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Weil-McLain UltraOil Manual

Weil-McLain UltraOil Manual

Oil-fired water boiler
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Download this manual See also: Instruction Manual
Boiler Manual
This manual must only be used by a qualified heating installer/service technician.
including this manual, the burner manual and any related supplements. 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
Before installing
• Maintenance
• Parts
, read all instructions,
Part number 550-141-986/1005

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Summary of Contents for Weil-McLain UltraOil

  • Page 1 Oil-Fired Water Boiler Boiler Manual • Installation • Maintenance • Startup • Parts Before installing This manual must only be used by a qualified heating installer/service technician. , read all instructions, including this manual, the burner manual and any related supplements. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage. Part number 550-141-986/1005...

  • Page 2: T He Water Boiler - H Ow It Works

    — Boiler Manual water boiler – h . . . waTer boiler ow iT works 1. Weil-McLain logo plate (standard) or glass is located at the 1:00 position. To view the burner flame, Remote Display Module (optional) loosen the center mounting bolt and rotate so the sight glass is The Remote Display Module (RDM) is used when the optional in the 6:00 position. AFM (item 8) is installed. The display shows boiler and system status and is used to adjust operating parameters. 18. Overfire pressure tapping 1/8” npt, with plug. 2. ON/OFF switch 19. Jacket crosstie 3. Control Pod cover fastener 20. Sensor wells 4. Pressure/Temperature gauge Boiler aquastat sensor and P/T gauge capillary and temperature Displays boiler water pressure and outlet water temperature. sensor are installed in the top of the rear section.
  • Page 3 — Boiler Manual water boiler waTer boiler Part number 550-141-986/1005...

  • Page 4: Table Of Contents

    — Boiler Manual water boiler Contents — h ........2–3 waTer boiler ow iT works Please read before proceeding ............5 Boiler location checklist ..............6 Prepare boiler location .................7 Connect breeching ................11 Connect water piping .................13 Connect wiring .................18 (Note 1) Connect oil piping ................21 Startup procedure ................22 Check-out procedure .................23 Annual service and start-up ..............24...

  • Page 5: Please Read Before Proceeding

    — 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: • Do not use crankcase drainings or any oil containing • Do not attempt to start burner when excess oil has ac- gasoline. See burner manual for proper fuel oil. cumulated in combustion chamber, when unit is full of vapor, or when combustion chamber is very hot. • Never burn garbage or paper in the boiler. Never leave combustible material around boiler. • Do not start burner unless breeching and burner mount- ing door are secured in place. Do not tamper with burner/controls • Always follow specific instructions when starting up boiler or performing routine maintenance or service.

  • Page 6: Boiler Location Checklist

    — Boiler Manual water boiler Boiler location checklist Before placing the boiler, verify: • Applicable state, local and national codes. United States installations must • National Electrical Code. comply with all applicable U. S. • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ codes: ASME CSD-1, when required.

  • Page 7: Prepare Boiler Location

    — Boiler Manual water boiler Prepare boiler location Provide minimum clearances Figure 1 Minimum clearances to combustible surfaces and From combustible materials (see Figure 1) 1. Hot water pipes • All directions — ½ inch. (not shown in Figure 1) . Double-wall vent pipe • All directions — 6 inches. . Single-wall vent pipe. • All directions — 18 inches. 4. Boiler jacket surfaces • Top of Control Pod cover — 1 inches. • Sides and back —  inches. . Burner cover • All directions —  inches.

  • Page 8: Flooring And Foundation

    — Boiler Manual water boiler Prepare boiler location (continued) Flooring and foundation Follow code requirements Follow state, provincial or local codes when sizing 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. Flooring may be combustible if boiler is in a confined room (defined by NFPA 1 as boiler leveling legs are installed.
  • Page 9 — Boiler Manual water boiler 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. . Remove the circulator and barometric damper cartons from the crate base. . UO- boilers only — Remove the two flue baffles fastened to the crate base behind the boiler. 4. Remove the two shipping channels by loosening and removing the four nuts. Save the shipping channels for leveling leg installation. . Remove the jacket crosstie fastened to the crate base. Install the leveling legs if used (required if boiler is placed on combustible flooring) The leveling legs must be installed if the boiler is placed on combustible flooring.

