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Finned copper tube gas boilers & water heaters – Boiler Manual
31
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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.
a. Th e probe on a probe low water cut off must be removed,
cleaned and inspected at least once a year.
b. Ensure that the low water cutoff s operate properly. If not,
replace them.
3. Th e 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 qualifi ed 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. Th e aquastat high limit controls the maximum water temperature
in the boiler.
a. 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 .
b. Th e water temperature should never exceed the maximum
set point of 250
o
F, 121
o
C, for boilers and 210
o
F, 99
o
C for
water heaters.
c. 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 Figure 21.
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 21
Main Burner Flame
Manometer test port manifold
1. Th e Futera XLF includes a manometer test manifold. Connect
the manometer pressure hose to the Pressure Tap port shown
in Figure 22.
Figure 22
Manometer connections to manifold
2. For pilot gas pressure and pilot air pressure readings, DO NOT
connect the other side of the manometer. Leave the other side
open to room pressure.
3. For Ps (pressure signal) readings, connect the other side of
the manometer to the manometer reference port as shown
in Figure 22. These pressure signals may be used for
troubleshooting when specifi ed by factory support.
4. Figure 23, page 32 shows the sensor hose connections inside the
Futera XLF air box.
