Weil-McLain 105 Boiler User Manual
Contents
1. WEIL McLAIN Mh ty Ve Gas fired water boiler nt Supplement Uitra 80 105 155 230 amp 310 NOTICE Installation of e Vent piping e Air piping Utra with PRECISION HYDRONIC DATA technology This document must only be used by a qualified heating installer service technician Read all instructions including this Supplement and the Boiler M anual 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 Part No 550 101 235 0903 Ulla GAS FIRED WATER BOILER Vent Supplement Contents Please read before proceeding ccsssceescceseccssecenseenseneneeensesenees 2 Vent and air piping materials ccsseceseseeeceeeseeeceeeseeeeeeseeesees 3 Prepare boiler location cccesceceseeceeseceeseeensesenseeensesenneseeseeeenees 4 Vent air termination through roof ccceccsescssssesseeesensseeseeeeees 6 Vent air termination sidewall ccssesssecseeceesseseceneseneeeneeees 8 Installing vent amp air piping ccceeeeseeeeeeceeeeeeeeeseeeeeeeseeeeeeeeesenes 11 Please read before proceeding Installer User WARNING Read all ins2. p betl Pe soran ie abat h o a i i 3 Part number 550 101 235 0903 Li Vent ppirig LE Mr Pp 8 Gard someon airi Prepare wall penetrations 1 Air pipe penetration a Cutaholefor theair pipe Sizetheair pipehole 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 e 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 Usea 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 iT EIERN A Nippa LE Siral emna pass 4 G banzed Phris 8 Blbow wam eminal HP tornado albos oreniabon 6 Gir ined alkemi Li Eero screen want jorma Ulla GAS FIRED WATER BOILER Vent Supplement 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 provided for either 3 inch U Itra 80 105 and 155 or 4 inch Ultra 230 and 310 fittings a Ifusing3 inch pipingfor an Ultra 230 cut the 4 inch bird screen s
3. to ease insertion 7 Insert pipe into adapter 8 Slide pipedown until the 34 inch mark is reached 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 Part number 550 101 235 0903 Installing vent or air piping For referencein following see 1 10 Ll Sidewall termination Figure 9 page 12 Through roof termination Figure 10 page 12 Work from the boiler to vent or air termination Do not exceed thelengths given in Table 2 for either the air or vent piping a Notethat the Ultra 230 may be installed with either 3 inch or 4 inch vent and air piping Table 2 provides shorter allowable piping lengths when using 3 inch piping Cut pipeto required lengths Deburr insideand outsideof pipe ends Chamfer outside of each pipe end to ensure even cement distribution when joining Clean all pipe ends and fittings Dry thoroughly Dry assemble entire vent or air piping to ensure proper fit before assembling any joint For each joint a Handle fittings and pipes carefully to prevent contamination of surfaces b Apply primer liberally to both joint surfaces pipe end and fitting socket c While primer is still damp lightly apply approved cement to both s
4. 0 degree return bend as shown in Figure 1 page 6 Locate the air inlet pipeno further than 2 feet from the center of the vent pipe This placement avoids recirculation of flue products into the combustion air stream The vent piping must terminate in an up turned coupling asshown in Figure 1 page 6 Thetop of the coupling must beat least 1 foot abovetheair intake Theair inlet pipeand vent pipecan belocated in any desired position on theroof but must always beno further than 2 feet apart and with thevent tamination at least 1 foot above the air intake Maintain the required dimensions of the finished termination piping as shown in Figure 1 page 6 Do not extend exposed vent pipe outside of building more than shown in this document Condensate could freezeand block vent pipe Part number 550 101 235 0903 Vent air termination through roof continues Multiple vent air terminations 1 2 i Figure 2 When terminating multiple U Itra boilers terminate each vent air connection as described in this supplement Terminate all vent pipes at thesameheight and all air pipes at thesameheight to avoid possibility of severe personal injury death or substantial property damage Placeroof penetrationsto obtain minimum clearance 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 B1
5. 49 1 or B149 2 Installation Code 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 Through roof terminations with multiple boilers 12 minenum between edga of alr Intake pipe and adacent veni pipe I fram another boiler f PF 4 NOTICE Ulla GAS FIRED WATER BOILER Vent Supplement Vent air termination sidewall 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 Failureto 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 Determine location Locate the vent air terminations using the following guidelines 1 The total length of piping for vent or air must not exceed the limits given in Table 2 page 12 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 Thevent piping must terminatein an elbow pointed outwa
6. aged by foreign objects such as stones or balls or subject to buildup of leaves or sediment 7 Donotconnect any other applianceto thevent pipe or multiple boilers to a common vent pipe Part number 550 101 235 0903 Ulla GAS FIRED WATER BOILER Vent Supplement Prepare roof penetrations 1 Air pipe penetration a Cutaholefor theair pipe Sizetheair pipeholeas closeas desired to theair pipe outsidediameter Vent pipepenetration 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 Spacetheair and vent holesto providetheminimum spacings shown in Figure 1 page 6 Follow all local codes for isolation of vent pipe when passing through floors ceilings and roofs Provideflashing and sealing boots sized for the vent pipe and air pipe Termination and fittings L Prepare the vent termination coupling and the air termination elbow Figure 1 page 6 by inserting the bird screens provided with the boiler Bird screens are provided for either 3 inch U Itra 80 105 and 155 or 4 inch Ultra 230 and 310 fittings a Ifusing3 inch pipingfor an Ultra 230 cut the 4 inch bird screen supplied by placing 3 inch fitting on screen and cutting around it as a template Theair piping must terminatein adown turned 18
