Gas-fired water boilers – Series 3
Featuring
User’s
Information Manual
Flexibility
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.
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 telephone in your building.
• Immediately call your gas supplier from a neighbor’s telephone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation & service must be performed by a qualified installer, service technician or the gas supplier.
Part number 550-100-067/0608
Download from Www.Somanuals.com. All Manuals Search And Download.
g a s -f i r e d w at e r b o il e r — User’s Information Manual
STOP! READ THIS BEFORE PROCEEDING . . .
Failure to adhere to the guidelines on this page can result in severe personal
injury, death or substantial property damage.
Boiler service and maintenance —
To avoid electric shock, disconnect electrical supply before performing mainte-
nance.
❏❏
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 de-
tails.
❏❏
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 techni-
cian.
❏❏
DO NOT use petroleum-based cleaning or sealing compounds in boiler system. Gas-
kets 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 fail-
ure. 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.
❏❏
3
Part number 550-100-067/0608
Download from Www.Somanuals.com. All Manuals Search And Download.
g a s -f i r e d w at e r b o il e r — User’s Information Manual
Prevent combustion air contamination
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 re-piped and
terminated to another location. Contaminated combustion air will damage the boiler, resulting in pos-
sible 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.
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.
4
Part number 550-100-067/0608
Download from Www.Somanuals.com. All Manuals Search And Download.
g a s -f i r e d w at e r b o il e r — User’s Information Manual
Annual startup and general maintenance
Figure 1 Service and maintenance schedules
OWNER MAINTENANCE (see the following pages for instructions)
Contact your boiler service technician to inspect, service and start
up your boiler. You must have an annual start-up performed by a
qualified service technician to ensure reliable operation of the boiler
and system.
BEGINNING OF SEASON
Check boiler area
Check air openings
DAILY
Check pressure/temperature gauge
Verify boiler front door is secure
Check vent piping
Check air piping
Check relief valve
MONTHLY
Check condensate drain system
Check automatic air vents (if used)
Test low water cutoff (if used)
PERIODICALLY
Check time and date on the U-Control display
Check boiler piping (gas and water)
Operate relief valve
EVERY
6 MONTHS
END
OF SEASON
Shut boiler down (unless boiler used for domestic water)
Follow the service and maintenance procedures given throughout this manual and in component literature
shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or
system. Failure to follow the directions in this manual and component literature could result in severe personal
injury, death or substantial property damage.
5
Part number 550-100-067/0608
Download from Www.Somanuals.com. All Manuals Search And Download.
g a s -f i r e d w at e r b o il e r — User’s Information Manual
Maintenance procedures — DAILY
Check air openings
The boiler must be serviced & maintained
1. Verify that combustion and ventilation air
openings to the boiler room and/or building
are open and unobstructed.
The boiler must be inspected and started annually, at the
beginning of the heating season, by a qualified service tech-
nician. 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 sys-
tem could result in equipment failure, causing possible severe
personal injury, death or substantial property damage.
2. Verify that boiler vent discharge and air intake
are clean and free of obstructions.
3. Remove any debris on the air intake or flue
exhaust openings.
4. If removing the debris does not allow the
boiler to operate correctly afterwards, contact
your qualified service technician to inspect the
boiler and vent/air systems.
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.
Check the pressure/
temperature gauge
1. Make sure the pressure reading on the boiler
pressure/temperature gauge does not exceed
25 psig.
Check boiler area
To prevent potential of severe personal injury, death or sub-
stantial property damage, eliminate all materials discussed
below from the boiler vicinity and the vicinity of boiler
combustion air inlet. If contaminants are found:
2. Contact a qualified service technician if prob-
lem persists.
Verify boiler front door is
secure
• 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.
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.
• If products cannot be removed,immediately call a qualified
service technician to re-pipe vent and air piping and locate
vent termination/air intake away from contaminated areas.
Reinstall the jacket front door after
servicing. The boiler front door
must be securely fastened to the
boiler to prevent boiler from draw-
ing 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.
Contact your installer or technician
immediately if the front door does
not correctly in place or if the door
gaskets are damaged.
Combustible/flammable materials — Do not store com-
bustible materials, gasoline or any other flammable vapors
or liquids near the boiler. Remove immediately if found.
