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Page 38
CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Heat Exchanger Cleaning
The burners should be removed to protect them from
falling rust and scale. Follow the BURNER REMOVAL
instructions in this manual.
1. Remove the front grill(s) and front access panel(s).
2. Remove the clean out covers and insulation, Figure
45 & 46.
3. Clean each flue passage with a wire brush.
4. Vacuum out the burner base and clean and inspect
all of the components. Replace any damaged or badly
corroded parts.
5. Replace the insulation and clean out covers,
6. Replace the front access panel.
7. Install the burners following the BURNER
INSTALLATION procedure outlined in this section.
8. Replace the front grill(s).
Vent System
Thoroughly inspect the vent system for any signs of
blockage, corrosion or leakage. Immediately replace any
unsound vent system piping.
Controls
Use the BOILER OPERATION and BOILER CHECKING
AND ADJUSTMENT sections of this manual for
reference.
1. Check the thermostat or operating controls for
proper operation.
2. A float type low water cutoff device must be flushed
out.
3. The relief valve should vent water when the test lever
is lifted. It should not weep or discharge water at normal
system pressure. NEVER try to clean or repair the relief
valve! If the valve fails to operate properly, replace it!
4. The aquastat high limit controls the maximum water
temperature in the boiler. It is adjustable from 140°F
(60°C) to 240°F (116°C). If the water temperature
reaches the set temperature before the demand for heat
has been met, the aquastat high limit should shut the
boiler off. The water temperature should never exceed
the maximum set point of 240°F (60°C). The aquastat
high limit cannot be repaired. If it fails to function properly
replace it.
5. Visually check the pilot and main burner flames to
ensure proper operation, see Figure 82 & 83.
WARNING: Yellow, floating flames indicate a lack
of combustion air. Do not operate the boiler until
the problem is solved or severe personal injury
or death may occur!
Figure 83
NORMAL
(HARD FLAME)
YELLOW TIPPING
(MARGINAL)
Main Burner Flames
LIFTING
(TOO MUCH AIR)
YELLOW FLAME
(TOO LITTLE AIR)
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