Rand & Reardon RRO179, RRO120C, RRO179C, RRO120 User Manual

INSTALLATION, OPERATING

AND SERVICE INSTRUCTIONS

RRO SERIES

CAST IRON OIL-FIRED BOILER

9700609

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 Part Number

RRO _

Heating Contractor Phone Number

Address

Boiler Serial Number Installation Date

106630-01 - 3/16

IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY

1. Read and understand all instructions, including all those contained in component manufacturers manuals which are provided with the appliance before installing, starting-up, operating, maintaining or servicing this appliance. Keep this manual and literature in legible condition and posted near appliance for reference by owner and service technician.

2. All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler.

3. All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ from this instruction manual. Authorities having jurisdiction should be consulted before installations are made.

In all cases, reference should be made to the following Standards:

USA BOILERS

A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for

recommended installation practices.

B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel

Burning Appliances”, For Venting requirements.

C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices for

Automatically Fired Boilers”, for assembly and operations of controls and safety devices.

D. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or

Local Regulations.

DANGER

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other appliance.

WARNING

This boiler is suitable for installation on combustible ooring. Do not install boiler on carpeting.

Installation is not complete unless a pressure relief valve is installed into the tapping located on top left corner of rear section - See Piping and Trim Sections of this manual for details.

This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e. wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All ammable debris, rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of re hazards.

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air.

This boiler must be connected to an approved chimney in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney ue must be inspected and cleaned before the start of the heating season for any obstructions. A clean and unobstructed chimney ue is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler's efciency.

Inspect ueways at least once a year - preferably at the start of the heating season. The inside of the combustion chamber, the vent system and boiler ueways should be cleaned if soot or scale has accumulated. When cleaning this boiler, do not damage combustion chamber liner and/or rear target wall. If damaged, combustion chamber insulation must be replaced immediately.

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable installer or service agency.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is completed. Do not tamper with or alter the boiler or controls.

Do not operate unit if any control, switch, component, or device has been subject to water.

Oil Burner and Controls must be checked at least once a year or as may be necessitated.

All boilers equipped with burner swing door have a potential hazard which if ignored can cause severe property damage, personal injury or loss of life. Before opening swing door, turn off service switch to boiler to prevent accidental ring of burner outside the combustion chamber. Be sure to tighten swing door fastener completely when service is completed.

Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance.

High water temperatures increase the risk of scalding injury. If this boiler is equipped with a tankless heater for domestic water supply, a ow regulator and automatic mixing valve must be installed properly in tankless heater piping. See Piping and Trim Sections of the manual for details.

TABLE OF CONTENTS

I. General Information...................................................................... 4

II. Installation Instructions ............................................................... 8

III. Indirect Water Heater Piping ...................................................... 19

IV. System Start-Up .......................................................................... 20

V. Operating ..................................................................................... 26

VI. Maintenance & Service Instructions........ ................................. 31

VII. Boiler Cleaning ........................................................................... 33

VIII. Troubleshooting .......................................................................... 35

IX. Repair Parts................................................................................. 38

X. Burner Specications................................................................. 44

Appendix A - Aftermarket Low Water Cut Off (LWCO) ................. 45

I. GENERAL INFORMATION

A. INSPECT SHIPMENT carefully for any signs of

damage.

1. ALL EQUIPMENT is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in good condition.

2. ANY CLAIMS for damage or shortage in shipment

must be led immediately against the carrier by

the consignee. No claims for variances from, or shortage in orders, will be allowed by the manufacturer unless presented within sixty (60) days after receipt of goods.

B. LOCATE BOILER in front of nal position before

removing crate. See Figures 1a and 1b for applicable positioning.

1. LOCATE so that smoke pipe connection to chimney will be short and direct. BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR. Boiler cannot be installed on carpeting.

2. FOR BASEMENT INSTALLATION, provide a

solid base, such as a concrete pad, if oor is not level, or if water may be encountered on oor

around boiler.

3. PROVIDE SERVICE CLEARANCE of at least

24” on top of boiler for cleaning ueways. Provide

at least 24” clearance from front jacket panel for servicing.

4. For minimum clearances to combustible materials. See Figure 2.

C. PROVIDE AIR SUPPLY AND VENTILATION to

accommodate proper combustion. If natural ventilation is inadequate, provide a screened opening or duct from the boiler room to the outside. The opening or duct must be sized so the boiler input will not exceed 4,000 BTUH/Sq. In. of free area. If other air consuming appliances are near the boiler, the air inlet should be larger. Consult respective manufacturers.

'A'

'B'

'C'

DIA.

RIGHT SIDE VIEW

SEE NOTE 2

CONTROL

BOILER

CONTROL

W/PRIMARY

OIL BURNER

SUPPLY

GAUGE

TEMP/PRESSURE

LINE

FLOOR

11"

BURNER SWING DOOR

CLEARANCE (OPEN 90°)

Figure 1a: RRO080 through RRO179 Boiler without Tankless Heater

FLUE

COLLAR

FRONT VIEW

DRAIN VALVE

RELIEF VALVE

PORT

FLAME

OBSERVATION

RETURN

'A'

'B'

CONTROL

BOILER

'C'

DIA.

CONNECTIONS

BUILT-IN DOMESTIC WATER

HEATER W/ 3/4"

RIGHT SIDE VIEW

SEE NOTE 2

LINE

FLOOR

OIL BURNER

CONTROL

W/PRIMARY

SUPPLY

GAUGE

TEMP/PRESSURE

11"

BURNER SWING DOOR

CLEARANCE (OPEN 90°)

FLUE

COLLAR

RELIEF VALVE

PORT

FLAME

OBSERVATION

RETURN

FRONT VIEW

DRAIN VALVE

Figure 1b: RRO080 through RRO179 Boiler with Tankless Heater

TABLE 1: DIMENSIONAL DATA (See Figures 1a and 1b)

Dimensions

Boiler Model

RRO080, RRO092,

RRO120

RRO111, RRO151,

RRO179

Maximum Working Pressure - Water: 50 PSI Boiler shipped from factory with a 30 PSI relief valve.

"A" "B" "C"

17-3/8" 8-1/4" 5-7/8" 16 14.33 560

22-3/8" 10-7/8" 6-7/8" 20 20.90 680

Approx. Water Content

(Gallons)

Heat Transfer

Surface Area

(Sq. Ft.)

Approx. Shipping

Weight (LBS.)

TABLE 2: RATING DATA

Boiler

Burner Capacity

Model

GPH MBH

RRO080 0.65 91 80 70 86.1 6 8 x 8 15

RRO092 0.75 105 92 80 86.0 6 8 x 8 15

RRO120 1.00 140 120 104 84.3 6 8 x 8 15

RRO111 0.90 126 111 97 86.0 7 8 x 8 15

RRO151 1.25 175 151 131 85.1 7 8 x 8 15

RRO179 1.50 210 179 156 84.0 8 8 x 8 15

Heating

Capacity

(MBH)

NET AHRI

Water Ratings

(MBH)

AFUE

Minimum Chimney Requirements

Round

In. Dia.

Rectangle

In. x In.

Height

Ft.

Figure 2: Minimum Installation Clearances To Combustible Materials (Inches)

Above

6 24 18 6 6

NOTE 1: Listed clearances comply with American National Standard NFPA 31, Standard for the Installation of Oil Burning Equipment.

Front

Chimney

Connector

Rear

Sides

NOTE 2: RRO™ Series boilers can be installed in rooms with clearances from combustible material as listed above. Listed clearances cannot be reduced for alcove or closet installations.

NOTE 3: For reduced clearances to combustible material, protection must be provided as described in the ANSI/NFPA 31 standard.

II. INSTALLATION INSTRUCTIONS

A. REMOVE CRATE

1. Remove all fasteners at crate skid.

2. Lift outside container and remove all other inside protective spacers and bracing. Remove miscellaneous water trim carton.

3. Using hand truck or pipe rollers under skid, move boiler into position along side installation site.

B. REMOVAL OF BOILER FROM SKID

1. Boiler is secured to base with 4 carriage bolts, 2 on left side and 2 on right side. See Figure 3. Remove all bolts.

Figure 3: Removal of Boiler From Skid

2. Tilt boiler to right and to rear. Using right rear leg as pivot, rotate boiler 90° in a clockwise direction,

and lower left side of boiler to oor. Tilt boiler

and remove crate skid. Care should be exercised to prevent damage to jacket or burner.

C. MOVE BOILER TO PERMANENT POSITION by

sliding or walking.

D. INSPECT COMBUSTION TARGET WALL AND

COMBUSTION CHAMBER LINER

1. OPEN FLAME OBSERVATION DOOR AND/ OR BURNER SWING DOOR on front of boiler.

Use ashlight to inspect target wall secured to

rear section with silastic sealant. Inspect ceramic

ber blanket secured to oor of boiler with water

glass adhesive. If either is damaged they must be replaced.

E. INSTALL TRIM AND CONTROLS, AS REQUIRED

(see Figure 1a or 1b)

1. Install return piping supplied with boiler. Apply

Teon or Sealant to all joints prior to assembly.

Thread 1½" NPT x 5" Lg. return nipple into 1½" NPT tapping located in lower left corner of front

section. Thread 1½" x ¾" x 1½" NPT tee onto 5" nipple. Thread ¾" drain valve into ¾" NPT connection on tee. Tighten all joints with wrench until water tight and 1½" NPT return connection on tee is facing away from boiler horizontally to allow for proper burner swing door clearance, see Figures 1 and 4.

NOTE: Vertical piping will prevent door from opening

fully for service and cleaning of boiler.

2. Thread relief valve onto factory installed ¾" NPT x 7¼" nipple located in left rear corner on top of boiler as shown in Figure 1a or 1b. Valve spindle must be in vertical position. Tighten with wrench. Pipe discharge as shown in Figure 4. Installation of the relief valve must be consistent with ANSI/ ASME Boiler and Pressure Vessel Code, Section IV.

F. CONNECT SUPPLY AND RETURN PIPING TO

HEATING SYSTEM.

1. CLEARANCES — Hot water pipes shall have clearances of at least ½” from all combustible construction.

2. See Figure 4 FOR PIPING. Also, consult Residential Hydronic Heating Installation and Design I=B=R Guide.

3. Use a boiler water bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperature may be encountered (i.e. converted gravity circulation system, etc.).

Install a pipe tee between the circulator and boiler

return along with a second tee in the supply piping as shown in Figure 4. The bypass should be the same size as the supply and return lines. Locate valves in the bypass and supply outlet as illustrated

in Figure 4 for regulation of water ow to maintain

higher boiler water temperature.

Set the by-pass and boiler supply valves to a half

throttle position to start. Operate boiler until the system water temperature is a normal operating range.

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

water temperature. Opening the boiler supply valves will raise the system temperature, while opening the bypass valve will lower the system supply temperature.

