BOILERS WITH EXTERNAL CIRCULATOR PUMPS... PAGES 4 5 4CC CC CC Kits with two rigid copper supply lines

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Ralph Edwards
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1 Thank you for choosing ydro-ore. This valve kit was designed to facilitate installation and regular maintenance of your boiler. t was not designed for installations exposed to subfreezing conditions. rain valves should remain closed during normal operation. o not rely on the drain cap to stop the water from draining. When draining, always remove drain caps slowly to ensure that no pressure exists. MPORTNT: ollow all federal/national, state and local codes when installing or performing work on systems. ll parts are covered by a lifetime warranty against manufacturing defects provided they are installed by a licensed plumber and operated under normal working conditions. isassembling parts other than the unions, strainer and handle will void this warranty. f you have any questions or comments, please contact us at (800) or visit us on the web - dentify Your Kit NSTLLTON ydro-ore lex ntroduction... 2 omplete Kits, oilers with nternal irculator Pumps... 3 omplete Kits, oilers with xternal irculator Pumps Near oiler omponent Kits Manifold-Only Kits... 8 Parts and ccessories... 8 SRVN Secondary System Purging... 9 illing/power Purging Strainer Servicing oiler eat xchanger escaling/leaning S WT XTRNL S PS 4 5 PS SYSTM PPN SWT SYSTM PPN Kits with two rigid copper supply lines WN WN PS SYSTM PPN SWT SYSTM PPN OMPLT NR PPN KTS Kits with one rigid copper & one ydro-ore lex line 44-S W W1R44 44-W1R54 44L-T144 44L-W144 44R-T144 44R-W R45 45-S T W255 45L-W245 45R-W S W W1R44 54-W1R54 54L-T144 54L-W144 54R-T144 54R-W R45 55-S T W255 55L-W245 55R-W245 S WT NTRNL S P 3 Kits with two ydro-ore lex lines 4K3-W 4K3-W-18 4K3-WS 4K3-WS-18 PS SYSTM PPN 4K4-W 4K4-W-18 4K5-5K3-W 5K3-W-18 5K3-WS 5K3-WS-18 SWT SYSTM PPN 5K4-W 5K4-W-18 5K5- S WT XTRNL S PS 6 7 PS SYSTM PPN SWT SYSTM PPN NR OMPONNT KTS Kits not including pre-fabricated supply lines S S T T W W W1R W1R S S S S T T2R W W W T W W S S T T W W W1R W1R S S S S T T2R W W W T W W245 LL STYLS P 8 MNOL ONLY Kits with Manifold and Union only PS SYSTM PPN SWT SYSTM PPN

Specifications & Preparing for nstallation (not applicable to all kits) ncluded in select omplete Near oiler Piping Kits lexible Supply/Return lines designed to

26 Max Operating Temperature 212 212 212 Max old Working Pressure 176 PS 147 PS 110 PS lex Pipe onforms to NS/NS 61, STM 312/312M, MPO, -233 PTNTS PNN MPORTNT!

Replace the loosened nut and internal components as shown in the illustration to the right. Turn the nut clockwise two revolutions on the threads.

f done correctly, the tubing should be approximately one inch, or four to fi ve corrugations inside the fi tting. 3.

NUT SOLTON RN SLON RN TTN Tube Size (nch) 3/4" 1" 1 1/4" 4-5 ORRUTONS Torque Value (t.

owever, tubing may be cut to suit the needs of your specifi c installation if so desired. Retaining excess length will not effect the performance of the system.

Measure one inch of exposed pipe above the insulation. This is the cut point. 5. Using a metal tube cutter, cut the tube at the cut point.

