Oilon GP-600 M User manual

M4219 2305EN
6 April 2023
Operation and maintenance manual
Burner models: GP-600 M - 700 M-III
Burner equipment: WDx00, FGR (UL)
Read these instructions carefully before installation, use, or maintenance

Contents
1 Introduction
1.1 Liability disclaimer.......................................................................................3
1.2 Safety precautions...................................................................................... 3
1.3 Product overview.........................................................................................7
1.4 Flue gas recirculation (optional)................................................................. 9
1.5 Handling and storing.................................................................................10
2 Technical data
2.1 Burner technical data................................................................................11
2.2 Other technical data and requirements.................................................... 12
2.3 Burner control technical data....................................................................13
2.4 Servomotor technical data........................................................................ 15
2.5 Display and operating unit technical data.................................................15
2.6 O2 module technical data (WD200)..........................................................15
2.7 Oxygen sensor technical data (WD200)...................................................16
2.8 Flame detector technical data.................................................................. 16
3 Installation
3.1 Lifting the burner.......................................................................................18
3.2 Space requirements.................................................................................. 18
3.3 Installing burner........................................................................................ 19
3.4 Combustion head and masonry dimensions............................................ 21
3.5 Burner hinges............................................................................................23
3.6 Installing burner to gas supply line...........................................................23
3.7 Gas valve selection table......................................................................... 25
3.8 Installing gas pressure regulating assembly.............................................25
3.9 Installing FGR duct system.......................................................................27
3.10 Changing the fuel type from natural gas to LPG...................................... 29
3.11 Electrical connections............................................................................... 29
4 Commissioning
4.1 First start-up.............................................................................................. 31
4.2 Adjusting combustion air...........................................................................32
4.3 Adjusting combustion head.......................................................................34
4.4 Adjusting combustion differential air pressure switch............................... 36
4.5 Adjusting gas pressure switch.................................................................. 37
4.6 Setting gas pressure regulator SKP......................................................... 39
4.7 Setting gas pressure regulator FRS......................................................... 40
4.8 Measuring gas pressure........................................................................... 42
4.9 Operating and display unit menu..............................................................45
4.10 Adjusting operating and display unit settings........................................... 48
4.11 Variable speed drive settings and standardization (WD200).................... 49
4.12 Checking O2 module (WD200)................................................................. 50
4.13 Manual start-up and program stop in pre-purge position..........................51
4.14 Ignition position......................................................................................... 52
M4219 2305EN 1 (111)

4.15 Setting ratio curve.....................................................................................54
4.16 Activating FGR.......................................................................................... 58
4.17 Setting FGR curve points......................................................................... 59
4.18 Measuring FGR.........................................................................................60
4.19 Capacity range..........................................................................................61
4.20 O2 min. value control (WD200)................................................................62
4.21 Setting O2 trim control (WD200)...............................................................64
4.22 O2 trim control operating mode (WD200)................................................ 65
4.23 O2 trim control load limitation (WD200)....................................................66
4.24 O2 trim control when load changes (WD200)...........................................67
4.25 Setting capacity controller operating mode.............................................. 67
4.26 Setting load controller parameters............................................................68
4.27 Capacity controller on/off.......................................................................... 72
4.28 Boiler temperature limiting with burner control......................................... 73
4.29 Cold start thermal shock protection..........................................................73
4.30 Measuring flue gas and combustion air temperature (WD200)................ 74
4.31 Activating O2 trim control (WD200).......................................................... 75
4.32 Backing up parameters.............................................................................75
5 Operation
5.1 WiseDrive system..................................................................................... 76
5.2 Control panel.............................................................................................79
5.3 Legend to time sequence diagrams......................................................... 80
5.4 Burner operation and PI diagram, gas..................................................... 83
5.5 Time sequence diagram, gas use............................................................ 85
5.6 Burner automation description, gas use...................................................86
5.7 Gas valve proving.....................................................................................89
6 Maintenance
6.1 Burner maintenance..................................................................................90
6.2 Maintenance during shutdown..................................................................93
6.3 Dismounting combustion head (GP, GKP)............................................... 93
6.4 Dismounting and changing burner motor................................................. 95
6.5 Assigning servomotors..............................................................................97
6.6 Dismounting and changing servomotors.................................................. 98
6.7 Fault and lockout history........................................................................ 100
6.8 Testing safety and control devices......................................................... 102
6.9 Troubleshooting.......................................................................................105
6.10 Troubleshooting error codes................................................................... 108
6.11 Burner parts (GP)................................................................................... 109
6.12 Burner part list........................................................................................ 110
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1 Introduction
1.1 Liability disclaimer
The delivered equipment with its accessories 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:
Use special caution. The DANGER symbol indicates an immediate
hazard that will result in serious injury or death.
Use special caution. The WARNING symbol indicates a hazard that
may result in serious injury or death.
M4219 2305EN 3 (111)

