Test Controls, Simulate flame failure | Burnham 81433101R16-1/10

of a faulty cut-off valve in the fuel pump, or it may be air trapped in the nozzle line. It may take several firing cycles for that air to be fully vented through the nozzle. Water in the fuel or poor flame shape can also cause shut down noises.

NOTICE

CHECK TEST PROCEDURE. A very good test for isolating fuel side problems is to disconnect the fuel system and with a 2 foot length of tubing, fire out of an auxiliary five gallon pail of clean, fresh, warm #2 oil from another source. If the burner runs successfully when drawing out of the auxiliary pail then the problem is isolated to the fuel or fuel lines being used on the jobsite.

G. TEST CONTROLS

WARNING

Before installation of the boiler is considered complete, the operation of all boiler controls must be checked, particularly the primary control and high limit control.

1.CHECK THERMOSTAT OPERATION. Raise and lower thermostat setting as required to start and stop burner.

2.VERIFY PRIMARY CONTROL SAFETY FEATURES using procedures outlined in Instructions furnished with control (See back of Control Cover) or Instructions as follows:

WARNING FOR HEATING SERVICEMAN ONLY

a.Simulate flame failure:

•Follow the starting procedure to turn on the burner.

•Close the hand valve in the oil supply line.

•Safety switch should lock out in approximately 15 seconds. Ignition should stop and oil valve should close. Blower will stop after postpurge period.

•Push red reset button to reset safety switch.

b.Simulate ignition failure:

•Follow the starting procedure to turn on the burner, but do not open the oil supply hand valve.

•Safety switch should lock out in approximately 15 seconds. Ignition and motor should stop and oil valve should close.

•Push red reset button to reset safety switch.

c.Simulate power failure:

•Follow the starting procedure to turn on the burner.

•With the burner running, turn off the power to the system by tripping the circuit breaker or removing the fuse.

•Burner should stop.

•Restore power. Burner should start.

d.If system does not operate as described, go to the

TROUBLESHOOTING AND MAINTENANCE section.

3.VERIFY HIGH LIMIT OPERATION.

a.Adjust thermostat to highest setting.

b.Observe temperature gauge. When temperature is indicated, adjust limit to setting below observed temperature. Burner should stop.

c.Adjust limit to setting above observed temperature. Burner should start.

d.Adjust thermostat to lowest setting. Adjust limit to desired setting.

4.CHECK LOW WATER CUTOFF (if so equipped).

a.Adjust thermostat to highest setting.

b.With boiler operating, open drain valve and slowly drain boiler.

c.Burner should stop when water level drops below low water cutoff probe. Verify limit, thermostat or other controls have not shut off boiler.

d.Adjust thermostat to lowest setting. Refill boiler.

H. Boiler is now ready to be put into service.

IMPORTANT

IF, DURING NORMAL OPERATION, IT IS NECESSARY TO ADD WATER MORE FREQUENTLY THAN ONCE A MONTH, CONSULT A QUALIFIED SERVICE TECHNICIAN TO CHECK YOUR SYSTEM FOR LEAKS.

A leaky system will increase the volume of make-up water supplied to the boiler which can significantly shorten the life of the boiler. Entrained in make-up water are dissolved minerals and oxygen. When the fresh, cool make-up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes as a gas. Both can result in reduced boiler life. The accumulation of sediment can eventually isolate the water from contacting the steel. When this happens the steel in that area gets extremely hot and eventually cracks. The presence of free oxygen in the boiler creates a corrosive atmosphere which, if the concentration becomes high enough, can corrode the