Lennox COWB3 Installation Instructions Manual

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PRODUCT LITERATURE

Lennox Industries Inc. Dallas, Texas

INSTALLATION

INSTRUCTIONS

COWB3

OIL FIRED BOILER

RETAIN THESE INSTRUCTIONS FOR

FUTURE REFERENCE

These instructions must be afxed on

or adjacent to the boiler.

Tested For 50 psi.

ASME

Working Pressure

Improper installation, adjustment, alteration, service, or maintenance could result in death or serious injury. Refer to this manual for assistance. For additional information consult

a qualied installer, service agency, or the oil

supplier.

WARNING

OIL FIRED BOILERS

These boilers are low pressure, sectional cast iron boilers constructed and hydrostatically tested for a maximum working pressure of psi in accordance with A.S.M.E. (American society of Mechanical Engineers) Section IV Standards for cast iron heating boilers.

P/N 240009550, Rev. E [12/2014]

SAFETY NOTICES

Safety Notices .....................................................2

Boiler Ratings And Capacities .............................3

Safe Installation And Operation ........................... 4

Locating The Boiler .............................................. 5

Fresh Air For Combustion.................................... 7

System Piping......................................................9

System Piping Arrangement .............................. 15

Chimney And Chimney Connections ................. 16

Typical Chimney Connection ............................. 17

Electrical Connections ....................................... 18

Filling The Boiler .............................................. 19

Operating The Boiler .......................................20

Checking And Adjusting Controls ...................... 23

Maintenance ...................................................... 24

Oil Boiler / Burner Cleaning Instructions ........... 25

Oil Burner Cleaning ........................................... 26

Service Hints .....................................................27

Introduction

Conservator 2 water boiler is a natural draft oil red hot

water boiler comprised of cast iron sections. Conservator 3 Water boiler is available with 3, 4, or 5 cast iron sections. These sections are held together by cast iron push nipples.

Conservator 2 water boiler is capable of ring #2 fuel oil

from 0.65 gph up to 1.75 gph. All packaged boilers include a swing door, Honeywell limit, temperature and pressure

gauge, safety relief valve, drain valve, ue brush, and extra boiler tap for expansion tank or air elimination.

Electrical Wiring .................................................28

Equipment and Optional Accessories ................ 30

Boiler installation shall be completed by qualied agency.

Become familiar with symbols identifying potential hazards.

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

DANGER

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal injury.

36”

20 1/2”

Figure 1 - Dimensions

BOILER RATINGS AND CAPACITIES

‡NET AHRI

RATING

WATER

*Mbh

A.F.U.E.++NO.

SEC.

MINIMUM

CHIMNEY

SIZE/

HEIGHT

BOILER MODEL

NO.

INPUT

**HEATING

CAPACITY

+gph *Mbh A B C

*Mbh

COWB3-3-.65 0.65 91 80 70 86.3 3 8” X 8” X 15” 14½ 6 8 COWB3-3-.75 0.75 105 92 80 85.2 3 8” X 8” X 15” 14½ 6 8

COWB3-3-1.00 1.00 140 120 104 84.0 3 8” X 8” X 15” 14½ 6 8

COWB3-4-.90 0.90 126 111 97 86.0 4 8” X 8” X 15” 17¾ 6 9⅝

COWB3-4-1.25 1.25 175 151 131 85.0 4 8” X 8” X 15” 17¾ 6 9⅝ COWB3-4-1.50 1.50 210 179 156 84.0 4 8” X 8” X 15” 17¾ 6 9⅝ » COWB3-5-1.20 1.20 168 147 128 86.5 5 8” X 8” X 15” 21 6 11½ COWB3-5-1.75 1.75 245 210 183 84.3 5 8” X 8” X 15” 21 6 11½

* Mbh = 1,000 BTU per hour [BTU = British Thermal Unit] **Heating Capacity based on 13% CO2 with a 0.02” w.c. draft over re, and a #1 smoke or less. Testing was done in

accordance with the D.O.E. (Department of Energy) test procedure.

+ gph = Gallons per hour oil at 140,000 BTU per gallon

++A.F.U.E. = Annual Fuel Utilization Efciency based upon D.O.E. test procedure. ‡ Net AHRI Water Ratings based on piping and pickup allowance of 1.15. Consult manufacturer before selecting boiler for

installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping

systems, etc.

>>Per Energy Star specications, AFUE is rounded to the nearest whole percentage point. As such, this product qualies for

Energy Star.

DIMENSIONS

(inches)

SAFE INSTALLATION AND OPERATION

NOTICE

This boiler has been designed for residential installations. If used for commercial applications, all jurisdictional requirements must be met. This

may require wiring and/or piping modications.

Manufacturer is not responsible for any changes to the original design.

Read the Owner’s Manual for Safe Operation. Failure to follow rules for safe operation and instructions can cause malfunction of boiler and result in death, serious bodily injury, and/or property damage.

Install boiler in accordance with requirements of authority having jurisdiction, or in the absence of such requirements

• United States. NFPA 31: Installation of Oil Burning Equipment

• Canada. CSA B139: Installation of Oil Burning Equipment

Before servicing, allow boiler to cool. Always shut off any electricity and oil to boiler when working on it.

Inspect oil line and connections for leaks.

Be certain oil burner nozzle is the size required. Over-

ring will result in early failure of the boiler sections.

This will cause dangerous operation.

Never vent this boiler into enclosed space. Always vent to outside. Never vent to another room or inside a building.

Be sure there is adequate air supply for complete combustion.

Follow regular service and maintenance schedule for

efcient and safe operation.

