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2 Maintenance
Copper-fin II/IIE Boiler and Water Heater Service Manual
Inspect and clean the heat exchanger
1. Turn off the main electrical power to the appliance.
2. Turn off the main manual gas shutoff to the appliance.
3. Remove the lower outer fron access door.
4. Disconnect the manifold(s) from the gas train using the
union(s) just below each gas valve.
5. Disconnect wiring to the hot surface igniter(s) and ground.
6. Disconnect burner pressure line at burner.
7. Remove the screws from the manifold mounting bracket(s)
and remove the manifold(s).
8. Remove the screws from the burner mounting flanges and
slide the burner(s) out toward the front of the unit. Use
caution to prevent damage to the burners, refractory, hot
surface igniter, and wiring.
9. Remove the inner jacket panel mounting screws and slide
the panel assembly out toward the front of the appliance.
Use caution to prevent damage to the refractory and hot
surface igniter.
10. Check “V” baffles along the front and back edges of the heat
exchanger (FIG. 2-5). Remove and clean if necessary.
11. Remove soot from the heat exchanger with a stiff bristle
brush. Use a vacuum to remove loose soot from the
surfaces and inner chamber.
12. If additional cleaning is required, the heat exchanger
can be removed by disconnecting all water piping to the
heat exchanger, removing the screws holding the heat
exchanger to the inner left side panel, and sliding the heat
exchanger towards the front of the appliance. Once the heat
exchanger is removed from the appliance, a garden hose can
be used to wash the tubes to ensure that all soot is removed
from the heat exchanger surfaces.
Do not wet the refractory located on the
inside of the combustion chamber.
NOTICE
15. Carefully reinstall inner jacket panels, burners, manifolds,
wires and hoses. Use new gasket material to ensure a
proper air seal.
16. Reassemble all gas and water piping. Test for gas leaks.
17. Reassemble outer jacket panels.
18. Cycle the appliance and check for proper operation.
HEAT
EXCHANGER
Figure 2-5_Location of the Heat Exchanger Inside Jacket
Make sure the frame runners seal securely
where they contact the front and rear
compartment refractory.
NOTICE
13. Ensure that all burner ports are cleaned to remove any soot
(reference this section).
14. Carefully reinstall the heat exchanger, “V” baffles, and
frame runners if removed from the appliance.
Review with owner
1. Review the User’s Information Manual with the owner.
2. Emphasize the need to perform the maintenance schedule
specified in the User’s Information Manual (and in this
manual as well).
3. Remind the owner of the need to call a licensed contractor
should the appliance or system exhibit any unusual behavior.
4. Remind the owner to follow the proper shutdown procedure
and to schedule an annual start-up at the beginning of the
next heating season.
Oiled bearing circulators
Inspect the pump every six (6) months and oil as necessary. Use
SAE 30 non-detergent oil or lubricant specified by the pump
manufacturer.
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