Weil-McLain Gold Series 2 User's Manual
Contents
1. Boiler service and MAT maintenance Indicates presence of hazards that will cause severe personal injury death or substantial property damage Indicates presence of hazards that can cause severe personal injury death or substantial property damage Indicates presence of hazards that will or can cause minor personal injury or property damage Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage The Boiler manual is for use only by a qualified heating installer service technician 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 When calling or writing about the boiler Please have the boiler model number NOTICE from the boiler rating label and the CP number from the boiler jacket How to use this manual To Read use Page s Learn z Warnings and definitions 1 3 precautions Read list of air contaminants y2. 11 23 on right side Part number 550 100 027 0404 All models NL Top parts removed for clarity 24a ZUlllsa GAS FIRED WATER BOILER SERIES 2 User s Information Manual Weil McLain 500 Blaine Street C Michigan City IN 46360 2388 http www weil mclain com 12 Part Number 550 100 027 0404
3. e Ignition electrode sand off any white oxide clean and reposition e Ignition and ground wiring e Wiring and connections e Perform start up checkout and performance verification per pages 23 through 26 e Flame inspection stable uniform a n a E a l lt z Z lt e Flame signal at least 4 vDc e Clean heat exchanger if flue temp more than 54 F above return water temp Additional if combustion or performance indicate need e Clean heat exchanger e Remove and clean burner using compressed air only e Vacuum the blower Review e Review with owner death or substantial property damage Part number 550 100 027 0404 Owner maintenance see Ultra User s Information Manual for instructions e Check boiler area e Check air openings e Check pressure temperature gauge e Verify boiler front door is securely in place e Check vent piping e Check air piping e Check relief valve Monthly e Check condensate drain system e Check automatic air vents if used Periodically e Test low water cutoff if used e Check boiler piping gas and Every water 6 months e Operate relief valve End of season e Shut boiler down unless boiler used for domestic water Follow the maintenance procedures given throughout this manual Failure to perform the service and maintenance or follow the directions in this manual could re
4. gauge does not exceed 24 psig Higher pressure may indicate a problem with the expansion tank Contact a qualified service technician if problem persists Visually inspect boiler front door to be sure it is sealed all around its perimeter Verify that the two lower thumb screws are tight WARNING Replace boiler 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 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 Part number 550 100 027 0404 Ulla GAS FIRED WATER BOILER SERIES 2 User s Information Manual Maintenance procedures continued Check vent piping Check air piping Check relief valve Check condensate drain system Check automatic air vents if used Part number 550 100 027 0404 I Visually inspect the flue gas vent piping for any signs of blockage leakage or deterioration of the piping Notify your qualified service technician at once if you find any problem WARNING 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 Visually inspect the air inlet elbow to be sure it is unobstructed Inspect entire length of air pipi
5. 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 gualified service technician Do not allow contaminated air to enter the boiler air inlet pipe See page 4 for details 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 e Do not use this boiler if any part has been under water Immediately call a gualified 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 technician DO NOT use petroleum based cleaning or sealing compounds in boiler system Gaskets and seals in the system may be damaged This can result in substantial property damage DO NOT use homemade cures or boiler patent medicines Serious damage to boiler personnel and or property may result e Continual fresh makeup water will reduce boiler life Mineral build up in boiler heat exchanger reduces heat transfer overheats the metal and causes heat exchanger failure 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 boil
6. Gas fired Water boiler Series 2 WEIL McLAIN Ultra Information Manual Ultra 80 105 155 230 amp 310 NOTICE Series 1 Series 2 identification Read the boiler rating plate to determine the series number The rating plate is located on the right side of the boiler Ultra ith PRECISION wit HYDRONIG DATA n technology 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 liguids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service technician or the gas supplier Part No 550 100 027 0404 Ulla GAS FIRED WATER BOILER SERIES 2 User s Information Manual Please read this page first 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 DANGER CAUTION NOTICE
7. S 2 User s Information Manual 10 Ultra boiler components 1 Cast aluminum heat exchanger 2 Exchanger access cover 3 Blower 4 Gas valve 4a Manual gas valve 4b Gas valve sensing line 5 Venturi 5a Air inlet silencer 6 Flue gas sensor 7 Outlet water temperature sensor 8 Return water temperature sensor 9 Temperature and pressure gauge 10 Electronic display amp buttons 10a On off Power switch 11 Flue pipe adapter 12 Burner 13 Water outlet pipe system supply 14 Water return pipe system return 15 16 16a 17 18 19 19a 19b 20 21 23 23a 24 24a 25 26 27 Gas connection pipe Ultra PhD Control Module Top front cover Transformer Air intake adapter Electrical entrance cover plate Low voltage terminal strip Line voltage terminal strip Boiler drain valve Line voltage receptacle P T gauge temperature sensor well Condensate drain connection Yo PVC tee Condensate trap Front door Thumb screws Ignitor electrode Flame inspection window Data port Part number 550 100 027 0404 Ultva GAS FIRED WATER BOILER SERIES 2 User s Information Manual Ultra GAS FIRED WATER BOILER SERIES 2 WITH PhD TECHNOLOGY Ultra 80 amp 105 front door removed 10 10a 9 _ 5a yw behind flue asses f adapter pipe as supply ine 21 on right side
