CARE AND MAINTENANCE
I.EXTENDED SHUTDOWN, CLEANING OR REMOVAL OF BOILER FROM SERVICE.
DANGER: Use CAUTION when handling chemicals and draining hot water from a boiler. Scalding water and/or chemicals can cause per- manent injury to the skin, eyes and respiratory system.
A.Shut down burner by disconnecting all electrical power to the burner by turning OFF the BURNER EMERGENCY SWITCH of this boiler. After shutting down burner, while the boiler is still hot (180°F to 200°F), drain water from the bottom of the boiler until it runs clear.
B.Provide corrosion protection conditioning to the boiler water in the heating system. There are a number of commercial heating sys- tem preparations available from your distributor. Follow the prepa- ration manufacturer’s instructions.
1.For steam boilers, maintain a sodium chromate solution strength of 16 oz. per 50 gallons of water; and refill to the top of the gauge glass.
2.For water boilers, maintain a sodium chromate solution strength of 6 oz. per 50 gallons of water, and refill to normal fill-pressure with system vented.
3.Raise water temperature to at least 180°F. for one hour to release dissolved gases.
4.Shut down burner by disconnecting the main switch.
C.To clean the fireside boiler surfaces, first shut down burner by dis- connecting all electrical power to the burner by turning OFF the OIL BURNER EMERGENCY SWITCH of this boiler in order to perform the following work in (1) through (10) below.
1.Remove the flue pipe from the boiler flue collar and clean thoroughly.
2.Inspect the entire vent connector back to the chimney and clean if necessary.
3.Inspect the chimney for soot, debris and other unsafe condi- tions of the chimney and take the necessary action.
4.Remove the flue collector by first removing the top jacket panel. The flue collector is held in place by two hex 1/4-20 screws. Remove the screws and carefully remove the flue col- lector. Try not to disturb the flat fiberglass rope under the flue collector.
5.When necessary to clean the combustion chamber you must first CLOSE the suction valve (and return valve if two pipe). Then disconnect the oil lines from the burner. The flexible electric conduit connected from the junction box on the boiler to the burner via a plastic connector must be disconnected from the burner by grasping the plastic half of the connector closest to the flexible conduit and gently pulling it in the direc- tion of the conduit until it is disconnected. Remove the single 3/8-16 hex head screw on the LEFT side of the swinging door. You will need a 9/16” drive socket. Open the door to complete- ly expose the combustion chamber for thorough cleaning and for inspection of target wall, blanket (provided in certain mod- els; see rating plate), main cast iron burner door insulation and burner door fiberglass sealing rope. If combustion cham- ber parts above are badly deteriorated then replace with origi- nal factory parts available at your distributor.
6.Use the flue brush to clean the pinned flueways between the sections.† A wire brush may be used to remove any carbon accumulation that may have developed in the combustion chamber. Vacuum the loose soot and debris from the boiler.
7.Inspect the burner combustion head. Clean if necessary and make sure all the adjustments are correct. (See burner data pages for the burner installed.) Replace oil nozzle with new one and readjust electrodes. To insure proper burner opera- tion ONLY THE NOZZLES SPECIFIED IN THIS MANUAL OR ON THE BURNER LABEL SHOULD BE USED FOR REPLACEMENT.
8.Close main cast iron burner door (door on which burner is mounted). Make sure that the entire seal (fiberglass rope) is making good contact with the boiler casting when replacing 3/8-16 x 1” long hex head bolt and tightening.
9.Check the flue collector seal. This is the flat rope seal on top of the heat exchanger. The rope must be in place adjacent to the long boss- es on front and rear sections and adjacent to the short bosses on the intermediate sections. The rope should be directly under the flue col- lector flanges when the flue collector is replaced. Use the two 1/4-20 x 3/4” washer hex head screws to fasten the flue collector. In order to assure a proper seal be sure that the flue collector is compressing the flat rope and not hanging up on the section bosses. Tighten the two screws.
D. If boiler room is damp, provide ventilation.
II.PROVIDING PROTECTION FOR FREEZING
Anti-freeze is sometimes used in hydronic heating systems to pro- tect against freeze-up in the event of power failure, or safety control shutdown when the building is unoccupied. It should be recognized that unless the building is kept above freezing temperature by some means, the plumbing system is not protected.
PROPYLENE GLYCOL is used in the quick-freeze food industry; it is practically non-toxic. Its use may be permitted when tankless heaters are used. When anti-freeze must be used, inhibited propylene glycol is recommended. Useful information on the characteristics, mixing proportions, etc. of glycol in heating systems is given in Technical Topics No. 2A, available from the Hydronics Institute, 35 Russo Place, Berkeley Heights, N.J. 07922. Consult glycol manufacturers for sources of propylene glycol. DO NOT use ethylene glycol because it is toxic.
III.OIL BURNER
Inspect and clean annually and following any period of improper operation. Recheck and adjust settings as specified for burner model and nozzle size. Set burner air and draft regulator, using test instru-
ments to obtain recommended CO2 and draft without smoke. Refer to page 8.
IV. GENERAL MAINTENANCE
These operations are recommended to be performed at regular intervals:
A. BOILER HEATING SURFACES: clean off all coatings found. Reseal covers.
B. BOILER CONTROLS: check contacts, settings, correct functioning.
C. PIPING: check piping and accessories for leaks.
D. CHIMNEY or STUB VENT and BREECHING: check for obstruc- tions and leaks.
E. COMBUSTION AIR TO BURNER: check for continued POSITIVE supply of air as required. Air needs are greatest in coldest weather. Refer to AIR SUPPLY, page 3.
F.WATER SYSTEM: check
1.System to be full of water and pressure to remain stable (between 12 psi and 25 psi).
2.Air-control system: noise and air binding in radiation should not occur.
3.Water lines: slightest leaks should be corrected.
4.Low water cut-off, for operation (see instructions furnished with unit). See page 9.
G.STEAM SYSTEM: check
1.Low water cut-off, for operation (see instructions furnished with unit). See page 9.
2.Check pressure cut-off for operation. See page 10.
3.Any unusual water conditions. Obtain water analysis and treat water.
H.BOILER ROOM AIR SUPPLY: air vents should be open and free of obstruction. See page 3.
†A flue brush (2-1/4" dia.) is supplied with boiler. Replacements are available from dealer or hardware stores.
