Odyssey CT80-250, CT80.3F9A1, CT120.3G9A, CT215.1H9A, CT80.3P9A1 Installation And Operation Instructions Manual

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Odyssey

Danger Sign: Indicates a hazardous situation which, if not avoided, will result in

Warning Sign: Indicates a hazardous situation which, if not avoided, could result

bol: Indicates a hazardous situation which, if

Caution Sign without Safety Alert Symbol: Indicates a hazardous situation

es a hazardous situation which, if not avoided, could result

Model Numbers: CT80-250 Version Date: 2013-03-15

NEW – OUTDOOR SENSOR

Meets Sept. 2012 requirements for

“Automatic Means”

INSTALLATION AND OPERATION INSTRUCTIONS ODYSSEY OIL BOILER

Venting Applications: Natural Draft or Direct Vent (Balanced Flue)

TABLE OF CONTENTS

1.0 INTRODUCTION...............................................................................................................3

2.0 SPECIFICATIONS..............................................................................................................6

3.0 BOILER LOCATION..........................................................................................................8

4.0 BOILER ASSEMBLY.........................................................................................................9

5.0 GENERAL VENTING......................................................................................................14

6.0 NATURAL DRAFT APPLICATIONS.............................................................................15

7.0 DIRECT VENT APPLICATIONS....................................................................................19

8.0 BOILER PIPING...............................................................................................................26

9.0 FIELD WIRING................................................................................................................28

10.0 INSTALLATION CHECKLIST .......................................................................................34

11.0 ANNUAL MAINTENANCE AND INSPECTION ..........................................................36

12.0 PARTS LIST .....................................................................................................................39

13.0 WARRANTY....................................................................................................................43

Odyssey CT80-250

HAZARD SYMBOLS AND DEFINITIONS

serious injury or death.

in serious injury or death. Caution Sign plus Safety Alert Sym

not avoided, could result in minor or moderate injury.

which, if not avoided, could result in property damage. Notice Sign: Indicat

in property damage.

This Boiler must be installed by a licensed and trained Heating Technician or the Warranty is Void. Failure to properly install this unit may result in

property damage, serious injury to occupants, or possibly death.

NTI # 84944

Odyssey

Read Before Proceeding

│

Installation and Operation Instructions CT80-250

If you do not follow these instructions exactly, a fire may result causing property damage, serious injury or death.

FOR YOUR SAFETY, READ BEFORE OPERATING_

BEFORE OPERATING: A. Do not start burner unless the smoke hood, clean out door, HydroStat 3250, flue breeching, and burner

door (if applicable) are secured in place and the boiler is filled with water.

B. Do not attempt to starter burner when excess oil has accumulated in combustion chamber, when unit is

full of vapour, or when combustion chamber is very hot.

C. Do not use gasoline, crankcase drainings, or any oil containing gasoline. D. Never burn garbage or paper in the unit and never leave combustible material around it. E. Always keep the oil supply valve shut off if the burner is shut down for an extended period of time. F. Do not tamper with the unit or controls - call your service personnel for service and maintenance. G. Do not use this boiler if any part has been under water. Immediately call a qualified service technician to

inspect the under water.

boiler and to replace any part of the

OPERATING INSTRUCTIONS_

control system and any oil control which has been

1. STOP! Read the safety information above very carefully.

2. Initial start-up and start-ups after periods of extended/seasonal shutdown must be performed by a

qualified service technician.

3. Check the boiler area for proper clearances.

4. Turn the thermostat(s) up.

5. Turn the emergency power isolation switch on.

6. If ignition does not occur, follow the instructions “To Turn Off Oil Boiler” and call a qualified service

technician.

TO TURN OFF OIL BOILER_

1. STOP! Read the safety information above very carefully.

2. Turn off emergency power isolation switch. Should be mounted on the wall near entrance to boiler room.

Void Warranty - This boiler must have water in it whenever the burner is on or it will damage the unit and void the warranty. Failure to follow these instructions may result in

serious injury or death.

