Service manual

25
11 OPERATION AND SERVICE
OPERATION:
Before operating the appliance, the entire
system must be filled with water, purged of air
and checked for leaks. Do not use Stop leak or
other appliance compounds. The gas piping
must also be leak tested.
With the boiler off, open makeup water valve
and allow system to fill slowly. Adjust the
pressure regulator to provide at least 15 PSIG in
the system when cold.
With all air vents open, run system circulating
pump for a minimum of 30 minutes with the
boiler off.
Open all strainers in the circulating system and
check for debris.
Check liquid level in expansion tank. With
system full of water at 15 PSIG, the level of
water in the expansion tank should not exceed
¼ of the total volume with the balance filled with
air.
Start up boiler following instructions provided.
Operate entire system including pumps and
radiation for at least 1 hour. Minimum operating
system pressure when hot must not drop below
30 PSIG.
Check water level in expansion tank. If level
exceeds ½ of tank volume, air is still trapped in
system. Shut down boiler and continue to run
pumps.
Within 3 days of start up, recheck all air vents
and expansion tank as described above.
Any safety devices including low water cutoff,
flow switch and high limit used in with this
appliance must receive periodic inspection
(every six months) to assure proper operation. A
low water cutoff of the float type should be
flushed every six months. All relief valves should
be inspected and manually operated every six
months.
For your safety follow the lighting and operating
instructions below and on the appliance.
To turn on main burner, slowly open firing valve
after pilot is established.
Set primary system controller to desired
temperature.
To turn off appliance close main manual gas
valve, close pilot manual valve and turn off
electric power to system.
SERVICE:
To maintain safe operation and the greatest
efficiency of the appliance, check the main
burner and pilot burner for proper flame
characteristics.
For hydronic heating applications the burner
should be checked at least yearly. For domestic
hot water applications the burner should be
checked every 6 (six) months.
Disconnect main power and turn off gas supply
before servicing unit.
To remove and clean the burner, follow the
detailed procedure in section 10.1 of this manual
After the first season of operation inspect the
heat exchanger and venting. Follow the detailed
instructions in section 7 of this manual.
CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation. Verify
proper operation after servicing.
Any audible sounds in the equipment, like
pinging, crackling or hissing are indications of
scaling or lack of sufficient water flow. Under
these conditions the appliance must be shut
down immediately and the heat exchanger
checked for damage. If the exchanger is
damaged from improper installation or operation,
it is not covered by warranty.
Should your equipment be subjected to fire,
flood or some other unusual condition, turn off
all gas and electrical supply. If you are unable to
turn off the gas, call your gas company or gas
supplier at once. Do not put the unit back in
operation until it has been checked by a
qualified service technician.
Units that are not operated for a period of 60
days or more are considered seasonal
operations. It is recommended that before
returning one of these units to service, the
proper operation of all controls be checked by a
qualified service technician.