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Adjustment & Replacement of
Components
Gas Valve Replacement
1. Shut-off electrical power and gas supply to the
boiler.
2. Remove gas piping to gas valve inlet.
3. Disconnect wiring connections, pilot tubing (when
present).
4. Remove screws (2) holding the burner tray.
5. Slide burner tray out.
6. Remove gas valve bracket screws and bracket.
7. Unscrew gas valve from gas pipe.
8. Reverse above procedure to re-install.
Pilot Burner Cleaning or
Replacement (Standing Pilot)
1. Shut-off electrical power and gas supply to the
boiler.
2. Disconnect gas piping to gas valve.
3. Disconnect wiring connections to gas valve.
4. Remove screws (2) holding the burner tray.
5. Slide burner tray out.
6. Remove screw holding pilot lighter tube.
7. Remove screws (2) holding pilot bracket on the
burner tray.
8. Disconnect thermocouple and pilot tubing from the
gas valve.
9. Remove pilot burner from pilot bracket.
10. Remove pilot orifice and blow away lint or dirt.
Clean with wire or small brush. NOTE: Make sure
pilot orifice is clear, but do not enlarge the hole.
11. Reverse above procedure to re-install.
DANGER—SHOCK HAZARD: Make sure
electrical power to the boiler is disconnected to avoid
potential serious injury or damage to components.
Pilot
Pilot
Orifice
Orifice
Air
Opening
Fig. 37: Pilots, Honeywell (Left) and Robertshaw (Right)
Flame Roll-out Switch Replacement
1. Shut-off electrical power to the boiler.
2. Remove wiring connections to switch.
3. Remove screws (2) holding the switch.
4. Reverse above procedure to re-install.
Vent Thermal Switch Replacement
1. Shut-off electrical power to the boiler.
2. Remove wiring connections to switch.
3. Remove the screws (2).
4. Reverse above procedure to re-install.
Ignition Module Replacement
1. Shut-off electrical power to the boiler.
2. Remove control cover screws and open control
compartment.
3. Disconnect wiring connections to module.
4. Remove screws (2) holding module.
5. Reverse above procedure to re-install.
Transformer Replacement
1. Shut-off electrical power to the boiler.
2. Remove control cover screws and open control
compartment.
3. Disconnect wiring connections from transformer
leads.
4. Remove screws (2) holding transformer.
5. Reverse above procedure to re-install.
Pump Relay Replacement
1. Shut-off electrical power to the boiler.
2. Remove control cover screws and open control
compartment.
3. Disconnect wiring to the relay.
4. Remove screws (2) holding relay.
5. Reverse above procedure to re-install.
High Limit Control
1. Shut-off electrical power to the boiler.
2. Remove control cover screws and open control
compartment.
3. The control is factory set at 180°F. To adjust set-
ting, use a small screw driver and turn dial
clockwise to lower the temperature or counter-
clockwise to raise the setting.
4. To replace the limit control, disconnect the wiring
connections.
5. Remove screws (2) holding the limit control.
6. Remove upper access panel.