Startup - Fill The System - Weil-McLain Series 2 Manual

® S
ERIES
Startup — fill the system
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.
If the system needs to be cleaned, use only Sentinel
X400 cleaner, available from Weil-McLain. See
Figure 119, page 115 for information. Follow
instructions supplied with the X400 cleaner.
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.
Do not use petroleum-based cleaning
or sealing compounds in boiler system.
Damage to elastomer seals and gaskets in
system could occur, resulting in substantial
property damage.
Before filling the boiler and system with
water, verify the following. Boiler corrosion
can occur.
Failure to comply could result in boiler
failure or unreliable operation.
Water chemistry
Water pH between 7.0 and 8.5
1. Maintain boiler water pH between 7.0 and 8.5. 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
1. Consult local water treatment companies for unusually hard
water areas (above 7 grains hardness).
Chloride concentration must be
LESS THAN 200 ppm
1. Filling with chlorinated fresh water should be acceptable
since drinking water chloride 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 chloride
in excess of 200 ppm.
Verify that the water chemistry meets the limitations
and requirements of all other equipment in the
system.
Part number 550-142-190/1218
2
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G
AS FIRED WATER BOILER
— Boiler Manual
Antifreeze
1. Use only antifreeze listed by Weil-McLain as suitable for
use with ECO Gas Boilers. See Figure 119, page 115 for
information.
2. See Replacement parts at the end of this manual for
Weil-McLain part numbers to obtain antifreeze through a
Weil-McLain distributor.
Use the correct amount of antifreeze
1. Determine the freezing temperature needed (to protect
against lowest likely temperature the system water will
encounter).
2. Find the antifreeze concentration by volume needed for this
temperature from the antifreeze manufacturer's data on the
antifreeze container.
3. Add up the volume (gallons) of all system piping and
components, including the expansion tank and boiler.
a. Boiler water content is listed in Figure 131, page 126.
b. Remember to include expansion tank water content.
4. Multiply this volume by the (percent) antifreeze needed to
find the number of gallons of antifreeze to add.
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. 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 24 PSIG.
4. At initial fill and during boiler startup and testing, check
system thoroughly for any 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 heat exchanger, and causing heat
exchanger failure.
Purge air from water system
1. Connect a hose to the purge valve (see purge/drain valves,
item 11, in piping diagrams beginning on page 51). Route
hose to an area where water can drain and be seen.
2. Close the boiler or system isolation valve between the purge
valve and fill connection to the system.
3. Close zone isolation valves.
4. Open quick-fill valve on cold water make-up line.
5. Open purge valve.
6. 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
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