Gas-fired water boilers – Series 3 Featuring ® Flexibility Boiler Manual • Installation • Maintenance • Startup • Parts Series 3 This manual must only be used by a qualified heating installer/service technician. Read all instructions, including this manual and all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
GAS-FIRED WATER BOILER Contents Hazard definitions. . . . . . . . . . . . . . . . . Ultra at-a-glance . . . . . . . . . . . . . . . . . Please read before proceeding . . . . . . . . . . Prepare boiler location . . . . . . . . . . . . . . Prepare boiler . . . . . . . . . . . . . . . . . . . Install water piping . . . . . . . . . . . . . . . . Install water piping — typical systems . . . . . . Using with Weil-McLain PLUS water heaters . . . Venting/air piping — general . . . . . . . . . . .
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GAS-FIRED WATER BOILER — Boiler Manual Please read before proceeding )NSTALLER— Read all instructions, including this manual and all other information shipped with the boiler, before installing. Perform steps in the order given. User — This manual is for use only by a qualified heating installer/service technician. Refer to User’s Information Manual for your reference. User — Have this boiler serviced/ inspected by a qualified service technician, at least annually.
GAS-FIRED WATER BOILER — Boiler Manual Installations must comply with: s Local, state, provincial, and national codes, laws, regulations and ordinances. s National Fuel Gas Code, ANSI Z223.1 – latest edition. s Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required. s National Electrical Code. s For Canada only: B149.1 or B149.2 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes. &IGURE "!3)# ).34!,,!4)/.
GAS-FIRED WATER BOILER — Boiler Manual Prepare boiler location (continued) Flooring and foundation Provide air openings to room Flooring Air openings — Ultra boiler alone in boiler room 1. The Ultra boiler is approved for installation on combustible flooring, but must never be installed on carpeting. Do not install boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death or substantial property damage. Foundation 1.
GAS-FIRED WATER BOILER — Boiler Manual Vent and air piping (page 16) 1. The Ultra boiler requires a special vent system, designed for pressurized venting. Ultra boilers are rated ANSI Z21.13 Category IV (pressurized vent, likely to condense in the vent). See instructions beginning on page 16. 2. You must also install air piping from outside to the boiler air intake adapter. The resultant installation is categorized as direct vent (sealed combustion).
GAS-FIRED WATER BOILER — Boiler Manual Prepare boiler (continued) $/ ./4 INSTALL A RELIEF VALVE WITH A PRESSURE HIGHER THAN 03)'. This is the maximum allowable relief &IGURE Hydrostatic test piping connections valve setting for the Ultra boiler. Perform hydrostatic pressure test Pressure test boiler before permanently attaching water or gas piping or electrical supply. Prepare boiler for test 1. See Figure 2 for reference in following steps. 2.
— Boiler Manual Install water piping Use two wrenches when tightening water piping at boiler, using one of the wrenches to prevent the boiler interior piping from turning. Failure to support the boiler piping connections to prevent them from turning could cause damage to boiler components. General piping information Additional controls, when required The U-Control module uses temperature sensors to provide both high limit protection and modulating temperature control.
GAS-FIRED WATER BOILER — Boiler Manual Install water piping (continued) System water piping methods Simplified pipe/circulator selection All piping methods shown in this manual use primary/ secondary connection to the boiler loop. These designs ensure proper flow through the Ultra boiler, for the most efficient and reliable operation of the boiler and the heating system. For other piping methods, consult your local Weil-McLain representative or see separate Ultra boiler piping guides.
GAS-FIRED WATER BOILER — Boiler Manual Expansion tank and make-up water &IGURE "!3)# ).34!,,!4)/. Install water piping (continued) Expansion tank piping 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Allow 3 gallons for boiler and its piping. 2. 3. 4. 5. Undersized expansion tanks cause system water to be lost from relief valve and make-up water to be added through fill valve. Eventual boiler failure can result due to excessive make-up water addition.
GAS-FIRED WATER BOILER — Boiler Manual Install water piping — typical systems Zoning with zone valves &IGURE Zone valve zoning plus optional DHW piping 1. Connect boiler to system as shown in Figure 5 when zone valve zoning. The primary/secondary piping shown ensures the boiler loop will have sufficient flow. It also avoids applying the high head of the boiler circulator to the zone valves. Also see the information on page 14 and page 15 for suggested piping and sizing. Use AT LEAST the -).
GAS-FIRED WATER BOILER — Boiler Manual Zoning with circulators &IGURE "!3)# ).34!,,!4)/. Install water piping — typical systems (continued) Circulator zoning plus optional DHW piping 1. Connect boiler to system as shown in Figure 6 when circulator zoning. The boiler circulator cannot be used for a zone. It must supply only the boiler loop. Also see the information on page 14 and page 15 for suggested piping and sizing. Use AT LEAST the -).
GAS-FIRED WATER BOILER — Boiler Manual Using with Weil-McLain PLUS LINE water heaters See !15! 0,53 - Product Manual for typical water piping. See ADVANCED INSTALLATION section for additional piping information and applications. PLUS DHW installation — quick-selection &IGURE The information in this section is for usage of Ultra boilers with Weil-McLain PLUS indirect water heaters.
— Boiler Manual Using with Weil-McLain PLUS LINE water heaters (cont.) See !15! 0,53 - Product Manual for typical water piping. &IGURE Ultra boiler with Ultra PLUS or PLUS-40, -60 or -80 water heater, zone valve zoning, typical piping 3YSTEM ZONE PIPE SIZING "OILER LOOP PIPE SIZE Ultra-80, 105 Ultr Ultra-155, 230 Ultr Ultra-299, 399 Ultr "ASEBOARD CONVECTOR OR CAST IRON RADIATORS /.
GAS-FIRED WATER BOILER — Boiler Manual Venting/air piping — general Do not install the Ultra boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage. Existing common vent systems may be too large for the appliances remaining connected after the existing boiler is removed.
