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GAS-FIRED WATER BOILER — Boiler Manual
Install water piping
Install relief valve
1.Install relief valve in ¾" street elbow piped from boiler supply piping tee (Figure 3, page 11). Pipe the relief valve only as shown, in the location shown.
2.Connect discharge piping to safe disposal location, following guidelines in the WARNING below.
To avoid water damage or scalding due to relief valve operation:
•Discharge line must be connected to relief valve outlet and run to a safe place of disposal. Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the valve discharge.
•Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length.
•Discharge line must pitch downward from the valve and terminate at least 6" above the floor drain where any discharge will be clearly visible.
•The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375 °F or greater.
•Do not pipe the discharge to any place where freezing could occur.
•No shutoff valve shall be installed between the relief valve and boiler, or in the discharge line. Do not plug or place any obstruction in the discharge line.
•Test the operation of the valve after filling and pressurizing system by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve.
•Failure to comply with the above guidelines could result in failure of the relief valve to operate, resulting in possibility of severe personal injury, death or substantial property damage.
Use two wrenches when tightening water piping at boiler, using one wrench to prevent the boiler return line or supply line from turning. Failure to support the boiler piping connections to prevent them from turning could cause damage to boiler components.
General piping information
Additional controls, when required
The Ultra control module uses temperature sensors to provide both high limit protection and modulating temperature control. The control module also provides low water protection by sensing the temperature of the heat exchanger. Some codes/jurisdictions may require additional external controls for high limit and/or low water cutoff protection.
Additional limit control:
Following standard industry practices, if installation is to comply with ASME or Canadian requirements, an additional high temperature limit is needed. Consult local requirements for other codes/standards to determine if needed.
1.Install additional high temperature limit constructed to prevent a temperature setting above 200°F in system supply piping between boiler and isolation valve. (Note that the Ultra control module operating limit function shuts the boiler down at 190°F or Parameter 4, whichever is lower.)
2.See Ultra Control Supplement for wiring.
a.If limit control is to cause a boiler hard lockout (requiring manual reset of Ultra control module), connect isolated contact to field control wiring terminals 6 and 8 as shown in wiring diagram.
b.Otherwise, connect isolated contact between terminals 6 and 7 for a soft lockout (automatic reset).
c.If using a manual reset limit control or wiring in the manual reset circuit, Parameter 4 should be no closer than 20°F to the limit control setting (i.e., no higher than 180°F for a 200°F limit setting, for example).
Separate low water cutoff:
A low water cutoff device is required when boiler is installed above piping level or by certain state or local codes or insurance companies. Consult local requirements to determine.
1.If required, use a low water cutoff designed for water installations. Electrode
2.Purchase low water cutoff and install in tee in supply piping above boiler.
3.See Ultra Control Supplement for wiring.
a.If limit control is to cause a boiler hard lockout (requiring manual reset of Ultra control module), connect isolated contact to field control wiring terminals 6 and 8 as shown in wiring diagram.
b.Otherwise, connect isolated contact between terminals 6 and 7 for a soft lockout (automatic reset).
Backflow preventer:
Use backflow check valve in cold water supply as required by local codes.
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