Webstone Hydro-Core User manual

1
MANIFOLD
SYSTEM
PURGING VALVE
BOILER
EXPANSION
TANK
AIR
SEPARATOR
W/ROTATING
FLANGE & DRAIN
PRESSURE
REDUCING
VALVE
BACKFLOW
PREVENTER
SECONDARY SYSTEM
CIRCULATOR PUMP
UNION
CONNECTION
UNION
CONNECTION
BOILER LOOP
CIRCULATOR
PUMP SYSTEM RETURN
PIPED ASSEMBLY
SYSTEM SUPPLY
PIPED ASSEMBLY
D
A
C
B
E
F
System Return Port /
Boiler Inlet
System Supply Port /
Boiler Outlet
Union Ball Valve
Connection
Rotating Flange
Ball Valve
Connection
Rotating Flange
“Y” Strainer
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 [phone] or visit us on the web - www.webstonevalves.com.
INSTALLATION
Complete Near Boiler Piping Kit
Installations ........................................... 4
Near Boiler Component Kit
Installations ........................................ 2-3
System Overview .................................... 1
SERVICING
Filling/Power Purging .............................. 6
Boiler Heat Exchanger
Descaling/Cleaning ................................ 8
Secondary System Purging ...................... 5
Strainer Servicing ................................... 7
Typical System Overview
Floor standing, side mount boiler with Complete Near Boiler Piping Kit.
MANIFOLD
BOILER
BOILER LOOP
CIRCULATOR
PUMP
D
A
System Return Por t /
Boiler Inlet
System Supply Por t /
Boiler Outlet
Union Ball Valve
Connection
Rotating Flange
Ball Valve
Connection
UNION
BODY
UNION
BODY
FLANGED PUMP
CONNECTION
HYDRO-CORE
END
Copper Tubing
Copper Tubing
UNION
CONNECTION
UNION
CONNECTION
H
G
E
F
I
J
Floor standing, side
mount boiler with
Near Boiler Component Kit.

2
Near Boiler Component Kit Installations
Available for select boiler models only.
Requirements
• Webstone Hydro-Core™Manifold
• Webstone Near Boiler Component Kit, suitable to your particular boiler
• Circulator Pump (sold separately—see boiler manufacturer for suitable models)
Near Boiler Component Kit
The Near Boiler Component Kit is used to eld fabricate
the system supply and return piping that connects the
Hydro-Core to the boiler.
1. Fabricate the System Return Piped Assembly:
Solder the Flanged Pump Connection and
Union Body component to either 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.
UNION
BODY
UNION
BODY
FLANGED PUMP
CONNECTION
HYDRO-CORE
END
Union Nut
Union Nut
Union Nut
BOILER
System Return Por t /
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
Floor Standing /
Side Mount Kit 1
FS-144 / FS-184 / FS-145 / FS-185
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 Por t /
Boiler Inlet
System Supply Port /
Boiler Outlet
Floor Standing /
Side Mount Kit 2
FS-245
UNION
BODY
UNION
BODY
FLANGED PUMP
CONNECTION
HYDRO-CORE
END
Union Nut Union Nut
Union Nut
BOILER
System Return Por t /
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
Floor Standing /
Side Mount Kit 3
FS-345
Boilers shown for illustration purposes only.

3
UNION
BODY UNION
BODY
FLANGED PUMP
CONNECTION
HYDRO-CORE
END
Union Nut Union Nut
Union Nut
BOILER
System Return Por t /
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
EF
IJ
UNION
BODY
UNION
BODY
FLANGED PUMP
CONNECTION
HYDRO-CORE
END
Union NutUnion 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
EF
IJ
System Return Por t /
Boiler Inlet
System Supply Port /
Boiler Outlet
Wall Hung Kit 1
WH-144 / WH-154 / WH-1R44
Floor Standing /
Top Mount Kit 1
FT-144
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
EF
IJ
System Return Por t /
Boiler Inlet
System Supply Port /
Boiler Outlet
UNION
BODY
UNION
BODY
FLANGED PUMP
CONNECTION
HYDRO-CORE
END
Union NutUnion Nut
Union Nut
BOILER
System Return Por t /
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
EF
IJ
Wall Hung Kit 2
WH-245 / WH-255
Floor Standing /
Top Mount Kit 2
FT-245 / FT-2R45
UNION
BODY
UNION
BODY
FLANGED PUMP
CONNECTION
HYDRO-CORE
END
Union Nut
Union Nut
Union Nut
BOILER
System Return Por t /
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
F
E
I
J
UNION
BODY
UNION
BODY
FLANGED PUMP
CONNECTION
HYDRO-CORE
END
Union Nut Union Nut
Union Nut
BOILER
System Return Por t /
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
IJ
Wall Hung Kit 3
WH-345
Floor Standing /
Top Mount Kit 3
FT-344
Boilers shown for illustration purposes only.