2 Specifications & Preparing for nstallation (not applicable to all kits) ncluded in select omplete Near oiler Piping Kits lexible Supply/Return lines designed to accommodate a wide variety of boiler installations Tubing may be cut for installations in close quarters 3/4" 1" 1 1/4" nner iameter 0.83" 1.03" 1.26 Max Operating Temperature Max old Working Pressure 176 PS 147 PS 110 PS lex Pipe onforms to NS/NS 61, STM 312/312M, MPO, -233 PTNTS PNN MPORTNT! Tighten nd s 1. Remove the nut and check that the fi tting internal components are in place (silicone ring and isolation ring). 2. Replace the loosened nut and internal components as shown in the illustration to the right. Turn the nut clockwise two revolutions on the threads. efore tightening the nut, insert the tubing completely in the fi tting to the tubing stop until it meets the internal wall. f done correctly, the tubing should be approximately one inch, or four to fi ve corrugations inside the fi tting. 3. old the fi tting on the pipe and tighten the nut onto the fi tting using the appropriate torque as shown in the table below. NUT SOLTON RN SLON RN TTN Tube Size (nch) 3/4" 1" 1 1/4" 4-5 ORRUTONS Torque Value (t./lb) To ut Tubing (f esired) The amount of ydro-ore lex Piping provided is suitable for wide range of boilers. owever, tubing may be cut to suit the needs of your specifi c installation if so desired. Retaining excess length will not effect the performance of the system. 1. Remove end connections. 2. Measure the desired pipe length and mark this point on the insulation. 3. Remove the insulation beyond this mark O NOT UT T TUN. 4. Measure one inch of exposed pipe above the insulation. This is the cut point. 5. Using a metal tube cutter, cut the tube at the cut point. ut MUST be centered in a valley between corrugations. 6. nsert tube into the fi tting, then tighten end connections. Warning: To avoid crimping the pipe, O NOT use excess force. RMOV 1" NSULTON UT MUST NTR N ONVOLUTON ut must be a clean cut. rough cut with irregular edges can perforate the silicone ring and cause leakage. aution should be used when handling the flex piping with the end fittings removed due to potential for injury on a sharp edge. 2

3 OMPLT NR PPN KTS omplete Near oiler Piping Kit nstallations S WT NTRNL S WRNN! oth end connections of the flex piping are loosely assembled at the factory & MUST be properly tightened as part of product installation. aution should be used when handling the flex piping with the end fittings removed due to potential for injury on a sharp edge. efore nstallation Review boiler manufacturers installation literature for any required/recommended clearances for manifold installation. nstallation 1. stablish the as installed location of the ydro-ore Manifold. 2. end the System Supply Piped ssembly and System Return Piped ssembly to the desired path using the maximum radius possible to minimize the frictional losses. 3. djust the System Supply Piped ssembly and System Return Piped ssembly length as desired per the instructions provided on page 2 making sure to include the length of piping installed into the fi ttings on both ends. 4. Tighten the end connection on both ends of each fl ex pipe & per the instructions provided on page Loosely assemble the System Supply Piped ssembly and System Return Piped ssembly to the respective boiler ports. 6. onnect the union nut of the System Supply Piped ssembly and System Return Piped ssembly to the respective ydro-ore Manifold ports and fully tighten. 7. Support the near boiler piping assembly with hangers and clamps. 8. onnect the ydro-ore Manifold to the remaining hydronic system. 9. ully tighten the System Supply Piped ssembly and System Return Piped ssembly fi ttings at the boiler. 10. ombi oiler Kits (4K5-/ 5K5-): Remove side pipe plug from System Supply Piped ssembly and screw the 30 PS pressure relief valve into the threaded port. The discharge line from the PRV should pitch downward and terminate 6" above drains where discharge will be clearly visible. The discharge end of the line shall be plain (unthreaded) and a minimum of 3/4" in diameter. The discharge line material must be suitable for water at least 180 ahrenheit. The discharge line shall be as short and straight as possible such that the arrangement does not reduce the relieving capacity of the pressure relief valve. No valve of any type may be installed in the discharge line of the pressure relief valve. See included solator XP/2/3 directions for omestic Water installation and servicing directions. 11. Pressure test the system to ensure that all connections are pressure tight. aution should be used during all pressure testing to avoid potential personal injury. OR WLL UN S WT NTRNL S OR WLL UN S WT NTRNL S OR SLT OM S 4K3-W 4K4-W 4K3-WS 5K3-W 5K4-W 5K3-WS 4K3-W-18 4K4-W-18 4K3-WS-18 5K3-W-18 5K4-W-18 5K3-WS-18 4K5-5K5- System Supply Port / oiler Outlet omestic Water / ot Outlet omestic Water / old nlet SYSTM SUPPLY SYSTM RTURN Pressure Relief Valve (150 PS) SYSTM SUPPLY SYSTM SUPPLY SYSTM RTURN SYSTM RTURN Pressure Relief Valve (30 PS) Pressure auge MNOL MNOL MNOL oilers shown for illustration purposes only. 3

