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Finned copper tube gas boilers & water heaters – Boiler Manual
34
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8. If there are no signs of damage, sooting or corrosion reassemble
the unit following the previous steps in reverse order.
9. A badly corroded or damaged heat exchanger must be replaced,
see the
Heat Exchanger Removal
section.
Heat Exchanger Removal, Cleaning
& Replacement - See Figure 20
1. Close the shut off valves in the inlet and outlet piping. On heating
systems close the system fi ll valve and relieve the system pressure
from the boiler by carefully lift ing the relief valve or opening the
drain valve.
2. Drain the boiler/water heater and disconnect it from the system
piping.
3. Remove the inlet/outlet and return headers.
4. Remove the front jacket panels.
5. Loosen, 4 turns, but
don't remove
the 6 screws (3 on each side)
holding the heat exchanger upper rails in place, Figure 21.
6. Disconnect gas piping at the ground joint union(s). Also
disconnect the pressure sensing lines, pilot tubing and ignition
and sensing leads.
7. Remove the upper partition panel, 1050 thru 2100 models.
8. Remove the 1/4 inch nuts and washers holding the upper com-
bustion chamber front panel in place and carefully remove it.
9. Carefully slide the heat exchanger out of the unit.
10. Remove the "V" baffl e straps and "V" baffl es.
11. Th oroughly inspect the heat exchanger for signs of damage. If
there is no damage, clean the heat exchanger with water from a
high-pressure hose. Use a soft bristle brush if necessary.
Never clean the heat exchanger while it’s in the boiler/
water heater or the combustion chamber will be
destroyed!
12. Sagging or distorted heat exchanger tubes are an indication of
low water fl ow through the system. A leaking or otherwise
damaged heat exchanger must be replaced and the condition that
caused the damage resolved before the boiler/water heater is
returned to service.
13. If the heat exchanger isn't damaged rewire the heat exchanger
baffl es in place and slide the heat exchanger back into the unit.
14. Reinstall all of the other components in the reverse order of their
removal.
15. Th e torque values for the bolts that secure the removable headers
are 17-20 ft lbs. Once bolts have been started and secured the
tightening sequence is as follows:
1) Middle Top
2) Middle Bott om
3) Right Top
4) Left Bott om
5) Left Top
6) Right Bott om
Figure20
Burner and Heat Exchanger Servicing
