Reassembly - IBC DC Series Installation And Operating Instructions Manual

NOTE
The safety warning regarding
burner refractory on page
4-2 of this manual must be
observed.
3-6
DC SERIES BOILERS / WATER HEATERS DC 15-95, DC 15-96, DC 20-125, DC 33-160
Disconnect the flue pipe from the condensate tray by rotating the nut
5.
counter-clockwise about 1/4 turn. Slide the flue pipe up and dis-engage the
bottom of the flue pipe from the condensate tray and slide down to remove.
Unplug the electrical connector at the gas valve.
6.
Loosen both the lower gas valve connection nut.
7.
O-ring in the lower gas connection and an O-ring and orifice in the upper
gas valve connection. Place these in a safe location to be used for re-
assembly. Cover the gas piping connections to prevent debris from
entering the gas piping.
When removing the heat exchanger cover in step 9, be careful
8. CAUTION:
not to damage the burner and refractory material located on the opposite
side of the heat exchanger cover. Use caution when handling refractory
materials. See Caution on page 4-2.
Remove all 9 or 11 – 6mm hex bolts and lock washers from the heat
9.
exchanger cover and carefully remove the front cover complete with the
fan and the gas valve attached. Carefully inspect the gasket sealing the
heat exchanger to the heat exchanger cover for damage, hardness, cracks,
and or discoloration. If damaged in any way the gasket must be replaced.
10. Place the heat exchanger cover in a safe location.
RE-ASSEMBLY
1. Carefully inspect the gasket sealing the heat exchanger to the heat
exchanger cover for damage, hardness, cracks, and/or discoloration. If
damaged in any way the gasket must be replaced. Inspect and clean if
necessary the mating gasket surface.
2. Place the heat exchanger cover onto the heat exchanger and loosely install
the 9 or 11 – 6mm hex bolts and lock washers removed in step 9. Tighten
the 6mm hex bolts in a cross pattern as shown in diagram on this page.
Connect the gas line to the gas valve ensuring the O-ring is in place.
3.
Tighten the gas valve nut. Ensure the upper gas valve connection is tight.
Re-connect the gas valve electrical connection.
Re-connect the electrical connections to the fan.
4.
5. Re-install the flue pipe to the vent connector at the top of the boiler / water
heater and to the condensate tray. Tighten the nut clockwise about 1/4
turn. Ensure the nut is properly engaged. Hand tighten only, Do Not Use
any tools to tighten the flue pipe nut.
6. Inspect the condensate trap for debris. Remove and clean if necessary. Fill
the condensate trap with water.
7. Turn on the gas supply valve to the boiler / water heater and inspect for
gas leaks. Use an approved leak detection solution; soap test all joints.
8. Ensure the boiler / water heater is full of water and purged of air if the
boiler / water heater was drained during dis-assembly - step 3.
Turn on the power to the boiler / water heater and create a call for heat or
9.
for domestic hot water.
Inspect the gasket around the heat exchanger cover and flue pipe
10.
connections for leaks.
Check flue gases for proper combustion. See Section 3.3 Commissioning
11.
for proper adjustments.
Re-install the boiler / water heater cover and set the boiler / water heater
12.
into normal operation.
NOTE:
INSTALLATION AND OPERATION INSTRUCTIONS
There is an