Benjamin Heating products DO110 User manual

A DIVISION OF
W.R. BENJAMIN
PRODUCTS LIMITED
OWNERS MANUAL
MODEL
DO110&DO180
IS CERTIFIED TO:
UL391
CAN/CSA B366.1
Unit Serial #
PurchasedFrom
Company Address
W
Name of Installer
Installer Telephone #
DateInstalled
IMPORTANT
Thismanualmust be given tothe homeowner.Pleaseread the warranty
and return the warrantycard to initiatecoverage.
We StronglyRecommend TheUseOfA CarbonMonoxideDetectorWhen Using
Any ProductThatConsumesFossilFuels.
THIS BOILER ISTOBE INSTALLED ASANADDON UNIT TOA PRIMARYHEATINGBOILER
ONLY. ITIS INTENDED TOBE INSTALLEDONLY WITHIN THE BUILDINGTHAT ITIS
HEATING.
It isthe responsibility ofthe person or companyinstallingthisboiler to verify before the
installation that the boilercertificationsshown on thispage,meet or exceed all local,state and
regulatory requirements for installation anduseof thisboiler.Failure todoso voids all claims
and warranties.
Oct 2006Aussidisponible
en Francais.

KEEP THIS MANUAL FOR FUTURE REFERENCE. Follow all instructions carefully for
installation, maintenance & operation of the DO 110 & DO 180 boilers.
«• CAUTION •»
DO NOT TAMPERWITH THE UNIT OR CONTROLS - CALL A QUALIFIEDSERVICE
TECHNICIAN.
DO NOT LEAVECOMBUSTIBLEMATERIALAROUND THE UNIT.
DO NOT stackitems onor around the unit - checkrequiredclearances on page 2.
DONOT start a fireinthe boileruntil all installationrequirements are complete andthe
operating instructions are understood.
DO NOT use automaticstoking or sawdust fueling withthisunit.
DO NOT BURNGARBAGE,PAPER(except to start fire), FLAMMABLELIQUIDS,DRIFTWOOD,
TREATEDWOOD(CREOSOTE,PRESERVATIVES,PAINT,STAIN,ETC.) IN YOURBOILER.DAMAGE
WILL RESULT AND VOIDYOURWARRANTY.
DO NOT allow anyonethat is unfamiliarwith the boiler, to attend it.
DONOT loadwoodabove the smoke flap inside the door,over-firing may result.
DO NOT adjust the draft regulatorabove - .05 " W.C., if thissetting is exceeded it couldcause thefireto burn
out of control.
DO know the location ofthe emergencydisconnectswitch forthe unit.
DO contact a qualified service technician before remodeling, for annual service/maintenance, before
extendedperiods of shutdown and beforestart-up.
-PRE INSTALLATION CONSIDERATIONS-
FUEL
Burn onlyclean, untreatedhardwood, and softwood.
Forthe bestperformance, we recommendusingseasoned(below 25% moisture)hardwood.Store the wood in
neat, wellsupportedpiles, at least 4' from the boilerloadingdoor.
BOILER
In thefirebox install ashor sand to within 1
1A"
ofthe bottom door frame or burnsoftwood atfirst, which creates
ash quickly.Thiswillimprove theairflow through the wood. The boilermust be installed bya qualified
technician currentlyactive inthe heatingtrade. The installationshouldmeet or exceed all local and national codes
having jurisdiction,including C.S.A. B365, the InstallationCode for SolidFuelBurningAppliances &
Equipment. The boiler has beenthoroughlytestedwithmodernbaseboardradiation.
UNDERFLOOR & CAST IRON RADIATORS
Specialconsiderationmust be taken whenconnecting the boiler to underfloor systemswithoutoxygenbarrier pipe
or whenhooked to castironradiators, to preventthermalshock or excesstemperaturewater from entering
underfloor heatingloops.Pleaseconsultwithyoursystemdesigner.
CHIMNEYSYSTEM
The specification ofthe chimney tobe usedcomplieswith the requirementthat,otherthan solid-fuel/oil
combinations and add-ons,woodburningappliancesshall notbe connected toa venting system serving
an appliancevented by anothertype of fuel. Connect the furnace toan approvedsolid fuel factory-built
chimney (CANADA-CAN/ULC S629standard for 650°chimney,UNITED STATES-UL103 '
Chimneys for ResidentialType and BuildingHeatingAppliances,Factory Built) ora safe, clean, sound
condition, masonrychimneyequipped with an approved liner (CANADA-CAN/ULC-S635-M90
Standard for LiningSystems for existingmasonry or Factory Built Chimneys and Vents, UNITED
STATES-UL1777 Chimney Liners)(e.g., stainlesssteel,clay,etc.) The chimneymust be capable of
maintaining a negative updraft atall times andinall conditions. Carefully inspect the chimney for safety
before making a connection.Locate the boiler as close tothe chimney as possible. DONOT pass the
smoke pipethrough the ceiling,wall or floor to reach the chimney. Installation of this equipment shall be
in accordancewithregulations of authorities having jurisdiction and(in Canada) CSA Standard B139
"Installation Code forOil BurningEquipment" andCSA B365 Installation Code for Solid Fuel Burning
Appliances and Equipment,(in UnitedStates) UL 391 SolidFuel and Combination Fuel Central and
Supplementary Furnaces.
-1-
1

