2.
Step 10 Start Burner & Check Safety Functions
Check & Record: Air box cover must be in place before testing.
Refer to burner manual for recommended settings.
1. Check manifold pressure by installing a hose barb fitting in the combination gas
valve outlet pressure tap and then starting the burner. Adjust valve regulator if
necessary so the reading is 3.5”w.c. for either LPG or natural gas.
2. Draft Test: Draft must be negative in the flue box port (1).
3. Check CO
2
/O
2
at over fire test port (2) Nat. Gas:
CO
2
:9.0%,
O
2
:5.0% Nominal
LPG:
CO
2
:10.4%,
O
2
: 5.0% Nominal
4. Stack Temp: 190
º
-290° F at flue box port (1).
5. Check CO: 400 ppm Max
Air-free
(Refer to installation manual for
Air-free
method of measuring CO).
6. Set Safety DualGard High Limit to 215
o
F with Differential set at 10
o
F.
7. Test Safety High Limit Aquastat:
a. Remove all heat and hot water calls (No input lights on left side of manager).
b. Turn System switch off, then remove red sensor lead from the left side quick
connect.
c. Restore power. The 100
o
light will flash on the manager’s temperature
display. The burner should start momentarily.
d. At approximately 205
o
F to 215
o
F, the high limit aquastat should shut off
burner.
8. Verify flame failure lockout of Carlin 60200FRS burner control.
a. Connect hose from manometer to hose barb fitting in the combination gas
valve outlet pressure tap.
b. Close the main manual gas valve and turn ON the combination gas valve.
c. Turn on power to Resolute RT boiler and adjust a thermostat to call for heat.
d. Burner motor will start. The burner control will run for 30 seconds (pre-purge)
and then start the ignitor. Approximately one second later, the combination
gas valve will open. The manometer should show almost no pressure
because the main manual gas valve is closed.
e. After 4 seconds, the burner control will lockout and turn on the red LED. The
ignitor will shut off and the gas valve will close. Turn off power and adjust the
thermostat to stop the call for heat.
If lockout does not occur, replace the burner control.
9. Dilution Air Exhaust Fan Safety Switch test:
a. Remove power from the inducer by turning Display Energy Manager Option
Switch 2 OFF.
b. Start burner. Safety lock-out should occur in approximately just over 30
seconds.
c. Restore power to the inducer by turning Option Switch 2 ON and reset burner
lockout.
Step 8 Check Zone Valves
Open/Close zone valves several times to see that they move freely.
Step 9 Backflush Plate Heat Exchanger
1.
Close the valve underneath the domestic hot water circulator.
2. Open drain valve above the circulator to back flush the heat exchanger.
3.
If domestic water supply is “hard” (lime), consider installing Scale Stopper (Item
no. 10-0650).
4. Set temperature feeding hot water tank (above heat exchanger) by adjusting the
ball valve below the bronze circulator. Adjust the ball valve with the burner running
and a continuous flow of hot water from a fixture. You should just be able to hold
your hand on the pipe.
Step 7 Close Front Cover, Tighten Rear Cover
1. Install (4) upper nuts and washers.
2. Tighten nuts (6) uniformly.
3. Check and tighten (6) rear cover nuts.
4. Check Flue Pipe.
Digital
Manometer
Completely remove cover nuts, washers
and jacket screws at back, sides and top.
With hands at top and bottom, pull
cover
and
insulation board straight
back as a single unit.
2
1
3
4
5
1
2
