RBI Futera XLF Series Manual

RBI Futera XLF Series Manual Manual pdf 30 page image

30Finned copper tube gas boilers & water heaters – Boiler manual FTXLF-IOM-HN-1-110308 Copyright 2008 Mestek, Inc.mAintenAnceDisconnect 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!The 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 identification.Improper burner servicing can result in prematureburner failure voiding the warranty!pilot and burner removalClose the manual shutoff valves in the gas supply line and turn1. off electrical power to the boiler/water heater.Remove the jacket top panel.2.Remove wires from the spark rods and remove the UV sensor3. from the transition piece.Remove the pilot assembly:4.Disconnect the compression nut at the front of the pilota. block.Remove the pilot gas tubing.b.Remove the (2) screws from the pilot block.c.Remove the pilot assembly.d.Disconnect the flexible gas line from the manifold.5.Disconnect the wires to the fan and remove the (2) bolts and the6. fan hold-down plates that secure the fan to the transition piece.Lift and remove the fan housing from the boiler/water heater, tak-7. ing care not to damage the spark rods and or their alignment.Remove the four nuts holding the transition piece to the heat8. exchanger.Remove the transition piece, taking care not to damage the9. O-ring.Remove the burner, taking care not to damage the gasket.10.Replace all components after servicing.11.Heat exchanger inspectionClose the manual shutoff valves in the gas supply lines and turn1. off electrical power to the boiler/water heater.Remove burner following the instructions in the Burner Removal2. section.Remove the front jacket panel and combustion chamber door.3.Inspect the inside and outside of the heat exchanger4. for signs of damage, sooting or corrosion.The outside surfaces of the copper tubes should be free of5. any 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.If there are no signs of damage, sooting or corrosion, reassemble6. the unit following the previous steps in reverse order.A badly corroded or damaged heat exchanger must7. be replaced, see the Heat Exchanger Repair & Replacement sec-tion.Heat exchanger cleaningClose the shut off valves in the inlet and outlet piping. On heating1. systems close the system fill valve and relieve the system pressurefrom the boiler by carefully lifting the relief valve or opening thedrain valve.Disconnect the boiler/water heater from the system piping.2.Remove the eight bolts on the rear pipe enclosure panel.3.Remove the front jacket panel and combustion chamber door.4.Slide the heat exchanger out of the unit.5.Remove the “V” baffle straps and “V” baffles.6.Thoroughly clean the heat exchanger with water from7. a high-pressure hose. Use a soft bristle brush if necessary.Replace the cleaned heat exchanger and other components in8. the reverse order of their removal.Heat exchanger repair & replacementA leaking or otherwise damaged tube(s) can be replaced as out-1. lined in steps 2 through 8.Remove the heat exchanger from the boiler/water heater as out-2. lined in the Heat Exchanger Cleaning section.Remove the pipe plugs from the inlet/outlet and return headers3. opposite from the ends of the tube(s) being replaced.Carefully cut the damaged tube(s) in half, taking care not to dam-4. age the adjacent tubes and remove.Install and swage/expand in place the new tube(s).5.