  • Page 10: Perform Hydrostatic Pressure Test

    — Boiler Manual water boiler Prepare boiler location (continued) Perform hydrostatic pressure test: Figure 4 Burner door hinge installation See pages  and  for boiler feature locations. 1. Install air vent in relief valve tapping. . Plug supply and return tappings. . Install the boiler drain valve shipped with boiler. 4. Fill boiler. . Vent all air. 6. Pressure test boiler at 1½ times working pressure. Do not leave boiler unattended. Cold water fill can expand and damage cast iron, resulting in severe personal injury, death or substantial property damage. 7. Check for maintained gauge pressure for at least 10 minutes. Visually check for leaks if gauge pressure drops. 8. Drain boiler. Repair leaks if found. Do not use petroleum-based sealing compounds to repair leaks. Damage to system components can result, causing property damage.

  • Page 11: Connect Breeching

    — Boiler Manual water boiler Prepare boiler location (continued) Install the burner . 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. Follow the burner manual and boiler manual the three bolts provided. (pages 19 to 1) to wire the burner and connect fuel . Check for secure placement of insulation and sealing lines. rope on the burner door. Connect breeching Direct venting Table 2 Chimney venting — vent sizing The Ultra Oil boiler can be direct vented using the Field Controls Direct Vent Kit, model number FDVS-46, and Minimum I=B=R...
  • Page 12 — Boiler Manual water boiler 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 page 9 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 chimney and breeching are constructed emissions, which can lead to severe per- of vent piping designed for pressurized...

  • Page 13: Connect Water Piping

    • See page 16. the discharge line. Do not plug or place any obstruction in the discharge line. Chiller system piping • Failure to comply with the above guide- • See page 17. lines could result in failure of the relief For multiple-boiler piping valve to operate, resulting in possibil- • Refer to Weil-McLain’s “Primary/Secondary Piping ity of severe personal injury, death or Guide.” substantial property damage. Relief valve • Test the operation of the valve after filling and pressurizing system by • Install relief valve vertically in elbow supplied. See lifting the lever. Make sure the valve Figure 6 or 7 for location.
  • Page 14 — Boiler Manual water boiler 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. See tank manufacturer’s instructions for details. Undersized expansion tanks cause system water to be lost from relief valve and makeup water added through fill valve. Eventual section failure can result. CLOSED expansion tank (Figure 7) Figure 7 Near-boiler piping, with closed expansion tank • Ensure expansion tank size will handle boiler and...
  • Page 15 . Zoning with zone valves (Figure 9) . Zoning with circulators (Figure 8) a. Install balancing valves to adjust flow to distribute heat to all zones. a. Size each circulator to individual circuit require- b. Separate transformer is required to power zone valves. ments. Refer to “Weil-McLain Zone Valve Wiring b. Remove circulator (when furnished as standard equip- Guide” for details. ment). c. Install balancing valves to adjust flow to distribute heat to all zones. Figure 8 Figure 9 Multiple zoning with circulators –...
  • Page 16 1. If system water temperature requirements are less . Zoning with zone valves (Figure 11) 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 to all zones. or 11. b. Separate transformer is required to power zone valves. Refer to “Weil-McLain Zone Valve Wiring . If system piping is plastic without an oxygen barrier, Guide” for details. a heat exchanger must be used. 6. To set the valves, and . Follow instructions on page 1 and 14 to install a. Set the valves while the system is cool, setting for the near-boiler piping.
  • Page 17 — Boiler Manual water boiler Connect water piping (continued) Piping boiler in refrigeration systems (Figure 12) • Install boiler so that chilled medium is piped in parallel with heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. Consult I=B=R Installation and Piping Guides. • If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air, use flow control valves or other automatic means to prevent gravity circulation during cooling cycle. Figure 12 Piping boiler in a system with chiller Part number 550-141-986/1005...

