Rand & Reardon RRG164, RRG130, RRG096 User Manual

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INSTALLATION, OPERATING

AND

SERVICE INSTRUCTIONS

RRG™ SERIES

CAST IRON GAS-FIRED BOILER

9700609

BEFORE INSTALLATION: READ THIS MANUAL

SAVE THESE INSTRUCTIONS

Installing contractor and homeowner should read and be informed as to the proper installation and operation of this boiler. The manufacturer will not be responsible for improper installation or operation. This manual and all associated instruction material should be conspicuously posted near the boiler.

For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.

Boiler Model Number

RRG _ _ _

Heating Contractor Phone Number

Address

Boiler Serial Number Installation Date

106655-02 - 7/16

Price - $5.00

The City of New York requires a Licensed Master Plumber supervise the installation of this product.

The Massachusetts Board of Plumbers and Gas Fitters has approved the RRG™ Series Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.

The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas tter.

The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life.

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

Table of Contents

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

NOTICE

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

I. Pre-Installation ....................................5

II. Unpack Boiler .....................................5

III. Water Piping and Trim ........................6

IV. Venting .............................................. 10

V. Gas Piping .........................................12

VI. Electrical ............................................13

VII. System Start-up and Checkout ..........17

VIII. Operation ..........................................20

IX. Service and Maintenance ...................22

X. Troubleshooting ................................24

XI. Repair Parts .......................................29

Table 1A: Connection Sizes

Boiler

Model

RRG062 1¼ 1¼ 4 ½ ¾ ¾ RRG096 1¼ 1¼ 5 ½ ¾ ¾ RRG130 1¼ 1¼ 6 ½ ¾ ¾ RRG164 1¼ 1¼ 6 ½ ¾ ¾

(1)

Refer to the National Fuel Gas Code for equivalent areas of circular and rectangular ue linings.

Supply NPT

(inch)

Return NPT

(inch)

Vent

(inch)

(1)

Gas NPT

(inch)

Relief Valve

NPT (inch)

Table 1B: Inputs, Weights and Volumes

Boiler Model Input (MBH)

RRG062 62 254 3.2 RRG096 96 298 4.0 RRG130 130 346 4.7 RRG164 164 408 5.5

(1)

Input ratings can be used for elevations up to 2000 ft.

Electrical Requirements: 120VAC, 60 Hz, 1-ph, Less than 12A Maximum Allowable Working Pressure - 50 psi. Boiler shipped from factory with a 30 psi relief valve.

(1)

Shipping Weight

(lbs)

Water Content

(gal)

Drain

Figure 1: Dimensional Drawing

Table 2: Dimensional Data

Boiler

Model

RRG062 21-1/2 12 6 4 45-3/4 8-1/2 4-3/4

RRG096 24-3/4 15-1/4 7-5/8 5 47-1/8 9-1/8 4-3/4

RRG130 28 18-1/2 9-1/4 6 48-1/2 9-3/4 5-1/4

RRG164 31-1/4 21-3/4 10-7/8 6 48-1/2 9-3/4 5-1/4

'A' 'B' 'C' 'D' 'E' 'F' 'G'

Dimensions [Inches]

Figure 2: Minimum Clearances to Combustible Construction for Closet Installation

I. Pre-Installation

WARNING

Carefully read all instructions before installing boiler. Failure to follow all instructions in proper order can cause personal injury or death.

A. Inspect shipment carefully for any signs of damage.

All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of boiler to carrier in good condition. Any claim

for damage or shortage in shipment must be led

immediately against carrier by consignee. No claims for variances or shortages will be allowed by Boiler Manufacturer, unless presented within sixty (60) days after receipt of equipment.

B. Installation must conform to the requirements of the

authority having jurisdiction. In the absence of such requirements, installation must conform to National Fuel Gas Code, ANSI Z223.1/NFPA 54.

C. Appliance is design certied for installation on

combustible ooring. The boiler must not be installed on carpeting.

D. Provide clearance between boiler jacket and

combustible material in accordance with local re

ordinance. Refer to Figure 1 for minimum clearance from combustible material for alcove installation. Provide 1/2" clearance from water piping to combustible materials.

E. Provide practical service clearances. A minimum

of 24" from the left side and front jacket panels is recommended for servicing but may be reduced to minimums shown in Figure 2.

F. Install on level oor. For basement installation provide

concrete base if oor is not level or if water may be encountered on oor around boiler.

G. Protect gas ignition system components from water

(dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap, control replacement, etc.).

H. Provide combustion and ventilation air in accordance

with the section "Air for Combustion and Ventilation," of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of local building codes.

WARNING

Adequate combustion and ventilation air must be provided to assure proper combustion.

I. Do not install boiler where gasoline or other

ammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored.

II. Unpack Boiler

CAUTION

Do not drop boiler. Do not bump boiler jacket

against oor.

A. Move boiler to approximate installed position.

B. Remove all crate fasteners.

C. Lift outside container and remove all shipped loose

items. Save two of the wooden slats from the container sleeve for use in Steps E and F.

D. Remove all boiler hold-down fasteners.

E. Tilt the boiler to one side and slide a wooden slat under

the two raised feet.

F. Tilt the boiler to the other side and slide another

wooden slat under the two raised feet.

G. Slide the boiler forward or backward off the skid using

the two wooden slats as runners.

H. Move boiler to its permanent location.

III. Water Piping and Trim

WARNING

Failure to properly pipe boiler may result in improper operation and damage to boiler or building.

A. Design and install boiler and system piping to

prevent oxygen contamination of boiler water.

Oxygen contamination sources are system leaks

requiring addition of makeup water, ttings, and

oxygen permeable materials in distribution system. Eliminate oxygen contamination by repairing system

leaks, repairing ttings, and using non-permeable

materials in distribution system.

B. Install circulator with anges, gaskets and bolts

provided.

C. Install Safety Relief Valve. Safety Relief Valve must

be installed with spindle in vertical position.

Figure 3: Recommended Piping for Combination

Heating & Cooling (Refrigeration) Systems

WARNING

Safety relief valve discharge piping must be piped

near oor to eliminate potential of severe burns.

Do not pipe in any area where freezing could occur. Do not install any shut-off valves.

D. Connect system supply and return piping to boiler.

Refer to Figures 4 and 5. Also consult Residential Hydronic Heating Installation and Design I=B=R Guide. Maintain minimum ½ inch clearance from hot water piping to combustible materials.

E. If boiler is used in connection with refrigeration

systems, boiler must be installed with chilled medium

piped in parallel with the heating boiler using appropriate valves to prevent chilled medium from entering boiler. See Figure 3. Also consult Residential Hydronic Heating Installation and Design I=B=R Guide.