8. er Thermal shock can cause boiler heat exchanger to crack Part number 550 100 027 0404 3 Ulla GAS FIRED WATER BOILER SERIES 2 User s Information Manual 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 repiped and terminated to another location Contaminated combustion air will damage the boiler resulting in possible 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 acids 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 Areas likely to have contaminants Spray cans containing chloro fluorocarbons D
9. he condensate 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 To fill condensate trap if necessary temporarily plug the end of the condensate drain line Then slowly pour water into the 2 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 1 2 inch tee stop filling Remove temporary plug from end of condensate drain line See illustration at right Remove the cap from any automatic air vent in the system and check operation by depressing valve B slightly with the tip of a screwdriver If the air vent valve appears to be working freely and not leaking replace cap A twisting all the way on Loosen cap A one turn to allow vent to operate Have vent replaced if it does not operate correctly amp 0 4 GAS FIRED WATER BOILER SERIES 2 User s Information Manual Maintenance procedures continued Periodically Be Test low water 1 Ifthe system is equipped with a low water cutoff test the low water cutoff periodically cutoff if install ed during the heating season following the low water cutoff manufacturer s instructions Ses fl Check boiler piping 1 Remove boiler front access door and perform gas leak inspection per steps 1 through 7 as and water Operating Instructions page 9 If gas odor or lea
10. k is detected immediately shut down g 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 WARNING Have leaks fixed at once by a gualifed service technician Failure to comply could result in severe personal injury death or substantial property damage 3 Replace door securely after inspections see WARNING page 6 Operate relief valve 1 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 WARNING 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 installed by a qualifed heating installer or service technician in accordance with the instructions 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 2 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 3 If water flows freely release the lever and allow the valve to seat Watch the e
11. l to gas piping Digit 3 or 4 indicates boiler is firing Turn OFF POWER switch on the Ultra Digit 0 means there is no call for heat all control panel room thermostats and domestic water Rotate two thumb screws at bottom of access heater satisfied y ed i CLOSED door counterclockwise to release door If the appliance will not operate when Remove boiler access door there is a call for heat and piping is not to OPEN hot follow the instructions To Turn Off Turn boiler manual gas valve knob Gas To Appliance below and call your counterclockwise to open gas supply service fechain or gas supplier i Yn Smell for gas in the boiler enclosure If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Replace jacket front panel Make sure panel is seated firmly in place and all joints are visually sealed Then tighten the two thumb screws at bottom of access door Boiler manual firmly gas valve TO TURN OFF GAS TO THE APPLIANCE M Set room thermostats to lowest setting Close external manual gas cock valve handle perpendicular Turn off all electric power to the boiler if service is to be to gas piping Remove boiler access door Turn boiler performed Turn OFF POWER switch on the Ultra manual gas valve knob clockwise to close gas supply control panel Replace boiler access door Part number 550 100 027 0404 9 Ulla GAS FIRED WATER BOILER SERIE
12. nd of the relief valve discharge 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 4 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 Shut boiler down 1 Follow TO TURN OFF GAS TO 3 Do not drain the system if it is filled with unless boiler used vibien on the page 9 of this an antifreeze solution for domestic water 4 DO NOT shut down boilers used for 2 Do not drain system unless exposure to domestic water heating They must operate freezing temperatures will occur year round 8 Part number 550 100 027 0404 Ulla GAS FIRED WATER BOILER SERIES 2 User s Information Manual Operating Instructions D FOR YOUR SAFETY READ BEFORE OPERATING ME WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped with C Use only your hand to turn the gas control knob Never an ignition device which automatically lights the burner use tools If the kn
13. ng to ensure piping is intact and all joints are properly sealed Call your qualified service technician if you notice any problems Inspect the boiler relief valve and the relief valve discharge pipe for signs of weeping or leakage If the relief valve often weeps the expansion tank may not be working properly Immediately contact your qualified service technician to inspect the boiler and system 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 lower right illustration page 11 for location of tee Make sure no flue gas is escaping from the condensate drain tubing or tee by holding your fingers in front of the opening If you notice flue gas escaping this indicates a dry condensate 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 WARNING Under some circumstances an Ultra vent system may not produce enough y condensate to keep the condensate trap full of liquid If the trap is 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 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 t
