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Part number 550-100-400/0119
37
Startup — fi nal checks
Check thermostat circuit(s)
1. Disconnect the two external wires connected to the boiler
thermostat terminals (see Field wiring, beginning on page 30
for terminal locations).
2. Connect a voltmeter across these two incoming wires. Close
each thermostat, zone valve and relay in the external circuit
one at a time and check the voltmeter reading across the
incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage does occur under any condition, check and correct
the external wiring. (This is a common problem when using
3-wire zone valves.)
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires. Allow the boiler to cycle.
Inspect/fi ll condensate system
Inspect/check condensate lines and fi ttings
1. Inspect the condensate drain line, condensate PVC fi ttings
and condensate trap. (See page 27 for component locations.)
2. Pour water into the top of the boiler’s ½” PVC condensate
tee and check for any leaks in the condensate drain line or
fi ttings. Repair any leaks.
Fill condensate trap with water
1. Loosen the hose clamp securing the right end of the conden-
sate trap to the PVC reducing elbow (see page 27 for details).
2. Slide the trap hose end off of the elbow.
3. Fill the trap with fresh water to within an inch of the end
of the hose.
4. Replace trap hose on PVC reducing elbow and tighten the
hose clamp.
The condensate trap must be fi lled with water dur-
ing all times of boiler operation to avoid fl ue gas
emission from the condensate drain line. [Prime
the condensate trap (by pouring water into the
outlet tee while restricting fl ow in drain tube) if
boiler has been out of service for an extended pe-
riod.] Failure to fi ll 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 at-
tached.
❏
Inspect vent piping and air piping for signs of deteriora-
tion from corrosion, physical damage or sagging. Verify air
piping and vent piping are intact and correctly installed per
this manual.
Check for gas leaks
Before starting the boiler, and during ini-
tial operation, use a leak detector or smell
near the fl 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 fi eld adjustment. At-
tempting 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 dam-
age.
Propane boilers only — Your propane sup-
plier 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.
®
Series 4
gas-fired water boiler — Boiler Manual
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