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MODU-FIRE® FORCED DRAFT
Gas-Fired Boiler Maintenance
5.0 MAINTENANCE
WARNING!
Installation and service must be performed by a
qualified and knowledgeable individual, such as a
PK representative, qualified installer, service
agency, or gas supplier.
WARNING!
Proper lockout / tagout procedures must be em-
ployed when servicing this unit.
Hazard analysis should be performed by end user to
insure safety of their employees and/or service tech-
nicians.
All weekly, monthly and annual maintenance
checks should be performed by qualified and
knowledgeable personnel.
5.1
MAINTENANCE AND INSPECTION SCHEDULE
WARNING!
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation.
Verify proper operation after servicing.
5.1.1 Daily
Observe operating temperature and general condi-
tions. Make sure that the flow of combustion and
ventilating air to the boiler is not obstructed. Deter-
mine the cause of any illuminated red indicators,
unusual noises or operating conditions and make the
necessary corrections.
WARNING!
Check daily to be sure that the boiler area is free
and clear of any combustible materials, including
flammable vapors and liquids.
5.1.2 Weekly
Observe the conditions of the main flame. A normal
high fire flame shows an orange screen with a blue
halo. In Low fire the burner should display a reddish
orange glow.
Correct air adjustment is essential for the efficient
operation of this boiler. If an adjustment to the
combustion is necessary, the flue gas composition
should be checked with a carbon dioxide (CO
2
) or
oxygen (O
2
) analyzer to set conditions. Refer to
Section 3.12.2 and 3.12.3.
5.1.3 Monthly
1. Test flame detection by voltage reading at the
control programmer.
2. Test high-limit control by reducing setting below
the operating temperature. Burner should shut
off. After readjusting the thermostat, press the
button to reset the switch.
3. Test operating temperature control by reducing
temperature setting as necessary to check burner
operation.
4. Check flue gas temperature at outlet. If there is
a temperature increase over previous readings,
the probable cause is soot or water-scale build-
up on the tubes.
5. Test the water flow switch by trying to restart
boiler with the system pump off. The boiler
should not operate and the red water flow indica-
tor should light.
6. Test low gas pressure switch and high gas pres-
sure switch utilizing the procedure in sections
3.11.4 & 3.11.5. The boiler should fail to start
and the red gas pressure indicator should light.
7. Inspect and clean the inlet screen of any accumu-
lated dust or lint.
8. The relief valve should be tested as per manufac-
turers instructions or every two months by lifting
the lever for 5 seconds and allowing the valve to
snap shut. Please see the manufacturer’s rec-
ommendations on the relief valve tag.
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