Weil-McLain Ultra Manual
  1. Manuals
  2. Brands
  3. Weil-McLain Manuals
  4. Boiler
  5. Ultra Electric Water Heater
  6. Manual

Weil-McLain Ultra Manual

Gas-fired water boilers – series 3
Hide thumbs Also See for Ultra:
Table of Contents

Advertisement

Quick Links

See also: Instructions , Installation Manual
Boiler Manual
This manual must only be used by a qualified heating installer/service technician. Read all instructions, including this
manual and all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to
comply could result in severe personal injury, death or substantial property damage.
Gas-fired water boilers – Series 3
Featuring
• Installation
• Startup
Flexibility
• Maintenance
• Parts
Part number 550-100-066/0608
Part number 550-100-066/0608

Advertisement

Table of Contents
loading

Related Manuals for Weil-McLain Ultra

Summary of Contents for Weil-McLain Ultra

  • Page 1 Gas-fired water boilers – Series 3 Featuring Flexibility Boiler Manual • Installation • Maintenance • Startup • Parts This manual must only be used by a qualified heating installer/service technician. Read all instructions, including this manual and all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 2 (boiler return, boiler supply, system return, system supply, flue temperature, and outdoor temperature, if used). The control The advanced blower design and air inlet silencer on Ultra boilers result module automatically adjusts blower speed (and gas flow rate) in very quiet operation.
  • Page 3 — Boiler Manual fired water boiler Gas-fired water boiler Featuring Flexibility Part number 550-100-066/0608...

  • Page 4: Table Of Contents

    Vertical vent/air termination: Separate pipes Ratings — Ultra boilers Install vent/air piping — boiler to termination Ratings — multiple Ultra boilers Install condensate line Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

  • Page 5: Please Read Before Proceeding

    Boiler water — You should write in the CP number in • The Ultra heat exchanger is made of aluminum, and requires that the space provided on the Installation system pH always be between 7.0 and 8.5 and water chemistry be certificate on page 77 if not already checked.

  • Page 6: Prepare Boiler Location

    The Ultra boiler must be installed so that gas control system com- ponents are protected from dripping or spraying water or rain during operation or service.
  • Page 7 Wall mounting (Models 80 – 310) Ultra boilers may be wall mounted, following the instructions on page 11. (See Repair parts section for part number of wall mounting kit.) When wall mounting boilers, provide approxi- mately 6 inches between boilers for easy removal of boiler jacket door.

  • Page 8: Flooring And Foundation

    Air openings — Ultra boiler alone in boiler Flooring room The Ultra boiler is approved for installation on combustible floor- No air ventilation openings into boiler room are needed ing, but must never be installed on carpeting. when clearances around Ultra boiler are at least equal to the SERVICE clearances shown in Figure 1, page 6.

  • Page 9: Prepare Boiler

    Vent and air piping (page 31) Prepare boiler for propane (when required) The Ultra boiler requires a special vent system, designed for pres- surized venting. Ultra boilers are rated ANSI Z21.13 Category IV (pressurized vent, likely to condense in the vent). See instructions beginning on page 31.
  • Page 10 Figure 6 or Figure 7. Secure gas valve inlet adapter to gas valve with 4 screws. Make sure the plastic hose is connected from gas valve to inlet elbow on Ultra-80 and -105. DO NOT ATTEMPT TO MEASURE VALVE OUTLET...
  • Page 11 WARNING with the boiler, and must be purchased separately. See below. Wall mount Ultra boilers only using the Weil- McLain Ultra boiler wall-mounting kit and accom- panying instructions. (See Repair parts section for part number of wall mounting kit.) DO NOT use the shipping bracket to wall mount the boiler.
  • Page 12 When piping will be routed out the top of the boiler, no special preparation is needed other than that given in this manual. Ultra-80 to -230 only: To route the piping through the bottom of the boiler enclosure: Remove knockouts from bottom piping penetrations as shown in Figure 8, page 11.

