diagram
Upstream Test Point
Step Start Adjustment
Down
s
t
r
e
a
m
Te s t P o
i
n
t
Gas Inlet
G
o
v
e
r
n
o
r
A
d
j
u
s
t
m
e
n
t
IMPORTIMPORT
IMPORTIMPORT
IMPORTANT - SAFETYANT - SAFETY
ANT - SAFETYANT - SAFETY
ANT - SAFETY
It is essential that the following
instructions and adjustments are carried
out by qualified engineers that are
experienced in blown gas burner
commissioning. In the U.K. it is a legal
requirement that these engineers should
also be CORGI registered. The
manufacturer cannot be held responsible
for any consequential damage, loss or
personal injury as a result of customers
failing to follow these instructions, or as a
result of misuse.
EMERGENCY INSTRUCTIONSEMERGENCY INSTRUCTIONS
EMERGENCY INSTRUCTIONSEMERGENCY INSTRUCTIONS
EMERGENCY INSTRUCTIONS
This product has been designed and
constructed to meet all of the essential
requirements of the GAS APPLIANCE
DIRECTIVE 90/396/EEC and under
normal circumstances should not give
occasion to any hazardous conditions. If
such a condition should occur during
commissioning or subsequent use of this
product, be it a fault of the burner, the
appliance or of any instrument, machine
or service in the proximity of the burner,
then the GAS and ELECTRICITY supply
to the burner should be IMMEDIATELY
ISOLATED until such time that the fault
has been investigated and rectified.

Model NG2 Revision 210798APage 8
Pre-Commissioning (Dry Run)
The NG2 burner is supplied for single stage (On/
Off) operation only. Flame supervision is by recti-
fication probe. The operating sequence begins with
an air pre-purge followed by start rate gas flame
followed by main flame, then to the OFF posi-
tion when the appliance has reached operating
temperature/pressure.
Air Control
Unlock the rotary air strap, set it to the position
shown in the Initial Setting Table for the burner
rating. Relock the air strap.
Note: The initial settings are for guidance at this
stage. Certain adjustments may be required later
to suit appliance requirements and site conditions.
Control
The control box is fixed on the left side viewed
from the rear of the burner. A light indicating burner
lockout is an integral part of the control box. Set
control and limit instruments to Call for Heat con-
dition. Momentarily switch on electrical supply to
the burner. Check for clockwise rotation of burner
motor, viewed from the air inlet side of the burner.
If the direction of rotation is wrong see Fault Find-
ing for procedure to correct it.
Switch On Electricity Supply
Depending on the control box fitted, the burner
will go through its operating sequence: (a) imme-
diately, if it has been switched off during its nor-
mal sequence of operation, (b) on pressing the Re-
set button if the burner is at lockout. Check that
ignition spark is present. For the actual times refer
to the Control Sequence Diagram. The ignition
spark ceases and burner goes to lockout.
If at this stage the burner locks out without an igni-
tion spark, then the air pressure switch is not chang-
ing over (see Fault Finding). If all is well, then the
safety lockout is proved, and the burner is in a safe
condition to proceed.
Main Gas Pressure Governor
With a screwdriver, turn the adjusting screw fully
anticlockwise to give a minimum gas flow rate.
Maximum allowable gas inlet pressure is 34.8 mb.
Commissioning - Live Run
The capacity of NG burners using natural gas has
been determined at a supply pressure of 17.5 mb,
and for LPG the supply pressure is 20.0 mb.
NG burners will operate satisfactorily on a gas sup-
ply pressure lower than those quoted above, but
the burner capacity will be reduced accordingly.
Fit a manometer or other approved pressure meas-
uring instrument at the pressure test point on the
upstream side of the burner governor. Turn on the
gas supply, and check the gas pressure. Check the
gas supply pipework for external leaks using a soap
solution.
Check For Valve Closure
Fit a manometer to the downstream pressure test
point on the gas valve body. If the reading indi-
cates positive pressure the gas valve is not closing
correctly and must be replaced. If the reading re-
mains at zero the valve is closed correctly.
Testing Main Flame
The NG2 burner is configured for main gas igni-
tion using a step-start valve to ensure a smooth
light up.
Control Box TW T1 T2 TS T3
Pre-Ignitio Ignition Safety
Time
Satronic
MMI810
MOD35
9s 30s 3s 5s 10s
Landis & Gyr
LGB21.350 A27 8s 30s 2s 5s 10s
Control Sequence Diagram
Burner
Model
Main Gas Governor Setting
Natural Gas L. P. G.
mb kPa mb kPa
NG2A 7.8 0.8 9.5 0.96
NG2B 4.8 0.49 90.91
NG2C 7.7 0.79 9.5 0.96
NG2E 12.5 1.27 9.7 0.99
NG2F 9.6 0.98 7.5 0.76
Gas Governor Settings

