Reznor RA 140 Installation/Operation/Maintenance Manual And Reference Manual
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Reznor RA 140 Installation/Operation/Maintenance Manual And Reference Manual

Reznor RA 140 Installation/Operation/Maintenance Manual And Reference Manual

Used-oil-fired heaters and boilers
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See also: Reference and Installation Manual
Installation/Operation/Maintenance
Heater Models
RA 140
RA 235
RAD 140
RAD 235
REZNOR
®
HEATERS AND BOILERS
Manual and
Reference Guide
CSA Certified to Electrical and Fuel Burning requirements only.
Form I-RA/D 140/235 (Version A)
USED-OIL-FIRED
Form I-RA/D 140/235 (Version A), Mfg No. 110318 Rev 4, Page 1
Obsoletes Form I-RA/D 140/235

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Summary of Contents for Reznor RA 140

  • Page 1 ® HEATERS AND BOILERS Installation/Operation/Maintenance Manual and Reference Guide Heater Models RA 140 RA 235 RAD 140 RAD 235 CSA Certified to Electrical and Fuel Burning requirements only. Form I-RA/D 140/235 (Version A), Mfg No. 110318 Rev 4, Page 1...
  • Page 2 Notice to Owner and Installer To ensure the long term benefits of burning your used oil in a Reznor® Used- Oil-Fired Heater, it is necessary to become familiar with the correct instal- lation and maintenance of your new furnace. Before installing or operating this heater, make sure you have read and understand this manual.

  • Page 3: Table Of Contents

    Table of Contents Heater Start-Up ..19 - 23 Installation ....4 - 18 System Check ......19 Introduction ........4 Priming and Leak Check .... 19 Use..........4 Codes and Regulations ....4 Heater Start-Up ......21 Warranty ......... 4 Start-Up Procedure .....

  • Page 4: Installation

    Installation Introduction This heater is for commercial or industrial use only. The heater should be installed by an experienced installer thoroughly trained and experienced with the installation of oil-fired appliances. The installer should be familiar with the special precautions neces- sary in the handling and storage of used automotive oils which may contain small amounts of gasoline.

  • Page 5: Safety Warnings

    Safety Conventions Used in this Manual Warnings Hazard Intensity Levels DANGER: Failure to comply will result in severe personal injury or death, and/or property damage. WARNING: Failure to comply can result in severe personal injury or death and/or property damage. CAUTION: Failure to comply could result in minor personal injury and or personal damage.

  • Page 6: Air For Combustion

    Safety Warnings Continued Air for WARNING: Care should be exercised to ensure that an adequate supply of combustion air is available Combustion and free to enter the air openings on all units. Room openings must equal one square inch per each 1,000 BTU heat input.

  • Page 7: Parts Carton

    Additional Parts Shipped with each heater is a remote fuel pump and a carton of parts. The carton contains parts required for installation. Before beginning actual installation, verify that the remote fuel pump and the parts listed below are at the installation site. Pump Parts Carton Item Part No.

  • Page 8: Heater Placement

    Heater Do not attempt to install this heater until you have read and understand this manual! Placement Placement is critical to the efficient operation of this heater. Measure all distances to comply with the specific code requirements and minimum clearances listed below. Refer to the section on Venting your heater for vent requirements and recommendations.

  • Page 9: High Altitude Installation

    High Altitude High Altitude Installation Standard Model RA/RAD 140 and 235 used-oil-fired heaters are Installation designed for use from sea level up to elevations of 3,000 ft. Without proper modifications severe overheating of the combustion chamber and heat exchanger will occur if installed above 3,000 ft. Also, the on- board air compressor will not deliver the correct amount of atomizing air to the fuel nozzle, resulting in poor combustion.

  • Page 10: Fuel Tank, Pump, And Supply

    Model 235 is 1.7 GPH (7.7 L/H). The oil supply tank and fuel lines must be installed in accordance with the National Board of Fire Underwriters requirements and all local ordinances. A UL-listed tank such as Reznor Model OT-250 or ®...

  • Page 11: Pump

    Pump Remote Fuel Pump The Model OT-250 tank has a platform designed for attaching the remote fuel pump. • Attach the fuel pump legs permanently either on the platform, directly to a field-supplied tank, or in a location very near to the oil tank.

