Weil-McLain UltraOil 2 Series User manual

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Series2
Oil-FiredWater Boiler
Boiler Manual
• Installation • Maintenance
• Startup • Parts
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'llht:afJit. Series 2 WATER BOILER - Boiler Manual
THE 'l/ttm0/t. WATER BOILER - How IT WORKS •••
1. Weii-McLain logo plate (standard) or
Remote Display Module (optional)
The Remote Display Module (RDM) is used when the optional
AFM (item 28) is installed.
The display shows boiler and system
status
and is used to adjust ope rating parameters.
2. ON/OFF switch
3. Control Pod cover fastener
4. Pressure/Temperature gauge
Displays boiler water pressure and outletwater temperature.
5. Jackettop rear panel
6. Control Pod cover
The 'IUhaf.JIL. Control Podcover is hinged to allow easy access to
the limit temperaturesensor, bo il erwiring and optionalAdvanced
Features Module (AFM).
7. Jacket side panels
1U«a01l jacketside panels are interchangeable.
8. Jacket rear panel, with insulation
9. Terminal strip
Electrical connections, both line and low voltage, connect to the
terminalstrip.
10. Front section
11. Intermediate sections
12. Back section
13. Burner wire harness
Line voltage wiring to burner, terminated in a Molex connector
in the jacket cross tie (item 19). An additional harness connects
from the cross tie connector to the
burne r.
14. Burner door hinge bracket
The hinge bracketcan be installed on eitherside to allow for right
or left-handswing.
15. Swing-away burner door
The 'IUhaf.JIL" burner door is hinged to provideeasy access to the
boiler heatexchanger for inspection
and cleaning.
16. Rotating observation port
The 'IUha()ll observation port is designed to prevent soot from
depositing
on the sight glass. During normal operation the sight
glass
is located at the 12:00 position. To view the burner flame,
loosen the center mounting
bolt and rotate so the sight glass is
in the6:00 position.
17. Overfire pressure tapping
1/8" npt, with plug.
18. Jacket cross tie
2
19. Sensor wells
Boiler limittemperaturesensor and P/Tgauge capillary and tem-
perature sensorare installed in the top
of the rearsection.
20. Outlet tapping
The boiler outlet water tapping is located in the top of the rear
section.
21. Return tapping
The boiler return tapping is located in the bottom of the rear
section.
22. Insulation blanket
23. Leveling legs
24. Boiler drain valve
25. Flue connection
'IUhaf.JIL. boilers can be chimney or direct vented from the rear
flue opening.
26. Knockouts in jacket rear for electrical conduits
All electrical connections enter in condu it s connected to these
knockouts.
27. Boiler relief valve
28. AFM (Advanced Features Module} -Optional
The'IUhaOI/ boiler can be equippedwiththeAdvanced Features
Module(AFM).
The AFM is a system control that provid es boiler
outdoor reset, a boiler setpoint temperature, domestic h
ot water
pump operation, and outdoor reset through the use of a mixing
valve
or a var ia blespeed injection pump . It also controls staging
and rotation of two boilers.
When equipped with an AFM, the boiler requires a 20-amp
service.
29. Temperature Limit/LWCO Control with Thermal
Targeting™ The UltraOilboiler is equipped with a Hydro-
level3250 HydroStat®,
LWCO and temperaturelimit control
withenergysaving technology. The 3250 senses the presences
of water, water temperature and monitors calls for heat and
activates the boiler pump and circulator. The control logic will
delay
pump or burner operation and adjust them for the target
water temperature
to optimize efficiency.
30. Burner, with cover
31. Jacketfront panel
Part number 550-141-987/0912

'lllka()ll' Series 2 WATER BOILER - Boiler Manual
THE 'lllka{}/t . WATER BOILER
Part number550-141-987/0912
I
~
3

'llht:afJit. Series 2 WATER BOILER - Boiler Manual
Contents
4
THE 'llltml!Jit. WATER BOILER - How IT woRKs •••••••••••••••••••••••••••• 2-3
Please read before proceeding ••••••••••••••••••••••••••••••••••••••••••••• 5
Owners Responsibilities •••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6
Boiler location checklist ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7
Prepare boiler location •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 8
Connect breeching •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12
Connect water piping •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 14
Connect wiring (Note 1) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 18
Connect oil piping ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 22
Startup procedure ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 23
Check-out procedure ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 24
Annual service and start-up •••••••••••••••••••••••••••••••••••••••••••••••• 25
Department of Energy Compliance ..................................... 28
Removing/replacing boiler jacket •••••••••••••••••••••••••••••••••••••••• 30
Replacement parts ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 32
D. .
•m~l1!51()11!5 •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
38
Rcati11g!t ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
39
Note 1: See burner manual for wiring and additional startup and operating informati on.
Also see AFM manual if used.
The terms beloware used throughout this manual to bring attention to the presence of hazards of various risklevels
or to important information concerning the life of the product.
lA WARNlNG I
NOTICE
Indicates presence of hazards that will cause
severe personal injury,
death or substantial
propertydamage.
Indicates presence
of hazards that can cause
severe personal injury,
death or substantial
propertydamage.
When calling or writing about the boiler-
Please have the boiler model number from
the boiler rating label and the CP number
from the boiler jacket. You may list the CP
number in the space provided on the Instal-
l
ation Certificate found on page 24 .
Considerpiping
and installation when deter -
mining boiler location.
Any claims for damage
or shortage in ship -
ment must be fil ed i mmed i ate ly against the
transportation company by the consignee.
lA CAUTlON I
NOTICE
Indicates presence of hazards that will or
cancause minor personalinjury or property
damage.
Indicates special instructions on in -
stallation, operation or maintenance
that are important but not related
to personal injury or property damage.
Co mmonwealth of Massachusetts
When the boileris installed within the Common -
wealth
of Massachusetts:
Thi s product must be i nsta ll ed by a licensed
plumber .
If antifreeze is used,a reducedpressure
back -
fl ow preventer device shall be used.
Part number 550 -1 41 -987/0912