Use caution. The CAUTION symbol indicates a hazard that may result
in an injury.
Pay attention. The NOTICE symbol indicates a risk of damage to the
equipment, components, or surroundings.
The ‘i’ (info) symbol indicates important information as well as useful
tips and hints.
Keep these instructions as well as the electrical diagrams available near the
device.
Oilon products are manufactured in accordance with general product standards and
directives as well as based on our best knowledge of product design and different
technologies. Operational 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:
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
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 the main fuel shut-off valve.
● Follow safety instructions.
● Contact the safety supervisor.
IN CASE OF A FUEL LEAK
● Do not light fire or touch electric equipment.
● Close the main fuel shut-off valve.
● Make sure there are no people in the leakage area.
● Make sure the leakage area is properly ventilated.
● Take appropriate action.
● Contact the safety supervisor.
4 (111) M4219 2305EN

Cut off power supply to the burner and close the manual shut-off valves
always before any maintenance work. Cutting power is adequate when
just inspecting the device.
Secure 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 protective footwear, gloves, and safety goggles when
necessary.
If burner start-up fails consecutively three 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...+122 °F. Pay special
attention to gas temperature when using LNG.
Fuel changeover shall always be done by an expert.
Pilot line is designed to be used at maximum 5% rating of full power.
Do not use PTFE tape in piping.
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.
M4219 2305EN 5 (111)

Take care of the boiler room
Never light a fire in the boiler room.
Do not store any inflammable materials in boiler room.
Keep the boiler hatch closed while starting the 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 the heating system.
● Make sure that the boiler and chimney are swept regularly.
● Check flue damper adjustment and the gate valve regularly.
● Make sure that the air inlet to the boiler room is open.
● Make sure shut-off valves in pressure gauges are shut.
● Make sure that the necessary components are regularly checked in accordance
with rules and regulations by public authorities. This includes the system’s pipework
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 WINDOW.
2. EXTINGUISH ANY OPEN FLAMES.
3. STAY AWAY FROM ELECTRICAL SWITCHES.
4. EVACUATE THE BUILDING.
5. IMMEDIATELY CALL THE GAS COMPANY.
WARNING
IN ACCORDANCE WITH OSHA STANDARDS, ALL EQUIPMENT, MACHINES AND
PROCESSES SHALL BE LOCKED OUT PRIOR TO SERVICING.
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.
6 (111) M4219 2305EN

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, steam boilers, hot air generators, and
various types of process heating. They are also designed to suit furnaces with high
back pressure.
As standard, the burners are mounted in horizontal orientation. The standard setup is
designed to operate in the altitude of max. 1,640 ft above sea level and the electrical
equipment in the altitude of max. 3280 ft above sea level.
See Other technical data and requirements 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.
In burners supplied with a control system, all burner operation systems are handled
automatically. In the event of a burner failure, the system will stop the burner
automatically. Only qualified personnel may operate the burner manually.
Each burner is tested separately before delivery to the customer.
This product is in accordance with
Our gas burners comply with standard UL295, oil burners with UL296, and dual-fuel
burners with both of the above-mentioned standards.
The manufacturing time is found in the type plate. The product's expected lifespan is at
least 15 years, if it and its components are used and maintained properly.
For more information on products, visit our website at www.oilon.com.
M4219 2305EN 7 (111)

