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III. Installation
A. Receiving the Boiler
The boiler is shipped from the factory with (4) shipping
feet/legs bolted to the skids. These are provided to
facilitate unloading/moving with a forklift. Lifting
points are also provided to enable over-head lifting
with spreader bars to prevent damage to the boiler.
The shipping feet/legs MUST BE REMOVED after
the boiler is set in-place on its concrete foundation
before any piping/electrical connections are made.
It is recommended that the plastic protective cover
be left on as long as possible to reduce finish damage
from the installation.
B. Boiler Water and Condensate Connections
Do not run any pipes along the tube access panel
side of the boiler. Maintain clearances as shown on
the dimensional drawing for servicing of the boiler
tubes. (See Figure 4 and Table 2). All piping should
be designed and installed to avoid any loadings on
the boiler connections or piping.
1. Flow Connection
a. The system supply and return flow connections
are shown on Figure 1. A gate valve should be
installed on the boiler outlet and inlet lines.
This allows the boiler to be isolated from the
heating system for draining and servicing.
2. Safety Relief Valve
a. Safety relief valve(s) are shipped loose.
Connections are provided in the top of the
boiler for the safety relief valve(s). The safety
relief valve discharge piping must be the
same size as the safety relief valve discharge
opening and run to a point of safe discharge.
No shutoff valves are to be placed between
the relief valve and the appliance or in the
discharge piping. Avoid over-tightening as
this can distort valve seats. All piping from the
safety relief valve(s) must be independently
supported with no weight carried by the
valve.
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Thermal Solutions, 1175 Manheim Pike, Lancaster, PA 17601 Website: www.thermalsolutions.com
Phone: 717-239-7642 Fax: 877-501-5212 Email: sales@thermalsolutions.com
NOTICE
NOTICE
If the relief valve discharges periodically, this may be
due to thermal expansion in a closed water supply
system. Contact the water supplier or local plumbing
inspector on how to correct this situation. DO NOT
PLUG THIS RELIEF VALVE.
b. The minimum relief valve setting for standard
systems shall be 30 psig. The system shall
operate with no less than 26 psig at all times.
c. For systems designed to operate at delta T's
greater than 40°F, the boiler shall be equipped
with a minimum relief valve setting of 60 psig.
The system shall operate with no less than
50 psig at all times. This will prevent boiler
water hammer.
3. Expansion Tank Connections
a. Connection(s) to an expansion tank are to
be provided by others in the system piping
separate from the boiler.
4. Drain Connections
a. A drain valve must be installed on the boiler
drain connection, the same pipe size as this
connection, to allow draining of the boiler.
5. Condensate Drain Connection
a. A condensate drain trap is shipped with
the boiler and is provided with a 1" npt
connection to drain the condensed products
of combustion from the boiler. Use Pipe with
continuous Teflon, high temperature silicone
tubing, or other tubing material compatible
with flue gas condensate. The condensate
temperature should never exceed 212° F and
the pH of the condensate should never have
a value lower than 3.5. NO VALVE is to be
installed in this line from the boiler to point
of discharge.
b. The condensate drain trap should be flushed
with water as part of your boiler maintenance
schedule to remove any debris that might
have accumulated over time.
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