Installation Pocket Guide

BEFORE INSTALLING . . .
Make sure there is enough clearance for the boiler and all •
water, gas and air piping. Verify vent/air termination can
be located as required.
All models are shipped with the items needed for propane •
conversion except the Ultra-80, which requires a separate
conversion kit (see material checklist).
When wall mounting the boiler, obtain the wall-mount kit •
(see material checklist).
START-UP, ADJUST & TEST
Follow the boiler manual instructions to clean the system •
if needed, then ll and check water chemistry.
Start up the boiler as directed in the manual. Use a •
combustion analyzer where specied.
88
INSTALL CONDENSATE PIPING /
TUBING AND COMPONENTS
Fill out the material checklist in this guide to ensure you •
have the tubing or PVC pipe and all components you will
need for the condensate piping.
Connection tee and internal components are supplied •
with the boiler.
44
INSTALL GAS PIPING
Install a union and shuto valve.•
No external drip leg is needed — it is already included in •
the boiler’s internal gas piping.
55
66
WIRE THE BOILER
Connect power wiring and control wiring per boiler •
manual wiring diagram.
Connect system and DHW circulator wiring to the •
terminals designated in the boiler manual.
INSTALL VENT & AIR PIPING
See vent / air piping options at left. •
Refer to the material checklist in this guide for a list of •
items needed.
INSTALL WATER PIPING
See information at right.•
Refer to the material checklist in this guide for a list of •
items needed.
Steps 2 – 6 can be done in any order —
just make sure that air, vent, water and gas
pipes will not interfere with one another.
77
Choose pre-loaded boiler settings, or customize settings •
for various applications.
22
33
(Follow all instructions in Boiler manual)
QUICK-STARTQUICK-START
VENT & AIR PIPING
(see boiler manual for details)
Slide the air inlet pipe and vent pipe into the boiler top
openings. Just tighten the restraining rings — no messy sealants
required. Reducers or adapters are required when the vent / air
pipe O. D. is dierent from the boiler connection diameter (see
below). All AL29-4C stainless pipe applications require adapters
made by the vent pipe manufacturer. See the material checklist
for items required.
Ultra boilers can be sidewall vented or vertically vented as shown
in the ve options below and in the manual. Choose either direct
vent (D. V. — requires air pipe for combustion air) or direct exhaust
(D. E. — uses inside air) as shown.
Make sure the terminations are placed as required in the
manual and that air intakes are at least 12 inches above normal
snow line.
Vertical D. V.
Concentric Pipes
termination
Requires kit
Vertical
Direct Exhaust (no air pipe)
–or–
Vertical Direct Vent with
Separate Pipes
termination
Requires bird screen(s)
Sidewall D. V.
with Weil-McLain
termination
Included with boiler
Sidewall Direct Exhaust (no air pipe) –or–
Sidewall Direct Vent with Separate Pipes
termination
Requires bird screen(s)
Sidewall D. V. with
Concentric Pipes
termination
Requires kit
33
Support pipes as
described in the
manual.
Vent / air pipe size options (PVC sizes):
Ultra-80, 105: 2" or 3”
Ultra-155: 3"
Ultra-230: 3" or 4”
Ultra-299, 399: 4”
Slope pipes ¼” per
foot toward boiler.
Direct Exhaust
Direct Vent
INSTALLING THE
PRIMARY/SECONDARY TEES
The near-boiler piping must be
primary/secondary as shown above
and left, with the boiler loop piping
entering the tees in the branch
connection.
DO NOT connect boiler piping to the
tee through connections as shown
at right. The system will not work
correctly this way.
The circulator supplied with the boiler (a) must be
used only in the boiler secondary loop as shown in the
schematic above and in the manual. System (
b) and zone
circulators and DHW circulator (
c) must be supplied by
the installer. Above right is a typical installation, showing
the near-boiler piping and connection to the system.
Boiler loop piping must be sized to the minimums
listed in the boiler manual. Using smaller piping will
cause performance problems.
Ultra-80 / Ultra-105• . . . . . use 1” or larger
Ultra-155 / Ultra-230• . . . . . use 1¼” or larger
Ultra-299 / Ultra-399• . . . . . use 1½” or larger
WATER PIPING
(see boiler manual for details)
22
WRONG
RIGHT
DHW
DHW
System
Sensor
Sensor
Gas
System
Typical piping, zone-valve zoning
Do not exceed
12 inches apart
Optional
Easy-Up Manifolds:
1¼” (W-M #383-500-649)
1½”
(W-M #383-500-661)
Do not exceed
12 inches apart
b
a
c
a
b
c