23
INITIAL OPERATIONAL BOILER TEST CHECK-OUT PROCEDURE
Cast Iron Gas-Fired Cast Iron Boilers
Check off each step as completed.
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Verify base insulation is securely fastened to base panels.
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Verify air purged from hydronic heating system.
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Purge air from gas piping; check gas piping for leaks.
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Verify proper orifi ces have been installed.
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Follow Lighting Instructions in Installation, Operation and Maintenance Manual furnished with boiler.
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Visually check the main burner fl ame and verify it has a well defi ned inner blue mantel with a lighter blue outer
mantel.
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Inspect vent system to verify it is functional, unobstructed, and not leaking.
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Test the temperature limit control: With burner operating, adjust indicator on limit control below actual boiler
water temperature. Verify burners turn off. Verify the circulator continues to operate. Adjust the indicator on
limit control above actual boiler water temperature and verify burners reignite.
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Test any additional fi eld-installed controls. If boiler has a low water cut-off or additional high limit, test for
operation as outlined by the controls manufacturer. Burners should be operating and should go off when controls
are tested. When controls are reset, burners should reignite.
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Test ignition system safety shutoff device after placing boiler in operation. See page 25.
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For multiple heating system zones, balance fl ow through each zone so that it is about equal per zone.
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Verify several operating cycles of proper operation.
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Measure Gas Input:
Natural Gas Procedure
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Operate boiler for 10 minutes.
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Turn off all other gas appliances piped with the boiler.
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At the gas meter, measure the cubic feet of gas used in 10 seconds (CF10).
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Calculate input: BTUh = CF10 x 360,000
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Verify the BTUh is approximate to the input rating on the boiler rating plate.
LP Gas Procedure
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LP gas input rate is determined by measuring gases produced during combustion. Refer to Boiler Manual
for combustion guidelines and corresponding BTUh input
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Verify the BTUh is approximate to the input rating on the boiler rating plate.
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Record the BTUh input on the OPERATIONAL BOILER TEST CERTIFICATE & SIGNED RECEIPT form.
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Set operating control (thermostat(s)) to the desired design requirement.
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Forward boiler manuals, instructions, wiring diagrams, piping diagrams, and supporting information shipped with
this boiler to owner and/or maintenance personnel.
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Complete and sign the INITIAL OPERATIONAL BOILER TEST CERTIFICATE & SIGNED RECEIPT form.