Keep boiler area clean and free of combustible material,

gasoline and other ammable vapors and liquids.

10.

Oil burners are not do-it-yourself items. This

boiler must be installed and serviced by qualied

professionals using combustion test instruments.

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.

11.

Be aware when piping the safety relief valve if system

pressure exceeds safe limit of 30 pounds per square

inch, the safety relief valve will automatically lift open. Lifting of the safety relief valve can discharge large quantities of steam and hot water, which may damage the surroundings. Before installing the safety relief valve read the manufacturer’s instructions and maintenance section of the manual on safety relief valves.

12.

Installation and sizing of the expansion tank must

consider heating systems total water volume,

temperature, boiler initial ll pressure, and system arrangement. Improperly installed and sized expansion

tank may result in frequent lifting of the safety relief valve or other heating system problems. For proper installation, sizing, and maintenance of the

expansion tank follow guidelines established by tank

manufacturer.

13.

Expansion tank performance and life expectancy can be hindered by overlling the boiler. Recommend initial ll pressure of 10-12 psig. For higher ll pressures expansion tank’s air charge will need to be increased to match ll pressure. Consult manufacturer’s guidelines

for sizing and selection.

14.

Purging the heating system of air and gases when

rst putting boiler into service is critical for proper

circulation and quiet performance. Once air and gases

are purged, for boiler installations using oat type

vents, air vents should be closed for normal operation. If air is heard or noticed by loss of heat, purge system and open vents for short period of time.

DO NOT USE GASOLINE CRANKCASE DRAININGS OR

ANY OIL CONTAINING GASOLINE.

LOCATING THE BOILER

Complete Prior To Installing Boiler.

A. Verify you have selected the right size boiler with

proper capacity. AHRI rating of boiler selected

should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by boiler and associated hot water heating

systems. See boiler rating and capacity table previously listed in this manual. Any heat loss calculations used should be based on approved methods.

B. Boiler must be supplied with proper oil supply and

oil piping, sufcient fresh combustion air, and suitable electrical supply.

C. Boiler must be connected to suitable venting system

and piping system adequate to distribute heating

load.

D. Properly locate and install thermostat for heating

system control.

Any doubts as to requirements, check with local authorities and obtain professional help where needed. OPERATING INSTRUCTIONS, FINAL CHECKS AND ADJUSTMENTS, and MAINTENANCE sections in this manual are vital to the

proper and safe operation of the heating system.

Place boiler in location centralized with the piping system and as close to chimney as possible.

Boiler must be level. If necessary use metal shims beneath boiler’s feet.

Use raised base if oor can become wet or damp. Maintain clearances for re safety as well as

servicing. 18” clearance must be maintained at side where passage is required for access to another side for cleaning, servicing, inspection or replacement of any parts that may normally require attention. Install boilers at least 6” from combustible material on left side, rear, and above, and at least 24” on right side and front. Allow at least 24” accessiblity clearance above for servicing.

Fresh air for combustion must be available at front of the boiler. Fresh air for ventilation must be available to front and rear of boiler. Air passages must be free of obstructions at all times. Ventilating and combustion air must enter boiler room without restrictions.

WARNING

Fire hazard. Do not install boiler on combustible

ooring or carpeting. Failure to follow these

instructions could result in death or serious injury.

Figure 2 - Clearances

6”

Min.

6”

Front

Min.

(Burner

Side)

24” Min.

Floor supporting boiler must be noncombustible and

sufciently stable. If it is combustible, place boiler

on 2” concrete patio blocks or 2” Cladlite Pad™. Blocks or pad must be under entire boiler to protect

the oor.

Install boiler in accordance with requirements of authority having jurisdiction, or in the absence of such requirements

• United States. NFPA31: Installation of Oil Burning Equipment

• Canada. CSA B139: Installation of Oil Burning Equipment

BOILER CLEARANCES

Unit

Top 6” 24”

Left Side 6”

Right Side 24”

Base non-combustible

Front 24”

Back 6”

Combustible

Clearance

All distances measured from the cabinet of the boiler.

Accessibility,

Cleaning, and

Servicing

Flue to

Combustible

Clearance

9”

OIL FILTER

LOCATING THE BOILER

Figure 3 - Boiler With Piping System

AUTOMATIC

FILL VALVE

AND SHUTOFF

DIAPHRAGM

EXPANSION TANK

DRAFT

REGULATOR

CHI

VENT

PIPE

MNE

RELIEF VALVE

TO RADIATION

FROM RADIATION

CIRCULATING

PUMP IN

TANK

OR AFTER THE

RETURN LINE

EXPANSION

ELECTRIC LINE

SERVICE LINE

PROTECTED

OVERCURRENT

SAFETY SWITCH

ENTRANCE

SWITCH

2" FILL

PIPE

VENT PIPE

MIN. 2" I.D.

LINES TO OTHER

APPLIANCES

TO OUTSIDE

OIL TANK

OIL BURNER

VALVE

FOUNDATIONS

GENERAL PRINCIPAL REQUIREMENTS FOR A TYPICAL INSTALLATION

OIL LINES

FRESH AIR FOR COMBUSTION

WARNING

EXAMPLE 2: Boiler Located in Conned Space

Asphyxiation, re hazard. Do not obstruct air

openings to combustion area. Follow instructions below, to maintain adequate combustion air.

NOTICE

Install outside air intake if you use replace or kitchen or bathroom exhaust fan. These devices rob

boiler and water heater of combustion air.

