TFTN 085-199 Installation and Operation Manual
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15.0
ANNUAL MAINTENANCE AND INSPECTION
This unit must be inspected at the beginning of every heating season by a Qualified Technician.
Annual Inspection Checklist
1.
Ignition is smooth and consistent, and the combustion fan is noise & vibration free.
2.
The condensate trap (siphon) and drain piping are cleaned of sediment, and the condensate flows freely. If a
condensate neutralizer is utilized, check the pH of the exiting condensate, if below 5 replace the neutralizer media.
3. Relief Valve and air vents are not weeping. If a relief valve discharges periodically, this may be due to thermal
expansion in a closed water supply system. Correct this situation and DO NOT PLUG THE RELIEF VALVE!
4. Low water cut off is tested (remove and clean a minimum of once every 5 years, see Section 10.0)
5. Examine all venting for evidence of leaks. Ensure vent screens are cleaned and clear of debris.
6.
Inspect the test port plug and gasket for leakage or signs of failure; replace if leaking or damaged.
7. Check the burner plate for signs of leaking.
8. The combustion chamber must be cleaned (cleaning frequency based on need for application
–
see below)
9.
Keep boiler area clear and free from combustible materials, gasoline, and other flammable vapors and liquids.
10. Ensure there is nothing obstructing the flow of combustion and ventilation air.
Note:
inform the owner about the need to keep the termination unobstructed, including preventing blockage by
snow buildup.
11. Listen for water flow noises indicating a reduction in boiler water flow rate or scaling.
Important
- The hydronic system may need to be flushed to eliminate hard water scale (Use Fernox DS-40 Descaler,
NTI p/n: 83450).
12.
Verify proper operation after servicing.
Wiring Labels
- Label all wires prior to disconnection when servicing controls. Wiring errors can
cause improper and dangerous operation.
Combustion Chamber Cleaning Procedure
NTI recommends having the combustion chamber cleaned after the first year of operation, with subsequent cleanings
scheduled based on the condition of the combustion chamber at the time. Units operating with LP Gas or in an industrial
environment may require more frequent cleanings.
Crystalline Silica
- Carefully read the warnings and handling instructions pertaining to Refractory
Ceramic Fibers before commencing any service work in the combustion chamber. Take all
necessary precautions and use recommended personal protective equipment as required.
Cleaning Checklist
1. Remove the demand for heat, allow the post-purge cycle to finish, turn gas and power supply off.
2. Working inside the cabinet, disconnect the cabling to the combustion blower, gas valve, spark igniter and flame
sensor, then remove the air intake piping and Gas Valve/Venturi assembly (gas line is disconnected at the factory
supplied union fitting).
3. Once the combustion chamber has cooled, remove the combustion blower followed by the burner plate
–
be
careful not to damage the insulation disc located underneath the burner plate.
4. Use a vacuum with a high efficiency filter to remove any loose debris or dust.
5. Remove the condensate trap from the bottom of the boiler and place a drain under the boiler condensate drain.
6. Wet the inside of the combustion chamber with warm water (do not use any chemicals). Use a garden hose with a
trigger nozzle to direct pressurized water through the heat exchanger tubes; the water will exit via the condensate
drain on the bottom. Continue process until the tubes are clear and the water runs clean. Use dry rags or plastic
to protect electrical components from being damaged by dripping or spraying water.
7. Disassemble the condensate trap and thoroughly clean it; then reassemble and securely connect it to the boiler
condensate drain, see Section 6.0.
8. Remove the burner from the burner plate; if necessary, clean using compressed air. Reattach the burner; ensure
the gasket is in perfect condition and is reinstalled (replace if necessary).
9. Inspect the insulation disc located on the under-side of the burner plate. Replace if damaged.
10. Re-install the burner plate; be sure the insulation disc is properly aligned. Reinstall remaining components in the
opposite order they were removed.
11. Perform the Start-up and Operational Checklist detailed in the previous section.
Replace any gaskets or insulation discs that show any signs of damage and do not re-use. Failure
to follow these instructions may result in fire, property damage or death.