4 OMPLT NR PPN KTS WRNN! oth end connections of the fl ex piping are loosely assembled at the factory & MUST be properly tightened as part of product installation. aution should be used when handling the fl ex piping with the end fi ttings removed due to potential for injury on a sharp edge. efore nstallation The irculator Pump is sold separately (see the boiler manufacturer for recommendation on suitable models). The ydro-ore kits are designed to accommodate a 6 1/2" long circulator pump. Review boiler manufacturers installation literature for any required/recommended clearances for manifold installation. nstallation omplete Near oiler Piping Kit nstallations S WT XTRNL S 1. isassembled the System Supply and Return Supply Union s from their respective piped assemblies. 2. ssemble the System Supply and Return Supply Union s to their respective boiler ports. 3. Loosely connect the irculator Pump to the ydro-ore fl anged ball valve connection making sure the fl ange gaskets are properly located. MPORTNT: Verify the installation direction of the circulator pump, it should pump into the boiler. 4. Loosely connect the irculator Pump fl ange to the fl ange on the System Return Piped ssembly. 5. ollow the instructions for your installation type. OPPR/OPPR - Loosely connect the union nut on the System Supply Piped ssembly to the ydro-ore union ball valve connection. Loosely connect the System Supply Piped ssembly and System Return Piped ssembly Union to their respective union connections already connected to the boiler. OPPR/LX - Loosely connect the System Return Piped ssembly to the Return Supply Union already connected to the boiler. 6. lign the irculator Pump to the desired position ensuring that both gaskets are properly aligned. 7. ully tighten the bolts to the two-fl anged connections on the irculator Pump (ydro-ore and pipe sides). 8. ollow the instructions for your installation type. OPPR/OPPR - ully tighten the System Supply union nut to the ydro-ore union ball valve connection. ully tighten the union nuts of the System Supply and Return Supply Union. OPPR/LX - ully tighten the union nut of the Return Piped ssembly and System Return Union. 9. Support the near boiler piping assembly with hangers and clamps. 10. OPPR/LX NSTLLTON ONLY (OPPR/OPPR skip to step 11) end the fl ex line of the System Supply Piped ssembly to the desired path using the maximum radius possible to minimize the frictional losses. djust the fl ex pipe length as desired/required per the instructions provided on page 2 making sure to include the length of piping installed into the fi ttings on both ends. Tighten the fl ex pipe end connection on both ends per the instructions provided on page 2. onnect & fully tighten the System Supply Piped ssembly to the system supply Union at the boiler. onnect and fully tighten the union nut on the System Supply Piped ssembly to the ydro-ore union ball valve connection. 11. onnect the ydro-ore Manifold to the remaining hydronic system. 12. Pressure test the system to ensure that all connections are pressure tight. aution should be used during all pressure testing to avoid potential personal injury. OR WLL UN S OR WLL UN S 44-WN 54-WN 44L-W144 45L-W245 54L-W144 55L-W245 SYSTM RTURN SYSTM SUPPLY Union SYSTM SUPPLY Rotating lange MNOL SYSTM RTURN Rotating lange MNOL 4 oilers shown for illustration purposes only. oiler fi ttings may vary from illustration.