'llltlta()lt. Series 2 WATER BOILER - Boiler Manual
Please read before proceeding
t
1
1
1
J!1 ~ 1ij4;1 Followthe 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
gasoline.See burner manual for proper fuel oil.
Never burn garbage or paper in the boiler. Never leave
combustible material around boiler.
Do not tamper with burner / controls
Always follow specific instructions when starting up
boiler or performing routine maintenance or service.
Do not attempt to start burner when excess oil has ac-
cumulated in combustion chamber, when unit is full of
vapor, or when combustion chamber is very hot.
Do not start burner unless breeching and burner mount-
ing door aresecured in place.
!A WAR N ING I Followthe guidelines below to prevent possible severe personal injury, death or substantial propertydamage.
Read all instructions -
Read all instructions, including this manual, the burner
manual and any related supplements. Perform steps in
the order given. Failure to comply could result in severe
personal injury, death or substantial property damage.
When servicing boiler -
To avoid electricshock,disconnectelectricalsupplybefore
performing maintenance.
To avoid severe burns,allowboilertocoolbefore perform-
ing maintenance.
Boiler operation -
Do not block flow of combustion or ventilation air to
burner.
Shouldoverheatingoccur or fuel supplyfail to shut off, do
not turn off or disconnect electricalsupply to circulator.
Instead, shut off the fuel supplyat a location external to
the appliance.
Do not use this boiler if any part has been under water.
Electrical
and mechanical failures may cause electric
shock and fire risks. Immediatelyinspectchimney or vent,
boiler, burner and controls.Cleanthe boilerflueways and
replace allelectrical and mechanicalcontrols;all electrical
wiring; oil
burner and controls; insulation and chamber
lining.
Boiler firing rate -
Do not reduce thefiringrate of theboiler. Use onlytheoil
nozzlesize specified. Reduced
input will causecondensa-
tion in the boiler and vent piping.
Part number 550-141-987/0912
Ceramic fiber materials -
The boiler contains ceramic fiber materials. Use care
when handling these materials per instructions
on
page 26 of thismanual. Failure to complycouldresult
in severe personal injury.
Boiler water -
Thoroughly flush the system (without boiler con -
nected) toremovesediment.Theboiler heatexchanger
canbedamagedbybuild- up or corrosiondue to sedi-
ment.
Do not use petroleum -based cleaning or sealing
compounds in boilersystem. Gaskets and seals in the
systemmaybedamaged.Thiscan resultinsubstantial
property damage.
Do not use"homemadecures" or "boilerpatentmedi-
cines." Serious damage to boiler, personnel and/or
property may result.
Continual fresh make-
up water will reduce boiler
life. Mineral buildup in boiler sections reduces heat
transfer, overheats the sections,
and causes failure.
Addition of oxygen carried in by make- up water can
cause internal corrosion. Leaks in boiler or piping
must be repaired at once to prevent make- up water.
Do
not add cold water to hot boiler. Thermal shock
can cause heat exchanger to crack.
Freeze protection fluids-
Whenusingantifreeze-Do not use automotive,eth-
yleneglycol, undiluted
or petroleum-basedantifreeze.
See theWARNING on page23 for more information.
5

'llht:afJit. Series 2 WATER BOILER - Boiler Manual
IA WAR NJNG Hom eow ner r espo nsibilities- r ea dand fo ll ow co mpletel y.
1. Have the boiler and burner installed by a qualified installer.
2. Have the boiler and burner servi c ed at least annually by a qualified
service t echnician.
3. Review and understand boiler st ar t -up and routine main t enance proce-
dures with the service technician.
4. Perform routine maintenance listed below.
Operation
tt j.@@#;l You must adhere to the following
to avoid severe personal injury,
death or substantial property
damage.
Fuel
Do not use crankcase drainings or any oil
containing gasoline. See burner manual for
proper fuel oil.
Never burn garbage or paper in the boiler.
Never leave combustible material around
boiler.
Do not tamper with burner /
control s
Always follow specific instructions when
starting up boiler or performing routine
maintenance or service.
Do not start burner if:
Do not attempt to start burner when excess
oil has accumulated in combustion chamber,
when unit is full of vapor, or when combus-
tion chamber is very hot.
Do not start burner unless breeching and
burner mounting door are secured in place.
Start-up
1. If burner does not fire, check and correct
Is boiler ON/OFF switch on, and are all other switches
feeding boiler turnedon?
Is fuse or breaker tripped?
Is thermostatset above roomtemperature?
Are fuel valves turned on?
Is thereenoughoil in theoil tank?
2. Ifburnerstill does not fire, removetheburnercover and
press the primary control reset button ONLY ONCE.
DO NOT repeat, because oilwill build up in the boiler
chamber.
t1 j1 J!1@#;1 ! he burner m~st never be fired w~en oil is
m thecombustionchamber. Immediatelycall
your qualified service technician.
3. Ifthe burnerstill does
not fire, callyourqualified service
technician.
6
Maintenance
Beginning of heating season
0 Call a qualified service technic ian to perform annual
service .
Every day during heating season
0 Keep area free of combustible materials:
Check thatboiler area is free of combustiblematerials,gasoline
and other flammable vapors and liquids.
Every week during heating season
0 Checkfor and removeanyobstructions to flow of combustion
or ventilation air to boiler.
0 Checkthat breeching is attachedbetweenboiler and chirrmey.
Ifbreeching
is loose or damaged, immediately turn offboiler
ON/OFF switch and call yourservice technician to repair.
0 Check for oil leaks in oil pipirig and around the burner. If
found, immediately call your service technician to repair.
0 Check for water leaks in boiler and piping. Iffound, immedi-
ately call your service technician to repair.
End of heating season
0 Perform all above daily and weekly procedures. Call your
service technician
if anyproblems are found.
Boiler shutdown
0 Do not dram boiler unle ss exposure to freezirig temperatures
will occur.
0 Always keep manualfuelsupplyshutoffifburner is shut down
for
an extended period of time. To do so:
l. Turn off the ON/OFF switch on the boiler and any external
sw itches feeding the boiler.
2. Close fuel valves.
3. Turn
off water feed valve.
4. Cover burner to protect from dust
and moisture.
Report problems
0 If you notice any unu sual behavi or of the boiler or system,
contact yo ur serv ice technician to ha ve th e problem
irivestigated and corrected.
Part number 550- 141 -987/0912

