OPERATING AND MAINTENANCE INSTRUCTIONS LIGHT OIL BURNERS

OPERATING AND MAINTENANCE INSTRUCTIONS LIGHT OIL BURNERS ❹ KP-6 ❹ KP-6 L ❹ KP-6 LH ❹ KP-6-2 ❹ KP-6 H-2 OILON OY P.O.Box 5 FIN-15801 LAHTI FINLAND +358-3-85 761 Fax +358-3-857 6239 E-mail info@oilon.com

Table of Contents 1. Conventions in this Manual... 1 2. General... 2 3. Burner Technical Data... 4 3.1. General... 4 3.2. Technical Data... 4 3.3. Basic Assembly Drawing... 5 3.4. Parts List... 6 3.5. Dimensions... 6 4. Burner Installation... 6 4.1. Burner Mounting... 7 4.2. Hinged Burner Housing...7 4.3. Electric Connections... 7 4.4. Connecting the Burner to the Mains... 8 4.5. Connecting the Burner to Oil Supply Line... 8 5. Fuel System... 9 5.1. Oil Piping... 9 5.2. Oil Pumps... 10 5.3. Oil Filter... 12 6. Burner Operation Principle... 13 6.1. 1-Stage Burners, KP-6, KP-6-2... 13 6.2. 1-Stage Burner with Preheater, KP-6 L... 13 6.3. 2-Stage Burners (H-Burners), KP-6 H-2... 15 6.4. 2-Stage Burner ( H Burner) with Preheater, KP-6 LH... 15 7. Burner Automation... 17 7.1. 1-Stage Burners... 17 7.2. 2-Stage Burners (H-Burners)... 19 8. Burner Adjustment... 21 8.1. Capacity Regulation... 21 8.1.1. Oil Pump Pressure Regulation... 22 8.2. Combustion Head Adjustment... 23 8.2.1. Setting the Nozzle and the Ignition Electrodes... 23 8.2.2. Adjusting the Air Velocity in the Combustion Head... 24 8.3. Combustion Air Adjustment... 25 8.3.1. 1-Stage Burners... 25 8.3.2. 2-Stage Burners ( H Burners)... 26 8.4. Air Cone Position... 27 8.5. Flame Inspection... 27 9. Control Unit LOA24/BHO64... 28 9.1. Time Sequence Diagram (Control Program)... 28 9.2. Control Functions in the Event of Faults... 29 9.3. Technical Data of Control Unit... 29 9.4. Current through Flame Detector... 29 9.5. Measurement of Flame Signal... 30 10. Maintenance... 31 11. Fault Conditions and Procedures... 32 12. Notes... 35

1. Conventions in this Manual 1 Read these instructions carefully before installation, commissioning or maintenance of the burner. The given instructions must be followed. Throughout this manual, the following three symbols are used to point out very important information: WARNING! A warning alerts you to possible danger to person, if the instructions are not followed. CAUTION! A caution alerts you to something, that has the potential to cause damage to component, burner, process or surroundings, if the instructions are not followed. Note! A note points out information of special interest. KEEP THESE OPERATING AND MAINTENANCE INSTRUCTIONS AS WELL AS THE ELECTRICAL SCHEMES AVAILABLE NEAR THE BURNER!

2. General 2 Oilon KP-6...KP-6 H-2 burners are fully automatic light oil burners. These burners can be used on most heating appliances such as hot water boilers, steam boilers and air heaters. A fan attached to the burner and dimensioned to provide a sufficiently high and even air pressure for efficient combustion in modern combustion chambers delivers the required air. The burners are suitable for use on light fuel oil with a viscosity of 4-12 mm²/s (cst) at a temperature of +20 C. The oil coming to the burner must be filtered before the burner oil pump. Filtration degree may be max. 100 µm. Oil atomising pressure: 1-stage burners 700-1400 kpa (7-14 bar) 2-stage burners 700-2500 kpa (7-25 bar). The H burners are high-low -burners and LH burners are equipped with a preheater. 2-stage burners ( H burners) have a maximum control range from 55 to 100 %. Required combustion air quantity: 15 m³ for each kg of oil to be burned. Burner operation is automatically controlled and supervised by the control unit. Boiler thermostats or pressurestats controls the burner capacity. Protection: IP20 Supply/control voltage 230 V (-15 %...+10 %), 50 Hz, 1-phase Input power: 260 W 1,13 A (KP-6, KP-6-2, KP-6 H-2) 500 W 2,2 A (KP-6 L, KP-6 LH) The ambient temperature during burner operation must be 0...+40 C. The following should be checked before first start-up: connections are correct, settings of regulating and control devices are correct, boiler and its equipment is in working condition, boiler room is adequately ventilated, valves in supply line are open, there is oil in the tank, oil temperature is adequate in such a way, that the oil viscosity is 4-12 mm²/s (max. +60 C).

