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, includ-
ing 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 550-100-090/1113
 GAS-FIRED WATER BOILER

Contents Ultra at-a-glance

Hazard definitions. . . . . . . . . . . . . . . . . . . . . . . . . 2 (see page 40 and page 42 for details of all models)
Ultra at-a-glance . . . . . . . . . . . . . . . . . . . . . . . . . 2
Please read before proceeding . . . . . . . . . . . . . . . . . . 4
Prepare boiler location . . . . . . . . . . . . . . . . . . . . . . 5
Prepare boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install water piping . . . . . . . . . . . . . . . . . . . . . . . . 9
Install water piping — typical systems . . . . . . . . . . . . . 12
Using with Weil-McLain PLUS water heaters . . . . . . . . . . 14
Venting/air piping — general . . . . . . . . . . . . . . . . . . 16
Sidewall vent/air termination: Weil-McLain cap. . . . . . . . . 18 Front
Install vent/air piping — boiler to W-M termination . . . . . . . 22
Install condensate line . . . . . . . . . . . . . . . . . . . . . 23
Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Field wiring — basic system . . . . . . . . . . . . . . . . . . 26
U-Control operation and setup . . . . . . . . . . . . . . . . . 28 Front door
Startup — fill the system . . . . . . . . . . . . . . . . . . . . 31
Startup — final checks . . . . . . . . . . . . . . . . . . . . . 33
Check-out/startup verification . . . . . . . . . . . . . . . . . . 38
The Gas-fired water boiler, Featuring Flexibility . 40
Prepare boiler — convert for propane . . . . . . . . . . . . . 44
Placing boiler — wall-mounting option . . . . . . . . . . . . . 46
Install water piping — advanced . . . . . . . . . . . . . . . . 48
Sizing direct-connected DHW piping . . . . . . . . . . . . . . 52 Supply
Multiple boiler installations . . . . . . . . . . . . . . . . . . . 54 Return
Prepare boiler location — multiple boilers . . . . . . . . . . . 55
Multiple boiler water piping . . . . . . . . . . . . . . . . . . . 56
Venting/air piping — Massachusetts installations. . . . . . . . 61
Vent/air piping — options . . . . . . . . . . . . . . . . . . . . 62
Sidewall vent/air termination: 3” PVC concentric . . . . . . . . 63 Air intake
Sidewall vent/air termination: Separate pipes . . . . . . . . . 66 Flue
Vertical vent/air termination: 3” PVC concentric . . . . . . . . 69
Vertical vent/air termination: Separate pipes . . . . . . . . . . 73
Install vent/air piping — boiler to termination . . . . . . . . . . 75
Gas piping — sizing gas lines . . . . . . . . . .
Field wiring — advanced . . . . . . . . . . . . .
.
.
. . . . .
. . . . .
. 77
. 78
Top
(control panel swung open)
U-Control operation and setup — advanced . . . . . . . . . . 83
Annual startup and general maintenance. . . . . . . . . . . . 92
Annual startup . . . . . . . . . . . . . . . . . . . . . . . . . 93
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 99
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Replacement parts . . . . . . . . . . . . . . . . . . . . . . . 112
Electronic display,
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 buttons & P/T gauge
Ratings — Ultra boilers . . . . . . . . . . . . . . . . . . . . . 121
Ratings — multiple Ultra boilers . . . . . . . . . . . . . . . . 122
Installation and Service Certificate . . . . . . . . . . . . . . . 124
Interior
(typical)
Hazard definitions
The following defined terms are used throughout this manual to bring Aluminum
attention to the presence of hazards of various risk levels or to important condensing
information concerning the life of the product. heat exchanger
Indicates presence of hazards that will cause severe
personal injury, death or substantial property
damage. Gas valve, blower
and venturi
Indicates presence of hazards that can cause severe
personal injury, death or substantial property
damage.
Condensate
Indicates presence of hazards that will or can cause drain
minor personal injury or property damage.
Indicates special instructions on installation,
operation or maintenance that are important but not
related to personal injury or property damage.

2 Part number 550-100-090/1113

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Pages 0ROCEDURE and to sidewall vent/air piping using the Weil-McLain
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Part number 550-100-090/1113 3

 GAS-FIRED WATER BOILER — Boiler Manual

Please read before proceeding

)NSTALLER— 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.
before installing. Perform steps in the
order given.
When servicing boiler —
User — This manual is for use only s To avoid electric shock, disconnect electrical supply before per-
by a qualified heating installer/service forming maintenance.
technician. Refer to User’s Informa-
tion Manual for your reference. s To avoid severe burns, allow boiler to cool before performing
maintenance.
User — Have this boiler serviced/
inspected by a qualified service tech- s This boiler contains ceramic fiber and fiberglass materials. Refer
nician, at least annually. to the WARNING and instructions on page 93.

Failure to comply with the above Boiler operation —

could result in severe personal injury,
death or substantial property dam- s Do not block flow of combustion or ventilation air to boiler.
age.
s Should overheating occur or gas supply fail to shut off, do not turn
off or disconnect electrical supply to circulator. Instead, shut off
the gas supply at a location external to the appliance.
When calling or writing about the s Do not use this boiler if any part has been under water. Immedi-
boiler— Please have the boiler model ately call a qualified service technician to inspect the boiler and to
number from the boiler rating label replace any part of the control system and any gas control that has
and the CP number from the boiler been under water.
jacket. (CP number is located on the
lower portion of the heat exchanger
mounting bracket.) Boiler water —
s The Ultra heat exchanger is made of aluminum, and requires that
You should write in the CP number in system pH always be between 7.0 and 8.5 and water chemistry be
the space provided on the Installation checked. Chemical treatment may be necessary. See page 31 for
certificate on page 124 if not already details.
shown.
s Thoroughly flush the system (without boiler connected) to remove
Consider piping and installation sediment. The high-efficiency heat exchanger can be damaged by
when determining boiler location. build-up or corrosion due to sediment.

Any claims for damage or shortage in s Do not use petroleum-based cleaning or sealing compounds in
shipment must be filed immediately boiler system. Gaskets and seals in the system may be damaged.
against the transportation company This can result in substantial property damage.
by the consignee. s Continual fresh make-up water will reduce boiler life. Mineral
buildup in heat exchanger reduces heat transfer, overheats the
aluminum heat exchanger, and causes failure. Addition of oxygen
carried in by make-up water can cause internal corrosion. Leaks
in boiler or piping must be repaired at once to prevent make-up
Commonwealth of water. Use this boiler ONLY in a closed-loop system.
Massachusetts
s Do not add cold water to hot boiler. Thermal shock can cause heat
When the boiler is installed within the Common- exchanger to crack.
wealth of Massachusetts:
s This product must be installed by a licensed Freeze protection fluids —
plumber or gas fitter.
NEVER use automotive or standard glycol antifreeze, even glycol made
s If antifreeze is used, a reduced pressure back- for hydronic systems. Use only freeze-protection fluids recommended
flow preventer device shall be used. in this manual (see page 31). Follow all guidelines given. Thoroughly
s Sidewall vent air installations — see instruction clean and flush any replacement boiler system that has used glycol
on page 61. before installing the new Ultra boiler.

4 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Prepare boiler location

"!3)#).34!,,!4)/.
Installations must comply with: &IGURE Clearances required
s Local, state, provincial, and national codes, laws, regulations and
ordinances.
s National Fuel Gas Code, ANSI Z223.1 – latest edition.
s Standard for Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1, when required.
s National Electrical Code.
s For Canada only: B149.1 or B149.2 Installation Code, CSA C22.1
Canadian Electrical Code Part 1 and any local codes.
The Ultra boiler gas manifold and controls met safe
lighting and other performance criteria when boiler
underwent tests specified in ANSI Z21.13 — latest edi-
tion.

Before locating the boiler, check:

1. Check for nearby connection to:
s System water piping
s Venting connections
s Gas supply piping
s Electrical power
s Condensate drain
2. Check area around boiler. Remove any combustible materials,
gasoline and other flammable liquids.
Failure to keep boiler area clear and free of combustible
materials, gasoline and other flammable liquids and
vapors can result in severe personal injury, death or
substantial property damage.
3. 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.
4. If new boiler will replace existing boiler, check for and correct
system problems, such as:
Clearances for service access
s System leaks causing oxygen corrosion or heat exchanger cracks
from hard water deposits. 1. See Figure 1 for recommended service clearances. If you
s Incorrectly-sized expansion tank. do not provide minimum clearances shown, it might
not be possible to service the boiler without removing
s Lack of freeze protection in boiler water causing system and
boiler to freeze and leak. it from the space.

Wall mounting option

Provide clearances:
1. Ultra boilers can be wall mounted (using special wall
Clearances from combustible materials mount kit) or floor mounted. .O CLEARANCE IS RE-
QUIREDATTHEREAROFTHEUNIT, either for service or
1. Hot water pipes — at least ½” from combustible materials. for clearance to combustible surfaces.
2. Vent pipe — at least ³⁄₁₆” from combustible materials. 2. Boilers can be wall mounted ONLY if using the optional
wall-mount kit available from Weil-McLain. See page 46
3. See Figure 1 for other clearance minimums. for instructions.

Part number 550-100-090/1113 5

 GAS-FIRED WATER BOILER — Boiler Manual

Prepare boiler location (continued)

Flooring and foundation Provide air openings to room

Flooring Air openings — Ultra boiler alone in boiler

room
1. The Ultra boiler is approved for installation on combustible floor-
ing, but must never be installed on carpeting. 1. No air ventilation openings into boiler room are needed
when clearances around Ultra boiler are at least equal
Do not install boiler on carpeting even if foundation is to the SERVICE clearances shown in Figure 1, page 5.
used. Fire can result, causing severe personal injury, death
or substantial property damage. 2. For spaces that do NOT supply this clearance, provide
two openings as shown in Figure 1, page 5. Each open-
ing must provide 1 square inch free area per 1,000 Btuh
Foundation of boiler input.

1. Provide a solid foundation pad, at least 2 inches above the floor, if Air openings — Ultra boiler in same
any of the following is true: space with other gas or oil-fired
s floor can become flooded. appliances
s the floor is dirt, sand, gravel or other loose material.
1. Follow the National Fuel Gas Code (U. S.) or CSA B149.1
s the boiler mounting area is severely uneven or sloped. and B149.2 (Canada) to size/verify size of the combus-
tion/ventilation air openings into the space.
2. The minimum foundation size is:
s Ultra-80 to -230: 24 inches wide x 20 inches deep.
The space must be provided with
s Ultra-299 to -399: 24 inches wide x 23 inches deep combustion/ventilation air openings
correctly sized for all other appliances
3. Foundation may be of wood, brick or concrete (minimum 2 inches
located in the same space as the Ultra
thick) construction.
boiler.
4. If flooding is possible, elevate boiler sufficiently to prevent water
from reaching boiler. Reinstall boiler jacket front door after
servicing. The boiler front door must be
securely fastened to the boiler to prevent
Residential garage installation boiler from drawing air from inside the
boiler room. This is particularly impor-
tant if the boiler is located in the same
Precautions room as other appliances.
1. Take the following special precautions when installing the boiler in
a residential garage. If the boiler is located in a residential garage: Failure to comply with the above warn-
ings could result in severe personal
s Mount the boiler at a height above the floor as specified in the injury, death or substantial property
National Fuel Gas Code, ANSI Z223.1 for U. S. installations, or damage.
CSA B149.1 and B149.2 for Canadian installations.
s Locate or protect the boiler so it cannot be damaged by a 2. Size openings only on the basis of the other appliances in
moving vehicle. the space. No additional air opening free area is needed
s Ensure that the installation complies with all applicable for the Ultra boiler because it takes its combustion air
codes. from outside (direct vent installation).

6 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Prepare boiler

"!3)#).34!,,!4)/.
Vent and air piping (page 16)
Prepare boiler for propane
1. The Ultra boiler requires a special vent system, designed for pres- (when required)
surized venting. Ultra boilers are rated ANSI Z21.13 Category IV
(pressurized vent, likely to condense in the vent). See instructions
beginning on page 16. Propane operation
2. You must also install air piping from outside to the boiler air 5LTRA BOILERS MUST BE CONVERTED
intake adapter. The resultant installation is categorized as direct FOR PROPANE OPERATION UNLESS SPE-
vent (sealed combustion). Note prevention of combustion air CIlCALLYMANUFACTUREDFORPROPANE.
contamination on page 16 when considering vent/air termination. Propane-ready boilers have suffix “LP”
3. Vent and air must terminate near one another and may be vented after the model number. All other boilers
vertically through the roof or out a side wall. You may use any of require conversion for propane opera-
the vent/air piping methods covered in this manual. Do not attempt tion.
to install the Ultra boiler using any other means. Refer to propane conversion instructions
4. Be sure to locate the boiler such that the vent and air piping can be beginning on page 44.
routed through the building and properly terminated. The vent/air Failure to comply could result in severe
piping lengths, routing and termination method must all comply personal injury, death or substantial
with the methods and limits in instructions beginning on page 16. property damage.

Remove boiler from crate

Placing floor-mounted boilers
Cold weather handling — If boiler has been stored in a
1. Set boiler in place and check level.
very cold location (below 0°F) before installation, handle
with care until the plastic components come to room a. Adjust legs, if necessary to level boiler.
temperature.
1. The Ultra boiler is generally easier to handle and maneuver after
Wall-mounted boilers
removing from crate. 1. Boilers can be wall mounted ONLY if using the optional
wall-mount kit available from Weil-McLain. See page 46
2. After removing outer shipping carton from boiler, REMOVE jacket for instructions.
front door by loosening two knurled-head screws at lower front.
Removing the door will prevent possible damage to the door dur-
ing handling.
3. To remove boiler from pallet (after removing jacket front door):
a. Remove the lag screws securing the shipping brackets.
b. Unscrew the two rear boiler legs and remove the shipping
brackets.
c. Replace legs.
d. Discard the cardboard protector insert on the rear of the
boiler.
Do not drop boiler or bump jacket on floor or pallet.
Damage to boiler can result.

Part number 550-100-090/1113 7

 GAS-FIRED WATER BOILER — Boiler Manual

Prepare boiler (continued)

$/./4INSTALLARELIEFVALVEWITHAPRESSUREHIGHER &IGURE Hydrostatic test piping connections
THAN  03)'. 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.

Prepare boiler for test

1. See Figure 2 for reference in following steps.
2. 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-299/399)
3. Temporarily plug the ¾” relief valve tapping in the street elbow
with a ¾” NPT pipe plug.
4. Connect a hose to the boiler drain valve, the other end connected
to a fresh water supply. Make sure the hose can also be used to
drain the boiler after test.
5. Connect a nipple and shutoff valve to system supply connection
on the supply tee. This valve will be used to bleed air during the
fill. (Valve and nipple are not included with boiler.)
6. Connect a shutoff valve to system return connection. (Valve is not
included with boiler.)
7. To avoid getting water on boiler, you may want to pipe street elbows
on top of shutoff valves and attach catch-buckets beneath.
8. If convenient, install the boiler circulator and any other piping
compatible with Figure 2 that would still allow bleeding air from
shutoff valves.
9. Follow guidelines in this manual for piping components, locations
and sizing.

Fill and pressure test

1. Open the shutoff valves you installed on supply and return con-
nections.
2. Slowly open boiler drain valve and fresh water supply to fill boiler
with water. The boiler will fill quickly because of its low water
content.
3. When water reaches shutoff valves, close boiler drain valve.
4. Close shutoff valves. Do not use petroleum-based cleaning or seal-
5. Slowly reopen boiler drain valve until test pressure on the pres- ing compounds in boiler system. Gaskets and
sure/temperature gauge reaches at least 45 psig, but no higher seals in the system may be damaged. This can
than 55 psig. result in substantial property damage.
6. Hold at test pressure for 10 minutes.
Do not leave boiler unattended. A cold water fill could Drain and remove fittings
expand and cause excessive pressure, resulting in severe
personal injury, death or substantial property damage. 1. Disconnect fill water hose from water source.
7. Make sure constant gauge pressure has been maintained through- 2. Drain boiler through drain valve. Remove hose after
out test. Check for leaks. Repair if found. draining.
3. Remove nipples and valves unless they will remain for
,EAKSMUSTBEREPAIREDATONCE Failure to do so use in the system piping.
can damage boiler, resulting in substantial property
4. Remove plug from relief valve street elbow. See page 9
damage.
to install relief valve.

8 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Install water piping

"!3)#).34!,,!4)/.
Use two wrenches when tightening water piping at boiler, 3. When required, use a low water cutoff designed for water
using one of the wrenches to prevent the boiler interior installations. Electrode probe-type is recommended. See
piping from turning. 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.
4. Purchase low water cutoff and install in a tee in the
supply piping above boiler.
General piping information
5. See field wiring instructions beginning on page 26 for
Additional controls, when required wiring additional limit controls.

The U-Control module uses temperature sensors to Backflow preventer

provide both high limit protection and modulating tem-
perature control. The U-Control module also provides 1. Use backflow check valve in cold water supply as re-
low water protection by sensing the temperature of the quired by local codes.
heat exchanger. Some codes/jurisdictions may require
additional external controls for high limit and/or low Install relief valve
water cutoff protection.
1. Install relief valve in ¾” street elbow piped from boiler
Additional limit controls supply piping tee (Figure 2, page 8). Pipe the relief valve
only as shown, in the location shown.
Following standard industry practices, if installation is to comply with
ASME or Canadian requirements, an additional high temperature limit 2. Connect discharge piping to safe disposal location, fol-
may be needed. Consult local requirements for other codes/standards lowing guidelines in the 7!2.).' below.
to determine if needed.
1. Install a manual reset high temperature limit constructed to prevent
a temperature setting above 200°F in system supply piping between 4OAVOIDWATERDAMAGEORSCALDING
DUETORELIEFVALVEOPERATIONASPER
boiler and isolation valve. (Note that the U-Control module op- LOCALORSTATECODES:
erating limit function shuts the boiler down at 195°F, or lower if
set to a lower value.) Discharge line must be connected to relief
valve outlet and run to a safe place of
-ULTI TEMPERATURESYSTEMS — If the heating system disposal. Terminate the discharge line in
includes circuits that require lower temperature water a manner that will prevent possibility of
(radiant slab circuits, for example) as well as higher severe burns or property damage should
temperature circuits, it is recommended to protect low- the valve discharge.
temperature circuits with limit controls that are wired to Discharge line must be as short as pos-
a U-Control external limit circuit (P13 terminals 1 and 2 sible and be the same size as the valve
for manual reset, or P13 terminals 3 and 4 for automatic discharge connection throughout its
reset). entire length.
2. See instructions beginning on page 26 for wiring information. Discharge line must pitch downward
from the valve and terminate at least 6”
a. Manual reset operation: If external limit controls are to cause above the floor drain where any discharge
MANUALRESET of the U-Control module, connect series-wired will be clearly visible.
isolated contacts to P13 terminals 1 and 2 (see page 26 for wir-
ing information). The discharge line shall terminate plain,
b. Automatic reset operation: If external limit controls are to not threaded, with a material serviceable
for temperatures of 375 °F or greater.
cause AUTOMATIC RESET of the U-Control module, connect
series-wired isolated contacts to P13 terminals 3 and 4 (see Do not pipe the discharge to any place
page 26 for wiring information). where freezing could occur.
c. If using a manual reset limit control or wiring in the manual No shutoff valve shall be installed be-
reset circuit, set U-Control boiler limit at least 20°F less than tween the relief valve and boiler, or in the
the external manual reset limit (i.e., set U-Control no higher discharge line. Do not plug or place any
than 180°F for a 200°F external limit, for example). obstruction in the discharge line.
Test the operation of the valve after fill-
Separate low water cutoff ing and pressurizing system by lifting
1. A low water cutoff device is recommended when the boiler is in- the lever. Make sure the valve discharges
stalled above piping level, and may be required by certain state or freely. If the valve fails to operate cor-
local codes or insurance companies. Consult local requirements to rectly, replace it with a new relief valve.
determine. See the NOTICE above regarding the inherent protec- Failure to comply with the above guide-
tion provided by the U-Control module. lines could result in failure of the relief
valve to operate, resulting in possibility
2. The U-Control’s integral protection is accepted in many jurisdic- of severe personal injury, death or sub-
tions as meeting the requirement for low water protection. See stantial property damage.
page 79 for details.

Part number 550-100-090/1113 9

 GAS-FIRED WATER BOILER — Boiler Manual

Install water piping (continued)

System water piping methods Simplified pipe/circulator selection
All piping methods shown in this manual use primary/ 1. Install the boiler and piping using the recommended
secondary connection to the boiler loop. These designs piping layouts beginning on page 12 and in the AD-
ensure proper flow through the Ultra boiler, for the most VANCED section of this manual.
efficient and reliable operation of the boiler and the heat- 2. Size the piping and components for each circuit in the
ing system. For other piping methods, consult your local space heating system using Figure 3. !TTHEmOWRATES
Weil-McLain representative or see separate Ultra boiler LISTED THE HEAD LOSS IN ALL PIPING WILL BE  FEET
piping guides. PERFOOTOFPIPE
a. Determine the heating load (Btuh) for each circuit.
b. Calculate the flow rate for each circuit using its load.
Circulators To use a 20°F temperature drop, just divide the
MBH (1,000’s of Btuh) by 10.
The boiler circulator (Taco 007 for Ultra-80 and -105; Taco 0014 for Example — Flow for 20°F temp drop with 35,000 Btuh:
Ultra-155, -230, and -299; Taco 0013 for Ultra-399) is shipped loose. FLOW = 35 MBH / 10 = 3.5 gpm
Locate it in the return piping, as shown in the appropriate piping c. Find the pipe size in Figure 3 that has a max flow rate just
diagram in this manual. larger than that required for the circuit.
d. Find the total equivalent length (TEL) of the circuit.
$/./4 use the boiler circulator in any location other TEL accounts for losses through fittings and valves by
than the ones shown in this manual. The boiler circula- using the equivalent length of pipe that would cause the
tor is selected to ensure adequate flow through the Ultra same head loss. Add these numbers to the measured length
of the circuit to find TEL in feet.
boiler.
TEL is usually close to 1.5 times the length of
Install the boiler circulator only on the boiler return pip- the circuit for residential baseboard, radiator or
ing. This ensures the pressure drop through the boiler convector applications.
will not cause low pressure in the circulator intake. e. Measure the length of each circuit from the circulator
Failure to comply could result in unreliable performance outlet back to its inlet. Then multiply this length times
1.5 to get the approximate TEL of the circuit.
and nuisance shutdowns from insufficient flow.
f. Find the head loss for each circuit:
4%, = 8#IRCUIT,ENGTH (feet)
Circulator flow rate
(%!$4%,8 (feet water column)
Size circulators based on the flow rate required to achieve the tem- g. NOTE: Size system header piping for the total flow of all
perature change needed. You can closely estimate temperature rise (or connected zones.
drop) through a circuit by using the following formula, where TD is 3. Example:
temperature rise (or drop), FLOW is flow rate (in gpm), and BTUH
a. For a circuit with heating load = 45,000 Btuh (= 45 MBH).
is the heat load for the circuit: Measured length of circuit is 88 feet.
"45( b. Flow = 45 MBH / 10 = 4.5 gpm.
&,/7 = ˆnˆnˆnˆn c. TEL = 1.5 x 88 feet = 132 feet.
4$X d. From Figure 3, select 1" pipe (max flow = 7.1 gpm).
%XAMPLES: e. Head loss = TEL x 0.04 = 132 x 0.04 = 5.28 feet.
Consider a system loop for a system with total heating load equal to f. Select a circulator that can deliver at least 4.5 gpm at a
head of 5.28 feet. (Read the NOTICE below.)
210,000 Btuh. The desired temperature drop through the system piping
is 20°F. Then the required flow rate is: To use this method, limit the flow through ¾"
finned-tube baseboard to 3.9 gpm, or use 1"
 baseboard and limit flow to 7.1 gpm. If the
&,/7 = ˆnˆnˆnˆn = GPM total load of the circuit requires more flow,
X split the circuit into two or more.
3)-0,)&)%$&OR—TEMPERATUREDROP&,/7-"( Also see Figure 9, page 15 for quick-selection
information for applications using Taco 007
circulators or equivalent for zone piping.
Circulator head requirement
The circulator must be capable of delivering the required flow against &IGURE Flow rates for 0.04 feet head loss per foot
the head loss that will occur in the piping. Determine the pipe size of pipe (140°F water)
needed and the resultant head loss using accepted engineering methods.
The simplified pipe sizing here is limited to residential systems, and Pipe size MAX Flow rate (GPM) Pipe size MAX Flow rate (GPM)
does not include systems with fan coil units or radiant tubing. (inches) @ 0.04 feet per foot (inches) @ 0.04 feet per foot

The following simplified method for pipe and circulator ¾ 3.9  45

sizing must be limited to residential applications using  7.1   75
baseboard (finned or cast iron), cast iron radiators or  16 3 140
convectors. DO NOT apply for radiant heating, fan coil
units or commercial installations.   24  290

10 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Install water piping (continued)

"!3)#).34!,,!4)/.
Expansion tank and make-up water &IGURE Expansion tank piping
1. 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. Eventual boiler failure can result due
to excessive make-up water addition.
2. Tank must be located as shown in this manual, or following rec-
ognized design methods. See tank manufacturer’s instructions
for details. When installing air vents and expansion tanks, refer to
manufacturer’s instructions.
3. Connect the expansion tank to the air separator only if the separa-
tor is on the suction side of the circulator. Always install the system
fill connection at the same point as the expansion tank connection
to the system.
-).)-5-
4. Most piping drawings in this manual show diaphragm expansion Boiler loop pipe size
tanks. See Figure 4 for piping from air separator to expansion tank Ultra-80, 105 1”
and make-up water line using a closed-type expansion tank. Ultra-155, 230 1¼”
5. Most chilled water systems are piped using a closed-type tank, as Ultra-299, 399 1½”
shown in Figure 51, page 51. See CAUTION at left.

Diaphragm (or bladder) expansion tank

1. (Figure 4) Always install an automatic air vent on top of the air
separator to remove residual air from the system.
When using diaphragm or bladder tanks only — when the
boiler is installed above the system main piping, install
an automatic air vent in the top of the outgoing boiler
piping to prevent air pocketing.

Closed-type expansion tank

1. See Figure 4, Alternate, for piping connections when using a closed-
type expansion tank.
2. Pitch any horizontal piping up towards tank 1 inch per 5 feet of
piping. Connect to tank with at least ¾” piping to allow room for
air to rise.
DO NOT install automatic air vents on closed-type
expansion tank systems. Air must remain in the system
and return to the tank to provide its air cushion. An au-
-).)-5-
tomatic air vent would cause air to leave system, resulting Boiler loop pipe size
in water-logging the expansion tank. Ultra-80, 105 1”
DO NOT use a closed-type expansion tank on a system Ultra-155, 230 1¼”
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.

Use AT LEAST the -).)-5- pipe size shown in

Figure 4 on all boiler loop piping (connecting boiler
to and from the primary/secondary connection,
item 9). 5SE ONLY PRIMARYSECONDARY PIPING
ASSHOWN Failure to follow these guidelines could
result in system problems.

Part number 550-100-090/1113 11

 GAS-FIRED WATER BOILER — Boiler Manual

Install water piping — typical systems

Zoning with zone valves &IGURE 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 sufficient flow. It also avoids applying the high head
of the boiler circulator to the zone valves. Also see the information
on page 14 and page 15 for suggested piping and sizing.
Use ATLEAST the -).)-5- pipe size shown in Figure 5
on all boiler loop piping (connecting boiler to and from
the primary/secondary connection, item 21). 5SEONLY
PRIMARYSECONDARYPIPINGASSHOWN Failure to fol-
low these guidelines could result in system problems.
2. When using a closed-type expansion tank, connect the expansion
tank and make-up water piping as shown in Figure 4, page 11. (DO
NOT use a closed-type tank with a PLUS water heater.)
3. Connect DHW (domestic hot water) piping to indirect storage
water heater as shown.
By default, the U-Control Module turns off space heating -).)-5-
during DHW heating (if DHW input is priority 1). The Boiler loop pipe size

boiler circulator will turn off, preventing hot water from Ultra-80, 105 1”
Ultra-155, 230 1¼”
circulating to the system (optional time out setting can Ultra-299, 399 1½”
be used to override). The flow/check valve shown on the
See CAUTION at left.
boiler outlet piping prevents gravity circulation in the
boiler loop during DHW heating.
4. Controlling the circulators
a. The U-Control can control up to three circulators (boiler cir-
culator and two others). Refer to Field wiring, beginning on
page 26, for instructions on wiring to circulators.
b. The factory default settings are: DHW circulator as Circula-
tor 1, boiler circulator as Circulator 2 and system circulator
as Circulator 3. See Field wiring instructions, beginning on
page 26, for details.

Legend — Figure 5

1 Ultra boiler 11 Purge/drain valves

2 Indirect water heater (DHW), if used 12 Boiler circulator
3 Boiler relief valve (see page 9 for piping details) 13 Zone valves, typical
4 Relief valve discharge piping (see page 9 for details) 20 Make-up water supply
21 Primary/secondary connection
5 DHW circulator (see page 52 for suggested sizing)
23 DHW connections — see water heater manual for piping
6 Isolation valves
24 Strap system supply and return sensors to lines as shown, at least 6 pipe
7 System circulator (see information above for wiring)
diameters (but no more than 3 feet) from boiler connection tees.
8 Diaphragm (or bladder) type expansion tank (see page 52 for piping of 25 Systems using high-head pumps may require a bypass pressure regulator
closed-type expansion tank, if used) to prevent damage to control valves.
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank] Items supplied with boiler
10 Flow/check valves Items supplied by others

Other piping alternatives

See page 14 and page 15 and ADVANCED INSTALLATION section for additional piping suggestions.

12 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Install water piping — typical systems (continued)

"!3)#).34!,,!4)/.
Zoning with circulators &IGURE 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. Also see the information on page 14
and page 15 for suggested piping and sizing.
Use ATLEAST the -).)-5- pipe size shown in Figure 6
on all boiler loop piping (connecting boiler to and from
the primary/secondary connection, item 21). 5SEONLY
PRIMARYSECONDARYPIPINGASSHOWN Failure to fol-
low these guidelines could result in system problems.
2. Install a separate circulator for each zone.
3. When using a closed-type expansion tank, connect the expansion
tank and make-up water piping as shown in Figure 4, page 11. (DO
NOT use a closed-type tank with a PLUS water heater.)
4. Connect DHW (domestic hot water) piping to indirect storage
water heater as shown.
By default, the U-Control Module turns off space heating -).)-5-
Boiler loop pipe size
during DHW heating (if DHW input is priority 1). The
Ultra-80, 105 1”
boiler circulator will turn off, preventing hot water from Ultra-155, 230 1¼”
circulating to the system (optional timeout setting can Ultra-299, 399 1½”
be used to override). The flow/check valve shown on the See CAUTION at left.
boiler outlet piping prevents gravity circulation in the
boiler loop during DHW heating.
5. Controlling the circulators
a. The U-Control can control up to three circulators (boiler cir-
culator and two others). Refer to Field wiring, beginning on
page 26, for instructions on wiring to circulators.
b. The factory default settings are: DHW circulator as Circula-
tor 1, boiler circulator as Circulator 2. See Field wiring instruc-
tions, beginning on page 26, for details.
c. The zone circulators in Figure 6 must be controlled by circula-
tor relays activated by the zone thermostats or zone controller.

Legend — Figure 6
1 Ultra boiler 10 Flow/check valves
2 Indirect water heater (DHW), if used (see page 52) 11 Purge/drain valves
3 Boiler relief valve (see page 9 for piping details) 12 Boiler circulator

4 Relief valve discharge piping (see page 9 for details) 14 Zone circulators, typical
20 Make-up water supply
5 DHW circulator (see page 52 for suggested sizing)
21 Primary/secondary connection (tees no more than 12 inches apart)
6 Isolation valves
23 DHW connections — see water heater manual for piping
7 System circulator (see information above for wiring)
24 Strap system supply and return sensors to lines as shown, at least 6 pipe
8 Diaphragm (or bladder) type expansion tank (see page 52 for piping of diameters (but no more than 3 feet) from boiler connection tees.
closed-type expansion tank, if used)
Items supplied with boiler
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank] Items supplied by others

Other piping alternatives

See page 14 and page 15 and ADVANCED INSTALLATION section for additional piping suggestions.

Part number 550-100-090/1113 13

 GAS-FIRED WATER BOILER — Boiler Manual

Using with Weil-McLain PLUS LINE water heaters

See !15!0,53 - Product Manual for typical water piping.
See ADVANCED INSTALLATION section for additional piping information and applications.
PLUS DHW installation — quick-selection
&IGURE Ultra boiler with Ultra PLUS or PLUS
water heater — dedicated water heating
The information in this section is for usage of Ultra boilers application, typical piping schematic
with Weil-McLain PLUS indirect water heaters.

For dedicated DHW applications, use the circulator supplied

with the boiler to circulate to the water heater as shown in
this section.

By default, the U-Control Module turns off space heating dur-

ing DHW heating (if DHW input is priority 1). The boiler cir-
culator will turn off, preventing hot water from circulating to
the system (optional timeout setting can be used to override).

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
waterlog. Always use a diaphragm- or bladder-type expansion 2. The PLUS water heater can also be installed as one
tank with PLUS water heaters. of the zones in the system. This method, however,
requires flow through the main system even during
1. Follow the guidelines on this page and page 15 to connect the water the summer (non-space heating) months. Piping
heater to the boiler. Use Figure 8 for dedicated water heating-only as shown in Figure 9 and Figure 10, page 15 allows
applications. Use Figure 9 and Figure 10, page 15 for combined space isolation of flow to just the water heater piping
heating/water heating applications. during non-heating periods.
&IGURE Use the table below to size DHW loop piping and select a circulator (see ADVANCED section for other DHW tanks)

"OILER 0ARTIALLOADSEE&IGUREAND&IGUREPAGE $EDICATEDBOILERSEE&IGURE

5LTRA COMBINEDSPACEHEATINGWATERHEATINGAPPLICATION WATERHEATINGONLY

0,53 '0- -"( '0( (EAD $(7 #)2# 0,53 '0- -"( '0( (EAD $(7 #)2#
MODEL   LOSSFT PIPESIZE MODEL   LOSSFT PIPESIZE

 40 6.5 71/71 160/124 8.5 1 007 40 6.5 71/71 160/124 8.5 1 007
-"(
60 6.5 71/71 168/132 8.5 1 007 60 6.5 71/71 168/132 8.5 1 007
80 6.5 71/71 176/140 8.5 1 007 80 6.5 71/71 176/140 8.5 1 007
 40 10.1 94/94 217/154 17.0 1¼ 0014 40 6.4 94/86 203/141 8.6 1 007
-"(
60 6.4 94/94 211/162 8.6 1 007 60 6.4 94/94 211/162 8.6 1 007
80 6.4 94/94 219/170 8.6 1 007 80 6.4 94/94 219/170 8.6 1 007
 40 12.1 119/98 248/160 15.9 1¼ 0014 40 12.1 119/98 248/160 15.9 1¼ 0014
-"(
60 12.1 139/120 295/220 15.9 1¼ 0014 60 12.1 139/120 295/220 15.9 1¼ 0014
80 12.1 139/139 305/230 15.9 1¼ 0014 80 12.1 139/139 305/230 15.9 1¼ 0014
 40 13.5 120/100 251/162 15.2 1¼ 0014 40 Not recommended — boiler capacity
-"(
60 18.4 169/128 350/207 23.7 1½ 1400-20 60 exceeds maximum output of water heater

80 13.5 207/207 430/325 15.2 1¼ 0014 80 13.5 207/207 430/325 15.2 1¼ 0014
 40 13.1 120/100 250/162 9.7 1¼ 0010 40
-"(
60 19.3 170/129 351/208 11.7 1½ 0014 60
80 24.9 252/252 510/381 18.4 1½ 1400-20 80 Not recommended —
boiler capacity exceeds
 40 13.1 120/100 250/162 9.7 1¼ 0010 40 maximum output of water heater
-"(
60 19.3 170/129 351/208 11.7 1½ 0014 60
80 24.9 320/253 636/382 18.4 1½ 1400-20 80

14 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Using with Weil-McLain PLUS LINE water heaters (cont.)

"!3)#).34!,,!4)/.
See !15!0,53 - Product Manual for typical water piping.
&IGURE Ultra boiler with Ultra PLUS or PLUS-40, -60 or -80 water heater, zone valve zoning, typical piping

"OILERLOOPPIPESIZE 3YSTEMZONEPIPESIZING
"ASEBOARDCONVECTORORCASTIRON
Ultra-80, 105
Ultr 1” or larger RADIATORS/.,9
Ultra-155, 230
Ultr 1¼” or larger For residential space heating appli-
Ultra-299, 399
Ultr 1½ or larger cations (other than radiant heating
or unit heaters) ONLY, you can use:

5LTRA-ODEL 3YSTEMHEADER


80 1” or larger
105, 155 1¼” or larger

230 1½” or larger
299, 399 2” or larger
 Recommendations are based on a 20°F temp
 
 drop through the system.



Zone piping selection for series loops
with finned-tube baseboard — general
 Copper pipe and Max recommended

baseboard size feet of baseboard
¾" 106
1" 179
Contact your supplier to size the system and zone
circulators needed. See below for zone piping
using Taco 007 or equivalent circulators.

