Oilon Junior Pro 1 J10 Operating And Maintenance Instructions Manual Download Page 1

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OPERATING AND MAINTENANCE

INSTRUCTIONS FOR LIGHT OIL

BURNERS

Burners without preheating

Junior Pro 1

J10

J18

Junior Pro 2

J20

J45

J50

Burners with preheating

Junior Pro 1

LJ10

LJ18

Junior Pro 2

LJ20

LJ45

LJ50

Read these instructions carefully before installation, commissioning or maintenance of
the burner!

OILON HOME OY

P.O. Box 5, 15801 Lahti

Visiting address:

Tarmontie 4,

15860 Hollola

Tel. (03) 85 761

fax (03) 857 6239

[email protected]

www.oilon.com

10090943EN

Summary of Contents for Junior Pro 1 J10

Page 1: ...J45 J50 Burners with preheating Junior Pro 1 LJ10 LJ18 Junior Pro 2 LJ20 LJ45 LJ50 Read these instructions carefully before installation commissioning or maintenance of the burner OILON HOME OY P O Box 5 15801 Lahti Visiting address Tarmontie 4 15860 Hollola Tel 03 85 761 fax 03 857 6239 info oilon com www oilon com 10090943EN ...

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Page 3: ...Operation Principle 15 7 Burner Adjustment 17 7 1 Capacity Regulation 17 7 1 1 Nozzle Selection 17 7 1 2 Oil Pump Pressure Regulation 18 7 1 3 Calculation of Burner Capacity 18 7 2 Nozzle Table 19 7 3 Nozzle and Ignition Electrode Settings 20 7 4 Change of nozzle 20 7 5 Adjusting the Air Velocity in the Combustion Head J50 LJ50 21 7 6 Adjusting the Distance and Centrality of the Nozzle 22 7 7 Comb...

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Page 5: ...ut very important information WARNING A warning alerts you to possible danger to person if the instructions are not followed CAUTION A caution alerts you to something that has the potential to cause damage to component burner process or surroundings if the instructions are not followed Note A note points out information of special interest KEEP THESE OPERATING AND MAINTENANCE INSTRUCTIONS AS WELL ...

Page 6: ...pprox 10 bar LJ burners are equipped with a preheater Required combustion air quantity 15 m combustion air for each burnt kg of oil Burner operation is controlled and monitored by the burner automation Boiler thermostats or pressurestats control the burner capacity Burner protection IP20 Supply voltage 230 V 15 10 50 Hz 1 phase Consumption approx 135 W 0 71 A 230 VAC 50 Hz 1 phase J10 J18 J20 J45 ...

Page 7: ...opriate actions WARNING Never use a naked flame while checking the burner or the boiler Never store any inflammable material in the boiler room WARNING Keep the boiler door closed while starting the burner and during burner operation Correct installation and adjustment together with regular servicing are the most reliable guarantees of trouble free burner operation Note Local regulations and requi...

Page 8: ...4 10090943EN 3 Burner Technical Data 3 1 Exploded View Junior Pro 1 LJ10 ...

Page 9: ... Fixing screw for motor 4 20 Oil pump coupling 1 21 Plug connector for oil pump 1 22 Nipple for pressure pipe 1 23 Oil pump 1 24 Cover plate for motorbox 1 25 Motorbox 1 26 Fixing screw for motorbox 2 27 Grommet for preheater cable 1 28 Flame detector photo resistor 1 29 Holder for flame detector 1 30 Plug connector socket 1 31 Fixing screw for socket 2 32 Plug connector plug in part 1 33 Limit sw...

Page 10: ... conduit 1 Pro 1 FPHB5 Pro 2 FPHB10 Nozzle holder nozzle conduit without preheating 62 Fixing screw for nozzle conduit holder 1 63 Nozzle conduit holder 1 J10 J18 J20 J45 J50 LJ10 LJ18 Ø 10 LJ20 LJ45 LJ50 Ø 18 5 64 Cover plate 1 65 Eccentric piece 1 66 Locking screw for eccentric piece 1 67 Ignition electrodes 1 68 Ignition electrode holder 1 69 Locking screw for ignition electrode holder 1 70 Sig...

Page 11: ...r control unit internally connected safety switch limit switch on the hinged burner housing stepless adjustable air regulation oil pump atomizing pressure 800 1400 kPa 8 14 bar factory setting approx 10 bar electrical connection with a plug connector standard equipment for two pipe system recommended nozzle types solid 45 60 Junior Pro 1 J10 J18 LJ10 LJ18 solid 60 Junior Pro 2 J20 J45 J50 LJ20 LJ4...

Page 12: ...7 Junior Pro 1 LJ10 1 4 2 3 17 27 LJ18 1 7 2 8 20 33 Junior Pro 2 LJ20 2 3 4 1 27 48 LJ45 3 0 4 8 36 57 LJ50 2 3 6 5 27 77 Burner capacities are achieved according to standard EN267 3 5 Name Plate Burner type is marked with a X Example Junior Pro 1 LJ10 Use only original spare parts When ordering spare parts please give burner type and serial number indicated on the burner nameplate ...

