HTP MODCON1000 - Check; Control Water Chemistry; Plumbing; Fill and Purge Heating System

LP-428 Rev. 6.6.16
17
NOTE: Boiler failure due to improper water chemistry is not
covered by warranty.
Water Chemistry*
• Sodium less than 20 mGL
• Water pH between 6.0 and 8.0
• Maintain water pH between 6.0 and 8.0. Check with
litmus paper or have it chemically analyzed by water
treatment company.
• If the pH diers from above, consult local water
treatment for treatment needed.
• Hardness less than 7 grains
• Consult local water treatment companies for
unusually hard water areas (above 7 grains hardness).
• Chlorine concentration less than 100 ppm
• Using chlorinated fresh water should be acceptable
as levels are typically less than 5 ppm.
• Do not connect the boiler to directly heat swimming
pool or spa water.
• Do not ll boiler or operate with water containing
chlorine in excess of 100 ppm.
*NOTE: It is recommended to clean the heat exchanger at
least once a year to prevent lime scale buildup. To clean the
heat exchanger, follow the maintenance procedure in this
manual.
Hardness: Less than 7 grains
Chloride levels: Less than 100 ppm
pH levels: 6 - 8
TDS: Less than 2000 ppm
Sodium: Less than 20 mGL
Clean system to remove sediment*
1. You must thoroughly ush the system (without boiler
connected) to remove sediment. The high-eciency heat
exchanger can be damaged by buildup or corrosion due to
sediment.
2. For zoned systems, ush 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 uid
1. For systems using freeze protection uids, follow uid
manufacturer’s instructions to verify inhibitor level and that
other uid characteristics are satisfactory.
2. Freeze protection uid must be replaced periodically
due to degradation of inhibitors over time. Follow all uid
manufacturer instructions.
Piping Components
Heating System Piping
System piping MUST be sized per technical pipe requirements
listed in Table 6. Reducing pipe size can restrict ow rate
H. Check / Control Water Chemistry
through the boiler, causing inadvertent short cycling and poor
system performance.
Check Valves
Field supplied. Check valves are recommended for installation
as shown in Applications.
Isolation Valves
Field supplied. Full port ball valves are required. Failure to use
full port ball valves could result in a restricted ow rate through
the boiler.
Anti-Scald Mixing Valve
Field supplied. An anti-scald mixing valve is recommended when
storing domestic hot water above 115°F.
Unions
Field supplied. Recommended for unit serviceability. DO
NOT USE DIELECTRIC UNIONS! ONLY BRASS, COPPER, OR
STAINLESS STEEL.
Pressure Relief Valve
Factory supplied on boiler. The pressure relief valve is sized to
ASME specications. Storage tank may require additional relief
valves depending on local codes.
Basic steps are listed below that will guide the installation of the
boiler.
1. Connect the system return marked “Boiler Return”.
2. Connect the system supply marked “Boiler Supply”.
3. Install purge and balance valve or shut o valve and drain on
system return to purge air out of each zone.
4. Install a back ow preventer on the cold feed make-up water
line.
5. Install a pressure reducing valve on the cold feed make-
up water line (15 PSI nominal on the system return). Check
temperature and pressure gauge when operating. It should read
a minimum pressure of 12 PSI.
6. Install a circulator as shown in piping details (this section).
Make sure the circulator is properly sized for the system and
friction loss.
7. Install an expansion tank on the system supply. Consult
the tank manufacturer’s instructions for specic information
relating to expansion tank installation. Size the expansion tank
for the required system volume and capacity.
8. Install an air elimination device on the system supply.
9. Install a drain valve at the lowest point of the system. NOTE:
The boiler cannot be drained completely of water without
purging the unit with an air pressure of 15 PSI.
10. The relief valve is installed at the factory. A pipe discharge
line should be installed to discharge 6” above the drain in the
event of pressure relief. The pipe size must be the same size as
the relief valve outlet. NEVER BLOCK THE OUTLET OF THE
SAFETY RELIEF VALVE.
I. Plumbing
This boiler should not be operated as a potable hot water heater.
It should not be used as a direct hot water heating device.
J. Fill and Purge Heating System
• Attach the hose to balance and purge hose connector or
drain valve and run hose to nearest drain.
• Close the other side of the balance and purge valve or the
shut o valve after the drain.
• Open rst zone balance and purge or drain valve to let