Crown Boiler Freeport ODV-100 User manual

Oil-Fired Direct Vent Hot Water Boilers
Freeport ODV Series
WARNING: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information
consult a qualied installer or service agency. This boiler
requires a special venting system. Read these instructions
carefully before installing.
These instructions must be afxed on or adjacent to the boiler.
Models
ODV-75•
ODV-100•
ODV-125•
DESIGNED TO LEAD
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
Tel: [phone] • Fax: [phone] • www.crownboiler.com

TABLE OF CONTENTS
Product Description 1
  Specications      2
  BeforeInstalling      3
  LocatingTheBoiler     3
  VentSystemInstallation    4
  SystemPiping      13
  FuelPiping      17
  Wiring       18
  Start-UpAndCheckout    19
  ServiceNotes      20
  Maintenance      22
Parts24

1
I Product Description
The ODV series boiler is a cast iron oil red boiler designed for use in forced hot water heating
systems. The ODV boiler must be vented using the factory supplied venting system with combus-
tion air taken from outdoors. The ODV uses the same three pass “scotch marine” heat exchanger as
the CT series boiler. The ODV series boiler is ideal for use in installations where a chimney is not
available.
The ODV boiler is not designed for use in gravity or “open” heating systems.
WARNING
FAILURE TO VENT THIS BOILER IN ACCORDANCE WITH THESE INSTRUCTIONS
COULD CAUSE FLUE GAS TO ENTER THE BUILDING RESULTING IN SEVERE
PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH:
Do not attempt to vent this boiler with galvanized, PVC, or any other vent components •
not described in this manual
Do not obtain combustion air from within the building. •
Do not install a barometric damper or vacuum relief valve in the vent system of this •
boiler.
CAUTION
Moisture and ice may form on the surfaces around the vent termination. To prevent
deterioration, surfaces should be in good repair (sealed, painted, etc.).
DANGER
THE VENT SYSTEM SUPPLIED WITH THE ODV IS NOT DESIGNED FOR VENTING
OF FLUE PRODUCTS FROM NATURAL GAS OR PROPANE. DO NOT ATTEMPT TO
CONVERT THE ODV TO EITHER GAS.
CAUTION
As with any oil appliance, certain adverse conditions can cause this boiler to operate at high
smoke levels. Since the ODV is vented through a wall, this can result in severe soot damage
to the side of the structure around the terminal. To minimize the risk of this:
• Follow these installation instructions exactly
• Oil burner must be set up by a qualied serviceman using combustion test instruments
• Use only the vent components supplied in the ODV vent kit
• Combustion air must be supplied from outdoors
• Follow the maintenance procedure in this manual
• Use only #2 fuel oil meeting ASTM D-396

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IISpecications
Ratings based on #2 fuel oil having a higher heating value of 140,000 BTU/Gal
Net ratings based on a piping and pickup loss allowance of 1.15
Exhaust pipe: 4” I.D. insulated exible vent pipe.
Maximum exhaust pipe length – 15 ft.
Inlet pipe: 4” I.D. Corrugated Aluminum
Maximum Inlet pipe length – 20 ft
Maximum Wall Thickness in which Terminal is Installed – 12”
D.O.E.
HEATING IBR NET FIG. 1
NO. INPUT CAPY. RATING DIMENSION
MODEL SECTIONS Gal/hr) (BTU/hr) (BTU/hr) AFUE (%) "A" (IN.)
ODV-75 3 0.75 91,000 79,000 85.0 32-1/4 24 14
ODV-100 3 1.00 119,000 103,000 83.1 32-1/4 24 14
ODV-125 4 1.25 150,000 130,000 83.5 37-1/4 24 14
FIG. 1 DIMENSION "B" (IN.)
STANDARD
CONNECTION
USING
OPTIONAL
TEE
TABLE 1: SPECIFICATIONS

