6.11Burner part list.......................................................................................... 95
2 (95)M5164 1640EN
1Introduction
1.1Liability disclaimer
Burner, with the delivered ancillary equipment, is always a part of a larger system.
This manual does not include comprehensive instructions for planning, installing
and operating a complete system. Thus, the designer, installer and operator of the
equipment should have sufficient qualifications and knowledge to design, install,
and operate the parts of the system, as well as the system as a whole. The system,
including burner control system, must be designed and constructed according to local
regulations and requirements.
The following information must be read and understood by the users of the appliance.
The users must be trained and fully qualified according to local legislation for the
specific work. The users of the appliances must also be capable to recognize possible
hazards in the system and in the environment where the appliance is used.
This manual contains information and instructions based on product standards and
regulations, and on our best knowledge. Failure to follow these instructions can lead
to damage to the appliance. Erroneous use of the appliance or the failure to follow any
instructions or warnings in the manual or this disclaimer can lead to property damage,
personal injury or death.
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
● use by unqualified personnel
● the use of spare parts not provided by Oilon.
Your legal rights are governed by a Limited warranty, the terms of which are
incorporated herein by reference. Any modification at the product, if not approved by
Oilon, is disclaimed and may void your rights under the Limited warranty.
1.2Safety precautions
Read these instructions carefully before installation, commissioning, operation or
maintenance of the device. The given instructions must be followed. Throughout this
manual, the following three symbols are used to point out very important information:
Be careful. The DANGER symbol indicates a possible danger of bodily
harm or lethal injury.
Pay attention. The CAUTION sign indicates a possible danger of
damage to the device, components or surroundings.
M5164 1640EN3 (95)
Note indicates tips, hints, and other essential information.
Keep these instructions as well as the electrical diagrams available near the
device.
Oilon products are manufactured according to general product standards and
directives, and based on our best knowledge about product design, and technologies.
Operation safety is one of the leading principles in our product development. However,
it is wise to be prepared, and think about safety. Read the following principal safety
warnings and instructions:
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.
The equipment shall be installed in accordance with the Provincial Installation
Requirements, or in their absence, the CGA B149.1 and B149.2 Installation Codes
shall prevail.
IN CASE OF FIRE OR OTHER EMERGENCY
● Cut off power supply.
● Close main fuel shut-off valve.
● Take appropriate actions.
● Contact operation controller.
IN CASE OF A GAS LEAKAGE
● Do not light fire or touch electric equipment.
● Close main fuel shut-off valve.
● Make sure there are no people in the leakage area.
● Make sure the leakage area is properly ventilated.
● Contact operation controller.
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.
Connectors in control box are under voltage. Only authorized users may
open safety cover.
Fasten 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 protection shoes and gloves when necessary.
4 (95)M5164 1640EN
Do not use Teflon tape in piping.
If burner start-up fails consecutively two times, do not restart burner
before carefully investigating the reason for the failure.
Do not touch hot pipes or surfaces during operation or maintenance.
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 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.
● Make sure that there is always enough water and pressure in heating system.
● Make sure boiler and chimney are swept regularly.
● Check flue damper adjustment and gate valve regularly.
● Make sure burner room air-inlet gap is open.
● Make sure shut-off valves on pressure gauges are shut.
● Make sure pipeworks tightness, boiler system safety appliances, pipeworks, and
burner are checked regularly according to the rules and regulations of public
authorities.
● Check boiler and its components.
We recommend a maintenance contract.
WARNING
IF YOU SMELL GAS, OPEN WINDOW, EXTINGUISH ANY OPEN FLAMES,
STAY AWAY FROM ELECTRICAL SWITCHES, EVACUATE THE BUILDING AND
IMMEDIATELY CALL THE GAS COMPANY.
IN ACCORDANCE WITH OSHA STANDARDS, ALL EQUIPMENT, MACHINES AND
PROCESSES SHALL BE LOCKED OUT PRIOR TO SERVICING.
M5164 1640EN5 (95)
IF THIS EQUIPMENT IS NOT INSTALLED, OPERATED AND MAINTAINED IN
ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS, THIS PRODUCT
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.
SERVICING MUST BE DONE BY A FULLY TRAINED AND QUALIFIED PERSONNEL.
