Nu-Way MOL 3400-410 Installation & Maintenance Manual Download

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CONTENTS

BURNER & COMPONENT IDENTIFICATION FOR MOL 3400 & 4100 BURNERS ……………………………

INTRODUCTION …………………………………………………………………………………………………...

FEATURES ……………………………………………………………………………………………………………

Burner Capacity …………………………………………………………………………….

Controls and Safety Systems

…………………………………………………………………………….

Operating Mode

…………………………………………………………………………….

Fuel …………………………………………………………………………….

SITE CONDITIONS AND SERVICES ……………………………………………………………………………….

Flue and Chimney Requirements …………………………………………………………………………….

Plant Room Ventilation

…………………………………………………………………………….

Combustion Chamber Conditions

…………………………………………………………………………….

Oil System …………………………………………………………………………….

Oil Storage Tank

…………………………………………………………………………….

Oil Supply to Burner

…………………………………………………………………………….

Single Pipe System …………………………………………………………………………….

Pumped Oil Ring Main

…………………………………………………………………………….

Burner Pump Capacitor …………………………………………………………………………….

Filtration …………………………………………………………………………….

Electrical Power Supply …………………………………………………………………………….

UNPACKING AND ASSEMBLY………………………………………………………………………………………

MODULATING BURNER OIL SYSTEM …………………………………………………………………………….

INSTALLATION ………………………………………………………………………………………………………

BURNER CONTROL OPERATION – MODULATING & HIGH/LOW ……………………………………………

BURNER CONTROLS ……………………………………………………………………………………………….

Oil Pumping Units

……………………………………………………………………………. 13

Modulating Unit

……………………………………………………………………………. 13

COMMISSIONING : GENERAL …………………………………………………………………………………….

Safety and Emergency Notes

……………………………………………………………………………. 14

Inspection ……………………………………………………………………………. 14

Pre-Firing Checks

……………………………………………………………………………. 15

COMMISSIONING : MODULATING ……………………………………………………………………………..

Modulating Unit

……………………………………………………………………………

COMMISSIONING : HIGH/LOW ..................................................................................................................

High/Low Burner Oil System

……………………………………………………………………………

FINAL CHECKS - COMMISSIONING ………………………………………………………................................

On Completing Commissioning

……………………………………………………………………….. 20

ROUTINE MAINTENANCE …………………………………………………………………………………………

General …………………………………………............................................. 21
Daily Checks

………………………………………………………........................... 21

Replenishing the Fuel Supply

………………………………………………………………………….

Boiler Combustion Services

………………………………………………………………………….

Inner Assembly Removal – High/Low

………………………………………………………........................... 21

Inner Assembly Removal - Modulating

………………………………………………………………………….

FAULT FINDING ………………………………………………………………….................................................

Burner fails to start

………………………………………………………………………….. 23

Flame occurs followed by lockout

………………………………………………………………………….. 23

Burner starts, no flame appears

………………………………………………………………………….. 23

Modulating system

………………………………………………………………………….. 23

Burner commissioning sheet

………………………………………………………………………….. 23

MOL 3400 & MOL 4100

Summary of Contents for MOL 3400-410

Page 1: ...Installation Maintenance Manual MOL 3400 4100 Oil 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: ...RNER CONTROL OPERATION MODULATING HIGH LOW 12 BURNER CONTROLS 13 Oil Pumping Units 13 Modulating Unit 13 COMMISSIONING GENERAL 14 Safety and Emergency Notes 14 Inspection 14 Pre Firing Checks 15 COMMI...

Page 3: ...hese engineers should also be CORGI registered Nu way cannot be held responsible for any consequential damage loss or personal injury as a result of customers failing to follow these instructions or a...

Page 4: ...ended for general assessment of the overall sizes of the burners and should not be used without reference to our engineering department for inclusion in drawings for installation purposes Certified di...

Page 5: ...MOL 3400 4100 Issue 2 10 08 Page 4 BURNER AND COMPONENT IDENTIFICATION FOR MODULATING BURNERS All dimensions are in mm 6 3 4 1 4 9 10 11 13 7 8...

Page 6: ...ck Release Connection 11 Burner Head Return Oil Quick Release Connection 12 Fan Inspection Cover 13 Ignition Transformer Burner Mounting Details On request MOL modulating burners can be supplied in th...

Page 7: ...0 kW 3 x 40 Amp 26 35 Amp 6mm2 MOL 4100 36 6 Amp 7 5 kW 3 x 20 Amp 11 16 Amp 4mm2 MOL 4100 41 6 Amp 11 0 kW 3 x 32 Amp 19 27 Amp 6mm2 MOL 4100 44 6 Amp 15 0 kW 3 x 40 Amp 26 35 Amp 6mm2 Pumping Unit d...

