Weil-McLain Ultra Electric Water Heater Installation And Start-Up Manual Download Page 1 | Manualshive

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Weil-McLain Ultra Electric Water Heater Installation And Start-Up Manual Download Page 1

This manual must only be used by a qualiﬁed heating installer/service technician. Read all instructions, including this
manual and all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to
comply could result in severe personal injury, death or substantial property damage.

s)NSTALLATION

s3TARTUP

s-AINTENANCE

s0ARTS

Boiler Manual

Gas-ﬁred water boilers

Featuring

Flexibility

Part number 550-100-086/0809

®

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Summary of Contents for Ultra Electric Water Heater

Page 1: ...nd all other information shipped with the boiler before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage s NSTA...

Page 2: ...SIZE FEMALE 0REMIX GAS BURNER NOT SHOWN Made with high grade stainless steel and ber mesh construction the burner uses pre mixed air and gas The burner and control provide modulating ring 7ATER OUTLE...

Page 3: ...Part number 550 100 086 0809 3 COMMERCIAL GAS FIRED WATER BOILER Boiler Manual The COMMERCIAL gas red water boiler Featuring Flexibility...

Page 4: ...3TARTUP lNAL CHECKS 72 HECK OUT STARTUP VERIlCATION 76 NNUAL STARTUP AND GENERAL MAINTENANCE 77 NNUAL STARTUP 78 4ROUBLESHOOTING 83 AINTENANCE 93 2EPLACEMENT PARTS 96 IMENSIONS 108 2ATINGS 5LTRA BOILE...

Page 5: ...es 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 Use this boiler ONLY in a closed loop...

Page 6: ...alled so that gas control system com 3 ponents are protected from dripping or spraying water or rain during operation or service If new boiler will replace existing boiler check for and correct 4 syst...

Page 7: ...ge 6 Also follow local codes Construct boiler foundation if boiler room oor 3 is uneven or if there is a danger of ooding Size foundation to allow for clearance and spacing di mensions shown in either...

Page 8: ...m DIRECT VENT 1 For direct vent installations air piped to boiler no air ventilation openings into boiler room are needed if clearances around the Ultra boiler are at least equal to the SERVICE cleara...

Page 9: ...adapter LUE COVER After removing the packaging lift boiler from the skid and place 4 in position Do not drop the boiler Damage to boiler components can result NSPECT THE BOILER BASE FOR CRACKS OR POS...

Page 10: ...ra 750 natural gas boilers do not use a blower plate The boiler is 3 shipped with a blower plate and gaskets that must be installed to oper ate the boiler on propane Obtain the two gaskets item 3 and...

Page 11: ...tra 750 propane but NOT on natural gas A PROPANE ORIlCE MUST be installed on both the Ultra 550 and Ultra 750 to operate on propane See opposite page for legend LOWER PLATE MOUNT WITH STAMPING LOCATED...

Page 12: ...compatible with 10 Figure 5 that would still allow bleeding air from shutoff valves Fill and pressure test Open the shutoff valves you installed on supply and return con 1 nections Slowly open boiler...

Page 13: ...4 see page 51 for wiring information Low water cutoff A push to test low water cutoff is included with the boiler The 1 low water cutoff is mounted on the boiler supply manifold and is available for t...

Page 14: ...irculators The boiler circulator must be supplied by others Locate the boiler circulator in the return piping as shown in the appropriate piping diagram in this manual 4 use the boiler circulator in a...

Page 15: ...up water line using a closed type expansion tank Most chilled water systems are piped using a closed type tank as 5 shown in Figure 12 page 20 Diaphragm or bladder expansion tank 1 Figure 7 Always ins...

Page 16: ...m ow rate Use only primary secondary piping as shown Failure to follow these guidelines could result in system problems s 5LTRA n v OR LARGER s 5LTRA v OR LARGER Install water piping continued Zone va...

