Weil-McLain Ultra Series 3 Guide

Part number 550-100-067/0608
User’s
Information Manual
Gas-firedwaterboilers–Series3
Featuring
Flexibility
If the information in this manual is not followed exactly, a fire or explosion may result,
causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS —
• Donottrytolightanyappliance.
• Donottouchanyelectricalswitch;donotuseanytelephoneinyourbuilding.
• Immediatelycallyourgassupplierfromaneighbor’stelephone.Followthegassupplier’sinstructions.
• Ifyoucannotreachyourgassupplier,calltheredepartment.
Installation & service must be performed by a qualified installer, service technician or the gas supplier.

Part number 550-100-067/0608
g a s -f i r e d w at e r b o i l e r — User’s Information Manual
2
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk
levels or to important information concerning the life of the product.
Indicates presence of hazards that will cause severe personal injury, death or
substantial property damage.
Indicates presence of hazards that can cause severe personal injury, death or
substantial property damage.
Indicates presence of hazards that will or can cause minor personal injury or
property damage.
Indicates special instructions on installation, operation or maintenance that are
important but not related to personal injury or property damage.
The Boiler manual is for use only by a qualified heating installer/service technician. Refer only to this User’s
Information Manual for your reference. Improper installation, adjustment, alteration, service or maintenance
can cause property damage, personal injury (exposure to hazardous materials) or loss of life. Installation and
service must be performed by a qualified installer, service agency or the gas supplier (who must read and follow
the supplied instructions before installing, servicing,or removing this boiler. This boiler contains materials that
have been identified as carcinogenic,or possibly carcinogenic,to humans).
Whencalling orwritingabouttheboiler—Pleasehavethe boilermodel numberfromtheboilerratinglabeland
the CP number from the boiler jacket.
Hazard definitions
Boiler service and maintenance
How to use this manual . . .
To . . . Read/use . . . See pages . . .
Learn precautions Warnings and definitions 1 – 3
Prevent air
contamination
Read the list of air contaminants you must avoid.
If found, either remove the products permanently, or have
your installer relocate boiler vent and air terminations to
an uncontaminated area.
4
Maintain the boiler Maintain the boiler using the schedule in this manual.
Schedule an annual start-up by a qualified service
technician before every heating season. 5 – 8
Start or shutdown the
boiler Use the OPERATING INSTRUCTIONS 9
Boiler components &
the U-Control display These illustrations and callouts will show you the location of main components and use of the U-Control display. 10 – 11

Part number 550-100-067/0608 3
g a s -f i r e d w at e r b o i l e r — User’s Information Manual
Failuretoadheretotheguidelinesonthispagecanresultinseverepersonal
injury,death or substantial property damage.
Boiler service and maintenance —
To avoid electric shock, disconnect electrical supply before performing mainte-
 nance.
To avoid severe burns, allow boiler to cool before performing maintenance.

Youmustmaintaintheboilerasoutlinedinthismanualand
 have the boiler started
up and serviced at least annuallybyaqualifiedservicetechniciantoensureboiler/
system reliability.
Boiler operation —
Do not block flow of combustion or ventilation air to boiler.This boiler is equipped
 with a control which will automatically shut down the boiler should air or vent be
blocked.Ifventorairblockageiseasilyaccessibleandremovable,removeit.Theboiler
should attempt to restart. If blockage is not obvious or cannot be removed,have the
boiler and system checked by a qualified service technician.
Do not allow contaminated air to enter the boiler air inlet pipe. See page 4 for de-
 tails.
Should overheatingoccur or gassupplyfail toshutoff,do notturn off ordisconnect
 electrical supply to boiler. Instead, shut off the gas supply at a location external to
the appliance.
Do not use this boiler if any part has been under water. Immediately call a qualified
 service technician to inspect the boiler and to replace any part of the control system
and any gas control,which has been under water.
Boiler water —
Have boiler water chemistry checked at least annually by a qualified service techni-
 cian.
DONOTusepetroleum-basedcleaningorsealingcompoundsinboilersystem.Gas-
 kets and seals in the system may be damaged.This can result in substantial property
damage.
DO NOT use “homemade cures” or “boiler patent medicines”. Serious damage to
 boiler, personnel and/or property may result.
Continualfreshmakeupwaterwill reduceboiler life.Mineralbuild-up inboilerheat
 exchangerreducesheat transfer,overheatsthe metal,and causes heatexchangerfail-
ure.Addition of oxygen can cause internal corrosion in system components. Leaks
in boiler or piping must be repaired at once to prevent makeup water.
Do not add cold water to hot boiler. Thermal shock can cause boiler heat exchanger
 to crack.
STOP! READ THIS BEFORE PROCEEDING . . .

