Oilon GP-600 M, Operation And Maintenance Manual

Page 1: ...M4219 2305EN 6 April 2023 Operation and maintenance manual Burner models GP 600 M 700 M III Burner equipment WDx00 FGR UL Read these instructions carefully before installation use or maintenance...

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Page 3: ...nstalling burner to gas supply line 23 3 7 Gas valve selection table 25 3 8 Installing gas pressure regulating assembly 25 3 9 Installing FGR duct system 27 3 10 Changing the fuel type from natural ga...

Page 4: ...combustion air temperature WD200 74 4 31 Activating O2 trim control WD200 75 4 32 Backing up parameters 75 5 Operation 5 1 WiseDrive system 76 5 2 Control panel 79 5 3 Legend to time sequence diagram...

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: ...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 d...

Page 10: ...II III Higher value higher capacity Label element 5 Control system additional code WD100 Electronic fuel air ratio control system WD200 Electronic fuel air ratio control system with O2 control and var...

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: ...h the device also with a second hand product Pass on the documents delivered with device to the owner at installation and advise them to keep them properly Make sure that operating instructions are av...

Page 13: ...peed rpm 20 0 23 5 3 510 Weight lbs 1014 Burner GP 700 M GP 700 M II GP 700 M III Capacity MMBtu h 4 5 31 8 5 1 36 0 5 7 39 8 Burner motor 3 208 600 V 60 Hz Output hp Current A 460 V Speed rpm 25 31 3...

Page 14: ...must be known Consult burner manufacturer on the suitability of the burner for special gases Gas inlet pressure to burner max Natural gas 8 200 W C LPG 11 200 W C Max demand for combustion air gas us...

Page 15: ...nditions 96 VAC Transformer primary side 120 VAC Transformer side 1 12 VAC Transformer side 2 2 x 12 VAC Mains frequency 50 60 Hz 6 Power consumption 30 W Permissible input current differential air pr...

Page 16: ...Block diagram of contact links Block diagram ver 7 14 111 M4219 2305EN...

Page 17: ...g time 10 s 120 s 30 s 120 s 60 s 120 s 30s Degree of protection NEMA 3 NEMA 3 NEMA 3 NEMA 4 Permissible ambient temperature 4 140 F 4 140 F 4 140 F 4 140 F 2 5 Display and operating unit technical da...

Page 18: ...10 VAC 15 10 Power consumption max 90 W typically 45 W controlled Measuring cell temperature 1292 F 122 F Measuring range 0 2 20 9 O2 Flue gas velocity 3 28 32 81 ft s Protection degree NEMA 2 Max tem...

Page 19: ...ignal amplifier continuous or interrupted use mains frequency filtering does not detect electric arc used for ignition spectral sensitivity range 1 3 m QRI2A2 B180B front viewing QRI2B2 B180B side vie...

Page 20: ...from all sides with a forklift When lifting the package the center of gravity must be in the middle between the forks to avoid falling B444K ver 3 1 Protective cover 2 Protective cover 3 Lifting stra...

Page 21: ...y the minimum requirements 3 3 Installing burner Prepare boiler front plate in accordance with the given dimensions Coat bolt threads with graphite bearing grease prior to fitting Install burner so th...

Page 22: ...700 M III 64 96 15 75 11 61 5 71 47 24 41 73 30 71 16 54 13 19 Burner B1 B2 B3 B4 D1 D2 R1 R2 600 M 17 13 25 39 10 63 21 65 15 55 16 73 56 69 55 12 700 M 19 29 27 56 12 01 21 65 15 55 16 73 58 66 60 6...

Page 23: ...17 91 4xM20 15 55 12 20 60 90 700 M 18 31 18 31 17 91 4xM20 15 55 12 20 60 90 700 M II 18 31 18 31 17 91 4xM20 15 55 12 20 60 90 700 M III 18 31 18 31 18 90 4xM20 16 73 15 75 60 90 Dimensions in inche...

