Installation Guide

Part number 550-100-066/0608
g a s -f i r e d w at e r b o i l e r — Boiler Manual
72
Startup — fill the system (continued)
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.
The system may have residual substances that could 5.
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
Connect a hose to the purge valve (see purge/1.
drain valves, item 11, in piping diagrams on
Figure 15, page 17 through Figure 19, page 21.
Route hose to an area where water can drain and
be seen.
Close the boiler or system isolation valve between 2.
the purge valve and fill connection to the system.
Close zone isolation valves.3.
Open quick-fill valve on cold water make-up line.4.
Open purge valve.5.
One zone at a time, open the isolation valves. Al-6.
low water to run through the zone, pushing out
the air. Run until no noticeable air ow is present.
Close the zone isolation valves and proceed with
the next zone. Follow this procedure until all zones
are purged.
Close the quick-fill water valve and purge valve 7.
and remove the hose. Open all isolation valves.
Watch that system pressure rises to correct cold-
fill pressure.
After the system has operated for a while, eliminate 8.
any residual air by using the manual air vents lo-
cated throughout the system.
If purge valves are not installed in system, open 9.
manual air vents in system one at a time, beginning
with lowest oor. Close vent when water squirts out.
Repeat with remaining vents.
Open automatic air vent (diaphragm-type or blad-10.
der-type expansion tank systems only) one turn.
Starting on the lowest oor, open air vents one at 11.
a time until water squirts out.
Repeat with remaining vents.12.
Refill to correct pressure.13.
Clean the cast aluminum heat exchanger
In order for the efficiency of boilers to increase beyond the con-1.
densing limit, new materials have been introduced for the heat
exchanger, including aluminum. Aluminum has excellent heat
transfer characteristics and is light in weight.
These new materials also require cleaning solutions that differ from 2.
those used in conventional cast iron and steel boilers. One common
cleaning method that CANNOT be used with systems contain-
ing aluminum is a solution of trisodium phosphate, commonly
referred to as “TSP.” The reason that trisodium phosphate cannot
be used is that the cleaning solution has a very high pH level that,
while removing the scale in the system, also removes the natural
protective oxide layer from the aluminum. The oxide layer will
reform, but if small amounts of the trisodium phosphate remain
in the system, the chemical will continue to remove the protective
oxide layer, leading to reduced heat exchanger life.
There are cleaning solutions that have been developed to clean and 3.
treat mixed metal systems. And these solutions have been successful
for years. It is important that the cleaning, treatment and freeze
protection products used on Ultra aluminum boilers are identified
as being safe and suitable for use in hydronic heating systems. The
following companies offer such products.
Hydronic Agencies, Ltd.
15363 117 Ave.
Edmonton, AB T5M 3X4, Canada
Ph 780-452-8661
Fx 780-488-2340
Web www.hydronicagencies.com
Rhomar Water Management, Inc.
P. O. Box 229
Springfield, MO 65801
Ph 800-543-5975
Fx 417-862-2610
Web www.rhomarwater.com
Fill and test water system
Fill system only after ensuring the water meets the requirements 1.
of this manual.
Close manual and automatic air vents and boiler drain valve.2.
Fill to correct system pressure. Correct pressure will vary with 3.
each application.
Typical cold water fill pressure for a residential system is 12 a.
psi.
Pressure will rise when boiler is turned on and system water b.
temperature increases. Operating pressure must never exceed
25 psig.
At initial fill and during boiler startup and testing, check system 4.
thoroughly for any leaks. Repair all leaks before proceeding fur-
ther.