SG Series Boilers – Installation and Service Manual
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper
If any part of this boiler has been under water, inspect the boiler and replace any part of the control
Service & Maintenance Instructions Section 4
4.1 SERVICE & MAINTENANCE INSTRUCTIONS
WARNING
and dangerous operation.
WARNING
system and any gas control which has been under water.
This boiler has been designed to provide years of trouble-free performance in normal installations. The
owner or user should conduct a general external examination covering all items on the "User Checklist" at
the beginning of each heating season and in mid-heating. In addition, the owner or user will have the boiler
inspected by qualified service technician or gas supplier’s service person at least once every year at the
beginning of the heating season for continued safe operation. Note that some operating conditions may
require more frequent inspections.
The qualified service technician or gas supplier's service person should follow the "Service Checklist". The
"Service Checklist" must only be used by a qualified service technician or gas supplier's service person.
Verify proper operation after servicing.
4.2 CLEANING PROCEDURE
1. Shutdown the boiler as described in the lighting instructions in Section 1.6.
2. Inspect flue gas passages and burners for the presence of soot, rust or scale.
3. If necessary, use a wire brush and vacuum to clean and remove any blockages. Plugged burner ports
must be cleared.
4. Replace any parts which have severely corroded.
5. Reassemble parts removed during cleaning as they were before, ensuring air tightness of flue gas
passages.
6. Corrosion can be caused by low return water temperature or a contaminated air supply. Sooting can
be caused by improper burner adjustment. Check and adjust as necessary.
7. Return boiler to operation following lighting instructions in Section 1.
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SG Series Boilers – Installation and Service Manual
4.3 SERVICE CHECKLIST
Do not store anything against the boiler or allow dirt or debris to accumulate in the
area immediately surrounding the boiler. The flow of supply and exhaust air must not
be obstructed.
Check air openings are not restricted and complies with applicable code(s).
Adequate supply air is necessary for combustion, flue gas dilution and ventilation.
When the boiler has operated for several minutes, check for spillage at draft hood,
venting ducts, and other areas susceptible to spillage.
Check externally the draft hood and vent system for soot, rust scale or corrosion.
Check for dislodged venting or possible leaks in venting ducts.
Remove the draft hood from the boiler and inspect the flueways for the presence of
soot or rust scale. Inspect the draft hood and smoke pipe connecting the draft hood to
the flue for rust or corrosion before replacing the draft hood. The presence of soot, rust
scale or corrosion indicates misadjustment.
Inspect and, if necessary, clean the pilot burner and main burner. Check burners to
see that they are not cracked or dislodged.
Visually check the pilot and main burner flames. A yellow flame caused by improper
adjustment is always accompanied by formation of soot which, if allowed to continue,
will partially restrict free passage of products of combustion to the flue.
Check that gas piping is secured. Smell for gas leaks around boiler and gas piping
connections. Gas leaks can also be checked for using a soap solution; do not use an
open flame to check for leaks. Note: Propane is heavier than air and pools in a low
area in the event of a leak.
Inspect boiler for signs of leaks or corrosion. Inspect for leaks in the water piping and
at water piping connections.
Circulating pumps used with hot water heating systems should be inspected for water
leaks.
Check for weeping at pressure relief valve outlet during normal operation.
Listen for unusual audible sounds in the boiler. Any audible sounds in the boiler
system may be indications of scaling or lack of sufficient water flow and the system
should be checked without delay. Scaling is due to improper maintenance. It is not
the fault of the boiler. Scale damage is not covered by warranty.
Check the temperature and pressure gauge and expansion tank pressure is within
an acceptable range for the heating system.
Keep boiler area clear and free from combustible materials, gasoline and other
flammable vapors and liquids. Combustible materials, gasoline and other flammable
vapors and liquids should not be stored in the area of the boiler.
Checks should be made on ignition system, operation controls and safety shut-off
valves for gas tightness.
If applicable, inspect low water cutoff for proper operation.
Check for proper operation of the blocked vent and flame roll-out safety switches.
The emergency shut-off devices are identified and the owner is aware of their location
and method of operation.
Reference
Section
2.2, 2.5,
2.6, 2.7
3.3, 4.2
2.12, 4.4
2.4, 3.9
2.5
3.7
4.2
3.3
3.9
2.13
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SG Series Boilers – Installation and Service Manual
The mineral block and fiberglass wool used in this product are RCFs (Refractory Ceramic Fibers).
4.4 CAUTION: WATER REPLENISHMENT
Avoid unnecessary replenishment of system water. It can allow oxygen to enter the system and cause
serious corrosion problems. As well, an excessive amount of minerals may be deposited in the heat
exchanger. Do not draw water from the heating system for cleaning, flushing, etc.
Any audible sounds in the boiler system may be indications of scaling or lack of sufficient water flow and
the system should be checked without delay. Scaling is due to improper maintenance. It is not the fault of
the boiler. Scale damage is not covered by warranty.
4.5 REFRACTORY HANDLING PROCEDURE
WARNING
RCFs pose a possible cancer hazard by inhalation and can cause respiratory, skin and eye
irritation.
After mineral block has been fired, it will produce increased levels of nuisance dust and poses
increased carcinogenic risk.
Follow the precautionary measures below before attempting service or access.
PRECAUTIONARY MEASURES:
Avoid breathing fibers and contact with skin and eyes.
Use a National Institute for Occupational Safety and Health (NIOSH) approved dust/mist respirator.
Wear long-sleeved, loose fitting clothing, gloves and eye protection.
Wash work clothes separately from other clothing. Rinse washer thoroughly.
Operations such as sawing, blowing, tear out and spraying may generate airborne fiber concentration
requiring additional protection.
Use a vacuum with a HEPA filter for clean up.
Dispose of all RCF scrap and dust in a closed airtight plastic bag.
FIRST AID MEASURES:
Eye contact – Flush eyes with water to remove dust for at least 15 minutes. If irritation persists, seek
immediate medical attention.
Skin contact – Wash affected area gently with soap and warm water after handling.
Difficulty breathing – Move to an area of clean fresh air. Seek immediate medical attention if difficulties
persist.
Ingestion – Do not induce vomiting. Drink plenty of water. Seek immediate medical attention.
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