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Oilon GP-350 Operation And Maintenance Manual

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M4248 2316EN
5 May 2023
Operation and maintenance manual
Burner models: GP-350 M - 450 M
Burner equipment: WDx00, FGR (UL)
Read these instructions carefully before installation, use, or maintenance

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Summary of Contents for Oilon GP-350

  • Page 1 M4248 2316EN 5 May 2023 Operation and maintenance manual Burner models: GP-350 M - 450 M Burner equipment: WDx00, FGR (UL) Read these instructions carefully before installation, use, or maintenance...

  • Page 3: Table Of Contents

    Contents Introduction Liability disclaimer..................3 Safety precautions..................3 Product overview..................7 Flue gas recirculation (optional)..............9 Handling and storing.................10 Technical data Burner technical data................11 Other technical data and requirements............ 12 Burner control technical data..............13 Servomotor technical data................ 15 Display and operating unit technical data..........15 module technical data (WD200)............15 Oxygen sensor technical data (WD200)...........16 Flame detector technical data..............
  • Page 4 4.16 Activating FGR..................61 4.17 Setting FGR curve points................. 61 4.18 Measuring FGR..................63 4.19 Capacity range..................64 4.20 O2 min. value control (WD200)..............65 4.21 Setting O trim control (WD200)...............67 4.22 O2 trim control operating mode (WD200)..........68 4.23 trim control load limitation (WD200)............69 4.24 trim control when load changes (WD200)...........70 4.25...

  • Page 5: Introduction

    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 ●...
  • Page 6 Keep these instructions as well as the electrical diagrams available near the device. Oilon products are manufactured in accordance with general product standards and directives as well as based on our best knowledge of product design and different technologies. Operational safety is one of the leading principles in our product development.
  • Page 7 Cut off power supply to the burner and close the manual shut-off valves always before any maintenance work. Cutting power is adequate when just inspecting the device. Secure 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 protective footwear, gloves, and safety goggles when necessary.
  • Page 8 Take care of the boiler room Never light a fire in the boiler room. Do not store any inflammable materials in boiler room. Keep the boiler hatch closed while starting the burner and during burner operation. ● Maintain tidiness in boiler room, and keep boiler room door closed. ●...

  • Page 9: Product Overview

    The manufacturing time is found in the type plate. The product's expected lifespan is at least 15 years, if it and its components are used and maintained properly. For more information on products, visit our website at www.oilon.com. M4248 2316EN...
  • Page 10 Label element 7: Combustion head length (additional code) -, C1, C2, C3 Combustion head length C only in use in LN80 burners. Type plate The following illustration shows an example of the type plate of Oilon burners: 8 (114) M4248 2316EN...

  • Page 11: Flue Gas Recirculation (Optional)

    Type plate US ver. 2 Pos. Description Pos. Description Burner type: Oil pump supply voltage, input power and KP = Light fuel oil current, V / Phase / Hz / hp / A RP = Heavy fuel oil Degree of protection GP = Gas Serial number GKP = Light fuel oil and gas...

  • Page 12: Handling And Storing

    1.5 Handling and storing Storing and recycling Store the device and its equipment in the manufacturer's packaging in a dry and airy place. Protect device from dust and humidity. Condensation, formation of ice and ingress of water are not permitted. If these requirements are not met, the device's safety functions may be compromised.

  • Page 13: Technical Data

    However, the manual is valid only for the burner, mentioned on the front page and in the burner data table. Following information applies to standard deliveries. Burner data Burner GP-350 M GP-450 M Capacity, MMBtu/h 2.6–16.1 3.2–20.8 Burner motor 3~ 208–600 V, 60 Hz...

  • Page 14: Other Technical Data And Requirements

    460 V 60 Hz 3-phase 575 V 60 Hz 3-phase Sound pressure level L 77.0 ± 0.5 dB For reducing noise level, contact the manufacturer or consult the Oilon Selection Tool (available for download on the Oilon website). 12 (114) M4248 2316EN...

  • Page 15: Burner Control Technical Data

    Degree of protection NEMA 3 Ambient temperature range 32...+ 122 °F 2.3 Burner control technical data Burner control LMV5... Mains voltage 120 VAC -15/+10 % Locking during undervoltage conditions < 96 VAC Transformer / primary side 120 VAC Transformer / side 1 12 VAC Transformer / side 2 2 x 12 VAC...
  • Page 16 Block diagram of contact links Block diagram ver. 7 14 (114) M4248 2316EN...

