Before Start-Up; Start-Up Instructions - Ace Heating Solutions Mini-Pack Operating And Maintenance Instruction Manual

Before Start-up

1. Verify the Mini-Pack is installed in accordance with the appropriate installation diagram located on
page 10 and 11.
2. The condensate outlet union has been factory installed with an orifice plate. Do not remove this
orifice, as it acts as a simple steam trap, unless it is substituted with an appropriately sized stream
trap.
3. The steam supply to the control valve must be installed with a blow down valve on the strainer and
drip leg with trap. This will keep condensate away from the valve.
4. Install a steam pressure gauge within close proximity of the steam inlet side of the control valve.
5. The condensate line must be piped and drained by gravity without lifts, to a vented receiver.
Failure to do so will void the warranty.
6. Verify 120/60/1 voltage supply to the control panel. No additional field wiring is required.
7. Caution: The toggle switch on the control panel must be in the "off" position prior to connection to
the power source. Failure to do so may damage the safety solenoid if so equipped.
8. Verify an air supply pressure of at least 35 PSI to the to the air filter regulator upstream of the
Accritem.

Start-Up Instructions

1. It is assumed that installation is complete and that all connections have been made, including:
electrical, steam, domestic water, instrument air, vents, drains and safety valve discharge lines.
Prior to start-up inspect the strainer for any dirt, scale, welding particles or debris that may have
accumulated during construction. Make sure the General Installation procedure has been followed
(See Page 7).
2. Make sure the power switch is in the "off" position.
3. Close the shut-off valve on the bonnet side (heating medium side). Slowly introduce domestic
3. Set the high limit control (figure 2.0) 12q to 15qF higher than the Accritem (figure 2.2) setting
water to the unit by opening the shut-off valves at the inlet and outlet of the shell. This will allow
(Domestic hot water outlet temperature). For example, if the system is heating domestic water from
water to circulate in the shell. Open the relief valve when filling to purge the trapped air from the
40 to 140qF, the high limit should be set at ~152qF. The high limit aquastat will automatically reset
unit.
when the temperature drops the set differential number of degrees. The adjustable differential
(figure 2.1) should be set so that the system does not start up again until the water temperature
4. Turn on the system by turning the control panel switch to the "ON" position (The manual steam
drops at least 5 degrees below the desired hot water outlet temperature (typically 135qF on a 140qF
supply valve should be closed at this time). The green light should come on. At the same time, it
system). Continuing the example, with the high limit set at 152qF, the differential should be set at
will energize the solenoid on the control panel allowing air to the control valve actuator, which in
least 17, thus ensuring that the system does not start heating until the water temperature drops 17
turn will open the control valve. Make sure the circulator pump is running. (Please refer to the
degrees down to 135qF. Remove the cover to access the adjustment wheel. Refer to the included
pump instruction manual for details.)
manufacturer's data sheet for adjustment information.
5. Turn on a number of hot water fixtures to establish a steady 50% load if possible, with at least a Figure 2.0
flow of 8 to 10 GPM for the initial startup. Make sure these stay on and there is not an additional
load applied elsewhere during initial startup.
6. Manually open the main steam shut-off valve upstream of the control valve and SLOWLY allow
steam to pass through the control valve. Continue until the shut-off valve is 100% open.
7. The Mini-Pack will now function automatically, reacting according to demand fluctuations and will
stabilize once limits are met.
8. Once stabilized, turn off the hot water fixtures one at a time and watch the temperature gauge on
the unit. There should only be slight temperature fluctuations. With no hot water fixtures on, the
4. Close the shut-off valve on the bonnet side (heating medium side). Slowly introduce domestic
temperature gauge should remain stable. Watch the temperature for 5 minutes to verify the steam
water to the unit by opening the shut-off valves at the inlet and outlet of the shell. This will allow
valve has closed. If the temperature slowly creeps up, the valve is leaking steam and may have
water to circulate in the shell. Open the relief valve when filling to purge the trapped air from the
debris on the seat or the valve requires "zeroing". "Zeroing" the valve requires adjusting the stem
unit.
length until the valve closes tightly.
Figure 2.1
See Page 15 under Trouble Shooting.
ACE BOILER INC.
Figure 2.2
Page 12