Vent pipe — at least 0. See Figure 1 for other clearance minimums. See Figure 1 for recommended service clearances. If you do not provide minimum clearances shown, it might not be possible to service the boiler without removing it from the space. Ultra boilers, except the Ultra, may be wall mounted using special wall mount kit or floor mounted. No clearance is required at the rear of the unit, either for service or for clearance to combustible surfaces. The Ultra boiler is approved for installation on combustible flooring, but must never be installed on carpeting.
Do not install boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death or substantial property damage.
Provide a solid foundation pad, at least 2 inches above the floor, if any of the following is true:. Foundation may be of wood, brick or concrete minimum 2 inches thick construction.
If flooding is possible, elevate boiler sufficiently to prevent water from reaching boiler. Replace boiler jacket front door after servicing. The boiler front door must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room. This is particularly important if the boiler is located in the same room as other appliances. Failure to comply with the above warnings could result in severe personal injury,death or substantial property damage.
Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the Ultra boiler because it takes its combustion air from outside direct vent installation. Take the following special precautions when installing the boiler in a residential garage.
For spaces that do NOT supply this clearance, provide two openings as shown in Figure 1. Each opening must provide 1 square inch free area per 1, Btuh of boiler input. The Ultra boiler requires a special vent system, designed for pressurized venting. You must also install air piping from outside to the boiler air intake adapter. The resultant installation is categorized as direct vent sealed combustion.
Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall. Do not attempt to install the Ultra boiler using any other means. Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated.
Refer to Table 1 for products and areas which may cause contaminated combustion air. You must pipe combustion air to the boiler air intake. Ensure that the combustion air will not contain any of the contaminants below. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage.
Do not pipe combustion air near a swimming pool, for example. Also avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.
Do not install the Ultra boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. Seal any unused openings in the common venting system. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.
Test vent system — Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed.
Do not operate a summer exhaust fan. Close fireplace dampers. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. Test for spillage at draft hood relief opening after 5 minutes of main burner operation.
Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.
Correct by resizing to approach the minimum size as determined using the appropriate tables in Part 11 of that code. Canadian installations must comply with B The Ultra boiler is generally easier to handle and maneuver after removing from crate.
After removing outer shipping carton from boiler, REMOVE jacket front door by loosening two knurledhead screws at lower front. Removing the door will prevent possible damage to the door during handling. To remove boiler from pallet after removing jacket front door :. Remove the four lag screws securing shipping brackets. Unscrew the two rear boiler legs and remove the shipping brackets. Discard the cardboard protector insert on the rear of the boiler.
Do not drop boiler or bump jacket on floor or pallet. Damage to boiler can result. Follow the instructions provided with the optional propane conversion kit. The propane conversion kit is NOT included as standard equipment for the Ultra Do not apply the following to conversion of a boiler already installed and connected to gas supply. For a boiler already installed, you must turn off gas supply, turn off power and allow boiler to cool before proceeding.
See separate natural to propane conversion instructions for conversion of an existing boiler. You must install the propane orifice to fire the Ultra boiler on propane. Verify when installing that the orifice size marking matches boiler size. UltraLP boilers are factory-equipped to operate on propane gas. With boiler on its back, remove jacket front door by removing two knurled head screws at lower front.
Then lift door away from boiler. Disconnect the gas valve electrical plug. Remove the 4 screws securing gas valve inlet adapter to valve. Locate propane orifice disc from conversion kit bag. Verify that the stamping on the orifice disk matches the boiler size. Place orifice in the black rubber grommet in the side of the gas valve and secure in valve Figure 2. Reposition gas valve against venturi and replace 3 TORX screws securing valve to venturi.
Secure gas valve inlet adapter to gas valve with 4 screws. Make sure the plastic hose is connected from gas valve to inlet elbow. Inspect the O-ring between the gas valve and gas valve inlet adapter block whenever they are disassembled.
The O-ring must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death. DO NOT attempt to adjust gas valve outlet pressure. Connect gas valve electrical plug to valve terminals. After installation is complete, attach the propane conversion label in conversion kit bag next to the boiler rating plate.
Replace jacket front panel. Disconnect the gas line union below the gas valve. Reconnect gas line union. Figure 2a Installing propane orifice Ultra and Ultra Ultra boilers cannot be equipped for propane firing as of October, Propane capability should be available in Set boiler in place and check level.
Ultra, , and boilers can be wall mounted. Use only the separately available Ultra boiler wall mounting kit and instructions. The wall must be vertically plumb and capable of carrying the weight of the boiler.
The operating weights are:. Ultra pounds. Wall mount Ultra boilers only using WeilMcLain Ultra boiler wall-mounting kit and accompanying instructions. This kit is not supplied as standard equipment with the boiler, and must be purchased separately.
Failure to comply with above could result in severe personal injury, death or substantial property damage. Pressure test boiler before permanently attaching water or gas piping or electrical supply.
See Figure 3 for reference in following steps. Pipe to boiler supply connection as shown. Use pipe dope sparingly. Connect a hose to boiler drain valve, the other end connected to a fresh water supply. Make sure hose can also be used to drain boiler after test. Connect a nipple and shutoff valve to system supply connection on the supply tee. This valve will be used to bleed air during the fill. Valve and nipple are not included with boiler.
Connect a shutoff valve to system return connection. Valve is not included with boiler. To avoid getting water on boiler, you may want to pipe street elbows on top of shutoff valves and attach catch-buckets beneath. If convenient, install the boiler circulator and any other piping compatible with Figure 3 that would still allow bleeding air from shutoff valves.
