Olsen OBC Series Technical Document

INSTALLATION MANUAL AND OPERATING INSTRUCTIONSINSTALLATION MANUAL AND OPERATING INSTRUCTIONS INSTALLATION MANUAL AND OPERATING INSTRUCTIONSINSTALLATION MANUAL AND OPERATING INSTRUCTIONS
INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
OBC Series
OIL FIRED CAST IRON BOILER
Olsen Technology, Inc. P.O. Box 900 Wallaceburg, Ont. N8A5E5

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TABLE OF CONTENTSABLE OF CONTENTS
ABLE OF CONTENTSABLE OF CONTENTS
ABLE OF CONTENTS
SAFETY SYMBOLS & WARNINGS ..................................................................... PAGE 1
INSTALLATION PROCEDURE........................................................................... PAGE 2
VENTILATION AND COMBUSTION AIR ....................................................... PAGES 3-5
CONNECTING SUPPLY AND RETURN PIPING........................................... PAGES 6-8
VENTING SYSTEM INSPECTION & INSTALLATION......................................... PAGE 9
OIL TANK PIPING.............................................................................................. PAGE 10
ELECTRICAL WIRING............................................................................... PAGES 11-12
THERMOSTAT INSTALLATION ....................................................................... PAGE 12
NORMAL SEQUENCE OF OPERATION........................................................... PAGE 12
OPERATING INSTRUCTIONS ................................................................. PAGES 13-15
SERVICE CHECK LIST..................................................................................... PAGE 16
JACKET DESCRIPTIONS & PART NUMBERS ...............................................PAGES 17
HEAT EXCHANGER DESCRIPTIONS & PART NUMBERS.............................. PAGE 18
BASE DESCRIPTIONS & PART NUMBERS ..................................................... PAGE 19
BURNER PARTS, CONTROLS AND MISC. PARTS ......................................... PAGE 20
RATINGS, DATA AND DIMENSIONS........................................................BACK COVER
KEEP THIS MANUAL NEAR BOILER. RETAIN FOR FUTURE REFERENCE
SERIES OBC
CAST IRON
OIL FIRED BOILER
INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
PUBLISHED MARCH 1997
PRINTED IN USA
MADE IN USA
TESTEDFOR30LBS.
ASMEWORKING
PRESSURE
®

PAGE 1
WARNING: ALLINSTALLATIONSOFBOILERSANDVENTINGSHOULD
BE DONE ONLY BY A QUALIFIED EXPERT AND IN ACCORDANCE WITH THE
APPROPRIATEOLSENTECHNOLOGY,INC. MANUAL. INSTALLINGORVENTING
A BOILER OR ANY OTHER GAS APPLIANCE WITH IMPROPER METHODS OR
MATERIALS MAY RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO
ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON MONOXIDE
WHICH IS ODORLESS AND INVISIBLE.
SAFETY SYMBOLSSAFETY SYMBOLS
SAFETY SYMBOLSSAFETY SYMBOLS
SAFETY SYMBOLS
The following defined symbols are used throughout this manual to notify the
reader of potential hazards of varying risk levels.
DANGER
DANGER -Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,WILL result
in death or serious injury.
WARNING
WARNING - Indicates a potentially hazardous situation which, if not avoided, COULD
result in death or serious injury
CAUTION
CAUTION - Indicates a potential hazardous situation which, if not avoided, MAY result
in minor or moderate injury. It may also be used to alert against unsafe practices.
IMPORTANT!READ ALL INSTRUCTIONS BEFORE INSTALLING.READ ALL INSTRUCTIONS BEFORE INSTALLING.
READ ALL INSTRUCTIONS BEFORE INSTALLING.READ ALL INSTRUCTIONS BEFORE INSTALLING.
READ ALL INSTRUCTIONS BEFORE INSTALLING.
WARNING:
1. Keep boiler area clear and free from combustible materials, gasoline and other
flammable vapors and liquids.
2. DO NOT obstruct air openings to the boiler room.
3. Modification, substitution or elimination of factory equipped, supplied or specified
components may result in property damage, personal injury or the loss of life.
4. To the owner: Installation and service of this boiler must be performed by a qualified
installer.
5. To the installer: Leave all instructions with the boiler for future reference.
6. For use with No. 2 fuel oil only.

