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hose from barbed fitting on gas valve. Disconnect 11/2"x2" flexible coupling from air
inlet. Disconnect air by-pass (1/2"transparent vinyl tube) from the bottom of the mixer.
c. Remove air baffle from 1½"x2" flexible coupling and clean air baffle if necessary.
Refer to repair parts diagram, mixer and pressure switch assembly.
d. Confirm that manual gas valve is closed and disconnect gas line to gas valve at union.
Disconnect wires to gas valve and igniter.
e. Loosen but do not remove five (5) nuts attaching mixer assembly to boiler. Remove two
(2) igniter screws and very carefully remove the igniter. Use care when removing the
igniter, it is very brittle!!
f. Remove five (5) nuts and remove mixer assembly. Remove burner and mixer gasket.
g. Aluminum oxide deposits are water soluble and may be rinsed away with spraying or
running water. Before rinsing, connect a 1/2"I.D. hose to the barbed fitting on the bottom
of the boiler and runthe hose to a bucket or drain.
h. Use a flexible handle nylon brush to loosen sediment and aluminum oxide on all heating
surfaces of boiler. Refer to the repair parts diagrams.
i. After brushing and rinsing, remove any remaining loosened sediment using a shop
vacuum with a snorkel attachment.
j. Inspect burner for any foreign matter in the flame ports or inside the burner. Any foreign
matter should be removed by blowing with compressed air or vacuuming.
k. Inspect interior of mixer for any signs of sediment or aluminum oxide and clean if
necessary.
1. Reinstall burner and mixer gasket and position mixer assembly over studs. Install five (5)
nuts but do not tighten. Reinstall igniter and igniter gasket and fasten with two (2)
screws. Use care when installing the igniter. It is very brittleIX Tighten five (5) nuts
holding mixer assembly.
m. Connect:
n,
O.
• gas line to gas valve
• condensate drain line to boiler
• pressure switch hose to gas valve
• air by-pass to mixer
• 11/2"x2" flexible coupling to air inlet and make sure to put air baffle back to
correct position
• igniter wires
• gas valve wires
Install cleanout cover plate and gasket. Fasten with screws.
Install inspection plate and fasten with screws.
.
Visually inspect condensate lines leading from the boiler sections and the vent tee to the
condensate trap. Refer to repair parts diagrams. Any foreign material or debris that is visible
in the condensate lines needs to be cleaned out as follows:
a. Raise condensate trap and drain condensate lines completely.
b. Once the condensate trap is emptied of water, disconnect condensate lines from the
fittings on the boiler, the vent tee, and the condensate outlet.
c. Remove the condensate trap and run cold water through the condensate lines to
thoroughly flush out any sediment or debris in the lines.
d. Reinstall and connect the condensate trap, using the hose clamps to secure the various
condensate lines to their fittings.
45
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