RBI FUTERA XLF Series Installation And Operation Instructions Manual

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RBI FUTERA XLF Series Installation And Operation Instructions Manual Manual pdf 30 page image

F d b b l & h B l M lFinned copper tube gas boilers & water heaters – Boiler Manual30FFMAINTENANCEDisconnect electrical power and close the manual gasshut off valve before performing maintenance or severepersonal injury may result!Servicing, inspection and adjustment must be done bya trained technician in accordance with all applicablelocal and national codes. Improper servicing oradjustment can damage the boiler/water heater!Th e boiler/water heater must be cleaned and inspected at least oncea year and before each heating season. Make sure that the burner andignition components are free from dust, soot, dirt, corrosion or otherdeposits that would impair the boiler/water heater ‘s performance.Refer to Figure 20, page 28 for component identifi cation.Improper burner servicing can result in prematureburner failure voiding the warranty!Pilot and burner removal1. Close the manual shutoff valves in the gas supply line and turnoff electrical power to the boiler/water heater.2. Remove the jacket top panel.3. Remove wires from the spark rods and remove the UV sensorfrom the transition piece.4. Remove the pilot assembly:a. Disconnect the compression nut at the front of the pilotblock.b. Remove the pilot gas tubing.c. Remove the (2) screws from the pilot block.d. Remove the pilot assembly.5. Disconnect the fl exible gas line from the manifold.6. Disconnect the wires to the fan and remove the (2) bolts and thefan hold-down plates that secure the fan to the transition piece.7. Lift and remove the fan housing from the boiler/water heater,taking care not to damage the spark rods and or their alignment.8. Remove the four nuts holding the transition piece to the heatexchanger.9. Remove the transition piece, taking care not to damage theO-ring.10. Remove the burner, taking care not to damage the gasket.11. Replace all components after servicing.Heat exchanger inspection1. Close the manual shutoff valves in the gas supply lines and turnoff electrical power to the boiler/water heater.2. Remove burner following the instructions in the Burner Removalsection.3. Remove the front jacket panel and combustion chamber door.4. Inspect the inside and outside of the heat exchangerfor signs of damage, sooting or corrosion.5. The outside surfaces of the copper tubes should be free ofany soot deposits. A slight black smudge is normal withsome types of gases. Black soot indicates poor combustion.Green deposits indicate condensation due to low return watertemperatures. In either case the heat exchanger must be cleanedthoroughly and the problem resolved before the boiler/waterheater is returned to service.6. If there are no signs of damage, sooting or corrosion, reassemblethe unit following the previous steps in reverse order.7. A badly corroded or damaged heat exchanger must be replaced,see the Heat Exchanger Repair & Replacement section.Heat exchanger cleaning1. Close the shut off valves in the inlet and outlet piping. On heatingsystems close the system fill valve and relieve the system pressurefrom the boiler by carefully lift ing the relief valve or opening thedrain valve.2. Disconnect the boiler/water heater from the system piping.3. Remove the eight bolts on the rear pipe enclosure panel.4. Remove the front jacket panel and combustion chamber door.5. Slide the heat exchanger out of the unit.6. Remove the “V” baffle straps and “V” baffles.7. Thoroughly clean the heat exchanger with water froma high-pressure hose. Use a soft bristle brush if necessary.8. Replace the cleaned heat exchanger and other components inthe reverse order of their removal.Heat exchanger repair & replacement1. A leaking or otherwise damaged tube(s) can be replaced asoutlined in steps 2 through 8.2. Remove the heat exchanger from the boiler/water heater asoutlined in the Heat Exchanger Cleaning section.3. Remove the pipe plugs from the inlet/outlet and return headersopposite from the ends of the tube(s) being replaced.4. Carefully cut the damaged tube(s) in half, taking care not todamage the adjacent tubes and remove.5. Install and swage/expand in place the new tube(s).