By WASTE OIL FIRED BOILER OWB Series Installation, Operation, And Service Instructions Manual Thank you and congratulations on your purchase of an Omni Waste Oil Fired Boiler. You have selected a high quality, precision-engineered piece of equipment, designed to give you many benefits as well as years of outstanding performance. Econo Heat♦5714 1st Avenue♦Spokane Washington 99212.♦(509)534-1022♦www.econoheat.
TABLE OF CONTENTS WASTE OIL BURNER ........................................................................5 OIL BURNER TECHNOLOGY ..........................................................8 OIL BURNER/PUMP TECHNICAL DATA .......................................10 BOILER SPECIFICATIONS ...............................................................11 STANDARD EQUIPMENT.................................................................12 COMBUSTION AIR SUPPLY ....................................................
PRECAUTIONS Waste oil may contain many foreign materials. Waste oil may also contain gasoline. Therefore, specific precautions on the handling and storage of waste oils are to be observed when using, cleaning and maintaining this heater. Use a screen in a funnel when pouring oil into storage tank to catch foreign material, i.e., gasket material and sealant fibers, etc.
IMPORTANT NOTICE TO OWNER AND INSTALLER To enjoy the long term benefits of burning your used oil in an Omni Waste Oil Boiler, it is necessary to become familiar with the correct installation operation and maintenance of your new boiler. Before installing or operating this appliance, make sure you read and understand this manual.
WASTE OIL BURNER WARNING ONLY Authorized Technicians strictly complying with the manufacturer’s instructions and the local standards should perform installation, maintenance and service on the unit’s internal components. Installation and use of this used oil burning appliance shall be in accordance with the standard for the Installation of Oil Burning Equipment – ANSI/NFPA 31 – 1987, and National Electric Code – ANSI/NFPA 70 – 1990 and the requirements of the inspection authorities having jurisdiction.
Pre-Heater Control Circuit Board Oil Pre-Heater Block Air Muffler/Filter Photo Eye Flame Sensor Electrical Terminal Block Transformer Igniter Springs Heater Electrical Schematic Figure 2 – Oil Burner (Back View Opened) Electrodes Oil Valve Nozzle Burner Motor Flame Cone Figure 3 – Oil Burner (Front View) 6 Installation, Operation, And Service Instructions
Oil Outlet Oil Inlet Figure 4 –Oil Pump Diagram Figure 5 –Oil Pump Assembly Installation, Operation, And Service Instructions 7
OIL BURNER TECHNOLOGY Omni’s patented burner technology improves the efficiency of the oil burn process by continuous stabilization of the oil viscosity. Optimum atomization (spray) is accomplished by precisely preheating the oil and air prior to introduction to the combustion chamber.
• Air Pressure Adjuster: (figure1) Adjusts the air pressure going to the pre-heater block. Should be adjusted between 12 PSI and 13PSI as indicated on the Air Pressure Gauge on the burner for thorough burn of the waste oil. Note: In order to insure proper air adjustment, air gauge must read 0 when burner is cycled off or powered down. • Oil Pressure Gauge: (figure1) Displays oil pressure at the burner.
OIL BURNER/PUMP TECHNICAL DATA BURNER ASSEMBLY Performance Ratings Voltage Cycles Total Operating Amperage (Burner Only) Total Operating Amperage (Burner and Oil Pump) Electrical Operating Consumption (Burner Only) Electrical Operating Consumption (Burner and Oil Pump) Weight Oil Primary Oil Valve Pre-Heater Block Pre-Heater Controller Board Igniter Transformer Burner Motor Amp Amp Watts Watts Lbs Amp Amp Amp Amp Amp Amp 115 VAC 60Hz 8.4 10.5 970 1,212 36.5 0.2 0.075 4.2 0.011 0.3 3.
BOILER SPECIFICATIONS Figure 6 –Boiler (OWB-35 & OWB-50) OWB series boilers are three pass Scotch Marine design with fully water backed transfer surfaces. Boilers are designed for use in forced hot water heating systems. Heating is supplied by a Waste Oil Burner that burns all petroleum products any weight combination up to SAE 90W as well as fuel oils. Boiler–Burner units operate with no less than 0 to –0.01WC over fire and may be vented using a conventional chimney.
CODE REQUIREMENTS Installations must comply with all state, local, and utility codes, laws, regulations, and ordinances, and CSA standard B139. Where required by the authority having jurisdiction, the installation must conform to American society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, No. CSD1. All electrical wiring must be done in accordance with the National Electrical codes latest edition and all state and local codes.