'llltlta()lt. Series 2 WATER BOILER - Boiler Manual
Boiler location checklist
Before placing the boiler, verify:
United States installations must .Applicable state, local
and national codes.
comply with all applicable
U. S. .National Electrical
Code .
.Standard
for Controls and Safety Devicesfor Automatically Fired Boilers, AN SI!
codes: ASME
CSD- 1, when required.
0 Canadian installations
must
.Canadian Standards Association
CSA B139, Installation Code for Oil-Burning Equip-
comply with all applicable Cana-
ment.
.
CSA C22 .1 Canadian Electrical Code Part One .
dian codes: Applicable provincial
and local codes.
.
.
The boiler area must be kept free of combustible materials, gasoline and other flam-
0 Consider
use of space 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.
.See manual
pages 38 and 39 for boilerdimensions and weights.
0 Moving boiler
to location . If necessary, the boilerjacket can be removed if desired for handling. See manual
pages 30 and 31 for instructions.
.Provide minimum clearances
to combustible materials and forservicing boiler .
0 Clearances .Ensure
that the swing-away burner door can swing open freely. (The hinge can be
mounted on right or left side.)
.See manual
page 11 for instructions on changing door hinge location.
.Provide level flooring (non-carpeted combustible flooring
is acceptable if boiler level-
0 Flooring
and foundation ing
legs are installed).
.Provide foundation
if necessary .
.See manual page 9 .
.Boiler room must provide adequate combustion air and ventilation.
0 Combustion and ventilation air .
Unless burner uses ducted outside air forcombustion, the boiler room must provide
openings combustion
air openings.
.See manual page 9.
Chimney venting:
.Ensure the vent pipe
can be routed to the chimney, and that the chimney connection
is higherthan the boiler flue outlet.
.Ensure
the vent piping will provide minimum clearances shown on manual pages 8
and 12.
0 Venting .See manual
pages 12 and 13 for venting information.
Direct venting:
.
The Ultra oil boiler can be direct vented, using the Field Controls Direct Vent Kit. Ver-
ify that the vent piping can be installed and routed to the outside wall as specified in
the Field Controls instruction manual.
.Ensure
the vent piping will provide minimum clearances shown on manual page 8.
.
Check location of system water piping connections to be sure boiler can be properly
0 System water piping connected.
.See manual
pages 14 through 18.
0 Fuel supply .See manual
page 22 for routing of fuel lines.
.
The boiler requires 1 20 vac power and connection to a room thermostat or other
0 Electrical
power
device to initiate call for heat.
.
If equipped with an AFM, the boiler requires a 20-amp service.
.See manual
pages 19 through 21.
lA WARNlNG I Failure tokeep boilerareaclear and free of combustiblematerials,gasoline and other flammable liquids and vapors can
result in severe personal injury, death or substantial property damage.
lA CAUTlON I
If the Ultraboilerwill replace an existing boiler, check for and correctsystem problems, such as:• System leaks causing
oxygen corrosion
or heat exchanger cracks from hard water deposits; • Incorrectly-sized expansion tank; • Lack
of freeze protectioninboilerwatercausingsystem and boilerto freeze and leak Failureto correct such conditionscould
result in failure of the new boiler.
Part number 550-141-987/0912 7

'llht:afJit. Series 2 WATER BOILER - Boiler Manual
Prepare boiler location
Provide minimum clearances
From combustible materials (see Figure 1) Figure 1 Minimum clearances to combustible surfaces and
recommended minimum service clearances
1. Hot water pipes
• All directions - Vz inch.
(notshown in Figure
1)
2. Double-wall vent pipe
• All directions - 6 inches.
3. Single-wall vent pipe.
• All directions - 18 inches.
4. Boiler jacket surfaces
• Top of Control P od cover - 12 inches.
• Sides andback- 2 inches.
5. Burner cover
• All directions - 2 inches.
NOTICE I Combustible clearances always take pre-
cedence overservice clearances.
For se rvice access (see Figure 1)
I NOTICE
If you do not provide the minimum
service clearances shown, it might not
be possible to service the boiler without
removing it from the space.
1. Recommended service clearances:
8
Front of burner cover -20 inches
Jacket top -24 inches
Jacket sides and back - 6 inches
Burner door swing clearance -
12 inches minimum
(doormustswing
fully open)
/
U<l004
0 //////// < /<- ------------,
1i V
~ : 211 :
op 1ew D ..-_ I . . t I
w -- " m1mmum o 1
---- - - .....L._
1 combustible 1
f
20
11
recommended
min - service
~c
: 611
-- ------- ~ recommended
: min
-s ervice
C _ 6" min forType "L" doublewall vent pipe
-18" min for single wall vent pipe
24
11
recommended
min -service
1
211
minimum to
combustible
I
I
I
•
Part number 550-141-987/0912

