NTI INSTALLATION MANUALS

Part 10 - Start-Up Preparation

6. Anti-freeze solutions expand more than water. For example: A 50% by volume solution expands 4.8% in volume for a temperature increase from 32 - 80 o F, while water expands 3% over the same temperature rise. Allowances must be made in system design for expansion. 7. A 30% mixture of glycol will result in a BTU output loss of 15% with a 5% increase in head against the system circulator. 8. A 50% mixture of glycol will result in a BTU output loss of 30% with a 50% increase in head against the system circulator. NOTE: BTU losses apply to both CH and DHW.

WARNING

WARNING 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. 2. Open hot water faucets in the DHW system. Start with the faucets nearest the boiler. 3. Keep faucets open until water runs freely and all air is purged. Then move on to faucets further away from the boiler in the system. 4. When water ows freely from all hot water faucets, DHW purging is complete. 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. Check if the condensate trap contains water. If not, it must be re lled. Open the manual air vent on the main exchanger until completely lled. Check the system pressure on the pressure gauge again. E. Purge Air from DHW System 1. Make sure the CH and DHW lines are open and full of water. Turn on all electric power to boiler. F. Check Thermostat Circuit(s) 1. Disconnect the two external wires connected to the boiler thermostat terminals TT1/TT2 (low voltage terminal strip). 2. Connect a voltmeter across these two incoming wires with power supplied to the thermostat circuits. Close each thermostat, zone valve and relay in the external circuit one at a time and check the 4. If a voltage reading does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.) 5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the boiler low voltage terminal strip. Allow the boiler to cycle. G. Condensate Removal 1. The boiler is a high e ciency condensing appliance. 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) 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. 2. The boiler is equipped with a barbed outlet tting, to which the supplied hose must be installed and routed to a local drain. It is very important that the condensate line is sloped downward away from the boiler to a suitable indoor drain. voltmeter reading across the incoming wires. 3. There should NEVER be a voltage reading.

CAUTION

It is highly recommended to carefully follow the glycol manufacturer’s recommended concentrations, expansion requirements, and maintenance recommendations (pH additive breakdown, inhibitor reduction, etc.) You must carefully calculate the additional friction loss in the system as well as the reduction in heat transfer coe cients.

D. System Water Fill, Purge, and Test

WARNING

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.

CAUTION

Connect the condensate discharge pipe before lling and purging the heating circuit. It is important to purge the system of air to avoid damage to the boiler.

The boiler and heating system must be thoroughly purged of air during the initial installation or system maintenance. Proceed as follows to purge the boiler and heating system: 1. Open the manual air vent positioned on the side of the primary exchanger. The valve is already connected to a discharge hose routed to the condensate trap. 2. Lift the cap on the automatic air release valve on the pump. Leave open permanently. 3. Gradually open the main water valve until water ows. Do not open fully. 4. Thoroughly purge each zone starting with the lowest point and close them only when clear water free of air is visible. 5. Close the manual air vent when clear water free of air is visible. 6. Continue lling the system until at least 12 psi registers on the pressure gauge.

Boiler Manual Air Vent

Figure 90 - Manual Air Vent Position

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