Install Instructions

92 103448-08- 9/16
IX. System Start-up (continued)
WARNING
Asphyxiation Hazard. Install ue temperature
sensor and sensor cap into two-pipe vent
connector port upon completion of combustion
test. Failure to properly secure the ue
temperature sensor into the port could lead to
property damage, personal injury or loss of life.
3. Reinstall ue temperature sensor with sensor cap
into two-pipe vent adapter.
a. Inspect ue temperature sensor cap for
degradation. Replace if needed.
b. Use Molykote 111 grease to lubricate outer
surface of two-pipe vent adapter stub where ue
temperature sensor is inserted. Also lubricate
tip of ue temperature sensor. Reinstall ue
temperature sensor with cap into two-pipe vent
adapter.
4. Return boiler to normal operating mode by
pressing “Auto”.
M. Checking / Adjusting Gas Input Rate
1. Turn off gas supply to all appliances other than
gas-red boiler.
2. Lock the boiler in high re, following Step 2a
in Paragraph L.
3. Clock gas meter for at least 2 revolutions of
the dial, typically labeled ½ or 1 cubic foot per
revolution on the gas meter.
4. Determine gas ow rate in cubic feet per hour
based on elapsed time for 2 revolutions.
Example:
Using a meter with dial labeled 1 cubic foot per
revolution, measured time is 72 seconds for 2
Revolutions, i.e. 36 seconds per 1 cubic foot.
Calculate hourly gas ow rate:
3600 sec/hr ÷ 36 sec/cu ft = 100 cu ft/hr
5. Obtain gas-heating value (BTU per cubic foot)
from gas supplier.
6. Multiply hourly gas ow rate by gas heating value
to determine the boiler input rate, BTU/hr
Example:
Natural gas heating value provided by local gas
utility is 1050 BTU per cubic foot.
Measured and calculated hourly gas ow rate is 100
cu ft/hr.
Measured boiler input rate is:
100 cu ft/hr * 1050 BTU/ cu ft = 105, 000 BTU/hr
7. Verify measured input rate is within 88% to
100% of the max. input listed on the boiler rating
label.
8. If measured input is too high, reduce maximum
modulation fan speed (either central heat or
domestic hot water, depending on source of call for
heat) in increments of 50 RPM and check the input
rate after each adjustment. Follow instructions in
Section X. “Operation” to adjust the maximum
modulation fan speed.
9. If measured input is too low, increase maximum
modulation fan speed (either central heat or
domestic hot water, depending on source of call for
heat) in increments of 50 RPM and check the input
rate after each adjustment. Follow instructions
in Section X “Operation” to adjust the maximum
modulation fan speed.
10. Return boiler to normal operating mode by
pressing “Auto”.
11. Return other gas-red appliances to previous
condition of use.
N. Test Safety Limits Controls
1. Test the ignition system safety shut-off by
disconnecting the ame sensor connector (black
plug with orange wire) from the ame ionization
electrode. See Figure 27. The boiler must shut
down and must not start with the ame sensor
disconnected.
2. Test low water cutoffs (if used).
a. Hydrolevel 1100H4 Autotmatic Reset LWCO
(100592-01). Press TEST button to simulate low
water condition. Amber “LOW WATER” LED
should illuminate and burner should turn off.
b. McDonnell & Miller 751 Manual Reset LWCO
(80160718 ). Press TEST button for 30 seconds
to activate test cycle; red LED will ash. When
test cycle activated red LED will turn on and
burner will turn off. Control must be reset by
pressing MANUAL RESET to resume normal
operation.
3. Test any other external limits or other controls
in accordance with the manufacturer’s instructions.
O. Check Thermostat Operation
Verify that the boiler starts and stops in response to
calls for heat from the heating thermostat and indirect
water heater thermostat. Make sure that the appropriate
circulators also start and stop in response to the
thermostats.