ICP OWB, OWT User Manual
Oil-Fired Water Boilers
Boiler Manual
Contents Page
1 Prepare boiler location ........................................................2
2 Prepare boiler ..................................................................... 5
3 Connect breeching .............................................................6
4 Connect water piping ..........................................................7
5 Connect tankless heater piping.........................................10
6 Connect wiring..................................................................11
7 Connect oil piping .............................................................14
8 Start-up ............................................................................15
9 Checkout procedure .........................................................16
10 Appendix ..........................................................................17
11 Service and maintenance ................................................. 1 8
12 Replacement parts ........................................................... 22
13 Dimensions ......................................................................26
14 Ratings .............................................................................27
Hazard definitions
Hazards that will cause severe personal injury,
death or substantial property damage.
Hazards that can cause severe personal injury,
death or substantial property damage.
INSTALLER — Read all instructions before
installing. Read page 2 first. Follow all instructions
in proper order to prevent personal injury or death.
• Consider piping and installation when determining
boiler location.
• Any claims for damage or shortage in shipment
must be filed immediately against the transportation
company by the consignee.
This manual must only be used by a qualified heating installer/service technician. Boiler and burner must be installed
and serviced only by a qualified heating installer/service technician. Failure to comply could result in se vere personal injury ,
death or substantial property damage.
When calling or writing about the boiler— Please have: • boiler model number from the boiler rating label and • CP number
from the boiler jacket. You ma y list the CP number in the space provided on the “Installation and service certificate” found on
page 16.
Hazards that will or can cause minor personal injury
or property damage.
Special instructions on installation, operation or
maintenance that are important but not related to
personal injury or property damage .
USER — Please read the following. Failure to
comply could result in severe personal injury , death
or substantial property damage.
• This manual is for use only by your qualified
heating installer/service technician.
• Please see the User’s Inf ormation Manual for your
reference.
• Have the boiler serviced by a qualified service
technician, at least annually .
Part Number 672 01 1005 00
OWB & OWT
Oil-Fired Water Boilers – Boiler Manual
1 Prepare boiler locationRead this first!
Failure to adhere to the guidelines below can
result in severe personal injury, death or
substantial property damage.
When servicing boiler —
1. To avoid electric shock, disconnect electrical supply
before performing maintenance.
2. To avoid severe burns, allow boiler to cool before
performing maintenance.
Boiler operation —
3. Do not bloc k flow of combustion or v entilation air to boiler.
4. Should overheating occur, do not turn off or disconnect
electrical supply to circulator. Instead, shut off the oil
supply at a location external to the appliance, if possible.
5. Do not use this boiler if any part has been under water.
Immediately call a qualified service technician to inspect
the boiler and to replace any part of the control system
and any burner control that has been under water .
Boiler water —
6. DO NOT use petroleum-based cleaning or sealing
compounds in boiler system. Water seal deterioration will
occur, causing leakage between boiler sections, circulator
flanges, diaphragm tanks or other system components.
This can result in substantial property damage.
7. DO NOT use "homemade cures" or "boiler patent
medicines". Serious damage to boiler , personnel and/or
property may result.
8. Continual fresh makeup water will reduce boiler life. Mineral
buildup in sections reduces heat transfer , ov erheats cast
iron, and causes section failure. Addition of oxygen and
other gases can cause internal corrosion. Leaks in boiler
or piping must be repaired at once to prevent makeup
water .
9. Do not add cold water to hot boiler. Thermal shock can
cause sections to crack.
Glycol — potential fire hazard —
All glycol is flammable when exposed to high temperatures. If
glycol is allowed to accumulate in or around the boiler or any
other potential ignition source, a fire can dev elop. In order to
prevent potential se vere personal injury , death or substantial
property damage from fire and/or structural damage:
• Never store glycol of any kind near the boiler or any
potential ignition source.
• Monitor and inspect the system and boiler regularly for
leakage. Repair any leaks immediately to prevent possible
accumulation of glycol.
• Never use automotive antifreeze or ethylene glycol in the
system. Using these glycols can lead to hazardous
leakage of glycol in the boiler system.