Limits for series loop zones with

finned-tube baseboard using
Taco 007 (or equivalent) circulators
Copper Max Max total
Max feet of
pipe and load length of
baseboard
baseboard MBH circuit (feet)
$(7LOOPPIPESIZE
¾" 50 82 93
See Figure 7, page 14 1" 79 104 123

,EGENDfor Figure 9 and Figure 10

&IGURE Ultra boiler with Ultra PLUS or PLUS water heater, typical piping schematics
 DHW circulator (see page 52 for suggested
sizing)
 System circulator (provided by installer)
 Diaphragm type expansion tank ONLY
— DO NOT use a closed-type tank with
PLUS water heaters, because the auto-
matic air vent will deplete the air from
the system, causing the expansion tank
:ONEVALVEZONING #IRCULATORZONING to waterlog.
 Air separator with automatic air vent
 Flow/check valves
 Boiler circulator — provided with boiler
 Zone valves, typical
 Make-up water supply
 Primary/secondary connection
 Strap system supply and return sensors to
lines as shown, at least 6 pipe diameters
(but no more than 3 feet) from boiler
connection tees.
 DHW connections — see water heater
manual for piping
 Automatic air vent must be installed in
the vent tapping on top of the PLUS water
heater.
Items supplied with boiler
Items supplied by others

Part number 550-100-090/1113 15

 GAS-FIRED WATER BOILER — Boiler Manual

Venting/air piping — general

Do not install the Ultra boiler into a common vent with 9OUMUSTPIPECOMBUSTIONAIRTOTHE
any other appliance. This will cause flue gas spillage or ap- BOILERAIRINTAKE.
pliance malfunction, resulting in possible severe personal Install air inlet piping for the Ultra boiler
injury, death or substantial property damage. as described in this manual.
Existing common vent systems may be too large for the The air termination fitting must be in-
appliances remaining connected after the existing boiler stalled with the clearances and geometry
is removed. relative to the vent outlet depicted in this
manual to ensure that flue products do
Failure to follow all instructions can result in flue gas not enter the air intake.
spillage and carbon monoxide emissions, causing severe Ensure that the combustion air will not
personal injury or death. contain any of the contaminants in Fig-
ure 11. Do not pipe combustion air near a
When removing a boiler from an existing swimming pool, for example. Avoid areas
subject to exhaust fumes from laundry
common vent system facilities. These areas will always contain
4HE5LTRABOILERCANNOTBECOMMONVENTEDWITHANYOTHERAPPLI- contaminants.
ANCE. When an existing boiler is replaced with an Ultra boiler, the Ultra Contaminated combustion air will dam-
boiler CANNOT use the existing common vent. The Ultra boiler requires age the boiler, resulting in possible severe
its own vent and air piping, as specified in this manual. This may cause a personal injury, death or substantial
problem for the appliances that remain on the old common vent, because property damage.
the vent may be too large. The following test is intended to check for proper
operation of the appliances remaining on the old common vent system. &IGURE Corrosive contaminants and sources
Vent system verification Products to avoid
At the time of removal of an existing boiler, the following steps shall be Spray cans containing chloro/fluorocarbons
followed with each appliance remaining connected to the common venting Permanent wave solutions
system placed in operation, while the other appliances remaining connected
to the common venting system are not in operation. Seal any unused open- Chlorinated waxes/cleaners
ings in the common venting system. Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Existing vent test procedure Sodium chloride used for water softening
(The following is intended to test whether the appliances Refrigerant leaks
remaining on an existing vent system will operate Paint or varnish removers
satisfactorily.) Hydrochloric acid/muriatic acid
1. Visually inspect the venting system for proper size and horizontal pitch Cements and glues
and determine there is no blockage or restriction, leakage, corrosion or Antistatic fabric softeners used in clothes dryers
other deficiencies which could cause an unsafe condition.
Chlorine-type bleaches, detergents, and cleaning
2. Test vent system — Insofar as is practical, close all building doors and solvents found in household laundry rooms
windows and all doors between the space in which the appliances
remaining connected to the common venting system are located and Adhesives used to fasten building products and other
similar products
other spaces of the building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on any exhaust Excessive dust and dirt
fans, such as range hoods and bathroom exhausts, so they will oper-
ate at maximum speed. Do not operate a summer exhaust fan. Close Areas likely to have contaminants
fireplace dampers. Dry cleaning/laundry areas and establishments
3. Place in operation the appliance being inspected. Follow the lighting in- Swimming pools
structions. Adjust thermostat so appliance will operate continuously.
Metal fabrication plants
4. Test for spillage at draft hood relief opening after 5 minutes of main
burner operation. Use the flame of a match or candle, or smoke from Beauty shops
a cigarette, cigar, or pipe. Refrigeration repair shops
5. After it has been determined that each appliance remaining connected Photo processing plants
to the common venting system properly vents when tested as outlined
herein, return doors, windows, exhaust fans, fireplace dampers, and any Auto body shops
other gas-burning appliance to their previous conditions of use. Plastic manufacturing plants
Any improper operation of common venting system should be corrected Furniture refinishing areas and establishments
so the installation conforms with the National Fuel Gas Code, ANSI Z223.1 New building construction
— latest edition. Correct by re-sizing to approach the minimum size as
determined using the appropriate tables in Part 11 of that code. Canadian Remodeling areas
installations must comply with B149.1 or B149.2 Installation Code. Garages with workshops

16 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Venting/air piping — general (continued)

"!3)#).34!,,!4)/.
Combustion air piping
5LTRA "OILERS MUST BE VENTED
AND SUPPLIED WITH COMBUSTION 1. Combustion air must be piped from outside to the boiler, following the
ANDVENTILATIONAIRUSINGPIPING instructions in this manual, and compliant with all applicable codes.
AND METHODS DESCRIBED IN THIS Read the warning in Figure 11, page 16, and ensure the air intake will
MANUAL. not be likely to draw in contaminated air.
2. Combustion air can be piped individually for each boiler, or it can be
%VERYBOILERMUSTHAVEITSOWN manifolded as shown in Figure 59, page 55. Air piping must always
VENT. $/./4 common vent with terminate on the same side (or roof ) of the building as the vent.
any other appliance. See page 16.
Vent piping
Inspect finished vent and air piping 1. Boiler flue gases must be piped from the boiler to outside, following the
thoroughly to ensure all are airtight instructions in this manual, and compliant with all applicable codes.
and comply with the instructions The vent pipe must terminate either through the sidewall or through
provided and with all requirements the roof, located with the correct separation from the air termination.
of applicable codes. See Figure 14, page 18, and the associated instructions referenced.
2. Each Ultra boiler requires a separate vent. Do not common vent.
Failure to provide a properly-in-
stalled vent and air system will cause Vent and air piping materials
severe personal injury or death. 1. See Figure 12 for approved vent and air piping materials.

Installations must comply with local &IGURE Use only the materials listed below, ensuring that all
requirements and with the National materials meet local codes
Fuel Gas Code, ANSI Z223.1 for
U.S. installations or CSA B149.1 or
B149.2 for Canadian installations. 3TANDARDSFORINSTALLATIONSIN
)TEM -ATERIAL
5NITED3TATES #ANADA
Use only the materials listed in this 0LASTICPIPINGMATERIALS
manual for vent and air pipe and fit-
PVC schedule 40 ANSI/ASTM D1785
tings. Failure to comply could result 6ENTOR Plastic vent pipe
in severe personal injury, death or AIRPIPE PVC-DWV ANSI/ASTM D2665 must be certified
substantial property damage.  to UL S636 when
CPVC schedule 40 ANSI/ASTM F441
lTTINGS required.
ABS-DWV schedule 40 ANSI/ASTM D2661
)FUSEDAMASONRYCHIMNEYCAN 06# PVC ANSI/ASTM D2564 & F656
Air pipe can be any
/.,9BEUSEDASA0)0%#(!3% !"3PIPE
of those listed at left
FORVENTANDAIRPIPES — The vent CPVC ANSI/ASTM F493 if acceptable for local
CEMENT
and air piping must be installed as codes.
PRIMER ABS ANSI/ASTM D2235
instructed in this manual and all !, #PIPINGMATERIALS
joints must be sealed. The chimney
6ENTPIPE Heat Fab, Inc.
must be used only for Ultra boilers. !, # Saf-T-Vent®
NO OTHER appliance or fireplace STAINLESS Certified for Category IV and Certified for Category
can be connected to the chimney. Z-Flex, Inc.
STEEL direct vent IV and direct vent
Z-Vent II
appliance venting appliance venting
The chimney must be straight, with Protech Systems
no offsets, and the vent and air pip- FasNSeal™
ing materials must comply with this AL29-4C vent piping — Install a PVC-to-stainless adapter
instruction manual. supplied by the vent pipe manufacturer at the boiler vent
connection and at the termination (when using Weil-
The chimney must be fitted with McLain plate or concentric PVC termination). DO NOT
a sealed access opening, through mix piping from different vent pipe manufacturers unless
which the interior of the chimney using adapters specifically designed for the purpose by the
can be inspected. manufacturer.
Plastic piping — Do not attempt to connect different types
The chimney and liner must be of plastic piping together.
inspected at least once annually to
verify condition. DO NOT use cellular core PVC (ASTM F891), cellular
core CPVC, or Radel (polyphenolsulfone) in venting
Failure to comply could result in systems.
severe personal injury, death or
substantial property damage. DO NOT cover non-metallic vent pipe and fittings with
thermal insulation.

Part number 550-100-090/1113 17

 GAS-FIRED WATER BOILER — Boiler Manual

Sidewall vent/air termination: Weil-McLain cap

Vent and air pipe termination Vent and air pipe installation sequence
options 3TEP Install the boiler.
1. This section covers sidewall termination using the 3TEP Determine the termination method — sidewall or vertical,
Weil-McLain sidewall vent cap kit supplied with concentric or separate pipes, etc.
each boiler.
a. Models 80, 105 and 155 are shipped with a 3TEP Determine proper location for wall or roof penetration for
3-inch pipe size kit. each termination.
b. Models 230, 299 and 399 are shipped with a 3TEP Install termination assembly as described in this manual.
4-inch pipe size kit.
c. The Weil-McLain sidewall vent/air cap kit in- 3TEP Install air and vent piping from boiler to termination.
cludes the termination cap, inside and outside 3TEP Install pipe supports and brackets as required.
wall plates, and mounting hardware to secure
the plates.
2. For other termination options and parts required, &IGURE 6ENTANDAIRTERMINATIONOPTIONS
see page 62.
Sidewall termination
Vent and air pipe requirements 7EIL -C,AINSIDEWALLTERMINATIONCAP
1. Vent and air pipe diameters can be as specified in
Figure 13.

&IGURE Vent and air pipe requirements

"OILER v v0LASTICOR v0LASTICOR

MODELS 0LASTIC v!, # v!, #
 9ES 9ES .O
 .O 9ES .O
 .O 9ES 9ES
 .O .O 9ES
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, -299 and
-399 boilers require 4.5 inch outside diameter pipe at the
boiler vent and air connections.

Vent and air pipe minimum length

1. Vent pipe and air pipe must each be at least 2 feet
long, with 2 elbows if sidewall venting or 1 elbow
if vertical venting.

Vent and air pipe maximum length

1. See Figure 15, page 19 for maximum length of
vent and air piping using the Weil-McLain sidewall
vent cap.

Commonwealth of Massachusetts
/THER VENTAIR PIPING ALTERNATIVES
— see information beginning on When the boiler is installed within the Commonwealth of Massa-
page 62. Options include other chusetts:
termination fittings and vertical s This product must be installed by a licensed plumber or gas fit-
terminations. ter.
s Sidewall vent air installations — see instructions on page 61.

18 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Sidewall vent/air termination: Weil-McLain cap (continued)

"!3)#).34!,,!4)/.
Provide pipe adapters as needed where pipe Connecting from termination to boiler
size is different from termination connections
or boiler connections, and for all AL29-4C 1. Install the termination as instructed in the following. Then pro-
vent pipe connections at the boiler and the ceed to page 22 to complete the air and vent piping between the
termination. termination and the boiler.

Determine location for termination cap

Allowable vent/air pipe materials
A gas vent extending through an exterior wall shall not
1. Use only the materials listed in Figure 12, page 17. terminate adjacent to the wall or below building exten-
sions such as eaves, parapets, balconies or decks. Failure
Maximum piping length to comply could result in severe personal injury, death
or substantial property damage.
1. Locate the termination such that the total air piping and 1. Locate the vent/air terminations using the following guidelines.
vent piping from the boiler to the termination will not 2. You must consider the surroundings when terminating the vent
exceed the maximum length given in Figure 15. and air:
2. Maximum lengths listed in Figure 15 allow for 2 elbows. a. Position the vent termination where vapors will not damage
Additional elbows required a reduction in maximum nearby shrubs, plants or air conditioning equipment or be
length as explained in the table notes. objectionable.
b. The flue products will form a noticeable plume as they con-
dense in cold air. Avoid areas where the plume could obstruct
&IGURE -AXIMUMPIPINGLENGTHSFOR7EIL window views.
-C,AINSIDEWALLVENTAIRPLATE c. Prevailing winds could cause freezing of condensate and
water/ice buildup where flue products impinge on building
surfaces or plants.
"OILER -AXIMUM -AXIMUM -AXIMUM
5LTRAn 0IPINGv
0IPINGv
0IPINGv

&IGURE Termination location — Weil-McLain vent/air plate —

height
g above g
grade or snow line
Feet Elbows Feet Elbows Feet Elbows

80 ** 100 2 100 2

Not
105 ** 100 2 100 2
allowed

155 Not allowed 100 2

230 Not allowed 30 2 100 2

299 Not allowed Not allowed 100 2

399 Not allowed Not allowed 100 2

* Install pipe reducers to adapt from pipe size used to the 3.5
inch outside diameter required at the termination. You do not
have to reduce allowable pipe length for the reducers. Also
install reducers as necessary where connecting to the boiler
vent and air connections.
** Ultra-80 and 105 boilers installed with 2-inch vent piping
automatically derate due to the pressure loss in the vent and
air piping. The derate ranges up to 10% for the Ultra-80 at 100
feet or 15% for the Ultra-105 at 100 feet.
For piping using more than 2 elbows, reduce maximum allow-
able length:
sFEETFOREACHADDITIONAL INCHELBOW—OR—
sFEETFOREACHADDITIONALOR INCHLONGRADIUSELBOW
sFEETFOREACHOR INCHSHORTRADIUSELBOW
sFEETFOREACHOR INCH DEGREEELBOW

Part number 550-100-090/1113 19

 GAS-FIRED WATER BOILER — Boiler Manual

Sidewall vent/air termination: Weil-McLain plate (cont.)

d. Avoid possibility of accidental contact of flue products with &IGURE Termination location — Weil-McLain vent/air
people or pets. plate — clearances to openings
e. 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.
f. Do not terminate above any door or window or under a deck.
Condensate can freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage to exterior
finishes.
3. Maintain clearances as shown in Figure 16, Figure 17, Figure 18
and Figure 19. Also maintain the following:
a. Vent must terminate:
s At least 6 feet from adjacent walls.
s No closer than 5 feet below roof overhang.
s At least 7 feet above any public walkway.
s At least 3 feet above any forced air intake within 10 feet.
s No closer than 12 inches below or horizontally from any
door or window or any other gravity air inlet.
b. Air inlet must terminate at least 12” above grade or snow line
c. Do not terminate closer than 4 feet horizontally (above or be-
low) from any electric meter, gas meter, regulator, relief valve
or other equipment.
4. Locate terminations so they are not likely to be damaged by foreign &IGURE Termination location — Weil-McLain vent/
air plate — clearances to public walkway or
objects, such as stones or balls, or subject to buildup of leaves or forced air intake
sediment.

Multiple vent/air terminations

1. 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.
2. Place wall penetrations to obtain minimum clearance as shown in
Figure 19 for U. S. installations. For Canadian installations, provide
clearances required by CSA B149.1 or B149.2 Installation Code.
3. 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.
4. Combustion air (NOT vent piping) can be manifolded as shown
in Figure 59, page 55.

&IGURE Termination location — Weil-McLain vent/air

plate — multiple boilers — clearance from
vent of one to air intake of the next

20 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Sidewall vent/air termination: Weil-McLain plate (cont.)

"!3)#).34!,,!4)/.
Install terminations — Weil-McLain vent/air cap &IGURE Hole preparation in wall — Weil-McLain vent/
air plate
The inside and outside cover plates are stamped to iden-
tify the exhaust (vent) and intake (air) openings. Make
sure to orient the plates correctly.
1. Locate termination opening and avoid obstructions:
a. Use the template supplied with the termination kit.
b. Locate the template on the outside building surface where the
penetration is to be made.
c. Make sure there will be no obstructions that might prevent
proper placement of the termination.
d. Use the template to mark the locations for the four mounting
holes, flue pipe and air pipe. 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.

e. Cut holes in the wall as shown in Figure 21, using the location
marks made with the template. For best results, use a small-
diameter, long drill bit to drill centering holes for the flue and &IGURE Termination assembly — Weil-McLain vent/
air pipe openings. Then drill the large openings from both the air plate
inside and outside.
f. The flue pipe and air pipe may be run through a rectangular
cutout (as marked on the template) in lieu of two separate
holes if desired.
2. Drill holes for the screws or plastic anchors to secure the outside
plate. Install the outside plate and mount the termination on the
plate (temporarily).
a. Cut the flue pipe so the extension through the wall will cause
the vent pipe to fully extend into the termination socket.
b. Cut the air pipe so the extension through the wall will butt the
air pipe against the stops inside the termination.
c. When using 3-inch vent piping with a 4-inch termination (Ul- 1 Vent termination (3” or 4”) 6 Outer mounting plate
tra-230 applications), increase the flue pipe size to 4 inch before 2 Lock washer, #10 (4) 7 Inner mounting plate
the pipe passes through the wall. This is required to obtain a 3 Sheet metal screw, #10 x ½” (4)
8 Vent pipe (butt to screen in termina-
seal between the flue pipe and the termination. tion)
4 Plastic wall anchor (8) 9 Air pipe (butt to stops in termina-
d. Temporarily slide the flue and air pipes through the opening(s). 5 Sheet metal screw, #10 x 1¼” (8) tion)
Slide the inside wall plate over the two pipes and into position
on the inside wall.
e. Position the inside plate so the flue pipe and air pipe slope
downward slightly toward the boiler (1/4” per foot). &IGURE Install termination plate
f. Mark the four (4) mounting holes for the plate.
g. Remove the vent and air pipe, drill the four mounting holes, 7EIL -C,AINSIDEWALL
and mount the inside plate. TERMINATIONPLATE
3. Test fit the vent/air termination on the vent pipe. Make sure the
vent pipe fully penetrates the termination socket and the air pipe sInstall pipe supports every 5
butts against the interior stops. feet on both the horizontal and
vertical runs.
4. Apply silicon RTV sealant to the interior of the vent termination sInstall a hanger support within
and slide onto vent pipe. Rotate slightly to spread the silicon to 6 inches of any upturn in the
ensure a tight seal around the vent pipe. piping.
sThe Weil-McLain plate
5. Secure the termination in place using the four #10 x ½” sheet metal termination must be installed
screws and lock washers (see Figure 21). before piping from the boiler to
the termination.
sSlope horizontal piping
downward toward the boiler at
least 1/4 inch per foot.

Part number 550-100-090/1113 21

 GAS-FIRED WATER BOILER — Boiler Manual

Install vent/air piping — boiler to W-M termination

Complete termination preparation &IGURE Boiler vent and air connections
1. Install vent and air terminations before proceeding. See
previous pages for instructions.

Installing vent and air piping

1. For reference in the following, see previous pages.
2. Work from the boiler to vent or air termination. Do not
exceed the lengths given in the previous pages for either
the air or vent piping.
a. As shown in the maximum length tables, the
Ultra-80 or Ultra-105 may be installed with either
2-inch or 3-inch vent and air piping.
b. As shown in the maximum length tables, the
Ultra-230 may be installed with either 3-inch or
4-inch vent and air piping.
c. You must install appropriate pipe reducers, where
required, at both the boiler and at the termination
assembly. Inserting/securing vent or air pipe into
3. See Figure 23 for attaching vent and air pipes at the boiler connectors
boiler.
AL29-4C vent pipe — If using AL29-4C stainless
4. Cut pipe to required lengths. vent pipe, you must install a PVC-to-vent pipe
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
distribution when joining. concentric termination). Use only the adapter made
by the vent pipe manufacturer.
7. Clean all pipe ends and fittings. Dry thoroughly.
8. Dry assemble entire vent or air piping to ensure proper 1. PVC/ABS pipe — Clean and chamfer insertion end of pipe.
fit before assembling any joint. Deburr inside of insertion end. Clean and deburr inside and
outside of other end of pipe.
9. For each joint:
a. Handle fittings and pipes carefully to prevent con- The pipe end must be smooth and chamfered to
tamination of surfaces. prevent possible damage to sealing gasket in vent
b. Apply primer liberally to both joint surfaces — pipe or air pipe adapter. Failure to comply could result
end and fitting socket. in leakage, causing possible severe personal injury
c. While primer is still damp, lightly apply approved or death.
cement to both surfaces in a uniform coating. 2. Inspect vent or air adapter (above) — verify no obstructions
d. Apply a second coat to both surfaces. Avoid using or foreign objects inside.
too much cement on sockets to prevent cement 3. Loosen clamp screw.
buildup inside.
e. With cement still wet, insert pipe into fitting, twist- 4. Measure 3½ inches from end of pipe and make a mark with
ing ¼ turn. Make sure pipe is fully inserted. felt-tip pen.
f. Wipe excess cement from joint. Check joint to be 5. Loosen adapter clamp screw.
sure a smooth bead of cement shows around the 6. Apply small amount of silicon grease to end of pipe to ease
entire joint. insertion.
10. Install pipe supports as shown in Figure 22, page 21. 7. Insert pipe into adapter.
11. Slope vent and air piping continuously toward boiler, 8. Slide pipe down until the 3½-inch mark is reached.
with at least 1/4 inch drop per foot of run. Do not allow
sags at any point. Do not apply excessive force or bend the adapter
12. Maintain minimum clearance of ³⁄₁₆ inch between vent or flue/air pipe when inserting. The adapter or seal
pipe and any combustible wall or material. could be damaged.
13. Seal wall or floor penetration openings following local 9. Secure vent or air pipe by tightening the adapter clamp se-
code requirements. curely. Do not overtighten. The seal is accomplished with the
internal gasket. The clamp is only to hold the pipe in place.

22 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Install condensate line

"!3)#).34!,,!4)/.
Prepare condensate fittings &IGURE Condensate trap assembly
1. Remove PVC fittings 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.
3. Clean nipple ends and all fittings. Dry thoroughly.
4. For each joint in the condensate line, apply the following. Assemble
parts ONLY in the order given.
a. Apply primer liberally to both joint surfaces — pipe end and
fitting socket.
b. While primer is still damp, lightly apply approved cement to
both surfaces in a uniform coating.
c. Apply a second coat of cement to both surfaces. Avoid using too
much cement on sockets to prevent cement buildup inside.
d. With cement still wet, insert pipe into fitting, twisting ¼ turn. &IGURE #ONDENSATETRAPASSEMBLYINTOJACKET
Make sure pipe is fully inserted.
e. Wipe excess cement from joint. Check joint to be sure a smooth
bead of cement shows around the entire joint.
5. See Figure 24.
6. Assemble the ½” PVC nipple to the PVC reducing elbow as
shown.
7. Allow joint to dry completely.
8. Then slide gasket over nipple as shown in Figure 25.
9. Slide nipple through jacket condensate line hole to position as
shown in Figure 25.
10. Cement the ½” tee to the protruding ½” nipple. Be sure both nipple
and reducing elbow finish upright.
Firmly press the reducing elbow and the tee together
while the cement sets to ensure the gasket is securely
compressed. The gasket ensures the jacket enclosure is
airtight at this location.

Connect condensate trap line and fittings

1. Remove condensate trap line from bag.
2. Ultra-80 & -105 only — Figure 26
a. Guide the condensate trap line through the bracket hole as &IGURE Condensate drain — Ultra-80 & -105
shown.
b. Place a hose clamp over the end of the condensate line.
c. Then slide the end of the trap line over the heat exchanger
condensate connection.
d. Tighten the hose clamp to secure the trap line.
e. Place a hose clamp over the other end of the condensate trap
line.
f. Slide the trap line over the reducing elbow and secure with
the hose clamp.
3. Ultra-155 and larger — Figure 28, page 24 or Figure 29, page 24
a. Slide a hose clamp over each end of the condensate trap line.
b. Slide the trap line onto the heat exchanger condensate connec-
tion and PVC reducing elbow as shown.
c. Tighten the hose clamps to secure the trap line.

Part number 550-100-090/1113 23

 GAS-FIRED WATER BOILER — Boiler Manual

Install condensate line (continued)

Condensate drain tubing &IGURE Condensate drain — Ultra-155 & -230 (PVC
1. Connect condensate drain tubing to the ½” PVC tee and run to tee installation shown applies to all models))
floor drain or condensate pump (see Figure 30). Use ½” PVC or
CPVC pipe; or 5/8” I.D. tubing.

Use materials approved by the authority having jurisdic-

tion. In the absence of other authority, PVC and CPVC
pipe must comply with ASTM D1785, F441 or D2665.
Cement and primer must comply with ASTM D2564,
F656, or F493. For Canada, use CSA or ULC certified
PVC or CPVC pipe, fittings and cement.

2. Leave the top of the ½” tee OPEN. This is needed as a vacuum

break.
3. When installing a condensate pump, select one approved for use
with condensing boilers and furnaces. The pump should have an
overflow switch to prevent property damage from condensate
spillage. See Figure 27 for required flow capacity.
4. When sizing condensate pumps, make sure to include the total
load of all Ultra boilers connected to it.
&IGURE Condensate drain — Ultra-299 & -399
The condensate line must remain unobstructed, allow-
ing free flow of condensate. If condensate is allowed to
freeze in the line or if the line is obstructed in any other
manor, condensate can exit from the boiler tee, resulting
in potential water damage to property.
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.

&IGURE Suggested condensate pump capacity, GPH

-INIMUMRECOMMENDEDCONDENSATEPUMP
"OILER
CAPACITYPERBOILER'0(
&IGURE Condensate pump (by others), typical
Ultra-80 2 Ultra-230 6

Ultra-105 3 Ultra-299 8

Ultra-155 4 Ultra-399 8

24 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Gas piping

"!3)#).34!,,!4)/.
Connecting gas supply piping
Use two wrenches when tightening gas
1. 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
a. Install ground joint union for servicing, when required.
turning. Failure to support the boiler gas
b. Install manual shutoff valve in gas supply piping outside boiler
jacket when required by local codes or utility requirements. connection pipe to prevent it from turn-
c. In Canada — When using manual main shutoff valve, it must ing could damage gas line components.
be identified by the installer.
2. Wall-mounted boilers
a. Refer to separate Ultra Boiler Wall-mounting instructions. &IGURE Connect gas supply piping
b. Gas connection may enter from the bottom of boiler as ex-
plained in the Wall-mounting instructions.
3. Support piping with hangers, not by boiler or its accessories.
4. Purge all air from gas supply piping.
5. Before placing boiler in operation, check boiler and its gas con-
nection for leaks.
a. Close manual main shutoff valve during any pressure testing
at less than 13” w.c.
b. Disconnect boiler and gas valve from gas supply piping during
any pressure testing greater than 13” w.c.
Do not check for gas leaks with an open flame — use
bubble test. Failure to use bubble test or check for gas
leaks can cause severe personal injury, death or substan-
tial property damage.
6. Use pipe dope compatible with propane gases. Apply sparingly
only to male threads of pipe joints so that pipe dope does not
block gas flow.
Failure to apply pipe dope as detailed above can result
in severe personal injury, death or substantial property
damage.

DO NOT adjust or attempt to measure gas valve outlet

pressure. The gas valve is factory-set for the correct outlet
pressure. This setting is suitable for natural gas and pro-
pane, requiring no field adjustment. Attempting to alter Natural gas supply pressure
or measure the gas valve outlet pressure could result in 1. Pressure required at gas valve inlet pressure port:
damage to the valve, causing potential severe personal
injury, death or substantial property damage. a. Maximum: 13” w.c. with no flow (lockup) or with
boiler on
Ultra boilers are shipped ready to fire natural gas ONLY. b. Minimum: 4” w.c. (for all except 5” for -299) with
(Exception: Ultra-80LP is propane-ready.) You must gas flowing (verify during boiler startup, while boiler
is at high fire)
install the propane orifice if the boiler will be connected
to propane. See page 44. Failure to comply could result 2. Install 100% lockup gas pressure regulator in supply line
in severe personal injury, death or substantial property if inlet pressure can exceed 13” w.c. at any time. Adjust
damage. lockup regulator for 13” w.c. maximum.

Propane supply pressure

Gas pipe sizing
1. Adjust propane supply regulator provided by gas sup-
1. See page 77 for gas line sizing information. plier for 13” w.c. maximum pressure.
2. Pressure required at gas valve inlet pressure port:
Check gas pressure at inlet to boiler a. Maximum: 13” w.c. with no flow (lockup) or with
boiler on
1. See Figure 37, page 36, Figure 38, page 36, or Figure 39, page 37 s Minimum: 4” w.c. with gas flowing (verify during
for location of the gas inlet pressure test port. boiler startup, while boiler is at high fire).

Part number 550-100-090/1113 25

 GAS-FIRED WATER BOILER — Boiler Manual

Field wiring — basic system

Make the following connections, some of which depend on
%,%#42)#!,3(/#+(!:!2$ — For your your system and how the U-Control will be programmed.
safety, turn off electrical power supply at service ❏ #ONNECT 6!# POWER MINIMUM  AMP
entrance panel before making any electrical con- SOURCE
nections to avoid possible electric shock hazard.
❏ #ONNECTWIRINGFORUPTOTHREECIRCULATORS
Failure to do so can cause severe personal injury
or death. ❏ #ONNECT THERMOSTATS ANDOR HEAT DEMAND CON-
TACTS
Wiring must be N.E.C. Class 1. If original wir- s The U-Control can regulate the boiler for up to three
ing as supplied with boiler must be replaced, use different heating systems.
only type 105 °C wire or equivalent. Boiler must ❏ )NSTALLSYSTEMOUTDOORSENSORSWHENUSED
be electrically grounded as required by National s The boiler is shipped with an outdoor sensor, a
Electrical Code ANSI/NFPA 70 – latest edition. system supply sensor and a system return sensor.
The system supply sensor will be required for most
space heating applications. The system return sensor
must also be installed when using the system supply
sensor. Use of the outdoor sensor is optional.
Installation must comply with:
s Locate the sensors on the system piping as shown
1. National Electrical Code and any other national, state, provincial
in Figure 4, page 11 and other piping drawings
throughout this manual.
or local codes or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any

local codes. Line voltage power input
1. Provide and install a fused disconnect or service switch
(15-ampere rated recommended) as required by ap-
plicable codes.
2. Connect minimum 15-ampere, 120 VAC power wiring
to Ultra boiler line voltage terminal strip as shown in
Wiring — general Figure 32, page 27, and Figure 98, page 80.

1. The U-Control provides plug-in, color-coded, non-interchangeable

terminal strips for all field wiring. See the schematic diagram (Fig- Wiring circulators
ure 98, page 80) & ladder diagram (Figure 99, page 81).
1. The U-Control provides for connection of up to three
2. The U-Control provides programmable flexibility in system op- circulators, one of which must be the boiler circulator.
eration, allowing control of heat supply for up to three different In addition, you can connect a system circulator and a
heating systems. Read this manual thoroughly before connecting DHW circulator, for examples.
the wiring to ensure trouble-free start-up and operation.
4HEMAXIMUMALLOWABLECURRENTFOREACH
CIRCULATOR IS  AMPS AT 6!#. For
Wiring — overview circulators with higher amp ratings, you must
install a circulator relay or starter to provide
line voltage to the circulator. For circulators
See this and following pages for wiring information. Also see the
rated over 2.2 amps, connect only the circula-
Advanced section of this manual for additional wiring connec- tor relay or starter coil to the Ultra circulator
tions and options. terminals.

See PAGE!DVANCEDSECTION FOROTHERWIRINGOPTIONS

26 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Field wiring — basic system (continued)

"!3)#).34!,,!4)/.
&IGURE 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.

Wire the DHW tank aquastat to the U-Control “heat demand 1” input, terminals P11 #4 and #5.

Wire the space heating thermostat (or zone controller or zone valve end switches) across the U-Control “heat demand 2”
input, terminals P15 #1 and #2.

Attach a sensor (supplied with boiler) to the system supply pipe and wire to terminals P14 #1 and #2.
[Locate sensor in the position shown in piping diagrams on page 11 through page 15.]

Attach a sensor (supplied with boiler) to the system return pipe and wire to terminals P14 #2 and #3.
[Locate sensor in the position shown in piping diagrams on page 11 through page 15.]

If you want to use outdoor reset for the space heating circuits, install the outdoor temperature sensor (supplied with boiler)
and wire to terminals P10 #1 and #2.

Wire the DHW circulator (supplied by installer) as circulator 1, following instructions on Connect the boiler circulator (sup-
plied with boiler) as circulator 2, following instructions on page 26.

Wire the boiler circulator (supplied with boiler) as circulator 2, following instructions on page 26.

Wire the system circulator (supplied by installer) as circulator 3, following the instructions on page 26.

$ETAILED CONTROL INFORMATION AND ADDITIONAL WIRING — see the ADVANCED INSTALLATION section of this
manual.

Part number 550-100-090/1113 27

 GAS-FIRED WATER BOILER — Boiler Manual

U-Control operation and setup

4EMPERATURESETTINGS — You must ensure that the U- &IGURE U-Control sequence of operation
Control is set for the proper water temperatures for the $ISPLAY #ONTROLACTION(also see Figure 34, page 29)
system. Excessive water temperature can cause significant s Check the boiler model listed on the power-up
property damage in some applications. screen. If it is not correct, turn off the boiler. See
0/7%2 Figure 102, page 86 to change setting.
s When power is turned on, the screen lists sen-
50 sors that are detected. If any sensor is not listed,
-ULTI TEMPERATURESYSTEMS — If the heating system make sure it is connected correctly. Turn off
power and restart.
includes circuits that require lower temperature water
s Standby — no calls for heat
(radiant slab circuits, for example) as well as higher s Toggles through no dots, 1 dot, 2 dots, then
temperature circuits (DHW, finned tube baseboard, etc.), 3 dots while in standby (wrench symbol will
3TANDBY show instead if maintenance is needed)
it is recommended to protect low-temperature circuits
s Call for heat detected
with limit controls that are wired to a U-Control external s Display on with BLUE light (space heating) or
limit circuit. Failure to provide regulation can result in PURPLE light (DHW)
s Start min/max on timers if more than one system
substantial property damage. is calling — highest priority starts first
s Start circulators for this priority setup
s Calculate target temp — If sensor temp is below
target temp, begin firing sequence
s Blower to ignition speed for prepurge
U-Control overview s -ULTIPLE BOILERSHEAT SOURCES ONLY — Start
"LOWERON additional-heat timer — type 1 boiler starts
The U-Control is fully programmable to meet system requirements, allow- immediately; type 2 activates other heat source
ing supply water regulation for up to three different systems. immediately, but doesn’t start unless the timer
times out; type 3 (LEAD boiler) starts immedi-
U-Control features include: ately and sends 0–10 VDC signal to others after
timer times out; type 4 receives signal from
❏ Blower speed modulation to control the Ultra boiler’s firing rate. LEAD boiler and starts immediately (and starts
timer for the next boiler, if programmed)
❏ Advanced PID response to anticipate system needs based on response s After prepurge times out, begin ignition cycle
to heat input. s Activate gas valve and ignition spark
❏ Graphic and robust text display for ease of operation monitoring and s
s
Continue ignition spark for ignition period
Turn off spark and use electrode to check for
troubleshooting. )GNITIONON
flame signal
❏ Preset operating parameters for typical heating systems (finned tube s Flame detected
baseboard, radiant floor, DHW, and others), including target tempera- s Hold boiler at low fire for 1 minute
tures, reset curves and circulator assignments. s Release boiler to modulation
s NOTE: If flame is not detected, the gas valve
❏ Control of up to three circulators (boiler circulator plus two others), is turned off, blower turns on (postpurge), and
control starts cycle again. After 5 failures, the
assignable for each of the three possible inputs. 3PACE
control waits 60 minutes, then tries again.
HEATING
❏ Programmable priority assignments for the heat inputs. s If priority timer times out, switch to next priority
and start priority timer
❏ Integral outdoor reset option, with reset curves matched to the system s If demand satisfied, go to postpurge
type selected. s Flame detected
s Release boiler to modulation immediately
❏ Multiple boiler/heat source sequencing or modulation. s NOTE: If flame is not detected, the gas valve
❏ Built-in 0–10 VDC signal generator to allow parallel modulation of is turned off, blower turns on (postpurge), and
control starts cycle again. After 5 failures, the
multiple boilers; also capable of accepting 0–10 VDC input. $(7 control waits 60 minutes, then tries again.
❏ Dual sensors for boiler outlet temperature and flue temperature, pro- HEATING s If priority timer times out, switch to next priority
and start priority timer
viding redundant protection. s If demand satisfied, go to postpurge
❏ Integral low water protection (by monitoring boiler heat exchanger s Demand satisfied (temperature reaches target
temperature). temperature or limit setting)
s Gas valve off
❏ Boiler is shipped with an outdoor sensor and strap-on system supply "LOWERON
s Blower to ignition speed for postpurge
and return sensors. s Return to standby after purge
s Display turns RED, toggling between graphic
screen and maintenance screen (occurs when
Sequence of operation maintenance schedule timer times out)
s Will show during standby only
-AINTENANCE
1. Figure 33 is a summary of the operating sequence for the U-Control. s Boiler operates as normal
s Display turns RED due to error or limit event
2. The symbols shown appear in the display as the U-Control cycles the s Flashing display means lockout condition —
boiler. display toggles between three screens as in
%RRORFAULT Figure 111, page 101.
3. The wrench symbol appears when a scheduled maintenance date arrives.
This informs the homeowner to call the contractor for service. s Warm weather shutdown — the boiler will not
be allowed to fire if the outside temperature is
4. The exclamation mark symbol appears when a problem has been greater than the WWSD setting.
773$
detected.

28 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

U-Control operation and setup (continued)

"!3)#).34!,,!4)/.
&IGURE U-Control display and navigation

1 — Screen color

NO BACKLIGHT
(Blue = space heating or when a button is pressed) H H : M M A M M M / D D / Y Y

(Screen will show solid red, with the exclamation

mark symbol, if a non-shutdown failure occurs; i.e.,
failure of a non-critical sensor, such as outdoor or
system supply or return sensor.)

H H : M M A M M M / D D / Y Y Time and date

MODULATION #########
I N F O

STANDBY
2 — Status graphic (Pressing any button changes
background to blue, below.)

BLUE BACKLIGHT
3 — Firing rate bar H H : M M A M M M / D D / Y Y

4 — Operating status /
Active system
MODULATION #########
I N F O
MODULATION #########
I N F O

Display above is typical

PURPLE BACKLIGHT
for normal operation. The Move selection up
H H : M M A M M M / D D / Y Y
center symbol changes BUTTONS
to show operation status. Move selection down

Press to switch to Next screen

INFO screen.
Previous screen MODULATION #########
The INFO screen, below I N F O

is for at-a-glance information Enter

DHW HEATING
during normal operation. (Domestic hot water heating)

HH:MM AM MM/DD/YY Time and date

STATUS: ######### Active system type
RED BACKLIGHT

(see Figure 101, page 85) H H : M M A M M M / D D / Y Y

MODULATION: Firing rate

TARGET: ###°F Setpoint temperature

SUPPLY: ###°F Supply temperature M O D U L A T I O N A L E R T
I N F O

RETURN: ###°F Return temperature Alternating colors

OUTDOOR: ###°F Outdoor air temperature
Systems with
DEMAND: ### ### ### heat demand (see Figure 101, page 85)
NO BACKLIGHT

PUMPS: # # # Pumps operating H H : M M A M M M / D D / Y Y

ADD'L HEAT DEMAND:### ON or OFF

SETTINGS Select to change settings

SELECT Scroll up or down MODULATION #########

I N F O

PREVIOUS ENTER Previous screen or ENTER BOILER IN LOCKOUT

(Attention required to
U5002 restart boiler)

Part number 550-100-090/1113 29

 GAS-FIRED WATER BOILER — Boiler Manual

U-Control operation and setup (continued)

EXPRESS SETUP — using default settings
&OR DETAILED CONTROL INFORMATION
ANDADDITIONALWIRING, see the AD- 1. The U-Control is factory programmed to supply a DHW circuit
(control priority 1) and finned tube baseboard space heating (control
VANCED INSTALLATION section
priority 2).
of this manual.
2. Control priority 3 is also available, and preset to run all three circulators
if desired, but requires settings to be configured.

&IGURE Factory default settings

,OW TEMPERATURE SYSTEMS (ra-
diant slab, etc.) — $/ ./4 use 0RIORITY 4YPE 4ARGETTEMPERATURE #IRCULATORS
ENABLED
the Ultra boiler control as the only
DHW
means of water temperature regula- 1 190°F #1 Only
Direct
tion for low-temperature systems if
180°F fixed (if no outdoor sensor) or
higher-temperature systems are also Finned
2 180°F at 0°F outside / 130°F at 70°F #2 and #3
tube BB
supplied. outside
180°F fixed (if no outdoor sensor) or
3 Custom 180°F at 0°F outside / 130°F at 70°F None
outside

3. You can use the factory default settings for most systems supplying
space heating with finned-tube baseboard with or without a DHW
tank, provided:
a. A DHW tank, if used, must be piped directly to the boiler, as in the
piping shown in Figure 5, page 12 or Figure 6, page 13.
b. If the DHW tank is a separate zone off of the system main, or if it is
piped as in Figure 48, page 48, you will need to enable additional cir-
culators for DHW operation. The U-Control is factory programmed
to operate only the DHW circulator during DHW heating.
c. The heat emitters in the system must be finned tube baseboard only.
Other heat emitters require changes in the U-Control setup. See
ADVANCED INSTALLATION section for information.
4. Wiring to use the factory default settings — see information in Fig-
ure 32, page 27 for wiring instructions.

