AI
SERIES STEAM BOILER WITH T100 CONTROL
INSTALLATION INSTRUCTIONS
4211-195 05-22-12
Page 15
OPERATING INSTRUCTIONS (continued)
The optional electronic Autodrain valve is normally closed, opening only when power is supplied by a Drain Clock or by the ELECTRONIC DRAIN switch
to start drain/blowdown. When the Autodrain valve is opened, the DRAIN VALVE OPEN light will turn on. Normal operation is controlled by a clock: use the
ELECTRONIC DRAIN switch to open the drain without resetting the clock. This switch has no effect when the electronic drain valve is not installed. The
manual drain ball valve must be left in the open position for the electronic Autodrain to function. There is a delay between seeing the DRAIN light turn on
and the drain valve opening. This delay could be a minute or more, depending on the valve installed.
ROUTINE MAINTENANCE
The boiler and controls should require very little maintenance. We recommend checking water level control periodically and frequent draining of the tank
to ensure continued safe operation. Check for smooth, rapid
fl
ow when
fi
lling or draining the boiler. Also look at the boiler frequently to check for leaks and
periodically check for loose or overheated wires and for indications of corrosion.
WATER LEVEL CONTROL
Your local code may require a low water cut-off test at certain intervals. This is a good idea whether or not it is required. We recommend checking water
level controls at least monthly. CAUTION A hot boiler can result in very hot water and steam being released to the drain and the operator may be exposed
to dangerously high temperatures on
fi
ttings, valves and pipes. This test may be done while the boiler is cold.
To check the water level control circuit,
fi
rst start the boiler using the BOILER OPERATION switch.
• Set the HEAT switch OFF. Turn on the steam bath and verify the room’s steam valve is open (this
will help the boiler drain more quickly in the following steps). Adjust the thermostat as needed
to open the steam valve.
• Check the water level showing in the gauge glass: when the level rises above the middle of the
glass, the water valve should close and stop
fi
lling the boiler.
• Open the boiler’s drain and reset the HEAT switch to its NORMAL position: the BOILER
HEATING light will turn on and the heating contactors will close.
• Watch the water level in the gauge glass: as the level reaches a depth of about 1/3 of the glass,
the water valve will turn on again.
• Set the FEEDWATER switch to STOP FILL and the water valve will close.
• Allow the water to continue to drain and watch the level in the glass. When the water level drops
to about ½” depth in the glass, the BOILER HEATING light will turn off and the heat contactor will
open. This is the low water cut-off level.
• Set the BOILER OPERATION switch to off, close the drain and reset all switches to their NORMAL
position. Reset the thermostat to its original position. The boiler is now ready for normal oper-
ation again.
BOILER BLOWDOWN/AUTODRAIN
The boiler is supplied with a manual drain valve and may be equipped with an (optional) electronic
Autodrain valve. An Autodrain valve is always a good idea to easily schedule frequent draining. Rinsing
or other cleaning of the tank is a manual operation. Draining the tank, particularly while under pressure,
is often referred to as “blowdown.” To avoid confusion, we will refer to emptying the boiler’s tank as
“draining” here.
When water is changed to steam, solids may be left behind, eventually interfering with the water level sensing and possibly causing premature element
failure. Frequent draining and periodic cleaning of the tank is necessary to help reduce the build-up of these solids (scale and sludge). Every installation
is unique in its water quality and maintenance requirements. Symptoms of excessive build up include faulty water level sensing, gauge glass stained or
water level not changing, plugged/slow running drains and early element failure. Draining the boiler tank at least once a day is recommended even with
good water, much more often could be necessary as water quality drops. For reliable operation, your site may require water treatment.
CAUTION
:
Draining a hot boiler may release dangerously hot water or steam, risking personal injury and damage to plumbing! Your local code
may require that boiler pressure be limited to under 5 psi and require a special drain system to drain a hot boiler while under pressure!
Local water conditions and the amount of time per day that the boiler operates will determine the necessary draining and cleaning intervals. We recom-
mend draining daily or after every use and inspecting for properly
fl
owing drain at least monthly. If you drain it shortly before starting the boiler you will start
your bath with clean, fresh water, too. A slow running drain or mineral build up in the gauge glass may indicate excessive build up in the tank and a more
thorough cleaning should be done immediately.
We recommend inspecting for a clear water gauge glass at least monthly. Also, the gauge glass should be drained at least monthly, more often with
poor water quality: while the boiler is pressured, use a wrench to open the drain cock on the bottom gauge valve for a couple seconds. A safety device is
included in each gauge valve to prevent loss of steam and water should the gauge glass be broken. The gauge glass drain procedure will reduce the risk
of plugging up the valve or its pressure stop.
Use CAUTION when performing this routine to protect yourself from the hot water and steam released from
the gauge drain!
