Installation & Maintenance Manual

Series NOL forced draught oil burner

Models NOL18 to 100-38 High/Low
Oil Burner

11/12

Tel: +44 (0) 1905 794331 Fax: +44 (0) 1905 794017 Email: [email protected] Web: www.nu-way.co.uk

Contents
IMPORTANT - SAFETY ....................................................................................................... 3
EUROPEAN BOILER EFFICIENCY DIRECTIVE (B.E.D.) ............................................................... 3
BURNER & COMPONENT IDENTIFICATION ............................................................................ 4
GENERAL ...................................................................................................................... 5
FEATURES ..................................................................................................................... 5
Air Regulation ............................................................................................................................... 5
Controls and Safety Systems .......................................................................................................... 5
Fuels ............................................................................................................................................. 5
Fuel System................................................................................................................................... 5
Construction ................................................................................................................................. 5
Manual Operation ........................................................................................................................ 5

GENERAL ...................................................................................................................... 5
SITE CONDITIONS AND SERVICES ....................................................................................... 5
Fuel Storage and Handling ............................................................................................................ 5
Fuel Supply ................................................................................................................................... 5
Single Pipe system ......................................................................................................................... 6
Two-Pipe System ........................................................................................................................... 6
Flue and Chimney Requirements ................................................................................................... 6
Plant Room Ventilation ................................................................................................................. 6
Existing Appliances ....................................................................................................................... 6
Combustion Chamber Conditions .................................................................................................. 6

INSTALLATION ................................................................................................................ 6

General ........................................................................................................................................ 6
Fitting to the Appliance ................................................................................................................. 6
Oil Supply Connections ................................................................................................................ 6
Electrical Power Connection .......................................................................................................... 6

BURNER AIR CONTROLS .................................................................................................. 6

Air Diffuser ................................................................................................................................... 6

Air Damper ................................................................................................................................... 6

BURNER OIL SYSTEM ...................................................................................................... 7

ELECTRICAL CONNECTIONS .............................................................................................. 7
BURNER OIL CONTROLS ................................................................................................. 8
Oil Pump ...................................................................................................................................... 8
Oil Nozzle .................................................................................................................................... 8

AIR DAMPER ADJUSTMENT ............................................................................................... 8

Hydraulic Oil Ram ........................................................................................................................ 8

OPERATION .................................................................................................................. 8
PUMP COMPONENT ID .................................................................................................. 9
COMMISSIONING ........................................................................................................... 9
IMPORTANT - SAFETY ....................................................................................................... 9
EMERGENCY INSTRUCTIONS .............................................................................................. 9
Inspection ..................................................................................................................................... 9
Pre-firing Checks ......................................................................................................................... 10
Commissioning the Burner .......................................................................................................... 10

ROUTINE MAINTENANCE

Page 2

OF

NOL BURNERS ...................................................................... 11

NOL 18-100 HL

General ...................................................................................................................................... 11
Daily Checks ............................................................................................................................... 11
Photoelectric Cell ........................................................................................................................ 11
Replenishing the Fuel Supply ....................................................................................................... 11
Boiler Combustion Surface .......................................................................................................... 11

FLAME FAILURE & SEQUENCE CONTROL ........................................................................... 12

FAULT CONDITIONS AND LOCKOUT INDICATION ................................................................. 12
SEQUENCE CONTROL TIMINGS ....................................................................................... 13
BURNER OIL NOZZLE ................................................................................................... 14
SERVICE & REPLACEMENT .............................................................................................. 14
FAULT FINDING ........................................................................................................... 14
BURNER COMMISSIONING SHEET .................................................................................... 14
BURNER PERFORMANCE CURVES ..................................................................................... 14
Burner Combustion Head ........................................................................................................... 16

ELECTRICAL DATA TABLE - SUPPLY 400-3-50 ..................................................................... 17

ELECTRODE SETTING ..................................................................................................... 17
COMMISSIONING SHEET ................................................................................................ 18
BURNER SERVICE RECORD ............................................................................................. 19

IMPORTANT - SAFETY
It is essential that the following instructions and adjustments are carried out by qualified engineers that
are experienced in pressure jet oil burner commissioning. 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. Your attention is drawn to the Emergency Instructions on page 10

EUROPEAN BOILER EFFICIENCY DIRECTIVE (B.E.D.)

