Weil-McLain -105, Manual

Page 1: ...rolSupplementandthe UltraVent Supplement before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage with Ultra 80 105 155 230 310 Gas fired Water boiler Series 2 NOTICE Series1 Series2identification Read the boiler rating plate to determine the series number The rating plate is located on the right side of the bo...

Page 2: ...temperature 9 Temperature and pressure gauge 10 Electronic display buttons The 4 digit electronic display is used to Set space heating temperature Show outlet water temperature normal or other operating conditions in Information mode Show boiler status and shutdown or lockout codes for easy troubleshooting The buttons allow changing display mode and reset after lockout The on off Power switch 10a ...

Page 3: ...GAS FIRED WATER BOILER SERIES 2 Boiler Manual Part number 550 100 026 0404 3 THE GAS FIRED WATER BOILER WITH Ph Ph Ph Ph PhD D D D D TECHNOLOGY ...

Page 4: ...presence of hazards that will or can cause minor personal injury or property damage Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage How it works 2 3 Hazard definitions 4 Please read before proceeding 5 1 Prepare boiler location 6 2 Prepare boiler 9 3 Install water piping 12 4 Venting combustion air con...

Page 5: ... make upwatercancauseinternalcorrosion Leaksinboilerorpiping must be repaired at once to prevent make up water Do not add cold water to hot boiler Thermal shock can cause heat exchanger to crack Freeze protection fluids NEVER use automotive or standard glycol antifreeze even glycol made forhydronicsystems Useonlyfreeze protectionfluidsrecommendedin the Ultra Boiler Freeze Protection Supplement Fol...

Page 6: ...ep boiler area clear and free of combustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage 3 The Ultra boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service 4 If newboilerwillreplaceexistingboiler checkforand correct system...

Page 7: ...must provide 1 square inch free area per 1 000 Btuh of boiler input Vent and air piping The Ultra boiler requires a special vent system designed for pressurized venting Ultra boilers are rated ANSI Z21 13 Category IV pressurized vent likely to condense in the vent You must also install air piping fromoutside to the boiler airintakeadapter Theresultantinstallationiscategorized as direct vent sealed...

Page 8: ...ed to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition c Test vent system Insofar as is practical close all building doors and windows and all ...

Page 9: ...dy installedandconnectedtogassupply Foraboileralreadyinstalled you must turn off gas supply turn off power and allow boiler to cool before proceeding You must also completely test the boiler after conversion to verify performance as described under Startup Section 6 of this manual See separate natural to propane conversion instructions for conversion of an existing boiler You must install the prop...

Page 10: ...ng on the orifice disk matches the boiler size Place orifice in the black rubber grommet in the side of the gas valve and secure in valve Figure 2a 6 Reposition gas valve against venturi and replace 3 TORX screws securing valve to venturi Reconnect gas line union 7 DO NOT attempt to adjust gas valve outlet pressure 8 Connect gas valve electrical plug to valve terminals 9 After installation is comp...

Page 11: ...ves Follow guidelines in this manual for piping components locations and sizing Fill and pressure test 1 Open the shutoff valves you installed on supply and returnconnections 2 Slowlyopenboilerdrainvalveandfreshwatersupply to fill boiler with water The boiler will fill quickly because of its low water content 3 Whenwaterreachesshutoffvalves closeboilerdrain valve 4 Close shutoff valves 5 Slowly re...

Page 12: ...tional external controls for high limit and or low water cutoff protection Additional limit control Following standard industry practices if installation is to comply with ASME or Canadian requirements an additionalhightemperaturelimitisneeded Consultlocal requirements for other codes standards to determine if needed 1 Installadditionalhightemperaturelimitconstructed topreventatemperaturesettingab...

Page 13: ...nsion tank and make up water 1 Ensure expansion tank size will handle boiler and system water volume and temperature Allow 3 gallons for boiler and its piping Undersized expansion tanks cause system watertobelostfromreliefvalveandmake up water to be added through fill valve Eventual boiler failure can result due to excessive make up water addition 2 Tank must be located as shown in this manual or ...

Page 14: ...nd H2 from the available head of the circulator This gives the maximum value for H3 head loss across the water heater 4 Procedure to select a circulator using Table 2 Step 1 From the water heater manufacturer s data find Required boiler water flow rate GPM at 180 F Pressure drop across the water heater at this flow rate in feet water column Step 2 Find your boiler model in Table 2 Select a flow ra...

