Maintenance - RBI FUTERA II Series Installation And Operation Instructions Manual

FUTERA II INSTALLATION AND OPERATION INSTRUCTIONS

MAINTENANCE

WARNING: Disconnect electrical power and close
the manual gas shut off valve before performing
maintenance or severe personal injury may result!
CAUTION: Servicing, inspection and adjustment must
be done by a trained technician in accordance with all
applicable local and national codes. Improper servicing
or adjustment can damage the boiler /water heater!
The boiler/water heater must be cleaned and inspected at
least once a year and before each heating season. Make
sure that the burner and ignition components are free from
dust, soot, dirt, corrosion or other deposits that would
impair the boiler/water heater's performance. Refer to page
34 for component identifi cation.
CAUTION: Improper burner servicing can result in
premature burner failure voiding the warranty!
Burner Removal & Inspection
1. Close the manual shutoff valves in the gas supply lines
and turn off electrical power to the boiler/water heater.
2. Remove the jacket top panel.
3. Remove the combustion chamber top panel.
4. Remove the air gas mixing tube.
5. Disconnect the pilot tubing and ignition/sensing lead
from the burner.
6. Remove the four nuts that attach the burner to the heat
exchanger.
7. Carefully lift the burner out of the unit.
8. Inspect the burner for damage or signs of deteri-
oration. Use a brush or compressed air to remove any
debris from the burner ports.
9. DO NOT install a damaged or badly corroded burner,
replace it.
10. Install the burner making sure that the burner gasket
is not torn or deteriorated. If it is, replace it.
11. Reassemble the unit following the removal steps in
reverse order.
Heat Exchanger Inspection
1. Close the manual shutoff valves in the gas supply lines
and turn off electrical power to the boiler/water heater.
2. Remove burner following the instructions in the Burner
Removal & Inspection section.
3. Remove the front jacket panel and combustion
chamber door.
4. Inspect the inside and outside of the heat exchanger
for signs of damage, sooting or corrosion.
5. The outside surfaces of the copper tubes should be free
of any soot deposits. A slight black smudge is normal
with some types of gases. Black soot indicates poor
combustion. Green deposits indicate condensation due
to low return water temperatures. In either case the heat
exchanger must be cleaned thoroughly and the problem
resolved before the boiler/water heater is returned to
service.
6. If there are no signs of damage, sooting or corrosion,
reassemble the unit following the previous steps in
reverse order.
7. A badly corroded or damaged heat exchanger must
be replaced, see the Heat Exchanger Repair &
Replacement section.
Heat Exchanger Cleaning
1. Close the shut off valves in the inlet and outlet piping.
On heating systems close the system fi ll valve and
relieve the system pressure from the boiler by carefully
lifting the relief valve or opening the drain valve.
2. Disconnect the boiler/water heater from the system
piping.
3. Remove the eight bolts on the rear pipe enclosure
panel.
4. Remove the front jacket panel and combustion
chamber door.
5. Slide the heat exchanger out of the unit.
6. Remove the "V" baffl e straps and "V" baffl es.
7. Thoroughly clean the heat exchanger with water from
a high-pressure hose. Use a soft bristle brush if
necessary.
8. Replace the cleaned heat exchanger and other
components in the reverse order of their removal.
Heat Exchanger Repair & Replacement
1. A leaking or otherwise damaged tube(s) can be
replaced as outlined in steps 2 through 8.
2. Remove the heat exchanger from the boiler/water
heater as outlined in the Heat Exchanger Cleaning
section.
3. Remove the pipe plugs from the inlet/outlet and return
headers opposite from the ends of the tube(s) being
replaced.
4. Carefully cut the damaged tube(s) in half taking care
not to damage the adjacent tubes and remove.
5. Install and swage/expand in place the new tube(s).
6. Replace the pipe plugs using a suitable tread sealant
on each one.
7. Sagging or distorted heat exchanger tubes are an
indication of low water fl ow through the system. A
damaged heat exchanger must be replaced and the
condition that caused the damage resolved before the
boiler/water heater is returned to service.
8. Replace the heat exchanger and other components in
the reverse order of their removal.
9. The torque values for the bolts that secure the
removable headers are 30-50 ft lbs. Once bolts have
been started and secured the tightening sequence is
as follows:
1) Middle top
2) Middle Bottom
3) Right Top
4)n Left Bottom
5) Left Top
6) Right Bottom
Air Intake & Vent System
Thoroughly inspect the air intake and vent systems for any
signs of blockage, corrosion or leakage. Immediately
replace any unsound vent system piping. Inspect the air
fi lter and wash with warm water and soap if dirty.
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