Assessments - 2, GPA: 3.5
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Yellow flame indicates clogging of air openings. Lifting or blowing flame indicates high gas pressure. Low flame indicates low gas pressure. Fig. #8144 MAIN BURNER FLAME NOTE: Modulating burner flame varies in height from approximately 1/4" at low fire to approximately 4" in high fire. Fig. #8964 PILOT BURNER FLAME (STANDING PILOT UNITS) INSPECTION SCHEDULE To be performed the first and third month after initial start up and then on an annual basis. If problems are found, refer to Troubleshooting Guide for additional directions. 1. Remove top of boiler and inspect heat exchanger for soot and examine venting system. 2. Remove rear header and inspect for scale deposits. *3. Inspect pilot and main burner flame and firing rate. *4. Inspect and operate all controls and gas valve. *5. Visually inspect system for water leaks. *6. Inspect oil pump motor and bearing assembly, if oil cups are provided. 7. Check flow switch paddle. 8. Clean room air intake openings to ensure adequate flow of combustion and ventilation air. 9. Keep boiler area clear and free from combustible materials, gasoline, and other flammable vapors and liquids. *Should be checked monthly. (Takes approximately 15 minutes). 28 LOW WATER CUT-OFF (WHEN INSTALLED) The low water cut-off automatically shuts down burner whenever water level drops below probe. 90 second time delay prevents premature lockout due to temporary conditions such as power failure or air pockets. Flush float type devices at beginning of each heating season. PROCEDURE FOR CLEANING FLUE GAS PASSAGEWAYS Soot will clog areas behind fins and eventually cause tube failure. Any sign of soot at base of burners or around outer jacket indicates a need for cleaning. 1. Lift off drafthood and flue collector by removing bolts and screws. 2. Remove "V" baffles from heat exchanger. 3. Remove burner tray, see Burner Tray Removal. 4. Take garden hose and wash heat exchanger, making sure soot is removed from between fins. (Avoid excessive water against refractory). 5. Reassemble; when boiler is fired, some steam will form from wet refractory. This is normal. NOTE: In extreme cases it may be necessary to remove the heat exchanger completely for cleaning. The simplest method is steam cleaning at a local car wash. DO NOT WIRE BRUSH! CAUTION: Soot is combustible, so exercise extreme care. BURNER TRAY REMOVAL 1. Shut-off power and gas supply to the boiler. Disconnect union(s) and pilot tubing when present; then loosen and remove burner hold-down screws. 2. Disconnect wires at gas valve and slide burner tray out. MAIN BURNER AND ORIFICE REMOVAL 1. Remove screws and burner hold-down bracket. NOTE: If the heat exchanger is sooted badly, the burner hold-down bracket and spacer can become distorted from direct flame impingement and this usually necessitates replacement of these parts. 2. Lift burners from slotted spacer and slide from orifices. Clean with a wire brush. 3. Orifices usually do not need to be replaced. To clean, run either copper wire or wood through orifice. Do not enlarge hole. To remove orifice, use a socket wrench and remove the manifold. DO NOT overtighten when reinstalling. RAYPAK TUBE CLEANING KIT Extension Pieces (5) Auger with Carbide Tip Wire Brush Fig. #8154 5/8" - PN 052871F 7/8" - PN 052870F REPAIR PROCEDURES TUBE CLEANING PROCEDURE (TYPICAL) Establish a regular inspection schedule, the frequency of which depends on the local water condition and severity of service. Do not let the tubes clog up solidly. Clean out deposits over 1/16" in thickness. The boiler may be cleaned from the side opposite the water connections as shown, without breaking pipe connections. It is preferable, however, to remove both headers for better visibility through the tubes and to be sure the residue does not get into the system. Note that you do not typically remove the top pan or the heat exchanger. After reaming with the auger, mount the wire brush and clean out the debris remaining in the tubes. Another method is to remove the heat exchanger, ream tubes and immerse heat exchanger in non-inhibited de-scale solvent. HEAT EXCHANGER REMOVAL 1. Shut water, gas and electricity off, close valves, relieve pressure and remove relief valve. Remove side inspection panels. 2. Remove top holding screws. 3. Remove draft diverter, lift and remove top and flue collector on stack type models. Remove inspection panels. 4. Loosen bolts and disconnect flange nuts on inlet- outlet header, loosen union(s) at gas pipe, and slide boiler away from piping until studs clear the heater. 5. Remove heat exchanger corner brackets. 29 6. Remove combustion chamber clips at the four corners of the heat exchanger. 7. Lift heat exchanger straight up using caution not to damage refractory. Fig# 9337 HEAT EXCHANGER RE-ASSEMBLY 1. Heat exchanger water header O-rings should be replaced with new ones. 2. Install in/out and return water headers and install header retainer nuts and torque nuts evenly. 3. Replace "V" baffles. 4. Install thermos...
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