Ngn15!25!35 Manual
Ngn15!25!35 Manual
Ngn15!25!35 Manual
Gas Burner
Tel: +44 (0) 1905 794331 Fax: +44 (0) 1905 794017 Email: info@nu-way.co.uk Web: www.nu-way.co.uk
Contents
IMPORTANT - SAFETY ....................................................................................................... 3
EUROPEAN BOILER EFFICIENCY DIRECTIVE (B.E.D.) ............................................................... 3
BURNER & COMPONENT IDENTIFICATION FOR NGN15 O/O ................................................. 4
BURNER & COMPONENT IDENTIFICATION FOR NGN15 & 25 H/L ......................................... 6
BURNER & COMPONENT IDENTIFICATION FOR NGN35 ......................................................... 8
FEATURES .................................................................................................................... 10
Burner Capacity ............................................................................................................................. 10
Air Regulation ................................................................................................................................ 10
Controls......................................................................................................................................... 10
Operation ...................................................................................................................................... 10
Fuel ............................................................................................................................................... 10
Weight .......................................................................................................................................... 10
GENERAL ..................................................................................................................... 10
Flue And Chimney Requirements ................................................................................................... 10
Plant Room Ventilation .................................................................................................................. 10
Existing Appliances ........................................................................................................................ 10
Combustion Chamber Conditions .................................................................................................. 11
PACKAGING FOR TRANSIT ............................................................................................... 11
Assembly ....................................................................................................................................... 11
SERVICES & SITE CONDITIONS ......................................................................................... 11
Gas Supply .................................................................................................................................... 11
INSTALLATION ............................................................................................................... 11
General ......................................................................................................................................... 11
Fitting To The Appliance ................................................................................................................ 11
Electrical Power Supply .................................................................................................................. 11
Wieland 7 and 4 Pin Connections .................................................................................................. 13
BURNER AIR CONTROLS ................................................................................................. 14
Single Stage (On/Off) Burner Only ................................................................................................. 14
Two Stage (High/Low) Burners........................................................................................................ 14
Air Diffuser .................................................................................................................................... 14
Air Pressure Switch ........................................................................................................................ 14
BURNER GAS CONTROLS ................................................................................................ 14
Gas Nozzle .................................................................................................................................... 14
High Gas Pressure Switch (High/Low Only) .................................................................................... 14
Low Gas Pressure Switch ............................................................................................................... 14
Gas Valve Multibloc - Single Stage (On/Off) NGN15 ....................................................................... 14
Gas Valve Train - Single Stage (On/Off) NGN25 & 35 ..................................................................... 14
Two Stage (High/Low) NGN15, 25 & 35 ......................................................................................... 14
Air Damper Motors ........................................................................................................................ 15
Valve Adjustment Diagram - Dungs Gas Valve NGN15 On/Off ....................................................... 16
Valve Adjustment Diagram - Landis & Staefa SKP7x Gas Valve High/Low Burners .......................... 17
Valve Adjustment Diagram - SKP2x Gas Valve NGN25 & 35 On/Off .............................................. 18
CONTROLS .................................................................................................................. 18
FLAME MONITOR .......................................................................................................... 18
BURNER OPERATING SEQUENCE ....................................................................................... 18
Single Stage (On/Off) Burners ........................................................................................................ 18
Two Stage (High/Low) Burners........................................................................................................ 18
Air/Gas Ratio Controller - Two Stage (High/Low) ............................................................................. 19
Initial Burner Setting - Two Stage (High/Low) .................................................................................. 19
Air/Gas Ratio Controller ................................................................................................................. 19
IMPORTANT - SAFETY
MPORTANT
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 anyone
working on gas installation, as defined in the “Gas Safety (Installation & Use) Regulations 1994” is
CORGI registered. The manufacturer cannot be held responsible for any consequential damage, loss or
personal injury as a result of failure to follow these instructions, or as a result of misuse. Your attention
is drawn to the Emergency Instructions on Page 20.