14. ob will not turn by hand don t try to Do not try to light the burner by hand repair it call a qualified service technician Force or Before OPERATING smell all around the appliance area attempted repair may result in a fire or explosion for gas Be sure to smell next to the floor because some D Do not use this appliance if any part has been under water gas is heavier than air and will settle on the floor See Immediately call a qualified service technician to inspect below 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 Do not try to light any appliance Immediately call your gas supplier from a neighbor s D TE Do not touch any electric switch do not use any phone phone Follow the gas supplier s instructions in your building I you cannot reach your gas supplier call the fire epartment OPERATING INSTRUCTIONS a Gas valve 1 Stop Read the safety information above 8 Turn ON POWER switch on the Ultra OPEN This appliance is equipped with an ignition control panel device which automatically lights the burner Set thermostat s to desired setting i o CLOS Donat O heht the purer hy Hand The Ultra control panel display left digit 8 Set room thermostat s to lowest setting will show a sequence of numbers 0 1 2 N Verify external manual gas valve is open etc that indicate boiler control sequence valve handle paralle
15. ou must avoid Prevent air If found either remove products 4 contamination permanently or have boiler vent and air terminations relocated to another area Maintain the boiler using the schedule included in this manual Maintain 5 8 boiler Schedule an annual start up by a gualified service technician before every heating season Start or Shutdown Use the Operating Instructions 9 boiler Identify boiler These illustrations and callouts will show you h A 10 11 components the location of the main components Part number 550 100 027 0404 Ulla GAS FIRED WATER BOILER SERIES 2 User s Information Manual STOP Read before proceeding WARNING Failure to adhere to the guidelines on this page can result in severe personal injury death or substantial property damage Boiler service and maintenance To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before performing maintenance e You must maintain the boiler as outlined in this manual and have the boiler started up and serviced at least annually by a gualified service technician to ensure boiler system reliability Boiler operation Do not block flow of combustion or ventilation air to boiler This boiler is eguipped 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
16. ry cleaning laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes cleaners Metal fabrication plants Chlorine based swimming pool chemicals Beauty salons Calcium chloride used for thawing Refrigeration repair shops Sodium chloride used for water softening Photo processing plants Refrigerant leaks Auto body shops Paint or varnish removers Plastic manufacturing plants Hydrochloric acid muriatic acid Furniture refinishing areas and establishments Cements and glues New building construction Antistatic fabric softeners used in clothes dryers Remodeling areas Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Garages with workshops Adhesives used to fasten building products and other similar products Part number 550 100 027 0404 Ulla GAS FIRED WATER BOILER SERIES 2 User s Information Manual Perform maintenance per schedule below Service technician see following pages for instructions General e Reported problems e Inspect interior clean and vacuum if necessary WARNING no solvents e Clean condensate trap and fill with fresh water e Check for leaks water gas flue condensate e Verify flue and air lines in good condition and sealed tight e Check system water pressure system piping expansion tank e Check control settings
17. sult in damage to the boiler or system resulting in severe personal injury Ulla GAS FIRED WATER BOILER SERIES 2 User s Information Manual Maintenance procedures Boiler must be serviced and maintained Check boiler area Check air openings Check pressure temperature gauge Verify boiler front door is securely in place The boiler must be inspected and started annually at the beginning of the heating season by a qualified service technician 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 system could result in equipment failure causing possible severe personal injury death or substantial property damage NoricE Lhe 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 WARNING To prevent potential of severe personal injury death or substantial 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 q
18. ualified service technician to inspect the boiler for possible damage from acid corrosion If products cannot be removed immediately call a qualified service technician to repipe vent and air piping and locate vent termination air intake away from contaminated areas Combustible flammable materials Do not store combustible materials gasoline or any other flammable vapors or liquids near the boiler Remove immediately if found Air contaminants Products containing chlorine or fluorine 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 See WARNING above 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 qualifed service technician to inspect the boiler and vent air systems Make sure the pressure reading on the boiler pressure temperature
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