Whew!
Thursday, November 20, 2008
Wednesday, October 1, 2008
Burner QP
BURNER TRAY MAINTENANCE
Hi-Delta 992B – 2342B
Tool / Equipment List
Cordless Drill
-5/16” Magnetic Socket Bit
-Med Phillips Head Bit
-4” Extension Bit Holder
6-Way Screw Driver
2 small pipe wrenches
Spray bottle with soapy water or Blue Gas Leak
Small air compressor with storage tank
Thumb control air blaster with hose
Medium Shop-Vac with hose
Parts List
Raypak Kit –Sensor “F” Electrode / Part # 006535F
Raypak Kit –Igniter HSI / Part # 007400F
Raypak Burner / Part # 007617F
Objective
Inspect and clean Burner Tubes. Replace worn or damaged Burner Tubes. Diagnose cause of replaced Burner Tubes. Inspect and clean Gas Line Orifices. Replace Proving Rod and Hot Surface Igniter components.
PROCEDURE
1. Remove the Upper and Lower boiler panels.
2. Turn the inner power toggle switch to the off position.
3. Create a call for heat; make sure the other boiler lights and satisfies the Tank.
4. Turn the 24v electric Raypak gas valve petcocks, located in the upper cabinet of the boiler you are working on, to the off position.
5. Break loose, the union, located below the gas valve.
6. Loosen only the union on the gas valve you are inspecting. Do not loosen all the unions at one time.
7. Remove the screws (2) in the lower cabinet, which secure the individual gas valve line to the cabinet floor.
8. Slide the lower part of the gas line toward you.
9. Slip the rubber grommet down through the upper cabinet floor, releasing the gas line to you.
10. Inspect the stainless steel orifices for any restriction, making sure there is clear air flow. Blast with compressed air.
11. Contact System Manager, should replacement be necessary.
12. Remove “Red “ wire from Proving Rod
13. Remove the screws (2), which attach the Proving Rod, to the combustion chamber wall.
14. Remove the Proving Rod
15. Remove “Orange” and Yellow” wire from Hot Surface Igniter
16. Remove the screws (2), which attach the Hot Surface Igniter, to the combustion chamber wall.
17. Remove the Hot Surface Igniter
18. Leave Hot Surface Igniter and Proving Rod OUT of combustion chamber, so as not to damage Burner Tubes during inspection and cleaning.
19. Unscrew the screws (3), which secure the Burner Tubes to the combustion chamber wall.
20. Gently slide the Burner Tube toward you and out of the combustion chamber.
21. Keep Burner Tubes in proper order as they come out, so that their position relative to the proving rod and hot surface igniter is maintained for diagnosis.
