Weil-McLain ULTRA299-S4 Manual
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Weil-McLain ULTRA299-S4 Manual

Gas-fired water boilers
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Gas-fi red water boilers – Series 4
Featuring
®
Flexibility
Boiler Manual
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This manual must only be used by a qualifi ed 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.
Part number 550-100-400/0717

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  • Page 1 ® Gas-fi red water boilers – Series 4 Featuring ® Flexibility Boiler Manual ® This manual must only be used by a qualifi ed 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

    Install water piping ......9 Using with Weil-McLain AQUA PLUS water heaters ..14 Venting/air piping —...
  • Page 3 This section covers basic installation and start-up for most applications. It is limited to Pages conventional systems and to sidewall vent/air piping using the Weil-McLain termination cap. For applications not covered in this section, see the ADVANCED INSTALLATION section. 5–6 7–8...

  • Page 4: Please Read Before Proceeding

    See the instructions contact with water, replace the boiler with a new Weil-McLain boiler. at right. Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.

  • Page 5: Prepare Boiler Location

    2. Boilers can be wall mounted ONLY if using the optional 2. Vent pipe — at least ” from combustible materials. 3/16 wall-mount kit available from Weil-McLain. See page 50 3. See Figure 1 for other clearance minimums. for instructions. Part number 550-100-400/0717...
  • Page 6 — Boiler Manual ® ERIES FIRED WATER BOILER Prepare boiler location (continued) Flooring and foundation Provide air openings to room Air openings — Ultra boiler alone in boiler Flooring room 1. The Ultra boiler is approved for installation on combustible fl oor- 1.

  • Page 7: Prepare Boiler

    1. The Ultra boiler is generally easier to handle and maneuver after removing from crate. 1. Boilers can be wall mounted ONLY if using the optional wall-mount kit available from Weil-McLain. See page 50 2. After removing outer shipping carton from boiler, REMOVE jacket for instructions.
  • Page 8 — Boiler Manual ® ERIES FIRED WATER BOILER Prepare boiler (continued) Hydrostatic test piping connections . 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

    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. 4. Purchase low water cutoff and install in a tee in the supply piping above boiler.
  • Page 10 Figure 3 . ing system. For other piping methods, consult your local Weil-McLain representative or see separate Ultra boiler piping guides. a. Determine the heating load (Btuh) for each circuit.
  • Page 11 DO NOT use a closed-type expansion tank on a system 1¼” Ultra-299/310, 1½” with a Weil-McLain AQUA PLUS water heater. The water heater must use an automatic air vent. Operation of the See CAUTION at left. automatic air vent will deplete air in the piping, causing the expansion tank to waterlog.
  • Page 12 — Boiler Manual ® ERIES FIRED WATER BOILER Install water piping — typical systems Zoning with zone valves Zone valve zoning plus optional DHW piping 1. Connect boiler to system as shown in Figure 5 when zone valve zoning. The primary/secondary piping shown ensures the boiler loop will have suffi...
  • Page 13 — Boiler Manual ® ERIES FIRED WATER BOILER Install water piping — typical systems (continued) Zoning with circulators Circulator zoning plus optional DHW piping 1. 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 Aqua Plus Water Heaters

    (optional timeout setting can be used to override). DO NOT use a closed-type expansion tank on a system with a Weil-McLain AQUA 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 waterlog.
  • Page 15 ® ERIES FIRED WATER BOILER Using with Weil-McLain AQUA PLUS water heaters (cont.) - Product Manual for typical water piping. Ultra boiler with Ultra PLUS or AQUA PLUS-40, -60 or -80 water heater, zone valve zoning, typical piping Ultra-80, -105 1”...

  • Page 16: Venting/Air Piping - General

    — Boiler Manual ® ERIES FIRED WATER BOILER Venting/air piping — general Do not install the Ultra boiler into a common vent with any other appliance. This will cause fl ue gas spillage or ap- — Install air inlet piping for the Ultra pliance malfunction, resulting in possible severe personal boiler as described in the Boiler manual and this ad- injury, death or substantial property damage.
  • Page 17 — Boiler Manual ® ERIES FIRED WATER BOILER Venting/air piping — general (continued) Combustion air piping 1. Combustion air must be piped from outside to the boiler, following the instructions in this manual, and compliant with all applicable codes. Read the warning in Figure 11, page 16, and ensure the air intake will not be likely to draw in con- taminated air.
  • Page 18 System 636. When using IPEX kits, use only IPEX product code 196006 for 3” venting or IPEX product code 196021 for 4” Note 1: venting. Contact Weil-McLain for ordering information and availability of Weil-McLain venting kits. Polypropylene - Separate pipe and concentric termination by respective manufacturers. a — Use 3”x2” reducer at boiler c —...
  • Page 19 AL29-4C vent piping — Install a PVC-to-stainless adapter supplied by the vent pipe manufacturer at the boiler vent connection and at the termination (when using Weil-McLain plate or concentric PVC termination). DO NOT mix piping from different vent pipe manufacturers unless using adapters specifi cally designed for the purpose by the manufacturer.

