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XIII. Service and Maintenance
i.
Unplug the ignition, ground, and flame rod wires from the ignition electrode and the flame rod (Figure
13.2).
j.
Use a 10 mm wrench to remove the four nuts securing the fire door to the heat exchanger (Figure
13.2). Carefully remove the door/blower/gas valve assembly from the heat exchanger, being careful
not to damage the refractory insulation on the inside of the door (see Refractory Warning on page 133)
or the electrodes.
k. Inspect the heat exchanger combustion chamber and vacuum any debris found on the coil surfaces.
If necessary, the coils may be brushed with a nonabrasive, nonmetallic brush. Do not use cleaning
agents, solvents, acid or alkali products of any type to clean the heat exchanger .
l.
Inspect the target wall and fire door insulation. If either shows signs of damage, it must be replaced.
m. Inspect the burner for heat damage or other deterioration. Use a non-metallic brush or source of
compressed air to clean off dust or debris from ports.
n. Inspect the ignition electrode and flame rod for deposits. Clean any found with steel wool. Do not
use sand paper or Emory cloth for this cleaning. Inspect the ceramic portion of both of these parts for
cracks and replace if any are found. Verify that the ignition electrode gap is within the range shown in
Figure 13.3.
o. Inspect the blower gas valve assembly, looking for dust, lint, or other debris that may have been drawn
into this assembly. Excessive deposits may be vacuumed out.
Inspect all rubber and plastic components on the blower/gas valve assembly, looking for deterioration.
Replace blower and/or gas valve if deterioration is found.
p. Inspect and clean the condensate trap. Place a bucket under the condensate cleanout cap on the
bottom of the boiler (see Figure 2.1) to catch water in the trap as well as the ball and ball support.
Unscrew the cap, being careful not to lose the ball or ball support. Flush any debris found in the trap
with water – do not use other cleaning agents. Reassemble the trap as shown in Figure 13.4.
q. Reinstall the fire door/blower/gas valve assembly, following the above steps in reverse order.
WARNING
Asphyxiation Hazard. Do not operate the boiler without the ball and ball support in
place. Doing so could result in flue gas leakage into the indoors resulting in personal injury or death from
Carbon Monoxide (CO) poisoning.
NOTICE Attempting to clean the heat exchanger or trap with anything other than water could result in
condensate backup, causing the boiler to shut-down.
CAUTION
Do not over tighten fire door mounting nuts. Doing so could break the fire door mounting
studs. If any of these studs are damaged, the heat exchanger must be replaced. Use of a short 10 mm box
wrench will reduce the risk of damaging these studs.
r.
Inspect the vent system to verify that:
•
All gaskets and joints between the boiler heat exchanger and terminal are leak tight.
•
All supports are intact and vent system is properly pitched
•
All pipe is in good condition. Look for damage such as cracks, heat distortion, discoloration, and
embrittlement. If any such damage is found, the pipe must be replaced and the cause of the
damage identified.
•
Vent/Intake terminals are in good condition, free from blockages, and still correctly located relative
to doors, windows, decks, etc.
•
There is no gasoline, flammable liquids/vapors, or halogen based products stored in the vicinity of
the vent or inlet terminals. Also verify that there are no chemical products containing chlorine,
chloride based salts, chlorofluorocarbons, paint removers, cleaning solvents, or detergents stored
near the air intake terminal.
107672-03 - 5/18
(continued)
137
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