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X Start-up and Checkout
Use the following procedure for initial start-up of the boiler:
1) Make sure that the boiler and system are fi lled with water.
2) Check all new gas piping for leaks and purge piping sections that are fi lled with air. See the National Fuel Gas Code for
additional information on testing and purging gas lines.
3) Verify that vent system is complete and free of obstructions before attempting to fi re boiler. Make sure that the silicone cure
time called for in the vent assembly instructions has passed before fi ring boiler.
4) Inspect all wiring for loose or uninsulated connections.
5) Adjust thermostat to the highest setting.
6) Start the boiler using the lighting instructions on the opposite page.
7) Upon initial start-up, the gas train will be fi lled with air. Even if the gas line has been completely purged of air, it may take
several tries for ignition before a fl ame is established. Once a fl ame has been established for the fi rst time, subsequent calls
for burner operation should result in a fl ame on the fi rst try.
8) Observe pilot burner fl ame. Pilot burner produces three fl ames. The center one should be a steady medium blue fl ame
covering around 3/8” to ½” of spark electrode / fl ame rod (Figure 42).
9) Inspect the main burner fl ames visible through the observation port in burner access panel. The fl ame should be stable and
mostly blue. No yellow tipping should be present; however, intermittent fl ecks of yellow and orange in the fl ame are normal
(Figure 43).
10) Check entire gas train for leaks using soap and water or other approved leak detection method while boiler is fi ring. Fix any
leaks found immediately.
11) Run gas valve safety shutdown test. With main burners fi ring, disconnect ignition cable from ignition module. Both pilot
burner and main burners should stop fi ring.
WARNING
• Never attempt to fi ll a hot empty boiler.
• Never use a fl ame to check for gas leaks.
• Make sure that the area around the boiler is clear and free from combustible materials, gasoline, and other fl am-
mable vapors and liquids.
• If antifreeze is used in the system, it must be a nontoxic type such as propylene glycol.
NOTE
Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the
boiler when the boiler underwent the tests specifi ed in Z21.13.