Crown Boiler ODV-100, ODV-125, ODV-75 User Manual
Freeport ODV Series
D ESIGNED TO L EAD
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com
Oil-Fired Direct Vent Hot Water Boilers
These instructions must be afxed on or adjacent to the boiler.
Models
ODV-75•
ODV-100•
ODV-125•
WARNING: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information
consult a qualied installer or service agency. This boiler
requires a special venting system. Read these instructions
carefully before installing.
TABLE OF CONTENTS
Product Description 1
Specications 2
BeforeInstalling 3
LocatingTheBoiler 3
VentSystemInstallation 4
SystemPiping 13
FuelPiping 17
Wiring 18
Start-UpAndCheckout 19
ServiceNotes 20
Maintenance 22
Parts 24
WARNING
FAILURE TO VENT THIS BOILER IN ACCORDANCE WITH THESE INSTRUCTIONS
COULD CAUSE FLUE GAS TO ENTER THE BUILDING RESULTING IN SEVERE
PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH:
Do not attempt to vent this boiler with galvanized, PVC, or any other vent components •
not described in this manual
Do not obtain combustion air from within the building. •
Do not install a barometric damper or vacuum relief valve in the vent system of this •
boiler.
CAUTION
Moisture and ice may form on the surfaces around the vent termination. To prevent
deterioration, surfaces should be in good repair (sealed, painted, etc.).
DANGER
THE VENT SYSTEM SUPPLIED WITH THE ODV IS NOT DESIGNED FOR VENTING
OF FLUE PRODUCTS FROM NATURAL GAS OR PROPANE. DO NOT ATTEMPT TO
CONVERT THE ODV TO EITHER GAS.
I Product Description
The ODV series boiler is a cast iron oil red boiler designed for use in forced hot water heating
systems. The ODV boiler must be vented using the factory supplied venting system with combustion air taken from outdoors. The ODV uses the same three pass “scotch marine” heat exchanger as
the CT series boiler. The ODV series boiler is ideal for use in installations where a chimney is not
available.
The ODV boiler is not designed for use in gravity or “open” heating systems.
CAUTION
As with any oil appliance, certain adverse conditions can cause this boiler to operate at high
smoke levels. Since the ODV is vented through a wall, this can result in severe soot damage
to the side of the structure around the terminal. To minimize the risk of this:
• Follow these installation instructions exactly
• Oil burner must be set up by a qualied serviceman using combustion test instruments
• Use only the vent components supplied in the ODV vent kit
• Combustion air must be supplied from outdoors
• Follow the maintenance procedure in this manual
• Use only #2 fuel oil meeting ASTM D-396
1
IISpecications
D.O.E.
HEATING IBR NET FIG. 1
NO. INPUT CAPY. RATING DIMENSION
MODEL SECTIONS Gal/hr) (BTU/hr) (BTU/hr) AFUE (%) "A" (IN.)
ODV-75 3 0.75 91,000 79,000 85.0 32-1/4 24 14
ODV-100 3 1.00 119,000 103,000 83.1 32-1/4 24 14
ODV-125 4 1.25 150,000 130,000 83.5 37-1/4 24 14
FIG. 1 DIMENSION "B" (IN.)
STANDARD
CONNECTION
USING
OPTIONAL
TEE
TABLE 1: SPECIFICATIONS
Ratings based on #2 fuel oil having a higher heating value of 140,000 BTU/Gal
Net ratings based on a piping and pickup loss allowance of 1.15
Exhaust pipe: 4” I.D. insulated exible vent pipe.
Maximum exhaust pipe length – 15 ft.
Inlet pipe: 4” I.D. Corrugated Aluminum
Maximum Inlet pipe length – 20 ft
Maximum Wall Thickness in which Terminal is Installed – 12”
2
IIIBeforeInstalling
1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in
strict accordance with this manual and the authority having jurisdiction.
• In the absence of an authority having jurisdiction, installation must be in accordance with this manual
and Installation of Oil-Burning Equipment (ANSI/NFPA 31).
• Where required by the authority having jurisdiction, this installation must conform to the
Standard for Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1)
2) Read Section VI to verify that the maximum combustion air and exhaust pipe lengths will not be
exceeded in the planned installation. Also verify that the vent terminal can be located in accordance with
Section VI. Note: The maximum wall thickness through which the terminal can be installed is 12”.
3) Make sure that the boiler is correctly sized:
• For heating systems employing convection radiation (baseboard or radiators) use an industry
accepted sizing method such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22)
published by the Hydronics Institute in Berkely Heights NJ.
• For new radiant heating systems refer to the radiant tubing manufacturer’s boiler sizing guidelines.
• For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the DOE
Heating Capacity required for the Mega-Stor or the net rating required for the heating system,
whichever results in the larger boiler.
• For systems that incorporate other indirect water heaters, refer to the indirect water heater manufac-
turer’s instructions for boiler output requirements.
4) Do not install this boiler at altitudes above 2000ft.
5) Inspect shipment. This boiler is shipped in three pieces:
a) Wire-bound crate with boiler
b) Vent terminal carton – Includes terminal, vent adapters, inlet piping and hardware
c) Vent pipe carton - Includes exible vent pipe.
