LP-428 Rev. 6.6.16
40
and must be piped with the correct materials. Never pipe the
condensate using 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 HTP (7350P-
611).
2. The boiler is equipped with a ¾ female socket weld tting
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 HTP (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
overow, 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.
E. Fill and Test Water System
Ensure the boiler is full of water before ring 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 ll 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 ll 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 aect
water chemistry. After the system has been lled and leak
tested, verify that water pH and chlorine concentrations are
acceptable by sample testing.
It is important to purge the system of air to avoid damage to
the boiler.
F. Purge Air from Water System
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 ll connection to the system.
c. Close zone isolation valves.
d. Open quick-ll 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 ow 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-ll water valve and purge valve and
remove the hose. Open all isolation valves. Watch the system
pressure rise to correct cold-ll 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 o. 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 o. 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 ve 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 oor. Close vent when water squirts out. Repeat with
remaining vents.
k. Rell to correct pressure.
G. Check Thermostat Circuit(s)
1. Disconnect the two external wires connected to the boiler
thermostat terminals (low voltage terminal strip).
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