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Main Burner and Orifice
Removal
1
. Remove screws and burner hold down bracket.
NOTE: If the heat exchanger is sooted badly, the
b
urner hold-down bracket and spacer can become
distorted from direct flame impingement and this
usually necessitates replacement of these parts.
2. Lift burners from slotted spacer and slide from ori-
fices. Clean with a wire brush.
3. Orifices usually do not need to be replaced. To
clean, run either copper wire or wood through ori-
fice. Do not enlarge hole. To remove orifice, use a
socket wrench and remove the manifold. DO NOT
overtighten when reinstalling.
Pilot Removal and Cleaning
1. Disconnect pilot tubing at pilot and sensor/igniter
wire. Remove screws holding pilot bracket to burn-
er drawer.
2. Remove pilot and bracket, clean pilot of debris,
small bugs, etc., with wire or small brush.
3. Replace pilot, pilot tubing, sensor ignition wires
and check for leaks.
Heat Exchanger Removal
1. Shut water, gas and electricity off, close valves,
relieve pressure and remove relief valve. Remove
side inspection panels.
2. Remove top holding screws.
3. Remove draft diverter, lift and remove top and flue
collector on stack type models. Remove inspec-
tion panels.
4. Loosen bolts and disconnect flange nuts on
inlet/outlet header, loosen union(s) at gas pipe,
and slide heater away from piping until studs clear
the heater.
5. Remove heat exchanger corner brackets.
6. Remove combustion chamber clips at the four cor-
ners of the heat exchanger.
7. Lift heat exchanger straight up using caution not to
damage refractory.
Heat Exchanger Reassembly
1. Heat exchanger header O-rings should be
replaced with new ones.
2. Install inlet-outlet and return water headers and
i
nstall header retainer nuts and torque nuts even-
ly.
3. Install the four (4) corner clips between tube
sheets and refractory. Replace "V" baffles.
4. Install thermostat sensing bulbs in header wells
and replace bulb retaining clips.
5. Install inlet and return pipes in water headers
using pipe thread sealant.
6. Install water pressure relief valve, flow switch, and
low water cutoff devices if so equipped.
7. Open water supply and return shutoff valves. Fill
heater and water piping system with water. Check
heater and piping system for leaks at full line pres-
sure. Run system circulating pump for a minimum
of 1/2 hour with heater shutoff.
8. Shut down entire system and vent all radiation
units and high points in system piping. Check all
strainers for debris.
9. Install flue collector, jacket top and inspection pan-
els. Install top holding screws. Install draft diverter
and vent piping if so equipped.
10. If gas piping was disconnected, reconnect gas pip-
ing system and check for leakage using a soap
solution.
11. Double check electrical circuits, grounding con-
nections and pump with wiring diagram supplied
with heater.
12. Check for correct water pressure and water level
in the system. Make sure that system pump oper-
ates immediately on the call for heat. The system
is ready for operation.