EPV SERIES CONDENSING WATER BOILER
34-501 07/13
12
START-UP PROCEDURES
WARNING: Start-up should only be performed by a qualified technician.
CAUTION: Do not relight pilot or start burner with combustion chamber full of gas or oil vapor, or with very
hot combustion chamber.
WARNING: You must connect the supplied gas train assembly to the burner union. Then connect the
gas supply to the gas train. Do not connect the gas supply directly to this union. Failure to install the
supplied gas train to the burner union before connecting the gas supply may result in uncontrolled gas
flow into the appliance and/or the appliance area. Failure to follow this warning could result in fire or
explosion causing property damage, personal injury or death.
1. The EPV gas valve and control train (gas train) provided with the appliance must be directly connected to the
union piped out of the burner. After the gas train is attached to the burner, the gas supply can be connected to
the gas shut-off valve (gas cock) at the gas train inlet. After gas plumbing is complete, verify the gas train is
adequately supported and connect the conduit and multi-pin plug into the multi-pin receptacle in the gas train
conduit box.
2. Carefully study the burner start-up information included in this manual.
3. Fill system tank with water. Some water boilers may be equipped with an optional air vent. If venting through
the safety valve when filling the boiler, insure gags or fixtures are removed from the safety valve prior to start-
up. Open the safety valve to allow air in the tank to escape.
4. Be sure all connections into the tank are tight, as leaks at tank fittings will damage the insulation.
5. The manual reset thermostat is a temperature limiting safety device set at 215°F; the operating thermostat is
set at the factory at 180°F for on-off operation. For two-stage models, a second operating thermostat is used
to control the second stage operation and should be set approximately 10°F below the primary operator.
Adjustment may be made by turning the thermostat dial to the desired temperature.
CAUTION: Conduct the following gas train leakage test before start-up, at annual intervals and prior to
investigating the cause of any reported occurrences of delayed ignition.
•
Using an appropriate bubble detection solution, thoroughly coat all gas train pipe connections. If
any bubbles are detected, the leaking connection must be tightened, recoated, and rechecked to
assure stoppage of the leak.
•
Attach a manometer to measure the gas pressure at the manual gas shutoff valve located just
upstream of the gas train. Adjust gas train inlet pressure to the specified value (e.g. 14" W.C.), and
tightly close the gas train manual shutoff valve closest to the burner.
•
Reattach the manometer to the gas train manual shutoff valve at the burner and record the
measured gas pressure in inches of water column (W.C.). Measure gas pressure again after 15
minutes. If gas pressure has increased 0.5" W.C. or more, the gas leak must be isolated to one or
more of the operating gas valves. (For example, a solenoid actuated gas shutoff valve.) After any
leaking valve is replaced, the reassembled gas train must be leak tested again before start-up is
attempted.
WARNING: Turn off all electrical service to the appliance when accessing the controls located inside the
control cabinet. The cabinet contains high voltage wiring and terminals. If the electrical service is not
turned off and these wires or terminals are touched, a dangerous shock causing personal injury or loss of
life could occur. Close the control cabinet before restoring electrical service to the appliance.
6. Remove enclosure panel cover on the boiler to expose control circuit. A wiring diagram, included in this
packet, will show the controls used in our circuitry.
7. Visually check that all components are intact and no damage has occurred during transit.