WARNING:
It is not recommended that a wire
brush be used to remove soot from the heat exchang-
er. This may cause a spark and ignite the gases
trapped within the soot.
Using a soft tipped brush such as a “paint brush”
apply a degreaser to the entire heat exchanger sur-
face top and bottom.
Note: If an old style heat
exchanger, remove “V” baffles prior to performing
any cleaning
. Allow the heat exchanger to sit for a
period of time to allow the degreaser to loosen the
soot. Wash the heat exchanger using a garden hose
ensuring both top and bottom surfaces are thoroughly
cleaned. Follow the above procedure steps in reverse
to re-install heat exchanger. Although the heat
exchanger should be cleaned of soot and reinstalled
in the heater, the fact that sooting occurred should be
investigated, as it may be indicative of other prob-
lems such as:
•
Insufficient air supply
•
Inadequate venting
•
High or low gas pressure
•
Blockage of burner tubes or orifices
•
Improper heater location installation
•
Incorrect gas supply pipe size
•
Excessive water flow through heat exchanger
•
LP tank below 30% full.
Combustion Chamber:
The combustion chamber is a “one piece” box. If
damaged, the entire chamber must be replaced.
Heat exchanger removal:
1. Turn pump, main gas valve and heater power off.
2. Drain heat exchanger.
3. Remove four screws from vent in top of heater
and remove top.
4. Remove access covers from both sides of heater.
5. Remove air deflector shield from around blower.
6. Unplug blower wire connector.
7. Disconnect pressure tap tubes from
blower/vent assembly.
8. Remove flue collector assembly.
9. Disconnect water pressure switch tube from
header.
10. Disconnect high limit wires from header.
11. Lift heat exchanger assembly straight up off
combustion chamber.
12. Installation is the reverse of removal.
29
Section VI. Qualified Technician - Maintenance/Servicing
General:
IMPORTANT:
Only qualified service technicians,
having appropriate test equipment, should be allowed
to service the heater. Bear in mind that all of the com-
ponents that comprise the system have an effect on
the heater operation. Before proceeding with heater
related troubleshooting tips covered in Section VII, be
certain that the pump is operating correctly, the filters
and strainers are not blocked, the valves in the piping
are properly positioned, and the time clocks are prop-
erly set.
WARNING:
Do not attempt to repair any compo-
nents of heater. Do not modify heater in any manner.
To do so may result in a malfunction which could
result in death, personal injury, or property damage.
Check with consumer to see if any part of heater has
been under water. Replace any part of the control
system and any gas control which has been under
water. Never use or attempt to use parts that have
been previously used.
Maintenance:
The following inspection procedures are recom-
mended to be performed as part of annual heater
maintenance and to assure safe operation.
1. External heat exchanger.
2. Internal heat exchanger.
3. Main burner flame patterns.
4. Main burner orifices.
5. Operating controls.
Inspection procedures are covered below. Some of
the procedures will require disconnecting and remov-
ing wires in the control department. See Control
Access below.
Control Access:
Access to the operating controls is gained by
removing the control panel on the front of the heater.
See Figure 45.
1. Turn the two screws counterclockwise, which
secure the control door.
2. Open the control panel to access the operating
controls.
3.
CAUTION:
Label all wires prior to disconnec-
tion when servicing controls. Wiring errors can
cause improper and dangerous operation.
4. Verify proper operation after servicing.
5. After servicing is complete, close control panel
door and secure by turning screws clockwise.
External heat exchanger inspection
and cleaning:
Remove the heater top and inspect the external
surfaces of the heat exchanger for soot accumulation.
If soot has accumulated it must be removed by fol-
lowing the recommended procedure.
1. Remove four main heater top screws.
2. Remove main heater top.
3. Remove screws from left and right side access
covers and remove panels.
4. Remove the front door panel.
5. Disconnect the high limit wires from the heat
exchanger.
6. Disconnect the thermistor leads from the control
panel.
7. Remove the pressure switch and tube from the
heat exchanger.
8. Remove four screws retaining air deflector, and
remove air deflector.
9. Unplug wires and pressure tap tubes from
combustion blower.
10. Remove screws retaining flue collector/combus-
tion blower assembly and remove.
11. Remove heater jacket screws securing heat
exchanger.
12. Remove heat exchanger and place on a clean
surface.
28
Control Access
Figure 45
