Oilon RP-130 H Operation And Maintenance Manual Download

Page: 46 / 58

5.4.

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

Components

Motor

Fan wheel

Oil pump

Intermediate shaft

Coupling head

Wedge

Intermediate bushing

Fixing screw for fan wheel

Base bushing

10. Air dampers
11. Fixing screw for mounting flange

5.4.2

Dismounting the fan wheel

Switch off the electric power from the burner.

Disconnect the electric cable of the motor.

Remove pressure pipe from the oil pump.

Remove air dampers. Do not let the air dampers hang on servomotor cable!

Unscrew screws of oil pump.

Support with hand the intermediate shaft and withdraw the oil pump.

Unscrew screws in the mounting flange of the motor and remove the motor (note the
weight of the motor).

A-429L

1-2

1-2 mm

46 (58)

RPMARINES 30870641GB

5. Maintenance

Summary of Contents for RP-130 H

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

Page 2: ...am 23 3 4 Installing hoses 24 3 5 Installing the oil filter 25 3 6 Electric connections 25 4 First start up and adjusting 4 First start up and adjusting 4 1 First start up and adjusting 26 4 2 Adjusting capacity 27 4 3 Adjusting combustion air 29 4 4 Adjusting pressure drop in combustion head 31 4 5 Setting the combustion head 32 4 6 Adjusting the oil pump TA model 34 4 7 Adjusting the oil pump E ...

Page 3: ...6 Technical data 6 Technical data 6 1 Technical data 52 6 2 Control unit technical Data 55 6 3 Control unit LAL 2 25 56 6 4 Flame Detector 57 RPMARINES 30870641GB 3 58 ...

Page 4: ...4 58 RPMARINES 30870641GB ...

Page 5: ...chnical 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 in this manual Read these instructions carefully before installation commissioning or maintenance of the burner The given instructions must be followed Symbols used are Be careful The DANGER symbol ...

Page 6: ...l 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 fan P High Low or modulating with an electronic controller LH High low with a preheater On Off Label element 4 possible additional code GRP 150 M II 1 2 3 4 6 58 RPMARINES 30870641GB 1 General ...

Page 7: ...o 100 degrees Celsius OIL FILTRATION The oil coming to the burner must be filtered before the oil pump Maximum filtration degree is 125 μm PREHEATER Oil is preheated in the burner s preheater to the atomizing temperature The oil temperature is controlled by an electronic regulator HEAT CARTRIDGES Oil pump and solenoid valves are equipped with heat cartridges ADDITIONAL HEATING The burner pipes are...

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 Local regulations and requirements must be adhered to when ins talling or servicing the burner Correct installation and adjustment together with regular servicing are the most reliable guarantees of trou...

Page 9: ...tem 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 naked flame while checking the burner or the boiler Never store any inflammable material in the boiler room Wear hearing protectors if there is noise in the boiler room RPMARINES 30870641GB 9 58 1 Gener...

Page 10: ...ontroller ensures adequate temperature has been reached for fuel atomizing During purging period solenoid valve NC is closed and solenoid valve NO is open During this time oil flows through the stage 1 nozzle control circuit but has not enough pressure to open the nozzle since the solenoid valve NO is open allowing a return flow to the tank After the end of the purging period servomotor turns the ...

Page 11: ...own air dampers close 2 1 4 2 1 4 PI diagram of 2 stage burner H PI diagram of 2 stage burner H 1 Oil pump By pass plug removed 2 Pressure gauge 3 Pressure switch 4 Closing valve normally closed 5 Three way valve 6 Main solenoid valves NC normally closed 7 Limit thermostat preheater 8 Temperature sensor 9 Temperature indicator and controller 10 Temperature indicator 11 Flame detector 12 Solenoid v...

Page 12: ...diagram 2 2 2 2 Oil circulation in burner Oil circulation in burner 2 2 1 2 2 1 Oil circulation phases on H burners Oil circulation phases on H burners Shut down period Purging period PS TI TZA TI C T M PS PI RE RE PS TI TZA TI C T M PS PI RE RE 12 58 RPMARINES 30870641GB 2 Burner operation ...

Page 13: ...Components marked with a star symbol may be included or excluded according to class and customer requirements PS TI TZA TI C T M PS PI RE RE PS TI TZA TI C T M PS PI RE RE RPMARINES 30870641GB 13 58 2 Burner operation ...

Page 14: ...mechanism 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 15 from start command t3n Post ignition time transformer connected to terminal 15 15 4 4 12 12 7 7 19 19 16 16 10 10 9 9 15 15 9 9 11 11 20 20 8 8 17 17 t11 t11 t1 t1 t12 t12 t6 t6 t20 t20 t13 t13 t10...

