Oilon KP-6 Manual

OILON OY
P.O.Box 5
FIN-15801 LAHTI FINLAND


[phone]
Fax [phone]
E-mail [email protected] 20039847GB
OPERATING AND MAINTENANCE
INSTRUCTIONS
LIGHT OIL BURNERS


KP-6


KP-6 L


KP-6 LH


KP-6-2


KP-6 H-2

20039847GB
Table of Contents
1. Conventions in this Manual............................................................................................................ 1
2. General.......................................................................................................................................... 2
3. Burner Technical Data................................................................................................................... 4
3.1. General................................................................................................................................ 4
3.2. Technical Data .................................................................................................................... 4
3.3. Basic Assembly Drawing..................................................................................................... 5
3.4. Parts List ............................................................................................................................. 6
3.5. Dimensions.......................................................................................................................... 6
4. Burner Installation.......................................................................................................................... 6
4.1. Burner Mounting.................................................................................................................. 7
4.2. Hinged Burner Housing .......................................................................................................7
4.3. Electric Connections............................................................................................................ 7
4.4. Connecting the Burner to the Mains.................................................................................... 8
4.5. Connecting the Burner to Oil Supply Line ........................................................................... 8
5. Fuel System................................................................................................................................... 9
5.1. Oil Piping ............................................................................................................................. 9
5.2. Oil Pumps.......................................................................................................................... 10
5.3. Oil Filter ............................................................................................................................. 12
6. Burner Operation Principle .......................................................................................................... 13
6.1. 1-Stage Burners, KP-6, KP-6-2 ......................................................................................... 13
6.2. 1-Stage Burner with Preheater, KP-6 L............................................................................. 13
6.3. 2-Stage Burners (H-Burners), KP-6 H-2 ........................................................................... 15
6.4. 2-Stage Burner (”H” Burner) with Preheater, KP-6 LH ...................................................... 15
7. Burner Automation....................................................................................................................... 17
7.1. 1-Stage Burners ................................................................................................................ 17
7.2. 2-Stage Burners (H-Burners) ............................................................................................ 19
8. Burner Adjustment....................................................................................................................... 21
8.1. Capacity Regulation .......................................................................................................... 21
8.1.1. Oil Pump Pressure Regulation ............................................................................. 22
8.2. Combustion Head Adjustment .......................................................................................... 23
8.2.1. Setting the Nozzle and the Ignition Electrodes ..................................................... 23
8.2.2. Adjusting the Air Velocity in the Combustion Head .............................................. 24
8.3. Combustion Air Adjustment............................................................................................... 25
8.3.1. 1-Stage Burners ................................................................................................... 25
8.3.2. 2-Stage Burners (”H” Burners) ............................................................................. 26
8.4. Air Cone Position............................................................................................................... 27
8.5. Flame Inspection ............................................................................................................... 27
9. Control Unit LOA24/BHO64......................................................................................................... 28
9.1. Time Sequence Diagram (Control Program) .................................................................... 28
9.2. Control Functions in the Event of Faults ........................................................................... 29
9.3. Technical Data of Control Unit .......................................................................................... 29
9.4. Current through Flame Detector ....................................................................................... 29
9.5. Measurement of Flame Signal .......................................................................................... 30
10. Maintenance ................................................................................................................................ 31
11. Fault Conditions and Procedures ................................................................................................ 32
12. Notes ........................................................................................................................................... 35

1
20039847GB
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:
WARNING! A warning alerts you to possible danger to person, if the instructions are not
followed.
CAUTION! A caution alerts you to something, that has the potential to cause damage
to component, burner, process or surroundings, if the instructions are not followed.
Note! A note points out information of special interest.
KEEP THESE OPERATING AND MAINTENANCE INSTRUCTIONS
AS WELL AS THE ELECTRICAL SCHEMES AVAILABLE NEAR THE
BURNER!