Provide adequate supply of combustion air in accordance with requirements of authority having jurisdiction. In absence of such requirements

• United States. NFPA 31: Installation of Oil Burning Equipment

• Canada. CSA B139: Installation of Oil Burning Equipment

EXAMPLE 1: Boiler Located in Unconned Space

If your boiler is in an open area (un-partitioned basement) in conventional house, air that leaks through cracks around doors and windows will usually be adequate to provide air

for combustion. Doors should not t tightly. Do not caulk

cracks around windows.

An unconned space is dened as space whose volume is

not less than 50 cubic feet per 1,000 Btu per hour of total input rating of all appliances installed in that space.

A. All Air from Inside the Building: Conned space

shall be provided with two permanent openings communi-

cating directly with additional room(s) of sufcient volume

so the combined volume of all spaces meets the criteria for

unconned space. Total input of all combustion equipment

installed in combined space shall be considered in making this determination. Each opening shall have minimum free area of one square inch per 1,000 Btu per hour of total

input rating of all combustion equipment in the conned

space, but not less than 100 square inches. One opening shall be within 12 inches of top and one within 12 inches of bottom of the enclosure.

Example: Your boiler is rated at 100,000 Btu per hour. Water heater is rated at 30,000 Btu per hour. Total is 130,000

Btu per hour. You need two grilles, each with 130 square

inches of FREE opening. Metal grilles have about 60% FREE

opening. To nd louvered area needed, multiply free opening required by 1.7 (130 x 1.7 = 221.0 sq. in. louvered area). In this example, two grilles each having 8” x 30”

(240 sq. in.) louvered area would be used.

Figure 4 - Air Openings For Boiler Located In

Conned Space (Utility Room)

FRESH AIR FOR COMBUSTION

B. All Air from Outdoors: Conned space shall be pro-

vided with two permanent openings, one commencing within 12 inches of top and commencing within 12 inches of bottom of enclosure. Openings shall communicate directly, or by ducts, with outdoors or spaces (crawl or attic) that freely communicate with outdoors.

1. When directly communicating with outdoors, each

opening shall have minimum free area of one square inch per 4,000 Btu per hour of total input rating of all equipment in the enclosure.

2. When communicating with outdoors through verti-

cal ducts, each opening shall have minimum free area of one square inch per 4,000 Btu per hour of total input rating of all equipment in the enclosure.

3. When communicating with outdoors through hori-

zontal ducts, each opening shall have minimum

free area of one square inch per 2,000 Btu per hour of total input rating of all equipment in the enclosure.

4. When ducts are used, they shall be of same cross sectional area as free area of openings to which they connect. Minimum dimension of rectangular air ducts shall be not less than three inches.

Figure 5 - Fresh Air Duct Capacities For Ducts Supplying Fresh Air To Boiler In Tightly Constructed Houses

FRESH AIR DUCT CAPACITIES

THROUGH LOUVERS

Fresh Air

Duct Size

3 ½” x 12” 144,000 36,000 108,000

8” x 8” 256,000 64,000 192,000

8” x 12” 384,000 96,000 288,000

8” x 16” 512,000 128,000 384,000

*Btuh = British Thermal Units per hour based on

opening covered by ¼” mesh screen , wood louvers,

¼” Mesh

Screen

(Btuh)* (Btuh)* (Btuh)*

or metal louvers.

Wood

Louvers

Metal

Louvers

SYSTEM PIPING

Installation of boiler for new heating system,

Install all of radiation units (panels, radiators, baseboard, or tubing) and supply and return mains

rst. After all heating system piping and components have been installed, make nal connection of system

piping to boiler. It is recommended to mount circulating pump on supply side piping, such that it pumps away

from expansion tank. Refer to gures on next pages.

Equip hot water boiler installed above radiation level with low water cut off device. Periodic inspection

is necessary, as is ushing of oat type devices, per low water cut off manufacturer’s specic instructions.

Packaged boiler is set up with 1¼” NPT supply and return piping from front of boiler. Boiler supply

and return piping can be moved to rear of boiler. Boiler should not be piped return line to front, supply line to rear, or vice versa, will cause boiler water to short

circuit heat exchanger. Piping connections may require additional ttings and parts.

Install drain valve provided with boiler in return tee.

See gure 1.

Install Safety Relief valve in rear section using ¾”

nipple and street elbow provided with boiler. See gure

6. A. Install safety relief valve with spindle in vertical

position.

B. Do not install shutoff valve between boiler and

safety relief valve.

C. Install discharge piping from safety relief valve.

• Use ¾” or larger pipe.

Low Design Water Temperature Systems (Below 140° F) And Large Water Content Systems

• Signicant condensation may form in this boiler and/ or venting system if boiler is operated with return temperatures of less than 120°F.

• Condensation is corrosive and can eventually cause damage to boiler and venting system. Minimum design return water temperature to prevent this condensation in boiler and venting is 120°F.

• Boiler used in heating system where design water

temperatures below 140°F are desired (e.g. radiant oor heating), a 3-way or 4-way mixing valve or suitable

alternative (e.g. Bypass Piping Arrangement shown in diagram on following page) is required to prevent low temperature (below return 120°F) return water

from entering boiler. When using mixing valve, follow

manufacturer’s installation instructions.

• Boiler connected to system having large water content (such as former gravity system), use of Bypass Piping Arrangement shown in diagram on following page is suggested.

Figure 6 - Safety Relief Valve Installation

• Use pipe suitable for temperatures of 375°F (191°C) or greater.

• Individual boiler discharge piping shall be independent of other discharge piping.

• Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.

• Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve outlet and downstream of union (if used).

• Terminate pipe with plain end (not threaded).

