Icp Owb series Guide

OWF

Oil-Fired Water Boilers

User's Information IVianual

Hazard definitions

CAUTION

[ .OT,CI

Hazards that will cause severe personal injury,

death or substantial property damage.

Hazards that can cause severe personal injury,

death or substantial property damage.

Hazards that will or can cause minor personal in-

jury or property damage.

Special instructions on installation, operation or

maintenance that are important but not related to

personal injury or property damage.

The User's Information Manual provides information to the boiler

owner/user for routine operation and maintenance and emergency

shutdown. Detailed information on boiler installation, operation,

start-up, service and parts is included in the Boiler Manual. The

Boiler Manual is intended only for use by a qualified installer/

service technician.

i INSTALLER -- Please take time to review this

User's Information Manual with the boiler owner.

Explain all maintenance and service procedures.

Failure to adhere to the guidelines on this page can result in severe

personal injury, death or substantial property damage,

At the beginning of each heating season, contact your qualified service technician to inspect, clean and start-up the

boiler per the Boiler Manual. Failure to comply could result in boiler failure, leading to potential severe personal injury,

death or substantial property damage.

Service and maintenance

1. To avoid electric shock, disconnect electrical supply before

performing maintenance.

2. To avoid severe burns, allow boiler to cool before performing

maintenance.

3. You must maintain the boiler as outlined in the manual and

have the boiler started up and serviced at least annually by a

qualified service technician to ensure boiler/system reliability.

Boiler operation

4. DO NOT block flow of combustion or ventilation air to boiler.

If vent or air blockage is easily accessible and removable,

remove it. If blockage is not obvious or cannot be removed,

have the boiler and system checked by a qualified service

technician.

5. Should overheating occur or oil supply fail to shut off, do not

turn off or disconnect electrical supply to pump. Instead, shut

off the oil supply at a location external to the appliance.

6. DO NOT use this boiler if any part has been under water.

immediately call a qualified service technician to inspect the

boiler and to replace any part of the control system and any

burner control that has been under water.

7. Have the building monitored when it is vacant for an extended

period. Safety controls can shut down the boiler at any time.

The loss of heat can result in significant damage due to

freezing.

Air contamination

8. Carefully read and follow instructions on page 2.

Boiler water

9. DO NOT use petroleum-based cleaning or sealing compounds

in boiler system. Water seal deterioration will occur, causing

leakage between sections and damage to heating system

components. This can result in substantial property damage.

10. DO NOT use "homemade cures" or "boiler patent medicines".

Serious damage to boiler, personnel and/or property may

result.

11. Continual fresh makeup water will reduce boiler life. Mineral

buildup in sections reduces heat transfer, overheats cast iron,

and causes section failure. Addition of oxygen and other gases

can cause internal corrosion. Leaks in boiler or piping must

be repaired at once to prevent makeup water.

12. DO NOT add cold water to hot boiler. Thermal shock can

cause sections to crack.

Glycol -- potential fire hazard --

13. All glycol is flammable when exposed to high temperatures.

If glycol is allowed to accumulate in or around the boiler or

any other potential ignition source, a fire can develop. In order

to prevent potential severe personal injury, death or substantial

property damage from fire and/or structural damage:

Never store glycol of any kind near the boiler or any potential

ignition source.

Inspect the boiler and system regularly for leaks. Have any

any leaks repaired immediately to prevent possible

accumulation of glycol.

Never use automotive antifreeze or ethylene glycol in the

system. Using these glycols can lead to hazardous leakage

of glycol in the boiler system.

Part Number 672 02 1005 00

O_l,z]E_ 8_: O_v_Tl[" Oil-Fired Water Boilers - User's Information Manual

Please read this page first

Air contamination

To prevent potential of severe personal injury or death, check for

products or areas listed in table below before installing boiler. If

any of these contaminants are found, do one of the following:

Remove contaminants permanently. -- or--

Isolate boiler and provide outside combustion air. See

applicable codes for further information. -- or--

Contact your qualified service technician to install an

outside air kit (if available) for the burner. An outside air

kit allows ducting of outside air directly to the burner.

Spray cans containing chloro/fluorocarbons

Chlorinated waxes/cleaners

ChloFine_based swimming pool chemicals

Calcium chloride used for thawing

Start-up

1. If burner does not fire, check for:

Boiler switch turned off?

Fuses blown or breaker tripped?

Thermostat set below room temperature?

Fuel valves turned off?

Not enough oil in tank to supply burner?

2. Correct problems found in step #1. if burner does not fire,

press the reset button on burner primary control only once.