'llltlta()lt. Series 2 WATER BOILER - Boiler Manual
Prepare boiler location (continued)
Flooring and foundation
Flooring
1. Install on any level, properly-supported, and non-
carpeted surface. Flooring may be combustible if
boiler leveling legs are installed.
2. Ensure theflooring is capable of handlingtheboiler
weight (see page 39 for weight and water volume).
Residential garage installations
In stall boilerso the burner is atleast 18 inches above the
floor
to avoid contactwith gasoline fumes.
Foundation
Provide a level concrete, masonry or cement block
foundation
if the flooring could become flooded or is
not level. See Table 1for foundation size required.
Table 1 Boilerfoundation size (when req'd)
Model
Length
Width
Height, min.
(i nches) (inches) (inches)
U0-3
49 23 2
U0-4 53 23 2
U0-5
57 23 2
Air openings for combustion and
ventilation air
IAWARNING I Adequatecombustion andventilation air
ensures proper combustion and reduces
risk
of severe personal injury or death
from possiblefluegas leakage andcarbon
monoxide emissions.
IAWARNING I Do not install exhaust fan in boiler
room.
Natural infiltration
Older buildings with single-pane windows, minimal
weather-stripping and no vapor barrier often provide
enough natural infiltration
and ventilation without
dedicated openin
gs .
Tight construction
New construction or remodeled buildings are most
often built tighter. Windows and doors are weather-
s
tripped , vapor barriers are used and openings in
walls are caulked. As a result, such tight construction
is unlikely
to allow proper natural air infiltration and
ventilation.
Part number 550-141-987/0912
Follow code requirements
Follow state, provincial or local codes when sizing
adequate combustion and ventilation air openings.
In
absence of codes, use the following guidelines when
boiler is
in a confined room (defined by NFPA 31 as
less than 7200 cubic feet per 1 GPH input of all appli-
ances in area. A room 8
ft. high x 33.5 ft. x 33.5 ft. is
7200 cu. ft .).
Provide two permanent openings
Provide two permanent opening s- one within 12
inches of ceiling, one within 12 inches of floor. Mini-
mum height or length dimension of each rectangular
opening should be at least 3 inches.
Air from inside the building
When inside air is used- each opening must freely
connect with areas having adequate infiltration from
outside. Each openingshould be
at least 140 sq .in. per
1 GPH input (l
sq . in. per 1000 Btu input) of all fuel-
burning appliances plus requirements for any equip-
ment that can pull air from room (including clothes
dryer and fireplace).
Air from outside the building
When outside air is used -connect each opening
directly
or by ducts to the ou td oors or to crawl or at-
tic space that freely connects with outdoors.
Size per
below:
Throughoutsidewall
or vertical ducts- at least35
sq. in.per 1GPH input
(1 sq. in.per4000 Btuinput)
of all fuel-burning appliances plus requirementsfor
anyequipmentthatcanpullair from room (includ-
ingclothes dryer and fireplace).
Throughhorizontal
ducts- at least70sq. in. per 1
GPH boilerinput (1 sq. in. per2000 Btuinput) of all
fuel-burning appliances plus requirements for any
equipment that can pull air from room (including
clothes dryer
and fireplace).
Whereductsare used,theyshouldhave samecross-
sectionalarea
as free area of openings to which they
connect. Compensate for louver, grille
or screen
blockage when calculating free air openings. Refer
to their manufacturer's instructions for details. If
unknown, use:
-Wood louvers, which provide 20-25% free air.
-Metal louvers or grilles,which provide
60-75% free air.
Lock louvers in open position or interlockwith equip-
ment to prove open before boiler operation.
9

'llht:afJit. Series 2 WATER BOILER - Boiler Manual
Prepare boiler location (continued)
Place the boiler:
Remove outer crate
1. Remove outer crate, leaving boiler on the crate base.
2. Remove the circulator and barometric damper cartons from the crate
base.
3. U0-3 boilers only-Remo ve the two flue baffles fastened to the crate
base behind the boiler.
4. Remove thetwoshippingchannelsbylooseningand removingthefour
nuts.Save the shipping channels for leveling leg installation.
5. Remove thejacket cross tie fastened to the crate base.
Install the leveling legs if used (required if boiler is placed on
combustible flooring)
I AWARNING I The leveling legs must be installed if the boiler is placed on
combustible flooring.
I AWARNING I Asecond person, or other means, is required to stabilize the
boiler during leveling leg installation. Failure to do so could
result in severe personal injury or property damage.
I AWARNING I Wear heavy leather workgloves when handling the shipping
channels in the following steps
to avoid potentialsevere per -
sonal injury.
1. (Figure 2a) Use one channel as a lever to raise the front of th e boiler.
2. (Figure 2a) Insert the other channel between
th e boiler leg and crate
base. Place the channel directlyover the crate base runner, as shown.
3. (Figure 2b) Lift the channel under the boiler leg slightly.
4. (Figure2b) Slide the other channelunder the otherboilerleg. Place the
channel directly over the crate base runner, as shown.
5. (Figure 3) Wi th th e boiler resting securely on the two shipping chan-
nels, screw a leveling leg in each boiler leg hole. Screw leveling legs in
completely.
I AWARNING I To avoid potential personal injury or property damage, DO
NOTattempt toinsertleveling legs unless the boiler is securely
seated on bothshipping channels.
6. Reversesteps2through4 above to remove theshippingchannels. Leave
the boiler
on the crate base.
7. Followsteps 2 through6
on thebackside of theboilerto install leveling
legs in th e rearsection legs.
8. Leave the boiler on th e crate base.
Remove boiler from crate base
I AWARNING I Boilers m~y.be top heavy. Use cautionwhenhandlingtoavoid
personal
ill JUry or property damage.
1. Attachthecross tie tothejacketside panels usingthetwo screws located
inthe barometricdampercarton.
Then remove theboilerfrom the crate
base.
I AWARNING I Do not remove the boiler from the crate base without first
installing the jacket cross t
ie . The boiler wiring harnesses or
connectors could be damaged.
2. Ifnecessary,theboilerjacketcan beremoved for handling.See pages 30
Figure 2a To install leveling legs: Insert first
shipping channel under boiler leg.
Lift boiler using channel
as a lev er
Figure 2a To install leveling legs: Insert second
shipping channel underother leg.
Figure3 Inserting levelling legs
and 31 in this manual for thejacket removal/replacement procedure. Screw leveling l egs compl ete ly into hol es in boiler l egs
10 Pa rt number 550-141-987/0912

