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Gas-fired
Water boiler
Series 2
Ultra-80, -105, -155, -230 & -310
NOTICE:
• Installation
Series 1/Series 2 identification
Read the boiler rating plate to
determine the series number. The
rating plate is located on the right
Startup
side of the boiler.
Maintenance
Parts
with
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 Vent Supplement, before installing. Perform ste
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual THE BOILER, WITH Ph Ph PhDDD TECHNOLOGY – HOW IT WORKS . . . Ph PhDD PhD PhD PhD PhD PhD technology 12. Burner PhD Technology, Precision hydronic Data, is an intelligent system that Made with high-grade stainless steel construction, the burner delivers Precision hydronic heating and hot water needs while maximizing uses pre-mixed air and gas and provides a wide range of firing efficiency by measuring the Data parameters of your heating system. r
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual THE GAS-FIRED WATER BOILER, WITH Ph Ph PhDDD TECHNOLOGY Ph PhDD Part number 550-100-026/0404 3
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual Contents How it works.................................................................................... 2–3 Hazard definitions .............................................................................. 4 Please read before proceeding ........................................................ 5 1 Prepare boiler location .................................................................. 6 2 Prepare boiler ......................................
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual Please read before proceeding Installer— Read all instructions, including this manual, the Ultra Control Supplement and Ultra Vent Supplement, before Failure to adhere to the guidelines on this page can result in installing. Perform steps in the order given. severe personal injury, death or substantial property damage. User — This manual is for use only by a qualified heating installer/service technician. Refer to User’s Information When servicing
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 1 Prepare boiler location Installations must comply with: Installations must comply with: Installations must comply with: Provide clearances: Installations must comply with: Installations must comply with: Local, state, provincial, and national codes, laws, Clearances from combustible materials regulations and ordinances. 1. Hot water pipes — at least ½" from combustible National Fuel Gas Code, ANSI Z223.1 – latest edition. materials. Standa
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 1 Prepare boiler location (continued) Flooring and foundation Ultra boiler in same space with other gas or oil-fired appliances Flooring 1. Follow the National Fuel Gas Code (U. S.) or CSA The Ultra boiler is approved for installation on B149.1 and B149.2 (Canada) to size/verify size of the combustible flooring, but must never be installed on combustion/ventilation air openings into the space. carpeting. The space must be provided with Do not inst
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 1 Prepare boiler location (continued) Prevent combustion air When removing a boiler from contamination existing common vent system: Install air inlet piping for the Ultra boiler as described in Do not install the Ultra boiler into a the Ultra Boiler Vent Supplement. Do not terminate vent/ common vent with any other appliance. air in locations that can allow contamination of This will cause flue gas spillage or appliance combustion air. Refer to Ta
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 2 Prepare boiler Remove boiler from crate Ultra-105 Series 1 and 2 ONLY Prepare for propane operation Cold weather handling — If boiler has been stored in a very cold location (below 0°F) before Do not apply the following to conversion of a boiler already installation, handle with care until the plastic installed and connected to gas supply. For a boiler already installed, components come to room temperature. you must turn off gas supply, turn off
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 2 Prepare boiler (continued) Ultra-310 Series 2 Placing floor-mounted boilers Ultra-155 Series 1 and 2 1. Set boiler in place and check level. Ultra-230 Series 1 and 2 a. Adjust legs, if necessary to level boiler. Prepare for propane operation Do not apply the following to conversion of a boiler already installed and connected to gas supply. For a boiler already installed, you must Placing wall-mounted boilers turn off gas supply, turn off power a
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 2 Prepare boiler (continued) Leaks must be repaired at once. Failure to Perform hydrostatic pressure test do so can damage boiler, resulting in Pressure test boiler before permanently attaching water substantial property damage. or gas piping or electrical supply. Do not use petroleum-based cleaning or sealing compounds in boiler system. Prepare boiler for test Gaskets and seals in the system may be damaged. This can result in substantial 1. See F
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 3 Install water piping Install relief valve General piping information 1. Install relief valve in ¾" street elbow piped from boiler Additional controls, when required supply piping tee (Figure 3, page 11). Pipe the relief The Ultra control module uses valve only as shown, in the location shown. temperature sensors to provide both high 2. Connect discharge piping to safe disposal location, limit protection and modulating following guidelines in the
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 3 Install water piping (continued) System water piping methods Figure 4 Expansion tank piping All piping methods shown in this manual use primary/secondary connection to the boiler loop. These designs ensure proper flow through the Ultra boiler, for the most efficient and reliable operation of the boiler and the heating system. For other piping methods, consult your local Weil-McLain representative or refer to separate Ultra boiler piping guides.
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 3 Install water piping (continued) Sizing DHW system piping When using the boiler for dedicated DHW circulators (Taco 007, 0011, 0012, 0013, 0014, B&G PL-36 or equivalent). Use applications, use the circulator supplied with these curves along with boiler pressure drop data from Table 2 to size the DHW the boiler (007 for Ultra-80/105; 0011 for piping and circulator. Or you can use Table 2 for a quick-selection method. Ultra-155/230/310) to circula
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 3 Install water piping (continued) Zoning with zone valves Figure 7 Zone valve zoning plus optional DHW piping 1. Connect boiler to system as shown in Figure 7 when zone valve zoning. The primary/secondary piping shown ensures the boiler loop will have sufficient flow. It also avoids applying the high head of the boiler circulator to the zone valves. 2. When using a closed-type expansion tank, connect the expansion tank and make-up water piping as
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 3 Install water piping (continued) Zoning with circulators Figure 8 Circulator zoning plus optional DHW piping 1. Connect boiler to system as shown in Figure 8 when circulator zoning. The boiler circulator cannot be used for a zone. It must supply only the boiler loop. 2. Install a separate circulator for each zone. 3. When using a closed-type expansion tank, connect the expansion tank and make-up water piping as shown in Figure 4, page 13. 4. Con
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 3 Install water piping (continued) Radiant heating applications Figure 9 Typical radiant heating system piping plus optional DHW 1. The Ultra boiler is ideal for use in radiant heating. The Ultra boiler’s unique heat exchanger design allows it to work well even in condensing mode. So there is no need to regulate boiler return water temperature in radiant heating applications. 2. Connect boiler to system as shown in Figure 9 for typical radiant hea
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 3 Install water piping (continued) Chilled water systems Figure 10 Chilled water system plus optional DHW piping 1. Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. See Figure 10 for typical installation of balancing valve and check valve. 2. The space heating system may be zoned with circulators if a separate circulator is supplied for the c
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 4 Venting, combustion air & condensate line Install vent and combustion air piping Figure 11 Condensate trap assembly Ultra Boiler must be vented and supplied with combustion and ventilation air as described in Weil-McLain Ultra Boiler V ent Supplement (included in envelope assembly). Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system and combustion air quality. See also Se
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GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual 4 Venting, combustion air & condensate line (continued) Connect condensate drain Figure 12 Condensate drain — Ultra-80 & -105 1. Remove condensate trap line from bag. Prepare and install per page 19. Secure to jacket by attaching PVC tee as shown in Figure 13. 2. Slide trap line onto flue outlet condensate connection and PVC reducing elbow as shown in Figure 12, 13 or 14. Secure with hose clamps. 3. Connect condensate drain tubing to the ½" PVC te