Fuel Oil - Use only No. 2 fuel oil for boiler models listed in this manual. Failure to follow these instructions may result in severe personal injury, property damage, or death.

Low Water Cut Off (LWCO) - To take advantage of the HydroStat’s LWCO feature, the

Odyssey is equipped with a special immersion well call the Electro-well™. Failure to use the Electro-well™ provided with the boiler will over-ride the LWCO feature and allow the boiler to operate during low water conditions which may result in over heating, fire, serious injury, or death.

Oil Supply Valve - Always keep the oil supply valve shut off if the burner is shut down

for an extended period of time.

CT80-250 Introduction - Installation & Operation Instructions

1.0 INTRODUCTION

│

Odyssey

General Installation Requirements

The installation of your NTI Odyssey oil boiler shall be in accordance with these instructions and the regulations of the authorities having jurisdiction and must comply with the following codes and standards:

United States

 State and local plumbing, heating, and electrical codes  NFPA 70 National Electric Code  NFPA 31 Installation Code for Oil Burning Equipment  Standard ANSI/ASME CSD-1, Controls and Safety Devices for Automatically Fired Boilers (if applicable)

Canada

 Provincial and local plumbing, heating, and electrical codes  CSA C22.1 Canadian Electrical Code Part One  CSA B139 Installation Code for Oil Burning Equipment

The Odyssey is a knock-down boiler constructed of cast iron. The venting application needs to be decided in advance, either Natural Draft or Direct Vent, prior to ordering the boiler as burner packages will vary depending on the venting application. The boiler package comes in three sections and requires field assembly. Check your boiler package when it arrives and ensure it includes the following:

1. Boiler

2. Jacket

3. Burner Kit This document pertains to the correct installation and operation of NTI Odyssey oil boilers for Natural Draft and

Direct Vent models. The instructions detailed in this document supersede any and all previous instructions provided by NTI, written or otherwise. The warranty is included in the Installation and Operation manual. Each unit comes complete with the following documentation:

1. Installation and Operating Instructions

2. Users Manual

Read and understand this entire document prior to proceeding with the installation of the

Odyssey. Failure to follow the instructions outlined in this document will result in property damage, serious injury or death.

User Responsibilities

This boiler must be installed and serviced by a qualified installer or service technician. This boiler must be serviced and inspected annually. As the User/Owner of this equipment, you are responsible for ensuring the maintenance is performed at the required intervals. See “Users Manual”.

Failure to have the boiler properly serviced and inspected on a regular basis by a qualified

service technician may result in property damage, serious injury or death.

Installer Responsibilities

As the installing technician it is your responsibility to ensure the installation is performed in accordance with this instruction manual as well as any applicable local or National installation codes. It is also your responsibility to inform the User/Owner of their obligation with respect to the above description under “User Responsibilities”. Failure to follow this warning could result in fire, serious injury, or death.

Odyssey

Natural Draft Applications

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Installation and Operation Instructions - Introduction CT80-250

Natural Draft Applications - All Odyssey models are certified as Natural Draft boilers

which require a “Chimney System”. The exhaust gases must be vented directly to the

chimney. Failure to follow these instructions will result in serious injury or death.

Blocked Vent Switch - All Natural Draft Odyssey boilers require a Blocked Vent Switch

which is factory supplied and packaged with the burner kit and is mandatory in Canada. The Block Vent Switch must be field installed as per the instructions in this manual and the manufacturers instructions included with the switch. Failure to follow the specified instructions may result in fire, property damage, personal injury, or death.

