Ultra Boiler Manual
Part number 550-100-440/0122
109
MAINTENANCE & SPECIFICATIONS
REMOVING BURNER GASKET or
COVER PLATE INSULATION
e Ultra burner gasket (models80
and 105) and cover plate insula-
tion (all models) contain ceramic
ber material. Ceramic bers can
be converted to cristobalite in very
high temperature applications. e
International Agency for Research
on Cancer (IARC) has concluded,
“Crystalline silica inhaled in the
form of quartz or cristobalite from
occupational sources is carcinogenic
to humans (Group 1).”:
Avoid breathing dust and contact with skin
and eyes.
• Use NIOSH certied dust respirator (N95).
This type of respirator is based on the
OSHA requirements for cristobalite at the
time this document was written. Other
types of respirators may be needed depend-
ing on the job site conditions. Current
NIOSH recommendations can be found on
the NIOSH web site at http://www.cdc.gov/
niosh/homepage.html. NIOSH approved
respirators, manufacturers, and phone
numbers are also listed on this web site.
• Wear long-sleeved, loose tting clothing,
gloves, and eye protection.
Apply enough water to the combustion
chamber lining or base insulation to prevent
airborne dust.
Remove combustion chamber lining or base
insulation from the boiler and place it in a
plastic bag for disposal.
Wash potentially contaminated clothes sepa-
rately from other clothing. Rinse clothes
washer thoroughly.
NIOSH stated First Aid
Eye: Irrigate immediately
Breathing: Fresh air.
FIRST
-
It is recommended that you obtain a Weil-McLain
Ultra Boiler Maintenance kit before attempting
may be needed are available
. is kit includes a
heat exchanger cover plate gasket, burner gasket (80
and 105 only), new ignitor, and ignitor gasket. See list-
ing in Replacement parts section of this manual. ese
parts must be on hand when you perform the rst-year
inspection in the event they must be replaced.
Failure to replace the items above when needed could
result in severe personal injury, death or substantial
property damage.
1.
No later than 12 months aer the boiler is installed, perform
a rst-year inspection of the boiler. is must include the fol-
lowing in addition to routine annual start-up procedures.
a. Remove the heat exchanger cover plate (see page112 for
instructions on removal and replacement).
b. Inspect the heat exchanger and clean if necessary (see
“Cleaning the heat exchanger — pin side when required” on
page125, and all referenced illustrations and instructions).
c. Inspect the cover plate insulation and gasket. Replace if not
in good condition.
d. Remove the burner and inspect carefully. Clean the burner
thoroughly using a vacuum cleaner and a so brush if
needed. Make sure there is no blockage or accumulation of
debris in the burner or the burner ports. Replace the burner
if necessary.
e. Models 80 and 105 only — inspect the burner gasket, and
replace if the gasket is not in good condition. Make sure
the burner is clean. en securely fasten it tightly to the
cover plate.
f. Disconnect condensate trap and drain lines. Inspect, then
ush thoroughly.
2. Determine follow-up maintenance and service needs based on
the condition of the heat exchanger and condensate lines.
a. If the heat exchanger shows substantial fouling, or if con-
densate lines show accumulation of sediment, schedule a
follow-up service call to perform the rst-year inspection
again, sooner than the normal twelve months between.
b. Heavy fouling of the exchanger or condensate lines indicates
possible combustion air contamination. Inspect the air in-
take area carefully, and remove possible contaminants. See
Figure11,page16, for products to avoid.
You must eliminate causes of corrosion and contami-
nation to ensure reliable operation of the boiler and
system.