FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS
32
RIOM-18-REV. A
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 thread 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.
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.
Controls
Use the “GENERAL OPERATION” and “CHECKING AND
ADJUSTMENTS” sections of this manual for reference.
1. Check the operating controls for proper operation.
2. A fl oat type low water cutoff device must be fl ushed
out per the manufacturers’ instructions. The probe on
a probe low water cut off must be removed, cleaned
and inspected at least once a year. Ensure that the
low water cutoffs operate properly. If not, replace
them.
3. The fl ow switch contacts must be open when water
fl ow is not present.
4. The relief valve should not weep or discharge water
at normal system pressure. If it does, contact a
qualified service technician to have it inspected.
NEVER try to clean or repair the relief valve! If the
valve fails to operate properly, have it replaced!
5. The aquastat high limit controls the maximum water
temperature in the boiler. If the water temperature
reaches the set temperature before the demand for heat
has been met, the aquastat high limit should shut the
boiler off. The water temperature should never exceed
the maximum set point of
250°F
,
121°C
, for boilers
and
210°F
,
99°C
for water heaters. The aquastat high
limit cannot be repaired. If it fails to function properly,
replace it.
6. Visually check the pilot and main burner fl ames to
ensure proper operation, see Figures 18 & 19.
WARNING: A yellow, fl oating fl ame indicates a lack
of combustion air. Do not operate the boiler/water
heater until the problem is solved or severe
personal injury or death may occur!
Figure 19 - Main Burner Flame