30 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Startup — fill the system

"!3)#).34!,,!4)/.
Clean system to remove sediment Antifreeze
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-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.
sediment. 2. See Replacement parts at the end of this manual for Weil-
2. For zoned systems, flush each zone separately through a purge McLain part numbers to obtain antifreeze through a Weil-
valve. (If purge valves and isolation valves are not already McLain distributor.
installed, install them to properly clean the system.)
3. Flush system until water runs clean and you are sure piping Use the correct amount of antifreeze
is free of sediment. 1. Determine the freezing temperature needed (to protect
against lowest likely temperature the system water will
encounter).
Do not use petroleum-based cleaning or
sealing compounds in boiler system. Dam- 2. Find the antifreeze concentration by volume needed for this
age to elastomer seals and gaskets in system temperature from the antifreeze manufacturer’s data on the
could occur, resulting in substantial prop- antifreeze container.
erty damage. 3. Add up the volume (gallons) of all system piping and com-
ponents, including the expansion tank and boiler.
Before filling the boiler and system with a. Boiler water content is listed on page 121.
water, verify the following. $/ ./4 lLL b. Remember to include expansion tank water content.
WITHSOFTENEDWATER Boiler corrosion can
occur. 4. Multiply this volume by the (percent) antifreeze needed to
find the number of gallons of antifreeze to add.
Failure to comply could result in boiler
failure or unreliable operation.
Fill and test water system
1. Fill system only after ensuring the water meets the require-
ments of this manual.
Water chemistry 2. Close manual and automatic air vents and boiler drain
valve.
Water pH between 7.0 and 8.5 3. Fill to correct system pressure. Correct pressure will vary
with each application.
1. Maintain boiler water pH between 7.0 and 8.5. Check with a. Typical cold water fill pressure for a residential system
litmus paper or have chemically analyzed by water treatment is 12 psi.
company. b. Pressure will rise when boiler is turned on and system
2. If pH differs from above, consult local water treatment com- water temperature increases. Operating pressure must
pany for treatment needed. never exceed 25 psig.
3. DO NOT use softened water. Softened water can cause cor- 4. At initial fill and during boiler startup and testing, check
rosion. system thoroughly for any leaks. Repair all leaks before
proceeding further.
Hardness less than 7 grains Eliminate all system leaks. Continual fresh make-up
1. Consult local water treatment companies for unusually hard water will reduce boiler life. Minerals can build up
water areas (above 7 grains hardness). in sections, reducing heat transfer, overheating heat
exchanger, and causing heat exchanger failure.
Chlorine concentration must be
LESS THAN 200 ppm
Use inhibitor supplied with boiler
1. Filling with chlorinated fresh water should be acceptable
since drinking water chlorine levels are typically less than 1. The Ultra boiler is shipped with Sentinel X100 inhibitor and
5 ppm. Sentinel inhibitor test kit. See Repair Parts at the end of this
manual for re-ordering information.
2. Do not use the boiler to directly heat swimming pool or
spa water. 2. After filling the system as directed in these instructions, use
a caulking gun to inject the X100 inhibitor into the system,
3. Do not fill boiler or operate with water containing chlorine following the instructions on the tube.
in excess of 200 ppm.
3. Inject all of the inhibitor supplied with the boiler. Allow time
for the water to circulate and mix. Then check the inhibitor
level. Add additional inhibitor if necessary.

Part number 550-100-090/1113 31

 GAS-FIRED WATER BOILER — Boiler Manual

Startup — fill the system (continued)

Check/verify water chemistry
Freeze protection (when used)
1. The system may have residual substances that could affect water
Follow these guidelines to prevent pos- chemistry.
sibility of severe personal injury, death 2. After the system has been filled and leak tested, verify water pH and
or substantial property damage: chlorine concentrations are acceptable.
.%6%2USEAUTOMOTIVEORSTANDARD 3. Verify antifreeze concentration, when used.
GLYCOLANTIFREEZE,EVENGLYCOLMADE
FOR HYDRONIC SYSTEMS . Use only 4. Follow the instructions on the Sentinel test kit to sample the system
freeze-prevention fluids recommended water and verify inhibitor concentration.
by Weil-McLain for application in Ultra
Boiler systems. Check inhibitor concentration annually
4HOROUGHLYmUSHANYSYSTEMTHAT
HASUSEDGLYCOL before installing the 1. Test the pH of a sample of system water at least annually. The pH of
new Ultra boiler. the water mixture must be between 7.0 and 8.5. (Or use the Sentinel
inhibitor test kit to check concentration.)
2EVIEW THE MATERIAL SAFETY DATA
SHEET-3$3 for the fluid used with 2. If pH is outside this range (or inhibitor test kit indicates low level), the
the boiler owner and leave a copy for inhibitor level may not be sufficient to prevent corrosion.
reference. The MSDS contains informa- 3. Test antifreeze concentration.
tion on potential hazards and first aid
procedures for exposure or ingestion. Test antifreeze concentration at least annually. If concentra-
tion is low, add antifreeze or drain system and refill with
#HECK ANTIFREEZE INHIBITOR LEVEL AT correct mixture.
LEAST ANNUALLY. Glycol concentration
and inhibitor levels may change over 4. Follow instructions on antifreeze container to determine the amount
time. Add antifreeze to increase con- of antifreeze needed. $/./4 exceed 50% by volume concentration
centration if necessary. Add inhibitor of antifreeze.
as needed to bring to acceptable level, 5. Check inhibitor level after adjustments are made.
using inhibitor test kit to verify.
When using freeze protection fluid with
automatic fill, INSTALLAWATERMETERTO Purge air from water system
MONITORWATERMAKE UP. Freeze pro-
tection fluid may leak before the water 1. Connect a hose to the purge valve (see purge/drain valves, item 11, in
begins to leak, causing concentration piping diagrams beginning on page 12 and page 48. Route hose to an
to drop, reducing the freeze protection area where water can drain and be seen.
level. 2. Close the boiler or system isolation valve between the purge valve and
$/ ./4 EXCEED  ANTIFREEZE fill connection to the system.
BY VOLUME. Antifreeze moves more 3. Close zone isolation valves.
sluggishly than water and can interfere 4. Open quick-fill valve on cold water make-up line.
with heat transfer. At antifreeze concen-
trations higher than 50%, sludge can 5. Open purge valve.
develop in the boiler, potentially causing 6. One zone at a time, open the isolation valves. Allow water to run through
damage to the heat exchanger. the zone, pushing out the air. Run until no noticeable air flow is present.
#LEAN THE SYSTEM BEFORE FILLING. Close the zone isolation valves and proceed with the next zone. Follow
Always drain and flush the system this procedure until all zones are purged.
thoroughly before filling with antifreeze. 7. Close the quick-fill water valve and purge valve and remove the hose.
Sludge, iron oxide deposits and other Open all isolation valves. Watch that system pressure rises to correct
sediment in the system inhibit flow and cold-fill pressure.
can cause rapid breakdown of inhibi-
tors. 8. After the system has operated for a while, eliminate any residual air by
using the manual air vents located throughout the system.
Use only antifreeze recommended by
Weil-McLain. 9. If purge valves are not installed in system, open manual air vents in
system one at a time, beginning with lowest floor. Close vent when
Weil-McLain provides information for water squirts out. Repeat with remaining vents.
application of the antifreeze products
listed in this document only for use in 10. Open automatic air vent (diaphragm-type or bladder-type expansion
Weil-McLain Ultra boilers. Do not apply tank systems only) one turn.
these products or instructions for other 11. Starting on the lowest floor, open air vents one at a time until water
applications. Local codes may require a squirts out.
backflow preventer or actual disconnec-
tion from city water supply. 12. Repeat with remaining vents.
13. Refill to correct pressure.

32 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Startup — final checks

"!3)#).34!,,!4)/.
Inspect/fill condensate system
Check for gas leaks
Inspect/check condensate lines and
Before starting the boiler, and during initial opera- fittings
tion, use a leak detector or smell near the floor and 1. Inspect the condensate drain line, condensate PVC
around the boiler for gas odorant or any unusual fittings and condensate trap. (See page 23 for com-
odor. Remove boiler front door and smell interior ponent locations.)
of boiler enclosure. Do not proceed with startup 2. Pour water into the top of the boiler’s ½” PVC
if there is any indication of a gas leak. Repair any condensate tee and check for any leaks in the con-
leak at once. densate drain line or fittings. Repair any leaks.

DO NOT adjust or attempt to measure gas valve Fill condensate trap with water
outlet pressure. The gas valve is factory-set for the 1. Loosen the hose clamp securing the right end of
correct outlet pressure. This setting is suitable for the condensate trap to the PVC reducing elbow
natural gas and propane, requiring no field adjust- (see page 23 for details).
ment. Attempting to alter or measure the gas valve 2. Slide the trap hose end off of the elbow.
outlet pressure could result in damage to the valve,
3. Fill the trap with fresh water to within an inch of
causing potential severe personal injury, death or
the end of the hose.
substantial property damage.
4. Replace trap hose on PVC reducing elbow and
tighten the hose clamp.
Propane boilers only — Your propane supplier
mixes an odorant with the propane to make its The condensate trap must be filled with
presence detectable. In some instances, the odorant water during all times of boiler operation
can fade, and the gas may no longer have an odor. to avoid flue gas emission from the con-
Before startup (and periodically thereafter), have densate drain line. [Prime the condensate
trap (by pouring water into the outlet
the propane supplier verify the correct odorant tee while restricting flow in drain tube)
level in the gas. if boiler has been out of service for an
extended period.] Failure to fill the trap
could result in severe personal injury or
death.

Check thermostat circuit(s) Final checks before starting

1. Disconnect the two external wires connected to boiler
the boiler thermostat terminals (see Field wiring,
beginning on page 26 for terminal locations).
❏ Read the instructions to adjust and set up the U-
Control module.
2. Connect a voltmeter across these two incoming
wires. Close each thermostat, zone valve and relay
❏ Verify that the boiler model is set correctly in the
U-Control, and that it displays correctly.
in the external circuit one at a time and check the
voltmeter reading across the incoming wires. ❏ Verify that the boiler and system are full of water
and all system components are correctly set for
3. There should NEVER be a voltage reading. operation.
4. If a voltage does occur under any condition, check
and correct the external wiring. (This is a common
❏ Fill vent condensate trap with water (by remov-
ing hose clamp and hose at PVC reducing elbow).
problem when using 3-wire zone valves.) Replace hose on PVC reducing elbow and tighten
5. Once the external thermostat circuit wiring is clamp.
checked and corrected if necessary, reconnect the
external thermostat circuit wires. Allow the boiler
❏ Verify electrical connections are correct and se-
curely attached.
to cycle.
❏ Inspect vent piping and air piping for signs of
deterioration from corrosion, physical damage or
sagging. Verify air piping and vent piping are intact
and correctly installed per this manual.

Part number 550-100-090/1113 33

 GAS-FIRED WATER BOILER — Boiler Manual

Startup — final checks (continued)

To start the boiler Venting system must be sealed gas-tight
to prevent flue gas spillage and carbon
1. Turn OFF the boiler ON/OFF switch. monoxide emissions which will result in
2. Read and follow the Operating Instructions, Fig- severe personal injury or death.
ure 36, page 35.
3. The U-Control display will show installed sensors ❏ Check gas piping
when first powered. Make sure the right sensors are
detected. If not, determine the cause and correct 1. Check around the boiler for gas odor following the
before proceeding. procedure of page 25 of this manual.
If you discover evidence of any gas leak,
If boiler does not start correctly shut down the boiler at once. Find the
leak source with bubble test and repair
1. Check for loose connections, blown fuse or service immediately. Do not start boiler again
switch off? until corrected. Failure to comply could
2. Is external limit control (if used) open? Is boiler result in severe personal injury, death or
water temperature above 200 °F? substantial property damage.
3. Is thermostat set below room temperature?
4. Is gas turned on at meter or boiler? ❏ Propane boilers — verify
5. Is incoming gas pressure less than 5” w.c. for natural conversion
gas or 4” w.c. for propane? 1. Verify propane orifice has been installed per Pro-
6. Are parameters set correctly in this manual? pane Conversion instructions.
7. Is the warm weather shutdown activated?
8. If none of the above corrects the problem, refer to DO NOT adjust or attempt to mea-
Troubleshooting, beginning on page 99. sure gas valve outlet pressure. The
gas valve is factory-set for the cor-
❏ Check system and boiler rect outlet pressure. This setting is
suitable for natural gas and propane,
requiring no field adjustment.
❏ Check water piping
Attempting to alter or measure the
9. Check system piping for leaks. If found, shut down gas valve outlet pressure could result
boiler and repair immediately. (See WARNING on in damage to the valve, causing po-
page 31 regarding failure to repair leaks.) tential severe personal injury, death
10. Vent any remaining air from system using manual or substantial property damage.
vents. Air in the system will interfere with circula- Ultra boilers are shipped ready to
tion and cause heat distribution problems and fire natural gas ONLY. Exception:
noise. The Ultra-80LP is factory-equipped
to fire propane. You must install the
❏ Check vent piping and air piping propane orifice if the boiler will be
1. Check for gas-tight seal at every connection and connected to propane. See page 44.
seam of air piping and vent piping. Failure to comply could result in
severe personal injury, death or
substantial property damage.

34 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Startup — final checks (continued)

"!3)#).34!,,!4)/.
&IGURE Operating instructions (WARNING — Verify that the U-Control is set for the correct boiler model before proceeding.)

Part number 550-100-090/1113 35

 GAS-FIRED WATER BOILER — Boiler Manual

Startup — final checks (continued)

❏ Check flame & combustion with instruments &IGURE -ODELSˆ4HROTTLESCREW

LOCATION/.,9FORUSEBYAQUALIlED
For Ultra-399 propane boilers, special start-up is re- TECHNICIANUSINGCALIBRATEDCOMBUSTION
quired. See page 37 for procedure. See DANGER on TESTINSTRUMENTS
page 45 before proceeding.
1. Initiate a call for heat on one of the heat demand inputs.
2. Access the U-Control installer menus by pressing and holding the
UP and DOWN arrow keys for five seconds.
3. Use the U-Control display to navigate to Manual test mode (see
Figure 102, page 86) and force the firing rate to MAX (high fire).
4. Look at the flame through the flame inspection window. The high
fire flame should be blue and should be stable. The burner surface
should be covered with orange dots.
5. Remove the flue temperature sensor from the flue pipe and in-
sert a combustion test probe., using a calibrated combustion test
instrument.
6. Test for CO2 (or O2) and for CO. The CO2 values must be within
1.0% of the values listed in Figure 40. If results are acceptable,
proceed to step 7.IF NOT, follow the instructions under “Throttle
screw adjustment procedure” to set the throttle screw position.
See WARNING below.

If combustion at either high or low fire is outside the

range given in Figure 40, follow the procedure given
on page 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
technician, using calibrated test instruments. Failure &IGURE -ODELSˆ4HROTTLESCREW
to comply could result in severe personal injury, LOCATION/.,9FORUSEBYAQUALIlED
death or substantial property damage. TECHNICIANUSINGCALIBRATEDCOMBUSTION
TESTINSTRUMENTS
7. Measure natural gas input:
a. Operate boiler 10 minutes.
b. Turn off other appliances.
c. At natural gas meter, measure time (in seconds) required to
use one cubic foot of gas.
d. Calculate gas input:
3600 x 1000
= Btuh
number of seconds from step c

e. Btuh calculated should approximate input rating on boiler

rating label.
8. Use the U-Control display to navigate to Manual test mode (see
Figure 102, page 86) and force the firing rate to MIN (low fire).
9. Look at the flame through the flame inspection window. The low
fire flame should be stable and evenly distributed over burner
surface with a uniform orange color.
10. Repeat the combustion test of steps 4 and 5 above.
11. Use the U-Control display to navigate to Manual test mode (see
Figure 102, page 86) and force the firing rate to AUTO (normal
operation).
12. Replace the flue gas temperature sensor. When replacing the sen-
sor, remove the rubber grommet from the probe. Insert the rubber

36 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Startup — final checks (continued)

"!3)#).34!,,!4)/.
grommet into the flue pipe, then insert the probe into the rubber &IGURE -ODELˆ4HROTTLESCREWLOCATION
grommet. /.,9FORUSEBYAQUALIlEDTECHNICIAN
You must replace the flue gas temperature sensor to USINGCALIBRATEDCOMBUSTIONTEST
prevent flue gas spillage into the boiler enclosure. Failure INSTRUMENTS
to comply could result in severe personal injury, death
or substantial property damage.

Ultra-399 propane conversion & start-up

Ultra-399 boilers are converted for propane by adjustment of the gas
valve throttle screw (no orifice change) — Figure 39. This must only
be done while using a combustion analyzer.
1. Turn the gas valve throttle screw clockwise 5 turns before starting
the boiler. Then follow the start-up procedure on page 36.
2. Once the boiler is started, make slight adjustments to the throttle
screw to obtain a CO2 of 10.2% with CO less than 100 ppm air
free. (Allow the combustion analyzer’s reading to stabilize before
making adjustments.)
3. After the boiler has been set up correctly, the conversion is com-
plete. Fill in the information on the propane conversion label and
attach the label to the boiler rating plate.

Throttle screw adjustment procedure

See Figure 37, page 36, Figure 38, page 36, or Figure 39, page 37 for
location of the throttle screw.
DO NOT attempt to adjust the throttle screw unless by
a qualified technician, and with the use of calibrated
combustion test instruments. Adjust the throttle screw ❏ Adjust and test boiler controls
only as needed to meet the combustion values given in 1. Follow instructions in this manual to set and verify
Figure 40. operation of the boiler controls.
1. This procedure is only necessary when specified elsewhere in this
manual or when combustion tests indicate the need, as explained
under “❏ Check flame & combustion with instruments, &IGURE Acceptable CO2 and CO values (CO2 values
page 36.” must be within 1.0% of the values listed)
2. Boiler behavior that might indicate a need to check combustion
values at high fire (as per page 36) to verify boiler is in adjustment (IGHlRE ,OWlRE
include: difficulty igniting, poor flame stability at low fire, combus- "OILER &UEL
#/ #/PPM #/ #/PPM
tion noise or high carbon monoxide values.
NG 8.6 < 60 7.8 < 60
3. Combustion readings must be taken at both high fire and low fire. Ultra-80
DO NOT attempt an adjustment of the throttle screw at low fire. LP 9.6 < 60 8.6 < 60
Just check the combustion values. NG 9.0 < 60 8.4 < 60
Ultra-105
4. Use the U-Control display to navigate to Manual test mode (see LP 10.1 < 60 9.2 < 60
Figure 102, page 86) and force the firing rate to MAX (high fire). NG 9.0 < 60 8.0 < 60
After the boiler has had time to stabilize, take a CO2 reading. Ultra-155
LP 10.0 < 60 8.5 < 60
a. If the CO2 is HIGH, turn the throttle screw CLOCKWISE to
NG 9.0 < 60 8.0 < 60
lower the input. Allow the boiler to stabilize and take another Ultra-230
reading. Continue until the desired CO2 value is achieved. LP 10.0 < 60 9.0 < 60
b. If the CO2 is LOW, turn the throttle screw COUNTERCLOCK- NG 9.0 < 60 8.0 < 60
Ultra-299
WISE to increase the input. Allow the boiler to stabilize and LP 10.0 < 60 9.0 < 60
take another reading. Continue until the desired CO2 value is NG 9.2 < 100 8.4 < 60
achieved. Ultra-399
LP 10.2 < 100 10.0 < 60
5. Lock the boiler into low fire. Check the combustion readings. If
results are acceptable at low fire, verify high fire readings again. The values above are with the boiler front door removed.
Values will typically increase about 0.2% once the door is
Restore firing rate to AUTO.
reinstalled.
6. 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. altitudes, CO2 may be slightly lower and CO slightly higher.

Part number 550-100-090/1113 37

 GAS-FIRED WATER BOILER — Boiler Manual

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
❏ Entered installation date and installer contact information manual reset lockout as desired.)
into U-Control?
❏ Set additional field-installed limit control(s) to system
❏ Boiler and heat distribution units filled with water? temperature requirements? Adjusted balancing valves and
controls to provide design temperature to system?
❏ Water chemistry verified per page 31?
❏ Sentinel X100 corrosion inhibitor added and water tested ❏ For multiple zones, adjusted for correct flow in each zone?
to be within range?
❏ Verified thermostat heat anticipator (if available) set prop-
erly?
❏ Automatic air vents, if used, open one full turn?
❏ Air purged from system? ❏ Cycled boiler with thermostat (and with DHW aquastat, if
installed) — Raised to highest setting and verified boiler goes
❏ Air purged from gas piping? Piping checked for leaks? through normal startup cycle? Lowered to lowest setting and
verified boiler goes off?
❏ Primed condensate trap?
❏ Measured natural gas input? (page 36)
❏ Propane orifice installed for propane firing and propane
conversion label affixed to jacket?
❏ Checked incoming gas pressure by connecting manometer
to gas valve ahead of boiler? (Gas pressure must be at least
Ultra boilers are shipped ready to fire natural
5 inches w.c. for natural gas, and 4 inches w.c. for propane,
gas ONLY. Exception: The Ultra-80LP is factory-
with boiler operating at high fire, and no more than 13 inches
equipped to fire propane. To fire on propane, for
w.c. with boiler operating or boiler off.)
all other models, you must follow the instructions
in this manual to install the propane orifice or
conversion kit, or make adjustments required, if ❏ Observed several operating cycles for proper operation?
the boiler will be connected to propane. See page 9.
Failure to comply could result in severe personal ❏ Set room thermostat to desired room temperature (and
injury, death or substantial property damage. DHW aquastat, if installed, to desired DHW storage tem-
perature)?
❏ Thermostat circuit wiring checked to ensure there are no
stray voltages? ❏ Reviewed all instructions shipped with this boiler with owner
or maintenance person?
❏ Followed Operating Instructions, Figure 36, page 35?
❏ Burner flame and combustion verified per page 36? ❏ Fill in )NSTALLATIONCERTIlCATE, page 124.

❏ Verified control operation for space heating and DHW (if ❏ Fill out the warranty registration card and send to Weil-
used) per this manual? McLain.

❏ Tested additional field-installed controls? — If boiler has ❏ Return instructions to envelope and give to owner or place
a low water cutoff, additional high limit or other controls, inside boiler housing.

Fill out start-up data on the In-

stallation and Service Certificate,
page 124.

38 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

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Part number 550-100-090/1113 39

 GAS-FIRED WATER BOILER — Boiler Manual

The Gas-fired water boiler, Featuring Flexibility

Models 80, 105, 155 and 230 16. U-Control-ODULE

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. Heat exchanger access cover temperature, and outdoor temperature, if used). The control
3. Blower module automatically adjusts blower speed (and gas flow rate)
to match boiler output to space heating and/or DHW heating
The advanced blower design and air inlet silencer on Ultra boilers result
demand.
in very quiet operation.
Models Ultra-80 & 105 — Air enters the boiler enclosure through the 17. Swing-away control panel assembly
air intake adapter (18), flows through the enclosure, enters the air inlet The Ultra control panel is mounted to a hinged subpanel, al-
silencer (5), then enters the blower. The blower pulls air through the lowing the panel to be swung forward and down for easy access
silencer and pushes it into the venturi (6), where it mixes with gas before to the electrical connections.
entering the burner.
18. Air intake adapter
Models Ultra-155 & 230 — Air enters the boiler enclosure through the
air intake adapter (18), flows through the enclosure, enters the air inlet The air intake adapter incorporates an internal drain on mod-
silencer (5), then enters the venturi (6). The blower pulls air and gas els 80 and 105.
through the venturi and pushes the mixture into the burner.
19. Electrical entrance
4. Gas valves and sense lines Knockouts are provided in the jacket top panel, allowing con-
The automatic gas valve (4a) senses the vacuum in the venturi caused by duit entry directly behind the control panel or near the wall.
flowing air, and allows gas to flow when power is applied. The manual gas
valve (4b) allows shutting off the gas supply for servicing or shutdown. 20. Boiler drain valve
Models 80 and 105 use a sensing line (4c) from the gas valve to the blower
21. Line voltage receptacle
outlet so the gas valve references the same pressure as the venturi inlet.
Use this connection to plug in line voltage meters or tools
5. Air inlet silencer while working on boiler. It can also be used for connecting a
The horn-shaped air inlet silencer significantly reduces fan noise, provid- condensate pump. Do not exceed 10-amp load.
ing exceptionally quiet operation.
22. P/T gauge temperature sensor well
6. Venturi The remote sensor for the panel-mounted pressure/temperature
When air flows through the venturi, it creates a vacuum. This vacuum gauge inserts into the outlet water pipe here.
pulls gas from the gas valve. So gas will only flow if air is flowing. On
model 80 and 105, the gas/air mixture enters the burner after the venturi. 23. Flue gas condensate drain
On models 155 and 230, the gas/air mixture enters the blower before Connect the boiler internal condensate trap line to the heat ex-
passing on to the burner. changer here (parts supplied with boiler, but field installed).
7. Outlet water temperature dual sensor 24. Flue gas condensate drain connection
This sensor monitors boiler outlet water temperature. The control mod- The condensate trap PVC fittings are field-installed, connected
ule adjusts boiler firing rate so the outlet temperature is correct, based to the condensate trap line as shown in this manual.
on boiler outlet and system supply temperatures.
25. Front door
8. Boiler return water temperature sensor
The front door is sealed to the boiler assembly around its entire
This sensor monitors return water temperature. The control module
perimeter.
reduces or increases boiler input, depending on how close the return
water temperature is to the outlet water temperature. 26. Knurled-head jacket door retainer screws
9. Temperature and pressure gauge Two knurled-head screws secure the door in place.

10. Electronic display & buttons 27. Ignition electrode/flame sensor

The electronic display is used to configure boiler settings and monitor The burner flame is ignited by applying a high voltage to the ig-
boiler operation. nition electrode. This causes a spark (from electrode to ground).
The buttons allow changing display mode, entering setting values, and After ignition, the electrode measures flame signal.
resetting after lockout.
28. Flame inspection window
11. Flue pipe adapter with internal drain The quartz glass window provides a view of the burner surface
and flame.
12. Burner (not shown)
Made with high-grade stainless steel construction, the burner uses pre- 29. Flue gas dual sensor
mixed air and gas. The burner and control provide modulating firing. This dual sensor monitors the flue gas exit temperature. The
13. Water outlet pipe (system supply) control module will shut down the boiler if flue gas temperature
gets too hot. This protects the flue pipe and the heat exchanger
14. Water return pipe (system return) from overheating.
15. Gas connection pipe 30. ON/OFF switch

40 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

The Gas-fired water boiler, Featuring Flexibility

!$6!.#%$).34!,,!4)/.

Part number 550-100-090/1113 41

 GAS-FIRED WATER BOILER — Boiler Manual

The Gas-fired water boiler, Featuring Flexibility

Models 299 and 399 16. U-Control-ODULE

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. Heat exchanger access cover temperature, and outdoor temperature, if used). The control
module automatically adjusts blower speed (and gas flow rate)
3. Blower to match boiler output to space heating and/or DHW heating
demand.
The advanced blower design and air inlet silencer on Ultra boilers result
in very quiet operation. 17. Swing-away control panel assembly
The Ultra control panel is mounted to a hinged subpanel, al-
Air enters the boiler enclosure through the air intake adapter (18), flows
lowing the panel to be swung forward and down for easy access
through the enclosure, enters the air inlet silencer (5), then enters the
to the electrical connections.
venturi (6). The blower pulls air and gas through the venturi and pushes
the mixture into the burner. 18. Air intake adapter
4. Gas valves and sense lines 19. Electrical entrance
The automatic gas valve (4a) senses the vacuum in the venturi caused by Knockouts are provided in the jacket top panel, allowing con-
flowing air, and allows gas to flow when power is applied. The manual gas duit entry directly behind the control panel or near the wall.
valve (4b) allows shutting off the gas supply for servicing or shutdown.
20. Boiler drain valve
5. Air inlet silencer
21. Line voltage receptacle
The horn-shaped air inlet silencer significantly reduces fan noise, provid-
Use this connection to plug in line voltage meters or tools
ing exceptionally quiet operation.
while working on boiler. It can also be used for connecting a
condensate pump. Do not exceed 10-amp load.
6. Venturi
When air flows through the venturi, it creates a vacuum. This vacuum 22. P/T gauge temperature sensor well
pulls gas from the gas valve. So gas will only flow if air is flowing. The The remote sensor for the panel-mounted pressure/temperature
gas/air mixture enters the blower before passing on to the burner. gauge inserts into the outlet water pipe here.

7. Outlet water temperature dual sensor 23. Flue gas condensate drain
This sensor monitors boiler outlet water temperature. The control mod- Connect the boiler internal condensate trap line to the heat ex-
ule adjusts boiler firing rate so the outlet temperature is correct, based changer here (parts supplied with boiler, but field installed).
on boiler outlet and system supply temperatures.
24. Flue gas condensate drain connection
8. Boiler return water temperature sensor The condensate trap PVC fittings are field-installed, connected
to the condensate trap line as shown in this manual.
This sensor monitors return water temperature. The control module
reduces or increases boiler input, depending on how close the return 25. Front door
water temperature is to the outlet water temperature.
The front door is sealed to the boiler assembly around its entire
perimeter.
9. Temperature and pressure gauge
26. Knurled-head jacket door retainer screws
10. Electronic display & buttons
Two knurled-head screws secure the door in place.
The electronic display is used to configure boiler settings and monitor
boiler operation. 27. Ignition electrode/flame sensor
The buttons allow changing display mode, entering setting values, and The burner flame is ignited by applying a high voltage to the ig-
resetting after lockout. nition electrode. This causes a spark (from electrode to ground).
After ignition, the electrode measures flame signal.
11. Flue pipe adapter with internal drain
28. Flame inspection window
12. Burner (not shown) The quartz glass window provides a view of the burner surface
and flame.
Made with high-grade stainless steel construction, the burner uses pre-
mixed air and gas. The burner and control provide modulating firing. 29. Flue gas dual sensor
This dual sensor monitors the flue gas exit temperature. The
13. Water outlet pipe (system supply) control module will shut down the boiler if flue gas temperature
gets too hot. This protects the flue pipe and the heat exchanger
14. Water return pipe (system return) from overheating.

15. Gas connection pipe 30. ON/OFF switch

42 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

The Gas-fired water boiler, Featuring Flexibility

!$6!.#%$).34!,,!4)/.

Part number 550-100-090/1113 43

 GAS-FIRED WATER BOILER — Boiler Manual

Prepare boiler — convert for propane

&IGURE Orifice identification

Prepare boiler for propane
(when required)

Propane operation
5LTRABOILERSMUSTBECONVERTEDFORPROPANE
OPERATION UNLESS SPECIlCALLY MANUFACTURED
FORPROPANE. Propane-ready boilers have suffix “LP”
after the model number. All other boilers require
conversion for propane operation.
5LTRA  natural gas boilers require installation of a
burner in addition to an orifice change. $/./4 use
the instructions in this manual for these boilers. Use
only the instructions included in the special-order
conversion kits.
#ONVERTINGEXISTINGNATURALGAS lREDBOILERFOR
PROPANE — For a boiler already installed, you must &IGURE Installing propane orifice
turn off gas supply, turn off power and allow boiler (Ultra-105 or Ultra-80LP ONLY)
to cool before proceeding. You must also completely
test the boiler after conversion to verify performance
and start up the boiler following instructions begin-
ning on page 31 of this manual.
(IGH ALTITUDE INSTALLATIONS — For installations
more than 5,500 feet above sea level, obtain the high
altitude propane orifice kit..
6ERIFYORIlCESIZE — See Figure 41. Verify when
installing that the orifice size marking matches boiler
size. Use only the special-order HIGHALTITUDE orifice
for altitudes above 5,500 feet.
Failure to comply could result in severe personal
injury, death or substantial property damage.

Installing propane orifice

)FBOILERISALREADYINSTALLED — You must turn off elec-
trical supply to the boiler and close the external manual
gas shut-off valve to isolate the boiler during conversion.
Allow the boiler to cool if it has been operating. Following
conversion of an installed boiler, follow all instructions
in this manual to start up the boiler and verify operation
of the boiler and all system components.
1. Locate propane orifice disc from conversion kit bag.
2. Verify that the stamping on the orifice disk matches the model
size (see Figure 41).
3. With the new boiler on its back, remove jacket front door by re-
moving two knurled head screws at lower front.

44 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Prepare boiler — convert for propane (continued)

4. Lift the door away from boiler. &IGURE Installing propane orifice
5. Remove the air inlet silencer from the adapter: (Ultra-155, -230, and -299)
a. Models 80 and 105: See Figure 121, page 117.
b. Models 155 and 230: See Figure 122, page 118.
c. Models 299 and 399: See Figure 123, page 119.
6. Disconnect the gas valve electrical plug.
7. See Figure 42, page 44 or Figure 43. Remove the 4 screws securing
gas valve inlet adapter to valve.
8. Use a 5-mm wrench to remove the three Allen-head screws secur-
ing the gas valve to the venturi (Figure 42, page 44 or Figure 43).
9. Place orifice in the black rubber grommet in the side of the gas
valve and secure in valve (Figure 42, page 44 or Figure 43).
See Figure 42, page 44 or Figure 43. Inspect the O-ring
between the gas valve and gas valve inlet adapter when-
ever they are disassembled. The O-ring must be in good
condition and must be installed. Failure to comply will
cause a gas leak, resulting in severe personal injury or

!$6!.#%$).34!,,!4)/.
death.
10. Reposition gas valve against venturi and replace (3) Allen-head
screws securing valve to venturi (Figure 42, page 44 or Figure 43).
11. See Figure 42, page 44 or Figure 43. Secure gas valve inlet adapter Ultra-399 boilers
to gas valve with 4 screws. Make sure the plastic hose is connected
from gas valve to inlet elbow on Ultra-80 and -105.
Ultra-399 boilers are converted for pro-
$/./4!44%-044/-%!352%6!,6%/54,%4 pane by adjustment of the gas valve throt-
02%3352% The valve could be damaged by manom- tling screw. See instructions on page 37
eter fluid contamination. Failure to comply could result of this manual.
in severe personal injury, death or substantial property Do not perform the propane conversion
damage. of an Ultra-399 boiler without using a
12. Connect gas valve electrical plug to valve terminals. flue gas analyzer. The proper use of a
flue gas analyzer is required to determine
13. Re-attach the air inlet silencer. proper gas valve settings. Improper gas
valve settings can cause severe personal
14. After installation is complete, attach the propane conversion label injury, death or substantial property
(in conversion kit bag) next to the boiler rating plate. damage.
15. Replace jacket front panel.

Part number 550-100-090/1113 45

 GAS-FIRED WATER BOILER — Boiler Manual

Placing boiler — wall-mounting option

Wall-mounted boilers (Ultra-80 through -399) &IGURE 5LTRA THROUGH5LTRA ONLYˆInstall
bottom-piping grommets if required
1. The wall-mounting kit is NOT supplied as standard equipment
with the boiler, and must be purchased separately. See 7!2.).'
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.
The wall must be vertically plumb and capable of
carrying the weight of the boiler. The operating
weights for wall-mountable boilers are:
Ultra-80: 139 pounds Ultra-105: 145 pounds
Ultra-155: 181 pounds Ultra-230: 192 pounds
Ultra-299: 229 pounds Ultra-399: 229 pounds
Failure to comply with above and the procedure
given below could result in severe personal injury,
death or substantial property damage. &IGURE Install wall-mount bracket

2. Verify kit contents:

a. Wall-mount bracket.
b. Black iron bushing, 1” x 1/8” NPT.
c. Lag screws, (2) 3/8” x 3” hex head.
d. Grommet, (1) 7/8” O.D. & grommets, (2) 1 3/8” O.D.
e. Automatic air vent, 1/8” NPT.
f. Items b through e are needed only if routing piping through
bottom of enclosure (applies only for Ultra-80 through
-230).
g. Verify all parts listed above are available before proceeding.
3. Stud spacing: Bracket holes are spaced for studs on 16-inch centers.
For other stud spacing, provide secure, solid mounting surface on &IGURE Place boiler on wall-mount bracket
which to attach the boiler wall-mounting bracket.
4. Wood stud wall: Install bracket with lag screws (3/8” x 3”) included
in kit, only into the studs.
5. Metal stud wall: Secure bracket to studs with 3/16-inch toggle bolts
and 3/16-inch flat washers (not included with kit).
6. $/./4 attempt to attach the wall mount bracket using anchors
or any means other than directly securing to the wall studs (or
equivalent wood structure if studs are not on 16-inch centers).
7. The boiler bracket must engage with the wall-mount bracket. Make
sure the brackets are not just resting edge to edge.
8. Mount the boiler on the wall following these instructions. Perform
all procedures given in the Boiler Manual on pages 1 through 9
before mounting the boiler.
The boiler is heavy. Use caution not to drop the boiler
or cause bodily injury while lifting and handling. Verify
that the boiler is securely attached to prevent possibility
of boiler falling after installation.

46 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Placing boiler — wall-mounting option (continued)

Prepare boiler for wall mounting &IGURE Bottom-piping configuration only (Ultra-80 to
1. Remove the jacket front panel. This will simplify lifting and han- -230 only)
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.
3. Ultra-80 to -230 only: To route the piping through the bottom of
the boiler enclosure:
a. Remove knockouts from bottom piping penetrations as shown
in Figure 44, page 46.
b. Insert grommets into the penetration holes as shown.

Install wall-mount bracket

1. Locate studs.
2. Place the wall-mount bracket on the wall, using a level to align
correctly.
3. Place the bracket so the mounting slots are centered over the
studs.
4. Level the bracket and trace the outline of the screw slots with a
pencil.

!$6!.#%$).34!,,!4)/.
5. Remove bracket and drill holes 1/4” diameter by 3 inches deep,
centered on the screw slot outlines. (For metal stud walls, using
3/16” toggle bolts, drill required clearance holes.)
6. See Figure 45, page 46. Position bracket on wall. Insert and loosely
tighten the two lag screws (or toggle bolts for metal studs).
7. Level the bracket. Then tighten screws securely. For drywall or
plaster lathe installations, avoid tightening so much that brackets
dig into wall surface.

Place boiler on bracket

1. Measure 30 3/4 inches below the bottom edge of the wall-mount
bracket for Ultra-80 to -230 (35 5/8” for Ultra-299/399). Strike a line
or place a piece of masking tape on the wall with its top edge even
with the 30-inch mark. (This line, or tape, will indicate whether the
boiler has been properly seated onto the wall-mount bracket.) 2. Remove pipe caps from bottoms of supply, return and
gas lines to route piping through bottom.
2. Obtain assistance to lift the boiler into position (see Fig-
ure 46, page 46): 3. Install items in Figure 47:
a. Lift the boiler high enough that its rear bracket will be above a. 1” pipe cap on top of return pipe (item 7).
the wall-mount bracket.
b. ½” pipe cap on top of gas line (item 8)
b. Let the rear of the boiler slide against the lag screw heads as
you lower the boiler into place. c. 1” x 1” x ¾” tee (item 4).
c. When the brackets are engaged correctly, the bottom of the d. ¾” steel elbow (item 5), relief valve (item 6).
boiler enclosure will be at or near the pencil line, or tape, you e. 1” x 1/8” bushing (item 9).
applied in step 1.
d. If the boiler does not slide down close to the mark, or tape, f. Air vent (item 10) on top of the supply pipe as
adjust until the brackets properly engage. shown.
4. See instructions beginning on page 9 to connect boiler
piping. Connect piping to:
Piping through the bottom of the boiler
a. 1” NPT male boiler return (item 1).
Use two wrenches when tightening piping at boiler, b. 1” NPT male boiler outlet (item 3).
using one wrench to prevent the boiler pipe from turn- c. ½” NPT male gas (item 2).
ing. Failure to support the boiler piping connections to
prevent them from turning could cause damage to boiler DO NOT use automatic air vent on systems
components. with closed-type expansion tanks. Instead,
1. Use the following procedure to arrange piping through the bottom replace item 10 above with a line to the expan-
of the boiler. See Figure 47. sion tank.

