Weil-McLain HE (Series 2) Leitfaden

Part No. 550-100-027/0404

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

•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.

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.

User’s

Information

Manual

with

Ultra-80, -105, -155, -230 & -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.

Gas-fired

Water boiler

Series 2

Part number 550-100-027/0404

GAS-FIRED WATER BOILER SERIES 2 — User’s Information Manual

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

from the boiler rating label and the CP number from the boiler jacket.

Please read this page first

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.

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.

Hazard definitions

Boiler service and

maintenance

How to use this

manual . . .

Part number 550-100-027/0404 3

GAS-FIRED WATER BOILER SERIES 2 — User’s Information Manual

STOP!! — Read before proceeding

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.

• You must maintain the boiler as outlined in this manual and have the

boiler started up and serviced at least annually by a qualified

service technician to ensure boiler/system reliability.

Boiler operation —

• 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.

• 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.

•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 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.

• 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 boiler. Thermal shock can cause boiler

heat exchanger to crack.

Failure to adhere to the guidelines on this page can result in severe

personal injury, death or substantial property damage.

Part number 550-100-027/0404

GAS-FIRED WATER BOILER SERIES 2 — User’s Information Manual

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.

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.

Prevent combustion air contamination

Part number 550-100-027/0404 5

GAS-FIRED WATER BOILER SERIES 2 — User’s Information Manual

Perform maintenance per schedule below

Follow the maintenance procedures given throughout this manual. Failure to perform the service and maintenance or

follow the directions in this manual could result in damage to the boiler or system, resulting in severe personal injury,

death or substantial property damage.

Part number 550-100-027/0404

GAS-FIRED WATER BOILER SERIES 2 — User’s Information Manual

Boiler must be

serviced and

maintained

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.

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.

Maintenance procedures

Daily

Verify boiler front

door is securely in

place

1. Visually inspect boiler front door to be sure it is sealed all around its perimeter. Verify that

the two lower thumb screws are tight.

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.

Check air openings 1. Verify that combustion and ventilation air openings to the boiler room and/or building

are open and unobstructed.

2. 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.

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 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 repipe vent and air piping and locate vent termination/air intake away from

contaminated areas.

1. Combustible/flammable materials — Do not store combustible materials, gasoline or

any other flammable vapors or liquids near the boiler. Remove immediately if found.

2. 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.

Check boiler area

1. Make sure the pressure reading on the boiler pressure/temperature gauge does not exceed

24 psig. Higher pressure may indicate a problem with the expansion tank.

2. Contact a qualified service technician if problem persists.

Check pressure/

temperature gauge

Part number 550-100-027/0404 7

GAS-FIRED WATER BOILER SERIES 2 — User’s Information Manual

Maintenance procedures

(continued)

Monthly

1. 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.

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 vent piping

Check air piping 1. Visually inspect the air inlet elbow 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 relief valve 1. Inspect the boiler relief valve and the relief valve discharge pipe for signs of weeping or

leakage.

2. 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.

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 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.

2. 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.

Under some circumstances an Ultra vent system may not produce enough

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.

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 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.

4. To fill condensate trap, if necessary, temporarily plug the end of the condensate drain line.

Then slowly pour water into the ½ 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 ½

inch tee, stop filling. Remove temporary plug from end of condensate drain line.

Check condensate

drain system

1. See illustration at right.

2. 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.

3. If the air vent valve appears to be working freely and not leaking,

replace cap “A”, twisting all the way on.

4. Loosen cap “A” one turn to allow vent to operate.

5. Have vent replaced if it does not operate correctly.

Check automatic

air vents (if used)

Part number 550-100-027/0404

GAS-FIRED WATER BOILER SERIES 2 — User’s Information Manual

1. Remove boiler front access door and perform gas leak inspection per steps 1 through 7,

Operating 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.

Have leaks fixed at once by a qualifed 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).

Periodically

1. If the system is equipped with a low water cutoff, test the low water cutoff periodically

during the heating season, following the low water cutoff manufacturer’s instructions.

Test low water

cutoff (if installed)

Every 6 months

Check boiler piping

(gas and water)

End of season

Maintenance procedures

(continued)

1. Follow “TO TURN OFF GAS TO

APPLIANCE” on the page 9 of this

manual.

2. Do not drain system unless exposure to

freezing temperatures will occur.

3. Do not drain the system if it is filled with

an antifreeze solution.

4. DO NOT shut down boilers used for

domestic water heating. They must operate

year-round.

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.

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 end 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

(unless boiler used

for domestic water)

Operate relief valve

Part number 550-100-027/0404 9

GAS-FIRED WATER BOILER SERIES 2 — User’s Information Manual

Operating Instructions

FOR YOUR SAFETY READ BEFORE OPERATING

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO THE APPLIANCE

• Do not try to light any appliance.

• Do not touch any electric 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.

WHAT TO DO IF YOU SMELL GAS

A. This appliance does not have a pilot. It is equipped with

an ignition device which automatically lights the burner.

Do not try to light the burner by hand.

B. Before OPERATING, smell all around the appliance area

for gas. Be sure to smell next to the floor because some

gas is heavier than air and will settle on the floor. See

below.

C. Use only your hand to turn the gas control knob. Never

use tools. If the knob will not turn by hand, don't try to

repair it, call a qualified service technician. Force or

attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water.

Immediately 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.

If you do not follow these instructions exactly, a fire or explosion may result

causing property damage, personal injury or loss of life.

1. Stop! Read the safety information above.

This appliance is equipped with an ignition

device which automatically lights the burner.

Do not try to light the burner by hand.

2. Set room thermostat(s) to lowest setting.

Verify external manual gas valve is open

(valve handle parallel to gas piping).

3. Turn OFF POWER switch on the Ultra

control panel.

4. Rotate two thumb screws at bottom of access

door counterclockwise to release door.

5. Remove boiler access door.

6. Turn boiler manual gas valve knob

counterclockwise to open gas supply.

7. 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.

8. Turn ON POWER switch on the Ultra

control panel.

9. Set thermostat(s) to desired setting.

10. The Ultra control panel display left digit

will show a sequence of numbers (0, 1, 2,

etc.) that indicate boiler control sequence.

Digit 3 or 4 indicates boiler is firing.

Digit 0 means there is no call for heat (all

room thermostats and domestic water

heater satisfied).

11. If the appliance will not operate when

there is a call for heat and piping is not

hot, follow the instructions "To Turn Off

Gas To Appliance" below and call your

service technician or gas supplier.

12. 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

firmly. Boiler manual

gas valve

1. Set room thermostats to lowest setting.

2. Turn off all electric power to the boiler if service is to be

performed. Turn OFF POWER switch on the Ultra

control panel.

3. Close external manual gas cock (valve handle perpendicular

to gas piping). Remove boiler access door. Turn boiler

manual gas valve knob clockwise to close gas supply.

4. Replace boiler access door.

Part number 550-100-027/0404

GAS-FIRED WATER BOILER SERIES 2 — User’s Information Manual

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 & 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. Gas connection pipe

16. PhD Control Module

16a. Top front cover

17. Transformer

18. Air intake adapter

19. Electrical entrance cover plate

19a. Low voltage terminal strip

19b. Line voltage terminal strip

20. Boiler drain valve

21. Line voltage receptacle

22. P/T gauge temperature sensor well

23. Condensate drain connection

(½" PVC tee)

23a. Condensate trap

24. Front door

24a. Thumb screws

25. Ignitor electrode

26. Flame inspection window

27. Data port

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