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If there is any carbon in the combustion chamber or the flue passages, clean the heat exchanger before proceeding further. See the cleaning procedure below. 3) Remove any debris found in the combustion chamber, being careful not to disturb combustion chamber insulation. 4) Remove all burners, noting the location of the pilot main burner. If burners show signs of deterioration, they should be replaced (some discoloration around the burner ports is normal). Clean the burners by first brushing the ports with a soft bristle brush and then vacuuming out any debris through the venturi opening. 5) Inspect the pilot assembly: • Standing Pilots - Check the thermocouple for deterioration (some discoloration of the thermocouple is normal). If any deterioration is present, replace the thermocouple. Inspect the pilot assembly for deposits and deterioration. Clean or replace the pilot assembly as necessary. • Intermittent Pilots - Clean any deposits found on the electrode and grounding strap. The ideal gap between the electrode and the ground strap is 1/8”. Inspect the porcelain for cracks or other deterioration. Replace pilot assembly if deterioration is found. 6) Inspect the combustion chamber insulation for deterioration. 7) (Intermittent Pilot Boilers) - Inspect the ignition cable insulation for cracks or other deterioration. If deterioration is found, replace cable. 8) Reinstall burners, being careful to put the pilot main burner in its original location. 9) Inspect all boiler wiring for loose connections or deterioration. CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING 10) Inspect the vent system: • Make sure that both the vent system is free of obstructions. • Make sure that all vent system supports are intact. • Inspect joints for signs of condensate or flue gas leakage. • Inspect venting components for corrosion or other deterioration. Replace any defective vent components. 11) Inspect the boiler and hydronic system for leaks. CAUTION WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR OTHER SYSTEM COMPONENTS. REPAIR ANY LEAKS FOUND IMMEDIATELY 12) Place the boiler back in operation using the procedure outlined in “Start-up”. Check the pilot line and any other gas piping disturbed during the inspection process for leaks. 27 Heat Exchanger Cleaning Procedure Heat Exchanger Cleaning Procedure r 2) Disconnect the damper and vent connector from the boiler. 3) Remove the upper front and top jacket panels. If possible, remove the rear and left side jacket panels 4) Remove the burners. 5) Remove the blocked vent (“spill”) switch 6) Remove the two .-20 nuts and washers holding the flue collector onto the heat exchanger. 7) Remove the flue collector from the heat exchanger. 8) Carefully remove the flue collector gasket strips and set them aside 9) Clean the flue passageways using a stiff bristle brush. Be certain that all foreign material is removed from the gaps between the pins 10) Clean the bottom surfaces of the heat exchanger 11) Put a light in the combustion chamber and look through the flue passages from the top to verify that they have been thoroughly cleaned. 12) Replace the flue collector gasket strips. If desired, RTV-732 silicone sealant with a 500F intermittent duty temperature rating may be substituted for this rope gasket. The flue collector must be thoroughly sealed to the heat exchanger. 13) Replace the .-20 nuts and washers that hold down the flue collector 14) Reattach all the jacket components. 15) Reinstall burners, being careful to put the pilot main burner in its original location. 16) Replace the blocked vent switch. 17) Reconnect the damper and vent system. WARNING SOOT DEPOSITS IN THE FLUE PASSAGES ARE A SIGN THAT THE BOILER MAY BE OPERATING AT HIGH CARBON MONOXIDE (CO) LEVELS. AFTER CLEANING THE BOILER OF SOOT DEPOSITS, CHECK THE CO LEVEL IN THE FLUE GAS TO INSURE THAT THE BOILER IS OPERATING PROPERLY. If it is necessary to check CO, use an combustion analyzer, or other instrument which is designed to measure CO in flue gas. A CO “sniffer” designed for testing CO levels in ambient air cannot be used to check boiler combustion. Take a flue gas sample by inserting a sample probe through the draft diverter opening and into the flue collector so that the sample is taken in the area directly over the heat exchanger. Do not take a sample until the boiler has been firing for at least five minutes. A normal CO reading for an AWI or TWI series boiler is less than 50ppm (0.005%). A reading of more than 100ppm (0.01%) is indicative of a combustion problem. Some causes of excessive CO include: • Incorrectly sized main burner orifice for the altitude at which boiler is installed • Crooked or out-of-round orifice holes (never attempt to drill orifice for this boiler in the field) • Partially plugged flue passages • Improper manifold pressure • Foreign material in burner venturi...

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