2
20039847GB
2. General
Oilon KP-6...KP-6 H-2 burners are fully automatic light oil burners.
These burners can be used on most heating appliances such as hot water boilers, steam boilers
and air heaters.
A fan attached to the burner and dimensioned to provide a sufficiently high and even air
pressure for efficient combustion in modern combustion chambers delivers the required air.
The burners are suitable for use on light fuel oil with a viscosity of 4 - 12 mm²/s (cSt) at a
temperature of +20 °C.
The oil coming to the burner must be filtered before the burner oil pump. Filtration degree may
be max. 100 µm.
Oil atomising pressure: • 1-stage burners 700 - 1400 kPa (7 - 14 bar)
• 2-stage burners 700 - 2500 kPa (7 - 25 bar).
The ”H” burners are high-low -burners and ”LH” burners are equipped with a preheater.
2-stage burners (”H” burners) have a maximum control range from 55 to 100 %.
Required combustion air quantity: 15 m³ for each kg of oil to be burned.
Burner operation is automatically controlled and supervised by the control unit.
Boiler thermostats or pressurestats controls the burner capacity.
Protection: IP20
Supply/control voltage 230 V (-15 %...+10 %), 50 Hz, 1-phase
Input power: 260 W 1,13 A (KP-6, KP-6-2, KP-6 H-2)
500 W 2,2 A (KP-6 L, KP-6 LH)
The ambient temperature during burner operation must be 0...+40 °C.
The following should be checked before first start-up:
●connections are correct,
●settings of regulating and control devices are correct,
●boiler and its equipment is in working condition,
●boiler room is adequately ventilated,
●valves in supply line are open,
●there is oil in the tank,
●oil temperature is adequate in such a way, that the oil viscosity is 4 - 12 mm²/s
(max. +60 °C).

3
20039847GB
CAUTION! The burner must be installed firmly. Vibrations may damage burner or its
components.
CAUTION! Prior to first start-up the oil pump must be vented. The pump must not
operate without oil. See chapter ”Oil Pumps”.
WARNING! 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.
WARNING! Never use a naked flame while checking the burner or the boiler. Never
store any inflammable material in the boiler room.
WARNING! Keep the boiler door closed while starting the burner and during burner
operation.
Correct installation and adjustment together with regular servicing are the most reliable
guarantees of trouble-free burner operation.
Note! Local regulations and requirements must be adhered to when installing or servicing
the burner.
The burner must be installed in such a position, that the motor shaft lies horizontally; but the
burner must not, however, be installed upside down.
Use only original spare parts. When ordering spare parts please give burner type and serial
number indicated on the burner nameplate.

4
20039847GB
3. Burner Technical Data
3.1. General
●burner types: • 1-stage burners
KP-6
KP-6 L
KP-6-2
• 2-stage burners (”H” burners)
KP-6 LH
KP-6 H-2
●on standard version the burner can be hinged to both sides
●the burner must be installed in such a position, that the motor shaft lies horizontally; but the
burner must not, however, be installed upside down.
●burner control unit internally connected
●safety switch (limit switch) on hinged flange
●control switch
●air regulation: • stepless adjustable (1-stage burners)
• servomotor (2-stage burners)
●oil pump atomising pressure:• 700 - 1400 kPa (7 - 14 bar) (1-stage burners)
• 700 - 2500 kPa (7 - 25 bar) (2-stage burners)
●standard version equipped for two-pipe system
●electrical connection with a plug connector (KP-6, KP-6 L, KP-6-2).
Extra equipment
●run hour counter
●filter Oilon 20
●de-aerator Tiger Loop
●oil meter
●oil pressure gauge and valve
3.2. Technical Data
Burner KP-6 KP-6 L KP-6 LH KP-6-2 KP-6 H-2
Capacity kg/h
kW
3,5 - 10,042 -
120
3,5 - 10,0
42 - 120
3,5 - 10,0
42 - 120
6,0 - 12,0
71 - 140
6,0 - 16,0
71 - 190
Burner motor
Voltage 50 Hz 230 V
Output kW
Current A
Speed rpm
0,125
1,0
2750
0,125
1,0
2750
0,125
1,0
2750
0,125
1,0
2750
0,125
1,0
2750
Control unit LOA24
/BHO64
LOA24
/BHO64
LOA24
/BHO64
LOA24
/BHO64
LOA24
/BHO64
Servo motor - - SQN - SQN
Oil hoses R ¼" R ¼" R ¼" R ¼" R ¼"
Oil pump AS 47 C/
BFP 21 L3
AS 47 C/
BFP 21 L3
BFP 52E L3
AT 2 45 C
AS 47 C/
BFP 21 L3
BFP 52E L3
AT 2 45 C
Preheater W - 30 - 240 30 - 240 - -
Light fuel oil 1 kg/h ≅11,86 kW

