20
BOiLer SYSTeM PiPiNg
existing water system evaluation
A good system will prevent oxygen contamination of boiler water.
Causes of oxygen contamination may be:
1.
Addition of excessive make up water as a result of leaks.
A.
Absorption through open tanks and fittings.
B.
Oxygen permeable materials in the distribution system.
C.
To ensure long product life, oxygen sources must be eliminated.
2.
Take the following measures:
Repairing system leaks.
A.
Eliminate open tanks from the system.
B.
Eliminate and/or repair fittings which allow oxygen absorption.
C.
Use non-permeable materials in the heating system.
D.
Connect system supply and return piping to boiler
See PIPING DIAGRAMS. Also, consult I=B=R Installation and
Piping Guides.
If this boiler is used in connection with refrigeration systems,
1.
the boiler must be installed so that the chilled medium is piped
in parallel with the heating boiler using appropriate valves to
prevent the chilled medium from entering the boiler. See
pip-
ing diagram 12
. Also, consult I=B=R installation and Piping
Guides.
If this boiler is connected to heating coils located in air han-
2.
dling units where they may be exposed to refrigerated air, the
boiler piping must be equipped with flow control valves to
prevent gravity circulation of boiler water during the operation
of the cooling system.
If a low water cut-off is required, it must be mounted in the
3.
3/4” supply manifold tapping or in the system piping above the
boiler. The minimum safe water level of a hot water boiler is
just above the highest water containing cavity of the boiler; that
is, a hot water boiler must be full of water to operate safely.
!
WARNING
The use of a low water cut off device is recommended.
When the installation of the boiler is for a new heating system,
4.
first install all of the radiation units (panels, radiators, base-
board, or tubing) and the supply and return mains. After all
heating system piping and components have been installed,
make final connection of the system piping to the boiler. It is
recommended to mount the circulating pump on the supply side
piping, such that it pumps away from the expansion tank. Refer
to the figures on the next pages.
A hot water
5.
boiler installed above radiation level must be
equipped with a low water cut off device. A periodic inspection
is necessary, per manufacturers specific instructions.
When connecting the cold water supply
6.
to the pressure reduc-
ing valve, make sure that a clean water supply is available. When
the water supply is from a well or pump, a sand strainer should
be installed at the pump.
Bypass Piping
For this section, refer to the Piping Diagrams for illustrations.
NOTICE
Bypass piping may be required for applications listed below.
Failure to do so may cause damage due to thermal shock and sus-
tained condensation within the boiler and void the warranty.
This high efficiency cast iron low mass boiler must be protected
from sustained operation of return water temperatures lower than
130°F (54C). Occasionally, temperatures as low as 70°F (21C)
may return back to the boiler as a zone that has not been activated
for some time is opened. However, most residential systems with
finned-tube (aluminum-copper) baseboard radiation contain a low
volume of water and will not adversely affect the boiler. Systems with
finned-tube baseboard radiation typically do not require a bypass.
The bypass piping details shown in the piping diagrams MUST be
used for any one of the following conditions:
All large water content systems, including cast iron standing
A.
radiators, cast iron baseboard, converted two-pipe steam sys-
tems, converted gravity circulation systems and other similar
systems.
Any system, including finned-tube baseboard, with a priority
B.
domestic hot water zone.
A ¾ inch bypass line must be installed as shown in the piping dia-
grams
for the systems identified above.
!
WARNING
System supply and return piping must be connected to correct
boiler fittings. The boiler manufacturer recommends sizing the
system circulator to supply sufficient flow (GPM) to allow a 20°F
temperature differential in the system. When sizing the system
circulator, the single most restrictive zone should be used to
determine maximum pressure drop.
NOTICE
Failure to pipe boiler correctly may result in excessive noise and
other related problems.