  • Page 12: Typical Installation

    Supply Lines Installation Continued Suction Line (cont’d) the suction line components as illustrated. With the vacuum gauge mounted on the outlet side of the filter, the gauge will indicate any suction line restriction including a dirty filter. A pump inlet manifold is supplied for direct connection of the filter to the inlet of the pump.

  • Page 13: Mounting The Heater

    Mounting the Weights Heater Before suspending the unit, check the supporting structure to ensure it has sufficient load-carrying capacity to support the weight of the heater. Net Weight Model RA140 RA235 RAD140 RAD235 Suspension Use four 1/2”-13 diameter threaded rods. Lock each threaded rod using a washer and nut as shown in the illustration below.

  • Page 14: Venting The Heater

    Venting the WARNING: Failure to provide proper venting could Heater result in death, serious injury, and/or property dam- age. Units must be installed with a flue connection and proper vent to the outside of the building. Safe operation of any gravity vented heating equipment requires a properly operating vent system, correct provision for combustion air, and regular mainte- nance and inspection.

  • Page 15: Detailed Requirements For The Vent System

    • Any portion of the �������� ������������������ vent system that passes through an ������������ unheated space or a ������� ������������ ������� concealed area such ���������������������������� as an “attic” must be �������������������������������������� a factory-built vent ������������������ that is approved to ������������� ������������������...

  • Page 16: Draft Regulator

    2 ft (610mm) higher than any portion of a building or obstruction within 10 ft (3M) of the chimney. Install a vent cap on the terminal end of the vent. A Reznor (Option CC1) or Type L Breidert Air-x-hauster vent cap ®...

  • Page 17: Installing Ducts

    Installing Inlet Air Duct Ducts Canadian installations require field installation of an inlet air duct (return air system) on a Model RAD heater. The blower-equipped heater has an inlet air duct flange. Inlet duct dimensions (inside) are: Duct Flange RAD140 RAD235 Height 32-1/8”...

  • Page 18: Power Installation

    Power DANGER: Make sure that the main circuit is OFF be- fore making any wiring connections. All wiring must Installation be done in accordance with appropriate Codes! Pump Power Pump Power To connect the electrical power from the heater to the pump, Installation •...

  • Page 19: Heater Start-Up

    Determine that fusing or circuit breakers are adequate for the load.  Check vents. Be sure that vent pipe and chimney meet the requirements and appropriate codes. A UL or CSA/UL listed draft regulator is required. A Reznor (Option CC1) or Type ® L Breidert Air-X-hauster vent cap is recommended.

  • Page 20: Leak Check

    Priming and 2. Set manual disconnect switch to the ON position. 3. Fill the suction line (line between the supply tank and the Leak Check pump) with clean used oil. (Do not use new motor oil.) Continued 4. Locate the rubber tubing connecting the pressure switch in the main control box and the compressor.

  • Page 21: Heater Start-Up

    Heater Start-Up Procedure Start-Up After installing and testing your unit, follow the procedure below to start the system. • Turn on the main electrical supply to the heater. • Set the manual disconnect switch to the “ON” position. • Set the thermostat to a temperature above room temperature. NOTE: When the low oil temperature limit senses the proper oil temperature, the green light on the burner junction box will come on and the heater will fire.
  • Page 22 Check-Test WARNING: If there is insufficient draft, it will create Continued a back pressure resulting in oil fumes in the build- ing and/or pulsating when the burner starts and stops. It may cause excess deposits of soot and overheat the heat exchanger resulting in premature failure of the chamber.
  • Page 23 Check-Test ■ Check Discharge Air Temperature - Model RAD with discharge ductwork only. Continued This heater is designed for a maximum of .25” w.c. static pressure and for discharge air temperature rises from 40° to 50°F. If the heater has been equipped with a duct, the discharge air tem- perature should be checked.

  • Page 24: Maintenance

    Maintenance General WARNING: Turn off electric power to the unit before Maintenance doing any service or maintenance on the heater. Requirements When burning used automotive diesel and truck oils, this heater will require more frequent service than conventional heating equipment. All used oils contain a small amount of ash.

  • Page 25: Maintenance Procedures

    Every Six months: • Clean the oil strainer at the burner. • Clean the foot valve screen. • Replace the air filter. • Clean the end cone. • Replace the oil nozzle. • Clean the external surfaces of the combustion chamber/heat exchanger.

