Instruction/ maintenance manual of the product 80 Ultra electronic
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Part number 550-100-026/0404 • Installation • Star tup • Maintenance • P ar ts This manual must only be used by a qualified heating installer/service technician. Read all instructions, including this manual, the Ultra Control Supplement and the Ultra V ent Supple ment, before installing.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 2 T HE BOILER , WITH Ph Ph Ph Ph Ph D D D D D TECHNOLOGY – H OW IT WORKS .
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 3 T HE GAS - FIRED W A TER BOILER , WITH Ph Ph Ph Ph Ph D D D D D TECHNOLOGY.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 4 Contents 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.
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 5 Please read before proceeding Failure to adhere to the guidelines on this page can result in severe personal injury , death or substantial pro pert y damage.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 6 Figure 1 Clearances required P repare boiler location 1 Installations must comply with: Installations must comply wi.
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 7 P repare boiler location (continued) 1 Flooring and foundation Flooring The Ultra boiler is approved for installation on combustible flooring, but must never be installed on carpeting.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 8 Table 1 Corrosive contaminants and sources Prevent combustion air contamination Install air inlet piping for the Ultra boiler as described in the Ultra Boiler V ent Supple ment.
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 9 Remove boiler from crate Cold weather handling — If boiler has been stored in a very cold location (below 0°F) before installation, handle with care until the plastic components come to room temperature.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 10 Figure 2a Installing propane orifice (Ultra-155, Ultra-230 & Ultra-310 Series 2 ) Ultra-310 Series 2 Ultra-155 .
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 11 Prepare boiler (continued) Perform hydrostatic pressure test Pressure test boiler before permanently attaching water or gas piping or electrical supply . Prepare boiler for test 1 .
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 12 Install water piping 3 Install relief valve 1 . Install relief valve in ¾" street elbow piped from boiler supply piping tee (Figure 3, page 11). Pipe the relief valve only as shown, in the location shown.
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 13 Install water piping (continued) 3 Figure 4 Expansion tank piping System water piping methods All piping methods shown in this manual use primary/secondary connection to the boiler loop.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 14 Install water piping (continued) 3 Figure 6 Pump curves for typical circulators suggested for DHW loop Ta b l e 2 P.
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 15 Install water piping (continued) 3 Figure 7 Zone valve zoning plus optional DHW piping Zoning with zone valves 1 . Connect boiler to system as shown in Figure 7 when zone valve zoning.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 16 Install water piping (continued) 3 Figure 8 Circulator zoning plus optional DHW piping Zoning with circulators 1 . Connect boiler to system as shown in Figure 8 when circulator zoning.
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 17 Figure 9 Typical radiant heating system piping plus optional DHW Radiant heating applications 1 . The Ultra b oiler is id eal for use in radiant heating. The Ultra boiler’ s unique heat exchanger design allows it to work well even in condensing mode.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 18 Chilled water systems 1 . Install boiler so that chilled medium is piped in parallel with the heating boiler . U se appropriat e valves to p reve nt chilled medium from ent er ing boiler .
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 19 V enting , combustion air & condensate line 4 Prepare condensate fittings 1 .
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 20 Connect condensate drain 1 . Remove condensate trap line from bag. Prepare and install per page 19. Secure to jack et by attaching PV C tee as shown in Figure 13. 2 .
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 21 Gas piping 5 Connecting gas supply piping 1 . Remove jacket front panel and refer to Figure 15 to pipe g as to boiler . a. Install ground joint union for servicing, when required.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 22 T able 4 Pipe capacity for 0.60 specific gra vity natural gas Gas piping (continued) 5 Natural Gas: Pipe sizing for natural gas 1 . Ref er to T able 4 for pipe length and diameter .
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 23 Startup 6 Check/control water chemistry Do not use petroleum-based cleaning or sealing compounds in boiler system. Damage to elastomer seals and gaskets in syst em could occur , resulting in substantial property damage.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 24 Startup (continued) 6 Final checks before starting boiler ❏ Read the Ultra Control Supplement to familiarize yourself with Ultra PhD control module operation. Read Operating Instructions in Control Supplement for pr oper steps t o start boiler .
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 25 Startup (continued) 6 ❏ Check flame & combustion 1 . Press and hold both the Ultra control panel “ M ode” and “+” butt ons simultaneously until “H” appears.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 26 Check - out/startup verification 7 ❏ Boiler and heat distribution units filled with water? ❏ W ater c hemistr y.
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 27 Installation certificate Boiler model __________________ CP number ___________ Date installed _______________ Measured Btuh input ____________ Fuel: ❏ Natural Gas ❏ Propane ❏ Installation instructions have been followed.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 28 Annual startup and general maintenance Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler .
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 29 Annual startup The boiler should be inspected and started annually , at the beginning of the heating season, only by a qualified serv ice t echnician.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 30 Annual startup (continued) Clean condensate trap 1 . Loosen condensate trap line hose clamps and remove trap line. 2 . Empty water from trap line and inspect. Flush out if needed w ith fresh water .
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 31 Inspect ignition electrode 1 . Remove the ignition electrode from the boiler heat exchanger a ccess c ov er . 2. Remove any white oxides accumulated on the ignition electrode using sandpaper .
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 32 Annual startup (continued) 8a Figure 16 Burner assembly Perform startup and checks 1 . Start boiler and perform checks and tests specified on pages 23 through 26 (and Control Supplement).
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 33 Maintenance — general 8b Replace boiler jacket front door after startup or servicing Replace boiler jacket front door after start or servicing.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 34 Cleaning boiler heat exchanger (continued from previous page) Access exchanger: Ultra-155, -230, -310 Only 1 . Remove gas valve electrical plug from gas valve. Also remove two electrical molex plugs from blower assembly .
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 35 Replacement parts 9 Miscellaneous parts and kits Replace boiler jacket front door after startup or servicing Replace boiler jacket front door after start or servicing.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 36 Replacement parts (continued) 9 Jacket parts.
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 37 Replacement parts (continued) 9 Jacket parts.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 38 Replacement parts (continued) 9 Heat exchanger and piping — Ultra-80 & -105.
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 39 Replacement parts (continued) 9 Heat exchanger and piping — Ultra-80 & -105.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 40 Replacement parts (continued) 9 Heat exchanger and piping — Ultra-155 to -310.
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 41 Replacement parts (continued) 9 Heat exchanger and piping — Ultra-155 to -310.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 42 9 Replacement parts (continued) Controls.
GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 43 10 Dimensions 1 . Boiler supply and return tappings are both 1" NPT (Ultra- 80/105/155/230) or 1¼" NPT (Ultra-310). See pages 14 through 18 for recommended system supply and return piping sizes.
Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 44 Ratings DOE 1 . A s an Energy Star Partner , W eil-McLain has determined that Ultra boilers meet the Energy Star guidelines for energy efficiency . 2 . Based on standard test procedures prescribed by the United States Department of Energy .
An important point after buying a device Ultra electronic 80 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Ultra electronic 80 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Ultra electronic 80 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Ultra electronic 80 you will learn all the available features of the product, as well as information on its operation. The information that you get Ultra electronic 80 will certainly help you make a decision on the purchase.
If you already are a holder of Ultra electronic 80, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Ultra electronic 80.
However, one of the most important roles played by the user manual is to help in solving problems with Ultra electronic 80. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Ultra electronic 80 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center