Install Instructions

64
Maintenance Procedures
When re-assembling the condensate pan
and flue pipe ensure all gaskets are in place
and correctly installed. Ensure all associat-
ed joints are complete, tight and secure.
Failure to comply can result in flue gas
leakage resulting in severe personal injury,
death or substantial property damage.
Check Expansion Tank
Refer to Section IV - Boiler Piping for rec-
ommended location of the expansion tank
and air eliminators.
Closed -Type Tank:
- Ensure tank is partially filled with
water leaving an air gap as a cushion.
Refer to the manufacturer’s instruction
for proper fill level.
- Ensure the tank is fitted with a device that
reduces gravity circulation of air-saturated
tank water back into the system. This device
prevents air from bubbling up through the
water as it returns from the system.
- Ensure no automatic air vents are used
in the system. This will allow air to
escape from the system instead of
returning to the tank.
Diaphragm Tank:
- Ensure the system contains a minimum of
one automatic air vent. Recommended
location of the air vent should be atop an
air eliminator.
- Remove the tank from the system and
check the charge pressure. For residential
applications the charge pressure is typical-
ly 12 psig [0.8 bar]. If tank does not hold
a charge pressure, then the membrane is
damaged and the tank should be replaced.
Check Relief Valve(s)
Inspect the relief valve(s) and lift the lever to
verify flow at least annually or as recommend-
ed on the warning tag of the valve.
Before manually operating the relief
valve(s), ensure the discharge piping is
directed to a suitable place of disposal to
avoid a potential scald hazard. The dis-
charge piping must be full size without
restriction and installed to permit com-
plete drainage of both the valve and line.
If after closing the valve, the valve fails to seat
properly or continually weeps, replace the
relief valve. Ensure the cause of the relief
valve to weep is the valve itself, not due to sys-
tem over-pressurization caused by an expan-
sion tank that is waterlogged or undersized.
Inspection of Ignition Electrode
Remove the ignition electrode using a 3 mm or
T-15 hex key inserted through the two top panel
holes located above the igniter. If necessary sep-
arate the top panel from the right side by insert-
ing a straight screw driver in two slots on right
side of top panel and bending metal tab in slots
away from the side. Lift top panel .
Remove any white oxides accumulated on the
electrode using fine grit sandpaper or steel wool.
If the electrode does not clean to a satisfactory
condition. Replace the ignitor .
When replacing the ignition electrode, ensure
the gasket is in good condition and correctly
positioned replace gasket if necessary.
Check igniter to Fig. 26, page 65.
Check Ignition Wiring and Ground Wiring
Inspect the ignition wiring from the burner con-
trol module to the ground at heat exchanger.
Ensure wiring is in good condition and secure-
ly connected.
Check ground continuity of the wiring to the
appliance heat exchanger or piping using a
continuity meter.
Replace and correct ground wire if ground con-
tinuity is not completed and satisfactory.
WARNING
WARNING