Oilon GP-350 Operation And Maintenance Manual Download

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M4248 2316EN

5 May 2023

Operation and maintenance manual
Burner models: GP-350 M - 450 M
Burner equipment: WDx00, FGR (UL)

Read these instructions carefully before installation, use, or maintenance

Summary of Contents for GP-350

Page 1: ...M4248 2316EN 5 May 2023 Operation and maintenance manual Burner models GP 350 M 450 M Burner equipment WDx00 FGR UL Read these instructions carefully before installation use or maintenance...

Page 2: ......

Page 3: ...tion table 24 3 6 Installing burner to gas supply line 24 3 7 Installing gas pressure regulating assembly 26 3 8 Changing the fuel type from natural gas to LPG 27 3 9 Installing FGR duct system 28 3 1...

Page 4: ...e WD200 77 4 31 Activating O2 trim control WD200 78 4 32 Backing up parameters 78 5 Operation 5 1 WiseDrive system 79 5 2 Control panel 82 5 3 Legend to PI diagrams 83 5 4 Burner operation and PI diag...

Page 5: ...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 can lead...

Page 6: ...afety warnings and instructions Connectors in the control box are under voltage Only authorized users may open the safety cover Installation commissioning or service of the appliance is to be carried...

Page 7: ...ee times do not restart burner before carefully investigating the reason for the failure Do not touch hot pipes or surfaces during operation or maintenance Permissible gas inlet temperature range is 5...

Page 8: ...ipework and its tightness safety appliances in the boiler system and the burner Check the boiler and its components We recommend obtaining a maintenance contract WARNING IF YOU SMELL GAS 1 OPEN A WIND...

Page 9: ...housing is finished with durable high gloss paint Electrical installations and burner service are easy to perform because the top cover is removable The stainless steel alloy combustion head and the d...

Page 10: ...II III Higher value higher capacity Label element 5 Control system additional code WD100 Electronic fuel air ratio control system WD200 Electronic fuel air ratio control system with O2 control and var...

Page 11: ...e Hz hp A 1 4 Flue gas recirculation optional The flue gas recirculation FGR reduces the NOx content of flue gases A certain proportion of flue gas is led back to the combustion chamber which causes t...

Page 12: ...h the device also with a second hand product Pass on the documents delivered with device to the owner at installation and advise them to keep them properly Make sure that operating instructions are av...

Page 13: ...ion applies to standard deliveries Burner data Burner GP 350 M GP 450 M Capacity MMBtu h 2 6 16 1 3 2 20 8 Burner motor 3 208 600 V 60 Hz Output hp Current A 460 V Speed rpm 10 11 9 3 510 15 17 3 510...

Page 14: ...as 8 200 W C LPG 11 200 W C Max demand for combustion air gas use 13 5 cfh MBtu Efficiency natural gas 35 31 ft n h 13 5 MBtu efficiency when heat value is 961 91 Btu ft Performance natural gas 950 10...

Page 15: ...AC Mains frequency 50 60 Hz 6 Power consumption 30 W Permissible input current differential air pressure switch 0 5 A 230 VAC 15 10 Permissible input current status input 1 5 mA 120 VAC 15 10 Perm cur...

Page 16: ...Block diagram of contact links Block diagram ver 7 14 114 M4248 2316EN...

Page 17: ...g time 10 s 120 s 30 s 120 s 60 s 120 s 30s Degree of protection NEMA 3 NEMA 3 NEMA 3 NEMA 4 Permissible ambient temperature 4 140 F 4 140 F 4 140 F 4 140 F 2 5 Display and operating unit technical da...

Page 18: ...10 VAC 15 10 Power consumption max 90 W typically 45 W controlled Measuring cell temperature 1292 F 122 F Measuring range 0 2 20 9 O2 Flue gas velocity 3 28 32 81 ft s Protection degree NEMA 2 Max tem...

Page 19: ...ignal amplifier continuous or interrupted use mains frequency filtering does not detect electric arc used for ignition spectral sensitivity range 1 3 m QRI2A2 B180B front viewing QRI2B2 B180B side vie...