4. If this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air the boiler piping must be equipped

with ow control valves to prevent gravity

circulation of boiler water during the operation of the cooling system.

Figure 4: Recommended Boiler Piping for Series Loop Hot Water System

5. If this boiler is used in connection with refrigeration systems, the boiler must be installed so that the chilled medium is piped in parallel with the heating boiler using appropriate valves to prevent the chilled medium from entering the boiler, see Figure

5. Also, consult Residential Hydronic Heating Installation and Design I=B=R Guide.

6. A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of the installation. See Section X, Low Water Cut-Off for additional details.

7. Oxygen Contamination:

a. There are many possible causes of oxygen

contamination such as:

i. Addition of excessive make-up water as a

result of system leaks.

ii. Absorption through open tanks and ttings.

iii. Oxygen permeable materials in the

distribution system.

b. In order to insure long product life, oxygen

sources should be eliminated. This can be accomplished by taking the following measures:

i. Repairing system leaks to eliminate the need

for addition of make-up water.

ii. Eliminating open tanks from the system. iii. Eliminating and/or repairing ttings which

allow oxygen absorption.

iv. Use of non-permeable materials in the

distribution system.

v. Isolating the boiler from the system water by

installing a heat exchanger.

See Section VI, Paragraph B for additional details.

TABLE 3: TANKLESS HEATER DATA

Figure 5: Recommended Piping for Combination

Heating & Cooling (Refrigeration) Systems

CAUTION

Oxygen contamination of the boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. RRO's Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.

G. CONNECT TANKLESS HEATER PIPING AS

SHOWN IN Figure 6. See Table 3 for Tankless Heater Ratings.

Boiler Model Rating (Gal/Min)

RRO080

RRO092

RRO120

RRO111

RRO151

RRO179

during “off” periods when it is possible for heat to be conducted back through the supply line. The

ow regulator also limits the ow of supply water

regardless of inlet pressure variations in the range of 20 to 125 psi.

2. TEMPERING OF HOT WATER — Installation of an automatic mixing valve will lengthen the delivery of the available hot water by mixing some cold water with the hot. This prevents excessive

and possibly scalding hot water at the xtures. In

addition, savings of hot water will be achieved since the user will not waste as much hot water while seeking water temperature to his liking. Higher temperature hot water required by dishwashers and automatic washers is possible by piping the hot water from the heater prior to entering the mixing valve. The mixing valve should be “trapped” by installing it below the cold water inlet to heater to prevent lime formation in the valve.

2.75 3.9

3.00 4.7

3.25 5.6

3.75 7.2

4.00 8.0

Pressure Drop

(PSI)

Figure 6: Schematic Tankless Heater Piping

THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED WHEN PIPING THE TANKLESS HEATER:

1. FLOW REGULATION — If ow through the heater

is greater than its rating, the supply of adequate hot water may not be able to keep up with the demand.

For this reason a ow regulator matching the heater

rating should be installed in the cold water line to

the heater. The ow regulator should preferably be

located below the inlet to the heater and a minimum of 3’ away from the inlet so that the regulator is not subjected to excess temperatures that may occur

WARNING

Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at xtures. Adjust and maintain the mixing valve in accordance with the manufacturer's instructions.

3. FLUSHING OF HEATER — All water contains some sediment which settles on the inside of the coil. Consequently, the heater should be periodically backwashed. This is accomplished by installing hose bibs as illustrated and allowing water at city pressure to run into hose bib A, through the heater, and out hose bib B until the discharge is clear. The tees in which the hose bibs are located should be the same size as heater connections to minimize pressure drop.

4. HARD WATER — A water analysis is necessary to determine the hardness of your potable water. This is applicable to some city water and particularly to well water. An appropriate water softener should be installed based on the analysis and dealer’s

recommendation. This is not only benecial to the tankless heater but to piping and xtures plus the many other benets derived from soft water.

WARNING

Vent this boiler according to these instructions. Failure to do so may cause products of combustion to enter the home resulting in severe property damage, personal injury or death.

Insufcient Combustion Air Supply may result in the production and release of deadly carbon monoxide (CO) into the home which can cause severe personal injury or death.

Improper venting may result in property damage and the release of ue gases which contain deadly carbon monoxide (CO) into the home, which can cause severe personal injury, death, or substantial property damage.

Inspect existing chimney and vent connector for obstructions and deterioration before installing boiler. Failure to clean or replace perforated pipe or chimney liner will cause severe injury or death.

Do not de-rate the appliance. Failure to re the boiler at it's designed input may cause excessive condensation upon the interior walls of the chimney. In addition, the lower input may not create enough draft to adequately evacuate the by-products of combustion.

H. CHIMNEY VENTING

1. Chimney venting is an important part of a safe

and efcient oil red appliance system. Contact your local re and building ofcials on specic

requirements for restrictions and the installation of fuel oil burning equipment. In addition, consult with a professional knowledgeable on the requirements of NFPA 31 – Standard for the Installation of Oil-Burning Equipment and NFPA 211 - Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances for installations in the United States. Installations in Canada must be reviewed with a professional knowledgeable on the requirements of CSA B139 – Installation Code for Oil-burning Equipment.

2. The safe venting of oil red boilers is dependant on

many factors. Some of these factors include:

a. sufcient draft during the entire heating season

to allow for the safe discharge of combustion byproducts and;

b. suitable corrosion protection in the event of

condensing ue gases. Only a trained and qualied

contractor may install this product.

3. The RRO shall be vented into any of the following:

a. Masonry or metal chimney. Build and install in

accordance with local buildings codes; or local authority having jurisdiction; or “Standards for Chimney, Fireplace, Vents, and Solid Fuel Burning Appliances”, ANSI/NFPA 211 and/or National Building Code of Canada. Masonry chimney must be lined with listed chimney

system. Listed clay ue lined masonry chimneys

meet venting requirements.

• External chimneys are more susceptible to ue gas condensation due to colder outside

air temperatures. To prevent corrosion

due to ue gas condensation, use a listed

corrosion-resistant metal liner in chimney.

Figure 7: Recommended Smokepipe Arrangement

and Chimney Requirements

• Oversized chimneys are more susceptible to ue gas condensation. To reduce the likelihood of ue gas condensation and

ensure proper draft, use a properly sized listed metal liner in oversized chimney.

4. Chimney Inspection – Prior to the installation of any new or replacement fuel burning equipment the

chimney shall be inspected by a qualied installer.

The chimney shall be inspected for integrity as well as for proper draft and condensate control. Some jurisdictions require the use of a liner when changing fuel types. Some jurisdictions require the use of a liner even when the same fuel is used. At a minimum, the chimney shall be examined

by a qualied person in accordance with the

requirements of Chapter 11 of NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid FuelBurning Appliances.

a. Loose Mortar – Loose mortar could be an indication

of a prior history of condensing ue gases upon

the inside walls of the chimney. Colder climates are more susceptible to this condition. Under no circumstances shall a chimney of this condition be used until it meets the requirements of NFPA 211 or CSA B139.

b. Unlined Chimney – Under no circumstances shall

a chimney constructed of brick only be used. Only approved clay liners or listed chimney lining systems

shall be used as specied in NFPA 31 or CSA B139.

c. Abandoned Openings – Openings through the

chimney wall that are no longer used shall be sealed in accordance to NFPA 211. Often abandoned openings are improperly sealed and usually covered by a gypsum wall covering.

d. Clean Chimney – Chimney shall be free of all loose

debris.

5. Draft Regulator – a draft regulator is not supplied with the boiler. A draft regulator must be used with this appliance. Refer to Figures 7 and 8.

CHIMNEY CONNECTOR

1. A chimney connector (vent pipe) is used to connect the boiler to the base of the chimney. The chimney connector should be kept as short as possible. The horizontal length of the chimney connector shall not be greater than 10 feet.

DANGER

The chimney and connector shall be inspected annually for signs of debris and corrosion. Loose mortar at the base of the chimney may be a sign of condensate damage to the chimney. A chimney professional shall be contacted immediately to examine the damage and recommend a solution. Long term operation while in this condition may cause a venting failure and force ue gases into the living space. If the chimney is to be re-lined use the recommendations in NFPA 31, Appendix E or CSA B139.

2. Vent Connector shall be any of the following and of the same size as the outlet of boiler.

a. Type L or a factory built chimney material that

complies with the Type HT requirements of ANSI/UL 103. Install in accordance with listing and manufacturer’s instructions.

b. Steel pipe having resistance to corrosion and

heat with a minimum wall thickness of 24 Gauge (0.024”).

Figure 8: Proper and Improper Locations of Draft Regulator

DANGER

Any signs of condensate seepage at the base of the chimney shall be inspected immediately. The discoloration may be a sign of chimney damage and must be remedied immediately.

DRAFT

1. The natural draft generated through a chimney is dependent on several factors including, chimney

height, temperature of ue gases, cross section area of

chimney, chimney wall insulation value, dilution air and

total volume of ue gases, to name a few. Make sure

that the boiler has been running for at least 5 minutes before measuring the draft.

2. Minimum Draft Overre – The draft induced by a

chimney must create at least a pressure of -0.02 inches water column (“ w.c.). The pressure at the canopy cannot be positive since this could create a condition

that allows ue gas by-products to escape from the

draft regulator. A negative pressure reading up to -.03 inches water column is acceptable for proper operation.

STACK TEMPERATURE

1. The temperature of the ue gases has a signicant effect

on the amount of draft created in a vertical chimney as well as the propensity to create condensate. The higher the stack temperature, the greater the amount of draft that can be generated. A lower stack temperature not only reduces the amount of draft that can be created

but it also increases the possibility that the ue gases

could condense in the chimney connector or stack.

2. NFPA 31 and CSA B139 have information to help the installer make an appropriate choice of venting materials. In some cases a chimney may have to be lined

to create sufcient draft. In other cases, the chimney

may have to be lined to prevent the corrosion of a masonry chimney. Consult with a chimney specialist knowledgeable on the requirements for chimney requirements in your area.

CAUTION

Any doubt on the condition of a chimney or it’s ability to prevent the generation and accumulation of ue gas condensate, must be relined according to NFPA 31 (United States) or CSA B139 (Canada).

CAUTION

Use the chimney venting tables as a guide. It is highly recommended that any borderline application should result in the relining of the chimney with a suitable liner that creates sufcient draft and to protect against corrosion caused by ue gas condensate.

I. INSPECT NOZZLE, ELECTRODES INSERTION

DEPTH AND TURBULATOR SETTING/CHANGE FIRING RATE:

1. Select the proper oil nozzle for the installation. Refer to Table 2 for Firing rates.

If the installed ring rate is desired, inspect the

installed nozzle and assure that the nozzle is

the correct size and type as specied in Burner Specications, Table 13 in Section X.