Item Description
1 Burner Casing
2 Hinged Ex tension
BURNER MOUNTING
3 Flame Tube DETAIL
4 Fan Motor
5 Air Inlet
Low Gas Pressure
D
6
PC
Switch
7
19
7 Burner Controls
45°
8 Control panel
9 Air Pressure Switch
10 Gas Multibloc Valve
4 OFF M12 x 40
PROJECTION
STUDS HOLE Ø168
240
9
10
4
369 200
1.1/4 BSP
8
7
5
BURNER
740 PROJ’N
1 2 3
100
100
210
305
Item Description
1 B urner Casing
2 Hinged Ex tension
3 Flame Tube BURNER MOUNTING
DETAIL
4 Fan Motor
5 Air Inlet
6 Air Damper Motor
D
PC
7 B urner Controls
7
19
8 Low Gas Pressure Switch
45°
9 High Gas Pressure Switch
10 Gas Valve B ody
11 Gas Control Valve (SKP7x )
12 Main Gas Valve (SKP1x )
13 Pilot Solenoid Gas Valve 4 OFF M12 x 40
14 Pilot Gas Governor PROJECTION
15 B urner Control Panel STUDS HOLE Ø168
16 Air Pressure Switch
555 200
16
330
10 11
12
8
125
13
NGN15 = 1.1/2” BSP
7 15
NGN25 = 2” BSP
480
14
9
5
BURNER
765 PROJ’N
1 2 3
118
100
226
305
9 5
16 6
3 2 1
14
480
13
4
15
2” BSP
132
105 470
BURNER 811
PROJ’N
11
12 7
140
260
10
D
6 Air Damper Motor
PC
4
7 B urner Controls
25
8 Low Gas Pressure Switch
9 High Gas Pressure Switch
10 Gas Valve B ody
11 Gas Control Valve (SKP7x )
12 Main Gas Valve (SKP1x )
13 Pilot Solenoid Gas Valve 8 OFF M10 x 35
14 Pilot Gas Governor PROJECTION HOLE Ø200
15 B urner Control Panel STUDS
16 Air Pressure Switch
555 210
363
A new range of valve actuators has been introduced by Siemens as an upgrade to the SKP range. The
new actuators SKP15, 25, 55 and 75, are replacements for the SKP10, 20, 50 & 70 which will
become obsolete. The new range of actuators will be introduced into the Nu-way range of Gas and
Duel Fuel Burners as from the 1st of June 2006.
The new range of SKP actuators have plug in connections so Nu-way can no longer use the actuators
as junction boxes and therefore a separate junction box will be introduced to gas trains (Similar to
valve proving configuration).
Spares supply for the SKP10, 20, 50 & 70 will continue until around January 2007 depending on
stock usage, in future the spares replacement for SKP valve actuators will be an upgrade kit
comprising of the new actuator plus the junction box and wiring harness to enable the fitting of the
SKP15, 25, 55 and 75 to burners originally fitted with the SKP10, 20, 50 & 70.
The new actuators are physically different however the function and adjustment remain the same,
they will fit all existing gas valves (VGD etc.) which are unaffected.
In accordance with the Requirements for Electrical Installations BS 7671:2001 Amendment No 2 (the
IEE wiring regulations), wiring colour coding has been amended to Brown (L) and Blue (N) for single
phase power circuits and Brown (L1) Black (L2) and Grey (L3) and Blue (N) in three phase power
circuits from 1 June 2006.
Full details of the changes can be found in Amendment No 2 (AMD 14905) to BS 7671:2001 - which
is a free download from the IEE website (www.iee.org/cablecolours). They are also within the new
version of BS7671:2001 (Incorporating Amds 1& 2) published on 31st March; this new version of the
Wiring Regulations can be identified by its brown cover.
3 Phase 400V/50Hz
Burner Motor Start Full Load Main Cable
Model (kW/rpm) Current (A) Current (A) Fuse (A) Size (mm2)
N GN 1 5 & 2 5 0.75/2800 8.0 2.0 10 1.0
N GN 3 5 1.1/2800 9.0 2.7 10 1.0
(1PH) 1 2 3 4
N/O AUXILLARY 13
BR = BURNER RUN.
CONTACT ON
LO = LOCKOUT.
