Omni OWB-25, OWB-35, OWB-50 Service Manual

Waste Oil Fired Boiler

Installation, operation and service instructions

OWB-25, OWB-35, OWB-50 120v Manual

EconoHeat • 5714 E. First Avenue • Spokane Valley, WA 99212 • 800.255.1363 • www.econoheat.com • Rev 09/2015

Table of Contents

Precautions ................................................................................... Page 3

Important Notice ......................................................................... Page 4

Oil Burner ....................................................................................... Page 5

Oil Burner Technology ............................................................... Page 7

Specifications ............................................................................... Page 9

Standard Equipment ................................................................ Page 11

Code Requirements ................................................................. Page 11

Combustion Air Supply ............................................................ Page 13

Chimney/Vent Requirements ................................................ Page 14

Installation ................................................................................... Page 15

Water/System Piping ................................................................ Page 19

Burner Mounting ........................................................................ Page 26

Boiler Jacket Assembly ............................................................ Page 27

Boiler Tube Insert Assembly .................................................... Page 29

Wiring ............................................................................................ Page 30

Start-up and Adjustments ....................................................... Page 34

Water Treatment ........................................................................ Page 35

Maintenance Schedule .......................................................... Page 36

Freeze Protection ........................................................................ Page 39

Troubleshooting ......................................................................... Page 39

OMNI Limited Warranty ............................................................ Page 40

Warranty Card ........................................................................... Page 41

Page 2OMNI by EconoHeat

PRECAUTIONS

Waste oil may contain many foreign materials. Waste oil may also contain
gasoline. Therefore, specific precautions on the handling and storage of waste
oils are to be observed when using, cleaning, and maintaining this heater. Use a

screen in a funnel when pouring oil into storage tank to catch foreign material,
i.e., gasket material and sealant fibers, etc. WARNING: This appliance is not
designated for use in hazardous atmospheres containing flammable vapors
or combustible dust, or atmospheres containing chlorinated or halogenated
hydrocarbons. Do not expose this unit to rain or moisture. If installed in high
moisture atmosphere, a special cover for the integrated air compressor
must be obtained from factory to avoid rusting of internal raw metals. If this
occurs, see trouble-shooting guide for remedy. OMNI burns the widest range of

used and new oils including, but not limited to: used motor oils up to 90 weight,
transmission and hydraulic fluid, used synthetic oils, crude oil, vegetable, fish, and
mineral oil,all diesel fuel and many more. Do not use old, contaminated oils that
have been stored in underground tanks or outside barrels for long periods of time.
Excessive water and sludge may be present, causing quick filter plugging.

NOTES: The instructions contained in this manual apply to the installation,
operation, and service of OMNI Waste oil fired boiler. The following instructions
should be carefully followed for obtaining the best possible installation, operation,
and service conditions. Specifications are subject to change without notice. This
product was designed to provide an economical disposal of wast oil. Proper
operation depends on the consistency of the oil. Any water or foreign material in
the oil may cause the unit to shut down. If a continuous stream of oil cannot be
guaranteed at the burner, the main system should be set above freezing which will
prevent any building damage if the waste oil heater were to become inoperative
during subfreezing weather, i.e. supply tank empty, filter plugged, etc.

UNCRATING: Immediately upon uncrating units, check rating plate for certainty
of electrical and mechanical characteristics. Also, check the unit for any damage
that may have been incurred in shipment, if any damage is found, file a claim
with the transporting agency. The unit has been tested and inspected at the
factory prior to crating and was in perfect condition at that time. If anything is
missing, check packing slip for indications of possible backorder of those parts or
components. Otherwise, a claim must be filed for those missing parts.

Page 3OMNI by EconoHeat

IMPORTANT

Notice to the owner and installer

To enjoy the long-term benefits of burning your used oil in an OMNI Waste Oil Burning appliance,
it is necessary to become familiar with the correct installation operation and maintenance
of your new furnace. Before installing or operating this appliance, make sure you read and
understand this manual.

IMPROPER INSTALLATION, ALTERATIONS, OR LACK OF MAINTENANCE WILL VOID THE
WAR RANT Y.

The most critical sections of this manual are in order of importance as follows:

• Basic Operation Knowledge

• Oil Suction Line Installation

• Correct Draft Over Fire

• General Maintenance Requirements

Identical to any gas or oil furnace, without adequate draft over the fire, the combustion
gases cannot escape the furnaces. The flame will lengthen resulting in an overheated
combustion chamber. Even if the boiler is installed correctly and adequate draft achieved,

a flue passage blockage will affect the draft. Burning used oil is similar to burning wood. A
fine gray ash accumulates in the chamber and flue passage. This accumulation of ash will
eventually affect the draft. It is important to remove this ash before the draft is affected.

These topics are discussed in detail on the pages listed above. Please familiarize yourself with
these sections of your manual. Spending a few minutes to review this material will assure that
you receive the return on investment that you expect from your OMNI boiler.

Note: All illustrations and specifications contained herein are based on latest information
available at the time of publication. EconoHeat reserves the right to make changes at any
time without notice.

Page 4OMNI by EconoHeat

Oil Burner

Installation and use of this used oil burning appliance shall be in accordance with
the standard for the Installation of Oil Burning Equipment – ANSI/NFPA 31 – 1987,
and National Electric Code – ANSI/NFPA 70 – 1990 and the requirements of the
inspection authorities having jurisdiction.

WARNING

Igniter
Transformer

Air Band

(combustion air
supply adjustment)

Power Indicator

Run Indicator

Figure 1 – Oil Burner (Back View Closed)

Oil Primary Control

Air Filter

Air Pressure Gauge

Air Pressure

Adjustment Screw

Motor Air Compressor

Pre-Heater Block

Figure 2 – Oil Burner (Back View Opened)

Pre-Heater Control Circuit BoardTransformer

Electrical Terminal Block

Page 5OMNI by EconoHeat

Vanes/Carbon Plate

(Remove Cover)

Mounting Flange

(3 or 4 bolt universal pattern)

Electrodes

Nozzle

Oil Valve Burner Motor

Figure 3 – Oil Burner (Front View)

Compressor

Oil Primer Switch

Inline Breaker

Oil Outlet

Flame Cone

Figure 4 – Oil Pump Diagram

Oil Inlet

Filter

Page 6OMNI by EconoHeat

Oil Flow Control Supply Pump has the ability to control flame even when various viscosities are
used- furnace or stove oil to 90 weight straight- flame remains stable

Oil Shut-off Valve

(Eliminates start delays due
to possible drain back)

Spin-On Filter

DC Motor

Figure 5 – Oil Pump Assembly

Oil Burner Technology

Inline Breaker

Oil Primer Switch

(Solenoid valve, on/off)

Adjustable

Motor Speed

(Initial set up only; Once

set, no adjustment
needed thereafter)

Atomization Through Low Pressure

Preheat & Air Induction At Nozzle

Air Line to Preheater

Mixes with Oil at Nozzle

Air Compressor

On Burner

Oil Preheater
Inside Burner

Air Filter

Flow Control

Oil Pump

Internal Pump Filter

Suction Line

Pressure Line

Oil Tank

Filter

OMNI’s patented burner technology improves the efficiency of the oil burn process by
continuous stabilization of the oil viscosity. Optimum atomization (spray) is accomplished
by precisely pre-heating the oil and air prior to introduction to the combustion chamber.
The waste oil enters into the Oil Pre-Heater Block (figure 4) and is pre-heated to operating
thermo set-point, then compressed air from the air compressor (figure 3) is mixed with the oil
prior to spraying out the nozzle similar to fuel injection, by breaking up the oil droplets into a
finer mist or spray (atomization). Electrodes mounted just above the nozzle (figure 5) provides
continuous electrical arc across electrode to electrode igniting the fine oil mist as it sprays out
of the nozzle. Once ignited the flame is forced into a swirl caused by the burners blower and
specially designed flame cone (figure 5) providing a very efficient and thorough burn of the
waste oil.