'
ELECTRICAL
Ensure the boilerdisconnectswitch is installedwithineasyreach.
Ensurewiringcables are protected from hot surfaces.
DONOT installwiringcables or controlswhere itis possible for water to drip on them.
The electrical installation must conform toall local and national codes standards as their jurisdiction may
apply.Whenconnecting toanoilfired boiler, the wiringshouldconform toour drawing on page 6.
PLUMBING
A 10 gallon or largerexpansiontank is required for thissystem.
The circulatorpumpshallhave a minimumcapacity of7.5 imperial GPM flow rate.
A safetypower failure loop or dumpzone and pipingshallconform tothe encloseddrawing on page 4
and also to local and nationalcodeshavingauthority.
EQUIPMENT (all controls maynotbe supplied for your system)
The following isthe minimumpartsthat are providedwith the boiler:
1 - TripleAquastat 1- SingleAquastat 1- InterlockRelay
2-24 VoltTransformers 1- J Box& Cover
1 - Damper Motor & Chain 2 - Wells(for aquastats)
1-30 PSI PressureReliefValve 1- ZoneValve(normallyopen)
1 -14" N.P. DrainValve 1- Tridicator(pressure & temperaturegauge)
INSTALLATIONINSTRUCTIONS
CLEARANCES
Observe the minimum clearances to combustible materials.
Front — 48" Smoke pipe -18"
Rear — 24" Side 1 24"
Above — 48 " Side 2 6 "
The boiler maybe placed ona combustible floorby using 9/32" noncombustible cover, extending 18"infront,
18" atthe rear & 6"on each side.
ELECTRICAL
WoodBoilerTripleAquastatSettings: Oil BoilerAquastatSettings:
HighSetting > 200°FHighSetting > 170° to 180° F.
Low Setting > 180°F Low Setting > 150° to 160° F.
WoodBoilerSingleAquastatSetting > 170° F.
When the woodboiler isnotin use, anda coil intheoil boilersupplies the domestic hot water,change
theoil boiler aquastat to High 200° andLow 180° (this isto ensure an adequate supply of domestic hot
water).
The electricalconnections to the oil fired boilershouldconform to our drawing on page 6 .
COMBUSTION AIR
To achievesatisfactorycombustion, an adequatesupply of fresh airis required. In confinedareas, a
grilled openingshall be provided. The minimumtotalarea of openings is1 square foot per gallon ofoil
burnt per hour.Withcombinationunitsthisareashould be doubled.Wherefans are used inthe fuel
storagearea,theyshould be installed soasnotto createnegativepressures inthe roomwhere the
boiler(s) are installed.
-2-