Page 15: ...ime 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 start up are valid for frequency of 50 Hz For 60 Hz frequency switching times are reduced by approx 20 2 4 2 4 Control Program under Fault Conditions and Lockout Indication Control Program under Fau...

Page 16: ...7 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 controlled shut down every air pressure failure triggers a lockout Too little difference in air pressure min triggers a lockout when differential air pressure switch connector C NC engages a control signa...

Page 17: ... of startup sequence follows Lockout Air pressure signal lost during operation 2 4 3 2 4 3 Restart Restart The control unit can be reset immediately after a lockout has occurred After resetting as well as after correction of a fault which resulted in a controlled shutdown or after each mains failure the sequence switch always returns to its start position whereby only terminals 7 9 10 and 11 recei...

Page 18: ...ways 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 5 2 5 Additional heating Additional heating 2 5 1 2 5 1 Description Description Additional heating keeps the burner ready for use Additional heater devices ensure oil fluency by keeping oil viscosity adequately low Keep heating on at all times If th...

Page 19: ...ing 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 Heating cartridges on solenoid valves Heating cartridges on solenoid valves Solenoid valves RPMARINES 30870641GB 19 58 2 Burner operation ...

Page 20: ...ot conduct heat into the pipings 2 5 5 2 5 5 Technical data Technical data Heating cartridge capacity 40 W 230 V Heating 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 C Heating cartridge case may be hot 20 58 RPMARINES 30870641GB 2 Burner operation ...

Page 21: ...20 230 275 275 275 3 1 2 3 1 2 Burner mounting Burner mounting The boiler front plate must be prepared in accordance with the given dimensions The threads of the bolts must be coated with graphite bearing grease prior to fitting The burner has to be installed in such a way that the motor shaft lies horizontally however it is not allowed to install the burner upside down Remove the transportation b...

Page 22: ...mponents 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 be changed to be hinged to the right by changing the position of the hinge pins Switch off the electric power from your burner before burner swing out 22 58 RPMARINES 30870641GB 3 Installing the burner ...

Page 23: ...essure 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 1 2 x 200 kg h 150 kg h 390 kg h Pay attention to instructions from the pump manufacturer when dimensioning the pipeworks M M A ZA B C D PI PI PI TI PS PS 25 B 552E_1 RPMARINES 30870641GB 23 58 3 Ins...

Page 24: ...oses 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 12 130 mm Ø 15 130 mm Ø 22 170 mm 24 58 RPMARINES 30870641GB 3 Installing the burner ...

Page 25: ...ions Connections The burner must be connected according to the electrical diagrams 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 to be configured with a switch that allows it to be disconnected from the low voltage supply mains RPMARINES 30870641...

Page 26: ...in 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 4 Check oil supply pressure and temperature See further instructions from adjusting the pump 5 Check there is oil in the pump 6 Check direction of rotation of the burner motor The electric connections are made correctly Chec...

Page 27: ...ing capacity Adjusting capacity 4 2 1 4 2 1 Capacity adjustments Capacity adjustments Adjust the burner capacity by altering the size of the nozzle and atomizing pressure from the oil pump On 2 stage burners H burners minimum capacity must be 50 60 of the total capacity of both nozzles Maximum capacity is printed on type label on the burner Burner capacity must not be adjusted below minimum capaci...

Page 28: ...110 115 C 380 mm2 s at 50 C 125 130 C 700 mm2 s at 50 C 135 140 C 4 2 3 4 2 3 Fuel consumption by boiler capacity Fuel consumption by boiler capacity q P μ Q P boiler capacity kW μ boiler efficiency 0 80 0 95 Q heat value kWh kg q fuel demand kg h Note all nozzles NOZZL E CAPACITY 28 58 RPMARINES 30870641GB 4 First start up and adjusting ...

Page 29: ...combustion chamber affects to type of nozzle needed Correct nozzle may differ from nozzle types suggested here After changing the nozzle check the quantity of combustion air and the position of the adjustment ring in the combustion head 4 3 4 3 Adjusting combustion air Adjusting combustion air Do a flue gas analyzis to verify adjustments RPMARINES 30870641GB 29 58 4 First start up and adjusting ...

Page 30: ... at stage 1 degree V Switching point of solenoid valve stage 2 I Air damper position at stage 2 degree The setting of the switch V should preferably be as high as possible The setting of the switch V is between switches III and I If the switch is set too high the flame will tear off the diffuser disc when changing over from stage 2 to stage 1 The servomotor is provided with a release lever When th...

Page 31: ...ack and fort thus altering 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 not positioned rear enough with a fuller load there is too much pressure drop in the combustion head the igniton is poor OR improper burning due to inadequate amount of air high CO ...

