Weil-McLain 230, 80, 310, 105, 155 manual Gas-fired water boiler

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Gas-fired water boiler

Ultra-80, -105, -155, -230 & -310

• Installation

• Startup

• Maintenance

• Parts

with

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 Vent Supplement, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.

Part number 550-101-233/0903

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Contents Gas-fired water boiler HOW IT Works GAS-FIRED Water BOILER, with PhD Technology Hazard definitions ContentsPlease read before proceeding When servicing boilerBoiler operation Boiler waterPrepare boiler location Installations must comply withBefore locating the boiler, check Provide clearancesFlooring and foundation Residential garage installationProvide air openings to room Vent and air pipingPrevent combustion air contamination When removing a boiler from existing common vent systemSeal any unused openings in the common venting system Remove boiler from crate Prepare boilerPrepare for propane if operating on propane Ultra-80 Placing floor-mounted boilers Prepare for propane if operating on propane Ultra-155 toPlacing wall-mounted boilers Set boiler in place and check levelPrepare boiler for test Perform hydrostatic pressure testFill and pressure test Drain and remove fittingsInstall relief valve Install water pipingAdditional controls, when required General piping informationCirculators System water piping methodsSizing space heat system piping Required boiler water flow rate, GPM, at 180F Sizing DHW system pipingConnect boiler to system as shown in when Zoning with zone valvesControlling the system circulator Zoning with circulators Radiant heating applications Setting boiler outlet water target temperatureChilled water system plus optional Chilled water systemsVenting, combustion air & condensate line Install vent and combustion air pipingPrepare condensate fittings Condensate drain Ultra-80 Connect condensate drainGas piping Connecting gas supply pipingWall-mounted boilers Propane Gas Natural GasPipe sizing for natural gas Natural gas supply pressure requirementsStartup Freeze protection when usedCheck/control water chemistry Fill and test water systemCheck thermostat circuits Check for gas leaks Final checks before starting boilerInspect/fill condensate system To start the boilerCheck system and boiler Adjust and test boiler controlsCheck flame & combustion Check-out/startup verification Check-out/startup verification Installation certificate Service and maintenance schedules Annual startup and general maintenanceHandling ceramic fiber materials Annual startupCheck water system Clean condensate trapCheck all piping for leaks Check expansion tank Check air openingsCheck all boiler wiring Check ignition ground wiringCheck control settings Check boiler relief valveCheck flue gas temperature Check flame signalPerform startup and checks Check burner flameGeneral maintenance Maintenance generalCleaning boiler heat exchanger Replace boiler jacket front door after startup or servicingAccess exchanger Ultra-155, -230, -310 Only Maintenance and annual startupExchanger cleaning ALL models Replacement parts Jacket parts Replacement parts Heat exchanger and piping Ultra-80 Replacement parts Heat exchanger and piping Ultra-155 to Replacement parts Controls Dimensions DOE Ratings

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