All burners and boiler bodies marketed 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 manufactures instructions, and these
must include flue gas temperatures, average water temperature, and CO2or O2 concentration.
NOL 18-100 HL

Page 3

BURNER & COMPONENT IDENTIFICATION

ITEM
1
2
3
4
5
6
7
8
9
10
11
12

Standard Burner Arrangement Shown

All dimensions are mm.

A
B

12
C

DESCRIPTION
Oil Pump
Safety Solenoid Valve
Twin Solenoid Valve
Burner Casing
Flame Tube
Viewing Window
Hydraulic Ram
Air Inlet
Reset Button
Control Panel
Fan Motor
Photo Cell

HOLE 'H'

Projection

8 HOLES M10 EQUI-SPACED

ON 'J' PCD FOR M10 x 35 PROJ. STUDS

10

G
7
11
8
BURNER
NOL18-34
NOL18-38
NOL30-25
NOL35-25
NOL35-34
NOL35-38
NOL50-28
NOL50-34
NOL50-38
NOL60-28
NOL60-34
NOL60-38
NOL85-38
NOL100-38

A
674
721
544
544
674
721
674
674
721
674
674
721
721
721

B
440
465
365
365
440
465
440
440
465
440
440
465
465
465

C*
420
457
307
307
420
457
420
457
480
457
480
480
537
537

D
250
250
250
250
250
250
250
250
250
250
250
250
250
250

E
335
335
300
300
335
340
335
335
340
335
335
340
340
340

* Motor dimension may vary according to motor size and type

Page 4

NOL 18-100 HL

F
265
295
215
215
265
295
265
265
295
265
265
295
295
295

G
400
475
315
315
400
475
400
400
475
400
400
475
475
475

H
230
230
230
230
230
230
254
254
254
254
254
254
280
280

J
305
305
254
254
305
305
305
305
305
305
305
305
305
305

BURNER MODEL DESIGNATION

G ENERAL

Burner Range & Outputs

Nu-way NOL18 to NOL100-38 pressure jet

burners are designed for automatic two stage
operation with burner outputs from 200 to
3000kW(Gross).
This manual is structured to enable the user to
proceed from the delivery of the burner to its
commissioning 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
installation and use. Pre-commissioning and Live
Run are described, and the location of necessary
controls and adjustments to undertake these are
illustrated and supported by appropriate tabular
matter and graphs.
Routine maintenance, Fault Finding and Spare
Parts identification complete the manual. Literature
on proprietary components is available on request.

NOL 18-100 HL

BURNER
NOL18-34
NOL18-38
NOL30-25
NOL35-25
NOL35-34
NOL35-38
NOL50-28
NOL50-34
NOL50-38
NOL60-28
NOL60-34
NOL60-38
NOL85-38
NOL100-38

MAX OUTPUT
(Kw)
560
560
960
1100
1025
1025
1465
1465
1465
1810
1810
1810
2460
2930

Page 5

FEATURES

SITE CONDITIONS

Developed from Worldwide field experience, the

NOL series sets standards in efficient and reliable
operation. The burners, which are designed to
meet the requirements of all International markets,
are designed for flange mounting to the appliance
front plate and are delivered ready to install with
a pre-wired packaged control system.

Air Regulation
Air for combustion at high and low firing rates can
be adjusted to give maximum efficiency.

Controls and Safety Systems

Flame supervision is by photocell with a sequence
controller for automatic start-up, running, and
shutdown of the burner.

Fuels
As supplied NOL burners are suitable for light
distillate oil class D (1.5-5.5 cSt @ 40C) with a
gross CV of 45.5 MJ/kg (12.6 kW/kg).
Burners can be supplied, on request, for use with
Kerosene Class C2 (1.0-2.0 cSt @ 40C) with a gross
CV 12.9kW/kg.

Fuel System
Suitable for single pipe gravity or two pipe suction
lift systems. The filter supplied with the burner is
of the disposable element type.

Construction
Of monobloc design using fasteners to ISO
standards and designed for flange mounting.

Manual Operation

SERVICES

Fuel Storage and Handling

The requirements of BS2869 will ensure that the
fuel is suitable. Under sustained cold and exposed
conditions, fuel should be stored and supplied to
the burner at a minimum temperature of 5C (41F).

