Ultra electronic 155, 105, 80 Startup, Check/control water chemistry, Freeze protection when used

6 GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual

Startup

Check/control water chemistry

Do not use petroleum-based cleaning or sealing compounds in boiler system. Damage to elastomer seals and gaskets in system could occur, resulting in substantial property damage.

Before filling the boiler and system with water, verify the following. Failure to comply could result in boiler failure or unreliable operation.

Water pH between 7.0 and 8.5

1.Maintain boiler water pH between 7.0 and 8.5. Check with litmus paper or have chemically analyzed by water treatment company.

2.If pH differs from above, consult local water treatment company for treatment needed.

Hardness less than 7 grains

1.Consult local water treatment companies for unusually hard water areas (above 7 grains hardness).

Chlorine concentration less than 200 ppm

1.Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are typically less than 5 ppm.

2.Do not use the boiler to directly heat swimming pool or spa water.

3.Do not fill boiler or operate with water containing chlorine in excess of 200 ppm.

Clean system to remove sediment

1.You must thoroughly flush the system (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by buildup or corrosion due to sediment.

2.For zoned systems, flush each zone separately through a purge valve. (If purge valves and isolation valves are not already installed, install them to properly clean the system.)

3.Flush system until water runs clean and you are sure piping is free of sediment.

Test/replace freeze protection fluid

1.For systems using freeze protection fluids, follow guidelines in Ultra Boiler Freeze Protection Supplement.

Freeze protection (when used)

NEVER use automotive or standard glycol antifreeze, even glycol made for hydronic systems. Use only freeze-protection fluids recommended in the Ultra Boiler Freeze Protection Supplement. Follow all guidelines in the Freeze Protection Supplement, and thoroughly clean and flush any replacement boiler system that has used glycol before installing the new Ultra boiler.

1.Determine freeze protection fluid quantity using total system water content, following fluid manufacturers’s instructions. Boiler water content is listed on page 43. Remember to include expansion tank water content.

2.Local codes may require back flow preventer or actual disconnect from city water supply.

3.When using freeze protection fluid with automatic fill, install a water meter to monitor water make-up. Freeze protection fluid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.

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. Typical cold water fill pressure for a residential system is 12 psi.

b. Pressure will rise when boiler is turned on and system water temperature increases. Operating pressure must never exceed 25 psig.

4.At initial fill and during boiler startup and testing, check system thoroughly for any leaks. Repair all leaks before proceeding further.

Eliminate all system leaks. Continual fresh make-up water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure.

5.The system may have residual substances that could affect water chemistry.After the system has been filled and leak tested, verify water pH and chlorine concentrations are acceptable.

Purge air from water system

1. Purge air from system:

a.Connect a hose to the purge valve (see purge/drain valves, item 11, in piping diagrams on pages 15 through 18. Route hose to an area where water can drain and be seen.

b. Close the boiler or system isolation valve between the purge valve and fill connection to the system.

c. Close zone isolation valves.

d.Open quick-fill valve on cold water make-up line. e. Open purge valve.

f.One zone at a time, open the isolation valves. Allow water to run through the zone, pushing out the air. Run until no noticeable air flow 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-fill water valve and purge valve and remove the hose. Open all isolation valves. Watch that system pressure rises to correct cold-fill pressure.

h.After 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 system, open manual air vents in system one at a time, beginning with lowest floor. Close vent when water squirts out. Repeat with remaining vents.

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.

Part number 550-100-026/0404 23