7. ation sidewall continuea Figure 7 Multiple vent air terminations must also comply with Figure 4 12 minimum between edge of air miake pipe and adjacent vent pipe 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 clearance above grade snow line 12 Minimum between edge of ali Part number 550 101 235 0903 S NOTICE Ulla GAS FIRED WATER BOILER Vent Supplement Installing vent amp air piping Installation must comply with local requirements and with the National Fuel Gas Code ANSI 2223 1 for U S installations or CSA B149 1 or B149 2 for Canadian installations Inserting securing vent or air pipe into boiler adapters 1 Clean and chamfer insertion end of pipe Debourr inside of insertion end Clean and deburr inside and outside of other end of pipe The pipe end must be smooth and Pranie chamfered to prevent possible damage to sealing gasket in vent or air pipe adapter Failureto comply could result in leakage causing possiblesevere personal injury or death Air pipe adapter Vent pipe adapter 2 Inspect vent or air adapter above verify no obstructions or foreign objects inside 3 Loosen clamp screw 4 Measure 3 inches from end of pipe and make a mark with felt tip pen 5 Loosen adapter clamp screw 6 Apply small amount of silicon greaseto end of pipe
8. ations g Locate or guard vent to prevent condensate damage to exterior finishes 5 Maintain clearances as shown in Figures 3 4 and 5 pages 8 9and 10 Also maintain thefollowing a Vent must terminate e At least 6 feet from adjacent walls e No closer than 5 feet below roof overhang e Atleast 7 feet above any public walkway e At lease 3 feet above any forced air intake within 10 feet e 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 or other equipment N ever terminate above or below any of these within 4 feet horizontally Part number 550 101 235 0903 Ulla GAS FIRED WATER BOILER Vent Supplement Vent air termination sidewall continues Determine location continued 6 Locate terminations so they are not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves or sediment 7 Donotconnect any other applianceto thevent pipe or multiple boilers to a common vent pipe Figure 4 Clearance to gravity air inlets Clearance to forced air inlets set pore Pe at a Figure 5 E Hi ee wale A
9. bustion 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 Do not operatean Ultra boiler if the boiler combustion air inlet is located in alaundry room or pool facility for example T hese areas will always contain hazardous contaminants 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 M UST e Remove products permanently OR e Relocateair inlet and vent terminationsto other areas Part number 550 101 235 0903 Table 1 Corrosive contaminants Products to avoid Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants NOTICE Ulla GAS FIRED WATER BOILER Vent Supplement Vent air termination through roof 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 w
10. ected 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 Vent and air piping Ventand airsystem 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 NOTICE TheUltra boiler requires a special vent system 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 CEE different systems The vent system could fail causing leakage of flue products into the living space Use only PVC CPVC or ABS pipe and fi
11. ice Ndicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Part number 550 101 235 0903 Ulla GAS FIRED WATER BOILER Vent Supplement 1 Vent and air piping materials WARNING Useonly thematerials listed in thetable below for vent and air pipeand fittings Failureto comply could result in severe personal injury death or substantial property damage Notice nstallation must comply with local requirements and with the N ational Fuel Gas Code ANSI 2223 1 for U S installations or CSA B149 1 or B149 2 for Canadian installations All combustion air and vent pipe materials and fittings must comply with the following and fittings CPVC schedule 40 ANSI ASTM F441 ABS DWV schedule 40 ANSI ASTM D2661 ee aan certified only Pipe cement primer CPVC ANSI ASTM F493 NOTICE DO NOT USE CELLULAR CORE PIPE Part number 550 101 235 0903 3 Ulla GAS FIRED WATER BOILER Vent Supplement Prepare boiler location Removing from existing vent DANGER 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 When removing exi
12. ith the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 or B149 2 for Canadian installations Determine location Locate the vent air terminations using the following guidelines 1 The total length of piping for vent or air must not exceed thelimits given in Table 2 page 12 2 Theair piping must terminatein adown turned 180 degreereturn bend asshown in Figure 1 Locatethe air inlet pipeno further than 2 feet from thecenter of thevent pipe This placement avoids recirculation of flue products into the combustion air stream 3 The vent piping must terminate in an up turned coupling as shown in Figurel The top of the coupling must beat least 1 foot abovetheair intake 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 Theflueproducts will form anoticeable plumeas they 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 Avoid possibility of accidental contact of flue products with people
13. or pets e Do not locate the terminations where wind eddies could affect performanceor causerecirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas f Do not terminate above any door or window Condensate can freeze causing ice formations g Locate or guard vent to prevent condensate damage to exterior finishes 5 Maintain clearances to vent termination as given below Figure 1 Vertical termination of air amp vent Air miat bard Bird screens vent termination coupling Alternate air pipa Walkers rals ieee within tae of ver a Legale Bir inet pipe Generation ma riha hamra feet from veri pipe persiaa a Vent must terminate e Atleast 6 feet from adjacent walls e No closer than 5 feet below roof overhang e Atleast 7 feet above any public walkway e Atleast 3 feet above any forced air intake within 10 feet e 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 snow lineand at least 12 below the vent termination as shown in Figure 1 c Do not terminate closer to 4 feet horizontally from any electric meter gas meter regulator relief valve or other equipment Never terminate above or below any of these within 4 feet horizontally 6 Locate terminations so they are not likely to be dam
