Ik
39006DP4-A 12/1/79
Residential
Indoor Gas-Fired
Boilers
-
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. Don’t touch electrical switches.
3. Extinguish any open flame.
4. Immediately call your gas supplier.
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
OPERATION
MAINTENANCE
SERVICE
Congratulations on your wise investment in a
modern, quality, gas-fired indoor boiler. Your boiler has
been designed and developed to provide safe, reliable, and
economic operation when properly installed and maintained.
Your boiler is a major investment for your home; therefore,
you will expect it to perform at its best. By reading this
manual, you can learn how to operate it, do recommended
routine maintenance, and what to do if a problem should
arise. Your new gas boiler should perform at the efficiency
level built into it if you will contribute a little of your time
and attention.
NOTE TO INSTALLER: This manual should be left with boiler owner.
Special Instructions to Equipment Owner
NOTE: Retain this manual for future reference.
Your boiler must have air for combustion and ventilation. Do
not enclose in an airtight room or enclosure.
W \IÍMN(. I) \N(.KIÌ: !.. minimize ilio po.-^'íibiliiy
of 'oritiU' jior.-ional injury, fire, tlamage loyour boiler,
or in’.pi'oper boiler oper.anon: never violate liie follou-
1. Always keep the area around your boiler free of
combustible materials, gasoline, and other flam
mable liquids and vapors.
Your Comfort System
Your efficient new gas boiler not only represents the very
latest in modern engineering development and design — it is
a result of over 70 years of experience in the home comfort in
dustry by the world’s leading manufacturer of residential
heating products.
The installation of your gas boiler was a major step toward
total home comfort and it will assure your family of reliable
comfort heat through the heating season. Additional steps
toward a total home comfort system may have been, or can be
taken. Ask your dealer for information about the options
available that will contribute to your total home comfort or
operating economy.
For your convenience, you or your installer should, or should
have, recorded (printed) the following information that is
applicable to your system.
2. Never cover, lean anything against, store trash, or
stand on your boiler.
W \li\l\ii. I mproper inhU'illalion. adju.<irnetii. alI oration, .-!er\ tee. maintenance, or use can cause carbon
motioxide poi.'Oning. e.\.plosiiin. fire, elect rii-al shock,
or other occurrences which may injure \ou or datiiago
your properly. Consult a (lualified in.slaller, service
agency, or the gas supiilier for information or
Boiler Identification
MODERNO.
PRODUCT NO.
SERIAL NO. _
DATE INSTALLED
_______
Dealer
NAME
_________
ADDRESS
CITY
____
PHONE
STATE
.ZIP.
Operating Your Gas Boiler
The key to operating your comfort system is the room
thermostat. A wide variety of thermostats can be used, but all
have one main function — to automatically maintain the
temperature in your home at a level -required for your
personal comfort. The thermostat maintains the indoor
temperature by controlling the operation of the boiler. Dur
Boiler Startup and Shutdown
Your boiler is equipped with one of the three following basic
types of gas control systems:
1. The automatic intermittent ignition system that does not
have a continuously burning pilot flame. This pilot is auto
matically lit by an electric sparking device each time your
thermostat “calls for heat.”
WARNING: Never auemiu to manually liglit the pilot
on a boiler thaï ha.-^ an iniermillent ignition sy.siem
w ith a match or other .'Ource of fharue.
2. The manual ignition system that has a continuously burn
ing pilot flame. This pilot is manually ignited with a
match and continues to burn.
ing the heating season whenever the air temperature around
your thermostat drops below the thermostat temperature
setting, the thermostat automatically starts your boiler.
All thermostats have a temperature control selector for
selecting the desired indoor temperature.
3. The self-generating system has a continuously burning
pilot flame. This pilot is manually ignited with a match
and continues to burn. The powerpile thermocouple
transforms the heat energy of the pilot flame into
electrical energy that operates the controls. No external
power is needed on this system to operate the controls.
WARNING: Read anti follow the lighting iiistrucl ion,'
on ill«' boiler r.ating plate.
WARNING: If a su<pected malfunction occur' with
either t,v[ie of gas control system, or if an intermittent
ignition jiilot docs not light when it should, refer to the
follow ing shutdown jirocedures to turn off your ^ystenl,
then call your liealer as soon as imssible.
Shutting Down Your Boiler
You will be required to, or will want to, turn off your boiler
system for one of two reasons: a suspected malfunction has
occurred or the heating season has ended.
To shut down a boiler that has an auto
matic intermittent ignition system.
1
To shut down a boiler that has a self
generating system with continuously
burning pilot.
step 1
Step 1— Set your room thermostat to the lowest tempera
ture setting.
Step 2— Turn OFF the electrical power to your boiler.
Step 3— Remove the control access door on your boiler (if
applicable). See Figure 3.
Step 4
Step 4— Turn the control dial on the gas valve to the OFF
position.
Step 5— Replace the control access door (if applicable).
Step 6— If the boiler is being shut down because of a mal
function, call your dealer as soon as possible.
Step 2
To shut down a boiler that has a manual
ignition system with continuously burning
pilot.
Step 1— Set your room thermostat to the lowest tempera
ture setting.