— Boiler Manual Venting/air piping — general (continued) 5LTRA "OILERS MUST BE VENTED AND SUPPLIED WITH COMBUSTION AND VENTILATION AIR USING PIPING AND METHODS DESCRIBED IN THIS MANUAL. %VERY BOILER MUST HAVE ITS OWN VENT. $/ ./4 common vent with Combustion air piping 1. Combustion air must be piped from outside to the boiler, following the instructions in this manual, and compliant with all applicable codes.
GAS-FIRED WATER BOILER — Boiler Manual Sidewall vent/air termination: Weil-McLain cap Vent and air pipe termination options Vent and air pipe installation sequence 3TEP Install the boiler. 1. This section covers sidewall termination using the Weil-McLain sidewall vent cap kit supplied with each boiler. a. Models 80, 105 and 155 are shipped with a 3-inch pipe size kit. b. Models 230, 299 and 399 are shipped with a 4-inch pipe size kit. c.
— Boiler Manual Sidewall vent/air termination: Weil-McLain cap (continued) Provide pipe adapters as needed where pipe size is different from termination connections or boiler connections, and for all AL29-4C vent pipe connections at the boiler and the termination. 1. Install the termination as instructed in the following. Then proceed to page 22 to complete the air and vent piping between the termination and the boiler. Determine location for termination cap Allowable vent/air pipe materials 1.
GAS-FIRED WATER BOILER — Boiler Manual Sidewall vent/air termination: Weil-McLain plate (cont.) d. Avoid possibility of accidental contact of flue products with people or pets. e. Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards or other recessed areas. f. Do not terminate above any door or window or under a deck.
— Boiler Manual Sidewall vent/air termination: Weil-McLain plate (cont.) Install terminations — Weil-McLain vent/air cap &IGURE Hole preparation in wall — Weil-McLain vent/ air plate The inside and outside cover plates are stamped to identify the exhaust (vent) and intake (air) openings. Make sure to orient the plates correctly. 1. Locate termination opening and avoid obstructions: a. Use the template supplied with the termination kit. b.
GAS-FIRED WATER BOILER — Boiler Manual Install vent/air piping — boiler to W-M termination Complete termination preparation &IGURE Boiler vent and air connections 1. Install vent and air terminations before proceeding. See previous pages for instructions. Installing vent and air piping 1. For reference in the following, see previous pages. 2. Work from the boiler to vent or air termination. Do not exceed the lengths given in the previous pages for either the air or vent piping. a.
GAS-FIRED WATER BOILER — Boiler Manual Prepare condensate fittings "!3)# ).34!,,!4)/. Install condensate line &IGURE Condensate trap assembly 1. Remove PVC fittings and gasket from the accessories bag. 2. Deburr and chamfer outside and inside of ½” x 1¼” PVC nipple to ensure even cement distribution when joining. 3. Clean nipple ends and all fittings. Dry thoroughly. 4. For each joint in the condensate line, apply the following. Assemble parts ONLY in the order given. a.
GAS-FIRED WATER BOILER — Boiler Manual Install condensate line (continued) Condensate drain tubing &IGURE Condensate drain — Ultra-155 & -230 (PVC 1. Connect condensate drain tubing to the ½” PVC tee and run to floor drain or condensate pump (see Figure 30). Use ½” PVC or CPVC pipe; or 5/8” I.D. tubing. tee installation shown applies to all models)) Use materials approved by the authority having jurisdiction.
— Boiler Manual Gas piping Connecting gas supply piping 1. Remove jacket front panel and refer to Figure 31 to pipe gas to boiler. a. Install ground joint union for servicing, when required. b. Install manual shutoff valve in gas supply piping outside boiler jacket when required by local codes or utility requirements. c. In Canada — When using manual main shutoff valve, it must be identified by the installer. 2. Wall-mounted boilers a. Refer to separate Ultra Boiler Wall-mounting instructions. b.
GAS-FIRED WATER BOILER — Boiler Manual Field wiring — basic system %,%#42)#!, 3(/#+ (!:!2$ — For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. If original wiring as supplied with boiler must be replaced, use only type 105 °C wire or equivalent.
GAS-FIRED WATER BOILER — Boiler Manual "!3)# ).34!,,!4)/. Field wiring — basic system (continued) &IGURE Simplified wiring — basic system with DHW and space heating (see ADVANCED section for more information) Locate the sensors on the system piping as shown in Figure 4, page 11 and other piping drawings throughout this manual. Wire the DHW tank aquastat to the U-Control “heat demand 1” input, terminals P11 #4 and #5.
GAS-FIRED WATER BOILER — Boiler Manual U-Control operation and setup 4EMPERATURE SETTINGS — You must ensure that the U- Control is set for the proper water temperatures for the system. Excessive water temperature can cause significant property damage in some applications. -ULTI TEMPERATURE SYSTEMS — If the heating system includes circuits that require lower temperature water (radiant slab circuits, for example) as well as higher temperature circuits (DHW, finned tube baseboard, etc.
— Boiler Manual U-Control operation and setup (continued) 1 — Screen color (Blue = space heating or when a button is pressed) (Screen will show solid red, with the exclamation mark symbol, if a non-shutdown failure occurs; i.e., failure of a non-critical sensor, such as outdoor or system supply or return sensor.) H H : M M A M M M / D D / Y Y Time and date NO BACKLIGHT &IGURE U-Control display and navigation H H : M M A M MODULATION (Pressing any button changes background to blue, below.
GAS-FIRED WATER BOILER — Boiler Manual U-Control operation and setup (continued) &OR DETAILED CONTROL INFORMATION AND ADDITIONAL WIRING, see the AD- VANCED INSTALLATION section of this manual. ,OW TEMPERATURE SYSTEMS (radiant slab, etc.) — $/ ./4 use the Ultra boiler control as the only means of water temperature regulation for low-temperature systems if higher-temperature systems are also supplied. EXPRESS SETUP — using default settings 1.
— Boiler Manual Startup — fill the system Clean system to remove sediment Antifreeze 1. You must thoroughly flush the system (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by buildup or corrosion due to sediment. 2. For zoned systems, flush each zone separately through a purge valve. (If purge valves and isolation valves are not already installed, install them to properly clean the system.) 3.
