Olsen OBC Series Documento tecnico
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.
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