Nu-Way MDFL 2800 - 38, Installation & Maintenance Manual

Page 1: ...Installation Maintenance Manual MDFL 2800 38 MDFL 2800 41 Dual Fuel Burner Tel 44 0 1905 794331 Fax 44 0 1905 794017 Email info nu way co uk Web www nu way co uk...

Page 2: ...r Damper Motor 13 Gas train 15 Oil Controls Single Spill Back Nozzle 19 Control Panel 24 Burner Controller 25 BURNER OPERATING SEQUENCE 26 MODULATING CONTROLS 27 Controller 27 Commissioning Controls 2...

Page 3: ...is essential that the following instructions and adjustments are carried out by qualified engineers that are experienced in forced draught gas and pressure jet oil burner commissioning In the UK it is...

Page 4: ...ystem 4 Fan Motor 16 Pilot Solenoid Valve 5 Air Inlet 17 Pilot Governor 6 Damper Motor 18 Low Gas Pressure Switch 7 Burner Terminal Panel 19 Flexible Oil Pipe 8 Casing Access Lid 20 Quick Release Oil...

Page 5: ...MGN 3300 MGN 4000 Page 4 BURNER MOUNTING ARRANGEMENT MDFL 2800 38 2800 41 Issue 1 08 08 Page 4...

Page 6: ...ving System 3 Flame Tube 16 Pilot Solenoid Valve 4 Fan Motor 17 Pilot Governor 5 Damper Motor 18 Low Gas Pressure Switch 6 Burner Control Panel 19 Flexible Oil Pipe 7 Air Inlet 20 Oil Pump 8 Casing Ac...

Page 7: ...MDFL 2800 38 2800 41 Issue 1 08 08 Page 6...

Page 8: ...air fan impellor Controls and Safety Systems MDFL burners are fitted with a combustion airflow control and an air fuel ratio control system which together ensure smooth starting and optimum operating...

Page 9: ...riately rated for the maximum gas flow rate anticipated It is essential that a 90 manual isolation valve is fitted upstream of the gas control train to allow the burner to be isolated for maintenance...

Page 10: ...steel pipe should not be used The supply pipework should include an appropriate filter The final connection to the oil pump inlet port should be made using the flexible pipes supplied with the burner...

Page 11: ...be maintained and all exposed pipework must be lagged 3 If a shut off valve is fitted in the supply line to the burner oil pump inlet then a pressure relief valve MUST also be fitted to prevent damag...

Page 12: ...It is recommended that lifting gear should be employed if necessary INSTALLATION General Ensure that the appliance is suitable for the heat input of the burner If there is any doubt in this area refe...

Page 13: ...Air flow failure at any stage beyond the first few seconds of the pre purge sequence will result in burner lockout GAS CONTROLS A typical gas train fitted is shown on page 15 High Gas Pressure Switch...

Page 14: ...nts mounted on a common shaft within the Modulating Cam Box 2 The operation and adjustment of the Modulating Cam Box arrangement should be fully understood before attempting to adjust the motor settin...

Page 15: ...tion with the same air damper settings 2 The fully closed cam 1 is factory set and under normal circumstances should not require further adjustment 3 Operation of the low and high fire air switches ca...

Page 16: ...Page 15 TYPICAL GAS TRAIN Item Description Item Description 1 Manual Gas Interlock Valve 5 Control Valve 2 Low Gas Pressure Switch 6 Pilot Solenoid Valve 3 Main Valve 7 Pilot Governor 4 Valve Proving...

Page 17: ...continuously operating flue gas damper or the combustion chamber pressure changes from negative to positive whilst moving from Low to High flame then a compensating circuit is required This means tha...

Page 18: ...the burner control circuit prior to burner start up The proving test is based upon the 2 stage pressure proving principal First the main safety valve V1 on the upstream side of the gas circuit is tes...

Page 19: ...MDFL 2800 38 2800 41 Issue 1 08 08 Page 18 VALVE PROVING SYSTEM LDU 11 Standard fitting...

Page 20: ...specified operating conditions Any queries regarding the size of the nozzle should be referred to Nu way The nozzle is held in position by the inner assembly lance through which oil flows from the ma...

Page 21: ...FL 2800 38 Suntec E7NC 1007 Manual Valve A manual valve is fitted to the output of the fuel pump and must be closed before firing on gas Oil Manifold Block The oil manifold block is located below the...

Page 22: ...OIL PUMPING SET FOR DISTILLATE FUELS Connection Sizes Item Description Size inches 1 Main Inlet Connection 1 2 Main Return Connection Optional 1 3 Burner Feed 4 Burner Return Mounting Dimensions Burn...

Page 23: ...Item Description Size P Pressure port R Return port S Suction port Pn Vacuum gauge i t l b l Ps Pressure gauge 1 Regulator cap nut 2 Washer 3 Regulator screw 4 Locknut N A Suntec E Series Oil Pump Co...

Page 24: ...1 All interconnecting pipework must have a minimum bore of 19mm and must be pressure rated for 42 kg cm2 2 Solenoid valves are shown as either NO normally open or NC normally closed 3 Pipework connect...

Page 25: ...EMPERATURE PRESSURE in the appliance Also located on this enclosure are the fuel selector switch and two additional neon lights The amber light is illuminated when OIL is the chosen fuel and the red l...

Page 26: ...to drive to open position proved by servo motor limit switch P Yes Lockout caused by the failure of the air pressure switch to changeover from the no air position shortly after the start of the pre p...

