Alpine Installation, Operating, and Service Instructions

88
103448-10- 6/18
IX. System Start-up
A. Verify that the venting, water piping, gas piping
and electrical system are installed properly.
Refer to installation instructions contained in this
manual.
B. Confirm all electrical, water and gas supplies
are turned off at the source and that vent is clear
of obstructions.
C. Confirm that all manual shut-off gas valves
between the boiler and gas source are closed.
D. If not already done, flush the system to remove
sediment, flux and traces of boiler additives.
This must be done with the boiler isolated from
the system. Fill entire heating system with water
meeting the following requirements:
Pressurize the system to at least 20 psi (140 kPa).
Purge air from the system.
E. Confirm that the boiler and system have no
water leaks.
F. Prepare to check operation.
1. Obtain gas heating value (in Btu per cubic
foot) from gas supplier.
2. Alpine gas valves have inlet and outlet
pressure taps with built-in shut off screw. Turn
each screw from fully closed position three
to four turns counterclockwise to open taps.
Connect manometers to pressure taps on gas
valve.
3. Temporarily turn off all other gas-fired
appliances.
4. Turn on gas supply to the boiler gas piping.
5. Open the field installed manual gas shut-off
valve located upstream of the gas valve on the
boiler.
6. Confirm that the supply pressure to the gas
valve is 13.5 in wc (3.4 kPa) or less. Refer
to Table 20 on page 72 for minimum supply
pressure.
7. Using soap solution, or similar non-
combustible solution, electronic leak detector
or other approved method, check that boiler
gas piping valves, and all other components
are leak free. Eliminate any leaks.
8. Purge gas line of air.
G. Operating Instructions
Start the boiler using the Operating Instructions,
see Figure 35. After the boiler is powered up, it
should go through sequence of operation shown in
Table 28 on page 100.
H. Purge Air From Gas Train
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. If more than 2 tries
for ignition are needed, it will be necessary to
press the reset button to restart the boiler. Once
a flame has been established for the first time,
subsequent calls for burner operation should
result in a flame on the first try.
NOTICE pH between 7.5 and 9.5.
If system contains aluminum components, pH
must be less than 8.5
Chlorides< 50 ppm
Total Dissolved Solids - less than 2500 PPM
Hardness - 3 to 9 grains/gallon.
NOTICE If it is required to perform a long term
pressure test of the hydronic system, the boiler
should first be isolated to avoid a pressure
loss due to the escape of air trapped in the
boiler.
Explosion Hazard.
Asphyxiation Hazard. Electrical Shock Hazard.
Start-up of this boiler should be undertaken
only by trained and skilled personnel from
a qualified service agency. Follow these
instructions exactly. Improper installation
adjustment, service or maintenance can cause
property damage, personal injury or loss of
life.
Burn Hazard. The maximum
operating pressure of this boiler is 30 psig (210
kPa), 50 psig
(340 kPa), 80 psig (550 kPa) or 100 psig
(689 kPa) depending on the model and safety
relief valve option selected. Never exceed the
maximum allowable working pressure on the
heat exchanger ASME plate.
WARNING
WARNING
Explosion Hazard. Do not
use matches, candles, open flames or other
ignition source to check for leaks.
DANGER
To perform a long term pressure test including
the boiler, ALL trapped air must first be
removed from the boiler.
A loss of pressure during such a test, with no
visible water leakage, is an indication that the
boiler contained trapped air.