Table 1-1 Odyssey Boiler Packages (Natural Draft)

MODEL

CT80

CT90

CT100

BOILER PACKAGE

BOILER PART NUMBER

Boiler

CT80.3F9A1 CT80

Burner Kit

Jacket

Natural

Draft 1

Only

Burner

82002

F3.CT

10618

Burner Kit Contents (Natural Draft)

Blast Tube

Nozzle

HydroStat

3250

Hydrolevel

0.65

84024

Tridicator

Electro-Well

OD Sensor

Relief Valve

Supply Tee

Block Vent

CT120

84654

0.85

60oB

1.5

60o W

0.75

70oB

84787

84788

81342

83604

13701

84829

CT150 CT180

Riello Burner

CT215 CT230 CT250 CT80 CT90 CT100

CT120.3G9A

CT215.1H9A1 CT215

CT80.3P9A1 CT80

CT120

F5.CT

10630

82003

F10.CT

82004

NYC601CT 81031

10632

82002

CT120 CT150 CT180

Becket Burner

CT215 CT230

CT120.3P9A1

CT215.3P9A1 CT215

CT120

CT250

Notes:

Boiler manual packaged with the Burner Kit.

Nozzle size included in Burner Kit. See below, “Attention: Nozzle Sizes”.

Burner and blast tube comes assembled c/w nozzle specified in this table. Nozzle may need to be changed depending on boiler output.

Models CT80-100 and CT180 are no longer offered as they do not meet new minimum efficiency regulations.

NYC602C T

82003

NYC602C T

82004

81032

1.10

60oB

1.10

60oB

Nozzle Sizes - The nozzle sent with each respective boiler burner kit is for the minimum

firing rate specified for that burner. To obtain a different firing rate, replace the factory supplied nozzle with the appropriate nozzle that meets the desired output. Refer to Tables 2-1 to 2-2 in Section

2.0 for nozzle specifications and performance ratings for Natural Draft boilers.

Manufacturer’s Instructions - For complete instructions on installation and control

operations, refer to the manufacturer’s instructions included with the Fuel Smart HydroStat 3250, Burner Package, and Blocked Vent Switch.

Switch

82905

CT10

CT80-250 Introduction - Installation & Operation Instructions

│

Odyssey

Direct Vent Applications

There are four Odyssey models, CT90-120, certified for installation as a Direct Vent boiler. This balanced flue system requires a special venting system in order to pressurize and essentially equalize the inlet and outlet pressure to ensure normal operation. Refer to section “General Venting” and “Specifications” for more details on Direct Vent applications and termination kits.

Balanced Flue Applications - Models CT90-120 are also certified as Direct Vent boilers

and must be ordered as such. Balance flue systems must use the NTI approved venting system. Note that the Direct Vent Terminal and Insulated Flex Pipe are sold separately (see Table 7-2 Direct Vent Kit Components for more details). This “Special Venting System” is designed for pressurized venting with NTI Direct Vent boilers. The exhaust gases must be piped directly to the outdoors using the vent materials and rules outlined in these instructions. Failure to follow these instructions will result in serious injury or death.

Table 1-2 Odyssey Boiler Packages (Direct Vent)

BOILER PACKAGE

Burner Kit Contents (Direct Vent)

Jacket

82002

82003

Burner

Kit

Direct

Vent

BF5.CT

Burner

Blast Tube

Nozzle

HydroStat

3250

Hydrolevel

Electro-Well

Tridicator

OD Sensor

Relief Valve

81122

0.85

60oB

0.85

60oB

84787

84788

81342

83604

13701

Supply Tee

Direct Vent

84829

Table 7-2

BOILER

MODEL

CT90

PART NUMBER

Only

Boiler

CT90.3T9A4 CT80

CT120

Riello Burner

Notes:

Boiler manual packaged with the Burner Kit.

Nozzle size included in the Burner Kit. See below, “Attention: Nozzle Sizes”.

Burner and blast tube comes assembled c/w nozzle specified in this table. Nozzle may need to be changed depending on boiler output.

Direct Vent Terminal not included in Kit. Refer to Table 7-2 for a list of components that must be ordered separately.

Riello BF5 burners are single line gravity feed. See burner manufacturers’ instructions for more details.

Models CT80-100 are no longer offered as they do not meet new minimum efficiency regulations.

