M5178 1647EN

20 December 2016

Operation and maintenance manual

GKP-350 M - 450 M WD100, WD200, FGR

Read these instructions carefully before installation, use, or maintenance

Original instructions
 Contents

1 Introduction

1.1 Liability disclaimer....................................................................................... 5

1.2 Safety precautions...................................................................................... 5
1.3 Product overview.........................................................................................8
1.4 Flue gas recirculation (optional)............................................................... 10
1.5 Handling and storing.................................................................................11

2 Technical data

2.1 Burner technical data................................................................................12

2.2 Profibus module technical data................................................................ 13
2.3 Flame detector technical data.................................................................. 14
2.4 Burner control technical data....................................................................15
2.5 Servomotor technical data........................................................................ 17
2.6 Display and operating unit technical data.................................................17
2.7 O2 module technical data (WD200)..........................................................18
2.8 Oxygen sensor technical data (WD200)...................................................18

3 Installation

3.1 Space requirements.................................................................................. 19

3.2 Removing protective covers and lifting the burner................................... 19
3.3 Mounting burner........................................................................................ 21
3.4 Gas valve selection table......................................................................... 24
3.5 Installing burner to gas supply line...........................................................24
3.6 Installing gas pressure regulating assembly.............................................25
3.7 Installing gas nozzle adjusting band (LPG).............................................. 27
3.8 Installing hoses......................................................................................... 28
3.9 Oil supply site diagram, example............................................................. 29
3.10 Connecting to oil line................................................................................ 30
3.11 Installing FGR duct system.......................................................................30
3.12 Electrical connections............................................................................... 32

4 Commissioning

4.1 First start-up.............................................................................................. 34

4.2 Nozzle selection........................................................................................ 35
4.3 Adjusting combustion head.......................................................................39
4.4 Setting ignition electrodes.........................................................................39
4.5 Adjusting supply oil pressure....................................................................40
4.6 Oil pump....................................................................................................40
4.7 Adjusting atomizing pressure....................................................................44
4.8 Oil pump coupling components and adjusting..........................................45
4.9 Adjusting combustion differential air pressure switch............................... 46
4.10 Adjusting gas pressure switch.................................................................. 48
4.11 Setting variable speed module parameters.............................................. 49
4.12 Setting gas pressure regulator SKP......................................................... 51
4.13 Setting gas pressure regulator FRS......................................................... 53

M5178 1647EN 1 (129)

 4.14 Measuring gas pressure........................................................................... 55
4.15 Operating and display unit menu..............................................................56
4.16 Adjusting operating and display unit settings........................................... 59
4.17 Setting frequency converter parameters (WD200)................................... 60
4.18 Frequency converter settings and standardization (WD200)....................60
4.19 Checking O2 module (WD200)................................................................. 61
4.20 Manual start-up and program stop in pre-purge position..........................62
4.21 Ignition position......................................................................................... 64
4.22 Setting ratio curve.....................................................................................66
4.23 Activating FGR.......................................................................................... 70
4.24 Setting FGR curve points......................................................................... 71
4.25 Measuring FGR.........................................................................................72
4.26 Capacity range.......................................................................................... 73
4.27 O2 min. value control (WD200)................................................................ 74
4.28 Setting O2 trim control (WD200)...............................................................76
4.29 O2 trim control operating mode (WD200).................................................78
4.30 O2 trim control load limitation (WD200)....................................................78
4.31 O2 trim control when load changes (WD200)...........................................79
4.32 Setting capacity controller operating mode.............................................. 79
4.33 Setting capacity controller parameters..................................................... 81
4.34 Capacity controller on/off.......................................................................... 85
4.35 Boiler temperature limiting with burner control......................................... 85
4.36 Cold start thermal shock protection..........................................................86
4.37 Measuring flue gas and combustion air temperature (WD200)................ 87
4.38 Activating O2 trim control (WD200).......................................................... 87
4.39 Backing up parameters.............................................................................88

5 Operation

5.1 Burner operation....................................................................................... 89

5.2 General description of burner operation................................................... 92
5.3 Gas valve proving..................................................................................... 94
5.4 Legend to time sequence diagrams......................................................... 94
5.5 Time sequence diagram, gas use............................................................ 98
5.6 Burner automation description, gas use................................................. 100
5.7 Time sequence diagram, oil use............................................................ 103
5.8 Burner automation description, oil use................................................... 103

6 Maintenance

6.1 Burner maintenance................................................................................106

6.2 Dismounting combustion head............................................................... 107
6.3 Dismounting and changing burner motor............................................... 108
6.4 Dismounting and changing servomotors................................................ 109
6.5 Oil filter.................................................................................................... 113
6.6 Nozzle valve operation and maintenance RPL-1................................... 114
6.7 Oil regulator............................................................................................ 115
6.8 Testing safety and control devices......................................................... 116
6.9 Fault and lockout history........................................................................ 119
6.10 Frequency converter (WD200)............................................................... 121
6.11 Adjusting gas valve proving....................................................................121
6.12 Troubleshooting.......................................................................................122
6.13 Troubleshooting error codes...................................................................127
6.14 Burner parts............................................................................................ 128

2 (129) M5178 1647EN

 6.15 Burner part list........................................................................................ 129

M5178 1647EN 3 (129)

4 (129) M5178 1647EN
 1 Introduction

1.1 Liability 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.

1.2 Safety 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.

M5178 1647EN 5 (129)

 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.

6 (129) M5178 1647EN

 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.

M5178 1647EN 7 (129)

 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.

1.3 Product 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 motor output components of the fan motor (short-circuit protection, thermal
protection, contactor) must be designed according to the site. The motor output
components are located in the customer’s system, and they are described in the
electrical diagram.

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.

8 (129) M5178 1647EN

 Information on components can be found under the headline Burner parts.

Type labelling

POLTINKOODI ver. 2

Label element 1: Fuel

KP Light fuel oil

RP Heavy fuel oil
GP Gas
GGP Dual gas
GKP Gas, light fuel oil
GRP Gas, heavy fuel oil

Label element 2: Burner size categorization

Label element 3: Method of control

H Two-stage
M Modulating
MH Modulating gas, two-stage oil
ME Modulating with a separate fan

Label element 4: Additional code, for example burner capacity I-III or automation, like
WD34

Type plate

The following illustration shows an example of the type plate of Oilon burners:

M5178 1647EN 9 (129)

 Type plate US ver. 1

Pos. Description Pos. Description

1 Burner type: 9 Degree of protection
KP = Light fuel oil
RP = Heavy fuel oil
GP = Gas
GKP = Light fuel oil and gas
GRP = Heavy fuel oil and gas
2 Overfire pressure min, IN.WC 10 Serial number
3 Overfire pressure max, IN.WC 11 Month and year of manufacture
4 Gas calorific value, BTU/scf 12 Capacity, gas, MBTU/hr
5 Gas type 13 Capacity, light fuel oil, GPH
6 Oil quality / viscosity 14 Gas pressure min, IN.WC
7 Supply voltage, input power and current, 15 Gas pressure max, IN.WC
V / Hz / A / kW
8 Manufacturer address 16 L LC US marking and certification
institute code

1.4 Flue gas recirculation (optional)

The flue gas recirculation (FGR) reduces the NOx content of flue gases. A certain
proportion of flue gas is led back to the combustion chamber, which causes the flame
temperature to drop. This influences the NOx content of flue gas.

In general, the amount of recirculated flue gas must be adjusted to the smallest
possible quantity needed to obtain the required NOx rate. The flue gas quantity is
adjusted with the throttle valve located on the FGR pipe.

If the quantity of recirculated flue gas is excessive the flame may become instable and
the CO rate may increase. The amount of flue gas to circulate is set on the control
panel. To optimize the result, burner is adjusted to operate according to preset FGR-
curves.

For detailed information and instructions, see the chapters Installation and
Commissioning.

10 (129) M5178 1647EN

 1.5 Handling 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.

M5178 1647EN 11 (129)

 2 Technical data

2.1 Burner technical data

Burner data

Burner GKP-450 M
Capacity gas, MMBtu/h 2.90 - 18.77
Capacity oil, MMBtu/h 7.51 - 18.77
Capacity oil, lb/h 408 - 1014
Max. turndown ratio, gas 1:6 (100–16.6%)
Max. turndown ratio, oil 1:2.5 (100–40%)
Nominal oil pump motor output, hp 10
Motor current A 19.4
Motor speed r/min 2940
Oil inlet pressure to pump PSI 14.5 - 72.5
Oil operating pressure (atomizing pressure), PSI 290 - 300
Oil regulator return flow pressure, ignition position 72 - 102
PSI
Oil regulator return flow pressure, partial load PSI 102 - 131
Input power hp 17
NO x-class Natural gas (2nd family): 1
Light fuel oil: 1
Weight kg 1113

Other technical data and requirements

Fuel, gas use Natural gas

Make sure the used gas is clean and non-condensed.
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. 10 PSI
Max. demand of combustion air, gas use 13.5 cfh/MBtu

DO NOT USE GASOLINE, CRANKCASE OIL, OR ANY OIL

CONTAINING GASOLINE.

Fuel, oil use # 2 fuel oil

Efficiency, # 2 fuel oil 2.20 lb ≈ 40.46 MBtu efficiency, when heat value is 1146.03
Btu/ft³
Max. demand for combustion air, oil use 529.72 cfh/lb

Control voltage 120 V (-15%...+10%) 50 Hz / 60 Hz 1-phase

Motor voltage 460 V 60 Hz 3-phase

12 (129) M5178 1647EN

 Ambient temperature range 0...+ 105 °F
Degree of protection NEMA 3

Working diagram

Working diagram ver. 3

Working diagram ver. 1

dashed line = oil

solid line = gas

2.2 Profibus module technical data

Profibus module PBM100

Power supply 24 VDC
Power consumption 100 mA
Electromagnetic compatibility EMC 2014/30/EC
Permissible ambient temperature -20...+60°C
-4...+140°F
Lengths of cables
Supply 24 VDC < 10 m
< 33 ft
LSB (screened) max. 100 m
max. 328 ft
PROFIBUS (screened) 100 m
328 ft

M5178 1647EN 13 (129)

 Profibus diagram ver. 1

Terminals may not be connected!

1 CAN/LSB
2 DC power supply (safety extra low voltage)

2.3 Flame detector technical data

QRI
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 1.8 m
max. length 5.9 ft
Auxiliary detector cable 100 m
max. length 328 ft
Protection degree NEMA 3
Permissible operation ambient temperature -20...+60 °C
-4...+140 °F

● integrated signal amplifier

● continuous or interrupted use
● mains frequency filtering
● does not detect ignition spark
● spectral sensitivity range ~1…3 μm
● QRI2A2.B180B frontal illumination
● QRI2B2.B180B lateral illumination.

14 (129) M5178 1647EN

 QRI connection

QRI connection ver. 1

A Black X10-02 / 6 Signal line

B Blue X10-02 / 4 Reference line
C Brown X10-02 / 2 Power line

2.4 Burner control technical data

Burner control LMV5...

Mains voltage 120 VAC –15/+10 %
Locking during undervoltage conditions < 96 VAC
Transformer / primary side 120 VAC
Transformer / side 1 12 VAC
Transformer / side 2 2 x 12 VAC
Mains frequency 50–60 Hz 6 %
Power consumption < 30 W
Permissible input current / differential air pressure 0.5 A / 230 VAC -15/+10 %
switch
Permissible input current / status input 1.5 mA/120 VAC -15/+10 %
Perm. current rating of control terminals 5 A / 120 VAC -15/+10 %
● fan motor contactor  
● burner failure ● 1 A/120 VAC -15/+10 %
● ignition transformer ● 1 A/120 VAC -15/+10 %
● gas valves ● 1.6 A/120 VAC -15/+10 %
● oil valves ● 1.6 A/120 VAC -15/+10 %
● 1.6 A/120 VAC -15/+10 %
Permissible operation ambient temperature -20...+60 °C
-4...+140 °F

M5178 1647EN 15 (129)

 Block diagram of contact links

Block diagram ver. 5

16 (129) M5178 1647EN

 Inputs / outputs (VSD)

Connection diagram ver. 3

2.5 Servomotor technical data

Servomotor SQM45... SQM48.497 SQM48.697

Mains voltage 2 x 12 VAC 2 x 12 VAC 2 x 12 VAC
Power consumption 9 – 15 VA 26 – 34 VA 26 – 34 VA
Angular adjustment 90° 90° 90°
Accuracy ±0.2° ±0.2° ±0.2°
Torques, operation / 3 / 1.5 Nm 20 / 20 Nm 35 / 35 Nm
holding 26.55 / 13.27 lbf·in 177 / 177 lbf·in 310 / 310 lbf·in
Running time 10 s 30 s 60 s
Degree of protection NEMA 3 NEMA 3 NEMA 3
Permissible ambient -20...+60 °C -20...+60 °C -20...+60 °C
temperature -4...+140 °F -4...+140 °F -4...+140 °F

2.6 Display and operating unit technical data

Display and operating unit AZL...

Mains voltage 24 VAC –15/+10 %
Power consumption <5W
Protection degree NEMA 3
Battery 3 V Lithium
Battery, Varta CR 2430
Battery, Duracell DL 2430
Permissible operation ambient temperature -20...+60 °C
-4...+140 °F

Protect the equipment from condensation, ice and water ingress.

M5178 1647EN 17 (129)

 2.7 O2 module technical data (WD200)

O2 module PLL52...
Mains voltage, sensor heating 110 VAC –15/+10 %
Mains voltage 2 x 12 VAC
Power consumption 4 VA
Analog inlet, oxygen sensor QGO20.000D27
Analog inlet, combustion temperature Pt1000 / LG-Ni 1000
Analog inlet, flue gas temperature Pt1000 / LG-Ni 1000
Analog inlet, bus interface CAN
Protection degree NEMA 3
Permissible ambient temperature -20...+60 °C
-4..+140 °F

Protect the equipment from condensation, ice and water ingress.

2.8 Oxygen sensor technical data (WD200)

Oxygen sensor QGO20...

Measuring cell ceramic zirconium dioxide cell
Mains voltage, measuring cell heating 110 VAC –15/+10 %
Power consumption max. 90 W, typically 35 W
Measuring cell temperature 700 °C ±50 °C
1292 °F ±122 °F
Measuring range 0.2…20.9 % O2
Flue gas velocity 1…10 m/s
3.28...32.81 ft/s
Protection degree NEMA 2
Max. temperature, flange +250 °C
+482 °F
Max. temperature, connecting head +70 °C
+158 °F
Max. temperature, flue gas +300 °C
+572 °F

Protect the equipment from condensation, ice and water ingress.

18 (129) M5178 1647EN

 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.

Minimum Minimum
Legend
dimension, cm dimension, ft
a 80 2.6
(left)
b 80 2.6
(front)
c 80 2.6
(right)
d 100 3.3
(top)

Space requirements ver. 1

It is recommended to leave more space around the burner. These are only the
minimum requirements.

3.2 Removing protective covers and lifting the 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.

If you set the burner on a pallet, always remove the oil filter.

M5178 1647EN 19 (129)

 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.

Use hexagonal key to remove and attach protective covers.

D042848 ver. 1

Pos. Item
1 End cover
2 End cover, fastening screws, 2 pcs
3 Frame cover (15 kg / 33 lbs)
4 Frame cover, tightening screw, 1 pcs
5 Frame cover, fastening screws, 2 pcs
6 Electric casing protective cover
7 Electric casing protective cover, fastening screws, 6 pcs

To remove protective covers

1. Loosen the screws of the end cover and remove the cover.
2. Loosen the tightening screw of the frame cover, and also remove its fastening
screws. Draw the cover about 20 mm (0.79 inch) towards yourself and remove it.
3. Loosen the screws of electric casing protective cover, and remove the cover.
4. Reassemble covers in reverse order.

To lift the burner

Remove end cover before placing the lifting straps. Use lifting straps or chains with
hooks to lift the burner as shown in the illustration. Protect the burner from possible
friction during lifting.

20 (129) M5178 1647EN

      
     
     
     
     
  1 Burner
  2 Lifting lug (1 pcs)
  3 Lifting eyes (2 pcs)
  4 Lifting straps
  5 Lifting hook
     
     
     
     
     
     

D046885 ver. 1

3.3 Mounting burner

● Coat bolt threads with graphite-bearing grease before fitting.
● Fasten burner to boiler in accordance with the given dimensions.
● Install burner so that motor axle is on horizontal level. Do not install burner upside
down.
● Install burner so that it can be turned fully open and combustion head can be
detached.
● Remove transportation support after fastening.
● Protect the burner from weather conditions during installation and when installed.

Install burner firmly. Vibration may damage burner or its components.

