Freestyle 2 Series - Annual Startup

Part number 550-142-950/0122
86
FreeStyle
®
series 2 wall mount gas-fired water boiler – boiler manual
36 Annual startup
HANDLING CERAMIC FIBER
MATERIALS
REMOVING BURNER GASKET or
COVER PLATE INSULATION
e FreeStyle® heat exchanger refractory
contain ceramic ber
materials that have
been identied as carcinogenic, or possibly
carcinogenic, to humans).
Ceramic bers
can be converted to cristobalite in very
high temperature applications.
e International Agency for Research on
Cancer (IARC) has concluded, “Crystal-
line 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.
• Use NIOSH certied dust respirator (N95). is
type of respirator is based on the OSHA require-
ments 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 respira-
tors, manufacturers, and phone numbers are also
listed on this web site.
• Wear long-sleeved, loose tting 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 thor-
oughly.
NIOSH stated First Aid
Eye: Irrigate immediately
Breathing: Fresh air.
FIRST-YEAR SPECIAL INSPECTION
1. No later than 12 months aer the boiler is installed,
perform a rst-year inspection of the boiler. is should
include the following in addition to routine annual
start-up procedures
.
a. e integrity of the ue system and the ue seals;
b. e integrity of the boiler combustion circuit and the
relevant seals;
c. e operational (working) gas inlet pressure at
maximum rate, as described on pages 51 and 82;
d. e gas rate, as described on page51;
e. e combustion performance, as described on pages81,
82 and 83 for combustion check.
f. Competence to carry out the check of combustion
performance.
g. e person carrying out a combustion measurement
should have been assessed as competent in the use of
a ue gas analyzer and the interpretation of the results;
Periodical check
h. To keep the unit working properly over time, it is necessary to
have qualied personnel make an annual check that includes
the following tests:
i. e control and safety devices (gas valve, ow meter,
thermostats, etc.) must function correctly.
j. e ue pipes must be fully intact, secure and clear.
k. e airtight chamber must be sealed.
l. e air-ue terminal and ducts must be free of obstructions
and leaks.
m. e condensate evacuation system must be ecient with
no leakage or obstructions and drain condensate without
backing up.
n. e burner and exchanger must be clean and free of scale.
When cleaning, do not use chemical products or wire brushes.
o. e electrode must be free of scale and properly positioned.
p. e gas and water systems must be leak free.
q. e water pressure in the heating system must be minimum
of 12 PSI, do not exceed 25 PSI. Fill the boiler to that pressure
or the system design pressure.
r. e circulation pump must not be blocked.
s. e expansion tank must be lled.
t. e gas ow and pressure must correspond to that given in
the respective tables.
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 con-
densate lines show accumulation of sediment, schedule a
follow-up service call to perform the rst-year inspection
again, sooner than the normal twelve months between.
b. Heavy fouling of the exchanger or condensate lines indicates
possible combustion air contamination. Inspect the air intake
area carefully, and remove possible contaminants. See page6,
for products to avoid.
You must eliminate causes of corrosion and
contamination to ensure reliable operation of
the boiler and system.