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22
CARE AND MAINTENANCE
CAUTION: DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS
OIL HAS ACCUMULATED, WHEN THE UNIT IS FULL OF VAPOR, OR
WHEN THE COMPBUSTION CHAMBER IS VERY HOT.
CAUTION: DO NOT TAMPER WITH THE UNIT OR CONTROLS –CALL
YOUR SERVICE PERSONNEL.
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 perma-
nent 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 system
preparations available from your distributor. Follow the preparation
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 the burner by disconnecting the main switch.
C. To clean the fireside boiler surfaces, first shut down burner by discon-
necting 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 thor-
oughly.
2.
Inspect the entire vent connector back to the chimney and clean
if necessary.
3.
Inspect the chimney for soot, debris and other unsafe conditions
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 collector. 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 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 grasp-
ing the plastic half of the connector closest to the flexible conduit
and gently pulling it in the direction of the conduit until it is discon-
nected. 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 completely expose the combustion chamber for thor-
ough 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.
6.
Remove the Baffles from between the casting sections. 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.
Reinstall all flue Baffles between the casting sections.
(see pg. 21 for Baffle Layout Chart)
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 operation 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 mak-
ing 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 sealant on top of the
heat exchanger. The sealant must be in place adjacent to the
long bosses on front and rear sections and adjacent to the
short bosses on the intermediate sections. The sealant should
be directly under the flue collector flange when the flue
collector is replaced. Use the 1/4-20 Wing Nut and washer to
fasten the flue collector. In order to assure a proper seal be
sure that the sealant is pressed tight against the flue collector
and castings.(For the Hinge Style the flue collectors. see 9A.)
9a. For the Hinge Style flue collectors (LD-30 and LD-40) only.
Inspect the Fiberglass rope seal to ensure its proper location
and close the Hinged top using the two latches.
D. If boiler room is damp, provide ventilation.
CAUTION: ALWAYS KEEP THE OIL SUPPLY VALVE SHUT OFF IF THE
BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME.
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
All service to the oil burner, oil filter, oil strainers, etc., should be
performed by a professionally trained service person.
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 CO 2 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.
LIBERTY II
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