Weil McLain ULTRA 230 User Manual

Gas-fired  
water boiler  
Ve n t S u p p le m e n t  
Ultra-80, -105, -155, -230 & -310  
Installation of:  
Vent piping  
• Air piping  
with  
This document must only be used by a qualified heating installer/service  
technician. Read all instructions, including this Supplement and the Boiler  
Manual, before installing. Perform steps in the order given. Failure to comply  
could result in severe personal injury, death or substantial property damage.  
Installation must comply with local requirements and with the National Fuel  
Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 or B149.2 for  
Canadian installations.  
Part No.550-101-235/0903  
GAS -FIRED WATER BOILER — Ve n t S u p p le m e n t  
1
Vent and air piping materials  
Use only the materials listed in the table below for vent and air pipe and fittings. Failure to comply could  
result in severe personal injury, death or substantial property damage.  
Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1  
for U.S.installations or CSA B149.1 or B149.2 for Canadian installations.  
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Part number 550-101-235/0903  
GAS -FIRED WATER BOILER — Ve n t S u p p le m e n t  
2
Prepare boiler location  
Removing from existing vent  
Any improper operation of common venting system  
should be corrected so the installation conforms with  
the National Fuel Gas Code, ANSI Z223.1 — latest  
edition. Correct by resizing to approach the minimum  
size as determined using the appropriate tables in  
Part 11 of that code. Canadian installations must  
comply with B149.1 or B149.2 Installation Code.  
Do not install the Ultra into a common  
vent with any other appliance. This will  
cause flue gas spillage or appliance  
malfunction, resulting in possible severe  
personal injury, death or substantial  
property damage.  
Failure to follow all instructions can  
result in flue gas spillage and carbon  
monoxide emissions, causing severe  
personal injury or death.  
Vent and air piping  
Vent and air system  
When removing existing boiler from  
existing common vent system:  
Installation must comply with local  
requirements and with the National Fuel  
Gas Code, ANSI Z223.1 for U.S.  
installations or CSA B149.1 or B149.2 for  
Canadian installations.  
At the time of removal of an existing boiler, the  
following steps shall be followed with each appliance  
remaining connected to the common venting system  
placed in operation, while the other appliances  
remaining connected to the common venting system  
are not in operation.  
The Ultra boiler requires a special vent system, designed  
for pressurized venting. Ultra boilers are rated ANSI  
Z21.13 Category IV (pressurized vent, likely to  
condense in the vent).  
a. Seal any unused openings in the common venting  
system.  
You must also install air piping from outside to the  
boiler air intake adapter. The resultant installation is  
categorized as direct vent (sealed combustion).  
b. Visually inspect the venting system for proper size  
and horizontal pitch and determine there is no  
blockage or restriction, leakage, corrosion or other  
deficiencies which could cause an unsafe condition.  
You may use any of the vent/air piping methods  
covered in this supplement. Do not attempt to install  
the Ultra boiler using any other means.  
c. Test vent system — Insofar as is practical, close all  
building doors and windows and all doors between  
the space in which the appliances remaining  
connected to the common venting system are  
located and other spaces of the building. Turn on  
clothes dryers and any appliance not connected to  
the common venting system. Turn on any exhaust  
fans, such as range hoods and bathroom exhausts,  
so they will operate at maximum speed. Do not  
operate a summer exhaust fan. Close fireplace  
dampers.  
d. Place in operation the appliance being inspected.  
Follow the lighting instructions. Adjust thermostat  
so appliance will operate continuously.  
e. Test for spillage at draft hood relief opening after 5  
minutes of main burner operation. Use the flame  
of a match or candle, or smoke from a cigarette,  
cigar, or pipe.  
DO NOT mix components from  
different systems. The vent system could  
fail, causing leakage of flue products into  
the living space. Use only PVC, CPVC or  
ABS pipe and fittings, with primer and  
cement specifically designed for the  
material used.  
