Ultra Boiler Manual

Part number 550-100-440/0122
52
  
Legend — Figure 48
1 Ultra boiler
2 Indirect water heater (DHW), if used
3 Boiler relief valve (see page9 for piping details)
4 Relief valve discharge piping (see page9 for details)
5 DHW circulator (see page56 for suggested sizing)
6 Isolation valves
7 System circulator (see information above for wiring)
8 Diaphragm (or bladder) type expansion tank (see page56 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, typical
20 Make-up water supply
21 Primary/secondary connection (tees no more than 12 inches apart)
23 DHW supply/return
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.
26 Temperature/Pressure gauge
27 DHW relief valve, if used
Items supplied with boiler
Items supplied by others

Figure 48 Zone valve zoning plus optional DHW piping

(alternate to piping shown in Figure 5, page 12)


1. For applications requiring DHW circuit ow rates higher than
allowable for the boiler, or for high pressure-drop coil-type
DHW tanks, connect the piping as in Figure48. e DHW
water only ows through the secondary circuit connector pip-
ing. NOTE: Make sure to size the connector piping (Figure48,
item23) to handle the total ow it must handle.
2. Connect boiler to system as shown in Figure48 when zone
valve zoning. e primary/secondary piping shown ensures
the boiler loop will have sucient ow. It also avoids apply-
ing the high head of the boiler circulator to the zone valves.
Use at least the MINIMUM pipe size shown in Fig-
ure48 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.
3. When using a closed-type expansion tank, connect the
expansion tank and make-up water piping as shown in
Figure4,page11.
4. Connect DHW (domestic hot water) piping to indirect stor-
age water heater as shown.
By default, the U-Control Module turns o space
heating during DHW heating (if DHW input is
priority 1). e boiler circulator will turn o, pre-
venting hot water from circulating to the system
(optional timeout setting can be used to override).
e ow/check valve shown on the boiler outlet
piping prevents gravity circulation in the boiler
loop during DHW heating.
Overriding the Outdoor Reset function by setting control
to DHW mode when system is intended for space heating
may violate Section 303 of the 2007 Energy Act. See
page137 for compliance information and exemptions.
5. Controlling the system circulator and boiler circulator
a. You will have to set up the U-Control to operate both the
boiler circulator and the DHW circulator during DHW
operation. e system circulator should be o during
DHW heating. Read the instructions on U-Control op-
eration and setup, beginning on page32.
MINIMUM
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1”
1¼”
1½”
See CAUTION at left.