Oilon RP-150 T Operation And Maintenance Manual
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Oilon RP-150 T Operation And Maintenance Manual

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Summary of Contents for Oilon RP-150 T

  • Page 2: Table Of Contents

    Table of contents 1. General 1. General 1.1. Forewords..........................5 1.2. Conventions in this Manual ..................... 5 1.3. Type labelling on Oilon burners ....................6 1.4. General information........................7 1.5. Inspecting boiler room ......................8 2. Burner operation 2. Burner operation 2.1.
  • Page 3 6. Technical data 6. Technical data 6.1. Technical data........................51 6.2. Control unit technical Data ....................54 6.3. Control unit LAL 2.25......................55 6.4. Flame Detector........................56 RPMARINES 30840641GB 3 (57)
  • Page 4 4 (57) RPMARINES 30840641GB...

  • Page 5: General

    Forewords Forewords Thank you for using Oilon-products. We hope you are content with the product and our service. This manual is intented to guide operation and maintenace of the product. We pursue to improve our products and services. Therefore we readily accept feedback about on our operation and maintenance manuals.

  • Page 6: Type Labelling On Oilon Burners

    1. General 1.3. 1.3. Type labelling on Oilon burners Type labelling on Oilon burners 1.3.1 1.3.1 Example of type labelling Example of type labelling GRP-150 M-II Label element 1: Fuel Light fuel oil Heavy fuel oil Gas + light fuel oil...

  • Page 7: General Information

    General information 1.4.1 1.4.1 Burner features and general information Burner features and general information BURNER CONTROL Oilon T-burners are fully automatic 3-stage burners BURNER APPLICATIONS Most heating appliances such as hot water boilers, steam boilers, air heaters and thermo fluid boilers...

  • Page 8: Inspecting Boiler Room

    1. General COMBUSTION AIR FAN The fan provides the air needed in the combustion. It is dimensioned to provide a sufficiently high and even air pressure for efficient combustion in modern combustion chamber. REQUIRED COMBUSTION AIR QUANTITY 15 m³ of combustion air for each burnt kilo of SERVOMOTOR AND COMPOUND Controls the burner capacity and the air/fuel REGULATOR...
  • Page 9 1. General Make sure the burner room combustion air gap (air in-let hole) is open. Make sure the shut-off valves on pressure gauges are shut. Make sure tightness of the pipeworks, safety appliances of the boiler system, pipeworks, and the burner are checked regularly according to rules and regulations of public authorities.

  • Page 10: Burner Operation

    2. Burner operation 2. 2. Burner operation Burner operation 2.1. 2.1. Burner operation 3-stage ( T ) burners Burner operation 3-stage ( T ) burners 2.1.1 2.1.1 Combustion air Combustion air A burner device has been provided with a fan that is tailored to produce high and steady enough air pressure that is required to get a flawless ignition and good combustion in a modern combustion chamber.
  • Page 11 2. Burner operation If the boiler temperature or pressure exceeds the set value of control device of stage 2, burner remains operating at stage 1. If the boiler temperature or pressure is below the set value of control device of stage 2, the air quantity increases and solenoid valve for stage 2 opens.

  • Page 12: Oil Circulation In Burner

    2. Burner operation 15. Solenoid valve, closed by default + throttle plug diam. 1,2 mm 16. Solenoid valve, stage 3, closed by default 17. Preheater A Oil, suction B Oil, return Components marked with a star symbol may be included or excluded according to class and customer requirements The burner has to be connected to the oil circulation system according to the oil supply diagram.
  • Page 13 2. Burner operation TI C Purging period TI C Stage 1 RPMARINES 30840641GB 13 (57)
  • Page 14 2. Burner operation TI C Stage 2 TI C Stage 3 Components marked with a star symbol may be included or excluded according to class and customer requirements 14 (57) RPMARINES 30840641GB...

