User`s Information Manual - Weil
Contents
1. OM UJEIL fc LAIN User s Information Manual CERTIFIED EEUWEN MLAN ENERGY STAR If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance Do not touch any electrical switch do not use any telephone in your building e Immediately call your gas supplier from a neighbor s telephone Follow the gas supplier s instructions e f you cannot reach your gas supplier call the fire department Installation amp service must be performed by a qualified installer service technician or the gas supplier Part number 550 100 067 0809 r HN r1 gu i m p _ a Y 2 Fao 45m ij Fe a a n mm s hm i WAA a Ln s Ee y EJ ra me mm o A fa pm Ea pm meus WNAE A f SW j 7 2 GFR Ge d Tu UN 12 mamme TU i Fe W u P mus Sm EK 4 amp mm LP E LAE AA E P LOFA mL Qu P eq a Ea M WW A I Tate wee lt 2 N10 pa aa L e um la i 1D VW Zo ll 3 FJ e 7 I u be amp cS CWN cH CWN IW HN B qu ll Z wJ lan s W WSA LES L We B an MR ew wu Wr 8 io BE EE YW E Vu eH WP EE aw ee f EE Ge i How to use this manual To Read use See pages Learn precautions Warnings and d2. OPERATING INSTRUCTIONS 100 S Stop Read the safety information at left on this label This appliance is Gas valve Gas valve equipped with an ignition device which automatically lights the burner Do not CLOSED OPEN try to light the burner by hand Set room thermostat s to lowest setting Verify external manual gas cock is g open valve handle parallel to gas piping to OPEN Turn OFF all electrical power to the appliance Rotate two thumb screws at bottom of access door counterclockwise to release door Remove boiler access door Turn boiler manual gas valve knob counterclockwise v to open gas supply Wait five 5 minutes to clear out any gas Then smell for gas including near X 7 the floor If you smell gas STOP Follow B in the safety information to the left If you don t smell gas go to the next step Turn ON all electrical power to the appliance 11 If the appliance will not operate when there is a call for heat and 9 Setthermostat s to desired setting piping is not hot follow the instructions To Turn Off Gas To The Ultra display will show symbols and text describing the status of the Ad dil anna Call aid OF a boiler as it proceeds through its operating sequence Standby status means there is no call for heat A faucet or flame symbol on the display means the 12 Replace jacket front panel Make sure panel is seated firmly in boiler is firing place and all joints are visually sealed Then tig
3. installed by a qualified heating installer or service technician in accordance with the in structions in the Ultra Boiler Manual The discharge line must be terminated so as to eliminate possibility of severe burns or property damage should the valve discharge 3 Read the boiler pressure temperature gauge to make sure the system is pressurized Lift the relief valve top lever slightly allowing water to relieve through the valve and discharge piping If water flows freely release the lever and allow the valve to seat Watch the end of the relief valve dis charge pipe to ensure that the valve does not weep after the line has had time to drain If the valve weeps lift the seat again to attempt to clean the valve seat If the valve continues to weep afterwards contact your qualified service technician to inspect the valve and system If water does not flow from the valve when you lift the lever completely the valve or discharge line may be blocked Immediately shut down the boiler following the operating instructions on page 9 Call your qualified service technician to inspect the boiler and system Maintenance procedures END OF SEASON 1 Follow TO TURN OFF GAS TO APPLIANCE on page 9 3 Do not drain the system if it is filled with an antifreeze of this manual solution 2 Donotdrain system unless exposure to freezing temperatures 4 DONOT shut down boilers used for domestic water heating will occur They must op
4. qualified service technician to ensure boiler system reliability Boiler operation J Do not block flow of combustion or ventilation air to boiler This boiler is equipped with a control which will automatically shut down the boiler should air or vent be blocked If vent or air blockage is easily accessible and removable remove it The boiler should attempt to restart If blockage is not obvious or cannot be removed have the boiler and system checked by a qualified service technician J Do not allow contaminated air to enter the boiler air inlet pipe See page 4 for de tails J Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to boiler Instead shut off the gas supply at a location external to the appliance Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water Boiler water Have boiler water chemistry checked at least annually by a qualified service techni cian J DO NOT use petroleum based cleaning or sealing compounds in boiler system Gas kets and seals in the system may be damaged This can result in substantial property damage J DO NOT use homemade cures or boiler patent medicines Serious damage to boiler personnel and or property may result J Continual fresh makeup w
