• Installation
• Startup
• Maintenance
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Boiler Manual
Gas-red water boilers – Series 4
Featuring
Part number 550-100-440/0723
is manual must only be used by a qualied heating installer/service technician. Read all instructions, including this manual and
all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to comply could result in
severe personal injury, death or substantial property damage.
Contents
(see page 44 and page 46 for details of all models)
e following dened terms are used throughout this manual to bring
attention to the presence of hazards of various risk levels or to important
information concerning the life of the product.
Indicates presence of hazards that will cause severe
personal injury, death or substantial property
damage.
Indicates presence of hazards that can cause severe
personal injury, death or substantial property
damage.
Indicates presence of hazards that will or can cause
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.
Hazard denitions
Part number 550-100-440/0723
2
Ultra at-a-glance
series
4
gas-fired water boiler
Hazard denitions & Ultra at-a-glance 2
Please read before proceeding 4
Prepare boiler location 5
Prepare boiler 7
Install water piping 9
Using with Weil-McLain AQUA PLUS water heaters 14
Venting/air piping — general 16
Sidewall vent/air termination: Separate pipes 20
DIRECT VENT Applications 25
DIRECT EXHAUST Applications 26
Install condensate line 27
Gas piping 29
Field wiring — basic system 30
U-Control operation and setup 32
Startup — ll the system 35
Startup — nal checks 37
Check-out/startup verication 42
The Ultra Gas-red water boiler, Featuring U-Control Flexibility 44
Prepare boiler — convert for propane 48
Placing boiler — wall-mounting option 50
Install water piping — advanced 52
Direct-connected DHW piping 56
Multiple boiler installations 58
Venting/air piping — Massachusetts installations 65
Vent/air piping — options 66
Sidewall vent/air termination: Weil-McLain cap 67
Sidewall vent/air termination: 3” or 4” concentric 72
Vertical vent/air termination: 3” or 4” concentric 75
Concentric vent/air termination assembly 78
DIRECT VENT: Vertical vent / sidewall air 79
Install vent/air piping — boiler to termination 82
DIRECT EXHAUST venting — general 83
DIRECT EXHAUST — Boiler room air openings 84
DIRECT EXHAUST — Sidewall 86
DIRECT EXHAUST — Vertical 89
Install vent/air piping — boiler to terminations 91
Gas piping — sizing gas lines 93
Field wiring — advanced 94
U-Control operation and setup — advanced 99
Annual startup and general maintenance 108
Annual startup 109
Troubleshooting 115
Maintenance 125
Replacement parts 128
Dimensions 136
Ratings — Ultra Series 4 boilers 137
Installation and Service Certicate 140
MAINTENANCE &
SPECIFICATIONS
(Pages 108–140)
This section covers maintenance requirements for
all boilers, repair parts lists, boiler dimensions and
specications.
BASIC INSTALLATION
Quick view . . .
Pages
Procedure
4
Please read before proceeding
y Read safety information before proceeding
5–6
Prepare boiler location
y Clearances, oor and foundation
y Air openings to room for ventilation
7–8
Prepare boiler
y Make sure vent/air piping can be connected
y Remove from crate
y Convert for propane, if required
y Hydrostatic test
y Place boiler in position
9–15
Install water piping
y Install boiler trim and near boiler piping
y Complete system piping and connections
16
Appliances left on an existing vent system
y For appliances remaining on a vent system aer old
boiler is disconnected — verify that the vent system
works for remaining appliances
16-26
Vent/air piping
y Locate air intake piping to prevent contaminants from
entering boiler
y Install vent/air termination
y Install vent and air piping using acceptable materials
27–28
Install condensate piping
y Connect condensate hose
y Install condensate pump and lter, if required
29
Gas piping
y Verify gas pipe size
y Connect boiler to gas line
30-31
Field wiring
y Connect wiring to boiler and components
32–34
U-Control operation and setup
y U-Control operation and setup information
35–42
Start-up
y Clean system, then ll; add inhibitor
y Verify water chemistry
y Purge air from system
y Perform nal checks
y Start and operate boiler
y Perform nal verication tests
y Fill out Installation and Service Certicate
BASIC INSTALLATION
ADVANCED INSTALLATION
(Pages 44–107)
Read and follow the instructions in the BASIC
INSTALLATION section rst. Then use the ADVANCED
section for additional information.
This section covers multiple boiler systems and
additional system types not covered under the BASIC
section. It also includes alternative vent/air piping
methods, water and gas pipe sizing guidelines and
advanced, detailed information on the U-Control.
Part number 550-100-440/0723
3
BASIC INSTALLATION
(Pages 4–42)
This section covers basic installation and start-up
for most applications. It is limited to conventional
systems and to sidewall vent/air piping using the
Weil-McLain termination cap.
For applications not covered in this section, see the
ADVANCED INSTALLATION section.
Part number 550-100-440/0723
4
series
4
gas-fired water boiler – boiler manual
Please read before proceeding
Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.
When servicing boiler —
y To avoid electric shock, disconnect all
electrical supplies to the boiler before
performing maintenance.
y To avoid severe burns, allow boiler to
cool before performing maintenance.
y is boiler contains ceramic ber and
berglass materials. Refer to the WARN-
ING and instructions on page109.
Boiler operation —
y Do not block flow of combustion or
ventilation air to boiler.
y Should overheating occur or gas supply
fail to shut o, do not turn o or discon-
nect electrical supply to pump. Instead,
shut off the gas supply at a location
external to the appliance.
Combustion air —
y
DO NOT install combustion air intake
where there is a risk of combustion air
contamination.
Carbon monoxide detector —
y
A carbon monoxide detector that is
wired on the same electrical circuit as
the boiler is strongly recommended.
SURGE PROTECTOR —
y
Provide surge protection in the boiler
power supply. is will reduce the pos-
sibility of damage to the boiler control.
Boiler water —
y e Ultra heat exchanger is made of
aluminum, and requires that system pH
always be between 7.0 and8.5 and water
chemistry be checked. Chemical treat-
ment may be necessary. ADDITIONAL
CHEMICAL TREATMENT MAY BE NECES-
SARY
. See page35 for details.
y oroughly ush the system (BEFORE
connecting boiler) to remove sediment.
e high-eciency heat exchanger can
be damaged by build-up or corrosion
due to sediment.
y Do not use petroleum-based cleaning
or sealing compounds in boiler system.
Gaskets and seals in the system may be
damaged. is can result in substantial
property damage.
y Continual fresh make-up water will
reduce boiler life. Mineral buildup in
eat 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 water. Use this boiler
ONLY in a closed-loop system.
y Do not add cold water to a hot boiler.
ermal shock can cause heat exchanger
to crack.
Freeze protection uids —
y NEVER use automotive or standard
glycol antifreeze. Use only freeze-protec-
tion uids made for hydronic systems.
Use only freeze-protection uids recom-
mended in this manual (see page140).
Follow all guidelines given by the anti-
freeze manufacturer. oroughly clean
and ush any replacement boiler system
that has used glycol before installing the
new Ultra boiler
Frozen Water Damage
Hazard
Residences or buildings that are unat-
tended in severely cold weather, boiler
system components failures, power out-
ages, or other electrical system failures
could result in frozen plumbing and water
damage in a matter of hours. For your
protection, take preventative actions such
as having a security system installed that
operates during power outages, senses low
temperature, and initiates an eective ac-
tion. Consult with your boiler contractor
or a home security agency.
If any part of a boiler, burner or its controls has
been sprayed with or submerged under water,
either partially or fully, DO NOT attempt to op-
erate the boiler until the boiler has been either
replaced or completely repaired, inspected, and
you are sure that the boiler and all components
are in good condition and fully reliable.
Otherwise, by operating this boiler, you will
cause a re or explosion hazard, and an electrical
shock hazard, leading to serious injury, death, or
substantial property damage. See the instructions
at right.
Saltwater Damage — e exposure of boiler components to
saltwater can have both immediate and long-term eects. While the
immediate eects of saltwater damage are similar to those of fresh-
water (shorting out of electrical components, washing out of critical
lubricants, etc.), the salt and other contaminants le behind can lead
to longer term issues aer the water is gone due to the conductive
and corrosive nature of the salt residue. erefore, Weil-McLain
equipment contaminated with saltwater or polluted water will no
longer be covered under warranty and should be replaced.
Electrical Damage — If any electrical component or wiring came
into contact with water, or was suspected to have come into contact
with water, replace the boiler with a new Weil-McLain boiler.
Commonwealth of
Massachusetts
When the boiler is installed within the Commonwealth of Massachusetts:
y is product must be installed by a licensed plumber or gas tter.
y If antifreeze is used, a reduced pressure back-ow preventer device shall be used.
y Sidewall vent air installations — see instruction on page65.
Installer— Read all instructions, including this
manual and all other information shipped with the
boiler, before installing. Perform steps in the order
given.
User — is manual is for use only by a qualied
heating installer/service technician. Refer to User’s
Information Manual for your reference.
User — Have this boiler serviced/inspected by a
qualied service technician, at least annually.
Failure to comply with the above could result in severe
personal injury, death or substantial property damage.
Write in the CP number in the space provided on
the Installation certicate on page140 if not already
shown.
When calling or writing about the boiler— Please
have the boiler model number from the boiler rating
label and the CP number from the boiler jacket.
Consider piping and installation when determining
boiler location.
Any claims for damage or shortage in shipment
must be led immediately against the transportation
company by the consignee.
Part number 550-100-440/0723
5
series
4
gas-fired water boiler – boiler manual
BASIC INSTALLATION
Figure 1 Clearances required
Prepare boiler location
Installations must comply with:
y Local, state, provincial, and national codes, laws, regulations and
ordinances.
y National Fuel Gas Code, ANSI Z223.1 /NFPA 54 – latest edition.
y Standard for Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1, when required.
y National Electrical Code.
y For Canada only: Natural Gas and Propane Installation Natural
Gas and Propane Installation
CAN/CSA
B149.1 or B149.2 Instal-
lation Code, CSA C22.1 Canadian Electrical Code Part 1 and any
local codes.
e Ultra boiler gas manifold and controls met safe
lighting and other performance criteria when boiler un-
derwent tests specied in ANSI Z21.13 — latest edition.
Before locating the boiler, check:
1. Check for nearby connection to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical power
• Condensate drain
2. Check area around boiler. Remove any combustible materials,
gasoline and other ammable liquids.
Failure to keep boiler area clear and free of combustible
materials, gasoline and other ammable liquids and
vapors can result in severe personal injury, death or
substantial property damage.
3. e 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:
• System leaks causing oxygen corrosion or heat exchanger cracks
from hard water deposits.
• Incorrectly-sized expansion tank.
• Lack of freeze protection in boiler water causing system and
boiler to freeze and leak.
Provide clearances:
Clearances from combustible materials
1. Hot water pipes — at least ½” from combustible materials.
2. Vent pipe — at least
3/16” from combustible materials.
3. See Figure1 for other clearance minimums.
Clearances for service access
1. See Figure1 for recommended service clearances. If you
do not provide minimum clearances shown, it might
not be possible to service the boiler without removing
it from the space.
Wall mounting option
1. Ultra boilers can be wall mounted (using special wall
mount kit) or oor mounted. No clearance is re-
quired at the rear of the unit
, either for service or
for clearance to combustible surfaces.
2. Boilers can be wall mounted ONLY if using the optional
wall-mount kit available from WM Technologies. See
page50 for instructions.
12" maximum above
floor of enclosure
12" maximum below
ceiling of enclosure
U3002
Air/ventilation openings when
required — see “Provide air
openings to room”
TOP:
Service —
12" min
Combustible
surfaces —
½" min
Right SIDE:
Service or
combustible
surfaces —
3" min
Left SIDE:
Service —
3" min
Combustible
surfaces —
½" min
BOTTOM:
Service —
0" min
Combustible
surfaces —
0" min
FLUE PIPE:
Combustible surfaces —
3/16” min —
Opening in combustible
wall, floor, ceiling or roof
3/8" larger than flue pipe
diameter, fitted with
galvanized steel thimble.
Combustible
surfaces —
½" min
FRONT:
Service —
24" min
Air/ventilation openings
(see instructions in this manual)
Part number 550-100-440/0723
6
series
4
gas-fired water boiler – boiler manual
Prepare boiler location (continued)
Flooring and foundation
Flooring
e Ultra boiler is approved for installation on combustible ooring,
but must never be installed on carpeting.
Do not install boiler on carpeting even if foundation
is used. Fire can result, causing severe personal injury,
death or substantial property damage.
Foundation
1. Provide a solid foundation pad, at least 2 inches above the oor, if
any of the following is true:
• oor can become ooded.
• the oor is dirt, sand, gravel or other loose material.
• the boiler mounting area is severely uneven or sloped.
2. e minimum foundation size is:
• Ultra-80 to -230: 24 inches wide x 20 inches deep.
• Ultra-299 to -399: 24 inches wide x 23 inches deep.
3. Foundation may be of wood, brick or concrete (minimum 2 inches
thick) construction.
4. If ooding is possible, elevate boiler suciently to prevent water
from reaching boiler.
Residential garage installation
Precautions
Take the following special precautions when installing the boiler in a
residential garage. If the boiler is located in a residential garage:
• Mount the boiler at a height above the oor as specied in
the National Fuel Gas Code, ANSI Z223.1 NFPA 54 for U. S.
installations, or Natural Gas and Propane Installation
CAN/
CSA
B149.1 and B149.2 for Canadian installations.
• Locate or protect the boiler so it cannot be damaged by a
moving vehicle.
• Ensure that the installation complies with all applicable codes.
Provide air openings to room
Air openings — Ultra boiler alone in boiler
room
1. No air ventilation openings into boiler room are needed
when clearances around Ultra boiler are at least equal
to the SERVICE clearances shown in Figure1,page5.
2. For spaces that do NOT supply this clearance, provide
two openings as shown in Figure1,page5. Each open-
ing must provide 1square inch free area per 1,000 Btuh
of boiler input.
Air openings — Ultra boiler in same space
with other gas or oil-red appliances
1. Follow the National Fuel Gas Code (U. S.) or Natural
Gas and Propane Installation
CAN/CSA
B149.1 and
B149.2 (Canada) to size/verify size of the combustion/
ventilation air openings into the space.
2. Size openings only on the basis of the other appliances in
the space. No additional air opening free area is needed
for the Ultra boiler because it takes its combustion air
from outside (direct vent installation).
e space must be provided with combus-
tion/ventilation air openings correctly
sized for all other appliances located in
the same space as the Ultra boiler.
Reinstall boiler jacket front door aer
servicing. e boiler front door must be
securely fastened to the boiler to prevent
boiler from drawing air from inside the
boiler room. is is particularly impor-
tant if the boiler is located in the same
room as other appliances.
Failure to comply with the above warn-
ings could result in severe personal
injury, death or substantial property
damage.
Part number 550-100-440/0723
7
series
4
gas-fired water boiler – boiler manual
BASIC INSTALLATION
Vent and air piping (page 16)
1. e Ultra boiler requires a special vent system, designed for pres-
surized venting. Ultra boilers are rated ANSI Z21.13 Category IV
(pressurized vent, likely to condense in the vent). See instructions
beginning on page16.
2. You must also install air piping from outside to the boiler air
intake adapter. e resultant installation is categorized as direct
vent (sealed combustion). Note prevention of combustion air
contamination on page16 when considering vent/air termination.
3. Vent and air must terminate near one another and may be vented
vertically through the roof or out a side wall. You may use any of
the vent/air piping methods covered in this manual. Do not attempt
to install the Ultra boiler using any other means.
4. Be sure to locate the boiler such that the vent and air piping can be
routed through the building and properly terminated. e vent/air
piping lengths, routing and termination method must all comply
with the methods and limits in instructions beginning on page16.
Remove boiler from crate
Cold weather handling — If boiler has been stored in a
very cold location (below 0°F) before installation, handle
with care until the plastic components come to room
temperature.
1. e Ultra boiler is generally easier to handle and maneuver aer
removing from crate.
2. Aer removing outer shipping carton from boiler, REMOVE jacket
front door by loosening two (2) screws at lower front. Removing
the door will prevent possible damage to the door during handling.
3. To remove boiler from pallet (aer 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 oor or pallet.
Damage to boiler can result.
Prepare boiler
Prepare boiler for propane
(when required)
Propane operation
Ultra boilers must be converted
for propane operation unless spe-
cically manufactured for propane
.
Propane-ready boilers have sux “LP”
aer the model number. All other boilers
require conversion for propane opera-
tion.
Refer to propane conversion instructions
beginning on page48.
Failure to comply could result in severe
personal injury, death or substantial
property damage.
Placing oor-mounted boilers
1. Set boiler in place and check level.
a. Adjust legs, if necessary to level boiler.
Wall-mounted boilers
1. Boilers can be wall mounted ONLY if using the optional
wall-mount kit available from WM Technologies. See
page50 for instructions.
Part number 550-100-440/0723
8
series
4
gas-fired water boiler – boiler manual
Prepare boiler (continued)
DO NOT install a relief valve with a pressure higher
than 30 PSIG
. is 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 Figure2 for reference in following steps.
2. Remove supply line tees* and 3/4” elbow from accessory bag.
Pipe to boiler supply connection as shown. Use pipe dope spar-
ingly. (* 1”x1”x1/4” and *1”x1”x3/4” tees with Ultra-80 to -230
or * 1-1/4”x1-1/4”x1/4” and *1-1/4”x1-1/4”x3/4” tees 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 aer test.
5. Connect a nipple and shuto valve to system supply connection
on the supply tee. is valve will be used to bleed air during the
ll. (Valve and nipple are not included with boiler.)
6. Connect a shuto 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 shuto valves and attach catch-buckets beneath.
8. If convenient, install the boiler circulator and any other piping
compatible with Figure2 that would still allow bleeding air from
shuto valves.
9. Follow guidelines in this manual for piping components, locations
and sizing.
Fill and pressure test
1. Open the shuto valves you installed on supply and return con-
nections.
2. Slowly open boiler drain valve and fresh water supply to ll boiler
with water. e boiler will ll quickly because of its low water
content.
3. When water reaches shuto valves, close boiler drain valve.
4. Close shuto valves.
5. Slowly reopen boiler drain valve until test pressure on the pres-
sure/temperature gauge reaches at least 45 psig, but no higher
than 55 psig.
6. Hold at test pressure for 10 minutes.
Do not leave boiler unattended. A cold water ll could
expand and cause excessive pressure, resulting in severe
personal injury, death or substantial property damage.
7. Make sure constant gauge pressure has been maintained through-
out test. Check for leaks. Repair if found.
Leaks must be repaired at once. Failure to do so
can damage boiler, resulting in substantial property
damage.
Do not use petroleum-based cleaning or seal-
ing compounds in boiler system. Gaskets and
seals in the system may be damaged. is can
result in substantial property damage.
Drain and remove ttings
1. Disconnect ll water hose from water source.
2. Drain boiler through drain valve. Remove hose aer
draining.
3. Remove nipples and valves unless they will remain for
use in the system piping.
4. Remove plug from relief valve street elbow. See page9
to install relief valve.
Figure 2 Hydrostatic test piping connections
Part number 550-100-440/0723
9
series
4
gas-fired water boiler – boiler manual
BASIC INSTALLATION
Install water piping
Use two wrenches when tightening water piping at boiler,
using one of the wrenches to prevent the boiler interior
piping from turning. Failure to support the boiler piping
connections to prevent them from turning could cause
damage to boiler components.
