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80/110/150/199
Boiler Manual
This manual must only be used by a qualifi ed 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.
Part number 550-100-260/0520
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Table of Contents
Related Manuals for Weil-McLain EcoTec 150
Summarization of Contents
ECO Tec Boiler Models
The ECO Tec Gas-fired water boilers
Overview of the ECO Tec Gas-fired water boilers.
The ECO Tec Heating Only Gas-fired water Boilers
Description of the ECO Tec Heating Only Gas-fired water boilers.
The ECO Tec Combi Gas-fired water boilers
Description of the ECO Tec Combi Gas-fired water boilers.
Boiler Location and Clearances
Residential Garage Installation
Specific installation precautions for boilers located in residential garages.
Combustion Air Requirements
Requirements for providing adequate combustion air for direct vent and direct exhaust installations.
Provide Air Openings to Room
Specifies required air openings for boiler rooms based on appliance load and clearances.
Vent and Air Piping
General guidelines and requirements for installing vent and air piping systems.
Provide Clearances for Service Access — RECOMMENDED
Recommended minimum clearances around the boiler for servicing and maintenance.
Provide Clearances from Combustible Materials — REQUIRED
Minimum required clearances from the boiler to combustible materials for safety.
Prepare Boiler Location
Flooring and Foundation
Guidelines for preparing the floor and foundation for boiler installation, including material and size requirements.
Remove Boiler from Crate
Instructions on safely removing the boiler from its shipping crate, including handling precautions.
Wall Mounting and Pedestal Installation
Wall-mounting the boiler
Essential requirements and precautions for mounting the boiler on a wall, emphasizing secure attachment.
Install the Wall-mount Bracket (by Installer)
Step-by-step instructions for installing the wall-mount bracket, including locating studs and leveling.
Pedestal Floor Stand Assembly
Instructions for assembling and installing the optional pedestal floor stand for boiler mounting.
Boiler Hydrostatic Test Procedure
Install Pipe Fittings for Relief Valve and P/T Gauge
Instructions for installing necessary fittings for the hydrostatic test and pressure/temperature gauge.
Fill and Pressure Test
Procedure for filling the boiler and piping with water and performing the pressure test.
Drain and Remove Fittings
Steps for draining the system and removing fittings after the hydrostatic test is completed.
Gas Conversions and Propane Setup
Prepare Boiler for Propane — ECO Tec 80/110/150/199 (If Required)
Instructions for converting the boiler from natural gas to propane operation, including safety precautions.
Natural Gas to Liquefied Petroleum (Propane) Conversion Kits
Lists the components included in the natural gas to propane conversion kits for different ECO Tec models.
Installing Propane Venturi
Step-by-step instructions for installing the propane venturi, including labeling and identification.
Gas Conversions (Continued)
Gas Valve Course Adjustments
Procedures for adjusting the gas valve throttle and offset regulating screws for proper combustion.
Adjust the Offset Regulating Screw
Detailed steps for adjusting the offset regulating screw, referencing a specific figure for guidance.
Final Conversion Steps
Final steps to complete the gas conversion, including control settings and verification.
Gas Conversions (Continued)
LP to Natural Gas Conversion
Instructions for converting the boiler from propane to natural gas, including control setting adjustments.
Perform Boiler Manual Start-up
Steps to perform after gas conversion, including system checks and initial startup.
Gas Piping — Sizing Gas Lines
Natural Gas:
Detailed information and tables for sizing natural gas piping based on length and input.
Propane Gas:
Guidelines for sizing propane gas piping, including pressure requirements and regulator information.
Venting and Air Piping — General
When Removing a Boiler from an Existing Common Vent System
Precautions and procedures when replacing a boiler connected to a common vent system.
Existing Vent Test Procedure
A procedure to test the functionality of existing common vent systems with remaining appliances.
Products to Avoid
List of materials and chemicals that should be avoided in the vicinity of the boiler's venting system due to corrosive properties.
