Frontier Gas Heat – PN 10-2027 – June 2018 24
START UP PROCEDURE
Turn on system supply switch and burner supply switch. The Digital Manager lights should come on briefly, the
circulator relay should close briefly, and then the Digital Manager should only show one red light next to 'power'.
1. Adjust a thermostat to call for heat. Burner and main circulator should come on at the same time. If not, check primary
control and reset it if necessary.
2. Check for burner light off. If gas piping is not well purged, then several starts may be required to clear air from gas
piping.
3. On light off, water temperature and chimney temperature will start to rise. A slight odor is common on initial light off as
combustion chamber and converter surfaces warm for the first time.
4.
NOTICE: Perform carbon monoxide test immediately after light off. If the carbon monoxide exceeds 400 ppm air-free
after one minute of operation, shut off boiler immediately and repeat "Prepare for Start Up" checklist. (
See “Air-free
method of measuring CO”)
5. Once the boiler heats up and reaches temperature, Digital Manager “Heating” light will signal heat distribution to
zone(s) calling for heat.
6. Allow system to run about 15 minutes before testing and recording burner operation. (See "Gas Burner Operation")
DANGER: Verify proper operation of high limit aquastat:
a. Remove all heat and hot water calls (No input lights on left side of manager).
b. Turn System switch off, then remove red sensor lead from the left side quick connect.
c. Restore power. The 100
o
light will flash on the manager’s temperature display, and the burner should start
momentarily.
d. At approximately 205
o
F to 215
o
F, the high limit aquastat should shut off burner.
2.
DANGER: Verify proper operation of boiler pressure relief valve by following instructions on pressure relief valve,
which calls for a 'try lever test'. Make sure discharge pipe is properly placed to safely contain discharge and open relief
valve using the try lever.
3.
NOTICE: Check that each thermostat operates proper zone.
4.
NOTICE: Bypass valve must be adjusted to raise return water temperature to approximately 130
o
F. on start up after
any zone valve opens. This prevents condensation from occurring in boiler passages. The digital manager provides
condensing protection by closing the zone valves when the return drops below 130
o
F (Check option switches on
the Digital Manager and verify that switch one (1) is set to “ON”). The following adjustments will help minimize
zone cycling.
a. On copper baseboard systems, valve normally should be ½ open.
b. On large water volume systems or high heat load systems, where the return temperature from the system is
below 130
o
F, open bypass completely and throttle zone returns to increase bypass flow.
5. Verify flame failure lockout of Carlin 60200FR burner control
a. Install a hose barb fitting in the combination gas valve outlet pressure tap and connect with a hose to a U-tube
manometer.
b. Close the main manual gas valve and turn the combination gas valve knob to ON.
c. Turn on power to System 2000 boiler and adjust a thermostat to call for heat.
d. Burner motor will start. The burner control will run for 30 seconds (pre-purge), and then start the ignitor.
Approximately one second later, the combination gas valve will open. (The manometer should show almost no
pressure, because the main manual gas valve is closed.)
e. After 6 seconds, the burner control will lockout and turn on the red LED. The ignitor will shut off and the gas
valve will close. Turn off power and adjust the thermostat to stop the call for heat.
f. If lockout does not occur, replace the burner control.
6.
WARNING: Sidewall Vent Safety or Failure Test:
a. Remove power from the inducer. (Option switch 2 on a Digital Manager)
b. Start burner. Safety lockout should occur in approximately 1 minute.
c. Restore power to the inducer.
To Next Page
Loading...
Need help?
General
