Burnham 101008-01R1-2/07 manual XI Start-up and Checkout, Never Attempt to Fill a HOT Empty Boiler

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XI Start-up and Checkout

NOTE

SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS TRAIN ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TEST SPECIFIED IN Z21.13.

Use the following procedure for initial start-up of the boiler:

1)If not already done, flush the system to remove sediment, flux, and traces of boiler additives. This should be done with the boiler isolated from the system.

2)Fill the boiler and hydronic system with water meeting the following requirements below (also see the note on the next page):

pH between 6.5 and 8.5

Total Solids less than 2500 PPM

Hardness less than 120 PPM (7 Grains/Gallon) Pressurize the system to at least 12 psi at the boiler

WARNING

NEVER ATTEMPT TO FILL A HOT EMPTY BOILER

3)Check all new piping for leaks and purge piping sections that are filled with air. See the National Fuel Gas Code for additional information on testing and purging gas lines.

WARNING

NEVER USE A FLAME TO CHECK FOR GAS LEAKS.

MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS

4)Vent system must be complete and free of obstructions before attempting to fire boiler. Make sure that the silicone cure time called for in the vent assembly instructions has passed before firing boiler.

5)Inspect all line voltage wiring for loose or uninsulated connections.

6)Remove the dust cap from the condensate trap (Fig 7.21). Add water to the trap until water runs out the condensate drain. Reinstall the dust cap.

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Contents Freedom Table of Contents Maximum Vent Lengths SpecificationsProduct Description II SpecificationsIV Locating the Boiler III Before InstallingClearances To Combustible Or Non-combustible Material Clearances from Vent Piping to Combustible Construction Floor Mounting Mounting The BoilerWall Mounting Wall Mounting Hole Locations Boiler Mounting/Hardware VI Air for Ventilation Page Vent System Design VII VentingPage Or PVC Summary of Horizontal Venting OptionsHorizontal Concentric Venting Vent Option Size Vent U.S. Boiler Concentric Vent Components Vent Option6c Positioning Vent Terminal Under Overhangs VENT/ AIR Intake Fitting Equivalent Length Roof Summary of Vertical Venting OptionsNever Common Vent a FCM Boiler with Other Appliances Removing an Existing Boiler From a Common ChimneyAssembly of U.S. Boiler 60/100mm Concentric Venting 11 Dimension L 12 Cutting Outer Pipe 14 Preparing Terminal Section for Installation in the Wall 16 Installation of Stainless Steel Vent Collar Assembly of Stainless Steel Venting17a Star-34 Connection to Vent Collar 18 Z-Vent III Connection to Vent Collar 19 SAF-T Vent EZ Seal Connection to Vent Collar 20 FasNSeal Connection to Vent Collar Condensate Trap and Drain Line 21 Condensate Piping Arrangement Gas Connection To Boiler Viii Gas PipingFlow Requirements Through Boiler General System Piping PrecautionsIX System Piping System DesignMethod 1 Primary/Secondary Piping Piping Method #1 Heat Only Piping Method #1 Heat + Indirect Water Heater 4b Piping Method #1 Indirect Water Heater Loop Piping Shaded Pipe and Circulator Sizing for Indirect Water Heater Loop Pipe and Circulator Sizing for Boiler LoopFitting Equivalent Lengths Boiler Head Loss Standard Piping Installation RequirementsPiping for Special Situations 11 Chiller Piping Wiring Wiring Connections Diagram Ladder Diagram Page Never Attempt to Fill a HOT Empty Boiler XI Start-up and CheckoutWater Quality and Boiler Water Additives FCM Series Lighting and Operating Instructions SWT Typical CO2/O2 Combustion Readings Range Gas Valve DetailPage XII Operation Normal Display In Standby ModePage Basic Menu Tree First Digit Boiler Status Boiler StatusOutdoor Reset Curve XIII. Service and Maintenance Page No Error Code Displayed XIV. TroubleshootingCode Condition Possible Causes Soft Lockout Codes DisplayedHard Lockout Codes Displayed XV Parts Page KEY Description Parts ListPage Parts List Page Page Page DISP4D 150 151 152 153 154 155 156 157 158 159 160 161 162 Page Page Page Page Page Limited Warranty