Weil-McLain 80 Maintenance and annual startup, Access exchanger Ultra-155, -230, -310 Only

Page 34

8b

GAS-FIRED WATER BOILER — Boiler Manual

 

Maintenance and annual startup (continued)

Cleaning boiler heat exchanger

(continued from previous page)

Access exchanger: Ultra-155, -230, -310 Only

1.Remove gas valve electrical plug from gas valve. Also remove two electrical molex plugs from blower assembly.

2.Disconnect gas line union with pipe wrench or Channel Lock Pliers.

3.Remove air silencer by lifting plastic clamp off gas line and then gently sliding air silencer down and off valve.

4.Remove two 5/32” Allen head screws securing blower assembly to heat exchanger front cover.

5.Remove blower and gas valve assembly.

6.Remove hex head nuts (10mm box end wrench) from burner cover plate and remove burner cover plate from heat exchanger.

7.Remove three M4 hex head screws (7mm box end wrench) and burner clips securing burner to cover plate. Remove cover plate.

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

9.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.

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

11.Place cover plate gasket in groove of heat exchanger cover plate. Replace cover plate.

12.Re-install hex head nuts (10mm box end wrench) on cover plate mounting studs and tighten in a staggering pattern until cover plate is uniformly tightened.

13.Re-install blower insuring new gasket, provided in this kit, is in proper alignment between blower and heat exchanger front cover.

14.Re-install air silencer by sliding on gas valve venturi and securing clamp to gas line.

15.Connect the two blower electrical molex plugs.

16.Re-connect gas valve union and gas valve electrical plug.

Exchanger cleaning continued (ALL models)

1.Close isolation valves on piping to isolate boiler from system. Attach a hose to boiler drain valve and flush boiler thoroughly with clean water by using purging valves to allow water to flow through water make- up line to boiler.

2.When boiler has been flushed, restore boiler to operation.

3.Perform startup and checkout procedures of pages 23 and 26.

4.Turn on gas supply and check for gas leaks.

Failure to properly check for gas leaks can cause severe personal injury, death, or substantial property damage.

5.Turn on boiler electrical supply and test boiler for proper operation as stated in the Ultra Boiler Manual.

6.Replace boiler jacket front door when servicing is completed. See Warning at top of page 33.

34

Part number 550-101-233/0903

Page 33 Page 35
Image 34
Page 33 Page 35
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 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 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 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 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 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 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 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
Related manuals
Manual 40 pages 58.65 Kb
Top Page Image Contents