General piping information
Additional controls, when required
e U-Control module uses temperature sensors to
provide both high limit protection and modulating tem-
perature control. e U-Control module also provides
low water protection by sensing the temperature of the
heat exchanger. Some codes/jurisdictions may require
additional external controls for high limit and/or low
water cuto protection.
Additional limit controls
Following standard industry practices, if installation is to comply with
ASME or Canadian requirements, an additional high temperature limit
may be needed. Consult local requirements for other codes/standards
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
boiler and isolation valve. (Note that the U-Control module op-
erating limit function shuts the boiler down at 195°F, or lower if
set to a lower value.)
Multi-temperature systems — If the heating system
includes circuits that require lower temperature water
(radiant slab circuits, for example) as well as higher
temperature circuits, it is recommended to protect low-
temperature circuits with limit controls that are wired to
a U-Control external limit circuit (P13 terminals1 and2
for manual reset, or P13 terminals3 and4 for automatic
reset).
2. See instructions beginning on page30 for wiring information.
a. Manual reset operation: If external limit controls are to cause
manual reset of the U-Control module, connect series-wired
isolated contacts to P13 terminals 1 and 2 (see page30 for wir-
ing information).
b. Automatic reset operation: If external limit controls are to
cause
automatic reset of the U-Control module, connect
series-wired isolated contacts to P13 terminals 3 and 4 (see
page30 for wiring information).
c. If using a manual reset limit control or wiring in the manual
reset circuit, set U-Control boiler limit at least 20°F less than
the external manual reset limit (i.e., set U-Control no higher
than 180°F for a 200°F external limit, for example).
Separate low water cutoff
1. A low water cuto device is recommended when the boiler is in-
stalled above piping level, and may be required by certain state or
local codes or insurance companies. Consult local requirements to
determine. See the NOTICE above regarding the inherent protec-
tion provided by the U-Control module.
2. e U-Control’s integral protection is accepted in many jurisdic-
tions as meeting the requirement for low water protection. See
page95 for details.
3. When required, use a low water cuto designed for water
installations. Electrode probe-type is recommended. See
Replacement parts section at the end of this manual for
the Weil-McLain low water cut-o kit.
4. Purchase low water cuto and install in a tee in the sup-
ply piping above boiler.
5. See eld wiring instructions beginning on page30 for
wiring additional limit controls.
Backow preventer
1. Use backow check valve in cold water supply as re-
quired by local codes.
Install relief valve
1. Install relief valve in ¾” street elbow piped from boiler
supply piping tee (Figure2,page8). Pipe the relief valve
only as shown, in the location shown.
2. Connect discharge piping to safe disposal location, fol-
lowing guidelines in the
WARNING below.
To avoid water damage or scalding
due to relief valve operation, as per
local or state codes
:
Discharge line must be connected to relief
valve outlet and run to a safe place of
disposal. Terminate the discharge line in
a manner that will prevent possibility of
severe burns or property damage should
the valve discharge.
Discharge line must be as short as pos-
sible and be the same size as the valve
discharge connection throughout its
entire length.
Discharge line must pitch downward from
the valve and terminate at least 6” above
the oor drain where any discharge will
be clearly visible.
e discharge line shall terminate plain,
not threaded, with a material serviceable
for temperatures of 375 °F or greater.
Do not pipe the discharge to any place
where freezing could occur.
No shuto valve shall be installed be-
tween the relief valve and boiler, or in the
discharge line. Do not plug or place any
obstruction in the discharge line.
Test the operation of the valve aer ll-
ing and pressurizing system by liing
the lever. Make sure the valve discharges
freely. If the valve fails to operate cor-
rectly, replace it with a new relief valve.
Failure to comply with the above guide-
lines could result in failure of the relief
valve to operate, resulting in possibility
of severe personal injury, death or sub-
stantial property damage.
Part number 550-100-440/0723
10
series
4
gas-fired water boiler – boiler manual
Install water piping (continued)
System water piping methods
All piping methods shown in this manual use primary/
secondary connection to the boiler loop. ese designs
ensure proper ow through the Ultra boiler, for the most
ecient and reliable operation of the boiler and the heat-
ing system. For other piping methods, consult your local
WM Technologies representative or see separate Ultra
boiler piping guides.
Circulators
e boiler circulator (Taco 007 for Ultra-80 and -105; Taco 0014 for
Ultra-155, -230, and -299; Taco 0013 for Ultra-399) is shipped loose.
Locate it in the return piping, as shown in the appropriate piping
diagram in this manual.
DO NOT use the boiler circulator in any location other
than the ones shown in this manual. e boiler circula-
tor is selected to ensure adequate ow through the Ultra
boiler.
Install the boiler circulator only on the boiler return pip-
ing. is ensures the pressure drop through the boiler
will not cause low pressure in the circulator intake.
Failure to comply could result in unreliable performance
and nuisance shutdowns from insucient ow.
Circulator ow rate
Size circulators based on the ow rate required to achieve the tem-
perature change needed. You can closely estimate temperature rise (or
drop) through a circuit by using the following formula, where TD is
temperature rise (or drop), FLOW is ow rate (in gpm), and BTUH is
the heat load for the circuit:
FLOW =
BTUH
—–—–—–—–
TD x 500
Examples:
Consider a system loop for a system with total heating load equal to
210,000 Btuh. e desired temperature drop through the system piping
is 20°F. en the required ow rate is:
FLOW =
210,000
—–—–—–—–
20 x 500
= 21 gpm
SIMPLIFIED: For 20° temperature drop, FLOW = MBH / 10.
Circulator head requirement
e circulator must be capable of delivering the required ow against
the head loss that will occur in the piping. Determine the pipe size
needed and the resultant head loss using accepted engineering meth-
ods. e simplied pipe sizing here is limited to residential systems,
and does not include systems with fan coil units or radiant tubing.
e following simplied method for pipe and circulator
sizing must be limited to residential applications using
baseboard (nned or cast iron), cast iron radiators or
convectors. DO NOT apply for radiant heating, fan coil
units or commercial installations.
Simplied pipe/circulator selection
1. Install the boiler and piping using the recommended
piping layouts beginning on page12 and in the AD-
VANCED section of this manual.
2. Size the piping and components for each circuit in the
space heating system using Figure3.
At the ow rates
listed, the head loss in all piping will be 0.04 feet
per foot of pipe.
a. Determine the heating load (Btuh) for each circuit.
b. Calculate the ow rate for each circuit using its load.
To use a 20°F temperature drop, just divide the
MBH (1,000’s of Btuh) by 10.
Example — Flow for 20°F temp drop with 35,000 Btuh:
FLOW = 35MBH / 10 = 3.5 gpm
c. Find the pipe size in Figure3 that has a max ow rate just
larger than that required for the circuit.
d. Find the total equivalent length (TEL) of the circuit.
TEL accounts for losses through ttings and valves by
using the equivalent length of pipe that would cause the
same head loss. Add these numbers to the measured length
of the circuit to nd TEL in feet.
TEL is usually close to 1.5 times the length of
the circuit for residential baseboard, radiator or
convector applications.
e. Measure the length of each circuit from the circulator
outlet back to its inlet. en multiply this length times
1.5 to get the approximate TEL of the circuit.
f. Find the head loss for each circuit:
TEL = 1.5 X Circuit Length
(feet)
HEAD = TEL X 0.04
(feet water column)
g. NOTE: Size system header piping for the total ow of all
connected zones.
3. Example:
a. For a circuit with heating load = 45,000 Btuh (= 45 MBH).
Measured length of circuit is 88 feet.
b. Flow = 45 MBH / 10 = 4.5 gpm.
c. TEL = 1.5 x 88 feet = 132 feet.
d. From Figure3, select 1" pipe (max ow = 7.1 gpm).
e. Head loss = TEL x 0.04 = 132 x 0.04 = 5.28 feet.
f. Select a circulator that can deliver at least 4.5gpm at a
head of 5.28feet. (Read the NOTICE below.)
To use this method, limit the ow through
¾" nned-tube baseboard to 3.9 gpm, or use
1" baseboard and limit ow to 7.1 gpm. If the
total load of the circuit requires more ow,
split the circuit into two or more.
Also see Figure9,page15 for quick-selection
information for applications using Taco 007
circulators or equivalent for zone piping.
Figure 3
Flow rates for 0.04 feet head loss per foot of
pipe
(140°F water)
Pipe size
(inches)
MAX Flow rate (GPM)
@ 0.04 feet per foot
Pipe size
(inches)
MAX Flow rate (GPM)
@ 0.04 feet per foot
¾ 3 9 2 45
1 7 1 2½ 75
1¼ 16 3 140
1½ 24 4 290
Part number 550-100-440/0723
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BASIC INSTALLATION
Install water piping (continued)
Expansion tank and make-up water
1. Ensure expansion tank size will handle boiler and system water
volume 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 ll 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 separator
is on the suction side of the circulator. Always install the system
ll connection at the same point as the expansion tank connection
to the system.
4. Most piping drawings in this manual show diaphragm expansion
tanks. See Figure4 for piping from air separator to expansion tank
and make-up water line using a closed-type expansion tank.
5. Most chilled water systems are piped using a closed-type tank, as
shown in Figure51,page55.
Diaphragm (or bladder) expansion tank
1. (Figure4) 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 Figure4, 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-
tomatic air vent would cause air to leave system, resulting
in water-logging the expansion tank.
DO NOT use a closed-type expansion tank on a system
with a Weil-McLain AQUA PLUS water heater. e 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.
Figure 4 Expansion tank piping
Use at least the MINIMUM pipe size shown in
Figure4 on all boiler loop piping (connecting boiler
to and from the primary/secondary connection,
item9).
Use only primary/secondary piping
as shown.
Failure to follow these guidelines could
result in system problems.
MINIMUM
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1”
1¼”
1½”
See CAUTION at left.
MINIMUM
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1”
1¼”
1½”
See CAUTION at left.
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
Legend — Figure 5
1 Ultra boiler
2 Indirect water heater (DHW), if used
3 Boiler relief valve (see page9 for piping details)
4 Relief valve discharge piping (see page9 for details)
5 DHW circulator (see page56 for suggested sizing)
6 Isolation valves
7 System circulator (see information above for wiring)
8 Diaphragm (or bladder) type expansion tank (see page56 for piping of
closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
10 Flow/check valves
11 Purge/drain valves
12 Boiler circulator
13 Zone valves, typical
20 Make-up water supply
21 Primary/secondary connection
23 DHW connections — see water heater manual for piping
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.
25 Systems using high-head pumps may require a bypass pressure regulator
to prevent damage to control valves.
26 Temperature/Pressure gauge
27 DHW relief valve, if used
Items supplied with boiler
Items supplied by others
Install water piping — typical systems
Figure 5 Zone valve zoning plus optional DHW piping
Zoning with zone valves
1. Connect boiler to system as shown in Figure5 when zone valve
zoning. e primary/secondary piping shown ensures the boiler
loop will have sucient ow. It also avoids applying the high head
of the boiler circulator to the zone valves. Also see the information
on page14 and page15 for suggested piping and sizing.
Use at least the MINIMUM pipe size shown in Figure5
on all boiler loop piping (connecting boiler to and from
the primary/secondary connection, item21). Use only
primary/secondary piping as shown.
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 Figure4,page11. (DO
NOT use a closed-type tank with a AQUA PLUS water heater.)
3. Connect DHW (domestic hot water) piping to indirect storage
water heater as shown.
By default, the U-Control Module turns o space heating
during DHW heating (if DHW input is priority 1). e
boiler circulator will turn o, preventing hot water from
circulating to the system (optional time out setting can
be used to override). e ow/check valve shown on the
boiler outlet piping prevents gravity circulation in the
boiler loop during DHW heating.
Overriding the Outdoor Reset function by setting control to
DHW mode when system is intended for space heating may
violate Section 303 of the 2007 Energy Act. See page137 for
compliance information and exemptions.
4. Controlling the circulators
a. e U-Control can control up to three circulators (boiler cir-
culator and two others). Refer to Field wiring, beginning on
page30, for instructions on wiring to circulators.
b. e factory default settings are: DHW circulator as Circula-
tor1, boiler circulator as Circulator2 and system circulator
as Circulator3. See Field wiring instructions, beginning on
page30, for details.
Other piping alternatives
See page14 and page15 and ADVANCED INSTALLATION section for additional piping suggestions.
MINIMUM
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1”
1¼”
1½”
See CAUTION at left.
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
BASIC INSTALLATION
Legend — Figure 6
1 Ultra boiler
2 Indirect water heater (DHW), if used (see page56)
3 Boiler relief valve (see page9 for piping details)
4 Relief valve discharge piping (see page9 for details)
5 DHW circulator (see page56 for suggested sizing)
6 Isolation valves
7 System circulator (see information above for wiring)
8 Diaphragm (or bladder) type expansion tank (see page56 for piping of
closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
10 Flow/check valves
11 Purge/drain valves
12 Boiler circulator
14 Zone circulators, typical
20 Make-up water supply
21 Primary/secondary connection (tees no more than 12 inches apart)
23 DHW connections — see water heater manual for piping
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.
26 Temperature/Pressure gauge
27 DHW relief valve, if used
Items supplied with boiler
Items supplied by others
Install water piping — typical systems (continued)
Figure 6 Circulator zoning plus optional DHW piping
Zoning with circulators
1. Connect boiler to system as shown in Figure6 when circulator
zoning. e boiler circulator cannot be used for a zone. It must
supply only the boiler loop. Also see the information on page14
and page15 for suggested piping and sizing.
Use at least the MINIMUM pipe size shown in Figure6
on all boiler loop piping (connecting boiler to and from
the primary/secondary connection, item21). Use only
primary/secondary piping as shown.
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 Figure4,page11. (DO
NOT use a closed-type tank with a AQUA PLUS water heater.)
4. Connect DHW (domestic hot water) piping to indirect storage
water heater as shown.
By default, the U-Control Module turns o space heat-
ing during DHW heating (if DHW input is priority 1).
e boiler circulator will turn o, preventing hot water
from circulating to the system (optional timeout setting
can be used to override). e ow/check valve shown
on the boiler outlet piping prevents gravity circulation
in the boiler loop during DHW heating.
Overriding the Outdoor Reset function by setting control to
DHW mode when system is intended for space heating may
violate Section 303 of the 2007 Energy Act. See page137 for
compliance information and exemptions.
5. Controlling the circulators
a. e U-Control can control up to three circulators (boiler cir-
culator and two others). Refer to Field wiring, beginning on
page30, for instructions on wiring to circulators.
b. e factory default settings are: DHW circulator as Circulator1,
boiler circulator as Circulator2. See Field wiring instructions,
beginning on page30, for details.
c. e zone circulators in Figure6 must be controlled by circula-
tor relays activated by the zone thermostats or zone controller.
Other piping alternatives
See page14 and page15 and ADVANCED INSTALLATION section for additional piping suggestions.
MINIMUM
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1”
1¼”
1½”
See CAUTION at left.
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
Using with Weil-McLain AQUA PLUS water heaters
See AQUA PLUS - Product Manual for typical water piping.
AQUA PLUS DHW installation — quick-
selection
e information in this section is for usage of Ultra boilers
with Weil-McLain AQUA 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 o space heating dur-
ing DHW heating (if DHW input is priority 1). e boiler cir-
culator will turn o, 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 AQUA PLUS water heater. e 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 tank with AQUA PLUS water heaters.
1. Follow the guidelines on this page and page15 to connect the water
heater to the boiler. Use Figure8 for dedicated water heating-only ap-
plications. Use Figure9,page15 and Figure10,page15 for combined
space heating/water heating applications.
See ADVANCED INSTALLATION section for additional piping information and applications.
Figure 7 Use the table below to size DHW loop piping and select a circulator (see ADVANCED section for other DHW tanks)
Boiler
Ultra
Partial load (see Figure 9, page 15 and Figure 10, page 15)
(combined space heating/water heating application)
Dedicated boiler (see Figure 8)
(water heating only)
PLUS
model
GPM MBH
115/140
GPH
115/140
Head
loss (ft)
DHW
pipe size
CIRC PLUS
model
GPM MBH
115/140
GPH
115/140
Head
loss (ft)
DHW
pipe size
CIRC
-80
(71 MBH)
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
-105
(94 MBH)
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
-155
(139 MBH)
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
-230
(207 MBH)
40 13.5 120/100 251/162 15.2 1¼ 0014 40
Not recommended — boiler capacity
exceeds maximum output of water heater
60 18.4 169/128 350/207 23.7 1½ 1400-20 60
80 13.5 207/207 430/325 15.2 1¼ 0014 80 13.5 207/207 430/325 15.2 1¼ 0014
-299
(252 MBH)
40 13.1 120/100 250/162 9.7 1¼ 0010 40
Not recommended —
boiler capacity exceeds
maximum output of water heater
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
-399
(365 MBH)
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 24.9 320/253 636/382 18.4 1½ 1400-20 80
Figure 8 Ultra boiler with AQUA PLUS water heater —
dedicated water heating application, typical piping
schematic
10
12
8
20
9
U3022
27
23
2. e AQUA PLUS water heater can also be installed
as one of the zones in the system. is method,
however, requires ow through the main system
even during the summer (non-space heating)
months. Piping as shown in Figure9,page15 and
Figure10,page15 allows isolation of ow to just
the water heater piping during non-heating periods.
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
BASIC INSTALLATION
U3020
27
13
13
7
8
20
Additional
Zones
9
Do not exceed
12 inches apart
21
13
5
10
10
12
ZONE 2
ZONE 1
23
24
24
25
27
U3021
10
14
14
10
8
9
5
10
20
Additional
Zones
10
Do not exceed
12 inches apart
21
14
10
ZONE 2
ZONE 1
12
23
2424
Legend for Figure9 and Figure10
5 DHW circulator (see page56 for sug-
gested sizing)
7 System circulator (provided by installer)
8 Diaphragm type expansion tank ONLY
— DO NOT use a closed-type tank with
AQUA PLUS water heaters, because the
automatic air vent will deplete the air
from the system, causing the expansion
tank to waterlog.
9 Air separator with automatic air vent
10 Flow/check valves
12 Boiler circulator — provided with boiler
13 Zone valves, typical
20 Make-up water supply
21 Primary/secondary connection
23 DHW connections — see water heater
manual for piping
24 Strap system supply and return sensors
to lines as shown, at least 6 pipe diam-
eters (but no more than 3 feet) from
boiler connection tees.
25 Systems using high-head pumps may
require a bypass pressure regulator to
prevent damage to control valves.
27
DHW relief valve must be installed in the
tapping on top of the AQUA PLUS water
heater.
Items supplied with boiler
Items supplied by others
Zone valve zoning
System/zone pipe sizing
(Baseboard, convector or cast iron
radiators ONLY)
For residential space heating appli-
cations (other than radiant heating
or unit heaters) ONLY, you can use:
Ultra Model System header
-80
-105, -155
-230
-299, 399
1” or larger
1¼” or larger
1½” or larger
2” or larger
Recommendations are based on a 20°F temp
drop through the system.