Vent and air piping and termination  
The Ultra boiler vent and air piping can be installed  
through the roof or through a side wall. Follow the  
procedures in this document for the method chosen.  
The maximum vent length depends on boiler size. Refer  
to the information in this supplement to determine  
acceptable vent and air piping length.  
f. After it has been determined that each appliance  
remaining connected to the common venting  
system properly vents when tested as outlined  
herein, return doors, windows, exhaust fans,  
Combustion air for the Ultra boiler must be ducted  
directly to the boiler from outside (direct vent  
installation).  
fireplace dampers, and any other gas-burning Follow all instructions in this document and the Ultra  
appliance to their previous conditions of use. Boiler Manual to install vent and air piping.  
4
Part number 550-101-235/0903  
GAS -FIRED WATER BOILER — Ve n t S u p p le m e n t  
2
Prepare boiler location  
(continued)  
Air contamination  
Table 1 Corrosive contaminants  
Pool and laundry products and common household  
and hobby products often contain fluorine or chlorine  
compounds. When these chemicals pass through the  
boiler, they can form strong acids. The acid can eat  
through the boiler wall, causing serious damage and  
presenting a possible threat of flue gas spillage or boiler  
water leakage into the building.  
Please read the information given in Table 1, listing  
contaminants and areas likely to contain them. If  
contaminating chemicals will be present near the  
location of the boiler combustion air inlet, have your  
installer pipe the boiler combustion air and vent to  
another location, per the Boiler Manual and Vent  
Supplement.  
If the boiler combustion air inlet is located in any area  
likely to cause air contamination, or if products which  
would contaminate the air cannot be removed, you  
must have the combustion air and vent repiped and  
terminated to another location. Contaminated  
combustion air will damage the boiler heat exchanger,  
resulting in possible severe personal injury, death or  
substantial property damage.  
Do not operate an Ultra boiler if the boiler combustion  
air inlet is located in a laundry room or pool facility,  
for example. These areas will always contain hazardous  
contaminants.  
To prevent the potential of severe personal injury or  
death, check for areas and products listed in Table 1  
before installing the boiler or air inlet piping.  
If contaminants are found, you MUST:  
• Remove products permanently. — OR —  
• Relocate air inlet and vent terminations to other areas.  
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Part number 550-101-235/0903  
GAS -FIRED WATER BOILER — Ve n t S u p p le m e n t  
3
Vent/air termination — through roof  
Follow instructions below when determining vent  
Figure 1 Vertical termination of air & vent  
location to avoid possibility of severe personal injury,  
death or substantial property damage.  
Installation must comply with local requirements and  
with the National Fuel Gas Code, ANSI Z223.1 for U.S.  
installations or CSA B149.1 or B149.2 for Canadian  
installations.  
Determine location  
Locate the vent/air terminations using the following  
guidelines:  
1. The total length of piping for vent or air must not  
exceed the limits given in Table 2, page 12.  
2. The air piping must terminate in a down-turned 180-  
degree return bend as shown in Figure 1. Locate the  
air inlet pipe no further than 2 feet from the center of  
the vent pipe. This placement avoids recirculation of  
flue products into the combustion air stream.  
3. The vent piping must terminate in an up-turned  
coupling as shown in Figure 1. The top of the  
coupling must be at least 1 foot above the air intake.  
The air inlet pipe and vent pipe can be located in  
any desired position on the roof, but must always  
be no further than 2 feet apart and with the vent  
termination at least 1 foot above the air intake.  
4. You must consider the surroundings when  
terminating the vent and air:  
a. Position the vent termination where vapors will not  
damage nearby shrubs, plants or air conditioning  
equipment or be objectionable.  
b. The flue products will form a noticeable plume as they  
condense in cold air. Avoid areas where the plume  
could obstruct window views.  
a. Vent must terminate:  
At least 6 feet from adjacent walls.  
