F Featuring Flexibility Installation guide and material checklists Series 3 This guide must only be used by a quali!ed heating installer/service technician. Read all instructions, including the boiler 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. t Connection tee and internal components are supplied with the boiler. t 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. INSTALL CONDENSATE PIPING / TUBING AND COMPONENTS t No external drip leg is needed — it is already included in the boiler’s internal gas piping. t Install a union and shutoff valve. INSTALL GAS PIPING t Connect system and DHW circulator wiring to the terminals designated in the boiler manual. t Connect power wiring and control wiring per boiler manual wiring diagram. WIRE THE BOILER t Choose pre-loaded boiler settings, or customize settings for various applications. t Start up the boiler as directed in the manual. Use a combustion analyzer where specified. t Follow the boiler manual instructions to clean the system if needed, then fill and check water chemistry. START-UP, ADJUST & TEST 4 5 6 7 8 (Follow all instructions in Boiler manual) 3 2 BEFORE INSTALLING . . . CLICK HERE CLICK HERE t Refer Ref to the material checklist in this guide for a list of ite needed. items t See vent / air piping options at left. INSTALL VENT & AIR PIPING t Refer Ref to the material checklist in this guide for a list of ite needed. items t See information at right. INSTALL WATER PIPING pipes will not interfere with one another. just make sure that air, vent, water and gas Steps 2 – 6 can be done in any order — t When wall mounting the boiler, obtain the wall-mount kit (see material checklist). t All models are shipped with the items needed for propane conversion except the Ultra-80, which requires a separate conversion kit (see material checklist). t Make Mak sure there is enough clearance for the boiler and all water, gas and air piping. Verify vent/air termination can wat be located as required. VENT & AIR PIPING (see boiler manual for details) Support pipes as described in the manual. per s ¼” r. e p i ile ep Slop ward bo o t t foo 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 different 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 five 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. 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” Sidewall D. V. with Weil-McLain Sidewall Direct Exhaust (no air pipe) –or– Sidewall Direct Vent with Separate Pipes Sidewall D. V. with Concentric Pipes Vertical D. V. Ve Concentric Pipes Conc termination Included with boiler termination Requires bird screen(s) termination Requires kit termination Requires kit Direct Exhaust Direct Vent Vertical Direct Exhaust (no air pipe) –or– Vertical Direct Vent with Separate Pipes termination Requires bird screen(s) TRIM OFF HERE RETURN TO PAGE 2 3 Material checklist — vent and air piping Canada Note 1: Note 2: D1785 D2665 F441 D2661 D2564 F493 D2235 F656 ANSI/ASTM PVC schedule 40 Pipe PVC-DWV (Note 1) & CPVC sch 40 (Note 1) Fittings ABS-DWV sch 40 (Note 1) PVC Cement CPVC (Note 1) ABS (Note 1) Primer PVC, CPVC or ABS Plastic vent pipe must be certified to ULC S636 when required. (Note 2) Air pipe can be any of those listed at left if acceptable for local codes. AL29-4C piping materials Heat Fab, Inc. Saf-T-Vent® Certified for Category IV and Z-Flex, Inc. Z-Vent II direct vent appliance venting Simpson Dura-Vent FasNSeal™ DO NOT use DWV, CPVC or ABS when using concentric vent termination. Use ONLY PVC schedule 40. IPEX PVC concentric terminations utilize PVC pipe/fittings certified to ULC S636. Where ULC S636 compliance is required, use only IPEX System 636 pipe, fittings and cement. AL29-4C vent piping — Install a PVC-to-stainless adapter supplied by the vent pipe manufacturer at the boiler vent connection and at the termination (when using Weil-McLain plate or concentric PVC termination). DO NOT mix piping from different vent pipe manufacturers unless using adapters specifically designed for the purpose by the manufacturer. Plastic piping — Do not attempt to connect different types of plastic piping together. DO NOT use cellular core pipe. All vent and air pipes require a bird screen at each termination where specified in the manual or vent supplement. Items required W-M P/N QTY (DV=Direct Vent; DE=Direct Exhaust) Sidewall with Weil-McLain Plate 3" 383-500-397 4" 383-500-398 Includes W-M sidewall vent/air termination cap and inside/ outside cover plates and mounting hardware; openings are sized for PVC pipe. 3" cap is shipped with Ultra-80–155. 