Ultra electronic 155, 105, 80 manual Perform hydrostatic pressure test, Prepare boiler for test

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2 GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual

Prepare boiler (continued)

Perform hydrostatic pressure test

Pressure test boiler before permanently attaching water or gas piping or electrical supply.

Prepare boiler for test

1.See Figure 3 for reference in following steps.

2.Remove supply line tee* and ¾” street elbow from accessory bag. Pipe to boiler supply connection as shown. Use pipe dope sparingly. (*1" x 1" x ¾" tee with Ultra-80 to -230 or 1¼" x 1¼" x ¾" tee with Ultra-310)

3.Temporarily plug the ¾" relief valve tapping in the street elbow with a ¾" NPT pipe plug.

4.Connect a hose to boiler drain valve, the other end connected to a fresh water supply. Make sure hose can also be used to drain boiler after test.

5.Connect a nipple and shutoff valve to system supply connection on the supply tee. This valve will be used to bleed air during the fill. (Valve and nipple are not included with boiler.)

6.Connect a shutoff valve to system return connection. (Valve is not included with boiler.)

7.To avoid getting water on boiler, you may want to pipe street elbows on top of shutoff valves and attach catch-buckets beneath.

8.If convenient, install the boiler circulator and any other piping compatible with Figure 3 that would still allow bleeding air from shutoff valves. Follow guidelines in this manual for piping components, locations and sizing.

Fill and pressure test

1.Open the shutoff valves you installed on supply and return connections.

2.Slowly open boiler drain valve and fresh water supply to fill boiler with water. The boiler will fill quickly because of its low water content.

3.When water reaches shutoff valves, close boiler drain valve.

4.Close shutoff valves.

5.Slowly reopen boiler drain valve until test pressure on the pressure/temperature gauge reaches at least 45 psig, but no higher than 55 psig.

6.Hold at test pressure for 10 minutes.

Do not leave boiler unattended. A cold water fill could expand and cause excessive pressure, resulting in severe personal injury, death or substantial property damage.

7.Make sure constant gauge pressure has been maintained throughout test. Check for leaks. Repair if found.

Leaks must be repaired at once. Failure to do so can damage boiler, resulting in substantial property damage.

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.

Drain and remove fittings

1.Disconnect fill water hose from water source.

2.Drain boiler through drain valve. Remove hose after draining.

3.Remove nipples and valves unless they will remain for use in the system piping.

4.Remove plug from relief valve street elbow. See section 3 (page 12) to install relief valve.

Figure 3 Hydrostatic test piping connections

Part number 550-100-026/0404

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Contents Series 1/Series 2 identification Gas-fired Water boiler SeriesBOILER, with PhD Technology HOW IT Works GAS-FIRED Water BOILER, with PhD Technology Hazard definitions ContentsBoiler water When servicing boilerPlease read before proceeding Boiler operationProvide clearances Installations must comply withPrepare boiler location Before locating the boiler, checkVent and air piping Residential garage installationFlooring and foundation Provide air openings to roomSeal any unused openings in the common venting system When removing a boiler from existing common vent systemPrevent combustion air contamination Ultra-310 Series 1 Boilers only Propane operation Prepare boilerRemove boiler from crate Ultra-80 Series 1 and 2 only Propane operationSet boiler in place and check level Placing floor-mounted boilersPlacing wall-mounted boilers Drain and remove fittings Perform hydrostatic pressure testPrepare boiler for test Fill and pressure testGeneral piping information Install water pipingInstall relief valve Additional controls, when requiredSizing space heat system piping System water piping methodsCirculators Required boiler water flow rate, GPM, at 180F Sizing DHW system pipingControlling the system circulator Zoning with zone valvesConnect boiler to system as shown in when Zoning with circulators Radiant heating applications Setting boiler outlet water target temperatureChilled water system plus optional Chilled water systemsPrepare condensate fittings Install vent and combustion air pipingVenting, combustion air & condensate line Vacuum break Connect condensate drainLeave the top of the ½ tee OPEN. This is needed as a Wall-mounted boilers Connecting gas supply pipingGas piping Natural gas supply pressure requirements Natural GasPropane Gas Pipe sizing for natural gasFill and test water system Freeze protection when usedStartup Check/control water chemistryTo start the boiler Check for gas leaks Final checks before starting boilerCheck thermostat circuits Inspect/fill condensate systemCheck flame & combustion Adjust and test boiler controlsCheck system and boiler Check-out/startup verification Check-out/startup verification Installation certificate Service and maintenance schedules Annual startup and general maintenanceHandling ceramic fiber materials Annual startupCheck air openings Clean condensate trapCheck water system Check all piping for leaks Check expansion tankCheck boiler relief valve Check ignition ground wiringCheck all boiler wiring Check control settingsCheck burner flame Check flame signalCheck flue gas temperature Perform startup and checksReplace boiler jacket front door after startup or servicing Maintenance generalGeneral maintenance Cleaning boiler heat exchangerExchanger cleaning ALL models Maintenance and annual startupAccess exchanger Ultra-155, -230, -310 Only Replacement parts Jacket parts Replacement parts Heat exchanger and piping Ultra-80 Replacement parts Heat exchanger and piping Ultra-155 to Replacement parts Controls Dimensions DOE Ratings

230 & -310, 105, 155, 80 specifications

Ultra Electronics, a recognized leader in advanced electronic systems, has developed various innovative products catering to different fields, particularly defense, aerospace, and security. Among its notable offerings are the Ultra 230 and demographic models such as the -310, -105, -155, and -80, each designed to meet specific operational requirements and challenges.

The Ultra 230 is renowned for its superior processing capabilities, which leverage high-performance computing to manage complex tasks efficiently. This platform integrates multifaceted technologies like electronic warfare, communications, and sensor data fusion, ensuring that users have real-time information for informed decision-making. The design emphasizes modularity, allowing end-users to customize the system according to their mission profiles.

The Ultra 310 variant extends the functionalities of the 230, providing enhanced connectivity options. Its robust communication interfaces facilitate seamless integration with various networks, ensuring effective data exchange across multiple platforms. This model is particularly effective in joint operations where interoperability is critical among allied forces.

Ultra's -105 model is designed specifically for ground vehicles, offering ruggedness and resilience under harsh conditions. It features advanced environmental protection, allowing it to withstand dust, moisture, and vibration. This makes the -105 ideal for tactical military applications where reliability in diverse terrains is crucial.

The -155 model emphasizes versatility and adaptability, boasting a wide range of components and configurations. This allows for easy upgrades and maintenance, enabling military and defense organizations to stay current with technological advancements without significant investments in new equipment.

Lastly, the Ultra 80 is aimed at the aviation sector, focusing on lightweight design without compromising on power or functionality. It employs cutting-edge materials that enhance performance while reducing overall weight, making it ideal for aerial applications.

In summary, Ultra Electronics' products - the 230, -310, -105, -155, and -80 - showcase a commitment to innovation and operational excellence. Each model brings forth unique features and technologies, ensuring they meet the diverse needs of their users across various industries. From advanced processing capabilities to rugged designs suitable for any environment, Ultra Electronics continues to push the boundaries of technological advancement, maintaining its position as a frontrunner in the electronic systems market.
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