Preventative Maintenance Schedule

KETTLE FURNACE

WARNING

TO ENSURE THAT THE DRIVEN EQUIPMENT IS SERVICED PROPERLY,

TURN OFF AND LOCKOUT OR TAG POWER SOURCE BEFORE

PROCEEDING. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT

IN BODILY INJURY.

1. Blower inlet filter should be removed and cleaned using dry

compressed air. The period should be every month. A new filter

should be installed 2 to 4 times a calendar year.

2. Calibration of all instruments and the thermocouples should be

checked at six (6) month intervals.

3. The metal temperature should be checked against an

independent hand held thermocouple at one (1) month intervals,

and this value checked against instrument and recorder displays.

4. External Kettle thermocouples should be checked semi-

annually to ensure their proper seating against the kettle wall.

5. External Kettle thermocouples should be replaced on yearly

basis.

6. All combustion limits should be tripped annually, to ensure

proper closing

of all natural gas solenoid valves, natural gas

blocking valves and opening of the natural gas vent valves.

The limits to be tripped are the following:

a. Low Gas Pressure Switch – one device.

b. Low Combustion Air Pressure Switch – one device.

c. High Gas Pressure Switch – eight devices.

d. Bath High Limit Controller – one device.

7. The flue temperature controller should be tripped yearly to insure its proper

operation. This is to make sure that the burners will be forced to the low

fire position when the combustion chamber exceeds its preset temperature.

8. The battery for backing-up the Random Access Memory (RAM) in the

recorder should be replaced every 2 to 3 years.

9. Visually inspect the perimeter of the furnace, looking for cracking in the

concrete or movement of the supporting steel structure. This should be

accomplished every three (3) months.

10. Turn off burners, one at a time, remove the flame rods and spark plugs

(igniter) and clean them using steel wool. This should be accomplished

every three (3) months or whenever a burner is difficult to light. If UV

scanners are used, they should be pulled out and the lens wiped with a

soft cloth to remove dust deposits.

11. If a standby or spare blower assembly is stored for a long period of time,

it must be carefully protected from dampness, dirt and vibration. The

inlet and discharge should be covered to keep foreign matter out. The

motor shaft should be periodically rotated a few times by hand, to keep

the shaft from warping. Failure to comply with any of the preceding will

void warranty.

12. Verify the proper settings for natural gas combustion air at both high and

low firing based on the original set up sheets. This procedure should be

done every three (3) months.

13. CAUTION: Serious burns can occur to exposed skin that is too close to

the furnace inspection ports! There will be excessive pressure and heat

surging from the port when the furnace is at high fire. Only trained

maintenance personal should perform this task. CAREFULLY open one of

the inspection doors and check for excessive amounts of back pressure

inside the combustion chamber. At high fire, you should be able to detect

pressure coming out of the port, from no more than 12” away from the

port opening, on the port opposite of the flue. If necessary, adjust waste gas

damper located in the exhaust flue stack.