Check thermostat circuits
1. Disconnect wires connected to the Input 1, Input 2 and
Input 3 thermostat terminals (see Field wiring, beginning
on page 52 for low voltage terminal locations and appli-
cation information). Mark the wires before removing to
avoid wiring errors when re-connecting them.
2. Connect a voltmeter across each pair of incoming wires.
Close each thermostat, zone valve and relay in the external
circuits one at a time and check the voltmeter reading
across the incoming wires.
3.
There should NEVER be a voltage reading.
4. If a voltage does occur under any condition, check and
correct the external wiring.
DO NOT connect the thermostat terminals to
3-wire zone valves
. This could cause control
damage.
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires.
Inspect/fill condensate system
Inspect/check condensate lines and fittings
1. Inspect the condensate drain line, condensate PVC fit-
tings and condensate trap. (See page 49 for component
locations.)
2. Pour water into the top of the boiler’s ½” PVC condensate
tee and check for any leaks in the condensate drain line or
fittings. Repair any leaks.
Fill condensate trap with water
1. Loosen the hose clamp securing the right end of the condensate
trap to the PVC reducing elbow (see page 49 for details).
2. Slide the trap hose end off of the elbow.
3. Fill the trap with fresh water to within an inch of the end of
the hose.
4. Replace trap hose on PVC reducing elbow and tighten the hose
clamp.
The condensate trap must be filled with water during
all times of boiler operation to avoid flue gas emission
from the condensate drain line. [Prime the conden-
sate trap (by pouring water into the outlet tee while
restricting flow in drain tube) if boiler has been out
of service for an extended period.] Failure to fill the
trap could result in severe personal injury or death.
Final checks before starting boiler
❏
Read the instructions to adjust and set up the control module.
❏
Verify that the boiler model is set correctly in the control, and
that it displays correctly.
❏
Verify that the boiler and system are full of water and all system
components are correctly set for operation.
❏
Fill vent condensate trap with water (by removing hose clamp
and hose at PVC reducing elbow). Replace hose on PVC reduc-
ing elbow and tighten clamp.
❏
Verify electrical connections are correct and securely attached.
❏
Inspect vent piping and air piping for signs of deterioration
from corrosion, physical damage or sagging. Verify air pip-
ing and vent piping are intact and correctly installed per this
manual.
To start the boiler
1. Follow the Operating Instructions, Figure 87, page 89.
2. The control display will show installed sensors when first pow-
ered. Make sure the right sensors are detected and the correct
boiler model is identified. If not, determine the cause and cor-
rect before proceeding.
If boiler does not start correctly
1. Check for loose connections, blown fuse or service switch off?
2. Are external limit controls (if used) open? Is boiler water tem-
perature above 200 °F?
3. Are thermostats set below room temperature?
4. Is gas turned on at meter and boiler?
5. Is incoming gas pressure less than the minimum values given
on page 18?
6. Are control settings correct for the application?
7. Is the warm weather shut down activated?
8. If none of the above corrects the problem, refer to Troubleshoot-
ing, beginning on page 102.
Part number 550-100-131/0120
– 88 –
®
gas
-
fired
water
boiler
— 220/299/300/399
Boiler Manual
Startup — final checks
Check for gas leaks
Before starting the boiler, and during initial operation,
use a leak detector or smell near the floor and around
the boiler for gas odorant or any unusual odor. Remove
boiler front door and smell the interior of the boiler
jacket.
Do not proceed with startup if there is any
indication of a gas leak. Repair any leak at once
.
DO NOT adjust or attempt to measure gas valve out-
let pressure.
The gas valve is factory-set for the correct
outlet pressure. This setting is suitable for natural gas
and propane, requiring no field adjustment. Attempting
to alter or measure the gas valve outlet pressure could
result in damage to the valve, causing potential severe
personal injury, death or substantial property damage.
Propane boilers only
— Your propane supplier mixes
an odorant with the propane to make its presence de-
tectable. In some instances, the odorant can fade, and
the gas may no longer have an odor. Before startup
(and periodically thereafter), have the propane supplier
verify the correct odorant level in the gas.
