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Part number 550-100-400/0119
35
Startup — fi ll the system
Antif reeze
1. Use only antifreeze listed by Weil-McLain as suitable for use
with Ultra Gas Boilers. A list of approved antifreeze products
is available at www.Weil-McLain.com.
2. See Replacement parts at the end of this manual for Weil-
McLain part numbers to obtain antifreeze through a Weil-
McLain distributor.
Use the correct amount of antifreeze
1. Determine the freezing temperature needed (to protect
against lowest likely temperature the system water will
encounter).
2. Find the antifreeze concentration by volume needed for this
temperature from the antifreeze manufacturer’s data on the
antifreeze container.
3. Add up the volume (gallons) of all system piping and com-
ponents, including the expansion tank and boiler.
a. Boiler water content is listed on page 137 .
b. Remember to include expansion tank water content.
4. Multiply this volume by the (percent) antifreeze needed to
fi nd the number of gallons of antifreeze to add.
Fill and test water system
1. Fill system only after ensuring the water meets the require-
ments of this manual.
2. Close manual and automatic air vents and boiler drain valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. Typical cold water fi ll pressure for a residential system
is 12 psi.
b. Pressure will rise when boiler is turned on and system
water temperature increases. Operating pressure must
never exceed 25 psig.
4. At initial fi ll and during boiler startup and testing, check
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.
X100 inhibitor is required
1. It is required that the Ultra boiler have Sentinel X100 added
to the system to prevent damage to the boilers’ heat exchanger.
Replacement Parts section at the end of this manual for re-
ordering information.
2. After fi lling the system as directed in these instructions, use
a caulking gun to inject the X100 inhibitor concentrate into
the system, or fi ll with the X100 in its liquid form, following
the instructions on the tube or container.
3. After adding the inhibitor to the system, allow time for the
water to circulate and mix. Then check the inhibitor level.
Add additional inhibitor if necessary.
4. See separate instructions or Weil-McLain website for sug-
gested guidelines to determine how much inhibitor to use.
Clean system to remove sediment
1. You must thoroughly flush the system (without boiler
connected) to remove sediment. The high-effi ciency heat
exchanger can be damaged by buildup or corrosion due to
sediment.
2. For zoned systems, fl ush each zone separately through a purge
valve. (If purge valves and isolation valves are not already
installed, install them to properly clean the system.)
3. Flush system until water runs clean and you are sure piping
is free of sediment.
Do not use petroleum-based cleaning or seal-
ing compounds in boiler system. Damage to
elastomer seals and gaskets in system could
occur, resulting in substantial property dam-
age.
Before fi lling the boiler and system with water,
verify the following.
Boiler corrosion can occur.
Failure to comply could result in boiler failure
or unreliable operation.
Water c hemistry
Water pH between 7.0 and 8.5
1. Maintain boiler water pH between 7.0 and 8.5. Check with
litmus paper or have chemically analyzed by water treatment
company.
2. If pH differs from above, consult local water treatment com-
pany for treatment needed.
3. DO NOT use softened water. Softened water can cause cor-
rosion.
Hardness less than 7 grains
1. Consult local water treatment companies for unusually hard
water areas (above 7 grains hardness).
Chlorine concentration must be
LESS THAN 200 ppm
1. Filling with chlorinated fresh water should be acceptable
since drinking water chlorine levels are typically less than
5 ppm.
2. Do not use the boiler to directly heat swimming pool or
spa water.
3. Do not fi ll boiler or operate with water containing chlorine
in excess of 200 ppm.
®
Series 4
gas-fired water boiler — Boiler Manual
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