Oilon GKP-350 M User manual

M5178 1647EN
20 December 2016
Original instructions
Operation and maintenance manual
GKP-350 M - 450 M WD100, WD200, FGR
Read these instructions carefully before installation, use, or maintenance

Contents
1 Introduction
1.1 Liability disclaimer.......................................................................................5
1.2 Safety precautions...................................................................................... 5
1.3 Product overview.........................................................................................8
1.4 Flue gas recirculation (optional)............................................................... 10
1.5 Handling and storing.................................................................................11
2 Technical data
2.1 Burner technical data................................................................................12
2.2 Profibus module technical data................................................................ 13
2.3 Flame detector technical data.................................................................. 14
2.4 Burner control technical data....................................................................15
2.5 Servomotor technical data........................................................................ 17
2.6 Display and operating unit technical data.................................................17
2.7 O2 module technical data (WD200)..........................................................18
2.8 Oxygen sensor technical data (WD200)...................................................18
3 Installation
3.1 Space requirements..................................................................................19
3.2 Removing protective covers and lifting the burner................................... 19
3.3 Mounting burner........................................................................................21
3.4 Gas valve selection table......................................................................... 24
3.5 Installing burner to gas supply line...........................................................24
3.6 Installing gas pressure regulating assembly.............................................25
3.7 Installing gas nozzle adjusting band (LPG).............................................. 27
3.8 Installing hoses......................................................................................... 28
3.9 Oil supply site diagram, example............................................................. 29
3.10 Connecting to oil line................................................................................ 30
3.11 Installing FGR duct system.......................................................................30
3.12 Electrical connections............................................................................... 32
4 Commissioning
4.1 First start-up.............................................................................................. 34
4.2 Nozzle selection........................................................................................35
4.3 Adjusting combustion head.......................................................................39
4.4 Setting ignition electrodes.........................................................................39
4.5 Adjusting supply oil pressure....................................................................40
4.6 Oil pump....................................................................................................40
4.7 Adjusting atomizing pressure....................................................................44
4.8 Oil pump coupling components and adjusting..........................................45
4.9 Adjusting combustion differential air pressure switch............................... 46
4.10 Adjusting gas pressure switch.................................................................. 48
4.11 Setting variable speed module parameters.............................................. 49
4.12 Setting gas pressure regulator SKP......................................................... 51
4.13 Setting gas pressure regulator FRS......................................................... 53
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4.14 Measuring gas pressure........................................................................... 55
4.15 Operating and display unit menu..............................................................56
4.16 Adjusting operating and display unit settings........................................... 59
4.17 Setting frequency converter parameters (WD200)................................... 60
4.18 Frequency converter settings and standardization (WD200)....................60
4.19 Checking O2 module (WD200)................................................................. 61
4.20 Manual start-up and program stop in pre-purge position..........................62
4.21 Ignition position......................................................................................... 64
4.22 Setting ratio curve.....................................................................................66
4.23 Activating FGR..........................................................................................70
4.24 Setting FGR curve points......................................................................... 71
4.25 Measuring FGR.........................................................................................72
4.26 Capacity range..........................................................................................73
4.27 O2 min. value control (WD200)................................................................ 74
4.28 Setting O2 trim control (WD200)...............................................................76
4.29 O2 trim control operating mode (WD200).................................................78
4.30 O2 trim control load limitation (WD200)....................................................78
4.31 O2 trim control when load changes (WD200)...........................................79
4.32 Setting capacity controller operating mode.............................................. 79
4.33 Setting capacity controller parameters..................................................... 81
4.34 Capacity controller on/off.......................................................................... 85
4.35 Boiler temperature limiting with burner control......................................... 85
4.36 Cold start thermal shock protection..........................................................86
4.37 Measuring flue gas and combustion air temperature (WD200)................ 87
