Oilon GP-6.10 P Operating manual

OILON OY
P.O.Box 5
FIN-15801 LAHTI FINLAND
Tel. [phone]
Fax [phone]
E-mail [email protected] 40180036GB
OPERATING AND MAINTENANCE
INSTRUCTIONS
GAS BURNERS
qGP-6.10 P
qGP-6.20 P

40180036GB
Table of Contents
1. Conventions in this Manual ............................................................................................................1
2. General...........................................................................................................................................2
3. Burner Technical Data ...................................................................................................................4
3.1. Technical Data .....................................................................................................................4
3.2. Basic Assembly Drawing......................................................................................................5
3.3. Parts List ..............................................................................................................................6
3.4. Burner Dimensions ..............................................................................................................6
3.5. Nozzle Table ........................................................................................................................6
4. Burner Installation ..........................................................................................................................7
4.1. Burner Mounting...................................................................................................................7
4.2. Hinged Burner Housing........................................................................................................7
4.3. Electric Connections ............................................................................................................7
4.4. Example of an Installation of Gas Supply Line ....................................................................8
4.5. Gas Pressure Regulating Assembly ....................................................................................9
5. Burner Automation .......................................................................................................................10
5.1. Time Sequence Diagram (High-Low) ................................................................................10
5.2. Time Sequence Diagram (Modulating) ..............................................................................11
5.3. Operation ...........................................................................................................................12
6. Burner Adjustments......................................................................................................................15
6.1. Capacity Regulation ...........................................................................................................15
6.2. PI-Diagram.........................................................................................................................16
6.3. Combustion Head Adjustments .........................................................................................17
6.3.1. Distance between Nozzle and Diffuser Disc and Ignition Electrode
Setting ...................................................................................................................17
6.3.2. Adjusting the Air Velocity in the Combustion Head...............................................17
6.3.3. Setting Values of Adjustment Ring........................................................................18
6.4. Combustion Air Adjustment ...............................................................................................19
6.5. Air Cone Position ...............................................................................................................20
6.6. Flame Inspection................................................................................................................20
6.7. Pressure Switches .............................................................................................................21
6.7.1. Gas Pressure Switch.............................................................................................21
6.7.2. Differential Air Pressure Switch.............................................................................22
7. Valve Leak Tester VPS 504 (only on request) .............................................................................23
8. Control Unit LFL1.322 ..................................................................................................................24
8.1. Internal Circuitry................................................................................................................24
8.2. Control Program of the Sequence Switch..........................................................................25
8.3. Control Program under Fault Conditions and Lockout Indication ......................................26
8.4. Detector Currents and Connection of Flame Detector FE (Ionization Electrode) ..............27
8.5. Technical Data ...................................................................................................................27
9. Maintenance.................................................................................................................................28
10. Fault Conditions and Procedures .................................................................................................29
11. Notes ............................................................................................................................................32

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1. Conventions in this Manual
Read these instructions carefully before installation, commissioning or
maintenance of the burner. The given instructions must be followed.
Throughout this manual, the following three symbols are used to point out very
important information:
DANGER! This symbol is used where there may be a danger to personnel, if the
instructions are not followed.
CAUTION! This symbol is used where there may be 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 AS THE ELECTRICAL SCHEMES AVAILABLE NEAR THE
BURNER!