Fuel Supply
The oil line should consist of metallic tube (NEVER
galvanised steel). The final connection to the pump
inlet port is made with a flexible pipe supplied with
the burner. Joints should be made with compression
fittings.
When gravity feed is used, the maximum head
should not exceed 4m (35 kPa).
On installations where the fuel tank is situated
below the level of the burner the maximum suction
permitted is 0.4bar (5.8psi) and a two-pipe (supply
and return) fuel supply system MUST be used.

Single Pipe system

On a single pipe (gravity feed) system, the pump
should be primed under gravity from the tank and
not by running the pump mechanically. To prime
the pump remove the pressure gauge plug, connect
the pressure gauge port to a suitable container.

Two-Pipe System
The suction line will require priming before
energising the pump mechanically. It is essential
to ensure that the return pipe is not obstructed in
any way. Any obstructions will damage the pump.
The fuel supply line may need priming if the oil
storage is allowed to drain completely.

The burner is normally fitted with a low flame

terminal link switch to assist commissioning.

Combustion Head
The burner head assembly is of a high quality
which ensures delivery of good combustion
performance which can be maintained over
extended periods of operation, leading to optimal
appliance thermal efficiency and reduced running
costs.
This high specification ensures low level emission
of pollutants and excellent flame stability.

Page 6

AND

NOL 18-100 HL

BURNER OIL SYSTEM

ELECTRICAL CONNECTIONS

ITEM
F2
H1
H2
N1

DESCRIPTION
Appliance Limit Instrument
Burner Fault Signal
Burner Operating Signal
Appliance On/Off Instrument

ITEM
DESCRIPTION
P1 Burner Operating Hours Run Counter
HL High/Low Instrument
LO Remote Lockout Signal

NOL 18-100 HL

Page 7

AIR DAMPER ADJUSTMENT

Hydraulic Ram

Air Control Damper

Hydraulic Ram
Linkage

Adjustable Stop
High Fire

Air Control
Damper Cam

Adjustable Stop
Low Fire
Air Control
Damper Shaft

Flue and Chimney Requirements

The flue and chimney must be constructed and
installed to the appropriate local conditions, Codes
and Standards. It shall be of sufficient size to satisfy
the volume of flue gases at all firing conditions.

Plant Room Ventilation

An adequate dust free supply of fresh air is required
for the burner at both high and low level in
accordance with the appropriate standards.

Existing Appliances
In preparing the appliance to receive the NOL oil
burner, a careful inspection should be made of its
condition after it has been cleaned thoroughly to
remove all adhering tars, scale and dirt.

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.

Page 8

INSTALLATION
General
Check that the burner is appropriate for the
appliance rating. Detailed burner performance
data is given on page 17 at the rear of this manual.

Fitting to the Appliance

If the burner is to be fitted to a new packaged unit,
refer to the manufacturers recommendations.
If the burner is being fitted to an existing appliance,
prepare the mounting flange as detailed on the
dimensions illustration on page 4.
Ensure the joint between appliance and burner is
effectively sealed with the gasket provided.
The flame tube projection is specified by the boiler
manufacturer.

Oil Supply Connections

Connect the oil supply to the burner oil pump
using the flexible pipes supplied. Refer to the
burner oil system diagram.

NOL 18-100 HL

BURNER AIR CONTROLS

PUMP COMPONENT ID
SUNTEC
AJ PUMP

Air Diffuser

Ps

The air diffuser creates a pressure drop to ensure

good fuel/air mixing and flame stability.

Air Damper

The air inlet control is operated by a hydraulic ram,

which is internally spring loaded to the low flame
position and hydraulically extended for high flame.
Manual adjustment screws facilitate air control
setting (see page 8).

Pn
R

Pn

SUNTEC
E7 & J7 PUMP

BURNER OIL CONTROLS

Pn

Ps

Oil Pump

B
All pumps are set for 2 pipe (suction & return)
system. Remove the by-pass plug for single pipe
operation.
ITEM
PORT
S
Suction Port
P
Pressure Port
R
Return Port
Pn
Vacuum Gauge

ITEM
PORT
Ps
Pressure Gauge
A
Adjustment Screw
B
By-pass Plug

Suntec pump models AJ6, J7 and E7 are fitted

to this range of NOL burners, see page 9 for
identification and location of connections and
adjustments.
Maximum flow rates are stated at the
recommended pump pressure for Class D oil of
20.7 Bar (recommended pump pressure for Class
C2 Oil (Kerosene)15 Bar.
If the burner is to be used with Kerosene ensure
that Nu-way are informaed when ordering, a
suitable pump can then be fitted to the burner.
BURNER MODEL

