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Oilon GP-50 M Operation And Maintenance Manual

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M4264 2423EN
5 August 2024
Operation and maintenance manual
Models: GP-50 M - 90 M
Equipment: WDx00i (UL)

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  • Page 1 M4264 2423EN 5 August 2024 Operation and maintenance manual Models: GP-50 M - 90 M Equipment: WDx00i (UL)

  • Page 3: Table Of Contents

    Contents Introduction Liability disclaimer....................5 Safety precautions....................5 Product overview....................9 Handling and storing..................11 Technical data Burner technical data..................13 Other technical data and requirements............14 Burner control technical data................14 Servomotor technical data................17 Display and operating unit technical data............17 Flame detector technical data................17 Installation Space requirements..................
  • Page 4 4.15 Setting capacity controller operating mode............57 4.16 Setting load controller parameters..............58 4.17 Capacity controller on/off................. 62 4.18 Boiler temperature limiting with burner control..........63 4.19 Cold start thermal shock protection..............63 4.20 Backing up parameters..................64 Operation WDx00 system....................66 Control panel....................

  • 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 IN CASE OF A FUEL LEAK ● Do not light fire or touch electric equipment. ● Close the main fuel shut-off valve. ● Make sure there are no people in the leakage area. ● Make sure the leakage area is properly ventilated. ●...
  • Page 8 Do not use PTFE tape in piping. Emergency shutdown In an emergency, cut off power supply to the burner. Close the manual shut-off valves. After safety check you can restart the burner. Check settings, and monitor that operation continues as normal. Take care of the boiler room Never light a fire in the boiler room.

  • Page 9: Product Overview

    COULD EXPOSE YOU TO SUBSTANCES IN FUEL OR FROM FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. IMPROPER SERVICING OF THIS EQUIPMENT MAY CREATE A POTENTIAL HAZARD TO EQUIPMENT AND OPERATORS.
  • Page 10 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. Type labelling...

  • Page 11: Handling And Storing

    Type plate The following illustration shows an example of the type plate of Oilon burners: Type plate US ver. 2 Pos. Description Pos. Description Burner type: Oil pump supply voltage, input power KP = Light fuel oil and current, V / Phase / Hz / hp / A...
  • Page 12 Recycle product packaging. The metal and plastic parts of the device are made of recyclable materials. Also all electrical components are recyclable, and should be handled according to local regulations. Follow international packing markings Symbol Description Symbol Description Arrows to indicate which side Fragile, handle with care is facing up (THIS WAY UP) Protected from water (KEEP...

  • Page 13: Technical Data

    Turndown ratio, gas 1:6 (100...16.6%) The weight varies depending on the content of the delivery. Working diagrams Using the burner outside the range shown in the working diagrams is not allowed. GP-50 M - 90 M (US) ver. 2 M4264 2423EN 13 (102)

  • Page 14: Other Technical Data And Requirements

    575 V 60 Hz 3-phase Sound pressure level L 77.5 ± 0.5 dB Sound power level L For reducing noise level, contact the manufacturer or consult the Oilon Selection Tool (available for download on the Oilon website). Degree of protection NEMA 1 Ambient temperature range 32...+ 122 °F...
  • Page 15 Burner control LMV5... Permissible input current / status input 1.5 mA/120 VAC -15/+10 % Perm. current rating of control terminals ● fan motor contactor ● 1 A/120 VAC -15/+10 % ● burner failure ● 1 A/120 VAC -15/+10 % ● ignition transformer ●...
  • Page 16 Block diagram of contact links Inputs / outputs (VSD) 16 (102) M4264 2423EN...

  • Page 17: Servomotor Technical Data

    Block diagram ver. 7 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 Operation type continuous Supply voltage, operation 14 VDC ±5% Supply voltage, testing 21 VDC ±5% Signal voltage 0–5 VDC Power consumption < 0.5 W Connected detector cable max. length 5.9 ft Auxiliary detector cable max. length 328 ft Protection degree NEMA 3 Permissible operation ambient temperature -4...+140 °F...