Page 15: ...dule add a circulator relay wired to the boilercirculatorterminalsasshownintheUltraControl Supplement Legend Figure 7 1 Ultra boiler 2 Indirect water heater DHW if used 3 Boiler relief valve see page 12 for piping details 4 Relief valve discharge piping see page 12 for details 5 DHW circulator see page 14 for suggested sizing 6 Isolation valves 7 System circulator 8 Diaphragm or bladder type expan...

Page 16: ...a boiler 2 Indirect water heater DHW if used 3 Boiler relief valve see page 12 for piping details 4 Relief valve discharge piping see page 12 for details 5 DHW circulator see page 14 for suggested sizing 6 Isolation valves 7 System circulator 8 Diaphragm or bladder type expansion tank see page 12 for piping of closed type expansion tank if used 9 Air separator with automatic air vent only on syste...

Page 17: ... control module add a circulator relay wired to the boiler circulator terminals as shown in the Ultra Control Supplement 7 Setting boiler outlet water target temperature a Follow procedure in Ultra Control Supplement to set space heating target temperature to the desired supply temperature for the system For outdoor reset operation install and connect the outdoor temperature sensor supplied with t...

Page 18: ...or other automatic means to prevent gravity circulationduringcoolingcycle Figure 10 Chilled water system plus optional DHW piping Legend Figure 10 Install water piping continued 3 1 Ultra boiler 2 Indirect water heater DHW if used 3 Boiler relief valve see page 12 for piping details 4 Relief valve discharge piping see page 12 for details 5 DHW circulator see page 14 for suggested sizing 6 Isolatio...

Page 19: ...ystem and combustion air quality See also Section 1 of this manual Inspect finished vent and air piping thoroughly to ensure all are airtight and complywiththeinstructionsprovidedand with all requirements of applicable codes Failuretoprovideaproperly installedvent and air system will cause severe personal injury or death c Apply a second coat of cement to both surfaces Avoid using too much cement ...

Page 20: ...rtified PVC or CPVC pipe fittings and cement 4 Leave the top of the tee OPEN This is needed as a vacuum break 5 When installing a condensate pump select one approved for use with condensing boilers and furnaces The pump should have an overflow switch topreventpropertydamagefromcondensatespillage 6 CondensatefromtheUltraboilerwillbeslightlyacidic typically with a pH from 3 2 to 4 5 Install a neutra...

Page 21: ...o use bubble test or check for gas leaks can cause severe personal injury death or substantial property damage 6 Usepipedopecompatiblewithpropanegases Apply sparingly only to male threads of pipe joints so that pipe dope does not block gas flow Failuretoapplypipedopeasdetailedabove can result in severe personal injury death or substantial property damage DO NOT adjust or attempt to measure gas val...

Page 22: ... exceed 13 w c at any time Adjust lockup regulator for 13 w c maximum Gas pipe length feet Capacity of pipe for pipe size of Capacity in cubic feet gas per hour 1 1 1 10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 860 40 63 130 245 500 760 50 56 115 215 440 670 75 45 93 175 360 545 100 38 79 150 305 460 150 31 64 120 250 380 Propane Gas Ultra boilers are shipped ready to fire na...

Page 23: ...buildupin sections reducing heat transfer overheating heat exchanger and causing heat exchanger failure 5 The system may have residual substances that could affect waterchemistry Afterthesystemhasbeenfilledandleaktested verify water pH and chlorine concentrations are acceptable Freeze protection when used NEVERuseautomotiveorstandardglycolantifreeze even glycol made for hydronic systems Use only f...

Page 24: ...orrect outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Propane boilers only Your propane supplier mixes an odorant with the propane to make its presence detectable In some in...

Page 25: ...the flue gas temperature sensor to prevent flue gas spillage into the boiler enclosure Failure to comply could result in severe personal injury death or substantial property damage Adjust and test boiler controls 1 Follow instructions in the Ultra Control Supplement to set and verify operation of the boiler controls Check system and boiler Check water piping 1 Check system piping for leaks If foun...

Page 26: ...peration as outlined by manufacturer Boiler should be operating and should go off when controls are tested Verify controls cause soft lockout or hard lockout as desired Set additional field installed limit control s to system temperature requirements Adjusted balancing valves and controls to provide design temperature to system Formultiplezones adjustedforcorrectflowineach zone Verified thermostat...