If a different ring rate is desired, remove the nozzle

which was factory installed. Locate the desired

ring rate nozzle (supplied with burner). Conrm

the nozzle is the proper size and type for the desired

ring rate as specied in Table 13 in Section

X. Install the proper nozzle in the burner nozzle adaptor.

2. Check the settings and to change the nozzle to a

different ring rate:

a. Loosen two (2) igniter latching screws, rotate

tabs and swing open igniter about hinge.

b. Loosen knurled nut and disconnect copper

connector tube.

c. Remove nozzle line electrode assembly.

d. If installed ring rate is desired, conrm the

nozzle is the proper size and type, refer to Table 13 in Section X, then proceed to Item i. below.

e. If a different ring rate is desired, remove the

nozzle that was factory installed. f. Remove Beckett MB(L1) or MD(V1) head. g. Locate the desired nozzle. Refer to Table 13 in

Section X for proper nozzle. The nozzle must

be securely installed to assure leak free joints

between the nozzle and adapter. When installing

the nozzle, be careful not to bump or move the

burner electrodes.

Note: On the RRO080 with ring rate of 0.65 GPH,

the low ring rate bafe is required.

h. Reinstall Beckett MB(L1) or MD(V1) Head.

i. Inspect and measure burner electrodes. Refer

to Figure 9 or the proper electrode setting.

Readjust electrode setting to the proper

dimensions if necessary. Refer to Figure 9.

j. Reinstall nozzle line electrode assembly.

k. Connect copper connector tube.

l. Inspect Beckett head setting on left side of

burner by insuring the line on the label MB(L1)

or the blue line MD(V1) are aligned, readjust if

necessary. Refer to Figure 9.

m. Tighten knurled nut.

n. Swing igniter closed, rotate tabs and tighten two

(2) igniter screws.

o. Locate the Conversion Label Envelope with the

desired ring rate in the Instruction Assembly

Envelope. Apply the Conversion Rating Label

Figure 9: "L1" and "V1" Head Electrode

Positioning and Gun Setting (Beckett AFG)

near the existing Rating Label on the boiler. DO NOT REMOVE or COVER-UP the existing Rating Label.

J. FUEL UNITS AND OIL LINES

SINGLE-PIPE OIL LINES Standard burners are

provided with single-stage 3450 rpm fuel units with the by-pass plug removed for single-pipe installations.

The single-stage fuel unit may be installed single-pipe

with gravity feed or lift. Maximum allowable lift is 8 feet. See Figure 10.

IMPORTANT

Single-pipe installations must be absolutely airtight or leaks or loss of prime may result. Bleed line and fuel unit completely.

TWO-PIPE OIL LINES For two-pipe systems

where more lift is required, the two-stage fuel unit is recommended. Table 4 (single-stage) and Table 5 (twostage) show allowable lift and lengths of 3/8-inch and 1/2-inch OD tubing for both suction and return lines. Refer to Figure 11.

Be sure that all oil line connections are absolutely

airtight. Check all connections and joints. Flared

ttings are recommended. Do not use compression ttings.

Open the air-bleed valve and start the burner. For clean

bleed, slip a 3/16" ID hose over the end of the bleed valve and bleed into a container. Continue to bleed for 15 seconds after oil is free of air bubbles. Stop burner and close valve.

TABLE 4: SINGLE STAGE UNITS (3450 RPM)

TWO PIPE SYSTEMS

Maximum Length of Tubing

Lift "H"

(See Figure)

0' 84' 100'

1' 78' 100'

2' 73' 100'

3' 68' 100'

4' 63' 100'

5' 57' 100'

6' 52' 100'

7' 47' 100'

8' 42' 100'

9' 36' 100'

10' 31' 100'

11' 26' 100'

12' 21' 83'

13' --- 62'

14' --- 41'

"H" + "R" (See Figure)

3/8" OD

Tubing (3 GPH)

1/2" OD

Tubing (3 GPH)

Figure 10

TABLE 5: TWO-STAGE UNITS (3450 RPM)

TWO-PIPE SYSTEMS

Maximum Length of Tubing

Lift "H"

(See Figure)

0' 93' 100'

2' 85' 100'

4' 77' 100'

6' 69' 100'

8' 60' 100'

10' 52' 100'

12' 44' 100'

14' 36' 100'

16' 27' 100'

18' --- 76'

"H" + "R" (See Figure)

3/8" OD

Tubing (3 GPH)

1/2" OD

Tubing (3 GPH)

K. SINGLE ZONE WIRING

1. 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt connections are made inside the HydroStat relay as follows (see Figures 11a and 11b).

• Hot (“black”) - Wire Nut with Black wire of ON/

OFF Toggle Switch

• Neutral (“white”) - Terminal “L2”

• Ground (“green” or bare) - Ground screw on the

case

2. Thermostat Wiring - Follow thermostat manufacturer instructions. To insure proper thermostat operation, avoid installation in areas of poor air circulation, hot spots (near any heat source or in direct sunlight), cold spots (outside walls, walls adjacent to unheated areas, locations subject to drafts). Provide Class II circuit between thermostat and boiler. Connect thermostat wire leads to terminals “T” and “T” (see Figures 11a and 11b).

Figure 11

REFER TO FIGURE 12 FOR

SCHEMATIC WIRING DIAGRAM OF

APPROPRIATE BURNER AND OIL

PRIMARY CONTROL OPTION

Figure 11a: Schematic Wiring Diagram, without Tankless Heater, Cold Start Control

REFER TO FIGURE 12 FOR

SCHEMATIC WIRING DIAGRAM

OF APPROPRIATE BURNER

AND OIL PRIMARY CONTROL

OPTION

Figure 11b: Schematic Wiring Diagram, with Tankless Heater, Warm Start Control

NOTE: APPLY THIS BURNER

SCHEMATIC TO APPROPRIATE

STEAM OR WATER BOILER

CONTROL SCHEMATIC, REFER

TO FIGURES 11 THRU 12

Figure 12: Schematic Wiring Diagrams For Burner Primary Controls

III. INDIRECT WATER HEATER PIPING

A. CONNECT Indirect Water Heater Piping as shown in Figure 13. Refer to Indirect Water Heater Instruction Manual for

additional installation information.

Figure 13: Indirect Water Heater Piping on RRO Series Water Boiler

RRO Series Water Boiler - Figure 13 shows indirect water heater piping on typical hot water heating system. Boiler

piping is the same as for any two-zone system. Figure 13 shows circulator zoning, which is usually preferred for indirect

water heaters. Size the circulator and indirect water heater piping to obtain the boiler water ow through the indirect

water heater called for by the indirect water heater manufacturer. Refer to the indirect water heater instruction manual for additional details.

IV. SYSTEM START-UP

WARNING

All boilers equipped with burner a swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental ring of burner outside the combustion chamber. Be sure to tighten swing door fastener completely when service is completed.

A. ALWAYS INSPECT INSTALLATION

BEFORE STARTING BURNER.

1. Verify that the venting, water piping, oil piping, and electrical system are installed properly. Refer to Installation Instructions contained in this manual.

2. Conrm all electrical, water and oil supplies are

turned off at the source and that the vent is clear from obstructions.

The maximum operating pressure of this boiler is posted on the ASME Data Label located on the top of the boiler. Never exceed this pressure. DO

NOT plug safety relief valve.

WARNING

NOTICE

WARNING

Completely read, understand and follow all instructions in this manual before attempting start up.

B. FILL HEATING SYSTEM WITH WATER.

Fill entire heating system with water and vent air from

system. Use the following procedure on a series loop or multi-zoned system installed as per Figure 4, to

remove air from system when lling:

1. Close full port ball valve in boiler system piping.

2. Isolate all zones by closing zone valves or shut-off valves in supply and return of each zone(s).

3. Attach a hose to vertical purge valve in boiler system piping.

(Note - Terminate hose in ve gallon bucket at a

suitable oor drain or outdoor area).

4. Starting with one zone at a time, open zone valve or shut-off valve in boiler supply and return piping.

5. Open purge valve.

6. Open shut-off valve in cold water supply piping located between the air scoop and expansion tank.

7. Allow water to overow from bucket until discharge

from hose is bubble free for 30 seconds.

8. When zone is completely purged of air, close zone valve or shut-off valve. Open zone valve to the next zone to be purged. Repeat this step until all zones have been purged. At completion, open all zone valves.

9. Close purge valve, continue lling the system until

the pressure gauge reads 12 psi. Close shut-off valve in cold water supply piping.

If make-up water line is equipped with pressure reducing valve, system will automatically ll to 12 psi. Follow ll valve manufacturer's instructions.

10. Open full port ball valve in boiler system piping.

11. Remove hose from purge valve.

12 Conrm that the boiler and system have no water

leaks.

C. CHECK CONTROLS, WIRING AND

BURNER to be sure that all connections are tight and

burner is rigid, that all electrical connections have been

completed and fuses installed, and that oil tank is lled

and oil lines have been tested.

D. ADJUST CONTROL SETTINGS with burner

service switch turned “ON”.

1. SET ROOM THERMOSTAT about 10°F below room temperature.

2. PRESS RED RESET BUTTON on front of burner cover. Hold button for one (1) second and release to reset primary control.

3. BOILERS WITHOUT TANKLESS HEATERS are equipped with an Intelligent Oil Boiler Control (Boiler Control). The Boiler Control is factory programmed with a High Limit setpoint of 180°F. The High Limit setpoint is adjustable between 140°F and 240°F. This temperature may be varied to suit the installation requirements.

HIGH LIMIT DIFFERENTIAL is factory

programmed at 15°F and is adjustable between 10°F and 30°F.

4. BOILERS WITH TANKLESS HEATERS are equipped with a Warm Start Intelligent Oil Boiler Control (Warm Start Boiler Control). The Warm Start Boiler Control is factory programmed with a High Limit setpoint of 180°F. The High Limit

setpoint is adjustable between 140°F and 240°F. High Limit Differential is factory programmed at 10°F. Additionally, the Warm Start Boiler Control is factory programmed with a Low Limit setpoint of 110°F. The Low Limit setpoint is adjustable between 110°F and 220°F. These temperatures may be varied to suit the installation requirements.

5. CHECKOUT

Put the system into operation and observe at least

one complete cycle to make sure that the controller operates properly. See Troubleshooting Section to use LED to assist in determining system operation.

E. ADJUST OIL BURNER BEFORE STARTING.

1. CHECK BURNER SETTINGS and readjust if necessary, see Table 13 in Section X.

a. Inspect burner head setting on left side of burner

housing by insuring the blue line MD(V1) or the line on the label MB(L1) are aligned, readjust if necessary. Refer to Figure 16 and Table 13 in Section X.

b. Check burner air band and air shutter settings.

Readjust if necessary, see Burner Specications

Table 13 in Section X.

c. OPEN ALL OIL LINE VALVES.

d. Attach a plastic hose to fuel pump vent tting

and provide a pan to catch the oil.

e. OPEN FLAME OBSERVATION PORT

COVER on burner swing door.