MOTOR STARTER.
L N
14
(3PH) 1 2 3 4 L 5 6 7 8 9 10 11 12 13 14 15 16 17 18
L1 L2 L3 N L BR LO
*
MULTI SINGLE
BOOSTER BOOSTER OUTLET INLET
Tp HIGH/LOW START START BOOSTER
INSTRUMENT INTERLOCKS
(IF REQUIRED)
LIMIT Tp
INSTRUMENT
*1 PH(IFCONTROL
FITTED) FOR CONNECTION OF
CIRCUIT SUPPLY ON
3 PH BURNERS ONLY
N PE L
BURNER
SOCKET
B4 S3 T2 T1 N L T8 T7 T6 B5
B4 S3 T2 T1 N L T8 T7 T6 B5
APPLIANCE
PLUG
N1 F2 N2
T T T
h h
P1 H1 H3 P2
S1
F1
N PE L
Berger Lahr
STM30 Q5
Cam Factory
Cam
State Setting
Full Air
1 0°
Shut-off
L ow
Flame 2 15°
Air
High
Flame 3 60°
Air
Note: The fully closed cam is factory set, and under normal circumstances
should not require further adjustment. Operation of the low and high flame air
switches is made by manually adjustable cams. A setting scale is provided at the
end of the cam stack for guidance, while adjustments are made using the screw
adjusters situated within the cam disk body (STM30 Q5), or with levers and fine
setting screw adjusters (STM30 B2).
Adjustment Description
Governor adjustment. Turn clockwise to increase pressure.
A
R ange = 4 - 20 mbar.
B Main Valve fast initial lift adjuster (R emove fluted cover).
Main Gas Adjustment. Slacken cheesehead screw and turn
C
fluted knob anti-clockwise to open.
D Low Gas pressure switch.
E Upstream pressure Test Point.
F Downstream pressure Test Point.
G Pilot R ate Adjuster. Turn anti-clockwise to increase rate.
H Test Point between valve seats.
COMBUSTION ATMOSPHERE
Adjustment Description
Adjustment and indication of the gas/air ratio (high fire
1
setting).
Adjustment and indication of the parallel displacement of the
2
characteristic (low fire setting).
3 Vented to atmosphere.
4 Connection to the gas line.
5 Connection to the combustion air supply at the burner head.
6 Indication of the valve stroke.
Air/Gas Ratio Controller - Two Stage (High/Low) Initial Burner Setting - Two Stage (High/Low)
The controller controls the gas pressure related to Remove the cover from the air damper motor on
the pressure of the combustion air so that the gas the end of the air inlet casing. Check and adjust
to air ratio remains constant over the entire output the cam positions (refer to settings on page 15).
range of the burner. When using the controller, a
separate gas pressure governor is not required. Air/Gas Ratio Controller
In installations with negative pressure in the com- Remove the small plate on top of the regulator and
bustion chamber, the air impulse pipe from the keep it in a safe place. Set the air/gas ratio at 0.8
burner to air/gas ratio valve must always be under on the visual scale by adjusting the screw (1) anti-
a positive pressure condition. clockwise to increase, or clockwise to decrease.
T total
Controller Type
Sequence
DMG MMI TMG7- L FL Sequence Description
Phase L GB 2 1
970 810 40-3 1.333
T1 40 40 30 40 40 Combustion Air Pre-purge
T2 3 4 2 4 6 Pre-ignition
Note: The pre-purge times shown refer to the control box only. The air damper control will extend the total burner
purge time up to 127 seconds depending upon the firing rate and air requirements of the appliance.