Codes & checklist
Installations must follow these codes:
• Local, state, provincial, and national codes, laws, regulations
and ordinances.
• NFP A-31, Installation of Oil-Burning Equipment.
• Standard for Controls and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD-1, when required.
• National Electrical Code.
• For Canada only: B149.1 or B149.2 Installation Code, CSA
C22.1 Canadian Electrical Code Part 1 and any local codes.
Certification
The OWB and OWT boilers, burners and controls
met safe lighting and other performance criteria when
boiler underwent tests specified in CSA B140.0 and
B140.7.1.
Before locating the boiler:
❏ Check for nearby connection to:
• System water piping
• V enting connections (page 6)
• Combustion and ventilation air provisions (page 4)
• Oil supply piping (page 14 and burner manual)
• Electrical power
❏ Check area around boiler. Remov e any combustible materials,
gasoline and other flammable liquids.
Failure to keep boiler area clear and free of
combustible materials, gasoline and other flammable
liquids and vapors can result in severe personal
injury, death or substantial property damage.
❏ Boiler must be installed so that burner and control system
components are protected from dripping or spraying water or
rain during operation or service.
❏ If new boiler will replace existing boiler, chec k f or and correct
system problems, such as:
1. System leaks causing oxygen corrosion or section cracks
from hard water deposits.
2. Incorrectly-sized expansion tank.
3. Lack of antifreeze (when required) in boiler water causing
system and boiler to freeze and leak.
2 Part Number 672 01 1005 00
OWB & OWT
Oil-Fired Water Boilers – Boiler Manual
1 Prepare boiler location
Clearances Flooring and foundation
Minimum clearance to combustible materials
1. Minimum clearances from vent pipe to combustible material (see
Figure 1, vent clearances indicated with “*”):
• Type “L” double wall vent — 6 inches minimum
• Singlewall vent — 18 inches minimum
Flue pipe clearances must take precedence over
jacket clearances (listed below).
Service clearances
1. Recommended service clearances (see Figure 1):
• Front and top — 24 inches
• Left side, back and right side — 6 inches
• Right side for burner door swing radius — 12 inches
2. Special close clearances (alcove, closet, under counters, etc.)
– see “Appendix,” page 17.
Figure 1 Minimum clearances
Flooring
The OWB and OWT boilers are approved for installation on
combustible flooring, but must never be installed on carpeting.
Do not install boiler on carpeting even if foundation is
used. Fire can result, causing se vere personal injury ,
death or substantial property damage.
Foundation
1. Provide a solid brick or minimum 2-inch thick concrete
foundation pad if any of the following is true:
• floor can become flooded.
• the boiler mounting area is not level.
2. See T ab le 1 for minimum f oundation dimensions.
Table 1 Minimum foundation size
Boiler
model
number
OWB/OWT3 17 22 2
OWB/OWT4 17 22 2
OWB/OWT5 20 22 2
OWB/OWT6 23 22 2
Length
inches
Width
inches
Minimum
height
inches
Residential garage installations
T ake the f ollowing special precautions when installing the boiler in
a residential garage. If the boiler is located in a residential garage:
• Mount the boiler a minimum of 18 inches above the floor of the
garage to ensure the burner and ignition devices will be no less
than 18 inches above the floor .
• Locate or protect the boiler so it cannot be damaged by a moving
vehicle.
3Part Number 672 01 1005 00
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Oil-Fired Water Boilers – Boiler Manual
1 Prepare boiler location continued
Air contaminationAir for combustion and ventilation
Adequate combustion and ventilation air:
• Assures proper combustion.
• Reduces risk of severe personal injury or death from
possible flue gas leakage and carbon monoxide
emissions.
• Do not install exhaust fan in boiler room.
Consider building construction
Older buildings with single-pane windows, minimal weather-stripping
and no vapor barrier often provide enough natural infiltration and
ventilation without dedicated openings.
New construction or remodeled buildings are most often built tighter .
Windows and doors are weather-stripped, vapor barriers are used
and openings in walls are caulked. As a result, such tight
construction is unlikely to allow proper natural air infiltration and
ventilation.
