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Oilon GKP-90 MH - User Manual

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M5164 1640EN
13 October 2016
Original instructions
Operation and maintenance manual
Burner models: GKP-50 MH - 90 MH
Burner equipment: WD34
Read these instructions carefully before installation, use, or maintenance

Table of Contents

Questions and Answers

  • J
    Joyce LyonsAug 20, 2025
    What to do if Oilon GKP-90 MH Burner fan motor starts but there is no ignition?
    • J
      jenniferhooverAug 20, 2025
      If the fan motor starts, control voltage from the burner control to the ignition transformer is switched on, but there is no ignition, and after a short time a lockout occurs, it could be due to dirty or worn-out ignition electrodes or a damaged insulator. Try cleaning or changing them. Also, check if the ignition electrodes are too far apart and adjust them according to the instructions. A damaged ignition cable or a faulty ignition transformer could also be the cause, in which case you should replace them.
  • R
    Rickey GardnerAug 22, 2025
    What to do if Oilon Burner fan motor starts, but lockout occurs during pre-purge?
    • S
      Stanley JohnsonAug 22, 2025
      If the fan motor starts, and a lockout occurs during the pre-purge period, the differential air pressure switch setting may be faulty, so check the setting and adjust if necessary. The differential air pressure switch impulse hoses or pipe could be dirty, so clean the hoses or pipe. The differential air pressure switch itself might be faulty, so replace it. A dirty fan or incorrect motor rotation direction can also cause this issue, so clean the fan or reconnect the motor.
  • H
    heatherwestAug 26, 2025
    What to do if Oilon Burner fan or oil pump motor does not start?
    • A
      aliciastoutAug 26, 2025
      If the fan or oil pump motor of your Oilon burner does not start and a lockout occurs, there may be a break in the main circuit; find out the cause of the break. The motor overload relay may have released; check the setting and reset it. A faulty motor contactor or the motor itself could also be the problem, requiring replacement. Additionally, there could be a break in the control circuit; find out the cause of the break, referring to the circuit diagram, and check the burner control operation, replacing it if faulty.
  • J
    Jessica SmithAug 28, 2025
    Why does my Oilon GKP-90 MH flame form, then lockout and restart?
    • J
      James RodriguezAug 28, 2025
      If the flame forms, but lockout and restart occurs with fault code 611, it could be due to gas pressure being too low because of an inoperative pressure regulator. Repair or change the regulator. Alternatively, the gas pressure may be too low because the minimum gas pressure switch released; check its operation and regulations. A blocked filter can also cause this issue, so clean or repair the filter.
  • A
    Angela SmithAug 29, 2025
    Why is oil leaking into the combustion chamber of my Oilon GKP-90 MH during idle time?
    • R
      Robert JenkinsAug 30, 2025
      If oil leaks into the combustion chamber of your Oilon burner during idle time, it is likely due to the solenoid valves not closing properly. To resolve this, clean, repair, or replace the valves.
  • G
    Gabriela EatonAug 31, 2025
    Why is oil leaking into the combustion chamber of my Oilon GKP-90 MH Burner during start-up?
    • M
      mosleytheresaSep 1, 2025
      If oil leaks into the combustion chamber of your Oilon burner during start-up, it's likely due to leaking valves. Clean, repair, or replace the leaking valves to resolve this issue.
  • S
    Scott SilvaSep 2, 2025
    Why does my Oilon GKP-90 MH lockout shortly after ignition when using oil?
    • K
      Kelli BishopSep 2, 2025
      If the fan motor starts and ignition is in order, but after a short period of time lockout occurs when using oil, it could be due to a malfunctioning solenoid valve (faulty valve or coil), a damaged cable, or a faulty burner control (Fault code 921). Replace the faulty part. Also, check for too low ignition load, too large air amount (adjust), or too high pressure loss in the combustion head (adjust).
  • E
    Eric MccormickSep 4, 2025
    Why does my Oilon GKP-90 MH Burner flame extinguish at full load?
    • M
      Megan ScottSep 4, 2025
      If, when using oil, the flame forms, then extinguishes and lockout occurs when the burner runs to full load (Fault code 4), it could be due to incorrect burner adjustment, so adjust it. It could also be due to a clogged nozzle, so change it.
  • R
    Robert Ross Jr.Sep 6, 2025
    Why does my Oilon Burner lockout after the flame forms?
    • K
      Katherine CampbellSep 6, 2025
      If the fan motor starts, flame forms, and then lockout occurs with fault codes 9 or 10, the flame detector position may be incorrect, so repair it. The flame detector might be dirty, so clean it. The flame could be too weak (light), so check the burner adjustments. The flame detector itself may be faulty, so replace it. Finally, the burner control could be faulty, so check the fault code and replace it if necessary.
  • K
    Kyle YoungSep 8, 2025
    Why does my Oilon GKP-90 MH Burner lockout during pre-purge?
    • J
      Jack HunterSep 8, 2025
      If a lockout occurs during the pre-purge phase of your Oilon burner, it could be due to a faulty flame detector, so replace it. A faulty burner control could also be the cause, so check the fault code and replace it. Additionally, an incorrect flame signal caused by extraneous light might be interfering, so block the extraneous light.

Summary

Introduction

Safety Precautions

Highlights important safety symbols and warnings for safe operation and maintenance.

General Safety Warnings

Provides critical safety warnings regarding installation, emergencies, maintenance, and PPE.

Emergency Shutdown and Boiler Room Safety

Details emergency shutdown procedures and essential safety measures for the boiler room environment.