Page 20: ...ns and requirements Space requirements ver 1 Legend Minimum dimension ft a left 2 6 b front 3 6 c right 2 6 d top 3 3 It is recommended to leave more space around the burner These are only the minimum...

Page 21: ...astening screws 2 pcs 3 Frame cover 15 kg 33 lbs 4 Frame cover tightening screw 1 pcs 5 Frame cover fastening screws 2 pcs 6 Electric casing protective cover 7 Electric casing protective cover fasteni...

Page 22: ...at bolt threads with graphite bearing grease before fitting Fasten burner to boiler in accordance with the given dimensions Install burner so that motor axle is on horizontal level Do not install burn...

Page 23: ...L2 L3 L5 H1 H2 H3 H5 B1 B2 B3 D1 GP 350 M 53 54 13 78 7 68 31 89 37 01 27 36 13 98 13 58 19 29 22 83 19 29 12 60 GP 450 M 57 87 13 78 7 68 35 83 41 34 30 31 15 55 16 54 20 08 25 59 21 65 14 57 Connec...

Page 24: ...Masonry Burner B6 H6 D4 M D1 L2 350 M 15 75 15 75 14 96 4xM20 12 60 13 78 60 90 450 M 18 31 18 31 17 32 4xM20 14 57 13 78 60 90 Dimensions in inches Installing extension plate optional The extension...

Page 25: ...te 3 Slide the first gasket into place over the stud screws 4 Using the strap or chain lift the extension plate Slide the plate onto the stud screws 5 Let the extension plate rest on the stud screws a...

Page 26: ...pply line If necessary decrease the supply gas pressure with pressure regulating assembly The gas supply line after the pressure regulator must be of the same size or one size larger than the valve tr...

Page 27: ...ss Vent gas piping before first start up Clean and check piping prior to the installation of gas pressure regulating assembly Installing gas valve and gas pipe support Install support if gas valve siz...

Page 28: ...safety shut off valve install these valves according to the instructions given by the manufacturer Also any impulse tubes must be installed according to the instructions given by the regulator manufa...

Page 29: ...Changing the fuel type from natural gas to LPG This information applies only when liquefied petroleum gas LPG is used Model 350 Gas nozzle adjusting band LPG ver 2 1 Adjusting band 2 Gas nozzle Model...

Page 30: ...or other marking indicating the type of gas fired in the burner 3 9 Installing FGR duct system FGR duct system FGR Installation_monoblock ver 3 Pos Item Pos Item 1 Control damper 5 Temperature sensor...

Page 31: ...during the expansion and contraction of the duct Provide condensation drains if needed Check the drain volume needs To mount FGR duct system 1 Place the inlet to the stack as close as possible to the...

Page 32: ...or electrical connections for electrical equipment Configure the burner installation with a switch that allows it to be disconnected from the supply mains Grounding must be in order before commissioni...

Page 33: ...trol circuit needs to be wired to the motor output Burner configurations may vary please refer to the electrical diagrams supplied with the burner Keep the cables and wires of different voltage circui...

Page 34: ...t start up First start up check list Check the following before first start up instructions from boiler and burner manufacturers are followed piping is done properly and joints on pipes and components...

Page 35: ...the burner control switch To stop the burner Turn the burner control switch to OFF position Commissioning data Gas type Wobbe index calorific value Volumetric gas flow rate Minimum and maximum heat ou...

Page 36: ...Adjusting combustion head GP Combustion head components GP 350 M Pos Item Pos Item 1 Combustion head 4 Gas nozzle 2 Diffuser disc Ignition gas nozzle 3 Ignition electrode A 10 63 in 34 114 M4248 2316...

Page 37: ...ne GP 350 M d081136 ver 1 The retaining ring for the pilot gas line is attached to the ignition electrode support pipe between the centering standoffs Combustion head components GP 450 M D043818 ver 2...

