Ultra electronic 80, 105, 230 & -310, 155 manual Prepare boiler, Remove boiler from crate

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2 GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual

Prepare boiler

Remove boiler from crate

Cold weather handling — If boiler has been stored in a very cold location (below 0°F) before installation, handle with care until the plastic components come to room temperature.

1.The Ultra boiler is generally easier to handle and maneuver after removing from crate.

2.After removing outer shipping carton from boiler, REMOVE jacket front door by loosening two knurled- head screws at lower front. Removing the door will prevent possible damage to the door during handling.

3.To remove boiler from pallet (after removing jacket front door):

a.Remove the four lag screws securing shipping brackets.

b.Unscrew the two rear boiler legs and remove the shipping brackets.

c.Replace legs.

d.Discard the cardboard protector insert on the rear of the boiler.

Do not drop boiler or bump jacket on floor or pallet. Damage to boiler can result.

Ultra-80 Series 1 and 2 ONLY Propane operation

Ultra-80: DO NOT apply the propane conversion instructions in this manual to Ultra-80 boilers. Follow the instructions provided with the optional propane conversion kit.

The propane conversion kit is NOT included as standard equipment for the Ultra-80.

Ultra-80-LPboilers are factory-equipped to operate on propane gas.

Ultra-310 Series 1 Boilers ONLY Propane operation

Ultra-310 Series 1: DO NOT apply the propane conversion instructions in this manual to Ultra-310Series 1 boilers. Follow the instructions provided with the optional propane conversion kit.

The propane conversion kit is NOT included as standard equipment for the Model Ultra-310 Series 1.

See the next page for Ultra-310 Series 2 and all Ultra-155 and Ultra-230 model propane instructions.

Ultra-105 Series 1 and 2 ONLY

Prepare for propane operation

Do not apply the following to conversion of a boiler already installed and connected to gas supply. For a boiler already installed, you must turn off gas supply, turn off power and allow boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance as described under “Startup,” Section 6 of this manual. See separate natural to propane conversion instructions for conversion of an existing boiler.

You must install the propane orifice to fire the Ultra boiler on propane. Verify when installing that the orifice size marking matches boiler size. Failure to comply could result in severe personal injury, death or substantial property damage.

1.With boiler on its back, remove jacket front door by removing two knurled head screws at lower front. Then lift door away from boiler.

2.Disconnect the gas valve electrical plug.

3.Remove the 4 screws securing gas valve inlet adapter to valve.

4.Remove (3) TORX screws securing gas valve to venturi (Figure 2).

5.Locate propane orifice disc from conversion kit bag.Verify that the stamping on the orifice disk matches the boiler size. Place orifice in the black rubber grommet in the side of the gas valve and secure in valve (Figure 2).

6.Reposition gas valve against venturi and replace (3) TORX screws securing valve to venturi. Secure gas valve inlet adapter to gas valve with 4 screws. Make sure the plastic hose is connected from gas valve to inlet elbow.

Inspect the O-ring between the gas valve and gas valve inlet adapter block whenever they are disassembled. The O-ring must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

7.DO NOT attempt to adjust gas valve outlet pressure.

8.Connect gas valve electrical plug to valve terminals.

9.After installation is complete, attach the propane conversion label (in conversion kit bag) next to the boiler rating plate.

10.Replace jacket front panel.

Figure 2 Installing propane orifice (Ultra-105 boiler ONLY)

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 ContentsPlease read before proceeding When servicing boilerBoiler operation Boiler waterPrepare boiler location Installations must comply withBefore locating the boiler, check Provide clearancesFlooring and foundation Residential garage installationProvide air openings to room Vent and air pipingWhen removing a boiler from existing common vent system Prevent combustion air contaminationSeal any unused openings in the common venting system Remove boiler from crate Prepare boilerUltra-80 Series 1 and 2 only Propane operation Ultra-310 Series 1 Boilers only Propane operationPlacing floor-mounted boilers Placing wall-mounted boilersSet boiler in place and check level Prepare boiler for test Perform hydrostatic pressure testFill and pressure test Drain and remove fittingsInstall relief valve Install water pipingAdditional controls, when required General piping informationSystem water piping methods CirculatorsSizing space heat system piping Required boiler water flow rate, GPM, at 180F Sizing DHW system pipingZoning with zone valves Connect boiler to system as shown in whenControlling the system circulator Zoning with circulators Radiant heating applications Setting boiler outlet water target temperatureChilled water system plus optional Chilled water systemsInstall vent and combustion air piping Venting, combustion air & condensate linePrepare condensate fittings Connect condensate drain Leave the top of the ½ tee OPEN. This is needed as aVacuum break Connecting gas supply piping Gas pipingWall-mounted boilers Propane Gas Natural GasPipe sizing for natural gas Natural gas supply pressure requirementsStartup Freeze protection when usedCheck/control water chemistry Fill and test water systemCheck thermostat circuits Check for gas leaks Final checks before starting boilerInspect/fill condensate system To start the boilerAdjust and test boiler controls Check system and boilerCheck flame & combustion Check-out/startup verification Check-out/startup verification Installation certificate Service and maintenance schedules Annual startup and general maintenanceHandling ceramic fiber materials Annual startupCheck water system Clean condensate trapCheck all piping for leaks Check expansion tank Check air openingsCheck all boiler wiring Check ignition ground wiringCheck control settings Check boiler relief valveCheck flue gas temperature Check flame signalPerform startup and checks Check burner flameGeneral maintenance Maintenance generalCleaning boiler heat exchanger Replace boiler jacket front door after startup or servicingMaintenance and annual startup Access exchanger Ultra-155, -230, -310 OnlyExchanger cleaning ALL models 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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