Page 7OMNI by EconoHeat

Burner Components

• Igniter Transformer: (figure 3) Supplies high voltage to the electrodes generating electrical

arc igniting the oil.

• Oil Valve: (figure 5) energizes when burner is running and de-energizes when burner is not
running eliminating bleed back of oil out of the Pre-heater block.

• Air Band: (figure 3) Adjusts amount of air introduced into the combustion chamber. Air
band is adjusted at the factory for optimum performance, approx. ½ to ¾ inch open. NO
FIELD ADJUSTMENT REQUIRED unless in high altitudes application where minor adjustment
may be required.

• Oil Primary Control: (figure 3) Controls the oil burner ignition. Checks for flame in the
combustion chamber, if no flame is detected within 45 seconds, the oil primary will shutdown
the oil burner. To restart the unit, reset the red button on the oil primary.

• Oil Pre-Heater Block: (figure 4) Pre-heats the oil and air before entering combustion
chamber.

• Photo Eye: (figure 4) Senses flame in combustion chamber and signals oil primary when
no flame is present.

• Igniter Springs: (figure 4) Transfers the high voltage from the igniter transformer to the
electrodes (when door is closed)

• Air Pressure Gauge: (figure 3) Displays air pressure supplied by on-board air compressor.

• Air Compressor: (figure 3) Supplies air used within pre-heater block to aid in atomization

of the oil.

• Air Muffler/Filter: (figure 3) Filters air and muffles the sound generated by the compressor.

• Pre-Heater Control Circuit Board: (figure 4) Precisely controls temperature of the Oil Pre-

Heater Block and controls safety feature of not allowing burner to energize until oil has
established operating thermo set-point or shutdown burner if Pre-Heater Block temperature
falls below shutdown thermo set-point.

• Electrodes: (figure 4 and 5) Provides continuous high voltage electrical arc from electrode
to electrode igniting the waste oil as it is being sprayed out of the nozzle.

• Nozzle: (figure 5) Low-pressure nozzle for oil spray pattern.

• Flame Cone: (figure 5) Specially engineered flame cone forces the flame into a swirl pattern

improving the burn thoroughness.

• Burner Motor: (figure 5) Multi-task motor turns the burner blower and integrated air
compressor.

• Air Pressure Adjuster: (figure 3) Adjusts the air pressure going to the pre-heater block.
Should be adjusted between 12 PSI and 13PSI as indicated on the Air Pressure Gauge on the
burner for thorough burn of the waste oil. Note: In order to insure proper air adjustment,

air gauge must read 0 when burner is cycled off or powered down.

• Oil Pressure Adjustment: Adjust flame length in the heater combustion chamber viewed
through the inspection port located directly above the burner gun assembly by increasing
CW or decreasing CCW the adjuster located on the oil delivery pump (figure7). The adjuster
increases or decreases the pump motors RPM, which increases or decreases the delivery
of fuel to the burner. When you increase or decrease the fuel to the burner, you will notice
the flame length will increase or decrease. Adjust flame length so flame is just slightly less
than halfway down main combustion chamber tube.

Page 8OMNI by EconoHeat

IMP OR TANT:

• Power Indicator: (figure 3) Indicates when power is present at the burner.

• Run Indicator: (figure 3) Indicates that the burner is ready for operation after the initial pre-

heat time of approx. 5 minutes from initial power up.

Oil Burner/Pump Specifications

Burner Assembly Performance Ratings

Voltage 115 VAC
Cycles 60Hz
Total Operating Amperage (Burner Only) 8.4 Amps
Total Operating Amperage (Burner and Oil Pump) 10.5 Amps
Electrical Operating Consumption (Burner Only) 970 Watts
Electrical Operating Consumption (Burner and Oil Pump) 1,212 Watts
Weight 36.5 Lbs.
Oil Primary 0.2 Amps
Oil Valve 0.075 Amps
Pre-Heater Block 4.2 Amps
Pre-Heater Controller Board 0.011 Amps
Igniter Transformer 0.3 Amps
Burner Motor 3.6 Amps

Pump Assembly Performance Ratings

Voltage 115 VAC
Cycles 60Hz
Total Operating Amperage (Pump Assembly Only) 2.1 Amps
Electrical Operating Consumption (Pump Assembly Only) 241.5 Watts
Weight 16 Lbs.
Oil Valve 0.075 Amps
Pump Motor 2.0 Amps

Page 9OMNI by EconoHeat

Boiler Specifications

Boiler

Manual

Burner

GPH

Input
BTU ’s

Output

Capacity

BTU ’s

Net

Rating

Water

BT U/hr

Rating

Water
Sq. Ft.

Approx.

Dry

Weight

(Lbs)

Vent

Connect

Diameter

(Inches)

Diameter

“L”

Inches

Water

Content

Gallons

Max

Water

Working

Pressure

OWB-25 1.7 250,000 212,000 184,700 1,450 902 7 4 4 -1/4 10.8 60PSI

OWB-35 2.4 350,000 297, 5 0 0 258,600 2,030 1654 10 52 28.5 75PSI

OWB-50 3.3 500,000 425,000 369,50 0 2,9 0 0 1831 10 57 31.7 75PSI

Notes:

1. Net ratings shown are based on piping and pick-up allowance of 1.15.

2. Net ratings in square feet are base on 170° Fahrenheit average water temperature in radiators.
For higher water temperatures, select boiler based on basis of net ratings in BTU per hour.

3. Firing rate in G.P.H. is based on oil having heat value of 150,000 BTU/gallon.

4. 4% reduction of output for every 1,000 feet of elevation.

1.5 M.P.T. Supply Connection

26”

Centerline of Burner Plate

17”

25”

21.5”

Circulator

15.5”

12. 25”

1.5 M.P.T. Return
Connection

L

Approx. 14”

OWB-25 Dimensions

9.375”

2.5 M.P.T. Supply Connection

36”

29.5”
20”

4”

33”

Approx. 14”

.75”

L

8”

2.5 M.P.T. Return Connection

OWB-35 and OWB-50 Dimensions

Page 10OMNI by EconoHeat

Standard Equipment

Components Model 250 Model 350 Model 500

Factory Assembled Cast Iron Sections X X X
Flow Control Oil Supply Pump X X X
Waste Oil Burner X X X
Insulated Jacket X X X
Long Well (35-1020) X X X
Short Well (35-1010) X X X
High Operating Limit (L4008A) X X
Supply Manifold X X X
Refractory Insulated Hinged Front Door w/ Sight Glass X X X
ASME Relief Valve 30 PSI X X X
Spin-on Oil Filter X X X
Low Water Cut-off Control X X X
Manual Reset High Limit Aquastat Control (L4006E) X X X
10” Damper X X
Temperature/Pressure Gauge X X X

Important Code Requirements

Installations must comply with all state, local, and utility codes, laws, regulations, and
ordinances, and CSA standard B139. Where required by the authority having jurisdiction,
the installation must conform to American society of Mechanical Engineers Safety Code for
Controls and Safety Devices for Automatically Fired Boilers, No. CSD-1.