WARNING
DO NOT ATTEMPT TO START, ADJUST OR MAINTAIN THIS BURNER WITHOUT
PROPER TRAINING OR EXPERIENCE. FAILURE TO USE KNOWLEDGEABLE
TECHNICIANS CAN RESULT IN EQUIPMENT DAMAGE, PERSONAL INJURY OR
DEATH.
1.3Product overview
Intended use
This is an automatic forced draught burner. The burner can be used on most heating
appliances; for warm and hot water boilers, hot air generators, and various types of
process heating. They are also designed to suit furnaces with high back pressure.
The burners can be mounted in horizontal, vertical and upward facing, or vertical and
downward facing orientation. Our burners are designed for operation in covered areas,
within the temperature range of 0 °C – +50 °C / + 32 °F – 105 °F. The standard setup is
designed to operate in the altitude of max. 500 m / 1,640 ft above sea level.
See Technical data for the information on standard applicable fuels. Burners using
other fuels are available upon request.
Construction
The surface of the housing is finished with durable high-gloss paint. Electrical
installations and burner service are easy to perform because the top cover is
removable. The stainless steel alloy combustion head and the diffuser disc can
withstand high temperatures.
The burner control system handles all burner operation sequences automatically. In the
event of a burner failure, the unit stops the burner automatically.
Each burner is tested separately before delivery to the customer.
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.
6 (95)M5164 1640EN
Type labelling
POLTINKOODI ver. 2
Label element 1: Fuel
KPLight fuel oil
RPHeavy fuel oil
GPGas
GGPDual gas
GKPGas, light fuel oil
GRPGas, heavy fuel oil
Label element 2: Burner size categorization
Label element 3: Method of control
HTwo-stage
MModulating
MHModulating gas, two-stage oil
MEModulating with a separate fan
Label element 4: Additional code, for example burner capacity I-III or automation, like
WD34
WD32BT 320 burner control (one fuel, non-permanent operation)
WD33BT 330 burner control (one fuel, permanent operation)
WD34BT 340 burner control (two fuels, permanent operation)
- capacity controller LCM100 as an option to LSB bus (WD32, WD33)
- capacity controller LCM100 and dual-fuel burner module DFM300 are mandatory to LSB bus with
WD34, when using a dual-fuel burner
Type plate
The following illustration shows an example of the type plate of Oilon burners:
M5164 1640EN7 (95)
Type plate US ver. 1
Pos.DescriptionPos.Description
1Burner type:
KP = Light fuel oil
RP = Heavy fuel oil
GP = Gas
GKP = Light fuel oil and gas
GRP = Heavy fuel oil and gas
2Overfire pressure min, IN.WC10Serial number
3Overfire pressure max, IN.WC11Month and year of manufacture
8Manufacturer address16L LC US marking and certification
9Degree of protection
15Gas pressure max, IN.WC
institute code
1.4Handling and storing
Storing and recycling
Store device and its equipment in a dry and airy place. Protect device from dust and
humidity. Follow storing and transporting instructions included in the package.
Documentation is part of the product, and it must be passed on together with device,
also with a second hand product. Pass on documents delivered with device to owner
at installation, and advise to keep them properly. Make sure that operating instructions
are available near the device.
Recycle product package. 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.
8 (95)M5164 1640EN
2Technical data
2.1Burner technical data
Burner data
BurnerGKP-50 MHGKP-90 MH
Capacity kW, gas100–800250–1460
Capacity MBtu, gas341–2,730853–4,981
Capacity kg/h, oil17–6830–130
Capacity lb/h, oil37.5–149.966.1–286.6
Max. turndown ratio, gas use1:8 (100–12.5%)1:6 (100–16.5%)
When using other gases than natural gas, the composition
of the gas must be known. Consult burner manufacturer on
the suitability of the burner for special gases.
Gas inlet pressure to burner max.500 mbar
Gas inlet pressure to burner max.7.25 PSI
Max. demand for combustion air, gas use13 m³ / 10 kW
Max. demand for combustion air, gas use459.09 ft³ / 13.5 MBtu
Fuel, oil use#2 fuel oil
Efficiency, #2 fuel oil2.20 lb ≈ 40.46 MBtu efficiency, when heat value is 1146.03
Btu/ft³
Max. demand for combustion air, oil use15 m³/kg
529.72 cfh/lb
Control voltage120 V (-15%...+10%) 50 Hz / 60 Hz 1-phase
Motor voltage options220 V 60 Hz 3-phase
460 V 60 Hz 3-phase
575 V 60 Hz 3-phase
Degree of protectionNEMA 1
Ambient temperature range0...+ 50 °C
32...+ 122 °F
L
Noise level
= 77.5 ± 0.5 dB
pfA
M5164 1640EN9 (95)
For reducing noise level, contact the manufacturer.