Repeated presses will deposit oil in chamber, creating a fire

hazard.

Burner must never be fired when oil is in combustion

chamber, immediately call a qualified service

technician.

3. If burner still does not fire, call a qualified service technician.

/....

Sodium chloride used for water softening

......................................................................................................................................................................................................................!

Paint Or ..............................................

Hydrochloric acid/muriatic acid

Cement s and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches detergents and cleaning solvents found in - !

household laundry rooms

usedto similar products

Area s likely t o hav e contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants !4

Refrigeration repair shops

Photo processing plants

Auto body shops i

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building _onstruc

Remodeling areas

Figure 1 Boiler and components

Pressure/temperature "-5 _/Circulator (install on either

gauge \ _)# supply or return piping)

Relief valve _\ y_,,.

(piped to back .... _'_-,_-_ _i( _ _ _ Circulator

harness

: \ "]'_'_t_- YI _ Limit control

',_,_ (OWB models)

r_ harness Combination limit

--_ control and tankless

-_ ((_/Te _nCo°drt ,rs°_

|_ _ Reset button on

burner primary control

I_b _ Burner primary

} \ _ control

/ I _! "--- Burner disconnect

b\-- p,ug

_' " _ === 75017

[] Check daily

Boiler area

1. Check that boiler area is free from combustible materials,

gasoline and other flammable vapors and liquids. Ensure that

no air-contaminating materials (see above) are present in the

area.

Pressure/temperature gauge

1. Pressure gauge should not show more than 24 psig. Higher

pressure may indicate a system problem. Contact a qualified

service technician if high pressure occurs.

Air openings

1. Verify that combustion and ventilation air openings to the boiler

room and/or building are open and unobstructed.

2 Part Number 672 02 1005 00

O_V]I_ _ O_v_i71 _ Oil-Fired Water Boilers - User's Information Manual

[] Check monthly

Boiler and system piping

1. Visually inspect for leaks around piping, circulators, relief valve

and other fittings. Check oil lines and boiler air for signs of oil

leakage, immediately call a qualified service technician to

repair any leaks.

Have leaks fixed at once by a qualified service tech-

nician. Continual fresh makeup water will reduce

boiler life. Minerals can build up in sections, reduc-

ing heat transfer, overheating cast iron, and caus-

ing section failure.

Do not use petroleum-based cleaning or sealing

compounds in boiler system. Severe damage to

boiler and system components can occur, resulting

in possible severe personal injury, death or sub-

stantial property damage.

Venting system

1. Visually inspect all parts or the flue gas venting system for

any signs of blockage, leakage or joints or deterioration of

the piping. Notify your qualified service technician at once if

you find any problem.

Failure to inspect the vent system as noted above

and have it repaired by a qualified service techni-

cian can result in vent system failure, causing se-

vere personal injury or death.

Boiler relief valve

1. inspect the boiler relief valve and the

relief valve discharge pipe for signs of

weeping or leakage.

2. If the relief valve often weeps, the

expansion tank may not be working

properly.

immediately contact your qualified

service technician to inspect the

boiler and system.

Automatic air vents (if used)

1. Remove the cap from any automatic B----_..

air vent in the system and check

operation by depressing valve B

slightly with the tip of a screwdriver.

2. If the air vent valve appears to be

working freely and not leaking, replace

cap A, twisting all the way on. Loosen

cap A one turn to allow vent to operate.

3. Have vent replaced if it does not

operate correctly. '....

[] Periodically

Test low water cut-off (if installed)

1. If the boiler or system is fitted with a low water cut-off device,

test the device following the cut-off manufacturer's instructions.

[] Periodically

Oil motors equipped with oil cups

1. Burner or circulator motors may require oiling. Such motors

are fitted with oiling cups. Use a few drops only of S.A.E. 20

detergent oil. Do not use household oils. Excessive oiling can

damage motors. Do not attempt to "fill up" the oiling cup.

[] Every 6 months

Operate boiler relief valve every 6months

To avoid water damage or scalding due to valve

operation, a metal discharge line must be connected

to relief valve outlet and run to a safe place of dis-

posal. This discharge line must be installed by a

qualified heating installer or service technician in

accordance with the instructions in the Boiler

Manual. The discharge line must be terminated so

as to eliminate possibility of severe burns should

the valve discharge.

1. Before proceeding, verify that the relief valve outlet has been

piped to a safe place of discharge, avoiding any possibility of

scalding from hot water.

2. Read the boiler pressure/temperature gauge to make sure

the system is pressurized.

3. Lift the relief valve top lever slightly, allowing water to relieve

through the valve and discharge piping.

