OPERATING AND MAINTENANCE

INSTRUCTIONS
LIGHT OIL BURNERS

KP-6

KP-6 L

KP-6 LH

KP-6-2

KP-6 H-2

OILON OY
P.O.Box 5
FIN-15801 LAHTI FINLAND

+358-3-85 761
Fax +358-3-857 6239
E-mail info@oilon.com 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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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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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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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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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 3,5 - 10,042 - 3,5 - 10,0 3,5 - 10,0 6,0 - 12,0 6,0 - 16,0
kW 120 42 - 120 42 - 120 71 - 140 71 - 190
Burner motor
Voltage 50 Hz 230 V
Output kW 0,125 0,125 0,125 0,125 0,125
Current A 1,0 1,0 1,0 1,0 1,0
Speed rpm 2750 2750 2750 2750 2750
Control unit LOA24 LOA24 LOA24 LOA24 LOA24
/BHO64 /BHO64 /BHO64 /BHO64 /BHO64
Servo motor - - SQN - SQN
Oil hoses R ¼" R ¼" R ¼" R ¼" R ¼"
Oil pump AS 47 C/ AS 47 C/ BFP 52E L3 AS 47 C/ BFP 52E L3
BFP 21 L3 BFP 21 L3 AT 2 45 C BFP 21 L3 AT 2 45 C
Preheater W - 30 - 240 30 - 240 - -

Light fuel oil 1 kg/h ≅ 11,86 kW

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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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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 BURNER Ø D2

2 Gasket KP-6, -6 L, -6 LH 95
3 Thermal insulation KP-6-2, -6 H-2 105
The mounting plate must have either two or four M10 threaded holes for the mounting of the
burner according to the drawing.

4.2. Hinged Burner Housing

On standard version the burners are delivered to be hinged to both sides.

4.3. Electric Connections

The burner must be connected according to the electrical diagrams delivered together with the
burner. General and local standards and regulations as well as requirements of electrical
equipment on electrical connections must be adhered to.

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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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5. Fuel System

5.1. Oil Piping

The oil tank and the oil pipes must be installed to avoid the risk of the oil cooling below cloud
point. The cloud point of heating oil depends on the oil quality. If the oil is allowed to cool to the
cloud point, valves and filters will block. The most suitable oil temperature is +15...+25 °C.
Note! The viscosity of oil coming to the burner must be 4 - 12 mm²/s (cSt).
The maximum lengths for other viscosities can be calculated by the simple ratio of viscosities
i.e. if the table shows lengths for 5 resp. 6 mm²/s (cSt) viscosity, multiply the length shown in the
table by 5 resp. 6 and divide by the value of the new viscosity mm²/s (cSt).
Keep in mind that absolute tightness is the fundamental pre-requisite for secure operation. A
leaking suction line may cause, among other things, afterspraying of oil into the boiler. It is
advisable to use ball valves instead of needle valves.

The tables give the maximum lengths (in meters) of return and suction lines.
Overlying oil tank Underlying oil tank
Hm DANFOSS BFP/MS (ø d mm) Hm DANFOSS BFP/MS (ø d mm)
ø 6 mm ø 8 mm ø 10 mm ø 6 mm ø 8 mm ø 10 mm
0 17 53 100 0 17 53 100
0,5 19 60 100 0,5 15 47 100
1,0 21 66 100 1,0 13 41 99
1,5 23 72 100 1,5 11 34 84
2,0 25 79 100 2,0 9 28 68
2,5 27 85 100 2,5 7 22 53
3,0 29 91 100 3,0 5 15 37
3,5 31 98 100 3,5 3 9 22
4,0 33 100 100 4,0 1 3 6
2800 rpm, 6 mm²/s (cSt) 2800 rpm, 6 mm²/s (cSt)
Hm SUNTEC 45/47 (ø d mm) Hm SUNTEC 45/47 (ø d mm)
ø6 ø8 ø 10 ø 12 ø6 ø8 ø 10 ø 12
mm mm mm mm mm mm mm mm
0 14 49 123 150 0 14 49 123 150
0,5 16 55 136 150 0,5 12 43 109 150
1,0 18 61 150 150 1,0 10 37 94 150
2,0 22 73 150 150 2,0 7 26 65 138
3,0 25 85 150 150 3,0 3 14 37 78
4,0 29 96 150 150 4,0 0 2 8 18
2850 rpm, 5 mm²/s (cSt) 2850 rpm, 5 mm²/s (cSt)
Dmax = 20 m Hmax = 4,5 m
(D-H)max = 4,5 m

