13
5. Boiler Piping
5.7 Expansion Tank and Makeup Water
Ensure the expansion tank is properly sized for the boiler water
volume (approximately 1 gallon [4 L]), the system water volume, and
system water temperature.
Undersized expansion tanks will cause system water to
be lost through the pressure relief valve and cause ad-
ditional makeup water to be added to the system. Even-
tual boiler heat exchanger failure can result due to this
excessive makeup water addition.
The expansion tank must be located as shown in Fig. 5 and Fig. 6, on
page 14, when using a primary/secondary piping arrangement or as
per recognized design methods. Refer to the expansion tank
manufacturer for additional installation details.
Connect the expansion tank to an air separator only if the air
separator is located on the suction side (inlet) of the system
circulator. Always locate and install the system fill connection at the
same location as the expansion tank connection to the system.
5.7.1 Diaphragm Expansion Tank
Always install an automatic air vent on top of the air separator to
remove residual air from the system.
5.7.2 Closed-Type Expansion Tank
It is recommended to pitch any horizontal piping upwards toward the
expansion tank 1 inch per 5 feet [2.5 cm per 1.5 meter] of piping. Use
3/4” piping to the expansion tank to allow air within the system to rise.
DO NOT install automatic air vents on a closed-type ex-
pansion tank system. Air must remain in the system
and be returned to the expansion tank to provide an air
cushion. An automatic air vent would cause air to be
vented from the system resulting in a water-logged ex-
pansion tank.
5.8 Central Heating (CH) Circulator
A Central Heating (CH) circulator with flow check must be utilized
with the CHALLENGER. The circulator when wired directly to the
CHALLENGER will provide circulation for the freeze protection feature
of the boiler control. See Graphs 3-6 on pages 65-66 for pressure drop
and minimum flow rate required through the boiler.
5.9 Sizing Primary Piping
See Fig. 7 and 8, on page 15, for recommended piping arrangements
based on various applications. Size the piping and system
components required in the space heating system using recognized
design methods.
CAUTION
CAUTION
5.10 System Piping - Zone Circulators
Connect the CHALLENGER to the system piping as shown in Fig. 7, on
page 15, when zoning with zone circulators.
The installer must provide a separate circulator for each zone of space
heating.
To ensure an adequate flow rate through the CHAL-
LENGER, the boiler supply and return piping size must
be a minimum of 1 inch.
5.11 System Piping - Zone Valves
Connect the CHALLENGER to the system piping as shown in Fig. 8, on
page 15, when zoning with zone valves.
To ensure an adequate flow rate through the CHAL-
LENGER, the boiler supply and return piping size must
be a minimum of 1 inch.
5.12 System Piping - Radiant Heating
The heat exchanger design of the CHALLENGER allows operation in a
condensing mode. This feature requires no regulation of the return
water temperature back to the boiler in radiant heating applications.
The maximum boiler water supply temperature can be maintained by
the CHALLENGER, potentially eliminating the need for a mixing
system to achieve the desired temperature if all zones of heat are at
the same temperature set point.
Size the system piping and circulator to provide the flow needed for
the radiant system.
To ensure an adequate flow rate through the CHAL-
LENGER, the boiler supply and return piping size must
be a minimum of 1 inch.
5.13 System Piping - Indirect Fired Water Heater
See Figs. 7 and 8, on page 15, for recommended piping of a ACV-
Triangle Tube SMART/COMFORT I.F.W.H. This application will provide
higher domestic hot water flow rates for a short period of time (dump
load). The SMART/COMFORT boiler piping should be piped off the
primary loop.
The boiler system piping must be a “closed” system to
avoid any oxygen contamination and potential failure of
the outer tank of the SMART/COMFORT I.F.W.H.
NOTICE
NOTICE
NOTICE
NOTICE
Summary of Contents for CC105
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