Verify clean cold water supply is available when connecting to pressure reducing valve. When water supply is from well or pump, a sand strainer should be installed at the pump.

Follow Instructions to install discharge piping from safety relief valve to drain.

SYSTEM PIPING

Figure 7 - Bypass Piping Arrangement Diagram

> LOW DESIGN WATER TEMPERATURE SYSTEMS

> LARGE WATER CONTENT SYSTEMS

> PIPING ARRANGED FOR “POWER PURGING”

AIR OUT OF THE SYSTEM PIPING, REFER TO THIS MANUAL’S SECTION ON “FILLING THE SYSTEM WITH WATER” OPTION #1

SYSTEM PIPING

Figure 8 - System Piping Arrangement Zoning With Zone Valves

> CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM

EXPANSION TANK

NOTE: CIRCULATOR CAN ALSO BE INSTALLED ON RETURN PIPING.

> PIPING ARRANGED FOR “POWER PURGING” AIR

OUT OF SYSTEM PIPING, REFER TO THIS MANUAL’S SECTION ON “FILLING THE SYSTEM WITH WATER”

OPTION #1

SYSTEM PIPING

Figure 9 - System Piping Arrangement Zoning With Circulators

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

> PIPING ARRANGED FOR “POWER PURGING”

AIR OUT OF SYSTEM PIPING, REFER TO THIS MANUAL’S SECTION ON “FILLING THE SYSTEM WITH WATER” OPTION #1

SYSTEM PIPING

Figure 10 - System Piping Arrangement Alternate Near Boiler Piping

> DIAPHRAGM EXPANSION TANK MOUNTED

> PER THIS MANUAL, USE OPTION #2 IN

OFF THE BOILER

> CIRCULATOR ON SUPPLY PIPING PUMPS

> THIS PIPING ARRANGEMENT CAN BE USED

AWAY FROM EXPANSION TANK

“FILLING THE SYSTEM WITH WATER”

WITH ZONE VALVES OR ZONE

CIRCULATORS

SYSTEM PIPING

Tankless Coil Piping Arrangement

Boilers may be factory packaged with tankless heater coil see gure below. Coil provides instantaneous heating

of water for domestic use if proper burner and water supply line controls are used. Tankless coils are meant to provide domestic hot water for intermittent draws, not continuous

ow.

NOTICE

Do not use tankless coil if your water is excessively

hard with lime or other deposits which will accumulate inside the coil.

When using tankless coil, boiler is congured so Honeywell

L7248 operates with Honeywell L4006 low limit mounted on well installed in tankless heater. Mount factory wired low limit on well.

Tempering valve (mixing valve) is required as shown below.

Flow restrictor may be required on tankless coil inlet piping

so that ow rates are matched to boiler heat input (see

table).

DANGER

Water temperatures exceeding 125°F will cause

severe burns instantly or death by scalding.

Boiler

Model

Burner

Input

Rate (gph)

Input

(MBH)

Tankless

Rating

(gpm)‡

COWB3-3-.65 0.65 91 2.90

COWB3-3-.75 0.75 105 3.00

COWB3-3-1.00 1.00 140 3.25

COWB3-4-.90 0.90 126 3.15

COWB3-4-1.25 1.25 175 3.50

COWB3-4-1.50 1.50 210 3.75

COWB3-5-1.20 1.20 168 3.45

COWB3-5-1.75 1.75 245 4.00

‡ Gallons of water per minute heated from 40°F to 140°F with 200°F boiler water temperature, intermittent draw

Figure 11 -Tankless Coil Piping Arrangement

SYSTEM PIPING ARRANGEMENT

Antifreeze added to boilers must be nontoxic, and

must be of type specically intended for use in closed

hydronic heating systems. Under no circumstances should automotive antifreeze be used. Antifreeze used in any boiler may reduce capacity by 10% or more and increase fuel consumption. Tankless coil performance will fall as concentration of antifreeze is increased. Refer to boiler and piping water volumes tables.

BOILER WATER VOLUMES

Number of

Boiler Section

Total Volume

(Gallons)

3 9.6 4 11.6 5 13.7

PIPING WATER VOLUMES

PIPE SIZE

COPPER PIPE

FACTOR

½” 82.5 63.5 ¾” 40.0 36.0

1” 23.3 22.2 1 ¼” 15.3 12.8 1 ½” 10.8 9.5

2” 6.2 5.8

Divide total length of piping in feet by appropriate factor in table to determine volume in gallons.

STEEL PIPE

FACTOR

CHIMNEY AND CHIMNEY CONNECTIONS

For oil red boilers for connections to vents or chimneys,

vent installations shall be in accordance with requirements of authority having jurisdiction, or in the absence of such requirements

• United States. NFPA 31: Installation of Oil Burning Equipment

• Canada. CSA B139: Installation of Oil Burning Equipment

Fire Hazard. Maintain minimum vent pipe clearance of 18” from surface of vent to wood and other combustible materials. Failure to comply may result in death or serious injury.

Chimney Connector And Draft Regulator

NOTICE

Fresh air (ventilation) is important to proper venting. Ventilation and venting are two parts of the same system. Inadequate ventilation will result in inadequate venting. Always be sure to have enough ventilation to support proper venting.

Inspect chimney. Verify construction in accordance with requirements of authority having jurisdiction, or in the absence of such requirements

• United States. ANSI/NFPA 211: National Standard for Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances.

• Canada. National Building Code of Canada, or CAN/ BSA A405.

WARNING

• Venting the boiler requires 6” diameter chimney connector pipe and use of manufacturer provided draft regulator.