Areas Likely to Have Contaminants
Identification of locations that may have contaminants affecting the boiler's air intake or venting system.
Venting/Air Piping — General (Continued)
Installing Vent and Air Piping
General instructions for installing vent and air piping, including material compatibility and joint preparation.
Venting with Flexible Polypropylene
Specific considerations and equivalent length calculations for using flexible polypropylene vent piping.
Code Compliance
Requirements for venting and combustion air piping installations to comply with national and local codes.
Venting & Air — General (Continued)
Venting and Air Piping — DIRECT VENT ONLY — Options and Piping Limits
Table detailing direct vent termination options, materials, sizes, and maximum/minimum piping lengths.
Venting & Air — General (Continued)
Vent and Air Piping Materials
Specification of approved vent and air piping materials and their compliance with local codes and standards.
Direct Vent System Installations
DIRECT VENT — Sidewall with Separate Pipes
Instructions for installing direct vent systems using separate pipes for sidewall termination.
Determine Termination Location
Guidelines for selecting an appropriate location for sidewall termination of vent and air piping, considering length limits and clearances.
Multiple Vent/Air Terminations
Instructions for terminating vent and air piping when multiple boilers are installed, ensuring proper spacing and height.
DIRECT VENT — Sidewall Concentric
Instructions for installing direct vent systems using concentric sidewall termination.
DIRECT VENT — Sidewall with W-M Vent/Air Plate
Instructions for installing direct vent systems using the Weil-McLain sidewall vent/air plate termination.
DIRECT VENT — Vertical with Separate Pipes
Instructions for installing direct vent systems using separate pipes for vertical termination.
DIRECT VENT — Vertical Concentric
Instructions for installing direct vent systems using concentric vertical termination.
DIRECT VENT — Vertical Vent /Sidewall Air
Instructions for installing direct vent systems using vertical vent and sidewall air termination.
Boiler Water Piping and DHW Connections
Install Boiler Water Piping
Detailed instructions for installing the boiler's water piping, covering various connections and requirements.
General Piping Information
Recommendations for installing boiler water piping, including unions and general advice.
Additional Limit Controls
Information on installing additional limit controls for temperature protection, especially in multi-temperature systems.
System/Zone Pipe Sizing
Guidance on sizing system headers and zone piping for residential space heating applications.
Domestic Water Piping – Combi Boiler
Specific instructions and precautions for installing domestic water piping for Combi boiler models, including water treatment.
Recirculation (If Used)
Information and requirements for installing a domestic hot water recirculation system, including code compliance.
Recirculation Piping Diagram (If Used)
A diagram illustrating the recommended piping layout for a domestic hot water recirculation system.
Direct Connect System Piping
System Water Piping Methods
Overview of system water piping methods, including direct connect and primary/secondary piping options.
Verify the Application Will Work:
Steps to verify if the direct connect piping strategy is suitable for the intended application based on system requirements.
Expansion Tank Location
Recommendations for the optimal location of the system expansion tank and air separator in the piping layout.
Diaphragm- or Bladder-Type Tank:
Specific instructions and considerations for installing diaphragm- or bladder-type expansion tanks.
Closed-type Expansion Tank:
Specific instructions and considerations for installing closed-type expansion tanks, including warnings about automatic air vents.
Install Relief Valve
Detailed instructions for installing the safety relief valve, including piping and disposal of discharge.
Zoning and Primary/Secondary Piping Strategies
ZONE VALVE Zoning – Direct Connection
Configuration for zone valve systems using direct connection piping, including expansion tank and DHW considerations.
Primary/Secondary System Piping - Single Boiler System
Guidelines for primary/secondary piping systems to ensure accurate system heating temperatures.
ZONE VALVE Zoning – Primary/Secondary
Configuration for zone valve systems using primary/secondary piping, requiring a system circulator.
Circulator Zoning Plus Optional DHW Piping
Diagram illustrating circulator zoning with optional DHW piping connections.
