Start-Up & Checkout - Crown Boiler FWZ Series Installation Instructions Manual

Use the following procedure for initial start-up of the boiler:
• Never attempt to fill a hot empty boiler.
• Make sure that the area around the boiler is clear and free from combustible materials,
gasoline, and other flammable vapors and liquids.
• Safe reliable operation of this boiler requires that the burner be checked and adjusted by a
qualified oil serviceman using combustion test instruments.
• Failure to perform all of the checks outlined in the following procedure could result in
unreliable operation, damage to the boiler not covered under warranty, property damage, or
unsafe operation.
• All boilers equipped with burner swing door have a potential hazard which can cause severe
property damage, personal injury or loss of life if ignored. Before opening swing door, turn
off service switch to boiler to prevent accidental firing of burner outside the combustion
chamber. Be sure to tighten swing door fastener completely when service is completed. In
addition, the burner power cord will have to be disconnected from the receptacle in the front
jacket.
1) Ensure that the boiler and entire heating system are filled with water.
2) Check all new piping for leaks and purge all heating system piping of air. Clean heating system if system water is dirty.
3) Verify that the venting system is properly installed and free of obstructions prior to start-up of the boiler. Refer to Section
VII for more information.
4) Inspect all wiring for loose or uninsulated connections, proper size fuses installed, etc.
5) Verify that oil tank is filled with #2 fuel oil meeting ASTM D396 specifications, oil piping has been tested and is air
tight, and shutoff valve(s) are closed.
6) Check initial settings of oil burner air band and air shutter, head setting etc., and readjust if needed. See Table 11.1 for
setup and combustion data pertaining to a particular boiler/ burner combination.
7) Ensure that burner is tightly secured to the burner swing door creating an airtight seal.
8) Attach plastic hose to oil pump vent fitting and provide a container to catch oil during oil pump bleeding procedure.
9) Install 0-200 PSI pressure gauge into oil pump gauge port.
10) Open all oil line shutoff valves.
11) Adjust system thermostat to highest setting.
12) Turn the service switch to "ON" position.
13) Crack open vent fitting on the oil pump and allow burner to run until a solid oil stream, free of air bubbles, flows for
15 seconds into container. As the vent fitting is closed, the burner should fire and flame should be visible through
observation port immediately (or after prepurge timing has expired, if a burner is so equipped). Refer to burner
instructions for more details.
14) Immediately upon firing the boiler, check the smoke level. If the smoke level is in excess of a #1, open the air adjustment
to bring the smoke level below a #1.
15) Make sure that the oil pressure matches that shown in Table 11.1 for the burner supplied. Adjust pressure if required.
16) Check the vacuum at the inlet of the fuel pump. Make sure that the vacuum does not exceed the fuel pump
manufacturer's limit (consult the pump manufacturer's instructions).
17) Close the flame observation cover.
XI Start-up and Checkout
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