Install Instructions

30
BOILER OPERATION
6. Check Main Burner Ignition
a. With the Operating Temperature Control turned
down, open the main gas shut-off valve(s).
b. Turn up the Operating Temperature Control for a
call for heat.
c. The electronic spark-ignited pilot(s) should ignite.
d. The main gas valves will then open and the main
burners should ignite.
e. Turn down the Operating Temperature Control to
stop the call for heat.
f. The electronic spark-ignited pilot(s) and main
burners should shut off.
E. CHECK MAIN BURNER SYSTEM
1. Remove the pressure test plug at the Main gas shut-
off valve. Attach a U-tube manometer.
2. Restart the boiler by turning up the Operating
Temperature Control for a call for heat.
3. Leak test all gas train joints with a soap suds
solution.
4. Check the gas pressure at the entrance to the Gas
Control train.
a. The pressure reading under flow should be
between 5.5 and 13.5 inches water column
b. If the pressure to the Gas Control Train exceeds
13.5 inches under any conditions, the system must
be provided with a lockup type gas pressure
regulator to provide 13.5 inches maximum.
5. Check the Manifold gas pressure.
a. Remove the 1/8" pipe plug from the manifold gas
pressure tapping.
b. Attach a U-tube manometer.
c. Adjust the Main Gas Pressure Regulator to obtain
3.5 inches water column on Natural Gas or 10
inches water column on Propane (LP) Gas.
d. NOTE: If the pressure is adjusted to set the
nameplate input to the boiler, do not set it more
than 0.3 inches plus or minus from the specified
settings. If more adjustment to the rate is needed, it
must be done by changing the burner gas orifices.
6. Check the burner input by reading the gas meter.
a. The required input rate is listed for each model in
Section II, Dimensions & Ratings.
b. Determine the input by multiplying “F” – Meter
Reading (Cubic Feet of Gas) times “H” – Heating
Value of Gas (Btu per Cubic Foot) times 3600.
Divide by “T” – the time in seconds at the meter
reading.
c. Note: If the meter is not automatically corrected
for temperature and pressure, the meter reading
must be corrected to actual conditions during the
rate test.
7. Check the burner and pilot flames (see Figure 8.1).
The flame inner cone should be about 1-1/2" high
and should have a very sharp blue color. Poor flame
conditions can be caused by dirty burners,
obstructed orifices or incorrect gas pressure.
F. CHECK BOILER CONTROLS
1. Limit and Operating Controls:
·
Lower the set point of each control until the
burners shut down. Note that the system pressure
(or temperature) corresponds to the limit setting.
·
Return the controls to the desired set point.
2. Low Water Cut-off (if used):
·
Consult the manufacturer’s instructions for the
low water cut-off operational check procedure.
3. Main Gas Safety Shut-off Valve:
·
Close main supply manual shut-off valve.
The main gas safety shut-off valve should
de-energize.
·
Open the manual supply valve. Re-light the
boiler in accordance with the lighting instructions.
G. PURGE AIR FROM THE SYSTEM
(WATER BOILERS ONLY)
1. Purge the system using purge valves, isolating zones
in the process or use system vents. Do not operate
the pump(s) while purging. Pumps will hold air in
the eye of the impeller.
2. Allow the system to reach 180°F and use manual
vents, if installed, to remove any remaining air.
H. CHECK THE SYSTEM PRESSURE
(WATER BOILERS ONLY)
Watch the pressure gauge as the system approaches
180°F. If the pressure exceeds the design operating
pressure, check:
a. Fill valve pressure.
b. Expansion or compression tank operation and sizing.
I. CLEAN THE BOILER
(STEAM BOILERS ONLY)
1. Clean the boiler as described below no later than
one week after the initial start-up. Cleaning will be
more effective if the boiler operates 24 to 48 hours
in order to loosen sediment and impurities in the
system.
2. The boiler must be cleaned to remove any
accumulation of oil, grease, sludge, or other
impurities that may be in the system. These
substances can cause foaming and surging of the
boiler water, producing an unstable water line and
water carryover to the system.
Rate, Btu/Hr =
F x H x 3600
T