Table of Contents
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NOTICE:
Series 1/Series 2 identification
Read the boiler rating plate to
determine the series number. The
rating plate is located on the right
side of the boiler.
Ultra-80, -105, -155, -230 & -310
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
Series 2
• Installation
• Startup
• Maintenance
• Parts
with
Part number 550-100-026/0404
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Table of Contents
Related Manuals for Weil-McLain -105
Summary of Contents for Weil-McLain -105
- Page 1 Ultra-80, -105, -155, -230 & -310 NOTICE: Series 1/Series 2 identification Read the boiler rating plate to determine the series number. The rating plate is located on the right side of the boiler. 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.
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Page 2: How It Works
FIRED WATER BOILER SERIES BOILER 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. 1. Cast aluminum heat exchanger 2. - Page 3 FIRED WATER BOILER SERIES FIRED WATER BOILER Part number 550-100-026/0404 2 — Boiler Manual PhD D D D D WITH TECHNOLOGY...
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Page 4: Table Of Contents
FIRED WATER BOILER SERIES Contents How it works... 2–3 Hazard definitions ... 4 Please read before proceeding ... 5 1 Prepare boiler location ... 6 2 Prepare boiler ... 9 3 Install water piping ... 12 4 Venting, combustion air & condensate line ... 19 5 Gas piping ... -
Page 5: Please Read Before Proceeding
FIRED WATER BOILER SERIES 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. -
Page 6: Prepare Boiler Location
FIRED WATER BOILER SERIES Prepare boiler location Installations must comply with: Installations must comply with: Installations must comply with: Installations must comply with: Installations must comply with: • Local, state, provincial, and national codes, laws, regulations and ordinances. • National Fuel Gas Code, ANSI Z223.1 – latest edition. •... -
Page 7: Flooring And Foundation
FIRED WATER BOILER SERIES Prepare boiler location 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. - Page 8 FIRED WATER BOILER SERIES Prepare boiler location 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.
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Page 9: Prepare Boiler
Part number 550-100-026/0404 2 — Boiler Manual Ultra-105 Series 1 and 2 ONLY Prepare for propane operation 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. - Page 10 10. Replace jacket front panel. See the previous page for Ultra- 310 Series 1 and all Ultra-80 and Ultra-105 model propane instructions. 2 — Boiler Manual Placing floor-mounted boilers 1. Set boiler in place and check level.
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Page 11: Perform Hydrostatic Pressure Test
FIRED WATER BOILER SERIES Prepare boiler (continued) Perform hydrostatic pressure test Pressure test boiler before permanently attaching water or gas piping or electrical supply. Prepare boiler for test 1. See Figure 3 for reference in following steps. 2. Remove supply line tee* and ¾” street elbow from accessory bag. -
Page 12: Install Water Piping
FIRED WATER BOILER SERIES Install water piping Install relief valve 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. -
Page 13: System Water Piping Methods
FIRED WATER BOILER SERIES Install water piping System water piping methods 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. - Page 14 FIRED WATER BOILER SERIES Install water piping 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.
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Page 15: Zoning With Zone Valves
(connecting boiler to and from the primary/secondary connection, item 21): Ultra-80 or Ultra-105 – 1" or larger. Ultra-155 or -230 – 1¼" or larger. Ultra-310 – 1½" or larger. - Page 16 (connecting boiler to and from the primary/secondary connection, item 21): Ultra-80 or Ultra-105 – 1" or larger. Ultra-155 or -230 – 1¼" or larger. Ultra-310 – 1½" or larger.
- Page 17 To ensure adequate flow rate through the boiler, use the following NOTE 1: pipe size on all boiler loop piping (connecting boiler to and from the primary/secondary connection, item 21): Ultra-80 or Ultra-105 – 1" or larger. Ultra-155 or -230 – 1¼" or larger. Ultra-310 – 1½" or larger. Legend...
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Page 18: Chilled Water Systems
NOTE 1: pipe size on all boiler loop piping (connecting boiler to and from the primary/secondary connection, item 21): Ultra-80 or Ultra-105 – 1" or larger. Ultra-155 or -230 – 1¼" or larger. Ultra-310 – 1½" or larger. Use at least the minimum piping size above and pipe the boiler using only primary/secondary piping as shown. -
Page 19: Venting, Combustion Air & Condensate Line
FIRED WATER BOILER SERIES Venting, combustion air & condensate line Install vent and combustion air piping 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... - Page 20 FIRED WATER BOILER SERIES Venting, combustion air & condensate line 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.
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Page 21: Gas Piping
FIRED WATER BOILER SERIES 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. - Page 22 FIRED WATER BOILER SERIES Gas piping (continued) Natural Gas: Pipe sizing for natural gas 1. Refer to Table 4 for pipe length and diameter. Base on rated boiler input (divide by 1,000 to obtain cubic feet per hour). a. Table 4 is only for natural gas with specific gravity 0.60, with a pressure drop through the gas piping of 0.30"...
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Page 23: Startup ( Note 1 )
FIRED WATER BOILER SERIES 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. - Page 24 FIRED WATER BOILER SERIES 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.
- Page 25 FIRED WATER BOILER SERIES 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.
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Page 26: Check-Out/Startup Verification
FIRED WATER BOILER SERIES 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? ❏... - Page 27 FIRED WATER BOILER SERIES Check-out/startup verification Installation certificate Boiler model __________________ CP number ___________ Date installed _______________ Measured Btuh input ____________ Fuel: ❏ Natural Gas ❏ Propane ❏ Installation instructions have been followed. ❏ Check out sequence has been performed. ❏...
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Page 28: Annual Startup And General Maintenance
FIRED WATER BOILER SERIES 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. -
Page 29: Annual Startup
FIRED WATER BOILER SERIES 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. -
Page 30: Check Expansion Tank
FIRED WATER BOILER SERIES Annual startup Clean condensate trap 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. -
Page 31: Check Boiler Relief Valve
FIRED WATER BOILER SERIES Annual startup Check boiler relief valve 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. -
Page 32: Check Flame Signal
FIRED WATER BOILER SERIES 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 pressure is correct and that operating pressure does not go too high. 3. -
Page 33: General Maintenance
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 valve from the gas line. -
Page 34: Maintenance And Annual Startup
FIRED WATER BOILER SERIES Maintenance and annual startup 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. -
Page 35: Replacement Parts
FIRED WATER BOILER SERIES 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. - Page 36 2 — Boiler Manual FIRED WATER BOILER SERIES Replacement parts (continued) Jacket parts Part number 550-100-026/0404...
- Page 37 2 — Boiler Manual FIRED WATER BOILER SERIES Replacement parts (continued) Jacket parts Part number 550-100-026/0404...
- Page 38 2 — Boiler Manual FIRED WATER BOILER SERIES Replacement parts (continued) Heat exchanger and piping — Ultra-80 & -105 Part number 550-100-026/0404...
- Page 39 2 — Boiler Manual FIRED WATER BOILER SERIES Replacement parts (continued) Heat exchanger and piping — Ultra-80 & -105 Part number 550-100-026/0404...
- Page 40 2 — Boiler Manual FIRED WATER BOILER SERIES Replacement parts (continued) Heat exchanger and piping — Ultra-155 to -310 Part number 550-100-026/0404...
- Page 41 2 — Boiler Manual FIRED WATER BOILER SERIES Replacement parts (continued) Heat exchanger and piping — Ultra-155 to -310 Part number 550-100-026/0404...
- Page 42 2 — Boiler Manual FIRED WATER BOILER SERIES Replacement parts (continued) Controls Part number 550-100-026/0404...
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Page 43: Dimensions
FIRED WATER BOILER SERIES Dimensions Notes . Boiler supply and return tappings are both 1" NPT (Ultra- 80/105/155/230) 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 wall- mounting kit. -
Page 44: Ratings
FIRED WATER BOILER SERIES Ratings Notes . 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.