'11/tm()d. Series 2 WATER BOILER - Boiler Manual
Prepare boiler location (continued)
Perform hydrostatic pressure test:
See pages 2 and 3 for boiler feature locations.
l. Install air vent in relief valve tapping.
2. Plug supply
and return tappings.
3. Install the boiler drain valve shipped with boiler.
4. Fill boiler.
5. Vent all air.
6. Pressure test bo
il er at l lf2 tim es working pressure.
I AWARNING I Do not leave bo il er una tt e nd ed. Cold water fill can expand
and damage cast iron, resulting in severe personal injury ,
death
or substantial property damage.
7. Check for maintained gauge pressure for at least
10 minutes.Visually
check for leaks ifgauge pressure drops.
8. Drain boiler. Repair leaks
if found.
I AWARNING I Do not use petroleum-based sealing compounds to repair
leaks. Damage to system components can result, causing
property damage.
9. Retest boiler after repairing leaks.
10 . Remove air vent and plugs. Reinstall reli ef valve.
Boiler preparation
Changing door hinge
Theboiler is shippedwiththe burnerdoorhinged on theleftside.The hinge
bracket can be relocated to the ri
gh t side if desired.See Figure 4.
l. Remove jacket front pane l.
2. Remove and retain burner door screws and washers used to fasten the
burner
door to the front section ( one on each side of door).
3. Carefully lift the burner door so the door pins li
ft ou t of the hinge
bracket.
4. Set t
he burner door aside temporarily.
I AWARNING I Theburner door is heavy.Handle carefully to avoid potential
for personal injury.
I AWARNING I Do not damage the burner door insulation when handling.
5. The hinge bracket has keyhole slots. Loosen the two screws securing
t
he hinge bracket to t he front section.Remove the hinge bracket.
6. Loosenthetwo screws
on the oppositeside. Place the hinge bracket on
t hat side and tighten the two screws to secure t he bracket.Also tighten
t
he two screws on the otherside.
7. Carefully lift the burner
door and position so the door pins slide into
t
he hinge bracketholes.Thelower pin is longer than the upper.Soalign
t
he lower pin, then the upper.
8. Replace burner
door screws and washers used to fasten theburnerdoor
to the front section (one
on eachside of door).
Flue baffles -
U0-3 ONLY -1.0 GPH firing rate ONLY
On U0- 3bo il ersfired at 1. 0 GPH ONLY ,install the twoflue baffles sup -
plied with the boiler.
See page 33 for location.
Part nu mb er 550-141-987/0912
Figure 4 Burner door hinge installation
Hinge bracket and screws
(factory-installed on left side)
U0 01 0
DO NOT in sta ll ba ffl es on U0- 3 boilers
fired at 0
.8 GPH. Flue gas co nd ensation
will result, causing corrosion damage to
boiler
and ventsystem.
Combustion chamber floor blanket -
All
Direct Vent and U0-3- 0.8 GPH firing rate
Place the ceramic fiber floor blanketon th e fl oo r
of the combusti on chamber. The blanket and instruc-
tions are supplied
in th e U0- 3 low firing rate kitfor
the 0.8 GPH boiler
or supplied with the burnerfor
direct vent.See page 33 for location.
t1 j.t!)@j;l If th e bo il er has flue ba ffl es installed, yo u
mu st remove th e b af fl es before chang in g
to
th e lowfiring rat e. Flue gas co nd ensa-
tionwill result,causingcorrosiondamage
to boiler and vent system.
Check chamber and burner door
1. Checkforsecure placement of insulation on burner
door .
2. All Direct Vent and U0-3 ,0.8 GPH firing ra te -
Checkforsecure placement
of combustionchamber
fl oo r bla nk et
3. Visually check burner mounting door
seal.
I AWARNING I Verify gas-tight seal to prevent possible
flue gas l
ea kage a nd ca rb on monoxide
emissions, which can lead to severe per-
sonal injury
or death.
11

'llht:afJit. Series 2 WATER BOILER - Boiler Manual
Prepare boiler location (continued)
Install the burner
l. Secure the burner flange to the burner door using
the three bolts provided.
2. Check for secure placement of insulationandsealing
rope
on the burner door.
Connect breeching
12
Direct venting
TheUltraOilboiler can bedirect ventedusing theField
ControlsDirectVent Kit, model number FDVS-46, and
vent pipe model number FVOP-415. Vent lengths are
limited to 15 feet. Air intake lengths are limited to 22
feet of rigid 4 -i nch pipe. Do not useflexible dryer vent.
Refer to instructionsprovidedwiththeventkitfor vent
and air piping installation procedures.
I NOTICE 1 Direct venting is allowed only with
Beckett NX and Riello BF5 burners.
Chimney venting
General chimney requirements:
T he UltraOil boileris designed for naturaldraftfiring.
Connect boiler to vertical chimney.
Insufficient draft can cause flue gas
leakage and carbon monoxide emis-
sions,whichwilllead tosevere personal
injury or death.
Inspectexisting chimneybeforeinstall-
ingnew boiler. Failure to do any of the
following will result insevere personal
injury or death:
Clean chimney, includi ng removal of
blockage.
Repair
or replacedamaged pipe or liner.
Repair
mortar and jo ints.
Use vent material approved by local codes for oil-
fired burners. In their absence, refer to:
NFPA 31,Installation of Oil-BurningEquipment.
NFPA 211, Standardfor Chimneys, Fireplaces,
Vents and Solid Fuel BurningAppliances.
In Canada,refer to CSA Bl39, Installation
Code for Oil-Burning Equipment.
3. Close the burner door and secure in place with the
burner door screws and washers.
4. Follow
the burner manual and boiler manual
(pages 19 to22) to wire theburner and connect fuel
lines.
Table 2 Chimneyventing -vent sizing
Minimum Minimum
l= B=R
Minimum
br ee ching
chimn eys iz e
chimney
Model
diam eter
(inches)
he ight
(inches)
Rect. Round
(feet)
U0- 3 5
8x8
U0-4
6
(63,4 X 63,4
6 15
U0-5
6 liner)
Note: boiler flue connection is 6-inch diameter
N FPA 211 requireschimneyto belinedbefore con-
necting to boiler.
To prevent downdrafts, extend chimney at least 3 feet
above highest point where it passes through roof and 2
feet higher than anyportion of buildingwithin 10 feet.
Increasechimneycross-sectional area and heightatleast
4% per 1,000 feet above sea level.
Minimum clearancesfromventpipe to combustible
material:
• Type"L" doublewall vent - 6 inches
• Single wall vent - 18 inches
Minimum chimneysizes should be used.
NOTICE
Oversized chimneys, outside masonry
chimneys and/or deratedinputscan result
in condensation in chimney.
Part number 550- 141 -987/0912

