Weil-McLain Ultra Quick Start Guide

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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.
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