No closer than 5 feet below roof overhang.  
At least 7 feet above any public walkway.  
At least 3 feet above any forced air intake within  
10 feet.  
c. Prevailing winds could cause freezing of condensate  
and water/ice buildup where flue products impinge  
on building surfaces or plants.  
No closer than 12 inches below or horizontally  
from any door or window or any other gravity  
air inlet.  
d. Avoid possibility of accidental contact of flue products  
with people or pets.  
e. Do not locate the terminations where wind eddies  
could affect performance or cause recirculation, such  
as inside building corners, near adjacent buildings or  
surfaces, window wells, stairwells, alcoves, courtyards  
or other recessed areas.  
b. Air inlet must terminate at least 6" above the roof or  
snow line and at least 12" below the vent termination  
as shown in Figure 1.  
c. Do not terminate closer to 4 feet horizontally from  
any electric meter, gas meter, regulator, relief valve or  
other equipment. Never terminate above or below  
any of these within 4 feet horizontally.  
f. Do not terminate above any door or window.  
Condensate can freeze, causing ice formations.  
g. Locate or guard vent to prevent condensate damage  
to exterior finishes.  
6. Locate terminations so they are not likely to be  
damaged by foreign objects, such as stones or balls,  
or subject to buildup of leaves or sediment.  
7. Do not connect any other appliance to the vent pipe  
or multiple boilers to a common vent pipe.  
5. Maintain clearances to vent termination as given  
below:  
6
Part number 550-101-235/0903  
GAS -FIRED WATER BOILER — Ve n t S u p p le m e n t  
3
Vent/air termination — through roof  
(continued)  
Prepare roof penetrations  
Multiple vent/air terminations  
1. Air pipe penetration:  
1. When terminating multiple Ultra boilers, terminate  
each vent/air connection as described in this  
supplement.  
a. Cut a hole for the air pipe. Size the air pipe hole as  
close as desired to the air pipe outside diameter.  
Terminate all vent pipes at the same height  
and all air pipes at the same height to avoid  
possibility of severe personal injury, death  
or substantial property damage.  
2. Vent pipe penetration:  
a. Cut a hole for the vent pipe. For either  
combustible or noncombustible construction,  
size the vent pipe hole at least 0.4" larger than  
the vent pipe diameter:  
• 4" hole for 3" PVC  
• 5" hole for 4" PVC  
b. Insert a galvanized metal thimble in the vent  
pipe hole.  
2. Place roof penetrations to obtain minimum clearance  
of 12 inches between edge of air intake elbow and  
adjacent vent pipe of another boiler for U. S.  
installations (see Figure 2). For Canadian  
installations, provide clearances required by CSA  
B149.1 or B149.2 Installation Code.  
3. Space the air and vent holes to provide the minimum  
spacings shown in Figure 1, page 6.  
4. Follow all local codes for isolation of vent pipe  
when passing through floors, ceilings and roofs.  
3. The air inlet of an Ultra boiler is part of a direct  
vent connection. It is not classified as a forced air  
intake with regard to spacing from adjacent boiler  
vents.  
5. Provide flashing and sealing boots sized for the vent  
pipe and air pipe.  
Figure 2 Through roof terminations with  
multiple boilers  
Termination and fittings  
1. Prepare the vent termination coupling and the air  
termination elbow (Figure 1, page 6) by inserting the  
bird screens provided with the boiler. Bird screens  
are provided for either 3-inch (Ultra-80, -105 and -  
155) or 4-inch (Ultra-230 and -310) fittings.  
a. If using 3-inch piping for an Ultra-230, cut the 4-  
inch bird screen supplied by placing 3-inch fitting  
on screen and cutting around it as a template.  
2. The air piping must terminate in a down-turned 180-  
degree return bend as shown in Figure 1, page 6.  
Locate the air inlet pipe no further than 2 feet from  
the center of the vent pipe. This placement avoids  
recirculation of flue products into the combustion  
air stream.  
