Related Manuals for Nu-Way MDFL 2800 – 38
Summary of Contents for Nu-Way MDFL 2800 – 38
- 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...
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Page 2: Table Of Contents
CONTENTS BURNER & COMPONENT INDENTIFICATION FOR MDFL 3300 & 4000 ………………………………… INTRODUCTION …………………………………………………………………………………………………... FEATURES ………………………………………………………………………………………………………… Burner Capacity ……………………………………………………………………………. Fuel ……………………………………………………………………………. Air Fan Size ……………………………………………………………………………. Controls and Safety Systems ……………………………………………………………………………. Operating Mode ……………………………………………………………………………. SITE CONDITIONS AND SERVICES ……………………………………………………………………………. Flue and Chimney Requirements ……………………………………………………………………………. - Page 3 In the UK it is a legal requirement that these 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 as a result of misuse.
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Page 4: Burner & Component Indentification For Mdfl 3300 & 4000
BURNER AND COMPONENT IDENTIFICATION FOR MDF MODULATING BURNER (MODEL MDFL 2800-41 SHOWN) Item Description Item Description Burner Casing Valve Proving Pressure Switch Hinged Extension Modulating Cam Box Flame Tube Valve Proving System Fan Motor Pilot Solenoid Valve Air Inlet Pilot Governor Damper Motor Low Gas Pressure Switch Burner Terminal Panel... - Page 5 MGN 3300 & MGN 4000 Page 4 BURNER MOUNTING ARRANGEMENT MDFL 2800-38 & 2800-41 Issue 1 08/08 Page 4...
- Page 6 BURNER AND COMPONENT IDENTIFICATION FOR MDF TWO STAGE (HIGH/LOW) BURNER (MODEL MDFL 2800-38 SHOWN) Item Description Item Description Burner Casing Connection Box Hinged Extension Valve Proving System Flame Tube Pilot Solenoid Valve Fan Motor Pilot Governor Damper Motor Low Gas Pressure Switch Burner Control Panel Flexible Oil Pipe Air Inlet...
- Page 7 MDFL 2800-38 & 2800-41 Issue 1 08/08 Page 6...
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Page 8: Introduction
INTRODUCTION This manual has been produced to enable users to install, commission and use the MDFL burners safely and efficiently. At each stage the conditions that should be met, the adjustments and other actions that should be carried out are detailed. The locations of the various components and adjustment mechanisms are identified. -
Page 9: Site Conditions And Services
SITE CONDITIONS AND SERVICES Flue and Chimney Requirements It is important that: The flue pipe from the appliance and the joint between this flue and the chimney are sealed to prevent leakage of combustion products. The flue pipe from the appliance does not protrude into the chimney beyond the inside wall. The top of the flue or chimney shall be higher than any roof within a radius of 10 metres. -
Page 10: Electrical Power Supply
ELECTRICAL POWER SUPPLY A 400 Volt, three-phase, 50Hz supply is required. Power requirements are listed in the table below. The power supply provided must comply with all relevant Codes and Standards. Fan Motor Pump Motor Start Current Cable Size HRC Fuse BURNER kW/hp kW/hp... -
Page 11: Pumped Oil Ring Main
A TYPICAL PUMPED OIL RING MAIN Notes: Duplex pumps are recommended for continuity and serviceability. Pre-heating Class D fuel is not normally required, but a minimum temperature of 5°C should be maintained and all exposed pipework must be lagged. 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 damage should the shut-off valve be inadvertently left closed during the burner start-up cycle. -
Page 12: Unpacking And Assembly
UNPACKING and ASSEMBLY To safeguard against damage in transit, MDFL burners are supplied in partly assembled form. Spill-back Burners MDFL burners systems comprise of the following units: The burner body, complete with hinged extension, flame tube assembly and control panel if fitted The gas control train The oil pump unit (Optional extra for the Model 2800-38) A free-standing or wall-mounted control panel, if supplied... -
Page 13: Burner Control And Operation
BURNER CONTROL and OPERATION AIR CONTROLS Air Regulator (MDFL 2800-41) The flow of combustion air into the burner is controlled by a multiple-aperture rotary type damper, fitted to the burner casing within the air inlet silencer on the right hand side of the burner. Air Damper Motor In all cases, the air damper is controlled by a servomotor containing adjustable limit switches for the low and high fire positions. -
Page 14: Air Damper Motor
AIR DAMPER SERVOMOTOR : SINGLE SPILL-BACK NOZZLE BURNERS Model : Landis & Staefa SQM 10 Factory Settings Function Setting High Fire Air 160° Firing Low Fire Air 0° High Fire Air 160° Firing Low Fire Air 0° Not Used Notes: 1. - Page 15 AIR DAMPER SERVOMOTOR : TWIN PRESSURE JET BURNERS Model : Berger Lahr STM6 Factory Settings Function Setting Full Air Shut-off 0° Low Fire Air 20° High Fire Air 60° High Flame Oil Valve Out 50° High Flame Oil Valve In 40°...