CAUTION

Air Band is set for maximum input and must be readjusted prior to starting burner, if nozzle was changed to a lower ring rate.

F. START OIL BURNER.

1. Open vent tting on fuel pump.

2. TURN ‘ON’ BURNER service switch and

allow burner to run until oil ows from vent tting in a SOLID stream without air bubbles for

approximately 10 seconds.

3. Close vent tting and burner ame should start

immediately after prepurge is completed. Prepurge

prevents burner ame until 10 seconds has elapsed

after initial power is applied to burner. During prepurge the motor and igniter will operate but the oil valve will remain closed. Refer to Oil Primary Control Instructions for more details.

4. Adjust oil pressure.

a. When checking a fuel unit's operating pressure, a

reliable pressure gauge may be installed in either the bleeder port or the nozzle port. For Beckett burner refer to Figure 14.

Figure 14: Adjusting Fuel Pump Pressure

b. Locate oil pressure adjusting screw and turn

screw to obtain proper pump pressure, refer to Table 13 in Section X.

c. To check the cutoff pressure, deadhead a reliable

pressure gauge onto the copper connector tube attached to the nozzle port. Run the burner for a short period of time. Shut the burner off. The pressure should drop and hold.

d. Remove the gauge and install bleeder port and/or

reconnect the nozzle port line.

G. ADJUST OIL BURNER WHILE OPERATING.

(ame present)

1. SET ROOM THERMOSTAT about 10°F below room temperature.

2. PRESS RED RESET BUTTON on Oil Primary Control and release.

3. READJUST THE HEAD SETTING only if necessary.

a. RRO080 thru RRO111:

Beckett MB(L1) Head burners have a xed head

which are non-adjustable.

b. RRO151 thru RRO179: Beckett MD(V1) (variable) Head burners have

the ability to control air by moving the head. It might be necessary to move the head forward or back one position at a time to optimize the smoke and CO2 readings. See Figure 16 and Table 13 in Section X.

4. READJUST THE AIR DAMPER SETTING (air Band/Air Shutter/Air Gate) on the burner for a

light orange colored ame while the draft over the re is -0.02”. Use a smoke tester and adjust

air for minimum smoke (not to exceed #1) with a

minimum of excess air. Make nal check using

suitable instrumentation to obtain a CO

of 11.5

to 12.5% with draft of -0.02” (water gauge) in re box. These settings will assure a safe and efcient operating condition. If the ame appears stringy instead of a solid re, try another nozzle of the same

type. Flame should be solid and compact. After all adjustments are made, recheck for a draft of -0.02”

over the re.

5. ONLY READJUST THE HEAD/TURBULATOR SETTING if necessary.

a. Move the setting forward or back one position at

a time to optimize the smoke and CO2 readings.

b. Steps outlined in Paragraph 3 and 4 above must

be repeated every time the Head/Turbulator or Air Damper Setting is readjusted.

WARNING

DO NOT loosen or remove any oil line ttings

while burner is operating.

6 FLAME FAILURE

The RRO boiler controls operate the burner

automatically. If for unknown reasons the burner

ceases to re and the reset button on the primary

control has tripped, the burner has experienced ignition failure. Refer to Oil Primary Control features, Paragraph D, Step 2 of this Section and Section VIII, Troubleshooting, Paragraph B. If the failure re-occurs, call your heating contractor immediately before pressing the reset button.

WARNING

DO NOT attempt to start the burner when excess

oil has accumulated, when the boiler is full of vapor, or when the combustion chamber is very hot.

7. CAD CELL LOCATION AND SERVICE

The burner is supplied with a cadmium sulde ame

detector mounted at the factory, mounted on the bottom of the electronic ignitor. See Figure 15. To service cad cell or to replace the plug in portion, swing open the ignitor. After service is complete, be sure to fasten down the ignitor.

H. CHECK FOR CLEAN CUT OFF OF

BURNER.

1. AIR IN THE OIL LINE between fuel unit and nozzle will compress when burner is on and will expand when burner stops, causing oil to squirt from nozzle at low pressure as burner slows down and causing nozzle to drip after burner stops. Usually cycling the burner operation about 5 to 10 times will rid oil line of this air.

2. IF NOZZLE CONTINUES TO DRIP, repeat Paragraph H, Step 1 above. If this does not stop the dripping, remove cut-off valve and seat, and wipe both with a clean cloth until clean, then replace and readjust oil pressure. If dripping or after burn persist replace fuel pump.

I. TEST CONTROLS.

1. Check thermostat operation. Raise and lower thermostat setting as required to start and stop burner.

WARNING

Before installation of the boiler is considered complete, the operation of all boiler controls must be checked, particularly the primary control and high limit control.

2. VERIFY OIL PRIMARY CONTROL FEATURES using procedures outlined in

Instructions furnished with control or instructions as follows:

GeniSys 7505 Control Features, see Figure 17.

a. The GeniSys 7505 is a microprocessor-based

control. The indicator light provides diagnostic information for lockout, recycling and cad cell status. There is a manual reset button to exit the Lockout Mode.

b. Pump Priming Cycle: To facilitate purging air

from the oil lines and lters, the 7505 can be

placed in a purge routine by:

• After the burner starts, press and hold the

reset button for 15 seconds until the yellow light turns on. This indicates that the button has been held long enough.

• Release the reset button. The yellow

light will turn off and the burner will start up again.

• At burner start up, click the reset button

while the igniter is till on. This will transition the control to a dedicated Pump Prime mode, during which the motor, igniter, and valve are powered for four (4) minutes. The yellow light will be on.

Figure 15: Cad Cell Location

Figure 16: "L1" and "V1" Head Electrode Positioning and Gun Setting

Figure 17: GeniSys 7505 Oil Primary Terminals,

LED's and Reset Button

• At the end of four (4) minutes, the yellow light

will turn off and the control will automatically return to standby mode.

c. Limited Recycle: This feature limits the number

of recycle trials (for each call for heat) to a

maximum of three trials. If the ame is lost

three times and does not successfully satisfy a call for heat, the 7505 locks out.

d. Limited Reset (Restricted Mode): In order to

limit the accumulation of unburned oil in the combustion area, the control can only be reset three times. The reset count returns to zero each time a call for heat is successfully completed.

e. T-T Jumper: Select models have pre-installed

T-T jumper. DO NOT remove jumper.

Note: DO NOT remove "T-T" jumper unless

wiring diagram indicates a direct connection from thermostat and/or tankless heater aquastat control to the oil burner primary control's "T-T" terminal. Refer to appropriate wiring diagram, see Figure 11a or 11b.

f. Diagnostic LED: The indicator light on oil

primary control provides lockout, recycle and cad cell indications as follows:

• Flashing at 1 Hz (½ second on, ½ second off):

system is locked out or in Restricted Mode.

• Flashing at ¼ Hz (2 seconds on, 2 seconds

off): control is in Recycle Mode.

• On: cad cell is sensing ame.

• Off: cad cell is not sensing ame.

vii. Cad Cell Resistance Check: For proper

operation it is important that the cad cell resistance is below 1600 ohms. During a normal call for heat, the cad cell leads can be unplugged from the control and the resistance measured with a meter in the conventional way.

Conduct these tests with ame present, see

chart below.

Flame Detection Range

Normal (0 - 1600 ohms)

Limited (1600 ohms to lockout)

3. CHECK OIL PRIMARY CONTROL

CAUTION

Due to the potential hazard of line voltage, only a trained, experienced service technician should perform the following safety checks.

This control contains no eld-serviceable parts. DO NOT attempt to take it apart. Replace entire control if operation is not as described.

a. Preliminary Steps

• Check wiring connections and power supply.

• Make sure power is on to the controls.

• Make sure limit control is closed.

• Check contacts between ignitor and the

electrodes.

• Check the oil pump pressure.

• Check the piping to the oil tank.

• Check the oil nozzle, oil supply and oil lter.

b. Check Safety Features

Safe Start:

• Place a jumper across cad cell terminals.

• Follow procedure to turn on burner. Burner

must not start, indicator light turns on and control remains in Idle Mode.

• Remove jumper.

c. Simulate Ignition or Flame Failure:

• Follow procedure to turn on burner.

• Check cad cell resistance. If resistance is

below 1600 OHMS and burner runs beyond safety cut-out time, cad cell is good.

• If safety switch shuts down burner and resistance is above 1600 OHMS, open line

switch to boiler. Access cad cell under ignitor, clean face of cad cell and see that cell is securely in socket. Check gasket around

perimeter of ignitor lid for proper seal. If gasket is missing or damaged, replace gasket. Room light can effect cad cell resistance. Reset safety switch.

• Close line switch to boiler. If burner starts

and runs beyond safety switch cut-off time, cell is good. If not, install new cell.

• Close hand valve in oil supply line.

• Failure occurs, device enters Recycle Mode.

• Device tries to restart system after

approximately 60 seconds.

• After third Recycle Mode trial, safety

switch locks out within safety switch timing indicated on label and control enters Restricted Mode. Ignition and motor stop and oil valves closes.

d. Power Failure Check: After Flame is

established, turn the power off to the control/ burner. The burner should shut down safely. When power is restored a normal ignition sequence should be started.

4. CHECK HIGH LIMIT

a. Adjust system thermostat(s) to highest setting.

b. Allow burner to run until boiler water

temperature exceeds high limit setting. The burner should shut down and circulators continue running.

c. Allow the temperature to drop below control

setting. The burner must restart.

d. Boiler installation is not considered complete

until this check has been made.

5. CHECK LOW WATER CUT-OFF CONTROL

See Appendix "A" for Low Water Cut Off

Installation.

6. CHECK OPERATING CONTROL on boiler applications equipped with tankless heater(s). With burner off, draw hot water until burner starts, then turn off hot water and check burner shut-down.

J. IF CONTROLS MEET REQUIREMENT

outlined in Paragraph I, allow boiler to operate for

approximately 30 minute, conrm the boiler and system

have no leaks.

WARNING

Cad Cell Jumper must be removed after this check.

K. IF CONTROLS DO NOT MEET

REQUIREMENTS outlined in Paragraphs I-1 thru

I-6, replace control and repeat checkout procedures.