3 CAUTION! The burner must be installed firmly. Vibrations may damage burner or its components. CAUTION! Prior to first start-up the oil pump must be vented. The pump must not operate without oil. See chapter Oil Pumps. WARNING! In case of fire or other danger: - switch off the main switch - close the main fuel shut-off valve outside the plant - take appropriate actions. WARNING! Never use a naked flame while checking the burner or the boiler. Never store any inflammable material in the boiler room. WARNING! Keep the boiler door closed while starting the burner and during burner operation. Correct installation and adjustment together with regular servicing are the most reliable guarantees of trouble-free burner operation. Note! Local regulations and requirements must be adhered to when installing or servicing the burner. The burner must be installed in such a position, that the motor shaft lies horizontally; but the burner must not, however, be installed upside down. Use only original spare parts. When ordering spare parts please give burner type and serial number indicated on the burner nameplate.

3. Burner Technical Data 4 3.1. General burner types: 1-stage burners KP-6 KP-6 L KP-6-2 2-stage burners ( H burners) KP-6 LH KP-6 H-2 on standard version the burner can be hinged to both sides the burner must be installed in such a position, that the motor shaft lies horizontally; but the burner must not, however, be installed upside down. burner control unit internally connected safety switch (limit switch) on hinged flange control switch air regulation: stepless adjustable (1-stage burners) servomotor (2-stage burners) oil pump atomising pressure: 700-1400 kpa (7-14 bar) (1-stage burners) 700-2500 kpa (7-25 bar) (2-stage burners) standard version equipped for two-pipe system electrical connection with a plug connector (KP-6, KP-6 L, KP-6-2). Extra equipment run hour counter filter Oilon 20 de-aerator Tiger Loop oil meter oil pressure gauge and valve 3.2. Technical Data Burner KP-6 KP-6 L KP-6 LH KP-6-2 KP-6 H-2 Capacity kg/h kw 3,5-10,042-120 3,5-10,0 42-120 3,5-10,0 42-120 6,0-12,0 71-140 6,0-16,0 71-190 Burner motor Voltage 50 Hz 230 V Output kw Current A Speed rpm 0,125 1,0 2750 0,125 1,0 2750 0,125 1,0 2750 0,125 1,0 2750 0,125 1,0 2750 Control unit LOA24 /BHO64 LOA24 /BHO64 LOA24 /BHO64 LOA24 /BHO64 LOA24 /BHO64 Servo motor - - SQN - SQN Oil hoses R ¼" R ¼" R ¼" R ¼" R ¼" Oil pump AS 47 C/ BFP 21 L3 AS 47 C/ BFP 21 L3 BFP 52E L3 AT 2 45 C AS 47 C/ BFP 21 L3 Preheater W - 30-240 30-240 - - BFP 52E L3 AT 2 45 C Light fuel oil 1 kg/h 11,86 kw

3.3. Basic Assembly Drawing 5

3.4. Parts List 6 1 Burner housing 19 Burner motor 2 Control unit 20 Fan wheel 3 Protective cover 21 Plug connector (KP-6, KP-6 L, KP-6-2) 4 Flame detector (photo resistor) 22 Air cone 5 Control switch (KP-6 LH, KP-6 H-2) 23 Coupling 6 Nozzle holder (KP-6, KP-6-2, KP-6 H-2) 24 Air damper/air adjustment ring Preheater (KP-6 L, KP-6 LH) 25 Air damper shaft 7 Limit switch (=safety switch) 26 Air intake 8 Swirler 27 Oil pump 9 Ignition electrode AS 47 C or BFP 21 L3 (KP-6, KP-6 L, KP-6-2) 10 Adjustment ring BFP 52E L3 or AT 2 45 C (KP-6 LH, KP-6 H-2) 11 Nozzle 28 Nozzle conduit 12 Diffuser disc 29 Cover plate 13 Ignition cable 30 Pressure pipe 14 Combustion head 31 Adjusting lever (KP-6, KP-6 L, KP-6-2) 15 Mounting flange Servomotor (KP-6 LH, KP-6 H-2) 16 Hinge pin 32 Oil hose, return 17 Ignition transformer 33 Oil filter 18 Sight glass 34 Oil hose, suction 3.5. Dimensions Burner Dimensions in mm L1 L2 H1 H2 B1 B2 ød KP-6 310 105 230 120 210 180 90 KP-6 L 310 105 230 120 210 180 90 KP-6 LH 400 105 255 120 210 180 90 KP-6-2 310 110 230 120 210 180 100 KP-6 H-2 400 110 255 120 210 180 100

4. Burner Installation 7 4.1. Burner Mounting The furnace, which has a flame-shaped design, does not require refractory. Boilers without bottom cooling require refractory to prevent heat from reaching boiler foundations. The flame must at no point come into contact with the furnace walls. If this cannot be avoided, such points must be covered with refractory. This applies especially to the refractory at the back wall of short furnaces. 1 Mounting plate BURNER Ø D2 2 Gasket KP-6, -6 L, -6 LH 95 3 Thermal insulation KP-6-2, -6 H-2 105 The mounting plate must have either two or four M10 threaded holes for the mounting of the burner according to the drawing. 4.2. Hinged Burner Housing On standard version the burners are delivered to be hinged to both sides. 4.3. Electric Connections The burner must be connected according to the electrical diagrams delivered together with the burner. General and local standards and regulations as well as requirements of electrical equipment on electrical connections must be adhered to.

