Zoning with circulators | Weil-McLain 230, 80, 310, 105, 155

3 GAS-FIRED WATER BOILER — Boiler Manual

Install water piping (continued)

Zoning with circulators				Figure 8	Circulator zoning plus optional
1.	Connect boiler to system as shown in Figure 8 when				DHW piping
1.	Connect boiler to system as shown in Figure 8 when
	circulator zoning. The boiler circulator cannot be used
	for a zone. It must supply only the boiler loop.
2.	Install a separate circulator for each zone.
3.	When using a closed-type expansion tank, connect
	the expansion tank and make-up water piping as
	shown in Figure 4, page 13.
4.	Connect DHW (domestic hot water) piping to indirect
	storage water heater as shown.
		The	PhDControl Module turns off
		The	PhDControl Module turns off

space heating during DHW heating. The boiler circulator will turn off, preventing hot water from circulating to the system. The flow/check valve shown on the boiler outlet piping prevents gravity circulation in the boiler loop during DHW heating.

NOTE 1: To ensure adequate flow rate through the boiler, use the following pipe size on all boiler loop piping (connecting boiler to and from the primary/secondary connection, item 21): Ultra-80 or Ultra-105 – 1" or larger.

Ultra-155 or -230 – 1¼" or larger. Ultra-310 – 1½" or larger.

Use at least the minimum piping size above and pipe the boiler using only primary/ secondary piping as shown. Failure to follow these guidelines could result in system problems.

Legend

Figure 8

1Ultra boiler

2Indirect water heater (DHW), if used

3Boiler relief valve (see page 12 for piping details)

4Relief valve discharge piping (see page 12 for details)

5DHW circulator (see page 14 for suggested sizing)

6Isolation valves

7System circulator

8Diaphragm (or bladder) type expansion tank (see page 12 for piping of closed-type expansion tank, if used)

9Air separator [with automatic air vent only on systems using diaphragm (or bladder) type expansion tank]

10Flow/check valves (with weighted seats to prevent gravity circulation)

11Purge/drain valves

12Boiler circulator

14Zone circulators, typical

20Make-up water supply

21 Primary/secondary connection

16	Part number 550-101-233/0903

Image 16

Weil-McLain 230, 80, 310, 105, 155 manual Zoning with circulators

Contents

Gas-fired water boiler HOW IT Works GAS-FIRED Water BOILER, with PhD Technology Contents Hazard definitions When servicing boiler Please read before proceedingBoiler operation Boiler water Installations must comply with Prepare boiler locationBefore locating the boiler, check Provide clearances Residential garage installation Flooring and foundationProvide air openings to room Vent and air piping Prevent 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 Prepare for propane if operating on propane Ultra-155 to Placing floor-mounted boilersPlacing wall-mounted boilers Set boiler in place and check level Perform hydrostatic pressure test Prepare boiler for testFill and pressure test Drain and remove fittings Install water piping Install relief valveAdditional controls, when required General piping information Circulators System water piping methodsSizing space heat system piping Sizing DHW system piping Required boiler water flow rate, GPM, at 180F Connect boiler to system as shown in when Zoning with zone valvesControlling the system circulator Zoning with circulators Setting boiler outlet water target temperature Radiant heating applications Chilled water systems Chilled water system plus optional Venting, combustion air & condensate line Install vent and combustion air pipingPrepare condensate fittings Connect condensate drain Condensate drain Ultra-80 Gas piping Connecting gas supply pipingWall-mounted boilers Natural Gas Propane GasPipe sizing for natural gas Natural gas supply pressure requirements Freeze protection when used StartupCheck/control water chemistry Fill and test water system Check for gas leaks Final checks before starting boiler Check thermostat circuitsInspect/fill condensate system To start the boiler Check system and boiler Adjust and test boiler controlsCheck flame & combustion Check-out/startup verification Check-out/startup verification Installation certificate Annual startup and general maintenance Service and maintenance schedules Annual startup Handling ceramic fiber materials Clean condensate trap Check water systemCheck all piping for leaks Check expansion tank Check air openings Check ignition ground wiring Check all boiler wiringCheck control settings Check boiler relief valve Check flame signal Check flue gas temperaturePerform startup and checks Check burner flame Maintenance general General maintenanceCleaning boiler heat exchanger Replace boiler jacket front door after startup or servicing Access 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 Ratings DOE