V: OPERATING

A. WATER BOILERS SEQUENCE OF

OPERATION

1. Water Boilers Without Tankless Heaters (Cold Start), Sequence Of Operation:

a. The RRO Boiler is equipped with an Intelligent

Oil Boiler Control (Cold Start Boiler Control). The boiler control replaces the traditional electronic aquastat and circulator relays 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.

b. The boiler’s sequence of operation is shown as

Status Codes on Boiler Control display. See Table 6 and Figure 18.

c. When the thermostat calls for heat the boiler

control starts the system circulator and the thermal purge (circulator pre-purge time) begins. If the time is completed or boiler temperature is less than the Start Temperature (140 F default) the start sequence continues by energizing the oil primary to operate the following sequence: blower is started and operates for pre-purge time; spark is energized and fuel valve is opened

for ignition trial time; burner res until the thermostat is satised.

d. If the thermostat is not satised and the

Operating Setpoint (SP) is reached the system circulator will continue to operate and the burner will stop. When the boiler water temperature drops below the setpoint less the differential setting the burner will restart.

e. After the thermostat is satised the burner and

circulator are stopped.

f. When an indirect water heater aquastat call for

heat is wired to the “ZR” terminal the Boiler Control starts a domestic hot water circulator connected to the “ZC” terminal and when the boiler temperature is less than Operating Setpoint (SP), the boiler control energizes the oil primary to turn on the burner without circulator pre-purge delay.

g. On burner start, if the CAD cell does not see

ame within approximately 15 seconds, primary

control will shut down the burner and enter into a lockout mode. A lockout is reset by pressing the reset button located on the primary control.

If the ame is lost while the burner is ring, the

primary control shuts down the burner, enters a 60 second recycle delay, and repeats the ignition sequence. If after three (3) trials for ignition,

ame is not detected, primary control will enter

into restricted mode. Restricted mode is reset by holding down the reset button for 15 seconds.

Figure 18: Intelligent Oil Boiler Control

2. Water Boilers with Tankless Heaters (Warm Start), Sequence Of Operation:

a. The RRO Boiler is equipped with a Warm Start

Intelligent Oil Boiler Control (Warm Start Boiler Control). The Warm Start Boiler Control replaces the traditional high and low limit aquastat and circulator relays.

b. The boiler’s sequence of operation is shown as

Status Codes on Boiler Control display. See Table 6 and Figure 18.

c. When the thermostat calls for heat the boiler

control starts the system circulator and the start sequence continues by energizing the oil primary to operate the following sequence: blower is started and operates for pre-purge time; spark is energized and fuel valve is

opened for ignition trial time; burner res until the thermostat is satised. Optionally, the

thermal purge (circulator pre-purge time) maybe added adjusting the Circulator Pre-purge time parameter. This feature saves energy by starting the circulator and delaying the burner start when there is residual heat available in the boiler .

TABLE 6: SEqUENCE OF OPERATION

Status Codes Displayed in  Mode

 Status Description



 Running

 Self Test Control internal checking

Standby

(burner off,

pump off)

Standby

(burner off,

pump on)

No call for heat detected

Either condition is true: a. Call for heat detected and boiler temperature higher than operating setpoint. b. Call for heat detected and boiler temperature higher than 140 F and Pump Pre-Purge Time has not expired.

The burner runs until the call for heat is

satised.

d. If the thermostat is not satised and the

e. After the thermostat is satised the burner and

circulator are stopped.

f. The Warm Start Boiler Control also includes

a low limit control function. When the boiler water temperature falls below the Low Limit Setpoint less the Low Limit Differential the “ZC” terminal and System Circulator outputs are de-energized and the oil primary is energized to start the burner. As temperature rises above the Low Limit Setpoint the burner is stopped, the “ZC” output is energized and the System Circulator is enabled to run in response to a call for heat.

g. On burner start, if the CAD cell does not see

ame within approximately 15 seconds, primary

control will shut down the burner and enter into a lockout mode. A lockout is reset by pressing the reset button located on the primary control.

If the ame is lost while the burner is ring, the

primary control shuts down the burner, enters a 60 second recycle delay, and repeats the ignition sequence. If after three (3) trials for ignition,

ame is not detected, primary control will enter

into restricted mode. Restricted mode is reset by holding down the reset button for 15 seconds.

3. Using Boiler Control The Boiler Control is located on front of boiler.

The Boiler Control display, along with Up ñ,

Down ò, and “I” keys may be used to view boiler operating status (Figure 19).

4. Viewing the Operating Mode Options In operating mode the user may view (but not

change) boiler operating status, settings and troubleshooting information. To view Boiler Control display information:

Press and release the

“I” key on the Boiler Control

to change from one parameter to the next. Each

setting will alternately ash between the relevant

display code and its corresponding value.

Operating Mode Options

Status Numbers:

 Standby

t

 Running  Self Test)

Boiler Temperature

Operating Setpoint (Outdoor Reset)

P

High Limit Setting

High Limit Differential

HdF

Low Limit Setpoint (warm start only)

Low Limit Differential (warm start only)

LdF

Heat Request Status

DHW Request Status

Boiler Error

Err

For example, when the “I” key is pressed on the

Boiler Control until “bt” is displayed, it will then ash a three digit number (such as “0”) followed by either “F” (or “C”). This indicates that the boiler water temperature is 180°F. Other operating parameters display the information in a similar fashion.

Figure 19: Boiler Control

Key Function & Orientation

Please note that in operating mode to hold the

display on the value the user can press and hold either the Up ñ or Down ò keys and the value will be continuously shown. This may be helpful in watching a value “live”.

5. Changing the Adjustable Parameters To adjust parameters such as the High Limit

Setpoint and High Limit Differential:

a. Using the Boiler Control display, access the

adjustment mode by pressing and holding the Up ñ, Down ò, and “I” keys simultaneously for three (3) seconds. This procedure is intended to discourage unauthorized changes or accidental changes to limit settings.

b. Press the "I" key to display available Adjustment

Mode options. Select an option.

Cold Start Boiler Control

Adjustment Mode Options

HL_ 140-240°F Adjust High Limit Setting HdF 10-30°F Adjust High Limit Differential ZC_ dh, ZR or ELL ZC and ZR Terminal Function Or_ 0-10 minutes Pump Overrun Time PP_ 2-20 minutes Pump Pre-purge Time t_ 140 - 180°F Start Temperature Pt_ On or Off Priority Time f-C F or C Select degrees F or C Mode bac Back to Operating Mode

Warm Start Boiler Control

Adjustment Mode Options

HL_ 140-240°F Adjust High Limit Setting LL_ 110-220°F Adjust Low Limit Setting

Ldf 10-25°F

ZC_ ZR or dh ZC and ZR Terminal Function Or_ 0-10 minutes Pump Overrun Time PP_ 0-20 minutes Pump Pre-purge Time t_ 140 - 180°F Start Temperature Pt_ On or Off Priority Time f-C F or C Select degrees F or C Mode bac Back to Operating Mode

Adjust Low Limit Differential Setting

c. Press the Up ñ and Down ò keys to adjust the

displayed setpoint to the desired value.

d. To return to the normal operating mode from

the Adjustment Mode, when the "bc” option is displayed, press either the Up ñ or Down ò key.

If no keys are pressed, after ve (5) minutes the

Boiler Control will automatically return to the Operating Mode.

6. More Information about Adjustable Parameters

a. High Limit (HL_)

The Boiler Control is factory programmed with

a High Limit Setpoint of 180°F. The boiler turns "off" when the boiler water temperature (bt) is above this value. The High Limit setpoint is adjustable between 140° and 240°F. The Operating Setpoint (P) will equal the High Limit Setpoint.

b. High Limit Differential (HdF)

i. The Cold Start Boiler Control is factory

programmed with a Differential of 15°F. The Differential is the number of degrees the boiler temperature must decrease below the Operating Setpoint before the boiler can restart. The differential is adjustable between 10° and 30°F.

ii. On Warm Start Boiler Control the High

Limit Differential is not adjustable and is

xed at 10°F.

c. Low Limit (LL_) The Warm Start Boiler Control is factory

programmed with a Low Limit Setpoint of 110°F. On falling temperature the boiler turns “on” and the “ZC” terminal and System Circulator outputs are de-energized when the boiler temperature is less than the Low Limit Setpoint less the differential. On a rising temperature when the boiler temperature is above the Low Limit Setpoint the boiler turns “off”, the “ZC” terminal output is energized and the System circulator is enabled to respond to a call for heat. The Low Limit Setpoint is adjustable between 110°F and 220°F.

d. Low Limit Differential (Ldf) The Warm Start Boiler Control is factory

programmed with a Low Limit Differential Setpoint of 10°F. The Low Limit Differential is the number of degrees the boiler temperature must decrease below the Low Limit Setpoint before the Warm Start Boiler Control takes actions to warm the boiler. These actions include

starting the burner and stopping water ow

through the boiler. The Low Limit Differential is adjustable between 10°F and 25°F.

e. Circulator Overrun Time (OR_) Circulator Overrun Time (also called “circulator

off delay” or “circulator post purge”) continues circulator operation after a call for heat has ended, sending excess heat from the boiler into the priority zone. Ensure system piping and zone

panel settings allow water ow to the priority

zone after the call for heat ends. The Circulator Overrun Time has a factor setting of 0 minutes

and is eld adjustable between 0 and 10 minutes.

f. Circulator Pre-Purge Time (PP_) When the boiler is warm [boiler water

temperature higher than 140°F (adjustable using Start Temperature parameter)] and there is a thermostat call for heat, the system circulator

is started and boiler ring is delayed pre-purge

minutes. If the temperature drops below 140°F or there is a DHW Call for Heat the boiler is started without delay. Additionally, the boiler is started without delay if the thermostat call for heat is initiated when the boiler water temperature is less than 140°F. This feature helps save energy by satisfying home heating needs with residual boiler heat rather than cycling the boiler. The Circulator Pre-purge time has a factory setting of

2 minutes and is eld adjustable between 2 and

20 minutes. Refer to Table 7.

The Warm Start Boiler Control Pre-purge Time is

factor set to 0 minutes.

TABLE 7: CIRCULATOR PRE-PURGE TIME ExAMPLE, PARAMETER PP_= 2 MINUTES

ZC and ZR

Call for

Heat

Terminal Function

Boiler

Temp.

Boiler Status,

(B1 Output)

(ZC_)

TT= on -- < 140 Start with no delay

TT = on -- >140 Start after 2 minute delay

ZR = on ZC_ = ZR <140 Start with no delay

ZR = on ZC_ = ZR >140 Start after 2 minute delay

ZR = on ZC_ = DH <140 Start with no delay

ZR = on ZC_ = DH >140 Start with no delay

g. Start Temperature (t_) The amount of “Heat available” is calculated by

taking the difference between measured boiler water temperature and the Start Temperature setting. Useful “Heat Available” is dependent on the type of heating emitter installed in the home. Heat emitters require a certain minimum temperature to operate effectively. Our default

settings reect cast iron radiators. Fan Coils

may require a start temperature setting of 180°F or 160°F before providing heat to the home. The Start Temperature has a factory setting of 140°F

and is eld adjustable between 140°F and 180°F.

h. Priority Time (Pt_) When the Priority Time parameter is set to “on”

and Domestic Hot Water (DHW) call for heat is “on” the DHW demand will take “Priority” over home heating demand and the system circulator will be forced “off”. Priority Time ends and the system circulator is released to service home heating demand when Domestic Hot Water call for heat is over. When Priority Time parameter is set to “Off” the DHW call for heat does not force “off” the system circulator. The Priority

Time has a factory setting of “On” and is eld

adjustable between “On” and “Off” Refer to Table 8.