  • Page 17: Servomotor Technical Data

    Inputs / outputs (VSD) Connection diagram ver. 3 2.4 Servomotor technical data Servomotor SQM45... SQM48.497 SQM48.697 SQM91.391A9 Mains voltage 2 x 12 VAC 2 x 12 VAC 2 x 12 VAC 2 x 12 VAC Power consumption 9 – 15 VA 26 –...

  • Page 18: Oxygen Sensor Technical Data (Wd200)

    module PLL52... Analog inlet, oxygen sensor QGO21.000D27 Analog inlet, combustion temperature Pt1000 / LG-Ni 1000 Analog inlet, flue gas temperature Pt1000 / LG-Ni 1000 Analog inlet, bus interface Protection degree NEMA 3 Permissible ambient temperature -4..+140 °F Protect the equipment from condensation, ice, and water ingress. 2.7 Oxygen sensor technical data (WD200) Oxygen sensor QGO20...
  • Page 19 Auxiliary detector cable max. length 328 ft Protection degree NEMA 3 Permissible operation ambient temperature -4...+140 °F ● integrated signal amplifier ● continuous or interrupted use ● mains frequency filtering ● does not detect electric arc used for ignition ● spectral sensitivity range ~1–3 μm ●...

  • Page 20: Installation

    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.
  • Page 21 If you set the burner on a pallet, always remove the oil filter. The burners are attached and supported to a transportation base. The base can be lifted 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.

  • Page 22: Installing Burner

    To lift the burner Remove end cover before placing the lifting straps. Use lifting straps or chains with hooks to lift the burner as shown in the illustration. Protect the burner from possible friction during lifting. Burner Lifting lug (1 pcs) Lifting eyes (2 pcs) Lifting straps Lifting hook...
  • Page 23 Burner dimensions (GP) D063648 - GP-320 M - 450 M WDx00 / WD3x ver. 1 Dimensions in inches Burner ØD1 GP-350 M 53.54 13.78 7.68 31.89 37.01 27.36 13.98 13.58 19.29 22.83 19.29 12.60 GP-450 M 57.87 13.78 7.68 35.83 41.34 30.31 15.55 16.54 20.08 25.59 21.65 14.57...

  • Page 24: Combustion Head And Masonry Dimensions

    3.4 Combustion head and masonry dimensions Combustion head mounting dimensions d071827 ver. 1 Masonry 1 ver. 3 Pos. Item Pos. Item Gasket, thickness 0.3 inch Ceramic wool or equivalent Mounting panel Masonry Burner øD4 øD1 α 350 M 15.75 15.75 14.96 4xM20 12.60...
  • Page 25 d078617 ver. 2 Pos. Item Pos. Item Stud screw, 4 pcs Burner flange with combustion head Flange gasket (boiler side) Washer, 4 pcs Extension plate Hex nut, 4 pcs Flange gasket (burner side) To install the extension plate: 1. Attach the supplied stud screws securely to the boiler. 2.

  • Page 26: Gas Valve Selection Table

    3.5 Gas valve selection table Gas valves Gas valve Min. inlet gas Max. inlet gas Burner pressure PSI" pressure PSI" Type Size inch 350 - 450 M 2.18 7.25 2" - 4" 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.
  • Page 27 Check that there 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 the installation of gas pressure regulating assembly.

  • Page 28: Installing Gas Pressure Regulating Assembly

    3.7 Installing gas pressure regulating assembly Adhere to the values given by the equipment manufacturer. Installing pressure regulator Consider the following factors when selecting pressure regulator: ● gas supply pressure ● secondary pressure ● the volume of gas to be fired ●...

  • Page 29: Changing The Fuel Type From Natural Gas To Lpg

    Pos. Item Pos. Item Pressure regulator with safety shut-off Pressure gauge, high pressure, when valve and safety relief valve necessary Pressure gauge valve Fuel flow meter, can also be on low pressure side, when necessary Pressure gauge, low pressure Pressure regulator 3.8 Changing the fuel type from natural gas to LPG This information applies only when liquefied petroleum gas (LPG) is used.

