58
LP-542 REV. 7.16.15
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 fill pressure for a CH residential system is 12 psi.
b. Pressure will rise when boiler is turned on and system water temperature increases. Operating pressure of the CH system
should never exceed 25 psi, and must never exceed the relief valve pressure setting.
4. At initial fill 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, causing heat exchanger failure and possibly resulting in property damage, severe
personal injury, or death.
5. The system may have residual substances that could affect water chemistry. After the system has been filled 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.
E. PURGE AIR FROM SYSTEM
IMPORTANT! While commissioning the system, the air vent on top of the boiler must remain fully open to allow the boiler to properly
fill. Failure to keep the air vent open could lead to improper boiler and system operation.
To 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 fill connection to the system.
c. Close zone isolation valves.
d. Open quick-fill 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 flow 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-fill water valve and purge valve and remove the hose. Open all isolation valves. Watch the system pressure
rise to correct cold-fill 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 terminal block. Apply power to the boiler.
After the control goes through the start-up sequence, the display will turn off.
i. Press and hold the button for five seconds. Then scroll to 34:AP by turning the dial . Press the button. AP:cP will
show on the display. Press the button to change the test time. The default is five minutes. Turn the dial
counterclockwise to lower or clockwise to raise the displayed value. Press the button again to save any changes.
j. Then use the dial to scroll to cP1:off. Press the button to turn on test mode. Turn the dial counterclockwise to
lower or clockwise to select on. Press the button again to start test mode.
k. The boiler and CH system pumps will come on. Run pumps 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.
Test mode will stop automatically after the set time (default is five minutes), or press the button to leave it manually.
m. Then use the dial to scroll to cP2:off. Press the button to turn on test mode. Turn the dial counterclockwise to
lower or clockwise to select on. Press the button again to start test mode.
n. The DHW indirect pump will come on. Run pump 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. Test mode will
stop automatically after the set time (default is five minutes), or press the button to leave it manually.
o. After the system has operated for some time, eliminate any residual air by using the manual air vents located throughout the
system.
p. If purge valves are not installed in the system, open manual air vents in the system one at a time, beginning with the lowest
floor. Close vent when water squirts out. Repeat with remaining vents.
q. Refill to correct pressure.
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