3. The vent piping must terminate in an up-turned  
coupling as shown in Figure 1, page 6. The top of the  
coupling must be at least 1 foot above the air intake.  
The air inlet pipe and vent pipe can be located in any  
desired position on the roof, but must always be no  
further than 2 feet apart and with the vent termination  
at least 1 foot above the air intake.  
4. Maintain the required dimensions of the finished  
termination piping as shown in Figure 1, page 6.  
5. Do not extend exposed vent pipe outside of building  
more than shown in this document. Condensate  
could freeze and block vent pipe.  
7
Part number 550-101-235/0903  
GAS -FIRED WATER BOILER — Ve n t S u p p le m e n t  
4
Vent/air termination — sidewall  
Follow instructions below when determining vent  
location to avoid possibility of severe personal injury,  
death or substantial property damage.  
Figure 3 Sidewall termination of air & vent:  
(Apply left illustration unless air termination ell  
would not provide the minimum 12 inch  
clearance to grade or snow line.  
A gas vent extending through an exterior wall shall not  
terminate adjacent to the wall or below building  
extensions such as eaves, parapets, balconies or decks.  
Failure to comply could result in severe personal injury,  
death or substantial property damage.  
Apply right illustration for other applications,  
where exit openings are too low to provide the  
minimum 12 inch clearance.)  
Installation must comply with local requirements and  
with the National Fuel Gas Code, ANSI Z223.1 for U.S.  
installations or CSA B149.1 or B149.2 for Canadian  
installations.  
Determine location  
Locate the vent/air terminations using the following  
guidelines:  
1. The total length of piping for vent or air must not  
exceed the limits given in Table 2, page 12.  
2. The air piping must terminate in a down-turned  
elbow as shown in Figure 3. This arrangement  
avoids recirculation of flue products into the  
combustion air stream.  
3. The vent piping must terminate in an elbow pointed  
outward or away from the air inlet, as shown in  
Figure 3.  
Do not exceed the maximum lengths of  
the outside vent piping shown in  
Figure 3. Excessive length exposed to the  
outside could cause freezing of  
condensate in the vent pipe, resulting in  
potential boiler shutdown.  
f. Do not terminate above any door or window.  
Condensate can freeze, causing ice formations.  
g. Locate or guard vent to prevent condensate damage  
to exterior finishes.  
5. Maintain clearances as shown in Figures 3, 4, and 5,  
pages 8, 9 and 10. Also maintain the following:  
4. You must consider the surroundings when  
terminating the vent and air:  
a. Vent must terminate:  
At least 6 feet from adjacent walls.  
a. Position the vent termination where vapors will not  
damage nearby shrubs, plants or air conditioning  
equipment or be objectionable.  
No closer than 5 feet below roof overhang.  
At least 7 feet above any public walkway.  
b. The flue products will form a noticeable plume as they  
condense in cold air. Avoid areas where the plume  
could obstruct window views.  
At lease 3 feet above any forced air intake within  
10 feet.  
No closer than 12 inches below or horizontally  
from any door or window or any other gravity  
air inlet.  
c. Prevailing winds could cause freezing of condensate  
and water/ice buildup where flue products impinge  
on building surfaces or plants.  
b. Air inlet must terminate at least 12" above grade or  
snow line; at least 12" below the vent termination;  
and the vent pipe must not extend more than 24"  
vertically outside the building as shown in Figure 3.  
d. Avoid possibility of accidental contact of flue products  
with people or pets.  
e. Do not locate the terminations where wind eddies  
could affect performance or cause recirculation, such  
as inside building corners, near adjacent buildings or  
surfaces, window wells, stairwells, alcoves, courtyards  
or other recessed areas.  
c. Do not terminate closer to 4 feet horizontally from  
any electric meter, gas meter, regulator, relief valve  
or other equipment. Never terminate above or below  
any of these within 4 feet horizontally.  