  • Page 30: Installing Fgr Duct System

    ● Adjust the final position of the band 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 by changing the air damper and the gas pressure.
  • Page 31 The temperature in the piping varies constantly during the operation causing expansion and contraction of the pipes. The temperature differences also cause condensation in the pipe line. In long pipe runs the pipe line length can change by over 1" per 212° F. Thus extra load builds up on pipe connection point, which may result in component failures.

  • Page 32: Electrical Connections

    Installing temperature sensor D055288 ver. 1 Temperature sensor Butterfly valve FGR pipe (*) Burner Sleeve (*) Min. 7.87 in * not included in delivery 3.10 Electrical connections Electrical installation may be carried out by authorized and trained personnel only. Connect the burner according to the electrical diagrams delivered with burner. Follow general and local standards and regulations as well as requirements set for electrical connections for electrical equipment.
  • Page 33 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. Also note that in certain models, the motor output is integrated in the burner wiring base.

  • Page 34: Commissioning

    4 Commissioning 4.1 First start-up Secure all safety covers, enclosures, and guards with all screws before start-up. Use appropriate tools. If burner start-up fails consecutively three times, do not restart burner before carefully investigating the reason for the failure. After the first start-up check the cleanliness of the gas filter weekly and replace if necessary.
  • Page 35 ● gas inlet pressure is correct ● equipment is installed correctly and is in working condition ● chimney is properly connected, unobstructed and flue gas damper is open To start the burner: 1. Open the manual fuel shut-off valves. 2. Switch on power supply. 3.

  • Page 36: Adjusting Combustion Head (Gp)

    4.2 Adjusting combustion head (GP) Combustion head components GP-350 M Pos. Item Pos. Item Combustion head Gas nozzle Diffuser disc Ignition gas nozzle Ignition electrode 10.63 in 34 (114) M4248 2316EN...
  • Page 37 Separate pilot gas line, GP-350 M d081136 ver. 1 *The retaining ring for the pilot gas line is attached to the ignition electrode support pipe between the centering standoffs. Combustion head components GP-450 M D043818 ver. 2 M4248 2316EN 35 (114)

  • Page 38: Adjusting Combustion Air (Gp-450 M)

    Pos. Description Combustion head Diffuser disc Adjustment ring Ignition electrode Gas nozzle Ignition gas nozzle 0.12 in ± 0.12 in Factory setting : 1.77 in Setting ignition electrodes GP-450 M Set the following as shown in the illustration: ● ignition electrode horizontal distance from the nozzle (L) ●...

  • Page 39: Adjusting Combustion Differential Air Pressure Switch

    If... Then... Result The adjustment ring is too There is too much pressure ● Poor ignition, OR far forwards at full capacity drop in the combustion ● Poor combustion due to inadequate amount head. of air (high CO content), OR ●...
  • Page 40 Pos. Item Higher pressure Lower pressure Electrical connections Adjustment wheel 1 and 2 Cross-head screw LGW A2 ver. 2 If the pressure difference does not rise above the switch setting value, the burner will shut down. The differential air pressure switch should be set to trigger before the CO concentration in the flue gas exceeds 1 vol-% (10,000 ppm).

  • Page 41: Adjusting Gas Pressure Switch

    4.5 Adjusting gas pressure switch Gas pressure switch, max. 1 Adjusting scale 2 Reset, gas pressure switch, max. 3 Pressure measuring connection A416M ver. 3 Gas pressure switch max. should cause a permanent interlocking if burner capacity increases to be more than 1.15 times the nominal value, or if the pressure exceeds more than 1.3 times the nominal pressure.

  • Page 42: Setting Gas Pressure Regulator Skp

    The operating area of the gas pressure regulator is determined by the spring installed inside the pressure regulator. Spring operating area is described in the table below. Springs can be ordered from Oilon Webshop. SKP ver. 1 To change spring:...

  • Page 43: Setting Gas Pressure Regulator Frs

    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 component’s screws. The component may become damaged. Spring type pG ("W.C.) ∆p / Color Model AGA29...
  • Page 44 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 combustion to safe level using flue gas analysis. Measure pressure regulator outlet pressure from gas valve measuring point.
  • Page 45 To replace setting spring 219598b ver. 1 1. Remove protective cap A. Release spring by turning adjustment 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 offset. 5.