F. If boiler is connected to heating coils located in

air handling units where they may be exposed to refrigerated air, boiler piping must be equipped with

ow control valves or other automatic means to prevent

gravity circulation of boiler water during operation of cooling system.

G. Use a boiler bypass if the boiler is to be operated

in a system which has a large volume or excessive radiation where low boiler water temperatures may be encountered (i.e. converted gravity circulation system, etc.).

CAUTION

Boiler return water cannot be lower than 130°F for proper function.

Install bypass between boiler supply and return in near

boiler piping as shown in Figures 4 and 5. Bypass should be same size as the supply and return lines with valves located in bypass and supply outlet as illustrated

in Figures 4 and 5 in order to regulate water ow to

maintain higher boiler water temperatures.

Set by-pass and boiler supply valves to half throttle

position to start. Operate boiler until system water temperature reaches normal operating range.

Adjust valves to provide 180° to 200°F supply water

temperature. Opening the boiler supply valve will raise system temperature, while opening by-pass valve will lower system supply temperature.

H. If it is required to perform a long term pressure

test of the hydronic system, the boiler should rst be

isolated to avoid a pressure loss due to the escape of air trapped in the boiler.

To perform a long term pressure test including the

boiler, ALL trapped air must rst be removed from the

boiler.

A loss of pressure during such a test, with no visible

water leakage, is an indication that the boiler contained trapped air.

Figure 4: Recommended Water Piping for Zone Valve Zoned Heating Systems

Figure 5: Recommended Water Piping for Circulator Zoned Heating Systems

I. Optional LWCO and Auxiliary High Limit

Installation

WARNING

DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off

(LWCO). Only use connections specically identied for Low Water Cut Off.

In all cases, follow the Low Water Cut Off (LWCO) manufacturer’s instructions.

1. A low water cutoff is required to protect a gas-red

hot water boiler when any connected heat distributor (radiation) is installed below the top of the hot water

boiler (i.e. baseboard on the same oor level as

the boiler). In addition, some jurisdictions require the use of a LWCO with a hot water boiler as a redundant safety control.

It is recommended that the LWCO control is

installed above the boiler to provide the highest level of protection. However, where the LWCO control is approved by the LWCO control manufacturer for installation in a high boiler tapping of a water boiler, the use of the listed LWCO control is permitted when it is installed according to the LWCO manufacturer's instructions.

2. The recommended location for a LWCO on gas hot water boilers is above the boiler, in the supply piping. The minimum safe water level of a water boiler is at the uppermost top of the boiler; that is, it must be full of water to operate safely.

3. Typically, in residential applications, a probe type

LWCO is used instead of a oat type, due to their

relative costs and the simplicity of piping for a probe LWCO.

4. Piping and ttings required to install LWCO are

eld supplied.

5. When constructing a piping tree to install LWCO

select ttings (tees, elbows etc) and nipples to have

the same size (NPT) as boiler supply connection. At minimum, 1-1/4” tee with ¾” branch outlet is required to connect the probe LWCO to the supply piping. See Figure 6 for location and piping of the LWCO. DO NOT REDUCE THE SIZE OF

NEAR BOILER SUPPLY FITTINGS AND NIPPLES.

6. Installation of manual shutoff valve located above the LWCO and the boiler is recommended to allow servicing. Thus LWCO probe can be removed for inspection without draining the heating system. An annual inspection of the probe is recommended.

7. The presence of water covering properly installed LWCO probe will cause the normally open contact of the LWCO to close, thus providing continuity of the 24 VAC service to the boiler gas valve. When water level drops below probe, LWCO contact opens up breaking 24V supply to gas valve and

preventing the boiler to re.

8. RRG Series gas hot water boilers have a “plug-in” provision in the factory wiring that will accept an optional 24VAC probe LWCO harness connector. The optional LWCO kit includes a 24VAC probe LWCO, Harness and Instructions addressing piping, wiring and testing after installation. See Figure 9 for wiring of the LWCO. Contact your local Rand & Reardon Distributor for LWCO Kits.

9. RRG Series gas hot water boilers have a "plugin" provision in the factory wiring that will accept an optional Auxiliary High Limit harness. The optional Auxiliary High Limit, Well, Harness and Instructions addressing piping, wiring and testing after installation. Contact your local Rand & Reardon Distributor for Auxiliary High Limit Kits.

10. Provisions are provided so that both the Optional LWCO Kit and the Auxiliary Kit can be installed on the same boiler.

Figure 6: Recommended Probe LWCO Location

IV. Venting

A. Install Draft Hood without modication on outlet of

ue collector. See Figure 1. Secure with sheet metal

screws.

WARNING

Do not alter boiler draft hood or place any obstruction or non-approved damper in the breeching or vent system. Flue gas spillage can

occur. ETL certication will become void.

B. Install Blocked Vent Switch. The Blocked Vent Switch

Assembly shipped taped to top of boiler includes power

cord and switch attached to mounting bracket.

1. Untape Blocked Vent Switch Assembly from top of boiler. Uncoil power cord.

2. Position mounting bracket onto lower edge of Draft Hood skirt. Locate center tooth (with #10 sheet metal screw) on outside and other two teeth inside Draft Hood skirt. See Figure 7.

3. Slide mounting bracket tight against lower edge of Draft Hood skirt. Position #10 sheet metal screw above skirt's stiffening rib.

4. Secure bracket in position by tightening #10 sheet metal screw against outer surface of Draft Hood skirt.

5. Verify power cord, mounting bracket and Blocked Vent Switch are secure and located as shown in Figure 7.

WARNING

Failure to properly install and use this Blocked Vent Switch may result in property damage, personal injury or loss of life.

C. Install Vent Damper

OPEN THE VENT DAMPER CARTON and remove the

Installation Instructions. READ THE INSTALLATION INSTRUCTIONS THOROUGHLY before proceeding.

WARNING

The pilot vent plug must be installed per the Installation Instructions.

The automatic gas control valve supplied on each RRG

Series boiler provides the redundancy referenced in the vent damper Installation Instructions.

CAUTION

Do not use one vent damper to control two heating appliances.

Figure 7: Vent Damper Installation

1. The vent damper must be the same size as the outlet of the Draft Hood supplied with the boiler (see Table 1A). Unpack the damper carefully - DO NOT FORCE IT CLOSED! Forcing the damper may damage the gear train and void the warranty.

2. Mount the vent damper assembly onto the canopy/ diverter. (Refer to Figure 7 and to instructions

packed with the vent damper for specic

instructions). Do not modify either the draft hood or vent damper.

NOTICE

Provide adequate clearance for servicing.