PUMP UNIT

NOL18 to NOL50
NOL60 to NOL85
NOL100

Suntec AJ6
Suntec J7
Suntec E7

Electrical Power Connection

Oil Nozzle

Connect either a three phase or single phase, 50

Hz electrical supply to the burner according to
specification of the burner, observing all applicable
Codes and Standards. The electrical connections
required are shown on page 7 and in the wiring
diagram contained in the instruction pack attached
to the burner. These diagrams also show the
auxiliary control connections, which must be
made.
If the burner is supplied as part of a packaged
appliance/burner unit refer to the appliance
manufacturers instructions.

Hydraulic Oil Ram

MAX FLOW
@ 20.7 Bar
155 l/h
280 l/h
355 l/h

The oil nozzles are of the simplex (single orifice)

atomising type and are fitted to the front end of
the inner assembly and located in the flame tube.
The nozzles should be sized to match the rating
and turndown requirements of the appliance.
There are two atomising nozzles arranged
horizontally, controlled by two magnetic valves.
The right hand nozzle (looking from the rear of the
burner) sprays only on low flame whilst both
nozzles spray together on high flame.

Adjustable stops set the position of the air damper

at high and low flame. Ensure that the locking bolts
have been tightened when commissioning is
complete.
NOL 18-100 HL

Page 9

OPERATION

Inspection

At commencement of the firing cycle, there is a prepurge with forced air and ignition.
After a time delay, the low flame magnetic valve is
energised and allows oil to flow to the low flame
nozzle and the burner lights on low flame.
After a further delay the high flame magnetic valve
is energised, allowing oil to flow to the high flame
nozzle and operate the air damper to the high
flame position. During the running cycle the high
flame magnetic valve is energised via the high/low
controlling instrument, but is always de-energised
at each burner start, thus giving a low flame light
up.
On reaching operating temperature the controlling
thermostat will open and the sequence controller
will shut-off the motor and close magnetic valves.
A limit instrument (hand reset) is also normally
fitted to the appliance.

C OMMISSIONING
IMPORTANT - SAFETY
It is essential that commissioning shall be
undertaken only by suitably qualified and
experienced personnel. In the case of NOL
burners, commissioning engineers should be
experienced in pressure jet oil burner
commissioning. Nu-way can accept no
responsibility for consequential loss, damage or
personal injury which results from a failure to follow
the commissioning instructions provided or from
commissioning procedures being undertaken by
unqualified personnel.

EMERGENCY I NSTRUCTIONS
NOL burners are designed and constructed to meet
current legislation. When used in accordance with
the instructions provided, NOL burners are unlikely
to produce a hazardous condition. If, however
such a condition should arise in connection with
the burner, the appliance or of any instrument,
machine or service in the vicinity of the burner, the
OIL AND ELECTRICITY SUPPLIES SHALL BE
ISOLATED IMMEDIATELY and they shall remain
isolated until the fault has been identified and
rectified.

Page 10

Before commissioning is begun it is important to:

Check that the electrical wiring is complete

and complies with all applicable Codes and
Standards.

Ensure that the fuses are fitted and are of the

correct rating.

Check electrical earthing.

Verify that the oil supply system is correctly

designed and that the supply pipework is
correctly sized and free from leaks.

Ensure that 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
points.

Establish that the appliance is in an

appropriate and safe condition to be fired;
for example, that there is water in the boiler.

Set the appliance controls to call for heat.

Check the appliance ventilation and flueing

arrangements.

Ensure that any warning notices appropriate

to the commissioning procedure are in
position.

Ensure that all necessary tools and test

equipment are available and ready for use.
Essential items include temperature
measuring instruments for measuring flue gas
and appliance water temperatures, and a
means of analysing the flue products for
carbon dioxide (CO2), oxygen (O2), carbon
monoxide (CO) and smoke.

Check that all relevant documentation is

available including, where appropriate:

The agreed plant performance

specifications.

Plant drawings and pipework layouts.

Electrical logic and wiring diagrams.

Certificates confirming satisfactory

completion of procedures such as
soundness testing and electrical safety
tests.

Commissioning, operating and

maintenance instructions for the plant.

