Install Instructions

65
MAINTENANCE
A. GENERAL (WITH BOILER IN USE)
General boiler observation can be performed by the
owner. If any potential problems are found, a qualified
installer or service technician/agency must be notified.
1. Remove any combustible materials, gasoline and
other flammable liquids and substances that generate
flammable vapors from the area where the boiler is
contained.
2. Observe general boiler conditions (unusual noises,
vibrations, etc.)
3. Observe operating temperature and pressure on the
combination gauge located in the supply piping on the
left side of the boiler. Boiler pressure should never be
higher than 5 psi below the rating shown on the safety
relief valve (25 psig maximum for a 30 psig rating).
Boiler temperature should never be higher than 240° F.
4. Check for water leaks in boiler and system piping.
5. Smell around the appliance area for gas. If you smell
gas, follow the procedure listed in the Lighting
Operating Instructions to shut down appliance in
Section 9, Start-Up Procedure Part B.
B. WEEKLY (WITH BOILER IN USE)
Flush float-type low-water cut-off (if used) to remove
sediment from the float bowl as stated in the
manufacturer’s instructions.
C. ANNUALLY (BEFORE START OF
HEATING SEASON)
1. Check boiler room floor drains for proper functioning.
2. Check function of the safety relief valve by
performing the following test:
a. Check valve piping to determine that it is
properly installed and supported.
b. Check boiler operating temperature and pressure.
c. Lift the try lever on the safety relief valve to the
full open position and hold it for at least five
seconds or until clean water is discharged.
d. Release the try lever and allow the valve to close.
If the valve leaks, operate the lever two or three
times to clear the valve seat of foreign matter. It
may take some time to determine if the valve has
shut completely.
e. If the valve continues to leak, it must be replaced
before the boiler is returned to operation.
f. Check that operating pressure and temperature
have returned to normal.
g. Check again to confirm that valve has closed
completely and is not leaking.
3. Test low-water cut-off (if used) as described by the
manufacturer.
4. Test limit as described in Section 9, Part D,
“Check Operation”.
5. Test function of ignition system safety shut-off
features as described in Section 9, Part D,
“Check Operation”.
6. Remove the top/front jacket panel and inspect for
any foreign debris that may have entered through air
intake vent.
7. Inspect burner for deterioration. Replace if necessary.
8. With boiler in operation check that condensate is
dripping from condensate tubing. Check for any
restriction in condensate drain line.
D. CONDENSATE CLEANING
INSTRUCTIONS
1. Removal of Condensate Tanks.
a. Close manual gas shutoff valve on top of boiler
and turn off power to the boiler by placing the
boiler service switch to the off position.
b. Remove the front jacket panel.
c. Remove the wing nut securing the front tank and
disconnect the tank from the upper right drain
hose. (Some condensate may spill out of this port).
d. Remove the cap from the tank and position a
container in front of the boiler and tilt the tank to
drain condensate into the container.
e. Tank and lower hose may be by removed by
disconnecting the lower hose from the rear tank.
f. Clean tank and hose with water and inspect the rear
tank for sediment in the lower connection port. The
rear tank can be removed for cleaning if required by
removing the wing nut and disconnecting the two
float switch wire leads. NOTE: Special care must be
taken when removing the hoses from the top of the
rear tank. They must be held secure and do not pull
hoses downward and away from their upper
connections to the heat exchanger and vent adapter.
g. After cleaning, replace tanks and reconnect hoses
and wire leads to float switch. Fill the front tank
with water and check for any leaks at connections.
h. Replace the front jacket panel, open the manual
gas valve and place the boiler service switch to
the on position.
The following annual inspection must be performed
by a qualified service technician.
CAUTION
When servicing or replacing components, be absolutely
certain that the following conditions are met:
• Water, gas and electricity are off.
• The boiler is at room temperature.
• There is no pressure in the boiler.
DANGER
The convenience outlet is powered even when the
service switch is off.
CAUTION