Weil-McLain Ultra Series 3 User manual

Series 3
Gas-fired water boilers – Series 3
Featuring
Flexibility
Installation guide and material checklists
This guide must only be used by a qualified 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.

BEFORE INSTALLING . . .
Make sure there is enough clearance for the boiler and all•
water, gas and air piping. Verify vent/air termination can
be located as required.
All models are shipped with the items needed for propane•
conversion except the Ultra-80, which requires a separate
conversion kit (see material checklist).
When wall mounting the boiler, obtain the wall-mount kit•
(see material checklist).
START-UP, ADJUST & TEST
Follow the boiler manual instructions to clean the system•
if needed, then fill and check water chemistry.
Start up the boiler as directed in the manual. Use a•
combustion analyzer where specified.
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INSTALL CONDENSATE PIPING /
TUBING AND COMPONENTS
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.
Connection tee and internal components are supplied•
with the boiler.
44
INSTALL GAS PIPING
Install a union and shutoff valve.•
No external drip leg is needed — it is already included in•
the boiler’s internal gas piping.
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66
WIRE THE BOILER
Connect power wiring and control wiring per boiler•
manual wiring diagram.
Connect system and DHW circulator wiring to the•
terminals designated in the boiler manual.
INSTALL VENT & AIR PIPING
See vent / air piping options POQBHFTBOE.•
Refer to the material checklist in this guide for a list of•
items needed.
INSTALL WATER PIPING
See information POQBHFTBOE.•
Refer to the material checklist in this guide for a list of•
items needed.
Steps 2 – 6 can be done in any order —
just make sure that air, vent, water and gas
pipes will not interfere with one another.
77
Choose pre-loaded boiler settings, or customize settings•
for various applications.
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33
(Follow all instructions in Boiler manual)
QUICK-STARTQUICK-START

TRIM OFF HERE
VENT & AIR PIPING
(see boiler manual for details)
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.
Make sure the terminations are placed as required in the
manual and that air intakes are at least 12 inches above
normal snow line.
Vertical
3”Concentric Pipe
termination
(requires W-M kit)
Vertical
Separate Pipes
termination
(requires 2 bird screens)
Sidewall with
Weil-McLain
termination
(included with boiler)
Sidewall with
Separate Pipes
termination
(requires 2 bird screens)
Air inlet can be snorkeled up as shown above.
See manual for details.
Sidewall with
3”Concentric Pipe
termination
(requires W-M kit)
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3
Support pipes as
described in the
manual.
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”
Slope pipes ¼” per
foot toward boiler.

TRIM OFF HERE
Ultra model
Vent or air
pipe size
• Allowable pipe sizes of vent/air piping
• Maximum equivalent feet of each
• Number of elbows allowed at these lengths
(All applications include allowance for the termination.)
Sidewall
with
W-M Plate
Sidewall
with
separate
pipes
3” PVC Concentric
Sidewall or Vertical
(Use only PVC pipe —
DO NOT use
CPVC or ABS)
Vertical
with
separate
pipes
Length Ells Length Ells Length Ells Length Ells
80/105
2” ** 100 (ab) 2 100 2 100 (ab) 1 100 1
3” 100 2 100 2 100 1 100 1
155 3” 100 2 100 2 100 1 100 1
230
3” 30 (c) 2 30 (c) 2 30 (c) 1 30 (c) 1
4” 100 (d) 2 100 2 70 (d) 1 100 1
299 4” 100 2 100 2 70 (d) 1 100 1
399 4” 100 2 100 2 NA 100 1
Equivalent feet for elbows — deduct from maximum equivalent length of piping:
• 7 feet per for each 4-inch elbow & 2 or 3-inch 90° long-radius or 45° elbow
• 16 feet for each 2- or 3-inch short-radius elbow
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.
Items Material Standards for installations in:
United States Canada
Plastic piping materials
Vent or air
pipe
&
fittings
PVC schedule 40 ANSI/ASTM D1785 Plastic vent
pipe must be
certified to UL
S636 when
required.
Air pipe can be
any of those
listed at left if
acceptable for
local codes.
PVC-DWV ANSI/ASTM D2665
CPVC schedule 40 ANSI/ASTM F441
ABS-DWV schedule
40 ANSI/ASTM D2661
PVC & ABS
pipe
cement &
primer
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
ABS ANSI/ASTM D2235
AL29-4C piping materials
Vent pipe
AL29-4C
stainless
steel
Heat Fab, Inc.
Saf-T-Vent®
Z-Flex, Inc.
Z-Vent II
Protech Systems
FasNSeal™
Certified for
Category IV
and direct vent
appliance
venting
Certified for
Category IV
and direct vent
appliance
venting
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 for vent or air piping.
Material checklist — vent and air piping
NOTE: Also obtain all required flashings, boots, thimbles, fire stops or
other items required for wall, ceiling and roof penetrations.
QUICK-START
QUICK-START
Pipe and fittings — Plastic
Material — PVC CPVC ABS
Size — 2” 3” 4”
ITEM QTY ✔
Straight pipe feet
Elbows, 90-degree (include termination elbows if required)
Couplings (include termination if vertical separate pipes)
Return bend, 180-degree (vertical separate-pipe termination)
1
Reducers: 3"x2" 4"x3"
Pipe and fittings — AL29-4C Stainless
Product — Saf-T-Vent®Z-Vent II FasNSeal™
Size — 2” 3” 4”
ITEM QTY ✔
Straight pipe feet
Adjustable lengths
Elbows, 90-degree
Termination elbows (with integral screen), when req’d
Elbows, 45-degree
Adapter at boiler (to fit diameter of boiler connection)
Adapter at termination, if required
Items required for: W-M P/N QTY ✔
Sidewall with Weil-McLain Plate
W-M sidewall term. kit 3"•
4"
383-500-397
383-500-398 1
Included
with boiler
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.
Sidewall with separate pipes
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.
Bird screens * 3"•
4"
383-500-105
383-500-110 2
* For 2”pipe, trim 3” bird screen to size
Vertical with separate pipes
Bird screens (see note) 3"•
4"
383-500-105
383-500-110 2
* For 2” pipe, trim 3” bird screen to size
Coupling (1)• Add to the table at right
180-degree return bend (1)• Add to the table at right
3" PVC concentric termination, sidewall or vertical
Concentric termination kit, 3"• 383-500-350 1
Reducers: 3”x2”• 4”x3” Add to the table at right
Fold out the opposite page to see venting details.
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3

TRIM OFF HERE
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.
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.
Ultra-80 / Ultra-105• . . . . . use 1” or larger
Ultra-155 / Ultra-230• . . . . . use 1¼” or larger
Ultra-299 / Ultra-399• . . . . . use 1½” or larger
WATER PIPING
(see boiler manual for details)
2
2
WRONG
RIGHT
DHW
DHW
System
Sensor Sensor
Gas
System
Typical piping, zone-valve zoning
Do not exceed
12 inches apart
Do not exceed
12 inches apart
b
a
c
a
b
c

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. Use the pipe sizes listed below.
Pipe, valves and fittings:
(including flow/check
valve)
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1” or larger
1¼” or larger
1½ or larger
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 pres-
sure 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)
Wall mounting
Weil-McLain Ultra wall-mounting kit, W-M p/n 389-900-180
Other
Water treatment company must treat system water if
required.
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 suit-
able 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
Material checklist — piping and other items
QUICK-START
QUICK-START
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
JOB NAME
TRIM OFF HERE
Fold out the opposite page to see piping details.
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