TABLE 8: DOMESTIC HOT WATER DEMAND,

(PARAMETER ZC_= DH)

Call for Heat Circulator Status

T-T

InputZRInput

on off On on off on on On off on off on On off on on off OFF on off on on OFF on on off on OFF off on

Priority

Time (Pt_)

System

Circulator

Output

DHW

Circulator

ZC Output

i. ZC and ZR Terminal Function (ZC_)

The boiler control allows conguration of the ZC

output functionality to help the RRO integrate into each installation more effectively. The ZC output can be connected to a domestic hot water circulator or a second heating zone circulator or be used to enable pumps in a warm start application. These applications are selected as follows:

i. When ZC_ is set equal to Domestic Hot

Water Demand (dh)

When there is an Indirect Water Heater

(IWH) the boiler control provides a “ZR” input terminal for the IWH Aquastat and “ZC” output terminal for the DHW Circulator. When there is a DHW call for heat, the System Circulator is “forced off”, the DHW Circulator terminal is energized and the circulator pre-purge time delay control logic is bypassed to allow

the boiler to re without delay. When

DHW demand ends the System Circulator “force off” is removed, the circulator can respond normally, and the DHW Circulator is de-energized. The DHW call for heat is detected by a voltage on to the "ZR" terminal. When a Priority Time parameter is set to “off” the System Circulator is not forced off for a DHW call for heat. Refer to Table 8.

ii. When ZC_ is set equal to Zone Request (ZR)

When there is no IWH the Cold Start Boiler

Control “ZC” output may be congured

to control a second heating zone. This is particularly helpful when the home uses only two heating zones. The boiler control replaces the need for a two circulator zone panel. When DHW Terminal Function (dh_) is set to ZR the boiler control’s two circulator outputs are used to control two independent heating zones. Refer to Table

9. A "TT" input causes a call for heat and energizes the System Circulator output to service heating zone 1. A second zone’s thermostat may be wired to the "ZR" input to energize heating zone 2 circulator wired to the "ZC" output. Both outputs function

TABLE 9: ZONE REqUEST, PARAMETER ZC_= ZR

Call for Heat Circulator Status

T-T

Input

off off off off on off on off on on on on off on off on

Input

Output

independently, "TT" input controls only the System Circulator output and the "ZR" input controls only the "ZC" output. Both inputs cause a boiler call for heat.

The Warm Start Boiler Control with ZC_

set equal to Zone Request (ZR) energizes the "ZC" terminal while the boiler is warm as described earlier in this section (refer to Paragraph A,2,f). The "ZR" input is a call for heat that starts the boiler.

iii. External Low Limit, Parameter ZC = ELL

The Cold Start Boiler Control is capable of

functioning as a warm start control when external limit control is installed that closes a contact when boiler water temperature falls below a setpoint. When an external limit contact closes (boiler water is cold) the boiler is started and the "ZC" and "C1" output terminals are de-energized. When

the "ZR" terminal is de-energized (boiler water temperature is above setpoint) the call for heat is ended and the "C1" terminal is released to operation and the "ZC" terminal is energized. An External Low Limit Request is detected by sensing a voltage on the "ZR" terminal. The Warm Start Boiler Control does not have the External Low Limit Option. Refer to Table 10.

TABLE 10: ExTERNAL LOW LIMIT, PARAMETER ZC_= ELL

Call for Heat Circulator Status

T-T

Input

off off off on on off on on on on off off off on off off

Input

Output

VI. MAINTENANCE AND SERVICE INSTRUCTIONS

A. WATER BOILERS

1. Filling of boiler and system.

GENERAL — In a hot water heating system, the

boiler and entire system (other than the expansion tank) must be full of water for satisfactory operation. Water should be added to the system until the boiler pressure gauge registers 12 psi. To insure that the system is full, water should come out of all air vents when opened.

2. BOILING OUT OF BOILER AND SYSTEM. The oil and grease which accumulate in a new hot water boiler can be washed out in the following manner:

a. Remove relief valve using extreme care to avoid

damaging it.

b. Add an appropriate amount of recommended boil

out compound. c. Replace relief valve. d. Fill the entire system with water.

e. Start ring the boiler.

f. Circulate the water through the entire system. g. Vent the system, including the radiation. h. Allow boiler water to reach operating

temperature, if possible. i. Continue to circulate the water for a few hours.

j. Stop ring the boiler.

k. Drain the system in a manner and to a location

that hot water can be discharged with safety. l. Remove plugs from all available returns and

wash the water side of the boiler as thoroughly as

possible, using a high-pressure water stream.

m. Rell the system with fresh water.

3. Add appropriate boiler water treatment compounds

as recommended by your qualied water treatment

company.

4. Make pH or Alkalinity Test.

After boiler and system have been cleaned and

relled as previously described, test the pH of

the water in the system. This can easily be done by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper, except it gives

specic readings. A color chart on the side of the

small hydrion dispenser gives the reading pH. Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist. The pH should be higher than 7 but lower than 11. Add some of the washout chemical (caustic soda), if necessary, to bring the PH within the

specied range.

5. Boiler is now ready to be put into service.

IMPORTANT

IF, DURING NORMAL OPERATION, IT IS NECESSARY TO ADD MORE WATER THAN INDICATED BELOW, CONSULT A qUALIFIED

SERVICE TECHNICIAN TO CHECK YOUR SYSTEM FOR LEAKS.

Boiler Model

RRO080, RRO092,

RRO120

RRO111, RRO151,

RRO179

Gallons Per

Month

0.3 4

0.4 5

B. EXCESSIVE MAKE-UP WATER

A leaky system will increase the volume of make-up

water supplied to the boiler, which can signicantly

shorten the life of the boiler. Entrained in makeup water are dissolved minerals, salts and oxygen. When the fresh, cool make-up water is heated in the boiler, the minerals fall out as sediment, the salts coat the inside of the boiler, and the oxygen escapes as a gas. The accumulation of sediment eventually isolates the water from contacting the cast iron. When this happens the cast iron in that area gets extremely hot and eventually cracks. The presence of free oxygen or chloride salts in the boiler corrodes the cast iron from the inside. More makeup water and higher concentrations of contaminants damage the boiler sooner. Our warranty does not cover corrosion and sediment-related damage. Clearly it is in everyone’s best interest to prevent this type of failure. You can do your part by ensuring that your system is leak-free, keeping leakage to less than 2 percent of the total water volume each month.

C. HINTS ON COMBUSTION

1. NOZZLES — Although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil burner. The selection of the nozzle supplied with the RRO boiler is the

result of extensive testing to obtain the best ame shape and efcient combustion. Other brands of the

same spray angle and spray pattern may be used but may not perform at the expected level of CO2 and smoke. Nozzles are delicate and should be protected from dirt and abuse. Nozzles are mass-produced and can vary from sample to sample. For all of those reasons a spare nozzle is a desirable item for a serviceman to have.

Gallons Per

Year

2. FUEL LEAKS — Any fuel leak between the pump and the nozzle will be detrimental to good combustion results. Look for wet surfaces in the air tube, under the ignitor, and around the air inlet. Any such leaks should be repaired as they may cause erratic burning

of the fuel and in the extreme case may become a re

hazard.

3. AIR LEAKS — Any such leaks should be repaired, as they may cause erratic burning of the fuel and in

extreme cases may become a re hazard.

4. SUCTION LINE LEAKS -

Whatever it takes, The Oil Must Be Free of Air. This

can be a tough problem , but it must be resolved. Try bleeding the pump through a clear tube. There must be no froth visible. There are various test kits available to enable you to look at the oil through clear tube. There must be no froth visible. There are various test kits available to enable you to look at the oil through clear

tubing adapted to the supply line at the pump tting.

Air eliminators are on the market that have potential. Also, electronic sight glasses are being used with good success. At times, new tubing must be run to the tank

or new ttings put on. Just make sure you get the air

out before you leave.

Any air leaks in the fuel line will cause an unstable

ame and may cause delayed ignition noises. Use only are ttings in the fuel lines.

5. GASKET LEAKS — If 11.5 to 12.5% CO smoke cannot be obtained in the breeching, look for air leaks around the burner mounting gasket, observation door, and canopy gasket. Such air leaks will cause a lower CO2 reading in the breeching. The smaller the

ring rate the greater effect an air leak can have on

CO2 readings.

6. DIRT — A fuel lter is a good investment. Accidental

accumulation of dirt in the fuel system can clog the nozzle or nozzle strainer and produce a poor spray

pattern from the nozzle. The smaller the ring rate, the

smaller the slots become in the nozzle and the more prone to plugging it becomes with the same amount of dirt.

7. WATER — Water in the fuel in large amounts will stall the fuel pump. Water in the fuel in smaller amounts will cause excessive wear on the pump, but more

importantly water doesn’t burn. It chills the ame

and causes smoke and unburned fuel to pass out of

the combustion chamber and clog the ueways of the

boiler.

8. COLD OIL — If the oil temperature approaching the fuel pump is 40°F or lower poor combustion or delayed ignition may result. Cold oil is harder to atomize at the nozzle. Thus, the spray droplets get larger and the

ame shape gets longer. An outside fuel tank that is

above grade or has fuel lines in a shallow bury is a good candidate for cold oil. The best solution is to bury the tank and lines deep enough to keep the oil above 40°F.

with a #1

9. FLAME SHAPE — Looking into the combustion

chamber through the observation door, the ame should

appear straight with no sparklers rolling up toward the

crown of the chamber. If the ame drags to the right

or left, sends sparklers upward or makes wet spots on the target wall, the nozzle should be replaced. If the condition persists look for fuel leaks, air leaks, water or dirt in the fuel as described above.

10. HIGH ALTITUDE INSTALLATIONS

Air settings must be increased at high altitudes. Use

instruments and set for 11.5 to 12.5% CO2.

11. START-UP NOISE — Late ignition is the cause of start-up noises. If it occurs recheck for electrode

settings, ame shape, air or water in the fuel lines.

12. SHUT DOWN NOISE — If the ame runs out of air

before it runs out of fuel, an after burn with noise may occur. That may be the result of a faulty cut-off valve in the fuel pump, or it may be air trapped

in the nozzle line. It may take several ring cycles for

that air to be fully vented through the nozzle. Water in

the fuel or poor ame shape can also cause shut down

noises.

NOTICE

CHECK TEST PROCEDURE. A very good test for isolating fuel side problems is to disconnect the fuel system and with a short length of tubing, re out of an auxiliary ve gallon pail of clean, fresh, warm #2 oil from another source. If the burner runs successfully when drawing out of the auxiliary pail then the problem is isolated to the fuel or fuel lines being used on the jobsite.