5. started annually at the beginning of the heating season by a qualified service tech nician In addition the maintenance and care of the boiler designated on page 5 and explained on pages 6 through 9 must be performed to assure maximum boiler efficiency and reliability Failure to service and maintain the boiler and sys tem could result in equipment failure causing possible severe personal injury death or substantial property damage The following information provides detailed instructions for completing the maintenance items listed in the maintenance schedule page 5 In addition to this maintenance the boiler must be serviced and started up at the beginning of each heating season by a qualified service technician Check boiler area To prevent potential of severe personal injury death or sub stantial property damage eliminate all materials discussed below from the boiler vicinity and the vicinity of boiler combustion air inlet If contaminants are found Remove products immediately from the area If they have been there for an extended period call a qualified service technician to inspect the boiler for possible damage from acid corrosion If products cannot be removed immediately call a qualified service technician to re pipe vent and air piping and locate vent termination air intake away from contaminated areas Combustible flammable materials Do not store com bustible materials gasoline or any other flammable
6. vapors or liquids near the boiler Remove immediately if found Air contaminants Products containing chlorine or fluo rine if allowed to contaminate the boiler intake air will cause acidic condensate in the boiler This will cause significant damage to the boiler if allowed to continue Read the list of potential materials listed on page 4 of this manual If any of these products are in the room from which the boiler takes its combustion air they must be removed immediately or the boiler combustion air and vent termination must be relocated to another area Check air openings l Verify that combustion and ventilation air openings to the boiler room and or building are open and unobstructed Verify that boiler vent discharge and air intake are clean and free of obstructions Remove any debris on the air intake or flue exhaust openings If removing the debris does not allow the boiler to operate correctly afterwards contact your qualified service technician to inspect the boiler and vent air systems Check the pressure temperature gauge l Make sure the pressure reading on the boiler pressure temperature gauge does not exceed 25 psig Contact a qualified service technician if prob lem persists Verify boiler front door is secure Visually inspect boiler front door to be sure it is sealed all around its perimeter Verify that the two lower thumb screws are tight AWARNING Reinstall the jacket fro
7. F MODEL ULTRA SUPP EYE HHHF RETURN HHRHF CPH HHHHHHHHHRH Select MANUAL RESET to OUTDOOR HHH F reset condition Make sure to DEMAND HEH HH F INSTALLED DD MM YY correct the cause of the PUMPS LAST DATE DD MM YY problem if possible ADD L HEAT DEMAND NEXT DATE DD MM YY SETTINGS INTERVAL SETTINGS MANUAL RESET RESET REMINDER ISELECTAWV PREVIOUS ENTERB PREVIOUS ENTERHE U5003 user 10 Part number 550 100 067 0809 y _ n _ _ 292 m B SC gt INIO MaL Ion IV anual Boiler components amp the U Control display o Figure 5 Ultra boilers U Control display MM DD YY rm WEI fficLAI MM AM MODULATION HEN 1 O 1 Screen color Display above is typical for normal operation The center symbol changes BUTTONS to show operation status Press P to switch to INFO screen The INFO screen below is for at a glance information during normal operation HH MM AM MM DD YY STATUS HHHHHHHHSH MODULATION 7 TARGET HHH F SUPPLY HHH F RETURN HHH F OUTDOOR HHH F DEMAND 8H F PUMPS H H H ADD L HEAT DEMAND SETTINGS SELECTAY PREVIOUS ENTERBM Part number 550 100 067 0809 Blue space heating or when a button is pressed Screen will show solid red with the exclamation mark symbol if a non shutdown failure occurs i e failure of a non critical sensor such as outdoor or sys
