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Weil-McLain ULTRA OIL Manual

Oil-fired water boiler
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Oil-Fired Water Boiler
Boiler Manual
This manual must only be used by a qualified heating installer/service technician. Read all instructions, includ-
ing 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.
Part number 550-141-986/0112

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Summary of Contents for Weil-McLain ULTRA OIL

  • Page 1 ® Oil-Fired Water Boiler Boiler Manual This manual must only be used by a qualified heating installer/service technician. Read all instructions, includ- ing this manual and all other information shipped with the boiler, before installing. Perform steps in the order given.

  • Page 2: Ow It Works

    . . . ® WATER BOILER OW IT WORKS Weil-McLain logo plate (standard) or 19. Sensor wells Remote Display Module (optional) Boiler aquastat sensor and P/T gauge capillary and temperature The Remote Display Module (RDM) is used when the optional sensor are installed in the top of the rear section.
  • Page 3 ® — Boiler Manual WATER BOILER ® WATER BOILER Part number 550-141-986/0112...

  • Page 4: Table Of Contents

    ® — Boiler Manual WATER BOILER Contents ® — H ......2–3 WATER BOILER OW IT WORKS Owners Responsibilities ............. 5 Please read before proceeding .......... 6 Boiler location checklist ............ 7 Prepare boiler location ............8 Connect breeching ............12 Connect water piping ............

  • Page 5: Owners Responsibilities

    ® — Boiler Manual WATER BOILER Please read before proceeding Follow the guidelines below to prevent severe personal injury, death or substantial property damage. Fuel Do not start burner if: cumulated in combustion chamber, when unit is full of vapor, or when combustion chamber is very hot. combustible material around boiler.

  • Page 6: Please Read Before Proceeding

    ® — Boiler Manual WATER BOILER +DYH WKH ERLOHU DQG EXUQHU LQVWDOOHG E\ D TXDOLÀHG LQVWDOOHU +DYH WKH ERLOHU DQG EXUQHU VHUYLFHG DW OHDVW DQQXDOO\ E\ D TXDOLÀHG service technician. Review and understand boiler start-up and routine maintenance proce- dures with the service technician. Perform routine maintenance listed below.

  • Page 7: Boiler Location Checklist

    ® — Boiler Manual WATER BOILER Boiler location checklist Before placing the boiler, verify: United States installations must comply with all applicable U. S. codes: ❏ ment. dian codes: ❏ ❏ ❏ ❏ ❏ ❏ ❏ connected. ❏ ❏ Failure to keep boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

  • Page 8: Prepare Boiler Location

    ® — Boiler Manual WATER BOILER Prepare boiler location Provide minimum clearances Minimum clearances to combustible surfaces and recommended minimum service clearances From combustible materials (see Figure 1) 1. Hot water pipes (not shown in Figure 1) 2. Double-wall vent pipe 4.
  • Page 9 ® — Boiler Manual WATER BOILER Prepare boiler location (continued) Flooring and foundation Follow code requirements Flooring adequate combustion and ventilation air openings. In 1. Install on any level, properly-supported, and non- absence of codes, use the following guidelines when carpeted surface.
  • Page 10 ® — Boiler Manual WATER BOILER Prepare boiler location (continued) Place the boiler: 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. Remove the circulator and barometric damper cartons from the crate base.
  • Page 11 ® — Boiler Manual WATER BOILER Prepare boiler location (continued) Perform hydrostatic pressure test: Burner door hinge installation Hinge bracket and screws 1. Install air vent in relief valve tapping. (factory-installed on left side) 2. Plug supply and return tappings. Burner door screws and washers 3.