• Regulator, when properly installed, automatically controls the draft.

• Install in horizontal section of pipe, may also be installed in angled or vertical section of pipe.

• Verify “top” of regulator is at the top and short pipe section which holds the vane is horizontal.

• Even though locating draft regulator close to chimney reduces noise, install draft regulator as close as

practicable to the boiler.

• Install chimney connector, start at boiler with vertical pipe, elbow, then install draft regulator horizontally.

• When regulator is in place, start at chimney and work back to the regulator.

• Join the two sections with draw-band.

• Horizontal pipe must slope up toward the chimney at least 1/4 inch per linear foot of venting.

• Chimney connector must not leak and must be rmly supported.

• Join each section with at least two sheet metal screws. Support every second section with a stovepipe wire.

• Install Vent Safety Switch. Follow instructions included with kit. See Figure 12.

RECOMMENDED MINIMUM CHIMNEY SIZES

FIRING RATE

(gph)

0.60 1.30 15 8” x 8” 6” 6 ¾” x 6 ¾”

1.31 1.80 15 8” x 8” 7” 6 ¾” x 6 ¾”

1.81 1.75 20 8” x 8” 8” 6 ¾” x 6 ¾”

For elevations above 2,000 feet above sea level, add 3 feet to the chimney heights.

CHIMNEY

HEIGHT (ft)

NOMINAL CHIMNEY

ROUND

LINER INSIDE

SQUARE

LINER INSIDE

TYPICAL CHIMNEY CONNECTION

Figure 12 -

Typical Chimney Connection

ELECTRICAL CONNECTIONS

WARNING

Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.

Thermostat

Install 24 Volt thermostat (not provided) in proper location. Location of thermostat has effect on boiler system operation. Follow instructions included with thermostat.

Electric Power Supply

Connect boiler to electrical supply in accordance with requirements of authority having jurisdiction, or in the absence of such requirements:

• United States. NFPA70: National Electrical Code

• Canada. Canadian Electrical Code, Part I, CSA-C22.1, Electrical Code.

Connect 115 volt electrical supply to L1 and L2 terminals on limit and two thermostat wires to T and T terminals on same limit. See wiring diagram page 28.

Run separate circuit from separate over current protection device in your electrical service entrance panel. Minimum 15 ampere circuit. Locate shutoff switch at boiler. Turn off during any maintenance.

Permanently ground boiler. Run 14 gauge or heavier copper wire from boiler to grounded connection in service panel or properly driven and electrically grounded ground rod.

FILLING THE BOILER

How A Hot Water System Operates

Entire heating system (boiler, piping, and radiation units)

is lled with water. As water in the boiler is heated, it is

circulated from top of boiler through supply main to ra-

diation units. Cooler water in radiation units ows back

through return piping through return main into the boiler. This arrangement provides positive and rapid response to the thermostat.

Filling The System With Water

OPTION #1 This method utilizes boiler piping as shown in

gure on page 6.

A. Close main shutoff valve, isolation valves, and zone

valves (if applicable). If bypass piping is installed, also close two throttling valves. Leave boiler service shutoff valve (if installed) and balancing valves to each heating zone fully open.

B. Open following valves in order: drain valve for power

purging, isolating valves before and after boiler circulator (if applicable), both throttling valves (if appli-

cable), and then open ll line shutoff valve. Water will ll bypass piping and push air through piping and out

power purging drain valve. When power purging drain valve runs air free, close bypass piping throttling valve (leaving throttling valve to supply piping fully open).

C. Next, open isolation valve (or zone valve) to rst

zone. Water will ll piping and push any air out power

purging drain valve. When power purging drain valve runs air free, close isolation valve or zone valve). Repeat this procedure for remaining heating zones.

OPTION #2

• Close air vents on all radiation units.

• Open valves to radiation units. Verify boiler drain

valve, expansion tank drain cock, and air bleed screw on expansion tank drain tting are closed.

• Open ll valve on piping to expansion tank.

• Open water inlet to boiler and leave it open.

• Open air vent on lowest radiation unit.

• When all air has escaped and water starts to ow from vent, close it.

• Go to next radiation unit, and repeat this process until

nishing with highest radiation unit.

• If heating system has automatic vents, this manual venting is unnecessary but it will speed up proper lling of the system.

If system is a closed expansion tank system, automatic ll valve is needed. Leave automatic ll valve open to rell

system automatically as needed.

Note initial ll pressure on boiler’s temperature / pressure

gauge, which should be 10-15 psig. Any lowering of pres-

sure from its initial ll pressure indicates loss of water due to leakage. Automatic ll valve should then compensate for

this water pressure loss. If it does not, manually open this

valve to rell system until needle is again pointing to same

pressure reading. Instructions are packaged with valve.

D. Once all zones are lled with water and purged of air,

close power purging drain valve and ll line shut off

valve, open main shutoff valve, and adjust throttling valves and balancing valves as required.

OPERATING THE BOILER

Start: Fill entire system with water. Vent all air from sys-

tem following section for Filling The Boiler.

Air Supply For Combustion:

Fuel Units And Oil Lines:

• Install oil line(s) to oil burner.

• Recommend using heavy wall copper tubing and

ared ttings, not compression ttings.

• All connections and joints must be absolutely airtight. Use an appropriate non-hardening thread sealing

compound on the threaded connections, not Teon

tape.

• See fuel unit data sheet furnished with the burner for sizing, lift, and length of tubing recommendations.

