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Weil-McLain -105 User's Manual

1. i 4 miri Openings when mquind sae manual page 7 Part number 550 101 233 0903 Prepare boiler location one Flooring and foundation Flooring The Ultra boiler is approved for installation on combustible flooring but must never be installed on carpeting Do not install boiler on carpeting even if foundation isused Firecan result causing severe personal injury death or substantial property damage Foundation Providea solid foundation pad at least 2 inches above thefloor if any of thefollowingistrue e floor can become flooded thefloor isdirt sand gravel or other loose material theboiler mounting areaisseverely uneven or sloped Theminimum foundation sizeis e Ultra 80to 230 24incheswidex 20 inches deep Ultra 310 24incheswidex 23 inchesdeep 24 inchesx 20 inches Foundation may beof wood brick or concrete minimum 2 inchesthick construction Iffloodingispossible elevateboiler sufficiently to prevent water from reaching boiler Residential garage installation Precautions Takethe following special precautions when installing theboiler in aresidential garage If theboiler islocated in aresidential garage per AN SI Z223 1 paragraph 5 1 9 e Mounttheboiler with aminimum of 18inchesabove thefloor of thegarageto the bottom of the boiler to ensuretheburner and ignition devices will beno less than 18 inches abovethefloor e Locateor protect theboiler so it cannot
2. All models isi p Pi rpm honi ratam aaa i m ee a Ultra 31 0 door rere ar Part number 550 101 233 0903 3 Ulva GAS FIRED WATER BOILER Boiler Manual Contents HOW it icm S 2 3 Hazard definitions 4 Please read before proceeding 5 1 Prepare boiler location eeseeessses 6 2 Prepare boiler eec 9 3 Install water piping nnmnnn 12 4 Venting combustion air amp condensate line 19 5 GAS DIU 21 6 Startup 23 7 Check out startup verification eere 26 8 Annual startup and general maintenance 28 9 Replacement parts ceri etat a nine tue nena nen Dao CUN e ESSE PESE 35 10 Iam 43 WA Ratings 44 Note1 See Ultra Control Supplement for wiring and additional startup and operating information Hazard definitions Thefollowingdefined terms areused throughout this manual to bringattention to the presenceof hazardsof various risk levelsor to important information concerningthelifeof theproduct DANGER Indicates presence of hazards that will cause severe p
3. GAS FIRED WATER BOILER Boiler Manual Gas piping Connecting gas supply piping 1 Removejacket front panel and refer to Figure 15 to pipegasto boiler a Install ground jointunion for servicing when required b Install manual shutoff valvein gassupply pipingoutside boiler jacket when required by local codes or utility requirements c In Canada When using manual main shutoff valve it must be identified by theinstaller Wall mounted boilers a Refer to separate Ultra Boiler Wall mounting instructions b Gas connection may enter from the bottom of boiler as explained in theWall mounting instructions Support piping with hangers not by boiler or its accessories Figure 15 Connect gas supply piping To gas supply Manual main gas valve Ground joint union Bailar gas connection Alternate gas conmection for wall hung Alternabe entrance bottom Kr wall hung could damage gas linecomponents Part number 550 101 233 0903 4 Purgeall air from gas supply piping 5 Beforeplacingboiler in operation check boiler and itsgas connection for leaks a Close manual main shutoff valve during any pressure testing at less than 13 w c b Disconnect boiler and gas valvefrom gas supply piping during any pressuretesting greater than 13 w c WARNING Do not check for gas leaks with an open flame use bubble test Failure to use bubbletest or check for ga
4. Boiler Manual Notice Ultra 80 LP boilersarefactory equipped to operate on propane gas Figure 2 Installing propane orifice Ultra 105 icd m Screws a O ring amp i valve 1 Grommet Venu 1 With boiler on its back remove jacket front door by removing two knurled head screws at lower front Then lift door away from boiler 2 Disconnectthe gas valve electrical plug 3 the 4 screws securing gas valve inlet adapter to valve 4 Remove 3 TORX screws securing gas valve to venturi Figure 2 5 Locatepropaneorificedisc from conversion kit bag Verify that the stamping on the orifice disk matches the boiler size Place orifice in the black rubber grommet in the side of the gas valve and securein valve Figure 2 6 Reposition gas valveagainst venturi and replace 3 TORX screws securing valve to venturi Secure gas valve inlet adapter to gas valve with 4 screws M ake sure the plastic hose is connected from gas valve to inlet elbow DANGER Inspect the O ring between the gas valve and gas valveinlet adapter block whenever they are disassembled The O ring must be in good condition and must be installed Failure to comply will causea gas leak resultingin severe personal injury or death 7 DO NOT attempt to adjust gas valve outlet pressure Connect gas valve electrical plug to valve terminals 9 After installation is complete attach the pro
5. Check pressure temperature gauge Verify boiler front door is securely in place Check vent piping Check air piping Monthly Check relief valve Check condensate drain system Check automatic air vents if used Periodically Test low water cutoff if used Check boiler piping gas and water Operate relief valve End Shut boiler down unless boiler of season used for domestic water WARNING Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler Failure to perform the service and maintenance could result in damageto the boiler or system Failureto follow thedirectionsin thismanual and component literature could result in severepersonal injury death or substantial property damage 28 Part number 550 101 233 0903 8a GAS FIRED WATER BOILER Boiler Manual Annual startup Theboiler should be inspected and started annually at the beginning of the heating season only bya qualified service technician In addition themaintenanceand careof theboiler designated in Table5 and explained on the following pages must be performed to assure maximum boiler efficiency and reliability Failureto serviceand maintain the boiler and system could result in equipment failure Electrical shock hazard Turn off power to theboiler beforeany serviceoperation on theboiler except as noted otherwise in this instruct
6. Ultra 155 230 amp 310 s retainer Um And Screws Bumar 32 gnati 155 2 30 310 Excharger cover plate 155 2300310 Uttra 155 230 amp 310 Alter tightening retainer screws band up tab each retainer to prevent screws from turning Litra 80 amp 105 Exchanger cover piaia BO T O5 Cover plale insulation 80105 Part number 550 101 233 0903 Maintenance general Sb GAS FIRED WATER BOILER Boiler Manual Replace boiler jacket front door after startup or servicing Replace boiler jacket front door after start or servicing Theboiler front door must besecurely fastened to the boiler to prevent boiler from drawing air from inside the boiler room This is particularly important if the boiler islocated in thesameroom as other appliances Failureto keep thedoor securely fastened could result in severe personal injury or death General maintenance 1 Oil motor in system requiring regular oiling 2 See Oil bearing circulators for motor oiling procedures Oiled bearing circulators 1 Thecirculator shipped with the Ultra boiler is water lubricated oilingisrequired 2 Check other circulators in the system Oil any circulators requiring oil following circulator manufacturer sinstructions ver oiling will damage thecirculator Cleaning boiler heat exchanger Theboiler containsceramic fiber materials Usecarewhen handling thesematerials per in
7. p JF a4 7 a a 1 g T and 127 circulator flanges areshipped with boiler on Ultra 80 105 155 230 Both 174 and 1 circulator flanges are shipped with boiler Ultra 310 Relief valve is shipped loose See page 11 for mounting details Relief valve mounts on supply pipe off of supply tee and 3 4 street elbow as shown 43 GAS FIRED WATER BOILER Boiler Manual Ratings DOE SRN THE ERR SANG YOUR Mone Boiler DOE CSA CSA Net Boiler DOE Weil McLain Vent Model Heating Input Output Water Seasonal Low temperature Size Number Capacity Ratings Content Efficiency seasonal efficiency Btuh Note 2 Btuh Note 9 Btuh Note 9 Btuh Note 3 Gallons AFUE Note 1 Note 5 Note 4 Ultra 80 71 000 80 000 71 000 62 000 0 69 93 0 98 0 3 Ultra 105 94 000 105 000 94 000 81 000 0 82 92 0 98 0 on Ultra 155 139 000 155 000 139 000 123 000 1 17 93 0 98 0 3 Ultra 230 207 000 230 000 207 000 183 000 12977 92 8 98 0 4 Boiler CSA CSA Net Boiler Combustion Thermal Weil McLain Vent Model Input Gross Water Efficiency Efficiency Low temperature Size Number Output Ratings Content efficiency Combustion Thermal Btuh Note 9 Btuh Note 9 Btuh Note 3 Gallons Note 6 Note 7 Note 8 Note 4 Ultra 310 310 000 289 000 252 000 2 1 93 3 92 9 95 6 95 2 4 Notes 1 Asan Energy St
8. or bladder type expansion tank Part number 550 101 233 0903 10 Flow check valves with weighted seats to prevent gravity circulation 11 Purge drain valves 12 Boiler circulator 13 Zone valves when used zoning may also be done using manifold mounted valve actuators 20 Make up water supply 21 Primary secondary connection 22 High limit temperature control set to protect radiant tubing Bl Supplied with boiler By others not included with boiler 17 3 GAS FIRED WATER BOILER Boiler Manual Install water piping Continued Chilled water systems 1 Install boiler so that chilled medium is piped in parallel with theheating boiler Use appropriate valves to prevent chilled medium from entering boiler See Figure 10 for typical installation of balancing valve and check valve The space heating system may be zoned with circulators if a separate circulator is supplied for the chilled water loop If boiler isconnected to heating coils located in air handling units where they can be exposed to refrigerated air use flow control valves or other automatic means to prevent gravity circulation during cooling cycle Caution Follow these piping guidelines below to ensure chilled water does not enter the boiler loop WARNING Chilled medium if used ispiped in parallel with heating boiler as shown in Figure 10 U seappropriate valves to prevent chi
9. Irrigateimmediately Breathing Fresh air Address reported problems 1 Inspect any problemsreported by owner and correct before proceeding Inspect boiler area 1 2 Verify that boiler area is free of any combustible materials gasoline and other flammable vaporsand liquids Verify that air intake area is free of any of the contaminants listed page 8 of this manual If any of these are present in the boiler intake air vicinity they must be removed If they cannot be removed reinstall theair and vent lines per this manual and the Ultra Boiler Vent Supplement Part number 550 101 233 0903 Inspect boiler interior 1 2 3 Remove jacket front door and inspect interior of boiler Remove the venturi air inlet silencer and clean if necessary Replace silencer Vacuum any sediment from the inside of the boiler and components Remove any obstructions Do not use solvents to clean any of the boiler components Thecomponents could be damaged resulting in unreliable or unsafe operation 29 GAS FIRED WATER BOILER Boiler Manual Annual Startup continued Clean condensate trap 1 2 Loosen condensatetrap linehoseclamps and remove trap line Empty water from trap lineand inspect Flush out if needed with fresh water Check condensateelbow and tee and condensateline to drain Flush if necessaryto clean Replacecondensatetrap lineand tighten hoseclamps Fill trap w
10. Retest boiler Check flame signal 1 Flamesignal DC volts from low voltage terminal strip terminal 9 to ground should beat least 4 VDC 2 A lower flamesignal may indicateafouled ignitor or damaged ignitor insulation If cleaning the ignitor does not improve ground wiring isin good condition and ground continuity is satisfactory replace the ignitor 3 SeeTroubleshooting the Ultra Control Supplement for other procedures to deal with low flame signal Check flue gas temperature 1 Placethe control display in Information mode while the boiler is operating at high fire See Ultra Control Supplement for details 2 Theflue gas temperature electronic display first digit shows 5 must not be more than 60 F higher than the return water temperature display first digit shows 2 3 Ifthefluetemperatureis higher than this shut down the boiler allow to cool and follow the procedure on pages 33 through 34 to clean the heat exchanger Review with owner 1 ReviewtheUser sInformation M anual with theowner 2 Emphasizetheneed to perform the maintenanceschedulespecdified in the User s Information M anual and in this manual as well 3 Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior 4 Remind the owner to follow the proper shutdown procedure and to schedulean annual startup atthe beginning of thenext heating season Figure 16 Burner assembly