Page 24: ...te 3 Slide the first gasket into place over the stud screws 4 Using the strap or chain lift the extension plate Slide the plate onto the stud screws 5 Let the extension plate rest on the stud screws a...

Page 25: ...nstalling burner to gas supply line Supply line If necessary decrease the supply gas pressure with pressure regulating assembly The gas supply line after the pressure regulator must be of the same siz...

Page 26: ...re is a separate filter upstream from gas equipment Install the gas valve so that the valve is not subjected to mechanical stress Vent gas piping before first start up Clean and check piping prior to...

Page 27: ...e PSI Type Size inch 600 700 M III 2 18 7 25 VGD 2 5 6 If the gas inlet pressure is less than 8 in WC or if some other gas except natural gas is used case specific evaluation must be made 3 8 Installi...

Page 28: ...re is not stable stabilize the pressure with the pressure regulator Example of gas pressure regulating assembly B311Z ver 4 Pos Item Pos Item 1 Gas pressure regulating assembly 9 Bellows compensator g...

Page 29: ...er constructions pos 2 and 3 are integrated parts of the burner Burner Minimum diameter of FGR pipe 300 M II 300 M III 6 400 M I 600 M 8 700 M 700 M III 10 Designing FGR piping When designing the pipi...

Page 30: ...s To mount FGR duct system 1 Place the inlet to the stack as close as possible to the boiler or economizer Set cutting in 45 angle 2 Set control damper close to the burner 3 Finish the FGR duct pipe j...

Page 31: ...d according to the capacity demand Note the quantity of gas flow in relation to function of the compound regulator Check the combustion values with flue gas analysis and if necessary adjust the burner...

Page 32: ...rdance with local rules and regulations Also note that in certain models the motor output is integrated in the burner wiring base In burners with an external control cabinet the supply for the control...

Page 33: ...t 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 components...

Page 34: ...motor positions 4 2 Adjusting combustion air Adjustment ring positioning Adjustment ring position has an effect on thif e pressure in the combustion head Adjust the pressure by moving the adjustment r...

Page 35: ...capacity Gas 2 4 If you alter the position of the adjustment ring in relation to the diffuser disc the quantity and velocity of combustion air in the combustion head will change Check combustion valu...

Page 36: ...ver 1 Pos Description Pos Description 1 Mounting flange 6 Oil nozzle valve GKP GRP KP RP 2 Combustion head 7 Oil nozzle GKP GRP KP RP 3 Adjusting ring 8 Ignition electrode 4 Diffuser disc 9 Ignition e...

Page 37: ...head C GP Dimensions in inches Burner model A B C GP 600 M GP 700 M 0 91 5 79 GP 700 M II 0 91 6 38 GP 700 M III 0 94 6 69 Setting ignition electrodes Set the following as shown in the illustration ig...

Page 38: ...ressure difference generated by the burner fan LGW A2 ver 2 Pos Item A Higher pressure B Lower pressure C Electrical connections D Adjustment wheel 1 and 2 Cross head screw If the pressure difference...

Page 39: ...t nominal burner capacity 1 Remove the screws and open the protective cover 2 Start the burner 3 Turn the switch slowly towards the maximum until the burner shuts down 4 Turn the switch approx 2 0 W C...

Page 40: ...red maximum capacity for example so that O2 content 2 5 3 0 and CO content 50 ppm 3 Increase the capacity by raising the gas pressure until the O2 content 1 0 and CO content 2000 ppm 4 Slowly turn the...

Page 41: ...To change spring 1 Remove the plug 2 Remove the slot head screw by turning counter clockwise with a chisel point screwdriver 3 Replace the spring Assemble in reverse order Do not overtighten the comp...

Page 42: ...d spring p2 is 4 12 in WC Springs can be ordered from Oilon Webshop Setting pressure regulator at minimum load 1 Start burner at minimum load At minimum load throttle valve setting is 5 10 2 Adjust co...

Page 43: ...djustment spindle B counterclockwise Turn spindle to stop 2 Unscrew complete adjustment spindle B and remove spring C 3 Insert new spring D 4 Assemble complete adjustment spindle and adjust desired of...