Follow state, provincial or local codes when sizing adequate
combustion and ventilation air openings. In absence of codes, use
the following guidelines when boiler is in a confined room (defined
by NFPA 31 as less than 7200 cubic feet per 1 GPH input of all
appliances in area. A room 8 ft. high x 30.0 ft. x 30.0 ft. is 7200 cu.
ft.).
Provide two permanent openings:
One within 12 inches of ceiling, one within 12 inches of floor. Minimum
height or length dimension of each rectangular opening should be
at least 3 inches.
When inside air is used:
Each opening must freely connect with areas having adequate
infiltration from outside. Each opening should be at least 140 sq. in.
per 1 GPH input (1 sq. in. per 1000 Btu input) of all fuel-burning
appliances plus requirements for any equipment that can pull air
from room (including clothes dryer and fireplace).
When outside air is used:
Connect each opening directly or by ducts to the outdoors or to
crawl or attic space that freely connects with outdoors. Size per
below:
• Through outside wall or vertical ducts — at least 35 sq. in. per
1 GPH input (1 sq. in. per 4000 Btu input) of all fuel burning
appliances plus requirements for any equipment that can pull
air from room (including clothes dryer and fireplace).
• Through horizontal ducts — at least 70 sq. in. per 1 GPH boiler
input (1 sq. in. per 2000 Btu input) of all fuel-burning appliances
plus requirements for any equipment that can pull air from room
(including clothes dryer and fireplace).
• Where ducts are used, they should have same cross-sectional
area as free area of openings to which they connect.
Compensate for louver, grille or screen blockage when
calculating free air openings. Refer to their manufacturer’s
instructions for details. If unknown, use:
• Wood louvers , which provide 20-25% free air.
• Metal louvers or grilles, which provide 60-75% free air .
Lock louvers in open position or interlock with equipment to
prove open before boiler operation.
Please review the following information on potential combustion air
contamination problems.
See Tab le 2 for products and areas which may cause contaminated
combustion air .
T o prev ent potential of severe personal injury or death,
check for products or areas listed below before
installing boiler. If any of these contaminants are found:
• remove contaminants permanently .
— OR —
• isolate boiler and provide outside combustion air. See
national, provincial or local codes for further
information.
Table 2 Corrosive contaminants and likely locations
Products to avoid
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents found in
household laundry rooms
Adhesives used to fasten building products and other similar products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
4 Part Number 672 01 1005 00
2 Prepare boiler
OWB & OWT
Oil-Fired Water Boilers – Boiler Manual
Place boiler
The boiler contains ceramic fiber and fiberglass
materials. Use care when handling these materials
per instructions on page 21 of this manual. F ailure to
comply could result in severe personal injury .
1. Remov e circulator carton strapped to pallet.
Circulator will be damaged if not removed before boiler
is lifted from pallet.
2. Remove boiler from pallet.
Do not drop boiler or bump jacket or burner on floor
or pallet. Damage to boiler or burner can result.
Smaller sized boilers may be top heavy . Use caution
when handling to avoid minor personal injury or
property damage.
3. Check level. Shim legs if needed.
4. Open burner mounting door. V erify that chamber ceramic liner
is securely in place on target wall, chamber floor and burner
door. V erify door seal is intact and in place. Close and securely
bolt the door.
6. Visually check:
a. Flue collector hood seal.
b . Burner mounting door seal.
Obtain gas-tight seal to prevent possible flue gas
leakage and carbon monoxide emissions, which can
lead to severe personal injury or death.
Hydrostatic pressure test
1. Install air vent in air vent tapping on top of boiler (see Figure 20,
page 26, for location).
3. Plug supply and return tappings.
4. Drain valve is factory-installed.
5. Fill boiler. V ent all air. Pressure test boiler at 1 ½ times w orking
pressure.
Do not leave boiler unattended. Cold water fill can
expand and damage cast iron, resulting in severe
personal injury, death or substantial property damage.
6. Verify that boiler maintains pressure for at least 10 minutes.
Visually check for leaks if gauge pressure drops.
7. Drain boiler. Repair leaks if f ound.
Using petroleum-based compounds to repair leaks
can damage system components, resulting in
property damage.
