Weil-McLain 105, 80, 230 Annual startup and general maintenance, Service and maintenance schedules

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8 GAS-FIRED WATER BOILER — Boiler Manual

Annual startup and general maintenance

Table 5 Service and maintenance schedules

Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.

28	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 definitionsWhen servicing boiler Please read before proceedingBoiler operation Boiler waterInstallations must comply with Prepare boiler locationBefore locating the boiler, check Provide clearancesResidential garage installation Flooring and foundationProvide 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 Prepare for propane if operating on propane Ultra-155 to Placing floor-mounted boilersPlacing wall-mounted boilers Set boiler in place and check levelPerform hydrostatic pressure test Prepare boiler for testFill and pressure test Drain and remove fittingsInstall water piping Install relief valveAdditional controls, when required 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 Natural Gas Propane GasPipe sizing for natural gas Natural gas supply pressure requirementsFreeze protection when used StartupCheck/control water chemistry Fill and test water systemCheck for gas leaks Final checks before starting boiler Check thermostat circuitsInspect/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 Annual startup and general maintenance Service and maintenance schedulesAnnual startup Handling ceramic fiber materialsClean condensate trap Check water systemCheck all piping for leaks Check expansion tank Check air openingsCheck ignition ground wiring Check all boiler wiringCheck control settings Check boiler relief valveCheck flame signal Check flue gas temperaturePerform startup and checks Check burner flameMaintenance general General maintenanceCleaning 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 Ratings DOE

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