CT120.3T9A4 CT120

Manufacturer’s Instructions - For complete instructions on installation and control operations, refer to the manufacturer’s instructions included with the Fuel Smart

HydroStat 3250, Burner Package, and Direct Vent Terminal.

Nozzle Sizes - The nozzle sent with each respective boiler burner kit is for the minimum

Intakes/Vents - Failure to keep the Vent and Combustion Air Intake clear of ice, snow,

and other debris may result in property damage, serious injury, or death.

which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE :

 An external energy management system is installed that reduces the boiler water temperature as the heating load

decreases.

 This boiler is not used for any space heating.  This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.  This boiler is equipped with a tankless coil.

Energy Saving Feature - This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override

Kit

Odyssey

2.0 SPECIFICATIONS Natural Draft Application

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Installation and Operation Instructions - Specifications CT80-250

Draft Settings (Natural Draft) - The Odyssey is designed to operate with -.03” w.c. draft

in the flue breaching. For proper operation, there must be enough natural or mechanical draft. Due to the design of the Odyssey, it may operate at a positive over fire pressure up to +.20 at -.03 draft. Due to installation and equipment variations, recommended air settings are a guideline and will require alteration. See Tables 2-1 and 2-2.

Insertion Depth (Natural Draft) - See General Notes section in Tables 2-1 and 2-2.

Table 2-1 Riello Burners with Odyssey Boilers (Natural Draft)

Boiler Model

CT80 CT90 CT100

Input

GPH (US)

0.65 77 67

0.75 88 77

0.85 99 86 CT120 1.00 121 105 CT150 1.25 149 130

CT180

1.50 176 153 CT215 1.75 212 184 CT230 1.85 223 194 CT250 2.00 240 209

General Notes:

Output is “Heating capacity” for models CT80-250.

Models CT80-250 use Riello 40 series burners.

Energy ratings for C85-250 have been confirmed by AHRI.

Models C80-100 - F3 burners have an insertion depth of 2.375”.

Models C120-180 - F5 burners come assembled with an insertion depth of 2.375”.

Models C215-250 - F10 burners have an insertion depth of 2.75”.

F10 burner heads - If head carbons on models CT215-250, reduce turbulator setting and increase air a little.

Models CT80-100 and CT180 are no longer offered as they do not meet new minimum efficiency regulations.

Table 2-2 Beckett Burners with Odyssey Boilers (Natural Draft)

Boiler Model

CT80 CT90 CT100

Input

GPH (US)

0.65 77 67

0.75 88 77

0.85 99 86 CT120 1.00 121 105 CT150 1.25 149 130

CT180

1.50 176 153 CT215 1.75 212 184 CT230 1.85 223 194 CT250 2.00 240 209

General Notes:

Models CT80-250 use Beckett AFG50 series burners.

Energy ratings for C85-250 have been confirmed by AHRI.

Models CT80-250 - MDL1 (NYC601) burners and MDV1 (NYC602) have an insertion depth of 3.75.

Models CT80-100 and CT180 are no longer offered as they do not meet new minimum efficiency regulations.

