Install Instructions

ManualsBrandsWebstone ManualsHeating Specialties1-1/4" IPS Complete Near Boiler Manifold & Piping Kit

Thank you for choosing Hydro-Core. This valve kit was designed to facilitate installation

and regular maintenance of your boiler. It was not designed for installations exposed to subfreezing

conditions. Drain valves should remain closed during normal operation. Do 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.

IMPORTANT: Follow all federal/national, state and local codes when installing or performing work on

systems. All parts are covered by a lifetime warranty against manufacturing defects provided they

are installed by a licensed plumber and operated under normal working conditions. Disassembling

parts other than the unions, strainer and handle will void this warranty. If you have any questions or

comments, please contact us at (800) 225-9529 or visit us on the web - www.webstonevalves.com.

INSTALLATION

Hydro-Core Flex Introduction ................... 2

Complete Kits, Boilers with

Internal Circulator Pumps ........................ 3

Complete Kits, Boilers with

External Circulator Pumps .................. 4–5

Near Boiler Component Kits ................ 6–7

Manifold-Only Kits .................................. 8

Parts and Accessories ............................ 8

SERVICING

Secondary System Purging ...................... 9

Filling/Power Purging ............................ 10

Strainer Servicing ................................ 11

Boiler Heat Exchanger

Descaling/Cleaning ............................. 12

Kits with two rigid

copper supply lines

Kits with one

rigid copper & one

Hydro-Core Flex line

Kits with two

Hydro-Core

Flex lines

NEAR BOILER

COMPONENT

KITS

Kits not including

pre-fabricated

supply lines

Kits with Manifold

and Union

Connection only

Identify Your Kit

BOILERS WITH EXTERNAL CIRCULATOR PUMPS . . . . . . . . . . . . . . . . . . . . . . PAGES 4–5

BOILERS WITH EXTERNAL CIRCULATOR PUMPS . . . . . . . . . . . . . . . . . . . . . . PAGES 6–7

ALL BOILER STYLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 8

BOILERS WITH INTERNAL CIRCULATOR PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 3

4CC4-080

4CC4-105

4CC4-150

4CC4-210

4CC4-WHN

IPS SYSTEM PIPING

4CF4-FS184

4CF4-WH154

4CF4-WH1R44

4CF4-WH1R54

4CF4L-FT144

4CF4L-WH144

4CF4R-FT144

4CF4R-WH144

4CF5-F2R45

4CF5-FS185

4CF5-FT245

4CF5-WH255

4CF5L-WH245

4CF5R-WH245

IPS SYSTEM PIPING

4FK3-WIF

4FK3-WIF-18

4FK3-WIS

4FK3-WIS-18

4FK4-WIF

4FK4-WIF-18

4FK5-CH

IPS SYSTEM PIPING

48754-FS144

48754-FS184

48754-FT144

48754-FT344

48754-WH144

48754-WH154

48754-WH1R44

48754-WH1R54

48765-FS145

48765-FS185

48765-FS245

48765-FS345

48765-FT245

48765-FT2R45

48765-WH245

48765-WH255

48765-WH345

48854-FT144

48854-WH144

48865-WH245

IPS SYSTEM PIPING

48354-43

48354-44

48754-43

48754-44

48755-45

48764-44

48765-45

48766-56

48854-44

48855-45

48864-44

48865-45

IPS SYSTEM PIPING

5CC4-080

5CC4-105

5CC4-150

5CC4-210

5CC4-WHN

SWT SYSTEM PIPING

5CF4-FS184

5CF4-WH154

5CF4-WH1R44

5CF4-WH1R54

5CF4L-FT144

5CF4L-WH144

5CF4R-FT144

5CF4R-WH144

5CF5-F2R45

5CF5-FS185

5CF5-FT245

5CF5-WH255

5CF5L-WH245

5CF5R-WH245

SWT SYSTEM PIPING

5FK3-WIF

5FK3-WIF-18

5FK3-WIS

5FK3-WIS-18

5FK4-WIF

5FK4-WIF-18

5FK5-CH

SWT SYSTEM PIPING

54754-FS144

58754-FS184

58754-FT144

58754-FT344

58754-WH144

58754-WH154

58754-WH1R44

58754-WH1R54

58765-FS145

58765-FS185

58765-FS245

58765-FS345

58765-FT245

58765-FT2R45

58765-WH245

58765-WH255

58765-WH345

58854-FT144

58854-WH144

58865-WH245

SWT SYSTEM PIPING

58354-43

58354-53

58354-54

58744-53

58744-54

58754-53

58754-54

58755-55

58764-54

58765-55

58766-56

58774-44

58775-45

58776-56

58854-54

58855-55

58864-54

58865-55

SWT SYSTEM PIPING

COMPLETE

NEAR BOILER

PIPING KITS

MANIFOLD

ONLY

Summary of content (12 pages)