Page 38: ...rom the nozzle H distance between electrodes K Maximum tightening torque of ignition electrodes is 1 Nm A496V ver 5 in H 0 35 K 0 12 L 0 40 4 3 Adjusting combustion air GP 450 M Adjustment ring positi...

Page 39: ...ion head Fuel W C Gas use 0 8 Combustion air US ver 1 Guideline values Capacity Fuel O2 level Ignition minimum and part capacity Gas 3 5 4 5 Full capacity Gas 2 4 If you alter the position of the adju...

Page 40: ...tting is set to 4 01 W C maximum adjustment range should be between 35 Hz and 50 Hz To ensure proper burner function the differential air pressure switch may have to be readjusted to match the actual...

Page 41: ...ale to the maximum position 2 Run burner to the desired maximum capacity 3 Increase burner capacity to be 1 15 times the desired maximum capacity by raising gas pressure 4 Slowly turn switch to the mi...

Page 42: ...burner 4 Close cover Gas pressure switch min should cause a permanent interlocking If gas pressure switch triggers a temporary burner shutdown during burner start up or during operation it has to be...

Page 43: ...P25 4 AGA23 602 8 245 red SKP25 4 SKP2 ver 1 To adjust gas pressure 1 Remove the plug 2 Adjust the outgoing pressure by turning the slot head screw counter clockwise with a chisel point screwdriver Wh...

Page 44: ...k combustion using flue gas analysis when raising pressure Adjust burner if necessary Check gas valve measuring point position from the gas valve manufacturer manual Adjust the pressure regulator outl...

Page 45: ...ired offset 5 Screw on protective cap A Stick adhesive label E onto typeplate Do not overtighten the component s screws The component may become damaged Sealing final settings 1 Check pressure regulat...

Page 46: ...229 907 229 915 Spring 8 40 2 60 3 pink 229 872 229 881 229 890 229 899 229 908 229 916 Spring 9 56 3 80 4 grey 229 873 229 882 229 891 229 900 243 416 243 417 4 8 Measuring gas pressure General rule...

Page 47: ...Measuring nozzle pressure D050332 ver 2 1 Nozzle pressure at nominal capacity Burner Test point 1 W C 350 M 17 7 450 M 11 2 Check the tables below for adjusted pressure values M4248 2316EN 45 114...

Page 48: ...s train d073474_2 ver 1 d073474_1 ver 3 A Gas inlet 2 Inlet pressure 3 Adjusted pressure 4 Measuring point 5 Inlet pressure pilot 6 Adjusted pressure pilot Burner Test point 2 W C Test point 3 W C 350...

Page 49: ...UserMaxLoad MaxLoadMod Max load modulating MaxLoadStage Max load stage Fuel Displaying and selecting the type of fuel CurrentFuel Information about the type of fuel currently burnt read only FuelSele...

Page 50: ...l volume gas Reset Date Oil Reset date fuel volume oil LockoutCounter Total number of lockouts that occurred read only O2 Module Actual O2 Value Actual O2 value O2 Setpoint O2 setpoint SupplyAirTemp S...

Page 51: ...ystem To ensure burner operation some functions and actuator settings can be adjusted only by trained service personnel Password is needed when logging into system Password protected menu levels Burne...

Page 52: ...ing set values 1 Select Params Display 2 Select the desired parameter 3 Select a new parameter value using the Select buttons 4 Save the selected new value by pressing Enter 5 Return to the menu by pr...

Page 53: ...ering and delays Set acceleration and deceleration time to 2 s Set the minimum frequency to 0 Hz Set the maximum frequency to 105 2 of the motor s nominal speed After the variable speed drive paramete...

Page 54: ...ation Setpoint Output The variable speed drive control signal can be set to 0 20 mA or 4 20 mA 4 12 Checking O2 module WD200 O2 module connected to burner control through CAN bus can be connected with...

Page 55: ...sensors If sensors are connected warning is displayed when flue gas temperature is too high and combustion efficiency will be calculated and displayed Check that the oxygen value sensor temperature he...