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IIIBeforeInstalling
1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in
strict accordance with this manual and the authority having jurisdiction.
• In the absence of an authority having jurisdiction, installation must be in accordance with this manual
and Installation of Oil-Burning Equipment (ANSI/NFPA 31).
• Where required by the authority having jurisdiction, this installation must conform to the
Standard for Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1)
2) Read Section VI to verify that the maximum combustion air and exhaust pipe lengths will not be
exceeded in the planned installation. Also verify that the vent terminal can be located in accordance with
Section VI. Note: The maximum wall thickness through which the terminal can be installed is 12”.
3) Make sure that the boiler is correctly sized:
• For heating systems employing convection radiation (baseboard or radiators) use an industry
accepted sizing method such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22)
published by the Hydronics Institute in Berkely Heights NJ.
• For new radiant heating systems refer to the radiant tubing manufacturer’s boiler sizing guidelines.
• For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the DOE
Heating Capacity required for the Mega-Stor or the net rating required for the heating system,
whichever results in the larger boiler.
• For systems that incorporate other indirect water heaters, refer to the indirect water heater manufac-
turer’s instructions for boiler output requirements.
4) Do not install this boiler at altitudes above 2000ft.
5) Inspect shipment. This boiler is shipped in three pieces:
a) Wire-bound crate with boiler
b) Vent terminal carton – Includes terminal, vent adapters, inlet piping and hardware
c) Vent pipe carton - Includes exible vent pipe.
IVLocatingtheBoiler
1) Observe the clearances below. Top, side and rear clearances are from jacket. Front clearance is from
burner door.
To Combustible Construction To Non-Combustible Construction
Front 24 15
Left* 6 2-1/2
Right 6 1
Rear Determined by clearance to Flexible Vent Pipe (below)
Top 24 24
Terminal 0 0
Flexible Vent Pipe 3 0
* 14 inch clearance required to open door.
2) Boiler must be installed on a non-combustible surface.
3) Boiler must be located so that the 15-foot vent pipe supplied with the boiler will reach the
planned
terminal location. Approximately 1.3 feet of pipe length is used up in making a 90-degree bend
(Fig 11). See Section V for more information on venting requirements.

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VVentSystemInstallation
The ODV boiler is shipped with a complete venting system consisting of the following components:
• FDVS-4 direct vent terminal
• Backing plate
• 15-ft length of insulated 4” FOVP exible oil vent pipe
• 4” x 7” appliance adapter
• (2) Cover rings
• (2) Cover sleeves
• Bagged hardware
• (4) Inner pipe clamps
• 20 ft length 4” exible aluminum air intake pipe
• (2) Hose clamps
• “Red” high temperature RTV silicone sealant
1) LOCATING THE TERMINAL – Observe the following requirements in locating the terminal:
a) Maximum wall thickness through which terminal can be installed is 12”.
b) Wall can be combustible or noncombustible.
c) Bottom of terminal must be at least 12 inches above the normal snowline. If normal snowfall is
negligible, terminal must be at least 12 inches above grade (Fig 2).
d) Bottom of Terminal must be at least 7 feet above a public walkway (Fig 2).
e) Locate edge of terminal at least 4 ft horizontally from doors, windows, or gravity air inlets. Do
not put terminal under windows which can be opened (Fig 2).
f) Terminal must be close enough to boiler to be connected to it using the vent components
supplied.
CAUTION
• Do not use vent system components other than those supplied with the boiler
• Use only the red RTV sealant provided with this boiler anywhere that this manual
calls for the use of “sealant”
• Combustion air must be brought from outside as shown in this manual
• Do not install a “vacuum relief” damper
• Do not attempt to splice vent piping
• Do not put holes in venting
WARNING
• Read the installation instructions carefully and completely before proceeding
with the installation of vent system.
• For continued safe operation, the appliance vent system must be inspected and
maintained annually by a qualied agency.
Failure to properly maintain the appliance vent system combination can lead to
Death, Personal Injury and or Property Damage.
• Plan the vent system layout before installation to avoid the possibility of
accidental contact with concealed wiring or plumbing inside walls.

