Operating instructions

B. Checking Thermostat Operation
When set above temperature indicated on thermometer, boiler burner should start. Make certain thermostat shuts boiler down when room
temperature reaches selected setting and starts boiler operating when room temperature falls a few degrees.
NOTE: Do not start burner unless all cleanout doors are secured in place.
MAINTENANCE
To assure trouble-free operation, we recommend that flue passages, burner, combustion chamber area (target wall and fire door insulation), burner
adjustment, operation of controls, and boiler seals (door gasket or silicone seal, cast iron seals and flue collector) be checked ONCE EACH YEAR
by a competent service technician.
BEFORE THE START OF EACH SEASON (or whenever system has been shut down for some time), recheck the whole system for leaks and
recheck boiler and vent pipe for leaks. Replace or patch any boiler seals that are faulty.
WARNING: Never burn garbage or paper in the unit, and never leave combustible material around it.
PROCEDURE 1—RELIEF VALVE
This valve should open automatically when system pressure exceeds the safe limit (30 psi). Should it ever fail to open under this condition, shut
system down. Drain it until pressure is reduced below safe limit, then have valve replaced immediately. The relief valve should be tested monthly
during heating season. Prior to testing, make certain a discharge pipe is properly connected to the valve outlet and arranged so as to contain and
safely dispose of boiler discharge. Hold the trip lever fully open for at least five seconds in order to flush free any sediment that may lodge on
the valve seat. Then permit the valve to snap shut.
PROCEDURE 2—CONVENTIONAL EXPANSION TANK
As previously noted, this tank may become waterlogged or may receive an excess of air. Frequent automatic opening of relief valve indicates
waterlogging. A high boiler temperature accompanied by unusually low radiation unit temperature (and ″knocking″) indicates excess air in tank.
To correct either condition, close valve between boiler and tank. Drain tank until it is empty. Check all tank plugs and fittings. Tighten as necessary.
Open valve between boiler and tank. Water will rise to normal height in tank if automatic fill valve is installed, otherwise, manually refill system.
PROCEDURE 3—DIAPHRAGM EXPANSION TANK
As previously noted, this tank may become waterlogged or may receive an excess of air. Frequent automatic opening of relief valve indicates
waterlogging. A high boiler temperature accompanied by unusually low radiation unit temperature (and ″knocking″) indicates excess air in tank.
To correct this condition, replace the diaphragm expansion tank.
PROCEDURE 4—WATER SYSTEM
If system is to remain out of service during freezing weather, always DRAIN IT completely. Water left in to freeze will crack pipes and/or boiler.
PROCEDURE 5—TANKLESS COIL (OR COVER PLATE) GASKET
The tankless coil gasket should be checked at least twice a year for leakage and replaced if necessary.
PROCEDURE 6—OIL BOILER/BURNER CLEANING INSTRUCTIONS
OIL BOILER CLEANING
1. Shut off all electrical power to the boiler/burner and shut off fuel oil supply.
2. Remove the vent pipe from the top of the boiler. Inspect the pipe and chimney for signs of corrosion and deterioration. Clean out the base
of the chimney. If the vent pipe shows any signs of corrosion or deterioration, replace it immediately. If chimney damage or deterioration
is discovered, contact a competent professional.
3. Remove the top jacket panel screws (5), the brass wing nuts (2) holding the flue collector top, and then the flue collector top. Inspect the
gasket on the underside of the flue collector and replace as necessary.
4. Before beginning to clean the flue passageways, ensure that the combustion chamber blanket is covered. If the blanket is not covered prior
to cleaning, replace the blanket once cleaning is complete.
5. Now with access to the flue passageways, remove the soot from the fireside surfaces by brushing diagonally through the flue passages (See
Fig. 18). Brushing can be made easier by cutting the end of the flue brush off and inserting it into a drill. When brushing, care should be
taken so as not to damage the target wall with the flue brush.
6. Carefully vacuum the soot accumulations from the combustion chamber area, being particularly careful to not damage any of the refractory
or blanket insulation. To gain access to the combustion chamber first double check that the shut off valve on the fuel line is closed and then
disconnect the fuel oil line. Then open the swing door by simply removing the whiz lock nut holding the door shut.
7. Now inspect the target wall, fire door refractory, and combustion chamber blanket (when included) for cracking and deterioration. If there
is any signs of cracking or deterioration, replace the refractory or blanket before reassembling the burner/front plate.
Table 8—Recommended Operating Control Settings
OPERATING CONTROL CONTROL SETTING
High Limit
Standing Radiators 180°F
Baseboard and Convectors 200°F
Low Limit (When Used) 140°F
Differential (When Used) 10°F
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