ENERGY KINETICS 90+RESOLUTE BOILER User manual

Annual Tune Up and
Inspection 90+ Resolute™
Gas Boiler
Step 1
Initial Test (Draft Loss &
CO
2
)
Air box cover must be in place before testing
1. Remove 1/8” brass plug from the “over fire” test port (2) next to the
burner and the flue box (1) next to the puff swit h. Che k draft through
the “over fire” test port (2) and at the flue box (1). Use a 12” long
pie e of ¼” O.D. steel or opper tubing and insert it approximately 8”
into the boiler. Conne t this tube to your test probe using a pie e of
hose.
Clean boiler flue passage if the draft differen e between the flue box (1)
and “over fire” test port (2) is greater than 0.04” w. .
2. Che k CO2 through the over fire test port (2). Insert the 12” long
steel or opper tube approximately 8” in through the test port.
3. Natural: CO2 : 8.6%-9.2%, O2 : 5.5%-4.5%
LPG: CO2 : 9.7%-10.7%, O2 : 6.0%-4.5%
Step 4
Clean Boiler
Do Not Touch, Vacuum or Remove Chamber! Note: If there is evidence of
condensing in last pass:
1. Check for cold returns.
2. Open b -pass valve full .
3. Verif Digital Manager Option Switch 1 to “ON”.
4. If condensing persists, increase firing rate.
Step 5
Remove Drawer Assembly
(Refer to burner manual for detailed instructions on removal and for burners
other than EZ-Gas)
1. Close the front cover and finger tighten a nut on the top center stud to hold the
cover closed while working on the burner. Do not tighten the rest of the nuts at this
time because ou will need to open the cover up again to check the drawer
assembl to the diffuser plate
2. Check porcelain condition.
3. Check and clean flame sense rod.
Step 3
Inspect Flue Passage
If passage is clean, no scale, then proceed to step 5. Clean ONLY if dirty.
DO NOT remove or touch combustion chamber for inspection or when
cleaning boiler!
Please refer to installation manual and burner manual for complete details and for burners other than EZ-Gas.
Drawer Assembly
Step
Check Burner
(Refer to burner manual for complete details and for burners other than EZ-Gas)
1. Check Fan/Air Inlet for dirt or lint.
2. Install drawer assembl carefull lining up the ignitor electrode and flame sense rod. Open
the front cover and check, neither should be an closer to the diffuser plate than 1/16”.
Adjust if necessar .
3. Check amulet for cracking or other ph sical damage. Replace if necessar .
(See amulet replacement section in installation manual).
4. Check burner diffuser plate. Some warping of plate is normal.
1 3/8”
1 3/4”
Step 2
Open Front Cover
Turn off power to system and close main manual gas valve when servicing.
1. Loosen, but DO NOT REMOVE (2) lower nylo k nuts on hinge bolts.
2. Remove (4) upper nuts and support over while opening.
2
1
Flame Sense
Rod Tip should
extend in front of
diffuser by 1-
1/4”.
Ignitor lectrode
Tip should be set
back 1/16” from
the inside surface
of diffuser.
Note: All burners
require “Amulet”
retention head
protector.
Diffuser Plate

Step 10
Start Burner & Chec Safety Functions.
Check & Record: Air box cover must be in place before testing.
Refer to burner manual for recommended settings.
1. Che k manifold pressure by installing a hose barb fitting in the ombination gas valve
outlet pressure tap and then starting the burner. Adjust valve regulator if ne essary so
the reading is 3.5”w. . for either LPG or natural gas.
2. Draft Loss: A differen e of 0.04”w. . or less between flue box (1) and “over fire” test port
(2).
Sidewall Vent: Draft over fire of -0.10” to -0.12”w. . after 15 minutes of ontinuous burner
operation.
3. Che k CO2/O2 at over fire test port (2) Natural: CO2 :8.6%-9.2%, O2 5.5%-4.5%
LPG: CO2 :9.7%-10.7%, O2 6.0%-4.5%
4. Sta k Temp: 190º-290° F (at sta k or flue box port).
5. Che k CO: 400 ppm Max Air free
(Refer to installation manual for Air free method of measuring CO).
6. Set Safety High Limit to 215 oF with Differential set at 10oF.
7. Test Safety High Limit Aquastat:
a. Remove all heat and hot water alls (No input lights on left side of manager).
b. Turn System swit h off, then remove red sensor lead from the left side qui k onne t.
. Restore power. The 100o light will flash on the manager’s temperature display. The
burner should start momentarily.
d. At approximately 205oF to 215oF, the high limit aquastat should shut off burner.
8. Verify flame failure lo kout of Carlin 60200FR burner ontrol.
a. Conne t hose from manometer to hose barb fitting in the ombination gas valve outlet
pressure tap.
b. Close the main manual gas valve and turn ON the ombination gas valve.
. Turn on power to System 2000 boiler and adjust a thermostat to all for heat.
d. Burner motor will start. The burner ontrol will run for 30 se onds (pre-purge) and then
start the ignitor. Approximately one se ond later, the ombination gas valve will open.
The manometer should show almost no pressure be ause the main manual gas valve
is losed.
e. After 4 se onds, the burner ontrol will lo kout and turn on the red LED. The ignitor
will shut off and the gas valve will lose. Turn off power and adjust the thermostat to
stop the all for heat.
If lo kout does not o ur, repla e the burner ontrol.
9. Sidewall Vent:
a. Remove power from the inducer by turning off option switch on Digital
Manager.
b. Start burner. Safety lock-out should occur in approximately 1 minute.
c. Restore power to the inducer.
Step 8
Chec Zone Valves
Open/Close zone valves several times to see that they move freely.
Step 9
Bac flush Plate Heat Exchanger
1. Close the valve underneath the domestic hot water circulator.
2. Open drain valve above the ir ulator to ba k flush the heat ex hanger.
3. If domesti water supply is “hard” (lime), onsider installing S ale Stopper (Item no. 10-
0650).
4. Set temperature feeding hot water tank (above heat ex hanger) by adjusting the ball valve
below the bronze ir ulator. Adjust the ball valve with the burner running and a ontinuous
flow of hot water from a fixture. You should just be able to hold your hand on the pipe.
Step 7
Close Front Cover, Tighten Rear Cover
1. Install (4) upper nuts and washers.
2. Tighten nuts (6) uniformly.
3. Che k and tighten (6) rear over nuts.
4. Check Flue Pipe.
Digital
Manometer
An
nual Tune Up & Inspection