8. ater will reduce boiler life Mineral build up in boiler heat exchanger reduces heat transfer overheats the metal and causes heat exchanger fail ure Addition of oxygen can cause internal corrosion in system components Leaks in boiler or piping must be repaired at once to prevent makeup water Do not add cold water to hot boiler Thermal shock can cause boiler heat exchanger to crack Part number 550 100 067 0809 3 f AC EIDEI WM BAS R E D VV emm tas P HE E Le L Bplay TER BOIL p 3 F Pn y P mmm S8 n n P mum E m FA L ED M E A amp WWW SA i 225 Ea om ER USeTr nia IViI ain udis EN Wap wv WP B m Sol WE WAN NE OE GSE N Prevent combustion air contamination If the boiler combustion air inlet is located in any area likely to cause contamination or if products which would contaminate the air cannot be removed you must have the combustion air and vent re piped and terminated to another location Contaminated combustion air will damage the boiler resulting in pos sible severe personal injury death or substantial property damage Do not operate an Ultra boiler if its combustion air inlet is located in a laundry room or pool facility for example These areas will always contain hazardous contaminants Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds When these chemicals pass through the boiler they can form strong aci
9. ds The acid can eat through the boiler wall causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building Please read the information listed below If contaminating chemicals will be present near the location of the boiler combustion air inlet have your installer pipe the boiler combustion air and vent to another location per the Boiler manual Products to avoid Spray cans containing chloro fluorocarbons Permanent wave solutions Chlorinated waxes cleaners Chlorine based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants Dry cleaning laundry areas and establishments Swimming pools Metal fabrication plants Beauty salons Refrigeration repair shops Photo processing plants Auto body shops Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops Part number 550 100 067 0809 ah ge ENTE LALA bP D J peu GAS FIRED WATER BOILER User s Information Manua Annual s
10. efinitions 1 3 Read the list of air contaminants you must avoid Prevent air If found either remove the products permanently or have 4 contamination your installer relocate boiler vent and air terminations to an uncontaminated area Maintain the boiler using the schedule in this manual Maintain the boiler Schedule an annual start up by a gualified service 9 8 technician before every heating season Start or shutdown the Use the OPERATING INSTRUCTIONS 9 Boiler components amp These illustrations and callouts will show you the location 10 11 the U Control display of main components and use of the U Control display Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product INN 4 Indicates presence of hazards that will cause severe personal injury death or substantial property damage AWARNING Indicates presence of hazards that can cause severe personal injury death or substantial property damage ACAUTION Indicates presence of hazards that will or can cause minor personal injury or property damage NOTICE Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Boiler service and maintenance The Boiler manual is for use only by a qualified heating installer service tech
11. erate year round Part number 550 100 067 0809 Ulta GAS FIRED WATER BOILER User s Information Manual OPERATING INSTRUCTIONS Figure 2 Operating instructions FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly a A WARNING fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot Itis C Use only your hand to turn the gas equipped with an ignition device which control knob Never use tools If the automatically lights the burner Do not knob will not turn by hand don ttry to try tolightthe burner by hand repair it call a qualified service technician Force or attempted repair Before OPERATING smell all around the may result in a fire or explosion appliance area for gas Be sure to smell next to the floor because some gas is Do not use this appliance if any part heavier than air and will settle on the has been under water Immediately floor See below call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water WHAT TO DO IF YOU SMELL GAS Donottrytolightany appliance Immediately call your gas supplier from a neighbor s phone Follow the Do not touch any electric switch do not gas supplier s instructions use any phone in your building If you cannot reach your gas supplier call the fire department M