Page 17: ...orresponding to the recommended maximum ow rate Use only primary secondary piping as shown Failure to follow these guidelines could result in system problems s 5LTRA n v OR LARGER s 5LTRA v OR LARGER...

Page 18: ...idelines could result in system problems s 5LTRA n v OR LARGER s 5LTRA v OR LARGER Install water piping continued Circulator zoning plus optional DHW IGURE piping Zoning with circulators Connect boile...

Page 19: ...plus IGURE optional DHW Radiant heating applications The Ultra boiler is ideal for use in radiant heating The Ultra 1 boiler s unique heat exchanger design allows it to work well even in condensing mo...

Page 20: ...ER Chilled water systems Install boiler so that chilled medium is piped in parallel with the 1 heating boiler Use appropriate valves to prevent chilled medium from entering boiler See Figure 12 for ty...

Page 21: ...eturn of each boiler as shown Each boiler is equipped with an internal low water cutoff and limit control Check local codes to see if additional controls may be needed Install main system air eliminat...

Page 22: ...enter as required by applicable codes 12 Isolation valve 13 Cold water supply 16 Water ow switch when used 17 Boiler circulator each boiler 18 System supply 19 System return 20 Boiler relief valve and...

Page 23: ...tems 10 11 and 12 as shown in Figure 15 page 22 17 Boiler circulator each boiler 18 System supply 19 System return 20 Boiler relief valve and discharge piping installed per Ultra Boiler Manual 30 Stra...

Page 24: ...supply Easy Fit Manifold 26 DHW boiler side return Easy Fit Manifold 27 Flow check valves to prevent induced or gravity ow in heating system or DHW pip ing 28 Check valve to prevent heat migration in...

Page 25: ...automatic air vent 13 Cold water supply connections requires items 10 11 and 12 as shown in Figure 15 page 22 17 Boiler circulator each boiler 18 Heating system supply 19 Heating system return 20 Boil...

Page 26: ...his instruction manual The chimney must be tted with a sealed access open ing through which the interior of the chimney can be inspected The chimney and liner must be inspected at least once annually...

Page 27: ...d in boiler room walls per instructions in this manual and applicable codes SIDEWALL direct vent option s 2EAD PAGE PAGE AND PAGE 4HEN GO TO PAGE VERTICAL direct vent option s 2EAD PAGE PAGE AND PAGE...

Page 28: ...of use Any improper operation of common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 latest edition Correct by re sizing to approach the...

Page 29: ...t a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size n...

Page 30: ...ntact is open and will shut down should it open during operation Combustion air provision The Ultra Commercial boiler can use inside air if no contaminants are present in the boiler space If contamina...

Page 31: ...opening each at least 1 square inch per 3 Btuh of all appliances in the room 47 openings each at least 1 square inch per 4 Btuh of all appliances in the room OR opening each at least 1 square inch pe...

Page 32: ...ble notes Connecting from termination to boiler Install the terminations as instructed in the following Then proceed 1 to page 46 to complete the vent piping between the termination and the boiler Max...

Page 33: ...onger lengths The chase must allow for inspection of the vent pipe and insulation must be protected from water DIRECT EXHAUST Sidewall con guration IGURE options and minimum clearances Consider the su...

Page 34: ...a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment Where the vent pen 5 etrates an outside wall the annular space around the penetration must...

Page 35: ...g with brack ets as shown in the termination instructions Install vent piping from boiler to 3TEP termination Install a hanger support within s 6 inches of any upturn in the pip ing Slope horizontal p...

Page 36: ...bjects such as stones or balls or subject to buildup of leaves or sediment Do not connect any other appliance to the vent pipe Do not con 7 nect multiple boilers to a common vent pipe Prepare roof pen...

Page 37: ...ntilation as well as combustion air to prevent overheating of the boiler controls and boiler space Air is also needed for other appliances located in the same space Use Figure 32 page 38 selecting the...

