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Cast Iron Condensing Boilers – Installation Manual
FlexCore Stainless Steel Condensing Boilers – Installation Manual
Ignition Safety
To test the ignition safety shutoff device, close the
manual shutoff valve 1 (Figure 17) in the gas supply line.
Within 5 seconds of main burner flame extinction, the
main gas valve solenoid should close. The control board
will lockout and display “LOW GAS PRESSURE”. Open
the manual shutoff valve in the gas supply line and reset
the control board by toggling the power switch.
To confirm the input of the unit follow the instructions in
the INPUT RATE section below.
Input Rate, Natural Gas
1. Turn off all other gas appliances that use the same
gas meter as the boiler.
2. Call your gas supplier and ask for the heating value
of the gas (Btu per cu/ft).
3. Start the boiler and let it run for 15 minutes.
4. With the boiler operation clock the time that it takes
to burn 10 cu/ft of gas at full fire.
5. Insert the heating value and the time, in seconds,
into the formula below.
6. Input = 10 / seconds (Btu per cu/ft)(3600).
7. If the computed rate exceeds the desired input
follow section “operating instructions” to make the
appropriate adjustments.
Never increase the input to the boiler above
that for which it is rated. Doing so can cause
premature failure of the boiler!
Low Water Cutoff
Ensure that the low water cutoff device(s) function
properly.
Test in accordance with the manufacturer’s instructions
included with the device(s).
DIAGNOSTICS
The FlexCore has a display that indicates the sequence
of operation, Figure 18. The display will also list faults
should the unit fail to operate. An explanation of each
fault is listed below.
STANDBY: Indicates that power is being supplied
to the unit and there is no call for heat.
STANDBY OPERATING LIMIT: Indicates that the
operating limit if used is open.
HONEYWELL ALARM “flashing”: Indicates that there
is a call for heat and the Honeywell 7895C is locked out.
STANDBY START DEMAND: Indicates that there is a
call for heat and the Honeywell 7895C is not functioning
or is locked out.
STANDBY WATER LIMIT: Indicates that either the high
limit, low water cut off, or both are open without a call
for heat.
LOCKOUT WATER LIMIT: Indicates that either the high
limit, low water cut off, or both are open with a call for
heat.
STANDBY GAS PRESSURE: Indicates that the low gas
pressure switch or the high gas pressure switch if used
is open without a call for heat.
LOCKOUT GAS PRESSURE: Indicates that the low gas
pressure switch or the high gas pressure switch if used
is open with a call for heat.
WAITING FOR FLOW: Indicates that minimum flow
hasn't been achieved.
FAULT INSUFFICIENT FLOW: Indicates that inadequate
flow is present.
LWCO LOCKOUT: Indicates low or no water in the
boiler.