M5178 1647EN 21 (129)

 Burner mounting dimensions (mm)

L1 L2
H2

H4

D1
H1

L4

H3
L5 B2 B1

B3

L3
D042664 ver. 1

Burner Dimensions in mm
  L1 L2 L3 L4 L5 H1 H2 H3 H4 B1 B2 B3 D1
450 M 1470 350 342 193 335 770 304 395 125 500 650 550 370

Burner Dimensions in inch

  L1 L2 L3 L4 L5 H1 H2 H3 H4 B1 B2 B3 D1
450 M 57.87 13.78 13.46 7.60 13.19 30.31 11.97 15.55 4.92 19.69 25.59 21.65 14.57

22 (129) M5178 1647EN

 Combustion head mounting dimensions

60
-90
L2

°
D3
4 xø

øD1

øD2

L2
øD4

L1
D042316 ver. 3

Pos. Item Pos. Item

1 Gasket, 10 mm / 0.39 in 3 Ceramic wool or similar
2 Mounting plate, 20 mm / 0.39 in 4 Refractory

Burner Dimensions in mm Fastening

screws
  D1 D2 D4 L1 L2 D3
450 M 370 440 440 350 465 M20

Burner Dimensions in inches Fastening

screws
  D1 D2 D4 L1 L2 D3
450 M 14.57 17.32 17.32 13.78 18.31 M20

M5178 1647EN 23 (129)

 3.4 Gas valve selection table

BURNER GAS VALVE BURNER CAPACITY RANGE kW

GAS INLET PRESSURE
SIZE TYPE 20 mbar 30 mbar 50 mbar 100 mbar 150 mbar
350 M DN 50 DMV-D   1700 2200 3100 3800
DN 65 DMV 2000 2500 3300 4400 4400
DN 80 DMV 2800 3400 4400 4400 4400
DN 100 DMV 3300 4100 4400 4400 4400
DN 125 DMV 3800 4400 4400 4400 4400
450 M DN 50 DMV-D     2200 3200 3900
DN 65 DMV   2600 3300 4700 5500
DN 80 DMV 3000 3700 4800 5500 5500
DN 100 DMV 3800 4600 5500 5500 5500
DN 125 DMV 4700 5500 5500 5500 5500

BURNER GAS VALVE BURNER CAPACITY RANGE MMBtu/h

GAS INLET PRESSURE
SIZE TYPE 8 in.WC 12 in.WC 20 in.WC 40 in.WC 60 in.WC
350 M DN 50 DMV-D   5.8 7.5 10.6 13.0
DN 65 DMV 6.8 8.5 11.3 15.0 15.0
DN 80 DMV 9.6 11.6 15.0 15.0 15.0
DN 100 DMV 11.3 14.0 15.0 15.0 15.0
DN 125 DMV 13.0 15.0 15.0 15.0 15.0
450 M DN 50 DMV-D     7.5 10.9 13.3
DN 65 DMV   8.9 11.3 16.0 18.8
DN 80 DMV 10.2 12.6 16.4 18.8 18.8
DN 100 DMV 13.0 15.7 18.8 18.8 18.8
DN 125 DMV 16.0 18.8 18.8 18.8 18.8

If the gas inlet pressure is less than 30 mbar / 12 in.WC or if some other
gas except natural gas is used, case-specific evaluation must be made.

The max. capacities shown in the table are achieved when the boiler
back pressure is 0.

3.5 Installing 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. 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.

24 (129) M5178 1647EN

 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.

3.6 Installing gas pressure regulating assembly

Installing pressure regulator

Consider the following factors when selecting pressure regulator:

● 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.

M5178 1647EN 25 (129)

 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. Follow the local legislation when you set the safety
relief valve to open at a higher pressure than the secondary pressure (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.

Example of gas pressure regulating assembly

B311Z ver. 4

Pos. Item Pos. Item

1 Gas pressure regulating assembly 9 Bellows compensator/gas hose
2 Ball valve 10 Safety shut-off valve, if not incl. in press.
regulator
3 Gas filter 11 Safety relief valve, if not incl. in press.
regulator
4 Pressure gauge valve 12 Blow-off, when necessary
5 Pressure gauge, high pressure 13 Pressure gauge valve, when necessary

26 (129) M5178 1647EN

 Pos. Item Pos. Item
6 Pressure regulator with safety shut-off 14 Pressure gauge, high pressure, when
valve and safety relief valve necessary
7 Pressure gauge valve 15 Fuel flow meter, can also be on low
pressure side, when necessary
8 Pressure gauge, low pressure 16 Pressure regulator

3.7 Installing gas nozzle adjusting band (LPG)

This information applies only when liquified petroleum gas (LPG) is

used.

1 Adjusting band
2 Gas nozzle
Fixing screw of adjusting
3
band

SAATOPANTAIMG ver. 2

When using liquified petroleum gas (LPG), install the adjusting band in the gas nozzle
to adjust the square area of the nozzle apertures.
● By default, the adjusting band is installed to overlap the apertures by approx. 50 %.
● Adjust the final position of the band according to the capacity demand.
● Note the quantity of gas flow in relation to function of the compound regulator.
● Check the combustion values with flue gas analysis.

M5178 1647EN 27 (129)

 3.8 Installing hoses
Avoid torsion stress on hoses

Leave neutral hose

ends long enough

Use rigid pipe

bends when
necessary

Minimum bend radius

Hose diameter Minimum bend radius ( r ) Minimum bend radius ( r )

Ø 12 130 mm 5.12 in
Ø 15 130 mm 5.12 in
Ø 22 170 mm 6.69 in

28 (129) M5178 1647EN

 3.9 Oil supply site diagram, example
Diagram

B-528V ver. 1

Pos. Item Details Pos. Item Details

1 Filter 400 µm 8 Filter 125 µm
2 Pressure gauge cock   9 Pressure gauge cock  
3 Pressure gauge Max. low pressure 10 Pressure gauge Oil pressure 1 - 5 bar
-0,3 bar
4 Filter 250 µm      
5 Pumping unit   A Oil to burner  
6 Air/gas separator   B Oil from burner  
7 Pressure regulating   C Oil to pumping unit  
valve

Pumping unit minimum output equation:

Required minimum output [kg/h] = (oil flow to be burned kg/h + 150 kg/h)×1,2

M5178 1647EN 29 (129)

 3.10 Connecting to oil line
Two-pipe system

The burner is equipped for two-pipe system. Two-pipe system has separate suction
and return lines for oil.

Fit oil filter according to PI diagram.

Pay attention to the instructions provided by the pump manufacturer

when dimensioning the pipeworks.

3.11 Installing FGR duct system

FGR duct system

FGR Installation_monoblock ver. 3

Pos. Item Pos. Item

1 Control damper 5 Temperature sensor
2 Combustion air fan 6 FGR duct
3 Combustion air throttle valve 7 Condensate drain valve
4 Combustion air    

30 (129) M5178 1647EN

 In monoblock burner constructions, pos. 3 and 4 are integrated parts of the burner.

Burner model Minimum diameter Minimum diameter

of FGR pipe of FGR pipe
Group 4 DN Inches
350 M 200 6”
450 M 200 8”

Designing FGR piping

When designing the piping, consider the special circumstances of FGR operation.

The temperature in the piping varies constantly during the operation causing expansion
and contraction of the pipes. The temperature differences also cause condensation in
the pipe line.

In long pipe runs the pipe line length can change by over 25 mm per 100 °C (1” per
212° F). Thus extra load builds up on pipe connection point, which may result in
component failures.

Apply the following rules of thumb for the construction:

● Use carbon or stainless steel for FGR piping. Pipe wall must not be too thick.
● Route the duct with a minimum number of elbows, still allowing a normal expansion
and contraction of the duct. Place pipe supports to avoid excessive load to pipe
connection.
● Leave space for the pipe joint movement during the expansion and contraction of
the duct.
● Provide condensation drains, if needed. Check the drain volume needs.

To mount FGR duct system:

1. Place the inlet to the stack as close as possible to the boiler or economizer. Set
cutting in 45° angle.
2. Set control damper close to the burner.
3. Finish the FGR duct pipe joint carefully with seal welding, flange or screw
connection. Make sure that the joint is tight and no air can enter the duct.
4. Place condensate drains both at the beginning and the end of pipe line.
5. Install one drain upstream from the FGR control valve, and another in the FGR
shut-off valve, if used.
6. In case of heavy condensation, add a condensate drain to the bottom of the
housing.
7. Anchor supports to provide stability in the duct.

Excessive load on pipe line may damage burner or its components. The
construction must be self-supporting.

M5178 1647EN 31 (129)

 Installing temperature sensor

D055288 ver. 1

1 Temperature sensor 4 Butterfly valve

2 FGR pipe (*) 5 Burner
3 Sleeve (*) A Min. 200 mm
Min. 7.87 in
* not included in delivery

3.12 Electrical connections

Connect burner according to the electrical diagrams delivered with burner.

Adhere to general and local standards and regulations as well as requirements set on
the connections of electrical equipment. Configure burner installation with a switch that
allows it to be disconnected from the low-voltage supply mains.

Grounding must be in order before commissioning burner.

See electrical diagram for maximum cable lengths.

Connection to power supply is implemented with two separate supply connections. The
supply of the control circuit of switching device directly to the burner switching base
and supply to the fan motor output are implemented according to the site. The motor
output is cabled both to the fan motor and control circuit to the burner wiring base.

Separate the base insulated wires of different voltage circuits from each other.

32 (129) M5178 1647EN

 ● When using frequency converter, do cabling work and grounding according to
manufacturer instructions.
● Locate frequency converter as near to motor as possible to avoid interference
caused by long cabling.
● Separate supply cables from control and bus cables in cable rack if they cannot be
installed in separate cable racks.
● Check that shielded cables have proper connections.

M5178 1647EN 33 (129)

 4 Commissioning

4.1 First start-up

Vent fuel lines before first start-up.

After the first start-up check the cleanliness of the filter weekly and
replace if necessary. If the filter remains clean, inspection period can be
extended to one month.

Pump must not operate without oil. Vent the oil pump before initial start-
up and when changing the pump.

While adjusting burner, make sure that minimum and maximum values
for burner capacity are not exceeded. Values are marked on the type
label.

Fasten all safety covers, enclosures, and guards with all screws before
start-up. Use appropriate tools.

If burner start-up fails consecutively two times, do not restart burner

before carefully investigating the reason for the failure.

First start-up check list

Check the following before first start-up:

● instructions from boiler and burner manufacturers are followed
● piping is done properly, and joints on pipes and components have been tested for
leaks
● check that all screws are in their places and carefully tightened after installation
● boiler and its components are in proper working order and ready for use
● there is adequate air inlet to boiler room for burner to have sufficiently air for
combustion
● connections are correct and motor rotation direction is correct
● 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
● oil temperature and viscosity are correct
● chimney is properly connected, unobstructed and flue gas damper is open

34 (129) M5178 1647EN

 To start the burner:
1. Open the fuel shut-off valves.
2. Switch on power supply.
3. Switch on the burner from the burner control switch.

To stop the burner:

Turn the burner control switch to OFF position.

4.2 Nozzle selection

Fuel consumption by boiler capacity

P = boiler capacity, kW
µ = boiler efficiency, 0,80-0,95
q = P/µ *Q
Q = heat value, kWh/kg
q = fuel demand, kg/h (Note! For all nozzles.)

Heat value for light fuel oil is approx. 11,86 kWh/kg and for heavy fuel oil approx. 11,22
kWh/kg. Check exact values from supplier.

Spill return nozzle Fluidics 12-W1

Table is applicable when atomizing viscosity is 5 mm²/s (cSt).

Nozzle No. Max. throughput kg/h at oil pump pressure of Min. throughput kg/h at oil
20 bar (2,0 MPa) when return line is closed pump pressure of 20 bar (2,0
MPa) when return line pressure
is 7 bar (0,7 MPa)
40 40 10 *)
50 50 12 *)
60 60 15 *)
70 70 18
80 80 20
90 90 22
100 100 25
112 112 28
125 125 31
140 140 35
160 160 40
180 180 45
200 200 50
225 225 56
250 250 62
275 275 68
300 300 75
330 330 82
360 360 90
400 400 100
450 450 112
500 500 125

*) Oil quantity return pressure10 bar (1,0 MPa)

M5178 1647EN 35 (129)

 When using any other oil pump pressure as shown in table, the throughput of nozzle is:

P2
Ax
P1
PAINEKAAVA1 ver. 2

A = Table value

P1 = 20 bar (Fluidics)

P2 = Oil pump pressure

For example: nozzle 12-W1 No. 100, oil pump pressure 30 bar (3,0 MPa) ⇒ throughput
of nozzle is:

30 bar ~ 122 kg/h

Max. 100 kg/h x ~
20 bar
PAINEKAAVA2 ver. 2

Calculated minimum output on return pressure 9 - 12 bar is:

Max kg/h
Min =
2,5
PAINEKAAVA4 ver. 2

Oil pump operating pressure (atomizing pressure) in heavy fuel oil is 2500 - 3000 kPa
(25 - 30 bar).

Oil pump operating pressure (atomizing pressure) in light fuel oil is 2000 - 2500 kPa
(20 - 25 bar).

Spill return nozzle Fluidics 12-W2

Table is applicable when atomizing viscosity is 5 mm²/s (cSt).

Nozzle No. Max. throughput kg/h at oil pump pressure of Min. throughput kg/h at oil
25 bar (2,5 MPa) when return line is closed pump pressure of 25 bar (2,5
MPa) when return line pressure
is 7 - 10 bar (0,7 - 1,0 MPa)
40 40 10
50 50 12
60 60 15
70 70 18
80 80 20
90 90 22
100 100 25
112 112 28
125 125 31
140 140 35
160 160 40

36 (129) M5178 1647EN

 Nozzle No. Max. throughput kg/h at oil pump pressure of Min. throughput kg/h at oil
25 bar (2,5 MPa) when return line is closed pump pressure of 25 bar (2,5
MPa) when return line pressure
is 7 - 10 bar (0,7 - 1,0 MPa)
180 180 45
200 200 50
225 225 56
250 250 62
275 275 68
300 300 75
330 330 82
360 360 90
400 400 100
450 450 112
500 500 125
550 550 138
600 600 150
650 650 162
700 700 175

When using any other oil pump pressure as shown in table, the throughput of nozzle is

P2
Ax
P1
PAINEKAAVA1 ver. 2

A = Table value

P1 = 25 bar (Fluidics)

P2 = Oil pump pressure

For example: Nozzle 12-W2 No. 100, oil pump pressure 30 bar (3,0 MPa) ⇒ throughput
of nozzle is:

30 bar ~ 110 kg/h

100 kg/h x ~
25 bar
PAINEKAAVA3 ver. 2

Calculated minimum output on return pressure 9 - 12 bar is:

Max kg/h
Min =
2,5
PAINEKAAVA4 ver. 2

Oil pump operating pressure (atomizing pressure) in heavy fuel oil is 2500 - 3000 kPa
(25 - 30 bar).

M5178 1647EN 37 (129)

 Oil pump operating pressure (atomizing pressure) in light fuel oil is 2000 - 2500 kPa
(20 - 25bar).

Spill return nozzle Bergonzo CBM B5 AA

Table is applicable when atomizing viscosity is 12 mm²/s (cSt)

Nozzle No. Max. throughput kg/h at oil pump pressure of Min. throughput kg/h at oil
25 bar (2,5 MPa) when return line is closed pump pressure of 25 bar (2,5
MPa) when return line pressure
is 3 bar (0,3 MPa)
450 450 90
500 500 100
600 600 120
700 700 140
800 800 160
900 900 180

For example: Nozzle CBM B5 AA No. 450, oil pump pressure 30 bar (3,0 MPa) ⇒
throughput of nozzle is:

30 bar ~ 493 kg/h

450 kg/h x ~
25 bar
PAINEKAAVA5 ver. 2

When viscosity increases the quantity of oil spraying from nozzle

increases approx. 5-15%.

38 (129) M5178 1647EN

 4.3 Adjusting combustion head
Combustion head components

D042327 ver. 1

Pos. Item
1 Combustion head
2 Diffuser disc
3 Adjustment ring
4 Ignition electrode
5 Gas nozzle
6 Ignition gas nozzle
7 Oil nozzle

H 8 mm 0.31 in

4.4 Setting ignition electrodes

Check and set ignition electrode spark gap and the distance of the nozzle to ignition
electrodes and diffuser disc as shown on the drawing.

M5178 1647EN 39 (129)

 Maximum tightening torque of ignition electrodes is 1 Nm.

D042321 ver. 1

L 10 mm 0.39 in
K 9 mm 0.35 in
M 3 mm 0.12 in

4.5 Adjusting supply oil pressure

In light fuel oil burners inlet pressure should be 1–4.5 bar or 14.5–65.3
PSI.

Pressure must not exceed 5 bars anywhere in the oil line.

4.6 Oil pump

Check the oil pump model used in your burner from the manufacturing
card or the information plate on the pump.

Fuel Typical atomizing pressure Oil hose connection

Light fuel oil 20–25 bar suction R ½”
#2 fuel oil 290–261 PSI return R ½”

To adjust pump pressure:

● Use the pressure adjustment screw.

● Turn the screw clockwise to increase the pressure.
● Install a pressure gauge/valve assembly, if necessary.

To vent the oil pump:

1. Loosen the plug of the pressure gauge port.

Do not remove the plug.

40 (129) M5178 1647EN

 2. Let the burner operate for a while. Air bubbles come out of the hole.
3. When no more bubbles come out, retighten the plug carefully.

If the atomizing pressure during capacity change from max. to min.

exceeds 2 bar / 29 PSI the pump must be replaced.

The pump is self-priming. The pump is intended for use in two-pipe

system.