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5.2. Oil Pumps

For KP-6, KP-6 L, KP-6-2 burners

Danfoss BFP 21 L3 Suntec AS 47 C

1 Suction line connection 1 Suction line connection

2 Return line connection 2 Return line connection
3 Nozzle connection 3 Nozzle connection
4 Pressure gauge connection 4 Pressure gauge connection
5 Vacuum meter connection 5 Vacuum meter connection
6 Pressure regulation 6 Pressure regulation
7 Air venting nipple/plug 7 Air venting plug
8 By-pass plug 8 By-pass plug
9 Filter 9 Filter
10 Solenoid valve, NC 10 Solenoid valve, NO

Oil pump venting

Two-pipe system needs no venting as the air comes away when starting the burner. In order to
speed up the air removal, the air venting plug or the pressure gauge connection (4) can be
loosened.
Oil supply to the burner can be noted on the oil pressure gauge fixed to the oil pump or on the oil
spray from the nozzle.

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For KP-6 LH, KP-6 H-2 burners

Danfoss BFP 52E L3 Suntec AT 2 45 C

1 Suction line connection 1 Suction line connection

2 Return line connection 2 Return line connection
3 Nozzle connection 3 Nozzle connection
4 Pressure gauge connection 4 Pressure gauge connection
5 Vacuum meter connection 5 Vacuum meter connection
6 Pressure regulation, stage 1 (P1) 6 Pressure regulation, stage 1 (P1)
7 Pressure regulation, stage 2 (P2) 7 Pressure regulation, stage 2 (P2)
8 By-pass plug 8 By-pass plug
9 Filter 9 Filter
10 Solenoid valve, stage 1 10 Solenoid valve, stage 1
normally closed, NC normally closed, NC
11 Solenoid valve, stage 2 11 Solenoid valve, stage 2
normally open, NO normally open, NO

Oil pump venting

Two-pipe system needs no venting as the air comes away when starting the burner. In order to
speed up the air removal, the air venting plug or the pressure gauge connection (4) can be
loosened.
Oil supply to the burner can be noted on the oil pressure gauge fixed to the oil pump or on the oil
spray from the nozzle.

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5.3. Oil Filter

1 Cover 4 O ring
2 Cup 5 Gasket
3 Element 6 Gasket

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

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6. Burner Operation Principle

See drawings Nos. A-382 A and A-422 K

6.1. 1-Stage Burners, KP-6, KP-6-2

When the control device (13) calls for heat the signal lamp lights up and the burner motor (7),
which drives the fan (6) and the oil pump (4), starts. An electric arc is created between the
ignition electrodes (9). After the pre-purge period has elapsed solenoid valve (10) opens (oil
pump BFP 21 L3) / closes (oil pump AS 47 C) and the oil, spraying from the nozzle (11), is
ignited by the electric arc. When the flame has established, the burner control will cut the arc
and the flame continues to burn.
If the flame is not ignited within the safety time, the control unit locks out in the flame failure
position and the burner shuts down, and will not start before resetting the control unit. The
burner makes then one attempt to start (see above). If the flame is extinguished during normal
operation, solenoid valve (10) closes (oil pump BFP 21 L3) / opens (oil pump AS 47 C). The
burner makes one normal attempt to start. If the flame is not ignited, the control unit locks out in
the flame failure position and the burner shuts down, and will not start before resetting the
control unit i.e. by pressing the reset button on the control unit.