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2. General
Oilon GP-6.10 P and GP-6.20 P -burners are fully automatic gas burners.
The burners can be used on most heating appliances such as hot water boilers, steam boilers
and air heaters.
Burners are tested and certified for the following gas types
·natural gas: - gases of the 2nd family, groups H and E (equipment categories I2H
and I2E)
- supply pressure (=inlet pressure) at burner 20 - 100 mbar
- gas temperature to gas valve -15…+40 °C.
·LPG: - gases of the 3rd family, group P (equipment category I3P)
- supply pressure (=inlet pressure) at burner 30 - 100 mbar
- gas temperature to gas valve 0…+40 °C.
When using other gases or supply pressures as the above mentioned, please consult the burner
manufacturer on the suitability of the burner.
When necessary the gas pressure is reduced in the pressure regulating assembly. The quantity
of gas is regulated by means of with the gas valve (MultiBloc) equipped with gas/air ratio
controller).
A fan attached to the burner and dimensioned to provide a sufficiently high and even air
pressure for efficient combustion in modern combustion chambers supplies the required air.
Max. required combustion air: 13 m³ of combustion air for each 10 kWh.
Burner operation is controlled and supervised by control unit.
The burner capacity is controlled by boiler thermostats or pressurestats (High-Low) or by
electronic controller (high-low or modulating).
Degree of protection: IP20
Supply/control voltage: 230 V (-15 %...+10 %) 50 Hz 1-phaese
Consumption: 200 W 1,0 A
A pre-requisite for burner operation is, that the ambient temperature during burner operation is
0...+40 °C.
The following should be checked before first start-up:
·connections are correct,
·settings of boiler regulating and control devices are correct,
·boiler and its equipment is in working condition,
·burner is getting sufficient air,
·valves in supply line are open,
·gas line is filled with gas,
·leak test on gas line has been carried out,
·gas pressure is adequate.

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CAUTION! The burner must be installed firmly. Vibrations may damage burner or its
components.
CAUTION! Prior to trial start the gas piping must be vented. See chapter ”Example of
an Installation of Gas Supply Line”.
DANGER! In case of gas leakage:
-do not make fire, do not touch the electrical equipment
- close the main fuel shut-off valve outside the plant
- make sure, that there is no people in the leakage area
- air the leakage area
- take appropriate actions.
In case of fire or other danger:
- switch off the main switch
- close the main fuel shut-off valve outside the plant
- take appropriate actions.
DANGER! Never use a naked flame while checking the burner or the boiler. Never
store any inflammable material in the boiler room.
DANGER! Keep the boiler door closed while starting the burner and during burner
operation.
DANGER! Wear hearing protectors, if there is noise in the boiler room.
Correct installation and adjustment together with regular servicing are the most reliable
guarantees of trouble-free burner operation.
Note! Local regulations and requirements must be adhered to when installing or servicing
the gas burner or the gas supply line.
The burner has to be installed in such a way that the motor shaft lies horizontally; however, it is
not allowed to install the burner upside down.
Use only original spare parts. When ordering spare parts please give the burner type and serial
number indicated on the burner nameplate.

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3. Burner Technical Data
3.1. Technical Data
Burner GP-6.10 P GP-6.20 P
Capacity kW 50 - 120 60 - 160
Burner motor
Voltage 50 Hz
Output kW
Current A
Speed rpm
1~ 230 V
0,125
1,0
2750
1~ 230 V
0,125
1,0
2750
Control unit LFL1.322 LFL1.322
Flame detector Electrode Electrode
Servomotor SQN… SQN…
Weight kg 22 22
Effect of gas inlet pressure on burner capacity range
Burner Gas valve Burner capacity range kW *) Pmax
inlet-
Conn. Gas inlet pressure pressure
size Type 20 mbar 50 mbar 100 mbar mbar
GP-6.10 P ¾" MB-VEF 407 B01 50 - 120 50 - 120 50 - 120 100
GP-6.20 P ¾"
1 ¼"
MB-VEF 407 B01
MB-VEF 412 B01
60 - 130
60 - 160
60 - 160
60 - 160
60 - 160
60 - 160
100
100
*) The max. capacities given in the table are obtained at a boiler backpressure of 0.

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3.2. Basic Assembly Drawing

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3.3. Parts List
1 Burner housing
2 Air intake
3 Flame tube
4 Diffuser disc
5 Gas nozzle
6 Adjustment ring
7 Ignition electrode
8 Ignition transformer
9 Air damper servomotor
10 Air damper
11 Differential air pressure switch
12 Burner motor
13 Fan wheel
14 Air control cone
15 Control unit
16 Ionization electrode
17 Limit switch (safety switch)
18 Sight glass
19 Protective cover
20 Control switch
3.4. Burner Dimensions
Burner Measures in mm
L1 L2 H1 H2 B1 B2 ÆD1
GP-6.10 P 400 110 255 120 210 180 95
GP-6.20 P 400 110 255 120 210 180 100
3.5. Nozzle Table
Burner Nozzle (pcs x hole size)
Natural gas LPG
GP-6.10 P 8 x Æ4,0 8 x Æ2,8
GP-6.20 P 8 x Æ4,0 8 x Æ2,8

