Part number 550-141-986/1005 • Installation • Startup This manual must only be used by a qualified heating installer/service technician. Before installing, read all instructions, including this manual, the burner manual and any related supplements. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage. Oil-Fired Water Boiler • Maintenance • Parts Boiler Manual
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13. EnviraCOM®wireharnessLowvoltagewireharnessfromL7�48aquastattotheHoneywellburnerprimarycontrol’sEnviraCOM®connector—acommu-nications port designed to optionally allow you to add greatersystem capability at the time of installation. Examples includetestinstrumentsanddial-inaccessand,inthefuture,efficiencyoptimization, zoning, and sequencers. Look for products withtheHoneywellEnviraCOM®nameindicatingproductsthatarecompatiblewithyournewboiler.
The waTer boiler — how iT works ......................................2–3Please read before proceeding ...........................................................5Boiler location checklist ......................................................................6Prepare boiler location .........................................................................7Connect breeching .............................................................................11Connect water piping .........................................................................13Connect wiring (Note 1) .........................................................................18Connect oil piping .............................................................................21Startup procedure ..............................................................................22Check-out procedure .........................................................................23Annual service and start-up ..............................................................24Appendix (removing/replacing boiler jacket, replacement parts, dimensions and ratings) ..................................................................... 29Note 1: See burner manual for wiring and additional startup and operating information. Also
see AFM manual if used.
Whencallingorwritingabouttheboil-er—Pleasehavetheboilermodelnumberfromtheboiler rating labeland theCPnumberfromtheboilerjacket.YoumaylisttheCPnumberinthespaceprovidedon the InstallationCertificate foundonpage��.
Consider piping and installation whendeterminingboilerlocation.
Any claims for damage or shortage inshipment must be filed immediatelyagainst the transportation company bytheconsignee.
• Donotusethisboilerifanyparthasbeenunderwater.Electrical and mechanical failures may cause electricshockandfirerisks.Immediatelyinspectchimneyorvent,boiler,burnerandcontrols.Cleantheboilerfluewaysandreplaceallelectricalandmechanicalcontrols;allelectricalwiring;oilburnerandcontrols;insulationandchamberlining.
• Do not use petroleum-based cleaning or sealingcompoundsinboilersystem.Gasketsandsealsinthesystemmaybedamaged.Thiscanresultinsubstantialpropertydamage.
• Donotuse“homemadecures”or“boilerpatentmedi-cines.” Serious damage to boiler, personnel and/orpropertymayresult.
• Continual fresh make-up water will reduce boilerlife.Mineralbuildupinboilersectionsreducesheattransfer, overheats the sections, and causes failure.Additionofoxygencarriedinbymake-upwatercancause internal corrosion. Leaks in boiler or pipingmustberepairedatoncetopreventmake-upwater.
United States installations must comply with all applicable U. S. codes:
• Applicable state, local and national codes.• National Electrical Code.• Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/
ASME CSD-1, when required.
Canadian installations must comply with all applicable Cana-dian codes:
• Canadian Standards Association CSA B139, Installation Code for Oil-Burning Equip-ment.
• CSA C22.1 Canadian Electrical Code Part One.• Applicable provincial and local codes.
❏ Consider use of space
• The boiler area must be kept free of combustible materials, gasoline and other flam-mable liquids.
• The boiler must be installed so that boiler and system components are protected from dripping or spraying water or rain during operation or service.
❏ Moving boiler to location• See manual pages 38 and 39 for boiler dimensions and weights.• If necessary, the boiler jacket can be removed if desired for handling. See manual
pages 30 and 31 for instructions.
❏ Clearances
• Provide minimum clearances to combustible materials and for servicing boiler.• Ensure that the swing-away burner door can swing open freely. (The hinge can be
mounted on right or left side.)• See manual page 10 for instructions on changing door hinge location.
❏ Flooring and foundation
• Provide level flooring (non-carpeted combustible flooring is acceptable if boiler level-ing legs are installed).
• Provide foundation if necessary.• See manual page 8.
❏ Combustion and ventilation air openings
• Boiler room must provide adequate combustion air and ventilation.• Unless burner uses ducted outside air for combustion, the boiler room must provide
combustion air openings.• See manual page 8.