3. Locate vent damper position indicating means to be visible following installation.

WARNING

Provide 6" minimum clearance between damper and combustible construction.

4. Plug the factory harness vent damper connector into damper motor polarized receptacle.

DANGER

Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause severe injury or death.

D. Inspect chimney and remove any obstructions or

restric tions. Clean chimney if previously used for solid

or liquid fuel-burning appliances or replaces.

E. Install vent system in accordance with "Venting of

Equipment" of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of local building codes. The RRG Series boiler is a Category I, draft hood equipped appliance.

WARNING

F. If an Existing Boiler is Removed:

When an existing boiler is removed from a common

venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.

At the time of removal of an existing boiler, the

following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation:

a. Seal any unused openings in the common venting

system.

b. Visually inspect the venting system for proper

size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, and other

deciencies which could cause an unsafe condition.

c. Insofar as is practical, close all building doors and

windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maxi mum speed. Do not operate a summer exhaust fan. Close

replace dampers.

d. Place in operation the appliance being inspected.

Follow the Lighting (or Operating) Instructions. Adjust thermo stat so appliance will operate continuously.

e. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the ame

of a match or candle, or smoke from a cigarette, cigar or pipe.

f. After it has been determined that each appliance

remain ing connected to the common venting system properly vents when tested as outlined above, return

doors, win dows, exhaust fans, replace dampers and

any other gas-burning appliance to their previous condition of use.

g. Any improper operation of the common venting

system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

V. Gas Piping

A. Size gas piping. Design system to provide adequate gas

supply to boiler. Consider these factors:

1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Actual point of delivery pressure may be less; contact gas supplier for additional information. Minimum gas valve inlet pressure is listed on rating label.

2. Maximum gas demand. Consider existing and expected future gas utilization equipment (i.e. water heater, cooking equipment).

3. See Table 1B for boiler inputs.

B. Connect boiler gas valve to gas supply system.

1. Use methods and materials in accordance with local plumbing codes and requirements of gas supplier. In absence of such requirements, follow National Fuel Gas Code, ANSI Z223.1/NFPA 54.

2. Use thread (joint) compounds (pipe dope) resistant

to action of liqueed petroleum gas.

3. Install sediment trap, ground-joint union and manual shut-off valve upstream of boiler gas control valve. See Figure 8.

4. All above ground gas piping upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as grounding electrode. Refer to National Electrical Code, ANSI/NFPA 70.

C. Pressure test. The boiler and its gas connection must

be leak tested before placing boiler in operation.

1. Protect boiler gas control valve. For all testing over ½ psig, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig or less, isolate boiler from gas supply piping by closing boiler's individual manual shutoff valve.

2. Locate leaks using approved combustible gas

detector, soap and water, or similar nonammable solution. Do not use matches, candles, open ames,

or other ignition source.

Figure 8: Pilot and Gas Piping

VI. Electrical

A. General. Install wiring and electrically bond boiler to

ground in accordance with requirements of authority having jurisdiction, or in absence of such requirements, with the National Electrical Code, ANSI/NFPA 70.

B. Install thermostat. Locate on inside wall

approximately 4 feet above oor. Do not install on outside wall, near replace, or where inuenced by drafts or restricted air ow, hot or cold water pipes, lighting xtures, television, or sunlight. Allow free air

movement by avoiding placement of furniture near thermostat.

C. Wire boiler. Boiler is rated for 120 VAC, 60 hertz,

less than 12 amperes. A separate electrical circuit must be run from the main electrical service with an over-current device/disconnect in the circuit. A service switch is recommended and may be required by some local jurisdictions. Connect to black and white wires and green ground screw. See Figures 9 and 10.

D. For installations using zone valves provide separate

transformer for zone valve wiring. Consult zone valve manufacturer for assistance. See Figures 11 and 12.

CAUTION

This boiler contains controls which may cause the boiler to shut down and not restart without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

Figure 9: Wiring Connection Diagram

Figure 10: Schematic Ladder Diagram

Figure 11: Wiring Schematic, Zone Valves

Figure 12: Wiring Schematic, Zone Circulators

VII. System Start-up and Checkout

A. Main Burner Check - Check main burners to see

that they were not dislodged during shipment. Rear of burners should be in the vertical slots in the rear of burner tray and the front of the burners should be seated

completely on the orices.

B. Initial start -

1. Fill entire heating system with water and vent air from system. Use the following procedure on a System equipped with zone valves.

a. Close isolation valve in boiler supply piping.

b. Isolate all circuits by closing zone valves or

balancing valves.

c. Attach a hose to hose bib located just below

isolation valve in boiler supply piping. (Note

- Terminate hose in ve gallon bucket, at a suitable oor drain, or outdoor area).

d. Starting with one circuit, open zone valve.

e. Open hose bib.

f. Open ll valve (Make-up water line should be

located directly above isolation valve in boiler supply piping).

g. Allow water to overow from bucket until

discharge from hose is bubble free for 30 seconds.

h. Open zone valve to the second zone to be

purged, then close the rst. Repeat this step until

all zones have been purged, but always have one zone open. At completion, open all zone valves.

i. Close hose bib, continue lling the system

until the pressure gauge reads 12 psi. Close ll

valve. (Note - If make-up water line is equipped with pressure reducing valve, system will

automatically ll to 12 psi. Leave globe valve

open).

j. Open isolation valve in boiler supply piping.

k. Remove hose from hose bib.

2. Turn ROOM THERMOSTAT to lowest setting.

3. Be sure that gas to pilot and main burners has been

off for at least ve minutes and vent damper has

been in the open position.

4. Turn "OFF" the electric switch serving boiler.

5. Open valve on main gas line at meter.

6. PURGE AIR FROM GAS PIPING. Adequate

ventilation must be provided and no smoking or

open ame permitted.

7. Turn "ON" electric switch serving boiler.

8. Open Manual Shut-off Valve upstream of Combination Gas Valve.

Figure 13: Top View of Honeywell Gas Valves

9. Loosen or remove Inlet Pressure Tap Plug in Combination Gas Valve and when purging is complete, tighten or replace plug. (See Figure 13).

10. Check pipe and ttings from meter to Combination

Gas Valve using soap solution or other approved methods.

CAUTION

11. Test gas piping and connections between

Combination Gas Valve and manifold, orices, and

pilot piping for leaks after boiler is operating. Use soap solution or other approved method.

C. Check Gas Input to Boiler

1. Input Rate and Maximum Inlet Pressure shown on Rating Label must not be exceeded. Inlet pressure must not be lower than minimum inlet pressure shown on Rating Label.

