Oilon GKP-50 MH Operation And Maintenance Manual Download Page 1

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M5164 1640EN

13 October 2016

Original instructions

Operation and maintenance manual
Burner models: GKP-50 MH - 90 MH
Burner equipment: WD34

Read these instructions carefully before installation, use, or maintenance

Summary of Contents for GKP-50 MH

Page 1: ...4 1640EN 13 October 2016 Original instructions Operation and maintenance manual Burner models GKP 50 MH 90 MH Burner equipment WD34 Read these instructions carefully before installation use or mainten...

Page 2: ......

Page 3: ...supply line 25 3 7 Installing gas pressure regulating assembly 25 3 8 Installing hoses 27 3 9 Oil piping 28 3 10 Electrical connections 30 4 Commissioning 4 1 First start up 32 4 2 Adjusting nozzle a...

Page 4: ...Time sequence diagram gas use without ignition gas 69 5 6 Operation description gas use 69 5 7 Time sequence diagram oil use 2 stage 73 5 8 Operation description oil use 73 6 Maintenance 6 1 Burner m...

Page 5: ...nowledge Failure to follow these instructions can lead to damage to the appliance Erroneous use of the appliance or the failure to follow any instructions or warnings in the manual or this disclaimer...

Page 6: ...Requirements or in their absence the CGA B149 1 and B149 2 Installation Codes shall prevail IN CASE OF FIRE OR OTHER EMERGENCY Cut off power supply Close main fuel shut off valve Take appropriate acti...

Page 7: ...in tidiness in boiler room and keep boiler room door closed Make sure that there is always enough water and pressure in heating system Make sure boiler and chimney are swept regularly Check flue dampe...

Page 8: ...ressure The burners can be mounted in horizontal vertical and upward facing or vertical and downward facing orientation Our burners are designed for operation in covered areas within the temperature r...

Page 9: ...dditional code for example burner capacity I III or automation like WD34 WD32 BT 320 burner control one fuel non permanent operation WD33 BT 330 burner control one fuel permanent operation WD34 BT 340...

Page 10: ...US marking and certification institute code 1 4 Handling and storing Storing and recycling Store device and its equipment in a dry and airy place Protect device from dust and humidity Follow storing a...

Page 11: ...her technical data and requirements Fuel gas use Natural gas When using other gases than natural gas the composition of the gas must be known Consult burner manufacturer on the suitability of the burn...

Page 12: ...T 300 series Power supply 115 VAC 15 10 Locking from undervoltage Less than 85 of nominal Mains frequency 50 Hz 60 Hz Power consumption 30 VA Internal shielding Safety equipment do not self service Ex...

Page 13: ...damper X34 continuous output 3 oil damper 1 SIC safety interlock chain 2 115 VAC 47 63Hz external fuse protection required max 10A slow blow 3 115 VAC for power supply to external devices 4 Fuel selec...

Page 14: ...nnector interface LCM connector interface ver 3 Cable assembly Type Shield Cable length m Cable length ft Network input AC in 100 328 24 V external DC out 100 328 LSB IO 1 3 CAN IO X 100 328 Fuel meas...

Page 15: ...Lamtec system bus Turning angle 90 90 90 Accuracy 0 2 0 2 0 2 Torque operation hold 1 2 0 8 Nm 10 62 7 08 lb in 3 2 8 Nm 26 55 24 78 lb in 9 6 Nm 79 65 53 10 lb in Running time 90 degrees 5 s 5 s 15...

Page 16: ...witch Type Dungs GMH GML GAO A4 4 Maximum operating pressure 7 PSI 500 mbar Adjustment range See cover of switch Hysteresis GAO A4 4 2 GAO A4 4 3 GAO A4 4 5 GAO A4 4 6 GAO A4 4 8 in W C 0 12 0 20 0 40...

Page 17: ...40 C to 60 C Switching voltage AC 24 250V DC 24 48V Switching current AC 5A resistive 120 VAC AC 3A inductive 120 VAC DC min 20 mA 24 VDC DC max 1A 12 48 VDC Degree of protection NEMA 12 Installation...

