Operating Boiler - Carrier BW4 Installation, Start-Up, And Operating Instructions Manual

3. Open valve in line from boiler to expansion tank.
4. Open water inlet to boiler and leave it open.
5. Start with the LOWEST radiation unit. Open the air vent on this radiation unit. When all air has escaped and water starts to flow from vent,
close air vent.
6. Proceed to next lowest radiation unit and repeat process outlined in item 5. Repeat until every radiation unit in system has been covered.
End with the highest unit in system.
If units have automatic vents, this manual venting is unnecessary but will speed up proper filling of system.
If system is a closed expansion tank system, there should be an automatic fill valve. It may be left open to refill system automatically as needed.
Check temperature-pressure gage. Note position of hand indicating pressure. This should be between 10 and 15 psi. Any lowering of this movable
hand below 10 psi indicates loss of water due to leakage. The automatic fill valve should compensate for this. If it does not, manually open this
valve to refill system until hand is again pointing to same pressure reading. Instructions are packaged with valve.
CAUTION: Do not tamper with the unit or controls.
IMPORTANT: Follow these instructions carefully.
PROCEDURE 1—TO START
Fill entire system with water. Vent all air from system. Refer to instructions included with oil burner.
PROCEDURE 2—FUEL UNITS AND OIL LINES
The oil burner is provided with a single-stage 3450 RPM fuel unit with by-pass plug removed for a single-pipe installation. This is satisfactory
where fuel supply is on same level or above burner, permitting gravity flow of oil. Never exceed 3 psi pressure to suction side of fuel unit. A
pressure over 3 psi may cause damage to shaft seat and allow it to leak oil. When it is necessary to lift oil to burner, a return line should run between
fuel unit and oil supply. If lift exceeds 10 ft, a 2-stage fuel unit must be used with a return line. When a 2-line installation is made, by-pass plug
must be installed. This is supplied with burner attached to fuel unit along with a fuel pump data sheet in a plastic bag. When oil lines are installed,
continuous runs of heavy wall copper tubing is recommended. Be sure that all connections are absolutely airtight. Check all connections and joints.
Flared fittings are recommended. Do not use compression fittings. See pump data sheet for sizing, lift, and length of tubing recommendations. Use
an oil filter of adequate size for all installations. Install inside building between tank shutoff valve and burner. For ease of servicing, locate shutoff
valve and filter near burner.
PROCEDURE 3—AIR SUPPLY FOR COMBUSTION
Do not install in rooms with insufficient air to supply combustion. Occasionally, it is necessary to install windows or cut holes in a door to these
rooms to obtain sufficient air and to prevent less than atmospheric air pressure in the room. If there is a lack of combustion air, the burner flame
will be yellow and formation of soot will occur in heating unit. In buildings of conventional frame, brick, or stone construction without utility
rooms, basement windows, or stair doors, infiltration is normally adequate to provide air for combustion and operation of barometric draft control.
The room should be isolated from any area served by exhaust fans. Do not install exhaust fans in this room. See Fresh Air for Combustion section
earlier in this document.
PROCEDURE 4—DRAFT REGULATORS (PROVIDED)
A draft regulator is required. It should preferably be mounted in smoke pipe. Use a draft gage to adjust to proper opening. When burner air supply
and draft are properly adjusted, combustion chamber draft will be approximately -0.01 to -0.02 in. wc and stack draft will be -0.02 to -0.04 in.
wc. The larger the installation, the greater the draft required at stack to obtain -0.01 to -0.02 in. wc at combustion chamber.
PROCEDURE 5—NOZZLES (PROVIDED)
Use the proper size, type, and spray pattern nozzle. To install nozzle, loosen clamping screw on retention ring assembly and slide assembly off
adapter. Install and tighten nozzle in adapter. Be careful not to damage electrode insulators or bend electrodes. Replace retention ring assembly
on adapter. Make sure clamp is tight against shoulder on adapter. Tighten clamping screw. Check electrode setting. (See Fig. 16-20.)
PROCEDURE 6—FINAL BURNER ADJUSTMENTS
A final adjustment must be made with the use of a COMBUSTION TEST KIT. Initial settings for burner are shown on label on top of ignition
transformer. Set burner accordingly. After operating 10 minutes to warm unit up, a smoke tester should be used to take a smoke reading in flue
pipe between boiler and draft regulator. Smoke should be zero (Shell Bacharach Scale). At times a new boiler requires more time than this to burn
clean due to oil film on a new heat exchanger. Check draft over the fire. This should be -0.01 to -0.02 in. wc as previously stated. Adjust draft
if necessary. Gradually close air shutter, and if necessary the air band, to obtain a smoke reading showing a trace of smoke. Measure CO
point. Increase air sufficiently to reduce CO
it will be necessary to verify head and electrode alignment. (See Fig. 16-20.) If fire is still smokey, replace nozzle with a correct replacement.
Record nozzle size, oil pressure, combustion readings and air settings then place a tag or label on boiler or burner with this information. Units
should be cycled several times to assure good operation with no fluttering or rumbling. Check for oil leaks.
PROCEDURE 7—OIL BURNER MAINTENANCE
The following preventative maintenance items should be performed annually, preferably prior to the heating season.
A. Oil Burner Motor
Add 2-3 drops of non-detergent electric motor oil to each oil cup located at front and rear of motor. Excessive oiling will shorten the life expectancy
of motor.
B. Fuel Filter
This should be replaced so as to prevent contaminated fuel from reaching the nozzle. A partially blocked fuel filter can cause premature failure
of fuel pump unit.

OPERATING BOILER

by 0.5 to 1 percent as an insurance margin. Smoke should be zero. If a clean fire cannot be obtained,
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at this
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