Weil-mclain ultra with phd technology manual

Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

Correct by resizing to approach the minimum size as determined using the appropriate tables in Part 11 of that code. Canadian installations must comply with B The Ultra boiler is generally easier to handle and maneuver after removing from crate. After removing outer shipping carton from boiler, REMOVE jacket front door by loosening two knurledhead screws at lower front. Removing the door will prevent possible damage to the door during handling.

To remove boiler from pallet after removing jacket front door :. Remove the four lag screws securing shipping brackets. Unscrew the two rear boiler legs and remove the shipping brackets. Discard the cardboard protector insert on the rear of the boiler. Do not drop boiler or bump jacket on floor or pallet. Damage to boiler can result.

Follow the instructions provided with the optional propane conversion kit. The propane conversion kit is NOT included as standard equipment for the Ultra Do not apply the following to conversion of a boiler already installed and connected to gas supply.

For a boiler already installed, you must turn off gas supply, turn off power and allow boiler to cool before proceeding. See separate natural to propane conversion instructions for conversion of an existing boiler. You must install the propane orifice to fire the Ultra boiler on propane. Verify when installing that the orifice size marking matches boiler size.

UltraLP boilers are factory-equipped to operate on propane gas. With boiler on its back, remove jacket front door by removing two knurled head screws at lower front. Then lift door away from boiler. Disconnect the gas valve electrical plug. Remove the 4 screws securing gas valve inlet adapter to valve. Locate propane orifice disc from conversion kit bag. Verify that the stamping 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 2.

Reposition gas valve against venturi and replace 3 TORX screws securing valve to venturi. Secure gas valve inlet adapter to gas valve with 4 screws. Make sure the plastic hose is connected from gas valve to inlet elbow. Inspect the O-ring between the gas valve and gas valve inlet adapter block whenever they are disassembled. The O-ring must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

DO NOT attempt to adjust gas valve outlet pressure. Connect gas valve electrical plug to valve terminals. After installation is complete, attach the propane conversion label in conversion kit bag next to the boiler rating plate.

Replace jacket front panel. Disconnect the gas line union below the gas valve. Reconnect gas line union. Figure 2a Installing propane orifice Ultra and Ultra Ultra boilers cannot be equipped for propane firing as of October, Propane capability should be available in Set boiler in place and check level.

Ultra, , and boilers can be wall mounted. Use only the separately available Ultra boiler wall mounting kit and instructions. The wall must be vertically plumb and capable of carrying the weight of the boiler.

The operating weights are:. Ultra pounds. Wall mount Ultra boilers only using WeilMcLain Ultra boiler wall-mounting kit and accompanying instructions. This kit is not supplied as standard equipment with the boiler, and must be purchased separately. Failure to comply with above could result in severe personal injury, death or substantial property damage. Pressure test boiler before permanently attaching water or gas piping or electrical supply.

See Figure 3 for reference in following steps. Pipe to boiler supply connection as shown. Use pipe dope sparingly. Connect a hose to boiler drain valve, the other end connected to a fresh water supply.

Make sure hose can also be used to drain boiler after test. Connect a nipple and shutoff valve to system supply connection on the supply tee. This valve will be used to bleed air during the fill. Valve and nipple are not included with boiler. Connect a shutoff valve to system return connection. Valve is not included with boiler.

To avoid getting water on boiler, you may want to pipe street elbows on top of shutoff valves and attach catch-buckets beneath. If convenient, install the boiler circulator and any other piping compatible with Figure 3 that would still allow bleeding air from shutoff valves. Follow guidelines in this manual for piping components, locations and sizing. Open the shutoff valves you installed on supply and return connections.

Slowly open boiler drain valve and fresh water supply to fill boiler with water. The boiler will fill quickly because of its low water content. When water reaches shutoff valves, close boiler drain valve. Hold at test pressure for 10 minutes. Do not leave boiler unattended. A cold water fill could expand and cause excessive pressure,resulting in severe personal injury, death or substantial property damage.

Make sure constant gauge pressure has been maintained throughout test. Check for leaks. Repair if found. Leaks must be repaired at once. Failure to do so can damage boiler, resulting in substantial property damage. Do not use petroleum-based cleaning or sealing compounds in boiler system. Disconnect fill water hose from water source. Drain boiler through drain valve.