Oil pump AFI

AFI-pump ver. 1

Pos. Item Pos. Description

1 Heating A Oil inlet
2 Pressure relief valve B Oil outlet
3 Shaft seal

M5178 1647EN 41 (129)

 Technical data
Max oil inlet pressure to burner 5 bar 72.5 PSI
Inlet oil viscosity range 4–70 mm²/s (cSt) 4–70 mm²/s (cSt)
Min oil inlet pressure to burner 2.5 bar or higher 36.25 PSI or higher
(Depends on oil temperature at the pump.)
Inlet oil maximum temperature + 150 °C + 302 °F
Filtration degree to pump max. 125 μm max. 125 μm

Oil pump T

A311BT ver. 4

Pos. Item Pos. Item

1 Suction line connection 3 Incoming oil pressure gauge port
2 Oil to nozzle 4 Oil pressure gauge port (to nozzle)/air
venting

Technical data
Viscosity limit for incoming fuel: light fuel oil 4–12 mm²/s (cSt) 4–12 mm²/s (cSt)
Viscosity limit for incoming fuel: heavy fuel oil 4–70 mm²/s (cSt) 4–70 mm²/s (cSt)
Max oil inlet pressure 5 bar 72.5 PSI
Pump operating pressure (atomizing pressure) 20–25 bar 290 PSI
Filtration degree to pump max. 300 μm max. 300 μm

42 (129) M5178 1647EN

 Oil pump TA

A212ZTA ver. 3

Pos. Item Pos. Item

1 Oil suction connection 5 Protective cap
2 Oil to nozzle 6 Oil inlet pressure/gauge port
3 Oil return connection 7 Pressure gauge connection plug / air
venting
4 Pressure adjustment 8 Opening for bypass plug

Pump has an integrated pressure regulation system.

Technical data
Operating viscosity 3–75 mm²/s (cSt) 3–75 mm²/s (cSt)
Inlet oil maximum pressure 5 bar 72.5 PSI
Inlet oil maximum temperature + 150 °C +284 °F
Operating pressure (=atomizing pressure) 7–40 bar 101–580 PSI
Filtration degree to pump max. 300 μm max. 300 μm

M5178 1647EN 43 (129)

 Oil pump TAR

A212ZTA ver. 3

Pos. Item Pos. Item

1 Oil suction connection 5 Protective cap
2 Oil to nozzle 6 Oil inlet pressure/gauge port
3 Oil return connection 7 Pressure gauge connection plug / air
venting
4 Pressure adjustment 8 Opening for bypass plug

Pump has an integrated pressure regulation system.

Technical data
Operating viscosity 1.25–75 mm²/s (cSt) 1.25–75 mm²/s (cSt)
Inlet oil max. pressure 5 bar 72.5 PSI
Inlet oil max. temperature + 150 °C + 302 °F
Operating pressure (=atomizing TAR 2/3/4: 7–40 bar TAR 2/3/4: 101–580 PSI
pressure) TAR 5: 7–30 bar TAR 5: 101–435 PSI
Operating pressure 1,5 mm²/s (cSt): 1,5 mm²/s (cSt):
max. 25 bar max. 362 PSI
2 mm²/s (cSt): max. 30 bar 2 mm²/s (cSt): max. 435 PSI
3 mm²/s (cSt): max. 35 bar 3 mm²/s (cSt): max. 507 PSI
(30 bar for TAR5) (435 PSI for TAR5)
Filtration degree to pump max. 300 μm max. 300 μm

4.7 Adjusting atomizing pressure

Oil pumps AFI and T

To adjust the thermal output of the burner, change the nozzle size and adjust the
oil atomizing pressure. Pump provides a constant pressure. Atomizing pressure is
adjusted with a separate pressure regulating valve.

44 (129) M5178 1647EN

 TVSAADINDANFOSS ver. 3

TVSAADIN ver. 2

Regulator valve option 1 Regulator valve option 2

Pos. Item Pos. Description

1 Protective cap A Oil from pump
2 Pressure regulation B Oil to nozzle
3 Pressure gauge connection C Return oil

4.8 Oil pump coupling components and adjusting

Oil pumps J, E, PON, TAR, T, TA and UHE

A296X ver. 2

1 Coupling head
2 Fixing screw

1. Set coupling between motor and oil pump.

2. Set the distance between coupling heads to be 1 – 2 mm / 0.039 – 0.078 in.

If coupling needs to be removed or adjusted during maintenance work,

you must first remove the air damper.

M5178 1647EN 45 (129)

 Oil pump AFI

BOWEX ver. 3

Pos. Item
1 Hub
2 Sleeve
3 Set screw

Set the distance between the hubs. See the image.

Note the correct direction of the hubs.

4.9 Adjusting combustion differential air pressure switch

Combustion differential air pressure switch

The combustion differential air pressure switch monitors pressure difference generated
by burner fan.

46 (129) M5178 1647EN

    
   
A Higher pressure
B Lower pressure
C Electrical connections
D Setup switch
1 and 2 cross head screw

LGW A2 ver. 2

If pressure difference does not rise above switch setting value, burner shuts down.
Differential air pressure switch should be set to trigger before CO-concentration of
combustion product exceeds 1 vol%, 10 000 ppm.

Burner size Factory setting Factory setting

mbar PSI
450 M 45 0.70

When using frequency converter (WD200):

● factory setting is set to 10 mbar / 0.15 PSI
● maximum adjustment range should be between 35Hz and 50Hz

Due to varying installation location circumstances, differential air

pressure switch setting may have to be reset to meet the actual
conditions in order to ensure proper burner function. Make sure not to
exceed the given CO limit.

To adjust differential air pressure switch setting at current nominal burner

capacity
1. Open the protective cover of the differential air pressure switch.
2. Start the burner.
3. Turn the switch slowly to the maximum until the burner shuts down.
4. Turn the switch approx. 5 mbar from this point backwards (to the minimum).
5. Close the protective cover and reset.

M5178 1647EN 47 (129)

 4.10 Adjusting gas pressure switch
Gas pressure switch, max.

   
   
   
1 Adjusting scale
2 Reset, gas pressure switch, max.
3 Pressure measuring connection

   

A416M ver. 3

Gas pressure switch max. should cause a permanent interlocking if burner capacity
increases to be more than 1.15 times the nominal value, or if the pressure exceeds
more than 1.3 times the nominal pressure.

Burner size Factory setting mbar Factory setting PSI

450 M 52 0.75

To adjust gas pressure switch to maximum, without flue gas analyzer

Adjust gas pressure switch after burner adjustments and flue gas analysis.
1. Turn gas pressure switch adjusting scale to the maximum position.
2. Run burner to the desired maximum capacity.
3. Increase burner capacity to be 1.15 times the desired maximum capacity by
increasing gas pressure.
4. Slowly turn switch to the minimum until burner shuts down. Now the adjustment is
correct.
5. Reset gas pressure switch.
6. Run burner back to the desired maximum capacity by decreasing gas pressure.

To adjust gas pressure switch to maximum, with flue gas analyzer

Adjust gas pressure switch after burner adjustments and flue gas analysis.
1. Turn the gas pressure switch to its maximum value
2. Adjust burner to the desired maximum capacity; for example so that O2 content =
2.5–3.0 % and CO content < 50 ppm.
3. Increase the capacity by raising the gas pressure until the O2 content = 1.0 % and
CO content < 2000 ppm.

48 (129) M5178 1647EN

 4. Slowly turn the gas pressure switch towards its minimum setting until the burner
shuts off. The pressure switch is now correctly configured.
5. Reset the error.
6. Decrease gas pressure to normal value. Check combustion values.

To adjust gas pressure switch, min.

Burner size Factory setting mbar Factory setting PSI

450 M 20 0.29

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. Close cover.

If gas pressure switch triggers a temporary burner shutdown during burner start-up or
during operation, it has to be set on lower pressure.

Gas pressure switch, gas valve proving

Gas valve leaking is tested by using a pressure switch. Switch adjustment according to
previous instructions.

4.11 Setting variable speed module parameters

Variable speed module (VSM) is an optional accessory that is connected to burner

control through LSB bus. Electrical connections (sensors, mA/V messages etc.) to
burner control are made according to electrical connections.

VSM module provides 0/4-20mA or 0-10V setpoint output for frequency converter. In
addition there is a changeover contact in the burner to get frequency converter started.

VSM basic settings are adjusted with DIP switches and parameter settings with PC
application (LSB remote).

DIP switches are located on the module cover. Following tables show factory settings
underlined:

DIP1 Setting
0 CAN terminating resistor deactivated
1 CAN terminating resistor activated

DIP 2–3, product family

DIP2 DIP3 LSB family
0 0 1
0 1 2
1 0 3
1 1 4

M5178 1647EN 49 (129)

 DIP 4–7, select sensor input
DIP4 DIP5 DIN6 DIN7 Input/ value range
0 0 0 1 Namur sensor 600-7200 pls/Min
0 0 1 0 Namur sensor 300-3600 pls/Min
0 1 0 0 3-wire sensor 30-300 pls/Min
0 1 0 1 3-wire sensor 600-7200 pls/Min
0 1 1 0 3-wire sensor 300-3600 pls/Min
1 0 0 0 Current input 0-20 mA
1 0 0 1 Current input 4-20 mA

DIP 8, setpoint output

DIP8 Setpoint output
0 0-20mA setpoint output
1 4-20mA setpoint output

To set parameters of the variable speed module

Before you can use the device you must set the parameters P0403 ...
P0406 in the BurnerTronic.

Param. nr Description Factory

setting
403 BT300 Specification of channel 4 functions: 3
0 = OFF
1 = Recirculation damper
2 = Fuel
3 = Air damper
4 = Reserved (error 107)
5 = Reserved (error 107)
6 = Reserved (error 107)
405 BT300 Channel release for curve set 1 13
Curve 1 = Oil
Selection via bit pattern
Channel 1 = Air → 1
Channel 2 = Gas → 0
Channel 3 = Oil → 1
Channel 4 = VSM →1
406 BT300 Channel release for curve set 2 11
Curve 2 = Gas
Selection via bit pattern
Channel 1 = Air → 1
Channel 2 = Gas → 1
Channel 3 = Oil → 0
Channel 4 = VSM → 1

50 (129) M5178 1647EN

 Additional parameter 368

Param. nr Description Factory

setting
368 BT300 Limit by which pre-ventilation can be completed with 999
channel 4 (VSM).
Pre-ventilation limit (also post-ventilation) is set with
channel 4. Enter the upper limit to which the channel runs
open during pre-ventilation. If you enter 999 (default value)
the channel runs to its upper stop. Set the pre-ventilation
limit for example with air dampers to shorten the pre-
ventilation period. In this case, remember to assure the
exchange of air.
Warning:
● A continuous output limits the setpoint. Note that you have to enter the range limits of the feedback
manually. With continuous outputs the feedback value for the limitation is calculated and saved in the
device during the automatic range-limit calculation.
● Note that the feedback reaches the value of the limitation during the automatic calculation of the
range limits. The feedback is used for the monitoring of the channel’s pre-ventilation position.
● After the activation or changing of the pre-ventilation limit of a continuous channel you have to run an
automatic calculation of the range limits.
Refer to the variable speed module user instructions.

Parameter value setting 0–999 equals 0–100% setpoint output for variable speed
module.

If burner fan motor nominal current value is exceeded, parameter value must be
lowered.

While changing the parameter value the burner must get enough air during prepurge.
During prepurge, the amount of air in the burner has to equal five times the volume of
combustion chamber and flue gas channel (industrial applications).

4.12 Setting gas pressure regulator SKP

The operating area of the gas pressure regulator is determined by the spring installed
inside the pressure regulator. There are three types of springs and their operating
areas are described in the table below.

Springs can be ordered from Oilon Webshop.

M5178 1647EN 51 (129)

 SKP ver. 1

To change spring:

1. Remove the plug.

2. Remove the slot-head screw by turning counter-clockwise with a chisel-point
screwdriver.
3. Replace the spring.

Assemble in reverse order.

Excessive tightening of screws may damage the component.

Spring type pG (mbar) ∆p / Color Model

360
AGA29 ≤ 22 2.2 blank SKP25.0
AGA22 15 ... 120 11.9 yellow SKP25.0
AGA23 100 ... 250 24.5 red SKP25.0
AGA22 100 ... 700 - yellow SKP25.4
AGA23 ≤ 1500 245 red SKP25.4

Spring type pG (in. W.C) ∆p / Color

360
AGA29 ≤ 8.8 2.2 blank SKP25.0
AGA22 6.0 ... 48.2 11.9 yellow SKP25.0
AGA23 40.2 ... 100.4 24.5 red SKP25.0
AGA23 ≤ 602.8 245 red SKP25.4

52 (129) M5178 1647EN

 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.

4.13 Setting gas pressure regulator FRS

The operating area of the gas pressure regulator is determined by the spring installed
inside the pressure regulator. The factory setting of standard spring p2 is 10-30 mbar.

Springs can be ordered from Oilon Webshop.

Setting pressure regulator at minimum load

1. Start burner at minimum load. At minimum load throttle valve setting is 5°-10°.
2. Adjust combustion to safe level using flue gas analysis. Measure pressure regulator
outlet pressure from gas valve measuring point.
3. Turn adjustment spindle clockwise until gas amount corresponds with required
burner minimum load. Check combustion using flue gas analysis, when raising
pressure. Adjust burner if necessary.

Check gas valve measuring point position from the gas valve
manufacturer manual.

Check and adjust pressure regulator outlet pressure level finally when
burner operates on full load.

M5178 1647EN 53 (129)

 To adjust outlet pressure

219598a ver. 1

1. Unscrew protective cap A.

2. Use a chisel-point screwdriver. to adjust spindle B:
a. Turn the spindle B clockwise. This increases the outlet pressure.
b. Turn the spindle B counterclockwise. This reduces the outlet pressure.
3. Check the setpoint.
4. Screw on the protective cap A.

To replace setting spring

219598b ver. 1

1. Remove protective cap A. Release spring by turning adjustment spindle B

counterclockwise. Turn spindle to stop.
2. Unscrew complete adjustment spindle B and remove spring C.
3. Insert new spring D.
4. Assemble complete adjustment spindle and adjust desired offset.
5. Screw on protective cap A. Stick adhesive label E onto typeplate.

Excessive tightening of screws may damage the component.

Sealing final settings

1. Check pressure regulator outlet pressure. If necessary, adjust it to be sufficient for
full load setting.
2. Finally seal setting by threading wire through sealing holes in protecting cap and
pressure regulator body.

54 (129) M5178 1647EN

 FRS4 ver. 2

1 Protecting cap sealing hole, ø 1.5 mm

2 Body sealing hole, ø 1.5 mm

Setpoint Color Nominal width Rp/DN

spring
range
(mbar)
    Rp 1 1/2, Rp 2, DN Rp 2 1/2, DN 100 DN 125 DN 150
DN40 50 DN65, 80
Spring 1 2,5...9 brown 229 851 229 874 229 883 229 892 229 901 229 909
Spring 2 5...13 white 229 852 229 875 229 884 229 893 229 902 229 910
Spring 3 5...20 orange 229 853 229 876 229 885 229 894 229 903 229 911
Spring 4 10...30 blue 229 854 229 877 229 886 229 895 229 904 229 912
Spring 5 25...55 red 229 869 229 878 229 887 229 896 229 905 229 913
Spring 6 30...70 yellow 229 870 229 879 229 888 229 897 229 906 229 914
Spring 7 60...110 black 229 871 229 880 229 889 229 898 229 907 229 915
Spring 8 100...150 pink 229 872 229 881 229 890 229 899 229 908 229 916
Spring 9 140...200 grey 229 873 229 882 229 891 229 900 243 416 243 417

4.14 Measuring gas pressure

General rules for gas pressure measurement
1. Shut off the burner.
2. Open the test point connection cover.
3. Attach a silicone hose to the test point connection. Attach a gauge to the other end
of the hose.
4. Start the burner.
5. While the burner is running record gas pressure readings using the instructions
below.
6. Perform adjustments if needed.
7. Shut off the burner.
8. Finally close all the test point connections and remove measurement equipment.

Make all adjustments when the burner is running!

All stated pressure values are only for reference. The actual values may
vary depending on operating conditions.

M5178 1647EN 55 (129)

 Measuring nozzle pressure

1. Nozzle pressure at nominal capacity

Burner Test point 1 Test point 1

(mbar) (in.Wc)
450 M 28 11.2

4.15 Operating and display unit menu

Menu structure

Menus are divided into two user levels.

First user level is User, and it does not require password.

Second user level is Service. It is a password protected level for commissioning and
maintenance personnel.

Operation

User can scroll through and change clock and counter settings for standard burner
operation.