'llltlta()lt. Series 2 WATER BOILER - Boiler Manual
Connect breeching (continued)
Chimney vent i ng (continued)
Conn ec t br eec hing:
IAWARNING I Long horizontal breechings, excessive
number of tees and elbows or other ob -
structionsrestrictingcombustiongasflow
can result in possibility
of condensation,
flue gas leakage
and carbon monoxide
emiss ion s, which can lead to severe per-
sonal injury
or death.
1. Connect full-sized breeching when possible. See
Table 2, page 12, and Figure 5, below.
2. Connectionmustbemadeabovebottom
of chimney
to avoid blockage. Breeching must not enter chim-
neyfar
enough to causeobs truc tion. Use thimble or
slip joint where breeching enters chimney to allow
removal for cleaning.
3.
When burner and boiler are properly installed,
breeching draft will be approximately -0.0
l" to
-0.02" W.C. Install barometric control in breech-
ing, per
con tr ol manufacturer's instructions, when
excess draft needs to be relieved or to complywith
applicablecodes
and regulations. Use draftgauge to
adjust proper opening.
NOTICE
The Ultra Oil boiler is capable of being
pressure fired. Overfire pressure
may be
positive even wi th a negative pressure
in the chimney. See the Ratings table
on
page 39 for boiler draft loss.
I AWARNI NGI The pressure in the breeching and chim-
ney
must always be negative unless the
chimney
and breeching are constructed
of vent piping designed for pressurized
ven
tin g.
4. An induceddraftfan forthechimneymaybeneces-
sary
if:
Ex cess i ve resistan ce to flow of combustion gases can
be
expected .
Cross-sectional area ofchimney
is smaller than mini-
mum recommended.
Chimney height
is l ess than re co mmended.
5. When using an induced draft fan:
S eal all ven t joints.
• Interlock burner with fan operation.
Fi gure 5 Breech connection, typical, for gravity venting into chimney
Part number 550-141-987/0912
---------- -- ...
---------- ...
U00 11
''I
I
............
' '''
'
'
Typical locations for barometric
draft control (also see draft
control manufacturer's instructions)
13

'llht:afJit. Series 2 WATER BOILER - Boiler Manual
Connect water piping
14
General piping information:
ASME or Canadian requirements
If installation
is to comply with ASME or Canadian
requirements,
an additional high temperature limit is
needed. Installcontrol insupply pipingbetween boiler
and isolation valve.Set control
to a minimum of 20 op
above set point of the boiler limit temperature senso r.
Maximum allowable set point is 220 °F. Wire control
as shown on wiring diagram (page 20 &21).
Low water cutoff devices
The Hydrostat 3250 control has
an integrated LWCO
device. The probe for the control is inserted into the
well located
on the top offtheboiler. Ensure the probe
is fully inserted into the well.
Backflow prevention
Use backtlow check valve in cold water supply as re-
quired bylocal codes.
Install piping:
Pipe sizing
See Table 3 for pipe sizing for near-boiler piping and
single-zone piping.
Near-boiler piping
(with diaphragm expansion tank)
See Figure 6,page 15.
Near-boiler piping
(with closed expansion tank)
See Figure 7,page 15.
Multiple-zone piping
See page 16.
Low-temperature system piping
See page 17.
Chiller system piping
See page 18.
For multiple-boiler piping
Refer
to Weil-McLain's "Primary/Secondary Piping
Guide."
Relief valve
Install relief valve vertically in elbow supplied. See
Figure 6 or 7 for location.
See WARNING at right.
Also refer
to tag attached to relief valve for manufac-
turer's instructions.
Table 3 Water piping sizing
Piping to Piping from
Model system system
( inches ) (inc hes )
U0-3
1% 1%
U0-4 1% 1%
U0-5
1112 1112
Note: sizing based on 20 °F temperature rise through boiler.
IAWARNING I Relief valve discharge piping:
To avoid water damage or scalding
due
to reliefvalve operation:
Discharge line
must be connected to
reliefvalve outlet
and run toasafe place
of disposal. Terminate the discharge
line to eliminate possibility
of severe
burns should the valve discharge.
Dischargeline
must beas short aspos-
sible
and be the same size as the valve
discharge connection throughout its
entire length.
Discharge line
must pitch downward
from the valve
and terminate at least
6" above the floor drain where any
discharge will be clearly visible.
• The discharge line shall terminate
plain, not threaded, with a material
serviceable for temperatures
of 375 op
or greater.
Do
not pipe the discharge to any place
where freezing could occur.
• No shutoffvalve shall be installed be-
tween the reliefvalve
and boiler, or in
thedischarge line. Do
not plug or place
any obstruction
in the discharge line.
Failure
to complywiththeabove guide-
lines could result in failure
of the relief
valve
to operate, resulting in possibil-
ity
of severe personal injury, death or
substantial property damage.
• Test the operation of the valve after
filling
and pressurizing system by
lifting the lever. Make sure the valve
discharges freely.
If the valve fails to
operatecorrectly, replace it with a new
relief valve.
Part number 550 -1 41 -987/0912