GAS-FIRED WATER BOILER — Boiler Manual Startup — fill the system (continued) Freeze protection (when used) Follow these guidelines to prevent possibility of severe personal injury, death or substantial property damage: .%6%2 USE AUTOMOTIVE OR STANDARD GLYCOL ANTIFREEZE, EVEN GLYCOL MADE FOR HYDRONIC SYSTEMS . Use only freeze-prevention fluids recommended by Weil-McLain for application in Ultra Boiler systems. 4HOROUGHLY mUSH ANY SYSTEM THAT HAS USED GLYCOL before installing the new Ultra boiler.
— Boiler Manual Startup — final checks Inspect/fill condensate system Check for gas leaks Before starting the boiler, and during initial operation, use a leak detector or smell near the floor and around the boiler for gas odorant or any unusual odor. Remove boiler front door and smell interior of boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Repair any leak at once. DO NOT adjust or attempt to measure gas valve outlet pressure.
GAS-FIRED WATER BOILER — Boiler Manual Startup — final checks (continued) Venting system must be sealed gas-tight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death. To start the boiler 1. Turn OFF the boiler ON/OFF switch. 2. Read and follow the Operating Instructions, Figure 36, page 35. 3. The U-Control display will show installed sensors when first powered. Make sure the right sensors are detected.
GAS-FIRED WATER BOILER — Boiler Manual "!3)# ).34!,,!4)/. Startup — final checks (continued) &IGURE Operating instructions (WARNING — Verify that the U-Control is set for the correct boiler model before proceeding.
GAS-FIRED WATER BOILER — Boiler Manual Startup — final checks (continued) ❏ 1. 2. 3. 4. 5. 6. Check flame & combustion with instruments For Ultra-399 propane boilers, special start-up is required. See page 37 for procedure. See DANGER on page 45 before proceeding. Initiate a call for heat on one of the heat demand inputs. Access the U-Control installer menus by pressing and holding the UP and DOWN arrow keys for five seconds.
— Boiler Manual Startup — final checks (continued) grommet into the flue pipe, then insert the probe into the rubber grommet. &IGURE -ODEL 4HROTTLE SCREW LOCATION /.,9 FOR USE BY A QUALIlED TECHNICIAN USING CALIBRATED COMBUSTION TEST INSTRUMENTS You must replace the flue gas temperature sensor to prevent flue gas spillage into the boiler enclosure. Failure to comply could result in severe personal injury, death or substantial property damage.
GAS-FIRED WATER BOILER — Boiler Manual Check-out/startup verification ❏ Verified that the U-Control is set for the correct boiler model? ❏ Entered installation date and installer contact information tested for operation as outlined by manufacturer? (Boiler should be operating and should go off when controls are tested. Verify controls cause automatic reset lockout or manual reset lockout as desired.
GAS-FIRED WATER BOILER 0AGES n READ AND FOLLOW INSTRUCTIONS IN THE BASIC INSTALLATION SECTION FIRST. This section is supplemental information only. This section covers multiple boiler systems and system types not covered under the BASIC section. It also includes alternative vent/air piping methods, water and gas pipe sizing guidelines and advanced, detailed information on the U-Control and boiler wiring. Part number 550-100-090/1113 !$6!.#%$ ).34!,,!4)/. Quick view . . .
GAS-FIRED WATER BOILER The — Boiler Manual Gas-fired water boiler, Featuring Models 80, 105, 155 and 230 1. Cast aluminum heat exchanger 2. Heat exchanger access cover 3. Blower The advanced blower design and air inlet silencer on Ultra boilers result in very quiet operation. Models Ultra-80 & 105 — Air enters the boiler enclosure through the air intake adapter (18), flows through the enclosure, enters the air inlet silencer (5), then enters the blower.
GAS-FIRED WATER BOILER Gas-fired water boiler, Featuring Flexibility !$6!.#%$ ).34!,,!4)/.
GAS-FIRED WATER BOILER The — Boiler Manual Gas-fired water boiler, Featuring Models 299 and 399 1. Cast aluminum heat exchanger 2. Heat exchanger access cover 3. Blower The advanced blower design and air inlet silencer on Ultra boilers result in very quiet operation. Air enters the boiler enclosure through the air intake adapter (18), flows through the enclosure, enters the air inlet silencer (5), then enters the venturi (6).
GAS-FIRED WATER BOILER Gas-fired water boiler, Featuring Flexibility !$6!.#%$ ).34!,,!4)/.
GAS-FIRED WATER BOILER — Boiler Manual Prepare boiler — convert for propane Prepare boiler for propane (when required) &IGURE Orifice identification Propane operation 5LTRA BOILERS MUST BE CONVERTED FOR PROPANE OPERATION UNLESS SPECIlCALLY MANUFACTURED FOR PROPANE. Propane-ready boilers have suffix “LP” after the model number. All other boilers require conversion for propane operation. 5LTRA natural gas boilers require installation of a burner in addition to an orifice change. $/ .
GAS-FIRED WATER BOILER — Boiler Manual Prepare boiler — convert for propane (continued) 4. Lift the door away from boiler. 5. Remove the air inlet silencer from the adapter: &IGURE Installing propane orifice (Ultra-155, -230, and -299) a. Models 80 and 105: See Figure 121, page 117. b. Models 155 and 230: See Figure 122, page 118. c. Models 299 and 399: See Figure 123, page 119. 6. Disconnect the gas valve electrical plug. 7. See Figure 42, page 44 or Figure 43.
GAS-FIRED WATER BOILER — Boiler Manual Placing boiler — wall-mounting option Wall-mounted boilers (Ultra-80 through -399) 1. The wall-mounting kit is NOT supplied as standard equipment with the boiler, and must be purchased separately. See 7!2.).' below. &IGURE 5LTRA THROUGH 5LTRA ONLY Install bottom-piping grommets if required Wall mount Ultra boilers only using the WeilMcLain Ultra boiler wall-mounting kit and accompanying instructions.
GAS-FIRED WATER BOILER — Boiler Manual Placing boiler — wall-mounting option (continued) Prepare boiler for wall mounting 1. Remove the jacket front panel. This will simplify lifting and handling the boiler when mounting. 2. When piping will be routed out the top of the boiler, no special preparation is needed other than that given in this manual. 3. Ultra-80 to -230 only: To route the piping through the bottom of the boiler enclosure: a.
