USERS` INFORMATION MANUAL
Contents
1. EE BOILER DESIGNED To LEAD USERS INFORMATION MANUAL GAS WATER BOILERS AWR CWI BWF CWD BWC 16 SERIES GAS STEAM BOILER BSI SERIES GAS WATER OR STEAM BOILER 32 SERIES TO THE BOILER OWNER READ THIS MANUAL IMMEDIATELY AFTER THIS BOILER IS PLACED IN SERVICE AND RETAIN IT FOR FUTURE REFERENCE WARNING If the information in this manual is not followed exactly a fire or ex plosion may result causing property damage personal injury or loss of life Do not store gasoline or other flammable va pors and liquids in the vicinity of this or any other appliance What to do if you smell gas Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier AVERTISSEMENT Assurez vous de bien suivre les instructions donn es dans cette notice pour r duire au minimum le risque d incendie ou d explosion ou pour viter tout dommage materiel toute blessure ou la Ne pas entreposer ni utiliser d essence ni d autres vapeurs ou liquides inflammables dans le voisinage de cet appareil ou de tout autre appareil QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ N2. LIGHTING INSTRUCTIONS BOILERS EQUIPPED WITH HONEYWELL VR8204 AND VR8304 SERIES GAS VALVES INTERMITTENT PILOT FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety informat
3. This switch has a reset button which must be pressed before the boiler can be restarted BWE CWD BWC Series boilers These boilers are equipped with a safety feature which will shut down the burners in the event that there is a blockage in the vent system In the event that the boiler fails to function and the boiler is vented through an outside wall accessible from the ground inspect the vent terminal on the outside wall for a blockage such as a bee s nest or ice If a blockage is found the burners should ignite approximately 30 seconds after the blockage is removed If no blockage is found or if the terminal is inaccessible from the ground the problem must be diagnosed and corrected by a qualified gas service technician Maintenance Safe reliable operation of this boiler depends upon proper periodic maintenance The following should be done on a continuous basis e Keep the area around the boiler free of objects which are flammable or which could obstruct the flow of air into and around the boiler e not store or use sources of hydrocarbons such as bleaches fabric softeners paints cleaners refrigerants and cat boxes near the boiler Traces of these chemicals can be drawn into the boiler causing severe corrosion damage to the boiler and or objectionable odors e Do not expose the boiler to large amounts of dust such as that generated by dry wall construction or woodworking 3 A qualified gas service technician should p
4. once a month a qualified gas service technician should inspect the system for leaks or defective vents Frequent additions of fresh water could result in severe damage to boiler Figure 3 Float Type Low Water Cut off 7 Auxilary Controls Many boilers are installed with equipment not supplied with the boiler but which is criti cal for safe reliable operation of the boiler Some examples of this type of equipment include Zone Controls Boiler Feed Pumps Draft Inducers and Power Venters Motorized Combustion Air Louvers Make sure that this equipment is maintained in accordance with its manufacturer s instructions Lighting Instructions Lighting instructions for all boilers appear on the following pages These instructions are listed by the model of the gas valve used The table below references the boiler model to the gas valve used and the page on which the appropri ate lighting instructions may be found Lighting Instructions on Boiler Model Ignition System Gas Valve Page AWRO38E AWR280E CWI103E CWI346E BSI069E BSI346E Honeywell VR8204 or BWFO69E BWF229E VR8304 CWD060 CWD245 Series 32 CWI 380E BSI 380E Robertshaw Series 16 7000DERHC Series 32 Honeywell VK8115 or BWC070 BWC425 Direct Spark 7 BWCOTOBWCAS Direct Spark Dungs GB WND MEA Gas valve numbers are to reference lighting instructions only Do not use this chart as a replacement parts list Intermittent Pilot
5. e pas tenter d allumer d appareils Ne touchez aucun interrupteur Ne pas vous servir des t l phones dans le b ti ment vous vous trouvez Appelez imm diatement votre fournisseur de gaz depuis un voisin Suivez les instructions du fournisseur Si vous ne pouvez rejoindre le fournisseur de gaz appelez le service des incendies L installation et l entretien doivent tre as surex par un installateur ou un service d entretien PN 980425 REV N DANGER THERE ARE NO USER SERVICABLE PARTS ON THIS BOILER ATTEMPTS TO SERVICE THIS BOILER BY SOMEONE OTHER THAN A QUALIFIED GAS SER VICE TECHNICIAN COULD VOID THE WARRANTY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE Do not use this boiler 1 any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance En cas de surchauffe ou si l admission de gaz ne peut tre coup e ne pas couper ni d brancher l alimentation lectrique de la pompe Fermer plutot le robinet d admission de gaz l ext rieur de l appareil This boiler may have parts containing refractory ceramic fibers RCF See the safety information on page 11 ifthis boi
6. e the boiler jacket door If any of the following are found a qualified gas ser vice technician should be consulted immediately Deterioration of the visible controls wiring and sheet metal components Heating system water Leaks Carbon soot in or near the burner compartment area BWC Boilers Only Make sure that the condensate drain system is unobstructed and leak tight 6 BSI Series and Steam Series 32 Boilers Only Steam boilers require the following maintenance e Some steam boilers are equipped with a float type low water cut off Figure 3 This control must be blown down on a weekly basis or more often if needed To do this follow the instructions on the label adjacent to the low water cut off e It will occasionally be necessary to add water to the boiler In most cases this will be true even if the boiler is equipped with an automatic water feeder most automatic water feeders maintain the water level at the minimum point required to assure boiler operation On a monthly basis turn the boiler off and wait at least 10 minutes for any water in the system to return to the boiler Add water to the boiler until the water level in the glass is approximately 6 about 3 4 of the way from the bottom of the glass CAUTION Failure to regularly blow down the float type low water cut off can result in severe damage to boiler If it is necessary to either manually or automatically add water to the boiler more than
