Reznor RAB 140, Installation And Reference Manual

Page 1: ...Form No RGM 465 REZNOR WASTE OIL FIRED BOILER Installation and Reference Guide Model RAB Sizes 140 235 350 500 Model RAB boilers meet EPA requirements for disposal of used oil ...

Page 2: ...al to any gas or oil burner without adequate draft over the fire the combustion gases cannot escape resulting in an overheated combustion chamber Even if the burner is installed correctly and adequate draft achieved a flue passage blockage will affect the draft Burning used oil is similar to burning wood A fine gray ash accumulates in the chamber and flue passages This accumulation of ash will eve...

Page 3: ...ower Installation 16 Thermostat Installation 16 Water Piping Connections 17 Controls 17 BURNER START UP System Check 18 Priming and Leak Check 18 19 Start Up Procedure 20 21 MAINTENANCE General Maintenance Requirements and Schedule 22 Maintenance Procedures 23 32 Cleaning the Supply Line Filter and Internal Pump Screen 23 Cleaning the Burner Oil Strainer 24 Inspecting Cleaning the Combustion Chamb...

Page 4: ...adian Electrical Code Part 1 Federal Provincial and local municipal codes Installation operating and maintenance permits may be required from regulation authorities covering environmental quality fuel fire and electrical safety Municipal permits may also be required Regulation requires that only used oil generated on the premises of the owner may be burned in this equipment unless written authoriz...

Page 5: ...ce of heat should always be provided to the building do not depend on used oil as your only source of heat This will prevent building damage should the heater become inoperable during subfreezing weather WARNING Approved fuels are No 2 fuel oil automotive transmission fluid and crankcase oils up to 50 weight Do not attempt to burn any grade of gasoline paint thinner or non approved fluids WARNING ...

Page 6: ...ator 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 system correct provision for combustion air and regular maintenance and inspection WARNING Care should be exercised to ensure that an adequate supply of combustion air is available and free to enter the air openings on all burners Room open...

Page 7: ...52 g g g g g Oil Pump Inlet Manifold 37866 h h h h h Draft Regulator shipped in separate carton 121030 i i i i i Recycling Window Decal 121603 j j j j j Warning label for inlet to fuel storage system tank 136864 k k k k k Foot Valve Strainer 176300 l l l l l Draft Proving Switch j j j j j i i i i i h h h h h g g g g g f f f f f e e e e e d d d d d c c c c c k k k k k l l l l l ...

Page 8: ... heater to combustibles In Canada for additional information on installation clearances refer to CAN CSA B139 M91 Installa tion Code for Oil Burning Equipment Clause 7 0 Installation Clearances Front Recommended for service access Size 140 87 2210mm Size 235 71 1803mm Size 350 85 2159mm Size 500 97 2462mm Absolute Minimum All Sizes 36 914mm Side with Recommended for service access 24 610mm electri...

Page 9: ... compliance with local ordinances and codes Installation of the tank and supply lines is the responsibility of the installer Fuel Tank CAUTION It is recommended that used oil be at a temperature of 50o F or higher when it enters the pump At a temperature below 50o F oil becomes more viscous and difficult to pump The heater may fire at a reduced rate and become erratic resulting in nuisance shutdow...

Page 10: ...epends on the installation Run the suction line using 1 2 standard black iron pipe between the inlet side of the filter and the foot valve Refer to the illustration A fuel line filter with a cleanable strainer a foot valve a foot valve strainer and a vacuum gauge are provided with the heater To prevent air from entering the line do not use union connections at joints Install the suction line com p...

Page 11: ...er Do not use TEFLON based pipe dope or TEFLON tape 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 remote pump union connections are not recommended for use in any por tion of an oil supply line NOTE Care must be exercised to ensure leak free connections ...

Page 12: ...1562 709 RAB500 1635 742 2074 941 The boiler must be placed on a level smooth concrete base of sufficient strength Sizes 350 and 500 require either 4 x 1 4 flat steel plate or 4 x 2 x 1 4 angle iron to be cemented in the platform as illustrated Di mensions of the foundation and support strips for Sizes 350 and 500 RAB 350 RAB 500 inches mm inches mm A Foundation Length 36 914 48 1 2 1232 B Foundat...