Installation

Space Requirements

Lifting the Burner

Installing the Burner

Details the main dimensions for the GKP-50 MH model, including mounting considerations.

GKP-90 MH Main Dimensions

Details the main dimensions for the GKP-90 MH model, including mounting considerations.

Mounting Dimensions

Burner Mounting Procedures and Warnings

Installing the Gas Module

Gas Module Assembly and Mounting

Servomotor Cable Connection and Burner Handling

Installing to Gas Supply Line

Installing Gas Pressure Regulating Assembly

Safety Relief and Shut-off Valve Installation

Oil Piping

Electrical Connections

Provides instructions for connecting the burner according to electrical diagrams and adhering to standards.

Electrical Connection Guidelines

Commissioning

First Start-up Procedures

Guides through the initial start-up process, including checks, precautions, and a start-up checklist.

Adjusting Nozzle and Ignition Electrodes

Explains how to set the spark gap and nozzle distance for optimal ignition.

Oil Pump Pressure Regulation

Details how to adjust oil pump pressure and provides formulas for calculating oil flow and capacity.

Defining Burner Capacity

Adjusting Combustion Air

Guides on adjusting the combustion air by positioning the adjustment ring for optimal combustion.

Oil Pump Pressure Adjustment and Venting

Details procedures for adjusting oil pump pressure, venting the pump, and handling potential issues.

Adjusting Differential Air Pressure Switch

Explains how to adjust the differential air pressure switch for proper burner function and CO limits.

Adjusting Gas Pressure Switch

Provides instructions for adjusting gas pressure switches, both minimum and maximum settings.

Setting Gas Pressure Regulator SKP

Guides on setting the SKP gas pressure regulator, including spring selection and adjustment.

Gas Pressure Regulator Spring and Adjustment

Details procedures for changing springs and adjusting gas pressure on the SKP regulator.

Setting Gas Pressure Regulator FRS

Provides instructions for adjusting the FRS gas pressure regulator's outlet pressure.

FRS Gas Pressure Regulator Spring Replacement

Details the process for replacing the setting spring in the FRS gas pressure regulator.

Measuring Gas Pressure

Explains general rules and procedures for measuring gas pressure at various points.

Manual Start-up and Servomotor Position Checking

Guides on performing manual start-ups and checking servomotor positions for correct operation.

Manual Drive Start-up Precautions

Pre-purge Position Checking

Setting Ignition Position

Provides steps to set the ignition position within the ratio control menu.

Setting Ignition Position for Oil (2-Stage)

Details how to set the ignition position for 2-stage oil operation using the ratio control menu.

Setting Ratio Curve

Setting Ratio Curve for Oil (2-Stage)

Load Controller Module Operating Mode

Setting Load Controller Parameters

Troubleshooting Incorrect PID Settings

Load Controller Parameter Settings

Maintenance

Burner Maintenance Procedures

Provides instructions for annual burner maintenance and safety checks.

Dismounting Combustion Head and Gas Nozzle

Combustion Head Structure (90-Model)

Dismounting Combustion Head from Burner

Dismounting and Changing Burner Motor

Motor and Fan Wheel Mounting and Dismounting

Dismounting and Changing Servomotors

Removing the Air Damper Servomotor

Testing Safety and Control Devices

Outlines tests for safety and control devices during maintenance.

Flame Detector Safety Test

Describes test methods and expected outcomes for the flame detector safety test.

Differential Pressure Switch Testing

Explains how to test the differential pressure switch, referring to its adjustment section.

Gas Pressure Switch Testing

Provides test methods and outcomes for gas pressure switches (minimum and maximum).

Gas Shut-off Valve Testing

Provides manual testing procedures for gas shut-off valves to check for leaks.

Oil Shut-off Valve Leak Testing

Outlines precautions and procedures for oil shut-off valve leak testing.

1- and 2-Stage Valve Leak Testing

Describes a method for testing 1- and 2-stage oil valves using a simulated flame signal.

Servomotor Operation Check

Resetting Faults and Reading History

Guides on how to reset faults and read fault history from the control panel.

Cleaning the Oil Filter

Troubleshooting

Lists basic operation requirements to check first and then guides on identifying faults.

Troubleshooting: Start Failures

Details possible causes and actions for various start-up failures and lockouts.

Troubleshooting: Motor Failures

Lists causes and actions for fan or oil pump motor failures and lockouts.

Troubleshooting: Flame Formation Issues

Addresses issues related to flame formation, including solenoid valve and air amount problems.

Troubleshooting: Lockout After Flame Establishment

Covers causes for lockout after flame establishment, like gas pressure or filter issues.

Troubleshooting: Oil Leaks

Identifies causes for oil leaks into the combustion chamber during idle time or start-up.

Troubleshooting: Flame Monitoring Faults

Covers flame monitoring faults, lockouts, and issues with extraneous light.

Troubleshooting: Combustion Head Issues

Addresses combustion head issues like diffuser disc burnout and carbon deposits.

Troubleshooting: Leakage Test Failures

Explains causes and actions for leakage test failures in gas systems.

Troubleshooting: Gas Pressure Switch Max. Fault

Covers causes for burner shutdown due to gas pressure issues or faulty pressure switches.

Troubleshooting: Oil Pump Issues

Addresses oil pump issues like no oil supply, low pressure, or mechanical noise.

Maintenance During Shutdown

Oilon GKP-90 MH Specifications

General IconGeneral
BrandOilon
ModelGKP-90 MH
CategoryBurner
LanguageEnglish

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