Remove hose after draining. Remove nipples and valves unless they will remain for use in the system piping. Remove plug from relief valve street elbow. See section 3 page 12 to install relief valve. Pipe the relief valve only as shown, in the location shown.

Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the valve discharge. Do not plug or place any obstruction in the discharge line. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve. Use two wrenches when tightening water piping at boiler, using one wrench to prevent the boiler return line or supply line from turning.

Failure to support the boiler piping connections to prevent them from turning could cause damage to boiler components. The Ultra control module uses temperature sensors to provide both high limit protection and modulating temperature control. The control module also provides low water protection by sensing the temperature of the heat exchanger.

Following standard industry practices, if installation is to comply with ASME or Canadian requirements, an additional high temperature limit is needed. See Ultra Control Supplement for wiring. If limit control is to cause a boiler hard lockout requiring manual reset of Ultra control module , connect isolated contact to field control wiring terminals 6 and 8 as shown in wiring diagram. Otherwise, connect isolated contact between terminals 6 and 7 for a soft lockout automatic reset.

A low water cutoff device is required when boiler is installed above piping level or by certain state or local codes or insurance companies.

Consult local requirements to determine. If required, use a low water cutoff designed for water installations. Electrode probe-type is recommended. Purchase low water cutoff and install in tee in supply piping above boiler. 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. Wall-mounted boilers — Piping can exit bottom of boiler enclosure.

See separate wall-mounting instructions for details. 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 water to be lost from relief valve and makeup water to be added through fill valve. Eventual boiler failure can result due to excessive make-up water addition. Tank must be located as shown in this manual, or following recognized design methods.

Connect the expansion tank to the air separator only if the separator is on the suction side of the circulator. Always install the system fill connection at the same point as the expansion tank connection to the system. Most piping drawings in this manual show diaphragm expansion tanks. See Figure 4 for piping from air separator to expansion tank and make-up water line using a closed-type expansion tank.

Most chilled water systems are piped using a closedtype tank, as shown in Figure 10, page Figure 4 Always install an automatic air vent on top of the air separator to remove residual air from the system. See Figure 4, Alternate, for piping connections when using a closed-type expansion tank.

Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping. DO NOT install automatic air vents on closed-type expansion tank systems. Air must remain in the system and return to the tank to provide its air cushion.

Verify proper flow direction of the boiler circulator. Verify proper boiler circulator speed setting in the control module.

If the resistance values are incorrect replace the temperature sensor. Refer to repair parts section for proper 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 parts section for kit number. In addition inspect heat exchanger combustion chamber and flueways for abnormal wear or buildup.

Inspect vent system for abnormal wear or damage. Check for a loose connection at the molex 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? If yes, trouble shoot the external limit to determine and correct the cause that opened the limit. Also check for loose wiring connections. Remove the top right electrical cover and inspect the connector.

Verify all isolation valves are open and circulators are programmed into the control module properly.

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. Burner may be operating too hot due to incorrect combustion. Inspect flame and conduct combustion test. We have sent a verification link to to complete your registration. Log In Sign Up. Forgot password?

Enter your email address and check your inbox. Please check your email for further instructions. Enter a new password. Ultra Series 2. PhD Technology - Precision Hydronic Data An intelligent system that delivers Precision Hydronic heating and hot water needs while maximizing efficiency by measuring and responding to the Data parameters of your heating system. The key components include A negative regulated gas valve that Precisely delivers gas to the boiler; A variable speed motor that matches combustion output to your heating needs; A venturi mixing body that Precisely mixes air and gas providing higher efficiency; System intelligence with the Ultra Control Module which maintains proper, efficient and Precise Hydronic heat through inputs of all system Data; A cast aluminum mono block heat exchanger designed to operate in low temperature condensing applications; Pre-mix stainless steel burner designed for perfect firing rate modulation, efficiency, clean combustion and quiet operation.

The cast aluminum heat exchanger features High grade stainless steel burner with woven a mono block design. This low mass heat steel fiber mesh. This aluminum block has modulating firing rate. The Ultra burner been specifically designed to work in low features long life, quiet operation, high returntemperatureapplicationsincondensing efficiency and cleaner combustion for low mode.

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