4.4. Connecting the Burner to the Mains 8 KP-6, KP-6 L, KP-6-2 Electrical connection on burner is with a plug connector. Connect the cable of the plug supplied with the burner to the boiler thermostat. The socket has been firmly attached to the burner housing. Disconnect the burner from the mains (burner switch in position 0) by pressing the locking button and pulling out the plug from the socket at the same time. 1 Socket (fixed on the burner housing) 2 Locking button 3 Plug (pull-out part) 4.5. Connecting the Burner to Oil Supply Line On standard version the burners is equipped for two-pipe system. Two-pipe system has both suction and return lines for fuel oil. Note! The by-pass plug in the oil pump must be fixed. 1 Filter 2 Suction line 3 Oil pump 4 Pressure line (to nozzle) 5 Return line 6 By-pass plug 7 Shut-off valve 8 Shut-off valve/non-return valve A-A Delivery limit

5. Fuel System 9 5.1. Oil Piping 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...+25 C. Note! The viscosity of oil coming to the burner must be 4-12 mm²/s (cst). The maximum lengths for other viscosities can be calculated by the simple ratio of viscosities i.e. if the table shows lengths for 5 resp. 6 mm²/s (cst) viscosity, multiply the length shown in the table by 5 resp. 6 and divide by the value of the new viscosity mm²/s (cst). Keep in mind that absolute tightness is the fundamental pre-requisite for secure operation. A leaking suction line may cause, among other things, afterspraying of oil into the boiler. It is advisable to use ball valves instead of needle valves. The tables give the maximum lengths (in meters) of return and suction lines. Overlying oil tank Underlying oil tank H m DANFOSS BFP/MS (ø d mm) H m DANFOSS BFP/MS (ø d mm) ø 6 mm ø 8 mm ø 10 mm ø 6 mm ø 8 mm ø 10 mm 0 17 53 100 0 17 53 100 0,5 19 60 100 0,5 15 47 100 1,0 21 66 100 1,0 13 41 99 1,5 23 72 100 1,5 11 34 84 2,0 25 79 100 2,0 9 28 68 2,5 27 85 100 2,5 7 22 53 3,0 29 91 100 3,0 5 15 37 3,5 31 98 100 3,5 3 9 22 4,0 33 100 100 4,0 1 3 6 2800 rpm, 6 mm²/s (cst) 2800 rpm, 6 mm²/s (cst) H m SUNTEC 45/47 (ø d mm) H m SUNTEC 45/47 (ø d mm) ø 6 mm ø 8 mm ø 10 mm ø 12 mm ø 6 mm ø 8 mm ø 10 mm ø 12 mm 0 14 49 123 150 0 14 49 123 150 0,5 16 55 136 150 0,5 12 43 109 150 1,0 18 61 150 150 1,0 10 37 94 150 2,0 22 73 150 150 2,0 7 26 65 138 3,0 25 85 150 150 3,0 3 14 37 78 4,0 29 96 150 150 4,0 0 2 8 18 2850 rpm, 5 mm²/s (cst) 2850 rpm, 5 mm²/s (cst) Dmax = 20 m Hmax = 4,5 m (D-H)max = 4,5 m

5.2. Oil Pumps 10 For KP-6, KP-6 L, KP-6-2 burners Danfoss BFP 21 L3 Suntec AS 47 C 1 Suction line connection 2 Return line connection 3 Nozzle connection 4 Pressure gauge connection 5 Vacuum meter connection 6 Pressure regulation 7 Air venting nipple/plug 8 By-pass plug 9 Filter 10 Solenoid valve, NC 1 Suction line connection 2 Return line connection 3 Nozzle connection 4 Pressure gauge connection 5 Vacuum meter connection 6 Pressure regulation 7 Air venting plug 8 By-pass plug 9 Filter 10 Solenoid valve, NO Oil pump venting Two-pipe system needs no venting as the air comes away when starting the burner. In order to speed up the air removal, the air venting plug or the pressure gauge connection (4) can be loosened. Oil supply to the burner can be noted on the oil pressure gauge fixed to the oil pump or on the oil spray from the nozzle.

For KP-6 LH, KP-6 H-2 burners 11 Danfoss BFP 52E L3 Suntec AT 2 45 C 1 Suction line connection 2 Return line connection 3 Nozzle connection 4 Pressure gauge connection 5 Vacuum meter connection 6 Pressure regulation, stage 1 (P1) 7 Pressure regulation, stage 2 (P2) 8 By-pass plug 9 Filter 10 Solenoid valve, stage 1 normally closed, NC 11 Solenoid valve, stage 2 normally open, NO 1 Suction line connection 2 Return line connection 3 Nozzle connection 4 Pressure gauge connection 5 Vacuum meter connection 6 Pressure regulation, stage 1 (P1) 7 Pressure regulation, stage 2 (P2) 8 By-pass plug 9 Filter 10 Solenoid valve, stage 1 normally closed, NC 11 Solenoid valve, stage 2 normally open, NO Oil pump venting Two-pipe system needs no venting as the air comes away when starting the burner. In order to speed up the air removal, the air venting plug or the pressure gauge connection (4) can be loosened. Oil supply to the burner can be noted on the oil pressure gauge fixed to the oil pump or on the oil spray from the nozzle.