  • Page 13: Perform Hydrostatic Pressure Test

    Remove supply line tee* and ¾” street elbow from accessory bag. Pipe to boiler supply connection as shown. Use pipe dope spar- ingly. (*1” x 1” x ¾” tee with Ultra-80 to -230 or 1¼” x 1¼” x ¾” tee with Ultra-310) Temporarily plug the ¾”...

  • Page 14: Install Water Piping

    Failure to support the boiler piping Replacement parts section at the end of this manual for connections to prevent them from turning could cause the Weil-McLain low water cut-off kit. damage to boiler components. Purchase low water cutoff and install in a tee in the supply piping above boiler.

  • Page 15: System Water Piping Methods

    The boiler circulator (Taco 007 for Ultra-80 and -105; Taco 0014 for For pipe sizes up to 2 inch, ensure a minimum flow Ultra-155, -230, and -310) is shipped loose. Locate it in the return pip- velocity of 2 fps (feet per second) and a maximum of ing, as shown in the appropriate piping diagram in this manual.
  • Page 16 — Boiler Manual fired water boiler Install water piping (continued) Expansion tank and make-up water Figure 14 Expansion tank piping Ensure expansion tank size will handle boiler and system water vol- ume and temperature. Allow 3 gallons for boiler and its piping. Undersized expansion tanks cause system water to be lost from relief valve and make-up water to be added through fill valve.

  • Page 17: Zoning With Zone Valves

    10 Flow/check valves as shown. Failure to follow these guidelines could result in system problems. 11 Purge/drain valves • Ultra-80 or Ultra-105 – 1” or larger. 12 Boiler circulator • Ultra-155 or -230 – 1¼” or larger. 13 Zone valves, typical •...
  • Page 18 10 Flow/check valves as shown. Failure to follow these guidelines could result in system problems. 11 Purge/drain valves • Ultra-80 or Ultra-105 – 1” or larger. 12 Boiler circulator • Ultra-155 or -230 – 1¼” or larger. 13 Zone valves, typical •...
  • Page 19 (or bladder) type expansion tank] as shown. Failure to follow these guidelines could result in system problems. 10 Flow/check valves • Ultra-80 or Ultra-105 – 1” or larger. 11 Purge/drain valves • Ultra-155 or -230 – 1¼” or larger. 12 Boiler circulator •...
  • Page 20 Typical radiant heating system piping plus optional DHW The Ultra boiler is ideal for use in radiant heating. The Ultra boiler’s unique heat exchanger design allows it to work well even in condensing mode. So there is no need to regulate boiler return water temperature in radiant heating applications.

  • Page 21: Chilled Water Systems

    12 Boiler circulator as shown. Failure to follow these guidelines could result in system problems. 13 Zone valves, typical • Ultra-80 or Ultra-105 – 1” or larger. 15 Closed-type expansion tank • Ultra-155 or -230 – 1¼” or larger. 16 Water chiller •...
  • Page 22 From the example water heater manufacturer’s data, the head loss across the water heater at 12 gpm is 5.5 feet water column. Read down the first column of Figure 22, page 23 for the Ultra-155 until you find a flow rate just larger than the required 12 gpm.
  • Page 23 Install water piping (continued) Figure 22 Figure 23 Pipe sizing and head losses for DHW Pump curves for typical circulators suggested for DHW applications loop (H1=Ultra boiler head loss; H2=piping head loss) Flow Temp Pipe rate rise size Boiler head Piping head °F...

  • Page 24: Multiple Boiler Water Piping

    The U-Control module proves water level using a dual temperature sensor installed in the Ultra heat exchanger . This will satisfy some code requirements for low water cutoff protection.
  • Page 25 Multiple boiler water piping (continued) Figure 26 Piping schematic — typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit manifolds Legend — Figure 26 1 Flow/check valve (each boiler) 11 Check valve or backflow preventer, as required by applicable codes...
  • Page 26 Multiple boiler water piping (continued) Figure 27 Piping layout — typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit manifolds Legend — Figure 27 1 Flow/check valve (each boiler) 9 System automatic air vent 13 Cold water supply...
  • Page 27 — Boiler Manual fired water boiler Multiple boiler water piping (continued) Figure 28 Piping layout — typical piping for multiple Ultra boilers, with DHW storage heaters Flow rate Size Flow rate Size 0 – 7 gpm 1” 45–75 gpm 2½”...
  • Page 28 — Boiler Manual fired water boiler Multiple boiler water piping (continued) Figure 29 Piping layout — typical piping for multiple Ultra boilers, using isolation exchanger Use isolation heat exchanger for: 1. Large volume systems with high mineral content in water.

