3
START UP
1. Place disconnect switch and control circuit
switch in the OFF position. Fill system with
water to pre-determined cold fill pressure (one
pound of pressure is required for every 2.31
feet of piping system height above the
pressure gauge).
2. Purge all air at the highest point in the system
and vent all points where air is likely to be
trapped.
3. Energize circulator pump and verify direction
of rotation on three phase units. DO NOT
energize the boiler unless circulator pump is
operating.
4. Close boiler control panel door and energize
the main disconnect switch.
5. Check all piping connections and valves for
leaks.
6. Turn boiler control circuit switch to the ON
position. If contactor(s) do not close, see
service section (page 4).
MAINTENANCE
A periodic check of all control components will
ensure proper operation.
1. Check wiring and terminations for tightness.
2. Check all controls and safety devises for
proper operation.
3. Check pressure relief valve to ensure that it is
not leaking and that no corrosion exists.
4.
Check circulator pump and lubricate
according to manufacturer’s instructions.
At least once a year, boiler elements should be
checked.
1. Disconnect all power to boiler.
2. If a faulty open element is indicated, the
element may be replaced in the following
manner:
a. Isolate boiler from system by closing hand
valves in supply and return piping.
b. Drain boiler completely of water.
c. Remove ALL wiring from the elements,
tagging both the wires and element
terminals.
d. Mark element flange position with respect
to the vessel flange for proper alignment
upon reinstallation; remove flange bolts.
e. Remove the element flange from the
vessel.
f. Remove element retaining nut using a
11/16 socket wrench.
g. Remove ferrules (2 compressed rings)
from the element ends and remove
element from back side of flange.
h. Insert new element and ferrules and
tighten element retaining nuts into flange.
i. Replace flange in boiler vessel using new
gasket. Align previously made marks on
flanges and install flange bolts, torqueing
each bolt to 70 foot pounds (minimum).
j. Reconnect electrical wiring, making sure
all wiring is connected to the proper
element termination.
k. Refill boiler following procedure listed in
INSTALLATION section.
l. Check elements and flanges for leaks.
m. Replace vessel enclosure cover.
n. Turn disconnect on.