11. gas valve electrical plug Exchangercleaning continued ALL models 1 Closeisolation valveson piping to isolate boiler from system Attach ahoseto boiler drain valve and flush boiler thoroughly with clean water by using purging valves to allow water to flow through water make up lineto boiler 2 When boiler has been flushed restore boiler to operation 3 Perform startup and checkout proceduresof pages 23 and 26 4 Turn on gassupply and check for gas leaks Failureto properly check for gas leakscan cause severe personal injury death or substantial property damage 5 Turn on boiler electrical supply and test boiler for proper operation asstated in theUltra Boiler M anual 6 Replace boiler jacket front door when servicing is completed See Warning at top of page 33 Part number 550 101 233 0903 Ulla GAS FIRED WATER BOILER Boiler Manual Replacement parts Replacement parts must bepurchased through alocal Weil M cLain distributor When ordering specify boiler model and sizeand include description and part number of replacement part Resultsfrom using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation NOTICE Wel M cLain partnumbersarefound in Weil M cLain Boilersand Controls Repair Parts Lists Theboiler containsceramicfiber materials U secare when handling these materials per instructions on page 29 of thismanual Failureto
12. it is correct usually around 12 psig Watch the system pressure as the boiler heats up during testing to ensure pressure doesn t rise too high Excessive pressure rise indicates expansion tank sizingor performanceproblem Inspect automatic air vents and air separators Removeair vent capsand briefly press push valveto flush vent Replace caps M akesurevents do not leak Replaceany leaking vents Check expansion tank 1 Expansion tanks provide space for water to move in and out as the heating system water expands dueto temperature increaseor contracts asthe water cools Tanks may be open closed or diaphragm or bladder type Seesection 3 of this manual for suggested best location of expansion tanksand air eliminators Open type located abovehighest radiator or baseboard unit usually in theatticor closet H as a gauge glass and overflow pipeto a drain Closed type welded gastight and located aboveboiler Tank is partially filled with water leaving an air cushion for expansion e Make sure this type of tank is fitted with a tank fitting such as the B amp G Tank Trol or Taco Taco Trol This fitting reduces gravity circulation of air saturated tank water back to the system and preventstheair from bubbling up through the water as it returns from the system e Donotuseautomatic air vents in systems with closed typetanks T heair will escape from thesystem instead of returning to thetank Eventually thetank will waterlog and
13. no longer control pressurization T heboiler relief valve will weep frequently Diaphragm or bladder type welded gas tight with a rubber membrane to separate the tank pressurizing air and the water M ay be located at any point in the system but most often found near the boiler Systems with this type of expansion tank require at least one automatic air vent preferably located on top of an air eliminator as shown in examplesin manual section 3 If relief valve has tended to weep frequently the expansion tank may be waterlogged or undersized Closed type tank tank ismost iay waterlogged Install a tank fitting if not already installed Then check fill level per fitting manufacturer s instructions If fill level iscorrect check tank size against manufacturer s instructions Replacewith alarger tank if necessary Diaphragm or bladder type first check tank sizeto besureit islarge enough for the system If size is too small add additional tank s as necessary to provide sufficient expansion If tank size is large o removetank from system and check charge pressure usually 12 psigfor residential applications If tank won t hold pressure membrane has been damaged Replacetank Part number 550 101 233 0903 8a GAS FIRED WATER BOILER Boiler Manual Annual Startup continued Check boiler relief valve 1 Inspect therelief valve and lift the lever to verify flow asin thefollowing warnings excerpted from
14. property damage Drain and remove fittings 1 Disconnect fill water hosefrom water source 2 Drain boiler through drain valve Removehoseafter draining 3 Removenipples and valves unlessthey will remain for usein the system piping 4 Remove plug from relief valve street elbow See section 3 page 12 to install relief valve Figure3 Hydrostatic test piping connections Aemme 117 pha bor ensi neil rni ask ober ladeostabr eg a ogie Folia in ha manal Termnporay shart Fi waive un Lec appi Wippe di a E len A plug F UE b afer Tepa woh t fata er 19 uluzi 2H whe ne 5 boder kam Spee wl ee met Ww uires skow ath beoder laces Sapte ppa 7 on 82 50 Lita FE 4 MPT en Lism T10 ipit comedian wnt rau Aled Drain valve Connect hiss bum fod deaur eee br 11 3 GAS FIRED WATER BOILER Boiler Manual Install water piping 12 Install relief valve 1 Install rdief valvein 34 street elbow piped from boiler supply piping tee Figure 3 page 11 Pipethe relief valve only as shown in thelocation shown 2 Connect discharge piping to safe disposal location following guidelinesin theWARNING below WARNING To avoid water damage scalding due to relief valve operation Dischargelin
15. sensor amp 518 00 ii ib Gas vive i a9 as Cork gasei Pr e am gt ai VOD Part number 550 101 233 0903 39 GAS FIRED WATER BOILER Boiler Manual Replacement parts continued Heat exchanger and piping Ultra 155 to 310 Item Description Poler Part P Models Number 1 Heat exchanger replacement kit Heat exchanger cover plate burner electrode water sensors Ultra 155 383 500 070 compression fittings gaskets and hardware Ultra 230 383 500 075 Ultra 310 383 500 375 2 Cover plate replacement kit Cover plate cover plate gasket burner gasket and hardware 155 230 310 383 500 395 4 Cover plate insulation 155 230 310 383 500 250 5 Cover plate gasket not shown 155 230 310 383 500 255 7 Water compression fitting 28 mm Ultra 155 230 383 500 260 9 Water supply piping assembly Pipe temperature well check valve cap assembled amp Ultra 155 230 383 501 036 compression fitting Ultra 310 383 500 380 10 NPT well for temperature gauge All 383 500 270 11 Pressure temperature gauge check valve All 383 500 275 14 Return water bushing 174 BSP x 1 BSP not used on Ultra 310 Ultra 155 230 383 500 280 15 Return water pipe assembly Pipe drain valve cap assembled amp compression fitting Ultra 155 230 383 500 285 Ultr
16. valve electrical plug Disconnect thegaslineunion below the gas valve Remove 3 TORX screwssecuring gas valveto venturi Figure 2a Locate propaneorificediscfrom conversion kit bag Verify that thestamping on theorifice disk matches the boiler size Place orifice in the black rubber grommet in the side of the gas valve and secure in valve Figure2 Reposition gas valve against venturi and replace 3 TORX screws securing valveto venturi Reconnect gaslineunion DO NOT attemptto adjust gas valveoutlet pressure Connect gas valveelectrical plugto valveterminals After installation is complete attach the propane conversion label in conversion kit bag next to the boiler rating plate 10 Replacejacket front panel Venturi Grass arfios Screws NOTICE uw Gas valve Ultra 310 boilers cannot be equipped for propanefiring as of October 2003 Propanecapability should beavailablein 2004 Placing floor mounted boilers 1 Set boiler in placeand check level a Adjust legs if necessary to level boiler Placing wall mounted boilers 1 Ultra 80 105 155 and 230 boilers can be wall mounted Use only the separately available Ultra boiler wall mounting kit and instructions See WARNING below The wall must be vertically plumb and capableof carryingtheweight of theboiler Theoperating weightsare Ultra 80 139 pounds Ultra 105 145 pounds Ultra 155 181 pounds Ultra 230 1
17. will damage the boiler resulting in possible severe personal injury death or substantial property damage Do not pipecombustion air near a swimming pool for example Also avoid areas subject to exhaust fumes from laundry facilities These areas will always contain contaminants Table 1 Corrosive contaminants and sources Products to avoid Spray cans containing chloro fluorocarbons Permanent wave solutions Chlorinated waxes cleaners Chlorine based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants Dry cleaning laundry areas and establishments Swimming pools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Auto body shops Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops GAS FIRED WATER BOILER Boiler Manual When removing a boiler from existing common vent system Do
18. 23 regardingfailureto repair leaks 2 Vent any remaining air from system using manual vents Air in thesystem will interfere with circulation and causeheat distribution problems and noise 2 Check vent piping and air piping 1 Check for gas tight seal at every connection and seam of air pipingand vent piping Ventingsystem must besealed gas tight to ELITS prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death LJ Check gas piping 1 Check around the boiler for gas odor following the procedure of page 21 of this manual If you discover evidence of any gas leak ELITS shut down theboiler at once Find theleak source with bubble test and repair immediately Do notstart boiler again until corrected Failureto comply could result in severe personal injury death or substantial property damage Propane boilers verify conversion 1 Verifypropaneorificehasbeen installed per Propane Conversion instructions wARNING DO NOT adjust or attempt to measure gas valve outlet pressure The gas valveis factory set for the correct outlet pressure Thissettingissuitablefor natural gas and propane requiring no field adjustment Attemptingto alter or measurethegas valve outlet pressure could result in damageto thevalve causing potential severepersonal injury death or substantial property damage Ultra boilers are shipped ready to fire natural gas ONLY Exception The U It
19. 92 pounds M Ultra 310 boilersareN OT designed for wall mounting Wall mount Ultra boilers only using Well McLain Ultra boiler wall mounting kit and accompanyinginstructions Thiskitisnot supplied as standard equipment with the boiler and must be purchased separately Failureto comply with above could result in severe personal injury death or substantial property damage Part number 550 101 233 0903 boi continued Perform hydrostatic pressure test Pressuretest boiler before permanently attaching water or gas piping or electrical supply Prepare boiler for test 1 SeeFigure3 for referencein following steps 2 Remove supply line tee and 34 street elbow from accessory bag Pipe to boiler supply connection as shown Use pipe dope sparingly 1 x 1 x 34 tee with Ultra 80 to 230 124 x 1 x 34 tee with Ultra 310 3 Temporarily plug the 3 4 relief valve tapping in the street elbow with a34 N PT pipeplug 4 Connectahoseto boiler drain valve the other end connected to a fresh water supply M ake sure hose can also beused to drain boiler after test 5 Connectanippleand shutoff valveto system supply connection on thesupply tee This valvewill beused to bleed air duringthefill Valveand nipplearenot included with boiler 6 Connectashutoff valveto system return connection Valveis not included with boiler 7 To avoid getting water on boiler you may want to p
20. U Control Supplement 7 Setting boiler outlet water target temperature a Follow procedurein Ultra Control Supplement to set space heating target temperature to the desired supply temperature for the system For outdoor reset operation install and connect theoutdoor temperature sensor supplied with the boiler NOTE 1 To ensureadequate flow ratethrough the boiler usethe following pipesizeon all boiler loop piping connecting boiler to and from theprimary secondary connection item 21 Ultra 80 or Ultra 105 1 or larger Ultra 155 or 230 1 or larger Ultra 310 1 or larger Figure9 Typical radiant heating system piping plus optional DHW te 7 cin piping Option Radiant man inida nnd a ubing typical Denm apart Useat least theminimum pipingsizeat left and pipe the boiler using only primary secondary piping as shown Failure to follow these guidelines could result in system problems CAUTION Legend Figure 9 Ultra boiler Indirect water heater DHW if used Boiler relief valve see page 12 for piping details Relief valve discharge piping see page 12 for details DHW circulator see page 14 for suggested sizing Isolation valves System circulator Diaphragm or bladder type expansion tank see page 12 for piping of closed type expansion tank if used Air separator with automatic air vent only on systems using diaphragm
21. WEIL McLAIN Gas fired MZA water boiler Boiler Manual Ultra 80 105 155 230 amp 310 Installation e Startup Maintenance Parts Ultra with PRECISION HYDRONIC DATA technology WARNING This manual must only beused by a qualified heating installer servicetechnician Read all instructions including this manual theU Itra Control Supplement and the Ultra Vent Supplement beforeinstalling Perform stepsin the order given Failure to comply could result in severe personal injury death or substantial property damage Part number 550 101 233 0903 GAS FIRED WATER BOILER Boiler Manual THE Ultra BOILER WITH PhD TECHNOLOGY How IT wonks PhDtechnology 10 11 PhD Technology Precision hydronic Data isan intelligent system that deliversPrecision hydronic heating and hot water needs whilemaximizing efficiency by measuring the Data parameters of your heating system Cast aluminum heat exchanger Heat exchanger access cover Blower The advanced blower design and air inlet silencer 5a on Ultra boilers resultin very quiet operation 80 amp 105 Air enters the boiler enclosurethrough theair intake adapter 18 flows through the enclosure enters the air inlet silencer 5a then enters the blower The blower pullsair through thesilencer and pushesit into the venturi 5 whereit mixes with gas before entering the burner 155 230 amp 310 Air enters the b
