Oilon GP-1000 M, Operation And Maintenance Manual

Page 1: ...63 2206EN 14 February 2022 Operation and maintenance manual Burner models GP 1000 M 1200 M Burner equipment WDx00 ME comb head FGR Read these instructions carefully before installation use or maintena...

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Page 3: ...ner 21 3 6 Combustion head and masonry dimensions 23 3 7 Rotating air cone 24 3 8 Gas valve selection table 24 3 9 Installing burner to gas supply line 25 3 10 Installing gas pressure regulating assem...

Page 4: ...trol 71 4 30 Cold start thermal shock protection 71 4 31 Measuring flue gas and combustion air temperature WD200 73 4 32 Activating O2 trim control WD200 73 4 33 Backing up parameters 73 5 Operation 5...

Page 5: ...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...

Page 6: ...afety 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...

Page 7: ...ee 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...

Page 8: ...ipework 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 WIND...

Page 9: ...e 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...

Page 10: ...er 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...

Page 11: ...e 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 t...

Page 12: ...ust be passed on together with device also with a second hand product Pass on documents delivered with device to owner at installation and advise to keep them properly Make sure that operating instruc...

Page 13: ...600 V 60 Hz Output hp Current A 460 V Speed rpm frequency converter 50 55 9 2 970 frequency converter 60 66 7 2 970 Control unit WDx00 WDx00 Weight lb 1 720 1 830 Burner only The weight varies depend...

Page 14: ...gases Gas inlet pressure to burner max Natural gas 40 200 W C LPG 48 200 W C Max demand for combustion air gas use 13 5 cfh MBtu Efficiency natural gas 35 31 ft n h 13 5 MBtu efficiency when heat valu...

Page 15: ...ide 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 Per...

Page 16: ...Block diagram of contact links Block diagram ver 7 14 102 M4263 2206EN...

Page 17: ...1A9 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...

Page 18: ...ting 110 VAC 15 10 Power consumption max 90 W typically 35 W 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 temperat...

Page 19: ...ly voltage 24 V DC 20 Protection class III Power consumption 4 W Response sensitivity 25 mV AC Output parameters Safety period Operation t VOff 1 s and or 3 s factory set Start up delay t VOn 1 s and...

Page 20: ...nly adhering to all local regulations and requirements Space requirements ver 1 Legend Minimum dimension ft a left 2 6 b front 3 6 c right 2 6 d top 3 3 It is recommended to leave more space around th...

Page 21: ...1 Burner 2 Lifting eyes 4 pcs 3 Lifting chain or strap 3 3 Detaching and fastening protective covers Secure all safety covers enclosures and guards with all screws before start up Use appropriate tool...

Page 22: ...d enough approx 0 79 inches 2 Set backcover s keyholes through the screw heads 3 Hold the cover slightly raised and slide it into position Be careful not to damage the gasket 4 Tighten all the screws...

Page 23: ...rt firmly against the floor 3 5 Installing burner Check before installation Diffuser disc and adjustment ring are in the correct position in relation to the combustion head Combustion head is then in...

Page 24: ...er 1 Measurements inch Burner L1 L2 L3 L5 H1 H2 H3 H5 B1 B2 B3 D1 GP 1000 M 62 99 17 09 11 93 39 37 57 87 43 31 20 08 23 03 35 63 34 65 29 53 19 53 GP 1200 M 62 99 17 09 11 93 39 37 57 87 43 31 20 08...

Page 25: ...d mounting dimensions D063900 ver 2 Masonry 1 ver 3 Pos Item Pos Item 1 Gasket thickness 0 3 inch 3 Ceramic wool or equivalent 2 Mounting panel 4 Masonry Burner D1 L2 1000 M 19 53 17 09 60 90 1200 M 2...

Page 26: ...ng eyelet thread length 0 39 inches and place a lifting hook through the eyelet 2 Remove the air cone mounting screws 3 Rotate the air cone towards the desired direction 4 Replace the mounting screws...

