AERCO KC1000 Boiler equipped with Mod-Box Controller - Manual (Page 38)

MAINTENANCE
33
SECTION 7 - MAINTENANCE
7.1 MAINTENANCE SCHEDULE
The unit requires regular routine maintenance to
keep up efficiency and reliability. For best
operation and life of the unit, the following
routine maintenance procedures should be
carried out in the time periods specified.
Table 1 Maintenance Schedule
Sect
Item
6 Mos.
12 Mos. 24
Mos.
Labor
Time
7.2 Spark
Ignitor
Inspect Replace 15
mins.
7.3 Flame
Detector
Inspect Replace 15
mins.
7.4 Combustion
Adj.
*Check Check 1 hr.
7.5 Testing of
Safety
Devices
Test 20
mins.
7.6 *Manifold &
Tubes
Inspe
ct &
clean
if
neces
sary 4 hrs.
* Recommended only when unit will be run in an
extreme condensing mode for prolonged periods
of time.
WARNING!
TO AVOID PERSONAL INJURY, BEFORE
SERVICING:
(A) DISCONNECT THE AC SUPPLY BY
TURNING OFF THE SERVICE SWITCH
AND AC SUPPLY CIRCUIT BREAKER
(B) SHUT OFF THE GAS SUPPLY AT THE
MANUAL SHUT-OFF VALVE PROVIDED
WITH THE UNIT
(C) ALLOW THE UNIT TO COOL TO A
SAFE TEMPERATURE TO PREVENT
BURNING OR SCALDING
7.2 SPARK IGNITOR
The spark ignitor assembly is located in the body
of the burner (see Fig. 7.1). The ignitor may be
HOT. Care should be exercised. It is easier to
remove the ignitor from the unit after the unit has
cooled to room temperature.
To inspect/replace the Ignitor :
1. Put the green ON/OFF button on the control
panel to the OFF position and disconnect AC
power to the unit.
2. Disconnect the plastic tubing from the
condensate cup to drain and remove the
rear cover panels from the unit. Access to
the spark ignitor may also be gained by
removing the unit’s right side panel
3. Disconnect the ignitor cable from the ignitor
contactor and unscrew the ignitor contactor
from the burner shell.
4. Insert the ignitor removal tool into the burner
shell, where the ignitor contactor was
removed. Screw the outer barrel of the tool
into the burner shell. Push the inner barrel
up and fit the hexagonal end of the tool over
the ignitor. Unscrew the ignitor from the
burner head and then the tool from the
burner shell.
5. The ignitor is gapped at 1/8-inch. If there is a
substantial erosion of the spark gap or
ground electrode, the ignitor should be
replaced. If carbon build-up is present, clean
the ignitor using fine emery cloth. Repeated
carbon build-up on the ignitor is an indication
that a check of the combustion settings is
required (see Sections 4.2 and 4.3 for
Combustion Calibration).
6. Prior to reinstalling the ignitor, an anti-seize
compound must be applied to the ignitor
threads.
CAUTION!
The ignitor must be removed and installed using
the ignitor removal tool provided with the unit(s).
Damage to the burner due to using a socket for
removal and installation of the ignitor is not
covered under warranty.
7. Reinstall the ignitor using the ignitor removal
tool. Do not over tighten the ignitor. A slight
snugging up is sufficient. Reinstall the ignitor
contactor (hand tight only) and reconnect the
ignitor cable.
8. Replace the rear cover panels or right side
panel. Replace the condensate cup to drain
tubing.
7.3 FLAME DETECTOR
The flame detector assembly is located in the
body of the burner (see Fig. 7.1). The flame
detector may be HOT. Allow the unit to cool
sufficiently before removing the flame detector.