6.2. 1-Stage Burner with Preheater, KP-6 L

When the control device (13) calls for heat the signal lamp lights up and the preheater (14)
°
heats the oil up to approx. +70 C. When the oil has reached the required temperature the
control unit starts the burner motor (7). The operation continues as on burners without
preheater.

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Drawings Nos. A-382 A and A-422 K

Oil pump BFP 21 L3

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

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See drawings Nos. A-421 K and A-442K

6.3. 2-Stage Burners (H-Burners), KP-6 H-2

The ”H” burners are equipped with a control switch 0-1-2. Switch in position 1 the burner
operates at stage 1 only controlled by control device. Switch in position 2 the burner operates
normally controlled by control devices.
When the control device (18) calls for heat an electric arc is created between ignition electrodes
(12) and the air damper servomotor (15) opens the air damper from ”closed” position (position
”II” of the limit switch in servomotor) to the position of stage 1 (position ”III” of the limit switch in
servomotor). Burner motor (6), which drives the fan (5) and the oil pump (4), starts.
After the pre-purge period has elapsed solenoid valve (7) opens. The oil spraying from the
nozzle is ignited by the electric arc. Ignition ends after the time determined by the control unit.
The burner operates at stage 1.
If the flame is not ignited within the safety time, the control unit locks out in the flame failure
position and the burner shuts down, and will not start before resetting the control unit. If the
flame is extinguished during normal operation, solenoid valve (7) closes. The burner makes one
normal attempt to start. If the flame is not ignited within the safety time, the control unit locks out
in the flame failure position and the burner shuts down, and will not start before resetting the
control unit i.e. by pressing the reset button on the control unit.
When boiler temperature or pressure exceeds the set value for control device of stage 2 (19),
the burner operates at stage 1. When the boiler temperature or pressure is below the set value
for control device of stage 2 (19), the quantity of air increases and the solenoid valve (8) closes
when the limit switch in servomotor is in position ”V” (pump pressure increases). The air damper
opens to the position of stage 2 (position of the limit switch ”I” in servomotor). The burner
operates at stage 2. When the temperature or pressure exceeds the set value for control device
of stage 2 (19), the burner switches on to the position of stage 1. When the temperature or
pressure exceeds the set value for control device of stage 1 (18), the burner shuts down (air
damper closes).
Set the control device of stage 2 (19) to a 5-10 °C lower temperature than the control device of
stage 1 (18). If the control device of stage 2 (19) is set to a higher temperature than the control
device of stage 1 (18), the burner starts at stage 1, but operates the whole operation period at
stage 2 and shuts down direct from stage 2, when the set value for control device of stage 1 (18)
will be exceeded.

6.4. 2-Stage Burner (”H” Burner) with Preheater, KP-6 LH

°
When the control device (18) calls for heat, the preheater (20) heats the oil up to approx. +70 C.
When the oil has reached the required temperature, an electric arc is created between the
ignition electrodes (12) and the air damper servomotor (15) opens the air damper from the
”closed” position (position of the limit switch ”II” in servomotor) to the position of stage 1
(position of the limit switch ”III” in servomotor). The operation continues as on burners without
preheater.

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Drawings Nos. A-421K and A-442K

Oil pump Danfoss BFP 52E L3 1 Oil filter

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

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7. Burner Automation

7.1. 1-Stage Burners

Required input signals to the control unit

Control signals from the control unit

TZ Limit thermostat M1 Burner motor (fan/oil pump)

TS Control thermostat T1 Ignition transformer
E1 Preheater EV1 Solenoid valve
TSW Thermostat of preheater B1 Flame detector/flame signal

Prerequisites for start-up

● burner is getting fuel
● interlocks are reset
● contact of switches of control voltage supply in control unit and contacts of thermostats
closed, whereupon the control voltage is received to the terminal 1 in control unit.

A´ Start on burner with preheating

● control signal from terminal 8 in control unit
● preheater begins to heat up the oil
● contact of lower limit thermostat (TSW) in preheater closes after time ”tw” (approx. 1
min), when the oil temperature is approx. 70 °C, whereupon the control signal is
applied to terminal 3 in control unit.