Part number 550-100-090/1113 47

 GAS-FIRED WATER BOILER — Boiler Manual

Install water piping — advanced

Zoning with zone valves &IGURE Zone valve zoning plus optional DHW piping
(alternate to piping shown in Figure 5, page 12)
High-flow-rate/high-head-loss DHW circuits
1. 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. The DHW water only
flows through the secondary circuit connector piping. NOTE: Make
sure to size the connector piping (Figure 48, item 23) to handle the
total flow it must handle.
2. Connect boiler to system as shown in Figure 48 when zone valve
zoning. The primary/secondary piping shown ensures the boiler
loop will have sufficient flow. It also avoids applying the high head
of the boiler circulator to the zone valves.
Use ATLEAST the -).)-5- pipe size shown in Figure 48
on all boiler loop piping (connecting boiler to and from
the primary/secondary connection, item 21). 5SEONLY
PRIMARYSECONDARYPIPINGASSHOWN Failure to fol-
low these guidelines could result in system problems.
-).)-5-
Boiler loop pipe size
3. When using a closed-type expansion tank, connect the expansion
Ultra-80, 105 1”
tank and make-up water piping as shown in Figure 4, page 11. Ultra-155, 230 1¼”
4. Connect DHW (domestic hot water) piping to indirect storage Ultra-299, 399 1½”
water heater as shown. See CAUTION at left.

By default, the U-Control Module turns off space heating

during DHW heating (if DHW input is priority 1). The
boiler circulator will turn off, preventing hot water from
circulating to the system (optional timeout setting can
be used to override). The flow/check valve shown on the
boiler outlet piping prevents gravity circulation in the
boiler loop during DHW heating.
5. Controlling the system circulator and boiler circulator
a. You will have to set up the U-Control to operate both the boiler
circulator and the DHW circulator during DHW operation.
The system circulator should be off during DHW heating. Read
the instructions on U-Control operation and setup, beginning
on page 28.

Legend — Figure 48
1 Ultra boiler 12 Boiler circulator
2 Indirect water heater (DHW), if used 13 Zone valves, typical
3 Boiler relief valve (see page 9 for piping details) 20 Make-up water supply
4 Relief valve discharge piping (see page 9 for details)
21 Primary/secondary connection (tees no more than 12 inches apart)
5 DHW circulator (see page 52 for suggested sizing)
23 DHW supply/return
6 Isolation valves
24 Strap system supply and return sensors to lines as shown, at least 6 pipe
7 System circulator (see information above for wiring) diameters (but no more than 3 feet) from boiler connection tees.
8 Diaphragm (or bladder) type expansion tank (see page 52 for piping of
25 Systems using high-head pumps may require a bypass pressure regulator
closed-type expansion tank, if used) to prevent damage to control valves.
9 Air separator [with automatic air vent only on systems using diaphragm
23 DHW secondary connector piping — no more than 12 inches apart
(or bladder) type expansion tank]
10 Flow/check valves Items supplied with boiler
11 Purge/drain valves Items supplied by others

48 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Install water piping — advanced (continued)

Example system with DHW as a zone, &IGURE Circulator zoning plus optional DHW piping
zoning with circulators
1. Connect boiler to system as shown in Figure 49 when circulator
zoning. The boiler circulator cannot be used for a zone. It must
supply only the boiler loop. Also see the information on page 10
for suggested piping and sizing.
Use ATLEAST the -).)-5- pipe size shown in Figure 49
on all boiler loop piping (connecting boiler to and from
the primary/secondary connection, item 21). 5SEONLY
PRIMARYSECONDARYPIPINGASSHOWN Failure to fol-
low these guidelines could result in system problems.
2. Install a separate circulator for each zone.
3. DO NOT use a closed-type tank with a PLUS water heater in the
system. The automatic air vent required on the water heater will
deplete air in the system, causing the expansion tank to waterlog.
Use only a diaphragm- or bladder-type tank, suitable for automatic
air vent applications.
-).)-5-
4. In this example, the PLUS 60 DHW tank is piped as a zone in the Boiler loop pipe size
system, with piping connections to the tank in accordance with Ultra-80, 105 1”

!$6!.#%$).34!,,!4)/.
Ultra-155, 230 1¼”
the PLUS manual. Ultra-299, 399 1½”
5. Wiring to the U-Control See CAUTION at left.
a. Priority 1 = PLUS 60 (zone 1): wire PLUS 60 aquastat terminals
to U-Control P11, pins 4 and 5. Wire DHW circulator, A, to
U-Control P2, terminals 1, 4 and 7 (H, N, G).
b. Wire zone pumps B and C to a two-zone circulator relay.
c. Priority 2 = finned-tube baseboard (zones 2 and 3): wire cir-
culator relay end switch 1 to U-Control P15, pins 1 and 2.
6. Make sure to set Priority 1 to DHW system, not DHW direct.
7. Controlling the system circulator and boiler circulator
a. You will have to set up the U-Control to operate both the boiler
circulator and the DHW circulator during DHW operation.
Read the instructions on U-Control operation and setup,
beginning on page 28.

Legend — Figure 49
1 Ultra boiler 10 Flow/check valves

2 Indirect water heater (DHW), if used 11 Purge/drain valves

12 Boiler circulator
3 Boiler relief valve (see page 9 for piping details)
20 Make-up water supply
4 Relief valve discharge piping (see page 9 for details)
21 Primary/secondary connection (tees no more than 12 inches apart)
6 Isolation valves
24 Strap system supply and return sensors to lines as shown, at least 6 pipe
diameters (but no more than 3 feet) from boiler connection tees.
8 Diaphragm (or bladder) type expansion tank (see page 52 for piping of
closed-type expansion tank, if used)
Items supplied with boiler
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank] Items supplied by others

Part number 550-100-090/1113 49

 GAS-FIRED WATER BOILER — Boiler Manual

Install water piping — advanced (continued)

Radiant heating applications &IGURE Typical radiant heating system piping plus
1. The Ultra boiler is ideal for use in radiant heating. The Ultra optional DHW
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.
2. Connect boiler to system as shown in Figure 50 for typical radiant
heating applications. The primary/secondary piping shown ensures
the boiler loop will have sufficient flow. Size the system piping and
circulator to provide the flow and pressure drop needed for the
radiant system.
Use ATLEAST the -).)-5- pipe size shown in Figure 50
on all boiler loop piping (connecting boiler to and from
the primary/secondary connection, item 21). 5SEONLY
PRIMARYSECONDARYPIPINGASSHOWN Failure to fol-
low these guidelines could result in system problems.
3. Adding the recommended high limit control (Figure 50, item 22)
can help ensure supply water temperature will not exceed the
maximum allowable for the radiant system. Wire this limit control
in either the manual reset or automatic reset external limit circuit
of the U-Control.
-).)-5-
4. When using a closed-type expansion tank, connect the expansion Boiler loop pipe size
tank and make-up water piping as shown in Figure 4, page 11. Ultra-80, 105 1”
5. Connect DHW (domestic hot water) piping to indirect storage Ultra-155, 230 1¼”
water heater as shown. Ultra-299, 399 1½”
See CAUTION at left.
By default, the U-Control Module turns off space heating
during DHW heating (if DHW input is priority 1). The
boiler circulator will turn off, preventing hot water from
circulating to the system (optional timeout setting can
be used to override). The flow/check valve shown on the
boiler outlet piping prevents gravity circulation in the
boiler loop during DHW heating.
6. Controlling the circulators
a. The U-Control can control up to three circulators (boiler cir-
culator and two others). Refer to Field wiring, beginning on
page 26, for instructions on wiring to circulators.
b. The factory default settings are: DHW circulator as Circula-
tor 1, boiler circulator as Circulator 2. See Field wiring instruc-
tions, beginning on page 26, for details.

Legend — Figure 50
1 Ultra boiler 12 Boiler circulator
2 Indirect water heater (DHW), if used 13 Zone valves, when used (zoning may also be done using manifold-mounted
valve actuators)
3 Boiler relief valve (see page 9 for piping details)
20 Make-up water supply
4 Relief valve discharge piping (see page 9 for details)
21 Primary/secondary connection (tees no more than 12 inches apart)
5 DHW circulator (see page 52 for suggested sizing)
22 Optional high limit temperature control, set to protect radiant tubing
6 Isolation valves
23 DHW supply/return
7 System circulator (see information above for wiring)
24 Strap system supply and return sensors to lines as shown, at least 6 pipe
8 Diaphragm (or bladder) type expansion tank (see page 52 for piping of diameters (but no more than 3 feet) from boiler connection tees.
closed-type expansion tank, if used)
25 Systems using high-head pumps may require a bypass pressure regulator
9 Air separator [with automatic air vent only on systems using diaphragm to prevent damage to control valves.
(or bladder) type expansion tank]
10 Flow/check valves Items supplied with boiler

11 Purge/drain valves Items supplied by others

50 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Install water piping — advanced (continued)

Chilled water systems &IGURE Chilled water system plus optional DHW
1. Install boiler so that chilled medium is piped in parallel with the piping
heating boiler. Use appropriate valves to prevent chilled medium
from entering boiler. See Figure 51 for typical installation of bal-
ancing valve and check valve.
Use ATLEAST the -).)-5- pipe size shown in Figure 51
on all boiler loop piping (connecting boiler to and from
the primary/secondary connection, item 21). 5SEONLY
PRIMARYSECONDARYPIPINGASSHOWN Failure to fol-
low these guidelines could result in system problems.
2. The space heating system may be zoned with circulators if a separate
circulator is supplied for the chilled water loop.
If antifreeze is used in the system, consider the effects of
antifreeze on circulator sizing and DHW performance.
Some local codes may require double-wall DHW heat
exchanger design.
Chilled medium, if used, is piped in parallel with heating
boiler as shown in Figure 51. Use appropriate valves to
prevent chilled medium from entering boiler. -).)-5-
Boiler loop pipe size
If boiler is connected to heating coils located in air han- Ultra-80, 105 1”

!$6!.#%$).34!,,!4)/.
dling units where they can be exposed to refrigerated Ultra-155, 230 1¼”
air, use flow control valves or other automatic means to Ultra-299, 399 1½”
prevent gravity circulation during cooling cycle. See CAUTION at left.

By default, the U-Control Module turns off space heating

during DHW heating (if DHW input is priority 1). The
boiler circulator will turn off, preventing hot water from
circulating to the system (optional timeout setting can
be used to override). The flow/check valve shown on the
boiler outlet piping prevents gravity circulation in the
boiler loop during DHW heating.
3. Controlling the circulators
a. The U-Control can control up to three circulators (boiler cir-
culator and two others). Refer to Field wiring, beginning on
page 26, for instructions on wiring to circulators.
b. The factory default settings are: DHW circulator as Circula-
tor 1, boiler circulator as Circulator 2. See Field wiring instruc-
tions, beginning on page 26, for details.

Legend — Figure 51
1 Ultra boiler 15 Closed-type expansion tank
2 Indirect water heater (DHW), if used 16 Water chiller
3 Boiler relief valve (see page 9 for piping details) 17 Check valve
4 Relief valve discharge piping (see page 9 for details) 18 Strainer
5 DHW circulator (see page 52 for suggested sizing) 19 Balancing valve
6 Isolation valves 20 Make-up water supply
7 System circulator (see information above for wiring) 21 Primary/secondary connection (tees no more than 12 inches apart)
8 Diaphragm (or bladder) type expansion tank (see page 52 for piping of 23 DHW supply/return
closed-type expansion tank, if used)
24 Strap system supply and return sensors to lines as shown, at least 6 pipe
9 Air separator [with automatic air vent only on systems using diaphragm diameters (but no more than 3 feet) from boiler connection tees.
(or bladder) type expansion tank]
25 Systems using high-head pumps may require a bypass pressure regulator
10 Flow/check valves to prevent damage to control valves.
11 Purge/drain valves
12 Boiler circulator Items supplied with boiler
13 Zone valves, typical Items supplied by others

Part number 550-100-090/1113 51

 GAS-FIRED WATER BOILER — Boiler Manual

Sizing direct-connected DHW piping

Direct-connected DHW piping The closest circulator selection (from Fig-
ure 55, page 53) that can deliver 12 gpm at
For 7EIL -C,AIN 0,53 WATER HEATERS, refer to the 22.7 feet head is either a Taco 1400 (topCHART
PLUS water heater manual for application information. or a Taco 0013 (bottom chart).
Also see quick-select information on page 14. The infor-
Note that, if the water heater were piped as in
mation here is for other water heater designs.
Figure 53, then H1 would be 0, so total head loss
When using the Ultra boiler for dedicated DHW appli- would be H2 + H3, or 9.4 feet (3.9 + 5.5). A Taco
cations, use the circulator supplied with the boiler (007 0010 would handle the load if piped this way.
for Ultra-80/105; 0014 for Ultra-155/230/299; 0013 for
Ultra-399) to circulate to the water heater, except where See previous pages in this manual for
higher flow rates may be required for the heater used. piping details not shown below. For
Use the following method to select a circulator for the DHW piping as shown below, use sizing
water heater on combined space heating/DHW systems. information in Figure 54, page 53.
1. To pipe the DHW tank and boiler, follow the suggested piping
diagrams beginning on page 12. &IGURE DHW piping direct-connected across the
2. Figure 55, page 53 shows the pump curves for typical DHW circu- boiler
lators. Use these curves along with boiler pressure drop data from
Figure 54, page 53 to size the DHW piping and circulator.
3. Procedure to select a DHW circulator:
3TEP:
From the water heater manufacturer’s data, find:
s2EQUIREDBOILERWATERmOWRATE'0-AT—&
s0RESSUREDROPACROSSTHEWATERHEATERATTHISmOWRATEINFEET
water column (this is H3 in the formula below).
3TEP:
Find your boiler model in Figure 54, page 53.
Select a flow rate in the Flow rate column just larger than the
required boiler water flow rate from Step 1.
3TEP:
Read across the row selected to find the boiler pressure drop, H1,
and the pressure drop in the piping, H2. Make sure to use the cop-
per pipe size given in column 3 when piping the water heater.
3TEP:
Add the pressure drop across the water heater, from Step 1, to the
&IGURE DHW piping as a secondary circuit — for
values of H1 and H2 for total head loss. high-flow-rate applications

(TOTAL(((

3TEP:
Select a circulator that can deliver the required flow rate, gpm,
against the total head loss found in Step 4.
%XAMPLE:
Consider an Ultra-155 used with a water heater that requires a
flow of 12 gpm with boiler water at 190°F. The water heater is to
be piped as in Figure 52.
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 54, page 53 for the Ultra-155
until you find a flow rate just larger than the required 12 gpm.
You’ll find a value of 13 gpm in the third row.
At 13 gpm, with an Ultra-155, the recommended pipe size is
1¼ inch. From the table, the head losses are:
H1 = 13.3 feet H2 = 3.9 feet
H3 = 5.5 feet (from water heater manufacturer’s data)
Htotal = 13.3 + 3.9 + 5.5 = 22.7 feet.

52 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Sizing direct-connected DHW piping (continued)

&IGURE Pipe sizing and head losses for DHW &IGURE Pump curves for typical circulators suggested for DHW loop
applications (H1=Ultra boiler head loss;
H2=piping head loss)

Flow Temp Pipe ! B & G PL-36

H1 H2
rate rise size
B Taco 0011
Boiler head Piping head # Taco 0010
GPM °F Inches loss loss
Feet w.c. Feet w.c. $ Taco 007

5LTRA "TUHOUTPUT + Taco 1400-30

7 20 1 6.6 2.7
9 16 1 11.6 4.2
10 14 1¼ 14.6 2.5
5LTRA "TUHOUTPUT
7 27 1 7.0 2.7
9 21 1 11.2 4.2
10 19 1¼ 13.6 2.5

!$6!.#%$).34!,,!4)/.
13 14 1¼ 22.2 3.9
5LTRA "TUHOUTPUT
9 31 1¼ 6.2 2.1
10.0 28 1¼ 7.7 2.5
13 21 1¼ 13.3 3.9 % Taco 0013
16 17 1¼ 20.5 5.7 & Grundfos 43-75
5LTRA "TUHOUTPUT G Taco 0014
13 32 1¼ 9.4 3.9 ( Grundfos 15-42
16 26 1¼ 13.7 5.7 J Taco 1400-20
21 20 1½ 22.0 2.9
, Taco 0012
5LTRA "TUHOUTPUT
18 31 1½ 6.6 2.2
22 25 1½ 9.5 3.1
29 19 2 17.4 2.9
5LTRA "TUHOUTPUT
22 34 1½ 9.5 3.1
29 25 2 15.5 2.9
36 20 2 22.8 4.3

Part number 550-100-090/1113 53

 GAS-FIRED WATER BOILER — Boiler Manual

Multiple boiler installations

Placing multiple boilers &IGURE Side-to-side mounting of multiple Ultra boilers
1. Locate multiple boilers in boiler room according
to:
a. Figure 56 (side-to-side), or
b. Figure 57 (back-to-back).
c. Figure 58 (wall mounting).
2. Provide indicated clearances around boilers for
access and servicing. If recommended dimensions
are not possible, provide at least the minimum
clearances given on page 5. Also follow local codes.
3. Construct boiler foundation if boiler room floor
is uneven or if there is a danger of flooding. Size
foundation to allow for clearance and spacing di-
mensions shown in the illustrations at right. &IGURE Back-to-back installation of multiple Ultra boilers
4. Chalk line boiler locations on foundation or boiler
room floor.
5. Uncrate, assemble and mount boilers according to
instructions in this manual.
6. Provide clearance for installation of venting, air
piping, gas piping, expansion tank, primary circula-
tor and other accessories.

Wall mounting (Models 80 – 399)

1. Ultra boilers may be wall mounted, following the
instructions on page 46. (See Repair parts section
for part number of wall mounting kit.)
2. When wall mounting boilers, provide approxi-
mately 6 inches between boilers for easy removal
of boiler jacket door. See Figure 58.
3. Follow all applicable codes regarding piping, electri-
cal connections and clearances.
4. When wall mounting boilers, verify the wall con-
struction is suitable for the structural load. See
page 46 for details. &IGURE Wall mounting multiple Ultra boilers

54 Part number 550-100-090/1113

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Prepare boiler location — multiple boilers

Manifolded combustion air option
1. Multiple Ultra boilers can use a common combustion air manifold.
a. See Figure 126, page 122 for minimum cross sectional area of
combined air ducts.
b. Provide minimum clearance to adjacent vents and grade/snow line
as shown in Figure 59.
c. Provide minimum free area in duct (adjusted for louver restriction)
of SQUAREINCHPER"TUH total boiler input.
d. If combustion air damper is used, wire to boilers to prevent opera-
tion except after damper has opened.
ONLY air piping can be combined. DO NOT use combined
vent piping. Flue gas leakage and boiler component damage
can occur. Failure to comply could result in severe personal
injury, death or substantial property damage.

&IGURE Manifolded combustion air option

!$6!.#%$).34!,,!4)/.
DO NOT use common venting — the manifold option is
only for combustion air — all vent pipes must be routed and
terminated individually as described in this manual.
See Figure 126, page 122 for minimum cross sectional area
of combined air ducts.
OR
Calculate required cross section (for area in square inches):
-).!2%!4/4!,-"().054$)6)$%$"9
Example: A multiple boiler system with (6) Ultra-155 boilers
has a total input of 6 x 155 =  MBH (930,000 Btuh). The
required duct cross sectional area is:
-).!2%!$)6)$%$"9SQINCHES

Part number 550-100-090/1113 55

 GAS-FIRED WATER BOILER — Boiler Manual

Multiple boiler water piping

Easy-Fit® piping installation
-AXIMUMCONNECTEDLOADPERMANIFOLD
1. Main header and Easy-Fit® Manifold pipe sizing.  INCHMANIFOLDˆ-"(
a. New system — See page 10.  INCHMANIFOLDˆ-"(
b. Replacing boilers in an existing system — Without reducing
 INCHMANIFOLDˆ-"(
size, connect system supply and return lines. Install tees or
crosses for Easy-Fit® manifolds as shown in Figure 60 or Fig-
ure 61. Size manifolds to handle total connected boiler output
as shown. &IGURE Single-sided EZ-Fit Header connection
2. Provide connections in main header for Easy-Fit® manifolds as
close as possible to the midpoint of multiple boilers.
a. Use tees for four or less boilers, as in Figure 60.
b. Use either tees (Figure 60) or crosses (Figure 61) for five or
more boilers.
3. Manifold placement:
a. To alternate spacing for supply and return lines to boilers,
reverse the short-end and long-end of the manifolds as shown
in Figure 60 and Figure 61.
b. Return manifold must be on the return side of the main and
supply manifold must be on the supply side of the main. Draw-
ings in this manual show flow in system main from right to
left. For system flowing left to right, reverse the locations of
the manifolds accordingly.
4. Connect from Easy-Fit® manifold branches to boiler supply and
return connections using copper or steel pipe, sized for the required
flow rate.
5. Provide a flow/check valve in the supply piping of each boiler as
shown in piping diagrams in this manual. Install an isolation valve
on the supply and return of each boiler as shown. Some local codes
may require the use of individual water level controls and limits
on each boiler when isolation valves are installed.
6. Install main system air eliminator and primary circulator in sup-
ply piping as shown in piping diagrams. Place expansion tank on
suction side of system circulator as shown. &IGURE Double-sided EZ-Fit Header connection
7. Install system accessories as shown in drawings.
8. Piping recommendation drawings:
a. Figure 60 and Figure 61 show details of Easy-Fit® manifolds.
b. Figure 62, page 57 is a schematic piping drawing showing the
locations of typical boiler piping and system piping, including
limits and other devices often required by local codes.
c. Figure 63, page 58 and Figure 64, page 59 are three-dimensional
piping drawings of typical multiple boiler installation.
d. Figure 65, page 60 shows recommended piping when an isolat-
ing heat exchanger is needed.
9. If desired, other primary/secondary piping arrangements can be
used.
When using isolation valves on each boiler, some codes
may require providing a low water control and additional
limit for each boiler. Consult local codes to determine
if omission of the individual boiler isolation valves
may allow the use of a single water level control and
additional limit for the entire multiple boiler system.
4HE5 #ONTROLMODULEPROVESWATERLEVELUSINGA
DUALTEMPERATURESENSORINSTALLEDINTHE5LTRAHEAT
EXCHANGER. This will satisfy some code requirements for
low water cutoff protection.

56 Part number 550-100-090/1113

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Multiple boiler water piping (continued)

&IGURE Piping schematic — typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit manifolds

!$6!.#%$).34!,,!4)/.
Legend — Figure 62

1 Flow/check valve (each boiler) 11 Check valve or backflow preventer, as required by applicable codes

12 Isolation valve
2 Isolation valves (when used)
13 Cold water supply
3 Cap
14 Supply water temperature control (when used)
4 Easy-Fit® Manifold (supply) — layout and size per page 56
15 Low water cutoff (when used) (place above primary header)

5 Easy-Fit® Manifold (return) — layout and size per page 56 16 Water flow switch (when used)

17 Boiler circulator (each boiler)

6 Primary circulator
18 System supply
7 Expansion tank (diaphragm type)
19 System return

8 System air eliminator

20 Boiler relief valve and discharge piping, installed per Ultra Boiler
Manual
9 System automatic air vent
24 Strap system supply and return sensors to lines as shown, at least 6
pipe diameters (but no more than 3 feet) from boiler connection
10 Pressure reducing valve tees.

Part number 550-100-090/1113 57

 GAS-FIRED WATER BOILER — Boiler Manual

Multiple boiler water piping (continued)

&IGURE 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) 19 System return
3 Caps 20 Boiler relief valve and discharge piping, installed per Ultra Boiler Manual
4 Easy-Fit® Manifold (supply) — layout and size per page 56 21 Indirect-fired storage water heaters (Weil-McLain PLUS Line shown) —
5 Easy-Fit® Manifold (return) — layout and size per page 56 Example is shown connected to one boiler of the system. Preferably, use
6 Primary circulator the last boiler in the lead/lag sequence and set its Priority to $(7$IRECT
7 Expansion tank (diaphragm type) so it will switch to DHW firing and turn off its boiler circulator on a call
8 System air eliminator for domestic water heating.
9 System automatic air vent 24 DHW boiler-side circulator
13 Cold water supply 30 Strap system supply and return sensors to lines as shown, at least 6 pipe
17 Boiler circulator (each boiler) diameters (but no more than 3 feet) from boiler connection tees.

58 Part number 550-100-090/1113

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Multiple boiler water piping (continued)

&IGURE Piping layout — typical piping for multiple Ultra boilers, with DHW storage heaters (4-boiler system)

!$6!.#%$).34!,,!4)/.
Flow rate Size Flow rate Size
Suggested DHW
boiler-side pipe 1 – 3.9 gpm ¾” 24 – 45 gpm 2”
sizing (for max 0.04 3.9 – 7.1 gpm 1” 45 – 75 gpm 2½”
feet head loss per foot of
total equivalent length, 7.1 – 16 gpm 1¼” 75 - 140 gpm 3”
TEL)
16 – 24 gpm 1½” 140 – 290 gpm 4”

Legend — Figure 64
1 Flow/check valve (each boiler) 21 Indirect-fired storage water heaters (Weil-McLain PLUS Line shown) — Example is This piping is sug-
2 Isolation valves (when used) shown with reverse-return boiler-side piping using a single circulator. Alternate: each gested only. The
3 Caps water heater could have its own circulator. layout above should be controlled
4 Easy-Fit® Manifold (supply) — layout 22 Boiler water inlet with a boiler sequencing panel that
and size per page 56 23 Boiler water outlet provides DHW operation as well.
Wire the heating system circulator
5 Easy-Fit® Manifold (return) — layout 24 DHW boiler-side circulators
to operate only on call for heat. Al-
and size per page 56 25 DHW boiler-side supply Easy-Fit® Manifold ternatively, use the boiler sequencing
6 Primary circulator 26 DHW boiler-side return Easy-Fit® Manifold panel to provide domestic priority
7 Expansion tank (diaphragm type) by disabling the heating system cir-
27 Flow/check valves (to prevent induced or gravity flow in heating system or DHW
8 System air eliminator piping) culator any time there is a DHW call
9 System automatic air vent for heat. The boiler circulators, item
28 Check valve to prevent heat migration in heating system
13 Cold water supply 17, must operate on any call for heat,
29 See water heater manual for DHW piping — The DHW piping must also be mani- whether heating system or DHW.
17 Boiler circulator (each boiler) folded together since the boiler-side piping is manifolded. If DHW heaters supply Offset the DHW boiler-side supply
18 System supply separate DHW circuits, provide an individual circulator for each water heater, and and return manifolds as shown so
19 System return control each circulator by its water heater’s aquastat. the total run of pipe and fittings to
20 Boiler relief valve and discharge piping, 30 Strap system supply and return sensors to lines as shown, at least 6 pipe each of the water heaters is approxi-
installed per Ultra Boiler Manual diameters (but no more than 3 feet) from boiler connection tees. mately equal.

Part number 550-100-090/1113 59

 GAS-FIRED WATER BOILER — Boiler Manual

Multiple boiler water piping (continued)

&IGURE 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.
3. Old systems severely contami-
nated with scale and rust buildup
inside piping and heat distribu-
tion units.
4. Process applications.
5. Commercial service water ap-
plications.
6. High water pressure applications,
requiring pressure relief setting
in heating system more than 30
PSIG (tall buildings). See notes
below.

Legend — Figure 65
1 Flow/check valve (each boiler) 9 System automatic air vent Notes:
2 Isolation valves (when used) 1. Contact heat exchanger manufacturer for heat exchanger
13 Cold water supply connections
shell-side and tube-side piping and circulator require-
3 Cap
17 Boiler circulator (each boiler) ments. Tube-side flow and temperatures must meet
4 Easy-Fit® Manifold (supply) — layout heating system requirements.
and size per page 56 18 Heating system supply
2. Contact heat exchanger manufacturer for sizing heat
5 Easy-Fit® Manifold (return) — layout 19 Heating system return exchanger.
and size per page 56 3. Heat exchanger shell-side circuit requires its own expan-
20 Boiler relief valve and discharge piping, sion tank as shown.
6a Heating system circulator (exchanger installed per Ultra Boiler Manual
tube-side) 4. Heating system circuit requires its own expansion tank,
30 Strap system supply and return sensors to as shown, plus its own relief valve set to protect heating
6b Heat exchanger shell-side circulator
lines as shown, at least 6 pipe diameters (but system and heat exchanger piping and components.
7 Expansion tanks (diaphragm type) no more than 3 feet) from boiler connection 5. When individual isolation valves are used, individual
8 System air eliminator tees. boiler and level controls may be required.

60 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

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.
whole or in part for residential purposes, including those
owned or operated by the Commonwealth and where the
side wall exhaust vent termination is less than seven (7) feet (b) %8%-04)/.3: The following equipment is exempt from
above finished grade in the area of the venting, including but 248 CMR 5.08(2)(a)1 through 4:
not limited to decks and porches, the following requirements 1. The equipment listed in Chapter 10 entitled “Equipment
shall be satisfied: Not Required To Be Vented” in the most current edition
1. ).34!,,!4)/. /& #!2"/. -/./8)$% $%4%#- of NFPA 54 as adopted by the Board; and
4/23. At the time of installation of the side wall horizon- 2. Product Approved side wall horizontally vented gas fueled
tal vented gas fueled equipment, the installing plumber
equipment installed in a room or structure separate from
or gas fitter shall observe that a hard wired carbon
monoxide detector with an alarm and battery back-up the dwelling, building or structure used in whole or in
is installed on the floor level where the gas equipment is part for residential purposes.

!$6!.#%$).34!,,!4)/.
to be installed. In addition, the installing plumber or gas
fitter shall observe that a battery operated or hard wired
carbon monoxide detector with an alarm is installed on (c) -!.5&!#452%22%15)2%-%.43ˆ'!3%15)0-%.4
each additional level of the dwelling, building or struc- 6%.4).'3934%-02/6)$%$. When the manufacturer of
ture served by the side wall horizontal vented gas fueled Product Approved side wall horizontally vented gas equip-
equipment. It shall be the responsibility of the property ment provides a venting system design or venting system
owner to secure the services of qualified licensed profes-
sionals for the installation of hard wired carbon monoxide components with the equipment, the instructions provided
detectors by the manufacturer for installation of the equipment and
a. In the event that the side wall horizontally vented gas the venting system shall include:
fueled equipment is installed in a crawl space or an 1. Detailed instructions for the installation of the venting
attic, the hard wired carbon monoxide detector with
system design or the venting system components; and
alarm and battery back-up may be installed on the
next adjacent floor level. 2. A complete parts list for the venting system design or
b. In the event that the requirements of this subdivision venting system.
can not be met at the time of completion of installa-
tion, the owner shall have a period of thirty (30) days
to comply with the above requirements; provided, (d) -!.5&!#452%22%15)2%-%.43ˆ'!3%15)0-%.4
however, that during said thirty (30) day period, a 6%.4).'3934%-./402/6)$%$. When the manufac-
battery operated carbon monoxide detector with an turer of a Product Approved side wall horizontally vented gas
alarm shall be installed. fueled equipment does not provide the parts for venting the
2. !002/6%$#!2"/.-/./8)$%$%4%#4/23. Each flue gases, but identifies “special venting systems”, the follow-
carbon monoxide detector as required in accordance with ing requirements shall be satisfied by the manufacturer:
the above provisions shall comply with NFPA 720 and be
ANSI/UL 2034 listed and IAS certified. 1. The referenced “special venting system” instructions shall
be included with the appliance or equipment installation
3. 3)'.!'%. A metal or plastic identification plate shall instructions; and
be permanently mounted to the exterior of the build-
ing at a minimum height of eight (8) feet above grade 2. The “special venting systems” shall be Product Approved
directly in line with the exhaust vent terminal for the by the Board, and the instructions for that system shall in-
horizontally vented gas fueled heating appliance or clude a parts list and detailed installation instructions.
equipment. The sign shall read, in print size no less than
one-half (1/2) inch in size, “GAS VENT DIRECTLY BE-
LOW. KEEP CLEAR OF ALL OBSTRUCTIONS.” (e) A copy of all installation instructions for all Product Approved
side wall horizontally vented gas fueled equipment, all venting
4. ).30%#4)/.. The state or local gas inspector of the
instructions, all parts lists for venting instructions, and/or all
side wall horizontally vented gas fueled equipment shall
not approve the installation unless, upon inspection, venting design instructions shall remain with the appliance
the inspector observes carbon monoxide detectors and or equipment at the completion of the installation.

Part number 550-100-090/1113 61

 GAS-FIRED WATER BOILER — Boiler Manual

Vent/air piping — options

Vent and air pipe termination options &IGURE 6ENTANDAIRTERMINATIONOPTIONS
1. Vent and air piping must terminate out the sidewall or through
the roof of the building, using only one of the methods described Sidewall Vertical
in this manual. termination termination
2. Sidewall options (see Figure 67, left side):
a. TOP: Weil-McLain termination cap (kit included with
boiler) — see page 18 for instructions.
b. MIDDLE: Concentric PVC pipe (requires special kit, 7EIL -C,AINSIDEWALL
page 113). TERMINATIONPLATE
c. BOTTOM: Separate air pipe and vent pipe. (See PAGE
3. Vertical options (Figure 67, right side):
a. TOP: Concentric PVC pipe (requires special kit, page 113).
b. BOTTOM: Separate air pipe and vent pipe.

Vent and air pipe diameters

1. Vent and air pipe diameters can be as specified in Figure 66.

&IGURE Vent and air pipe options — summary

t
.BYJNVN
FRVJWBMFOU
GFFU
PG
QJQJOH
t
/VNCFS
PG
FMCPXT
BMMPXFE
BU
UIFTF
MFOHUIT
(All applications include allowance for the termination.) 7EIL -C,AIN
Ultra model

Vent or air
pipe size

Sidewall Sidewall 3” PVC Concentric Vertical v06#CONCENTRIC

with with Sidewall or Vertical with TERMINATION
W-M Cap separate (Use only PVC pipe DO separate 7EIL -C,AIN (See PAGE
pipes NOT use CPVC or ABS) pipes v06#CONCENTRIC
TERMINATION
Length Ells Length Ells Length Ells Length Ells (See PAGE
2” * 100 (ab) 2 100 2 100 (ab) 1 100 1
80/105
3” 100 2 100 2 100 1 100 1
155 3” 100 2 100 2 100 1 100 1
3” 30 (c) 2 30 (c) 2 30 (c) 1 30 (c) 1
230
4” 100 (d) 2 100 2 70 (d) 1 100 1
299 4” 100 2 100 2 70 (d) 1 100 1
399 4” 100 2 100 2 NA 100 1
Equivalent feet for elbows — deduct from maximum equivalent length of piping:
t


GFFU
QFS
GPS
FBDI
JODI
FMCPX


PS
JODI
¡
MPOHSBEJVT
PS
¡
FMCPX
t


GFFU
GPS
FBDI

PS
JODI
TIPSUSBEJVT
FMCPX
a — Use 3"x2" reducer at boiler C

‰
Use 3”x2” PVC reducers at termination
c — Use 4”x3” reducer at boiler d — Use 4"x3" PVC reducers at termination
Stainless (AL29-4C) vent pipe — install an adapter at the boiler for all applications. 3IDEWALLTERMINATION
"MTP
JOTUBMM
BO
BEBQUFS
BU
UIF
UFSNJOBUJPO
VOMFTT
VTJOH
TFQBSBUFQJQF
UFSNJOBUJPO WITHSEPARATEVENT 6ERTICALTERMINATION


6MUSB
BOE

CPJMFST
JOTUBMMFE
XJUI
JODI
WFOU
QJQJOH
BVUPNBUJDBMMZ
EFSBUF
ANDAIRPIPES WITHSEPARATEVENT
due to the pressure loss in the vent and air piping. The derate ranges up to 10% for (See PAGE ANDAIRPIPES
UIF
6MUSB
BU

GFFU
PS

GPS
UIF
6MUSB
BU

GFFU (See PAGE

Vent and air pipe minimum length

1. Vent pipe and air pipe must each be ATLEASTFEETLONG, with 3TEP Determine proper location for wall or roof
2 elbows if sidewall venting or 1 elbow if vertical venting. penetration for each termination.
3TEP Install termination assembly as described in
Vent and air pipe installation sequence this manual.
3TEP Install the boiler. 3TEP Install air and vent piping from boiler to ter-
mination.
3TEP Determine the termination method — sidewall or vertical,
concentric or separate pipes, etc. 3TEP Install pipe supports and brackets as required.

62 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Sidewall vent/air termination: 3” PVC concentric

Termination kit — Weil-McLain 3” PVC concentric &IGURE -AXIMUMPIPINGLENGTHSFOR7EIL
termination -C,AINv06#CONCENTRICTERMINATION
1. The Weil-McLain 3” PVC concentric termination kit must be
purchased separately. See Figure 117, page 113 for part number. "OILER -AXIMUM -AXIMUM -AXIMUM
5LTRAn 0IPINGv
0IPINGv
0IPINGv

Use only the Weil-McLain 3” PVC concentric termina-

tion kit for concentric venting. Provide pipe adapters as
needed for 2” or 4” plastic piping or for AL29-4C vent Feet Elbows Feet Elbows Feet Elbows
pipe.
80 ** 100 1 100 1

Commonwealth of Massachusetts Not

105 ** 100 1 100 1
allowed
When the boiler is installed within the Commonwealth of Mas-
sachusetts: 155 Not allowed 100 1
s This product must be installed by a licensed plumber or gas
fitter. 230 Not allowed 30 1 70 1
s See instruction on page 61.
299 Not allowed Not allowed 70 1

Allowable vent/air pipe materials 399 Not allowed for any application

!$6!.#%$).34!,,!4)/.
1. Use only the materials listed in Figure 12, page 17.
* Install pipe reducers to adapt from pipe size used to the 3.5 inch
outside diameter required at the termination. You do not have to
Maximum piping length reduce allowable pipe length for the reducers. Also install reduc-
1. Locate the termination such that the total air piping and vent piping ers as necessary where connecting to the boiler vent and air
from the boiler to the termination will not exceed the maximum connections.
length given in Figure 68. ** Ultra-80 and 105 boilers installed with 2-inch vent piping
2. Maximum lengths listed in Figure 68 allow for 1 elbow. Additional automatically derate due to the pressure loss in the vent and
air piping. The derate ranges up to 10% for the Ultra-80 at 100
elbows required a reduction in maximum length as explained in feet or 15% for the Ultra-105 at 100 feet.
the table notes.
You do not have to reduce allowable pipe length for the 45° elbow
Connecting from termination to boiler used to connect to the air fitting on the concentric assembly.
For piping using more than 1 elbow, reduce maximum allowable
1. Install the termination as instructed in the following. Then pro- length:
ceed to page 75 to complete the air and vent piping between the sFEETFOREACHADDITIONAL INCHELBOW—OR—
termination and the boiler. sFEETFOREACHADDITIONALOR INCHLONGRADIUSELBOW
sFEETFOREACHOR INCHSHORTRADIUSELBOW
2. The center lines between the air and vent are wider at the concentric sFEETFOREACHOR INCH DEGREEELBOW
termination connections than at the boiler. See Figure 86, page 72
for suggestions on adjusting the spacing when required. In addi-
tion to the method given there, you can rotate the Y-fitting slightly,
which will cause the air pipe to be slightly higher or lower than &IGURE Termination location — Weil-McLain vent/air
the vent, but the center lines will match those at the boiler vent p
plate — height
g above g
grade or snow line
and air connections.

Determine locations for terminations

A gas vent extending through an exterior wall shall not
terminate adjacent to the wall or below building exten-
sions such as eaves, parapets, balconies or decks. Failure
to comply could result in severe personal injury, death
or substantial property damage.

Part number 550-100-090/1113 63

 GAS-FIRED WATER BOILER — Boiler Manual

Sidewall vent/air termination: 3” PVC concentric (cont.)

