Install Instructions

Part number 550-100-090/1113
23
GAS-FIRED WATER BOILER — Boiler Manual
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Install condensate line
Prepare condensate fittings
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. Apply primer liberally to both joint surfaces — pipe end and
fitting socket.
b. While primer is still damp, lightly apply approved cement to
both surfaces in a uniform coating.
c. Apply a second coat of cement to both surfaces. Avoid using too
much cement on sockets to prevent cement buildup inside.
d. With cement still wet, insert pipe into fitting, twisting ¼ turn.
Make sure pipe is fully inserted.
e. Wipe excess cement from joint. Check joint to be sure a smooth
bead of cement shows around the entire joint.
5. See Figure 24.
6. Assemble the ½” PVC nipple to the PVC reducing elbow as
shown.
7. Allow joint to dry completely.
8. Then slide gasket over nipple as shown in Figure 25.
9. Slide nipple through jacket condensate line hole to position as
shown in Figure 25.
10. Cement the ½” tee to the protruding ½” nipple. Be sure both nipple
and reducing elbow finish upright.
Firmly press the reducing elbow and the tee together
while the cement sets to ensure the gasket is securely
compressed. The gasket ensures the jacket enclosure is
airtight at this location.
Connect condensate trap line and fittings
1. Remove condensate trap line from bag.
2. Ultra-80 & -105 only — Figure 26
a. Guide the condensate trap line through the bracket hole as
shown.
b. Place a hose clamp over the end of the condensate line.
c. Then slide the end of the trap line over the heat exchanger
condensate connection.
d. Tighten the hose clamp to secure the trap line.
e. Place a hose clamp over the other end of the condensate trap
line.
f. Slide the trap line over the reducing elbow and secure with
the hose clamp.
3. Ultra-155 and larger — Figure 28, page 24 or Figure 29, page 24
a. Slide a hose clamp over each end of the condensate trap line.
b. Slide the trap line onto the heat exchanger condensate connec-
tion and PVC reducing elbow as shown.
c. Tighten the hose clamps to secure the trap line.
&IGURE Condensate trap assembly
&IGURE  #ONDENSATETRAPASSEMBLYINTOJACKET
&IGURE Condensate drain — Ultra-80 & -105