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Ultra electronic 80 manual

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Table of contents for the manual

  • Page 1

    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. Pe rform steps in the o rder given. Failure to co mpl[...]

  • Page 2

    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 . . . PhD PhD PhD PhD PhD technology PhD T e chnology , P r e cision h ydr onic D ata, is an intelligent system that delivers Precision hydronic heating and hot water needs while maximizing eff[...]

  • Page 3

    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[...]

  • Page 4

    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. Indicates pr esence o f hazards that w ill cause severe per sona[...]

  • Page 5

    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. When servicing boiler — • T o avoid electric shock, disc onnect electr ical supply before performing mai[...]

  • Page 6

    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 with: Installations must comply with: Installations must comply with: Installations must comply with: • Local, state, provincial, and national codes, [...]

  • Page 7

    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. Do not install boiler on carpeting even if foundation is used. Fire can result, c[...]

  • Page 8

    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. Do not terminate vent/ air in locations that can allow contamination of co mbust ion air[...]

  • Page 9

    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. 1 . The Ultra boiler is generally easier to handle and mane[...]

  • Page 10

    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 Series 1 and 2 Ultra-230 Series 1 and 2 Prepare for propane operation Do not apply the following to conversion of a boiler already installed and conne[...]

  • Page 11

    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 . See Figure 3 for reference in following steps. 2 . Remove supply line tee* and ¾?[...]

  • Page 12

    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. 2 . Connect discharge piping to safe disposal location[...]

  • Page 13

    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. These designs ensure proper flow through the Ul tra boiler , f or the most eff[...]

  • Page 14

    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 Pipe sizing and head losses for DHW applications (H1=boiler head loss; H2=piping head loss; H3=maximum allowable head loss through water heater based o[...]

  • Page 15

    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. The primary/secondary piping shown ensures the boiler loop will have sufficient [...]

  • Page 16

    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. The boiler circulator cannot be used for a zone. It must supply only the boiler [...]

  • Page 17

    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. So there is [...]

  • Page 18

    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 . S ee Figure 10 for typical installation of balancing valv e and check valve.[...]

  • Page 19

    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 . Remov e PV C fitting s and gasket from the a ccessories bag. 2 . Deburr and chamfer outside and inside of ½" x 1¼" PV C nipple to ensure ev en cement distribution when joi[...]

  • Page 20

    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 . Slide trap line onto flue outlet condensate connection and PV C reducing elbow as sho w n in Figur[...]

  • Page 21

    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. b. Install manual shutoff valve in gas supply piping outside boiler jacket when requi[...]

  • Page 22

    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 . Base on rated boiler input (divide by 1,000 to obtain cubic feet per hour). a. T ab[...]

  • Page 23

    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. Before filling the boiler and system with wat[...]

  • Page 24

    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 . ❏ V er ify the [...]

  • Page 25

    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. 2 . T he “H” in the first dig it of the display means the boiler will operate at high [...]

  • Page 26

    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 verified per page 23? ❏ A utomatic air ve nts, if used, open one full turn? ❏ Air purged from system? ❏ Air purged from gas piping? Piping chec[...]

  • Page 27

    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. ❏ Check out sequence has been perfor[...]

  • Page 28

    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 . Fail ure to perfo rm the ser vice and maintenanc e could result in damage to the boiler or system[...]

  • Page 29

    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. In addition, the maint enance and care of the boiler designated in T able 5 and explained on the following pages m[...]

  • Page 30

    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 . 3 . Check condensate elbow and tee and condensate line to drain. F[...]

  • Page 31

    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 . If the ignit ion electro de cannot be cleaned satisfactorily , replace i[...]

  • Page 32

    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). 2 . V erify cold fill pressure is c or r ect and that operating pressure does[...]

  • Page 33

    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. The boiler front door must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler[...]

  • Page 34

    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 . 2 . Disconnect gas line union with pipe wre[...]

  • Page 35

    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. The boiler front door must be securely fastened to the boiler to prevent boiler from drawing air [...]

  • Page 36

    Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 36 Replacement parts (continued) 9 Jacket parts[...]

  • Page 37

    GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual Part number 550-100-026/0404 37 Replacement parts (continued) 9 Jacket parts[...]

  • Page 38

    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[...]

  • Page 39

    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[...]

  • Page 40

    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[...]

  • Page 41

    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[...]

  • Page 42

    Part number 550-100-026/0404 GAS - FIRED WA TER BOILER SERIES 2 — Boiler Manual 42 9 Replacement parts (continued) Controls[...]

  • Page 43

    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. W all-hung boilers: water piping and g as pipe can be route[...]

  • Page 44

    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 . 3. Net I=B=R ratings are[...]