U.S. Boiler Company K2, Installation Instructions Manual

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Use the following procedure for initial start-up of the boiler:
1) Verify that the venting, water piping, gas piping and electrical system are installed properly.
2) Confirm all electrical, water and gas supplies are turned off at the source and that vent is clear of obstructions.
3) Confirm that all manual shut-off gas valves between the boiler and gas source are closed.
4) If not already done, flush the system to remove sediment, flux, and traces of boiler additives.
5) Fill the boiler and hydronic system with water meeting the following requirements below (also see the note on the next
page):
• pH between 6.5 and 9.5
• Hardness less than 7 grains/gallon
• Chlorides less than 200 ppm
• Pressurize the system to at least 12 psi at the boiler
6) Bleed air from the heat exchanger using the manual air vent in the top left side of the heat exchanger (Figure 11.1). To do
this install a piece of ¼” ID clear tubing over the hose barb and route the tubing to a location where water will not dam-
age controls or nearby construction. Turn vent counter clockwise and allow heat exchanger to vent until a steady stream
of water is observed. Close vent and remove hose.
7) Check all gas piping for leaks and purge piping sections that are filled with air. Refer to the National Fuel Gas Code for
additional information on testing and purging gas lines.
8) Confirm vent system is complete and free of obstructions before attempting to fire boiler.
9) Inspect all wiring for loose, uninsulated or miswired connections.
10) If the boiler is to be converted to propane, convert as described in Appendix A. If boiler is operating at elevations above
2000ft, see Appendix B of this manual for setup instructions.
XI. Start-Up and Checkout
Warning
Burn Hazard. The maximum operating pressure of this boiler is 30 psig (210 kPa) or 50 psig (340 kPa),
depending on the model and safety relief valve option selected. Never exceed the maximum allowable
working pressure on the heat exchanger aSME plate.
DangEr
Explosion Hazard. Do not use matches, candles, open flames or other ignition source to check for
leaks.
Make sure that the area around the boiler is clear and free from combustible materials, gasoline and
other flammable vapors and liquids.
Warning
Completely read, understand and follow all instructions in this manual before attempting start-up.
nOTiCE
Safe lighting and other performance criteria were met with the gas train assembly provided on the boiler
when the boiler underwent the test specified in Z21.13.