4.38 Activating O2 trim control (WD200).......................................................... 87
4.39 Backing up parameters.............................................................................88
5 Operation
5.1 Burner operation....................................................................................... 89
5.2 General description of burner operation................................................... 92
5.3 Gas valve proving.....................................................................................94
5.4 Legend to time sequence diagrams......................................................... 94
5.5 Time sequence diagram, gas use............................................................ 98
5.6 Burner automation description, gas use................................................. 100
5.7 Time sequence diagram, oil use............................................................ 103
5.8 Burner automation description, oil use................................................... 103
6 Maintenance
6.1 Burner maintenance................................................................................106
6.2 Dismounting combustion head............................................................... 107
6.3 Dismounting and changing burner motor............................................... 108
6.4 Dismounting and changing servomotors................................................ 109
6.5 Oil filter.................................................................................................... 113
6.6 Nozzle valve operation and maintenance RPL-1................................... 114
6.7 Oil regulator............................................................................................ 115
6.8 Testing safety and control devices......................................................... 116
6.9 Fault and lockout history........................................................................ 119
6.10 Frequency converter (WD200)............................................................... 121
6.11 Adjusting gas valve proving....................................................................121
6.12 Troubleshooting.......................................................................................122
6.13 Troubleshooting error codes...................................................................127
6.14 Burner parts............................................................................................ 128
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6.15 Burner part list........................................................................................ 129
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1 Introduction
1.1 Liability disclaimer
Burner, with the delivered ancillary equipment, is always a part of a larger system.
This manual does not include comprehensive instructions for planning, installing
and operating a complete system. Thus, the designer, installer and operator of the
equipment should have sufficient qualifications and knowledge to design, install,
and operate the parts of the system, as well as the system as a whole. The system,
including burner control system, must be designed and constructed according to local
regulations and requirements.
The following information must be read and understood by the users of the appliance.
The users must be trained and fully qualified according to local legislation for the
specific work. The users of the appliances must also be capable to recognize possible
hazards in the system and in the environment where the appliance is used.
This manual contains information and instructions based on product standards and
regulations, and on our best knowledge. 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 to property damage,
personal injury or death.
Oilon is unable to accept any liability for damage in case of:
● failure to follow these instructions
● other use than what is explained in this manual
● use by unqualified personnel
● the use of spare parts not provided by Oilon.
Your legal rights are governed by a Limited warranty, the terms of which are
incorporated herein by reference. Any modification at the product, if not approved by
Oilon, is disclaimed and may void your rights under the Limited warranty.
1.2 Safety precautions
Read these instructions carefully before installation, commissioning, operation or
maintenance of the device. The given instructions must be followed. Throughout this
manual, the following three symbols are used to point out very important information:
Be careful. The DANGER symbol indicates a possible danger of bodily
harm or lethal injury.
Pay attention. The CAUTION sign indicates a possible danger of
damage to the device, components or surroundings.
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Note indicates tips, hints, and other essential information.
Keep these instructions as well as the electrical diagrams available near the
device.
Oilon products are manufactured according to general product standards and
directives, and based on our best knowledge about product design, and technologies.
Operation safety is one of the leading principles in our product development. However,
it is wise to be prepared, and think about safety. Read the following principal safety
warnings and instructions:
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.
The equipment shall be installed in accordance with the Provincial Installation
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 actions.
● Contact operation controller.
IN CASE OF A GAS LEAKAGE
● Do not light fire or touch electric equipment.
● Close main fuel shut-off valve.
● Make sure there are no people in the leakage area.
● Make sure the leakage area is properly ventilated.
● Contact operation controller.
Cut off power supply to burner and close manual shut-off valves always
before any maintenance work. Cutting power is adequate when just
inspecting the device.
Connectors in control box are under voltage. Only authorized users may
open safety cover.
Fasten all safety covers, enclosures, and guards with all screws before
start-up. Use appropriate tools.
Wear proper hearing protection and personal protective equipment,
such as protection shoes and gloves when necessary.
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Do not use Teflon tape in piping.
If burner start-up fails consecutively two times, do not restart burner
before carefully investigating the reason for the failure.
Do not touch hot pipes or surfaces during operation or maintenance.
Emergency shutdown
In an emergency, cut off power supply to the burner. Close the manual shut-off
valves. After safety check you can restart the burner. Check settings, and monitor that
operation continues as normal.
