Oilon RP-130 M, Operation And Maintenance Manual

Page 1: ...ARINE BURNERS 0 2 4 4 5 URNERS 20 20 20 20 20 41...

Page 2: ...n 20 2 7 Additional heating 23 3 Installing the burner 3 Installing the burner 3 1 Burner Installation 27 3 2 Burner hinges 28 3 3 Examplery Oil supply diagram 29 3 4 Installing hoses 30 3 5 De aerato...

Page 3: ...r motor 52 5 5 Nozzle Valve RPL 1 54 5 6 Adjusting cam 56 5 7 The Oil regulator 58 5 8 Disassembling and assembling and the oil regulator 59 5 9 Trouble shooting 63 6 Technical data 6 Technical data 6...

Page 4: ...4 77 RPMARINES 30820641GB...

Page 5: ...hnical support Contact information can be found on our website at www oilon com 1 2 1 2 Conventions in this Manual Conventions in this Manual 1 2 1 1 2 1 Warning symbols in this manual Warning symbols...

Page 6: ...GP Gas GKP Gas light fuel oil GRP Gas heavy fuel oil Label element 2 burner size categorization Label element 3 method of control H Two stage T Three stage M Modulating ME Modulating with a separate...

Page 7: ...ILTRATION The oil coming to the burner must be filtered before the oil pump Maximum filtration degree is 125 m PREHEATER Oil is preheated in the burner s preheater to the atomizing temperature The oil...

Page 8: ...hearing protectors if there is noise in the boiler room IN CASE OF FIRE OR OTHER EMERGENCY Switch off the main switch Close the main fuel shut off valve outside the plant Take appropriate actions Loca...

Page 9: ...em pipeworks and the burner are checked regularly according to rules and regulations of public authorities Check boiler and it s components Making a maintenance contract is recommended Never use a nak...

Page 10: ...ture has been reached for fuel atomizing During purging period solenoid valve NC is closed and solenoid valves NO and main solenoid valves NC are open During this time oil does not flow through the co...

Page 11: ...lose For safety reason there is a throttle plug in the control flow line fitted to the connection of solenoid valve NC with an aperture of 1 5 mm This plug reduces the strong control flow which is dir...

Page 12: ...ion open 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...

Page 13: ...ncluded or excluded according to class and customer requirements M M EL TR EL TR EL TR EL TR EL TR EL TR PS TI TZA TE PS PI PI RE RE TT B 526A_1 PS M M EL TR EL TR EL TR EL TR EL TR EL TR PS TI TZA TE...

Page 14: ...ignals to control unit Control signals Permissible input signals to control unit 15s X PID ON OFF 35s 5s p_103154 1 2 1 1 3 4 5 6 7 8 9 10 11 LAL2 25 12 13 P 3 LAL2 25 M 4 M 7 NC NO 5 p M CC I V IV II...

Page 15: ...d X Sequence switch idle steps Required start signal to control unit terminal 8 2 3 3 2 3 3 Adjustable switching points on the cam switches of the servomotor Adjustable switching points on the cam swi...

Page 16: ...2 2 4 2 Sequence point 1 1 Start up lockout indicator of the control unit is at symbol Sequence point 1 1 Start up lockout indicator of the control unit is at symbol Control loop closes Control progr...

Page 17: ...n control circuit of nozzle valve solenoid valve NC opens and solenoid valve NO closes Oil pressure is released to control circuit of the nozzle valve Nozzle valve needle moves back and opens the nozz...

Page 18: ...he factory 2 4 13 2 4 13 Sequence point 12 Controlled shuttdown control loop opens Sequence point 12 Controlled shuttdown control loop opens Sequence switch starts and begins to program the permissibl...

Page 19: ...echanism t1 Pre purge time with air dampers open 22 5 t2 Safety time 5 t3 Pre ignition time SHORT transformer connected to terminal 16 2 5 t3 Pre ignition time LONG transformer connected to terminal 1...

