Oilon KP-6 Manuale
OILON OY
P.O.Box 5
FIN-15801 LAHTI FINLAND
+358-3-85 761
Fax +358-3-857 6239
OPERATING AND MAINTENANCE
INSTRUCTIONS
LIGHT OIL BURNERS
KP-6
KP-6 L
KP-6 LH
KP-6-2
KP-6 H-2
20039847GB
Table of Contents
1. Conventions in this Manual............................................................................................................ 1
2. General.......................................................................................................................................... 2
3. Burner Technical Data................................................................................................................... 4
3.1. General................................................................................................................................ 4
3.2. Technical Data .................................................................................................................... 4
3.3. Basic Assembly Drawing..................................................................................................... 5
3.4. Parts List ............................................................................................................................. 6
3.5. Dimensions.......................................................................................................................... 6
4. Burner Installation.......................................................................................................................... 6
4.1. Burner Mounting.................................................................................................................. 7
4.2. Hinged Burner Housing .......................................................................................................7
4.3. Electric Connections............................................................................................................ 7
4.4. Connecting the Burner to the Mains.................................................................................... 8
4.5. Connecting the Burner to Oil Supply Line ........................................................................... 8
5. Fuel System................................................................................................................................... 9
5.1. Oil Piping ............................................................................................................................. 9
5.2. Oil Pumps.......................................................................................................................... 10
5.3. Oil Filter ............................................................................................................................. 12
6. Burner Operation Principle .......................................................................................................... 13
6.1. 1-Stage Burners, KP-6, KP-6-2 ......................................................................................... 13
6.2. 1-Stage Burner with Preheater, KP-6 L............................................................................. 13
6.3. 2-Stage Burners (H-Burners), KP-6 H-2 ........................................................................... 15
6.4. 2-Stage Burner (”H” Burner) with Preheater, KP-6 LH ...................................................... 15
7. Burner Automation....................................................................................................................... 17
7.1. 1-Stage Burners ................................................................................................................ 17
7.2. 2-Stage Burners (H-Burners) ............................................................................................ 19
8. Burner Adjustment....................................................................................................................... 21
8.1. Capacity Regulation .......................................................................................................... 21
8.1.1. Oil Pump Pressure Regulation ............................................................................. 22
8.2. Combustion Head Adjustment .......................................................................................... 23
8.2.1. Setting the Nozzle and the Ignition Electrodes ..................................................... 23
8.2.2. Adjusting the Air Velocity in the Combustion Head .............................................. 24
8.3. Combustion Air Adjustment............................................................................................... 25
8.3.1. 1-Stage Burners ................................................................................................... 25
8.3.2. 2-Stage Burners (”H” Burners) ............................................................................. 26
8.4. Air Cone Position............................................................................................................... 27
8.5. Flame Inspection ............................................................................................................... 27
9. Control Unit LOA24/BHO64......................................................................................................... 28
9.1. Time Sequence Diagram (Control Program) .................................................................... 28
9.2. Control Functions in the Event of Faults ........................................................................... 29
9.3. Technical Data of Control Unit .......................................................................................... 29
9.4. Current through Flame Detector ....................................................................................... 29
9.5. Measurement of Flame Signal .......................................................................................... 30
10. Maintenance ................................................................................................................................ 31
11. Fault Conditions and Procedures ................................................................................................ 32
12. Notes ........................................................................................................................................... 35
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20039847GB
1. Conventions in this Manual
Read these instructions carefully before installation, commissioning or
maintenance of the burner. The given instructions must be followed. Throughout
this manual, the following three symbols are used to point out very important
information:
WARNING! A warning alerts you to possible danger to person, if the instructions are not
followed.
CAUTION! A caution alerts you to something, that has the potential to cause damage
to component, burner, process or surroundings, if the instructions are not followed.
Note! A note points out information of special interest.
KEEP THESE OPERATING AND MAINTENANCE INSTRUCTIONS
AS WELL AS THE ELECTRICAL SCHEMES AVAILABLE NEAR THE
BURNER!
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20039847GB
2. General
Oilon KP-6...KP-6 H-2 burners are fully automatic light oil burners.
These burners can be used on most heating appliances such as hot water boilers, steam boilers
and air heaters.