INSTALLATION PROCEDURE
WARNING: Improper installation, adjustment, alteration, service or
maintenance can cause property damage, personal injury or loss of life.
All installations must conform to the requirements of the authority having jurisdiction.
Such applicable requirements take precedence over the general instructions of this
manual.
Where required by the authority having jurisdiction, the installation must conform to the
American Society of Mechanical Engineers Safety Code for Controls and Safety Devices
for Automatically Fired Boilers, ANSI/ASME No. CSD-1, if in the US, or the CSA standard
B139, Installation COde for Oil Burning Equipment, when in Canada.
LOCATE BOILER in front of final position before removing crate. Provide a level solid
baseasnearchimneyaspossibleandcentrallylocatedwithrespectto theheatdistribution
system as practical.
WARNING: BOILER MAY NOT BE INSTALLED ON COMBUSTIBLE
FLOORING.
Allow 24 inches in the front and top for servicing and cleaning. Allow 24 inches on the
right hand side for removal of tankless coil if so equipped.
When installed in a utility room, the door should be wide enough to allow the largest
boiler part to enter, or to permit replacement of another appliance such as a water heater.
FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY. The boiler
must not be installed on carpeting, wood or vinyl flooring. Minimum clearances to
combustible construction are:
TOP............................................................. 24 IN.
FRONT........................................................ 24 IN.
FLUE CONNECTOR ..................................... 9 IN.
REAR ............................................................ 6 IN.
LEFT HAND SIDE .......................................... 6 IN.
RIGHT HAND SIDE..................................... 24 IN.
NOTE: CLEARANCE FOR ACCESS SHOULD EXCEED FIRE PROTECTION
CLEARANCE.
REMOVECRATEandplasticprotectivewrapperandinspectfordamage.Allequipment
is carefully manufactured, inspected and packaged by experienced workers. Our
responsibilityceasesupondeliveryofthecratedboilertothecarrieringoodcondition.Any
claimsfordamageorshortagein shipment mustbefiledimmediatelyagainstthecarrier by
the cosignee. Move boiler to permanent position by sliding or walking.
PAGE 2

PAGE 3
VENTILATION & COMBUSTION AIR
WARNING: AIR OPENINGS TO COMBUSTION AREA MUST NOT BE
OBSTRUCTED. BY FOLLOWING THE CHART BELOW , ADEQUATE COMBUSTION
AIR CAN BE MAINTAINED.
COMBUSTION AIR REQUIREMENTS
(Minimum Opening Requirements)
*UNCONFINED AREA **CONFINED AREA
Outside Inside Outside Combustion Air
Combustion Combustion VERT. DUCTS HORZ. DUCTS
BTU/HR Air 1 IN.2Air 1 IN.21 IN.21 IN.2
INPUT /5000 BTU/HR /1000 BTU/HR /4000 BTU/HR /2000 BTU/HR
(Paragraph 4) (See Fig 1) (See Fig 2 & 3) (See Fig 4)
(MIN. 100 IN2)
107,800 22 108 27 54
140,000 28 140 35 70
196,000 40 196 49 98
*Unconfined area: A space whose volume is not less than 50 cubic feet per 1000
BTU per hour of all appliances installed in that space (cubic feet of space = height x
width x length).
**Confined area: A space whose volume is less than 50 cubic feet per 1000 BTU
per hour of all appliances installed in that space (cubic feet of space = height x width x
length).
1. Ventilation of boiler room must be adequate enough to provide sufficient air to
properly support combustion.
2. When a boiler is located in an unconfined space in a building of conventional
construction frame, masonry or metal, infiltration normally is adequate to provide air for
combustion and ventilation. However, in any building which has been altered to conserve
energy or to minimize infiltration, the boiler area should be considered as a CONFINED
SPACE. If there is any doubt, install air supply provisions for combustion and ventilation in
accordancewithsection5.3,AirforCombustionandVentilation,ofthemostrecentrevision
oftheNFPA541988code,therecommendationsthatfollow,orapplicableprovisionsofthe
local building codes.
3. When a boiler is installed in an unconfined space, in a building of unusually tight
construction, air for combustion and room ventilation must be obtained from outdoors or
from spaces freely communicating with the outdoors. A permanent opening or openings

