Page 34 | GT INSTALLATION AND OPERATION INSTRUCTIONS |
BOILER MAINTENANCE
The boiler should be cleaned and inspected once a year, before each heating season.
CAUTION: Servicing, inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes. Improper servicing or adjustment could damage the boiler!
Controls
Use a soft brush and/or a vacuum cleaner to ensure that the electrical components are free from dust or deposits that would impair the boiler’s performance.
Heat Exchanger Cleaning
Natural Gas - once every two years.
Propane - once per year.
The burner door should be removed so the combustion chamber can be inspected for flue gas blockage, see BURNER REMOVAL & REPLACEMENT below. Once the burner has been removed remove the heat exchanger baffle. Blockage of the heat exchanger will reduce the boiler’s capacity/firing rate and can negatively impact on how smooth and efficiently the burner lights. Vacuum out any loose
Heat Exchanger Flushing
Listen for water fl ow noises that indicate a drop in the boiler water fl ow rate. The boiler and hydronic system may need to be flushed to eliminate hard water scale. A
Burner Removal & Replacement
WARNING: The ceramic door disc on the rear of the burner contains crystalline silica. Wear proper respiration protection when servicing the burner and gently handle the burner and its disc to prevent inhalation of airborne fibers. Crystalline silica fibers have been identified as carcinogenic, or possibly carcinogenic when inhaled.
CAUTION:The burner should not be removed unless there is a problem with it. Careless handling can damage the burner!
1.Close the manual shutoff valve in the gas supply line and turn off electrical power to the boiler.
2.Remove the front and left jacket panels.
3.Disconnect the wires going to the igniter, flame rod, ground rod, blower and gas valve.
4.Carefully disconnect the gas piping at the union, Figure 27.
5.Carefully disconnect the air inlet piping at the valve, Figure 2.
6.Remove the nuts used to attach the burner to the heat exchanger.
7.Carefully slide the burner out of the unit.
8.Inspect the burner for damage or signs of deterioration. Use a brush or vacuum cleaner to remove any debris from the burner ports.
9.DO NOT install a damaged or badly corroded burner, replace it.
10.Inspect the ceramic burner disc for signs of damage or deterioration and replace it if necessary.
11.Inspect the burner door gasket for signs of damage or deterioration and replace it if necessary.
12.Inspect the ignition components for signs of damage or deterioration and replace them if necessary.
13.Reassemble the unit following the removal steps in reverse order.
14.All gas connections MUST be leak tested before putting the boiler into operation.
WARNING: Never use an open flame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this WARNING could result in an explosion!
15.Confi rm proper operation of the boiler and replace the jacket panels.
Condensate System
Ensure that the condensate removal system is clean, sound and working properly.
Vent System
The entire vent system must be thoroughly inspected for any signs of blockage, damage or leaks. Immediately replace any unsound vent system piping. Remove any foreign matter in or near the vent and air inlet terminals that might obstruct them.
Low Water Cutoff
If the system has been equipped with a low water
Relief Valve
The relief valve should vent water when the test lever is lifted. It should not weep or discharge water at normal system pressure. NEVER try to clean or repair the relief valve! If the valve fails replace it!