Page 13: ...e and inspection The vent system must comply with all local codes and in the event that local codes do not exist the vent system must comply with a regional or national code General Guidelines for the Vent System The requirements for the vent system are dependent on 1 the location of the boiler within a building and 2 the type of building If the boiler and the vent system are within the same heate...

Page 14: ...st be at least 6 152mm in diameter Sizes 350 and 500 the vent system must be at least 8 203mm Horizontal Length and Slope The horizontal portion of the vent must not exceed 15 feet 4 5M and may include up to three elbows Horizontal portions must be sloped upward 1 4 for each foot of pipe Vertical Vent If installing a factory built vent follow the manufacturer s instructions If a masonry chimney is...

Page 15: ... above the highest point of exit and at least 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 A different style of vent cap could cause nuisance problems Type L Air X hauster is a trademark of the G C Breidert Company A b...

Page 16: ...priate conduit from the boiler to the junction box Connect the black wire to the hot lead Connect the white wire to the neutral lead Connect the green wire to the ground lead Install a fused manual reset line voltage switch field supplied in this main line Electrical Ratings Total Minimum Maximum Current Circuit Fuse Size Model Amperes Ampacity Supply RAB140 10 13 20 RAB235 11 14 20 RAB350 17 22 3...

Page 17: ...ecial tap in the supply manifold Aquastat The adjustable aquastat located on the top rear of the boiler controls burner operation to maintain the temperature of the water in the boiler The aquastat has a temperature range from 140o to 240o F It is recommended that the water temperature be set at 160o F or higher If the application requires water temperatures below 160o F the use of tempering valve...

Page 18: ...otate Check to verify that the boiler is level Check the electrical supply Be sure that all wire gauges are as recommended and that the supply voltage is as stated on the rating plate Determine that fusing or circuit breakers are adequate for the load 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 induc...

Page 19: ...l terminals F1 F2 on the ignition controller Observe the remote fuel pump motor to make certain it is running Open the bleeder valve on the remote pump and wait until a full flow of oil is obtained without any air IMPORTANT NOTE If air bubbles are present and do not stop there is a suction line leak Check the piping between the tank and the pump and correct the leak Once a full flow of oil is pres...

Page 20: ...ctrical supply Set the manual disconnect switch to the ON position Set the adjustable water temperature setting Recommended water tem perature is 160o F 71o C or higher Set the thermostat to a temperature above room temperature NOTE When the low oil temperature limit senses the proper oil tempera ture the green light on the main control box will come on and the burner will fire A 10 minute delay m...

Page 21: ...ield conditions such as high altitude may require a change We recommend that the need for a change be determined by the use of instruments When obtaining the CO2 readings do so with a hot system that has the correct draft settings With a clean heat exchanger these settings should result in Bacharach smoke readings not greater than No 1 and thermal efficiencies of approximately 82 If it is necessar...

Page 22: ...of fuel Running out of fuel oil will require you to re prime the system Weekly Check the vacuum gauge on the filter for an indication that the oil line filter and or motor pump screen needs cleaning Check the hour meter Cleaning is recommended every 300 hours If needed clean the combustion chamber the flueway passages the flue pipe and draft inducer Record the hour meter reading for future referen...

Page 23: ...ion of the supply line from the tank to the remote pump If air leaks develop in the suction line the burner will not operate properly Follow all instructions including recharging the Suction Line page 24 to avoid creating an air leak Replacing the Supply Line Filter Unscrew the replaceable canister portion from the bottom of the supply line filter and replace Replacement filter canister is P N 176...

Page 24: ...e Pump Continued Recharging the Suction Line Remove the fill plug from the inlet manifold and slowly fill the suction line with oil allow time for air to escape Replace the plug Check vacuum gauge connections and filter housing to be sure that everything is tight The suction line must be full of oil and all connections tight for the heater to operate properly NOTE Refer to the section Priming and ...

Page 25: ...nd flueway passages through the access door on the end of the boiler where burner is mounted 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 Remove the bolts Sizes 140 235 2 bolts 16mm socket Sizes 350 and 500 4 bolts 18mm socket and open the hinged access door being careful not to damage burner NOTE Remove only the d...