2. Input ratings shown on boiler rating label can be used for elevations up to 2000 ft.

3. All Rate checks and all adjustments are to be made

while boiler is ring - all other appliances connected

to the same meter as the boiler must be off.

4. With boiler off, water Manometer or water column gauge should be connected to a shut-off valve installed in the 1/8" outlet pressure tap in the gas valve (see Figure 13). By installing gas valve upstream of manometer, gas pressure can be introduced gradually - without shut-off valve; surge of pressure when boiler is turned on, could blow liquid out of manometer. Replace plug in gas valve

when rate check is nished.

5. Lp Gas Input:

Adjust Regulator on Gas Valve so that manifold

pressure is 10 inches water column. Turning Regulator Adjusting Screw Clockwise increases pressure. Counterclockwise rotation decreases pressure.

Figure 14: Operating Instructions

6. Natural Gas Input: Adjust Regulator on Gas Valve so that manifold

pressure is 3½ inches water column. Turning Regulator Adjusting Screw Clockwise increases pressure. Counter-clockwise rotation decreases pressure.

D. Check Main Burner Flame. See Figure 15. Flame

should have a clearly dened inner cone with no yellow

tipping. Orange-yellow streaks caused by dust should not be confused with true yellow tipping.

Figure 16: Pilot Burner Flame

G. Check Vent Damper Operation. Vent Damper must

be in open position when main burners are operating.

Figure 15: Main Burner Flame

CAUTION

Avoid operating this boiler in an environment

where saw dust, loose insulation bers, dry wall

dust, etc. are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and inspected daily to insure proper operation.

E. Check Pilot Burner Flame.

1. See Figure 16. The pilot burner should be lit only if thermostat is calling for heat. The pilot burner

produces three (3) ames. The center ame should

be steady, medium hard blue enveloping 3/8 to 1/2 inch of sensing probe.

F. Check Ignition System Safety Shut-off Device.

Remove 3-wire plug from gas valve.

If burners do not shut down determine cause of

malfunction. Replace necessary items and check operation.

H. Check High Limit Control.

Jumper Thermostat connections in boiler wiring

harness. Allow burners to operate until shutdown by limit. REMOVE JUMPER.

I. Check Thermostat Operation. Raise and lower

temperature setting to start and stop boiler operation. Adjust thermostat to normal setting.

J. Combustion Chamber Burn-off

1. The mineral wool combustion chamber panels may contain a cornstarch based binder that must be burned out at installation to prevent odors during subsequent boiler operation.

2. Ventilate the boiler room, set the high limit to its maximum setting, set the thermostat to call for heat.

Allow the boiler to re for at least an hour or until

the odor from the cornstarch has dissipated.

3. Return the high limit and thermostat to their desired settings.

K. Review User's Information Manual and system

operation with owner or operator.

L. Post instructions near boiler for reference by owner

and service personnel.

VIII. Operation

A. BOILER SEQUENCE OF OPERATION

NORMAL OPERATION

1. The RRG Series Boilers are equipped with an Integrated Boiler Control (IBC). This IBC replaces the traditional separate ignition control, high limit switch and circulator relay and adds energy saving thermal purge features. Energy is saved by starting the circulator and delaying the burner start when there is residual heat available in the boiler.

2. The boiler’s sequence of operation is shown in Table 3.

3. When the thermostat calls for central heat (CH) the IBC starts the system circulator and the thermal purge begins. If the boiler temperature is less than 140°F, the start sequence continues by energizing the vent damper. Once the vent damper is fully open the ignition sequence is started allowing gas

ow and ignition of the burners. Damper must be

in open position when appliance main burners are operating.

4. If the call for CH is not satised and the operating

setpoint is reached the system circulator will continue to operate and the burners will stop. When the boiler water temperature drops below the setpoint less the differential setting the burners will restart.

5. After the call for CH is satised the burners and

circulator are stopped and vent damper is closed.

6. When the Domestic Hot Water (DHW) calls for heat, the control starts the circulator and, if the boiler temperature is less than the operating setpoint less differential, the vent damper is energized without delay. Once the vent damper is fully open,

the ignition sequence is started allowing gas ow

and ignition of the burners.

The default DHW high limit is 200°F. The DHW

high limit will match CH set point if CH set point is below 200°F.

B. BOILER FAULT

In the event the boiler fails to start, the control provides

status information to help determine the cause of the problem. Table 4 from Section X: Troubleshooting

(page 24) provides a list of boiler ash codes indicating

the source of the lockout. Refer to the Troubleshooting Section for more information.

Figure 17: Integrated Boiler Control

C. USING DISPLAY AND ADJUSTMENT KNOBS

The control is located inside the boiler. (Figure 17).

The IBC display, along with two adjustment knobs may

be used to change two parameters. The status LEDs are located to the right of the display. When powered the POWER LED is green and the remaining LEDs will light up red depending on the state of the control (see Figure 18).

1. High limit setpoint The High Limit Setpoint is user adjustable by

turning the top knob labeled “BOILER TEMP”. Adjustment range is 140°F to 220°F. During normal operation the LED display will show

Table 3: Sequence of Operation Using the Controls LEDs

Status POWER TSTAT/CIRC LIMIT DAMPER FLAME

1 Standby

2 Call for heat - Circulator on

3 Limit circuit closed

4 Vent Damper - Proven open

5 Pilot ame proven

 - LED illuminated  - LED off

    

    

    

    

    

Figure 18: Boiler Display

0°F Diff. Setting

boiler temperature. When a change is made to the setpoint knob the display will brighten and show the setpoint. Factory programmed with High Limit Setpoint of 140°F.

Outdoor Reset

2. Outdoor Reset Differential Setpoint (when outdoor sensor installed)

The Outdoor Reset Differential Setpoint is user

adjustable by turning the bottom knob labeled “OUTDOOR RESET DIFF”. Adjustment range is 0°F to 50°F. When no outdoor sensor is present, the IBC uses the user setpoint as the operating setpoint. When an outdoor temperature sensor is attached, the IBC adjusts the Conditioned space demand operating setpoint based on outdoor temperature. See graph below.

190

180

170

160

150

Boiler Operating Setpoint (°F)

140

130

-10 0 10 20 30 40 50 60 70 80

Outdoor Temperature (°F)

25°F (default)

IX. Service and Maintenance

Refractory Ceramic Fiber Product

Important Product Safety Information

Warning:

The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator

2. Long sleeved, loose fitting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing

machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada.

First Aid Procedures:

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

WARNING

Service on this boiler should be undertaken only by trained and skilled personnel from a qualied service agency. Inspections should be performed at intervals specied in this manual. Maintain

manual in a legible condition.