8. Retest boiler after repairing leaks.
9. Remove air vent and plugs.
5Part Number 672 01 1005 00
OWB & OWT
Oil-Fired Water Boilers – Boiler Manual
3 Connect breeching
General venting requirements
Failure to follo w all instructions can result in flue gas
spillage and carbon monoxide emissions, causing
severe personal injury or death.
Inspect existing chimney before installing boiler.
Insufficient draft can cause flue gas leakage and
carbon monoxide emissions. Failure to clean or
replace perforated pipe or tile lining and/or patch
mortar and joints can cause severe personal injury
or death.
• The OWB and OWT boilers are designed to operate with an
over-fire draft of -0.01" to -0.02" w.c. Proper draft f or these oil
boilers may be achieved using either a conventional chimney
(natural draft) or a power vent (sidewall) system that has been
properly designed for use with oil-fired equipment. Pow er vent
manufacturer’s instructions must be f ollowed.
• Use vent material approved by local codes for oil-fired burners.
In their absence, refer to:
• NFP A 31, Installation of Oil-Burning Equipment.
• NFP A 211, Standard f or Chimneys, Fireplaces , Vents and
Solid Fuel Burning Appliances.
• In Canada, refer to CSA B139, Installation Code for Oil-
Burning Equipment.
• NFPA 211 requires chimney to be lined before connected
to boiler.
• To prevent downdrafts, extend chimney at least 3 feet above
highest point where it passes through roof and 2 feet higher
than any portion of building within 10 feet. Increase chimney
cross-sectional area and height at least 4% per 1,000 feet above
sea level.
• Provide minimum clearances from vent (flue) pipe to combustible
material:
• Type “L” double wall vent — 6 inches minimum
• Singlewall vent — 18 inches minimum
• Minimum chimney sizes should be used. See Table 3.
Oversized chimneys, outside masonry chimneys
and/or derated inputs can result in condensation in
chimney.
Connect breeching
Long horizontal breechings, excessive number of
tees and elbows, or other obstructions restricting
combustion gas flow can result in possibility of
condensation, flue gas leakage and carbon monoxide
emissions, which can lead to severe personal injury
or death.
1. See Figure 2.
2. Connect full-sized breeching when possible. See Table 3.
3. Connection must be made above bottom of chimney to avoid
blockage. Breeching must not enter chimney far enough to
Figure 2 Chimney and breeching connections
Table 3 Chimney and breeching minimum sizes
Boiler
model
number
OWB/OWT3 5" 8" x 8" 6" 15'
OWB/OWT4 6" 8" x 8" 6" 15'
OWB/OWT5 6" 8" x 8" 7" 15'
OWB/OWT6 7" 8" x 8" 7" 15'
Notes:
1. Flue collar on boiler is7" diameter
2. 6 ¾"x6¾"insideliner
cause obstruction. Use thimble or slip joint where breeching
enters chimney to allow removal for cleaning.
4. When burner and boiler are properly installed, draft overfire will
be approximately -0.01" to -0.02" W .C . Install barometric control
in breeching, per control manufacturer's instructions, when
excess draft needs to be relieved or to comply with applicable
codes and regulations. Use draft gauge to adjust proper opening.
5. An induced draft fan for the chimney may be necessary if:
• Excessive resistance to flow of combustion gases can be
expected.
• Cross-sectional area of chimney is smaller than minimum
recommended.
• Chimney height is less than recommended.
• Seal all vent joints. Interlock burner with fan operation.
Minimum
breeching
diameter
Note 1
Minimum I=B=R
chimney size
Rectangle
Note 2
Round
Minimum
chimney
height
6 Part Number 672 01 1005 00
OWB & OWT
4 Connect water piping
Oil-Fired Water Boilers – Boiler Manual
General
If installation is to comply with ASME or Canadian requirements,
an additional high temperature limit is needed. Install control in supply
piping between boiler and isolation valve. Set second control to
minimum 20 °F above setpoint of first control. Maximum allowable
setpoint is 240 °F. See page 11 for wiring.
A low water cutoff device is required when boiler is installed above
radiation level or by cer tain state or local codes or insurance
companies. Use low water cutoff designed for water installations.