NOL 18-100 HL

Establish that the operation of plant other

than that being commissioned will not have
an adverse effect on the operation of the
plant to be commissioned and similarly, that
the operation of the plant to be
commissioned will not have and adverse
effect on other plant.
Confirm that the operation of adjacent plant
and machinery will not constitute a hazard
to the personnel involved in commissioning.

Pre-firing Checks
With the oil and power switched off, carry out the
following checks.

Check the nozzle size and position relative

to the diffuser plate. (The burner head
dimensional details are given on page 17).

Check that the electrode positions and H.T.

leads are correct.

Check the fan motor overload settings.

If the appliance is a boiler, check that the

water level is correct, the controlling valves
are open and that the water pumps are in
working order.

If a flue damper is fitted, check that it is

correctly interlocked to the burner or fixed
in the fully open position.

Ensure that there is a good oil supply to the

burner pump. Bleed one or two gallons from
the flexible to eliminate any pipe scale and
air from the system.

Check that the oil supply is of the

recommended temperature and pressure.

For single pipe systems bleed the burner

pump manually by opening a pressure port
until air-free oil flows. With two pipe
operation bleeding is automatic.

Switch on the electricity supply to the burner.

Switch on the burner at the control panel.

The hydraulic ram will remain in the low fire
position during the pre-purge period.

Allow the fan motor to run up to speed,

switch off the burner and check the fan
rotation (Anticlockwise as viewed from the
motor side) as the fan slows down.

Remove and cover the photoelectric cell with

a clean lint free cloth, switch on the burner,
and allow it to run through to lockout.
During this run check that the ignition spark
is occurring, and note oil pressures at the
moment of ignition. Reset the sequence
control and repeat the run if necessary to
check these functions. If necessary, adjust the
pump to the required pressure and recheck.

Replace the photoelectric cell.

THE BURNER IS NOW READY TO BE
COMMISSIONED.

Commissioning the Burner

NOL 18-100 HL

Open the low flame hold switch (LFC) or

temporarily disconnect the live feed to the
H/L thermostat from its connection in the
burner terminal block.
Switch on the burner, the hydraulic ram will
remain in the low fire position during the prepurge period (approx. 30 Seconds).
The burner should light in the low fire
position. If ignition is not achieved refer to
the fault finding section at the rear of the
handbook
Check the flame visually. If the flame is dirty,
adjust the low fire stop until the flame
becomes clean.
Allow the burner to run until the system is at
normal operating temperature. Turn off the
burner, the flame should go out immediately
and the pressure gauge drop to, or just
above, zero.
Switch off the electricity supply and close the
low flame hold switch. Restart the burner and
allow the burner to change to high flame.
Adjust the high flame stop until the damper
is sufficiently open to give clean combustion.
Check the oil consumption. If this is not
correct for the full burner rating then further
adjustments to the fuel pressure and the high
flame stop will be required.
Switch the burner back to the low flame
position. The oil consumption rate should
now be up to 50% of the rated maximum.
The burner can now be switched between
the high and low position whilst measuring
the flue gas composition. Adjust the
combustion air volume as necessary to give
a high flame CO2 should be within 11% and
12% and the low flame about 1% lower than
these figures.
Page 11

Smoke readings should not exceed No. 2 on

low flame and No.1 on high flame on the
Bacharach Scale under steady flow
conditions.
When a satisfactory setting has been achieved
tighten the lock nuts on the adjustment device.
Check the correct function of all saftey controls and
interlocks
If the burner control panel is inclusive of Low
Excess low and High Water interlocks and alarms,
test that these function correctly. Ensure that the
boiler feed pump switchgear provided in the panel
is operating satisfactorily.
Allow the boiler to attain the correct working
pressure/temperature and adjust the controlling
instruments to the desired values.
Finally check all ancillary controls and equipment
such as damper interlocks etc.

Ignition and flame should be inspected and any

irregularities observed should be rectified i.e.
nozzles and/or electrodes cleaned and any
deposits removed from the inside of the flame tube
and diffuser.

ROUTINE MAINTENANCE
BURNERS

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 temperature. Always cover up the burner
during boiler cleaning operations.
If a burner becomes troublesome then the
assistance of a qualified commissioning engineer
should be obtained. To assist in his diagnosis, notes
should be made detailing the events leading up to
the lockout situation. The symbol appearing in the
lockout window should also be noted prior to
resetting the burner. (Refer to the Sequence
Diagram and Timing Chart).

