Boiler Manual • Maintenance • Startup • Partsigate.northernplumbing.com/manuals/wm/ultra.pdf · • Startup This manual must ... Startup procedure ... • Do not add cold water

Part number 550-141-986/1005

• Installation

• Startup

Thismanualmustonlybeusedbyaqualifiedheatinginstaller/servicetechnician.Beforeinstalling,readallinstructions,includingthismanual,theburnermanualandanyrelatedsupplements.Performstepsintheordergiven.Failuretocomplycouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.

Oil-Fired Water Boiler

• Maintenance

• PartsBoiler Manual

Part number 550-141-986/1005

water boiler — Boiler Manual

�

The waTer boiler – how iT works . . .

1. Weil-McLainlogoplate(standard)orRemoteDisplayModule(optional)TheRemoteDisplayModule(RDM)isusedwhentheoptionalAFM(item�8)isinstalled.Thedisplayshowsboilerandsystemstatusandisusedtoadjustoperatingparameters.

2. ON/OFFswitch

3. ControlPodcoverfastener

4. Pressure/TemperaturegaugeDisplaysboilerwaterpressureandoutletwatertemperature.

5. Jackettoprearpanel

6. ControlPodcoverThe ControlPodcover ishinged toalloweasyaccessto the aquastat, boiler wiring and optionalAdvanced FeaturesModule(AFM).

7. Jacketsidepanelsjacketsidepanelsareinterchangeable.

8. Jacketrearpanel,withinsulation

9. TerminalstripElectricalconnections,bothlineandlowvoltage,connecttotheterminalstrip.

10. Frontsection

11. Intermediatesections

12. Backsection

13. EnviraCOM®wireharnessLowvoltagewireharnessfromL7�48aquastattotheHoneywellburnerprimarycontrol’sEnviraCOM®connector—acommu-nications port designed to optionally allow you to add greatersystem capability at the time of installation. Examples includetestinstrumentsanddial-inaccessand,inthefuture,efficiencyoptimization, zoning, and sequencers. Look for products withtheHoneywellEnviraCOM®nameindicatingproductsthatarecompatiblewithyournewboiler.

14. BurnerwireharnessLinevoltagewiringtoburner,terminatedinaMolexconnectorinthejacketcrosstie(item19).Anadditionalharnessconnectsfromthecrosstieconnectortotheburner.

15. BurnerdoorhingebracketThehingebracketcanbeinstalledoneithersidetoallowforrightorleft-handswing.

16. Swing-awayburnerdoorThe burnerdoorishingedtoprovideeasyaccesstotheboilerheatexchangerforinspectionandcleaning.

17. RotatingobservationportThe observationportisdesignedtopreventsootfromdepositingonthesightglass.Duringnormaloperationthesight

glassislocatedatthe1�:00position.Toviewtheburnerflame,loosenthecentermountingboltandrotatesothesightglassisinthe6:00position.

18. Overfirepressuretapping1/8”npt,withplug.

19. Jacketcrosstie

20. SensorwellsBoileraquastatsensorandP/Tgaugecapillaryandtemperaturesensorareinstalledinthetopoftherearsection.

21. OutlettappingTheboileroutletwatertappingislocatedinthetopoftherearsection.

22. ReturntappingThe boiler return tapping is located in the bottom of the rearsection.

23. Insulationblanket

24. Boilerdrainvalve

25. Flueconnectionboilerscanbechimneyordirectventedfromtherear

flueopening.

26. KnockoutsinjacketrearforelectricalconduitsAll electrical connections enter in conduits connected to theseknockouts.

27. Boilerreliefvalve

28. AFM(AdvancedFeaturesModule)—OptionalThe boilercanbeequippedwiththeAdvancedFeaturesModule(AFM).TheAFMisasystemcontrolthatprovidesboileroutdoorreset,aboilersetpointtemperature,domestichotwaterpumpoperation,andoutdoorresetthroughtheuseofamixingvalveoravariablespeedinjectionpump.Italsocontrolsstagingandrotationoftwoboilers.

When equipped with anAFM, the boiler requires a �0-ampservice.

29. ElectronicAquastatThe boilerisequippedwithaHoneywellL7�48electronicaquastat.TheL7�48sensesboilerwatertemperatureandcallforheatfromthesystemthermostatorAFMtooperatetheburnerandboilercirculator.

30. Burner, with cover

31. Jacketfrontpanel

32. Levelinglegs

Part number 550-141-986/1005 �


The waTer boiler

Part number 550-141-986/1005


4

Commonwealth of Massachusetts

WhentheboilerisinstalledwithintheCommon-wealthofMassachusetts:

• Thisproductmustbeinstalledbyalicensedplumber.

• Ifantifreezeisused,areducedpressureback-flowpreventerdeviceshallbeused.

Contents

The waTer boiler — how iT works ......................................2–3Please read before proceeding ...........................................................5Boiler location checklist ......................................................................6Prepare boiler location .........................................................................7Connect breeching .............................................................................11Connect water piping .........................................................................13Connect wiring (Note 1) .........................................................................18Connect oil piping .............................................................................21Startup procedure ..............................................................................22Check-out procedure .........................................................................23Annual service and start-up ..............................................................24Appendix (removing/replacing boiler jacket, replacement parts, dimensions and ratings) ..................................................................... 29Note 1: See burner manual for wiring and additional startup and operating information. Also

see AFM manual if used.

Whencallingorwritingabouttheboil-er—Pleasehavetheboilermodelnumberfromtheboiler rating labeland theCPnumberfromtheboilerjacket.YoumaylisttheCPnumberinthespaceprovidedon the InstallationCertificate foundonpage��.

Consider piping and installation whendeterminingboilerlocation.

Any claims for damage or shortage inshipment must be filed immediatelyagainst the transportation company bytheconsignee.

Thetermsbelowareusedthroughoutthismanualtobringattentiontothepresenceofhazardsofvariousrisklevelsortoimportantinformationconcerningthelifeoftheproduct.

Indicatespresenceofhazardsthatwillcauseseverepersonalinjury,deathorsubstantialpropertydamage.

Indicatespresenceofhazardsthatcancauseseverepersonalinjury,deathorsubstantialpropertydamage.

Indicatespresenceofhazards thatwillorcancauseminorpersonalinjuryorpropertydamage.

Indicatesspecialinstructionsoninstallation,operationormaintenancethatareimportantbutnotrelatedtopersonalinjuryorpropertydamage.

Part number 550-141-986/1005 �


Please read before proceeding

Read all instructions —• Readallinstructions,includingthismanual,theburner

manualandanyrelatedsupplements.Performstepsintheordergiven.Failuretocomplycouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.

When servicing boiler —• Toavoidelectricshock,disconnectelectricalsupplybefore

performingmaintenance.

• Toavoidsevereburns,allowboilertocoolbeforeperform-ingmaintenance.

Boiler operation —• Donotblockflowofcombustionorventilationair to

burner.

• Shouldoverheatingoccurorfuelsupplyfailtoshutoff,donotturnoffordisconnectelectricalsupplytocirculator.Instead,shutoffthefuelsupplyatalocationexternaltotheappliance.

• Donotusethisboilerifanyparthasbeenunderwater.Electrical and mechanical failures may cause electricshockandfirerisks.Immediatelyinspectchimneyorvent,boiler,burnerandcontrols.Cleantheboilerfluewaysandreplaceallelectricalandmechanicalcontrols;allelectricalwiring;oilburnerandcontrols;insulationandchamberlining.

Boiler firing rate —• Donotreducethefiringrateoftheboiler.Useonlytheoil

nozzlesizespecified.Reducedinputwillcausecondensa-tionintheboilerandventpiping.

Ceramic fiber materials —• Theboilercontainsceramicfibermaterials.Usecare

when handling these materials per instructions onpage��ofthismanual.Failuretocomplycouldresultinseverepersonalinjury.

Boiler water —• Thoroughly flush the system (without boiler con-

nected)toremovesediment.Theboilerheatexchangercanbedamagedbybuild-uporcorrosionduetosedi-ment.

• Do not use petroleum-based cleaning or sealingcompoundsinboilersystem.Gasketsandsealsinthesystemmaybedamaged.Thiscanresultinsubstantialpropertydamage.

• Donotuse“homemadecures”or“boilerpatentmedi-cines.” Serious damage to boiler, personnel and/orpropertymayresult.

• Continual fresh make-up water will reduce boilerlife.Mineralbuildupinboilersectionsreducesheattransfer, overheats the sections, and causes failure.Additionofoxygencarriedinbymake-upwatercancause internal corrosion. Leaks in boiler or pipingmustberepairedatoncetopreventmake-upwater.

• Donotaddcoldwatertohotboiler.Thermalshockcancauseheatexchangertocrack.

Freeze protection fluids —• When using antifreeze — Do not use automotive,

ethylene glycol, undiluted or petroleum-based an-tifreeze. See theWARNING on page �� for moreinformation.

Followtheguidelinesbelowtopreventpossibleseverepersonalinjury,deathorsubstantialpropertydamage.

