Weil-McLain Ultra 3 series User Manual
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Weil-McLain Ultra 3 series User Manual

Gas-fired water boilers ultra 3 series;
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See also: User's Information Manual
Boiler Manual
Series 3
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 550-100-090/0809

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Summary of Contents for Weil-McLain Ultra 3 series

  • Page 1 ® Gas-fired water boilers – Series 3 Featuring ® Flexibility Boiler Manual • Installation • Maintenance • Startup • Parts Series 3 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: Table Of Contents

    Prepare boiler location Prepare boiler Install water piping Install water piping — typical systems Using with Weil-McLain PLUS water heaters Venting/air piping — general Sidewall vent/air termination: Weil-McLain cap Install vent/air piping — boiler to W-M termination Install condensate line Gas piping Field wiring —...
  • Page 3 This section covers basic installation and start-up for most applications It is limited to conventional systems Pages Procedure and to sidewall vent/air piping using the Weil-McLain termination cap Please read before proceeding For applications not covered in this section, see the •...

  • Page 4: Please Read Before Proceeding

    — Boiler Manual fired water boiler Please read before proceeding Installer— Read all instructions, Failure to adhere to the guidelines on this page can result including this manual and all other in severe personal injury, death or substantial property information shipped with the boiler, damage.

  • Page 5: Prepare Boiler Location

    Hot water pipes — at least ½” from combustible materials. Boilers can be wall mounted ONLY if using the optional Vent pipe — at least C\zn” from combustible materials. wall-mount kit available from Weil-McLain. See page 46 Figure 1 for other clearance minimums. for instructions. Part number 550-100-090/0809...

  • Page 6: Flooring And Foundation

    — Boiler Manual fired water boiler Prepare boiler location (continued) Flooring and foundation Provide air openings to room 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.

  • Page 7: Prepare Boiler

    The Ultra boiler is generally easier to handle and maneuver after Boilers can be wall mounted ONLY if using the optional removing from crate. wall-mount kit available from Weil-McLain. See page 46 for instructions. After removing outer shipping carton from boiler, REMOVE jacket front door by loosening two knurled-head screws at lower front.

  • Page 8: Perform Hydrostatic Pressure Test

    — Boiler Manual fired water boiler Prepare boiler (continued) DO NOT install a relief valve with a pressure higher Figure 2 Hydrostatic test piping connections than 30 PSIG . This is the maximum allowable relief valve setting for the Ultra boiler. Perform hydrostatic pressure test Pressure test boiler before permanently attaching water or gas piping or electrical supply.

  • Page 9: 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 10: System Water Piping Methods

    Figure 3. ing system. For other piping methods, consult your local listed, the head loss in all piping will be 0.04 feet Weil-McLain representative or see separate Ultra boiler per foot of pipe. piping guides. Determine the heating load (Btuh) for each circuit.
  • Page 11 DO NOT use a closed-type expansion tank on a system Ultra-299, 399 1½” with a Weil-McLain PLUS water heater. The water heater must use an automatic air vent. Operation of the auto- See CAUTION at left. matic air vent will deplete air in the piping, causing the expansion tank to waterlog.

  • Page 12: Install Water Piping - Typical Systems

    — Boiler Manual fired water boiler Install water piping — typical systems Zoning with zone valves Figure 5 Zone valve zoning plus optional DHW piping Connect boiler to system as shown in Figure 5 when zone valve zoning. The primary/secondary piping shown ensures the boiler loop will have sufficient flow.
  • Page 13 — Boiler Manual fired water boiler Install water piping — typical systems (continued) Zoning with circulators Figure 6 Circulator zoning plus optional DHW piping Connect boiler to system as shown in Figure 6 when circulator zoning. The boiler circulator cannot be used for a zone. It must supply only the boiler loop.

  • Page 14: Using With Weil-Mclain Plus Water Heaters

    DO NOT use a closed-type expansion tank on a system with a Weil-McLain PLUS water heater. The water heater must use an automatic air vent. Operation of the automatic air vent will deplete air in the piping, causing the expansion tank to The PLUS water heater can also be installed as one waterlog.
  • Page 15 — Boiler Manual fired water boiler Using with Weil-McLain PLUS water heaters (continued) Figure 9 Ultra boiler with Ultra PLUS or PLUS-40, -60 or -80 water heater, zone valve zoning, typical piping System/zone pipe sizing Boiler loop pipe size (Baseboard, convector or cast iron...