  • Page 20: Sidewall Vent/Air Termination: Separate Pipes

    Allowable vent/air pipe materials 1. Use only the materials listed in Figure 13, page 19 . 2. The Weil-McLain vent termination kit includes inside and outside wall plates, bird screens, and mounting hardware to secure the plates (kit included with boiler).
  • Page 21 — Boiler Manual ® ERIES FIRED WATER BOILER Sidewall vent/air termination: Separate pipes (continued) 4. You must consider the surroundings when terminating the vent Sidewall termination with separate pipes — and air: clearances to openings a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.
  • Page 22 — Boiler Manual ® ERIES FIRED WATER BOILER Sidewall vent/air termination: Separate pipes (continued) Multiple vent/air terminations Multiple terminations — separate pipes — clearance from vent of one to air intake of the 1. When terminating multiple Ultra boilers, terminate each vent/air next —...
  • Page 23 — Boiler Manual ® ERIES FIRED WATER BOILER Vertical vent/air termination: Separate pipes Allowable vent/air pipe materials 1. Use only the materials listed in Figure 13, page 19 . 2. Purchase bird screens for vent and air terminations separately. See the parts list at the end of this manual. Maximum piping length Feet Elbows...
  • Page 24 — Boiler Manual ® ERIES FIRED WATER BOILER Vertical vent/air termination: Separate pipes (continued) 5. Maintain clearances to vent termination as given below: Termination location — separate pipes — a. Vent must terminate: terminations for multiple boilers At least 6 feet from adjacent walls. No closer than 5 feet below roof overhang.

  • Page 25: Direct Vent

    — Boiler Manual ® ERIES FIRED WATER BOILER DIRECT VENT DIRECT VENT DIRECT VENT DIRECT VENT DIRECT VENT VERTICAL vent and SIDEWALL termination VERTICAL termination SIDEWALL air Install the boiler. Determine the termination method — sidewall or vertical, concentric or separate pipes, etc. Determine proper location for wall or roof penetration for each termination.
  • Page 26 — Boiler Manual ® ERIES FIRED WATER BOILER DIRECT EXHAUST DIRECT EXHAUST DIRECT EXHAUST DIRECT EXHAUST Sidewall termination Vertical termination Install the boiler. Determine the proper location for roof or wall penetration for each termination. Prepare roof penetrations before installing vent piping. Finish by attaching external pipe and fi...

  • Page 27: Install Condensate Line

    — Boiler Manual ® ERIES FIRED WATER BOILER Install condensate line Prepare condensate fi ttings Condensate trap assembly 1. Remove PVC fi ttings and gasket from the accessories bag. 2. Deburr and chamfer outside and inside of ½” x 1¼” PVC nipple to ensure even cement distribution when joining.
  • Page 28 (typically with a pH from 3.2 to 4.5). Install a neutralizing fi lter if required by local codes. See Replacement parts section at the end of this manual for the Weil-McLain kit. Suggested condensate pump capacity, GPH Condensate pump (by others), typical...

  • Page 29: Gas Piping

    — Boiler Manual ® ERIES FIRED WATER BOILER Gas piping Connecting gas supply piping Use two wrenches when tightening gas 1. Remove jacket front panel and refer to Figure 33 to pipe gas to piping at boiler, using one wrench to pre- boiler.

  • Page 30: Field Wiring - Basic System

    — Boiler Manual ® ERIES FIRED WATER BOILER Field wiring — basic system Wiring must be N.E.C. Class 1. If original wiring — For your as supplied with boiler must be replaced, use only safety, turn off electrical power supply at service type 105 °C wire or equivalent.
  • Page 31 — Boiler Manual ® ERIES FIRED WATER BOILER Field wiring — basic system (continued) Simplifi ed 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 32: U-Control Operation And Setup

    — Boiler Manual ® ERIES FIRED WATER BOILER U-Control operation and setup U-Control sequence of operation — You must ensure that the U- Control is set for the proper water temperatures for the (also see Figure 36, page 33 ) system.
  • Page 33 — Boiler Manual ® ERIES FIRED WATER BOILER U-Control operation and setup (continued) U-Control display and navigation (see Figure 114, page 101 ) (see Figure 114, page 101 ) Part number 550-100-400/0717...
  • Page 34 — Boiler Manual ® ERIES FIRED WATER BOILER U-Control operation and setup (continued) EXPRESS SETUP — using default settings 1. The U-Control is factory programmed to supply a DHW circuit (control , see the priority 1) and fi nned tube baseboard space heating (control priority 2). ADVANCED INSTALLATION 2.

  • Page 35: Startup - Fi Ll The System

    Antif reeze 1. You must thoroughly flush the system (without boiler 1. Use only antifreeze listed by Weil-McLain as suitable for use connected) to remove sediment. The high-effi ciency 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 36 . Use only water and verify inhibitor concentration. freeze-prevention fl uids recommended by Weil-McLain for application in Ultra Boiler systems. Check inhibitor concentration annually 1. Test the pH of a sample of system water at least annually. The pH of before installing the the water mixture must be between 7.0 and 8.5.

