Ultra Boiler Manual

Part number 550-100-440/0122
127
  
MAINTENANCE & SPECIFICATIONS
 (continued)
Accessing & cleaning exchanger: Ultra-155, -230,
-299 and -399 Only
1. Close the external manual gas valve.
2. Disconnect wiring: •gas valve electrical plug •two electrical Molex
plugs from the blower assembly •ignition cable •ground wire.
3. Disconnect the exible gas line at its are tting.
4. Remove the air silencer by liing the plastic clamp o of the gas
line and then gently sliding the air silencer down and o the valve.
5. Remove hex head nuts (10mm box end wrench) from heat exchang-
er cover plate and remove burner cover plate from heat exchanger.
6. Pull the entire blower/venturi/gas valve/cover plate assembly out
of the boiler. (See Replacement parts section for component iden-
tication and locations.)
7. Remove three (3) M4 hex head screws (7mm box end wrench) and
burner clips securing burner to cover plate. Remove cover plate.
8. Use a vacuum cleaner to remove any accumulation on the heating
surfaces. Do not use any solvent.
9. 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,page126.
See water spraying notice.
10. Inspect the heat exchanger cover plate insulation and gasket. Re-
place if damaged. Read the ceramic ber WARNING on page109
before handling or disposing of ceramic ber materials.
11. Replace the burner, hex head screws and burner clips removed in
step 7. See Figure120,page112.
12. Place cover plate gasket in groove of heat exchanger cover plate.
Replace cover plate.
13. Reinstall hex head nuts on the cover plate mounting studs and tight-
en in a staggering pattern until cover plate is uniformly tightened.
You must gradually tighten the cover plate nuts. For
Ultra-155 through -399, follow the tightening sequence
shown in Figure128, making two or three passes with
a torque wrench. e nal torque MUST NOT exceed
50inch-pounds, +/- 10inch-pounds.
14. Reinstall air silencer by sliding on gas valve venturi and securing
clamp to gas line.
15. Reconnect wiring: •gas valve electrical plug •two electrical Molex
plugs from the blower assembly •ignition cable •ground wire.
16. Reconnect the exible gas line and gas valve electrical plug.
17. Perform a soap suds leak test on all interior gas piping aer start-
ing 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,
beginning on page35.
Figure 128 Nut tightening sequence —
155 to 399 — Gradually tighten the
nuts, repeating the sequence shown
below until the torque reaches 50
inch-pounds (+/- 10 inch-pounds)
WATER SPRAY HEAT EXCHANGER PINS
AFTER USING CLEANING TOOL
1. After using the cleaning tool as shown in Fig-
ure127, page126, spray water downward from
above the pins to ush remaining sediment.
2. Remove sediment from the bottom of the heat
exchanger.
3. en disconnect the condensate line at the bottom
of the heat exchanger.
a. Loosen the hose clamps at both ends of the
condensate line.
b. Remove the line and place a pan under the trap
connection.
c. Spray water into the bottom of the heat ex-
changer to ush remaining sediment to the
condensate outlet.
d. Spray water through the condensate line to
clean it thoroughly.
e. Remove pan and replace the condensate line.
f. Follow instructions on page126 or on this
page to check components and replace burner
and cover.