Page 13: ...he flame must at no point come into contact with the furnace walls If this cannot be avoided such points must be covered with refractory This applies especially to the refractory at the back wall of short furnaces 1 Mounting plate 5 7 mm 2 Gasket 3 5 mm 3 Thermal insulation approx 50 mm The mounting plate must have either two M10 threaded holes or four M8 threaded holes for the mounting of the bur...

Page 14: ...necting the Burner to the Mains Electrical connection on burner is with a plug connector Connect the cable of the plug supplied with the burner to the boiler thermostat or pressurestat The socket has been firmly attached to the burner housing Disconnect the burner from the mains burner switch in position 0 by pressing the locking button and pulling out the plug from the socket at the same time 1 S...

Page 15: ...ator unit We recommend use of an Oilon Plus filter and deaerator unit where the oil flows from the tank in one pipe to the unit The oil pump is connected as in two pipe system The by pass plug must be fixed in the oil pump The pressure gauge of the unit indicates if the filter possibly clogs 1 Oilon Plus filter and deaerator unit 2 Suction hose 3 Oil pump 4 Return hose 5 Siphonage stop valve optio...

Page 16: ...boiler It is advisable to use ball valves instead of needle valves The tables give the maximum lengths in meters of return and suction lines Overlying oil tank Underlying oil tank H m DANFOSS BFP MS ø d mm H m DANFOSS BFP MS ø d mm ø 6 mm ø 8 mm ø 10 mm ø 6 mm ø 8 mm ø 10 mm 0 17 53 100 0 17 53 100 0 5 19 60 100 0 5 15 47 100 1 0 21 66 100 1 0 13 41 99 1 5 23 72 100 1 5 11 34 84 2 0 25 79 100 2 0 ...

Page 17: ...wo pipe system needs no venting as the air comes away when starting the burner In order to speed up the air removal nipple 4 in the pressure gauge connection can be loosened Removal of oil pump and pump coupling Remove the oil pump 1 from the motor 4 by loosening three fixing screws 3 and withdraw the oil pump Check the condition of the oil pump coupling 2 and replace if necessary 1 Oil pump 2 Oil...

Page 18: ...ermostat pressurestat 6 Burner fan 14 Preheater LJ burners only 7 Burner motor 15 Flame detector 8 Ignition transformer 6 2 Operating Scheme Oil Pump AS 47C 1 Oil filter 9 Ignition electrodes 2 Return hose 10 Solenoid valve normally open NO 3 Suction hose 11 Nozzle 4 Oil pump 12 Control unit 5 Pressure pipe 13 Control device thermostat pressurestat 6 Burner fan 14 Preheater LJ burners only 7 Burne...

Page 19: ...om control unit terminal 8 preheater begins to heat up the fuel contact of lower limit thermostat TSW in preheater closes after time tw approx 1 min when the oil temperature has reached approx 70 C whereby the control signal is applied to terminal 3 in control unit A Start on burner without preheating control signal is applied from terminal 8 to terminal 3 in control unit burner motor fan oil pump...

Page 20: ...started post ignition 2 s control from terminal 7 C Control unit burner in normal operating condition control program of control unit ends burner remains operating supervised by control unit flame and controlled by regulating thermostat D Controlled shut down with regulating thermostat burner motor stops solenoid valve closes flame extinguishes See chapter Control Functions in the Event of Faults ...

Page 21: ...to be used Calculation example Nozzle for a boiler of 25 kW with an efficiency of 0 90 and pressure to be used is 10 bar kg h 2 34 1 00 0 90 11 86 25 kg h nozzle select nozzle 2 37 kg h Nozzle selection according to USgal h The marking according to USgal h US gallon is valid at an atomizing pressure of 7 bar viscosity of 3 4 mm s cSt and density of 820 kg m kp 3 2 Ha P USgal h η 1 USgal approx 3 2...

Page 22: ...alculation example Calculate the nozzle capacity when the nozzle size is 2 37 kg h 0 6 USgal h and pressure is set at 13 bar According to CEN standard kg h 2 7 1 14 kg h 2 37 bar 10 bar 13 kg h 2 37 P1 P2 V1 V2 P2 P1 V2 V1 According to USgal h kg h 2 7 approx USgal h 0 82 1 36 USgal h 6 0 bar 7 bar 13 USgal h 0 6 P1 P2 V1 V2 7 1 3 Calculation of Burner Capacity If the nozzle size is known the burn...

Page 23: ...ure 8 bar 10 bar 12 bar 14 bar 1 46 0 40 14 16 17 19 1 66 0 45 16 18 20 21 1 87 0 50 18 20 22 24 2 11 0 55 20 22 24 26 2 37 0 60 21 24 26 28 2 67 0 65 23 26 29 31 2 94 0 75 27 30 33 36 3 31 0 85 31 34 37 40 3 72 1 00 36 40 43 48 4 24 1 10 40 45 50 53 4 45 1 20 43 48 52 57 4 71 1 25 45 51 56 60 5 17 1 35 49 55 60 65 5 84 1 50 54 61 67 72 6 08 1 65 60 66 72 77 6 55 1 75 64 71 77 2 00 73 77 ...

