Weil-McLain 80, 230, 310, 105, 155 Clean condensate trap, Check water system, Check air openings

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GAS-FIRED WATER BOILER — Boiler Manual

 

Annual startup (continued)

Clean condensate trap

1.Loosen condensate trap line hose clamps and remove trap line.

2.Empty water from trap line and inspect. Flush out if needed with fresh water.

3.Check condensate elbow and tee and condensate line to drain. Flush if necessary to clean.

4.Replace condensate trap line and tighten hose clamps.

5.Fill trap with fresh water by pouring into upturned end of PVC condensate tee.

Check water system

1.Verify all system components are correctly installed and operational.

2.Check the cold fill pressure for the system. Verify it is correct (usually around 12 psig).

3.Watch the system pressure as the boiler heats up (during testing) to ensure pressure doesn’t rise too high. Excessive pressure rise indicates expansion tank sizing or performance problem.

4.Inspect automatic air vents and air separators. Remove air vent caps and briefly press push valve to flush vent. Replace caps. Make sure vents do not leak. Replace any leaking vents.

Check all piping for leaks

Check expansion tank

Eliminate all system or boiler leaks. Continual fresh make-up water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure. Leaking water may also cause severe property damage.

1.Inspect all water and gas piping and verify to be leak free.

2.Look for signs of leaking lines and correct any problems found.

3.Check gas line using procedure on page 21.

Check air openings

1.Verify that combustion and ventilation air openings to the boiler room and/or building are open and unobstructed. Check operation and wiring of automatic combustion air dampers, if used.

2.Verify that boiler vent discharge and air intake are clean and free of obstructions.

Flue vent system and air piping

1.Visually inspect entire flue gas venting system (and air piping, if installed) for blockage, deterioration or leakage. Repair any joints that show signs of leakage in accordance with vent manufacturer’s instructions. When air is ducted to boiler, verify that air inlet hose is connected and properly sealed.

Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.

1.Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See section 3 of this manual for suggested best location of expansion tanks and air eliminators.

Open-type — located above highest radiator or baseboard unit, usually in the attic or closet. Has a gauge glass and overflow pipe to a drain.

Closed-type — welded gas tight and located above boiler. Tank is partially filled with water, leaving an air cushion for expansion.

•Make sure this type of tank is fitted with a tank fitting, such as the B & G Tank-Trol or Taco Taco-Trol. This fitting reduces gravity circulation of air- saturated tank water back to the system and prevents the air from bubbling up through the water as it returns from the system.

•Do not use automatic air vents in systems with closed-type tanks. The air will escape from the system instead of returning to the tank. Eventually, the tank will waterlog and no longer control pressurization. The boiler relief valve will weep frequently.

Diaphragm- or bladder-type— welded gas tight with a rubber membrane to separate the tank pressurizing air and the water. May be located at any point in the system, but most often found near the boiler.

•Systems with this type of expansion tank require at least one automatic air vent, preferably located on top of an air eliminator, as shown in examples in manual section 3.

2.If relief valve has tended to weep frequently, the expansion tank may be waterlogged or undersized.

Closed-type tank — tank is most likely waterlogged. Install a tank fitting if not already installed. Then check fill level per fitting manufacturer’s instructions. If fill level is correct, check tank size against manufacturer’s instructions. Replace with a larger tank if necessary.

Diaphragm- or bladder-type— first, check tank size to be sure it is large enough for the system. If size is too small, add additional tank(s) as necessary to provide sufficient expansion. If tank size is large enough, remove tank from system and check charge pressure (usually 12 psig for residential applications). If tank won’t hold pressure, membrane has been damaged. Replace tank.

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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 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 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 informationSystem water piping methods CirculatorsSizing space heat system piping Sizing DHW system piping Required boiler water flow rate, GPM, at 180FZoning with zone valves Connect boiler to system as shown in whenControlling the system circulator Zoning with circulators Setting boiler outlet water target temperature Radiant heating applicationsChilled water systems Chilled water system plus optionalInstall vent and combustion air piping Venting, combustion air & condensate linePrepare condensate fittings Connect condensate drain Condensate drain Ultra-80Connecting gas supply piping Gas 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 boilerAdjust and test boiler controls Check system and boilerCheck 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 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 Ratings DOE
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