  • Page 46: Measuring Gas Pressure

    Setpoint Color Nominal width Rp/DN spring range ("W.C) Rp 1 1/2, Rp 2, DN Rp 2 1/2, DN 100 DN 125 DN 150 DN40 DN65, 80 Spring 1 1.0–3.6 brown 229 851 229 874 229 883 229 892 229 901 229 909 Spring 2 2.0–5.2...
  • Page 47 Measuring nozzle pressure D050332 ver. 2 1. Nozzle pressure at nominal capacity Burner Test point 1 ("W.C.) 350 M 17.7 450 M 11.2 Check the tables below for adjusted pressure values. M4248 2316EN 45 (114)
  • Page 48 Measuring inlet and adjusted pressure Main gas train + pilot gas train d073474_2 ver. 1 d073474_1 ver. 3 A. Gas inlet 4. Measuring point 2. Inlet pressure 5. Inlet pressure (pilot) 3. Adjusted pressure 6. Adjusted pressure (pilot) Burner Test point 2 Test point 3 ("W.C.) ("W.C.)

  • Page 49: Operating And Display Unit Menu

    4.9 Operating and display unit menu Menu structure Menus are divided into two user levels. First user level is User, and it does not require password. Second user level is Service. It is a password protected level for commissioning and maintenance personnel.
  • Page 50 StartCounter Displaying the start counter readings GasStartCount Number of startups gas, start counter (selectable) OilStartCount Number of startups oil, start counter (selectable) TotalStartCountR Total number of startups, start counter (can be reset) TotalStartCount Total number of startups, start counter (read only) Fuel Meter Displaying the current counter readings...
  • Page 51 Description ManualOperation SetLoad Target load setting manually, percent of maximum load (%) Autom/Manual/Off Select manual or automatic operation Auto Burner capacity adjusts automatically controlled by capacity controller according to boiler temperature or pressure Burner on Burner on manual operation according to SetLoad Burner off Burner stopped...

  • Page 52: Adjusting Operating And Display Unit Settings

    VSD Module ● Configuration ● Process Data ● ProductID ● SW Version 4.10 Adjusting operating and display unit settings Scrolling menus For scrolling and changing set values of the operating and display unit menu, use the four buttons on the panel. AZL buttons ver.

  • Page 53: Variable Speed Drive Settings And Standardization (Wd200)

    4.11 Variable speed drive settings and standardization (WD200) The variable speed drive is used for fan motor control. The burner controller starts and stops the variable speed drive with a potential-free release contact. The VSD sends alarm data to the burner controller using a 12–24 V DC alarm signal. When active, the signal initiates a burner safety stop.

  • Page 54: Checking O Module (Wd200)

    Num Puls per R Three pulses per round. Do not change the setting manually! Standardization automatic test for fan maximum rotation speed. Burner control should be in standby position when the test begins. Select activated from the menu to start the test. 1.

  • Page 55: Manual Start-Up And Program Stop In Pre-Purge Position

    QGO SensorTemp QCO sensor temperature in °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-intervals. Test requires constant O level, for e.g. after pre-purge or on steady load. If constant O level is not reached within 24 hours, burner control locks down operation load to reach constant O level for next test.
  • Page 56 52 Interv 2 72 PostPPos 76 PostPFGR Manual start-up Prerequisites: ● Variable speed drive parameters have been set and adjusted. ● Interlocks and failures have been reset. ● Program phase is 12, Stand by. Activate manual burner start-up from the Autom/Manual/Off menu level by selecting BurnerOn: ManualOperation Autom/Manual/Off...

  • Page 57: Ignition Position

    If servomotors do not drive full motion at full load curve point, the burner start-up can be accelerated, because the servomotor running times remain shorter. Gas use ● At full load air amount prepurge time is at least 20 s. ●...

  • Page 58: Setting Ratio Curve

    IgnitionPos IgnitionPos- Gas IgnitionPos- Air IgnitionPos- Aux1 IgnitionPos- Aux2 IgnitionPos- Aux3 IgnitionPos- Check combustion values with ignition load using flue gas analysis. 4.15 Setting ratio curve Curve points There can be 15 curve points at the maximum. Set curve points in the following menu level: Params.
  • Page 59 Curve point 2 ver. 4 The pointer is positioned at the colon below the text Point. The running number of the stored curve point is shown after the colon. Curve points are stored according to capacity from smallest to biggest. Curve points can be added at any order.
  • Page 60 When the servomotors drive to position for a set curve point, the display shows “>” instead of “:”. When the servomotors have reached their positions, “:” returns to the display. Servomotor settings can be modified only when each servomotor has reached its position.
  • Page 61 Curve point 7 ver. 4 If you want to save the changes to curve point settings, press Enter. If you want to leave without saving changes, press Esc. After this, you will return to the point where you can scroll through curve points. Return to the menu by pressing Esc. Creating curve point manually by changing load 1.
  • Page 62 ● 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% When you have made the required changes, save the maximum load curve point. If the curve point for maximum load has an influence in the linear gas supply pressure, check the setting at the minimum point and adjust, if necessary.