  • Page 19: 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 20 Oilon 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 21: Installing Burner

    ● Make sure there is enough free space on the side to allow burner to swing fully open. Install the burner firmly. Vibration may cause damage to the burner or its components. Burner mounting dimensions d078610 ver. 3 Measurements in inches. Burner GP-50 M 37.12 9.45 7.28 3.54 20.08 12.80 6.50 GP-90 M 37.12...

  • Page 22: Combustion Head And Masonry Dimensions

    3.4 Combustion head and masonry dimensions Combustion head mounting dimensions GP/GKP-50 d071344 ver. 1 KP-50, GP/GKP/KP-80 - 90 Masonry 1 ver. 3 d071827 ver. 1 Pos. Item Pos. Item Gasket, thickness 0.3 inch Ceramic wool or equivalent Mounting panel Masonry Burner øD4 øD5...
  • Page 23 The extension plate is heavy. Be careful not to injure your fingers while lifting the plate off a surface. 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)

  • Page 24: Burner Hinges

    3.5 Burner hinges Swinging the burner open ver. 4 GP/GKP-50 models swing only to the left, and the orientation cannot be changed. Switch off electric power from the burner before swinging the burner open. 3.6 Gas valve selection table Gas valves Gas valve Min.
  • Page 25 Gas module, VGG D077536 ver. 1 1.3 1.4 D046558 US ver. 1 M4264 2423EN 25 (102)
  • Page 26 Gas module, VGD d097593 ver. 1 Pos. Item Pos. Item Gas valve assembly Manual shut-off valve Mounting flange, burner side Gas inlet pipe Mounting flange, gas supply Elbow fitting Servomotor Adjustable elbow fitting Control valve Coupling unit Servomotor cable Elbow Gas pressure switch, low Gas pressure switch, high Gasket...

  • Page 27: Installing Burner To Gas Supply Line

    Pos. Item Servomotor, air Servomotor, gas JB300 CC100 Gas connection point D077621 ver. 2 VGG valve in the image. VGD valve is installed in the same way. To mount the gas module to the burner: 1. Screw the coupling unit (4.1) of the adjustable elbow fitting to the burner gas frame. The nut (4.3) must be with the coupling unit.
  • Page 28 B352U ver. 3 If the gas inlet pressure is not stable, stabilize with pressure regulator. Install gas lines in accordance with regulations by local public authorities. 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.

  • Page 29: Installing Gas Pressure Regulating Assembly

    B-349T ver. 1 Place the supports under the gas pipe (1) and gas valves (2) as depicted in the illustration. 3.9 Installing gas pressure regulating assembly Installing pressure regulator Adhere to the values given by the equipment manufacturer. Consider the following factors when selecting pressure regulator: ●...

  • Page 30: Changing The Fuel Type From Natural Gas To Lpg

    Example of gas pressure regulating assembly B311Z ver. 4 Pos. Item Pos. Item Gas pressure regulating assembly Bellows compensator/gas hose Ball valve Safety shut-off valve, if not incl. in press. regulator Gas filter Safety relief valve, if not incl. in press. regulator Pressure gauge valve Blow-off, when necessary...

  • Page 31: Electrical Connections

    Adjusting band Gas nozzle Fixing screw of adjusting band Gas nozzle adjusting band (LPG) ver. 3 To use the burner with liquefied petroleum gas (LPG), install an adjusting band in the gas nozzle, allowing you to adjust the square area of the nozzle apertures. ●...
  • Page 32 In burners with an external control cabinet, the supply for the control circuit needs to be connected to the cabinet. In the cabinet, the burner control circuit needs to be wired to the motor output. Burner configurations may vary; please refer to the electrical diagrams supplied with the burner.

  • Page 33: 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 34: Commissioning Data

    ● valves in supply line(s) are open and fuel is available at a suitable pressure ● manual control valves are in correct positions ● fuel filter is installed ● gas inlet pressure is correct ● equipment is installed correctly and is in working condition ●...