GAS-FIRED WATER BOILER — Boiler Manual Install water piping — advanced Zoning with zone valves &IGURE Zone valve zoning plus optional DHW piping (alternate to piping shown in Figure 5, page 12) High-flow-rate/high-head-loss DHW circuits 1. For applications requiring DHW circuit flow rates higher than allowable for the boiler, or for high pressure-drop coil-type DHW tanks, connect the piping as in Figure 48. The DHW water only flows through the secondary circuit connector piping.
GAS-FIRED WATER BOILER — Boiler Manual Install water piping — advanced (continued) Example system with DHW as a zone, zoning with circulators &IGURE Circulator zoning plus optional DHW piping 1. Connect boiler to system as shown in Figure 49 when circulator zoning. The boiler circulator cannot be used for a zone. It must supply only the boiler loop. Also see the information on page 10 for suggested piping and sizing. Use AT LEAST the -).
GAS-FIRED WATER BOILER — Boiler Manual Install water piping — advanced (continued) Radiant heating applications &IGURE Typical radiant heating system piping plus optional DHW 1. The Ultra boiler is ideal for use in radiant heating. The Ultra boiler’s unique heat exchanger design allows it to work well even in condensing mode. So there is no need to regulate boiler return water temperature in radiant heating applications. 2.
GAS-FIRED WATER BOILER — Boiler Manual Install water piping — advanced (continued) Chilled water systems &IGURE Chilled water system plus optional DHW piping 1. Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. See Figure 51 for typical installation of balancing valve and check valve. Use AT LEAST the -).
GAS-FIRED WATER BOILER — Boiler Manual Sizing direct-connected DHW piping Direct-connected DHW piping For 7EIL -C,AIN 0,53 WATER HEATERS, refer to the PLUS water heater manual for application information. Also see quick-select information on page 14. The information here is for other water heater designs.
GAS-FIRED WATER BOILER — Boiler Manual Sizing direct-connected DHW piping (continued) &IGURE Pipe sizing and head losses for DHW &IGURE Pump curves for typical circulators suggested for DHW loop applications (H1=Ultra boiler head loss; H2=piping head loss) Flow rate GPM Temp rise °F Pipe size H1 H2 Inches Boiler head loss Feet w.c. Piping head loss Feet w.c. 5LTRA "TUH OUTPUT 7 20 1 6.6 2.7 9 16 1 11.6 4.2 14 1¼ 14.6 2.
GAS-FIRED WATER BOILER — Boiler Manual Multiple boiler installations Placing multiple boilers &IGURE Side-to-side mounting of multiple Ultra boilers 1. Locate multiple boilers in boiler room according to: a. Figure 56 (side-to-side), or b. Figure 57 (back-to-back). c. Figure 58 (wall mounting). 2. Provide indicated clearances around boilers for access and servicing. If recommended dimensions are not possible, provide at least the minimum clearances given on page 5. Also follow local codes. 3.
GAS-FIRED WATER BOILER — Boiler Manual Prepare boiler location — multiple boilers Manifolded combustion air option 1. Multiple Ultra boilers can use a common combustion air manifold. a. See Figure 126, page 122 for minimum cross sectional area of combined air ducts. b. Provide minimum clearance to adjacent vents and grade/snow line as shown in Figure 59. c. Provide minimum free area in duct (adjusted for louver restriction) of SQUARE INCH PER "TUH total boiler input. d.
GAS-FIRED WATER BOILER — Boiler Manual Multiple boiler water piping Easy-Fit® piping installation 1. Main header and Easy-Fit® Manifold pipe sizing. a. New system — See page 10. b. Replacing boilers in an existing system — Without reducing size, connect system supply and return lines. Install tees or crosses for Easy-Fit® manifolds as shown in Figure 60 or Figure 61. Size manifolds to handle total connected boiler output as shown. 2.
GAS-FIRED WATER BOILER — Boiler Manual Multiple boiler water piping (continued) !$6!.#%$ ).34!,,!4)/.
GAS-FIRED WATER BOILER — Boiler Manual Multiple boiler water piping (continued) &IGURE Piping layout — typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit manifolds (2-boiler system) Legend — Figure 63 1 2 3 4 5 6 7 8 9 13 17 58 Flow/check valve (each boiler) Isolation valves (when used) Caps Easy-Fit® Manifold (supply) — layout and size per page 56 Easy-Fit® Manifold (return) — layout and size per page 56 Primary circulator Expansion tank (diaphragm type) System air eliminator Sys
GAS-FIRED WATER BOILER — Boiler Manual Multiple boiler water piping (continued) Suggested DHW boiler-side pipe sizing (for max 0.04 feet head loss per foot of total equivalent length, TEL) Flow rate Size Flow rate Size 1 – 3.9 gpm ¾” 24 – 45 gpm 2” 3.9 – 7.1 gpm 1” 45 – 75 gpm 2½” 7.1 – 16 gpm 1¼” 75 - 140 gpm 3” 16 – 24 gpm 1½” 140 – 290 gpm 4” !$6!.#%$ ).34!,,!4)/.
GAS-FIRED WATER BOILER — Boiler Manual Multiple boiler water piping (continued) &IGURE Piping layout — typical piping for multiple Ultra boilers, using isolation exchanger Use isolation heat exchanger for: 1. Large volume systems with high mineral content in water. 2. Systems exposed to untreated quantities of makeup water. 3. Old systems severely contaminated with scale and rust buildup inside piping and heat distribution units. 4. Process applications. 5. Commercial service water applications. 6.
GAS-FIRED WATER BOILER — Boiler Manual Venting/air piping — Massachusetts installations Instructions for the Commonwealth of Massachusetts 1. ).34!,,!4)/. /& #!2"/. -/./8)$% $%4%#4/23. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed.