5

6
g) Do not locate terminal under decks.
h) It is preferable to install the terminal on the wall that is away from the prevailing wind.
i) Do not put terminal under a soft or other overhang deeper than 18 inches. Top edge of terminal
must be at least 2 ft below soft or overhang (Fig 3).
j) Position terminal to avoid accidental contact with people or pets.
k) Over time, the area around the terminal may become stained. Locate the terminal on a wall
where this is not objectionable.
l) No part of an inside corner should extend into the shaded area shown in Figure 4.
m) Terminal must be positioned so that no other buildings are within the shaded area shown in
Figure 4. Other permanent objects in this area may become stained or otherwise effected by ue
gas.
n) The terminal is a potential source of odors. Although the above restrictions will generally prevent
inltration of these odors into the building, care should be taken in positioning the terminal near
outdoor areas where people congregate, such as patios. This is particularly true when the boiler is
used with an indirect water heater that will cause the boiler to run during warm months.
2) INSTALLING THE FDVS-4 VENT TERMINAL
a) Remove vent system components from box and inspect for damage. If the carton has been
crushed or mutilated, check components very carefully for damage. DO NOT install if any
damage is apparent.
b) Remove the combustion air tee assembly from the vent terminal. Set the tee aside for later
use.
c) After determining the location of the vent terminal (Figures 2,3 & 4), cut a 7-1/4” square hole in
the wall. (Figure 5a) Note: Maximum wall thickness: 12”
d) Seal the back side of the base plate around the outer pipe of the vent terminal with a bead
of standard silicone sealant (not supplied). (Figure 5b) Mount the vent terminal through
the wall, keeping the outer pipe centered in the hole. (Figure 5a) Fasten the vent terminal to
the outside wall with appropriate fasteners. Seal the edges of the vent terminal base
plate to the wall with standard silicone sealant.
e) Mount the backing plate over the outer pipe. Fasten the backing plate to the inside wall with
appropriate fasteners. (Figure 5b)
DO NOT BLOCK the intake or exhaust openings, or the intake access panel on the vent terminal body.
Wood or vinyl siding should be cut so that the unit mounts directly on the wallboard to provide a stable
support. If the siding is greater than 1/2” thick use a spacer plate or board behind the vent terminal
mounting plate. (Figure 5b)
f) If the inside terminal section is not supported by the wall through which it passes, install
additional supports or bracing to rigidize the terminal. Bracing in contact with the co-axial
section of the terminal may be combustible.
CAUTION
Failure to apply this bead of silicone properly can cause ue gas to recirculate into
the air inlet resulting in sooting of the boiler, vent system, and side of the strucure.

7

8
3) INSTALLATION OF THE VENT TERMINAL COMBUSTION AIR TEE (Figure 5c)
a) Assemble the combustion air tee assembly body to the vent terminal outer pipe, and rotate to the
desired position. Attach the tee assembly body to the vent terminal outer pipe with at least 3 sheet
metal screws evenly spaced apart (not included).
b) Perform step 3c only after installing the exible oil vent pipe to the inner pipe on the terminal as
outlined in step 6. (Figure 6)
c) Apply standard silicone sealant (not supplied) to the cover pan around the inner pipe, around the joint
between the collar and the tee assembly, and seal or tape the joint from the FDVS terminal to the tee
assembly.

