Install Instructions

Part number 550-100-090/1113
93
GAS-FIRED WATER BOILER — Boiler Manual
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Annual startup
HANDLING CERAMIC FIBER
MATERIALS
REMOVING BURNER GASKET or
COVER PLATE INSULATION
The Ultra burner gasket (models 80
and 105) and cover plate insula-
tion (all models) contain ceramic
fiber material. Ceramic fibers can
be converted to cristobalite in very
high temperature applications. The
International Agency for Research
on Cancer (IARC) has concluded,
“Crystalline silica inhaled in the
form of quartz or cristobalite from
occupational sources is carcinogenic
to humans (Group 1).”:
■ Avoid breathing dust and contact with skin and
eyes.
s Use NIOSH certified dust respirator (N95).
This type of respirator is based on the
OSHA requirements for cristobalite at the
time this document was written. Other
types of respirators may be needed depend-
ing on the job site conditions. Current
NIOSH recommendations can be found on
the NIOSH web site at http://www.cdc.gov/
niosh/homepage.html. NIOSH approved
respirators, manufacturers, and phone
numbers are also listed on this web site.
s Wear long-sleeved, loose fitting clothing,
gloves, and eye protection.
■ Apply enough water to the combustion
chamber lining or base insulation to prevent
airborne dust.
■ Remove combustion chamber lining or base
insulation from the boiler and place it in a
plastic bag for disposal.
■ Wash potentially contaminated clothes
separately from other clothing. Rinse clothes
washer thoroughly.
NIOSH stated First Aid
■ Eye: Irrigate immediately
■ Breathing: Fresh air.
FIRST-YEAR SPECIAL INSPECTION
)TISRECOMMENDEDTHATYOUOBTAINA7EIL-C,AIN
5LTRA "OILER -AINTENANCE KIT BEFOREATTEMPTING
THElRSTYEARINSPECTIONTOENSUREALLPARTSTHAT
MAYBENEEDEDAREAVAILABLE
. This kit includes a heat
exchanger cover plate gasket, burner gasket (80 and 105
only), new ignitor, and ignitor gasket. See listing in Re-
placement parts section of this manual. These parts must
be on hand when you perform the first-year inspection
in the event they must be replaced.
Failure to replace the items above when needed could
result in severe personal injury, death or substantial
property damage.
1.
.OLATERTHANMONTHS after the boiler is installed, perform a
first-year inspection of the boiler. This must include the following
INADDITIONTOROUTINEANNUALSTARTUPPROCEDURES.
a. Remove the heat exchanger cover plate (see page 96 for instruc-
tions on removal and replacement).
b. Inspect the heat exchanger and clean if necessary (see “Cleaning
the heat exchanger — pin side when required,” page 109, and
all referenced illustrations and instructions).
c. Inspect the cover plate insulation and gasket. Replace if not
in good condition.
d. Remove the burner and inspect carefully. Clean the burner
thoroughly using a vacuum cleaner and a soft brush if needed.
Make sure there is no blockage or accumulation of debris in
the burner or the burner ports. Replace the burner if necessary.
e. Models 80 and 105 only — inspect the burner gasket, and
replace if the gasket is not in good condition. Make sure the
burner is clean. Then securely fasten it tightly to the cover plate.
f. Disconnect condensate trap and drain lines. Inspect, then
flush thoroughly.
2. Determine follow-up maintenance and service needs based on the
condition of the heat exchanger and condensate lines.
a. If the heat exchanger shows substantial fouling, or if condensate
lines show accumulation of sediment, schedule a follow-up
service call to perform the first-year inspection again, sooner
than the normal twelve months between.
b. Heavy fouling of the exchanger or condensate lines indicates
possible combustion air contamination. Inspect the air intake
area carefully, and remove possible contaminants. See page 16,
for products to avoid.
You must eliminate causes of corrosion and contamina-
tion to ensure reliable operation of the boiler and system.