  • Page 16: Venting/Air Piping - General

    — Boiler Manual fired water boiler Venting/air piping — general You must pipe combustion air to the Do not install the Ultra boiler into a common vent with boiler air intake any other appliance. This will cause flue gas spillage or ap- Install air inlet piping for the Ultra boiler pliance malfunction, resulting in possible severe personal injury, death or substantial property damage.

  • Page 17: Combustion Air Piping

    — Boiler Manual fired water boiler Venting/air piping — general (continued) Combustion air piping Ultra Boilers must be vented and supplied with combustion Combustion air must be piped from outside to the boiler, following the and ventilation air using piping instructions in this manual, and compliant with all applicable codes.

  • Page 18: Sidewall Vent/Air Termination: Weil-Mclain Cap

    2 elbows if sidewall venting or 1 elbow if vertical venting. Vent and air pipe maximum length Figure 15, page 19 for maximum length of vent and air piping using the Weil-McLain sidewall vent cap. Commonwealth of Massachusetts Other vent/air piping alternatives When the boiler is installed within the Commonwealth of Massa- —...
  • Page 19 Boiler Maximum Maximum Maximum Ultra– Piping, 2” * Piping, 3” * Piping, 4” * Figure 16 Termination location — Weil-McLain vent/air plate — height above grade or snow line Feet Elbows Feet Elbows Feet Elbows 80 ** 105 **...
  • Page 20 Weil-McLain plate (cont.) Avoid possibility of accidental contact of flue products with Figure 17 Termination location — Weil-McLain vent/air people or pets. plate — clearances to openings Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards or other recessed areas.
  • Page 21 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 20. Failure to comply could result in severe personal injury, death or substantial property damage.

  • Page 22: Install Vent/Air Piping - Boiler To W-M Termination

    Deburr inside and outside of pipe ends. the boiler vent connection (and at the termination if using the Weil-McLain plate or the concentric Chamfer outside of each pipe end to ensure even cement termination). Use only the adapter made by the distribution when joining.

  • Page 23: Install Condensate Line

    — Boiler Manual fired water boiler Install condensate line Prepare condensate fittings Figure 24 Condensate trap assembly Remove PVC fittings and gasket from the accessories bag. Deburr and chamfer outside and inside of ½” x 1¼” PVC nipple to ensure even cement distribution when joining. Clean nipple ends and all fittings.
  • Page 24 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. Figure 27...

  • Page 25: Gas Piping

    — Boiler Manual fired water boiler Gas piping Connecting gas supply piping Use two wrenches when tightening gas Remove jacket front panel and refer to Figure 31 to pipe gas to piping at boiler, using one wrench to pre- boiler. vent the boiler gas line connection from Install ground joint union for servicing, when required.

  • Page 26: Field Wiring - Basic System

    — Boiler Manual fired water boiler Field wiring — basic system Make the following connections, some of which depend on your system and how the U-Control will be programmed. ELECTRICAL SHOCK HAZARD — For your safety, turn off electrical power supply at service Connect 120VAC power (minimum 15-amp ❏...
  • Page 27 — Boiler Manual fired water boiler Field wiring — basic system (continued) Figure 32 Simplified wiring — basic system with DHW and space heating (see ADVANCED section for more information) Locate the sensors on the system piping as shown in Figure 4, page 11 and other piping drawings throughout this manual.

  • Page 28: U-Control Operation And Setup

    — Boiler Manual fired water boiler U-Control operation and setup Figure 33 U-Control sequence of operation Temperature settings — You must ensure that the U- Control is set for the proper water temperatures for the Display Control action (also see Figure 34, page 29) system.
  • Page 29 — Boiler Manual fired water boiler U-Control operation and setup (continued) Figure 34 U-Control display and navigation (see Figure 101, page 85) (see Figure 101, page 85) Part number 550-100-090/0809...
  • Page 30 — Boiler Manual fired water boiler U-Control operation and setup (continued) EXPRESS SETUP — using default settings For detailed control information The U-Control is factory programmed to supply a DHW circuit and additional wiring , see the AD- (control priority 1) and finned tube baseboard space heating (control VANCED INSTALLATION section priority 2).

  • Page 31: Startup - Fill The System

    Clean system to remove sediment Antifreeze You must thoroughly flush the system (without boiler Use only antifreeze listed by Weil-McLain as suitable for use connected) to remove sediment. The high-efficiency heat with Ultra Gas Boilers. A list of approved antifreeze products exchanger can be damaged by buildup or corrosion due to is available at www.Weil-McLain.com.
  • Page 32 . Use only water and verify inhibitor concentration. freeze-prevention fluids recommended by Weil-McLain for application in Ultra Boiler systems. Check inhibitor concentration annually Thoroughly flush any system that Test the pH of a sample of system water at least annually. The pH of...