Circulator Zoning – Multiple Temperature Zones with Primary/Secondary
Configuration for systems with multiple temperature zones using primary/secondary piping and circulators.
Condensate Drain System Installation
Prepare Condensate Drain Line Assembly
Steps to prepare and assemble the condensate drain line and trap components.
Install the Condensate Trap Assembly
Instructions for installing the condensate trap assembly into the boiler's condensate outlet tube.
Condensate Drain System
Requirements for the condensate drain system, including materials, pump selection, and line maintenance.
Gas Piping
Connecting Gas Supply Piping
Instructions for connecting the gas supply piping to the boiler, including shut-off valves and leak testing.
Field Wiring and Electrical Connections
Field Wiring
General overview of field wiring, including terminal connections and wiring considerations.
A. 120VAC Power Supply – REQUIRED
Instructions for connecting the required 120VAC power supply to the boiler.
B. 120VAC Power Outputs, 1, 2, 3 & 4 (Demands)
Configuration of 120VAC outputs for system demands like circulators or auxiliary devices.
C. Inputs, 1, 2, 3 & 4 (Demands)
Configuration of inputs for system demands such as thermostats, aquastats, or switches.
D. System Supply and Return Temperature Sensors
Recommendations for installing system supply and return temperature sensors, especially for primary/secondary piping.
E. Outdoor Temperature Sensor – REQUIRED unless Exempted
Instructions for installing the outdoor temperature sensor, which is required for reset operation.
F. External Limits – OPTIONAL
Information on optional external limits that can be connected for manual or automatic reset control.
J. Proof of Closure (Flow Switch and/or CAD)
Configuration options for proof of closure interlocks, such as flow switches or combustion air dampers.
K. 0–10 VDC Remote TARGET Input – OPTIONAL
Instructions for connecting an optional 0-10 VDC input for remote target temperature adjustment.
L. 0–10 VDC Remote MODULATION Input – OPTIONAL
Instructions for connecting an optional 0-10 VDC input for remote modulation control.
Wiring Diagrams
Wiring Diagram — Schematic
Schematic wiring diagram illustrating boiler components and their electrical connections.
Wiring Diagram — Ladder
Ladder wiring diagram showing electrical connections for boiler components and controls.
Control Zoning Strategies
A. Zoning with Circulators, Suggested Applications
Suggested applications and configurations for zoning systems using circulators with the ECO Tec control.
B. Zoning with Zone Valves, Suggested Applications
Suggested applications and configurations for zoning systems using zone valves with the ECO Tec control.
ECO Tec Control Operation and Setup
ECO Tec Control Overview
Overview of the ECO Tec control's capabilities, inputs, outputs, and response to system demands.
ECO Tec Control Wizard
Description of the step-by-step setup procedure for the ECO Tec control using the Wizard function.
Control Features
Highlights of the ECO Tec control's features, including display, priorities, and connectivity options.
ECO Tec Control Operation
Explanation of how the ECO Tec control operates, responds to signals, and manages system demands.
DHW Target
Settings related to domestic hot water target temperatures, including factory defaults and adjustment procedures.
Outdoor Reset Operation
Explanation of the outdoor reset function, which adjusts supply temperature based on outdoor conditions.
Remote Target Operation (0–10VDC Input)
Instructions for connecting and configuring a 0-10 VDC input for remote target temperature adjustment.
Boiler Essential Settings
Screen Branching Options
Description of various screen sequences encountered during control operation and setup.
Express Setup Examples
EXPRESS SETUP — Example A
Example setup configuration for space heating with circulators and direct-piped DHW.
EXPRESS SETUP — Example B
Example setup configuration for space heating with circulators (without relays) and direct-piped DHW.
EXPRESS SETUP — Example C
Example setup configuration for space heating with zone valves and direct-piped DHW.
Diagnostic Menu and Faults
DIAGNOSTIC Menu
Menu for viewing diagnostic information, including sensor status, inputs, outputs, and fault codes.
