2 User Manual

2
Service Manual
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hazard definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Please read before proceeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
What is in this manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Access Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Access Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Burner removal and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Heat exchanger cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Combustion air shutter adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Facts about water chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Heat exchanger inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Prevention of freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Winterizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Troubleshooting Chart - No Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Checking temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Troubleshooting Chart - Noisy System . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Troubleshooting Chart - Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . 25
Gas Manifold Pressure Adjustment Procedure . . . . . . . . . . . . . . . . . . . . 28
Checking Gas Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Contents
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels
or to important information concerning the life of the product.

DANGER

WARNING

CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but
not related to personal injury or property damage.