All electrical wiring must be done in accordance with the National Electrical codes latest
edition and all state and local codes.

P a g e 11OMNI by EconoHeat

Waste Oil

Burning Gun

Assembly

Complete

L 4008A Hi Limit Switch

Relief Valve Manual Reset Limit

Modulating

Agustat Tapping

Supply

Manifold

Pressure/

Temp

Gauge

Transition Piece

to Flue Pipe w/

Quadrant Locking

Damper for Draft

Control

Figure 6 – Boiler (OWB-25, OWB-35 & OWB-50)

Rear Clean Out Ports

OWB series boilers are three pass Scotch Marine design with fully water backed transfer
surfaces. Boilers are designed for use in forced hot water heating systems. Heating is supplied
by a Waste Oil Burner that burns all petroleum products any weight combination up to SAE
90W as well as fuel oils. Boiler–Burner units operate with no less than 0.01WC or greater over fire
and may be vented using a conventional chimney.

OMNI Three Pass Design

Third Pass

Second Pass

First Pass

Water flows
through all heat
transfer elements

Pag e 12OMNI by EconoHeat

Combustion Air Supply

WARNING

Failure to provide an adequate supply of fresh air for combustion will result in
hazardous operating conditions. If you use a fireplace or a kitchen or bathroom
exhaust fan, you should install an outside air intake. These devices will rob the
boiler and water heater of combustion air.

1. In unconfined spaces in buildings infiltration may be adequate to provide air for combustion
and ventilation. However, in buildings of unusually tight construction, additional air must
be provided as described in Item2. (b) below.

2. Boiler located in confined space: [Note: Confined space may be defined as a space whose
volume is less than 50 cubic feet per 1000 Btuh of total input of all appliances installed in
that space.]
a) All air from inside of building: Providing infiltration in the rest of the building is adequate,
the confined space may be provided with two permanent openings communicating
directly with another room or rooms of sufficient volume that the total volume of all spaces
meets the criteria for unconfined space. One opening must be within 12 inches of the
bottom of the enclosure. See Figure 7.
b) All Air From Outdoors:
The confined space shall be provided with two permanent openings, one within 12 inches
of the top and another within 12 inches of the bottom of the enclosure. The openings
shall communicate directly, or by ducts, with the outdoors or crawl or attic spaces which
communicate freely with the outdoors.

Chimney

Opening

Figure 7 – Air from inside

Note: Each
opening shall
have a free area
of not less than
one square inch
per 1,000 Btu per
hour of the total
input rating of all
equipment in the
enclosure, but
not less than 100
square inches.

Opening

Chimney

Outlet Air

Alternative
Air Inlet

Ventilation Louvers

(for unheated crawl space)

Ventilation Louvers
(each end of the attic)

Figure 8 – Air from outdoors

Note: The inlet
and outlet air
openings shall
each have a free
area of not less
than one square
inch per 4,000
Btu per hour of
total input rating
of all equipment
in the enclosure.

Inlet Air

Page 13OMNI by EconoHeat

NOTE: All wall openings directly to outdoors must be screened to prevent entry by birds or
small animals.

Chimney

Ventilation Louvers
(each end of the attic)

Chimney

Note: Each air duct opening shall
have a free area of not less than
one square inch per 2,000 BTU per
hour of the total input rating of all
equipment in the enclosure.*

Outlet Air

Alternative
Air Inlet

Figure 9 – With vertical ducts

Note: The inlet
and outlet air
openings shall
each have a free
area of not less
than one square
inch per 4,000
Btu per hour of
total input rating
of all equipment
in the enclosure.

Inlet Air

*If the equipment room is located against an outside
wall and the air openings communicate directly with
the outdoors, each opening shall have a free area of
not less than one square inch per 4,000 BTU per hour of
the total input rating of all equipment in the enclosure.

Figure 10 – With horizontal ducts

Chimney or Vent Requirements

Outlet Air Duct

Inlet Air Duct

WARNING

Inspect existing chimney to make sure it is clean, the right size, properly constructed
and in good condition before installing boiler. Failure to do so may cause a
hazardous operating condition.

Table 1: Minimum Recommended Breaching and Chimney Size

Boiler Model Minimum Breaching

Diameter (inches)

OWB-25 7" 8" 20'
OWB-35 10" 10" 15'
OWB-50 10" 10" 15'

NOTE: Venting must conform with applicable local codes and National Board of Fire Underwriters.

1. Chimney must be a Class A chimney.

Minimum Recommend
Chimney Diameter (inches)

Minimum Recommend
Chimney Height (feet)

Pag e 14OMNI by EconoHeat

2. This is a high efficiency boiler which operates with a low stack temperature which may be subject

to condensation in a cool or improperly designed chimney. Accordingly, the right vent or liner is
very important.

• Masonry chimney with three walls exposed to outdoors may require the use of a 316 stainless
steel liner.

• Masonry chimney with all inside walls—use a tile liner.

3. Breaching

• See Table 1 for minimum recommended breaching and chimney sizes.

• Keep run boiler to chimney as short as possible.

• Use as few elbows as possible.

• Slope upward towards chimney at not less than 1/4” per foot.

• Use a sealed-in thimble for the chimney connection.

• Connect together all sections and fittings with sheet metal screws and seal with silicone sealant.

4. When more than one appliance is connected to the same chimney, the chimney’s internal cross­sectional area must be at a minimum equal to the area of the largest vent plus 50% of the area of
each additional vent.

5. Clearances—vent pipe between boiler and chimney must be a minimum of 6” from any
combustible material.

6. An oil-fired unit shall be connected to a flue having sufficient draft at all times, to assure safe
proper operation of the unit.

SIDE-WALL VENTING---IMPORTANT NOTE

Two problems arise when side wall venting any oil appliance;

1. There can be an accelerated rate at which soot builds up on the cad-cell, spinner, etc.

2. There is the potential for severe soot damage to the side of the structure in the event that
the boiler operates at a high smoke level. This can happen for many reasons, some of
which are out of the control of both the installer and appliance manufacturer.

EconoHeat recommends the use of a chimney to vent our residential oil boilers. If a power
venter must be used, it is the responsibility of the installer and power vent manufacturer to
“engineer” the power vent system.

ECONOHEAT WILL ASSUME NO RESPONSIBILITY FOR SOOT DAMAGE TO SIDING FROM A
POWER VENTED OIL BOILER. THIS APPLIES REGARDLESS OF THE CAUSE OF THE SOOTING.

Locating the Boiler

WARNING

Boiler must not be installed in an area where gasoline, paint or other combustible
materials or flammable vapors or liquids are present.

Consider all piping and venting connections before selecting a location. Locate as close to
the chimney as possible, observing the following clearances requirements from combustible
surfaces:

Page 15OMNI by EconoHeat

Front – Additional clearance is required for insertion and removal of the Tube Insert as noted for
each model:

• OWB -25 38.5”

• OWB-35 38.5”

• OWB-50 43.5”
Top – 6” above controls
Left Side – 6”
Right Side – 6”
Back – 18”

Boiler is not intended for installation on combustible floor. Further, to facilitate servicing it is
desirable to raise the boiler at least 8” off the floor. It is recommended that concrete blocks be
employed to build up a foundation. Ensure that top surface of foundation is level.