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Page 16: Gas Train
TYPICAL GAS TRAIN Item Description Item Description Manual Gas Interlock Valve Control Valve Low Gas Pressure Switch Pilot Solenoid Valve Main Valve Pilot Governor Valve Proving System High Gas Pressure Switch MDFL 2800-38 & 2800-41 Issue 1 08/08 Page 15... - Page 17 SKP75 Air/Gas Ratio Controller The air/gas ratio controller, shown below, varies the gas pressure in response to changes in combustion air pressure to ensure that the air/gas ratio remains constant over the operating range of the burner. A separate gas pressure governor is not necessary. Two impulse pipes (both factory supplied) are connected to the air/gas ratio controller.
- Page 18 Valve Proving System Valve proving systems are standard on both MDFL 2800 burners. The standard model fitted is the Landis & Staefa LDU11. (See page 18) When the burner operating sequence is initiated the burner control box energises the proving system, which then carries out the following checks: The LDU11 control unit is designed to provide automatic gas valve proving (leakage test) based on the pressure proving principle.
- Page 19 VALVE PROVING SYSTEM : LDU 11 (Standard fitting) MDFL 2800-38 & 2800-41 Issue 1 08/08 Page 18...
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Page 20: Oil Controls - Single Spill-Back Nozzle
MDFL burners use a single oil nozzle (see drg) within the inner assembly (refer to the Appendix). This nozzle is factory-specified to deliver optimum performance under the specified operating conditions. Any queries regarding the size of the nozzle should be referred to Nu-way. Fluidics W1 Nozzle The nozzle is held in position by the inner assembly lance, through which oil flows from the manifold block to the nozzle and recirculated through the spill regulating valve. - Page 21 The two oil nozzles (high and low fire) are held in a nozzle block located within the flame tube (refer to the Appendix). The nozzles are pre-sized by Nu-way in accordance with the heat inputs required and the available operating pressure.
- Page 22 OIL PUMPING SET FOR DISTILLATE FUELS Connection Sizes Size Item Description (inches) Main Inlet Connection Main Return Connection (Optional) Burner Feed ¾ Burner Return ¾ Mounting Dimensions Burner Model MDFL 2800-38 & 2800-41 MDFL 2800-38 & 2800-41 Issue 1 08/08 Page 21...
- Page 23 SUNTEC OIL PUMP IDENTIFICATION AND PORT SIZING Suntec T Series Oil Pump with TV Pressure Regulator Connection Sizes Item Description Size Pressure port ¾” Return port ¾” Suction port ¾” Vacuum gauge & ¼” Pressure gauge ¼” Regulator cap nut Washer Regulator screw Locknut...
- Page 24 2. Solenoid valves are shown as either NO (normally open) or NC (normally closed). 3. Pipework connections between the burner oil system and the separate pumping set are not supplied by Nu-way. See Note on Page 19. MDFL 2800-38 & 2800-41 Issue 1 08/08...
