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the main burner (models 300-2500) and pilot (models 3000
– 5000).
10.7 HEAT EXCHANGER INSPECTION
•
The heat exchanger should be inspected at the time of
burner maintenance.
•
Turn off all power to the appliance.
•
Turn off main gas to the appliance.
•
Remove top cover.
•
Remove fan assembly and burner as detailed in the Burner
and Cleaning section.
•
Check the heat exchanger surface for soot. If soot is
present, heat exchanger must be cleaned
•
Remove the front outer jacket door.
•
Remove the top wrap to expose the baffles.
•
Remove baffles from the exchanger.
•
Use detergent water pressure wash to remove soot from
heat exchanger and surfaces of the inner wrap.
•
When necessary, the heat exchanger can be removed by
disconnecting all water piping and removing the six flange
mounting bolts at the rear of the appliance. The heat
exchanger can now be removed from the front of the
appliance.
•
Reinstall baffles, stainless steel bands and stainless steel
wrap. Replace any damaged gaskets to ensure a proper air
seal. Replace any ceramic facing tape damaged on the
baffles.
•
Reinstall the burner and fan assembly.
•
Reassemble all gas and water piping. Test for gas leaks.
•
Reassemble outer jacket panels. Keep top cover off.
•
Cycle unit and check for proper operation.
•
Once proper operation is confirmed replace the top cover.
10.8 RE-INSTALL HEAT EXCHANGER
•
Carefully reinstall the heat exchanger if removed from the
appliance
•
Check all silicon and viton gaskets and replace if damaged
•
Reassemble inner wrap
•
Cycle unit and check for proper operation
•
Replace the top cover
10.9 COMBUSTION AIR FAN
Combustion air fan should be checked every 6 months. Clean
the internal filter as required when installed in a dust or dirt
contaminated location. The motor and bearings on the
combustion air fan are sealed and permanently lubricated
requiring no addition of oil or lubricants.
10.10 COMBUSTION AND VENTILATION AIR
Check frequently to be sure that the flow of combustion and
ventilation air to the appliance is not obstructed. Combustion
and ventilation air must be provided to the mechanical room with
openings sized per the requirements of the B149 or National
Fuel Gas Code. The optional outdoor air kit brings combustion
air from the outdoors directly to the appliance.
10.11 CONTROL CIRCUIT VOLTAGE
This appliance uses a transformer to supply a low voltage
control circuit. The voltage on the secondary side should be 24
to 28VAC when measured with a voltmeter. A secondary voltage
of 21VAC or less supplied to 24VAC components may cause
operational problems. A 4A circuit breaker is provided on the
secondary side of the transformer. A tripped circuit breaker
indicates a short in the 24VAC controls and must be corrected.
10.12 COMBUSTIBLE MATERIALS
CAUTION
Keep appliance clear from combustible materials; do not
store
GASOLINE
and other flammable vapors and liquids in
the proximity of the appliance.
10.13 FREEZE PROTECTION
Installations are not recommended in areas where the danger of
freezing exists. Proper freeze protection must be provided for
appliances installed outdoors, in unheated mechanical rooms or
where temperatures may drop to the freezing point or lower. If
freeze protection is not provided for the system, a low ambient
temperature alarm is recommended for the mechanical room.
Damage to the appliance by freezing is non-warrantable.
•
Location
- Heating boilers, hot water supply boilers or
water heaters must be located in a room having a
temperature of at least 50ºF (10ºC)
•
Caution
- A mechanical room operating under a negative
pressure may experience a downdraft in the flue of an
appliance that is not firing. The cold outside air may be
pulled down the flue and freeze a heat exchanger. This
condition must be corrected to provide adequate freeze
protection.
•
Freeze protection for the appliance using an indirect coil
can be provided by using hydronic system antifreeze.
Follow the manufacturer’s instructions.
DO NOT
use
undiluted or automotive type antifreeze.
•
Shut-down and draining
- If for any reason, the unit is to
be shut off where danger of freezing exists, the following
precautionary measures must be taken:
o
Shut off gas supply
o
Shut off water supply
o
Shut off electrical supply
o
Drain the heat exchanger completely
o
Ensure the pump and connecting piping are fully drained
10.14 FREEZE PROTECTION FOR A HEATING
BOILER SYSTEM (Optional)
•
Use only properly diluted inhibited glycol antifreeze
designed for hydronic systems.
•
Follow the instructions from the antifreeze manufacturer.
Quantity of antifreeze required is based on total system
volume including expansion tank volume.
•
Antifreeze is denser than water and changes the viscosity
of the system. The addition of antifreeze will decrease heat
transfer and increase frictional loss in the boiler and related
piping.
Where antifreeze has been used, to maintain the
temperature rise across the appliance confirm that the
recommended GPM for pure water has been increased by
15% and the head loss by 20%.
•
Local codes may require a back flow preventer or actual
disconnect from city water supply when antifreeze is added
to the system.
•
When filling or topping-up the system with water mixed with
the antifreeze always used distilled or RO (reverse
osmosis) water. This will prevent the reaction of the water
with antifreeze which can create sludge.
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