  • Page 12: Connect Breeching

    ® — Boiler Manual WATER BOILER Prepare boiler location (continued) Install the burner 3. Close the burner door and secure in place with the burner door screws and washers. 4. Follow the burner manual and boiler manual the three bolts provided. (pages 20 to 22) to wire the burner and connect fuel 2.
  • Page 13 ® — Boiler Manual WATER BOILER Connect breeching (continued) Chimney venting (continued) Connect breeching: positive even with a negative pressure page 39 for boiler draft loss. number of tees and elbows or other ob- structions restricting combustion gas flow The pressure in the breeching and chim- can result in possibility of condensation, ney must always be negative unless the flue gas leakage and carbon monoxide...

  • Page 14: Connect Water Piping

    ® — Boiler Manual WATER BOILER Connect water piping General piping information: Water piping sizing ASME or Canadian requirements Piping to Piping from Model system system requirements, an additional high temperature limit (inches) (inches) is needed. Install control in supply piping between of 20 °F above set point of the boiler aquastat.
  • Page 15 ® — Boiler Manual WATER BOILER Connect water piping (continued) DIAPHRAGM expansion tank (Figure 6) Near-boiler piping, with diaphragm expansion tank system water volume and temperature. Tank must tank manufacturer’s instructions for details. water to be lost from relief valve and makeup water added through fill valve.
  • Page 16 ® — Boiler Manual WATER BOILER Connect water piping (continued) Piping MULTIPLE ZONES — System temperature 140 °F or higher 1. Follow instructions on page 14 and 15 to install piping near boiler. 2. Zoning with circulators (Figure 8) a. Install balancing valves to adjust flow to distribute ments.
  • Page 17 ® — Boiler Manual WATER BOILER Connect water piping (continued) Piping MULTIPLE ZONES — System temperature below 140 °F 1. If system water temperature requirements are less than 140 °F, such as radiant panels or converted a. Install balancing valves to adjust flow to distribute heat gravity systems, use piping as shown in Figure 10 or 11.

  • Page 18: Connect Wiring (Note 1)

    ® — Boiler Manual WATER BOILER Connect water piping Connect wiring (continued) Piping boiler in refrigeration systems Wire requirements (Figure 12) 105 °C wire or equivalent must be used. dium from entering boiler. Consult I=B=R Installation and Piping Guides. units where they can be exposed to refrigerated air, use flow Electrical requirements control valves or other automatic means to prevent gravity circulation during cooling cycle.
  • Page 19 ® — Boiler Manual WATER BOILER Connect wiring Burner harness routing remove, push the Control Pod cover to one side, and gently work the cover retainer hinge on the other side out of the jacket slot.) 120-volt wiring Conduits from the boiler to a conduit opening in the upper portion of the jacket rear panel.
  • Page 20 ® — Boiler Manual WATER BOILER Connect wiring (continued) This wiring diagram is for standard boiler Boiler and burner wiring, standard equipment equipment. For wiring with optional AFM, see AFM instructions. Part number 550-141-986/0112...
  • Page 21 ® — Boiler Manual WATER BOILER Connect wiring (continued) Part number 550-141-986/0112...

  • Page 22: Connect Oil Piping

    ® — Boiler Manual WATER BOILER Connect oil piping General oil piping requirements: Make swing joints so they will tighten as tank settles. used on all threads. burners must follow: Do not use Teflon tape as an oil pipe seal- Equipment.

  • Page 23: Startup Procedure

    ® — Boiler Manual WATER BOILER Startup procedure Tips for water systems: 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. stantial property damage: Failure to maintain recommended pH and repair leaks can cause section iron corrosion, leading to section failure and...

  • Page 24: Check-Out Procedure

    ® — Boiler Manual WATER BOILER Check-out procedure ❏ 1. Boiler and heat distribution units filled with water? be operating and should go off when controls are tested. When controls are restored, burner should re-ignite. ❏ 2. Automatic air vent, if used, opened one full turn? ❏...

  • Page 25: Annual Service And Start-Up

    ® — Boiler Manual WATER BOILER Annual service and start-up The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service to the boiler before any service operation technician. In addition, the maintenance and care of the boiler on the boiler except as noted otherwise designated in Table 4 must be performed to assure maximum in this instruction manual.
  • Page 26 ® — Boiler Manual WATER BOILER 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. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.