4” cap is shipped with Ultra-230–399. Inside and outside cover plates and mounting hardware supplied with boiler can be used at wall penetrations if size is the same as the pipe used. (Cut plates to size for direct exhaust applications.) (For 2” pipe, trim 3” bird screen to size) 3" 4" 383-500-105 383-500-110 1 DE 2 DV Vertical DV with separate pipes or DE (coupling) t Bird screens (For 2” pipe, trim 3” bird screen to size) 3” 4” 383-500-105 383-500-110 3” (Use only PVC pipe DO NOT use CPVC or ABS) [Note 1] Length Ells Length Ells 100 2 100 (ab) 1 Length NA Ells Length Ells 100 (a) 1 100 2 100 1 NA 100 1 2 100 1 NA 100 1 100 3” 30 (c) 2 30 (c) 2 30 (c) 1 30 (c) 1 30 (c) 1 4” 100 (d) 2 100 2 70 (d) 1 70 (d) 1 100 1 299 4” 100 2 100 2 70 (d) 1 100 1 100 1 399 4” 100 2 100 2 100 1 100 1 230 NA Equivalent feet for elbows — deduct from maximum equivalent length of piping: tGFFUQFSGPSFBDIJODIFMCPXPSJODI¡MPOHSBEJVTPS¡FMCPX tGFFUGPSFBDIPSJODITIPSUSBEJVTFMCPX a — Use 3"x2" reducer at boiler b — Use 3”x2” PVC reducers at termination c — Use 4”x3” reducer at boiler d — Use 4"x3" PVC reducers at termination Stainless (AL29-4C) vent pipe — install an adapter at the boiler for all applications. Also install an adapter at the termination unless using separate-pipe termination. ** Ultra-80 and 105 boilers installed with 2-inch vent piping automatically derate due to the pressure loss in the vent and air piping. The derate ranges up to 10% for the Ultra-80 at 100 feet or 15% for the Ultra-105 at 100 feet. Note 1: IPEX 3” and 4” PVC concentric vent kits can be used with standard PVC pipe, fittings and cement (ANSI/ASTM D1785) except where ULC S636 compliance is required. For ULC S636 compliance, all pipe, fittings and cement must be IPEX System 636. When using IPEX kits, use only IPEX product code 196006 for 3” venting or IPEX product code 196021 for 4” venting. Contact Weil-McLain for ordering information and availability of Weil-McLain venting kits. Pipe and fittings — PLASTIC Material — 2” 3” 4” feet Elbows, 90-degree (include termination elbows if required) Couplings (include termination if vertical separate pipes) Return bend, 180-degree (vertical separate-pipe termination) Reducers: 3"x2" 1 4"x3" Pipe and fittings — AL29-4C Stainless Size — Add to the table at right ABS Straight pipe Add to the table at right 1 CPVC QTY 1 DE 2 DV PSw17$DPODFOUSJDUFSNJOBUJPOTJEFXBMMPSWFSUJDBM PVC ITEM t 180-degree return bend (1) (DV only) 4”x3” Vertical Direct Vent with Separate Pipes 2 Product — t Reducers: 3”x2” (Use only PVC pipe DO NOT use CPVC or ABS) [Note 1] Sidewall or Vertical Direct Vent 4” PVC Concentric 100 155 Add to the table at right 383-500-350 Consult factory Consult factory — or — Sidewall or Vertical Length Ells 80 or 2” ** 100 (ab) 2 105 3” 100 2 t Coupling (1) t Standard C. T. kit, 3" t S636 compliant C. T. kit, 3” S636 compliant C. T. kit, 4” Sidewall Direct Vent Sidewall or Vertical with Direct Vent Separate Pipes 3” PVC Concentric Direct Exhaust Size — Sidewall DV with separate pipes or DE (elbow) t Bird screens Sidewall Direct Vent with Weil-McLain Vent/air cap 1 Included with boiler t W-M sidewall term. kit Vent or air pipe size United States PLASTICQJQJOHNBUFSJBMTWFOUPSBJSQJQJOH Vent pipe t"MMPXBCMFTJ[FTPGWFOUBJSQJQJOHt.BYFRVJWBMFOUGFFUPGFBDI t/VNCFSPGFMCPXTBMMPXFEBUUIFTFMFOHUIT (All applications include allowance for the termination.) Standards for installations in: Material Ultra model Items Saf-T-Vent® Z-Vent II FasNSeal™ 2” 3” 4” ITEM QTY feet Straight pipe Adjustable lengths Elbows, 90-degree Termination elbows (with integral screen), when req’d NOTE: Also obtain all required flashings, boots, thimbles, fire stops or other items required for wall, ceiling and roof penetrations. Elbows, 45-degree Adapter at boiler (to fit