  • Page 37: Startup - Fi Nal Checks

    — Boiler Manual ® ERIES FIRED WATER BOILER Startup — fi nal checks Inspect/fi ll condensate system Check for gas leaks Inspect/check condensate lines and fi ttings Before starting the boiler, and during ini- 1. Inspect the condensate drain line, condensate PVC fi ttings tial operation, use a leak detector or smell and condensate trap.
  • Page 38 — Boiler Manual ® ERIES FIRED WATER BOILER Startup — fi nal checks (continued) ❏ To start the boiler Check gas piping 1. Turn OFF the boiler ON/OFF switch. 1. Check around the boiler for gas odor following the proce- 2.
  • Page 39 — Boiler Manual ® ERIES FIRED WATER BOILER Startup — fi nal checks (continued) Operating instructions (WARNING — Verify that the U-Control is set for the correct boiler model before proceeding.) Part number 550-100-400/0717...
  • Page 40 41 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 qualifi ed technician, using calibrated test instruments. Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 41 The values above are for altitudes up to 5,500 feet. For higher altitudes, CO may be slightly lower and CO slightly higher. 6. Consult your local Weil-McLain representative if acceptable results cannot be obtained for both high and low fi re. Part number 550-100-400/0717...

  • Page 42: Check-Out/Startup Verifi Cation

    Burner fl ame and combustion verifi ed per page 40 ? ❏ Fill out the warranty registration card and send to ❏ Verifi ed control operation for space heating and DHW (if Weil-McLain. used) per this manual? ❏ ❏ Tested additional fi eld-installed controls? — If boiler has...
  • Page 43 — Boiler Manual ® ERIES FIRED WATER BOILER Quick view . . . READ AND FOLLOW Pages INSTRUCTIONS IN THE BASIC INSTALLATION SECTION FIRST. This 44 –47 section is supplemental information only. This section covers 48–49 multiple boiler systems and system types not covered under the BASIC section.

  • Page 44: The Gas-Fi Red Water Boiler, Featuring Flexibility

    — Boiler Manual ® ERIES FIRED WATER BOILER Gas-fi red water boiler Featuring Flexibility Ultra Models -80, -105 , -155 and -230 15. U-Control 1. Cast aluminum Nanogate coated heat exchanger The U-Control Module responds to signals from the room ther- 2.
  • Page 45 — Boiler Manual ® ERIES FIRED WATER BOILER Gas-fi red water boiler Featuring Flexibility Part number 550-100-400/0717...
  • Page 46 — Boiler Manual ® ERIES FIRED WATER BOILER Gas-fi red water boiler Featuring Flexibility Ultra Models -299/310 and -399 15. U-Control 1. Cast aluminum Nanogate coated heat exchanger The U-Control responds to signals from the room ther- Module 2. Heat exchanger access cover mostats, DHW aquastats (when used), boiler sensors (boiler return, boiler supply, system return, system supply, fl...
  • Page 47 — Boiler Manual ® ERIES FIRED WATER BOILER Gas-fi red water boiler Featuring Flexibility Part number 550-100-400/0717...

  • Page 48: Prepare Boiler - Convert For Propane

    — Boiler Manual ® ERIES FIRED WATER BOILER Prepare boiler — convert for propane Installing propane orifi ce Prepa re boiler for propane — You must turn (when required) off electrical supply to the boiler and close the external manual gas shut-off valve to isolate the Propane operation boiler during conversion.
  • Page 49 — Boiler Manual ® ERIES FIRED WATER BOILER Prepare boiler — convert for propane (continued) 4. Lift the door away from boiler. Installing propane orifi ce (Ultra-155, -230, & -299/310) 5. Remove the air inlet silencer from the adapter: a. Models 80 and 105: See Figure 134, page 133 . b.

  • Page 50: Placing Boiler - Wall-Mounting Option

    — Boiler Manual ® ERIES FIRED WATER BOILER Placing boiler — wall-mounting option Wall-mounted boilers (Ultra-80 through -399) Install wall-mount bracket 1. The wall-mounting kit is NOT supplied as standard equipment with the boiler, and must be purchased separately. See below.
  • Page 51 — Boiler Manual ® ERIES FIRED WATER BOILER Placing boiler — wall-mounting option (continued) Prepare boiler for wall mounting 1. Remove the jacket front panel. This will simplify lifting and han- dling the boiler when mounting. 2. When piping will be routed out the top of the boiler, no special preparation is needed other than that given in this manual.

