ACV CC105s, Installation & Maintenance Manual

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10. Startup Preparation
Section X: Startup Preparation
10.1 Check Boiler System Water Chemistry
10.1.1Water pH Level
Maintain the boiler water pH between 6.5 and 8.5. Check using litmus
paper or contact a water treatment company for a chemical analysis.
If the pH does not meet this requirement, do not operate the
CHALLENGER or leave the appliance filled until the condition is
corrected.
10.1.2 Water Hardness
Maintain the boiler water hardeness below 7 grains/gallon or 120 ppm
[mg/l]. For areas with unusually hard water (above stated limit)
consult a water treatment company.
10.1.3 Chlorinated Water
Do not use the CHALLENGER to heat a swimming pool or spa directly.
Maintain the chlorine level of the water at levels considered safe for
drinking.
10.1.4 Antifreeze
For boiler systems containing antifreeze solutions, follow the
antifreeze manufacturer’s instructions in verifying the inhibitor level
and to ensure the fluid characteristics are within specified
requirements.
Due to degradation of inhibitors over time, antifreeze fluids must be
periodically replaced. Refer to the manufacturer of the antifreeze for
additional instructions.
Do not use petroleum-based cleaning or sealing com-
pounds in the boiler system. Damage to seals and gas-
kets in the system could occur, resulting in substantial
property damage.
WARNING
System water including additives must be practically
non-toxic, having a toxicity rating or Class of 1, as listed
in Clinical Toxicology of Commerical Products.
NOTICE
System water including additives must be practically
non-toxic, having a toxicity rating or Class of 1, as listed
in Clinical Toxicology of Commerical Products.
NOTICE
10.2 Flush Boiler System to Remove Sediment
The installer must flush the boiler system to remove any sediment to
allow proper operation of the CHALLENGER.
Flush the system until the water runs clean and is free of sediment.
For zoned systems, each zone should be flushed through a purge
valve. Purge valves and isolation valves should be installed on each
zone to allow proper flushing of the system.
10.3 Use of Antifreeze in the Boiler System
Determine the antifreeze fluid quantity using the system water
content volume and following the antifreeze manufacturer
instructions.
The boiler water volume of the CHALLENGER CC50s and CC85s is
0.37 gallons [1.4 l], CC105s is 0.42 gallons [1.6 l], and CC125s,
CC125Hs, and CC150s is 0.50 gallons [1.9 l]. Remember to include
this volume in sizing of the expansion tank.
Check with local code requirements for the installation of backflow
preventers or actual disconnection from the boiler’s cold water make
up water supply line.
Ensure the concentration of antifreeze to water does not exceed a
50/50 ratio.
10.4 Filling the Boiler System
Close the boiler drain valve located on the bottom of the 1.
appliance and any manual or automatic air vents in the system.
Open all system isolation valves.
2.
Fill the boiler system to correct system pressure. Correct 3.
pressure will vary with each application.
Typical residential system fill pressure is 12 psi [0.8
bar]. System pressure will increase when system tem-
perature increases. Operating pressure of the system
should never exceed 25 psi [1.7 bar].
NOTICE
Massachusetts Code requires the installation of a back-
flow preventer if antifreeze is used in the system.
NOTICE
System water including additives must be practically
non-toxic, having a toxicity rating or Class if 1, as listed
in Clinical Toxicology of Commercial Products
NOTICE
NEVER use automotive/ethylene glycol antifreeze or
undiluted antifreeze in the boiler system. This can re-
sult in substantial property damage, serious injury, or
death.
WARNING