Summary of Contents for Reznor RAB 140
- Page 1 Form No. RGM 465 REZNOR ® WASTE OIL FIRED BOILER Installation Reference Guide Model RAB Sizes 140, 235, 350, 500 Model RAB boilers meet EPA requirements for disposal of used oil.
- Page 2 IMPORTANT Notice to Owner and Installer To ensure the long term benefits of burning your used oil in a Reznor ® Waste Oil Fired Boiler, it is necessary to become familiar with the correct installation and maintenance of your new boiler. Before installing or operating, make sure you have read and understand this manual and the boiler manual.
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Page 3: Table Of Contents
Table of Contents by Page No. INSTALLATION BURNER START-UP Introduction .......... 4 System Check ........18 Use ............. 4 Priming and Leak Check ....18-19 Codes and Regulations ......4 Start-Up Procedure ......20-21 Warranty............. 4 Safety Warnings ......... 5-6 MAINTENANCE Conventions Used in this Manual.... -
Page 4: Introduction
Installation Introduction This boiler is for commercial or industrial use only. The boiler 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 necessary 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 CAUTION: Failure to comply could result in minor personal injury and or personal damage. -
Page 6: Safety Warnings
Safety WARNING: Failure to provide proper venting could result in death, serious injury, and/or property damage. Warnings Units must be installed with a flue connection, draft Continued regulator, draft inducer, and proper vent to the outside of the building. Safe operation of any gravity-vented oil- burning equipment requires a properly operating vent Venting system, correct provision for combustion air, and regular... -
Page 7: Parts Carton
Parts Part No. Description 91919 Thermostat Carton 96388 Oil Filter 135986 Vacuum Gauge 110320 Foot Valve 130952 Oil Pump Inlet Manifold 37866 Draft Regulator (shipped in separate carton) 121030 Recycling Window Decal 121603 Warning label (for inlet to fuel storage system/tank) 136864 Foot Valve Strainer... -
Page 8: Boiler Location
Boiler Do not attempt to install this boiler until you have read and understand this manual! Location Refer to Boiler Mounting requirements for specific requirements for mount- ing Models RAB350 and RAB500. Measure all distances to comply with the specific code requirements and minimum clearances listed below. -
Page 9: Lines
F, oil becomes more viscous and difficult to pump. The heater may fire at a reduced rate and become erratic resulting in nuisance shutdowns. Install either a UL listed Reznor ® Model OT-250 oil supply tank or a field- supplied equivalent indoor storage tank. -
Page 10: Pump
Pump Remote Fuel Pump The Model OT-250 tank has a platform designed for attaching the remote fuel pump. • Mount the remote pump assembly in an upright, horizontal position as shown in the illustration. • Attach the fuel pump legs permanently either on the platform, directly to a field-supplied tank, or in a location within five feet of the oil tank. -
Page 11: Lines
Oil Supply protected from possible damage and be rigidly fastened in place in a work- manlike manner. Do not use TEFLON ® based pipe dope or TEFLON ® tape Line at the connections in an oil line. Use an oil-resistant pipe dope. Do not use union connections in the suction line (line between the oil supply and the Installation remote pump);... -
Page 12: Mounting The Boiler
Mounting the General Requirements Boiler Before preparing a place for the boiler, check the supporting structure to ensure it has sufficient load-carrying capacity to support the weight of the heater. Model Net Dry Weight Operating Weight RAB140 RAB235 RAB350 1247 1562 RAB500 1635... -
Page 13: Venting The Boiler
Venting the WARNING: Failure to provide proper venting could result in death, serious injury, and/or property damage. Boiler Units must be installed with a flue connection and proper vent to the outside of the building. Safe operation of any gravity-vented oil-burning equipment requires a properly operating vent system, correct provision for combustion air, and regular maintenance and inspection. - Page 14 • 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 Standard UL 103 or UL 641. See illustration ..•...
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Page 15: Draft Regulator
2 feet (610mm) higher than any portion of a building or obstruction within 10 feet (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 is recommended. - Page 16 Electrical Supply Connections DANGER: Make sure that the main circuit is OFF before making any wiring connections. All wiring must be done in accordance with appropriate Codes! Pump Power Connect Power to Remote Oil Pump Installation To connect the electrical power from the burner to the oil pump, •...