DIAGNOSTICS Menu (Continued)
Continued access to diagnostic information, including fault history and manual reset options.
System Fill and Water Preparation
Startup — Fill the System
Critical procedure for filling the boiler and system with water, including sediment removal and water chemistry checks.
Clean System to Remove Sediment
Pre-startup cleaning steps to remove sediment from the heating system and boiler.
Water Chemistry
Requirements for boiler water chemistry, including pH, hardness, and inhibitor levels.
Fill and Test Water System
Procedure for filling the system with water, checking pressure, and verifying for leaks.
Purge Air from Water System
Instructions for purging air from the water system using manual and automatic air vents.
Freeze Protection (If Used)
Guidelines for preventing freeze protection issues, including antifreeze and inhibitor requirements.
X100 Inhibitor is Required
Requirement to add Sentinel X100 inhibitor to the system to prevent boiler damage.
Check/Verify Water Chemistry
Steps to verify water chemistry after filling, checking pH, chloride, and inhibitor levels.
Final Checks Before Boiler Startup
Check for Gas Leaks
Critical safety check for gas leaks around the boiler and piping before startup.
Check Thermostat Circuits
Procedure to check thermostat wiring and voltage to ensure correct operation.
Inspect/Fill Condensate System
Maintenance check of the condensate drain line, fittings, and trap to ensure proper function.
Boiler Startup Procedures and Checks
To Start the Boiler
Steps to initiate boiler startup after all checks are completed, including control setup.
If Boiler Does Not Start Correctly
Troubleshooting guide for common issues encountered during boiler startup.
Check System and Boiler
Essential checks of the system piping, DHW system, and venting for proper operation.
Check Gas Piping
Verification of gas piping connections for leaks and proper odorant level.
Combustion Analysis and Tuning
Re-check the Maximum and Minimum CO2 and CO Rate
Procedure to re-verify and adjust CO2 and CO rates after gas valve adjustments.
Annual Startup and General Maintenance
Service Technician
Schedule of tasks and inspections to be performed annually by a qualified service technician.
Owner Maintenance
Routine maintenance tasks recommended for the owner to perform on a daily and monthly basis.
Annual Startup (Continued)
HANDLING CERAMIC FIBER MATERIALS
Safety precautions and guidelines for handling ceramic fiber materials found in the boiler.
FIRST-YEAR SPECIAL INSPECTION
Specific inspection procedures and recommended replacement parts for the first year of boiler operation.
Annual Startup (Continued)
Address Reported Problems
Procedure for addressing any reported issues or problems with the boiler or system.
Inspect Boiler Area
Inspection of the area surrounding the boiler for combustible materials and air intake contaminants.
Inspect Boiler Interior & Jacket Door Gaskets
Inspection of the boiler interior and jacket door gaskets for damage or wear.
Clean Condensate Trap
Maintenance procedure for cleaning the condensate trap to ensure proper drainage and prevent flue gas emission.
Check All Piping for Leaks
Procedure for checking all water and gas piping for leaks and correcting any found.
Annual Startup (Continued)
Check Air Openings
Verification of combustion and ventilation air openings to ensure they are unobstructed.
Flue Vent System and Air Piping
Inspection of the flue gas venting system and combustion air piping for blockages or damage.
Check Water System
Verification of water system components, cold fill pressure, and expansion tank performance.
Check Expansion Tank(s)
Inspection and potential troubleshooting of expansion tanks, including type identification and pressure checks.
Inspect Ignition Electrode
Procedure for inspecting, cleaning, or replacing the ignition electrode for proper ignition.
Annual Startup (Continued)
Check Ignition Wiring
Inspection of ignition cable resistance and wiring connections for proper operation.
Check All Boiler Wiring
Inspection of all boiler wiring, connectors, and attachments to ensure secure and correct connections.
Check Control Settings
Verification and adjustment of control settings to match the system design and application requirements.
