Page 1
INSTALLING THE BOILER
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Placing The Boiler (OWB-9 – OWB-25)
1. Move the boiler as close as possible to its final location in the crate.
2. Remove the two lag screws holding the rear feet to the skid.
3. Remove the front jacket panel. Cut the band holding the front of the boiler to the
skid.
4. Move the boiler into the final position.
5. Waste Oil Piping: USE ONLY 3/8” nominal ID copper tubing with flare fittings only on the
oil suction from the tank to the oil pump and oil pump to burner. DO NOT use ferrule
fittings or teflon tape on any pipe fittings. Keep suction line approximately 6” from
bottom of oil tank to prevent suction of sludge (Figure 11). Use only an inside oil storage
tank. Do Not draw from an outside tank, especially not an underground tank directly to
burner. A separate transfer pump from an outside tank with proper filtration to the inside
supply tank is acceptable.
6. The fuel pump included with burner is to be mounted at tank level or below. PUMP MUST
BE MOUNTED HORIZONTAL AND LOCATED NEXT TO WASTE OIL SUPPLY TANK.
Oil Feed Line, 3/8” to connector on burner gun assembl
1,
O Suction Line, 3/8” copper tubing
2,
Suction Line 6” min from bottom of tank to prevent sludge from being introduced into
3,
the su
line
1
2
3
Waste Oil Supply Tank
Figure 11.
Waste Oil Pum
Boile
BREECHING INSTALLATION
The breeching connection on OWB-9, OWB-15 and OWB-25 is 7 inches regardless of
input. Refer to Table 1 for minimum breeching sizes. Breeching run should be as short
as possible with as few elbows a practical. Unless marginal draft conditions exist, a
brametric draft control must be installed in the breeching and should be approximately 18
inches from the boiler breeching connection. Breeching should not project into the
chimney beyond the inside wall of the chimney. Connect the breeching to the chimney
with a thimble or slip joint to facilitate cleaning. See Figure 12.
Econo Heat♦5714 1st Avenue♦Spokane Washington 99212.♦(509)534-1022♦www.econoheat.com
100270 Rev A4
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Pitch Up 1/4” per foo
Barometric Draft Control
Figure 12.
18”
Straight Run Preferred
INSTALLING THE BOILER CONTROLS AND
1. Accessories for Boilers OWB-9, OWB-15, and OWB-25:
a) Take the L8148A Aquastat relay, the well, the pressure relief valve with pipe
nipple and the temperature/pressure gauge from the large carton which was
packed in the wirebound crate. Install in tappings provided at the top rear of the
boiler as shown in Figure 13.
ACCESSORIES
Figure 13.
b) Take the boiler drain from the same carton and connect it to the 3/4 inch opening
of the 1 1/4 x 3/4 x 1 1/4 inch tee in the boiler return manifold at the bottom rear
of boiler.
c) Install 1 1/4 x 3” Nipple and Circulator Flange.
2 Installation, Operation, And Service Instructions
Page 3
d) Remove the circulating pump from its carton in the crate and mount it to the
pump flange on the end of the return manifold.
2. Bare Boiler:
a) The pressure relief valve and temperature/pressure gauge are supplied with the
boiler and should be mounted as shown in Figure 13.
b) The bare boiler does not include the return manifold. The installer must make up
his own manifold to connect to the 2 x 1 1/4 inch bushing which is supplied in the
boiler supply and return ports, and must provide his own boiler drain and
circulating pump.
1. Accessories for Boilers OWB-35 and OWB-50:
Figure 14. Supply Manifold Assembly
Figure 15. Return Diffuser Installation
a) Attach supply manifold as shown in Figure 14.
b) Install return port diffuser and attach return flange as shown in Figure 15. Make
sure diffuser SLOTS face upward.
c) Screw threading used on these parts are metric. There is no english thread
equivalent to the nuts or studs supplied. Attempts to use any english threaded
stud in place of those supplied will damage the boiler block.