4
UNION
CONNECTION
UNION
CONNECTION
Union Nut
Union Nut
Union Nut
Union Ball Valve
Connection
Rotating Flange
Ball Valve
Connection
BOILER
CIRCULATOR
PUMP
HYDROCORE
MANIFOLD
SYSTEM RETURN
PIPED ASSEMBLY
SYSTEM SUPPLY
PIPED ASSEMBLY
System Return Port /
Boiler Inlet
System Supply Port /
Boiler Outlet
D
A
C
B
E
F
Rotating Flange
“Y” Strainer
System Return
Union Connection
System Supply
Union Connection
Union Nut Union Nut
Union Nut
Union Ball
Valve Connection
Rotating Flange
Ball Valve
Connection
BOILER
System Return Port /
Boiler Inlet
System Supply Port /
Boiler Outlet
SYSTEM RETURN
PIPED ASSEMBLY
SYSTEM SUPPLY
PIPED ASSEMBLY
C
B
CIRCULATOR
PUMP
D
HYDROCORE
MANIFOLD
A
“Y” Strainer
Complete Near
Boiler Piping (NBP)
Kit Installations
Available for select boiler models only.
Requirements
• Webstone Hydro-Core™Manifold Flange
Right (487 Series / 587 Series)
• Webstone Complete NBP Kit, suitable to your
particular boiler (oor mount boiler shown)
• Circulator Pump (sold separately—see
boiler manufacturer for suitable models)
Webstone Complete NBP Kits are designed to
accommodate 6 1 ⁄2” long circulators.
Webstone Complete NBP
1. Ensure that the System Supply and
Return Union Connections are disassembled
from their respective piped assemblies.
2. Assemble the System Supply and System Return Union
Connections to their respective boiler ports.
Floor mount boilers: The system return union connection is
longer than the system supply union connection.
Wall Mount Boilers: Parts are interchangeable.
3. Loosely connect the Circulator to the
Hydro-Core anged ball valve connection.
IMPORTANT: The circulator should pump into the boiler.
4. Loosely connect the circulator ange to the ange
on the System Return Piped Assembly.
5. Loosely connect the union nut, o-ring and tting on the
System Supply Piped Assembly to the
Hydro-Core union ball valve connection.
6. Connect the System Supply and System Return
Union Connections to their respective piped assemblies.
7. Align the Circulator into the desired position.
Ensure both pump gaskets are properly aligned.
8. Fully tighten the bolts to the two anged connections.
9. Fully tighten the union nut to the Hydro-Core
union ball valve connection.
10. Fully tighten the union nuts to the union ttings at the boiler.
11. Support the NBP assembly with hangers and clamps.
12. Connect the Hydro-Core manifold to
the remaining hydronic system.
13. Pressure test the system to ensure that all
connections are pressure tight.
Boilers shown for illustration purposes only.

5
Secondary System Purging
Typically boiler manufacturers want to make sure that any foreign
matter (dirt, shavings, PTFE thread tape, etc.) is ushed out of the
Hydronic Piping System before uid begins to ow 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. Turn the lever handles on both Hydro-
Core ball valves so that they are
parallel to the ange and the main
valves are in the closed position.
This will prevent any debris from
entering the near boiler loop during
ushing. If multiple circuits are
present, repeat for each circuit.
8. Close the purging valve on the
drain in the secondary loop.
9. Remove the hose and replace the cap.
10. Open the main valve on the drain
valve in the secondary loop.
6. Turn on the circulator pump in the
secondary system to purge the
entire loop with fresh water.
7. Once the debris has been purged
out and the drainage from the hose
runs clear, turn off the circulator.
2. Close the main valve and
remove the cap from the drain
valve in the secondary loop.
3. Connect the hose to the
purging port on the drain valve
in the secondary loop.
4. Direct the other end of the
hose into a bucket or drain.
5. With the main water supply on
and owing into the system,
open the purging valve on the
drain in the secondary loop.
11. Return the lever handled ball
valves on the Hydro-Core manifold
to their normal operating position
(handles perpendicular to the
ange). Repeat for each circuit.

