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Part number 550-101-233/0903
GAS-FIRED WATER BOILER — Boiler Manual
32
GAS-FIRED WATER BOILER — Boiler Manual
Annual startup
(continued)
8a
Figure 16 Burner assembly
Perform startup and checks
1. Start boiler and perform checks and tests specified
on pages 23 through 26 (and Control Supplement).
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
3. Complete the check-out procedure on page 26.
Check burner flame
The boiler contains ceramic fiber materials.
Use care when handling these materials per
instructions on page 29 of this manual.
Failure to comply could result in severe
personal injury.
1. Inspect flame through observation window using the
procedure on page 25.
2. If flame is unsatisfactory at either high fire or low fire,
turn off boiler and allow boiler to cool down. Then remove
burner and clean it thoroughly using a vacuum cleaner or
compressed air. Do not use compressed air to clean burner
if performed inside a building.
3. To access burner, remove the heat exchanger cover plate
following the procedure on page 33.
4. When replacing burner, ensure gasket is in good condition
and correctly positioned. After tightening the three retainer
screws, bend up the retainer tabs as shown in Figure 16 to
prevent screw rotation.
5. After servicing, replace boiler components. Retest boiler.
Check flame signal
1. Flame signal (DC volts from low voltage terminal strip terminal 9 to ground)
should be at least 4 VDC.
2. A lower flame signal may indicate a fouled ignitor or damaged ignitor insulation.
If cleaning the ignitor does not improve, ground wiring is in good condition,
and ground continuity is satisfactory, replace the ignitor.
3. See Troubleshooting in the Ultra Control Supplement for other procedures to
deal with low flame signal.
Check flue gas temperature
1. Place the control display in Information mode while the boiler is operating at
high fire. See Ultra Control Supplement for details.
2. The flue gas temperature (electronic display first digit shows “5”) must not be
more than 60°F higher than the return water temperature (display first digit
shows “2”).
3. If the flue temperature is higher than this, shut down the boiler, allow to cool,
and follow the procedure on pages 33 through 34 to clean the heat exchanger.
Review with owner
1. Review the User’s Information Manual with the owner.
2. Emphasize the need to perform the maintenance schedule specified in the
User’s Information Manual (and in this manual as well).
3. Remind the owner of the need to call a licensed contractor should the
boiler or system exhibit any unusual behavior.
4. Remind the owner to follow the proper shutdown procedure and to
schedule an annual startup at the beginning of the next heating season.