'llltlta()lt. Series 2 WATER BOILER - Boiler Manual
Connect water piping (continued)
DIAPHRAGM expansion tank (Figure 6)
Makesureexpansion tanksizewillhandleboiler and
system water volume and temperature. Tank must
be located near boiler before inlet to circulator. See
tank manufacturer's instructions for details.
lA CAUTlON I Undersizedexpansiontankscausesystem
water to be lost from relief valve and
makeup water added through fill valve.
Eventual section failure can result.
CLOSED expansion tank (Figure 7)
Ensure expansion tank size will handle boiler and
system water volume and temperature.
lA CAUTlON I Undersizedexpansiontankscausesystem
water
to be lost from relief valve and
makeup water added through fill valve.
Eventual section failure can result.
Pitch anyhorizontal piping up towards tank 1inch
per 5 feet
of piping.
Part number 550-141-987/0912
Figure 6
Supply
Figure 7
Near-boiler piping, with diaphragm expansion tank
(!)ou tlet
@Return
®Re l ie f valve
@ Pfpeto drain
@ Drain va l ve
@ Isolation valves
®Boilercirculator
®Diaphragm-type
expansiontank
®Air separatorand
auto airvent
·- By others
•- Suppli ed with
boi le r
Near-boiler piping, with closed expansion tank
(!)Ou tlet
@Return
®Re l ie f va l ve
@ Pipe to drain
@ Dra in valve
@ Isolation
va lves
®Sollercirculator
@C iosed·type
expansion tank
®Air separator
· -By others
·- Suppliedwith
boi le r
15

'llht:afJit. Series 2 WATER BOILER - Boiler Manual
Connect water piping (continued)
Piping MULTIPLE ZONES - System temperature 140 oF or higher
16
l. Follow instructions on page 14 and 15 to install
piping near boiler.
2. Zoning with circulators (Figure 8)
a. Size each circu l ator to individual circuit require-
ments.
b. Remove circulator (when furnished
as standardequip-
ment).
c. Installbalancingvalves to adjustflow to distributeheat
to all zones.
Figure 8 Multiple zoning with circulators-
Temperatures 140 °F and higher
5
U0014
1 Isolation va l ve
2 Flowcontrol valve
3 Circulator
5
d. Separate relay is required for eachcirculator.
3. Zoningwith zone valves (Figure 9)
a. Install balancing valves to adjust flow to distribute
heat to all zones.
b. Separate
tran sformer is required to powerzonevalves.
Refer
to "Well-McLain Zone Valve Wiring
Guide" for details.
Figure 9 Multiple zoning with zone valves -
Temperatures 140 °F and higher
r
-----.
-+------ Zone 2 r---------- +..
T L----- T
I I
1 Zone 1 1
I I
~ ~
I
I
I
I
I
I
~ -+I++Tt---I)I(J----1..,.
5
U 0015
4 Zone valve
5 Drain valve
4 I
~
I
I
I
r+---f:lcl--+,r+-+LI- ofT
Part number 550-141-987/0912