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NOTE: The tee may be rotated into any position so that the collar is in a convenient orientation.
4) APPLIANCE ADAPTER INSTALLATION
a) Apply a bead of red silicone sealant (supplied) to the boiler vent collar approx. 1” from end of
collar. (Figure 7a)
b) Remove all oil and grease from the inside of the appliance adapter, and apply a bead of red
silicone sealant to inside of adapter ½” from end (Figure 7a).
c) With a twisting motion, assemble the appliance adapter onto the vent collar.
d) Using a block of wood on the end of the adapter, push the adapter onto the vent collar, using care
to avoid damaging the vent collar or the adapter (Figure 7b).
e) Keep the sampling port in the 12 o’clock position and align the prepunched slots in the appliance
adapter to the threaded holes on the vent collar.
f) Secure the appliance adapter to the boiler vent collar with (3) 1/4-20 x 1/2” stainless steel cap
screws inserted into the three tapped holes in the appliance collar and tighten. (Figure 6b).
g) Apply red silicone sealant to the end of the adapter and anchoring screws. (Figure 7b).
h) After testing and burner adjustments have been made, apply red silicone sealant to the supplied
3/8” sampling port plug screw and install the screw in the sampling port (Figure 7b).
i) Maintain clearances to combustibles. If the appliance adapter is within 18” of combustible
material, wrap minimum 1-1/2” ceramic insulation (installer-supplied) around the exposed
portion of the appliance adapter.
5) OPTIONAL REDUCING TEE ADAPTER INSTALLATION
a) An optional reducing tee adapter is available for use in place of the standard appliance
adapter (Figure 8a). This reduces the clearance needed from the back of the boiler.
b) Apply a bead of red silicone sealant (supplied) to appliance collar approx. 1” from end of the
boiler vent collar. (Figure 8a)
c) Remove all oil and grease from the inside of the reducing tee adapter, and apply a bead of red
silicone sealant to inside of adapter ½” from end (Figure 8b).

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d) With a twisting motion, assemble the reducing tee adapter onto the boiler vent collar.
e) Push the adapter onto the vent collar, using care to avoid damaging the appliance collar or the
adapter (Figure 8b).
f) Keep the sampling port in the 12 o’clock position and align the prepunched slots in the
reducing tee adapter to the threaded holes on the vent collar.
g) Secure the reducing tee adapter to the vent collar with (3) 1/4-20 x 1/2” stainless steel cap screws
inserted into the three tapped holes in the vent collar and tighten. (Figure 8b).
h) Apply red silicone sealant to the end of the adapter and anchoring screws. (Figure 8b).
i) After testing and burner adjustments have been made, apply red silicone sealant to the
supplied 3/8” sampling port plug screw and install the screw in the sampling port (Figure 8b).
j) Maintain clearances to combustibles. If the reducing tee adapter is within 18” of combustible
material, wrap minimum 1-1/2” ceramic insulation (installer-supplied) around the exposed
portion of the reducing tee adapter.

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CAUTION
• Do not enclose vent pipe in walls or ceilings
• If necessary, the vent pipe may be cut to length with a hacksaw or cut off saw.
Use safety glasses and other appropriate safety gear when cutting.
• Make sure that the vent pipe route is nalized and pipe is accurately
marked before cutting. Pipe cannot be spliced if accidently cut too short.
6) VENT PIPE INSTALLATION
a) Pull outer vent pipe back 1”-2” from inner vent pipe end and remove insulation (Figure 9a).
b) Slide Cover Sleeve onto end of vent pipe a few inches back from end of outer vent pipe
(Figure 9a).
c) Slide Cover Ring over stop bead on termination inner pipe or appliance adapter (Figure 9a).
d) Assemble inner pipe clamp halves using the supplied ¼” bolts and square nuts, and position
inner pipe clamp ¼” from end of inner pipe (Figure 9a).
e) Remove all oil and grease from end of termination inner pipe or appliance adapter, and apply a
bead of red silicone sealant to between the stop bead and retainer bead (Figure 9b).
f) Apply a thick bead of red silicone sealant to inside of inner vent pipe ½” from the end of pipe,
working the sealant into the corrugations (Figure 9b).