Page 18: ...400 ANSI Z21 21 CSA 6 5 C I Type Siemens VGD 20 40 Maximum operating pressure 240 88 in W C Allowed ambient and medium temperature 5 F 140 F Group according to EN 161 2 Installation position Pressure...

Page 19: ...ng to all local regulations and requirements Space requirements ver 1 Legend Minimum dimension cm Minimum dimension ft a left 80 2 6 b front 80 2 6 c right 80 2 6 d top 100 3 3 It is recommended to le...

Page 20: ...Item 1 Lifting belt 2 Lifting support 3 Gas frame To lift the burner 1 Remove the burner cover 2 Set the lifting belt 1 around the flame sight tube and the gas frame 3 3 Place the lifting support 2 b...

Page 21: ...3 3 Installing burner GKP 50 MH main dimensions D048897 ver 3 M5164 1640EN 19 95...

Page 22: ...GKP 90 MH main dimensions D048844 ver 3 Mounting dimensions 1 Mounting plate 2 Insulating plate 3 Ceramic wool or similar A 349A ver 2 Burner L mm 240 300 300 400 L inch 20 95 M5164 1640EN...

Page 23: ...e bearing grease prior to fitting 3 Install the burner so that the motor shaft lies horizontally 4 Remove the transportation bracket after the burner is attached to the boiler 5 Make sure there is eno...

Page 24: ...The parts are delivered separately The regulator valve servomotor and connection flange are ready fitted to the double solenoid valve The following illustration describes the gas module parts 1 2 2 3...

Page 25: ...lve 13 Cable gland for gas high pressure switch 6 1st stage oil valve 14 Gas valve cable gland 7 Main oil valve 15 Injector hoses 8 Gas high pressure switch 16 Hinge locking screw 9 Gas low pressure s...

Page 26: ...ange locking screw 16 Now you can open the burner from the hinged joint When closing the burner perform the steps in reverse order To detach the burner from the boiler 1 Switch off the power from the...

Page 27: ...al public authority Check that there is a separate filter before gas equipment Prior to installing gas pressure regulator block to piping use compressed air to blow supply piping clean Clean and check...

Page 28: ...than the secondary pressure aka pressure after the regulator Set the safety shut off valve to closed position at an approx 60 higher pressure than the secondary pressure Closing the pressure of the sa...

Page 29: ...auge valve when necessary 6 Pressure regulator with safety shut off valve and safety relief valve 14 Pressure gauge high pressure when necessary 7 Pressure gauge valve 15 Fuel flow meter can also be o...

Page 30: ...uivalent nationally recognized manual valve safety standard A 429T ver 2 1 Filter 2 Oil hose suction 3 Oil pump 4 Pressure pipe to nozzle 5 Oil hose return 6 By pass plug 7 Shut off valve 8 Shut off v...

Page 31: ...t absolute tightness is the fundamental prerequisite for secure operation A leaking suction line may cause among other things afterspraying of oil into the boiler It is advisable to use ball valves in...

Page 32: ...0 12 0 39 0 79 1 42 2 0 0 08 0 24 0 51 0 94 3 0 0 0 12 0 28 0 51 4 0 0 0 0 0 08 2850 rpm 20 mm s cSt H max 14 ft 3 10 Electrical connections Connect burner according to the electrical diagrams deliver...

Page 33: ...ed outside the burner s wiring base When using frequency converter do cabling work and grounding according to manufacturer instructions Locate frequency converter as near to motor as possible to avoid...

Page 34: ...refully investigating the reason for the failure First start up check list Check the following before first start up instructions from boiler and burner manufacturers are followed piping is done prope...

Page 35: ...rner control switch to OFF position 4 2 Adjusting nozzle and ignition electrodes Check and set the ignition electrode spark gap and the distance of the nozzle to the ignition electrodes and diffuser d...

Page 36: ...low and pressure follow the following formula V1 capacity marked on the nozzle V2 nozzle capacity at a pressure of P2 P1 7 bar gives USgal h P2 pressure to be used Example Nozzle capacity when the noz...

Page 37: ...CO content OR flame tear off from diffuser disc when switching to higher capacity adjustment ring is too rear with low capacity there is not enough pressure drop deficient combustion O values too high...