Installation, Operation, And Service Instructions 3
Page 4
WATER PIPING CONNECTIONS
1. OWB-9, OWB-15, and OWB-25 boilers are shipped complete with circulating pump.
To make the piping connections to the boiler ready to connect to the system piping,
the following will also be required at a minimum:
1 – Air Purger (same size as supply pipe)
1 – Pressure reducing Fill Valve
1 – Expansion Tank (sized to system design requirements)
1 – Automatic Air Vent
2. The following accessories may also be required, depending upon overall system
design and code requirements:
1 – Low Water Cutoff may be required if boiler is located above radiation level.
Check requirements of state or local code bodies and insurance companies. If
required use a probe-type designed for water system use and install in tee in
supply piping above the boiler.
1 – Manual Reset High Limit----Required by some state or local codes. Also
required if system is to comply with ASME code.
1 – Backflow Preventer----- Required by many State and local codes.
3. Additional circulating pumps or zone valves may also be required if the system is to
be multi-zone or if it is to include a domestic hot water storage tank with coil.
WARNING
The expansion tank must be properly sized to system requirements. An under-sized
expansion tank will cause system water to be lost through the relief valve and make-up
water to be introduced through the fill valve. Continual introduction of fresh water into
the system will cause mineral build-up in the boiler sections and eventual section failure.
4. There are two types of expansion tanks used, the closed type and the pre-pressurized
diaphragm tank Most new installations use the diaphragm type tank, however some
installations still employ the closed type tank.
(a) Piping Connections with closed type expansion tank----See Figure 16. Piping
from tee in supply to tank should be 3/4 inch. If horizontal piping is
employed, pipe must be pitched up toward tank 1/4 inch per foot.
4 Installation, Operation, And Service Instructions
Page 5
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Closed Type Expansion Tank
Supply
to
System
Cold Water Feed
Return From System
Figure 16.
(b) Piping connections with diaphragm expansion tank--- See Figure 17.
The cold water feed to the pressure reducing fill valve may be piped with 1/2
inch pipe.
Shutoff Valve
3/4 in.
Fill Valve
Circulation Pump
Pressure Relief Valve
S
Drain Cock
Shutoff Valve
Purger
Auto Air Vent
Cold Water Feed
Diaphragm Type
ansion Tank
Ex
Figure 17.
Installation, Operation, And Service Instructions 5
Circulator Pum
S
Drain Coc
Page 6
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SYSTEM PIPING
Supply and return and system piping should be sized by determining the pressure drop,
required flow rate and pump capacity.
WARNING
Discharge piping from relief valve must be piped to a drain or must terminate 6” above
floor to eliminate damage to the structure or personal injury. It must not be piped to a
point where freezing might occur.
1. MULTIPLE ZOINING WITH ZONE VALVES -----
See Figure 18. Install a balancing valve in each zone and adjust so that flow is about
the same in each zone.
Zone Valves
Figure 18.
Isolation Valves
Shutoff Valves
S
Cold Water Feed
Drain Cock
Circulation Pump
6 Installation, Operation, And Service Instructions
Page 7
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Isolation Valves
Flow Control Valves
Shutoff Valve
S
Cold Water Feed
Drain Cock
Isolation Valves
Circulating Pumps
Figure 19.
2. MULTIPLE ZONING WITH CIRCULATORS -----
Each pump will require a separate relay (Honeywell R845A or White Rodgers 829A845, or equivalent). Install a flow control valve in each zone including the indirect
water heater to prevent gravity circulation. Install a balancing valve in each zone and
adjust so that flow in each zone is about the same. See Figure 19.
3. RADIANT PANEL OR OTHER LOW TEMPERATURE SYSTEM----
The temperature of the system water coming back to the return port of the boiler must
not be permitted to drop below about 135 Degree F for an extended period of time.
Return water temperatures of 130 Degree F or lower will cause condensation on the
exterior surface of the heat exchanger and corrosion and eventual heat exchanger
failure will result. Radiant floor and ceiling panel heating systems typically operate
with maximum supply water temperatures of 140 Degree F or less. A standard piping
arrangement would, under these circumstances, permit return water temperatures of
120 Degree F and lower. Accordingly, such systems must be piped such that the
return water temperature will be high enough at all times to prevent condensation.