  • Page 52: Install Water Piping - Advanced

    — Boiler Manual ® ERIES FIRED WATER BOILER Install water piping — advanced Zoning with zone valves Zone valve zoning plus optional DHW piping (alternate to piping shown in Figure 5, page 12 ) High-fl ow-rate/high-head-loss DHW circuits 1. For applications requiring DHW circuit fl ow rates higher than allowable for the boiler, or for high pressure-drop coil-type DHW tanks, connect the piping as in Figure 48 .
  • Page 53 — Boiler Manual ® ERIES FIRED WATER BOILER Install water piping — advanced (continued) Example system with DHW as a zone, Circulator zoning plus optional DHW piping zoning with circulators 1. Connect boiler to system as shown in Figure 49 when circula- tor zoning.
  • Page 54 — Boiler Manual ® ERIES FIRED WATER BOILER Install water piping — advanced (continued) Radiant heating applications Typical radiant heating system piping plus optional DHW 1. 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 55 — Boiler Manual ® ERIES FIRED WATER BOILER Install water piping — advanced (continued) Chilled water systems Chilled water system plus optional DHW piping 1. 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 56: Direct-Connected Dhw Piping

    — Boiler Manual ® ERIES FIRED WATER BOILER Sizing dire ct-connected DHW piping Direct-connected DHW piping The closest circulator selection (from Figure 55, page 57 that can deliver 12 gpm at 22.7 feet head is either a Taco 1400 (top chart) or a Taco 0013 (bottom chart). refer to the AQUA PLUS water heater manual for Note that, if the water heater were piped as in Figure 53 , application information.
  • Page 57 — Boiler Manual ® ERIES FIRED WATER BOILER Sizing dire ct-connected DHW piping (continued) 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 rate rise...

  • Page 58: Multiple Boiler Installations

    — Boiler Manual ® ERIES FIRED WATER BOILER Multiple boiler installations Placing multiple boilers Side-to-side mounting of multiple Ultra boilers 1. 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). 2.
  • Page 59 — Boiler Manual ® ERIES FIRED WATER BOILER Multiple boiler installations (continued) Manifolded combustion air option 1. Multiple Ultra boilers can use a common combustion air manifold. a. See Figure 139, page 138 for minimum cross sectional area of combined air ducts. b.
  • Page 60 — Boiler Manual ® ERIES FIRED WATER BOILER Multiple boiler installations (continued) ® Easy-Fit piping installation ® 1. Main header and Easy-Fit Manifold pipe sizing. a. New system — See page 10 . b. Replacing boilers in an existing system — Without reducing size, connect system supply and return lines.
  • Page 61 FIRED WATER BOILER Multiple boiler installations (continued) 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 backfl ow preventer, as required by applicable codes...
  • Page 62 ® ERIES FIRED WATER BOILER Multiple boiler installations (continued) 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 19 System return 2 Isolation valves (when used)
  • Page 63 140 – 290 gpm 4” Legend — Figure 64 Flow/check valve (each boiler) Indirect-fi red storage water heaters (Weil-McLain AQUA PLUS shown) — Example This piping is sug- is shown with reverse-return boiler-side piping using a single circulator. Alternate: gested only. The Isolation valves (when used) each water heater could have its own circulator.
  • Page 64 — Boiler Manual ® ERIES FIRED WATER BOILER Multiple boiler installations (continued) 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. Systems exposed to untreated quantities of makeup water.

  • Page 65: Venting/Air Piping - Massachusetts Installations

    — Boiler Manual ® ERIES FIRED WATER BOILER Venting/air piping — Massachusetts installations Instructions for the Commonwealth of Massachusetts (a) For all sidewall horizontally-vented gas-fueled equipment : The following equipment is exempt from installed in every dwelling, building or structure used in 248 CMR 5.08(2)(a)1 through 4: whole or in part for residential purposes, including those 1.

  • Page 66: Vent/Air Piping - Options

    2. Sidewall options (see Figure 12, page 18 , left side): a. TOP: Weil-McLain termination cap (kit included with boiler) — see page 67 for instructions. b. MIDDLE: Concentric PVC pipe (requires special kit, page 129 ).

  • Page 67: Sidewall Vent/Air Termination: Weil-Mclain Cap

    Determine proper location for wall or roof penetration c. The Weil-McLain sidewall vent/air cap kit includes the for each termination. termination cap, inside and outside wall plates, and mounting hardware to secure the plates.
  • Page 68 fl ue products impinge on building surfaces or plants. Feet Elbows Feet Elbows Feet Elbows Termination location – Weil-McLain vent/air plate -80 ** – height above grade or snow line -105 ** allowed -155 Not allowed -230...
  • Page 69 Sidewall vent/air termination: Weil-McLain cap (cont.) d. Avoid possibility of accidental contact of fl ue products with Termination location – Weil-McLain vent/air people or pets. plate – clearances to openings e. Do not locate the terminations where wind eddies could affect...
  • Page 70 fl ue pipe and air pipe. Level the template with a spirit level. For the Weil-McLain plate, the template must be level to ensure the fl ue and air pipe will be side-to-side, as shown in Figure 74 . Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 71 5. Deburr inside and outside of pipe ends. adapter at the boiler vent connection (and at the 6. Chamfer outside of each pipe end to ensure even cement termination if using the Weil-McLain plate or the concentric termination). Use only the adapter made distribution when joining.

