User Guide

36
IX: MAINTENANCE & SERVICE INSTRUCTIONS
A. WATER BOILERS:
1. Filling of boiler and system.
GENERAL — In a hot water heating system, the
boiler and entire system (other than the expansion
tank) must be full of water for satisfactory
operation. Water should be added to the system until
the boiler pressure gauge registers 12 psi. To insure
that the system is full, water should come out of all
air vents when opened.
2. BOILING OUT OF BOILER AND SYSTEM. The
oil and grease which accumulate in a new hot water
boiler can be washed out in the following manner:
a. Remove relief valve using extreme care to avoid
damaging it.
b. Add an appropriate amount of recommended boil
out compound.
c. Replace relief valve.
d. Fill the entire system with water.
e. Start ring the boiler.
f. Circulate the water through the entire system.
g. Vent the system, including the radiation.
h. Allow boiler water to reach operating
temperature, if possible.
i. Continue to circulate the water for a few hours.
j. Stop ring the boiler.
k. Drain the system in a manner and to a location
that hot water can be discharged with safety.
l. Remove plugs from all available returns and
wash the water side of the boiler as thoroughly as
possible, using a high-pressure water stream.
m. Rell the system with fresh water.
3. Add appropriate boiler water treatment compounds
as recommended by your qualied water treatment
company.
4. Make pH or Alkalinity Test.
After boiler and system have been cleaned and
relled as previously described, test the pH of the
water in the system. This can easily be done by
drawing a small sample of boiler water and testing
with hydrion paper which is used in the same
manner as litmus paper, except it gives specic
readings. A color chart on the side of the small
hydrion dispenser gives the reading pH. Hydrion
paper is inexpensive and obtainable from any
chemical supply house or through your local
druggist. The pH should be higher than 7 but lower
than 11. Add some of the washout chemical (caustic
soda), if necessary, to bring the pH within the
specied range.
5. Boiler is now ready to be put into service.
B. EXCESSIVE MAKE-UP WATER
A leaky system will increase the volume of make-up
water supplied to the boiler, which can signicantly
shorten the life of the boiler. Entrained in make-up
water are dissolved minerals, salts and oxygen. When
the fresh, cool make-up water is heated in the boiler,
the minerals fall out as sediment, the salts coat the
inside of the boiler, and the oxygen escapes as a gas.
The accumulation of sediment eventually isolates the
water from contacting the steel. When this happens
the steel in that area gets extremely hot and eventually
cracks. The presence of free oxygen or chloride salts
in the boiler creates a corrosive atmosphere which, if
the concentration becomes high enough, can corrode
the steel through from the inside. More make-up water
and higher concentrations of contaminants damage
the boiler sooner. Our warranty does not cover
corrosion and sediment-related damage. Clearly
it is in everyone’s best interest to prevent this type of
failure. You can do your part by ensuring that your
system is leak-free, keeping leakage to less than 2
percent of the total water volume each month. Refer to
Chart below.
IMPORTANT
IF, DURING NORMAL OPERATION, IT IS NECESSARY
TO ADD MORE WATER THAN INDICATED BELOW,
CONSULT A QUALIFIED SERVICE TECHNICIAN
TO CHECK YOUR SYSTEM FOR LEAKS.
Model No.
Gallons Per
Month
Gallons Per
Year
AP-490U 0.2 3
AP-590U 0.2 3
AP-690U 0.3 4
AP-790U 0.3 4
C. ATTENTION TO BOILER WHILE NOT IN
OPERATION
1. IMPORTANT
IF BOILER IS NOT USED DURING WINTER
TIME, IT MUST BE FULLY DRAINED TO
PREVENT FREEZE DAMAGE.
2. Spray inside surfaces with light lubricating or
crankcase oil using gun with extended stem so as to
reach all corners.
3. With steam boilers, at end of season add sufcient
water to ll boiler to top of water column and leave
it that way until fall when water should be drained
again to proper level. If, at this time, boiler water is
dirty, drain water, ush out boiler, and rell with
clean water to prescribed water level.