Installing the Boiler

1. Move the boiler as close as possible to its final location in the crate.

2. Remove the two lag screws holding the rear feet to the skid.

3. Remove the front jacket panel. Cut the band holding the front of the boiler to the skid.

4. Move the boiler into the final position.

5. Waste Oil Piping: USE ONLY 3/8” nominal ID copper piping with flare fittings only on the oil

suction from the tank to the oil pump and oil pump to burner. DO NOT use ferrule fittings
or teflon tape on any pipe fittings. Keep suction line approximately 6” from bottom of
oil tank to prevent suction of sludge (Figure 11). Use only an inside oil storage tank. Do
not draw from an outside tank, especially not an underground tank directly to burner. A
separate transfer pump from an outside tank with proper filtration to the inside supply tank
is acceptable.

6. The fuel pump included with burner is to be mounted at tank level or below. PUMP MUST

BE MOUNTED HORIZONTAL AND LOCATED NEXT TO WASTE OIL SUPPLY TANK.

Oil Feed Line, 3/8” to connector on burner gun assembly
O Suction Line, 3/8” copper piping
Suction Line 6” min from bottom of tank to prevent sludge from being introduced into the supply line

Figure 11

Waste Oil Supply Tank Waste Oil Pump

2

3

1

Boiler

Page 16OMNI by EconoHeat

Breaching Installation

The over fire draft should be minimum of -0.02 or more. Refer to Table 1 for minimum breaching
sizes. Breaching run should be as short as possible with as few elbows a practical. Unless
marginal draft conditions exist, a barometric draft control must be installed in the breaching
and should be approximately 18 inches from the boiler breaching connection. Breaching
should not project into the chimney beyond the inside wall of the chimney. Connect the
breaching to the chimney with a thimble or slip joint to facilitate cleaning. See Figure 12.

Pitch Up 1/4” per foot

Barometric Draft Control

18"

Straight Run Preferred

Figure 12

Installing the Boiler Controls & Accessories

1. Accessories for Boilers OWB-25:

a) Take the L-7248C Aquastat relay, the well, the pressure relief valve with pipe nipple and

the temperature/pressure gauge from the large carton. Install in taps provided at the
top rear of the boiler as shown in Figure 13.

Figure 13

P a g e 17OMNI by EconoHeat

b) Take the boiler drain from the same carton and connect it to the 3/4 inch opening of

the 1 1/4 x 3/4 x 1 1/4 inch tee in the boiler return manifold at the bottom rear of boiler.
c) Install 1 1/4 x 3” Nipple and Circulator Flange.
d) Remove the circulating pump from its carton in the crate and mount it to the pump

flange on the end of the return manifold.

2. Bare Boiler:
a) The pressure relief valve and temperature/pressure gauge are supplied with the boiler

and should be mounted as shown in Figure 13.

b) The bare boiler does not include the return manifold. The installer must make up his

own manifold to connect to the 2 x 1 1/4 inch bushing which is supplied in the boiler
supply and return ports, and must provide his own boiler drain and circulating pump.

3. Accessories for Boilers OWB-35 and OWB-50:

Figure 14 – Supply Manifold Assembly

Figure 15 – Return Diffuser Installation

a) Attach supply manifold as shown in Figure 14.
b) Install return port diffuser and attach return flange as shown in Figure 15. Make sure

diffuser SLOTS face upward.

c) Screw threading used on these parts are metric. There is no English thread equivalent

to the nuts or studs supplied. Attempts to use any English threaded stud in place of
those supplied will damage the boiler block.

Page 18OMNI by EconoHeat

Water Piping Connections

1. To make the piping connections to the boiler ready to connect to the system piping, the
following will also be required at a minimum:

• 1 – Air Purger (same size as supply pipe)

• 1 – Pressure reducing Fill Valve

• 1 – Expansion Tank (sized to system design requirements)

• 1 – Automatic Air Vent

2. The following accessories may also be required, depending upon overall system design
and code requirements:

• 1 – Low Water Cutoff may be required (Electronic Probe Type 550 LWCL included) if boiler

is located above radiation level. Check requirements of state or local code bodies and
insurance companies. If required use a probe-type designed for water system use and
install in tee in supply piping above the boiler.

• 1 – Manual Reset High Limit----Required by some state or local codes. Also required if

system is to comply with ASME code.

• 1 – Backflow Preventer----- Required by many State and local codes.

3. Additional circulating pumps or zone valves may also be required if the system is to be
multi-zone or if it is to include a domestic hot water storage tank with coil.

4. There are two types of expansion tanks used, the closed type and the pre-pressurized
diaphragm tank Most new installations use the diaphragm type tank, however some
installations still employ the closed type tank.

• Piping Connections with closed type expansion tank----See Figure 16. Piping from tee in

supply to tank should be 3/4 inch. If horizontal piping is employed, pipe must be pitched
up toward tank 1/4 inch per foot.

• Piping connections with diaphragm expansion tank--- See Figure 17. The cold water

feed to the pressure reducing fill valve may be piped with 1/2 inch pipe.

WARNING

The expansion tank must be properly sized to system requirements. An under-sized
expansion tank will cause system water to be lost through the relief valve and
make-up water to be introduced through the fill valve. Continual introduction of
fresh water into the system will cause mineral build-up in the boiler sections and
eventual section failure.

Page 19OMNI by EconoHeat

Closed Type Expansion Tank

Supply to

System

Return from System

Shutoff Valve

Figure 16

3/4 in.

Fill ValveCold Water Feed

Circulation Pump

Pressure Relief Valve

S

R

Drain Cock

Purger

Auto Air Vent

Cold Water Feed

Discharge Type
Expansion Tank

Figure 17

Shutoff Valve

S

Circulation Pump

R

Drain Cock

Page 20OMNI by EconoHeat

System Piping

Discharge piping from relief valve must be piped to a drain or must terminate 6”
above floor to eliminate damage to the structure or personal injury. It must not be
piped to a point where freezing might occur.

Isolation Valves

Shutoff Valve

S

WARNING

Supply and return and system
piping should be sized by
determining the pressure drop,
required flow rate and pump
capacity.

1. Multiple zoning with zone
valves: Install a balancing valve in

each zone and adjust so that flow
is about the same in each zone.
See Figure 18.

Cold Water Feed

Zone Valves

Circulation Pump Drain Cock

Figure 18

2. Multiple zoning with

circulation: Each pump

will require a separate
relay (Honeywell R845A or
White Rodgers 829A-845, or
equivalent). Install a flow control
valve in each zone including the
indirect water heater to prevent
gravity circulation. Install a
balancing valve in each zone
and adjust so that flow in each
zone is about the same. See
Figure 19.

R

Isolation Valves

Isolation Valves

Shutoff Valve

Cold Water Feed

Circulation
Pumps

S

R

Drain Cock

Figure 19

Pag e 21OMNI by EconoHeat

3. Radiant panel or other low temperature system: The temperature of the system water

coming back to the return port of the boiler must not be permitted to drop below about 135
Degree F for an extended period of time. Return water temperatures of 130 Degree F or lower
will cause condensation on the exterior surface of the heat exchanger and corrosion and
eventual heat exchanger failure will result. Radiant floor and ceiling panel heating systems
typically operate with maximum supply water temperatures of 140 Degree F or less. A standard
piping arrangement would, under these circumstances, permit return water temperatures of
120 Degree F and lower. Accordingly, such systems must be piped such that the return water
temperature will be high enough at all times to prevent condensation. See Figure 20.