  • Page 72: Sidewall Vent/Air Termination: 3" Or 4" Concentric

    . Most kits do not include the screens. Purchase separately A gas vent extending through an exterior wall shall not from Weil-McLain or vent kit supplier if terminate adjacent to the wall or below building exten- not included. sions such as eaves, parapets, balconies or decks. Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 73 — Boiler Manual ® ERIES FIRED WATER BOILER Sidewall vent/air termination: 3” or 4” concentric (cont.) b. The fl ue products will form a noticeable plume as they con- Termination location — 3” or 4” concentric dense in cold air. Avoid areas where the plume could obstruct termination —...
  • Page 74 — Boiler Manual ® ERIES FIRED WATER BOILER Sidewall vent/air termination: 3” or 4” concentric (cont.) Install terminations — concentric pipes Installing and supporting the concentric sidewall vent assembly 1. Assemble the vent termination as described for vertical concen- tric terminations, beginning on page 76 . If necessary, you can shorten the lengths of the inner and outer pipes for a shorter fi...

  • Page 75: Vertical Vent/Air Termination: 3" Or 4" Concentric

    4. Maintain clearances to termination as given below: All vent and air pipes require a a. Vent outlet must be located: . Most kits do not include the screens. Purchase separately from Weil-McLain or vent kit supplier if not included. Part number 550-100-400/0717...
  • Page 76 — Boiler Manual ® ERIES FIRED WATER BOILER Vertical vent/air termination: 3” or 4” concentric (cont.) At least 6 feet from adjacent walls. 3. Partially assemble the vent termination kit in the sequence shown in Figure 89, page 78 . No closer than 5 feet below roof overhang.
  • Page 77 — Boiler Manual ® ERIES FIRED WATER BOILER Vertical vent/air termination: 3” or 4” concentric (cont.) When inserting the partially-assembled termination kit 3” or 4” concentric termination supports through the roof penetration, wrap plastic or other protection over the end of the exposed assembly to prevent debris from entering the pipes.

  • Page 78: Concentric Vent/Air Termination Assembly

    — Boiler Manual ® ERIES FIRED WATER BOILER Concentric vent/air termination assembly 3” or 4” concentric termination assembly 3” or 4” concentric termination assembly (see kit — DO NOT attach the rain cap until the manufacturer’s instructions for details) termination has been inserted through the roof or wall and all supports have been installed.

  • Page 79: Direct Vent: Vertical Vent / Sidewall Air

    — Boiler Manual ® ERIES FIRED WATER BOILER DIRECT VENT: Vertical vent / sidewall air Allowable vent/air pipe materials Determine location 1. Use only the materials listed in Figure 13, page 19 . 1. Locate the vent termination using the following guidelines: 2.
  • Page 80 — Boiler Manual ® ERIES FIRED WATER BOILER DIRECT VENT: Vertical vent / sidewall air (continued) Termination and fi ttings Vent termination (through the roof) for direct vent: vertical vent / sidewall air 1. Prepare the vent termination coupling by inserting a bird screen. Bird screens must be purchased separately.
  • Page 81 — Boiler Manual ® ERIES FIRED WATER BOILER DIRECT VENT: Vertical vent / sidewall air (continued) Multiple air terminations Sidewall air inlet installation for direct vent: vertical vent / sidewall air 1. When terminating multiple Ultra boiler air connections, terminate each air connection as described in this manual.

  • Page 82: Install Vent/Air Piping - Boiler To Termination

    — Boiler Manual ® ERIES FIRED WATER BOILER Install vent/air pipi ng — boiler to termination Complete termination preparation Boiler vent and air connections 1. Install vent and air terminations before proceeding. See previ- ous pages for instructions. Installing vent and air piping 1.

  • Page 83: Direct Exhaust Venting - General

    VERTICAL direct exhaust option 1. Read and follow instructions in Boiler manual, including page 65 for Massachusetts installations when applicable. Every vent pipe requires a . Bird screens are not supplied with the Ultra boiler. Purchase separately from Weil-McLain. Part number 550-100-400/0717...

  • Page 84: Direct Exhaust - Boiler Room Air Openings

    — Boiler Manual ® ERIES FIRED WATER BOILER DIRECT EXHAUS T — Boiler room air openings Combustion air provision Special considerations The Ultra boiler can use inside air if no contaminants are pres- Tight construction ent in the boiler space. (If contaminants are likely to be present, install the boiler as a direct vent appliance, using the appropriate ANSI Z223.1 defi...
  • Page 85 — Boiler Manual ® ERIES FIRED WATER BOILER DIRECT EXHAUST — Boiler room air openings (continued) MINIMUM combustion air openings for direct exhaust applications — Air openings Ultra boiler Ultra boiler The required air opening sizes below are FREE AREA, WITH other WITHOUT other after reduction for louver obstruction.

