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46
PROPANE BOILERS ONLY – The propane supplier mixes an
odorant with the propane to make its presence detectable. In
some instances the odorant can fade, and the gas may no longer
have an odor. Before startup (and periodically thereafter), have
the propane supplier verify the correct odorant level in the gas.
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.
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
WHL-016 Rev. 4.14.16
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
1. 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
THERMOSTAT terminals of the customer connection
board. Apply power to the boiler. The display will show
the temperature of the water in the boiler. Press the v and
ENTER keys simultaneously and hold for 1 second. The
display will read:
The central heating pump will come on. If you then press the
^ key, the central heating pump will shut off. The display will
read:
The DHW pump will come on. If the boiler is set up as a
cascade master and you then press the ^ key again, the
DHW pump will shut off. The display will read:
The system pump will come on. Use the ^ and v keys to toggle
between running each pump in the system as required to
help bleed out all entrapped air. Some good indicators that
air is removed include the absence of gurgling noises in the
pipes and pump operation becoming very quiet. Pressing ^
and v together at any time will return the boiler to normal
operation.
i. After the system has operated for five minutes, eliminate
any residual air by using the manual air vents located
throughout the system.
j. If purge valves are not installed in the system, open manual
air vents in the system one at a time, beginning with the
lowest floor. Close vent when water squirts out. Repeat with
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