5 OR LOOR STNN, S MOUNT S OR LOOR STNN, S MOUNT S OR LOOR STNN, TOP MOUNT S S S S S T T2R45 44R-T T T2R45 54R-T144 MNOL MNOL MNOL SYSTM SUPPLY Y Strainer SYSTM RTURN SYSTM SUPPLY Y Strainer SYSTM RTURN SYSTM SUPPLY Y Strainer SYSTM RTURN OR LOOR STNN, TOP MOUNT S 44L-T144 54L-T144 OR WLL UN S 44-W1R44 44R-W W W1R54 45R-W W1R44 54R-W W W1R54 55R-W245 OR WLL UN S 45-W W255 MNOL SYSTM SUPPLY Y Strainer SYSTM RTURN SYSTM RTURN SYSTM RTURN SYSTM SUPPLY SYSTM SUPPLY MNOL MNOL oilers shown for illustration purposes only. oiler fi ttings may vary from illustration. 5

6 NR OMPONNT KTS Near oiler omponent Kit nstallations efore nstallation irculator Pump sold separately (see boiler manufacturer for suitable models). nstallation 1. abricate the System Return Piped ssembly: Solder the langed Pump and Union ody omponent to opposite ends of a length of copper tubing sized appropriately for your boiler s return line. 2. Remove the o-ring from the ydro-ore nd and save for reinstallation. 3. abricate the System Supply Piped ssembly: Solder the ydro-ore nd and Union ody omponent to either ends of a length of copper tubing sized appropriately for your boiler s supply line. 4. ssemble the System Supply Union to the system supply port. 5. ssemble the System Return Union to the system return port. 6. Loosely connect the irculator to the ydro-ore fl anged ball valve connection. MPORTNT: The irculator should pump into the boiler. 7. Loosely connect the irculator fl ange to the fl ange on the System Return Piped ssembly. 8. Loosely connect the union nut, o-ring and fi tting on the System Supply Piped ssembly to the ydro-ore union ball valve connection. 9. onnect the System Supply and System Return Union s to their respective piped assemblies. 10. lign the irculator into the desired position. nsure both pump gaskets are properly aligned. 11. ully tighten the bolts to the two fl anged connections. 12. ully tighten the union nut to the ydro-ore union ball valve connection. 13. ully tighten the union nuts to the union fi ttings at the boiler. 14. Support the near boiler piping assembly with hangers and clamps. 15. onnect the ydro-ore Manifold to the remaining hydronic system. 16. Pressure test the system to ensure that all connections are pressure tight. aution should be used during all pressure testing to avoid potential personal injury. OR LOOR STNN, S MOUNT S OR LOOR STNN, S MOUNT S OR LOOR STNN, S MOUNT S S S S S S S S S S S S S345 MNOL MNOL MNOL YRO-OR N YRO-OR N YRO-OR N LN LN LN OY OY OY OY OY OY 6 oilers shown for illustration purposes only.

7 OR LOOR STNN, TOP MOUNT S OR LOOR STNN, TOP MOUNT S OR LOOR STNN, TOP MOUNT S T T T T T T2R T T2R T T344 MNOL MNOL MNOL YRO-OR N YRO-OR N YRO-OR N LN LN LN OY OY OY OY OY OY OR WLL UN S OR WLL UN S OR WLL UN S W W W W1R W1R W W W W1R W1R W W W W W W W W345 OY OY OY LN OY OY LN OY LN YRO-OR N YRO-OR N YRO-OR N MNOL MNOL MNOL oilers shown for illustration purposes only. 7

