Specifications

Part number 550-100-090/0809
99
g a s -f i r e d w a t e r b o i l e r — Boiler Manual
MAINTENANCE & SPECIFICATIONS
Troubleshooting
Reinstall boiler jacket front door
Reinstall boiler jacket front door after
servicing. The boiler front door must be
securely fastened to the boiler to prevent
boiler from drawing air from inside the
boiler room. This is particularly impor-
tant 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.
Before troubleshooting:
See 1. Figure 109 for tools and kits recommended for
troubleshooting Ultra boilers.
Check for 120 VAC (minimum 102 VAC to maxi-2.
mum 132 VAC) to boiler.
Check the U-Control’s last three lockout histo-3.
ries.
See a. page 83, “ADVANCED SETUP – OVER-
VIEW.”
Scroll down to DIAGNOSTICS and press the b.
enter key.
Scroll down to ERRORS and press the enter c.
key.
Record the first four data records and then high-d.
light the history record you want to view.
Follow information at the bottom of the screen e.
to navigate through your lockout histories.
VERIFY PROPER OPERATION AFTER SERVICING. VERIFY PROPER OPERATION AFTER SERVICING.
Before servicing and making connections . . .
ALWAYS TURN POWER OFF TO THE BOILER TO
PREVENT ELECTRICAL SURGES, WHICH CAN
DAMAGE BOILER COMPONENTS.
ELECTRICAL SHOCK HAZARD — The boiler ON/
OFF switch does not turn off all power to the boiler.
TURN OFF ALL POWER TO THE BOILER WHEN
SERVICING
. Internal wiring is still powered when
the switch is off.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dan-
gerous operation. Always disconnect power to boiler
before servicing. Failure to comply could result in
severe personal injury, death or substantial property
damage.
Never jumper (bypass) any device except for momen-
tary testing. Severe personal injury, death or substan-
tial property damage can result.
Before calling, always complete the “Ultra Gas Data
Collection Sheet
” (page 108). Record the boiler size
and CP number (located on the lower center support
frame in the center of the boiler).
Tools and kits for troubleshootingFigure 109
Tools needed for troubleshooting Purpose
#2 Phillips Screwdriver Remove 4 screws to remove the top front cover
U-Control Screwdriver or 1/16" flat blade screwdriver Used for wiring on terminal blocks for the U-Control (comes with boiler)
1/8" Allen Wrench (Hex Key) To add orifice to change from natural to propane
7mm Nut driver (Ultra 155/230/299/399) To change the burner (#2 Phillips Screwdriver for the 80 and 105)
11mm Nut driver To remover the front cover plate on the burner
4mm Allen wrench (long handled preferred) To remove the blower assembly from the heat exchanger
Multimeter To take measurement readings on sensors and electrical components
Manometer (Incline or digital) To measure the gas pressure coming to the boiler.
Combustion analyzer (Digital preferred) For combustion testing.
Contact thermometer For checking surface temperatures of heat exchanger and pipes
383-500-605 Maintenance Kit (80 and 105) This kit should be on hand when performing annual maintenance in the
event replacement is required.
383-500-620 Maintenance Kit (155/230/299/399) This kit should be on hand when performing annual maintenance in the
event replacement is required.