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manual abstract
The BOILER MATE™ is intended to provide a tank service life of many years. Components, however, may be subject to failures that require service. Failure to use the correct procedures or parts in these circumstances may make the unit unsafe. Do not over-drain the tank. Improper thermostatic control could result during Step 6 and lead to damage to the BOILER MATE™. 6. Using a funnel, pour one gallon of commercial • DO NOT OPEN DOWN-STREAM FIXTURE IF YOU phosphoric acid solution (commercial icemaker HAVE LOOSENED THE TOP CONNECTIONS. cleaning solution) into the water tank through the top • DO NOT OVER-DRAIN THE TANK - THE HEAT EXCHANGER MUST REMAIN COVERED BY WATER TO AVOID DAMAGE TO THE LINER. The owner should arrange to have the following inspections and simple maintenance procedures done at the frequencies suggested. a. Domestic Water Piping - Yearly Visual Inspection Check all piping for a signs of leakage at joints, unions and shutoff valves. Remedy as needed. b. Boiler Water Piping - yearly Visual Inspection Check all piping for signs of leakage at joints, unions and shut-off valves. remedy as needed. c. T & P Relief Valve - Yearly Inspection d. Sediment - Monthly Inspection - depending on water conditions Depending on water conditions, a varying amount of sediment may collect in the tank. This is normal. Levels requiring service are indicated by a small temperature difference in the supply and return lines. (See also "Scale" below.) Repeated flushing usually clears such material. As a preventive measure, each month water should be drawn from the tank at the drain valve until it runs clear. e. Scale - Monthly Inspection A small temperature difference between the water entering and leaving the coil may indicate a scale build-up. A water softener will prevent this problem. (See also "Sediment" above.) Repeated flushing should also resolve the problem. If not, proceed as follows: 1. To avoid water damage to nearby areas in subsequent steps, shut off the cold water supply to the BOILER MATE™. 2. Make a note of the temperature control setting on the BOILER MATE™, then turn the unit off by depressing the key switch on the Smart Control™ until the unit reads "OFF". 3. Relieve the water pressure in the tank by opening a hot water faucet. This will reduce the risk of scalding injury. 4. Remove the relief valve from the top of the BOILER MATE™, taking care to avoid contact with the hot water which may drain out of the lines leading to the domestic uses. 5. Drain the BOILER MATE™ until the water within the tank is even with the top of the heat exchanger roughly 15 gallons for 41-gallon units and 5 gallons for 26-gallon units. opening. Be sure that the manufacturer’s directions, cautions, and warning on the container are followed: 7. Set the temperature control to its highest setting and operate the system until the control is satisfied. Note: Boiler may cycle on its high limit several times during this period. If the tank temperature setting has not been satisfied after 45 minutes of boiler operation, turn it to its lowest setting to stop boiler operation. 8. Allow heated solution to set in tank for 30 minutes. then drain tank completely using fitting and hose, as required, to reach a floor drain. 9. Fill water tank with fresh, cold, conditioned water and drain completely at least two time to flush all phosphoric acid mixture from the tank. 10.Reinstall the temperature pressure relief valve, being sure the (1) the temperature pressure relief valve temperature probe reaches into the top portion of the tank and (2) the top half union fitting is firmly in place. 11.Open the cold water supply and fill the tank with water. Then purge air from lines and tank by operating hot and cold water faucets in the house. 12.Return the Smart Control™ to the setting noted in Step 2 and verify it is working properly as described on page 17. As an alternative to the above, the heat exchanger may be removed from the BOILER MATE™, cleaned, and reinstalled (with a new gasket); or, in some cases, a simple high velocity washing by water from a wand may be used in place of Steps 5-9. The chemical cleaning process, however, is the most effective if done properly. -11 7. REPLACEMENT PARTS RESIDENTIAL BOILER MATE™ CLASSIC (TD-7Z and TD-41Z) ELECTROCUTION HAZARD. THE BOILER MATE™ MUST BE ELECTRICALLY GROUNDED. NOTES: 1. THE BOILER MATE™ MUST BE ELECTRI- CALLY GROUNDED AND INSTALLED IN ACCORDANCE WITH LOCAL CODES, OR IN THE ABSENCE OF LOCAL CODES, WITH THE NATIONAL ELECTRIC CODE. 2. HEAT EXCHANGER PACKAGE INCLUDE ITEMS 5-11 3. TORQUE NUTS 12 TO 14 FT. LBS. FAILURE TO USE THE CORRECT REPLACEMENT PARTS MAY MAKE YOUR UNIT UNSAFE. 613425 ITEM DESCRIPTION PART NUMBER 1 AQUASTAT CONTROL 2704-093 2 HEAT EXCHANGER - COMPLETE 2700-5004 3 GASKET ONLY 2704-403 4 THERMISTOR DRY WELL 2700-924 5 TOP COVER 20-0001 6 DRAIN VALVE 9340-087 -12 8. TROUBLE SHOOTING CHECKLIST PROBLEM CAUSE SOLUTION 1. No hot water at faucet. 1.Boiler does not operate. 2.Circulator d...
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