NOTE: Bypass A shown in Figure 20, below, should not exceed 12 inches in length. If it is not practical to
maintain a 12 inch length or less then increase the pipe size of the bypass by one size.

Return from System

Supply to System

Stem Thermometer

Shutoff Valve

Circulation
Pump

S

Supply to System

Shutoff Valve

Return from System

Cold Water

Feed

Bypass A

Cold Water Feed

Drain Cock

Circulation Pump

R

Drain Cock

Figure 20

4. Large water content systems: Such

systems as converted gravity systems,
old systems with cast iron radiators, and
also newer systems that employ outdoor
reset control present a potential problem
with low return water temperatures
and condensation. The boiler must be

S

protected from condensation in such
cases by using a by-pass as shown in
Figure 21.

R

Circulation Pump

Figure 21

Drain Cock

Page 22OMNI by EconoHeat

5. Integrated system (heat

and domestic hot water): With

a single heating zone priority
for domestic hot water may be
provided through the use of a
3-port zone valve. This system
assures that full boiler output is
available to recover the storage
tank quickly and should be used
where supply of domestic hot
water on demand is critical. For
this application use a full throated
valve with a minimum pressure
drop. See Figure 22.

Indirect Water Heater

(Storage Tank with Coil)

Supply to
System

3 Port Zone
Valve

Return from System

Figure 22

Shutoff Valve

Cold Water

Feed

Circulation Pump

S

R

Drain Cock

6. Integrated system with multiple heating zones and no priority for domestic hot water using zone

valves: Where the boiler output is large relative to the heating capacity of the coil in the indirect water

heater priority for domestic hot water is not necessary. Further, with multiple heating zones there is less
likelihood that all zones will call for heat at once and require full boiler output for heating. Because the
tank is usually close to the boiler, the pressure drop through the coil circuit will generally be less than
through a heating zone circuit, which will provide some measure of priority for domestic hot water. This
can be enhanced by increasing the pipe size to the coil e.g. if 3/4 inch pipe is used on the heating zones
run 1 inch pipe to the coil. (See Figure 23.) Should priority for domestic hot water be mandatory, it can be
provided as shown in Wiring Section, Figure 24.

Indirect Water Heater

(Storage Tank with Coil)

Supply to
System

Shutoff Valve

S

Zone Valves

Cold Water

Feed

Return from System

Circulation Pump

Figure 23

R

Drain Cock

Page 23OMNI by EconoHeat

7. Integrated system, single or multiple heating zones, using circulating pumps rather than zone valves:

Each pump will require a separate relay (Honeywell R845A or White Rodgers 828A-845, or equivalent).
Install a flow control valve in each zone including the indirect water heater to prevent gravity circulation.
Install a balancing valve in each zone and adjust so that flow in each zone is about the same. (see Figure

24.) While this basic system does not provide priority for domestic hot water, priority can be provided as

shown in Wiring Section, Figure 27.

Indirect Water Heater

(Storage Tank with Coil)

Supply to
System

Shutoff Valve

S

Flow Control Valves

Insulation
Valve #4

Supply to
System

Circulation Pump
Insulation
Valve #4

Return
from
System

Flow Check

Insulation
Valve #4

Chiller

Cold Water

Feed

Return
from
System

Figure 24

S

Circulation Pump

R

Cold Water

Feed

R

Drain Cock

8. Combination heating/
cooling system with chilled
water: The chiller must

be piped in parallel with
the boiler and isolation
valves installed to prevent
the chilled water from
circulating through the
boiler and heated water
from circulating through the
chiller. See Figure 25.

Figure 25

Drain Cock

Page 24OMNI by EconoHeat

9. Single boiler piping with blend pump: When

burner is operating the water flow throughout
the boiler shall be not less than 1.8 GPM for each
100,000 BTU/HR of gross boiler output. Size blend
pump accordingly. See table below and Figure 26.

Amtrol #720 Air

Eliminator or Equal

System
Supply

S

Air

Separator

System

Circulation

Blend Pump

Primary/

Secondary Pump

Boiler Model GPM GPM

OWB-35 16.3 78.9

OWB-50 19.6 94.9

Maximum water flow resistance for boilers is 14" w.c.

S

S

Secondary

Pump

Check Valve

R

R

System

Return

12" M A X

Figure 27

To size Blend Pump

see table left

Figure 26

Secondary

Pump

Expansion Tank

Eliminator or Equal

Check Valve

Separator

Blend Pump

Check Valve

Amtrol #720 Air

System
Supply

Air

12" M A X

R

Expansion Tank

System

Circulation

Backflow

Prevention

Pressure

Reduction

Valve

From City

Water

Supply

Backflow

Prevention

Pressure

Reduction

System
Return

Valve

From City

Water

Supply

10. Single or multiple
boiler piping for
primary/secondary
pumping:

Size
secondary pump
GPM at gross boiler
output for 20” Drop.
When calculating
pump head, the
maximum boiler
resistance for
any boiler will not
exceed 14 in. W.C.
head. See Figure 27.

11. Multiple boiler
piping, reverse return
flow with blend
pump: See Figure 28.

Figure 28

S

R

*Blend

Pump

Check Valve

System

Return

Amtrol #720 Air

*Blend

Pump

S

R

Expansion Tank

Eliminator or Equal

Check

Valve

Air

Separator

System
Supply

System

Circulation

Backflow

Prevention

Pressure

Reduction

Valve

From

City

Water

Supply

Page 25OMNI by EconoHeat

Burner Mounting

Note: When the burner is field installed, the installer must fill in the space between the burner
blast tube and the insulation block on the inside of the burner door with refractory mix provided

Figure 29 – OWB-25, OWB-35 and OWB-50 Burner Mounting & Boiler Door Detail

Page 26OMNI by EconoHeat

Boiler Jacket Assembly

OWB-35 and OWB-50 Jacket Installation Instructions

• Screw the four extension setscrews (43) into the four outer holes in the corners of the rear
sections. Securely tighten the setscrews and other fastening bolts of the flue outlet cover
(22)

• Place the large wraparound insulation mat (40) over boiler block (aluminum foil side
facing out).

• Place smaller piece of insulation on top of wraparound insulation. This will provide double
thick insulation on top of the boiler block.

• Remove flue collector clean-out covers (62)

• Push the two smaller pieces of insulation (60) onto the flue collector (22) so that the four
extension setscrews (43) protrude through the insulation.

• Attach rear jacket panels (36) and (38) to the two extension screws(43) using the M6x10
pan head screws. Screw the rear panels together in the center using sheet metal screws
provided. Reattach the clean-out covers.

• Place right and left side panels (93) (94) into the factory mounted hinge bracket (18) and
hook into the rear panels (36) (38).

• Hook center panel (33) with flange edge down between side panels (93) and (94).

• Attach the upper front trim panel (41) between the right and left side panels over the
front door.

• Place the top
panel (86) in
position. Hook
to the side
panels.

• Remove sight
glass plug in
front door and
install sight
glass assembly.
Sight Glass (25)
Sight Glass
Tube Cap(26)
and Sight Class
Gas ket(48).

