lp-666 Rev. 003 Rel. 001 Date 2.25.20
19
NOTE: Boiler failure due to improper water chemistry is not
covered by warranty.
• Water pH between 6.5 and 8.5
• Hardness between 5 and 12 grains (71.3 and 205 mg/L)
• Chloride concentration less than 150 ppm (mg/L)
• Total Dissolved Solids (TDS) between 100 and 450 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-eciency 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.
*NOTE: It is recommended you clean heat exchanger at least once a
year to prevent lime scale buildup. Follow the maintenance procedure
to clean the heat exchanger in the Maintenance Section of this manual.
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.
H. Check / Control Water Chemistry
Piping Components
Heating System Piping
System piping MUST meet the technical pipe requirements listed in
Table 7. Reducing pipe size can restrict ow rate through the boiler,
causing inadvertent short cycling and poor system performance.
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.
Steel Flanges
Field supplied. Recommended for unit serviceability.
Pressure Relief Valve
Factory supplied on boiler. The pressure relief valve is sized to ASME
specications. Storage tank may require additional relief valves
depending on local codes.
I. Plumbing
This boiler should not be operated as a potable hot water heater. It
should not be used as a direct hot water heating device.
Basic steps are listed below that will guide the installation of the boiler.
1. Connect the system return marked “Inlet”.
2. Connect the system supply marked “Outlet”.
3. Install purge and balance valve or shut o valve and drain on 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). Check temperature and
pressure gauge when operating. It should read a minimum pressure
of 12 PSI.
6. Install a circulator as shown in piping details (this section). Make
sure the circulator is properly sized for the system and friction loss.
7. Install an expansion tank on the system supply. Consult the tank
manufacturer’s instructions for specic 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. The relief valve is installed at the factory. A pipe discharge line
should be installed to discharge 6” above the drain in the event of
pressure relief. The pipe size must be the same size as the relief valve
outlet. NEVER BLOCK THE OUTLET OF THE SAFETY RELIEF VALVE.
J. Fill and Purge Heating System
• Attach the hose to balance and purge hose connector or
drain valve and run hose to nearest drain.
• Close the other side of the balance and purge valve or the
shut o valve after the drain.
• Open rst zone balance and purge or drain valve to let
water ow out the hose. If zone valves are used, open the
valves one at a time manually. (NOTE: You should check the
valve manufacturer’s instructions prior to opening valves
manually, so as not to damage the valves.)
• Manually operate ll valve regulator. When water runs out
of the hose, you will see a steady stream of water (without
bubbles). Close balance and purge valve or drain to stop the
water from owing. Disconnect the hose and connect it to
next zone to be purged.
• Repeat this procedure for additional zones (one at a time).
For installation that incorporates standing iron radiation and
systems with manual vents at the high points, follow previous
section and, starting with the nearest manual air vent, open until
water ows out. Then close vent. Repeat procedure, working your
way toward the furthest air vent. It may be necessary to install
a basket or magnetic strainer in an older system where larger
amounts of sediment may be present. Annual cleaning of the
strainer may be necessary.
Table 7 - Minimum Pipe Size
Minimum Water Pipe Size
Model Size
400 - 1000 2” NPT
1500 - 2000 2 1/2” Flange
Upon completion, make sure that the ll valve is in the automatic
position and each zone balance and purge or shut o is in an open
position and zone valves are positioned for automatic operation.
K. Freeze Protection Fluids
Use only inhibited 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%.
1. Glycol in hydronic applications is specially formulated for this
purpose, and includes inhibitors that prevent the glycol from
attacking metallic system components. Make certain that the
system uid is checked for the correct glycol concentration and
inhibitor level.
2. The glycol solution should be tested at least once a year and as
recommended by the glycol manufacturer.
3. Anti-freeze solutions expand more than water. For example: A
50% by volume solution expands 4.8% in volume for a temperature
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