4. If water flows freely, release the lever and allow the valve to

seat. Watch the end of the relief valve discharge pipe to ensure

that the valve does not weep after the line has had time to

drain. If the valve weeps, lift the seat again to attempt to clean

the valve seat. If the valve continues to weep afterwards,

contact your qualified service technician to inspect the valve

and system.

5. If water does not flow from the valve when you lift the lever

completely, the valve or discharge line may be blocked.

Immediately turn off switch to the boiler and close fuel valves.

Call your qualified service technician to inspect the boiler and

system.

[] End of season shutdown

Do not drain boiler unless exposure to freezing temperatures

will occur.

Always keep manual fuel supply shut off if burner is shut down

for an extended period.

a. Turn off switch to boiler.

b. Close fuel valves.

c. Turn off water feed valve.

d. Cover burner to protect from dust and dampness.

[] Troubleshooting

1. See page 4.

Part Number 672 02 1005 00 3

O_l,Z]l_ _: O_v_F1 _ Oil-Fired Water Boilers - User's Information Manual

[] Troubleshooting

Troubleshooting -Common problems and possible solutions ................................... __;

iSymptom Common Causes Possi'_ble Corrections I

Rapid cycling - Thermostat installed where Locatethermostat on innerwall awayfrom heatsources or cool drafts.

boiler turns on and drafts or heataffect reading i i

off frequently .... ..............................................................................................................................

adjusted incorrectly i

Incorrect limit setting Set limit according to system needs. Maximum setting is 220T. Increaselimit

setting to decreasecycling.

Insufficient waterflow through i Checkall valvesto and from boiler. Returnto proper setting.

boiler _..............................................................................................................................................................................................................................................................................................................................

i Confirm circulator size.

Frequent release of / Expansiontank sizedtoo small Caliqualified service technician to check expansion tank operation and size.

water through relief

valve Fioodeci &_-nk .........................................Gall c]_heck _ion _]on. "...............................................

........................... ........ iiCaiiqua,,_::f,e# .serv ttcihn,c!a, tO...............re .............................i_-i" __

Need to frequently Leaksin boiler or piping Havequalified service technician repair leaksatonce to avoid constant useof

add makeup water makeup water. Makeup watercan cause mineral deposits which, in turn. can

cause boiler section failure. Do not use petroleum-basestop-leak compounds.

} Black water condition Oxy.gencorrosion dueto leaksin Havequalified servicetechnician repairat once. KeeppH of water between 7.0

'.boderand piping 8.5. _

Popping or Mineral deposits in sections due i Callqualified service technician to de-lime boiler if necessary.In somecases i

percolating noise to constant use of makeupwater deposits will be too heavyto remove with de-liming procedures.

heard in boiler i Havequalified servicetechnician repairleaksto eliminate needfor constant

makeupwater.

_t....................................................................................................................................................................................................................................................................

Incorrect pH of boiler water i Callqualified service technician to check pH level and correct, pH should be

i maintained between 7.0 to 8.5.

boiler I Confirm circulator size.

............................................................................. 1

Metal flakes found in Contaminatedcombustion air . s: Seepage2 _th!s manua!:................................................

vent outlet or vent supply Seepage2 Inthis

i fluewa c rosio " manual-- Provide outside air for combustion. Kit availablethrough localdistributor. Have

y or n

i'qualified service technician pipe-up kit.

Condensationof combustion Havequalified servicetechnician inspectsystem piping andcontrols to verify

I gases in boiler sections proper regulation of return watertemperature.

Air in system

Some radiators or Bleedair from system through air vents in radiators or baseboardunits.

baseboard units do ....[._owsystem piessure.................................................., I_iiltocoirecii_ressurel ..........................................................................................................................................................................................................................................

not heat or are noisy Checkfor leaksin boiler or piping. Havequalified servicetechnician repairat

once.

Highlimit settoo low Adjust high limit to higher setting.

Domestic water from Mineral deposits insulate internal Havequalified servicetechnician @lime or replacecoil.

tankless heater is hot waterways of heater

i then suddenly turns 3o er stop- eak compound has Havequa fed serv cetechnician remove and c eanco and drain anc flush bo ler i

CO Q• beenaddedto boiler waterand is to removestop-leak.

;.. or -.. .. insulating outside of coil

uomes[Ic water from ...............................................................................................................................................................................................................................................................................................................................................................................................

tankless heater is Incorrect mixing valvesettingfor Havequalified servicetechnician adjust mixing valvesetting.

i always lukewarm. !ankless heater..................................................................................................................................................................................................................................................................................................................................................................................................................................................