Oil burner is equipped with single stage fuel unit with bypass plug removed for single pipe installation. Satisfactory where fuel supply is on same level as or above burner per-

mitting gravity ow of oil. Per NFPA 31 requirements, never exceed 3 psig pressure to inlet side of fuel unit.

When necessary to lift oil to burner, two pipe installation is required. Run return line between fuel unit and oil supply. When two pipe installation is used, bypass plug (furnished with burner) must be installed in fuel unit. Refer to fuel unit

instructions furnished with burner for specic instructions on installing bypass plug. Do not exceed fuel unit manufac-

turer’s recommendations for running vacuum.

Draft Regulators: Barometric draft regulator is required

for controlling draft through boiler. Mount barometric draft regulator in chimney connector. Refer back to section on “Chimney And Chimney Connections”. Once draft regulator is installed, use draft gauge to adjust to proper opening:

NOTICE

If lift exceeds 14 feet for Beckett or Carlin burners

or 11 feet for Riello burners, two stage fuel unit is required with return line.

• Do not install boiler in rooms with insufcient air, unless corrective steps are taken.

• It may be necessary to install windows or cut holes in

a door to rooms used for supply air to obtain sufcient

combustion air and prevent less than atmospheric air pressure in that room.

• If there is a lack of combustion air, burner ame will be dark orange and formation of soot will occur in heating unit.

• In buildings of conventional frame, brick, or stone construction that do not have utility rooms, basement win-

dows, or stair doors, air inltration is normally adequate

to provide enough air for combustion and for operation of barometric draft control.

• Room used for supplying combustion air should be iso-

lated from any area served by exhaust fans.

• Refer back to the section on Fresh Air For Combustion for additional sizing guidelines.

A. Combustion chamber over re draft will be approxi-

mately -0.01” WC to -0.02” WC.

B. Stack draft will be approximately -0.02” WC. to

-0.04” WC.

C. Larger installation, greater draft will be required in

stack to obtain desired over re draft.

Install oil lter of adequate size inside building between

tank shutoff valve and oil burner. For ease of servicing,

locate shutoff valve and lter near oil burner.

OPERATING THE BOILER

Nozzles And Electrodes: Use proper size, spray angle,

and spray pattern nozzle. Refer to recommended nozzle selection charts.

To install nozzle, remove nozzle line electrode assembly, if necessary remove retention ring assembly, and install and tighten nozzle. Take care not to damage electrode insulators or bend electrode tips.

After installing nozzle, reassemble nozzle line electrode assembly and set electrode tip spacing.

Depending on burner type, electrode tip spacing may need to be set prior to reassembling nozzle line electrode assembly.

Refer to following pages for setting electrode tip spacing.

Oil Burner Maintenance: Perform following

preventative maintenance annually, preferably prior to heating season.

Final Burner Adjustments: Final burner adjustments

must be made using combustion test instruments. Refer to “Burner Settings”. Set burner accordingly.

• Check draft over re to verify it is between 0.01” WC and 0.02” WC, adjust draft as necessary.

• After operating 10 minutes to warm up boiler, use combustion test equipment to take smoke reading in

ue pipe between boiler and draft regulator.

Fuel Filter Replace to prevent contaminated fuel from

reaching nozzle. Partially blocked fuel lter can cause

premature failure of fuel pump.

Fuel Pump Unit Replace pump screen and clean pump unit to maintain fuel delivery to nozzle.

Ignition Electrodes Clean and adjust per manufacturer’s recommendations, to maintain reliable ignition of oil.

Nozzle Replace to maintain safe and reliable

combustion efciency. Replace with nozzle as required

in charts located in this manual.

Fan and Blower Housing Must be kept clean, free of dirt, lint and oil to maintain proper amount of air fuel requires to burn.

Check Final Burner Adjustments.

• Smoke reading should be zero to trace (Shell Bacharach Scale).

• A new boiler requires more than 10 minutes to burn

clean due to oil lm on new heat exchanger.

• If smoke reading is zero, gradually close burner’s air adjustment to obtain smoke reading showing trace smoke reading. Once smoke reading is trace, measure CO2 and as insurance margin increase air to sufciently reduce CO2 by ½% to 1%.

If clean re cannot be obtained, it is necessary to verify

burner head and electrode alignment. Proper electrode

alignment gures are presented on following pages. If re continues to be smoky, replace nozzle with correct

replacement. Once burner is completely adjusted, burner should

be started and stopped several times to assure good

operation with no uttering or rumbling. Verify there

are no oil leaks and record nozzle size, oil pressure, combustion readings, and air settings on tag or label attached to burner or boiler.

If any component parts must be replaced, always use parts recommended by burner manufacturer.

OPERATING THE BOILER

Figure 13 -Burner Adjustments and Settings

CHECKING AND ADJUSTING CONTROLS

WARNING

Burn, scald hazard. Do not attempt to start the

burner when excess oil has accumulated, when

the unit is full of vapor, or when the combustion chamber is very hot.

NOTICE

You or your installer must follow these instructions

carefully.

Adjust Operating Controls: Use following settings for

rst adjustment:

High Limit:

Baseboard and Convectors 200°F Standing Radiators 180°F

Low Limit (when used) 140º (increase if hotter domestic

water is required, low limit set point must be at least 20°F less than high limit set point)

When low limit is used, set ELL parameter on L7248 Honeywell Control to ON. Boilers factory equipped with tankless coils, are already set to ON.

Check Thermostat Operation:

Follow instructions included with your thermostat.

Locate thermostat ve feet above the oor on inside wall.