D. ATTENTION TO BOILER WHILE NOT IN OPERATION

1. IMPORTANT:

IF BOILER IS NOT USED DURING WINTER TIME,

IT MUST BE FULLY DRAINED TO PREVENT FREEZE DAMAGE.

2. Always keep the manual fuel supply valve shut off if the burner is shut down for an extended period of time.

WARNING

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.

3. To recondition the heating system in the fall season after a prolonged shut down, follow the instructions outlined in Section IV, Paragraphs A through K.

VII. BOILER CLEANING

WARNING

All boiler cleaning must be completed with burner service switch turned off.

A. CLEAN THE FLUEWAYS (See Figure 20).

1. Disconnect oil line(s) and remove burner and burner mounting plate. See Figure 1a or 1b.

2. Lay protective cloth or plastic over combustion chamber blanket.

3. Remove the smokepipe as necessary to gain access to the boiler canopy.

4. Remove the jacket top panels.

5. Remove the canopy being careful not to damage the canopy gaskets.

6. Using a 1¼” diameter wire or bre bristle brush (30” handle) clean the ueways. Brush from the top

using diagonal strokes for best results. DO NOT allow brush to strike the target wall or liner in the chamber.

B. CLEAN TOP OF BOILER SECTIONS.

1. Brush and vacuum the tops of the boiler sections.

C. CLEAN THE FIREBOX.

1. Using wire or bre bristle brush, clean crown

of boiler and inside of water legs. DO NOT allow brush to strike target wall or blanket in the combustion chamber.

D. AFTER CLEANING, remove protective cloth with

debris and vacuum as necessary, but be careful not to damage blanket. Inspect target wall, combustion chamber blanket and burner mounting plate insulation for signs of damage. If damaged, replace as needed.

E. REASSEMBLE BOILER.

CAUTION: Do not start the burner unless canopy,

smokepipe and burner swing door are secured in place.

1. Install the canopy taking care to align the gaskets

without blocking the ueways. If gasket is damaged,

replace as needed.

2. Close and secure burner swing door to front section with fasteners.

3. Reconnect oil line(s).

4. Reinstall Top Panels and secure with sheet metal screws.

5. Reinstall smokepipe on canopy and secure to collar with sheet metal screws.

Figure 20: Cleaning of Boiler Flueways

WARNING

The boiler must be connected to an approved chimney in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney ue must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions. A clean and unobstructed chimney ue is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler's efciency.

Important Product Safety Information

Refractory Ceramic Fiber Product

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.

VIII: TROUBLESHOOTING

A. COMBUSTION

result of extensive testing to obtain the best ame shape and efcient combustion. Other brands of the

same spray angle and spray pattern may be used but may not perform at the expected level of CO smoke. Nozzles are delicate and should be protected from dirt and abuse. Nozzles are mass-produced and can vary from sample to sample. For all of those reasons a spare nozzle is a desirable item for a serviceman to have.

may become a re hazard.

3. SUCTION LINE LEAKS — Any such leaks should be repaired, as they may cause erratic burning of the

fuel and in extreme cases may become a re hazard.

Whatever it takes, The Oil Must Be Free of Air. This can be a tough problem, but it must be resolved. Try bleeding the pump through a clear tube. There must be no froth visible. There are various test kits available to enable you to look at the oil through clear tubing adapted to the supply line at the pump

tting. Air eliminators are on the market that have

potential. Also, electronic sight glasses are being used with good success. At times, new tubing must

be run to the tank or new ttings put on. Just make

sure you get the air out before you leave.

Any air leaks in the fuel line will cause an unstable

ame and may cause delayed ignition noises. Use only are ttings in the fuel lines.

4. GASKET LEAKS — If 11.5 to 12.5% CO #1 smoke cannot be obtained in the breeching, look for air leaks around the burner mounting gasket, observation door, and canopy gasket. Such air leaks will cause a lower CO2 reading in the breeching. The

smaller the ring rate the greater effect an air leak

can have on CO2 readings.

5. DIRT — A fuel lter is a good investment.

Accidental accumulation of dirt in the fuel system can clog the nozzle or nozzle strainer and produce a poor spray pattern from the nozzle. The smaller the

ring rate, the smaller the slots become in the nozzle

and the more prone to plugging it becomes with the same amount of dirt.

and

with a

6. WATER — Water in the fuel in large amounts will stall the fuel pump. Water in the fuel in smaller amounts will cause excessive wear on the pump, but more importantly water doesn’t burn. It chills

the ame and causes smoke and unburned fuel to

pass out of the combustion chamber and clog the

ueways of the boiler.

7. COLD OIL — If the oil temperature approaching the fuel pump is 40°F or lower, poor combustion or delayed ignition may result. Cold oil is harder to atomize at the nozzle. Thus, the spray droplets get

larger and the ame shape gets longer. An outside

fuel tank that is above grade or has fuel lines in a shallow bury is a good candidate for cold oil. The best solution is to locate the tank near the boiler in the basement utility room or bury the tank and lines deep enough to keep the oil above 40°F. Check environmental issues with local authorities having jurisdiction.

8. FLAME SHAPE — Looking into the combustion

chamber through the observation port, the ame

should appear straight with no sparklers rolling up

toward the crown of the chamber. If the ame drags

to the right or left, sends sparklers upward or makes wet spots on the target wall, the nozzle should be replaced. If the condition persists look for fuel leaks, air leaks, water or dirt in the fuel as described above.

9. HIGH ALTITUDE INSTALLATIONS — Air openings must be increased at higher altitudes. Use instruments and set for 11.5 to 12.5% CO

10. START-UP NOISE — Late ignition is the cause of start-up noises. If it occurs recheck for electrode

settings, ame shape, air or water in the fuel lines.

11. SHUT DOWN NOISE — If the ame runs out of

air before it runs out of fuel, an after burn with noise may occur. That may be the result of a faulty cut-off valve in the fuel pump, or it may be air trapped in the

nozzle line. It may take several ring cycles for that

air to be fully vented through the nozzle. Water in the

fuel or poor ame shape can also cause shut down

noises.

NOTICE

CHECK TEST PROCEDURE. A very good test for isolating fuel side problems is to disconnect the fuel system and with a 24" length of tubing, re out of an auxiliary ve gallon pail of clean, fresh, warm #2 oil from another source. If the burner runs successfully when drawing out of the auxiliary pail then the problem is isolated to the fuel or fuel lines being used on the jobsite.

B. OIL PRIMARY CONTROL (Oil Primary)

1. Burner (Oil Primary) will not come on.

a. No power to Oil Primary. b. Oil Primary is in lockout or restricted mode.

Press reset button for one (1) second to exit lockout. If control has recycled three times within the same call for heat, it will enter into restricted mode. To reset from restricted mode,

refer to Section V, Paragraph I, Step 2 for details. c. CAD cell seeing light. d. CAD assembly defective. e. Control motor relay is stuck closed (see note

below).

2. Burner (control) will light, then shut down after a short time, then restart after one (1) minute.

a. CAD cell is defective.

b. Air leaking into oil line causing ame out. c. Defective nozzle causing ame to be erratic. d. Excessive airow or draft causing ame to leave

burner head.

e. Excessive back pressure causing ame to be

erratic.

3. Control locks out after Trial For Ignition (TFI).

a. No oil to burner. b. Shorted electrodes. c. Nozzle clogged.

d. Airow too high.

e. Ignitor module defective. f. CAD cell defective. g. Oil valve stuck open or closed.

Note: The Safety Monitoring Circuit (SMC) is

designed to provide lockout in the event of a stuck or welded motor relay.

Also refer to Model EZ-1/2/3 Oil Burner - Instruction

Manual (Form #MNEZ123) for additional information.

NOTICE

If ame is not established within 15 seconds of oil valve actuation (known as Trial For Ignition [TFI]) lockout will occur. Lockout is indicated by a red LED solid-on located on the oil primary control.

Hard Lockout will occur if the Oil Primary Control locks-out three (3) times during a call for heat. This is indicated by red light reset button solid-on.

C. INTELLIGENT OIL BOILER CONTROL

 •ColdStartBoilerControlis used on Boilers without Tankless Heaters.

• Warm Start Boiler Control is used on Boilers with Tankless Heaters

1. When a problem occurs with the boiler operation,

the Boiler Control easily provides specic, valuable

information to help resolve the issue quickly. The

display on the Boiler Control should be the rst

place to check.

a. If an Error Code "Err" IS NOT displayed on

the Boiler Control: In this circumstance, Table 11 can be used to determine the problem and possible causes.

TABLE 11: TROUBLESHOOTING GUIDE

System Condition Diagnostic Condition Check Action

Boiler is cold, house is

cold.

Boiler is hot, house is

cold.

Display is OFF. 120 Vac System power. Turn system power on.

Display is ON. 24 Vac T-T No 24 V; replace control.

24 V present; disconnect

thermostat, short T-T.

120 Vac at B1-B2

Refer to Err on display. -----

Display is ON.

120 Vac at C1-C2

Boiler below the Low Limit

temperature, wait for boiler to go

above Low Limit temperature.

Boiler above LL? If yes, check

for 120 Vac between ZC and L2.

Boiler starts, check wiring and thermostat.

• If no, replace control.

• If yes, check burner and wiring.

• 120 Vac at C1-C2, check wiring to

pump.

• Wiring OK, is pump running?

• If not, replace the pump.

• If pump is running, check for trapped air

or closed zone valves

• If no 120 Vac , replace control.

• If yes, check zone relays, circulators

and wiring.

-----

b. If the Boiler Control detects an error it will ash "Err" (boiler control error) followed by a number. Use this text and

number to identify the boiler problem and corrective action in Table 12 below.

TABLE 12: BOILER CONTROL ERROR NUMBERS

Display Status Recommended Corrective Actions

Temperature sensor failure, wire harness loose or shorted connection or control hardware failure:

Err  Temperature Sensor Fault

Err 2 Communication Fault

Err 3 Internal Hardware Fault

Err 4 Burner Output (B1) Fault

Err 5 Line Voltage Fault (< 80 Vac) AC voltage out of specication high or low; check L1, L2, 110 VAC.

Err 6 Fuse missing

Err 

Err 

User settings lost, (reset to

factory defaults)

Manual Reset Lockout

(resettable)

- Check sensor is securely attached to boiler control

- Check that sensor wire is not damaged

- If secure and in good condition, replace sensor

- If problem persists, replace control

Enviracom terminal is shorted to ground or line voltage.

- Check wiring to EnviraCOM terminals 1,2 and 3. Wiring to external EnviraCom device is incorrect.

Error detected with AC power supply frequency or boiler control failure. Cycle power to the control. Replace control if problem persists.

B1 output sensed powered during safety output relay check sequence or un-powered during running, or powered in idle in combination with water temperature above 264°F limit. Cycle power to the control. Replace control if problem persists.

