Start-Up & Checkout - Crown Boiler KSB 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 service technician 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, unplug the burner disconnect located inside the junction box on the front of the
boiler any time the burner door is opened.
1) Ensure that the boiler is filled to the normal water level.
2) Verify that the vent system is complete and free of obstructions prior to start-up of the boiler.
3) Inspect all wiring for loose or uninsulated connections, proper size fuses installed, etc.
4) Verify that oil tank is filled with #2 fuel oil meeting ASTM D396 specifications, oil piping has been tested and is air tight,
and shut-off valve(s) are closed.
5) Check initial settings of oil burner air band and air shutter, head setting etc. and readjust if needed. See Table 12.0 for setup
and combustion data pertaining to a particular boiler/ burner combination.
6) Attach plastic hose to oil pump vent fitting and provide a container to catch oil during oil pump bleeding procedure.
7) Install 0-200 PSI pressure gauge into oil pump gauge port.
8) Open all oil line shut-off valves.
9) Open flame observation port cover on burner swing door to see flame.
10) Adjust system thermostat to highest setting.
11) Set pressure limit control to suit individual requirements of the installation. For most steam systems, the cut-in pressure
should be set at 0.5 psi with a 1 psi differential.
12) Turn the line 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 12.0 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.
18) After chimney has warmed-up to operating temperature, adjust barometric draft regulator for a draft of -0.02 inch w. c.
over the fire.
19) Check the CO and confirm that it is between the minimum and maximum limits shown in Table 12.0 (also see NOTICE
2
on page 34). Adjust if necessary.
XII Start-up and Checkout
WARNI NG
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