Locate thermostat to sense average room temperature, avoid the following:

THERMOSTAT LOCATIONS TO AVOID

DEAD

SPOTS

HOT SPOTS COLD SPOTS

Concealed pipes Concealed pipes

Behind

doors

Fireplace

or ducts

TV sets Stairwells drafts

Radios Doors drafts

Corners &

alcoves

When temperature on thermostat is set above indicated thermostat temperature, boiler’s burner should start. Verify that when room temperature reaches selected temperature setting, thermostat should turn boiler’s burner off, and once room temperature falls few degrees boiler starts operating again.

Do not start burner unless all cleanout doors are secured in place.

Lamps

Direct sunlight

Kitchens

Unheated room on other side of

wall

Adjust Thermostat Heat Anticipator To: 0.2

Amps

MAINTENANCE

Annually: Recommend ue passages, combustion cham-

ber area (target wall, re door insulation, durablanket), burner adjustment, control operation, and boiler seals (re door gasket or silicone seal, cast iron sectional seals, ue

collector) be checked once each year by trained Service Technician.

Before The Start Of Each Heating Season (or when

system has been shut down for extended periods of time)

recheck whole system for water, oil, and vent piping leaks. Replace or patch any leaks or faulty seals.

Diaphragm Expansion Tank: Tank may become water

logged. Frequent automatic opening of safety relief valve indicates water logging. High boiler temperature accompanied by unusually low radiation unit temperature (and

“knocking” noises) indicates excess air in the tank. To correct this condition, replace diaphragm expansion tank.

Water System: If system is to remain out of service

during freezing weather, drain it completely (water left in system may freeze and will crack pipes and/or boiler).

Tankless Coil (Or Cover Plate) Gasket: Gasket

Vent Pipe: Visually inspect entire venting system once a

month for any signs of leakage, deterioration, or soot build up. If vent pipe shows any signs of leaking or deterioration, replace it immediately. If it shows any signs of soot build up, clean vent pipe and have burner settings and combustion checked by trained Service Technician.

Safety Relief Valve: Valve should open automatically

when system pressure exceeds pressure rating (usually 30

psi) of safety relief valve. Should valve ever fail to open under this condition, shut down the system. Drain system until system pressure is reduced below safety relief valve pressure rating. Contact Service Technician to replace the valve and inspect heating system to determine cause, may indicate equipment malfunction. Safety relief valve should be tested monthly during heating season. Prior to testing, make certain discharge pipe is properly connected to valve outlet and arranged so as to contain and safely dispose of

boiler discharge. Hold trip lever fully open for at least ve seconds in order to ush free any sediment that may lodge

on valve seat. Permit valve to snap shut. Refer to valve manufacturer’s instructions packaged for more details.

should be checked at least twice year for leakage, replace if necessary. If gasket is replaced, make sure that when coil plate (or cover plate) is reattached, ten nuts are torqued in alternating pattern to insure equal force is applied to entire gasket creating good seal. Nuts should be torqued so gasket does not squeeze out from behind the plate.

Oil Burner: Oil burner maintenance is listed in this

manual under “Operating The Boiler”.

Never burn garbage or paper in the unit, never leave combustible material around it.

Conventional Expansion Tank: Tank may become

water logged or may receive excess air. Frequent automatic

opening of safety relief valve indicates water logging. High boiler temperature accompanied by unusually low radiation

unit temperature (and “knocking” noises) indicates excess

air in the tank. To correct either condition, close valve between boiler and tank. Drain tank until empty. Check all

tank plugs and ttings, tighten as necessary. Open valve

between boiler and tank. Water will rise to normal height in

tank if system has automatic ll valve, otherwise manually rell system.

OIL BOILER / BURNER CLEANING INSTRUCTIONS

Oil Boiler Cleaning:

Shut off all electrical power to boiler / burner and shut off fuel oil supply.

Remove vent pipe from top of boiler. Inspect pipe and chimney for signs of corrosion and deterioration. Clean out base of chimney. If vent pipe shows any signs of corrosion or deterioration, replace it immediately. If chimney damage or deterioration is discovered, contact a service technician.

Remove top jacket panel screws (5), brass wing nuts

(2) holding ue collector top, and ue collector top. Inspect gasket on underside of ue collector and replace

as necessary.

Before beginning to clean ue passageways, insure

combustion chamber blanket is covered. If blanket is not covered prior to cleaning, replace blanket once cleaning is completed.

With access to ue passageways, remove soot from reside surfaces by brushing diagonally through ue

passages (see drawing below). Brushing can be made

easier by cutting end of ue brush off and inserting

it into drill. When brushing, take care to not damage

target wall with ue brush.

Carefully vacuum soot accumulations from combustion chamber area, take care to not damage any of refractory or blanket insulation. To gain access to

combustion chamber rst check that shut off valve

on fuel oil line is closed and disconnect fuel oil line. Open swing door by removing whiz lock nut holding door shut.

Inspect target wall, re door refractory, and combustion chamber blanket (when included) for cracking and deterioration. If there are signs of cracking or deterioration, replace refractory or blanket before reassembling burner / front plate.

Inspect door’s braided gasket for wear and damage. Replace when necessary with braided gasket of same material and size.

Inspect and clean oil burner.

NOTICE

Important operating and maintenance requirements:

• Keep your boiler and the area around it clean

• Never burn refuse or any material other than

specied fuel in your boiler

Figure 14 -

Passages

Brush Diagonally Through Flue

OIL BURNER CLEANING

These are general instructions for cleaning an oil burner. For specics, consult burner manufacturer’s instructions.

WARNING

Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.

Verify all electrical power to boiler / burner and fuel supply to burner are shut off.