Working diagrams
GKP-50 MH
1 kg/h = 11.86 kW
GKP-50 MH
2.20 lb ≈ 40.46 MBtu
Usage of burner outside the heat input and pressure curves is
forbidden.
GKP-90 MH
GKP-90 MH
2.2Burner control technical data
Burner controlBT 300 series
Power supply115 VAC –15/+10 %
Locking from undervoltageLess than 85 % of nominal
Mains frequency50 Hz / 60 Hz
Power consumption< 30 VA
Internal shieldingSafety equipment, do not self-service.
External fusemax. 10 A slow
Input signalsCapacitance should be below 2.2mF.
Output signals3 fuel valves max. 1 A cos 0.4
fan max. 2 A cos 0.4
oil pump max. 2 A cos 0.4
ignition transformer
alarm output
Allowed ambient and medium temperature5 °F ... +140 °F
Group, according to EN 1612
Installation positionPressure regulator determines position
Component standardUL/429, FM/7400
CSA/ANSI Z21.21/CGA 6.5 Commercial/Industrial
Oil valve
TypeASCO 8262H011V
Maximum operating pressure350 PSI
Capacity9.1 W
Allowed ambient temperature5–131 °F
Allowed medium temperature210 °F
Component standardUL429
16 (95)M5164 1640EN
3Installation
3.1Space 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.
Space requirements ver. 1
Legend
a
(left)
b
(front)
c
(right)
d
(top)
Minimum
dimension, cm
802.6
802.6
802.6
1003.3
Minimum
dimension, ft
It is recommended to leave more space around the burner. These are only the
minimum requirements.
3.2Lifting burner
● Lifting the device can only be performed by a qualified person, who
knows the regulations and safety instructions for lifting.
● Always use all lifting points of the lifting direction.
● Do not go under a supported device.
M5164 1640EN17 (95)
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.
Lifting D047033 ver. 2
Pos.Item
1Lifting belt
2Lifting support
3Gas frame
To lift the burner:
1. Remove the burner cover.
2. Set the lifting belt (1) around the flame sight tube and the gas frame (3).
3. Place the lifting support (2) between belts according to the drawing. Make sure, that
the lifting devices do not touch electrical devices.
4. Lift the burner as shown in the illustration.
5. After lifting, remove the lifting devices and fasten the cover on its place.
18 (95)M5164 1640EN
3.3Installing burner
GKP-50 MH main dimensions
D048897 ver. 3
M5164 1640EN19 (95)
GKP-90 MH main dimensions
D048844 ver. 3
Mounting dimensions
A-349A ver. 2
1 Mounting plate
2 Insulating plate
3 Ceramic wool or similar
L (mm)
Burner
240 / 300
300 / 400
L (inch)
20 (95)M5164 1640EN
50 H / M / MH90 H / M / MH
Burner
ø D2R1L
50 H / M / MH165117.5-135240 / 300
Burner
ø D2R1L
50 H / M / MH6.504.63–5.319.45 / 11.81
90 H / M / MH8.2711.81 / 15.75
Mounting dimensions, mm
Mounting dimensions, inches
To mount the burner:
1. Prepare the boiler front plate according to the given dimensions.
2. Coat the bolt threads with graphite-bearing grease prior to fitting.
3. Install the burner so that the motor shaft lies horizontally.
4. Remove the transportation bracket after the burner is attached to the boiler.
5. Make sure there is enough free space on the side to allow the burner to swing fully
open.
As standard, the burner swings to the left. The GKP-90 MH model can also be hinged
to the right side.
Install burner firmly. Vibration may damage burner or its components.
Switch off electric power from the burner before burner swing-out.
M5164 1640EN21 (95)
Do not install the burner upside down. Make sure the burner is firmly
attached.
3.4Gas valve selection table
The max. capacities shown in the table are achieved when the boiler
back pressure is 0.
3.5Installing gas module to burner
The gas module consists of a double solenoid valve, gas pipe, elbow fitting, and
an adjustable elbow fitting. The parts are delivered separately. The regulator valve,
servomotor, and connection flange are ready-fitted to the double solenoid valve.