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Page 25: Control Panel
CONTROL PANEL On MDFL 2800-38 and MDFL 2800-41 burners the enclosure mounted on the left side of the burner serves mainly as a housing for electrical connections, although it also contains the ignition transformers and carries the burner On/Off switch, the Hand/Auto switch, and the Inching switch required by modulating burners. -
Page 26: Burner Controller
BURNER CONTROLLER : SIEMENS LFL 1 In the event of a fault condition the sequence disc stops rotating, with the symbol appearing above the indicator mark indicating the nature of the fault. If the fault leads to a lockout condition the Enlarged Detail of Sequence Indicator orange lockout indicator will be illuminated. -
Page 27: Burner Operating Sequence
BURNER OPERATING SEQUENCE The MDFL burner operating sequence (refer to the controller sequence table below) begins with a pre-purge period on full air. When gas is selected, the fuel is then supplied to the burner at start rate and ignition initiated. Start gas flame proving is followed by establishment of the main flame. When oil is selected, on completion of the pre-purge period the appropriate oil valve or valves open, ignition is initiated and the flame is established. -
Page 28: Modulating Controls
MODULATING CONTROLS Controller The standard method of operation is based on the Landis & Staefa RWF40 Universal Controller, which has been designed for use on gas fired installation, where it provides temperature or pressure control of modulating burners with continuously adjustable fuel throughput. The control output of the RWF40 is a potential free 3-position switch, which is used for the control of reversible motors. -
Page 29: Commissioning : General
In the UK, it is a legal requirement that anyone working on gas installations, as defined in the “Gas Safety (Installation and Use) Regulations 1994”, is CORGI registered. Nu-way can accept no responsibility for consequential loss, damage or injury which results from a failure to follow the commissioning instructions provided or from commissioning procedures being undertaken by unqualified personnel. -
Page 30: Initial Settings
Inspection (cont..) Check that all relevant documentation is available, including, where appropriate: - The agreed plant performance specification - Plant drawings and pipework layouts - Certificates confirming satisfactory completion of procedures such as soundness testing, purging and electrical safety tests. - Commissioning, operating, emergency shutdown and maintenance instructions for the plant. -
Page 31: Commissioning : Oil
COMMISSIONING : OIL Burner Dry Run – MDFL 2800-41 The following procedure should be followed. It is important that a complete and flawless dry run be completed before fuel is supplied to the system: Check that the gas, oil and electrical supplies to the burner are turned off. Turn the fuel selector switch on the control panel to the oil position. -
Page 32: Burner Live Run
Burner Live Run – MDFL 2800-41 The instructions in this section are presented as a continuous sequence. No separate set of actions (for example, checking the flame signal) should be followed in isolation without paying particular attention to any safety precautions such as isolating the electrical supply to the burner which should precede such actions. - Page 33 Check the oil consumption. If this is not correct for the full burner rating, the oil cam must be adjusted as follows:- a. Inch the burner to low flame and note the spill pressure. b. To increase the minimum rate, adjust as shown on page 35. c.
- Page 34 COMMISSIONING : OIL Burner Dry Run – MDFL 2800-38 Two Stage (High/Low) The following procedure should be followed. It is important that a complete and flawless dry run be completed before fuel is supplied to the system: Check that the gas, oil and electrical supplies to the burner are turned off. Turn the fuel selector switch on the control panel to the oil position.
- Page 35 Burner Live Run MDFL 2800-38 The instructions in this section are presented as a continuous sequence. No separate set of actions (for example, checking the flame signal) should be followed in isolation without paying particular attention to any safety precautions such as isolating the electrical supply to the burner which should precede such actions.
- Page 36 MODULATING CAM BOX MDFL 2800-38 & 2800-42 Issue 2 08/08 Page 35...
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Page 37: Commissioning : Gas
COMMISSIONING : GAS Burner Dry Run – MDFL 2800-38 & MDFL 2800-41 The following procedure should be followed. It is important that complete and flawless dry run be completed before fuel is supplied to the system: IT IS RECOMMENDED THAT THE BURNER SHOULD BE COMMISSIONED FOR OIL FIRING IN THE FIRST INSTANCE. -
Page 38: Burner Live Run
Burner Live Run – MDFL 2800-38 & 2800-41 The instructions in this section are presented as a continuous sequence. No separate set of actions (for example, checking the flame signal) should be followed in isolation without paying particular attention to any safety precautions such as isolating the electrical supply to the burner which should precede such actions. - Page 39 Setting Main Flame Rates and Air/Gas Ratios From this point the gas commissioning process is concerned with setting the main and start gas flow rates to appropriate values and ensuring that the combustion quality of the system is within acceptable limits. During this process: AFTER EACH ADJUSTMENT check the flue gas analysis and gas flow rate.
