Weil-McLain 155, 80, 230 Maintenance and annual startup continued, Cleaning boiler heat exchanger

8b GAS-FIRED WATER BOILER — Boiler Manual

Maintenance and annual startup (continued)

Cleaning boiler heat exchanger

(continued from previous page)

Access exchanger: Ultra-155, -230, -310 Only

1.Remove gas valve electrical plug from gas valve. Also remove two electrical molex plugs from blower assembly.

2.Disconnect gas line union with pipe wrench or Channel Lock Pliers.

3.Remove air silencer by lifting plastic clamp off gas line and then gently sliding air silencer down and off valve.

4.Remove two 5/32” Allen head screws securing blower assembly to heat exchanger front cover.

5.Remove blower and gas valve assembly.

6.Remove hex head nuts (10mm box end wrench) from burner cover plate and remove burner cover plate from heat exchanger.

7.Remove three 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 necessary, use a piece of 20-gauge or lighter sheet metal ¾" wide by about 18 inches long to loosen deposits.

10.Inspect the heat exchanger cover plate insulation and gasket. Replace if damaged. Read the ceramic fiber WARNING on page 29 before handling or disposing of ceramic fiber materials.

11.Place cover plate gasket in groove of heat exchanger cover plate. Replace cover plate.

12.Re-install hex head nuts (10mm box end wrench) on cover plate mounting studs and tighten in a staggering pattern until cover plate is uniformly tightened.

13.Re-install blower insuring new gasket, provided in this kit, is in proper alignment between blower and heat exchanger front cover.

14.Re-install air silencer by sliding on gas valve venturi and securing clamp to gas line.

15.Connect the two blower electrical molex plugs.

16.Re-connect gas valve union and gas valve electrical plug.

Exchanger cleaning continued (ALL models)

1.Close isolation valves on piping to isolate boiler from system. Attach a hose to boiler drain valve and flush boiler thoroughly with clean water by using purging valves to allow water to flow through water make- up line to boiler.

2.When boiler has been flushed, restore boiler to operation.

3.Perform startup and checkout procedures of pages 23 and 26.

4.Turn on gas supply and check for gas leaks.

Failure to properly check for gas leaks can cause severe personal injury, death, or substantial property damage.

5.Turn on boiler electrical supply and test boiler for proper operation as stated in the Ultra Boiler Manual.

6.Replace boiler jacket front door when servicing is completed. See Warning at top of page 33.

34 Part number 550-101-233/0903