Page 56: ...filled The program phase proceeds 12 20 21 and so on and stops in phase 24 The message Special position reached appears on the display The burner has reached the pre purge position and the servomotor...

Page 57: ...e to the ignition position Set default values for ignition position If oil is selected as fuel check oil pump operating pressure 2 When adjustments are set select program stop at 44 Interval 1 As the...

Page 58: ...e maximum Set curve points in the following menu level Params Display RatioControl GasSettings CurveSettings Point Manual Creating curve point individually Current servomotor positions in degrees vari...

Page 59: ...new curve point press Enter when XXXX is displayed as the set value The ignition position will automatically be set as the first ratio curve point from which the burner minimum load point is adapted...

Page 60: ...sition During that time the display shows instead of Confirm the change by pressing Enter or undo by pressing Esc Then you return to the previous menu level The servomotor turning angle is 0 90 and se...

Page 61: ...xygen value can be monitored on the display When increasing load monitor that combustion values do not increase to a hazardous level If necessary set curve point for interval by pressing Enter and cor...

Page 62: ...uipped with O2 trim control The residual oxygen level is set 1 higher than the normal level There can be 15 curve points at the maximum Set at least 10 curve points for O2 trim control Measure fuel co...

Page 63: ...for FGR mode have been set at the factory The commissioning personnel will adjust the settings at start up if needed For further instructions see the section Setting FGR curve points 4 17 Setting FGR...

Page 64: ...tored to each curve point Current FGR temperature can be viewed from display using buttons Make sure capacity is stable and FGR temperature is within the normal operation limits before storing curve p...

Page 65: ...epending on the application Flue gas percentage is counted as follows FGR Flue gas amount recirculated ppm Flue gas amount recirculated ppm combustion air amount in ppm To define flue gas percentage 1...

Page 66: ...r capacity range can be set as required at service level The minimum capacity can be greater than the first curve point and the maximum capacity can be below the last curve point During start up the b...

Page 67: ...tional point to smooth the curve Even ratio curve improves O2 ratio control In dual fuel burners set the O2 ratio control individually for both fuels and they are not correlating Start O2 ratio curve...

Page 68: ...he second line Use the Select buttons Point26 ver 4 3 Accept the value by pressing Enter Exit by pressing Esc Measuring O2 min values by reducing air 1 Select desired point from previous menu level by...

Page 69: ...capacity burner operates according to ratio curve without O2 trim control 1 Select O2 Control from the following menu level Params Display O2Contr Guard Fuel Settings O2 Control 2 The first O2 trim c...

Page 70: ...ntrol calculates PID parameters and time delays for O2 monitor by driving the burner back to ratio curve After that the display returns to initial state Select next curve points from the menu by press...

Page 71: ...active Burner starts though oxygen sensor has not reached its operating temperature Burner operates along parameterized ratio curves When oxygen sensor has reached its operating temperature and sensor...

Page 72: ...gs Type ofAir Change O2 OffsetGas Oil LoadCtrlSuspend FilterTimeLoad Parameters Type ofAirChange Impact of air density change on O2 value like P air gas use like theory oil use O2 OffsetGas Oil O2 tri...

Page 73: ...al set value W1 in use Can be changed to internal set values W1 and W2 using contactors IntLC Bus Internal burner control capacity controller Set value for burner control through Modbus or eBus IntLC...

Page 74: ...ControllerParam ContrlParamList P Part Xp I Part Tn D Part Tv By increasing the proportional band the temperature pressure deviation is lowered Using too great a proportion will result in temperature...

Page 75: ...e and then run with full load This occurs automatically according to the following diagram Boiler load should stay constant throughout adaptation Flow chart_WD capacity ver 3 O2 trim control must not...

Page 76: ...v 4 6 Examples of typical incorrect settings and the optimal setting to change the set value Xp too low Xp too high Tn and Tv too low Tn and Tv too high Optimum setting If load control is not complete...

Page 77: ...oo high the internal load controller becomes unstable The factory setting is 3s 4 27 Capacity controller on off If temperature or pressure has been given a set value burner start up and shut down limi...