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g) Push the inner vent pipe onto the termination inner pipe or appliance adapter all the way up to
the stop bead.
h) Tighten the inner pipe clamp bolts until both clamp halves are within 1/8” of each other at each
end (Figure 9c).
i) Slide the cover sleeve and cover ring together to engage the ring in the groove of the sleeve, and
tighten the cover sleeve clamp (Figure 9d).
j) To maintain 3” clearance to combustibles, wrap minimum 1-1/2” thick ceramic insulation
(installer-supplied) around the exposed portion of the termination inner pipe (Figure 9d), and
secure with foil tape (installer supplied).
k) Allow sealant to cure for at least one hour before ring boiler.
l) Use the same procedure to install vent pipe on Reducing Tee (Figure 9e).
8) AIR INTAKE PIPE INSTALLATION
a) Attach exible air intake pipe to the terminal and the collar on the burner and secure it with the
hose clamps provided.

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VISystemPiping
StandardPiping
Figure 17 shows typical boiler system connections on a single zone system. Additional information
on hydronic system design may be found in Installation of Residential Hydronic Systems (Pub. #200)
published by the Hydronics Institute in Berkely Heights NJ. The components in this system and their
purposes are as follows:
1) Relief valve (Required) – The relief valve is factory mounted and must not be moved. The relief
valve shipped with the boiler is set to open at 30 psi. This valve may be replaced with one
having a setting of up to the MAWP shown on the boiler rating plate. If the valve is replaced, the
replacement must have a relief capacity in excess of the DOE heating capacity for the boiler.
Pipe the discharge of the relief valve to a location where water or steam will not create a hazard or cause
property damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe.
If the relief valve discharge is not piped to a drain it must terminate at least 6 inches above the oor. Do
not run relief valve discharge piping through an area that is prone to freezing. The termination of the
relief valve discharge piping must be in an area where it is not likely to become plugged by debris.
2) Circulator (Required) – Although the circulator is shipped on the boiler return, it can be installed on
the boiler supply. If the circulator is moved to the supply it should be positioned just downstream of
the expansion tank as shown in Figure 17.
3) Expansion Tank (Required) – If this boiler is replacing an existing boiler with no other changes in
the system, the old expansion tank can generally be reused. If the expansion tank must be replaced,
consult the expansion tank manufacturer’s literature for proper sizing.
CAUTION
• Operation of this boiler with continuous return temperatures below 120f can
cause severe heat exchanger corrosion damage
• Operation of this boiler in an system having signicant amounts of dissolved
oxygen can cause severe heat exchanger corrosion damage
• Do not use toxic additives, such as automotive antifreeze, in a hydronic system
DANGER
• PIPE RELIEF VALVE DISCHARGE TO A SAFE LOCATION
• DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE
• RELIEF VALVE MUST BE INSTALLED IN BOILER AT LOCATION
SHOWN IN FIGURE 17.
• DO NOT PLUG RELIEF VALVE DISCHARGE

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4) Fill Valve (Required) – Either a manual or automatic ll valve may be used. The ideal location
for the ll is at the expansion tank.
5) Automatic Air Vent (Required) – At least one automatic air vent is required. Manual vents will
usually be required in other parts of the system to remove air during initial ll.
6) Low Water Cut-Off (Required in some situations) – A low water cut-off is required when the
boiler is installed above radiation. In addition, some codes such as ASME CSD-1 require
low water cut-offs. Codes may also require that this low water cut-off have a manual reset
function. The low water cut-off may be a oat type or probe type but must be designed for use
in a hot-water system. The low water cut-off should be piped into the boiler supply just above the
boiler with no intervening valve between it and the boiler.
Use a low water cut-off that breaks the line voltage electrical supply to the boiler.
7) Manual Reset High Limit (Required by some codes) – This control is required by ASME CSD-1
and some other codes. Install the high limit in the boiler supply piping just beyond the boiler
with no intervening valves. Set manual reset high limit as far above the operating limit setting
as possible, but not over 240F. Wire the control to break the line voltage electrical supply to the
boiler.
8) Flow control valve (Required under some conditions) – The ow control valve prevents ow
through the system unless the circulator is operating. A ow control valve may be necessary
on converted gravity systems to prevent gravity circulation. Flow control valves are also used to
prevent “ghost ows” in circulator zone systems through zones that are not calling for heat.
9) Isolation Valves (Optional) – Isolation valves are useful if the boiler must be drained, as they will
eliminate having to drain and rell the entire system.