PAGE 1
INSTALLATION Thank you for choosing Hydro-Core. This valve kit was designed to facilitate installation and regular maintenance of your boiler. It was not designed for installations exposed to subfreezing conditions. Drain valves should remain closed during normal operation. Do 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.
PAGE 2
Speciﬁcations & Preparing for Installation (not applicable to all kits) • Included in select Complete Near Boiler Piping Kits • Flexible Supply/Return lines designed to accommodate a wide variety of boiler installations • Tubing may be cut for installations in close quarters 3/4" Inner Diameter 0.83" Max Operating Temperature 212° Max Cold Working Pressure 176 PSI 1" 1.03" 212° 147 PSI Flex Pipe Conforms to NSF/ANSI 61, ASTM A 312/312M, IAMPO, IGC-233 1 1/4" 1.
PAGE 3
Complete Near Boiler Piping Kit Installations BOILERS WITH INTERNAL CIRCULATOR PUMPS COMPLETE NEAR BOILER PIPING KITS WARNING! • Both end connections of the flex piping are loosely assembled at the factory & MUST be properly tightened as part of product installation. Caution should be used when handling the flex piping with the end fittings removed due to potential for injury on a sharp edge.
PAGE 4
Complete Near Boiler Piping Kit Installations BOILERS WITH EXTERNAL CIRCULATOR PUMPS COMPLETE NEAR BOILER PIPING KITS 6. Align the Circulator Pump to the desired position ensuring that both gaskets are properly aligned. WARNING! • Both end connections of the flex piping are loosely assembled at the factory & MUST be properly tightened as part of product installation. Caution should be used when handling the flex piping with the end fittings removed due to potential for injury on a sharp edge.
PAGE 5
FOR FLOOR STANDING, SIDE MOUNT BOILERS FOR FLOOR STANDING, SIDE MOUNT BOILERS FOR FLOOR STANDING, TOP MOUNT BOILERS IPS System Piping SWT System Piping IPS System Piping SWT System Piping IPS System Piping SWT System Piping 4CC4-080 4CC4-105 4CC4-150 4CC4-210 5CC4-080 5CC4-105 5CC4-150 5CC4-210 4CF4-FS184 4CF5-FS185 5CF4-FS184 5CF5-FS185 4CF5-FT245 4CF5-FT2R45 4CF4R-FT144 5CF5-FT245 5CF5-FT2R45 5CF4R-FT144 A HYDROCORE MANIFOLD A Rotating Flange Ball Valve Connection HYDROCORE MANIFOLD A
PAGE 6
Near Boiler Component Kit Installations NEAR BOILER COMPONENT KITS Before Installation • Circulator Pump sold separately (see boiler manufacturer for suitable models). Installation 8. Loosely connect the union nut, o-ring and fitting on the System Supply Piped Assembly to the Hydro-Core union ball valve connection. 1.
PAGE 7
FOR FLOOR STANDING, TOP MOUNT BOILERS FOR FLOOR STANDING, TOP MOUNT BOILERS FOR FLOOR STANDING, TOP MOUNT BOILERS IPS System Piping SWT System Piping IPS System Piping SWT System Piping IPS System Piping SWT System Piping 48754-FT144 48854-FT144 58754-FT144 58854-FT144 48765-FT245 48765-FT2R45 58765-FT245 58765-FT2R45 48754-FT344 58754-FT344 HYDROCORE MANIFOLD A HYDROCORE MANIFOLD A Rotating Flange Ball Valve Connection Union Ball Valve Connection Rotating Flange Ball Valve Connection
PAGE 8
Manifold Only Installations MANIFOLD • Note: Not all installation steps applicable to all Manifold styles. Installation 1. Remove the o-ring from the Hydro-Core End(s) 2. Connect the Hydro-Core End (s) A and save for reinstallation. HYDROCORE MANIFOLD to branch tubing. 3. Loosely connect the Circulator to the Hydro-Core flanged ball valve connection. IMPORTANT: The Circulator should pump into the boiler, if applicable. 4.
PAGE 9
Secondary System Purging Typically boiler manufacturers want to make sure that any foreign matter (dirt, shavings, PTFE thread tape, etc.) is flushed out of the Hydronic Piping System before fluid begins to flow between the boiler and the piping system. To purge the secondary system the following is needed: • A hose w/ 3⁄4" hose thread connection • A water source • Power to the circulator pump in the secondary loop 1.
PAGE 10
Filling/Power Purging The Hydro-Core and associated NBP offers several beneficial features for a system’s startup and future maintenance. At 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.
PAGE 11
Strainer Servicing RETURN SUPPLY 1. Turn the lever handles on both Hydro-Core ball valves so that they are parallel to the flange. The T-Flow handle logo indicates the flow pattern inside the valve. The logo should indicate that flow 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 flange).
PAGE 12
Boiler Heat Exchanger Descaling/Cleaning To Descale/Clean the boiler the following is needed: • Boiler Manufacturer Maintenance Instructions Should there be a discrepancy or conflict with these instructions, follow the Boiler Manufacturer’s instructions. • Descaling/cleaning solution • 2 hoses • Bucket • Ability to activate the NBP System Circulator RETURN SUPPLY RETURN OW OW T T CKE CKE BU BU 2. Remove both purging valve caps. 3.