  • Page 15: Control Program Of The Sequence Switch

    2. Burner operation 2.3. 2.3. Control Program of the Sequence Switch Control Program of the Sequence Switch 2.3.1 2.3.1 Control program diagram Control program diagram t1 t1 t6 t6 4 4 12 t4 t4 t7 t7 t3 t3 t3" t3" t5 t5 VIII t2 t2...

  • Page 16: Control Program Under Fault Conditions And Lockout Indication

    2. Burner operation Interval between beginning of t2 and release of voltage at terminal Interval between end of t4 and release of voltage at terminal 20 Post-purge time Interval between start-up command and release of voltage at terminal 7 Duration of start-up (without t11 and t12) 47,5 Running time for air dampers to OPEN position (air dampers optional...
  • Page 17 2. Burner operation 2.4.2 2.4.2 Fault indications on a modulating burner Fault indications on a modulating burner SYMBOL FAULT CAUSE Note ◄ Lockout the CLOSE signal has not been delivered to terminal 8 from air damper servomotor or contact have not been closed between terminals 12 and 4 or 4 and 5.
  • Page 18 2. Burner operation Lockout Flame signal has not Every flame signal been received during failure after safety safety time. time sequence leads to a lockout Lockout Return line pressure Pressure switch is switch (max) optional component. triggering stops fuel May not be included injection.

  • Page 19: Additional Heating

    2. Burner operation 2.4.4 2.4.4 Control unit LAL 2.25 Control unit LAL 2.25 1. Reset button 2. Program indicator 3. Fuses Control unit is a safety device. It is NOT allowed to open nor make altera- tions or adjustments to it. The control unit must be completely separated from supply voltage before carrying out any procedures to it.
  • Page 20 2. Burner operation If the oil viscosity is too high : ignition does not happen or it is difficult the oil pump and sealing components are overstressed which may lead to premature degrading. 2.5.2 2.5.2 Heating cartridges on pumps Heating cartridges on pumps Pump Suntec 2.5.3 2.5.3...
  • Page 21 2. Burner operation 2.5.4 2.5.4 Heating the pipes and hoses with heating cables Heating the pipes and hoses with heating cables The heating cables must run in direct contact with the pipe surface. Loose cable does not conduct heat into the pipings. 2.5.5 2.5.5 Technical data...

  • Page 22: Installing The Burner

    3. Installing the burner 3. 3. Installing the burner Installing the burner 3.1. 3.1. Burner Installation Burner Installation 3.1.1 3.1.1 Mounting dimensions Mounting dimensions 60 ° 1. Gasket 2. Mounting plate 3. Ceramic wool or similar 4. Refractory Burner Dimensions in mm RP150 RP250 RP280...

  • Page 23: Burner Hinges

    3. Installing the burner Make sure there is enough free space on the side to allow the burner to swing fully open The burner must be installed firmly. Vibrations may damage burner or its components. 3.2. 3.2. Burner hinges Burner hinges 3.2.1 3.2.1 Standard composition...

  • Page 24: Examplery Oil Supply Diagram

    3. Installing the burner 3.3. 3.3. Examplery Oil supply diagram Examplery Oil supply diagram 3.3.1 3.3.1 Oil supply diagram Oil supply diagram B-552E_1 25 - double closing valve (accessory) A - Oil from tank B - Return line to tank C - Oil from pumping unit D - Pressure regulating valve The oil throughput from the pumping unit must be at least 1,2 x quantity of oil to be burned...

  • Page 25: Installing Hoses

    3. Installing the burner 3.4. 3.4. Installing hoses Installing hoses 3.4.1 3.4.1 Avoid torsion stress on hoses Avoid torsion stress on hoses Leave neutral hose ends long enough Use rigid pipe pends when necessary 3.4.2 3.4.2 Minimum bend radius Minimum bend radius Hose diameter Minimum bend radius ( r ) Ø...

