Specifications
Part number 550-100-090/0809
31
g a s -f i r e d w a t e r b o i l e r — Boiler Manual
BASIC INSTALLATION
Startup — fill the system
Antifreeze
Use only antifreeze listed by Weil-McLain as suitable for use 1.
with Ultra Gas Boilers. A list of approved antifreeze products
is available at www.Weil-McLain.com.
See Replacement parts at the end of this manual for Weil-2.
McLain part numbers to obtain antifreeze through a Weil-
McLain distributor.
Use the correct amount of antifreeze
Determine the freezing temperature needed (to protect 1.
against lowest likely temperature the system water will
encounter).
Find the antifreeze concentration by volume needed for this 2.
temperature from the antifreeze manufacturer’s data on the
antifreeze container.
Add up the volume (gallons) of all system piping and com-3.
ponents, including the expansion tank and boiler.
Boiler water content is listed on a. page 121.
Remember to include expansion tank water content.b.
Multiply this volume by the (percent) antifreeze needed to 4.
find the number of gallons of antifreeze to add.
Fill and test water system
Fill system only after ensuring the water meets the require-1.
ments of this manual.
Close manual and automatic air vents and boiler drain 2.
valve.
Fill to correct system pressure. Correct pressure will vary 3.
with each application.
Typical cold water fill pressure for a residential system a.
is 12 psi.
Pressure will rise when boiler is turned on and system b.
water temperature increases. Operating pressure must
never exceed 25 psig.
At initial fill and during boiler startup and testing, check 4.
system thoroughly for any leaks. Repair all leaks before
proceeding further.
Eliminate all system leaks. Continual fresh make-up
water will reduce boiler life. Minerals can build up
in sections, reducing heat transfer, overheating heat
exchanger, and causing heat exchanger failure.
Use inhibitor supplied with boiler
The Ultra boiler is shipped with Sentinel X100 inhibitor and 1.
Sentinel inhibitor test kit. See Repair Parts at the end of this
manual for re-ordering information.
After filling the system as directed in these instructions, use 2.
a caulking gun to inject the X100 inhibitor into the system,
following the instructions on the tube.
Inject all of the inhibitor supplied with the boiler. Allow time 3.
for the water to circulate and mix. Then check the inhibitor
level. Add additional inhibitor if necessary.
Clean system to remove sediment
You must thoroughly flush the system (without boiler 1.
connected) to remove sediment. The high-efficiency heat
exchanger can be damaged by buildup or corrosion due to
sediment.
For zoned systems, flush each zone separately through a purge 2.
valve. (If purge valves and isolation valves are not already
installed, install them to properly clean the system.)
Flush system until water runs clean and you are sure piping 3.
is free of sediment.
Do not use petroleum-based cleaning or
sealing compounds in boiler system. Dam-
age to elastomer seals and gaskets in system
could occur, resulting in substantial prop-
erty damage.
Before filling the boiler and system with
water, verify the following. DO NOT ll
with softened water.
Boiler corrosion can
occur.
Failure to comply could result in boiler
failure or unreliable operation.
Water chemistry
Water pH between 7.0 and 8.5
Maintain boiler water pH between 7.0 and 8.5. Check with 1.
litmus paper or have chemically analyzed by water treatment
company.
If pH differs from above, consult local water treatment com-2.
pany for treatment needed.
DO NOT use softened water. Softened water can cause cor-3.
rosion.
Hardness less than 7 grains
Consult local water treatment companies for unusually hard 1.
water areas (above 7 grains hardness).
Chlorine concentration must be
LESS THAN 200 ppm
Filling with chlorinated fresh water should be acceptable 1.
since drinking water chlorine levels are typically less than
5 ppm.
Do not use the boiler to directly heat swimming pool or 2.
spa water.
Do not fill boiler or operate with water containing chlorine 3.
in excess of 200 ppm.