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56
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
must be approved for use
with stainless steel and
FDA approved for use in a potable water system.
3. Thoroughly flush the heat exchanger before commissioning the unit
back in service.
D. Maintaining the Condensate System
The condensate trap assembly MUST BE PROPERLY INSTALLED
according to these instructions when operating the boiler. Operating
the boiler without the condensate trap assembly will cause flue
gases to leak and result in serious personal injury or death.
WHL-053 Rev. 00 Rel. 003 Date 7.21.17
When servicing is complete, make sure the condensate collector
cap is replaced securely. Failure to do so will cause venting issues
that will result in serious injury or death.
1. Ensure the boiler is powered off and has had time to cool.
2. Remove the hose clamp attaching the condensate trap to the
condensate hose from the heat exchanger. Remove the clear plastic
hose from the hose barb. Remove the condensate hose clamp
to detach the condensate trap from the drain tube. Remove the
condensate trap from the boiler.
3. Remove the bottom cap from the condensate trap.
4. Flush trap with fresh water to remove debris from the trap.
NOTE: Ensure the float moves freely within the trap. If the float does
not move, DO NOT reinstall the trap.
5. When the condensate trap is sufficiently clean, reinstall the
bottom cap on the trap.
NOTE: Ensure all parts shown in Figure 29, Condensate Detail, are
installed with the condensate trap. If any parts are missing, DO NOT
reinstall the trap. Replace the entire assembly.
Do not install the condensate assembly if a component is lost or
missing. Replace the entire assembly. Failure to follow this warning
could result in property damage, serious personal injury, or death.
6. Fill the condensate trap with fresh water prior to reassembly on
the boiler.
7. Install the condensate trap on the condensate hose from the
heat exchanger. Use the hose clamp to secure the trap. Attach the
clear plastic hose onto the hose barb. Reinstall the condensate hose
clamp to detach the condensate trap from the drain tube.
Do not operate the boiler without the clear hose attached from
the hose barb to the pressure switch. Failure to follow this warning
could result in property damage, serious personal injury, or death.
8. If a condensate neutralizer kit is installed with the boiler, check
the assembly when cleaning the condensate trap, and replenish
the limestone chips if necessary. When replacing limestone chips,
take care to ensure chips are no smaller than ½" to avoid blockage in
condensate piping (for piping details, refer to condensate neutralizer
installation instruction.)
9. Check condensate piping for sagging and/or leakage. Repair any
sags or leaks before restoring power to the boiler.
It is very important that the condensate piping be no smaller than
¾". To prevent sagging and maintain pitch, condensate piping
should be supported with pipe supports, and pitched ¼" per foot
to allow for proper drainage. Failure to maintain proper pipe size
and pitch could result in condensate leakage and potential water
damage to property.
The condensate line must remain unobstructed, allowing free
flow of condensate. If condensate freezes in the line, or if line is
obstructed in any other manner, condensate can exit from the tee,
resulting in potential water damage to property.
10. If the boiler has a condensate pump, ensure the pump operates
properly before considering maintenance complete.
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