21
4. Visually inspect the PVC condensate drain pipe for proper
operation. If the drain pipe shows any signs of blockage,
leakage, or deterioration contact a qualified service agency
to clean, repair, or replace it immediately.
5. Check air vent(s) for leakage.
STEP 4
—
Periodically During Heating Season
Where low water cut offs are used, a periodic inspection of the
low water cut off is necessary, including flushing of float type
devices. Refer to low water cut off manufacturer’s specific
instructions.
STEP 5
—
End of Heating Season--Annual Shutdown
Procedure
1. Follow instructions “TO TURN OFF GAS TO
APPLIANCE.”
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. Otherwise, do not
drain system or boiler.
STEP 6
—
Annual Examination and Cleaning of Boiler
Components
The following service procedures must be performed only by a
qualified service agency. Boiler owner should not attempt these
procedures.
1. Before Servicing, turn off electrical power to boiler at
service switch. Close manual gas valve to turn off gas
supply to boiler.
2. Flue passages are examined by removing the blower
assembly from the casting. Refer to the repair parts
diagram for the boiler block and piping assembly at the
end of this manual. The procedure for examining and
cleaning the burner is described below.
Any buildup of sediment or aluminum oxide (white
powdery or flaky substance) in the flue passages must be
cleaned as follows:
a. Remove jacket front and top panels.
b. Confirm that manual gas valve is closed and
disconnect gas line to gas valve at union.
c. Disconnect wires to gas valve and igniter.
d. Remove air inlet assembly from gas valve.
e. Loosen but do not remove five (5) nuts attaching
blower adapter assembly to boiler.
f. Remove two (2) igniter screws and very carefully
remove the igniter.
Use care when removing the
igniter, it is very brittle!
Do not touch the igniter
element with your fingers or hands as oil or debris will
cause premature failure to the igniter.
g. Remove five (5) nuts and remove blower adapter
assembly. Remove burner and gaskets.
h. Aluminum oxide deposits are water soluble and may
be rinsed away with spraying or running water.
i. Use a flexible handle nylon brush to loosen sediment
and aluminum oxide on all heating surfaces of boiler.
Refer to the repair parts diagrams.
Be sure that you
do not get brush stuck in heat exhanger!
j. After brushing and rinsing, remove any remaining
loosened sediment using a shop vacuum with a snorkel
attachment.
k. Inspect burner for any foreign matter in the flame ports
or inside the burner. Any foreign matter should be
removed by blowing with compressed air or
vacuuming.
l. Reinstall burner and gaskets and position blower
adapter assembly over studs. Install five (5) nuts but
do not tighten. Reinstall igniter and igniter gasket and
fasten with two (2) screws.
Use care when installing
the igniter. It is very brittle!
Do not touch the igniter
element with your fingers or hands as oil or debris will
cause premature failure to the igniter. Tighten five (5)
nuts holding blower adapter assembly.
m. Connect:
(1.) gas line to gas valve
(2.) air inlet assembly to gas valve using 2” x 1--1/2”
flexible coupling
(3.) pressure switch hose to gas valve and air inlet
assembly
(4.) 2 inch flexible coupling to boiler exhaust port
(5.) igniter wires
(6.) gas valve wires
3. Visually inspect the condensate trap. Refer to repair parts
diagrams. Any foreign material or debris that is visible in
the condensate lines needs to be cleaned out as described
below.
a. Remove 1/2” PVC cap from 1/2” PVC tee.
b. Inspect for sediment or blockage.
c. Flush out with water or vacuum.
d. Follow the instructions under “NEAR BOILER
PIPING” for filling condensate trap with water.
e. Replace 1/2” PVC cap.
4. Inspection of the flue connector requires the following
steps (Refer to the repair parts diagram.)
a. Loosen the clamp on the draft inducer end of the 2
inch flexible coupling that connects the vent tee to the
exhaust port.
b. Inspect interior of vent tee. Any buildup of sediment
on the inside surface must be cleaned.
c. Reconnect the 2 inch flexible coupling to the draft
inducer outlet.
STEP 7
—
Differential Air Pressure Switch Check
The following steps and diagram indicate the locations of the
connection points required to check the differential air pressure.
The differential air pressure switch is a safety device which will
prevent the boiler from firing if there is an air intake, boiler heat
exchanger or vent blockage.
Turn off service switch, or lower thermostat setting.
Remove vinyl caps from tee. Install testing lines as shown to
inclined manometer or differential pressure gauge with the ability
to read 0.01” to 5.0” w.c.
Turn on service switch and set thermostat to call for heat. (See
Fig. 20.)
If manometer readings do not correspond to the chart above,
check for possible causes:
S
Blockage or moisture in suction lines to switch.
S
Blockage in air intake or vent pipes.
S
Undersized air intake or vent pipes.
S
Loose blower wheel on motor shaft.
S
Incorrect pressure switch or pressure switch setpoint
When pressure reading is proper and the pressure switch is
operating properly, remove testing lines and reinstall vinyl caps to
Tee and 3--way connector.
SERVICE HINTS AND TROUBLESHOOTING
See Fig. 21--32.