Followtheguidelinesbelowtopreventseverepersonalinjury,deathorsubstantialpropertydamage.

Fuel• Donotusecrankcasedrainingsoranyoil containing

gasoline.Seeburnermanualforproperfueloil.

• Neverburngarbageorpaperintheboiler.Neverleavecombustiblematerialaroundboiler.

Do not tamper with burner/controls• Always follow specific instructions when starting up

boilerorperformingroutinemaintenanceorservice.

Do not start burner if:• Donotattempttostartburnerwhenexcessoilhasac-

cumulatedincombustionchamber,whenunitisfullofvapor,orwhencombustionchamberisveryhot.

• Donotstartburnerunlessbreechingandburnermount-ingdooraresecuredinplace.

Part number 550-141-986/1005


6

Boiler location checklist

Before placing the boiler, verify:

❏

United States installations must comply with all applicable U. S. codes:

• Applicable state, local and national codes.• National Electrical Code.• Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/

ASME CSD-1, when required.

Canadian installations must comply with all applicable Cana-dian codes:

• Canadian Standards Association CSA B139, Installation Code for Oil-Burning Equip-ment.

• CSA C22.1 Canadian Electrical Code Part One.• Applicable provincial and local codes.

❏ Consider use of space

• The boiler area must be kept free of combustible materials, gasoline and other flam-mable liquids.

• The boiler must be installed so that boiler and system components are protected from dripping or spraying water or rain during operation or service.

❏ Moving boiler to location• See manual pages 38 and 39 for boiler dimensions and weights.• If necessary, the boiler jacket can be removed if desired for handling. See manual

pages 30 and 31 for instructions.

❏ Clearances

• Provide minimum clearances to combustible materials and for servicing boiler.• Ensure that the swing-away burner door can swing open freely. (The hinge can be

mounted on right or left side.)• See manual page 10 for instructions on changing door hinge location.

❏ Flooring and foundation

• Provide level flooring (non-carpeted combustible flooring is acceptable if boiler level-ing legs are installed).

• Provide foundation if necessary.• See manual page 8.

❏ Combustion and ventilation air openings

• Boiler room must provide adequate combustion air and ventilation.• Unless burner uses ducted outside air for combustion, the boiler room must provide

combustion air openings.• See manual page 8.

❏ Venting

Chimney venting:• Ensure the vent pipe can be routed to the chimney, and that the chimney connection

is higher than the boiler flue outlet.• Ensure the vent piping will provide minimum clearances shown on manual pages 7

and 11.• See manual pages 11 and 12 for venting information.

Direct venting:• The Ultra oil boiler can be direct vented, using the Field Controls Direct Vent Kit,

model number FDVS-46, and vent pipe model number FVOP-415. Verify that the vent piping can be installed and routed to the outside wall as specified in the Field Con-trols instruction manual.

• Ensure the vent piping will provide minimum clearances shown on manual page 7.

❏ System water piping• Check location of system water piping connections to be sure boiler can be properly

connected.• See manual pages 13 through 17.

❏ Fuel supply • See manual page 21 for routing of fuel lines.

❏ Electrical power

• The boiler requires 120 vac power and connection to a room thermostat or other device to initiate call for heat.

• If equipped with an AFM, the boiler requires a 20-amp service.• See manual pages 18 through 20.

Failuretokeepboilerareaclearandfreeofcombustiblematerials,gasolineandotherflammableliquidsandvaporscanresultinseverepersonalinjury,deathorsubstantialpropertydamage.

IftheUltraboilerwillreplaceanexistingboiler,checkforandcorrectsystemproblems,suchas:•Systemleakscausingoxygencorrosionorheatexchangercracksfromhardwaterdeposits;•Incorrectly-sizedexpansiontank;•Lackoffreezeprotectioninboilerwatercausingsystemandboilertofreezeandleak.Failuretocorrectsuchconditionscouldresultinfailureofthenewboiler.

Part number 550-141-986/1005 7


Prepare boiler location

Figure 1 Minimum clearances to combustible surfaces and Provide minimum clearancesFromcombustiblematerials(seeFigure1)1. Hotwaterpipes

• Alldirections—½inch. (notshowninFigure1)

�. Double-wallventpipe• Alldirections—6inches.

�. Single-wallventpipe.• Alldirections—18inches.

4. Boilerjacketsurfaces• TopofControlPodcover—1�inches.• Sidesandback—�inches.

�. Burnercover• Alldirections—�inches.

Combustibleclearancesalwaystakepre-cedenceoverserviceclearances.

Forserviceaccess(seeFigure1)

If you do not provide the minimumservice clearances shown, it might notbepossibletoservicetheboilerwithoutremovingitfromthespace.

1. Recommendedserviceclearances:• Frontofburnercover—�0inches• Jackettop—�4inches• Jacketsidesandback—6inches• Burnerdoorswingclearance—1�inchesminimum

(doormustswingfullyopen)

Part number 550-141-986/1005


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Air openings for combustion and ventilation air

Adequatecombustionandventilationairensurespropercombustionandreducesrisk of severe personal injury or deathfrompossiblefluegasleakageandcarbonmonoxideemissions.

Do not install exhaust fan in boilerroom.

Natural infiltrationOlder buildings with single-pane windows, minimalweather-strippingandnovaporbarrieroftenprovideenough natural infiltration and ventilation withoutdedicatedopenings.

Tight constructionNew construction or remodeled buildings are mostoften built tighter.Windows and doors are weather-stripped, vapor barriers are used and openings inwallsarecaulked.Asaresult,suchtightconstructionisunlikelytoallowpropernaturalairinfiltrationandventilation.

Follow code requirementsFollow state, provincial or local codes when sizingadequatecombustionandventilationairopenings.Inabsence of codes, use the following guidelines whenboiler is inaconfinedroom(definedbyNFPA�1aslessthan7�00cubicfeetper1GPHinputofallappli-ancesinarea.Aroom8ft.highx��.�ft.x��.�ft.is7�00cu.ft.).

Provide two permanent openingsProvide two permanent openings — one within 1�inchesofceiling,onewithin1�inchesoffloor.Mini-mumheightorlengthdimensionofeachrectangularopeningshouldbeatleast�inches.

Air from inside the buildingWhen insideair isused—eachopeningmust freelyconnectwithareashavingadequate infiltration fromoutside.Eachopeningshouldbeatleast140sq.in.per1GPHinput(1sq.in.per1000Btuinput)ofallfuel-burningappliancesplus requirements foranyequip-ment thatcanpull air fromroom(includingclothesdryerandfireplace).

Air from outside the buildingWhen outside air is used — connect each openingdirectlyorbyductstotheoutdoorsortocrawlorat-tic space that freelyconnectswithoutdoors.Sizeperbelow:

• Throughoutsidewallorverticalducts—atleast��sq.in.per1GPHinput(1sq.in.per4000Btuinput)ofallfuel-burningappliancesplusrequirementsforanyequipmentthatcanpullairfromroom(includ-ingclothesdryerandfireplace).

• Throughhorizontalducts—atleast70sq.in.per1GPHboilerinput(1sq.in.per�000Btuinput)ofallfuel-burningappliancesplusrequirementsforanyequipmentthatcanpullairfromroom(includingclothesdryerandfireplace).

• Whereductsareused,theyshouldhavesamecross-sectionalareaasfreeareaofopeningstowhichtheyconnect. Compensate for louver, grille or screenblockagewhencalculatingfreeairopenings.Referto theirmanufacturer’s instructions fordetails. Ifunknown,use:—Woodlouvers,whichprovide�0-��%freeair.—Metallouversorgrilles,whichprovide 60-7�%freeair.

Locklouversinopenpositionorinterlockwithequip-menttoproveopenbeforeboileroperation.

Flooring and foundationFlooring1. Installonanylevel,properly-supported,andnon-

carpeted surface.Flooringmaybe combustible ifboilerlevelinglegsareinstalled.

�. Ensuretheflooringiscapableofhandlingtheboilerweight(seepage�9forweightandwatervolume).

ResidentialgarageinstallationsInstallboilersotheburnerisatleast18inchesabovethefloortoavoidcontactwithgasolinefumes.

FoundationProvide a level concrete, masonry or cement blockfoundationiftheflooringcouldbecomefloodedorisnotlevel.SeeTable1forfoundationsizerequired.

Table 1 Boiler foundation size (when req’d)

ModelLength(inches)

Width(inches)

Height, min.(inches)

UO-3 49 23 2

UO-4 53 23 2

UO-5 57 23 2

Prepare boiler location (continued)

Part number 550-141-986/1005 9



Place the boiler:Removeoutercrate1. Removeoutercrate,leavingboileronthecratebase.

�. Removethecirculatorandbarometricdampercartonsfromthecratebase.

�. UO-�boilersonly—Removethetwofluebafflesfastenedtothecratebasebehindtheboiler.

4. Removethetwoshippingchannelsbylooseningandremovingthefournuts.Savetheshippingchannelsforlevelingleginstallation.

�. Removethejacketcrosstiefastenedtothecratebase.

