Oilon RP-130 H User manual

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Table of contents
1. General1. 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 operation2. Burner operation
2.1. Burner operation 2-stage ( H ) burners................................................................................. 10
2.2. Oil circulation in burner.......................................................................................................... 12
2.3. Control Program of the Sequence Switch ............................................................................ 14
2.4. Control Program under Fault Conditions and Lockout Indication ........................................ 15
2.5. Additional heating................................................................................................................... 18
3. Installing the burner3. Installing the burner
3.1. Burner Installation .................................................................................................................. 21
3.2. Burner hinges......................................................................................................................... 22
3.3. Examplery Oil supply diagram............................................................................................... 23
3.4. Installing hoses ...................................................................................................................... 24
3.5. Installing the oil filter .............................................................................................................. 25
3.6. Electric connections ............................................................................................................... 25
4. First start-up and adjusting4. 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-model ) ....................................................................................... 36
4.8. Burning light fuel oil ............................................................................................................... 39
4.9. Preheater................................................................................................................................ 40
4.10. Temperature Controller for Preheater ................................................................................. 41
4.11. Preheater limit thermostat settings...................................................................................... 42
5. Maintenance5. Maintenance
5.1. Burner maintenance............................................................................................................... 43
5.2. Dismounting the combustion head........................................................................................ 44
5.3. Oil Filter .................................................................................................................................. 45
5.4. Changing the burner motor.................................................................................................... 46
5.5. Trouble shooting, 2-stage burner, oil use ............................................................................. 47
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6. Technical data6. 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)

4 (58) RPMARINES 30870641GB

1.1. GeneralGeneral
1.1.1.1. ForewordsForewords
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. Feedback may be sent to info@oilon.
com
Installation and maintenance of the device must be performed by a certified personnel. If
you need help with maintenance issues, please contact your nearest representative or
Oilon Oy technical support. Contact information can be found on our website at www.
oilon.com
1.2.1.2. Conventions in this ManualConventions in this Manual
1.2.11.2.1 Warning symbols in this manualWarning 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 indicates a possible danger of bodily
harm or lethal injury.
Pay attention. The CAUTION sign indicates a possible danger of
damage to the device, components or surroundings.
Notes indicate tips, hints and other essential information.
KEEP THIS MANUAL ALONG WITH THE INSTALLATION RECORD AND THE
ELECTRICAL SCHEMES AVAILABLE NEAR THE BURNER!
RPMARINES 30870641GB 5 (58)
1. General

1.3.1.3. Type labelling on Oilon burnersType labelling on Oilon burners
1.3.11.3.1 Example of type labellingExample of type labelling
Label element 1: Fuel
KP Light fuel oil
RP Heavy fuel oil
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
12
34
6 (58) RPMARINES 30870641GB
1. General

1.4.1.4. General informationGeneral information
1.4.11.4.1 Burner features and general informationBurner features and general information
BURNER CONTROL Oilon H-burners are fully automatic 2-stage
burners
BURNER APPLICATIONS Most heating appliances such as hot water
boilers, steam boilers, air heaters and thermo
fluid boilers
APPLICABLE FUEL .The burners are suitable for use on
heavy fuel oil, with a viscosity of max.
380 mm²/s (cSt) at a temperature of +50
°C and on burners with electric tracing
max. 700 mm²/s (cSt) at a temperature
of +50 °C.
.Temporarily light fuel oil
MINIMUM VISCOSITY FOR IN-LET OIL 1.5 mm²/s (cSt)
IN-LET OIL TEMPERATURE The temperature of oil coming to the burner
should be from 60 to 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 equipped with trace
heating
HEAVY FUEL OIL ATOMIZING VISCOSITY Oil coming to the nozzles should be between
14 and 16 mm²/s (cSt)
LIGHT FUEL OIL ATOMIZING VISCOSITY 1.5 to 12 mm²/s (cSt) at a temperature of +20
°C
OIL ATOMIZING PRESSURE 25 - 30 bar for heavy fuel oil
20 - 25 bar for light fuel oil
OIL PUMP RP 130 H : E7
RP 140 H : E7
RP 150 H : TA2
NUMBER OF NOZZLES 2
NOZZLE CONTROL Two nozzles are controlled with separate
solenoid valves
BURNER MAX. TURNDOWN RATIO 1:2 (100 - 50 %)
RPMARINES 30870641GB 7 (58)
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
oil
SERVOMOTOR AND COMPOUND
REGULATOR
Controls the burner capacity and the air/fuel
ratio according to the capacity demand.
OPERATING TEMPERATURE 0... + 45 C°
.The burner must be installed firmly. Vibrations may damage burner
or its components.
.Never store any inflammable material in the boiler room.
.Never use a naked flame while checking the burner or the boiler.
.Keep the boiler door closed while starting the burner and during
burner operation.
.Do not touch the oil pipes during burner operation. They may be
hot.
.Do not touch the levers of the compound-regulator or adjusting rod
leading out from the compound-regulator, and do not leave things
lying close to them when burner is operating.
.Wear 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 trouble-free burner operation.
.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.
.Use only original spare parts. When ordering spare parts please
give the burner type and serial number indicated on the burner na-
meplate.
1.5.1.5. Inspecting boiler roomInspecting boiler room
1.5.11.5.1 Take care of the boiler roomTake care of the boiler room
.Maintain tidiness in the boiler room and keep the door closed
.Make sure the there is always enough water (pressure) in the heating system.
.Make sure the boiler and the chimney are swept regularly, at least once a year
.Check the correct adjustment of the flue damper and the gate valve regularely.
8 (58) RPMARINES 30870641GB
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.
.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. General