  • Page 27: Check Expansion Tank

    ® — Boiler Manual WATER BOILER Annual service and start-up (continued) Check all piping for leaks Check expansion tank Eliminate all system or boiler leaks. Con- General guidelines tinual fresh make-up water will reduce Expansion tanks provide space for water to move in and boiler life.

  • Page 28: Check Boiler Relief Valve

    ® — Boiler Manual WATER BOILER Annual service and start-up (continued) Check boiler relief valve Check all boiler wiring 1. Inspect the relief valve and lift the lever to verify flow as Inspect all boiler wiring, making sure wires are in good in the following warnings, excerpted from a relief valve condition and securely attached.
  • Page 29 ® — Boiler Manual WATER BOILER Annual service and start-up (continued) Clean boiler flueways and check Access to boiler flueways refractory linings Make sure all electrical connections to boiler are turned off and wait until boiler is warm, not hot, before cleaning. Failure to do so will result in severe personal injury, death or substantial property damage.

  • Page 30: Removing/Replacing Boiler Jacket

    ® — Boiler Manual WATER BOILER Removing/replacing boiler jacket Removing the boiler jacket Jacket components and hardware The following procedure assumes the boiler has not been wired. If the boiler has been wired, you must disconnect all power to the boiler. Then label all wires before disconnecting them at the boiler terminal strip.
  • Page 31 ® — Boiler Manual WATER BOILER Removing/replacing boiler jacket (cont.) 9. Push the Control Pod cover to one side, and gently Jacket components and hardware work the cover retainer hinge on the other side out of the jacket slot to remove the cover. 10.

  • Page 32: Replacement Parts

    ® — Boiler Manual WATER BOILER 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-3 560-234-468 UO-4 560-234-472 UO-5 560-234-477 Nuts (8 required) 561-928-221 Washers (4 required) 562-248-668...
  • Page 33 ® — Boiler Manual WATER BOILER Replacement parts (continued) Boiler section assembly parts Part number 550-141-986/0112...
  • Page 34 ® — Boiler Manual WATER BOILER Replacement parts (continued) Burner door parts Item Description Part Number %XUQHU ÀDQJH EROWV  HDFK ´ [ ´ +H[ KHDG 6WDLQOHVV 6WHHO Purchase locally Burner door 330-054-308 Burner door hinge bracket 466-900-000 +LQJH EUDFNHW VFUHZV  UHTXLUHG  ´ [ Purchase locally 2EVHUYDWLRQ SRUW DVVHPEO\ LQFOXGHV REVHUYDWLRQ SRUW EROW REVHUYDWLRQ SRUW 386-902-000...
  • Page 35 ® — Boiler Manual WATER BOILER Replacement parts (continued) Burner door parts Part number 550-141-986/0112...
  • Page 36 ® — Boiler Manual WATER BOILER Replacement parts (continued) Jacket and control parts Item Description Part Number -DFNHW IURQW SDQHO DVVHPEO\ LQFOXGHV VKHHW PHWDO SODVWLF VWULNHU 386-902-005 Jacket front panel plastic 595-000-009 Jacket side panel (left and right sides are the same) UO-3 426-900-002 UO-4...
  • Page 37 ® — Boiler Manual WATER BOILER Replacement parts (continued) Jacket and control parts Part number 550-141-986/0112...

  • Page 38: Dimensions

    ® — Boiler Manual WATER BOILER Dimensions 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 550-141-986/0112...

  • Page 39: Ratings

    ® — Boiler Manual WATER BOILER Ratings Boiler I=B=R Boiler Shipping Flue Draft Water Weight, Seasonal Conn. Loss Model Burner Heating Input Output I=B=R Number Capacity Capacity Ratings Content Approx. (I¿FLHQF\ Size Through Boiler Inches *3+  2LO Btuh *DOORQV Pounds $)8( ZF...
  • Page 40 ® — Boiler Manual WATER BOILER...

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