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 3.0 Boiler consists of the following:
•
Complete installation (Chapter 2)
•
Set proper controls and limits (Chapter 3)
•
Perform combustion calibration (Chapter 4)
•
Set up mode of operation (Chapter 5)
•
Test safety devices (see Chapter 6)
All applicable Installation procedures in Chapter
2 must be fully completed before performing
initial start-up. The initial start-up must be
successfully completed 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 performing the start-up
procedures 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 all initial
start-up requirements.
AERCO Gas Fired Startup Sheets, included with
each Benchmark Boiler, must be completed for
each unit for warranty validation. A copy of these
sheets 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 front door and left side panels
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.
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