GAS-FIRED WATER BOILER — Boiler Manual Vent/air piping — options Vent and air pipe termination options &IGURE 6ENT AND AIR TERMINATION OPTIONS 1. Vent and air piping must terminate out the sidewall or through the roof of the building, using only one of the methods described in this manual. 2. Sidewall options (see Figure 67, left side): a. TOP: Weil-McLain termination cap (kit included with boiler) — see page 18 for instructions. b. MIDDLE: Concentric PVC pipe (requires special kit, page 113). c.
GAS-FIRED WATER BOILER — Boiler Manual Sidewall vent/air termination: 3” PVC concentric 1. The Weil-McLain 3” PVC concentric termination kit must be purchased separately. See Figure 117, page 113 for part number. Use only the Weil-McLain 3” PVC concentric termination kit for concentric venting. Provide pipe adapters as needed for 2” or 4” plastic piping or for AL29-4C vent pipe.
GAS-FIRED WATER BOILER — Boiler Manual Sidewall vent/air termination: 3” PVC concentric (cont.) 1. Locate the vent/air terminations using the following guidelines. 2. You must consider the surroundings when terminating the vent and air: a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable. b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views. c.
GAS-FIRED WATER BOILER — Boiler Manual Sidewall vent/air termination: 3” PVC concentric (cont.) Install terminations — concentric pipes 1. Assemble the vent termination as described for vertical concentric terminations, beginning on page 70. &IGURE Installing and supporting the concentric sidewall vent assembly The vent and air piping must be securely supported, and must not rest its weight on the boiler fittings.
GAS-FIRED WATER BOILER — Boiler Manual Sidewall vent/air termination: Separate pipes Allowable vent/air pipe materials &IGURE -AXIMUM PIPING LENGTHS FOR SEPARATE VENT AND AIR PIPE SIDEWALL TERMINATION 1. Use only the materials listed in Figure 12, page 17. 2. Purchase termination plates and bird screens separately. See the parts list at the end of this manual.
GAS-FIRED WATER BOILER — Boiler Manual Sidewall vent/air termination: Separate pipes (continued) 5. Maintain clearances as shown in the illustrations in this manual section. Also maintain the following: a. Vent must terminate: s At least 6 feet from adjacent walls. s No closer than 5 feet below roof overhang. s At least 7 feet above any public walkway. s At lease 3 feet above any forced air intake within 10 feet.
GAS-FIRED WATER BOILER — Boiler Manual Sidewall vent/air termination: Separate pipes (continued) 2. Place wall penetrations to obtain minimum clearance of 12 inches between vent pipe and adjacent air inlet elbow, as shown in Figure 78, page 67 for U. S. installations. 3. For Canadian installations, provide clearances required by CSA B149.1 or B149.2 Installation Code. 4. The air inlet of an Ultra boiler is part of a direct vent connection.
GAS-FIRED WATER BOILER — Boiler Manual Vertical vent/air termination: 3” PVC concentric 1. The Weil-McLain 3” PVC concentric termination kit must be purchased separately. See Figure 117, page 113 for part number. Use only the Weil-McLain 3” PVC concentric termination kit for concentric venting. Provide pipe adapters as needed for 2” or 4” plastic piping or for AL29-4C vent pipe. Allowable vent/air pipe materials 1. Use only the materials listed in Figure 12, page 17. Maximum piping length 1.
GAS-FIRED WATER BOILER — Boiler Manual Vertical vent/air termination: 3” PVC concentric (continued) 4. Maintain clearances to termination as given below: a. Vent outlet must be located: s At least 6 feet from adjacent walls. s No closer than 5 feet below roof overhang. s At least 7 feet above any public walkway. s At lease 3 feet above any forced air intake within 10 feet. s No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet. b.
GAS-FIRED WATER BOILER — Boiler Manual Vertical vent/air termination: 3” PVC concentric (continued) &IGURE Weil-McLain 3” PVC concentric termination &IGURE Weil-McLain 3” PVC concentric termination assembly !$6!.#%$ ).34!,,!4)/. assembly — DO NOT attach the rain cap until the termination has been inserted through the roof and all supports have been installed.
GAS-FIRED WATER BOILER — Boiler Manual Vertical vent/air termination: 3” PVC concentric (continued) 10. For each joint: a. Handle fittings and pipes carefully to prevent contamination of surfaces. b. Apply primer liberally to both joint surfaces — pipe end and fitting socket. c. While primer is still damp, lightly apply approved cement to both surfaces in a uniform coating. d. Apply a second coat to both surfaces. Avoid using too much cement on sockets to prevent cement buildup inside. e.
GAS-FIRED WATER BOILER — Boiler Manual Vertical vent/air termination: Separate pipes Allowable vent/air pipe materials &IGURE -AXIMUM PIPING LENGTHS FOR SEPARATE VENT AND AIR PIPE VERTICAL TERMINATION 1. Use only the materials listed in Figure 12, page 17. 2. Purchase bird screens for vent and air terminations separately. See the parts list at the end of this manual.
GAS-FIRED WATER BOILER — Boiler Manual Vertical vent/air termination: Separate pipes (continued) 5. Maintain clearances to vent termination as given below: a. Vent must terminate: s At least 6 feet from adjacent walls. s No closer than 5 feet below roof overhang. s At least 7 feet above any public walkway. s At least 3 feet above any forced air intake within 10 feet. s No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet. b.
GAS-FIRED WATER BOILER — Boiler Manual Install vent/air piping — boiler to termination Complete termination preparation &IGURE Boiler vent and air connections 1. Install vent and air terminations before proceeding. See previous pages for instructions. Installing vent and air piping 1. For reference in the following see: a. Sidewall terminations: see Figure 92, page 76. b. Vertical terminations: see Figure 93, page 76. 2. Work from the boiler to vent or air termination.
GAS-FIRED WATER BOILER — Boiler Manual Install vent/air piping — boiler to terminations (cont.) &IGURE 3IDEWALL TERMINATION METHODS AND INSTALLATION REQUIREMENTS 7EIL -C,AIN SIDEWALL TERMINATION PLATE (install termination — page 19) &IGURE 6ERTICAL TERMINATION METHODS AND INSTALLATION REQUIREMENTS 7EIL -C,AIN v 06# CONCENTRIC TERMINATION (install termination — page 69) s Install pipe supports every 5 feet on both the horizontal and vertical runs.
