Weil-McLain 230, 80, 310, 105, 155 manual Check-out/startup verification

Page 26

7 GAS-FIRED WATER BOILER — Boiler Manual

Check-out/startup verification

❏Boiler and heat distribution units filled with water?

❏Water chemistry verified per page 23?

❏Automatic air vents, if used, open one full turn?

❏Air purged from system?

❏Air purged from gas piping? Piping checked for leaks?

❏Propane orifice installed for propane firing and propane conversion label affixed to jacket?

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 or conversion kit (Ultra-80NG) 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.

❏Thermostat circuit wiring checked to ensure there are no stray voltages per page 24, “Check Thermostat Wires?”

❏Followed Operating Instructions in Ultra Control Supplement?

❏Burner flame and combustion verified per page 25?

❏Verified control operation for space heating and DHW (if used) per Ultra Control Supplement?

❏Tested additional field-installed controls — If boiler has a low water cutoff, additional high limit or other controls, tested for operation as outlined by manufacturer? (Boiler should be operating and should go off when controls are tested. Verify controls cause soft lockout or hard lockout as desired.)

❏Set additional field-installed limit control(s) to system temperature requirements? Adjusted balancing valves and controls to provide design temperature to system?

❏For multiple zones, adjusted for correct flow in each zone?

❏Verified thermostat heat anticipator (if available) set properly? Refer to Ultra Control Supplement.

❏Cycled boiler with thermostat (and with DHW aquastat, if installed) — Raised to highest setting and verified boiler goes through normal startup cycle? Lowered to lowest setting and verified boiler goes off?

❏Measured natural gas input? (per page 25)

❏Checked incoming gas pressure by connecting manometer to gas valve ahead of boiler? (Gas pressure must be at least 5 inches w.c. for natural gas, and 4 inches w.c. for propane, with boiler operating at high fire, and no more than 13 inches w.c. with boiler operating or boiler off.)

❏Observed several operating cycles for proper operation.

❏Set room thermostat to desired room temperature (and DHW aquastat, if installed, to desired DHW storage temperature)?

❏Reviewed all instructions shipped with this boiler with owner or maintenance person?

❏Fill in Installation certificate on page 27.

❏Return instructions to envelope and give to owner or place inside boiler housing.

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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 pipingSeal any unused openings in the common venting system When removing a boiler from existing common vent systemPrevent combustion air contamination Prepare for propane if operating on propane Ultra-80 Prepare boilerRemove boiler from crate 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 informationSizing space heat system piping System water piping methodsCirculators Sizing DHW system piping Required boiler water flow rate, GPM, at 180FControlling the system circulator Zoning with zone valvesConnect boiler to system as shown in when Zoning with circulators Setting boiler outlet water target temperature Radiant heating applicationsChilled water systems Chilled water system plus optionalPrepare condensate fittings Install vent and combustion air pipingVenting, combustion air & condensate line Connect condensate drain Condensate drain Ultra-80Wall-mounted boilers Connecting gas supply pipingGas piping 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 flame & combustion Adjust and test boiler controlsCheck system and boiler 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 servicingExchanger cleaning ALL models Maintenance and annual startupAccess exchanger Ultra-155, -230, -310 Only 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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