International Thermal Research CO105D, Operator'S Manual

Page: 26 / 55

3.25 WATER FILLING PROCEDURE
After your system has been completely installed, filled with straight water, purged of all air, and
operating for a period of time at normal operating temperatures, you should now
double check all connections for leaks. If no leaks are found, the system can be drained
and filled with a 50/50 mixture of antifreeze and water.
PRECAUTION: Where there is a chance of contamination of your domestic water when using a
heating system, use antifreeze specifically intended for hydronic heating systems. Inhibited
propylene glycol is recommended. Do not use automotive, ethylene glycol, or any undiluted or
petroleum based antifreeze as they can cause severe personal injury.
To fill the system use a separate self priming pressure pump with a hose on the suction side. Put the
hose into a 5 gallon container. Remove the systems hose from the outlet of the expansion tank, which is
feeding the systems circulating pump and attach it to the outlet of the self priming pressure pump.
Remove the hose from the inlet of the expansion tank and hang it into the 5 gallon container.
Make a final check to ensure all of the air vents and drains are closed. Pour a mixture of antifreeze and
water into the container and start the pump. As the mixture is pumped out, slowly add more mixture
keeping the level above the inlet of the suction hose until all air has been expelled and the mixture
starts coming out of the return hose hanging in the container. This will flush the system of any debris
and purge the lines of air. Continue to run the pump for about 15 minutes.
When no more air is being expelled, stop the pump and reconnect the lines to the expansion tank. Top
off the expansion tank with the mixture and turn on the system’s circulating pump with the jumper,
located on the main control board just right of the pump fuse, marked “Circ. Pump Override”. When
the jumper is on, the pump will run continuously and the bottom LED will be lit.
Check for a good flow through the expansion tank and double check all joints for leaks. Open and close
all air vents to eliminate any remaining air bubbles. Recheck the mixture level and circulation in the
expansion tank.
CAUTION: Make sure you have a good, quiet circulation of water through the heater. Check the
pump to make sure it does not run dry. If the heater has air pockets trapped in the water jacket
when it is turned on, it could overheat and damage the unit. None of this is covered by warranty
.