Dunkirk Q95M-200 Installation, Operation & Maintenance Manual page 26

Following service procedures must be performed by
qualified service agent. Boiler owner shall not attempt
these steps. Failure to do so could result in death or
serious injury.
Perform regular service and maintenance by qualified
service agency at least once every 12 months to
assure safe, trouble free operation and maximum
efficiency.
Verify proper operation after servicing.
14,4 Annual Shut Down Procedure
1. Turn off gas to boiler as described in "To Turn Off Gas
To Appliance" Section 13.3 page 24.
2. If heating system is to remain out of service during
freezing weather and does not contain antifreeze, drain
system completely. If boiler will be exposed to freezing
temperatures, drain condensate lines.
14.5 Annual Examination And Cleaning Of Boiler
Components
1. Following service procedures must be performed by
qualified service agency. Boiler owner should not
attempt these steps.
2. Before servicing, turn off electrical power to boiler at
service switch. Close manual gas valve to turn off gas
supply to boiler.
3. Examine flue passages by removing blower/burner
assembly from casting. Procedure for examining and
cleaning the burner is described below.
4. Clean any buildup of sediment or aluminum oxide (white
powdery or flaky substance) in flue passages as follows:
A. Remove jacket front and top panels.
B. Confirm manual gas valve is closed and disconnect
gas line to gas valve at union. Disconnect pressure
switch hoses to gas valve and air inlet.
C. Disconnect wires to gas valve and igniter.
D. Loosen but do not remove five nuts attaching
blower adapter assembly to boiler.
E. Remove two igniter screws and carefully remove
igniter.
F. Remove five nuts and remove blower adapter
assembly, burner, and gaskets.
,
,
G. Aluminum oxide deposits are water soluble and
may be rinsed away by inserting hose into burner
opening of casting and slowly run water through
flue side of boiler and out condensate drain. Debris
rinsed away by this method will exit through
condensate drain. Be wary of drain lines getting
clogged and causing water to back up in the bottom
of casting.
H. Use flexible handle nylon brush to loosen sediment
and aluminum oxide on all accessible heating
surfaces of boiler. Take care not to get brush stuck
in heat exchanger.
I. After brushing and rinsing, remove any remaining
loosened sediment using shop vacuum with snorkel
attachment.
]. Inspect burner for any foreign matter in flame
ports or inside burner. Remove any foreign matter
by blowing with compressed air or vacuuming. If
burner cannot be cleaned, it must be replaced.
K. Reinstall burner and gaskets and position blower
adapter assembly over studs. Install five nuts do
not tighten, Reinstall igniter and igniter gasket
and fasten with two screws. Tighten five nuts
holding blower adapter assembly.
L. Connect gas line to gas valve, pressure switch hose
to gas valve and air inlet assembly, igniter wires,
and gas valve wires.
Inspect condensate trap. Clean out any foreign material
visible in condensate lines.
A. Inspect for sediment or blockage.
B. Flush out with water or vacuum.
C. Follow instructions in, "Filling Condensate Trap With
Water."
Inspect flue connector.
A. Loosen clamp on vent tee side of 2" flexible
coupling that connects vent tee to exhaust port.
B. Inspect interior of vent tee. Clean any buildup of
sediment on inside surface.
C. Reconnect 2" flexible coupling to vent tee.