Step 5 - Install Supply And Return Piping; Hose Kits; Step 6 - Install Condensate Piping; Pre-Start-Up - Carrier Aquazone 50PEC09-18 Installation, Start-Up And Service Instructions Manual

tep 5 — Install Supply and Return Piping
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The following items should be adhered to in addition to applicable
piping codes.
• A drain valve at the base of each riser to enable proper
flushing of the system at startup and during servicing.
• Shutoff/isolation ball valves at the supply and return con-
nections and unions at each unit to permit proper flow bal-
ancing and unit servicing.
• Strainers at the inlet of each circulating pump. Use Teflon
tape on threaded pipe fittings to eliminate water leaks and
ensure against air entering the system.
• Flexible hose connections between the unit and the rigid
system to eliminate the possibility of vibration transmis-
sion through the piping.
• Insulation is not normally required on supply and return
piping for boiler tower installations except in unheated
sections or outdoor runs.
• Insulation is required for closed-loop Geothermal installa-
tions as loop temperatures may fall below the dew point
and can even fall below the freezing point of water during
heating season.

Hose Kits

When using optional hose kits follow the manufacturer's recom-
mendations for installation. Never stretch or twist hoses and never
use hoses that show external wear or damage or are suspected of
having damage. Never exceed the manufacturer's maximum
working pressure recommendations.
Step 6 — Install Condensate Piping
Console units are designed with a blow-through configuration in
the air-handling section. This means that there is positive pressure
at the unit drain pan and thus trapping is not required. Condensate
is routed from the drain pan via a
hose that is located below the supply and return water connec-
tions.
Though horizontal runs of condensate piping are usually too short
to pose problems, horizontal runs should be pitched at least 1 in.
for every 10 ft of piping. Avoid low spots or no sloped piping, as
these areas can collect sediment and eventually block condensate
flow. Always inspect both internal and external condensate piping
for kinks that could block condensate flow.

PRE-START-UP

System Cleaning and Flushing

Cleaning and flushing the unit and system is the single most im-
portant step to ensure proper start-up and continued efficient oper-
ation of the system. See Tables 3 and 4.
WARNING
To prevent injury or death due to electrical shock or contact
with moving parts, open unit disconnect before servicing unit.
CAUTION
TO AVOID POSSIBLE DAMAGE DO NOT FLUSH SYS-
TEM THROUGH THE UNIT!
1. Teflon is a registered trademark of Dupont.
/ in. non-pressure rated vinyl
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Follow the instructions below to properly clean and flush the sys-
tem:
1. Verify that electrical power to the units is disconnected, and
that the circulation pump is deenergized.
2. Connect the supply hose directly to the return riser valve. Use
a single length of flexible hose.
NOTE: If the length of hose is too short (i.e., the resulting
connection would exceed the minimum bend radius of the hose),
substitute two lengths of flexible hose joined together with a field-
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supplied, standard NPT coupling and the flare-fitting-to-pipe
adapters provided with the hose kit.
3. Open all air vents. Fill the system with water. Do not allow
system to overflow. Bleed all air from the system. Check the
system for leaks and repair appropriately.
4. Check and adjust the water and air level in the expansion
tank.
5. Verify all strainers are in place. Start the pumps, and system-
atically check each vent to ensure all air is bled from the sys-
tem.
6. Verify make-up water is available. Adjust make-up water
appropriately to replace the air that was bled from the system.
Pressure test and inspect the system for leaks and make any
necessary repairs. Check and adjust the water and air level in
the expansion tank.
7. Open a drain at the lowest point in the system. Adjust the
make-up water replacement rate to equal the rate of bleed.
Continue to bleed the system until the water appears clean or
for at least three hours, whichever is longest; then, completely
drain the system.
8. Refill the system with clean, chemically treated water. Since
water varies for each locality, contact a local water treatment
company for the correct treatment chemicals to use in the
area. See Table 4. Set the boiler to raise the loop temperature
to approximately 85°F.
.
To avoid possible damage to piping systems constructed of
plastic piping DO NOT allow loop temperature to exceed
110°F.
Circulate the solution for a minimum of 8 to 24 hours. At the
end of this period, shut off the circulating pump and drain the
solution. Repeat system cleaning as necessary.
9. When the cleaning process is complete, remove the short-cir-
cuited hoses. Connect the hoses to the proper supply and
return connections on each unit. Refill the system and bleed
off all air.
10. Test the system pH with litmus paper. The system water
should be slightly alkaline (pH 7.0 to 8.5). Add chemicals, as
appropriate, to maintain acidity levels.
DO NOT use "Stop-Leak" or any similar chemical agent in
this system. Addition of these chemicals to the loop water will
foul the system and will inhibit unit operation.
11. When the system is successfully cleaned, flushed, refilled and
bled, check the main system panels, safety cutouts and
alarms. Set the controls to properly maintain loop
temperatures.
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CAUTION
CAUTION