8
Part number 550-101-235/0903  
GAS -FIRED WATER BOILER — Ve n t S u p p le m e n t  
4
Vent/air termination — sidewall  
(continued)  
Determine location (continued)  
Prepare wall penetrations  
6. Locate terminations so they are not likely to be 1. Air pipe penetration:  
damaged by foreign objects, such as stones or balls,  
a. Cut a hole for the air pipe. Size the air pipe hole  
or subject to buildup of leaves or sediment.  
7. Do not connect any other appliance to the vent pipe  
or multiple boilers to a common vent pipe.  
as close as desired to the air pipe outside  
diameter.  
2. Vent pipe penetration:  
a. Cut a hole for the vent pipe. For either  
combustible or noncombustible construction,  
size the vent pipe hole at least 0.4" larger than  
the vent pipe diameter:  
Figure 4 Clearance to gravity air inlets  
• 4" hole for 3" PVC  
• 5" hole for 4" PVC  
b. Insert a galvanized metal thimble in the vent  
pipe hole as shown in Figure 6.  
3. Use a sidewall termination plate as a template for  
correct location of hole centers.  
4. Follow all local codes for isolation of vent pipe  
when passing through floors or walls.  
5. Seal exterior openings thoroughly with exterior  
caulk.  
Figure 6 Sidewall termination assembly  
Figure 5 Clearance to forced air inlets  
9
Part number 550-101-235/0903  
GAS -FIRED WATER BOILER — Ve n t S u p p le m e n t  
4
Vent/air termination — sidewall  
(continued)  
Termination and fittings  
Figure 7 Multiple vent/air terminations (must  
also comply with Figure 4)  
1. Prepare the vent termination elbow and the air  
termination elbow (Figure 6) by inserting the bird  
screens provided with the boiler. Bird screens are  
provided for either 3-inch (Ultra-80, -105 and -155)  
or 4-inch (Ultra-230 and -310) fittings.  
a. If using 3-inch piping for an Ultra-230, cut the 4-  
inch bird screen supplied by placing 3-inch fitting  
on screen and cutting around it as a template.  
2. When completed, the air termination coupling must  
be oriented at least 12 inches below the vent  
termination and at least 12 inches above grade or  
snow line as shown in Figure 3, page 8.  
3. You can orient the vent termination elbow either  
directly outward or 90 degrees away from the air  
inlet elbow as shown in Figure 3, page 8.  
4. Maintain the required dimensions of the finished  
termination piping as shown in Figure 3, page 8.  
5. Do not extend exposed vent pipe outside of building  
more than shown in this document. Condensate  
could freeze and block vent pipe.  
Figure 8 Multiple vent/air terminations (must  
also comply with Figure 4)  
(Apply this method only where exit openings  
are too low to provide minimum 12 inch  
clearance above grade/snow line.)  
Multiple vent/air terminations  
1. When terminating multiple Ultra boilers, terminate  
each vent/air connection as described in this  
supplement.  
All vent pipes and air inlets must  
terminate at the same height to avoid  
possibility of severe personal injury, death  
or substantial property damage.  
2. Place wall penetrations to obtain minimum  
clearance of 12 inches between vent pipe and  
adjacent air inlet elbow, as shown in Figure 7 or  
Figure 8 for U. S. installations. For Canadian  
installations, provide clearances required by CSA  
B149.1 or B149.2 Installation Code.  
3. The air inlet of an Ultra boiler is part of a direct  
vent connection. It is not classified as a forced air  
intake with regard to spacing from adjacent boiler  
vents.  
10  
Part number 550-101-235/0903  
GAS -FIRED WATER BOILER — Ve n t S u p p le m e n t  
5
Installing vent & air piping  
Installation must comply with local requirements and  
Installing vent or air piping  
with the National Fuel Gas Code, ANSI Z223.1 for U.S.  
installations or CSA B149.1 or B149.2 for Canadian  
installations.  