  • Page 86: Direct Exhaust - Sidewall

    2. Install a bird screen in each vent pipe termination (coupling or elbow). Bird screens are not supplied with the Ultra boiler. Purchase separately from Weil-McLain. Maximum piping length 1. Locate the termination such that the total vent piping from the boiler to the termination will not exceed the maximum length given in Figure 12, page 18 .
  • Page 87 — Boiler Manual ® ERIES FIRED WATER BOILER DIRECT EXHAUST — Sidewall (continued) DIRECT EXHAUST — Sidewall — confi guration options DIRECT EXHAUST — Sidewall — and minimum clearances clearances to openings DIRECT EXHAUST — Sidewall — clearances from vent exit to forced air 4.
  • Page 88 Insert the galvanized metal thimble (by installer) in the vent pipe hole as shown in Figure 101 . The Weil-McLain sidewall termination kit 2. Follow all local codes for isolation of vent pipe when passing supplied with each boiler includes metal through fl...

  • Page 89: Direct Exhaust - Vertical

    2. Install a bird screen in each vent pipe termination (coupling or elbow). Bird screens are not supplied with the Ultra boiler. Purchase separately from Weil-McLain. Maximum piping length 1. Locate the termination such that the total vent piping from the boil- er to the termination will not exceed the maximum length given in Figure 12, page 18 .
  • Page 90 1. Prepare the vent termination coupling ( Figure 103 ) by inserting a bird screen. Bird screens are not supplied with the Ultra boiler. Purchase separately from Weil-McLain. 2. The vent piping must terminate in a coupling as shown in Figure 103 .

  • Page 91: Install Vent - From Boiler To Termination

    AL29-4C vent pipe — If using AL29-4C stain- less vent pipe, you must install a PVC-to-vent pipe adapter at the boiler vent connection (and at the termination if using the Weil-McLain plate or the concentric termination). Use only the adapter made by the vent pipe manufac- turer.
  • Page 92 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 93: Gas Piping - Sizing Gas Lines

    — Boiler Manual ® ERIES FIRED WATER BOILER Gas piping — sizing gas lines Natural Gas: Common gas line for multiple boilers Pipe sizing for natural gas 1. Size gas piping from meter outlet to entrance of boiler in accor- dance with Figure 108 and Figure 109 .

  • Page 94: Field Wiring - Advanced

    — Boiler Manual ® ERIES FIRED WATER BOILER Field wiring — advanced secondary heat source when another heat source, — For your such as a heat pump or another boiler is available. safety, turn off electrical power supply at service ❏...
  • Page 95 2. The factory default confi guration is for “heat demand 1” to be DHW and “heat demand 2” to be space heating. 3. When possible, use the Weil-McLain Ultra low water cut-off kit For factory default operation: listed in the back of this manual. It includes a probe-type low water a.
  • Page 96 — Boiler Manual ® ERIES FIRED WATER BOILER Field wiring — advanced (continued) Schematic wiring diagram — Ultra-80 through Ultra-399 Part number 550-100-400/0717...
  • Page 97 — Boiler Manual ® ERIES FIRED WATER BOILER Field wiring — advanced (continued) Ladder wiring diagram — Ultra-80 through Ultra-399 Part number 550-100-400/0717...
  • Page 98 — Boiler Manual ® ERIES FIRED WATER BOILER Field wiring — advanced (continued) Add itional limits Outdoor temperature sensor 1. The U-Control allows connection of external limit controls, 1. The U-Control provides programmable options when both for manual reset and for automatic reset operation of the using an outdoor temperature sensor.

  • Page 99: U-Control Operation And Setup - Advanced

    — Boiler Manual ® ERIES FIRED WATER BOILER U-Control operation and setup — advanced (radiant slab, etc.) — use the Ultra boiler 1. Use this setting to adjust the outdoor sensor temperature control as the only means of water tem- to account for solar or other effects that would cause the perature regulation for low-temperature sensor to read incorrectly.
  • Page 100 — Boiler Manual ® ERIES FIRED WATER BOILER U-Control operation and setup — advanced (continued) f. An alternate method is to daisy chain the other a. Outdoor temp for max target means the outdoor temperature boilers. That is, connect the output of each to the at which the target temperature reaches its maximum value.
  • Page 101 — Boiler Manual ® ERIES FIRED WATER BOILER U-Control operation and setup — advanced (continued) U-Control system types and preset parameters 8-character 3-char Max Target Outdoor Temp Min Target Outdoor Temp Temp for Max Target Temp for Min Target Fan-coil FAN-COIL Finned tube baseboard FIN BASE...
  • Page 102 — Boiler Manual ® ERIES FIRED WATER BOILER U-Control operation and setup — advanced (continued) U-Control menus (press and hold the UP and DOWN arrow keys for 5 seconds to enter contractor menus) Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data BOILER SETTINGS BOILER MODEL ##### HIGH ALTITUDE ###...
  • Page 103 — Boiler Manual ® ERIES FIRED WATER BOILER U-Control operation and setup — advanced (continued) U-Control menus, continued (press and hold the UP and DOWN arrow keys for 5 seconds to enter contractor menus) Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data SET DATE AND TIME SET YR/MN/DAY/HR/MIN DIAGNOSTICS...
  • Page 104 — Boiler Manual ® ERIES FIRED WATER BOILER U-Control operation and setup — advanced (continued) U-Control setup options (see Figure 115, page 102 for location in menu sequence) Boiler Model 80, 105, 155, factory . Adjusts blower speeds 230, 299, 310, and fl...
  • Page 105 — Boiler Manual ® ERIES FIRED WATER BOILER U-Control operation and setup — advanced (continued) U-Control setup options (see Figure 115, page 102 for location in menu sequence), continued 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 106 — Boiler Manual ® ERIES FIRED WATER BOILER U-Control operation and setup — advanced (continued) U-Control diagnostic inform ation (see Figure 115, page 102 for location in menu sequence Status Text data Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being satisfi...
  • Page 107 — Boiler Manual ® ERIES FIRED WATER BOILER U-Control operation and setup — advanced (continued) U-Control diagnostic inform ation (see Figure 115, page 102 for location in menu sequence), continued Manual Reset yes or none data Choose this to view the details of manual reset lockouts Auto Reset yes or none data...