Check For Valve Closure. The space between the upstream manual valve and
the gas train inlet should now be filled with gas at
All gas train assemblies are fully tested for function inlet pressure. If the pressure remains stable over
and valve security before despatch. A test of the one minute then this indicates that the valve train
gas valves is difficult without specialised testing is secure, but not necessarily in the main valve. If
equipment. However, the following check can be the pressure decreases then this indicates that the
performed to test the security of the valve system. main and one other valve is leaking or that there is
Ensure the gas supply pipework to the burner gas a leak between the upstream manual valve and
line inlet is sound and gas is available at the re- the main gas valve.
quired inlet pressure for the burner. Fit a manom- Secure the upstream test point and fit the manom-
eter to the test point at the inlet to the upstream eter to the test point situated between the main
main safety valve. Open the main upstream manual and control valves. Check the reading on the ma-
valve for a few seconds, then close and secure the nometer, this should now show near atmospheric
gas supply. pressure. Open the upstream manual valve and
look for an increase in pressure over one minute. If
no rise is detected, this indicates that the main valve
is closing correctly.
Item Description
1 B urner Gas Nozzle
2 B urner Flame Tube
Diffuser Mounting
3
Stud
4 Ignition Electrode
Inner Assembly
5
Elbow
6 Diffuser Plate
Ionisation Probe (if
7 3.0
fitted) 3.5
Probe Insulation
8
Piece (if fitted)
5
Inner Assembly
9
Sealing R ing
Inner Assembly
10
A d a p t or
IONISATION PROBE
OMITTED WHEN
U.V. CELL FITTED
146 DIA
8 x 8.0 DIA HOLES
135 DIA
2
PROJECTION
96
6
6
8
45
3
71
1
115
7
4
9
5
10
Item Description
1 B urner Gas Nozzle
2 B urner Flame Tube
Diffuser Mounting
3
Stud
4 Ignition Electrode
Inner Assembly
5
Elbow
6 Diffuser Plate
Ionisation Probe (if
7
fitted)
PILOT
TUBE
Probe Insulation 3.0
8
Piece (if fitted) 3.5
40
Inner Assembly
9
Sealing R ing
5
Inner Assembly
10
A d a p t or
146 DIA
135 DIA
2
PROJECTION
96
6
6
8
45
3
71
1
115
7
4
9
5
10
Item Description
1 B urner Gas Nozzle
2 B urner Flame Tube
Diffuser Mounting
3
Stud
4 Ignition Electrode
Inner Assembly
5
Elbow
6 Diffuser Plate
Inner Assembly
7
Sealing R ing
Inner Assembly
8
A d a p t or
PILOT
TUBE
3.0
3.5
40
5
172 DIA
8 x 9.5 DIA HOLES
152 DIA
2
90
12
PROJECTION
3 6
45
65
1
4
105
7
5
15 15
d)
ar
nd
h)
in c
ta
(S
(1
h)
0
inc
41
re
su
5
.2
es
(1
Pr
2
ad
41
He
as
10 10
G
e
s ur
es
Pr
ad
He
r
Ai
Combustion Chamber Resistance (mbar)
.
mb
Co
5 5
Burner Performance
Envelope
0 0
200 300 400 500
40
Combined Burner Head and Line Loss (mbar)
30 30
n
ai
Tr
as
lG
na
io
pt
O
ch
in
20 20
1
in
Ga
s Tra
Combustion Chamber Resistance (mbar)
d.
St e
inc
h sur
P res
1 .5 ead
10 sH 10
Ga e
su r
P res
ead
. Air H
Co mb
Burner Performance
Envelope
0 0
200 300 400 500
ne
Li
as
lG
na
io
15 15
pt
O
ch
ne
in Li
5
as
1.
G
d. e
St ur
ch ess
in Pr
2 ad
He
as
G
re
su
res
P
d
ea
10 ri H 10
A
b.
om
C
5 5
Burner Performance
Envelope
0 0
350 450 550 650
40
Combined Burner Head and Line Loss (mbar)
30 30
ain
in
Tr
a
Tr
s
Ga
s
Ga
d.
St
al
on
ch
ti
In
Op
20 20
h
In c
1 .5
e
ur
ess
Pr
d
ea ur
e
H ss
as Pr
e
G d
ea
.A
irH Combustion Chamber Resistance (mbar)
b
m
Co
10 10
Burner Performance
Envelope
0 0
400 600 800 1000 1200
Address : ________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
Tel: +44 (0) 1905 794331 Fax: +44 (0) 1905 794017
Email: info@nu-way.co.uk Web: www.nu-way.co.uk