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4. Burner Installation
4.1. Burner Mounting
The furnace which has a flame-shaped design does not require refractory. Boilers without
bottom cooling require refractory to prevent heat from reaching boiler foundations.
The 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
2 Gasket plate
3 Thermal insulation
Burner ÆD2 R1
GP-6.10 P 100 70 - 74
GP-6.20 P 105 70 - 74
The mounting plate must have 2 or 4 pcs M10 threaded holes for the mounting of the burner
according to the drawing.
4.2. Hinged Burner Housing
On standard version the burner can be hinged to the left.
4.3. Electric Connections
The burner must be connected according to the electrical diagrams delivered together with the
burner. General and local standards and regulations as well as requirements of electrical
equipment on electrical connections must be adhered to.

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4.4. Example of an Installation of Gas Supply Line
The gas supply line after the pressure regulator must be of the same size or one size larger than
the valve train size.
As standard the gas connection to the burner is from the right side.
Note! A hand-operated shut-off valve must be fitted before the gas valve train.
CAUTION! A separate filter must be fitted before the gas valve train.
CAUTION! The gas valve must be mounted tension free.
Gas pipe venting
A pipe or hose is connected, leading into the open from the measuring connection of inlet
pressure in the gas valve, to discharge the air. For venting open slowly the ball valve in the
supply line and fill the piping with gas. After this close measuring connection.
A - A delivery limit

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4.5. Gas Pressure Regulating Assembly
If the gas inlet pressure is higher than the Pmax. value given in burner technical data, the gas
inlet pressure must be reduced in the regulating assembly or if the gas inlet pressure is not
stable, then the pressure must be stabilised by means of the pressure regulator. If the pressure
regulator is not fitted with a safety relief valve and a safety shut-off valve, they must be installed
according to the instructions given by the manufacturer. Also any impulse tubes must be
installed according to the instructions given by the regulator manufacturer.
The safety relief valve should be dimensioned so that the safety shut-off valve does not release
if the burner shuts down at full load for ex. because of mains interruption. The safety shut-off
valve must be set to close at an approx. 60 % higher pressure than the secondary pressure (=
the pressure after the pressure regulator). The closing pressure of the safety shut-off valve must
not exceed the Pmax pressure. The safety relief valve must be set to open at an approx. 30%
higher pressure than the secondary pressure. Gas inlet pressure, secondary pressure, gas
quantity to be burnt and gas type have effect on the selection of the pressure regulator.
1 Gas pressure regulating assembly 6 Pressure gauge valve
2 Shut-off valve 7 Bellows compensator/gas hose
3 Gas filter 8 Pressure gauge, high pressure
4 Pressure gauge valve 9 Pressure gauge, low pressure
5 Pressure regulator with safety
shut-off valve and safety relief valve

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5. Burner Automation
5.1. Time Sequence Diagram (High-Low)
Required input signals to control unit Control signals Permissible input signals to control unit
A Control loop Q Servomotor
B Fan motor
D Differential air pressure switch PL Fan pressure 0,4 - 100 mbar
E Thermostat/pressurestat, partial load PF Combustion chamber pressure -2…+5 mbar
F Thermostat/pressurestat, full load PBr Burner pressure, gas 0,5 - 100 mbar
G Ignition transformer V Gas/air ratio control
H Main gas valve, NC (PBr:PL) 0,75:1…3:1
L Gas/air ratio controller N Zero point correction +/- 1 mbar
M Gas valve, NC
P Flame signal W Sequence switch stopped (LFL)
O Air damper
Adjustable switching points on the cam switches of the servomotor
I= switching point of full load
I= switching point of ”closed” position
III = switching point of ignition/partial load

