Weil-McLain 80, 230, 310, 105 manual Prepare for propane if operating on propane Ultra-155 to

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2 GAS-FIRED WATER BOILER — Boiler Manual

Prepare boiler (continued)

Prepare for propane if operating on propane — Ultra-155 to -230

Ultra-80: DO NOT apply the following instructions to conversion of Ultra-80 boilers. Follow the instructions provided with the optional propane conversion kit. The propane conversion kit is NOT included as standard equipment for the Ultra-80.

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. 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 propane orifice to fire the Ultra boiler on propane. Verify when installing that the orifice size marking matches boiler size. Failure to comply could result in severe personal injury, death or substantial property damage.

1.With boiler on its back, remove jacket front door by removing two knurled head screws at lower front. Then lift door away from boiler.

2.Disconnect the gas valve electrical plug.

3.Disconnect the gas line union below the gas valve.

4.Remove (3) TORX screws securing gas valve to venturi (Figure 2a).

5.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).

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 complete, attach the propane conversion label (in conversion kit bag) next to the boiler rating plate.

10.Replace jacket front panel.

Figure 2a Installing propane orifice (Ultra-155 and Ultra-230)

Ultra-310 boilers cannot be equipped for propane firing as of October, 2003. Propane capability should be available in 2004.

Placing floor-mounted boilers

1.Set boiler in place and check level.

a. Adjust legs, if necessary to level boiler.

Placing wall-mounted boilers

1.Ultra-80, -105, -155 and -230 boilers can be wall mounted. Use only the separately available Ultra boiler wall mounting kit and instructions. See WARNING below.

The wall must be vertically plumb and capable of carrying the weight of the boiler. The operating weights are:

Ultra-80: 139 pounds.

Ultra-105: 145 pounds.

Ultra-155: 181 pounds.

Ultra-230: 192 pounds.

Model Ultra-310 boilers are NOT designed for wall mounting.

Wall mount Ultra boilers only using Weil- McLain 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.

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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 Contents Hazard definitionsBoiler operation When servicing boilerPlease read before proceeding Boiler waterBefore locating the boiler, check Installations must comply withPrepare boiler location Provide clearancesProvide air openings to room Residential garage installationFlooring and foundation 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 wall-mounted boilers Prepare for propane if operating on propane Ultra-155 toPlacing floor-mounted boilers Set boiler in place and check levelFill and pressure test Perform hydrostatic pressure testPrepare boiler for test Drain and remove fittingsAdditional controls, when required Install water pipingInstall relief valve General piping informationCirculators System water piping methodsSizing space heat system piping Sizing DHW system piping Required boiler water flow rate, GPM, at 180FConnect boiler to system as shown in when Zoning with zone valvesControlling the system circulator Zoning with circulators Setting boiler outlet water target temperature Radiant heating applicationsChilled water systems Chilled water system plus optionalVenting, combustion air & condensate line Install vent and combustion air pipingPrepare condensate fittings Connect condensate drain Condensate drain Ultra-80Gas piping Connecting gas supply pipingWall-mounted boilers Pipe sizing for natural gas Natural GasPropane Gas Natural gas supply pressure requirementsCheck/control water chemistry Freeze protection when usedStartup Fill and test water systemInspect/fill condensate system Check for gas leaks Final checks before starting boilerCheck thermostat circuits To start the boilerCheck system and boiler Adjust and test boiler controlsCheck flame & combustion Check-out/startup verification Check-out/startup verification Installation certificate Annual startup and general maintenance Service and maintenance schedulesAnnual startup Handling ceramic fiber materialsCheck all piping for leaks Check expansion tank Clean condensate trapCheck water system Check air openingsCheck control settings Check ignition ground wiringCheck all boiler wiring Check boiler relief valvePerform startup and checks Check flame signalCheck flue gas temperature Check burner flameCleaning boiler heat exchanger Maintenance generalGeneral maintenance 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 Ratings DOE
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