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MAINTENANCE
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)
CAUTION
The following annual inspection must be performed
by a qualified service technician.
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".
DANGER
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.
CAUTION
The convenience outlet is powered even when the
service switch is off.
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6. Remove the top/front jacket panel and inspect for
any foreign debris that may have entered through air
intake vent.
7. Remove burner plate for inspection of burner and
coils. Refer to paragraph 11.E.1 for removal
procedure.
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.
2. Before re-starting the boiler follow the steps below:
a. Reconnect the thermostat wires.
b. Open the manual gas shutoff valve and reset the
thermostats.
c. Observe the boiler function to make sure you see
a condensate flow.
d. If you do not observe a condensate flow, repeat
the above procedure.
3. If the problem is not corrected at this point, it is possible
that there is a material deposit problem. Follow the Coil
Cleaning Instructions (Subsection 9E) below to dissolve
deposits and clean the heat exchanger.
WARNING
It is extremely important to make sure there is no
blockage in the exhaust vent. Failure to do so may
result in serious personal injury or death.
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