Modular hydronic heating system core

A method for producing a modular pre-assembled, pre-fabricated, hydronic system core boiler board, the method comprising:

• providing a wall mountable substrate;
• disposing a hydronic fluid flow conduit on the substrate, the hydronic fluid flow conduit configured to convey a hydronic heat transfer fluid therethrough, and configuring the fluid flow conduit to include:
• a header with closely spaced tees, disposed in fluid communication with a distribution supply portion and with a distribution return portion, wherein the heat transfer fluid is configured to flow in a downstream direction from the header to the distribution supply portion, and from the distribution return portion to the header;
• the header forming a single fluid flow path between the closely spaced tees, wherein the distribution supply portion the distribution return portion are hydraulically independent of one another outside the header;
• a boiler supply port extending from the header in fluid communication with the distribution supply portion, and a boiler return port extending from the header in fluid communication with the distribution return portion, the boiler supply port and the boiler return port forming the closely spaced tees and configured for being disposed in fluid communication with a boiler;
• the distribution supply portion including a supply manifold communicably coupled to a plurality of parallel branch feeders, each of said parallel branch feeders configured for supporting a circulator pump or a zone valve in fluid communication therewith;
• at least one ECM (Electronically Commutated Motor) circulator pump disposed along the fluid flow conduit, the ECM circulator pump configured to pump the fluid through at least a portion of the fluid flow conduit;
• a Bluetooth transmitter communicably coupled to the at least one EMC circulator pump, the transmitter configured to capture and transmit flow rate and pressure of the fluid through the portion of the fluid flow conduit;
• the distribution return portion including a return manifold communicably coupled to a plurality of parallel branch returns, each of said parallel branch returns including a purge/shutoff valve;
• the parallel branch feeders and parallel branch returns configured for being disposed in fluid communication with a distribution system having heating elements;
• the distribution supply portion disposed in fluid communication with an air separator, a dirt separator, and an iron remover, respectively configured to remove air, dirt and iron from the fluid;
• an expansion tank bracket with gauge mount, disposed on the substrate and in fluid communication with the conduit and with a water feeder, the expansion tank bracket configured to support a pressure gauge and an expansion tank thereon, wherein the expansion tank is supportable by the expansion tank bracket in fluid communication with the conduit and with the pressure gauge;
• and
• communicably coupling a zone relay to the at least one ECM circulator pump and any zone valves supported by the parallel branch feeders, the zone relay including a plurality of thermostat terminals respectively configured for being communicably coupled to a plurality of thermostats, the zone relay configured to capture inputs from the plurality of thermostats to control operation of the at least one ECM circulator pump and any zone valves supported by the parallel branch feeders.