Zone piping selection for series loops
with nned-tube baseboard — general
Copper pipe and
baseboard size
Max recommended
feet of baseboard
¾"
1"
106
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
nned-tube baseboard using
Taco 007 (or equivalent) circulators
Copper
pipe and
baseboard
Max
load
MBH
Max feet of
baseboard
Max total
length of
circuit (feet)
¾"
1"
50
79
82
104
93
123
Circulator zoning
Figure 9 Ultra boiler with Ultra PLUS or AQUA PLUS-40, -60 or -80 water heater, zone valve zoning, typical piping
12
20
23
27
10
10
7
5
9
8
Boiler loop pipe size
Ultra-80, -105
Ultra-155, -230
Ultra-299, 399
1” or larger
1¼” or larger
1½ or larger
DHW loop pipe size
See Figure 7, page 14
Figure 10 Ultra boiler with AQUA PLUS water heater, typical piping schematics
Using with Weil-McLain AQUA PLUS water heaters
(cont.)
See AQUA PLUS - Product Manual for typical water piping.
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
Venting/air piping — general
Figure 11 Corrosive contaminants and sources
Do not install the Ultra boiler into a common vent with
any other appliance. is will cause ue gas spillage or ap-
pliance malfunction, resulting in possible severe personal
injury, death or substantial property damage.
Existing common vent systems may be too large for the
appliances remaining connected aer the existing boiler
is removed.
Failure to follow all instructions can result in ue gas
spillage and carbon monoxide emissions, causing severe
personal injury or death.
Use ONLY the venting materials and venting manufac-
turers’ components and systems approved by WM Tech-
nologies. Follow all instructions provided by the venting
component and system manufacturer. Failure to do so can
cause ue gas spillage and carbon monoxide emissions,
resulting in severe personal injury or death.
Replacing a boiler from an existing common
vent system
The Ultra boiler cannot be common vented with any other appli-
ance
. When an existing boiler is replaced with an Ultra boiler, the Ultra
boiler CANNOT use the existing common vent. e Ultra boiler requires
its own vent and air piping, as specied in this manual. is may cause a
problem for the appliances that remain on the old common vent, because
the vent may be too large.
Perform the test sequence below for each appliance remaining on the
original common vent system. Operate each appliance individually with
other appliances turned o. is procedure will test whether the common
vent system can properly vent each appliance.
Existing vent test procedure
(The following is intended to test whether the appliances remaining on an
existing vent system will operate satisfactorily.)
1. Visually inspect the venting system for proper size and horizontal pitch
and determine there is no blockage or restriction, leakage, corrosion or
other deciencies which could cause an unsafe condition.
2. Test vent system — Insofar as is practical, close all building doors and
windows and all doors between the space in which the appliances
remaining connected to the common venting system are located and
other spaces of the building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so they will oper-
ate at maximum speed. Do not operate a summer exhaust fan. Close
replace dampers.
3. Place in operation the appliance being inspected. Follow the lighting
instructions. Adjust thermostat so appliance will operate continuously.
4. Test for spillage at dra hood relief opening aer 5 minutes of main
burner operation. Use the ame of a match or candle, or smoke from
a cigarette, cigar, or pipe.
5. Aer it has been determined that each appliance remaining connected
to the common venting system properly vents when tested as outlined
herein, return doors, windows, exhaust fans, replace dampers, and
any other gas-burning appliance to their previous conditions of use.
Any improper operation of common venting system should be corrected so
the installation conforms with the National Fuel Gas Code, ANSI Z223.1
— latest edition. Correct by re-sizing to approach the minimum size as
determined using the appropriate tables in Part13 of that code. Canadian
installations must comply with B149.1 or B149.2 Installation Code.
Products to avoid
Spray cans containing chloro/uorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents found in
household laundry rooms
Adhesives used to fasten building products and other similar products
Excessive dust and dirt
You must provide combustion air.
Direct vent — Install air inlet piping for the Ultra
boiler as described in the Boiler manual and this ad-
dendum. e air termination tting must be installed
with the clearances and geometry relative to the vent
outlet depicted in this manual to ensure that ue
products do not enter the air intake.
Direct exhaust — Provide combustion air openings
to boiler room/building as specied in this adden-
dum and as required by all applicable codes.
Ensure that the combustion air will not contain
any of the contaminants in Figure 11
. DO NOT
place combustion air supply opening or intake near
a swimming pool, for example. Avoid areas subject
to exhaust fumes from laundry facilities. ese areas
will always contain contaminants.
Contaminated combustion air will damage the boiler,
resulting in possible severe personal injury, death or
substantial property damage.
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture renishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
Buildings under construction (where air is contaminated
with particulates)
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
BASIC INSTALLATION
Venting/air piping — general (continued)
Ultra Boilers must be vented and supplied
with combustion and ventilation air using
piping and methods described in this
manual
.
Every boiler must have its own vent. DO
NOT
common vent with any other appliance.
See page16.
Inspect nished vent and air piping thoroughly
to ensure all are airtight and comply with the
instructions provided and with all requirements
of applicable codes.
Failure to provide a properly-installed vent and
air system will cause severe personal injury or
death.
Venting/combustion air piping - Installations
must provide provisions for combustion and
ventilation air in accordance with the sec-
tion “Air for Combustion and Ventilation,” of
the National Fuel Gas Code - ANSI Z223.1/
NFPA54 – latest edition, or Sections 8.2, 8.3,
or 8.4 of Natural Gas and Propane Installation
Code - CAN/CSA B149.1, or applicable provi-
sions of the local building codes.
Use only the materials listed in this manual for
vent and air pipe and ttings. Failure to comply
could result in severe personal injury, death or
substantial property damage.
If used, a masonry chimney can ONLY be
used as a PIPE CHASE for vent and air pipes
— e vent and air piping must be installed as
instructed in this manual and all joints must be
sealed. e chimney must be used only for Ul-
tra boilers. NO OTHER appliance or replace
can be connected to the chimney.
e chimney must be straight, with no osets,
and the vent and air piping materials must
comply with this instruction manual.
e chimney must be tted with a sealed ac-
cess opening, through which the interior of the
chimney can be inspected.
e chimney and liner must be inspected at
least once annually to verify condition.
Failure to comply could result in severe personal
injury, death or substantial property damage.
Combustion air piping
1. Combustion air must be piped from outside to the boiler, fol-
lowing the instructions in this manual, and compliant with
all applicable codes. Read the warning in Figure11,page16,
and ensure the air intake will not be likely to draw in con-
taminated air.
2. Combustion air can be piped individually for each boiler, or
it can be manifolded as shown in Figure59,page59. Air pip-
ing must always terminate on the same side (or roof ) of the
building as the vent.
Vent piping
1. Boiler ue gases must be piped from the boiler to outside, fol-
lowing the instructions in this manual, and compliant with all
applicable codes. e vent pipe must terminate either through
the sidewall or through the roof, located with the correct
separation from the air termination. See Figure14,page20,
and the associated instructions referenced.
2. Each Ultra boiler requires a separate vent. Do not common
vent.
Vent and air piping materials
1. See Figure13,page19 for approved vent and air piping ma-
terials.
Part number 550-100-440/0723
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Venting & air — general (cont.)
Figure 12 Vent and air pipe options and maximum allowable piping lengths
Ultra model
Vent or air
pipe size
• Maximum equivalent feet of piping
• Number of elbows allowed at these lengths
(All applications include allowance for the terminations.)
Direct vent
Sidewall
with
Weil-McLain
vent/air cap
Direct vent
Sidewall with
separate pipes
— or —
Direct exhaust
(sidewall or vertical)
3” Concentric
Sidewall or Vertical
DO NOT use CPVC
or ABS
[Note 1]
4” Concentric
Sidewall or Vertical
DO NOT use CPVC
or ABS)
[Note 1]
Direct vent
Vertical
with separate
pipes
Direct vent
Vertical exhaust
Sidewall air
Direct vent
only
Direct vent or
Direct exhaust
Direct vent
only
Direct vent
only
Direct vent
only
Direct vent
only
Length Ells Length Ells Length Ells Length Ells Length Ells Length Ells
-80/105
2” * 100 (ab) 2 100 (a) 2 100 (ab) 1 NA 100 (a) 1 100 (a) 1
3” 100 2 100 2 100 1 NA 100 1 100 1
-155
3” 100 2 100 2 100 1 NA 100 1 100 1
-230
3” 30 (c) 2 30 (c) 2 30 (c) 1 30 (c)(d) 1 30 (c) 1 30 (c) 1
4” 100 (d) 2 100 2 70 (d) 1 100 1 100 1 100 1
-299
4” 100 2 100 2 70 (d) 1 100 1 100 1 100 1
-399
4” 100 2 100 2 NA 100 1 100 1 100 1
Note 1:
IPEX 3” and 4” PVC concentric vent kits can be used with standard PVC pipe, ttings and cement (ANSI/ASTM D1785)
except where ULC S636 compliance is required. For ULC S636 compliance, all pipe, ttings and cement must be IPEX
System 636. For UL 1738 compliance all pipe, ttings and cement must be IPEX System 1738. When using IPEX kits, use
only IPEX product code 196006 for 3” venting or IPEX product code 196021 for 4” venting.
Contact WM Technologies for ordering information and availability of Weil-McLain venting kits.
Polypropylene - Separate pipe and concentric termination by respective manufacturers.
Additional
notes
a —
Use 3”x2” reducer at boiler
b —
Use 3”x2” reducers at termination
c —
Use 4”x3” reducer at boiler
d —
Use 4”x3” reducers at termination
* Ultra-80 and 105 boilers installed with 2-inch vent piping automatically derate due to the pressure loss in the vent and air
piping. e derate ranges up to 10% for the Ultra-80 at 100 feet or 15% for the Ultra-105 at 100 feet.
Equivalent feet for elbows — deduct from maximum equivalent length of pip-
ing:
PVC • 7 feet per for each 4-inch elbow & 2 or 3-inch 90° long-radius or 45° elbow
• 16 feet for each 2- or 3-inch short-radius elbow
PP • Centrotherm 3” = 6’ 4” = 20’ Duravent 3” = 17’ 4” = 22’
Stainless steel (AL29-4C) vent pipe
install an adapter at the boiler for all applications. Also install
an adapter at the termination unless using separate-pipe
termination.
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BASIC INSTALLATION
Venting & air — general (cont.)
Figure 13 Vent and air piping materials — Use only the materials listed below, ensuring that all materials meet local codes
Item Material
Standards for installations in:
United States Canada
Plastic piping materials
Vent or air pipe
&
ttings
PVC schedule 40 ANSI/ASTM D1785/UL1738/ULC S636
Plastic vent pipe must be certied to
ULC S636 when required. (Note 2)
Air pipe can be any of those listed at left
if acceptable for local codes.
PVC-DWV (Note 1) ANSI/ASTM D2665
CPVC schedule 40 (Note 1) ANSI/ASTM F441/ULC S636
ABS-DWV schedule 40 (Note 1) ANSI/ASTM D2661
PVC & ABS pipe
cement & primer
PVC ANSI/ASTM D2564/UL1738
CPVC (Note 1) ANSI/ASTM F493
ABS (Note 1) ANSI/ASTM D2235
Polypropylene
vent pipe, ttings,
terminations
Simpson-Duravent — Obtain all materials from M&G
Simpson-Duravent
Centrotherm Eco Systems InnoFlue® Single-wall
— Obtain all materials from Centrotherm
See manufacturer’s literature for detailed information
MUST USE LOCKING COLLAR ON EVERY
JOINT
ULC S636
AL29-4C piping materials
Vent pipe
AL29-4C
stainless
steel
Heat Fab, Inc. — Saf-T-Vent
®
Z-Flex, Inc. — Z-Vent II
Simpson Dura-Vent — FasNSeal™
Certied for Category IV and direct vent
appliance venting
Certied for Category IV and direct vent
appliance venting
Weil-McLain bird screens (purchase separately)
Weil-McLain
bird
screens
For 2” or 3” vent or air termination
(cut to size if necessary)
3” vent screen:
W-M part number 383-500-105
For 3” or 4” vent or air termination
(cut to size if necessary)
4” vent screen:
W-M part number 383-500-110
Note 1: DO NOT use DWV, CPVC or ABS when using concentric vent termination. Use ONLY PVC schedule 40.
Note 2: IPEX PVC concentric terminations utilize PVC pipe/ttings certied to ULC S636. Where ULC S636 compliance is required, use only IPEX System 636 pipe, ttings
and cement. If UL1738 compliance is required, use only System 1738 pipe, ttings and cement.
AL29-4C vent piping — Install a PVC-to-stainless adapter supplied by the vent pipe manufacturer at the boiler vent connection and at the termination (when using
Weil-McLain plate or concentric PVC termination). DO NOT mix piping from dierent vent pipe manufacturers unless using adapters specically designed for the
purpose by the manufacturer.
Plastic piping — Do not attempt to connect dierent types of plastic piping together.
DO NOT use cellular core pipe.
All vent and air pipes require a bird screen at each termination where specied in the manual or vent supplement. Purchase bird screens separately from WM
Technologies or vent kit supplier. Note that most kits do not include the screens.
For boilers allowed to utilize polypropylene vent systems.
Tests have determined that ex vent has a greater pressure drop than rigid polypropylene vent
which changes the maximum allowable length of venting. Below are the equivalent lengths.
Supplier and Size of Flex Pipe Vent Length - Equivalent
Duravent 2” diameter - 1 foot 3.3
Duravent 3” diameter - 1 foot 1.7
Duravent 4” diameter - 1 foot 3.0
Centrotherm 2” diameter - 1 foot 5.0
Centrotherm 3” diameter - 1 foot 2.3
Centrotherm 4” diameter - 1 foot 2.1
Example: Using 20 feet of Duravent 4” 20’ x 3.0 = 60’ of equivalent length of straight pipe.
Calculated equivalent feet shall not exceed maximum values listed in Figure12,page18.
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Sidewall vent/air termination: Separate pipes
Figure 14 Maximum piping lengths for separate vent
and air pipe sidewall termination
Boiler
Ultra
Maximum
Piping, 2” *
Maximum
Piping, 3” *
Maximum
Piping, 4” *
Feet Elbows Feet Elbows Feet Elbows
-80 ** 100 2 100 2
Not
allowed
-105 ** 100 2 100 2
-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 outside diameter
required at the boiler. You do not have to reduce allowable pipe length for the
reducers.
** 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 allowable length:
• 7 feet for each additional 4-inch elbow (90° or 45°)
• 7 feet for each additional 2 or 3-inch long radius elbow
• 16 feet for each 2 or 3-inch short radius elbow
• 7 feet for each 2 or 3-inch 45-degree elbow.
Figure 15 Sidewall termination — separate pipes — conguration
options and minimum clearances from vent to air
terminations
Allowable vent/air pipe materials
1. Use only the materials listed in Figure13,page19.
2. e Weil-McLain vent termination kit includes inside and
outside wall plates, bird screens, and mounting hardware to
secure the plates (kit included with boiler).
Maximum piping length
1. Locate the terminations such that the total air piping and vent
piping from the boiler to the termination will not exceed the
maximum length given in Figure14.
2. Maximum lengths listed in Figure14 allow for 2 elbows. Ad-
ditional elbows required a reduction in maximum length as
explained in the table notes.
Connecting from termination to boiler
1. Install the terminations as instructed in the following. en
proceed to page82 to complete the air and vent piping be-
tween the termination and the boiler.
Determine location — separate elbows
A gas vent extending through an exterior wall shall
not terminate adjacent to the wall or below build-
ing extensions such as eaves, parapets, balconies
or decks. Failure to comply could result in severe
personal injury, death or substantial property dam-
age.
1. Locate the vent/air terminations using the following guide-
lines.
2. e air piping must terminate in a down-turned elbow as
shown in Figure15. is arrangement avoids recirculation
of ue products into the combustion air stream.
a. Apply the conguration on the le side of Figure15 unless
the terminations would fail to meet minimum clearance
to grade or snow line.
b. Apply the conguration on the right side of Figure15
when the terminations need to be raised higher to meet
clearance to grade or snow line.
c. e vent and air pipes may run up as high as 4 feet, as
shown in Figure15 right side with no enclosure. e vent
and air pipes must be secured with braces, and all clear-
ances 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
enclosure around the vent and air pipes. e vent and air
terminations must exit through the enclosure as shown in
Figure15, maintaining all required clearances.
3. e vent piping must terminate in an elbow pointed outward
or away from the air inlet, as shown in Figure15.
Do not exceed the maximum lengths of the outside
vent piping shown in Figure15. Excessive length
exposed to the outside could cause freezing of con-
densate 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. e chase must allow
for inspection of the vent pipe, and insulation must
be protected from water.
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BASIC INSTALLATION
Figure 16 Sidewall termination with separate pipes — clearances
to openings
Figure 17 Sidewall termination with separate pipes — clearances
to public walkway or forced air intake
Figure 18 Multiple terminations — separate pipes — clearance
from vent of one to air intake of the next
Sidewall vent/air termination: Separate pipes (continued)
Maintain all requirements
shown in
Figure 15, page 20
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. e ue 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 ue products impinge on building
surfaces or plants.
d. Avoid possibility of accidental contact of ue products with
people or pets.
e. Do not locate the terminations where wind eddies could aect
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
nishes.
5. Maintain clearances as shown in the illustrations in this manual
section. Also maintain the following:
a. Vent must terminate:
• At least 6 feet from adjacent walls.
• No closer than 5 feet below roof overhang.
• At least 7 feet above any public walkway.
• At lease 3 feet above any forced air intake within 10feet.
• 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.
Completing the vent/air piping
1. Install vent/air penetrations as explained in the following pages
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 page71 to complete piping from
boiler to termination.
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Sidewall vent/air termination: Separate pipes (continued)
Figure 19 Multiple terminations — separate pipes — clearance
from vent of one to air intake of the next — alternate
conguration of air and vent terminations
Figure 20 Sidewall termination assembly — using separate pipes
1 Vent piping
2 Air piping
3 Sidewall termination plates, by
installer
4 Galvanized thimbles, by installer
5 Bird screen (air), by installer
6 Air inlet elbow
7 Elbow
8 Nipple
9 Elbow (vent termination)
10 Alternate elbow orientation
11 Bird screen (vent termination) —
supplied by installer
Maintain all requirements
shown in Figure 15, page 20
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 of 12 inches
between vent pipe and adjacent air inlet elbow, as shown in Fig-
ure18,page21 for U. S. installations.
3. For Canadian installations, provide clearances required by Natural
Gas and Propane Installation
CAN/CSA
B149.1 or B149.2 Instal-
lation Code.
4. e air inlet of an Ultra boiler is part of a direct vent connection.
It is not classied 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
Figure59,page59.
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 noncom-
bustible construction, size the vent pipe hole at least 0.4” larger
than the vent pipe diameter:
• 2¾” hole for 2”
• 4” hole for 3”
• 5” hole for 4”
b. Insert a galvanized metal thimble in the vent pipe hole as shown
in Figure20.
3. Use a sidewall termination plate as a template for correct location of
hole centers. Sidewall termination plates must be purchased sepa-
rately. See the parts list at the end of this manual for part numbers.
4. Follow all local codes for isolation of vent pipe when passing through
oors or walls.
5. Seal exterior openings thoroughly with exterior caulk.
Termination and ttings
1. Prepare the vent termination elbow and the air termination elbow
(Figure20) by inserting bird screens. Bird screens must be pur-
chased 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 Figure15,page20.
3. You can orient the vent termination elbow either directly outward
or 90 degrees away from the air inlet elbow as shown in Fig-
ure15,page20.
4. Maintain the required dimensions of the nished termination piping
as shown in Figure15,page20.
5. Do not extend exposed vent pipe outside of building more than
shown in this document. Condensate could freeze and block vent
pipe.
If extending the vent and air pipes out from the wall, in-
stall a coupling on each pipe. Mount the piping with the
coupling ush with the outer plate.
