RBI Gas boilers Installation And Operation Instructions Manual

Contents

RBI Gas boilers Installation And Operation Instructions Manual Manual pdf 31 page image

Finned copper tube gas boilers & water heaters – Boiler ManualFinned copper tube gas boilers & water heaters – Boiler Manual31FMAINTENANCEDisconnect electrical power and close the manual gasshut off valve before performing maintenance or severepersonal injury may result!Servicing, inspection and adjustment must be doneby a trained technician in accordance with all applicablelocal and national codes. Improper servicing or adjust-ment 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 21 for component identifi cation.Improper burner servicing can result in prematureburner failure voiding the warranty!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. Disconnect the wires to the fan and remove the four bolts thatsecure the fan to the transition piece.4. Remove wires from the spark rods and remove the UV sensefrom the transition piece.5. Disconnect the compression nut at the back of the transitionpiece to remove pilot gas tubing.6. Remove the four nuts holding the transition piece to the heatexchanger.7. Lift and remove the transition piece and burner together fromthe boiler/water heater, taking care not to damage the sparkrods and or their alignment.8. Disconnect the compression nut from the inside of the transi-tion piece.9. Remove the transition piece, taking care not to damage the sparkrods and or their alignment.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 BurnerRemoval section.3. Remove the front jacket panel and combustion chamber door.4. Inspect the inside and outside of the heat exchanger for signsof damage, sooting or corrosion.5. The outside surfaces of the copper tubes should be free of anysoot deposits. A slight black smudge is normal with some typesof gases. Black soot indicates poor combustion. Green depositsindicate condensation due to low return water temperatures. Ineither case the heat exchanger must be cleaned thoroughly andthe problem resolved before the boiler/water heater is returnedto 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 lifting the relief valve or openingthe drain 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 from a 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).6. Replace the pipe plugs using a suitable thread sealant on eachone.7. Sagging or distorted heat exchanger tubes are an indication oflow water fl ow through the system. A damaged heat exchangermust be replaced and the condition that caused the damageresolved before the boiler/water heater is returned to service.8. Replace the heat exchanger and other components in the reverseorder of their removal.Air Intake & Vent SystemThoroughly inspect the air intake and vent systems for any signs ofblockage, corrosion or leakage. Immediately replace any unsoundvent system piping. Inspect the air filter and wash with warm waterand soap if dirty.