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• MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE, AND OTHER FLAMMABLE VAPORS AND LIQUIDS. • DAMPER MUST BE IN OPEN POSITION WHEN APPLIANCE MAIN BURNER IS OPERATING. 3) Verify that vent system is complete and free of obstructions before attempting to fire boiler. 4) Inspect all wiring for loose or uninsulated connections. 5) Make sure the main burners are seated properly in the rear of burner tray and on orifices. 6) Adjust steam pressure limit control for a cut-in pressure of 0.5 psi and a differential pressure of 1 psi. 7) Adjust thermostat to the highest setting. 8) Start the boiler using the appropriate lighting instructions for the gas valve on the boiler on pages 25-28. 9) Upon initial start-up, the gas train will be filled with air. Even if the gas line has been completely purged of air, it may take several tries for ignition before a flame is established. Once a flame has been established for the first time, subsequent calls for burner operation should result in a flame on the first try. 10) Observe pilot burner flame: • See Figure 20 for standing pilot. Pilot burner should produce single steady medium blue flame covering around 3/8” to .” of thermocouple tip. • See Figure 21 for intermittent ignition. Pilot burner produces three flames. The center one should be a steady medium blue flame covering around 3/8” to .” of spark electrode/flame rod. 12) Make sure vent damper is in open position when main burners are firing. 13) Inspect the main burner flames visible through the observation port in burner access panel. The flame should be stable and mostly blue (see Figure 22). No yellow tipping should be present; however, intermittent flecks of yellow and orange in the flame are normal. 14) Check entire gas train for leaks using soap and water or other approved leak detection method while boiler is firing. Fix any leaks found immediately. 15) Run gas valve safety shutdown test: • For standing pilot boiler models, disconnect the thermocouple from gas valve. Both pilot burner and main burners should stop firing. • For intermittent ignition boiler models, with main burners firing, disconnect ignition cable from ignition module. Both pilot burner and main burners should stop firing. 23 16) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: WARNING FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER-FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD. a) Connect a manometer to the inlet pressure tap on the gas valve (see Figures 23 and 24). b) Check the inlet pressure with all gas appliances on and off. The inlet pressure at the boiler must be within the following limits regardless of what combination of appliances is firing: Inlet Press (inches w.c.) Natural Gas LPGas Min. 5.0 11.0 Max. 14.0 13.0 If the inlet pressure falls outside of these limits, find and correct the cause of the problem before proceeding further. c) Connect a manometer to the manifold (outlet) pressure tap on the gas valve (see Figures 23 and 24). d) Read the manifold pressure. It should be set at: Natural Gas LPGas Manifold Press. (inches w.c.) 3.5 10.0 e) If a manifold pressure adjustment is needed, make the adjustment by turning the pressure regulator (see Figures 23 and 24) screw clockwise to raise the pressure and counter clockwise to reduce the pressure. If a manifold pressure adjustment is made, recheck the line pressure to be certain that it is still within acceptable limits. Replace the cover screw on the regulator. FIGURE 20: STANDING PILOTFIGURE 21: INTERMITTENT IGNITION BURNER FLAME PILOT BURNER FLAME 24 LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL VR8200 AND VR8300 SERIES GAS VALVES (STANDING PILOT) FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosionmay result causing property damage, personal injury or loss of life. A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electric switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. 1. STOP! Read the safety information above on this label. 2. Set the thermostat to lowest setting. 3. Turn off all electric power to the appliance. 4. Remove front access panel. 5. Rotate the gas control knob clockwise to OFF. pilot burner. PILOT THERMO BURNER COUPLE RESET BUTTON GAS INLET GAS CONTROL KNOB (SHOWN IN “ON” POSITION) GAS OUTLET GAS VALVE -TOP VIEW 6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you then smell gas, STOP! Follow “B” in the safety inform- atio...

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