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Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Operating Instructions
1. STOP! Read the safety information above. If, at any
time, the appliance will not operate properly, follow the
instructions "TO TURN OFF GAS TO APPLIANCE"
and call your service technician or gas supplier.
2. Set the operating control to off and disable any
outside (BMS) call for heat.
3. Turn off all electric power to the appliance.
4. Remove the front cover.
5. Close manual main shut-off valves 1 and 2 and the
pilot gas shut-off valve, Figure 17. Follow the same
procedure for multiple gas train configurations
(CK3500 - CK9000).
6. Purge the gas piping up to the manual valve ahead of the
main gas control of air. When the bleeding is complete,
check all gas joints up to the gas valve for leaks.
7. Wait five (5) minutes to clear out any gas.
8. Install a fitting at the supply test port and connect a
manometer having a minimum range of
20 in, 508
mm WC to it, Figure 17.
9. See the "Gas Supply Piping" section for the required
static and run gas pressure.
10. Open the manual main shut-off valves 1 and 2 and
the pilot gas shut-off valve, Figure 17. Follow the
same procedure for multiple gas train configurations
(CK3500 - CK9000).
11. Place the "Remote/Local" switch to Remote.
12. Turn the power switch on the front of the boiler to
"on". It will light up when the power is on. If all
interlocks are properly closed, the display will say
"Standby", Figure 18.
13. Slide the HeatNet controls low fire switch (on the
HeatNet control board) to the low fire position.
14. The boiler will begin the start sequence.
15. When the main display reads "PILOT RUNNING"
and the flame current is 5VDC, switch the Honey
well 7800 test/run switch into the "test" position,
Figure 18. This will hold the Honeywell 7800 in its
ignition state. For boiler sizes (CK3500 - CK9000)
place the test/run switch on both flame safeguards
into the "test" position. Both modules must be in the
"test" position otherwise the unit will shutdown.
16. Adjust the pilot pressure per the CHECKING,
ADJUSTMENT & OPERATION on page 29.
17. To adjust the IGNITION value as shown in the display,
place the ‘S2’ Calibration switch located on the 3.0
HeatNet board to the ‘CAL’ position. A reload message
will be displayed then the calibrate screen. Press the
‘Adjust’ button under the Ignition (%) setting. The
percentage value will turn green and the boiler will
ramp to the ignition setting. Set the Blower speed,
using the arrow keys, to provide the desired rate for
ignition. When the adjustment is satisfactory, press the
check key to save the setting. When complete place
the ‘S2’ switch back to the ‘NORM’ position.
For boiler sizes (CK3500-CK9000) press
the "Exchanger" graphical symbol to access
the Calibration screen, (Ignition %, Minimum
VFD%, Maximum VFD%), of each individual
heat exchanger module. The following
screen illustrates the menu selector.
The Calibration (Min % & Max %) represents
the mapped signal sent to the blower
and doesn’t reflect the (modulation %) as
indicated on the Master/Member Screens.