5
20039847GB
3.3. Basic Assembly Drawing

6
20039847GB
3.4. Parts List
1 Burner housing 19 Burner motor
2 Control unit 20 Fan wheel
3 Protective cover 21 Plug connector (KP-6, KP-6 L, KP-6-2)
4 Flame detector (photo resistor) 22 Air cone
5 Control switch (KP-6 LH, KP-6 H-2) 23 Coupling
6 Nozzle holder (KP-6, KP-6-2, KP-6 H-2) 24 Air damper/air adjustment ring
Preheater (KP-6 L, KP-6 LH) 25 Air damper shaft
7 Limit switch (=safety switch) 26 Air intake
8 Swirler 27 Oil pump
9 Ignition electrode AS 47 C or BFP 21 L3 (KP-6, KP-6 L, KP-6-2)
10 Adjustment ring BFP 52E L3 or AT 2 45 C (KP-6 LH, KP-6 H-2)
11 Nozzle 28 Nozzle conduit
12 Diffuser disc 29 Cover plate
13 Ignition cable 30 Pressure pipe
14 Combustion head 31 Adjusting lever (KP-6, KP-6 L, KP-6-2)
15 Mounting flange Servomotor (KP-6 LH, KP-6 H-2)
16 Hinge pin 32 Oil hose, return
17 Ignition transformer 33 Oil filter
18 Sight glass 34 Oil hose, suction
3.5. Dimensions
Burner Dimensions in mm
L1 L2 H1 H2 B1 B2 øD
KP-6 310 105 230 120 210 180 90
KP-6 L 310 105 230 120 210 180 90
KP-6 LH 400 105 255 120 210 180 90
KP-6-2 310 110 230 120 210 180 100
KP-6 H-2 400 110 255 120 210 180 100

7
20039847GB
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
2Gasket
3 Thermal insulation
BURNER Ø D2
KP-6, -6 L, -6 LH 95
KP-6-2, -6 H-2 105
The mounting plate must have either two or four M10 threaded holes for the mounting of the
burner according to the drawing.
4.2. Hinged Burner Housing
On standard version the burners are delivered to be hinged to both sides.
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.

8
20039847GB
4.4. Connecting the Burner to the Mains
KP-6, KP-6 L, KP-6-2
Electrical connection on burner is with a plug connector. Connect the cable of the plug supplied
with the burner to the boiler thermostat. The socket has been firmly attached to the burner
housing. Disconnect the burner from the mains (burner switch in position 0) by pressing the
locking button and pulling out the plug from the socket at the same time.
1 Socket (fixed on the burner
housing)
2 Locking button
3 Plug (pull-out part)
4.5. Connecting the Burner to Oil Supply Line
On standard version the burners is equipped for two-pipe system. Two-pipe system has both
suction and return lines for fuel oil.
Note! The by-pass plug in the oil pump must be fixed.
1 Filter
2 Suction line
3 Oil pump
4 Pressure line (to nozzle)
5 Return line
6 By-pass plug
7 Shut-off valve
8 Shut-off valve/Non-return valve
A-A Delivery limit

9
20039847GB
5. Fuel System
5.1. Oil Piping
The oil tank and the oil pipes must be installed to avoid the risk of the oil cooling below cloud
point. The cloud point of heating oil depends on the oil quality. If the oil is allowed to cool to the
cloud point, valves and filters will block. The most suitable oil temperature is +15...+25 °C.
Note! The viscosity of oil coming to the burner must be 4 - 12 mm²/s (cSt).
The maximum lengths for other viscosities can be calculated by the simple ratio of viscosities
i.e. if the table shows lengths for 5 resp. 6 mm²/s (cSt) viscosity, multiply the length shown in the
table by 5 resp. 6 and divide by the value of the new viscosity mm²/s (cSt).
Keep in mind that absolute tightness is the fundamental pre-requisite for secure operation. A
leaking suction line may cause, among other things, afterspraying of oil into the boiler. It is
advisable to use ball valves instead of needle valves.
The tables give the maximum lengths (in meters) of return and suction lines.
Overlying oil tank Underlying oil tank
H m DANFOSS BFP/MS (ø d mm) H m DANFOSS BFP/MS (ø d mm)
ø 6 mm ø 8 mm ø 10 mm ø 6 mm ø 8 mm ø 10 mm
0 17 53 100 0 17 53 100
0,5 19 60 100 0,5 15 47 100
1,0 21 66 100 1,0 13 41 99
1,5 23 72 100 1,5 11 34 84
2,0 25 79 100 2,0 9 28 68
2,5 27 85 100 2,5 7 22 53
3,0 29 91 100 3,0 5 15 37
3,5 31 98 100 3,5 3 9 22
4,0 33 100 100 4,0 1 3 6
2800 rpm, 6 mm²/s (cSt) 2800 rpm, 6 mm²/s (cSt)
H m SUNTEC 45/47 (ø d mm) H m SUNTEC 45/47 (ø d mm)
ø 6
mm
ø 8
mm
ø 10
mm
ø 12
mm
ø 6
mm
ø 8
mm
ø 10
mm
ø 12
mm
0 14 49 123 150 0 14 49 123 150
0,5 16 55 136 150 0,5 12 43 109 150
1,0 18 61 150 150 1,0 10 37 94 150
2,0 22 73 150 150 2,0 7 26 65 138
3,0 25 85 150 150 3,0 3 14 37 78
4,0 29 96 150 150 4,0 0 2 8 18
2850 rpm, 5 mm²/s (cSt) 2850 rpm, 5 mm²/s (cSt)
Dmax = 20 m Hmax = 4,5 m
(D-H)max = 4,5 m

10
20039847GB
5.2. Oil Pumps
For KP-6, KP-6 L, KP-6-2 burners
Danfoss BFP 21 L3 Suntec AS 47 C
1 Suction line connection
2 Return line connection
3 Nozzle connection
4 Pressure gauge connection
5 Vacuum meter connection
6 Pressure regulation
7 Air venting nipple/plug
8 By-pass plug
9 Filter
10 Solenoid valve, NC
1 Suction line connection
2 Return line connection
3 Nozzle connection
4 Pressure gauge connection
5 Vacuum meter connection
6 Pressure regulation
7 Air venting plug
8 By-pass plug
9 Filter
10 Solenoid valve, NO
Oil pump venting
Two-pipe system needs no venting as the air comes away when starting the burner. In order to
speed up the air removal, the air venting plug or the pressure gauge connection (4) can be
loosened.
Oil supply to the burner can be noted on the oil pressure gauge fixed to the oil pump or on the oil
spray from the nozzle.

11
20039847GB
For KP-6 LH, KP-6 H-2 burners
Danfoss BFP 52E L3 Suntec AT 2 45 C
1 Suction line connection
2 Return line connection
3 Nozzle connection
4 Pressure gauge connection
5 Vacuum meter connection
6 Pressure regulation, stage 1 (P1)
7 Pressure regulation, stage 2 (P2)
8 By-pass plug
9 Filter
10 Solenoid valve, stage 1
normally closed, NC
11 Solenoid valve, stage 2
normally open, NO
1 Suction line connection
2 Return line connection
3 Nozzle connection
4 Pressure gauge connection
5 Vacuum meter connection
6 Pressure regulation, stage 1 (P1)
7 Pressure regulation, stage 2 (P2)
8 By-pass plug
9 Filter
10 Solenoid valve, stage 1
normally closed, NC
11 Solenoid valve, stage 2
normally open, NO
Oil pump venting
Two-pipe system needs no venting as the air comes away when starting the burner. In order to
speed up the air removal, the air venting plug or the pressure gauge connection (4) can be
loosened.
Oil supply to the burner can be noted on the oil pressure gauge fixed to the oil pump or on the oil
spray from the nozzle.

