Reznor RA 140 Installation And Reference Manual
Used-oil-fired heaters and boilers
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- Page 1 Form No. RZ-NA I-RA/D 140/235 (Version A) Obsoletes Form I-RA/D 140/235 ® REZNOR USED-OIL-FIRED HEATERS AND BOILERS Installation Reference Guide Heater Models RA 140 RA 235 RAD 140 RAD 235 CSA Certified to Electrical and Fuel Burning requirements only. P/N 110318 Rev 2...
- Page 2 Notice to Owner and Installer ® To ensure the long term benefits of burning your used oil in a Reznor Used-Oil- Fired Heater, it is necessary to become familiar with the correct installation and maintenance of your new furnace. Before installing or operating this heater, make sure you have read and understand this manual.
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Page 3: Table Of Contents
Table of Contents by Page No. HEATER START-UP INSTALLATION System Check ....... 19 Introduction ........4 Priming and Leak Check ..19-20 Use ............. 4 Codes and Regulations ......4 Start-Up Procedure ....21-23 Warranty............. 4 MAINTENANCE Safety Warnings ......5-6 Conventions Used in this Manual .... -
Page 4: Installation
Installation Introduction This heater is for commercial or industrial use only. The heater should be installed by an experienced installer thoroughly trained and experienced with the installation of oil-fired appliances. The installer should be familiar with the special precautions necessary in the handling and storage of used automotive oils which may contain small amounts of gasoline. -
Page 5: Safety Warnings
Safety Conventions Used in this Manual Warnings Hazard Intensity Levels DANGER: Failure to comply will result in severe personal injury or death, and/or property damage. WARNING: Failure to comply can result in severe personal injury or death and/or property damage. CAUTION: Failure to comply could result in minor personal injury and or personal damage. -
Page 6: Air For Combustion
Safety Warnings Continued Air for WARNING: Care should be exercised to ensure that an adequate supply of combustion air is available and free Combustion to enter the air openings on all units. Room openings must equal one square inch per each 1,000 BTU heat input. Non-Compliance Failure to install or maintain this heater properly will void the warranty. -
Page 7: Parts Carton
Additional Parts Shipped with each heater is a remote fuel pump and a carton of parts. The carton contains parts required for installation. Before beginning actual in- stallation, verify that the remote fuel pump and the parts listed below are at the installation site. -
Page 8: Heater Placement
Heater Do not attempt to install this heater until you have read and under- stand this manual! Placement Placement is critical to the efficient operation of this heater. Measure all distances to comply with the specific code requirements and minimum clearances listed below. Refer to the section on Venting your heater for vent requirements and rec- ommendations. -
Page 9: High Altitude Installation
High Altitude High Altitude Installation Installation Standard Model RA/RAD 140 and 235 used-oil-fired heaters are designed for use from sea level up to elevations of 3,000 ft. Without proper modifica- tions severe overheating of the combustion chamber and heat exchanger will occur if installed above 3,000 ft. -
Page 10: Fuel Tank, Pump, And Supply Lines
The heater may fire at a reduced rate and become erratic resulting in nuisance shutdowns. ® Install either a UL listed Reznor Model OT-250 oil supply tank or a field- supplied equivalent indoor storage tank. • If installing a Model OT-250 tank, follow the installation requirements and instructions on the tank. -
Page 11: Pump
Pump Remote Fuel Pump The Model OT-250 tank has a platform designed for attaching the remote fuel pump. • Attach the fuel pump legs permanently either on the platform, directly to a field-supplied tank, or in a location very near to the oil tank. -