Page 20: ...me 15 t16 Interval from start up to OPEN command for air dampers 5 t20 Interval up to the self shutdown of the sequence mechanism idle steps 35 Switching times in seconds in the sequence of the burner...

Page 21: ...and 15 remain under voltage until the fault is corrected P Lockout Lockout because the air pressure signal has not been received at the start of the air pressure control From this point on till contr...

Page 22: ...of startup sequence follows Lockout Air pressure signal lost during operation 2 6 3 2 6 3 Restart Restart The control unit can be reset immediately after a lockout has occurred After resetting as well...

Page 23: ...ays be tested when using for the first time and after changing the fuse The control unit must be kept safe from water drops and sprays at all times 2 7 2 7 Additional heating Additional heating 2 7 1...

Page 24: ...ng components are overstressed which may lead to premature degrading 2 7 2 2 7 2 Heating cartridges on pumps Heating cartridges on pumps Pump Suntec 2 7 3 2 7 3 Heating cartridges on solenoid valves H...

Page 25: ...opening Top view of the nozzle valve 2 7 5 2 7 5 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...

Page 26: ...eating cartridge dimensions 10 x 50 mm Heating cartridge electric cable 2500 mm Heating cable Self adjusting capasity decreases as the pipe temperature rises Heating cable capacity 230 V 45 W m in 10...

Page 27: ...10 340 M16 M16 M16 M16 M16 215 255 285 290 320 200 220 230 300 312 275 275 275 365 365 3 1 2 3 1 2 Burner mounting Burner mounting The boiler front plate must be prepared in accordance with the given...

Page 28: ...Vibrations may damage burner or its components 3 2 3 2 Burner hinges Burner hinges 3 2 1 3 2 1 Standard composition Standard composition As standard the burner can be hinged to the left The burner can...

Page 29: ...ssure regulating valve The oil throughput from the pumping unit must be at least 1 2 x quantity of oil to be burned kg h 150 kg h Example If If Then Then burner capacity is 200kg h throughput must be...

Page 30: ...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 12...

Page 31: ...line from de aerator to tank is marked with TWO lines II The accumulated gas must be able to vent from the deaerator Always install the degassing unit upright In case the de aerator is installed sepa...

Page 32: ...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 Burner instru mentation has...

Page 33: ...vy fuel oil 1 Connect main voltage 2 Switch ON additional heaters at least 2 hours before start up 3 Check the installation of the drilled ball valve on the return line Check that the valve is CLOSED...

Page 34: ...ed at the factory 19 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 Wear hearing prote...

Page 35: ...140 W1 125 W1 112 W1 100 W1 90 W1 80 W1 70 80 100 120 140 160 180 200 220 240 260 280 300 320 340 25 26 27 28 29 30 W1 500 W1 450 W1 400 W1 360 W1 330 W1 300 W1 275 W1 550 W1 600 W1 650 320 340 360 3...

Page 36: ...1 86 kWh kg and for heavy fuel oil approx 11 22 kWh kg Check exact values from supplier W2 NOZZLE CAPACITY W2 275 W2 250 W2 225 W2 200 W2 180 W2 160 W2 145 W2 130 W2 115 W2 100 W2 90 W2 80 80 100 120...

Page 37: ...the basic positions of the cam discs Cam switches limit switches are set at the factory during testing as follows II burner shutdown III ignition load IV load when changing over from ignition load to...

Page 38: ...kes it possible to turn the cam discs manually Difference between switches IV and V must be approx 3 5 The black scale is in use Cam switches VI VII and VIII are free ASZ potentiometer in use when nec...

Page 39: ...tering the gap between the adjustment ring and the diffuser plate With a small load the adjustment ring is positioned to the front and with a full load in the rear If Then And the adjustment ring is n...

Page 40: ...lus oxygen level from the gas flue after every adjustment with a flue gas analysator 2 Set the combustion air levels within the operation range of the servomotor Guideline values CAPACITY FUEL O2 LEVE...

