Weil-McLain 80 Check system and boiler, Check flame & combustion, Adjust and test boiler controls

6 GAS-FIRED WATER BOILER — Boiler Manual

Startup (continued)

❏Check system and boiler

❏Check water piping

1.Check system piping for leaks. If found, shut down boiler and repair immediately. (See WARNINGS on page 23 regarding failure to repair leaks.)

2.Vent any remaining air from system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.

❏Check vent piping and air piping

1.Check for gas-tight seal at every connection and seam of air piping and vent piping.

Venting system must be sealed gas-tight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death.

❏Check gas piping

1.Check around the boiler for gas odor following the procedure of page 21 of this manual.

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with bubble test and repair immediately. Do not start boiler again until corrected. Failure to comply could result in severe personal injury, death or substantial property damage.

❏Propane boilers — verify conversion

1.Verify propane orifice has been installed per Propane Conversion instructions.

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: The Ultra- 80LP is factory-equipped to fire propane. 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.

❏Check flame & combustion

1.Press and hold both the Ultra control panel “Mode” and “+” buttons simultaneously until “H” appears.

2.The “H” in the first digit of the display means the boiler will operate at high fire when the blower speed reaches maximum.

3.Look at the flame through the flame inspection window. The high fire flame should be blue and should be stable. The burner surface should be covered with orange dots.

4.Remove the flue temperature sensor from the flue pipe and insert a combustion test probe.

5.Testing is suggested for either CO2 or O2 and for CO. The values should be in the range listed in the table below. The CO should not exceed 100 ppm when combustion is correct.

If combustion at either high or low fire is outside the range given below, shut down the boiler and contact your local Weil- McLain representative. Failure to comply could result in severe personal injury, death or substantial property damage.

6.Measure natural gas input:

a.Operate boiler 10 minutes.

b.Turn off other appliances.

c.At natural gas meter, measure time (in seconds) required to use one cubic

foot of gas.

d. Calculate gas input:	3600 x 1000	= Btuh
	number of seconds from step c

e. Btuh calculated should approximate input rating on boiler rating label.

7.Press and hold the Ultra control panel “Mode” and “-” buttons simultaneously until the display shows “L”.

8.The“L”in the first digit means the boiler will operate at low fire when the blower speed reaches minimum.

9.Look at the flame through the flame inspection window. The low fire flame should be stable and evenly distributed over burner surface with a uniform orange color.

10.Repeat the combustion test of steps 4 and 5 above.

11.Press and hold the “+” and “-” buttons to return boiler to automatic firing.

12.Replace flue gas temperature sensor.

You must replace the flue gas temperature sensor to prevent flue gas spillage into the boiler enclosure. Failure to comply could result in severe personal injury, death or substantial property damage.

❏Adjust and test boiler controls

1.Follow instructions in the Ultra Control Supplement to set and verify operation of the boiler controls.

Part number 550-101-233/0903 25