Page 38: ...fter every adjustment with a flue gas analysator 2 Set combustion air levels within servomotor operation range Guideline values Capacity Fuel O2 level Soot index Ignition minimum and part power Light...

Page 39: ...g 2 Let the burner operate for a while Air bubbles come out of the hole 3 When no more bubbles come out retighten the plug carefully If the atomizing pressure during capacity change from max to min ex...

Page 40: ...al air pressure switch Connectors in control box are under voltage Only authorized users may open safety cover Differential air pressure switch monitors pressure difference generated by burner fan A40...

Page 41: ...in W C from this point backwards to minimum 5 Replace the protective cover and reset 4 8 Adjusting gas pressure switch Gas pressure switch A461R ver 2 1 Adjusting scale 2 Pressure measuring connectio...

Page 42: ...d gas 4 9 Setting gas pressure regulator SKP The operating area of the gas pressure regulator is determined by the spring installed inside the pressure regulator There are three types of springs and t...

Page 43: ...e the component Spring type pG mbar p 360 Color Model AGA29 22 2 2 blank SKP25 0 AGA22 15 120 11 9 yellow SKP25 0 AGA23 100 250 24 5 red SKP25 0 AGA22 100 700 yellow SKP25 4 AGA23 1500 245 red SKP25 4...

Page 44: ...erating area of the gas pressure regulator is determined by the spring installed inside the pressure regulator The factory setting of standard spring p2 is 10 30 mbar Springs can be ordered from Oilon...

Page 45: ...DN 125 DN 150 Spring 1 2 5 9 brown 229 851 229 874 229 883 229 892 229 901 229 909 Spring 2 5 13 white 229 852 229 875 229 884 229 893 229 902 229 910 Spring 3 5 20 orange 229 853 229 876 229 885 229...

Page 46: ...s if needed 7 Shut off the burner 8 Finally close all the test point connections and remove measurement equipment Make all adjustments when the burner is running All stated pressure values are only fo...

Page 47: ...KP 90 MH 50 34 20 13 7 4 12 Operating and display unit User interface For scrolling and changing the values use the buttons shown on the display Control panel ver 2 1 Display 2 Back 3 Arrow keys 4 Ent...

Page 48: ...password Service level 1 password protected for commissioning and maintenance personnel Burner manufacturer level 2 password protected 4 13 Display menus Menu structure Menu structure ver 4 A Main men...

Page 49: ...Selected burner information 2 Fault history 3 Software version 4 Check sum display 5 Serial number 6 Configuration of actual value of actuating outputs 7 Digital inputs outputs Info ver 3 C2 Manual me...

Page 50: ...urner control Ratio ratio curves The system automatically returns from any user level to the basic user level after a delay If you enter an incorrect password the system also returns to the basic user...

Page 51: ...utputs Ratio curve editor 3400 ver 3 editing the ratio curves Deleting ratio curves 3600 ver 3 deletes all curves Setting parameters for controllers 3700 ver 4 parameters for load controller module LC...

Page 52: ...and restoring dataset During these actions the burner should be shut down To save the dataset from the burner control to the operating panel press the saving dataset icon To restore the dataset to the...

Page 53: ...oller module start up limit missing symbol is blinking Hint 2001 Ignition happens only towards the end of safety time Hint 2002 Intermittent operation automatic restart 4 14 Manual start up and servom...

Page 54: ...purge must ventilate combustion chamber to fresh air level Oil use Pre purge minimum duration is set at 15 s when air amount should be 30 of full load air amount Servomotor settings should be the half...

Page 55: ...ignition position 1 stage 1 To set the condition press Enter 2 To change the setting move to the setting with the arrow keys S row The set values of the servomotor air are shown in the following figu...

Page 56: ...mark indicates the active page 11 I row actual values channel 1 Select the desired curve point page with arrow keys 2 To enter the editing state press Enter 3 On the setting row set the cursor with ar...

Page 57: ...g ratio curve oil 2 stage Creating 2 stage operation curve points 1 1 stage point same as the ignition point 1 2 2 stage valve opening point when shifting from 1 stage to 2 stage 1 2 2 stage valve clo...

