Install Instructions

Full Flow Application
It is acceptable for the Solution boiler to be installed
in a full flow application, as long as the following
requirements are met:
1. The performance loop is in place and functional.
2. The system flow is not lower than the minimum
boiler flow.
3. The boiler set point is 140°F or higher.
4. Boiler return water temperatures are 140°F or
higher.
Boiler Flow Rates
 CAUTION
The maximum flow rate through the
boil er with a copper heat exchanger must not ex ceed
30 GPM.
The heat exchanger is generally capable of op er at ing within
the flow rates of a residential heating system. Should the flow
rate exceed the maximum allowable flow rate through the boiler
30 GPM) an external bypass must be installed. The bypass should be fully
sized with a balancing valve to al low for proper ad just ment of flow. Flow
rate can be determined by measuring the temperature rise through the
boiler.
The basic guide for minimum flow in this boiler is based on a
40°F temperature rise in most in stal la tions. Low er flow and a
higher temperature rise is acceptable if the boiler system
is specifically de signed for the char ac ter is tics of a higher
tem per a ture rise. A system not specifically designed for a higher
temperature rise may experience over heat ing of the boiler water. This
can cause short burn er on cycles, system noise and in ex treme cases,
a knocking flash to steam. These con di tions can lead to operational
problems and non-war rant able fail ures of the boiler. High temperature
rise systems must be designed by a qualified engineer.
 WARNING
Varying the flow through a
Solution boiler can cause harmonic
noises and high limit trips if the
flow is below the minimum boiler
flow rate found in Table 4A.
4 Water connections
28
Installation & Service Manual
 CAUTION
At no time should the system
pressure be less than 12 PSIG.
A boiler operated with an inlet temperature of less
than 140°F (60°C) must have a bypass to prevent
problems with condensation. A bypass as shown in
FIG. 4-5 (see page 30) must be piped into the system
at the time of installation.
A primary/secondary piping system is ideal for systems
filled with a propylene glycol and water mixture. A
glycol and water mixture is more dense than water
only and may result in a lower boiler flow rate. A
lower boiler flow may cause noisy operation or short
cycling of the burners. A larger secondary pump
may be used on a primary/sec ond ary system to
pro vide an increased boiler flow rate. A glycol and
water system may require from 10 to 20% more flow to
compensate for the in creased density of the glycol and
its effect on the heat transfer process in the boiler. The
exact in crease in flow that may be required is based on
the type and percentage of glycol added to the boiler
system. Consult the manufacturer of the glycol for
additional recommendations when using a gly col and
water fill for your boiler system.
The installer must ensure that the boiler has adequate
flow without excessive temperature rise. The
temperature rise on a multiple zone system should be
made when only the zone with the longest length and/
or high est head loss is open. Low system flow can result
in overheating of the boiler water which can cause
short burner on cycles, system noise and in extreme
cases, a knocking flash to steam. System noise may also
indicate an oversized boiler.
Primary/Secondary Boiler Piping (continued)
Low Temperature Bypass Requirements
For systems which require lower operating temperatures, a bypass
must be installed to guarantee the boiler inlet water temperature is
above 140°F (60°C). Inlet water temperatures below 140°F (60°C) can
excessively cool the prod ucts of combustion re sult ing in condensation on
the heat exchanger and in the flue. Condensation can cause operational
problems, bad combustion, sooting, flue gas spillage and reduced service
life of the vent system and related components. The bypass allows part
of the boiler discharge water to be mixed with the cooler boiler return
water to in crease the boiler inlet temperature above 140°F (60°C). This
should prevent the prod ucts of com bus tion from condensing in most
in stallations.
Systems requiring a low temperature bypass should use the provided
system sensor and VAL30000 (1 1/2" LTV Valve Kit) piped in a Primary/
Secondary arrangement as shown in FIG. 4-5. It is recommended to
install the system sensor a minimum distance of 10 pipe diameters from
the boiler piping. The Low Temperature Valve (LTV) is ready to install
with a non-adjustable 140°F return temperature setting. It is important
thtat the valve is installed with the proper port orientation. Failure to
observe port markings on the valve body prior to installation could result
in damage to the unit. The recommended maximum high temperature
to the valve is 175°F (79°C).