  • Page 33: Startup - Final Checks

    — Boiler Manual fired water boiler Startup — final checks Inspect/fill condensate system Check for gas leaks Inspect/check condensate lines and fittings Before starting the boiler, and during initial opera- tion, use a leak detector or smell near the floor and Inspect the condensate drain line, condensate PVC around the boiler for gas odorant or any unusual fittings and condensate trap.
  • Page 34 — Boiler Manual fired water boiler Startup — final checks (continued) To start the boiler Venting system must be sealed gas-tight to prevent flue gas spillage and carbon Turn OFF the boiler ON/OFF switch. monoxide emissions which will result in Read and follow the Operating Instructions, Fig- severe personal injury or death.
  • Page 35 — Boiler Manual fired water boiler Startup — final checks (continued) Figure 36 Operating instructions (WARNING — Verify that the U-Control is set for the correct boiler model before proceeding ) Part number 550-100-090/0809...
  • Page 36 37 for adjusting the throttle screw on the venturi. If throttle screw adjustment does not correct the problem, then shut down the boiler and contact your local Weil-McLain representative. Throttle screw adjustment must be done only by a qualified Figure 38 Models 155, 230 &...
  • Page 37 Values will typically increase about 0 2% once the door is Restore firing rate to AUTO. reinstalled Consult your local Weil-McLain representative if acceptable results The values above are for altitudes up to 5,500 feet For higher cannot be obtained for both high and low fire.

  • Page 38: Check-Out/Startup Verification

    — Boiler Manual fired water boiler Check-out/startup verification Verified that the U-Control is set for the correct boiler tested for operation as outlined by manufacturer? (Boiler ❏ model? should be operating and should go off when controls are tested. Verify controls cause automatic reset lockout or ❏...
  • Page 39 — Boiler Manual fired water boiler ADVANCED INSTALLATION ADVANCED Quick view . . . INSTALLATION (Pages 39–91) READ AND FOLLOW Pages Procedure INSTRUCTIONS IN THE BASIC INSTALLATION SECTION FIRST This Identify and locate boiler components section is supplemental 40–43 • Read about boiler features and functions.

  • Page 40: The Gas-Fired Water Boiler, Featuring Flexibility

    — Boiler Manual fired water boiler Gas-fired water boiler Featuring Flexibility Models 80, 105, 155 and 230 16. U-Control Module The U-Control Module responds to signals from the room 1. Cast aluminum heat exchanger thermostats, DHW aquastats (when used), boiler sensors (boiler return, boiler supply, system return, system supply, flue 2.
  • Page 41 — Boiler Manual fired water boiler Gas-fired water boiler Featuring Flexibility Part number 550-100-090/0809...
  • Page 42 — Boiler Manual fired water boiler Gas-fired water boiler Featuring Flexibility Models 299 and 399 16. U-Control Module The U-Control Module responds to signals from the room 1. Cast aluminum heat exchanger thermostats, DHW aquastats (when used), boiler sensors (boiler return, boiler supply, system return, system supply, flue temperature, and outdoor temperature, if used).
  • Page 43 — Boiler Manual fired water boiler Gas-fired water boiler Featuring Flexibility Part number 550-100-090/0809...

  • Page 44: Prepare Boiler - Convert For Propane

    — Boiler Manual fired water boiler Prepare boiler — convert for propane Figure 41 Orifice identification Prepare boiler for propane (when required) Propane operation Ultra boilers must be converted for propane operation unless specifically manufactured for propane . Propane-ready boilers have suffix “LP” after the model number.
  • Page 45 — Boiler Manual fired water boiler Prepare boiler — convert for propane (continued) Lift the door away from boiler. Figure 43 Installing propane orifice (Ultra-155, -230, and -299) Remove the air inlet silencer from the adapter: Models 80 and 105: See Figure 121, page 117.

  • Page 46: Placing Boiler - Wall-Mounting Option

    — Boiler Manual fired water boiler Placing boiler — wall-mounting option Wall-mounted boilers (Ultra-80 through -399) Figure 44 Ultra-80 through Ultra-230 only — Install bottom-piping grommets if required The wall-mounting kit is NOT supplied as standard equipment WARNING with the boiler, and must be purchased separately. See below.
  • Page 47 — Boiler Manual fired water boiler Placing boiler — wall-mounting option (continued) Prepare boiler for wall mounting Figure 47 Bottom-piping configuration only (Ultra-80 to -230 only) Remove the jacket front panel. This will simplify lifting and han- dling the boiler when mounting. When piping will be routed out the top of the boiler, no special preparation is needed other than that given in this manual.