26 25 26A

48

94

86

33 60

38

36

43

Figure 30 – OWB-35 and OWB-50 Assembly Detail

18

1841

40

93

Page 27OMNI by EconoHeat

OWB-25 Jacket Installation Instructions

• Attach the rear jacket mounting brackets (7) to rear tie rod ends on back of boiler using
the 12mm nut (9) provided on the end of each tie rod.

• Attach the rear jacket panel (3) to the rear jacket mounting bracket using the 1/4-20 screws
(11) ans nuts (10) provided.

• Assemble front jacket mounting bracket (23) to the heat exchanger using the two M10x16mm
cap screws (27).

• Drape the foil faced fiberglass insulation mat (not shown) over the top and sides of the
boiler. Make sure that the insulation is behind the Door Hinge and Front Mounting Bracket
and that the tappings in the top of the boiler are not covered by the insulation.

• Attach one door bracket (18) to the bottom of both the left and right side jacket panels.
Use two 8-32x1/2” screws (19) and nuts (20) to assemble each door bracket.

• Attach the left and right side jacket panels to the boiler. The front end of the right side
panel is attached to the hinge using 10-24x3/4 screws (21). The front end of the left side
panel is also attached to the front jacket mounting bracket (23) using 10-24x3/4 screws.
The rear of both the left and right panels are attached to the rear panel using #10x1/2 sheet
metal screws.

• Install a #10x1/2 sheet metal screw into the remaining hole in the rear of the right side jacket
panel which secures the rear of the wireway.

• Attach the top jacket panel (5) using four #10x1/2 sheet metal screws.

• Attach the flue collector cover (4) using four #10x 1/2 sheet metal screws.

• Press the door switch (16) into the door switch bracket (17). Connect the door switch leads
to the switch (it does not matter which wire is connected to which side of the switch).
Attach the door switch bracket to the right side jacket panel using a 10-24x3/4 machine
screw (21).

• Mount the door
knobs (25) to the
front panel (24)
using two 8-32x1/4
screws (26).

• Mount the front
jacket panel on
the boiler.

• Connect the
loose end of the 6”
conduit assembly
to the limit
control. Connect
the black wire to
terminal “B1” and
the white wire to
terminal “B2”.

Figure 31 – OWB-25 Assembly Detail

Page 28OMNI by EconoHeat

Boiler Tube Insert Assembly

Install Stainless Steel Tube Insert with external stitch weld touching first water section high point
of casting and the dam located at the 6 o’clock position (bottom of boiler). When boiler door
is closed, stainless tube will embed into door refractory at least 1/4”.

Dam

Page 29OMNI by EconoHeat

Wiring

WARNING

All wiring and grounding must be done in accordance with the authority having
jurisdiction or, in the absence of such authority, with the National Electrical Code
(ANSI/NFPA70).

1. 120 Volt Wiring—The boiler should be provided with its own 20A branch circuit with fused
disconnect. All 120 volt connections are made inside the L8148A aqua-stat relay as follows
(also see Fig. 31 or 32):

• Hot (“black”)- Terminal “L1”

• Neutral (“white”)- Terminal “L2”

• Ground (“Green” or bare)- Ground screw on case of L8148A

2. Thermostat Wiring—Follow thermostat manufacturer instructions. To insure proper
thermostat operation, avoid installation in areas of poor air circulation, hot spots (near any
heat source or in direct sunlight), cold spots (outside walls, walls adjacent to unheated
areas, locations subject to drafts). Provide Class II circuit between thermostat and boiler.
Connect thermostat wire leads to terminals “T” and “T” inside L8148A aqua-stat relay.

Wiring Variations

1. Multiple Circulator Zones—Figure 36 shows wiring for two or more circulator zones using
Honeywell R845As. One R845A is required for each circulator zone. Circulator terminals
“C1” and “C2” on the L8148A are not used. A DPST Honeywell RA832A may be substituted in
place of the R845A using the “X” and “X” terminals in place of the “5” and “6” terminals on a
R845A. A call for heat from any thermostat will energize the DPST relay in that zone”s R845A.
When this relay is energized, electrical continuity is created between terminals 3 and 4,
energizing the circulator for that zone. At the same time, electrical continuity is created
between terminals 5 and 6 on the R845A, creating a current path from terminal “T” to “T”
on the L8148A. Assuming that the supply water temperature is below the high limit setting,
the normal ignition sequence will be initiated.

2. Multiple Zones using Zone Valves—Figure 35 shows wiring for multiple zones using Honeywell
V8043F zone valves. This wiring diagram may be used for other 24-volt zone valves as long
as they are equipped with end switches. Do not attempt to use the transformer on the
L8148A to power the zone valves; use a separate transformer. Up to five V8043Fs may be
powered by one 48VA transformer, such as the Honeywell AT87A. A call for heat from a
given thermostat will result in the application of 24 volts across the TH and TR terminals
on the corresponding zone valve, energizing the zone valve motor. The zone valve opens
and the end switch contacts are then made. The end switches are connected in parallel
with each other and to the “T” and “T” thermostat connections so that any zone valve that
opens will also start the circulator and fire the boiler(assuming the high limit is not open).
Zone valve terminal TH/TR has no internal connection on the zone valve; it is merely a
“binding post” used to connect two or more wires.

Page 30OMNI by EconoHeat

WHT

BLU

RED

BLK

ORN

OIL

PREHEATER BLOCK

CONTROLLER

WHT

RED

HTR

PRI

L2

L1

BLOWER MOTOR

WHT

HIGH

VOLTAGE

TRANS-

FORMER

BLK

PHOTO EYE

FLAME SENSOR

OIL PRIMARY CONTROL

(IE, Honeywell, etc.)

BLK

ORN

WHT

THERMOSTAT
CONNECTION

500W
HEAT
ROD

Bi
METAL
HIGH
LIMIT
SWITCH

THERMO­COUPLE

OIL

PREHEATER

BLOCK

Fuse

Power Switch

BLK

BLK

WHT

WHT

RED

WHT

WHT

WHT

RED

BLU

RED

Power Plug

(Looking at Terminal Side)

BLK

Oil Valve

BLK

GRN

Electrical Box

(Looking at Socket Side)

Burner Assembly

Thermostat

Circulator

Honeywell

L8148A Aquastat

T

T L1

L2

3

B1 B2

C2C1

Jumper

N

H

Oil Pump

WHT

BLK

Service Switch

Fused Disconnect Switch

H

N

GND

(Items Supplied By Installer)

120 VAC

(Supplied By Installer)

Low
Water
Cutof f

Manual

High
Limit

L4006E

RED

WHT

WHT

RED

GRN

W

X

G

Y

BLK

Power

Socket

WHT

YEL

RED

W

XGY

GRN

Figure 32 – Wiring diagram, single heat zone only, OWB-25

Page 31OMNI by EconoHeat

WHT

BLU

WHT

RED

BLK

ORN

OIL

PREHEATER BLOCK

CONTROLLER

WHT

RED

HTR

PRI

L2

L1

BLOWER MOTOR

WHT

HIGH

VOLTAGE

TRANS-

FORMER

BLK

PHOTO EYE

FLAME SENSOR

OIL PRIMARY CONTROL

(IE, Honeywell, etc.)

