Hot Water Generator Installation and Operation Manual
3Operation
After all installation procedures have been completed, and all water, energy source joints, and power connections have been double checked, the unit is ready for operation. As a precaution, it is strongly suggested that the following Startup and Shutdown procedures be followed.
Startup procedure
1. Assure that all manual shutoff valves on the water and |
WARNING
Steam or boiler water present situations that can be very dangerous because of the high temperatures and pressures. Use common sense and follow all accepted and
recommended procedures when performing installation, operation, and maintenance procedures to avoid possible injury or death.
energy source lines are closed. |
2. Slowly open the manual shutoff valve on the cold water |
inlet line, checking to assure that there are no leaks at the |
valve or any joints. Allow the tank to fill with water. As |
the tank is filling, hold the pressure relief valve open to |
allow air to bleed out of the tank. This will speed the |
filling process. |
3. Adjust the operating temperature control to the desired |
operating temperature. |
4. Set the high temperature limit thermostat at 10 to 15 |
degrees Fahrenheit (10°F to 15°F) above the desired |
operating temperature. |
5. If the unit is so equipped, turn on the internal circulating |
pump. The circulating pump will operate constantly as |
long as power is supplied to the pump. |
Shutoff valves are located on the inlet and/or outlet side |
of the circulating pump line. These valves should be |
opened before the pump is turned on. After the power to |
the pump is turned on verify that the pump is working. |
If the pump is an oil lubricated unit, verify proper oiling. |
6. Open the valve on the condensate drain line, or boiler |
water return line. |
7. For steam to water controls, slowly open the manual |
shutoff valve on the steam inlet. Create a load/demand |
situation of approximately 10 to 25% of the system |
design conditions. As the valves are being opened, |
check for leaks at the valves and all pipe joints. |
8. For water to water controls, slowly open the manual |
shutoff valves on the boiler water inlet and outlet lines. |
Create a load/demand situation of approximately 10 to |
25% of the system design conditions. As the valves are |
being opened, check for leaks at the valves and all pipe |
joints. Open the bypass loop ball valve approximately |
half way. Allow the system to push air out of the tube |
bundle and the piping slowly. |
Note: It should be noted that when the control valve is closed the boiler water will flow through the bypass loop. When the valve is open, less water will “bypass”. Adjustment of the bypass loop ball valve will be necessary to balance your system. For initial installation the bypass valve should be closed.
9.Turn on power to the rest of the electrically controlled components of the unit (if equipped).
10.As the unit is initially heating the water, carefully
11.As the unit approaches the desired operating temperature, adjust the temperature control valve.
12.After the unit has reached operating temperature, re- inspect all joints for signs of leakage. In addition, check all gauges and controls to verify that the water temperature and pressure, as well as energy source pressure, are within design specifications.
13.The unit is now ready for normal operation.
Shutdown procedure
1.Turn off all power to the circulating pump and/or electric controls, if equipped.
2.Close all valves in the steam inlet line (or boiler water line).
3.Relieve the pressure from the energy source line (steam or boiler water), where possible.
4.Close all remaining valves in the system in this order:
•the hot water outlet line;
•the cold water inlet line; and
•the condensate return line (or boiler water return line)
5.After the system has cooled, drain the unit by opening the tank drain valve and holding the pressure relief valve in the open position. This will prevent the formation of a vacuum and increase the drainage flow.
6.Proceed with the required maintenance or repairs.
7.After performing the required maintenance or repairs, return the unit to operation by following the Startup Procedure.
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