Keep boiler area clear and free of combustible materials, gasoline and other ammable vapors and

liquids.

Do not place any obstructions in boiler room that will hinder ow of combustion and ventilation air.

A. General. Inspection and service should be conducted

annually. Turn off electrical power and gas supply while conducting service or maintenance. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 14.

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

B. Inspect Vent System.

1. Remove obstructions in vent pipe and chimney.

2. Remove soot accumulations with wire brush and vacuum.

3. Repair or replace deteriorated vent pipe and vent accessories.

4. Provide proper support. Repair sags, particularly in horizontal sections.

5. Repair leaking joints.

C. Inspect Boiler Flue Passages for blockage or soot

accumulation.

1. Remove vent pipe, vent damper and blocked vent switch.

2. Remove sheet metal screws securing Jacket Top Panel. Remove Top Panel.

3. Remove screws securing Canopy to Section Assembly. Remove Canopy.

4. Using ashlight, examine all ue passageways.

a. If passageways are free of soot and obstruction,

replace canopy, secure and seal.

b. If passageways need cleaning, remove burners

as described in Paragraph D. Using long handle

wire or bristle ue brush and vacuum, brush ueways thoroughly from top of boiler.

5. Install new gasket material (See Section XI: Repair Parts). Install canopy.

6. Install Jacket Top Panel, Blocked Vent Switch, Vent Damper, and vent pipe.

D. Clean Main Burners and Firebox.

1. To remove burners for cleaning, changing orices,

or repairs: a. Remove Jacket Front Panel. b. Disconnect pilot tubing at gas valve. c. Disconnect 3-wire plug at the gas valve.

d. Remove wires to ame roll-out switch.

e. Remove the burner access panel. f. Mark the location of the pilot main burner on the

manifold if the marking on manifold is missing or obliterated.

g. Hold burner at throat. Lift front of burner to

clear orice. Burner which holds pilot can only

be removed by lifting the burner adjacent to its

right rst.

2. Brush top of burners with a soft bristle brush. Vacuum burners.

3. Check orices. Drilled passageways must be free of

lint or dirt.

4. Vacuum tip of Pilot Burner.

5. Clean rebox by vacuuming. Exercise care not to

damage base insulation.

6. Install burners by reversing procedure used to remove burners. Make sure burner with pilot assembly is in same location as original installation.

Check burners to see that they are located properly

in slot at rear of burner tray. Reinstall burner access

panel. Reconnect ame roll-out switch wires, pilot

gas supply, thermocouple lead or pilot lead.

7. Connect pilot gas supply, igniter/sensor wire, and ground wire at Boiler Control.

8. Install Burner Access Panel. Connect Flame Rollout Switch wires.

E. Check Operation. Follow steps C through J from

Section VII: System Start-up and Checkout.

F. Lubrication. There are no parts requiring lubrication

by service technician or owner. Circulator bearings are water lubricated.

X. Troubleshooting

A. BEFORE TROUBLESHOOTING

The following pages contain troubleshooting tables for

use in diagnosing control problems. When using these tables the following should be kept in mind:

1. This information is only meant to be used by a professional heating technician as an aid in diagnosing boiler problems.

2. In general, these tables assume that there are no loose or miswired electrical connections. Before using these tables inspect all electrical connections on the boiler to make sure that they are tight. Also, check the wiring on the boiler against the wiring diagram in Figures 9 and 10. Ensure that incoming

120 Vac power polarity is correct and that the boiler is properly grounded. Further, ensure that the control power supply is 24 VAC (minimum 18 VAC to maximum 30 VAC) and polarity is correct.

4. All controls on the RRG Series are tested at least once in the manufacturing process and a defective control or component is generally the least likely cause. Before replacing a component, try to rule out all other possible causes.

5. When checking voltage across wiring harness pins be careful not to insert the meter probes into the pins. Doing so may damage the pin, resulting in a loose connection when the harness is reconnected.

Table 4: Troubleshooting Using the Control's LED

Flashing LED Fault Condition

POWER

Steady 1 Hz ash

Flash code 2 Flash code 3 Flash code 4 Flash code 5 Flash code 6

POWER + TSTAT/CIRC 48 volts on Thermostat circuit

DAMPER Damper switch opened after it had been proved closed. Continues ashing until demand for heat

POWER + DAMPER Damper switch stuck open or closed (control in damper switch lockout)

LIMIT Fault detected in temperature sensing hardware

FLAME Flame loss, or ame not sensed during trial for ignition. Continues ashing until either ame is

POWER + FLAME Flame sensed without call for heat or out of sequence during ignition trial.

Reverse polarity of 115 VAC supply voltage Faults internal to microprocessor (RAM, ROM, etc.) Unused Unused Water thermistors disagree Gas valve outputs in improper state

removed or Damper switch proven closed in ignition sequence.

established or demand for heat is removed.

Lockouts

1. Lockout from internal hardware faults (listed above under POWER) automatically resets after the hardware fault has not been present for 60 minutes. Lockouts from internal hardware faults may not be manually reset except by removing power from the control.

2. Lockout from damper switch failing to close within 45 seconds automatically resets after 60 minutes. Lockout may be manually reset by opening the thermostat for more than 2 but less then 20 seconds.

B. USE CONTROL LEDS TO DIRECT TROUBLESHOOTING EFFORTS

If the control detects an error, the LEDs will ash. Use the LEDs to identify the boiler problem and corrective action in the

table below. If LEDs are not ashing, proceed to Paragraph C:

Flashing

LEDs

Blank Boiler or Control is not powered

POWER

Steady 1 Hz

ash

POWER

Flash Code 2

POWER

Flash Code 5

POWER

Flash Code 6

POWER

TSTAT/CIRC

DAMPER

POWER

DAMPER

POWER

DAMPER

LIMIT Temperature Sensor Failure

FLAME

POWER

FLAME

Line Voltage Reversed Reverse polarity of 115 VAC supply voltage.

Microprocessor Failure Cycle power to control. Replace control if problem persists.

Water thermistors disagree

Gas Valve Outputs in improper state

Thermostat Input Higher than Threshold

Damper Switch opened after proven closed

Damper Failed to Open

Damper Failed to Close

Flame Current Lower than Threshold

Flame Sensed Out of Normal Sequence

Status Recommended Corrective Action

No 120 Vac Power at boiler, check breaker and wiring between breaker panel and boiler

Conrm sensor is fully in well. If secure and good condition, replace

sensor.

Flame sensed during pre-purge (before gas valve signaled open). Check the gas valve for proper operation. Replace gas valve if problem persists.

Check thermostat wiring.

LEDs continue ashing until demand for heat is removed or damper switch

proven closed in ignition sequence.