5.3. Oil Filter 12 1 Cover 4 O ring 2 Cup 5 Gasket 3 Element 6 Gasket Cleaning instruction: Unscrew the cup (2) off the cover (1). Clean and check the element (3) and the cup (2). Check, that they are not damaged. Place the gasket (6) on the bolt of the cup and reassemble the element (3) so that the holes at the end of the element are forwards the cover (1). Place the gasket (5) on the element (3). Place the O-ring (4) in its place and screw the cup (2) tight. Check the tightness.

6. Burner Operation Principle See drawings Nos. A-382 A and A-422 K 6.1. 1-Stage Burners, KP-6, KP-6-2 13 When the control device (13) calls for heat the signal lamp lights up and the burner motor (7), which drives the fan (6) and the oil pump (4), starts. An electric arc is created between the ignition electrodes (9). After the pre-purge period has elapsed solenoid valve (10) opens (oil pump BFP 21 L3) / closes (oil pump AS 47 C) and the oil, spraying from the nozzle (11), is ignited by the electric arc. When the flame has established, the burner control will cut the arc and the flame continues to burn. If the flame is not ignited within the safety time, the control unit locks out in the flame failure position and the burner shuts down, and will not start before resetting the control unit. The burner makes then one attempt to start (see above). If the flame is extinguished during normal operation, solenoid valve (10) closes (oil pump BFP 21 L3) / opens (oil pump AS 47 C). The burner makes one normal attempt to start. If the flame is not ignited, the control unit locks out in the flame failure position and the burner shuts down, and will not start before resetting the control unit i.e. by pressing the reset button on the control unit. 6.2. 1-Stage Burner with Preheater, KP-6 L When the control device (13) calls for heat the signal lamp lights up and the preheater (14) heats the oil up to approx. +70 C. When the oil has reached the required temperature the control unit starts the burner motor (7). The operation continues as on burners without preheater.

Drawings Nos. A-382 A and A-422 K 14 Oil pump BFP 21 L3 Oil pump AS 47 C 1 Oil filter 2 Oil, return 3 Oil, suction 4 Oil pump 5 Pressure pipe 6 Burner fan 7 Burner motor 8 Ignition transformer 9 Ignition electrodes 10 Solenoid valve - normally closed, NC (oil pump BFP 21) - normally open, NO (oil pump AS) 11 Nozzle 12 Control unit 13 Control device (thermostat/pressurestat) 14 Preheater, LH burners only

See drawings Nos. A-421 K and A-442K 15 6.3. 2-Stage Burners (H-Burners), KP-6 H-2 The H burners are equipped with a control switch 0-1-2. Switch in position 1 the burner operates at stage 1 only controlled by control device. Switch in position 2 the burner operates normally controlled by control devices. When the control device (18) calls for heat an electric arc is created between ignition electrodes (12) and the air damper servomotor (15) opens the air damper from closed position (position II of the limit switch in servomotor) to the position of stage 1 (position III of the limit switch in servomotor). Burner motor (6), which drives the fan (5) and the oil pump (4), starts. After the pre-purge period has elapsed solenoid valve (7) opens. The oil spraying from the nozzle is ignited by the electric arc. Ignition ends after the time determined by the control unit. The burner operates at stage 1. If the flame is not ignited within the safety time, the control unit locks out in the flame failure position and the burner shuts down, and will not start before resetting the control unit. If the flame is extinguished during normal operation, solenoid valve (7) closes. The burner makes one normal attempt to start. If the flame is not ignited within the safety time, the control unit locks out in the flame failure position and the burner shuts down, and will not start before resetting the control unit i.e. by pressing the reset button on the control unit. When boiler temperature or pressure exceeds the set value for control device of stage 2 (19), the burner operates at stage 1. When the boiler temperature or pressure is below the set value for control device of stage 2 (19), the quantity of air increases and the solenoid valve (8) closes when the limit switch in servomotor is in position V (pump pressure increases). The air damper opens to the position of stage 2 (position of the limit switch I in servomotor). The burner operates at stage 2. When the temperature or pressure exceeds the set value for control device of stage 2 (19), the burner switches on to the position of stage 1. When the temperature or pressure exceeds the set value for control device of stage 1 (18), the burner shuts down (air damper closes). Set the control device of stage 2 (19) to a 5-10 C lower temperature than the control device of stage 1 (18). If the control device of stage 2 (19) is set to a higher temperature than the control device of stage 1 (18), the burner starts at stage 1, but operates the whole operation period at stage 2 and shuts down direct from stage 2, when the set value for control device of stage 1 (18) will be exceeded. 6.4. 2-Stage Burner ( H Burner) with Preheater, KP-6 LH When the control device (18) calls for heat, the preheater (20) heats the oil up to approx. +70 C. When the oil has reached the required temperature, an electric arc is created between the ignition electrodes (12) and the air damper servomotor (15) opens the air damper from the closed position (position of the limit switch II in servomotor) to the position of stage 1 (position of the limit switch III in servomotor). The operation continues as on burners without preheater.