A Start on burner without preheating

● control signal is applied from contact 8 to contact 3 in control unit
● burner motor (fan/oil pump) starts
● pre-ignition begins
● pre-purge begins.

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B´ Solenoid valve receives control signal
● safety time begins (max. 10 s)
● solenoid valve opens (Danfoss) / closes (Suntec)
● oil atomising begins
● flame has to be ignited during the safety time, otherwise the control unit goes to
lockout.

B Flame ignites
● flame relay is energised, whereupon terminals 8 and 3 in control unit connect on flame
relay's contact. Opening of contact in thermostat of preheater does not stop the burner
during flame
● burner has started
● post-ignition till operating position of control unit.

C Control unit/burner in normal operating position

● control program of control unit ends
● burner remains operating supervised by the control unit (flame) and controlled by
control thermostat.

D Controlled shutdown with control thermostat

● burner motor stops
● solenoid valve closes
● flame extinguishes.

See chapter ”Control Functions in the Event of Faults”.

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7.2. 2-Stage Burners (H-Burners)

Required input signals to the control unit

Control signals from the control unit

TZ Limit thermostat M2 Servo motor

TS1 Control thermostat, stage 1 AD Air damper
TS2 Control thermostat, stage 2 T1 Ignition transformer
E1 Preheater EV1 Solenoid valve, stage 1
TSW Thermostat of preheater EV2 Solenoid valve, stage 2
M1 Burner motor (fan/oil pump) B1 Flame detector/flame signal

Adjustable switching points on the cam switch of the servomotor

I = switching point of stage 2
II = switching point of air damper ”closed” position after controlled shut-down
III = switching point of ignition load and stage 1
IV = fixed with cam switch III, difference +6°
V = switching point of solenoid valve stage 2

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Prerequisites for start-up
● burner is getting fuel
● interlocks are reset
● contact of switches of control voltage supply in control unit and contacts of thermostats
are closed, whereupon the control voltage is received to the terminal 1 in control unit.

A´ Start on burner with preheating

● control signal from terminal 8 in control unit
● preheater begins to heat up the oil
● contact of lower limit thermostat (TSW) in preheater closes after time ”tw” (approx. 1
min), when the oil temperature is approx. 70 °C, whereupon the control signal is
applied to terminal 3 in control unit.

A Start on burner without preheating

● control signal is applied is applied from contact 8 to contact 3 in control unit
● pre-ignition begins
● servomotor runs to switching point III (stage 1/ignition load) via switching point IV
● burner motor (fan/oil pump) starts in switching point IV
● pre-purge begins.

B´ Solenoid valve 1 receives control signal

● safety time begins (max. 10 s)
● solenoid valve 1 opens
● oil atomising begins
● flame has to be ignited during the safety time, otherwise the control unit goes to
lockout.

B Flame forms
● flame relay is energised, whereupon terminals 8 and 3 in control unit connect on flame
relay's contact. Opening of contact in thermostat of preheater does not stop the burner
during flame
● burner has started
● post-ignition until operating position of control unit.

C Control unit/burner in normal operating position

● control program of control unit ends
● control signal for the running time from terminal 5 in the control unit
● if the burner control switch is in position 2 and the contact of thermostat of stage 2 is
closed, servomotor runs to switching point I (position of stage 2 of air damper)
● solenoid valve of stage 2 opens under control of limit switch V in servomotor
● burner remains operating supervised by control unit (flame) and controlled by
thermostat of stage 2 at stage 2 or at stage 1.

D Controlled shutdown with control thermostat of stage 1

● burner motor stops
● solenoid valves close
● flame extinguishes
● servomotor runs to switching point II (air damper closed)

See chapter ”Control Functions in the Event of Faults”.