Atmospheric Damper End Switch failed to close (end switch contacts stuck open). Refer to Troubleshooting Section, C4.

Damper open. Voltage should not be present on P6-5. Control, vent damper or wire harness is defective. While the POWER + DAMPER LEDs

ash on the control, perform the following tasks:

• Remove the call for heat (adjust thermostat or remove wire from TT

terminals.

• Check for 24Vac between P6-5 and ground.

• If voltage not present, attempt to start boiler again.

• If 24Vac is present, unplug the vent damper harness from control.

• With wire harness unplugged, check for 24Vac between P6-5 (on

Control) and ground.

• If voltage present, replace the control.

• If voltage not present, failed vent damper or wiring harness.

• Check wiring harness for shorts or mis-wiring. Replace if defective.

• If harness not defective, replace vent damper.

Temperature sensor or interface failure (open or short connection, increased connection resistance, dual sensor mismatch) or control hardware failure.

- Check sensor is securely attached to control P7 connector.

- Check sensor wire is not damaged.

- If secure and in good condition, replace sensor.

- If problem persists, replace control.

Flame loss, or ame not sensed during trial for ignition. Continues ashing until either ame is established or demand for heat is removed.

Check pilot assembly. Refer to Troubleshooting Section, C5.

Flame sensed out of normal sequence (before opening gas valve or after closing gas valve). Check the gas valve for proper operation.

C. USE STATUS LEDS TO GUIDE TROUBLESHOOTING

The control LEDs will light to indicate status. Use these LEDs to identify the boiler problem in the table below:

1. Boiler and Circulator Off

LED / Status Recommended Corrective Action

The boiler has not detected a call for heat

- POWER Standby

Burner off

Circulator off

Check that the thermostat:

- When a thermostat call for heat is detected control TSTAT/CIRC LED will be lit.

- Make sure thermostat is calling for heat and contacts (including appropriate zone controls) are closed. Check for loose connection.

Check the DHW demand:

- When a domestic call for heat is detected control TSTAT/CIRC LED will be lit.

- Make sure the DHW aquastat contact is closed. Check for loose connection.

2. Circulator is On, But Boiler is Off

LED / Status Recommended Corrective Action

- POWER

- TSTAT/CIRC Circulator

Pre-purge Burner off

Circulator on

The boiler is warm and circulator is providing residual boiler heat to building:

Check boiler temperature

- The boiler will not start until boiler water temperature is 15°F less than the Setpoint

- If boiler water temperature is higher than 140° F, boiler start will be delayed until water temperature drops below 140°F.

3. Circulator is On But Damper is Not Open

LED / Status Recommended Corrective Action

Waiting for Limit to Open.

- Check Blocked Vent Switch, in the event of a blocked vent or poor draft condition, the blocked vent switch will open interrupting power to control P4-1. The main burners will be extinguished immediately and the circulator will remain on until the thermostat is turned off. The source of blockage must be corrected by

trained and skilled personnel from a qualied service agency before resetting switch.

Blocked Vents are caused by a collapsed chimney resulting in full or partial blockage, chimney cross

- POWER

- TSTAT/CIRC Limit Open

sectional area too small, height insufcient or cold chimney causing sustained poor draft. Always follow

the recommendations in Section I, Figure 1 and Section IV: Venting.

- Check Flame Rollout Switch, in the event of excessive blockage of the boiler section ue passageways is developed the ame rollout switch will open interrupting power to control P4-1. The main burners will

be extinguished immediately and the circulator will remain on until the thermostat is turned off. If the

ame rollout switch is activated, do not attempt to place the boiler in operation. The source of the blockage must be corrected and the identical ame rollout switch replaced by trained and skilled personnel from a qualied service agency.

- Check External Limit.

4. Circulator is On But Damper is Not Open

LED / Status Recommended Corrective Action

The control is waiting for the damper to open. Damper end switch has failed to close (end switch contact is stuck open). Combustion can never take place unless the damper blade is in the fully open position. Check the following:

- POWER

- TSTAT/CIRC

- LIMIT

Damper Failed

to Open

- Conrm if control terminal “P6 - 5” (yellow wire) is energized.

- Check for loose connection between control and vent damper, check damper harness.

- Check for obstruction in path of damper

- When damper is open (end switch closed) control terminal “P6 – 2” should receive power from the vent damper.

- Place jumper between control terminal P6-5 and P6-2. If DAMPER LED does not light, replace control.

- Defective harness or vent damper.

5. Circulator is On, Damper is Open But Boiler Fails to Start

LED / Status Description

- POWER

- TSTAT/CIRC

- LIMIT

- DAMPER

Retry / Recycle

Delay

The Boiler is in “Retry Delay”:

- The burner failed to light (no ame signal). After a 5 minute delay, Control will attempt to light the burner

again. There is no limit to the number of retries. Recycle Delay

- The burner loses ame during running mode. Immediately, Control will attempt to light the burner again. If ame is lost 5 times within the same call for heat, the control locks out for one hour before retrying

ignition.

5. Circulator is On, Damper is Open But Boiler Fails to Start (continued)

LED / Status Recommended Corrective Action

1. No Spark

a. Can you hear sparking?

- If there is no spark noise replace the control. b. If you can hear spark noise check the following:

- Loose connection in ignition cable or ground wire

- Continuity of ignition cable

- Break in ignition cable insulation

- Loose ground connection

- Break in pilot ceramic insulator

- Incorrect pilot spark gap

2. No Pilot Flame

a. If pilot does not light check the following:

- All manual gas valves are open

- Supply tubing is not plugged, kinked or leaking

- Gas line pressures are good

- POWER

- TSTAT/CIRC

- LIMIT

- DAMPER

Retry / Recycle

Delay

- Gas line is purged of air

- Pilot orice is not plugged (pilot gas is owing)

- Condensate quenching pilot Note: It may be necessary to recycle the “call for heat” more than once to clear the pilot supply tubes of air.

b. If no gas ow check the following:

- 24 volts across PV and MV/PV at gas valve, if voltage ok replace defective gas valve

- Check for break in wiring harness to gas valve

- 24 volts across control connector P4-6 and P4-7, if no voltage at control replace defective control

3. Spark does Not Stop When Pilot Lights

If the spark does not stop when the pilot lights check the following:

- Loose connection in ignition cable or ground wire

- Continuity of ignition cable

- Clean ame rod

- Pilot electrode porcelain cracked

- Pilot ame covers ame rod and is steady and blue, if not adjust pilot ame

- Low gas pressure at gas valve inlet

- Defective control

4. Main Flame Does Not Light

If the main burners do not light check the following:

- Check orice size and/or blockage

- 24 volts across control terminals P4-5 and P4-7? If no voltage while in defective control.