  • Page 48: Install Water Piping - Advanced

    — Boiler Manual fired water boiler Install water piping — advanced Zoning with zone valves Figure 48 Zone valve zoning plus optional DHW piping (alternate to piping shown in Figure 5, page 12) High-flow-rate/high-head-loss DHW circuits For applications requiring DHW circuit flow rates higher than al- lowable for the boiler, or for high pressure-drop coil-type DHW tanks, connect the piping as in Figure 48.
  • Page 49 — Boiler Manual fired water boiler Install water piping — advanced (continued) Example system with DHW as a zone, Figure 49 Circulator zoning plus optional DHW piping zoning with circulators Connect boiler to system as shown in Figure 49 when circulator zoning.
  • Page 50 — Boiler Manual fired water boiler Install water piping — advanced (continued) Radiant heating applications Figure 50 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.

  • Page 51: Chilled Water Systems

    — Boiler Manual fired water boiler Install water piping — advanced (continued) Chilled water systems Figure 51 Chilled water system plus optional DHW piping Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler.

  • Page 52: Sizing Direct-Connected Dhw Piping

    The closest circulator selection (from Fig- ure 55, page 53 that can deliver 12 gpm at Weil-McLain PLUS water heaters , refer to the 22.7 feet head is either a Taco 1400/2400-30 (top PLUS water heater manual for application information.
  • Page 53 — Boiler Manual fired water boiler Sizing direct-connected DHW piping (continued) Figure 54 Figure 55 Pipe sizing and head losses for DHW Pump curves for typical circulators suggested for DHW loop applications (H1=Ultra boiler head loss; H2=piping head loss) Flow Temp Pipe B &...

  • Page 54: Multiple Boiler Installations

    — Boiler Manual fired water boiler Multiple boiler installations Placing multiple boilers Figure 56 Side-to-side mounting of multiple Ultra boilers Locate multiple boilers in boiler room according a. Figure 56 (side-to-side), or b. Figure 57 (back-to-back). c. Figure 58 (wall mounting). Provide indicated clearances around boilers for ac- cess and servicing.

  • Page 55: Prepare Boiler Location - Multiple Boilers

    — Boiler Manual fired water boiler Prepare boiler location — multiple boilers Manifolded combustion air option Multiple Ultra boilers can use a common combustion air manifold. Figure 126, page 122 for minimum cross sectional area of combined air ducts. Provide minimum clearance to adjacent vents and grade/snow line as shown in Figure 59.

  • Page 56: Multiple Boiler Water Piping

    — Boiler Manual fired water boiler Multiple boiler water piping Easy-Fit® piping installation Maximum connected load per manifold: Main header and Easy-Fit ® Manifold pipe sizing. 2-inch manifold — 450 MBH New system — See page 10. 3-inch manifold — 1400 MBH Replacing boilers in an existing system —...
  • Page 57 Multiple boiler water piping (continued) Figure 62 Piping schematic — typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit manifolds Legend — Figure 62 1 Flow/check valve (each boiler) 11 Check valve or backflow preventer, as required by applicable codes...
  • Page 58 Multiple boiler water piping (continued) Figure 63 Piping layout — typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit manifolds (2-boiler system) Legend — Figure 63 1 Flow/check valve (each boiler) 18 System supply 2 Isolation valves (when used)
  • Page 59 140 – 290 gpm 4” Legend — Figure 64 Flow/check valve (each boiler) Indirect-fired storage water heaters (Weil-McLain PLUS Line shown) — Example is This piping is sug- shown with reverse-return boiler-side piping using a single circulator. Alternate: each gested only. The Isolation valves (when used) water heater could have its own circulator.
  • Page 60 — Boiler Manual fired water boiler Multiple boiler water piping (continued) Figure 65 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. 2.

  • Page 61: Venting/Air Piping - Massachusetts Installations

    — Boiler Manual fired water boiler Venting/air piping — Massachusetts installations Instructions for the Commonwealth of Massachusetts (a) For all sidewall horizontally-vented gas-fueled equipment signage installed in accordance with the provisions of installed in every dwelling, building or structure used in 248 CMR 5.08(2)(a) 1 through 4.

