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Part number 550-100-400/0119
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
Install water piping — advanced
Figure 48one ale onin plus optional pipin
Zoning with zone valves
(alternate to piping shown in Figure 5, page 12 )
High-fl ow-rate/high-head-loss DHW
circuits
1. For applications requiring DHW circuit fl ow rates higher than
allowable for the boiler, or for high pressure-drop coil-type
DHW tanks, connect the piping as in Figure 48 . The DHW
water only fl ows through the secondary circuit connector pip-
ing. NOTE: Make sure to size the connector piping ( Figure 48 ,
item 23) to handle the total fl ow it must handle.
2. Connect boiler to system as shown in Figure 48 when zone
valve zoning. The primary/secondary piping shown ensures
the boiler loop will have suffi cient fl ow. It also avoids apply-
ing the high head of the boiler circulator to the zone valves.
Use the pipe size shown in Fig-
ure 48 on all boiler loop piping (connecting boiler
to and from the primary/secondary connection,
item 21).
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 off space
heating during DHW heating (if DHW input is
priority 1). The boiler circulator will turn off, pre-
venting hot water from circulating to the system
(optional timeout setting can be used to override).
The fl 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 heat-
ing 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. The system circulator should be off during
DHW heating. Read the instructions on U-Control op-
eration and setup, beginning on page 32 .
®
Series 4
gas-fired water boiler — Boiler Manual
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299/310,
399
1”
1¼”
1½”
See CAUTION at left.
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