Instinct Installation Manual

CHAPTER 17 - MAINTENANCE PROCEDURES
79
17.13. Check Ignition Cable and Ground Wiring
• Inspect the ignition cable from the spark generator
t o the ig nit or .
• Inspect the ground wire from the spark generator
t o the ig nit or .
• Ensure wiring is in good condition and securely connected.
• Check ground continuity using a continuity meter.
• Replace ground wire if ground continuity is not
satisfactory.
17.14. Check Control Wiring
I nspec t all control wir ing . Ensur e wir ing is in good con -
dition and properly connected.
17.15. Check Control Settings
• Review all boiler settings in the Heating & DHW
EZ S etup menus . A djust settings as necessary , see
Section 9.7 onpage 48 and Section 9.8 onpage 50.
• Check any external limit control settings (if used).
Adjust settings as necessary.
17.16. Perform Start-up and Checkout Proce-
dures
• Start the unit and perform the start-up procedures
as listed in Chapter 11 on page 63 .
• Verify the cold water fill pressure is correct and the
operating pressure of the boiler is within normal
operating range.
• Complete the checkout procedures as outlined in
Chapter 14 on page 71.
17.17. Check Burner Flame
• Inspect the flame pattern through the observation
port of the heat exchanger.
• If flame pattern is not fully blue and covers the entire
burner surface during high fire, shut the unit down
and allow it to cool thoroughly before disassembly.
• Close the external manual gas valve on the gas
supply line and disconnect the gas piping and gas
valve wire harness connector.
• Disconnect the wiring harness connectors from the
blo w er and r emo v e the blo w er . R emo v e the blo w er
from the unit.
• Remove the mounting nuts securing the burner
plate to the heat exchanger and set aside. Also re-
move the two screws* securing the burner plate to
the back panel at the r ear and discar d .
* These two screws are for transportation purposes
only and can be discarded.
• Carefully remove the burner plate assembly from
the heat exchanger by lifting the front of the
burner plate initially then disengage the plate from
rear studs. Ensure that the combustion chamber
2-in-1 insulation is not damaged during removal of
burner mounting plate assembly.
• Remove the burner head mounting screws and re-
move the burner head. Inspect the burner head for
deterioration. Use compressed air or a vacuum to
clean the burner head.
• Remove the venturi and gas valve assembly from
the
blo w er .
• Use a vacuum cleaner or compressed air to clean
the interior of the blower assembly. Inspect the
blower blades to ensure they are clean and not
damaged
.
• Re-assemble the venturi and gas valve onto the
blo
w er . Ensur e the v entur i gask et or o -r ing is in
good condition and positioned correctly. Replace
gasket or o-ring if necessary.
• Re-assemble the burner head onto the burner
mounting plate. Ensure the burner head gasket is
in good condition and positioned correctly. Replace
gasket if necessary.
• Re-assemble the burner plate assembly onto the
heat exchanger. Ensure the combustion chamber
2-in-1 insulation is in place and positioned correctly.
Replace if necessary.
• Remove the blower gasket from the burner plate
assembly and clean with fresh water. Reinstall
blower gasket onto burner plate assembly with the
check
valve hinge at the t op .
• Re-assemble the blower onto the burner plate and
reconnect the wiring harness connectors.
• Re-assemble the gas supply connection and wire
harness to the gas valve. Open the external manual
gas valve. Check gas piping for any leaks as outlined
in Section 10.5 on page 62 and repair if necessary.
• T or que all scre ws , bolts , and nuts in accor dance
with specifications in Section 17.24 on page 80 .
• Place the unit back into service.
17.18. Check Flame Signal
• The flame signal can be read from the Boiler Infor-
mation screen. It should be a min. 2-3 μΑ at low fire.
• Check the ig nit or condition if flame sig nal is lo w .
• Check ground wire for continuity if flame signal is
lo
w . Replace ig nit or if conditions ar e satisfac t ory .
CHAPTER 17