❏ Venting
Chimney venting:• Ensure the vent pipe can be routed to the chimney, and that the chimney connection
is higher than the boiler flue outlet.• Ensure the vent piping will provide minimum clearances shown on manual pages 7
and 11.• See manual pages 11 and 12 for venting information.
Direct venting:• The Ultra oil boiler can be direct vented, using the Field Controls Direct Vent Kit,
model number FDVS-46, and vent pipe model number FVOP-415. Verify that the vent piping can be installed and routed to the outside wall as specified in the Field Con-trols instruction manual.
• Ensure the vent piping will provide minimum clearances shown on manual page 7.
❏ System water piping• Check location of system water piping connections to be sure boiler can be properly
connected.• See manual pages 13 through 17.
❏ Fuel supply • See manual page 21 for routing of fuel lines.
❏ Electrical power
• The boiler requires 120 vac power and connection to a room thermostat or other device to initiate call for heat.
• If equipped with an AFM, the boiler requires a 20-amp service.• See manual pages 18 through 20.
Adequatecombustionandventilationairensurespropercombustionandreducesrisk of severe personal injury or deathfrompossiblefluegasleakageandcarbonmonoxideemissions.
Do not install exhaust fan in boilerroom.
Natural infiltrationOlder buildings with single-pane windows, minimalweather-strippingandnovaporbarrieroftenprovideenough natural infiltration and ventilation withoutdedicatedopenings.
Tight constructionNew construction or remodeled buildings are mostoften built tighter.Windows and doors are weather-stripped, vapor barriers are used and openings inwallsarecaulked.Asaresult,suchtightconstructionisunlikelytoallowpropernaturalairinfiltrationandventilation.
Follow code requirementsFollow state, provincial or local codes when sizingadequatecombustionandventilationairopenings.Inabsence of codes, use the following guidelines whenboiler is inaconfinedroom(definedbyNFPA�1aslessthan7�00cubicfeetper1GPHinputofallappli-ancesinarea.Aroom8ft.highx��.�ft.x��.�ft.is7�00cu.ft.).
Provide two permanent openingsProvide two permanent openings — one within 1�inchesofceiling,onewithin1�inchesoffloor.Mini-mumheightorlengthdimensionofeachrectangularopeningshouldbeatleast�inches.
Air from inside the buildingWhen insideair isused—eachopeningmust freelyconnectwithareashavingadequate infiltration fromoutside.Eachopeningshouldbeatleast140sq.in.per1GPHinput(1sq.in.per1000Btuinput)ofallfuel-burningappliancesplus requirements foranyequip-ment thatcanpull air fromroom(includingclothesdryerandfireplace).
Air from outside the buildingWhen outside air is used — connect each openingdirectlyorbyductstotheoutdoorsortocrawlorat-tic space that freelyconnectswithoutdoors.Sizeperbelow:
Verify gas-tight seal to prevent possibleflue gas leakage and carbon monoxideemissions,whichcanleadtosevereper-sonalinjuryordeath.
Part number 550-141-986/1005 11
water boiler — Boiler Manual
Connect breeching
Direct ventingTheUltraOilboilercanbedirectventedusingtheFieldControlsDirectVentKit,modelnumberFDVS-46,andventpipemodelnumberFVOP-41�.Ventlengthsarelimitedto1�feet.Airintakelengthsarelimitedto��feetofrigid4-inchpipe.Donotuseflexibledryervent.Refertoinstructionsprovidedwiththeventkitforventandairpipinginstallationprocedures.
Figure 5 Breech connection, typical, for gravity venting into chimney
Chimney venting (continued)
Connectbreeching:
Long horizontal breechings, excessivenumberofteesandelbowsorotherob-structionsrestrictingcombustiongasflowcanresultinpossibilityofcondensation,flue gas leakage and carbon monoxideemissions,whichcanleadtosevereper-sonalinjuryordeath.
1. Connect full-sized breeching when possible. SeeTable�,page11,andFigure�,below.
�. When burner and boiler are properly installed,breeching draft will be approximately -0.01” to-0.0�”W.C. Install barometric control in breech-ing,percontrolmanufacturer’sinstructions,whenexcessdraftneedstoberelievedortocomplywithapplicablecodesandregulations.Usedraftgaugetoadjustproperopening.