22. The FLAT portion of the mounting flange is ALWAYS installed UP to insure the proper burner opening orientation.
23. Inspect the openings in the top of the Burner Tube for cracks or residue build up, that may restrict gas flow.
24. Inspect the Burner Tube ends for corrosion or separation.
25. Replace damaged Burner Tubes with Raypak Burner / Part # 007617F
26. Clean un-damaged Burner Tubes.
27. Blow compressed air into and across the openings on the top of the Burner Tube.
28. Vacuum any debris out of Burner Tube by inserting Shop-Vac hose into the large Burner Tube opening on the end.
29. Repeat inspection and cleaning process for each Burner Tube attached to that gas line.
30. Inspect each hole in the combustion chamber, for any black particulate or soot.
31. Reinstall each Burner Tube with the FLAT SIDE of the mounting flange UP.
32. Install new Proving Rod Raypak Kit –Sensor “F” Electrode / Part # 006535F
33. Re attach the “Red” wire to the new Proving Rod
34. Install new Hot Surface Igniter Raypak Kit –Igniter HSI / Part # 007400F
35. Re attach the “Orange” and “Yellow” wires to the new Hot Surface Igniter
36. Slide Gas Line back up through the upper cabinet floor.
37. Align stainless steel orifices with Burner Tubes.
38. Re-Position the rubber grommet BEFORE making gas line connections.
39. Hand-tighten the gas line union.
40. Replace the screws (2), which secure each gas line leg to the lower cabinet floor.
41. Fully tighten the gas line connections.
42. Repeat the process for each gas valve.
43. Open the gas valves and check for leaks with leak detection spray.
44. Turn power on to the boiler.
45. Create a call for heat on all stages and make sure all stages achieve flame rectification.
46. Remove call for heat.
47. Repeat entire procedure for second boiler.
Hi-Delta 992B – 2342B
Tool / Equipment List
Cordless Drill
-5/16” Magnetic Socket Bit
-Med Phillips Head Bit
-4” Extension Bit Holder
6-Way Screw Driver
2 small pipe wrenches
Spray bottle with soapy water or Blue Gas Leak
Small air compressor with storage tank
Thumb control air blaster with hose
Medium Shop-Vac with hose
Parts List
Raypak Kit –Sensor “F” Electrode / Part # 006535F
Raypak Kit –Igniter HSI / Part # 007400F
Raypak Burner / Part # 007617F
Objective
Inspect and clean Burner Tubes. Replace worn or damaged Burner Tubes. Diagnose cause of replaced Burner Tubes. Inspect and clean Gas Line Orifices. Replace Proving Rod and Hot Surface Igniter components.
PROCEDURE
1. Remove the Upper and Lower boiler panels.
2. Turn the inner power toggle switch to the off position.
3. Create a call for heat; make sure the other boiler lights and satisfies the Tank.
4. Turn the 24v electric Raypak gas valve petcocks, located in the upper cabinet of the boiler you are working on, to the off position.
5. Break loose, the union, located below the gas valve.
6. Loosen only the union on the gas valve you are inspecting. Do not loosen all the unions at one time.
7. Remove the screws (2) in the lower cabinet, which secure the individual gas valve line to the cabinet floor.
8. Slide the lower part of the gas line toward you.
9. Slip the rubber grommet down through the upper cabinet floor, releasing the gas line to you.
10. Inspect the stainless steel orifices for any restriction, making sure there is clear air flow. Blast with compressed air.
11. Contact System Manager, should replacement be necessary.
12. Remove “Red “ wire from Proving Rod
13. Remove the screws (2), which attach the Proving Rod, to the combustion chamber wall.
14. Remove the Proving Rod
15. Remove “Orange” and Yellow” wire from Hot Surface Igniter
16. Remove the screws (2), which attach the Hot Surface Igniter, to the combustion chamber wall.
17. Remove the Hot Surface Igniter
18. Leave Hot Surface Igniter and Proving Rod OUT of combustion chamber, so as not to damage Burner Tubes during inspection and cleaning.
19. Unscrew the screws (3), which secure the Burner Tubes to the combustion chamber wall.
20. Gently slide the Burner Tube toward you and out of the combustion chamber.
21. Keep Burner Tubes in proper order as they come out, so that their position relative to the proving rod and hot surface igniter is maintained for diagnosis.
22. The FLAT portion of the mounting flange is ALWAYS installed UP to insure the proper burner opening orientation.
23. Inspect the openings in the top of the Burner Tube for cracks or residue build up, that may restrict gas flow.
24. Inspect the Burner Tube ends for corrosion or separation.
25. Replace damaged Burner Tubes with Raypak Burner / Part # 007617F
26. Clean un-damaged Burner Tubes.
27. Blow compressed air into and across the openings on the top of the Burner Tube.
28. Vacuum any debris out of Burner Tube by inserting Shop-Vac hose into the large Burner Tube opening on the end.
29. Repeat inspection and cleaning process for each Burner Tube attached to that gas line.
30. Inspect each hole in the combustion chamber, for any black particulate or soot.
31. Reinstall each Burner Tube with the FLAT SIDE of the mounting flange UP.
32. Install new Proving Rod Raypak Kit –Sensor “F” Electrode / Part # 006535F
33. Re attach the “Red” wire to the new Proving Rod
34. Install new Hot Surface Igniter Raypak Kit –Igniter HSI / Part # 007400F
35. Re attach the “Orange” and “Yellow” wires to the new Hot Surface Igniter
36. Slide Gas Line back up through the upper cabinet floor.
37. Align stainless steel orifices with Burner Tubes.
38. Re-Position the rubber grommet BEFORE making gas line connections.
39. Hand-tighten the gas line union.
40. Replace the screws (2), which secure each gas line leg to the lower cabinet floor.
41. Fully tighten the gas line connections.
42. Repeat the process for each gas valve.
43. Open the gas valves and check for leaks with leak detection spray.
44. Turn power on to the boiler.
45. Create a call for heat on all stages and make sure all stages achieve flame rectification.
46. Remove call for heat.
47. Repeat entire procedure for second boiler.
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