  • Page 35: Adjusting Combustion Air

    A405Y ver. 5 Pos. Item Ignition electrodes Gas nozzle Diffuser disc Burner 0.16 in 0.35 in 0.16 in 0.67 in 80 - 90 0.16 in 0.47 in 0.28 in 0.67 in 4.3 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 ring back and forth.

  • Page 36: Adjusting Combustion Differential Air Pressure Switch

    If... Then... Result The adjustment ring is There is too much ● Poor ignition, OR too far forwards at full pressure drop in the ● Poor combustion due to inadequate capacity combustion head. amount of air (high CO content), OR ●...
  • Page 37 Pos. Item Higher pressure Lower pressure Electrical connections Adjustment wheel 1 and 2 Cross-head screw LGW A2 ver. 3 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 38: Adjusting Gas Pressure Switch

    4.5 Adjusting gas pressure switch Gas pressure switch, max and low Pos. Item Adjusting scale Reset, gas pressure switch, max. 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 39: Close Cover

    To adjust gas pressure switch to minimum Scale precision ±15 % 1. Open switch transparent cover. 2. Set burner to full capacity. 3. Set the switch to trigger on a 20–40 % lower pressure than the gas inlet pressure to burner. 4.
  • Page 40 Gas pressure measuring connection, VGD d097596 ver. 1 Pos. Item Measuring connection for nozzle pressure Measuring connection for adjusted gas Gas pressure switch, gas valve proving Gas valve leaking is tested by using a pressure switch. Switch adjustment according to previous instructions.

  • Page 41: 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: 1.

  • Page 42: Measuring Gas Pressure

    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. ● When turning counter-clockwise, the pressure drops. ● When turning clockwise, the pressure rises. Measure the gas pressure with a pressure gauge when the burner is on.
  • Page 43 Measuring nozzle pressure D046520 ver. 2 1. Nozzle pressure at nominal capacity Burner Test point 1 ("W.C.) 50 M 80 M 90 M 11.7 Measuring inlet and adjusted pressure Check the tables below for adjusted pressure values. VGG valve + SKP pressure regulator 2 Inlet pressure 3 Adjusted pressure Gas module, VGG ver.

  • Page 44: Operating And Display Unit Menu

    1 Burner Test point 2 Test point 3 ("W.C.) ("W.C.) GP-50 M GP-90 M 13.7 4.8 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.
  • 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) FuelSelect Fuel selection via DOU when fuel selector is set to "Internal" SetClock Setting the display of date...

  • Page 46: Manual Operation

    Volume Gas R Fuel volume gas (resettable) Volume Oil R Fuel volume oil (resettable) Reset Date Gas Reset date fuel volume Reset Date Oil Reset date fuel volume LockoutCounter Total number of lockouts that occurred (read only) O2 Module Actual O2 Value Actual O2 value O2 Setpoint O2 setpoint...

  • Page 47: Logging In To System

    Burner on Burner on manual operation according to SetLoad Burner off Burner stopped Logging in to 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: ●...

  • Page 48: Adjusting Operating And Display Unit Settings

    4.9 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. 3 AZL ver. 4 Scroll through the menus with the Select -/+ buttons. Select the desired submenu by pressing Enter.

  • Page 49: Variable Speed Drive Settings And Standardization (Wd200)

    4.10 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 50: Manual Start-Up And Program Stop In Pre-Purge Position

    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. The servomotor for air drives to pre-purge position. The fan motor starts. Burner control adjusts the variable speed drive setting to 95%.

  • Page 51: Ignition Position

    ● Variable speed drive parameters are set and adjusted. ● Interlocking and failures are reset. ● Program phase is 12, Stand by. ● In heavy fuel oil use preheater temperature is sufficient. Activate manual burner start-up from menu level Autom/Manual/Off by choosing BurnerOn: ManualOperation Autom/Manual/Off...