diameter of boiler connection) Ada Fold out the opposite page to see venting details. Adapter at termination, if required Ada RETURN TO VENT AND AIR PIPING WATER PIPING (see boiler manual for details) Syst em RETURN TO PAGE 2 Sens or Do not exceed 12 inches apart Sens or b Syst em a DHW b c Gas a c Optional Easy-Up Manifolds: 1¼” (W-M #383-500-649) 1½” (W-M #383-500-661) DHW Typical piping, zone-valve zoning 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. t Ultra-80 / Ultra-105 . . . . . use 1” or larger t Ultra-155 / Ultra-230 . . . . . use 1¼” or larger t Ultra-299 / Ultra-399 . . . . . use 1½” or larger WRONG RIGHT Do n o 12 in t exceed ches apar t 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. 2 4 5 6 8 Material checklist — piping and other items JOB NAME ITEMS Boiler loop piping and components NOTICE — The piping must be installed as primary/secondary, with the boiler on its own loop as shown in the Ultra boiler manual and in this guide. (This requirement is met when using optional Easy-up Manifolds.) Use the pipe sizes listed below. Pipe, valves and fittings: Ultra-80, 105 (including flow/check Ultra-155, 230 valve) Ultra-299, 399 Optional Ultra Easy-Up Manifolds (complete, pre-assembled boiler loop piping; circulator shipped loose with boiler) — 1¼” for Ultra-80/-105; 1½” for -155 to -399 1” or larger 1¼” or larger 1½ or larger Part numbers: 1¼” (383-500-649) 1½” (383-500-661) System and zone piping System circulator and zone circulators (or zone valves) Pipe, valves and fittings for system and zone piping Air separator and expansion tank Fresh water make-up piping and components DHW piping DHW circulator Pipe, valves and fittings (including flow/check valve) Other piping Gas piping, valves and fittings; ground-joint union and manual shut-off valve for boiler gas connection; gas pressure regulator, if required ¾” pipe and elbows for relief valve discharge piping Condensate line Pipe or tubing for condensate line — ½” PVC or CPVC pipe; or 5/8” I.D. tubing Condensate neutralizing kit when required Weil-McLain part number 383-500-631 Condensate pump (required when condensate cannot drain by gravity to an appropriate location) Water treatment Sentinel X100 inhibitor is shipped with each boiler and must be applied as directed in the boiler manual. Water treatment company must provide additional system water treatment if required. RETURN TO WATER PIPING ITEMS Electrical components Wiring materials and fused shut-off switch Zone valves and other system control devices, as required Carbon monoxide detector, when required Antifreeze, when required Use only antifreeze listed in Ultra boiler manual as suitable for use with Ultra Gas boilers (antifreeze is available from Weil-McLain) — Ask your Weil-McLain distributor for information or visit us online at www.weil-mclain.com to review Ultra literature for recommendations. Ventilation openings Louvers for ventilation openings, when specified in boiler manual Propane applications Ultra-80 can be ordered as propane or you can obtain the Ultra-80 propane conversion kit. For Ultra-80 at altitude up to 5,500 feet, use W-M p/n 383-501-020. All other Ultra boilers are shipped with items needed to set up the boiler for propane, for altitude up to 5,500 feet. High altitude propane, Ultra-80 only — For altitude above 5,500 feet, all Ultra boilers require a high-altitude propane conversion kit. The Ultra-80 must first be equipped for propane (either purchased as Ultra-80LP or converted to Ultra-80LP using the kit listed above). Ultra-80LP 383-500-644 High altitude propane, Ultra-105–399 — For altitude above 5,500 feet, all Ultra boilers (except Ultra-399) require a high-altitude propane conversion kit. Obtain the kit listed below: Ultra-105 383-500-645 Ultra-155 383-500-646 Ultra-230 383-500-647 Ultra-299 383-500-648 Wall mounting option Weil-McLain Ultra wall-mounting kit, p/n 389-900-180 Recommended equipment Use a combustion analyzer to verify boiler operation, following the instructions in the Ultra boiler manual. U-tube manometer for checking gas line pressure Volt-ohmmeter may be required for troubleshooting Fold out the opposite page to see piping details.