Install Instructions
12
Part number 550-100-055/0618
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 mount-
ing 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.
Flue/Inlet Air Installation follow
Steps 11-17, pages 8 & 9
13. Reinstall boiler water supply pipe and tighten pipe nut.
14. Reinstall boiler return water pipe and tighten pipe nut.
15. Install new flue sensor to grommet in the vent pipe.
16. Reinstall the four (4) Phillips head screws in the top rear
plastic panel.
17. Reinstall the front plastic panel with the four (4) Phillips
head screws removed earlier.
18. Reconnect the vent and intake PVC into the new Poly Pro
adapters ensuring the adapter gaskets are properly in place.
If the PVC vent and/or intake had to be cut, install a repair
coupling to connect the two pieces of vent/intake. Utilize
proper PVC gluing technique.
19. Clean out any PVC shavings from the area.
20. Inspect the venting system for any shifting or damage
during the procedure. Check the termination, support, and
rubber boot if using a through-the-roof installation.
21. Open the external isolation valves on boiler water supply
and return.
22. Fill boiler with water, purge air from boiler, and check for
leaks.
23. Reinstall condensate trap and tighten band clamp.
24. Reinstall air silencer by sliding on gas valve venturi and
securing clamp to gas line.
25. Reconnect the two (2) blower electrical plugs, water tem-
perature sensors and gas valve electrical plug.
26. Turn on gas supply and check for gas leaks.
Inspect the gas pipe tting connections on the gas
valve, checking the seal of the connections. Failure
to comply will cause a gas leak, resulting in severe
personal injury or death.
Do not check for gas leaks with an open ame —
use bubble test. Failure to use bubble test or check
for gas leaks can cause severe personal injury,
death or substantial property damage.
27. Turn on boiler electrical supply.
Replace boiler jacket front door aer servicing.
e boiler front door must be securely fastened
to the boiler to prevent boiler from drawing air
from inside the boiler room. is is particularly
important 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.
28. Restore boiler to normal operation.
Perform complete start-up procedure
1. Follow all instructions in the Ultra Boiler Manual to start
up, test and adjust the boiler.
2. Make sure to perform the inspection mirror leak test around
all ue gas joints as instructed in the boiler Start-up section
of the manual.
Removing and reinstalling components can
change boiler behavior. Aer any maintenance
procedure, you must prove the boiler is operating
correctly. To do so, follow the complete procedure
for boiler and system start-up as instructed in the
Ultra Boiler Manual. Failure to comply could re-
sult in severe personal injury, death or substantial
property damage.