Installation Guide

WHL-648 Rev. 000 Rel. 002 Date 1.3.18
59
C. Freeze Protection (When Used)
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 appliances, veried in the uid manufacturer’s
literature. Thoroughly clean and ush any system that has used
glycol before installing the new appliance. Provide the appliance
owner with a material safety data sheet (MSDS) on the uid 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.
4. Glycol in hydronic applications should include inhibitors that
prevent the glycol from attacking metallic system components.
Make certain that the system uid is checked for the correct glycol
concentration and inhibitor level.
5. The glycol solution should be tested at least once a year or as
recommended by the glycol manufacturer.
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.
D. Fill and Test Water System
Ensure the appliance is full of water before ring the burner.
Failure to do so will damage the appliance. 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 appliance drain
valve.
3. Fill to the correct system pressure. Correct pressure will vary with
each application.
a. Typical cold water ll pressure for a CH residential system is 12
psi.
b. Pressure will rise when appliance 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 ll and during appliance startup and testing, check
system thoroughly for leaks. Repair all leaks before proceeding
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.
Eliminate all system leaks. Continual fresh make-up water will reduce
appliance 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 aect water
chemistry. After the system has been lled and leak tested, verify
that water pH and chloride concentrations are acceptable by sample
testing.
It is important to purge the system of air to avoid damage to the
appliance.
further.
E. Purge Air from CH and Internal Storage Tank
1. 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 appliance 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 terminal block. Apply power to the appliance. After
the control goes through the start-up sequence, the display will turn
o.
i. Press and hold the button for ve seconds. Then scroll to 29: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 ve 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 cP:o. 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 CH and internal circulation 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 ve minutes), or press the
button to leave it manually.
l. After the system has operated for some time, eliminate any residual
air by using the manual air vents located throughout the system.
m. 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.
IMPORTANT! While commissioning the system, the air vent on top
of the appliance must remain fully open to allow the appliance to
properly ll. Failure to keep the air vent open could lead to improper
appliance and system operation.