Take care of the boiler room
Never use open fire while checking burner or boiler.
Do not store any inflammable materials in boiler room.
Keep boiler door closed while starting burner, and during burner
operation.
● Maintain 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 damper adjustment and gate valve regularly.
● Make sure burner room air-inlet gap is open.
● Make sure shut-off valves on pressure gauges are shut.
● Make sure pipeworks tightness, boiler system safety appliances, pipeworks, and
burner are checked regularly according to the rules and regulations of public
authorities.
● Check boiler and its components.
We recommend a maintenance contract.
WARNING
IF YOU SMELL GAS, OPEN WINDOW, EXTINGUISH ANY OPEN FLAMES,
STAY AWAY FROM ELECTRICAL SWITCHES, EVACUATE THE BUILDING AND
IMMEDIATELY CALL THE GAS COMPANY.
IN ACCORDANCE WITH OSHA STANDARDS, ALL EQUIPMENT, MACHINES AND
PROCESSES SHALL BE LOCKED OUT PRIOR TO SERVICING.
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IF THIS EQUIPMENT IS NOT INSTALLED, OPERATED AND MAINTAINED IN
ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS, THIS PRODUCT
COULD EXPOSE YOU TO SUBSTANCES IN FUEL OR FROM FUEL COMBUSTION
WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO
CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
IMPROPER SERVICING OF THIS EQUIPMENT MAY CREATE A POTENTIAL
HAZARD TO EQUIPMENT AND OPERATORS.
SERVICING MUST BE DONE BY A FULLY TRAINED AND QUALIFIED PERSONNEL.
WARNING
DO NOT ATTEMPT TO START, ADJUST OR MAINTAIN THIS BURNER WITHOUT
PROPER TRAINING OR EXPERIENCE. FAILURE TO USE KNOWLEDGEABLE
TECHNICIANS CAN RESULT IN EQUIPMENT DAMAGE, PERSONAL INJURY OR
DEATH.
1.3 Product overview
Intended use
This is an automatic forced draught burner. The burner can be used on most heating
appliances; for warm and hot water boilers, hot air generators, and various types of
process heating. They are also designed to suit furnaces with high back pressure.
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 range of 0 °C – +50 °C / + 32 °F – 105 °F. The standard setup is
designed to operate in the altitude of max. 500 m / 1,640 ft above sea level.
See Technical data for the information on standard applicable fuels. Burners using
other fuels are available upon request.
Construction
The surface of the 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 diffuser disc can
withstand high temperatures.
The motor output components of the fan motor (short-circuit protection, thermal
protection, contactor) must be designed according to the site. The motor output
components are located in the customer’s system, and they are described in the
electrical diagram.
The burner control system handles all burner operation sequences automatically. In the
event of a burner failure, the unit stops the burner automatically.
Each burner is tested separately before delivery to the customer.
For more information on products, visit our web site at www.oilon.com: Oilon –>
Industries –> Product material.
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Information on components can be found under the headline Burner parts.
Type labelling
POLTINKOODI ver. 2
Label element 1: Fuel
KP Light fuel oil
RP Heavy fuel oil
GP Gas
GGP Dual gas
GKP Gas, light fuel oil
GRP Gas, heavy fuel oil
Label element 2: Burner size categorization
Label element 3: Method of control
H Two-stage
M Modulating
MH Modulating gas, two-stage oil
ME Modulating with a separate fan
Label element 4: Additional code, for example burner capacity I-III or automation, like
WD34
Type plate
The following illustration shows an example of the type plate of Oilon burners:
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Type plate US ver. 1
Pos. Description Pos. Description
1 Burner type:
KP = Light fuel oil
RP = Heavy fuel oil
GP = Gas
GKP = Light fuel oil and gas
GRP = Heavy fuel oil and gas
9 Degree of protection
2 Overfire pressure min, IN.WC 10 Serial number
3 Overfire pressure max, IN.WC 11 Month and year of manufacture
4 Gas calorific value, BTU/scf 12 Capacity, gas, MBTU/hr
5 Gas type 13 Capacity, light fuel oil, GPH
6 Oil quality / viscosity 14 Gas pressure min, IN.WC
7 Supply voltage, input power and current,
V / Hz / A / kW
15 Gas pressure max, IN.WC
8 Manufacturer address 16 L LC US marking and certification
institute code
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 the flame
temperature to drop. This influences the NOx content of flue gas.