  • Page 52: Setting Ratio Curve

    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, the main flame burns. If oil is selected as the fuel, the ignition is direct, and program phases have only different program phase durations.
  • Page 53 RatioControl GasSettings CurveSettings Point Manual Creating curve point individually Current servomotor positions in degrees, variable speed drive control and capacity in percentages are shown on the right side of the display, starting from the top corner. The pointer is positioned at Point. Curve point 1 ver.
  • Page 54 Curve point 3 ver. 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 servomotor drives to position for a set curve point, the display shows “>”...
  • Page 55 The servomotor turning angle is 0–90° and setting accuracy 0.1°. The capacity and variable speed drive setting range is 0–100% and they can be set at 0.1 % accuracy. Adjust at point 1: ● burner minimum load, note ratio ● set fan rotation speed as small as possible, but not under 60% ●...
  • Page 56 Larger gas amount flow is reached when gas regulator valve angle is 62%. If gas consumption is not sufficient, check gas supply line control pressure and adjust if necessary. If the required oil consumption is not reached when the oil regulator valve’s setting is 90°, check the oil pump’s operating pressure, and adjust if necessary.

  • Page 57: Capacity Range

    After adjusting burner maximum capacity, adjust the gas pressure maximum switch. See section Adjusting gas pressure switch. After commissioning the burner, check air pressure switch settings. See section Adjusting combustion differential air pressure switch. 4.14 Capacity range Burner 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.

  • Page 58: Setting Load Controller Parameters

    SetpointW1 Internal setpoint W1, °F Internal setpoint W1, 2. Start the burner manually by setting the Autom/Manual/Off option to Autom. The preset value from burner control is IntLC. 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.
  • Page 59 Params. & Display Load- Controller Controller- Param ContrlParam- List Standard- Param Adaption very fast fast normal slow very slow Standard parameters are listed in the following table: Proportional band [%] Integral action time [s] Derivative action time Very fast 42.5 Fast 14.5 Normal...
  • Page 60 Using too great a proportion will result in temperature/pressure fluctuation. ● The integral action time defines the time that it takes for the temperature/pressure deviation to return back to zero. ● The derivative action time speeds up control. Set the P and I parts while the value for the D part is 0.
  • Page 61 Flow chart_WD capacity ver. 3 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 62: 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 63: Boiler Temperature Limiting With Burner Control

    4.18 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 64: Backing Up Parameters

    ColdStart ColdStartOn activated 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 4.20 Backing up parameters 1.
  • Page 65 AZL –> LMV5x 2. Start backing up by pressing Enter. 3. Parameter backup is done when the text Parameters saved appears on the display. M4264 2423EN 65 (102)

  • Page 66: Operation

    5 Operation 5.1 WDx00 system LMV operation ver. 8 Boiler pressure/ temperature measurement Oil valves Safety devices Oil pressure switch O2 sensor (WD200) Gas pressure switch O2 module (WD200) Gas valves CAN BUS Air pressure switch Control unit Motor CAN BUS Speed sensor Gas damper Variable speed drive for variable speed...

  • Page 67: Burner Control

    In the WiseDrive system, burner operation is controlled and supervised by a separate burner controller. The burner control adjusts the burner’s fuel and air ratio as well as solenoid valves. The system includes an operating and display unit for local use. A remote PC application can be used during commissioning and servicing.

  • Page 68: Control Panel

    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. Fan (50 - 280) ver.

  • Page 69: Control Switch

    WDx00 A100 Operating and display unit S/H1 Control switch with pilot light Gas flame Boiler failure Burner failure Control panel GP ver. 4 Control switch Switch position State 0 - STOP Burner start-up by control devices is prevented. If the switch is turned to the ‘0’...

  • Page 70: Legend To Pi Diagrams

    GP WDx00i A100 Operating and display unit S/H1 Control switch with pilot light Control switch Switch Switch position State 0 - STOP Control voltage is cut off from burner automation and burner is shut down. 1 - CONTROL Control voltage is switched on to burner automation (burner control, servomotors).