  • Page 62: Vent/Air Piping - Options

    Sidewall options (see Figure 67, left side): TOP: Weil-McLain termination cap (kit included with boiler) — see page 18 for instructions. Weil-McLain sidewall MIDDLE: Concentric PVC pipe (requires special kit, termination plate page 113).

  • Page 63: Sidewall Vent/Air Termination: 3" Pvc Concentric

    Termination kit — Weil-McLain 3” PVC concentric Figure 68 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 117, page 113 for part number. Boiler Maximum...
  • Page 64 3” PVC concentric (cont.) Locate the vent/air terminations using the following guidelines. Figure 70 Termination location — Weil-McLain vent/air plate — clearances to openings You must consider the surroundings when terminating the vent and air: Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.
  • Page 65 — Boiler Manual fired water boiler Sidewall vent/air termination: 3” PVC concentric (cont.) Install terminations — concentric pipes Figure 73 Installing and supporting the concentric sidewall vent assembly Assemble the vent termination as described for vertical concentric terminations, beginning on page 70. If necessary, you can shorten the lengths of the inner and outer pipes for a shorter finished assembly.

  • Page 66: Sidewall Vent/Air Termination: Separate Pipes

    — Boiler Manual fired water boiler Sidewall vent/air termination: Separate pipes Allowable vent/air pipe materials Figure 74 Maximum piping lengths for separate vent and air pipe sidewall termination Use only the materials listed in Figure 12, page 17. Purchase termination plates and bird screens separately. See the Boiler Maximum Maximum...
  • Page 67 — Boiler Manual fired water boiler Sidewall vent/air termination: Separate pipes (continued) You must consider the surroundings when terminating the vent Figure 76 Sidewall termination with separate pipes — and air: clearances to openings Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

  • Page 68: Termination And Fittings

    — Boiler Manual fired water boiler Sidewall vent/air termination: Separate pipes (continued) Place wall penetrations to obtain minimum clearance of 12 inches Figure 79 Multiple terminations — separate pipes — between vent pipe and adjacent air inlet elbow, as shown in Fig- clearance from vent of one to air intake of the ure 78, page 67 for U.

  • Page 69: Vertical Vent/Air Termination: 3" Pvc Concentric

    3” PVC concentric Termination kit — Weil-McLain 3” PVC concentric Figure 81 Maximum piping lengths for Weil- termination McLain 3” PVC concentric termination The Weil-McLain 3” PVC concentric termination kit must be pur- Boiler Maximum Maximum Maximum chased separately. See Figure 117, page 113 for part number.
  • Page 70 Vertical vent/air termination: 3” PVC concentric (continued) Maintain clearances to termination as given below: Figure 83 Vertical termination — Weil-McLain 3” PVC concentric — multiple boilers Vent outlet must be located: • At least 6 feet from adjacent walls. •...
  • Page 71 3” PVC concentric (continued) Figure 84 Figure 85 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 72 Vertical vent/air termination: 3” PVC concentric (continued) For each joint: Figure 86 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 73: Vertical Vent/Air Termination: Separate Pipes

    — Boiler Manual fired water boiler Vertical vent/air termination: Separate pipes Allowable vent/air pipe materials Figure 88 Maximum piping lengths for separate vent and air pipe vertical termination Use only the materials listed in Figure 12, page 17. Purchase bird screens for vent and air terminations separately. See Boiler Maximum Maximum...

  • Page 74: Prepare Roof Penetrations

    — Boiler Manual fired water boiler Vertical vent/air termination: Separate pipes (continued) Maintain clearances to vent termination as given below: Figure 90 Termination location — separate pipes — Vent must terminate: terminations for multiple boilers • At least 6 feet from adjacent walls. •...

  • Page 75: Install Vent/Air Piping - Boiler To Termination

    Figure 91 for attaching vent and air pipes at the boiler. vent connection (and at the termination Cut pipe to required lengths. if using the Weil-McLain plate or the concentric termination). Use only the Deburr inside and outside of pipe ends.

  • Page 76: 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 77: Gas Piping - Sizing Gas Lines

    — Boiler Manual fired water boiler Gas piping — sizing gas lines Natural Gas: Figure 94 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 95 and Figure 96. Use total input of all boilers.