Page 9
Model NG2 Revision 210798A
Check that the Low Gas Pressure switch is set to
minimum. Fit a manometer or other approved pres-
sure measuring instrument to the test point on the
downstream side of the gas valve. Open the up-
stream manual isolating valve approximately 15 to
20 deg and switch on the burner. With the fan
running, make a mental note of the pressure and
look for an increase in pressure during the ignition
stage. If no increase in pressure is detected then
increase the governor setting and restart the burner.
Note that it may be necessary to re-cycle the burner
a few times to purge air from the pipework. When
the flame is established, the flame relay is ener-
gised by the flame detection circuit and the burner
continues to run on main flame.
Make a quick visual check on the flame stability
and if it is O.K. then slowly open the manual gas
valve to the fully open position whilst checking for
excessive CO. Adjust the combustion air setting if
necessary to maintain the combustion figures within
acceptable limits.
Setting Main Flame Gas Rate
With the manometer still attatched, the main flame
gas rate can be set. Adjust the governed pressure
to that shown in the Gas Governor Settings table.
Check the gas flow rate at the meter. Ensure that
other appliances served by the same meter are iso-
lated when the flow tests are carrried out. Adjust-
ments to the governor setting can now be made to
obtain the required flow rate.
Combustion Air Settings
With the gas flow rate set and the burner running
with stable flame, the flue gases can be checked
for C02 and 02with suitable combustion testing in-
struments. Acceptable figures are given in the Al-
lowable Combustion Analysis table. For safety rea-
sons, the CO should not exceed 93 ppm. To
achieve good combustion efficiency, or if the CO
content is exceeded, adjustments to air and gas
can be made whilst the burner is on main flame.
To adjust the air flow, loosen the retaining screw
on the rotary air strap situated on the right hand
side of the burner. To increase the flow of air, turn
the air strap anti-clockwise as viewed from the right
hand side. To decrease combustion air flow, turn
the rotatry strap clockwise. Tighten the retaining
screw after each adjustment.
Setting The Step Start Facillity
The step start is used to reduce the gas rate during
the ignition period, therefore ensuring a smooth
quiet light up. Re-start the burner and note the
quality of ignition. If the light up is heavy, reduce
the amount of start rate gas by turning the adjust-
ing screw anti-clockwise. If the light up is weak,
then increase the amount of start rate gas by turn-
ing the adjusting screw clockwise. Repeat until a
satisfactory setting is achieved.
Important
After each adjustment, gas flow rate and flue gas
analysis should be re-checked.
Always
Use approved test equipment (Continually moni-
toring electronic equipment is recommended).
Never
Rely on a visual inspection of the flame as a guide
to combustion quality.
Air Pressure Switch Setting
Isolate the burner and remove the air pressure
switch cover. Switch on the electrical supply and
allow the burner to establish main flame. Slowly
turn the adjustment dial on the air pressure switch
clockwise until the flame is extinguished and the
burner locks out. Turn the dial one division anti-
clockwise and reset the burner control. The burner
will restart and continue its cycle to the main flame
condition or lock out. If the burner locks out re-
peat the adjustment procedure once per burner
cycle until main flame is established. Recheck the
performance and then turn the dial a further two
divisions anticlockwise. Switch off the burner and
replace the air pressure switch cover.
Low Gas Pressure Switch Setting
The low gas pressure switch is wired in series with
the appliance controlling instruments and will cause
the burner to effect a safety shut down if a loss of
inlet gas pressure is detected.
Gas Type %CO2 %O2
Min Max Min Max
Natural 99.5 3.5 5
L.P.G. 10.5 11 3.5 5
Allowable Combustion Analysis