  • Page 26: Installing The Oil Filter

    3. Installing the burner 3.5. 3.5. Installing the oil filter Installing the oil filter 3.5.1 3.5.1 Installation illustration Installation illustration Pay attention to oil flow directions 3.6. 3.6. Electric connections Electric connections 3.6.1 3.6.1 Connections Connections The burner must be connected according to the electrical diagrams delivered together with the burner.

  • Page 27: First Start-Up And Adjusting

    4. First start-up and adjusting 4. 4. First start-up and adjusting First start-up and adjusting 4.1. 4.1. First start-up and adjusting First start-up and adjusting Keep the boiler doors closed during ignition and operation. 4.1.1 4.1.1 Prepatory to first start up Prepatory to first start up Check the boiler and it's components are in proper working order Check the pipings are installed correctly and the joints are tight and have no leaks...

  • Page 28: Adjusting Capacity

    4. First start-up and adjusting 14. Use an oil flow meter to check capacity for stages 1,2 and 3. 15. Use a gas analyzer to adjust optimum values for the combustion. 16. Test the safety equipments on the burner. Never use a naked flame while checking the burner or the boiler. Never store any inflammable material in the boiler room.
  • Page 29 4. First start-up and adjusting 4.2.2 4.2.2 Nozzle capacity chart USgal / h Nozzle capacity chart USgal / h NOZZL E CA PAC ITY FOR EXAMPLE Oil viscosity Atomizing temperature 180 mm2/s at 50 °C 110...115 °C 380 mm2/s at 50 °C 125...130 °C 700 mm2/s at 50 °C 135...140 °C...

  • Page 30: Adjusting Combustion Air

    4. First start-up and adjusting Heat value for light fuel oil approx. 11,86 kWh/kg and for heavy fuel oil approx. 11,22 kWh/kg. Check exact values from supplier. Turn OFF preheater when using light fuel oil The shape of the boiler combustion chamber affects to type of nozzle needed.
  • Page 31 4. First start-up and adjusting 4.3.1 4.3.1 Cam switch positions in principle Cam switch positions in principle 2 3 4 5 6 7 30 0 30 0 30 0 B-428C 1. Air damper closure 2. Air regulation, stage 2 3. Switching point of correcting movement of stage 2 4.

  • Page 32: Adjusting Pressure Drop In Combustion Head

    4. First start-up and adjusting Orange Switching point of solenoid valve stage 2, moves together with cam switch 2. The setting of this cam switch is between 7 and 2. ( factory setting 40°) Air dampers position at stage 3 /degree . Adjustment of this cam switch affects adjustment of 6.
  • Page 33 4. First start-up and adjusting 4.4.2 4.4.2 Effect of the adjustmen ring Effect of the adjustmen ring Position of the adjustment ring effects on the pressure drop in the combustion head. Pressure drop is adjusted by moving the adjustment ring back and fort thus altering the gap between the adjustment ring and the diffuser plate.

  • Page 34: Adjusting The Burner Head

    4. First start-up and adjusting 4.5. 4.5. Adjusting the burner head Adjusting the burner head 4.5.1 4.5.1 Setting the ignition electrodes Setting the ignition electrodes Check and set the ignition electrode spark gap and the distance of the nozzle to the ignition electrodes and diffuser disc as show on the drawing 4.5.2 4.5.2...

  • Page 35: Adjusting The Oil Pump ( Ta-Model )

    4. First start-up and adjusting 4.6. 4.6. Adjusting the oil pump ( TA-model ) Adjusting the oil pump ( TA-model ) 4.6.1 4.6.1 Oil Pump TA Oil Pump TA A-212Z 1. Suction line connection 2. Oil to nozzle 3. Return line connection 4.
  • Page 36 4. First start-up and adjusting Min. oil inlet pressure to burner Depending on oil temperature at the pump. See illustration. In-let oil temperature range: Heavy fuel oil 60 - 100 C° Pump operating pressure (=atomizing 25 - 30 bar pressure) for heavy fuel oil Pump operating pressure (=atomizing 20 - 25 bar pressure) for light fuel oil...

