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Figure 17. Normal Flame Characteristics NOTE: Cleaning of main burners. Shut off all gas and electricity to unit. 1. Remove main burners from unit. 2. Check that burner venturi and ports are free of foreign matter. 3. Clean burners with bristle brush and/or vacuum cleaner. DO NOT distort burner ports. 4. Reinstall burners in unit. Ensure that all the screws on the burner flange are tightened securely so that the gasket will provide a good seal. Also, ensure that each orifice is centered with the venturi opening of every burner. The washer of the orifice must be inserted a minimum of 1/4" into the burner tube. This is critical for proper operation. See Figure 18. 5. Also check for good flow of combustion and ventilating air to the unit. This is a powered burner and the flame is not supposed to be on the burner. The flame should be just above the burner deck approximately 1/8” and blue in color (see Figure 17). Visually check flame characteristics through the view port located under the left-hand header on the boiler. Figure 17 shows the normal flame condition. Also, refer to the flame label on the unit (adjacent to the view port). Figure 18. Orifice Insertion After placing the boiler in operation, check the ignition system safety shut-off devices for proper operation. To accomplish this with the main burners operating, close the valve on the manifold. Within four seconds the main burners should extinguish. If this does not occur immediately, discontinue gas supply by closing main manual shut-off and call a qualified serviceman to correct the situation. If the burners extinguish, then light boiler in accordance with lighting and operating instructions. For installations above 4,500 feet (1350 m), refer to HIGH ALTITUDE INSTALLATIONS in the installation section. THE FLOW OF COMBUSTION AIR TO THE BOILER MUST NOT BE OBSTRUCTED. THE BOILER AREA MUST BE KEPT CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS. Any safety devices including low water cutoffs used in conjunction 31 with this boiler should receive periodic (every six months) inspection to assure proper operation. A low water cutoff device of the float type should be flushed every six months. Periodic checks, at least twice a year, should be made for water and/or gas leaks. More frequent inspections may be necessary depending on water conditions. The boiler-mounted gas and electrical controls have been designed to give both dependable service and long life. However, malfunction can occur, as with any piece of equipment. It is therefore recommended that all components be checked periodically by a qualified serviceman for proper operation. RELIEF VALVE The safety relief valve should be opened at least twice a year to check its working condition. This will aid in assuring proper pressure relief protection. Lift the lever at the top of the valve several times until the valve seats properly and operates freely. DANGER THE WATER PASSING OUT OF THE VALVE DURING CHECKING OPERATION MAY BE EXTREMELY HOT. BEFORE OPERATING RELIEF VALVE, MAKE SURE DRAIN LINE IS INSTALLED TO DIRECT DISCHARGE TO A SAFE LOCATION SUCH AS AN OPEN DRAIN, TO AVOID SCALDING OR WATER DAMAGE. WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE. COMBUSTION AIR FILTER If the combustion air supply to the boiler contains dust, dirt, drywall dust etc. a filter must be installed. Air filter is not supplied with the boiler as shipped from the factory. The installer must provide a filtering system in the air inlet to the boiler if dust, dirt or construction dirt can be pulled into the boiler through the inlet air piping. BLOWER COMPARTMENT The blower compartment should be cleaned annually to remove any dirt and lint that may have accumulated in the compartment or on the blower and motor. Buildups of dirt and lint on the blower and motor can create excessive loads on the motor resulting in higher that normal operating temperatures and possible shortened service life. VENTING MAINTENANCE It is recommended that the intake and exhaust piping of the appliance be checked every 6 months for dust, condensate leakage, deterioration and carbon deposits. WARNING DO NOT USE A NYLON BRUSH OR OTHER STATIC CREATING MATERIAL TO CLEAN DUST AND CARBON DEPOSITS FROM HEATING SURFACES AND VENT. SUCH DEPOSITS ARE FLAMMABLE AND MAY BE IGNITED BY STATIC ELECTRICITY. USE A METAL BRUSH TO MINIMIZE THE DANGER OF EXPLOSION. Qualified serviceman should follow this procedure when the boiler's intake and exhaust piping need cleaning: 1. Turn off the electrical power, and manual gas shut-off. • Allow boiler parts to cool before disassembly. 2. Remove the vent pipe. • Check parts and chimney for obstructions and clean as necessary. 3. Remove burners from boiler and other metal parts as required to clean as necessary. • Refer to parts list supplied with this manual for disassembly aid. 4. Clean and reinstall the parts remov...

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