Installation / Operation Instruction Manual

Page 114
After the valve has been removed, reassemble in
reverse order making sure to include all gaskets and
O-rings. Turn on the manual gas valves and check for
gas leaks. Turn on the main power. Place the unit in
operation following the instructions in SECTION 10.
Once the boiler is operating, check for leaks again and
conrm all fasteners are tight.
11.B.3 Controller
Each unit has an integrated controller that incorporates
manual reset high limit control, operating temperature
control, modulating control, ignition control, outdoor
reset control, pump control and many other features.
If any of these features are thought to be defective,
please consult the factory for proper troubleshooting
practices before replacing a control.
If it is necessary to replace a controller, turn o󰀨 all
power to the unit and shut o󰀨 all manual gas valves to
the unit. Open the front doors to the unit. Remove all
wire connections from the control board. The control
board connections are keyed to only allow connection
in the proper location, but proper handling techniques
should be used to avoid damage to the wiring or
connectors. To remove the control, undo the mounting
screws. To replace the control repeat the steps listed
above in the reverse order making sure to connect all
wires in the proper locations. Place the unit in operation
following the steps outlined in Section 10.
11.B.4 Spark Ignition Electrodes
The spark ignition electrode is a dual rod assembly.
The ground rod is fastened to the mounting bracket
of spark electrode assembly. The spark electrode
passes through a ceramic insulator and then aligns
with the ground rod. In order for a proper spark to form,
the mounting bracket must be grounded to the boiler
chassis. To remove the spark ignition electrodes shut o󰀨
the power to the unit, turn o󰀨 the main gas supply and
open the front door of the boiler to gain access to the
top portion of the unit. Remove the high tension ignition
wire from the spark electrode. Remove the two nuts and
spacer holding the spark electrode assembly in place.
Pull the spark ignition electrodes out of the boiler slowly
making sure to move the assembly as need, so the
electrodes are not bent as they are being removed. If
the old assembly is determined to be defective, install a
new spark assembly in the reverse order, replacing the
gasket if necessary.
11.B.5 Flame Sensor
The ame sensor is a single rod system. The minimum
ame signal that will allow the unit to re is 0.8 volts. To
replace the ame sensor electrode, shut o󰀨 the power
supply to the boiler. Turn o󰀨 all manual gas valves
connecting the boiler to the main gas supply line. Open
the front doors of the boiler to gain access to the ame
sensor electrode. Remove the ame sensor wire from the
electrode. Remove the two nuts fastening the electrode
to the burner plate. Remove and replace the old ame
sensor gasket. If the old electrode is determined to be
defective, reinstall a new ame
sensor electrode in the reverse order.
CAUTION
The igniters and sensors can become very hot.
If you touch these parts accidentally, this can
cause burns or injury.
11.B.6 Blower 1600
The combustion air blower is a high pressure centrifugal
blower with a variable speed motor. The blower is driven by
the control system using a PWM signal.
If it is necessary to service, remove or replace the blower,
the Main Power MUST be disconnected and the main gas
supply to the unit must be turned o󰀨. Open the doors and
remove the doors from their hinges. Remove the top and
top side jacket panels. Remove the fasteners holding the
fuel/air mixer to the blower inlet. Remove the hardware
that is connecting the blower outlet to the unit’s adapter
plate. If the blower is determined to be defective, replace
the existing blower with a new one and assemble in the
reverse order. Be sure to install all of the required gaskets
and O-rings between the blower adapter plate and air/fuel
mixer.
11.B.7 Blower 2000-4000
The combustion air blower is a high pressure centrifugal
blower with a variable speed motor driven by a factory
installed VFD located in the high voltage box. The
speed of the motor is determined by the controls logic
which is delivered to the VFD by a 0-10VDC signal.
If it is necessary to service, remove or replace the
blower, the Main Power MUST be disconnected and
the main gas supply to the unit must be turned o󰀨. To
replace or remove the blower, turn o󰀨 main power,
remove hardware that connects the Fuel/Air mixer to
the blower, then remove the hardware that connects the
blower to the adapter plate. If the fan is determined to
be defective, replace the existing fan with a new one
by reversing the steps listed above. Be sure to install
all the required gaskets and o-rings between blower,
adapter plate, and Fuel/Air mixer.