  • Page 29: Appliances Remaining On An Existing Vent System

    Ultra boiler CANNOT use the existing common vent. main burner operation. Use the flame of a match or candle, The Ultra boiler requires its own vent and air piping, as specified in this manual. This may cause a problem for the appliances that or smoke from a cigarette, cigar, or pipe.

  • Page 30: Air Piping - General

    You must pipe combustion air to the boiler air contamination intake Install air inlet piping for the Ultra boiler as de- The air termination fitting must be installed with the scribed in this manual. clearances and geometry relative to the vent outlet de-...

  • Page 31: Venting/Air Piping - General

    See Figure 34, page 32, and the associated instructions referenced. Failure to provide a properly-in- Each Ultra boiler requires a separate vent. Do not common vent. stalled vent and air system will cause severe personal injury or death.
  • Page 32 Use appropriate adapters where needed — Ultra-80 through -155 require 3.5 inch outside diameter pipe at the boiler vent and air connections. Ultra-230 & -310 boilers require 4.5 inch outside diameter pipe at the boiler vent and air connections. Concentric terminations and the Weil- McLain sidewall plate require 3.5 inch outside diameter pipe.
  • Page 33 Sidewall vent/air termination: Weil-McLain plate Termination kit — Weil-McLain vent/air plate Figure 35 Maximum piping lengths for Weil- McLain sidewall vent/air plate The Weil-McLain sidewall vent/air kit is shipped with each Ultra boiler. Boiler Maximum Maximum Maximum Provide pipe adapters as needed for 2” or 4” plastic piping Ultra–...

  • Page 34: Sidewall Vent/Air Termination: Weil-Mclain Plate

    Figure 39 for U. S. installations. For Canadian installations, provide clearances required by CSA B149.1 or B149.2 Installation Code. The air inlet of an Ultra boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from Figure 39 Termination location —...
  • Page 35 Level the template with a spirit level. For the Weil-McLain plate, the template must be level to ensure the flue and air pipe will be side-to-side, as shown in Figure 40. Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 36 Termination kit — Weil-McLain 3” PVC concentric Figure 42 Maximum piping lengths for Weil- termination McLain 3” PVC concentric termination The Weil-McLain 3” PVC concentric termination kit must be pur- chased separately. See Figure 101, page 93 for part number. Boiler Maximum Maximum Maximum Ultra–...

  • Page 37: Sidewall Vent/Air Termination: 3" Pvc Concentric

    Figure 39 for U. S. installations. For Canadian installations, provide clearances required by CSA B149.1 or B149.2 Installation Code. The air inlet of an Ultra boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from Figure 46 Termination location —...
  • Page 38 — Boiler Manual fired water boiler Sidewall vent/air termination: 3” PVC concentric (continued) Wall penetration — Preferably, use a thimble with a 4½-inch hole. Figure 47 Installing and supporting the concentric If not using a thimble, carefully use a hole saw to cut a hole not sidewall vent assembly larger than 4¾...
  • Page 39 Figure 32, page 31. Purchase termination plates and bird screens separately. See the Boiler Maximum Maximum Maximum parts list at the end of this manual. Ultra– Piping, 2” * Piping, 3” * Piping, 4” * Maximum piping length Feet Elbows...

  • Page 40: Sidewall Vent/Air Termination: Separate Pipes

    48 to complete piping from boiler to termination. Multiple vent/air terminations When terminating multiple Ultra boilers, terminate each vent/air connection as described in this manual. All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death or substantial property damage.