The following illustration describes the gas module parts.
D046558 US ver. 1
4.3
4.1
4.4
4.2
4
2
3
1.3
1.5
1.1
1.4
1.2
1
Pos.ItemPos.Item
1Gas valve assembly2Gas inlet pipe
1.1Mounting flange, burner side3Elbow fitting
1.2Manual shut-off valve4Adjustable elbow fitting
1.3Servomotor4.1Coupling unit
1.4Control valve4.2Elbow part
1.5Servomotor cable4.3Nut
4.4Gasket
22 (95)M5164 1640EN
The assembly may vary depending on the scope of delivery.
To assemble the gas module:
Gas module parts are connected to each other with threaded connections. Use thread
seal to seal the connections (for example Loctite 577).
1. Screw the gas inlet pipe to the mounting flange (1.1).
2. Screw the elbow fitting to the gas inlet pipe. Adjust the fitting to point straight to the
right, in gas flow direction (when gas inlet to burner is on the right).
3. Screw the elbow part (4.2) of the adjustable elbow fitting and adjust it to point
upwards.
a029409 ver. 1
Pos.ItemPos.Item
52nd stage oil valve13Cable gland for gas high
pressure switch
61st stage oil valve14Gas valve cable gland
7Main oil valve15Injector hoses
8Gas high pressure switch16Hinge locking screw
9Gas low pressure switch17Control unit
10Manual shut-off valveaFlame detector gland
11Gas valve assembly with pressure regulatorbGas damper servo gland
12Cable gland for gas low pressure switchcLead in plate
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.
2. Lift the mounted gas module to the adjustable elbow fitting.
3. Check that the gasket (4.4) is in its place and undamaged.
4. Connect the gas line by screwing the nut (4.3) to the elbow part (4.2).
M5164 1640EN23 (95)
No tape or glue is used in this threaded connection. When dismounting the burner
from the boiler, the gas line is disconnected from this connection.
5. Support the mounted gas assembly to eliminate any torsional tension.
To connect the servomotor cable to the burner control unit:
1. Remove gas damper servo gland (b) from the lead in plate (c).
2. Push the servomotor plug through the lead-in plate hole and lead the plug to the
control unit terminal X33.
3. Push the plug into the connector.
4. Pull excess length of the cable into the burner but leave a loop of cable outside to
enable the burner to be swung open.
5. Re-attach the gland (b)
To open the burner:
You can open the burner from its hinged joint, for example, to adjust the ignition
electrodes or to change or clean nozzles.
1. Switch off the power from the burner by turning the control switch.
2. Close the gas supply from the gas shut-off valve.
3. Close the oil supply from the oil shut-off valve.
4. Detach the oil hoses (15) other end from the connector.
Clean the possible oil dripping from the oil line with oil soaking fabric, for example.
5. Open the hinged flange locking screw (16).
Now you can open the burner from the hinged joint.
When closing the burner, perform the steps in reverse order.
To detach the burner from the boiler:
1. Switch off the power from the burner by turning the control switch
2. Close the gas supply from the gas shut-off valve.
3. Close the oil supply from the oil shut-off valve.
If needed, open the burner oil line from the suction and return hoses. Clean the
possible oil dripping from the oil line for example with oil soaking fabric.
4. Detach the electrical plugs from the gas valve.
5. Detach the servomotor cable (1.5) from the burner control unit (17).
For more instructions, see step 2 in section To connect the servomotor cable to the
burner control unit.
6. Open the gas supply line from the connection of the adjustable elbow fitting.
For more instructions, see step 2 in section To mount the gas module to the burner.
7. Support the burner on solid platform and detach the burner tightening screws.
8. Pull the burner out from the boiler.
When attaching the burner to the boiler, perform the steps in reverse order.
When pushing the burner to the boiler, check that the insulating material
around the combustion head is undamaged and in its place.
Check that gas and oil lines are leak-proof before taking the burner into
use again.
24 (95)M5164 1640EN
3.6Installing burner to gas supply line
Supply line
If necessary, decrease the gas pressure with pressure regulating assembly. The gas
supply line after the pressure regulator must be of the same size or one size larger
than the burner’s gas pressure regulating assembly. The gas valve capacity adjustment
disc must be upwards. In installation, observe the valve manufacturer’s instructions.