See Figure 20.
Installation, Operation, And Service Instructions 7
Page 8
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Return from System
Supply to Syste
Stem Thermomete
Shutoff Valve
Circulating Pumps
Bypass A
Cold Water Feed
Circulating Pumps
S
Drain Cock
Adjust the two manual valves to maintain 160 degree F or more in the boiler while holding the supply water
Figure 20.
temperature at the stem thermometer at 140 degree F or whatever minimum temperature system requires.
Bypass A shown in figure 20. above should not exceed 12 inches in length. If it
is not practical to maintain a 12 inch length or less then increase the pipe size of
the bypass by one size.
NOTE
4. LARGE WATER CONTENT SYSTEMS------
Such systems as converted gravity systems, old systems with cast iron radiators, and
also newer systems that employ outdoor reset control present a potential problem with
low return water temperatures and condensation. The boiler must be protected from
condensation in such cases by using a by-pass as shown in Figure 21.
8 Installation, Operation, And Service Instructions
Page 9
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b
Supply to System
Return from System
Adjust the two manual valves to maintain 135 degree F or more in the
oiler with return water at the lowest temperature to be expected.
Shutoff Valve
Cold Water Feed
Circulating Pumps
S
Drain Cock
Figure 21.
5. INTEGRATED SYSTEM (HEAT AND DOMESTIC HOT WATER) -----
With a single heating zone priority for domestic hot water may be provided through
the use of a 3-port zone valve. This system assures that full boiler output is available
to recover the storage tank quickly and should be used where supply of domestic hot
water on demand is critical.
For this application use a full throated valve with a minimum pressure drop. See
Figure 22.
Installation, Operation, And Service Instructions 9
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(
)
Supply to System
3 Port Zone Valve
Return from System
Shutoff Valve
Indirect Water Heater
Storage Tank With Coil
S
Cold Water Feed
Drain Cock
Circulating Pumps
Figure 22.
6.
INTEGRATED SYSTEM WITH MULTIPLE HEATING ZONES AND NO
PRIORITY FOR DOMESTIC HOT WATER, USING ZONE VALVES-----
Where the boiler output is large relative to the heating capacity of the coil in the
indirect water heater priority for domestic hot water is not necessary. Further, with
multiple heating zones there is less likelihood that all zones will call for heat at once
and require full boiler output for heating. Because the tank is usually close to the
boiler, the pressure drop through the coil circuit will generally be less than through a
heating zone circuit, which will provide some measure of priority for domestic hot
water. This can be enhanced by increasing the pipe size to the coil e.g. if 3/4 inch
pipe is used on the heating zones run 1 inch pipe to the coil. (See Figure 23.) Should
priority for domestic hot water be mandatory, it can be provided as shown in Wiring
Section, Figure 24.
10 Installation, Operation, And Service Instructions
Page 11
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Supply to System
Indirect Water Heater
Shutoff Valve
S
Zone Valves
Cold Water Feed
Return from System
Drain Cock
Circulating Pumps
Figure 23.
7. INTEGRATED SYSTEM, SINGLE OR MULTIPLE HEATING ZONES,
USING CIRCULATING PUMPS RATHER THAN ZONE VALVES----
Each pump will require a separate relay (Honeywell R845A or White Rodgers 828A845, or equivalent). Install a flow control valve in each zone including the indirect
water heater to prevent gravity circulation. Install a balancing valve in each zone and
adjust so that flow in each zone is about the same. (see Figure 24.) While this basic
system does not provide priority for domestic hot water, priority can be provided as
shown in Wiring Section, Figure 27.
Indirect Water Heater
Supply to System
Shutoff Valve
Flow Control Valves
Return from System
Cold Water Feed
Circulating Pumps
S
Drain Cock
Figure 24.
Installation, Operation, And Service Instructions 11
Page 12
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8. COMBINATION HEATING/COOLING SYSTEM WITH CHILLED WATER
The chiller must be piped in parallel with the boiler and isolation valves installed to
prevent the chilled water from circulating through the boiler and heated water from
circulating through the chiller. See Figure 25.