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Page 17: Water Piping Connections
Water Piping Supply and Return Connections Connections Supply 1-1/2” 1-1/2” 2” 2” Return 1-1/2” 1-1/2” 2” 2” For additional For overall system protection, it is recommended to install a filter and sludge information, removal system in the boiler return piping. consult the boiler literature. -
Page 18: System Check
Check the vent. Be sure that vent pipe or chimney meet the require- ments and appropriate codes. A UL or CSA/UL listed draft regula- tor and draft inducer are required. A Reznor (Option CC1) or Type ® L Breidert Air-X-hauster vent cap is recommended. -
Page 19: Priming And Leak Check
Oil Priming 2. Set manual disconnect switch to the ON position. 3. Fill the suction line (line between the supply tank and the pump) and Leak with clean waste oil or new oil. Check 4. Locate the rubber tubing connecting the pressure switch in the main control box and the compressor. -
Page 20: Start-Up Procedure
Start-Up Procedure Burner Start-Up After installing and testing your unit, follow the procedure below to start the system. • Turn on the main electrical supply. • Set the manual disconnect switch to the “ON” position. • Set the adjustable water temperature setting. Recommended water tem- perature is 160 F (71 C) or higher. - Page 21 Check-Test CAUTION: If there is a backdraft or downdraft, do not continue operation of the boiler until the situation is Continued corrected. Equipment and/or property damage could result. Back pressure (backdraft or downdraft) may be caused by the chimney being lower than surrounding objects, such as buildings, hills, trees, rooftops, etc.
- Page 22 Maintenance General WARNING: Turn off electric power to the unit before doing any service or maintenance on the boiler. Maintenance Requirements When burning used automotive diesel and truck oils, this boiler will require more frequent service than conventional oil-fired equipment. All used oils contain a small amount of ash.
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Page 23: 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. • Check for oil leaks. • Inspect the electrodes •... -
Page 24: Cleaning The Burner Oil Strainer
Reznor P/N 123450. Cover 3. Reassemble the pump • 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 Bolts being sure that the connection is tight. -
Page 25: Chamber And Flue Passages
Maintenance Cleaning Combustion Chamber, Continued Flueway Passages, Flue Pipe, and Draft Inducer WARNING: Waste oils may contain engine-wear metal compounds and foreign materials. When burned, these compounds are deposited within or exhausted from this boiler. Therefore, care should be taken when using, cleaning and maintaining this equipment. - Page 26 Maintenance Removing Soot and Ash Continued WARNING: The ash that is removed from this heater may contain heavy metal compounds that are Cleaning environmentally undesirable and should be disposed of in a conscientious manner. Wear protective clothing, Combustion including gloves and a face mask or respirator. Chamber, 1) These instructions assume that the boiler door remains open follow- Flueway...
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Page 27: Tools Required
Repairing or Determine the condition of the liner. If the liner has only cracks, it may be patched with a ceramic fiber product Replacing the specifically designed for the purpose. The patching material (P/N 176148) Combustion comes in a tube and may be applied by using a caulking gun. Follow the instructions on the caulking and fill in all cracks in the liner. -
Page 28: Nozzle And Electrodes
Maintenance Cleaning the Burner End Cone, Nozzle Procedures and Electrodes Continued 1. To access the burner • Remove the outer cover on the front of the boiler. Slightly pick up the panel, tilt it toward you, and slide up to clear the burner. •... - Page 29 Removing Fuel Line Assembly to Service Controls and Spark Electrodes (Alternate method for servicing nozzle) WARNING: Turn off the electric power before removing the fuel line assembly. NOTE: In order to service the fuel line assembly controls and spark elec- trodes, it is necessary to remove the fuel line assembly.
- Page 30 Maintenance Servicing/Replacing Spark Electrodes Procedures To service or replace the Spark Electrodes Remove any carbon formation on the spark electrodes. Continued • Check the electrodes for deterioration and the insulators for cracks or damage. • Replace the electrode assemblies if any damage or deterioration Removing Fuel exists.
