Instinct Installation Manual

CHAPTER 17 - MAINTENANCE PROCEDURES
80
17.19. Check Combustion Levels
Refer to Section 11.3.4 on page 65 for measuring
combustion levels and burner adjustments.
17.20. Check Flue Gas Temperature
• Manually place the boiler into high fire. See Section
11.3.4 on page 65 for procedure.
• Navigate to the Boiler Information Menu to observe the
flue gas temperature. See Section 9.14 on page 53 .
• If the flue gas temperature is more than 54°F [30°C]
above the supply water temperature, shut the boil-
er down and follow the heat exchanger cleaning
pr ocedur e belo w .
17.21. Clean Heat Exchanger
Shut down the boiler:
• Follow the instructions on page 64 “To Turn
Off Gas to Appliance”
• Do not drain the boiler unless the boiler will be
subject to freezing conditions.
• Do not drain the boiler if antifreeze is used in
the system.
• Allow the boiler to cool down to room temperature
before servicing.
• 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
blower and remove the blower clamp. Remove the
blower from the unit.
• Remove the mounting nuts securing the burner
plate to the heat exchanger and set aside.
• Carefully remove the burner plate assembly from
the heat exchanger. Ensure that the combustion
chamber 2-in-1 insulation is not damaged during
removal of burner mounting plate assembly.
• Use compressed air or water to remove any accu-
mulation from the heat exchanger flue ways.
• Re-assemble the burner plate assembly onto the
heat exchanger. Ensure the combustion chamber
2-in-1 insulation is in place and positioned correct-
ly. 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.
• Reconnect the gas piping 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 .
• Close isolation valves on the boiler water piping to
isolate the boiler from the heating system.
• Attach a hose to the boiler drain valve and flush
the boiler thoroughly with fresh water by using the
purge valves to allow water to enter through the
make-up water line to the boiler.
• Once the boiler has been completely flushed,
return the boiler back into operation.
• Perform the required startup and checkout
procedures as outlined in Chapter 10 on page 59
and Chapter 14 on page 71.
17.22. Check Carbon Monoxide Detectors
Verify that at least two (2) carbon monoxide detectors
are installed and operating properly. One must be in-
stalled in the mechanical room where the INSTINCT is
located and another installed in the living area outside
the bedroom(s).
17.23. Review With Owner
Ensure the owner understands the importance of per-
forming the maintenance schedule specified in this
manual.
17.24. Torque Specifications Table
Torque Req’d (in-lbs)
Item Min. Max.
Burner Plate Nuts
44
53
Burner Head Bolts
26.5
31
Blower Bolts
62
71
Gas Valve Screws 31 35
Venturi Screws 31 35
Ignitor Screws
26.5
31
Hydroblock screws 2.2 3.7
Water piping nuts
31
35
Gas pipe nuts
12
15
CHAPTER 17