Page 32: ...nalysator 2 Set the combustion air levels within the operation range of the servomotor Guideline values CAPACITY FUEL O2 LEVEL Ignition minimum and part power Heavy fuel oil 4 5 6 Full power Heavy fuel oil 3 4 5 Ignition minimum and part power Light fuel oil 3 5 4 5 Full power Light fuel oil 3 4 4 5 4 5 Setting the combustion head Setting the combustion head 4 5 1 4 5 1 Setting the nozzles and the...

Page 33: ...I Nozzle 1 II Nozzle 2 1 Nozzle 2 Ignition electrodes 3 Air guide RP 140 H and RP 150 H BURNER H H2 K L N P M RP130H 18 15 4 8 12 4 4 RP140H 20 18 5 4 9 12 4 8 RP150H 22 20 5 4 9 12 4 8 H M K P N H2 3 II I 1 2 3 A 547E L RPMARINES 30870641GB 33 58 4 First start up and adjusting ...

Page 34: ... to nozzle air venting 8 By pass plug Pump body includes a drilling to accept an electric preheater Note Note By pass plug must be REMOVED when installing to H and T burners 4 6 2 4 6 2 Pump TA Pump TA The pump has an built in pressure control system TECHNICAL DATA PUMP TA In let oil viscosity range Light fuel oil 1 5 12 mm s cSt Max oil inlet pressure to burner 5 bar A 212Z TA TA 5 5 1 1 2 2 3 3 ...

Page 35: ...m 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 illustrated in gray Temperature curve Oil temperature at the ring line before pump Example A Oil temperature at the ring line In let oil pressure to burner Status 65 C 1 5 bar OK Example B Oil temperature at the ring line In ...

Page 36: ... the plug 2 Let 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 main system 4 7 4 7 Adjusting the oil pump E model Adjusting the oil pump E model 4 7 1 4 7 1 Oil pump E Oil pump E 1 Oil suction connection 2 Oil to nozzle 3 Oil return connection 4 Pres...

Page 37: ...vy fuel oil 25 30 bar Pump operating pressure atomizing pressure for light fuel oil 20 25 bar Pressure 1 bar 100kPa Check the correct atomizing pressure value if the fuel is switched temporarely to light fuel oil 4 7 3 4 7 3 Checking the pump functions Checking the pump functions 1 Check the pump pressure regulationing is operational 2 Check the pump is able to stabilize the pressure throughout th...

Page 38: ...atus 90 C 1 5 bar LOW PRESSURE Pressure must be lifted over 2 bar 4 7 6 4 7 6 Venting the oil pump Venting the oil pump 1 Loosen the plug of the pressure gauge port Note Do NOT remove the plug 2 Let 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 main...

Page 39: ...ng light fuel oil Burning light fuel oil Burner is suitable for temporary use of light fuel oil Pay attention to following Turn OFF preheater when burning light fuel oil Decrease the atomizing pressure Turn OFF preheater when using light fuel oil RPMARINES 30870641GB 39 58 4 First start up and adjusting ...

Page 40: ...consists 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 opened only by authorized staff 4 9 2 4 9 2 Temperature regulation Temperature regulation Oil atomizing temperature is adjusted with the controller Check the oil atomizing temperature on the thermometer...

Page 41: ...o 30 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 potentiometer C first completely anti clockwise and then clockwise until the LED E just lights Rotate the definition scale back to the right set point atomising temperature D D LED is lit when the out...

Page 42: ...t is possible to modulate the temperature controller for 110 V voltage Contact Oilon technical support for further assistance 4 11 4 11 Preheater limit thermostat settings Preheater limit thermostat settings 4 11 1 4 11 1 Limit thermostat setting Limit thermostat setting The limit thermostat is adjusted at the factory and sealed with paint Set value is 180 C The limit thermostat has a reset button...

Page 43: ...often 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 pump capacity 10 Clean your burner from dust and moisture 11 Check regularly the combustion characteristics by flue gas measurements after refilling of the storage tank or at least once a year 12 Che...

Page 44: ...d pull the combustion head out Irrota palopään kiinnitysruuvit ja vedä palopää pois paikaltaan Combustion head extension is attached to combustion head with spring cotters Assemble in reverse order 1 Burner flange 2 Combustion head screw 3 Combustion head guide 4 Adjustment ring 5 Diffuser disc 6 Combustion head extension 1 3 4 5 6 2 A 495V 44 58 RPMARINES 30870641GB 5 Maintenance ...

Page 45: ... 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 cleaning of the element If there is some dirt in the filter it can be removed by for ex vacuuming Check the condition of O rings as well as the condition of the washer Lock the plug with nut Place the ...

Page 46: ...r 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 Remove pressure pipe from the oil pump Remove air dampers Do not let the air dampers hang on servomotor cable Unscrew screws of oil pump Support with hand the intermediate shaft and withdraw the oil pu...