Page 38: ...tallation provides at least the Recommended service clearances shown on page 6 If the space is smaller provide ONE opening to a larger room with at least 1 square inch per Btuh of Ultra boiler input 4...

Page 39: ...ditional elbows require a reduction in maximum length as explained in the table notes Connecting from termination to boiler Install the terminations as instructed in the following Then proceed to 1 pa...

Page 40: ...ndensate in the vent pipe resulting in potential boiler shutdown In extremely cold climates install an insulated chase around the vent piping particularly when using longer lengths The chase must allo...

Page 41: ...here condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment Where the vent 7 or air pipe penetrates an outside wa...

Page 42: ...2 at least 20 inches and no more than 36 inches below the vent termination and at least 12 inches above grade or snow line as shown in Figure 35 page 40 You can orient the vent termination elbow eithe...

Page 43: ...piping from 3TEP boiler to termination Install a hanger support within s 6 inches of any upturn in the pip ing Slope horizontal piping downward s toward the boiler at least 1 4 inch per foot Connect...

Page 44: ...tally from any s door or window or any other gravity air inlet Air inlet must terminate at least 12 inches above the roof or j snow line and at least 12 inches below the vent termination as shown in F...

Page 45: ...tion on the roof but must always be no further than 2 feet apart and with the vent termination at least 1 foot above the air intake Maintain the required dimensions of the nished termination 5 piping...

Page 46: ...to c both surfaces in a uniform coating Apply a second coat to both surfaces Avoid using too much d cement on sockets to prevent cement buildup inside With cement still wet insert pipe into tting twi...

Page 47: ...ting twisting turn Make sure pipe is fully inserted Wipe excess cement from joint Check joint to e be sure a smooth bead of cement shows around the entire joint Assemble the 1 PVC nipple to the PVC c...

Page 48: ...for use 3 with condensing boilers and furnaces The pump should have an over ow switch to prevent property damage from condensate spillage See Figure 48 for required ow capacity When sizing condensate...

Page 49: ...page 9 through page 11 for instructions Failure to comply could result in severe personal injury death or substantial property damage Install a 100 lockup gas pressure regulator in the gas supply lin...

Page 50: ...size pipes tanks and 100 1 lockup gas pressure regulator Propane supply pressure Pressure required at gas pressure tap near boiler gas 1 connection see Figure 51 page 49 Maximum 14 w c with no ow loc...

Page 51: ...he U Control will s require manual reset for one of these circuits The U Control will automatically reset after limit operation and re closure for limits in the other circuit ONNECT THERMOSTATS AND OR...

Page 52: ...Part number 550 100 086 0809 COMMERCIAL GAS FIRED WATER BOILER Boiler Manual 52 Field wiring SEE IGURE IGURE continued Schematic wiring diagram Ultra 550 Ultra 750 continued on next page IGURE...

Page 53: ...Part number 550 100 086 0809 53 COMMERCIAL GAS FIRED WATER BOILER Boiler Manual Field wiring SEE IGURE IGURE continued IGURE continued from previous page Schematic wiring diagram Ultra 550 Ultra 750...

Page 54: ...Part number 550 100 086 0809 COMMERCIAL GAS FIRED WATER BOILER Boiler Manual 54 Field wiring SEE IGURE IGURE continued Ladder wiring diagram Ultra 550 Ultra 750 continued on next page IGURE...

Page 55: ...Part number 550 100 086 0809 55 COMMERCIAL GAS FIRED WATER BOILER Boiler Manual Field wiring SEE IGURE IGURE continued IGURE continued from previous page Ladder wiring diagram Ultra 550 Ultra 750...

Page 56: ...lator to terminals 1 4 and 7 on connector P2 see Figure 59 Connect the boiler circulator per Figure 56 page 51 Circulator 4 requires a separate power supply as shown The 4 FACTORY DEFAULT for space he...