Step 2— To shut off the main burners but keep the pilot
light burning, turn the control dial to the PILOT
position only.
Step 3— To shut off the complete gas control system (pilot
and main burners), depress the control dial on the
gas valve and turn it to the OFF position.
Step 4— If the boiler is being shut down because of a mal
function, call your dealer as soon as possible.
Starting Your Boiler
The general procedures for starting all gas-fired boilers are
similar, however, there are some basic differences depend
ing on whether your boiler has automatic or manual pilot
ignition. Refer to whichever of the two starting procedures
that follow which applies to your boiler.
WARNING: Hefore attempting to start any boile,r,
familiarize yourself with all of the procedures that
mu.st be followed.
Starting a boiler that has an automatic
intermittent ignition pilot.
After you have familiarized yourself with the procedures
that must be followed, and all of the applicable warnings and
cautions that appear in the “Boiler Startup and Shutdown”
section of this manual, proceed as follows to start your auto
matic intermittent ignition boiler.
step 1
Step 1—
Step 2—
Step 3—
Step 4—
Step 5— To shut off the complete gas control system (pilot
Step 6— Replace the control access door (if applicable).
Step 7— If the boiler is being shut down because of a mal
Set your room thermostat to the lowest tempera
ture setting.
Turn OFF the electrical supply to your boiler
(if applicable).
Remove the boiler control access door (if appli
cable). See Figure 3.
To shut off the main burners but keep the pilot
light burning, turn the control dial to the PILOT
position.
and main burners)jdepress the control dial on the
gas valve and turn it to the OFF position.
function, call your dealer as soon as possible.
\
k.
Step 1
Step 1— Set your room thermostat to the lowest tempera
ture setting.
Step 2— Turn OFF the electrical supply to your boiler.
Step 3— Remove the boiler control access door (if appli
cable). See Figure 3
Step 4— Turn the control dial on the gas valve to the OFF
position and wait 5 minutes.
Step 5— After waiting 5 minutes, turn the control dial on
the gas valve to the ON position.
Step 6— Turn on the electrical supply to the boiler.
Step 2
step 5
Step 6
Pressure Limit
Control
Low-Water
Cutoff
Drain Cock
Combination Gas Valve,
Regulator, and Shut-off Cock
Pressure Gauge
Sight Glass
Figure 1 - Model 234C & D
Gas-Fired Steam Boiler
Temperature
Altitude Gauge
Figure 3
Optional Control Enclosure
step 8 Step 9
Step 7— Replace the control access door (if applicable).
Step 8— Set the room thermostat temperature selector
slightly above room temperature to start your
boiler.
Step 9— The pilot ignition system now begins sparking and
the pilot flame lights. After a 40- to 70-second timedelay that takes place while the system is auto
matically verifying that a pilot flame has been es
tablished, the gas valve opens, permitting gas to
flow to the main burners, and the pilot lights the
burners. Now set the temperature selector on your
room thermostat to your personal comfort setting.
\VAIl\I.\(r: If tlie uiloi faiN lo light, or the rnmn
burners fail In light, 'hut nownyour linile>‘iSeo iirneedures in this section, i .nticl call \'our ilt'.ale'’ for service.
Starting a boiler that has a manual pilot
ignition
Step 5
Step 5— After waiting 5 minutes, turn the control dial on
the gas valve to PILOT position.
Step 6— Place a lighted match or other suitable source of
flame near the top of the pilot, depress the con
trol dial on the gas valve, and hold it down. Pilot
will light. Continue to hold dial down for at least
60 seconds. Release the control dial. The pilot will
remain lit.
NOTE: if the pilot flame does not remain lit, repeat steps 1
through 5; however, hold control dial down for a longer
period of time (at least 90 seconds). If the pilot flame does not
remain lit after this second attempt, the thermocouple
should be checked for a possible malfunction. Call your
dealer for service.
After you have familiarized yourself with the procedures
that must be followed, and all the applicable warnings and
cautions that appear in the “Boiler Startup and Shutdown”
section of this manual, proceed as follows to start your
manual-ignition-type boiler.
\
Step 1 Step 2
Step 1-
Set your room thermostat to the lowest tempera
ture setting.
Step 2— Turn OFF the electrical supply to your boiler
(if applicable).
Step 3
Step 3—
Remove the boiler control access door (if appli
cable). See Figure 3.
Step 4—
Depress the control dial on the gas valve and
turn the control dial to the OFF position. Wait
5 minutes.
Step 9
Step 7 — After a pilot flame has been established, turn the
control dial on the gas valve to the ON position.
Step 8— Replace the boiler control access door (if
applicable).
Step 9— Restore power to your boiler (if applicable).
Step 10 Step 11
Step 10-
Set the room thermostat temperature selector
slightly above room temperature to start your
boiler.
Step 11—
Boiler main burners should light shortly after
your room thermostat is set to “call for heat.”
Now set the temperature selector on your room
thermostat to your personal comfort setting.
W.MJNINC: If ihc main burners fail lo lighi, >niil
down your boiler ami call yoiii' dealer for .-ierviee.