TheUltraOilboiler iscapableofbeingpressurefired.Overfirepressuremaybepositive even with a negative pressureinthechimney.SeetheRatingstableonpage�9forboilerdraftloss.
Thepressureinthebreechingandchim-ney must always be negative unless thechimney and breeching are constructedof vent piping designed for pressurizedventing.
4. Aninduceddraftfanforthechimneymaybeneces-saryif:• Excessiveresistancetoflowofcombustiongases can
• Discharge line must be connected toreliefvalveoutletandruntoasafeplaceof disposal. Terminate the dischargeline to eliminate possibility of severeburnsshouldthevalvedischarge.
• Dischargelinemustbeasshortaspos-sibleandbethesamesizeasthevalvedischarge connection throughout itsentirelength.
• Discharge line must pitch downwardfromthevalveand terminateat least6” above the floor drain where anydischargewillbeclearlyvisible.
• The discharge line shall terminateplain, not threaded, with a materialserviceablefortemperaturesof�7�°Forgreater.
• Test the operation of the valve afterfilling and pressurizing system bylifting the lever. Make sure the valvedischarges freely. If the valve fails tooperatecorrectly,replaceitwithanewreliefvalve.
Connect water piping
Table 3 Water piping sizing
ModelPiping tosystem(inches)
Piping from system(inches)
UO-3 1¼ 1¼
UO-4 1¼ 1¼
UO-5 1½ 1½
Note: sizing based on 20°F temperature rise through boiler.
d. Notethatvalve7aregulatestheamountofhotwaterfromtheboilersupply,whichmixeswithreturnwater.Valve7bregulatestheamountofsystemwaterflowingthroughtheboilersecondaryloop.
Piping MULTIPLE ZONES — System temperature below 140 °F
1 Isolation valve2 Flow control valve3 Circulator4 System temperature gauges5 Zone valve
6 Drain valve7 System temperature valves. Adjust valves 8 Blend temperature gauge9 Boiler temperature gauge (not shown)
Part number 550-141-986/1005 17
water boiler — Boiler Manual
Connect water piping (continued)
Piping boiler in refrigeration systems (Figure 12)
• Release the Control Pod cover by loosening theretainerscrewinthetopcenterofthecover.Swingthecoveropentorevealtheboilerterminalstrip.
• Remove the Control Pod cover to facilitate wirerouting.(Toremove,pushtheControlPodcovertooneside,andgentlyworkthecoverretainerhingeontheothersideoutofthejacketslot.)
Fill the system:1. Closemanualandautomaticairventsandboiler
draincock.
�. Filltocorrectsystempressure.Correctpressurewillvarywitheachinstallation.Normalcoldwaterfillpressure for residential systems is 1� psig. BoilerwaterpH7.0to8.�isrecommended.
• Never leave combustible materialaroundtheboiler.
When using antifreeze—Donotuseautomotive,ethyleneglycol,undilutedorpetroleum-basedantifreeze.Severepersonal injury, death or substantialpropertydamagecanresult.
• Use antifreeze especially made forhydronicsystems.Inhibitedpropyleneglycolisrecommended.
• Local codes may require back-flowpreventer or actual disconnect fromcitywatersupply.
• Determinequantityaccordingtosys-temwatercontent.Boilerwatercontentis listed on page �9 of this manual.Percentofsolutionwillaffectsizingofheatdistributionunits,circulatorandexpansiontank.
• Follow antifreeze manufacturer’s in-structions.
Part number 550-141-986/1005 ��
water boiler — Boiler Manual
Check-out procedure
o 1. Boilerandheatdistributionunitsfilledwithwater?
o �. Automaticairvent,ifused,openedonefullturn?
o �. Airpurgedfromsystem?Pipingcheckedforleaks?
o 4. Airpurgedfromoilpiping?Pipingcheckedforleaks?
o �. Burnerdoorclosed,sealedandboltstight?Observationport bolt tight? Burner harness plugged in and boilerON/OFFswitchon?
o 6. Properdraftandburnerflame?Finaladjustmentmadewithcombustiontestequipment?
o 7. Testlimitcontrol:Whileburnerisoperating,adjustlimitcontrol below actual boiler water temperature. Burnershouldgooffwhilecirculatorcontinuestooperate.Raisesetting on limit control above water temperature andburnershouldre-ignite.
o 8. Testadditionalfield-installedcontrols:Ifboilerhasalowwatercutoff,additionalhighlimitorothercontrols,testforoperationasoutlinedbymanufacturer.Burnershould
Annual service call check list(follow in the order listed below) D
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1 Check that boiler area is free from combustible materials, gasoline and other flammable vapors and liquids.