Electrode probe-type is recommended. Purchase and install in tee
in supply piping above boiler .
Use backflow check valve in cold water supply if required by local
codes.
Near -boiler piping
See Figure 3 (diaphragm-type or bladder-type expansion tank) or
Figure 4 (closed-type expansion tank) on page 8, and Table 4, for
near-boiler and single-zone systems designed for return water at
least 130 °F. See Figure 6 or 7, page 9 for low return temperature
applications.
See this page for multiple-zone piping.
See page 8 for boilers used with refrigeration systems.
Relief valve
Install relief valve v ertically in ¾" tapping on rear of boiler using ¾"
nipple and elbow supplied in bag with valve. See the tag attached to
the relief valve f or manufacturer’s instructions.
To avoid water damage or scalding due to valve
operation, discharge line must be connected to relief
valve outlet and run to a safe place of disposal.
T erminate the discharge line to eliminate possibility
of severe burns should the valve discharge.
• Discharge line must be as short as possible and be
the same size as the valve discharge connection
throughout its entire length.
• Discharge line must pitch downward from the valve
and terminate at least 6" above the floor drain where
any discharge will be clearly visible.
• The discharge line shall terminate plain, not threaded,
with a material serviceable for temperatures of 375 °F
or greater.
• Do not pipe the discharge to any place where freezing
could occur.
• No shutoff valve shall be installed between the relief
valve and boiler , or in the discharge line. Do not plug
or place any obstruction in the discharge line.
• Failure to comply with the above guidelines could
result in failure of the relief valve to operate, resulting
in possibility of severe personal injury, death or
substantial property damage.
• Test the operation of the valve after filling and
pressurizing system by lifting the lever. Make sure
the valve discharges freely. If the valve f ails to operate
correctly , replace it with a new relief v alv e.
Near -boiler piping continued
Table 4 Water pipe size (based on 20 °F rise)
Boiler
model
number
OWB/OWT3 1 ¼" 1 ¼"
OWB/OWT4 1 ¼" 1 ¼"
OWB/OWT5 1 ½" 1 ½"
OWB/OWT6 1 ½" 1 ½"
All piping sizes based on 20 °F temperaturerise through boiler.
Circulator
The circulator is shipped loose (wiring pre-attached to boiler) to
allow you to locate it either in the return or supply piping, as desired.
See page 8 for a typical installation. Pipe the expansion tank to the
suction side of the circulator whenever possible. Install an air
separator in the supply piping. Connect the expansion tank to the
air separator only if the separator is on the suction side of the
circulator. Always install the system fill connection at the same point
as the expansion tank connection to the system. Figures 3 and 4,
on page 8, show typical near-boiler piping connections.
Expansion tank
Diaphragm- or bladder-type expansion tank — Figur e 3,
page 8
1. Ensure expansion tank size will handle boiler and system water
volume and temperature. T ank m ust be located in boiler return
piping as close to boiler as possible, bef ore inlet side of circulator.
See tank manufacturer’s instructions for details.
2. Install an automatic air vent as shown.
Closed-type expansion tank — Figure 4, page 8
1. Ensure expansion tank size will handle boiler and system water
volume and temperature. See tank manuf acturer’s instructions
for details.
2. Connect tank to ½" NPT tapping located behind supply outlet,
using ½" NPT piping. Pitch any horizontal piping up towards
tank 1 inch per 5 feet of piping.
Undersized expansion tanks cause system water to
be lost from relief valve and makeup water to be
added through fill valve. Eventual section failure can
result.
Water piping — multiple zone systems
Install system piping using either circulator zoning or zone valve
zoning. Install expansion tank on suction side of system pump.
Always connect fill line only at the expansion tank — never at
another point in the system.
To
system
From
system
7Part Number 672 01 1005 00
OWB & OWT
Oil-Fired Water Boilers – Boiler Manual
4 Connect water piping continued
Figure 3 Diaphragm- or bladder-type expansion tank:
Piping to single-zone system using
diaphragm-type or bladder-type expansion
tank. See Table 4, page 7, for piping sizes.