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8. Burner Adjustment

8.1. Capacity Regulation

Adjust the burner output by changing the size of the nozzle or the oil pump atomising pressure.
Combustion air quantity and position of the adjustment ring must be checked after having the
nozzle changed. When removing nozzle, two set spanners are needed; one to support the
nozzle holder.
The marking giving information on the nozzle capacity
*) The marking according to CEN standard. Kg/h is valid at an atomising pressure of 10 bar,
viscosity of 3,4 mm²/s (cSt) and density of 840 kg/m³. In this case the nozzle is marked with
EN.
**) The marking according to USgal/h. US gallon is valid at an atomising pressure of 7 bar,
viscosity of 3,4 mm²/s (cSt) and density of 820 kg/m³.
Select the nozzle size according to the boiler capacity.
*) Nozzle selection according to CEN-standard

P P = boiler capacity in kW
kg/h = Ha = lower calorific value for fuel oil in kWh/kg
Ha × η × kp η = 0,80 - 0,95 (efficiency 80 - 95 %)
Also the following formula gives the kp = pressure factor (see table)
pressure factor: P1 = 10 bar (according to CEN standard)
P2 P2 = pressure to be used
kp =
P1

Calculation example:
Nozzle for a boiler of 100 kW with an efficiency of 0,80 and pressure to be used is 9 bar.
100
nozzle kg/h = = 11 kg/h
11,86 × 0,80 × 0,95
**) Nozzle selection according to USgal/h

P 1 USgal = approx. 3,2 kg of oil

USgal/h = P1 = 7 bar (according to USgal/h)
Ha × η × 3,2 × kp

Calculation example:
Nozzle for a boiler of 100 kW with an efficiency of 0,80 and pressure to be used is 9 bar.

100
nozzle USgal/h = = 2,9 USgal/h
11,86 × 0,80 × 3,2 × 1,13
Pressure factor table
Oil pressure bar 7 8 9 10 11 12 13 14 15 16
P2 kPa 700 800 900 1000 1100 1200 1300 1400 1500 1600
Pressure CEN *) 0,84 0,89 0,95 1 1,05 1,10 1,14 1,18 1,22 1,26
factor P1=10 bar
kp USgal/h **) 1 1,07 1,13 1,20 1,25 1,31 1,36 1,41 1,46 1,51
P1=7 bar

Oil pressure bar 17 18 19 20 21 22 23 24 25

P2 kPa 1700 1800 1900 2000 2100 2200 2300 2400 2500
Pressure CEN *) 1,30 1,34 1,38 1,41 1,45 1,48 1,52 1,55 1,58
factor P1=10 bar
kp USgal/h **) 1,56 1,60 1,65 1,69 1,73 1,77 1,81 1,85 1,89
P1=7 bar

To convert kg/h into l/h, divide kg/h by the density of fuel oil (0,833 g/cm³).
On burners KP-6 L and -6 LH the nozzle capacities are approx. 10-15 % smaller than on burners
KP-6, -6-2 and -6 H-2.

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8.1.1. Oil Pump Pressure Regulation
1-stage burners
Fit a pressure gauge in the connection (see chapter ”Oil Pumps”). Adjust the oil pressure by
turning the pressure regulating screw. The pressure increases by turning the screw clockwise
and decreases counter-clockwise.
When the pressure is altered the oil flow and pressure follow the following formula:

V1 = capacity marked on the nozzle

V1 P1 V2 = nozzle capacity at a pressure of P2
= P1 = 7 bar gives USgal/h
V2 P2 10 bar gives kg/h according to CEN-standard
P2 = pressure to be used

Calculation example according to CEN-standard.

Nozzle capacity when the nozzle size is 11 kg/h and pressure 13 bar.

V1 P1 P2 13 bar
= => V2 = V1× = 11 kg/h × = 11 kg/h × 1,14 = 12,5 kg/h
V2 P2 P1 10 bar

2-stage burners
The oil pump gives two different pressures to the nozzle. Changing the nozzle pressures by
means of the pressure regulating screw regulates the pump’s capacities 1 and 2. Capacity 1
must be 55 - 70 % of the calculated capacity.
Design values for nozzle pressures: stage 1: 8 - 10 bar
stage 2: 20 - 25 bar
When adjusting the oil pressures, note that the burner capacity must remain on the capacity
range indicated on the type plate.
Calculation example according to CEN-standard.
Nozzle for a boiler of 100 kW with an efficiency of 0,80 and pressure to be used for stage 2 is
21 bar.