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BASIC INSTALLATION
Figure 21 Maximum piping lengths for separate vent
and air pipe vertical termination
Boiler
Ultra
Maximum
Piping, 2” *
Maximum
Piping, 3” *
Maximum
Piping, 4” *
Feet Elbows Feet Elbows Feet Elbows
-80** 100 1 100 1
Not
allowed
-105** 100 1 100 1
-155 Not allowed 100 1
-230 Not allowed 30 1 100 1
-299 Not allowed Not allowed 100 1
-399 Not allowed Not allowed 100 1
* 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 de-rate
due to the pressure loss in the vent and air piping. The de-rate 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 1 elbow, reduce maximum allowable length:
• 7 feet for each additional 4-inch elbow (90° or 45°)
• 7 feet for each additional
2 or 3-inch long radius elbow
• 16 feet for each
2 or 3-inch short radius elbow
• 7 feet for each 2 or 3-inch 45-degree elbow.
NOTE: The 180-degree return bend is included in the allowed ttings. No deduc-
tion is required.
Figure 22 Vertical termination — separate pipes
Vertical vent/air termination: Separate pipes
Allowable vent/air pipe materials
1. Use only the materials listed in Figure13,page19.
2. Purchase bird screens for vent and air terminations separately.
See the parts list at the end of this manual.
Maximum piping length
1. Locate the terminations such that the total air piping and vent
piping from the boiler to the termination will not exceed the
maximum length given in Figure21.
2. Maximum lengths listed in Figure21 allow for 1 elbow. Ad-
ditional elbows required a reduction in maximum length as
explained in the table notes.
Connecting from termination to boiler
1. Install the termination penetrations as instructed in the follow-
ing. en proceed to page82 to complete the piping between
the termination and the boiler.
Determine location
1. Locate the vent/air terminations using the following guidelines:
2. e air piping must terminate in a down-turned 180-degree
return bend as shown in Figure22. e edge of the air inlet
elbow must be at least 12 inches above the roof or snow line.
3. e vent piping must terminate in an up-turned coupling as
shown in Figure22. e top of the coupling must be at least
12 inches above the air intake in order to avoid recirculation
of ue products into the combustion air stream.
4. You must consider the surroundings when terminating the
vent and air:
a. Position the vent termination where vapors will not dam-
age nearby shrubs, plants or air conditioning equipment
or be objectionable.
b. e ue products will form a noticeable plume as they
condense 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 ue products impinge on building
surfaces or plants.
d. Avoid possibility of accidental contact of ue products
with people or pets.
e. Do not locate the terminations where wind eddies could
aect 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 nishes.
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5. Maintain clearances to vent termination as given below:
a. Vent must terminate:
• At least 6feet from adjacent walls.
• No closer than 5feet below roof overhang.
• At least 7feet above any public walkway.
• At least 3feet above any forced air intake within
10feet.
• No closer than 12inches below or horizontally from
any door or window or any other gravity air inlet.
b. Air inlet must terminate at least 12inches above the roof
or snow line and at least 12inches below the vent termina-
tion as shown in Figure22,page23.
c. Do not terminate closer to 4feet 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 mul-
tiple 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
noncombustible construction, size the vent pipe hole at
least 0.4” larger than the vent pipe diameter:
• 2¾” hole for 2”
• 4” hole for 3”
• 5” hole for 4”
b. Insert a galvanized metal thimble in the vent pipe hole.
3. Space the air and vent holes to provide the minimum spacings
shown in Figure23.
4. Follow all local codes for isolation of vent pipe when passing
through oors, ceilings and roofs.
5. Provide ashing and sealing boots sized for the vent pipe
and air pipe.
Termination and ttings
1. Prepare the vent termination elbow and the air termination
elbow (Figure22, page23) by inserting bird screens. Bird
screens must be purchased separately. See the parts list at the
end of this manual for part numbers.
a. If using 3-inch piping for an Ultra-230, cut a 4-inch bird
screen by placing 3-inch tting on screen and cutting
around it as a template.
2. e air piping must terminate in a down-turned 180-degree
return bend as shown in Figure22,page23. e edge of the
air intake elbow must be at least 12 inches above the roof or
snow line.
Vertical vent/air termination: Separate pipes (continued)
Figure 23 Termination location — separate pipes — terminations for
multiple boilers
3. e vent piping must terminate in an up-turned coupling as
shown in Figure22,page23 in order to avoid recirculation of
ue products into the combustion air stream.
4. Maintain the required dimensions of the nished termination
piping as shown in Figure22,page23.
5. Do not extend exposed vent pipe outside of building more
than shown in this document. Condensate could freeze and
block vent pipe.
Multiple vent/air terminations (Figure23)
1. When terminating multiple Ultra boilers, terminate each vent/
air connection as described in this section.
Terminate all vent pipes at the same height and all
air pipes at the same height to avoid possibility of
severe personal injury, death or substantial property
damage.
2. Place roof penetrations to obtain minimum clearance of
12inches between edge of air intake elbow and adjacent vent
pipe of another boiler for U. S. installations (see Figure23).
For Canadian installations, provide clearances required by
Natural Gas and Propane Installation
CAN/CSA
B149.1 or
B149.2 Installation Code.
3. e air inlet of an Ultra boiler is part of a direct vent connec-
tion. It is not classied as a forced air intake with regard to
spacing from adjacent boiler vents.
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BASIC INSTALLATION
DIRECT VENT Applications
Figure 24 DIRECT VENT APPLICATIONS — Vent and air termination options
DIRECT VENT
SIDEWALL termination
DIRECT VENT
VERTICAL termination
DIRECT VENT
VERTICAL vent and
SIDEWALL air
Weil-McLain
sidewall
termination
cap
(See Boiler
manual
page 67)
3” or 4”
concentric
termination
(See Boiler
manual
page 75)
U3511-bw
VENT
VENT
AIR
AIR
Vertical
vent
termination
and
Sidewall
air
termination
(See Boiler
manual
page 79)
U3505VS-bw
VENT
VENT
AIR
AIR
3” or 4”
concentric
termination
(See Boiler
manual
page 72)
Vertical
termination with
separate vent
and
air pipes
(See Boiler
manual
page 66)
Sidewall
termination with
separate vent
and
air pipes
(See Boiler
manual
page 66)
Direct vent
installation
sequence
Step 1
Install the boiler.
Step 2 Determine the termination method — sidewall or vertical, concentric or separate pipes, etc.
Step 3 Determine proper location for wall or roof penetration for each termination.
Step 4 Install termination assembly as described in this manual.
Step 5 Install air and vent piping from boiler to termination.
Step 6 Install pipe supports and brackets as required.
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DIRECT EXHAUST Applications
Figure 25 DIRECT EXHAUST APPLICATIONS — Vent termination options (combustion air from room)
DIRECT EXHAUST
Sidewall termination
DIRECT EXHAUST
Vertical termination
Sidewall vent
termination
(See Boiler
manual page 83)
Vertical vent
termination
(See Boiler
manual page 83)
Direct
exhaust in-
stallation
sequence
Step 1
Install the boiler.
Step 2 Determine the proper location for roof or wall penetration for each termination.
• Prepare roof penetrations before installing vent piping.
• Finish by attaching external pipe and ttings as shown in the termination instructions.
• Vertical terminations only — Install terminations as described in this addendum.
• Support vertical runs on the outside of the building with brackets as shown in the termination
instructions.
Step 3 Install vent piping from boiler to termination.
• Install a hanger support within 6inches of any upturn in the piping.
• Slope horizontal piping downward toward the boiler at least 1/4 inch per foot.
Step 4 Connect the vent piping at the boiler per manual instructions.
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BASIC INSTALLATION
Install condensate line
Figure 26 Condensate trap assembly
Figure 27 Condensate trap assembly into jacket
Figure 28 Condensate drain — Ultra-80 & -105
Prepare condensate ttings
1. Remove PVC ttings and gasket from the accessories bag.
2. Deburr and chamfer outside and inside of ½” x 1¼” PVC nipple
to ensure even cement distribution when joining.
3. Clean nipple ends and all ttings. 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
tting 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 tting, twisting ¼ turn.
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 Figure26.
6. Assemble the ½” PVC nipple to the PVC reducing elbow as shown.
7. Allow joint to dry completely.
8. en slide gasket over nipple as shown in Figure27.
9. Slide nipple through jacket condensate line hole to position as
shown in Figure27.
10. Cement the ½” tee to the protruding ½” nipple. Be sure both nipple
and reducing elbow nish upright.
Firmly press the reducing elbow and the tee together
while the cement sets to ensure the gasket is securely
compressed. e gasket ensures the jacket enclosure is
airtight at this location.
Connect condensate trap line and ttings
1. Remove condensate trap line from bag.
2. Ultra-80 & -105 only — Figure28
a. Guide the condensate trap line through the bracket hole as
shown.
b. Place a hose clamp over the end of the condensate line.
c. en 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 — Figure30,page28 or Figure31,page28
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.
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Install condensate line (continued)
Figure 30 Condensate drain — Ultra-155 & -230 (PVC tee
installation shown applies to all models)
Figure 31 Condensate drain — Ultra-299 & -399
Figure 32 Condensate pump (by others), typical
Condensate drain tubing
1. Connect condensate drain tubing to the ½” PVC tee and run to
oor drain or condensate pump (see Figure32). Use ½” PVC or
CPVC pipe; or 5/8” I. D. tubing.
Use materials approved by the authority having juris-
diction. 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
certied PVC or CPVC pipe, ttings and cement.
2. Leave the top of the ½” tee OPEN. is is needed as a vacuum
break.
3. When installing a condensate pump, select one approved for use
with condensing boilers and furnaces. e pump should have an
overow switch to prevent property damage from condensate
spillage. See Figure29 for required ow capacity.
4. When sizing condensate pumps, make sure to include the total
load of all Ultra boilers connected to it.
e condensate line must remain unobstructed, allow-
ing free ow 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 lter if required by local codes. See
Replacement parts section at the end of this manual
for the Weil-McLain kit.
Figure 29 Suggested condensate pump capacity, GPH
Boiler
Minimum recommended condensate pump
capacity, per boiler, GPH
Ultra-80 2 Ultra-230 6
Ultra-105 3 Ultra-299 8
Ultra-155 4 Ultra-399 8
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BASIC INSTALLATION
Gas piping
Connecting gas supply piping
1. Remove jacket front panel and refer to Figure33 to pipe gas to
boiler.
a. Install ground joint union for servicing, when required.
b. Install manual shuto valve in gas supply piping outside boil-
er jacket when required by local codes or utility requirements.
c. In Canada — When using manual main shuto valve, it must
be identied by the installer.
2. Wall-mounted boilers
a. Refer to separate Ultra Boiler Wall-mounting instructions.
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 shuto valve during any pressure testing
at less than 13” w.c.
b. Disconnect boiler and gas valve from gas supply piping dur-
ing any pressure testing greater than 13” w.c.
Do not check for gas leaks with an open ame — use
bubble test. Failure to use bubble test or check for gas
leaks can cause severe personal injury, death or sub-
stantial 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 ow.
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. e gas valve is factory-set for the correct
outlet pressure. is setting is suitable for natural gas
and propane, requiring no eld adjustment. Attempt-
ing to alter or measure the gas valve outlet pressure
could result in damage to the valve, causing potential
severe personal injury, death or substantial property
damage.
Ultra boilers are shipped ready to re natural gas ONLY.
(Exception: Ultra-80LP is propane-ready.) You must
install the propane orice if the boiler will be connected
to propane. See page48. Failure to comply could result
in severe personal injury, death or substantial property
damage.
Gas pipe sizing
1. See page93 for gas line sizing information.
Check gas pressure at inlet to boiler
1. See Figure39,page40, Figure40,page40, or Figure41,page41
for location of the gas inlet pressure test port.
Use two wrenches when tightening gas
piping at boiler, using one wrench to pre-
vent the boiler gas line connection from
turning. Failure to support the boiler gas
connection pipe to prevent it from turn-
ing could damage gas line components.
Figure 33
Connect gas supply piping
Natural gas supply pressure
1. Pressure required at gas valve inlet pressure port:
a. Maximum: 13” w.c. with no ow (lockup) or with
boiler on
b. Minimum: 4” w.c. (for all except 5” for -299) with
gas owing (verify during boiler startup, while boiler
is at high re)
2. Install 100% lockup gas pressure regulator in supply line
if inlet pressure can exceed 13” w.c. at any time. Adjust
lockup regulator for 13” w.c. maximum.
Propane supply pressure
1. Adjust propane supply regulator provided by gas sup-
plier for 13” w.c. maximum pressure.
2. Pressure required at gas valve inlet pressure port:
a. Maximum: 13” w.c. with no ow (lockup) or with
boiler on
b. Minimum: 4” w.c. with gas owing (verify during
boiler startup, while boiler is at high re).
Manual main gas
shutoff valve
Ground joint
union
To gas supply
Boiler gas
connection
U3012
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Field wiring — basic system
See page 94 (Advanced section) for other wiring options
ELECTRICAL SHOCK HAZARD — For your
safety, turn o electrical power supply at service
entrance panel before making any electrical connec
-
tions to avoid possible electric shock hazard. Failure
to do so can cause severe personal injury or death.
e installation must comply with: National Electrical
Code and any other national, state, provincial or local
codes or regulations. In Canada, CSA C22.1 Canadian
Electrical Code Part 1, and any local codes.
Wiring must be N.E.C. Class 1. If original wiring
as supplied with boiler must be replaced, use only
type 105 °C wire or equivalent. Boiler must be
electrically grounded as required by National Elec
-
trical Code ANSI/NFPA 70 – latest edition, and/
or the Canadian Electrical Code Part I, CSA C22.1,
Electrical Code.
e boiler when installed, must be electrically bonded
to ground in accordance with the requirements of the
authority having jurisdiction or, in the absence of
such requirements, with the National Electrical Code,
ANSI/NFPA 70 – latest edition, and/or the Canadian
Electrical Code Part I, CSA C22.1, Electrical Code.
Line voltage power input
1. Provide and install a fused disconnect or service switch
(15-ampere rated recommended) as required by applicable
codes.
2. Connect minimum 15-ampere, 120 VAC power wir-
ing to Ultra boiler line voltage terminal strip as shown in
Figure34,page31, and Figure111,page96.
Wiring circulators
1. e U-Control provides for connection of up to three circula-
tors, one of which must be the boiler circulator. In addition,
you can connect a system circulator and a DHW circulator,
for examples.
The maximum allowable current for each
circulator is 2.2 amps at 120 VAC
. For circula-
tors with higher amp ratings, you must install a
circulator relay or starter to provide line voltage to
the circulator. For circulators rated over 2.2 amps,
connect only the circulator relay or starter coil to
the Ultra circulator terminals.
Wiring — general
1. The U-Control provides plug-in, color-coded, non-in-
terchangeable terminal strips for all eld wiring. See the
schematic diagram (Figure111,page96) & ladder diagram
(Figure112,page97).
2. e U-Control provides programmable exibility in system
operation, allowing control of heat supply for up to three dif-
ferent heating systems. Read this manual thoroughly before
connecting the wiring to ensure trouble-free start-up and
operation.
Wiring — overview
See this and following pages for wiring information. Also
see the Advanced section of this manual for additional wir-
ing connections and options
.
Make the following connections, some of which depend on
your system and how the U-Control will be programmed.
Connect 120VAC power (minimum 15-amp source)
Connect wiring for up to three circulators
Connect thermostats and/or heat demand contacts
• e U-Control can regulate the boiler for up to three dif-
ferent heating systems.
Install system & outdoor sensors, when used
• e boiler is shipped with an outdoor sensor, a system
supply sensor and a system return sensor. e system
supply sensor will be required for most space heating ap-
plications. e system return sensor must also be installed
when using the system supply sensor. Use of the outdoor
sensor is optional.
• Locate the sensors on the system piping as shown in
Figure4,page11 and other piping drawings throughout
this manual.
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BASIC INSTALLATION
Field wiring — basic system (continued)
Detailed control information and additional wiring — see the ADVANCED INSTALLATION section of this
manual.
Figure 34 Simplied wiring — basic system with DHW and space heating (see ADVANCED section for more information)
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 ]
Install the outdoor temperature sensor (supplied with boiler) and wire to terminals P10 #1 and #2.
The outdoor sensor must be installed unless specically exempted in the Energy Act statement on page 137.
Wire the DHW circulator (supplied by installer) as circulator 1, following instructions on Connect the boiler circulator (supplied with boiler) as circula-
tor 2, following instructions on page 30
Wire the boiler circulator (supplied with boiler) as circulator 2, following instructions on page 30
Wire the system circulator (supplied by installer) as circulator 3, following the instructions on page 30
Locate the sensors on the system
piping as shown in Figure 4, page 11
and other piping drawings throughout
this manual.
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U-Control operation and setup
Temperature settings — You must ensure that the
U-Control is set for the proper water temperatures for
the system. Excessive water temperature can cause sig-
nicant property damage in some applications.
Multi-temperature systems — If the heating system
includes circuits that require lower temperature water
(radiant slab circuits, for example) as well as higher
temperature circuits (DHW, nned tube baseboard, etc.),
it is recommended to protect low-temperature circuits
with limit controls that are wired to a U-Control external
limit circuit. Failure to provide regulation can result in
substantial property damage.
Figure 35 U-Control sequence of operation
U-Control overview
e U-Control is fully programmable to meet system requirements, allow-
ing supply water regulation for up to three dierent systems.
U-Control features include:
Blower speed modulation to control the Ultra boiler’s ring rate.
Advanced PID response to anticipate system needs based on response
to heat input.
Graphic and robust text display for ease of operation monitoring and
troubleshooting.
Preset operating parameters for typical heating systems (nned tube
baseboard, radiant oor, DHW, and others), including target tempera-
tures, reset curves and circulator assignments.
Control of up to three circulators (boiler circulator plus two others),
assignable for each of the three possible inputs.
Programmable priority assignments for the heat inputs.
Integral outdoor reset option, with reset curves matched to the system
type selected.
Multiple boiler/heat source sequencing or modulation.
Built-in 0–10 VDC signal generator to allow parallel modulation of
multiple boilers; also capable of accepting 0–10 VDC input.
Dual sensors for boiler outlet temperature and ue temperature, pro-
viding redundant protection.
Integral low water protection (by monitoring boiler heat exchanger
temperature).
Boiler is shipped with an outdoor sensor and strap-on system supply
and return sensors.
Sequence of operation
1. Figure35 is a summary of the operating sequence for the U-Control.
2. e symbols shown appear in the display as the U-Control cycles the
boiler.
3. e wrench symbol appears when a scheduled maintenance date ar-
rives. is informs the homeowner to call the contractor for service.
4. e exclamation mark symbol appears when a problem has been
detected.
Display Control action (also see Figure36,page33)
POWER
UP
y Check the boiler model listed on the power-up
screen. If it is not correct, turn o the boiler. See
Figure115,page102 to change setting.
y When power is turned on, the screen lists sen-
sors that are detected. If any sensor is not listed,
make sure it is connected correctly. Turn o
power and restart.
