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D ESIGNED T O L EAD
Freeport ODV Series
Oil-Fired Direct Vent Hot Water Boilers
These instructions must be affixed on or adjacent to the boiler.
Models
• ODV-75
WARNING: Improper installation, adjustment, alteration,
• ODV-100
service or maintenance can cause property damage, injury,
• ODV-125
or loss of life. For assistance or additional information
consult a qualified installer or service agency. This boiler
requires a special venting system. Read these instructions
carefully before i
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TABLE OF CONTENTS Product Description 1 Specifications 2 Befor e Installing 3 Locating The Boiler 3 V ent System Installation 4 System Piping 13 Fuel Piping 17 W iring 18 Start-Up And Checkout 19 Service Notes 20 Maintenance 22 Parts 24
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WARNING FAILURE TO VENT THIS BOILER IN ACCORDANCE WITH THESE INSTRUCTIONS COULD CAUSE FLUE GAS TO ENTER THE BUILDING RESULTING IN SEVERE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH: • Do not attempt to vent this boiler with galvanized, PVC, or any other vent components not described in this manual • Do not obtain combustion air from within the building. • Do not install a barometric damper or vacuum relief valve in the vent system of this boiler. CAUTION Moisture and ice may form on the surf
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II Specifications TABLE 1: SPECIFICATIONS D.O.E. FIG. 1 DIMENSION "B" (IN.) HEATING IBR NET FIG. 1 USING STANDARD NO. INPUT CAPY. RATING DIMENSION OPTIONAL CONNECTION MODEL SECTIONS Gal/hr) (BTU/hr) (BTU/hr) AFUE (%) "A" (IN.) TEE ODV-75 3 0.75 91,000 79,000 85.0 32-1/4 24 14 ODV-100 3 1.00 119,000 103,000 83.1 32-1/4 24 14 ODV-125 4 1.25 150,000 130,000 83.5 37-1/4 24 14 Ratings based on #2 fuel oil having a higher heating value of 140,000 BTU/Gal Net ratings based on a piping and pickup l
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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-Burning Equipment (ANSI/NFPA 31). • Where required by the authority having jurisdiction, this installation must conform to the Standard f
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V V ent System Installation WARNING • Read the installation instructions carefully and completely before proceeding with the installation of vent system. • For continued safe operation, the appliance vent system must be inspected and maintained annually by a qualified agency. Failure to properly maintain the appliance vent system combination can lead to Death, Personal Injury and or Property Damage. • Plan the vent system layout before installation to avoid the possibility of
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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 soffit or other overhang deeper than 18 inches. Top edge of terminal must be at least 2 ft below soffit or overhang (Fig 3). j) Position terminal to avoid accidental contact with people or pets. k) Over time, the area around the terminal may become stained. Locate the terminal on a wall where this is not objectionable.
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3) INSTALLATION 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 after installing the flexible oil vent pipe to the inner pipe on the terminal as outlined in step 6. (Figure 6) c) Apply standard silicone seala
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NOTE: The tee may be rotated into any position so that the collar is in a convenient orientation. 4) APPLIANCE ADAPTER INSTALLATION 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 red silicone sealant to inside of adapter ½” from end (Figure 7a). c) With a twisting motion, assemble the appliance adapter onto the vent coll
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d) With 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 holes on the vent collar. g) Secure the reducing tee adapter to the vent collar with (3) 1/4-20 x 1/2” stainless steel cap screws inserted into the
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6) VENT PIPE INSTALLATION 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 finalized and pipe is accurately marked before cutting. Pipe cannot be spliced if accidently cut too short. a) Pull outer vent pipe back 1”-2” from inner vent pipe end and remove insulation (Figure 9a). b) Sl
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g) Push the inner vent pipe onto the termination inner pipe or appliance adapter all the way up to the stop bead. h) Tighten 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 cover sleeve clamp (Figure 9d). j) To maintain 3” clearance to combustibles, wrap minimum 1-1/2” thick ceramic insulation (installer-
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VI System Piping CAUTION • Operation of this boiler with continuous return temperatures below 120f can cause severe heat exchanger corrosion damage • Operation of this boiler in an system having significant amounts of dissolved oxygen can cause severe heat exchanger corrosion damage • Do not use toxic additives, such as automotive antifreeze, in a hydronic system Standard Piping Figure 17 shows typical boiler system connections on a single zone system. Additional information on hydr
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4) Fill Valve (Required) – Either a manual or automatic fill valve may be used. The ideal location for the fill is at the expansion tank. 5) Automatic Air Vent (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 fill. 6) Low Water Cut-Off (Required in some situations) – A low water cut-off is required when the boiler is installed above radiation. In addition, some codes such as
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Piping for Special Situations Certain types of heating systems have additional requirements. Some of the more common variations follow: 1) Indirect Water 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 indirect water heaters. Size the circulator and indirect water heater piping to obtain the boiler water flow through the indirect water heater
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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 the boiler is to be used in such a system, it must be separated from the oxygenated water being heated with a heat exchanger as shown in Figure
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VII Fuel Piping IMPORTANT • Installation of oil storage tanks, fill pipes, and oil lines must conform to local code requirements. In the absence of any codes, installation must be in conformance with ANSI/NFPA-31. • Use of this boiler with an unenclosed above ground outdoor oil tank is not recommended. Two 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.