BLK

ORN

WHT

THERMOSTAT

CONNECTION

500W
HEAT
ROD

Bi
METAL
HIGH
LIMIT
SWITCH

THERMO­COUPLE

OIL

PREHEATER

BLOCK

Fuse

Power Switch

BLK

BLK

WHT

WHT

RED

WHT

WHT

WHT

RED

BLU

RED

Power Plug

(Looking at Terminal Side)

BLK

Oil Valve

BLK

GRN

Power

Socket

Electrical Box

(Looking at Socket Side)

Burner Assembly

N

H

Oil Pump

WHT

BLK

WHT

YEL

Service Switch

Fused Disconnect Switch

H

N

GND

(Items Su pplied By Installer)

120 VAC

T T

Circulator

Thermostat

T T

2 1

3

4

5

6

Honeywell

R845A

Low
Water
Cutoff

High
Limit

L4006E

High

Limit

L4008A

Set Temp 20

Deg High er

Than L4008A

(Supplied by Installer)

(Supplied by Installer)

(Supplied by Installer)

RED

W

X

G

Y

W

XGY

BLK

BLK

Figure 33 – Wiring diagram, single heat zone only, OWB-35 and OWB-50

Page 32OMNI by EconoHeat

Figure 34 – Wiring diagram, zone wiring using Honeywell V8043F valves
(factory boiler wiring not shown here – see figure 32 or 33)

Figure 35 – Wiring diagram, circulator zone wiring using Honeywell R845A valves
(factory boiler wiring not shown here – see figure 32 or 33)

Page 33OMNI by EconoHeat

Boiler Start-up and Adjustments

FILL SYSTEM

1. Close manual air vents (if used) and automatic air vents. Attach hose to boiler drain on
return connection and run to a drain or to outdoors. Open drain cock and close shutoff
valve on boiler supply pipe.

2. HEATING ONLY – SINGLE ZONE SYSTEM – Open manual valve in cold water feed line and set
the fill valve to fast fill. Allow water to flow through the system and out the hose until there is
a steady flow of water through the hose with no air bubbles. Next, open the shutoff valve
in the drain until air bubbles cease. Then take the fill valve off fast fill, close the drain cock,
remove the hose and open all automatic air vents. Also open all manual air vents one at a
time and close when water squirts out. Observe the temperature/pressure gauge. System
pressure with a cold fill should be in the 12 to 14 psi range.

3. MULTI-ZONE SYSTEMS-HEATING ONLY OR HEAT & DOMESTIC HOT WATER WITH ZONE VALVES
– To ensure good circulation through all zones with no air pockets, each zone should be
purged of air individually. With all zone valves in the manual open position let water flow
through the system by opening the drain cocks so water can exit the system through a
hose as in 1 above. When the system seems to be full and free of air, close the drain cock,
and the shutoff valve on the boiler supply pipe, leaving the manual valve on the cold water
feed open. Now release the manual openers to close all but one zone valve. Open the
drain cock and put the fill valve on fast fill. When the flow through hose becomes steady
with no air bubbles, take the fill valve off fast fill and then close the drain cock. Repeat this
procedure with each zone until all zones have been purged. Open the shutoff valve on the
boiler supply pipe. Then open all manual air vents one at a time. When water sprays out of
the air vents should have the cap loosened so it can vent air.

4. MULTI-ZONE SYSTEMS ZONED WITH CIRCULATORS – Following the same procedures as in 3
above using the manual shutoff valves to isolate a zone instead of zone valves.

5. Check system pressure on the temperature/pressure gauge on the boiler. Pressure should
be in the 12 to 14 psi range. If pressure is over 14 psi drain a little water out with the drain
cock. Watch gauge for a few minutes to ensure pressure does not build back up. If pressure
is too high with system cold there is a good possibility the relief valve will blow off when the
system is brought up to temperature. Too high a pressure with the system cold indicates a
faulty fill valve.

Page 34OMNI by EconoHeat

Waste Oil Burner Start-up Procedure

1. IMPORTANT – Prior to starting the unit, pre-fill the filter and fuel line with oil to assist priming

procedure. Oil pump motor turns at low RPM’s and would take significant time to complete
priming process if not pre-filled. Make sure the oil supply line fittings are air tight. Vacuum
leaks are notoriously hard to find. Pressurizing the line with oil in it can help to locate leaks.

2. Proper draft. Draft is the gases traveling through the heater and out the stack or flue. If
exhaust fans are present in your building, chances are a draft inducer will be needed. Call
our factory or see our website for help, www.econoheat.com

3. During the initial power up process the burner is locked out from energizing until the oil has
been properly pre-heated to operating thermo set-point, approx 3 to 5 minute duration.
Once the oil has been pre-heated, power is then applied to burner components and oil
pump.

4. Making sure the thermostat is turned off, apply power to the burner. Switch burner main
power switch to ON position. After allowing the oil pre-heater time to establish temperature
set-point, approximately 5 minutes. Jump the “T” terminals on the Oil Primary Control (figure

3). Once the burner is running, temporarily jump the “F” terminals on the Oil Primary. This
will allow the burner to run during the pump priming process.

5. Priming the oil pump: Open bleeder valve one turn until all air is expelled (figure 6). This
may need to be done twice to insure all air is removed. IMPORTANT: When fully purged and
flame is established remove temporarily jumpers on “F” terminals of the Oil Primary to allow
safety features of the unit to operate properly.

6. Adjust air supply of integrated air compressor to 12–13 P.S.I. This is factory preset, however,
due to freight handling settings may be compromised.

7. Combustion air band (figure 3) should be open approximately 1/2” or until flame is clear
yellow, not orange. Opening the air band too far may cause delayed in starting or even
prevent the flame from starting.

Inspect flame length through inspection door located above burner gun assembly. End
of flame should reach no further than ½ way down combustion tube. To accomplish this
flame length, use adjustment knob on opposite side of oil pump. NEVER ATTEMPT TO START

HEATER WHEN COMBUSTION CHAMBER IS HOT AND A DELAYED START.

Water Treatment

Generally no water treatment will be required. Care should be taken to ensure that the system
does not lose water from leaks, or continual relief valve operation since continual make-up
water will reduce boiler life.

Page 35OMNI by EconoHeat

Maintenance Schedule

WEE KLY

• Drain water from storage tank.

MONTHLY

• Check your ash accumulation for best performance, remove if excessive (the size of unit,
type of oil and run time are all contingent factors).

• Change or Replace Spin-On Filter or Filter screen located in the pancake style housing (figure
14 below). NOTE: every application is different and may vary depending on contamination
of oils being used.

ONCE EACH SEASON (or more often, depending upon usage or contamination of oil)

• Open the burner side clean-out door to access and clean flame cone (figure 5 above,
and figure 8 below).

• Open the swing out doors on both sides of the furnace. The swing out door opposite of
the burner assembly requires the removal of the access panel allowing simple entry to the
combustion chamber and heat exchanger(s) to vacuum out the accumulated ash & soot
(hepafilter filter recommended) (figure 12 below).

• Clean Suntec pump filter. Remove pump cover for access (figure 13 below). CAUTION: Be
careful of gasket.

• Clean air compressor filter element.

YEARLY

• Clean flue pipe stack-to loosen soot remove stack at top of heater and tap thoroughly.
Then vacuum upper heat exchanger(s).

• Inspect electrode adjustment (figure 10 below). Due to erosion, adjustment may change.

• Replace nozzle every 3-5 years depending on usage (figure 5 above, and figures 9, 10 and
11 below). Will lose efficiency due to erosion. This can be accessed by swinging the burner
clean out door open (figure 8 below).

