Crown Boiler ODV-100 manual

Oil-Fired Direct V ent Hot W ater Boilers F r ee p o r t O D V S e ri es W ARNING: 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 [...]

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T ABLE OF CONTENTS Product Description 1   Specications      2   Befor eInstalling      3   LocatingTheBoiler      3   V entSystemInstallation    4   SystemPiping      13   FuelPiping      ?[...]

1 I Pr oduct 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 OD[...]

2 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 W all[...]

3 IIIBefor e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-Burnin[...]

4 V V ent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[...]

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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. T op edge of terminal must be at least 2 ft below soft or overhang (Fig 3). j) Position terminal to avoid accidental contact with p[...]

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8 3) INST ALLA TION 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 afte[...]

9 NOTE: The tee may be rotated into any position so that the collar is in a convenient orientation. 4) APPLIANCE ADAPTER INST ALLA TION 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[...]

10 d) W ith 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 hole[...]

11 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 [...]

12 g) Push the inner vent pipe onto the termination inner pipe or appliance adapter all the way up to the stop bead. h) T ighten 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[...]

13 VISystemPiping S tandard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 a[...]

14 4) Fill V alve (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 V ent (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 W ater Cut-[...]

15 PipingforSpecialSituations Certain types of heating systems have additional requirements. Some of the more common variations follow: 1) Indirect W ater 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 [...]

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[...]

17 VIIFuelPiping T wo 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) T wo-Pipe – Recommended where the fuel pump is above the lowest possible level of the oil in the tank.[...]

2) Do not use compression ttings in oil piping. 3) Do not use T eon tape in oil piping 4) Do not manifold multiple oil appliances on a two-pipe system. Run dedicated lines for each appliance back to the tank or use a transfer pump and day tank to get oil to a location where it can be gravity fed to each appliance. 5) Do not use check valves i[...]

19 19 IXStart-upandCheckout Use the following procedure for initial start-up of the boiler: 1) Make sure that the boiler and system are lled with water . 2) Check all system and fuel piping for leaks. Repair any leaks found immediately . 3) V ent system must be complete and free of obstructions before attempting to re boiler . Do not[...]

20 6) Start the boiler . Immediately take a smoke. If any smoke is present, open the air adjustment to obtain a zero smoke. 7) Allow boiler to warm up for about 15 minutes or until the binder has completely burned out of the combustion chamber . Adjust the air to obtain a CO2 between 1 1.0% and 12.5% with a zero smoke. If a zero smoke cannot be obt[...]

21 2) If a zero smoke cannot be obtained at a CO2 between 1 1.0 and 12.5%, check the following: a) Check nozzle and settings against those shown in T able 2 below . Nozzle must be identical to that called for in T able 2 including manufacturer . Check the burner manufacturer ’ s manual for dimensional settings not shown in this manual (e.g. elect[...]

22 XIMaintenance Steps 1 – 10 below should be performed on an annual basis to assure reliable operation of the ODV boiler . If the boiler is used to power an indirect water heater , such as a Mega-Stor , it is advisable to check the CO2 and smoke level approximately half way between annual cleanings. 1) Shut off power to the boiler 2) Open the[...]

23 Important Product Safety Information Refractory Ceramic Fiber Product Warning : The Parts list designates parts that contain refractory ceramic fibers (RCF). RFC has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RFC changes into crystalline silica, a known carcino[...]

24 1 Sight Glass Retaining Clip 110007 2 Sight Glass Retaining Ring 110008 3 Sight Glass Gasket 110009 4 Sight Glass 110010 5 Door Refractory Retaining Screw (1/4-14 x 7/8" w/ Washer) 110050 6 Door Refractory Retaining Clip 110055 7 Setscrew 10MT x 50mm 90-027 8 Setscrew 10MT x 16mm 90-022 9 Hinge Bracket for Burner Plate 110023 10 CT-3 Tie Ro[...]

25 Figure 24: Boiler Parts[...]

26 ODV-75, ODV 100 ODV-125 1 RIGHT SIDE JACKET PANEL 1 ea. 110300 110400 2 LEFT SIDE JACKET PANEL 1 ea. 110310 110410 3 REAR JACKET PANEL 110210 1 ea. 1 ea. 4 FLUE COLLECTOR COVER 110215 1 ea. 1 ea. 5 TOP PANEL 1 ea. 110320 110420 7 REAR JACKET MOUNTING BRACKET 700110 2 ea. 2 ea. 8 M12 WASHER 90-033 2 ea. 2 ea. 9 M12 NUT 90-026 2 ea. 2 ea. 10 1/4-2[...]

27 KEY # IT EM # DESCRIPTION QTY Consi sting of : ODV-75 ODV-100 ODV-125 N/P 13-151 CARLIN BURNER ASSY. ODV- 75 1 * N/P 13-152 CARLIN BURNER ASSY. ODV- 100 1 * N/P 13-153 CARLIN BURNER ASSY. ODV- 125 1 * N/P 13-150 CARLI N EZ-1 MODI FIED B URNER 1 *** N/P 13-167 D ELAVAN 0.65/70W N OZZ LE 1 * N/P 13-114 D ELAVAN 0.85.60A NOZZ LE 1 * N/P 13-136 D EL[...]

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PN: 98-100 10/10 Rev .4 Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134 T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com[...]