Air contaminants — Products containing chlorine or fluo-
rine, 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.
6
Part number 550-100-067/0608
Download from Www.Somanuals.com. All Manuals Search And Download.
g a s -f i r e d w at e r b o il e r — User’s Information Manual
Maintenance procedures — MONTHLY
2. If you notice flue gas escaping, this indicates a dry conden-
Check vent piping
sate 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.
1. Visually inspect the flue gas vent piping for any signs of block-
age, leakage or deterioration of the piping. Notify your quali-
fied service technician at once if you find any problem.
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.
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.
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 con-
densate 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.
Check air piping
1. Visually inspect the air inlet to be sure it is unobstructed.
Inspect entire length of air piping to ensure piping is intact
and all joints are properly sealed.
4. To fill the 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.
2. Call your qualified service technician if you notice any
problems.
Check the relief valve
1. Inspect the boiler relief valve and the relief valve discharge
pipe for signs of weeping or leakage.
Check automatic air vents (if used)
1. See illustration at right.
2. Remove the cap from any automatic
air vent in the system and check oper-
ation by depressing valve“B”slightly
with the tip of a screwdriver.
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.
3. If the air vent valve appears to be
working freely and not leaking,
replace cap “A”, twisting all the way
on.
Check the condensate drain 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 Figure 3, page 10 for locations). Make
sure no flue gas is escaping from the condensate drain tubing
or tee by holding your fingers in front of the opening.
4. Loosen cap“A”one turn to allow vent
to operate.
5. Have vent replaced if it does not
operate correctly.
Maintenance procedures — PERIODICALLY
Test the low water cutoff (if installed)
Check U-Control date and time
1. Check the time shown on the U-Control display.
1. If the system is equipped with a low water cutoff, test the low
water cutoff periodically during the heating season. Follow
the low water cutoff manufacturer’s instructions.
2. If time is incorrect, set the correct date and time as shown
on pages 10 and 11.
2. Reset the boiler control after testing.
7
Part number 550-100-067/0608
Download from Www.Somanuals.com. All Manuals Search And Download.
g a s -f i r e d w at e r b o il e r — User’s Information Manual
Maintenance procedures — EVERY 6 MONTHS
To avoid water damage or scalding due
Check the boiler piping
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 qualified heating installer or service
technician in accordance with the in-
structions 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.
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 qualified service technician.
Failure to comply could result in severe personal injury, death
or substantial property damage.
3. 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.
Operate relief valve
4. If water flows freely, release the lever and allow the
valve to seat. Watch the end of the relief valve dis-
charge 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.
1. Reinstall door securely after inspections.
Reinstall the 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 par-
ticularly 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. Contact your
installer or technician immediately if the front door does not
correctly in place or if the door gaskets are damaged.
5. 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.
2. 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.
Maintenance procedures — END OF SEASON
1. Follow “TO TURN OFF GAS TO APPLIANCE” on page 9
of this manual.
3. Do not drain the system if it is filled with an antifreeze
solution.
2. Do not drain system unless exposure to freezing temperatures
will occur.
4. DO NOT shut down boilers used for domestic water heating.
They must operate year-round.
8
Part number 550-100-067/0608
Download from Www.Somanuals.com. All Manuals Search And Download.
g a s -f i r e d w at e r b o il e r — User’s Information Manual
OPERATING INSTRUCTIONS
Figure 2 Operating instructions
9
Part number 550-100-067/0608
Download from Www.Somanuals.com. All Manuals Search And Download.
g a s -f i r e d w at e r b o il e r — User’s Information Manual
Boiler components & the U-Control display
Figure 3 Ultra component locations
Figure 4 U-Control display turns red when boiler locks out — select MANUAL RESET to reset boiler as shown below.
10
Part number 550-100-067/0608
Download from Www.Somanuals.com. All Manuals Search And Download.
g a s -f i r e d w at e r b o il e r — User’s Information Manual
Boiler components & the U-Control display
(continued)
Figure 5 Ultra boiler’s U-Control display
11
Part number 550-100-067/0608
Download from Www.Somanuals.com. All Manuals Search And Download.
g a s -f i r e d w at e r b o il e r — User’s Information Manual
12
Part number 550-100-067/0608
Download from Www.Somanuals.com. All Manuals Search And Download.
|