  • Page 41: Prepare Wall Penetrations

    For Canadian installations, provide clearances required by CSA terminations B149.1 or B149.2 Installation Code. The air inlet of an Ultra boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

  • Page 42: Determine Location

    Termination kit — Weil-McLain 3” PVC concentric Figure 55 Maximum piping lengths for Weil- termination McLain 3” PVC concentric termination The Weil-McLain 3” PVC concentric termination kit must be pur- chased separately. See Figure 101, page 93 for part number. Boiler Maximum Maximum Maximum Ultra–...
  • Page 43 The air inlet of an Ultra boiler is part of a direct vent connection. Follow instructions to cover the end of the It is not classified as a forced air intake with regard to spacing from assembly with plastic before inserting through adjacent boiler vents.
  • Page 44 3” PVC concentric (continued) Figure 58 Figure 59 Weil-McLain 3” PVC concentric termination Weil-McLain 3” PVC concentric termination assembly assembly — DO NOT attach the rain cap until the termination has been inserted through the roof and all supports have been installed.

  • Page 45: Vertical Vent/Air Termination: 3" Pvc Concentric

    Vertical vent/air termination: 3” PVC concentric (continued) For each joint: Figure 60 Weil-McLain 3” PVC concentric Handle fittings and pipes carefully to prevent contamination of termination supports surfaces. Apply primer liberally to both joint surfaces — pipe end and fit- ting socket.
  • Page 46 Figure 32, page 31. Purchase bird screens for vent and air terminations separately. See Boiler Maximum Maximum Maximum the parts list at the end of this manual. Ultra– Piping, 2” * Piping, 3” * Piping, 4” * Maximum piping length Feet Elbows...

  • Page 47: Prepare Roof Penetrations

    Figure 63, page 46. Locate the air inlet pipe no further than 2 feet from the center of the vent pipe. This place- The air inlet of an Ultra boiler is part of a direct vent ment avoids recirculation of flue products into the combustion connection.

  • Page 48: Installing Vent And Air Piping

    Ultra-105 may be installed with either 2-inch or 3-inch vent and air piping. Inserting/securing vent or air As shown in the maximum length tables, the Ultra-230 may be pipe into boiler connectors installed with either 3-inch or 4-inch vent and air piping.

  • Page 49: Installation Requirements

    6 inches of any upturn in the • The Weil-McLain plate piping. termination must be installed • The Weil-McLain 3” PVC before piping from the boiler to concentric termination assembly the termination. must be installed before piping • Slope horizontal piping downward from the boiler to the termination.

  • Page 50: Install Condensate Line

    Slide trap line onto flue outlet condensate connection and PVC reducing elbow as shown in Figure 71, page 51 and Fig- ure 72, page 51. (Also see special assembly for Ultra-80 and -105 in step 4. below.) Secure line with hose clamps.
  • Page 51 Condensate from the Ultra boiler will be slightly acidic (typically with a pH from 3.2 to 4.5). Install a neutralizing filter if required by local codes. See Replacement parts section at the end of this manual for the Weil-McLain kit.

  • Page 52: Gas Piping

    When gas line enters from top of the boiler, the boiler internal gas piping provides a drip leg. Ultra boilers are shipped ready to fire natural gas ONLY. (Exception: Ultra-80LP is propane-ready.) You must A ¾” NPT gas piping riser from header to boiler will be install the propane orifice if the boiler will be connected large enough for most jobs.

  • Page 53: Pipe Sizing For Natural Gas

    — Boiler Manual fired water boiler Gas piping (continued) Natural Gas: Figure 75 Common gas line for multiple boilers Pipe sizing for natural gas Size gas piping from meter outlet to entrance of boiler in accordance with Figure 76 and Fig- ure 77.