Standby
y Standby — no calls for heat
y Toggles through no dots, 1 dot, 2 dots, then
3dots while in standby (wrench symbol will
show instead if maintenance is needed)
Blower on
y Call for heat detected
y Display on with BLUE light (space heating) or
PURPLE light (DHW)
y Start min/max on timers if more than one system
is calling — highest priority starts rst
y Start circulators for this priority setup
y Calculate target temp — If sensor temp is below
target temp, begin ring sequence
y Blower to ignition speed for prepurge
y Multiple boilers/heat sources only — Start
additional-heat timer — type 1 boiler starts
immediately; type 2 activates other heat source
immediately, but doesn’t start unless the timer
times out; type 3 (LEAD boiler) starts immedi
-
ately and sends 0–10 VDC signal to others aer
timer times out; type 4 receives signal from
LEAD boiler and starts immediately (and starts
timer for the next boiler, if programmed)
Ignition on
y Aer prepurge times out, begin ignition cycle
y Activate gas valve and ignition spark
y Continue ignition spark for ignition period
y Turn o spark and use electrode to check for
ame signal
Space
heating
y Flame detected
y Hold boiler at low re for 1 minute
y Release boiler to modulation
y NOTE: If ame is not detected, the gas valve
is turned o, blower turns on (postpurge), and
control starts cycle again. Aer 5 failures, the
control waits 60 minutes, then tries again.
y If priority timer times out, switch to next priority
and start priority timer
y If demand satised, go to postpurge
DHW
heating
y Flame detected
y Release boiler to modulation immediately
y NOTE: If ame is not detected, the gas valve
is turned o, blower turns on (postpurge), and
control starts cycle again. Aer 5 failures, the
control waits 60 minutes, then tries again.
y If priority timer times out, switch to next priority
and start priority timer
y If demand satised, go to postpurge
Blower on
y Demand satised (temperature reaches target
temperature or limit setting)
y Gas valve o
y Blower to ignition speed for postpurge
y Return to standby aer purge
Maintenance
y Display turns RED, toggling between graphic
screen and maintenance screen (occurs when
maintenance schedule timer times out)
y Will show during standby only
y Boiler operates as normal
Error/fault
y Display turns RED due to error or limit event
y Flashing display means lockout condition —
display toggles between three screens as in
Figure124,page117.
WWSD
y Warm weather shutdown — the boiler will not
be allowed to re if the outside temperature is
greater than the WWSD setting.
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BASIC INSTALLATION
U-Control operation and setup (continued)
I N F O
M O D U L A T I O N # # # # # # # # #
H H : M M A M M M / D D / Y Y
M O D U L A T I O N :
H H : M M A M M M / D D / Y Y
S T A T U S : # # # # # # # # #
T A R G E T : # # # ° F
S U P P L Y : # # # ° F
R E T U R N : # # # ° F
O U T D O O R : # # # ° F
D E M A N D : # # # # # # # # #
P U M P S : # # #
A D D ' L H E A T D E M A N D : # # #
S E T T I N G S
P R E V I O U S E N T E R
Press to switch to
INFO screen.
Display above is typical
for normal operation. The
center symbol changes
to show operation status.
The INFO screen, below
is for at-a-glance information
during normal operation.
U5002
Time and date
1 — Screen color
(Blue = space heating or when a button is pressed)
(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.)
2 — Status graphic
Time and date
Active system type
Supply temperature
Return temperature
Outdoor air temperature
Systems with
heat demand
Pumps operating
ON or OFF
Select to change settings
Scroll up or down
Previous screen or ENTER
Move selection up
Next screen
Previous screen
Enter
Move selection down
S E L E C T
Firing rate
Setpoint temperature
I N F O
M O D U L A T I O N A L E R T
H H : M M A M M M / D D / Y Y
I N F O
M O D U L A T I O N # # # # # # # # #
H H : M M A M M M / D D / Y Y
I N F O
M O D U L A T I O N # # # # # # # # #
H H : M M A M M M / D D / Y Y
Alternating colors
I N F O
M O D U L A T I O N # # # # # # # # #
H H : M M A M M M / D D / Y Y
STANDBY
(Pressing any button changes
background to blue, below.)
I N F O
M O D U L A T I O N # # # # # # # # #
H H : M M A M M M / D D / Y Y
DHW HEATING
(Domestic hot water heating)
BOILER IN LOCKOUT
(Attention required to
restart boiler)
BUTTONS
3 — Firing rate bar
4 — Operating status /
Active system
NO BACKLIGHTBLUE BACKLIGHTPURPLE BACKLIGHTRED BACKLIGHTNO BACKLIGHT
Figure 36 U-Control display and navigation
(see Figure114,page101)
(see Figure114,page101)
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U-Control operation and setup (continued)
EXPRESS SETUP — using default settings
1. e U-Control is factory programmed to supply a DHW circuit (control
priority1) and nned tube baseboard space heating (control priority2).
2. Control priority 3 is also available, and preset to run all three circulators
if desired, but requires settings to be congured.
Figure 37 Factory default settings
Priority Type Target temperature Circulators
enabled
1
DHW
Direct
190°F #1 Only
2
Finned
tube BB
180°F xed (if no outdoor sensor) or
180°F at 0°F outside / 130°F at 70°F outside
#2 and #3
3 Custom
180°F xed (if no outdoor sensor) or
180°F at 0°F outside / 130°F at 70°F outside
None
3. You can use the factory default settings for most systems supplying
space heating with nned-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 Figure5,page12 or Figure6,page13.
b. If the DHW tank is a separate zone o of the system main, or if it is
piped as in Figure48,page52, you will need to enable additional cir-
culators for DHW operation. e U-Control is factory programmed
to operate only the DHW circulator during DHW heating.
c. e heat emitters in the system must be nned 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
Figure34,page31 for wiring instructions.
For detailed control information
and additional wiring
, see the
ADVANCED INSTALLATION
section of this manual.
Low-temperature systems (ra-
diant slab, etc.) —
DO NOT use
the Ultra boiler control as the only
means of water temperature regula-
tion for low-temperature systems if
higher-temperature systems are also
supplied.
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BASIC INSTALLATION
Startup — ll the system
Antifreeze
See Replacement parts at the end of this manual for Weil-
McLain part numbers to obtain antifreeze through a WM
Technologies distributor.
Use the correct amount of antifreeze
1. Determine the freezing temperature needed (to protect
against lowest likely temperature the system water will
encounter).
2. Find the antifreeze concentration by volume needed for this
temperature from the antifreeze manufacturer’s data on the
antifreeze container.
3. Add up the volume (gallons) of all system piping and com-
ponents, including the expansion tank and boiler.
a. Boiler water content is listed on page137.
b. Remember to include expansion tank water content.
4. Multiply this volume by the (percent) antifreeze needed to
nd the number of gallons of antifreeze to add.
Fill and test water system
1. Fill system only aer ensuring the water meets the require-
ments of this manual.
2. Close manual and automatic air vents and boiler drain valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. Typical cold water ll pressure for a residential system
is 12 psi.
b. Pressure will rise when boiler is turned on and system
water temperature increases. Operating pressure must
never exceed 25 psig.
4. At initial ll and during boiler startup and testing, check
system thoroughly for any leaks. Repair all leaks before
proceeding further.
Eliminate all system leaks. Continual fresh make-up
water will reduce boiler life. Minerals can build up
in sections, reducing heat transfer, overheating heat
exchanger, and causing heat exchanger failure.
X100 inhibitor is required
1. It is required that the Ultra boiler have Sentinel X100 added to
the system to prevent damage to the boilers’ heat exchanger.
Replacement parts section at the end of this manual for re-
ordering information.
2. Aer lling the system as directed in these instructions, ll
with the X100, following the instructions on the container.
3. Aer adding the inhibitor to the system, allow time for the
water to circulate and mix. en check the inhibitor level.
Add additional inhibitor if necessary.
4. See separate instructions or weil-mclain.com for suggested
guidelines to determine how much inhibitor to use.
Check/verify water chemistry
1. e system may have residual substances that could aect
water chemistry.
2. Aer the system has been lled and leak tested, verify water
pH and chlorine concentrations are acceptable.
Clean system to remove sediment
1. You must thoroughly flush the system (without boiler
connected) to remove sediment. e high-eciency heat
exchanger can be damaged by buildup or corrosion due to
sediment.
2. For zoned systems, ush each zone separately through a purge
valve. (If purge valves and isolation valves are not already
installed, install them to properly clean the system.)
3. Flush system until water runs clean and you are sure piping
is free of sediment.
Do not use petroleum-based cleaning or seal-
ing compounds in boiler system. Damage to
elastomer seals and gaskets in system could
occur, resulting in substantial property dam-
age.
Before lling the boiler and system with water,
verify the following.
DO NOT ll with soft-
ened water.
Boiler corrosion can occur.
Failure to comply could result in boiler failure
or unreliable operation.
Water chemistry
Water pH between 7.0 and 8.5
1. Maintain boiler water pH between 7.0 and 8.5. Check with
litmus paper or have chemically analyzed by water treatment
company.
2. If pH diers from above, consult local water treatment com-
pany for treatment needed.
3. DO NOT use soened water. Soened water can cause cor-
rosion.
Hardness less than 7 grains
1. Consult local water treatment companies for unusually hard
water areas (above 7 grains hardness).
Chlorine concentration must be
LESS THAN 200 ppm
1. Filling with chlorinated fresh water should be acceptable
since drinking water chlorine levels are typically less than
5 ppm.
2. Do not use the boiler to directly heat swimming pool or
spa water.
3. Do not ll boiler or operate with water containing chlorine
in excess of 200ppm.
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Startup — ll the system (continued)
Freeze protection (when used)
Follow these guidelines to prevent pos-
sibility of severe personal injury, death
or substantial property damage:
NEVER use automotive or standard
glycol antifreeze
, even glycol made
for hydronic systems
. Use only
freeze-prevention uids recommended
by WM Technologies for application in
Ultra Boiler systems.
Thoroughly ush any system that
has used glycol
before installing the
new Ultra boiler.
Review the material safety data
sheet (MSDS)
for the uid used with
the boiler owner and leave a copy for
reference. e MSDS contains informa-
tion on potential hazards and rst aid
procedures for exposure or ingestion.
Check antifreeze inhibitor level at
least annually
. Glycol concentration
and inhibitor levels may change over
time. Add antifreeze to increase con-
centration if necessary. Add inhibitor
as needed to bring to acceptable level,
using inhibitor test kit to verify.
When using freeze protection uid with
automatic ll,
install a water meter to
monitor water make-up
. Freeze pro-
tection uid may leak before the water
begins to leak, causing concentration
to drop, reducing the freeze protection
level.
DO NOT exceed 50% antifreeze
by volume
. Antifreeze moves more
sluggishly than water and can interfere
with heat transfer. At antifreeze con-
centrations higher than 50%, sludge can
develop in the boiler, potentially causing
damage to the heat exchanger.
Clean the system before filling.
Always drain and flush the system
thoroughly before lling with antifreeze.
Sludge, iron oxide deposits and other
sediment in the system inhibit ow and
can cause rapid breakdown of inhibitors.
Use only antifreeze recommended by
WM Technologies.
WM Technologies provides information
for application of the antifreeze products
listed in this document only for use in
Weil-McLain Ultra boilers. Do not apply
these products or instructions for other
applications. Local codes may require a
backow preventer or actual disconnec-
tion from city water supply.
3. Verify antifreeze concentration, when used.
4. Follow the instructions on the Sentinel test kit to sample the system
water and verify inhibitor concentration.
Check inhibitor concentration annually
1. Test the pH of a sample of system water at least annually. e pH of
the water mixture must be between 7.0 and 8.5. (Or use the Sentinel
inhibitor test kit to check concentration.)
2. If pH is outside this range (or inhibitor test kit indicates low level), the
inhibitor level may not be sucient to prevent corrosion.
3. Test antifreeze concentration.
Test antifreeze concentration at least annually. If concentra-
tion is low, add antifreeze or drain system and rell with
correct mixture.
4. Follow instructions on antifreeze container to determine the amount
of antifreeze needed.
DO NOT exceed 50% by volume concentration
of antifreeze.
5. Check inhibitor level aer adjustments are made.
Purge air from water system
1. Connect a hose to the purge valve (see purge/drain valves, item 11, in
piping diagrams beginning on page12 andpage52. Route hose to an
area where water can drain and be seen.
2. Close the boiler or system isolation valve between the purge valve and
ll connection to the system.
3. Close zone isolation valves.
4. Open quick-ll valve on cold water make-up line.
5. Open purge valve.
6. One zone at a time, open the isolation valves. Allow water to run
through the zone, pushing out the air. Run until no noticeable air ow
is present. Close the zone isolation valves and proceed with the next
zone. Follow this procedure until all zones are purged.
7. Close the quick-ll water valve and purge valve and remove the hose.
Open all isolation valves. Watch that system pressure rises to correct
cold-ll pressure.
8. Aer the system has operated for a while, eliminate any residual air by
using the manual air vents located throughout the system.
9. If purge valves are not installed in system, open manual air vents in
system one at a time, beginning with lowest oor. Close vent when
water squirts out. Repeat with remaining vents.
10. Open automatic air vent (diaphragm-type or bladder-type expansion
tank systems only) one turn.
11. Starting on the lowest oor, open air vents one at a time until water
squirts out.
12. Repeat with remaining vents.
13. Rell to correct pressure.
Part number 550-100-440/0723
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BASIC INSTALLATION
Startup — nal checks
Check thermostat circuit(s)
1. Disconnect the two external wires connected to the boiler
thermostat terminals (see Field wiring, beginning on page30
for terminal locations).
2. Connect a voltmeter across these two incoming wires. Close
each thermostat, zone valve and relay in the external circuit
one at a time and check the voltmeter reading across the
incoming wires.
3. ere should NEVER be a voltage reading.
4. If a voltage does occur under any condition, check and correct
the external wiring. (is is a common problem when using
3-wire zone valves.)
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires. Allow the boiler to cycle.
Inspect/ll condensate system
Inspect/check condensate lines and ttings
1. Inspect the condensate drain line, condensate PVC ttings
and condensate trap. (See page27 for component locations.)
2. Pour water into the top of the boiler’s ½” PVC condensate
tee and check for any leaks in the condensate drain line or
ttings. Repair any leaks.
Fill condensate trap with water
1. Loosen the hose clamp securing the right end of the conden-
sate trap to the PVC reducing elbow (see page27 for details).
2. Slide the trap hose end o of the elbow.
3. Fill the trap with fresh water to within an inch of the end
of the hose.
4. Replace trap hose on PVC reducing elbow and tighten the
hose clamp.
e condensate trap must be lled with water dur-
ing all times of boiler operation to avoid ue gas
emission from the condensate drain line. [Prime
the condensate trap (by pouring water into the
outlet tee while restricting ow in drain tube) if
boiler has been out of service for an extended pe-
riod.] Failure to ll the trap could result in severe
personal injury or death.
Final checks before starting boiler
Read the instructions to adjust and set up the U-Control
module.
Verify that the boiler model is set correctly in the U-Control,
and that it displays correctly.
Verify that the boiler and system are full of water and all
system components are correctly set for operation.
Fill vent condensate trap with water (by removing hose
clamp and hose at PVC reducing elbow). Replace hose on
PVC reducing elbow and tighten clamp.
Verify electrical connections are correct and securely at-
tached.
Inspect vent piping and air piping for signs of deteriora-
tion from corrosion, physical damage or sagging. Verify
air piping and vent piping are intact and correctly installed
per this manual.
Check for gas leaks
Before starting the boiler, and during
initial operation, use a leak detector or
smell near the oor and around the boiler
for gas odorant or any unusual odor. Re-
move boiler front door and smell interior
of boiler enclosure. Do not proceed with
startup if there is any indication of a gas
leak. Repair any leak at once.
DO NOT adjust or attempt to measure
gas valve outlet pressure. e gas valve is
factory-set for the correct outlet pressure.
is setting is suitable for natural gas and
propane, requiring no eld adjustment. At-
tempting to alter or measure the gas valve
outlet pressure could result in damage to
the valve, causing potential severe personal
injury, death or substantial property dam-
age.
Propane boilers only — Your propane sup-
plier mixes an odorant with the propane
to make its presence detectable. In some
instances, the odorant can fade, and the
gas may no longer have an odor. Before
startup (and periodically thereaer), have
the propane supplier verify the correct
odorant level in the gas.
Part number 550-100-440/0723
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To start the boiler
1. Turn OFF the boiler ON/OFF switch.
2. Read and follow the Operating Instructions,
Figure38,page39.
3. e U-Control display will show installed sensors when rst
powered. Make sure the right sensors are detected. If not,
determine the cause and correct before proceeding.
If boiler does not start correctly
1. Check for loose connections, blown fuse or service switch
o?
2. Is external limit control (if used) open? Is boiler water tem-
perature above 200 °F?
3. Is thermostat set below room temperature?
4. Is gas turned on at meter or boiler?
5. Is incoming gas pressure less than 5” w.c. for natural gas or
4” w.c. for propane?
6. Are parameters set correctly in this manual?
7. Is the warm weather shutdown activated?
8. If none of the above corrects the problem, refer to Trouble-
shooting, beginning on page115.
Check system and boiler
Check water piping
9. Check system piping for leaks. If found, shut down boiler and
repair immediately. (See WARNING on page35 regarding
failure to repair leaks.)
10. Vent any remaining air from system using manual vents. Air
in the system will interfere with circulation and cause heat
distribution problems and noise.
Check vent piping and air piping
1. Check for gas-tight seal at every connection and seam of air
piping and vent piping.
Venting system must be sealed gas-tight to prevent
ue gas spillage and carbon monoxide emissions
which will result in severe personal injury or
death.
Startup — nal checks (continued)
Check gas piping
1. Check around the boiler for gas odor following the proce-
dure of page29 of this manual.
If you discover evidence of any gas leak, shut
down the boiler at once. Find the leak source with
bubble test and repair immediately. Do not start
boiler again until corrected. Failure to comply
could result in severe personal injury, death or
substantial property damage.
Propane boilers — verify conversion
1. Verify propane orice has been installed per Propane Con-
version instructions.
DO NOT adjust or attempt to measure gas
valve outlet pressure. e gas valve is factory-
set for the correct outlet pressure. is setting
is suitable for natural gas and propane, requir-
ing no eld adjustment.
Attempting to alter or measure the gas valve
outlet pressure could result in damage to
the valve, causing potential severe personal
injury, death or substantial property damage.
Ultra boilers are shipped ready to re natu-
ral gas ONLY. Exception: e Ultra-80LP is
factory-equipped to re propane. You must
install the propane orice if the boiler will be
connected to propane. See page48.
Failure to comply could result in severe per-
sonal injury, death or substantial property
damage.
Part number 550-100-440/0723
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BASIC INSTALLATION
Startup — nal checks (continued)
FOR YOUR SAFETY
READ BEFORE OPERATING
WHAT TO DO IF YOU SMELL GAS
A.
This appliance does not have a
pilot. It is equipped with an
i g n i t i o n d e v i c e w h i c h
autom atica ll y lig hts the
burner. Do not try to light the
burner by hand.
B. Before OPERATING, smell all
around the appliance area for
gas. Be sure to smell next to
the floor because some gas is
heavier than air and will settle
on the floor. See below.
C. Use only your hand to toggle the power
switch and/or turn the manual gas valve.
If the switch or valve will not turn by
hand, don't try to repair it, call a qualified
service technician. Force or attempted
repair may result in a fire or explosion.
D. Do not use this appliance if any part has
been under water. Immediately call a
qualified service technician to inspect
the appliance and to replace any part of
the control system and any gas control,
which has been under water.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier,
call the fire department.
• Do not try to light any appliance.
• Do not touch any electric
switch; do not use any phone in
your building.
