18
STEP 4
—
Placing Boiler in Operation
READ BEFORE OPERATING APPLIANCE
1. This appliance does not have a pilot. It is equipped with an
ignition device which automatically lights the burner. Do
NOT try to light this burner by hand.
2. Before operating, smell all around the appliance area for
gas. Be sure to smell next to the floor because some gas is
heavier than air and will settle to the floor.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch or use any phone in the building.
Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.
If you cannot contact your gas supplier, call the fire department.
3. Use only your hand to turn the gas ball valve. Never use
tools. If the valve will not turn by hand, do not try to
repair it, call a qualified service technician. Force or
attempted repair may cause fire or explosion.
4. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect
the appliance and to replace any part of the control system
and any gas control which has been under water.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above before
operating this appliance.
2. Set the thermostat to the lowest setting.
3. Turn off all electrical power to the appliance.
4. This appliance does not have a pilot. It is equipped with an
ignition device which automatically lights the burner. Do
NOT try to light this burner by hand.
5. Remove the front jacket panel.
6. Turn off the gas ball valve. Valve handle should be
perpendicular to the gas pipe.
7. Wait five minutes for any gas to clear. Then smell for gas,
including near the floor. If you smell gas STOP! Follow
instructions under “WHAT TO DO IF YOU SMELL
GAS” above. If you do not smell gas, go to next step.
8. Turn the gas ball valve to the “on” position. The handle on
the valve should be parallel to the gas pipe.
9. Replace the front jacket panel.
10. Turn on all electrical power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions
“TO TURN OFF GAS TO APPLIANCE” and call your
service technician or gas supplier.
IF BURNER APPEARS TO PULSATE DURING IGNITION
1. Turn off boiler power and shut off gas supply to the boiler.
2. Take the burner assembly apart by removing the
combustion air blower and gas valve/venturi assembly
from the boiler and visually inspect the inside of the
burner. Look for any debris (PVC shavings, etc.) and if
anything is present, remove it.
3. Reassemble burner assembly, turn gas supply and boiler
power back on, and relight boiler.
IF BURNER STILL PULSATES OR FAILS TO LIGHT
1. Check for proper vent and intake pipe sizing and for
proper vent lengths and vent configuration by referring to
Step 2, “Before Installing the Boiler,” and Step 5,
“Combustion Air and Vent Pipe,” located in the
INSTALLATION section in this manual.
2. Check for proper gas supply pressure and proper gas line
sizing to the boiler by referring to Step 6, “Gas Supply
Piping,” located in the INSTALLATION section in this
manual.
3. Check for orifice in negative pressure hose at gas valve
and 2” air intake pipe upstream of gas valve.
4. Relight boiler.
5. If boiler still does not light, the air inlet pipe may need to
be disconnected to allow the boiler to start in order to
verify the boiler firing rate and combustion properties.
The inlet air pipe can be disconnected by removing the
PVC inlet air piping from the Femco fitting located on the
air inlet of the gas valve/venturi assembly. Relight boiler.
6. When the boiler lights, the firing rate and combustion
should be checked per the “Adjustments and Checkout”
procedure in Step 5 of the START--UP AND
CHECK--OUT PROCEDURES section of this manual. If
the air inlet piping was disconnected in step 4 (above),
leave it disconnected and make the first adjustment.
Reconnect air inlet piping, recheck combustion CO
2
, and
adjust again if necessary.
7. If burner pulsation continues or boiler fails to light after
performing the above procedures, please contact Technical
Service at 1--800--325--5479 for further assistance.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to the lowest setting.
2. Turn off all electric power to the appliance if service is to
be performed.
3. Remove the front jacket panel.
4. Turn gas ball valve off. The handle should be
perpendicular to the gas pipe.
5. Replace the front jacket panel.
Safe lighting and other performance criteria were met with the gas
manifold and control assembly provided on the boiler when the
boiler underwent tests specified in ANSI Z21.13-- latest revision.
STEP 5
—
Check Out Procedure and Adjustments
VERIFY PROPER SEQUENCE OF OPERATION
The sequence can be followed via the diagnostic indicator lamps
on the integrated boiler control in Fig. 18. This is the normal
sequence of operation. (See Table 4.) A more detailed sequence
of operation containing potential faults can be found in the
service hints section.
INSPECT VENTING AND AIR INTAKE SYSTEM
Operate the boiler and verify that all vent/air intake connections
are gastight and watertight. Repair any leaks immediately.
INSPECT CONDENSATE DRAIN
Verify that all connections are watertight, and that condensate
flows freely. Repair any leaks immediately.
INSPECT SYSTEM PIPING
Verify that all connections are watertight. Repair any leaks
immediately.
TEST IGNITION SYSTEM SAFETY SHUTOFF DEVICE
1. Turn off manual gas ball valve.
2. Set thermostat to call for heat.
3. Boiler begins normal sequence of operation.
4. After approximately 30 seconds (prepurge and igniter
warm--up period), lamp D illuminates, indicating gas valve
is powered.
5. After 4 seconds, gas valve closes, lamp D goes out as
integrated boiler control senses that flame is not present.
6. To restart system, follow operating instructions under
“Step 4--Placing Boiler in Operation.”
