26
BOILER START UP AND OPERATIONS
After placing the boiler into operation, the ignition system safety
shutoff device must be tested by the following test method
.
1. Reset High Limit Temperature Control to lowest setting.
(See Figure 3 on Page 9).
2. Reset System Controller to maximum setting, causing a call
for heat and allowing unit to run until High Limit Temperature
Control trips.
3. Resetting the High Limit Temperature Control to a higher
setting, unit should run.
4. Reset System Controller and High Limit Temperature Control
to desired temperature. If unit fails to run, see Trouble-
Shooting in this manual.
Before operating the boiler, the entire system must be filled with
water, purged of air and checked for leaks. Do not use Stop Leak
or other boiler compounds. The gas piping should also be leak
tested.
Any safety devices including low water cutoffs used in conjunction
with this boiler should receive periodic (every six months)
inspection to assure proper operation. A low water cutoff device
of the float type should be flushed every six months. All pressure
relief valves should be inspected and manually operated at least
twice a year.
IMPORTANT
It is recommended that a qualified service technician perform
the initial firing of the boiler. At this time the user should not
hesitate to ask the individual any questions which he may
have in regard to the operation and maintenance of the unit.
FILLING THE SYSTEM
1. Fast fill system through bypass until pressure approaches
desired system pressure. Close bypass valve and permit
pressure to be established by the pressure reducing valve.
2. Vent all high points in system to purge system of air.
If pressure bleeding of system is desired, install valves as shown
in Figure 29 to Figure 42 on Pages 47 to 60.
Where cast iron radiation and motorized valves are used,
conventional system pressure and installation practices should
be followed.
Provisions should be made to permit manual venting of radiators
or convectors.
PRECAUTIONS
If the unit is exposed to the following, do not operate boiler
until all corrective steps have been made by a qualified service
technician:
• Flooding to level of burner or controls or higher.
• Exposure to fire.
• If damaged.
• Firing without water.
• Sooting.
PILOT AND MAIN BURNER
To maintain safe operation of the boiler, check the pilot and
the main burner once every six months for proper flame
characteristics.
1. MAIN BURNER
The main burner, Figure 19, should display the following
characteristics:
• Provide complete combustion of gas.
• Cause rapid ignition and carryover of flame across entire
burner.
• Give reasonably quiet operation during ignition, burning
and extinction.
• Cause no excessive lifting of flame from burner ports.
If the proceeding burner characteristics are not evident, check
for accumulation of lint or other foreign material that restricts or
blocks the air openings to the burner or boiler.
Also check for good flow of combustion and ventilating air to the
unit. Maintain a clear area around the boiler at all times.
The boiler should be periodically inspected by a qualified servicer
for continuous safe operation.
Qualified servicers should follow this procedure when the boiler’s
burners need cleaning.
a. Turn off the electrical power and close the main manual gas
shutoff valve. Refer to Lighting & Operating Instructions on
Pages 30 and 31.
• Allow boiler parts to cool before disassembly.
b. Remove main burner manifold assembly from boiler.
• Refer to parts list supplied with this manual for
disassembly aid.
c. Remove any loose foreign material such as dust or lint with
a vacuum. Check all ports, orifices, and air openings for
blockage. Dislodge any foreign material causing blockage.
Remove any soot or carbon deposits with a rag making sure
to remove any lint left on burner by vacuuming again.
d. Reinstall the burner manifold assembly on boiler.
e. Restore electrical power and gas supply to boiler.
• Put the boiler back in operation by following the lighting
instructions in this manual or on the lighting and
operating label on the boiler. Refer to Pages 30 and 31.
• Check for gas leaks and proper boiler and vent operation.
FIGURE 19. MAIN BURNER