Installthelevelinglegsifused(requiredifboilerisplacedoncombustibleflooring)

Thelevelinglegsmustbeinstallediftheboilerisplacedoncombustibleflooring.

Asecondperson,orothermeans,isrequiredtostabilizetheboilerduringlevelingleginstallation.Failuretodosocouldresultinseverepersonalinjuryorpropertydamage.

Wearheavyleatherworkgloveswhenhandlingtheshippingchannelsinthefollowingstepstoavoidpotentialsevereper-sonalinjury.

1. (Figure�a)Useonechannelasalevertoraisethefrontoftheboiler.

�. (Figure�a)Inserttheotherchannelbetweentheboilerlegandcratebase.Placethechanneldirectlyoverthecratebaserunner,asshown.

�. (Figure�b)Liftthechannelundertheboilerlegslightly.

4. (Figure�b)Slidetheotherchannelundertheotherboilerleg.Placethechanneldirectlyoverthecratebaserunner,asshown.

�. (Figure�)Withtheboilerrestingsecurelyonthetwoshippingchan-nels,screwalevelinglegineachboilerleghole.Screwlevelinglegsincompletely.

Toavoidpotentialpersonalinjuryorpropertydamage,DONOTattempttoinsertlevelinglegsunlesstheboilerissecurelyseatedonbothshippingchannels.

6. Reversesteps1through4abovetoremovetheshippingchannels.Leavetheboileronthecratebase.

7. Followsteps1through6onthebacksideoftheboilertoinstalllevelinglegsintherearsectionlegs.

8. Leavetheboileronthecratebase.

Removeboilerfromcratebase

Boilersmaybetopheavy.Usecautionwhenhandlingtoavoidpersonalinjuryorpropertydamage.

1. Attachthecrosstietothejacketsidepanelsusingthetwoscrewslocatedinthebarometricdampercarton.Thenremovetheboilerfromthecratebase.

Donotremovetheboilerfromthecratebasewithoutfirstinstallingthejacketcrosstie.Theboilerwiringharnessesorconnectorscouldbedamaged.

�. Ifnecessary,theboilerjacketcanberemovedforhandling.Seepages�0and�1inthismanualforthejacketremoval/replacementprocedure.

Figure 2a To install leveling legs: Insert first shipping channel under boiler leg.

Figure 3 Inserting levelling legs

Figure 2b To install leveling legs: Insert second shipping channel under

Part number 550-141-986/1005


10

Perform hydrostatic pressure test:Seepages�and�forboilerfeaturelocations.

1. Installairventinreliefvalvetapping.

�. Plugsupplyandreturntappings.

�. Installtheboilerdrainvalveshippedwithboiler.

4. Fillboiler.

�. Ventallair.

6. Pressuretestboilerat1½timesworkingpressure.

Donotleaveboilerunattended.Coldwaterfillcanexpandanddamagecastiron,resultinginseverepersonalinjury,deathorsubstantialpropertydamage.

7. Checkformaintainedgaugepressureforatleast10minutes.Visuallycheckforleaksifgaugepressuredrops.

8. Drainboiler.Repairleaksiffound.

Do not use petroleum-based sealing compounds to repairleaks. Damage to system components can result, causingpropertydamage.

9. Retestboilerafterrepairingleaks.

10.Removeairventandplugs.Installthereliefvalve(shippedinbarometricdampercarton).

Boiler preparationChangingdoorhingeTheboilerisshippedwiththeburnerdoorhingedontheleftside.Thehingebracketcanberelocatedtotherightsideifdesired.SeeFigure4.

1. Removejacketfrontpanel.

�. Removeandretainburnerdoorscrewsandwashersusedtofastentheburnerdoortothefrontsection(oneoneachsideofdoor).

�. Carefully lift theburnerdoor so thedoorpins liftoutof thehingebracket.

4. Settheburnerdoorasidetemporarily.

Theburnerdoorisheavy.Handlecarefullytoavoidpotentialforpersonalinjury.

Donotdamagetheburnerdoorinsulationwhenhandling.

�. Thehingebrackethaskeyholeslots.Loosenthetwoscrewssecuringthehingebrackettothefrontsection.Removethehingebracket.

6. Loosenthetwoscrewsontheoppositeside.Placethehingebracketonthatsideandtightenthetwoscrewstosecurethebracket.Alsotightenthetwoscrewsontheotherside.

7. Carefullylifttheburnerdoorandpositionsothedoorpinsslideintothehingebracketholes.Thelowerpinislongerthantheupper.Soalignthelowerpin,thentheupper.

8. Replaceburnerdoorscrewsandwashersusedtofastentheburnerdoortothefrontsection(oneoneachsideofdoor).

Fluebaffles—UO-3ONLY–1.0GPHfiringrateONLYOnUO-�boilersfiredat1.0GPHONLY,installthetwoflue bafflessup-pliedwiththeboiler.Seepage��forlocation.

Figure 4 Burner door hinge installation


DONOTinstallbafflesonUO-�boilersfiredat0.8GPH.Fluegascondensationwillresult,causingcorrosiondamagetoboilerandventsystem.

Combustionchamberfloorblanket—UO-3ONLY–0.8GPHfiringrateONLYOnUO-�boilersfiredat0.8GPHONLY,placethece-ramic fiber floor blanket(suppliedintheUO-�lowfiringratekit)onthefloorofthecombustionchamber.Seepage��forlocation.

Iftheboilerhasfluebafflesinstalled,youmustremovethebafflesbeforechangingtothelowfiringrate.Fluegascondensa-tionwillresult,causingcorrosiondamagetoboilerandventsystem.

Checkchamberandburnerdoor1. Checkforsecureplacementofinsulationonburner

door.

�. UO-�,0.8GPHfiringrateONLY—Checkforsecureplacementofcombustionchamberfloorblanket.

�. Visuallycheckburnermountingdoorandobservationportseals.

Verify gas-tight seal to prevent possibleflue gas leakage and carbon monoxideemissions,whichcanleadtosevereper-sonalinjuryordeath.

Part number 550-141-986/1005 11


Connect breeching

Direct ventingTheUltraOilboilercanbedirectventedusingtheFieldControlsDirectVentKit,modelnumberFDVS-46,andventpipemodelnumberFVOP-41�.Ventlengthsarelimitedto1�feet.Airintakelengthsarelimitedto��feetofrigid4-inchpipe.Donotuseflexibledryervent.Refertoinstructionsprovidedwiththeventkitforventandairpipinginstallationprocedures.

Chimney ventingGeneralchimneyrequirements:TheUltraOilboilerisdesignedfornaturaldraftfiring.Connectboilertoverticalchimney.

• NFPA�11requireschimneytobelinedbeforecon-nectingtoboiler.

Topreventdowndrafts,extendchimneyatleast�feetabovehighestpointwhereitpassesthroughroofand�feethigherthananyportionofbuildingwithin10feet.Increasechimneycross-sectionalareaandheightatleast4%per1,000feetabovesealevel.

• Minimumclearancesfromventpipetocombustiblematerial:

•Type“L”doublewallvent— 6inches

•Singlewallvent— 18inches

• Minimumchimneysizesshouldbeused.

Oversized chimneys, outside masonrychimneysand/orderatedinputscanresultincondensationinchimney.

Table 2 Chimney venting — vent sizing

Model

Minimum breeching diameter(inches)

Minimum I=B=R chimney size

(inches)

Minimum chimneyheight(feet)

Rect. Round

UO-3 58 x 8

(6¾ x 6¾ liner)

6 15UO-4 6

UO-5 6

Note: boiler flue connection is 6-inch diameter

Install the burner1. Securetheburnerflangetotheburnerdoorusing

thethreeboltsprovided.

�. Checkforsecureplacementofinsulationandsealingropeontheburnerdoor.


�. Closetheburnerdoorandsecureinplacewiththeburnerdoorscrewsandwashers.

4. Follow the burner manual and boiler manual(pages19to�1)towiretheburnerandconnectfuellines.

• Useventmaterialapprovedbylocalcodesforoil-firedburners.Intheirabsence,referto:• NFPA�1,InstallationofOil-BurningEquipment.• NFPA�11,StandardforChimneys,Fireplaces, VentsandSolidFuelBurningAppliances.• InCanada,refertoCSAB1�9,Installation CodeforOil-BurningEquipment.

Insufficient draft can cause flue gasleakage and carbon monoxide emis-sions,whichwillleadtoseverepersonalinjuryordeath.

Inspectexistingchimneybeforeinstall-ingnewboiler.Failuretodoanyofthefollowingwillresultinseverepersonalinjuryordeath:

• Cleanchimney, includingremovalofblockage.

• Repair or replace damaged pipe orliner.

• Repairmortarandjoints.

