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6
Startup
Check for gas leaks
Before starting the boiler, and during initial
⚠ WARNING
operation, smell near the floor and around the
boiler for gas odorant or any unusual odor.
Remove the front access panel and smell the
interior of the boiler enclosure. Do not proceed
with startup if there is any indication of a gas
leak. Use an approved leak detection solution.
Repair any leaks at once.
Propane boilers only – Your propane supplier
⚠ WARNING
mixes an odorant with the propane to make
its presence detectable. In some instances, the
odorant can fade, and the gas may no longer
have an odor. Before startup (and periodically
thereafter), have the propane supplier verify
the correct odorant level in the gas.
Check thermostat circuit(s)
1. Disconnect the two external wires connected to the enable
terminals on the connection board.
2. Connect a voltmeter across these two incoming wires.
Close each thermostat, zone valve, and relay in the external
circuit one at a time and check the voltmeter reading across
the incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage does occur under any condition, check and
correct the external wiring. (This is a common problem
when using 3-wire zone valves.)
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires to the connection board. Allow the boiler to
cycle.
Check vent and air piping
1.
Inspect vent piping and air piping for signs of
deterioration from corrosion, physical damage or
sagging.
Verify air piping and vent piping are intact
and correctly installed per this manual.
Placing the boiler in operation
Boiler operational checks
2.
Turn the boiler main power switch to the "ON"
position.
3.
Confirm the settings of the temperature control.
4.
Push the reset for the low water cutoff (if equipped).
5.
Ensure that maximum flow to the boiler does not exceed
55 GPM on Models 402 - 752 and 90 GPM on Models
992 - 2072. Verify by checking temperature rise while
burner is firing at 100% of rated input.
6.
Install a manometer on the gas supply to the boiler and
verify minimum gas supply pressure as the burner fires at
100% of rated input.
7.
Verify operation of safeties as necessary (low water
cutoff, high limit, gas pressure, etc.,).
50
Installation & Service Manual
Boiler operation
8.
Verify that all adjustable points in the Operator
Interface are set as required.
9.
Boiler should begin the start-up process for the
sequence of operation.
10. The boiler will ignite and operate to meet the system
demand.
11. Ensure that inlet water temperature does not fall below
the specified minimum for the boiler.
12. As system demand is satisfied, the burner will cycle off
and the combustion air blower will run for a post
purge operation before the boiler shuts down.
Start the boiler
1. Read and follow the Lighting Instructions in FIG. 6-1, on
page 47.
If boiler does not start correctly
1. Check for loose connections, blown fuse or service switch
off?
2. Is external limit control (if used) open? Is boiler water
temperature above 200°F (93.3°C)?
3. Is thermostat set below room temperature?
4. Is gas turned on at meter or boiler?
5. Is incoming gas pressure less than 4 inches water column?
If none of the above corrects the problem, refer to the
Maintenance Section of this manual.
⚠ WARNING
The venting system must be installed so that
it will prevent flue gas spillage and carbon
monoxide emissions, which will result in
severe personal injury or death.
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