If you do not follow these instructions
exactly, a fire or explosion may result
causing property damage, personal injury
or loss of life.
550-101-272 (0617)
OPERATING INSTRUCTIONS
1.
STOP!
Read the safety information at left on this label. This appliance is equipped with an
ignition device which automatically lights the burner. Do not try to light the burner by hand.
2. Set room thermostat(s) to lowest setting.
3. Turn OFF all electrical power to the appliance.
4. Toggle the power switch located on Boiler to “off” position.
5. Locate boiler manual gas valve (in the gas piping connected to the boiler).
6. Turn boiler manual gas valve knob counterclockwise to open gas supply.
7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor.
8. If you smell gas,
STOP!
Turn the boiler manual gas valve to OFF. Then follow
WHAT TO DO IF YOU SMELL GAS. If you don't smell gas, go to step 9, below.
9. Turn ON all electrical power to the appliance including the power switch located on Boiler.
10. Set thermostat(s) to desired setting.
11. The boiler display will show symbols and/or text describing the status of the boiler as it
proceeds through its operating sequence. "Standby" status means the burner is off.
12. If the appliance will not operate when there is a call for heat and piping is not hot, follow the
instructions "To Turn Off Gas To Appliance" below and call your service technician or gas
supplier.
TO TURN OFF GAS TO THE APPLIANCE
1. Set room thermostats to lowest setting.
2. Turn OFF all electrical power to the appliance
including the power switch located on Boiler.
3. Close external manual gas cock (valve handle perpendicular to gas piping). Turn
gas valve knob clockwise to close gas supply.
4. Replace boiler access door.
(ON Position Shown)
Gas valve
CLOSED
Gas valve OPEN
(Typical gas valve shown;
Actual valve may vary)
to CLOSE
to OPEN
Figure 38 Operating instructions (WARNING — Verify that the U-Control is set for the correct boiler model before proceeding.)
Part number 550-100-440/0723
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Startup — nal checks (continued)
Check ame & combustion with instruments
For Ultra-399 propane boilers, special start-up is re-
quired. See page 41 for procedure. See DANGER on
page49 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 ve seconds.
3. Use the U-Control display to navigate to Manual test mode (see
Figure115,page102) and force the ring rate to MAX (high re).
4. Look at the ame through the ame inspection window. e high
re ame should be blue and should be stable. e burner surface
should be covered with orange dots.
5. Remove the ue temperature sensor from the ue pipe and insert
a combustion test probe., using a calibrated combustion test in-
strument.
6. Test for CO
2
(or O
2
) and for CO. e CO
2
values must be within
1.0% of the values listed in Figure42,page41. If results are ac-
ceptable, proceed to the next step. IF NOT, follow the instructions
under “rottle screw adjustment procedure” on page41 to set the
throttle screw position. See WARNING below.
If combustion at either high or low re is outside
the range given in Figure42, page41, follow the
procedure given on page41 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 WM Technologies
representative. rottle screw adjustment must be
done only by a qualied technician, using calibrated
test instruments. Failure to comply could result in
severe personal injury, death or substantial property
damage.
7. Measure natural gas input:
a. Operate boiler 10 minutes.
b. Turn o other appliances.
c. At natural gas meter, measure time (in seconds) required to
use one cubic foot of gas.
d. Calculate gas input:
e. Btuh calculated should approximate input rating on boiler
rating label.
8. Use the U-Control display to navigate to Manual test mode (see
Figure115,page102) and force the ring rate to MIN (low re).
9. Look at the ame through the ame inspection window. e low
re ame 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
Figure115,page102) and force the ring rate to AUTO (normal
operation).
12. Replace the ue gas temperature sensor. When replacing the
sensor, remove the rubber grommet from the probe. Insert the
Figure 39 Models 80 & 105 — Throttle screw
location (ONLY for use by a qualied
technician, using calibrated combustion
test instruments)
3600 x 1000
number of seconds from step c
= Btuh
Figure 40 Models 155, 230 & 299 — Throttle
screw location (ONLY for use by a
qualied technician, using calibrated
combustion test instruments)
Part number 550-100-440/0723
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BASIC INSTALLATION
Startup — nal checks (continued)
Figure 41 Model 399 — Throttle screw location (ONLY
for use by a qualied technician, using
calibrated combustion test instruments)
rubber grommet into the ue pipe, then insert the probe into
the rubber grommet.
You must replace the ue gas temperature sensor to
prevent ue gas spillage into the boiler enclosure.
Failure 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 orice change) — Figure41. is must
only be done while using a combustion analyzer.
1. Turn the gas valve throttle screw clockwise 5 turns before start-
ing the boiler. en follow the start-up procedure on page40.
2. Once the boiler is started, make slight adjustments to the throttle
screw to obtain a CO
2
of 10.2% with CO less than 100 ppm air
free. (Allow the combustion analyzer’s reading to stabilize before
making adjustments.)
3. Aer the boiler has been set up correctly, the conversion is
complete. Fill in the information on the propane conversion
label and attach the label to the boiler rating plate.
Throttle screw adjustment procedure
See Figure39,page40, Figure40,page40, or Figure41 for location
of the throttle screw.
DO NOT attempt to adjust the throttle screw unless by
a qualied technician, and with the use of calibrated
combustion test instruments. Adjust the throttle
screw only as needed to meet the combustion values
given in Figure42.
1. is procedure is only necessary when specied elsewhere in
this manual or when combustion tests indicate the need, as
explained under “ Check ame & combustion with
instruments, page 40.”
2. Boiler behavior that might indicate a need to check combustion
values at high re (as per page40) to verify boiler is in adjust-
ment include: diculty igniting, poor ame stability at low re,
combustion noise or high carbon monoxide values.
3. Combustion readings must be taken at both high re and low
re. DO NOT attempt an adjustment of the throttle screw at
low re. Just check the combustion values.
4. Use the U-Control display to navigate to Manual test mode
(see Figure115,page102) and force the ring rate to MAX
(high re). Aer the boiler has had time to stabilize, take a
CO
2
reading.
a. If the CO
2
is HIGH, turn the throttle screw CLOCKWISE
to lower the input. Allow the boiler to stabilize and take
another reading. Continue until the desired CO
2
value is
achieved.
b. If the CO
2
is LOW, turn the throttle screw COUNTER-
CLOCKWISE to increase the input. Allow the boiler to
stabilize and take another reading. Continue until the
desired CO
2
value is achieved.
5. Lock the boiler into low re. Check the combustion readings. If
results are acceptable at low re, verify high re readings again.
Restore ring rate to AUTO.
6. Consult your local WM Technologies representative if accept-
able results cannot be obtained for both high and low re.
Adjust and test boiler controls
1. Follow instructions in this manual to set and verify
operation of the boiler controls.
Figure 42 Acceptable CO2 and CO values (CO2 values must be
within 1.0% of the values listed)
Boiler
Ultra
Fuel
High re Low re
%CO
2
CO ppm %CO
2
CO ppm
-80
NG 8 6 < 60 7 8 < 60
LP 9 6 < 60 8 6 < 60
-105
NG 9 0 < 60 8 4 < 60
LP 10 1 < 60 9 2 < 60
-155
NG 9 0 < 60 8 0 < 60
LP 10 0 < 60 8 5 < 60
-230
NG 9 0 < 60 8 0 < 60
LP 10 0 < 60 9 0 < 60
-299
NG 9 0 < 60 8 0 < 60
LP 10 0 < 60 9 0 < 60
-399
NG 9 2 < 100 8 4 < 60
LP 10 2 < 100 10 0 < 60
The values above are with the boiler front door removed. Values will typically
increase about 0.2% once the door is reinstalled.
The values above are for altitudes up to 5,500 feet. For higher altitudes, CO
2
may be slightly lower and CO slightly higher.
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
Check-out/startup verication
Veried that the U-Control is set for the correct boiler model?
Entered installation date and installer contact information
into U-Control?
Boiler and heat distribution units lled with water?
Water chemistry veried per page35?
Sentinel X100 corrosion inhibitor added and water tested to
be within range?
Automatic air vents, if used, open one full turn?
Air purged from system?
Air purged from gas piping? Piping checked for leaks?
Primed condensate trap?
Propane orice installed for propane ring and propane
conversion label axed to jacket?
Ultra boilers are shipped ready to fire natural
gas ONLY. Exception: e Ultra-80LP is factory-
equipped to re propane. To re on propane, for
all other models, you must follow the instructions
in this manual to install the propane orice or
conversion kit, or make adjustments required, if the
boiler will be connected to propane. See page48
Failure to comply could result in severe personal
injury, death or substantial property damage.
ermostat circuit wiring checked to ensure there are no
stray voltages?
Followed Operating Instructions, Figure38,page39?
Burner ame and combustion veried per page40?
Veried control operation for space heating and DHW (if
used) per this manual?
Tested additional eld-installed controls? — If boiler has
a low water cuto, additional high limit or other controls,
tested for operation as outlined by manufacturer? (Boiler
should be operating and should go o when controls are
tested. Verify controls cause automatic reset lockout or
manual reset lockout as desired.)
Set additional field-installed limit control(s) to system
temperature requirements? Adjusted balancing valves and
controls to provide design temperature to system?
For multiple zones, adjusted for correct ow in each zone?
Veried thermostat heat anticipator (if available) set prop-
erly?
Cycled boiler with thermostat (and with DHW aquastat, if
installed) — Raised to highest setting and veried boiler goes
through normal startup cycle? Lowered to lowest setting and
veried boiler goes o?
Measured natural gas input? (page40)
Checked incoming gas pressure by connecting manometer
to gas valve ahead of boiler? (Gas pressure must be at least
5 inches w.c. for natural gas, and 4 inches w.c. for propane,
with boiler operating at high re, and no more than 13 inches
w.c. with boiler operating or boiler o.)
Observed several operating cycles for proper operation?
Set room thermostat to desired room temperature (and DHW
aquastat, if installed, to desired DHW storage temperature)?
Reviewed all instructions shipped with this boiler with owner
or maintenance person?
Fill in Installation certicate, page140.
Fill out the warranty registration card and send to
WM Technologies.
Return instructions to envelope and give to owner or place
inside boiler housing.
Fill out start-up data on the Installation and
Service Certicate, page140.
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
ADVANCED INSTALLATION
43
ADVANCED INSTALLATION
Quick view . . .
Pages
Procedure
44–47
Identify and locate boiler components
y Read about boiler features and functions.
48–49
Modify boilers for propane operation, if required
y All boilers except the Ultra-399 require an orice change to
operate on propane — follow instructions.
50–51
Wall mounting option
y Wall mounting Ultra boilers requires a special kit.
y Follow instructions in this section to wall mount the boiler.
52–55
Additional system piping applications
y is section provides additional piping suggestions not covered
in the BASIC section.
y It includes an application with an existing indirect water heater
piped as a zone.
56–57
Sizing DHW piping and circulators
y is section provides information on boiler head loss vs ow
and other information needed for sizing DHW piping.
58–64
Installing multiple Ultra boilers
y is section provides application information and suggested
piping for multiple boiler systems.
66–92
Vent / air piping alternatives
y This section provides installation instructions for four
additional vent / air piping methods not covered in the
BASIC section (two sidewall congurations and two vertical
congurations).
93
Gas piping
y Size or verify sizing of gas supply lines with the information
in this section.
94–98
Field wiring
y is section includes wiring diagrams and additional wiring
options available with the U-Control module.
99–107
U-Control operation and setup — advanced
y is section provides a complete description of U-Control
setting options and diagnostics.
ADVANCED
INSTALLATION
(Pages 44–107)
READ AND FOLLOW
INSTRUCTIONS IN THE
BASIC INSTALLATION
SECTION FIRST. This section
is supplemental information
only.
This section covers multiple
boiler systems and system
types not covered under
the BASIC section. It also
includes alternative vent/air
piping methods, water and
gas pipe sizing guidelines and
advanced, detailed information
on the U-Control and boiler
wiring.
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
The
U
ltra Gas-red water boiler, Featuring U-Control Flexibility
Ultra Models -80, -105, -155 and -230
1. Cast aluminum Nanogate coated heat exchanger
2. Heat exchanger access cover
3. Blower
e advanced blower design and air inlet silencer on Ultra boilers
result in very quiet operation.
Models Ultra-80 & 105 — Air enters the boiler enclosure through
the air intake adapter (18), ows through the enclosure, enters the
air inlet silencer (5), then enters the blower. e blower pulls air
through the silencer and pushes it into the venturi (6), where it mixes
with gas before entering the burner.
Models Ultra-155 & 230 — Air enters the boiler enclosure through
the air intake adapter (18), ows through the enclosure, enters the
air inlet silencer (5), then enters the venturi (6). e blower pulls air
and gas through the venturi and pushes the mixture into the burner.
4. Gas valves and sense lines
e automatic gas valve (4a) senses the vacuum in the venturi
caused by owing air, and allows gas to ow when power is applied.
Models 80 and 105 use a sensing line (4c) from the gas valve to the
blower outlet so the gas valve references the same pressure as the
venturi inlet.
5. Air inlet silencer
e horn-shaped air inlet silencer signicantly reduces fan noise,
providing exceptionally quiet operation.
6. Venturi
When air ows through the venturi, it creates a vacuum. is vacuum
pulls gas from the gas valve. So gas will only ow if air is owing.
On model 80 and 105, the gas/air mixture enters the burner aer
the venturi. On models 155 and 230, the gas/air mixture enters the
blower before passing on to the burner.
7. Outlet water temperature dual sensor
is sensor monitors boiler outlet water temperature. e control
module adjusts boiler ring rate so the outlet temperature is correct,
based on boiler outlet and system supply temperatures.
8. Boiler return water temperature sensor
is sensor monitors return water temperature. e control module
reduces or increases boiler input, depending on how close the return
water temperature is to the outlet water temperature.
9. Electronic display & buttons
e electronic display is used to congure boiler settings and moni-
tor boiler operation.
e buttons allow changing display mode, entering setting values,
and resetting aer lockout.
10. Flue pipe adapter with internal drain
11. Burner (not shown)
Made with high-grade stainless steel construction, the burner uses
pre-mixed air and gas. e burner and control provide modulating
ring.
12. Water outlet pipe (system supply)
13. Water return pipe (system return)
14. Gas connection pipe
15. U-Control Module
e U-Control
Module responds to signals from the room thermo-
stats, DHW aquastats (when used), boiler sensors (boiler return,
boiler supply, system return, system supply, ue temperature, and
outdoor temperature, if used). e control module automatically
adjusts blower speed (and gas ow rate) to match boiler output to
space heating and/or DHW heating demand.
16. Swing-away control panel assembly
e Ultra control panel is mounted to a hinged sub panel, allow-
ing the panel to be swung forward and down for easy access to the
electrical connections.
17 Air intake adapter
e air intake adapter incorporates an internal drain on models80
and 105.
18. Electrical entrance
Knockouts are provided in the jacket top panel, allowing conduit
entry directly behind the control panel or near the wall.
19. Boiler drain valve
20. Flue gas condensate drain
Connect the boiler internal condensate trap line to the heat ex-
changer here (parts supplied with boiler, but eld installed).
21. Flue gas condensate drain connection
e condensate trap PVC ttings are eld-installed, connected to
the condensate trap line as shown in this manual.
22. Front door
e front door is sealed to the boiler assembly around its entire
perimeter.
23. Jacket door retainer screws
Two (2) screws secure the door in place.
24. Ignition electrode/ame sensor
e burner ame is ignited by applying a high voltage to the igni-
tion electrode. is causes a spark (from electrode to ground). Aer
ignition, the electrode measures ame signal.
25. Flame inspection window
e quartz glass window provides a view of the burner surface and
ame.
26. Flue gas dual sensor
is dual sensor monitors the ue gas exit temperature. e control
module will shut down the boiler if ue gas temperature gets too hot.
is protects the ue pipe and the heat exchanger from overheating.
27. ON/OFF switch
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
ADVANCED INSTALLATION
Front view
(all models)
U3001
Ultra-80 & 105
(front door removed)
Top view
(all models)
Top is shown with top cover
removed and control panel
swung down for easy
access to wiring terminals.
2222
2323
1111
66
88
33
4a4a
22
1010
55
11
99
1313
1212
1414
1919
1212
2020
2121
2424
2525
2626
77
4c4c
Ultra-155 & 230
(front door removed)
77
1111
66
88
33
4a4a
22
1010
55
11
99
1313
1212
1919 2020
2121
2424
2525
2626
1414
1212
(at supply pipe exit)
1616
2626
1717
1313
1212
1414
1818
1010
1515
2727
The Gas-red water boiler, Featuring Flexibility
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
The Gas-red water boiler, Featuring Flexibility
Ultra Models -299 and -399
1. Cast aluminum Nanogate coated heat exchanger
2. Heat exchanger access cover
3. Blower
e advanced blower design and air inlet silencer on Ultra boilers
result in very quiet operation.
Air enters the boiler enclosure through the air intake adapter (18),
ows through the enclosure, enters the air inlet silencer (5), then
enters the venturi (6). e blower pulls air and gas through the
venturi and pushes the mixture into the burner.
4. Gas valves and sense lines
e automatic gas valve (4a) senses the vacuum in the venturi caused
by owing air, and allows gas to ow when power is applied. e
manual gas valve (4b) allows shutting o the gas supply for servic-
ing or shutdown.
5. Air inlet silencer
e horn-shaped air inlet silencer signicantly reduces fan noise,
providing exceptionally quiet operation.
6. Venturi
When air ows through the venturi, it creates a vacuum. is vacuum
pulls gas from the gas valve. So gas will only ow if air is owing. e
gas/air mixture enters the blower before passing on to the burner.
7. Outlet water temperature dual sensor
is sensor monitors boiler outlet water temperature. e control
module adjusts boiler ring rate so the outlet temperature is correct,
based on boiler outlet and system supply temperatures.
8. Boiler return water temperature sensor
is sensor monitors return water temperature. e control module
reduces or increases boiler input, depending on how close the return
water temperature is to the outlet water temperature.
9. Electronic display & buttons
e electronic display is used to congure boiler settings and moni-
tor boiler operation.
e buttons allow changing display mode, entering setting values,
and resetting aer lockout.
10. Flue pipe adapter with internal drain
11. Burner (not shown)
Made with high-grade stainless steel construction, the burner uses
pre-mixed air and gas. e burner and control provide modulating
ring.
12. Water outlet pipe (system supply)
13. Water return pipe (system return)
14. Gas connection pipe
15. U-Control Module
e U-Control
Module responds to signals from the room thermo-
stats, DHW aquastats (when used), boiler sensors (boiler return,
boiler supply, system return, system supply, ue temperature, and
outdoor temperature, if used). e control module automatically
adjusts blower speed (and gas ow rate) to match boiler output to
space heating and/or DHW heating demand.
16. Swing-away control panel assembly
e Ultra control panel is mounted to a hinged sub panel, allow-
ing the panel to be swung forward and down for easy access to the
electrical connections.
17. Air intake adapter
18. Electrical entrance
Knockouts are provided in the jacket top panel, allowing conduit
entry directly behind the control panel or near the wall.
19. Boiler drain valve
20. Flue gas condensate drain
Connect the boiler internal condensate trap line to the heat ex-
changer here (parts supplied with boiler, but eld installed).
21. Flue gas condensate drain connection
e condensate trap PVC ttings are eld-installed, connected to
the condensate trap line as shown in this manual.
22. Front door
e front door is sealed to the boiler assembly around its entire
perimeter.
