Install Instructions
38
4 Water connections
The installer must ensure that the boiler is supplied with
adequate flow without excessive temperature rise. It is
recommended that this boiler be installed with a bypass in the
piping if the maximum recommended flow rate is exceeded.
The bypass will help to ensure that the boiler can be supplied
with adequate water flow. Flow rates exceeding the maximum
recommended flow will result in erosion of the boiler tubes.
A typical bypass with a valve as shown in FIG. 4-6 will allow
control of boiler flow.
Boiler bypass requirements
Temperature / pressure gauge
This boiler is equipped with a dial type temperature / pressure
gauge. This gauge is factory installed in the outlet side of the
boiler piping. The gauge has one scale to read system pressure
and a separate scale to read water temperature in degrees
Fahrenheit. The temperature / pressure gauge is provided to
meet code requirements. Water temperatures can be more
accurately monitored from the data provided in the digital
display in the Operator Interface.
All air must be purged from the system for proper operation.
An air scoop and air vent must be located close to the boiler
outlet and there should be a minimum distance between the
cold water feed and the system purge valve.
1. Close all drain cocks and air vents.
2. Open the makeup water valve and slowly fill the
system.
3. If a makeup water pump is employed, adjust the
pressure to provide a minimum of 12 psi at the highest
point in the system. If a pressure regulator is also
installed in the line, it should be adjusted to the same
pressure.
4. Close all valves. Purge one circuit at a time as follows:
A. Open one circuit drain valve and let the water
drain for at least five minutes. Ensure that
there are no air bubbles visible in the water
stream before closing the drain valve.
B. Repeat this procedure for each circuit.
5. Open all valves after all circuits have been purged.
Make sure there are no system leaks.
Filling the system
⚠ CAUTION
Do not use petroleum based stop leak
products. All system leaks must be repaired.
The constant addition of make-up water can
cause damage to the boiler heat exchanger
due to scale accumulation. Scale reduces
flow and heat transfer, causing overheating
of the heat exchanger.
6. Run the system circulating pump for a minimum of 30
minutes with the boiler turned off.
7. Open all strainers in the system and check for debris.
8. Recheck all air vents as described in step 4.
9. Inspect the liquid level in the expansion tank. The system
must be full and under normal operating pressure to
ensure proper water level in the expansion tank. Ensure
that diaphragm type expansion tanks are properly charged
and not water logged.
10. Start the boiler according to the operating instructions in
this manual. Operate the system, including the pump,
boiler and radiation units, for one hour.
11. Recheck the water level in the expansion tank. If it exceeds
half the tank volume, open the tank to reduce the water
level. Recheck pressure charge on diaphragm type tanks.
12. Shut down the entire system and vent all radiation units
and high points in the system.
13. Close the water makeup valve and check the strainer and
pressure reducing valve for sediment or debris. Reopen
the water makeup valve.
14. Verify system pressure with the boiler pressure gauge
before beginning regular operation.
15. Within three days of startup, recheck and bleed all air
vents and the expansion tank using these instructions.
Water treatment
In hard water areas, water treatment should be used to reduce
the introduction of minerals to the system. Minerals in the
water can collect in the heat exchanger tubes and cause noise on
operation. Excessive build up of minerals in the heat exchanger
can cause a non-warrantable failure.
Installation & Service Manual