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Part number 550-100-260/0520
128
ECO
®
Tec
GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL
1. See Figure 115, page 130 part G.
a. Slide the bottom cover plate insulation with integrated
seal (Item 19) off of the burner. Set the insulation aside
where it will be kept clean and protected from damage.
If the insulation and/or the seal is damaged, it must be
discarded and replaced with a new one.
b. Remove the burner and its gasket (Items 14 and 15)
by
removing the screws with a T20 Torx driver. Discard
old burner gasket.
c. Inspect burner insulation resting on top of cover
plate bottom. If damaged or worn, replace with new
component. Burner Insulation may be resting on top
of inner burner. If on burner, remove, inspect, and
replace if necessary.
d. Clean burner flange and cover plate surface where
burner gasket sits removing all old gasket material.
e. Inspect the interior of the burner. Brush and vacuum the
interior if needed to remove lint or sediment. Alternative
burner thoroughly in a bucket of mild liquid laundry
detergent water, then rinse thoroughly.
f. Inspect the burner exterior. It must be in good condition,
with no visible damage.
g. Obtain a new burner gasket before re-installing the
burner.
1. Access the heat exchanger interior by following the previous
instructions.
2. See Figure 115, page 130 part F.
3. Before using water to clean the heat exchanger, remove the
circuit board. Label wires if they are not labeled. Set aside.
Remove all connectors and wire harnesses from the circuit
board and then remove the four (4) screws securing it to
the bracket and
undo plastic snap-fit standoffs holding
circuit board to bracket.
4. Use a strong light to visually inspect the interior of the
heat exchanger. Make sure the flue ways (tubes) are clear
and unobstructed.
5. Use a vacuum cleaner to remove any accumulation on
the heating surfaces. This includes removing any pieces
of insulation that may have dropped into the exchanger.
DO NOT use any solvent when cleaning the
exchanger.
6. If the vacuum cleaner is unable to clean completely, wash
the heating surfaces with clean, warm water.
a. Place a shallow pan under the boiler condensate tube
connection.
b. Loosen the condensate tube hose clamp and slide the
trap off of the drain connection. (See Figure 67, page 56
for reference.)
c. Spray fresh water into the heat exchanger and tubes
to remove sediment. Collect water in the pan below.
1. See Figure 114, page 129
and Figure 115, page 130 for reference.
2. Reinstall the circuit board to the control bracket and reconnect
all connectors and wire harnesses.
3. Reinstall the burner (Item 14), burner insulation (Item 16 and
burner gasket (Item 15) on to the cover plate (Item 10).
Burner
insulation must be aligned on cover plate with blower inlet hole
and the two ends of the blower mounting studs. The small holes
in the insulation are to align with the two ends of the blower
mounting studs. The beveled edge of the insulation should
be face up while resting on the bottom side of the cover plate.
Tighten the burner screws (Item 17) using a torque wrench.
The screws must be secure, but the torque must not exceed
20 inch-pounds. Use new burner screws from Weil-McLain that
include thread sealant. If reusing burner screws, apply a High
Temperature Loctite to burner screw threads, such as Loctite 638,
to ensure proper sealing of combustion chamber.
4. Slide bottom cover plate insulation with integrated seal over
burner and align outer seal holes and igniter hole with cover
plate heat exchanger mounting holes and igniter hole.
5. Reinstall cover plate / burner / insulation assembly on heat
exchanger and secure the cover plate with 10mm hex nuts (Item
11). Be careful to avoid damaging the insulation on the heat
exchanger studs.
You must gradually tighten the cover plate nuts using
a torque wrench. The final torque MUST NOT exceed
45 inch-pounds. Alternate tightening until all nuts
reach 45 inch-pounds.
6. Reinstall the igniter assembly (Item 13).
a. The ignition electrode gasket must be replaced with a new
gasket.
b. Insert the ignition electrode (Item 13) into the cover plate
opening, with the gasket in position.
c. Reinstall the two (2) Socket head Allen screws finger tight.
Use a torque wrench to tighten the ignition electrode screws.
DO NOT exceed 20 inch-pounds torque.
7. Reinstall cover plate top insulation by sliding it on top of the
cover plate and over the igniter. Secure insulation by using
two (2) pieces of high temperature tape, aluminum foil tape
recommended. Tape should secure the insulation to the Heat
Exchanger.
8. Reinstall the blower / venturi/gas valve assembly (Items 3, 4
and 7).
a. Reinstall burner tube (80/110/199 models only) inside top
of cover plate. Make sure burner tube flange is flush with
cover plate surface when installing. Flange notch should
align with the index alignment feature in the Cover Plate
burner tube recess.
b. Install blower gasket (Item 9) between blower and cover plate.
c. Use 8mm wrench to secure blower to cover plate with two
(2) locknuts (Item 8).
d. Reconnect the two (2) blower wiring harnesses.
9. Reconnect the ignition cable and the igniter ground wire.
10. Replace the gas valve-to-venturi fiber washer (Item 6
Figure 114, page 129 part C) with a new fiber gasket. Slide
Cleaning heat exchanger flue side (continued)
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