Install Instructions

6
Before Installation
• Circulator Pump sold separately (see boiler manufacturer for suitable models).
Installation
1. Fabricate the System Return Piped Assembly:
Solder the Flanged Pump Connection and
Union Body Component to opposite ends of a length of
copper tubing sized appropriately for your boiler’s return line.
2. Remove the o-ring from the Hydro-Core End
and save for reinstallation.
3. Fabricate the System Supply Piped Assembly:
Solder the Hydro-Core End
and Union Body
Component to either ends of a length of copper
tubing sized appropriately for your boiler’s supply line.
4. Assemble the System Supply Union Connection
to
the system supply port.
5. Assemble the System Return Union Connection
to
the system return port.
6. Loosely connect the Circulator
to the
Hydro-Core  anged ball valve connection.
IMPORTANT: The Circulator should pump into the boiler.
7. Loosely connect the Circulator
 ange to the
 ange on the System Return Piped Assembly.
8. Loosely connect the union nut, o-ring and  tting on the
System Supply Piped Assembly to the
Hydro-Core union ball valve connection.
9. Connect the System Supply
and System Return Union
Connections to their respective piped assemblies.
10. Align the Circulator
into the desired position.
Ensure both pump gaskets are properly aligned.
11. Fully tighten the bolts to the two  anged connections.
12. Fully tighten the union nut to the Hydro-Core
union ball valve connection.
13. Fully tighten the union nuts to the union  ttings at the boiler.
14. Support the near boiler piping assembly
with hangers and clamps.
15. Connect the Hydro-Core Manifold
to
the remaining hydronic system.
16. Pressure test the system to ensure that all connections
are pressure tight. Caution should be used during all
pressure testing to avoid potential personal injury.
NEAR BOILER
COMPONENT KITS
Near Boiler Component Kit Installations
UNION
BODY
UNION
BODY
FLANGED PUMP
CONNECTION
HYDRO-CORE
END
Union Nut
Union Nut
Union Nut
BOILER
System Return Port /
Boiler Inlet
System Supply Port /
Boiler Outlet
Copper Tubing
Copper Tubing
Union Ball Valve
Connection
Rotating Flange
Ball Valve
Connection
UNION
CONNECTION
UNION
CONNECTION
CIRCULATOR
PUMP
HYDROCORE
MANIFOLD
D
A
H
G
E
F
I
J
UNION
BODY
UNION
BODY
FLANGED PUMP
CONNECTION
HYDRO-CORE
END
Union Nut
Union Nut
Union Nut
BOILER
Copper Tubing
Copper Tubing
Union Ball Valve
Connection
Rotating Flange
Ball Valve
Connection
UNION
CONNECTION
UNION
CONNECTION
CIRCULATOR
PUMP
HYDROCORE
MANIFOLD
D
A
H
G
E
F
I
J
System Return Port /
Boiler Inlet
System Supply Port /
Boiler Outlet
UNION
BODY
UNION
BODY
FLANGED PUMP
CONNECTION
HYDRO-CORE
END
Union Nut
Union Nut
Union Nut
BOILER
System Return Port /
Boiler Inlet
System Supply Port /
Boiler Outlet
Copper Tubing
Copper Tubing
Union Ball Valve
Connection
Rotating Flange
Ball Valve
Connection
UNION
CONNECTION
UNION
CONNECTION
CIRCULATOR
PUMP
HYDROCORE
MANIFOLD
D
A
H
G
E
F
I
J
FOR FLOOR STANDING,
SIDE MOUNT BOILERS
IPS System Piping SWT System Piping
48754-FS144
48754-FS184
48765-FS145
48765-FS185
54754-FS144
58754-FS184
58765-FS145
58765-FS185
FOR FLOOR STANDING,
SIDE MOUNT BOILERS
IPS System Piping SWT System Piping
48765-FS245 58765-FS245
FOR FLOOR STANDING,
SIDE MOUNT BOILERS
IPS System Piping SWT System Piping
48765-FS345 58765-FS345
Boilers shown for illustration purposes only.