  • Page 54: Field Wiring

    U-Control will be programmed. Connect minimum 15-ampere, 120 VAC power wiring See this and following pages for more information to Ultra boiler line voltage terminal strip as shown in Connect 120VAC power (minimum 15-amp source) ❏...
  • Page 55 — Boiler Manual fired water boiler Field wiring (see Figure 78 & Figure 79) (continued) Figure 78 Schematic wiring diagram — Ultra-80 through Ultra-310 Part number 550-100-066/0608...
  • Page 56 — Boiler Manual fired water boiler Field wiring (see Figure 78 & Figure 79) (continued) Figure 79 Ladder wiring diagram — Ultra-80 through Ultra-310 Part number 550-100-066/0608...
  • Page 57 (this can be customized for each of the heating systems supplied by the boiler). The U-Control and internal sensors in the Ultra boiler provide both temperature control and low water protection (using default...

  • Page 58: Outdoor Temperature Sensor

    — Boiler Manual fired water boiler Field wiring (see Figure 78 & Figure 79) (continued) Additional limits Outdoor temperature sensor The U-Control allows connection of external limit controls, both for The U-Control provides programmable options manual reset and for automatic reset operation of the U-Control. when using an outdoor temperature sensor.

  • Page 59: U-Control Operation And Setup

    3 (master boiler) starts imme- ❏ Blower speed modulation to control the Ultra boiler’s firing rate. diately and sends 0–10 VDC signal to others Advanced PID response to anticipate system needs based on response ❏...
  • Page 60 — Boiler Manual fired water boiler U-Control operation and setup (continued) Figure 81 U-Control display and navigation Part number 550-100-066/0608...
  • Page 61 ADVANCED SETUP – OVERVIEW Low-temperature systems (radiant slab, etc.) — use the Ultra boiler control as the only means of Access contractor menus by pressing and holding the water temperature regulation for low-temperature sys- UP and DOWN arrow keys for 5 seconds.
  • Page 62 If wired and setup per 6d above, it also starts its additional heat delay timer immediately. When the Type 1 — This means the Ultra boiler is the primary heat delay timing is reached, the U-Control sends out a source.
  • Page 63 — Boiler Manual fired water boiler U-Control operation and setup (continued) Figure 84 U-Control system types and preset parameters System type Display Preset temperatures Note 8-character 3-char Max Target Outdoor Temp Min Target Outdoor Temp Temp for Max Target Temp for Min Target Fan-coil FAN-COIL...
  • Page 64 ADJUST OUTDOOR °F ADD’L HEAT DEMAND TYPE: ########### TYPE 1 — ULTRA = PRIMARY HEAT SOURCE TYPE 2 — ULTRA = BACKUP HEAT SOURCE TYPE 3 — ULTRA = MASTER (0–10V OUTPUT) TYPE 4 — ULTRA = SLAVE (0–10V INPUT) ADD’L HEAT DEMAND...
  • Page 65 — Boiler Manual fired water boiler U-Control operation and setup (continued) Figure 85 U-Control menus, continued (press and hold the UP and DOWN arrow keys for 5 seconds to enter contractor menus) Menus Next screen Next screen Next screen Next screen Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data SET DATE AND TIME SET HR/MIN/DAY/MN/YR...
  • Page 66 Type 2 — Ultra is secondary source, starts primary immediately Type 3 — Boilers operate in parallel, Ultra boiler is master, outputs 0–10 VDC to others Type 4 — Boilers operate in parallel, Ultra boiler is slave, receives 0–10 VDC input Add’l Heat Demand Time...
  • Page 67 — Boiler Manual fired water boiler U-Control operation and setup (continued) Figure 86 U-Control setup options (see Figure 85, page 64 for location in menu sequence), continued Menu/Item Units High Default Comment Value Value Max On Time minutes Longest time boiler will satisfy this system before switching to an active lower priority Min On Time minutes Time boiler will satisfy this system before switching to the next active priority...
  • Page 68 — Boiler Manual fired water boiler U-Control operation and setup (continued) Figure 87 U-Control diagnostic information (see Figure 85, page 64 for location in menu sequence Menu/Item Units High Default Comment Value Value Diagnostics Temperatures Status Text data Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being satisfied, post purge, Warm Weather Shutdown, Trouble System Supply °F...
  • Page 69 — Boiler Manual fired water boiler U-Control operation and setup (continued) Figure 87 U-Control diagnostic information (see Figure 85, page 64 for location in menu sequence), continued Menu/Item Units High Default Comment Value Value Manual Reset yes or none data Choose this to view the details of manual reset lockouts Auto Reset yes or none...