A fan attached to the burner and dimensioned to provide a sufficiently high and even air
pressure for efficient combustion in modern combustion chambers delivers the required air.
The burners are suitable for use on light fuel oil with a viscosity of 4 - 12 mm²/s (cSt) at a
temperature of +20 °C.
The oil coming to the burner must be filtered before the burner oil pump. Filtration degree may
be max. 100 µm.
Oil atomising pressure: • 1-stage burners 700 - 1400 kPa (7 - 14 bar)
• 2-stage burners 700 - 2500 kPa (7 - 25 bar).
The ”H” burners are high-low -burners and ”LH” burners are equipped with a preheater.
2-stage burners (”H” burners) have a maximum control range from 55 to 100 %.
Required combustion air quantity: 15 m³ for each kg of oil to be burned.
Burner operation is automatically controlled and supervised by the control unit.
Boiler thermostats or pressurestats controls the burner capacity.
Protection: IP20
Supply/control voltage 230 V (-15 %...+10 %), 50 Hz, 1-phase
Input power: 260 W 1,13 A (KP-6, KP-6-2, KP-6 H-2)
500 W 2,2 A (KP-6 L, KP-6 LH)
The ambient temperature during burner operation must be 0...+40 °C.
The following should be checked before first start-up:
●connections are correct,
●settings of regulating and control devices are correct,
●boiler and its equipment is in working condition,
●boiler room is adequately ventilated,
●valves in supply line are open,
●there is oil in the tank,
●oil temperature is adequate in such a way, that the oil viscosity is 4 - 12 mm²/s
(max. +60 °C).
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20039847GB
CAUTION! The burner must be installed firmly. Vibrations may damage burner or its
components.
CAUTION! Prior to first start-up the oil pump must be vented. The pump must not
operate without oil. See chapter ”Oil Pumps”.
WARNING! In case of fire or other danger:
- switch off the main switch
- close the main fuel shut-off valve outside the plant
- take appropriate actions.
WARNING! Never use a naked flame while checking the burner or the boiler. Never
store any inflammable material in the boiler room.
WARNING! Keep the boiler door closed while starting the burner and during burner
operation.
Correct installation and adjustment together with regular servicing are the most reliable
guarantees of trouble-free burner operation.
Note! Local regulations and requirements must be adhered to when installing or servicing
the burner.
The burner must be installed in such a position, that the motor shaft lies horizontally; but the
burner must not, however, be installed upside down.
Use only original spare parts. When ordering spare parts please give burner type and serial
number indicated on the burner nameplate.
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20039847GB
3. Burner Technical Data
3.1. General
●burner types: • 1-stage burners
KP-6
KP-6 L
KP-6-2
• 2-stage burners (”H” burners)
KP-6 LH
KP-6 H-2
●on standard version the burner can be hinged to both sides
●the burner must be installed in such a position, that the motor shaft lies horizontally; but the
burner must not, however, be installed upside down.
●burner control unit internally connected
●safety switch (limit switch) on hinged flange
●control switch
●air regulation: • stepless adjustable (1-stage burners)
• servomotor (2-stage burners)
●oil pump atomising pressure:• 700 - 1400 kPa (7 - 14 bar) (1-stage burners)
• 700 - 2500 kPa (7 - 25 bar) (2-stage burners)
●standard version equipped for two-pipe system
●electrical connection with a plug connector (KP-6, KP-6 L, KP-6-2).
