Install Instructions

Ultra-80 - 105
Heat Exchanger Block Replacement
Part number 550-100-055/0618
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. With a sawzall or other appropriate cutting device, cut
approximately 1” up and across from side to side as shown
in the photo. Vacuum and/or clean all plastic cutting residue
from boiler top panel, top of heat exchanger and from inside
boiler jacket.
Figure 6 Plastic flange removal for new vent adapters
14. Remove support holding top rear plastic panel and let panel
rest on top boiler panel.
Refer to the Ultra Boiler Manual for compo-
nent locations and illustrations
Weil-McLain changed the Ultra heat exchanger
sensors in June 2014. Ultra Series 1 & 2 boilers
utilized a supply and return temperature sensor
that has an M4 thread with two stake on terminals.
Series 3 Ultra boilers utilize a supply and return
temperature sensor that has an M4 thread with a 4
pin molex connector. Aer June 2014, Weil-McLain
began using a supply and return sensor with an M6
thread with a 4 pin molex connector.
All replacement heat exchangers come with the supply
and return sensor with the M6 thread. To connect
the sensors to the Ultra Series 3 wiring, simply plug
in the supply and return, 4 pin molex connector to
the new sensors in the heat exchanger. To connect
the new sensors in the replacement heat exchanger
to the Ultra Series 1 & 2 sensor wiring, two (2) 4 pin
molex adapters with butt connectors are included
with the heat exchanger replacement kit. To connect
the new 4 pin molex connectors to the Series 1 & 2
wiring, cut and strip the boiler sensor wiring close to
the stake on terminals, connect and crimp the sensor
wires into the butt connectors of the adapters. Aer
crimping the butt connectors, plug in the 4 pin molex
connector to the supply sensor and the return sensor.
• This heat exchanger is coated to extend the intervals
between cleanings. Cleaning the heat exchanger via
mechanical means (cleaning tools, blade, or brush)
could shorten the life of the coating.
• Heat exchanger inspection is recommended at year-
ly intervals. Only clean heat exchanger if soiling is
clearly present. If cleaning is necessary ush only
with water and a mild detergent. From the cover
plate opening, inspect the collection area and un-
derneath the vent pipe to ensure that it is free of de-
bris. If cleaning is necessary ush only with water
and a mild detergent.
• Cleaning the heat exchanger should not be neces-
sary until 5 years after commissioning date.
NOTICE !
For new Ultra Series 3 boilers manufactured aer
July 2016 (tagged, and visually marked/stamped on
the
right side of the block):
Limit cleaning to the use of vacuum or
water-only rinsing for the first 5 years of
operation.
No tool cleaning is necessary.