Heating

Capacity

MBH

Heating

Capacity

MBH

Net I=B=R

Rating Water

MBH

Net I=B=R

Rating Water

MBH

AFUE

Efficiency

83.6% 117

Pump

PSIG

Delevan

Nozzle

0.60 60oW

83.0% 133 0.65 60oW

82.4% 128 0.75 60oW

85.1% 138 0.85 60oW

84.0% 156 1.00 60oW

82.8% 144 1.25 60oW

85.8% 136 1.50 60oW

85.5% 152 1.50 60oW

85.0% 178 1.50 60oW

AFUE

Efficiency

83.6% 117

83.0% 133 0.65 60oW

82.4% 128 0.75 60oW

85.1% 138 0.85 60oW

84.0% 156 1.00 60oW

82.8% 144 1.25 60oW

85.8% 136 1.50 60oW

85.5% 152 1.50 60oW

85.0% 178 1.50 60oW

Pump

PSIG

Delevan

Nozzle

0.60 60oW

Recommended Burner Settings

Burner Air Turbulator

F3 5 0 F3 7 0 F3 7 2 F5 3 2 F5 5 2

F5 9 3.5 F10 F10

3.5 7

2 2

F10 6 3

Recommended Burner Settings

Burner

MBL1 MBL1

MBL1 MDV1 MDV1 MDV1 MDV1 MDV1 MDV1

Head Shutter

- 5 0.5

- 6 1

- 10 0 0 5 1 1 6 2 2 8 3 3 10 6 4 10 5 4 8 7

Band

CT80-250 Specifications - Installation & Operation Instructions

Direct Vent Application

│

Odyssey

Draft Settings (Direct Vent) - Due to the design of the balanced flue system, the Odyssey

will operate at a positive draft pressure and a positive over fire pressure at all times. It is designed to operate with a maximum stack draft of 0.25” w.c. and a maximum over fire draft of 0.33” w.c. when little or no wind is present. In extreme wind conditions, the maximum stack draft is 0.35” w.c. and the maximum over fire draft is 0.45” w.c. Due to installation and equipment variations, recommended air settings are a guideline and will require alteration. See Table 2-3.

Insertion Depth (Direct Vent) - See General Notes section in Table 2-3.

Table 2-3 Riello Burners with Odyssey Boilers (Direct Vent)

Boiler Model

CT90 CT100

Input

GPH (US)

0.75 88 77

0.85 99 86

CT120 1.00 121 105

General Notes:

Models CT90-120 use Riello 40 series burners.

Energy ratings for CT90-120 have been confirmed by AHRI.

Models CT90-120 - BF5 burners come assembled with an insertion depth of 2.375”.

Models CT80-100 are no longer offered as they do not meet new minimum efficiency regulations.

Heating

Capacity

MBH

Net I=B=R

Rating Water

MBH

AFUE

Efficiency

83.0% 133

82.4% 128

85.1% 138

Pump

PSIG

Delevan

Nozzle

0.65 60oW

0.75 60oW

0.85 60oW

Recommended Burner Settings

Model Air Turbulator

BF5 4 BF5 BF5

5 6

0 0

1.5

Boiler Characteristics

Table 2-4 Odyssey Boiler Characteristics

Description

CT80-100 CT120-180 C215-250

Boiler Shell Weight [lbs] 260 390 500 Fuel Type No. 2 Oil Water Connections – NPT [in.] 1.25 1.25 1.25 Dimensions H x W x D [in.] Approx. Boiler Weight with Water [lbs] Approx. Boiler Water Content [usg] Stack Size Electrical Rating

30 x 17.5 x 15.5 30 x 25.5 x 15.5 30 x 33.5 x 15.5

290 435 560

3.6 5.4 7.3 5 5 5

120V / 1Ph / 60Hz / < 12A

Boiler Shell

1, 2

Odyssey

3.0 BOILER LOCATION

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Installation and Operation Instructions - Boiler Location CT80-250

In all cases, the Odyssey must be installed indoors in a dry location where the ambient temperature must be maintained above freezing and below 100°F [38°C]. All boiler components must be protected from dripping, spraying water, or rain during operation and servicing. Consider the proximity to the following when determining the best boiler location.

 System Water Piping  Oil Supply  Electrical Power  Combustion Air / Ventilation Air  Chimney

Components - Water or flood damaged components must be replaced immediately with new components (see parts list). Failure to do so may result in fire, serious injury, or death.

Clearances - Clearances to combustibles represent the minimum clearances required for safety and service. Recommended clearances are for ease of piping installation, annual maintenance, and service access. Refer to Table 3-1 and Figure 3-1.

Table 3-1 Minimum Clearances for Installation and Service

Model Clearances

CT80-250

Notes:

Minimum clearances from flue pipe to combustibles is 9” for single-wall pipe; 6” for double-wall pipe (Type-L).

Flue pipe clearances take precedence over all other clearances.

