SG Series Boilers – Installation and Service Manual
23
Startup Instructions Section 3
3.1 PRE-STARTUP
a. Fill entire heating system with water and vent or purge air from system. Add water as needed to
reach boiler operating pressure. Water should be of suitable quality. Do not use water with high
hardness.
b. Check for and repair any leaks in water piping.
c. Check burners to see that they are not dislodged.
d. Check for proper installation of pressure relief valve, draft hood, and venting.
e. Check that the electrical wiring matches the wiring diagram in this manual or on the boiler.
f. Check if the flame roll out safety switch and blocked vent safety switch are properly located and
wired. (Applicable on models SG-135 to SG-270)
g. Use a soap solution to check for leaks in gas piping from meter to boiler pilot and manifold. Repair
and retest any leaks found.
h. Operate circulating pump and vent all radiation units and high points in system piping.
3.2 STARTUP
WARNING
The following instructions are intended as a guide for qualified persons. Before lighting the
boiler, the pre-startup instructions of Section 3.1 MUST be performed. If you do not follow these
instructions exactly, a fire or explosion may result causing property damage, personal injury or
loss of life.
WARNING
Should boiler overheat, or the gas supply fail to shut off, do not turn off or disconnect the
electrical supply to the circulating pump. Instead, shut off the gas supply at a location external
to the boiler.
a. Intermittent pilot with combination gas valve
This boiler does not have a continuous pilot flame. It is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot by hand.
In the event of failure of any component, either the system will not operate or it will go into safety lockout.
1) Make sure the Gas Valve and all electrical power to the boiler are "OFF".
2) Set room thermostat to the lowest setting.
3) Connect a manometer at pressure tapping on downstream section of gas valve.
4) Wait five minutes to clear out any gas. If you smell gas, STOP! Follow the safety instructions
provided in Section 1.1 under WHAT TO DO IF YOU SMELL GAS. Remember that propane does
not vent upward naturally.
5) Set the controller as described in Section 1.6 and check operation as follows:
a) Set thermostat above room temperature to call for heat and turn power on for the boiler.
b) Watch for spark at pilot burner. All models will automatically lockout if no pilot flame is
detected within 15 seconds. Automatic retry will occur in 5 minutes.
6) Turn Gas Valve to ON. Pilot burner should ignite, followed by main burners. Check main and
pilot burners and adjust pilot, if necessary, as described in Section 3.3.
7) Assure that all other gas appliances are turned off, including their pilot flames.
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