26
11. Startup Procedures
Section XI: Startup Procedures
11.1 Final Checks Before Startup
Read Sections 11.5 through 12.4 regarding the operation of the
1.
CHALLENGER control.
Verify the CHALLENGER and the boiler system are full of water
2.
and all system components are correctly set for operation,
including the minimum flow rate through the boiler, see pages
53-55.
Verify all Startup Preparation items outlined in Section 10 have
3.
been completed.
Verify all electrical connections are correct and securely
4.
fastened.
Inspect vent and combustion air piping for signs of
5.
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.
6.
Check for proper labeling on the gas valve (propane
a.
only) and the rating label for proper gas configuration.
If there is doubt on the burner configuration, remove
b.
the gas valve and check for proper gas orifice size. See
Sections 7.2.3 and 7.3.3 for correct orifice sizes.
Ensure the Condensate Drain Assembly is filled with water.
7.
11.2 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 28.
2.
11.3 CHALLENGER Startup Troubleshooting
If CHALLENGER does not start correctly:
Verify parameter 1 is set to “3”. Read Setting the Appliance
1.
Parameters, Section 11.9, for more information.
Check for loose electrical connections, blown fuse (external
2.
or 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.
11.4 Check the CHALLENGER and System
Check Piping:
1.
Check heating system for leaks. If found, shut down
a.
the appliance and repair immediately.
Purge any remaining air from the system. Air in the
b.
system will interfere with circulation, causing heat
distribution problems and system noise.
Check Vent Piping and Combustion Air Piping
2.
Check for gas-tight seal at every connection and seam
a.
of the venting and combustion air piping.
Check Gas Piping
3.
Check around the appliance for gas odor following the
a.
procedure outlined in Section 10.6.
Verify Flame Pattern and Combustion
4.
Check the flame pattern through the inspection port
a.
on the left side of the heat exchanger. The flame
should be blue and stable over the length of the
burner.
Test for CO2 or 02 and for CO during high and low
b.
firing rate. Reference High Fire Test Mode, Section
11.8.3, and Low Fire Test Mode, Section 11.8.4, 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 27. 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
Summary of Contents for CC105s
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