INSTALLATION INSTRUCTIONS
Adjustments of damper motor and
chain: Damperchainshould be
adjusted when the damperdoor isinthe
downposition. In thisposition the
chain should be adjusted so there isa
small amount of slack.
The amount of lift or opening ofthe
damperdoor is adjusted by moving the
two pinchnuts onthe stoveboltthread
closer or furtherawayfrom the lift
strap.
After properadjustment ofthe draft
chain and damper door the thermostat
and limitcontrolswillkeep the fire
within safe limits.
CAUTION: Thissettingshould not
be altered for increased firing for
any reason.
DAMPER MOTOR
NUTS
MAGNIFIED VIEW
BOILER
FRONT
FIREDOOR
CHIMNEYSYSTEM
The chimneyinnersizeshould bethe equivalent to7" round min. or8" roundmax.
The woodboilerpipe andtheoil boilerpipeshouldenter the chimneyseparately.
If morethan one opening isinthe chimney,install oilontopand wood onthe bottom.
A minimum of4"of masonry(vertically)shall be left betweeneachopening. The smokepipeshould be
blue or blacksteel, 24ga.or heavier. Useasfew turns as possiblebetween the boiler andthe chimney,
each 90° elbowadds 10' of restriction anda 45° elbowadds 5' of restriction. The draftregulator setat
-.05" W.C.maximum.Install the regulator a minimum of18"anda maximum of24" from the boiler
breech.Maintain a minimum of 1/2" rise per foot of pipe fromthe boiler tothe chimney.
DONOTrunthe pipedownhill from the boiler tothe chimney.Confirmthat the installationclearances
aremetor exceeded. All pipejointsshould fit relatively gas tight, asonlow fires,carbonmonoxide is
formed. Secure all smokepipejointswiththreesheetmetalscrews.
NORMALOPERATION
Theoil burnerwillstart ifthe systemtemperature is below the settings ontheoil boileraquastat.
The dampermotorwillopen the damperwhen the temperature ofthe woodboiler falls below 170°F.
The thermostatsoperate the n.c.zonevalves.
When any n.c.zonevalve is open or when the thermostatcalls for heat, the circulatorstarts.
Should the temperaturereach the high limit(200°F), the dampermotorwillclose the damper andthe
circulator starts (if the normally openzone valve ends-witch wires are connected). Theoil burnerwill not
run ifthe highlimit is reached.
-3-

PLUMBING
The pipingshallconform tothe encloseddrawingbelow and also to local and nationalcodeshaving
authority.
The dumpzoneshould be yourexistinglargestzone (that hasall piping above the boiler.-eg. Livingroom
*• master bedroom). With a homebuilt on slab or heatingwith an underfloor radiantsystem, a separate
-one should be addedabove the boiler.Thiszonewould beof adequatesize to dissipate at least10,000
btu/hr.on the DO110 & 15,000 btu/hr onthe DO 180. The pipingmust bea minimum of 3/4" (18mm)
diameter & able to withstand a minimumtemperature of 225°F (107°C). Thisloopshall be suchthat it
can only be madeinoperative bya deliberatemanualaction.
Pleaseensurethat the pressurereliefvalve andthe boilerdrainvalve are piped toa safedrain (water
discharging from either could be extremely hot and dangerous).
All pipingwill be such that excessive pressurewill notbe developed inany portion ofthe boiler
or system.
DO110 & DO180WOOD-FIREDBOILERS
PARALLELPIPING
1. NORMALLYCLOSEDZONE VALVE
2. NORMALLYOPENZONE VALVE
3. GATEVALVE
4. GRAVITYFLOW-CHECK
5. PRESSURE RELIEF VALVE
PIPE TOA SAFEDRAIN)
6. SINGLEAQUASTAT
7. TRIPLEAQUASTAT
8. GAUGE(TRIDICATOR)
9.THROTTLE (GLOBE) VALVE
10. PRESSUREREDUCING VALVE
11. BACKFLOWPREVENTER
12. STOP VALVE
13.AIR CUSHIONTANK
PL PRIMARYCIRCULATORPUMP
(EXISTING)
P2. MIXINGCIRCULATORPUMP
THIS METHOD ISTHE PREFERRED SYSTEM
DESIGN, THIS WILL PROVIDE MORE EVEN
HEATING OF BOTH WOOD AND OIL BOILERS,
-4-