2.2. Burner operationBurner operation
2.1.2.1. Burner operation 2-stage ( H ) burnersBurner operation 2-stage ( H ) burners
2.1.12.1.1 Combustion airCombustion 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. A servomotor controls the amount of air feeded according
to the amount of fuel combusted.
2.1.22.1.2 Pre-ventilation, purging and ignitionPre-ventilation, purging and ignition
Before ignition the burner runs through the pre-ventilation and purging periods.
During the pre-ventilation phase the burner fan is run with full load settings to exhaust
explosive fumes from the boiler.
Purging period flushes the nozzle valves and the utilisation circuit. The nozzle valve is
preheated and the oil temperature controller 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 air dampers to stage-1 position
and solenoid valve (NO) closes. The oil pressure begins to take effect on the nozzle
piston and the spring-loaded nozzle valve opens. Oil flows from nozzle 1. Spark between
the ignition electrodes ignites oil spraying from the nozzle. Burner operates at stage 1.
2.1.32.1.3 AtomizingAtomizing
To get a sufficient viscosity for the fuel atomizing the oil temperature is raised with a
preheater device. The temperature of the heated oil is controlled electronically.
In-let oil pressure to the pump varies case-specificly; See 'Pump adjustments'.
Atomizing pressure is provided by the burner oil pump.
10 (58) RPMARINES 30870641GB
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 (NC)
opens. Oil is delivered to the nozzle of stage 2. The air dampers turn to the position of
stage 2. Burner operates at stage 2.
If the boiler temperature or pressure exceeds the set value of control device of stage 2,
burner runs to stage 1. If the boiler temperature or pressure exceeds the set value of
control device of stage 1, burner shuts down (air dampers close).
2.1.42.1.4 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 valve, stage 1, normally open, NO
13. Non-return valve
14. Servo motor
15. Solenoid valve, NC (normal closed) + throttle plug diam. 1,2 mm
16. Preheater
A Oil, suction
B Oil, return
Components marked with a star symbol may be included or excluded according to
class and customer requirements
PS
TI
TZA
TIC
TE
M
PS
PI
RE
RE
*
*
*
*
1
23
45
6 6
3
7
8 9
10
11 11
A
B
12
13
15
14
16
RPMARINES 30870641GB 11 (58)
2. Burner operation

The burner has to be connected to the oil circulation system according
to the oil supply diagram.
2.2.2.2. Oil circulation in burnerOil circulation in burner
2.2.12.2.1 Oil circulation phases on H-burnersOil circulation phases on H-burners
Shut down period
Purging period
PS
TI
TZA
TIC
T
M
PS
PI
RERE
*
*
*
*
PS
TI
TZA
TIC
T
M
PS
PI
RERE
*
*
*
*
12 (58) RPMARINES 30870641GB
2. Burner operation

Stage 1
Stage 2
Components marked with a star symbol may be included or excluded according to
class and customer requirements
PS
TI
TZA
TIC
T
M
PS
PI
RE
RE
*
*
*
*
PS
TI
TZA
TIC
T
M
PS
PI
RE
RE
*
*
*
*
RPMARINES 30870641GB 13 (58)
2. Burner operation

