OPERATION AND START-UP INSTRUCTIONS
WARNING
After placing 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 2 on page 8).
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
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 relief valves should be inspected and manually operated at least twice a year.
IMPORTANT
IT IS RECOMMENDED THAT A QUALIFIED PERSON 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 7 on page 14.
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 serviceman:
1.Flooding to level of burner or controls or higher.
2.Exposure to fire.
3.If damaged.
4.Firing without water.
5.Sooting.
CAUTION
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, DO NOT TURN OFF OR DISCONNECT THE ELECTRICAL SUPPLY TO THE PUMP. INSTEAD, SHUTOFF THE GAS SUPPLY AT A LOCATION EXTERNAL TO THE APPLIANCE.
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 34, 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.
FIGURE 34.
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.
1.Turn off the electrical power and close the main manual gas shutoff valve. See L&O instructions on pages 43 and 44.
•Allow boiler parts to cool before disassembly.
2.Remove main burner manifold assembly from boiler.
•Refer to parts list supplied with this manual for disassembly aid.
3.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.
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