Page 27: ...correct Information received and left with owner maintenance person Installer ________________________________ company _____________________ phone ________________________________ address ________________________________ address __________________________________ installer s signature Check out startup verification 7 Comments _______________________________________ ________________________________...

Page 28: ...dures given throughout this manual and in component literature shipped with the boiler Failure to perform the service and maintenance could result in damagetotheboilerorsystem Failuretofollowthedirectionsinthismanualandcomponentliterature could result in severe personal injury death or substantial property damage Table 5 Service and maintenance schedules 8 ...

Page 29: ... be convertedtocristobaliteinveryhightemperatureapplications TheInternationalAgencyforResearch on Cancer IARC has concluded Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements f...

Page 30: ...ush valve to flush vent Replace caps Make sure vents do not leak Replace any leaking vents Check expansion tank 1 Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type Seesection3ofthismanualforsuggestedbestlocationofexpansion tanks and air elim...

Page 31: ...ther Safety relief valves should be reinspected AT LEAST ONCE EVERY THREEYEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tamperedwithillegally Certainnaturallyoccurringconditions may corrode the valve or its components over ...

Page 32: ...rvicing replace boiler components Retest boiler Check flame signal 1 Flame signal DC volts from low voltage terminal strip terminal 9 to ground should be at least 4 VDC 2 A lower flame signal may indicate a fouled ignitor or damaged ignitor insulation If cleaning the ignitor does not improve ground wiring is in good condition and ground continuity is satisfactory replace the ignitor 3 See Troubles...

Page 33: ...anger interior Accessexchanger Ultra 80andUltra 105Only 1 Remove 4 Phillips head screws securing gas valve inletadaptertogasvalve Thiswilldisconnectthegas valve from the gas line 2 Remove the air silencer by separating it from the air adapter on the blower inlet 3 Disconnect the gas valve plug blower power supply plug and blower control connector 4 Release the exchanger cover plate by removing the...

Page 34: ...he ceramic fiber WARNING on page 29 before handling or disposing of ceramic fiber materials 11 Place cover plate gasket in groove of heat exchanger cover plate Replace cover plate 12 Re installhexheadnuts 10mmboxendwrench on coverplatemountingstudsandtighteninastaggering pattern until cover plate is uniformly tightened 13 Re install blower insuring new gasket provided in this kit is in proper alig...

Page 35: ... appliances Failure to keep the door securely fastened could result in severe personal injury or death Weil McLainpartnumbersarefoundinWeil McLain Boilers and Controls Repair Parts Lists Replacementpartsmustbepurchasedthroughalocal Weil McLain distributor When ordering specify boiler model and size and include description and partnumberofreplacementpart Resultsfromusing modified or other manufactu...

Page 36: ...Part number 550 100 026 0404 GAS FIRED WATER BOILER SERIES 2 Boiler Manual 36 Replacement parts continued 9 Jacket parts ...

Page 37: ...GAS FIRED WATER 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 WATER BOILER SERIES 2 Boiler Manual 38 Replacement parts continued 9 Heat exchanger and piping Ultra 80 105 ...

Page 39: ...GAS FIRED WATER 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 WATER BOILER SERIES 2 Boiler Manual 40 Replacement parts continued 9 Heat exchanger and piping Ultra 155 to 310 ...

Page 41: ...GAS FIRED WATER 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 WATER BOILER SERIES 2 Boiler Manual 42 9 Replacement parts continued Controls ...

Page 43: ...er piping and gas pipe can be routed through bottom of enclosure using wall mounting kit 2 Boiler circulator is shipped loose Circulator may be mounted on either boiler supply or return piping Both 1 Notes and1 circulatorflangesareshippedwithboileronUltra 80 105 155 230 Both 1 and 1 circulator flanges are shipped with boiler on Ultra 310 3 Relief valve is shipped loose See page 11 for mounting det...

Page 44: ...ect vented Ultra 230 can be vented with either 3 or 4 vent pipe Vent length limits for 3 vent are not as long as for 4 vent Notes Notes 5 Weil McLain Low temperature seasonal efficiency is based on ASHRAE 103 test method using boiler return water temperature of 90 F with boiler outlet water temperature of 110 F 6 CombustionefficiencyisbasedonI B Rtestingprocedure BTS 2000 and equal to 100 minus fl...