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XII Service and Maintenance
On a continuous basis:
1) Keep the area around the boiler free and clear from combustible materials, gasoline, and other flammable vapors and
liquids.
2) Keep the area around the boiler and boiler room ventilation openings clear of objects which might obstruct the flow of
combustion and ventilation air.
On at least a weekly basis:
For boilers equipped with a #67 low water cut-off, blow down the low water cut-off following the instructions on the yellow
sticker adjacent to the low water cut-off. During this blow down, the low water cutoff should shut down the burners. If it does
not the low water cut-off should be replaced immediately.
On an annual basis:
1) Turn off electrical power and gas supply to the boiler
2) 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.
3) Remove any debris found in the combustion chamber, being careful not to disturb combustion chamber insulation.
4) Remove all burners, noting the location of the pilot main burner. If burners show signs of deterioration, they should be
replaced (some discoloration around the burner ports is normal). Clean the burners by first brushing the ports with a soft
bristle brush and then vacuuming out any debris through the venturi opening.
5) Inspect the pilot assembly:
•Standing Pilots - Check the thermocouple for deterioration (some discoloration of the thermocouple is normal). If any
deterioration is present, replace the thermocouple. Inspect the pilot assembly for deposits and deterioration. Clean or
replace the pilot assembly as necessary.
•Intermittent Pilots - 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.
6) Inspect the combustion chamber insulation for deterioration.
7) (Intermittent Pilot Boilers) - Inspect the ignition cable insulation for cracks or other deterioration. If deterioration is found,
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE
IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING
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NOTE
When substantial amount of make-up water is used due to lost condensate, or when make-up water is hard or corrosive,
water treatment is required. Contact qualified water treatment company for recommended water treatment compounds
and procedures.
e) Turn off gas supply to boiler per the appropriate Lighting and Operating instructions on pages 25 - 28. Drain hot
water from boiler through boiler drain valve to a location where hot water can be safely discharged. Refill the boiler
to normal water line level. If water in the gauge glass does not look clear, repeat above boil-out procedure again until
water is clears.
f) Reinstall safety valve and related piping.
g) Conduct pH and Alkalinity test of water in the system. The pH reading should be in 7 to 11 range.