Perform Startup and Checks
Steps for performing boiler startup, including combustion checks and system pressure verification.
Check Low Water Cutoff
Procedure to check the low water cutoff for proper operation according to manufacturer's instructions.
Check Burner Flame
Inspection of the burner flame during operation for proper ignition and combustion characteristics.
Check Flame Signal
Procedure to check the flame signal value and troubleshoot low flame signal issues.
Check Blower Speeds
Procedure to check and record blower speeds at different firing rates and altitudes.
Annual Startup (Continued)
Natural Gas Firing Rates and Corresponding Blower Speeds
Table of natural gas firing rates and blower speeds for various altitudes and boiler models.
Annual Startup (Continued)
Propane (LP) Gas Firing Rates and Corresponding Blower Speeds
Table of propane (LP) gas firing rates and blower speeds for various altitudes and boiler models.
Annual Startup (Continued)
Check Blower Speeds (Continued)
Continued procedure for checking blower speeds and comparing them to specified values.
Check Flue Gas Temperature
Procedure for checking flue gas temperature and diagnosing potential heat exchanger issues.
Manual Test Mode for Boilers
Instructions for navigating and using the Manual Test Mode for boiler diagnostics and testing.
3 Way Valve Test (Combi Model Only)
Specific test procedure for verifying the operation of the 3-way valve in Combi models.
Annual Startup (Continued)
Check Boiler Relief Valve
Procedure for inspecting and testing the boiler's safety relief valve to ensure proper operation.
Review with Owner
Guidance on reviewing the user's manual and maintenance schedule with the boiler owner.
Reinstall Jacket Door After Servicing
Instructions for securely reinstalling the boiler jacket door after completing service or maintenance.
Check Combi 3-way Valve, DHW Function and Brazed Plate
Check procedures for Combi models, focusing on the 3-way valve, DHW function, and brazed plate.
Troubleshooting Guide
VERIFY PROPER OPERATION AFTER SERVICING
Steps to verify proper boiler and system operation after any servicing or maintenance.
BEFORE TROUBLESHOOTING —
Preliminary steps and recommended tools needed before beginning troubleshooting procedures.
Check the Following:
Initial checks to perform before diving into specific troubleshooting steps, covering basic system and control conditions.
Check Control Fuses
Procedure for checking and replacing control fuses, identifying low and line voltage fuse types.
Checking Temperature Sensors
Method for checking temperature sensors by measuring resistance values and comparing them to specifications.
Control Fault Indications
Explanation of how the control displays fault information and how to reset conditions.
Troubleshooting Suggestions — Fault Displays, Diagnostics and Corrective Actions
Detailed guide to interpreting fault displays, diagnostics, and recommended corrective actions for various errors.
How to Read the Last 6 Lockout Histories:
Instructions on how to access and interpret the last six lockout histories recorded by the control.
How to Clear All Lockout Histories:
Procedure for clearing all lockout histories stored in the control's memory.
Restart Wizard
Option to restart the setup wizard, which erases user settings and returns to initial configuration.
Reset to Factory Default
Procedure to reset all control settings back to factory defaults, clearing all stored information.
Faults
List of common faults, their conditions, diagnostics, and corrective actions for troubleshooting.
Warnings
Specific warnings related to sensor errors, flow rates, temperature reductions, and clock/software issues.
Faults
List of common faults, their conditions, diagnostics, and corrective actions for troubleshooting.
Faults
List of common faults, their conditions, diagnostics, and corrective actions for troubleshooting.
Faults
List of common faults, their conditions, diagnostics, and corrective actions for troubleshooting.
Faults
List of common faults, their conditions, diagnostics, and corrective actions for troubleshooting.
Faults
List of common faults, their conditions, diagnostics, and corrective actions for troubleshooting.
Maintenance Procedures
Disconnect Power
Essential safety step: Disconnect all electrical power before performing maintenance.