2 Check for and remove any obstruction to combustion and ventilation air flow to boiler.
3 Check breeching and chimney or vent for obstructions, damage, etc.Repair or replace as necessary.
4 Clean boiler flueways.See instructions in boiler manual.
5 Perform service on relief valve.See instructions in boiler manual.
6 Check boiler and piping for leaks.Repair if found.
7 Inspect and adjust burner. See burner manual and:• change nozzle.• check ignition electrode settings.• clean blower housing and wheel.• make sure blower wheel turns freely.• oil burner motor if required.• clean air inlet.• clean or change fuel filter and strainer.
8 Make sure boiler is filled with water.
9 Start unit and verify combustion settings with combustion test equipment.
10 Verify operation of all controls on boiler.See boiler manual and burner manual for procedures.
Theboilershouldbeinspectedandstartedannually,atthebeginningoftheheatingseason,onlybyaqualifiedservicetechnician.Inaddition,themaintenanceandcareoftheboilerdesignatedinTable4mustbeperformedtoassuremaximumboilerefficiencyandreliability.Seethefollowingpagesfordetailed instructions. Failure to service and maintain theboilerandsystemcouldresultinequipmentfailure.
was written. Other types of respirators may beneededdependingonthejobsiteconditions.Cur-rent NIOSH recommendations can be found ontheNIOSHwebsiteathttp://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators,manufacturers,andphonenumbersarealsolistedonthiswebsite.
Check all piping for leaks Eliminateallsystemorboilerleaks.Con-
tinual fresh make-up water will reduceboilerlife.Mineralscanbuildupinsec-tions, reducing heat transfer, overheat-ing heat exchanger, and causing heatexchangerfailure.Leakingwatermayalsocauseseverepropertydamage.
Flue vent system and air pipingVisually inspect entire flue gas venting system (andairpiping, if installed) forblockage,deteriorationorleakage. Repair any joints that show signs of leakagein accordance with vent manufacturer’s instructions.Whenairisductedtoburner,verifythatairinletpipingisconnectedandproperlysealed.
Failure to inspect for the above condi-tionsandhavethemrepairedcanresultinseverepersonalinjuryordeath.
Check water system1. Verifyallsystemcomponentsarecorrectlyinstalled
�. Watch the system pressure as the boiler heats up(duringtesting)toensurepressuredoesn’trisetoohigh. Excessive pressure rise indicates expansiontanksizingorperformanceproblem.
4. Inspect automatic air vents and air separators.Removeairventcapsandbrieflypresspushvalvetoflushvent.Replacecaps.Makesureventsdonotleak.Replaceanyleakingvents.
suchastheB>ank-TrolorTacoTaco-Trol.Thisfittingreducesgravitycirculationofair-saturatedtankwaterback to the systemandprevents the air frombubblingupthroughthewaterasitreturnsfromthesystem.
• Donotuseautomaticairventsinsystemswithclosed-typetanks.Theairwillescapefromthesysteminsteadof returning to the tank. Eventually, the tank willwaterlog and no longer control pressurization. Theboilerreliefvalvewillweepfrequently.
Diaphragm or bladder-type—weldedgastightwitharubbermembranetoseparatethetankpres-surizingairand thewater.Maybe locatedatanypointinthesystem,butmostoftenfoundneartheboiler.• Systemswiththistypeofexpansiontankrequireatleast
Closed-type tank — tank is most likely water-logged.Installatankfittingifnotalreadyinstalled.Then check fill level per fitting manufacturer’sinstructions.Iffillleveliscorrect,checktanksizeagainstmanufacturer’s instructions.Replacewithalargertankifnecessary.
