34
Part number 550-100-029/0810
GAS
-
FIRED
WATER
BOILER
SERIES
1 & 2
—
Control supplement & Service guide
Boiler maintenance procedure
(continued)
Perform ALL of the (
14
) procedures listed in the following, in the ORDER SHOWN.
(You must have the correct maintenance kit to proceed. See page 33 for details.)
Order Procedure
Description
1
Shut down the boiler.
Follow “To Turn Off Gas to Appliance” instructions under Lighting instructions on boiler label and
s
in Ultra Boiler manual. Make sure to close the external manual gas cock to prevent gas flow to the
boiler.
Do not drain boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid
s
in system, do not drain.
Allow time for boiler to cool to room temperature if it has been firing.
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Remove jacket front door by removing two knurled head screws at lower front. Lift door away from
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boiler to remove.
2
Clean or replace the
igniter.
Remove the igniter from the cover plate.
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Use steel wool or equivalent to clean any white oxides on the igniter rod.
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Make sure the igniter electrodes are parallel to one another.
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If the igniter is damaged or cannot be cleaned satisfactorily, discard it.
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3
Remove combustion
chamber cover plate, gas
valve / venturi and blower
The boiler contains ceramic fiber materials. Use care when handling these materials per
instructions on page 29 of the Ultra Boiler manual. Failure to comply could result in
severe personal injury.
5LTRAOR5LTRA
Remove (4) Phillips-head screws securing gas valve inlet adapter to gas valve. This will disconnect the
s
gas valve from the gas line.
Remove the air silencer by separating it from the air adapter on the blower inlet.
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Disconnect the gas valve plug, blower power supply plug and blower control connector.
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Release the exchanger cover plate by removing the nuts securing it to the exchanger.
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Pull the entire blower/venturi/gas valve/cover plate assembly out of the boiler. (See Ultra Boiler manual
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page 39 for component identification and locations.)
5LTRAOR
$ISCONNECTWIRINGsGASVALVEELECTRICALPLUGsTWOELECTRICAL-OLEXPLUGSFROMTHEBLOWERASSEMBLY
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sIGNITIONCABLEsGROUNDWIRE
Disconnect the flexible gas line at its flare fitting.
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Remove the air silencer by lifting the plastic clamp off of the gas line and then gently sliding the air
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silencer down and off the valve.
Remove hex head nuts (use box end wrench, 10 mm for series 1 boilers or 11 mm for series 2 boilers)
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from heat exchanger cover plate and remove burner cover plate from heat exchanger.
Pull the entire blower/venturi/gas valve/cover plate assembly out of the boiler.
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Remove three M4 hex head screws (7mm box end wrench) and burner clips securing burner to cover
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plate. Remove cover plate.
4
Clean the venturi.
Separate the venturi from the combustion chamber cover plate on Ultra-80 or Ultra-105. Separate the
s
venturi from the blower on Ultra-155, -230 or -310.
Hold the gas valve/venturi assembly so the venturi is vertical.
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Use a soft brush, such as a toothbrush, to clean the interior of the venturi. DO NOT use a wire brush.
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Make sure to clean slots.
Avoid getting any debris in the gas valve orifice while cleaning the venturi.
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Re-attach the venturi to the cover plate (Ultra-80 or -105) or to the blower (Ultra-155, -230 or
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-310).
Set combustion chamber cover plate assembly aside in a safe place while cleaning the heat exchang-
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er.
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