AERCO KC1000 Boiler July 2011 - Manual (Page 52)

MAINTENANCE
7-2
10. Replace the rear cover panels or right side
panel. Replace the condensate cup to drain
tubing.
SPARK IGNITOR
ASSEMBLY
BURNER
SHELL
FLAME
DETECTOR
SILICONE
PLUG
Figure 7.1
Spark Ignitor and Flame Detector Locations
7.3 FLAME DETECTOR
The flame detector assembly (part no.
GM 123428) is located in the body of the burner
(see Figure 7.1). The flame detector may be
HOT. Allow the unit to cool sufficiently before
removing the flame detector.
To inspect or replace the flame detector (part
no. GM 123428):
1. Set the ON/OFF switch on the control panel
to the OFF position and disconnect AC
power from the unit.
2. Remove the left side panel from the unit.
3. Disconnect the flame detector lead wire.
Unscrew the flame detector and remove it
from its guide tube. The detector is flexible
and may be bent to ease its removal.
4. Inspect the detector thoroughly. If eroded,
the detector should be replaced. Otherwise
clean the detector with a fine emery cloth.
5. Reinstall the flame detector hand-tight only.
6. Reconnect the flame detector lead wire.
7. Replace the rear cover panels or left side
panel and reconnect the rear covers to the
unit. Replace the condensate cup to drain
tubing.
7.4 COMBUSTION CALIBRATION
Combustion settings must be checked at the
intervals shown in Table 7-1 as part of the
maintenance requirements. Refer to Section 4
for the combustion calibration instructions.
7.5 SAFETY DEVICE TESTING
Systematic and thorough tests of the operating
and safety devices should be performed to
ensure that they are operating as designed.
Certain code requirements, such as ASME
CSD-1, require that these tests be performed on
a scheduled basis. Test schedules must
conform to local jurisdictions. The results of the
tests should be recorded in a log book. See
Section 6-Safety Device Testing Procedures.
7.6 MANIFOLD AND EXHAUST TUBES
The presence of even trace amounts of
chlorides and/or sulfur, in the combustion air and
fuel sources, can lead to the formation of
deposits on the inside of the exchanger tubes,
the exhaust manifold, and/or the condensate
cup. The degree of deposition is influenced by
the extent of the condensing operation and the
chloride and sulfur levels that vary significantly
from application to application.
The following parts will be necessary for
reassembly after inspection:
GP-122537 Exhaust Manifold to
Combustion Chamber
Gasket
GP-18900 Manifold to Tubesheet
Gasket
GP-18899 Burner Gasket
GP-122551 Burner Release Gasket
*GP-161151 Combustion Chamber Liner
*Change only if damage occurs during the
inspection.
To remove the manifold for inspection:
1. Disconnect AC power and turn off the gas
supply to the unit.
2. Remove the sheet metal covers from the
unit.
3. Disconnect the plastic tubing from the
condensate cup to drain and remove the
rear covers.
4. Remove the condensate cup from under the
unit and the condensate drainage tubing
from the manifold.