Gas-fired water boiler Ultra-80, -105, -155, -230 & -310 • Installation • Startup • Maintenance • Parts with This manual must only be used by a qualified heating installer/service technician. Read all instructions, including this manual, the Ultra Control Supplement and the Ultra Vent Supplement, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
GAS-FIRED WATER BOILER THE BOILER, WITH Ph D PhD — Boiler Manual TECHNOLOGY – HOW IT WORKS . . . PhD technology PhD Technology, Precision hydronic Data, is an intelligent system that delivers Precision hydronic heating and hot water needs while maximizing efficiency by measuring the Data parameters of your heating system. 12. Burner Made with high-grade stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of firing rates. 1. Cast aluminum heat exchanger 13.
GAS-FIRED WATER BOILER THE Part number 550-101-233/0903 — Boiler Manual GAS-FIRED WATER BOILER, WITH Ph D PhD TECHNOLOGY 3
GAS-FIRED WATER BOILER — Boiler Manual Contents How it works.................................................................................... 2–3 Hazard definitions .............................................................................. 4 Please read before proceeding ........................................................ 5 1 Prepare boiler location .................................................................. 6 2 Prepare boiler ............................................................
GAS-FIRED WATER BOILER — Boiler Manual Please read before proceeding Installer— Read all instructions, including this manual, the Ultra Control Supplement and Ultra Vent Supplement, before installing. Perform steps in the order given. User — This manual is for use only 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 service technician, at least annually.
1 GAS-FIRED WATER BOILER — Boiler Manual Prepare boiler location Installations must comply with: Provide clearances: • Clearances from combustible materials 1. Hot water pipes — at least ½" from combustible materials. 2. Vent pipe — at least 0.20" from combustible materials. 3. See Figure 1 for other clearance minimums. Clearances for service access 1. See Figure 1 for recommended service clearances.
1 GAS-FIRED WATER BOILER — Boiler Manual Prepare boiler location (continued) 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 is used. Fire can result, causing severe personal injury, death or substantial property damage.
1 GAS-FIRED WATER BOILER — Boiler Manual Prepare boiler location (continued) Prevent combustion air contamination Install air inlet piping for the Ultra boiler as described in the Ultra Boiler Vent Supplement. Do not terminate vent/ air in locations that can allow contamination of combustion air. Refer to Table 1 for products and areas which may cause contaminated combustion air. You must pipe combustion air to the boiler air intake.
2 GAS-FIRED WATER BOILER — Boiler Manual Prepare boiler Ultra-80-LP boilers are factory-equipped to operate on propane gas. Remove boiler from crate Cold weather handling — If boiler has been stored in a very cold location (below 0°F) before installation, handle with care until the plastic components come to room temperature. Figure 2 Installing propane orifice (Ultra-105) 1. The Ultra boiler is generally easier to handle and maneuver after removing from crate. 2.
2 GAS-FIRED WATER BOILER — Boiler Manual Prepare boiler (continued) Prepare for propane if operating on propane — Ultra-155 to -230 Figure 2a Installing propane orifice (Ultra-155 and Ultra-230) Ultra-80: DO NOT apply the following instructions to conversion of Ultra-80 boilers. Follow the instructions provided with the optional propane conversion kit. The propane conversion kit is NOT included as standard equipment for the Ultra-80.
2 GAS-FIRED WATER BOILER — Boiler Manual Prepare boiler (continued) Perform hydrostatic pressure test Leaks must be repaired at once. Failure to do so can damage boiler, resulting in substantial property damage. Pressure test boiler before permanently attaching water or gas piping or electrical supply. 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 property damage. Prepare boiler for test 1.
3 GAS-FIRED WATER BOILER — Boiler Manual Install water piping Install relief valve General piping information 1. Install relief valve in ¾" street elbow piped from boiler supply piping tee (Figure 3, page 11). Pipe the relief valve only as shown, in the location shown. 2. Connect discharge piping to safe disposal location, following guidelines in the WARNING below.
3 GAS-FIRED WATER BOILER — Boiler Manual Install water piping (continued) System water piping methods Figure 4 Expansion tank piping All piping methods shown in this manual use primary/secondary connection to the boiler loop. These designs ensure proper flow through the Ultra boiler, for the most efficient and reliable operation of the boiler and the heating system. For other piping methods, consult your local Weil-McLain representative or refer to separate Ultra boiler piping guides.
3 GAS-FIRED WATER BOILER — Boiler Manual Install water piping (continued) Sizing DHW system piping When using the boiler for dedicated DHW applications, use the circulator supplied with the boiler (007 for Ultra-80/105; 0011 for Ultra-155/230/310) to circulate to the water heater except where higher flow rates may be required for the heater used. Use the following method to select a circulator for the water heater on combined space heating/DHW systems. 1.
3 GAS-FIRED WATER BOILER — Boiler Manual Install water piping (continued) Zoning with zone valves 1. Connect boiler to system as shown 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 the zone valves. 2. When using a closed-type expansion tank, connect the expansion tank and make-up water piping as shown in Figure 4, page 13. 3.
3 GAS-FIRED WATER BOILER — Boiler Manual Install water piping (continued) Zoning with circulators 1. Connect boiler to system as shown in Figure 8 when circulator zoning. The boiler circulator cannot be used for a zone. It must supply only the boiler loop. 2. Install a separate circulator for each zone. 3. When using a closed-type expansion tank, connect the expansion tank and make-up water piping as shown in Figure 4, page 13. 4.
3 GAS-FIRED WATER BOILER — Boiler Manual Install water piping (continued) Radiant heating applications 1. The Ultra boiler is ideal for use in radiant heating. The Ultra boiler’s unique heat exchanger design allows it to work well even in condensing mode. So there is no need to regulate boiler return water temperature in radiant heating applications. 2. Connect boiler to system as shown in Figure 9 for typical radiant heating applications.
3 GAS-FIRED WATER BOILER — Boiler Manual Install water piping (continued) Chilled water systems Figure 10 1. Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. See Figure 10 for typical installation of balancing valve and check valve. 2. The space heating system may be zoned with circulators if a separate circulator is supplied for the chilled water loop. 3.
4 GAS-FIRED WATER BOILER — Boiler Manual Venting, combustion air & condensate line Install vent and combustion air piping Figure 11 Condensate trap assembly Ultra Boiler must be vented and supplied with combustion and ventilation air as described in Weil-McLain Ultra Boiler Vent Supplement (included in envelope assembly). Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system and combustion air quality.
4 GAS-FIRED WATER BOILER — Boiler Manual Venting, combustion air & condensate line (continued) Connect condensate drain 1. Remove condensate trap line from bag. Prepare and install per page 19. Secure to jacket by attaching PVC tee as shown in Figure 13. 2. Slide trap line onto flue outlet condensate connection and PVC reducing elbow as shown in Figure 12, 13 or 14. Secure with hose clamps. 3. Connect condensate drain tubing to the ½" PVC tee and run to floor drain or condensate pump.
5 GAS-FIRED WATER BOILER — Boiler Manual Gas piping Connecting gas supply piping 1. Remove jacket front panel and refer to Figure 15 to pipe gas to boiler. a. Install ground joint union for servicing, when required. b. Install manual shutoff valve in gas supply piping outside boiler jacket when required by local codes or utility requirements. c. In Canada — When using manual main shutoff valve, it must be identified by the installer. 2. Wall-mounted boilers a.
5 GAS-FIRED WATER BOILER — Boiler Manual Gas piping (continued) Natural Gas: Propane Gas: Ultra boilers are shipped ready to fire natural gas ONLY (exception: Ultra-80-LP 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. Pipe sizing for natural gas 1. Refer to Table 4 for pipe length and diameter.
6 GAS-FIRED WATER BOILER — Boiler Manual Startup Check/control water chemistry Do not use petroleum-based cleaning or sealing compounds in boiler system. Damage to elastomer seals and gaskets in system could occur, resulting in substantial property damage. Before filling the boiler and system with water, verify the following. Failure to comply could result in boiler failure or unreliable operation. Water pH between 7.0 and 8.5 1. Maintain boiler water pH between 7.0 and 8.5.
6 GAS-FIRED WATER BOILER — Boiler Manual Startup (continued) Check for gas leaks Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove boiler front door and smell interior of boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Repair any leak at once. DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure.
6 GAS-FIRED WATER BOILER — Boiler Manual Startup (continued) ❏ Check system and boiler ❏ Check water piping 1. Check system piping for leaks. If found, shut down boiler and repair immediately. (See WARNINGS on page 23 regarding failure to repair leaks.) 2. Vent any remaining air from system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise. ❏ Check vent piping and air piping 1.
