Perform steps in the order. Failure to comply could result in severe personal injury, death or substantial property damage. Previous Page. Next Page. Read all instructions, includ- ing this manual and all other information shipped with the boiler, before installing.
Perform steps in the order given. Page 2: Ow It Works. Fuel Do not start burner if: cumulated in combustion chamber, when unit is full of vapor, or when combustion chamber is very hot. Review and understand boiler start-up and routine maintenance proce- dures with the service technician. Perform routine maintenance listed below. Hot water pipes not shown in Figure 1 2. Double-wall vent pipe 4. Install on any level, properly-supported, and non- absence of codes, use the following guidelines when carpeted surface.
Make sure the plastic hose is connected from gas valve to inlet elbow on Ultra and See below. Wall mount Ultra boilers only using the Weil- McLain Ultra boiler wall-mounting kit and accom- panying instructions. DO NOT use the shipping bracket to wall mount the boiler. Page 12 When piping will be routed out the top of the boiler, no special preparation is needed other than that given in this manual. Ultra to only: To route the piping through the bottom of the boiler enclosure: Remove knockouts from bottom piping penetrations as shown in Figure 8, page Pipe to boiler supply connection as shown.
Use pipe dope spar- ingly. Page Install Water Piping Failure to support the boiler piping Replacement parts section at the end of this manual for connections to prevent them from turning could cause the Weil-McLain low water cut-off kit. Purchase low water cutoff and install in a tee in the supply piping above boiler.
Page System Water Piping Methods The boiler circulator Taco for Ultra and ; Taco for For pipe sizes up to 2 inch, ensure a minimum flow Ultra, , and is shipped loose. Locate it in the return pip- velocity of 2 fps feet per second and a maximum of ing, as shown in the appropriate piping diagram in this manual.
Page 16 — Boiler Manual fired water boiler Install water piping continued Expansion tank and make-up water Figure 14 Expansion tank piping Ensure expansion tank size will handle boiler and system water vol- ume and temperature.
Allow 3 gallons for boiler and its piping. Undersized expansion tanks cause system water to be lost from relief valve and make-up water to be added through fill valve. Failure to follow these guidelines could result in system problems. Page 19 or bladder type expansion tank] as shown. So there is no need to regulate boiler return water temperature in radiant heating applications. Page Chilled Water Systems 12 Boiler circulator as shown.
Read down the first column of Figure 22, page 23 for the Ultra until you find a flow rate just larger than the required 12 gpm. This will satisfy some code requirements for low water cutoff protection. Page 28 — Boiler Manual fired water boiler Multiple boiler water piping continued Figure 29 Piping layout — typical piping for multiple Ultra boilers, using isolation exchanger Use isolation heat exchanger for: 1.
Large volume systems with high mineral content in water. Use the flame of a match or candle, The Ultra boiler requires its own vent and air piping, as specified in this manual. This may cause a problem for the appliances that or smoke from a cigarette, cigar, or pipe. Page Air Piping - General You must pipe combustion air to the boiler air contamination intake Install air inlet piping for the Ultra boiler as de- The air termination fitting must be installed with the scribed in this manual.
Failure to provide a properly-in- Each Ultra boiler requires a separate vent. Do not common vent. Page 32 Use appropriate adapters where needed — Ultra through require 3. Concentric terminations and the Weil- McLain sidewall plate require 3. The air inlet of an Ultra boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from Figure 39 Termination location — Page 35 Level the template with a spirit level.
For the Weil-McLain plate, the template must be level to ensure the flue and air pipe will be side-to-side, as shown in Figure See Figure , page 93 for part number. If this are not being used they will always be shown as OPEN. This is normal unless the sensors were installed. Check wire harness for loose connections and pin engagement at sensor connection, chassis mount connection through control housing, and the control module. Unplug connection at sensor and at control module and check continuity between ends.
If problem persists after checking items above replace control module. Refer to repair pans section for kit number. In addition inspect heat exchanger combustion chamber and flue ways for abnormal wear or buildup. Inspect vent system for abnormal wear or damage. Manual reset of control module if contacts are open longer than 5 seconds Check for low water condition in system. If low water condition does not exist, check Diagnostics - Inputs screen to view status of Low Water Cutoff.
Check for a loose connection at the index plug on the control and connection on the back of the display. Automatic external limit will reset 2. Manual limit fault must be reset by choosing Reset Lockout on the display. Is there an external safety device connected? Also check for loose wiring connections. Remove the top right electrical cover and inspect the connector. The internal boiler circulator can be configured to turn on or off with DHW and heating zones.
Refer to the control module Setup section to configure these properly for the system. Verify water pipe is installed correctly per instructions in this manual. Verify proper circulator sizing for boiler size and system requirements. Inspect flame and conduct combustion test.
Force boiler into hi-fire. Check flue gases with combustion analyzer and correct using the maintenance an startup procedure in this manual. Check for flame at burner via flame current with burner off. Turn boiler off and watch flame through observation port. If flame continues after shutdown replace gas valve and venture.
GASVALVE FAULT The control module has detected a problem with it gas valve output circuit Control will do automatic retry; lockout if retry unsuccessful; retry 1 hour after lockout — restart if condition cleared, but lockout permanently if condition still present. Requires manual reset if control is in lockout Check wire harness connections between gas valve and control module.
Check resistance between control and gas valve. If lockout reoccurs replace control module. Unplugging the low voltage blower wire harness will not allow or cause the boiler to rotate. Reset using manual reset screen on display; control module will check again after 1 hour and will automatically restart if condition is corrected Check wire harness for loose connections and pin engagement at blower connections, chassis mount connection through control housing, and control module.
Unplug connection at blower and at control module and check continuity between ends. Blower is connected to both low voltage and line voltage harness. Check Diagnostics - Inputs screen with boiler in standby mode and blower not running. If blower does not rotate during ignition sequence check for V power at blower connection. If Vac power at blower motor and it doesn't start replace blower. Check power at control module. If Vac is not present at control module when boiler is powered replace control module.
Check condensate trap for blockage allowing condensate to accumulate inside heat exchanger. Check ignition cable connection. Fouled, worn, bent, or faulty igniter. Fouled igniters can be cleaned for additional use with fine grit sand paper or steel wool. Worn or badly fouled igniters should be replaced with the proper repair part. Igniter rods should be parallel with a 35mm 0. Follow procedure in maintenance section of this manual to clean burner and heat exchanger using flue cleaning tool and rinse method.
Visual inspection of flue ways will often will not be able to diagnose condition. Check combustion settings on high and low fire and adjust per setup instructions if necessary. Check incoming gas pressure with boiler off and at high fire. Adjust within limits on rating label. Verify correct boiler model is selected in control and high altitude is selected for installations ft above sea level.
Check ignition cable resistance. Skip to content. Set limit according to system needs. Call qualified service technician to de-lime boiler, if necessary. Call qualified service technician to check pH level and correct. Have qualified service technician check operation of mixing system. This product does not comply with the "Safe Drinking Water Act," which requires that products meet low-lead standards in order to be used in systems providing water for human consumption drinking or cooking.
This item is for non-potable non-human consumption water applications only. This product does not comply with the Safe Drinking Water Act, which requires that products used in any system providing water for human consumption drinking or cooking to meet low-lead standards.
Please check the box below to confirm you are aware that this item is for non-potable water applications only. This product will NOT be used in the installation or repair of a potable water human consumption application. When you order this item, we then special order it for you from the manufacturer. Therefore, our standard return policy does not apply to this item. Manufacturer's warranty still applies. I understand that once I order this item I cannot cancel or return it.
Failure to comply with this could result in substantial property damage, severe personal injury or death.
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