  • Page 26: Cleaning The Burner Oil Strainer

    Reznor P/N 123450. 3. Reassemble the pump Cover • Check the gasket and if a replacement is needed, replace it with Reznor P/N 123451. • Re-assemble the pump and reconnect the inlet oil line being sure that the connection is Bolts tight.
  • Page 27 Cleaning Combustion Chamber, Heat Exchanger and Flue Pipe WARNING: Used oils may contain engine-wear metal compounds and foreign materials. When burned, these compounds are deposited within or exhausted from this heater. Therefore, care should be taken when using, cleaning and maintaining this equipment.
  • Page 28 Maintenance Inspecting and Cleaning the Heat Exchanger/Combustion Chamber (cont’d Continued View with Inner Access Door Combustion Removed Chamber If tubes are 25% blocked, leave covers off and proceed with cleaning. Heat Exchanger Tubes Removing Soot and Ash from the Combustion Chamber, Heat Exchanger, and Flue Pipe 1.
  • Page 29 • Remove the wing nut, the cover plate, and the filter. Continued • Properly discard the old filter and replace with a new filter (Reznor P/N 107216, Wix Filter No. 43274, or NAPA No. 2374). • Fasten with cover and wing nut.
  • Page 30 Maintenance • Clean nozzle by disassembling, washing thoroughly, and blowing dry with compressed air. Procedures • If nozzle face appears worn, replace the oil nozzle with P/N 102997. Annual nozzle replacement is recommended. This Continued nozzle is custom designed. Do not substitute nozzle. •...

  • Page 31: Electrode Adjustment

    Maintenance 6. The fuel line assembly may now be removed by either • Pulling the assembly up slightly and toward the rear of the Procedures burner housing. Continued • OR removing the burner and end cone and pulling straight out of the blast tube.
  • Page 32 Maintenance Reassembling the Fuel Line Assembly 1. To reassemble the Fuel Line Assembly Procedures • Slide the fuel line assembly into the burner housing and the Continued burner tube. 2. Connect the fuel connection assembly to the fuel line as- sembly.
  • Page 33 Maintenance 3. Clean the Pre-heater • Place the pre-heater in a vice and carefully remove the outer Procedures cylinder and the “O” ring. NOTE: There will be oil in the pre- heater. Continued • Clean the inner section with a cloth and degreaser such as Cleaning Oil carburetor cleaner.

  • Page 34: Service

    For your safety, we suggest that if you are unfamiliar with servicing this type of equipment, contact a qualified service person. The material contained in this section is prepared to aid an experienced service person in diagnosing and repairing Reznor Model RA/RAD used oil heaters. General...
  • Page 35 General Compressed air for atomizing the used oil is supplied by a piston-type compressor mounted on the service tray. Model RA/RAD 140 and Operation 235 heaters require air pressure within a 9 to 12 psi range for proper oil atomization. To assure that the correct atomizing air pressure is Continued available, a pressure switch permits oil flow to the nozzle only when a minimum of 9 psi is sensed.

  • Page 36: Troubleshooting

    Troubleshooting Oil Burner Troubleshooting To diagnose malfunctions properly, the following test equipment is required: 1) An electrical test meter that can measure AC volts, ohms, and amps; 2) A combustion analyzer kit to measure oxygen and/or carbon dioxide, smoke, stack temperature, and draft; and 3) Two pressure gauges with scales of 0-100 PSIG and 0-30 PSIG.

  • Page 37: Troubleshooting Chart Guide

    Backflow • Burning off-specification fuel • Changes in outside ambient temperature Sensor Switch Location - The backflow sensor switch is mounted on a bracket on Continued the hinged viewport cover on the control side of the heater. The lo- cation is important in the operation of this switch. Except for limited observation, the viewport cover must be kept closed for the sensor (and heater) to operate properly.

  • Page 38: Location Of Components Referenced In Troubleshooting Charts

    Troubleshooting Continued Location of Components Referenced in Troubleshooting Charts Backflow Sensor Switch on the Viewport Door (not 10 amp fuse mounted on the end of the illustrated) - on heaters electric box. See wiring diagram. NOTE: installed in Canada Fuse is on all units installed in Canada; beginning 1/96;...

