Install Instructions

Part number 550-100-131/0715
– 92 –
™
GAS-FIRED WATER BOILER — Boiler Manual
Annual startup
HANDLING CERAMIC FIBER
MATERIALS
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The Evergreen
TM
cover plate refractory contains
ceramic fiber material.
Ceramic fibers can be converted to cristobalite in
very high temperature applications.
The International Agency for Research on Cancer
(IARC) has concluded, “Crystalline silica inhaled in
the form of quartz or cristobalite from occupational
sources is carcinogenic to humans (Group 1).”:
■ Avoid breathing dust and contact with skin and eyes.
s Use NIOSH certified dust respirator (N95). This type
of respirator is based on the OSHA requirements for
cristobalite at the time this document was written. Other
types of respirators may be needed depending on the job
site conditions. Current NIOSH recommendations can
be found on the NIOSH web site at http://www.cdc.gov/
niosh/homepage.html. NIOSH approved respirators,
manufacturers, and phone numbers are also listed on
this web site.
s Wear long-sleeved, loose fitting clothing, gloves, and
eye protection.
■ Handle carefully to minimize dust that could be caused by
abrasion.
■ If replacement is necessary, remove the refractory from the
boiler and place it in a plastic bag for disposal.
■ Wash potentially contaminated clothes separately from other
clothing. Rinse clothes washer thoroughly.
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■ Eye: Irrigate immediately.
■ Breathing: Fresh air.
FIRST-YEAR SPECIAL
INSPECTION
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A7EIL-C,AIN
%VERGREEN
4-
 "OILER
-AINTENANCE KIT BEFOREATTEMPTING
THE lRSTYEAR INSPECTIONTO ENSURE
ALL PARTS THAT MAY BE NEEDED ARE
AVAILABLE
. This kit includes essential
components, gaskets and seals required to
perform the annual start-up procedures.
See listing in Replacement parts section of
this manual. These parts must be on hand
when you perform the first-year inspec-
tion in the event they must be replaced.
Failure to replace the items above when
needed could result in severe personal
injury, death or substantial property dam-
age.
1.
.OLATERTHANMONTHS after the boiler is in-
stalled, perform a first-year inspection of the boiler.
This should include the following
INADDITIONTO
ROUTINEANNUALSTARTUPPROCEDURES
.
a. Inspect the heat exchanger and clean if nec-
essary (see page 109 for access and cleaning
procedures).
b. Inspect the cover plate refractory and gasket.
Replace if not in good condition.
c. Inspect the burner carefully. Clean the burner
thoroughly using a vacuum cleaner or com-
pressed air if needed.
d. Make sure there is no blockage or accumulation
of debris in the burner or the burner ports.
Replace the burner if necessary.
e. Check the burner for tightness.
f. Disconnect the condensate trap and drain lines.
Inspect, then flush thoroughly. Reinstall and
refill the trap per page 86.
g. Check heat exchanger seals and vent seals, pro-
cedure described on page 90, “Check exchanger
and vent seals”.
2. Determine any follow-up maintenance and service
needs based on the condition of the heat exchanger
and condensate lines.
a. If the heat exchanger shows substantial fouling,
or if condensate lines show accumulation of
sediment, schedule a follow-up service call to
perform the first-year inspection again, sooner
than the normal twelve months between.
b. Heavy fouling of the exchanger or condensate
lines indicates possible combustion air contami-
nation. Inspect the air intake area carefully, and
remove possible contaminants. See page 17, for
products to avoid.
You must eliminate causes of corrosion
and contamination to ensure reliable
operation of the boiler and system.
ANNUAL STARTUP
The boiler should be inspected and started
annually, at the beginning of the heating season,
only by a qualified service technician. In addition,
the maintenance and care of the boiler designated
in Figure 87, page 91 and explained on the follow-
ing pages must be performed to assure maximum
boiler efficiency and reliability. Failure to service
and maintain the boiler and system could result in
equipment failure.
TOOLS REQUIRED
Before beginning annual start-up or first-year special inspec-
tion, obtain the tools listed on page 100.