NOTE: To conserve energy when the heating season has
ended, you should shut down your manually ignited pilot.
Follow the procedures in “Shutting Down Your Boiler” at
the beginning of this section.
Maintenance by Qualified Service Personnel
At least once every year, your boiler should be inspected by a
trained and equipped service person. During this inspection,
the qualified service person should at least:
1. Inspect, clean, and lubricate pump motor as required on a
PW Boiler.
2. Inspect all flue product passages including the burners,
pilot, heat exchanger drafthood, vent pipe, and vent
damper (if installed).
3. Inspect all combustion and ventilation air passages and
openings.
4. Inspect electrical wiring, connections, and components
for loose connections.
5. Check gas pipes leading to, and inside of, your boiler for
leaks.
6. Readjust the air/gas mixture if the burner flames are not
bright blue.
7. Perform an operational checkout to determine whether
your boiler is working properly, and if it requires
adjustments.
8. Check all safety controls such as safety pilot, limit switch,
pressure relief valve, etc. for proper operation.
9. Blow down low-water cutoff and check it for proper
operation.
Maintenance and Care for the Equipment Owner
Before covering those things you may want to maintain your
self; please carefully consider the following:
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sKi:\ u'i\t. <<i: m i\i m \i\ i i-a’ i;
WARNING: When performing rnainlenancc func
tions insiile vour boiler, be aware of sharp sheet metal
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T" \ MiMMi M. m. K\’imAii;iA i.
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Combustion Area and Vent System
The combustion area and vent system should be visually
inspected before each heating season. The normal
accumulation of dirt, soot, and rust can result in loss of
efficiency and improper performance if allowed to build up.
Accumulations on the main burners can result in the burners
firing out of normal time sequence which is characterized by
an extra loud ignition that can be quite alarming.
CAUTION: If your boiler makes an especially loud
noise when the main burners are ignited by the pilot,
shut off your boiler and call your flealer.
Using a flashlight, proceed as follows to visually inspect the
combustion area and vent system of your boiler.
1. Turn OFF the electrical supply to your boiler and remove
the control access door (if applicable). Turn OFF gas on
self-generating system.
2. Carefully inspect the control compartment main burners,
and pilot areas for dirt, soot, or rust. Then, inspect the
drafthood, flue connection area, and flue pipe for soot and
rust.
i’AT.iTION: If dirt. soul, or rust accumulations arc
found, (.all your dealer and if possible, do not operate
3. Inspect the flue pipe for sag, holes, or disconnection.
WARNING: if holes are found in the flue pipe or if it
has become disconnected, call your dealer before opér
ât ing your boiler to prevent toxic fume.s from escaping
into your home.
4. Replace the control access door and restore electrical
power to your boiler (if applicable).
5. Start your boiler and observe its operation. If possible,
observe the burner flames to see if they are bright blue. If
you observe_a-suspected malfunction, or that the burner
flames are not bright blue, call your dealer.
NOTE: Burner flames that have a mixture of yellow, orange,
or red flames together with the blue, are not burning gas
efficiently. Your dealer will have to adjust the air/gas
mixture and/or clean the burners.
Before Calling’ for Service
If your boiler does not appear to be performing properly, or
does not operate at all, it may save you the cost of an un
scheduled service call if you check a few things yourself
before calling for service.
Boiler Fails to Operate
Sometimes a boiler will stop operating because an actual
malfunction occurred; however, it is common for a boiler to
appear to have stopped operating because an easily remedied
situation has taken place.
If your boiler fails to operate, follow these step-by-step pro
cedures, and proceed only to the next step if theboiler fails to
start:
1. Check to be sure that your room thermostat temperature
selector is set above room temperature.
2. Check to be sure that the electrical power supply to your
boiler is ON.
3. Check to be sure that the manual shut-off valve in the gas
supply pipe leading to your boiler is in the open position.
The valve is open if the lever points in the same direction
the pipe runs, and it is closed if the lever is at a right angle
to the pipe. If the valve is closed, open it, and then follow
the startup procedures on your boiler rating plate.
NOTE: Before proceeding, turn off the electrical power
supply to your boiler and remove the control access door.
4. If you have a manually ignited continuous burning pilot,
be sure that it is burning. If not, see the startup pro
cedures in this manual. If it is burning, check the control
dial on the gas valve. If the dial is in the PILOT position,
turn it to the ON position, and follow the startup pro
cedures in this manual.
5. If you have an intermittent ignition pilot, check the con
trol dial on the gas valve to be sure that it is in the ON
position. If not, follow the startup procedures in this
manual.
6. If your boiler still fails to operate, call your dealer for
service.
When Calling for Service
The product, model, and serial numbers for your boiler, to
gether with the date installed, should have been, or should
be, recorded in the space provi(ied at the front of this manual.
If the dealer knows exactly what you have, he may be able to
offer some suggestions over the phone to remedy the
problem. This could save you a needless expense and the
dealer a needless visit.
NOTE: If you do not already have a dealer, refer to your
telephone directory or yellow pages for the nearest dealer for
your brand name boiler.
COPYRIGHT © 1979
BDP Company
Division of Carrier Corp.
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