PAGE 4
having a total free area of not less than 1 square inch per 5,000 BTU per hour of total input
rating of all appliances shall be provided. Ducts may be used to convey make-up air from
the outdoors and shall have the same cross-sectional area of the openings to which they
are connected.
4. When air for combustion and room ventilation is from inside buildings, the confined
space shall be provided with two permanent openings, one starting 12 inches from the top
and one 12 inches from the bottom of the enclosed space. Each opening shall have a
minimumfreeareaof1squareinchperonethousand(1,000)BTUperhourofthetotalinput
ratingofall appliances in the enclosed space, but must not be less than one hundred (100)
square inches. These openings must freely communicate with the interior areas having
adequate infiltration from the outside. See figure 1 below.
5.Whentheboilerisinstalledinaconfinedspaceandallairisprovidedfromtheoutdoors,
theconfinedspaceshallbeprovidedwithtwopermanentopenings,onecommencingwithin
12inchesfromthetopandonecommencing12inchesfromthebottomoftheenclosure.The
openingsshallcommunicatedirectly,orbyducts,withtheoutdoorsorspaces(crawlorattic)
that freely communicate with the outdoors. One of the following methods must be used to
provide adequate air for ventilation and combustion.
A.Whendirectlycommunicatingwiththeoutdoors,eachopeningshallhaveaminimum
free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in
the enclosure. See figure 2, above.
B. When communicating with the outdoors by means of vertical ducts, each opening
shall have a minimum free area 1 square inch per 4,000 BTU per hour of total input rating
of all appliances in the enclosed space. See figure 3 on page 5.
C. If horizontal ducts are used, each opening shall have a minimum free area 1 square
inch per 2,000 BTU per hour total input rating of all appliances in the enclosed space. See
figure 4 on page 5.
D.Whenductsare used,theyshallbe ofthesamecrosssectional areaasthefree area
of the area of the openings to which they connect. The minimum dimension of rectangular
FIGURE1 FIGURE2

PAGE 5
air ducts shall not be less than 3 inches.
6. In calculating free area using louvers, grills or screens for the above, consideration
shallbegiventotheirblockingeffect.Screensusedshallnotbesmallerthan1/4inchmesh.
If the free area through a design of louver or grill is known, it should be used in calculating
the size opening required to provide the free area specified. If the design and free area is
not known, it may be assumed that wood louvers will have 20-25% free area and metal
louvers and grills will have 60-75% free area. Louvers and grills shall be fixed in the open
position or interlocked with the boiler so that they are opened automatically during boiler
operation. See chart on page 3 for combustion air minimum opening requirements.
FIGURE3
FIGURE4

