Lochinvar 500, 90 service manual Primary/Secondary Boiler Piping, 4Hydronic piping, Notice

Installation & Service Manual

4Hydronic piping

PUMP INSTALLATION AND MAINTENANCE: The boiler circulating pump must be purchased locally. For installation and maintenance information on the circulator pump, refer to the pump manufacturers instruction package included with the pump.

Primary/Secondary Boiler Piping

Heating boilers with inputs of 315,000 - 500,000 Btu/hr or

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 highest 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.

larger installed on multiple zone systems are recommended to be installed with a primary/secondary piping system as shown in FIG. 4-4. A primary/secondary piping system uses a dedicated pump to supply flow to the boiler only. This pump is sized based on desired boiler flow rate, heat exchanger head loss and head loss in the secondary system piping only. The secondary pump, installed in the boiler piping, ensures a constant water flow rate to the boiler for proper operation. Boiler installation with a primary/secondary piping system can prevent noise problems caused by low system water flows. A primary/secondary piping system is recommended on any boiler where low water flow conditions may present an operational problem.

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 noise on operation or short cycling of the burners. A larger secondary pump may be used on a primary/secondary system to provide an increased boiler flow rate. A glycol and water system may require from 10 to 20% more flow to compensate for the increased density of the glycol and its effect on the heat transfer process in the boiler. The exact increase 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 glycol and water fill for your boiler system.

￿CAUTION

NOTICE

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 low temperature bypass to prevent problems with condensation. A VAL3048 - 1 1/2” LTV Valve Kit may be used. Follow the piping diagram in FIG. 4-5 to complete installation.

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