Type labelling
Label element 1: Series, fuel
KP Light fuel oil
RP Heavy fuel oil
GP Gas
GKP Light fuel oil
GRP Gas, heavy fuel oil
Label element 2: Burner frame size categorization
50... 1200 Higher value = higher capacity
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: Burner capacity size categorization
-, I, 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 variable speed drive (VSD)
Label element 6: Combustion head type referring to typical NOx-emissions (additional code)
LN30
LN60
LN80
LN30 = 30mg/kWh
LN60 = 60mg/kWh
LN80 = 80mg/kWh
Label element 7: Combustion head length (additional code)
-, C1, C2, C3 Combustion head length C only in use in LN80 burners.
Type plate
The following illustration shows an example of the type plate of Oilon burners:
8 (111) M4219 2305EN

Type plate US ver. 2
Pos. Description Pos. Description
9 Oil pump supply voltage, input power and
current, V / Phase / Hz / hp / A
10 Degree of protection
11 Serial number
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 12 Month and year of manufacture
2 Overfire pressure min, IN.WC 13 Capacity, gas, MBTU/hr
3 Overfire pressure max, IN.WC 14 Capacity, light fuel oil, GPH
4 Gas calorific value, BTU/scf 15 Oil pressure, PSI
5 Gas type 16 Gas pressure min, IN.WC
6 Oil quality / viscosity 17 Gas pressure max, IN.WC
7 Control voltage, V / Phase / hp / A 18 Manufacturer address
8 Fan supply voltage, input power and
current, V / Phase / 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 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.
M4219 2305EN 9 (111)

1.5 Handling and storing
Storing and recycling
Store the device and its equipment in the manufacturer's packaging in a dry and airy
place. Protect device from dust and humidity. Condensation, formation of ice and
ingress of water are not permitted. If these requirements are not met, the device's
safety functions may be compromised. The storage time is one year after which the
product and its components must be checked before commissioning.
Documentation is a part of the product, and it must be passed on together with 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 available near the device.
Recycle product packaging. 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.
Follow international packing markings
Symbol Description Symbol Description
Fragile, handle with care Arrows to indicate which side
is facing up (THIS WAY UP)
Protected from water (KEEP
DRY) Non stackable
Center of gravity Chain images to indicate lifting
points (SLING HERE)
10 (111) M4219 2305EN

2 Technical data
2.1 Burner technical data
This manual may include additional information about other burner
types. However, the manual is valid only for the burner, mentioned on
the front page and in the burner data table.
Following information applies to standard deliveries.
Burner data
Burner GP-600 M
Capacity, MMBtu/h 3.7–25.6
Burner motor
3~ 208–600 V 60 Hz
● Output, hp
● Current, A/460 V
● Speed, rpm
20.0
23.5
3,510
Weight, lbs* 1014
Burner GP-700 M GP-700 M-II GP-700 M-III
Capacity, MMBtu/h 4.5–31.8 5.1–36.0 5.7–39.8
Burner motor
3~ 208–600 V 60 Hz
● Output, hp
● Current, A/460 V
● Speed, rpm
25
31
3,510
30
35.8
3,510
+variable
speed drive
40
45
2,970**
Weight, lbs* 1,179 1,246 1,488
*Burner only. The weight varies depending on the content of the delivery.
Turndown ratio, gas 1:6 (100...16.6%)
**The frequency must be converted to 50 Hz.
In 700 M-III burners with a 60-Hz configuration, use 50 Hz instead of
the nominal frequency. Make sure that the motor rpm does not exceed
3000.
M4219 2305EN 11 (111)