OF

NOL

General
It is vitally important that personnel responsible
for the day to day operation and maintenance of
the plant are instructed by the commissioning
engineer on the basic function of the burner as well
as the need for routine maintenance and daily
checking of burner operations.
Final adjustments, which will have been made
during the commissioning, must be recorded on
the Commissioning Sheet at the back of this manual
and in the appliance logbook. A copy of the
commissioning data must be sent to the appliance
manufacturer.
The burner should be kept clean inside and out. It
will be more reliable, and if an oil leak occurs it
will be spotted more readily.
Inspect the burner regularly to check if there is any
variation from the correct operating sequence.
Check the correct oil pump pressure.

Page 12

Photoelectric Cell
Remove the photoelectric cell and clean with a
soft lint free cloth if necessary. Be careful not to
touch the glass bulb of the cell as this can lead to
premature failure of the unit.

Replenishing the Fuel Supply

It is usual practice to shut boiler(s) off whilst delivery
of fuel is being made and allow approximately 30
minutes for any sediment to settle before restarting
the burners.

Boiler Combustion Surface

NOL 18-100 HL

FLAME FAILURE & SEQUENCE

C ONTROL

COLOUR

Various types of control boxes are fitted to the NOL

18-100 High/Low series of burners. This manual
covers the standard models from Satronic and
Landis & Staefa.
The units are designed to provide control and
supervision for atomising oil burners of medium
to large capacity. They are suitable for use on multistage and modulating burners.
For safety reasons, at least one controlled
shutdown must be provided within each 24-hour
period of continuous operation.

WHERE

WHAT

GREEN

End

Does
not start

BLUE

Anywhere

Lockout

YELLOW
(NO
FLAME)

End

Lockout

YELLOW
(WITH
FLAME)

End

Lockout

REASON
Incorrect wiring
No voltage at terminal
9
No neutral connection
Stray Light
Photo Cell faulty
Solenoid Leaking
Flame monitoring
circuit broken
No ignition
Fuel supply problem
Solenoid valve
defective
Photo cell dirty
Photo cell or circuit
faulty
No voltage at terminal
20

SEQUENCE CONTROL TIMINGS

Tp

t6

t5
t3

t2

t4

t1

T7

Burner Motor
Air Damper High
Air Damper Low
Ignition
Oil Valves Low
Main Oil High
Flame On
Run

Ts
T

TIME (secs)
PERIOD
t1
t2
t3
t4
t5
t6
t7
Ts
Tp
T

LAL1.25
2.5
5
22.5
11.5
34
15
5
36.5
15
51.5

TMO720
2.5
5
30
7.5
30
7.5
5
40
0
40

DESCRIPTION
Start up time for fan motor
Delay to damper open
Full air pre-purge
Delay to 'High flame'
Pre-ignition
Post Ignition Time
Safety period
Total start up time
Post purge time
Control re-cycle time

NOL 18-100 HL

Page 13

When a burner failure is encountered the box goes

into lockout mode. This is indicated by an red light,
which displays within the lockout window of the
control and is repeated at the lockout lamp on the
panel facia.
If a lockout situation occurs, the burner will not
start until it is manually reset by pressing the
lockout window on the control. (The control can
also be reset by the off/on/reset switch situated on
the control panel facia)
If the burner fails to fire and persists in locking out,
no more than three attempts should be made. To
do so may create a dangerous situation.
When lockout occurs, the control can be reset
immediately. After the resetting (and also after the
correction of a fault which resulted in a controlled
shutdown, or after each mains failure) the sequence
switch always runs through to the start position,
whereby only selected terminals receive voltage in
accordance with the control program. It is only
then that the control unit programs a fresh burner
start up.
Note: Do not press the lockout reset button (or
remote reset switch) for more than 10 seconds.
PLEASE NOTE. When the control box goes to
lockout it is generally performing the function it is
designed for.

FAULT CONDITIONS AND LOCKOUT

I NDICATION
LAL1.25
In the event of fault conditions the sequence
switch stops and simultaneously the lockout
indicator. The symbol appearing above the reading
mark indicates the kind of fault encountered.
No start, because, one or more of the
contacts has not closed or extraneous light
due to leaking fuel valves or faulty flame
supervision circuit.

