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2. Do not connect the boiler to directly heat a swimming pool or
spa water.
3. Do not fill boiler or operate with water containing chlorine in
excess of 100 ppm.
Hardness: Less than 7 grains
Chloride Levels: Less than 100 ppm
pH Levels: 6-8
TDS: Less than 2000 ppm
Sodium: Less than 20 mGL
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 of this manual.
Test/replace freeze protection fluid
1. For systems using freeze protection fluids, follow fluid
manufacturer's instructions to verify inhibitor level and that
other fluid characteristics are satisfactory.
2. Freeze protection fluid must be replaced periodically due to
degradation of inhibitors over time. Follow all fluid manufacturer
instructions.
NOTE: Boiler failure due to improper water chemistry is not
covered by warranty.
B. Check for Gas Leaks
Before starting the boiler, and during initial operation, smell
near the floor and around the boiler for gas odorant or any
unusual odor. Remove boiler front door and smell interior of
boiler enclosure. Do not proceed with startup if there is any
indication of a gas leak. Repair any leaks at once.
C. Freeze Protection (When Used)
NEVER use automotive or standard glycol antifreeze. Do
not use ethylene glycol made for hydronic systems. Use only
freeze-protection fluids certified by fluid manufacturer as
suitable for use with stainless steel boilers, verified in the fluid
manufacturer's literature. Thoroughly clean and flush any
system that has used glycol before installing the new boiler.
Provide the boiler owner with a material safety data sheet
(MSDS) on the fluid used.
1. Determine the freeze protection fluid quantity using total
system water content following the fluid manufacturer's
instructions. Remember to include expansion tank water
content.
2. Local codes may require back flow preventer or actual
disconnect from city water supply.
WHL-038 Rev. 1.29.16
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.
D. Fill and Test Water System
Ensure the boiler is full of water before firing the burner.
Failure to do so will damage the boiler. Such damage IS NOT
covered by warranty, and could result in property damage,
severe personal injury, or death.
1. Fill the system only after ensuring water chemistry meets
the requirements listed in this manual.
2. Close the manual and automatic air vents and boiler drain
valve.
3. Fill to the 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 the relief valve pressure setting.
4. At initial fill and during boiler startup and testing, check
system thoroughly for 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 the heat exchanger,
reducing heat transfer, overheating the 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 that water pH and chlorine concentrations are
acceptable by sample testing.
It is important to purge the system of air to avoid damage to
the boiler.
E. Purge Air from Water System
Purge air from the system:
a. Connect a hose to the purge valve and 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. Open the isolation valves one zone at a time. Allow water to
run through the zone, pushing out the air. Run water 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 the system
pressure rise to correct cold-fill pressure. It is recommended
that you put the pumps into manual operation to assist in
purging the circuits.
h. Disconnect the wires that are connected to the
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