Check For Gas Leaks; Startup - Final Checks - Weil-McLain Ultra Manual

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gas fired water boiler
Startup — final checks

Check for gas leaks

Before starting the boiler, and during initial opera-
tion, use a leak detector or smell near the floor and
around the boiler for gas odorant or any unusual
odor. Remove boiler front door and smell interior
of boiler enclosure. Do not proceed with startup if
there is any indication of a gas leak. Repair any leak
at once.
DO NOT adjust or attempt to measure gas valve
outlet pressure. The gas valve is factory-set for the
correct outlet pressure. This setting is suitable for
natural gas and propane, requiring no field adjust-
ment. Attempting to alter or measure the gas valve
outlet pressure could result in damage to the valve,
causing potential severe personal injury, death or
substantial property damage.
Propane boilers only — Your propane supplier
mixes an odorant with the propane to make its
presence detectable. In some instances, the odorant
can fade, and the gas may no longer have an odor.
Before startup (and periodically thereafter), have the
propane supplier verify the correct odorant level in
the gas.
Check thermostat circuit(s)
1. Disconnect the two external wires connected to the boiler thermo-
stat terminals (see Field wiring, beginning on page 54 for terminal
locations).
2. Connect a voltmeter across these two incoming wires. Close each
thermostat, zone valve and relay in the external circuit one at a time
and check the voltmeter reading across the incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage does occur under any condition, check and correct the
external wiring. (This is a common problem when using 3-wire
zone valves.)
5. Once the external thermostat circuit wiring is checked and cor-
rected if necessary, reconnect the external thermostat circuit wires.
Allow the boiler to cycle.
Inspect/fill condensate system
Inspect/check condensate lines and fittings
1. Inspect the condensate drain line, condensate PVC fittings and
condensate trap. (See page 50 for component locations.)
2. Pour water into the top of the boiler's ½" PVC condensate tee and
check for any leaks in the condensate drain line or fittings. Repair
any leaks.
Fill condensate trap with water
1. Loosen the hose clamp securing the right end of the condensate
trap to the PVC reducing elbow (see page 50 for details).
2. Slide the trap hose end off of the elbow.
Part number 550-100-066/0608
— Boiler Manual
3.
4.
Final checks before starting boiler
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To start the boiler
1.
2.
3.
If boiler does not start correctly
1.
2.
3.
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6.
7.
8.
Fill the trap with fresh water to within an inch of the
end of the hose.
Replace trap hose on PVC reducing elbow and tighten
the hose clamp.
The condensate trap must be filled with water
during all times of boiler operation to avoid
flue gas emission from the condensate drain
line. [Prime the condensate trap (by pouring
water into the outlet tee while restricting flow
in drain tube) if boiler has been out of service
for an extended period.] Failure to fill the
trap could result in severe personal injury or
death.
Read the instructions to adjust and set up the U-Control
module.
Verify that the boiler model is set correctly in the U-
Control, and that it displays correctly.
Verify that the boiler and system are full of water and all
system components are correctly set for operation.
Fill vent condensate trap with water (by removing hose
clamp and hose at PVC reducing elbow). Replace hose
on PVC reducing elbow and tighten clamp.
Verify electrical connections are correct and securely
attached.
Inspect vent piping and air piping for signs of dete-
rioration from corrosion, physical damage or sagging.
Verify air piping and vent piping are intact and correctly
installed per this manual.
Turn OFF the boiler ON/OFF switch.
Read and follow the Operating Instructions,
ure 90, page 76.
The U-Control display will show installed sensors
when first powered. Make sure the right sensors are
detected. If not, determine the cause and correct before
proceeding.
Check for loose connections, blown fuse or service
switch off?
Is external limit control (if used) open? Is boiler water
temperature above 200 °F?
Is thermostat set below room temperature?
Is gas turned on at meter or boiler?
Is incoming gas pressure less than 5" w.c. for natural gas
or 4" w.c. for propane?
Are parameters set correctly in this manual?
Is the warm weather shutdown activated?
If none of the above corrects the problem, refer to
Troubleshooting, beginning on page 84.
Fig-
73