Weil-McLain 230, 80, 310, 105, 155 Gas piping, Connecting gas supply piping, Wall-mounted boilers

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5 GAS-FIRED WATER BOILER — Boiler Manual

Gas piping

Connecting gas supply piping

1.Remove jacket front panel and refer to Figure 15 to pipe gas to boiler.

a.Install ground joint union for servicing, when required.

b.Install manual shutoff valve in gas supply piping outside boiler jacket when required by local codes or utility requirements.

c.In Canada — When using manual main shutoff valve, it must be identified by the installer.

2.Wall-mounted boilers

a.Refer to separate Ultra Boiler Wall-mounting instructions.

b.Gas connection may enter from the bottom of boiler as explained in the Wall-mounting instructions.

4.Purge all air from gas supply piping.

5.Before placing boiler in operation, check boiler and its gas connection for leaks.

a.Close manual main shutoff valve during any pressure testing at less than 13" w.c.

b.Disconnect boiler and gas valve from gas supply piping during any pressure testing greater than 13" w.c.

Do not check for gas leaks with an open flame — use bubble test. Failure to use bubble test or check for gas leaks can cause severe personal injury, death or substantial property damage.

3.Support piping with hangers, not by boiler or its accessories.

6.Use pipe dope compatible with propane gases. Apply sparingly only to male threads of pipe joints so that pipe dope does not block gas flow.

Failure to apply pipe dope as detailed above

Figure 15 Connect gas supply pipingcan result in severe personal injury, death or substantial property damage.

DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct 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.

Ultra boilers are shipped ready to fire natural gas ONLY. (Exception: Ultra-80LP is propane-ready.) You must install the propane orifice if the boiler will be connected to propane. See page 9. Failure to comply could result in severe personal injury, death or substantial property damage.

Use two wrenches when tightening gas piping at boiler, using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components.

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 pipingWhen removing a boiler from existing common vent system Prevent combustion air contaminationSeal any unused openings in the common venting system Prepare boiler Remove boiler from cratePrepare 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 informationSystem water piping methods CirculatorsSizing space heat system piping Required boiler water flow rate, GPM, at 180F Sizing DHW system pipingZoning with zone valves Connect boiler to system as shown in whenControlling the system circulator Zoning with circulators Radiant heating applications Setting boiler outlet water target temperatureChilled water system plus optional Chilled water systemsInstall vent and combustion air piping Venting, combustion air & condensate linePrepare condensate fittings Condensate drain Ultra-80 Connect condensate drainConnecting gas supply piping Gas 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 boilerAdjust and test boiler controls Check system and boilerCheck 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 servicingMaintenance and annual startup Access exchanger Ultra-155, -230, -310 OnlyExchanger 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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