'llltlta()lt. Series 2 WATER BOILER - Boiler Manual
Connect water piping (continued)
Piping MULTIPLE ZONES - System temperature below 140 oF
1. Ifsystem water temperature requirements are less
than 140 °F, such as radiant panels or converted
gravity systems, use piping as shown
in Figure 10
or 11 .
2.
If system piping is plasticwithout an oxygenbarrier,
a heat exchanger must be used.
3. Follow instructions on page 14 and 15 to install
near-boiler piping.
4. Zoning with circulators (Figure 10)
a. Size each circulator to individual circuit require-
ment s.
b. Removecirculator(when furnished
as standardequip-
ment ).
c. Installbalancingvalves to adjust flow to distributeheat
to all zones.
d. Separate relay
is required for each circulator.
Figure 10 Multiple zoning with circulators-
Tem peratures below 140 °F
r
---,
fr---- Zone 2 _____ ....,. __ _.,__
T ----.J T
I I
1 Zone 1 1
~ ~
~~~9
6
8
U0016
1 Isolation va l ve
2 Flow control valve
3 Circulator
7b
4 System temperature gauges
5 Zone
va l ve
Part number 550-141-987/0912
6
5. Zoning with zone valves (Figure 11 )
a. Installbalancingvalves to adjustflow to distributeheat
to all zones.
b. Separatetransfo
rmer isrequired to powerzonevalves.
Refer
to "Weil-McLain Zone Valve Wiring
Guide" for details.
6. To set the valves, 7a and 7b:
a. Set the valves while the system is cool,setting for the
coldest expected water
temperature (usually 60 °F
since thesystem will often drop to room temperature
between cycles).
b.
Start withvalve 7a fully closed and 7b fully open.
c. Gradually open valve
7a while closing 7b until the
temperature at gauge 8 reads
130 °F when gauge 4a
reads 60 °F.
d. Note that valve 7a regulates the amount of hot water
from theboilersupply,whichmixes withreturn water.
Valve 7b regulatesthe amount of systemwaterflowing
through
the boilersecondaryloop.
Figure 11 Multiple zoning with zone valves-
Temperatures below 140 °F
V0017
6 Drain valve
7 System temperature va l ves. Adjust valves
8 Blend temperature gauge
9 Boilertemperature gauge (not shown)
17

'llht:afJit. Series 2 WATER BOILER - Boiler Manual
Connect water piping
(continued)
Piping boiler in refrigeration systems
(Figure 12)
Install boilerso that chilled medium is piped in parallel with
heating boiler. Use appropriate valves to prevent chilled
me -
dium from entering boiler. Consult AHRI Installation and
Piping Guides.
If boiler isconnected to heatingcoils located in air handling
units where theycan be exposed
to refrigerated air, use flow
control valves
or other automatic means to prevent gravity
circulation during cooling cycle.
Figure 12 Piping boiler in a system with chiller
Supply I
so lat ion
valve
I
so lation valve
Circulator
Ch ill er
Strainer
Balancing
valve
Return I
so lation
valve
U0013
Connect wiring
General wiring requirements
I AWARNING I El ect ri c sh oc k hazard. Can cause severe personal
injury
or death if power source, including service
switch
on boiler, is not disconnectedbefore install-
ing
or servicing.
Installa ti ons mu st follow th ese co des:
18
United States:
National Electrical Code, ANSI/NFPA 70, latest edition and
anyadditional national, state or local codes.
Canada:
CSA C22.1 Canadian Electrical Code Part 1 and any local
codes.
Connect wiring
Wir e re qu ireme nt s
Wiring must be N.E.C. Class 1.
If original wire supplied with boiler must be replaced, type
105 oc wire or equivalent must be used.
Supplywiring:
• Boiler only - 14 gauge or heavier.
• Boiler with optional AFM - 12 gauge or heavier.
El ec tri ca l re qu ireme nt s
Boilers not equipped with an AFM can be supplied by a 15-
amp service.
Boilers equipped with
an AFM require a 20- amp service.
El ec tr ica l gro und i ng
Provide electrical ground at boileras required by codes.
Wiring entrances (see Figure 13)
Te rm inal str ip access
Remove thetworetainerscrews in thejacket top panel (at rear
of the boiler) and remove the jacket top panel.
Release theControlPodcover bylooseningtheretainerscrew
in the top center
of the cover.Swing the cover open to reveal
the boiler terminalstrip.
Figur e 13 Terminal strip access
Contro l Pod cover
000 18
Part number 550-141-987/0912

'11/tm()d. Series 2 WATER BOILER - Boiler Manual
Connect wiring
Remove the Control Pod cover to facilitate wire routing. (To Figure 14 Burner harness routing
remove, push th e Control Pod cover to one sid e, and gently
work the cover retainer hinge
on the other side out of the
jacketslot.)
120-volt wiring
Conduits
Connect each conduit supplying line-voltage wiring to or
from the boiler to a conduit opening in th e upper portion of
thejacket rear panel.
All field-provided line-voltage wiring must be sheathed in
flexible metal conduit.
Additional limits
If required bystate or local codes, provide additional limits
as needed.
When using additional limits, remove the factory-installed
jumper between boiler terminalstrip terminals
19 and 20.
Connect the additional limits in series and wire to boiler
terminalstrip terminals
19 and 20.
Circulator
The circulator is shipped wi th th e boiler, but not installed or
wired.
Wire the circulator to the boiler terminal strip as shown on
the boiler wiring diagram. Provide hot, neutral and ground
wires, routed in metal conduit.
Thermostat wiring
Install thermostat on inside wall away from influences of
drafts, hot or cold water pipes, lighting fixtures, televisions,
sun rays or fireplaces.
-r
See detail below t
Jacket crosstie
Power harness
Follow instructionswith thermostat
Ifthethermostathasaheatanticipator,settheheatanticipator
per the limit control manufac
tur er's recommendati on .
Burner wiring (see Figure 14)
--
~Power harness, burner to eras::
Theburnerharnesses incorporate disconnect plugs, providing
aconvenient
way todisconnect wiringwhenburnermounting
door is opened.
I AWARNING I Failure to disconnect the burner wiring harness
before opening the burner door can cause damage
to the burner and boilerwiring.
Optional AFM installat ion
See separateAFM instructions when used.
When wiring is completed:
Reinstall the Control Pod cover, close cover and tight en the
retainer screw.
Replace jackettop
and secure with screws.
Part number 550-141-987/0912
19

'llht:afJit. Series 2 WATER BOILER - Boiler Manual
Connect wiring (continued)
Figure 15 Boiler and burner wiring, standard equipment
NOTICE
This wiring diagram is for standard boiler
equipment. ForwiringwithoptionalAFM,
see AFM instructions.
ADVANCED FEATURES MODULE • OR • TH ERMOSTAT (NOTE 7)
Wiring Diagram
r;::::========r·-· : ·-·~
BOILER
:~:~ I..Q=f------"\
I!OIL£R
2
ALERT OUTPUT
F ROM LWCO OFF BOILER 2
G
--------------------.
'
I
I
I
'
BLOCKED VENT !
UTOF F S'M T CH !
(CANADA ON LY) 1
TEMPERATURE I
LI ~T CONTROL :
------ ---··--- ------- ___ J
JU MPER
(NO TE 51 FIELD WIRI NG
D
AD VANCED FEATURES MODULE
--- --- ~ l l
0000
REMO TE
DISPLAY
MODULE
SEE AFM INSTAU.A ll ON I NSTRUCTIONS FOR
APP LI CATION SPEC I FIC wtRI NG
- 120VAC F1 ELDW IRI NG
- LOW VOlTAGE FIE LDWIRI NG
- 120VAC FACTORY WIR I NG
- LOW VOLTAGE FACTORY WIR IN G
IA WARH14GI Electrical shock hazard- can cause severe injuryor death .
I NOTICE I Burners with Beckett Clean Cut Pump must be used with a
pri mary control that has a valve-on delay (pre-purge).
Controls shown have valve on delay (see control
~ WEIL·mcLAII
Wti ~ Mcuin 500 lllai ne S1 . Miclligan City. IN 403ro-2388
PART NUMBER ULTO·EODB·B/0112
(OO'T I ONAI. E<lUI P MENl)
._ _______ o__o_a [o- ~ ~ (£i]J
COMB I NA TI ON
HGH LIMIT. RELAY
AND TRANSFORMER
W OJ
I
BOI LER W IRIN G B
URNE RDI SCON NEC TS
--------------------------------------------- ____ _I
NO TES:
1. Al lwi ring must be i nsta led in accordancewith N.E.C. andanyother nationa l, state, or localcode reqlir ements..
For Canadian i nsta l at io ns. al wimg must comp ly with lhe Canad ia nBeclrical COOe .
2.All wiring musl be N.E.C. Class I.
3. Electrica l Serv i ce :
Bo iler on ly· requires 15ampservi oe
Bo iler with opliona l AFM . requires 20 amp seMee.
4. 11 any origina l wire as sup pli ed with boiler must be re pl aced . uS<> m inimum 10s• C wire of same gage .
S. Connect addttiona lli mi ls ( ~ requi r ed) between l erminals 18 and 19. Remove fact ory j umper .
6. Re f er to con trol oompo nenli nstruct ions packed with the boiler for a ppli cation infonnation.
7. Setlhermoslal healanlicipator
as percon trol manu f actu rer's r eoommenda li on .
8.1 nsla lll im il senso r in W<ll lwilh cli p.
9. See Advanced FeallJres Modu lel nsla llalion In struct i ons for a ppli cation for specific wiring.
20 Part number 550 -1 41 -987/0912