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Gas-fired
water boiler
Installation Manual
Multiple-boiler systems with
®
Weil-McLain Easy-Fit piping
• Selection data
Installation
Piping
Water treatment
with
This manual must only be used by a qualified heating installer/service technician.
Before installing, read all instructions, including this manual, the Ultra Boiler
Manual and all applicable Supplements. Consider all connections to the boilers
before selecting a location and layout. Failure to comply could result in severe
personal
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Contents Hazard definitions .................................................................................................................................. 3 Selection data Controls .................................................................................................................... 3 Domestic hot water ................................................................................................. 3 Vent
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems 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. Indicates presence of hazards that will Indicates presence of hazards that will or cause severe personal injury, death or can cause minor personal injury or substantial property damage. property damage. Indicates pr
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Ratings and engineering data Figure 1 Ratings and engineering data (see page 5 for notes) DOE 4 Part number 550-101-232/0703
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Figure 1 Ratings and engineering data (continued) For simplicity, the table on page 4 lists only systems using multiples of the same Ultra boiler module. Any combination of Ultra boilers can be installed as a multiple boiler system. Water header piping Determine the flow rate that the system header and other pipes will handle. Then use the table at right to determine the minimum pipe size. This table shows pipe sizing both
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Dimensions Figure 2 Dimensional data Notes 1. Boiler supply and return tappings are both 1" NPT. 2. Boiler circulator is shipped loose. Mount 3. Relief valve is shipped loose. See Boiler Connect to headers with 1” pipe for Ultra-80 and boiler circulator in connecting piping Manual pages 14 and 15 for mounting Ultra-105; 1¼" pipe for Ultra-155 and Ultra-230. as shown in this manual. Boiler is details. Relief valve mounts on
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Placement and mounting information Placement, general Figure 3 Side-to-side installation of multiple Ultra-80/-105/-155/-230 boilers 1. Locate multiple boilers in boiler room according to: Figure 3 (side-to-side), or Figure 4 (back-to-back). For wall mounting, see below. 2. Provide indicated clearances around boilers for access and servicing. If recommended di- mensions are not possible, re- fer to Ultra Boiler Manual
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems ® Easy-Fit Piping Easy-Fit® Piping installation Figure 6 Single-sided connection — Maximum connected boiler output: ® 1. Main header and Easy-Fit Manifold pipe sizing. 2-inch manifolds — 450 MBH 3-inch manifolds — 1400 MBH a. New system: 4-inch manifolds — 2900 MBH Refer to Figure 1 on pages 4 and 5 for recommendations. b. Replacing boilers in an existing system: Without reducing size, connect system supply and
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems ® Figure 8 Piping schematic — Typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit Manifolds 1 Flow/check valve (each boiler) 8 System air eliminator 15 Low water cutoff (when used) (place above primary header) 2 Isolation valves (when used) 9 System automatic air vent 16 Water flow switch (when used) 3 Cap 10 Pressure reducing valve ® 17 Boiler circulator (each boiler) 4 Easy-Fit Manifold (supply
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems ® Easy-Fit Piping (continued) ® Figure 9 Typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit Manifolds 1 Flow/check valve (each boiler) 6 Primary circulator 18 System supply 2 Isolation valves (when used) 7 Expansion tank (diaphragm type) 19 System return 3 Caps 8 System air eliminator 20 Boiler relief valve and discharge piping, ® installed per Ultra Boiler Manual 4 Easy-Fit Manifold (supply),
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems ® Figure 10 Typical piping for multiple Ultra boilers, Weil-McLain Easy-Fit Manifolds, and indirect water heaters Suggested DHW boiler-side pipe sizing (based on 500 milinch per foot head loss in piping): 0 – 7 gpm .......................... 1 inch 7 – 16 gpm ........................ 1¼ inch 16 – 24 gpm ...................... 1½ inch 24 – 45 gpm ...................... 2 inch 45 – 75 gpm ...................... 2½ inch 75 –14
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems ® Easy-Fit Piping (continued) ® Figure 11 Typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit Manifolds and heat exchanger Use isolation heat exchanger for: 1. Large volume systems with high mineral content in water. 2. Systems exposed to untreated quan- tities of makeup water. 3. Old systems severely contaminated with scale and rust buildup inside piping and heat distribution units. 4. Process application
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Combustion air & vent piping installation Vent piping Combustion air manifolds 1. When combustion air supplied from a common air 1. Each boiler requires an individual vent pipe, in- manifold pipe as in Figure 12, size the common air stalled and terminated per the Ultra Boiler Manual duct and louver free area from the minimum free and Ultra Boiler Venting Suppments. area given in Figure 1, pages 4 and 5. 2. The vent pipes of
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Gas piping Connecting gas supply piping 3. Support piping with hangers, not by boiler or its 1. Remove jacket front panel and refer to Figure 13 to pipe gas to boiler. accessories. a. Install ground joint union for servicing, when 4. Purge all air from gas supply piping. required. 5. Before placing boiler in operation, check boiler and b. Install manual shutoff valve in gas supply pip- its gas connection for leaks. ing outs
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Common gas piping installation 1. Construct gas header for multiple boilers using Figure 14 and 4. Size gas piping from meter outlet to entrance of gas header in the sizing tables below. Refer to the National Fuel Gas Code for accordance with Tables 1 and 2 below. For gases with other other conditions. specific gravity or for different pressure drop or other pipe sizes, refer to the National Fuel Gas Code or applicable loca
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GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems Additional instructions Air for boiler room ventilation 1. Follow instructions in Ultra Boiler Manual to ensure the boiler room provides sufficient air infiltration. Wiring 1. Refer to boiler sequencing control instructions and Ultra Boiler Manual for wiring re- quirements. Water treatment Multiple boilers used with large water volume systems will require water softening and conditioning. Consult a local water treatment com