      Description
Operation      
BoilerSetpoint    
  SetpointW1 Internal setting W1, °C /
°F
Internal setting W1, bar /
PSI
  SetpointW2 Internal setting W2, °C /
°F
Internal setting W2, bar /
PSI
UserMaxLoad    
  MaxTmeMod Max. load modulating
  MaxTmeStage 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
  Date  
  TimeOfDay  
HoursRun   Displaying the current
hours run readings
  GasFiring Hours run gas
(selectable)

56 (129) M5178 1647EN

   OilStage1/Mod Hours run oil stage 1 or
modulating (selectable)
  OilStage2 Hours run oil stage 2
(selectable)
  OilStage3 Hours run oil stage 3
(selectable)
  TotalHoursReset Hours run total (can be
reset)
  TotalHours Hours run total (read
only)
  SystemOnPower Hours run device under
voltage (read only)
StartCounter   Displaying the start
counter readings
  GasStartCount Number of startups gas,
start counter (selectable)
  OilStartCount Number of startups oil,
start counter (selectable)
  TotalStartCountR Total number of startups,
start counter (can be
reset)
  TotalStartCount Total number of startups,
start counter (read only)
Fuel Meter   Displaying the current
counter readings
  Curr Flow Rate Current fuel throughput
  Volume Gas Fuel volume gas (read
only)
  Volume Oil Fuel volume oil (read
only)
  Volume Gas R Fuel volume gas
(resettable)
  Volume Oil R Fuel volume oil
(resettable)
  Reset Date Gas Reset date fuel volume
gas
  Reset Date Oil Reset date fuel volume
oil
LockoutCounter Total number of lockouts
that occurred (read only)
O2 Module
Actual O2 Value Actual O2 value
O2 Setpoint O2 setpoint
SupplyAirTemp Supply air temperature in
°C / °F
FlueGas Temp Flue gas temperature in
°C / °F
CombEfficiency Combustion efficiency
BurnerID Identification of burner
OptgModeSelect Operating mode selection
of AZL5... for serial port
and eBus
  InterfacePC Setting the serial port
(RS-232) of the AZL5... to
interface operation for PC
tool
  GatewayBASon Activating the eBus port

M5178 1647EN 57 (129)

   GatewayBASoff Deactivating the eBus
port
  Type of Gateway
O2Ctrl activate O2 trim controller
activated/deactivated

Manual operation

User can scroll through and change manual operation settings from operating and
display unit.

      Description
ManualOperation      
  SetLoad   Target load setting
manually, percent of
maximum load (%)
  Autom/Manual/Off   Select manual or
automatic operation
    Auto Burner capacity adjusts
automatically controlled
by capacity controller
according to boiler
temperature or pressure
    Burner on Burner on manual
operation according to
SetLoad
    Burner off Burner stopped

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:

● Burner control
● Ratio control
● Servomotors
● Frequency converter

Give password as follows:

1. Select Ss-password.
2. Give password.
3. Press Enter.

Burner Control menu level

● Times
● Configuration
● ProductID
● SW Version

Ratio Control menu level

● OilSettings
● Autom/Manual/Off
● Times
● ShutdownBehav
● ProgramStop

58 (129) M5178 1647EN

 Servomotors
● Addressing
● DirectionRot
● SW Version
● ProductID

VSD Module
● Configuration
● Process Data
● ProductID
● SW Version

4.16 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.

AZLNAPIT ver. 3

AZL ver. 4

Scroll through the menus with the Select -/+ buttons. Select the desired submenu by
pressing Enter. Return to the higher menu level by pressing Esc.

Changing set values

1. Select Params. & Display.
2. Select the desired parameter.
3. Select a new parameter value using the Select -/+ buttons.
4. Save the selected new value by pressing Enter.
5. Return to the menu by pressing Esc.

Adjusting display contrast

1. Press Enter.
2. Keep Enter pressed, and adjust the contrast using the Select -/+ buttons.
3. Release Enter and return to the menu.

M5178 1647EN 59 (129)

 Activating safety check function

    Description
SafetyCheckFunct    
  LossFlameTest Loss of flame test
  SLT test Safety limit thermostat test

Burner lockout function is triggered by pressing the Enter and Esc

buttons simultaneously.

4.17 Setting frequency converter parameters (WD200)

Parameters for frequency converter used for fan motor control must be set before the
first start-up.

Initial state of parameters.

● Start/stop is controlled by burner control.
● Frequency converter alarm contact sends alarm data to burner control.
● Burner control controls output frequency with 0 / 4…20 mA signal.
● Remove control signal filtering and delays.
● Set acceleration and deceleration time at 2 s.
● Set the minimum frequency to 0 Hz.
● Set the maximum frequency to 105.2 % of the motor's nominal speed.

The inductive sensor detects the fan motor rotation speed from the motor axle. It
generates 60°, 120° and 180° pulse intervals, from which rotation direction and speed
are acquired.

Acquisition of speed is a safety function.

See frequency converter manual for instructions for setting parameters.

After frequency converter parameters are set, the rotation speed must be set to
standard.

4.18 Frequency converter settings and standardization

(WD200)

Standardize the rotation speed after setting the frequency converter parameters. Turn
the control selection switch S1 to position 1. The control voltage is switched on to
burner control.

Settings are in the following menu level:

60 (129) M5178 1647EN

 Params. & Display        
VSD Module      

  Configuration    

    Speed  

        Num Puls per R

      Standardization

        StandardizedSp
        Setpoint Output
        Settling Time

Num Puls per R Three pulses per round. Do not change the setting manually!
Standardization Automatic fan maximum rotation speed test. Burner control should be in
standby position when the test begins. Select activated from the menu to
start the test.
1. Servomotor for air drives to pre-purge position.
2. Fan motor starts.
3. Burner control steers frequency converter setting to 95 %.
When the fan reaches stable rotation speed, its value is set as
StandardizedSp value in the menu. This value is equal to 100 % of fan
rotation speed, 5 % is reserved for possible environmental condition change.
StandardizedSp Do not change the setting manually! Perform standardization as described
above.
SettlingTime Rotation speed measured by frequency converter control. At stable output,
the frequency measurement result stays almost the same. If the result varies
notably, check the sensor operation.
Setpoint Output Frequency converter control value can be set to 0…20 mA or 4…20 mA.

If automatic speed standardization is activated or standardized speed is

changed manually, burner must be readjusted.

4.19 Checking O2 module (WD200)

O2 module, connected to burner control through CAN bus, can be connected with
oxygen sensor.

When control voltage is switched on, and oxygen sensor is activated, heating is on and
oxygen sensor is ready for operation.

Activate oxygen sensor during first start-up, and always after power failure, to start
heating. Oxygen sensor is ready for operation when 700 °C / 1292 °F is reached. It
takes approx. 10 min to reach the temperature.

Oxygen sensor is self testing. Self test monitors aging of the device, based on
measurement cell resistance and response time. If measurement cell resistance and
response time exceed 400Ω and 25 seconds, self test gives an alarm, and sensor must
be changed.

O2 module settings are in the following menu level:

M5178 1647EN 61 (129)

         Description
Params. & Display        
O2 Module      

  Displayed Values    

    Actual O2 Value Actual O2 Value

      O2 Setpoint O2 Setting
      SupplyAirTemp Supply air
temperature in °C /
°F
      FlueGasTemp Flue gas
temperature °C / °F
      CombEfficiency Combustion
efficiency
      QGO SensorTemp QCO-sensor
temperature °C / °F
      QGO HeatingLoad Control value of
QGO... heating,
0,1%
      QGO Resistance Internal resistance
of QGO's Nernst
cell

Self test is made at 23-intervals. Test requires constant O2 level, for e.g. after pre-
purge or on steady load. If constant O2 level is not reached within 24 hours, burner
control locks down operation load to reach constant O2 level for next test. If burner is in
stand by mode, test is made during next burner start-up.

Flue gases containing aggressive acids may strongly shorten oxygen

sensor durability.

O2 module can be connected with burner combustion air and flue gas temperature
sensors. If sensors are connected, warning is displayed when flue gas temperature is
too high, and combustion efficiency will be calculated and displayed.

Check that oxygen value and sensor temperature, heating efficiency

and resistance values are displayed. If temperature sensors are
connected and activated, values should be displayed.

4.20 Manual start-up and program stop in pre-purge position

Program stop

With burner control ProgramStop parameter burner start-up can be stopped in

selected program phase, and servomotor position can be adjusted.

62 (129) M5178 1647EN

 Pre-purge position phase 24–34
Ignition position phase 36
Transition 1 phase 44
Transition 2 phase 52
Post-purge phase 72–78

Active program stop in phase 24.

Params & Display      

Ratio Control    

  Program Stop  

      deactivate
    24 PrePurgP

      32 PreP FGR
      36 IgnitPos
      44 Interv 1
      52 Interv 2
      72 PostPPos
      76 PostPFGR

Manual start-up

Prerequisites:
● Frequency converter 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  

    Auto
  BurnerOn

    BurnerOff

Checking pre-purge position

Turn the burner control switch into position 2, autom. The burner starts if all
prerequisites for start-up are fulfilled. Program phase changes12…20…21, etc. and
stops at phase 24. A message Special position reached appears on the display.
The burner has reached the pre-purge position, and the servomotor positions can be
modified if necessary. The final pre-purge setting is done when burner ignition load and
curves are set.

M5178 1647EN 63 (129)

 Param. &          
Display
RatioControl        

  GasSettings      

    Special-    
Positions
      Pre-purgePos  

        Pre-purgePos-
Air
          Pre-purgePos-
Aux1
          Pre-purgePos-
Aux2
          Pre-purgePos-
Aux3
          Pre-purgePos-
VSD

When the curve point for full load is set, adapt this point and frequency converter
settings for pre-purge position.

If servomotors do not drive full motion at full load curve point, burner start-up can be
accelerated, because servomotor running times remain shorter.

Gas use
● at full load air amount pre-purge time is 20 s
● 50% air amount pre-purge time is at least 40 s
● 33% air amount pre-purge time is at least 60 s

Oil use
● Pre-purge minimum duration is set at 15 s, and air amount should be 30% of full
load air amount. The servomotor settings should be the half of full load settings,
and frequency converter setting should be at the middle of minimum and full load
settings. Check from ratio curve that servomotor settings and frequency converter
settings are over 30% of load settings.

If curve point setting for full load is changed, changes must be adapted
to pre-purge position settings.

Pre-purge must ventilate combustion chamber to fresh air level.

If servomotor Aux 3 is in use, it does not move until phase 32, when
program stop is changed to phase 32.

4.21 Ignition position

Set program stop at phase 36, ignition.

Burner control carries out automatic gas valve leak test during pre-purge, if:

64 (129) M5178 1647EN

 ● gas is selected as fuel, and it is the first start-up
● burner control has been unenergized
● it has been a long time from previous shutdown
● it is a start-up after safety shutdown or lockout reset

During standard stop, valve leak test is carried out before pre-purge period.
1. Servomotors drive to the ignition position. Set default values for ignition position. If
oil is selected as fuel, check oil pump operating pressure.
2. When adjustments are set, select program stop at 44 Interval 1. As program moves
forward, spark ignites.
Preignition phase begins. Preignition phase is longer in oil use, so that purging
period is implemented at nozzle to ensure good ignition. After preignition phase fuel
nozzle opens and flame ignites. Program progress is interrupted.
3. Optimize ignition position values.
If gas is selected as fuel in program phase 44, only ignition gas flame burns and in
program phase 52 main flame burns.
If oil is selected as fuel ignition is direct, program phases have only different
program phase durations. Ignition position setting can be adjusted in program stop
phases 36, 44 and 52.
4. Select program stop deactivated. Burner shifts in to standard operation, phase 60,
to set minimum load. Ignition position settings become first curve point settings for
fuel/air ratio curve, that can be changed.

Set ignition position settings at the following menu level:

Params &          
Display
RatioControl        

  GasSettings      

    Special    
Positions
      IgnitionPos  

        IgnitionPos- Gas

          IgnitionPos- Air
          IgnitionPos-
Aux1
          IgnitionPos-
Aux2
          IgnitionPos-
Aux3
          IgnitionPos-
VSD

Check combustion values of ignition capacity with flue gas analysis.

It is not recommended to set fan rotation speed under 70% at ignition

position.

M5178 1647EN 65 (129)

 4.22 Setting ratio curve
Curve points

There can be 15 curve points at the maximum.

Set curve points in the following menu level:

Params. & Display        

RatioControl      

  GasSettings    

    CurveSettings  

      Point

        Manual

Creating curve point individually

Current servomotor positions in degrees, frequency converter control and capacity in

percentages are shown at the right corner on display. Pointer is positioned at Point.

Curve point 1 ver. 3

Press Enter to scroll through stored curve points.

Curve point 2 ver. 3

The pointer is positioned at the colon below the Point text. After the colon, there is the
running number of the stored curve point.

Curve points are stored according to capacity from smallest to biggest. Curve points
can be added at any order. Scroll through curve points using the Select -/+ buttons.

The unused curve point setting is XXXX and its running number is one number greater
than last stored curve point running number.

66 (129) M5178 1647EN

 If you want to set a new curve point, press Enter, when XXXX is displayed as set
value.

The ignition position will automatically be the first ratio curve point, from which the
burner minimum load point is adapted.

Editing individual curve point

To change the existing curve point:

1. Select the desired point and press Enter.
2. The pointer is positioned on change? below Point. The running number of the curve
point to be changed is displayed after the colon.

Curve point 3 ver. 3

3. Select 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. 3

When the servomotors drive to position for set curve point, the display
shows ">" instead of ":".
When the servomotors have reached their positions, ":" returns to the
display .
Servomotors settings can be modified only when each servomotor has
reached its position.

Operation can be interrupted by pressing Esc. The display returns to the initial state.

Capacity, servomotor and frequency converter settings can be scrolled through using
the Select -/+ buttons.

Curve point 5 ver. 3

M5178 1647EN 67 (129)

 Press Enter at the desired parameter.

Curve point 6 ver. 3

Change setting using the Select -/+ buttons. Then servomotors drive to their new
position. During that time the display shows ">" instead of ":". Confirm the change by
pressing Enter or undo by pressing Esc. Then you return to the previous menu level.

The servomotor turning angle is 0…90° and they can be set at 0.1° accuracy. The
capacity and frequency converter 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%
● check combustion values with flue gas analysis
● check combustion flame
● set load value, point load is determined according to current fuel consumption as
percentages from maximum load

In servomotors for air and frequency converter control, residual oxygen is adjusted as
desired for each curve point.

When you have made changes, press Esc.

Curve point 7 ver. 3

If you want to save curve point setting changes, press Enter. If you want to leave
without saving changes, press Esc. Return to point where you can scroll through curve
points. Return to menu using Esc.

Creating curve point manually by changing load

1. At the menu level CurveSetting, move the pointer to Manually.

68 (129) M5178 1647EN

 Curve point 8 ver. 3

2. Press Enter, and use the Select -/+ buttons to increase or decrease burner start
capacity.

Curve point 9 ver. 3

3. Servomotors follow imaginary linear towards maximum or minimum load.

Oxygen value can be monitored from display. When increasing load, monitor that
combustion values do not increase to a hazardous level. If necessary, set curve
point for interval by pressing Enter, and correct servomotor positions to return
combustion values to normal level. Press Esc to return to the initial state. The curve
point for maximum load will be set when fuel consumption for full load is reached.

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 required oil consumption is not reached when oil regulator valve

setting is 90°, check oil pump operating pressure, and adjust if
necessary.

Adjust at full load curve point:

● burner capacity, note ratio
● set fan rotation speed as small as possible
● check combustion values with flue gas analysis
● check combustion flame
● set point load setting at 100%

When you have made the required changes, save the maximum load curve point.

If linear pressure for gas supply has been affected at maximum load
curve point, check minimum point setting and adjust, if necessary.

If oil pump pressure has been changed at maximum load curve point,
check minimum point setting, and adjust if necessary.

M5178 1647EN 69 (129)

 Middle points are set manually by decreasing load manually for example in 10%
distances. Note that residual oxygen level is sufficiently over aired if the burner is
equipped with O2 trim control. Oxygen residual level is set 1% higher than the normal
level. There can be 15 curve points at the maximum. Set at least 10 curve points for O2
trim control.

Measure fuel consumption on every adjusting point so that the set of

curves correspond to the genuine load situation.

Check combustion values of ignition capacity with flue gas analysis.

When curve points have been set, exit from curve setting menu level, and set the
burner to operate on minimum load from manual operation menu level.

    Description
ManualOperation    
  SetLoad  
    Fixed load setting on manual
operation, percentages of
maximum load (%)

When exiting the Params. & Display menu level, changes can be stored to the
operating and display unit memory.

Store changes by answering yes.

4.23 Activating FGR

Burner equipped with FGR can also be used without FGR. Whenever
you change FGR on or off, you need to recheck fuel-air ratio curves.

FGR can be activated from: Params. & Display↵ Flue gas recirc. ↵ FGR mode↵ TC
autodeact↵

It is recommended to commission the plant first without flue gas recirculation (FGR).
Thus the fuel-air ratio control system is set as if the plant operated without the FGR
function.

When all other settings have been made, create FGR curve points at ratio curve. The
FGR function will become active after you have stored the curve point settings.

During the time the curve menu is in use, the state of the FGR function does not
change. This means that the AUX3 for FGR is still at the FGR closed position until
parameter setting is completed.

The parameters for FGR mode have been set at the factory. The commissioning
personnel will adjust the settings at start-up if needed.

For further instructions, see the section Setting FGR curve points.

70 (129) M5178 1647EN

 4.24 Setting FGR curve points

The FGR curve points are set at the fuel-air ratio curve. During the time the curve menu
is in use, the state of the FGR function does not change. This means that if the AUX3 is
still at the ignition position when setting parameters, it maintains the position until the
curve setting is completed.

At this position, the recirculation duct remains in ignition position, and the AUX3 is
marked with # on the screen. The position value of the AUX3 can be changed, but it
will not follow the readjustment for that period of time. The changed value can also be
stored.

If the AUX3 is not marked with # when setting parameters, it is already on the ratio
control curve, and follows the readjustment of the position value immediately.

After time period or temperature is reached, AUX3 will be released and FGR curve can
be made.