Page 12: Typical Installation
Supply Lines Installation Continued as illustrated. With the vacuum gauge mounted on the outlet side of the Suction Line (cont’d) filter, the gauge will indicate any suction line restriction including a dirty filter. A pump inlet manifold is supplied for direct connection of the filter to the inlet of the pump. -
Page 13: Mounting The Heater
Mounting the General Requirements Heater Before suspending the unit, check the supporting structure to ensure it has sufficient load-carrying capacity to support the weight of the heater. Model Net Weight RA140 RA235 RAD140 RAD235 Use four 1/2”-13 diameter threaded rods. Lock each threaded rod using a Suspension washer and nut as shown in the illustration below. -
Page 14: Venting The Heater
Venting the WARNING: Failure to provide proper venting could result in death, serious injury, and/or property damage. Heater Units must be installed with a flue connection and proper vent to the outside of the building. Safe operation of any gravity vented heating equipment requires a properly operating vent system, correct provision for combustion air, and regular maintenance and inspection. -
Page 15: Detailed Venting Requirements
Vent Cap • Any portion of the vent Factory Built Vent system that passes 2 ft (6.0mm) through an unheated minimum 3 ft (914mm) space or a concealed minimum Roof jack recommended by the area such as an “attic” manufacturer of the factory built vent must be a factory-built Factory Built Vent vent that is approved to... -
Page 16: Draft Regulator
2 ft (610mm) higher than any portion of a building or obstruction within 10 ft (3M) of the chimney. Install a vent cap on the terminal end of the vent. A Reznor (Option ®... -
Page 17: Installing Ducts
Installing Inlet Air Duct Ducts Canadian installations require field installation of an inlet air duct (re- Inlet Air Duct turn air system) on a Model RAD heater. The blower-equipped heater has an inlet air duct flange. Inlet duct dimensions (inside) should be: RAD140 RAD235 Height... -
Page 18: Main Power Installation
Heater Power Installation DANGER: Make sure that the main circuit is OFF before making any wiring connections. All wiring must be done in accordance with appropriate Codes! Pump Power Pump Power Installation To connect the electrical power from the heater to the pump, •... -
Page 19: Heater Start-Up
Check vents. Be sure that vent pipe and chimney meet the require- ments and appropriate codes. A UL or CSA/UL listed draft regula- ® tor is required. A Reznor (Option CC1) or Type L Breidert Air-X- ® ®... -
Page 20: Priming And Leak Check
Priming and 2. Set manual disconnect switch to the ON position. 3. Fill the suction line (line between the supply tank and the pump) with Leak Check clean used oil. (Do not use new motor oil.) Continued 4. Locate the rubber tubing connecting the pressure switch in the main control box and the compressor. -
Page 21: Start-Up Procedure
Heater Start-Up Procedure Start-Up After installing and testing your unit, follow the procedure below to start the system. • Turn on the main electrical supply to the heater. • Set the manual disconnect switch to the “ON” position. • 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 burner junction box will come on and the heater will fire. - Page 22 Check-Test WARNING: If there is insufficient draft, it will create a back pressure resulting in oil fumes in the building and/ Continued or pulsating when the burner starts and stops. It may cause excess deposits of soot and overheat the heat exchanger resulting in premature failure of the chamber.
- Page 23 Check-Test Check Discharge Air Temperature - Model RAD with discharge ductwork only. Continued This heater is designed for a maximum of .25” w.c. static pressure and for discharge air temperature rises from 40° to 50°F. If the heater has been equipped with a duct, the discharge air temperature should be checked.