6
C
O
N
N
E
C
T
T
O
W
A
T
E
R
S
O
U
R
C
E
R
U
N
F
O
R
D
R
A
I
N
A
G
E
SUPPLYRETURN
F
L
O
W
F
L
O
W
SUPPLYRETURN
1. Turn the Lever Handles on both
Hydro-Core ball valves so that they
are parallel to the ange. The T-Flow
handle logo indicates the ow pattern
inside the valve. The logo should
indicate that ow can go through the
purging valve and both the supply
and return piped assemblies.
2. Remove both purging valve caps
3. Using a hose, connect a water source
to the system return purging valve
(located above the ange connection).
4. Connect a hose to the system
supply purging valve for drainage.
5. Turn the drain handles on both the
system return & system supply
purging valves into the open position
(drain handles parallel with the ange).
6. Turn on the water source and
allow water to ow into the
circulator from the hose.
7. Allow water to run until all excess
air has been purged from the boiler
and the water coming from the
drainage hose appears clear. If
needed, turn on the circulator pump
to force water through the system.
8. Once the air has been purged out
and the drainage runs clear, turn
off the circulator, close the two
purging valves, remove the hoses,
and replace the drain caps.
9. The boiler and NBP loop will now
be lled with clean fresh water. If a
glycol solution is preferred, see steps
2–14 on the next page and follow
the instructions for “Descaling the
Boiler Heat Exchanger” utilizing glycol
rather than a descaling solution.
10. Return the lever handled ball valves
to their normal operating position
(handles perpendicular to the ange).
Filling/Power Purging
The Hydro-Core and associated NBP offers several benecial 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.
To Power Purge and/or ll the boiler the following is needed:
• Two hoses w/ 3⁄4” hose thread connection
• A water source
• Power to the circulator pump in the NBP Loop
• 5 gallon bucket (for glycol lling only)

7
Strainer Servicing
SUPPLYRETURN
1. Turn the lever handles on both
Hydro-Core ball valves so that they
are parallel to the ange. The T-Flow
handle logo indicates the ow pattern
inside the valve. The logo should
indicate that ow 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
ange). Pressure release should
emit a small amount of uid.
5. Reinstall the plug, ensuring that it is
seated properly in the strainer cap.
3. Remove the strainer plug by
turning it counterclockwise.
4. Clean out the strainer.
6. Close the purging valve (drain handle
perpendicular to the ange).
7. Return the lever handled ball
valves to their normal operating
position (handles perpendicular to
the ange) and replace the cap.
8. Pressure test the system to
ensure that all connections
are pressure tight.

8
Boiler Heat Exchanger Descaling/Cleaning
To Descale/Clean the boiler the following is needed:
• Boiler Manufacturer Maintenance Instructions
Should there be a discrepancy or conict with these instructions, follow the Boiler Manufacturer’s instructions.
• Descaling/cleaning solution
• 2 hoses
• Bucket
• Ability to activate the NBP System Circulator
T
O
B
U
C
K
E
T
T
O
B
U
C
K
E
T
SUPPLYRETURN
F
L
O
W
F
L
O
W
SUPPLYRETURN
SUPPLYRETURN
C
O
N
N
E
C
T
T
O
W
A
T
E
R
S
O
U
R
C
E
T
O
B
U
C
K
E
T
1. Turn the lever handles on both
Hydro-Core ball valves so that they
are parallel to the ange. The T-Flow
handle logo indicates the ow pattern
inside the valve. The logo should
indicate that ow can go through the
purging valve and both the supply
and return piped assemblies.
2. Remove both purging valve caps.
3. Connect one of the hoses to the
system return purging valve (located
above the ange connection).
4. Connect the other hose to the
system supply purging valve.
5. Fill a 5 gallon bucket with the boiler
manufacturer’s recommended
cleaning/descaling solution.
6. Place the ends of both hoses
into bucket of solution.
7. Turn the drain handles on both the
system return & system supply
purging valves into the open position
(drain handles parallel with the ange).
8. Turn on the circulator pump in the
NBP Loop and allow the solution to
ow into and out of the NBP System.
9. See boiler manufacturer maintenance
instructions to determine when
system is sufciently cleaned.
10. When boiler is sufciently cleaned,
remove the hose connected to the
system return’s purging valve from
the bucket (system return is the
side with the ange connection).
11. Connect system return purging
valve hose to a water source.
12. Turn on the water source and allow
water to ow into the circulator to
purge the entire loop with fresh water.
If needed, turn on the circulator pump
to force water through the system.
13. Once the solution has been
purged out in the bucket and the
drainage from the hose on the
system supply purging valve runs
clear, turn off the circulator.
14. Close the two purging valves, remove
the hoses, and replace the caps.
15. The boiler and NBP loop will now
be lled with clean fresh water.
If a glycol solution is preferred,
repeat steps 2–14 above with glycol
rather than a descaling solution.
16. Return the lever handled ball valves
to their normal operating position
(handles perpendicular to the ange).
The Isolator®and Pro-Pal®are registered trademarks of Webstone Company, Inc.
© 2011 Webstone Company
HCM-0112