Install Instructions

Part number 550-100-055/0618
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
16. Ensure the condensate drain plastic nipple is protruding
from the bottom of the condensate drain of the boiler. Align
vent adapter so flue sensor opening is toward front of boiler.
17. Install Poly Pro vent adapter and align screw lugs. Secure
the intake adapter with new 5/16” screws provided in this
kit, see Figure 13.
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.
20. Reinstall the front plastic panel with the four (4) Phillips
head screws removed earlier.
21. 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.
22. Clean out any PVC shavings from the area.
23. 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.
24. Open the external isolation valves on boiler water supply
and return.
25. Fill boiler with water, purge air from boiler and check for leaks.
26. Reinstall condensate trap and tighten band clamp.
27. Reinstall air silencer.
28. Reconnect the two (2) blower electrical plugs, water tempera-
ture sensors and gas valve electrical plug.
29. 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.
30. Turn on boiler electrical supply.
Replace boiler jacket front door aer servicing. e
boiler front door must be securely fastened to the
boiler to prevent boiler from drawing air from in-
side the boiler room. is is particularly important
if the boiler is located in the same room as other ap-
pliances. Failure to keep the door securely fastened
could result in severe personal injury or death.
31. 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. Aer 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 result in severe
personal injury, death or substantial property
damage.
Figure 13 Vent adapter screw lugs aligned