7. erform the maintenance procedure shown in the installation manual on an annual basis 4 The owner should visually inspect the venting system on a monthly basis If any of the following condi tions are found the boiler should be shut down and a qualified gas service technician called to correct the problem before the boiler is placed back in service e Loose joints corrosion or other deterioration e Condensate leakage e Sags in horizontal runs of vent pipe CAUTION BWC BOILERS The BWC has a heat exchanger made from a special aluminum alloy which can be severely damaged by frequent addi tions of water or by the addition of boiler water additives which are not designed for use with aluminum boilers If it is nessasary to add water to the boiler have a service technican check the system for leaks Do not add any chemicals to the boiler not listed in the BWC installation manual Warranty is void if the service and maintenance procedure shown in the BWC installation manual is not followed WARNING Carbon soot in or near the burner compartment area is an indication of a potential carbon monoxide hazard If carbon is found the boiler should be shut down immediately and inspected by a qualified gas service technician The cause of the sooting should be found and corrected before the boiler is restarted 5 The owner should also perform a monthly visual inspection of the boiler and the surrounding system piping To do this remov
8. ermit the boiler to fire there is either a problem with the igntion system an occurrence of flame rollout or a problem with the vent system Call a qualified gas service technician to diagnose and correct the problem A tripped rollout switch must be replaced by an identical switch having the same temperature setting Figure 1 Flame Rollout Switch Figure 2 Blocked Vent Switch A shutdown of the burners due to the blocked vent switch is an indication that there is a problem with the vent system such as a blockage The blocked vent switch should only be reset after a qualified gas service technician has diagnosed and corrected the venting problem that caused the blocked vent switch to open 3 4 5 1 2 WARNING boilers except the CWD BWC and Series 32 boilers are equipped with a flame rollout switch Figure 1 This switch will shut the burners down in the event that flames exit the burner compartment through the front opening The CWD and BWC use an electronic means built into the ignition system to extinguish the burner s in the event that flames exit the combustion chamber If the boiler fails to fire call a qualified heating service agency to diagnose and correct the problem The AWR CWI BSI Series 16 and some Series 32 Boilers are equipped with a blocked vent shut off switch Figure 2 This switch will shut the boiler down in the event that there is an excessive block age in the vent system
9. follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition If you cannot reach your gas supplier call device which automatically lights the pilot the fire department Do not try to light the pilot by hand C Use only your hand to push in or turn the gas BEFORE LIGHTING smell all around the control knob Never use tools If the knob will appliance area for gas Be sure to smell next not push in or turn by hand don t try to repair it to the floor because some gas is heavier than call a qualified service technician Force or air and will settle on the floor attempted repair may result in a fire or explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been Do nottry to light any appliance under water Immediately call a qualified service Do not touch any electric switch do not technician to inspect the appliance and to use any phone in your building replace any part of the control system and any Immediately call your gas supplier from gas control which has been under water a neighbor s phone Follow the gas supplier s instructions OPERATING INSTRUCTIONS STOP Read the safety information above on Remove front access panel this label Set the thermostat to lowest setting Rotate the gas control knob clockwise to OFF 3 Turn off all electric power to the appliance Wai
10. hich automatically lights the burner Do not try to light the burner by hand Set the thermostat to the desired setting The first digit of the control display panel will show a series of numbers that indicate the boiler control sequence The number 3 or 4 means the Closed burner is firing The number 0 means there is no call for heat from the thermostat or the domestic water heater If the appliance will not operate follow the instructions To Turn Off Gas To Appliance below and call your service technician or gas supplier External Boiler Manual Gas Valve TO TURN OFF GAS TO THE APPLIANCE 1 Turn off all electric power to the appliance if 3 Turn the external boiler manual gas valve T service is to be performed handle clockwise to close the gas supply ON 2 Set the thermostat to the lowest setting Important Product Safety Information Refractory Ceramic Fiber Product Warning This boiler may include parts that contain refractory ceramic fibers RCF RCF has been classified as a possible human carcinogen When exposed to temperatures about 1805 F such as during direct flame contact RCF changes into crystalline silica a known carcinogen When disturbed as a result of servicing or repair these substances become airborne and if inhaled may be hazardous to your health AVOID Breathing Fiber Particulates and Dust Precautionary Measures Do not remove or replace RCF parts or attempt any service or
