Ultra electronic 105 Check for gas leaks Final checks before starting boiler, To start the boiler

6 GAS-FIRED WATER BOILER SERIES 2 — Boiler Manual

Startup (continued)

Check for gas leaks Final checks before starting boiler

Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove boiler front door and smell interior of boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Repair any leak at once.

DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death or substantial property damage.

Propane boilers only — Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.

Check thermostat circuit(s)

1.Disconnect the two external wires connected to the boiler thermostat terminals (low voltage terminal strip terminals 5 and 6).

2.Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.

3.There should NEVER be a voltage reading.

4.If a voltage does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.)

5.Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to boiler low voltage terminal strip terminals 5 and 6. Allow the boiler to cycle.

Inspect/fill condensate system

Inspect/check condensate lines and fittings

1.Inspect the condensate drain line, condensate PVC fittings and condensate trap. (See page 20 for component locations.)

2.Pour water into the top of the boiler’s ½" PVC condensate tee and check for any leaks in the condensate drain line or fittings. Repair any leaks.

Fill condensate trap with water

1.Loosen the hose clamp securing the right end of the condensate trap to the PVC reducing elbow (see page 20).

2.Slide the trap hose end off of the elbow.

3.Fill the trap with fresh water to within a inch of the end of the hose.

4.Replace trap hose on PVC reducing elbow and tighten the hose clamp.

The condensate trap (page 3, item 23a) must be filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line. Failure to fill the trap could result in severe personal injury or death.

❏Read the Ultra Control Supplement to familiarize yourself with Ultra PhD control module operation. Read Operating Instructions in Control Supplement for proper steps to start boiler.

❏Verify the boiler and system are full of water and all system components are correctly set for operation.

❏Verify the preparation procedures of section 6, pages 23 and 24 have been completed.

❏Fill vent condensate trap with water (by removing hose clamp and hose at PVC reducing elbow). Replace hose on PVC reducing elbow and tighten clamp.

❏Verify electrical connections are correct and securely attached.

❏Inspect vent piping and air piping for signs of deterioration from corrosion, physical damage or sagging.Verify air piping and vent piping are intact and correctly installed per Ultra Boiler Vent Supplement.

To start the boiler

1.Turn OFF Power switch on Ultra display panel. Turn on power to boiler.

2.Read and follow the Operating Instructions in the Ultra Control Supplement.

If boiler does not start correctly

1.Check for loose connections, blown fuse or service switch off?

2.Is external limit control (if used) open? Is boiler water temperature above 200 °F?

3.Is thermostat set below room temperature?

4.Is gas turned on at meter or boiler?

5.Is incoming gas pressure less than 4" w.c. for natural gas or 5” w.c. for propane?

6.Are parameters set correctly as instructed in the Ultra Control Supplement?

If none of the above corrects the problem, refer to Troubleshooting in the Ultra Control Supplement.

24 Part number 550-100-026/0404