Page 47: ...quirements for correct operation must be first examined 1 Check the electric supply control and supply voltages 2 Check the fuse on the control unit by pressing the control unit reset button If the fuse is intackt this should cause a fault condition lockup 3 Check that all regulating and control devices are correctly set 4 Check that all the safety devices are in normal operating condition 5 Check...

Page 48: ... camswitches are in correct 3 Faulty airdampers servo motor Repair break 1 Change the control unit 2 Fix the setting of cams witches 3 Change servomotor 5 5 4 5 5 4 Ignition failure Ignition failure 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 1 1 D...

Page 49: ...et pressure to the burner 2 In let oil temperatur too low 3 In let oil pipings con nected incorrectly 1 Tighten joints Clean the filter check and adjust pressure 2 Raise in let oil tempe rature 3 Check joints 5 5 7 5 5 7 Lock out after flame establishment Lock out after flame establishment CONDITION POSSIBLE CAUSE ACTION Flame established When burner runs to stage 2 or 3 flame extinguishes shutdow...

Page 50: ...nclean 3 The flame is too weak not bright enough 4 Faulty flame detector due to damage or age 5 Faulty control unit 6 Incorrect flame signal due to extraneous light 1 Fix position 2 Clean the flame detector 3 Check burner adjust ments 4 Change the flame de tector 5 Change control unit 6 Prevent extraneous light from reaching the flame detector Lockout during pre purge 1 Faulty flame detector 2 Fau...

Page 51: ... or has heavy carbon deposits 1 Distance between dif fuser disc and nozzle in correct 2 Combustion air settings are not correct 3 Not enough supply air for constant combustion 4 Nozzle incorrectly sized or of wrong type 5 Nozzle is worn 1 Correct the adjustments 2 Correct the adjustments 3 Enhance air supply 4 Replace with an appro priate nozzle type of correct size 5 Change the nozzle RPMARINES 3...

Page 52: ...PLC Oil pump RP 130 H E7 RP 140 H E7 RP 150 H TA2 Oilhose connection suction R Oilhose connection return R Degree of protection IP44 Control voltage 230 V 15 10 50 Hz 1 phase Control voltage on request 230 V 60 Hz 1 phase Control voltage on request 110 V 50 Hz 1 phase Control voltage on request 110 V 60 Hz 1 phase Supply voltage 380 420 V 50 Hz 3 phase Supply voltage on request 440 V 60 Hz 3 phase...

Page 53: ...H 6 RP 150 H 12 Preheater current A RP 130 H 8 7 RP 140 H 8 7 RP 150 H 17 4 6 1 3 6 1 3 Suply voltage option 440 V 60 Hz Suply voltage option 440 V 60 Hz Burner motor capacity kW RP 130 H 3 7 RP 140 H 4 6 RP 150 H 6 4 Burner motor current A RP 130 H 6 3 RP 140 H 7 6 RP 150 H 10 4 Burner motor speed r min RP 130 H 3455 RP 140 H 3440 RP 150 H 3445 Burner motor efficiency RP 130 H 86 RP 140 H 85 8 RP...

Page 54: ...RP 140 H 6 RP 150 H 12 Preheater current A RP 130 H 5 RP 140 H 5 RP 150 H 10 6 1 5 6 1 5 Suply voltage option 690 V 60 Hz Suply voltage option 690 V 60 Hz Burner motor capacity kW RP 130 H 3 5 RP 140 H 4 6 RP 150 H 6 4 Burner motor current A RP 130 H 4 1 RP 140 H 4 9 RP 150 H 6 6 Burner motor speed r min RP 130 H 3470 RP 140 H 3450 RP 150 H 3455 Burner motor efficiency RP 130 H 86 RP 140 H 87 4 RP...

Page 55: ...6 3H250V IEC 127 Fuse external max 10 A Electromagnetic compatibility EMC 89 336 Permissible inlet current to terminal 1 5 A continuous instantaneous max 20 A Permissible load of control terminals 4 A continuous instantaneous max 20 A in total max 5 A Required switching capacity of switching devices 1 A between terminals 4 and 5 Degree of protection IP 40 Permissible ambient temperature 20 60 C RP...

Page 56: ...switch XI XI XIII XIII 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 4 4 12 12 13 13 14 14 6 6 7 7 5 5 a a b b a a b b a a b b b b a a a a b b b b a a b b a a a a b b a a b b a a b b a a b b a a b b a a b b 1 1 2 2 E E M M A A 1 K E 1 K E NTC NTC a...

Page 57: ...nguished during burner operation 6 4 6 4 Flame Detector Flame Detector 6 4 1 6 4 1 Technical data Technical data TYPE RAR Min required detector current with 230 VAC 6 5 μA Max permissible detector current without flame Max possible detector current 25 μA Instrument s pole to terminal 22 Cable run to detector in the same cable as control lines not perm Cable run to detector with a separate cable in...

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