Table of Contents
Troubleshooting
Related Manuals for Oilon KP-6
Summary of Contents for Oilon KP-6
- Page 1 M2003 1743EN 6 November 2017 Operation and maintenance manual Burner models: KP-6, KP-6 L, KP-6 LH, KP-6-2, KP-6 H-2 Burner equipment: LMO Read these instructions carefully before installation, use, or maintenance...
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Page 3: Table Of Contents
Contents Introduction Burner models covered in this manual............3 Liability disclaimer..................3 Safety precautions..................4 Product overview..................6 Handling, transportation and storing............8 Technical data Burner technical data................10 Assembly drawing..................12 LMO program relay technical data............13 Installation Space requirements.................. 14 Mounting the burner..................14 Burner hinges....................16 Connecting to oil supply line.............. - Page 4 Flame detector..................44 Changing pump filter.................48 Troubleshooting and monitoring............... 48 Burner failures and troubleshooting............50 2 (51) M2003 1743EN...
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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: Safety Precautions
Children must be controlled to make sure, that they do not play with the device. Oilon products are manufactured according to general product standards and directives, and based on our best knowledge about product design, and technologies. - Page 7 IN CASE OF FIRE OR OTHER EMERGENCY ● Cut off power supply. ● Close main fuel shut-off valve. ● Take appropriate actions. Cut off power supply to burner and close manual shut-off valves always before any maintenance work. Cutting power is adequate when just inspecting the device.
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Page 8: Product Overview
Take care of the boiler room Never use open fire while checking burner or boiler. Do not store any inflammable materials in boiler room. Keep boiler door closed while starting burner, and during burner operation. ● Maintain tidiness in boiler room, and keep boiler room door closed. ●... - Page 9 Our gas burners comply with standard EN 676, oil burners with EN 267, and dual-fuel burners with both of the above-mentioned standards. For more information on products, visit our web site at www.oilon.com: Oilon –> Industries –> Product material. Information on components can be found under the headline Burner parts.
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Page 10: Handling, Transportation And Storing
Type plate EU ver. 4 Pos. Description Pos. Description Burner type: Serial number KP = Light fuel oil RP = Heavy fuel oil GP = Gas GKP = Light fuel oil and gas GRP = Heavy fuel oil and gas NOx classes, gas Year of manufacture NOx class, oil... - Page 11 The use of materials is in conformity with the provisions of the European RoHS Directive on the restriction of the use of certain hazardous substances in electrical and electronic equipment. The maximum permitted concentrations for following substances are not exceeded: ●...
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Page 12: Technical Data
FILTRATION OF OIL TO BURNER Oil to burner must be filtered with a filtration ratio of 100 µm. It is recommended to install Oilon filter or Oilon Plus filter and deaerator. MOTOR OUTPUT 125 W... - Page 13 Working diagrams according to EN 267 KP-6 LH KP-6, KP-6 L A558A ver. 1 A559A ver. 1 KP-6-2 KP-6 H-2 A561A ver. 1 A560A ver. 1 M2003 1743EN 11 (51)
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Page 14: Assembly Drawing
2.2 Assembly drawing D330D ver. 1 Dimensions, mm Burner KP-6 KP-6 L KP-6 LH KP-6-2 KP-6 H-2 12 (51) M2003 1743EN... -
Page 15: Lmo Program Relay Technical Data
Part list Air intake Air intake interflange Nozzle conduit Program relay Cover combination Relay base Coupling Circuit plate Pressure pipe Cover plate Ignition transformer Cover plate Ignition transformer Lead-in Limit switch Lead-in Limit mounting plate Type plate Limit hinge pin Danger label Burner motor Label sheet... -
Page 16: 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 17 Mounting the flange SW00010 ver. 3 The burner is mounted in the boiler with either 2 or 4 M10 screws. Cover all unused holes in the boiler. Permitted mounting positions If you mount the burner to a non-standard structure, make sure the motor shaft lies horizontally.
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Page 18: Burner Hinges
If a mounting plate is needed, the plate needs 2 or 4 M10 threaded holes. A380A ver. 2 Burner KP-6, KP-6 L, KP-6 LH KP-6-2, KP-6 H-2 3.3 Burner hinges Standard burners can be hinged to both sides. Switch off electric power from the burner before burner swing-out. - Page 19 Connecting to the oil supply line using an oil filter A364D ver. 3 1. Filter cover 2. Filter 3. Suction line 4. Oil pump 5. Pressure line to nozzle 6. Return line 7. By-pass plug 8. Shut-off valve 9. Shut-off/Non-return line A - A Delivery limit Line installation directions Danfoss...
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Page 20: Fuel System
3.5 Fuel system Oil piping Install the oil tank and the oil pipes in such a way that the oil will not cool down below the cloud point. If the oil cools below the cloud point, the valves and filters will clog. The cloud point of fuel oil depends on its quality. - Page 21 Return and suction line maximum lengths in a two-pipe system Overlying oil tank Underlying oil tank PUMP: Danfoss BFB [2800 r/min, 6 mm²/s (cSt)] PUMP Danfoss BFB [2800 r/min, 6 mm²/s (cSt)] PUMP: Suntec 45/47 [2850 r/min, 5 mm²/s (cSt)] PUMP: Suntec 45/47 [2850 r/min, 5 mm²/s (cSt)] D max.