  • Page 70: Startup - Fill The System

    Use only antifreeze recommended by Weil-McLain. Weil-McLain provides information for application of the antifreeze products listed in this docu- ment only for use in Weil-McLain Ultra boilers. Do not apply these products or instructions for other applications. Local codes may require back flow preventer or actual disconnect from city water supply.

  • Page 71: Water Chemistry

    Antifreeze Source Filling with chlorinated fresh water should be ac- ceptable since drinking water chlorine levels are ALPHI-11 Weil-McLain 500 Blaine Street typically less than 5 ppm. Michigan City, IN 46360-2388 Do not use the boiler to directly heat swimming —...
  • Page 72 It is important that the cleaning, treatment and freeze the purge valve and fill connection to the system. protection products used on Ultra aluminum boilers are identified Close zone isolation valves. as being safe and suitable for use in hydronic heating systems. The following companies offer such products.

  • Page 73: Check For Gas Leaks

    — Boiler Manual fired water boiler Startup — final checks Fill the trap with fresh water to within an inch of the Check for gas leaks end of the hose. Replace trap hose on PVC reducing elbow and tighten Before starting the boiler, and during initial opera- the hose clamp.
  • Page 74 Ultra- substantial property damage. < 60 < 60 < 60 < 60 Ultra boilers are shipped ready to fire natural Ultra- gas ONLY. Exception: The Ultra-80LP is factory- < 60 < 60 10.1 equipped to fire propane. You must install the <...
  • Page 75 Allow the boiler to stabilize and take another reading. Continue until the desired CO value is achieved. Consult your local Weil-McLain representative if ac- ceptable results cannot be obtained for both high and If the is LOW, turn the throttle screw COUNTERCLOCK- low fire.
  • Page 76 — Boiler Manual fired water boiler U-Control operation and setup (continued) Figure 90 Operating instructions (WARNING — Verify that the U-Control is set for the correct boiler model before proceeding.) Part number 550-100-066/0608...

  • Page 77: Check-Out/Startup Verification

    ❏ Measured natural gas input? ( page 75) conversion label affixed to jacket? Ultra boilers are shipped ready to fire natural ❏ Checked incoming gas pressure by connecting manometer gas ONLY. Exception: The Ultra-80LP is factory- to gas valve ahead of boiler? (Gas pressure must be at least equipped to fire propane.

  • Page 78: Annual Startup And General Maintenance

    Annual startup and general maintenance Figure 91 Service and maintenance schedules Service technician Owner maintenance (see following pages for instructions) (see Ultra User’s Information Manual for instructions) General: Reported problems Check boiler area Inspect interior; clean and vacuum if Check air openings necessary;...

  • Page 79: Annual Startup

    Annual startup HANDLING CERAMIC FIBER FIRST-YEAR SPECIAL INSPECTION MATERIALS It is recommended that you obtain a Weil-McLain Ultra Boiler Main- REMOVAL OF COMBUSTION tenance kit before attempting the CHAMBER LINING first-year inspection, to ensure all parts that may be needed are avail-...

  • Page 80: Address Reported Problems

    Visually inspect entire flue gas venting system (and air pip- manual and the Ultra Boiler Vent Supplement. ing, if installed) for blockage, deterioration or leakage. Repair any joints that show signs of leakage in accordance with vent manufacturer’s instructions.

  • Page 81: Check Expansion Tank

    — Boiler Manual fired water boiler Annual startup (continued) Inspect ignition electrode Inspect automatic air vents and air separators. Remove air vent caps and briefly press push valve to flush vent. Reinstall caps. Make sure vents do not leak. Replace any leaking vents. Remove the ignition electrode from the boiler heat exchanger access cover.