Page 27: ...he valves shown in the following example may vary from those delivered B352U ver 3 If the gas inlet pressure is not stable stabilize with pressure regulator Install gas lines in accordance with regula...

Page 28: ...electing pressure regulator gas supply pressure secondary pressure the volume of gas to be fired type of gas If the gas inlet pressure is higher than the Pmax value given in burner s technical data or...

Page 29: ...press regulator 3 Gas filter 11 Safety relief valve if not incl in press regulator 4 Pressure gauge valve 12 Blow off when necessary 5 Pressure gauge high pressure 13 Pressure gauge valve when necessa...

Page 30: ...r Designing FGR piping When designing the piping consider the special circumstances of FGR operation The temperature in the piping varies constantly during the operation causing expansion and contract...

Page 31: ...the burner 3 Finish the FGR duct pipe joint carefully with seal welding flange or screw connection Make sure that the joint is tight and no air can enter the duct 4 Place condensate drains both at the...

Page 32: ...otor output s control circuit and the motor output to the motor The exact connections depend on the installation s configuration and must be made on site in accordance with local rules and regulations...

Page 33: ...first start up First start up check list Check the following before first start up instructions from boiler and burner manufacturers are followed piping is done properly and joints on pipes and compon...

Page 34: ...Turn the burner control switch to OFF position Commissioning data It is recommended to note down the following data when commissioning the burner Gas type Wobbe index calorific value Volumetric gas fl...

Page 35: ...ep 1 Remove all the primary nozzles Z1 and Z2 and test the burner 2 Replace the secondary gas nozzles X and Y with new nozzles in the cardboard box Test the burner 3 Add adjusting bands and test the b...

Page 36: ...W C maximum adjustment range should be between 35 Hz and 50 Hz To ensure proper burner function the differential air pressure switch may have to be readjusted to match the actual conditions at the ins...

Page 37: ...le to the maximum position 2 Run burner to the desired maximum capacity 3 Increase burner capacity to be 1 15 times the desired maximum capacity by raising gas pressure 4 Slowly turn switch to the min...

Page 38: ...o burner 4 Close cover Gas pressure switch min should cause a permanent interlocking If gas pressure switch triggers a temporary burner shutdown during burner start up or during operation it has to be...

Page 39: ...P25 4 AGA23 602 8 245 red SKP25 4 SKP2 ver 1 To adjust gas pressure 1 Remove the plug 2 Adjust the outgoing pressure by turning the slot head screw counter clockwise with a chisel point screwdriver Wh...

Page 40: ...k combustion using flue gas analysis when raising pressure Adjust burner if necessary Check gas valve measuring point position from the gas valve manufacturer manual Adjust the pressure regulator outl...

Page 41: ...ired offset 5 Screw on protective cap A Stick adhesive label E onto typeplate Do not overtighten the component s screws The component may become damaged Sealing final settings 1 Check pressure regulat...

Page 42: ...229 907 229 915 Spring 8 40 2 60 3 pink 229 872 229 881 229 890 229 899 229 908 229 916 Spring 9 56 3 80 4 grey 229 873 229 882 229 891 229 900 243 416 243 417 4 7 Measuring gas pressure General rule...

Page 43: ...ressure D048665 ver 2 1 Nozzle pressure at nominal capacity Burner Test point 1 W C 1000 M 29 7 1200 M 29 7 Check the tables below for adjusted pressure values Measuring inlet and adjusted pressure M4...

Page 44: ...train d073474 ver 2 A Gas inlet 2 Inlet pressure 3 Adjusted pressure 4 Measuring point 5 Inlet pressure pilot 6 Adjusted pressure pilot Burner Test point 2 W C Test point 3 W C 1000 M 1200 M max 280 V...

Page 45: ...UserMaxLoad MaxLoadMod Max load modulating MaxLoadStage Max load stage Fuel Displaying and selecting the type of fuel CurrentFuel Information about the type of fuel currently burnt read only FuelSele...

Page 46: ...l volume gas Reset Date Oil Reset date fuel volume oil LockoutCounter Total number of lockouts that occurred read only O2 Module Actual O2 Value Actual O2 value O2 Setpoint O2 setpoint SupplyAirTemp S...

Page 47: ...system To ensure burner operation some functions and actuator settings can be adjusted only by trained service personnel Password is needed when logging into system Password protected menu levels Burn...

Page 48: ...ing set values 1 Select Params Display 2 Select the desired parameter 3 Select a new parameter value using the Select buttons 4 Save the selected new value by pressing Enter 5 Return to the menu by pr...

Page 49: ...M burners with a 60 Hz configuration the maximum output frequency is 52 5 Hz 4 11 Setting frequency converter parameters WD200 Parameters for frequency converter used for fan motor control must be set...

Page 50: ...tarts 3 Burner control steers frequency converter setting to 95 When the fan reaches stable rotation speed its value is set as StandardizedSp value in the menu This value is equal to 100 of fan rotati...

Page 51: ...cy Combustion efficiency QGO SensorTemp QCO sensor temperature F QGO HeatingLoad Control value of QGO heating 0 1 QGO Resistance Internal resistance of QGO s Nernst cell Self test is made at 23 interv...

Page 52: ...Active program stop in phase 24 Params Display Ratio Control Program Stop deactivate 24 PrePurgP 32 PreP FGR 36 IgnitPos 44 Interv 1 52 Interv 2 72 PostPPos 76 PostPFGR Manual start up Prerequisites F...

Page 53: ...lt values for ignition position If oil is selected as fuel check oil pump operating pressure 2 When adjustments are set select program stop at 44 Interval 1 As the program moves forward an electric ar...

Page 54: ...tting ratio curve Curve points There can be 15 curve points at the maximum Set curve points in the following menu level Params Display RatioControl GasSettings CurveSettings Point Manual Creating curv...

Page 55: ...last stored curve point If you want to set a new curve point press Enter when XXXX is displayed as the set value The ignition position will automatically be set as the first ratio curve point from wh...

Page 56: ...frequency converter settings can be scrolled through using the Select buttons Curve point 5 ver 4 Press Enter at the desired parameter Curve point 6 ver 4 Change setting using the Select buttons Then...

Page 57: ...where you can scroll through curve points Return to the menu by pressing Esc Creating curve point manually by changing load 1 At the menu level CurveSetting move the pointer to Manually Curve point 8...

Page 58: ...y over aired if the burner is equipped with O2 trim control The residual oxygen level is set 1 higher than the normal level There can be 15 curve points at the maximum Set at least 10 curve points for...

Page 59: ...for FGR mode have been set at the factory The commissioning personnel will adjust the settings at start up if needed For further instructions see the section Setting FGR curve points 4 18 Setting FGR...

Page 60: ...tored to each curve point Current FGR temperature can be viewed from display using buttons Make sure capacity is stable and FGR temperature is within the normal operation limits before storing curve p...

Page 61: ...the application Flue gas percentage is counted as follows FGR Flue gas amount recirculated ppm Flue gas amount recirculated ppm combustion air amount in ppm To define flue gas percentage 1 First meas...

Page 62: ...splay RatioControl GasSettings LoadLimits MinLoadGas Minimum load Low fire gas MaxLoadGas Maximum load High fire gas On user level maximum load can be set individually as follows Description Operation...

Page 63: ...ed values CO 4000 ppm 2 on the Shell Bacharach scale Values may vary depending on the type of the configuration If you change the ratio curves at a later date the minimum value must also be readjusted...

Page 64: ...value control is set 4 22 Setting O2 trim control WD200 O2 min value O2Control must be set first It is important that environmental conditions do not change when setting O2 trim control If you change...

Page 65: ...e When desired oxygen level is reached press Enter Point23 ver 4 5 The display changes Save or reject by pressing Enter or Esc Point24 ver 4 At curve point 2 and at the highest curve point the burner...

