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Part number 550-100-400/0119
40
Startup — fi nal checks (continued)
❏ Chec k fl ame & combustion with instruments
For Ultra-399 propane boilers, special start-up is re-
quired. See page 41 for procedure. See DANGER on
page 49 before proceeding.
1. Initiate a call for heat on one of the heat demand inputs.
2. Access the U-Control installer menus by pressing and holding the
UP and DOWN arrow keys for fi ve seconds.
3. Use the U-Control display to navigate to Manual test mode (see
Figure 115, page 102 ) and force the fi ring rate to MAX (high fi re).
4. Look at the fl ame through the fl ame inspection window. The high
fi re fl ame should be blue and should be stable. The burner surface
should be covered with orange dots.
5. Remove the fl ue temperature sensor from the fl ue pipe and in-
sert a combustion test probe., using a calibrated combustion test
instrument.
6. Test for CO
2
(or O
2
) and for CO. The CO
2
values must be within
1.0% of the values listed in Figure 42, page 41 . If results are ac-
ceptable, proceed to step 7. IF NOT, follow the instructions under
“Throttle screw adjustment procedure” to set the throttle screw
position. See WARNING below.
If combustion at either high or low fi re is outside the
range given in Figure 42 , follow the procedure given
on page 41 for adjusting the throttle screw on the
venturi. If throttle screw adjustment does not correct
the problem, then shut down the boiler and contact
your local Weil-McLain representative. Throttle
screw adjustment must be done only by a qualifi ed
technician, using calibrated test instruments. Failure
to comply could result in severe personal injury,
death or substantial property damage.
7. Measure natural gas input:
a. Operate boiler 10 minutes.
b. Turn off other appliances.
c. At natural gas meter, measure time (in seconds) required to
use one cubic foot of gas.
d. Calculate gas input:
3600 x 1000
number of seconds from step c
= Btuh
e. Btuh calculated should approximate input rating on boiler
rating label.
8. Use the U-Control display to navigate to Manual test mode (see
Figure 115, page 102 ) and force the fi ring rate to MIN (low fi re).
9. Look at the fl ame through the fl ame inspection window. The low
fi re fl ame should be stable and evenly distributed over burner
surface with a uniform orange color.
10. Repeat the combustion test of steps 4 and 5 above.
11. Use the U-Control display to navigate to Manual test mode (see
Figure 115, page 102 ) and force the fi ring rate to AUTO (normal
operation).
12. Replace the fl ue gas temperature sensor. When replacing the sen-
sor, remove the rubber grommet from the probe. Insert the rubber
grommet into the fl ue pipe, then insert the probe into the rubber
grommet.
Figure 39
®
Series 4
gas-fired water boiler — Boiler Manual
Figure 40
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