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Check burner flame 1. Inspect flame through observation windows. 2. If the flame is unsatisfactory at either high fire or low fire, remove and clean the burner. Clean the burner thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to clean the burner if cleaning is performed inside a building. • Shut down the boiler: - Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 9 - Startup of the Crest Installation and Operation Manual. - Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain. 3. Allow time for the boiler to cool to room temperature if it has been firing. 4. Remove the top access panel to remove the gas/air manifold assembly. 5. Remove the nuts securing the burner to the burner mounting plate. Remove the burner (FIG. 2-2). 6. When replacing the burner, ensure gaskets are in good condition and positioned correctly (FIG. 2-2). 7. When securing the burner, be sure to tighten the nuts, but DO NOT over-tighten. Tighten the nuts to a torque setting of no more than 6.2 ft.-lbs. When securing the burner mounting plate be sure to tighten the nuts, but DO NOT over-tighten. Tighten the nuts to a torque setting of no more than 15.5 ft.-lbs. BURNER ASSEMBLY MANIFOLD GASKET AIR/GAS MANIFOLD INSULATION BURNER GASKET BURNER PLATE FIBERBOARD Figure 2-2 Burner Assembly Check flame signal 1. At high fire of each combustion system, the flame signal shown on the display should be at least 10 microamps. 2. A lower flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense electrodes does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the flame sense electrode. 3. See Section 3 - Troubleshooting in this manual for other procedures to deal with low flame signal. Service Manual 2 Maintenance (continued) Review with owner 1. Review the Crest User’s Information Manual with the owner. 2. Emphasize the need to perform the maintenance schedule specified in the Crest User’s Information Manual (and in this manual as well). 3. Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior. 4. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season. Cleaning boiler heat exchanger WARNING 1. Shut down boiler: • Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 9 - Startup. • Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain. 2. Allow time for the boiler to cool to room temperature if it has been firing. 3. Remove the top access panel to remove the gas/air manifold assembly. 4. Remove the nuts securing the burner to the burner mounting plate. Remove the burner (FIG. 11-2). 5. Remove the nuts securing the burner mounting plate from the heat exchanger and set aside. Remove the entire burner mounting plate assembly. The boiler contains ceramic fiber materials. WARNING Use care when handling these materials per instructions on this page. Failure to comply could result in severe personal injury. 6. Use a vacuum cleaner to remove any accumulation on the tube sheet surfaces. Do not use any solvent. 7. Brush the heat exchanger (tube sheet, combustion chamber walls, and tube entry) while dry using a nylon bristle brush. Caution: DO NOT use a metal brush. Re-vacuum the heat exchanger. 8. Finish cleaning using a clean cloth dampened with warm water. 9. Temporarily remove the condensate drain line from the condensate trap and route directly to a drain. 10. Rinse out debris with a low pressure water supply. The water will drain through the condensate connection. 11. Allow the heat exchanger to thoroughly dry. 12. Reconnect the condensate drain line to the condensate trap. 13. Close isolation valves on piping to isolate boiler from system. Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make-up line to the boiler. 14. When securing the burner, be sure to tighten the nuts, but DO NOT over-tighten. Tighten the nuts to a torque setting of no more than 6.2 ft.-lbs. When securing the burner mounting plate be sure to tighten the nuts, but DO NOT over-tighten. Tighten the nuts to a torque setting of no more than 15.5 ft.-lbs. 15. Replace the burner mounting plate assembly and gas/air manifold assembly. Ensure gaskets are in good condition and positioned properly. Restore boiler to operation. 16. Perform start-up and check-out procedures in the Check Flame and Combustion - Section 9 - Startup of the Crest Installation and Operation Manual. Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers c...

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