Temperature value can be changed from: Params. & Display↵ Flue gas recirc. ↵
ThresholdFGR Gas↵

Time period value can be changed from: Params. & Display↵ Flue gas recirc. ↵
DelaytimeFGR Gas↵

To create curve points:

1. Go to Params. & Display↵ Ratio control ↵ Gas settings ↵ Curve Param ↵
2. Select the required curve point and press ↵.
3. To edit the curve point, select change, and press ↵ to continue.

Curve point 3 ver. 3

4. Select should the servomotors follow the adjustment during operation, Followed or
Not followed.
5. On the next screen, press Enter to continue.

Curve point 3 FGR ver. 1

FGR temperature is stored to each curve point. Current FGR temperature can be
viewed from display using +/- buttons.

Make sure capacity is stable and FGR tempererature is within the normal operation
limits before storing curve point. This temperature is used to module the FGR valve
during operation.

M5178 1647EN 71 (129)

 Changing curve settings may have an impact on the combustion
settings. Check the servomotors regulating fuel and air. Readjust if
needed.

You can save changes to the operating and display unit memory. Answer yes to the
screen message that appears when leaving Params. & Display menu level.

For more detailed instructions on setting, monitoring, and editing curve points, see
section Setting ratio curve.

4.25 Measuring FGR

FGR principle monoblock ver. 1

Pos. Item Pos. Item

1 FGR duct 3 FGR control valve
2 Temperature sensor 4 Measuring point of residual oxygen in flue
gas

Recirculated flue gas amount is typically 10–20 % of the flue gas/combustion air
mixture amount, depending on the application. Flue gas percentage is counted as
follows:

3 3
FGR % = Flue gas amount recirculated m n / (Flue gas amount recirculated m n +
3
combustion air amount in m n) %

72 (129) M5178 1647EN

 To define flue gas percentage
1. First measure the amount of O2 in the flue gas/combustion air mixture. The optimal
measuring point is the burner wind box.
2. Measure the residual O2 in flue gas.
3. Read the FGR percentage value in the diagram below.

Natural gas combustion, Flue Gas Recirculation (%)

20 %

18 %
Flue gas O2 = 2 %
16 %
Flue gas O2 = 3 %
14 %
Flue gas O2 = 4 %
12 %
FGR -%

10 %

8%

6%

4%

2%

0%
17,5 % 18,0 % 18,5 % 19,0 % 19,5 % 20,0 % 20,5 % 21,0 %
Mixture O2 content (dr y), %

FGR natural gas ver. 1

FGR may cause unstable combustion. To avoid noise, vibration or other disturbance,
the settings must always be defined for each burner separately.

4.26 Capacity range

Burner capacity range can be set as required at service level. The minimum capacity
can be larger than the first curve point, and the maximum capacity can be larger than
the last curve point. During start-up, the burner runs from ignition capacity to minimum
capacity, and continues to normal operation. Ignition capacity can be smaller or larger
than the first curve point capacity or it can be the same.

Set minimum and maximum capacity for each fuel individually from menu as follows:

          Description
Params. &          
Display
RatioControl        

  GasSettings      

M5178 1647EN 73 (129)

     LoadLimits    

      MinLoadGas. Minimum load

"Low fire" (gas)
      MaxLoadGas Maximum load
"High fire" (gas)

On user level, maximum load can be set individually as follows:

      Description
Operation      
User Maxload    

  User MaxLoadMod Maximum load on

modulating burner

4.27 O2 min. value control (WD200)

O2 ratio control can be set after setting the ratio curve.

Ratio curve air amount should be approx. 1 % higher than O2 ratio

control, so that environmental changes do not set residual oxygen level
below O2 trim control level.

Ratio curve should be as smooth as possible. If the curve has sharp breakpoints, set
one additional point to smooth the curve. Even ratio curve improves O2 ratio control.
In dual-fuel burners, set the O2 ratio control individually for both fuels, and they are not
correlating.

Start O2 ratio curve by setting O2 min. value control.

O2 min. value control

When setting for the first time O2 monitor should be deactivated with man deact.

Params. & Display        

O2Contr/Guard      

  FuelSettings    

    OptgMode  

      man deact

Set O2 min. value control as low as possible to ensure a high availability. O2 min. value
is between the permanently non-hazardous range and the potentially hazardous range.
O2 ratio curve is set at lowest 0.5 %–1 % above O2 min. value, so during normal burner
operation this level should not be reached.

74 (129) M5178 1647EN

 Hazardous conditions must not permanently occur above or at O2 min.
value.

Maximum permitted values: CO = 4000 ppm, #2 on the Shell-Bacharach scale.

Values may vary depending on the type of plant.

If the ratio curves are changed later, min. value must also be
readjusted.

O2 min. value direct entry

1. Select O2 Monitor from menu as follows:

Params. & Display      

O2Contr/Guard    

  Fuel Settings  

    O2 Monitor

2. If the limit values of a plant are known, O2 min. values can be entered directly to
curve points during burner operation.
The first line shows curve point number. Scroll through points by pressing the
Select -/+ buttons. By pressing Enter twice, you can enter residual oxygen level as
percentages to the second line. Use the Select -/+ buttons.

Point26 ver. 3

3. Accept the value by pressing Enter. Exit by pressing Esc.

Measuring O2 min. values by reducing air

1. Select desired point from previous menu level by pressing the Select -/+ buttons
during burner operation. Press Enter.
2. Select third line P-Air Man by pressing the Select -/+ buttons, and press Enter. The
display changes as follows:

Point27 ver. 3

3. Second line shows residual oxygen level. You can reduce air by pressing the
Select -/+ buttons. Larger value at P-Air Man means larger air throttle.

M5178 1647EN 75 (129)

 O2 min. value surface is verified by throttling air and measuring CO level at the
same time.
4. When desired oxygen level is reached, accept the value by pressing Enter. Exit by
pressing Esc. Repeat for each curve point.

Start setting O2 ratio control after O2 min. value control is set.

4.28 Setting O2 trim control (WD200)

O2 min. value O2Control must be set first.

It is important that environmental conditions do not change when setting O2 trim

control.

If the curves are changed later, adjust also O2 trim control.

The first curve point from which O2 trim control begins is preset at curve point 2. That
is the first point to be set for O2 trim control. At this point burner control calculates low
capacity settings for O2 trim control. At lower capacity burner operates according to
ratio curve, without O2 trim control.
1. Select O2 Control from the following menu level:

Params. & Display      

O2Contr/Guard    

  Fuel Settings  

    O2 Control

 
2. The first O2 trim control point is curve point 2.
At lower capacity burner operates according to ratio curve.
Confirm the selection by pressing Enter. The burner runs to point 2 capacity.

Point2 ver. 3

3. The display changes. The second line O2ratioCon shows current residual oxygen
level. Wait until the level stabilizes, and corresponds with ratio curve level. The
burner control uses this level when calculating O2 trim control settings.
Confirm the selection by pressing Enter.

76 (129) M5178 1647EN

 Point22 ver. 3

4. Display the changes. The third line shows the current residual oxygen level. The
pointer is on StandardVal. Reduce the air by pressing the Select -/+ buttons, if
necessary. Larger level at this point, means larger air throttle. When desired oxygen
level is reached, press Enter.

Point23 ver. 3

5. Display the changes.

 
Save or reject by pressing Enter.

Point24 ver. 3

At curve point 2, and at the highest curve point, the burner control calculates PI
parameters, and time delays for O2 monitor by driving the burner back to ratio
curve. After that the display returns to initial state.
Select next curve points from the menu by pressing the Select -/+ buttons, and
set O2 setpoints from them. If flue gas speed in ratio curve point 2 is too low, O2
monitoring set value calculation does not succeed. The burner control notifies this in
the operating and display unit.
O2 monitoring first point can be set later using the parameter Adapt.Pointsmall.

Point25 ver. 3

M5178 1647EN 77 (129)

 4.29 O2 trim control operating mode (WD200)

Select the suitable O2 trim control operating mode as follows:

Params. & Display        

O2Contr/Guard      

  FuelSettings    

    OptgMode  

      auto deact

        man deact
        O2 Limiter
        O2 Control
        conAutoDeac

O2 trim control operating modes

man deact Use this setting when creating O2 ratio curve.

Both O2Limiter and O2Control are deactivated. Burner operates according to
parameterized ratio curves.
O2 Limiter Only O2Limiter is active. Oxygen sensor must have reached its operating
temperature. If not, start-up will be prevented. If oxygen sensor or O2 module
causes a failure during burner operation, burner stops, tries to restart or lockout
occurs.
O2 Control Both O2Limiter and O2Control are active. Oxygen sensor must have reached its
operating temperature. If not, start-up will be prevented. If oxygen sensor or O2
module causes a failure during burner operation, burner stops, tries to restart or
lockout occurs.
conAutoDeac Use this setting during normal operation.
Both O2Limiter and O2Control are active. Burner starts, though oxygen sensor
has not reached its operating temperature. Burner operates along parameterized
ratio curves. When oxygen sensor has reached its operating temperature and
sensor test has been successfully completed, both O2Limiter and O2Control are
active. If oxygen sensor or O2 module cause failure during burner operation, both
O2Limiter and O2Control are deactivated. Burner operates along parameterized
ratio curves. O2 trim control status in operating and display unit is automatically
set to auto deact, and error code is displayed. Error code is maintained until O2
trim control is manually deactivated or activated.
auto deact O2 trim control has automatically been deactivated and burner operates along
parameterized ratio curves. Do not select this option!

If O2 trim has been automatically deactivated, then you can reactivate it

from: Operation↵ O2Ctrl Activate ↵ Activate↵.

4.30 O2 trim control load limitation (WD200)

Select O2CtrlThreshold from the operating and display unit menu as follows:

78 (129) M5178 1647EN

 Params. & Display
O2Contr/Guard

Fuel settings

O2CtrlThreshold

Apadt.Point small
Type of Fuel
Fuel user def

If load drops below this limit, the burner operates along parameterized ratio curves
without O2 trim control. Set load limitation after setting O2 trim control ratio curve. Load
limitation is usually curve point 2 load from basic parameterized ratio curve.

4.31 O2 trim control when load changes (WD200)

When load changes under unfavourable setting conditions, the actual O2 value will
drop below the minimum limit. To prevent this, parameterize an increase of the O2
value during capacity change O2 OffsetGas/Oil.

Params. & Display      

O2Contr/Guard    

  FuelSettings  

      Type ofAir-Change
    O2 OffsetGas/Oil

      LoadCtrlSuspend
      FilterTimeLoad

Parameters

Type ofAirChange Impact of air density change on O2 value

● like P air, gas use
● like theory, oil use
O2 OffsetGas/Oil O2 trim control setting increase during capacity
control. Presetting 0,5 %.
LoadCtrlSuspend Limit of load difference when O2 trim controller will
be locked. Presetting 5%.
FilterTimeLoad Delay time of previous parameter, 5 => 5 x τ,
presetting.

4.32 Setting capacity controller operating mode

1. Set boiler temperature set value W1 for capacity controller.

M5178 1647EN 79 (129)

       Description
Operation      
BoilerSetpoint    

  SetpointW1 Internal setpoint W1, °C

/ °F
Internal setpoint W1, bar
/ PSI

 
2. Select burner start-up manually by activating Autom/Manual/Off option Autom.
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 modulating burner capacity as necessary. Capacity controller shuts down and
restarts the burner if necessary. Select capacity controller control parameters from
the menu as follows:

Params. & Display      

Configuration    

  LC_OptgMode  

    ExtLC X5-03
IntLC
IntLC Bus
IntLC X62
ExtLC X62
ExtLC Bus

Capacity controller operating modes:

ExtLC X5-03 External capacity controller with contactors.

IntLC Internal burner control capacity controller. Internal set value W1 in use. Can be
changed to internal set values W1-W2 using contactors.
IntLC Bus Internal burner control capacity controller. Set value for burner control through
Modbus or eBus.
IntLC X62 Internal burner control capacity controller. Set value for burner control through
analog signal. Can be changed to internal set value W1 using contactors.
ExtLC X62 External capacity control with analog signal.
ExtLC Bus External capacity control using Modbus or eBus.

80 (129) M5178 1647EN

 4.33 Setting capacity controller parameters
Standard parameter setting

Capacity controller contains 5 standard parameter settings that can be selected and
activated, depending on characteristics of controlled process.

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:

  P [%] I [s] D [s]

Very fast 42.5 68 12
Fast 14.5 77 14
Normal 6.4 136 24
Slow 4.7 250 44
Very slow 3.4 273 48

P = Proportional band

I = Integral action time

D = Derivative action time

Setting parameters individually

PID parameters can also be set individually according to the following value range:
● P-Part (Xp) 2…500% of the measurement range
● I-Part (Tn) 0…2000s, 0=no I part
● D-Part (Tv) 0…1000s, 0=no D part

Params. & Display        

LoadController      

  ControllerParam    

    ContrlParamList  

M5178 1647EN 81 (129)

       P -Part (Xp)

        I -Part (Tn)
        D -Part (Tv)

● By increasing the proportional band, the temperature/pressure deviation is lowered.

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.
● Using too great a derivative action time will result in temperature/pressure
fluctuation.

Parameter adaptation

During adaptation, the burner control calculates PID parameters for process which is
controlled based on the characteristics.

Params. & Display      

LoadController    

  Adaption  

    StartAdaption

      AdaptionLoad

The burner and boiler are ready for 10 min. run, where boiler temperature or pressure
is dropped below 5 % set value, and then run with full load. This occurs automatically
according to the following diagram. Boiler load should stay constant throughout
adaptation.

82 (129) M5178 1647EN

 Flow chart_WD capacity ver. 2

O2 trim control must not be active during adaptation.

In the WD200 system, deactivate O2 trim control from the operating and display unit
menu:

Operation    
O2Ctrl activate  

  deactivated

    activated

Select StartAdaption.

Parameter evaluation

Capacity 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.

M5178 1647EN 83 (129)

 Practical value for Tn / Tv = 4…6.

Examples of typical incorrect settings, and the optimal setting to change the set value:

Xp too low Xp too high

Tn and Tv too low

Tn and Tv too high
 

Optimum setting

If load control is not completely stabilized, but fluctuates continuously near the setpoint
value, the following parameters can be used to control this.

Always make sure that the PID parameters are correctly set before
using the following parameters. A noticeable fluctuation of load near the
set value indicates poor setting of PID parameters.

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 settings is 1%.

84 (129) M5178 1647EN

 SW_FilterTimeCon. can be used to delay the internal load controller. If the value for this
parameter is too high, the internal load controller becomes unstable. The factory setting
is 3s.

4.34 Capacity controller on/off

If temperature or pressure has been given a set value, burner start-up and shut
down limits are percentages of the set value. Calculate switching points according to
following example:

  Setting 70 °C
158 °F
Mod_On Burner start -10 % (=7 °C) 70 – 7 = 63 °C
-10 % (=44.6 °F) 158 – 44.6 = 113.4 °F
Mod_Off Burner shutdown +5 % (=3,5 °C) 70 + 3,5 = 73,5 °C
+5 % (=38.3 °F) 158 + 38.3 = 196.3 °F
Mod_On is possible to set between –50…+50 %
Mod_Off is possible to set between 0…+50 %

Params. & Display      

LoadController    

  ControllerParam  

    Mod_On

      Mod_OFF

Example running period.

KAYNTIJAKSO ver. 2

4.35 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. Burner restarts
when temperature limiter is reset.

Example:

M5178 1647EN 85 (129)

 TL_ThresholdOff Limiter switch-on point 80 °C
176 °F
TL_SwiDiff_On Temperature difference percentages -10 % (=8 °C)
-10 % (46.4 °F)
  Limiter reset temperature 72 °C
161.6 °F

        Description
Params. & Display        
LoadController      

  TempLimiter    

    TL_ThreshOff Temperature limiter

OFF threshold, °C /
°F
      TL_SD_On Temperature limiter
switching differential
ON

4.36 Cold start thermal shock protection

Cold start thermal shock protection protects the boiler from thermal stress if the boiler
has cooled down. The burner starts with small load and the load increases as the boiler
warms up. Without protection, the burner runs straight to full load.

If boiler temperature or pressure has dropped under set value ThresholdOn, the burner
starts with minimum load. The load depends on two factors:
1. If the set value does not reach the set step within the maximum time, the load will
be increased by one stage step.
2. If the set value has reached the set step before the maximum time has elapsed, the
load increases by one stage step.

The menu shows values used in the chart example.

        Example,
Set value 10 bar
Params. & Display        
LoadController      

  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

86 (129) M5178 1647EN

 Cold start thermal protection operation example.

KYLMAKAYNNISTYS ver. 3

4.37 Measuring flue gas and combustion air temperature

(WD200)

Flue gas and combustion air temperature measuring sensor can be connected to O2
module.

Alarm for high flue gas temperature can be set individually for both fuels.

Select the sensor type and set the alarm threshold from the menu as follows:

Params. & Display      

O2 Module    

  Configuration  

    O2 Sensor

      SupAirTempSens
      FlueGasTempSens
      MaxTempFlGasGas
      MaxTempFlGasOil

4.38 Activating O2 trim control (WD200)

At the end of commissioning activate O2 trim control from the display and operation unit
menu.

