Instructions / Assembly

LP-387 Rev. 011 Rel. 006 Date 6.28.19
19
NOTE: Boiler failure due to improper water chemistry is not
covered by warranty.
• Water pH between 6.5 and 8.5
• Hardness less than 7 grains (120 mg/L) (Water temperatures
of 140
o
F and greater)
• Chloride concentration less than 100 ppm (mg/L)
• Total Dissolved Solids (TDS) less than 500 ppm (mg/L)
*NOTE: It is recommended to clean the heat exchanger at least once a
year to prevent lime scale buildup. To clean the heat exchanger, follow
the maintenance procedure in this manual.
Clean system to remove sediment*
1. You must thoroughly ush the system (without boiler connected)
to remove sediment. The high-eciency heat exchanger can be
damaged by buildup or corrosion due to sediment.
2. For zoned systems, ush each zone separately through a purge
valve. (If purge valves and isolation valves are not already installed,
install them to properly clean the system.)
3. Flush system until water runs clean and you are sure piping is free
of sediment.
Test/replace freeze protection uid
1. For systems using freeze protection uids, follow uid manufacturer’s
instructions to verify inhibitor level and that other uid characteristics
are satisfactory.
2. Freeze protection uid must be replaced periodically due to
degradation of inhibitors over time. Follow all uid manufacturer
instructions.
Piping Components
Heating System Piping
System piping MUST be sized per technical pipe requirements listed
in Tables 7 and 8. Reducing pipe size can restrict ow rate through the
boiler, causing inadvertent short cycling and poor system performance.
H. Check / Control Water Chemistry
Model Minimum Pipe Sizes
55 / 80 / 110 1” NPT
155 / 199 / 285 1 1/4” NPT
399 1 1/2” NPT
Table 8 - Minimum Pipe Sizes
I. Plumbing
NOTE: Observe the minimum 1” clearance around all uninsulated hot
water pipes when openings around pipes are not protected by non-
combustible materials.
Basic steps are listed below, with illustration that will guide you
This boiler should not be operated as a potable hot water heater. It
should not be used as a direct hot water heating device.
J. Fill and Purge Heating System
1. Attach the hose to balance and purge hose connector or drain
valve and run hose to nearest drain.
2. Close the other side of the balance and purge valve or shut o
valve after the drain.
3. Open the rst zone balance and purge or drain valve to let water
ow out of the hose. If zone valves are used, open the valves one at
a time manually. NOTE: You should check zone valve manufacturer’s
instructions prior to opening valves manually, so as not to damage
the zone valve.
4. Manually operate ll valve regulator. When water runs out of
the hose, you will see a steady stream without bubbles. Close the
balance and purge valve or drain to stop the water from owing.
Disconnect the hose and connect it to next zone to be purged.
5. Repeat this procedure for additional zones (one at a time).
For installations that incorporate standing iron radiation and
systems with manual vents at the high points, follow the previous
section and, starting with the nearest manual air vent, open
the vent until water ows out. Then close the vent. Repeat the
procedure, working your way toward the furthest air vent. It may
be necessary to install a basket strainer in an older system where
larger amounts of sediment may be present. Annual cleaning of
the strainer may be necessary.
Upon completion, make sure that the ll valve and zone valves are
in automatic positions. You must also assure the purge and shut o
valves are in open positions.
K. Glycol Antifreeze Solutions
Use only inhibited propylene glycol solutions which are specially
formulated for hydronic systems. Ethylene glycol is toxic and can
attack gaskets and seals used in hydronic systems. Glycol mixtures
should not exceed 50%. Failure to do so could result in property
damage, severe personal injury, or death due to scalds.
Check Valves
Field supplied. Check valves are recommended for installation as
shown in Applications.
Isolation Valves
Field supplied. Full port ball valves are required. Failure to use full port
ball valves could result in a restricted ow rate through the boiler.
Anti-Scald Mixing Valve
Field supplied. An anti-scald mixing valve is recommended when
storing domestic hot water above 115°F.
Unions
Field supplied. Recommended for unit serviceability. DO NOT USE
DIELECTRIC UNIONS! ONLY BRASS, COPPER, OR STAINLESS STEEL.
Pressure Relief Valve
Factory supplied on boiler. The pressure relief valve is sized to ASME
specications. Storage tank may require additional relief valves
depending on local codes.
through the installation of the boiler.
1. Connect the system return marked “Boiler Return”.
2. Connect the system supply marked “Boiler Supply”.
3. Install a purge and balance valve or shut o valve and drain on the
system return to purge air out of each zone.
4. Install a back ow preventer on the cold feed make-up water line.
5. Install a pressure reducing valve on the cold feed make-up water
line (15 psi nominal on the system return). This boiler has a maximum
working pressure of 160 psi. You may order a higher pressure relief
valve kit from the factory. Check temperature and pressure gauge
when operating. It should read a minimum pressure of 12 psi.
6. Install a circulator as shown in Applications (this manual). Make
sure the circulator is properly sized for the system and friction loss.
7. Install an expansion tank on the system supply. Consult the
expansion tank manufacturer’s instruction manual (see Part 4,
Section D for water volume) for specic information relating to
expansion tank installation. Size the expansion tank for the required
system volume and capacity.
8. Install an air elimination device on the system supply.
9. Install a drain valve at the lowest point of the system. Note: The
boiler cannot be drained completely of water without purging the
unit with an air pressure of 15 PSI.
10. The relief valve and temperature and pressure gauge are included
in the accessory kit. A discharge line should be installed 6” above the
drain in the event of a pressure relief. The pipe size must be the same
size as the relief valve outlet. NEVER BLOCK THE OUTLET OF THE
SAFETY RELIEF VALVE.