6. Remove the electrical connection to the fan.
7. For instructions on removing the fan, see Replacing the fan on page 78.
8. Remove the ignitor cables (green and red).
9. Remove the four (4) nuts securing the lid to the heat exchanger. The burner is attached to the
underside of the heat exchanger lid.
10. Carefully lift the lid upwards away from the studs. The gasket/refractory/burner should stay with
the lid as it is removed.
11. Remove the screws securing the ignitor, and then remove the ignitor and ignitor gasket.
12. Remove the refractory by sliding it over the burner.
13. Turn the heat exchanger lid over.
14. Remove the screws securing the burner to the heat exchanger lid, and remove the burner and
gasket. The burner gasket will likely be damaged during removal, and will need to be replaced.
15. Install the new burner and gasket, ensuring that all screws are tightened evenly by repeating the
tightening sequence a few times as shown in the images below.
16. Reinstall the refractory. Carefully slide it over the burner all the way to the lid, ensuring that the
openings for the ignitor, view port and heat exchanger studs are aligned correctly.
17. Reinstall the ignitor gasket and ignitor with two screws.
18. Re-install the lid with burner and gasket/refractory assembly. Ensure that you tighten each nut
evenly by following the order indicated in the pattern below.
19. Re-install the remaining components in reverse order.
20. Turn on the electric power and gas supply to the boiler.
21. After firing the boiler, check for leaks at the gas valve inlet and at the connection between the fan
and the heat exchanger lid (if the fan was removed).
22. Check the gas valve tuning, and adjust as needed.
Figure 46 Order for tightening screws on burner and nuts on the lid
7.4 Cleaning the sight glass
When a new boiler is first fired up, gases in the system can cloud up the viewport. If so, you will need to
clean the sight glass to view the presence of a flame.
7.4 Cleaning the sight glass
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