22. a 310 383 500 385 17 Boiler drain valve 34 NPT All 511 246 392 18 Blower assembly kit Blower gasket and hardware Ultra 155 383 500 035 Blower assembly kit Blower gasket molex adapter and hardware Ultra 230 383 500 040 Blower assembly kit Blower gasket and hardware Ultra 310 383 500 360 19 Gas pipe assembly Gas pipe and shut off valve Ultra 155 230 383 500 290 Gas pipe Ultra 310 only Ultra 310 560 907 679 19a Flexible gas line section and shut off valve Ultra 310 only Ultra 310 560 900 016 20 Gas valve venturi kit Gas Valve venturi assembly adapter block O ring and hardware Ultra 155 383 500 025 For LP boilers make sure to reinstall the existing propane orifice Ultra 230 383 500 030 Ultra 310 383 500 390 21 Ground joint union NPT Ultra 155 230 Obtain locally 22 Manual gas valve 1 NPT Ultra 155 230 Obtain locally 23 Air silencer kit Air silencer and gasket Ultra 155 230 383 500 295 Ultra 310 383 500 355 25 Condensate trap kit Condensate trap hose clamps pvc fittings and gasket Ultra 155 383 501 031 Ultra 230 383 500 060 Ultra 310 383 500 365 26 Ignition electrode kit Ignition electrode suppressor gasket and hardware All 383 500 045 27 Ignition cable kit not shown Ignition cable suppressor and wire tie All 383 500 050 28 Inspection glass kit Bracket glass gasket and hardware All 383 500 020 29 Burner replacement kit Burner gaskets and h
23. a relief valve manufacturer s warning label Beforeoperating any relief valve ensurethat it is piped with its discharge in a safe area to avoid severe scald potential Read manual section 3 page 12 beforeproceedingfurther Safety relief valves should be reinspected AT LEAST ONCE EVERY THREE YEARS by alicensed plumbing contractor or authorized inspection agency to ensurethat the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrodethevalveor itscomponentsover time rendering thevalveinoperative Such conditionsarenot detectableunless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not bytheowner Failureto reinspecttheboiler relief valveas directed could result in unsafe pressure buildup which can result in Severe personal injury death or substantial property damage Following installation the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to thevalve renderingit inoperative W hen manually operating thelever water will dischargeand precautionsmust betaken to avoid contact with hot water and to avoid water damage Before operating lever check to seethat a dischargelineis con
24. ad loss across the boiler ek combined space heating DH W c H2 head loss across the DH W piping d Table 2 subtracts 1 and H2 from the available head of the circulator This 1 Figure 5 showsrecommended DHW piping asshown in gives the maximum value for H 3 head loss across the water heater Figures 7 through 10 pages 15 18 All show direct 4 Procedureto select acirculator using Table 2 connection of the DH W piping to the boiler because the Step 1 From the water heater manufacturer s data find boiler circulator shuts down duringD HW operation Required boiler water flow rate GPM at 180 F 2 Figure 6 shows the pump curves for suggested DHW Pressuredrop acrossthewater heater at this flow rate in feet water column Step 2 Find your boiler model in Table 2 Select a flow rate column 1 just larger than the required flow ratefrom step 1 Step 3 Thevaluein column H 3 must belarger than the water heater pressure Figure5 DHW piping see Table 2 for approxi drop from step 1 4 mate head losses BN pg rpm T Table 2 Pipe sizing and head losses for DHW applications H1 boiler head loss H2 piping head loss allowable head loss through water heater based on available head of circulator chosen i e Taco 007 0011 0012 0013 or 0014 Bell biter rid or Gossett 36 wg mi eran dud elle uos a He Available head e t
25. ant heating applications 1 The Ultra boiler is ideal for use in radiant heating The Ultra boiler s uniqueheat exchanger design allowsitto work well even in condensing mode So thereis need to regulate boiler return water temperaturein radiant heating applications 2 Connect boiler to system as shown in Figure 9 for typical radiant heating applications The primary secondary piping shown ensures the boiler loop will have sufficient flow Size the system piping and circulator to providetheflow and pressure drop needed for theradiant system 3 Addthehigh limit control Figure 9 item 22 to ensure supply water temperature will not exceed the maximum allowable for the radiant system Wirethislimit control between low voltageterminal strip terminals 6and 7 4 When usingaclosed type expansion tank connect the expansion tank and make up water pipingas shown in Figure4 page 13 5 Connect DHW domestic hot water piping to indirect storage water heater as shown PhD Control M oduleturnsoff spaceheating during DHW heating Theboiler circulator will turn off preventing hot water from circulatingto the system T heflow check valve shown on theboiler outlet piping prevents gravity circulation in theboiler loop during DHW heating NOTICE 6 Controllingthesystem circulator a To cyde the system circulator from the Ultra PhD control module add a circulator relay wired to the boiler circulator terminalsasshown in the
26. ar Partner Weil M cLain has determined Weil M cLain Low temperatureseasonal efficiency is based that Ultra boilers meet the Energy Star guidelinesfor energy efficiency Based on standard test procedures prescribed by the United States Department of Energy B R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup Ratings are based on a piping and pickup allowance of 1 15 An additional allowance should be made for unusual pipingand pickup loads Ultra boilers require special venting consistent with Category IV boiler Use only the vent materials and methods specified in Ultra vent supplements U Itra boilers must be direct vented U Itra 230 can bevented with either 3 or 4 vent pipe Vent length limitsfor 3 vent arenot as long asfor 4 vent um WEIL Mc LAIN on ASHRAE 103 test method using boiler return water temperature of 90 F with boiler outlet water temperature of 110 F Combustion efficiency is based on testing procedure BTS 2000 and equal to 10096 minus flue loss Thermal efficiency is based B R testing procedure BT S 2000 Weil M cLain Low temperature efficiency is based on the B R testing procedures using boiler return water temperature of 90 F and boiler outlet water temperature of 110 F Ratings shown are for sea level applications only For altitudes from sea level to 5 500
27. ardware Ultra 155 383 500 085 Ultra 230 383 500 090 Ultra 310 383 500 370 32 Return supply sensor kit 1 sensor All 383 500 300 40 Part number 550 101 233 0903 GAS FIRED WATER BOILER Boiler Manual Replacement parts continued Heat exchanger and piping Ultra 155 to 310 18 Ultra 155 amp Ultra 230 Ultra 310 Part number 550 101 233 0903 41 GAS FIRED WATER BOILER Boiler Manual Replacement parts continued Controls Item Description Part Number 1 Ultra control module Ultra 80 105 155 230 383 500 190 Ultra 310 511 330 258 2 Transformer 120v 24v 383 500 195 3 Display board kit Includes display bracket label and off set 383 500 200 4 On off power switch 383 500 205 5 Pressure temperature gauge assy Includes temperature and pressure sensor 383 500 210 6 Ribbon cable control module to display board 383 500 215 7 Low voltage wire harness assembly for Ultra 80 amp 105 not shown 591 300 002 Low voltage wire harness assembly for Ultra 155 amp 230 not shown 383 500 220 Low voltage wire harness assembly for Ultra 310 not shown 591 391 941 8 Line voltage wire harness assembly for Ultra 80 amp 105 not shown 591 300 001 Line voltage wire harness assembly for Ultra 155 amp 230 not shown 383 500 230 Line voltage wire harness assembly for Ultra 310 not shown 591 391 940 9 Control module fuses
28. at exchanger and piping Ultra 80 amp 105 Item Description Borer Models Number 1 Heat exchanger replacement kit Heat exchanger cover plate burner electrode water sensors Ultra 80NG 383 501 023 compression fittings condensate fitting gaskets and hardware Ultra 80LP 383 501 024 Ultra 105 383 501 035 2 Cover plate replacement kit Cover plate cover plate gasket burner gasket and hardware Ultra 80 105 383 501 022 3 Cover plate gasket insulation Ultra 80 105 591 200 000 6 Burner gasket Ultra 80 105 590 300 000 7 Water compression fitting 28 mm Ultra 80 105 383 500 260 8 Water compression fitting 22 mm Ultra 80 105 564 100 002 9 Water supply piping assembly Pipe temperature well check valve cap assembled amp Ultra 80 105 383 501 036 compression fitting 10 NPT well for temperature gauge All 383 500 270 11 Pressure temperature gauge check valve All 383 500 275 15 Return water pipe assembly Pipe drain valve cap assembled amp compression fitting Ultra 80 105 383 501 037 17 Boiler drain valve 34 NPT All 511 246 392 18 Blower assembly kit Blower gasket and hardware Ultra 80 105 383 501 027 19 Gas pipe assembly Gas pipe shut off valve 1 1 2 nipple adapter block O ring and hardware Ultra 80 105 383 501 038 20 Gas valve venturi kit Gas Valv
29. be damaged byamoving vehicle Provide air openings to room Ultra boiler alone in boiler room 1 No air ventilation openings into boiler room are needed when clearances around Ultra boiler are at least equal to the SERVICE clearances shown in Figure 1 For spaces that do NOT supply this clearance providetwo openingsas shown in Figure 1 Each opening must provide 1 square inch free area per 1 000 Btuh of boiler input Part number 550 101 233 0903 Ultva GAS FIRED WATER BOILER Boiler Manual Ultra boiler in same space with other gas or oil fired appliances 1 Follow the National Fuel Gas Code U S or CSA B149 1 and B149 2 Canada to size verify sizeof the combustion ventilation air openingsinto thespace WARNING The space must be provided with combustion ventilation air openings correctly sized for all other appliances located in thesamespaceastheU Itraboiler Replace boiler jacket front door after servicing The boiler front door must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room Thisisparticularly important iftheboiler islocated in thesameroom as other appliances Failureto comply with theabove warnings could result in severe personal injury death or substantial property damage 2 Sizeopeningsonly on thebasisof theother appliances in the space N o additional air opening free area is needed for the Ultra boiler because it takes its combustion air fro
30. boiler 10 minutes b Turn off other appliances c At natural gas meter measure time in seconds required to use one cubic foot of gas d Calculate gas input ____ __ 985 number of seconds from step e Btuh calculated should approximate input rating on boiler rating label 7 Press and hold the Ultra control panel M ode and buttons simultaneously until thedisplay shows L 8 The L inthefirst digit meanstheboiler will operateatlow firewhen the blower speed reaches minimum 9 Look at theflame through the flame inspection window Thelow fire flame should be stable and evenly distributed over burner surface with a uniform orangecolor 10 Repeat the combustion test of steps 4 and 5 above 11 Press and hold the and buttons to return boiler to automatic firing 12 Replacefluegastemperature sensor wARNING You must replacethe flue gas temperature sensor to prevent flue gas spillage into the boiler enclosure Failure to comply could result in severe personal injury death or substantial property damage Btuh 1 Adjust and test boiler controls l Follow instructions in the Ultra Control Supplement to set and verify operation of the boiler controls 25 7 GAS FIRED WATER BOILER Boiler Manual Check out startup verification 26 L L U L L Boiler and heat distribution unitsfilled with water Water chemistry verified per page 23 Automatic air vents if used op
31. c air vent only on systems using diaphragm or bladder type expansion tank Part number 550 101 233 0903 Figure 7 Zone valve zoning plus optional DHW piping B oe ZONE 1 Da rei incited 12 inde me 10 Flow check valves with weighted seats to prevent gravity circulation 11 Purge drain valves 12 Boiler circulator 13 Zone valves typical 20 Make up water supply 21 Primary secondary connection Bl Supplied with boiler m By others not included with boiler 3 GAS FIRED WATER BOILER Boiler Manual Install water piping Continued 16 Zoning with circulators 1 Connect boiler to system as shown in Figure8 when circulator zoning T heboiler circulator cannot beused for azone It must supply only the boiler loop Install aseparatecirculator for each zone When using a closed type expansion tank connect the expansion tank and make up water piping as shown in Figure 4 page 13 Connect DHW domestichot water pipingto indirect storage water heater as shown NOTICE PhD Control M oduleturns off space heating during DH W heating The boiler circulator will turn off preventing hot water from circulating to the system Theflow check valve shown on theboiler outlet piping prevents gravity circulation in theboiler loop during DH W heating NOTE 1 To ensure adequate flow rate through the boiler usethefollowing pipesiz
