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GAS-FIRED WATER BOILER — Boiler Manual
Part number 550-101-233/0903
9
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.
Prepare for propane if operating
on propane — Ultra-80 & -105
Ultra-80: DO NOT apply the following
instructions to conversion of 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.
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.
Prepare boiler
2
Figure 2 Installing propane orifice (Ultra-105)
Ultra-80-LP boilers are factory-equipped
to operate on propane gas.
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.