Drawings Nos. A-421K and A-442K 16 Oil pump Danfoss BFP 52E L3 Oil pump Suntec AT 2 45 C 1 Oil filter 2 Oil, suction 3 Oil, return 4 Oil pump 5 Burner fan 6 Burner motor 7 Solenoid valve, stage 1 normally closed, NC 8 Solenoid valve, stage 2 normally open, NO 9 Pressure regulating valve, stage 1 (P1) 10 Pressure regulating valve, stage 2 (P2) 11 Ignition transformer 12 Ignition electrodes 13 Pressure pipe 14 Nozzle 15 Servo motor 16 Air damper 17 Control unit 18 Control device, stage 1 (thermostat/pressurestat) 19 Control device, stage 2 (thermostat/pressurestat) 20 Preheater, LH burners only

7. Burner Automation 17 7.1. 1-Stage Burners Required input signals to the control unit Control signals from the control unit TZ Limit thermostat M1 Burner motor (fan/oil pump) TS Control thermostat T1 Ignition transformer E1 Preheater EV1 Solenoid valve TSW Thermostat of preheater B1 Flame detector/flame signal Prerequisites for start-up burner is getting fuel interlocks are reset contact of switches of control voltage supply in control unit and contacts of thermostats closed, whereupon the control voltage is received to the terminal 1 in control unit. A Start on burner with preheating control signal from terminal 8 in control unit preheater begins to heat up the oil contact of lower limit thermostat (TSW) in preheater closes after time tw (approx. 1 min), when the oil temperature is approx. 70 C, whereupon the control signal is applied to terminal 3 in control unit. A Start on burner without preheating control signal is applied from contact 8 to contact 3 in control unit burner motor (fan/oil pump) starts pre-ignition begins pre-purge begins.

18 B Solenoid valve receives control signal safety time begins (max. 10 s) solenoid valve opens (Danfoss) / closes (Suntec) oil atomising begins flame has to be ignited during the safety time, otherwise the control unit goes to lockout. B Flame ignites flame relay is energised, whereupon terminals 8 and 3 in control unit connect on flame relay's contact. Opening of contact in thermostat of preheater does not stop the burner during flame burner has started post-ignition till operating position of control unit. C Control unit/burner in normal operating position control program of control unit ends burner remains operating supervised by the control unit (flame) and controlled by control thermostat. D Controlled shutdown with control thermostat burner motor stops solenoid valve closes flame extinguishes. See chapter Control Functions in the Event of Faults.

7.2. 2-Stage Burners (H-Burners) 19 Required input signals to the control unit Control signals from the control unit TZ Limit thermostat M2 Servo motor TS1 Control thermostat, stage 1 AD Air damper TS2 Control thermostat, stage 2 T1 Ignition transformer E1 Preheater EV1 Solenoid valve, stage 1 TSW Thermostat of preheater EV2 Solenoid valve, stage 2 M1 Burner motor (fan/oil pump) B1 Flame detector/flame signal Adjustable switching points on the cam switch of the servomotor I = switching point of stage 2 II = switching point of air damper closed position after controlled shut-down III = switching point of ignition load and stage 1 IV = fixed with cam switch III, difference +6 V = switching point of solenoid valve stage 2

20 Prerequisites for start-up burner is getting fuel interlocks are reset contact of switches of control voltage supply in control unit and contacts of thermostats are closed, whereupon the control voltage is received to the terminal 1 in control unit. A Start on burner with preheating control signal from terminal 8 in control unit preheater begins to heat up the oil contact of lower limit thermostat (TSW) in preheater closes after time tw (approx. 1 min), when the oil temperature is approx. 70 C, whereupon the control signal is applied to terminal 3 in control unit. A Start on burner without preheating control signal is applied is applied from contact 8 to contact 3 in control unit pre-ignition begins servomotor runs to switching point III (stage 1/ignition load) via switching point IV burner motor (fan/oil pump) starts in switching point IV pre-purge begins. B Solenoid valve 1 receives control signal safety time begins (max. 10 s) solenoid valve 1 opens oil atomising begins flame has to be ignited during the safety time, otherwise the control unit goes to lockout. B Flame forms flame relay is energised, whereupon terminals 8 and 3 in control unit connect on flame relay's contact. Opening of contact in thermostat of preheater does not stop the burner during flame burner has started post-ignition until operating position of control unit. C Control unit/burner in normal operating position control program of control unit ends control signal for the running time from terminal 5 in the control unit if the burner control switch is in position 2 and the contact of thermostat of stage 2 is closed, servomotor runs to switching point I (position of stage 2 of air damper) solenoid valve of stage 2 opens under control of limit switch V in servomotor burner remains operating supervised by control unit (flame) and controlled by thermostat of stage 2 at stage 2 or at stage 1. D Controlled shutdown with control thermostat of stage 1 burner motor stops solenoid valves close flame extinguishes servomotor runs to switching point II (air damper closed) See chapter Control Functions in the Event of Faults.