  • Page 71: Burner Operation And Pi Diagram, Gas

    Compound regulator Pressure switch, low Air dampers Pressure switch, high Butterfly valve Gauging position switch Oil pump Pressure indicator 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...

  • Page 72: Burner Operation

    Pre-purge and ignition After the pre-purge, the servomotors run to ignition position, the ignition begins and ignition gas valves open. Gas is released to the nozzle and ignited by an electric arc. After the first safety time, both fuel valves open and the ignition flame ignites the main flame.

  • Page 73: Legend To Time Sequence Diagrams

    Gas use, VGD valve, M series PI000921/16 ver. 1 Pos. Item Pos. Item Manual shut-off valve Servomotor Pressure switch, low Air damper Safety shut-off valve Servomotor Combustion air fan 3.1 Valve 3.2 Actuator (VGD only) Electric motor 3.3 Actuator with pressure regulator Differential pressure switch for air 3.4 Proof of closure switch Flame detector...
  • Page 74 Pre-purge time (tv2) (flue gas recirculation Post-purge time (tn3) ARF) Ignition position Direct start Pre-ignition (Z) ON Valve proving evacuating time Burner valve ON Valve proving time atmospheric pressure Ignition OFF Valve proving filling time Interval 1 (ti1) Valve proving time gas pressure Times: Post-purge lockout position Post-purge time 3 gas / oil (tn3)
  • Page 75 Post-purge position Ignition load position Symbols: Indices: Signal ON Signal OFF Next phase 00, repetition = 0 12, repetition > 0 Parameter NormalDirectstart Checking with controller ON Deviation → 10 No repetition decrement Without valve proving → 70 With valve proving → 80 Stop, up to phase maximum time →...
  • Page 76 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 77: Time Sequence Diagram, Gas Use

    5.6 Time sequence diagram, gas use 7550f64e/0515, G ver. 4 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. ●...
  • Page 78 ● Burner control in stand-by position. ● Manual or automatic mode selected in burner control. If automatic mode is selected, the capacity controller must also be switched on. ● Remote control contacts closed. ● Boiler thermostat/pressure switch contact closed. ● Differential air pressure switch contact open. 20, 21 Start-up ●...
  • Page 79 ● Gas flows through a gas butterfly valve to the nozzle.* ● Main flame is ignited by the ignition flame.* 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.* ●...
  • Page 80 ● Requires manual reset. 80 (102) M4264 2423EN...

  • Page 81: 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 82: Maintenance Recommendations

    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 83: Maintenance During Shutdown

    Before reinstalling the burner to the boiler, check that the insulating material around the combustion head is undamaged. Replace if necessary. It is not advised to detach the burner unless absolutely necessary. Check that gas lines are leak-proof before putting the burner back into service.

  • Page 84: Dismounting Combustion Head And Gas Nozzle

    If you need help with maintenance and service, contact your nearest representative or Oilon customer service. 6.3 Dismounting combustion head and gas nozzle Combustion head structure in 50-model D044979 ver. 1 Pos. Item Pos. Item Gas nozzle Fixing screw of adjusting shaft...
  • Page 85 Combustion head structure in 90-model D045461 ver. 1 Pos. Item Pos. Item Gas nozzle Locking screw of adjusting shaft (indicator) Locking screw of gas nozzle Adjusting shaft Locking screw of ignition electrode Fixing screw of adjusting shaft assembly O-ring Fixing screw of combustion head Dismounting combustion head from the burner 1.

  • Page 86: Dismounting And Changing Burner Motor

    Check the O-ring during assembly. Replace if necessary. 6.4 Dismounting and changing burner motor Cut off electricity from the burner and ensure the motor has no voltage. The burner control switch does not function as isolating switch to the fan motor circuit. Fan cross section D044985 ver.

  • Page 87: Dismounting And Changing Servomotors

    5. Detach the fan wheel fixing screw. 6. Pull out the fan wheel from the motor shaft using an extractor. 7. Loosen the wedge. To mount motor and fan wheel: 1. Set the wedge into the shaft slot. 2. Place the fan wheel to its place so that the distance between the fan wheel and the motor mounting flange is 1.5 …...