Page 44: ...9 879 229 888 229 897 229 906 229 914 Spring 7 24 1 44 2 black 229 871 229 880 229 889 229 898 229 907 229 915 Spring 8 40 2 60 3 pink 229 872 229 881 229 890 229 899 229 908 229 916 Spring 9 56 3 80...

Page 45: ...on operating conditions Measuring nozzle pressure D048641 ver 2 1 Nozzle pressure at nominal capacity Burner Test point 1 W C 300 M II 8 4 400 M I 8 4 500 M 12 5 600 M 15 3 700 M 22 1 700 M II 30 1 7...

Page 46: ...et 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 300 M II max 280 VGD 34 400 M I max 280 VGD 34 500 M max 280...

Page 47: ...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 48: ...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 49: ...ystem 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 Burne...

Page 50: ...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 51: ...he first start up Remove control signal filtering and delays Set acceleration and deceleration time to 2 s Set the minimum frequency to 0 Hz Set the maximum frequency to 105 2 of the motor s nominal s...

Page 52: ...ation Setpoint Output The variable speed drive control signal can be set to 0 20 mA or 4 20 mA 4 12 Checking O2 module WD200 O2 module connected to burner control through CAN bus can be connected with...

Page 53: ...gas temperature sensors If sensors are connected warning is displayed when flue gas temperature is too high and combustion efficiency will be calculated and displayed Check that the oxygen value sens...

Page 54: ...Primary safety control Prepurge four air changes in max 90 s Burners not exceeding 2 500 MBtu h Prepurge 30 s at maximum air damper opening high fire If a curve point setting for full load is changed...

Page 55: ...ame ignites Program progress is interrupted 3 Optimize ignition position values If gas is selected as fuel in program phase 44 only the ignition gas flame if applicable burns and in program phase 52 t...

Page 56: ...he top corner The pointer is positioned at Point Curve point 1 ver 4 Press Enter to scroll through stored curve points Curve point 2 ver 4 The pointer is positioned at the colon below the text Point T...

Page 57: ...er 4 3 Select the desired value using the Select buttons and press Enter change changes the curve point settings delete deletes the curve point Pointer positioned at Load Curve point 4 ver 4 When the...

Page 58: ...is check the combustion flame set load value and point load is determined according to current fuel consumption as a percentage of maximum load In the settings for air servomotors and variable speed d...

Page 59: ...t at full load curve point burner capacity note ratio set fan rotation speed as small as possible check combustion values with flue gas analysis check combustion flame set point load setting at 100 Wh...

Page 60: ...ivating FGR Burners equipped with FGR can also be used without FGR Whenever you activate and deactivate FGR you will need to recheck fuel air ratio curves FGR can be activated from Params Display Flue...

Page 61: ...position value immediately After time period or temperature is reached AUX3 will be released and FGR curve can be made Temperature value can be changed from Params Display Flue gas recirc ThresholdFG...

Page 62: ...oblock ver 3 Pos Item 1 FGR duct 2 FGR control valve 3 Measuring point of residual oxygen in flue gas Recirculated flue gas amount is typically 5 20 of the flue gas combustion air mixture amount depen...

Page 63: ...r capacity range can be set as required at service level The minimum capacity can be greater than the first curve point and the maximum capacity can be below the last curve point During start up the b...

Page 64: ...tional point to smooth the curve Even ratio curve improves O2 ratio control In dual fuel burners set the O2 ratio control individually for both fuels and they are not correlating Start O2 ratio curve...

Page 65: ...he second line Use the Select buttons Point26 ver 4 3 Accept the value by pressing Enter Exit by pressing Esc Measuring O2 min values by reducing air 1 Select desired point from previous menu level by...

Page 66: ...capacity burner operates according to ratio curve without O2 trim control 1 Select O2 Control from the following menu level Params Display O2Contr Guard Fuel Settings O2 Control 2 The first O2 trim c...