Diaphragm or bladder-type—first,checktanksizetobesureitislargeenoughforthesystem.Ifsize is toosmall,addadditional tank(s)asneces-sarytoprovidesufficientexpansion.Iftanksizeislargeenough,removetankfromsystemandcheckchargepressure(usually1�psigforresidentialap-plications).Iftankwon’tholdpressure,membranehasbeendamaged.Replacetank.
Annual service and start-up (continued)
Part number 550-141-986/1005 �7
water boiler — Boiler Manual
Annual service and start-up (continued)
Check boiler relief valve1. Inspect the reliefvalveand lift the lever toverify
flowasinthefollowingwarnings,excerptedfromareliefvalvemanufacturer’swarninglabel.Beforeoperating any relief valve, ensure that it is pipedwithitsdischargeinasafeareatoavoidseverescaldpotential.Readpage1�regardingreliefvalvesbeforeproceedingfurther.
Safetyreliefvalvesshouldbereinspectedat least once every three years,byalicensedplumbingcontractororautho-rized inspection agency, to ensure thatthe product has not been affected bycorrosivewaterconditionsandtoensurethatthevalveanddischargelinehavenotbeen altered or tampered with illegally.Certain naturally occurring conditionsmaycorrodethevalveoritscomponentsover time, rendering the valve inopera-tive. Such conditions are not detectableunlessthevalveanditscomponentsarephysically removed and inspected. Thisinspection must only be conducted bya plumbing contractor or authorizedinspectionagency—notby theowner.Failuretoreinspecttheboilerreliefvalveasdirectedcouldresultinunsafepressurebuildup,whichcanresult insevereper-sonalinjury,deathorsubstantialpropertydamage.
Followinginstallation,thevalvelevermustbeoperatedat least once each yeartoensurethatwaterwaysareclear.Certainnaturallyoccurringmineraldepositsmayadheretothevalve,renderingitinopera-tive.Whenmanuallyoperatingthelever,waterwilldischargeandprecautionsmustbetakentoavoidcontactwithhotwaterandtoavoidwaterdamage.Beforeoper-atinglever,checktoseethatadischargeline is connected to this valve directingtheflowofhotwaterfromthevalvetoaproperplaceofdisposal.Otherwiseseverepersonal injury may result. If no waterflows, valve is inoperative. Shut downboiler until a new relief valve has beeninstalled.
�. Afterfollowingthewarningdirections,ifthereliefvalve weeps or will not seat properly, replace thereliefvalve.Ensurethatthereasonforreliefvalveweepingisthevalveandnotover-pressurizationofthesystemduetoexpansiontankwaterloggingorundersizing.
Check all boiler wiringInspectallboilerwiring,makingsurewiresareingoodconditionandsecurelyattached.
Check control settings1. Checkboilerlimitcontrolsetting,Adjustifneces-
Clean boiler flueways and check refractory linings
Make sure all electrical connections toboilerareturnedoffandwaituntilboileriswarm,nothot,beforecleaning.Failureto do so will result in severe personalinjury,deathorsubstantialpropertydam-age.
Removing the boiler jacket Electrical shock hazard — The following
procedureassumestheboilerhasnotbeenwired. If the boiler has been wired, youmustdisconnect allpower to theboiler.Thenlabelallwiresbeforedisconnectingthemattheboilerterminalstrip.
Theboilercontainsfiberglassandceramicfiber materials. Use care when handlingthesematerials,perinstructionsonpage��ofthismanual.Failuretocomplycouldresultinseverepersonalinjury.
1. See Figures18 through�1 for jacket components,hardwareandlocations.
�. Removejacketfrontpanel(Figure18).
�. If the burner has been installed in the burnerdoor:• Removetheburnercover.• Disconnect the two burner wiring harnesses at the
jacketcrosstie(locatedbeneaththeburnerdoor).
Failure todisconnect theburnerwiringhar-nesses before opening the burner door cancause damage to the burner and boiler wir-ing.
19.Loosen the four �/8–16 x 1” screws securing thejacketbackpaneltotherearsection.Thescrewsarelocatedattherecessedopeningsonthejacketbackpanel(Figure�1).