dynatherm FP Series - Boiler Maintenance Procedures; Inspection Steps; Disassembly Process; Reassembly Process

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BOILER MAINTENANCE
INSPECTION
A Dynatherm™ boiler is operating properly when
there is no smoke. A zero smoke reading on the
Bacharach scale is an acceptable indication. The
CO
2
level should be between 11% and 13%. If
either of these two conditions is not obtainable,
an inspection of the equipment and the functional
parameters is indicated. Only a qualified
Dynatherm™ technician should perform the
inspection and maintenance on this boiler.
⚠ IMPORTANT
Replace the front head and end head rope
gaskets during every maintenance and cleaning.
1. Examine the gaskets on the front head, end
head, inspection plate and burner gasket.
Small soot deposits forming on the tube sheet
may be an indication of a leak.
a. If a leak is found, tighten the bolts or
replace the gaskets as necessary.
2. Check the domestic hot water coil plate and
gasket for any water leaks.
a. If a leak is found, tighten the bolts or
replace the gasket.
3. Inspect the 13 fire tube expansion joints at
both tube sheets for any signs of water leaks.
Water buildup in the front head, end head
and third pass chamber may be an indication
of a leak.
a. If a leak is found, contact Dynatherm™ for
the proper procedure to repair or replace
the leaking tube(s). Do not attempt to
repair or replace the leaking tube(s)
unless you’ve been properly trained by a
Dynatherm™ employee on tube rolling.
4. Verify the boiler water temperature and
pressure on the temperature/pressure gauge
(tridicator) are at the recommended settings.
5. If the boiler water is hot enough but the
domestic hot water is still not satisfactory, the
system could have some oil film which may
have insulated the fins on the hot water coil.
a. This can be corrected by flushing acid
through the coil to remove the buildup.
DISASSEMBLY
1) Remove the four (4) brass nuts on the end
head.
2) Lower the end head to the horizontal position
by the hinge, being careful not to let the scroll
drop.
3) Mark an area on top of the scroll with a black
marker for reassembly and then remove the
scroll. Take note of which side of the scroll
goes against tube sheet.
4) Remove the hinge bolt. The end head should
now be free from the boiler.
5) Disconnect the electrical wiring from the
burner.
6) Disconnect the fuel line(s) from the burner.
7) Remove the four (4) brass nuts from the front
head assembly. Carefully remove the
assembly from the boiler in order to avoid
damaging the gaskets and air tube insulator.
REASSEMBLY
1) Replace the rope gaskets on the front head
and end head. Use a high temperature spray
adhesive to secure the rope in place.
2) Place the front head in position.
3) Tighten the four (4) brass nuts evenly and
across corners to further assure a tight seal.
4) Mount the burner and reconnect the
electrical wiring and fuel line(s).
5) Make sure the combustion tube liner is fully
seated against air tube insulator.
6) Mount the scroll on the fire tubes. Make sure
the black mark you made with the marker is
on the top and the scroll is facing the correct
way against the tube sheet.
7) Replace the hinge bolt through end head
casting and carefully close the end head. Use
care so you do not disturb the scroll.
8) Tighten the four (4) brass nuts evenly and
across corners until the gasket is tight.
9) Bleed the fuel line(s) to the pump. The boiler
is now ready for firing.
10) Proceed with the Initial Burner Setup & Start-
Up procedure, record CO
2
levels, smoke
readings and air adjustments for the
homeowner.