  • Page 18: Connect Wiring (Note 1)

    — Boiler Manual water boiler Connect wiring General wiring requirements Figure 13 Terminal strip access Electric shock hazard . Can cause severe personal injury or death if power source, including service switch on boiler, is not disconnected before installing or servic- ing. Installations must follow these codes: • United States: National Electrical Code, ANSI/NFPA 70, latest edition and any additional national, state or local codes. • Canada: CSA C.1 Canadian Electrical Code Part 1 and any local codes. Wire requirements • Wiring must be N.E.C. Class 1.

  • Page 19: Thermostat Wiring

    — Boiler Manual water boiler Connect wiring (continued) Circulator Figure 14 Burner harness and EnviraCOM ® • The circulator is shipped with the boiler, but not installed or wired. • Wire the circulator to the boiler terminal strip as shown on the boiler wiring diagram. Provide hot, neutral and ground wires, routed in metal con- duit. Thermostat wiring • Install thermostat on inside wall away from influ- ences of drafts, hot or cold water pipes, lighting fixtures, televisions, sun rays or fireplaces.
  • Page 20 — Boiler Manual water boiler Connect wiring (continued) This wiring diagram is for standard boiler Figure 15 Boiler and burner wiring, standard equipment equipment. For wiring with optional AFM, see AFM instructions. Part number 550-141-986/1005...

  • Page 21: Connect Oil Piping

    — Boiler Manual water boiler 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. burners must follow: • NFPA 1, Standard for the Installation of Oil-Burning Do not use Teflon tape as an oil pipe seal- Equipment. ant. It can cause valves to fail, creating haz- • In Canada, CSA B19, Installation of Oil-Burning ards. Do not use compression fittings. Equipment. • Underground pipe must be run in a casing to pre- • Local codes and regulations.

  • Page 22: Startup Procedure

    — Boiler Manual water boiler 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. stantial property damage: • Do not use gasoline crankcase drain- Failure to maintain recommended pH and repair leaks can ings or any oil containing gasoline. See cause section iron corrosion, leading to section failure and burner manual for proper fuel oil. leaks. Do not use petroleum-based sealing or stop-leak com- • Do not attempt to start burner when pounds in boiler systems. Damage to system components can excess oil has accumulated, when unit...

  • Page 23: Check-Out Procedure

    — Boiler Manual water boiler Check-out procedure be operating and should go off when controls are tested. o 1. Boiler and heat distribution units filled with water? When controls are restored, burner should re-ignite. o . Automatic air vent, if used, opened one full turn? o 9. Limit control set to system temperature requirements (max. 0 °F)? o . Air purged from system? Piping checked for leaks? o 10. For multiple zones, flow adjusted to distribute heat in all o 4. Air purged from oil piping? Piping checked for leaks? zones? o . Burner door closed, sealed and bolts tight? Observation o 11. Thermostat heat anticipator setting (if available) set port bolt tight? Burner harness plugged in and boiler properly? Refer to “Thermostat wiring,” page 19.

  • Page 24: Annual Service And Start-Up

    — Boiler Manual water boiler 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. In addition, the maintenance and care of the boiler on the boiler except as noted otherwise in designated in Table 4 must be performed to assure maximum this instruction manual. Failure to turn off boiler efficiency and reliability. See the following pages for electrical power could result in electrical detailed instructions. Failure to service and maintain the shock, causing severe personal injury or boiler and system could result in equipment failure. death. Table 4 Annual service and start-up procedure Annual service call check list Comments (follow in the order listed below) Check that boiler area is free from combustible...

  • Page 25: Handling Ceramic Fiber And Fiberglass Materials

    — 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 lit- erature could result in severe personal injury, death or substantial property damage. Handling ceramic fiber and fiberglass materials This product contains fiberglass jacket was written. Other types of respirators may be insulation and ceramic fiber materials in needed depending on the job site conditions. Cur- rent NIOSH recommendations can be found on combustion chamber lining or base panels...

  • Page 26: Check Expansion Tank

    — Boiler Manual water boiler Annual service and start-up (continued) Check all piping for leaks Check expansion tank General guidelines Eliminate all system or boiler leaks. Con- tinual fresh make-up water will reduce Expansion tanks provide space for water to move in and boiler life. Minerals can build up in sec- out as the heating system water expands due to tempera- tions, reducing heat transfer, overheat- ture increase or contracts as the water cools. Tanks may ing heat exchanger, and causing heat be open, closed or diaphragm or bladder type. Follow exchanger failure. Leaking water may also guidelines in this manual for the best location of the...

