10
Start-up
Installation & Operation Manual
Oxygen prevention
Dissolved oxygen can have a negative eff ect on the boiler
system. Oxygen can cause iron oxide to generate iron
deposits. Oxygen may also increase the rate of corrosion
on non-stainless steel parts of the system. A low pH level
combined with oxygen further enhances its corrosive eff ects.
Aft er boiler installation, check for air leaks in the following
areas:
• Suction gasket
•
Pump
• Air valve
• O-ring gaskets
Precautions include installing a water meter to evaluate the
fresh water volume entering the system. Additional volumes
of fresh water could indicate that a leak is present.
Fill and test water system
1. Fill system only aft er ensuring the water meets the
requirements of this manual.
2. Close automatic and manual air vents and boiler drain
valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. Th
e minimum cold water fi ll pressure for a system is
12 psi.
b. Pressure will rise when the boiler is turned ON and
system water temperature increases.
4. At
initial
fi ll and during boiler startup and testing, check
the system thoroughly for any leaks. Repair all leaks before
proceeding further.
Purge air from water system
1. Purge air from system:
a. Connect a hose to the purge valve (see purge/drain
valve in the piping diagrams on pages 42 through 47).
Route the hose to an area where water can drain and be
seen.
b. Close the boiler or system isolation valve between the
purge valve and fi ll connection to the system.
c.
Close zone isolation valves.
d. Open the quick-fi ll valve on the cold water makeup
line.
e.
Open purge valve.
f.
Open the isolation valves one zone at a time. Allow
water to run through the zone, pushing out the air.
Run until no noticeable air fl ow is present. Close
the zone isolation valves and proceed with the next
zone. Follow this procedure until all zones are purged.
g. Close the quick-fi ll water valve and purge valve and
remove the hose. Open all isolation valves. Watch that
system pressure rises to correct cold-fi ll pressure.
h.
Aft er the system has operated for a while, eliminate
any residual air by using the manual air vents located
throughout the system.
i.
If purge valves are not installed in the system, open the
manual air vents in the system one at a time, beginning
with the lowest fl oor. Close the vent when water
squirts out. Repeat with remaining vents.
2. Open the automatic air vent (diaphragm-type or bladder
type expansion tank systems only) one turn.
3. Open
other
vents:
a. Starting on the lowest fl oor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
4. Refi ll to correct pressure.
CAUTION
Boiler water
• Monitoring pH, TDS and hardness levels can
prolong the life of the appliance by reducing lime
scale buildup, corrosion, and erosion. Check for
leaks to ensure that fresh water is not entering the
system.
•
Continual fresh make-up water will reduce boiler
life.
•
Mineral buildup in the heat exchanger reduces heat
transfer, overheats the stainless steel heat exchanger,
and causes failure.
• Th
e addition of oxygen carried in by make-up water
can cause internal corrosion in system components.
•
Leaks in the boiler or piping must be repaired at
once to prevent make-up water. It could be helpful
to install a water meter for this purpose to easily
check the amount of make-up water entering the
system.
CAUTION
Do not use petroleum based cleaning or
sealing compounds in the boiler system.
Gaskets and seals in the system may be
damaged. Th
is can result in substantial
property damage.
DO NOT use "homemade cures" or
"boiler patent medicines". Serious
damage to boiler, personnel, and/or
property may result.
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.
CAUTION
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