Weil-McLain 105 Maintenance general, Replace boiler jacket front door after startup or servicing

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GAS-FIRED WATER BOILER — Boiler Manual

 

Maintenance — general

Replace boiler jacket front door after startup or servicing

Replace boiler jacket front door after start or servicing. The boiler front door must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room. This is particularly important if the boiler is located in the same room as other appliances. Failure to keep the door securely fastened could result in severe personal injury or death.

General maintenance

1.Oil motor in system requiring regular oiling.

2.See Oil bearing circulators for motor oiling procedures.

Oiled bearing circulators

1.The circulator shipped with the Ultra boiler is water- lubricated. No oiling is required.

2.Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instructions. Over-oiling will damage the circulator.

Cleaning boiler heat exchanger

The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on page 29 of this manual. Failure to comply could result in severe personal injury.

1.Shut down boiler:

a.Follow “To Turn Off Gas to Appliance” instructions on boiler and Lighting instructions.

b.Do not drain boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.

2.Allow time for boiler to cool to room temperature if it has been firing.

3.Remove jacket front door by removing two knurled head screws at lower front. Lift door away from boiler to remove.

4.Follow procedure below to access the heat exchanger interior.

Access exchanger: Ultra-80 and Ultra-105 Only

1.Remove (4) Phillips-head screws securing gas valve inlet adapter to gas valve. This will disconnect the gas valve from the gas line.

2.Remove the air silencer by separating it from the air adapter on the blower inlet.

3.Disconnect the gas valve plug, blower power supply plug and blower control connector.

4.Release the exchanger cover plate by removing the nuts securing it to the exchanger.

5.Pull the entire blower/venturi/gas valve/cover plate assembly out of the boiler. (See pages 39 or 41 for component identification and locations.)

6.Use a vacuum cleaner to remove any accumulation on the heating surfaces. Do not use any solvent.

7.If the vacuum cleaner is unable to clean completely, wash the heating surfaces with clean, warm water. If necessary, use a piece of 20-gauge or lighter sheet metal ¾" wide by about 18 inches long to loosen deposits.

8.Inspect the heat exchanger cover plate insulation. Replace if insulation is damaged. Read the ceramic fiber WARNING on page 29 before handling or disposing of ceramic fiber materials.

9.Re-install the blower/venturi/gas valve/cover plate assembly and secure the cover plate with nuts.

10.Connect gas valve electrical plug and blower power and control connectors.

Inspect the O-ring that should still be in the gas valve inlet adapter block. The O- ring must be in good condition and must be installed when gas valve is reconnected. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

11.Secure gas valve inlet adapter to gas valve with (4) Phillips-head screws.

12.Re-install the air silencer by pressing onto the air inlet adapter.

13.Install access cover gasket, chamber insulation assembly and cover. Secure cover with nuts.

14.See continued instructions on next page.

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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