Install Instructions

ManualsBrandsWeil-McLain ManualsBoiler PartsHeat Exchanger Replacement Kit for Ultra 230

Series 1-4

Gas-ﬁred

water boiler

Part number 550-100-055/0618

Ultra-80 S1-4 Heat Exchanger Block Replacement Kit, Part No. 383-500-773

Ultra-105 S1-4 Heat Exchanger Block Replacement Kit, Part No. 383-500-774

Ultra-155 S1-4 Heat Exchanger Block Replacement Kit, Part No. 383-500-775

Ultra-230 S1-4 Heat Exchanger Block Replacement Kit, Part No. 383-500-776

Ultra-299/310/399 S1-4 Heat Exchanger Block Replacement Kit, Part No. 383-500-777

Heat Exchanger Block Replacement Instructions

Verify kit contents before proceeding with installation:

Tools/materials required

• Ultra Boiler Manual

• Phillips and at blade screwdrivers

• 5/16” Nut driver

• 7mm wrench or socket

• 10mm wrench or socket

• Pipe wrench or channel lock pliers

• T25 TORX wrench

• 5/32 long-handled Allen wrench

• Sawzall

• PVC cement and cleaner

• Silicone grease

STOP!

Read before proceeding

Hazard deﬁnitions

The following deﬁned terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to

important information concerning the life of the product.

Indicates presence of hazards that will cause severe personal injury, death or substantial property damage.

Indicates presence of hazards that can cause severe personal injury, death or substantial property damage.

Indicates special instructions on installation, operation or maintenance that are important but not related to personal

injury or property damage.

These instructions must only be used by a qualiﬁed installer/service technician. Read all Instructions

completely before beginning the installation. Failure to follow all instructions can cause severe personal injury, death or

substantial property damage.

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury

(exposure to hazardous materials) or loss of life. Refer to the user’s information manual provided with this boiler or

available on-line at Weil-McLain.com. Installation and service must be performed by a qualied installer, service agency

or the gas supplier (who must read and follow the supplied instructions before installing, servicing, or removing this

boiler. is boiler contains ceramic ber and berglass materials that have been identied as carcinogenic, or possibly

carcinogenic, to humans).

You must refer to the Ultra Boiler Manual to follow these instructions.

DO NOT proceed with the replacement procedure without having an

Ultra Boiler Manual. Failure to comply can result in severe personal injury, death or substantial property damage.

Summary of content (12 pages)