Re-install Boiler Jacket Door After Startup or Servicing
Instructions for securely reinstalling the boiler jacket door after completing service or maintenance.
Start-up and Check/out
Procedure to verify proper boiler and system operation after maintenance, following startup steps.
Heat Exchanger Flue Side Cleaning
Tools Required
List of tools and equipment necessary for cleaning the heat exchanger flue side.
Before Proceeding:
Pre-procedure steps including shutting down the boiler and allowing it to cool.
Remove Components to Access Heat Exchanger Side
Instructions for removing components like the jacket door, control bracket, and display assembly.
Inspect and Clean the Heat Exchanger Interior
Procedure for inspecting and cleaning the interior surfaces of the heat exchanger.
Accessing the Burner or Heat Exchanger, Air Silencer and Gas Valve Removal.
Steps for accessing and removing the burner, air silencer, and gas valve for cleaning or servicing.
DHW and Brazed Plate Heat Exchanger Cleaning
Procedure for Chemical Cleaning of DHW Circuit
Detailed instructions for chemically cleaning the domestic hot water circuit, including safety and disposal.
Actions for Chemical Cleaning of Domestic Hot Water Circuit (Refer to Figure 117)
Specific actions and steps for performing chemical cleaning of the domestic hot water circuit.
Before Servicing Brazed Plate Heat Exchanger Assembly
Pre-service steps for the brazed plate heat exchanger assembly, including cooling down the boiler.
Brazed Plate Heat Exchanger Removal for Cleaning
Procedure for removing the brazed plate heat exchanger from the boiler for cleaning.
Cleaning/Maintenance for Domestic Water Inlet & Outlet Manifolds
Brazed Plate Heat Exchanger Reinstalled
Instructions for reinstalling the brazed plate heat exchanger, including gasket placement and screw torque.
Domestic Water Inlet Manifold Components
Identification of components within the domestic water inlet manifold for maintenance.
Replacement Parts Information
OBTAIN PARTS ONLY THROUGH WEIL-McLAIN
Guidance on where and how to purchase genuine Weil-McLain replacement parts.
THE BOILER CONTAINS CERAMIC FIBER MATERIALS
Safety warning regarding ceramic fiber materials and handling precautions.
REINSTALL Jacket Door
Instructions for securely reinstalling the boiler jacket door after servicing.
Miscellaneous Service Parts and Kits
List of various service parts and kits available for the ECO Tec boiler, including part numbers.
Jacket Parts — ECO Tec 80/110/150/199
Part numbers and descriptions for jacket components of ECO Tec boilers.
Heat Exchanger Parts ECO Tec 80/110/150/199
Part numbers for heat exchanger components specific to ECO Tec boiler models.
Combustion Components Parts ECO Tec 80/110/150/199
Part numbers for combustion system components of ECO Tec boilers.
Combi Water Piping for ECO Tec 80/110/150/199
Part numbers for water piping components specific to Combi models.
Heating Only Water Piping for ECO Tec 80/110/150/199
Part numbers for water piping components specific to Heating Only models.
Controls and Electrical Components - ECO Tec 80/110/150/199
Part numbers for controls, sensors, wiring harnesses, and other electrical components.
Boiler Ratings and Engineering Data
Ratings — ECO Tec Boilers
Table of technical ratings, efficiency, capacity, and vent/air connection data for ECO Tec boilers.
Notes
Important notes regarding Energy Star guidelines, AHRI certification, and vent/air piping requirements.
THE OUTDOOR SENSOR SUPPLIED MUST BE INSTALLED UNLESS EXEMPTED BELOW:
Requirement to install the outdoor sensor unless specifically exempted by the Energy Act.
IMPORTANT OVERRIDE NOTICE
Notice regarding the override feature for external energy management systems affecting boiler water temperature.
Engineering Data — ECO Tec 80/110/150/199 Boilers
Detailed engineering data including shipping weight, operating weight, water content, and flow rates.
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