Use and Care Manual

31
VI. MAINTENANCE AND 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 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 total water volume each month.
C. HINTS ON COMBUSTION
1. NOZZLES — Although the nozzle is a relatively
inexpensive device, its function is critical to the
successful operation of the oil burner. The selection
of the nozzle supplied with the RRO boiler is the
result of extensive testing to obtain the best ame
shape and efcient combustion. Other brands of the
same spray angle and spray pattern may be used but
may not perform at the expected level of CO
2
and
smoke. Nozzles are delicate and should be protected
from dirt and abuse. Nozzles are mass-produced
and can vary from sample to sample. For all of
those reasons a spare nozzle is a desirable item for a
serviceman to have.
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.
Boiler Model
Gallons Per
Month
Gallons Per
Year
RRO080, RRO092,
RRO120
0.3 4
RRO111, RRO151,
RRO179
0.4 5