Cleaning Heat Exchanger Flue Side - Weil-McLain EcoTec 80 Manual

G -
®
ECO Tec
AS FIRED WATER BOILER
Cleaning heat exchanger flue side
Cleaning the heat exchanger FLUE
SIDE or accessing the burner, if
required
The boiler contains ceramic fiber materials. Use care
when handling these materials per instructions on
page 106 of this manual. Failure to comply could
result in severe personal injury.
Long-handled Torx driver, #20 - burner screws
3mm Allen wrench - ignition electrode screws
8mm Wrench - blower lock nuts
10mm Wrench or socket - heat exchanger cover nuts
Torque wrench - proper tightening
(1) Large Crescent wrench - gas valve removal
(1) Pipe wrench - gas valve removal
1. Shut down the boiler:
a. Follow "To Turn Off Gas to Appliance" instructions on
boiler and Operating instructions.
b. Close the boiler manual gas valve.
2. Allow time for the boiler to cool to room temperature if it
has been firing.
3. Remove jacket door by undoing the two (2) latches on each side.
4. Lift the jacket door up and away from the boiler to remove.
5. Remove Control Bracket Cover by removing the two (2)
screws and lifting it up.
6. Unplug display cable from control module and lift display
bracket assembly up from bottom. Once bottom tabs are
disengaged from control bracket, move assembly down to
disengage tabs from top cabinet and place assembly in a safe
location.
1. See Figure 114, page 129 part A to locate components
referenced in the following.
2. Remove the air silencer and disconnect gas valve and gas
flex line:
a. See Figure 114, page 129 part A, B and C.
b. Locate the clip (Item 2) connecting the air silencer
(Item 1) to the venturi (Item 7). Gently pull clip out and
away from the venturi, set aside. Slide silencer away back
and off of the venturi. Set the air silencer aside.
Label all wires, if they are not already labeled
prior to disconnection, when servicing controls.
Wiring errors can cause improper and dangerous
operation.
c. Disconnect wire harness connected to gas valve, the low
voltage wire harness connected to the blower, and the
high voltage wire harness connected to the blower High
Voltage jumper harness.
Support the gas valve. DO NOT allow it to hang
from the gas valve flex line.
Part number 550-100-260/0520
–
80/110/150/199
d. Disconnect the gas valve and gas flex line where it connects
to venturi to by loosening the gas valve swivel nut to
disconnect gas valve from venturi. Set the valve & gas
line to the side.
swivel nut and gas line to prevent damage to the
gas valve and other gas line components.
3. Remove the blower/venturi assembly.
a. See Figure 115, page 130, part D.
b. Remove the two (2) 5mm locknuts connecting the blower
and cover plate with 8mm wrench. Remove blower
assembly. Inspect blower gasket, replace if gasket has taken
a set or if any signs of wear.
c. Remove burner tube (80/110/199 models only) from cover
plate located under blower gasket. Inspect and set aside
d. Cut tape, 2 locations, that secures cover plate top
insulation to heat exchanger. Remove cover plate top
insulation, set to the side.
e. Gently set blower/venturi assembly aside. Inspect blower/
cover plate gasket (Item 9). If gasket appears damaged,
discard and replace with a new gasket.
f. Disconnect the ground wire and ignition cable from the
ignition electrode (Item 13).
g. Remove the ignition electrode (Item 13) by removing
the two (2) Socket head 3mm Allen igniter bolts, see
Figure 115, page 130 part E. Set the ignition electrode
and screws aside. Discard used gasket. Be careful when
handling the ignition electrode not to damage the igniter
ceramic. Obtain a new ignition electrode gasket before
reinstalling the ignition electrode.
h. Inspect the igniter ceramic and electrodes. Clean the
electrodes carefully with steel wool. If the igniter ceramic
is cracked or damaged, replace the igniter with a new one.
4. Remove the heat exchanger cover plate and burner:
a. See Figure 115, page 130 part F and part G.
Handle the heat exchanger cover plate/ burner
assembly carefully to avoid damage to the bottom
cover plate insulation with integrated seal. Place the
assembly on a clean, flat surface with the assembly
upside down, as shown in Figure 115, page 130
part F and part G.
b. Use a 10mm wrench or socket to remove the nuts (Item 11)
that secure the heat exchanger cover plate (Item 10) to the
heat exchanger. [Four (4) nuts (ECO Tec 80/110), five
(5) nuts (ECO Tec 150), six (6) nuts (ECO Tec 199).]
c. Carefully lift the cover plate assembly (part F, Item 10)
straight up vertically until the cover plate insulation with
integrated seal clears the heat exchanger studs.
d. Pull the assembly forward and out of the cabinet.
e. Turn the cover plate assembly over and place on a flat
surface.
f. Be aware of blower studs to avoid damaging studs,
insulation or burner.
B M
OILER ANUAL
when disconnecting the
127