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Page 31: Cleaning Oil Pre-Heater System
Reassembling the Fuel Line Assembly 1. To reassemble the Fuel Line Assembly • Slide the fuel line assembly into the burner housing and the burner tube. 2. Connect the fuel connection assembly to the fuel line assembly. • Tighten the 5/16” inverted flare nut firmly. Then tighten the con- nection nut. -
Page 32: Maintenance Procedures
Remove the wing nut, the cover plate, Air Filter and the filter. • 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 33: Service Notes
The material con- tained in this section is prepared to aid an experienced service person in diagnosing problems and repairing the burner on a Reznor Model RAB used oil boiler. How the used-oil burner on a Reznor ®... -
Page 34: Burner Operation
Compressed air for atomizing the used oil is supplied by a piston-type com- pressor mounted on the side of the boiler. Models RAB 140 and 235 require air pressure within a 9 to 12 psi range for proper oil atomization. Model RAB 350 requires air pressure in a range of 12 to 15 psi. -
Page 35: Oil Burner Troubleshooting
Troubleshooting To diagnose malfunctions properly, the following test equipment is required: Oil Burner 1) An electrical test meter that can measure AC volts, ohms, and amps; Troubleshooting 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 36: Troubleshooting
(pre- Button Connections heater) with heating 11-18 are in element and the burner temperature controls. junction box. Remove cover from *RAB 140, 235 and 350 - 115V other end to access. RAB 500 - 230V Form 465, Page 36... - Page 37 Troubleshooting Check Has there been Turn on or correct for line voltage at the Continued line voltage across Terminals supply. Wait 15 manual disconnect switch. Is 1 and 2 for at least 15 minutes for heater to voltage read? minutes? warm up.
- Page 38 Oil Heat Exchanger and Fuel Line Assembly Reference Chart No. 1, page 37 Locations and Replacement Instructions for Heating Element and Temperature Controls on Oil Pre-heat Heat Exchanger Refer to illustration on page 36. Low Oil Oil Temperature Temperature Limit Control (white dot) (yellow dot) To remove the...
- Page 39 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. Refer to illustration NOTE: After ignition control is reset, you will have 30 SECONDS to per- on page 36.
- Page 40 Troubleshooting Continued Chart No. 3 - Thermostat is calling for heat. Burner motor runs for about 30-45 seconds. System does not attempt to ignite. Transformer and Electrode Checks: First, check combustion chamber for excess oil. Measure voltage between transformer/primary lead NOTE: After ignition control is reset, you will have 30 and neutral connection.
- Page 41 Troubleshooting Continued Chart No. 4 - Burner ignites and burns steadily until the system goes into lockout. 1. Remove cad cell wires from the ignition controller. 2. Start the burner. 3. Jumper F-F terminals on the ignition controller. Does Replace ignition ignition controller controller.
- Page 42 Troubleshooting Chart No. 5 - Thermostat calling for heat. Burner operation erratic/unstable flame Continued pattern. Refer to illustration on page 36 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 43 Troubleshooting Chart No. 6 - Oil Delivery System Continued CAUTION: If the heater will be shut down for a long period, turn off the electric power. Is there sufficient oil Replace or Fill oil tank. in the supply tank? repair. Check pump coupling and Is there line Replace fuel...
- Page 44 Appendix Wiring Diagram - Models RAB 140, 235, and 350, No. 175034 MANUAL DISCONNECT CONNECTION IN PUMP ENCLOSURE FACTORY WIRING TERMINAL STRIP - BURNER JUNCTION BOX SWITCH CONNECTION IN OIL HEATER COMPARTMENT FIELD WIRING TERMINAL BLOCK - MAIN CONTROL BOX #12 GA.
- Page 45 Wiring Diagram - Model RAB 500, No. 175035 RGM 465, Mfg No. 175758, Page 45...
- Page 46 Hour Meter/Cleaning Record Cleaning Meter Cleaning Meter Date Reading Initials Date Reading Initials Form 465, Page 46...
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Page 47: Troubleshooting
Index by page Air Band and Air Shutter Indicator Lights ......35 Priming and Leak Check ....18 Settings ........21 Inspecting the Flue Passageways Pump ..........9 Aquastat ......... 17 and Combustion Chamber ..25 Recharging the Suction Line ..24 Boiler Location ...... - Page 48 ©2000 Thomas & Betts Corporation, All rights reserved. Printed in the U.S.A. MANUFACTURER OF GAS, OIL, ELECTRIC HEATING AND VENTILATING SYSTEMS Trademark Note: Reznor is registered in the United States and other countries. All other ® Form 465, Page 48 trademarks are the property of their respective organizations.
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