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Page 24: Maintenance
Maintenance General WARNING: Turn off electric power to the unit before doing any service or maintenance on the heater. Maintenance When burning used automotive diesel and truck oils, this heater will re- Requirements quire more frequent service than conventional heating equipment. All used oils contain a small amount of ash. -
Page 25: Maintenance Procedures
Every Six months: • Clean the oil strainer at the burner. • Clean the foot valve screen. • Replace the air filter. • Clean the end cone. • Replace the oil nozzle. • Clean the external surfaces of the combustion chamber/heat ex- changer. -
Page 26: Cleaning The Burner Oil Strainer
Reznor P/N 123450. 3. Reassemble the pump Cover • Check the gasket and if a replacement is needed, replace it with Reznor P/N 123451. • Re-assemble the pump and reconnect the inlet oil line being sure that the connection is tight. Bolts Recharging the Suction Line •... -
Page 27: Combustion Chamber
Cleaning Combustion Chamber, Heat Maintenance Exchanger and Flue Pipe Continued WARNING: Used oils may contain engine-wear metal compounds and foreign materials. When burned, these compounds are deposited within or exhausted from this heater. Therefore, care should be taken when using, cleaning and maintaining this equipment. -
Page 28: Combustion Chamber
Inspecting and Cleaning the Heat Maintenance Exchanger/Combustion Chamber Continued (cont’d) View with Inner Access Door Combustion Removed Chamber If tubes are 25% blocked, leave covers off and proceed with cleaning. Heat Exchanger Tubes Removing Soot and Ash from the Combustion Chamber, Heat Exchanger, and Flue Pipe 1. -
Page 29: Replacing Compressed Air Filter
Locate the compressed air filter. • Remove the wing nut, the cover plate, and the filter. Continued • Properly discard the old filter and replace with a new filter (Reznor P/N 107216, Wix Filter No. 43274, or NAPA No. 2374). • Fasten with cover and wing nut. - Page 30 Maintenance • Clean nozzle by disassembling, washing thoroughly, and blowing dry with compressed air. Procedures • If nozzle face appears worn, replace the oil nozzle with P/N Continued 102997. Annual nozzle replacement is recommended. This nozzle is custom designed. Do not substitute nozzle. •...
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Page 31: Electrode Adjustment
Maintenance 6. The fuel line assembly may now be removed by either • Pulling the assembly up slightly and toward the rear of the burner Procedures housing. Continued • OR removing the burner and end cone and pulling straight out of the blast tube. -
Page 32: Cleaning Oil Pre-Heater System
Maintenance Reassembling the Fuel Line Assembly Procedures 1. To reassemble the Fuel Line Assembly • Slide the fuel line assembly into the burner housing and the burner Continued tube. 2. Connect the fuel connection assembly to the fuel line assembly. •... -
Page 33: Cleaning Cabinet
3. Clean the Pre-heater Maintenance • Place the pre-heater in a vice and carefully remove the outer cylin- Procedures der and the “O” ring. NOTE: There will be oil in the pre-heater. Continued • Clean the inner section with a cloth and degreaser such as carbure- tor cleaner. -
Page 34: Service
For your safety, we suggest that if you are unfamiliar with servicing this type of equipment, contact a qualified service person. The material con- tained in this section is prepared to aid an experienced service person in diagnosing and repairing Reznor Model RA/RAD used oil heaters. ® How a Reznor... -
Page 35: Service
General assure that the correct atomizing air pressure is available, a pressure switch permits oil flow to the nozzle only when a minimum of 9 psi is sensed. Operation Combustion air is supplied by a blower contained in the burner housing. An Continued adjustable air shutter and air band located on the outside of the burner hous- ing control the quantity of combustion air. -
Page 36: Troubleshooting
Troubleshooting To diagnose malfunctions properly, the following test equipment is required: Oil Burner 1) An electrical test meter that can measure AC volts, ohms, and amps; Troubleshooting 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. -
Page 37: Troubleshooting Guide
Backflow Location - The backflow sensor switch is mounted on a bracket on the hinged viewport cover on the control side of the heater. The location is Sensor Switch important in the operation of this switch. Except for limited observation, Continued the viewport cover must be kept closed for the sensor (and heater) to oper- ate properly. -
Page 38: Location Of Components
Troubleshooting Continued Location of Components Referenced in Troubleshooting Charts Backflow Sensor Switch on the Viewport Door (not 10 amp fuse mounted on the end of the illustrated) - on heaters electric box. See wiring diagram. installed in Canada NOTE: Fuse is on all units installed in beginning 1/96;... -
Page 39: Troubleshooting Charts
Troubleshooting Chart No. 1 - Thermostat calling for heat; Burner motor never attempts to run. Continued Refer to illustrations on page 38 and 40. Has there Turn on or correct Check for line been line voltage across supply. Wait 15 voltage at the manual Terminals 1 and 2 for at least FIRST, turn on the main... - Page 40 Troubleshooting Oil Heat Exchanger and Fuel Line Assembly Reference Chart No. 1 Continued Locations and Replacement Instructions for Heating Low Oil Element and Temperature Temperature Limit Controls on Oil Pre-heat (black leads) Heat Exchanger Oil Temperature High Oil Refer to illustra- Control (blue leads) Temperature Limit tion on page 38.