With swing door open, clean any soot accumulations from end of burner and if applicable burner head.

Remove burner drawer assembly, clean electrodes and then reset electrode spark gap per manufacturer’s recommendations.

Replace oil nozzle with same size and type recommended for use on this boiler.

Install burner drawer assembly make sure head location (and size if applicable) are per manufacturer’s recommendations. If burner being used has damaged head, replace head with same head recommended for use on this boiler.

Inspect and clean oil burner blower wheel.

Remove oil pump cover and clean / replace pump screen. Carefully reassemble insuring pump cover creates proper seal.

Securely fasten swing door shut.

Replace fuel lter (if applicable).

10.

Connect electrical and fuel supplies.

11.

Fire burner, check for proper combustion using combustion test equipment and making adjustments as necessary.

12.

Insure all safety controls and operating controls are functioning properly.

SERVICE HINTS

You may avoid inconvenience and service calls by checking these points before you call for service:

IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .

POSSIBLE CAUSE WHAT TO DO

Thermostat is not set correctly Reset thermostat

Check ame. If it is yellow, the burner is not getting enough air.

Burner is not operating properly

Or, if ame is blue and noisy and seems to lift off the burner, the

burner is getting too much air. Contact your service technician.

No electric power to boiler

Controls out of adjustment Reset according to instructions.

Radiators not heating

Circulating pump not running Check over-current protection. Check relay operation.

Poor electrical contact Check all control terminals and wire joints.

Chimney ue is blocked Have the chimney professionally cleaned.

Circulator running when boiler water temperature is below low limit setpoint (tankless coil equipped boilers only)

POSSIBLE CAUSE WHAT TO DO

Corrosion and/or deposits on seat.

Water logged expansion tank Drain tank, see instructions.

Check over-current protection. Check to be sure electric power supply circuit is “ON”.

Open radiator vents to excess air. Check ow control valve (if

used). It may be in closed position.

Conrm ELL parameter on L7248 control is set to ON. Refer to

Honeywell L7248L instructions furnished with boiler.

RELIEF VALVE LEAKING . . .

Open valve manually. Allow water to run and clear valve seat.

HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU

ARE UNABLE TO CORRECT.

ELECTRICAL WIRING

Figure 16 -

Boiler Honeywell L7248L Control

* When Low Limit Is Used, Set ELL Parameter On L7248 Honeywell Control

To On. Boilers Factory Equipped With Tankless Coil Are Factory Set To On.

ELECTRICAL WIRING

Figure 17 -

Honeywell L7248L Control With Reillo F5/F10 Burner

* When Low Limit Is Used, Set ELL Parameter On L7248 Honeywell Control

To On. Boilers Factory Equipped With Tankless Coil Are Factory Set To On.

ELECTRICAL WIRING

Figure 18 -

(With Tankless coil Shown)

Honeywell L7248L Control Wiring with Zone Pumps and Argo ARM Switching Relay

EQUIPMENT AND OPTIONAL ACCESSORIES

MAIN AIR VENT: for down ow systems or diaphragm

type expansion tanks (not provided)

Before system is lled with water, there is air in pipes and radiation units. Some air will be trapped as system is lled.

It is possible to eliminate most of this air through air vents on radiation units. Main air vent will speed and simplify this process. Install main air vent on highest point in supply main when all radiation is below top of boiler.

AUTOMATIC FILL VALVE (not provided)

For safe, efcient operation, hot water system must be lled with water. Adding new water, when needed can be

done manually (by use of hand valve in water supply line). This requires regular attention to system’s needs. Auto-

matic ll valve or pressure reducing valve accomplishes this

without attention. Install in supply line on hot water boilers only. Valve operates through water pressure differentials. It does not require electrical connection.

BURNER SOLENOID VALVE (provided)

Beckett and Carlin oil burner’s use standard solenoid valve.

Upon burner shut down, standard solenoid valve stops ow

of oil to nozzle. Without solenoid valve, oil pump continues to pump oil to burner nozzle until burner motor winds down below pumps cutoff speed. Riello oil burner has delay solenoid valve. Delay solenoid valve provides same shut down action as standard solenoid valve, plus on burner start up delay solenoid valve remains closed for additional 15 seconds. Allows burner fan motor to pre-purge combustion chamber and oil pump to bring supply oil pressure up to its set point helping to provide clean light off.

CIRCULATOR (provided)

Every forced hot water system requires circulator. Separate circulator or zone valve is required for each zone, if there are two or more zones. Circulator must have capacity to provide circulation required by heating system. Circulator should be connected to supply main and must be wired into boiler’s electrical system. See “System Piping” section for

piping congurations with circulator located on supply main

piping using zone circulators or zone valves. When piping is arranged with zone circulators and no bypass piping, circulator provided with boiler may be used as zone circulator. Both piping arrangements allow circulator to pump

away from expansion tank and show how piping should be

arranged to allow heating system to be easily

purged of air.

Taco 007 Pump Curve

LIMIT CONTROL (provided) Refer to manufacturer instructions provided with limit control

Water temperature limit control in limit is adjustable and may be set: as low as 140°F so long as return water temperatures to boiler are no less than 120°F, or as high as 220°F so long as boiler and heating system have adequate circulation to remove heat from boiler otherwise steam may be created in boiler. Refer back to “System Piping” section for more information.

DRAIN VALVE (provided)

Drain valve is manually operated valve provides means of draining all water from boiler and heating system. It should be installed in reducing tee where return line enters boiler.

PRODUCT LITERATURE

Lennox Industries Inc.

Dallas, Texas

Lennox COWB3 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual