Initial Operational Boiler Test Check-Out Procedure - Dunkirk PWXL Installation, Operation & Maintenance Manual

Cast Iron Gas-Fired Cast Iron Boilers
Check off each step as completed.
o Verify base insulation is securely fastened to base panels.
o Verify air purged from hydronic heating system.
o Purge air from gas piping; check gas piping for leaks.
o Verify proper orifices have been installed.
o Follow Lighting Instructions in Installation, Operation and Maintenance Manual furnished with boiler.
o Visually check the main burner flame and verify it has a well defined inner blue mantel with a lighter blue outer mantel.
o Inspect vent system to verify it is functional, unobstructed, and not leaking.
o Test the temperature limit control: With burner operating, adjust indicator on limit control below actual boiler water temperature.
Verify burners turn off. Verify the circulator continues to operate. Adjust the indicator on limit control above actual boiler water
temperature and verify burners reignite.
o Test any additional field-installed controls. If boiler has a low water cut-off or additional high limit, test for operation as outlined by
the controls manufacturer. Burners should be operating and should go off when controls are tested. When controls are reset, burn
ers should reignite.
o Test safety control circuit: With main burner operating, disconnect the ignition cable from the intermittent pilot control box. Verify
that the main gas control closes, shutting off the gas to the main burner. After verifying safety control circuit, turn off electric power
and reconnect ignition cable. Once ignition cable securely reset to intermittent pilot control box, turn electric power on.
o For multiple heating system zones, balance flow through each zone so that it is about equal per zone.
o Verify several operating cycles of proper operation.
o Measure Gas Input:
Natural Gas Procedure
o Operate boiler for 10 minutes.
o Turn off all other gas appliances piped with the boiler.
o At the gas meter, measure the cubic feet of gas used in 10 seconds (CF10).
o Calculate input: BTUh = CF10 x 360,000
o Verify the BTUh is approximate to the input rating on the boiler rating plate.
LP Gas Procedure
o LP gas input rate is determined by measuring gases produced during combustion. Refer to Boiler Manual for combustion
guidelines and corresponding BTUh input
o Verify the BTUh is approximate to the input rating on the boiler rating plate.
o Record the BTUh input on the OPERATIONAL BOILER TEST CERTIFICATE & SIGNED RECEIPT form.
o Set operating control (thermostat(s)) to the desired design requirement.
o Forward boiler manuals, instructions, wiring diagrams, piping diagrams, and supporting information shipped with this
boiler to owner and/or maintenance personnel.
o Complete and sign the INITIAL OPERATIONAL BOILER TEST CERTIFICATE & SIGNED RECEIPT form.

iNiTiAL OpErATiONAL BOiLEr TEST ChECk-OuT prOCEdurE

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