M5178 1647EN 87 (129)

 Operation    
O2Ctrl activate  

  deactivated
activated

4.39 Backing up parameters

1. Start backing up parameters by selecting following from the display and operating
unit:

Updating    
ParamBackup  

    BackupInfo
  LMV5x –> AZL

    AZL –> LMV5x

2. Start backing up by pressing Enter.

3. Parameter backup is done, when text Parameters saved appears on display.

88 (129) M5178 1647EN

 5 Operation

5.1 Burner operation

WiseDrive 100 / 200

LMV operation ver. 4

The assembly may vary depending on the scope of delivery.

In the WiseDrive system, burner operation is controlled and supervised by an

integrated burner control.

In the WD200 system, the burner can be equipped with O2 module to increase
combustion efficiency.

The burner control adjusts fuel and air ratio.

The system includes an operating and display unit for local use.

To enable continuous operation, the WiseDrive system uses components designed

specifically for this system. The system supervises components related to safety
functions with continuous self-testing.

M5178 1647EN 89 (129)

 Burner control

Burner controller is a microprocessor-based burner

control and safety system.
Burner control can have the following features:
● Burner control and safety functions
● Electronic fuel/air ratio
● Gas valve proving
● Capacity controller
● Fan frequency converter control (WD200)
● Residual oxygen control (WD200)
● Boiler cold start thermal shock protection
● Fuel flow meter (WD200)
● Burner efficiency measuring (WD200)
● Start-up and running time counters
● Fault and lockout history
● Real-time clock
LMV5 ver. 3
● Bus interface

Burner control is a safety device. Do not open it or interfere with it.

Servomotors

Servomotors are used to drive fuel regulators and

other actuating devices.

SW00017 ver. 3

● Electrostatic dischargecan damage servomotor.

● Do not dismount servomotor. Do not interfere with or modify unit or
equipment connected to it. It may damage servomotor, and change
burner settings.
● Do not use servomotor that might be damaged.

90 (129) M5178 1647EN

 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 group 4 ver. 3

Operating and display unit

The WiseDrive system operating and display unit is

used for monitoring and adjusting settings.
The menu is available in several languages.
The operating and display unit has an internal
memory backed up by a battery. The memory stores
the burner control parameters. Battery durability is
approximately 10 years.

AZL ver. 4

O2 module (WD200)

O2 module and oxygen sensor measure the residual

oxygen content of the flue gases. Burner control
uses the measurements to monitor and optimise
the combustion process. Flue gas and combustion
air temperature sensors can be connected to the
system to measure efficiency.

PLL52 ver. 3

M5178 1647EN 91 (129)

 Oxygen sensor (WD200)

Oxygen sensor measures the amount of residual

oxygen from flue gas. The sensor is a ceramic
zirconium dioxide cell and self-testing.

QG020 ver. 3

Flame detector

QRI is a flame detector for use with gas, oil

and other flames that emit infrared light. Flame
signal intensity can be monitored on display.
Flame detector is equipped with self-test
function and is suitable for continuous use.
QRI ver. 3

5.2 General description of burner operation

Burner has to be connected to the oil circulating system according to

site diagram.

Burner start-up, pre-purge, ignition

Prepurge starts with full capacity and needed amount of air. After prepurge
servomotors turn to ignition capacity position and solenoid valves open. Oil spray is
generated by oil pump pressure of the burner and enters the nozzle valve control circuit
and nozzle. Nozzle is controlled by oil pressure in control circuit.

Oil spray from nozzle ignites by spark between ignition electrodes. The oil amount
to be burnt is adjusted by oil regulator valve. Adjustment is made by throttling the
oil return flow. At minimum capacity the oil regulator valve is open and at maximum
capacity it is closed.

Burner operation

During burner operation capacity controller controls the servomotor. Servomotor in turn
controls oil regulator valve and air dampers according to the boiler capacity demand.
If burner stops, solenoid valves close and oil pressure of the control circuit is released
from nozzle valve.

Burner shutdown

If burner minimum load exceeds the capacity demand of the boiler, burner shuts down
and solenoid valves close.

92 (129) M5178 1647EN

 If burner shuts down, solenoid valves (NC) close and control flow oil pressure releases
from nozzle valve. Nozzle valve spring power closes nozzle needle valve and oil supply
from nozzle.

Post-purge

The post-purge position of servomotors is adjusted according to the fuel type. After
burner shutdown, servomotors drive to their post-purge positions. The fuel valves are
closed. The combustion air fan is running, to clear the combustion chamber of unburnt
fuel and products of combustion.

Burner start-up, pre-purge, ignition

During pre-purge, the burner fan ventilates the boiler and smoke flue. At the time, the
double solenoid valve is closed. The fan manages to create a full air pressure before
gas inlet. Air in the boiler and in the smoke flue will be circulated, which reduces the
pressure, developing in combustion chamber during flame ignition.

After the pre-purge, the servomotors run to the ignition position, the ignition begins,
and the double solenoid valve opens. Gas releases to the nozzle, and ignites by spark.
Ignition ends after time determined by the burner control. The flame burns with set
ignition load.

Burner operation

During burner operation, the capacity controller controls the burner control, which
controls the servomotors. Servomotors adjust the gas regulator valve and air dampers
between partial load and full load according to the capacity demand.

Burner shutdown

If burner minimum load exceeds the capacity demand of the boiler, burner shuts down
and gas valves close.

Gas valve proving

Gas valve proving is carried out with a switch, that tests double solenoid valve and
possible ignition gas valve tightness according to burner control program phase.
Pressure switch carries out gas valve testing during controlled shutdown or during next
prepurge period.

Post-purge

The post-purge position of servomotors is adjusted according to the fuel type. After
burner shutdown, servomotors drive to their post-purge positions. The fuel valves are
closed. The combustion air fan is running, to clear the combustion chamber of unburnt
fuel and products of combustion.

M5178 1647EN 93 (129)

 5.3 Gas valve proving

Valve proving system is carried out with pressure switch that supervises piping section
between valves. Burner control opens and closes gas valves during proving according
to the programmed times. If leak is detected, gas valve proving function prevents gas
valves from opening, and ignition from beginning. Safety shutdown activates. Burner
control display shows the leaking valve.

Gas valve proving is carried out during normal burner shutdown, between phases 62
and 70. If the previous shutdown was not normal, for example, because lockout or
burner control has been de-energized, it takes place during next start-up sequence,
during pre-purge period, between phases 30 and 32.

Valve proving sequence phases are 80... 83.

      
Phase 80:   Evacuate. Gas valve V2 on burner side is opened to
V1 PS V2 bring test space to atmospheric pressure. Valve V1
VP on gas network side stays closed.
   
Phase 81:   Atmospheric pressure test. Both gas valves are
closed. Gas pressure may not exceed the preset limit
V1 V2 PS-VP of the valve proving pressure switch during test.
   
Phase 82:   Fill. Gas train is filled by opening gas valve V1 on gas
t80 network side. Gas valve V2 on burner side is closed.
   
Phase 83:   Pressure test. Both gas valves are closed. Gas
t81
pressure may not drop below the preset limit of the
pressure switch valve proving pressure switch during
test.
t82

t83

TIIVIYDENTESTAUSPAINEKYTK ver. 3

5.4 Legend to time sequence diagrams

Phases:

00 Lockout phase 50 2nd safety time

01 Safety phase 52 Interval 2 (ti2)
10 Homerun 54 Low-fire position
12 Standby (stationary) 60 Operation 1 (stationary)
21 Shutoff valve ON (start release) 62 Operation 2
Low-fire position
22 Fan motor ON 70 Post-combustion time
24 Prepurge position 72 Postpurge position

94 (129) M5178 1647EN

 30 Prepurge time (tv1) 74 Postpurge time (tn1)
32 Prepurge time (tv) 76 Flue gas recirculation postpurge position
34 Prepurge time (tv2) (flue gas recirculation ARF) 78 Postpurge time (tn3)
36 Ignition position 79 Direct start
38 Preignition (Z) ON 80 Valve proving evacuating time
40 Burner valve ON 81 Valve proving time atmospheric pressure
42 Ignition OFF 82 Valve proving filling time
44 Interval 1 (ti1) 83 Valve proving time gas pressure

Times:

t0 Postpurge lockout position t78 Postpurge time 3 gas / oil (tn3)

t01 Max. time safety phase t80 Valve proving evacuate time
t10 Min. time home run t81 Valve proving time atmospheric pressure
t21 Min. time start release t82 Valve proving filling time
t22 Fan running time t83 Valve proving time gas pressure
t30 Prepurge time part 1 tmn1 Min. time extraneous light test (5 s) after
skipping prepurge
t34 Prepurge time part 3 tmx1 Max. damper running time
t36 Min. ON time oil pump tmx2 Max. time startup release
t38 Preignition time gas/oil tmx3 Max. time circulation heavy oil
t42 Preignition time OFF tn Postpurge time
t44 Interval 1 gas/oil TSA1 First safety time gas/oil
t62 Max. time low-fire TSA2 Second safety time gas/oil
t70 Post-combustion time tv Prepurge time gas/oil
t74 Postpurge time 1 gas / oil (tn1)    

Abbreviations:

AL Alarm PV Pilot valve

ARF FGR = flue gas recirculation R Temperature or pressure controller ON
(internal + external)
CPI Closed Position Indicator RP No-load position
DP Pressure switch SK Safety loop (safety limit thermostat, water
shortage)
DW-DK Pressure switch + valve proving SP Setpoint position
DWmin Pressure switch-min SR Safety relay internal
DWmax Pressure switch-max STB Safety limit thermostat
FS Flame signal SV Shutoff valve
GSK Fan contactor contact TW Temperature switch internal
KL Low-fire position V1 Fuel valve 1
LK Air damper V2 Fuel valve 2
LP Air pressure switch V3 Fuel valve 3
M Fan motor VL Prepurge position
N Postpurge Z Ignition
NL Postpurge position ZL Ignition load position

M5178 1647EN 95 (129)

 Symbols:

Signal ON Signal OFF Next phase

00, repetition = 0
01  12, repetition > 0
  Parameter NormalDirectstart
Checking with controller ON
Deviation → 10
No repetition decrement
  10

  70

  Without valve proving → 70

With valve proving → 80
  62

Stop, up to phase maximum time → 01

Stop, up to phase maximum time → 10

0...3 s
00, repetition = 0
0...30 s 01  12, repetition > 0
0...3 s

Output OFF / input Irrelevant

Output ON / input ON

Permissible positioning range

In Standby: actuator can move within the permissible positioning range, but is always driven
to the home position. It has to be in the home position before changing the phase.

0° Position as supplied (0°)

90° Actuator fully open (90°)

Indices:

1) Param.: ValveProvingType→ Valve proving takes place between phases 30/32 and/or phases
60/70
2) Param.: Short / long preignition time for oil only
Short / long oil pump – ON – time
3)   Delayed shutdown within safety time
5) Param.: Normal / direct startup
Normal startup → sequential phase = 10
Direct startup → sequential phase = 79 (when R = ON)
6)   Sequential phase = 24
7)   Only with valve proving during startup
8) Param.: With/without alarm on prevention of startup
9) Param.: With continuous purge the shown output signals are inverted
10)   Fan controlled as before
Postpurge in lockout position = PostpurgeLockout
11) Param.: With / without extraneous light test in STANDBY
12)   With valve proving during startup phase 10

96 (129) M5178 1647EN

 13) Param.: Normal / continuous purge
Normal purge:
Checking for OFF in 10 and 12, stop to phase-max time → 01
Continuous purge:
Checking for ON in 10 and 12, stop up to phase-max time → 01
14) Param.: OilPressureMin, act from ts → no check before first safety time (LO, HO) or second
safety time (LOgp, HOgp)
15) Param.: GasPressureMin, deact xOGP→ pressure switch-min (Pmin) can be deactivated for oil
programs with gas pilot
16) Param.: OilPumpCoupling:
direct_coupl → shutoff valve - oil to be connected to output Oil pump / magnetic clutch.
Output is active when fan is on and for another 15 s after fan is switched off.
18) Param.: Alarm act / deact, deactivated→ alarm output can temporarily be deactivated (for
current error only)
19) Param.: Only LMV50... and LMV52...: Continuous pilot gas/oil: Activated → pilot valve is also
activated in operation
20) Param.: Only LMV50... and LMV52...: Extraneous light, pilot phase, operating phase gas/oil →
Separate flame supervision possible
22) Param.: Depending on parameter StartPoint Op
23) Param.: Depending on parameter DriveLowfire Gas or DriveLowfire Oil
24) Param.: Depending on parameter HeavyOilDirStart
25) Param.: Air pressure test = deactivated in standby → irrelevant in phase 10 and 12
26) Param.: Long postpurge time tn3 (PostpurgeT3long)
27) Param.: Only LMV50... → cooling function in standby
28) Param.: Continuous purge

k) Heavy oil direct start

l) Restricted startup behavior
n) Restricted safety loop

M5178 1647EN 97 (129)

 5.5 Time sequence diagram, gas use

Time sequence diagram, G ver. 3

98 (129) M5178 1647EN

 Time sequence diagram, Gp1 ver. 5

M5178 1647EN 99 (129)

 Time sequence diagram, Gp2 ver. 2

5.6 Burner automation description, gas use

Time sequence phases

Prerequisites for start-up

● Fuel selector switch in position 2 (gas).
● Failures and interlocks reset.
● Limit switch on burner flange closed.
● Safety loop closed.
● Boiler temperature limiter not activated.
● Control switch in position 1.
● Burner control in standby position.
● Manual or automatic mode selected in burner control, also capacity controller must
be switched on.
● Remote control contacts closed.
● Boiler thermostat/pressure switch contact closed.
● Differential air pressure switch contact open.

100 (129) M5178 1647EN

 20, 21 Start-up
● Burner control safety functions activate.
● Gas safety valve opens (optional).
● Gas pressure recognition, pressure switch min. closed.
● ”Gas start release” closed (optional ).

22 Fan motor starts

24 Servomotors drive to pre-purge position

● Fan contactor must be closed or in frequency converter use motor sensor must
detect motor rotation speed and direction
● Differential air pressure switch contact closes when air pressure is sufficient.
Otherwise burner goes to a lockout. Control is active until controlled shutdown.

30... 34 Pre-purge
● Pre-purge begins.
● Automatic gas valve proving, if previous shutdown was not normal or burner has
been switch-off.
● Lockout if burner control receives flame signal. Control is active until the beginning
of preignition.

36 Servomotors drive to ignition position

38 Preignition begins

40... 42 Safety time begins TSA1, 2 s

● Ignition gas valve opens.
● Gas valve 1 opens.
● Ignition gas is released to ignition nozzle.
● Ignition flame is ignited by spark.
● Gas maximum pressure control period begins, pressure switch max. contact must
be closed, otherwise burner control goes to a lockout.

44 Interval 1, safety time ends TSA2, 2 s

● Safety time ends, 2 s.
● Ignition ends.
● Ignition flame has to be ignited by now. Otherwise burner control goes to lockout,
because flame signal has not been received.
● Flame signal has to be available to burner control from the end of the 1st safety
time until controlled shutdown.
● Flame burns with set ignition load.

50 Second safety time begins

● Gas valve 2 opens.
● Gas flows through gas butterfly valve to nozzle.
● Main flame is ignited by ignition flame.

52 Interval 2
● Second safety time ends.
● Ignition gas valve closes.
● Main flame has to be ignited by now. Otherwise burner control goes to lockout,
because main flame signal has not been received.
● Main flame burns with set ignition load.

M5178 1647EN 101 (129)

 54 Servomotors run to min. capacity

60 Operation
● Burner control in automatic operation: burner control capacity controller adjusts
burner capacity on modulating range to correspond to the load by controlling air
dampers, gas regulator and fan motor rotation speed. Burner operates controlled
by burner control and capacity controller according to set parameters and functions.
Burner is switch off if process value exceeds the controller setting.
● Burner in manual operation: burner operates on capacity set by user. Burner is
switch-off controlled by boiler thermostat or pressure switch.
● Lockout, if flame signal or air pressure signal is lost during operation.
● Lockout, if gas pressure rises too high
● Lockout, if fan contactor contact opens or fan motor rotation speed signal
disappears during burner operation.
● Lockout, if servomotors do not reach the defined position during operation.
● Lockout, if the Esc and Enter buttons on operating and display unit are pressed
simultaneously during operation.
● Immediate shutdown, if gas pressure goes too low during operation.
● Immediate shutdown, if start release opens during operation.
● Immediate shutdown, if safety loop opens during operation.
● Immediate shutdown, if boiler temperature limiter activates during operation.

62 Controlled shutdown
● Servomotors run to min. load.
● Burner control carries out automatic gas valve proving.

70 Post-purge begins
● Gas shut-off valve (optional) closes.
● Gas safety valves 1 and 2 close.

72... 78 Post-purge begins

● Servomotors run to post-purge position.
● Lockout, if burner control receives flame signal.
● Fan motor stops at the end of phase 78.
● Burner control safety functions end at the end of phase 78.

10 Servomotors run to standby position

Restart possible, when standby position 12 is reached.

80... 83 Gas valve proving

● 80: emptying of piping between valves, gas valve 1 closed and valve 2 open.
● 81: test of normal pressure in piping between valves, gas valves 1 and 2 closed.
● 82: filling of piping between valves, gas valve 1 open and valve 2 closed.
● 83: pressure test of piping between valves, gas valves 1 and 2 closed.