Page 41: ...4 5 2 4 5 2 Ignition electrodes drawing Ignition electrodes drawing H 17 mm K 3 5 mm L 6 mm M 8 mm N 12 mm P 4 mm M H N L K P A 459Z RPMARINES 30820641GB 41 77 4 First start up and adjusting...

Page 42: ...air venting 8 By pass plug Pump body includes a drilling to accept an electric preheater Note Note By pass plug must be FITTED in when installing to M burners 4 6 2 4 6 2 Pump values Pump values The p...

Page 43: ...ssure The diagram shows the required oil inlet pressure to the burner Check the inlet pressure to the burner from the the pressure gauge fitted to the filter cover Recommended operating zone illustrat...

Page 44: ...et the burner operate for a while Bubbles of air come out of the opening 3 Retighten the plug when no more bubbles appear The pump is self priming The pump is intended for use in two pipe system ring...

Page 45: ...onsists of one or several heating units The heating units have one common regulator and individual thermostats The connectors in the control box are under voltage The safety cover is allowed to be ope...

Page 46: ...0 C below set point by means of the potentiometer Rotate the definition scale G until the LED F lights up Rotate the definition scale 20 to 30 C above the operation set point After this rotate the pot...

Page 47: ...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 set...

Page 48: ...at maximum and return flow pressure and nozzle capacity are adequate At full load the oil regulator is closed whereupon the oil throughput is at minimum and the pressure at maximum The air quantity i...

Page 49: ...ften depending on circumstantial conditions 7 Check the air dampers lock screws and the servomotor axle lock Retighten if necessary 8 Check and lubricate the joints on adjustment rods 9 Check the oil...

Page 50: ...d and withdraw the combustion head The combustion head extension is fixed with rivets to the combustion head guide Reassemble in reverse order 1 Burner body 2 Fixing screw for combustion head 3 Combus...

Page 51: ...Remove the plug by loosening the nut Loosen the hexagonal screw and open the filter cover and remove the element A suitable solvent and a soft brush which does not damage the screen can be used for cl...

Page 52: ...dampers 11 Fixing screw for mounting flange 5 4 2 5 4 2 Dismounting the fan wheel Dismounting the fan wheel Switch off the electric power from the burner Disconnect the electric cable of the motor Re...

Page 53: ...e bushing Place the coupling head and the intermediate bushing Fasten the fan wheel with fixing screws to the motor shaft Place the motor and fasten the screws Support with hand the intermediate shaft...

Page 54: ...6 O ring for piston 12 x 2 Viton 7 O ring for bottom plate 18 72 x 2 62 Viton 8 O ring for spindle 6 x 2 Viton 9 Oil nozzle 10 Cylinder 11 Piston 12 Spindle C Control circuit R Return from nozzle S O...

Page 55: ...needle in the nozzle valve is complete withdrawn when the oil pressure in the control circuit is approx 1800 kPa approx 18 bar 5 5 3 5 5 3 When to change nozzle When to change nozzle If the nozzle se...

Page 56: ...function The adjusting cam regulates the air flow into the burner relative to the quantity of atomized fuel Profile of the spring band sets the dampers positions at any point within the adjusting ran...

Page 57: ...slashes 5 6 4 5 6 4 Changing the spring band Changing the spring band 1 Remove the servomotor along with its locking plate from the compound regulator 2 Release the first adjusting lever from compound...

Page 58: ...tting 6 Compression spring 7 Thrust washer 8 Roller bearing 9 Spring cotter 10 Front flange 11 Hexagonal socket screw 12 O ring 45 x 2 Viton 13 X ring 10 2 x 2 62 Viton 14 Ball bearing 15 Non return v...

Page 59: ...ize of the groove on the shaft 5 8 5 8 Disassembling and assembling and the oil regulator Disassembling and assembling and the oil regulator 5 8 1 5 8 1 Detaching the oil regulator Detaching the oil r...

Page 60: ...itch Turn the adjusting lever so that your able to loosen the shaft locking screws 5 Unscrew the screws holding the servomotor mounting plate Pull out the servomotor Place and fasten the servomotor so...

