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XI Service and Maintenance
The following routine maintenance should be performed on an annual basis:
1) Turn off electrical power and gas supply to the boiler.
2) Remove the burner tray. To do this:
a) Remove the intake cover.
b) Remove the four Allen head screws holding the elbow fl ange onto the gas valve.
c) Remove the three 10-32 screws holding the manifold gasket plate to the intake box.
d) Remove the four 5-16 nuts holding the burner tray in the boiler.
f) Carefully remove the burner assembly being careful not to damage the fi redoor insulation or the manifold gasket.
3) Inspect the fl ue passages for signs of blockage. If there is any carbon in the combustion chamber or the fl ue passages, clean
the heat exchanger before proceeding further. See the cleaning procedure below.
4) Remove any debris found in the combustion chamber, being careful not to disturb combustion chamber insulation.
5) Inspect and clean the burners. Clean the burners by fi rst brushing the ports with a soft bristle brush and then vacuuming out
any debris through the venturi opening. If burners show signs of deterioration, they should be replaced (some discoloration
around the burner ports is normal).
6) Inspect the pilot assembly. Clean any deposits found on the electrode and grounding strap. The ideal gap between the
electrode and the ground strap is 1/8”. Inspect the porcelain for cracks or other deterioration. Replace pilot assembly if
deterioration is found. Inspect the ignition cable insulation for cracks or other deterioration. If deterioration is found,
replace cable assembly.
7) Inspect the combustion chamber insulation for deterioration. Replace insulation if necessary.
8) Inspect all boiler wiring for loose connections or deterioration.
9) Inspect the vent system:
• Make sure that the vent system is free of obstructions.
• Make sure that all vent system supports are intact.
• Inspect joints for signs of condensate or fl ue gas leakage.
• Inspect venting components for corrosion or other deterioration. Replace any defective vent components.
10) Inspect the boiler and hydronic system for leaks.
11) Place the boiler back in operation using the procedure outlined in Part X. Check the pilot line and any other gas piping
disturbed during the inspection process for leaks.
CAUTION
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous
operation. Verify proper operation after servicing.
CAUTION
Water leaks can cause severe corrosion damage to the boiler or other system components. Repair any leaks found
immediately.