- Page 40 Changing the low fire setting on the air/gas ratio controller will have a slight effect on the high fire setting. It may therefore be necessary to repeat steps 13 to 15 several times in order to achieve acceptable levels of CO at both firing rates.
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Page 41: Final Commissioning Stages - Oil And Gas
FINAL COMMISSIONING STAGE – OIL AND GAS Checking the Flame Signal Remove the control panel cover and disconnect the flame signal check link. Connect a DC micro-ammeter across the terminals. Establish the electrical supply to the burner and switch on the burner. Allow the burner to light and operate normally. -
Page 42: Modulating Control : Siemens Rwf 40
Modulating Control : Siemens RWF 40 Basic display The diagram below shows the RWF40 after switching on the supply voltage. This conditions is called the basic display. The actual valve and the currently active set-pint are shown here. Manual operation, self-optimisation, the operating parameter and configuration levels can be activated from here. -
Page 43: Final Checks
Final Checks Check that all covers have been replaced and that all locking devices are secure. Check the operation of the appliance control instruments and safety interlocks. Ensure that the appliance safety controls and any other interlocks are set to safe limits. COMMISSIONING IS NOW COMPLETE. -
Page 44: Full Changeover Procedure
FUEL CHANGEOVER PROCEDURE Note that on completion of the commissioning procedure detailed above the burner is set for gas firing. The procedure to be followed when switching fuels during normal operation is as follows: Switching from Gas to Oil Switch off the burner and the electrical power supply to the burner. Close the manual gas isolation valve. -
Page 45: Routine Maintenance
ROUTINE MAINTENANCE ALWAYS SWITCH OFF THE ELECTRICAL POWER AND FUEL SUPPLIES TO THE BURNER BEFORE CARRYING OUT MAINTENANCE. Combustion Air Fan – All Models Remove the burner top cover to gain access to the combustion air fan. Clean the fan blades with a stiff brush, taking care not to damage them. -
Page 46: Fault Finding
FAULT FINDING Any changes made in control settings as a result of identifying and remedying fault conditions as described below may necessitate partial or complete recommissioning. Recommissioning shall be undertaken only by appropriately qualified and experienced personnel. Burner Motor Fails to Start Fan Starts and Burner goes to Lockout 1. -
Page 47: Start Flame Failure
Air setting incorrect Reset SPARE PARTS For spare parts contact Nu-way’s Parts and Components Division at the address and telephone number listed on the rear cover of this manual. To avoid delays, please provide the burner model, serial and specification numbers. -
Page 48: Appendix
APPENDIX This appendix contains additional information and documentation, including: Burner head details and dimensions Electrode setting details Burner performance envelopes Commissioning sheets (oil and gas). Blank sheets are provided which must be filled in by the engineer on completion of commissioning. For two stage (high/low) burners the pressure, combustion quality and temperature data should be obtained for both high and low fire settings for both oil and gas firing. -
Page 49: Electrode Setting Detail
Electrode Setting Details MDFL 2800-41 MDFL 2800-38 All dimensions in mm MDFL 2800-38 & 2800-41 Issue 1 08/08 Page 48... -
Page 50: Performance Envelopes
Performance Envelopes : MDFL 2800-38 & MDFL 2800-41 MDFL 2800-38 & 2800-41 Issue 1 08/08 Page 49... -
Page 51: Oil Commissioning Sheet
Oil Commissioning Sheet The details below are to be completed by the Commissioning Engineer. The completed sheet must then be photocopied and a copy forwarded to the appliance manufacturer. Installer’s Name: Address: Site Address: Serial Type: Size: Appliance Number: Serial Type: Size: Burner... -
Page 52: Gas Commissioning Sheet
Gas Commissioning Sheet The details below are to be completed by the Commissioning Engineer. The completed sheet must then be photocopied and a copy forwarded to the appliance manufacturer. Installer’s Name: Address: Site Address: Serial Type: Size: Appliance Number: Serial Type: Size: Burner... -
Page 53: Burner Service Record
BURNER SERVICE RECORD 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 Issue 1 08/08 Page 52... -
Page 54: Notes
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...
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