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User’s Information
Manual
Gas-red water boilers – Series 4
Featuring
If the information in this manual is not followed exactly, a re or explosion may result, causing
If the information in this manual is not followed exactly, a re or explosion may result, causing
property damage, personal injury or loss of life.
property damage, personal injury or loss of life.
Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or any other appliance.
Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS —
— WHAT TO DO IF YOU SMELL GAS —
• Do not try to light any appliance.
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any telephone in your building.
• 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.
• 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 re department.
• If you cannot reach your gas supplier, call the re department.
Installation & service must be performed by a qualied installer, service technician or the gas supplier.
Installation & service must be performed by a qualied installer, service technician or the gas supplier.
Part number 550-100-441/0122
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e following dened terms are used throughout this manual to bring attention to the presence of hazards of various risk levels
or to important information concerning the life of the product.
Indicates presence of hazards that will cause severe personal injury, death or
substantial property damage.
Indicates presence of hazards that can cause severe personal injury, death or
substantial property damage.
Indicates presence of hazards that will or can cause minor personal injury or
property damage.
Indicates special instructions on installation, operation or maintenance that are
important but not related to personal injury or property damage.
e Boiler manual is for use only by a qualied heating installer/service technician. Refer only to this User’s
Information Manual for your reference. Improper installation, adjustment, alteration, service or maintenance
can cause property damage, personal injury (exposure to hazardous materials) or loss of life. Installation and
service must be performed by a qualied installer, service agency or the gas supplier (who must read and follow
the supplied instructions before installing, servicing, or removing this boiler. is boiler contains materials that
have been identied as carcinogenic, or possibly carcinogenic, to humans).
When calling or writing about the boiler— Please have the boiler model number from the boiler rating label and
the CP number from the boiler jacket.
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Part number 550-100-441/0122
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Failure to adhere to the guidelines on this page can result in severe personal
injury, death or substantial property damage.
To avoid electric shock, disconnect electrical supply before performing maintenance.
❏
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
system reliability.
Do not block ow of combustion or ventilation air to boiler. is 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. e boiler
should attempt to restart. If blockage is not obvious or cannot be removed, have the
boiler and system checked by a qualied service technician.
by a qualied service technician to ensure boiler/
Do not allow contaminated air to enter the boiler air inlet pipe. See page 4 for details.
❏
Should overheating occur or gas supply fail to shut o, do not turn o or disconnect
❏
electrical supply to boiler. Instead, shut o 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 qualied
❏
service technician to inspect the boiler and to replace any part of the control system
and any gas control, which has been under water.
Have boiler water chemistry checked at least annually by a qualied service technician.
❏
DO NOT use petroleum-based cleaning or sealing compounds in boiler system. Gas-
❏
kets and seals in the system may be damaged. is 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 failure. 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. ermal shock can cause boiler heat exchanger
❏
to crack.
Part number 550-100-441/0122
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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 possible
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. ese areas will always contain hazardous contaminants.
Pool and laundry products and common household and hobby products oen contain uorine or chlorine
compounds. When these chemicals pass through the boiler, they can form strong acids. e acid can eat
through the boiler wall, causing serious damage and presenting a possible threat of ue 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.
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Part number 550-100-441/0122
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Service and maintenance schedules
(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
qualied service technician to ensure reliable operation of the boiler
and system.
Check boiler area
Check air openings
Check pressure/temperature gauge
Verify boiler front door is secure
Check vent piping
Check air piping
Check relief valve
Check condensate drain system
Check automatic air vents (if used)
Test low water cuto (if used)
Check time and date on the U-Control display
Check boiler piping (gas and water)
Operate relief valve
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.
Part number 550-100-441/0122
Shut boiler down (unless boiler used for domestic water)
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The boiler must be serviced & maintained
e boiler must be inspected and started annually, at the
beginning of the heating season, by a qualied service technician. In addition, the maintenance and care of the boiler
designated on page 5 and explained on pages6 through9
must be performed to assure maximum boiler eciency
and reliability. Failure to service and maintain the boiler and
system could result in equipment failure, causing possible
severe personal injury, death or substantial property damage.
e 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
qualied service technician.
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:
• Remove products immediately from the area. If they have
been there for an extended period, call a qualied service
technician to inspect the boiler for possible damage from
acid corrosion.
• If products cannot be removed, immediately call a qualied
service technician to re-pipe vent and air piping and locate
vent termination/air intake away from contaminated areas.
— Do not store com-
bustible materials, gasoline or any other ammable vapors
or liquids near the boiler. Remove immediately if found.
— Products containing chlorine or uo-
rine, if allowed to contaminate the boiler intake air, will cause
acidic condensate in the boiler. is will cause signicant
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.
1. Verify that combustion and ventilation air
openings to the boiler room and/or building
are open and unobstructed.
2. Verify that boiler vent discharge and air intake
are clean and free of obstructions.
3. Remove any debris on the air intake or ue
exhaust openings.
