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8. Check Draft gauge to ensure boiler base has at least -,005 to -.01" WC, clean fire tubes per the following
procedure if draft is too low or there is evidence of moisture in the hopper lid/slight sulpher smell in
hopper.
CAUTION: THE FOLLOWING STEPS INVOLVE WORKING WITH HEATED METAL SURFACES. APPROPRIATE
WELDING GLOVES OR OTHER HIGH HEAT HAND PROTECTION AND SAFETY GLASSES SHALL BE USED. A DUST
MASK IS OPTIONAL IF THE PERSON PERFORMING THE TASK IS SENSITIVE TO DUST.
9. If the boiler is equipped with the optional cleanout (refer to photo above to aid in identification), shut the
unit off, remove the sheet metal cover using gloves and open the clean out door, vacuum the tubes out
from the top and close the door, restore power and re-install the sheet metal cover.
10. If not equipped with the optional flue clean out remove four sheetmetal screws that hold top jacket on
boiler
11. Shut off boiler power and quickly remove flue pipe and remove sheet metal and insulation from top of
boiler. Re-connect flue pipe and power boiler back on for the following two steps.
12. Tools needed for next steps include: a shop vacuum with HEPA filter, 9/16" deep socket on ¼" drive
ratchet or cordless drill motor, bright flashlight or drop light.
13. Remove the four 9/16" brass nuts from boiler flue pipe adapter cover,.
14. Make sure shop vac and light source are plugged in and ready to go.
15. Shut off boiler power and remove flue pipe and set to the side, vacuum each tube and then move
economizer up and down so as to loosen any remaining fly ash and re-vacuum that tube, inspect each
tube with the light and verify free of obstructions and clear of most of the fly ash.
16. Replace cover and flue pipe, re-apply boiler power and re-install the four 9/16" nuts.
17. Shut off boiler power and quickly remove flue pipe and install sheet metal and insulation to top of
boiler. Re-connect flue pipe and power boiler back on
Resolution of Common Problems
1. If there is black dust evident on the horizontal surfaces in the home, shut down the fans and try adding
the coal to the hopper more slowly, or get oiled coal. Check your coal supply, if there are many small
broken pieces and dust mixed in, try an alternate source to see if cleaner coal is available.
2. A moist hopper lid indicates a draft issue that must be resolved immediately. Make sure all flue pipes
are clean, ensure that the barometric damper is adjusted properly and is not stuck open, ensure that the
coal is not dripping wet when added to the hopper, check that the chimney is not restricted if the
preceding items do not correct the issue. If the boiler is on a power vent ensure that the unit has been
maintained per the manual and is spinning fast enough to provide sufficient draft.
3. A coal fire that is burning toward the back of the grate is indication of insufficient or too much draft and
must be resolved immediately. Check all items in paragraph 2, if all those items are not the source of
the issue, shut the boiler down and check the fiberglass gasket that is between the back edge of the grate
and feeder body. This gasket will often fall out when the grate is removed and must be replaced if
missing.
4. If the combustion fan or feeder motor stop operating, plug the motor directly into a power outlet to
verify that the issue is not with the boiler wiring or controls. Often a motor will stop operating after the
boiler is shut down even after a power outage, cleaning the motor and oiling the bearings will often
solve the issue.
CAUTION: EXCESSIVE CORROSION WILL REULST FROM BOILER SHUT DOWN FOR MORE THAN A WEEK
WITHOUT PROPERLY CLEANING AND PROTECTING THE SURFACE EXPOSED TO COAL ASH. THE RESULTING
CORROSION WILL VOID THE WARRANTY ON THE PRESURE VESSEL.
DANGER - Risk of Fire or Explosion - Do not burn garbage, gasoline, drain oil or other flammable liquids.
CAUTION – HOT SURFACES – KEEP CHILDREN AWAY – DO NOT TOUCH APPLIANCE DURING OPERATION
DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING ANOTHER APPLIANCE
WARNING –
RISK OF FIRE – DO NOT OPERATE WITH A FLUE DRAFT EXCEEDING -.07" wc,
OPERATING AT A DRAFT ABOVE -.07" wc CAN CAUSE UNIT TO BURN BACK INTO THE HOPPER
DO NOT OPERATE WITH ASH REMOVAL DOOR OPEN
DO NOT STORE FUEL OR OTHER COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES
CAUTION – BURN RICE OR BUCKWHEAT SIZED ANTHRACITE COAL ONLY
PLEASE SAVE THESE INSTRUCTIONS
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