GAS-FIRED WATER BOILER — Boiler Manual Gas piping — sizing gas lines Natural Gas: &IGURE Common gas line for multiple boilers Pipe sizing for natural gas 1. Size gas piping from meter outlet to entrance of boiler in accordance with Figure 95 and Figure 96. 2. Use total input of all boilers. Divide total input in Btuh by 1,000 to obtain cubic feet per hour of natural gas. a. Pipe lengths in Figure 95 are equivalent length of straight pipe.
GAS-FIRED WATER BOILER — Boiler Manual Field wiring — advanced ondary heat source when another heat source, such as a heat pump or another boiler is available. %,%#42)#!, 3(/#+ (!:!2$ — For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1.
GAS-FIRED WATER BOILER — Boiler Manual Field wiring — advanced &IGURE Wiring to circulators (see &IGURE &IGURE (continued) The U-Control module provides internal low water protection 1. The U-Control and internal sensors in the Ultra boiler provide both temperature control and low water protection (using temperature senors), as explained below: The U-Control module uses temperature sensors to provide both high limit protection and modulating temperature control.
GAS-FIRED WATER BOILER — Boiler Manual Field wiring — advanced (see &IGURE &IGURE (continued) &IGURE Schematic wiring diagram — Ultra-80 through Ultra-299 80 Part number 550-100-090/1113
GAS-FIRED WATER BOILER — Boiler Manual Field wiring — advanced (see &IGURE &IGURE (continued) !$6!.#%$ ).34!,,!4)/.
GAS-FIRED WATER BOILER — Boiler Manual Field wiring — advanced (see &IGURE &IGURE (continued) Additional limits Outdoor temperature sensor 1. The U-Control allows connection of external limit controls, both for manual reset and for automatic reset operation of the U-Control. 2. -ANUAL RESET OF THE 5 #ONTROL ON LIMIT ACTION — Connect external limits across P13, terminals 1 and 2 if the U-Control is to require manual reset when a limit opens, even if the limit re-closes.
GAS-FIRED WATER BOILER — Boiler Manual U-Control operation and setup — advanced 4. The outdoor sensor must be installed to use this function. !$*534 /54$//2 1. Use this setting to adjust the outdoor sensor temperature to account for solar or other effects that would cause the sensor to read incorrectly. ADVANCED SETUP – OVERVIEW !$$)4)/.!, (%!4 $%-!.$ 1. Access contractor menus by pressing and holding the UP and DOWN arrow keys at the same time for 5 seconds. 2. The contractor screen will show: a.
GAS-FIRED WATER BOILER — Boiler Manual U-Control operation and setup — advanced (continued) e. Connect these output terminals to the SHADOW boilers’ 0–10 VDC input terminals, P15 #5 and #6. The SHADOW boilers will start and modulate based on the signal strength. The SHADOW boilers must be set up as Type 4 (see below). They do not need their additional heat timers to be setup. f. An alternate method is to daisy chain the other boilers. That is, connect the output of each to the input of the next.
GAS-FIRED WATER BOILER — Boiler Manual U-Control operation and setup — advanced (continued) &IGURE U-Control system types and preset parameters $ISPLAY 0RESET TEMPERATURES .
GAS-FIRED WATER BOILER — Boiler Manual U-Control operation and setup — advanced (continued) &IGURE U-Control menus (press and hold the UP and DOWN arrow keys for 5 seconds to enter contractor menus) -ENUS .EXT SCREEN .EXT SCREEN .EXT SCREEN .
GAS-FIRED WATER BOILER — Boiler Manual U-Control operation and setup — advanced (continued) &IGURE U-Control menus, continued (press and hold the UP and DOWN arrow keys for 5 seconds to enter contractor menus) -ENUS .EXT SCREEN .EXT SCREEN .EXT SCREEN .
GAS-FIRED WATER BOILER — Boiler Manual U-Control operation and setup — advanced (continued) &IGURE U-Control setup options (see Figure 102, page 86 for location in menu sequence) -ENU )TEM 5NITS ,OW 6ALUE (IGH 6ALUE $EFAULT #OMMENT "OILER 3ETTINGS Boiler Model 80, 105, 155, 230, 299, 310, 399, 550, 750 factory 4()3 -534 "% 3%4 #/22%#4,9 &/2 3!&% /0%2!4)/.. Adjusts blower speeds and flame sense (Display will show “HA” after the model number if high altitude has been selected, below.
GAS-FIRED WATER BOILER — Boiler Manual U-Control operation and setup — advanced (continued) &IGURE U-Control setup options (see Figure 102, page 86 for location in menu sequence), continued -ENU )TEM 5NITS ,OW 6ALUE (IGH 6ALUE $EFAULT #OMMENT minutes off 240 30 Longest time boiler will satisfy this system before switching to an active lower priority Min On Time minutes off 240 15 Time boiler will satisfy this system before switching to the next active priority Boost Interval minutes
GAS-FIRED WATER BOILER — Boiler Manual U-Control operation and setup — advanced (continued) &IGURE U-Control diagnostic information (see Figure 102, page 86 for location in menu sequence -ENU )TEM 5NITS ,OW 6ALUE (IGH 6ALUE $EFAULT #OMMENT $IAGNOSTICS 4EMPERATURES Status Text data System Supply System Return Boiler Out1 Boiler Out2 Boiler In1 Flue1 Flue2 Outdoor °F °F °F °F °F °F °F °F data data data data data data data data )NPUTS Status Text data Priority 1 Priority 2 Priority 3 Analo
GAS-FIRED WATER BOILER — Boiler Manual U-Control operation and setup — advanced (continued) &IGURE U-Control diagnostic information (see Figure 102, page 86 for location in menu sequence), continued Manual Reset Auto Reset Inputs Outputs Temperatures Lockout History 3 Time & Date Status Manual Reset Auto Reset Inputs Outputs Temperatures 3OFTWARE 6ERSIONS Display Main Micro Second Micro -ANUAL 4EST -ODE Status Target Modulation System Supply System Return Boiler Out Boiler In Flame Signal Blower Sign
GAS-FIRED WATER BOILER — Boiler Manual Annual startup and general maintenance Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.