100
nozzle kg / h = = 7,27 kg / h
11,86 × 0,80 × 1,45 => select nozzle of 7,10 kg/h
Capacity 2, which can be reached by the nozzle at a pressure of 21 bar:

21 bar
7,10 kg / h = = 10,3 kg / h
10 bar
Capacity 1 must be 55 - 70 % (0,55 - 0,70) of the calculated capacity of the nozzle:
10,3 kg/h x 0,63 = 6,49 kg/h
Nozzle pressure of capacity 1 is thus:

P1× (V2)
2
V1 P1 V12 P1
= => = => P2 =
V2 P2 V2 2
P2 (V1)2

10 bar × (6,49 kg/h )

2
P2 = = 8,4 bar
(7,10 kg / h)2
The pressure of capacity 1 must be at least 7 bar.

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8.2. Combustion Head Adjustment

8.2.1. Setting the Nozzle and the Ignition Electrodes

The following drawing shows the distance of the nozzle (4) from the diffuser disc (6). Set the
ignition electrode spark gap and distance from the diffuser disc (6) and from the nozzle (4) as
shown on the drawing.

1 Mounting flange 5 Ignition electrode(s)

2 Retaining screw 6 Diffuser disc
3 Flame tube 7 Adjustment ring
4 Nozzle

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

1 Flame tube 3 Adjustment ring

2 Diffuser disc 4 Locking screw for adjustment ring
L
mm

STAGE 1
kg/h

If the position of the adjustment ring has to be altered in relation to the diffuser disc,
Note!
the air velocity and quantity in the combustion head will change. Check the
combustion values by flue gas analysis and, if necessary, adjust the combustion air
quantity to be adequate.

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8.3. Combustion Air Adjustment

8.3.1. 1-Stage Burners

Loosen the locking screw (1) and turn the air adjustment ring (4) from the indicator (2). The
indicator shows the position of the adjustment ring. When the right air quantity has been found,
retighten the locking screw.

1 Locking screw for adjustment ring

2 Indicator
3 Air intake
4 Adjustment ring

Position of Nut on Adjustment Ring

The adjustment ring has three slots for the nut of the locking screw. On burners KP-6, KP-6 L
and KP-6 H-2 the nut is placed on the middle slot (pre-set at the factory.

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8.4. 2-Stage Burners (”H” Burners)
Functions of cam discs in servomotor SQN
Set the switching points of cam discs manually or by turning with the adjusting key.
II: Air damper ”closed”/(°). The adjustment has been made at the factory.
III: Air damper position at stage 1/(°)
V: Solenoid valve of stage 2
I: Air damper position at stage 2/(°)
The setting of the disc V should preferably be as high as possible, not, however, so high that the
flame does not react when changing over from stage 2 to stage 1 (the setting of the disc V is
between discs III and I).
The servomotor is provided with a release lever (5). When the lever is pressed down, the air
damper can be moved by hand.

Note! Difference III - I must be at least 10° on the scale.

Set the final settings of the air damper (= combustion air) to be correct by means of flue gas
analysis.

Cam disc positions in principle

1 Air regulation, stage 2 4 Control of solenoid valve for stage 2

2 Air damper closure 5 Release lever
3 Air regulation, stage 1 6 Adjusting key

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8.5. Air Cone Position
If the air cone has to be replaced or removed, it has to be installed in the right position with
respect to the burners housing. The right position is shown in the drawing below. After
replacement check by turning the fan wheel by hand, that it does not touch the cone. The fan
wheel can be turned after loosening the sight glass.

1 Burner housing
2 Air cone
3 Tip of air cone
4 Sight glass

8.6. Flame Inspection

The ignition process may be observed through the sight glass by turning aside the cover. It must
be replaced in the normal operating position after inspection.