  • Page 108: Annual Startup And General Maintenance

    — Boiler Manual ® ERIES 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 109: Annual Startup

    — Boiler Manual ® ERIES FIRED WATER BOILER Annual startup HANDLING CERAM IC FIBER FIRST-YEAR SPECIAL INSPECTION MATERIALS REMOVING BURNER GASKET or COVER PLATE INSULATION . This kit includes a heat exchanger cover plate gasket, burner gasket (80 The Ultra burner gasket (models 80 and 105 only), new ignitor, and ignitor gasket.
  • Page 110 — Boiler Manual ® ERIES FIRED WATER BOILER Annual startup (continued) Clean condensate trap The boiler should be inspected and 1. Loosen condensate trap line hose clamps and remove trap started annually, at the beginning of the line. heating season, only by a qualifi ed service 2.
  • Page 111 — Boiler Manual ® ERIES FIRED WATER BOILER Annual startup (continued) 4. Inspect automatic air vents and air separators. Remove air vent caps Inspect ignition electrode and briefl y press push valve to fl ush vent. Reinstall caps. Make sure vents do not leak.
  • Page 112 — Boiler Manual ® ERIES FIRED WATER BOILER Annual startup (continued) Check burner fl ame Check fl ame signal 1. Navigate to Diagnostics/Inputs on the U-Control display (see The boiler contains ceramic fi ber materials. Figure 115, page 102 ). The fl ame signal value must be at least 20 Use care when handling these materials per above the Shutdown values given in Figure 119 .
  • Page 113 — Boiler Manual ® ERIES FIRED WATER BOILER Annual startup (continued) 4. If fl ame signal still remains low, inspect the vent and air 6. Set the fi ring rate to MEDIUM (ignition rate). piping. Then inspect the heat exchanger, following the pro- 7.
  • Page 114 — Boiler Manual ® ERIES FIRED WATER BOILER Annual startup (continued) Check boiler relief valve 1. Inspect the relief valve and lift the lever to verify fl ow 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 115: Troubleshooting

    — Boiler Manual ® ERIES FIRED WATER BOILER Tro ubleshooting Reinstall boiler jacket front door Before servicing and making connections . . . Reinstall boiler jacket front door after servicing. The boiler front door must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room.
  • Page 116 — Boiler Manual ® ERIES FIRED WATER BOILER Troubleshooting (continued) Check the following: Do not jumper fuse or replace with any fuse except as specifi ed. Failure to comply 1. 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 117 — Boiler Manual ® ERIES 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 1. 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 118 — Boiler Manual ® ERIES FIRED WATER BOILER Troubleshooting (continued) 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 119 — Boiler Manual ® ERIES FIRED WATER BOILER Troubleshooting (continued) Figure 125 Troubleshooting suggestions for Ultra boilers (continued) Condition Diagnostics Corrective Action(s) Display Nothing Control is not receiving 120V Check service switch and/or Turn on service switch to power boiler. is shown power.
  • Page 120 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 121 — Boiler Manual ® ERIES FIRED WATER BOILER Troubleshooting Troubleshooting (continued) (continued) Figure 125 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 communications out for 30 communication is re- connection on the back of the display.
  • Page 122 — Boiler Manual ® ERIES FIRED WATER BOILER Troubleshooting (continued) Figure 125 Troubleshooting suggestions for Ultra boilers (continued) Condition Diagnostics Corrective Action(s) Display Blower unable to reach Automatically resets after 1 hour Check wire harness for loose connections and pin engagement at blower required speed or does not or can be reset by using manual connections, chassis mount connection through sheet metal cabinet,...
  • Page 123 — Boiler Manual ® ERIES FIRED WATER BOILER Troubleshooting (continued) Figure 125 Troubleshooting suggestions for Ultra boilers (continued) Condition Diagnostics Corrective Action(s) Display The U-Control has detected Automatic retry when condition Check wire harness connections between gas valve and U-Control. a problem with it gas valve exists.
  • Page 124 — Boiler Manual ® ERIES FIRED WATER BOILER Contact: Name: Contractor: Phone: Job name: Model: City, state: CP#: Distributor: Installed: Near boiler pipe size: Please note the placement of system sensors Boiler circulator model: DHW tank (yes/no): DHW direct/system: Dhw model: Dhw pipe size: DHW circulator model: Is there air in system?:...

