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.
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.
WARNING This boiler is suitable for installation on combustible flooring. 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.
Table of Contents I. General Information...................................................................... 4 II. Installation Instructions................................................................ 8 III. Indirect Water Heater Piping....................................................... 19 IV. System Start-Up........................................................................... 20 V. Operating......................................................................................
121" RETURN FLAME OBSERVATION PORT 321" DRAIN VALVE 3158" RELIEF VALVE 334" 1421" 5" 11" BURNER SWING DOOR CLEARANCE (OPEN 90°) 138" TEMP/PRESSURE GAUGE 121" SUPPLY FLOOR LINE OIL BURNER W/PRIMARY CONTROL 9" SEE NOTE 2 BOILER CONTROL 1241" 421 Figure 1a: RRO080 through RRO179 Boiler without Tankless Heater FRONT VIEW FLUE COLLAR 2458" 358" 'C' DIA.
121" RETURN FLAME OBSERVATION PORT 321" DRAIN VALVE 3158" RELIEF VALVE 334" 1421" 5" 11" BURNER SWING DOOR CLEARANCE (OPEN 90°) 138" 641" FLOOR LINE OIL BURNER W/PRIMARY CONTROL TEMP/PRESSURE GAUGE 121" SUPPLY 9" SEE NOTE 2 1241" 358" 'A' 'C' DIA.
TABLE 1: DIMENSIONAL DATA (See Figures 1a and 1b) Dimensions Heat Transfer Surface Area (Sq. Ft.) Approx. Shipping Weight (LBS.) "A" "B" "C" Approx. Water Content (Gallons) RRO080, RRO092, RRO120 17-3/8" 8-1/4" 5-7/8" 16 14.33 560 RRO111, RRO151, RRO179 22-3/8" 10-7/8" 6-7/8" 20 20.90 680 Boiler Model Maximum Working Pressure - Water: 50 PSI Boiler shipped from factory with a 30 PSI relief valve. table 2: rating data Burner Capacity GPH MBH Heating Capacity (MBH) RRO080 0.
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. section.
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.
Table 3: Tankless Heater Data Boiler Model RRO080 RRO092 RRO120 RRO111 RRO151 RRO179 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.
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. Insufficient 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.
a. Loose Mortar – Loose mortar could be an indication of a prior history of condensing flue 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.
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 flue gases, cross section area of chimney, chimney wall insulation value, dilution air and total volume of flue gases, to name a few.
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.
table 5: two-stage units (3450 rpm) two-pipe systems Lift "H" (See Figure) Maximum Length of Tubing "H" + "R" (See Figure) 3/8" OD Tubing (3 GPH) 1/2" OD Tubing (3 GPH) 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' K. SINGLE ZONE WIRING 1. 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect.
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 Refer to Figure 12 for Schematic wiring diagram of appropriate burner and oil primary control option
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.
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 firing 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.
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.
to 12.5% with draft of -0.02” (water gauge) in fire box. These settings will assure a safe and efficient operating condition. If the flame appears stringy instead of a solid fire, 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 fire. 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.
Figure 16: "L1" and "V1" Head Electrode Positioning and Gun Setting
• On: cad cell is sensing flame. • Off: cad cell is not sensing flame. 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 flame present, see chart below. Flame Detection Range Normal (0 - 1600 ohms) Limited (1600 ohms to lockout) 3.
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.
V: OPERATING A. WATER BOILERS SEQUENCE OF OPERATION 1. 26 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.
d. If the thermostat is not satisfied 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 satisfied the burner and circulator are stopped. f. The Warm Start Boiler Control also includes a low limit control function.
Cold Start Boiler Control Adjustment Mode Options HL_ HdF ZC_ Or_ PP_ St_ Pt_ f-C bac 140-240°F 10-30°F dh, ZR or ELL 0-10 minutes 2-20 minutes 140 - 180°F On or Off F or C Adjust High Limit Setting Adjust High Limit Differential ZC and ZR Terminal Function Pump Overrun Time Pump Pre-purge Time Start Temperature Priority Time Select degrees F or C Mode Back to Operating Mode Warm Start Boiler Control Adjustment Mode Options HL_ LL_ 140-240°F 110-220°F Ldf 10-25°F ZC_ Or_ PP_ St_ Pt_ f-C bac ZR or
Table 7: circulator pre-purge time example, parameter pp_= 2 minutes Call for Heat ZC and ZR Terminal Boiler Function Temp. (ZC_) Boiler Status, (B1 Output) 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.
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.
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.
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 fire 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 fire hazard. 4.
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.
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.
VIII: Troubleshooting A. 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 flame shape and efficient 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.
B. OIL PRIMARY CONTROL (Oil Primary) Note: The Safety Monitoring Circuit (SMC) is designed to provide lockout in the event of a stuck or welded motor relay. 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.
b. If the Boiler Control detects an error it will flash "" (boiler control error) followed by a number. Use this text and number to identify the boiler problem and corrective action in Table 12 below.
IX. Repair Parts Bare Boiler Assembly (Exploded View) All RRO™ repair parts may be obtained by contacting your local HAJOCA branch.
Item Description No. Boiler Size / Quantity RRO120 RRO111 & RRO179 Part No.
Jacket Assembly (Exploded View) Item No. Boiler Size / Quantity Description RRO120 RRO111, RRO179 Part No.
RRO120 , RRO111 and RRO179 - Trim and Controls Item Description No. Boiler Size / Quantity RRO111, RRO120 RRO179 Part No. Trim and Controls 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Beckett GeniSys 7505B Oil Primary Control Honeywell L7248L1090 Hi Limit, Circ. Relay (WL) --- (OR)--Honeywell L7224C1010 Hi & Lo Limit, Circ. Relay (WT) 1/2" NPT x 1-1/2" Immersion Well, Honeywell 123869A (WL) --- (OR)--3/4" NPT x 3" Immersion Well, Honeywell 123871A (WT) Temperature / Pressure Gauge, ¼" NPT x 2-1/2" Dia.
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.
X. Burner Specifications Table 13: Beckett Afg Burner Specifications Beckett AFG Firing Rate Boiler Model GPH 1 Settings Head Air (Setting) Shutter Nozzle Air Band GPH x Angle Type 3 2 Shipped Pump Pressure 0.65 L1 8 0 0.55 x 70B (Delavan) Loose 140 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.
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 specifically identified 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.
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 46 valve and relief valve once completed. Generate a boiler demand by turning up thermostat. Boiler should not attempt to operate.
