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Page 16
Heating Surface Cleaning
WARNING: Failure to disconnect all electrical
power to the boiler before cleaning it could
result in a fi re or severe personal burn injuries!
WARNING: Never attempt to operate the boiler
with the cleanout cover plates removed! Failure
to comply with this warning can result in a fi re
which could cause extensive property damage,
severe personal injury or death!
Disconnect all electrical power to the boiler before
proceeding. Remove the cleanout cover access panel
from the left side of the boiler. Remove the cleanout
cover(s) taking care not to damage the insulation
between the cover(s) and the boiler. Use a wire brush
to thoroughly clean the fi reside surfaces. For the best
results, start brushing from the top and work down toward
the combustion chamber. Disconnect the fl ue pipe and
inspect it and the smoke hood for soot build up. Clean
them thoroughly before reconnecting them. Open the
cleanout door on the right side of the burner mounting
plate. Carefully vacuum any soot or scale from the bottom
of the combustion chamber. Do not contact the ceramic
blanket in the bottom of the combustion chamber or it
will be damaged.
IMPORTANT - If the ceramic blanket is damaged
it must be replaced! Failure to replace a
damaged ceramic blanket can result in the
failure of the cast iron sections!
Inspect the cleanout door gasket and insulation and
replace them if damaged. Close the cleanout door and
tighten it into place. Inspect the cleanout cover insulation
and replace it if damaged. It is important to maintain
the integrity of the gas seal by careful installation of
the cleanout cover plate. Be sure there is no opening
to allow gases to escape. Install the cleanout cover(s)
and tighten into place. Install the cleanout cover access
panel. Restore electrical power to the boiler and ensure
that it operates properly.
Chimney and Smoke Pipe
Be sure that the chimney and smoke pipe do not become
obstructed by birds nests, squirrels, soot, chimney liner
deterioration, or other debris. Keep chimney cleanout
doors closed and sealed tight around the frames. Be sure
the smoke pipe is inserted only at the nearest chimney
liner surface and seal around the pipe with insulating
cement.
WARNING: Be sure that no combustible
materials are stored close to the boiler or
smoke pipe. Fires can cause personal injury and
property damage.
8 SERIES BOILER INSTALLATION AND OPERATING INSTRUCTIONS
8-SERIES WIRING
The 8-Series boiler comes pre-wired with factory
harnesses that connect the safety control system. These
boilers are equipped with a harness system utilizing a
6-pin electrical connector that joins the boiler to the
burner. Burners from Carlin, Beckett and Riello can be
connected to both steam and water boilers utilizing this
connector. The harness system is designed to make
burner replacement and routine servicing quicker and
safer to perform. The high limit control system on this
boiler is 120 VAC power. Only trained technicians should
attempt to troubleshoot or repair the control system.
All power should be turned off before attempting any
service work.
When troubleshooting the electrical system on an 8-
Series boiler it is only necessary to check the wires
that apply to the specifi c burner and boiler combination
being used. There may be wires in the harness that are
not used for the particular application at hand. These
wires have been included to allow for all the various
combinations of boiler and burner choices. Consult the
Electrical Wiring Book shipped with each boiler for
details.
Special Boiler Harness Requirements
On each boiler there are two harnesses with a 6-pin
connector -- the "Boiler Harness", which is provided
by the factory, and the "Burner Harness", provided by
the burner manufacturer. The factory manufactures two
different "Boiler Harnesses":
1. The "Water" harness is primarily used on water
boilers but is also found on steam boilers with the
optional Float Low Water Cut-off. It runs from the
junction box directly to the burner (Part #79004).
2. The "Steam" harness is only used for the steam
boiler with the Probe Low Water Cut-off. This
harness is shorter and has an additional ORANGE
wire used to signal the Cycle Guard timer to reset
at the beginning of the call for heat. (See the steam
boiler section on the Probe Low Water Cut-off for a
description of the Cycle Guard feature). The steam
harness runs from the Low Water Cut-off to the
burner (Part #79002).
Both boiler harnesses have a RED wire that provides
a constant 120V power supply used by the Carlin and
Riello burners. This RED wire is always provided, but
not used, on boilers equipped with the Beckett burner.
The Beckett "Burner Harness will not have a red wire or
corresponding pin in the connector.
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