Inspection position Operating position

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9. Control Unit LOA24/BHO64

9.1. Time Sequence Diagram (Control Program)

Required input signals to the control unit

Control signals from the control unit

Legend
TZ Limit thermostat
TS Control thermostat
E1 Preheater
TSW Thermostat for preheater
M1 Burner motor (fan/oil pump)
T1 Ignition transformer
EV1 Solenoid valve, stage 1
EV2 Solenoid valve, stage 2
B1 Flame detector/flame signal

tw Heating up time of oil preheater up to the readiness signal

given by contact ”OW” approx. 1 min
t1 Pre-purge time approx. 13 s
t3 Pre-ignition time approx. 13 s
t3n Post-ignition time approx. 15 s
t2 Safety time max 10 s
t4 Interval between detection of flame and release of terminal 5 approx. 15 s
--- Reaction time on flame failure <1s

A' Commencement of start-up with burners with oil preheater.

A Commencement of start-up with burners without preheater.
B Time, when flame is detected (burner started).
C Control unit (burner) in normal operating position (control program has ended).
D Controlled shutdown by control thermostat TS.

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9.2. Control Functions in the Event of Faults
Extraneous light / premature flame signal
During pre-purge and/or pre-ignition period there must never be a flame signal. If there is a
signal during this period, caused possibly by premature ignition due to a leaking oil valve,
extraneous light, a short-circuit in the flame detector (photo resistor) or its wiring, a fault in the
flame signal amplifier, etc., the control unit locks out on expire of the pre-purging and safety
period. Under these circumstances the oil valve does not open during the safety time.

Non-appearance of the flame signal

If no flame signal has appeared by the end of the safety period, the control unit immediately
locks out.

Flame failure during operation

On flame failure during operation the control unit immediately shuts down the fuel supply and
automatically attempts to restart. On completion of ”t4” the control unit performs the full starting
sequence.
With every lockout control outputs 3 to 8 and terminal 11 are de-energised in less than 1
second, while terminal 10 for the remote signalling of lockouts receives voltage. Resetting the
control is possible only when, after lockout, at least 50 seconds have elapsed.

Protection against under-voltages

The electronic protection against under-voltages ensures that in the event of mains disturbances
with dangerous under-voltages (< 165 V) the control unit shuts down the burner and prevents a
new start-up.

9.3. Technical Data of Control Unit

Supply voltage 220 VAC -15 %...240 VAC +10 %
Protection against under-voltages < 165 V
Frequency 50 - 60 Hz, ± 6 %
External fuse max. 10A
Permissible ambient temperature -20...+60 °C

9.4. Current through Flame Detector

Photo resistor (flame detector) QRB 220 VAC 240 VAC
Min. required detector current with flame 65 µA DC 75 µA DC
Max. permissible detector current without flame 5 µA DC 6 µA DC
Max. possible detector current with flame 200 µA DC 220 µA DC
Internal resistance of the d.c. measuring instrument max. 5 kOhm (+pole to terminal 12)

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9.5. Measurement of Flame Signal

WARNING! This control unit is a safety unit! Do not open it. Any unauthorised
tampering can result in unforeseen detrimental consequences.

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10. Maintenance

WARNING! Always switch off the electric power from your burner and shut the
manual shut-off valves in the fuel supply line before servicing your burner. When
inspecting your burner you only have to switch off the electric power from your burner.
The manual shut-off valves in the fuel supply line can then be open.

Burner maintenance
In order to ensure reliable operation clean the ignition electrodes and check their setting.
Flame detector has to be kept clean.
Clean filters if necessary.
Change the nozzle if it is worn or damaged.
Clean your burner from damp and other airborne impurities and keep the burner clean.
Check regularly the combustion values by flue gas analysis (for ex. always after the refilling of
the storage tank or at least once a year).
An authorised person should inspect the burner at least once a year.

Heating appliance control

Keep the boiler room always clean and the door closed.
Make sure, that there is always sufficient water (pressure) in the heating system.
Have the furnace and the chimney swept regularly.
Check regularly, that the smoke damper is correctly adjusted.
Protect your burner against splash water.
The oil tank must be cleaned when needed, at least every 4 - 5. years.
The boiler room fresh air ventilator must be open.
Check safety devices of heating appliance and burner according to the local requirements.
Check that the boiler and its equipment are on working condition.