Insulation Valve # 4
Chille
Supply to System
Circulating Pumps
Insulation Valve # 3
Return from System
Flow Check
Note:
1. When in cooling mode isolation valves 1 and 2 must be closed and valves 3 and 4 open.
2. When in heatin
mode isolation valves 1 and 2 must be open and valves 3 and 4 closed.
Insulation
Valve # 4
S
Cold Water Feed
Drain Cock
Figure 25.
9.
SINGLE BOILER PIPING WITH BLEND PUMP
When burner is operating the water flow throughout the boiler shall be not less than
1.8 GPM for each 100,000 BTU/HR of gross boiler output. Size blend pump
accordingly. See Table 3
Blend Pump Primary/Secondary
Pump
Boiler Model GPM GPM
OWB-9
OWB-15
OWB-25
OWB-35 16.3 78.9
OWB-50 19.6 94.9
Maximum water flow resistance for boilers is 14” w.c
Table 3.
12 Installation, Operation, And Service Instructions
Page 13
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ump
pply
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ump
RSR
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To Size Blend
See Table 3
Pum
Blend Pum
Check Valve
Amtrol #720 Air
Eliminator or E
Air
Se
System
Return
Expansion Tan
arato
ual
System
Su
System
Circulato
Pressure
Reduction
Valve
Backflow
Prevente
From City
Water Su
Figure 26.
10. SINGLE OR MULTIPLE BOILER PIPING FOR PRIMARY/SECONDARY
PUMPING
Size Secondary Pump GPM at Gross Boiler Output for 20” Drop. When Calulating
Pump Head, the Maximum Boiler Resistance for any Boiler will not Exceed 14 in.
W.C. Head.
Figure 27.
System
Return
Amtrol #720 Air
Eliminator or E
Secondary
S
S
Secondary
P
Check Valve
12” MAX
P
Check Valve
Air Separator
12” MAX
Expansion Tank
ual
System
Su
System
Circulato
Pressure
Reduction
Valve
Backflow
Prevente
From
City
Water
Su
Installation, Operation, And Service Instructions 13
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11. MULTIPLE BOILER PIPING- REVERSE RETURN FLOW WITH BLEND
PUMP
Figure 28.
*Blend Pump
Check Valve
S
System
Return
S
*Blend Pump
Check Valve
Air Separator
Expansion Tank
Amtrol #720 Air
Eliminator or E
System
Su
ual
System
Circulato
Pressure
Reduction
Valve
Backflow
Prevente
From
City
Water
Su
14 Installation, Operation, And Service Instructions
Page 15
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BOILER ASSEMBLY & WIRING
Burner Mounting
When the burner is field installed the installer must fill in the space between the burner
blast tube and the insulation block on the inside of the burner door with refractory mix
rovided.
NOTE:
Figure 29. OWB-35 and OWB-50 Burner Mounting & Boiler Door Detail
Figure 30. OWB-9, OWB-15 and OWB-25 Burner Mounting & Boiler Door Detail
Installation, Operation, And Service Instructions 15
Page 16
Boiler Jacket Assembly
26
25
48
26A
Sight
Class
Assy
86
33 60
38
94
18
18 41
40
Figure 31. OWB-35 and OWB-50 Assembly Detail
OWB-35 and OWB-50 Jacket Installation Instructions
1. Screw the four extension setscrews (43) into the four outer holes in the corners of
the rear sections. Securely tighten the setscrews and other fastening bolts of the
flue outlet cover (22)
2. Place the large wraparound insulation mat (40) over boiler block (aluminum foil
side facing out).
3. Place smaller piece of insulation on top of wraparound insulation. This will
provide double thick insulation on top of the boiler block.
4. Remove flue collector clean-out covers (62)
5. Push the two smaller pieces of insulation (60) onto the flue collector (22) so that
the four extension setscrews (43) protrude through the insulation.
6. Attach rear jacket panels (36) and (38) to the two extension screws(43) using the
M6x10 pan head screws. Screw the rear panels together in the center using sheet
metal screws provided. Reattach the clean-out covers.
7. Place right and left side panels (93) (94) into the factory mounted hinge bracket
(18) and hook into the rear panels (36) (38).
