106636-04 - 8/22
21
X-2
Installation, Operating & Service Manual
10
System Start-up and Checkout
1. Visual Main Burner Check.
Inspect burners for dislodgement during
shipment. Rear of burners should be in vertical
slots in rear of burner tray and front of burners
should be seated completely on orifices.
2. Fill Boiler with Water.
Refer to Appendix B for
important information on water quality and boiler
additives.
3. Purge Air from System.
A. Fill entire heating system with water and
vent air from boiler, radiators and system,
one zone at a time.
B. Isolate boiler by closing isolation valves. For
primary - secondary systems, close additional
isolation valve to ensure water flows through
zones.
C. Isolate all circuits by closing zone valves
or turning off zone circulators.
D. Attach hose to drain valve located
on return piping (see Figure 7-2 and 7-3).
Note-Terminate hose in five gallon bucket,
at a suitable floor drain, or outdoor area).
E. Starting with one circuit, open zone valve or
start circulator.
F. Open drain valve.
G. Open fill valve.
H. Allow water to flow through system until
discharge from hose is bubble free for 30
seconds.
I. Open zone valve or start circulator to second
zone to be purged, then close first.
Repeat this step until all zones have
been purged, but always have one zone
open. At completion, open all zone valves or
start all circulators.
J. Close hose bib, open boiler isolation
valve, continue filling system until
pressure gauge reads 12 psi.
Close fill valve. (Note - If make-up water
line is equipped with pressure reducing
valve, system will automatically fill to 12
psi).
K. Remove hose from drain valve.
DANGER
Explosion Hazard.
Do not use matches, candles, open flames, or
other ignition sources to check for leaks. Failure
to comply could result in severe personal injury,
death, or substantial property damage.
!
WARNING
• Make sure that the area around the boiler is clear
and free from combustible materials, gasoline,
and other flammable vapors and liquids.
• Damper must be in open position when
appliance main burner is operating.
!
4. Perform gas leak test upstream of boiler shutoff
valve.
A. Protect boiler gas valve.
i. For all testing over ½ psig, boiler
and manual shutoff valve must be
disconnected from gas supply piping.
ii. For testing at ½ psig or less, isolate
boiler from gas supply piping by closing
boiler manual shutoff valve.
B. Locate leaks using listed combustible
gas detector, a noncorrosive leak detection
fluid or other listed leak detection method.
C. Tighten appropriate pipe connections.
5. Perform limit check.
A. Ensure gas to boiler is off.
B. Set ROOM THERMOSTAT to lowest setting.
C. If limits are functioning properly (LWCO,
Auxiliary limit, flame rollout switch, blocked
vent switch, damper), boiler should spark.
If boiler does not spark, see Section 14
"Troubleshooting" for guidance.
D. Turn "OFF" the electric switch to boiler.
6. Start boiler according to "Operating Instructions"
in Figure 10-1.
7. Perform gas leak test downstream of boiler
manual shutoff valve.
A. Open manual shutoff valve.
B. PURGE AIR FROM GAS PIPING by loosening
(or removing) “Inlet Pressure Tap” plug on gas
valve (See Figure 10-2). Tighten (or replace)
plug when you start to smell gas. Adequate
ventilation must be provided and no smoking
or open flame permitted.