Page 57: ...6 and 7 Connect these terminals to call for heat from the other heat 2 source See ADVANCED SETUP instructions beginning on page 60 Alarm contacts The U Control s alarm dry contact P16 terminals 4 and...

Page 58: ...satis ed go to postpurge s 7 HEATING Flame detected s Release boiler to modulation immediately s NOTE If ame is not detected the gas valve s is turned off blower turns on postpurge and control starts...

Page 59: ...Part number 550 100 086 0809 59 COMMERCIAL GAS FIRED WATER BOILER Boiler Manual U Control operation and setup continued U Control display and navigation IGURE...

Page 60: ...e system return pipe d and wire to terminals P14 2 and 3 If you want to use outdoor reset for the space heating circuits e install the outdoor temperature sensor supplied with boiler and wire to termi...

Page 61: ...as a Type 4 see below and each needs its additional heat timer set for the desired delay between boilers Type 4 This assigns the boiler as a SHADOW boiler in a multiple 6 boiler system For Type 4 boil...

Page 62: ...er an automatic notice for maintenance default is 12 months Because this shows on the display it is an au tomatic means of notifying the homeowner of the need forscheduledmaintenancebythetechnician Up...

Page 63: ...DIANT SLAB ON GRADE RADIANT THIN SLAB RADIANT BELOW FLOOR RADIANT ABOVE FLOOR CUSTOM DHW DIRECT DHW SYSTEM TEMPERATURES MAX SUPPLY F MIN SUPPLY F MAX OUTDOOR F MIN OUTDOOR F MODULATE ON DIFF F MODULAT...

Page 64: ...MM AM MM DD YY STATUS MANUAL RESET AUTO RESET INPUTS OUTPUTS TEMPERATURES LIST OF LOCKOUTS LIST OF LOCKOUTS INPUT STATUS OUTPUT STATUS TEMPERATURES LOCKOUT HISTORY 2 LOCKOUT HISTORY 3 SAME AS HISTORY...

Page 65: ...late On Diff F 2 10 5 Boiler turns on if temperature drops below target minus differential on Modulate Off Diff F 2 10 5 Boiler shuts down if modulates past target plus differential off Max On Time mi...

Page 66: ...n Modulate Off Diff F 2 10 5 Boiler shuts down if modulates past target plus differential off Max On Time Priority 3 does not have this setting Min On Time minutes off 240 15 Time boiler will satisfy...

Page 67: ...or F data Temperature of the remote outdoor air temperature sensor NPUTS Status Text data Current operating status of the boiler Prepurge Ignition Name of the system Type being satis ed post purge War...

Page 68: ...recent error recorded Time Date text data Displays time and date that lockout occurred Status text data Displays what the status of the boiler at the time of the error Manual Reset yes or none data C...

Page 69: ...o the control Force Rate Low Med High or Auto Auto Used to manually force a rate during a call for heat Choose auto for normal operation ANUAL 2ESET Reset selected condition AINTENANCE NFO AINTENANCE...

Page 70: ...er can drain and be seen Close the boiler or system isolation valve between the purge 2 valve and ll connection to the system Close zone isolation valves 3 Open quick ll valve on cold water make up li...

Page 71: ...the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purged Close the quick ll water valve and purge valve and remove the hose 7 Open all isolation valves...

Page 72: ...for gas leaks Before starting the boiler and during initial opera tion use a leak detector or smell near the oor and around the boiler for gas odorant or any unusual odor Remove boiler front door and...

Page 73: ...s are for altitudes up to 5 500 feet For higher altitudes CO2 may be slightly lower and CO slightly higher O Check system and boiler O Check water piping Check system piping for leaks If found shut do...

Page 74: ...combus tion noise or high carbon monoxide values Combustion readings must be taken at both high re and low 3 re Adjust valve at high re Use the U Control display to navigate to Manual test mode see 1...

Page 75: ...0 086 0809 75 COMMERCIAL GAS FIRED WATER BOILER Boiler Manual Operating instructions WARNING IGURE Verify that the U Control is set for the correct boiler model before proceeding U Control operation a...

