Part number 550-142-850/0716
77
FreeStyle
®
WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual
31 Annual startup
HANDLING CERAMIC FIBER
MATERIALS
2%-/6).'"52.%2'!3+%4OR
#/6%20,!4%).35,!4)/.
The FreeStyle®HEATEXCHANGERREFRACTORY
contain ceramic fiber
materials that have
been identified as carcinogenic, or possibly
carcinogenic, to humans).
Ceramic fibers
can be converted to cristobalite in very
high temperature applications.
4HE)NTERNATIONAL!GENCYFOR2ESEARCHON
#ANCER)!2#HAS CONCLUDEDh#RYSTAL-
LINESILICAINHALEDINTHEFORMOFQUARTZOR
CRISTOBALITEFROMOCCUPATIONALSOURCESIS
carcinogenic to humans (Group 1).”:
■ !VOIDBREATHINGDUSTANDCONTACTWITHSKINANDEYES
s Use NIOSH certified dust respirator (N95). This
TYPEOFRESPIRATORISBASEDONTHE/3(!REQUIRE-
MENTSFORCRISTOBALITEATTHETIMETHISDOCUMENT
WASWRITTEN/THERTYPESOFRESPIRATORSMAYBE
needed depending on the job site conditions.
#URRENT.)/3(RECOMMENDATIONSCANBEFOUND
on the NIOSH web site at http://www.cdc.gov/
niosh/homepage.html. NIOSH approved respira-
TORSMANUFACTURERSANDPHONENUMBERSAREALSO
listed on this web site.
s Wear long-sleeved, loose fitting clothing, gloves,
and eye protection.
■ (ANDLECAREFULLYTO MINIMIZEDUST THAT COULD BE
caused by abrasion.
■ )FREPLACEMENTISNECESSARYREMOVETHEREFRACTORY
FROMTHEBOILERANDPLACEITINAPLASTICBAGFOR
disposal.
■ Wash potentially contaminated clothes separately
FROMOTHERCLOTHING2INSECLOTHESWASHERTHOR-
oughly.
.)/3(STATED&IRST!ID
■ Eye: Irrigate immediately
■ Breathing: Fresh air.
FIRST-YEAR SPECIAL INSPECTION
1. .O LATER THAN MONTHSAFTER THE BOILERISINSTALLED
PERFORMAlRSTYEARINSPECTIONOFTHEBOILER4HISSHOULD
INCLUDETHEFOLLOWING
in addition to routine annual
STARTUPPROCEDURES
.
a. 4HEINTEGRITYOFTHEmUESYSTEMANDTHEmUESEALS
b. 4HEINTEGRITYOFTHEBOILERCOMBUSTIONCIRCUITANDTHE
relevant seals;
c. The operational (working) gas inlet pressure at
maximum rate, as described on pages 49 and 73;
d. The gas rate, as described on page 49;
e. 4HECOMBUSTIONPERFORMANCEASDESCRIBEDON
pages 72ANDFORCOMBUSTIONCHECK
F #OMPETENCETO CARRY OUTTHECHECK OFCOMBUSTION
PERFORMANCE
g. The person carrying out a combustion measurement
SHOULDHAVEBEENASSESSEDASCOMPETENTINTHEUSEOFA
mUEGASANALYZERANDTHEINTERPRETATIONOFTHERESULTS
Periodical check
h. To keep the unit working properly over time, it is necessary to
have qualified personnel make an annual check that includes
THEFOLLOWINGTESTS
i. 4HECONTROLANDSAFETYDEVICESGASVALVEmOWMETER
THERMOSTATSETCMUSTFUNCTIONCORRECTLY
j. 4HEmUEPIPESMUSTBEFULLYINTACTSECUREANDCLEAR
k. The airtight chamber must be sealed.
l. 4HEAIRmUETERMINALANDDUCTSMUSTBEFREEOFOBSTRUCTIONS
and leaks.
m. 4HE CONDENSATEEVACUATION SYSTEMMUSTBE EFlCIENTWITH
no leakage or obstructions and drain condensate without
backing up.
n. 4HEBURNERANDEXCHANGERMUSTBECLEANANDFREEOFSCALE
When cleaning, do not use chemical products or wire brushes.
o. 4HEELECTRODEMUSTBEFREEOFSCALEANDPROPERLYPOSITIONED
p. 4HEGASANDWATERSYSTEMSMUSTBELEAKFREE
q. The water pressure in the heating system must be about 18
pounds; fill the boiler to that pressure or the system design
pressure.
r. The circulation pump must not be blocked.
s. The expansion tank must be filled.
t. The gas flow and pressure must correspond to that given in
the respective tables.
2. $ETERMINEANYFOLLOWUPMAINTENANCEANDSERVICENEEDSBASED
ONTHECONDITIONOFTHEHEATEXCHANGERANDCONDENSATELINES
a. )FTHEHEATEXCHANGERSHOWSSUBSTANTIALFOULINGORIFCON-
DENSATELINESSHOWACCUMULATIONOFSEDIMENTSCHEDULE A
FOLLOWUPSERVICE CALL TOPERFORM THElRSTYEARINSPECTION
again, sooner than the normal twelve months between.
b. (EAVYFOULINGOFTHEEXCHANGERORCONDENSATELINESINDICATES
possible combustion air contamination. Inspect the air intake
AREACAREFULLYANDREMOVEPOSSIBLECONTAMINANTS3EEpage 8,
FORPRODUCTSTOAVOID
9OU MUST ELIMINATE CAUSES OF CORROSION AND
CONTAMINATIONTOENSURERELIABLEOPERATION OF
the boiler and system.
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