AERCO KC1000 Boiler July 2011 - Manual (Page 33)

INITIAL START-UP
4-1
SECTION 4 - INITIAL START- UP
4.1 INITIAL START- UP REQUIREMENTS
The initial start-up of the KC-1000 Boiler is
comprised of the following steps:
• installation completed 100%
• combustion calibration
• proper setting of controls and limits
• mode of operation settings (see Section 5)
• safety device testing (see Section 6)
Installation procedures should be completed
100% before performing initial start-up and initial
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 void the product’s warranty.
These start-up instructions should be precisely
followed in order for the unit to operate safely, at
a high thermal efficiency, and 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
section, it will be necessary to perform the mode
of operation settings in section 5, and the safety
control test procedures in section 6 to complete
the initial unit start-up.
An AERCO Gas Fired Startup Sheet included
with each KC-1000 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 FIRE THE UNIT
WITHOUT FULL WATER LEVEL. THIS
CAN SERIOUSLY DAMAGE THE UNIT
AND MAY RESULT IN PERSONAL
INJURY OR PROPERTY DAMAGE. THIS
IS NOT COVERED BY WARRANTY.
CAUTION!
All installation procedures in Section 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 installed on the unit. The following
paragraphs outline the necessary tools and
instrumentation as well as their installation.
4.2.1 REQUIRED TOOLS AND
INSTRUMENTATION
The following tools and instrumentation are
necessary to perform combustion calibration of
the unit:
1. A digital combustion analyzer with oxygen
accuracy to 0.4%, and carbon monoxide in
PPM.
2. *A 16" W.C. manometer and plastic tubing.
3. One 1/4” and two 1/8” NPT-to-barbed fittings
for use with manometers.
4. A flat-tip screwdriver for adjusting the
AERCO differential gas pressure regulator.
5. Small and large flat blade screwdrivers.
6. 7/16" open end wrench and small adjustable
wrenches.
7. Tube of silicone adhesive
*For propane fired units: an additional 8" W.C.
manometer and 1/2" NPT to barbed fitting is
needed.
4.2.2 INSTALLING THE SUPPLY GAS
MANOMETER
1. Close the main manual gas supply valve up
stream of the unit.
2. Remove the 1/4" NPT pipe plug from the
port on the inlet side of the safety shut off
valve (see Figure 4.1).
3. Install a barbed fitting into the pipe plug
tapping.
4. Attach one end of a length of plastic tubing
to the barbed fitting and one end to the 16"
W.C. manometer.