Aerco Benchmark 2.0, Installation, Operation & Maintenance Instructions Manual

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INITIAL START-UP
4-1
CHAPTER 4 INITIAL START-UP
4.1 INITIAL START-UP REQUIREMENTS
The requirements for the initial start-up of the
Benchmark 2.0 Low NOx (LN) Boiler consist of
the following:
•
Complete installation
•
Perform combustion calibration
•
Set proper controls and limits
•
Set up mode of operation (see Chapter 5)
•
Test safety devices (see Chapter 6)
Installation should be fully completed before
performing initial start-up. The start-up must be
complete prior to putting the unit into service.
Starting a unit without the proper piping, venting,
or electrical systems can be dangerous and may
void the product warranty. The following start-up
instructions should be followed precisely in order
to operate the unit safely and at a high thermal
efficiency, with low flue gas emissions.
Initial unit start-up is to be performed ONLY by
AERCO factory trained start-up and service
personnel. After following the steps in this
chapter, it will be necessary to perform the Mode
of Operation settings in Chapter 5, and the
Safety Device Testing procedures in Chapter 6
to complete the initial unit start-up.
AERCO Gas Fired Startup Sheets, included with
each Benchmark Boiler, must be completed for
each unit for warranty validation and a copy
must be returned promptly to AERCO at:
AERCO International, Inc.
159 Paris Ave.
Northvale, NJ 07647
WARNING
DO NOT ATTEMPT TO DRY FIRE
THE BOILER. STARTING THE UNIT
WITHOUT A FULL WATER LEVEL
CAN SERIOUSLY DAMAGE THE
UNIT AND MAY RESULT IN INJURY
TO PERSONNEL OR PROPERTY
DAMAGE. THIS SITUATION WILL
VOID ANY WARRANTY.
CAUTION
All applicable installation procedures
in Chapter 2 must be completed
before attempting to start the unit.
4.2 TOOLS AND INSTRUMENTATION
FOR COMBUSTION CALIBRATION
To properly perform combustion calibration, the
proper instruments and tools must be used and
correctly attached to the unit. The following
paragraphs outline the necessary tools and
instrumentation as well as their installation.
4.2.1 Required Tools & Instrumentation
The following tools and instrumentation are
necessary to perform combustion calibration of
the unit:
•
Digital Combustion Analyzer: Oxygen
accuracy to ± 0.4%; Carbon Monoxide
(CO) and Nitrogen Oxide (NOx) resolution
to 1PPM.
•
16 inch W.C. manometer or equivalent
gauge and plastic tubing.
•
1/8 inch NPT-to-barbed fittings for use with
gas supply manometer or gauge.
•
Small and large flat blade screwdrivers.
•
Tube of silicone adhesive
4.2.2 Installing Gas Supply Manometer
The gas supply manometer is installed in the
gas train as follows:
1. Close the main manual gas supply shut-off
valve upstream of the unit.
2. Remove the top panel and left or right side
panel from the boiler to access the gas train
components.
3. Remove the 1/8 inch NPT pipe plug from the
leak detection ball valve on the downstream
side of the Safety Shut Off Valve (SSOV) as
shown in Figure 4-1.
4. Install a NPT-to-barbed fitting into the
tapped plug port.