14. rd 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 Theflueproducts will form anoticeable plumeas they 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 Avoid possibility of accidental contact of flue products with people or pets e Do not locate the terminations where wind eddies could affect performanceor causerecirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas Sidewall termination of air amp vent Apply left illustration unless air termination ell would not provide the minimum 12 inch clearance to grade or snow line Apply right illustration for other applications where exit openings are too low to provide the minimum 17 inch clearance Figure 3 f Do not terminate above any door or window Condensate can freeze causing ice form
15. sidewall terminations notice 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 1 ae WARNING Do not insulate vent piping Exception Where vent pipes pass through unheated spaces such as crawl spaces or unheated garages apply 1 2 inch fiberglass insulation to the portion of the vent pipe in the unheated space only Weil McLain E 500 Blaine Street Michigan City IN 46360 2388 http www weil mclain com Part number 550 101 235 0903
16. sting boiler from existing common ventsystem 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 deficiencies which could causean unsafecondition c 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 d Place in operation the appliance being inspected Follow the lighting instructions 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 conn
17. tructions before installing This document is for use only by your qualified Follow all instructions in proper order heating installer service technician to prevent personal injury or death e Please refer to the User s Information M anual for e This document is intended only as a supplement your reference to the Ultra Boiler M anual It s purpose is for the Keep this supplement near the boiler for use by installation of vent and air piping for the boiler your installer or technician WARNING All Ultra boilers must be installed as direct vent This requires piping installation for both flue products vent and combustion air air piping All vent and air piping must be installed terminated and sealed as described in this supplement Failure to adhere to the guidelines in this supplement can result in severe personal injury death or substantial property damage Hazard definitions Thefollowing defined terms areused throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning thelifeof the product DANGER Indicates presence of hazards that will cause severe personal injury death or substantial property damage WARNING Indicates presence of hazards that can cause severe personal injury death or substantial property damage CAUTION Ndicates presence of hazards that will or can cause minor personal injury or property damage Not
18. ttings 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 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 M anual to install vent and air piping Part number 550 101 235 0903 Ulla GAS FIRED WATER BOILER Vent Supplement Prepare boiler location wonne 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 presenting a possible threat of flue gas spillage or boiler 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 com
19. upplied by placing 3 inch fitting on screen and cutting around it as atemplate 2 When completed theair termination coupling must be oriented at least 12 inches below the vent termination and at least 12 inches above grade or snow lineas shown in Figure 3 page 8 3 You can orient the vent termination elbow either directly outward or 90 degrees away from the air inlet elbow asshown in Figure 3 page 8 4 Maintain the required dimensions of the finished termination piping as shown in Figure 3 page 8 5 Do not extend exposed vent pipeoutsideof building more than shown in this document Condensate could freeze and block vent pipe Multiple vent air terminations 1 When terminating multiple U Itra boilers terminate each vent air connection as described in this supplement WARNING All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury 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 Theair 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 10 Make foe and adjacent vent pipe Vent air termin
20. urfacesin a uniform coating d Apply a second coat to both surfaces Avoid using too much cement on sockets to prevent cement buildup inside e With cement still wet insert pipeinto fitting twisting 4 turn M ake sure pipeis fully inserted f Wipeexcess cement from joint Check joint to besure a smooth bead of cement shows around the entire Joint Install perforated metal pipesupports or equivalent as shown in Figures 9 and 10 page 12 Slope vent and air piping continuously toward boiler with at least 1 4 inch drop per foot of run Do not allow sags at any point Maintain minimum clearance of 0 2 inch between vent pipe and any combustible wall or material Seal wall or floor penetration openings following local code requirements Use exhaust terminal plates on inside and outside walls at sidewall terminations 11 S Ulla GAS FIRED WATER BOILER Vent Supplement Installing vent amp air piping connuea Table 2 Min max lengths of either air piping Figure 10 Piping to through roof terminations or vent piping Vent amp air piping limits i E VENT Minimum Maximum Maximum os Boiler Piping Piping 3 Piping 4 a IR Ultra aaa RRS LKA APPLICABLE sor PAC For piping using more than 2 elbows reduce maximum allowable length e 7 feet for each additional 4 inch elbow e 7 feet for each additional 3 inch long radius elbow e 16 feet for each 3 inch short radius elbow Figure 9 Piping to
Download Pdf Manuals
Related Search