  • Page 63: Activating Fgr

    After commissioning the burner, check air pressure switch settings. See section Adjusting combustion differential air pressure switch. 4.16 Activating 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.
  • Page 64 Time period value can be changed from: Params. & Display→ Flue gas recirc. → DelaytimeFGR Gas→ To create curve points: 1. Go to Params. & Display→ Ratio control → Gas settings → Curve Param → 2. Select the required curve point and press →. 3.

  • Page 65: Measuring Fgr

    4.18 Measuring FGR Pos. Item FGR duct FGR control valve Measuring point of residual oxygen in flue gas FGR principle monoblock ver. 3 Recirculated flue gas amount is typically 5–20 % of the flue gas/combustion air mixture amount, depending on 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...

  • Page 66: Capacity Range

    Natural gas combustion, flue gas recirculation (%) FGR natural gas ver. 2 Flue gas O2 = 2% Flue gas O2 = 3% Flue gas O2 = 4% Y axis: FGR, %, X axis: Mixture O2 content (dry), %. FGR may cause unstable combustion. To avoid noise, vibration or other disturbance, the settings must always be defined for each burner separately.

  • Page 67: O2 Min. Value Control (Wd200)

    LoadLimits MinLoadGas. Minimum load "Low fire" (gas) MaxLoadGas Maximum load "High fire" (gas) At the user level, maximum load can be set individually as follows: Description Operation User Maxload User MaxLoadMod Maximum load on modulating burner 4.20 O2 min. value control (WD200) O2 ratio control can be set after setting the ratio curve.
  • Page 68 Maximum permitted 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. O2 min. value direct entry 1.

  • Page 69: Setting O Trim Control (Wd200)

    4.21 Setting O trim control (WD200) min. value O2Control must be set first. It is important that environmental conditions do not change when setting O trim control. If you change the curves at a later date, O trim control must also be adjusted.

  • Page 70: O2 Trim Control Operating Mode (Wd200)

    Point22 ver. 4 4. The display changes. The third line shows the current residual oxygen level. The pointer is on StandardVal. Reduce the air by pressing the Select -/+ buttons, if necessary. A larger number at this point means larger without air throttle. When desired oxygen level is reached, press Enter.

  • Page 71: O 2 Trim Control Load Limitation (Wd200)

    Params. & Display O2Contr/Guard FuelSettings OptgMode auto deact man deact O2 Limiter O2 Control conAutoDeac O2 trim control operating modes Use this setting when creating O2 ratio curve. man deact Both O2Limiter and O2Control are deactivated. Burner operates according to parameterized ratio curves.

  • Page 72: Trim Control When Load Changes (Wd200)

    Apadt.Point small Type of Fuel Fuel user def If load drops below this limit, the burner operates along parameterized ratio curves without O trim control. Set load limitation after setting O trim control ratio curve. Load limitation is usually curve point 2 load from basic parameterized ratio curve. 4.24 O trim control when load changes (WD200) When load changes under unfavourable setting conditions, the actual O...

  • Page 73: Setting Load Controller Parameters

    ManualOperation Autom/Manual/Off Autom Burner on Burner off 3. Burner control capacity controller keeps boiler temperature or pressure constant by changing burner capacity as necessary. The capacity controller shuts down and restarts the burner as necessary. Select the control parameters for the capacity control from the menu as follows: Params.
  • Page 74 very fast fast normal slow very slow Standard parameters are listed in the following table: Proportional band [%] Integral action time [s] Derivative action time [s] Very fast 42.5 Fast 14.5 Normal Slow Very slow Setting parameters individually PID parameters can also be set individually according to the following value range: ●...
  • Page 75 Params. & Display LoadController Adaption StartAdaption AdaptionLoad The burner and boiler 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 should stay constant throughout adaptation.
  • Page 76 Select StartAdaption. Parameter evaluation Load control does not cause variation in boiler temperature or pressure with optimum PID parameters. 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.