9-3/8” Centerline Of Burner Plate 2-1/2 M.P.T. Supply Connection 36” 29-1/2” 20” 17” 3/4” L 33” 4” 8” 2-1/2 F.P.T. Return Connection Approx. 14” OWB-35 and OWB-50 Specifications 1-1/2” Supply Connection 26” Circulator 21-1/2” 15-1/2” 12-1/4” 1-1/2” Return Connection L 25” Approx. 14” OWB-9, OWB-15, and OWB-25 Specifications Boiler Model Burner GPH Input BTU’s Output Capacity BTU’s NET Rating Water BTU/HR. NET Rating Water SQ.FT. Approx. Dry Weight Lbs. Vent Connect Dia.
COMBUSTION AIR SUPPLY WARNING Failure to provide an adequate supply of fresh air for combustion will result in hazardous operating conditions. Note If you use a fireplace or a kitchen or bathroom exhaust fan, you should install an outside air intake. These devices will rob the boiler and water heater of combustion air. 1. In unconfined spaces in buildings infiltration may be adequate to provide air for combustion and ventilation.
(b) All Air From Outdoors: The confined space shall be provided with two permanent openings, one within 12 inches of the top and another within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or crawl or attic spaces which communicate freely with the outdoors. Direct To Outdoors, See Figure 8.
NOTE All wall openings directly to outdoors must be screened to prevent entry by birds or small animals. With Horizontal Ducts See Figure 10. Chimney Note: Each air duct opening shall have a free area of not less than one square inch per 2,000 Btu per hour of the total input rating of all equipment in the enclosure.
3. Breeching • See Table 2 for minimum recommended breeching and chimney sizes. • Keep run boiler to chimney as short as possible. • Use as few elbows as possible. • Slope upward towards chimney at not less than 1/4” per foot. • Use a sealed-in thimble for the chimney connection. • Connect together all sections and/or fittings with sheet metal screws and seal with silicone sealant. 4.
SIDE-WALL VENTING---IMPORTANT NOTE Two problems arise when side wall venting any oil appliance; 1. There is sometimes an accelerated rate at which soot builds up on the cad-cell, spinner, etc. 2. There is the potential for severe soot damage to the side of the structure in the event that the boiler operates at a high smoke level. This can happen for many reasons, some of which are out of the control of both the installer and appliance manufacturer.
INSTALLING THE BOILER Placing The Boiler (OWB-9 – OWB-25) 1. Move the boiler as close as possible to its final location in the crate. 2. Remove the two lag screws holding the rear feet to the skid. 3. Remove the front jacket panel. Cut the band holding the front of the boiler to the skid. 4. Move the boiler into the final position. 5. Waste Oil Piping: USE ONLY 3/8” nominal ID copper tubing with flare fittings only on the oil suction from the tank to the oil pump and oil pump to burner.
Pitch Up 1/4” per foot Barometric Draft Control 18” Straight Run Preferred Figure 12. INSTALLING THE BOILER CONTROLS AND ACCESSORIES 1. Accessories for Boilers OWB-9, OWB-15, and OWB-25: a) Take the L8148A Aquastat relay, the well, the pressure relief valve with pipe nipple and the temperature/pressure gauge from the large carton which was packed in the wirebound crate. Install in tappings provided at the top rear of the boiler as shown in Figure 13. Figure 13.
d) Remove the circulating pump from its carton in the crate and mount it to the pump flange on the end of the return manifold. 2. Bare Boiler: a) b) 1. The pressure relief valve and temperature/pressure gauge are supplied with the boiler and should be mounted as shown in Figure 13. The bare boiler does not include the return manifold.
WATER PIPING CONNECTIONS 1. OWB-9, OWB-15, and OWB-25 boilers are shipped complete with circulating pump. To make the piping connections to the boiler ready to connect to the system piping, the following will also be required at a minimum: 1 – Air Purger (same size as supply pipe) 1 – Pressure reducing Fill Valve 1 – Expansion Tank (sized to system design requirements) 1 – Automatic Air Vent 2.
Closed Type Expansion Tank Pressure Relief Valve 3/4 in. Supply to System Shutoff Valve S Cold Water Feed Fill Valve R Return From System Drain Cock Circulation Pump Figure 16. (b) Piping connections with diaphragm expansion tank--- See Figure 17. The cold water feed to the pressure reducing fill valve may be piped with 1/2 inch pipe. Shutoff Valve Purger Auto Air Vent S Cold Water Feed Diaphragm Type Expansion Tank R Drain Cock Circulator Pump Figure 17.