7 GAS-FIRED WATER BOILER — Boiler Manual Check-out/startup verification ❏ Boiler and heat distribution units filled with water? ❏ Water chemistry verified per page 23? ❏ Automatic air vents, if used, open one full turn? ❏ Air purged from system? ❏ ❏ Air purged from gas piping? Piping checked for leaks? Followed Operating Instructions in Ultra Control Supplement? ❏ Burner flame and combustion verified per page 25? ❏ 26 Thermostat circuit wiring checked to ensure there are no stray voltages
7 GAS-FIRED WATER BOILER — Boiler Manual Check-out/startup verification Installation certificate Boiler model __________________ Comments: CP number ___________ _______________________________________ Date installed _______________ _______________________________________ Measured Btuh input ____________ Fuel: ❏ Natural Gas ❏ Propane _______________________________________ ❏ Installation instructions have been followed.
8 GAS-FIRED WATER BOILER — Boiler Manual Annual startup and general maintenance Table 5 Service and maintenance schedules 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 damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.
8a GAS-FIRED WATER BOILER — Boiler Manual Annual startup The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 5 and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.
8a GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) Clean condensate trap Check water system 1. Loosen condensate trap line hose clamps and remove trap line. 2. Empty water from trap line and inspect. Flush out if needed with fresh water. 3. Check condensate elbow and tee and condensate line to drain. Flush if necessary to clean. 4. Replace condensate trap line and tighten hose clamps. 5. Fill trap with fresh water by pouring into upturned end of PVC condensate tee. 1.
8a GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) Check boiler relief valve Inspect ignition electrode 1. Inspect the relief valve and lift the lever to verify flow as in the following warnings, excerpted from a relief valve manufacturer’s warning label. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read manual section 3, page 12, before proceeding further. 1.
8a GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) Perform startup and checks Check flame signal 1. Start boiler and perform checks and tests specified on pages 23 through 26 (and Control Supplement). 3. Complete the check-out procedure on page 26. 1. Flame signal (DC volts from low voltage terminal strip terminal 9 to ground) should be at least 4 VDC. 2. A lower flame signal may indicate a fouled ignitor or damaged ignitor insulation.
8b GAS-FIRED WATER BOILER — Boiler Manual Maintenance — general 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 inside the boiler room. This is particularly important if the boiler is located in the same room as other appliances. Failure to keep the door securely fastened could result in severe personal injury or death.
8b GAS-FIRED WATER BOILER — Boiler Manual Maintenance and annual startup (continued) Cleaning boiler heat exchanger (continued from previous page) Access exchanger: Ultra-155, -230, -310 Only 1. Remove gas valve electrical plug from gas valve. Also remove two electrical molex plugs from blower assembly. 2. Disconnect gas line union with pipe wrench or Channel Lock Pliers. 3. Remove air silencer by lifting plastic clamp off gas line and then gently sliding air silencer down and off valve. 4.
9 GAS-FIRED WATER BOILER — Boiler Manual Replacement parts Replacement parts must be purchased through a local Weil-McLain distributor. When ordering, specify boiler model and size and include description and part number of replacement part. Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation. Weil-McLain part numbers are found in Weil-McLain Boilers and Controls Repair Parts Lists. The boiler contains ceramic fiber materials.
9 GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) Jacket parts 36 Part number 550-101-233/0903
9 GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) Jacket parts Part number 550-101-233/0903 37
9 GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) Heat exchanger and piping — Ultra-80 & -105 38 Part number 550-101-233/0903
9 GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) Heat exchanger and piping — Ultra-80 & -105 Part number 550-101-233/0903 39
9 GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) Heat exchanger and piping — Ultra-155 to -310 40 Part number 550-101-233/0903
9 GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) Heat exchanger and piping — Ultra-155 to -310 Part number 550-101-233/0903 41
9 GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) Controls 42 Part number 550-101-233/0903
10 GAS-FIRED WATER BOILER — Boiler Manual Dimensions Notes 1. Boiler supply and return tappings are both 1" NPT (Ultra80/105/155/230) or 1¼" 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 wallmounting kit. and 1¼" circulator flanges are shipped with boiler on Ultra80/105/155/230. Both 1¼" and 1½" circulator flanges are shipped with boiler on Ultra-310. 3.
11 GAS-FIRED WATER BOILER — Boiler Manual Ratings DOE Notes Notes 44 1. As an Energy Star Partner, Weil-McLain has determined that Ultra boilers meet the Energy Star guidelines for energy efficiency. 2. Based on standard test procedures prescribed by the United States Department of Energy. 3. Net I=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.