Part number 550-141-986/1005


1�

Connect breeching (continued)

Figure 5 Breech connection, typical, for gravity venting into chimney

Chimney venting (continued)

Connectbreeching:

Long horizontal breechings, excessivenumberofteesandelbowsorotherob-structionsrestrictingcombustiongasflowcanresultinpossibilityofcondensation,flue gas leakage and carbon monoxideemissions,whichcanleadtosevereper-sonalinjuryordeath.

1. Connect full-sized breeching when possible. SeeTable�,page11,andFigure�,below.

�. Connectionmustbemadeabovebottomofchimneytoavoidblockage.Breechingmustnotenterchim-neyfarenoughtocauseobstruction.Usethimbleorslipjointwherebreechingenterschimneytoallowremovalforcleaning.

�. When burner and boiler are properly installed,breeching draft will be approximately -0.01” to-0.0�”W.C. Install barometric control in breech-ing,percontrolmanufacturer’sinstructions,whenexcessdraftneedstoberelievedortocomplywithapplicablecodesandregulations.Usedraftgaugetoadjustproperopening.

TheUltraOilboiler iscapableofbeingpressurefired.Overfirepressuremaybepositive even with a negative pressureinthechimney.SeetheRatingstableonpage�9forboilerdraftloss.

Thepressureinthebreechingandchim-ney must always be negative unless thechimney and breeching are constructedof vent piping designed for pressurizedventing.

4. Aninduceddraftfanforthechimneymaybeneces-saryif:• Excessiveresistancetoflowofcombustiongases can

beexpected.• Cross-sectionalareaofchimneyissmallerthanmini-

mumrecommended.• Chimneyheightislessthanrecommended.

�. Whenusinganinduceddraftfan:• Sealallventjoints.• Interlockburnerwithfanoperation.

Part number 550-141-986/1005 1�


General piping information:ASMEorCanadianrequirements• IfinstallationistocomplywithASMEorCanadian

requirements,anadditionalhightemperaturelimitisneeded.Installcontrolinsupplypipingbetweenboilerandisolationvalve.Setcontroltoaminimumof�0°Fabovesetpointoftheboileraquastat.Maxi-mumallowablesetpointis��0°F.Wirecontrolasshownonwiringdiagram(page�0).

Lowwatercutoffdevices• Usealowwatercutoffdevicewhen:

• Boilerisinstalledaboveradiationlevel.• Requiredbycertainstateorlocalcodesorinsurance

companies.

• Usealowwatercutoffdesignedforwaterinstalla-tions.

• Probe-typeisrecommended.

• Purchase and install in tee in supply line aboveboiler.Wireperwiringdiagram,page�0.

Backflowprevention• Usebackflowcheckvalve incoldwater supplyas

requiredbylocalcodes.

Install piping:Pipesizing• SeeTable�forpipesizingfornear-boilerpipingand

single-zonepiping.

Near-boilerpiping(with diaphragm expansion tank)• SeeFigure6,page14.

Near-boilerpiping(with closed expansion tank)• SeeFigure7,page14.

Multiple-zonepiping• Seepage1�.

Low-temperaturesystempiping• Seepage16.

Chillersystempiping• Seepage17.

Formultiple-boilerpiping• RefertoWeil-McLain’s“Primary/SecondaryPiping

Guide.”

Reliefvalve• Installreliefvalveverticallyinelbowsupplied.See

Figure6or7forlocation.

• SeeWARNINGatright.

• Alsorefertotagattachedtoreliefvalveformanu-facturer’sinstructions.

Relief valve discharge piping:Toavoidwaterdamageorscaldingduetoreliefvalveoperation:

• Discharge line must be connected toreliefvalveoutletandruntoasafeplaceof disposal. Terminate the dischargeline to eliminate possibility of severeburnsshouldthevalvedischarge.

• Dischargelinemustbeasshortaspos-sibleandbethesamesizeasthevalvedischarge connection throughout itsentirelength.

• Discharge line must pitch downwardfromthevalveand terminateat least6” above the floor drain where anydischargewillbeclearlyvisible.

• The discharge line shall terminateplain, not threaded, with a materialserviceablefortemperaturesof�7�°Forgreater.

• Donotpipethedischargetoanyplacewherefreezingcouldoccur.

• Noshutoffvalveshallbeinstalledbe-tweenthereliefvalveandboiler,orinthedischargeline.Donotplugorplaceanyobstructioninthedischargeline.

• Failuretocomplywiththeaboveguide-linescouldresultinfailureofthereliefvalvetooperate,resultinginpossibil-ityofseverepersonalinjury,deathorsubstantialpropertydamage.

• Test the operation of the valve afterfilling and pressurizing system bylifting the lever. Make sure the valvedischarges freely. If the valve fails tooperatecorrectly,replaceitwithanewreliefvalve.

Connect water piping

Table 3 Water piping sizing

ModelPiping tosystem(inches)

Piping from system(inches)

UO-3 1¼ 1¼

UO-4 1¼ 1¼

UO-5 1½ 1½

Note: sizing based on 20°F temperature rise through boiler.

Part number 550-141-986/1005


14

Connect water piping (continued)

DIAPHRAGMexpansiontank(Figure6)• Makesureexpansiontanksizewillhandleboilerand

systemwatervolumeandtemperature.Tankmustbelocatednearboilerbeforeinlettocirculator.Seetankmanufacturer’sinstructionsfordetails.

Undersizedexpansiontankscausesystemwater to be lost from relief valve andmakeup water added through fill valve.Eventualsectionfailurecanresult.

CLOSEDexpansiontank(Figure7)• Ensureexpansiontanksizewillhandleboilerand

systemwatervolumeandtemperature.

Undersizedexpansiontankscausesystemwater to be lost from relief valve andmakeup water added through fill valve.Eventualsectionfailurecanresult.

• Pitchanyhorizontalpipinguptowardstank1inchper�feetofpiping.

Figure 6 Near-boiler piping, with diaphragm expansion tank

Figure 7 Near-boiler piping, with closed expansion tank

Part number 550-141-986/1005 1�



Piping MULTIPLE ZONES — System temperature 140 °F or higher

1. Follow instructions on page 1� and 14 to installpipingnearboiler.

�. Zoningwithcirculators(Figure8)a. Size each circulator to individual circuit require-

ments.b. Removecirculator(whenfurnishedasstandardequip-

ment).c. Installbalancingvalvestoadjustflowtodistributeheat

toallzones.

Figure 8 Multiple zoning with circulators – Figure 9 Multiple zoning with zone valves – Temperatures 140 °F and higher

d. Separaterelayisrequiredforeachcirculator.

�. Zoningwithzonevalves(Figure9)a. Install balancing valves to adjust flow to distribute

heattoallzones.b. Separatetransformerisrequiredtopowerzonevalves.

Referto“Weil-McLainZoneValveWiring Guide”fordetails.

1 Isolation valve

2 Flow control valve

3 Circulator

4 Zone valve

5 Drain valve

Part number 550-141-986/1005


16


Figure 11 Multiple zoning with zone valves – Figure 10 Multiple zoning with circulators –

1. Ifsystemwatertemperaturerequirementsarelessthan 140 °F, such as radiant panels or convertedgravitysystems,usepipingasshowninFigure10or11.

�. Ifsystempipingisplasticwithoutanoxygenbarrier,aheatexchangermustbeused.

�. Follow instructions on page 1� and 14 to installnear-boilerpiping.

4. Zoningwithcirculators(Figure10)a. Size each circulator to individual circuit require-

ments.b. Removecirculator(whenfurnishedasstandardequip-

ment).c. Installbalancingvalvestoadjustflowtodistributeheat

toallzones.d. Separaterelayisrequiredforeachcirculator.

�. Zoningwithzonevalves(Figure11)a. Installbalancingvalvestoadjustflowtodistributeheat

toallzones.b. Separatetransformerisrequiredtopowerzonevalves.

Referto“Weil-McLainZoneValveWiring Guide”fordetails.

6.Tosetthevalves,7aand7b:a. Setthevalveswhilethesystemiscool,settingforthe

coldest expected water temperature (usually 60 °Fsincethesystemwilloftendroptoroomtemperaturebetweencycles).

b. Startwithvalve7afullyclosedand7bfullyopen.c. Graduallyopenvalve7awhileclosing7buntil the

temperatureatgauge8reads1�0°Fwhengauge4areads60°F.

d. Notethatvalve7aregulatestheamountofhotwaterfromtheboilersupply,whichmixeswithreturnwater.Valve7bregulatestheamountofsystemwaterflowingthroughtheboilersecondaryloop.

Piping MULTIPLE ZONES — System temperature below 140 °F

1 Isolation valve2 Flow control valve3 Circulator4 System temperature gauges5 Zone valve

6 Drain valve7 System temperature valves. Adjust valves 8 Blend temperature gauge9 Boiler temperature gauge (not shown)

Part number 550-141-986/1005 17



Piping boiler in refrigeration systems (Figure 12)

• Installboilersothatchilledmediumispipedinparallelwithheatingboiler.Useappropriatevalvestopreventchilledmediumfromenteringboiler.ConsultI=B=RInstallationandPipingGuides.

