Install Instructions

Cleaning heat exchanger flue side, 70/110 (continued)
)NSPECTANDCLEANTHEBURNER
1. See Figure 105, page 101 part D.
a. Slide the refractory (item 12) over the burner and off.
Set the refractory aside where it will be kept clean and
protected from damage. If the refractory is damaged, it
must be discarded and replaced with a new one.
b. Remove the three #20 Torx screws (item 14) securing the
burner (item 10) to the cover plate. Set aside.
c. Remove the burner and its gasket (item 13).
d. Inspect the interior of the burner. Brush and vacuum the
interior if needed to remove lint or sediment. Alternative
CLEANINGMETHODSsBLOWAIRORNITROGENFROMTHEINSIDE
OUTsCLEANWITHAWATERSPRAYFROMINSIDETHEBURNER
sSWIRLTHEBURNERTHOROUGHLYINABUCKETOFMILDLIQUID
laundry detergent water, then rinse thoroughly.
e. Inspect the burner exterior. It must be in good condition,
with no visible damage.
f. Inspect the burner gasket. If the gasket is damaged, obtain
a new gasket before re-installing the burner.
)NSPECTANDCLEANTHEHEATEXCHANGER
1. Access the heat exchanger interior by following the previous
instructions.
2. See Figure 105, page 101 part E.
3. Before using water to clean the heat exchanger, remove the
control module (item 16). Label wires if they are not labeled.
Set aside. Remove all connectors and wire harnesses from the
control module and then remove the two screws securing it
to the bracket.
4. Use a strong light to visually inspect the interior of the heat
exchanger. Make sure the flueways (tubes) are clear and
unobstructed.
5. Use a vacuum cleaner to remove any accumulation on the
heating surfaces. This includes removing any pieces of refrac-
tory that may have dropped into the exchanger.
DO NOT use any solvent when cleaning the ex-
changer.
6. If the vacuum cleaner is unable to clean completely, wash the
heating surfaces with clean, warm water.
a. Place a bucket under the boiler condensate drain con-
nection.
b. Then loosen the condensate trap upper nut and slide the
trap off of the drain connection. (See Figure 59, page 54
for reference.)
c. Spray fresh water into the heat exchanger and tubes to
remove sediment. Collect water in the bucket below.
7. Inspect the heat exchanger cover plate refractory. Replace if
insulation is damaged.
2EINSTALLCOMPONENTS
1. See Figure 105, page 101 for reference.
2. Reinstall the control module (item 16) to the control bracket
and reconnect all connectors and wire harnesses.
3. Reinstall the burner (item 10) and burner gasket (item 13) on
the cover plate (item 6). Tighten the burner screws (item 14)
using a torque wrench. The screws must be secure, but the
torque must not exceed 20 inch-pounds.
4. Apply a ring of silicone adhesive on the cover plate (to secure
the refractory).
5. Slide the refractory (item 12) over the burner. Align the re-
fractory and press in place.
6.
"EFORE handling the assembly, allow the adhesive to set
enough that the refractory is firmly held in place.
7. Reinstall the igniter assembly (item 7).
a. The igniter gasket must be intact and in good condition.
Replace with a new gasket if necessary.
b. Insert the igniter into the cover plate opening, with the
gasket in position.
c. Reinstall the two Phillips head screws finger tight.
d. Use a torque wrench to tighten the igniter screws. DO
NOT exceed 20 inch-pounds torque.
8. Reinstall the venturi/cover plate assembly (items 5 and 6)
and secure the cover plate with 10-mm hex nuts (item 9).
You must gradually tighten the cover plate nuts us-
ing a torque wrench. The final torque MUST NOT
exceed 45 inch-pounds. Alternate tightening until
all nuts reach 45 inch-pounds.
9. Reconnect the ignition cable and the igniter ground wire.
10. Reinstall the blower (items 2).
a. Reconnect the two blower wiring harnesses.
b. Slide the blower up onto the venturi sleeve.
c. Reinstall the blower retainer clip, item 15.
11. Reinstall the air inlet silencer (item 1) by pressing onto the
air inlet adapter. Rotate into the normal vertical position (see
part A) of Figure 105, page 101.
12. Slide the gas valve (item 3) outlet collar into the venturi
(item 5) opening. Make sure the gas valve-to-venturi O-ring
(item 5, Figure 10, page 15) is in place and in good condition.
Inspect the gas valve flex line, making sure there are no signs
of wear or damage. Replace if necessary.
13. Slide the gas valve retainer clip (item 4) into position to
secure the gas valve.
14. Reinstall the condensate trap on the boiler condensate drain
connection, if removed. (See Figure 59, page 54 for reference.)
Perform a complete start-up procedure when put-
ting the boiler back into service. See page 75 and all
instructions for start-up and verification. Include a
soap suds leak test on all interior and exterior gas
piping after starting the boiler.
Part number 550-142-122/0513
102
TM
GAS-FIRED WATER BOILER — Boiler Manual