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#200) published by the Hydronics Institute in Berkeley Heights NJ. One of the primary purposes of this near boiler piping is to separate tiny water droplets from the steam exiting the boiler so that “dry” steam is sent to the system. If the near boiler piping is not correct, wet steam will enter the system and the following problems may occur: • Short cycling on low water • Boiler or system Flooding • Hammering • Failure to heat one or more radiators Avoid the three common piping mistakes shown in Figure 12. This applies even if the existing boiler has one of the piping mistakes shown in Figure 12 and appears to be working. If two or more steam mains must be connected to the boiler, connect a separate take-off for each main into the header between the riser(s) and equalizer. Also note the following points: 1) A size reduction must be made to connect the header to the equalizer. This reduction must be made in the equalizer line. Do not make this size reduction in the horizontal header. 2) One pipe steam systems require air vents on each radiator, as well as at the end of each main. For the system to work properly, these vents must be properly installed, sized, and be in good condition. Inspect and replace any defective vents. If there are no vents at the ends of the mains, install them. 3) Do not attempt to manifold multiple BSIs with gravity returns. 4) For installations with condensate or boiler feed pumps, follow the pump manufacturer’s piping instructions. Such systems generally do not require Hartford loops. 5) Do not use a check valve in place of, or in addition to, a Hartford loop on a gravity return system. 6) Pipe the fill connection from a clean source of cold water. When the water supply is from a well, make sure that a strainer is installed in the well system. 7) Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler in parallel with chiller. Use isolation valves to prevent chilled water from entering the boiler. 12 Piping Installation 1) Remove parts bag from boiler crate. 2) Install safety valve (spindle must be in vertical position) into tapping on boiler left side (see Figure 1) using the 3/4” NPT nipples and elbow supplied. 3) Pipe the discharge of the safety relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the safety valve discharge is not piped to a drain it must terminate at least 6 inches above the floor. The termination of the safety valve discharge piping must be in an area where it is not likely to become plugged by debris or subjected to freezing. DANGER • PIPE SAFETY VALVE DISCHARGE TO A SAFE LOCATION. • DO NOT INSTALL A VALVE IN THE SAFETY VALVE DISCHARGE LINE. • DO NOT MOVE SAFETY VALVE FROM FACTORY LOCATION. • DO NOT PLUG SAFETY VALVE DISCHARGE. • DO NOT INSTALL A SAFETY VALVE WITH A SETTING GREATER THAN 15 PSI. 4) Install drain valve into tapping on boiler left side using the 2 x 3/4 bushing provided (see Figure 1). 5) Connect system supply and return to boiler. See Figure 11. The BSI069 - BSI172 require only one supply riser. Two supply risers are required on the BSI207 and larger sizes. 6) Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler in parallel with chiller. Use isolation valves to prevent chilled water from entering the boiler. 13 WRONG- HEADER BULLHEADED INTO TAKE-OFF AND EQUALIZER WRONG - TAKE-OFF BULLHEADED INTO TWO MAINS WRONG -TAKE-OFF BETWEEN RISERS FIGURE 12: COMMON NEAR-BOILER PIPING MISTAKES FIGURE 11: STEAM BOILER PIPING FOR GRAVITY RETURN "A" "B" "C" "D" BSI069 * 2 1 1/2 1 1/4 BSI103 * 2 1 1/2 1 1/4 BSI138 * 2 1 1/2 1 1/4 BSI172 * 2 1 1/2 1 1/4 BSI207 2 3 1 1/2 1 1/4 BSI241 2 3 2 1 1/2 BSI276 2 3 2 1 1/2 BSI310 2 3 2 1 1/2 BSI345 2 3 2 1 1/2 BSI379 2 3 2 1 1/2 MINIMUM PIPE DIA. (IN NPT) BOILER MODEL * SECOND 2" SUPPLY RISER OPTIONAL BOILER FRONT WRONG- HEADER BULLHEADED INTO TAKE-OFF AND EQUALIZER WRONG - TAKE-OFF BULLHEADED INTO TWO MAINS WRONG -TAKE-OFF BETWEEN RISERS FIGURE 12: COMMON NEAR-BOILER PIPING MISTAKES FIGURE 11: STEAM BOILER PIPING FOR GRAVITY RETURN "A" "B" "C" "D" BSI069 * 2 1 1/2 1 1/4 BSI103 * 2 1 1/2 1 1/4 BSI138 * 2 1 1/2 1 1/4 BSI172 * 2 1 1/2 1 1/4 BSI207 2 3 1 1/2 1 1/4 BSI241 2 3 2 1 1/2 BSI276 2 3 2 1 1/2 BSI310 2 3 2 1 1/2 BSI345 2 3 2 1 1/2 BSI379 2 3 2 1 1/2 MINIMUM PIPE DIA. (IN NPT) BOILER MODEL * SECOND 2" SUPPLY RISER OPTIONAL BOILER FRONT 14 IX Indirect Water Heater Piping All BSI series boilers are equipped with tappings to permit the connection of a Crown Mega-Stor, or other indirect water heater. In this type of system, hot boiler water is drawn from below the water line and passed through the heat exchanger in the indirect water heater. This section describes boiler-side piping only. Refer to the indirect water heater instruction manual for domestic water piping. The components in this system and their fun...

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