• Ifboilerisconnectedtoheatingcoilslocatedinairhandlingunitswheretheycanbeexposedtorefrigeratedair,useflowcontrolvalvesorotherautomaticmeanstopreventgravitycirculationduringcoolingcycle.

Figure 12 Piping boiler in a system with chiller

Part number 550-141-986/1005


18

Connect wiring

General wiring requirements Electric shock hazard.Cancausesevere

personalinjuryordeathifpowersource,includingserviceswitchonboiler,isnotdisconnectedbeforeinstallingorservic-ing.

Installationsmustfollowthesecodes:• UnitedStates:

National Electrical Code,ANSI/NFPA 70, latesteditionandanyadditionalnational,stateorlocalcodes.

• Canada:

CSAC��.1CanadianElectricalCodePart1andanylocalcodes.

Wirerequirements• WiringmustbeN.E.C.Class1.

• If original wire supplied with boiler must be re-placed, type 10� °C wire or equivalent must beused.

• Supplywiring:• Boileronly—14gaugeorheavier.• BoilerwithoptionalAFM—1�gauge.

Electricalrequirements• BoilersnotequippedwithanAFMcanbesupplied

bya1�-ampservice.

• Boilers equippedwithanAFMrequirea�0-ampservice.

Electricalgrounding• Provideelectricalgroundatboilerasrequiredby

codes.

Wiring entrances (see Figure 13)Terminalstripaccess• Remove the tworetainer screws in the jacket top

panel(atrearoftheboiler)andremovethejackettoppanel.

• Release the Control Pod cover by loosening theretainerscrewinthetopcenterofthecover.Swingthecoveropentorevealtheboilerterminalstrip.

• Remove the Control Pod cover to facilitate wirerouting.(Toremove,pushtheControlPodcovertooneside,andgentlyworkthecoverretainerhingeontheothersideoutofthejacketslot.)

Figure 13 Terminal strip access

120-volt wiringConduits• Connecteachconduitsupplyingline-voltagewiring

toorfromtheboilertoaconduitopeningintheupperportionofthejacketrearpanel.

• All field-provided line-voltage wiring must besheathedinflexiblemetalconduit.

Additionallimits• Ifrequiredbystateorlocalcodes,provideadditional

limitsasneeded.

• Whenusingadditionallimits,removethefactory-installedjumperbetweenboilerterminalstripter-minals18and19.

• Connecttheadditionallimitsinseriesandwiretoboilerterminalstripterminals18and19.

Part number 550-141-986/1005 19


Circulator• Thecirculator is shippedwiththeboiler,butnot

installedorwired.

• Wirethecirculatortotheboilerterminalstripasshownontheboilerwiringdiagram.Providehot,neutral and ground wires, routed in metal con-duit.

Thermostat wiring• Installthermostatoninsidewallawayfrominflu-

ences of drafts, hot or cold water pipes, lightingfixtures,televisions,sunraysorfireplaces.

• Followinstructionswiththermostat.

• Ifthethermostathasaheatanticipator,settheheatanticipator per the limit control manufacturer’srecommendation.

Burner wiring (see Figure 14)• Theburnerharnessesincorporatedisconnectplugs,

providing a convenient way to disconnect wiringwhenburnermountingdoorisopened.

Failuretodisconnecttheburnerwiringhar-nesses before opening the burner door cancausedamage to theburnerandboilerwir-ing.

Optional AFM installation• SeeseparateAFMinstructionswhenused.

When wiring is completed:• Reinstall the Control Pod cover, close cover and

tightentheretainerscrew.

• Replacejackettopandsecurewithscrews.

Figure 14 Burner harness and EnviraCOM®

Connect wiring (continued)

Part number 550-141-986/1005


�0

Connect wiring (continued)

Figure 15 Boiler and burner wiring, standard equipment Thiswiringdiagramisforstandardboilerequipment.ForwiringwithoptionalAFM,seeAFMinstructions.

Part number 550-141-986/1005 �1


Connect oil piping

Figure 16 Recommended oil piping connection to burner (follow applicable code requirements and burner manual for component locations)

General oil piping requirements:• Locationandinstallationofoiltanks,oilpipingand

burnersmustfollow:• NFPA�1,StandardfortheInstallationofOil-Burning

Equipment.• In Canada, CSA B1�9, Installation of Oil-Burning

Equipment.• Localcodesandregulations.• Informationprovidedwithburnerandfuelpump.

• Ifanypartoffueloiltankisabovelevelofburner,theuseofananti-siphondeviceishighlyrecommendedtopreventflowofoilincaseofoillinebreak.

• Supportoillinesasrequiredbycodes.

• Maketankconnectionswithswingjointsorcoppertubingtopreventbreaking,incasethetanksettles.

Makeswingjointssotheywilltightenastanksettles.Non-hardening pipe joint compounds should beusedonallthreads.

DonotuseTeflontapeasanoilpipeseal-ant.Itcancausevalvestofail,creatinghaz-ards.Donotusecompressionfittings.

• Undergroundpipemustberuninacasingtopre-ventoilleakingintogroundorunderfloor.Checklocalcodesforinformation.

Oil piping connection at burner:• See Figure 16 for recommended connection at

burner,allowingburnermountingdoor toswingopencompletelyforservicing.

Part number 550-141-986/1005


��

Startup procedure

Tipsforwatersystems:• Check boiler and system piping for leaks. Continual makeup water

willreduceboilerlife.Mineralscanbuildupinsections,reducingheattransferandcausingcastirontooverheat,resultinginsectionfailure.

FailuretomaintainrecommendedpHandrepairleakscancausesectionironcorrosion,leadingtosectionfailureandleaks.Donotusepetroleum-basedsealingorstop-leakcom-poundsinboilersystems.Damagetosystemcomponentscanresult.

• ForpHconditionsoutside7.0to8.�rangeorunusuallyhardwaterareas(above7grainshardness),consultlocalwatertreatmentcompany.

To place in operation:1. Verifyboilerisfilledwithwater.

�. Openburnermountingdoorandverifyburnerdoorinsulationsectionsareinproperposition.FormodelUO-�,0.8-GPHfiringrate,ensurethechamberfloorinsulationblanketiscorrectlypositioned.

�. Verifyburnermountingdoorisclosedtightly,observationportboltistightandburnerwiringharnessesareconnectedatthejacketcrosstie.

4. Factoryburneradjustmentandsettingsmaynotbesuitableforspecificjobconditions.Alwaysusecombustiontestequipmenttocheckandadjust.a. Followburnermanualforstart-up.

b. Allowboilertoheattodesignconditions.

c. Usingcombustiontestequipment,adjusttheburnerandbarometricdamperforCO

�between11%and1�%,0smoke,andbreechingdraftbetween–0.01

and–0.0�inchesw.c.

�. Toobservetheflame,loosentheobservationportcenterbolt.Rotatetheobservationportsothesightglassisatthe6:00position.Retightenthecenterbolt.Whenfinishedviewing,loosenthecenterbolt.Rotatetheobservationportsotheglassisatthe1�:00position.Thenretightenthebolt.Thiswillpreventsootfromdepositingontheglass.

Makefinalburneradjustmentsusingcombustiontestequip-menttoassureproperoperation.Donotfireboilerwithoutwater.Sectionswilloverheat,damagingboilerandresultinginsubstantialpropertydamage.

6. Ventairfromsystem.Repeatsteps4and�under“Fillthesystem.”Airinsystemcaninterferewithwatercirculationandcauseimproperheatdistribution.

7. Check boiler and system piping for leaks. See“Tips for water sys-tems.”

8. Inspectbreechingandventingforproperoperation.

Follow additional instructions:

ReadandfollowtheBurner Manualandallotherinstruc-tionspackedwiththeboilerorcomponents.

Fill the system:1. Closemanualandautomaticairventsandboiler

draincock.

�. Filltocorrectsystempressure.Correctpressurewillvarywitheachinstallation.Normalcoldwaterfillpressure for residential systems is 1� psig. BoilerwaterpH7.0to8.�isrecommended.

�. Openautomaticairventoneturn.

4. Openothervents.a. Startingonthe lowestfloor,openairventsoneata

timeuntilwatersquirtsout.Closevent.b. Repeatwithremainingvents.

�. Refilltocorrectpressure.

Follow information below to preventsevere personal injury, death or sub-stantialpropertydamage:

• Donotusegasolinecrankcasedrain-ingsoranyoilcontaininggasoline.Seeburnermanualforproperfueloil.

• Donotattempttostartburnerwhenexcessoilhasaccumulated,whenunitis full of vapor or when combustionchamberisveryhot.

• Donotstartburnerunlessbreeching,burnermountingdoorandobservationportaresecuredinplace.

• Never burn garbage or paper in theboiler.

• Never leave combustible materialaroundtheboiler.

When using antifreeze—Donotuseautomotive,ethyleneglycol,undilutedorpetroleum-basedantifreeze.Severepersonal injury, death or substantialpropertydamagecanresult.