  • Page 37: Burning Light Fuel Oil

    4. First start-up and adjusting 4.6.4 4.6.4 Pump pressure adjustment Pump pressure adjustment Use the pressure adjustment screw. Turn the screw clockwise to increase the pressure. Install a pressure gauge/valve -assembly if necessary. 4.6.5 4.6.5 Venting the oil pump Venting the oil pump 1.

  • Page 38: Preheater

    4. First start-up and adjusting 4.8. 4.8. Preheater Preheater 4.8.1 4.8.1 Preheater components Preheater components B-348M 100 C 200 C 1. Heater 2. Temperature sensor of limit thermostat 3. Controller sensor 4. Temperature controller 5. Limit thermostat Limit set point - Low 7.

  • Page 39: Temperature Controller For Preheater

    4. First start-up and adjusting 4.9. 4.9. Temperature Controller for Preheater Temperature Controller for Preheater 4.9.1 4.9.1 CAL 8000 CAL 8000 CAL 8000 p_101739.10 Removable top fascia of potentiometers (manual reset and low limit). Remove sliding the fascia parallel with the display panel. Manual reset potentiometer for correction of deviation.

  • Page 40: Preheater Limit Thermostat Settings

    Set value ± 2°C 2 - 6 °C above set value more than 6 °C above set value It is possible to modulate the temperature controller for 110 V voltage. Contact Oilon technical support for further assistance. 4.10. 4.10. Preheater limit thermostat settings Preheater limit thermostat settings 4.10.1...

  • Page 41: Maintenance

    5. Maintenance 5. 5. Maintenance Maintenance 5.1. 5.1. Burner maintenance Burner maintenance Cut off electric current from the burner and close manual shut-off valves always before any maintenance work. Cutting power is adequate when just inspecting the device. 5.1.1 5.1.1 To maintain flawless operation it is recommended to do the following at least once a year: To maintain flawless operation it is recommended to do the following at least once a year: 1.

  • Page 42: Dismounting The Combustion Head

    5. Maintenance 5.2. 5.2. Dismounting the combustion head Dismounting the combustion head 5.2.1 5.2.1 Detaching the combustion head Detaching the combustion head Unscrew the combustion head screws and pull the combustion head out. Irrota palopään kiinnitysruuvit ja vedä palopää pois paikaltaan. Combustion head extension is attached to combustion head with spring cotters.

  • Page 43: Oil Filter

    5. Maintenance 5.3. 5.3. Oil Filter Oil Filter 5.3.1 5.3.1 Oil Filter components Oil Filter components Mantle Cover O-ring Gasket Hexagon head plug Hexagonal screw Gasket Spring Filter element Washer O-ring Label A-525G Plug A - Oil to filter B - Oil to burner 5.3.2 5.3.2 Note!!

  • Page 44: Changing The Burner Motor

    5. Maintenance 5.4. 5.4. Changing the burner motor Changing the burner motor Switch off the electric power from the burner and ensure the motor is not under voltage. Remove motor fuses if necessary. 5.4.1 5.4.1 Components Components 1-2 mm A-429L 1.