1. Locate the vent/air terminations using the following guidelines. &IGURE Termination location — Weil-McLain vent/air
2. You must consider the surroundings when terminating the vent plate — clearances to openings
and air:
a. Position the vent termination where vapors will not damage
nearby shrubs, plants or air conditioning equipment or be
objectionable.
b. The flue products will form a noticeable plume as they con-
dense in cold air. Avoid areas where the plume could obstruct
window views.
c. Prevailing winds could cause freezing of condensate and water/
ice buildup where flue products impinge on building surfaces
or plants.
d. Avoid possibility of accidental contact of flue products with
people or pets.
e. 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.
f. Do not terminate above any door or window or under a deck.
Condensate can freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage to exterior
finishes. &IGURE Termination location — Weil-McLain vent/
3. Maintain clearances as shown in Figure 69, Figure 70, Figure 71 air plate — clearances to public walkway or
and Figure 72. Also maintain the following: forced air intake
a. Vent must terminate:
s At least 6 feet from adjacent walls.
s No closer than 5 feet below roof overhang.
s At least 7 feet above any public walkway.
s At least 3 feet above any forced air intake within 10 feet.
s No closer than 12 inches below or horizontally from any
door or window or any other gravity air inlet.
b. Air inlet must terminate at least 12” above grade or snow line
c. Do not terminate closer than 4 feet horizontally (above or be-
low) from any electric meter, gas meter, regulator, relief valve
or other equipment.
4. Locate terminations so they are not likely to be damaged by foreign
objects, such as stones or balls, or subject to buildup of leaves or
sediment.

Multiple vent/air terminations

1. When terminating multiple Ultra boilers, terminate each vent/air &IGURE Termination location — Weil-McLain vent/air
connection as described in this manual. plate — multiple boilers — clearance from
vent of one to air intake of the next
All vent pipes and air inlets must terminate at the same
height to avoid possibility of severe personal injury, death
or substantial property damage.
2. Place wall penetrations to obtain minimum clearance as shown in
Figure 72 for U. S. installations. For Canadian installations, provide
clearances required by CSA B149.1 or B149.2 Installation Code.
3. 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.
4. Combustion air (NOT vent piping) can be manifolded as shown
in Figure 59, page 55.

64 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Sidewall vent/air termination: 3” PVC concentric (cont.)

Install terminations — concentric pipes &IGURE Installing and supporting the concentric
1. Assemble the vent termination as described for vertical concentric sidewall vent assembly
terminations, beginning on page 70.
If necessary, you can shorten the lengths of the inner and
outer pipes for a shorter finished assembly. But you must
ensure the pipes butt correctly at both ends. Failure to
properly assemble the concentric termination can result
in flue gas recirculation, causing possible severe personal
injury or death.
2. Wall penetration — Preferably, use a thimble with a 4½-inch hole.
If not using a thimble, carefully use a hole saw to cut a hole not
larger than 4¾ inches in diameter through the wall. The finished
hole must provide a solid stop for the rain cap ribs, as shown in
the inset to Figure 73.
3. Secure the termination in place so the rain cap will butt against the
outside wall or outer thimble plate as shown in Figure 73.
4. Before beginning vent and air piping from the boiler to the con-
centric termination, mount and secure the concentric termination
as shown in Figure 73.

!$6!.#%$).34!,,!4)/.
The vent and air piping must be securely supported, and
must not rest its weight on the boiler fittings. Failure to
properly support the vent and air piping could result in
vent piping damage, resulting in possible severe personal
injury, death or substantial property damage.
The supports/bracing used must support the termination
assembly to prevent slippage or movement. Ensure that the wall material is strong enough
The clamps used on the outside of the termination pipe to prevent the rain cap from being pushed
must not cut into the pipe or contain sharp edges that inward if struck or pushed from the outside.
could cause a crack to form.
When inserting the partially-assembled termination
kit through the roof penetration, wrap plastic or other
protection over the end of the exposed assembly to pre-
vent debris from entering the pipes. If the air passages
become blocked, the boiler will not operate. Once the
rain cap has been cemented to the assembly, there is no
way to correct the problem. The assembly would have
to be replaced if it were cut to be removed and cleaned.
Altering the assembly in any way could result in severe
personal injury or death due to toxic flue product emis-
sions.
When using AL29-4C stainless vent pipe, use the vent pipe
manufacturer’s 3-inch PVC adapter when connecting to
the concentric vent attachment.
5. After the assembly has been positioned in the opening and all
supports have been attached, install the bird screen and rain cap
as
a. follows:
Place the bird screen on the end of the inner pipe as in Fig-
ure 84, page 71.
b. Cement the rain cap in place as shown.

Part number 550-100-090/1113 65

 GAS-FIRED WATER BOILER — Boiler Manual

Sidewall vent/air termination: Separate pipes

Allowable vent/air pipe materials &IGURE -AXIMUMPIPINGLENGTHSFORSEPARATEVENT
ANDAIRPIPESIDEWALLTERMINATION
1. Use only the materials listed in Figure 12, page 17.
2. Purchase termination plates and bird screens separately. See the "OILER -AXIMUM -AXIMUM -AXIMUM
parts list at the end of this manual. 5LTRAn 0IPINGv
0IPINGv
0IPINGv

Maximum piping length

Feet Elbows Feet Elbows Feet Elbows
1. Locate the terminations such that the total air piping and vent pip-
ing from the boiler to the termination will not exceed the maximum 80 ** 100 2 100 2
length given in Figure 74. Not
105 ** 100 2 100 2
allowed
2. Maximum lengths listed in Figure 74 allow for 2 elbows. Additional 155 Not allowed 100 2
elbows required a reduction in maximum length as explained in
the table notes. 230 Not allowed 30 2 100 2
299 Not allowed Not allowed 100 2
Connecting from termination to boiler
399 Not allowed Not allowed 100 2
1. Install the terminations as instructed in the following. Then pro- * Install pipe reducers to adapt from pipe size used to the out-
ceed to page 75 to complete the air and vent piping between the side diameter required at the boiler. You do not have to reduce
termination and the boiler. allowable pipe length for the reducers.
** Ultra-80 and 105 boilers installed with 2-inch vent piping
Determine location — separate elbows automatically derate due to the pressure loss in the vent and
air piping. The derate ranges up to 10% for the Ultra-80 at 100
A gas vent extending through an exterior wall shall not feet or 15% for the Ultra-105 at 100 feet.
terminate adjacent to the wall or below building exten- For piping using more than 2 elbows, reduce maximum allow-
sions such as eaves, parapets, balconies or decks. Failure able length:
to comply could result in severe personal injury, death sFEETFOREACHADDITIONAL INCHELBOW—OR—
or substantial property damage. sFEETFOREACHADDITIONALOR INCHLONGRADIUSELBOW
sFEETFOREACHOR INCHSHORTRADIUSELBOW
1. Locate the vent/air terminations using the following guidelines. sFEETFOREACHOR INCH DEGREEELBOW
2. The air piping must terminate in a down-turned elbow as shown in
Figure 75. This arrangement avoids recirculation of flue products
into the combustion air stream.
a. Apply the configuration on the left side of Figure 75 unless &IGURE Sidewall termination — separate pipes
the terminations would fail to meet minimum clearance to — configuration options and minimum
grade or snow line. clearances from vent to air terminations
b. Apply the configuration on the right side of Figure 75 when
the terminations need to be raised higher to meet clearance to
grade or snow line.
c. The vent and air pipes may run up as high as 4 feet, as shown in
Figure 75 right side with no enclosure. The vent and air pipes
must be secured with braces, and all clearances and lengths
must be maintained. Space braces no further than 24 inches
apart. (See WARNING below for extremely cold climates.)
d. External venting greater than 4 feet requires an insulated enclo-
sure around the vent and air pipes. The vent and air termina-
tions must exit through the enclosure as shown in Figure 75,
maintaining all required clearances.
3. The vent piping must terminate in an elbow pointed outward or
away from the air inlet, as shown in Figure 75.
Do not exceed the maximum lengths of the outside vent
piping shown in Figure 75. Excessive length exposed to
the outside could cause freezing of condensate in the vent
pipe, resulting in potential boiler shutdown. In extremely
cold climates, install an insulated chase around the vent
piping, particularly when using longer lengths. The chase
must allow for inspection of the vent pipe, and insulation
must be protected from water.

66 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Sidewall vent/air termination: Separate pipes (continued)

4. You must consider the surroundings when terminating the vent &IGURE 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.
b. The flue products will form a noticeable plume as they con-
dense in cold air. Avoid areas where the plume could obstruct
window views.
c. Prevailing winds could cause freezing of condensate and water/
ice buildup where flue products impinge on building surfaces
or plants.
d. Avoid possibility of accidental contact of flue products with
people or pets.
e. 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.
f. Do not terminate above any door or window or under a deck.
Condensate can freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage to exterior
finishes.

!$6!.#%$).34!,,!4)/.
5. Maintain clearances as shown in the illustrations in this manual &IGURE Sidewall termination with separate pipes —
clearances to public walkway or forced air
section. Also maintain the following: intake
a. Vent must terminate:
s At least 6 feet from adjacent walls.
s No closer than 5 feet below roof overhang.
s At least 7 feet above any public walkway.
s At lease 3 feet above any forced air intake within 10 feet.
s No closer than 12 inches below or horizontally from any
door or window or any other gravity air inlet.
b. Do not terminate closer to 4 feet horizontally from any electric
meter, gas meter, regulator, relief valve or other equipment.
Never terminate above or below any of these within 4 feet
horizontally.
6. Locate terminations so they are not likely to be damaged by foreign
objects, such as stones or balls, or subject to buildup of leaves or
sediment.
7. Do not connect any other appliance to the vent pipe or multiple
boilers to a common vent pipe.
&IGURE Multiple terminations — separate pipes —
Completing the vent/air piping clearance from vent of one to air intake of the
1. Install vent/air penetrations as explained in the following pages next
before installing vent and air piping from the boiler to the termi-
nations. Insert piping from boiler air and vent connections, then
attach exterior termination piping.
2. Follow instructions beginning on page 22 to complete piping from
boiler to termination.

Multiple vent/air terminations

-AINTAINALLREQUIREMENTS
1. When terminating multiple Ultra boilers, terminate each vent/air SHOWNIN
connection as described in this manual. &IGUREPAGE

All vent pipes and air inlets must terminate at the same
height to avoid possibility of severe personal injury, death
or substantial property damage.

Part number 550-100-090/1113 67

 GAS-FIRED WATER BOILER — Boiler Manual

Sidewall vent/air termination: Separate pipes (continued)

2. Place wall penetrations to obtain minimum clearance of 12 inches &IGURE 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. S. installations.
next — alternate configuration of air and vent
3. For Canadian installations, provide clearances required by CSA terminations
B149.1 or B149.2 Installation Code.
4. 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.
5. Combustion air (NOT vent piping) can be manifolded as shown
in Figure 59, page 55.

Prepare wall penetrations

1. Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as close as
desired to the air pipe outside diameter.
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or non-
combustible construction, size the vent pipe hole at least 0.4”
larger than the vent pipe diameter:
s 2¾” hole for 2” PVC -AINTAINALLREQUIREMENTS
s 4” hole for 3” PVC SHOWNIN&IGUREPAGE
s 5” hole for 4” PVC
b. Insert a galvanized metal thimble in the vent pipe hole as
shown in Figure 80.
3. Use a sidewall termination plate as a template for correct location
of hole centers. Sidewall termination plates must be purchased &IGURE Sidewall termination assembly — using
separately. See the parts list at the end of this manual for part separate pipes
numbers.
4. Follow all local codes for isolation of vent pipe when passing
through floors or walls.
5. Seal exterior openings thoroughly with exterior caulk.

Termination and fittings

1. Prepare the vent termination elbow and the air termination el-
bow (Figure 80) by inserting bird screens. Bird screens must be
purchased separately. See the parts list at the end of this manual
for part numbers.
2. When completed, the air termination coupling must be oriented
at least 12 inches below the vent termination and at least 12 inches
above grade or snow line as shown in Figure 75, page 66.
3. You can orient the vent termination elbow either directly out-
ward or 90 degrees away from the air inlet elbow as shown in
Figure 75, page 66.
4. Maintain the required dimensions of the finished termination
piping as shown in Figure 75, page 66.
1 Vent piping 7 Elbow
5. Do not extend exposed vent pipe outside of building more than 2 Air piping 8 Nipple
shown in this document. Condensate could freeze and block vent 3 Sidewall termination plates, by
9 Elbow (vent termination)
pipe. installer
4 Galvanized thimbles, by installer 10 Alternate elbow orientation
If extending the vent and air pipes out from the wall, 5 Bird screen (air), by installer 11 Bird screen (vent termination) —
install a coupling on each pipe. Mount the piping with 6 Air inlet elbow supplied by installer
the coupling flush with the outer plate.

68 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Vertical vent/air termination: 3” PVC concentric

Termination kit — Weil-McLain 3” PVC concentric &IGURE -AXIMUMPIPINGLENGTHSFOR7EIL
termination -C,AINv06#CONCENTRICTERMINATION
1. The Weil-McLain 3” PVC concentric termination kit must be
purchased separately. See Figure 117, page 113 for part number. "OILER -AXIMUM -AXIMUM -AXIMUM
5LTRAn 0IPINGv
0IPINGv
0IPINGv

Use only the Weil-McLain 3” PVC concentric termina-

tion kit for concentric venting. Provide pipe adapters as
Feet Elbows Feet Elbows Feet Elbows
needed for 2” or 4” plastic piping or for AL29-4C vent
pipe.
80 ** 100 1 100 1
Allowable vent/air pipe materials Not
105 ** 100 1 100 1
allowed
1. Use only the materials listed in Figure 12, page 17.
155 Not allowed 100 1
Maximum piping length 230 Not allowed 30 1 70 1
1. Locate the termination such that the total air piping and vent piping
from the boiler to the termination will not exceed the maximum 299 Not allowed Not allowed 70 1
length given in Figure 81.
399 Not allowed for any application
2. Maximum lengths listed in Figure 81 allow for 1 elbow. Additional
elbows required a reduction in maximum length as explained in * Install pipe reducers to adapt from pipe size used to the 3.5 inch
outside diameter required at the termination. You do not have to
the table notes.

!$6!.#%$).34!,,!4)/.
reduce allowable pipe length for the reducers. Also install reduc-
ers as necessary where connecting to the boiler vent and air
Connecting from termination to boiler connections.
1. Install the termination as instructed in the following. Then pro- ** Ultra-80 and 105 boilers installed with 2-inch vent piping
ceed to page 75 to complete the piping between the termination automatically derate due to the pressure loss in the vent and
and the boiler. air piping. The derate ranges up to 10% for the Ultra-80 at 100
feet or 15% for the Ultra-105 at 100 feet.
Determine location You do not have to reduce allowable pipe length for the 45° elbow
used to connect to the air fitting on the concentric assembly.
Locate the concentric vent/air termination using the following guide- For piping using more than 1 elbow, reduce maximum allowable
lines: length:
sFEETFOREACHADDITIONAL INCHELBOW—OR—
1. The concentric vent/air assembly must terminate as shown in sFEETFOREACHADDITIONALOR INCHLONGRADIUSELBOW
Figure 82. sFEETFOREACHOR INCHSHORTRADIUSELBOW
sFEETFOREACHOR INCH DEGREEELBOW
2. The vent and air piping connected to the termination assembly
must comply with the instructions in this supplement.
3. You must consider the surroundings when terminating the vent
and air: &IGURE Vertical termination — Weil-McLain 3” PVC
concentric
a. Position the termination where vent vapors will not damage
nearby shrubs, plants or air conditioning equipment or be
objectionable.
b. The flue products will form a noticeable plume as they con-
dense in cold air. Avoid areas where the plume could obstruct
window views.
c. Prevailing winds could cause freezing of condensate and water/
ice buildup where flue products impinge on building surfaces
or plants.
d. Avoid possibility of accidental contact of flue products with
people or pets.
e. Do not locate the termination 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.
f. Locate or guard vent outlet to prevent condensate damage to
exterior finishes.

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 GAS-FIRED WATER BOILER — Boiler Manual

Vertical vent/air termination: 3” PVC concentric (continued)

4. Maintain clearances to termination as given below: &IGURE Vertical termination — Weil-McLain 3” PVC
a. Vent outlet must be located: concentric — multiple boilers
s At least 6 feet from adjacent walls.
s No closer than 5 feet below roof overhang.
s At least 7 feet above any public walkway.
s At lease 3 feet above any forced air intake within 10 feet.
s No closer than 12 inches below or horizontally from any door
or window or any other gravity air inlet.
b. Air inlet must terminate at least 12 inches above the roof or
snow line as shown in Figure 82, page 69. (For Canada, the
minimum is 18 inches.)
c. Do not terminate closer than 4 feet horizontally from any
electric meter, gas meter, regulator, relief valve or other equip-
ment. Never terminate above or below any of these within
4 feet horizontally.
5. Locate termination so it is not likely to be damaged by foreign
objects, such as stones or balls, or subject to buildup of leaves or
sediment.
6. Do not connect any other appliance to the vent pipe or multiple
boilers to a common vent pipe.
Assembling the concentric termination
Multiple vent/air terminations
1. See Figure 85, page 71 for the dimensions and details of
1. When terminating multiple Ultra boilers, install the concentric the termination assembly.
vent/air termination assemblies as described in this supplement.
2. Prepare the bird screen supplied with the concentric
All vent outlets must terminate at the same height to avoid vent kit.
possibility of severe personal injury, death or substantial a. Cut the bird screen to fit the outside diameter of the
property damage. 2½-inch PVC inner pipe supplied with the termina-
tion kit (inner pipe O.D. is 27/8 inches).
2. Place roof penetrations to obtain minimum of 12 inches between
centers of adjacent vent pipe of another boiler for U. S. installa- 3. Partially assemble the vent termination kit in the se-
tions (see Figure 83). quence shown in Figure 84, page 71.
3. For Canadian installations, provide clearances required by CSA $/./4 install the rain cap and bird screen
B149.1 or B149.2 Installation Code. until the assembly has been inserted through
4. The air inlet of an Ultra boiler is part of a direct vent connection. the roof and all supports have been installed.
It is not classified as a forced air intake with regard to spacing from Follow instructions to cover the end of the
adjacent boiler vents. assembly with plastic before inserting through
the roof penetration to prevent debris from
blocking the air passages.
Prepare roof penetration
4. Use the following procedures to prepare termination
1. Roof penetration hole: components and cement together.
a. Cut a 5-inch diameter hole to clear the 4½-inch termination
outside diameter. 5. Deburr inside and outside of pipe ends.
b. Insert a galvanized metal thimble in the vent pipe hole. 6. Chamfer outside of each pipe end to ensure even cement
distribution when joining.
2. Follow all local codes for isolation of vent pipe when passing
through floors, ceilings and roofs. 7. Clean all pipe ends and fittings.
3. Provide flashing and sealing boots sized for the concentric termina- 8. Dry thoroughly.
tion outside diameter, 4½ inches.
9. Dry assemble entire vent or air piping to ensure proper
4. Mount the termination as shown in Figure 86, page 72. fit before assembling any joint.

70 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Vertical vent/air termination: 3” PVC concentric (continued)

&IGURE Weil-McLain 3” PVC concentric termination &IGURE 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.

!$6!.#%$).34!,,!4)/.

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 GAS-FIRED WATER BOILER — Boiler Manual

Vertical vent/air termination: 3” PVC concentric (continued)

10. For each joint: &IGURE Weil-McLain 3” PVC concentric
a. Handle fittings and pipes carefully to prevent contamination of termination supports
surfaces.
b. Apply primer liberally to both joint surfaces — pipe end and fit-
ting socket.
c. While primer is still damp, lightly apply approved cement to both
surfaces in a uniform coating.
d. Apply a second coat to both surfaces. Avoid using too much cement
on sockets to prevent cement buildup inside.
e. With cement still wet, insert pipe into fitting, twisting ¼ turn. Make
sure pipe is fully inserted.
If necessary, you can shorten the lengths of the inner and outer
pipes for a shorter finished assembly. But you must ensure the
pipes butt correctly at both ends. Failure to properly assemble
the concentric termination can result in flue gas recirculation,
causing possible severe personal injury or death.

Mount concentric termination

1. Before beginning vent and air piping from boiler, mount and secure
the concentric termination as shown in Figure 86.
The vent and air piping must be securely supported, and must
not rest its weight on the boiler fittings. DO NOT drill or
screw into either the vent pipe or air pipe. Failure to properly
support the vent and air piping could result in vent piping
damage, resulting in possible severe personal injury, death or
substantial property damage.
When inserting the partially-assembled termination kit
through the roof penetration, wrap plastic or other protection
over the end of the exposed assembly to prevent debris from
entering the pipes. If the air passages become blocked, the &IGURE Alternate piping configuration, using (3)
boiler will not operate. Once the rain cap has been cemented 45-degree elbows to obtain closer pipe
to the assembly, there is no way to correct the problem. The as- centers
sembly would have to be replaced if it were cut to be removed
and cleaned. Altering the assembly in any way could result
in severe personal injury or death due to toxic flue product
emissions.
When using AL29-4C stainless vent pipe, use the vent pipe
manufacturer’s 3-inch PVC adapter when connecting to the
concentric vent attachment.
2. After the assembly has been positioned in the roof opening and all
supports have been attached, install the bird screen and rain cap as
follows:
a. Place the bird screen on the end of the inner pipe as in Fig-
ure 84, page 71.
b. Cement the rain cap in place as shown.

Vent termination support

1. Support the concentric vent/air termination at the roof penetration
as shown in Figure 86.
s The supports/bracing used must support the termination assembly
to prevent vertical slippage or sideways movement.
s The clamps used on the outside of the termination pipe must not
cut into the pipe or contain sharp edges that could cause a crack
to form.

72 Part number 550-100-090/1113

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Vertical vent/air termination: Separate pipes

Allowable vent/air pipe materials &IGURE -AXIMUMPIPINGLENGTHSFORSEPARATEVENT
ANDAIRPIPEVERTICALTERMINATION
1. Use only the materials listed in Figure 12, page 17.
2. Purchase bird screens for vent and air terminations separately. See
the parts list at the end of this manual. "OILER -AXIMUM -AXIMUM -AXIMUM
5LTRAn 0IPINGv
0IPINGv
0IPINGv

Maximum piping length

Feet Elbows Feet Elbows Feet Elbows
1. Locate the terminations such that the total air piping and vent pip-
ing from the boiler to the termination will not exceed the maximum 80 30 1 100 1
length given in Figure 88. Not
105 30 1 100 1
allowed
2. Maximum lengths listed in Figure 88 allow for 1 elbow. Additional 155 Not allowed 100 1
elbows required a reduction in maximum length as explained in
the table notes. 230 Not allowed 30 1 100 1
299 Not allowed Not allowed 100 1
Connecting from termination to boiler 399 Not allowed Not allowed 100 1
1. Install the termination penetrations as instructed in the follow- * Install reducers as necessary where connecting to the boiler
ing. Then proceed to page 75 to complete the piping between the vent and air connections.
termination and the boiler. For piping using more than 1 elbow, reduce maximum allow-

!$6!.#%$).34!,,!4)/.
able length:
Determine location sFEETFOREACHADDITIONAL INCHELBOW—OR—
sFEETFOREACHADDITIONAL2 or 3-inch long radius elbow
sFEETFOREACH2 or 3-inch short radius elbow
1. Locate the vent/air terminations using the following guidelines: sFEETFOREACH2 or 3-inch 45-degree elbow.
2. The air piping must terminate in a down-turned 180-degree return NOTE: The 180-degree return bend is included in the allowed
bend as shown in Figure 89. Locate the air inlet pipe no further fittings. No deduction is required.
than 2 feet from the center of the vent pipe. This placement avoids
recirculation of flue products into the combustion air stream.
3. The vent piping must terminate in an up-turned coupling as shown &IGURE Vertical termination — separate pipes
in Figure 89. The top of the coupling must be at least 1 foot above
the air intake. The air inlet pipe and vent pipe can be located in
any desired position on the roof, but must always be no further
than 2 feet apart and with the vent termination at least 1 foot
above the air intake.
4. You must consider the surroundings when terminating the vent
and air:
a. Position the vent termination where vapors will not damage
nearby shrubs, plants or air conditioning equipment or be
objectionable.
b. The flue products will form a noticeable plume as they con-
dense in cold air. Avoid areas where the plume could obstruct
window views.
c. Prevailing winds could cause freezing of condensate and water/
ice buildup where flue products impinge on building surfaces
or plants.
d. Avoid possibility of accidental contact of flue products with
people or pets.
e. 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.
f. Do not terminate above any door or window. Condensate can
freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage to exterior
finishes.

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 GAS-FIRED WATER BOILER — Boiler Manual

Vertical vent/air termination: Separate pipes (continued)

5. Maintain clearances to vent termination as given below: &IGURE Termination location — separate pipes —
a. Vent must terminate: terminations for multiple boilers
s At least 6 feet from adjacent walls.
s No closer than 5 feet below roof overhang.
s At least 7 feet above any public walkway.
s At least 3 feet above any forced air intake within 10 feet.
s No closer than 12 inches below or horizontally from any
door or window or any other gravity air inlet.
b. Air inlet must terminate at least 6 inches above the roof or
snow line and at least 12 inches below the vent termination as
shown in Figure 89, page 73.
c. Do not terminate closer to 4 feet horizontally from any electric
meter, gas meter, regulator, relief valve or other equipment.
Never terminate above or below any of these within 4 feet
horizontally.
6. Locate terminations so they are not likely to be damaged by foreign
objects, such as stones or balls, or subject to buildup of leaves or
sediment.
7. Do not connect any other appliance to the vent pipe or multiple
boilers to a common vent pipe.

Prepare roof penetrations

1. Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as close as
desired to the air pipe outside diameter.
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or non- 3. The vent piping must terminate in an up-turned cou-
combustible construction, size the vent pipe hole at least 0.4” pling as shown in Figure 89, page 73. The top of the
larger than the vent pipe diameter: coupling must be at least 1 foot above the air intake. The
s 2¾” hole for 2” PVC air inlet pipe and vent pipe can be located in any desired
s 4” hole for 3” PVC position on the roof, but must always be no further than
2 feet apart and with the vent termination at least 1 foot
s 5” hole for 4” PVC above the air intake.
b. Insert a galvanized metal thimble in the vent pipe hole.
4. Maintain the required dimensions of the finished termi-
3. Space the air and vent holes to provide the minimum spacings nation piping as shown in Figure 89, page 73.
shown in Figure 89, page 73. 5. Do not extend exposed vent pipe outside of building
4. Follow all local codes for isolation of vent pipe when passing more than shown in this document. Condensate could
through floors, ceilings and roofs. freeze and block vent pipe.
5. Provide flashing and sealing boots sized for the vent pipe and air Multiple vent/air terminations (Figure 90)
pipe.
1. When terminating multiple Ultra boilers, terminate each
Termination and fittings vent/air connection as described in this section.
1. Prepare the vent termination elbow and the air termination elbow Terminate all vent pipes at the same height
(Figure 89, page 73) by inserting bird screens. Bird screens must be and all air pipes at the same height to avoid
purchased separately. See the parts list at the end of this manual possibility of severe personal injury, death or
for part numbers. substantial property damage.
a. If using 3-inch piping for an Ultra-230, cut a 4-inch bird screen 2. Place roof penetrations to obtain minimum clearance of
by placing 3-inch fitting on screen and cutting around it as a 12 inches between edge of air intake elbow and adjacent
template. vent pipe of another boiler for U. S. installations (see
2. The air piping must terminate in a down-turned 180-degree return Figure 2). For Canadian installations, provide clearances
bend as shown in Figure 89, page 73. Locate the air inlet pipe no required by CSA B149.1 or B149.2 Installation Code.
further than 2 feet from the center of the vent pipe. This place- 3. The air inlet of an Ultra boiler is part of a direct vent
ment avoids recirculation of flue products into the combustion connection. It is not classified as a forced air intake with
air stream. regard to spacing from adjacent boiler vents.

74 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Install vent/air piping — boiler to termination

Complete termination preparation &IGURE Boiler vent and air connections
1. Install vent and air terminations before proceeding. See previous
pages for instructions.

Installing vent and air piping

1. For reference in the following see:
a. Sidewall terminations: see Figure 92, page 76.
b. Vertical terminations: see Figure 93, page 76.
2. Work from the boiler to vent or air termination. Do not exceed
the lengths given in the previous pages for either the air or vent
piping.
a. As shown in the maximum length tables, the Ultra-80 or
Ultra-105 may be installed with either 2-inch or 3-inch vent
and air piping.
b. As shown in the maximum length tables, the Ultra-230 may be Inserting/securing vent or air
installed with either 3-inch or 4-inch vent and air piping. pipe into boiler connectors
c. You must install appropriate pipe reducers, where required, at

!$6!.#%$).34!,,!4)/.
both the boiler and at the termination assembly. AL29-4C vent pipe — If using AL29-4C
stainless vent pipe, you must install a
3. See Figure 91 for attaching vent and air pipes at the boiler. PVC-to-vent pipe adapter at the boiler
vent connection (and at the termination
4. Cut pipe to required lengths. if using the Weil-McLain plate or the
concentric termination). Use only the
5. Deburr inside and outside of pipe ends. adapter made by the vent pipe manufac-
6. Chamfer outside of each pipe end to ensure even cement distribu- turer.
tion when joining. 1. PVC/ABS pipe — Clean and chamfer insertion
7. Clean all pipe ends and fittings. Dry thoroughly. end of pipe. Deburr inside of insertion end. Clean
and deburr inside and outside of other end of pipe.
8. Dry assemble entire vent or air piping to ensure proper fit before
assembling any joint. The pipe end must be smooth and
chamfered to prevent possible damage to
9. For each joint: sealing gasket in vent or air pipe adapter.
Failure to comply could result in leakage,
a. Handle fittings and pipes carefully to prevent contamination causing possible severe personal injury or
of surfaces. death.
b. Apply primer liberally to both joint surfaces — pipe end and
fitting socket. 2. Inspect vent or air adapter (above) — verify no
obstructions or foreign objects inside.
c. While primer is still damp, lightly apply approved cement to
both surfaces in a uniform coating. 3. Loosen clamp screw.
d. Apply a second coat to both surfaces. Avoid using too much 4. Measure 3½ inches from end of pipe and make a
cement on sockets to prevent cement buildup inside. mark with felt-tip pen.
e. With cement still wet, insert pipe into fitting, twisting ¼ turn. 5. Loosen adapter clamp screw.
Make sure pipe is fully inserted. 6. Apply small amount of silicon grease to end of pipe
f. Wipe excess cement from joint. Check joint to be sure a smooth to ease insertion.
bead of cement shows around the entire joint. 7. Insert pipe into adapter.
10. Install pipe supports as shown in Figure 92, page 76 or Fig- 8. Slide pipe down until the 3½-inch mark is reached.
ure 93, page 76.
Do not apply excessive force or bend the
11. Slope vent and air piping continuously toward boiler, with at least adapter or flue/air pipe when inserting.
1/4 inch drop per foot of run. Do not allow sags at any point. The adapter or seal could be damaged.
12. Maintain minimum clearance of ³⁄₁₆ inch between vent pipe and 9. Secure vent or air pipe by tightening the adapter
any combustible wall or material. clamp securely. Do not overtighten. The seal is ac-
complished with the internal gasket. The clamp is
13. Seal wall or floor penetration openings following local code re- only to hold the pipe in place.
quirements.

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Install vent/air piping — boiler to terminations (cont.)

&IGURE 3IDEWALLTERMINATIONMETHODSAND &IGURE 6ERTICALTERMINATIONMETHODSAND

INSTALLATIONREQUIREMENTS INSTALLATIONREQUIREMENTS

7EIL -C,AINSIDEWALL
TERMINATIONPLATE 7EIL -C,AINv06#
(install termination — page 19) CONCENTRICTERMINATION
(install termination — page 69)
sInstall pipe supports every 5 feet
on both the horizontal and vertical sInstall pipe supports every 5 feet
runs. on both the horizontal and vertical
sInstall a hanger support within runs.
6 inches of any upturn in the sInstall a hanger support within
piping. 6 inches of any upturn in the
sThe Weil-McLain plate piping.
termination must be installed sThe Weil-McLain 3” PVC
before piping from the boiler to concentric termination assembly
the termination. must be installed before piping
sSlope horizontal piping downward from the boiler to the termination.
toward the boiler at least 1/4 inch Support the termination at
per foot. the ceiling and above the roof
as shown in the termination
7EIL -C,AINv06# instructions.
CONCENTRICTERMINATION sSlope horizontal piping downward
(install termination — page 63) toward the boiler at least 1/4 inch
per foot.
sInstall pipe supports every 5 feet sUse long-radius elbows for air
on both the horizontal and vertical piping when using 2” or 3” pipe to
runs. reduce pressure drop.
sInstall a hanger support within sRotate the concentric termination
6 inches of any upturn in the Y-fitting about 30° to result in pipe
piping. centers the same as at the boiler.
sThe Weil-McLain 3” PVC
concentric termination assembly
must be installed before piping
from the boiler to the termination. 6ERTICALTERMINATIONWITH
Support the termination at the SEPARATEVENTANDAIR
wall as shown in the termination PIPES
instructions. (install termination — page 73)
sSlope horizontal piping downward
toward the boiler at least 1/4 inch sPrepare roof penetrations before
per foot. installing vent and air piping.
sRotate the concentric termination Finish by attaching termination
Y-fitting about 30° to result in pipe fittings as shown in termination
centers the same as at the boiler. instructions.
sInstall pipe supports every 5 feet
3IDEWALLTERMINATIONWITH on both the horizontal and vertical
SEPARATEVENTANDAIR runs.
PIPES sInstall a hanger support within
(install termination — page 66) 6 inches of any upturn in the
piping.
sPrepare wall penetrations before sSlope horizontal piping downward
installing vent and air piping. toward the boiler at least 1/4 inch
Finish by attaching external per foot.
pipe and fittings as shown in the sAir piping may be offset as
termination instructions. shown at left so termination
sInstall pipe supports every 5 feet can be located as required in the
on both the horizontal and vertical installation instructions.
runs. sUse long-radius elbows for air
sInstall a hanger support within piping when using 2” or 3” pipe to
6 inches of any upturn in the reduce pressure drop.
piping.
sSupport vertical runs on the
outside of the building with
brackets as shown in the
termination instructions.
sSlope horizontal piping downward
toward the boiler at least 1/4 inch
per foot.

76 Part number 550-100-090/1113

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Gas piping — sizing gas lines

Natural Gas: &IGURE Common gas line for multiple boilers

Pipe sizing for natural gas

1. Size gas piping from meter outlet to entrance of boiler in accordance
with Figure 95 and Figure 96.
2. Use total input of all boilers. Divide total input in Btuh by 1,000 to
obtain cubic feet per hour of natural gas.
a. Pipe lengths in Figure 95 are equivalent length of straight pipe. Con-
vert pipe fittings to equivalent lengths using data from Figure 96.
b. Figure 95 is only for natural gas with specific gravity 0.60, with a
pressure drop through the gas piping of 0.30” w.c.
c. For additional gas pipe sizing information, refer to ANSI Z223.1
(or B149.1 or B149.2 for Canadian installations).

Natural gas supply pressure

&IGURE Pipe capacity for 0.60 specific gravity
1. Pressure required at gas valve inlet pressure port: natural gas
a. Maximum: 13” w.c. with no flow (lockup) or with boiler on
b. Minimum: 4” w.c. (for all except 5” for -299) with gas flowing #APACITY
(verify during boiler startup, while boiler is at high fire) 'ASPIPE
TOTALLENGTH (cubic feet per hour, 0.60 specific gravity)

!$6!.#%$).34!,,!4)/.
2. Install 100% lockup gas pressure regulator in supply line if inlet pres- FEET
sure can exceed 13” w.c. at any time. Adjust lockup regulator for 13” v v  v v  v
w.c. maximum.
 520 1050 1600 3050 4800
 350 730 1100 2100 3300

Propane Gas:  285 590 890 1650 2700

 245 500 760 1450 2300
You must follow the instructions, beginning on page 7, to
operate the boiler on propane. Failure to comply could result  215 440 670 1270 2000
in severe personal injury, death or substantial property dam-  175 360 545 1020 1650
age.
 150 305 460 870 1400
Pipe sizing for propane gas  120 250 380 710 1130
1. Contact gas supplier to size pipes, tanks and 100% lockup gas pressure
regulator.

Propane supply pressure &IGURE Equivalent lengths of straight pipe for

typical gas line fittings
1. Adjust propane supply regulator provided by gas supplier for 13” w.c.
maximum pressure. %QUIVALENTLENGTHFEET
0IPESIZE
2. Pressure required at gas valve inlet pressure port:
inches —%LBOW 4EE
a. Maximum: 13” w.c. with no flow (lockup) or with boiler on
s Minimum: 4” w.c. with gas flowing (verify during boiler startup,  2.62 5.24
while boiler is at high fire).
 3.45 6.90

Manifolded gas supply lines   4.02 8.04

1. Construct gas header for multiple boilers using Figure 94 and the sizing  5.17 10.3
tables below. Refer to the National Fuel Gas Code for other conditions.
2. Provide manual shutoff gas valve and ground joint union as shown in   6.16 12.3
Figure 31 and Figure 94 for each boiler. When gas line enters from top
of the boiler, the boiler internal gas piping provides a drip leg.
3. A ¾” NPT gas piping riser from header to boiler will be large enough
for most jobs. Ensure the piping is large enough so that the minimum
pressure at the boiler will be at least 5 inches water column with all
connected appliances firing.