Model NG2 Revision 210798APage 10
Isolate the burner and remove the gas pressure
switch cover. Switch on the electrical supply and
allow the burner to establish main flame. Slowly
turn the adjustment dial on the gas pressure switch
clockwise until the flame is extinguished and the
burner shuts down. Turn the dial slowly anticlock-
wise one division at a time until the burner restarts
and establishes main flame. Recheck the perform-
ance and then turn the dial a further two divisions
anticlockwise. Switch off the burner and replace
the gas pressure switch cover.
Final Check
Check that all covers to components have been
replaced and locking devices are properly secured,
in particular the rotary air strap. Check that appli-
ance control instruments are set to safe limits.
Commissioning Is Now Complete
Switch on the electrical supply. Burner will now
operate until switched off: (a) by controlling in-
struments of the appliance, (b) manually, (c) by
power failure. Upon restoration of power, burner
will restart automatically and follow sequence.
CC
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COMMISSIONINGOMMISSIONING
OMMISSIONINGOMMISSIONING
OMMISSIONING & R& R
& R& R
& ROUTINEOUTINE
OUTINEOUTINE
OUTINE SS
SS
SAFETYAFETY
AFETYAFETY
AFETY
CC
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CHECKSHECKS
HECKSHECKS
HECKS
To Be Carried Out Only By Qualified And Experi-
enced Personnel.
Check that the Plant Room is well ventilated at all
times. Frequently inspect air inlet of the burner and
ensure there are no obstructions to air flow.
Flame Detection System
Flame probe (flame rectification rod).
Switch off electrical supply at the mains isolator.
Remove burner lid and disconnect lead to flame
probe. Replace burner lid and secure. Switch on
electrical supply to the burner. Check that burner
locks out at the end of the ignition cycle. Switch
off electrical supply. Remove burner lid, reconnect
lead to flame probe, replace lid and secure. Switch
on electrical supply. Reset lockout.
Routine Maintenance
Switch off electrical and gas supply to the burner.
Combustion Air Fan
Clean blades regularly with a stiff brush. Access is
obtained via the burner lid. Care should be taken
to avoid damaging the fan blades. Check that the
air inlet into the fan is clean.
Inner Assembly
To remove the inner assembly, remove the burner
lid. Disconnect inner assembly pipe from the valve
unit by loosening the pipe coupling, the two screws
securing the assembly to the burner body. Care-
fully withdraw the inner assembly from the body.
Air Diffuser And Gas Nozzle
Clean using a stiff brush.
Ignition Electrode and Probe
Clean and check that they are not cracked or worn.
Check settings of the ignition electrode and probe.
See the Technical Specifications section.
Draught Tube and Swirler
Remove the burner from the appliance by loosen-
ing the socket head grub screw, and remove from
the mounting bracket. Remove the draught tube
by unscrewing the two pozidrive screws. Check
the draught tube for distortion/damage. Renew if
necessary. Clean the air swirler (to be found in the
draught tube) with a stiff brush. Check the air swirler
for distortion/damage. Renew if necessary. Replace
all the components and covers and secure all the
fittings. The burner is now ready for operation.
Switch on the electrical and gas supply to the
burner.
FF
FF
FAA
AA
AULUL
ULUL
ULTT
TT
TFF
FF
FINDINGINDING
INDINGINDING
INDING
Any modifications to the installation or component
settings resulting from actions suggested below may
require the re-establishment of the various settings
as indicated earlier in this manual.
Burner Motor Fails To Start
Check electrical supply is available and burner is
correctly wired. Checks all fuses for continuity and
size. Check that all control instruments are calling
for heat.
Check that the control box is not locked out (e.g.
signal lamp may be faulty). If the control box is
locked out press the reset button. Check that the
burner probe is not grounded to earth. Check the
motor capacitor .
Fan Starts And Burner Goes To Lockout
Starting Flame Failure. If the start rate flame is not
properly established, the safety circuit of the se-
quence controller will cause lockout in one sec-
ond. The cause may be insufficient signal to the
flame detection device which is the flame rectifi-
cation probe.