  • Page 77: Capacity Controller On/Off

    Params. & Display LoadController ControllerParam MinActuatorStep SW_FilterTimeCon MinActuatorStep is the minimum possible actuator step. This affects the load controller accuracy but may stabilize its action. If the value for this parameter is too high, the load control becomes unstable. The factory setting is 1%. SW_FilterTimeCon.

  • Page 78: Boiler Temperature Limiting With Burner Control

    4.28 Boiler temperature limiting with burner control Boiler temperature can be limited with burner control. It can be implemented with the same sensor used for temperature control, or with a separate sensor. When pressure control is selected, temperature limiter is not in use. If limiter temperature switch-on point is reached, burner shuts down.

  • Page 79: Measuring Flue Gas And Combustion Air Temperature (Wd200)

    ThresholdOn 40% of set value StageLoad 15% load step StageSetp_Mod 10% of set value StageSetp_Stage MaxTmeMod 5 minutes MaxTmeStage ThresholdOff 80% of set value AdditionalSens Setp AddSensor 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 can be connected to O module.

  • Page 80: Activating O Trim Control (Wd200)

    FlueGasTempSens MaxTempFlGasGas MaxTempFlGasOil 4.31 Activating O trim control (WD200) At the end of commissioning activate O trim control from the display and operation 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 81: Operation

    5 Operation 5.1 WiseDrive system WiseDrive 100 / 200 WiseDrive system components 1. Boiler pressure/ temperature measurement 2. Safety devices 3. O2 sensor (WD200) 4. O2 module (WD200) 5. CAN BUS 6. Control unit 7. CAN BUS 8. Gas damper 9.
  • Page 82 The system includes an operating and display unit for local use. A remote PC application can be used during commissioning and servicing. To enable continuous operation, the WiseDrive system uses components designed specifically for this system. The system supervises components related to safety functions with continuous self-testing.
  • Page 83 Combustion air Combustion air provides the needed air pressure and volume for efficient combustion. In the WD200 system, the fan motor can be fitted with a variable speed drive. The variable speed drive adjusts air pressure according to burner’s capacity by controlling the fan speed.

  • Page 84: Control Panel

    Oxygen sensor (WD200) Oxygen sensor measures the amount of residual oxygen from flue gas. The sensor is a ceramic zirconium dioxide cell and self-testing. QG020 ver. 3 Flame detector QRI is a flame detector for use with gas, oil and other flames that emit infrared light. Flame signal intensity can be monitored on display.

  • Page 85: Legend To Pi Diagrams

    Control switch Switch State position 0 - STOP Burner start-up by control devices is prevented. If the switch is turned to the ‘0’ position while the burner is running, a controlled shutdown is initiated. The green indicator light on the switch indicates that the control voltage for burner automation (burner control, servomotors) is switched on.

  • Page 86: Burner Operation And Pi Diagram, Gas

    Oil pressure regulator Motor Flame arrester Ball valve Pneumatic shut-off valve Solenoid valve Safety valve One way valve Pressure regulator Adjustable valve Mesh Valve open softener Orifice 5.4 Burner operation and PI diagram, gas Combustion air Fan (50 - 280) ver. 1 The burner is equipped with a fan which is designed to produce consistently high air pressure.
  • Page 87 Burner operation During burner operation, the control unit adjusts servomotors according to capacity controller inputs. Servomotors adjust the gas regulator valve and air dampers between partial load and full load according to the capacity demand. Burner shutdown If the current partial load exceeds the capacity demand, the burner shuts down and the double solenoid valve closes.

  • Page 88: Legend To Time Sequence Diagrams

    5.5 Legend to time sequence diagrams Phases: Lockout phase 2nd safety time Safety phase Interval 2 (ti2) Homerun Low-fire position Standby (stationary) Operation 1 (stationary) Shutoff valve ON (start release) Operation 2 Low-fire position Fan motor ON Post-combustion time Pre-purge position Post-purge position Pre-purge time (tv1) Post-purge time (tn1)
  • Page 89 Fan contactor contact Temperature switch internal Low-fire position Fuel valve 1 Air damper Fuel valve 2 Air pressure switch Fuel valve 3 Fan motor Pre-purge position Post-purge Ignition Post-purge position Ignition load position Symbols: Signal ON Signal OFF Next phase 00, repetition = 0 12, repetition >...
  • Page 90 Sequential phase = 24 Only with valve proving during startup Param.: With/without alarm on prevention of startup Param.: With continuous purge the shown output signals are inverted Fan controlled as before Post-purge in lockout position = PostpurgeLockout Param.: With / without extraneous light test in STANDBY With valve proving during startup phase 10 Param.: Normal / continuous purge...

