MC2: 10/03/12 Page
64
of
90
AERCO International, Inc.
•
100 Oritani Dr.
•
Blauvelt, NY 10913
•
Ph: 800-526-0288
GF-115-H
OMM-0083_0B
Modulex MLX Series Gas Fired Boiler System
Operation and Maintenance Manual
Chap 9:
Maintenance
9.4.4 Re-Assembly After Burner Section Replacement
Reverse the disassembly procedures to assemble. Follow instructions below.
Unit Reassembly After Burner Section Replacement
1. Reattach the flue collector back onto the condensate tray end (
Figure 8-17
).
2. Reattach the electrical connections (igniter cable, ground lead, and flame detector lead) back onto the
appropriate components on each aluminum section (Figure
8-20
).
3. Reattach the flow and return header assemblies with hardware and gaskets (
Figure 8-19
).
4. Replace the burner modules and NEW replacement burner gaskets onto the burner assembly top.
See
Paragraph 8.3.4
for instructions.
5. Disengage support rods from burner lid and lower into the down position (
Figure 8-11
).
6. Reposition manifold ends (
Figures 8-9
,
8-10
) and reinstall filters to both ends (
Figure 8-8
).
7. Reinstall bolts
D1
,
D2
,
D3
, and
D4
(
Figure 8-7
) and re-install the plastic protectors onto bolt recesses
(
Figure 8-6
).
8. Reassemble cover back onto fan assembly (
Figure 8-5
).
9. Prior to replacing the front panel on the boiler, check to ensure that:
10. All igniter cables and ground leads are firmly attached.
11. All flame detector wire leads are firmly attached.
12. All igniter and flame detector mounting screws are secure.
13. Replace the side and top cover panels.
14. Reconnect all ground wire clips to the underside of the top cover. Re-secure the top cover to the pins
and spring clips on the frame and sheet metal panels.
15. Apply external AC power to the unit by setting the external circuit breaker to the ON position.
16. Open the external gas shutoff valve to the boiler.
17. Before starting the boiler, verify that the condensate siphon is filled with water.
18. Before opening the gas cock on the burner manifold, make sure that the coupling is securely
tightened. To do this, open the gas cock and check the union for leaks using a non-corrosive soap
solution.
19. As soon as a burner is put into operation, check immediately for leakage between the gas valve
and the relevant premixing chamber.
20. Perform the combustion analysis and check the combustion parameters.
9.5 Final Testing and Return To Service
Upon completion of all inspections, maintenance tasks, and reassembly and prior to returning the
Modulex boiler to service use, perform the Initial Startup Procedure specified in
Sub-section 7.5
of this
manual (
GF-115-H
). Perform the combustion analysis and check the combustion parameters per
Sub-
section 7.5.5
).