PAGE 6
CONNECTING SUPPLY AND RETURN PIPING
1. Connect supply and return piping as suggested in figure 5, below. When the boiler is
used in connection with refrigerated systems:
A. The chilled medium MUST BE IN PARALLEL with the boiler.
B. Use appropriate valves to prevent the chilled medium from entering the heating
boiler.
2. During the heating cycle open valves Aand B, close valves Cand D.
3. During heating cooling cycle open valves Cand D, close valves Aand B.
A. Maintain a minimum clearance of one inch to hot water pipes.
Inairhandlingunitswheretheymaybeexposedtorefrigeratedaircirculation,theboiler
piping system MUST be supplied with flow control valves or other automatic means to
prevent gravity circulation of the boiler water during the cooling cycle.
4. Hot water boilers installed above radiation level must be provided with a low water
device either as part of the boiler or at the time of boiler installation.
5. When a boiler is connected to a heating system that utilizes multiple zoned
circulators, each circulator must be supplied with a flow control valve to prevent gravity
circulation.
*Reduced pressure back flow preventer must be present under provisions required by
the Environmental Protection Agency, (EPA).
6. Bypass piping is an option which gives the ability to adjust the supply boiler water
temperature to fit the system or condition of the installation. Although, this method of
piping is not typically required for baseboard heating systems.
A. This method is used to protect systems using radiant panels and the material they
are encased in from high temperature supply water from the boiler. See figure 6 above.
B. This method is used to protect boilers from condensate forming due to low
temperature return water. Generally noticed in large converted gravity systems or other
large water volume systems. See figure 7 on page 7.
FIGURE6
FIGURE5

C.Thismethodisused to protect boilersfromcondensateformingaswell as protecting
the heating system from high water temperature. See figure 8, below.
7. Note: When using bypass piping, adjust valves Aand Buntil desired system
temperature is obtained.
8. Bypass loop piping must be the same size piping for the supply and return.
9. Typical installation using circulators is shown in figure 9, below.
FIGURE7 FIGURE8
FIGURE9
PAGE 7

PAGE 8
FIGURE10
FIGURE11
10. Typical installation using zone valves is shown in figure 10 below.
11. See figure 11 below for typical piping for domestic hot water heater.
12. For further piping information refer to the I=B=R installation and piping guide.

PAGE 9
VENTING SYSTEM INSPECTION & INSTALLATION
WARNING: BOILER IS TO BE VENTED BY NATURAL DRAFT AND
SHALL NOT BE CONNECTED INTO A MECHANICAL DRAFT SYSTEM OPERATING
UNDER A POSITIVE PRESSURE.
INSPECT CHIMNEY to make certain it is constructed according to the lastest revision
ofNFPA21,whenintheU.S.,ortheNationalBuildingCodeorCSA-A405,wheninCanada.
Localcodesmaydifferfromthiscodeandshouldbechecked.Wherethereisaconflict,the
local code will prevail.
This boiler must be installed into a chimney which has a tile lined masonry or metallic
chimney liner.
An unlined chimney will have leaks that will cause poor chimney performance (NO
DRAFT), and could result in poor positive pressure in the combustion chamber.
Horizontalportionsoftheventingsystemshouldnotexceed10feetinlength.Horizontal
lengths over 10 feet will have a negative effect on the chimney performance.
The chimney should extend at least 2 feet above any portion of the building within 10
feet. See figure 12 below. It should produce a negative draft of .06 to .08 inches of water
column, (W.C.), as measured with a draft gauge between the boiler and barometric draft
control while maintaining an .02 inch W.C. negative draft in the combustion chamber. See
chart below for recommended chimney or vent sizes.
Inadequate draft will cause improper combustion, resulting in dirty flue ways and high
fuel bills.
CONNECT FLUE PIPE same size as boiler outlet to chimney, sloping upward continu-
ouslytowardthe chimneyapproximately1/4"per foot.Boltorscrew jointstogethertoavoid
sag.
If an oil fired water heater is vented into the same flue as the boiler, provide a separate
hole into the chimney whenever possible. When this isn’t possible, use a “Y” connection in
thefluepipe,usingaseparatedraftregulatorforeachunit.Whenachimneywillnotprovide
adequatedrafttohandletheinputfromthewaterheaterandboilersimultaneously,wirethe
units so that only one will operate at a time, favoring the water heater.
FIGURE12
CHIMNEYORVENTSIZES
ROUND SQUARE HEIGHT
MODELNO. INCHES INCHES FEET
MIN MAX MIN MAX MIN MAX
OBC4 6 8 8x8 8x10 15 40
OBC3 6 8 8x8 8x10 15 40