• Use antifreeze especially made forhydronicsystems.Inhibitedpropyleneglycolisrecommended.

• �0% solution provides protection toabout-�0°F.Donotexceed�0%mix-ture.

• Local codes may require back-flowpreventer or actual disconnect fromcitywatersupply.

• Determinequantityaccordingtosys-temwatercontent.Boilerwatercontentis listed on page �9 of this manual.Percentofsolutionwillaffectsizingofheatdistributionunits,circulatorandexpansiontank.

• Follow antifreeze manufacturer’s in-structions.

Part number 550-141-986/1005 ��


Check-out procedure

o 1. Boilerandheatdistributionunitsfilledwithwater?

o �. Automaticairvent,ifused,openedonefullturn?

o �. Airpurgedfromsystem?Pipingcheckedforleaks?

o 4. Airpurgedfromoilpiping?Pipingcheckedforleaks?

o �. Burnerdoorclosed,sealedandboltstight?Observationport bolt tight? Burner harness plugged in and boilerON/OFFswitchon?

Obtaingas-tightseal topreventpossiblefluegasleakageandcarbonmonoxideemissions, leadingtoseverepersonalinjuryordeath.

o 6. Properdraftandburnerflame?Finaladjustmentmadewithcombustiontestequipment?

o 7. Testlimitcontrol:Whileburnerisoperating,adjustlimitcontrol below actual boiler water temperature. Burnershouldgooffwhilecirculatorcontinuestooperate.Raisesetting on limit control above water temperature andburnershouldre-ignite.

o 8. Testadditionalfield-installedcontrols:Ifboilerhasalowwatercutoff,additionalhighlimitorothercontrols,testforoperationasoutlinedbymanufacturer.Burnershould

beoperatingandshouldgooffwhencontrolsaretested.Whencontrolsarerestored,burnershouldre-ignite.

o 9. Limit control set to system temperature requirements(max.��0°F)?

o 10.Formultiplezones,flowadjustedtodistributeheatinallzones?

o 11.Thermostat heat anticipator setting (if available) setproperly?Referto“Thermostatwiring,”page19.

o 1�.Boilercycledwiththermostat?Raisetohighestsettingandverifyboilergoesthroughnormalstart-upcycle.Lowertolowestsettingandverifyboilergoesoff.

o 1�.Observedseveraloperatingcyclesforproperoperation?

o 14.Setroomthermostat(s)todesiredroomtemperature?

o 1�.CompletedInstallation Certificatebelow?

o 16. Reviewed User’s Information Manual with owner ormaintenancepersonand instructedperson tokeep forfuturereference?

o 17.Returnedallinstructionsprovidedwithboilertoitsen-velopeandplacedwithboilerforfuturereference?

Installation Certificate

Boilermodel __________________________Series_________

CPnumber _______________________

Dateinstalled __________________________________________

Nozzlesize,GPH____________Fuelunitpressure,PSIG__________

o Installationinstructionshavebeenfollowed.

o Checkoutsequencehasbeenperformed.

o Aboveinformationiscertifiedtobecorrect.

o Informationreceivedandleftwithowner/maintenanceperson.

Installer ________________________________(company) ________________________________(phone)

________________________________(address)

________________________________(address) _______________________________________

(Installer’ssignature)

Comments:

_______________________________________

_______________________________________

_______________________________________

_______________________________________

_______________________________________

_______________________________________

Part number 550-141-986/1005


�4

Annual service and start-up

Annual service call check list(follow in the order listed below) D

ate

Dat

e

Dat

e

Dat

e

Dat

e

Dat

e

Dat

e

Dat

e

Dat

e

Dat

e

Comments

1 Check that boiler area is free from combustible materials, gasoline and other flammable vapors and liquids.

2 Check for and remove any obstruction to combustion and ventilation air flow to boiler.

3 Check breeching and chimney or vent for obstructions, damage, etc.Repair or replace as necessary.

4 Clean boiler flueways.See instructions in boiler manual.

5 Perform service on relief valve.See instructions in boiler manual.

6 Check boiler and piping for leaks.Repair if found.

7 Inspect and adjust burner. See burner manual and:• change nozzle.• check ignition electrode settings.• clean blower housing and wheel.• make sure blower wheel turns freely.• oil burner motor if required.• clean air inlet.• clean or change fuel filter and strainer.

8 Make sure boiler is filled with water.

9 Start unit and verify combustion settings with combustion test equipment.

10 Verify operation of all controls on boiler.See boiler manual and burner manual for procedures.

Theboilershouldbeinspectedandstartedannually,atthebeginningoftheheatingseason,onlybyaqualifiedservicetechnician.Inaddition,themaintenanceandcareoftheboilerdesignatedinTable4mustbeperformedtoassuremaximumboilerefficiencyandreliability.Seethefollowingpagesfordetailed instructions. Failure to service and maintain theboilerandsystemcouldresultinequipmentfailure.

Electricalshockhazard—Turnoffpowertotheboilerbeforeanyserviceoperationontheboilerexceptasnotedotherwiseinthisinstructionmanual.Failuretoturnoffelectricalpowercouldresultinelectricalshock,causingseverepersonalinjuryordeath.

Table 4 Annual service and start-up procedure

Part number 550-141-986/1005 ��


Followtheserviceandmaintenanceproceduresgiventhroughoutthismanualandincomponentliteratureshippedwiththeboiler.Failuretoperformtheserviceandmaintenancecouldresultindamagetotheboilerorsystem.Failuretofollowthedirectionsinthismanualandcomponentlit-eraturecouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.

This product contains fiberglass jacketinsulation and ceramic fiber materials incombustionchamberliningorbasepanelsingasfiredproducts.AirbornefibersfromthesematerialshavebeenlistedbytheStateofCaliforniaasapossiblecauseofcancerthroughinhalation.Thecombustioncham-berliningorbaseinsulationpanelsinthisproduct contain ceramic fiber materials.Ceramicfiberscanbeconvertedtocristo-baliteinveryhightemperatureapplications.TheInternationalAgencyforResearchonCancer (IARC) has concluded,“Crystal-linesilicainhaledintheformofquartzorcristobalite from occupational sources iscarcinogenictohumans(Group1).”:

Suppliersoffiberglasswoolproductsrecom-mend the following precautions be takenwhenhandlingthesematerials:

Precautionarymeasures• Avoid breathing fiberglass dust and contact with

skinoreyes.• UseNIOSHcertifieddustrespirator(N9�). This

typeofrespiratorisbasedontheOSHArequire-mentsforfiberglasswoolatthetimethisdocument

was written. Other types of respirators may beneededdependingonthejobsiteconditions.Cur-rent NIOSH recommendations can be found ontheNIOSHwebsiteathttp://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators,manufacturers,andphonenumbersarealsolistedonthiswebsite.

• Wearlong-sleeved,loosefittingclothing,gloves,andeyeprotection.

• Apply enough water to the combustion chamberliningorbaseinsulationtopreventairbornedust.

• Removecombustionchamberliningorbaseinsula-tionfromtheboilerandplaceitinaplasticbagfordisposal.

• Operationssuchassawing,blowing,tearoutandsprayingmaygenerateairbornefiberconcentrationrequiringadditionalprotection.Bagfordisposal.

• Washpotentiallycontaminatedclothes separatelyfrom other clothing. Rinse clothes washer thor-oughly.

NIOSHstatedFirstAid.• Eye:Irrigateimmediately

• Breathing:Freshair.

Handling ceramic fiber and fiberglass materials

Annual service and start-up (continued)

Address reported problemsInspectanyproblemsreportedbyownerandcorrectbeforeproceeding.

Inspect boiler area1. Verify that boiler area is free of any combustible

materials,gasolineandotherflammablevaporsandliquids.

�. Verifythatairintakeareaisunobstructedandfreeofcorrosivecontaminants.Ifanyofthesearepres-ent in theboiler intakeairvicinity, theymustberemoved.

Inspect boiler interior1. LoosentheControlPodcoverretainingscrewand

openthecover.

�. Inspectcontrolsandwiringtoverifyallareingoodcondition.

�. Checkforanypossibleleaksthatmighthavedrippedwateronthewiringorcontrols.

4. Inspecttheboilerinsulationblanket.

�. Ifinspectionsshowpossibleleaks,findandcorrectthecauseoftheleaks.

Part number 550-141-986/1005


�6

Check all piping for leaks Eliminateallsystemorboilerleaks.Con-

tinual fresh make-up water will reduceboilerlife.Mineralscanbuildupinsec-tions, reducing heat transfer, overheat-ing heat exchanger, and causing heatexchangerfailure.Leakingwatermayalsocauseseverepropertydamage.

1. Inspectallwaterandoilpipingandverifytobeleakfree.

�. Lookforsignsofleakinglinesandcorrectanyprob-lemsfound.

�. Checkfuellinesandfuelunitasrecommendedinfuelunitandburnermanuals.

Check air openings1. Verify that combustion and ventilation air open-

ingstotheboilerroomand/orbuildingareopenandunobstructed.Checkoperationandwiringofautomaticcombustionairdampers,ifused.