Page 76: ...lled to desired DHW storage temperature Reviewed all instructions shipped with this boiler with O owner or maintenance person Fill in O NSTALLATION CERTIlCATE on page 112 Fill out the warranty registr...

Page 77: ...ed Verify ue and air lines in good condition and sealed tight Check system water pressure system piping expansion tank Check control settings Ignition electrode clean with steel wool and reposition Ig...

Page 78: ...y O from other clothing Rinse clothes washer thor oughly NIOSH stated First Aid Eye Irrigate immediately O Breathing Fresh air O FIRST YEAR SPECIAL INSPECTION O LATER THAN MONTHS 1 after the boiler is...

Page 79: ...s Do not use solvents to clean any of the boiler components The components could be damaged resulting in unreliable or unsafe operation Clean condensate trap Remove ue inspection plug item 46 1 page 3...

Page 80: ...cated on top of an air elimina tor as shown in examples in this manual If relief valve has tended to weep frequently the expansion tank may 2 be waterlogged or undersized s Closed type tank tank is mo...

Page 81: ...Do not used compressed air unless doing so outside and wearing eye protection To replace the burner 6 Insert the burner rst When inserting place your hand a inside the burner throat and tilt the back...

Page 82: ...heck boiler relief valve Inspect the relief valve and lift the lever to verify 1 ow as in the following warnings excerpted from arelief valvemanufacturer swarninglabel Before operating any relief valv...

Page 83: ...g errors can cause improper and dan gerous operation Always disconnect power to boiler before servicing Failure to comply could result in severe personal injury death or substantial property damage Ne...

Page 84: ...Do not jumper fuse or replace with any fuse except as speci ed Failure to comply could result in severe personal injury death or substantial property damage Reinstall jacket top panel and boiler jacke...

Page 85: ...available on the U Control display 2 Figure 79 shows the screen behavior during an automatic or manual reset condition The table below the display illustration lists manual reset conditions and how t...

Page 86: ...Ignition Retries Displays the number of ignition attempts in the current ignition sequence Manual Reset Count Records number of lockouts that required a manual reset since this count was last cleared...

Page 87: ...the burner is on Automatically resets after 1 minute delay or using manual reset on display Manual reset is necessary after 5 automatic resets have occurred during the same Priority heat demand Reset...

Page 88: ...inspect heat exchanger combustion chamber and ueways for abnormal wear or buildup Inspect vent system for abnormal wear or damage Contact Weil McLain Technical Support Occurs when dual temperature se...

Page 89: ...Force boiler into hi re Check ue gases with combustion analyzer and correct using the maintenance and startup procedure in this manual Verify FLAME SIGNAL value quickly goes to zero on the DIAGNOSTIC...

Page 90: ...ng manual reset screen on display Look into the ame inspection window for the spark during the ignition cycle Watch the two indicator lights on the gas valve during the ignition cycle The lights shoul...

Page 91: ...sue with it s hardware and has locked out Requires a manual reset Check boiler size selected in U Control against boiler rating label Correct if necessary to select the proper boiler size GV FAULT EXP...

Page 92: ...riority 1 Priority 1 Priority 1 Priority 2 Priority 2 Priority 2 Priority 3 Priority 3 Priority 3 Manual limit Manual limit Manual limit Auto limit Auto limit Auto limit Air press switch Air press swi...

Page 93: ...luminum The oxide layer will reform but if small amounts of the trisodium phosphate remain in the system the chemical will continue to remove the protective oxide layer leading to reduced heat exchang...

Page 94: ...re 81 page 95 Vacuum most of the debris out of the base through 3 the ue inspection opening Water spray the heat exchanger Disconnect the condensate line at the bottom of the 1 heat exchanger so debri...

