ENERGY KINETICS Resolute RT Installation instructions

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 nylock nuts on hinge bolts.
2. Remove (3) upper nuts and support cover while opening.
ANNUAL TUNE UP & INSPECTION
Annual Tune Up and
Inspection Resolute™RT
Gas Boiler
Please refer to installation manual and burner manual for complete details and for burners other than EZ-Gas.
AIR BOX
Step 1 Initial Test (Draft Test & CO2)
Air box cover must be in place before testing.
1. Remove 1/8” brass plug flue box test port (1) next to the puff
switch. Check draft through the flue box (1) using 12” long
piece of ¼” O.D. steel or copper tubing inserted approximately
8” into the boiler. Connect this tube to your test probe using a
piece of hose.
Draft must be negative.
2. Check CO2through the over fire test port (2). Insert the 12”
long steel or copper tube approximately 8” in through the test
port.
LPG Target CO2: 10.4% Target O2: 5.0%
NAT. Target CO2: 9.0% Target O2: 5.0%
Step 4 Clean Boiler
Note: If there is evidence of condensing in last pass:
If cold returns:
1. Verify Display Manager Option Switch 1 to “ON”.
2. Open by-pass valve fully.
3. 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 you will need to open the cover up again
to check the drawer assembly to the diffuser plate.
2. Check porcelain condition.
3. Check and clean flame sense rod.
Step 6 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 assembly carefully lining up the ignitor electrode and flame sense rod.
Open the front cover and check, neither should be any closer to the diffuser plate than
1/16”. Adjust if necessary.
3. Check amulet for cracking or other physical damage. Replace if necessary.
(See amulet replacement section in installation manual).
4. Check burner diffuser plate. Some warping of plate is normal as long as it does not
interfere with the operation of the burner.
Note: All burners require
“Amulet” retention head
protector.
Step 3 Inspect Flue Passage and Vent System
If passage is clean, no scale, then proceed to step 5.
Clean ONLY if dirty.
Check vent system joints for proper connections, including flexible coupling clamps and condensate
drain.
Drawer Assembly
Flame Sense Rod
Tip should extend
in front of diffuser
by 1-1/4”.
Diffuser Plate
Ignitor Electrode
Tip should be set
back 1/16” from
the inside surface
of diffuser.
1 3/8”
1 3/4”
2
1
1
2
Electronic Analyzer

2.
Step 10 Start Burner & Check Safety Functions
Check & Record: Air box cover must be in place before testing.
Refer to burner manual for recommended settings.
1. Check manifold pressure by installing a hose barb fitting in the combination gas
valve outlet pressure tap and then starting the burner. Adjust valve regulator if
necessary so the reading is 3.5”w.c. for either LPG or natural gas.
2. Draft Test: Draft must be negative in the flue box port (1).
3. Check CO2/O2 at over fire test port (2) Nat. Gas: CO2:9.0%, O2:5.0% Nominal
LPG: CO2:10.4%, O2: 5.0% Nominal
4. Stack Temp: 190º-290° F at flue box port (1).
5. Check CO: 400 ppm Max Air-free
(Refer to installation manual for Air-free method of measuring CO).
6. Set Safety DualGard High Limit to 215oF with Differential set at 10oF.
7. Test Safety 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 100olight 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 lockout of Carlin 60200FRS burner control.
a. Connect hose from manometer to hose barb fitting in the combination gas
valve outlet pressure tap.
b. Close the main manual gas valve and turn ON the combination gas valve.
c. Turn on power to Resolute RT 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 4 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.
If lockout does not occur, replace the burner control.
9. Dilution Air Exhaust Fan Safety Switch test:
a. Remove power from the inducer by turning Display Energy Manager Option
Switch 2 OFF.
b. Start burner. Safety lock-out should occur in approximately just over 30
seconds.
c. Restore power to the inducer by turning Option Switch 2 ON and reset burner
lockout.
Step 8 Check Zone Valves
Open/Close zone valves several times to see that they move freely.
Step 9 Backflush Plate Heat Exchanger
1. Close the valve underneath the domestic hot water circulator.
2. Open drain valve above the circulator to back flush the heat exchanger.
3. If domestic water supply is “hard” (lime), consider installing Scale Stopper (Item
no. 10-0650).
4. Set temperature feeding hot water tank (above heat exchanger) by adjusting the
ball valve below the bronze circulator. Adjust the ball valve with the burner running
and a continuous 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. Check and tighten (6) rear cover nuts.
4. Check Flue Pipe.
Digital
Manometer
Completely remove cover nuts, washers
and jacket screws at back, sides and top.
With hands at top and bottom, pull
cover and insulation board straight
back as a single unit.
2
1
3
4
5
1
2