30
Flame pattern should have hard, uniform blue flames surrounding
the burner, see figure 19.
If the flame is pulsing, floating, yellow and/or lifting off the burner,
check the manifold gas pressure and combustion air supply;
maintain a clear area around the boiler at all times.
If the aforementioned flame characteristics are not evident, check
for accumulation of lint or other foreign material that restricts or
blocks the air/gas openings to the burner or boiler.
FIGURE 19. BURNER FLAMES
BURNER MAINTENANCE
Qualified servicers should follow this procedure when the boiler’s
burner needs cleaning.
1. Turn off the electrical power to the boiler and close the main
manual gas shutoff valve(s). Allow the boiler parts to cool before
disassembly.
2. Separate the blower from the manifold assembly by first
removing the four (4) screws, nuts and washers and
subsequently, the blower gaskets and air orifice. Then loosen
the nut that holds the blower bracket which supports the
blower. The blower should be free to move at this point.
FOR DIRECT VENT UNITS: It is necessary to loosen and slide
the rubber coupling on the blower adaptor in order to move the
blower.
3. Loosen the union orifice and separate the gas train from the
manifold assembly.
4. Loosen the nuts (7) at the manifold base and move the burner
ground wire (Green) aside.
5. Lift the manifold assembly up from the six (6) studs located on
the cover plate and remove the burner gasket.
6. Lift the burner and cone assembly up from the cover plate.
Ensure that the white insulation disc (1/2” [13 mm] thick, 3 3/4”
[9.5 cm] diameter) is attached to the burner base (closed end).
7. Remove any loose foreign material such as dust or lint with a
vacuum. Check all ports for blockage. Dislodge any foreign
material causing blockage. Remove any soot or carbon
deposits with a rag making sure to remove any lint left on the
burner by vacuuming again.
8. Reverse the steps to reassemble the unit.
Ensure that the insulation disc is affixed to the burner base. If
not, clean the burner base from the residual insulation. Apply
spray adhesive to the cleaned area and press the insulation
against the base. Allow it to set a sufficient time before
reassembly.
9. Restore electrical power and gas supply to the boiler.
• Put the boiler back in operation by following the Lighting
and Operating instructions in this manual.
• Check for gas leaks and proper boiler and vent operation.
CONDENSATE REMOVAL SYSTEM
Due to the highly efficient operation of this unit, condensate is
formed during operation and must be removed by the condensate
drain systems. Inspect the condensate drains and tubes at least
once a month and insure they will allow the free flow of
condensate at all times. The system must be inspected more
frequently in cold weather if the drain system is located in an
area, such as along the floor, where freezing temperatures are
likely to occur. The condensate drain system must be protected
against freezing. Contact a qualified service agent to inspect and
correct the condition if freezing of the condensate lines is a
problem. The unit is equipped with a blocked flue switch which
will shut the unit off if condensate is unable to drain and backs up
in the unit. The Dia-Scan II display board red light indication
when sufficient condensate accumulates for this condition will
be BLOCKED FLUE.
The transparent drain lines and condensate drain on the bottom
of the vent collector should be visually inspected at one month
intervals for blockage, particularly in the areas of the loops in the
lines which trap a small amount of condensate, and the exit point
of the vent collector drain. Condensate in portions of the line
other than the loop area indicates a blockage in the drain line.
Flush the lines with air or water and clear or replace the blocked
portions of the line as necessary. Note that areas of the drain line
which include a sag or low spot in the line will also form a
condensate trap which can be removed by levelling the tube and
does not indicate a blocked system.
Inspect the metal vent drain and vent collector drain connectors
at six month intervals. Remove the hoses from the connections,
then check with a small wooden dowel or plastic rod passed up
through the metal connection to insure the passage is clear,
using caution to not bend or damage the connector. Call a
qualified service agent to inspect and correct the problem if any
obstructions are found in the connectors. Replace all hoses and
clamps immediately after inspection and before starting the boiler
in accordance with the Lighting and Operating Instructions.
DO NOT OPERATE THE BOILER UNLESS ALL CONDENSATE
DRAIN LINES ARE PROPERLY CONNECTED AND WORKING.
When
a means to neutralize condensate has been installed you must
also follow operating, inspection and maintenance procedures
specified by the manufacturer of the product. Inspect the installed
device to insure that it does not cause condensate to remain in
the boiler or vent for any reason.
DIA-SCAN II
SELF DIAGNOSTIC SYSTEM
The WHC1502 ignition control is a fully integrated, state of the art
electronic control system. The ignition control includes a
microprocessor, which governs all temperature and ignition
control functions for the appliance.
Inherent in the design are the normal operating sequences and
safety features associated with a gas ignition control system.
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