- Page 41 Troubleshooting Chart No. 2 - Thermostat calling for heat, burner motor never attempts to run (green Continued 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.
- Page 42 Troubleshooting Continued Chart No. 3 - Thermostat is calling for heat. Burner motor runs for about 30-45 seconds. System does not attempt to ignite. First, check combustion chamber for excess oil. NOTE: After ignition control is reset, you will have 30 SECONDS to perform the tests shown below before the controller locks out.
- Page 43 Troubleshooting Chart No. 4 - Burner ignites and burns steadily until the system goes into lockout. Continued 1. Remove cad cell wires from the ignition controller. 2. Start the burner. 3. Jumper F-F terminals on the ignition controller. Does Replace ignition ignition controller controller.
- Page 44 Troubleshooting Chart No. 5 - Thermostat calling for heat. Burner operation erratic/unstable flame pat- Continued tern. Refer to illustration on page 38. Bleed oil from burner tee bleeder for ten minutes. Run vacuum Is stream of oil test on suction line to perfectly solid and Repair suction line check for air leaks.
- Page 45 Troubleshooting Chart No. 6 - High Temperature Limit Cycles* Continued Refer to illustration on page 46. Check for line Does the fan/blower voltage across fan/blower Replace operate? leads. Is voltage fan/blower motor. read? Check for line Replace air voltage across Terminals discharge limit 1 and 2.
- Page 46 Troubleshooting Fan and Limit Controls Continued Model RA/RAD 140 and 235 heaters are equipped with a fan control and limit control assembly consisting of a specially designed control mounting bracket with a fan control, a circulating air high limit control, and a super high limit control attached.
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Page 47: Troubleshooting
Troubleshooting Chart No. 7 - Oil Delivery System CAUTION: If the heater will be shut down for a long Continued period, turn off the electric power. Is there sufficient oil Fill oil Replace in the supply tank? tank. or repair. Check pump and motor Is there line Replace fuel... -
Page 48: Wiring Diagram
Form I-RA/D 140/235 (Version A), Page 48... - Page 49 Form I-RA/D 140/235 (Version A), Mfg No. 110318 Rev 3, Page 49...
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Page 50: Hour Meter/Cleaning Record
Hour Meter/Cleaning Record Cleaning Meter Cleaning Meter Date Reading Initials Date Reading Initials Form I-RA/D 140/235 (Version A), Page 50... -
Page 51: Index
Index Air Band and Air Shutter Settings ....... 22 Measuring Draft Over Fire ........21 Backflow Sensor Switch ........36 Hour Meter ............24 Nozzle ..............29 Belt Tension ............6 Oil Burner Troubleshooting ......... 36 Burner ..............29 Oil Heat Exchanger ..........40 Cleaning Record .......... - Page 52 (800) 695-1901 Press 2 www.ReznorHeaters.com ©2005 Thomas & Betts Corporation, All rights reserved. MANUFACTURER OF GAS, OIL, ELECTRIC HEATING AND VENTILATING SYSTEMS Trademark Note: Reznor ® is registered in the United States and other countries. Form I-RA/D 140/235 (Version A), Page 52...
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