8 MNOL Manifold Only nstallations Note: Not all installation steps applicable to all Manifold styles. nstallation 1. Remove the o-ring from the ydro-ore nd(s) and save for reinstallation. MNOL 2. onnect the ydro-ore nd (s) to branch tubing. 3. Loosely connect the irculator to the ydro-ore fl anged ball valve connection. MPORTNT: The irculator should pump into the boiler, if applicable. 4. Loosely connect the ydro-ore nd(s) union nut, o-ring and fi tting to the ydro-ore union ball valve connection. 5. lign the irculator into the desired position. nsure both pump gaskets are properly aligned. 6. ully tighten the bolts to the fl anged connection. ranch Tubing YRO-OR N 7. ully tighten the union nut to the ydro-ore union ball valve connection. 8. Support the piping assembly with hangers and clamps. 9. onnect the ydro-ore Manifold to the remaining hydronic system. 10. Pressure test the system to ensure that all connections are pressure tight. aution should be used during all pressure testing to avoid potential personal injury. Parts and ccessories nterested in upgrading your Manifold Kit to a omplete or omponent kit? Or do you have an unusual set of system requirements or a particularly unique area to work within? raft your own kit - all ydro-ore components are available for individual purchase. solution is available for any given need. See for a complete list of parts and accessories. MNOLS S UL SL PRSSUR U S S kpa psi 30 W W W. W S T O N V L V S. O M 8

9 Secondary System Purging Typically boiler manufacturers want to make sure that any foreign matter (dirt, shavings, PT thread tape, etc.) is fl ushed out of the ydronic Piping System before fl uid begins to fl ow between the boiler and the piping system. To purge the secondary system the following is needed: hose w/ 3 4" hose thread connection water source Power to the circulator pump in the secondary loop 1. Turn the lever handles on both ydro- ore ball valves so that they are parallel to the fl ange and the main valves are in the closed position. This will prevent any debris from entering the near boiler loop during fl ushing. f multiple circuits are present, repeat for each circuit. 2. lose the main valve and remove the cap from the drain valve in the secondary loop. 3. onnect the hose to the purging port on the drain valve in the secondary loop. 4. irect the other end of the hose into a bucket or drain. 5. With the main water supply on and fl owing into the system, open the purging valve on the drain in the secondary loop. 6. Turn on the circulator pump in the secondary system to purge the entire loop with fresh water. 7. Once the debris has been purged out and the drainage from the hose runs clear, turn off the circulator. 8. lose the purging valve on the drain in the secondary loop. 9. Remove the hose and replace the cap. 10. Open the main valve on the drain valve in the secondary loop. 11. Return the lever handled ball valves on the ydro-ore manifold to their normal operating position (handles perpendicular to the fl ange). Repeat for each circuit. 9

10 illing/power Purging The ydro-ore and associated NP offers several benefi cial features for a system s startup and future maintenance. t startup the boiler can be isolated from the remaining hydronic system and the trapped air in the boiler and associated piping can be power purged out. To Power Purge and/or fi ll the boiler the following is needed: Two hoses w/ 3 4" hose thread connection water source Power to the circulator pump in the NP Loop 5 gallon bucket (for glycol fi lling only) RTURN SUPPLY RTURN SUPPLY ONNT TO WTR SOUR RUN OR RN LOW LOW 1. Turn the Lever andles on both ydro-ore ball valves so that they are parallel to the fl ange. The T-low handle logo indicates the fl ow pattern inside the valve. The logo should indicate that fl ow can go through the purging valve and both the supply and return piped assemblies. 2. Remove both purging valve caps 3. Using a hose, connect a water source to the system return purging valve (located above the fl ange connection). 4. onnect a hose to the system supply purging valve for drainage. 5. Turn the drain handles on both the system return & system supply purging valves into the open position (drain handles parallel with the fl ange). 6. Turn on the water source and allow water to fl ow into the circulator from the hose. 7. llow water to run until all excess air has been purged from the boiler and the water coming from the drainage hose appears clear. f needed, turn on the circulator pump to force water through the system. 8. Once the air has been purged out and the drainage runs clear, turn off the circulator, close the two purging valves, remove the hoses, and replace the drain caps. 9. The boiler and NP loop will now be fi lled with clean fresh water. f a glycol solution is preferred, see steps 2 14 on the next page and follow the instructions for escaling the oiler eat xchanger utilizing glycol rather than a descaling solution Return the lever handled ball valves to their normal operating position (handles perpendicular to the fl ange).