  • Page 82: Check Burner Flame

    Flame signal shutdown values dure on page 74. Model Shutdown Model Shutdown Ultra – flame signal Ultra – flame signal If flame is unsatisfactory at either high fire or low fire, turn off boiler and allow boiler to cool down. Then remove burner...

  • Page 83: Check Boiler Relief Valve

    — Boiler Manual fired water boiler Annual startup (continued) If flame signal still remains low, inspect the vent and Check boiler relief valve air piping. Then inspect the heat exchanger, follow- ing the procedures given in this manual for removal and reinstallation of the head exchanger cover plate and other boiler components.

  • Page 84: Troubleshooting

    — Boiler Manual fired water boiler Troubleshooting Navigate the U-Control’s Diagnostics menus to check Label all wires prior to disconnection when servic- both lockout and current conditions. ing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to Always check control module fuses boiler before servicing.

  • Page 85: Checking Temperature Sensors

    — Boiler Manual fired water boiler Troubleshooting (continued) U-Control fault indications 3. Figure 95 shows the screen behavior during an auto- matic or manual reset condition. The table below the The U-Control provides information for both automatic reset display illustration lists manual reset conditions and conditions and manual reset conditions.
  • Page 86 — Boiler Manual fired water boiler Troubleshooting (continued) Figure 95 U-Control display toggles when in lockout, with screen flashing red to gray Message displayed Condition causing manual reset / lockout Reset action Manual reset limit open Set if manual reset limit open Reset with manual reset on control Heat exchanger temp high Set if either the heat exchanger outlet or inlet is higher than 200f...
  • Page 87 — Boiler Manual fired water boiler Troubleshooting (continued) Figure 96 Ultra wire harness details ( = factory jumper) Pins Function Wire ID / Color Pin — In Pin — Out Wire ID / Color Pin — In Pin — Out...
  • Page 88 — Boiler Manual fired water boiler Troubleshooting (continued) Figure 96 Ultra wire harness details ( = factory jumper), continued Pins Function Wire ID / Color Pin — In Pin — Out Wire ID / Color Pin — In Pin — Out...

  • Page 89: Maintenance

    Oiled bearing circulators damage. The circulator shipped with the Ultra boiler is water- lubricated. No oiling is required. Install boiler jacket front door after Check other circulators in the system. Oil any circula- startup or servicing tors requiring oil, following circulator manufacturer’s...
  • Page 90 (continued) Accessing & cleaning exchanger: Figure 97 Nut tightening sequence — 80 & 105 Ultra-80 and Ultra-105 Only Gradually tighten the nuts, repeating the sequence shown below until the Close the external manual gas valve. torque reaches 50 inch-pounds (+/- 10 inch-pounds) Disconnect the flexible gas line at its flare fitting.
  • Page 91 You must gradually tighten the cover plate nuts. For Ultra-155 through -310, follow the tightening sequence shown in Figure 99, making two or three passes with a torque wrench. The final torque MUST NOT exceed 50 inch-pounds, +/- 10 inch-pounds.