Part number 550-100-090/1113 77

 GAS-FIRED WATER BOILER — Boiler Manual

Field wiring — advanced

ondary heat source when another heat source, such
%,%#42)#!, 3(/#+ (!:!2$ — For your as a heat pump or another boiler is available.
safety, turn off electrical power supply at service
entrance panel before making any electrical connec- ❏ #ONNECTTOREMOTEALARMWHENUSED
tions to avoid possible electric shock hazard. Failure ❏ #ONNECTWIRINGFORMULTIPLEBOILEROPERATION
to do so can cause severe personal injury or death. s The U-Control provides the flexibility for control
of multiple Ultra boilers.
Wiring must be N.E.C. Class 1. If original wiring as s You will need to program the boilers’ U-Controls
supplied with boiler must be replaced, use only type based on the interconnection method you choose.
105 °C wire or equivalent. Boiler must be electrically
grounded as required by National Electrical Code ❏ )NSTALLSYSTEMOUTDOORSENSORSWHENUSED
ANSI/NFPA 70 – latest edition. s The boiler is shipped with an outdoor sensor, a
system supply sensor and a system return sensor.
The system supply sensor will be required for most
space heating applications. The system return sensor
Installation must comply with: must also be installed when using the system supply
sensor. Use of the outdoor sensor is optional.
1. National Electrical Code and any other national, state, provincial or
local codes or regulations.
2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local
codes. Line voltage power input

Wiring — general
1. The U-Control provides plug-in, color-coded, non-interchangeable
terminal strips for all field wiring. See the schematic diagram (Fig-
ure 98, page 80) & ladder diagram (Figure 99, page 81).
2. The U-Control provides programmable flexibility in system op- 1. Provide and install a fused disconnect or service switch
eration, allowing control of heat supply for up to three different (15-ampere rated recommended) as required by ap-
heating systems. Read this manual thoroughly before connecting plicable codes.
the wiring to ensure trouble-free start-up and operation. 2. Connect minimum 15-ampere, 120 VAC power wiring
to Ultra boiler line voltage terminal strip as shown in
Figure 98, page 80 and above.
Wiring — overview
You will need to make the following connections, some of which Wiring circulators
depend on your system and how the U-Control will be programmed.
(See this and following pages for more information.) 1. The U-Control provides for connection of up to three
circulators, one of which must be the boiler circulator.
❏ #ONNECT6!#POWERMINIMUM AMPSOURCE In addition, you can connect a system circulator and a
DHW circulator, for examples. See Figure 97, page 79.
❏ #ONNECTWIRINGFORUPTOTHREECIRCULATORS
4HEMAXIMUMALLOWABLECURRENTFOREACH
❏ #ONNECTEXTERNALLIMITSIFUSED
CIRCULATOR IS  AMPS AT 6!#. For
s Two different circuits are available — The U-Control will circulators with higher amp ratings, you must
require manual reset for one of these circuits. The U-Control install a circulator relay or starter to provide
will automatically reset after limit operation and re-closure for line voltage to the circulator. For circulators
limits in the other circuit. rated over 2.2 amps, connect only the circula-
❏ #ONNECTTHERMOSTATSANDORHEATDEMANDCONTACTS tor relay or starter coil to the Ultra circulator
s The U-Control can regulate the boiler for up to three different terminals.
heating systems.
2. You can connect any of the circulators you use to any of
❏ #ONNECTREMOTEOPERATIONINPUTIFUSED
the three circulator activation terminals. The U-Control
s The U-Control will operate and modulate the boiler based setup allows you to assign which circulators activate on
on a 0–10 VDC control signal from a remote controller, when a call for heat (this can be customized for each of the
desired. heating systems supplied by the boiler).
❏ #ONNECTTHEhADDITIONALHEATDEMANDvCIRCUITTOASECOND 3. The U-Control factory DEFAULT settings for DHW heat-
HEATINGSOURCEWHENUSED ing are configured for direct piping to the boiler, with
s The U-Control allows the boiler to act as the primary or sec- Circulator 1 being the only circulator being activated

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 GAS-FIRED WATER BOILER — Boiler Manual

Field wiring — advanced (see &IGURE&IGURE (continued)

&IGURE Wiring to circulators

The U-Control module provides internal
low water protection
1. The U-Control and internal sensors in the Ultra boiler provide
both temperature control and low water protection (using
temperature senors), as explained below:

The U-Control module uses temperature sensors to

provide both high limit protection and modulating
temperature control.
The U-Control module also provides LOW WATER
PROTECTION by using a dual sensor to monitor the
temperature of the heat exchanger. [The U-Control
constantly monitors the sensor signals to ensure
they are within 10 °F of one another. If the sensor
difference exceeds 10 °F, the boiler is shutdown on
automatic reset.] This method is accepted in many
areas as meeting the requirement for a low water
cut-off.

!$6!.#%$).34!,,!4)/.
Some codes or jurisdictions may require additional
external controls for high limit and/or low water
cutoff protection. Follow the guidelines in this man-
ual to install additional controls when required.

during DHW heating. To use factory default settings,

make sure to connect the DHW circulator to terminals 1, 3. Install thermostats on inside walls away from the influences of
4 and 7, as below: drafts, hot or cold water pipes, lighting fixtures, television, sun
4. The factory DEFAULT for space heating is designed for rays, or fireplaces.
finned-tube baseboard, and set up to activate Circula-
tor 2 and Circulator 3 on a call for heat. Connect the 4. Thermostat anticipator (if applicable):
boiler circulator to terminals 2, 5 and 8 and the system
circulator to terminals 3, 6 and 9 to use these default s If connected directly to the boiler, set anticipator for
settings. 0.1 amps.
5. Make sure the U-Control is programmed to activate s If connected to relays or other devices, set to match total elec-
the system circulator when it is required (during space trical power requirements of connected devices. See device
heating, for instance). manufacturers’ specifications and the thermostat instructions
for details.
Thermostats & DHW tank
temperature control connections
Low water cut-offs
Use isolating relays if using 3-wire zone valves
to avoid damage and nuisance problems due 1. See the ./4)#% on this page regarding internal low water protec-
to stray voltage. tion provided by the U-Control.
1. The U-Control allows operation by up to three different
2. When an external low water cut-off is installed, connect as shown
heating systems.
in the U-Control wiring diagrams (Figure 98, page 80 & Fig-
2. The factory default configuration is for “heat demand 1” ure 99, page 81).
to be DHW and “heat demand 2” to be space heating.
For factory default operation: 3. When possible, use the Weil-McLain Ultra low water cut-off kit
a. 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.
setup.
b. Connect the DHW tank temperature control across
terminal strip P11, terminals 4 and 5 to use the
default setup. #ONTINUEDAFTERPAGE

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 GAS-FIRED WATER BOILER — Boiler Manual

Field wiring — advanced (see &IGURE&IGURE (continued)

&IGURE Schematic wiring diagram — Ultra-80 through Ultra-299

80 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Field wiring — advanced (see &IGURE&IGURE (continued)

&IGURE Ladder wiring diagram — Ultra-80 through Ultra-299

!$6!.#%$).34!,,!4)/.

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Field wiring — advanced (see &IGURE&IGURE (continued)

Additional limits Outdoor temperature sensor

1. The U-Control allows connection of external limit controls, both for 1. The U-Control provides programmable options
manual reset and for automatic reset operation of the U-Control. when using an outdoor temperature sensor. This
2. -ANUALRESETOFTHE5 #ONTROLONLIMITACTION — Connect exter- sensor is supplied with the boiler, and can be used
nal limits across P13, terminals 1 and 2 if the U-Control is to require if desired (not required). See the following section
manual reset when a limit opens, even if the limit re-closes. (Remove for outdoor temperature options.
the factory jumper when using these terminals.) 2. Mount the outdoor sensor on an exterior wall,
The U-Control will lockout when a limit in its manual reset shielded from direct sunlight or flow of heat or
circuit opens. The U-Control activates its alarm terminals and cooling from other sources.
shuts the boiler down until an operator manually resets the 3. Connect the sensor leads to P10, terminals 1 and 2,
U-Control (as explained in this manual). This reset function as shown in the wiring diagrams. Thermostat wire
can be done by a homeowner or a service technician. can be used to connect the sensor.
3. !UTOMATIC RESET OF THE 5 #ONTROL ON LIMIT ACTION — Connect
external limits across P13, terminals 3 and 4 if the U-Control is to
reset automatically when the limit circuit closes after a limit condition.
(Remove the factory jumper when using these terminals.) System supply & return
temperature sensors
(see Figure 4, page 11 for placement of sensors)
Remote operation/modulation
1. The boiler is also shipped with two strap-on tem-
1. The U-Control module provides terminals to input a remote 0–10 VDC perature sensors, intended for system supply and
operating signal. This can be provided by a separate controller if the return.
boiler is configured as Type 4 (SHADOW boiler mode).
2. Connect the 0–10 VDC signal positive terminal to P15 terminal 6, and 2. These sensors can be attached to piping up to
the signal common to terminal 5. 3-inch diameter.
3. When receiving a remote operating signal, the boiler starts when the sig- 3. Thermostat wire can be used to connect these
nal exceeds 1.0 VDC (and shuts off if the signal drops below 0.5 VDC). sensors.
The boiler remains at low fire until the signal exceeds 2.0 VDC. Between
2.0 and 10.0 VDC, the boiler firing rate increases with the signal value,
reaching full input at 10.0 VDC.
4. The U-Control continues to monitor boiler temperatures, based on
the values set up under Priority 1 operation. See the following section
for details.

Additional heat demand option

1. The U-Control module can be set up to activate another heat source
using its additional heat demand dry contracts (P16, terminals 6
and 7). 4. The system supply temperature sensor allows the
U-Control to regulate temperature in the system
2. Connect these terminals to call for heat from the other heat source. main piping.
(See the following section to program the boiler to activate the other
source, either as the primary or secondary heat source.) 5. Locate the supply sensor at least six pipe diameters,
but no further than 3 feet, downstream from the
boiler connection to the main to ensure adequate
Alarm contacts (low voltage ONLY) mixing.
1. The U-Control’s alarm dry contact (P16, terminals 4 and 5) closes when 6. The system return sensor allows the U-Control to
the boiler enters lockout. monitor and display system return temperature.
2. Connect these terminals for remote alarm notification. 7. For multiple boiler applications, install a system
supply temperature sensor and system return sen-
sor wired to the LEAD boiler.
Multiple boiler wiring options
8. The U-Control also compares the system return
1. The U-Control can be programmed to sequence multiple boilers or temperature with the system supply temperature.
operate/modulate in tandem from a 0–10 VDC source generated by Should the return temperature ever exceed the
the lead boiler or from a remote controller. supply temperature, the U-Control knows there is
2. See “ADDITIONAL HEAT DEMAND,” page 83 for recommended likely a sensor failure and will report this problem
wiring. on the display.

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U-Control operation and setup — advanced

,OW TEMPERATURE SYSTEMS (radiant 4. The outdoor sensor must be installed to use this
slab, etc.) — $/./4use the Ultra boiler function.
control as the only means of water tem-
perature regulation for low-temperature !$*534/54$//2
systems if higher-temperature systems 1. Use this setting to adjust the outdoor sensor tem-
are also supplied. perature to account for solar or other effects that
would cause the sensor to read incorrectly.
ADVANCED SETUP – OVERVIEW !$$)4)/.!,(%!4$%-!.$
1. Access contractor menus by pressing and holding 1. This setting is for multiple boilers or multiple heat-
the UP and DOWN arrow keys at the same time ing sources (an Ultra boiler collaborating with a
for 5 seconds. heat pump or a different boiler, for examples).
2. The contractor screen will show: 2. For Type 4 boilers, this function only applies to the
a. BOILER SETTINGS Priority 1 system.
b. SYSTEM SETTINGS 3. OFF — Function disabled.
c. DIAGNOSTICS
d. MAINTENANCE INFO 4. Type 1 — This means the Ultra boiler is the primary
e. SET DATE AND TIME heat source.
3. Navigate through the menus as shown in Fig- a. When the Ultra boiler receives a call for heat,
ure 102, page 86. For a description of each of the it begins its startup sequence and also starts a
menu options, see Figure 103, page 88. delay timer (set as ADD’L HEAT DEMAND
TIME).

!$6!.#%$).34!,,!4)/.
4. You will need to adjust settings as required for the
systems supplied by the boiler and connect the b. When the delay timing is reached, the U-
Control closes the “Additional heat demand
wiring accordingly. contact,” terminals P16 #6 and #7. Use this
contact to start the next heat source.
ADVANCED SETUP – c. If the next heat source is an Ultra boiler, con-
BOILER SETTINGS nect this contact to the boiler’s “heat demand 1”
terminals (P11 #4 and #5). Program the second
"/),%2-/$%, boiler’s delay timer to start a third boiler the
same way, and so on to sequentially fire mul-
Check the BOILERMODEL against the model tiple boilers.
listed on the boiler’s rating plate. Change
the selection to the correct model if not. 5. Type 2 — This means the boiler is the secondary
Also verify the model number on the heat source.
U-Control display at power-up. Failure a. When the U-Control receives a call for heat,
to correct could result in severe personal it immediately activates the “Additional heat
injury, death or substantial property demand contact,” terminals P16 #6 and #7.
damage. This contact is used to start the next heat source
immediately.
()'(!,4)45$% b. When the delay timing is reached, the Ultra
If the boiler is installed at an altitude boiler begins its startup sequence and continues
above 5,500 feet, select YES for high to heat until the demand is satisfied.
altitude. The U-Control will automati- c. Type 2 assignment would generally only be used
cally adjust firing rates (blower speeds) if the other heat source is a different boiler or a
to compensate for altitude. heat pump, for example.
6. Type 3 — This assigns the boiler as the LEAD boiler
773$
in a multiple boiler system.
1. WWSD stands for “warm weather shutdown.” It
means the boiler will not be allowed to fire if the a. This LEAD boiler must have system supply and
outside temperature is greater than the WWSD return sensors mounted on the system supply
and return pipes and wired to the boiler.
setting.
b. When the U-Control receives a call for heat, it
2. When the boiler is kept off because the outside begins its heating sequence and starts the ad-
temperature is above WWSD, the graphic display ditional heat demand delay timer.
will show “WWSD,” and the boiler will remain in
standby until the outside temperature drops below c. When the delay timing is reached, the U-
Control sends a 0–10 VDC proportional signal
WWSD temperature. out its 0–10 VDC output terminals, P16 #1
3. WWSD does not apply to DHW systems. and #2.
d. If the heat demand is satisfied before the timer
runs out, the next boiler is not started.

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U-Control operation and setup — advanced (continued)

e. Connect these output terminals to the ADVANCED SETUP –
SHADOW boilers’ 0–10 VDC input termi- SYSTEM TYPE
nals, P15 #5 and #6. The SHADOW boilers
will start and modulate based on the signal 1. For each priority being used, select the appropriate
strength. The SHADOW boilers must be set system type. See Figure 101, page 85 for system options
up as Type 4 (see below). They do not need and preset temperatures.
their additional heat timers to be setup. 2. The temperature presets are chosen based on normal
f. An alternate method is to daisy chain the best setting for these systems. The temperature values
other boilers. That is, connect the output can be changed, if desired, under “TEMPERATURES.”
of each to the input of the next. Each of
these boilers would be set up as a Type 4 ADVANCED SETUP –
(see below), and each needs its additional
heat timer set for the desired delay between
TEMPERATURES
boilers. 1. Setup desired temperatures for each of the priorities
7. Type 4 — This assigns the boiler as a SHADOW used.
boiler in a multiple boiler system. 2. For an explanation of the target temperatures and as-
a. The boiler can be wired and setup to run in sociated outdoor temperatures, see Figure 100.
parallel with the other SHADOW boilers a. Outdoor temp for max target means the outdoor
as in 6c, above. Or they can be set up for temperature at which the target temperature reaches
sequential operation following 6d, above. its maximum value. In the example of Figure 100,
this occurs at 25 °F outside.
b. When the boiler receives a 0–10 VDC in-
b. Outdoor temp for min target means the outdoor
put on terminals P15 #5 and #6, it starts temperature at which the target temperature reaches
up and modulates firing rate according to its minimum. In the example of Figure 100, this
the signal. occurs at 70 °F.
c. If wired and setup per 6d above, it also c. Note that the reset lines are curved. The shape of this
starts its additional heat delay timer imme- curve is matched (or characterized) to the response
diately. When the delay timing is reached, of the system type chosen to ensure the most effec-
the U-Control sends out a 0–10 VDC signal tive reset operation.
(on terminals P16 #1 and #2) for the next
boiler. &IGURE Typical outdoor reset curves
d. The boiler uses the settings for Priority 1
while receiving the 0–10 VDC signal.

ADVANCED SETUP –
PRIORITY 1, 2, 3
1. Priority 1, 2 and 3 refer to the three possible
heating inputs that can be handled by the U-
Control.
2. Select the priority level desired for the applica-
tion. Priority 1 is usually assigned to domestic
water heating, because of the need for quick
response. Priority 2 and 3 usually used for
space heating circuits.
3. Each of the three inputs has its own set of
operating parameters, programmed using the
menus shown in Figure 102, page 86.
3. -ODULATEONDIFFERENTIAL — The temperature must
4. The inputs to the U-Control are: drop this many degrees below target temperature for
a. Priority 1 — P11 #4 and #5, “heat de- the boiler to come on.
mand 1” 4. -ODULATE OFF DIFFERENTIAL — While the boiler is
b. Priority 2 — P15 #1 and #2, “heat de- firing, as the temperature increases above the target
mand 2” temperature, the boiler firing rate is reduced. At this
c. Priority 3 — P15 #3 and #4, “heat de- many degrees above the target temperature, the boiler
mand 3” shuts down.

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U-Control operation and setup — advanced (continued)

&IGURE U-Control system types and preset parameters

3YSTEMTYPE $ISPLAY 0RESETTEMPERATURES .OTE

8-character 3-char Max Target Outdoor Temp Min Target Outdoor Temp
Temp for Max Target Temp for Min Target

Fan-coil FAN-COIL FCL 190 0 140 70

Finned tube baseboard FIN BASE FTB 180 0 130 70

Cast iron baseboard IRN BASE CIB 180 0 120 70

Cast iron radiators RADIATOR CIR 180 0 120 70

Radiant – slab on grade RAD SLAB RSG 120 0 80 70

Radiant – thin slab RAD SLAB RTS 140 0 80 70

Radiant – below floor RADFLOOR RSU 160 0 90 70

(staple up)

Radiant – above floor RADFLOOR RAF 140 0 90 70

(sleeper system)

!$6!.#%$).34!,,!4)/.
Custom CUSTOM CUS 190 0 70 70 s$OESNOTPASSALONG!DDL(EAT$EMAND

DHW – system DOMESTIC DHW 190 s5 #ONTROLMODULATESTOSYSTEMTEMPERA-

ture sensors.
DHW heating ignores outdoor reset and
DHW – direct DOMESTIC DHW 190 warm weather shutdown s5 #ONTROLMODULATESTOBOILERTEMPERATURE
sensors.
s$OESNOTPASSALONG!DDL(EAT$EMAND

ADVANCED SETUP – ADVANCED SETUP –

CIRCULATOR EXERCISING FREEZE PROTECTION CIRCULATORS
1. For each circulator, select whether you want the U-Control to 1. This function automatically fires the boiler at low fire
automatically start the circulator and run for 10 seconds for each and starts the circulators chosen if the heat exchanger
72-hour period of inactivity. sensor detects a temperature less than 40 °F. The circula-
tors turn off when the temperature rises above 45 °F.

ADVANCED SETUP –
MAINTENANCE INFO
1. Use this section to enter contractor’s information and
to enter an automatic notice for maintenance (default
is 12 months). Because this shows on the display, it is an
automatic means of notifying the homeowner of need
for scheduled maintenance by the technician. Update
the screen reminder to reset for the next maintenance
date.

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U-Control operation and setup — advanced (continued)

&IGURE U-Control menus (press and hold the UP and DOWN arrow keys for 5 seconds to enter contractor menus)

-ENUS .EXTSCREEN .EXTSCREEN .EXTSCREEN .EXTSCREEN

Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data
BOILER SETTINGS BOILER MODEL ##### 80 299
105 310 #AREFULLYVERIFYTHATTHEBOILERMODEL
155 399 NUMBERONTHEDISPLAYNOWAGREES
230 550 (commercial model) WITHTHEBOILERRATINGPLATE3ETTING
750 (commercial model) THESE INCORRECTLY COULD RESULT IN
SEVERE PERSONAL INJURY DEATH OR
HIGH ALTITUDE ### NO
YES SUBSTANTIALPROPERTYDAMAGE

HIGH TEMP LIMIT ###

WWSD SETTING ### ###

°F
ADJUST OUTDOOR ### ###
°F
ADD’L HEAT DEMAND OFF
TYPE: ########### TYPE 1 — ULTRA = PRIMARY HEAT SOURCE
TYPE 2 — ULTRA = BACKUP HEAT SOURCE
TYPE 3 — ULTRA = LEAD (0–10V OUTPUT)
TYPE 4 — ULTRA = SHADOW (0–10V INPUT)
ADD’L HEAT DEMAND ##
TIME: ### MINUTES MINUTES
SYSTEM SETTINGS BOILER PRIORITY 1 SYSTEM TYPE: ### OFF
FAN COIL
FINNED TUBE BASEBOARD
CAST IRON BASEBOARD
CAST IRON RADIATOR
RADIANT — SLAB ON GRADE
RADIANT — THIN SLAB
RADIANT — ABOVE FLOOR
CUSTOM
DHW – DIRECT
DHW – SYSTEM
TEMPERATURES MAX SUPPLY: ### °F MIN SUPPLY, MAX
MIN SUPPLY: ### °F OUTDOOR AND MIN
MAX OUTDOOR: ### °F OUTDOOR are not
MIN OUTDOOR: ### °F shown for DHW types
MODULATE ON DIFF: ### °F
MODULATE OFF DIFF:### °F
TIMES MAX ON TIME: ### MIN not on Priority 3
MIN ON TIME: ### MIN not on Priority 1
BOOST INTERVAL: ### MIN
PRE PUMP TIME: ### SEC
POST PUMP TIME: ### SEC
CIRCULATORS: # # # CIRCULATOR 1: ### ON/OFF
CIRCULATOR 2: ### ON/OFF
CIRCULATOR 3: ### ON/OFF
MAXIMUM RATE: ___% ### %
MINIMUM RATE: ___% ### %
BOILER PRIORITY 2 SAME MENUS AS FOR PRIORITY 1
BOILER PRIORITY 3 SAME MENUS AS FOR PRIORITY 1
CIRCULATOR EXERCISING CIRCULATOR 1: ### ON/OFF
CIRCULATOR 2: ### ON/OFF
CIRCULATOR 3: ### ON/OFF
FREEZE PROTECT CIRCS CIRCULATOR 1: ### ON/OFF
CIRCULATOR 2: ### ON/OFF
CIRCULATOR 3: ### ON/OFF
MAINTENANCE INFO NAME ################
PHONE ###-###-####
MODEL ULTRA #####
CP# ##########
INSTALLED MM/DD/YY
LAST DATE MM/DD/YY
NEXT DATE DD/MM/YY
INTERVAL SETTINGS ## MONTHS
RESET REMINDER PRESS ENTER TO RESET

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U-Control operation and setup — advanced (continued)

&IGURE U-Control menus, continued (press and hold the UP and DOWN arrow keys for 5 seconds to enter contractor menus)

-ENUS .EXTSCREEN .EXTSCREEN .EXTSCREEN .EXTSCREEN

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 TEMPERATURES STATUS: ##########
SYSTEM SUPPLY: ###°F
SYSTEM RETURN: ###°F
BOILER OUT1: ###°F
BOILER OUT2: ###°F
BOILER IN1: ###°F
FLUE 1: ###°F
FLUE 2: ###°F
OUTDOOR: ###°F

INPUTS STATUS: ##########

PRIORITY 1: ###
PRIORITY 2: ###
PRIORITY 3: ###
ANALOG IN: ####
MANUAL LIMIT: ######
AUTO LIMIT: ######
LOW WTR CUTOFF: ######
BLOWER TACH: ####RPM

!$6!.#%$).34!,,!4)/.
FLAME SIGNAL: ###

OUTPUTS STATUS: ##########

GAS VALVE: ###
CIRCULATOR 1: ###
CIRCULATOR 2: ###
CIRCULATOR 3: ###
BLOWER SIGNAL: ###%
ADD’L HEAT DEMAND: ###
ALARM: ###
ANALOG OUT: ####

ERRORS CONTROL FAULT ###

IGNITION RETRIES ###

MANUAL RESET CNT ###

AUTO RESET CNT ###

LOCKOUT HISTORY 1 LOCKOUT HISTORY #

HH:MM AM MM/DD/YY
STATUS: ##########
MANUAL RESET LIST OF LOCKOUTS
AUTO RESET LIST OF LOCKOUTS
INPUTS INPUT STATUS
OUTPUTS OUTPUT STATUS
TEMPERATURES TEMPERATURES

LOCKOUT HISTORY 2 . . . SAME AS HISTORY 1

LOCKOUT HISTORY 3 . . . SAME AS HISTORY 1

SOFTWARE VERSIONS DISPLAY V#.##

NOTE: Display will show
MAIN MICRO V#.##
C#.## for CSD-1 control.
SECOND MICRO V#.##

MANUAL TEST MODE STATUS: ##########

TARGET: ###°F
MODULATION: ###°F
SYSTEM SUPPLY: ###°F
SYSTEM RETURN: ###°F
BOILER OUT: ###°F
BOILER IN: ###°F
FLAME SIGNAL: ###
BLOWER SIGNAL: ###%
BLOWER TACH: ####RPM
FORCE RATE AUTO

MANUAL RESET PRESS ENTER TO RESET THE FOLLOWING

ERROR (SCREEN SHOWS A LIST OF ERRORS)

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U-Control operation and setup — advanced (continued)

&IGURE U-Control setup options (see Figure 102, page 86 for location in menu sequence)
-ENU)TEM 5NITS ,OW (IGH $EFAULT #OMMENT
6ALUE 6ALUE

"OILER3ETTINGS
Boiler Model 80, 105, 155, factory 4()3-534"%3%4#/22%#4,9&/23!&%/0%2!4)/.. Adjusts blower speeds
230, 299, 310, and flame sense (Display will show “HA” after the model number if high altitude has been
399, 550, 750 selected, below.) NOTE: Ultra-550 and -750 are commercial models.
High Altitude yes or no no Adjusts ignition and low fire fan speed (for altitudes above 5, 500 feet only)
High Limit °F 50 200 200 If boiler out temperature reaches this temperature boiler will lockout which requires a
manual reset
WWSD Temp °F Off, 50 100 70 Boiler will not respond to heating calls above this outdoor temp
Adjust Outdoor °F -10 +10 0 This value plus outdoor sensor reading equals outdoor temp (Use this setting to
(difference) compensate for solar gain or other factors that cause a shift in sensor temperature.)
Add’l Heat Demand Type Types Off Type 4 Off Type 1 — Ultra is primary source, starts secondary after delay (requires system sensors)
Type 2 — Ultra is secondary source, starts primary immediately
Type 3 — Boilers operate in parallel, Ultra boiler is LEAD, outputs 0–10 VDC to others
Type 4 — Boilers operate in parallel, Ultra boiler is SHADOW, receives 0–10 VDC input
Add’l Heat Demand Time minutes 0 240 0 Delay before bringing on additional heating appliances

3YSTEM3ETTINGS
"OILER0RIORITY
System Type Types Off Custom DHW - direct DHW-direct doesn’t use ODR, boost, or Add’l heat demand output
Max Supply °F 60 190 190 Boiler enters manual reset lockout at 200°F
Min Supply °F 60 190 N/A N/A - DHW does not use reset
Max OD Reset °F 50 100 N/A N/A - DHW does not use reset
Min OD Reset °F –20 50 N/A N/A - DHW does not use reset
Modulate On Diff °F 2 10 5 Boiler turns on if temperature drops below target minus differential on
Modulate Off Diff °F 2 10 5 Boiler shuts down if modulates past target plus differential off
Max On Time minutes off 240 30 Longest time boiler will satisfy this system before switching to an active lower priority
Min On Time — — — — Priority 1 does not have this setting
Boost Interval minutes off 240 N/A (not used) When operating on ODR increases target 10F when this time expires until reaching MAX
Prepump Time: ### SEC seconds 0 240 20 Additional time to run circulators longer than standard 10 second time
Postpump Time: ### SEC seconds off 240 30 Circulator run time after call for heat ends
Circulator 1 on-off off on on Circulator activates on this call for heat if on
Circulator 2 on-off off on off Circulator activates on this call for heat if on
Circulator 3 on-off off on off Circulator activates on this call for heat if on
Maximum Rate %Rate 21% 100% 96% Boiler Model and altitude specific (derated to 96% from factory)
NOTE: Adjusting boiler firing rate will affect AFUE rating.
Minimum Rate %Rate 20% 99% 33% (80-299) Boiler Model and altitude specific
20% (399)

"OILER0RIORITY
System Type Types FTB Finned-Tube Baseboard
Max Supply °F 60 190 180 Highest target the control will calculate based on outdoor temperature
Target temperature if outdoor sensor is not detected (manual reset lockout at 200°F)
Min Supply °F 60 190 130 Lowest target the control will calculate based on outdoor air temperature
Max OD Reset °F 50 100 70 Outdoor air temperature that forces the minimum supply water to be target temperature
Min OD Reset °F –20 50 0 Outdoor air temperature that forces the maximum supply water to be target temperature
Modulate On Diff °F 2 10 5 Boiler turns on if temperature drops below target minus differential on
Modulate Off Diff °F 2 10 5 Boiler shuts down if modulates past target plus differential off

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U-Control operation and setup — advanced (continued)

&IGURE U-Control setup options (see Figure 102, page 86 for location in menu sequence), continued

-ENU)TEM 5NITS ,OW (IGH $EFAULT #OMMENT

6ALUE 6ALUE

Max On Time minutes off 240 30 Longest time boiler will satisfy this system before switching to an active lower priority
Min On Time minutes off 240 15 Time boiler will satisfy this system before switching to the next active priority
Boost Interval minutes off 240 off When operating on ODR increase target 10F when this time expires until reaching MAX
Prepump Time: ### SEC seconds 0 240 20 Additional time to run circulators longer than standard 10 second time
Postpump Time: ### SEC seconds off 240 30 Circulator run time after call for heat ends
Circulator 1 on-off off on off Circulator activates on this call for heat if on
Circulator 2 on-off off on on Circulator activates on this call for heat if on
Circulator 3 on-off off on on Circulator activates on this call for heat if on
Maximum Rate %Rate 21% 100% 96% Boiler Model and altitude specific (derated to 96% from factory)
NOTE: Adjusting boiler firing rate will affect AFUE rating.
Minimum Rate %Rate 20% 99% 33% (80-299) Boiler Model and altitude specific
20% (399)
"OILER0RIORITY
System Type Types Custom

!$6!.#%$).34!,,!4)/.
Max Supply °F 60 190 190 Highest target the control will calculate based on outdoor temperature
Target temperature if outdoor sensor is not detected
(manual reset lockout at 200°F)
Min Supply °F 60 190 70 Lowest target the control will calculate based on outdoor air temperature
Max OD Reset °F 50 100 70 Outdoor air temperature that forces the minimum supply water to be target temperature
Min OD Reset °F –20 50 0 Outdoor air temperature that forces the maximum supply water to be target temperature
Modulate On Diff °F 2 10 5 Boiler turns on if temperature drops below target minus differential on
Modulate Off Diff °F 2 10 5 Boiler shuts down if modulates past target plus differential off
Max On Time — — — — Priority 3 does not have this setting
Min On Time minutes off 240 15 Time boiler will satisfy this system before switching to the next active priority
Boost Interval minutes off 240 off When operating on ODR increase target 10F when this time expires until reaching MAX
Prepump Time: ### SEC seconds 0 240 20 Additional time to run circulators longer than standard 10 second time
Postpump Time: ### SEC seconds off 240 30 Circulator run time after call for heat ends
Circulator 1 on-off off on on Circulator activates on this call for heat if on
Circulator 2 on-off off on on Circulator activates on this call for heat if on
Circulator 3 on-off off on on Circulator activates on this call for heat if on
Maximum Rate %Rate 21% 100% 96% Boiler Model and altitude specific (derated to 96% from factory)
NOTE: Adjusting boiler firing rate will affect AFUE rating.
Minimum Rate %Rate 20% 99% 33% (80-299) Boiler Model and altitude specific
20% (399)

#IRCULATOR%XERCISING
Circulator 1 on-off off on on Circulators exercise 10 seconds every 72 hours of inactivity if on
Circulator 2 on-off off on on Circulators exercise 10 seconds every 72 hours of inactivity if on
Circulator 3 on-off off on on Circulators exercise 10 seconds every 72 hours of inactivity if on

&REEZE0ROTECT#IRCS
Circulator 1 on-off off on off If HxOut sensor out falls below 40F boiler fires low and turns on this circ until 45F
Circulator 2 on-off off on on If HxOut sensor out falls below 40F boiler fires low and turns on this circ until 45F
Circulator 3 on-off off on off If HxOut sensor out falls below 40F boiler fires low and turns on this circ until 45F

Part number 550-100-090/1113 89

 GAS-FIRED WATER BOILER — Boiler Manual

U-Control operation and setup — advanced (continued)

&IGURE U-Control diagnostic information (see Figure 102, page 86 for location in menu sequence

-ENU)TEM 5NITS ,OW (IGH $EFAULT #OMMENT

6ALUE 6ALUE

$IAGNOSTICS
4EMPERATURES
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 data Temperature of the remote system supply sensor
System Return °F data Temperature of the remote system return sensor
Boiler Out1 °F data Temperature of the first sensing element of the boiler’s heat exchanger outlet sensor
Boiler Out2 °F data Temperature of the second sensing element of the boiler’s heat exchanger outlet sensor
Boiler In1 °F data Temperature of the boiler’s heat exchanger inlet sensor
Flue1 °F data Temperature of the first sensing element of the boiler’s flue gas sensor
Flue2 °F data Temperature of the second sensing element of the boiler’s flue gas sensor
Outdoor °F data Temperature of the remote outdoor air temperature sensor
)NPUTS
Status Text data Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being
satisfied, post purge, Warm Weather Shutdown, Trouble
Priority 1 on-off data Call for heat status on Priority 1 Input
Priority 2 on-off data Call for heat status on Priority 2 Input
Priority 3 on-off data Call for heat status on Priority 3 Input
Analog Input vdc data Value of 0–10 VDC input signal on P15 #5 and #6
Manual Limit open-closed data External manual limit P13-1 & P13-2
Auto Limit open-closed data External auto limit P13-3 & P13-4
Low Wtr Cutoff open-closed data Low water cutoff device on P12-3 & P12-4
Blower Tach rpm data Feedback from blower sensor
Flame Signal no units data Number indicating the presence and quality of the flame used to shutdown boiler
/UTPUTS
Gas Valve on-off data Control’s gas valve circuit status
Circulator 1 on-off data Control’s circulator 1 relay status
Circulator 2 on-off data Control’s circulator 2 relay status
Circulator 3 on-off data Control’s circulator 3 relay status
Blower Signal % of rate data Control’s signal controlling the blower speed
Add’l Heat Demand on-off data Control’s signal controlling the additional heat demand
Alarm on-off data Control’s alarm contact status
Analog Output vdc data Value of 0–10 VDC output signal on P16 #1 and #2
%RRORS
Control Fault # 0 Displays number of control faults
Ignition Retries # 0 Displays number of ignition attempts boiler is currently on
Manual Reset Cnt # 0 Displays number of manual reset lockouts since last cleared
Auto Reset Cnt # 0 Displays number of auto reset lockouts since last cleared
Lockout History 1 Choose this to view the most recent error recorded
Time & Date text data Displays time and date that lockout occurred
Status text data Displays what the status of the boiler at the time of the error
Manual Reset yes or none data Choose this to view the details of manual reset lockouts
Auto Reset yes or none data Choose this to view the details of auto reset lockouts
Inputs menu menu Choose this to view the status of the Boiler Inputs at the time of the error
Outputs menu menu Choose this to view the status of the Boiler Outputs at the time of the error
Temperatures menu menu Choose this to view the Boiler Temperatures at the time of the error
Lockout History 2 Choose this to view the second most recent error recorded
Time & Date text data Displays time and date that lockout occurred
Status text data Displays what the status of the boiler at the time of the error

90 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

U-Control operation and setup — advanced (continued)

&IGURE U-Control diagnostic information (see Figure 102, page 86 for location in menu sequence), continued

-ENU)TEM 5NITS ,OW (IGH $EFAULT #OMMENT

6ALUE 6ALUE

Manual Reset yes or none data Choose this to view the details of manual reset lockouts
Auto Reset yes or none data Choose this to view the details of auto reset lockouts
Inputs menu menu Choose this to view the status of the Boiler Inputs at the time of the error
Outputs menu menu Choose this to view the status of the Boiler Outputs at the time of the error
Temperatures menu menu Choose this to view the Boiler Temperatures at the time of the error
Lockout History 3 Choose this to view the third most recent error recorded
Time & Date text data Displays time and date that lockout occurred
Status text data Displays what the status of the boiler at the time of the error
Manual Reset yes or none data Choose this to view the details of manual reset lockouts
Auto Reset yes or none data Choose this to view the details of auto reset lockouts
Inputs menu menu Choose this to view the status of the Boiler Inputs at the time of the error
Outputs menu menu Choose this to view the status of the Boiler Outputs at the time of the error
Temperatures menu menu Choose this to view the Boiler Temperatures at the time of the error
3OFTWARE6ERSIONS
Display #.## format data Software version of the microprocessor on the display circuit board

!$6!.#%$).34!,,!4)/.
Main Micro #.## format data Software version of the main microprocessor on the control circuit board
Second Micro #.## format data Software version of the second microprocessor on the control circuit board
-ANUAL4EST-ODE
Status text data Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being
satisfied, post purge, Warm Weather Shutdown, Trouble
Target °F data Calculated target temperature based on outdoor temp or the max setpoint if no ODR
Modulation °F data Temperature of the sensor the boiler is using to base its modulation
System Supply °F data Temperature of the remote mounted system water supply sensor
System Return °F data Temperature of the remote mounted system water return sensor
Boiler Out °F data Temperature of the outlet sensor on the boiler heat exchanger
Boiler In °F data Temperature of the inlet sensor on the boiler heat exchanger
Flame Signal no units data Number indicating the presence and quality of the flame used to shutdown boiler
Blower Signal % of rate data Control’s output to the blower
Blower Tach rpm data Blower’s feedback to the control
Force Rate Low, Med, High, or Auto Auto Used to manually force a rate during a call for heat. Choose auto for normal operation.
-ANUAL2ESET Reset selected condition
-AINTENANCE)NFO
Name text blank Contractor name to appear in maintenance reminders and during lockouts
Phone text blank Contractor phone number
Model text blank Displays the boiler model selected in the boiler setup
CP Number text blank Enter the CP# of the boiler
Installed text blank Enter the date the boiler was installed
Last Date text data Date automatically entered when Reset Reminder is choose by contractor
Next Date text data Date automatically calculated when Reset Reminder is selected by contractor
Interval Settings months 6 24 12 Contractor selects maintenance reminder frequency based on service history
Reset Reminder menu menu Contractor selects this to update Last maintenance Date and Next Date. Homeowner uses
this to ignore the reminder and update only the Next Date.

3ET4IMEAND$ATE
Year text 2009 Set year (homeowner or contractor)
Month text 1 Set month (homeowner or contractor)
Day text 1 Set day (homeowner or contractor)
Hour text 12 Set hour (homeowner or contractor)
Minute text 0 Set minute (homeowner or contractor)

Part number 550-100-090/1113 91

 GAS-FIRED WATER BOILER — Boiler Manual

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.

