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Part number 550-100-400/0119
126
Maintenance (continued)
Figure 126
For the fi rst 5 years, vacuum or rinse heat exchanger with water only.
No tool cleaning is necessary.
Figure 127
®
Series 4
gas-fired water boiler — Boiler Manual
Accessing & cleaning heat exchanger:
Ultra-80 and Ultra-105 Only
1. Close the external manual gas valve.
2. Disconnect the fl exible gas line at its fl are fi tting.
3. Remove the air silencer by separating it from the air adapter on the
blower inlet.
4.
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 identifi 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 .
.
9. Inspect the heat exchanger cover plate insulation. Replace if insulation
is damaged. Read the ceramic fi ber WARNING on page 109 before
handling or disposing of ceramic fi 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. The fi nal
torque MUST NOT exceed 50 inch-pounds, +/- 10 inch-
pounds.
11.
If the valve adapter block is removed, carefully inspect the
O-ring that should still be in the gas valve inlet adapter block.
The 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 fl 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 after starting
the boiler.
Cleaning the hea t exchanger — water side (ALL
models)
1. Follow the procedure given in “Clean the cast aluminum heat exchanger
when required — water side,” 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 .
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