Installation Guide

Part number 550-100-066/0608
73
g a s -f i r e d w at e r b o i l e r — Boiler Manual
Startup — final checks
Fill the trap with fresh water to within an inch of the 3.
end of the hose.
Replace trap hose on PVC reducing elbow and tighten 4.
the hose clamp.
The condensate trap must be filled with water
during all times of boiler operation to avoid
ue gas emission from the condensate drain
line. [Prime the condensate trap (by pouring
water into the outlet tee while restricting ow
in drain tube) if boiler has been out of service
for an extended period.] Failure to fill the
trap could result in severe personal injury or
death.
Final checks before starting boiler
Read the instructions to adjust and set up the U-Control

module.
Verify that the boiler model is set correctly in the U-

Control, and that it displays correctly.
Verify that the boiler and system are full of water and all

system components are correctly set for operation.
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 dete-

rioration from corrosion, physical damage or sagging.
Verify air piping and vent piping are intact and correctly
installed per this manual.
To start the boiler
Turn OFF the boiler ON/OFF switch.1.
Read and follow the Operating Instructions, 2. Fig-
ure 90, page 76.
The U-Control display will show installed sensors 3.
when first powered. Make sure the right sensors are
detected. If not, determine the cause and correct before
proceeding.
If boiler does not start correctly
Check for loose connections, blown fuse or service 1.
switch off?
Is external limit control (if used) open? Is boiler water 2.
temperature above 200 °F?
Is thermostat set below room temperature?3.
Is gas turned on at meter or boiler?4.
Is incoming gas pressure less than 5” w.c. for natural gas 5.
or 4” w.c. for propane?
Are parameters set correctly in this manual?6.
Is the warm weather shutdown activated?7.
If none of the above corrects the problem, refer to 8.
Troubleshooting, beginning on page 84.
Check for gas leaks
Before starting the boiler, and during initial opera-
tion, use a leak detector or smell near the oor 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 adjust-
ment. 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)
Disconnect the two external wires connected to the boiler thermo-1.
stat terminals (see Field wiring, beginning on page 54 for terminal
locations).
Connect a voltmeter across these two incoming wires. Close each 2.
thermostat, zone valve and relay in the external circuit one at a time
and check the voltmeter reading across the incoming wires.
There should NEVER be a voltage reading.3.
If a voltage does occur under any condition, check and correct the 4.
external wiring. (This is a common problem when using 3-wire
zone valves.)
Once the external thermostat circuit wiring is checked and cor-5.
rected if necessary, reconnect the external thermostat circuit wires.
Allow the boiler to cycle.
Inspect/fill condensate system
Inspect/check condensate lines and fittings
Inspect the condensate drain line, condensate PVC fittings and 1.
condensate trap. (See page 50 for component locations.)
Pour water into the top of the boiler’s ½” PVC condensate tee and 2.
check for any leaks in the condensate drain line or fittings. Repair
any leaks.
Fill condensate trap with water
Loosen the hose clamp securing the right end of the condensate 1.
trap to the PVC reducing elbow (see page 50 for details).
Slide the trap hose end off of the elbow.2.