Startup - Dunkirk Q90-200 Installation, Operation & Maintenance Manual

Water Treatment And Freeze Protection
Consult local water treatment specialist for
1.
recommendations if your water pH levels are below of
7.0 or hardness is above 7 grains hardness.
A. This boiler is designed for use in a closed hydronic
heating system ONLY!
B. Excessive feeding of fresh make-up water to the
boiler may lead to premature failure of the boiler
sections.
Use clean fresh tap water for initial fi ll and periodic
2.
make-up of boiler.
A. A sand fi lter must be used if fi ll and make-up water
from a well is to be used.
B. Consideration should be given to cleaning the
heating system, particularly in retrofi t situations
where a new boiler is being installed in an older
piping system.
C. In older systems, obviously discolored, murky,
or dirty water, or a pH reading below 7, are
indications that the system should be cleaned.
D. A pH reading between 7 and 8 is preferred when
antifreeze is not used in the system.
Antifreeze, if needed, must be of a type specifi cally
3.
designed for use in closed hydronic heating systems
and be compatible with type 356 T6 aluminum at
operating temperatures between 20°F and 250°F.
A. Use of antifreeze must be in accordance with local
plumbing codes.
B. Pure glycol solutions are very corrosive, therefore
hydronic system antifreeze typically contains
corrosion inhibitors. Different brands of hydronic
system antifreeze contain different types of
corrosion inhibitors. Some brands have corrosion
inhibitors that break down more rapidly or become
ineffective at higher temperatures when used with
aluminum. This could lead to premature failure
of the aluminum boiler. Consult the antifreeze
manufacturer on the compatibility of their product
with aluminum.
C. Follow the antifreeze manufacturer's instructions
on determining proper ratio of antifreeze to water
for the expected low temperature conditions,
and for maintaining the quality of the antifreeze
solution from year to year. Improperly maintained
antifreeze solutions will gradually lose their ability
to protect the aluminum boiler from corrosion.
D. Recommended premixed antifreeze solution
is INTERCOOL NFP-50. This product is sold direct
to distributors by the manufacturer. Please contact
Interstate Chemical Company at 1-800-422-2436
or your distributor for more information.
Use of an alternate manufacturer's premix antifreeze is
acceptable if the product specifi cations are comparable
with those of the recommended premix antifreeze and the
antifreeze is compatible with type 356 T6 aluminum. Use of
incompatible antifreeze could damage the heat exchanger
and will void the product warranty.

STARTUP

Antifreeze must be maintained per specifi cations of
manufacturer. Failure to do so will result in warranty being
voided. Follow antifreeze manufacturer's instructions on
determining proper ratio of antifreeze to water for expected
low temperature conditions and for maintaining antifreeze
solution from year to year.
E. DO NOT USE AUTOMOTIVE ANTIFREEZE
the type of corrosion inhibitors used will coat the
boiler's heat transfer surfaces and greatly reduce
capacity and effi ciency.
F. Use of antifreeze in any boiler will reduce heating
capacity by as much as 10-20% due to differing
heat transfer and pumping characteristics. This
must be taken into consideration when sizing the
heating system, pump(s) and expansion tank.
Consult antifreeze manufacturer's literature for
specifi c information on reduced capacity.
G. Water content of the boiler is 2.6 gallons (10
liters).
H. Antifreeze will raise the pH of the water in a
heating system to between 8.0 and 10.0. This is
due to the corrosion inhibitors in the antifreeze.
Filling Boiler With Water And Purging Air For Systems
With Diaphragm Type Expansion Tanks
Refer to the appropriate diagrams on pages 10-12 of this
document, "Near Boiler Piping," for more information.
Close all zone service valves on the supply and return
1.
piping. Open the feed valve and fi ll boiler with water.
Make sure air vent is open. Hold relief valve open until
water runs air free for fi ve seconds to rapidly bleed air
from boiler, then let the relief valve snap shut.
Open the zone service valve on the
2.
fi rst zone. Open the purge valve on the fi rst zone. Feed
water will fi ll the zone, pushing air out the purge valve.
Close the purge valve when the water runs air free.
Close the zone service valve.
Repeat step 2 for all remaining zones.
3.
Open all service valves. Any air remaining trapped in
4.
the return lines between the service valves and the
boiler will be pushed towards the air vent when the
boiler is placed in operation.
Inspect piping system. Repair any leaks immediately.
5.
Filling Boiler With Water And Purging Air For Systems
With Conventional Closed Type Expansion Tanks
Refer to the appropriate diagrams on pages 10-12 of this
document, "Near Boiler Piping," for more information.
Close all zone service valves on the supply and return
1.
piping and close the expansion tank service valve.
Drain expansion tank. Open the feed valve and fi ll
boiler with water. Hold relief valve open until water
runs air free for fi ve seconds to rapidly bleed air from
boiler, then let the relief valve snap shut.
22
, as
supply pipe for the