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Boiler Manual
This manual must only be used by a qualifi ed 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.
Series 3
Oil-Fired Water Boiler
• Installation
• Startup
• Maintenance
• Parts
Part number 550-142-182/1014
®
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Table of Contents
Related Manuals for Weil-McLain UltraOil Series 3
Summary of Contents for Weil-McLain UltraOil Series 3
- Page 1 ® Series 3 Oil-Fired Water Boiler Boiler Manual • Installation • Maintenance • Startup • Parts This manual must only be used by a qualifi ed 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.
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Page 2: Ow It Works
– H . . . WATER BOILER OW IT WORKS Weil-McLain logo plate (standard) or 19. Sensor wells Remote Display Module (optional) Boiler limit temperature sensor and P/T gauge capillary and tem- The Remote Display Module (RDM) is used when the optional perature sensor are installed in the top of the rear section. - Page 3 ® Series 3 — Boiler Manual WATER BOILER ® WATER BOILER Part number 550-142-182/1014...
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Page 4: Table Of Contents
® Series 3 — Boiler Manual WATER BOILER Contents ® — H ......2–3 WATER BOILER OW IT WORKS Please read before proceeding ..........5 Owners Responsibilities ............6 Boiler location checklist ............7 Prepare boiler location ............8 Connect breeching .............. 12 Connect water piping ............ -
Page 5: Please Read Before Proceeding
® Series 3 — 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 •... -
Page 6: Owners Responsibilities
® Series 3 — Boiler Manual WATER BOILER Homeowner responsibilities— read and follow completely. Have the boiler and burner installed by a qualifi ed installer. Have the boiler and burner serviced at least annually by a qualifi ed service technician. Review and understand boiler start-up and routine maintenance proce- dures with the service technician. -
Page 7: Boiler Location Checklist
® Series 3 — 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: ❏... -
Page 8: Prepare Boiler Location
® Series 3 — Boiler Manual WATER BOILER Prepare boiler location Provide minimum clearances Figure 1 Minimum clearances to combustible surfaces and recommended minimum service clearances From combustible materials (see Figure 1) 1. Hot water pipes • All directions — ½ inch. (not shown in Figure 1) 2. -
Page 9: Flooring And Foundation
® Series 3 — 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. -
Page 10: Place The Boiler
® Series 3 — Boiler Manual WATER BOILER Prepare boiler location (continued) Place the boiler: Figure 2a To install leveling legs: Insert fi rst shipping channel under boiler leg. Remove outer crate 1. Remove outer crate, leaving boiler on the crate base. 2. -
Page 11: Perform Hydrostatic Pressure Test
® Series 3 — Boiler Manual WATER BOILER 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. -
Page 12: Connect Breeching
® Series 3 — 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. 1. Secure the burner fl ange to the burner door using 4. - Page 13 ® Series 3 — Boiler Manual WATER BOILER Connect breeching (continued) Chimney venting The Ultra Oil boiler is capable of being (continued) pressure fi red. Overfi re pressure may be Connect breeching: positive even with a negative pressure in the chimney. See the Ratings table on Long horizontal breechings, excessive 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. Relief valve •... - Page 15 ® Series 3 — 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.
- Page 16 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).
- Page 17 Figure 10 to all zones. or 11. b. Separate transformer is required to power zone valves. Refer to “Weil-McLain Zone Valve Wiring 2. If system piping is plastic without an oxygen barrier, Guide” for details. a heat exchanger must be used.
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Page 18: Connect Wiring (Note 1)
® Series 3 — Boiler Manual WATER BOILER 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: Thermostat Wiring
® Series 3 — Boiler Manual WATER BOILER Connect wiring • Remove the Control Pod cover to facilitate wire routing. (To Figure 14 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... - Page 20 ® Series 3 — 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 550-142-182/1014...
- Page 21 ® Series 3 — Boiler Manual WATER BOILER Connect wiring (continued) Part number 550-142-182/1014...
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Page 22: Connect Oil Piping
® Series 3 — 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. -
Page 23: Startup Procedure
® Series 3 — 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. -
Page 24: Check-Out Procedure
® Series 3 — Boiler Manual WATER BOILER Check-out procedure ❏ 1. Boiler and heat distribution units fi lled 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
® Series 3 — 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 qualifi ed service to the boiler before any service operation technician. - Page 26 ® Series 3 — 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.
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Page 27: Check Expansion Tank
® Series 3 — 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: Department Of Energy Compliance
® Series 3 — Boiler Manual WATER BOILER Annual service and start-up (continued) Check boiler relief valve Following installation, the valve lever must be operated to ensure that at least once each year 1. Inspect the relief valve and lift the lever to verify fl ow as in the waterways are clear. -
Page 29: Review With Owner
® Series 3 — Boiler Manual WATER BOILER Annual service and start-up (continued) Clean boiler fl ueways and check Figure 17 Access to boiler fl ueways refractory linings Make sure all electrical connections to boiler are turned off and wait until boiler is warm, Flue baffl... -
Page 30: Removing/Replacing Boiler Jacket
® Series 3 — Boiler Manual WATER BOILER 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 — Boiler Manual WATER BOILER 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.
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Page 32: Replacement Parts
® Series 3 — 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 316-900-220 560-234-468 Tie rods (4 required) UO-3 & UO-3R UO-4 560-234-472 UO-5 560-234-477... - Page 33 ® Series 3 — Boiler Manual WATER BOILER Replacement parts (continued) Boiler section assembly parts Part number 550-142-182/1014...
- Page 34 ® Series 3 — Boiler Manual WATER BOILER Replacement parts (continued) Burner door parts Item Description Part Number Burner fl ange 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...
- Page 35 ® Series 3 — Boiler Manual WATER BOILER Replacement parts (continued) Burner door parts Part number 550-142-182/1014...
- Page 36 ® Series 3 — Boiler Manual WATER BOILER Replacement parts (continued) Jacket and control parts Item Description Part Number Jacket front panel assembly (includes sheet metal, plastic, & striker) 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 ® Series 3 — Boiler Manual WATER BOILER Replacement parts (continued) Jacket and control parts Part number 550-142-182/1014...
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Page 38: Dimensions
® Series 3 — Boiler Manual WATER BOILER 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 550-142-182/1014... -
Page 39: Ratings
® Series 3 — Boiler Manual WATER BOILER Ratings ® AHRI Certifi ed Ratings Draft Boiler Flue Shipping Loss Heating Seasonal Rating Water Conn. Weight, Through Boiler Burner Input Capacity Effi ciency (water) Content Size Approx. Boiler Model AFUE % Gallons Inches Pounds... - Page 40 ® Series 3 — Boiler Manual WATER BOILER...