Page 78: ...rature limiter switching differential ON 4 29 Cold start thermal shock protection Cold start thermal shock protection protects the boiler from thermal stress if the boiler has cooled down The burner s...

Page 79: ...Release Stages Cold start thermal protection operation example Cold start ver 4 4 30 Measuring flue gas and combustion air temperature WD200 Flue gas and combustion air temperature measuring sensor ca...

Page 80: ...unit menu Operation O2Ctrl activate deactivated activated 4 32 Backing up parameters 1 Start backing up parameters by selecting the following from the display and operating unit Updating ParamBackup...

Page 81: ...ressure switch 16 Gas pressure switch 17 Gas valves 18 Air pressure switch 19 Motor 20 Speed sensor 21 Variable speed drive for variable speed drive WD200 22 Display and operating unit 23 MOD BUS 24 C...

Page 82: ...controller Fan variable speed drive control WD200 Residual oxygen control WD200 Boiler cold start thermal shock protection Fuel flow meter WD200 Burner efficiency measuring WD200 Start up and running...

Page 83: ...unit is used for monitoring and adjusting settings The menu is available in several languages The operating and display unit has an internal memory backed up by a battery The memory stores the burner...

Page 84: ...emit infrared light Flame signal intensity can be monitored on display Flame detector is equipped with self test function and is suitable for continuous operation 5 2 Control panel The control panel...

Page 85: ...r control supervises burner operation and performs a controlled shutdown or if necessary a safety shutdown and lockout R RESET Burner failures are reset Signal lamps Signal lamp State H8 Gas flame the...

Page 86: ...controls the air volume according to fuel combustion Pre purge and ignition After the pre purge the servomotors run to ignition position the ignition begins and ignition gas valves open Gas is release...

Page 87: ...ut off valve 2 Pressure switch low 41 Air damper 42 Servomotor 43 Combustion air fan 44 Electric motor 3 Safety shut off valves 3 1 Valve 3 2 Actuator 3 4 optional 3 3 Actuator with pressure regulator...

Page 88: ...n t81 Valve proving time atmospheric pressure t21 Min time start release t82 Valve proving filling time t22 Fan running time t83 Valve proving time gas pressure t30 Pre purge time part 1 tmn1 Min time...

Page 89: ...s Stop up to phase maximum time 10 0 3 s 0 30 s 01 00 repetition 0 12 repetition 0 Output OFF input Irrelevant Output ON input ON Permissible positioning range In Standby actuator can move within the...

Page 90: ...mpCoupling direct_coupl shutoff valve oil to be connected to output Oil pump magnetic clutch Output is active when fan is on and for another 15 s after fan is switched off 18 Param Alarm act deact dea...

Page 91: ...5 6 Time sequence diagram gas use 7550f64e 0515 G ver 4 M4248 2316EN 89 114...

Page 92: ...7550f57e 0515 Gp1 ver 6 90 114 M4248 2316EN...

Page 93: ...rerequisites for start All failures and interlocks reset Burner flange limit switch closed Safety loop closed Boiler safety devices not activated Control switch in position 1 Burner control in stand b...

Page 94: ...ntrol receives a flame signal burner control goes to a lockout Control remains active until the beginning of pre ignition 36 Servomotors drive to ignition position 38 Pre ignition begins 40 42 First s...

Page 95: ...s or fan motor rotation speed signal disappears during burner operation Lockout if the user presses the operating and display unit s Esc and Enter button simultaneously during operation Immediate shut...

Page 96: ...mal for example because of a lockout or because burner control has been de energized it will take place during the next start up sequence during the pre purge period between phases 30 and 32 Valve pro...

Page 97: ...there is no pressure in the piping If required discharge the pressure Check the combustion opening regularly for fouling even during periods when the burner is out of use A blockage in the combustion...

Page 98: ...at least once a year Maintenance recommendations Correct installation and adjustment as well as regular maintenance ensure trouble free burner operation Service the burner annually Use only original s...