  • Page 45: Trouble Shooting, 3-Stage Burner, Oil Use

    5. Maintenance Unscrew the fixing screw of the fan wheel. Remove intermediate bushing and coupling head. Withdraw the fan wheel from the motor shaft using an extractor. Loosen the wedge and the base bushing. 5.4.3 5.4.3 Mounting the fan wheel Mounting the fan wheel Place the base bushing.
  • Page 46 5. Maintenance 5.5.2 5.5.2 Start failure Start failure CONDITION POSSIBLE CAUSE ACTION Control loop closed, signal Break control Clear the break lamp for start limit is on, circuit between con- Change the control unit burner or the start-up nectors 6 and 8 in the program of the control unit control unit does not start.
  • Page 47 5. Maintenance 5.5.3 5.5.3 Motor failure Motor failure CONDITION POSSIBLE CAUSE ACTION Burner motor does not start. Break in main circuit Repair break Lockout occurs. Symbol1 1 Motor overload relay trig- Check relay trigger level gered , reset or change Fuse triggered Reset or change fuse Faulty motor contactor...
  • Page 48 5. Maintenance 5.5.6 5.5.6 Oil pump failure Oil pump failure CONDITION POSSIBLE CAUSE ACTION Supplies no oil or atomizing Dirty filter Clean or change filter pressure is too low Leaking suction line of Fix the leaks transfer pump Change the pump Pump capacity dec-...
  • Page 49 5. Maintenance 5.5.9 5.5.9 Premature flame establishment Premature flame establishment CONDITION POSSIBLE CAUSE ACTION Burner motor starts then Faulty solenoid valve or Clean or change the valve. lockout (long ignition) leaking nozzlevalve. 5.5.10 5.5.10 Flame monitoring fault (=lockout) Flame monitoring fault (=lockout) CONDITION POSSIBLE CAUSE ACTION...
  • Page 50 5. Maintenance 5.5.11 5.5.11 Damage in burner head Damage in burner head CONDITION POSSIBLE CAUSE ACTION Diffuser disc burned-out Change diffuser disc Burner head extension Change burner head damaged extension Inside of the burner head is Distance between dif- Correct the adjustments oily or has heavy carbon fuser disc and nozzle in- Correct the adjustments...

  • Page 51: Technical Data

    RP-150 T : 152 kg RP-250 T : 181 kg RP-280 T : 182 kg Capacity kW RP-150 T : 680 - 2700 RP-250 T : 650 - 3200 RP-280 T : 900 - 3500 Capacity kg/h RP-150 T : 60 - 240...
  • Page 52 6.1.2 Suply voltage option 380 V 50 Hz Suply voltage option 380 V 50 Hz Burner motor output kW RP-150 T : 5,5 RP-250 T : 7,5 RP-280 T : 7,5 Burner motor current IN [ A ] RP-150 T : 10,5...
  • Page 53 6.1.4 6.1.4 Suply voltage option 690 V 50 Hz Suply voltage option 690 V 50 Hz Burner motor output kW RP-150 T : 5,5 RP-250 T : 7,5 RP-280 T : 7,5 Burner motor current A RP-150 T : 5,7...

  • Page 54: Control Unit Technical Data

    6. Technical data 6.2. 6.2. Control unit technical Data Control unit technical Data 6.2.1 6.2.1 Technical data (LAL 1.25 and 2.25) Technical data (LAL 1.25 and 2.25) Mains voltage 230 VAC -15 / +10% 50 – 6%...60 Hz +6% Mains frequency Power consumption 3,5 VA Fuse, built-in...

  • Page 55: Control Unit Lal 2.25

    6. Technical data 6.3. 6.3. Control unit LAL 2.25 Control unit LAL 2.25 6.3.1 6.3.1 Internal Circuitry LAL2.25 Internal Circuitry LAL2.25 1 K E 1 K E pic_101472.10_MODIFIED_TRu LAL2.25 LAL2.25 IX IX XI XI XIII XIII IV IV II II III III VIII VIII...

  • Page 56: Flame Detector

    6. Technical data Lockout warning lamp Flame detector Motor of sequence switch Flame signal amplifier NTC-thermistor *) The wire link B has been cut away at the factory. This allows an automatic repetition of start-up sequence, if the flame extinguishes during burner operation. If the wire link B has not been cut away, lockout occurs, if the flame is extinguished during burner operation.
  • Page 57 Oilon Oy Metsä-Pietilänkatu 1 PL 5 15801 LAHTI Finland +358 (03) 85 761 +358 (03) 857 6239 info@oilon.com www.oilon.com...

This manual is also suitable for:

Rp-250 tRp-280 t

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