32. comply could result in severe personal injury Replace boiler jacket front door after startup or servicing Replace boiler jacket front door after start or servicing The boiler front door must be securely fastened to the boiler to prevent boiler from drawing air from insidethe boiler room Thisis particularly important if the boiler is located in the sameroom asother appliances Failureto keep the door securely fastened could result in severe personal injury or death Miscellaneous parts and kits Item Description Part Number 1 Pressure relief valve ASME 30 PSI 34 npt male watts 330 383 500 095 2 Boiler circulator without flanges Ultra 80 amp 105 Taco Model 007 511 405 113 Ultra 155 230 amp 310 Taco Model 0011 511 405 124 3 Circulator hardware kit inlet 1 1 flange 2 nuts 2 screws and 1 gasket Ultra 80 to 230 381 354 525 4 Circulator hardware kit flange nuts screws and gasket Ultra 80 to 310 114 381 354 526 Ultra 310 1 381 354 531 5 Vent air termination plate 2 required for each boiler 383 500 100 6 Vent termination bird screen 2 required for Ultra 80 105 amp 155 3 vent 383 500 105 7 Vent termination bird screen 2 required for Ultra 230 amp 310 only 4 vent 383 500 110 8 Natural to propane conversion kit for Ultra 80 _ 383 501 020 Natural to propane conversion kit for Ultra 105 orifice bag assembly 540 100 001 9 Propane to natu
33. cted to ensure adequate flow through the Ultra boiler Failure to comply could result in unreliable performance and nuisance shutdowns from insufficient flow Sizing space heat system piping 1 See Figures 7 through 10 pages 15 18 for recommended piping In all diagrams the space heating system isisolated from theboiler loop by the primary secondary connection 2 Sizethepipingand componentsin thespaceheating system using recognized design methods 13 3 GAS FIRED WATER BOILER Boiler Manual Install water piping Continued Sizing DHW system piping When using the boiler for dedicated DHW applications usethe circulator supplied with the boiler 007 for Ultra 80 105 0011 for Ultra 155 230 310 to circulate to the water NOTICE circulators Taco 007 0011 0012 0013 0014 B amp G PL 36 or equivalent Use these curves along with boiler pressure drop data from Table 2 to sizetheDH W piping and circulator Or you can use Table 2 for a quick selection method 3 Table2 uses the available head from the circulators listed to help you select the heater except where higher flow rates may be right circulator required for the heater used U sethe following See Figure5 method to select a circulator for the water b 1 15 the he
34. ction in boiler water causing system and boiler to freeze and leak GAS FIRED WATER BOILER Boiler Manual Provide clearances Clearances from combustible materials 1 Hot water pipes at least 1 2 from combustible materials 2 Vent pipe at least 0 20 from combustible materials 3 SeeFigurel for other clearanceminimums Clearances forservice access 1 SeeFigurel for recommended service clearances If you do not provide minimum clearances shown it might not be possible to service the boiler without removing it from the space Ultra boilers except the U Itra 310 may be wall mounted using special wall mount kit or floor mounted No clearance is required at of the unit either for service or for clearance to combustible surfaces NOTICE Figure1 Clearances required FLUE PIPE Combustible surfaces min Opening in combustible wall floor ceiling or roof EF larger ean nue pos diameter fitted wills gabarmi steel thimble Ain vantilatian openiegs when aquired cee manual page 7 iF maximum below coding of enclosum Sal Senare a Service 12 min surati 5 min SIDES Samice min Combustbie Right 4 min H min 4 BOTTOM Service O min Combustible amp urtares IY min 12 maximum abym lae of anckieeuns FRONT Service 24 min
35. e Table 4 Pipe capacity for 0 60 specific gravity natural gas Gas pipe usin pipe for pipe size of length pacity in cubic feet gas per hour yo 34 2 1 1v 10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 860 40 63 130 245 500 760 50 56 115 215 440 670 75 45 93 175 360 545 100 38 79 150 305 460 150 31 64 120 250 380 Part number 550 101 233 0903 6 Ulla GAS FIRED WATER BOILER Boiler Manual Startup Check control water chemistry Do not use petroleum based cleaning or sealing compoundsin boiler system Damageto elastomer seals and gaskets system could occur resultingin substantial property damage Beforefilling the boiler and system with water verify thefollowing Failureto comply could result in boiler failureor unreliable operation Water pH between 7 0 and 8 5 1 Maintain boiler water pH between 7 0 and 8 5 Check with litmus paper or have chemically analyzed by water treatment company 2 If pH differs from above consult local water treatment company for treatment needed Hardness less than 7 grains 1 Consult local water treatment companies for unusually hard water areas above 7 grains hardness Chlorine concentration less than 200 ppm l Fillingwith chlorinated fresh water should beacceptablesince drinking water chlorine levelsare typically lessthan 5 ppm 2 Do not use the boiler to directly heat swimming pool or s
36. e venturi 90 elbow gaskets and hardware assembled Ultra 80 383 501 029 For LP boilers make sure to reinstall the existing propane orifice Gas valve venturi kit Gas Valve venturi 90 elbow gaskets and hardware assembled Ultra 105 383 501 030 For LP boilers make sure to reinstall the existing propane orifice 22 Manual gas valve Ultra 80 105 Obtain locally 23 Air silencer kit Air silencer and gasket Ultra 80 105 383 501 026 24 Air silencer adapter kit Air silencer adapter and hardware Ultra 80 105 383 501 025 25 Condensate trap kit Condensate trap hose clamps fittings and gasket Ultra 80 105 383 501 031 26 Ignition electrode kit Ignition electrode suppressor gasket and hardware All 383 500 045 27 Ignition cable kit not shown Ignition cable suppressor and wire tie All 383 500 050 28 Inspection glass kit Bracket glass gasket and hardware All 383 500 020 29 Burner replacement kit Burner gaskets and hardware Ultra 80NG 383 501 032 Ultra 80LP 383 501 033 Ultra 105 383 501 034 30 Gasket Ultra 80 105 590 300 003 31 Condensate fitting Ultra 80 105 561 200 000 32 sensor kit 1 sensor All 383 500 300 38 Part number 550 101 233 0903 GAS FIRED WATER BOILER Boiler Manual Replacement parts continued Heat exchanger and piping Ultra 80 amp 105 Gas wave
37. e CP number in the space provided on the Installation and servicecertificatefound on page 27 Consider piping and installation when determiningboiler location Any claims for damage or shortage in shipment must be filed immediately against thetransportation company by the consignee Commonwealth of Massachusetts When theboiler isinstalled within theCommonwealth of M assachusetts This product must be installed by a licensed plumber or gas fitter e Ifantifreezeisused areduced pressureback flow preventer deviceshall beused Part number 550 101 233 0903 WARNING Failureto adhereto theguidelineson thispagecan result in severe personal injury death or substantial property damage When servicing boiler Toavoidelectric shock disconnect electrical supply beforeperforming maintenance To avoid severe burns allow boiler to cool before performing maintenance Boiler operation e Donotblock flow of combustion or ventilation air to boiler Should overheating occur or gas supply fail to shut off do notturn off or disconnect electrical supply to circulator Instead shut off the gas supply at alocation external to the appliance Donotusethisboiler if any parthas been under water Immediately call a qualified servicetechnician to inspect the boiler and to replace any part of the control system and any gas control that has been under water Boiler water TheUltra heat exchanger is made of alumin
38. ection 6 pages 23 and 24 havebeen completed Fill vent condensatetrap with water by removing hose clamp and hose at PVC reducing elbow Replace hoseon PVC reducing elbow and tighten damp Verify electrical connectionsarecorrect and securely attached Inspect vent piping and air piping for signs of deterioration from corrosion physical damageor sagging Verify air pipingand vent piping areintact and correctly installed per Ultra Boiler Vent Supplement To start the boiler 1 Turn OFF Power switch on Ultra display panel Turn on power to boiler 2 Read and follow the Operating Instructionsin the UltraControl Supplement If boiler does not start correctly 1 Check for loose connections blown fuse or service switch off 2 Isexternal limit control if used open Is boiler water temperature above 200 F 3 Isthermostat set below room temperature Isgasturned on at meter or boiler 5 sincoming gas pressurelessthan 4 w c for natural gas or 5 w c for propane 6 Areparameters set correctly asinstructed in theUltra Control Supplement If none of the above corrects the problem refer to Troubleshootingin theU Itra Control Supplement Part number 550 101 233 0903 6 Ulla GAS FIRED WATER BOILER Boiler Manual S t a rt u p continued 1 Check system and boiler LJ Check water piping l Check system piping for leaks If found shut down boiler and repair immediately SeeWARNIN GS on page
39. emust beconnected to relief valve outlet and run to a safe place of disposal Terminatethe dischargelinein a manner that will prevent possibility of severe burns or property damage should thevalve discharge Dischargelinemust beas short as possible and bethesamesizeasthevalvedischarge connection throughout its entirelength e Dischargelinemust pitch downward from the valve and terminate at least 6 above thefloor drain whereany dischargewill be Clearly visible Thedischargelineshall terminateplain not threaded with a material serviceable for temperatures of 375 F or greater Do not pipe the discharge to any place wherefreezing could occur Noshutoff valveshall beinstalled between therelief valveand boiler or in thedischarge line Do not plugor placeany obstruction in thedischargeline Testtheoperation of thevalveafter filling and pressurizing system by liftingthelever M akesurethe valvedischarges freely If the valve fails to operate correctly replace it with anew relief valve Failureto comply with theaboveguiddines could result in failureof therelief valveto operate resulting in possibility of severe personal injury death or substantial property damage WARNING Usetwo wrenches when tightening water piping at boiler using one wrench to preventtheboiler return lineor supply line from turning Failureto support the boiler piping connectionsto prevent them from turning could cause damage to boiler c
40. en onefull turn Air purged from system Air purged from gas piping Piping checked for leaks Propane orifice installed for propane firing and propaneconversion label affixed to jacket WARNING Ultra boilers are shipped ready to fire natural gas ONLY Exception The U Itra 80LP is factory equipped to fire propane You must install the propane orifice or conversion kit U Itra 80N G if the boiler will be connected to propane See page 9 Failure to comply could result in severe personal injury death or substantial property damage Thermostat circuit wiring checked to ensurethere are no stray voltages per page 24 Check Thermostat W ires Followed peratingInstructionsin U Control Supplement Burner flameand combustion verified per page 25 Verified control operation for space heating and DHW if used per Ultra Control Supplement Tested additional fidd installed controls If boiler hasalow water cutoff additional high limitor other controls tested for operation as outlined by manufacturer Boiler should be operating and should go off when controls are tested Verify controls cause soft lockout or hard lockout as desired d Set additional field installed limit control s to system temperature requirements Adjusted balancing valves and controls to provide design temperatureto system For multiple zones adjusted for correct flow in each zone Verified thermostat heat anticipato
41. eon all boiler loop piping connecting boiler to and from theprimary secondary connection item 21 Ultra 80 Ultra 105 1 or larger Ultra 155 or 230 11 4 or larger Ultra 310 17 or larger Useatleasttheminimum piping sizeabove Figure 8 Circulator zoning plus optional DHW piping a Zones mp m a ZONE i A CAUTION 5 E 5 and pipe the boiler using only primary secondary piping as shown Failure to follow these guidelines could result in system problems Legend Figure 8 1 Ultra boiler 10 Flow check valves with weighted seats to prevent gravity 2 Indirect water heater DHW if used circulation 3 Boiler relief valve see page 12 for piping details 11 Purge drain valves 4 Relief valve discharge piping see page 12 for details 12 Boiler circulator 5 DHW circulator see page 14 for suggested sizing 14 Zone circulators typical 6 Isolation valves 20 Make up water supply 7 System circulator 21 Primary secondary connection 8 Diaphragm or bladder type expansion tank see page 12 for piping of closed type expansion tank if used Air separator with automatic air vent only on systems using diaphragm or bladder type expansion tank Supplied with boiler others not included with boiler Part number 550 101 233 0903 3 Ulla GAS FIRED WATER BOILER Boiler Manual Install water piping continued Radi
42. er column t vallab e head Teet water column to overcome head loss through water heater teile MM Teor i n Ultra 80 Circulator model 007 0012 0011 3 5 min 7 9 11 4 25 9 6 7 2 0 6 2 18 6 Md Haad freed botai Hrrrogh vues hag Not rec Not rec Mb Head loss throagh DW piping Circulator model 007 0012 0011 4 5 min 5 6 9 3 23 1 Figure6 Pump curves for typical circulators 82 Not rec 20 13 2 suggested for DHW loop 11 f Not rec Not rec 2 5 45 Circulator model PRU 0012 0014 0011 Taco 0013 7 0 min 7 0 12 2 19 1 10 0 2 0 6 8 13 2 25 13 Not rec 2 2 Circulator model 9 0012 0014 0011 2 0 6 1 11 7 2 0 5 6 10 4 Not rec Not rec 3 0 Ultra 310 Circulator model 0011 0013 PL 36 11 0 16 7 19 9 4 1 10 9 14 4 0 5 10 15 20 25 30 35 40 Flow rate GPM oss Not rec 3 5 7 1 14 Part number 550 101 233 0903 3 Ultva GAS FIRED WATER BOILER Boiler Manual Install water piping continued Zoning with zone valves L Connect boiler to system asshown in Figure 7 when zone valve zoning The primary secondary piping shown ensures the boiler loop will have sufficient flow It also avoids applying the high head of the boiler circulator to thezonevalves When using a closed type expansion tank connect the expansion tank and make up water piping as shown in Figure 4 page 13 ConnectDH W domestichot water pipingto indirect st
43. ersonal injury death or substantial property damage WARNING Indicates presence of hazards that can cause severe personal injury death or substantial property damage Caution Ndicates presence of hazards that will or can cause minor personal injury or property damage notice Indicates special instructions on installation operation or maintenance that important but not related to personal injury or property damage 4 Part number 550 101 233 0903 GAS FIRED WATER BOILER Boiler Manual Please read before proceeding NOTICE Installer Read all instructions including this manual theU Itra Control Supplement and Ultra Vent Supplement before installing Perform stepsin theorder given User This manual isfor useonly by a qualified heating installer service technician Refer to User s Information Manual for your reference User Have this boiler serviced inspected by a qualified servicetechnician at least annually Failure to comply with the above could result in severe personal injury death or substantial property damage Theboiler containsceramicfiber materials Usecarewhen handlingthesematerials per instructions on page 29 of this manual Failure to comply could result in severe personal injury When callingor writingabouttheboiler Please havethe boiler model number from theboiler ratinglabel and theCP number from the boiler jacket You may listth
44. et metal 34 wide by about 18 inches long to loosen deposits Inspect the heat exchanger cover plate insulation Replace if insulation is damaged Read the ceramic fiber WARNING on page 29 before handling or disposing of ceramicfiber materials Reinstall the blower venturi gas valve cover plate assembly and securethe cover plate with nuts Connect gas valveelectrical plug and blower power and control connectors Inspect the O ring that should still be in the gas valve inlet adapter block The O ring must bein good condition and must beinstalled when gasvalveis reconnected Failure to comply will cause a gas leak resultingin severepersonal injury or death Secure gas valve inlet adapter to gas valve with 4 Phillips head screws Reinstall the air silencer by pressing onto the air inlet adapter Install access cover gasket chamber insulation assembly and cover Secure cover with nuts Seecontinued instructions on next page 8b GAS FIRED WATER BOILER Boiler Manual Maintenance and annual startup continued 34 Cleaning boiler heat exchanger continued from previous page Access exchanger Ultra 155 230 310 Only 1 10 Removegas valve electrical plug from gas valve Also remove two electrical molex plugs from blower assembly Disconnect gas line union with pipe wrench or Channel Lock Pliers Remove air silencer by lifting plastic clamp off gas lineand then gently slidi
45. feet above sea level the Ultra boiler requires no modifications and automatically derates itself by approximately 4 per 1000 feet abovesea level For elevations above 5 500 feet contact your local Weil M cLain sales officefor details Weil McLain 500 Blaine Street Michigan City IN 46360 2388 http www weil mclain com 44 Part number 550 101 233 0903
46. heck valve Strainer Balancing valve Make up water supply Primary secondary connection Supplied with boiler O By others not included with boiler Part number 550 101 233 0903 4 GAS FIRED WATER BOILER Boiler Manual Venting combustion air amp condensate line Install vent and combustion air piping Ultra Boiler must be vented and supplied panon with combustion and ventilation air as described Weil M cLain U Itra Boiler Vent Supplement included in envelope assembly Ensurethe vent and air piping and the combustion air supply comply with these instructions regarding vent system air system and combustion air quality Seealso Section 1 of this manual Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with theinstructionsprovided and with all requirements of applicablecodes Failureto provideaproperly installed vent and air system will cause severe personal injury or death Prepare condensate fittings 1 RemovePVC fittings and gasket from the accessories bag 2 Deburr and chamfer outsideand insideof 1 x 11 4 PVC nippleto ensureeven cement distribution when joining 3 Clean nippleendsand all fittings Dry thoroughly 4 For each joint in the condensate line apply the following Assemble parts ON LY in theorder given a Apply primer liberally to both joint surfaces pipe end and fitting socket b Whileprimerisstill damp lightly apply ap
47. ion manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING Avoid breathing dust and contact with skin and eyes Thecombustion chamber lining in this product contains ceramic fiber material Ceramic fiberscan be converted to cristobalitein very high temperatureapplications T helnternational Agency for Research on Cancer IARC has concluded Crystalline silicainhaled in the form of quartz or cristobalitefrom occupational sourcesiscarcinogenicto humans Group 1 e UseNIOSH certified dust respirator 95 Thistypeof respirator is based on the OSH requirementsfor cristobaliteat thetimethis document was written Other types of respirators may beneeded dependingon thejob siteconditions Current NIOSH recommendations can befound on theNIOSH web siteat http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers arealso listed on this web site e Wear long sleeved loosefitting clothing gloves and eye protection BI Apply enough water to thecombustion chamber lining or baseinsulation to prevent airborne dust Removecombustion chamber lining or baseinsulation from theboiler and placeitin aplastic bag for disposal II Wash potentially contaminated clothes separately from other clothing Rinseclothes washer thoroughly NIOSH stated First Aid E Eye
48. ipe street elbows on top of shutoff valves and attach catch buckets beneath 8 If convenient install the boiler circulator and any other piping compatible with Figure 3 that would still allow bleeding air from shutoff valves Follow guidelines in this manual for piping components locationsand sizing Fill and pressure test 1 Open theshutoff valves you installed on supply and return connections 2 Slowly open boiler drain valveand fresh water supply to fill boiler with water The boiler will fill quickly because of its low water content 3 When water reaches shutoff valves closeboiler drain valve 4 Closeshutoff valves 5 Slowly reopen boiler drain valve until test pressure on the pressure temperature gauge reaches at least 45 psig but no higher than 55 psig 6 Hold attest pressurefor 10 minutes Do not leave boiler unattended A cold water fill could expand and causeexcessive pressure resulting in severepersonal injury death or substantial property damage 7 Make sure constant gauge pressure has been maintained throughout test C heck for leaks Repair if found Part number 550 101 233 0903 2 Ultva GAS FIRED WATER BOILER Boiler Manual Leaks must be repaired at once Failureto do so can damage boiler resulting in substantial property damage Do not use petroleum based cleaning or sealing compounds in boiler system Gaskets and seals in the system may be damaged This can result in substantial
49. ith fresh water by pouringinto upturned end of PVC condensatetee Check all piping for leaks Eliminate all system or boiler leaks Continual fresh make up water will reduce boiler life M ineralscan build up in sections reducing heat transfer overheating heat exchanger and causing heat exchanger failure Leaking water may also causesevere property damage Inspect all water and gas piping and verify to beleak free Look for signs of leaking lines and correct any problemsfound Check gasline using procedureon page 21 Check air openings 1 Verify that combustion and ventilation air openings to the boiler room and or building are open and unobstructed Check operation and wiring of automatic combustion air dampers if used Verify that boiler vent discharge and air intake are clean and free of obstructions Flue vent system and air piping l 30 Visually inspect entire flue gas venting system and air piping if installed for blockage deterioration or leakage Repair any joints that show signs of leakage in accordancewith vent manufacturer sinstructions When air is ducted to boiler verify that air inlet hose isconnected and properly sealed Failureto inspect for the aboveconditions and havethem repaired can resultin severe personal injury or death Check water system 1 2 3 Verify all system components correctly installed and operational Check the cold fill pressure for the system Verify
50. lled medium from entering boiler If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air use flow control valves or other automatic means to prevent gravity circulation during cooling cycle NOTE 1 To ensureadequateflow ratethrough theboiler usethe following pipesizeon all boiler loop piping connecting boiler to and from theprimary secondary connection item 21 Ultra 80 Ultra 105 1 or larger Ultra 155 or 230 14 or larger Ultra 310 1 or larger caution Useatleasttheminimum piping size aboveand pipethe boiler using only primary secondary piping as shown Failure to follow these guidelines could resultin system problems Legend Figure 10 ON Oa Ultra boiler Indirect water heater DHW if used Boiler relief valve see page 12 for piping details Relief valve discharge piping see page 12 for details DHW circulator see page 14 for suggested sizing Isolation valves System circulator Air separator DO NOT use automatic air vents on systems fitted with closed type tanks 10 Flow check valves with weighted seats to prevent gravity circulation 11 Purge drain valves 18 Figure 10 Chilled water system plus optional 21 DHW piping z H E Ones _ _ 12 inches apari M Boiler circulator Zone valves typical Closed type expansion tank Water chiller C
51. m outside direct vent installation Vent and air piping TheUltra boiler requires a special vent system designed for pressurized venting Ultra boilers are rated ANSI 221 13 Category IV pressurized vent likely to condense in thevent You mustalso install air pipingfrom outsideto theboiler air intakeadapter T heresultant installation is categorized as direct vent sealed combustion N ote prevention of combustion air contamination on page 8 when considering vent air termination Vent and air must terminatenear oneanother and may be vented vertically through the roof or out aside wall You may useany of thevent air piping methods covered in the Ultra Boiler Vent Supplement included in the envelope assembly Do not attempt to install the Ultra boiler using any other means Be sureto locate the boiler such that the vent and air pipingcan berouted through thebuildingand properly terminated The vent air piping lengths routing and Prepare boiler location one Prevent combustion air contamination Install air inlet piping for the Ultra boiler asdescribed in the Ultra Boiler Vent Supplement Do not terminatevent air in locations that can allow contamination of combustion air Refer to Table 1 for products and areas which may causecontaminated combustion air WARNING You must pipecombustion air to theboiler air intake Ensurethat thecombustion air will not contain any of the contaminants below Contaminated combustion air
52. moving jacket front door Removethefour lag screws securing shipping brackets b Unscrew the two rear boiler legs and remove the shipping brackets c Replacelegs d Discard the cardboard protector insert on the rear of the boiler Notice Donotdrop boiler or bump jacket on floor or pallet Damage to boiler can result Prepare for propane if operating on propane Ultra 80 amp 105 WARNING Ultra 80 DO NOT apply the following instructions to conversion of Ultra 80 boilers Follow the instructions provided with the optional propaneconversion kit The propane conversion kit is NOT included as standard equipment for the Ultra 80 Do not apply the following to conversion of a boiler already installed and connected to gas supply For a boiler already installed you must turn off gas supply turn off power and allow boiler to cool before proceeding You must also completely test the boiler after conversion to verify performanceas described under Startup Section 6 of this manual See separate natural to propane conversion instructions for conversion of an existing boiler You must install the propane orifice to firethe Ultra boiler on propane Verify when installing that the orifice size marking matches boiler size Failure to comply could result in severe personal injury death or substantial property damage Part number 550 101 233 0903 im Brass orilice 2 GAS FIRED WATER BOILER
53. ndensate drain tubingto the 1 2 PVC tee and run to floor drain or condensate pump Use PVC or CPVC pipe or 5 8 1 D tubing Figure 12 Condensate drain Ultra 80 amp 105 NOTICE U se materials approved by the authority Routa lini rhrough havingjurisdiction In theabsenceof other bracket as at lott authority PVC and CPVC pipe must comply with ASTM D 1785 F441 or D2665 Cement and primer must comply with ASTM D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittingsand cement Figure 13 Condensate drain Ultra 155 amp 230 PVC tee installation shown applies 4 Leavethetop ofthe teeO PEN Thisisneeded asa _ to all models vacuum break 5 When installing a condensate pump select one approved for use with condensing boilers and furnaces Thepump should havean overflow switch to prevent property damagefrom condensate spillage 6 Condensatefrom theU Itra boiler will beslightly acidic typically with a pH from 3 2 to 4 5 Install a neutralizing filter if required by local codes Caution Ihe condensate line must remain unobstructed allowing free flow of condensate If condensate is allowed to freezein thelineor ifthelineisobstructed in any other manor condensate can exit from the boiler tee resulting in potential water damageto property Figure 14 Condensate drain Ultra 310 reducing nipple 20 Part number 550 101 233 0903 5
54. nected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valveisinoperative Shut down boiler until anew relief valvehas been installed 2 After following the above warning directions if therelief valveweepsor will not seat properly replace therelief valve Ensurethat the reason for relief valveweeping isthe valveand not over pressurization of thesystem dueto expansion tank waterlogging or undersizing Part number 550 101 233 0903 Inspect ignition electrode 1 Removetheignition electrode from the boiler heat exchanger access cover Removeany whiteoxidesaccumulated on theignition electrode using sandpaper If the ignition electrode cannot becleaned satisfactorily replaceignitor with anew one Replace ignition electrode making sure gasket is in good condition and correctly positioned M akesurethe electrodes are parallel to each other Check ignition ground wiring 1 Inspect boiler ground wirefrom heat exchanger access cover to ground terminal strip Verify all wiring isin good condition and securely attached Check ground continuity of wiring usingcontinuity meter Replace ground wires if ground continuity is not satisfactory Check all boiler wiring 1 Inspect all boiler wiring making sure wires are in good condition and securely attached Check control settings L 2 Set the control mod
55. ng Connect to tank with at least 3 4 piping to allow room for air to rise CAUTION Part number 550 101 233 0903 DO NOT install automatic air vents on closed type expansion tank systems Air must remain in the system and return to the tank to provide its air cushion An automatic air vent would causeair to leave system resulting in water logging the expansion tank Figure4 Expansion tank piping to diaphragm or bladder expansion tank Sysiom L 1 4 Do nct excead 12 inches mel a 3 bo mo e oC I 4 5 5 To dd Botar Boiler T meu ni A Alternate Piping t clasad type expansion tank System mium supply i Do net enced Tz aar T I 4 ut 1 A Bod r Boiler D 11 s mzpansion tk Tank fiti Cinzed expansion tank T Sytem LE wal supply B Avia air vent A Fil ae B Prmarg emcondary Air m Circulators The boiler circulator Taco 007 for Ultra 80 and 105 Taco 0011 for U Itra 155 230 and 310 isshipped loose Locateit either in thereturn or supply piping asshown in theappropriate piping diagram in this manual WARNING DO NOT usethe boiler circulator in any location other than theones shown in this manual The boiler circulator issele
56. ng air silencer down and off valve Removetwo 5 32 Allen head screws securing blower assembly to heat exchanger front cover Remove blower and gas valve assembly Removehex head nuts 10mm box end wrench from burner cover plate and remove burner cover plate from heat exchanger Remove three M 4 hex head screws 7mm box end wrench and burner clips securing burner to cover plate Removecover plate Usea vacuum cleaner to removeany accumulation on theheating surfaces Do not useany solvent If the vacuum cleaner isunableto clean completely wash the heating surfaces with clean warm water If necessary use a piece of 20 gauge or lighter sheet metal 34 wide by about 18 inches long to loosen deposits Inspect theheat exchanger cover plateinsulation and gasket Replace if damaged Read the ceramic fiber WARNING on 29 before handlingor disposing of ceramic fiber materials 11 Place cover plate gasket in groove of heat exchanger cover plate Replace cover plate 12 Reinstall hex head nuts 10mm box end wrench on cover platemountingstudsand tighten astaggering pattern until cover plateis uniformly tightened 13 Reinstall blower insuring new gasket provided in this kit isin proper alignment between blower and heat exchanger front cover 14 Reinstall air silencer by sliding on gas valve venturi and securing clamp to gasline 15 Connect thetwo blower electrical molex plugs 16 Re connect gas valve union and
57. not install the Ultra boiler into a common vent with any other appliance Thiswill causefluegasspillageor appliance malfunction resulting in possible severe personal injury death or substantial property damage Failureto follow all instructionscan result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death Atthetimeof removal of an existing boiler thefollowing steps shall be followed with each appliance remaining connected to the common venting system placed in operation whiletheother appliancesremaining connected to thecommon venting system arenot in operation a Seal any unused openings in the common venting system 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 causean unsafecondition 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 thecommon 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 rangehoodsand bathroom exhausts so they will operate at maximum speed Do not operate summer exhaust fan Closefireplace dampers d Place in operation the appliance being inspected Follow thelighting instructions Adju
58. not shown F1 5 amp fast blow 5 fuses 383 500 235 F3 4 amp slow blow 5 fuses 383 500 240 10 120 volt 3 wires receptacle not shown 383 500 245 11 Circulator relay Ultra 310 only not shown White Rodgers 90 362 SPST 120 VAC 510 350 200 42 ag Part number 550 101 233 0903 GAS FIRED WATER BOILER Boiler Manual Dimensions i Supply connection mote T 2 Return connection mete T DE Low valtege wire opening a Electrical entrance openings IE Vani connection Litira BD 105 amp 155 3 Utra 230 310 4 imedai 22 jumaaio 2 98 Uti aa Uti 300 44 min 1 8 max Notes 1 Boilersupplyand return tappingsareboth 1 NPT Ultra 80 105 155 230 or 174 NPT Ultra 310 See pages 14 through 18 for recommended system supply and return piping sizes Wall hung boilers water piping and gas pipe can be routed through bottom of enclosure using wall mounting kit 2 Boiler circulator is shipped loose Circulator may be mounted on either boiler supply or return piping Both 1 Part number 550 101 233 0903 ALL EONS IN INCHES EEEEEEENE 5 Pressureitemperature gauge Gas connactian note f A Drain valve inside enclosure Condensate drain 1 PIC ws Air connection Liltra BD0 105 amp 155 4 Lira 230 amp 310 4 Toe Umm Boe 155 2305 ae Ulim 3t00 F
59. oiler enclosure through the air intake adapter 18 flows through the enclosure enters the air inlet silencer 5a then entersthe venturi 5 Theblower pulls air and gas through the venturi and pushes the mixture into the burner Gas valve The gas valve senses the vacuum in the venturi caused by flowingair and allows gas to flow when power isapplied T he manual gas valve 4a allows shutting off the gas supply for servicing or shutdown odels 80 and 105 usea sensing line 4b from the gas valve to the blower outlet so the gas valve references the same pressure as the venturi inlet Venturi When air flows through the venturi it creates a vacuum This vacuum pulls gas from the gas valve So gas will only flow if air is flowing On 80 and 105 models the gas air mixture enters the burner after the venturi On 155 230 and 310 models the gas air mixture enters the blower before passing on to the burner Flue gas sensor This sensor monitors the flue gas exit temperature The control module will shut down the boiler if fluegas temperature gets too hot This protects the flue pipe and the heat exchanger from overheating Outlet water temperature sensor This sensor monitors boiler outlet water temperature system supply Thecontrol module adjusts boiler firing rateso the outlet temperatureis correct Return water temperature sensor This sensor monitors return water temperature system return The control module reduces or increase
60. omponents General piping information Additional controls when required Notice The Ultra control module uses temperaturesensorsto provide both high limit protection and modulating temperaturecontrol Thecontrol module also provides low water protection by sensing the temperature of the heat exchanger Some codes jurisdictions may require additional external controls for high limit and or low water cutoff protection Additional limit control Following standard industry practices if installation is to comply with ASM E or Canadian requirements an additional high temperaturelimitisneeded Consult local other codes standards to determine if n 1 Install additional high temperaturelimit constructed to prevent atemperaturesetting above 200 F in system supply piping between boiler and isolation valve Notethat theU Itra control moduleoperating limit function shutstheboiler down at 190 F or Parameter 4 whichever islower 2 Control Supplementfor wiring a Iflimitcontrol isto causeaboiler hard lockout requiring manual reset of Ultra control module connect isolated contact to field control wiring terminals 6 and 8 as shown in wiring diagram b Otherwise connect isolated contact between terminals 6 and 7 for a soft lockout automatic reset c If using a manual reset limit control or wiring in the manual reset circuit Parameter 4 should beno closer than 20 F to the limit control se
61. ons must comply with Local state provincial and national codes laws regulationsand ordinances National Fuel GasCode ANSI Z223 1 latest edition Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASM E CSD 1 when required National Electrical Code e For Canadaonly B149 1 or B149 2 Installation Code CSA 22 1 Canadian Electrical Code Part 1 and any local codes TheUltra boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in AN SI Z21 13 latest edition NOTICE Before locating the boiler check 1 Check for nearby connection to System water piping Venting connections Gassupply piping Electrical power 2 Checkareaaround boiler Removeany combustible materials gasolineand other flammable liquids WARNING Failureto keep boiler area clear and free of combustible materials gasoline and other flammableliquids and vaporscan result in severe personal injury death or substantial property damage 3 TheUltraboiler must beinstalled so that gas control system components are protected from dripping or spraying water or rain during operation or service 4 Ifnew boiler will replace existing boiler check for and correct system problems such as System leaks causing oxygen corrosion or heat exchanger cracksfrom hard water deposits Incorrectly sized expansion tank Lack of freeze prote
62. ontrol module for the gas valve and blower signal Air intake adapter Electrical entrance cover plate Remove the electrical cover plate to access the line voltage terminal strip 19b and the low voltage terminal strip 19a Attach line voltage conduits to the three holes at the left of the line voltage terminal strip for power CH pump and DHW pump Routelow voltage wiresthrough theopeningto theright of thelow voltageterminal strip Boiler drain valve Line voltage receptacle Usethisconnection to plugin linevoltage meters or tools while working on boiler Do not exceed 10 amp load P T gauge temperature sensor well Theremotesensor for thepanel mounted pressure temperature gauge inserts into the outlet water pipehere Flue gas condensate drain connection Connect condensate drain line to 2 PVC tee here The condensate trap 23a and PVC fittings are field installed Frontdoor Thefront door issealed to the boiler assembly around its entire perimeter Two knurled head screws 24a secure the door in place Ignition electrode The burner flame is ignited by applying a high voltage to the ignition electrode This causes aspark from electrodeto ground Flame inspection window The quartz glass window providesa view of the burner surface and flame Part number 550 101 233 0903 GAS FIRED WATER BOILER Boiler Manual THE Ultra GAS FIRED WATER BOILER WITH PhD TECHNOLOGY Ultra 80 amp 105 frond decor rere
63. orage water heater as shown Notice Thera PhD Control M oduleturnsoff 4 space heating during DH W 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 theboiler loop during DH W heating Controllingthesystem circulator a To cycle the system circulator from the Ultra PhD control module add a circulator relay wired to the boiler circulator terminalsasshown in theU Itra Control Supplement NOTE 1 To ensure adequate flow rate through the boiler usethefollowing pipesizeon all boiler loop piping connecting boiler to and from theprimary secondary connection item 21 Ultra 80 or Ultra 105 1 or larger Ultra 155 or 230 174 or larger Ultra 310 1 or larger caution Useatleasttheminimum pipingsizeabove and pipe the boiler using only primary secondary piping as shown Failure to follow these guidelines could result in system problems Legend Figure 7 OOA ON gt Ultra boiler Indirect water heater DHW if used Boiler relief valve see page 12 for piping details Relief valve discharge piping see page 12 for details DHW circulator see page 14 for suggested sizing Isolation valves System circulator Diaphragm or bladder type expansion tank see page 12 for piping of closed type expansion tank if used Air separator with automati
64. pa water 3 Donotfill boiler or operate with water containingchlorinein excess of 200 ppm Clean system to remove sediment 1 You must thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by buildup or corrosion due to sediment 2 Forzoned systems flush each zoneseparately through a purge valve If purge valves and isolation valves are not already installed install them to properly clean thesystem 3 Flush system until water runsclean and you aresurepipingis freeof sediment Test replace freeze protection fluid 1 Forsystemsusing freeze protection fluids follow guidelinesin Ultra Boiler Freeze Protection Supplement Freeze protection when used NEVER useautomotiveor standard glycol antifreeze even glycol made for hydronic systems Use only freeze protection fluids recommended the Ultra Boiler Freeze Protection Supplement Follow all guidelinesin the Freeze Protection Supplement and thoroughly clean and flush any replacement boiler system that has used glycol before installing thenew Ultra boiler 1 Determinefreezeprotection fluid quantity using total system water content following fluid manufacturers s instructions Boiler water content islisted on page 43 Remember to include expansion tank water content Part number 550 101 233 0903 2 Local codes may require back flow preventer or actual disconnect from city water supply 3 When u
65. pane conversion label in conversion kit bag next to the boiler rating plate 10 Replace jacket front panel 2 GAS FIRED WATER BOILER Boiler Manual Prepare boiler continues 10 Prepare for propane if operating on propane Ultra 155 to 230 Figure 2a Installing propane orifice Ultra 155 and Ultra 230 WARNING Ultra 80 DO NOT apply the following po instructions to conversion of Ultra 80 boilers Follow the instructions provided with the optional propaneconversion kit The propane conversion kit is NOT included as standard equipment for the Ultra 80 Do not apply the following to conversion of aboiler already installed and connected to gas supply For a boiler already installed you must turn off gas supply turn off power and allow boiler to cool before proceeding You must also completely test the boiler after conversion to verify performanceas described under Startup Section 6 of this manual See separate natural to propane conversion instructions for conversion of an existing boiler You must install the propane orificeto fire the Ultra boiler on propane Verify when installing that the orifice size marking matches boiler size Failureto comply could result in severe personal injury death or substantial property damage With boiler on its back remove jacket front door by removing two knurled head screws at lower front Then lift door away from boiler Disconnect the gas
66. ping can exit bottom of boiler enclosure See separate wall mountinginstructionsfor details Expansion tank and make up water 1 Ensure expansion tank size will handle boiler and system water volume and temperature Allow 3 gallonsfor boiler and its piping CAUTION Undersized expansion tankscause system water to belostfrom relief valveand make up water to be added through fill valve Eventual boiler failure can result due to excessive make up water addition 2 Tank must be located as shown in this manual or following recognized design methods See tank manufacturer sinstructionsfor details 3 Connecttheexpansion tank to theair separator only if theseparator ison thesuction sideof thecirculator Alwaysinstall thesystem fill connection at thesame point astheexpansion tank connection to the system 4 Most piping drawings in this manual show diaphragm expansion tanks SeeFigure 4for piping from air separator to expansion tank and make up water lineusinga closed typeexpansion tank 5 Mostchilled water systemsare piped using a closed typetank asshown in Figure 10 page 18 Diaphragm or bladder expansion tank 1 Figure4 Always install an automatic air vent on top of theair separator to removeresidual air from thesystem Closed type expansiontank 1 SeeFigure 4 Alternate for piping connections when using aclosed type expansion tank 2 Pitch any horizontal piping up towards tank 1 inch per 5 feet of pipi
67. proved cement to both surfaces in a uniform coating Part number 550 101 233 0903 Figure 11 Condensate trap assembly PVC elbow e Apply asecond coat of cement to both surfaces Avoid using too much cement on sockets to prevent cement buildup inside With cement still wet insert pipeinto fitting twisting Y4 turn ake sure pipe is fully inserted Wipe excess cement from joint Check joint to besure a smooth bead of cement shows around the entire joint cx D SeeFigure1l Assemble the PVC nipple to the PVC reducing elbow as shown Allow joint to dry completely Then slide gasket over nippleasshown Slide nipplethrough jacket condensate line holeto position asshown in Figure 13 page 20 Cement the 1 2 teeto the protruding Y nipple Be sureboth nippleand reducing elbow finish upright IMPORTANT Firmly pressthereducing elbow and theteetogether whilethe cement setsto ensurethe gasket issecurely compressed T he gasket ensuresthe jacket enclosureisairtight atthislocation 19 4 GAS FIRED WATER BOILER Boiler Manual Venting combustion air amp condensate line continued Connect condensate drain 1 Removecondensatetrap linefrom bag Prepareand install per page 19 Secureto jacket by attaching PVC teeas shown in Figure 13 2 Slidetrap lineonto flueoutle condensateconnection and PVC reducing elbow asshown in Figure 12 13 or 14 Securewith hose clamps 3 Connect co
68. put divide by 1 000 to obtain cubic feet per hour a Table4isonly for natural gaswith specific gravity 0 60 with a pressure drop through the gas piping of 0 30 W C b For additional gas pipe sizing information refer to ANSI Z223 1 or B149 1 or B149 2 for Canadian installations Natural gas supply pressure requirements 1 Pressurerequired at gasvalveinlet pressure port Maximum 13 w c with no flow lockup or with boiler on e Minimum 5 w c with gasflowing verify during boiler startup whileboiler isat high fire 2 Install 100 lockup gas pressureregulator in supply line if inlet pressure exceed 13 w c at any time Adjust lockup regulator for 13 w c maximum Propane Gas Ultra boilers are shipped ready to fire EA natural gas ONLY exception U Itra 80 LP 15 propane ready You must install the propane orifice if the boiler will be connected to propane See 9 Failure to comply could result in severe personal injury death or substantial property damage Pipe sizing for natural gas 1 Contact gas supplier to size pipes tanks and 100 lockup gas pressure regulator Propane supply pressure requirements 1 Adjust propane supply regulator provided by gas supplier for 13 w c maximum pressure 2 Pressurerequired at gas valveinlet pressure port Maximum 13 w c with no flow lockup or with boiler on e Minimum 4 w c with gas flowing verify during boiler startup while boiler is at high fir
69. r if available set properly Refer to Ultra Control Supplement Cyded boiler with thermostat and with DHW aquastat if installed Raised to highest setting and verified boiler goes through normal startup cycle Lowered to lowest setting and verified boiler goes off easured natural gas input per page 25 Checked incoming gas pressure by connecting manometer to gas valve ahead of boiler Gas pressure must beat least 5 inches w c for natural gas and 4 inches w c for propane with boiler operatingat high fire and no morethan 13 inches w c with boiler operating or boiler off Observed several operating cycles for proper operation Set room thermostat to desired room temperature and DHW aquastat if installed to desired DH W storage temperature Reviewed all instructions shipped with this boiler with owner or maintenanceperson Fillin Installation certificate on page 27 Return instructions to envelope and giveto owner or placeinsideboiler housing Part number 550 101 233 0903 7 Ultva GAS FIRED WATER BOILER Boiler Manual Check out startup verification Installation certificate Boilemodl CP number Dateinsaled Measured Btuhinput Fue 2 Natural Gas Propane Installation instructions havebeen followed Checkoutsequencehasbeen performed Aboveinformation is certified to becorrect Information received and left with owner main
70. r gas odorant or any unusual odor Remove boiler front door and smell interior of boiler enclosure Do not proceed with startup if thereisany indication of a gasleak Repair any leak at once WARNING DO NOT adjustor attemptto measuregas valveoutlet pressure Thegas valveis factory set for thecorrect outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attemptingto alter or measure thegas valve outlet pressure could result in damage to the valve causing potential severepersonal injury death or substantial property damage WARNING Propane boilers only Your propane supplier mixes an odorant with the propaneto make its presence detectable some instances the odorant can fade and the gas may no longer have an odor Before startup and periodically thereafter havethepropanesupplier verify thecorrect odorant level in thegas Check thermostat circuit s 1 Disconnect the two external wires connected to the boiler thermostat terminals low voltage terminal strip terminals5 and 6 2 Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit oneat atimeand check the voltmeter reading acrosstheincoming wires 3 Thereshould NEVER beavoltagereading 4 favoltagedoesoccur under any condition check and correct theexternal wiring Thisisacommon problem when using 3 wirezonevalves 5 Oncetheexternal thermostat ci
71. r system isolation valve between the purge valve and fill connection to the system Close zone isolation valves Open quick fill valve on cold water make up line Open purge valve One zone at a time open the isolation valves Allow water to run through the zone pushing out the air Run until no noticeable air flow is present Close the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purged Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rises to correct cold fill pressure After the system has operated for a while eliminate any residual air by using the manual air vents located throughout the system i If purge valves are not installed in system open manual air vents in system one at a time beginning with lowest floor Close vent when water squirts out Repeat with remaining vents 2 Open automatic air vent diaphragm type or bladder type expansion tank systems only oneturn 3 Open other vents a Starting on the lowest floor open air vents one at a time until water squirts out b Repeat with remaining vents 4 Refill to correct pressure Oo 23 5 GAS FIRED WATER BOILER Boiler Manual S t ar t u p continued Check for gas leaks WARNING Beforestartingthe boiler and during initial operation smell near the floor and around the boiler fo
72. ra 80LP isfactory equipped to firepropane You must install thepropaneorificeif the boiler will be connected to propane See page 9 Failure to comply could result in severe personal injury death or substantial property damage Part number 550 101 233 0903 L Check flame amp combustion 1 Press and hold both the Ultra control panel Mode and buttons simultaneously until appears 2 The H in thefirst digit of the display means the boiler will operate at high firewhen theblower speed reachesmaximum 3 Look at the flame through the flame inspection window Thehigh fire flameshould beblueand should bestable Theburner surface should be covered with orange dots 4 Remove the flue temperature sensor from the flue pipe and insert a combustion test probe 5 Testing is suggested for either CO or O and for CO Thevalues should bein therangelisted in the table below TheCO should not exceed 100 ppm when combustion is correct WARNING If combustion at either high or low fire is outside the range given below shut down theboiler and contact your local Weil M cLain representative Failureto comply could result in severe personal injury death or substantial property damage Natural gas Propane Oo Oo min max min max min max min max 8 0 10 0 3 5 7 0 9 5 11 5 3 1 5 9 6 Measurenatural gasinput a Operate
73. ral conversion kit for Ultra 80 383 501 021 10 Natural to propane conversion kit for Ultra 155 orifice bag assembly 383 500 115 Natural to propane conversion kit for Ultra 230 orifice bag assembly 383 500 120 11 Alarm control kit 383 500 080 12 Outdoor temperature sensor 383 500 125 Part number 550 101 233 0903 35 GAS FIRED WATER BOILER Boiler Manual Replacement parts continued J acket parts Item Description Part Number 1 Jacket front door 383 500 135 2 Boiler leg kit 4 Required 383 500 065 3 Knurled head screw for jacket front door 2 Required 383 500 320 4 Knurled head screw clip on receptacle not shown 2 Required 383 500 180 5 Flue temperature sensor replacement kit 383 500 055 6 Air adapter assembly Includes adapter gasket and mounting bracket Ultra 80 105 155 3 383 500 145 Ultra 230 310 4 383 500 150 7 Flue outlet pipe adapter Ultra 80 amp 105 3 560 900 001 Ultra 155 3 383 500 155 Ultra 230 310 4 383 500 160 8 Top cover front 383 500 165 9 Top cover rear Ultra 80 to 230 383 500 170 Ultra 310 595 000 006 10 Electrical cabinet door 383 500 175 36 Part number 550 101 233 0903 GAS FIRED WATER BOILER Boiler Manual Replacement parts continued J acket parts la Part number 550 101 233 0903 37 GAS FIRED WATER BOILER Boiler Manual Replacement parts continued He
74. rcuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wiresto boiler low voltageterminal strip terminals5 and 6 Allow the boiler to cycle Inspect fill condensate system Inspect check condensate lines and fittings l Inspectthecondensatedrain line condensateP VC fittings and condensate trap Seepage 20for component locations 2 Pour water into thetop of theboiler s 2 PVC condensatetee and check for any leaksin thecondensate drain lineor fittings Repair any leaks Fill condensate trap with water l Loosen thehoseclamp securingtheright end of the condensatetrap to thePVC reducing elbow seepage 20 2 Slidethetrap hose end off of the elbow 3 Fill thetrap with fresh water to within ainch of theend of the hose 4 Replacetrap hoseon PVC reducing elbow and tighten thehose clamp WARNING Thecondensatetrap page 3 item 23a must befilled with water duringall timesof boiler operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death 24 Final checks before starting boiler Read theUltraControl Supplement to familiarize yourself with Ultra PhD control module operation Read OperatingI nstructionsin Control Supplement for proper stepsto start boiler Verifytheboiler and system arefull of water and all System components correctly set for operation Verify the preparation procedures of s
75. s boiler input depending on how close the return water temperature is to the outlet water temperature Temperature and pressure gauge Electronic display amp buttons The4 digit electronic display is used to Set space heating temperature Show outlet water temperature normal or other operating conditions in Information mode Show boiler status and shutdown or lockout codes for easy troubleshooting The buttons allow changing display mode and reset after lockout The on off Power switch 10a turns power to the boiler controls on or off Flue pipe adapter 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Burner M ade with high grade stainless steel construction the burner uses premixed air and gas and provides a wide range of firing rates Water outlet pipe system supply Water return pipe system return Gas connection pipe Ultra Control Module The 20 Control Module responds to signals from the room thermostat supply water sensor return water sensor flue gas sensor and if used domestic hot water aquastat outdoor temperature sensor and summer winter switch The control module automatically adjusts blower speed and gasflow rate to match boiler output to space heating and or DHW heating demand Thecontrol moduleis accessed by removingtop front cover 16a Transformer The transformer reduces line voltage from 120 vac to 24 vac providing 24 vac to the c
76. singfreezeprotection fluid with automatic fill install a water meter to monitor water make up Freezeprotection fluid may leak before the water begins to leak causing concentration to drop reducing thefreeze protection level Fill and test water system 1 Fill system only after ensuring the water meetstherequirements of this manual 2 Closemanual and automatic air vents and boiler drain valve 3 Fill to correct system pressure Correct pressure will vary with each application a Typical cold water fill pressure for a residential system is 12 psi b Pressure will rise when boiler is turned on and system water temperature increases Operating pressure must never exceed 25 psig 4 Atinitial fill and during boiler startup and testing check system ao for any leaks Repair all leaks before proceeding urther Eliminateall system leaks Continual fresh make up water will reduceboiler life M ineralscan build upin sections reducing heat transfer overheating heat exchanger and causing heat exchanger failure 5 The system may have residual substances that could affect water chemistry After thesystem has been filled and leak tested verify water pH and chlorineconcentrationsare acceptable Purge air from water system l Purgeairfrom system a Connect a hose to the purge valve see purge drain valves item 11 in piping diagrams on pages 15 through 18 Route hose to an area where water can drain and be seen b Close the boiler o
77. sleaks can cause severe personal injury death or substantial property damage 6 Usepipedopecompatible with propane gases Apply sparingly only to malethreads of pipe joints so that pipedopedoesnot block gasflow wARNING Failureto apply pipedopeas detailed above can result in severepersonal injury death or substantial property damage wARNING DO NOT adjust or attempt to measure gas valve outlet pressure The gas valveis factory set for the correct outlet pressure Thissettingissuitablefor natural gas and propane requiring no field adjustment Attemptingto alter or measurethegas valve outlet pressure could result in damageto thevalve causing potential severepersonal injury death or substantial property damage WARNING Ultra boilers are shipped ready to fire natural gas ONLY Exception U Itra 80LP is propane ready You must install the propane orifice if the boiler will be connected to propane See page 9 Failure to comply could result in severe personal injury death or substantial property damage Usetwo wrenches when tightening gas piping at boiler using onewrench to prevent theboiler gasline connection from turning Failureto support the boiler gas connection pipeto prevent it from turning 21 5 GAS FIRED WATER BOILER Boiler Manual G as p p continued 22 Natural Gas Pipe sizing for natural gas 1 Refer to Table4 for pipelength and diameter Baseon rated boiler in
78. st thermostat so appliancewill operatecontinuously e Testfor spillageat draft hood relief opening after 5 minutesof main burner operation U setheflame of a match or candle smoke from a cigarette cigar or pipe f After it has been determined that each appliance remaining connected to thecommon venting system properly vents when tested asoutlined herein return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use Any improper operation of common venting system should be corrected so the installation conforms with theN ational Fuel GasCode ANSI 2223 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 Part number 550 101 233 0903 Prepare boiler Remove boiler from crate Cold weather handling If boiler has been stored in avery cold location below 0 F before installation handle with care until the plastic components come to room temperature CAUTION 1 TheUltra boiler is generally easier to handleand maneuver after removing from crate 2 After removing outer shipping carton from boiler REMOVE jacket front door by loosening two knurled head screwsat lower front Removing thedoor will prevent possibledamageto thedoor during handling 3 Toremoveboiler from pallet after re
79. structions on page 29 of this manual Failure to comply could result in severe personal injury 1 Shutdown boiler a Follow To Turn Off Gasto Appliance instructionson boiler and Lighting instructions b Donot drain boiler unlessit will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain 2 Allow timefor boiler to cool to room temperatureif it has been firing 3 Removejacket front door by removing two knurled head screws at lower front Lift door away from boiler to remove 4 Follow procedure below to access the heat exchanger interior Access exchanger Ultra 80 and Ultra 105 Only 1 Remove 4 Phillips head screws securing gas valve inlet adapter to gas valve This will disconnect the gas valvefrom the gas line Part number 550 101 233 0903 Removetheair silencer by separating it from theair adapter on theblower inlet Disconnect thegas valve plug blower power supply plugand blower control connector Release the exchanger cover plate by removing the nuts securing it to the exchanger Pull the entire blower venturi gas valve cover plate assembly out of the boiler See pages 39 or 41 for component identification and locations Usea vacuum cleaner to removeany accumulation on theheating surfaces Do not useany solvent If thevacuum cleaner isunableto clean completely wash the heating surfaces with clean warm water If necessary use a piece of 20 gauge or lighter she
80. tenance person lastalla he ee company address address Part number 550 101 233 0903 Comments installer s signature 8 Ulva GAS FIRED WATER BOILER Boiler Manual Annual startup and general maintenance Table 5 Service and maintenance schedules Service technician see following pages for instructions General Reported problems Inspect interior clean and vacuum if necessary WARNING no solvents Clean condensate trap and fill with fresh water Check for leaks water gas flue condensate Verify flue and air lines in good condition and sealed tight Check system water pressure system piping expansion tank Check control settings gnition electrode sand off any white oxide clean and reposition gnition and ground wiring Wiring and connections Perform start up checkout and performance verification per pages 23 through 26 Flame inspection stable uniform 2 E lt n 2 2 2 lt e Flame signal at least 4 Clean heat exchanger if flue temp more than 54 F above return water temp Additional if combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Vacuum the blower Review Review with owner Owner maintenance see Ultra User s Information Manual for instructions Check boiler area Check air openings
81. tting i e no higher than 180 F for 200 F limit setting for example Separate low water cutoff A low water cutoff device is required when boiler is installed above piping level or by certain state or local codes or insurance companies Consult local requirementsto determine l Ifrequired usealow water cutoff designed for water installations Electrode probe typeisrecommended 2 Purchaselow water cutoff and install in teein supply piping above boiler 3 SeeUltra Control Supplementfor wiring a Iflimitcontrol isto causeaboiler hard lockout requiring manual reset of Ultra control module connect isolated contact to field control wiring terminals 6 and 8 as shown in wiring diagram b Otherwise connect isolated contact between terminals 6 and 7 for a soft lockout automatic reset Backflow preventer Usebackflow check valvein cold water supply as required by local codes Part number 550 101 233 0903 3 Ulla GAS FIRED WATER BOILER Boiler Manual Install water piping continued System water piping methods NOTICE All piping methods shown in this manual use primary secondary connection to the boiler loop These designs ensure proper flow through theU Itra boiler for themost efficient and reliableoperation of theboiler and the heating system For other piping methods consult your local Weil M cLain representative or refer to separate Ultra boiler piping guides Wall mounted boilers Pi
82. ule display to Parameter mode and check all settings Adjust settings if necessary See Ultra Control Supplement for details Check settings of external limit controls if any and adjust if necessary 31 GAS FIRED WATER BOILER Boiler Manual Annual startup Perform startup and checks 1 Start boiler and perform checks and tests specified on pages 23 through 26 and Control Supplement 2 Verify cold fill pressureis correct and that operating pressure doesnot go too high 3 Completethecheck out procedure on page 26 Check burner flame Theboiler containsceramic fiber materials Usecarewhen handling these materials per instructions on page 29 of this manual Failure to comply could result in severe personal injury 1 Inspect flame through observation window using the procedure on page 25 2 If flame is unsatisfactory at either high fire or low fire turn off boiler and allow boiler to cool down Then remove burner and clean it thoroughly using avacuum cleaner or compressed air Do not use compressed air to clean burner if performed insidea building 3 To access burner remove the heat exchanger cover plate following the procedure on page 33 4 When replacing burner ensure gasket isin good condition and correctly positioned After tighteningthethree retainer screws bend up theretainer tabs as shown in Figure 16to prevent screw rotation 5 After servicing replace boiler components
83. um and requires that System pH always be between 7 0 and 8 5 and water chemistry be checked Chemical treatment may benecessary See page 24 for details Thoroughlyflush thesystem without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion dueto sediment e Donotusepetroleum based cleaning or sealing compoundsin boiler System Gaskets and seals in the system may be damaged This can result in substantial property damage e Donotuse homemadecures or boiler patent medicines Serious damageto boiler personnel and or property may result e Continual fresh make up water will reduce boiler life M ineral buildup in heat exchanger reduces heat transfer overheats the aluminum heat exchanger and causesfailure Addition of oxygen carried in by make up water can causeinternal corrosion Leaksin boiler or piping must berepaired at onceto prevent make up water Donotadd cold water to hot boiler T hermal shock can cause heat exchanger to crack Freeze protection fluids NEVER useautomotiveor standard glycol antifreeze even glycol made for hydronic systems U seonly freeze protection fluids recommended in the Ultra Boiler FreezeProtection Supplement Follow all guidelinesin the Ultra Boiler Freeze Protection Supplement Thoroughly clean and flush any replacement boiler system that has used glycol beforeinstallingthenew Ultra boiler Prepare boiler location Installati

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