11. ion above on this label Set the thermostat to lowest setting 3 Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand GAS CONTROL KNOB SHOWN IN ON POSITION GAS INLET GAS OUTLET GAS VALVE TOP VIEW Remove front access panel Rotate the gas control knob clockwise to OFF Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you then smell gas STOP Follow B in the safety inform ation above on this label If you don t smell gas go to the next step Rotate the gas control knob counter clockwise x to ON Replace front access panel Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Push in gas control knob slightly and turn clockwise to OFF Do not Force LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH SHAW 7000DERHC SERIES GAS VALVES INTERMITTENT PILOT FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not
12. ler must be serviced or repaired CAUTION Like all central heating appliances this boiler is equipped with safety devices which could cause it to shutdown requiring service to restore normal operation Where such a shutdown could result in damage from low temperatures such as frozen pipes do not leave the heating system unattended during cold weather unless alarms or other safe guards are in place to prevent damage 1 This manual covers the proper care and use of the following boilers AWR Aruba IV series gas water boiler CWI Cayman series gas water boiler BWF Bali series fan assisted water boiler CWD Cabo2 series gas direct vent water boiler BWC Bimini series gas condensing direct vent water boiler BSI Bermuda series gas steam boiler Series 16 commercial gas hot water boiler Series 32 commercial gas hot water or steam boiler Most of the information in this manual applies to all of the above boilers Information that is unique to a par ticular series is clearly marked with the series to which it applies 2 Instructions to safely light and shut down this boiler are shown on pages 5 7 as well as on a label af fixed to the boiler WARNING In the event that the flame rollout switch opens the cause of the flame rollout must be diagnosed and cor rected by a qualified gas service technician before the boiler is restarted In the event that the ignition system on a CWD or BWC does not p
13. nt automatically lights the burner Do not try to light the burner by hand Use only your hand to turn the gas control knob Never use tools If the knob will not push in or turn by BEFORE OPERATING smell all around the hand don t try to repair it call a qualified service appliance area for gas Be sure to smell technician Force or attempted repair may result in a next to the floor because some gas is fire or explosion heavier than air and will settle on the floor Do not use this appliance if any part has been under WHAT TO DO IF YOU SMELL GAS water Immediately call a qualified service technician Do not try to light any appliance to inspect the appliance and to replace any part of the Do not touch any electric switch do control system and any gas control which has been not use any phone in your building under water e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions OPERATING INSTRUCTIONS STOP Read the safety information above on 5 Turn the external boiler manual gas valve T this label handle counterclockwise to open gas supply Set the thermostat to the lowest setting Smell for gas in the boiler enclosure If you smell gas STOP Follow B in the safety information above If Turn off all electric power to the appliance you don t smell gas go to the next step This appliance is equipped with an ignition Turn on all electric power to the appliance device w
14. repair work involving RCF without wearing the following protective gear A National Institute for Occupational Safety and Health NIOSH approved respirator Long sleeved loose fitting clothing Gloves Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada First Aid Procedures e f contact with eyes Flush with water for at least 15 minutes Seek immediate medical attention if irritation persists If contact with skin Wash affected area gently with soap and water Seek immediate medical attention if irritation persists If breathing difficulty develops Leave the area and move to a location with clean fresh air Seek immediate medical attention if breathing difficulties persist Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention THIS PAGE INTENTIONALLY LEFT BLANK THIS PAGE INTENTIONALLY LEFT BLANK veu BE OW CE ILER N Manufacturer of Hydronic Heating Products Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com
15. t five 5 minutes to clear out any gas Then smell for gas including near the floor If you then This appliance is equipped with an ignition smell gas STOP Follow in the safety inform device which automatically lights the pilot ation above on this label If you don t smell gas Do not try to light the pilot by hand go to the next step Rotate the gas control knob counter clockwise __ POSITION Kk to ON A INDICATOR Replace front access panel Turn on all electric power to the appliance LE m Set thermostat to desired setting If the appliance will not operate follow the instructions Turn Off Gas To Appliance and GAS CONTROL KNOB call your service technician or gas supplier SHOWN IN OFF POSITION TO TURN OFF GAS TO APPLIANCE 3 Push in gas control knob slightly and turn 1 Set the thermostat to lowest setting clockwise to OFF Do not Force 2 Turn off all electric power to the appliance if service is to be performed LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEY WELL VK8115 OR DUNGS GB WND SERIES GAS VALVES DIRECT SPARK FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is e If you cannot reach your gas supplier call the equipped with an ignition device which fire departme
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