8. Burner Adjustment 21 8.1. Capacity Regulation Adjust the burner output by changing the size of the nozzle or the oil pump atomising pressure. Combustion air quantity and position of the adjustment ring must be checked after having the nozzle changed. When removing nozzle, two set spanners are needed; one to support the nozzle holder. The marking giving information on the nozzle capacity *) The marking according to CEN standard. Kg/h is valid at an atomising pressure of 10 bar, viscosity of 3,4 mm²/s (cst) and density of 840 kg/m³. In this case the nozzle is marked with EN. **) The marking according to USgal/h. US gallon is valid at an atomising pressure of 7 bar, viscosity of 3,4 mm²/s (cst) and density of 820 kg/m³. Select the nozzle size according to the boiler capacity. *) Nozzle selection according to CEN-standard P kg/h = Ha η kp Also the following formula gives the pressure factor: kp = P2 P1 P = boiler capacity in kw Ha = lower calorific value for fuel oil in kwh/kg η = 0,80-0,95 (efficiency 80-95 %) kp = pressure factor (see table) P1 = 10 bar (according to CEN standard) P2 = pressure to be used Calculation example: Nozzle for a boiler of 100 kw with an efficiency of 0,80 and pressure to be used is 9 bar. 100 nozzle kg/h = = 11kg/h 11,86 0,80 0,95 **) Nozzle selection according to USgal/h P USgal/h = Ha η 3,2 kp 1 USgal = approx. 3,2 kg of oil P1 = 7 bar (according to USgal/h) Calculation example: Nozzle for a boiler of 100 kw with an efficiency of 0,80 and pressure to be used is 9 bar. 100 nozzle USgal/h = = 11,86 0,80 3,2 1,13 Pressure factor table 2,9 USgal/h Oil pressure bar 7 8 9 10 11 12 13 14 15 16 P2 kpa 700 800 900 1000 1100 1200 1300 1400 1500 1600 Pressure CEN *) 0,84 0,89 0,95 1 1,05 1,10 1,14 1,18 1,22 1,26 factor P1=10 bar kp USgal/h **) P1=7 bar 1 1,07 1,13 1,20 1,25 1,31 1,36 1,41 1,46 1,51 Oil pressure bar 17 18 19 20 21 22 23 24 25 P2 kpa 1700 1800 1900 2000 2100 2200 2300 2400 2500 Pressure CEN *) 1,30 1,34 1,38 1,41 1,45 1,48 1,52 1,55 1,58 factor P1=10 bar kp USgal/h **) P1=7 bar 1,56 1,60 1,65 1,69 1,73 1,77 1,81 1,85 1,89 To convert kg/h into l/h, divide kg/h by the density of fuel oil (0,833 g/cm³). On burners KP-6 L and -6 LH the nozzle capacities are approx. 10-15 % smaller than on burners KP-6, -6-2 and -6 H-2.

22 8.1.1. Oil Pump Pressure Regulation 1-stage burners Fit a pressure gauge in the connection (see chapter Oil Pumps ). Adjust the oil pressure by turning the pressure regulating screw. The pressure increases by turning the screw clockwise and decreases counter-clockwise. When the pressure is altered the oil flow and pressure follow the following formula: V1 V2 = P1 P2 V1 = capacity marked on the nozzle V2 = nozzle capacity at a pressure of P2 P1 = 7 bar gives USgal/h 10 bar gives kg/h according to CEN-standard P2 = pressure to be used Calculation example according to CEN-standard. Nozzle capacity when the nozzle size is 11 kg/h and pressure 13 bar. V1 V2 = P1 => V2 = V1 P2 P2 P1 = 11kg/h 13 bar 10 bar = 11kg/h 1,14 = 12,5 kg/h 2-stage burners The oil pump gives two different pressures to the nozzle. Changing the nozzle pressures by means of the pressure regulating screw regulates the pump s capacities 1 and 2. Capacity 1 must be 55-70 % of the calculated capacity. Design values for nozzle pressures: stage 1: 8-10 bar stage 2: 20-25 bar When adjusting the oil pressures, note that the burner capacity must remain on the capacity range indicated on the type plate. Calculation example according to CEN-standard. Nozzle for a boiler of 100 kw with an efficiency of 0,80 and pressure to be used for stage 2 is 21 bar. 100 nozzle kg / h = = 7,27 kg / h 11,86 0,80 1,45 => select nozzle of 7,10 kg/h Capacity 2, which can be reached by the nozzle at a pressure of 21 bar: 21 bar 7,10 kg / h = =10,3 kg/h 10 bar Capacity 1 must be 55-70 % (0,55-0,70) of the calculated capacity of the nozzle: 10,3 kg/h x 0,63 = 6,49 kg/h Nozzle pressure of capacity 1 is thus: V1 = V2 P1 P2 V1 => V2 2 2 P1 = P2 P1 => P2 = ( V2) 2 ( V1) 2 10 bar P2 = ( 6,49 kg/h) 2 ( 7,10 kg / h) 2 = 8,4 bar The pressure of capacity 1 must be at least 7 bar.

8.2. Combustion Head Adjustment 23 8.2.1. Setting the Nozzle and the Ignition Electrodes The following drawing shows the distance of the nozzle (4) from the diffuser disc (6). Set the ignition electrode spark gap and distance from the diffuser disc (6) and from the nozzle (4) as shown on the drawing. 1 Mounting flange 5 Ignition electrode(s) 2 Retaining screw 6 Diffuser disc 3 Flame tube 7 Adjustment ring 4 Nozzle