To Combustibles 24 [610] 5 [124] 12 [305] 5 [124] 9 [228] Combustible Recommended 36 [915] 24 [610] 24 [610] 24 [610] 9 [228] Combustible

Front Rear Top Sides

Dimensions - inches [mm]

Flue Pipe

Floor

Boiler Location - Even if all installation codes are met, good judgment and common

sense must also be used when selecting a boiler location. Refer to minimum clearances in

Table 3-1 and vent clearances for chimney or direct vent applications.

Figure 3-1 Minimum Clearances to Combustibles

Flue Pipe

9” minimum

Flue pipe clearances take precedence over all clearances, refer to Table 3-1.

Rear 5”

Top 12”

Right Side 5”

Front 24”

Left Side 5”

nuts and washers at

the rear of the boiler

C 85-340 Boiler Assembly - Installation & Operation Instructions

4.0 BOILER ASSEMBLY

│

Odyssey

The installation of the boiler shall be in accordance with the authorities having jurisdiction and must comply with Standard CSA B139 (Canada) or NFPA 31 (USA).

Fiberglass Materials - Before installing the insulation, read “Handling Instructions” in Section 11.0 and the protective measures recommended when handling fiberglass.

Assembly Procedure

The boiler assembly procedure is to be completed in sequence and in conjunction with the illustrated assembly diagrams, Figures 4-1 through 4-12.

1. Do not fully tighten screws until jacket assembly is complete.

2. Level the boiler before commencing jacket installation.

3. Install rear brackets on the boiler, secure by tightening nuts (Figures 4-1 to 4-3).

4. Install front brackets on the boiler, secure by tightening nuts (Figures 4-4 to 4-6).

5. Install fiberglass insulation on the boiler by wrapping it around the heat exchanger. Secure with factory

supplied twine (Figure 4-7).

6. Remove all protective plastic film on the jacket panels before installing.

7. Attach side panels to front and back brackets (Figure 4-8).

8. Install control panel between side panels, secure with screws provided (Figure 4-9).

9. Mount HydroStat 3250 by sliding it down over the tabs on the control panel. Secure in place with hold down

bracket as shown (Figure 4-10).

10. Mount bottom back panel to boiler (Figure 4-10); Recommend installing top back panel after flue breeching

connected, sealed, and supported. (See also Figure 6-1 Flue Breeching).

11. Fully tighten all jacket screws to secure panels in place.

12.

Insert sensor fully into the Electro-well or boiler overheating may occur (Figure 4-11). See “Danger” warning on page 11.

13. Feed the green wire, connected to the boiler ground screw, through the knockout in the back of the HydroStat.

Connect the other end of the wire to the HydroStat ground screw inside the control (green screw).

14. Installation of burner and completion of wiring must be done with front cover removed.

15. Install top cover. Align the top panel clips into the slots in the top of the side panels and slide cover forward

to lock clips in place (Figure 4-12).

HydroStat 3250 Instructions - For complete installation and operation instructions, refer to the manufacturer’s instructions included with the Fuel Smart HydroStat 3250.

Figure 4-1 Rear Brackets Figure 4-2 Mount Rear Brackets

Top

Bottom

Slide the rear brackets behind the

as shown.

Tighten the nuts,

Before installing the insulation, read the

Remove protective

plastic coating from

Odyssey

│

Installation and Operation Instructions - General Venting CT80-250

Figure 4-3 Tighten Bracket Nuts (Rear) Figure 4-4 Front Brackets

Tighten nuts, top and bottom, to secure the rear brackets to the boiler.

Figure 4-5 Mount Front Brackets Figure 4-6 Tighten Bracket Nuts (Front)

Top

Bottom

Slide the front brackets behind the nuts and washers at the front of the boiler.

Insulation

Twine

top and bottom, to secure the front brackets to the boiler.

See Figure 4-6

Figure 4-7 Insulate Heat Exchanger Figure 4-8 Attach Side Panels To Brackets

“Handling Instructions” in Section 11.0.

all jacket pieces before installing.

