Oilon KP-6 User manual

M2003 1743EN
6 November 2017
Operation and maintenance manual
Burner models: KP-6, KP-6 L, KP-6 LH, KP-6-2, KP-6 H-2
Burner equipment: LMO
Read these instructions carefully before installation, use, or maintenance

Contents
1 Introduction
1.1 Burner models covered in this manual.......................................................3
1.2 Liability disclaimer.......................................................................................3
1.3 Safety precautions...................................................................................... 4
1.4 Product overview.........................................................................................6
1.5 Handling, transportation and storing...........................................................8
2 Technical data
2.1 Burner technical data................................................................................10
2.2 Assembly drawing.....................................................................................12
2.3 LMO program relay technical data........................................................... 13
3 Installation
3.1 Space requirements..................................................................................14
3.2 Mounting the burner..................................................................................14
3.3 Burner hinges............................................................................................16
3.4 Connecting to oil supply line.................................................................... 16
3.5 Fuel system...............................................................................................18
3.6 Connecting to the mains...........................................................................20
4 Commissioning
4.1 First start-up.............................................................................................. 21
4.2 Nozzle selection........................................................................................22
4.3 Oil pump pressure regulation................................................................... 24
4.4 Combustion head adjustment................................................................... 25
4.5 Combustion air adjustment for 1–stage burner.........................................27
4.6 Servomotor settings SQN......................................................................... 28
4.7 Adjusting the air velocity in the combustion head................................... 29
5 Operation
5.1 1-stage burner operating principle............................................................32
5.2 2-stage burner operating principle............................................................34
5.3 Operating status signals........................................................................... 36
5.4 Troubleshooting and monitoring.............................................................. 36
5.5 Time sequence diagram........................................................................... 38
5.6 Oil pump....................................................................................................40
6 Maintenance
6.1 Burner maintenance..................................................................................42
6.2 Position of air cone...................................................................................43
6.3 Flame observation.....................................................................................44
6.4 Changing the nozzle.................................................................................44
M2003 1743EN 1 (51)

6.5 Flame detector.......................................................................................... 44
6.6 Changing pump filter.................................................................................48
6.7 Troubleshooting and monitoring............................................................... 48
6.8 Burner failures and troubleshooting..........................................................50
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1 Introduction
1.1 Burner models covered in this manual
Burner item code Burner description
KP6210 KP-6
KP62210 KP-6-2
KP6H2210 KP-6 H-2
KP6L210 KP-6 L
KP6LH210 KP-6 LH
1.2 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.
M2003 1743EN 3 (51)

1.3 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.
Note indicates tips, hints, and other essential information.
Keep these instructions as well as the electrical diagrams available near the
device.
This device can be used by at least 8-year-old childen and other
persons, whose physical, perceptual, or mental qualities are lowered or
who do not have experience and knowledge, and they are guarded or
they have been guided to use the device safely, and if they understand
dangers related to the usage of the device. Children must not play with
the device. Children must not to clean the device and they most not
perform any maintenance tasks without surveillance.
The usage of this device is not intended to persons (including children),
whose physical, perceptual, or mental qualities are lowered, or who do
not have experience and knowledge unless they are guarded, or guided
to use the device by the person responsible for the safety. Children
must be controlled to make sure, that they do not play with 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:
Firing with too low residual oxygen may cause an explosion hazard.
Firing with too high residual oxygen may cause unstable combustion
and faults in burner operation.
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.
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IN CASE OF FIRE OR OTHER EMERGENCY
● Cut off power supply.
● Close main fuel shut-off valve.
● Take appropriate actions.
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.
Do not touch hot pipes or surfaces during operation or maintenance.
If burner start-up fails consecutively two times, do not restart burner
before carefully investigating the reason for the failure.
Make sure that the burner gets sufficiently combustion air.
If the burner control system, including all related components, does not
support continuous operation, a controlled shutdown is performed every
24 hours to ensure safe operation.
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.
M2003 1743EN 5 (51)

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.
1.4 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.
100 % bio oil can also be used as a fuel. The features, adjustment measures and
possible structural changes of bio-oil are presented in the sections commissioning and
maintenance of this manual.
As standard, the burners are mounted in horizontal orientation. Our burners are
designed for operation in covered areas, within the temperature range of 0 °C – +40 °C
. The standard setup is designed to operate in the altitude of max. 500 m 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.
6 (51) M2003 1743EN

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.
Our gas burners comply with standard EN 676, oil burners with EN 267, and dual-fuel
burners with both of the above-mentioned standards.
For more information on products, visit our web site at www.oilon.com: Oilon –>
Industries –> Product material.
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
L With preheater
LH With preheater, two-stage
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:
M2003 1743EN 7 (51)

Type plate EU ver. 4
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
10 Serial number
2 NOx classes, gas 11 Year of manufacture
3 NOx class, oil 12 Heat input, gas, kW
4 Burner category : I2R = natural gas I3R =
liquefied petroleum gas
13 Heat input, light fuel oil, kg/h
5 Gas families: 2 = groups H and E | 3 =
group P
14 Gas pressure min, mbar
6 Oil quality / viscosity 15 Gas pressure max, mbar
7 Supply voltage, input power and current,
V / Hz / A / kW
16 CE marking and certification institute
code
8 Manufacturer address 17 PIN code (gas burner)
9 Degree of protection, IP 18 Countries of destination
1.5 Handling, transportation and storing
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 a part of the product, and it must be passed on together with the
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.
8 (51) M2003 1743EN

The use of materials is in conformity with the provisions of the European RoHS
Directive on the restriction of the use of certain hazardous substances in electrical and
electronic equipment. The maximum permitted concentrations for following substances
are not exceeded:
● Lead (Pb)
● Mercury (Hg)
● Cadmium (Cd)
● Hexavalent chromium (Cr6+)
● Polybrominated biphenyls (PBB)
● Polybrominated diphenyl ether (PBDE)
M2003 1743EN 9 (51)

2 Technical data
2.1 Burner technical data
CONTROL VOLTAGE 230 VAC (-15%...+10%) | 50 Hz 1-phase
INPUT POWER
KP-6, KP-6-2, KP-6 H-2
KP-6 L, KP-6 LH

260 W | 1,13 A
500 W | 2,2 A
CAPACITY RANGE, kW
KP-6, KP-6 L, KP-6 LH
KP-6-2
KP-6 H-2

42 - 120
71 - 140
71 - 190
CAPACITY RANGE kg/h
KP-6, KP-6 L, KP-6 LH
KP-6-2
KP-6 H-2

3,5 - 10,0
6,0 - 12,0
6,0 - 16,0
FUEL VISCOSITY 4 - 12 mm²/s (cSt) when temperature is +20 °C
RECOMMENDED AMBIENT TEMPERATURE
RANGE
0... +40 °C
TEMPERATURE OF OIL TO BURNER + 8... +40 °C
If the oil storage is located in cold premises, it is
recommended to use Oilon Plus filter and deaerator,
which helps to raise the start-up temperature.
FILTRATION OF OIL TO BURNER Oil to burner must be filtered with a filtration ratio of
100 µm.
It is recommended to install Oilon filter or Oilon Plus
filter and deaerator.
MOTOR OUTPUT 125 W
MOTOR CURRENT 1 A
MOTOR SPEED 2750 r/min
PREHEATER OUTPUT
KP-6 L, KP-6 LH

30 - 240 kW
SERVOMOTOR
KP-6 LH, KP-6 H-2

SQN
OIL PUMP
KP-6, KP-6 L, KP-6-2
KP-6 LH, KP-6 H-2

AS 47 C
BFP 52E L3 or AT 2 45 C
OIL HOSES R1/4"
ATOMIZING PRESSURE
1-stage burners
2-stage burners

700 - 1400 kPa (7-14 bar)
700 - 2500 kPa (7-25 bar)
COMPATIBILITY TO PIPE SYSTEM Can be installed to a two-pipe system.
DEGREE OF PROTECTION IP 20
NOISE LEVEL 60 - 64 dBA
NOx-CLASS (EN267)
KP-6, KP-6 L, KP-6 LH, KP-6-2
KP-6 H-2

1
2
WEIGHT
KP-6, KP-6 L, KP-6-2
KP-6 LH, KP-6 H-2

17 kg
19 kg
See product specific standards and directives in the EC Declaration of
Conformity for burners.
10 (51) M2003 1743EN

Working diagrams according to EN 267
KP-6, KP-6 L
A558A ver. 1
KP-6 LH
A559A ver. 1
KP-6-2
A560A ver. 1
KP-6 H-2
A561A ver. 1
M2003 1743EN 11 (51)

2.2 Assembly drawing
D330D ver. 1
Dimensions, mm
Burner L1 L2 H1 H2 B1 B2 D
KP-6 310 105 230 130 210 180 90
KP-6 L 310 105 230 130 210 180 90
KP-6 LH 400 105 255 130 210 180 90
KP-6-2 310 110 230 130 210 180 100
KP-6 H-2 400 110 255 130 210 180 100
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Part list
1. Air intake 20. Air intake interflange
2. Nozzle conduit 21. Program relay
3. Cover combination 22. Relay base
4. Coupling 23. Circuit plate
5. Pressure pipe 24. Cover plate
6. Ignition transformer 25. Cover plate
7. Ignition transformer 26. Lead-in
8. Limit switch 27. Lead-in
9. Limit mounting plate 28. Type plate
10. Limit hinge pin 29. Danger label
11. Burner motor 30. Label sheet
12. Photoresistor 31. Cross recessed screw
13. Line 32. SVD screw
15. Burner housing 43. Plug connector rack
16. Air cone 45. Cable roller
17. Protective cover 48. Cable seal
18. Sight glass 51. Plug
19. Hinge pin  
2.3 LMO program relay technical data
Mains voltage 230 VAC -15 / +10 %
120 VAC +10 % / -15 %
Mains frequency 50–60 Hz ±6 %
Power consumption 12 VA
Electromagnetic compatibility EMC 2014/30/EC
Fuse max. 6.3 A (slow)
Degree of protection IP 40
Permissible ambient temperature:
- during operation
- during transportation and storage
-20...+60 °C
-20...+60 °C
Permissible mounting orientation optional
Permissible values for
terminals at cosφ ≥ 0,6:
LMO14... LMO24...
Terminal 1 Max. 5 A Max. 5 A
Terminals 3 and 8 Max. 3 A Max. 3 A
Terminals 4 and 5 Max. 1 A Max. 1 A
Terminal 6 Max. 1 A Max. 2 A
Terminal 10 Max. 1 A Max. 1 A
M2003 1743EN 13 (51)

3 Installation
3.1 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.
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.
Space requirements ver. 1
Legend Minimum
dimension, cm
a
(left)
80
b
(front)
80
c
(right)
80
d
(top)
100
It is recommended to leave more space around the burner. These are only the
minimum requirements.
3.2 Mounting the burner
Install burner firmly. Vibration may damage burner or its components.
14 (51) M2003 1743EN

Mounting the flange
SW00010 ver. 3
The burner is mounted in the boiler with either 2 or 4 M10 screws.
Cover all unused holes in the boiler.
Permitted mounting positions
If you mount the burner to a non-standard structure, make sure the motor shaft lies
horizontally.
Do not install the burner upside down. Make sure the burner is firmly
attached.
The flame must not at any 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.
A349A ver. 3
1. Mounting plate
2. Gasket
3. Thermal insulation
M2003 1743EN 15 (51)

If a mounting plate is needed, the plate needs 2 or 4 M10 threaded holes.
A380A ver. 2
Burner D2
KP-6, KP-6 L, KP-6 LH 95
KP-6-2, KP-6 H-2 105
3.3 Burner hinges
Standard burners can be hinged to both sides.
Switch off electric power from the burner before burner swing-out.
3.4 Connecting to oil supply line
Do not remove the bypass plug from the oil pump.
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Connecting to the oil supply line using an oil filter
A364D ver. 3
1. Filter cover
2. Filter
3. Suction line
4. Oil pump
5. Pressure line to nozzle
6. Return line
7. By-pass plug
8. Shut-off valve
9. Shut-off/Non-return line
A - A Delivery limit
Line installation directions
Danfoss Suntec
Line installation direction depends on the pump type. Make sure the correct direction is
used.
M2003 1743EN 17 (51)

3.5 Fuel system
Oil piping
Install the oil tank and the oil pipes in such a way that the oil will not cool down below
the cloud point. If the oil cools below the cloud point, the valves and filters will clog.
The cloud point of fuel oil depends on its quality. Check the suitable oil temperature
from the technical data.
Make sure the viscosity of oil coming to burner is as recommended.
Two-pipe system with a standard oil filter
A266Y ver. 3
The suction line has to be absolutely tight. A leaking suction line may cause, among
other things, afterspraying of oil into the boiler. The ball valve is more reliable option
than the needle valve.
See the maximum lengths of return and suction lines from the table.
The tables are compiled to the announced oil viscosity.
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