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Part 9 - Start-Up Preparation
Thoroughly clean and flush any system that has used glycol before
installing the boiler. Provide the customer with a material safety
data sheet (MSDS) on the fluid used.
A. Check / Control Water Chemistry
Chemical imbalance of your water can cause severe damage
to your boiler and associated equipment, and may also affect
efficiency. You may have to have your water quality professionally
analyzed to determine whether you need to install a water
softener. It is important that the water chemistry on both the
domestic hot water and central heating sides are checked before
installing the boiler, as water quality will affect the reliability of the
system. Outlined below are those water quality parameters which
need to be met in order for the system to operate efficiently for
many years. Failure of a heat exchanger due to lime scale build-up
on the heating surface, low pH or other imbalance IS NOT covered
by the warranty.
To assure extended service life, it is recommended to test water
quality prior to installation. Listed below are some guidelines.
Do not use petroleum-based cleaning or sealing compounds in
the boiler system. Damage to elastomer seals and gaskets in the
system could occur, resulting in substantial property damage.
•
Water pH between 6.5 and 8.5
• Maintain water pH between 6.5 and 8.5. pH levels below
6.5 can cause an increase in the rate of corrosion. pH of 8.5
or higher can potentially cause lime scale build-up
•
Hardness less than 7 grains (120 mg/L)
• Hardness levels above the required amounts can lead to
lime scale build-up throughout the system. Water below 5
grains/gallon (85 mg/L) may be over softened.
•
Chloride concentration less than 100 ppm (mg/L)
• Do not fill appliance or operate with water containing
chlorides in excess of 100 ppm (mg/L).
•
Total Dissolved Solids (TDS) less than 500 ppm (mg/L)
• If using softened water to fill the appliance, it is still
possible to have high TDS. This water can be corrosive.
Consult local water treatment companies
treatment solutions to reduce this affect.
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.
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.
*NOTE: It is recommended you clean heat exchanger at least
once a year to prevent lime scale buildup. Follow the maintenance
procedure to clean the heat exchanger in the Maintenance Section
of this manual.
Test/replace freeze protection fluid
1. For systems using freeze protection fluids, follow fluid
manufacturer's instructions to verify inhibitor level and that other
fluid characteristics are satisfactory.
2. Freeze protection fluid must be replaced periodically due to
degradation of inhibitors over time. Follow all fluid manufacturer
instructions.
NOTE: Boiler failure due to improper water chemistry is not
covered by warranty.
B. Check for Gas Leaks
Before starting the boiler, and during initial operation, smell near
the floor and around the boiler for gas odorant or any unusual odor.
Remove boiler front door and smell interior of boiler enclosure.
Do not proceed with startup if there is any indication of a gas leak.
Repair any leaks at once.
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. Condensate Removal
1. The boiler is a high efficiency condensing boiler. Therefore, the unit
has a condensate drain. Condensate fluid is nothing more than water
vapor, derived from combustion products, similar to that produced by
an automobile when it is initially started.
Condensation is slightly acidic (typically with a pH of 3 to 5) and must
be piped with the correct materials. Never pipe the condensate using
for other
steel, copper, brass or other materials that will be subject to corrosion.
Plastic PVC or CPVC pipe are the only approved materials.
A condensate neutralizer, if required by local authorities, can be made
up of lime crystals, marble or phosphate chips that will neutralize the
condensate. This may be done by the installer or you may purchase a
condensate neutralizer from Westinghouse (7350P-611).
2. The boiler is equipped with a ¾ female socket weld fitting connection
that must be piped to a local drain. It is very important that the
condensate line is sloped downward away from the boiler to a suitable
inside drain. If the condensate outlet on the appliance is lower than
the drain, you must use a condensate removal pump, available from
Westinghouse (554200). This pump is equipped with two leads that
can be connected to an alarm or another type of warning device to
alert the user of a condensate overflow, which, if not corrected, could
cause property damage.
3. If a long horizontal run is used, it may be necessary to create a vent
in the horizontal run to prevent a vacuum lock in the condensate line.
4. Do not expose the condensate to freezing temperatures.
5. It is very important you support the condensation line to assure
proper drainage.
whl-428-r1 Rev. 001 Rel. 012 Date 7.21.20
39
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