11 Strainer Servicing RTURN SUPPLY 1. Turn the lever handles on both ydro-ore ball valves so that they are parallel to the fl ange. The T-low handle logo indicates the fl ow pattern inside the valve. The logo should indicate that fl ow can go through the purging valve and both the supply and return piped assemblies. 2. Release internal pressure by removing the system return purging valve cap and turning the drain handle on the system return purging valve into the open position (parallel with the fl ange). Pressure release should emit a small amount of fl uid. 3. Remove the strainer plug by turning it counterclockwise. 4. lean out the strainer. 5. Reinstall the plug, ensuring that it is seated properly in the strainer cap. 6. lose the purging valve (drain handle perpendicular to the fl ange). 7. Return the lever handled ball valves to their normal operating position (handles perpendicular to the fl ange) and replace the cap. 8. Pressure test the system to ensure that all connections are pressure tight. 11

12 oiler eat xchanger escaling/leaning To escale/lean the boiler the following is needed: oiler Manufacturer Maintenance nstructions Should there be a discrepancy or confl ict with these instructions, follow the oiler Manufacturer s instructions. escaling/cleaning solution 2 hoses ucket bility to activate the NP System irculator RTURN SUPPLY RTURN SUPPLY TO UKT TO UKT LOW LOW 1. Turn the lever handles on both ydro-ore ball valves so that they are parallel to the fl ange. The T-low handle logo indicates the fl ow pattern inside the valve. The logo should indicate that fl ow can go through the purging valve and both the supply and return piped assemblies. 2. Remove both purging valve caps. 3. onnect one of the hoses to the system return purging valve (located above the fl ange connection). 4. onnect the other hose to the system supply purging valve. 5. ill a 5 gallon bucket with the boiler manufacturer s recommended cleaning/descaling solution. 6. Place the ends of both hoses into bucket of solution. 7. Turn the drain handles on both the system return & system supply purging valves into the open position (drain handles parallel with the fl ange). 8. Turn on the circulator pump in the NP Loop and allow the solution to fl ow into and out of the NP System. 9. See boiler manufacturer maintenance instructions to determine when system is suffi ciently cleaned. 10. When boiler is suffi ciently cleaned, remove the hose connected to the system return s purging valve from the bucket (system return is the side with the fl ange connection). RTURN SUPPLY ONNT TO WTR SOUR TO UKT 11. onnect system return purging valve hose to a water source. 12. Turn on the water source and allow water to fl ow into the circulator to purge the entire loop with fresh water. f needed, turn on the circulator pump to force water through the system. 13. Once the solution has been purged out in the bucket and the drainage from the hose on the system supply purging valve runs clear, turn off the circulator lose the two purging valves, remove the hoses, and replace the caps. 15. The boiler and NP loop will now be fi lled with clean fresh water. f a glycol solution is preferred, repeat steps 2 14 above with glycol rather than a descaling solution. 16. Return the lever handled ball valves to their normal operating position (handles perpendicular to the fl ange). M-0514 The solator and Pro-Pal are registered trademarks of Webstone ompany, nc Webstone ompany

PATENTED TECHNOLOGY THE CORE OF ANY PROFESSIONAL HYDRONIC INSTALLATION

PATENTED TECHNOLOGY THE CORE OF ANY PROFESSIONAL HYDRONIC INSTALLATION On Off Combine a forged brass manifold and components to streamline boiler and secondary loop installations. Eliminates costly field