12
20039847GB
5.3. Oil Filter
1 Cover 4 O ring
2 Cup 5 Gasket
3 Element 6 Gasket
Cleaning instruction:
Unscrew the cup (2) off the cover (1).
Clean and check the element (3) and the cup (2). Check, that they are not damaged.
Place the gasket (6) on the bolt of the cup and reassemble the element (3) so that the holes at
the end of the element are forwards the cover (1).
Place the gasket (5) on the element (3).
Place the O-ring (4) in its place and screw the cup (2) tight. Check the tightness.

13
20039847GB
6. Burner Operation Principle
See drawings Nos. A-382 A and A-422 K
6.1. 1-Stage Burners, KP-6, KP-6-2
When the control device (13) calls for heat the signal lamp lights up and the burner motor (7),
which drives the fan (6) and the oil pump (4), starts. An electric arc is created between the
ignition electrodes (9). After the pre-purge period has elapsed solenoid valve (10) opens (oil
pump BFP 21 L3) / closes (oil pump AS 47 C) and the oil, spraying from the nozzle (11), is
ignited by the electric arc. When the flame has established, the burner control will cut the arc
and the flame continues to burn.
If the flame is not ignited within the safety time, the control unit locks out in the flame failure
position and the burner shuts down, and will not start before resetting the control unit. The
burner makes then one attempt to start (see above). If the flame is extinguished during normal
operation, solenoid valve (10) closes (oil pump BFP 21 L3) / opens (oil pump AS 47 C). The
burner makes one normal attempt to start. If the flame is not ignited, the control unit locks out in
the flame failure position and the burner shuts down, and will not start before resetting the
control unit i.e. by pressing the reset button on the control unit.
6.2. 1-Stage Burner with Preheater, KP-6 L
When the control device (13) calls for heat the signal lamp lights up and the preheater (14)
heats the oil up to approx. +70 °C. When the oil has reached the required temperature the
control unit starts the burner motor (7). The operation continues as on burners without
preheater.

14
20039847GB
Drawings Nos. A-382 A and A-422 K
Oil pump BFP 21 L3
Oil pump AS 47 C
1 Oil filter
2 Oil, return
3 Oil, suction
4 Oil pump
5 Pressure pipe
6 Burner fan
7 Burner motor
8 Ignition transformer
9 Ignition electrodes
10 Solenoid valve
- normally closed, NC
(oil pump BFP 21)
- normally open, NO
(oil pump AS)
11 Nozzle
12 Control unit
13 Control device
(thermostat/pressurestat)
14 Preheater, ”LH” burners
only

15
20039847GB
See drawings Nos. A-421 K and A-442K
6.3. 2-Stage Burners (H-Burners), KP-6 H-2
The ”H” burners are equipped with a control switch 0-1-2. Switch in position 1 the burner
operates at stage 1 only controlled by control device. Switch in position 2 the burner operates
normally controlled by control devices.
When the control device (18) calls for heat an electric arc is created between ignition electrodes
(12) and the air damper servomotor (15) opens the air damper from ”closed” position (position
”II” of the limit switch in servomotor) to the position of stage 1 (position ”III” of the limit switch in
servomotor). Burner motor (6), which drives the fan (5) and the oil pump (4), starts.
After the pre-purge period has elapsed solenoid valve (7) opens. The oil spraying from the
nozzle is ignited by the electric arc. Ignition ends after the time determined by the control unit.
The burner operates at stage 1.
If the flame is not ignited within the safety time, the control unit locks out in the flame failure
position and the burner shuts down, and will not start before resetting the control unit. If the
flame is extinguished during normal operation, solenoid valve (7) closes. The burner makes one
normal attempt to start. If the flame is not ignited within the safety time, the control unit locks out
in the flame failure position and the burner shuts down, and will not start before resetting the
control unit i.e. by pressing the reset button on the control unit.
When boiler temperature or pressure exceeds the set value for control device of stage 2 (19),
the burner operates at stage 1. When the boiler temperature or pressure is below the set value
for control device of stage 2 (19), the quantity of air increases and the solenoid valve (8) closes
when the limit switch in servomotor is in position ”V” (pump pressure increases). The air damper
opens to the position of stage 2 (position of the limit switch ”I” in servomotor). The burner
operates at stage 2. When the temperature or pressure exceeds the set value for control device
of stage 2 (19), the burner switches on to the position of stage 1. When the temperature or
pressure exceeds the set value for control device of stage 1 (18), the burner shuts down (air
damper closes).
Set the control device of stage 2 (19) to a 5-10 °C lower temperature than the control device of
stage 1 (18). If the control device of stage 2 (19) is set to a higher temperature than the control
device of stage 1 (18), the burner starts at stage 1, but operates the whole operation period at
stage 2 and shuts down direct from stage 2, when the set value for control device of stage 1 (18)
will be exceeded.
6.4. 2-Stage Burner (”H” Burner) with Preheater, KP-6 LH
When the control device (18) calls for heat, the preheater (20) heats the oil up to approx. +70 °C.
When the oil has reached the required temperature, an electric arc is created between the
ignition electrodes (12) and the air damper servomotor (15) opens the air damper from the
”closed” position (position of the limit switch ”II” in servomotor) to the position of stage 1
(position of the limit switch ”III” in servomotor). The operation continues as on burners without
preheater.