PAGE 1
Series 1-4 Gas-fired water boiler Heat Exchanger Block Replacement Instructions Ultra-80 S1-4 Heat Exchanger Block Replacement Kit, Ultra-105 S1-4 Heat Exchanger Block Replacement Kit, Ultra-155 S1-4 Heat Exchanger Block Replacement Kit, Ultra-230 S1-4 Heat Exchanger Block Replacement Kit, Ultra-299/310/399 S1-4 Heat Exchanger Block Replacement Kit, Part No. 383-500-773 Part No. 383-500-774 Part No. 383-500-775 Part No. 383-500-776 Part No.
PAGE 2
gas-fired water boilers — Heat Exchanger Block Replacement Instructions Heat Exchanger Block Replacement Ultra 80, 105 and 155 Kits: Verify kit contents before proceeding with installation: P/N 383-500-773 Heat Exchanger Block Kit Ultra 80 Contents: Part No.
PAGE 3
gas-fired water boilers — Heat Exchanger Block Replacement Instructions Block Replacement Ultra 230, 299, 310 and 399 Kits: Verify kit contents before proceeding with installation: P/N 383-500-776 Block Kit Ultra 230 Contents: P/N 383-500-777 Block Kit Ultra 299/310/399 Contents: Part No. Qty Part No. Qty Section Cast Aluminum Heat-Exchanger Coat 230 319-000-023 1 Section Cast Al. Heat-Exch.
PAGE 4
gas-fired water boilers — Heat Exchanger Block Replacement Instructions You must refer to the Ultra Boiler Manual to follow these instructions. DO NOT proceed with the replacement procedure without having an Ultra Boiler Manual. Failure to comply can result in severe personal injury, death or substantial property damage. Ultra jacket and front top cover removal Turn off gas before replacing air inlet adapter. If boiler is hot from operation, allow time to cool before proceeding.
PAGE 5
gas-fired water boilers 5. 6. — Heat Exchanger Block Replacement Instructions Remove the (4) Phillips head screws from the top rear plastic panel. Remove and discard flue sensor and grommet from stainless vent pipe inside boiler, see Figure 3. Figure 2 pipes, cut either or both the PVC intake and vent pipes above the top of the vent and intake adapters for adequate clearance. Figure 4 Flue pipe cut off for removal Front top removal PVC air pipe must be supported.
PAGE 6
gas-fired water boilers — Heat Exchanger Block Replacement Instructions 11. Cover the heat exchanger flue outlet with a rag or tape to prevent plastic particles from entering. 12. Raise the front of the top rear plastic panel as much as possible and support it securely so as to cut a portion of the inside piece away as shown in the Figure 6, (required for Ultra 299/310/399 only). This will allow proper fit of the top rear panel with the new Poly Pro intake and vent adapters. 13.
PAGE 7
gas-fired water boilers — Heat Exchanger Block Replacement Instructions See Figures 7 and 8, below showing location of the M6 sensors with adapters. Figure 7 M6 sensor (Lower sensor) 8. Remove blower and gas valve assembly. Inspect the O-ring that should still be in gas valve inlet adapter block. The O-ring must be in good condition and must be installed when gas valve is reconnected. Failure to comply will cause a gas leak, resulting in severe personal injury or death. 9.
PAGE 8
gas-fired water boilers — Heat Exchanger Block Replacement Instructions 5. Secure the original cover plate to the replacement heat exchanger block mounted inside of the boiler cabinet. For Ultra-80 and Ultra-105, follow the tightening sequence shown in Figure 9 below making a minimum of two passes with a torque wrench. Final torque = 50 +/- 10 inch-pounds.
PAGE 9
gas-fired water boilers — Heat Exchanger Block Replacement Instructions 15. Place snap style clamp around Poly Pro vent pipe and around the rectangle “Offset flange” of L bracket. Be sure clamp is 1/8” above the lip of the first section of the Poly Pro vent pipe, see Figure 12 below. Secure clamp by snapping lever. Figure 12 Offset flange of L bracket, clamp in place 18. Reinstall new flue sensor to grommet in the vent pipe. 19. Reinstall the four (4) Phillips head screws in the top rear plastic panel.
PAGE 10
gas-fired water boilers — Heat Exchanger Block Replacement Instructions You must refer to the Ultra Boiler Manual to follow these instructions. DO NOT proceed with the replacement procedure without having an Ultra Boiler Manual. Failure to comply can result in severe personal injury, death or substantial property damage. Ultra-155, -230, 299, 310 & 399 Heat Exchanger Block Replacement STOP! Read before proceeding Shut off power to the boiler and close main gas valve. Close all isolation valves.
PAGE 11
gas-fired water boilers Figure 15 1. 2. — Heat Exchanger Block Replacement Instructions M6 sensor (Upper sensor) Close external isolation valves on boiler water supply and return. Drain water from boiler using boiler drain valve. Close manual gas valve to shut off gas supply. Wait for the heat exchanger to cool down before proceeding. Failure to do so can result in severe personal injury. Label wires before removing Label all wires prior to disconnection when servicing controls.
PAGE 12
gas-fired water boilers — Heat Exchanger Block Replacement Instructions 9. Install new igniter, gasket and mounting hardware provided in this kit. Secure the ground wire ring terminal with mounting screw. 10. Reconnect ignition cable to igniter. 11. Reinstall blower to heat exchanger cover plate with bolts and nuts or with the two (2) nuts if studs are used in the cover plate. Insure gasket is seated properly. 12. Reconnect gas line union with pipe wrench or channel lock pliers. 27.