Install insulation around the heat exchanger and secure in place with factory supplied twine.

Attach both side panels to brackets using sheet metal screws provided.

C 85-340 Boiler Assembly - Installation & Operation Instructions

side panels, secure

the HydroStat 3250

to the control panel

Secure bottom back panel.

Ground Wire

- Connect green

wire between ground screw

Installation of burner and

Figure 4-9 Attach HydroStat 3250 Bracket Figure 4-10 Attach Back Panels & Electro-well

│

Odyssey

Control Panel

Recommend installing top back after flue breeching connected and sealed.

Hold Down Bracket

HydroStat 3250

Attach hold down bracket

Attach the control panel between the

as shown.

Figure 4-11 Install Ground Wire and Sensor Figure 4-12 Install Top and Front Covers

to top edge of HydroStat control panel to secure it in place.

completion of wiring must be done with front cover removed.

See Figure 4 -11

Ground Screw

Electro-well



and HydroStat ground screw. Sensor - Insert fully into the

Electro-well  or overheating may occur. See “Danger”.

Sensor - Insert the sensor fully into the Electro-well or the boiler may overheat resulting in fire, property damage, serious injury, or death.

Odyssey

│

Installation and Operation Instructions - General Venting CT80-250

Burner Installation

The Odyssey boiler is designed to work with burners described in this manual. The use of other nozzles, and/or burners, may cause unsafe operation and will void any and all responsibility by NY Thermal for the safety and reliability of the system.

The burner kit should be installed in accordance with the instructions in this manual and the burner manufacturer’s instructions included with the burner. Refer to specification Tables 2-1 to 2-3 for nozzle sizes, burner settings, insertion depths, and air setting guidelines.

Fuel Oil - Odyssey boilers operate with No. 2 oil as their only approved fuel source. DO NOT USE GASOLINE, CRANKCASE DRAININGS, OR ANY OIL CONTAINING

GASOLINE. Failure to follow these instructions may result in severe personal injury, property damage, or death.

Combustion Analyzer -

capable of measuring CO

To calibrate burner operation, use a calibrated combustion analyzer

and O2 from oil burning boilers

Smoke Test - All tests must be done with the burner covers or air intakes in place to simulate normal operation.

Smoke Pump - A reliable, certified smoke pump is required to correctly set up this equipment.

Avoid Condensation - Due to the high combustion efficiencies and low stack gas temperatures, great care must be taken to ensure the chimney isn’t subjected to flue gas

condensation. The gas temperature where the flue pipe enters the chimney must be a minimum of 240oF.

Burner Installation Procedure:

1. Burner Package: a. Prepare the burner in accordance with the burner manufacturers instructions included with the burner. b. Refer to specification Tables 2-1 to 2-3 to determine the appropriate nozzle size for the boiler output. See

“Attention: Nozzle Sizes” in Section 2.0.

c. Riello Burners (extra step required): Mount the burner gasket and burner flange to the boiler. Secure to

the boiler using washers and nuts provided (Figure 4-5). Seal around the burner gasket and the blast tube ring with high temperature silicone (i.e. 83ml tube of silicone included in the burner kit).

d. Mount prepared burner package to the boiler. Seal around burner flange with high temperature silicone.

Combustion Air Settings - Refer to Section 10.0 Installation Checklist for instruction regarding adjusting combustion air settings.

Oil Supply Tank and Oil Piping

The oil supply tank and piping should be installed in accordance with the instructions in this manual; the burner and pump manufacturer’s instructions; National codes NFPA 31 (USA) or CSA B139 (Canada), and local codes.

General Installation Guidelines:

1. Install the oil supply tank as per tank manufacturer’s instructions.

2. Install oil supply piping from the tank to the burner.

3. Recommend installing a low pressure-drop fuel oil filter to prevent burner nozzles plugging at low flow rates.

4. Shut-off valves should be installed to control the flow during operation and to avoid spills during servicing.

5. Oil can be fed from the supply tank by gravity (single pipe system) or by transfer pump (two-pipe lift system).

6. Refer to burner manufacturer’s instructions before installing oil piping systems as some burner packages are not equipped to work with two-pipe lift systems (i.e. Riello BF5).

