6 Start-up
Check/control water chemistry
Do not use
Hardness less than 7 grains
1.Consult local water treatment companies for hard water areas (above 7 grains hardness).
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 chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower.
3.Do not use the boiler to directly heat swimming pool or spa water.
Test/replace freeze protection fluid
1.For systems using freeze protection fluids, follow fluid manufacturer’s instructions.
2.Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer’s instructions.
Freeze protection (when used)
1.Determine freeze protection fluid quantity using system water content, following fluid manufacturer’s instructions. Appliance water content is listed on page 8. 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.
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 should be |
| 12 PSI. |
Installation & Operation Manual
WARNING 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:
a.Connect a hose to the purge valve (see purge/drain valves, in the piping diagrams on pages 39 - 42). 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 fill connection to the system.
c.Close zone isolation valves.
d.Open
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
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 the system, open the manual air vents in the system one at a time, beginning with the lowest floor. Close the vent when water squirts out. Repeat with remaining vents.
2.Open automatic air vent
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.
Check for gas leaks
WARNING Before starting the boiler, and during initial operation, smell near the floor and around
the boiler for gas odorant or any unusual odor. Remove the front access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Use an approved leak detection solution. Repair any leaks at once.
b. Pressure will rise when boiler is turned on and |
system water temperature increases. |
4. At initial fill and during boiler startup and testing, |
check system thoroughly for any leaks. Repair all leaks |
before proceeding further. |
WARNING
Propane boilers only – Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.
47 