23. Jacket door retainer screws
Two (2) screws secure the door in place.
24. Ignition electrode/ame sensor
e burner ame is ignited by applying a high voltage to the igni-
tion electrode. is causes a spark (from electrode to ground). Aer
ignition, the electrode measures ame signal.
25. Flame inspection window
e quartz glass window provides a view of the burner surface and
ame.
26. Flue gas dual sensor
is dual sensor monitors the ue gas exit temperature. e control
module will shut down the boiler if ue gas temperature gets too hot.
is protects the ue pipe and the heat exchanger from overheating.
27. ON/OFF switch
Part number 550-100-440/0723
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ADVANCED INSTALLATION
The Gas-red water boiler, Featuring Flexibility
Part number 550-100-440/0723
48
series
4
gas-fired water boiler – boiler manual
Prepare boiler — convert for propane
Installing propane orice
If boiler is already installed — You must turn
o electrical supply to the boiler and close the
external manual gas shut-o 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 orice disc from conversion kit bag.
2. Verify that the stamping on the orice disk matches the model
size (see Figure43).
3. With the new boiler on its back, remove jacket front door by
removing two (2) screws at lower front.
Figure 43 Orice identication
Figure 44 Installing propane orice
(Ultra-105 or Ultra-80LP ONLY)
Prepare boiler for propane
(when required)
Propane operation
Ultra boilers must be converted for pro-
pane operation unless specically manu-
factured for propane
. Propane-ready boilers
have sux “LP” aer the model number. All
other boilers require conversion for propane
operation.
Ultra-80 natural gas boilers require installation
of a burner in addition to an orice change.
DO NOT use the instructions in this manual
for these boilers. Use only the instructions
included in the special-order conversion kits.
Converting existing natural gas-fired
boiler for propane
— For a boiler already
installed, you must turn o gas supply, turn
off power and allow boiler to cool before
proceeding. You must also completely test the
boiler aer conversion to verify performance
and start up the boiler following instructions
beginning on page35 of this manual.
High altitude installations — For instal-
lations more than 5,500 feet above sea level,
obtain the high altitude propane orice kit..
Verify orice size — See Figure43. Verify
when installing that the orice size marking
matches boiler size. Use only the special-order
high altitude orice for altitudes above 5,500
feet.
Failure to comply could result in severe per-
sonal injury, death or substantial property
damage.
Part number 550-100-440/0723
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ADVANCED INSTALLATION
4. Li the door away from boiler.
5. Remove the air inlet silencer from the adapter:
a. Models 80 and 105: See Figure134,page133.
b. Models 155 and 230: See Figure135,page134.
c. Models 299 and 399: See Figure136,page135.
6. Disconnect the gas valve electrical plug.
7. See Figure43,page48 or Figure45. Remove the 4 screws
securing gas valve inlet adapter to valve.
8. Use a 5mm wrench to remove the three Allen-head screws
securing the gas valve to the venturi (Figure43,page48
or Figure45).
9. Place orice in the black rubber grommet in the side of
the gas valve and secure in valve (Figure43,page48 or
Figure45).
See Figure43,page48 or Figure45. Inspect the
O-ring between the gas valve and gas valve inlet
adapter whenever they are disassembled. e
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 death.
10. Reposition gas valve against venturi and replace (3) Allen-
head screws securing valve to venturi (Figure43,page48
or Figure45).
11. See Figure43,page48 or Figure45. Secure gas valve inlet
adapter to gas valve with 4 screws. Make sure the plastic
hose is connected from gas valve to inlet elbow on Ultra-80
and -105.
DO NOT ATTEMPT TO MEASURE VALVE
OUTLET PRESSURE.
e valve could be dam-
aged by manometer uid contamination. Failure
to comply could result in severe personal injury,
death or substantial property damage.
12. Connect gas valve electrical plug to valve terminals.
13. Re-attach the air inlet silencer.
14. Aer installation is complete, attach the propane conver-
sion label (in conversion kit bag) next to the boiler rating
plate.
15. Reinstall boiler door.
Figure 45 Installing propane orice (Ultra-155, -230, & -299)
Ultra-399 boilers
Ultra-399 boilers are converted for propane by
adjustment of the gas valve throttling screw.
See instructions on page41 of this manual.
Do not perform the propane conversion of
an Ultra-399 boiler without using a ue gas
analyzer. e proper use of a ue gas analyzer
is required to determine proper gas valve set-
tings. Improper gas valve settings can cause
severe personal injury, death or substantial
property damage.
Prepare boiler — convert for propane (continued)
Part number 550-100-440/0723
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Placing boiler — wall-mounting option
Figure 46 Install wall-mount bracket
Figure 47 Place boiler on wall-mount bracket
Wall-mounted boilers (Ultra-80 through -399)
1. e wall-mounting kit is NOT supplied as standard equipment
with the boiler, and must be purchased separately. See WARNING
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.
e wall must be vertically plumb and capable of
carrying the weight of the boiler. e 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.
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
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 at washers (not included with kit).
6.
DO NOT 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. e 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. Read all
information and perform all procedures given in the Boiler Manual
on pages 4 through9 before mounting the boiler.
e boiler is heavy. Use caution not to drop the boiler
or cause bodily injury while liing and handling. Verify
that the boiler is securely attached to prevent possibility
of boiler falling aer installation.
Part number 550-100-440/0723
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ADVANCED INSTALLATION
Prepare boiler for wall mounting
1. Remove the jacket front panel. is will simplify liing and han-
dling the boiler when mounting.
2. When piping will be routed out the top of the boiler, no special
preparation is needed other than that given in this manual.
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.
5. Remove bracket and drill holes 1/4” diameter by 3inches deep,
centered on the screw slot outlines. (For metal stud walls, using
3/16” toggle bolts, drill required clearance holes.)
6. See Figure47,page50. Position bracket on wall. Insert and loosely
tighten the two lag screws (or toggle bolts for metal studs).
7. Level the bracket. en 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. (is line, or tape, will indicate whether
the boiler has been properly seated onto the wall-mount bracket.)
2. Obtain assistance to li the boiler into position:
a. Li the boiler high enough that its rear bracket will be above
the wall-mount bracket.
b. Let the rear of the boiler slide against the lag screw heads as
you lower the boiler into place.
c. When the brackets are engaged correctly, the bottom of the
boiler enclosure will be at or near the pencil line, or tape, you
applied in step 1.
d. If the boiler does not slide down close to the mark, or tape,
adjust until the brackets properly engage.
Placing boiler — wall-mounting option (continued)
Part number 550-100-440/0723
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Legend — Figure 48
1 Ultra boiler
2 Indirect water heater (DHW), if used
3 Boiler relief valve (see page9 for piping details)
4 Relief valve discharge piping (see page9 for details)
5 DHW circulator (see page56 for suggested sizing)
6 Isolation valves
7 System circulator (see information above for wiring)
8 Diaphragm (or bladder) type expansion tank (see page56 for piping of
closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
10 Flow/check valves
11 Purge/drain valves
12 Boiler circulator
13 Zone valves, typical
20 Make-up water supply
21 Primary/secondary connection (tees no more than 12 inches apart)
23 DHW supply/return
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.
25 Systems using high-head pumps may require a bypass pressure regulator
to prevent damage to control valves.
26 Temperature/Pressure gauge
27 DHW relief valve, if used
Items supplied with boiler
Items supplied by others
Install water piping — advanced
Figure 48 Zone valve zoning plus optional DHW piping
Zoning with zone valves
(alternate to piping shown in Figure 5, page 12)
High-ow-rate/high-head-loss DHW
circuits
1. For applications requiring DHW circuit ow rates higher than
allowable for the boiler, or for high pressure-drop coil-type
DHW tanks, connect the piping as in Figure48. e DHW
water only ows through the secondary circuit connector pip-
ing. NOTE: Make sure to size the connector piping (Figure48,
item23) to handle the total ow it must handle.
2. Connect boiler to system as shown in Figure48 when zone
valve zoning. e primary/secondary piping shown ensures
the boiler loop will have sucient ow. It also avoids apply-
ing the high head of the boiler circulator to the zone valves.
Use at least the MINIMUM pipe size shown in Fig-
ure48 on all boiler loop piping (connecting boiler
to and from the primary/secondary connection,
item21). Use only primary/secondary piping
as shown.
Failure to follow these guidelines could
result in system problems.
3. When using a closed-type expansion tank, connect the
expansion tank and make-up water piping as shown in
Figure4,page11.
4. Connect DHW (domestic hot water) piping to indirect stor-
age water heater as shown.
By default, the U-Control Module turns o space
heating during DHW heating (if DHW input is
priority 1). e boiler circulator will turn o, pre-
venting hot water from circulating to the system
(optional timeout setting can be used to override).
e ow/check valve shown on the boiler outlet
piping prevents gravity circulation in the boiler
loop during DHW heating.
Overriding the Outdoor Reset function by setting control
to DHW mode when system is intended for space heating
may violate Section 303 of the 2007 Energy Act. See
page137 for compliance information and exemptions.
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. e system circulator should be o during
DHW heating. Read the instructions on U-Control op-
eration and setup, beginning on page32.
MINIMUM
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1”
1¼”
1½”
See CAUTION at left.
Part number 550-100-440/0723
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ADVANCED INSTALLATION
Install water piping — advanced (continued)
Legend — Figure 49
1 Ultra boiler
2 Indirect water heater (DHW), if used
3 Boiler relief valve (see page9 for piping details)
4 Relief valve discharge piping (see page9 for details)
6 Isolation valves
8 Diaphragm (or bladder) type expansion tank (see page56 for piping of
closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
10 Flow/check valves
11 Purge/drain valves
12 Boiler circulator
20 Make-up water supply
21 Primary/secondary connection (tees no more than 12 inches apart)
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.
26 Temperature/Pressure gauge
Items supplied with boiler
Items supplied by others
Figure 49 Circulator zoning plus optional DHW piping
Example system with DHW as a zone,
zoning with circulators
1. Connect boiler to system as shown in Figure49 when circula-
tor zoning. e boiler circulator cannot be used for a zone.
It must supply only the boiler loop. Also see the information
on page10 for suggested piping and sizing.
Use at least the MINIMUM pipe size shown in
Figure49 on all boiler loop piping (connecting
boiler to and from the primary/secondary connec-
tion, item21). Use only primary/secondary pip-
ing as shown.
Failure to follow 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 AQUA PLUS water
heater in the system. e automatic air vent required on the
water heater will deplete air in the system, causing the expan-
sion tank to waterlog. Use only a diaphragm- or bladder-type
tank, suitable for automatic air vent applications.
4. In this example, the AQUA PLUS60 DHW tank is piped as
a zone in the system, with piping connections to the tank in
accordance with the AQUA PLUS manual.
5. Wiring to the U-Control
a. Priority 1 = AQUA PLUS 60 (zone 1): wire AQUA PLUS
60 aquastat terminals to U-Control P11, pins 4 and 5.
Wire DHW circulator, A, to U-Control P2, terminals1,
4 and 7 (H, N, G).
b. Wire zone pumps B and C to a two-zone circulator relay.
c. Priority 2 = nned-tube baseboard (zones 2 and 3): wire
circulator 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.
Overriding the Outdoor Reset function by setting control
to DHW mode when system is intended for space heating
may violate Section 303 of the 2007 Energy Act. See
page137 for compliance information and exemptions.
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 page32.
MINIMUM
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1”
1¼”
1½”
See CAUTION at left.
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
Legend — Figure 50
1 Ultra boiler
2 Indirect water heater (DHW), if used
3 Boiler relief valve (see page9 for piping details)
4 Relief valve discharge piping (see page9 for details)
5 DHW circulator (see page56 for suggested sizing)
6 Isolation valves
7 System circulator (see information above for wiring)
8 Diaphragm (or bladder) type expansion tank (see page56 for piping of
closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
10 Flow/check valves
11 Purge/drain valves
12 Boiler circulator
13 Zone valves, when used (zoning may also be done using manifold-mounted
valve actuators)
20 Make-up water supply
21 Primary/secondary connection (tees no more than 12 inches apart)
22 Optional high limit temperature control, set to protect radiant tubing
23 DHW supply/return
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.
25 Systems using high-head pumps may require a bypass pressure regulator
to prevent damage to control valves.
26 Temperature/Pressure gauge
27 DHW relief valve, if used
Items supplied with boiler
Items supplied by others
Figure 50 Typical radiant heating system piping plus optional
DHW
Radiant heating applications
1. e Ultra boiler is ideal for use in radiant heating. e Ultra
boiler’s unique heat exchanger design allows it to work well
even in condensing mode. So there is no need to regulate boil-
er return water temperature in radiant heating applications.
2. Connect boiler to system as shown in Figure50 for typical
radiant heating applications. e primary/secondary piping
shown ensures the boiler loop will have sucient ow. Size the
system piping and circulator to provide the ow and pressure
drop needed for the radiant system.
Use at least the MINIMUM pipe size shown in Fig-
ure50 on all boiler loop piping (connecting boiler
to and from the primary/secondary connection,
item21). Use only primary/secondary piping
as shown.
Failure to follow these guidelines could
result in system problems.
3. Adding the recommended high limit control (Figure50,
item22) 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.
4. When using a closed-type expansion tank, connect the
expansion tank and make-up water piping as shown in
Figure4,page11.
5. Connect DHW (domestic hot water) piping to indirect stor-
age water heater as shown.
By default, the U-Control Module turns o space
heating during DHW heating (if DHW input is
priority 1). e boiler circulator will turn o, pre-
venting hot water from circulating to the system
(optional timeout setting can be used to override).
e ow/check valve shown on the boiler outlet
piping prevents gravity circulation in the boiler
loop during DHW heating.
Overriding the Outdoor Reset function by setting control
to DHW mode when system is intended for space heating
may violate Section 303 of the 2007 Energy Act. See
page137 for compliance information and exemptions.
6. Controlling the circulators
a. e U-Control can control up to three circulators (boiler
circulator and two others). Refer to Field wiring, begin-
ning on page30, for instructions on wiring to circulators.
Install water piping — advanced (continued)
b. e factory default settings are: DHW circulator as Circu-
lator1, boiler circulator as Circulator2. See Field wiring
instructions, beginning on page30, for details.
MINIMUM
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1”
1¼”
1½”
See CAUTION at left.
Part number 550-100-440/0723
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gas-fired water boiler – boiler manual
ADVANCED INSTALLATION
Legend — Figure 51
1 Ultra boiler
2 Indirect water heater (DHW), if used
3 Boiler relief valve (see page9 for piping details)
4 Relief valve discharge piping (see page9 for details)
5 DHW circulator (see page56 for suggested sizing)
6 Isolation valves
7 System circulator (see information above for wiring)
8 Diaphragm (or bladder) type expansion tank (see page56 for piping of
closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
10 Flow/check valves
11 Purge/drain valves
12 Boiler circulator
13 Zone valves, typical
15 Closed-type expansion tank
16 Water chiller
17 Check valve
18 Strainer
19 Balancing valve
20 Make-up water supply
21 Primary/secondary connection (tees no more than 12 inches apart)
23 DHW supply/return
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.
25 Systems using high-head pumps may require a bypass pressure regulator
to prevent damage to control valves.
26 Temperature/Pressure gauge
27 DHW relief valve, if used
Items supplied with boiler
Items supplied by others
Chilled water systems
1. Install boiler so that chilled medium is piped in parallel with
the heating boiler. Use appropriate valves to prevent chilled
medium from entering boiler. See Figure51 for typical instal-
lation of balancing valve and check valve.
Use at least the MINIMUM pipe size shown in Fig-
ure51 on all boiler loop piping (connecting boiler
to and from the primary/secondary connection,
item21). Use only primary/secondary piping
as shown.
Failure to follow these guidelines could
result in system problems.
2. e 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 ef-
fects 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 Figure51. Use appropri-
ate valves to prevent chilled medium from entering
boiler.
If boiler is connected to heating coils located in
air handling units where they can be exposed to
refrigerated air, use ow control valves or other
automatic means to prevent gravity circulation
during cooling cycle.
By default, the U-Control Module turns o space
heating during DHW heating (if DHW input is
priority 1). e boiler circulator will turn o, pre-
venting hot water from circulating to the system
(optional timeout setting can be used to override).
e ow/check valve shown on the boiler outlet
piping prevents gravity circulation in the boiler
loop during DHW heating.
Overriding the Outdoor Reset function by setting control
to DHW mode when system is intended for space heating
may violate Section 303 of the 2007 Energy Act. See
page137 for compliance information and exemptions.
3. Controlling the circulators
a. e U-Control can control up to three circulators (boiler
circulator and two others). Refer to Field wiring, begin-
ning on page30, for instructions on wiring to circulators.
Figure 51 Chilled water system plus optional DHW piping
Install water piping — advanced (continued)
b. e factory default settings are: DHW circulator as
Circulator1, boiler circulator as Circulator2. See Field
wiring instructions, beginning on page30, for details.
MINIMUM
Boiler loop pipe size
Ultra-80, 105
Ultra-155, 230
Ultra-299, 399
1”
1¼”
1½”
See CAUTION at left.
Part number 550-100-440/0723
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Sizing direct-connected DHW piping
e closest circulator selection (from Figure55,page57)
that can deliver 12gpm at 22.7feet head is either a Taco
1400 (top chart) or a Taco0013 (bottom chart).
Note that, if the water heater were piped as in Figure53,
then H1 would be 0, so total head loss would be H2 + H3,
or 9.4 feet (3.9 + 5.5). A Taco 0010 would handle the load
if piped this way.
See previous pages in this manual for piping details
not shown below. For DHW piping as shown below,
use sizing information in Figure54,page57.
Figure 52 DHW piping direct-connected across the boiler
Figure 53 DHW piping as a secondary circuit — for high-ow-rate
applications
Direct-connected DHW piping
For Weil-McLain AQUA PLUS water heaters,
refer to the AQUA PLUS water heater manual for
application information. Also see quick-select in-
formation on page14. e information here is for
other water heater designs.
When using the Ultra boiler for dedicated DHW ap-
plications, use the circulator supplied with the boiler
(007 for Ultra-80/105; 0014 for Ultra-155/230/299;
0013 for Ultra-399) to circulate to the water heater,
except where higher ow rates may be required for
the heater used. Use the following method to select
a circulator for the water heater on combined space
heating/DHW systems.
1. To pipe the DHW tank and boiler, follow the suggested piping
diagrams beginning on page12.
2. Figure55,page57 shows the pump curves for typical DHW
circulators. Use these curves along with boiler pressure drop
data from Figure54, page57 to size the DHW piping and
circulator.
3. Procedure to select a DHW circulator:
Step 1:
From the water heater manufacturer’s data, nd:
• Required boiler water ow rate, GPM, at 190°F.
• Pressure drop across the water heater at this ow rate, in
feet water column (this is H3 in the formula below).
Step 2:
Find your boiler model in Figure54,page57.
Select a ow rate in the Flow rate column just larger than the
required boiler water ow rate from Step1.
Step 3:
Read across the row selected to nd the boiler pressure drop,
H1, and the pressure drop in the piping, H2. Make sure to
use the copper pipe size given in column 3 when piping the
water heater.
Step 4:
Add the pressure drop across the water heater, from Step 1,
to the values of H1 and H2 for total head loss.
H
total
= H1 + H2 + H3
Step 5:
Select a circulator that can deliver the required ow rate,
gpm, against the total head loss found in Step 4.