Part number 550-100-067/0608
g a s -f i r e d w at e r b o i l e r — User’s Information Manual
4
Prevent combustion air contamination
If theboiler combustionair inletislocatedin anyarealikelytocause contamination,or if productswhich
wouldcontaminatethe aircannotbe removed,youmust havethecombustionair andventre-piped and
terminated to another location. Contaminated combustion air will damage the boiler, resulting in pos-
sible severe personal injury, death or substantial property damage.
Do notoperate anUltra boilerif its combustionair inletis locatedin alaundryroomor pool facility,for
example.These areas will always contain hazardous contaminants.
Poolandlaundryproductsandcommonhouseholdandhobbyproductsoftencontainfluorineorchlorine
compounds.When these chemicals pass through the boiler, they can form strong acids. The acid can eat
through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or
boiler water leakage into the building.
Please read the information listed below.If contaminating chemicals will be present near the location of
the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another
location,per the Boiler manual.

Part number 550-100-067/0608 5
g a s -f i r e d w at e r b o i l e r — User’s Information Manual
Annual startup and general maintenance
Figure 1 Service and maintenance schedules
OWNER MAINTENANCE (see the following pages for instructions)
BEGINNING OF SEASON Contact your boiler service technician to inspect, service and start
up your boiler. You must have an annual start-up performed by a
qualified service technician to ensure reliable operation of the boiler
and system.
DAILY
Check boiler area
Check air openings
Check pressure/temperature gauge
Verify boiler front door is secure
MONTHLY
Check vent piping
Check air piping
Check relief valve
Check condensate drain system
Check automatic air vents (if used)
PERIODICALLY Test low water cutoff (if used)
Check time and date on the U-Control display
EVERY
6 MONTHS Check boiler piping (gas and water)
Operate relief valve
END
OF SEASON Shut boiler down (unless boiler used for domestic water)
Follow the service and maintenance procedures given throughout this manual and in component literature
shipped with the boiler.Failure to perform the service and maintenance could result in damage to the boiler or
system.Failure to follow the directions in this manual and component literature could result in severe personal
injury,death or substantial property damage.

Part number 550-100-067/0608
g a s -f i r e d w at e r b o i l e r — User’s Information Manual
6
Maintenance procedures — DAILY
Check air openings
Verify that combustion and ventilation air1. openings to the boiler room and/or building
are open and unobstructed.
Verifythatboilerventdischargeandairintake2. are clean and free of obstructions.
Remove any debris on the air intake or flue3. exhaust openings.
If removing the debris does not allow the4. boilertooperatecorrectlyafterwards,contact
yourqualifiedservicetechniciantoinspectthe
boiler and vent/air systems.
Check the pressure/
temperature gauge
Make sure the pressure reading on the boiler1. pressure/temperature gauge does not exceed
25 psig.
Contactaqualifiedservicetechnicianif prob-2. lem persists.
Verify boiler front door is
secure
Visuallyinspectboilerfrontdoortobesureit1. is sealed all around its perimeter. Verify that
the two lower thumb screws are tight.
Reinstallthe jacket front doorafter
servicing. The boiler front door
must be securely fastened to the
boilertopreventboilerfromdraw-
ingairfrominsidetheboilerroom.
Thisisparticularlyimportantifthe
boilerislocatedinthesameroomas
otherappliances.Failuretokeepthe
door securely fastened could result
in severe personal injury or death.
Contactyourinstallerortechnician
immediately if the front door does
notcorrectly inplaceor if thedoor
gaskets are damaged.
The boiler must be serviced & maintained
The boiler must be inspected and started annually, at the
beginning of the heating season,by a qualified service tech-
nician. In addition, the maintenance and care of the boiler
designated on page 5 and explained on pages 6 through 9
mustbeperformedtoassuremaximumboilerefficiencyand
reliability.Failuretoserviceandmaintaintheboilerandsys-
temcouldresultinequipmentfailure,causingpossiblesevere
personal injury,death or substantial property damage.
Thefollowinginformationprovidesdetailedinstructionsfor
completingthemaintenanceitemslistedinthemaintenance
schedule,page 5.
In addition to this maintenance,the boiler must be serviced
and started up at the beginning of each heating season by a
qualified service technician.
Check boiler area
To prevent potential of severe personal injury,death or sub-
stantial property damage, eliminate all materials discussed
below from the boiler vicinity and the vicinity of boiler
combustion air inlet.If contaminants are found:
 •Removeproductsimmediatelyfromthearea.Iftheyhave
been there for an extended period, call a qualified service
technician to inspect the boiler for possible damage from
acid corrosion.
 •Ifproductscannotberemoved,immediatelycallaqualied
service technician to re-pipe vent and air piping and locate
vent termination/air intake away from contaminated areas.
Combustible/flammable materials—Donotstorecom-
bustible materials, gasoline or any other flammable vapors
or liquids near the boiler.Remove immediately if found.
Air contaminants —Productscontainingchlorineorfluo-
rine,ifallowedtocontaminatetheboilerintakeair,willcause
acidic condensate in the boiler. This will cause significant
damage to the boiler if allowed to continue. Read the list of
potential materials listed on page 4 of this manual.If any of
these products are in the room from which the boiler takes
its combustion air, they must be removed immediately or
the boiler combustion air (and vent termination) must be
relocated to another area.

