VIII. System Start-up

A.Safe operation and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests specified in

American National Standard for Gas-Fired Low- Pressure Steam and Hot Water Boilers, ANSI Z21.13.

B.Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer to installation instructions contained in this manual.

C.Confirm all electrical, water and gas supplies are turned off at the source and that vent is clear of obstructions.

D.Confirm that all manual shut-off gas valves between the boiler and gas source are closed.

WARNING

Completely read, understand and follow all instructions in this manual before attempting start up.

E.Fill entire heating system with water and vent air from system. Use the following procedure on a Series Loop or multi-zoned system installed as per Figure 25 or 26 to remove air from system when filling.

WARNING

The maximum operating pressure of this boiler is 30 psig. Never exceed this pressure. Do not plug or change pressure relief valve.

NOTICE

If it is required to perform a long term pressure test of the hydronic system, the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped in the boiler.

To perform a long term pressure test including the boiler, ALL trapped air must first be removed from the boiler.

A loss of pressure during such a test, with no visible water leakage, is an indication that the boiler contained trapped air.

1.Close full port ball valve in boiler supply piping.

2.Isolate all zones by closing zone valves or shut-off valves in supply and return of each zone(s).

3.Attach a hose to the vertical hose bib located prior to the full port ball valve in the system supply piping.

(Note - Terminate hose in five gallon bucket at a suitable floor drain or outdoor area).

4.Starting with one circuit at a time, open zone valve

or shut-off valve in system supply and return piping.

5.Open hose bib.

6.Open fill valve (Make-up water line should be located directly after full port ball valve in system supply piping between air scoop and expansion tank).

7.Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds.

8.Close the opened zone valve or shut-off valve for the zone being purged of air, then open the zone valve or shut-off valve for the next zone to be purged. Repeat this step until all zones have been purged. At completion, open all zone valves or shut-off valves.

9.Close hose bib, continue filling the system until the pressure gauge reads 12 psi. Close fill valve.

(Note - If make-up water line is equipped with pressure reducing valve, system will automatically fill to 12 psi. Follow fill valve manufacturer’s instructions).

10.Open isolation valve in boiler supply piping.

11.Remove hose from hose bib.

F.Confirm that the boiler and system have no water leaks.

G.Prepare to check operation.

1.Obtain gas heating value (in Btu per cubic foot) from gas supplier.

2.Connect manometer to pressure tap on gas valve. Use 1/8 NPT tapping provided.

3.Temporarily turn off all other gas-fired appliances.

4.Turn on gas supply to the boiler gas piping.

5.Confirm that the supply pressure to the gas valve is

14 in. w.c. or less. Refer to Table 5 for minimum supply pressure.

6.Open the field installed manual gas shut-off valve located upstream of the gas valve on the boiler.

7.Using soap solution, or similar non-combustible solution, electronic leak detector or other approved method. Check that boiler gas piping valves, and all other components are leak free. Eliminate any leaks.

DANGER

Do not use matches, candles, open flames or other ignition source to check for leaks.

8. Purge gas line of air.