24 8.2.2. Adjusting the Air Velocity in the Combustion Head Adjust the air velocity in the combustion head by loosening the locking screw (4) of the adjustment ring and moving the ring in the direction of the flame tube (1) to change the distance between the adjustment ring and the edge of the diffuser disc (2). At low capacity the adjustment ring (3) is advanced and at high capacity retracted. If the adjustment ring is too far forward at the set full load, the air velocity in the combustion head is too high. Hence it follows, that the ignition is more difficult or there is not enough air to support combustion. If the adjustment ring is too far back with respect to the capacity, the air velocity in the combustion head is too low. Hence it follows, that the combustion values become worse. Check the combustion values by means of flue gas analysis. The following drawing shows the way to measure the distance of the adjustment ring (3) and the directive L-measure in relation to the nozzle of stage 1. The measurement must be carried out from the back edge of the adjustment ring to the back edge of the diffuser disc (2). The measurement can be made for example with a calliper rule. 1 Flame tube 3 Adjustment ring 2 Diffuser disc 4 Locking screw for adjustment ring L mm STAGE 1 kg/h Note! If the position of the adjustment ring has to be altered in relation to the diffuser disc, the air velocity and quantity in the combustion head will change. Check the combustion values by flue gas analysis and, if necessary, adjust the combustion air quantity to be adequate.

8.3. Combustion Air Adjustment 25 8.3.1. 1-Stage Burners Loosen the locking screw (1) and turn the air adjustment ring (4) from the indicator (2). The indicator shows the position of the adjustment ring. When the right air quantity has been found, retighten the locking screw. 1 Locking screw for adjustment ring 2 Indicator 3 Air intake 4 Adjustment ring Position of Nut on Adjustment Ring The adjustment ring has three slots for the nut of the locking screw. On burners KP-6, KP-6 L and KP-6 H-2 the nut is placed on the middle slot (pre-set at the factory.

8.4. 2-Stage Burners ( H Burners) 26 Functions of cam discs in servomotor SQN Set the switching points of cam discs manually or by turning with the adjusting key. II: Air damper closed /( ). The adjustment has been made at the factory. III: Air damper position at stage 1/( ) V: Solenoid valve of stage 2 I: Air damper position at stage 2/( ) The setting of the disc V should preferably be as high as possible, not, however, so high that the flame does not react when changing over from stage 2 to stage 1 (the setting of the disc V is between discs III and I). The servomotor is provided with a release lever (5). When the lever is pressed down, the air damper can be moved by hand. Note! Difference III - I must be at least 10 on the scale. Set the final settings of the air damper (= combustion air) to be correct by means of flue gas analysis. Cam disc positions in principle 1 Air regulation, stage 2 4 Control of solenoid valve for stage 2 2 Air damper closure 5 Release lever 3 Air regulation, stage 1 6 Adjusting key

8.5. Air Cone Position 27 If the air cone has to be replaced or removed, it has to be installed in the right position with respect to the burners housing. The right position is shown in the drawing below. After replacement check by turning the fan wheel by hand, that it does not touch the cone. The fan wheel can be turned after loosening the sight glass. 1 Burner housing 2 Air cone 3 Tip of air cone 4 Sight glass 8.6. Flame Inspection The ignition process may be observed through the sight glass by turning aside the cover. It must be replaced in the normal operating position after inspection. Inspection position Operating position

9. Control Unit LOA24/BHO64 28 9.1. Time Sequence Diagram (Control Program) Required input signals to the control unit Control signals from the control unit Legend TZ Limit thermostat TS Control thermostat E1 Preheater TSW Thermostat for preheater M1 Burner motor (fan/oil pump) T1 Ignition transformer EV1 Solenoid valve, stage 1 EV2 Solenoid valve, stage 2 B1 Flame detector/flame signal tw Heating up time of oil preheater up to the readiness signal given by contact OW approx. 1 min t1 Pre-purge time approx. 13 s t3 Pre-ignition time approx. 13 s t3n Post-ignition time approx. 15 s t2 Safety time max 10 s t4 Interval between detection of flame and release of terminal 5 approx. 15 s --- Reaction time on flame failure < 1 s A' A B C D Commencement of start-up with burners with oil preheater. Commencement of start-up with burners without preheater. Time, when flame is detected (burner started). Control unit (burner) in normal operating position (control program has ended). Controlled shutdown by control thermostat TS.

29 9.2. Control Functions in the Event of Faults Extraneous light / premature flame signal During pre-purge and/or pre-ignition period there must never be a flame signal. If there is a signal during this period, caused possibly by premature ignition due to a leaking oil valve, extraneous light, a short-circuit in the flame detector (photo resistor) or its wiring, a fault in the flame signal amplifier, etc., the control unit locks out on expire of the pre-purging and safety period. Under these circumstances the oil valve does not open during the safety time. Non-appearance of the flame signal If no flame signal has appeared by the end of the safety period, the control unit immediately locks out. Flame failure during operation On flame failure during operation the control unit immediately shuts down the fuel supply and automatically attempts to restart. On completion of t4 the control unit performs the full starting sequence. With every lockout control outputs 3 to 8 and terminal 11 are de-energised in less than 1 second, while terminal 10 for the remote signalling of lockouts receives voltage. Resetting the control is possible only when, after lockout, at least 50 seconds have elapsed. Protection against under-voltages The electronic protection against under-voltages ensures that in the event of mains disturbances with dangerous under-voltages (< 165 V) the control unit shuts down the burner and prevents a new start-up. 9.3. Technical Data of Control Unit Supply voltage 220 VAC -15 %...240 VAC +10 % Protection against under-voltages < 165 V Frequency 50-60 Hz, ± 6 % External fuse max. 10A Permissible ambient temperature -20...+60 C 9.4. Current through Flame Detector Photo resistor (flame detector) QRB 220 VAC 240 VAC Min. required detector current with flame 65 µa DC 75 µa DC Max. permissible detector current without flame 5 µa DC 6 µa DC Max. possible detector current with flame 200 µa DC 220 µa DC Internal resistance of the d.c. measuring instrument max. 5 kohm (+pole to terminal 12)

9.5. Measurement of Flame Signal 30 WARNING! This control unit is a safety unit! Do not open it. Any unauthorised tampering can result in unforeseen detrimental consequences.