Page 58: ...ad situation Check combustion values of ignition capacity with flue gas analysis 4 19 Capacity range The burner capacity range can be set at service level The minimum capacity can be higher than the f...

Page 59: ...4 22 Setting load controller parameters In the following table the marking w stands for water and s for steam Param no Description Factory setting 0040 BT300 Type of output regulator 0 OFF 1 constant...

Page 60: ...In this control mode LCM s own PID controller is not in operation Hence the start up and shutdown limits must be formed externally controlled to the start up circuit BURNER ON X10 External set point v...

Page 61: ...ency to oscillate slower start up P term too high P term diagram ver 1 Characteristic Control process Control mode Start up procedure I term higher decrease of attenuation stronger reaction with tende...

Page 62: ...oad controller use The load controller functions are available on the control panel Main menu 0000 modified ver 1 measurement unit C bar load controller actual value I 105 C load controller set value...

Page 63: ...type selection C bar measurement unit 1 and 2 settings and limit settings PID terms 3714 ver 2 3719 ver 1 OFF shut off limit in this example 15 90 max setting in this example 10 90 S1 min setting 90 O...

Page 64: ...system burner operation is controlled and supervised by burner control integrated to the burner In dual fuel burners a separate dual fuel module DFM as well as a load control module LCM are needed The...

Page 65: ...es are provided separately For more precise software user instructions see control program manufacturer s instructions Burner control Burner control is a microprocessor based burner control and safety...

Page 66: ...4 ver 3 A fan attached to the burner provides sufficiently high and even air pressure for efficient combustion Operating and display unit Control panel photo ver 2 The WiseDrive system operating and...

Page 67: ...lectrode for permanent operation Shape of the ionization electrode can vary depending on burner type D043884 ver 2 UV sensor FFS 08 for permanent operation FFS08 ver 2 5 2 Switch panel In standard del...

Page 68: ...device is prevented 2 AUTOMATIC Burner starts as the start signal is received from control device Burner control start up program begins Burner operates controlled by the capacity controller or on a...

Page 69: ...er start up Pre purging ignition During pre purge the burner fan ventilates the boiler and chimney At the time the fuel valves are closed The fan creates a full air pressure before fuel inlet Air in t...

Page 70: ...r a defined time period The burner must be connected to the oil circulation system according to the oil supply diagram 5 4 Legend to time sequence diagram symbols and safety times Pos Description Fact...

Page 71: ...ion description gas use Prerequisites for start up Control switch is in flame position or in position 2 Fuel selector switch in position 2 GAS Failures and interlocks are reset Limit switch on burner...

Page 72: ...ontrol is active until a controlled shutdown Pre purge 0023 ver 2 0019 ver 2 Pre purge begins Models with double gas valve Automatic leak test for gas valves begins if it is selected to be run during...

Page 73: ...spark Safety time t9 ends Ignition ends X04 Flame signal must be available from the end of safety time to controlled shutdown Main flame burns at the ignition load position A and B Servomotors drive...

Page 74: ...ler temperature or pressure limit switch is activated during operation Controlled shutdown Servomotors drive to their minimum capacity position Afterburning begins Gas valve 1 closes X01 Gas valve 2 c...

Page 75: ...on description oil use Prerequisites for start up Fuel selector switch in position 1 OIL Failures and interlocks are reset Limit switch on burner flange and oil pressure switch X06 are closed Boiler s...

Page 76: ...utdown will be initiated Control is active until a controlled shutdown Pre purge 0023 ver 2 Pre purge begins If the control unit receives a flame detection signal it will initiate a safety shutdown Co...

Page 77: ...cuit opens during operation Safety shutdown if the boiler temperature or pressure limit switch is activated during operation Controlled shutdown Servomotors drive to their minimum capacity position Oi...

Page 78: ...lowing at least once a year 1 Check the burner head extension and change it if necessary 2 Check the diffuser disc and change it if necessary 3 Check the ignition cable condition from the whole length...