Page 24: ...nge 2 Fixing screw of combustion head 3 Combustion head 4 Nozzle 5 Ignition electrodes 6 Locking screw Burner L measure J10 7 J18 7 J20 7 J45 7 J50 7 LJ10 5 LJ18 5 LJ20 5 LJ45 5 LJ50 5 7 4 Change of nozzle Loosen the screw 6 and withdraw the ignition electrodes 5 with holder and ignition cables forward When removing nozzle two set spanners of 16 mm are needed After having changed the nozzle adjust...

Page 25: ...h air to support combustion at full load If the adjustment ring is too far back the air velocity in the combustion head is too low Hence it follows that the combustion values become worse Check burner combustion characteristics by means of flue gas analysis 1 Mounting flange 2 Flame tube 3 Adjustment ring 4 Diffuser disc 5 Setting screw Normative positions of the adjustment ring when the nozzle pr...

Page 26: ...in the eccentric piece Adjust the vertical centrality of the nozzle by turning the eccentric piece by key Adjust the horizontal centrality of the nozzle by moving the nozzle conduit 5 in the hole of the eccentric piece Check the centrality of the nozzle in comparison with the hole of the diffuser disc Screw the screw 4 of the eccentric piece and tighten Screw the cover plate s screws 2 and tighten...

Page 27: ...ound the right combustion air quantity 1 Air setting scale 2 Locking screw of air adjustment 3 Indicator 4 Air intake 5 Self closing air flap Coarse combustion air setting as example burner LJ 10 Oil pump pressure 10 bar factory setting Nozzle USgal h Position of air setting scale 0 50 approx 3 5 0 55 approx 5 0 0 60 approx 10 0 Note Only coarse adjustment can be made by observation Fine setting u...

Page 28: ...d in the normal operating position after inspection Inspection position Operation position 1 Sight glass 2 Cover 3 Fixing screw for sight glass Removal of sight glass Unscrew the fixing screw 3 approx 4 turns Move the sight glass to the right and withdraw The sight glass is now loose Mounting of the sight glass in reverse order Check that the sight glass is tight ...

Page 29: ...t3 Pre ignition time approx 13 s approx 13 s t3n Post ignition time control from terminal 6 approx 15 s approx 20 s t3n Post ignition time control from terminal 7 approx 2 s approx 2 s t2 Safety time max 10 s max 10 s t4 Interval between detection of flame and release of terminal 5 approx 15 s approx 20 s Reaction time on loss of flame 1 s 1 s A Commencement of start up with burners with oil prehe...

Page 30: ... control unit performs the full starting sequence With every lock out control outputs 3 to 8 and terminal 11 are de energized in less than 1 second while terminal 10 for the remote signalling of lock outs receives voltage Resetting the control is possible only when after lock out at least 50 seconds have elapsed Protection against under voltages The electronic protection against under voltages ens...

Page 31: ...27 10090943EN 8 5 Measurement of Flame Signal WARNING This control unit is a safety unit Do not open it Any unauthorized tampering can result in unforeseen detrimental consequences ...

Page 32: ...n needed Use for ex normal washing up liquid as cleaning agent Clean oil and grease spots from burner housing and plastic cover surfaces with a clean wet cloth Use as cleaning agent a slightly alkaline washing agent or normal hand washing up liquid Check regularly the combustion characteristics by flue gas measurements An authorized person should inspect the burner at least once a year Heating app...

Page 33: ...ng the fault CONDITION POSSIBLE CAUSE REMEDY 1 Motor Burner motor does not start Faulty motor Faulty control unit Faulty preheater on LJ burners Replace Replace Replace 2 Ignition failure Burner motor starts control voltage from control unit to ignition transformer is switched on no ignition and after a short time burner goes to lock out Dirty or worn ignition electrodes Insulator cracked Ignition...

Page 34: ...e Tighten joints Replace filter Check the size of the suction line Replace coil or pump 5 Premature flame formation Burner motor starts flame forms under pre purge period then lock out occurs Leaking solenoid valve Danfoss leaking shut off valve Suntec Clean or replace pump 6 Flame monitoring fault Burner motor starts flame forms then lock out occurs Flame detector wrong positioned Dirty flame det...

Page 35: ...e as appropriate Replace 8 Other possible causes Control unit goes to lock out Boiler smoke damper is closed Boiler or chimney is blocked Boiler room not adequately ventilated Adjust Clean Add supply of air No smoke comes out of chimney only bluish smoke and heat noticeable as a rippling effect at the chimney mouth An oily smell in the yard Excessive air supply Adjust Dark oil bearing smoke is com...

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