Piping System Cleaning & Flushing - Heat Controller HKV Installation, Operation & Mainenance Manual

Heat Controller, Inc.
CAUTION!
CAUTION! To avoid possible damage to a plastic (PVC)
piping system, do not allow temperatures to exceed 110°F
[43°C].
CAUTION!
CAUTION! 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 inhibit unit operation.
Note:
Heat Controller strongly recommends all piping
connections, both internal and external to the unit, be
pressure tested for leakage by an appropriate method
prior to any finishing of the interior space or before
access to all connections is limited. Heat Controller
will not be responsible or liable for damages from water
leaks due to inadequate or a lack of pressurized leak
testing during installation.
Cleaning and flushing of the WLHP piping system is the
single most important step to ensure proper start-up and
continued efficient operation of the system.
Follow the instructions below to properly clean and flush
the system:
1. Verify electrical power to the unit is disconnected.
2. Install the system with the supply hose connected
directly to the return riser valve. Use a single length of
flexible hose.
3. Open all air vents. Fill the system with the water. DO
NOT allow system to overflow. Bleed all air from the
system. Pressurize and check the system for leaks
and repair appropriately.
4. Verify all strainers are in place. (Heat Controller recom-
mends a strainer with a #20 stainless steel wire mesh.)
Start the pumps, and systematically check each vent
to ensure all air is bled from the system.
5. Verify make-up water is available. Adjust make-up wa-
ter appropriately to replace the air which was bled from
the system. Check and adjust the water/air level in the
expansion tank.
6. Set the boiler to raise the loop temperature to approxi-
mately 85°F [29°C]. Open the a drain at the lowest
point in the system. Adjust the make-up water replace-
ment rate to equal the rate of bleed.
7. Refill the system and add trisodium phosphate in a
proportion of approximately one pound per 150 gallons
[1/2 kg per 750 L] of water (or other equivalent ap-
proved cleaning agent). Reset the boiler to raise the
HKV LArge CommerCiAL
loop temperature to about 100°F [38°C]. 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 if desired.
8. When the cleaning process is complete, remove the
short-circuited hoses. Reconnect the hoses to the
proper supply, and return the connections to each of
the units. Refill the system and bleed off all air.
9. Test the system pH with litmus paper. The system
water should be slightly alkaline (pH 7.5-8.5). Add
chemicals, as appropriate, to maintain acidity levels.
10. When the system is successfully cleaned, flushed,
refilled and bled, check the main system panels,
safety cutouts and alarms. Set the controls to prop-
erly maintain loop temperatures.
BEFORE POWERING SYSTEM, please check
the following:
Unit Checkout
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Piping System Cleaning & Flushing
Balancing/Shutoff Valves: Ensure all isolation
valves are open, water control valves wired and
open or coax may freeze and burst.
Line Voltage and Wiring: Ensure Voltage is
within an acceptable range for the unit and wiring
and fuses/breakers are properly sized. Low
voltage wiring is complete.
Unit Control Transformer: Ensure transformer
has properly selected control voltage tap. 208-
230V units are factory wired for 208V operation
unless specified otherwise.
Entering Water and Air: Ensure entering water
and air temperatures are within operating limits of
Table 6.
Low Water Temperature Cutout: Verify low
water temperature cut-out on CXM is properly set.
Unit Fan: Manually rotate fans to assure free
rotation and ensure blower wheel is secured to
motor shaft. Be sure to remove any shipping
supports if needed. DO NOT oil motors upon
start-up. Fan motors are pre-oiled at factory.
Verify unit fan speed selected is correct.
Condensate Line: Condensate line is open and
properly pitched toward drain.
Water Flow Balancing: Verify inlet and outlet
water temperatures are recorded for each heat
pump upon startup. This check can eliminate
nuisance trip outs and high velocity water flows
that can erode heat exchangers.
Unit Air Coil & Filters: Ensure filter is clean and
accessible. To obtain maximum performance and
avoid possible condensate blow-off the coil should
IOM Instructions