Internal fuse is blown or missing. The fuse protects the Aquastat from miswiring the L1 and L2 on Oil Primary. When the Oil Primary is correctly wired the fuse is useless and not detected. If Primary is wired incorrectly the fuse is blown out and Aquastat report

error 6. EnviraCOM message is sent when the wiring is xed and the error disappears

to indicate the end of the error state. Check wiring and replace fuse.

Warning: Generated if user adjustments are lost and the device uses factory default values. Error is cleared by entering and exiting the Adjustment mode. Replace control if problem persists.

Set if Err 4 was invoked four times in a row. Check wiring and clear Lockout by pressing all three user keys for 30 seconds.

IX. REPAIR PARTS

All RRO™ repair parts may be obtained by contacting your local HAJOCA branch.

Bare Boiler Assembly (Exploded View)

Item

No.

Description

Boiler Size / Quantity

RRO120

RRO111 &

RRO179

Part No.

Bare Boiler Assembly

Water Replacement Block Assembly, less coil

Water Replacement Block Assembly, with coil

2 Rear Target Wall Insulation 1 1 82020002

Combustion Chamber Liner, 1/2" x 19-1/2" x 9-3/4" 1 --- 82020031

Combustion Chamber Liner, 1/2" x 19-1/2" x 14-3/4" --- 1 82020041

4 BSD Hinge Loop Bracket 2 2 100795-02

5 5/16" Flat Washer - Plated 4 4 80860611

6 5/16-18 x 1" Lg. Cap Screw, Plated 2 2 80861341

7 5/16-18 x 1-1/2" Lg. Cap Screw, Plated 2 2 80861349

8 Burner Swing Door (only), Machined / Painted 1 1 100793-01

9 Burner Swing Door Insulation 1 1 82020001

10 Observation Port Cover, Machined / Painted 1 1 71728004

11 5/16-18 x 3/4" Lg. Cap Screw, Plated 1 1 80861340

12 Canopy Sealing Strip (1/2" x 1-1/4" x 10') in Poly Bag 1 1 6206001

Canopy Assembly - 3 Section, 5-7/8" Dia. Collar 1 --- 104585-03

Canopy Assembly - 4 Section, 6-7/8" Dia. Collar --- 1 104585-04

14 1/4"-20 x 3" Lg. Carriage Bolt, Plated 2 2 80860119

15 1/4"-20 x 3-1/2" Lg. Carriage Bolt, Plated 2 2 100838-01

16 1/4"-20 Wing Nut - Plated 4 4 80860910

17 1/4" Flat Washer - Plated 4 4 80860603

18 Heater Cover Plate Gasket - Rear Heater 1 1 8036058

19 V1-2 Heater Carton (WT[R] & ST[R]) Rear Heater 1 1 6036031

20 5/16" Flat Washer - Plated 8 8 80860611

28 3/8"-16 x 7/8" Lg. Cap Screw, ASME Grade, Marked SA307B 8 8 80861337

1 --- CL3-WN

--- 1 CL4-WN

1 --- CL3-WR

--- 1 CL4-WR

Jacket Assembly (Exploded View)

Item

No.

Description

Boiler Size / Quantity

RRO120

RRO111,

RRO179

Part No.

Jacket Components -- Items 1 thru 6 Include Insulation as Part of Assembly

1 Jacket Front Panel Assembly 1 1 100819-01

2 Jacket Rear Panel Assembly 1 1 100820-01

Jacket Reversible Side Panel As-

sembly

Jacket Left Side Heater Panel Assembly

(WT[R] & ST[R]) Heater Builds)

5 Jacket Split Front Top Panel Assembly 1 1 100823-01

6 Jacket Split Rear Top Panel Assembly

Non-Heater Build

With Heater Build

2 --- 100821-03

--- 2 100821-04

1 --- 100821-03

--- 1 100821-04

1 --- 100824-03

--- 1 100824-04

1 --- 100822-03

--- 1 100822-04

RRO120 , RRO111 and RRO179 - Trim and Controls

Item

No.

Description

Boiler Size / Quantity

RRO120

RRO111,

RRO179

Part No.

Trim and Controls

1 Beckett GeniSys 7505B Oil Primary Control 1 1 103447-01

Honeywell L7248L1090 Hi Limit, Circ. Relay (WL)

--- (OR)--Honeywell L7224C1010 Hi & Lo Limit, Circ. Relay (WT)

3 1/2" NPT x 1-1/2" Immersion Well, Honeywell 123869A (WL)

--- (OR)--3/4" NPT x 3" Immersion Well, Honeywell 123871A (WT)

4 Temperature / Pressure Gauge, ¼" NPT x 2-1/2" Dia. x 1-1/2" Lg. Shank 1 1 100282-01 5 3/4" NPT x 7-1/4" Lg. Nipple, SCH 80, Black 1 1 100839-01

6 Relief Valve, 3/4" F x 3/4" F, 30 PSI, #10-408-05 1 1 81660319 7 1-1/2" NPT x 5" Lg. Nipple, Black 1 1 806600060 8 1-1/2" x 3/4" x 1-1/2" NPT Tee, Black 1 1 806601003 9 3/4" NPT Ball Drain Valve, Conbraco #35-302-03 1 1 806603061

10 Circulator w/Gaskets

11 Circulator Flange, 1-1/2" NPT 2 2 806602014 12 Cap Screw, Hex Head, 7/16" -14 x 1-1/2" Lg. 4 4 80861301 13 Hex Nut, 7/16" -14 4 4 80860406

14 Taco "00" Series Flange Gasket (Gasket Only) 2 2 806602006

Taco 007 1 1 8056170 Grundfos UP15-42F 1 1 8056173

1 1

103850-01

103854-01

80160456

80160452

Beckett AFG Burner

BECKETT AFG OIL BURNER PART NOS. FOR RRO SERIES BOILERS

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below.

Boiler Model RRO080, RRO092, RRO120 RRO111 RRO151, RRO179

Air Tube Combination AFG70MBAS AFG70MBAS AFG70MDAS

Beckett's Spec No. BCB8906 NY2702 NY2703

Air Band 3492A 3492A 3492A

Air Band Nut 4150 4150 4150

Air Band Screw 4198 4198 4198

Air Shutter 3709 3709 3709

Air Shutter Screw 4198 4198 4198

Blower Wheel 2999 2999 2999

Coupling 2454 2454 2454

Low Firing Rate Bafe 5880[1] ---- ----

Bulkhead Knurled Locknut 3-666 3-666 3-666

Connector Tube Assembly 5636 5636 5636

Electrode Clamp 1-49 1-49 1-49

Electrode Clamp Screw 4219 4219 4219

Electrode Insulator Assembly 5780 5780 5780

Spider Spacer Assembly 5653 5653 5653

Escutcheon Plate 3493 3493 ----

Adjusting Plate Assembly ---- ---- 5941

Head 5912 5912 5913

Head Screws 4221 4221 4221

Flange Gasket 3416 3416 3416

AFG Housing 5874BK 5874BK 5874BK

Motor 21805 21805 21805

Nozzle Adapter 2-13 2-13 2-13

Nozzle Line Electrode Assembly NL70MB NL70MB NL70MD

Oil Pump, Clean Cut (Single Stage)

Oil Pump, Clean Cut (Two Stage)

Static Plate 3384 3384 3384

Ignitor 51771U 51771U 51771U

Ignitor Hinge Screw 4217 4217 4217

Ignitor Holding Screw 4292 4292 4292

Ignitor Gasket Kit 51304 51304 51304

Junction Box 5770 5770 5770

Flame Detector 7006 7006 7006

Oil Solenoid Valve Coil 21755 21755 21755

Oil Solenoid Valve Cord 21807 21807 21807

[1] 5880 used on CL3-091 ring rate only

2184404U 2184404U 2184404U

21941U 21941U 21941U

X. BURNER SPECIFICATIONS

TABLE 13: BECKETT AFG BURNER SPECIFICATIONS

Beckett AFG

Boiler Model

RRO080

RRO092 0.75 L1 6 0 0.65 x 45B (Hago) Loose 140

RRO120 1.00 L1 10 1 0.85 x 45B (Hago) Installed 140

RRO111 0.90 L1 7 0 0.75 x 45B (Delavan) Installed 140

RRO151 1.25 V1(0) 10 1 1.00 x 45B (Hago) Loose 175

RRO179 1.50 V1(3) 10 2 1.10 x 45B (Hago) Installed 175

Beckett low ring rate bafe required on RRO080 (0.65 GPH) application only; shipped loose with nozzle.

Nozzle(s) for alternate boiler model ring rate(s) are shipped loose in bag attached to the

burner.

Single stage fuel pump is standard. Burner manufacturer has preset single stage fuel pump to settings shown in

table above.

Firing Rate

GPH

Head

(Setting)

0.65 L1 8 0 0.55 x 70B (Delavan) Loose 140

Air

Shutter

Air

Band

GPH x Angle Type

Shipped

Settings Nozzle

Pump

Pressure

APPENDIX A - AFTERMARKET LOW WATER CUT OFF (LWCO)

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.

When

A low water cutoff is required to protect a 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.

Where

The universal location for a LWCO on oil hot water

boilers is above the boiler, in either the supply or return 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.

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

What Kind

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.

Select the appropriate size tee using the LWCO

manufacturer’s instructions. Often, the branch

connection must have a prevent bridging between the probe and the tee. Also, the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee.

Ideally, manual shutoff valves should be located

above the LWCO and the boiler to allow for servicing. This will allow probe removal for inspection without draining the heating system. Many probe LWCO manufacturers recommend an annual inspection of the probe.

minimum diameter to

How to Wire

LWCO’s are available in either 120 VAC or 24 VAC

congurations. The 120 VAC conguration must be

applied to oil boilers by wiring it in the line voltage service to the boiler (after the service switch, if so equipped). Refer to Figure A2.

The presence of water in a properly installed LWCO

will cause the normally open contact of the LWCO to close, thus providing continuity of the 120 VAC service to the boiler.

It is recommended to supply power to the probe LWCO

with the same line voltage servicing the boiler as shown below.

How to Pipe

A “tee” is commonly used to connect the probe LWCO in the supply or return piping, as shown below.

Figure A1: LWCO Location

Figure A2: Wiring of Typical LWCO

How to Test

Shut off fuel supply. Close shut-off valves in system supply and return piping located in near boiler piping above LWCO as shown in Figure A1. Open drain valve to lower water level until water is below the LWCO probe. It may be necessary to open relief valve seat to allow air into system for the water to drain, close drain

valve and relief valve once completed. Generate a boiler demand by turning up thermostat. Boiler should

not attempt to operate. Open ll valve to increase the water level by lling the system. It may be necessary to open relief valve to allow air to escape during lling

process. The boiler should attempt to operate once the water level is above the LWCO.

Rand & Reardon RRO179, RRO120C, RRO179C, RRO120 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual