Weil-McLain ULTRA Ultra-105 Owner's manual

Vent Supplement
This document must only be used by a qualified heating installer/service
technician. Read all instructions, including this Supplement and the Boiler
Manual, before installing. Perform steps in the order given. Failure to comply
could result in severe personal injury, death or substantial property damage.
Installation must comply with local requirements and with the National Fuel
Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 or B149.2 for
Canadian installations.
PartNo.550-101-235/0903
Installation of:
•Vent piping
• Air piping
with
Gas-fired
water boiler
Ultra-80, -105, -155, -230 & -310

Part number 550-101-235/0903
2
GAS-FIRED WATER BOILER — Vent Supplement
Please read before proceeding
Installer Read all instructions before installing.
Follow all instructions in proper order
to prevent personal injury or death.
• This document is intended only as a supplement
to the Ultra Boiler Manual. It’s purpose is for the
installation of vent and air piping for the boiler.
User
• This document is for use only by your qualified
heating installer/service technician.
• Please refer to the User’s Information Manual for
your reference.
• Keep this supplement near the boiler for use by
your installer or technician.
All Ultra boilers must be installed as direct vent. This requires piping
installation for both flue products (vent) and combustion air (air piping).
Allventandairpipingmustbeinstalled,terminatedandsealedasdescribed
in this supplement. Failure to adhere to the guidelines in this supplement
can result in severe personal injury,death or substantial property damage.
Contents
Hazard definitions
Thefollowingdefinedtermsareusedthroughoutthismanualtobringattentiontothepresenceofhazardsofvarious
risklevelsortoimportantinformationconcerningthelifeoftheproduct.
Indicates presence of hazards that will cause severe personal injury, death or substantial property
damage.
Indicates presence of hazards that can cause severe personal injury, death or substantial property
damage.
Indicates presence of hazards that will or can cause minor personal injury or property damage.
Indicates special instructions on installation, operation or maintenance that are important but not
related to personal injury or property damage.
Please read before proceeding ........................................................ 2
Vent and air piping materials ............................................................ 3
Prepare boiler location ...................................................................... 4
Vent/air termination — through roof ................................................ 6
Vent/air termination — sidewall ........................................................ 8
Installing vent & air piping .............................................................. 11

Part number 550-101-235/0903 3
GAS-FIRED WATER BOILER — Vent Supplement
Vent and air piping materials
Useonlythematerialslistedinthetablebelowforventandairpipeandfittings.Failuretocomplycould
resultinseverepersonalinjury,deathorsubstantialpropertydamage.
1
InstallationmustcomplywithlocalrequirementsandwiththeNationalFuelGasCode,ANSIZ223.1
forU.S.installationsorCSAB149.1orB149.2forCanadianinstallations.

Part number 550-101-235/0903
4
GAS-FIRED WATER BOILER — Vent Supplement
Prepare boiler location
Vent and air piping
Vent and air system
Installation must comply with local
requirements and with the National Fuel
Gas Code, ANSI Z223.1 for U.S.
installationsorCSAB149.1 orB149.2 for
Canadian installations.
TheUltraboilerrequiresaspecialventsystem,designed
for pressurized venting. Ultra boilers are rated ANSI
Z21.13 Category IV (pressurized vent, likely to
condense in the vent).
You must also install air piping from outside to the
boiler air intake adapter. The resultant installation is
categorized as direct vent (sealed combustion).
You may use any of the vent/air piping methods
covered in this supplement. 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.Use only PVC, CPVC or
ABS pipe and fittings, with primer and
cement specifically designed for the
material used.
Vent and air piping and termination
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.
Themaximumventlengthdependsonboilersize.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.
Do not install the Ultra 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.
2
Removing from existing vent
When removing existing boiler from
existingcommonvent system:
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.
a. Seal any unused openings in the common venting
system.
b. Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion or other
deficiencieswhichcouldcauseanunsafecondition.
c. Test vent system — Insofar as is practical, close all
buildingdoorsandwindowsandalldoorsbetween
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.
d. Place in operation the appliance being inspected.
Followthe lightinginstructions.Adjust thermostat
so appliance will operate continuously.
e. 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.
f. 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.
Any improper operation of common venting system
should be corrected so the installation conforms with
the National Fuel Gas Code, ANSI Z223.1 — latest
edition.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 B149.1 or B149.2 Installation Code.

Part number 550-101-235/0903 5
GAS-FIRED WATER BOILER — Vent Supplement
Prepare boiler location (continued)
Table 1 Corrosive contaminants
2
To prevent the potential of severe personal injury or
death, check for areas and products listed in Table 1
before installing the boiler or air inlet piping.
If contaminants are found, you MUST:
• Removeproductspermanently.—OR—
• Relocateairinletandventterminationstootherareas.
Air contamination
Pool and laundry products and common household
and hobby products often contain fluorine or chlorine
compounds. When these chemicals pass through the
boiler, they can form strong acids. The acid can eat
through the boiler wall, causing serious damage and
presentingapossiblethreatoffluegasspillageorboiler
water leakage into the building.
Please read the information given in Table 1, listing
contaminants and areas likely to contain them. If
contaminating chemicals will be present near the
location of the boiler combustion air inlet, have your
installer pipe the boiler combustion air and vent to
another location, per the Boiler Manual and Vent
Supplement.
If the boiler combustion air inlet is located in any area
likely to cause air contamination, or if products which
would contaminate the air cannot be removed, you
must have the combustion air and vent repiped and
terminated to another location. Contaminated
combustion air will damage the boiler heat exchanger,
resulting in possible severe personal injury, death or
substantial property damage.
DonotoperateanUltraboileriftheboilercombustion
air inlet is located in a laundry room or pool facility,
forexample.Theseareaswillalwayscontainhazardous
contaminants.

Part number 550-101-235/0903
6
GAS-FIRED WATER BOILER — Vent Supplement
Vent/air termination — through roof3
Figure 1 Vertical termination of air & vent
Determine location
Locate the vent/air terminations using the following
guidelines:
1. The total length of piping for vent or air must not
exceedthelimitsgiveninTable2,page12.
2. Theairpipingmustterminateinadown-turned180-
degreereturnbendasshowninFigure 1.Locatethe
airinletpipenofurtherthan2feetfromthecenterof
theventpipe.Thisplacementavoidsrecirculationof
flueproductsintothecombustionairstream.
3. The vent piping must terminate in an up-turned
coupling as shown in Figure 1. The top of the
couplingmustbeatleast1footabovetheairintake.
The air inlet pipe and vent pipe can be located in
any desired position on the roof, but must always
be no further than 2 feet apart and with the vent
termination at least 1 foot above the air intake.
4. You must consider the surroundings when
terminating the vent and air:
a. Position the vent termination where vapors will not
damage nearby shrubs, plants or air conditioning
equipment or be objectionable.
b. Theflueproductswillformanoticeableplumeasthey
condense in cold air. Avoid areas where the plume
could obstruct window views.
c. Prevailing winds could cause freezing of condensate
and water/ice buildup where flue products impinge
on building surfaces or plants.
d. Avoidpossibilityofaccidentalcontactofflueproducts
with people or pets.
e. Do not locate the terminations where wind eddies
couldaffectperformanceorcauserecirculation,such
asinsidebuildingcorners,nearadjacentbuildingsor
surfaces,windowwells,stairwells,alcoves,courtyards
or other recessed areas.
f. Do not terminate above any door or window.
Condensatecanfreeze,causingiceformations.
g. Locate or guard vent to prevent condensate damage
to exterior finishes.
5. Maintain clearances to vent termination as given
below:
a. Vent must terminate:
• At least 6 feet from adjacent walls.
• No closer than 5 feet below roof overhang.
• At least 7 feet above any public walkway.
• At least 3 feet above any forced air intake within
10 feet.
• No closer than 12 inches below or horizontally
from any door or window or any other gravity
air inlet.
b. Air inlet must terminate at least 6" above the roof or
snowlineandatleast12"belowtheventtermination
asshown inFigure 1.
c. Do not terminate closer to 4 feet horizontally from
anyelectricmeter,gasmeter,regulator,relief valveor
other equipment. Never terminate above or below
any of these within 4 feet horizontally.
6. Locate terminations so they are not likely to be
damagedby foreignobjects,suchasstones orballs,
or subject to buildup of leaves or sediment.
7. Donotconnectanyotherappliancetotheventpipe
or multiple boilers to a common vent pipe.
Follow instructions below when determining vent
location to avoid possibility of severe personal injury,
death or substantial property damage.
Installation must comply with local requirements and
with the NationalFuelGasCode,ANSI Z223.1 for U.S.
installations or CSA B149.1 or B149.2 for Canadian
installations.

Part number 550-101-235/0903 7
GAS-FIRED WATER BOILER — Vent Supplement
Vent/air termination — through roof (continued) 3
Prepare roof penetrations
1. Airpipepenetration:
a. Cutaholefortheairpipe.Sizetheairpipeholeas
closeasdesiredtotheairpipeoutsidediameter.
2. Ventpipepenetration:
a. Cut a hole for the vent pipe. For either
combustible or noncombustible construction,
size the vent pipe hole at least 0.4" larger than
the vent pipe diameter:
• 4" hole for 3" PVC
• 5" hole for 4" PVC
b. Insert a galvanized metal thimble in the vent
pipe hole.
3. Spacetheairandventholestoprovidetheminimum
spacingsshowninFigure 1,page 6.
4. Follow all local codes for isolation of vent pipe
when passing through floors, ceilings and roofs.
5. Provideflashingandsealingbootssizedforthevent
pipe and air pipe.
Termination and fittings
1. Prepare the vent termination coupling and the air
terminationelbow(Figure 1,page 6)byinsertingthe
bird screens provided with the boiler. Bird screens
areprovidedforeither3-inch(Ultra-80,-105and-
155)or4-inch (Ultra-230and-310)fittings.
a. Ifusing3-inchpipingforanUltra-230,cutthe4-
inchbirdscreensuppliedbyplacing3-inchfitting
onscreenandcuttingarounditasatemplate.
2. Theairpipingmustterminateinadown-turned180-
degree return bend as shown in Figure 1, page 6.
Locatethe airinletpipe nofurtherthan 2feetfrom
the center of the vent pipe. This placement avoids
recirculation of flue products into the combustion
airstream.
3. The vent piping must terminate in an up-turned
couplingasshowninFigure 1,page 6.Thetopofthe
couplingmustbeatleast1footabovetheairintake.
Theairinletpipeandventpipecanbelocatedinany
desiredpositionontheroof,butmustalwaysbeno
furtherthan2feetapartandwiththeventtermination
atleast1footabovetheairintake.
4. Maintain the required dimensions of the finished
terminationpipingasshowninFigure 1,page 6.
5. Donotextendexposedventpipeoutsideofbuilding
more than shown in this document. Condensate
couldfreezeandblockventpipe.
Multiple vent/air terminations
1. WhenterminatingmultipleUltraboilers,terminate
each vent/air connection as described in this
supplement.
Terminateallventpipesatthesameheight
andallairpipesatthesameheighttoavoid
possibilityofseverepersonalinjury,death
orsubstantial propertydamage.
2. Placeroofpenetrationstoobtainminimumclearance
of 12 inches between edge of air intake elbow and
adjacent vent pipe of another boiler for U. S.
installations (see Figure 2). For Canadian
installations, provide clearances required by CSA
B149.1 or B149.2 Installation Code.
3. The air inlet of an Ultra boiler is part of a direct
vent connection. It is not classified as a forced air
intake with regard to spacing from adjacent boiler
vents.
Figure 2 Through roof terminations with
multiple boilers

Part number 550-101-235/0903
8
GAS-FIRED WATER BOILER — Vent Supplement
Vent/air termination — sidewall4
Determine location
Locate the vent/air terminations using the following
guidelines:
1. The total length of piping for vent or air must not
exceedthelimitsgiveninTable2,page12.
2. The air piping must terminate in a down-turned
elbow as shown in Figure 3. This arrangement
avoids recirculation of flue products into the
combustion air stream.
3. Theventpipingmustterminateinanelbowpointed
outward or away from the air inlet, as shown in
Figure 3. Do not exceed the maximum lengths of
the outside vent piping shown in
Figure 3. Excessive length exposed to the
outside could cause freezing of
condensate in the vent pipe, resulting in
potential boiler shutdown.
4. You must consider the surroundings when
terminating the vent and air:
a. Position the vent termination where vapors will not
damage nearby shrubs, plants or air conditioning
equipment or be objectionable.
b. Theflueproductswillformanoticeableplumeasthey
condense in cold air. Avoid areas where the plume
could obstruct window views.
c. Prevailing winds could cause freezing of condensate
and water/ice buildup where flue products impinge
on building surfaces or plants.
d. Avoidpossibilityofaccidentalcontactofflueproducts
with people or pets.
e. Do not locate the terminations where wind eddies
couldaffectperformanceorcauserecirculation,such
asinsidebuildingcorners,nearadjacentbuildingsor
surfaces,windowwells,stairwells,alcoves,courtyards
or other recessed areas.
Follow instructions below when determining vent
location to avoid possibility of severe personal injury,
death or substantial property damage.
A gas vent extending through an exterior wall shall not
terminate adjacent to the wall or below building
extensions such as eaves, parapets, balconies or decks.
Failuretocomplycouldresultinseverepersonalinjury,
death or substantial property damage.
Installation must comply with local requirements and
with the NationalFuelGasCode,ANSI Z223.1 for U.S.
installations or CSA B149.1 or B149.2 for Canadian
installations.
f. Do not terminate above any door or window.
Condensatecanfreeze,causingiceformations.
g. Locate or guard vent to prevent condensate damage
to exterior finishes.
5. MaintainclearancesasshowninFigures 3,4,and 5,
pages 8,9and 10.Alsomaintainthefollowing:
a. Vent must terminate:
• At least 6 feet from adjacent walls.
• No closer than 5 feet below roof overhang.
• At least 7 feet above any public walkway.
• At lease 3 feet above any forced air intake within
10 feet.
• No closer than 12 inches below or horizontally
from any door or window or any other gravity
air inlet.
b. Air inlet must terminate at least 12" above grade or
snow line; at least 12" below the vent termination;
and the vent pipe must not extend more than 24"
vertically outside the building as shown in Figure 3.
c. Do not terminate closer to 4 feet horizontally from
any electric meter, gas meter, regulator, relief valve
orotherequipment.Neverterminateaboveorbelow
any of these within 4 feet horizontally.
Figure 3 Sidewall termination of air & vent:
(Apply left illustration unless air termination ell
would not provide the minimum 12 inch
clearanceto grade or snow line.
Apply right illustration for other applications,
where exit openings are too low to provide the
minimum12 inch clearance.)

Part number 550-101-235/0903 9
GAS-FIRED WATER BOILER — Vent Supplement
Prepare wall penetrations
1. Air pipe penetration:
a. Cutahole fortheairpipe.Size theairpipehole
as close as desired to the air pipe outside
diameter.
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either
combustible or noncombustible construction,
size the vent pipe hole at least 0.4" larger than
the vent pipe diameter:
• 4" hole for 3" PVC
• 5" hole for 4" PVC
b. Insert a galvanized metal thimble in the vent
pipe hole as shown in Figure 6.
3. Use a sidewall termination plate as a template for
correct location of hole centers.
4. Follow all local codes for isolation of vent pipe
when passing through floors or walls.
5. Seal exterior openings thoroughly with exterior
caulk.
Figure 6 Sidewall termination assembly
Vent/air termination — sidewall (continued) 4
Determine location (continued)
6. Locate terminations so they are not likely to be
damagedby foreignobjects,suchasstones orballs,
or subject to buildup of leaves or sediment.
7. Donotconnectanyotherappliancetotheventpipe
or multiple boilers to a common vent pipe.
Figure 4 Clearance to gravity air inlets
Figure 5 Clearance to forced air inlets

Part number 550-101-235/0903
10
GAS-FIRED WATER BOILER — Vent Supplement
Figure 7 Multiple vent/air terminations (must
also comply with Figure 4)
Figure 8 Multiple vent/air terminations (must
also comply with Figure 4)
(Apply this method only where exit openings
are too low to provide minimum 12 inch
clearanceabove grade/snowline.)
Vent/air termination — sidewall (continued) 4
Multiple vent/air terminations
1. WhenterminatingmultipleUltraboilers,terminate
each vent/air connection as described in this
supplement.
All vent pipes and air inlets must
terminate at the same height to avoid
possibilityofseverepersonalinjury,death
or substantial property damage.
2. Place wall penetrations to obtain minimum
clearance of 12 inches between vent pipe and
adjacent air inlet elbow, as shown in Figure 7 or
Figure 8 for U. S. installations. For Canadian
installations, provide clearances required by CSA
B149.1 or B149.2 Installation Code.
3. The air inlet of an Ultra boiler is part of a direct
vent connection. It is not classified as a forced air
intake with regard to spacing from adjacent boiler
vents.
Termination and fittings
1. Prepare the vent termination elbow and the air
termination elbow (Figure 6) by inserting the bird
screens provided with the boiler. Bird screens are
providedforeither3-inch(Ultra-80,-105and-155)
or4-inch (Ultra-230and-310)fittings.
a. Ifusing3-inchpipingforanUltra-230,cutthe4-
inchbirdscreensuppliedbyplacing3-inchfitting
onscreenandcuttingarounditasatemplate.
2. Whencompleted,theairterminationcouplingmust
be oriented at least 12 inches below the vent
termination and at least 12 inches above grade or
snowlineasshowninFigure 3,page 8.
3. You can orient the vent termination elbow either
directly outward or 90 degrees away from the air
inletelbowasshowninFigure 3,page 8.
4. Maintain the required dimensions of the finished
terminationpipingasshowninFigure 3,page 8.
5. Donotextendexposedventpipeoutsideofbuilding
more than shown in this document. Condensate
couldfreezeandblockventpipe.

Part number 550-101-235/0903 11
GAS-FIRED WATER BOILER — Vent Supplement
Installing vent & air piping5
Inserting/securing vent or air
pipe into boiler adapters
1. Clean and chamfer insertion end of pipe. Deburr
inside of insertion end. Clean and deburr inside
and outside of other end of pipe.
The pipe end must be smooth and
chamferedtopreventpossibledamageto
sealing gasket in vent or air pipe adapter.
Failuretocomplycould resultin leakage,
causingpossibleseverepersonalinjuryor
death.
2. Inspect vent or air adapter (above) — verify no
obstructions or foreign objects inside.
3. Loosen clamp screw.
4. Measure 3½ inches from end of pipe and make a
mark with felt-tip pen.
5. Loosen adapter clamp screw.
6. Applysmallamountofsilicongreasetoendofpipe
to ease insertion.
7. Insert pipe into adapter.
8. Slidepipedownuntilthe3½-inchmarkisreached.
Do not apply excessive force or bend the
adapter or flue/air pipe when inserting.
The adapter or seal could be damaged.
9. Secure vent or air pipe by tightening the adapter
clamp securely. Do not overtighten. The seal is
accomplished with the internal gasket. The clamp
is only to hold the pipe in place.
Installing vent or air piping
Forreferenceinfollowingsee:
• Sidewalltermination—Figure 9,page 12.
• Through-rooftermination—Figure 10,page12.
1. Workfromtheboilertoventorairtermination.Do
notexceedthelengthsgiveninTable 2foreitherthe
airorventpiping.
a. Note that the Ultra-230 may be installed with either
3-inchor4-inchventandairpiping.Table 2provides
shorter allowable piping lengths when using 3-inch
piping.
2. Cutpipetorequiredlengths.
3. Deburrinsideandoutsideofpipeends.
4. Chamfer outside of each pipe end to ensure even
cement distribution when joining.
5. Clean all pipe ends and fittings. Dry thoroughly.
6. Dry assemble entire vent or air piping to ensure
proper fit before assembling any joint.
7. For each joint:
a. Handle fittings and pipes carefully to prevent
contamination of surfaces.
b. Apply primer liberally to both joint surfaces — pipe
endandfitting socket.
c. While primer is still damp, lightly apply approved
cementto bothsurfaces in a uniform coating.
d. Apply a second coat to both surfaces. Avoid using
too much cement on sockets to prevent cement
buildup inside.
e. Withcementstillwet,insertpipeintofitting,twisting
¼turn. Make surepipe is fullyinserted.
f. Wipeexcesscementfromjoint.Checkjointtobesure
a smooth bead of cement shows around the entire
joint.
8. Installperforatedmetalpipesupportsorequivalent
asshowninFigures 9and 10,page 12.
9. Slopeventandairpipingcontinuouslytowardboiler,
with at least ¼ inch drop per foot of run. Do not
allowsags at any point.
10. Maintain minimum clearance of 0.2 inch between
ventpipeandanycombustiblewallormaterial.Seal
wall or floor penetration openings following local
code requirements.
11. Use exhaust terminal plates on inside and outside
walls at sidewall terminations.
Installation must comply with local requirements and
with the NationalFuel Gas Code,ANSIZ223.1forU.S.
installations or CSA B149.1 or B149.2 for Canadian
installations.

Part number 550-101-235/0903
12
GAS-FIRED WATER BOILER — Vent Supplement
Installing vent & air piping (continued) 5
Figure 10 Piping to through-roof terminations
Figure 9 Piping to sidewall terminations
Table 2 Min/max lengths of either air piping
or vent piping
When a large number of elbows is
needed with 3-inch piping, use long
radius elbows to reduce pressure drop.
This allows a longer run of piping. See
Table 2 notes for details.
Do not insulate vent piping. Exception: Where vent pipes pass through unheated spaces, such as
crawl spaces or unheated garages, apply ½ inch fiberglass insulation to the portion of the vent pipe
in the unheated space only.