IVLocatingtheBoiler
1) Observe the clearances below. Top, side and rear clearances are from jacket. Front clearance is from
burner door.
To Combustible Construction To Non-Combustible Construction
Front 24 15
Left* 6 2-1/2
Right 6 1
Rear Determined by clearance to Flexible Vent Pipe (below)
Top 24 24
Terminal 0 0
Flexible Vent Pipe 3 0
* 14 inch clearance required to open door.
2) Boiler must be installed on a non-combustible surface.
3) Boiler must be located so that the 15-foot vent pipe supplied with the boiler will reach the
terminal location. Approximately 1.3 feet of pipe length is used up in making a 90-degree bend
(Fig 11). See Section V for more information on venting requirements.
3
planned
VVentSystemInstallation
WARNING
• Read the installation instructions carefully and completely before proceeding
with the installation of vent system.
• For continued safe operation, the appliance vent system must be inspected and
maintained annually by a qualied agency.
Failure to properly maintain the appliance vent system combination can lead to
Death, Personal Injury and or Property Damage.
• Plan the vent system layout before installation to avoid the possibility of
accidental contact with concealed wiring or plumbing inside walls.
The ODV boiler is shipped with a complete venting system consisting of the following components:
• FDVS-4 direct vent terminal
• Backing plate
• 15-ft length of insulated 4” FOVP exible oil vent pipe
• 4” x 7” appliance adapter
• (2) Cover rings
• (2) Cover sleeves
• Bagged hardware
• (4) Inner pipe clamps
• 20 ft length 4” exible aluminum air intake pipe
• (2) Hose clamps
• “Red” high temperature RTV silicone sealant
CAUTION
• Do not use vent system components other than those supplied with the boiler
• Use only the red RTV sealant provided with this boiler anywhere that this manual
calls for the use of “sealant”
• Combustion air must be brought from outside as shown in this manual
• Do not install a “vacuum relief” damper
• Do not attempt to splice vent piping
• Do not put holes in venting
1) LOCATING THE TERMINAL – Observe the following requirements in locating the terminal:
a) Maximum wall thickness through which terminal can be installed is 12”.
b) Wall can be combustible or noncombustible.
c) Bottom of terminal must be at least 12 inches above the normal snowline. If normal snowfall is
negligible, terminal must be at least 12 inches above grade (Fig 2).
d) Bottom of Terminal must be at least 7 feet above a public walkway (Fig 2).
e) Locate edge of terminal at least 4 ft horizontally from doors, windows, or gravity air inlets. Do
not put terminal under windows which can be opened (Fig 2).
f) Terminal must be close enough to boiler to be connected to it using the vent components
supplied.
4
5
g) Do not locate terminal under decks.
h) It is preferable to install the terminal on the wall that is away from the prevailing wind.
i) Do not put terminal under a soft or other overhang deeper than 18 inches. Top edge of terminal
must be at least 2 ft below soft or overhang (Fig 3).
j) Position terminal to avoid accidental contact with people or pets.
k) Over time, the area around the terminal may become stained. Locate the terminal on a wall
where this is not objectionable.
l) No part of an inside corner should extend into the shaded area shown in Figure 4.
m) Terminal must be positioned so that no other buildings are within the shaded area shown in
Figure 4. Other permanent objects in this area may become stained or otherwise effected by ue
gas.
n) The terminal is a potential source of odors. Although the above restrictions will generally prevent
inltration of these odors into the building, care should be taken in positioning the terminal near
outdoor areas where people congregate, such as patios. This is particularly true when the boiler is
used with an indirect water heater that will cause the boiler to run during warm months.
2) INSTALLING THE FDVS-4 VENT TERMINAL
a) Remove vent system components from box and inspect for damage. If the carton has been
crushed or mutilated, check components very carefully for damage. DO NOT install if any
damage is apparent.
b) Remove the combustion air tee assembly from the vent terminal. Set the tee aside for later
use.
c) After determining the location of the vent terminal (Figures 2,3 & 4), cut a 7-1/4” square hole in
the wall. (Figure 5a) Note: Maximum wall thickness: 12”
d) Seal the back side of the base plate around the outer pipe of the vent terminal with a bead
of standard silicone sealant (not supplied). (Figure 5b) Mount the vent terminal through
the wall, keeping the outer pipe centered in the hole. (Figure 5a) Fasten the vent terminal to
the outside wall with appropriate fasteners. Seal the edges of the vent terminal base
plate to the wall with standard silicone sealant.
CAUTION
Failure to apply this bead of silicone properly can cause ue gas to recirculate into
the air inlet resulting in sooting of the boiler, vent system, and side of the strucure.
e) Mount the backing plate over the outer pipe. Fasten the backing plate to the inside wall with
appropriate fasteners. (Figure 5b)
DO NOT BLOCK the intake or exhaust openings, or the intake access panel on the vent terminal body.
Wood or vinyl siding should be cut so that the unit mounts directly on the wallboard to provide a stable
support. If the siding is greater than 1/2” thick use a spacer plate or board behind the vent terminal
mounting plate. (Figure 5b)
f) If the inside terminal section is not supported by the wall through which it passes, install
additional supports or bracing to rigidize the terminal. Bracing in contact with the co-axial
section of the terminal may be combustible.
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