Page 66: ...er operation burner stops tries to restart or lockout occurs conAutoDeac Use this setting during normal operation Both O2Limiter and O2Control are active Burner starts though oxygen sensor has not rea...

Page 67: ...itions the actual O2 value will drop below the minimum limit To prevent this parameterize an increase of the O2 value during capacity change O2 OffsetGas Oil Params Display O2Contr Guard FuelSettings...

Page 68: ...Bus Capacity controller operating modes ExtLC X5 03 External capacity controller with contactors IntLC Internal burner control capacity controller Internal set value W1 in use Can be changed to intern...

Page 69: ...0 of the measurement range I Part Tn 0 2000s 0 no I part D Part Tv 0 1000s 0 no D part Params Display LoadController ControllerParam ContrlParamList P Part Xp I Part Tn D Part Tv By increasing the pro...

Page 70: ...must be ready for 10 min run where boiler temperature or pressure is dropped to 5 below set value and then run with full load This occurs automatically according to the following diagram Boiler load...

Page 71: ...meters When changing the setting boiler temperature or pressure should stabilize without going up and down Pressure and temperature must not go under or exceed set values A common ratio for Tn Tv 4 6...

Page 72: ...ameter is too high the load control becomes unstable The factory setting is 1 SW_FilterTimeCon can be used to delay the internal load controller If the value for this parameter is too high the interna...

Page 73: ...emperature difference percentages 10 46 4 F Limiter reset temperature 161 6 F Description Params Display LoadController TempLimiter TL_ThreshOff Temperature limiter OFF threshold F TL_SD_On Temperatur...

Page 74: ...step The menu shows values used in the chart example Example Set value 145 PSI Params Display LoadController ColdStart ColdStartOn activated ThresholdOn 40 of set value StageLoad 15 load step StageSet...

Page 75: ...GasGas MaxTempFlGasOil 4 32 Activating O2 trim control WD200 At the end of commissioning activate O2 trim control from the display and operation unit menu Operation O2Ctrl activate deactivated activat...

Page 76: ...essure switch 16 Gas pressure switch 17 Gas valves 18 Air pressure switch 19 Motor 20 Speed sensor 21 Frequency converter for variable speed drive WD200 22 Display and operating unit 23 MOD BUS 24 Con...

Page 77: ...controller Fan frequency converter control WD200 Residual oxygen control WD200 Boiler cold start thermal shock protection Fuel flow meter WD200 Burner efficiency measuring WD200 Start up and running...

Page 78: ...unit is used for monitoring and adjusting settings The menu is available in several languages The operating and display unit has an internal memory backed up by a battery The memory stores the burner...

Page 79: ...Flame detector is equipped with self test function and is suitable for continuous operation F200K ver 1 F200K is a flame detector for use with gas and oil burners Depending on type it can detect eith...

Page 80: ...ire position 12 Standby stationary 60 Operation 1 stationary 21 Shutoff valve ON start release 62 Operation 2 Low fire position 22 Fan motor ON 70 Post combustion time 24 Pre purge position 72 Post pu...

Page 81: ...st purge time 1 gas oil tn1 Abbreviations AL Alarm PV Pilot valve ARF FGR flue gas recirculation R Temperature or pressure controller ON internal external CPI Closed Position Indicator RP No load posi...

Page 82: ...ntion of startup 9 Param With continuous purge the shown output signals are inverted 10 Fan controlled as before Post purge in lockout position PostpurgeLockout 11 Param With without extraneous light...

Page 83: ...is equipped with a fan which is designed to produce consistently high air pressure This is required for flawless ignition and good combustion in modern combustion chambers A servomotor controls the a...

Page 84: ...ut off valve 2 Pressure switch low 41 Air damper 42 Servomotor 43 Combustion air fan 44 Electric motor 3 Safety shut off valves 3 1 Valve 3 2 Actuator 3 4 optional 3 3 Actuator with pressure regulator...

Page 85: ...5 5 Time sequence diagram gas use 7550f57e 0515 Gp1 ver 6 M4263 2206EN 83 102...

