Oilon GP-6.10 P Operating And Maintenance Instruction Manual

Summary of GP-6.10 P

  • Page 1

    Oilon oy p.O.Box 5 fin-15801 lahti finland tel. +358 3 85 761 fax +358 3 857 6239 e-mail info@oilon.Com 40180036gb operating and maintenance instructions gas burners q gp-6.10 p q gp-6.20 p.

  • Page 3: Table of Contents

    40180036gb table of contents 1. Conventions in this manual ............................................................................................................1 2. General............................................................................................................................

  • Page 4: Burner!

    1 40180036gb 1. Conventions in this manual read these instructions carefully before installation, commissioning or maintenance of the burner. The given instructions must be followed. Throughout this manual, the following three symbols are used to point out very important information: danger! This sy...

  • Page 5: 2. General

    2 40180036gb 2. General oilon gp-6.10 p and gp-6.20 p -burners are fully automatic gas burners. The burners can be used on most heating appliances such as hot water boilers, steam boilers and air heaters. Burners are tested and certified for the following gas types · natural gas: - gases of the 2 nd...

  • Page 6

    3 40180036gb caution! The burner must be installed firmly. Vibrations may damage burner or its components. Caution! Prior to trial start the gas piping must be vented. See chapter ”example of an installation of gas supply line”. Danger! In case of gas leakage: - do not make fire, do not touch the el...

  • Page 7: 3.  Burner Technical Data

    4 40180036gb 3. Burner technical data 3.1. Technical data burner gp-6.10 p gp-6.20 p capacity kw 50 - 120 60 - 160 burner motor voltage 50 hz output kw current a speed rpm 1~ 230 v 0,125 1,0 2750 1~ 230 v 0,125 1,0 2750 control unit lfl1.322 lfl1.322 flame detector electrode electrode servomotor sqn...

  • Page 8

    5 40180036gb 3.2. Basic assembly drawing.

  • Page 9

    6 40180036gb 3.3. Parts list 1 burner housing 2 air intake 3 flame tube 4 diffuser disc 5 gas nozzle 6 adjustment ring 7 ignition electrode 8 ignition transformer 9 air damper servomotor 10 air damper 11 differential air pressure switch 12 burner motor 13 fan wheel 14 air control cone 15 control uni...

  • Page 10: 4. Burner

    7 40180036gb 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. I...

  • Page 11

    8 40180036gb 4.4. Example of an installation of gas supply line the gas supply line after the pressure regulator must be of the same size or one size larger than the valve train size. As standard the gas connection to the burner is from the right side. Note! A hand-operated shut-off valve must be fi...

  • Page 12

    9 40180036gb 4.5. Gas pressure regulating assembly if the gas inlet pressure is higher than the pmax. Value given in burner technical data, the gas inlet pressure must be reduced in the regulating assembly or if the gas inlet pressure is not stable, then the pressure must be stabilised by means of t...

  • Page 13: 5. Burner

    10 40180036gb 5. Burner automation 5.1. Time sequence diagram (high-low) required input signals to control unit control signals permissible input signals to control unit a control loop q servomotor b fan motor d differential air pressure switch pl fan pressure 0,4 - 100 mbar e thermostat/pressuresta...

  • Page 14

    11 40180036gb 5.2. Time sequence diagram (modulating) required input signals to control unit control signals permissible input signals to control unit a control loop q servomotor b fan motor d differential air pressure switch in increase function cc electronic capacity controller de decrease functio...

  • Page 15

    12 40180036gb 5.3. Operation 1 prerequisites for start-up · failures and interlocks are reset · limit switch on burner flange is closed · control switch in position 1 · control unit is reset (lockout indicator at symbol ) · contact c/nc of differential air pressure switch is closed (air pressure · g...

  • Page 16

    13 40180036gb 7 servomotor has run to switching point iii (ignition load) · required start signal from the limit switch of switching point iii to the terminal 8 in control unit. Otherwise the start-up program interrupts and the control unit remains (symbol ) waiting for start signal (no failure). 8 ...

  • Page 17

    14 40180036gb 13 lockout indicator of the control unit is at symbol · sequence switch stops · fan motor stops · flame simulation tests (lfl) initiate. Lockout due to flame signal with a short delay e.G. - flame not extinguished; leaking fuel valves - faulty flame signal; fault in flame supervision c...

  • Page 18: 6. Burner

    15 40180036gb 6. Burner adjustments 6.1. Capacity regulation 1 gas/air ratio control v 2 zero point correction n 3 combustion chamber connection p f 4 fan pressure connection p l 5 gas pressure connection p br 6 gas inlet pressure measuring connection 7 gas outlet pressure measuring connection 8 thr...

