SERIES 8800 & 8900 INSTALLATION AND OPERATING INSTRUCTIONS
Page 18
6.
Pull the burner drawer out until the burners are fully
exposed.
7.
Inspect each burner for damage or signs of
deterioration. Use a brush or compressed air to
remove any debris from the burner ports.
8.
DO NOT
install damaged or badly corroded burners,
replace them.
9.
Install the burners making sure that they are
properly seated in the burner drawer.
10. Replace the Burner Drawer and Flame Roll Out
Shield, 8900 only, following the removal steps in
reverse order.
Heat Exchanger Inspection & Cleaning
1.
Close the shut off valves in the inlet and outlet
piping. Relieve the system pressure from the boiler
by carefully lifting the relief valve or opening the
drain valve.
2.
Disconnect the boiler/water heater from the system
piping.
3.
Remove the left and right headers and mounting
studs.
4.
Remove the left & right upper and left & right lower
jacket end panels, items 5 & 24 (8900) or items 5
& 26 (8800).
5.
Remove the left & right front corner trim panels,
8900.
6.
Remove the flue collector front panel shown as part
of item 19 (8900) or item 21 (8800).
7.
Remove the upper front refractor y channel
assembly and front refractory panels.
8.
Slide the heat exchanger out and thoroughly
inspect it.
9.
The outside surfaces of the copper tubes should be
free of any soot deposits, A slight black smudge is
normal with some types of gases. Black soot
indicates poor combustion. Green deposits indicate
condensation due to low return water temperatures.
In either case the heat exchanger must be cleaned
thoroughly with water and the problem resolved
before the boiler/water heater is returned to service.
10. Replace the cleaned heat exchanger and other
components in the reverse order of their removal.
Heat Exchanger Replacement
1.
Sagging or distorted heat exchanger tubes are an
indication of low water flow through the system.
2.
A damaged heat exchanger must be replaced and
the condition that caused the damage resolved
before the boiler/water heater is returned to service.
Vent System
Thoroughly inspect the vent system for any signs of
blockage, corrosion or leakage. Immediately replace any
unsound vent system piping.
Controls
Use the BOILER/WATER HEATER OPERATION and
CHECKING AND ADJUSTMENT sections of this
manual for reference.
1.
Check the thermostat or operating controls for
proper operation.
2.
A float type low water cutoff device must be flushed
out per the manufacturers’ instructions. 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. In not,
replace them.
3.
The relief valve should not weep or discharge water
at normal system pressure. 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!
4.
The aquastat high limit controls the maximum water
temperature in the boiler. It is adjustable from 140°F
(60C) to 250°F (121°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 250°F
(121°C). The aquastat high limit cannot be repaired.
If it fails to function properly replace it.
5.
Visually check the pilot and main burner flames to
ensure proper operation, see Figures 8 & 9.
WARNING: Yellow, floating flames indicate a lack
of combustion air. Do not operate the boiler until
the problem is solved or severe personal injury
or death may occur!
Figure 9 - Main Burner Flames
NORMAL
(HARD FLAME)
LIFTING
(TOO MUCH AIR)
YELLOW TIPPING
(MARGINAL)
YELLOW FLAME
(TOO LITTLE AIR)