16
20039847GB
Drawings Nos. A-421K and A-442K
Oil pump Danfoss BFP 52E L3
Oil pump Suntec AT 2 45 C
1 Oil filter
2 Oil, suction
3 Oil, return
4 Oil pump
5 Burner fan
6 Burner motor
7 Solenoid valve, stage 1
normally closed, NC
8 Solenoid valve, stage 2
normally open, NO
9 Pressure regulating valve,
stage 1 (P1)
10 Pressure regulating valve,
stage 2 (P2)
11 Ignition transformer
12 Ignition electrodes
13 Pressure pipe
14 Nozzle
15 Servo motor
16 Air damper
17 Control unit
18 Control device, stage 1
(thermostat/pressurestat)
19 Control device, stage 2
(thermostat/pressurestat)
20 Preheater, ”LH” burners only

17
20039847GB
7. Burner Automation
7.1. 1-Stage Burners
Required input signals to the control unit
Control signals from the control unit
TZ Limit thermostat M1 Burner motor (fan/oil pump)
TS Control thermostat T1 Ignition transformer
E1 Preheater EV1 Solenoid valve
TSW Thermostat of preheater B1 Flame detector/flame signal
Prerequisites for start-up
●burner is getting fuel
●interlocks are reset
●contact of switches of control voltage supply in control unit and contacts of thermostats
closed, whereupon the control voltage is received to the terminal 1 in control unit.
A´ Start on burner with preheating
●control signal from terminal 8 in control unit
●preheater begins to heat up the oil
●contact of lower limit thermostat (TSW) in preheater closes after time ”tw” (approx. 1
min), when the oil temperature is approx. 70 °C, whereupon the control signal is
applied to terminal 3 in control unit.
A Start on burner without preheating
●control signal is applied from contact 8 to contact 3 in control unit
●burner motor (fan/oil pump) starts
●pre-ignition begins
●pre-purge begins.

18
20039847GB
B´ Solenoid valve receives control signal
●safety time begins (max. 10 s)
●solenoid valve opens (Danfoss) / closes (Suntec)
●oil atomising begins
●flame has to be ignited during the safety time, otherwise the control unit goes to
lockout.
B Flame ignites
●flame relay is energised, whereupon terminals 8 and 3 in control unit connect on flame
relay's contact. Opening of contact in thermostat of preheater does not stop the burner
during flame
●burner has started
●post-ignition till operating position of control unit.
C Control unit/burner in normal operating position
●control program of control unit ends
●burner remains operating supervised by the control unit (flame) and controlled by
control thermostat.
D Controlled shutdown with control thermostat
●burner motor stops
●solenoid valve closes
●flame extinguishes.
See chapter ”Control Functions in the Event of Faults”.