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XI Start-up and Checkout
Use the following procedure for initial start-up of the boiler:
1) Make sure that the boiler is filled with water to the normal water line (28 3/4 inches above the floor or pad on which the
boiler is installed)
2) Check all new gas piping for leaks and purge piping sections that are filled with air. See Part 4 of the National Fuel Gas
Code for additional information on testing and purging gas lines.
3) Verify that vent system is complete and free of obstructions before attempting to fire boiler.
4) Inspect all wiring for loose or uninsulated connections.
5) Make sure the main burners are seated properly in the rear of burner tray and on orifices.
6) Adjust steam pressure limit control for a cut-in pressure of 0.5 psi and a differential pressure of 1 psi.
7) Adjust thermostat to the highest setting.
8) Start the boiler using the appropriate lighting instructions for the gas valve on the boiler on pages 25-28.
9) Upon initial start-up, the gas train will be filled with air. Even if the gas line has been completely purged of air, it may take
several tries for ignition before a flame is established. Once a flame has been established for the first time, subsequent
calls for burner operation should result in a flame on the first try.
10) Observe pilot burner flame:
• See Figure 20 for standing pilot. Pilot burner should produce single steady medium blue flame covering around 3/8”
to ½” of thermocouple tip.
• See Figure 21 for intermittent ignition. Pilot burner produces three flames. The center one should be a steady medium
blue flame covering around 3/8” to ½” of spark electrode/flame rod.
12) Make sure vent damper is in open position when main burners are firing.
13) Inspect the main burner flames visible through the observation port in burner access panel. The flame should be stable
and mostly blue (see Figure 22). No yellow tipping should be present; however, intermittent flecks of yellow and orange in
the flame are normal.
14) Check entire gas train for leaks using soap and water or other approved leak detection method while boiler is firing. Fix
any leaks found immediately.
15) Run gas valve safety shutdown test:
• For standing pilot boiler models, disconnect the thermocouple from gas valve. Both pilot burner and main burners
should stop firing.
• For intermittent ignition boiler models, with main burners firing, disconnect ignition cable from ignition module. Both
pilot burner and main burners should stop firing.
NOTE
SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS MANIFOLD AND
CONTROL ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TESTS
SPECIFIED IN Z21.13.
WARNING
•
NEVER USE A FLAME TO CHECK FOR GAS LEAKS.
• MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE
MATERIALS, GASOLINE, AND OTHER FLAMMABLE VAPORS AND LIQUIDS.
• DAMPER MUST BE IN OPEN POSITION WHEN APPLIANCE MAIN BURNER IS OPERATING.
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