  • Page 78: Field Wiring - Advanced

    — Boiler Manual fired water boiler Field wiring — advanced ondary heat source when another heat source, such ELECTRICAL SHOCK HAZARD — For your as a heat pump or another boiler is available. safety, turn off electrical power supply at service Connect to remote alarm, when used ❏...
  • Page 79 DHW and “heat demand 2” to be space heating. For factory default operation: When possible, use the Weil-McLain Ultra low water cut-off kit Connect the space heating thermostat to terminal listed in the back of this manual. It includes a probe-type low water strip P15, terminals 1 and 2 to use the default cut-off and provides a simple harness connection for the wiring.
  • Page 80 — Boiler Manual fired water boiler Field wiring — advanced (see Figure 98 & Figure 99) (continued) Figure 98 Schematic wiring diagram — Ultra-80 through Ultra-299 Part number 550-100-090/0809...
  • Page 81 — Boiler Manual fired water boiler Field wiring — advanced (see Figure 98 & Figure 99) (continued) Figure 99 Ladder wiring diagram — Ultra-80 through Ultra-299 Part number 550-100-090/0809...

  • Page 82: Outdoor Temperature Sensor

    — Boiler Manual fired water boiler Field wiring — advanced (see Figure 98 & Figure 99) (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 83: U-Control Operation And Setup - Advanced

    — Boiler Manual fired water boiler U-Control operation and setup — advanced Low-temperature systems (radiant The outdoor sensor must be installed to use this slab, etc.) — DO NOT use the Ultra boiler function. control as the only means of water tem- ADJUST OUTDOOR perature regulation for low-temperature systems if higher-temperature systems...
  • Page 84 — Boiler Manual fired water boiler U-Control operation and setup — advanced (continued) ADVANCED SETUP – Connect these output terminals to the SHADOW boilers’ 0–10 VDC input termi- SYSTEM TYPE nals, P15 #5 and #6. The SHADOW boilers For each priority being used, select the appropriate will start and modulate based on the signal system type.
  • Page 85 — Boiler Manual fired water boiler U-Control operation and setup — advanced (continued) Figure 101 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...
  • Page 86 — Boiler Manual fired water boiler U-Control operation and setup — advanced (continued) Figure 102 U-Control menus (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 BOILER SETTINGS...
  • Page 87 — Boiler Manual fired water boiler U-Control operation and setup — advanced (continued) Figure 102 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...
  • Page 88 — Boiler Manual fired water boiler U-Control operation and setup — advanced (continued) Figure 103 U-Control setup options (see Figure 102, page 86 for location in menu sequence) Menu/Item Units High Default Comment Value Value Boiler Settings Boiler Model 80, 105, 155, factory THIS MUST BE SET CORRECTLY FOR SAFE OPERATION .
  • Page 89 — Boiler Manual fired water boiler U-Control operation and setup — advanced (continued) Figure 103 U-Control setup options (see Figure 102, page 86 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...
  • Page 90 — Boiler Manual fired water boiler U-Control operation and setup — advanced (continued) Figure 104 U-Control diagnostic information (see Figure 102, page 86 for location in menu sequence Menu/Item Units High Default Comment Value Value Diagnostics Temperatures Status Text data Current operating status of the boiler.
  • Page 91 — Boiler Manual fired water boiler U-Control operation and setup — advanced (continued) Figure 104 U-Control diagnostic information (see Figure 102, page 86 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...

  • Page 92: Annual Startup And General Maintenance

    — Boiler Manual fired water boiler Annual startup and general maintenance Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.

  • Page 93: Annual Startup

    Annual startup HANDLING CERAMIC FIBER FIRST-YEAR SPECIAL INSPECTION MATERIALS It is recommended that you obtain a Weil-McLain REMOVING BURNER GASKET or Ultra Boiler Maintenance kit before attempting the first-year inspection, to ensure all parts that COVER PLATE INSULATION may be needed are available .

  • Page 94: Address Reported Problems

    — Boiler Manual fired water boiler Annual startup (continued) Clean condensate trap The boiler should be inspected and Loosen condensate trap line hose clamps and remove trap started annually, at the beginning of line. the heating season, only by a qualified Empty water from trap line and inspect.

  • Page 95: 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 96: Check Burner Flame

    — Boiler Manual fired water boiler Annual startup (continued) Check burner flame Check flame signal Navigate to Diagnostics/Inputs on the U-Control display (see The boiler contains ceramic fiber materials. Use care when handling these materials per Figure 102, page 86). The flame signal value must be at least 20 instructions on page 93 of this manual.

  • Page 97: Check Flue Gas Temperature

    — Boiler Manual fired water boiler Annual startup (continued) If flame signal still remains low, inspect the vent and air Set the firing rate to MEDIUM (ignition rate). piping. Then inspect the heat exchanger, following the pro- Write down the blower RPM value. It should be within 200 cedures given in this manual for removal and reinstallation RPM of the value listed in Figure 108.