Page 79: ...Gas nozzle fixing screw 8 Combustion head fixing screw 3 pcs 3 Locking screw of oil nozzle ignition electrode holder 9 Combustion head body 4 O ring 10 Combustion head extension and diffuser disc 5 Lo...

Page 80: ...ng screw of adjusting shaft indicator Dismounting combustion head from the burner 1 Swing the burner open 2 Remove ignition electrode holder 3 Remove gas nozzle 4 Remove combustion head adjusting mech...

Page 81: ...t 2 Fan wheel 11 Coupling rubber 3 Fan wheel fixing screw 12 Coupling rubber support pipe 4 Wedge 13 Coupling head to pump shaft 5 Mounting flange 14 Pump shaft 6 Fixing screw of mounting flange 15 Pu...

Page 82: ...etween the fan wheel and the motor mounting flange is 1 5 2 5 mm 4 Screw down the fan wheel to the motor shaft so that the wedge is locked in 5 Set the wedge into the shaft slot of the coupling frame...

Page 83: ...ke sure that the locking plate is aligned with the aligning surface of servomotor s shaft the air damper turns freely by turning the servomotor 5 Tighten the locking plate fixing screws 6 Tighten the...

Page 84: ...1 Prevent any light from reaching the detector and start the burner 2 Start the burner The burner must shut down and lockout at the end of safety time Fault code H009 Step 2 1 Start the burner 2 Acti...

Page 85: ...itch After testing reconnect both hoses to the original positions The burner should shut down immediately after hoses are disconnected Fault code H613 Gas pressure switches For instructions on adjusti...

Page 86: ...d 1 Open the test nipple located on the side of the gas low pressure switch 2 Attach the other end of the tube to the nipple and the gauge to the other end 3 Open the manual gas shutoff valve and noti...

Page 87: ...mulated flame signal during the ignition phase The simulated flame signal enables longer testing time for valves The creation of the simulated flame signal has to be timed to the ignition phase that f...

Page 88: ...he dripping continues change valves Step 3 End testing by turning the control switch S1 off from the fire position or by removing the connection that creates the artificial flame signal Step 4 1 Disas...

Page 89: ...ectrical diagram The burner does not start and hint 9 is flashing 6 6 Resetting fault and reading fault history Resetting fault Press the lit Enter button until the the fault is reset Example 1211 ver...

Page 90: ...trol and supply voltage All regulating and control devices are correctly set Safety devices are in normal operating condition Burner is getting fuel There is sufficiently water in the heating system M...

Page 91: ...motor Servomotors do not reach desired position Fault code 241 251 261 271 281 Check and adjust Faulty differential air pressure switch Fault code 613 Change Lack of air pressure fault code 613 Condit...

Page 92: ...place faulty part Too low ignition load Check Too large air amount Adjust Too high pressure loss in combustion head Adjust Nozzle does not spray Too low atomizing pressure See section Oil pump Lockout...

Page 93: ...inguish leaking gas valves Replace Oil use Lockout during shutdown period Oil or carbon deposits in combustion head See section Combustion head Solenoid valves do not close Repair or change faulty par...

Page 94: ...ized and trained personnel only adhering to all local regulations and requirements Completely isolate burner control system from the mains before performing any work on it Check all safety functions b...

Page 95: ...ervice contact your nearest representative or Oilon customer service at http www oilon com customer service 6 10 Burner parts GKP 50 MH Exploded view D048897 ver 1 The assembly may vary depending on t...

Page 96: ...GKP 90 MH Exploded view D048844 ver 1 The assembly may vary depending on the scope of delivery Gas valve VGG ver 1 94 95 M5164 1640EN...

Page 97: ...Control switch X 27 Coupling complete X 31 Lead in flange X 32 Combustion head X 36 Ignition transformer X 37 Flame detector QRA X KLC X 38 Ignition cable X 39 Nozzle X 40 Ignition electrode X 44 Pres...

Page 98: ...96 95 M5164 1640EN...

Page 99: ......

Page 100: ...Tarmontie 4 FI 15860 HOLLOLA FINLAND Tel 358 3 85 761 Fax 358 3 857 6239 Email info oilon com www oilon com...

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