Page 99: ...ntenance during shutdown Installation commissioning or service of the appliance is to be carried out by authorized and trained personnel only adhering to all local regulations and requirements Before...

Page 100: ...Air guide fastening screws 2 Air guide 3 Ignition gas nozzle 4 Gas pressure impulse tube 5 Ignition electrode support fastening screw 6 Ignition electrode support 7 Gas nozzle fastening screws 8 Gas n...

Page 101: ...electrical cable of the motor 3 If in use detach the rotation speed sensor from the motor s fan casing 4 Screw off screws in the motor mounting flange and lift the motor away 5 Screw off the fan wheel...

Page 102: ...ir servomotor 2 blinks Gas servomotor 3 blinks Oil servomotor 4 blinks Combustion head servomotor 4 Check address If address is incorrect keep red button pressed approx 10 until green light is steady...

Page 103: ...n these positions and return servomotor to initial position 6 6 Dismounting and changing servomotors The permissible tightening torque for the elastic coupling clamping screw is 2 Nm The permissible t...

Page 104: ...ment plate of the motor coupling motor coupling stays on butterfly valve s shaft 5 Unscrew the servomotor fixing screws and remove the servomotor 6 Connect the cables to the still loosen servomotor as...

Page 105: ...screws and take out the servomotor 5 Connect a new servomotor to the shaft coupling 6 Make sure that the shaft coupling aligning screw is aligned with the servomotor axle plane 7 Make sure that the c...

Page 106: ...ng will cause a lockout Consequently the button can be used as an emergency stop button Fault history stores the last 21 error messages Use the Select buttons to scroll through the historical data To...

Page 107: ...ions LV5 1000 Remote reset EN 14459 requirements for remote control must be followed The reset device must be able to reset the burner in an appropriate way Unintended or spontaneous resets from locko...

Page 108: ...re hose Boiler pre purging begins The burner must shut down before the pre purge cycle is completed Error code 28 and a text Air pressure off appear on the display Step 2 1 Disconnect the low pressure...

Page 109: ...ll shut down before the minimum setting Error code 30 and text Gas Pressure has exceeded maximum Limit appear on the display Gas shut off valves If the burner is equipped with an automatic valve provi...

Page 110: ...an not be found in the First start up check the individual burner functions Reset the burner controller if it is in lockout position The burner goes to standby position When the prerequisites for star...

Page 111: ...overload thermal relay released Check setting reset Faulty motor contactor Change Faulty motor Change Fault in variable speed drive or soft starter if equipped Check error and reset Lack of fan air pr...

Page 112: ...ug regulator pressure switch and adjust Faulty fuel air ratio Adjust Faulty combustion head adjustment Check and adjust Nozzle dirty or blocked Clean or change Too low ignition load Check Burners with...

Page 113: ...t extinguish leaking gas valves Replace Poor combustion Condition Possible cause Action CO content is too high or smoke number too high Pressure drop in combustion head too low Adjust pressure drop Di...

Page 114: ...Faulty differential air pressure switch 28 Lack of air pressure 31 32 Leakage test failure 34 No oil supply or too low atomizing pressure Faulty oil pump 35 Main solenoid valve does not open Return o...

Page 115: ...nge gasket X 3 Fan motor X 4 Fan wheel X 7 Diffuser disc X 8 Head extension X 9 Gas nozzle X 12 Gas valve block X 250 000 23 Capacity controller X 28 Pressure regulator X 36 Ignition transformer X 38...

Page 116: ...name 1 2 year 3 5 years 10 years on demand start up max 66 Ionization electrode X 67 Ignition electrode support X 250 000 69 Manual shut off valve X 71 Valve actuator with pressure regulator X 72 Valv...

Page 117: ......

Page 118: ...Oilon US Inc P O Box 1041 Tel 1 229 236 6546 info northamerica oilon com www oilon com Contact information of Oilon dealer Date of installation...

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Oilon GP-350, Operation And Maintenance Manual

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Summary of Contents for GP-350

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