  • Page 88: Assigning Servomotors

    Pos. Item Pos. Item Servomotor fixing screw Shaft coupling 1. Disconnect the cables according to the instructions. 2. Loosen the shaft coupling locking plate fixing screws (shaft coupling is left attached to the air damper). 3. Remove the servomotor fixing screws and remove the servomotor. 4.
  • Page 89 4. Keep red button pressed until next display appears. 5. Addressing is completed when green light for servomotor address starts to blink according to servomotor addressing number. 6. Place protective cover. Testing servomotor Burner control switch is in position 1, control. Choose parameters of initial stage setting from control panel.

  • Page 90: Fault And Lockout History

    6.7 Fault and lockout history Reading fault and lockout history from display menu The active burner control fault status is shown on the display. Fault and lockout history can be accessed from the display menu. OperationalStart FaultHistory LockoutHistory Resetting fault You can also reset the burner lockout from the control panel.
  • Page 91 Burner manual lockout example ● 3. lockout in history ● Occurred 23.03.2005 at 15:43 ● C = error code A7 ● D = diagnostic code 09 ● V = phase 34 ● Start-No = start counter reading at the time the fault occurred 123456 ●...

  • Page 92: Remote Reset

    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 lockout are not allowed. If the burner can be reset without being within sight of the burner, the following conditions must be met: ●...

  • Page 93: Gas Pressure Switches

    Test method Outcome Step 1 Boiler pre-purging begins. The burner must shut down before the pre-purge Disconnect the high pressure hose (+) from the switch. cycle is completed. Start the burner. Error code 28 and a text Air pressure After testing, reconnect the high pressure hose. off appear on the display.
  • Page 94 Gas shut-off valves To manually test the tightness of a single valve gas train, follow the procedure below. Prerequisites for the test: fuel gas available, gauge for measuring gas pressure, a length of flexible tube (ID 1/8"), a flat head screwdriver Test method Outcome Step 1...

  • Page 95: Troubleshooting

    Boiler safety devices Test method Outcome When the burner is in standby position, activate, for example, The burner does not start and the text the temperature limiter switch from the boiler safety chain Safety loop open switches with Safety (X3–04:1) and start the burner. Perform this test to all safety shutdown on the display.

  • Page 96: Motor Failure

    Motor failure Condition Possible cause Action Fan or oil pump motor does not Break in main circuit. Find out cause of the break. start. Lockout occurs. Break in control circuit. Find out cause of the break, see circuit diagram. Check burner control operation.

  • Page 97: Poor Combustion

    Condition Possible cause Action Break in control circuit. Find out cause of the break. Faulty actuator. Replace faulty part. Faulty fuel pressure. Check components (filter, throttle plug, regulator, pressure switch) and adjust. Faulty fuel/air ratio. Adjust. Faulty combustion head Check and adjust. adjustment.

  • Page 98: Troubleshooting Error Codes

    Condition Possible cause Action Diffuser disc burned out Too low combustion air velocity: Adjust, change diffuser disc if incorrect adjustment ring position necessary. Too low partial load Adjust, change diffuser disc if necessary. Incorrect distance between Adjust. nozzle and diffuser disc 6.10 Troubleshooting error codes Fault codes See the complete fault code list in the control unit manufacturer’s...
  • Page 99 GP-50 M - 90 M WDx00i D078439 ver. 2 M4264 2423EN 99 (102)

  • Page 100: Burner Part List

    Gas module, VGG Gas module, VGD d097598 ver. 1 VGG WDx00 US ver. 1 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.
  • Page 101 Recommended change interval Part name 1–2 3–5 on demand/ year years years start-up max. Pressure switch, gas Differential air pressure switch Control unit 250 000 Servomotor, air Servomotor, gas Operating panel Air cone Ignition electrode support 250 000 Manual shut-off valve Regulating valve Valve actuator with pressure regulator Power transformer...
  • Page 102 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:

Gp-90 m

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