  • Page 27: Check Boiler Relief Valve

    — Boiler Manual water boiler Annual service and start-up (continued) Check boiler relief valve . After following the warning directions, if the relief valve weeps or will not seat properly, replace the 1. Inspect the relief valve and lift the lever to verify relief valve. Ensure that the reason for relief valve flow as in the following warnings, excerpted from weeping is the valve and not over-pressurization of a relief valve manufacturer’s warning label. Before the system due to expansion tank waterlogging or operating any relief valve, ensure that it is piped undersizing.

  • Page 28: Review With Owner

    — Boiler Manual water boiler 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, not hot, before cleaning. Failure to do so will result in severe personal injury, death or substantial property dam- age.

  • Page 29: Appendix (Removing/Replacing Boiler Jacket, Replacement Parts, Dimensions And Ratings)

    — Boiler Manual water boiler Appendix Removing/replacing boiler jacket .............30 Boiler section assembly parts ............32 Burner door parts ................34 Jacket and control parts ..............36 Dimensions ..................38 Ratings ....................39 Part number 550-141-986/1005...
  • Page 30 — Boiler Manual water boiler Appendix — 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. Then label all wires before disconnecting them at the boiler terminal strip.
  • Page 31 — Boiler Manual water boiler Appendix — Removing/replacing boiler jacket (cont.) 9. Push the Control Pod cover to one side, and gently Figure 20 Jacket components and hardware work the cover retainer hinge on the other side out of the jacket slot to remove the cover. 10. Remove the limit temperature sensor and P/T gauge capillary from the wells in top of the boiler back section. 11. Remove the jacket crosstie by loosening the two screws securing it to the side panels (Figure 19). Lift the crosstie up and disengage the screws from the keyholes.
  • Page 32 — Boiler Manual water boiler Appendix — 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)
  • Page 33 — Boiler Manual water boiler Appendix — Replacement parts (continued) Boiler section assembly parts Part number 550-141-986/1005...
  • Page 34 — Boiler Manual water boiler Appendix — Replacement parts (continued) Burner door parts Item Description Part Number Burner flange bolts (3) each, 5/16"-18 x 3/4" Hex HD SS 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 — Boiler Manual water boiler Appendix — Replacement parts (continued) Burner door parts Part number 550-141-986/1005...
  • Page 36 Control tray assembly (includes tray, limit control, terminal strips, P/T gauge, 386-902-008 ON/OFF switch, wiring, labels) Pressure/Temperature gauge 510-218-052 ON/OFF switch 511-624-645 Weil-McLain logo plate 550-404-306 High limit control, Honeywell L7248C-1030 386-902-006 Wire harness (Not shown) 386-902-011 Barometric draft control (Not shown)
  • Page 37 — Boiler Manual water boiler Appendix — Replacement parts (continued) Jacket and control parts Part number 550-141-986/1005...
  • Page 38 — Boiler Manual water boiler Appendix — 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 550-141-986/1005...
  • Page 39 0.020 1.0 GPH UO-4 1.20 18.3 86.2 6” 0.025 Notes UO-5 1.40 21.5 86.5 6” 0.040 (1) Based on standard test procedures prescribed by the piping and pick-up allowance of 1.1. An addi- United States Department of Energy at combustion tional allowance should be made for unusual pip- condition of 1.0% CO and –0.0” w.c. breeching ing and pick-up loads. Consult local Weil-McLain draft. Sales Office. () Ratings shown are for sea level applications only. (4) See page 11 for minimum breeching and chimney For altitudes above ,000 feet, derate the product sizing. capacity by 4% per 1,000 feet above sea level. () Boiler draft losses are based on operation at 11.% () Net I=B=R ratings are based on net installed radia- . Set breeching draft at –0.0 inch water col- tion of sufficient quantity for the requirements of umn. the building and nothing need be added for normal piping and pick-up. Water ratings are based on a (6) MBH refers to thousands of Btu per hour. Part number 550-141-986/1005...
  • Page 40 — Boiler Manual water boiler Part number 550-141-986/1005...

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