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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.
Rate, Btu/Hr = F x H x 3600
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.
18
INSTALLATION AND OPERATING INSTRUCTIONS
T
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:
·
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. CLEAN THE BOILER
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.
WARNING
Cleaning the boiler requires the use of very hot water
and corrosive chemicals. Use care when handling to
prevent injury.
3. Thread a 1-1/4" NPT Pipe Nipple into the "Skim
Tapping" (Connection "J" in Figure 11.1). Tighten
firmly.
4. Thread a 1-1/4" NPT ball valve onto the nipple and
connect a 1-1/4" drain line.
5. Close all valves to the system. Provide a means of
supplying fresh water to the boiler.
CAUTION
Do not leave the boiler unattended while performing
boil out. Do not allow the water to drop below the
bottom of the gauge glass or allow make up water to
enter too quickly. This will avoid the possibility of
causing failure of the boiler sections.
6. Use common washing soda (such as Arm &
Hammer Super Washing Soda). For each 800 square
feet EDR net boiler rating, mix one pound of
washing soda with water. Pour mixture into safety
relief valve tapping.
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