Carrier BW4 Owner's Manual
Contents
1. lock nut holding door shut 7 Inspect target wall fire door refractory and combustion chamber blanket when included for cracking and deterioration If there are signs of cracking or deterioration replace refractory or blanket before reassembling burner front plate 8 Inspect door s braided gasket for wear and damage Replace when necessary with braided gasket of same material and size 9 Use caution when vacuuming in the chamber area Damage to chamber could result 10 Reinstall the burner 11 Reinstall the flue collector 12 Reinstall top jacket panel Reconnect flue pipe 13 Reconnect electrical and fuel supplies 14 Fire burner check for proper combustion using combustion test equipment make adjustments as necessary 15 Verify all safety controls and operating controls are functioning properly INSTRUCTIONS FOR BLOW DOWN OF A STEAM BOILER Before blowing down the boiler fill it to the water line Turn in burner and allow five pounds of steam pressure to build up Run a temporary connection from one of the drain valves to a nearby sewer Connect to a drain valve on the opposite end of the boiler from the feed water inlet if possible Shut off the oil burner open drain valve and blow down the entire contents of boiler WATER WILL BE BOILING HOT USERS INFORMATION MANUAL Allow boiler to thoroughly cool and slowly refill to water line Repeat as many times as required until blow off water is clear2. Owner should blow down boiler at least once each month of the heating season Contact a qualified service technician before remodeling for annual service maintenance before extended periods of shutdown and before start up A CAUTION DO NOT TAMPER WITH THE UNIT OR CONTROLS CALL YOUR QUALIFIED SERVICE TECHNICIAN Service Personnel Information Name Address Telephone Number CAC BDP Company 7310 W Morris Street Indianapolis IN 46231
3. USERS INFORMATION MANUAL OIL BURNING EQUIPMENT STEAM AND HOT WATER BOILERS IMPORTANT e READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE USE ONLY NUMBER 2 FUEL OIL DONOT USE GASOLINE CRANKCASE DRAININGS OR ANY OIL CONTAINING GASOLINE NEVER BURN GARBAGE OR PAPER IN THE UNIT AND NEVER LEAVE COMBUSTIBLE MATERIAL AROUND IT KEEP YOUR BOILER AND THE SPACE AROUND THE APPLIANCE CLEAR OF DEBRIS DO NOT STACK ITEMS ON OR AROUND THE APPLIANCE WITHIN THE REOUIRED CLEARANCES TO COMBUSTIBLES e ENSURE THAT THE SUPPLY OF COMBUSTION AIR TO THE APPLIANCE IS NOT OBSTRUCTED OR CUT OFF ENSURE THAT THE PROPER VENTILATION TO THE APPLIANCE AREA IS MAINTAINED OG BW4 01 P N 240006274G Rev B 12 2012 INSTRUCTIONS TO OBTAIN PROPER OPERATION OF THE BOILER CAUTION e DO NOT START THE BURNER UNLESS ALL CLEAN OUT DOORS ARE SECURED IN PLACE e DO NOT ATTEMPT TO START THE BURNER WHEN THE COMBUSTION CHAMBER HAS ACCUMULATED OIL OR IS FULL OF VAPOR OR IS VERY HOT 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 CO indicator and draft gauge Bacharach o
4. boiler reduces operating costs The boiler and vent pipe should be inspected for accumulation of soot or scale deposits periodically but at least once every year before the start of each heating season When soot is present on the section walls and flue ways improper combustion will result causing additional sooting and scaling until flue ways are completely closed Periodic inspection and tightening of the tank less heater cover plate bolts if applicable will reduce the risk of leaks ALWAYS DISCONNECT POWER TO THE BOILER WITH THE EMERGENCY POWER ISOLATION SWITCH WHEN SERVICING THE BOILER THE EMERGENCY POWER ISOLATION SWITCH IS FIELD INSTALLED AND SHOULD BE WITHIN 5 FEET OF THE BOILER OIL BURNER MAINTENANCE 1 Oil Burner Motor Refer to burner manual provided with boiler 2 Fuel Filter Replace to prevent contaminated fuel from reaching nozzle Partially blocked fuel filter can cause premature failure of fuel pump 3 Fuel Pump Unit Replace pump screen and clean pump unit to maintain fuel delivery to nozzle 4 Ignition Electrodes Clean and adjust per manufacturer s recommendations to maintain reliable ignition of oil 5 Nozzle Replace to maintain safe and reliable combustion efficiency Replace with nozzle as required in charts located in this manual 6 Fan and Blower Housing Must be kept clean free of dirt lint and oil to maintain proper amount of air fuel requires to burn 7 Check Final Bu
5. r Dwyer test kits include these instruments A 1 diameter slot is provided in the inspection cover plate to take draft readings in the combustion chamber A 14 diameter hole will be required in the flue pipe between the boiler and barometric damper if used to take draft CO smoke and temperature readings Adjust air shutter on oil burner to obtain a trace of smoke Measure CO at this point Increase air adjustment to lower CO approximately one 1 percent Check to ensure zero 0 smoke and correct draft is obtained for the unit installed reference the Boiler Installation Manual for correct draft settings If the proper draft can not be maintained changes and or modifications may be required in the venting chimney or combustion air supply SHUTTING DOWN THE BOILER FOR EXTENDED PERIODS OF TIME A CAUTION ALWAYS KEEP THE OIL SUPPLY VALVE SHUT OFF IF THE BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME Always turn off electrical power to the boiler via the field installed fused disconnect switch if the boiler is shut down for an extended period of time When restarting the boiler from an extended shutdown follow the Operating Instructions in the Installation Manual and Operating Instructions GENERAL MAINTENANCE DURING OPERATION The following preventative maintenance should be performed by a qualified service technician annually prior to the heating season Preventative maintenance of an oil fired
6. rner Adjustments BOILER CLEANING INSTRUCTIONS 1 Shut off all electrical power to the boiler ourner and shut off fuel supply 2 Remove vent pipe from top of boiler Inspect pipe and chimney for signs of corrosion and deterioration Clean out base of chimney If vent pipe shows any signs of corrosion or deterioration replace it immediately If chimney damage or deterioration is discovered contact a service technician 3 Remove top jacket panel screws 5 brass wing nuts 2 holding flue collector top and flue collector top Inspect gasket on underside of flue collector and replace as necessary 4 Before beginning to clean flue passageways insure combustion chamber blanket is covered If blanket is not covered prior to cleaning replace blanket once cleaning is completed 5 With access to flue passageways remove soot from fireside surfaces by brushing diagonally through flue passages see drawing below Brushing can be made easier by cutting end of flue brush off and inserting it into drill When brushing take care to not damage target wall with flue brush or to damage the combustion chamber with the flue brush BOILER CLEANING INSTRUCTIONS 6 Carefully vacuum soot accumulations from combustion chamber area take care to not damage any of refractory or blanket insulation To gain access to combustion chamber first check that shut off valve on fuel oil line is closed and disconnect fuel oil line Open swing door by removing whiz
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