Shut down of start up sequence, because

the OPEN signal has not been supplied to
control box terminal 8 by the servo motor
limit switch. Terminals 6,7 and 15 remain
under voltage until the fault is corrected.
Lockout due to a fault in the flame
supervision circuit.
Shut down of start up sequence, because
the signal for the low flame position has not
been supplied to control box terminal 8 by
the servo motor auxiliary switch. Terminals
6,7 and 15 remain under voltage until the
fault is corrected.
Lockout, because no flame signal has been
received on completion of the safety time.
Lockout, because the flame signal has been
lost during burner operation or an air pressure
failure has occurred.
Lockout on completion or after completion
of the control program sequence due to
extraneous light (e.g. flame not extinguished,
leaking fuel valves) or due to a faulty flame
signal (e.g. fault in the flame supervision
a
circuit or similar).

Landis & Staefa

LAL1. Program
Sequence Disk.

b
a-b
b - b
b(b) - a
Page 14

NOL 18-100 HL

Start up sequence.
idle steps up to the self shut down
of the sequence switch.
Post purge sequence.

TMO 720
Loss of flame during operation results in immediate
cancellation of fuel release, followed by direct
lockout or repeat of start sequence if jumper II has
been cut..
Start without flame establishment causes
cancellation of fuel release within 5 sec. of its initial
release.
Fuel is supplied only when all parts of the unit are
functioning correctly. All safety circuits are
automatically checked before fuel is released.
Failure of the mains supply always results in a
normal start sequence on restoration of power. If
the control box is at lockout, failure of the mains
supply does not cause it to reset.
Stray light during the pre-purge phase leads to
shutdown and lockout.

BURNER OIL NOZZLE

When the nozzle has completed 3000 hours of
operation, it should be replaced with the same
Make, Type and Size as fitted. Failure to do so will
alter the characteristics of the burner and may
impair the performance and efficiency of the plant.
The nozzle identification code is stamped onto the
face of the hexagonal nut section of the nozzle
body as shown below.
Should any doubts arise concerning the suitability
or performance of the burner nozzle, please
contact the Nu-way Technical dept..

SERVICE & REPLACEMENT

Nu-way Ltd. Parts & Components Division carry a
comprehensive stock making up the burner systems
described in this handbook. Should it become
necessary to order replacement parts, it is
important to quote the burner model, specification
and serial numbers to ensure correct expedition
of your order.
Nu-way Ltd. is able to offer on site
Commissioning, Service and Repair through its
worldwide network of authorised distributors and
sales offices. Please contact the Nu-way Service
Department for further information.

FAULT FINDING
If the Burner Fails to Start
Make sure that all the thermostats and switches in
the control circuit are in the made position.
Check that the electricity supply to the burner is
live and that the control and main circuit fuses
are intact. If a fuse is found to be blown then the
cause should be investigated and rectified before
proceeding further.
On steam boilers, check that the water level
interlocks are in the made position.

If the burner is found at lockout (red )lockout

lamp illuminated
Reset the burner and observe the starting
sequence. (Make reference to the Sequence
Diagram and Timing Charts for the Flame Failure
controls on page 13 for further information).
Check the fan motor overload and reset if necessary.

Flame Occurs Followed by Immediate

Lockout
Check the PE cell and the air damper for correct
operation. Check that the oil pressures are correct.
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 are fully open.

The Burner Starts With The Correct Oil

Pressure But No Flame Appears
Check the ignition system, HT lead connections,
electrode gap and the condition of the electrode
insulators. Check that the air damper mechanism
is not broken or disconnected. It is important to
note that continued resetting of the burner should
be avoided as this can lead to a dangerous
situation.

NOL 18-100 HL

Page 15

BURNER COMMISSIONING SHEET

This manual contains a record of the essential
information and will have been completed by the
commissioning engineer with individual details of
the burner. These details should be verified
periodically and adjusted if variations are noted.
Commissioning details must also be recorded in
the appliance logbook.

BURNER PERFORMANCE CURVES

The Performance Graph shown on page 15 plots
burner input against the appliance running
resistance. The appliance starting resistance is
derived from a combination of the combustion
chamber shape, volume, start rate and flue
conditions. It may be necessary to select 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 intensity of 2 MW/M3 and
an operating resistance between 40 and 90 mm
wg. it is recommended that a burner with a higher
fan static pressure is selected, i.e. if the graph selects
a burner with a 28 cm fan then use the 34 cm fan
model for correct combustion.
All outputs quoted are based on gross C.V.