  • Page 98: Check Boiler Relief Valve

    — Boiler Manual fired water boiler Annual startup (continued) Check boiler relief valve Inspect the relief valve and lift the lever to verify flow as in the following warnings, excerpted from a relief valve manufac- turer’s warning label. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential.

  • Page 99: Troubleshooting

    — Boiler Manual fired water boiler Troubleshooting VERIFY PROPER OPERATION AFTER SERVICING. VERIFY PROPER OPERATION AFTER SERVICING. Reinstall boiler jacket front door Before servicing and making connections . . . Reinstall boiler jacket front door after ALWAYS TURN POWER OFF TO THE BOILER TO servicing.

  • Page 100: Checking Temperature Sensors

    — Boiler Manual fired water boiler Troubleshooting (continued) Check the following: Do not jumper fuse or replace with any fuse except as specified. Failure to comply Make sure thermostat is calling for heat and con- could result in severe personal injury, tacts (including appropriate zone controls) are death or substantial property damage.
  • Page 101 — Boiler Manual fired water boiler Troubleshooting (continued) Make sure to determine the causes of outages. Do not leave the boiler operating without a complete diagnosis. U-Control fault indications The U-Control provides diagnostic information for below the display illustration lists manual reset conditions and how both automatic reset conditions and manual reset to reset from them.
  • Page 102 — Boiler Manual fired water boiler Troubleshooting (continued) Figure 112 Troubleshooting suggestions for Ultra boilers U-Control Error Condition Log The U-control is able to record information about the boiler’s condition at the time of the three previous faults or errors. This information is available to view in Contractor Menus under “DIAGNOSTICS”...
  • Page 103 — Boiler Manual fired water boiler Troubleshooting (continued) Figure 112 Troubleshooting suggestions for Ultra boilers (continued) Condition Diagnostics Corrective Action(s) Display Control is not receiving 120V Check service switch and/or Turn on service switch to power boiler. Nothing power circuit breaker to boiler turned is shown is on.
  • Page 104 Manual reset is required if the Inspect vent system for abnormal wear or damage. temperature rises above 225°F. Reset using manual reset screen Contact Weil-McLain Technical Support. on display Occurs when dual Automatically resets when Follow procedure for above for SHORT and OPEN sensor conditions temperature sensors values sensors are within 10ºF.
  • Page 105 — Boiler Manual fired water boiler Troubleshooting Troubleshooting (continued) (continued) Figure 112 Troubleshooting suggestions for Ultra boilers (continued) Condition Diagnostics Corrective Action(s) Display Occurs when display Automatically resets when Check for a loose connection at the molex plug on the control and DISPLAY COMM communications out for 30 communication is re-...
  • Page 106 — Boiler Manual fired water boiler Troubleshooting (continued) Figure 112 Troubleshooting suggestions for Ultra boilers (continued) Condition Diagnostics Corrective Action(s) Display Blower unable to reach Reset using manual reset screen Check wire harness for loose connections and pin engagement at blower BLOWER FAULT required speed or does not on display...
  • Page 107 — Boiler Manual fired water boiler Troubleshooting (continued) Figure 112 Troubleshooting suggestions for Ultra boilers (continued) Condition Diagnostics Corrective Action(s) Display The U-Control has detected Reset using manual reset screen Check wire harness connections between gas valve and U-Control. GAS VALVE a problem with it gas valve on display FAULT...
  • Page 108 — Boiler Manual fired water boiler Ultra Gas Boiler Data Collection Sheet Customer Info: Maintenance Info: Contact: Name: Contractor: Phone: Job name: Model: City, state: CP#: Distributor: Installed: System Components: Boiler/System Piping Details (Please Sketch) Near boiler pipe size: Please note the placement of system sensors Boiler circulator model: DHW tank (yes/no): DHW direct/system:...

  • Page 109: Maintenance

    — Boiler Manual fired water boiler Maintenance Cleaning the heat exchanger — pin Disconnect power side when required Electrical shock hazard — Disconnect all electrical The boiler contains ceramic fiber materials. power to the boiler before attempting maintenance Use care when handling these materials per instructions on page 93 of this manual.
  • Page 110 — Boiler Manual fired water boiler Maintenance (continued) Accessing & cleaning exchanger: Figure 113 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 Disconnect the flexible gas line at its flare fitting.
  • Page 111 — Boiler Manual fired water boiler Maintenance (continued) Accessing & cleaning exchanger: Ultra-155, Figure 115 Nut tightening sequence — -230, 299 and -399 Only 155 to 399 — Gradually tighten the nuts, repeating the sequence shown Close the external manual gas valve. below until the torque reaches 50 Disconnect wiring: •...