12. hten the two thumb screws at bottom of access door firmly UUN TO TURN OFF GAS TO THE APPLIANCE 1 Setroomthermostats to lowest setting 3 Close external manual gas cock valve handle perpendicular to gas 2 Turn OFF all electrical power to the appliance piping Remove boiler access door Turn boiler manual gas valve knob clockwise vto close gas supply Replace boiler access door 550 101 248 0409 Part number 550 100 067 0809 9 Ulta GAS FIRED WATER BOILER User s Information Manual Boiler components amp the U Control display Figure 3 Ultra component locations Front view Ultra 80 Ultra 105 Ultra 155 Ultra 230 Ultra 299 Utra 399 L 2 Pod m Condensate trap tee Condensate line to drain or pump Manual gas shut off valve location Ua001 user Figure 4 U Control display turns red when boiler locks out select MANUAL RESET to reset boiler as shown below e o or A ternate 3 from RED om bac C e it are y screer l m WEIL Me LAIN MM AM MM DD YY MM DD YY HH MM AM ___ MM DD YY MODULATION ALERT MODULATION ALERT MODULATION ALERT 7 990000 INFORN SEE TOP LINE OF DISPLAY FOR ERROR 3 V MAINTENANCE Ba Alternating Date Time amp Error Info Here STATUS HHHHHHHHRH NAME HHHHHHHHHHHHHEHRH MODULATION LF PHONE TARGET HHH
13. lowly pour water into the inch plastic tee on boiler right side Pour until water fills drain line then overflows into the boiler trap tubing When water fills up to top of inch tee stop filling Remove temporary plug from end of condensate drain line Check automatic air vents if used 1 See illustration at right A 2 Remove the cap from any automatic air vent in the system and check oper p ation by depressing valve B slightly 29 with the tip of a screwdriver 3 If the air vent valve appears to be working freely and not leaking replace cap A5 twisting all the way on 4 Loosen cap A one turn to allow vent to operate 5 Have vent replaced if it does not 9 operate correctly Maintenance procedures PERIODICALLY Test the low water cutoff if installed 1 Ifthe system is equipped with a low water cutoff test the low water cutoff periodically during the heating season Follow the low water cutoff manufacturer s instructions 2 Resetthe boiler control after testing Part number 550 100 067 0809 Check U Control date and time 1 Check the time shown on the U Control display 2 If time is incorrect set the correct date and time as shown on pages 10 and 11 Ulta GAS FIRED WATER BOILER User s Information Manual Maintenance procedures EVERY 6 MONTHS Check the boiler piping 1 Remove boiler front access door and perform gas leak inspection per steps 1 through 7 Ope
14. nician Refer only to this User s Information Manual for your reference Improper installation adjustment alteration service or maintenance can cause property damage personal injury exposure to hazardous materials or loss of life Installation and service must be performed by a qualified installer service agency or the gas supplier who must read and follow the supplied instructions before installing servicing or removing this boiler This boiler contains materials that have been identified as carcinogenic or possibly carcinogenic to humans NOTICE When calling or writing about the boiler Please have the boiler model number from the boiler rating label and the CP number from the boiler jacket 2 Part number 550 100 067 0809 ERE m EN UE BE i 7 y EIRBED WATER BOILFR leave TraATArKEm NM a FIRED WATER BOILER User Ss inrOrmna ED GE le u NM a Vanal LN A Ee d anual Te DNE EM eU me STOP READ THIS BEFORE PROCEEDING AWARNING Failure to adhere to the guidelines on this page can result in severe personal injury death or substantial property damage Boiler service and maintenance J To avoid electric shock disconnect electrical supply before performing mainte nance To avoid severe burns allow boiler to cool before performing maintenance You must maintain the boiler as outlined in this manual and have the boiler started up and serviced at least annually by a
15. nt door after servicing The boiler front door must be securely fastened to the boiler to prevent boiler from draw ing 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 Contact your installer or technician immediately if the front door does not correctly in place or if the door gaskets are damaged Part number 550 100 067 0809 Ulta GAS FIRED WATER BOILER User s Information Manual Maintenance procedures MONTHLY Check vent piping 1 Visually inspect the flue gas vent piping for any signs of block age leakage or deterioration of the piping Notify your quali fied service technician at once if you find any problem AWARNING Failure to inspect the vent system as noted above and have it repaired by a qualifed service technician can result in vent system failure causing severe personal injury or death Check air piping 1 Visually inspect the air inlet to be sure it is unobstructed Inspect entire length of air piping to ensure piping is intact and all joints are properly sealed 2 Call your qualified service technician if you notice any problems Check the relief valve 1 Inspect the boiler relief valve and the relief valve discharge pipe for signs of weeping or leakage 2 Iftherelief valve often weeps the expansion tank may not be wo
