Cleaning Heat Exchanger Flue Side, 155 - Weil-McLain Series 2 Manual

® S
ERIES
Cleaning heat exchanger flue side, 70
Inspect and clean the burner
1. See Figure 113, page 106 part D.
a. Slide the refractory (item 12) over the burner and off.
Set the refractory aside where it will be kept clean and
protected from damage. If the refractory is damaged, it
must be discarded and replaced with a new one.
b. Remove the three (3) #20 Torx screws (item 14) securing
the burner (item 10) to the cover plate. Set aside.
c. Remove the burner and its gasket (item 13).
d. Inspect the interior of the burner. Brush and vacuum the
interior if needed to remove lint or sediment. Alternative
cleaning methods: • blow air or nitrogen from the inside
out; • clean with a water spray from inside the burner;
• swirl the burner thoroughly in a bucket of mild liquid
laundry detergent water, then rinse thoroughly.
e. Inspect the burner exterior. It must be in good condition,
with no visible damage.
f. Inspect the burner gasket. If the gasket is damaged, obtain
a new gasket before re-installing the burner.
Inspect and clean the heat exchanger
1. Access the heat exchanger interior by following the previous
instructions.
2. See Figure 113, page 106 part E.
3. Before using water to clean the heat exchanger, remove the
control module (item 16). Label wires if they are not labeled.
Set aside. Remove all connectors and wire harnesses from the
control module and then remove the two (2) screws securing
it to the bracket.
4. Use a strong light to visually inspect the interior of the heat
exchanger. Make sure the flue ways (tubes) are clear and
unobstructed.
5. Use a vacuum cleaner to remove any accumulation on
the heating surfaces. This includes removing any pieces of
refractory that may have dropped into the exchanger.
DO NOT use any solvent when cleaning the
exchanger.
6. If the vacuum cleaner is unable to clean completely, wash the
heating surfaces with clean, warm water.
a. Place a bucket under the boiler condensate drain
connection.
b. Loosen and move the condensate bracket, then loosen
the condensate trap upper nut and slide the trap off of the
drain connection. (See Figure 65, page 58 for reference.)
c. Spray fresh water into the heat exchanger and tubes to
remove sediment. Collect water in the bucket below.
7. Inspect the heat exchanger cover plate refractory. Replace if
insulation is damaged.
Reinstalling ECO 70 components
1. See Figure 113, page 106 for reference.
2. Reinstall the control module (item 16) to the control bracket
and reconnect all connectors and wire harnesses.
3. Reinstall the burner (item 10) and burner gasket (item 13) on
the cover plate (item 6). Tighten the burner screws (item 14)
using a torque wrench. The screws must be secure, but the
torque must not exceed 20 inch-pounds.
Part number 550-142-190/1218
2
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G
AS FIRED WATER BOILER
— Boiler Manual
4. Apply a ring of silicone adhesive on the cover plate (to secure
the refractory).
5. Slide the refractory (item 12) over the burner. Align the
refractory and press in place.
6. handling the assembly, allow the adhesive to set
Before
enough that the refractory is firmly held in place.
7. Reinstall the igniter assembly (item 7).
a. The igniter gasket must be intact and in good condition.
Replace with a new gasket if necessary.
b. Insert the igniter into the cover plate opening, with the
gasket in position.
c. Reinstall the two (2) Socket head Allen bolts finger tight.
d. Use a torque wrench to tighten the igniter bolts. DO NOT
exceed 20 inch-pounds torque.
8. Reinstall the venturi/cover plate assembly (items 5 and 6) and
secure the cover plate with 10mm hex nuts (item 9).
You must gradually tighten the cover plate nuts
using a torque wrench. The final torque MUST
NOT exceed 45 inch-pounds. Alternate tightening
until all nuts reach 45 inch-pounds.
9. Reconnect the ignition cable and the igniter ground wire.
10. Reinstall the blower (items 2).
a. Reconnect the two (2) blower wiring harnesses.
b. Slide the blower up onto the venturi sleeve.
c. Reinstall the blower retainer clip, item 15.
11. Reinstall the air inlet silencer (item 1) by pressing onto the
air inlet adapter. Rotate into the normal vertical position (see
part A) of Figure 113, page 106.
12. Slide the gas valve (item 3) outlet collar into the venturi
(item 5) opening. Make sure the gas valve-to-venturi O-ring
(item 5, Figure 12, page 16) is in place and in good condition.
Inspect the gas valve flex line, making sure there are no signs
of wear or damage. Replace if necessary.
13. Slide the gas valve retainer clip (item 4) into position to
secure the gas valve.
14. Reinstall the condensate trap and bracket on the
boiler condensate drain connection, if removed. (See
Figure 65, page 58 for reference).
Perform a complete start-up procedure when
putting the boiler back into service. See page 79
and all instructions for start-up and verification.
Include a soap suds leak test on all interior and
exterior gas piping after starting the boiler.
(continued)
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