  • Page 91: Time Sequence Diagram, Gas Use

    5.6 Time sequence diagram, gas use 7550f64e/0515, G ver. 4 M4248 2316EN 89 (114)
  • Page 92 7550f57e/0515, Gp1 ver. 6 90 (114) M4248 2316EN...

  • Page 93: Burner Automation Description, Gas Use

    7550f60e/0515, Gp2 ver. 2 5.7 Burner automation description, gas use Items marked with an asterisk (*) apply only if the burner is equipped with an ignition gas valve. Prerequisites for start ● All failures and interlocks reset. ● Burner flange limit switch closed. ●...
  • Page 94 ● Remote control contacts closed. ● Boiler thermostat/pressure switch contact closed. ● Differential air pressure switch contact open. 20, 21 Start-up ● Burner control safety functions are activated. ● Gas safety valve (optional) opens. ● Gas pressure recognition, pressure switch min. closed. ●...
  • Page 95 52* Interval 2, second safety time ends. ● Ignition gas valve closes.* ● The main flame must have been ignited by now. Otherwise, burner control does not receive a flame signal and goes to a lockout.* ● Main flame burns at a set ignition load.* 54 Servomotors run to min.

  • Page 96: Gas Valve Proving

    00 Lockout phase ● Servomotors run to stand-by position. ● Burner failure activates. ● Requires manual reset. 5.8 Gas valve proving The system performs gas valve proving using a pressure switch or transmitter that monitors the section of pipe between the valves. During gas valve proving, burner control opens and closes gas valves at programmed intervals.

  • Page 97: Maintenance

    A blockage in the combustion head may cause a hazard. If you need help with maintenance issues, contact your nearest representative or visit the Oilon website (https://oilon.com) for technical support. The burner contains electric and electronic components. Adhere to rules and regulations from local authorities when disposing.
  • Page 98 To maintain flawless operation, do the following at least once a year: 1. Check burner head extension, and change if necessary. 2. Check diffuser disc, and change if necessary. Check burner adjustments if diffuser disc appears dirty. 3. Check ignition cable condition from the whole length. Change, if necessary. 4.

  • Page 99: Maintenance During Shutdown

    ● Check piping, valve operation, filters, and gaskets. Start operation only after a thorough inspection. Before start-up, make sure that the appliance is in good working order. If you need help with maintenance and service, contact your nearest representative or Oilon customer service. M4248 2316EN 97 (114)

  • Page 100: Dismounting Combustion Head

    6.3 Dismounting combustion head Combustion head components and dismounting (GP) D043819 ver. 2 Disassemble the combustion head components in the same order as in the table, and reassemble in reverse order. Pos. Item Air guide fastening screws Air guide Ignition gas nozzle Gas pressure impulse tube Ignition electrode support fastening screw Ignition electrode support...

  • Page 101: Dismounting And Changing Burner Motor

    6.4 Dismounting and changing burner motor Cut off electricity from the burner and ensure that the motor has no voltage. Fan cross section Motor Fan wheel Fixing sleeve Wedge Fixing screw of fan wheel Base bushing Fixing screw of mounting flange A416L ver.

  • Page 102: Assigning Servomotors

    6. Place the motor and attach screws. 7. Connect the electrical cable to the motor. 8. Connect the burner to the mains. Check motor rotation direction. 6.5 Assigning servomotors Addressing servomotor 1. Open servomotor protecting cover fixing screws, and remove cover. 2.