Working diagrams
Using the burner outside the range shown in the working diagrams is
not allowed.
‘’W.C.
GP-600 M - 700 M-III (UL) ver. 1
Tested in laboratory conditions (ambient temperature 68 °F).
2.2 Other 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 burner for special gases.
Gas inlet pressure to burner max. Natural gas: 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 ft³n/h ≈ 13.5 MBtu efficiency, when heat value is
961.91 Btu/ft³
Performance, natural gas 950 - 1050 btu/sc.ft
Control voltage 115 V (-15%...+10%) 50 Hz / 60 Hz 1-phase
Motor voltage options 220 V 60 Hz 3-phase
400 V 60 Hz 3-phase
460 V 60 Hz 3-phase
575 V 60 Hz 3-phase
12 (111) M4219 2305EN

Sound pressure level LpfA 91.0 ± 0.5 dB
Sound power level LwA 108.5 ± 0.5 dB
For reducing noise level, contact the manufacturer or consult the Oilon
Selection Tool (available for download on the Oilon website).
Degree of protection NEMA 1
Ambient temperature range 32...+ 122 °F
2.3 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
● 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 -4...+140 °F
M4219 2305EN 13 (111)

Block diagram of contact links
Block diagram ver. 7
14 (111) M4219 2305EN

Inputs / outputs (VSD)
Connection diagram ver. 3
2.4 Servomotor technical data
Servomotor SQM45... SQM48.497 SQM48.697 SQM91.391A9
Mains voltage 2 x 12 VAC 2 x 12 VAC 2 x 12 VAC 2 x 12 VAC
Power consumption 9 – 15 VA 26 – 34 VA 26 – 34 VA 40 VA
Angular adjustment 90° 90° 90° 90°
Accuracy ±0.2° ±0.2° ±0.2° ±0.8°
Torques, operation /
holding
26.55 / 13.27 lbf·in 177 / 177 lbf·in 310 / 310 lbf·in 531 / 531 lbf·in
Running 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 data
Display and operating unit AZL...
Supply voltage 24 VDC –15/+10 %
Power consumption < 5 W
Protection degree NEMA 3
Permissible operation ambient temperature -4...+140 °F
Protect the equipment from condensation, ice, and water ingress.
2.6 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
M4219 2305EN 15 (111)

O2 module PLL52...
Analog inlet, oxygen sensor QGO21.000D27
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 -4..+140 °F
Protect the equipment from condensation, ice, and water ingress.
2.7 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 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. temperature, flange +482 °F
Max. temperature, connecting head +158 °F
Max. temperature, flue gas +572 °F
Protect the equipment from condensation, ice, and water ingress.
2.8 Flame detector technical data
Flame detector values and connections depend on burner control
system.
QRI
Operation type continuous
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 5.9 ft
16 (111) M4219 2305EN

QRI
Auxiliary detector cable max. length 328 ft
Protection degree NEMA 3
Permissible operation ambient temperature -4...+140 °F
● integrated signal amplifier
● continuous or interrupted use
● mains frequency filtering
● does not detect electric arc used for ignition
● spectral sensitivity range ~1–3 μm
● QRI2A2.B180B front-viewing
● QRI2B2.B180B side-viewing
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
M4219 2305EN 17 (111)

3 Installation
3.1 Lifting the burner
● The unit may be lifted only by qualified personnel with a good
understanding of the regulations and safety instructions for lifting.
● Always use all indicated lifting points of the particular lifting direction.
● Do not go under the burner or any other suspended load.
The burners are attached and supported to a transportation base. The base can be
lifted from all sides with a forklift. When lifting the package, the center of gravity must
be in the middle between the forks to avoid falling.
B444K ver. 3
1 Protective cover
2 Protective cover
3 Lifting strap
4 Lifting support
1. Take off protective covers (1 and 2).
2. Place the lifting strap (3) to the lifting eyes and around the lifting support (4).
3. Lift the burner as shown in the drawing.
3.2 Space requirements
Leave enough space on each side of the burner for installation, commissioning,
and maintenance purposes. The minimum space requirements are presented in the
following.
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