PAGE 10
OIL TANK AND PIPING
OILTANKANDPIPINGshouldbeinstalledinaccordancewiththeNationalBoardofFire
Underwriters and local regulations. Oil storage tank, vent, fill pipe and caps should be as
prescribedbylocalcodes.Innocaseshouldtheventpipebesmallerthan1-1/4"I.P.S.The
fill pipe should not be less than 2" I.P.S.
The suction line from the tank to the burner should be one continuous piece of tubing
to prevent air entering the line. The suction line, must be 3/8" O.D. copper tubing for runs
of 50 feet or less, and 1/2" O.D. for longer runs. An oil return line, same size as the suction
line, must be used on any installation where the bottom of the tank is below the fuel unit of
the burner. Oil lines should be buried or otherwise protected from mechanical injury. Flare
fittings on all oil lines are required. Compression fittings on the suction line often allow air
to be drawn into the fuel pump, making it difficult to maintain oil pressure at the nozzle. Do
not run overhead fuel lines from tank to oil burner.
Fuelpumpconnectionsandby-passshouldbemadeaccordingtoinstructionsattached
to the fuel pump. If tank is more than 20' from the boiler, a two stage fuel unit should be
installedinplace ofthesingle stagepumpsuppliedasstandardequipmentwith theburner.
Make certain the rotation and speed are the same and the pump is suitable for the burner
horsepower rating.
An oil line filter and shut-off valve should be installed in the suction line. Shut-off valves
should be installed in both the suction and return lines at the burner for convenience in
servicing burner. Allow extra tubing at burner so burner may be removed from boiler for
cleaning without disconnecting tubing. (See figures 13 &14, below). An optional flexible oil
line is available.
FIGURE13 FIGURE14
TYPICAL INSTALLATIONTWO
PIPE OIL SYSTEM
TYPICALINSTALLATIONSINGLE
PIPE OIL SYSTEM

PAGE 11
ELECTRICAL WIRING
Electrical wiring must conform with National Electrical Code, ANSI/NFPA No. 70 when
installed in the United States, the CSA C22.1 Canadian Electrical Code, Part 1, when
installed in Canada, and/or the local authority having jurisdiction. A separate electrical
circuit should be run from the entry box with a fused disconnect switch in this circuit. See
wiringdiagram’sinfigures 15 below,&16,page12, for suggestedcircuitryandfieldwiring.
Wiring for zone valve installations are furnished with zone valve packages.
1. COMPONENT CODING
TH-1 Thermostat (millivolt)
TH-2 Thermostat (24 Volt)
TH-3 Thermostat (Line Voltage)
TR-1 Transformer (120V/24V 40VA)
TR-2 Transformer (120V/24V 50VA)
LGV 24 Volt Gas Valve
PS Pressure Switch
MR-PS Manual Reset Pressure Sw.
Control Terminal
1K Relay Coil
2. WIRING CODE
LINE VOLTAGE BY FACTORY
LOW VOLTAGE BY FACTORY
LINE VOLTAGE BY INSTALLER
LOW VOLTAGE BY INSTALLER
* NOT ALL COMPONENTS LISTED ARE USED IN ALL CONTROL SYSTEMS.
1K1 RelayContacts
1K2 Relay Contacts
LS Limit Switch
MS Manual Switch
CIR Circulator
ECO Energy Cut-Off
PSC Pilot Safety Coil
Wire Connection
LWCO Low Water Cut Off
EWF Electric Water Feeder
PG Power Generator
FIGURE15
WIRING DIAGRAM FOR OIL FIRED BOILERSWITH A CIRCULATOR ZONE SYSTEM
LESSTANKLESS HEATERW/R8404 INTERRUPTED IGNITION

