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9
Start-up
Installation & Operation Manual
Fill and test water system
1. Fill system only after ensuring the water meets the
requirements of this manual.
2. Close manual and automatic air vents and boiler drain
valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. The minimum cold water fill pressure for a
commercial system is 12 psi (82.7 kPa).
b. Pressure will rise when boiler is turned on and
system water temperature increases.
Eliminate all system leaks. Continual
fresh makeup water will reduce boiler
life. Minerals can build up in the heat
exchanger, reducing heat transfer,
overheating the heat exchanger, and
causing heat exchanger failure.
Purge air from water system
1. Purge air from system:
2. Open automatic air vent (diaphragm-type or bladder-
type expansion tank systems only) one turn.
3. Open
other
vents:
a.
Starting on the lowest floor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
4. Refill to correct pressure.
4. At initial fill and during boiler startup and testing, check
system thoroughly for any leaks. Repair all leaks before
proceeding further.
WARNING
Check/control fill water chemistry
Conduct water quality testing prior to
installing the appliance. Various solutions
are available to adjust water quality.
Hardness between 5 and 15 grains per gallon
1. Consult local water treatment companies for hard water
areas (above 15 grains per gallon hardness).
2. Hardness levels that are above 15 grains/gallon can lead
to lime scale buildup throughout the boiler system. If the
fill water is below 5 grains/gallons, usually due to use of a
water softener, it is recommended to mix in some potable
water at the inlet to increase the hardness of the water to
above 5 grains/gallons.
pH between 6.5 and 9.5
1. pH levels below 6.5 can cause an increase in the rate of
corrosion. pH of 9.5 or higher can potentially cause lime
scale buildup.
Total Dissolved Solids (TDS) below 2,000 ppm
1. Total dissolved solids are all minerals, salts, metals, and
charged particles that are dissolved in water.
2. The greater the amounts of TDS present, the higher the
corrosion potential due to increased conductivity in the
water.
3. If using softened water to fill the boiler, it is still possible
to have high TDS. This water can be corrosive. It is
recommended to mix in some potable water with the
softened water to reduce this affect.
Chlorine concentration less than 200 ppm
1. Do not fill boiler or operate with water containing
chlorine in excess of 200 ppm.
2. Filling with fresh drinking water should be acceptable.
3. Do not use the boiler to directly heat swimming pool or
spa water.
IMPORTANT
Fill water
The manufacturer recommends the following for properly
filling your boiler with the appropriate water chemistry for
closed loop boilers. Good fill water quality will help extend
the life of the appliance by reducing the effects of lime scale
buildup and corrosion in closed loop systems.
Freeze protection (when used)
1. Determine freeze protection fluid quantity using
system water content, following fluid manufacturer’s
instructions. Boiler water content is listed on page 6.
Remember to include expansion tank water content.
2. Local codes may require a backflow preventer or actual
disconnect from city water supply.
3. When using freeze protection fluid with automatic fill,
install a water meter to monitor water makeup. Freeze
protection fluid may leak before the water begins to
leak, causing concentration to drop, reducing the freeze
protection level.