SYSTEM PIPING Supply and return and system piping should be sized by determining the pressure drop, required flow rate and pump capacity. WARNING Discharge piping from relief valve must be piped to a drain or must terminate 6” above floor to eliminate damage to the structure or personal injury. It must not be piped to a point where freezing might occur. 1. MULTIPLE ZOINING WITH ZONE VALVES ----- See Figure 18. Install a balancing valve in each zone and adjust so that flow is about the same in each zone.
Isolation Valves Flow Control Valves Shutoff Valve S Cold Water Feed R Drain Cock Isolation Valves Circulating Pumps Figure 19. 2. MULTIPLE ZONING WITH CIRCULATORS ----- Each pump will require a separate relay (Honeywell R845A or White Rodgers 829A845, or equivalent). Install a flow control valve in each zone including the indirect water heater to prevent gravity circulation. Install a balancing valve in each zone and adjust so that flow in each zone is about the same. See Figure 19. 3.
Return from System Supply to System Stem Thermometer Shutoff Valve Circulating Pumps S Bypass A Cold Water Feed R Drain Cock Circulating Pumps Adjust the two manual valves to maintain 160 degree F or more in the boiler while holding the supply water temperature at the stem thermometer at 140 degree F or whatever minimum temperature system requires. Figure 20. NOTE Bypass A shown in figure 20. above should not exceed 12 inches in length.
Supply to System Shutoff Valve S Cold Water Feed R Return from System Circulating Pumps Drain Cock Adjust the two manual valves to maintain 135 degree F or more in the boiler with return water at the lowest temperature to be expected. Figure 21. 5. INTEGRATED SYSTEM (HEAT AND DOMESTIC HOT WATER) ----- With a single heating zone priority for domestic hot water may be provided through the use of a 3-port zone valve.
Indirect Water Heater (Storage Tank With Coil) Supply to System Shutoff Valve S 3 Port Zone Valve Cold Water Feed R Return from System Drain Cock Circulating Pumps Figure 22. 6. INTEGRATED SYSTEM WITH MULTIPLE HEATING ZONES AND NO PRIORITY FOR DOMESTIC HOT WATER, USING ZONE VALVES----Where the boiler output is large relative to the heating capacity of the coil in the indirect water heater priority for domestic hot water is not necessary.
Indirect Water Heater Supply to System Shutoff Valve S Zone Valves R Cold Water Feed Return from System Drain Cock Circulating Pumps Figure 23. 7. INTEGRATED SYSTEM, SINGLE OR MULTIPLE HEATING ZONES, USING CIRCULATING PUMPS RATHER THAN ZONE VALVES---Each pump will require a separate relay (Honeywell R845A or White Rodgers 828A845, or equivalent). Install a flow control valve in each zone including the indirect water heater to prevent gravity circulation.
8. COMBINATION HEATING/COOLING SYSTEM WITH CHILLED WATER The chiller must be piped in parallel with the boiler and isolation valves installed to prevent the chilled water from circulating through the boiler and heated water from circulating through the chiller. See Figure 25. Chiller Insulation Valve # 4 Supply to System Insulation Valve # 4 S Circulating Pumps Insulation Valve # 3 Return from System Cold Water Feed R Flow Check Drain Cock Note: 1.
Amtrol #720 Air Eliminator or Equal System Supply Air Separator S System Circulator R Pressure Reduction Valve Blend Pump To Size Blend Pump See Table 3 Backflow Preventer System Return Check Valve From City Water Supply Expansion Tank Figure 26. 10. SINGLE OR MULTIPLE BOILER PIPING FOR PRIMARY/SECONDARY PUMPING Size Secondary Pump GPM at Gross Boiler Output for 20” Drop. When Calulating Pump Head, the Maximum Boiler Resistance for any Boiler will not Exceed 14 in. W.C. Head.
11. MULTIPLE BOILER PIPING- REVERSE RETURN FLOW WITH BLEND PUMP Amtrol #720 Air Eliminator or Equal S S R Check Valve Air Separator System Supply System Circulator R Pressure Reduction Valve *Blend Pump Backflow Preventer *Blend Pump Check Valve System Return Expansion Tank From City Water Supply Figure 28.
BOILER ASSEMBLY & WIRING Burner Mounting NOTE: When the burner is field installed the installer must fill in the space between the burner blast tube and the insulation block on the inside of the burner door with refractory mix provided. Figure 29. OWB-35 and OWB-50 Burner Mounting & Boiler Door Detail Figure 30.
Boiler Jacket Assembly 26 25 26A Sight Class Assy 33 86 60 38 48 94 36 43 18 41 93 18 40 Figure 31. OWB-35 and OWB-50 Assembly Detail OWB-35 and OWB-50 Jacket Installation Instructions 1. Screw the four extension setscrews (43) into the four outer holes in the corners of the rear sections. Securely tighten the setscrews and other fastening bolts of the flue outlet cover (22) 2. Place the large wraparound insulation mat (40) over boiler block (aluminum foil side facing out). 3.