PAGE 12
NORMAL SEQUENCE OF OPERATION
On a call for heat, the thermostat will actuate, completing the circuit to the aquastat. In
turn, the circulator and ignition systems are activated and ignition will begin.
In the event the boiler water temperature exceeds the high limit setting on the boiler
mountedaquastat,power willbeinterrupted betweentheaquastatandtheignitionsystem.
The power will remain off until the boiler water temperature drops below the high limit
setting. The circulator will continue to operate under this condition until the thermostat is
satisfied.
THERMOSTAT INSTALLATION
1. Thermostat should be installed on an inside wall about four feet above the floor.
2. NEVER install a thermostat on an outside wall.
3. Do not install a thermostat where it will be affected by:
A. Drafts
B. Hot or cold pipes
C. Sun light
D. Lighting fixtures
E. Television sets
F. A fireplace or chimney
4. Check thermostat operation by raising and lowering thermostat as required to start
and stop the burner.
5. Instructions for the final adjustment of the thermostat are packaged with the
thermostat ( adjusting heating anticipator, calibration, ect.).
FIGURE16
WIRING DIAGRAM FOR OIL FIRED BOILERSWITH A CIRCULATOR
ZONED SYSTEM AND ATANKLESS HEATER

PAGE 13
OPERATING INSTRUCTIONS
Theventingsystemshould beinspectedatthestartofeachheatingseason.Checkthe
vent pipe from the boiler to the chimney for signs of deterioration by rust or sagging joints.
Repair if necessary.
Remove the vent pipe at the base of the chimney or flue and, using a mirror, check for
obstruction.
The lever of the pressure relief valve, shown in Figure 17, on page 16, on the boiler
should be operated periodically to make sure that it is functioning properly. The pressure
reliefvalveshouldopenbeforethewaterpressureexceedsthe30lb.readingonthegauge.
If this pressure is exceeded and the pressure relief valve leaks water when the boiler is
operating at normal pressures, it should be immediately replaced. Corrosion can build up
rapidly at the valve seat and prevent its functioning as a safety device.
WARNING: WW
WW
WAA
AA
ATERTER
TERTER
TER WILL BE BOILING HOWILL BE BOILING HO
WILL BE BOILING HOWILL BE BOILING HO
WILL BE BOILING HOTT
TT
T
..
..
.
START-UP AND ADJUSTMENT OF OIL BURNER (See oil burner instructions for
nozzle and electrode setting).
A. Check oil burner nozzle to make certain it is tight in adapter. Burner mounting bolts
should be tight.
B. Check electrode setting, as they may have been jarred out of position during
transportation.
C. Lubricate burner motor and circulator motor if required. Some circulators are water
lubricated and do not require oiling.
D.Setroomthermostattocallforheat,orjumpthermostatcontactsontheboilercontrol.
E. Open all oil line valves.
F. Turn service switch on. Burner should start.
G. On one pipe fuel systems only, vent pump as soon as burner starts. Allow oil to run
until all traces of air in the suction line disappear.
H. Turn “OFF” burner and install pressure gauge port on pump.
I. Start burner again and check oil pressure for 140 lbs. Adjust if necessary.
CAUTION: DO NOT SET FIRE VISUALLY.
Instruments are the only reliable method to determine proper air adjustments. An
improperly adjusted burner causes soot and high fuel bills because of incomplete
combustion of the fuel oil. This in turn may require excessive boiler maintenance, service
costs, and in some instances, house cleaning or redecorating. A competent service
mechanic should be consulted to make the proper adjustments with a smoke tester, CO2
indicator and draft gauge. Bacharach or Dwyer test kits include these instruments.
INSTRUCTIONS TO OBTAIN PROPER OPERATION
OF THE BOILER-BURNER UNIT
A1/4"diameterslotisprovidedinthe inspectioncoverplatetotakedraftreadingsinthe
combustion chamber. See figure 17, on page 16. A 1/4" diameter hole will be required in
the flue pipe between the boiler and barometric damper (if used) to take draft, CO2, smoke
and temperature readings. Adjust air shutter on oil burner to obtain a “trace” of smoke.
Measure CO2at this point. Increase air adjustment to lower CO2approximately one (1)