Page 11
Model NG2 Revision 210798A
CC
CC
COMMISSIONINGOMMISSIONING
OMMISSIONINGOMMISSIONING
OMMISSIONING SS
SS
SHEETHEET
HEETHEET
HEET
The details below are to be completed by the Commissioning Engineer
Installers Name : _________________________________________________________________
Address :________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
Site Address : ____________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
Appliance : Type : ____________ Size : _____________ Serial No. : _____________
Burner : Type : ____________ Size : _____________ Serial No. : _____________
Commissioning date : _____________________________________
Guarantee Expiry date : ___________________________________
Gas type : _______________________________________________
Gas Pressure upstream of main gas governor :
a) Standing : _____________________ mbar b) Running : _____________________ mbar
Gas pressure at burner head __________________mbar _______________ in.w.g.
Gas rate __________________m3_______________ ft3/ht
Heat input __________________MJ/hr _______________ Btu/h
CO __________________% _______________ %
CO2__________________% _______________ %
Gross flue gas temperature __________________°C _______________ °F
Ambient temperature __________________°C _______________ °F
Nett flue gas temperature __________________°C _______________ °F
Efficiency __________________% _______________ %

Model NG2 Revision 210798APage 12
BB
BB
BURNERURNER
URNERURNER
URNER MM
MM
MODIFICODIFIC
ODIFICODIFIC
ODIFICAA
AA
ATIONTION
TIONTION
TION RR
RR
RECORDECORD
ECORDECORD
ECORD
DateDate
DateDate
Date Details of ModificationDetails of Modification
Details of ModificationDetails of Modification
Details of Modification

Page 13
Model NG2 Revision 210798A
Burner Selection Chart, based on a gross C.V. for Natural
Gas of 38.56 MJ/m3and Liquid Petroleum Gas of 92.6
MJ/m3. Outputs quoted are achieved @ 500 Mtr A.S.L.
within an ambient air temperature of 20°C
Burner Performance Range - a) Ascending Range
Overlap, b) Descending Range Overlap
Combustion Head Details
Burner
Model Fuel Type Swirler Cone øA
Gas
Nozzle øB
Diffuser
Holes øC
NGN2A Natural 74.2 1.95 2
NGL2A L.P.G. 74.2 1.4 2
NGN2B Natural 75.6 2.5 2
NGL2B L.P.G. 75.6 1.6 2
NGN2C Natural 77 2.5 2
NGL2C L.P.G. 77 1.8 2
NGN2E Natural 79.9 2.5 2
NGL2E L.P.G. 79.9 1.9 2
NGN2F Natural 79.9 32.5
NGL2F L.P.G. 79.9 2.25 2
Technical Specifications
AA
AA
APPENDIXPPENDIX
PPENDIXPPENDIX
PPENDIX
a)
b)
NGN2E NGN2F
NGN2C
NGN2A
NGN2A
NGN2C
NGN2F
NGN2B
NGN2B
NGN2E

Model NG2 Revision 210798APage 14
NN
NN
NOTESOTES
OTESOTES
OTES

Page 15
Model NG2 Revision 210798A
NN
NN
NOTESOTES
OTESOTES
OTES

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