36
43
93
16 Installation, Operation, And Service Instructions
Page 17
8. Hook center panel (33) with flange edge down between side panels (93) and (94).
9. Attach the upper front trim panel (41) between the right and left side panels over
the front door.
10. Place the top panel (86) in position. Hook to the side panels.
11. Remove sight glass plug in front door and install sight glass assembly. Sight Glass
(25) Sight Glass Tube Cap(26) and Sight Class Gasket(48).
Figure 32. OWB-9, OWB-15 and OWB-25 Assembly Detail
OWB-9, OWB-15 and OWB-25 Jacket Installation Instructions
1. Attach the rear jacket mounting brackets (7) to rear tie rod ends on back of boiler
using the 12mm nut (9) provided on the end of each tie rod.
2. Attach the rear jacket panel (3) to the rear jacket mounting bracket using the 1/4-
20 screws (11) ans nuts (10) provided.
3. Assemble front jacket mounting bracket (23) to the heat exchanger using the two
M10x16mm cap screws (27).
4. Drape the foil faced fiberglass insulation mat (not shown) over the top and sides
of the boiler. Make sure that the insulation is behind the Door Hinge and Front
Mounting Bracket and that the tappings in the top of the boiler are not covered by
the insulation.
Installation, Operation, And Service Instructions 17
Page 18
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5. Attach one door bracket (18) to the bottom of both the left and right side jacket
panels. Use two 8-32x1/2” screws (19) and nuts (20) to assemble each door
bracket.
6. Attach the left and right side jacket panels to the boiler. The front end of the right
side panel is attached to the hinge using 10-24x3/4 screws (21). The front end of
the left side panel is also attached to the front jacket mounting bracket (23) using
10-24x3/4 screws. The rear of both the left and right panels are attached to the
rear panel using #10x1/2 sheet metal screws.
7. Install a #10x1/2 sheet metal screw into the remaining hole in the rear of the right
side jacket panel which secures the rear of the wireway.
8. Attach the top jacket panel (5) using four #10x1/2 sheet metal screws.
9. Attach the flue collector cover (4) using four #10x 1/2 sheet metal screws.
10. Press the door switch (16) into the door switch bracket (17). Connect the door
switch leads to the switch (it does not matter which wire is connected to which
side of the switch). Attach the door switch bracket to the right side jacket panel
using a 10-24x3/4 machine screw (21).
11. Mount the door knobs (25) to the front panel (24) using two 8-32x1/4 screws (26).
12. Mount the front jacket panel on the boiler.
13. Connect the loose end of the 6” conduit assembly to the lim it control. Connect
the black wire to terminal “B1” and the white wire to terminal “B2”.
Boiler Tube Insert Assembly
Install Stainless Steel Tube Insert with external stitch weld touching 1
water section high point of casting and the dam located at the 6 O’clock
position. (bottom of boiler). When boiler door is closed, stainless tube
will inbed into door refractory at least 1/4”.
s
18 Installation, Operation, And Service Instructions
Page 19
(
Single Zone Wiring
All wiring and grounding must be done in accordance with the authority having
jurisdiction or, in the absence of such authority, with the National Electrical Code
ANSI/NFPA70).
1) 120 Volt Wiring—The boiler should be provided with its own 20A branch circuit
with fused disconnect. All 120 volt connections are made inside the L8148A aquastat
relay as follows (also see Fig. 31 or 32):
• Hot (“black”)- Terminal “L1”
• Neutral (“white”)- Terminal “L2”
• Ground (“Green” or bare)- Ground screw on case of L8148A
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” inside
L8148A aquastat relay.
WARNING
Wiring Variations
1) Multiple Circulator Zones—Figure 35 shows wiring for two or more circulator zones
using Honeywell R845As. One R845A is required for each circulator zone.