  • Page 125: Maintenance

    2. Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instruc- 4. Use ONLY the cleaning product available from Weil-McLain, tions. Over-oiling will damage the circulator. Sentinel X400. See the Repair Parts section at the end of this manual for ordering information.
  • Page 126 — Boiler Manual ® ERIES FIRED WATER BOILER Maintenance (continued) For the fi rst 5 years, vacuum or rinse heat exchanger with water only. No tool cleaning is necessary. Accessing & cleaning heat exchanger: Ultra-80 and Ultra-105 Only 1. Close the external manual gas valve. 2.
  • Page 127 — Boiler Manual ® ERIES FIRED WATER BOILER Maintenance (continued) Accessing & c leaning exchanger: Ultra-155, -230, -299/310 and -399 Only 1. Close the external manual gas valve. 3. Disconnect the fl exible gas line at its fl are fi tting. 4.

  • Page 128: Replacement Parts

    Results from using modifi ed 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. . Use care when handling these materials per instructions on page 109 of this manual.
  • Page 129 — Boiler Manual ® ERIES FIRED WATER BOILER Replacement parts (continued) Miscellaneous parts and kits Description Part Number CHEMICALS BOILER ACCESSORIES AND CONTROLS VENT / AIR TERMINATIONS CONDENSATE HANDLING Part number 550-100-400/0717...
  • Page 130 — Boiler Manual ® ERIES FIRED WATER BOILER Replacement parts (continued) Jacket parts Boiler Part Boiler Part Description Description models number models number Flue outlet pipe adapter 3” Jacket front door 383-500-135 80/105 560-907-771 3” Boiler leg kit (4 required) 383-500-065 560-907-771 Screw fl...
  • Page 131 — Boiler Manual ® ERIES FIRED WATER BOILER Replacement parts (continued) Controls Part Description Number Ultra U-Control module 383-500-658 Transformer, 120V/24V 383-500-628 Display board assembly (includes plastic and display screen) 383-500-756 On/off power switch 383-500-205 Flue temperature sensor replacement kit 383-500-600 System temperature sensors (2 required) 383-500-601...
  • Page 132 — Boiler Manual ® ERIES FIRED WATER BOILER Replacement parts (continued) Heat exchanger and piping — Ultra-80 and -105 Boiler Item Description Part Number Models 80LP 80LP Part number 550-100-400/0717...
  • Page 133 — Boiler Manual ® ERIES FIRED WATER BOILER Replacement parts (continued) Heat exchanger and piping — Ultra-80 and -105 Part number 550-100-400/0717...
  • Page 134 — Boiler Manual ® ERIES FIRED WATER BOILER Replacement parts (continued) Heat exchanger and piping Boiler Part Description models number Heat exchanger replacement kit - Heat 383-500-673 exchanger, cover plate, burner, electrode, 383-500-674 Boiler Part Description water sensors, compression fi ttings, models number condensate fi...
  • Page 135 — Boiler Manual ® ERIES FIRED WATER BOILER Replacement parts (continued) Heat exchanger and piping Boiler Part Boiler Part Description Description models number models number Heat exchanger replacement kit - Heat 299/310/399 383-500-675 15 Gas pipe lower clamp and hardware 299/310 383-500-625 exchanger, cover plate, burner, electrode,...

  • Page 136: Dimensions

    — Boiler Manual ® ERIES FIRED WATER BOILER Dimensions Dimensional data Notes Boiler supply and return tappings are both 1” NPT (Ultra-80/105/155/230) or 1¼” NPT (Ultra-299/310). See page 10 for recommended piping sizes. Wall-hung boiler option — water piping and gas pipe can only be routed through top of enclosure using wall-mounting kit. See page 5 for mounting instructions.

  • Page 137: Ratings - Ultra Series 4 Boilers

    Ultra-399 Notes As an Energy Star Partner, Weil-McLain has determined that Ultra boilers meet the Energy Star guidelines for energy effi ciency. NOTE: Adjusting boiler fi ring rate will affect AFUE rating. Based on standard test procedures prescribed by the United States Department of Energy.
  • Page 138 — Boiler Manual ® ERIES FIRED WATER BOILER Ratings — Multiple Ultra Series 4 boilers Ratings and engineering data Figure 141 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...
  • Page 139 Based on standard test procedures outlined by DOE for individual boilers. Net AHRI ratings are based on piping and pickup allowance of 1.15. Consult Weil-McLain Technical Services for other allowances. Foundation sizes in Figure 139 provide 6 inches between boilers and 2 inches from boiler to edge of foundation.

  • Page 140: Installation And Service Certifi Cate

    — Boiler Manual — Boiler Manual ® FIRED WATER BOILER ERIES FIRED WATER BOILER Installation and Service Certifi cate Boiler Model Series CP Number Date Installed ❏ Installation instructions have been followed. BTU Input ❏ Check-out sequence has been performed. ❏...

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