P/N 42-9450 8/08 Copyright 2008 Hydrotherm
Page 30 KN INSTALLATION AND OPERATION INSTRUCTIONS
Fill and test the system
Failure to adhere to the following could result in
boiler section failure, resulting in potential for
severe personal injury, death or substantial property
damage.
Flush and clean the system before lling.
Provide clean water to ll the system
Water quality must be as prescribed in this manual.
Follow the system water checklist
Follow the guidelines in this section to ll and test the system. e system
water quality must meet the conditions given, and you and the owner must
make sure the conditions will be maintained throughout the life of the boiler.
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Closed systems only
Do not apply the KN boiler on open systems, such as direct heating of domestic
water, swimming pool heating or process applications that use system water. For
these applications, you must install a heat exchanger.
Hard water conditions
If water hardness exceeds 7 grains, use a water so ener in the ll line to so en the
water before it enters the system.
On multiple boiler commercial installations, the large volume of water in the
system can contain substantial mineral salts, even if the ll water hardness is less
than 7 grains. ese salts can deposit in the boiler heat exchanger as limestone,
causing possible section damage. Commercial installations should usually be lled
with so water to avoid this problem.
Prevent oxygen corrosion
Make sure the system is provided with adequate automatic air elimination, including
an in-line air separator and automatic air vents (diaphragm or bladder tank systems) or
piping to the expansion tank (closed-type expansion tank systems).
Do not connect the KN boiler to a system that contains non-barrier radiant
tubing. Non-barrier tubing can allow oxygen to enter the system, causing oxygen
corrosion of the boiler heat exchanger.
Flush and clean the system
Flush the system to remove sediment, ux, lings and other foreign ma er. Use
cleaning chemicals sold for use in hydronic systems.
Replacement boiler installations o en have large amounts of accumulated
sediment and corrosion that must be removed to ensure boiler life and reliable
operation.
Flush each zone of multi-zone systems individually using the purge valves and
isolation valves in the system.
Flush until the water runs clean.
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A er ushing the system thoroughly, use trisodium phosphate
or other chemical sold for cleaning hydronic systems to remove
sediment and sludge.
Use caution when working with chemicals,
following all guidelines speci ed by the chemical
supplier and the applicable codes.
Purge air from the system
e system should be installed with purge valves such as
those shown in the suggested piping in this manual. Purging
is the most e cient way to ll the system and remove most
of the air.
Connect a hose to a purge valve and run the hose to an
appropriate draining area. (When lling with antifreeze
solution, run the hose back to the solution tank.)
Close all isolation valves in the system.
Open the manual valve (or quick- ll valve) on the make-up
water line. (When lling the system with glycol, connect
from the glycol pump to one of the purge valves with a
hose.)
Purge each zone separately by opening the isolation valves
for that zone, allowing water to push the air through and ll
the zone. A er lling the zone, close the isolation valves and
move to the next zone.
Fill and purge the boiler loop in the same manner.
A er the boiler is operated for a while, air entrained in the
ll water will bubble out of the water as it heats, and will
have to be removed by using air vents in the system.
Add a chemical inhibitor
A er purging and lling the system, add a chemical inhibitor
sold for use in hydronic systems to prevent limestone and
magnetite deposits from forming, and to protect the boiler
from galvanic corrosion.
Water pH
e boiler water must be slightly basic, never acidic. Use
litmus paper to check pH, which should range from 6.5
minimum to 11 maximum.
If pH does not comply, provide water chemistry correction
from a quali ed water treatment specialist. If required, make
sure that the owner is aware and that the regimen will be
continued.
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