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P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler
— Installation and operation manual
Figure 27
Flue gas sampling hole
Figure 28
Electrical panel
Starting the boiler
(continued)
Turn the boiler OFF
Turn
OFF
the boiler on/off switch and allow the boiler to cycle off .
2.
CLOSE
the manual gas valve.
3. Multiple boiler SmartCycle applications — Disconnect the communications
cable or 3-wire connection to the boiler connection board. (Replace when done.)
Check ignition
With the manual gas valve
CLOSED
, start the boiler with the on/off switch.
Look into the fl ame window, left side of the boiler (Figure 29, page 38).
When ignition starts, the spark should jump between the electrodes, not to other
surfaces.
Th e spark should be strong and steady. If the spark is acceptable, turn the boiler
on/off switch
OFF
. Th en proceed with the start-up adjustment procedure.
If the spark jumps to ground or is unsteady, turn the boiler
OFF
. See the Maintenance
section of this manual for the procedure to remove and inspect the electrode as-
sembly. Replace the electrode assembly if it is damaged or not within specifi cations.
Insert combustion analyzer probe
Th e boiler must be checked and adjusted using combustion test
instruments. Failure to accurately measure fl ue gas analysis and adjust
the boiler as needed could result in severe personal injury, death or
substantial property damage.
Aft er the boiler has cycled off , loosen the hose clamp covering the fl ue gas sam-
pling hole (Figure 27).
Th e fl ue gas vent pipe may be hot. Touching the pipe with unprotected
skin could result in a severe burns.
2. Slide the hose clamp off of the sample opening.
3. Insert the combustion analyzer probe into the sample opening.
4. If using an electronic analyzer, zero and calibrate it before proceeding.
5. If using a chemical analyzer, make sure that the fl uid is fresh and is at room tem-
perature. Have a monoxer and test tubes available to test carbon monoxide levels.
Check high fi re operation
Remove the electrical panel cover on the right side of the boiler (see item 11,
page 3) as in Figure 28.
Electrical shock hazard
— Th e electrical box contains line-voltage
wiring and contacts. Use caution when working in the electrical box to
avoid contact with line-voltage elements. Turn off power to the boiler
panel if necessary.
2. Connect a jumper wire across the high-fi re terminals of the connector board
(Figure 28). Th ese terminals are located on the lower row as shown.
3. Turn the boiler on/off switch
ON
.
4. Th
e boiler will start at about 30% of maximum input and immediately go to high fi re.
5. Observe the fl ame through the fl ame window (left side of boiler; see Figure 29).
Th e fl ame should be blue and well-defi ned, with white traces.
If the fl ame is too lean (too much air), it will be light blue and unsteady.
If the fl ame appears reddish, or there are red areas on the burner surface, turn
the boiler
OFF
and reduce fuel with the gas valve thrott le (see page 38).
6. Check the analyzer. A rapid increase in CO is an indicator of bad combustion.
Turn the boiler
OFF
and reduce fuel input as explained on page 38.
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5.
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