16. rating Instructions page 9 If gas odor or leak is detected immediately shut down boiler following procedures on page 9 Call a qualified service technician 2 Visually inspect for leaks around internal water piping Also inspect external water piping circulators relief valve and fittings Immediately call a qualified service technician to repair any leaks AWARNING Have leaks fixed at once by a qualified service technician Failure to comply could result in severe personal injury death or substantial property damage Operate relief valve 1 Reinstall door securely after inspections AWARNING Reinstall the jacket front door after 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 par ticularly 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 Contact your installer or technician immediately if the front door does not correctly in place or if the door gaskets are damaged 2 Before proceeding verify that the relief valve outlet has been piped to a safe place of discharge avoiding any possibility of scalding from hot water AWARNING To avoid water damage or scalding due to valve operation a metal discharge line must be connected to relief valve outlet and run to a safe place of disposal This discharge line must be
17. rking properly Immediately contact your qualified service technician to inspect the boiler and system Check the condensate drain system 1 While the boiler is running check the discharge end of the condensate drain tubing and the open top of the condensate tee at the boiler see Figure 3 page 10 for locations Make sure no flue gas is escaping from the condensate drain tubing or tee by holding your fingers in front of the opening 2 If you notice flue gas escaping this indicates a dry conden sate drain trap See step 4 for procedure to fill trap Call your qualified service technician to inspect the boiler and condensate line and refill the condensate trap if problem persists regularly AWARNING Under some circumstances an Ultra vent system may not produce enough condensate to keep the condensate trap full of liquid If the trap 1s not full small amounts of flue products can be emitted into the boiler room through the condensate drain line or tee Follow procedure below to fill trap 3 Verify that the condensate drain line is unobstructed by slowly pouring water into the top of the PVC tee on the side of the boiler The water should run out the end of the con densate drain line If the water does not run out call your qualified service technician to inspect the boiler and clean or replace the condensate drain line 4 To fill the condensate trap if necessary temporarily plug the end of the condensate drain line Then s
18. tartup and general maintenance Figure 1 Service and maintenance schedules OWNER MAINTENANCE see the following pages for instructions BEGINNING OF SEASON MONTHLY PERIODICALLY EVERY 6 MONTHS END OF SEASON Contact your boiler service technician to inspect service and start up your boiler You must have an annual start up performed by a qualified service technician to ensure reliable operation of the boiler and system Check boiler area Check air openings Check pressure temperature gauge Verify boiler front door is secure Check vent piping Check air piping Check relief valve Check condensate drain system Check automatic air vents if used Test low water cutoff if used Check time and date on the U Control display Check boiler piping gas and water Operate relief valve Shut boiler down unless boiler used for domestic water 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 Part number 550 100 067 0809 Ulla GAS FIRED WATER BOILER User s Information Manual Maintenance procedures DAILY The boiler must be serviced amp maintained The boiler must be inspected and
19. tem supply or return sensor Time and date 2 Status graphic 3 Firing rate bar 4 Operating status Active system e lt Move selection up V lt Move selection down Q o 9 o lt lt Next screen Q lt Previous screen lt Enter lt Time and date lt Active system type Firing rate lt Setpoint temperature lt Supply temperature lt Return temperature Outdoor air temperature Systems with heat demand Pumps operating lt ON or OFF lt Select to change settings Scroll up or down lt Previous screen or ENTER U5002 user _ umJUJEIL fOcLAIN o HH MM AM MM DD YY 5 Up 3 al O Z MODULATION HHH H HHH HH WR b L 0 INFOS STANDBY Pressing any button changes background to blue below mm UJEIL fcLAIN HH MM AM MM DD YY q 212 OLIOJI BLUE BACKLIGHT PUHPLE BACKLIGHT DHW HEATING Domestic hot water heating RED BACKLIGHT Alternating t colors mj WEI McLAIN MM DD YY NO BACKLIGHT BOILER IN LOCKOUT Attention required to restart boiler 11 Ulla GAS FIRED WATER BOILER User s Information Manual Weil McLain mH 500 Blaine Street E Michigan City IN 46360 2388 http www weil mclain com 12 Part number 550 100 067 0809
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