  • Page 112: Replacement Parts

    Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation. Weil-McLain part numbers are found in Weil-McLain Boilers and Controls Repair Parts Lists. The boiler contains ceramic fiber materials .
  • Page 113 4” vent (Ultra-230/299/399) 383-500-110 Weil-McLain sidewall vent/air cap termination kit — Includes W-M sidewall vent/air termination cap, inside and outside cover plates, and mounting hardware; openings are sized for PVC pipe. (3” is shipped with Ultra-80 – 155; 4” is shipped with Ultra-230 – 399) 3”...
  • Page 114 299/399 383-500-609 Air adapter kit (Includes adapter, 3” 80/105 383-500-655 Door Gasket replacement kit (not shown) 383-500-610 gasket and mounting bracket) 3” 383-500-145 10 Handle (2 required) 383-500-611 4” 230–399 383-500-150 Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-100-090/0809...
  • Page 115 Ultra U-Control terminal block kit, (includes 1 high voltage 383-500-642 terminal block, 6 low voltage terminal blocks, and U-Control screwdriver) (not shown) 24-V LWCO kit with quick connect harness (not shown) 511-100-005 Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-100-090/0809...
  • Page 116 — Boiler Manual fired water boiler Replacement parts (continued) Figure 120 Heat exchanger and piping — Ultra-80 and -105 Boiler Item Description Part Number Models Heat exchanger replacement kit - Heat exchanger, cover plate, burner, 80NG 383-500-612 electrode, water sensors, compression fittings, condensate fitting, gaskets, 80LP 383-500-613 and hardware...
  • Page 117 — Boiler Manual fired water boiler Replacement parts (continued) Figure 121 Heat exchanger and piping — Ultra-80 and -105 Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-100-090/0809...
  • Page 118 28 Burner replacement kit - Burner, gaskets and 383-500-085 hardware 383-500-090 17 Blower assembly kit - Blower, gasket, and 383-500-035 29 Return/supply sensor kit - (1) sensor 383-500-602 hardware 383-500-040 Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-100-090/0809...
  • Page 119 — Boiler Manual fired water boiler Replacement parts (continued) Figure 123 Heat exchanger and piping Ultra-299 & -399 Boiler Part Boiler Part Description Description models number models number Heat exchanger replacement kit - Heat 299/399 383-500-623 20 Gas pipe lower clamp and hardware 383-500-625 exchanger, cover plate, burner, electrode, water 21 Gas valve/venturi kit - Gas valve, venturi,...

  • Page 120: Dimensions

    — Boiler Manual fired water boiler Dimensions Figure 124 Dimensional data Notes Boiler supply and return tappings are both 1” NPT (Ultra-80/105/155/230) or 1¼” NPT (Ultra-299). See page 10 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 5 for mounting instructions.

  • Page 121: Ratings - Ultra Boilers

    Ultra-399 Notes As an Energy Star Partner, Weil-McLain has determined that Ultra boilers meet the Energy Star guidelines for energy efficiency. NOTE: Adjusting boiler firing rate will affect AFUE rating. Based on standard test procedures prescribed by the United States Department of Energy.

  • Page 122: Ratings - Multiple Ultra Boilers

    — Boiler Manual fired water boiler Ratings — multiple Ultra boilers Figure 126 Ratings and engineering data (see Figure 128 for notes) Manifolded Foundation size Total Boiler combustion Side-to-side Back-to-back Heating water Boilers in system H.P. air duct arrangement arrangement input capacity ratings...
  • Page 123 Based on standard test procedures outlined by DOE for individual boilers. Net I=B=R ratings are based on piping and pickup allowance of 1.15. Consult Weil-McLain Technical Services for other allowances. Foundation sizes in Figure 126 provide 6 inches between boilers and 2 inches from boiler to edge of foundation.

  • Page 124: Installation And Service Certificate

    — Boiler Manual — Boiler Manual fired water boiler fired water boiler Installation and Service Certificate Boiler Model Series CP Number Date Installed BTU Input ❏ Installation instructions have been followed. ❏ Check-out sequence has been performed. ❏ Above information is certified to be correct. ❏...

This manual is also suitable for:

Ultra 80Ultra 105Ultra 155Ultra 230ж ultra 299Ultra 399Plus 60 ... Show all

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