Page 16

NOL 18-100 HL

BURNER PERFORMANCE CURVES

Burner outputs are based on a gross calorific value of class D fuel of 12.66 kW/Kg.
Graphs produced in accordance with BS EN 267.

NOL 18-100 HL

Page 17

BURNER COMBUSTION HEAD

ITEM
1
2
3
4
5
6
7
8
9
10
11

PROJECTION

64

DESCRIPTION
Diffuser
Primary Air Disc
Primary Air Tube
Ignition Electrodes
Oil Line
Inner Assembly Union
Draught Tube Adaptor
Draught Tube
Flame Tube
Restrictor Ring
Oil Nozzles

1
2
3
4
5
6
7
8
9
10

11

BURNER
NOL18-34
NOL18-38
NOL30-25
NOL35-25
NOL35-34
NOL35-38
NOL50-28

Page 18

A
178
178
178
178
178
178
220

B
165
165
165
165
165
165
197

C
152
152
152
140
152
152
178

D
165
165
NONE
NONE
NONE
NONE
206

BURNER
NOL50-34
NOL50-38
NOL60-28
NOL60-34
NOL60-38
NOL85-38
NOL100-

NOL 18-100 HL

A
220
220
220
220
220
254
254

B
197
197
206
206
206
228
228

C
178
178
178
178
178
203
203

D
206
206
NONE
NONE
NONE
NONE
NONE

ELECTRICAL DATA TABLE - SUPPLY 400-3-50

Burner
Model

Motor
(kW/rpm)

Start
Current (A)

Full Load
Current (A)

Overload

Cable
Size (mm 2 )

NOL18-34

2.2/2800

25

5.0

4 - 6.2

1.5

NOL18-38

3.0/2800

35

6.6

6 - 9.2

1.5

NOL30-25

1.1/2800

15

3.6

1.8 - 2.8

1.5

NOL35-25

1.1/2800

15

3.6

1.8 - 2.8

1.5

NOL35-34

2.2/2800

25

4.6

4 - 6.2

1.5

NOL35-38

3.0/2800

35

6.1

6 - 9.2

1.5

NOL50-28

2.2/2800

25

4.6

4 - 6.2

1.5

NOL50-34

3.0/2800

35

6.1

6 - 9.2

1.5

NOL50-38

4.0/2800

45

8.0

6 - 9.2

2.5

NOL60-28

3.0/2800

35

6.1

6 - 9.2

1.5

NOL60-34

4.0/2800

45

8.0

6 - 9.2

2.5

NOL60-38

4.0/2800

45

8.0

6 - 9.2

2.5

NOL85-38

5.5/2800

40

11.5

8 - 12

2.5

NOL100-38

7.5/2800

60

14.4

11 - 16

4.0

ELECTRODE SETTING

NOL 18-100 HL

Page 19

COMMISSIONING SHEET
The details below are to be completed by the Commissioning Engineer
CUSTOMER/SITE ADDRESS:

CONTRACT NO:

BOILER TYPE/DETAILS:

Rating:

BURNER TYPE/DETAILS:

Serial No:

Nozzles (Make/Size/Angle):

Spec No:

Oil Viscosity:

Production Date:

Boiler Room Ventilation (BS 6644)

Satisfactory

Unsatisfactory

Flue Check (Visual)

Satisfactory

Unsatisfactory

Satisfactory

Unsatisfactory

Oil Leaks

(BS 5440)

(Visual)

COMBUSTION DETAILS
CO2

Smoke Number
Ambient Temp.

Gross Stack Temperature

Chamber Pressure

mbar

Draught Smoke Hood

Fan Static
Oil Temperature

mbar/mm
C

Oil Pressure Atomising bar

bar

Return Pressure

bar

Oil Throughput

cal/metre

Boiler Temperature / Pressure

Boiler Starting Resistance
Air Control Setting %

mbar/mm
%

P E Signal

CHANGE TO SPECIFICATION: ..

SATISFACTORY / UNSATISFACTORY

NAME: ..
SIGNED: .

Page 20

NOL 18-100 HL

DATE:

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

NOL 18-100 HL

Signature

Page 21

N OTES

Page 22

NOL 18-100 HL

NOL 18-100 HL

Page 23

Enertech Limited,
P O Box 1,
Vines Lane
Droitwich,
Worcestershire,
WR9 8NA
Tel:
+44 (0) 1905 794331
Email: [email protected]

Fax:
Web:

+44 (0) 1905 794017

www.nu-way.co.uk