percent. Check to insure minimum negative .02 W.C., (water column), “overfire” draft and
zero (0) smoke. If - .02 W.C. “overfire” draft can not be maintained, changes and/or
modifications may be required in the venting or the chimney.
The following table is provided as a guideline for initial start-up. Final adjustments
MUST be made using combustion instruments as previously mentioned.
MODEL END STATIC AIR AIR NOZZLE
NO. CONE DISC BAND SHUTTER FURNISHED
SETTING SETTING
OBC3D F-0 2-3/4 0 8 .65X80B
OBC3 F-3 2-3/4 1 8 .85X80B
OBC4D F-3 2-3/4 1 8 .85X80B
OBC4 F-6 2-3/4 3 10 1.25X80B
Information in above table uses Beckett model AF burner for both model numbers OBC-
3 and OBC-4.
OBC3D and OBC4D are derated boilers which require derate kits; part numbers 5612206
for OBC3D and 5612209 for OBC4D.
CHECK SAFETY CONTROL CIRCUIT after burner adjustments have been made for
satisfactory performance.
A.Highlimitcontrol:removecoverandnotetemperature setting.Seefigure 17onpage
16. With the burner operating, decrease this setting to the minimum point. When boiler
water temperature exceeds this set point, the high limit switch will open, shutting off the
power to the oil burner. Return setting to desired high limit point. Burner should re-start.
B. Primary control and flame sensor:
To Check:
A. Flame failure - simulate by shutting off oil supply with hand valve while burner is on.
Sixtysecondsafter flameout,thesafetyswitchlocksout,ignitionstops,motor stopsandoil
valve - when used - closes. To restart, open oil supply valve and reset safety switch.
B. Ignition failure - with burner off, close oil supply valve and run through start-up
procedure, The safety switch should lock out as in flame failure.
C. Power failure - Turn off main power supply switch while burner is operating. When
burner stops, restore power and burner should start.
If operation is not as described as above, check wiring and controls.
PREVENTIVEMAINTENANCEofanoilfiredboilerreducesoperatingcosts.Theboiler,
vent and vent pipe should be inspected for accumulation of soot or scale deposits
periodicallybutatleastonceeveryyearbeforethestartofeachheatingseason.Whensoot
is present on the section walls and flueways, improper combustion will result, causing
additional sooting and scaling until flueways are completely closed. To remove soot and
scale from the flueways, remove top jacket panel, top clean-out plate and burner. See
instructions on page 15 for instructions on removal of the oil burner. Using a wire brush,
brush the soot and scale into the combustion chamber where it can be removed through
PAGE 14

PAGE 15
the burner opening. Carefully vacuum debris from the combustion chamber. Inspect
combustionchamberforsignsofdamage,i.e.cracks.Intheeventthecombustionchamber
isdamaged,replaceitimmediately.Failuretodosowillcauseprematurefailureoftheunit,
and may result in personal injury. See figure 17 on page 16.
PERIODIC INSPECTION and tightening of the tankless heater/cover plate bolts will
reduce the risk of leaks. Refer to OBC series exploded heat exchanger drawing on page
18, part numbers x and x. CAUTION: Do not overtighten bolts.
INSTRUCTIONS FOR REMOVING OIL BURNER
1. Turn off power to boiler.
2. Allow boiler to cool down.
3. Remove three (3) 1/2" nuts from burner flange.
4. Close oil valve. See figures 13 and 14 on page 10.
5. Disconnect oil line from burner.
CAUTION: USE CAUTION WHEN VACUUMING IN THE CHAMBER
AREA. DAMAGE TO CHAMBER COULD RESULT.
It is recommended to replace the nozzle at the start of each heating season. Lubricate
theburnermotorandcirculator motor -ifrequired-with a fewdropsofagoodgrade of light
motor oil. Do not over oil. Have a competent service person service the burner and check
thecontrolsandchecktheelectrodesfor carbonorcracksintheinsulators.Burnersshould
be adjusted to produce the conditions shown in Start-up and Adjustment of Oil Burner
procedure.
INSTRUCTIONS FOR REPLACING OIL BURNER
CAUTION:CAUTION:
CAUTION:CAUTION:
CAUTION: "USE ONLY NUMBER 2 FUEL OIL."
WW
WW
WARNING:ARNING:
ARNING:ARNING:
ARNING: "DO NOT USE GASOLINE CRANKCASE DRAINGINGS OR
ANY OIL CONTAINING GASOLINE."
WW
WW
WARNING:ARNING:
ARNING:ARNING:
ARNING: "DO NOT ATTEMPT TO START THE BURNER WHEN
EXCESS OIL HAS ACCUMULATED, WHEN THE UNIT IS FULL OF VAPOR, OR
WHEN THE COMBUSTION CHAMBER IS VERY HOT."
1. Reconnect oil line.
2. Open oil valve. See figures 13 and 14 on page 10.
3. Install and tighten three (3) 1/2" nuts on the burner flange.
4. Turn on power to boiler.
5. Bleed the oil line.

