Finned copper tube gas boilers & water heaters – Boiler Manual
32
Heat Exchanger Removal, Cleaning
& Replacement - See Figure 20
1. Close the shut off valves in the inlet and outlet piping. On heating
systems close the system fill valve and relieve the system pressure
from the boiler by carefully lifting the relief valve or opening
the drain valve.
2. Drain the boiler/water heater and disconnect it from the system
piping.
3. Remove the inlet/outlet and return headers.
4. Remove the jacket front panels.
5. Loosen, 4 turns, but
don’t remove
the 6 screws, (3 on each
side) holding the heat exchanger upper rails in place, Figure 21.
6. Disconnect the gas piping at the ground joint unions. Also
disconnect the pressure sensing lines, pilot tubing and ignition
and sensing leads.
7. Remove the upper partition panel, 1050 through 2300 models.
8. Remove the 1/4 in nuts and washers holding the upper
combustion chamber front panel in place and carefully remove
it.
9. Carefully slide the heat exchanger out of the unit.
10. Remove the “V” baffle straps and “V” baffles.
11. Thoroughly inspect the heat exchanger for signs of damage. If
there is no damage, clean the heat exchanger with water from
a high-pressure hose. Use a soft bristle brush if necessary.
Never clean the heat exchanger while it’s in the boiler/
water heater or the combustion chamber will be
destroyed!
12. Sagging or distorted heat exchanger tubes are an indication of
low water flow through the system. A leaking or otherwise
damaged heat exchanger must be replaced and the condition
that caused the damage resolved before the boiler/water heater
is returned to service.
13. If the heat exchanger isn’t damaged rewire the heat
exchanger baffles in place and slide the heat exchanger back
into the unit.
14. Reinstall all of the other components in the reverse order of
their removal.
15. The torque values for the bolts that secure the removable headers
are 17-20 ft lbs. Once bolts have been started and secured the
tightening sequence is as follows:
1) Middle Top
2) Middle Botom
3) Right Top
4) Left Bottom
5) Left Top
6) RightBottom
Figure 20
Burner and heat exchanger servicing