00 Lockout phase
● Servomotors run to stand-by position.
● Burner failure activates.
● Requires manual reset.

102 (129) M5178 1647EN

 5.7 Time sequence diagram, oil use

Time sequence diagram, LO ver. 5

5.8 Burner automation description, oil use

Prerequisites for start-up
● All malfunctions and lockouts must be reset.
● Burner flange limit switch must be closed.
● Safety switch circuit must be closed.
● Boiler temperature limiter has not been triggered.
● Control switch must be in position 2.
● Main unit must be in stand-by mode.

M5178 1647EN 103 (129)

 ● Main unit must be set to either manual use or automatic use. If automatic use is
selected, the capacity controller must also be switched on.
● Remote start-up circuit contacts must be closed
● Boiler thermostat / pressure switch contacts must be closed.

20, 21 Start-up
● Main unit safety features activate.
● Oil safety valve opens (optional)
● Return oil pressure must be below the set maximum of the pressure switch
throughout normal operation until a controlled shutdown. If the pressure switch is
triggered, fuel intake is cut and the burner shuts down.
● Oil start-up release switch must be closed (optional).

22 Fan motor starts and pre-ignition is initiated

24 Servomotors drive to their pre-purge position

● Fan contactor must be closed.
If frequency converter is in use, motor sensor must detect motor rotation speed and
direction.

30... 34 Pre-purge
● Pre-purge begins.
● Lockout if burner control receives flame signal. Control is active until the beginning
of pre-ignition.

36 Servomotors drive to ignition position

38 Pre-ignition begins

Oil pump motor starts.

40... 42 Safety time begins

● Control circuit nozzle valve solenoid valve NC opens.
● Nozzle valve opens when pressurized oil reaches nozzle valve control circuit.
● Oil atomizing begins with ignition position atomizing pressure.
● Oil is ignited by spark.

44 Interval 1, safety time ends

● Safety time ends.
● Ignition ends.
● Flame has to be ignited by now. Otherwise burner control goes to lockout, because
flame signal has not been received.
● Flame burns with set ignition load.

54 Servomotors run to min. capacity

60 Operation
● Burner control in automatic operation: burner control capacity controller adjusts
burner capacity on modulating range to correspond to the load by controlling air
dampers, fuel regulator and fan motor rotation speed. Burner operates controlled
by burner control and capacity controller according to set parameters and functions.
Burner is switch off if process value exceeds the controller setting.
● Burner in manual operation: burner operates on capacity set by user. Burner is
switch-off controlled by boiler thermostat or pressure switch.
● Lockout, if flame signal or air pressure signal is lost during operation.
● Lockout, if return oil pressure rises too high.

104 (129) M5178 1647EN

 ● Lockout, if fan contactor contact opens or fan motor rotation speed signal
disappears during burner operation.
● Lockout, if servomotors do not reach the defined position during operation.
● Lockout, if the Esc and Enter buttons on the operating and display unit are pressed
simultaneously during operation.
● Immediate shutdown, if start release opens during operation.
● Immediate shutdown, if safety loop opens during operation.
● Immediate shutdown, if boiler temperature limiter activates during operation.

62 Controlled shutdown
● Servomotors run to min. load.

70 Post-purge begins
● Oil pump motor stops.
● Main oil valve closes.
● Nozzle valve closes when oil pressure in control circuit disappears.
● Flame extinguishes.

72... 78 Post-purge begins

● Servomotors run to post-purge position.
● Lockout, if burner control receives flame signal.
● Fan motor stops at the end of phase 78.
● Burner control safety functions end at the end of phase 78.

10 Servomotors run to stand-by position

Restart possible, when stand-by position is reached.

00 Lockout phase
● Servomotors run to stand-by position.
● Burner failure activates.
● Requires manual reset.

In fault conditions fuel supply is shut off immediately, and the fan stops. If lockout
occurs, the fault is shown on the operating and display unit. Lockout can be reset
immediately. After resetting servomotors run to stand-by position. Only then burner
control begins with a new burner start-up.

Immediate shutdown means that fuel supply will be cut off immediately
regardless of load. System continues normal shutdown sequence from
phase 70.

Controlled shutdown means that burner capacity will be run down. Fuel
supply will be cut off, and shutdown sequence continues from phase 70.

Pressing of burner failure reset button during burner operation causes a

lockout. Button is also used as emergency stop button.

Lockout means that fuel supply is cut off immediately regardless of load.
Fan stops and servomotors run to stand-by position.

M5178 1647EN 105 (129)

 6 Maintenance

6.1 Burner maintenance

Installation, commissioning, or service of the appliance is to be carried

out by authorized and trained personnel only, adhering to all local
regulations and requirements.

Fasten all safety covers, enclosures, and guards with all screws before
start-up. Use appropriate tools.

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.

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 oily.
3. Check ignition cable condition from the whole length. Change, if necessary.
4. Clean and check ignition electrodes, and check correct position. Change, if
necessary.
5. Change oil nozzle if it is worn out or damaged.
6. Check flame detector position, condition and cleanness.
7. Clean filters at least once a year. Filters may have to be cleaned more often
depending on circumstantial conditions.
8. Check air dampers fixing screws and servomotor axle lock. Retighten if necessary.
9. Check and lubricate adjustment rod joints.
10. Check oil pump capacity.
11. Clean burner from dust and moisture.
12. Check gas pipings for leaks.
13. Check combustion characteristics by flue gas measurements regularly or when
sooting boiler.
14. Check regularly combustion characteristics by flue gas measurements, after refilling
storage tank or at least once a year.
15. Check if oil tank needs to be cleaned. Oil tank must be cleaned at least every 4–5
years.

Recommended maintenance

Accurate installation, and adjustments, as well as regular maintenance ensure correct

burner operation.

Correct installation, adjustments, and regular maintenance ensure trouble-free burner

operation.

106 (129) M5178 1647EN

 ● Service the burner annually.
● Use only original spare parts.
● When ordering spare parts, give the burner type and serial number indicated on the
burner type label or manufacturing card.

If you need help with maintenance issues, contact your nearest representative or Oilon
customer service at http://www.oilon.com/customer-service/.

Burner contains electric and electronic components. Adhere to rules and regulations
from local authorities when disposing. See also section Handling and storing.

6.2 Dismounting combustion head

Disassemble the combustion head components in the same order as in the table, and
reassemble in reverse order.

Components

D042330 ver. 1

Pos. Item
1 Air guide
2 Air guide fastening screws
3 Oil hoses
4 Ignition gas nozzle
5 Gas pressure impulse tube
6 Nozzle valve
7 Nozzle valve fastening screw
8 Gas nozzle

M5178 1647EN 107 (129)

 Pos. Item
9 Gas nozzle fastening screws
10 Combustion head
11 Combustion head fastening screws

Check that gas nozzle is centralized in relation to the adjustment ring.

Check O-ring when assembling. Change if necessary.

6.3 Dismounting and changing burner motor

Cut off electricity from burner and ensure the motor has no voltage.

Fan cross section

1 Motor
2 Fan wheel
3 Fixing sleeve
4 Wedge
5 Fixing screw of fan wheel
6 Base bushing
7 Fixing screw of mounting flange

A416L ver. 3

Use a lifting device or belt for lifting fan motor, if necessary.

To dismount motor and fan wheel:

1. Switch off the burner from the mains.

2. Disconnect the electrical cable of the motor.
3. If in use, detach the rotation speed sensor from the motor’s fan casing.

108 (129) M5178 1647EN

 4. Screw off screws in the motor mounting flange and lift the motor away.
5. Screw off the fan wheel fixing screw and fixing sleeve.
6. Pull out the fan wheel from motor shaft using an extractor.
7. Loosen the wedge and base bushing.

To mount motor and fan wheel:

1. Place base bushing.

2. Set the wedge into the shaft slot.
3. Pull the fan wheel to its place using a binder plug. The fan wheel lies against base
bushing.
4. Place the fixing sleeve.
5. Screw down the fan wheel with a fixing screw to the motor shaft.
6. Place the motor and attach screws.
7. Connect the electrical cable to the motor.
8. Connect the burner to the mains. Check motor rotation direction.

6.4 Dismounting and changing servomotors

To disconnect cables:
1. Switch off the power from the burner by turning the control switch.
2. Detach the connector from the burner control’s side.

Connect in reverse order.

Servomotor of gas butterfly valve DMK-Q

D041453 ver. 1

M5178 1647EN 109 (129)

 Pos. Item Pos. Item
1 Servomotor 4 Shaft coupling aligning screw and
clamping screw
2 Servomotor fixing screw 5 Butterfly valve DMK-Q
3 Shaft coupling 6 Aligning surface of servomotor’s shaft

1. Disconnect the cables according to the instructions.

2. Loosen the clamping and aligning screw of the shaft coupling (shaft coupling stays
on butterfly valve’s shaft)
3. Detach the servomotor fixing screws and remove the servomotor.
4. Fix the new servomotor to the shaft coupling.
5. Check first that the shaft coupling aligning screw is at engine shaft level.
6. Tighten the clamping screw.
7. Tighten the servomotor fixing screws.
8. Connect the cables according to the instructions.

Servomotor of gas butterfly valve VKF41

D033571 ver. 1

Pos. Item Pos. Item

1 Servomotor 5 Motor side of shaft coupling
2 Servomotor’s holder 6 Shaft coupling clamping screw (M5x8
din913)
3 Shaft coupling 7 Servomotor fixing screw
4 Regulating valve 8 Shaft’s aligning surface

1. Disconnect the cables according to the instructions.

2. Loosen the servomotor fixing screws; the shaft coupling half stays on motor shaft.
3. Loosen the clamping screw of the shaft coupling half and remove it from motor
shaft.
4. Fix the new servomotor to the shaft coupling.
5. Check that the shaft coupling half goes down to bottom on motor shaft.
6. Check that the shaft coupling clamping screw is aligned with the motor shaft
surface. Tighten the screw.

110 (129) M5178 1647EN

 7. Place the new servomotor.
8. Tighten the servomotor fixing screws.
9. Connect the cables according to the instructions.

Removing the air damper servomotor

D031517 ver. 1

Pos. Item Pos. Item

1 Servomotor 4 Shaft coupling aligning screw
2 Servomotor bracket 5 Shaft coupling clamping screw
3 Shaft coupling 6 Servomotor fixing screw

1. Disconnect the cables according to the instructions.

2. Loosen the shaft coupling clamping screw and aligning screw; shaft coupling is left
on air damper axle.
3. Remove the servomotor fixing screws and take out the servomotor.
4. Connect a new servomotor to the shaft coupling.
5. Make sure that the shaft coupling aligning screw is aligned with the servomotor
axle.
6. Make sure that the clamping screw of the shaft coupling is securely fastened.
7. Mount the new servomotor.
8. Tighten the servomotor fixing screws.
9. Connect the cables according to the instructions.

M5178 1647EN 111 (129)

 Removing regulating unit motor

D033674 ver. 1

Pos. Item Pos. Item

1 Servomotor 4 Shaft coupling
2 Servomotor fixing screw 5 Shaft coupling aligning screw
3 Servomotor shaft and aligning level 6 Shaft coupling clamping screw

1. Disconnect the cables according to the instructions.

2. Loosen the clamping and aligning screw of the shaft coupling; shaft coupling stays
on regulator valve shaft.
3. Detach the servomotor fixing screws and remove the servomotor.
4. Fix the new servomotor to the shaft coupling.
5. Check that the shaft coupling aligning screw is at servomotor shaft level.
6. Check that the shaft coupling clamping screw is tightened.
7. Place the new servomotor.
8. Tighten the servomotor fixing screws.
9. Connect the cables according to the instructions.

Addressing servomotor

The address is determined by connector position (X32-X34). Determination can be

changed with a PC tool.

112 (129) M5178 1647EN

 6.5 Oil filter

A525G ver. 4

Pos. Item Pos. Item

1 Filter housing 9 Filter element
2 Filter cover 10 Washer
3 O-ring 11 O-ring
4 Gasket 12 Plug
5 Hexagon head plug 13 Nut
6 Hexagonal screw    
7 Gasket A Oil to filter
8 Spring B Oil to burner

Make sure that oil viscosity is low enough for successful maintenance.

To clean the filter:

1. Close fuel supply valves.
2. Drain the filter housing (1) by loosing the nut (13) and removing the plug (12).
3. Loosen the hexagonal screw (6) and open the filter cover (2).
4. Remove the filter element (9) and replace or clean it.
5. Remove dirt from the bottom of the filter housing (1).
6. Replace gasket (7), spring (8), washer (10) and O-ring (11) together with the filter
element (9).
7. If head plug (5) is opened, then also replace gasket (4).
8. Lock plug (12) with nut (13).
9. Place the filter element (9) back into the filter housing (1).

M5178 1647EN 113 (129)

 10. Make sure that the O-ring (3) is properly placed and put the cover (2) on.
11. Fasten the cover (2) with hexagonal screw (6) to a torque of 25–30 Nm.
12. Open fuel supply valves.

6.6 Nozzle valve operation and maintenance RPL-1

Nozzle valve RPL-1 components

B384E ver. 3

Pos. Item Pos. Item

1 Body 10 Cylinder
2 Break spring 11 Piston
3 Rear cover 12 Spindle
4 Hexagonal socket screw    
5 O-ring for cover 18.72 x 2.62 Viton C Control circuit
6 O-ring for piston 12 x 2 Viton R Return from nozzle
7 O-ring for bottom plate 18.72 x 2.62 Viton S Outlet to nozzle
8 O-ring for spindle 6 x 2 Viton L Nominal size of nozzle valve
9 Oil nozzle L1 Nozzle open position, checking the
spindle movement

114 (129) M5178 1647EN

 RPL-1 Operation principle

The opening of the nozzle valve is controlled by solenoid valves and oil pressure. The
force of oil pressure on piston must exceed the force of the spring. The pressure of the
spring closes the nozzle valve, when oil pressure stops having effect on nozzle valve.
The needle valve of the nozzle closes. The needle in the nozzle valve is completely
drawn when oil pressure in control circuit is approx. 18 bar18 bar / 261 PSI261 PSI
(1800 kPa).

When to change nozzle

If nozzle is functioning improperly, clean nozzle with diesel oil. If cleaning does not fix
problem, nozzle has to be changed. New nozzle has to be of the same type as the
original.

If there is an oil leak from hole in rear cover, change nozzle or install a repair kit.

6.7 Oil regulator

Oil regulator function

When swing angle of servomotor shaft is in position 0º, dosing shaft is in open position.
Return flow is at the maximum, and return pressure at the minimum.

When swing angle of servomotor shaft is at its maximum 90º, dosing shaft is in closed
position. Return flow is at the minimum, and return pressure at the maximum.

● Pressure gauge on regulator shows return pressure.

● The size of the groove on dosing shaft is marked to shaft’s end.

M5178 1647EN 115 (129)

 Oil regulator components for models 300 - 600

D033714 ver. 1

Pos. Item Pos. Item

1 Body 13 O-ring
2 Dosing shaft 14 Needle bearing
3 Dosing nozzle 15 Retaining ring
4 Nipple 16 Retaining ring
5 Spring 17 Switch/scale
6 Thrust washer 18 Hexagon socket grub screw
7 Roller bearing 19 Connector
8 Spring cotter 20 Washer
9 Front flange 21 Hexagon socket-head screw
10 Hexagon socket-head screw    
11 O-ring A Oil to regulator
12 X-ring B Oil from regulator

6.8 Testing safety and control devices

Perform safety tests for the following components always during burner maintenance or
checking. Perform tests at least once a year.

The following components should be tested:

● flame detector
● differential pressure switch
● gas pressure switches
● oil pressure switches

116 (129) M5178 1647EN

 ● servomotors
● O2 /CO trim control (if equipped)
● boiler safety devices

Flame detector

Test method Outcome

Step 1
The burner must shut down and lockout at the end
1. Prevent any light from reaching the detector and
of safety time. Error code 25 and the text No flame
start the burner.
at end of safety time.
2. Start the burner.
Step 2
The burner must shut down and lockout at pre-
1. Start the burner.
purge program phase. Error code 23 appears on the
2. Activate the flame detector with a light source
display.
during pre-purge.
Step 3
1. Start the burner. Wait until the start-up
The burner shuts down. Error code 26 and the text
sequence is finished.
Loss of Flame appear on the display.
2. Remove the flame detector from the burner, and
prevent any light from reaching the detector.

Differential pressure switch

For the physical location of the ports and for adjusting the switch, see section Adjusting
combustion differential air pressure switch.

Test method Outcome

Step 1 Boiler pre-purging begins. The burner
1. Disconnect the high pressure hose (+) from the switch. must shut down before the pre-purge
2. Start the burner. cycle is completed.
After testing, reconnect the high pressure hose. Error code 28 and a text Air pressure off
appear on the display.
Step 2 Boiler pre-purging begins. The burner
1. Disconnect the low pressure hose (-) from the switch. must shut down before the pre-purge
2. Start the burner. cycle is completed.
After testing, reconnect the low pressure hose. Error code 28 and a text Air pressure off
appear on the display.
Step 3 The burner should shut down before the
1. Start the burner. Wait until the start-up sequence is maximum setting.
finished. Error code 28 and text Air pressure off
2. After the start-up is completed, rotate the setting wheel on appear on the display.
the switch towards the maximum setting.
After testing, return the setting wheel to its original position.
Step 4 The burner should shut down
1. Start the burner. Wait until the start-up sequence is immediately after hoses are
finished. disconnected.
2. After the start-up is completed, disconnect both pressure The burner will shut down immediately.
hoses from the switch. Error code 28 and text Air pressure off
After testing, reconnect both hoses to the original positions. appear on the display.