  • Page 103: Dismounting And Changing Servomotors

    Param. & Display RatioControl Fuel settings Special settings Initial stage Initialstage Gas Initialstage Air Initialstage Aux1 Initialstage Aux2 Initialstage Aux3 In standby position run servomotor´s axle between 2°- 88°. After maintenance check servomotor´s proper function by running servomotor´s axle in these positions and return servomotor to initial position.
  • Page 104 Servomotor of gas butterfly valve VKF-10 d074074 ver. 1 Pos. Description Pos. Description Servomotor Butterfly valve VKF-10 Servomotor fixing screw Aligning surface of servomotor’s shaft Shaft coupling Flange gasket Shaft coupling aligning plate and Cable fitting clamping screw 1. Run the servomotor to 90° position so that the clamping screw on the servomotor shaft turns horizontally.

  • Page 105: Fault And Lockout History

    Servomotor of air damper D031517 ver. 1 Pos. Description Pos. Description Servomotor Shaft coupling aligning screw Servomotor bracket Shaft coupling clamping screw Shaft coupling Servomotor fixing screw 1. Turn off the burner power supply. 2. Disconnect the cables. 3. Loosen the shaft coupling clamping screw and aligning screw; shaft coupling is left on air damper axle.
  • Page 106 OperationalStart FaultHistory LockoutHistory Resetting fault You can also reset the burner lockout from the control panel. Reset the fault as follows: 1. Press Esc until you access the menu level 1. 2. Select Operational Stat -> Status/Reset. 3. The fault code display appears on the display. Press Esc. The following text appears: 4.

  • Page 107: Testing Safety And Control Devices

    trim activation example for WD200 ● 12. fault in history ● Class = 05, see the following table ● Oil = Oil as fuel ● Code = BF, error code ● Diag = 00, diagnostic code ● Phase = 60, phase ●...
  • Page 108 ● flame detector ● differential pressure switch ● gas pressure switches ● gas shut-off valves ● servomotors ● O /CO trim control (if equipped) ● boiler safety devices Flame detector Test method Outcome Step 1 The burner must shut down and lockout at the end 1.
  • Page 109 Test method Outcome Step 1 Boiler pre-purging begins. The burner 1. Rotate the setting wheel on the switch to its maximum must shut down before the pre-purge value. cycle is completed. Error code 2F and the text Gas Pressure 2. Start the burner. has dropped below minimum Limit After testing, return the setting wheel to its original position and reset the switch.

  • Page 110: Troubleshooting

    Variable Speed Module (if equipped) Test method Outcome 1. Turn control switch S1 to position 0 (STOP) to cut off During prepurge, the burner stops due power supply from burner control. to a fault. The error code is 15 and the 2.
  • Page 111 Condition Possible cause Action Fan motor starts. Jammed or damaged servomotor. Check and adjust or change. Lockout during pre-purge. Servomotors do not reach desired position. Burner control stays waiting for Start-up release loop is open. Find out cause, repair. start release. Low gas pressure.
  • Page 112 No electric arc for ignition Condition Possible cause Action Fan motor starts, control voltage Dirty or damaged ignition Clean or change. from burner control to ignition electrodes. transformer is switched on, no electric arc is formed, and after a short time lockout occurs. Ignition electrodes too far apart.

  • Page 113: Troubleshooting Error Codes

    Flame monitoring fault, lockout Condition Possible cause Action Lockout during pre-purge. Faulty flame detector Change. Faulty burner control Check fault code. Replace. Incorrect flame signal because of Block extraneous light. extraneous light Flame forms. Lockout during Incorrect flame detector position Repair.

  • Page 114: Burner Parts (Gp)

    Leakage test failure. No oil supply or too low atomizing pressure. Faulty oil pump. Main solenoid valve does not open. Return oil pressure too high. 6.11 Burner parts (GP) Exploded view GP-350 M - 450 M ver. 3 112 (114) M4248 2316EN...

  • Page 115: Burner Part List

    Pilot gas train Main gas train The assembly may vary depending on the scope of delivery. 6.12 Burner part list Recommended change interval Part name 1–2 3–5 on demand/ year years years start-up max. Protective cover Flange gasket Fan motor Fan wheel Diffuser disc Head extension...
  • Page 116 Recommended change interval Part name 1–2 3–5 on demand/ year years years start-up max. Ionization electrode Ignition electrode support 250 000 Manual shut-off valve Valve actuator with pressure regulator Valve actuator 114 (114) M4248 2316EN...
  • Page 118 Contact information of Oilon dealer: Oilon US Inc. P.O.Box 1041 Tel: +1 229 236 6546 info.northamerica@oilon.com www.oilon.com Date of installation:...

This manual is also suitable for:

M-450 m

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