Page 67: ...ntrol calculates PID parameters and time delays for O2 monitor by driving the burner back to ratio curve After that the display returns to initial state Select next curve points from the menu by press...

Page 68: ...active Burner starts though oxygen sensor has not reached its operating temperature Burner operates along parameterized ratio curves When oxygen sensor has reached its operating temperature and sensor...

Page 69: ...gs Type ofAir Change O2 OffsetGas Oil LoadCtrlSuspend FilterTimeLoad Parameters Type ofAirChange Impact of air density change on O2 value like P air gas use like theory oil use O2 OffsetGas Oil O2 tri...

Page 70: ...al set value W1 in use Can be changed to internal set values W1 and W2 using contactors IntLC Bus Internal burner control capacity controller Set value for burner control through Modbus or eBus IntLC...

Page 71: ...ControllerParam ContrlParamList P Part Xp I Part Tn D Part Tv By increasing the proportional band the temperature pressure deviation is lowered Using too great a proportion will result in temperature...

Page 72: ...e and then run with full load This occurs automatically according to the following diagram Boiler load should stay constant throughout adaptation Flow chart_WD capacity ver 3 O2 trim control must not...

Page 73: ...v 4 6 Examples of typical incorrect settings and the optimal setting to change the set value Xp too low Xp too high Tn and Tv too low Tn and Tv too high Optimum setting If load control is not complete...

Page 74: ...oo high the internal load controller becomes unstable The factory setting is 3s 4 27 Capacity controller on off If temperature or pressure has been given a set value burner start up and shut down limi...

Page 75: ...rature limiter switching differential ON 4 29 Cold start thermal shock protection Cold start thermal shock protection protects the boiler from thermal stress if the boiler has cooled down The burner s...

Page 76: ...Release Stages Cold start thermal protection operation example Cold start ver 4 4 30 Measuring flue gas and combustion air temperature WD200 Flue gas and combustion air temperature measuring sensor ca...

Page 77: ...unit menu Operation O2Ctrl activate deactivated activated 4 32 Backing up parameters 1 Start backing up parameters by selecting the following from the display and operating unit Updating ParamBackup...

Page 78: ...ressure switch 16 Gas pressure switch 17 Gas valves 18 Air pressure switch 19 Motor 20 Speed sensor 21 Variable speed drive for variable speed drive WD200 22 Display and operating unit 23 MOD BUS 24 C...

Page 79: ...controller Fan variable speed drive 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 80: ...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 81: ...emit infrared light Flame signal intensity can be monitored on display Flame detector is equipped with self test function and is suitable for continuous operation 5 2 Control panel The control panel...

Page 82: ...n burner operation and lockout is active 5 3 Legend to time sequence diagrams Phases 00 Lockout phase 50 2nd safety time 01 Safety phase 52 Interval 2 ti2 10 Homerun 54 Low fire position 12 Standby st...

Page 83: ...e switch SK Safety loop safety limit thermostat water shortage DW DK Pressure switch valve proving SP Setpoint position DWmin Pressure switch min SR Safety relay internal DWmax Pressure switch max STB...

Page 84: ...r OFF in 10 and 12 stop to phase max time 01 Continuous purge Checking for ON in 10 and 12 stop up to phase max time 01 14 Param OilPressureMin act from ts no check before first safety time LO HO or s...

Page 85: ...After the first safety time both fuel valves open and the ignition flame ignites the main flame Gas valve proving Gas valve proving is carried out by a pressure switch that tests the double solenoid...

Page 86: ...re regulator 3 4 3 4 Proof of closure switch IRI 2 pcs when capacity 12 5 MBTU h 45 Differential pressure switch for air 4 Pressure switch optional when capacity 12 5 MBTU h 51 Flame detector 5 Pressu...

Page 87: ...5 5 Time sequence diagram gas use 7550f57e 0515 Gp1 ver 6 M4219 2305EN 85 111...

Page 88: ...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 89: ...ntrol 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 s...

