Install Instructions

Part number 550-100-090/1113
49
GAS-FIRED WATER BOILER — Boiler Manual
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Install water piping — advanced (continued)
Legend — Figure 49
1 Ultra boiler
2 Indirect water heater (DHW), if used
3 Boiler relief valve (see page 9 for piping details)
4 Relief valve discharge piping (see page 9 for details)
6 Isolation valves
8 Diaphragm (or bladder) type expansion tank (see page 52 for piping of
closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
10 Flow/check valves
11 Purge/drain valves
12 Boiler circulator
20 Make-up water supply
21 Primary/secondary connection (tees no more than 12 inches apart)
24 Strap system supply and return sensors to lines as shown, at least 6 pipe
diameters (but no more than 3 feet) from boiler connection tees.
Items supplied with boiler
Items supplied by others
&IGURE Circulator zoning plus optional DHW piping
Example system with DHW as a zone,
zoning with circulators
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 -).)-5- pipe size shown in Figure 49
on all boiler loop piping (connecting boiler to and from
the primary/secondary connection, item 21). 5SEONLY
PRIMARYSECONDARYPIPINGASSHOWN
Failure to fol-
low these guidelines could result in system problems.
2. Install a separate circulator for each zone.
3. DO NOT use a closed-type tank with a PLUS water heater in the
system. The automatic air vent required on the water heater will
deplete air in the system, causing the expansion tank to waterlog.
Use only a diaphragm- or bladder-type tank, suitable for automatic
air vent applications.
4. In this example, the PLUS 60 DHW tank is piped as a zone in the
system, with piping connections to the tank in accordance with
the PLUS manual.
5. Wiring to the U-Control
a. Priority 1 = PLUS 60 (zone 1): wire PLUS 60 aquastat terminals
to U-Control P11, pins 4 and 5. Wire DHW circulator, A, to
U-Control P2, terminals 1, 4 and 7 (H, N, G).
b. Wire zone pumps B and C to a two-zone circulator relay.
c. Priority 2 = finned-tube baseboard (zones 2 and 3): wire cir-
culator relay end switch 1 to U-Control P15, pins 1 and 2.
6. Make sure to set Priority 1 to DHW system, not DHW direct.
7. Controlling the system circulator and boiler circulator
a. You will have to set up the U-Control to operate both the boiler
circulator and the DHW circulator during DHW operation.
Read the instructions on U-Control operation and setup,
beginning on page 28.
-).)-5-
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1”
1¼”
1½”
See CAUTION at left.