Page 26: ...ut Covers Tension Spring 3 Disconnect the vent pipe 4 In the combustion chamber and flueway passages use a shop vacuum to remove the ash Use a stiff brush to loosen soot from the flue passages Use a softer brush in the combustion chamber being careful not to damage the liner Vacuum accumulated soot and ash 5 Check the integrity of the combustion chamber liner and the sealing ropes on the cleanout ...

Page 27: ...0 18mm socket to open the door To mold the liner with your hands latex gloves are recommended If the back plate of the combustion chamber cannot be reached an extension tool is needed The three metal bands supplied with the liner kit Instructions Verify that the kit is the appropriate size for the boiler being serviced Follow the illustrated instructions Form RGM CPW 44 that are included with the ...

Page 28: ...the end cone opening Rotate the insulator approximately 1 to lock it in place 3 To Remove the Nozzle requires both a 1 and a 5 8 open end wrench To prevent the fuel line assembly from twisting use a 1 open end wrench to hold the nozzle adapter while removing the nozzle with a 5 8 open end wrench Clean by blowing high pressure compressed air through the nozzle If nozzle face appears worn replace th...

Page 29: ...he escutcheon plate Pull the fuel connection assembly clear of the burner housing 3 Loosen the two transformer hold down screws Lift the hinged transformer to its open position 4 There are eight wires in the fuel line assembly wire bundle Mark and disconnect the wires from their terminals in the burner junction box 5 Disconnect the nozzle air hose from the fitting at the air compressor Pull the ho...

Page 30: ... cone Flush to 1 16 ahead NEVER BEHIND Servicing Replacing Spark Electrodes To service or replace the Spark Electrodes Remove any carbon formation on the spark electrodes Check the electrodes for deterioration and the insulators for cracks or damage Replace the electrode assemblies if any damage or deterioration exists After service or replacement check the position of the elec trodes Adjust the e...

Page 31: ...carbure tor cleaner Be careful not to clean the electrical controls Do not immerse in cleaning fluid 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 Do not mov...

Page 32: ...lter and replace with a new filter Reznor P N 107216 Wix Filter No 43274 or NAPA No 2374 Fasten with cover and wing nut Compressed Air Filter Maximum operating pressure is 58 psi 4bar Maintain the water pressure within the required levels Verify system water level add water and vent as needed Automati cally add water to the system and vent during operation If continu ous makeup water must be added...

Page 33: ...ump to the burner regardless of the oil viscosity Oil pressure at the outlet of the pump will vary depending upon oil grade the length and height of the supply line and the oil temperature If a pressure in excess of 50 psi is experienced at the pump a relief valve will open and return the oil to the supply tank Oil pressure at the atomizing nozzle will vary from 25 psi to 4 psi depend ing on the t...

Page 34: ...ss the two electrodes located near the atomizing nozzle Ignition of the oil is detected by a cadmium sulfide flame sensor Light produced by the flame lowers the electrical resistance of the cad cell This change is sensed by the ignition controller which allows a continued flow of oil and shuts off the spark transformer after a 30 second trial for ignition period If for some reason ignition does no...

Page 35: ...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 Before test firing check the combustion chamber for an excessive accumu lation of unburned oil and restore to safe condition before firing See page 25 WARNING Do not attempt to start the...

Page 36: ...CAUTION The items on the Troubleshooting Charts that are marked with an asterisk represent events that have occurred due to the improper functioning of the heater It is necessary to observe the operation of the heater to determine what caused these events to occur RAB 140 235 and 350 115V RAB 500 230V Transformer NOTE To access cad cell open transformer Model RAB for Canada has a 10 amp fuse mount...

Page 37: ...0 element Is there sufficient ohms Replace oil heater temperature control pre heater Replace oil heating element pre heater Replace oil heater low temperature limit pre heater Check for line voltage across 14 and 11 Is voltage read Check for continuity of 30 watt heating elements Is continuity read Is cold air discharging from burner tube Verify draft inducer is operating properly Replace 30 watt ...

Page 38: ...ort Nozzle Low Oil Temperature Limit Black Wires Electrode Ceramic Insulator Buss Bar Static Plate Nozzle Temperature Control Red Wires Nozzle Adapter Nozzle Inlet Heater Remove the silicone rubber to free heating element 30 watt When re placing use silicone rubber to retain the new element The nozzle adapter contains a 30 watt heating element To replace the ele ment 1 Remove the buss bars 2 Unscr...