In general, the amount of recirculated flue gas must be adjusted to the smallest
possible quantity needed to obtain the required NOx rate. The flue gas quantity is
adjusted with the throttle valve located on the FGR pipe.
If the quantity of recirculated flue gas is excessive the flame may become instable and
the CO rate may increase. The amount of flue gas to circulate is set on the control
panel. To optimize the result, burner is adjusted to operate according to preset FGR-
curves.
For detailed information and instructions, see the chapters Installation and
Commissioning.
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1.5 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 and transporting instructions included in the package.
Documentation is part of the product, and it must be passed on together with device,
also with a second hand product. Pass on documents delivered with device to owner
at installation, and advise to keep them properly. Make sure that operating instructions
are available near the device.
Recycle product package. The metal and plastic parts of the device are made of
recyclable materials. Also all electrical components are recyclable, and should be
handled according to local regulations.
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2 Technical data
2.1 Burner technical data
Burner data
Burner GKP-450 M
Capacity gas, MMBtu/h 2.90 - 18.77
Capacity oil, MMBtu/h 7.51 - 18.77
Capacity oil, lb/h 408 - 1014
Max. turndown ratio, gas 1:6 (100–16.6%)
Max. turndown ratio, oil 1:2.5 (100–40%)
Nominal oil pump motor output, hp 10
Motor current A 19.4
Motor speed r/min 2940
Oil inlet pressure to pump PSI 14.5 - 72.5
Oil operating pressure (atomizing pressure), PSI 290 - 300
Oil regulator return flow pressure, ignition position
PSI
72 - 102
Oil regulator return flow pressure, partial load PSI 102 - 131
Input power hp 17
NO x-class Natural gas (2nd family): 1
Light fuel oil: 1
Weight kg 1113
Other technical data and requirements
Fuel, gas use Natural gas
Make sure the used gas is clean and non-condensed.
When using other gases than natural gas, the composition
of the gas must be known. Consult burner manufacturer on
the suitability of the burner for special gases.
Gas inlet pressure to burner max. 10 PSI
Max. demand of combustion air, gas use 13.5 cfh/MBtu
DO NOT USE GASOLINE, CRANKCASE OIL, OR ANY OIL
CONTAINING GASOLINE.
Fuel, oil use # 2 fuel oil
Efficiency, # 2 fuel oil 2.20 lb ≈ 40.46 MBtu efficiency, when heat value is 1146.03
Btu/ft³
Max. demand for combustion air, oil use 529.72 cfh/lb
Control voltage 120 V (-15%...+10%) 50 Hz / 60 Hz 1-phase
Motor voltage 460 V 60 Hz 3-phase
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Ambient temperature range 0...+ 105 °F
Degree of protection NEMA 3
Working diagram
Working diagram ver. 3
Working diagram ver. 1
dashed line = oil
solid line = gas
2.2 Profibus module technical data
Profibus module PBM100
Power supply 24 VDC
Power consumption 100 mA
Electromagnetic compatibility EMC 2014/30/EC
Permissible ambient temperature -20...+60°C
-4...+140°F
Lengths of cables
Supply 24 VDC < 10 m
< 33 ft
LSB (screened) max. 100 m
max. 328 ft
PROFIBUS (screened) 100 m
328 ft
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Profibus diagram ver. 1
Terminals may not be connected!