GAS-FIRED WATER BOILER — Boiler Manual Annual startup REMOVING BURNER GASKET or COVER PLATE INSULATION The Ultra burner gasket (models 80 and 105) and cover plate insulation (all models) contain ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).
GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) Clean condensate trap The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Figure 105, page 92 and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure. 1.
GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) 4. Inspect automatic air vents and air separators. Remove air vent caps and briefly press push valve to flush vent. Reinstall caps. Make sure vents do not leak. Replace any leaking vents. 5. Check system water chemistry (pH, hardness and inhibitor level). See page 31. Check expansion tank 1.
GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) Check burner flame The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on page 93 of this manual. Failure to comply could result in severe personal injury. 1. Inspect flame through observation window using the procedure on page 36. 2. If flame is unsatisfactory at either high fire or low fire, turn off boiler and allow boiler to cool down.
GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) 4. If flame signal still remains low, inspect the vent and air piping. Then inspect the heat exchanger, following the procedures given in this manual for removal and reinstallation of the head exchanger cover plate and other boiler components. Clean the exchanger as described in this manual if necessary. 6. Set the firing rate to MEDIUM (ignition rate). 7. Write down the blower RPM value.
GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) Check boiler relief valve 1. Inspect the relief valve and lift the lever to verify flow as in the following warnings, excerpted from a relief valve manufacturer’s warning label. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read page 9 before proceeding further.
GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting VERIFY PROPER OPERATION AFTER SERVICING. Reinstall boiler jacket front door Before servicing and making connections . . . Reinstall boiler jacket front door after servicing. The boiler front door must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room. This is particularly important if the boiler is located in the same room as other appliances.
GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) Check the following: 1. Make sure thermostat is calling for heat and contacts (including appropriate zone controls) are closed. Check for 24 VAC between thermostat wire nuts and ground. 2. Make sure all external limit controls are either installed (and closed) or temporarily jumpered for testing. 3. Make sure that connectors to control module are securely plugged in at module and originating control. 4. Gas pressures: s Maximum: 13” w.c.
GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) Make sure to determine the causes of outages. Do not leave the boiler operating without a complete diagnosis. U-Control fault indications 1. The U-Control provides diagnostic information for both automatic reset conditions and manual reset conditions. See Figure 104, page 90 for information available on the U-Control display. 2. Figure 111 shows the screen behavior during an automatic or manual reset condition.
GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) &IGURE Troubleshooting suggestions for Ultra boilers U-Control Error Condition Log The U-control is able to record information about the boiler’s condition at the time of the three previous faults or errors. This information is available to view in Contractor Menus under “DIAGNOSTICS” by selecting “ERRORS.
GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) Figure 112 Troubleshooting suggestions for Ultra boilers (continued) Display Nothing is shown in display screen and no other boiler components are operating Nothing is shown on display screen, but boiler is operating 5&.1 3*4& 500 QUICKLY Condition Control is not receiving 120V power.
GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) Figure 112 Troubleshooting suggestions for Ultra boilers (continued) Display 3&563/ 4611-: Condition Occurs when a return water temperature is greater than the corresponding supply temperature by 10ºF or more. Diagnostics Automatically resets when condition no longer exists. Condition must occur for 10 minutes for system sensors. Occurs when a temperature sensor has electrically shorted (SHORT) or has become disconnected (OPEN).
GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) Figure 112 Troubleshooting suggestions for Ultra boilers (continued) Display Condition Diagnostics Corrective Action(s) %*41-": $0.. Occurs when display communications out for 30 seconds. Automatically resets when DPNNVOJDBUJPO JT SF established. Check for a loose connection at the molex plug on the control and connection on the back of the display. -*.*5 01&/ Occurs when manual or automatic reset limit opens.
GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) Figure 112 Troubleshooting suggestions for Ultra boilers (continued) Display Condition Diagnostics Corrective Action(s) #-08&3 '"6-5 Blower unable to reach required speed or does not reach 0 RPM when turned off. Automatically resets after 1 hour or can be reset by using manual reset on screen.
GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) Figure 112 Troubleshooting suggestions for Ultra boilers (continued) Display ("4 7"-7& FAULT Condition 5IF 6 $POUSPM IBT EFUFDUFE a problem with it gas valve output circuit Diagnostics Automatic retry when condition exists. Boiler will reset if conditions clears. If condition does not clear boiler will retry in 1 hour. If condition is not clear after 1 hour, boiler will require manual reset.
GAS-FIRED WATER BOILER — Boiler Manual 5LTRA 'AS "OILER $ATA #OLLECTION 3HEET #USTOMER )NFO -AINTENANCE )NFO Name: Phone: Model: CP#: Installed: Contact: Contractor: Job name: City, state: Distributor: 3YSTEM #OMPONENTS Near boiler pipe size: Boiler circulator model: DHW tank (yes/no): DHW direct/system: Dhw model: Dhw pipe size: DHW circulator model: Is there air in system?: "OILER 3YSTEM 0IPING $ETAILS 0LEASE 3KETCH Please note the placement of system sensors $IAGNOSTIC %RRORS Control fault: Ig
GAS-FIRED WATER BOILER — Boiler Manual Maintenance Disconnect power Electrical shock hazard — Disconnect all electrical power to the boiler before attempting maintenance procedures. Failure to complete could result in severe personal injury, death or substantial property damage. Cleaning the heat exchanger — pin side when required The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on page 93 of this manual.
GAS-FIRED WATER BOILER — Boiler Manual Maintenance (continued) Accessing & cleaning exchanger: Ultra-80 and Ultra-105 Only 1. Close the external manual gas valve. 2. Disconnect the flexible gas line at its flare fitting. 3. Remove the air silencer by separating it from the air adapter on the blower inlet. 4. $ISCONNECT WIRING s GAS VALVE PLUG s BLOWER POWER SUPPLY PLUG s BLOWER CONTROL CONNECTOR s IGNITION CABLE s GROUND WIRE 5.