�. Verifythatboilerventdischargeandairintakearecleanandfreeofobstructions.

Flue vent system and air pipingVisually inspect entire flue gas venting system (andairpiping, if installed) forblockage,deteriorationorleakage. Repair any joints that show signs of leakagein accordance with vent manufacturer’s instructions.Whenairisductedtoburner,verifythatairinletpipingisconnectedandproperlysealed.

Failure to inspect for the above condi-tionsandhavethemrepairedcanresultinseverepersonalinjuryordeath.

Check water system1. Verifyallsystemcomponentsarecorrectlyinstalled

andoperational.

�. Checkthecoldfillpressureforthesystem.Verifyitiscorrect(usuallyaround1�psig).

�. Watch the system pressure as the boiler heats up(duringtesting)toensurepressuredoesn’trisetoohigh. Excessive pressure rise indicates expansiontanksizingorperformanceproblem.

4. Inspect automatic air vents and air separators.Removeairventcapsandbrieflypresspushvalvetoflushvent.Replacecaps.Makesureventsdonotleak.Replaceanyleakingvents.

Check expansion tankGeneralguidelinesExpansiontanksprovidespaceforwatertomoveinandoutastheheatingsystemwaterexpandsduetotempera-tureincreaseorcontractsasthewatercools.Tanksmaybeopen,closedordiaphragmorbladdertype.Followguidelinesinthismanualforthebest locationoftheexpansiontank.

Open-type — located above highest radiator orbaseboardunit,usuallyintheatticorcloset.Hasagaugeglassandoverflowpipetoadrain.

Closed-type—weldedgastightandlocatedaboveboiler.Tankispartiallyfilledwithwater,leavinganaircushionforexpansion.• Makesurethistypeoftankisfittedwithatankfitting,

suchastheB&GTank-TrolorTacoTaco-Trol.Thisfittingreducesgravitycirculationofair-saturatedtankwaterback to the systemandprevents the air frombubblingupthroughthewaterasitreturnsfromthesystem.

• Donotuseautomaticairventsinsystemswithclosed-typetanks.Theairwillescapefromthesysteminsteadof returning to the tank. Eventually, the tank willwaterlog and no longer control pressurization. Theboilerreliefvalvewillweepfrequently.

Diaphragm or bladder-type—weldedgastightwitharubbermembranetoseparatethetankpres-surizingairand thewater.Maybe locatedatanypointinthesystem,butmostoftenfoundneartheboiler.• Systemswiththistypeofexpansiontankrequireatleast

oneautomaticairvent,preferablylocatedontopofanaireliminator,asshownintheexampleonpage14.

TroubleshootingaweepingreliefvalveIfreliefvalvehastendedtoweepfrequently,theexpan-siontankmaybewaterloggedorundersized.

Closed-type tank — tank is most likely water-logged.Installatankfittingifnotalreadyinstalled.Then check fill level per fitting manufacturer’sinstructions.Iffillleveliscorrect,checktanksizeagainstmanufacturer’s instructions.Replacewithalargertankifnecessary.

Diaphragm or bladder-type—first,checktanksizetobesureitislargeenoughforthesystem.Ifsize is toosmall,addadditional tank(s)asneces-sarytoprovidesufficientexpansion.Iftanksizeislargeenough,removetankfromsystemandcheckchargepressure(usually1�psigforresidentialap-plications).Iftankwon’tholdpressure,membranehasbeendamaged.Replacetank.


Part number 550-141-986/1005 �7



Check boiler relief valve1. Inspect the reliefvalveand lift the lever toverify

flowasinthefollowingwarnings,excerptedfromareliefvalvemanufacturer’swarninglabel.Beforeoperating any relief valve, ensure that it is pipedwithitsdischargeinasafeareatoavoidseverescaldpotential.Readpage1�regardingreliefvalvesbeforeproceedingfurther.

Safetyreliefvalvesshouldbereinspectedat least once every three years,byalicensedplumbingcontractororautho-rized inspection agency, to ensure thatthe product has not been affected bycorrosivewaterconditionsandtoensurethatthevalveanddischargelinehavenotbeen altered or tampered with illegally.Certain naturally occurring conditionsmaycorrodethevalveoritscomponentsover time, rendering the valve inopera-tive. Such conditions are not detectableunlessthevalveanditscomponentsarephysically removed and inspected. Thisinspection must only be conducted bya plumbing contractor or authorizedinspectionagency—notby theowner.Failuretoreinspecttheboilerreliefvalveasdirectedcouldresultinunsafepressurebuildup,whichcanresult insevereper-sonalinjury,deathorsubstantialpropertydamage.

Followinginstallation,thevalvelevermustbeoperatedat least once each yeartoensurethatwaterwaysareclear.Certainnaturallyoccurringmineraldepositsmayadheretothevalve,renderingitinopera-tive.Whenmanuallyoperatingthelever,waterwilldischargeandprecautionsmustbetakentoavoidcontactwithhotwaterandtoavoidwaterdamage.Beforeoper-atinglever,checktoseethatadischargeline is connected to this valve directingtheflowofhotwaterfromthevalvetoaproperplaceofdisposal.Otherwiseseverepersonal injury may result. If no waterflows, valve is inoperative. Shut downboiler until a new relief valve has beeninstalled.

�. Afterfollowingthewarningdirections,ifthereliefvalve weeps or will not seat properly, replace thereliefvalve.Ensurethatthereasonforreliefvalveweepingisthevalveandnotover-pressurizationofthesystemduetoexpansiontankwaterloggingorundersizing.

Check all boiler wiringInspectallboilerwiring,makingsurewiresareingoodconditionandsecurelyattached.

Check control settings1. Checkboilerlimitcontrolsetting,Adjustifneces-

sary.

�. Checksettingsofexternallimitcontrols(ifany)andadjustifnecessary.

Part number 550-141-986/1005


�8

Clean boiler flueways and check refractory linings

Make sure all electrical connections toboilerareturnedoffandwaituntilboileriswarm,nothot,beforecleaning.Failureto do so will result in severe personalinjury,deathorsubstantialpropertydam-age.

Theboilercontainsfiberglassandceramicfibermaterials.Usecarewhenhandlingthesematerials,perinstructionsonpage��ofthismanual.Failuretocomplycouldresultinseverepersonalinjury.

1. Removejacketfrontpanelandburnercover.

�. Shutoffoilvalves.Arrangedrippansundertheareasofoilpipingthatwillbedisconnected.

�. Disconnecttheoillineattheburner.Providemeanstopreventoilfromdripping.

4. Disconnectburner1�0-voltandEnviraCOM®har-nesses at the jacket crosstie (located beneath theburnerdoor).

Failuretodisconnecttheburnerwiringhar-nesses before opening the burner door cancausedamage to theburnerandboilerwir-ing.

�. Swing theburnerdooropencompletely.SeeFig-ure17.

6. Linethecombustionchamberfloorwithnewspapertocatchanysootthatwillbeloosenedinthecleaningprocess.

7. ModelUO-�,1.0-GPHfiringrateonly—Removethetwofluebaffles.

8. Startingatthetopoftheboiler,useawirefluebrushtothoroughlycleanallfins.

9. Oncethefluewaysarecleaned,carefullyremovethepaperfromthefloorofthecombustionchamber.

10.Verifyburnerdoorsealingropeisintact.

11.Visuallycheckconditionandpositionoftherefrac-tories in the burner mounting door. Replace anypartsasnecessary.

1�.ModelUO-�,1.0-GPHfiringrateonly—Replacethetwofluebaffles.

1�.Close burner mounting door. Insert and tightenburnerdoorboltssecurely.

Maintainagas-tightsealtoavoidpossibleflue gas leakage and carbon monoxideemissions,whichcanleadtosevereper-sonalinjuryordeath.

Figure 17 Access to boiler flueways


14.Checkthebreechingforsootingandcleanifneces-sary.

1�.Replacethejacketfrontpanelandbreeching.

16.Reconnect the oil line and all electrical connec-tions.

Perform boiler start-up1. Followinstructionsinthismanualandtheburner

manualtostart-upandadjustburnerandboiler.

�. Verifyoperationofallcontrols,includingalllimitdevicesandcombustioncontrols.

Review with ownerReviewtheUser’sInformationManualwiththeownerorboileroperator.

Record the service callRecordtheservicecallontheformonpage�4.

Part number 550-141-986/1005 �9


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


�0

Appendix — Removing/replacing boiler jacket

Removing the boiler jacket Electrical shock hazard — The following

procedureassumestheboilerhasnotbeenwired. If the boiler has been wired, youmustdisconnect allpower to theboiler.Thenlabelallwiresbeforedisconnectingthemattheboilerterminalstrip.

Theboilercontainsfiberglassandceramicfiber materials. Use care when handlingthesematerials,perinstructionsonpage��ofthismanual.Failuretocomplycouldresultinseverepersonalinjury.