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11. Fault Conditions and Procedures

In the event of fault conditions the basic requirements for correct operation must be first
examined:
1. Check the electric supply (control voltage).
2. Check that all control devices are correctly set.
3. Are the safety devices in normal operating condition?
4. Is the burner getting fuel, are the valves in fuel line open, is there oil in the tank?

When it is established, that the fault is not due to above mentioned, the individual burner
functions must be checked. Reset the burner control unit if it is in lockout position (signal lamp
lights). Burner starts. Observe the burner functions. Measuring instruments can be used for
finding of the fault.

CAUTION POSSIBLE CAUSE REMEDY

1. Motor
Burner motor does not start Break in motor control circuit: Find cause and remedy
- faulty control unit Replace control unit
- faulty preheater (”LH” burners) Replace
- faulty air damper servomotor Replace
(”H” burners)
- incorrect setting on cam disc of Correct setting
the servomotor (”H” burners)

Faulty motor Replace

2. Ignition failure
Burner motor starts, control Dirty or worn ignition electrodes, Clean or replace
voltage from control unit to insulator cracked
ignition transformer is
switched on, no ignition and Incorrect position of ignition Adjust according to instructions
after a short time lockout electrodes
occurs.
Damaged ignition cable Replace

Faulty ignition transformer Replace

3. No flame establishment
Burner motor starts, ignition Solenoid valve does not function:
is in order, after a short time - faulty solenoid valve or coil or Replace faulty part
lockout occurs. cable damaged
- faulty control unit.

Main solenoid valve does not

function:
- incorrect setting on cam disc of Correct setting
the servomotor

Nozzle supplies no oil Oil atomising pressure too low See section ”Oil pumps”

Blocked or worn nozzle Clean or replace

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CAUTION POSSIBLE CAUSE REMEDY

4. Oil pump
Supplies no oil or atomising Dirty filter Clean
pressure is too low
Leaking suction line Seal

Pump capacity decreases: Replace

- faulty or worn pump

Nozzle supplies no oil Valve does not open to the Replace solenoid valve coil or
nozzle: pump
- solenoid valve (pump AS 47 C)
does not close
- solenoid valve (other pump
types) does not open

Severe mechanical noise Pump sucks air Tighten joints

Vacuum in oil piping too high Clean filter

Check size of suction line

5. After flame establishment lock-out

Flame forms. When burner Incorrect burner adjustment Correct adjustment
runs to stage 2, lockout
occurs and then re-start Dirty filters Clean
(H-burners).
Blocked nozzle Replace

Faulty solenoid valve Replace

6. Premature flame formation

Burner motor starts, then Leaking valves Clean or replace
lockout occurs.

7. Flame monitoring fault (=lock-out)

Burner motor starts, flame Incorrect position of flame Correct
forms, then lock-out occurs detector

Dirty flame detector Clean

Too weak flame (illumination) Check burner adjustments

Faulty flame detector Replace

Faulty control unit Replace

Lock-out during pre-purge Faulty flame detector Replace

period
Faulty control unit Replace

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CAUTION POSSIBLE CAUSE REMEDY

8. Combustion head
Inside oily or has heavy Distance between diffuser disc Correct adjustment
carbon deposits and nozzle incorrect

Incorrect combustion air Adjust

adjustment

Boiler room not adequately Increase air supply

ventilated

Nozzle incorrect sized or of Change nozzle as appropriate

wrong type

Nozzle worn Replace

Incorrect position of adjustment Adjust

ring

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12. Notes

Boiler type ___________________________________________________________

___________________________________________________________

Burner type ___________________________________________________________

___________________________________________________________

Burner serial No.

Date of installation ___________________________________________________________

Installed by ___________________________________________________________

___________________________________________________________

Miscellaneous ___________________________________________________________

___________________________________________________________

___________________________________________________________

___________________________________________________________

___________________________________________________________

___________________________________________________________

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