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Page 20
INSTALLATION & OPERATING INSTRUCTIONS
BOILER MAINTENANCE
WARNING: The ceramic combustion chamber in the
burner box and its gasket contain crystalline silica.
Wear a tightly fitted dust mask when servicing the
burner and gently handle the burner and its gasket to
prevent inhalation of airborne fibers. Crystalline silica
fibers have been identified as carcinogenic, or possibly
carcinogenic when inhaled.
CAUTION: Servicing, inspection and adjustment must be
done by a trained technician in accordance with all
applicable local and national codes. Verify proper operation
after servicing. Improper servicing or adjustment can
damage the boiler!
The boiler should be cleaned and inspected once a year, before
each heating season. Use a soft brush and/or a vacuum
cleaner to ensure that the burners and ignition components are
free from dust, soot, dirt, corrosion or other deposits that would
impair the boiler's performance. Refer to page 22 for
component identification.
Burner Removal
1.
Close the manual shutoff valve in the gas supply line and
turn off electrical power to the boiler.
2.
Remove the front access panel.
3.
Disconnect the gas supply, see FIG. NO. 8.
4.
Where applicable, disconnect the wires and pilot tube from
the gas valve.
5.
Remove the two nuts holding the manifold assembly and
remove the assembly.
6.
Remove the top half of the burner support panel and the
burners.
Burner Installation
1.
Do not install damaged or badly corroded burners - replace
them.
2.
Insert the crimped end of each burner into the slot in the
burner base rear panel.
3.
Work the manifold assembly into position and start the
two retaining nuts. Slide the top half of the burner support panel
in place and tighten the nuts.
4.
Reconnect all wires, tubing and anything else disconnected
during the burner removal operation.
5.
Complete the reassembly and follow the instructions in the
BOILER OPERATION section of this manual.
GV100W BOILER
Heat Exchanger Cleaning
Remove the burners to protect them from falling rust and scale
by following the Burner Removal instructions.
1.
Remove the vent pipe, front access and top panels.
2.
Disconnect the inducer wires and carefully separate the
inducer from the flue collector.
3.
Remove the two flue collector retaining clips. Cut the RTV
seal and remove the flue collector.
4.
Clean the flue passages with a wire brush.
5.
Vacuum out the burner base and clean and inspect the
ignition system components. Damaged or badly corroded parts
must be replaced.
6.
Remove the old flue collector sealant and reseal the flue
collector. Use Dow Corning #732 RTV or an equivalent silicone
sealant. Install the flue collector retaining clips and screws.
7.
Clean then reseal the inducer using Dow Corning #732
RTV or an equivalent silicone sealant before reattaching it to
the flue collector.
8.
Replace the top panel.
WARNING: The flue collector and inducer must be
properly sealed. Allow the RTV sealant 24 hours to
cure before using the boiler. Improper sealing could
result in carbon monoxide poisoning!
9.
Reconnect the inducer wires and the vent system.
10. Follow the Burner Installation procedure above.
11. Once the sealant has cured, fire the boiler to make sure
that it operates properly.
Vent System
At least once a year the entire vent system must be thoroughly
inspected for any signs of blockage, corrosion or leaks.
Immediately replace any unsound vent system piping. Remove
any foreign matter in or near the vent terminal or around the
boiler that might obstruct the flow of combustion and ventilation
air. Inspect the condensate trap, if installed, for blockage and
clean if necessary. Every 3 to 6 months, lubricate the inducer
motor using 2 drops of 20W non detergent motor oil in each
oil port.
WARNING : Failure to properly inspect the vent system
on a regular basis may leave problems undetected that
can result in excessive levels of carbon monoxide
which can cause severe personal injury or death!
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