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5.2. Time Sequence Diagram (Modulating)
Required input signals to control unit Control signals Permissible input signals to control unit
A Control loop Q Servomotor
B Fan motor
D Differential air pressure switch IN Increase function
CC Electronic capacity controller DE Decrease function
E Thermostat/pressurestat and/or
switch-off threshold of capacity controller PL Fan pressure, air 0,4 - 100 mbar
F Increase/decrease functions in cap. controller PF Comb. chamber pressure -2…+5 mbar
G Ignition transformer PBr Burner pressure, gas 0,5 - 100 mbar
H Main gas valve, NC V Gas/air ratio control
L Gas/air ratio controller (PBr:PL) 0,75:1…3:1
M Gas valve, NC N Zero point correction +/- 1 mbar
P Flame signal
O Air damper W Sequence switch stopped (LFL)
Adjustable switching points on the cam switches of the servomotor
I= switching point of full load
II = switching point of ”closed” position
III = switching point of ignition load/partial load at the low limit of the modulating area (I- III)

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5.3. Operation
1 Prerequisites for start-up
·failures and interlocks are reset
·limit switch on burner flange is closed
·control switch in position 1
·control unit is reset (lockout indicator at symbol )
·contact C/NC of differential air pressure switch is closed (air pressure < min)
·gas pressure > min. Pressure switch (min.) has switched its contact to position C/NO (A)
·valve leak tester has carried out the test and has given a start signal (option) (A)
·control switch in position 1 (A)
·external contacts connected to the control loop are closed (A)
·contact of boiler thermostat/pressurestat (partial load) and/or the switch-on threshold of
the capacity controller are closed (A)
·required start signal from the limit switch of the switching point II in the servomotor to
terminal 8 in the control unit (the motor of the sequence switch).
(A) = control loop
1.1 Start-up (lockout indicator of the control unit is at symbol )
·control loop closes
·control program (sequence switch) of control unit starts
·fan motor starts.
2 Lockout indicator of the control unit is at symbol
·servomotor runs to switching point I(air damper is open)
·sequence switch is stopped for the running time.
3 Servomotor has run to switching point I(air damper is open)
·required start signal from the limit switch of switching point Ito the terminal 8 in control
unit. Otherwise the start-up program interrupts and the control unit remains
(symbol ) waiting for start signal (no failure).
·pre-purge (36 s) with nominal air quantity begins.
4 Lockout indicator of the control unit is at symbol P
·differential air pressure switch has to change its contact over to position C/NO.
Otherwise the control unit goes to lockout, because the air pressure signal has not
been received at the start of the air pressure check. Every air pressure failure after this
point also causes the control unit to go to lockout.
5 Lockout indicator of the control unit is at symbol n
·control of flame supervision circuit (LFL)
·lockout due to a fault in flame supervision circuit.
6 Lockout indicator of the control unit is at symbol
·pre-purge (36 s) completed
·servomotor runs to switching point III (ignition load)
·sequence switch is stopped for the running time.

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7 Servomotor has run to switching point III (ignition load)
·required start signal from the limit switch of switching point III to the terminal 8 in
control unit. Otherwise the start-up program interrupts and the control unit
remains (symbol ) waiting for start signal (no failure).
8 Ignition begins
·pre-ignition 4 s
9 Safety time (2 s) begins
·main gas valve (1) opens
·gas valve (2) opens
·gas flows via gas/air ratio controller to the nozzle
·ignition flame is ignited by the ignition spark.
10 Lockout indicator of the control unit is at symbol 1
·safety time (2 s) ends
·ignition ends
·flame has to be ignited by now
·every flame signal failure after completion of safety time leads to lockout
·flame burns at the set ignition load.
11 Lockout indicator of the control unit is at symbol │(operation)
·sequence switch stops for the running time
·control signal from terminal 20 on the control unit for the running time
·if the contact C/NC of full load thermostat/pressurestat is closed or the capacity
controller carries out an increase function, servomotor runs to switching point I(full
load). The gas/air ratio controller adjusts the gas quantity in relation to the
increasing/decreasing air quantity according to the set ratio (V) in the ratio controller.
·burner operates on capacity regulation range (I- III) supervised by the control unit and
controlled by the control device (thermostat/pressurestat or capacity controller) at partial
load or full load (high-low) or between partial load or full load (modulating) according to
the heat requirement.
·lockout, if the flame signal or the air pressure signal is lost during operation
·if the gas pressure falls bellow the set value of the gas pressure switch (min.), burner
shuts down controlled. When the pressure returns to normal level, burner starts
according to the start-up program.
12 Controlled shutdown (control loop opens)
·main gas valve (1) closes
·gas valve (2) closes
·flame extinguishes
·gas/air ratio controller closes
·sequence switch starts and begins to program the permissible post-purge
time (12 s)
·with control signal from terminals 10 and 11 servomotor runs to or remains at switching
point II (air damper and gas valve (MultiBloc) to ”closed” position.