Page 61: ...pes from the oil regulator 9 Dismount the valve from burner by detaching the mounting plate from the body 5 8 2 5 8 2 Disassembling Disassembling These instructions illustrate the disassemblying of th...

Page 62: ...or allignment 3 Attach the washers and the plate needle bearing 4 Attach the spring and the tube connector 5 Check the shaft rotation The saft should roll 360 steady and smooth 5 8 4 5 8 4 Attaching A...

Page 63: ...s there sufficiently water in the heating system 7 Check that the direction of motor rotation is correct When it is established that the fault is not due to above mentioned the individual burner funct...

Page 64: ...ase the dampers lubricate Burner motor starts program remains at pre purge period Servomotor does not reach the position of full load of air dampers limit switch I 1 faulty servomotor 2 faulty limit s...

Page 65: ...lure CONDITION POSSIBLE CAUSE ACTION Burner motor starts control voltage from control unit to ignition transformer IS switched on ignition does not happen and after a short time lockout occurs Symbol1...

Page 66: ...ltySuuttimen O rengas on viallinen See pump adjustments Cahnge the O ring Main solenoid valve does not open 1 Return oil pressure is too high 2 Faulty return oil pressure switch max 1 Examine isolate...

Page 67: ...r s capacity is inadequate 3 incorrect setting on low limit of oil temperature 1 Repair or change the preheater 2 Check and adjust the in let oil temperature 5 9 8 5 9 8 Oil flows into the combustion...

Page 68: ...n Symbol 1 Faulty flame detector due to damage or age 2 Faulty control unit 3 Incorrect flame signal due to extraneous light 4 Oil or carbon deposits burn in combustion head 5 Valves don not close 1 C...

Page 69: ...80 308 Control unit LAL 2 25 LOK16 PLC Oil pump RP 130 M TA2 RP 140 M TA2 RP 150 M TA2 RP 250 M TA3 RP 280 M TA3 Oilhose connection suction R Oilhose connection return R Degree of protection IP44 Cont...

Page 70: ...5 RP 250 M 14 7 RP 280 M 14 7 Burner motor efficiency RP 130 M 86 RP 140 M 83 9 RP 150 M 87 6 RP 250 M 85 1 RP 280 M 85 1 Burner motor speed r min RP 130 M 2880 RP 140 M 2840 RP 150 M 2855 RP 250 M 29...

Page 71: ...250 M 14 6 RP 280 M 14 6 Burner motor speed r min RP 130 M 3455 RP 140 M 3440 RP 150 M 3445 RP 250 M 3430 RP 280 M 3430 Burner motor efficiency RP 130 M 86 RP 140 M 85 8 RP 150 M 87 6 RP 250 M 86 5 RP...

Page 72: ...0 M 5 7 RP 250 M 8 1 RP 280 M 8 1 Burner motor speed r min RP 130 M 2893 RP 140 M 2850 RP 150 M 2855 RP 250 M 2855 RP 280 M 2855 Burner motor efficiency RP 130 M 85 5 RP 140 M 86 RP 150 M 86 5 RP 250...

Page 73: ...M 85 6 RP 280 M 85 6 Preheater capacity kW RP 130 M 6 RP 140 M 6 RP 150 M 12 RP 250 M 12 RP 280 M 12 Preheater current A RP 130 M 5 RP 140 M 5 RP 150 M 10 RP 250 M 10 RP 280 M 10 6 2 6 2 Control unit...

Page 74: ...I XII XII AR AR BR BR L1 L1 AS AS FR FR V V XIV XIV IV IV VII VII III III V V VI VI VIII VIII X X II II I I 1 1 2 2 3 3 21 21 15 15 16 16 17 17 18 18 19 19 20 20 9 9 11 11 10 10 8 8 22 22 23 23 24 24...

Page 75: ...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 6 4 6 4 Flame Detect...

Page 76: ...22 23 LAL2 RAR 76 77 RPMARINES 30820641GB 6 Technical data...

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