&IGURE Service and maintenance schedules

Service technician Owner maintenance

(see following pages for instructions) (see Ultra User’s Information Manual for instructions)

General:
s 2EPORTEDPROBLEMS s #HECKBOILERAREA
s #HECKAIROPENINGS
s )NSPECTINTERIORCLEANANDVACUUMIF
NECESSARY7!2.).'ˆNOSOLVENTS $AILY s #HECKPRESSURETEMPERATUREGAUGE
s #LEANCONDENSATETRAPANDlLLWITHFRESHWATER s 6ERIFYBOILERFRONTDOORISSECURELYIN
PLACE
s #HECKFORLEAKSWATERGASmUECONDENSATE 
!..5!,34!24 503EE&IRST YEARSPECIALINSPECTION

s #HECKSYSTEMWATERCHEMISTRYINHIBITORLEVEL
ANDANTIFREEZECONCENTRATIONIFUSED
s 6ERIFYmUEANDAIRLINESINGOODCONDITIONAND s #HECKVENTPIPING
SEALEDTIGHT s #HECKAIRPIPING
s #HECKSYSTEMWATERPRESSURESYSTEMPIPING -ONTHLY s #HECKRELIEFVALVE
EXPANSIONTANK
s #HECKCONDENSATEDRAINSYSTEM
s #HECKCONTROLSETTINGS s #HECKAUTOMATICAIRVENTSIFUSED 
s )GNITIONELECTRODECLEANWITHSTEELWOOLAND
REPOSITION ˆREPLACEIFWORN
s )GNITIONANDGROUNDWIRING
s 7IRINGANDCONNECTIONS
s 0ERFORMSTART UPCHECKOUTANDPERFORMANCE 0ERIODICALLY s 4ESTLOWWATERCUTOFFIFUSED 
VERIlCATIONBEGINNINGWITH3TARTUPˆlLLTHE
SYSTEMPAGE
s &LAMEINSPECTIONSTABLEUNIFORM 
s &LAMESIGNALSEE&IGUREPAGE 
s #LEANHEATEXCHANGERIFmUETEMPISMORETHAN
ª&ABOVERETURNWATERTEMP
s )NSPECTJACKETFRONTDOORGASKETSREPLACEIF
NECESSARY %VERY s #HECKBOILERPIPINGGASANDWATER
MONTHS s /PERATERELIEFVALVE

Additional if combustion or
performance indicate need:
s #LEANHEATEXCHANGER
s 2EMOVEANDCLEANBURNERUSINGCOMPRESSED
AIRONLY
s 6ACUUMTHEBLOWER %ND s 3HUTBOILERDOWNUNLESSBOILERUSED
OFSEASON FORDOMESTICWATER 
Review:
s 2EVIEWWITHOWNER

92 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Annual startup

HANDLING CERAMIC FIBER FIRST-YEAR SPECIAL INSPECTION

MATERIALS
)TISRECOMMENDEDTHATYOUOBTAINA7EIL -C,AIN
REMOVING BURNER GASKET or 5LTRA "OILER -AINTENANCE KIT BEFORE ATTEMPTING
COVER PLATE INSULATION THElRST YEARINSPECTIONTOENSUREALLPARTSTHAT
MAYBENEEDEDAREAVAILABLE. This kit includes a heat
The Ultra burner gasket (models 80 exchanger cover plate gasket, burner gasket (80 and 105
and 105) and cover plate insula- only), new ignitor, and ignitor gasket. See listing in Re-
placement parts section of this manual. These parts must
tion (all models) contain ceramic
be on hand when you perform the first-year inspection
fiber material. Ceramic fibers can in the event they must be replaced.
be converted to cristobalite in very
high temperature applications. The
International Agency for Research Failure to replace the items above when needed could
result in severe personal injury, death or substantial
on Cancer (IARC) has concluded,
property damage.
“Crystalline silica inhaled in the
form of quartz or cristobalite from
1. .OLATERTHANMONTHS after the boiler is installed, perform a
occupational sources is carcinogenic
first-year inspection of the boiler. This must include the following
to humans (Group 1).”: INADDITIONTOROUTINEANNUALSTART UPPROCEDURES.
■ Avoid breathing dust and contact with skin and
eyes. a. Remove the heat exchanger cover plate (see page 96 for instruc-
tions on removal and replacement).
s Use NIOSH certified dust respirator (N95).
This type of respirator is based on the b. Inspect the heat exchanger and clean if necessary (see “Cleaning
OSHA requirements for cristobalite at the the heat exchanger — pin side when required,” page 109, and
all referenced illustrations and instructions).
time this document was written. Other
types of respirators may be needed depend- c. Inspect the cover plate insulation and gasket. Replace if not
ing on the job site conditions. Current in good condition.
NIOSH recommendations can be found on
the NIOSH web site at http://www.cdc.gov/ d. Remove the burner and inspect carefully. Clean the burner
niosh/homepage.html. NIOSH approved thoroughly using a vacuum cleaner and a soft brush if needed.
Make sure there is no blockage or accumulation of debris in
respirators, manufacturers, and phone the burner or the burner ports. Replace the burner if necessary.
numbers are also listed on this web site.
e. Models 80 and 105 only — inspect the burner gasket, and
s Wear long-sleeved, loose fitting clothing, replace if the gasket is not in good condition. Make sure the
gloves, and eye protection. burner is clean. Then securely fasten it tightly to the cover plate.
■ Apply enough water to the combustion
f. Disconnect condensate trap and drain lines. Inspect, then
chamber lining or base insulation to prevent flush thoroughly.
airborne dust.
■ Remove combustion chamber lining or base 2. Determine follow-up maintenance and service needs based on the
insulation from the boiler and place it in a condition of the heat exchanger and condensate lines. -!).4%.!.#%30%#)&)#!4)/.3
plastic bag for disposal.
a. If the heat exchanger shows substantial fouling, or if condensate
■ Wash potentially contaminated clothes lines show accumulation of sediment, schedule a follow-up
service call to perform the first-year inspection again, sooner
separately from other clothing. Rinse clothes than the normal twelve months between.
washer thoroughly.
b. Heavy fouling of the exchanger or condensate lines indicates
possible combustion air contamination. Inspect the air intake
area carefully, and remove possible contaminants. See page 16,
NIOSH stated First Aid for products to avoid.
■ Eye: Irrigate immediately
You must eliminate causes of corrosion and contamina-
■ Breathing: Fresh air. tion to ensure reliable operation of the boiler and system.

Part number 550-100-090/1113 93

 GAS-FIRED WATER BOILER — Boiler Manual

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 line.
the heating season, only by a qualified
service technician. In addition, the 2. Empty water from trap line and inspect. Flush out if needed
maintenance and care of the boiler with fresh water.
designated in Figure 105, page 92 and 3. Check condensate elbow and tee and condensate line to drain.
explained on the following pages must Flush if necessary to clean.
be performed to assure maximum
4. Reinstall condensate trap line and tighten hose clamps.
boiler efficiency and reliability. Fail-
ure to service and maintain the boiler 5. Fill trap with fresh water by pouring into upturned end of
and system could result in equipment PVC condensate tee.
failure.
Check all piping for leaks
Electrical shock hazard — Turn off
power to the boiler before any service Eliminate all system or boiler leaks. Continual fresh
operation on the boiler except as noted make-up water will reduce boiler life. Minerals
otherwise in this instruction manual. can build up in sections, reducing heat transfer,
Failure to turn off electrical power overheating heat exchanger, and causing heat
could result in electrical shock, causing exchanger failure. Leaking water may also cause
severe personal injury or death. severe property damage.
1. Inspect all water and gas piping and verify to be leak free.
2. Look for signs of leaking lines and correct any problems
found.
Address reported problems 3. Check gas line using procedure on page 25.

1. Inspect any problems reported by owner and correct before

proceeding.
Check air openings
1. Verify that combustion and ventilation air openings to the
boiler room and/or building are open and unobstructed.
Inspect boiler area Check operation and wiring of automatic combustion air
dampers, if used.
1. Verify that boiler area is free of any combustible materials,
gasoline and other flammable vapors and liquids. 2. Verify that boiler vent discharge and air intake are clean and
free of obstructions.
2. Verify that air intake area is free of any of the contaminants
listed on page 16 of this manual. If any of these are present
in the boiler intake air vicinity, they must be removed. If Flue vent system and air piping
they cannot be removed, reinstall the air and vent lines per
1. Visually inspect entire flue gas venting system and combus-
this manual.
tion air piping for blockage, deterioration or leakage. Repair
any joints that show signs of leakage in accordance with vent
Inspect boiler interior & door gaskets manufacturer’s instructions. When air is ducted to boiler,
verify that air inlet hose is connected and properly sealed.
1. Remove jacket front door and inspect interior of boiler. Failure to inspect for the above conditions and have
2. Visually inspect the door gaskets. Make sure all are in good them repaired can result in severe personal injury
condition. Obtain replacements if any gasket is damaged. or death.

Door gaskets must be intact, and must provide a

reliable seal. Replace any damaged gasket. Check water system
3. Remove the venturi air inlet silencer and clean if necessary. 1. Verify all system components are correctly installed and
Replace silencer. operational.
2. Check the cold fill pressure for the system. Verify it is correct
4. Vacuum any sediment from the inside of the boiler and
(usually around 12 psig).
components. Remove any obstructions.
3. Watch the system pressure as the boiler heats up (during
Do not use solvents to clean any of the boiler testing) to ensure pressure doesn’t rise too high. Excessive
components. The components could be damaged, pressure rise indicates expansion tank sizing or performance
resulting in unreliable or unsafe operation. problem.

94 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Annual startup (continued)

4. Inspect automatic air vents and air separators. Remove air vent caps Inspect ignition electrode
and briefly press push valve to flush vent. Reinstall caps. Make sure
vents do not leak. Replace any leaking vents. 1. Remove the ignition electrode from the boiler heat
exchanger access cover.
5. Check system water chemistry (pH, hardness and inhibitor level). See
page 31. 2. Remove any white oxides accumulated on the
ignition electrode using steel wool. If the ignition
electrode cannot be cleaned satisfactorily, replace
ignitor with a new one.
Check expansion tank
3. Reinstall ignition electrode, making sure gasket is
in good condition and correctly positioned.
1. Expansion tanks provide space for water to move in and out as the
heating system water expands due to temperature increase or contracts 4. Make sure the electrodes are parallel to each
as the water cools. Tanks may be open, closed or diaphragm or bladder other.
type. See page 11 of this manual for suggested location of expansion
tanks and air eliminators.
Check ignition wiring
s Open-type — located above highest radiator or baseboard unit,
usually in the attic or closet. Has a gauge glass and overflow pipe 1. Check ignition cable electrical resistance. A good
to a drain. cable will have resistance between 900 and 1000
ohms. Replace if not acceptable.
s Closed-type — welded gas tight and located above boiler. Tank is
partially filled with water, leaving an air cushion for expansion. 2. Inspect boiler ground wire from heat exchanger
access cover to ground terminal strip.
s Make sure this type of tank is fitted with a tank fitting, such
as the B & G Tank-Trol or Taco Taco-Trol. This fitting reduces 3. Verify all wiring is in good condition and securely
gravity circulation of air-saturated tank water back to the system attached.
and prevents the air from bubbling up through the water as it
returns from the system. 4. Check ground continuity of wiring using continu-
ity meter.
s Do not use automatic air vents in systems with closed-type
tanks. The air will escape from the system instead of returning to 5. Replace ground wires if results are not satisfac-
the tank. Eventually, the tank will waterlog and no longer control tory.
pressurization. The boiler relief valve will weep frequently.

s Diaphragm- or bladder-type — welded gas tight with a rubber Check all boiler wiring
membrane to separate the tank pressurizing air and the water. May
be located at any point in the system, but most often found near 1. Inspect all boiler wiring, making sure wires are in
the boiler. good condition and securely attached.

s Systems with this type of expansion tank require at least one

automatic air vent, preferably located on top of an air elimina- Check control settings
tor, as shown in examples in this manual.
1. Use the U-Control display to navigate through all
2. If relief valve has tended to weep frequently, the expansion tank may settings. Adjust settings if necessary.
be waterlogged or undersized.
2. Check settings of external limit controls (if any) -!).4%.!.#%30%#)&)#!4)/.3
s Closed-type tank — tank is most likely waterlogged. Install a and adjust if necessary.
tank fitting if not already installed. Then check fill level per fitting
manufacturer’s instructions. If fill level is correct, check tank size
against manufacturer’s instructions. Replace with a larger tank if Perform startup and checks
necessary.
1. Start boiler and perform checks and tests specified
s Diaphragm- or bladder-type — first, check tank size to be sure it in this manual.
is large enough for the system. If size is too small, add additional
tank (or tanks) as necessary to provide sufficient expansion. If tank 2. Verify cold fill pressure is correct and that operating
size is large enough, remove tank from system and check charge pressure does not go too high.
pressure (usually 12 psig for residential applications). If tank won’t
hold pressure, membrane has been damaged. Replace tank. 3. Complete the check-out procedure on page 38.

Part number 550-100-090/1113 95

 GAS-FIRED WATER BOILER — Boiler Manual

Annual startup (continued)

Check burner flame Check flame signal
The boiler contains ceramic fiber materials. 1. Navigate to Diagnostics/Inputs on the U-Control display (see
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. Fail- above the Shutdown values given in Figure 106.
ure to comply could result in severe personal
injury.
&IGURE Flame signal shutdown values
1. Inspect flame through observation window using the
-ODEL 3HUTDOWN -ODEL 3HUTDOWN
procedure on page 36. 5LTRAn mAMESIGNAL 5LTRAn mAMESIGNAL
2. If flame is unsatisfactory at either high fire or low fire,    
turn off boiler and allow boiler to cool down. Then (!  (! 
remove burner and clean it thoroughly using a vacuum
   
cleaner or compressed air. Do not use compressed air to
clean burner if performed inside a building. (!  (! 
   
3. To access the burner, remove the heat exchanger cover
(!  (! 
plate following the procedure beginning on page 109.
NOTE: “HA” means high altitude, 5500 feet or more above seal level.
4. When replacing burner, ensure gasket is in good condi-
tion and correctly positioned. After tightening the three 2. If the flame signal drops to less than 20 above the Shutdown
retainer screws, bend up the retainer tabs as shown in values, the U-Control will attempt to correct by increasing the
Figure 107 to prevent screw rotation. boiler firing rate to increase flame signal.
5. Reattach the cover plate using the method given in 3. A lower flame signal may indicate a fouled ignitor or damaged ig-
Figure 113, page 110 or Figure 115, page 111. nitor insulation. If cleaning the ignitor does not improve, ground
wiring is in good condition, and ground continuity is satisfactory,
6. After servicing, reinstall boiler components. Retest
boiler. replace the ignitor.

&IGURE Burner assembly

96 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Annual startup (continued)

4. If flame signal still remains low, inspect the vent and air 6. Set the firing rate to MEDIUM (ignition rate).
piping. Then inspect the heat exchanger, following the pro- 7. 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.
of the head exchanger cover plate and other boiler compo-
nents. Clean the exchanger as described in this manual if 8. Set the firing rate to MAXIMUM (high fire).
necessary. 9. Write down the blower RPM value. It should be within 200
RPM of the value given in Figure 108.
10. If any of the values are outside the ranges listed in the previous
Check blower speeds steps, contact the factory for technical assistance.
1. For installations at altitudes above 5,500 feet, make sure the
control is set up for high altitude in the boiler setup menu.
The U-Control module automatically adjusts low fire and Check flue gas temperature
ignition rates to compensate for high altitude conditions. 1. Set the boiler to high fire. Then adjust the U-Control mod-
2. For installations below 5,500 feet, high altitude should NOT ule display to view flue gas temperature and boiler return
be enabled. temperature.
3. Use the U-Control display to navigate to Manual test mode 2. The flue gas temperature should be no more than 54 °F higher
(see Figure 102, page 86). than the boiler return temperature.
4. Set the firing rate to MINIMUM (low fire). 3. If the flue temperature is higher than this, shut down the
5. Write down the blower RPM value shown and compare to boiler, allow to cool, and follow the procedure starting on
the value in Figure 108. The value should no less than the page 109 to clean the heat exchanger.
“Minimum setting” and no higher than the Ignition “Fac-
tory setting” listed. Low fire rate (and corresponding blower
speed) is adjusted in the boiler setup menu.

&IGURE Firing rates and corresponding blower speeds (low fire, ignition, and high fire) — for altitudes up to 5,500 feet

5,42!-ODEL      

% RPM Btu/Hr % RPM Btu/Hr % RPM Btu/Hr % RPM Btu/Hr % RPM Btu/Hr % RPM Btu/Hr

Low fire

Minimum setting 20 1,300 16,000 20 1,300 21,000 20 1,300 31,000 20 1,300 46,000 20 1,400 62,000 20 1,520 79,800

Factory setting 33 1,983 26,400 33 1,983 34,650 33 1,983 51,150 33 1,983 75,900 33 2,156 102,300 20 1,520 79,800

High altitude 33 1,983 26,400 33 1,983 34,650 33 1,983 51,150 33 1,983 75,900 30 1,981 93,000 28 2,002 111,720
-!).4%.!.#%30%#)&)#!4)/.3
Ignition (“Medium” setting in manual test mode)

Factory setting 47 2,300 37,600 47 2,300 49,350 47 2,300 72,850 47 2,300 108,100 36 2,330 111,600 33 2,303 131,670

High altitude 62 3,500 49,600 62 3,500 65,100 62 3,500 96,100 62 3,500 142,600 51 3,202 158,100 40 2,725 159,600

High fire (adjust if desired to match maximum system load — High fire % rate = Max heat load / Boiler output)

Factory setting 94 5,200 75,200 94 5,200 98,700 94 5,200 145,700 94 5,200 216,200 96 5,818 297,600 96 6,099 383,040

Maximum setting 100 5,500 80,000 100 5,500 105,000 100 5,500 155,000 100 5,500 230,000 100 6,050 299,000 100 6,340 399,000

Part number 550-100-090/1113 97

 GAS-FIRED WATER BOILER — Boiler Manual

Annual startup (continued)

Check boiler relief valve

1. 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. Read page 9 before proceeding further.

Safety relief valves should be reinspected AT LEAST

ONCE EVERY THREE YEARS, by a licensed plumb-
ing contractor or authorized inspection agency, to
ensure that the product has not been affected by cor-
rosive water conditions and to ensure that the valve
and discharge line have not been altered or tampered
with illegally. Certain naturally occurring conditions Review with owner
may corrode the valve or its components over time,
rendering the valve inoperative. Such conditions are 1. Review the User’s Information Manual with the
owner.
not detectable unless the valve and its components
are physically removed and inspected. This inspec-
2. Emphasize the need to perform the maintenance
tion must only be conducted by a plumbing con- schedule specified in the User’s Information
tractor or authorized inspection agency — not by Manual (and in this manual as well).
the owner. Failure to reinspect the boiler relief valve
as directed could result in unsafe pressure buildup, 3. Remind the owner of the need to call a licensed
contractor should the boiler or system exhibit
which can result in severe personal injury, death or any unusual behavior.
substantial property damage.
4. Remind the owner to follow the proper shutdown
Following installation, the valve lever must be procedure and to schedule an annual startup at
operated AT LEAST ONCE A YEAR to ensure that the beginning of the next heating season.
waterways are clear. Certain naturally occurring
mineral deposits may adhere to the valve, rendering
it inoperative. When manually operating the lever,
water will discharge and precautions must be taken
to avoid contact with hot water and to avoid water
damage. Before operating lever, check to see that a
discharge line is connected to this valve directing
the flow of hot water from the valve to a proper
place of disposal. Otherwise severe personal injury
may result. If no water flows, valve is inoperative.
Shut down boiler until a new relief valve has been
installed.

2. After following the above warning directions, if the relief

valve weeps or will not seat properly, replace the relief valve.
Ensure that the reason for relief valve weeping is the valve and
not over-pressurization of the system due to expansion tank
waterlogging or under-sizing.

98 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Troubleshooting

VERIFY PROPER OPERATION AFTER SERVICING.

Reinstall boiler jacket front door

Before servicing and making connections . . .
!,7!93452.0/7%2/&&4/4(%"/),%24/ Reinstall boiler jacket front door after
02%6%.4%,%#42)#!,352'%37()#(#!. servicing. The boiler front door must be
securely fastened to the boiler to prevent
$!-!'%"/),%2#/-0/.%.43
boiler from drawing air from inside the
boiler room. This is particularly impor-
%,%#42)#!,3(/#+(!:!2$ — The boiler ON/ tant if the boiler is located in the same
OFF switch does not turn off all power to the boiler. room as other appliances. Failure to keep
452./&&!,,0/7%24/4(%"/),%27(%. the door securely fastened could result in
3%26)#).'. Internal wiring is still powered when severe personal injury or death.
the switch is off.
Before troubleshooting:
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dan- 1. See Figure 109 for tools and kits recommended for
gerous operation. Always disconnect power to boiler troubleshooting Ultra boilers.
before servicing. Failure to comply could result in 2. Check for 120 VAC (minimum 102 VAC to maxi-
severe personal injury, death or substantial property mum 132 VAC) to boiler.
damage. 3. Check the U-Control’s last three lockout histo-
ries.
Never jumper (bypass) any device except for momen- a. See page 83, “ADVANCED SETUP – OVER-
tary testing. Severe personal injury, death or substan- VIEW.”
tial property damage can result. b. Scroll down to DIAGNOSTICS and press the
enter key.
Before calling, always complete the “5LTRA'AS$ATA c. Scroll down to ERRORS and press the enter
key.
#OLLECTION3HEET” (page 108). Record the boiler size
d. Record the first four data records and then high-
and CP number (located on the lower center support light the history record you want to view.
frame in the center of the boiler). e. Follow information at the bottom of the screen
to navigate through your lockout histories.

&IGURE Tools and kits for troubleshooting

4OOLSNEEDEDFORTROUBLESHOOTING 0URPOSE
#2 Phillips Screwdriver Remove 4 screws to remove the top front cover
U-Control Screwdriver or 1/16" flat blade screwdriver Used for wiring on terminal blocks for the U-Control (comes with boiler)
1/8" Allen Wrench (Hex Key) To add orifice to change from natural to propane -!).4%.!.#%30%#)&)#!4)/.3
7mm Nut driver (Ultra 155/230/299/399) To change the burner (#2 Phillips Screwdriver for the 80 and 105)
11mm Nut driver To remover the front cover plate on the burner
4mm Allen wrench (long handled preferred) To remove the blower assembly from the heat exchanger
Multimeter To take measurement readings on sensors and electrical components
Manometer (Incline or digital) To measure the gas pressure coming to the boiler.
Combustion analyzer (Digital preferred) For combustion testing.
Contact thermometer For checking surface temperatures of heat exchanger and pipes
383-500-605 Maintenance Kit (80 and 105) This kit should be on hand when performing annual maintenance in the
event replacement is required.
383-500-620 Maintenance Kit (155/230/299/399) This kit should be on hand when performing annual maintenance in the
event replacement is required.

Part number 550-100-090/1113 99

 GAS-FIRED WATER BOILER — Boiler Manual

Troubleshooting (continued)
Check the following: Do not jumper fuse or replace with any
fuse except as specified. 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.
closed. Check for 24 VAC between thermostat wire
nuts and ground. 5. Reinstall jacket top panel and boiler jacket door
after checking the fuses.
2. Make sure all external limit controls are either
installed (and closed) or temporarily jumpered 6. Restore power to boiler at external line switch and
for testing. verify boiler operation after completing boiler
service.
3. Make sure that connectors to control module are
securely plugged in at module and originating
control. Checking temperature sensors
4. Gas pressures: 1. The boiler temperature sensors (flue, outdoor,
s Maximum: 13” w.c. with no flow (lockup) or return water and supply water) are all resistance-
with boiler on type devices.
s Minimum: 4” w.c. (for all except 5” for -299)
for natural gas, or 4” w.c. for propane, with gas 2. Figure 110 shows the correct value for the sensor
flowing (verify during startup with boiler at at various temperatures.
high fire) 3. Use the resistance values at 32°F, 60°F, 70°F and
212°F to measure the sensor resistance at known
temperatures (ice point, room temperature and sea
Always check control module fuses level boiling point). For ice point and boiling point,
ALWAYS check control module fuses insert the sensor in water at that temperature. Use
before replacing control module or any an ohmmeter to read resistance value.
major components (blower, etc.). If one 4. To check whether the control module is correctly
of these fuses is blown, it can prevent sensing temperature, you can use a resistance de-
control module or other components cade box. Connect the decade box temporarily in
from operating. place of a sensor and read the corresponding tem-
perature on the U-Control display. The temperature
1. Turn OFF power to boiler at external line switch. should be close to the value corresponding to the
2. Remove jacket door and jacket top panel. Rotate input resistance.
the swing-away control panel forward to expose
the U-Control module. &IGURE Sensor resistance values
3. Remove and inspect the two fuses (located as shown
below). Sensor resistance values

Temp Sensor ohms Temp Sensor ohms

(°F) Min Max (°F) Min Max

 34265 37871  4517 4992

 27834 30764  3698 4088

 21630 23907  3043 3364

 16944 18727  2517 2782

 13372 14780  2091 2311

 10629 11747  1744 1928

 8504 9399  1461 1615

 6847 7568  1229 1359

4. If necessary, replace the fuse:
a. Low voltage circuit fuse is 3-amp fast-blow  5545 6129  1038 1147
(Littelfuse 257003).
b. Line voltage circuit fuse is 12-amp slow-blow
(Littelfuse 326012P).

100 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

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.
conditions. See Figure 104, page 90 for information 3. Figure 112, page 102 lists conditions that will cause the control to dis-
available on the U-Control display. play a constant red screen. The boiler will automatically restart if the
2. Figure 111 shows the screen behavior during an condition self-corrects or the technician uses the U-Control’s manual
automatic or manual reset condition. The table reset screens to reset.

&IGURE U-Control display toggles when in lockout, with screen flashing red to gray

-!).4%.!.#%30%#)&)#!4)/.3

Part number 550-100-090/1113 101

 GAS-FIRED WATER BOILER — Boiler Manual

Troubleshooting (continued)

&IGURE 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” by selecting “ERRORS.” The control will display
the following information:

*OGPSNBUJPO Description Action

$POUSPM
'BVMU Records the number of internal control faults Select and press the enter key to reset this count

*HOJUJPO
3FUSJFT Displays the number of ignition attempts in the current

ignition sequence.

.BOVBM
3FTFU
$PVOU Records number of lockouts that required a manual reset Select and press the enter key to reset this count
since this count was last cleared.

"VUP
3FTFU
$PVOU Records number of lockouts that have automatically reset Select and press the enter key to reset this count
since this count was last cleared.

-PDLPVU
)JTUPSZ
 Details of present or last recorded lockout Select and press the enter key for more details

-PDLPVU
)JTUPSZ
 Details of boiler during the second oldest lockout still in Select and press the enter key for more details
memory

-PDLPVU
)JTUPSZ
 Details of boiler during the oldest lockout still in memory Select and press the enter key for more details

)PX
UP
SFBE
UIF
MBTU

MPDLPVU
IJTUPSJFT: 1. Scroll down to “DIAGNOSTICS” and press the the fault condition that was recorded.
enter key (Square Key in center)

Press the left arrow key to return to the LOCKOUT
2. Scroll down to “ERRORS” and press the enter key HISTORY # screen. Scroll up or down to highlight
(Square Key in center) other choices and press the enter key to view the
details of the boiler’s condition when the lockout
3. Scroll down to “LOCKOUT HISTORY #” and press was recorded.
the enter key.

TO CLEAR ALL LOCKOUT HISTORIES: While on the
4. Scroll to choose the either “MANUAL RESET” or “ERRORS” screen, hold the Left and Right arrow
“AUTO RESET” and press the enter key to display CVUUPOT
TJNVMUBOFPVTMZ
GPS

TFDPOET

U-Control Fault Displays, Diagnostics and Suggested Corrective Actions

Display Condition Diagnostics Corrective Action(s)

Nothing shown Control is not receiving 24V Check wiring for short circuit or Correct wiring per wiring diagram including connection of transformer
on display power incorrect wiring. UP
UIF
6$POUSPM
screen and
blower running $IFDL
BNQ
MPX
WPMUBHF
GVTF
Replace fuse with proper part found in replacement part section of this
at full speed PO
6$POUSPM
TIPXO
PO
QBHF
manual. If fuse blows again recheck wiring per diagram.
100.

Check transformer connection Replace transformer if it is receiving 120Vac, but not outputting 24Vac.
UP
UIF
6DPOUSPM
QFS
XJSJOH

diagram. Check for 24V output
of transformer.

102 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Troubleshooting (continued)

Figure 112 Troubleshooting suggestions for Ultra boilers (continued)

Display Condition Diagnostics Corrective Action(s)

Nothing Control is not receiving 120V Check service switch and/or Turn on service switch to power boiler.
is shown power. circuit breaker to boiler turned
in display is on.
screen and no
other boiler Is there 120 Volts at the service Troubleshoot and correct the power supply to the service switch.
components are switch?
operating
Is the Ultra's ON/OFF POWER Turn the Ultra's power switch behind the control pod to ON.
SWITCH located behind the
control pod turned on?

Check for 120 volts at the line Correct wiring inside the control pod using the wiring diagram in this
voltage terminal block located manual.
inside the control pod.

*OTQFDU
BNQ
GVTF
BT
TIPXO
Replace the fuse with proper part found in the replacement part section
on page 100. Replace if of this manual. If fuse blows again recheck wiring per diagram.
necessary.

Nothing is Occurs when the Check for loose connections Check for continuity on the wire harness from the display to the
shown on communication is lost from and proper pin alignment/ 6DPOUSPM

4FF
SFQBJS
QBSUT
TFDUJPO
GPS
QSPQFS
SFQMBDFNFOU
QBSU
display screen, UIF
6DPOUSPM
UP
UIF
EJTQMBZ FOHBHFNFOU
PO
UIF
6$POUSPMhT

but boiler is QMVH
1
BOE
UIF
CBDL
PG
UIF

operating display circuit board.

Cycle power off and on using Replace with new display module. See repair parts section for proper
boiler power switch and check replacement part.
for operation.

5&.1
3*4&
500
Occurs when supply Automatically resets after 1 Verify water pipe is installed correctly using primary/secondary
QUICKLY water temperature in heat minute delay or using manual connection to the boiler loop. Refer to Figure 4 page 11 for example of
exchanger rises faster than reset on display. primary/secondary connection.
2ºF per second during the
first two minutes the burner Minimum pipe sizes
.BOVBM
SFTFU
JT
OFDFTTBSZ
BGUFS


is on. 6MUSB


NJOJNVN
 inch
automatic resets have occurred
during the same Priority heat 6MUSB


NJOJNVN
 inch
demand. Reset using manual 6MUSB


NJOJNVN
 inch
reset screen on display.
Verify proper circulator sizing for boiler size and system requirements
TUBSUJOH
PO
QBHF

Boiler ship with proper size circulators:
6MUSB


5BDP


6MUSB


5BDP

6MUSB


5BDP
0013
See message displayed TEMPERATURE SENSOR and follow procedure for
loose connections.

4611-:
'

Boiler Out temperature Automatically resets after 30 Verify water pipe is installed correctly using primary/secondary
3&563/ connection to the boiler loop. Refer to Figure 4 page 11 for example of
-!).4%.!.#%30%#)&)#!4)/.3
has exceeded the Boiler In second delay or using manual
temperature by more than reset on display. primary/secondary connection.
', when burner is on.
Minimum pipe sizes
6MUSB


NJOJNVN
 inch
6MUSB


NJOJNVN
 inch
6MUSB


NJOJNVN
 inch
Verify proper circulator sizing for boiler size and system requirements
TUBSUJOH
PO
QBHF

Boiler ship with proper size circulators:
6MUSB


5BDP


6MUSB


5BDP

6MUSB


5BDP
0013
See message displayed TEMPERATURE SENSOR and follow procedure for
loose connections.

Part number 550-100-090/1113 103

 GAS-FIRED WATER BOILER — Boiler Manual

Troubleshooting (continued)

Figure 112 Troubleshooting suggestions for Ultra boilers (continued)

Display Condition Diagnostics Corrective Action(s)

3&563/

Occurs when a return water Automatically resets when Verify proper flow direction of the boiler circulator. This circulator should
4611-: temperature is greater than condition no longer exists. be installed to push water through the boiler's return pipe as shown in
the corresponding supply Figure 4 on page 11.
temperature by 10ºF or more.
Verify proper placement of system sensors for single or multiple boiler
Applies to system sensors or systems. System sensors should be on system piping not on the boiler
boiler sensors. loop.

Condition must occur for 10 System sensors may need located further away from boiler loop
minutes for system sensors. connection to the system if proximity to the boiler loop is causing
sensors to be heated inaccurately.

5&.1&3"563&
Occurs when a temperature Automatically resets when $IFDL
BMM
UIF
UFNQFSBUVSF
SFBEJOHT
PG
UIF
CPJMFS
PO
UIF
%*"(/045*$4


4&/403 sensor has electrically shorted condition no longer exists. TEMPERATURES menu to determine if any sensors are currently displayed
(SHORT) or has become as SHORT or OPEN. Compare this to the boiler temperatures recorded
disconnected (OPEN). JO
UIF
%*"(/045*$4

&33034

-0$,065
)*4503:


5&.1&3"563&4

during the last several lockout conditions.

Determine which sensors are suspect and measure their resistance

WBMVF
BOE
DPNQBSF
JU
UP
UIF
WBMVFT
TIPXO
JO
'JHVSF


*G
UIF
SFTJTUBODF

values are incorrect replace the temperature sensor. Refer to repair parts
section for proper part number.

OUTDOOR TEMP, SYSTEM SUPPLY, and SYSTEM RETURN are the optional
outdoor air temperature and system water temperature sensors. If these
are not being used they will always be shown as OPEN. This is normal
unless the sensors were installed.

Check wire harness for loose connections and pin engagement at sensor
connection, chassis mount connection through sheet metal cabinet, and
6$POUSPM
NPEVMF

6OQMVH
DPOOFDUJPO
BU
TFOTPS
BOE
BU
6$POUSPM
BOE

check continuity between ends.

*G
QSPCMFN
QFSTJTUT
BGUFS
DIFDLJOH
JUFNT
BCPWF
SFQMBDF
6$POUSPM

3FGFS

to repair parts section for kit number.

'-6&
5&.1 Occurs when flue Automatic reset occurs if Follow procedure for above for SHORT and OPEN sensor conditions
500
)*() temperature sensor exceeds UFNQFSBUVSF
ESPQT
CFMPX
ºF to properly diagnose sensor. In addition inspect heat exchanger
'. GPS

NJO. combustion chamber and flueways for abnormal wear or buildup.

Manual reset is required if the Inspect vent system for abnormal wear or damage.
UFNQFSBUVSF
SJTFT
BCPWF
¡'

Reset using manual reset screen $POUBDU
8FJM.D-BJO
5FDIOJDBM
4VQQPSU

on display.

5&.1&3"563& Occurs when dual Automatically resets when Follow procedure for above for SHORT and OPEN sensor conditions
4&/403 temperature sensors values sensors are within 10ºF. to properly diagnose sensor. If measured resistance values of sensors
have spread by more that convert to temperatures separated by more than 10ºF replace the sensor.
10ºF.

-08
853
Occurs when Low Water Requires manual reset of Check for low water condition in system. Repair system as necessary
$650''
01&/ Cutoff Device contacts open 6$POUSPM
BOE
NBZ
SFRVJSF
refer to piping section of this manual.
for more than 1 second. manual reset of LWCO device
depending on model. *G
MPX
XBUFS
DPOEJUJPO
EPFT
OPU
FYJTU
DIFDL
%JBHOPTUJDT

*OQVUT
TDSFFO
UP

view status of Low Water Cutoff. If shown as OPEN check wiring between
-8$0
BOE
6$POUSPM

104 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Troubleshooting (continued)

Figure 112 Troubleshooting suggestions for Ultra boilers (continued)

Display Condition Diagnostics Corrective Action(s)

%*41-":
$0.. Occurs when display Automatically resets when Check for a loose connection at the molex plug on the control and
communications out for 30 DPNNVOJDBUJPO
JT
SF connection on the back of the display.
seconds. established.

-*.*5
01&/ Occurs when manual or Automatic external limit will Is there an external safety device connected? If yes, trouble shoot the
automatic reset limit opens. SFTFU

NJOVUFT
BGUFS
FYUFSOBM
external limit to determine and correct the cause that opened the limit.
limit device closes. Also check for loose wiring connections.

Manual limit fault must be reset 3FNPWF
UIF
UPQ
GSPOU
DPWFS
BOE
JOTQFDU
UIF
03"/(&


1*/
DPOOFDUPS

by choosing Reset Lockout on P13.
the display. &OTVSF
B
KVNQFS
JT
JOTUBMMFE
CFUXFFO
QJOT

JG
OPU
VTJOH
B
NBOVBM
SFTFU

external limit.
&OTVSF
B
KVNQFS
JT
JOTUBMMFE
CFUXFFO
QJOT

JG
OPU
VTJOH
B
BVUPNBUJD

reset external limit.

)*()
5&.1
Boiler temperature sensor Reset using manual reset screen Verify all isolation valves are open and circulators are programmed into
-*.*5 reached High Temp Limit on display. UIF
6$POUSPM
QSPQFSMZ

&BDI
1SJPSJUZ
JOQVU
DBO
CF
DPOmHVSFE
UP
UVSO

TFUUJOH
OP
IJHIFS
UIBO
¡'
 PO
BOZ
DPNCJOBUJPO
PG
UISFF
DJSDVMBUPS
PVUQVUT

3FGFS
UP
UIF
6$POUSPM

Setup section to configure these properly for the system.

Verify water pipe is installed correctly using primary/secondary

connection to the boiler loop. Refer to Figure 4 page 11 for example of
primary/secondary connection.

Minimum pipe sizes

6MUSB


NJOJNVN
 inch
6MUSB


NJOJNVN
 inch
6MUSB


NJOJNVN
 inch

Verify proper circulator sizing for boiler size and system requirements
TUBSUJOH
PO
QBHF

Boiler ship with proper size circulators:
6MUSB


5BDP


6MUSB


5BDP

6MUSB


5BDP
0013

See message displayed TEMPERATURE SENSOR and follow procedure for

loose connections.

'-".&
'"6-5 Occurs when flame is Reset using manual reset screen Burner may be operating too hot due to incorrect combustion. Inspect
detected when there should on display. flame and conduct combustion test.
be no flame. 'PSDF
CPJMFS
JOUP
IJmSF
$IFDL
nVF
HBTFT
XJUI
DPNCVTUJPO
BOBMZ[FS
BOE

correct using the maintenance and startup procedure in this manual.

7FSJGZ
'-".&
4*(/"-
WBMVF
RVJDLMZ
HPFT
UP
[FSP
PO
UIF
%*"(/045*$4


INPUTS screen when the gas valve closes.
-!).4%.!.#%30%#)&)#!4)/.3
Check for flame at burner via flame current with burner off. Turn boiler
off and watch flame through observation port. If flame continues after
shutdown replace gas valve and venturi.

Part number 550-100-090/1113 105

 GAS-FIRED WATER BOILER — Boiler Manual

Troubleshooting (continued)

Figure 112 Troubleshooting suggestions for Ultra boilers (continued)

Display Condition Diagnostics Corrective Action(s)

#-08&3
'"6-5 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,
reach 0 RPM when turned off. reset on screen. BOE
6$POUSPM
NPEVMF

6OQMVH
DPOOFDUJPO
BU
TFOTPS
BOE
BU
6$POUSPM

and check continuity between ends. Blower is connected to both low
voltage and line voltage harness.

$IFDL
%JBHOPTUJDT

*OQVUT
TDSFFO
XJUI
CPJMFS
JO
TUBOECZ
NPEF
BOE

blower not running. If BLOWER SPEED is not 0 RPM then replace blower.

If blower does not rotate during ignition sequence check for 120V power
at blower connection. If 120Vac power at blower motor and it doesn't
TUBSU
SFQMBDF
CMPXFS

$IFDL
QPXFS
BU
6$POUSPM

*G
7BD
JT
OPU
QSFTFOU

BU
6$POUSPM
XIFO
CPJMFS
JT
QPXFSFE
SFQMBDF
6$POUSPM
3FGFS
UP
SFQBJS

parts section.

*(/*5*0/
#PJMFS
XFOU
UISPVHI

JHOJUJPO
Automatically resets after 1 hour Check condensate trap for blockage allowing condensate to accumulate
FAULT attempts and never detected or can be reset by using manual inside heat exchanger
flame. reset on screen.
Fouled, worn, bent, or faulty igniter.
Fouled igniters can be cleaned for additional use with fine grit sand
paper or steel wool.
Worn or badly fouled igniters should be replaced with the proper repair
part.
*HOJUFS
SPET
TIPVME
CF
QBSBMMFM
XJUI
B
NN

JO) spark gap.

Dirty burner and/or heat exchanger will cause high back pressure and
poor ignition. Follow procedure in maintenance section of this manual
to clean burner and heat exchanger using flue cleaning tool and rinse
method.

Visual inspection of flueways will often will not be able to diagnose

condition.

Check combustion settings on high and low fire and adjust per setup
instructions if necessary.

Check incoming gas pressure with boiler off and at high fire. Adjust
within limits on rating label.

Verify correct boiler model is selected in control and high altitude is

selected for installations 
GU above sea level.

$IFDL
JHOJUJPO
DBCMF
SFTJTUBODF

4IPVME
NFBTVSF

0INT



Ohms)

Check for flue pipe and intake pipe restrictions or blockage

Check burner fasteners and gaskets

Check venturi gaskets and proper propane orifice

Check condensate trap for blockage allowing condensate to accumulate

inside heat exchanger

106 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Troubleshooting (continued)

Figure 112 Troubleshooting suggestions for Ultra boilers (continued)

Display Condition Diagnostics Corrective Action(s)

("4
7"-7&
5IF
6$POUSPM
IBT
EFUFDUFE
Automatic retry when condition $IFDL
XJSF
IBSOFTT
DPOOFDUJPOT
CFUXFFO
HBT
WBMWF
BOE
6$POUSPM

FAULT a problem with it gas valve exists. Boiler will reset if
output circuit conditions clears. If condition
does not clear boiler will retry in
1 hour. If condition is not clear
after 1 hour, boiler will require Check resistance between
manual reset.