Gas pressure switches

For instructions on adjusting the switches, see section Adjusting gas pressure
switches.

Gas pressure, minimum

M5178 1647EN 117 (129)

 Test method Outcome
Step 1 Boiler pre-purging begins. The burner
1. Rotate the setting wheel on the switch to its maximum must shut down before the pre-purge
value. cycle is completed.
2. Start the burner. Error code 2F and the text Gas Pressure
After testing, return the setting wheel to its original position and has dropped below minimum Limit
reset the switch. appear on the display.
Step 2 The burner should shut down before the
1. Start the burner. Wait until the start-up sequence is maximum setting.
finished. Error code 2F and the text Gas Pressure
2. Rotate the setting wheel on the switch towards the has dropped below minimum Limit
maximum value while the burner is running. appear on the display.
After testing, return the setting wheel to its original position and
reset the switch.

Gas pressure, maximum

Test method Outcome

1. Start the burner. Wait until the start-up sequence is The burner will shut down before the
finished. minimum setting.
2. Drive the burner to maximum capacity. Error code 30 and text Gas Pressure
3. Rotate the setting wheel on the switch towards the has exceeded maximum Limit appear
minimum value while the burner is running. on the display
After testing, return the setting wheel to its original position and
reset the switch.

Oil pressure switches

For instructions on adjusting the switches, refer to section Adjusting oil pressure
switches.

Minimum pressure switch

Test method Outcome

Step 1
Starting sequence is aborted automatically. Error
1. Move the setting on the switch to its maximum
code 34 and the text Oil Pressure below Minimum
position.
appear on the screen.
2. Start the burner.
Step 2
1. Return the switch setting to its original position. The burner starts normally.
2. Start the burner.

Return oil pressure switch (max.)

Test method Outcome

Step 1
Starting sequence is aborted automatically. Error
1. Move the setting on the switch to its minimum
code 35 and text Oil Pressure above maximum
position.
appear on the screen.
2. Start the burner.
Step 2
1. Return the switch setting to its original position. The burner starts normally.
2. Start the burner.

After the test, return the dial to its original position.

118 (129) M5178 1647EN

 Servomotors

During burner start-up the burner control drives the servomotors to maximum position
and during shutdown to 0-position. The burner control supervises the correlation of the
position settings and back coupling.

During burner shutdown, check the air damper and the locking screws of the fuel
adjusting valve. Push air damper lightly to make sure they are firmly attached.

O2 /CO trim control (if equipped)

● The system is self-checking during start-up.
● Confirm proper fuel/air ratio with flue gas analysis.

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 (X3– Safety loop open switches with Safety
04:1) and start the burner. Perform this test to all safety circuit shutdown on the display.
devices one by one.
Devices connected to the safety circuit are described in the
electrical diagram.

6.9 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 read from the display menu.

OperationalStart  
  FaultHistory
  LockoutHistory

Resetting fault

You can reset the burner lockout also from the control panel. Reset the fault as follows:
1. Press Esc until you access the menu level 1.
2. Select Operational Stat -> Status/Reset.
3. The fault code display appears on the display. Press Esc.
The following text appears:

NAYTTO1 ver. 4

4. To reset the failure, press Enter.

5. To return to the menu level, press Esc.

M5178 1647EN 119 (129)

 Burner failure can also be reset by pressing burner failure reset button on the control
panel longer than 1 s, or by giving a remote reset signal.

Pressing of burner failure reset button during burner operation causes a

lockout. Button is also used as emergency stop button.

Fault history stores the last 21 error messages.

Scroll history data with the Select -/+ buttons. To change the display from code display
to clear text and back, press Enter.

Lockout history stores the last 9 burner lockout indications. Lockout always causes
shutdown.

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
NAYTTO2 ver. 2
● Load = load at the time the fault occurred
0,0 %
● Gas = gas as fuel

Burner control can be reset immediately after shutdown. The servomotor runs to the
stand-by position after resetting, and the burner control allows a new burner start-up.

Shutdown means failure interlocking.

O2 trim activation example for WD200

● 12. fault in history

● Class = 05, see the following table
● Oil = Oil as fuel
● Code = BF, error code
● Diag = 00, diagnostic code
● Phase = 60, phase
● Lod = 65.4%, load at the time the fault
Point28 ver. 3 occurred
● Start-No = start counter reading at the
time the fault occurred

Fault class Description

00 Lockout
01 Safety reset
02 Safe mode
03 Home run
04 Control stop
05 Attention

120 (129) M5178 1647EN

 For more detailed information about fault and lockout codes, refer to
Basic Documentation LMV5.

6.10 Frequency converter (WD200)

Frequency converter is started and stopped using potential-free release contact in

burner control. Frequency converter alarm is connected to burner control with 12…24
VDC voltage signal that causes burner safety stop.

Frequency converter is controlled with 0 / 4…20 mA signal, the same way as

servomotors. Frequency converter operation must be linear.

Control signal filters and decelerations must be removed. Acceleration and

deceleration time ramps must be shorter than servomotor time ramps programmed in
burner control. Minimum output frequency must be set to 0 Hz to ensure that fan motor
will reach required speed under all operating conditions. Maximum output frequency
must be set to 105.2 % of mains frequency, because burner control maximum speed
value is 95 %.

6.11 Adjusting gas valve proving

Adjusting

Test times are set at the factory.

Density test formula ver. 2

Item Unit Description

QLeak l/h leakage rate, volume per hour
cf/h
PG mbar gas pressure effecting on burner
PSI
PW mbar pressure switch setting (normally 50 % of gas pressure)
PSI
Patm mbar absolute air pressure 1 013 mbar / 14,692 PSI
PSI
V 1 interspace volume
tTest s pressure test time

Example: Calculating test time and leakage rate.

M5178 1647EN 121 (129)

 EU density test 1 ver. 3

US density test 1 ver. 2

Result: Test time is 7 seconds.

EU density test 2 ver. 3

US density test 2 ver. 2

Result: Leakage rate is 45,7 l/h / 1.6 cf/h.

6.12 Troubleshooting

Before troubleshooting check section First start-up

If the fault can not be found in the First start-up, check the individual burner functions.
Reset the burner control if it is in lockout position. The burner goes to standby position.
When the prerequisites for start are fulfilled, the burner starts. Observe the burner
functions, program phase, and possible faults from the operating and display unit. Use
measuring instruments for identifying the fault.

For further information, refer to Troubleshooting fault codes or burner control

manufacturer manual.

122 (129) M5178 1647EN

 Start failure

Condition Possible cause Action

Burner does not start. Burner Break in control loop. Find out the cause of the break.
control remains in stand-by Required start-up signal from
position. Set temperature or burner control terminal X5-03.4
pressure too low. does not transfer to terminal
X5-03.1.
  Control unit is damaged. Change.
Control loop closed, burner or 1. Faulty servomotor 1. Change servomotor.
control unit start-up program does 2. Faulty control unit 2. Change control unit.
not start. 3. Mechanical jam in levers or 3. Check and release.
couplings.
  Safety loop open. Find out cause of the break.
Check burner control terminals
X3-04.1 and X3-04.2
  Faulty differential air pressure Change.
switch.
  Fuel selector switch S2 in position Choose fuel.
0.
Fan motor starts. Jammed or damaged servomotor. Check and adjust or change.
Lockout during pre-purge. Servomotors do not reach desired
position.
Burner control stays waiting for Start-up release loop is open. Find out cause, repair.
start release.
  Low gas pressure. Find cause and repair.
  Faulty differential air pressure Change.
switch.
  Return oil pressure too high or oil Find cause and repair.
pressure too low.

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. Replace faulty
burner control.
  Motor overload/thermal relay Check setting, reset.
released.
  Faulty motor main relay. Change.
  Faulty motor. Change.
  Fault in frequency converter or Check error and reset.
soft starter (if equipped).

Lack of fan air pressure

Condition Possible cause Action

Fan motor starts, but during pre- Faulty differential air pressure Check setting, adjust if necessary.
purge period lockout occurs. switch setting.
  Dirty or damaged differential air Clean or replace.
pressure switch impulse tubes.
  Faulty differential air pressure Change.
switch.
  Fan suction blocked. Clean.
  Incorrect motor rotation direction. Reconnect motor.

M5178 1647EN 123 (129)

 Leakage test failure

Condition Possible cause Action

Leakage test failure Gas block failure See section Gas valve proving.
  Gas inlet pressure to burner too Find out cause and repair.
low
  Faulty pressure switch Change.
  Faulty gas valve Change.

No ignition spark

Condition Possible cause Action

Fan motor starts, control voltage Dirty or damaged ignition Clean or change.
from burner control to ignition electrodes.
transformer is switched on, no
ignition spark is formed, and after
a short time lockout occurs.
  Ignition electrodes too far apart. Adjust electrodes according to
instructions in section Adjusting
combustion head.
  Damaged or disconnected ignition Change.
cable.
  Faulty ignition transformer. Change.

Faulty oil pump

Condition Possible cause Action

Oil pump motor does not start Break in main circuit Find out cause of the break, repair
  Motor overload relay released Check setting, reset
  Fuse released Tune or replace
  Faulty motor contactor Replace
  Faulty motor Replace
  Faulty oil pump output. Change burner control.
No oil supply or too low atomizing Dirty filter Clean or replace.
pressure.
  Leaking transfer pump suction line Fix leakage.
  Pump capacity decreases. Faulty Change.
or worn-out pump.
Loud mechanical noise. Pump is sucking air. Tighten joints.
  Too low inlet pressure to pump. Clean filter. Check and adjust
pressure.

Premature flame establishment, oil use

Condition Possible cause Action

Burner motor starts then lockout Faulty solenoid valve or leaking Clean or change valve.
(long ignition) nozzle valve.

124 (129) M5178 1647EN

 Flame does not form

Condition Possible cause Action

Gas or oil use: Fuel valves do not open or open  
Fan motor starts, ignition spark too slowly:
is in order. After a short period of
time lockout occurs.
  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.
See section Oil pump.
  Faulty fuel/air ratio. Adjust.
  Faulty combustion head Check and adjust.
adjustment.
  Nozzle dirty or blocked. Clean or change.
  Too low ignition load. Check.
Oil use: Nozzle valve does not open. Change nozzle.
Fan motor starts, ignition spark
is in order. After a short period of
time lockout occurs.
  Nozzle valve piston is stuck. Change piston or O-ring.
  Faulty nozzle O-ring. Change.

Burners with ignition pilot gas valve, ignition flame does not form

Condition Possible cause Action

Fan motor starts, ignition is in Incorrect ignition gas valve setting Adjust ignition gas valve.
order. After a short time lockout
occurs.
Gas valve 1 or ignition gas
valve(s) do not open or open too
slowly.
  Faulty actuator. Change faulty part.
  Cable damaged. Change.
  Break in valve control circuit. Find out cause of the break.

Burners with ignition pilot oil valve, ignition flame does not form

CONDITION POSSIBLE CAUSE ACTION

Fan motor starts, ignition is in Too low oil pressure:  
order. After a short time lockout 1. Oil pump does not produce 1. Adjust, repair or change
occurs. enough pressure. pump.
Ignition oil nozzle does not spray 2. Oil pump rotation direction is 2. Change rotation direction.
oil. incorrect.
  Other symptom.  
1. Blocked or worn-out nozzle. 1. Clean or change nozzle.
2. Faulty solenoid valve. 2. Change valve.
3. Break in control circuit. 3. Find out cause of the break.

M5178 1647EN 125 (129)

 Lockout occurs after flame establishment

Condition Possible cause Action

Flame forms. Occurs lockout. Gas pressure unstable. Check and repair.
  Incorrect burner adjustment Adjust.
When burner runs to full load, Gas pressure too low because Check operation and regulations.
flame extinguishes, shutdown min. gas pressure switch released.
occurs and then re-start.
  Blocked filter Clean or replace filter.
Oil use: 1. Incorrect burner adjustment 1. Correct settings.
Flame forms. Flame extinguishes 2. Dirty filters 2. Clean filters.
and lockout occurs when burner 3. Clogged nozzle 3. Change nozzle.
runs to full load. 4. Nozzle valve piston stuck 4. Repair or change piston.
5. Faulty solenoid valve or coil or 5. Change faulty component.
damaged cable.

Flame monitoring fault, lockout

Condition Possible cause Action

Lockout during pre-purge. Faulty flame detector Change.
  Faulty burner control Check fault code. Replace.
  Incorrect flame signal because of Block extraneous light.
extraneous light
Flame forms. Lockout during Incorrect flame detector position Repair.
ignition phase or in normal
operation.
  Dirty flame detector Clean.
  Too weak flame (light) Check burner adjustments.
  Faulty flame detector Change.
  Faulty burner control Check fault code. Replace.
Lockout in shut-down period. Faulty flame detector Change.
  Faulty burner control Check fault code. Replace.
  Incorrect flame signal because of Block extraneous light.
extraneous light
  Diffuser disc overheated due to Adjust minimum capacity.
too low minimum capacity.
  Diffuser disc overheated due Adjust pressure loss.
to too low pressure drop in
combustion head.
Gas use: Flame does not extinguish: leaking Replace.
Lockout during shutdown period gas valves.
Oil use: Oil or carbon deposits in Clean combustion head. Check
Lockout during shutdown period. combustion head combustion values.
  Nozzle valve and main solenoid Repair or change faulty part.
valve or nozzle valve and non-
return valve do not close.

Oil leaks to combustion chamber

Condition Possible cause Action

Oil leaks to combustion chamber Nozzle valve and main solenoid Clean, repair or replace.
during idle time. valve or nozzle valve and non-
return valve do not close.
Oil leaks to combustion chamber Leaking valves Clean, repair or replace.
during pre-purge.
Continuous oil leak from nozzle Leak in non-return valve or in main Change.
valve when nozzle is detached. solenoid valve

126 (129) M5178 1647EN

 Poor combustion

CONDITION POSSIBLE CAUSE ACTION

Poor oil atomizing. Oil atomizing or return pressure Check and adjust.
too low.
  Nozzle spraying angle incorrect. Try nozzle with a different
spraying angle.
CO-content is too high or smoke Pressure drop in combustion head Adjust pressure drop.
number too high. too low.
  Incorrect diffuser disc location. Adjust diffuser disc.
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 nozzle Adjust.
and diffuser disc
Oil use: Incorrect nozzle type or size Change.
Oil or heavy carbon deposits
inside of boiler furnace.
  Incorrect oil temperature setting. Adjust.
  Incorrect atomizing or return Adjust.
pressure.
  Worn-out nozzle Change.
  Leaking nozzle valve. Change.

6.13 Troubleshooting error codes

See complete fault code list from manufacturer manual

Fault codes

Code Diag Description

1E XX Servomotors do not reach pre-purge or ignition position. Faulty servomotor.
2F XX Low gas pressure. Flame forms. Lockout and re-start occur.
1F, 2A, 29 XX Motor failure.
5 XX Faulty flame detector.
21 XX Safety loop open.
22 XX Temperature limiter released.
23 XX Lockout during pre-purge.
24 XX Lockout during shutdown.
25 XX Flame does not form
26 XX Fan motor starts, flame forms then lockout occurs. Flame monitoring fault.
27, 28 XX Faulty differential air pressure.
28 XX Lack of air pressure
31, 32 XX Leakage test failure
34 XX No oil supply or too low atomizing pressure. Faulty oil pump.
35 XX Main solenoid valve does not open. Return oil pressure too high.

M5178 1647EN 127 (129)

 6.14 Burner parts

Exploded view D054888 ver. 1

The assembly may vary depending on the scope of delivery.

Gas valve FGR

FGR ver. 2

VGD40... ver. 1

Gas line for pilot burner optional

128 (129) M5178 1647EN

 6.15 Burner part list

Recommended change interval

# Part name 1–2 3–5 10 on demand/
year years years start-up max.
1 Protective cover       X
2 Flange gasket       X
3 Fan motor       X
7 Diffuser disc       X
9 Gas nozzle       X
10 Nozzle valve     X 250 000
12 Gas valve block     X 250 000
14 Filter casing       X
18 Pump motor       X
19 Servomotor     X  
20 Spring band       X
22 Oil regulator     X  
23 Capacity controller     X  
28 Pressure regulating valve     X  
32 Combustion head       X
36 Ignition transformer   X    
37 Flame detector        
       QRI   X    
38 Ignition cable   X    
39 Nozzle X      
40 Ignition electrode   X    
44 Pressure switch, gas     X  
48 Pressure gauge   X    
49 Main solenoid valve   X    
50 Oil pump   X    
51 Pressure switch, oil     X  
52 Coupling head for pump   X    
53 Flexible element   X    
56 Differential air pressure switch     X  
59 Servomotor, air     X  
60 Servomotor, gas     X  
64 Nozzle holder       X
69 Manual shut-off valve       X
71 Valve actuator with pressure regulator   X    
72 Valve actuator   X    
73 Power transformer   X    
76 Servomotor, FGR     X  

M5178 1647EN 129 (129)

130 (129) M5178 1647EN
Contact information of Oilon dealer:

OILON GROUP
P.O. Box 5
FI-15801 LAHTI
FINLAND
Tel: +358 3 85 761
Fax: +358 3 857 6239
Email: info@oilon.com
Date of installation: www.oilon.com