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Part number 550-100-400/0119
125
Cleaning the hea t exch anger — pin side
when required
The boiler contains ceramic fi ber materials. Use care
when handling these materials per instructions on
page 109 of this manual. Failure to comply could
result in severe personal injury.
1. Shut down boiler:
a. Follow “To Turn Off Gas to Appliance” instructions on
boiler and Lighting instructions.
b. Do not drain boiler unless it will be exposed to freezing
temperatures. If using freeze prevention fl uid in system,
do not drain.
2. Allow time for boiler to cool to room temperature if it has
been fi ring.
3. Remove jacket front door by removing two (2) screws at lower
front. Lift door away from boiler to remove.
4. Follow the applicable procedures under
heat exchanger: Ultra-80 and Ultra-105 Only,” page 126 or
and -399 Only,” page 127 .
Clean the c ast aluminum heat exchanger
when required — water side
1. In order for the effi ciency of boilers to increase beyond the
condensing limit, new materials have been introduced for the
heat exchanger, including aluminum.
2. Aluminum has excellent heat transfer characteristics and is
light in weight.
3. These new materials also require cleaning solutions that differ
from those used in conventional cast iron and steel boilers.
One common cleaning method that be
used with systems containing aluminum is a solu-
tion of trisodium phosphate, commonly referred to
as “TSP.”
The reason that trisodium phosphate cannot be
used is that the cleaning solution has a very high pH
level — while removing the scale in the system, it
also removes the natural protective oxide layer from
the aluminum. The oxide layer will reform, but if
small amounts of the trisodium phosphate remain
in the system, the chemical will continue to remove
the protective oxide layer, leading to reduced heat
exchanger life.
4. Use ONLY the cleaning product available from Weil-McLain,
Sentinel X400. See the Repair Parts section at the end of this
manual for ordering information.
General maintenance
1. Oil motor in system requiring regular oiling.
2. See Oiled bearing circulators for motor oiling procedures.
Oiled bearing circulators
1. The circulator shipped with the Ultra boiler is water-lubri-
cated. No oiling is required.
2. Check other circulators in the system. Oil any circulators
requiring oil, following circulator manufacturer’s instruc-
tions. Over-oiling will damage the circulator.
Disconnect power
Electrical shock hazard — Disconnect all elec-
trical power to the boiler before attempting
maintenance procedures. Failure to complete
could result in severe personal injury, death
or substantial property damage.
Install boiler j acket front door after
startup or servicing
Reinstall boiler jacket front door after start-
up or servicing. The boiler front door must
be securely fastened to the boiler to prevent
boiler from drawing air from inside the boiler
room. This is particularly important if the
boiler is located in the same room as other
appliances.
Inspect boiler jacket door gaskets. Gaskets
must be in good condition, with no tears or
gaps. Replace if necessary.
Failure to keep the door securely sealed and
fastened could result in severe personal injury
or death.
Perform start-up and check/out
Removing and reinstalling components can
change boiler behavior. After any mainte-
nance procedure, you must prove the boiler
is operating correctly. To do so, follow the
complete procedure for boiler and system
start-up, beginning on page 35 . Failure to
comply could result in severe personal injury,
death or substantial property damage.
Maintenance
Attention to homeowners and installers
of Ultra Series 4 boilers– see page 126
for the latest cleaning information for
our newly coated heat exchangers.
®
Series 4
gas-fired water boiler — Boiler Manual
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