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60
Part 12 - Maintenance
A. Procedures
Periodic maintenance should be performed once a year by a
qualified service technician to assure that all the equipment
is operating safely and efficiently. The owner should make
necessary arrangements with a qualified heating contractor
for periodic maintenance of the boiler. The installer must also
inform the owner that a lack of proper care and maintenance of
the boiler may result in a hazardous condition.
BEFORE EACH HEATING SEASON a trained and qualified
service technician should perform the inspections as per the
boiler inspection and maintenance schedule in this manual.
Failure to do so could result in death or serious injury.
The combustion chamber insulation in this product contains
ceramic fiber material. Ceramic fibers can be converted
to cristobalite in very high temperature applications. The
International Agency for Research on Cancer (IARC) has
concluded, "Crystalline 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 a NIOSH certified dust respirator (N95). This type
of respirator is based on the OSHA requirements for
cristobalite at the time this document was written. Other
types of respirators may be needed depending on job
site conditions. Current NIOSH recommendations can
be found on the NIOSH website: http://www.cdc.gov/
niosh/homepage.html.
manufacturers, and phone numbers are also listed on this
website.
• Wear long-sleeved, loose fitting clothing, gloves, and eye
protection.
• Apply enough water to the combustion chamber lining to
prevent dust.
• Wash potentially contaminated clothes separately from
other clothing. Rinse clothes washer thoroughly.
NIOSH stated First Aid.
• Eye: Irrigate immediately.
• Breathing: Fresh air.
B. Combustion Chamber Coil Cleaning Instructions
*Before beginning this procedure, have on hand the following
items:
• a nylon, stainless steel, or brass brush (not steel)
• an FDA approved liquid lime scale remover in a spray bottle
• gloves and eye protection
1. Shut down the boiler by using the following steps:
a. Close the gas valve. Shut down the unit, and wait for it to
be cool to the touch.
b. Disconnect the condensate piping from the outside
connection, (not from the boiler side), so flow from
condensate reservoir can be observed.
c. Disconnect electrical connections from the gas valve, spark
electrode, flame rectification probe, and combustion blower.
d. Remove the four (4) screws on the aluminum ¾" NPT
connector on the right side of the gas valve.
e. Disconnect the wiring connected to the combustion blower
WHL-052 Rev. 4.28.16
NIOSH
approved
respirators,
motor.
f. Remove the six (6) 10MM nuts from the burner plate
assembly.
g. Pull the entire burner plate assembly with blower still
attached towards you, while removing or pushing aside any
wiring to allow removal of the assembly.
2. Spray the coils liberally with the FDA approved liquid lime
scale remover. Confine the spray to the area being cleaned.
Avoid getting the ceramic target wall wet. If the condensate
system is blocked, use a vacuum to clear it.
3. Scrub coils of any buildup with a nylon, stainless steel, or
brass brush. Do not use a steel brush. Vacuum the debris from
the coils.
4. Spray the coils again with clear tap water. Confine the spray
to the area being cleaned. Flush the combustion chamber with
fresh water until it runs clear from the condensate reservoir.
At this point, the boiler should be ready to be reassembled.
a. Inspect gaskets.
b. Reinstall the burner assembly
c. Replace and tighten the six (6) 10MM nuts to the burner
plate using staggered tightening sequence. (See detail.)
d. Reconnect all wiring connections
e. Inspect the gas valve. Ensure the O-ring is in place.
f. Replace the four (4) screws on the aluminum connector
on the gas valve. Turn the gas back on. (IMPORTANT:
CHECK FOR GAS LEAKS!)
g. Turn boiler power back on and create a heat demand.
When boiler is lit observe condensate flow from the boiler.
Be sure the boiler is operating properly.
h. Reconnect the condensate piping to the outside
condensate connection.
Do not use solvents to clean any of the burner components.
The components could be damaged, resulting in unreliable or
unsafe boiler operation, substantial property damage, severe
personal injury, or death.
Figure 28 - Heat Exchanger Detail
C. Cleaning Water Side of Heat Exchanger
1. Make sure power is turned off to the boiler. Run water
through the hot water system to ensure it is below room
temperature.
2. Close isolation valves on the return and supply connections
to the boilers as shown in the piping diagrams in this manual.
Slowly open the ball valves and release pressure into a bucket.
Once pressure is released, connect a hose to the water line
to flush the boiler. Scale removing solution may be used, but
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