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Page 22: Connecting To The Mains
2. Locking button 3. Plug Plug connection for KP-6, KP-6 L, KP-6-2 The burner is equipped with a plug connector. Connect the cable of the plug supplied with the burner to the boiler thermostat or a separate junction box. The other side of the plug is attached to the burner housing. -
Page 23: Commissioning
4 Commissioning 4.1 First start-up Vent fuel lines before first start-up. Pump must not operate without oil. Vent the oil pump before initial start- up and when changing the pump. While adjusting burner, make sure that minimum and maximum values for burner capacity are not exceeded. -
Page 24: Nozzle Selection
To start the burner: 1. Open the fuel shut-off valves. 2. Switch on power supply. 3. Switch on the burner from the burner control switch. To stop the burner: Turn the burner control switch to OFF position. 4.2 Nozzle selection The thermal output of the burner is regulated by changing the size of the nozzle and adjusting the oil atomizing pressure. - Page 25 pressure factor 10 bar pressure to be used Calculation example: Nozzle for a boiler of 100 kW with COP of 0.80 and operating pressure 9 bar. KPLASKENTAESIMERKKI ver. 2 Nozzle selection according to USgal/h Test pressure is 7 bar. The marking according to USgal/h is valid, when: ●...
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Page 26: Oil Pump Pressure Regulation
P1 = 7 To convert kg/h into l/h, divide kg/h by the density of fuel oil 0.833 g/cm The nozzle performances are approx. 10 - 15 % lower in KP-6 L and KP-6 LH burners. Calculated values: Light fuel oil: ●... -
Page 27: Combustion Head Adjustment
When using biofuel, it is recommended to adjust the oil pump pressure between 10 and 12 bar. capacity marked on the nozzle nozzle capacity at a pressure of P2 7 bar gives USgal/h 10 bar gives kg/h according to CEN standard pressure to be used 2-stage burners The oil pump gives two different pressures to the nozzle. - Page 28 1. Mounting flange 2. Retaining screw 3. Combustion head tube 4. Nozzle 5. Ignition nozzle(s) 6. Diffuser disc 7. Adjustment ring The nozzle distance from the diffuser disc Set the nozzle distance from the diffuser disc as shown on the drawing. The nozzle distance from the diffuser disc A432V1 ver.
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Page 29: Combustion Air Adjustment For 1-Stage Burner
Set the distance between the ignition electrodes according to the drawing. The distance between the ignition electrodes A432V3 ver. 1 4.5 Combustion air adjustment for 1–stage burner A-463J ver. 1 1. Adjust combustion air by loosening adjustment ring locking screw. 2. -
Page 30: Servomotor Settings Sqn
A-303F ver. 1 The adjustment ring has three slots for the nut of the locking screw. On burners KP-6 and KP-6 L the nut is placed on the middle slot. Installation has been made at the factory. 4.6 Servomotor settings SQN Cam switch positions in principle B-482M ver. -
Page 31: Adjusting The Air Velocity In The Combustion Head
Air dampers closed/degree (°). Preadjusted at the factory. Air damper position at stage 1/degree (°). Switching point of solenoid valve stage 2 Air damper position at stage 2/degree (°) Switch V setting should preferably be as high as possible. Switch V setting is between switches III and I. - Page 32 A431V ver. 2 Measurement L is standard for 1-stage nozzle. Measure the distance from the rear edge of adjustment ring to the rear edge of the diffuser disc using a calliper rule, for example. 1. Combustion head tube 2. Diffuser disc 3.
- Page 33 If the position of adjustment ring is changed in relation to diffuser disc, the speed and amount of combustion air change in combustion head. Check the combustion values with flue gas analysis. Adjust the amount of combustion air to the correct value if needed. M2003 1743EN 31 (51)
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Page 34: Operation
1-Stage Burner with Preheater, KP-6 L When the control device (13) calls for heat the signal lamp lights up and the preheater °... - Page 35 Oil pump BFP 21 L3 A382A ver. 2 Oil pump AS 47 C A422K ver. 1 Oil filter Ignition transformer Oil, return Ignition electrodes Oil, suction Solenoid valve ● normally closed, NC (oil pump BFP 21) ● normally open, NO (oil pump AS) Oil pump Nozzle Pressure pipe...
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Page 36: 2-Stage Burner Operating Principle
2 and shuts down direct from stage 2, when the set value for control device of stage 1 will be exceeded. 2-Stage Burner (H burner) with Preheater, KP-6 LH ° When the control device calls for heat, the preheater heats the oil up to approx. +70... - Page 37 Oil pump Danfoss BFP 52E L3 A421K ver. 1 Oil pump Suntec AT 2 45 C A442K ver. 1 Oil filter Ignition transformer Oil, suction Ignition electrodes Oil, return Pressure pipe Oil pump Nozzle Burner fan Servomotor Burner motor Air damper Solenoid valve, stage 1 normally closed, NC 17 Control unit M2003 1743EN...