For reference in following see:  
Sidewall termination — Figure 9, page 12.  
Through-roof termination — Figure 10, page 12.  
1. Work from the boiler to vent or air termination. Do  
not exceed the lengths given in Table 2 for either the  
air or vent piping.  
Inserting/securing vent or air  
pipe into boiler adapters  
1. Clean and chamfer insertion end of pipe. Deburr  
inside of insertion end. Clean and deburr inside  
and outside of other end of pipe.  
a. Note that the Ultra-230 may be installed with either  
3-inch or 4-inch vent and air piping. Table 2 provides  
shorter allowable piping lengths when using 3-inch  
piping.  
2. Cut pipe to required lengths.  
3. Deburr inside and outside of pipe ends.  
sealing gasket in vent or air pipe adapter. 4. Chamfer outside of each pipe end to ensure even  
The pipe end must be smooth and  
chamfered to prevent possible damage to  
Failure to comply could result in leakage,  
causing possible severe personal injury or  
death.  
cement distribution when joining.  
5. Clean all pipe ends and fittings. Dry thoroughly.  
6. Dry assemble entire vent or air piping to ensure  
proper fit before assembling any joint.  
7. For each joint:  
a. Handle fittings and pipes carefully to prevent  
contamination of surfaces.  
b. Apply primer liberally to both joint surfaces — pipe  
end and fitting socket.  
c. While primer is still damp, lightly apply approved  
cement to both surfaces in a uniform coating.  
d. Apply a second coat to both surfaces. Avoid using  
too much cement on sockets to prevent cement  
buildup inside.  
2. Inspect vent or air adapter (above) — verify no  
obstructions or foreign objects inside.  
e. With cement still wet, insert pipe into fitting, twisting  
¼ turn. Make sure pipe is fully inserted.  
3. Loosen clamp screw.  
4. Measure 3½ inches from end of pipe and make a  
mark with felt-tip pen.  
5. Loosen adapter clamp screw.  
6. Apply small amount of silicon grease to end of pipe  
to ease insertion.  
f. Wipe excess cement from joint. Check joint to be sure  
a smooth bead of cement shows around the entire  
joint.  
8. Install perforated metal pipe supports or equivalent  
as shown in Figures 9 and 10, page 12.  
9. Slope vent and air piping continuously toward boiler,  
with at least ¼ inch drop per foot of run. Do not  
allow sags at any point.  
10. Maintain minimum clearance of 0.2 inch between  
vent pipe and any combustible wall or material. Seal  
wall or floor penetration openings following local  
code requirements.  
7. Insert pipe into adapter.  
8. Slide pipe down until the 3½-inch mark is reached.  
Do not apply excessive force or bend the  
adapter or flue/air pipe when inserting.  
The adapter or seal could be damaged.  
9. Secure vent or air pipe by tightening the adapter  
clamp securely. Do not overtighten. The seal is  
accomplished with the internal gasket. The clamp 11. Use exhaust terminal plates on inside and outside  
is only to hold the pipe in place. walls at sidewall terminations.  
11  
Part number 550-101-235/0903  
GAS -FIRED WATER BOILER — Ve n t S u p p le m e n t  
5
Installing vent & air piping  
(continued)  
Table 2  
Min/max lengths of either air piping  
or vent piping  
Figure 10 Piping to through-roof terminations  
Figure 9 Piping to sidewall terminations  
When a large number of elbows is  
needed with 3-inch piping, use long  
radius elbows to reduce pressure drop.  
This allows a longer run of piping. See  
Table 2 notes for details.  
Do not insulate vent piping. Exception: Where vent pipes pass through unheated spaces, such as  
crawl spaces or unheated garages, apply ½ inch fiberglass insulation to the portion of the vent pipe  
in the unheated space only.  
12  
Part number 550-101-235/0903  

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