Service And Maintenance - Crown Boiler CWD060 Installation Instructions Manual

• THE BOILER CONTAINS REFRACTORY CERAMIC FIBER, A POSSIBLE HUMAN
CARCINOGEN. USE A NIOSH APPROVED RESPIRATOR WHEN SERVICING
HIGH-TEMPERATURE INSULATION AND GASKET MATERIALS. WASH EXPOSED
SKIN GENTLY WITH SOAP AND WATER AFTER CONTACT. WASH EXPOSED
CLOTHING SEPERATE FROM NORMAL LAUNDRY.
• LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.
WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.
VERIFY PROPER OPERATION AFTER SERVICING.
• FAILURE TO MAINTAIN THE BOILER IN PROPER WORKING CONDITION MAY
LEAD TO FIRE, EXPLOSION, PERSONAL INJURY OR DEATH AND EXTENSIVE
PROPERTY DAMAGE.
• TURN OFF ALL GAS AND ELECTRIC POWER SUPPLIES TO THE BOILER BEFORE
SERVICING. CONTACT WITH OR RELEASE OF DANGEROUS FLAMMABLE
GAS, ELECTRICAL VOLTAGE, MOVING PARTS AND VERY HOT WATER UNDER
PRESSURE MAY CAUSE SERIOUS PERSONAL INJURY, PROPERTY DAMAGE OR
DEATH.
• LOCK ELECTRICAL BOXES AND GAS VALVES CLOSED TO PREVENT SOMEONE
FROM INADVERTENTLY RESTORING POWER OF GAS BEFORE THE HEATING
SYSTEM IS SAFE TO OPERATE.
• WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR
OTHER SYSTEM COMPONENTS. REPAIR ANY LEAKS FOUND IMMEDIATELY.
The following routine maintenance should be performed on an annual basis:
1) Turn off electrical power and gas supply to the boiler.
2) Remove the burner tray. To do this:
a) Remove the intake cover.
b) Remove the four Allen head screws holding the elbow flange onto the gas valve.
c) Remove the three 10-32 screws holding the manifold gasket plate to the intake box.
d) Remove the four 5-16 nuts holding the burner tray in the boiler.
f) Carefully remove the burner assembly being careful not to damage the firedoor insulation or the manifold gasket.
3) Inspect the flue passages for signs of blockage. If there is any carbon in the combustion chamber or the flue passages, clean
the heat exchanger before proceeding further. See the cleaning procedure below.
4) Remove any debris found in the combustion chamber, being careful not to disturb combustion chamber insulation.
5) Inspect and clean the burners. Clean the burners by first brushing the ports with a soft bristle brush and then vacuuming out
any debris through the venturi opening. If burners show signs of deterioration, they should be replaced (some discoloration
around the burner ports is normal).
6) Inspect the pilot assembly. Clean any deposits found on the electrode and grounding strap. The ideal gap between the
electrode and the ground strap is 1/8". Inspect the porcelain for cracks or other deterioration. Replace pilot assembly if
deterioration is found. Inspect the ignition cable insulation for cracks or other deterioration. If deterioration is found,
replace cable assembly.
7) Inspect the combustion chamber insulation for deterioration. Replace insulation if necessary.
8) Inspect all boiler wiring for loose connections or deterioration.
XII Service and Maintenance
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