4. If removing the debris does not allow the
boiler to operate correctly aerwards, contact
your qualied service technician to inspect the
boiler and vent/air systems.
1. Make sure the pressure reading on the pressure/temperature gauge does not exceed 25
psig.
2. Contact a qualied service technician if problem persists.
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.
Reinstall the jacket front door aer
servicing. The boiler front door
must be securely fastened to the
boiler to prevent boiler from drawing air from inside the boiler room.
is 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.
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Part number 550-100-441/0122
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1. Visually inspect the ue gas vent piping for any signs of
blockage, leakage or deterioration of the piping. Notify your
qualied service technician at once if you nd any problem.
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.
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.
2. Call your qualied service technician if you notice any
problems.
1. Inspect the boiler relief valve and the relief valve discharge
pipe for signs of weeping or leakage.
2. If the relief valve oen weeps, the expansion tank may not be
working properly. Immediately contact your qualied service
technician to inspect the boiler and 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 Figure3,page10 for locations). Make
sure no ue gas is escaping from the condensate drain tubing
or tee by holding your ngers in front of the opening.
2. If you notice ue gas escaping, this indicates a dry condensate drain trap. See step 4 for procedure to ll trap. Call
your qualied service technician to inspect the boiler and
condensate line and rell the condensate trap if problem
persists regularly.
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 ue products can be emitted into
the boiler room through the condensate drain line
or tee. Follow procedure below to ll trap.
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. e water should run out the end of the condensate drain line. If the water does not run out, call your
qualied service technician to inspect the boiler and clean
or replace the condensate drain line.
4. To ll the condensate trap, if necessary, temporarily plug the
end of the condensate drain line. en slowly pour water into
the ½ inch plastic tee on boiler right side. Pour until water
lls drain line, then overows into the boiler trap tubing.
When water lls up to top of ½ inch tee, stop lling. Remove
temporary plug from end of condensate drain line.
(if used)
1. See illustration at right.
2. Remove the cap from any automatic
air vent in the system and check
operation by depressing valve “B”
slightly with the tip of a screwdriver.
3. If the air vent valve appears to be
working freely and not leaking, replace cap “A”, twisting all the way on.
4. Loosen cap “A” one turn to allow vent
to operate.
5. Have vent replaced if it does not
operate correctly.
(if installed)
1. If the system is equipped with a low water cuto, test the low
water cuto periodically during the heating season. Follow
the low water cuto manufacturer’s instructions.
2. Reset the boiler control aer testing.
Part number 550-100-441/0122
1. Check the time shown on the U-Control display.
2. If time is incorrect, set the correct date and time as shown
on pages10 and 11.
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1. Remove boiler front access door and perform gas leak inspection per
steps 1 through7, Operating Instructions, page9. If gas odor or leak
is detected, immediately shut down boiler following procedures on
page9. Call a qualied service technician.
2. Visually inspect for leaks around internal water piping. Also inspect
external water piping, circulators, relief valve and ttings. Immediately
call a qualied service technician to repair any leaks.
Have leaks xed at once by a qualied service technician.
Failure to comply could result in severe personal injury, death
or substantial property damage.
1. Reinstall door securely aer inspections.
Reinstall the jacket front door aer servicing. e boiler
front door must be securely fastened to the boiler to prevent
boiler from drawing air from inside the boiler room. is 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.
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.
To avoid water damage or scalding due
to valve operation, a metal discharge line
must be connected to relief valve outlet
and run to a safe place of disposal. is
discharge line must be installed by a qualied heating installer or service technician in accordance with the instructions
in the Ultra Boiler Manual. e discharge
line must be terminated so as to eliminate
possibility of severe burns or property
damage should the valve discharge.
3. Read the pressure/temperature gauge to make sure
the system is pressurized. Li the relief valve top
lever slightly, allowing water to relieve through the
valve and discharge piping.
4. If water ows freely, release the lever and allow
the valve to seat. Watch the end of the relief valve
discharge pipe to ensure that the valve does not
weep aer the line has had time to drain. If the
valve weeps, li the seat again to attempt to clean
the valve seat. If the valve continues to weep aerwards, contact your qualied service technician to
inspect the valve and system.
5. If water does not ow from the valve when you li
the lever completely, the valve or discharge line
may be blocked. Immediately shut down the boiler,
following the operating instructions on page9. Call
your qualied service technician to inspect the
boiler and system.
1. Follow “TO TURN OFF GAS TO APPLIANCE” on page9
of this manual.
2. Do not drain system unless exposure to freezing temperatures will occur.
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3. Do not drain the system if it is lled with an antifreeze
solution.
4. DO NOT shut down boilers used for domestic water heating.
ey must operate year-round.
Part number 550-100-441/0122
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Operating instructions
Part number 550-100-441/0122
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Ultra component locations
U-Control display turns red when boiler locks out — select MANUAL RESET to reset boiler as shown below.
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Part number 550-100-441/0122
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(continued)
Ultra boiler’s U-Control display
Part number 550-100-441/0122
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Part number 550-100-441/0122
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