Weil-McLain 155 Venting, combustion air & condensate line, Install vent and combustion air piping

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4 GAS-FIRED WATER BOILER — Boiler Manual

Venting, combustion air & condensate line

Install vent and combustion air piping

Ultra Boiler must be vented and supplied with combustion and ventilation air as described in Weil-McLain Ultra Boiler Vent Supplement (included in envelope assembly). Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system and combustion air quality. See also Section 1 of this manual.

Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.

Failure to provide a properly-installed vent and air system will cause severe personal injury or death.

Prepare condensate fittings

1.Remove PVC fittings and gasket from the accessories bag.

2.Deburr and chamfer outside and inside of ½" x 1¼" PVC nipple to ensure even cement distribution when joining.

3.Clean nipple ends and all fittings. Dry thoroughly.

4.For each joint in the condensate line, apply the following. Assemble parts ONLY in the order given.

a.Apply primer liberally to both joint surfaces — pipe end and fitting socket.

b.While primer is still damp, lightly apply approved cement to both surfaces in a uniform coating.

Figure 11 Condensate trap assembly

c.Apply a second coat of cement to both surfaces. Avoid using too much cement on sockets to prevent cement buildup inside.

d.With cement still wet, insert pipe into fitting, twisting ¼ turn. Make sure pipe is fully inserted.

e.Wipe excess cement from joint. Check joint to be sure a smooth bead of cement shows around the entire joint.

5.See Figure 11.

6.Assemble the ½" PVC nipple to the PVC reducing elbow as shown.

7.Allow joint to dry completely. Then slide gasket over nipple as shown.

8.Slide nipple through jacket condensate line hole to position as shown in Figure 13, page 20.

9.Cement the ½" tee to the protruding ½" nipple. Be sure both nipple and reducing elbow finish upright. IMPORTANT: Firmly press the reducing elbow and the tee together while the cement sets to ensure the gasket is securely compressed. The gasket ensures the jacket enclosure is airtight at this location.

Part number 550-101-233/0903

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Contents Gas-fired water boiler HOW IT Works GAS-FIRED Water BOILER, with PhD Technology Hazard definitions ContentsBoiler water When servicing boilerPlease read before proceeding Boiler operationProvide clearances Installations must comply withPrepare boiler location Before locating the boiler, checkVent and air piping Residential garage installationFlooring and foundation Provide air openings to roomPrevent combustion air contamination When removing a boiler from existing common vent systemSeal any unused openings in the common venting system Remove boiler from crate Prepare boilerPrepare for propane if operating on propane Ultra-80 Set boiler in place and check level Prepare for propane if operating on propane Ultra-155 toPlacing floor-mounted boilers Placing wall-mounted boilersDrain and remove fittings Perform hydrostatic pressure testPrepare boiler for test Fill and pressure testGeneral piping information Install water pipingInstall relief valve Additional controls, when requiredCirculators System water piping methodsSizing space heat system piping Required boiler water flow rate, GPM, at 180F Sizing DHW system pipingConnect boiler to system as shown in when Zoning with zone valvesControlling the system circulator Zoning with circulators Radiant heating applications Setting boiler outlet water target temperatureChilled water system plus optional Chilled water systemsVenting, combustion air & condensate line Install vent and combustion air pipingPrepare condensate fittings Condensate drain Ultra-80 Connect condensate drainGas piping Connecting gas supply pipingWall-mounted boilers Natural gas supply pressure requirements Natural GasPropane Gas Pipe sizing for natural gasFill and test water system Freeze protection when usedStartup Check/control water chemistryTo start the boiler Check for gas leaks Final checks before starting boilerCheck thermostat circuits Inspect/fill condensate systemCheck system and boiler Adjust and test boiler controlsCheck flame & combustion Check-out/startup verification Check-out/startup verification Installation certificate Service and maintenance schedules Annual startup and general maintenanceHandling ceramic fiber materials Annual startupCheck air openings Clean condensate trapCheck water system Check all piping for leaks Check expansion tankCheck boiler relief valve Check ignition ground wiringCheck all boiler wiring Check control settingsCheck burner flame Check flame signalCheck flue gas temperature Perform startup and checksReplace boiler jacket front door after startup or servicing Maintenance generalGeneral maintenance Cleaning boiler heat exchangerAccess exchanger Ultra-155, -230, -310 Only Maintenance and annual startupExchanger cleaning ALL models Replacement parts Jacket parts Replacement parts Heat exchanger and piping Ultra-80 Replacement parts Heat exchanger and piping Ultra-155 to Replacement parts Controls Dimensions DOE Ratings
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