HTP MODCON1000 - Part 8 - Start-Up Preparation; Check; Control Water Chemistry; Check for Gas Leaks; Freeze Protection (When Used)

LP-428 Rev. 6.6.16
39
Part 8 - Start-Up Preparation
A. Check / Control Water Chemistry
Chemical imbalance of your water can cause severe damage
to your boiler and associated equipment, and may also
aect eciency. 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 aect the reliability of the system. Outlined below are
those water quality parameters which need to be met in order
for the system to operate eciently 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.
Sodium less than 20 mGL
Water pH between 6.0 and 8.0
1. Maintain boiler water pH between 6.0 and 8.0. Check
with litmus paper or have it chemically analyzed by a water
treatment company.
2. If the pH diers from above, consult local water treatment
company 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
1. Using chlorinated fresh water should be acceptable since
drinking water chlorine levels are typically less than 5 ppm.
2. Do not connect the boiler to directly heat a swimming pool
or spa water.
3. Do not ll boiler or operate with water containing chlorine
in excess of 100 ppm.
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.
D. Condensate Removal
1. The boiler is a high eciency condensing boiler. Therefore, the
unit has a condensate drain. Condensate uid 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)
Thoroughly clean and ush any system that has used glycol
before installing the boiler. Provide the customer with a
material safety data sheet (MSDS) on the uid used.
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.
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 oor 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)
1. Determine the freeze protection uid quantity using total
system water content following the uid manufacturer’s
instructions. Remember to include expansion tank water
content.
2. Local codes may require back ow preventer or actual
disconnect from city water supply.
3. When using freeze protection uid with automatic ll, install
a water meter to monitor water makeup. Freeze protection uid
may leak before the water begins to leak, causing concentration
to drop, reducing the freeze protection level.
NEVER use automotive or standard glycol antifreeze. Do
not use ethylene glycol made for hydronic systems. Use only
freeze-protection uids certied by uid manufacturer as
suitable for use with stainless steel boilers, veried in the uid
manufacturer’s literature. Thoroughly clean and ush any
system that has used glycol before installing the new boiler.
Provide the boiler owner with a material safety data sheet
(MSDS) on the uid used.