Figure 4 Closed-type expansion tank: Piping to
single-zone system using closed-type
expansion tank. See Table 4, page 7, for
piping sizes.
Use Figure 3 or Figure 4 only for systems designed
for return water at least 130 °F. For systems with low
return water temperature possible, such as
converted gravity systems and radiant heating
systems, install by-pass piping (see page 9) to protect
boiler against condensation. Failure to prevent low
return water temperature to the boiler could cause
corrosion of the boiler sections or burners, resulting
in severe personal injury, death or substantial
property damage.
If system includes radiant heating circuits, provide
piping and controls to regulate the temperature
supplying the radiant circuits. Failure to comply could
result in substantial property damage.
Install boiler so that chilled medium is piped in parallel
with heating boiler. Use appropriate valves to pre vent
chilled medium from entering boiler. Consult I=B=R
Installation and Piping Guides.
If boiler is connected to heating coils located in air
handling units where they can be exposed to
refrigerated air, use flow control valves or other
automatic means to prevent gravity circulation during
cooling cycle. Circulation of cold water through the
boiler could result in damage to the heat exchanger ,
causing possible severe personal injury, death or
substantial property damage.
Water piping — refrigeration systems
Prevent chilled water from entering boiler
Install boiler so that chilled medium is piped in parallel with the
heating boiler. Use appropriate valves to prevent chilled medium
from entering boiler. See Figure 5 for typical installation of balancing
valve and check valve.
Figure 5 Piping refrigeration systems
8 Part Number 672 01 1005 00
OWB & OWT
4 Connect water piping continued
Near -boiler piping continued
Oil-Fired Water Boilers – Boiler Manual
Figure 6 System bypass piping in boiler loop with
separate system circulator, using primary/
secondary piping.
Figure 7 Boiler bypass piping — use only for high
water content systems —DO NOT use for
radiant panel systems.
System bypass method
1. Apply bypass piping of Figure 6 to high water content systems,
radiant panel systems or any system that is likely to operate
with low return water temperature for extended periods.
2. The bypass arrangement shown protects the boiler from damage
caused by condensate corrosion due to low return water
temperature and protects low temperature systems from too
high a supply temperature.
3. Adjust the bypass valves as indicated below .
Adjust Bypass valves 1 and 2 as follows:
1. Start with valve 2 fully closed, valv e 1 fully open.
2. Slowly open valve 2 while closing valve 1. Adjust the valves
until the boiler pressure/temperature gauge reads 160 °F or
higher. As you open the valves, pause long enough to allow
temperatures to level off. It takes a while for the boiler water
temperature to rise as the flow changes.
3. Bypass valve 2 allows hot boiler outlet water to blend with colder
return water, raising the supply temper ature to the boiler. Bypass
valve 1 balances the pressure drop through valve 2.
4. The purpose of this piping is to raise the return water temperature
to the boiler enough to prevent condensation of flue gases.
Install all components specified above and adjust valv es as described to prev ent low temper ature in the boiler . Fa ilure to
prevent low water temperature in the boiler could cause corrosion of the boiler sections or burners, resulting in severe
personal injury, death or substantial property damage.
Boiler bypass method
1. Apply bypass piping of Figure 7 to high water content systems,
such as converted gravity systems.
2. The bypass arrangement shown protects the boiler from damage
caused by condensate corrosion due to low return water
temperature. This method does not pro vide protection from high
temperature water being supplied to the system.
3. DO NOT apply this piping to radiant panel systems.
4. Adjust the bypass valves as indicated below .
Adjust Bypass valves 1 and 2 as follows:
1. Start with valve 1 fully closed, valv e 2 fully open.
2. Slowly open valve 1 while closing valve 2. Adjust the valves
until the boiler pressure/temperature gauge reads approximately
60 °F higher than the system temperature gauge. As you open
the valves, pause long enough to allow temperatures to level
off. It takes a while for the boiler water temperature to rise as
the flow changes.
3. Bypass valve 1 controls system flow rate. Bypass valve 2
controls flow through the boiler.
4. The purpose of this piping is to cause a high enough temperature
rise in the boiler that the average temperature will be warm
enough to prevent condensation of flue gases.
9Part Number 672 01 1005 00
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