- 24 volts across MV and MV/PV at gas valve? Check for break in wiring harness to gas valve

- Defective gas valve

XI. Repair Parts

All RRG™ repair parts may be obtained by contacting your local Rand & Reardon Distributor.

Section Assembly and Canopy Assembly ....................................30

Base Assembly ............................................................................32

Burner Tray, Main Burners and Manifold ...................................34

Pilot Burner and Gas Valve ......................................................... 36

Jacket Assembly, Complete ......................................................... 37

Controls and Trim ......................................................................38

Draft Hood and Vent Damper ...................................................38

Key

No.

Description Part Number

Section Assembly and Canopy Assembly

Boiler Model

RRG062 RRG096 RRG130 RRG164

6171703 1 --- --- ---

1 Cast Iron Section Assembly (Complete)

2 Flue Bafe 71106001 2 3 4 5

3 Canopy Assembly

Cerafelt Sealing Strip ½" x 1" x 10'

(Canopy for Section Assembly)

Carriage Bolt ¼" - 20 x 1" 80860115

Nut, Hex ¼" - 20 80860407

6171704 --- 1 --- ---

6171705 --- --- 1 ---

6171706 --- --- --- 1

611170302 1 --- --- ---

611170402 --- 1 --- ---

611170502 --- --- 1 ---

6111706010 --- --- --- 1

6206001 1 1 1 1

2 2 2 2Flat Washer, ¼" 80860603

Section Assembly and Canopy Group

Key

No.

Base Assembly

Boiler Model

Description Part Number

RRG062 RRG096 RRG130 RRG164

718600391 1 --- --- ---

6 Base Tray

7 Base Wrapper

8 Base Side Insulation 720601 2 2 2 2

9 Base Rear Insulation

10 Base Front Panel Assembly

11 Base Leg Assembly 6186001 4 4 4 4

718600491 --- 1 --- ---

718600591 --- --- 1 ---

718600691 --- --- --- 1

718600311 1 --- --- ---

718600411 --- 1 --- ---

718600511 --- --- 1 ---

718600611 --- --- --- 1

72060035 1 --- --- ---

72060045 --- 1 --- ---

72060055 --- --- 1 ---

72060065 --- --- --- 1

618600341 1 --- --- ---

618600441 --- 1 --- ---

618600541 --- --- 1 ---

618600641 --- --- --- 1

12 Base Leg 71860021 4 4 4 4

13 Nylon Glide 8186006 4 4 4 4

718600361 1 --- --- ---

14 Burner Access Panel

15 Self-Tapping Screw ¼ - 20 x ½ 80860700 20 20 20 20

16 Self-Tapping Screw 5/16 - 18 x 1¼ 80860717 4 4 4 4

17 Flat Washer 5/16", USS 80860601 4 4 4 4

18 Hex Lock Nut 5/16 - 18 80860464 4 4 4 4

Cerafelt Sealing Strip ½" x 2" x 10'

(Section Assembly to Base)

718600461 --- 1 --- ---

718600561 --- --- 1 ---

718600661 --- --- --- 1

6206002 1 1 1 1

Key

No.

Description Part Number

Burner Tray, Main Burners and Manifold

Boiler Model

RRG062 RRG096 RRG130 RRG164

100307-01 1 --- --- ---

20 Burner Tray / Burner Tray Assembly

21 Main Burner w/Slotted Orice Bracket 8236119 2 4 6 8

22 Main Burner with Pilot Bracket 8236118 1 1 1 1

23 Manifold

718600405 --- 1 --- ---

718600505 --- --- 1 ---

718600605 --- --- --- 1

82219031 1 --- --- ---

82219041 --- 1 --- ---

82219051 --- --- 1 ---

82219061 --- --- --- 1

Burner Gas Orice - Natural Gas

24 Main Burner Orice #45 (Pink) 822711 3 5 7 9

Burner Gas Orice - LP Gas

Main Burner Orice 1.25mm (Purple) 822705 --- 5 7 9

Main Burner Orice #55 (Green) 822708 3 --- --- ---

31 Self-Tapping Screw ¼ - 20 x ½ 80860700 4 4 4 4

Manifold and Main Burners

Key No. Description Part Number

Pilot Burner and Gas Valve (Natural or LP/Propane Gas)

Boiler Model

RRG062 RRG096 RRG130 RRG164

34 Ground Wire Assembly 103776-01 1 1 1 1

Pilot Burner, Honeywell Q3481B1206 (Nat. Gas) 103704-01 1 1 1 1

Pilot Burner, Honeywell Q3481B1420 (LP) 103705-01 1 1 1 1

Pilot Tubing 1/4" OD x 30" Lg. Aluminum 8236122 1 1 1 ---

Pilot Tubing 1/4" OD x 40" Lg. Aluminum 8236123 --- --- --- 1

Gas Valve, Honeywell VR8204C3007 (Nat. Gas) 81660145 1 1 1 1

Gas Valve, Honeywell VR8204C3015 (LP) 81660146 1 1 1 1

Key

No.

Jacket Assembly, Complete

Boiler Model

Description Part Number

RRG062 RRG096 RRG130 RRG164

106896-03 1 --- --- ---

37 Jacket Assembly, Complete

106896-04 --- 1 --- ---

106896-05 --- --- 1 ---

106896-06 --- --- --- 1

Key No.

Description

Part

Number

RRG062 RRG096 RRG130 RRG164

Boiler Model

Controls and Trim

38 Temperature / Pressure Gauge 100282-01 1 1 1 1

39 Drain Valve, Conbraco 35-302-03 806603061 1 1 1 1

40 Safety Relief Valve, 30 psi, 3/4 NPT Conbraco 10-408-05 81660319 1 1 1 1

41 Flame Rollout Switch 80160044 1 1 1 1

42 Flame Rollout Switch Mounting Bracket 7186018 1 1 1 1

43 Blocked Vent Switch Replacement Assembly 6016066 1 1 1 1

44 Limit Rated Temperature Sensor, 48" Lg. 106644-01 1 1 1 1

45 1/2" Immersion Well 80160456 1 1 1 1

46 Temperature Sensor Cap 106804-01 1 1 1 1

47 Boiler Control, Atmospheric Draft 106541-01 1 1 1 1

48 Transformer, 40 VA 106529-01 1 1 1 1

49 Circulator w/Gaskets and Hardware, Taco 007 8056182 1 1 1 1

Draft Hood and Vent Damper (Natural or LP/Propane Gas)

50 Draft Hood

51 Vent Damper

8116067 1 --- --- ---

8111702 --- 1 --- ---

8111703 --- --- 1 1

102284-01 1 --- --- ---

102284-02 --- 1 --- ---

102284-03 --- --- 1 1

User's Information

Manual

RRG™ Series

Gas Boiler

WARNING: If the information in this

manual is not followed exactly, a re or

explosion may result causing property damage, personal injury or loss of life.