  • Page 19

    16 40180036gb 6.2. Pi-diagram 1 gas valve (multibloc) 1.5 gas/air ratio controller 1.1 gas filter 2 fan pressure connection p l 1.2 gas pressure switch, min 3 combustion chamber connection p f 1.3 main gas valve 4 gas pressure p br 1.4 gas valve 5 valve leak tester (when necessary).

  • Page 20

    17 40180036gb 6.3. Combustion head adjustments 6.3.1. Distance between nozzle and diffuser disc and ignition electrode setting the distance between gas nozzle (3) and diffuser disc (2) and the gas nozzle angle (7 ° ) must be set according to the drawing. Also the distance between the ignition electr...

  • Page 21

    18 40180036gb 6.3.3. Setting values of adjustment ring normative setting value of adjustment ring. 1 flame tube 3 adjustment ring 2 diffuser disc 4 locking screw for the adjustment ring note! If the position of the adjustment ring has to be altered in relation to the diffuser disc, the air velocity ...

  • Page 22

    19 40180036gb 6.4. Combustion air adjustment set the switching points of cam discs manually or by turning with the adjusting key. Cam discs: 1 set desired full load. 2 air damper to ”closed” position. 3 set desired partial load. 1 full load adjustment 4 release lever 2 air damper closure 5 adjusting...

  • Page 23

    20 40180036gb 6.5. Air cone position if the air control cone has to be changed or removed, it has to be installed to the right position with respect to the burner housing. The right position is shown in the drawing below. After installation check by turning the fan wheel by hand, that it does not to...

  • Page 24

    21 40180036gb 6.7. Pressure switches 6.7.1. Gas pressure switch 1 adjusting scale 2 pressure measuring connection 3 cover adjust the gas pressure switch (min) on a 20 - 40 % lower pressure than the gas inlet pressure to burner during burner operation at full load. If the gas pressure switch occurs d...

  • Page 25

    22 40180036gb 6.7.2. Differential air pressure switch danger! The connectors of the differential air pressure switch are under voltage. Work on the differential air pressure switch may only be performed by specialist staff. 1 low pressure connection (suction side of fan) 2 high pressure connection (...

  • Page 26

    23 40180036gb 7. Valve leak tester vps 504 (only on request) the valve leak tester checks the gas valves for leaks automatically after burner shutdown, when the control unit has returned to its "start-up" position (symbol ) and the control voltage is connected to the valve leak tester. The motor pum...

  • Page 27: 8.  Control Unit Lfl1.322

    24 40180036gb 8. Control unit lfl1.322 8.1. Internal circuitry legend ar as br ek fr l sm v ntc h qra... Fe main relay (load relay) with contacts ”ar” control unit fuse lockout relay with contacts ”br” lockout reset button flame relay with contacts ”fr” lockout warning lamp motor of sequence switch ...

  • Page 28

    25 40180036gb 8.2. Control program of the sequence switch control outputs from terminals lockout indication a - b start-up sequence b operation b - a post-purge sequence (reset of control unit) switching times (in seconds) of the control program of the sequence switch t1 pre-purge time 36 t2 1 st sa...

  • Page 29

    26 40180036gb 8.3. Control program under fault conditions and lockout indication in the event of fault conditions, the fuel supply is always interrupted immediately and, simultaneously, the sequence switch stops and thus the lockout indicator. The symbol appearing above the reading mark indicates th...

  • Page 30

    27 40180036gb 8.4. Detector currents and connection of flame detector fe (ionization electrode) electrode voltage operation 330 v ± 10 % test 380 v ± 10 % short-circuit current max. 0,5 ma min. Required detector current 6 m a max. Possible detector current during operation 150 m a length of detector...

  • Page 31: 9. Maintenance

    28 40180036gb 9. Maintenance danger! Always switch off the electric power from your burner and shut the manual shut-off valves in the fuel supply line before servicing your burner. When inspecting your burner you only have to switch off the electric power from your burner. Burner maintenance in orde...

  • Page 32

    29 40180036gb 10. Fault conditions and procedures in the event of fault conditions the basic requirements for correct operation must be first examined: 1. Is the valve leak tester (if any) in operation (yellow indicating lamp is lit)? 2. Check the electric supply. 3. Check that all regulating and co...

  • Page 33

    30 40180036gb caution possible cause remedy 4. No flame establishment burner motor starts, ignition is in order. After a short time lockout occurs. Gas valves do not open: - blocked pulse lines - faulty actuator - cable damaged - break in control circuit incorrect gas quantity incorrect setting of c...

  • Page 34

    31 40180036gb caution possible cause remedy 8. Combustion head diffuser disc burned-out too low capacity at partial load incorrect combustion air adjustment boiler room not adequately ventilated too low combustion air velocity: - incorrect position of adjustment ring adjust adjust increase air suppl...

  • Page 35: 11. Notes

    32 40180036gb 11. Notes boiler type ___________________________________________________________ ___________________________________________________________ burner type ___________________________________________________________ ___________________________________________________________ burner seria...