Follow guidelines in this manual for piping components, locations and sizing. Open the shutoff valves you installed on supply and return connections. Slowly open boiler drain valve and fresh water supply to fill boiler with water. The boiler will fill quickly because of its low water content.
When water reaches shutoff valves, close boiler drain valve. Hold at test pressure for 10 minutes. Do not leave boiler unattended. A cold water fill could expand and cause excessive pressure,resulting in severe personal injury, death or substantial property damage. Make sure constant gauge pressure has been maintained throughout test. Check for leaks. Repair if found. Leaks must be repaired at once. Failure to do so can damage boiler, resulting in substantial property damage.
Do not use petroleum-based cleaning or sealing compounds in boiler system. Disconnect fill water hose from water source. Drain boiler through drain valve. Remove hose after draining. Remove nipples and valves unless they will remain for use in the system piping. Remove plug from relief valve street elbow. See section 3 page 12 to install relief valve. Pipe the relief valve only as shown, in the location shown.
Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the valve discharge. Do not plug or place any obstruction in the discharge line. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve.
Use two wrenches when tightening water piping at boiler, using one wrench to prevent the boiler return line or supply line from turning. Failure to support the boiler piping connections to prevent them from turning could cause damage to boiler components. The Ultra control module uses temperature sensors to provide both high limit protection and modulating temperature control. The control module also provides low water protection by sensing the temperature of the heat exchanger.
Following standard industry practices, if installation is to comply with ASME or Canadian requirements, an additional high temperature limit is needed. See Ultra Control Supplement for wiring. If limit control is to cause a boiler hard lockout requiring manual reset of Ultra control module , connect isolated contact to field control wiring terminals 6 and 8 as shown in wiring diagram. Otherwise, connect isolated contact between terminals 6 and 7 for a soft lockout automatic reset. A low water cutoff device is required when boiler is installed above piping level or by certain state or local codes or insurance companies.
Consult local requirements to determine. If required, use a low water cutoff designed for water installations. Electrode probe-type is recommended. Purchase low water cutoff and install in tee in supply piping above boiler. These designs ensure proper flow through the Ultra boiler, for the most efficient and reliable operation of the boiler and the heating system.
For other piping methods, consult your local Weil-McLain representative or refer to separate Ultra boiler piping guides. Wall-mounted boilers — Piping can exit bottom of boiler enclosure.
See separate wall-mounting instructions for details. Ensure expansion tank size will handle boiler and system water volume and temperature. Allow 3 gallons for boiler and its piping. Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through fill valve.
Eventual boiler failure can result due to excessive make-up water addition. Tank must be located as shown in this manual, or following recognized design methods. Connect the expansion tank to the air separator only if the separator is on the suction side of the circulator. Always install the system fill connection at the same point as the expansion tank connection to the system. Most piping drawings in this manual show diaphragm expansion tanks. See Figure 4 for piping from air separator to expansion tank and make-up water line using a closed-type expansion tank.
Most chilled water systems are piped using a closedtype tank, as shown in Figure 10, page Figure 4 Always install an automatic air vent on top of the air separator to remove residual air from the system. See Figure 4, Alternate, for piping connections when using a closed-type expansion tank. Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping. DO NOT install automatic air vents on closed-type expansion tank systems. Air must remain in the system and return to the tank to provide its air cushion.
An automatic air vent would cause air to leave system, resulting in water-logging the expansion tank. The boiler circulator Taco for Ultra and ; Taco for Ultra, , and is shipped loose. Locate it either in the return or supply piping, as shown in the appropriate piping diagram in this manual.
DO NOT use the boiler circulator in any location other than the ones shown in this manual. The boiler circulator is selected to ensure adequate flow through the Ultra boiler. Failure to comply could result in unreliable performance and nuisance shutdowns from insufficient flow.
See Figures 7 through 10, pages 15 — 18, for recommended piping. Size the piping and components in the space heating system using recognized design methods. Figure 5 shows recommended DHW piping, as shown in Figures 7 through 10, pages 15 — All show direct connection of the DHW piping to the boiler because the boiler circulator shuts down during DHW operation.
Figure 6 shows the pump curves for suggested DHW. Figure 5 DHW piping see Table 2 for approximate head losses. Use these curves along with boiler pressure drop data from Table 2 to size the DHW piping and circulator. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.
Test vent system — Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building.
Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. Test for spillage at draft hood relief opening after 5 minutes of main burner operation.
Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.
Correct by resizing to approach the minimum size as determined using the appropriate tables in Part 11 of that code. Canadian installations must comply with B The Ultra boiler requires a special vent system, designed for pressurized venting.
You must also install air piping from outside to the boiler air intake adapter. The resultant installation is categorized as direct vent sealed combustion.
Do not attempt to install the Ultra boiler using any other means. DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the living space.
The Ultra boiler vent and air piping can be installed through the roof or through a side wall. Follow the procedures in this document for the method chosen. The maximum vent length depends on boiler size. Refer to the information in this supplement to determine acceptable vent and air piping length.
Combustion air for the Ultra boiler must be ducted directly to the boiler from outside direct vent installation. Follow all instructions in this document and the Ultra Boiler Manual to install vent and air piping. Welcome to ManualMachine. We have sent a verification link to to complete your registration.
Log In Sign Up. Forgot password? Enter your email address and check your inbox. Please check your email for further instructions. Enter a new password. Installer Read all instructions before installing. 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. Removing from existing vent Do not install the Ultra into a common vent with any other appliance.
0コメント