- Do not store or use gasoline or other

ammable vapors and liquids in the vicinity of this or any other appliance.

- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch;

do not use any phone in your

building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the re department.

- Installation and service must be performed by a qualied installer, service agency or the gas supplier.

106657-02 - 7/16

The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels.

WARNING

Indicates a potentially hazardous situation which,

if not avoided, could result in death, serious injury or substantial property damage.

Important Product Safety Information

Refractory Ceramic Fiber Product

Warning:

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear:

CAUTION

Indicates a potentially hazardous situation which,

if not avoided, may result in moderate or minor

injury or property damage.

1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator

2. Long sleeved, loose fitting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing

machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada.

First Aid Procedures:

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

Basic Operation

CAUTION

Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical

supply to the circulator. Instead, shut off the gas supply at a location external to the appliance.

Do not use this boiler if any part has been under water. Immediately call a qualied service technician to inspect the boiler and to replace any part of the control system and any gas control which has been

under water.

A. General. This water boiler is equipped with controls

for proper operation. All controls must be in proper

working order. Contact a qualied service agency to provide annual maintenance as specied in Installation, Operating and Service Instructions.

1. Limit. See Figure 1. A device which automatically

interrupts boiler operation when the water temperature exceeds the set point. Maximum allowable temperature is 220°F.

Original equipment with this boiler is an Integrated

Boiler Control (IBC) and Limit Rated Sensor combination. The IBC shuts off boiler main

burners when boiler water temperature exceeds

pre-programmed IBC water temperature set point. Boiler main burners will re-light automatically, providing the call for heat is present, when boiler

water temperature falls below pre-programmed control water temperature set point less the set point differential.

2. Flame Rollout Switch. See Figure 1. A device

which automatically interrupts boiler operation when ames or excessive heat are present in the

combustion area enclosure. The control is a single use device. The control is located in the combustion

area enclosure. If the control was activated to interrupt boiler operation, do not attempt to place boiler in operation. Contact a qualied service agency.

Do not reset Blocked Vent Switch unless a qualied service agency has determined and corrected the cause of any blockage in the vent

system or chimney.

3. Blocked Vent Switch See Figure 1. A device

which automatically interrupts boiler operation when excessive vent system blockage occurs. If the control was activated to interrupt boiler operation,

do not attempt to place boiler in operation. Contact

a qualied service agency.

4. Electronic Ignition System - see Figure 1. The

Electronic Ignition (EI) System consists of:

a. a solid state ignition control with integral

ignition module to initiate, monitor and stop burner operation. The IBC performs this

function.

b. a combination gas valve to regulate gas ow to

the main burners.

c. a pilot burner to provide the ignition source for

the main burners.

B. Instructions to place the boiler in operation and to turn

off the boiler are shown on the Operating Instruction Label posted on the inside of the front door. The Operating Instruction Label is shown in Figure 2.

WARNING

Service on this boiler should be undertaken only by trained and skilled personnel from a qualied service agency.

C. The Sequence of Operation is shown in Figure 3.

Figure 1: Control Locations

Figure 2: Operating Instructions

POWER

(Control LED’s

Illuminated)

TSTAT/CIRC

Standby

Thermostat Calls

for Heat

Circulator Output

Energizes

Self Testing

LIMIT

DAMPER

FLAME

Limits Closed Checked

Vent Damper Energized

Waiting For

Damper to Open

Ignition Source Energized

Pilot Gas On

Trial For Ignition

Pilot Flame Proven

Ignition Source Off

Main Gas On

Pilot Flame Not Proven

Ignition Source Off

Pilot Gas Off

Continuous

Retry

POWER

Call For Heat Ends

Main Gas Off

Vent Damper De-Energized

Circulator Output De-Energized

Standby

Figure 3: Sequence of Operation

Delay 5 Minutes

User Maintenance

WARNING

Service on this boiler should be undertaken only by trained and skilled personnel from a qualied service agency. Inspections should be performed at intervals specied in Installation, Operating and Service Instructions and this manual. Maintain manuals in a legible condition.

Keep boiler area clear and free of combustible materials, gasoline and other ammable vapors and liquids.

Do not place any obstructions in boiler room that will hinder ow of combustion and ventilation air.

A. General Housekeeping (Continuous).

1. Keep boiler area clear and free of combustible

materials and obstructions to the free ow of

combustion and ventilation air to the boiler.

2. Do not store or use gasoline, other ammable vapors, liquids or sources of hydrocarbons in the vicinity of the boiler or any other appliance.

3. Do not store or use halogen-containing products

(bleaches, cleaners, fabric softeners, refrigerants, chemicals, etc.) in the vicinity of the boiler.

B. Inspect Inlet Air and Vent System (Monthly). Check

the following. If corrective action is required contact qualied service agency.

1. Blocked vent switch must be attached to the canopy.

2. Vent pipe must be full round shape, showing no

damage from impact or excessive temperature.

3. All vent pipe joints must be secure.

4. Horizontal runs must not sag.

5. The vent system must be free of corrosion and other

deterioration.

6. Supports must not be loose or broken.

C. Inspect Pilot and Main Burner Flames (Monthly).

1. Remove jacket front panel.

2. View ames through burner access panel. See

Figure 1.

3. Adjust thermostat to highest setting.

4. Check pilot ame. See Figure 4. The pilot produces one ame. The ame should be steady, medium

hard blue enveloping

If ame is yellow and lazy, follow instructions TO TURN OFF GAS TO APPLIANCE (see Figure 2), and contact qualied service agency.

5. Check main burner ames. See Figure 5. Flame should have clearly dened inner cone with no yellow tipping. Orange-yellow streaks caused by dust should not be confused with true yellow tipping. If yellow ames are observed, follow instructions TO TURN OFF GAS TO APPLIANCE (see Figure 2), and contact qualied service agency.

6. Adjust thermostat to normal setting.

/8 to ½ inch of sensing probe.

D. Schedule Inspection by Qualied Service Agency

(Annual or at Beginning of Heating Season). For

continued safe operation a qualied service agency must provide a more detailed inspection of burners, heat exchanger and vent system, and provide maintenance as specied in Installation, Operating and Service Instructions.

Figure 4: Pilot Burner

Figure 5: Main Burner Flame

Rand & Reardon RRG164, RRG130, RRG096 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual