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Boiler Manual
This manual must only be used by a qualified heating installer/service technician. Read all instructions, including this manual and
all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to comply could result in
severe personal injury, death or substantial property damage.
Oil-Fired Water Boiler
• Installation
• Startup
Part number 550-143-013/0621
Series 3
• Maintenance
• Parts
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Table of Contents
Related Manuals for Weil-McLain ULTRA Oil 3 Series
Summary of Contents for Weil-McLain ULTRA Oil 3 Series
- Page 1 Series 3 Oil-Fired Water Boiler Boiler Manual • Installation • Maintenance • Startup • Parts This manual must only be used by a qualified heating installer/service technician. Read all instructions, including this manual and all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
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Page 2: The Water Boiler - How It Works
Series 3 water boiler — Boiler Manual water boiler – How it works . . . 1. ON/OFF switch Boiler limit temperature sensor and P/T gauge capillary and tem- perature sensor are installed in the top of the rear section. 2. - Page 3 Series 3 water boiler — Boiler Manual water boiler W Q/223 Part number 550-143-013/0621...
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Page 4: Table Of Contents
Series 3 water boiler — Boiler Manual Contents water boiler — How it works....2–3 Please read before proceeding ..........5 Owners Responsibilities ............6 Boiler location checklist ............7 Prepare boiler location ............8 Connect breeching .............. 12 Connect water piping ............14 Connect wiring ............ -
Page 5: Please Read Before Proceeding
Therefore, Weil-McLain equipment con- Boiler firing rate — taminated with saltwater or polluted water will no longer be covered under warranty and should be replaced. -
Page 6: Owners Responsibilities
Series 3 water boiler — Boiler Manual Homeowner responsibilities— read and follow completely. Have the boiler and burner installed by a qualified installer. Have the boiler and burner serviced at least annually by a qualified service technician. Review and understand boiler start-up and routine maintenance proce- dures with the service technician. -
Page 7: Boiler Location Checklist
Series 3 water boiler — Boiler Manual Boiler location checklist Before placing the boiler, verify: • Applicable state, local and national codes. United States installations must • National Electrical Code, ANSI/NFPA 70 – latest edition. comply with all applicable • Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ U. -
Page 8: Prepare Boiler Location
Series 3 water boiler — Boiler Manual Prepare boiler location Installations must comply with Figure 1 Minimum clearances to combustible surfaces and United States recommended minimum service clearances State and local plumbing, heating and electrical codes. National codes where applicable. •... - Page 9 Series 3 water boiler — Boiler Manual Prepare boiler location (continued) Flooring and foundation Follow state, provincial or local codes when sizing adequate combustion and ventilation air openings. In Flooring absence of codes, use the following guidelines when 1. Install on any level, properly-supported, and non- boiler is in a confined room (defined by NFPA 31 as less carpeted surface.
- Page 10 Series 3 water boiler — Boiler Manual Prepare boiler location (continued) Place the boiler: Figure 2a To install leveling legs: Insert first shipping channel under boiler leg. Remove outer crate 1. Remove outer crate, leaving boiler on the crate base. 2.
- Page 11 Series 3 water boiler — Boiler Manual Prepare boiler location (continued) Perform hydrostatic pressure test: Figure 4 Burner door hinge installation See pages 2 and 3 for boiler feature locations. 1. Install air vent in relief valve tapping. 2. Plug supply and return tappings. 3.
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Page 12: Connect Breeching
Series 3 water boiler — Boiler Manual Prepare boiler location (continued) Install the burner 3. Close the burner door and secure in place with the burner door screws and washers. 1. Secure the burner flange to the burner door using 4. - Page 13 Series 3 water boiler — Boiler Manual Connect breeching (continued) Chimney venting The Ultra Oil boiler is capable of being (continued) pressure fired. Overfire pressure may be Connect breeching: positive even with a negative pressure in the chimney. See the Ratings table on Long horizontal breechings, excessive num- page 39 for boiler draft loss.
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Page 14: Connect Water Piping
For multiple-boiler piping • No shutoff valve shall be installed be- tween the relief valve and boiler, or in • Refer to Weil-McLain’s “Primary/Secondary Piping the discharge line. Do not plug or place Guide. ” any obstruction in the discharge line. - Page 15 Series 3 water boiler — Boiler Manual Connect water piping (continued) DIAPHRAGM expansion tank (Figure 6) Figure 6 Near-boiler piping, with diaphragm expansion tank • Make sure expansion tank size will handle boiler and system water volume and temperature. Tank must be located near boiler before inlet to circulator.
- Page 16 2. Zoning with circulators (Figure 8) b. Separate transformer is required to power zone valves. a. Size each circulator to individual circuit requirements. Refer to “Weil-McLain Zone Valve Wiring b. Remove circulator (when furnished as standard equip- Guide” for details.
- Page 17 140 °F, such as radiant panels or converted gravity systems, use piping as shown in Figure 10 b. Separate transformer is required to power zone valves. Refer to “Weil-McLain Zone Valve Wiring or 11. Guide” for details. 2. If system piping is plastic without an oxygen barrier, 6.
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Page 18: Connect Wiring
Series 3 water boiler — Boiler Manual Connect water piping Connect wiring (continued) Piping boiler in refrigeration systems Wire requirements (Figure 12) • Wiring must be N.E.C. Class 1. • If original wire supplied with boiler must be replaced, type •... - Page 19 Series 3 water boiler — Boiler Manual Connect wiring remove, push the Control Pod cover to one side, and gently Figure 14 Burner harness routing work the cover retainer hinge on the other side out of the jacket slot.) 120-volt wiring Conduits •...
