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Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
MAINTENANCE
Disconnect electrical power and close the
manual gas shut off valve before performing
maintenance or severe personal injury may
result!
Servicing, inspection and adjustment must be
done by a trained technician in accordance
with all applicable local and national codes.
Improper servicing or adjustment can damage
the boiler!
The boiler must be inspected at least once a year and
before each heating season. Make sure that combustion
readings and air box pressures are taken on each
boiler and match the desired emissions outlined under
the specification in the Installation Manual — adjust
as necessary. Accessing the burner compartment
isn't necessary during normal maintenance unless
combustion values or air box pressures don't meet
specification.
Improper burner servicing can result
in premature burner failure voiding the
warranty!
Burner Removal & Inspection
Wear a tightly fitted dust mask when
servicing the burner and gently handle the
burner and its gasket to prevent inhalation
of airborne fibers.
Do not attempt to remove the burner without
having a burner gasket kit on hand.
Heat Exchanger Cleaning
In the unlikely event that the heat exchanger becomes
blocked consult the factory for the proper cleaning
procedure.
Air Intake & Vent System
Thoroughly inspect the air intake and vent system
for any signs of blockage, corrosion, or leakage and
periodically clean screen in the vent terminal (where
applicable).Immediately replace any unsound vent
system piping. Inspect the air filter and replace when
required.
Controls
Use the BOILER OPERATION and CHECKING AND
ADJUSTMENT sections of this manual for reference.
1. Check the operating controls for proper operation.
2. The probe on a probe low water cut off must be
removed, cleaned and inspected at least once a
year. Ensure that the low water cutoffs operate
properly. If not, replace them.
3. The flow sensor isolation valves must be open in
order for proper operation.
In the unlikely event that the SIKA flow sensor
requires cleaning, in order to flush the flow
sensor, close the ball valve installed upstream
of the flow sensor, connect a hose to the drain
fitting provided and open the drain valve. Drain
approximately a gallon of water to properly
flush the flow sensor. The drain is then closed
and the upstream valve reopened.
4. The relief valve should not weep or discharge water at
normal system pressure - this may be due to thermal
expansion in a closed water supply system. If it does
contact a qualified service technician to have it
inspected. NEVER try to clean or repair the relief valve!
If the valve fails to operate properly, have it replaced!
5. The aquastat high limit controls the maximum
water temperature in the boiler. It is adjustable
from
100°F, 38°C to 210°F, 99°C. If the water
temperature reaches the set temperature before
the demand for heat has been met, the aquastat
high limit should shut the boiler off. The water
temperature should never exceed the maximum set
point of
210°F, 99°C. The aquastat high limit cannot
be repaired. If it fails to function properly replace it.
6. Visually check the pilot and main burner flames to
ensure proper operation, see Figure 20.
Visual flame appearance with proper
combustion will have a red and blue striped
appearance at low fire and flecked areas of
red with a majority of blue across the metal
mesh burner at high fire. Areas of deep red
indicate an infrared condition requiring a
combustion adjustment to reduce CO
2
levels.
Figure 20 - Main Burner Flame