15
PipingforSpecialSituations
Certain types of heating systems have additional requirements. Some of the more common variations
follow:
1) Indirect Water Heaters – Figure 18 shows typical indirect water heater piping. Boiler piping is
the same as for any two-zone system. Figure 18 shows circulator zoning, which is usually
preferred for indirect water heaters. Size the circulator and indirect water heater piping to obtain
the boiler water ow through the indirect water heater called for by the indirect water heater
manufacturer.
2) Gravity and “Large Water Volume” Systems – The piping shown in Figure 19 will minimize the
amount of time that the boiler operates with return temperatures below 120F on these systems.
A bypass is installed as shown to divert some supply water directly into the return water. The
bypass pipe should be the same size as the supply. The two throttling valves shown are
adjusted so that the return temperature rises above 120F during the rst few minutes of opera-
tion. A three-way valve can be substituted for the two throttling valves shown. If the circulator is
mounted on the supply, the bypass must be on the discharge side of the circulator.
3) Low Temperature Systems – Some systems, such as radiant tubing systems, require the system
water temperature to be limited to a value below the temperature of the water leaving the ODV.
These systems also typically have return temperatures well below the 120F minimum.
Figure 20 illustrates the use of a heat exchanger to connect an ODV boiler to this type of system.
The heat exchanger will permit the transfer of heat from the boiler water to the low temperature
system while holding the system supply and boiler return temperatures within their limits.
For this system to work properly the heat exchanger must be properly sized and the correct ow
rates are required on either side of the heat exchanger. Consult the heat exchanger manufacturer
for sizing information. The water in the boiler is completely isolated from the water in the
system. This means that separate ll and expansion tanks are required for the heating system
loop.
There are several other ways to connect low temperature systems to the non-condensing boilers like
the ODV such as four way mixing valve and variable speed injection pumping systems.

16
4) Systems containing oxygen – Many hydronic systems contain enough dissolved oxygen to cause
severe corrosion damage to a cast iron boiler such as the ODV. Some examples include:
• Radiant systems that employ tubing without an oxygen barrier.
• Systems with routine additions of fresh water
• Systems which are open to the atmosphere
If the boiler is to be used in such a system, it must be separated from the oxygenated water being
heated with a heat exchanger as shown in Figure 20. Consult the heat exchanger manufacturer
for proper heat exchanger sizing as well as ow and temperature requirements. All components
on the oxygenated side of the heat exchanger, such as the pump and expansion tank, must be
designed for use in oxygenated water.

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VIIFuelPiping
Two basic piping systems are used to connect the boiler to the oil supply:
1) One-Pipe – Recommended where the fuel pump is below the lowest possible level of the oil in
the tank. Basic piping is shown in Figure 21a.
2) Two-Pipe – Recommended where the fuel pump is above the lowest possible level of the oil in
the tank. This system is self-priming. Basic piping is shown in Figure 21b.
Consult the instructions supplied with the pump for limitations on lift, horizontal run, and required line
sizes. Pumps supplied with the ODV boiler generally require the installation of a bypass plug when
converted for use in a two-pipe system. See the pump instructions for specic information. Also note the
following:
1) If the boiler is being installed as a replacement, the existing oil system may be two-pipe even
though the pump is below the lowest level in the oil tank. Such systems should be converted
to one-pipe systems as doing so will result in warmer oil temperatures, lower vacuums, and
longer lter life.
IMPORTANT
• Installation of oil storage tanks, ll pipes, and oil lines must conform to local code
requirements. In the absence of any codes, installation must be in conformance
with ANSI/NFPA-31.
• Use of this boiler with an unenclosed above ground outdoor oil tank is not
recommended.