- Page 20 Series 3 water boiler — Boiler Manual Connect wiring (continued) This wiring diagram is for standard boiler Figure 15 Boiler and burner wiring, standard equipment equipment. Part number 550-143-013/0621...
- Page 21 Series 3 water boiler — Boiler Manual Connect wiring (continued) Part number 550-143-013/0621...
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Page 22: Connect Oil Piping
Series 3 water boiler — Boiler Manual Connect oil piping General oil piping requirements: Make swing joints so they will tighten as tank settles. Non-hardening pipe joint compounds should be • Location and installation of oil tanks, oil piping and used on all threads. -
Page 23: Startup Procedure
Series 3 water boiler — Boiler Manual Startup procedure Tips for water systems: • Check boiler and system piping for leaks. Continual makeup water Follow information below to prevent will reduce boiler life. Minerals can build up in sections, reducing heat severe personal injury, death or sub- transfer and causing cast iron to overheat, resulting in section failure. -
Page 24: Check-Out Procedure
Series 3 water boiler — Boiler Manual Check-out procedure o 1. Boiler and heat distribution units filled with water? o 9. Limit control set to system temperature requirements (max. 220 °F)? o 2. Automatic air vent, if used, opened one full turn? o 10. -
Page 25: Annual Service And Start-Up
Series 3 water boiler — Boiler Manual Annual service and start-up The boiler should be inspected and started annually, at the Electrical shock hazard — Turn off power beginning of the heating season, only by a qualified service to the boiler before any service operation technician. - Page 26 Series 3 water boiler — Boiler Manual Annual service and start-up (continued) 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 27 Series 3 water boiler — Boiler Manual Annual service and start-up (continued) Check all piping for leaks Check expansion tank Eliminate all system or boiler leaks. General guidelines Continual fresh make-up water will re- Expansion tanks provide space for water to move in and duce boiler life.
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Page 28: Department Of Energy Compliance
Series 3 water boiler — Boiler Manual Annual service and start-up (continued) Check boiler relief valve Following installation, the valve lever must be oper- ated at least once each year to ensure that 1. Inspect the relief valve and lift the lever to verify flow as in the waterways are clear. - Page 29 Series 3 water boiler — Boiler Manual Annual service and start-up (continued) Clean boiler flueways and check Figure 17 Access to boiler flueways refractory linings Make sure all electrical connections to boiler are turned off and wait until boiler is warm, Flue baffles not hot, before cleaning.
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Page 30: Removing/Replacing Boiler Jacket
Series 3 water boiler — Boiler Manual Removing/replacing boiler jacket Removing the boiler jacket Figure 18 Jacket components and hardware The following Electrical shock hazard — procedure assumes the boiler has not been wired. If the boiler has been wired, you must disconnect all power to the boiler. - Page 31 Series 3 water boiler — Boiler Manual Removing/replacing boiler jacket (cont.) lift cover up. Figure 20 Jacket components and hardware 9. Push the Control Pod cover to one side, and gently work the cover retainer hinge on the other side out of the jacket slot to remove the cover.
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Page 32: Replacement Parts
Series 3 water boiler — Boiler Manual Replacement parts (continued) Boiler section assembly parts Item Description Part Number Boiler front section 316-900-200 Boiler intermediate section 316-900-210 Boiler back section 316-900-220 Tie rods (4 required) UO-3 & UO-3R 560-234-468 UO-4 560-234-472 UO-5 560-234-477 Nuts (8 required) - Page 33 Series 3 water boiler — Boiler Manual Replacement parts (continued) Boiler section assembly parts Part number 550-143-013/0621...
- Page 34 Series 3 water boiler — Boiler Manual Replacement parts (continued) Burner door parts Item Description Part Number Burner flange bolts (3) each, 5/16”-18 x 3/4” Hex head Stainless Steel Purchase locally Burner door 330-054-308 Burner door hinge bracket 466-900-000 Hinge bracket screws (2 required), 3/8”-16 x 1 Purchase locally Observation port assembly (includes observation port, bolt, observation port 386-902-000...
- Page 35 Series 3 water boiler — Boiler Manual Replacement parts (continued) Burner door parts Part number 550-143-013/0621...
- Page 36 Series 3 water boiler — Boiler Manual Replacement parts (continued) Jacket and control parts Item Description Part Number Jacket front panel assembly (includes sheet metal, plastic, & striker) 386-902-021 Jacket front panel plastic 595-000-009 Jacket side panel (left and right sides are the same) UO-3 386-902-023 UO-4...
- Page 37 Series 3 water boiler — Boiler Manual Replacement parts (continued) Jacket and control parts Part number 550-143-013/0621...
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Page 38: Dimensions
Series 3 water boiler — Boiler Manual Dimensions Notes 1. Boiler circulator is shipped loose. Circulator may be mounted on either boiler supply or return piping. . Relief valve is shipped loose, supplied with elbow and nipple to install in rear section tapping. Part number 550-143-013/0621... -
Page 39: Ratings
Series 3 water boiler — Boiler Manual Ratings ® AHRI Certified Ratings Draft Boiler Flue Shipping Loss Heating Seasonal Rating Water Conn. Weight, Through Boiler Burner Input Capacity Efficiency (water) Content Size Approx. Boiler Model AFUE % Gallons Inches Pounds Inches w.c. - Page 40 Series 3 water boiler — Boiler Manual...