Gas-fired water boiler Installation Manual Multiple-boiler systems with Weil-McLain Easy-Fit® piping • Selection data • Installation • Piping • Water treatment with This manual must only be used by a qualified heating installer/service technician. Before installing, read all instructions, including this manual, the Ultra Boiler Manual and all applicable Supplements. Consider all connections to the boilers before selecting a location and layout.
GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Contents Hazard definitions .................................................................................................................................. 3 Selection data Controls .................................................................................................................... Domestic hot water .................................................................................................
GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. Indicates presence of hazards that will cause severe personal injury, death or substantial property damage. Indicates presence of hazards that will or can cause minor personal injury or property damage.
GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Ratings and engineering data Figure 1 Ratings and engineering data (see page 5 for notes) DOE 4 Part number 550-101-232/0703
GAS-FIRED WATER BOILER Figure 1 — Installation Manual — Multiple-boiler Systems Ratings and engineering data (continued) For simplicity, the table on page 4 lists only systems using multiples of the same Ultra boiler module. Any combination of Ultra boilers can be installed as a multiple boiler system. Water header piping Determine the flow rate that the system header and other pipes will handle. Then use the table at right to determine the minimum pipe size.
GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Dimensions Figure 2 Dimensional data Notes 1. Boiler supply and return tappings are both 1" NPT. Connect to headers with 1” pipe for Ultra-80 and Ultra-105; 1¼" pipe for Ultra-155 and Ultra-230. For wall-hung boilers, water piping and gas pipe can be routed through bottom of enclosure using wall-mounting kit. 6 2. Boiler circulator is shipped loose. Mount boiler circulator in connecting piping as shown in this manual.
GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Placement and mounting information REVIEW & COMMENT ONLY Placement, general 2. 3. 5. CONFIDENTIAL Side-to-side installation of multiple Ultra-80/-105/-155/-230 boilers Figure 4 Back-to-back installation of multiple Ultra-80/-105/-155/-230 boilers Figure 5 Wall mounting multiple Ultra-80/-105/-155/-230 boilers 1. Locate multiple boilers in boiler room according to: • Figure 3 (side-to-side), or 4. 06-24-03 Figure 3 6.
GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Easy-Fit® Piping 8 Maximum connected boiler output: 2-inch manifolds — 450 MBH 3-inch manifolds — 1400 MBH 4-inch manifolds — 2900 MBH Figure 7 Double-sided connection — Maximum boiler output (each side): 2-inch manifolds — 450 MBH 3-inch manifolds — 1400 MBH 4-inch manifolds — 2900 MBH REVIEW & COMMENT ONLY Single-sided connection — CONFIDENTIAL 1. Main header and Easy-Fit® Manifold pipe sizing. a.
GAS-FIRED WATER BOILER Piping schematic — Typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit® Manifolds 06-24-03 CONFIDENTIAL REVIEW & COMMENT ONLY Figure 8 — Installation Manual — Multiple-boiler Systems Flow/check valve (each boiler) Isolation valves (when used) Cap Easy-Fit® Manifold (supply), sized per Fig. 6 or Fig. 7, page 8 5 Easy-Fit® Manifold (return), sized per Fig. 6 or Fig.
GAS-FIRED WATER BOILER Easy-Fit® Piping Figure 9 10 (continued) Typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit® Manifolds Flow/check valve (each boiler) Isolation valves (when used) Caps Easy-Fit® Manifold (supply), sized per Fig. 6 or Fig. 7, page 8 5 Easy-Fit® Manifold (return), sized per Fig. 6 or Fig.
GAS-FIRED WATER BOILER Figure 10 — Installation Manual — Multiple-boiler Systems Typical piping for multiple Ultra boilers, Weil-McLain Easy-Fit® Manifolds, and indirect water heaters Suggested DHW boiler-side pipe sizing (based on 500 milinch per foot head loss in piping): 0 – 7 gpm .......................... 1 inch 7 – 16 gpm ........................ 1¼ inch 16 – 24 gpm ...................... 1½ inch 24 – 45 gpm ...................... 2 inch 45 – 75 gpm ...................... 2½ inch 75 –140 gpm .....
GAS-FIRED WATER BOILER Easy-Fit® Piping Figure 11 — Installation Manual — Multiple-boiler Systems (continued) Typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit® Manifolds and heat 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.
GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Combustion air & vent piping installation Vent piping Combustion air manifolds 1. Each boiler requires an individual vent pipe, installed and terminated per the Ultra Boiler Manual and Ultra Boiler Venting Suppments. 2. The vent pipes of multiple boilers must terminate on the same side of the building as their air inlet piping, and per all requirements of the Ultra Boiler Manual and Vent Supplements. 1.
GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Gas piping Connecting gas supply piping 1. Remove jacket front panel and refer to Figure 13 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.
GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Common gas piping installation 1. Construct gas header for multiple boilers using Figure 14 and the sizing tables below. Refer to the National Fuel Gas Code for other conditions. 2. Provide manual shutoff gas valve and ground joint union as shown in Figures 13 and 14 for each boiler. When gas line enters from top of the boilerl, the boiler internal gas piping provides a drip leg. See boiler manual for details. 3.
GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Additional instructions Air for boiler room ventilation 1. Follow instructions in Ultra Boiler Manual to ensure the boiler room provides sufficient air infiltration. Wiring 1. Refer to boiler sequencing control instructions and Ultra Boiler Manual for wiring requirements. Water treatment Multiple boilers used with large water volume systems will require water softening and conditioning.
