Weil-McLain Series 2 Manual page 111

® S
ERIES
Cleaning heat exchanger flue side, 155
Cleaning the ECO 155 heat exchanger
FLUE SIDE or accessing the burner,
when required
The boiler contains ceramic fiber materials. Use
care when handling these materials per instructions
on page 89 of this manual. Failure to comply could
result in severe personal injury.
Tools required
• Metric wrench or socket, 10mm
• Phillips head screwdriver, #2
• Socket with 8" extension,
• Torque wrench
• Putty knife
• 3mm Allen wrench
• (2) Large Cresent wrenches
Before proceeding:
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 removing two (2) screws at the bottom
of the jacket door.
4. Lift the jacket door up and away from the boiler to remove.
Remove and inspect the igniter assembly
1. See Figure 117, page 113 part A.
2. Disconnect the ground wire and ignition cable from the
igniter (item 7).
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
3. Remove the two (2) Socket head Allen bolts securing the
igniter to the heat exchanger cover plate (item 6).
4. Carefully slide the igniter out of its mounting slot.
5. Remove and inspect the igniter gasket. Replace with a new
gasket if necessary.
6. 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.
Remove components to allow access
1. See Figure 117, page 113 part A to locate components
referenced in the following.
2. Remove the air silencer and disconnect gas line:
a. See Figure 117, page 113 part A.
b. Locate the air silencer clip, item 8. Pull on the right side of
the clip until it rotates forward as shown in part A inset.
c. Slide the air silencer (item 1) down and off of the venturi
(item 5). Set the air silencer aside.
d. Disconnect the flexible gas line where it connects just
below the gas valve (item 3). Lay the free end of the
flexible gas line to the side.
Use two wrenches when disconnecting the flexible
gas line to prevent damage to the gas valve and other
gas line components.
Part number 550-142-190/1218
2
-
G
AS FIRED WATER BOILER
"
5/16
— Boiler Manual
e. Disconnect the two wire harnesses connected to the
blower and the wire harness connected to the gas valve.
3. It is RECOMMENDED to remove the blower/gas valve
venturi assembly (item 2) from the cover plate (item 6) by
removing the two " locknuts attaching them. This will
5/16
make removing the cover plate significantly easier.
4. Remove the heat exchanger cover plate assembly:
a. See Figure 117, page 113 part A, part C and part D.
b. Use a 10mm wrench to remove the five (5) M6 nuts (item
9) that secure the heat exchanger cover plate (item 6) to
the heat exchanger.
c. Lift the cover plate assembly vertically until the refractory
(part D, item 16) clears the heat exchanger.
d. Slide the cover plate forward as you tilt the front
downward until the rear lip clears the cabinet. Avoid
gouging the refractory on the heat exchanger studs.
DO NOT gouge or crack the refractory. The
refractory is made of ceramic fiber materials. Read
the ceramic fiber WARNING on page 89 before
handling or disposing of ceramic fiber materials.
e. Carefully place the cover plate assembly aside.
Handle the cover plate assembly carefully to avoid
damage to the components or refractory. Place the
assembly on a clean, flat surface.
Inspect and clean the burner
1. See Figure 117, page 113 part C and part D.
2. Use a Phillips screwdriver to remove the three (3) M4 screws
and flat washers (item 10) that secure the burner access cover
(item 4) to the heat exchanger cover plate (item 6).
3. Remove the burner cover plate (item 4) and the burner (item 11).
4. Remove the burner gasket (item 12) from the heat exchanger
cover plate if still in place. This gasket is graphite and may pull
apart or stick to the burner on removal. Replace the gasket
with a new one during reassembly.
5. Inspect the burner access cover seal (item 13). Discard and
use a new seal during re-assembly if the seal is damaged in
any way.
6. 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.
7. Inspect the burner exterior. It must be in good condition,
with no visible damage.
8. Clean the underside of the burner flange (see item 14) with
a soft brush to remove any gasket fragments remaining.
Inspect refractory and replace burner gasket
1. See Figure 117, page 113 part B.
a. Inspect the refractory (item 15) to make sure it is intact,
with no visible damage.
b. If the refractory must be replaced, use a wide-blade putty
knife to gently pry the refractory from the heat exchanger
cover plate. The refractory is attached with silicone
adhesive and should separate with a little pressure on the
putty knife.
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