• IMPORTANT: TO TURN POWER OFF, Remove electrical plug from heater cabinet to burner.
Remove 9/16” burner door securing nuts, swing open the burner side clean-out door.
Remove nozzle with 5/8” socket (figures 8 and 9 below).

BOILER

1. Clean Boiler using procedure below.

2. Check all water system piping for leaks. Repair any found.

3. Check pressure relief valve operation by opening with manual lever. If it fails to relieve,
replace immediately.

4. Check operation of safety controls, low water cutoff and manual reset high limit (if provided).

5. Check breeching connections to ensure there are no flue gas leaks. Seal any leaks found
with High Temperature Silicone Sealant.

6. Check flue gas temperature at the test point in the breeching. If gross flue gas temperature
is 550 degrees F or above, suspect that cleaning of the boiler flue-ways is required.

Page 36OMNI by EconoHeat

BOILER CLEANING

Turn off the power with the line switch. Disconnect the electrical plug at the J-Box by the
Aquastat Relay. Remove the four hex head bolts from the outer corners of the burner mounting
plate and swing open the burner door with burner mounted to provide access to the boiler
flue-ways. Remove sludge and deposits from Stainless Steel Insert. When all deposits are
removed, close burner door, and plug in the electrical lead, restore the power and turn burner
on. If a boiler is to be shut down and taken out of service for a period of time, the boiler
should be cleaned immediately upon shut down while the flue-ways are still warm. When the
boiler gets cold, the deposits harden making cleaning difficult. Further, hardened deposits will
absorb moisture and cause corrosion.

When cleaning, inspect all

three pieces thoroughly. When
disassembling and reassembling
nozzle, keep facing up as shown.

Figure 36 – Nozzle Assembly Detail

Figure 37 – Electrode Adjustment Detail

Washer

Nut

Figure 38 – Pancake
Style Filter Assembly

Filter Housing

Bolt

Filter Housing

Stainless Filter Screen

Page 37OMNI by EconoHeat

Thermocouple

Snap Switch

Pre Heater Oil Block

Pre-Heater
Control Card

Figure 39 – Pre-Heater Block Detail (Removed From Burner for Clarity)

Remove 4 bolts for access to strainer filter.
CAUTION: must be careful not to destroy the
inner gasket during removal of the housing.

Electrodes

Nozzle

Figure 40 – Pump Strainer

Figure 41 – Oil Filter (Spin-On Filter above,

Pancake Style Filter below)

Page 38OMNI by EconoHeat

Freeze Protection

Where freeze protection is required use antifreeze made especially for hydrolic systems such
as inhibited Propylene Glycol. DO NOT use automotive type antifreeze. Follow antifreeze
manufacturer’s directions for quantity. A 50% solution provides protection to –30 degree F. For
boiler water content see page 11.

Troubleshooting

NO HEAT:

• Check burner power switch and make sure power is available to the whole control system.

• If included in system, check low-water cutoff and/or manual reset high limit.

• Check room thermostat(s) and zone valves or pump relays (if used).

• Make sure there is oil in tank.

• Inquire if reset button on burner oil primary control has been tripped. If reset button continues
to trip then DO NOT ATTEMPT TO START BURNER. Open burner door by disconnecting the
plug-in lead and remove the four hex head bolts. Examine the combustion chamber for
unburned oil and oil vapor. If present, clean up oil. With burner door open check cad
cell for soot or dirt deposits, check nozzle and if clogged, replace with nozzle of identical
make and style. Check electrodes for proper gap and for soot or oil deposits. Also check
porcelains for cracks. Close burner door and re-connect electric cord. Press reset button
while watching through the observation port. If burner fires immediately and flame looks
good, cycle several times. If burner does not fire immediately, or if it fires but flame looks
ragged and/or smoky, shut burner down and check the fuel delivery system. The problem
may be air in the intake line so tighten all fittings and tighten the unused intake port plug.
Also check the filter cover and gasket. Also check the pump filter and clean it with a brush
and fuel oil or kerosene if it looks dirty.

INADEQUATE HEAT:

• Check thermostat and heat anticipatory setting. A wrong setting can cause short cycling
and inadequate heating.

• Check to see if the distribution system is air-bound. If pump and boiler are running and the
pipe connection to the boiler supply port is hot, check the pipe temperature at the inlet to
the first radiator. If it is cool or only lukewarm, then the problem is lack of circulation. Look
for air in the system, a valve partially closed, a zone valve failed in the closed position, a
pump failure. The most common fault is air in the system.

Page 39OMNI by EconoHeat

RELIEF VALVE LEAKS CONSTANTLY:

• Check system pressure. With system hot, pressure should be in the 20 psi to 25 psi range,
not to exceed 25 psi. With system cold, pressure should be in the 12-14 psi range. If pressure
is over these ranges, then suspect the pressure reducing fill valve or the expansion tank.
A diaphragm tank may be too small, may have a ruptured diaphragm (this would cause
a very sharp rise in pressure as system water heats up and a sudden opening of the relief
valve) or may be over-pressurized. A closed type expansion tank may be undersized, may
be improperly piped to the boiler, may be water logged.

• Relief valve may be defective, or it may have foreign material lodged on the seat.

OMNI Waste Oil Boiler Limited Warranty

EconoHeat (manufacturer) warrants to the purchaser of Unit Heaters listed above will be free
from defects in materials and workmanship for the durations specified below, which duration
begins on the date of delivery to the customer. Customer is responsible for maintaining proof
of date of delivery.

If return is deemed necessary for warranty evaluation and determination of repair or
replacement, unit heater is to be sent to the factory with freight prepaid. EconoHeat reserves
the right to determine appropriate action for repair or replacement.

No parts will be accepted by EconoHeat without RA# (return authorization number) clearly marked
on outside of shipping package. Obtaining RA# requires model and serial numbers, description
of part being replaced and nature of defect. Call factory to receive RA#.

Warranty Covers:

• Boiler cast iron jacket, one (1) year (parts only)

• Stainless steel combustion tube Insert, five (5) years limited (part only)

• Oil heater block, twenty (20) years (parts only)

• Oil heater block controller PCB, three (3) years (parts only)

• All other components, one (1) year (parts only)

This warranty is void if:

• Warranty registration card is not returned within sixty (60) days of purchase

• Any part or component subject to abuse or altered from original manufactures specifications

• Installation not in accordance with instructions

• Has not been properly maintained, operated or has been misused

• Wiring not in accordance with diagram furnished with unit heater

• Unit heater is operated in the presence of chlorinated vapors

• Air through unit heater is not in accordance with rating plate and specifications

• Target plate or clean out door warped/discolored from excessive heat

Page 40OMNI by EconoHeat

Warranty is limited to the original purchaser and is non-transferable.

The above warranty is in lieu of all other warranties expressed or implied. EconoHeat does not
authorize any person or representative to make or assume any other obligation or liability that
is not in accordance with above warranty. EconoHeat is not responsible for any labor and/

or shipping cost, unless prior authorization in writing has been obtained.

Warranty Card

Please fill out, tear off and return to manufacturer within sixty (60) days of purchase, or warranty will
not be valid. Please print or type.

Date of Purchase:

Serial #:

Model #:

Customer (Company) Name:

Address:

City: State: Zip Code:

Dealer:

Address:

City: State: Zip Code:

Installed By:

Page 41OMNI by EconoHeat