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Nu-Way XGN Series User Manual

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XGN Handbook
HANDBOOK
Series XGN fully automatic burners
Models XGN450 to XGN3000
Natural Gas
®

Table of Contents

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Nu-Way XGN Series Specifications

General IconGeneral
Fuel TypeNatural Gas, Propane
ControlModulating
ConstructionHeavy-duty steel
Air SupplyForced Draft
ApplicationsIndustrial heating, Process heating
Ignition TypeDirect Spark Ignition (DSI)

Summary

Safety Precautions

Emergency Instructions

Procedures for isolating gas and electricity supply in hazardous conditions.

European Boiler Efficiency Directive (B.E.D.)

Burner compliance with EU directives and adjustment requirements.

Important Notice

Warning about isolating the MBC unit before handling wiring or components.

Burner Component Identification

Combustion Head Details

Control Panel and Electrical Data

Connecting the Electrical Supply

1 or 3 Phase Connections to the Motor Contactor

Details electrical connections for single and three-phase motor contactors.

Connections to the 7 & 4 Pin Plugs - H/L Burner

Wiring diagrams for 7 and 4-pin plugs for High/Low burners.

Connections to the 6 Pin Plug - Modulating Burner

Wiring diagrams for 6-pin plugs for modulating burners.

Auxiliary Connections

Details for optional auxiliary connections like volt-free contacts and limit instruments.

FEATURES

Air Regulation

How combustion air is adjusted for maximum efficiency with a closed position control.

Controls & Operation

Information on two-stage (high-low) or modulating operation via the burner controller.

Fuel

Handbook covers natural gas only; refer to Nu-way Ltd. for other requirements.

GENERAL

Handbook structure to guide users from delivery to use, covering controls and adjustments.

SERVICES & SITE CONDITIONS

Gas Supply

Requirements for gas supply pipework, isolation valve, and pipe size.

Flue and Chimney Requirements

Requirements for flue and chimney construction and installation for sufficient gas volume.

Plant Room Ventilation

Need for adequate dust-free fresh air supply for the burner in the plant room.

Existing Appliances

Inspection of appliance condition after cleaning before fitting the burner.

Combustion Chamber Conditions

Requirement for combustion chamber draught not to exceed 0.25 mbar.

Packaging for Transit

Burner may be despatched partly assembled in two or three units to prevent damage.

Assembly

Instructions for fitting the hinged extension, flame tube, and gas train.

INSTALLATION

General

Check burner suitability for appliance rating and review performance data.

Fitting to the Appliance

Instructions for fitting the burner to new or existing appliances, ensuring proper sealing.

Electrical

Requirements for main electrical supply, disconnection, IEE regulations, and earthing.

Air Pressure Switch

Function of the air pressure switch to prove adequate airflow and its lockout behaviour.

BURNER GAS CONTROLS

Gas Nozzle

Details on gas nozzle design for specific burner models and gas types.

Gas Pressure Switch

Functions of the low gas pressure switch for monitoring and leak testing.

INTEGRATED VALVE PROVING SYSTEM

Functional sequence

Describes the step-by-step process of the integrated valve proving test.

OPERATION

Gas Supply Pressures

Guidelines for checking gas supply pressures at full firing rate using a manometer.

Adjust IR Detector

Instructions for adjusting the IR detector sensitivity for proper flame monitoring.

COMMISSIONING THE BURNER

Check for Valve Closure

Procedure to test the security of the gas valve system for leaks.

ESTABLISHING MAIN FLAME

Measuring Gas Flow

Emphasizes using the gas meter for accurate throughput determination and checking gas/flue analysis.

MULTI-FUNCTIONAL DISPLAY

Microprocessor Burner Control Unit (MBC)

Guide for engineers unfamiliar with the MBC unit, including pass-code entry.

Entering the pass code

Detailed steps for entering the pass code to access commissioning or part commissioning functions.

Commissioning Procedure

Initial settings for air and gas

Overview of initial air and gas settings (P9, P1, P0) for burner setup.

Firing the burner

Procedure for starting the burner, checking fan rotation, and initial flame adjustments.

Final ADJUSTMENTS

Setting the Air Pressure Switch

Steps to adjust the air pressure switch for correct operation and lockout behaviour.

Setting the Flame Signal

Procedure for setting the flame signal sensitivity using LED indicators and microammeter.

Setting the Low Gas Pressure Switch

FINAL CHECK

THE RWF40 MODULATION CONTROL

Basic display

Explanation of the RWF40 controller's basic display showing actual and set-point values.

To change the working set point

Instructions for altering the set point on the RWF40 using the PGM and up/down buttons.

RWF40 Recommended Parameters

Configuration Values

To enter a new parameter

MBC DISPLAYS

Standby Display

Information about different screen messages displayed when the burner is in standby.

Operating Display

Details on the information displayed during burner operation and sequence steps.

Information Display

How to access and navigate the information display for burner status and data.

Service Display

Procedure to access the service display for maintenance and advanced diagnostics.

ROUTINE Safety Checks

Flame Detection System (IRD Cell)

Procedures for checking the IRD cell's functionality and lockout behaviour under various conditions.

ROUTINE MAINTENANCE

Combustion Air Fan

Cleaning instructions for the combustion air fan blades and air inlet.

Inner Assembly

Steps for opening the hinged extension to access the inner assembly.

Fault Finding

MBC Error Codes

Table listing MBC error codes and their descriptions for troubleshooting.

Troubleshooting Burner Operation

Incorrect Rotation of Burner Motor

Checks and fixes for incorrect burner motor rotation direction.

Motor & Fan Removal

Steps for removing the motor and fan assembly from the burner.

Burner Motor Fails to Start

Checks for common causes of the burner motor failing to start.

Starting Flame Failure Without Ignition

Troubleshooting steps for flame failure when ignition does not occur.

Starting Flame Failure Without Flame

Troubleshooting steps for flame failure when ignition occurs but flame is not established.

Burner Fails to Establish Main Flame

Checks for issues preventing the burner from establishing a main flame.

IR Detector Possible Faults

Common faults related to the IR detector and their causes.

6FH Error - Air Servo Motor Failure

Diagnosis and resolution for the 6FH error indicating air servo motor failure.

6FH Error - Gas Servo Motor Failure

SPARE PARTS

BURNER PERFORMANCE CURVES

Commissioning Sheet

Burner Service Record

Notes

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