CARE OFTHE BOILER WHEN NOTINUSE
When the boiler is going tobeoutof service foran extended period of time,carefully and thoroughlyclean
the smokepipe,chimney,firebox andany partwhich has been in contactwith hot gases.This is extremely
important as rusting and corrosionoccurwhen the boiler is idle.
REPLACING THEHOT WATER COIL
.The rearcasingpanel of yourboilermust be removed to gainaccess tothehot watercoilmounting plate.'tf
is necessary to remove the smokepipebeforeremoving the rearpanel.(ENSURETHAT NO FIRE IS
PRESENT AND POWERDISCONNECTS AREOFF BEFOREREMOVINGSMOKEPIPE). The water
must be drained from the boilerbeforeremovingcoilmountingplate,ensure the watersupply tothe coil is
off before removing.
CLEANING AND SERVICING
It is necessary to remove ashand occasionallybrush the innersurfaceswith a wirebrush and check the
smoke pipe forashor creosote as necessary.Leave 2"ofashinthe wood firebox whencleaning, toaidin
combustion.
•
IMPORTANT: Fire canbe caused by improperstorage of ashescontainingdormant hot coals.Store
ashes ina tightlycoveredmetalcontainer. DONOT placeotherwaste in thiscontainer.
VERY IMPORTANT: Replace all damaged or worngasketsbeforereassembling.Firedoorgaskets
and sealsmust be maintained in goodcondition for safe operation.
SPECIAL PROCEDURES
ELECTRICAL POWER FAILURE
PLEASE NOTE: Consult -with your installer atthe time of installation, to verify howto
operate your system without electricity.
^
1. Maintain Va the normal fire load.
2.The damperdoormust be manuallyoperated. DO NOT prop ortie open.
3. Be careful when firing the boiler at thispoint. Ina no powersituation,extremecaremust be useduntil
a safefiring rate is known for yoursystem.Remember youarenowon thermalcirculationonly. Itmay
be necessary to manuallyopenzonevalves (if used).Eachsystem is different. NOTE: Ifyou have an
underfloor radiantsystem, you likelycannot usethe woodboilerwithoutelectricity.
EXTREME WOODFIRE (Due to improperoperation)
1. Disconnect the damperchain to prevent the damperdoor from opening.
2. Block the over-fire draft slot inthe door.
3. Increase all thermostats to maximum.
4. Excessiveheat may causesafetyreliefvalve to open.(Ensure itis piped toa safe drain.)
5. DO NOT shut power off.
FLUE FIRE
1. Call the FireDepartment.
2. Shut offthe mainpowerswitch tothe boiler.
3. Diminish thefireinthe boiler by closing all combustion air openings.
4.DONOT remove theflue pipesuntil thefireis completelyout.
5. Prepare to evacuate the house.
6. Have the chimneyinspected and repair theflueif necessary before using it again.
w
-5-

LINE IN
V/1/60 Hz
White (Neutral)
Black (Power)
WOOD
TripleAquastat
SingleAquastatDamperMotor
Black
Low LimitHighLimit
set@18tfF set@200°P
24 Volt
Transformer
24 Volt
Transformer
Interlock Relay
Normally Open
ZoneValve
MAXIMUM LOAD 30VA (LOAD 24V)
OIL Aquastat
Burner Control
NOTE: Ifyouare using the
domestic coils from the boiler,
adjust theoil aquastat to
LOW-18Cf F and HIGH-200°F
for the summer months. I Primary
Circulator
Blocked Flue
Sensor
Blac
Low Limit set@ 15ffF\ B1
HighLimit set@ 17CFF
Blocked Flue
^Sensor
W.R. BenjaminProductsLimited
Wiring schematic for
DO110/180 Addon boiler
MAY 2006
N C Z.V. - Normally Closed Zone Valve
N O Z.V. - Normally Open Zone Valve
E.S. End Switch
MO Motor
- 120 Volts 60 HZ
- 24 Volts
AERO OR
BECKETT
BURNER