Bosch Buderus SSB255 Referenzhandbuch

Technical Service Bulletin:

Heat Exchanger: Refractory Replacement Procedure

Models: SSB255, SSB399, SSB512

Data subject to change without notice | Printed in the USA | BTC 438002102 B | 08.2019 Bosch Thermotechnology Corp.

WARNING:

The operations described here-below must be performed by

qualified personnel.

WARNING:

Before replacing the refractory, disconnect the equipment

from the power supply with the main ON/OFF switch and

close the manual gas shutoff valve.

CAUTION:

During every maintenance operation, always replace the

gaskets, especially the burner gaskets.

Replacement Procedure

Please follow the following steps for the refractory replacement:

1. Disconnect the two electrical connectors from the fan as shown in Fig.1

Figure 1

Electrical connectors

2. After closing the gas valve, disconnect the gas hose ﬁtting as shown in

Fig.2.

Figure 2

Gas hose fitting

3. Disassemble the fan by unscrewing the 4 nuts that lock the ﬂange to the burner

head as shown in Fig. 3.

Figure 3

4. Pull the fan upwards as shown in Fig. 4.

Figure 4

Fig. 2

Fan Flange

Data subject to change without notice | Printed in the USA | BTC 438002102 B | 08.2019 Bosch Thermotechnology Corp.

Technical Service Bulletin

2 | Heat Exchanger: Refractory Replacement Procedure

5. Remove the gaskets as shown in Fig.5 and Fig. 6 and pull up the burner as

shown in Fig. 7.

Figure 5

Figure 6

Figure 7

After removing the burner, continue as follows:

6. Unscrew the nuts that lock the burner ﬂange as shown in Fig. 8.

Figure 8

7. Pull up the refractory ring, the ﬂange sealing ring, and the steel basket as

shown in Fig. 9 and Fig. 10.

Figure 9

Refractory ring

Burner flange o-ring

Figure 10

Steel refractory holder

8. Access the refractory disk via the hole in the top of the combustion chamber

as shown in Fig. 11 and 12.

Figure 11

Data subject to change without notice | Printed in the USA | BTC 438002102 B | 08.2019 Bosch Thermotechnology Corp.

Technical Service Bulletin Heat Exchanger: Refractory Replacement Procedure | 3

Figure 12

Refractory disc

9. Pull the refractory disc out and carefully remove all of the debris from the

holder, as shown in Fig 13.

Figure 13

Place for dented

refractory disc

10. The replacement kit (part# 7738006357) contains 2 refractory half-discs,

a sealant cartridge and a ﬁber disc, shown in Fig. 14.

Figure 14

REFRACTORY

FIBER DISC

SEALANT

REFRACTORY

FIBER DISC

SEALANT

11. Place the ﬁber disc on the disc holder of the combustion chamber as shown

in Fig. 15.

Figure 15

12. Place the dented refractory half-disc (ﬁg. 16) on the ﬁber disc;

Figure 16

13. Make sure the dented half disc is placed as shown in Fig. 17. Also make sure

it matches perfectly to the disc holder and to the coil by turning it with your

hand.

Figure 17

Data subject to change without notice | Printed in the USA | BTC 438002102 B | 08.2019 Bosch Thermotechnology Corp.

Technical Service Bulletin

4 | Heat Exchanger: Refractory Replacement Procedure

Bosch Thermotechnology Corp.

65 Grove Street

Watertown, MA 02472

Tel: 1-866-642-3198

Fax: 1-954-776-5529

www.boschheatingandcooling.com

14. Mark the steel coil at the two edges of the refractory half-disc as a reference

for the ﬁnal assembly as shown in Fig. 18.

Figure 18

15. Remove the dented half-disk and place a strip of sealant on its inner edge as

shown in Fig.19.

Figure 19

16. Place the half-disk again on the disc holder by keeping the sealant upwards;

make sure the edges match with the marks previously taken as shown in

Fig. 20.

Figure 20

17. Take the second half-disk and place a strip of sealant at the inner edge as

shown in Fig. 21

Figure 21

18. Place the second half-disk matching the ﬁrst one and press carefully by

hands without using any tools in order to avoid any possible breakage. See

Fig.22.

Figure 22

WARNING:

Please wait at least 12 hours before turning on the burner, or

you could risk damaging the heat exchanger.

19. Re-assemble all components, and check all gaskets (burner / o-ring ﬂange

gaskets).

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