Part number 550-100-067/0608 7
g a s -f i r e d w at e r b o i l e r — User’s Information Manual
Maintenance procedures — MONTHLY
Maintenance procedures — PERIODICALLY
Test the low water cutoff (if installed)
Ifthesystemisequippedwithalowwatercutoff,testthelow1. water cutoff periodically during the heating season.Follow
the low water cutoff manufacturer’s instructions.
Reset the boiler control after testing.2.
Check U-Control date and time
Check the time shown on the U-Control display.1. If time is incorrect, set the correct date and time as shown2. on pages 10 and 11.
Check vent piping
Visuallyinspectthefluegasventpipingforanysignsof block-1. age,leakageordeteriorationofthepiping.Notifyyourquali-
fied service technician at once if you find any problem.
Failure to inspect the vent system as noted above
andhaveitrepairedbyaqualifedservicetechnician
can result in vent system failure, causing severe
personal injury or death.
Check air piping
Visually inspect the air inlet to be sure it is unobstructed.1. Inspect entire length of air piping to ensure piping is intact
and all joints are properly sealed.
Call your qualified service technician if you notice any2. problems.
Check the relief valve
Inspect the boiler relief valve and the relief valve discharge1. pipe for signs of weeping or leakage.
Ifthereliefvalveoftenweeps,theexpansiontankmaynotbe2. workingproperly.Immediatelycontactyourqualifiedservice
technician to inspect the boiler and system.
Check the condensate drain system
While the boiler is running, check the discharge end of the1. condensatedraintubingandtheopentopof thecondensate
tee at the boiler (see Figure 3,page 10 for locations). Make
surenofluegasisescapingfromthecondensatedraintubing
or tee by holding your fingers in front of the opening.
If you notice flue gas escaping, this indicates a dry conden-2. sate drain trap. See step 4 for procedure to fill trap. Call
your qualified service technician to inspect the boiler and
condensate line and refill the condensate trap if problem
persists regularly.
Under some circumstances an Ultra vent system
may not produce enough condensate to keep the
condensatetrapfullofliquid.Ifthetrapisnotfull,
smallamountsofflueproductscanbeemittedinto
theboilerroomthroughthecondensatedrainline
or tee.Follow procedure below to fill trap.
Verify that the condensate drain line is unobstructed by3. slowlypouring water intothe topof thePVCteeon theside
of the boiler.The water should run out the end of the con-
densate drain line. If the water does not run out, call your
qualified service technician to inspect the boiler and clean
or replace the condensate drain line.
Tofillthecondensatetrap,if necessary,temporarilyplugthe4. endofthecondensatedrainline.Thenslowlypourwaterinto
the ½ inch plastic tee on boiler right side. Pour until water
fills drain line, then overflows into the boiler trap tubing.
Whenwaterfillsuptotopof½inchtee,stopfilling.Remove
temporary plug from end of condensate drain line.
Check automatic air vents (if used)
See illustration at right.1. Remove the cap from any automatic2. airventinthesystemandcheckoper-
ationbydepressingvalve“B”slightly
with the tip of a screwdriver.
If the air vent valve appears to be3. working freely and not leaking,
replace cap “A”, twisting all the way
on.
Loosencap“A”oneturntoallowvent4. to operate.
Have vent replaced if it does not5. operate correctly.