  • Page 92: Replacement Parts

    Figure 100 Propane conversion kits and instructions The conversion kits listed below are only for use with Ultra Series 3 boilers. For series 1 or series 2 boilers, refer to the boiler manual or contact Weil-McLain for the correct parts.
  • Page 93 Vent termination bird screen (2 required) 3” vent (Ultra-80, -105 & -155) 383-500-105 4” vent (Ultra-230 & -310) 383-500-110 WM - PVC sidewall vent termination kit 3” 383-500-397 4” 383-500-398 Go to www weil-mclain com to locate Weil-McLain distributors Part number 550-100-066/0608...
  • Page 94 Ultra-230, -310, 4” 383-500-160 Top cover, front 383-500-607 Top cover, rear Ultra-80 to -230 383-500-608 Ultra-310 383-500-609 Door Gasket replacement kit (not shown) 383-500-610 Handle (2 required) 383-500-611 Go to www weil-mclain com to locate Weil-McLain distributors Part number 550-100-066/0608...
  • Page 95 — Boiler Manual fired water boiler Replacement parts (continued) Figure 103 Jacket parts Part number 550-100-066/0608...
  • Page 96 — Boiler Manual fired water boiler Replacement parts (continued) Figure 104 Heat exchanger and piping — Ultra-80 and -105 Boiler Item Description Part Number Models Heat exchanger replacement kit - Heat exchanger, cover plate, burner, Ultra-80NG 383-500-612 electrode, water sensors, compression fittings, condensate fitting, gaskets,...
  • Page 97 — Boiler Manual fired water boiler Replacement parts (continued) Figure 105 Heat exchanger and piping — Ultra-80 and -105 Part number 550-100-066/0608...
  • Page 98 1/2” NPT well for temperature gauge 383-500-270 Pressure/temperature gauge check valve 383-500-275 Return water bushing, 1 1/4” BSP x 1” BSP (not use on Ultra-310) Ultra-155/-230 383-500-280 Return water pipe assembly - Pipe, drain valve, cap (assembled) & Ultra-155, -230...
  • Page 99 — Boiler Manual fired water boiler Replacement parts (continued) Figure 107 Heat exchanger and piping — Ultra-155 & -230 Part number 550-100-066/0608...
  • Page 100 Pressure/temperature gauge check valve 383-500-275 Return water pipe assembly - Pipe, drain valve, cap (assembled) & Ultra-310 383-500-385 compression fitting Supply/Return water piping square cut EPDM gasket (Ultra-310 only) Ultra-310 562-248-743 Fitting, double nipple for Ultra-310 supply/return Ultra-310 561-326-828 Boiler drain valve, 3/4” NPT...
  • Page 101 — Boiler Manual fired water boiler Replacement parts (continued) Figure 109 Heat exchanger and piping — Ultra-310 Part number 550-100-066/0608...
  • Page 102 383-500-604 Jumper for low voltage terminal blocks, (5 jumpers) (not shown) 383-500-641 Ultra U-Control terminal block kit, (includes 1 high voltage terminal block, 6 low voltage terminal 383-500-642 blocks, and U-control screwdriver) (not shown) 24-V LWCO kit with quick connect harness (not shown)
  • Page 103 — Boiler Manual fired water boiler Replacement parts (continued) Figure 111 Controls Part number 550-100-066/0608...

  • Page 104: Dimensions

    Dimensional data Notes Boiler supply and return tappings are both 1” NPT (Ultra-80/105/155/230) or 1¼” NPT (Ultra-310). See page 15 for recommended piping sizes. Wall-hung boiler option — water piping and gas pipe can be routed through bottom of enclosure using wall-mounting kit. See page 6 for mounting instructions.

  • Page 105: Ratings - Ultra Boilers

    Use only the vent materials and methods specified in this manual. Ultra-80 and -105 vent/air pipes can be either 2” or 3” pipe. Vent/air pipe length limits for 2” piping are not as long as for 3” piping. Ultra-230 vent/air pipes can be either 3” or 4” pipe. Vent/air pipe length limits for 3” piping are not as long as for 4” piping.

  • Page 106: Ratings - Multiple Ultra Boilers

    — Boiler Manual fired water boiler Ratings — multiple Ultra boilers Figure 114 Ratings and engineering data (see Figure 116 for notes) Foundation size Manifolded Total combustion Boiler Side-to-side Back-to-back Heating water air duct Boilers in system H.P. arrangement arrangement...
  • Page 107 Operating weight is the total weight of the boiler, including water. Ultra-80 and -105 vent/air pipes can be either 2” or 3” pipe. Vent/air pipe length limits for 2” piping are not as long as for 3” piping. Ultra-230 vent/air pipes can be either 3” or 4” pipe. Vent/air pipe length limits for 3” piping are not as long as for 4” piping.
  • Page 108 — Boiler Manual fired water boiler Part number 550-100-066/0608...

This manual is also suitable for:

Ultra-80Ultra-105Ultra-155Ultra-230Ultra-310

Table of Contents