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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 Ameri-
can 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 instal-
lation 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 attempt-
ing 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 to
remove air from the system while filling.
WARNING
The maximum operating pressure of this
boiler is 150 psig. Never exceed this pres-
sure. Do not plug or change pressure relief
valve.
NOTICE
If it is required to perform a long term pres-
sure 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 includ-
ing the boiler, ALL trapped air must first be
removed from the boiler.
A loss of pressure during such a test, with
no viable 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 locat-
ed 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 indicates required system operating
pressure. Close fill valve.
(Note - If make-up water line is equipped with
pressure reducing valve, system will automatically
fill to set pressure. Follow fill valve manufacturer's
instructions).
10. Open isolation valve in boiler supply piping.
11. Remove hose from hose bib.
F.
Confirm that the water flow switch is operating prop-
erly.
G.
Turn on the electrical supply to the boiler and circula-
tion system at the fused disconnect.
H. Confirm that water flow switch is operating properly.
I. Prepare to check operation.
1. Obtain the gas heating value (in Btu per cubic feet)
from the gas supplier.
2. Connect a monometer to the pressure taping
upstream V1 on the main gas valve. Use the G 1/8
test nipple provided. Reference item 7 on figure 28.
3. Temporarily turn off all other gas-fired appliances.
4. Turn on gas supply to the boiler gas piping.
5. Purge the gas line of air.
6. Reset the low gas pressure switch.
7. Confirm that the supply pressure to the gas valve is
14 in. w.c. or less. Refer to Table 3 for the minimum
supply pressure.
9
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