Part number 550-100-067/0608
g a s -f i r e d w at e r b o i l e r — User’s Information Manual
8
Maintenance procedures — END OF SEASON
Maintenance procedures — EVERY 6 MONTHS
Follow “TO TURN OFF GAS TO APPLIANCE” on page 91. of this manual.
Donotdrainsystemunlessexposuretofreezingtemperatures2. will occur.
Do not drain the system if it is filled with an antifreeze3. solution.
DONOTshutdownboilersusedfordomesticwaterheating.4. They must operate year-round.
Check the boiler piping
Remove boiler front access door and perform gas leak inspection per1. steps 1 through 7, Operating Instructions, page 9. If gas odor or leak
is detected, immediately shut down boiler following procedures on
page 9.Call a qualified service technician.
Visually inspect for leaks around internal water piping. Also inspect2. externalwaterpiping,circulators,reliefvalveandfittings.Immediately
call a qualified service technician to repair any leaks.
Have leaks fixed at once by a qualified service technician.
Failuretocomplycouldresultinseverepersonalinjury,death
or substantial property damage.
Operate relief valve
Reinstall door securely after inspections.1.
Reinstallthejacketfrontdoorafterservicing.Theboilerfront
doormustbesecurelyfastenedtotheboilertopreventboiler
from drawing air from inside the boiler room. This is par-
ticularly important if the boiler is located in the same room
asotherappliances.Failuretokeepthedoorsecurelyfastened
couldresultinseverepersonalinjuryordeath.Contact your
installerortechnicianimmediatelyifthefrontdoordoesnot
correctly in place or if the door gaskets are damaged.
Before proceeding, verify that the relief valve outlet has been piped2. to a safe place of discharge, avoiding any possibility of scalding from
hot water.
To avoid water damage or scalding due
to valve operation, a metal discharge
line must be connected to relief valve
outletand runtoasafeplaceof disposal.
This discharge line must be installed by
a qualified heating installer or service
technician in accordance with the in-
structions in the Ultra Boiler Manual.
The discharge line must be terminated
so as to eliminate possibility of severe
burns or property damage should the
valve discharge.
Read the boiler pressure/temperature gauge to3. make sure the system is pressurized.Lift the relief
valve top lever slightly, allowing water to relieve
through the valve and discharge piping.
If waterflowsfreely,releasetheleverandallowthe4. valve to seat.Watch the end of the relief valve dis-
charge pipe to ensure that the valve does not weep
after the line has had time to drain. If the valve
weeps, lift the seat again to attempt to clean the
valveseat.Ifthevalvecontinuestoweepafterwards,
contactyourqualifiedservicetechniciantoinspect
the valve and system.
If water does not flow from the valve when you5. liftthe lever completely,the valveor dischargeline
maybeblocked.Immediatelyshutdowntheboiler,
followingtheoperatinginstructionsonpage9.Call
your qualified service technician to inspect the
boiler and system.

Part number 550-100-067/0608 9
g a s -f i r e d w at e r b o i l e r — User’s Information Manual
Operating instructionsFigure 2
OPERATING INSTRUCTIONS

Part number 550-100-067/0608
g a s -f i r e d w at e r b o i l e r — User’s Information Manual
10
Ultra component locationsFigure 3
U-Control display turns red when boiler locks out — select MANUAL RESET to reset boiler as shown below.Figure 4
Boiler components & the U-Control display

Part number 550-100-067/0608 11
g a s -f i r e d w at e r b o i l e r — User’s Information Manual
Ultra boiler’s U-Control displayFigure 5
Boiler components & the U-Control display (continued)

Part number 550-100-067/0608
g a s -f i r e d w at e r b o i l e r — User’s Information Manual
12