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