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SlimFit
COMMERCIAL CONDENSING GAS
Annual startup
Check burner flame
The boiler contains ceramic fiber materials. Use care
when handling these materials per instructions on
page 85 of this manual. Failure to comply could
result in severe personal injury.
1. Inspect flame through the observation window using the
procedure on page 80.
a. The high fire flame should be blue and should be stable.
The burner surface should be covered with orange dots.
b. The low fire flame should be stable and evenly distributed
over burner surface with a uniform orange color.
2. If the flame is unsatisfactory at either high fire or low fire,
perform the testing specified on page 80. If the problem re-
mains, turn off the boiler and allow the boiler to cool down.
3. To access the burner, first turn off all power to the boiler:
a. Disconnect the two wire harnesses connected to the
blower.
b. Use a 13-mm socket wrench to remove the three nuts that
secure the mixing tube to the right-end heat exchanger
section (Figure 77).
c. The mixing tube, blower, venturi and gas train can be
pulled to the right to clear the mounting stud, then
pulled forward and placed on a support while working.
(If necessary, disconnect the ignitor ground wire and the
wire harnesses to the gas valve and gas pressure switches.)
4. Remove the burner gasket and burner (see Figure 78).
5. Clean the burner ports both inside and outside surfaces, us-
ing a vacuum cleaner or compressed air. If necessary, use a
soft-bristled brush to loosen particles.
Do not used compressed air unless doing so outside
and wearing eye protection.
6. To replace the burner:
a. Insert the burner first. When inserting, place your hand
inside the burner throat and tilt the back end of the burner
up until the burner flange meets the heat exchanger. This is
necessary to prevent the burner from rubbing on the heat
exchanger burner support stubs on the left end section.
b. Align the burner flange notch with the notch in the casting
above the burner opening.
c. Inspect the burner gasket. It must be in good condition.
If not, replace with a new gasket (see Replacement parts
at the end of this manual).
d. Place the gasket over the three studs.
The burner-opening studs are unevenly spaced to
ensure the gasket and the mixing tube are properly
positioned.
7. Position the mixing tube over the studs. Replace the three nuts.
Tighten securely (to 12 N-m/106 in-lbs/8.8 ft-lbs).
8. Reconnect any wiring that was disconnected.
9. Retest the boiler, making sure the flame is acceptable after
the cleaning.
Check flame signal
1. Navigate to Diagnostics/Inputs on the Control display (see
Figure 65, page 71). The flame signal value must be at least
20 above the Shutdown values given in Figure 79.
2. If the flame signal drops to less than 20 above the Shutdown
values, the Control will attempt to correct by increasing the
boiler firing rate to increase flame signal.
88
-
FIRED WATER BOILER
(continued)
(See Figure 77)
—
Boiler Manual Series 2
Burner access
Observation
window
Nuts
NOTE: Ignitor ground wire must be attached
to the top ignitor mounting screw.
Burner removal and replacement
IMPORTANT — Align the
burner flange notch with the
notch in the casting.
Burner
Flame signal shutdown values
550
110
750
110
3. A lower flame signal may indicate a fouled ignitor or dam-
aged ignitor insulation. If cleaning the ignitor does not
improve, ground wiring is in good condition, and ground
continuity is satisfactory, replace the ignitor.
4. If flame signal still remains low, inspect the vent and air
piping. Then inspect the heat exchanger, following the
procedures given in this manual for removal and reinstal-
lation of the heat exchanger cover plate and other boiler
components. Clean the heat exchanger as described in this
manual if necessary.
Mixing tube
Gasket
Mixing tube
130
130
Part number 550-100-162/0815
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