1 CAN/LSB
2 DC power supply (safety extra low voltage)
2.3 Flame detector technical data
QRI
Supply voltage, operation 14 VDC ±5 %
Supply voltage, testing 21 VDC ±5 %
Signal voltage 0…5 VDC
Power consumption < 0,5 W
Connected detector cable
max. length
1.8 m
5.9 ft
Auxiliary detector cable
max. length
100 m
328 ft
Protection degree NEMA 3
Permissible operation ambient temperature -20...+60 °C
-4...+140 °F
● integrated signal amplifier
● continuous or interrupted use
● mains frequency filtering
● does not detect ignition spark
● spectral sensitivity range ~1…3 μm
● QRI2A2.B180B frontal illumination
● QRI2B2.B180B lateral illumination.
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QRI connection
QRI connection ver. 1
A Black X10-02 / 6 Signal line
B Blue X10-02 / 4 Reference line
C Brown X10-02 / 2 Power line
2.4 Burner control technical data
Burner control LMV5...
Mains voltage 120 VAC –15/+10 %
Locking during undervoltage conditions < 96 VAC
Transformer / primary side 120 VAC
Transformer / side 1 12 VAC
Transformer / side 2 2 x 12 VAC
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. current rating of control terminals
● fan motor contactor
● burner failure
● ignition transformer
● gas valves
● oil valves
5 A / 120 VAC -15/+10 %

● 1 A/120 VAC -15/+10 %
● 1 A/120 VAC -15/+10 %
● 1.6 A/120 VAC -15/+10 %
● 1.6 A/120 VAC -15/+10 %
● 1.6 A/120 VAC -15/+10 %
Permissible operation ambient temperature -20...+60 °C
-4...+140 °F
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Block diagram of contact links
Block diagram ver. 5
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Inputs / outputs (VSD)
Connection diagram ver. 3
2.5 Servomotor technical data
Servomotor SQM45... SQM48.497 SQM48.697
Mains voltage 2 x 12 VAC 2 x 12 VAC 2 x 12 VAC
Power consumption 9 – 15 VA 26 – 34 VA 26 – 34 VA
Angular adjustment 90° 90° 90°
Accuracy ±0.2° ±0.2° ±0.2°
Torques, operation /
holding
3 / 1.5 Nm
26.55 / 13.27 lbf·in
20 / 20 Nm
177 / 177 lbf·in
35 / 35 Nm
310 / 310 lbf·in
Running time 10 s 30 s 60 s
Degree of protection NEMA 3 NEMA 3 NEMA 3
Permissible ambient
temperature
-20...+60 °C
-4...+140 °F
-20...+60 °C
-4...+140 °F
-20...+60 °C
-4...+140 °F
2.6 Display and operating unit technical data
Display and operating unit AZL...
Mains voltage 24 VAC –15/+10 %
Power consumption < 5 W
Protection degree NEMA 3
Battery 3 V Lithium
Battery, Varta CR 2430
Battery, Duracell DL 2430
Permissible operation ambient temperature -20...+60 °C
-4...+140 °F
Protect the equipment from condensation, ice and water ingress.
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2.7 O2 module technical data (WD200)
O2 module PLL52...
Mains voltage, sensor heating 110 VAC –15/+10 %
Mains voltage 2 x 12 VAC
Power consumption 4 VA
Analog inlet, oxygen sensor QGO20.000D27
Analog inlet, combustion temperature Pt1000 / LG-Ni 1000
Analog inlet, flue gas temperature Pt1000 / LG-Ni 1000
Analog inlet, bus interface CAN
Protection degree NEMA 3
Permissible ambient temperature -20...+60 °C
-4..+140 °F
Protect the equipment from condensation, ice and water ingress.
2.8 Oxygen sensor technical data (WD200)
Oxygen sensor QGO20...
Measuring cell ceramic zirconium dioxide cell
Mains voltage, measuring cell heating 110 VAC –15/+10 %
Power consumption max. 90 W, typically 35 W
Measuring cell temperature 700 °C ±50 °C
1292 °F ±122 °F
Measuring range 0.2…20.9 % O2
Flue gas velocity 1…10 m/s
3.28...32.81 ft/s
Protection degree NEMA 2
Max. temperature, flange +250 °C
+482 °F
Max. temperature, connecting head +70 °C
+158 °F
Max. temperature, flue gas +300 °C
+572 °F
Protect the equipment from condensation, ice and water ingress.
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