GAS-FIRED WATER BOILER — Boiler Manual Maintenance (continued) Accessing & cleaning exchanger: Ultra-155, -230, 299 and -399 Only 1. Close the external manual gas valve. 2. $ISCONNECT WIRING s GAS VALVE ELECTRICAL PLUG s TWO ELECTRICAL -OLEX PLUGS FROM THE BLOWER ASSEMBLY s IGNITION CABLE s GROUND WIRE 3. Disconnect the flexible gas line at its flare fitting. 4. Remove the air silencer by lifting the plastic clamp off of the gas line and then gently sliding the air silencer down and off the valve. 5.
GAS-FIRED WATER BOILER — Boiler Manual Replacement parts Replacement parts must be purchased through a local Weil-McLain distributor. When ordering, specify boiler model and size and include description and part number of replacement part. Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation. Weil-McLain part numbers are found in Weil-McLain Boilers and Controls Repair Parts Lists. 4HE BOILER CONTAINS CERAMIC lBER MATERIALS.
GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Miscellaneous parts and kits Item Description Part Number CHEMICALS !NTIFREEZE ALUMINUM SAFE 3ENTINEL 8 GALLON !NTIFREEZE ALUMINUM SAFE 3ENTINEL 8 GALLON #ORROSION INHIBITOR 3ENTINEL 8 ONE TUBE ML )NHIBITOR QUICK TEST KIT #LEANER 3ENTINEL 8 ONE TUBE ML
GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) 1 2 3 4 5 Description Jacket front door Boiler leg kit (4 required) Knurled head screw for jacket front door (2 required) Knurled head screw clip-on receptacle (not shown) (2 required) Air adapter kit (Includes adapter, 3” gasket and mounting bracket) 3” 4” Boiler models Part number Item Item &IGURE Jacket parts All All All 383-500-135 383-500-065 383-500-320 6 Flue outlet pipe adapter All 383-500-180 7 8 Top cover, fr
GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) Item &IGURE Controls Description Ultra U-Control module 383-500-658 2 Transformer, 120v/24v 383-500-628 Display board assembly (includes plastic and display screen) 383-500-659 4 On/off power switch 383-500-205 5 Pressure/temperature gauge assembly (Includes temperature and pressure sensor) 383-500-630 Flue temperature sensor replacement kit 383-500-600 System temperature sensors (2 required) 383-500-60
GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Heat exchanger and piping — Ultra-80 and -105 Description Boiler Models Part Number (EAT EXCHANGER REPLACEMENT KIT (EAT EXCHANGER COVER PLATE BURNER ELECTRODE WATER SENSORS COMPRESSION lTTINGS CONDENSATE lTTING GASKETS AND HARDWARE .
GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) -!).4%.!.#% 30%#)&)#!4)/.
GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Heat exchanger and piping 1 2 3 4 5 6 7 8 9 10 11 12 13 16 17 Description Heat exchanger replacement kit - Heat exchanger, cover plate, burner, electrode, water sensors, compression fittings, condensate fitting, gaskets, and hardware Cover plate replacement kit - Cover plate, cover plate gasket, burner gasket, and hardware Cover plate insulation Cover plate gasket Cover plate studs, M6, 1 pitch Cover plate nuts, M6, 1 pitch
GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Heat exchanger and piping 2 3 4 5 6 8 10 11 13 14 15 16 17 18 19 Heat exchanger replacement kit - Heat exchanger, cover plate, burner, electrode, water sensors, compression fittings, condensate fitting, gaskets, and hardware Cover plate replacement kit - Cover plate, cover plate gasket, burner gasket, and hardware Cover plate insulation Cover plate gasket Cover plate studs, M6, 1 pitch Cover plate nuts, M6, 1 pitch Supply wat
GAS-FIRED WATER BOILER — Boiler Manual Dimensions &IGURE Dimensional data Notes 120 1 Boiler supply and return tappings are both 1” NPT (Ultra-80/105/155/230) or 1¼” NPT (Ultra-299). See page 10 for recommended piping sizes. Wall-hung boiler option — water piping and gas pipe can be routed through bottom of enclosure using wall-mounting kit. See page 5 for mounting instructions. 2 Boiler circulator is shipped loose. Circulator must be mounted in the return piping.
GAS-FIRED WATER BOILER — Boiler Manual Ratings — Ultra boilers &IGURE Ratings and engineering data DOE Boiler Model Number DOE Heating Capacity CSA Input Output Net AHRI Ratings Boiler Water Content DOE Seasonal Efficiency Vent/Air Pipe Size Btuh (Note 2) Btuh (Note 7) Btuh (Note 7) Btuh (Note 3) Gallons AFUE, % (Note 1) (Note 4) Ultra-80-CT 71,000 80,000 71,000 62,000 0.69 93.5 2” or 3” Ultra-105-CT 94,000 105,000 94,000 82,000 0.82 94.
GAS-FIRED WATER BOILER — Boiler Manual Ratings — multiple Ultra boilers &IGURE Ratings and engineering data (see Figure 128 for notes) Boilers in system Model Ultra – 80 105 155 230 299 399 -CT -CT -CT -CT -CT -CT 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 7 7 8 8 8 8 8 8 122 Manifolded Net combustion water air duct ratings size Total CSA input DOE Heating capacity Boiler H.P.
GAS-FIRED WATER BOILER — Boiler Manual Ratings — multiple Ultra boilers (continued) &IGURE Engineering data (see Figure 128 for notes) Boiler Model Ultra – Shipping weight Pounds per boiler Operating weight Pounds per boiler Water content Gallons per boiler Water flow rate per boiler GPM @ 20°F rise GPM @ 40°F rise Vent/air pipe size — Provide a separate vent for each boiler Electrical service required Note 5 Note 6 Note 4 Amps per boiler 80-CT 199 139 0.7 7.1 3.6 2” or 3” 15.
GAS-FIRED WATER BOILER — Boiler Manual Installation and Service Certificate Boiler Model Series ❏ ❏ ❏ ❏ BTU Input CP Number Date Installed Installation instructions have been followed. Check-out sequence has been performed. Above information is certified to be correct. Information received and left with owner/maintenance person.