AERCO KC1000 Low NOx Boiler July 2011 - Manual (Page 56)

MAINTENANCE
7-2
7.3 FLAME DETECTOR
The flame detector assembly (124837) is located
in the body of the burner (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
(124837):
1. Set the ON/OFF switch on the control panel
to the OFF position and disconnect AC
power from the unit.
2. To access the flame detector, remove the
unit’s left side panel and left rear cover.
3. Disconnect the flame detector wire lead.
4. Using a 15/16” open-end wrench, loosen
and remove the flame detector from the
burner shell.
5. Inspect the detector thoroughly. If eroded,
the detector should be replaced. Otherwise,
clean the detector with a fine emery cloth.
6. Reinstall the flame detector in the burner
shell. Do Not over-tighten. A slight snugging
up is sufficient.
7. Reconnect the flame detector wire lead.
8. Replace the left side panel and left rear
cover on the unit.
7.4 COMBUSTION CALIBRATION
Combustion settings must be checked at the
intervals shown in Table 1 as part of the sched-
uled maintenance requirements. Refer to the
combustion calibration instructions in Section 4..
7.5 SAFETY DEVICE TESTING
Systematic and thorough testing of the operating
and safety devices should be performed to
ensure that they are operating properly. 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,
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 replacement parts will be required
for reassembly after inspection:
GP-122537 Combustion Chamber
Gasket
GP-18900 Manifold to Tubesheet
Gasket
124749 Burner Head/Plate Gasket
124834 Burner Plate/Shell Gasket
*124839 Combustion Chamber Liner
*Not necessary to change but should be on
hand in case damage occurs during the
inspection.
To remove the manifold for inspection:
1. Remove the sheet metal covers from the
unit.
2. Disconnect the plastic tubing from the
condensate cup to drain and remove the
rear covers.
3. Remove the condensate cup from under the
unit Disconnect AC power and turn off the
gas supply to the unit.
4. and disconnect the condensate drain tubing
from the exhaust manifold.
5. Remove the flame detector and ignition
cable wires from the flame detector and
igniter contactor. Remove the igniter and
flame detector per paragraphs 7.2, and 7.3.
6. Remove the grounding terminal from the
burner by loosening the upper screw and
sliding the connector from the grounding
rod. (See Fig. 7.2)
GROUND
TERMINAL
UPPER
SCREW LOWER
BURNER
SHELL
FLAME
DETECTOR
IGNITER
GND WIRE FROM
TRANSFORMER
Figure 7.2
Grounding Terminal Location