7. Connect oil supply piping to the fuel oil pump as per the pump manufacturer’s instructions and system type.

Pipe Dope / Teflon Tape - DO NOT use on direct oil connection to the fuel pump. Failure to follow instructions may cause valve failure and dangerous operating conditions.

C 85-340 Boiler Assembly - Installation & Operation Instructions

Figure 4-5 Burner Installation

Prepare the burner as per the burner manufacturer’s instructions. Refer to Tables 2-1 to 2-3 for nozzle sizes, burner settings, insertion depths, air settings, and specifications.

Set insertion depth (Tables 2-1 to 2-3)

Blast Tube Ring

│

Odyssey

Burner Gasket

Burner Flange

Washers and Nuts

Blast Tube

Burner

Odyssey

5.0 GENERAL VENTING

│

Installation and Operation Instructions - General Venting CT80-250

Natural Draft Applications

All Odyssey models are certified as Natural Draft boilers. The Natural Draft installation draws combustion air from the room and uses the stack effect and draft system to exhaust flue gases using a chimney.

Air Supply - Allowances for combustion air must be supplied to the appliance space, due to the fact that the heating appliance consumes large volumes of combustion air. In most instances, a permanent opening with an unobstructed or “free area” of 1 square inch for every 1000 BTU’s of input will provide a sufficient amount of combustion air for the boiler to operate properly. If the building is fairly new and relatively air tight, compensate for the air tightness by using a “free area” that is 15% larger that what was calculated above. Do not place the boiler in, or adjacent to, a room where an exhaust fan is operating. Refer to “Combustion Air” in Section 6.0 Natural Draft Applications for more details. Installation must comply with Standard CSA B139 (Canada) and NFPA 31 (USA).

Stack Draft - Sufficient draft by natural or mechanical means is necessary for ensuring optimal and consistent operation. The appliance should have a stack draft sufficient to support stable operation. See Draft Settings (Natural Draft).

Avoiding Condensation - Due to the high combustion efficiencies and low stack gas

temperatures, great care must be taken to ensure that the chimney isn’t subjected to gas condensation. The exhaust gas temperature where the flue pipe enters the chimney must be a minimum of 240oF or condensation may occur.

Draft Regulator - A draft regulator must be used and set to regulate the draft of the boiler. Make sure that the damper is free to operate without sticking, for this will affect the boiler’s combustion system. It is important that the draft be adequate because poor draft conditions will cause poor operation and a possible hazardous condition.

Draft Settings (Natural Draft) - The Odyssey is designed to operate with a -.03” w.c.

draft in the flue breaching; therefore, ensure there is enough natural or mechanical draft for proper operation. Due to the design of the Odyssey it may operate at a positive over fire pressure up to +.20 at a -.03 draft.

Direct Vent Applications

Odyssey models C85-150 are also certified for direct vent applications. The Direct Vent installation uses a special venting system where exhaust gases are vented directly to the outside using a special venting system which equalizes the pressure between the air inlet and the flue outlet resulting in a balanced flue system. Refer to Section

7.0 Direct Vent Applications for more details. Installation must comply with Standard CSA B139 (Canada) and NFPA 31 (USA).

Draft Settings (Direct Vent) - Due to the design of the balanced flue system, the Odyssey

will operate at a positive draft pressure and a positive over fire pressure at all times. It is designed to operate with a maximum stack draft of 0.25” w.c and a maximum over fire draft of 0.33” w.c. when little or no wind is present. In extreme wind conditions, the maximum stack draft is 0.35” w.c. and the maximum over fire draft is 0.45” w.c.

+ 30 hidden pages

Odyssey CT80-250, CT80.3F9A1, CT120.3G9A, CT215.1H9A, CT80.3P9A1 Installation And Operation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual