User Guide

24
B. CONTROL DESCRIPTIONS
See Figure 6.1 in Section 6 (Electrical) for locations of
these devices.
1. FLAME ROLL-OUT SAFETY SHUT-OFF SWITCH
(FLAME ROLL-OUT SWITCH) – A thermally
activated switch located between the first burner
from the left and the manifold bracket. The flame
roll-out safety shut-off switch will sense excessive
temperature caused by continued flame roll-out and
shut down main burner gas. This is a non-recycling
switch that must be replaced once it has been
activated and the cause of the roll-out eliminated.
2. VENT SAFETY SHUT-OFF SWITCH (SPILL
SWITCH) – A thermally activated, manually
resetable switch located in the draft hood relief
opening. If venting system becomes partially or
totally blocked, the vent safety shut-off switch will
sense excessive temperature caused by flue products
exiting the draft hood relief opening and shut down
main burner gas.
3. MULTI-FUNCTION BOILER CONTROL (LIMIT/
IGNITION CONROL) - The Hydrolevel 4200 control
provides the following functions:
a. Boiler water temperature limit control - burner gas
will shut down if the supply water temp exceeds
the control target setpoint. The target setpoint is
determined by the dial temperature setting and
the economy dial setting, and when reached is
indicated by the “target” lamp on the control.
The control will automatically reset when the
boiler supply water temp drops below the control
target setpoint.
b. Low water cut-off – The low water cut-off function
is active using default control settings. Burner
gas will shut down if the water level in the boiler
drops below the control’s sensing well. The
“low water” lamp on the control will illuminate.
The low water cut-off switch will automatically
reset when the water level is above the control’s
sensing well.
c. Ignition sequencing and flame safety – burner
gas will shut down if pilot flame is not detected
during the trial for ignition period. Control will
restart ignition sequence after a wait period.
The ignition status is indicated on the “Ignition”
lamps on the control. See Figure 6.6 in Section
6 (Electrical) for ignition sequence and flame
safety operation.
See Hydrolevel instructions for further information.
REGULATOR
1. Using the manometer setup installed in part 7A, set
manifold pressure as follows for various gases.
a. Natural Gas ...3.5″ Water Column (0.9 kPa)
b. LP Gas ......10.0″ Water Column (2.5 kPa)
2. To adjust gas pressure, turn adjusting screw of gas
pressure regulator counterclockwise to decrease
pressure, clockwise to increase pressure. Refer to
Figure 7.2 for location of gas pressure regulator.
Replace the cap screw when adjustment is complete.
3. In no case should the final manifold pressure vary
more than ±0.3 inches water column (0.07 kPa)
from the above specified pressures. Any necessary
major changes in the flow should be made by
changing the size of the burner orifice spuds.
4. When adjustment is complete, turn off boiler, gas
flow and electricity to boiler. Remove manometer
connection from valve and plug tapping with
plug provided. Turn utilities back on and resume
checkout.
D. CHECKING BURNER INPUT
1. Refer to rating label mounted on the jacket top panel
to obtain the rated BTU per hour input. In no case
shall the input to the boiler exceed the value shown
on the rating label.
2. Check input by use of the following formulas
(PB Heat, LLC suggests reading meter for 2 Cu. Ft.):
U.S. Customary Units
Input (BTU/Hr.)= 3600 x F x H
T
Where:
3600 = Seconds per hour
F = Cubic Feet of Gas Registered on Meter
H = Heat Value of Gas in BTU/Cubic Feet
T = Time in Seconds the Meter is Read
SI Metric Units
Input (kW)= 3600 x F x H
T x 3.6
Where:
3600 = Seconds per hour
3.6 = Megajoule (MJ) per kilowatt hour (kwhr)
F = Cubic Meters of Gas Registered on Meter
H = Heating Value of Gas in MJ/Cubic Meter
T = Time in Seconds the Meter is Read
3. As an alternative, use Table 7.1(a) and 7.1(b). Use
the heating value provided by gas supplier. Use a
stopwatch to record the time it takes for 2 cubic
feet (0.0566 cubic meter) of gas to pass through the
meter. Read across and down to determine rate.
START-UP PROCEDURES