As standard, the gas connection to the burner is from the right side. The valves shown
in the following example may vary from those delivered.
B352U ver. 3
● Install gas pipings according to the regulations of local public
authority.
● Check that there is a separate filter before gas equipment.
● Prior to installing gas pressure regulator block to piping, use
compressed air to blow supply piping clean.
● Clean and check piping prior to the installation of gas pressure
regulating assembly.
● Install gas valve so that no mechanical stress is directed to it.
● Vent gas piping before the first start-up.
To vent gas pipe:
1. Lead pipe to an open outdoor location either from the gas valve or from the blow-off
valve fixed to the pipe.
2. Open the blow-off valve.
3. Open the ball valve slowly in main supply line and fill piping with gas.
4. Close the blow-off valve.
3.7Installing gas pressure regulating assembly
Installing pressure regulator
Consider the following factors when selecting pressure regulator:
M5164 1640EN25 (95)
● gas supply pressure
● secondary pressure
● the quantity of gas to be combusted
● type of gas
If the gas inlet pressure is higher than the Pmax. value given in the burner technical
data, reduce the gas inlet pressure in regulating assembly. Also, if the gas inlet
pressure is not stable, stabilize the pressure with pressure regulator. If pressure
regulator is not equipped with safety relief valve and safety shut-off valve, they
must be installed according to the instructions given by the manufacturer. Also any
impulse tubes must be installed according to the instructions given by the regulator
manufacturer.
Installing safety relief valve and safety shut-off valve
Check that the safety relief valve is dimensioned so that the safety shut-off valve does
not release if the burner shuts down at full load. The burner may be shut down for
example due to mains interruption. Set the safety relief valve to open at an approx.
30% higher pressure than the secondary pressure aka pressure after the regulator.
Set the safety shut-off valve to closed position at an approx. 60 % higher pressure than
the secondary pressure. Closing the pressure of the safety shut-off valve must not
exceed the Pmax. pressure.
Prerequisites for manual shut-off valve
The gas pressure regulating assembly must be equipped with a manual shut-off valve
(pos. 2 in the diagram below). The valve must fulfill the following requirements:
● The flow cross-sectional area must be at least of the same size as the nominal size
of the gas pressure regulating assembly.
● The valve must be of such type that it can be closed quickly (for example, inversion
90°). It must also be easily accessible but protected from unintentional use.
● Pressure endurance of the valve must be at least 1.5 times the supply pressure,
and it must be equipped with mechanical limiters in open and closed positions.
● The open and closed positions must be marked separately, if it is not evident from
the valve structure.
The valve is not necessarily included in the burner delivery.
2Ball valve10Safety shut-off valve, if not incl. in press.
regulator
3Gas filter11Safety relief valve, if not incl. in press.
regulator
4Pressure gauge valve12Blow-off, when necessary
5Pressure gauge, high pressure13Pressure gauge valve, when necessary
6Pressure regulator with safety shut-off
valve and safety relief valve
7Pressure gauge valve15Fuel flow meter, can also be on low
8Pressure gauge, low pressure16Pressure regulator
14Pressure gauge, high pressure, when
necessary
pressure side, when necessary
3.8Installing hoses
Avoid torsion stress on hoses
Leave neutral hose
ends long enough
Use rigid pipe
bends when
necessary
Minimum bend radius
Hose diameterMinimum bend radius ( r )
Ø 12130 mm
Ø 15130 mm
Ø 22170 mm
M5164 1640EN27 (95)
3.9Oil piping
Oil piping manual shut-off valve
The oil supply piping must be equipped with a manual shut-off valve. The flow area
of the valve must correspond to the remaining oil piping. The valve must be of quickly
closable type (for example, inversion 90°). It must also be easily accessible but
protected from unintentional use. The valve is not necessarily included in the burner
delivery.
The manual shut-off valve must be according to UL 842, or equivalent nationally
recognized manual valve safety standard.
The oil tank and the oil pipes must be installed to avoid the risk of the oil cooling below
cloud point. The cloud point of heating oil depends on the oil quality. If the oil is allowed
to cool to the cloud point, valves and filters will block. The most suitable oil temperature
is +15°C–+25 °C / + 59 °F–77 °F.
The viscosity of oil coming to the burner must be from 4 to 12 mm²/s
(cSt).
28 (95)M5164 1640EN
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