8. Hook center panel (33) with flange edge down between side panels (93) and (94). 9. Attach the upper front trim panel (41) between the right and left side panels over the front door. 10. Place the top panel (86) in position. Hook to the side panels. 11. Remove sight glass plug in front door and install sight glass assembly. Sight Glass (25) Sight Glass Tube Cap(26) and Sight Class Gasket(48). Figure 32. OWB-9, OWB-15 and OWB-25 Assembly Detail OWB-9, OWB-15 and OWB-25 Jacket Installation Instructions 1.
5. Attach one door bracket (18) to the bottom of both the left and right side jacket panels. Use two 8-32x1/2” screws (19) and nuts (20) to assemble each door bracket. 6. Attach the left and right side jacket panels to the boiler. The front end of the right side panel is attached to the hinge using 10-24x3/4 screws (21). The front end of the left side panel is also attached to the front jacket mounting bracket (23) using 10-24x3/4 screws.
Single Zone Wiring WARNING All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such authority, with the National Electrical Code (ANSI/NFPA70). 1) 120 Volt Wiring—The boiler should be provided with its own 20A branch circuit with fused disconnect. All 120 volt connections are made inside the L8148A aquastat relay as follows (also see Fig.
thermostat connections so that any zone valve that opens will also start the circulator and fire the boiler(assuming the high limit is not open). Zone valve terminal TH/TR has no internal connection on the zone valve; it is merely a “binding post” used to connect two or more wires.
WHT RED YEL Figure 33.
WHT RED YEL Figure 34.
Figure 35. WIRING DIAGRAM, ZONE WIRING USING HONEYWELL V8043F VALVES (FACTORY BOILER WIRING NOT SHOWN –SEE FIGURE 33 OR 34) Figure 36.
BOILER START-UP AND ADJUSTMENTS FILL SYSTEM 1. Close manual air vents (if used) and automatic air vents. Attach hose to boiler drain on return connection and run to a drain or to outdoors. Open drain cock and close shutoff valve on boiler supply pipe. 2. HEATING ONLY – SINGLE ZONE SYSTEM--Open manual valve in cold water feed line and set the fill valve to fast fill. Allow water to flow through the system and out the hose until there is a steady flow of water through the hose with no air bubbles.
WASTE OIL BURNER STARTUP WARNING DO NOT fire boiler without water or boiler sections will overheat and eventually crack 6. IMPORTANT- Prior to starting the unit, pre-fill the filter and fuel line with oil to assist priming procedure. Oil pump motor turns at low RPM’s and would take significant time to complete priming process if not pre-filled. Make sure the oil supply line fittings are air tight. Vacuum leaks are notoriously hard to find. Pressurizing the line with oil in it can help to locate leaks. 7.
MAINTENANCE WASTE OIL BURNER: 1. Weekly Drain water from storage tank. 2. Monthly Clean pump screen on oil pump assembly of sludge and remove any water. Access to screen is by removing pump cover. Clean flame cone of deposits. 3. Yearly Inspect and adjust electrodes per (figure 37). CAUTION: turn off main electrical power before checking or adjusting electrode settings. Inspect and check alignment of nozzle in relation to flame cone/burner tube (figure 37).
Figure 37 –Electrode Adjusment Diagram When cleaning, inspect all three pieces thoroughly. When disassembling and reassembling nozzle, keep facing up as shown.
TROUBLE-SHOOTING GUIDE NO HEAT: 1. Check burner power switch and make sure power is available to the whole control system. 2. If included in system, check low-water cutoff and/or manual reset high limit. 3. Check room thermostat(s) and zone valves or pump relays (if used). 4. Make sure there is oil in tank. 5. Inquire if reset button on burner oil primary control has been tripped. If reset button continues to trip then DO NOT ATTEMPT TO START BURNER.
Omni Waste Oil Boilers Limited Warranty Econo Heat (manufacturer) warrants to the purchaser of Waste Oil Boilers will be free from defects in materials and workmanship for the durations specified below, which duration begins on the date of delivery to the customer. Customer is responsible for maintaining proof of date of delivery. If return is deemed necessary for warranty evaluation and determination of repair or replacement, boiler is to be sent to the factory with freight prepaid.
Installation, Operation, And Service Instructions
WARRANTY CARD Please fill our, tear off and return to manufacturer Return following warranty information to manufacturer within thirty (30) days of purchase or warranty will not be valid. (Please print or type).