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59
PART 9 – START-UP PREPARATION
Thoroughly clean and flush any system that has used glycol before installing the boiler. Provide the customer with a material safety data sheet (MSDS) on the fluid used.
A. CHECK / CONTROL WATER CHEMISTRY
Chemical imbalance of your water can cause severe damage to your boiler and associated equipment, and may also affect efficiency.
You may have to have your water quality professionally analyzed to determine whether you need to install a water softener. It is important that the water chemistry on both the domestic hot water and central heating sides are checked before installing the boiler, as water quality will affect the reliability of the system. Outlined below are those water quality parameters which need to be met in order for the system to operate efficiently for many years.
Failure of a heat exchanger due to lime scale build-up on the heating surface, low pH or other imbalance IS NOT covered by the warranty.
To assure good extended service life, it is recommended that you test your water quality prior to installation. Listed below are some guidelines.
Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage.
Sodium less than 20 mGL
Water pH between 6 and 8
1. Maintain boiler water pH between 6 and 8. 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
Consult local water treatment companies for unusually hard water areas (above 7 grains hardness).
Chlorine concentration less than 100 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 100 ppm.
ACIDITY
CONDUCTIVITY
CHLORIDE
IRON
COPPER
SODIUM
HARDNESS
Table 16
6 to 8 pH
Less than 400 uS/cm at 25 o
C
Less than 100 ppm
Less than 0.5 mg/L
Less than 0.1 mg/L
Less than 20 mg/L
Less than 7 Grains
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.
*NOTE:
It is recommended you clean heat exchanger at least once a year to prevent lime scale buildup. Follow the maintenance procedure to clean the heat exchanger in the Maintenance Section (Part 14 of this manual).
Test/replace freeze protection fluid
1. For systems using freeze pro tection fluids, follow fluid manufacturer’s instructions to verify inhibitor level and that other fluid characteristics are satisfactory.
LP-387 REV. 3.4.15
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Table of contents
- 8 – GENERAL SAFETY INFORMATION
- 8 A. PRECAUTIONS
- 8 B. IMPROPER COMBUSTION
- 8 C. GAS
- 8 D. WHEN SERVICING THE BOILER
- 8 E. BOILER SYSTEM
- 9 F. BOILER WATER CHEMISTRY
- 9 G. FREEZE PROTECTION FLUIDS
- 9 – BEFORE YOU START
- 9 A. WHAT’S IN THE BOX
- 10 B. HOW BOILER OPERATES
- 11 C. OPTIONAL EQUIPMENT
- 11 – PREPARE BOILER LOCATION
- 11 A. BEFORE LOCATING THE BOILER
- 12 B. LEVELING
- 12 C. CLEARANCES FOR SERVICE ACCESS
- 15 D. RESIDENTIAL GARAGE, CLOSET, AND ALCOVE INSTALLATIONS
- 15 E. EXHAUST VENT AND INTAKE PIPE
- 15 1. DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE
- 15 2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE
- 16 F. PREVENT COMBUSTION AIR CONTAMINATION
- 17 G. REMOVING AN BOILER FROM A COMMON VENT SYSTEM
- 17 – PREPARE BOILER
- 17 A. REMOVE THE BOILER FROM PACKAGING
