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Repeat for remaining standing pilots. 6. Turn on main electric switch. 7. Reset safety switch on flame safeguard relay. 8. Immediately light constant burning rectification pilot(s) Q179D with a lighted match. If pilot is not lighted in 15 seconds, Step (7) must be repeated. Electric pilot valve(s) are automatic, opening after Step (7). (“OP” System). 8a. Intermittent electric ignition rectification pilot(s) Q179C light up automatically when thermostat or operating control calls for heat. (“EP” System). 9. Replace burner access panel(s). 10. Open manual main shut-off valve(s). 11. Adjust room thermostat and operating controls to desired setting. Figure 4 : Lighting / Operating Instructions (OP/EP-CSD- ) 5 Figure 48: Honeywell Q3 4 Pilot Flame (24V Standing Pilot) Figure 48: Honeywell Q3 4 Pilot Flame (24V Standing Pilot) Figure 4 : Honeywell Q348 Pilot Flame (24V Electronic Ignition) I. Check pilot burner flame and main burner flames through observation port. 1. Check pilot flame. Refer to Table 11 for appropriate pilot detail. 2. Adjust thermostat to highest setting. 3. Check main burner flames. See Figure 52. Flame should have clearly defined inner cones with no yellow tipping. Orange-yellow streaks caused by dust should not be confused with true yellow tipping. Yellow-tipping indicates lack of primary air. Improper burner alignment on Main Burner Orifice will also affect primary air injection. Adjust primary air as follows: Figure 50: Honeywell Q D Pilot Flame (OP) Figure 5 : Honeywell Q C Pilot Flame (EP) Figure 52: Main Burner Flame CAUTION Avoid operating this boiler in an environment where saw dust, loose insulation fibers, dry wall dust, etc. are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and inspected daily to insure proper operation. a. Loosen lock screw. b. Close air adjustment until yellow tips appear on flames. c. Slowly open air adjustment until clearly defined inner cones are visible. d. Tighten lock screw. 4. Adjust thermostat to normal setting. J. Check thermostat or operating control operation. Raise and lower temperature setting to start and stop boiler operation. K. Check ignition system shut-off. 1. Standing Pilot (24V): Disconnect thermocouple lead at Gas Valve. Gas Valve must close and pilot and main burners extinguish. If not, replace the gas valve. 2. Honeywell EI: Disconnect ignitor/sensor cable from ignition module. Gas valve must close and pilot and main burners extinguish. If not, measure voltage across gas valve terminals “TH” and “TR”. a. If voltage is not present, replace gas valve. b. If voltage is present, replace ignition module. 3. EP and OP: Refer to instructions supplied with the Honeywell RM7890 Burner Control. L. Check Limit(s). 1. Adjust thermostat to highest setting. 2. Observe temperature gauge. When temperature exceeds limit set point main burners should extinguish. 3. Adjust limit to setting above observed reading. Main burners should reignite. 4. Adjust thermostat to lowest setting. Adjust limit to desired setting. M. Adjust gas input rate to boiler. Natural Gas. 1. Adjust thermostat to highest setting. 2. Check manifold gas pressure. Manifold pressure is listed on rating label. Adjust gas valve pressure regulator as necessary (turn adjustment screw counterclockwise to decrease manifold pressure, or clockwise to increase manifold pressure). If pressure can not be attained, check gas valve inlet pressure. If less than minimum gas supply pressure listed on rating label, contact gas supplier for assistance. 3. Clock gas meter for at least 30 seconds. Use Table 12 to determine gas flow rate in Cubic Feet per Hour. Table 2: Input Rate Seconds for One Revolution Size of Gas Meter Dial One-Half Cu. Ft. 60 56 53 50 45 47 45 43 41 39 37 36 35 33 32 31 30 29 29 29 28 26 25 24 24 23 22 One Cu. Ft. Two Cu. Ft. 120 240 Five Cu. Ft. 60030 32 34 36 40 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 113 225 563 106 212 529 100 200 500 90 180 450 95 189 474 90 180 450 86 172 430 82 164 410 78 157 391 75 150 375 72 144 360 69 138 346 67 133 333 64 129 321 62 124 310 60 120 300 58 116 290 56 112 281 54 109 273 53 106 265 51 103 257 50 100 250 48 97 243 47 95 237 46 92 45 90 231 225 4. Determine Input Rate. Multiply gas flow rate by gas heating value. Warning Failure to properly adjust gas input rate will result in over firing or under firing of the appliance. Improper and unsafe boiler operation may result. 5. Compare measured input rate to input rate stated on rating label. a. Boiler must not be overfired. Reduce input rate by decreasing manifold pressure. Do not reduce more than 0.3 inch w.c. If boiler is still overfired, contact your Burnham distributor or Regional Office for replacement Gas Orifices. 5 b. Increase input rate if less than 98% of rating plate input. Increase manifold gas pressure no more than 0.3 inch w.c. If measured input rate is still less than 98% of rated input: i. Remove Main Burner...

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