Check-Out/Startup Verification - Weil-McLain Ultra Commercial Installation And Start-Up Manual

COMMERCIAL GAS
Check-out/startup verification
Fill out start-up data on the Installation
and Service Certificate, page 112.
Verified that the U-Control is set for the correct boiler
model?
Boiler and heat distribution units filled with water?
Water chemistry verified per page 70?
Automatic air vents, if used, open one full turn?
Air purged from system?
Air purged from gas piping? Piping checked for leaks?
Primed condensate trap?
Propane conversion kit installed for propane firing and
propane conversion label affixed to jacket?
Ultra boilers are shipped ready to fire natural gas
ONLY. You must install the propane conversion
kit if the boiler will be connected to propane. See
page 9. Failure to comply could result in severe
personal injury, death or substantial property
damage.
Thermostat circuit wiring checked to ensure there are no
stray voltages?
Followed Operating Instructions, Figure 70, page 75
Burner flame and combustion verified per page 73?
Verified control operation for space heating and DHW (if
used) per this manual?
Tested additional field-installed controls — If boiler has
additional limits, have they been tested for operation as
outlined by manufacturer? (Boiler should be operating
and should go off when controls are tested. Verify controls
cause automatic reset lockout or manual reset lockout as
desired.)
Set additional field-installed limit control(s) to system
temperature requirements? Adjusted balancing valves and
controls to provide design temperature to system?
For multiple zones, adjusted for correct flow in each
zone?
Verified thermostat heat anticipator (if available) set prop-
erly (see page 55 for requirements)?
Cycled boiler with thermostat (and with DHW aquastat,
if installed) — Raised to highest setting and verified boiler
goes through normal startup cycle? Lowered to lowest set-
ting and verified boiler goes off?
Measured natural gas input? ( page 74)
Checked incoming gas pressure as specified on page 50
(natural gas) or page 50 (propane).
Observed several operating cycles for proper operation.
Set room thermostat to desired room temperature (and
DHW aquastat, if installed, to desired DHW storage
temperature)?
Reviewed all instructions shipped with this boiler with
owner or maintenance person?
Fill in
Fill out the warranty registration card and send to Weil-
McLain.
Return instructions to envelope and give to owner or place
inside boiler housing.
76
-
FIRED WATER BOILER
on page 112.
— Boiler Manual
Gas valve leakage testing
DO NOT connect a manometer to the manual gas valve or
the automatic gas valve. The high vacuum from the blower
could pull fluid into the gas line, possibly damaging the
gas valves.
1. Refer to the gas valve manufacturer's instructions for the procedure
to test the valve.
2. To operate the two valve solenoids independently, navigate to the
Valve Test Screen on the U-Control (see Figure 65, page 63 for ac-
cess sequence).
3. When in the Gas Valve Test Screen, you will see two options
a. Open Gas Valve 1
b. Open Gas Valve 2
4. To open only gas valve 1, highlight it and press enter/save.
5. While still in the Gas Valve test screen, give the boiler a call for heat.
The boiler will go through it's normal Ignition sequence, but will
only open Gas Valve 1.
6. After gas valve 1 has opened, end the call for heat.
7. This procedure can be repeated by selecting and entering Open Gas
Valve 2.
8. After the testing is complete and the call for heat has been removed,
use the back button to exit the Gas Valve Test Screen. This will then
reset the control to open both Gas Valves for any call for heat.
Gas valve test pressure tappings
Use tapping P on gas valve body for pressure con-
nection after gas valve 1 or between the gas valve seats.
Gas pressure switch settings
1. After testing the gas pressure switches, restore the settings to the
following:
a. High gas pressure switch — 14" w.c.
b. Low gas pressure switch — 2" w.c.
Install a 100% lockup gas pressure regulator in the gas
supply line if inlet pressure can exceed 14" w.c. at any
time. Adjust the lockup regulator for 7 to 10" w.c. inlet
pressure. This setting provides a cushion below the set-
ting of the high gas pressure switch. Failure to comply
could result in shutdown by the high gas pressure switch,
resulting in possible serious property damage due to
freeze-up.
:
Use manual gas valve
side tapping for pressure
connection after gas valve 2.
Part number 550-100-086/0809