- 18 B. WALL MOUNTING CONSIDERATIONS
- 18 C. WALL MOUNTING INSTRUCTIONS
- 18 1. MOUNTING TO A WOOD STUDDED WALL
- 19 2. MOUNTING TO A METAL FRAME
- 19 – BOILER PIPING
- 20 A. GENERAL PIPING INFORMATION
- 20 B. RELIEF VALVE
- 21 C. BACKFLOW PREVENTER
- 21 D. SYSTEM WATER PIPING METHODS
- 21 E. CIRCULATORS
- 22 F. HYDRONIC PIPING WITH CIRCULATORS, ZONE VALVES, AND MULTIPLE BOILERS
- 22 G. PIPING DETAILS
- 30 H. PIPING INSTALLATION
- 30 I. CIRCULATOR SIZING
- 31 J. CHECK/CONTROL WATER CHEMISTRY
- 32 K. FILL AND PURGE HEATING SYSTEM
- 33 L. GLYCOL ANTIFREEZE SOLUTIONS
- 33 M. ZONING WITH ZONE VALVES
- 33 N. ZONING WITH CIRCULATORS
- 33 O. MULTIPLE BOILERS
- 34 – VENTING, COMBUSTION AIR, AND CONDENSATE REMOVAL
- 34 A. GENERAL
- 35 B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE
- 35 C. REQUIREMENTS FOR INSTALLATION IN CANADA
- 36 D. EXHAUST VENT AND INTAKE PIPE LOCATION
- 40 E. EXHAUST VENT AND INTAKE PIPE SIZING
- 41 F. LONGER VENT RUNS
- 41 G. EXHAUST VENT AND INTAKE PIPE INSTALLATION
- 42 H. VENTING DRAWINGS
- 42 1. DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE
- 45 2. VENTING THROUGH AN EXISTING SYSTEM
- 47 3. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE
- 49 – GAS PIPING
- 49 A. GAS CONNECTION
- 49 B. GAS PIPING
- 50 C. CHECK INLET GAS PRESSURE
- 51 D. BOILER GAS VALVE
- 52 – FIELD WIRING
- 52 A. INSTALLATION MUST COMPLY WITH
- 52 B. FIELD WIRING TERMINATIONS
- 52 C. FIELD WIRING
- 53 D. LINE VOLTAGE WIRING FOR STANDARD BOILER
- 53 E. ALARM CONNECTIONS
- 53 F. LOW VOLTAGE CONNECTIONS FOR STANDARD BOILER
- 53 G. THERMOSTAT
- 54 H. OUTDOOR SENSOR
- 54 I. INDIRECT SENSOR
- 54 J. OPTIONAL 0-10 VOLT BUILDING CONTROL SIGNAL
- 55 K. OPTIONAL UL353 LOW WATER CUT-OFF INTERFACE KIT
- 55 L. WIRING OF CASCADE SYSTEM COMMUNICATION BUS
- 56 M. CASCADE MASTER PUMP AND SENSOR WIRING
- 56 N. CASCADE FOLLOWER PUMP AND SENSOR WIRING
- 59 – START-UP PREPARATION
- 59 A. CHECK / CONTROL WATER CHEMISTRY
- 60 B. CHECK FOR GAS LEAKS
- 60 C. FREEZE PROTECTION (WHEN USED)
- 60 D. FILL AND TEST WATER SYSTEM
- 61 E. PURGE AIR FROM WATER SYSTEM
- 61 F. CHECK THERMOSTAT CIRCUIT(S)
- 61 G. CONDENSATE REMOVAL
- 62 H. FINAL CHECKS BEFORE STARTING BOILER
- 62 I. CASCADE SYSTEM
- 63 J. LOCKOUT CONDITION
- 63 – START-UP PROCEDURE
- 63 A. CONTROL OVERVIEW
- 63 B. NAVIGATION OF THE DISPLAY
- 64 C. OPERATING INSTRUCTIONS
- 64 D. PROGRAMMING BOILER SETTINGS
- 65 E. PROGRAMMING THE SYSTEM SETTING
- 65 F. SYSTEM SETTING PROGRAM NAVIGATION
- 68 G. RESETTING THE MAINTENANCE SCHEDULE
- 68 – START-UP PROCEDURES FOR INSTALLER
- 68 A. BOILER CONTROL STATUS MENU
- 70 B. CASCADE MENU
- 70 C. BOILER TEST MODE
- 71 – SHUTDOWN
- 71 A. SHUTDOWN PROCEDURE
- 71 B. VACATION PROCEDURE
- 71 C. FAILURE TO OPERATE
- 72 – TROUBLESHOOTING
- 72 A. BOILER ERROR CODE
- 72 B. BOILER ERROR
- 72 C. BOILER FAULT
- 73 D. USER INTERFACE DISPLAY
- 77 – MAINTENANCE
- 77 A. MAINTENANCE PROCEDURES
- 78 B. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS FOR BOILER
- 78 C. CLEANING WATER SIDE OF HEAT EXCHANGER
- 79 D. MAINTAINING THE CONDENSATE SYSTEM
- 85 BOILER START-UP REPORT
- 85 MAINTENANCE REPORT
- 89 MAINTENANCE NOTES
- 90 HTP CUSTOMER INSTALLATION RECORD FORM