Installation, Start-Up, Adjustment and Maintenance Manual
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4 HYDRONIC AND OIL/GAS INSTALLATION
4.1 WATER PIPING DESIGN AND INSTALLATION
Piping for the chiller is to be designed and installed as a closed hydronic circuit.
The following items (not supplied) must be installed close to the unit (see the Figure 9):
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FLEXIBLE CONNECTIONS to avoid vibration transmission to the chiller water lines.
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PRESSURE / TEMPERATURE TAPS in the inlet and outlet chiller water lines to set and
measure proper water flow and water temperatures.
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CHILLED WATER FILTER mounted in the water inlet line to remove debris from the chiller
water lines.
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REGULATION VALVES for adjusting proper water flow rate.
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WATER PUMP properly sized for system.
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EXPANSION TANK must be properly sized based on the hydronic system size, maximum
thermal expansion, and maximum water pressure.
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FILL VALVE for filling, draining or flushing the hydronic system.
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AIR BLEED set at the highest point in the hydronic system for removal of air.
To ensure the correct operation of the unit and to avoid the water freezing, add 10% by volume
of mono-ethylene glycol (antifreeze) to the circulation water. Add more mono-ethylene glycol as
needed for the minimum external temperature of the installation zone (see Table 10).
When using an automatic water charge system, the glycol percentage must be checked once a year.
There must be correct chilled water flow when the unit is operating and during the shut down period
(215 seconds, between turning the burner off and complete shutdown of the appliance).
Piping (diameters of tubes etc.) must be sized appropriately in order to ensure the correct chilled
water flow necessary for the proper operation of the unit. The water lines should also be sized so the
maximum velocity of the water/glycol solution in the lines does not exceed 6 feet per second to avoid
excessive noise.
When rigid pipes are used, it is recommended to use flexible connections between the unit and piping
to avoid vibration transmission.
All piping must be properly insulated according to federal and local codes to avoid thermal losses and
condensate on the water lines. All seams and joints should be carefully made so as to be air and
watertight.
For size of water connections on the unit, refer to TECHNICAL DATA sheet in SECTION 2.
Connections at the coil or heat exchanger must be performed in accordance with the
recommendations of the coil or heat exchanger manufacturer. For best performance, the supply-
chilled water line must attach to the side of the coil or heat exchanger nearest the exit of the leaving
cooled medium.
If the heat exchanger is an air coil, the air coil must be installed downstream from the furnace to avoid
condensation in the furnace. Additionally if the heat exchanger is an air coil, a “P” trap must be
provided to drain
condensate. The height of the “P” trap must be sufficient to ensure drainage of
condensate. Any horizontal run of the condensate drain line must slope ¼” for each running foot and
not be smaller than ¾” I.P.S. to assure the condensate will drain by gravity. The condensate drain line
must be insulated and ran to a suitable drain.
WARNING