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13 Lockout indicator of the control unit is at symbol
·sequence switch stops
·fan motor stops
·flame simulation tests (LFL) initiate. Lockout due to flame signal with a short
delay e.g.
- flame not extinguished; leaking fuel valves
- faulty flame signal; fault in flame supervision circuit or similar.
14 Re-start possible, if the prerequisites for start-up are fulfilled (see section 1).
In the event of fault conditions fuel supply is always shut off immediately. The sequence switch
stops and simultaneously the lockout indicator. The symbol above the reading mark indicates
the kind of the fault. When lockout occurs, the control can be reset immediately. After resetting
(and also after the correction of a fault which resulted in a controlled shutdown, or after each
mains failure), the sequence switch always runs through to its start position, whereby only
terminals 7, 9, 10 and 11 receive voltage in accordance with the control program. It is only then
that the control unit begins with a new burner start-up.
Note! Do not press the lockout reset button longer than 10 seconds.

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6. Burner Adjustments
6.1. Capacity Regulation
1 Gas/air ratio control V
2 Zero point correction N
3 Combustion chamber connection pF
4 Fan pressure connection pL
5 Gas pressure connection pBr
6 Gas inlet pressure measuring connection
7 Gas outlet pressure measuring connection
8 Throttle nipple (pL)
9 Test point connection of intermediate pressure
GAS/AIR RATIO CONTROLLER DUNGS MB-VEF…
Coarse adjustment
- Adjust the combustion head to required full load.
-UsealwaysO
2 measuring when starting or adjusting.
- At first adjust gas/air ratio V = 1,5 and adjust by means of the parallel displacement
screw N = 0.
- Start the burner with partial load. If the burner does not start, turn screw N slightly in the
direction (+) and repeat the start.
- Slowly move to full load.
- Adjust gas/air ratio at screw V.
- Don't set the parallel displacement ratio too high.
Fine adjustment
- Set burner to partial load.
- Limit the air damper servomotor to the partial load position.
- Measure O2 content of the flue gas.
- Correct the gas pressure at screw N so, that O2content is 2 - 4 %.
- Finally check the settings on many different loads by measuring the O2 content. If necessary,
correct.
- Check the flue gas values on partial load and full load without changing the set
values (N and V).

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6.2. PI-Diagram
1 Gas valve (MultiBloc) 1.5 Gas/air ratio controller
1.1 Gas filter 2 Fan pressure connection pL
1.2 Gas pressure switch, min 3 Combustion chamber connection pF
1.3 Main gas valve 4 Gas pressure pBr
1.4 Gas valve 5 Valve leak tester (when necessary)

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6.3. Combustion Head Adjustments
6.3.1. Distance between Nozzle and Diffuser Disc and Ignition Electrode Setting
The distance between gas nozzle (3) and diffuser disc (2) and the gas nozzle angle (7°) must be
set according to the drawing. Also the distance between the ignition electrode (5) and the earth
screw as well as the distance between ionization electrode (6) and the burner housing must be
set according to the drawing.
1 Flame tube 6 Ionization electrode
2 Diffuser disc 7 Nozzle holes
3 Gas nozzle 8 Pulse pipe, Combustion chamber
4 Adjustment ring pressure
5 Ignition electrode 9 Pulse pipe, fan pressure
6.3.2. Adjusting the Air Velocity in the Combustion Head
Adjust the air velocity in the combustion head by loosening the locking screw in the adjustment
ring (4) and moving the ring in the direction of the flame tube (1) to change the distance between
the adjustment ring and the edge of the diffuser disc (2). On low capacity the adjustment ring is
advanced and on high capacity retracted. If the adjustment ring is at the set full load too far
forward, the combustion air velocity in the combustion head is too high, the ignition is more
difficult or there is not enough air to support combustion. If the adjusting ring is too far back with
respect to the capacity, the combustion air velocity is too low and the combustion characteristics
become worse (high carbon monoxide content = CO). Check the combustion figures by means
of flue gas analysis.