Ultra Boiler Manual

Part number 550-100-440/0122
11
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BASIC INSTALLATION
 (continued)

1. Ensure expansion tank size will handle boiler and system water
volume and temperature. Allow 3 gallons for boiler and its piping.
Undersized expansion tanks cause system water to be
lost from relief valve and make-up water to be added
through ll valve. Eventual boiler failure can result due
to excessive make-up water addition.
2. Tank must be located as shown in this manual, or following rec-
ognized design methods. See tank manufacturer’s instructions for
details. When installing air vents and expansion tanks, refer to
manufacturer’s instructions.
3. Connect the expansion tank to the air separator only if the separator
is on the suction side of the circulator. Always install the system
ll connection at the same point as the expansion tank connection
to the system.
4. Most piping drawings in this manual show diaphragm expansion
tanks. See Figure4 for piping from air separator to expansion tank
and make-up water line using a closed-type expansion tank.
5. Most chilled water systems are piped using a closed-type tank, as
shown in Figure51,page55.
Diaphragm (or bladder) expansion tank
1. (Figure4) Always install an automatic air vent on top of the air
separator to remove residual air from the system.
When using diaphragm or bladder tanks only — when the
boiler is installed above the system main piping, install
an automatic air vent in the top of the outgoing boiler
piping to prevent air pocketing.
Closed-type expansion tank
1. See Figure4, Alternate, for piping connections when using a closed-
type expansion tank.
2. Pitch any horizontal piping up towards tank 1 inch per 5 feet of
piping. Connect to tank with at least ¾” piping to allow room for
air to rise.
DO NOT install automatic air vents on closed-type
expansion tank systems. Air must remain in the system
and return to the tank to provide its air cushion. An au-
tomatic air vent would cause air to leave system, resulting
in water-logging the expansion tank.
DO NOT use a closed-type expansion tank on a system
with a Weil-McLain AQUA PLUS water heater. e water
heater must use an automatic air vent. Operation of the
automatic air vent will deplete air in the piping, causing
the expansion tank to waterlog.
Figure 4 Expansion tank piping
Use at least the MINIMUM pipe size shown in
Figure4 on all boiler loop piping (connecting boiler
to and from the primary/secondary connection,
item9).
Use only primary/secondary piping
as shown.
Failure to follow these guidelines could
result in system problems.
MINIMUM
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1”
1¼”
1½”
See CAUTION at left.
MINIMUM
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1”
1¼”
1½”
See CAUTION at left.