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15
IV. GENERAL MAINTENANCE
These operations are recommended to be performed at regular
intervals:
A. CLEAN BOILER HEATING SURFACES THOROUGHLY, DOWN
TO CLEAN METAL.
1. 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.
2. Remove the flue pipe from the boiler flue collar and clean thor-
oughly.
3. Inspect the entire vent connector back to the chimney and clean
if necessary.
4. Inspect the chimney for soot, debris and other unsafe conditions
of the chimney and take the necessary action.
5. 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 collector. Try
not to disturb the flat fiberglass rope under the flue collector.
6. When necessary to clean the combustion chamber you must first
CLOSE the suction valve (and return valve if two pipe). Then dis-
connect 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 direction 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 14 mm (9/16")
drive socket. Open the door to completely expose the combus-
tion chamber for thorough cleaning and for inspection of target
wall, blanket (provided in certain models; see rating plate), main
cast iron burner door insulation and burner door fiberglass
sealing rope. If combustion chamber parts above are badly
deteriorated then replace with original factory parts available at
your distributor.
Thermostatic bypass valves type TV are designed to allow
boilers to reach their optimum operating temperature
quickly and to prevent cool/cold return temperatures from
affecting them.
Operation/Installation: The thermostat within the "TV" valve
allows full flow through the bypass until the predetermined
temperature is reached.
Start Up: With the balancing valve on the bypass fully
open, operate the boiler until it reaches its normal
operating temperature. If hot water does not automatically flow
to the system then adjust (throttle) the bypass
balancing valve until flow (hot water) to the system is
TYPICAL MOUNTING
SIZE
25 mm (1") NPT (female x female)
32 mm (1-1/4") NPT (female x female)
38 mm (1-1/2") NPT (female x female)
Max. operating pressure 6 bar (85 psi) Maximum operating temperature 110°C (230°F)
The flow factor Kv is the number of cubic meters per hour of water at 20°C which will flow through the valve with a pressure drop of 1kg/cm
The flow coefficient Cv is the flow of water at 60°F in US gallons per minute at a pressure drop of 1lb/in
APPENDIX A
THERMOSTATIC BYPASS VALVE
S/F PART NO.
OPEN TEMP .
116040
46 ºC
115 ºF
116041
46 ºC
115 ºF
116042
46 ºC
115 ºF
7. Use the flue brush to clean the pinned flueways between the sec-
tions.† A wire brush may be used to remove any carbon accumu-
lation that may have developed in the combustion chamber.
Vacuum the loose soot and debris from the boiler.
B. BOILER CONTROLS: check contacts, settings, correct
functioning.
C. PIPING: check piping and accessories for leaks.
D. CHIMNEY or STUB VENT and Breaching: check for obstructions,
corrosion 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, pages 4&5.
F. WATER SYSTEM: check
1.
System to be full of water and pressure to remain stable
(between 83 kPa and 173 kPa [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 10.
G. STEAM SYSTEM: check
1.
Low water cut-off, for operation (see instructions furnished
with unit). See page 10.
2.
Check pressure cut-off for operation. See page 11.
3.
Any unusual water conditions. Obtain water analysis and treat
water.
H. BOILER ROOM AIR SUPPLY: supply air openings should be open
and free of obstruction. See pages 4&5.
†
A flue brush (57 mm [2-1/4"] dia.) is supplied with boiler.
Replacements are available from dealer or hardware stores.
established. If flow is already to the system, no adjustment
is required.
Return Mounting: On the return "TV" allows full bypass until the
return temperature reaches 46 degrees Celsius (115 degrees
Fahrenheit). "TV" will begin opening while maintaining a 46
degrees Celsius (115 degrees Fahrenheit) minimum return
temperature. When return temperatures reach approximately 54
degrees Celsius (130 degrees Fahrenheit) most of the flow will
be through the system.
Mounting: "TV" can be installed in any position. An adjustable
balancing valve (or ball valve) must be installed on
the bypass.
TYPICAL RETURN VALVE MOUNTING
TO SYSTEM
FROM SYSTEM
A
A/2
107 mm 4.2"
53 mm 2.1"
114 mm 4.5"
57 mm 2.25"
119 mm 4.7"
60 mm 2. 35"
across the valve.
2
TR Series
BOILER
Kv
Cv
WEIGHT
8.96
10.5
1.5 kg
3.3 lb
13.99
16.4
2.0 kg
4.4 lb
17.23
2.4 kg
5.3 lb
20.2
(1 bar).
2
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