  • Page 39: Troubleshooting Charts

    Troubleshooting Chart No. 1 - Thermostat calling for heat; Burner motor never attempts to run. Charts Refer to illustrations on page 38 and 40. Has there Turn on or correct Check for line been line voltage across supply. Wait 15 voltage at the manual FIRST, turn on the main Terminals 1 and 2 for at least...
  • Page 40 Troubleshooting Oil Heat Exchanger and Fuel Line Assembly Reference Chart No. 1 Continued Locations and Replacement Instructions for Heating Element and Temperature Controls Low Oil on Oil Pre-heat Heat Temperature Limit Exchanger (black leads) Oil Temperature High Oil Temperature Refer to illustra- Control (blue leads) Limit Switch (yellow tion on page 38.

  • Page 41: With Thermostat Calling For Heat, Burner Motor Runs Momentarily

    Troubleshooting Chart No. 2 - Thermostat calling for heat, burner motor never attempts to run (green Continued light is lit) indicating “System Ready”. Chart No. 1 has been successfully completed. NOTE: After ignition control is reset, you will have 30 SECONDS to perform the tests shown below before the controller locks out.

  • Page 42: System Does Not Attempt To Ignite

    Troubleshooting Continued Chart No. 3 - Thermostat is calling for heat. Burner motor runs for about 30-45 seconds. System does not attempt to ignite. First, check combustion chamber for excess Transformer and Electrode Checks: oil. Measure voltage between transformer/primary NOTE: After ignition control is reset, you will lead and neutral connection.

  • Page 43: Burner Ignites And Burns Steadily Until System Goes Into Lockout

    Troubleshooting Chart No. 4 - Burner ignites and burns steadily until the system goes into lockout. Continued 1. Remove cad cell wires from the ignition controller. 2. Start the burner. Jumper F-F terminals on the ignition controller. Replace Does ignition ignition controller controller.

  • Page 44: Burner Operation Erratic/Unstable Flame Pattern

    Troubleshooting Chart No. 5 - Thermostat calling for heat. Burner operation erratic/unstable flame pat- Continued tern. Refer to illustration on page 38. Bleed oil from burner tee bleeder for ten minutes. Run vacuum Is stream of oil test on suction line to perfectly solid and Repair suction line check for air leaks.

  • Page 45: High Temperature Limit Cycles

    Chart No. 6 - High Temperature Limit Cycles* Refer to illustration on page 46. Check Does for line Replace voltage across fan/blower fan/blower fan/blower leads. motor. operate? Is voltage read? Check for line voltage Replace air across Terminals discharge limit 1 and 2.
  • Page 46 Troubleshooting Fan and Limit Controls Model RA/RAD 140 and 235 heaters are equipped with a fan control Continued and limit control assembly consisting of a specially designed control mounting bracket with a fan control, a circulating air high limit control, and a super high limit control attached.

  • Page 47: Oil Delivery System Troubleshooting

    Chart No. 7 - Oil Delivery System CAUTION: If the heater will be shut down for a long period, turn off the elec- tric power. Is there Fill oil sufficient oil in the tank. supply tank? Replace or repair. Check pump and Is there Is the...

  • Page 48: Appendix

    Form I-RA/D 140/235 (Version A), Page 48...
  • Page 49 Form I-RA/D 140/235 (Version A), Mfg No. 110318 Rev 4, Page 49...

  • Page 50: Hour Meter / Cleaning Record

    Hour Meter / Cleaning Record Cleaning Date Meter Reading Initials Cleaning Date Meter Reading Initials Form I-RA/D 140/235 (Version A), Page 50...

  • Page 51: Index

    Index Main Power 18 Fuel Tank 10 Pump Power 18 Fuse 38 Air Band and Air Shutter Set- Pre-Heater System 32, 33 tings 22 Priming and Leak Check 19 Air band settings 22 Hazard Intensity Levels 5 Pump 10, 11 Air for Combustion 6 Hazardous Atmosphere 5 Air Moving Device 33...
  • Page 52 BUILDING OWNER OR MAINTENANCE PERSONNEL: For service or repair • Contact the installer listed above. • If you need additional assistance, contact the Reznor Distributor listed above. • For more information, contact your Reznor Representative by calling 800-695-1901. Reznor/Thomas & Betts 150 McKinley Avenue...

This manual is also suitable for:

Ra 235Rad 140Rad 235

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