Page 27: ...ed by the pressure and or temperature requirements of the appliance Time seconds LFL 1 333 Description T1 40 Pre purge T2 6 Pre ignition T3 3 Safety lockout time T4 Not applicable to two stage or full...

Page 28: ...sition between low and high flame Commissioning Controls Two switches Hand Auto and Inching are included in the burner panel In auto mode the burner will respond to the demand of the boiler via the RW...

Page 29: ...hat the electrical wiring is complete and complies with all applicable Codes and Standards 2 Ensure that the fuses are fitted and of the correct ratings 3 Check electrical earthing 4 Verify that the g...

Page 30: ...o on scale 1 to 0 8 by adjusting screw 1 anti clockwise to increase clockwise to decrease Set the ratio on the remaining scale to half a division on the positive side of 0 by adjusting screw 2 in the...

Page 31: ...e burner at the control panel The modulating unit cam shaft should now rotate to the high flame setting and the combustion fan motor will start the air pre purge phase 11 Allow the fan motor to run up...

Page 32: ...t it gives approximately 1 5mm throw 3mm stroke and lock in position 2 Check to ensure that the spill valve push rod bears slightly against the oil cam refer to page 35 3 Rotate the air cam adjusting...

Page 33: ...satisfactory flame is achieved again check the line and spill pressures 11 Inch the camshaft back to the low flame position The oil consumption rate should now be between 40 and 50 of the rated maximu...

Page 34: ...um 7 Establish the electricity supply to the burner and momentarily switch on the burner Observe the rotation of the combustion air fan motor which should be anti clockwise viewed from the motor cowl...

Page 35: ...cam air damper servo refer to the diagram on page 14 Adjust the low fire air control cam cam 2 if necessary so that the appearance of the flame is satisfactory 6 Sample the flue products and check the...

Page 36: ...MDFL 2800 38 2800 42 Issue 2 08 08 Page 35 MODULATING CAM BOX...

Page 37: ...rcial Premises 4 Open the control panel cover and set the burner for low flame hold On modulating burners not fitted with a low flame hold switch set the Hand Auto switch to the Hand position 5 If a g...

Page 38: ...ed for the maximum required continuous output from the burner and not more than 100 mbar for the MDFL 2800 38 and 200 mbar for the MDFL 2800 41 1 Fit a manometer or other approved pressure measuring i...

Page 39: ...the diagram on page 16 until an acceptable figure is achieved In extreme cases the adjustment on screw 2 may be exhausted without achieving an acceptable CO level In this event reset the high fire ad...

Page 40: ...burner Allow the burner to light and establish the start gas flame 4 Check the gas flow rate The appropriate setting is usually found between 25 and 30 of the main flame gas rate The start gas rate mu...

Page 41: ...other approved pressure measuring instrument to the pressure switch to enable a comparison to be made between the pressure switch indicator and the measured pressure if required 3 Remove the control p...

Page 42: ...made in small increments with time given to see how the burner is reacting to the changed parameter Press and hold the PGM button down until the green set point figure changes to an AL the larger uppe...

Page 43: ...eer shall prepare a report which shall contain the following 1 Details of any modifications made to the system together with revised drawings if necessary 2 Customer and plant details including any se...

Page 44: ...on oil for a prolonged period it may be necessary to purge the gas line of air 6 If the burner is to be operated with gas for a prolonged period it may be desirable to remove the oil pump couplings RO...

Page 45: ...t the ignition leads Remove the two screws which secure the oil manifold within the hinged extension Remove the four bolts which locate the inner assembly and withdraw the assembly taking care not to...

Page 46: ...al Landis Staefa LFL 1 333 Terminals 13 and 14 4 If the air pressure switch is not in the start position turn the setting dial clockwise fully to the maximum setting Check again for continuity between...

Page 47: ...e followed 1 Switch off the burner and the electrical power supply to the burner 2 Disconnect the multi pin plug from the socket on the control system 3 Remove the screw which holds the control system...

Page 48: ...and low fire settings for both oil and gas firing For fully modulating burners additional data at intermediate positions in the operating range between high and low fire are required A copy of the com...

Page 49: ...Electrode Setting Details MDFL 2800 38 2800 41 Issue 1 08 08 Page 48 All dimensions in mm MDFL 2800 41 MDFL 2800 38...

Page 50: ...MDFL 2800 38 2800 41 Issue 1 08 08 Page 49 Performance Envelopes MDFL 2800 38 MDFL 2800 41...

Page 51: ...ntee Expiry Date Fuel Oil Type Oil pressure upstream of pump Standing bar or psi Running bar or psi Firing Rate High Fire Intermediate Positions if required Low Fire Units 1 Oil bar or psi Pressure at...

Page 52: ...piry Date Fuel Oil Type Gas pressure upstream of main governor Standing mbar or ins wg Running mbar or ins wg Firing Rate High Fire Intermediate Positions Low Fire Units 1 Gas mbar or ins wg Pressure...

Page 53: ...CORD The details below are to be completed by the Servicing Engineer This sheet to be completed and signed following each service adjustment Date Details of Service Signature MDFL 2800 38 2800 41 Issu...

Page 54: ...NOTES MDFL 2800 38 2800 41 Issue 1 08 08 Page 53...

Page 55: ...Enertech Limited P O Box 1 Vines Lane Droitwich Worcestershire WR9 8NA Tel 44 0 1905 794331 Fax 44 0 1905 794017 Email info nu way co uk Web www nu way co uk...