Page 86: ...rerequisites for start All failures and interlocks reset Burner flange limit switch closed Safety loop closed Boiler safety devices not activated Control switch in position 1 Burner control in stand b...

Page 87: ...trol receives a flame signal burner control goes to a lockout Control remains active until the beginning of pre ignition 36 Servomotors drive to ignition position 38 Pre ignition begins 40 42 First sa...

Page 88: ...s or fan motor rotation speed signal disappears during burner operation Lockout if the user presses the operating and display unit s Esc and Enter button simultaneously during operation Immediate shut...

Page 89: ...mal for example because of a lockout or because burner control has been de energized it will take place during the next start up sequence during the pre purge period between phases 30 and 32 Valve pro...

Page 90: ...stion head may cause a hazard Before maintenance Cut off power supply Close fuel valves Discharge pressure from piping Disconnect ignition cables Remove rods for adjustable combustion head To maintain...

Page 91: ...ts and regular maintenance ensure trouble free burner operation Service the burner annually Use only original spare parts When ordering spare parts give the burner type and serial number indicated on...

Page 92: ...rom lower end 4 Detach combustion head adjusting rods 5 Detach ignition cables 6 Detach fixing screws of combustion head regulating axle and lift out the regulating axle 7 Detach fixing screws of comb...

Page 93: ...Pull the fan wheel to its place using a binder plug The fan wheel lies against base bushing 4 Place the fixing sleeve 5 Screw down the fan wheel with a fixing screw to the motor shaft 6 Place the mot...

Page 94: ...nment plate of the motor coupling motor coupling stays on butterfly valve s shaft 5 Unscrew the servomotor fixing screws and remove the servomotor 6 Connect the cables to the still loosen servomotor a...

Page 95: ...ombustion head servomotor 4 Check address If address is incorrect keep red button pressed approx 10 until green light is steady Assigning servomotor bus address 1 Select Params Display from display an...

Page 96: ...equipped boiler safety devices Flame detector Test method Outcome Step 1 1 Prevent any light from reaching the detector and start the burner The burner must shut down and lockout at the end of safety...

Page 97: ...Error code 28 and text Air pressure off appear on the display Gas pressure switches For instructions on adjusting the switches see section Adjusting gas pressure switches Gas pressure minimum Test met...

Page 98: ...e fuel adjusting valve Push air damper plates lightly to make sure they are firmly attached O2 CO trim control if equipped The system is self checking during start up Confirm proper fuel air ratio wit...

Page 99: ...ntrol unit is damaged Change Control loop closed burner or control unit start up program does not start 1 Faulty servomotor 2 Faulty control unit 3 Mechanical jam in levers or couplings 1 Change servo...

Page 100: ...air Faulty pressure switch Change Faulty gas valve Change No electric arc for ignition Condition Possible cause Action Fan motor starts control voltage from burner control to ignition transformer is s...

Page 101: ...w because min gas pressure switch released Check operation and regulations Blocked filter Clean or replace filter Flame monitoring fault lockout Condition Possible cause Action Lockout during pre purg...

Page 102: ...authorized and trained personnel only adhering to all local regulations and requirements Before performing any work on the burner control system completely isolate the control system from the mains C...

Page 103: ...6 9 Burner parts GP d067537 GP 1000 M 1200 M WDx00 US ver 1 Pilot gas train Main gas train FGR The assembly may vary depending on the scope of delivery M4263 2206EN 101 102...

Page 104: ...X 28 Pressure regulator X 32 Combustion head X 33 Support leg X 37 Flame detector QRI X F200K X 38 Ignition cable X 40 Ignition electrode X 43 Valve leak tester X 250 000 44 Pressure switch gas X 59...

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Page 106: ...OILON GROUP P O Box 5 FI 15801 LAHTI FINLAND Tel 358 3 85 761 Fax 358 3 857 6239 Email info oilon com www oilon com Contact information of Oilon dealer Date of installation...