Weil-McLain ULTRA ULTRA-105 Service Manual page 36

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GAS FIRED WATER BOILER SERIES
Boiler maintenance procedure
Perform ALL of the (
(You must have the correct maintenance kit to proceed. See page 33 for details.)
Order Procedure
Re-install the combustion
9
chamber cover plate
assembly and igniter.
You must have the
maintenance kit specified
on page 33.
10 Re-install the igniter and
check ignition ground
wiring.
Check all boiler wiring.
11
12 Check flue vent and air
piping system.
Restart boiler and run
13
combustion tests.
14 If combustion results are
unacceptable, follow the
procedure beginning on
page 38.
36
—
1 & 2
14
) procedures listed in the following, in the ORDER SHOWN.
Description
Inspect the heat exchanger cover plate insulation. Replace if insulation is damaged. Read the ceramic
fiber WARNING on page 93 of the Ultra Boiler manual before handling or disposing of ceramic fiber
materials.
When re-installing the heat exchanger cover plate, you must gradually tighten the cover
plate nuts. Follow the tightening sequence shown in Figure 21, page 37, making two or
three passes with a torque wrench. The final torque MUST NOT exceed 50 inch-pounds,
+/- 10 inch-pounds.
Reinstall the blower/venturi/gas valve/cover plate assembly. Follow the tightening sequence shown in
Figure 21, page 37, making two or three passes with a torque wrench to install the nuts.
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.
Reconnect the flexible gas line.
Reinstall the air silencer by pressing onto the air inlet adapter.
Perform a soap suds leak test on all interior gas piping after starting the boiler.
Place cover plate gasket in groove of heat exchanger cover plate. Re-install cover plate.
Follow the tightening sequence shown in Figure 21, page 37, making two or three passes with a torque
wrench to install the nuts
Reinstall air silencer by sliding on gas valve venturi and securing clamp to gas line.
Perform a soap suds leak test on all interior gas piping after starting the boiler.
After the cover plate is re-installed on the heat exchanger, install the igniter.
If the existing igniter was successfully cleaned, you can re-install it. If not, or to reduce the possibil-
ity of problems, install the new igniter included in the Maintenance kit. Attach igniter, making sure
the gasket is in good condition and correctly positioned.
Reconnect green ground wire. Check ground wire, ignition wire and connections.
Inspect all boiler wiring, making sure all wires are in good condition and securely attached.
Visually inspect entire flue gas venting system and air piping for blockage, deterioration or leakage. Re-
pair any joint that shows signs of leakage in accordance with the vent manufacturers instructions. Where
combustion air is ducted to boiler, verify that air inlet piping is connected and properly sealed.
Verify that all combustion and ventilation air openings are to the boiler room and/or building are open
and unobstructed. Check operation and wiring of automatic combustion air dampers, if used.
Verify that boiler discharge and air intake is clean and free of obstructions.
Follow the Ultra Boiler manual Start-up procedures.
Start the boiler and perform combustion tests as specified in the Ultra Boiler manual.
Ultra boilers do no typically require field adjustment of the gas valve. However, it may be necessary to
verify and possibly adjust the combustion settings.
When combustion results obtained using the Ultra Boiler manual procedures, see page 38 for procedure
to adjust for proper combustion.
The adjustment specified in the procedure of page 38 must only be performed by a quali-
fied service technician, using combustion test instruments. Failure to comply could result
in severe personal injury, death or substantial property damage.
(continued)
Part number 550-100-029/0810