Circulator terminals “C1” and “C2” on the L8148A are not used. A DPST
Honeywell RA832A may be substituted in place of the R845A using the “X” and “X”
terminals in place of the “5” and “6” terminals on a R845A. A call for heat from any
thermostat will energize the DPST relay in that zone”s R845A. When this relay is
energized, electrical continuity is created between terminals 3 and 4, energizing the
circulator for that zone. At the same time, electrical continuity is created between
terminals 5 and 6 on the R845A, creating a current path from terminal “T” to “T” on
the L8148A. Assuming that the supply water temperature is below the high limit
setting, the normal ignition sequence will be initiated.
2) Multiple Zones using Zone Valves
Honeywell V8043F zone valves. This wiring diagram may be used for other 24-volt
zone valves as long as they are equipped with end switches. Do not attempt to use the
transformer on the L8148A to power the zone valves; use a separate transformer. Up
to five V8043Fs may be powered by one 48VA transformer, such as the Honeywell
AT87A. A call for heat from a given thermostat will result in the application of 24
volts across the TH and TR terminals on the corresponding zone valve, energizing the
zone valve motor. The zone valve opens and the end switch contacts are then made.
The end switches are connected in parallel with each other and to the “T” and “T”
—Figure 34 shows wiring for multiple zones using
Installation, Operation, And Service Instructions 19
Page 20
thermostat connections so that any zone valve that opens will also start the circulator
and fire the boiler(assuming the high limit is not open). Zone valve terminal TH/TR
has no internal connection on the zone valve; it is merely a “binding post” used to
connect two or more wires.
20 Installation, Operation, And Service Instructions
Page 21
(Supplied By Installer)
Honeywell
L8148A Aquastat
Thermostat
T T L1 L2
Jumper
Manual
High
Limit
L4006E
BLK
WHT
3
B1 B2C2C1
Low
Water
Cutoff
Servi c e Switch
Fused Disconnect Switch
(Items Supplied By Installer)
120 VAC
H
N
GND
Circulator
THERMOCOUPLE
Bi
METAL
HIGH
LIMIT
SWITCH
500W
HEAT
ROD
OIL
PREHEATER
BLOCK
Oil Pump
RED
PREHEATER BLOCK
HTR
L1
RED
BLU
BLU
CONTROLLER
RED
RED
WHT
L2
WHT
WHT
OIL
WHT
WHT
WHT
WHT
WHT
N
BLK
H
Electrical Box
(Looking at Socket Side)
RED
Pow er Soc ket
Oil Valve
PRI
WHT
Fuse
RED
Pow er Sw itch
BLK
BLK
WHT
GRN
BLK
Pow er Plug
(Looking at Terminal Side)
BLK
BLK
ORN
BLOWER MOTOR
WHT
BLK
HIGH
VOLTAGE
TRANS-
FORMER
OIL PRIMARY CONTROL
(IE, Honeywell , etc.)
FLAME SENSOR
Figure 33. WIRING DIAGRAM, SINGLE HEATING ZONE ONLY, OWB-90, OWB-150, OWB350
Installation, Operation, And Service Instructions 21
PHOTO EYE
WHT
BLK
ORN
THERMOSTAT
CONNECTION
Burner Assembly
Page 22
TT
(Supplied by Installe r)
TT
Honeywell
R845A
21
Thermostat
(Supplied by Installe r)
3
5
4
6
High
Limit
L4008A
High
Limit
L4006E
Set Temp 20
Deg Highe r
Than L4008A
Low
Water
Cutoff
BLK
WHT
Service Swi t ch
Fused Disconnect Switch
(Items Supplied By Installer)
120 VAC
H
N
GND
Electrical Box
(Looking at Socket Side)
Circulator
(Supplied by Installer)
THERMOCOUPLE
Bi
METAL
HIGH
LIMIT
SWITCH
500W
HEAT
ROD
OIL
PREHEATER
BLOCK
Oil Pump
RED
PREHEATER BLOCK
WHT
CONTROLLER
HTR
L1
RED
BLU
BLU
RED
RED
L2
WHT
WHT
OIL
WHT
WHT
WHT
BLK
BLK
WHT
BLK
N
H
PRI
WHT
Fuse
GRN
BLK
BLK
ORN
BLOWER MOTOR
WHT
YEL
Oil Valve
RED
Power Switch
RED
Pow er Socket
Power Plug
(Looking at Terminal Side)
WHT
BLK
HIGH
VOLTAGE
TRANS-
FORMER
PHOTO EYE
FLAME SENSOR
Figure 34. WIRING DIAGRAM, SINGLE HEATING ZONE ONLY, OWB-350 AND OWB-500
22 Installation, Operation, And Service Instructions
WHT
OIL PRIMARY CONTROL
(IE, Honeywel l, et c.)