10. Maintenance 31 WARNING! Always switch off the electric power from your burner and shut the manual shut-off valves in the fuel supply line before servicing your burner. When inspecting your burner you only have to switch off the electric power from your burner. The manual shut-off valves in the fuel supply line can then be open. Burner maintenance In order to ensure reliable operation clean the ignition electrodes and check their setting. Flame detector has to be kept clean. Clean filters if necessary. Change the nozzle if it is worn or damaged. Clean your burner from damp and other airborne impurities and keep the burner clean. Check regularly the combustion values by flue gas analysis (for ex. always after the refilling of the storage tank or at least once a year). An authorised person should inspect the burner at least once a year. Heating appliance control Keep the boiler room always clean and the door closed. Make sure, that there is always sufficient water (pressure) in the heating system. Have the furnace and the chimney swept regularly. Check regularly, that the smoke damper is correctly adjusted. Protect your burner against splash water. The oil tank must be cleaned when needed, at least every 4-5. years. The boiler room fresh air ventilator must be open. Check safety devices of heating appliance and burner according to the local requirements. Check that the boiler and its equipment are on working condition.

32 11. Fault Conditions and Procedures In the event of fault conditions the basic requirements for correct operation must be first examined: 1. Check the electric supply (control voltage). 2. Check that all control devices are correctly set. 3. Are the safety devices in normal operating condition? 4. Is the burner getting fuel, are the valves in fuel line open, is there oil in the tank? When it is established, that the fault is not due to above mentioned, the individual burner functions must be checked. Reset the burner control unit if it is in lockout position (signal lamp lights). Burner starts. Observe the burner functions. Measuring instruments can be used for finding of the fault. CAUTION POSSIBLE CAUSE REMEDY 1. Motor Burner motor does not start Break in motor control circuit: - faulty control unit - faulty preheater ( LH burners) - faulty air damper servomotor ( H burners) - incorrect setting on cam disc of the servomotor ( H burners) Find cause and remedy Replace control unit Replace Replace Correct setting 2. Ignition failure Burner motor starts, control voltage from control unit to ignition transformer is switched on, no ignition and after a short time lockout occurs. Faulty motor Dirty or worn ignition electrodes, insulator cracked Incorrect position of ignition electrodes Damaged ignition cable Faulty ignition transformer Replace Clean or replace Adjust according to instructions Replace Replace 3. No flame establishment Burner motor starts, ignition is in order, after a short time lockout occurs. Solenoid valve does not function: - faulty solenoid valve or coil or cable damaged - faulty control unit. Main solenoid valve does not function: - incorrect setting on cam disc of the servomotor Replace faulty part Correct setting Nozzle supplies no oil Oil atomising pressure too low Blocked or worn nozzle See section Oil pumps Clean or replace

33 CAUTION POSSIBLE CAUSE REMEDY 4. Oil pump Supplies no oil or atomising pressure is too low Dirty filter Clean Leaking suction line Seal Nozzle supplies no oil Severe mechanical noise Pump capacity decreases: - faulty or worn pump Valve does not open to the nozzle: - solenoid valve (pump AS 47 C) does not close - solenoid valve (other pump types) does not open Pump sucks air Vacuum in oil piping too high Replace Replace solenoid valve coil or pump Tighten joints Clean filter Check size of suction line 5. After flame establishment lock-out Flame forms. When burner Incorrect burner adjustment runs to stage 2, lockout occurs and then re-start Dirty filters (H-burners). Blocked nozzle Faulty solenoid valve Correct adjustment Clean Replace Replace 6. Premature flame formation Burner motor starts, then lockout occurs. Leaking valves Clean or replace 7. Flame monitoring fault (=lock-out) Burner motor starts, flame forms, then lock-out occurs Incorrect position of flame detector Dirty flame detector Too weak flame (illumination) Faulty flame detector Faulty control unit Correct Clean Check burner adjustments Replace Replace Lock-out during pre-purge period Faulty flame detector Faulty control unit Replace Replace

34 CAUTION POSSIBLE CAUSE REMEDY 8. Combustion head Inside oily or has heavy carbon deposits Distance between diffuser disc and nozzle incorrect Correct adjustment Incorrect combustion air adjustment Boiler room not adequately ventilated Nozzle incorrect sized or of wrong type Nozzle worn Incorrect position of adjustment ring Adjust Increase air supply Change nozzle as appropriate Replace Adjust

12. Notes 35 Boiler type Burner type Burner serial No. Date of installation Installed by Miscellaneous