User Guide

46
103876-08 - 1/19
CL Installation & Service Manual
f. Boiler is now ready to be put into service.
2. Water Boilers:
a. 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.
b. 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:
i. Remove relief valve using extreme care
to avoid damaging it.
ii. Add an appropriate amount of
recommended boil out compound.
iii. Replace relief valve.
iv. Fill the entire system with water.
v. Start firing the boiler.
vi. Circulate the water through the entire
system.
vii. Vent the system, including the radiation.
viii. Allow boiler water to reach operating
temperature, if possible.
ix. Continue to circulate the water for a few
hours.
x. Stop firing the boiler.
xi. Drain the system in a manner and
to a location that hot water can be
discharged with safety.
xii. Remove plugs from all available returns
and wash the water side of the boiler as
thoroughly as possible, using a high-
pressure water stream.
xiii. Refill the system with fresh water.
c. Add appropriate boiler water treatment
compounds as recommended by your
qualified water treatment company.
d. Make pH or Alkalinity Test.
After boiler and system have been cleaned
and refilled 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 specific
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 specified range.
e. Boiler is now ready to be put into service.
3. Excessive Make-up Water
A leaky system will increase the volume of
make-up water supplied to the boiler, which
can significantly 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 cast iron. When this happens the cast iron
in that area gets extremely hot and eventually
cracks. The presence of free oxygen or
chloride salts in the boiler corrodes the cast
iron 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
boiler water volume each month.
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
CL3 0.3 4
CL4 0.4 5
CL5 0.5 6
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.
7 Maintenance and Service Instructions (continued)