Ultra Boiler Manual

Part number 550-100-440/0122
126
  
 (continued)
Figure 126 Nut tightening sequence — 80 & 105
Gradually tighten the nuts, repeating
the sequence shown below until the
torque reaches 50 inch-pounds (+/-
10 inch-pounds
For the rst 5 years, vacuum or rinse heat exchanger with water only.
No tool cleaning is necessary.
y This heat exchanger is coated to prevent the formation of Aluminum Oxide. Cleaning the heat exchanger via
mechanical means (cleaning tools, blade, or brush) could shorten the life of the coating.
y Heat exchanger inspection is recommended at yearly intervals. Only clean heat exchanger if soiling is clearly


only with water and a mild detergent.
y Cleaning the heat exchanger should not be necessary until 5 years after commissioning date.
Figure 127 Cleaning the exchanger pin-side
Accessing & cleaning heat exchanger:
Ultra-80 and Ultra-105 Only
1. Close the external manual gas valve.
2. Disconnect the exible gas line at its are tting.
3. Remove the air silencer by separating it from the air adapter on the
blower inlet.
4. Disconnect wiring: •gas valve plug •blower power supply plug
• blower control connector •ignition cable •ground wire.
5. Release the heat exchanger cover plate by removing the nuts securing
it to the exchanger.
6. Pull the entire blower/venturi/gas valve/cover plate assembly out of the
boiler. (See Replacement parts section for component identication
and locations.)
7. Use a vacuum cleaner to remove any accumulation on the heating
surfaces. Do not use any solvent.
8. If the vacuum cleaner is unable to clean completely, wash the heating
surfaces with clean, warm water. If further cleaning is necessary, use
the Heat Exchanger Cleaning Tool (see Replacement parts at the end
of this manual) or a piece of 20-gauge or lighter sheet metal ¾” wide
by about 18 inches long to loosen deposits. See Figure127.
See water
spraying notice on next page
.
9. Inspect the heat exchanger cover plate insulation. Replace if insulation
is damaged. Read the ceramic ber WARNING on page109 before
handling or disposing of ceramic ber materials.
10. Reinstall the blower/venturi/gas valve/cover plate assembly and secure
the cover plate with nuts.
You must gradually tighten the cover plate nuts. For Ultra-80
and -105, follow the tightening sequence shown in Figure126,
making two or three passes with a torque wrench. e nal
torque MUST NOT exceed 50inch-pounds, +/- 10inch-
pounds.
11. Reconnect wiring: •gas valve plug •blower power supply plug
• blower control connector •ignition cable •ground wire.
If the valve adapter block is removed, carefully inspect the
O-ring that should still be in the gas valve inlet adapter block.
e 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.
12. Reconnect the exible gas line.
13. Reinstall the air silencer by pressing onto the air inlet adapter.
14. Perform a soap suds leak test on all interior gas piping aer starting
the boiler.
Cleaning the heat exchanger — water side (ALL
models)
1. Follow the procedure given in “Clean the cast aluminum heat exchanger
when required — water side” on page125 to clean the water side of
the exchanger.
2. Follow the complete procedure for boiler and system start-up, begin-
ning on page35.