1. See Figures18 through�1 for jacket components,hardwareandlocations.

�. Removejacketfrontpanel(Figure18).

�. If the burner has been installed in the burnerdoor:• Removetheburnercover.• Disconnect the two burner wiring harnesses at the

jacketcrosstie(locatedbeneaththeburnerdoor).

Failure todisconnect theburnerwiringhar-nesses before opening the burner door cancause damage to the burner and boiler wir-ing.

• Turnofffuelsupplyvalve(s)anddisconnectfuelline(s)toburner.Placedrippansunderendsoflinestocatchanyoil.

4. Remove the burner door bolts and washers (Fig-ure19).

�. Carefullylifttheburnerdoorsothedoorpinsliftoutofthehingebracket(Figure19).Settheburnerdoorasidetemporarily.

Theburnerdoorisheavy.Handlecarefullytoavoidpotentialforpersonalinjury.

Donotdamagetheburnerdoorinsulationwhenhandling.

6. Loosenthefour#10x�/8”screwssecuringthejackettopandsidepanelstothebackpanel(Figure�0).

7. Removethejackettoppanel.

8. LoosentheControlPodcoverretainerscrewandliftcoverup.

Figure 18 Jacket components and hardware


Part number 550-141-986/1005 �1


9. PushtheControlPodcovertooneside,andgentlyworkthecoverretainerhingeontheothersideoutofthejacketslottoremovethecover.

10.RemovethelimittemperaturesensorandP/Tgaugecapillary fromthewells in topof theboilerbacksection.

11.Remove the jacket crosstie by loosening the twoscrewssecuringittothesidepanels(Figure19).Liftthecrosstieupanddisengagethescrewsfromthekeyholes.

1�.Loosenthefour�/8-16x1”jacketfrontscrews.Donotremovethescrews.

1�.Liftthehingebracketandpullouttodisengagethekeyholesfromthescrews.

14.Remove the four #10 x �/8” screws securing theelectricaltraytothejacketsidepanels(Figure�0).Leavetheelectricaltrayinposition.

1�.Removethejacketsidepanelsbypullingbackedgeawayfromthebackoftheboilerandthendisengag-ingthekeyholesfromthejacketfrontscrews.

16.Removetheelectricaltray,keepingthewiringhar-nessesconnectedtothejacketcrosstie.

17.Removetheinsulationblanket.

18.Removethereliefvalveandsupplypipingifalreadyinstalled.

19.Loosen the four �/8–16 x 1” screws securing thejacketbackpaneltotherearsection.Thescrewsarelocatedattherecessedopeningsonthejacketbackpanel(Figure�1).

�0.Liftthejacketbackpanelandpullforwardtodis-engagethekeyholesfromthescrews.

Replacing the jacket1. Toinstallthejacket,reversetheprecedingprocedure.

RoutethepowerandEnviraCOM®cablesasshowninFigure14,page19.

Appendix — Removing/replacing boiler jacket (cont.)



Part number 550-141-986/1005


��

Appendix — Replacement parts (continued)

Boiler section assembly parts

Item Description Part Number

1 Boiler front section 316-900-200

2 Boiler intermediate section 316-900-210

3 Boiler back section 316-900-220

4 Tie rods (4 required) UO-3UO-4UO-5

560-234-468560-234-472560-234-477

5 Nuts (8 required) 561-928-221

6 Washers (4 required) 562-248-668

7 P/T gauge temperature sensor well 592-300-025

8 Limit control sensor well 592-300-006

9 Mounting clip for P/T gauge and limit well 512-400-001

10 P/T gauge pressure sensor check valve 512-400-000

11 Boiler relief valve 511-546-920

12 Flue collar 446-900-000

13 Flue collar gasket 590-318-028

14 Flue collar replacement Kit (flue collar plate, gasket, (4) bolts) 386-902-002

15 Flueway baffles (for UO-3 1.0 gph input only) — (2) required 452-800-455

16 Front/Intermediate section replacement kit (includes seals & rope) 386-902-004

17 Back section replacement kit (includes seals, rope, flue gasket) 386-902-003

18 Leveling legs (4) 386-902-013

19 UO-3 0.80 GPH ONLY combustion chamber floor blanket 591-221-287

20 UO-3 0.80 GPH ONLY low firing rate kit (Not shown)(includes blanket, water glass, nozzle)

386-902-007

Part number 550-141-986/1005 ��



Boiler section assembly parts

Part number 550-141-986/1005


�4


Burner door parts


1 Burner flange bolts (3) each, 5/16"-18 x 3/4" Hex HD SS Purchase locally

2 Burner door 330-054-308

3 Burner door hinge bracket 466-900-000

4 Hinge bracket screws (2 required), 3/8"-16 x 1 Purchase locally

5 Observation port assembly (includes observation port, bolt, observation port gasket, sight glass gasket, sight glass, water glass)

386-902-000

6 Observation port gasket (requires water glass adhesive) 590-318-027

7 Water glass for observation port gasket (Not shown) 591-632-612

8 Sight glass gasket 590-317-580

9 Burner door retainer bolts and washers (2) each, 3/8"-16 x 2" Hex HD ZP Purchase locally

10 Burner door insulation kit (includes refractories, insulation blankets, & rope) 386-902-001

Part number 550-141-986/1005 ��



Burner door parts

Part number 550-141-986/1005


�6


Jacket and control parts


1 Jacket front panel assembly (includes sheet metal, plastic, striker) 386-902-005

2 Jacket front panel plastic 595-000-009

3 Jacket side panel (left and right sides are the same) UO-3UO-4UO-5

426-900-002426-900-003426-900-004

4 Control Pod cover 595-000-011

5 Jacket top panel UO-3UO-4UO-5

426-900-005426-900-006426-900-007

6 Jacket rear panel (if required order insulation below) 426-900-001

7 Jacket rear panel insulation 591-222-181

8 Jacket crosstie 426-900-008

9 Boiler insulation (Not shown) UO-3UO-4UO-5

591-222-178591-222-179591-222-180

10 Control tray assembly (includes tray, limit control, terminal strips, P/T gauge, ON/OFF switch, wiring, labels)

386-902-008

11 Pressure/Temperature gauge 510-218-052

12 ON/OFF switch 511-624-645

13 Weil-McLain logo plate 550-404-306

14 High limit control, Honeywell L7248C-1030 386-902-006

15 Wire harness (Not shown) 386-902-011

16 Barometric draft control (Not shown) 510-512-270

17 Limit control sensor (Not shown) 511-724-291

Part number 550-141-986/1005 �7



Jacket and control parts

Part number 550-141-986/1005


�8

Appendix — Dimensions

1. Boiler circulator is shipped loose. Circulator may bemountedoneitherboilersupplyorreturnpiping.

�. Relief valve is shipped loose, supplied with elbow andnippletoinstallinrearsectiontapping.

Notes

Part number 550-141-986/1005 �9


Appendix — Ratings

DOE

Notes

(1)BasedonstandardtestproceduresprescribedbytheUnitedStatesDepartmentofEnergyatcombustionconditionof1�.0%CO�and–0.0�”w.c.breechingdraft.

(�)Ratingsshownare forsea levelapplicationsonly.Foraltitudesabove�,000feet,deratetheproductcapacityby4%per1,000feetabovesealevel.

(�)NetI=B=Rratingsarebasedonnetinstalledradia-tionofsufficientquantityfortherequirementsofthebuildingandnothingneedbeaddedfornormalpipingandpick-up.Waterratingsarebasedona

BoilerModel

Number

I=B=RBurner

Capacity

DOEHeatingCapacity

CSAInput

CSAOutput

NetI=B=R

Ratings

BoilerWater

Content

ShippingWeight,Approx.

DOESeasonalEfficiency

FlueConn.Size

DraftLoss

ThroughBoiler

GPH #2 Oil MBH MBH Btuh MBH Gallons Pounds AFUE, % Inches w.c.

Notes: Notes 1, 6 Notes 2, 6 Note 2 Notes 3, 6 Note 4 Note 5

UO-30.8 GPH

0.80 98 112 98 85 15.0 636 86.5 6” 0.000

UO-31.0 GPH

1.00 122 140 122 106 15.0 636 86.5 6” 0.020

UO-4 1.20 146 168 146 127 18.3 737 86.2 6” 0.025

UO-5 1.40 172 196 172 150 21.5 852 86.5 6” 0.040

pipingandpick-upallowanceof1.1�.Anaddi-tionalallowanceshouldbemadeforunusualpip-ingandpick-uploads.ConsultlocalWeil-McLainSalesOffice.

(4)Seepage11forminimumbreechingandchimneysizing.

(�)Boilerdraftlossesarebasedonoperationat11.�%CO

�.Setbreechingdraftat–0.0�inchwatercol-

umn.

(6)MBHreferstothousandsofBtuperhour.

Part number 550-141-986/1005


40

Documents

Boiler Manual • Maintenance • Startup • Partsigate.northernplumbing.com/manuals/wm/ultra.pdf · • Startup This manual must ... Startup procedure ... • Do not add cold water