33
12. Startup Procedures
Section XII: Startup Procedures
12.1 Final Checks Before Startup
□
Read Sections 12.5 through 13.4 regarding the operation of the
CHALLENGER control.
□
Verify the CHALLENGER and the boiler system are full of water
and all system components are correctly set for operation,
including the minimum flow rate through the boiler, 65-66
□
Verify all Startup Preparation items outlined in Section 11 have
been completed.
□
Verify all electrical connections are correct and securely
fastened.
□
Inspect vent and combustion air piping for signs of
deterioration from corrosion, physical damage or sagging.
Verify combustion air and vent piping are intact and correctly
installed and supported. Reference the proper CHALLENGER
vent supplement.
□
Verify burner configuration - gas orifice size.
-
Check for proper labeling on the gas valve (propane only)
and the rating label for proper gas configuration.
- If there is doubt on the burner configuration, remove the
gas valve and check for proper gas orifice size. See
Sections 8.2.3 and 8.3.3 for correct orifice sizes.
□
Ensure the Condensate Drain Assembly is filled with water.
12.2 CHALLENGER Startup
Turn ON the electrical supply/service to the appliance. Press
1.
the ON/OFF button “
” located on the front control panel.
Read and follow the Operating Instructions outlined on page
2.
35.
12.3 CHALLENGER Startup Troubleshooting
If CHALLENGER does not start correctly:
Verify DHW and CH systems are turned ON and parameter 1 is
1.
set to “0”. Read Section 12.11 for more information.
Check for loose electrical connections, blown fuse (external or
2.
internal at the appliance control) or open service switch.
Is the external limit control (if applicable) open? Ensure the
3.
external limit is reset to the closed position.
Is the gas supply valve(s) open at the appliance and meter?
4.
Is incoming gas supply pressure at the appliance more than
5.
5”w.c. [13 mbar] and less than 13” w.c. [32 mbar] with all gas
appliances ON or OFF.
Are the room thermostats set above room temperature?
6.
If none of these conditions correct the problem, contact ACV - Triangle
Tube Technical Support.
12.4 Check the CHALLENGER and System
Check Piping:
1.
a. Check heating system for leaks. If found, shut down the
appliance and repair immediately.
b. Purge any remaining air from the system. Air in the system will
interfere with circulation, causing heat distribution
problems and system noise.
Check Vent Piping and Combustion Air Piping
2.
a. Check for gas-tight seal at every connection and seam of the
venting and combustion air piping.
Check Gas Piping
3.
a. Check around the appliance for gas odor following the
procedure outlined in Section 11.6.
Verify Flame Pattern and Combustion
4.
a. Check the flame pattern through the inspection port on the left
side of the heat exchanger. The flame should be blue and
stable over the length of the burner.
b. Test for CO2 or 02 and for CO during high and low firing rate.
Reference High Fire Test Mode, Section 12.10.4, and Low Fire
Test Mode, Section 12.10.5 for procedure to manually place
unit into high or low fire. The combustion readings should be
within the range listed in Table 5 on page 34. The CO level
should not exceed 100 ppm for natural gas or 150ppm for
propane gas.
Venting system must be sealed gas-tight to prevent
flue gas spillage and potential carbon monoxide emis-
sions, which will result in substantial property damage,
serious injury, or death.
DANGER
If any gas leaks are found or suspected, shut down the
appliance immediately. Use a gas detection device or
bubble test to locate the source of the gas leak and re-
pair at once. Do not operate the appliance until the
leak is corrected. Failure to comply with this procedure
can result in substantial property damage, serious in-
jury, or death.
WARNING
The combustion testing and adjustments must be per-
formed by a qualified installer, service agency, or the
gas supplier. All combustion measurements must be
performed with calibrated equipment to ensure proper
reading and accuracy.
WARNING
The combustion levels must be measured at high and
low firing rates. If the combustion levels are not within
the range given in Table 5, shut down the appliance and
contact ACV - Triangle Tube Technical Support. Failure
to comply with this requirement can result in substan-
tial property damage, serious injury, or death.
WARNING
Summary of Contents for CC105
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