Page 39: ... for heat burner motor never attempts to run green 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 per form the tests shown below before the controller locks out Reset ignition control Press the RED BUTTON hold for four seconds and release DO NOT RESET MORE THAN ONE TIME Reset button on the motor activ...

Page 40: ...tage between transformer primary lead and neutral connection Check transformer insula tors and electrodes The secondary terminals of a good transformer de liver 5000 volts arc to ground for a total of 10 000 volts between terminals Measure this with a trans former tester or use a well insulated screwdriver to draw an arc across the two springs This should be at least 3 4 in length Check each secon...

Page 41: ...Correct short circuit Is resistance greater than 1500 ohms Open transformer and clean cell face and seat firmly into holder Is resistance greater than 1500 ohms Is the over fire draft correct Is the CO2 correct Replace the cad cell Adjust for proper CO2 Adjust barometric damper Cad cell and ignition controller are OK YES NO YES NO YES NO YES NO YES NO YES NO Chart No 4 Burner ignites and burns ste...

Page 42: ...pply from the compressor to the nozzle for leaks and restrictions Check the end cone for deterioration and or restrictions Check oil delivery system See Chart No 7 Adjust for proper CO2 Adjust barometric damper and or clean draft inducer Change to a suitable fuel Run vacuum test on suction line to check for air leaks Did suction line pass vacuum test Repair suction line leak YES NO YES NO YES NO Y...

Page 43: ...e blocked Is the oil flow in the aluminum oil pre heater blocked Dissassemble and clean the aluminum oil pre heater Is the burner tee strainer blocked Remove and clean the srainer Does the fuel valve open when energized Is there oil flowing in the return line Replace the relief valve Start the unit Check for proper operation Replace the fuel valve Clear blockage or replace line Replace the fuel pu...

Page 44: ... F 15O F 14O F 1O5 F CONTROL STYLE ACTIVATE RESET CONTROL TEMPERATURE LIMITS TERMINAL STRIP BURNER JUNCTION BOX COMPRESSOR AND REMOTE OIL PUMP AQUASTAT LOW WATER CUT OFF R BK P1 P2 L1 CUSTOMER S 115V CIRCULATING PUMP C1 C2 W T T B2 B1 L2 W RAB 140 235 350 175034 REV 3 BK GN H W DO NOT RESET MORE THAN ONE TIME ON THE RED RESET BUTTON FOR FOUR 4 SECONDS AND THEN RELEASING IT OUT IF THE UNIT LOCKS OU...

Page 45: ...OX G G G W B 1 1 TRANSFORMER BL 120 V BR BK 220 V W CONTROL 50 VA 2 A B BL W B CONTACTOR COIL BURNER 24 1 L1 T1 CONTACTOR CONTACTS 21 BURNER A 12 C C 2 2 15 W W W BR BL BK BK PR BK BK BK BL BR BR BL H H W RELAY COIL BURNER TIME DELAY 7 RELAY CONTACTS 20 BURNER TIME DELAY 6B 6F O O B C BK PUMP RELAY BK LOW WATER CUT OFF BK P1 R H GN P2 W W T L1 L2 AQUASTAT T C1 C2 W B2 B1 R W B W W W Y X RELAY CONT...

Page 46: ...Form 465 Page 46 Hour Meter Cleaning Record Cleaning Meter Cleaning Meter Date Reading Initials Date Reading Initials ...

Page 47: ...e Requirements 22 Maintenance Schedule 22 Measuring Draft Over Fire 20 Hour Meter 22 Mounting the Boiler 12 Nozzle 28 Oil Burner Troubleshooting 35 Oil Heat Exchanger 38 Operation 31 Parts Carton 7 Main Power 16 Pump Power 16 Pre Heater System 31 Priming and Leak Check 18 Pump 9 Recharging the Suction Line 24 Internal Pump Screen 23 Safety Warnings 5 Service 33 Burner Oil Strainer 24 Start Up Proc...

Page 48: ...ame ___________________________________ Address ___________________________________ ___________________________________ ___________________________________ Phone ___________________________________ SECOND Contact the nearest distributor See Yellow Pages If no listing contact Authorized Factory Representative 1 800 695 1901 Press 2 THIRD Contact REZNOR Thomas Betts Corporation 150 McKinley Avenue M...