AERCO KC1000 Boiler July 2011 - Manual (Page 51)

MAINTENANCE
7-1
SECTION 7 - MAINTENANCE
7.1 MAINTENANCE SCHEDULE
The unit requires regular routine maintenance to
keep up efficiency and reliability. For best opera-
tion and life of the unit, the following routine
maintenance procedures should be carried out
in the time periods specified in Table 7-1.
Appendix J contains recommended spare parts
lists for maintenance of the KC1000 Boiler.
Table 7-1. Maintenance Schedule
Sect Item
6
Mos.
12
Mos.
24
Mos.
Labor
Time
7.2 Spark
Ignitor
(GP-122435-S) Inspect Replace 15
mins.
7.3 Flame Detector
(GM-123428) 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
Inspect
& clean
if
neces-
sary
4 hrs.
7.7 Water Side
Inspection
Inspect 2 hr.
7.8 Condensate
Drain
Inspect Inspect
& Clean
30
mins.
* 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 (part no.
GP-122435-S) is located in the body of the
burner (see Figure 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. Set the ON/OFF switch on the control panel
to the OFF position and disconnect AC
power from the unit.
2. For access to the spark ignitor
(GP-122435-S), remove the unit’s right side
panel. Access can also be gained by
removing the rear panels and condensate
drainage system
3. Disconnect the ignitor cable from the ignitor
extension. Remove the silicone ignitor plug
from the burner shell by simultaneously
twisting and pulling downward.
4. Insert the ignitor removal tool into the burner
shell, where the ignitor plug 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 re-
placed. 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 Section 4 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 assembly using the
ignitor removal tool. Do not over tighten the
ignitor. A slight snugging up is sufficient.
8. Reinstall the ignitor plug into the burner shell
by simultaneously twisting and pushing it
into the shell.
9. Reattach the ignitor cable to the extension
and verify that it “clicks” into place.