Page 90: ...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 91: ...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 92: ...there is no pressure in the piping If required discharge the pressure Check the combustion opening regularly for fouling even during periods when the burner is out of use A blockage in the combustion...

Page 93: ...stion head 10 Clean burner from dust and moisture 11 Check that the boiler room fresh air inlet is open 12 Check combustion characterstics with flue gas measurement at regular intevals or when sooting...

Page 94: ...rm the steps in reverse order Detaching the burner from the boiler Follow lifting instructions when lifting the burner Before reinstalling the burner to the boiler check that the insulating material a...

Page 95: ...ins Check all safety functions before use During a longer shutdown perform a visual check of the unit s overall condition and cleanliness Follow these general instructions Check and clean nozzles Chec...

Page 96: ...mbustion head components GP B 340R ver 4 1 Gas nozzle 2 Gas nozzle fixing screw 3 Ignition gas nozzle 4 Support pipe fixing screw 5 Support pipe 6 O ring Appearance of parts may vary 94 111 M4219 2305...

Page 97: ...Note O ring at the nozzle bottom flange Dismounting combustion head from burner 1 Disassemble nozzle valve s according to previously mentioned instruction 2 Remove diffuser disc 3 Remove adjustment ri...

Page 98: ...or mounting flange and lift the motor away 5 Screw off the fan wheel fixing screw and fixing sleeve 6 Pull out the fan wheel from motor shaft using an extractor 7 Loosen the wedge and base bushing To...

Page 99: ...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 100: ...in these positions and return servomotor to initial position 6 6 Dismounting and changing servomotors The permissible tightening torque for the elastic coupling clamping screw is 2 Nm The permissible...

Page 101: ...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 102: ...screws and take out the servomotor 5 Connect a new servomotor to the shaft coupling 6 Make sure that the shaft coupling aligning screw is aligned with the servomotor axle plane 7 Make sure that the c...

Page 103: ...ng will cause a lockout Consequently the button can be used as an emergency stop button Fault history stores the last 21 error messages Use the Select buttons to scroll through the historical data To...

Page 104: ...ions LV5 1000 Remote reset EN 14459 requirements for remote control must be followed The reset device must be able to reset the burner in an appropriate way Unintended or spontaneous resets from locko...

Page 105: ...re hose Boiler pre purging begins The burner must shut down before the pre purge cycle is completed Error code 28 and a text Air pressure off appear on the display Step 2 1 Disconnect the low pressure...

Page 106: ...ll shut down before the minimum setting Error code 30 and text Gas Pressure has exceeded maximum Limit appear on the display Gas shut off valves If the burner is equipped with an automatic valve provi...

Page 107: ...an not be found in the First start up check the individual burner functions Reset the burner controller if it is in lockout position The burner goes to standby position When the prerequisites for star...

Page 108: ...overload thermal relay released Check setting reset Faulty motor contactor Change Faulty motor Change Fault in variable speed drive or soft starter if equipped Check error and reset Lack of fan air pr...

Page 109: ...ug regulator pressure switch and adjust Faulty fuel air ratio Adjust Faulty combustion head adjustment Check and adjust Nozzle dirty or blocked Clean or change Too low ignition load Check Burners with...

Page 110: ...t extinguish leaking gas valves Replace Poor combustion Condition Possible cause Action CO content is too high or smoke number too high Pressure drop in combustion head too low Adjust pressure drop Di...

Page 111: ...ault 27 28 Faulty differential air pressure switch 28 Lack of air pressure 31 32 Leakage test failure 34 No oil supply or too low atomizing pressure Faulty oil pump 35 Main solenoid valve does not ope...

Page 112: ...asket X 3 Fan motor X 4 Fan wheel X 9 Gas nozzle X 12 Gas valve block X 250 000 28 Pressure regulator X 32 Combustion head X 36 Ignition transformer X 37 Flame detector QRI X 40 Ignition electrode X 4...

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Page 116: ...Oilon US Inc P O Box 1041 Tel 1 229 236 6546 info northamerica oilon com www oilon com Contact information of Oilon dealer Date of installation...