Page 95: ...E Gasket Silicone cord starts and nishes at the top center UT TIGHTENING SEQUENCE 5LTRA IGURE RADUALLY TIGHTEN THE NUTS REPEATING THE SEQUENCE SHOWN BELOW UNTIL THE TORQUE REACHES INCH POUNDS INCH POU...

Page 96: ...acket front door after startup or servicing Inspect boiler jacket front door gaskets and reinstall boiler jacket front door after start or servicing The boiler front door must be securely fastened to...

Page 97: ...tion 6 inch for 6 inch vent or air pipe 8 inch for 8 inch vent or air pipe 560 907 633 560 907 634 5 CHEMICALS Antifreeze aluminum safe Sentinel X500 5 liters Corrosion inhibitor Sentinel X100 one tub...

Page 98: ...k Jacket 383 600 050 5 Jacket seal kit base seal door seal grommets and gaskets 383 600 053 6 Plastic top cover includes cover gaskets and hardware 383 600 054 7 Inlet outlet adapter kit includes adap...

Page 99: ...Part number 550 100 086 0809 99 COMMERCIAL GAS FIRED WATER BOILER Boiler Manual Replacement parts continued Jacket parts IGURE...

Page 100: ...5 section supply distribution tube kit distribution tube o ring and nuts 550 383 600 033 12 6 section supply distribution tube kit distribution tube o ring and nuts 750 383 600 032 13 5 section return...

Page 101: ...Part number 550 100 086 0809 101 COMMERCIAL GAS FIRED WATER BOILER Boiler Manual Heat exchanger IGURE Replacement parts continued...

Page 102: ...In Item 1 7 Section manifold o ring 60 mm included in Item 1 also see Item 6 Figure 90 page 101 550 750 590 318 039 8 Supply return pipe grommet 2 NPT x 3 diameter included in Item 1 550 750 562 248...

Page 103: ...Part number 550 100 086 0809 103 COMMERCIAL GAS FIRED WATER BOILER Boiler Manual Piping IGURE Replacement parts continued...

Page 104: ...ter pipe 590 318 042 10 High gas pressure switch replacement kit includes switch and nipple 383 600 048 11 Low gas pressure switch replacement kit includes switch and nipple 383 600 049 12 Gas pressur...

Page 105: ...Part number 550 100 086 0809 105 COMMERCIAL GAS FIRED WATER BOILER Boiler Manual Burner blower venturi and gas train IGURE Replacement parts continued...

Page 106: ...628 16 Pressure temperature gauge assembly 570 218 054 17 120 volt 3 wire receptacle pre wired 591 391 959 18 Air pressure switch kit includes switch tube and mounting screws 383 600 073 19 Hose barb...

Page 107: ...Part number 550 100 086 0809 107 COMMERCIAL GAS FIRED WATER BOILER Boiler Manual Controls IGURE Replacement parts continued...

Page 108: ...l data IGURE Notes 1 Boiler supply and return connections are both 2 NPT 2 Circulator must be mounted in the return piping 3 Relief valve is shipped loose See page 13 for mounting details Relief valve...

Page 109: ...tional allowance should be made for unusual piping and pickup loads 2 Ultra boilers can be direct vent ducted combustion air or direct exhaust vented combustion air from boiler room either through a s...

Page 110: ...ent height 2 to 4 Input MBH Output MBH MBH Square inches Length INCHES Width INCHES Length INCHES Width INCHES 550 750 Note 1 Note 2 Figure 31 page 37 Note 3 2 1100 1034 550 106 21 51 40 2 1500 1404 1...

Page 111: ...y 2 inches from boiler to edge of foundation Smaller foundations are possible with reduced service clearances See page 7 for details For side to side installations see s Figure 2 page 7 For back to ba...

Page 112: ...upply F Min Supply F Min Supply F Min Supply F Max OD Reset F Max OD Reset F Max OD Reset F Min OD Reset F Min OD Reset F Min OD Reset F Modulate On Diff F Modulate On Diff F Modulate On Diff F Modula...

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