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Page 38: Operating Status Signals
Solenoid valve, stage 2 normally open, NO Control device, stage 1 (thermostat/pressure switch) Pressure regulating valve, stage 1 (P1) Control device, stage 2 (thermostat/pressure switch) Pressure regulating valve, stage 2 (P2) Preheater, LH burners only 5.3 Operating status signals Control unit LMO The multi-colour blinking lamp signals the burner’s operating status, e.g. - Page 39 Monitoring and troubleshooting using a computer connection It is possible to monitor using a computer with a user interface adapter and software. Starting monitoring mode 1. Start the monitoring mode by pressing and holding the reset button for over 3 seconds during normal operation.
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Page 40: Time Sequence Diagram
5.5 Time sequence diagram Control unit LMO14 Required input Control signals signals to control unit 38 (51) M2003 1743EN... - Page 41 Control unit LMO24 Required input Control signals Permissible input signals signals to control unit Starting the start-up phase in burners with a preheater Starting the start-up phase in burners without a preheater Flame forming Operation Controlled shutdown with control thermostat TS or pressure switch PS Switching times ...
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Page 42: Oil Pump
Release contact of oil preheater Ignition transformer Oil preheater 5.6 Oil pump KP-6, KP-6 L, KP-6-2 A265Y ver. 3 A224X ver. 3 1. Suction line connection 1. Suction line connection 2. Return line connection 2. Return line connection 3. - Page 43 A420K ver. 3 A441K ver. 3 1. Suction line connection 1. Suction line connection 2. Return line connection 2. Return line connection 3. Nozzle connection 3. Nozzle connection 4. Pressure gauge connection 4. Pressure gauge connection 5. Vacuum meter connection 5.
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Page 44: Maintenance
6 Maintenance 6.1 Burner maintenance 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. Fasten all safety covers, enclosures, and guards with all screws before start-up. -
Page 45: Position Of Air Cone
● When ordering spare parts, give the burner type and serial number indicated on the burner type label or manufacturing card. If you need help with maintenance issues, contact your nearest representative or Oilon customer service at http://www.oilon.com/customer-service/. Burner contains electric and electronic components. Adhere to rules and regulations from local authorities when disposing. -
Page 46: Flame Observation
6.3 Flame observation KPLIEKINTARKKAILULASI ver. 2 You can observe the ignition of oil mist and the flame through sight glass. Slide the cover plate aside and after observing back to the normal position. 6.4 Changing the nozzle D460B ver. 1 You need two open-end wrenches. - Page 47 The presence of the wavelength of yellow light, typical for QRB flame detector, in the flame decreases, when the bio oil content increases. QRB1A-A... flame detector Flame detector position Flame detector beaded edge must be aligned with groove on frame. LIEKINILMASENTO5L ver.
- Page 48 LMO... Burner control QRB... Flame detector µA DC Microammeter (RI max. 5 kΩ) Black cable Blue cable 7130v01 ver. 1 Burner should be de-energized before installing the multimeter. 1. Set a multimeter between flame detector cables according to drawing. 2. Start the burner. 3.
- Page 49 Adjusting the flame detector While the burner is running turn the potentiometer gradually from the maximum position counterclockwise (numerical value decreases) until LED1 extinguishes. Then turn the potentiometer backwards just so that the LED1 lights up. The adjustment is then correct.
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Page 50: Changing Pump Filter
LMO... Burner control IRD.. Flame detector µA DC Microammeter (RI max. 5 kΩ) Blue cable Brown cable Black cable 6.6 Changing pump filter The pump is equipped with an oil filter. Clean filter regularly and change if necessary. Danfoss Suntec SW00031 ver. - Page 51 Monitoring and troubleshooting using computer connection Burner operation can be monitored with computer using interface adapter and software. Selecting monitoring mode 1. Activate monitoring mode by pressing reset button over 3 seconds at standard mode. Indication light starts blinking rapidly. 2.
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Page 52: Burner Failures And Troubleshooting
IL00020 ver. 5 Failure Error code from the table Troubleshooting using PC diagnostics Reset 6.8 Burner failures and troubleshooting Burner control LMO, error codes Blinking red light, the amount of AL connector Possible cause Action blinks No flame formation at 1. - Page 53 Too many lost flames 1. Change or clean during burner operation 2. Change or clean (repetitions are limited) 3. Check settings and 1. Faulty or dirty fuel readjust valve 2. Faulty or dirty flame detector 3. Incorrect burner settings Preheater failure (time Check connections.
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- Page 56 Contact information of Oilon dealer: OILON GROUP P.O. Box 5 FI-15801 LAHTI FINLAND Tel: +358 3 85 761 Fax: +358 3 857 6239 Email: info@oilon.com Date of installation: www.oilon.com...