Page 8: ...ng burner can provide a turndown range of up to 3 1 The High Low version will be limited to a maximum of 2 5 1 Fuels MOL burners covered in this manual are designed to fire distillate fuel SITE CONDIT...

Page 9: ...the total swept volume of the burner oil pumps connected to the supply system All oil supply pipes must be constructed and installed to comply with local conditions and appropriate codes of practice a...

Page 10: ...and washers provided The pumping unit is supplied as a separate component to modes 1 and 2 and is inclusive of flexible pipes to make all the necessary oil connections Mode 3 On request MOL modulatin...

Page 11: ...nimum 19mm and pressure rated for 42 kg cm2 600 psi All burners require a pump inlet pressure of 0 35 to 0 70 kg cm2 5 to 10 psi If a shut off valve is fitted in the inlet line a pressure relief valve...

Page 12: ...burner component and pumping unit drawings on pages 4 13 Connect the oil supply to the burner pumping unit with reference to the oil system diagrams and pumping unit drawings on pages 10 19 Electrica...

Page 13: ...29 of this handbook When the boiler control calls for heat the burner modulating unit will travel to the high flame position and interlock the control circuit An air pre purge will take place at this...

Page 14: ...urner nozzle A return line from the back of the nozzle is connected to a spill regulating valve which regulates the oil pressure at the nozzle according to the position of an internal piston which is...

Page 15: ...hat all manual fuel isolation valves are operable fully closed and leak tight Make all personnel involved in the commissioning aware of the location of the emergency fuel and electricity isolation poi...

Page 16: ...to run through to lockout During this run check that the ignition spark is occurring and note the spill and line oil pressures at the moment of ignition Reset the sequence control and repeat the run...

Page 17: ...mper is fully closed i e until all the slack is taken up on the cable Note Cams one and two control the high cam one and low cam two limits of the mechanism These are factory set and should not requir...

Page 18: ...MOL 3400 4100 Issue 2 10 08 Page 17 MODULATING UNIT Cams shown in the Low Flame Position...

Page 19: ...ing 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...

Page 20: ...rt its cycle again It should lock out five seconds after the low flame solenoid valve is energised The air regulator should now be set to give a CO2 reading of 10 11 with a smoke number of 0 1 HIGH FL...

Page 21: ...gineer 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...

Page 22: ...the burners Boiler Combustion Services 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 tempera...

Page 23: ...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 operation after which wear will...

Page 24: ...the pre heater hot oil filter ensure that there is sufficient oil in the storage tank bleed the oil pump in case it is partially air locked Check to ensure that all stop fire valves in the supply line...

Page 25: ...BURNER HEAD DETAILS ELECTRODE SETTING MOL 3400 4100 Issue 2 10 08 Page 24 MODULATING HIGH LOW 6 3 8 13...

Page 26: ...re the reverse of the quoted rotation The Oil Pump is completely pre piped as part of the pumping or pumping and heating set Should the Oil Pump performance become suspect then a replacement unit shou...

Page 27: ...pump with positive feed pressure an external bypass has to be made between the return port and the suction port Media The pump specification stipulates mineral based fuel oil or media of a correspond...

Page 28: ...ly create a dangerous situation If a burner becomes troublesome then the assistance of a qualified engineer should be obtained To assist in his diagnosis notes should be made detailing the events lead...

Page 29: ...witch or a contact has not been closed between control box terminals 12 and 4 or 4 and 5 Shut down of start up sequence because the OPEN signal has not been supplied to control box terminal 8 by the s...

Page 30: ...be 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...

Page 31: ...ition Fuel supply problem YELLOW NO FLAME End Lockout Solenoid valve defective Photocell dirty Photocell or circuit faulty YELLOW WITH FLAME End Locknut No voltage at terminal 20 When a burner failure...

Page 32: ...e of the hexagonal nut section of the nozzle body as shown opposite Should any doubts arise concerning the suitability or performance of the burner nozzle please contact the Nu way Technical departmen...

Page 33: ...elect a burner with a higher fan static pressure than would normally be chosen if the appliance has a high starting resistance Similarly when firing a reverse pass boiler up to 2 MW with a combustion...

Page 34: ...erial No ________________ Burner Type ___________________ Rating ____________________ Spec No _________________ Serial No _______________ Nozzles ___________________ Oil Pump ________________ Commissi...

Page 35: ...NOTES...

Page 36: ...NOTES...

Page 37: ...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...

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