2.3.2.3. Control Program of the Sequence SwitchControl Program of the Sequence Switch
2.3.12.3.1 Control program diagramControl program diagram
Lockout indication
.a - b = start-up sequence
.b - b' = idle steps (operation)
.b(b') - a = post-purge sequence (reset of control unit)
Numbers 4...20 are the control output contacts from the sequence switch relay
2.3.22.3.2 Switching times (in seconds) of the control program of the sequence mechanismSwitching times (in seconds) of the control program of the sequence 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
44 1212
77
19191616
1010
99
1515 99
1111
2020
88
1717
t11t11 t1t1 t12t12 t6t6
t20t20
t13t13t10t10
t8t8
t2t2
t3t3
t3nt3n
t3"t3"
t7t7
t16t16
t4t4
t5t5
I
II
III
IV
V
VI
VII
VIII
IX
X
XI
XII
XIII
XIV
a
b
a
b
a
b
a
b
a
b
a
b
a
b
a
b
a
b
a
b
a
b
p_101472.20p_101472.20
1818
p_101472.4p_101472.4
11
aabbb'b' aa
PP
LAL2.25LAL2.25
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2. Burner operation

t4 Interval between beginning of t2 and release of voltage at terminal
19
7,5
t5 Interval between end of t4 and release of voltage at terminal 20 7,5
t6 Post-purge time 15
t7 Interval between start-up command and release of voltage at
terminal 7
2,5
t8 Duration of start-up (without t11 and t12) 47,5
t11 Running time for air dampers to OPEN position (air dampers
position control)
optional
t12 Running time for air dampers to IGNITION position (air dampers
position control)
optional
t13 Permissible after-burn time 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 IndicationControl Program under Fault Conditions and Lockout Indication
2.4.12.4.1 PrinciplePrinciple
In case of any fault fuel injection is stopped immediatly. The sequence mechanism stops
along with the lockout indicator. The symbol above the reading mark of the indicator gives
the type of fault.
RPMARINES 30870641GB 15 (58)
2. Burner operation

2.4.22.4.2 Fault indications on a modulating burnerFault 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.
◄Lockout Extraneous light (e.g.
non-extinguished
flame, leaking fuel
valves, defect flame
supervision circuit,
etc.).
▲Interruption of start-
up sequence
the OPEN signal has
not been delivered to
terminal 8 from the
air damper
servomotor.
Terminals 6, 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
signal to control unit
terminal 13.
■Lockout Fault in the flame
detection circuit
▼Interruption of start-
up sequence
The ignition position
signal has not been
delivered to terminal
8 from air damper
servomotor
Terminals 6, 7 and
15 remain under
voltage until the fault
is corrected!
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2. Burner operation

1 Lockout Flame signal has not
been received during
safety time.
Every flame signal
failure after safety
time sequence leads
to a lockout
1 Lockout Return line pressure
switch (max)
triggering stops fuel
injection.
Pressure switch is
optional component.
May not be included
to delivery.
| Lockout The flame signal has
been lost during
burner operation
If the wire link B has
been cut from the
plug section of the
control unit, repetition
of startup sequence
follows
| Lockout Air pressure signal
lost during operation
2.4.32.4.3 RestartRestart
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 receive voltage in accordance with the control program. It is only
then that the control unit begins with a new burner start-up.
Do not keep the reset button pressed for more than 10 seconds.
RPMARINES 30870641GB 17 (58)
2. Burner operation

2.4.42.4.4 Control unit LAL 2.25Control 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.
.All safety functions must always 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 heatingAdditional heating
2.5.12.5.1 DescriptionDescription
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 the heaters are turned off they must be turned ON AT
LEAST 2 HOURS BEFORE starting the burner.
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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.
2.5.22.5.2 Heating cartridges on pumpsHeating cartridges on pumps
Pump Suntec
2.5.32.5.3 Heating cartridges on solenoid valvesHeating cartridges on solenoid valves
Solenoid valves
RPMARINES 30870641GB 19 (58)
2. Burner operation

2.5.42.5.4 Heating the pipes and hoses with heating cablesHeating 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.
2.5.52.5.5 Technical dataTechnical 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
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2. Burner operation