PAGE 16
*
x
x
x
x
x
x
x
Inspect Chimney and Flue pipe
Inspect and Clean Appliance
Inspect Oil Line - Size/Leaks
Inspect Electrical Connections
Install New Filter
Room Make-up Air
Electrode setting
Nozzle-Size, Angle, Type
SERVICE CHECK LIST
*
*
*
*
*
x
*
PumpPressure/Vacuum
Line Voltage/Motor Amps
Smoke Test
Draft-Overfire/In Flue
CO2 or O2
Flue Gas Temperature
Proper Light-Off (Hot & Cold)
Controls and Safety Devices
x
*MeasurewithInstrumentsandRecord results onchartprovidedbelow
FIGURE17
Pump Flue
Date Nozzle Pressure Smoke Draft CO2or O2Temperature
Size Angle Type PSI NO. O.F. INF oF

PAGE 17
OBC SERIES JACKET AND FLUE COLLECTOR
ASSEMBLY
No. P/N Description Qty.
1 2162801 Pnl Jkt Wrapper Assy. OBC 3 1
2162802 Pnl Jkt Wrapper Assy. OBC 4 1
2 2462101 Flue Collestor Assy. OBC 3 1
2462102 Flue Collestor Assy. OBC 4 1
3 2162701 Pnl Jkt Top Assy. OBC 3 1
2162702 Pnl Jkt Top Assy. OBC 4 1
4 HW-009.01 Scr 8-18x1/2 Stl Hx Wash Hd 16
5 HW09501 Scr 5/16-18x1x5 Type F Slh X 2
6 2162501 Pnl Jkt Top Frt Assy. OBC 1
7 2162601 Pnl Jkt Low Frt Assy. OBC 1
FIGURE18

PAGE 18
OBC SERIES HEAT EXCHANGER ASSEMBLY
No. P/N Description Qty.
1 HW-003.02 Nut1/4-20HexStlZP 2
2 HW-008.01 Wash - 5/16 Flat Stl ZP 2
3 HW-011.02 TieRod1/4-20x13x3IHWHOBC3 2
HW-011.04 TieRod1/4-20x17x3IHWHOBC4
4 100-2-3.01 Right Section B 1
5 43300976 PushNipple2"
OBC3(4) OBC4(6)
6 100-2-1.0 Center Section B
OBC3(1) OBC4(2)
7 100-2-4.01 TanklessSectionB 1
8 HW06901 Nut 5/16-18 Wislock 4
9 HW-012.02 Bolt7/16-14x1-1/2SqHd 8
10 252-2-2.00 GasketBtankless 1
11 252-3-1.02 TanklessCoilL-24 1
12 HW-013.01 Nut 7/16-14 Sq Stl 8
13 202-2-1.00 CoverplateB/SFSTankless 1
FIGURE19