BLK
ORN
THERMOSTAT
CONNECTION
Burner A ssembly
Page 23
Figure 35. WIRING DIAGRAM, ZONE WIRING USING HONEYWELL V8043F VALVES
(FACTORY BOILER WIRING NOT SHOWN –SEE FIGURE 33 OR 34)
Figure 36. WIRING DIAGRAM, CIRCULATOR ZONE WIRING USING HONEYWELL
R845A’S (FACTORY DIAGRAM WIRING NOT SHOWN –SEE FIGURE 33 OR 34)
Installation, Operation, And Service Instructions 23
Page 24
BOILER START-UP AND ADJUSTMENTS
FILL SYSTEM
1. Close manual air vents (if used) and automatic air vents. Attach hose to boiler drain
on return connection and run to a drain or to outdoors. Open drain cock and close
shutoff valve on boiler supply pipe.
2. HEATING ONLY – SINGLE ZONE SYSTEM---
Open manual valve in cold water feed line and set the fill valve to fast fill. Allow
water to flow through the system and out the hose until there is a steady flow of water
through the hose with no air bubbles.
Next, open the shutoff valve in the drain until air bubbles cease. Then take the fill
valve off fast fill, close the drain cock, remove the hose and open all automatic air
vents.
Also open all manual air vents one at a time and close when water squirts out.
Observe the temperature/pressure gauge. System pressure with a cold fill should be
in the 12 to 14 psi range.
3. MULTI-ZONE SYSTEMS-HEATING ONLY OR HEAT & DOMESTIC HOT
WATER WITH ZONE VALVES--To ensure good circulation through all zones with no air pockets, each zone should be
purged of air individually. With all zone valves in the manual open position let water
flow through the system by opening the drain cocks so water can exit the system
through a hose as in 1. above.
When system seems to be full and free of air, close the drain cock, and the shutoff
valve on the boiler supply pipe, leaving the manual valve on the cold water feed open.
Now release the manual openers to close all but one zone valve. Open the drain cock
and put the fill valve on fast fill. When the flow through hose becomes steady with
no air bubbles, take the fill valve off fast fill and then close the drain cock.
Repeat this procedure with each zone until all zones have been purged. Open the
shutoff valve on the boiler supply pipe. Then open all manual air vents one at a time.
When water sprays out of the air vents should have the cap loosened so it can vent air.
4. MULTI-ZONE SYSTEMS ZONED WITH CIRCULATORS---
Following the same procedures as in 3. above using the manual shutoff valves to
isolate a zone instead of zone valves.
5. Check system pressure on the temperature/pressure gauge on the boiler. Pressure
should be in the 12 to 14 psi range. If pressure is over 14 psi drain a little water out
with the drain cock. Watch gauge for a few minutes to ensure pressure does not build
back up. If pressure is too high with system cold there is a good possibility the relief
valve will blow off when the system is brought up to temperature. Too high a
pressure with the system cold indicates a faulty fill valve.
24 Installation, Operation, And Service Instructions
Page 25
WASTE OIL BURNER STARTUP
DO NOT fire boiler without water or boiler sections will overheat and eventually crack
WARNING
6. IMPORTANT- Prior to starting the unit, pre-fill the filter and fuel line with oil to assist priming
procedure. Oil pump motor turns at low RPM’s and would take significant time to complete
priming process if not pre-filled. Make sure the oil supply line fittings are air tight. Vacuum
leaks are notoriously hard to find. Pressurizing the line with oil in it can help to locate leaks.
7. During the initial power up process the burner is locked out from energizing until the oil has
been properly pre-heated to operating thermo setpoint, approx 3 to 5 minute duration. Once
the oil has been pre-heated, power is then applied to burner componenets an d oil pump.
