Installation Guide

Part number 550-100-066/0608
g a s -f i r e d w at e r b o i l e r — Boiler Manual
20
Legend — Figure 18
1 Ultra boiler
2 Indirect water heater (DHW), if used (see page 22)
3 Boiler relief valve (see page 14 for piping details)
4 Relief valve discharge piping (see page 14 for details)
5 DHW circulator (see page 22 for suggested sizing)
6 Isolation valves
7 System circulator (see information above for wiring)
8 Diaphragm (or bladder) type expansion tank (see page 22 for piping of
closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
10 Flow/check valves
11 Purge/drain valves
12 Boiler circulator
13 Zone valves, when used (zoning may also be done using manifold-
mounted valve actuators)
20 Make-up water supply
21 Primary/secondary connection (tees no more than 12 inches apart)
22 Optional high limit temperature control, set to protect radiant tubing
24 Strap system supply and return sensors to lines as shown, at least 6 pipe
diameters (but no more than 3 feet) from boiler connection tees.
25 Systems using high-head pumps may require a bypass pressure regulator
to prevent damage to control valves.
Items supplied with boiler
Items supplied by others
NOTE 1:
Use at least the following pipe sizes on all boiler
loop piping (connecting boiler to and from the
primary/secondary connection, item 21). Use only primary/secondary piping
as shown. Failure to follow these guidelines could result in system problems.
•Ultra-80orUltra-105–1”orlarger.
•Ultra-155or-230–1¼”orlarger.
•Ultra-310–1½”orlarger.
 Typical radiant heating system piping plus
optional DHW
Radiant heating applications
The Ultra boiler is ideal for use in radiant heating. The Ultra 1.
boiler’s unique heat exchanger design allows it to work well even
in condensing mode. So there is no need to regulate boiler return
water temperature in radiant heating applications.
Connect boiler to system as shown in 2. Figure 18 for typical radiant
heating applications. The primary/secondary piping shown ensures
the boiler loop will have sufficient ow. Size the system piping and
circulator to provide the ow and pressure drop needed for the
radiant system.
Adding the recommended high limit control (3. Figure 18, item 22)
can help ensure supply water temperature will not exceed the
maximum allowable for the radiant system. Wire this limit control
in either the manual reset or automatic reset external limit circuit
of the U-Control.
When using a closed-type expansion tank, connect the expansion 4.
tank and make-up water piping as shown in Figure 14, page 16.
Connect DHW (domestic hot water) piping to indirect storage 5.
water heater as shown.
By default, the U-Control Module turns off space heating
during DHW heating (if DHW input is priority 1). The
boiler circulator will turn off, preventing hot water from
circulating to the system (optional timeout setting can
be used to override). The ow/check valve shown on the
boiler outlet piping prevents gravity circulation in the
boiler loop during DHW heating.
Controlling the circulators6.
The U-Control can control up to three circulators (boiler cir-a.
culator and two others). Refer to Field wiring, beginning on
page 54, for instructions on wiring to circulators.
The factory default settings are: DHW circulator as Circula-b.
tor 1, boiler circulator as Circulator 2. See Field wiring instruc-
tions, beginning on page 54, for details.
Install water piping (continued)