*G
MPDLPVU
SFPDDVST
SFQMBDF
6$POUSPM

"*3
13&4463&
Air Pressure switch is open Ultra residential boilers do not $IFDL
CPJMFS
TJ[F
TFMFDUFE
JO
6$POUSPM
BHBJOTU
CPJMFS
SBUJOH
MBCFM

$PSSFDU

48
'"6-5 use an air pressure switch, but if necessary to select the proper boiler size.
instead have a wire jumper
JOTUBMMFE
CFUXFFO
1
QJOT




Reset using manual reset screen $IFDL
UIF
1
DPOOFDUJPO
BT
TFFO
PO
'JHVSFT


 to determine proper

on display jumper wire location.

("4
13&4463&
Gas pressure switch is open Residential Ultra Boilers do $IFDL
CPJMFS
TJ[F
TFMFDUFE
JO
6$POUSPM
BHBJOTU
CPJMFS
SBUJOH
MBCFM

$PSSFDU

48
'"6-5 (high or low) not use gas pressure switches. if necessary to select the proper boiler size.
Requires manual reset.

)8
'"6-5
Expansion Control Board Residential Ultra Boilers do not $IFDL
CPJMFS
TJ[F
TFMFDUFE
JO
6$POUSPM
BHBJOTU
CPJMFS
SBUJOH
MBCFM

$PSSFDU

&91"/4*0/
hardware has failed. use an Expansion Control Board. if necessary to select the proper boiler size.
#3% Requires manual reset.

(7
'"6-5
Gas valve output of the Residential Ultra Boilers do not $IFDL
CPJMFS
TJ[F
TFMFDUFE
JO
6$POUSPM
BHBJOTU
CPJMFS
SBUJOH
MBCFM

$PSSFDU

&91"/4*0/
Expansion Board use an Expansion Control Board. if necessary to select the proper boiler size.
#3% Requires manual reset.

&91
#0"3%
Communication between the Residential Ultra Boilers do not $IFDL
CPJMFS
TJ[F
TFMFDUFE
JO
6$POUSPM
BHBJOTU
CPJMFS
SBUJOH
MBCFM

$PSSFDU

$0.
'"6-5 Expansion Control Board and use an Expansion Control Board. if necessary to select the proper boiler size.
UIF
6$POUSPM
#PBSE
IBT
GBJMFE Requires manual reset.

-!).4%.!.#%30%#)&)#!4)/.3

Part number 550-100-090/1113 107

 GAS-FIRED WATER BOILER — Boiler Manual

5LTRA'AS"OILER$ATA#OLLECTION3HEET
#USTOMER)NFO -AINTENANCE)NFO
Contact: Name:
Contractor: Phone:
Job name: Model:
City, state: CP#:
Distributor: Installed:

3YSTEM#OMPONENTS "OILER3YSTEM0IPING$ETAILS0LEASE3KETCH
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?:

$IAGNOSTIC%RRORS
Control fault:
Ignition retries:
Manual reset CNT:
Auto reset CNT:

3OFTWARE6ERSIONS
Display:
Main micro:
Second micro:

,OCKOUT(ISTORY ,OCKOUT(ISTORY ,OCKOUT(ISTORY

HH:MM MM/DD/YY: HH:MM MM/DD/YY: HH:MM MM/DD/YY:
Status: Status: Status:
Manual reset: Manual reset: Manual reset:
If yes-description: If yes-description: If yes-description:
Auto reset: Auto reset: Auto reset:
If yes-description: If yes-description: If yes-description:

Priority 1: Priority 1: Priority 1:

Priority 2: Priority 2: Priority 2:
Priority 3: Priority 3: Priority 3:
Manual limit: Manual limit: Manual limit:
Auto limit: Auto limit: Auto limit:
Low WTR Cutoff: Low WTR Cutoff: Low WTR Cutoff:
Blower tach: Blower tach: Blower tach:
Flame Signal: Flame Signal: Flame Signal:
/UTPUTS /UTPUTS /UTPUTS
Gas valve: Gas valve: Gas valve:
Circulator 1: Circulator 1: Circulator 1:
Circulator 2: Circulator 2: Circulator 2:
Circulator 3: Circulator 3: Circulator 3:
Blower signal: Blower signal: Blower signal:
Additional heat demand: Additional heat demand: Additional heat demand:
Alarm: Alarm: Alarm:
4EMPERATURES 4EMPERATURES 4EMPERATURES
System supply: System supply: System supply:
System return: System return: System return:
Boiler out 1: Boiler out 1: Boiler out 1:
Boiler out 2: Boiler out 2: Boiler out 2:
Boiler in 1: Boiler in 1: Boiler in 1:
Flue 1: Flue 1: Flue 1:
Flue 2: Flue 2: Flue 2:
Outdoor: Outdoor: Outdoor:

108 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

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
procedures. Failure to complete could result in se- instructions on page 93 of this manual. Fail-
vere personal injury, death or substantial property ure to comply could result in severe personal
damage. injury.
1. Shut down boiler:
a. Follow “To Turn Off Gas to Appliance” instructions
Install boiler jacket front door after on boiler and Lighting instructions.
startup or servicing b. Do not drain boiler unless it will be exposed to freez-
ing temperatures. If using freeze prevention fluid in
Reinstall boiler jacket front door after start-up or system, do not drain.
servicing. The boiler front door must be securely 2. Allow time for boiler to cool to room temperature if it
fastened to the boiler to prevent boiler from drawing has been firing.
air from inside the boiler room. This is particularly
3. Remove jacket front door by removing two knurled
important if the boiler is located in the same room
head screws at lower front. Lift door away from boiler
as other appliances. to remove.
Inspect boiler jacket door gaskets. Gaskets must be 4. Follow the applicable procedures under “Accessing
in good condition, with no tears or gaps. Replace if & cleaning exchanger: Ultra-80 and Ultra-105 Only,”
page 110 or “Accessing & cleaning exchanger: Ultra-155,
necessary.
-230, 299 and -399 Only,” page 111.
Failure to keep the door securely sealed and fastened
could result in severe personal injury or death.
Clean the cast aluminum heat exchanger
when required — water side
Perform start-up and check/out 1. In order for the efficiency of boilers to increase beyond
the condensing limit, new materials have been intro-
Removing and reinstalling components can change duced for the heat exchanger, including aluminum.
boiler behavior. After any maintenance procedure, 2. Aluminum has excellent heat transfer characteristics
you must prove the boiler is operating correctly. To and is light in weight.
do so, follow the complete procedure for boiler and
3. These new materials also require cleaning solutions
system start-up, beginning on page 31. Failure to
that differ from those used in conventional cast iron
comply could result in severe personal injury, death and steel boilers.
or substantial property damage.
One common cleaning method that #!../4
be used with systems containing aluminum is
a solution of trisodium phosphate, commonly
referred to as “TSP.”
-!).4%.!.#%30%#)&)#!4)/.3
General maintenance The reason that trisodium phosphate cannot
be used is that the cleaning solution has a very
1. Oil motor in system requiring regular oiling. high pH level — while removing the scale in
the system, it also removes the natural pro-
2. See Oiled bearing circulators for motor oiling procedures. tective oxide layer from the aluminum. The
oxide layer will reform, but if small amounts
Oiled bearing circulators of the trisodium phosphate remain in the
system, the chemical will continue to remove
1. The circulator shipped with the Ultra boiler is water-lubricated. the protective oxide layer, leading to reduced
No oiling is required. heat exchanger life.
2. Check other circulators in the system. Oil any circulators requiring 4. Use ONLY the cleaning product available from Weil-
oil, following circulator manufacturer’s instructions. Over-oiling McLain, Sentinel X400. See the Repair Parts section at
will damage the circulator. the end of this manual for ordering information.

Part number 550-100-090/1113 109

 GAS-FIRED WATER BOILER — Boiler Manual

Maintenance (continued)
Accessing & cleaning exchanger: &IGURE .UTTIGHTENINGSEQUENCEˆ
Ultra-80 and Ultra-105 Only 'RADUALLYTIGHTENTHENUTSREPEATING
1. Close the external manual gas valve. THESEQUENCESHOWNBELOWUNTILTHE
TORQUEREACHESINCH POUNDS 
2. Disconnect the flexible gas line at its flare fitting. INCH POUNDS
3. Remove the air silencer by separating it from the air adapter on
the blower inlet.
4. $ISCONNECTWIRINGsGASVALVEPLUGsBLOWERPOWERSUPPLYPLUG
sBLOWERCONTROLCONNECTORsIGNITIONCABLEsGROUNDWIRE
5. Release the heat exchanger cover plate by removing the nuts secur-
ing it to the exchanger.
6. Pull the entire blower/venturi/gas valve/cover plate assembly out
of the boiler. (See Replacement parts section for component iden-
tification and locations.)
7. Use a vacuum cleaner to remove any accumulation on the heating
surfaces. Do not use any solvent.
8. If the vacuum cleaner is unable to clean completely, wash the heat-
ing surfaces with clean, warm water. If further cleaning is necessary,
use the Heat Exchanger Cleaning Tool (see Replacement parts at the
end of this manual) or a piece of 20-gauge or lighter sheet metal
¾” wide by about 18 inches long to loosen deposits. See Figure 114.
3EEWATERSPRAYINGNOTICEONNEXTPAGE.
9. Inspect the heat exchanger cover plate insulation. Replace if insu-
lation is damaged. Read the ceramic fiber WARNING on page 93
before handling or disposing of ceramic fiber materials.
10. Reinstall the blower/venturi/gas valve/cover plate assembly and
secure the cover plate with nuts.
You must gradually tighten the cover plate nuts. For Ul-
tra-80 and -105, follow the tightening sequence shown
in Figure 113, making two or three passes with a torque
wrench. The final torque MUST NOT exceed 50 inch-
pounds, +/- 10 inch-pounds. &IGURE#LEANINGTHEEXCHANGERPIN SIDE
11. 2ECONNECTWIRINGsGASVALVEPLUGsBLOWERPOWERSUPPLYPLUG
sBLOWERCONTROLCONNECTORsIGNITIONCABLEsGROUNDWIRE
If the valve adapter block is removed, carefully inspect the
O-ring that should still be in the gas valve inlet adapter
block. The O-ring must be in good condition and must
be installed when gas valve is reconnected. Failure to
comply will cause a gas leak, resulting in severe personal
injury or death.
12. Reconnect the flexible gas line.
13. Reinstall the air silencer by pressing onto the air inlet adapter.
14. Perform a soap suds leak test on all interior gas piping after start-
ing the boiler.

Cleaning the heat exchanger — water side (ALL

models)
1. Follow the procedure given in “Clean the cast aluminum heat ex-
changer when required — water side,” page 109 to clean the water
side of the exchanger.
2. Follow the complete procedure for boiler and system start-up,
beginning on page 31.

110 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Maintenance (continued)
Accessing & cleaning exchanger: Ultra-155, &IGURE .UTTIGHTENINGSEQUENCEˆ
-230, 299 and -399 Only TOˆ'RADUALLYTIGHTENTHE
1. Close the external manual gas valve. NUTSREPEATINGTHESEQUENCESHOWN
BELOWUNTILTHETORQUEREACHES
2. $ISCONNECTWIRINGsGASVALVEELECTRICALPLUGsTWOELECTRICAL-OLEX INCH POUNDS INCH POUNDS
PLUGSFROMTHEBLOWERASSEMBLYsIGNITIONCABLEsGROUNDWIRE
3. Disconnect the flexible gas line at its flare fitting.
4. Remove the air silencer by lifting the plastic clamp off of the gas line
and then gently sliding the air silencer down and off the valve.
5. Remove hex head nuts (10mm box end wrench) from heat ex-
changer cover plate and remove burner cover plate from heat
exchanger.
6. Pull the entire blower/venturi/gas valve/cover plate assembly out
of the boiler. (See Replacement parts section for component iden-
tification and locations.)
7. Remove three M4 hex head screws (7mm box end wrench) and
burner clips securing burner to cover plate. Remove cover plate.
8. Use a vacuum cleaner to remove any accumulation on the heating
surfaces. Do not use any solvent.
9. If the vacuum cleaner is unable to clean completely, wash the heat-
ing surfaces with clean, warm water. If further cleaning is necessary,
use the Heat Exchanger Cleaning Tool (see Replacement parts at the
end of this manual) or a piece of 20-gauge or lighter sheet metal
¾” wide by about 18 inches long to loosen deposits. See Figure 114.
3EEWATERSPRAYINGNOTICE
10. Inspect the heat exchanger cover plate insulation and gasket. Re-
place if damaged. Read the ceramic fiber WARNING on page 93
before handling or disposing of ceramic fiber materials.
11. Replace the burner, hex head screws and burner clips removed in
step 7. See Figure 107, page 96.
12. Place cover plate gasket in groove of heat exchanger cover plate.
Replace cover plate.
13. Reinstall hex head nuts on the cover plate mounting studs and
tighten in a staggering pattern until cover plate is uniformly
tightened. WATER SPRAY HEAT EXCHANGER
PINS AFTER USING CLEANING TOOL
You must gradually tighten the cover plate nuts. For
Ultra-155 through -399, follow the tightening sequence 1. After using the cleaning tool as shown in Figure 114,
shown in Figure 115, making two or three passes with spray water downward from above the pins to flush
a torque wrench. The final torque MUST NOT exceed remaining sediment.
50 inch-pounds, +/- 10 inch-pounds. 2. Remove sediment from the bottom of the heat
14. Reinstall air silencer by sliding on gas valve venturi and securing exchanger.
clamp to gas line. 3. Then disconnect the condensate line at the bottom
15. 2ECONNECTWIRINGsGASVALVEELECTRICALPLUGsTWOELECTRICAL-OLEX of the heat exchanger. -!).4%.!.#%30%#)&)#!4)/.3
PLUGSFROMTHEBLOWERASSEMBLYsIGNITIONCABLEsGROUNDWIRE a. Loosen the hose clamps at both ends of the
16. Reconnect the flexible gas line and gas valve electrical plug. condensate line.
b. Remove the line and place a pan under the trap
17. Perform a soap suds leak test on all interior gas piping after start- connection.
ing the boiler.
c. Spray water into the bottom of the heat ex-
Cleaning the heat exchanger — water side (ALL changer to flush remaining sediment to the
condensate outlet.
models) d. Spray water through the condensate line to
1. Follow the procedure given in “Clean the cast aluminum heat ex- clean it thoroughly.
changer when required — water side,” page 109 to clean the water e. Remove pan and replace the condensate line.
side of the exchanger. f. Follow instructions on page 110 or page 111
2. Follow the complete procedure for boiler and system start-up, to check components and replace burner and
beginning on page 31. cover.

Part number 550-100-090/1113 111

 GAS-FIRED WATER BOILER — Boiler Manual

Replacement parts

Replacement parts must be purchased through a local Weil-McLain distributor. When ordering,
specify boiler model and size and include description and part number of replacement part.
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.

4HEBOILERCONTAINSCERAMIClBERMATERIALS. Use care when handling these materials per

instructions on page 93 of this manual. Failure to comply could result in severe personal injury.

Reinstall boiler jacket front door after startup or servicing

Inspect boiler jacket front door gaskets and reinstall boiler jacket front door after start or
servicing. The boiler front door must be securely fastened to the boiler to prevent boiler from
drawing air from inside the boiler room. This is particularly important if the boiler is located
in the same room as other appliances. Failure to keep the door securely fastened could result in
severe personal injury or death.

&IGURE 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.

.ATURALTOPROPANECONVERSIONˆSERIES 3 BOILERS ONLY

(not required for Ultra-399 — adjustment is made with throttle screw, not with orifice)

3EALEVELTOFEETALTITUDE (IGHALTITUDEABOVEFEET

-ODEL +ITPART +ITLOCATION )NSTRUCTIONS -ODEL +ITPART +ITLOCATION )NSTRUCTIONS

30%#)!, 30%#)!, See page 44

5LTRA  383-501-020 Ultra-80LP 383-500-644
/2$%2 In kit only /2$%2 or kit

540-100-001 30%#)!, See page 44

5LTRA  See page 44 Ultra-105 383-500-645
Supplied with boiler /2$%2 or kit

383-500-115 30%#)!, See page 45

5LTRA  See page 45 Ultra-155 383-500-646
Supplied with boiler /2$%2 or kit

383-500-120 30%#)!, See page 45

5LTRA  See page 45 Ultra-230 383-500-647
Supplied with boiler /2$%2 or kit

540-202-832 30%#)!, See page 45

5LTRA  See page 45 Ultra-299 383-500-394
Supplied with boiler /2$%2 or kit

0ROPANETONATURALCONVERSION

30%#)!,
5LTRA  383-501-021 Contact factory
/2$%2 In kit only
Boilers marked with this symbol require special installation procedures. Do not use the instructions in this manual — use
only the instructions supplied in the conversion kit.

112 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Replacement parts (continued)

&IGURE Miscellaneous parts and kits

Item Description Part Number

CHEMICALS
!NTIFREEZEALUMINUM SAFE3ENTINEL8GALLON                        
!NTIFREEZEALUMINUM SAFE3ENTINEL8GALLON                        

#ORROSIONINHIBITOR3ENTINEL8ONETUBEML                       
)NHIBITORQUICK TESTKIT                                       
#LEANER3ENTINEL8ONETUBEML                             

BOILER ACCESSORIES AND CONTROLS

"OILERCIRCULATORWITHOUTmANGES 5LTRA  4ACO-ODEL   

2 5LTRA  4ACO-ODEL   
5LTRA  4ACO-ODEL   

#IRCULATORHARDWAREKITnINLETmANGENUTSSCREWSANDGASKET

v   

—v   
žv   

4 ,OWWATERCUT OFFWITHTESTBUTTON   

5 (EATEXCHANGERCLEANINGTOOL   

!NNUALMAINTENANCEKIT)GNITERIGNITERGASKETCOVER 5LTRA    

 PLATEGASKETCOVERPLATEINSULATIONBURNERGASKET 5LTRA n   
mUESENSORGASKETANDVENTURIGASKET

0RESSURERELIEFVALVE!3-%03)v.04MALE 5LTRA n   


5LTRA n   

8 5LTRABOILERWALL MOUNTKIT   

VENT / AIR TERMINATIONS

 6ENTAIRTERMINATIONWALLPENETRATECOVERPLATEREQUIREDFOREACHBOILER   

6ENTTERMINATIONBIRDSCREENREQUIRED vVENT5LTRA    


vVENT5LTRA    

7EIL -C,AINSIDEWALLVENTAIRCAPTERMINATIONKITˆ)NCLUDES7 -SIDEWALLVENTAIR

TERMINATIONCAPINSIDEANDOUTSIDECOVERPLATESANDMOUNTINGHARDWAREOPENINGSARESIZED
 FOR06#PIPEvISSHIPPEDWITH5LTRA nvISSHIPPEDWITH5LTRA n
vKIT    -!).4%.!.#%30%#)&)#!4)/.3
vKIT   

 #ONCENTRICVENTKITFORSIDEWALLORVERTICALTERMINATION v06#ONLY   

CONDENSATE HANDLING

 #ONDENSATENEUTRALIZERKIT   

'OTOWWWWEIL MCLAINCOMTOLOCATE7EIL -C,AINDISTRIBUTORS

Part number 550-100-090/1113 113
 GAS-FIRED WATER BOILER — Boiler Manual

Replacement parts (continued)

&IGURE Jacket parts

Item

Item

Boiler Part Boiler Part

Description Description
models number models number
1 Jacket front door All 383-500-135 6 Flue outlet pipe adapter 3” 80/105 560-900-001
2 Boiler leg kit (4 required) All 383-500-065 3” 155 383-500-656
3 Knurled head screw for jacket front door All 383-500-320 4” 230–399 383-500-657
(2 required) 7 Top cover, front All 383-500-607
4 Knurled head screw clip-on receptacle (not All 383-500-180 8 Top cover, rear 80/230 383-500-608
shown) (2 required) 299/399 383-500-609
5 Air adapter kit (Includes adapter, 3” 80/105 383-500-655 9 Door Gasket replacement kit (not shown) All 383-500-610
gasket and mounting bracket) 3” 155 383-500-145 10 Handle (2 required) All 383-500-611
4” 230–399 383-500-150
'OTOWWWWEIL MCLAINCOMTOLOCATE7EIL -C,AINDISTRIBUTORS
114 Part number 550-100-090/1113
 GAS-FIRED WATER BOILER — Boiler Manual

Replacement parts (continued)

&IGURE Controls
Item

Part
Description
Number

 Ultra U-Control module 383-500-658

2 Transformer, 120v/24v 383-500-628
 Display board assembly (includes plastic and display screen) 383-500-659
4 On/off power switch 383-500-205
5 Pressure/temperature gauge assembly (Includes temperature 383-500-630
and pressure sensor)
 Flue temperature sensor replacement kit 383-500-600
 System temperature sensors (2 required) 383-500-601
8 Outdoor temperature sensor 510-312-218
 Display to U-Control wire harness (not shown) 383-500-633
 Upper line voltage wire harness (male) (not shown) 383-500-634
 Lower line voltage wire harness (female) (not shown) 383-500-635
 Upper low voltage wire harness (male) (not shown) 383-500-636
 Lower low voltage wire harness (female) (not shown) 383-500-637
 120 volt, 3-wire receptacle (not shown) 383-500-638
 Ultra U-Control module fuses (not shown)
F1 - 3-amp, fast-blow ATO (5 fuses) 383-500-603
F2 - 12-amp, slow-blow AG (5 fuses) 383-500-604
 Jumper for low voltage terminal blocks, (5 jumpers) 383-500-641
(not shown)
 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

-!).4%.!.#%30%#)&)#!4)/.3

'OTOWWWWEIL MCLAINCOMTOLOCATE7EIL -C,AINDISTRIBUTORS

Part number 550-100-090/1113 115
 GAS-FIRED WATER BOILER — Boiler Manual

Replacement parts (continued)

&IGURE Heat exchanger and piping — Ultra-80 and -105

Boiler
Item Description Part Number
Models

 (EATEXCHANGERREPLACEMENTKIT (EATEXCHANGERCOVERPLATEBURNER .'   

ELECTRODEWATERSENSORSCOMPRESSIONlTTINGSCONDENSATElTTINGGASKETS ,0   
ANDHARDWARE    
2 #OVERPLATEREPLACEMENTKIT #OVERPLATECOVERPLATEGASKETBURNERGASKET    
ANDHARDWARE
 #OVERPLATEGASKETINSULATION    
4 "URNERGASKET    
5 #OVERPLATESTUDS-PITCH !LL   
 #OVERPLATENUTS-PITCH !LL   
 7ATERCOMPRESSIONlTTINGMM n   
8 7ATERCOMPRESSIONlTTINGMM    
 3UPPLYWATERPIPEASSEMBLY 0IPETEMPERATUREWELLCHECKVALVECAP    
ASSEMBLED COMPRESSIONlTTING
 3UPPLYWATERLOWERPIPECLAMPANDHARDWARE    
 v.04WELLFORTEMPERATUREGAUGE !LL   
 0RESSURETEMPERATUREGAUGECHECKVALVE !LL   
 2ETURNWATERPIPEASSEMBLY 0IPEDRAINVALVECAPASSEMBLED     
COMPRESSIONlTTING
 "OILERDRAINVALVEv.04 !LL   
 "LOWERASSEMBLYKIT "LOWERGASKETANDHARDWARE    
 'ASPIPE    
 &LEXIBLEGASLINESECTIONANDSHUT OFFVALVE    
 'AS0IPELOWERPIPECLAMPANDHARDWARE    
 'ASVALVEVENTURIKIT 'ASVALVEVENTURIªELBOWGASKETSANDHARDWARE    
ASSEMBLED &OR,0BOILERSMAKESURETOREINSTALLTHEEXISTINGPROPANEORIlCE    
 'ASKETCORKFORINBETWEENGASVALVEVENTURIBURNERINLET !LL   
 !IRSILENCERKIT !IRSILENCERANDGASKET    
22 !IRSILENCERADAPTERKIT !IRSILENCERADAPTERANDHARDWARE    
 #ONDENSATETRAPKIT #ONDENSATETRAPHOSECLAMPSPVClTTINGSANDGASKET    
24 2ETURNSUPPLYSENSORKIT  SENSOR !LL   
25 )GNITIONELECTRODEKIT )GNITIONELECTRODESUPPRESSORGASKETANDHARDWARE !LL   
)GNITIONELECTRODEGASKET/.,9 !LL   
 )GNITIONCABLEKITNOTSHOWN )GNITIONCABLESUPPRESSORANDWIRETIE !LL   
 )NSPECTIONGLASSKIT "RACKETGLASSGASKETANDHARDWARE !LL   
28 "URNERREPLACEMENTKIT "URNERGASKETSANDHARDWARE .'   
,0   
   
 'ASKETRUBBERBLOWER    

 #ONDENSATElTTING    

116 Part number 550-100-090/1113

 GAS-FIRED WATER BOILER — Boiler Manual

Replacement parts (continued)

&IGURE Heat exchanger and piping — Ultra-80 and -105

-!).4%.!.#%30%#)&)#!4)/.3

'OTOWWWWEIL MCLAINCOMTOLOCATE7EIL -C,AINDISTRIBUTORS

Part number 550-100-090/1113 117
 GAS-FIRED WATER BOILER — Boiler Manual

Replacement parts (continued)

&IGURE Heat exchanger and piping
5LTRA  
Item

Boiler Part
Description
models number
Item

1 Heat exchanger replacement kit - Heat 155 383-500-621 Boiler Part

Description
exchanger, cover plate, burner, electrode, 230 383-500-622 models number
water sensors, compression fittings, 18 Gas pipe 155/230 560-907-683
condensate fitting, gaskets, and hardware 19 Flexible gas line section and shut-off valve 155/230 383-500-624
2 Cover plate replacement kit - Cover plate, 155/230 383-500-395 20 Gas pipe lower clamp and hardware 155/230 383-500-617
cover plate gasket, burner gasket, and
21 Gas valve/venturi kit - Gas valve, venturi, 155 383-500-025
hardware
adapter block, O-ring and hardware 230 383-500-030
3 Cover plate insulation 155/230 383-500-250
(assembled) be sure to reinstall the existing
4 Cover plate gasket 155/230 383-500-255 propane orifice)
5 Cover plate studs, M6, 1 pitch All 560-340-598 22 Gasket cork, for in between gas valve venturi All 590-317-310
6 Cover plate nuts, M6, 1 pitch All 561-928-449 & burner inlet
7 Water compression fitting, 28 mm 80–230 383-500-260
23 Air silencer kit - Air silencer and gasket 155/230 383-500-295
8 Supply water pipe assembly - Pipe, 155/230 383-500-265
24 Condensate trap kit - Condensate trap, hose 155/230 383-500-060
temperature well, check valve, cap
(assembled) & compression fitting clamps, pvc fittings, and gasket
9 Supply water lower pipe clamp and hardware 155/230 383-500-615 25 Ignition electrode kit - Ignition electrode, All 383-500-045
10 1/2” NPT well for temperature gauge All 383-500-270 suppressor, gasket, and hardware
11 Pressure/temperature gauge check valve All 383-500-275 Ignition electrode gasket ONLY 511-330-253
12 Return water bushing, 1 1/4” BSP x 1” BSP 155/230 383-500-280 26 Ignition cable kit (not shown) - Ignition cable, All 383-500-619
(not use on Ultra-299) suppressor, and wire tie
13 Return water pipe assembly - Pipe, drain 155/230 383-500-285 27 Inspection glass kit - Bracket, glass, gasket All 383-500-020
valve, cap (assembled) & compression fitting and hardware
16 Boiler drain valve, 3/4” NPT All 511-246-392 28 Burner replacement kit - Burner, gaskets and 155 383-500-085
17 Blower assembly kit - Blower, gasket, and 155 383-500-035 hardware 230 383-500-090
hardware 230 383-500-040 29 Return/supply sensor kit - (1) sensor All 383-500-602
'OTOWWWWEIL MCLAINCOMTOLOCATE7EIL -C,AINDISTRIBUTORS
118 Part number 550-100-090/1113
 GAS-FIRED WATER BOILER — Boiler Manual

Replacement parts (continued)

&IGURE Heat exchanger and piping
5LTRA  
Item

Item

Boiler Part Boiler Part

Description Description
models number models number
1 Heat exchanger replacement kit - Heat 299/399 383-500-623 20 Gas pipe lower clamp and hardware 299 383-500-625
exchanger, cover plate, burner, electrode, water 21 Gas valve/venturi kit - Gas valve, venturi, 299 383-500-390
sensors, compression fittings, condensate (For 310LP boilers, make sure to reinstall the
fitting, gaskets, and hardware existing propane orifice)
2 Cover plate replacement kit - Cover plate, cover 299/399 383-500-395 Gas valve kit - Gas valve, venturi, adapter 399 383-500-652
plate gasket, burner gasket, and hardware block, O-ring and hardware (assembled)
3 Cover plate insulation 299/399 383-500-250 22 Gas valve outlet adapter/nipple kit 399 383-500-651
4 Cover plate gasket 299/399 383-500-255 23 Gasket cork, for in between gas valve venturi & All 590-317-310
5 Cover plate studs, M6, 1 pitch All 560-340-598 burner inlet
6 Cover plate nuts, M6, 1 pitch All 561-928-449 24 Air silencer kit - Air silencer and gasket 299 383-500-355
8 Supply water pipe assembly - Pipe, temperature 299/399 383-500-380 399 383-500-654
well, check valve, cap (assembled) & 25 Ignition electrode kit - Ignition electrode, All 383-500-045
compression fitting suppressor, gasket, and hardware -!).4%.!.#%30%#)&)#!4)/.3
10 1/2” NPT well for temperature gauge All 383-500-270 Ignition electrode gasket ONLY 511-330-253
11 Pressure/temperature gauge check valve All 383-500-275 Ignition electrode and gasket 511-330-253
13 Return water pipe assembly - Pipe, drain valve, 299/399 383-500-385 26 Ignition cable kit (not shown) - Ignition cable, All 383-500-619
cap (assembled) & compression fitting suppressor, and wire tie
14 Supply/Return water piping square cut EPDM 299/399 562-248-755 27 Inspection glass kit - Bracket, glass, gasket and All 383-500-020
gasket (Ultra-299 only) hardware
15 Fitting, double nipple for supply/return 299/399 561-326-828 28 Burner replacement kit - Burner, gaskets and 299 383-500-407
16 Boiler drain valve, 3/4” NPT All 511-246-392 hardware
17 Blower assembly kit - Blower, gasket, and 299 383-500-360 29 Return/supply sensor kit - (1) sensor All 383-500-602
hardware 399 383-500-650 30 Condensate trap kit - Condensate trap, hose 299/399 383-500-626
18 Gas pipe 299/399 560-907-679 clamps, pvc fittings, and gasket
19 Flexible gas line section and shut-off valve 299 560-900-016
399 383-500-653

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Dimensions

&IGURE 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.
1
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.
Boiler circulator is shipped loose.
Circulator must be mounted in the return piping.
2
Both 1” and 1¼” circulator flanges are shipped with boiler on Ultra-80/105/155/230.
Both 1¼” and 1½” circulator flanges are shipped with boiler on Ultra-299 and Ultra-399.
Relief valve is shipped loose.
3
See page 9 for mounting details. Relief valve mounts on supply pipe off of supply tee and ¾” street elbow as shown.

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Ratings — Ultra boilers

&IGURE Ratings and engineering data

DOE

Boiler DOE CSA Net Boiler DOE Vent/Air

Model Heating Input Output AHRI Water Seasonal Pipe
Number Capacity Ratings Content Efficiency Size

Btuh (Note 2) Btuh (Note 7) Btuh (Note 7) Btuh (Note 3) Gallons AFUE, % (Note 1) (Note 4)

Ultra-80-CT 71,000 80,000 71,000 62,000 0.69 93.5 2” or 3”

Ultra-105-CT 94,000 105,000 94,000 82,000 0.82 94.0 2” or 3”

Ultra-155-CT 139,000 155,000 139,000 121,000 1.17 94.0 3”

Ultra-230-CT 207,000 230,000 207,000 180,000 1.57 94.1 3” or 4”

Ultra-299-CT 270,000 299,000 270,000 235,000 2.10 92.5 4”

Boiler CSA Gross Net Boiler Combustion Thermal Vent/Air

Model Input Output AHRI Water Efficiency Efficiency Pipe
Number Ratings Content Size

Btuh (Note 7) Btuh (Note 7) Btuh (Note 3) Gallons % (Note 5) % (Note 6) (Note 4)

Ultra-399-CT 399,000 364,000 317,000 2.1 91.7 91.3 v

Notes
As an Energy Star Partner, Weil-McLain has determined that Ultra boilers meet the Energy Star guidelines for energy efficiency.
1
NOTE: Adjusting boiler firing rate will affect AFUE rating.
2 Based on standard test procedures prescribed by the United States Department of Energy.
Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be
3 added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15. An additional allowance should be -!).4%.!.#%30%#)&)#!4)/.3
made for unusual piping and pickup loads.
Ultra boilers must be direct-vented.
Ultra boilers require special venting, consistent with Category IV boiler.
4 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.
5 Combustion efficiency is based on AHRI testing procedure BTS-2000, and equal to 100% minus flue loss.
6 Thermal efficiency is based on AHRI testing procedure BTS-2000.
Ratings shown are for sea level applications only. For altitudes from sea level to 5,500 feet above sea level, the Ultra boiler requires no
7
modifications and automatically derates itself by approximately 4% per 1000 feet above sea level.

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Ratings — multiple Ultra boilers

&IGURE Ratings and engineering data (see Figure 128 for notes)

Manifolded Foundation size

Total DOE Net
Boiler combustion Side-to-side Back-to-back
Boilers in system CSA Heating water
H.P. air duct arrangement arrangement
Model Ultra – input capacity ratings
size (height 2” to 4”) (height 2” to 4”)
Input, Output, Square Length Length Length Length
- MBH
MBH MBH inches (inches) (inches) (inches) (inches)
80 105 155 230 299 399
- Note 1 - Note 2 Figure 59, page 55 Note 3
-CT -CT -CT -CT -CT -CT
2 160 142 4.2 123 80
2 210 188 5.6 163 105
2 310 278 8.3 242 155
56 23 27 48
2 460 414 12.4 360 230
2 598 540 16.1 468 299
2 798 730 21.8 634 385
3 240 213 6.4 185 120
3 315 282 8.4 245 157
3 465 417 12.5 363 232
85 23 56 48
3 690 621 18.6 540 345
3 897 810 24.2 702 449
3 1197 1095 32.7 951 578
4 320 284 8.5 247 160
4 420 376 11.2 327 210
4 620 556 16.6 483 310
114 24 56 49
4 920 828 24.7 720 460
4 1196 1080 32.3 936 598
4 1596 1460 43.6 1268 770
5 400 355 10.6 309 200
5 525 470 14 409 267
5 775 695 20.8 604 387
143 24 85 49
5 1150 1035 30.9 900 575
5 1495 1350 40.3 1170 748
5 1995 1825 54.5 1585 963
6 480 426 12.7 370 240
6 630 564 16.8 490 315
6 930 834 24.9 725 465
172 24 85 49
6 1380 1242 37.1 1080 690
6 1794 1620 48.4 1404 897
6 2394 2190 65.4 1902 1155
7 560 497 14.8 432 280
7 735 658 19.7 572 367
7 1085 973 29.1 846 542
201 24 114 49
7 1610 1449 43.3 1260 805
7 2093 1890 56.5 1638 1047
7 2793 2555 76.3 2219 1348
8 640 568 17 494 320
8 840 752 22.5 654 420
8 1240 1112 33.2 967 620
230 24 114 49
8 1840 1656 49.5 1440 920
8 2392 2160 64.5 1872 1196
8 3192 2920 87.2 2536 1539

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Ratings — multiple Ultra boilers (continued)

&IGURE Engineering data (see Figure 128 for notes)

Vent/air pipe Electrical

Shipping Operating Water Water flow rate
Boiler size — service
weight weight content per boiler
Model Provide a required
Pounds separate vent Amps
Ultra – Pounds per boiler Gallons GPM GPM for each boiler per boiler
per boiler per boiler @ 20°F rise @ 40°F rise
Note 4 Note 5 Note 6

80-CT 199 139 0.7 7.1 3.6 2” or 3” 15.0

105-CT 207 145 0.8 9.4 4.7 2” or 3” 15.0

155-CT 234 181 1.2 13.9 7.0 3” 15.0

230-CT 246 192 1.6 20.7 10.4 3” or 4” 15.0

299-CT 297 229 2.1 27.9 14.0 4” 15.0

399-CT 297 229 2.1 36.5 18.2 4” 15.0

&IGURE Notes for Figure 126 and Figure 127-

Based on standard test procedures outlined by DOE for individual boilers.

1

Net AHRI ratings are based on piping and pickup allowance of 1.15.
2
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.
Smaller foundations are possible with reduced service clearances.
3 See page 54 for details.
s For side-to-side installations, see Figure 56, page 54.
s For back-to-back installations, see Figure 57, page 54.
-!).4%.!.#%30%#)&)#!4)/.3
4 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.
5 All Ultra installations require a separate vent pipe and termination for each boiler. 6ENTPIPINGCANNOTBEMANIFOLDED. Install and
terminate vents as described in vent/air installation instructions in this manual.
Combustion air piping can be individually piped or manifolded. See Figure 59, page 55, for manifolded air piping.

6 Total amp requirement includes up to three circulators, not exceeding 2.2 amps per circulator.

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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.
❏ Information received and left with owner/maintenance person.

Installer

(Company) (Address) (Phone) (Installer's Signature)

34!24 50$!4!
Boiler Model CO2 High fire % CO2 Low fire %
Fuel Natural ____ LP ____ CO High fire ppm CO Low fire ppm
Was orifice changed? ______________________________________ Was gas valve throttle adjusted (Ultra-399) for propane? __________________
Natural gas input rate measured _________________________ Btuh
5 #/.42/,3%4 50$!4!
Boiler Model WWSD Temp °F Add’l Heat Demand Type 1___ 2___ 3___ 4___
High Altitude yes ____ no _____ Adjust Outdoor °F Add’l Heat Demand Time minutes
Manual Reset Temp °F

02)/2)493ETTINGS 02)/2)493ETTINGS 02)/2)493ETTINGS

System Type System Type System Type
Max Supply °F Max Supply °F Max Supply °F
Min Supply °F Min Supply °F Min Supply °F
Max OD Reset °F Max OD Reset °F Max OD Reset °F
Min OD Reset °F Min OD Reset °F Min OD Reset °F
Modulate On Diff °F Modulate On Diff °F Modulate On Diff °F
Modulate Off Diff °F Modulate Off Diff °F Modulate Off Diff °F
Max On Time minutes Max On Time minutes Max On Time —
Min On Time — Min On Time minutes Min On Time minutes
Boost Interval minutes Boost Interval minutes Boost Interval minutes
Pre-pump Time: seconds Pre-pump Time: seconds Pre-pump Time: seconds
Post-pump Time: seconds Post-pump Time: seconds Post-pump Time: seconds
Circulator 1 on-off Circulator 1 on-off Circulator 1 on-off
Circulator 2 on-off Circulator 2 on-off Circulator 2 on-off
Circulator 3 on-off Circulator 3 on-off Circulator 3 on-off
Maximum Rate %Rate Maximum Rate %Rate Maximum Rate %Rate
Minimum Rate %Rate Minimum Rate %Rate Minimum Rate %Rate
#IRCULATOR%XERCISING &REEZE0ROTECTION#IRCULATORS
Circulator 1 on _______ off _______ Circulator 1 on _______ off _______
Circulator 2 on _______ off _______ Circulator 2 on _______ off _______
Circulator 3 on _______ off _______ Circulator 3 on _______ off _______

124