8. Making sure the thermostat is turned off, apply power to the burner. Switch burner main
power switch to ON position. After allowing the oil pre-heater time to establish temperature
setpoint, approximately 5 minutes. Jump the “T” terminals on the Oil Primary (Figure 1).
Once the burner is running,
allow the burner to run during the pump priming process.
9. Priming the oil pump: Open bleeder valve one turn until all air is expelled (Figure 4). This
may need to be done twice to insure all air is removed. IMPORTANT: When fully purged and
flame is established remove temporarily jumpers on “F” terminals of the Oil Primary to allow
safety features of the unit to operate properly.
10. Adjust air supply of integrated air compressor to 8-12 P.S.I. This is factory preset, however,
due to freight handling settings may be compromised.
11. Combustion air band (Figure1) should be open approximately 1/2” or until flame is clear
yellow, not orange. Opening the air band too far may cause delayed in starting or even
prevent the flame from starting.
temporarily jump the “F” terminals on the Oil Primary. This will
WATER TREATMENT
Generally no water treatment will be required. Care should be taken to ensure that the
system does not lose water from leaks, or continual relief valve operation since continual
make-up water will reduce boiler life.
FREEZE PROTECTION
Where freeze protection is required use antifreeze made especially for hydronic systems
such as inhibited Propylene Glycol. DO NOT use automotive type antifreeze. Follow
antifreeze manufacturer’s directions for quantity. A 50% solution provides protection to
–30 degree F. For boiler water content see page 11.
Installation, Operation, And Service Instructions 25
Page 26
MAINTENANCE
WASTE OIL BURNER:
1. Weekly
2. Monthly
Drain water from storage tank.
Clean pump screen on oil pump assembly of sludge and remove
any water. Access to screen is by removing pump cover. Clean flame
cone of deposits.
3. Yearly Inspect and adjust electrodes per (figure 37). CAUTION: turn off
main electrical power before checking or adjusting electrode
settings. Inspect and check alignment of nozzle in relation to flame
cone/burner tube (figure 37). Tip of nozzle must be 1/4” forward of inside
radius of flame cone. If nozzle is behind inside radius of flame cone,
coking will occur and flame cone can clog. To adjust, loosen Pre-Heater
block securing nut and set screw, push fore or aft as needed then
retighten securing nut and set screw.
BOILER:
1. Clean Boiler using procedure below.
2. Check all water system piping for leaks. Repair any found.
3. Check pressure relief valve operation by opening with manual lever. If it fails to
relieve, replace immediately.
4. Check operation of safety controls, low water cutoff and manual reset high limit
(if provided).
5. Check breeching connections to ensure there are no flue gas leaks. Seal any leaks
found with High Temperature Silicone Sealant.
6. Check flue gas temperature at the test point in the breeching. If gross flue gas
temperature is 550 degrees F or above, suspect that cleaning of the boiler
flueways is required.
BOILER CLEANING:
Turn off the power with the line switch. Disconnect the electrical plug at the J-Box by
the Aquastat Relay. Remove the four hex head bolts from the outer corners of the burner
mounting plate and swing open the burner door with burner mounted to provide access to
the boiler flueways. Remove sludge and deposits from Stainless Steel Insert. When all
deposits are removed, close burner door, and plug in the electrical lead, restore the power
and turn burner on. If a boiler is to be shut down and taken out of service for a period of
time, the boiler should be cleaned immediately upon shut down while the flueways are
still warm. When the boiler gets cold, the deposits harden making cleaning difficult.
Further, hardened deposits will absorb moisture and cause corrosion.
It is essential that the boiler be cleaned on an annual basis, even if no soot is present.
Sulfer, and other deposits which may be present, can cause severe corrosion damage
if they are not removed periodically.
IMPORTANT
26 Installation, Operation, And Service Instructions
Page 27
Figure 37 –Electrode Adjusment Diagram
When cleaning, inspect all three
pieces thoroughly. When
disassembling and reassembling
nozzle, keep facing up as shown.
Figure 38 –Nozzle Assembly Detail
Installation, Operation, And Service Instructions 27
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