Extra equipment
●run hour counter
●filter Oilon 20
●de-aerator Tiger Loop
●oil meter
●oil pressure gauge and valve
3.2. Technical Data
Burner KP-6 KP-6 L KP-6 LH KP-6-2 KP-6 H-2
Capacity kg/h
kW
3,5 - 10,042 -
120
3,5 - 10,0
42 - 120
3,5 - 10,0
42 - 120
6,0 - 12,0
71 - 140
6,0 - 16,0
71 - 190
Burner motor
Voltage 50 Hz 230 V
Output kW
Current A
Speed rpm
0,125
1,0
2750
0,125
1,0
2750
0,125
1,0
2750
0,125
1,0
2750
0,125
1,0
2750
Control unit LOA24
/BHO64
LOA24
/BHO64
LOA24
/BHO64
LOA24
/BHO64
LOA24
/BHO64
Servo motor - - SQN - SQN
Oil hoses R ¼" R ¼" R ¼" R ¼" R ¼"
Oil pump AS 47 C/
BFP 21 L3
AS 47 C/
BFP 21 L3
BFP 52E L3
AT 2 45 C
AS 47 C/
BFP 21 L3
BFP 52E L3
AT 2 45 C
Preheater W - 30 - 240 30 - 240 - -
Light fuel oil 1 kg/h ≅11,86 kW
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20039847GB
3.3. Basic Assembly Drawing
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3.4. Parts List
1 Burner housing 19 Burner motor
2 Control unit 20 Fan wheel
3 Protective cover 21 Plug connector (KP-6, KP-6 L, KP-6-2)
4 Flame detector (photo resistor) 22 Air cone
5 Control switch (KP-6 LH, KP-6 H-2) 23 Coupling
6 Nozzle holder (KP-6, KP-6-2, KP-6 H-2) 24 Air damper/air adjustment ring
Preheater (KP-6 L, KP-6 LH) 25 Air damper shaft
7 Limit switch (=safety switch) 26 Air intake
8 Swirler 27 Oil pump
9 Ignition electrode AS 47 C or BFP 21 L3 (KP-6, KP-6 L, KP-6-2)
10 Adjustment ring BFP 52E L3 or AT 2 45 C (KP-6 LH, KP-6 H-2)
11 Nozzle 28 Nozzle conduit
12 Diffuser disc 29 Cover plate
13 Ignition cable 30 Pressure pipe
14 Combustion head 31 Adjusting lever (KP-6, KP-6 L, KP-6-2)
15 Mounting flange Servomotor (KP-6 LH, KP-6 H-2)
16 Hinge pin 32 Oil hose, return
17 Ignition transformer 33 Oil filter
18 Sight glass 34 Oil hose, suction
3.5. Dimensions
Burner Dimensions in mm
L1 L2 H1 H2 B1 B2 øD
KP-6 310 105 230 120 210 180 90
KP-6 L 310 105 230 120 210 180 90
KP-6 LH 400 105 255 120 210 180 90
KP-6-2 310 110 230 120 210 180 100
KP-6 H-2 400 110 255 120 210 180 100
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20039847GB
4. Burner Installation
4.1. Burner Mounting
The furnace, which has a flame-shaped design, does not require refractory. Boilers without
bottom cooling require refractory to prevent heat from reaching boiler foundations.
The flame must at no point come into contact with the furnace walls. If this cannot be avoided,
such points must be covered with refractory. This applies especially to the refractory at the back
wall of short furnaces.
1 Mounting plate
2Gasket
3 Thermal insulation
BURNER Ø D2
KP-6, -6 L, -6 LH 95
KP-6-2, -6 H-2 105
The mounting plate must have either two or four M10 threaded holes for the mounting of the
burner according to the drawing.
4.2. Hinged Burner Housing
On standard version the burners are delivered to be hinged to both sides.
4.3. Electric Connections
The burner must be connected according to the electrical diagrams delivered together with the
burner. General and local standards and regulations as well as requirements of electrical
equipment on electrical connections must be adhered to.
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4.4. Connecting the Burner to the Mains
KP-6, KP-6 L, KP-6-2
Electrical connection on burner is with a plug connector. Connect the cable of the plug supplied
with the burner to the boiler thermostat. The socket has been firmly attached to the burner
housing. Disconnect the burner from the mains (burner switch in position 0) by pressing the
locking button and pulling out the plug from the socket at the same time.
1 Socket (fixed on the burner
housing)
2 Locking button
3 Plug (pull-out part)
4.5. Connecting the Burner to Oil Supply Line
On standard version the burners is equipped for two-pipe system. Two-pipe system has both
suction and return lines for fuel oil.
Note! The by-pass plug in the oil pump must be fixed.
1 Filter
2 Suction line
3 Oil pump
4 Pressure line (to nozzle)
5 Return line
6 By-pass plug
7 Shut-off valve
8 Shut-off valve/Non-return valve
A-A Delivery limit
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