Example:
Consider an Ultra-155 used with a water heater that requires
a ow of 12 gpm with boiler water at 190°F. e water heater
is to be piped as in Figure52.
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 rst column of Figure54,page57 for the
Ultra-155 until you nd a ow rate just larger than the re-
quired 12 gpm. You’ll nd a value of 13 gpm in the third row.
At 13 gpm, with an Ultra-155, the recommended pipe size
is 1¼inch. 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)
H
total
= 13.3 + 3.9 + 5.5 = 22.7 feet.
Part number 550-100-440/0723
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ADVANCED INSTALLATION
Figure 55 Pump curves for typical circulators suggested for DHW loopFigure 54 Pipe sizing and head losses for DHW applications
(H1=Ultra boiler head loss; H2=piping head
loss)
Flow
rate
Temp
rise
Pipe
size
H1 H2
GPM °F Inches
Boiler head loss
Feet w.c.
Piping head
loss
Feet w.c.
Ultra-80 (71,000 Btuh output)
7 20 1 6 6 2 7
9 16 1 11 6 4 2
10 14 1¼ 14 6 2 5
Ultra-105 (94,000 Btuh output)
7 27 1 7 0 2 7
9 21 1 11 2 4 2
10 19 1¼ 13 6 2 5
13 14 1¼ 22 2 3 9
Ultra-155 (139,000 Btuh output)
9 31 1¼ 6 2 2 1
10 0 28 1¼ 7 7 2 5
13 21 1¼ 13 3 3 9
16 17 1¼ 20 5 5 7
Ultra-230 (207,000 Btuh output)
13 32 1¼ 9 4 3 9
16 26 1¼ 13 7 5 7
21 20 1½ 22 0 2 9
Ultra-299 (279,000 Btuh output)
18 31 1½ 6 6 2 2
22 25 1½ 9 5 3 1
29 19 2 17 4 2 9
Ultra-399 (365,000 Btuh output)
22 34 1½ 9 5 3 1
29 25 2 15 5 2 9
36 20 2 22 8 4 3
A B & G PL-36
B Taco 0011
C Taco 0010
D Taco 007
K Taco 1400-30
E Taco 0013
F Grundfos 43-75
G Taco 0014
H Grundfos 15-42
J Taco 1400-20
L Taco 0012
Sizing direct-connected DHW piping (continued)
Part number 550-100-440/0723
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Multiple boiler installations
Placing multiple boilers
1. Locate multiple boilers in boiler room according to:
a. Figure56 (side-to-side), or
b. Figure57 (back-to-back).
c. Figure58 (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 page5. Also follow local codes.
3. Construct boiler foundation if boiler room oor
is uneven or if there is a danger of ooding. Size
foundation to allow for clearance and spacing di-
mensions shown in the illustrations at right.
4. Chalk line boiler locations on foundation or boiler
room oor.
5. Uncrate, assemble and mount boilers according to
instructions in this manual.
6. Provide clearance for installation of venting, air pip-
ing, gas piping, expansion tank, primary circulator
and other accessories.
Wall mounting
(Ultra Models 80 –
399)
1. Ultra boilers may be wall mounted, following the
instructions on page50. (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 Figure58.
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
page50 for details.
Figure 56 Side-to-side mounting of multiple Ultra boilers
Figure 57 Back-to-back installation of multiple Ultra boilers
29"
29"
29"
30"
6"
30"
U3152
6" 6" 6"
Figure 58 Wall mounting multiple Ultra boilers
29"
29"
29"
29"
29"
29"
30"
30"
U3153
6" 6"6"
Provide minimum 30-inch walkway, or per applicable codes.
Provide minimum 30-inch walkway, or per applicable codes.
Part number 550-100-440/0723
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ADVANCED INSTALLATION
Figure 59 Manifolded combustion air option
U3160
Air Vent
12" min
Grade or
snow line
Minimum 3 feet below any vent termination within 10 feet
Air VentAir Vent
Air duct
Multiple boiler installations (continued)
Manifolded combustion air option
1. Multiple Ultra boilers can use a common combustion air manifold.
a. See Figure 139,page138 for minimum cross sectional area of
combined air ducts.
b. Provide minimum clearance to adjacent vents and grade/snow line
as shown in Figure59.
c. Provide minimum free area in duct (adjusted for louver restriction)
of
1 square inch per 2,000 Btuh total boiler input.
d. If combustion air damper is used, wire to boilers to prevent opera-
tion except aer 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.
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 Figure139,page138 for minimum cross sectional area
of combined air ducts.
OR
Calculate required cross section (for area in square inches):
MIN. AREA = TOTAL MBH INPUT DIVIDED BY 2
Example: A multiple boiler system with (6) Ultra-155 boilers
has a total input of 6 x 155 = 930 MBH (930,000 Btuh). e
required duct cross sectional area is:
MIN. AREA = 930 DIVIDED BY 2 = 465 sq. inches
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Multiple boiler installations (continued)
Easy-Fit
®
piping installation
1. Main header and Easy-Fit
®
Manifold pipe sizing.
a. New system — See page10.
b. Replacing boilers in an existing system — Without reducing
size, connect system supply and return lines. Install tees or
crosses for Easy-Fit
®
manifolds as shown in Figure60 orFig-
ure61. Size manifolds to handle total connected boiler output
as shown.
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 Figure60.
b. Use either tees (Figure60) or crosses (Figure61) for ve 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 Figure60 andFigure61.
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 ow in system main from right to
le. For system owing le 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
ow rate.
5. Provide a ow/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.
7. Install system accessories as shown in drawings.
8. Piping recommendation drawings:
a. Figure60 andFigure61 show details of Easy-Fit
®
manifolds.
b. Figure62,page61 is a schematic piping drawing showing the
locations of typical boiler piping and system piping, including
limits and other devices oen required by local codes.
c. Figure63,page62 and Figure64,page63 are three-dimensional
piping drawings of typical multiple boiler installation.
d. Figure65,page64 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.
The U-Control module proves water level using a
dual temperature sensor installed in the Ultra heat
exchanger
. is will satisfy some code requirements for
low water cuto protection.
Maximum connected load per manifold:
2-inch manifold — 450 MBH
3-inch manifold — 1400 MBH
4-inch manifold — 2900 MBH
Figure 60
Single-sided EZ-Fit Header connection
Figure 61 Double-sided EZ-Fit Header connection
Part number 550-100-440/0723
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ADVANCED INSTALLATION
Multiple boiler installations (continued)
Legend — Figure 62
1 Flow/check valve (each boiler)
2 Isolation valves (when used)
3 Cap
4 Easy-Fit® Manifold (supply) — layout and size per page60
5 Easy-Fit® Manifold (return) — layout and size per page60
6 Primary circulator
7 Expansion tank (diaphragm type)
8 System air eliminator
9 System automatic air vent
10 Pressure reducing valve
11 Check valve or backow preventer, as required by applicable codes
12 Isolation valve
13 Cold water supply
14 Supply water temperature control (when used)
15 Low water cuto (when used) (place above primary header)
16 Water ow switch (when used)
17 Boiler circulator (each boiler)
18 System supply
19 System return
20 Boiler relief valve and discharge piping, installed per Ultra Boiler
Manual
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.
26 Temperature/pressure gauge
Figure 62 Piping schematic — typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit manifolds
Part number 550-100-440/0723
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Multiple boiler installations (continued)
Legend — Figure 63
1 Flow/check valve (each boiler)
2 Isolation valves (when used)
3 Caps
4 Easy-Fit® Manifold (supply) — layout and size per page60
5 Easy-Fit® Manifold (return) — layout and size per page60
6 Primary circulator
7 Expansion tank (diaphragm type)
8 System air eliminator
9 System automatic air vent
13 Cold water supply
17 Boiler circulator (each boiler)
18 System supply
19 System return
20 Boiler relief valve and discharge piping, installed per Ultra Boiler Manual
21 Indirect-red storage water heaters (Weil-McLain AQUA PLUS shown) —
Example is shown connected to one boiler of the system. Preferably, use
the last boiler in the lead/lag sequence and set its Priority to DHW Direct
so it will switch to DHW ring and turn o its boiler circulator on a call
for domestic water heating.
24 DHW boiler-side circulator
30 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.
31 Temperature/pressure gauge
Figure 63 Piping layout — typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit manifolds (2-boiler system)
Part number 550-100-440/0723
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ADVANCED INSTALLATION
Figure 64 Piping layout — typical piping for multiple Ultra boilers, with DHW storage heaters (4-boiler system)
Suggested DHW
boiler-side pipe
sizing
(for max 0.04
feet head loss per foot of
total equivalent length,
TEL)
Flow rate Size Flow rate Size
1 – 3.9 gpm ¾” 24 – 45 gpm 2”
3.9 – 7.1 gpm 1” 45 – 75 gpm 2½”
7.1 – 16 gpm 1¼” 75 - 140 gpm 3”
16 – 24 gpm 1½” 140 – 290 gpm 4”
Multiple boiler installations (continued)
Legend — Figure 64
1 Flow/check valve (each boiler)
2 Isolation valves (when used)
3 Caps
4 Easy-Fit® Manifold (supply) — layout
and size per page60
5 Easy-Fit® Manifold (return) — layout
and size per page60
6 Primary circulator
7 Expansion tank (diaphragm type)
8 System air eliminator
9 System automatic air vent
13 Cold water supply
17 Boiler circulator (each boiler)
18 System supply
19 System return
20 Boiler relief valve and discharge piping,
installed per Ultra Boiler Manual
21 Indirect-red storage water heaters (Weil-McLain AQUA PLUS shown) — Example
is shown with reverse-return boiler-side piping using a single circulator. Alternate:
each water heater could have its own circulator.
22 Boiler water inlet
23 Boiler water outlet
24 DHW boiler-side circulators
25 DHW boiler-side supply Easy-Fit® Manifold
26 DHW boiler-side return Easy-Fit® Manifold
27 Flow/check valves (to prevent induced or gravity ow in heating system or DHW
piping)
28 Check valve to prevent heat migration in heating system.
29 See water heater manual for DHW piping — e DHW piping must also be manifolded
together since the boiler-side piping is manifolded. If DHW heaters supply separate
DHW circuits, provide an individual circulator for each water heater, and control
each circulator by its water heater’s aquastat.
30
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.
31 Temperature/pressure gauge
This piping is
suggested only.
The layout above should be
controlled with a boiler se-
quencing panel that provides
DHW operation as well. Wire
the heating system circulator to
operate only on call for heat.
Alternatively, use the boiler se-
quencing panel to provide do-
mestic priority by disabling the
heating system circulator any
time there is a DHW call for
heat. e boiler circulators, item
17, must operate on any call for
heat, whether heating system or
DHW. Oset the DHW boiler-
side supply and return mani-
folds as shown so the total run
of pipe and ttings to each of the
water heaters is approximately
equal.
20
31
20
31
20
31
U3158-sp
20
31
1
17
2
Drain
valves
2
2
25
26
29
2
2
17
2
17
2
17
1
22
23
24
21
23
27
24
21
22
23
27
24
21
21
21
3
4
5
6
7
8
9
13
18
19
2
2
2
27
28
2
1
1
2
30
30
Part number 550-100-440/0723
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Multiple boiler installations (continued)
Figure 65 Piping layout — typical piping for multiple Ultra boilers, using isolation exchanger
Use isolation heat
exchanger for:
1. Large volume systems with high
mineral content in water.
2. Systems exposed to untreated
quantities of makeup water.
3. Old systems severely con
-
taminated with scale and rust
buildup inside piping and heat
distribution units.
4. Process applications.
5. Commercial service water ap
-
plications.
6. High water pressure applica
-
tions, 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)
2 Isolation valves (when used)
3 Cap
4 Easy-Fit® Manifold (supply) — layout
and size per page60
5 Easy-Fit® Manifold (return) — layout
and size per page60
6a Heating system circulator (exchanger
tube-side)
6b Heat exchanger shell-side circulator
7 Expansion tanks (diaphragm type)
8 System air eliminator
9 System automatic air vent
13 Cold water supply connections
17 Boiler circulator (each boiler)
18 Heating system supply
19 Heating system return
20 Boiler relief valve and discharge piping,
installed per Ultra Boiler Manual
30 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.
31 Temperature/pressure gauge
Notes:
1. Contact heat exchanger manufacturer for heat exchanger
shell-side and tube-side piping and circulator require-
ments. Tube-side ow and temperatures must meet heat-
ing system requirements.
2. Contact heat exchanger manufacturer for sizing heat
exchanger.
3. Heat exchanger shell-side circuit requires its own expan-
sion tank as shown.
4. Heating system circuit requires its own expansion tank,
as shown, plus its own relief valve set to protect heating
system and heat exchanger piping and components.
5. When individual isolation valves are used, individual
boiler and level controls may be required.
2
17
31
20
2
17
31
U3159
1
3
4
5
6b
7
8
9
13
18
19
2
2
2
2
13
7
6a
2
2
2
Heat exchanger
8
9
Boiler-side circuit
Heating system circuit
31
2
17
31
2
17
30
30
20
31
2
17
20
20
20
1
2
1
2
1
2
Part number 550-100-440/0723
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ADVANCED INSTALLATION
Venting/air piping — Massachusetts installations
(a) REQUIREMENTS: For all sidewall horizontally-vented gas-
fueled equipment installed in every dwelling, building or
structure used in 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 above nished grade in the area of the venting,
including but not limited to decks and porches, the following
requirements shall be satised:
1.
INSTALLATION OF CARBON MONOXIDE DETEC-
TORS
. At the time of installation of the side wall horizon-
tal vented gas fueled equipment, the installing plumber
or gas fitter shall observe that a hard wired carbon
monoxide detector with an alarm and battery back-up
is installed on the oor level where the gas equipment is
to be installed. In addition, the installing plumber or gas
tter shall observe that a battery operated or hard wired
carbon monoxide detector with an alarm is installed on
each additional level of the dwelling, building or struc-
ture served by the side wall horizontal vented gas fueled
equipment. It shall be the responsibility of the property
owner to secure the services of qualied licensed profes-
sionals for the installation of hard wired carbon monoxide
detectors
a. In the event that the side wall horizontally vented gas
fueled equipment is installed in a crawl space or an
attic, the hard wired carbon monoxide detector with
alarm and battery back-up may be installed on the
next adjacent oor level.
b. In the event that the requirements of this subdivision
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,
however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an
alarm shall be installed.
2.
APPROVED CARBON MONOXIDE DETECTORS. Each
carbon monoxide detector as required in accordance with
the above provisions shall comply with NFPA720 and be
ANSI/UL2034 listed and IAS certied.
3.
SIGNAGE. A metal or plastic identication plate shall
be permanently mounted to the exterior of the build-
ing at a minimum height of eight(8)feet above grade
directly in line with the exhaust vent terminal for the
horizontally vented gas fueled heating appliance or
equipment. e sign shall read, in print size no less than
one-half(1/2) inch in size, “GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”
4.
INSPECTION. e state or local gas inspector of the
side wall horizontally vented gas fueled equipment shall
not approve the installation unless, upon inspection,
the inspector observes carbon monoxide detectors and
signage installed in accordance with the provisions of
248CMR5.08(2)(a)1 through4.
(b)
EXEMPTIONS: e following equipment is exempt from
248CMR5.08(2)(a)1 through 4:
1. e equipment listed in Chapter 10 entitled “Equipment
Not Required To Be Vented” in the most current edition
of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled
equipment installed in a room or structure separate from
the dwelling, building or structure used in whole or in
part for residential purposes.
(c)
MANUFACTURER REQUIREMENTS — GAS EQUIPMENT
VENTING SYSTEM PROVIDED
. When the manufacturer of
Product Approved side wall horizontally vented gas equip-
ment provides a venting system design or venting system
components with the equipment, the instructions provided
by the manufacturer for installation of the equipment and
the venting system shall include:
1. Detailed instructions for the installation of the venting
system design or the venting system components; and
2. A complete parts list for the venting system design or
venting system.
(d)
MANUFACTURER REQUIREMENTS — GAS EQUIPMENT
VENTING SYSTEM NOT PROVIDED
. When the manufac-
turer of a Product Approved side wall horizontally vented gas
fueled equipment does not provide the parts for venting the
ue gases, but identies “special venting systems”, the follow-
ing requirements shall be satised by the manufacturer:
1. e referenced “special venting system” instructions shall
be included with the appliance or equipment installation
instructions; and
2. e “special venting systems” shall be Product Approved
by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.
(e)
PLASTIC VENTING SYSTEMS.
e only plastic piping which may be used for venting ap-
pliances shall be:
1. Allowed by the appliance manufacturer.
2. Listed to a national/international standard for plastic
venting systems.
3. Product-accepted for that purpose by the board.
(f)
INSTALLATION INSTRUCTIONS. A copy of all installation
instructions for all Product Approved side wall horizontally
vented gas fueled equipment, all venting instructions, all
parts lists for venting instructions, and/or all venting design
instructions shall remain with the appliance or equipment at
the completion of the installation.
Commonwealth of Massachusetts Installations
Commonwealth of Massachusetts — When the boiler is installed within the Commonwealth of Massachusetts, the
boiler must be installed by a licensed plumber or gas tter. Read and comply with the instructions below.
Part number 550-100-440/0723
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Vent/air piping — options
Vent and air pipe termination options
1. Vent and air piping must terminate out the sidewall or through
the roof of the building, using only one of the methods described
in this manual.
2. Sidewall options (see Figure12,page18, le side):
a. TOP: Weil-McLain termination cap (kit included with
boiler) — see page67 for instructions.
b. MIDDLE: Concentric PVC pipe (requires special kit,
page129).
c. BOTTOM: Separate air pipe and vent pipe.
3. Vertical options (Figure12,page18, right side):
a. TOP: Concentric PVC pipe (requires special kit, page129).
b. BOTTOM: Separate air pipe and vent pipe.
Vent and air pipe diameters
1. Vent and air pipe diameters can be as specied in Figure12,page18.
Vent and air pipe minimum length
1. Vent pipe and air pipe must each be at least 2 feet long, with
2elbows if sidewall venting or 1 elbow if vertical venting.
Vent and air pipe installation sequence
Step 1 Install the boiler.
Step 2 Determine the termination method — sidewall or vertical,
concentric or separate pipes, etc.
Step 3 Determine proper location for wall or roof penetration for
each termination.
Step 4 Install termination assembly as described in this manual.
Step 5 Install air and vent piping from boiler to termination.
Step 6 Install pipe supports and brackets as required.
Figure 66 Sidewall and vertical termination
options
Sidewall
termination
Weil-McLain sidewall
termination plate
(See page 67)
Weil-McLain
3” or 4” concentric
termination
(See page 72)
Sidewall termination
with separate vent
and air pipes
(See page 20)
Vertical
termination
Weil-McLain
3” or 4” concentric
termination
(See page 75)
Vertical termination
with separate vent
and air pipes
(See page 23)
Part number 550-100-440/0723
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ADVANCED INSTALLATION
Figure 67 Vent and air pipe requirements
Vent and air pipe installation sequence
Step 7 Install the boiler.
Step 8 Determine the termination method — sidewall or vertical,
concentric or separate pipes, etc.
Step 9 Determine proper location for wall or roof penetration
for each termination.
Step 10 Install termination assembly as described in this manual.
Step 11 Install air and vent piping from boiler to termination.
Step 12 Install pipe supports and brackets as required.
Other vent/air piping alternatives
— see information beginning on
page66. Options include other
termination fittings and vertical
terminations.
Commonwealth of Massachusetts
When the boiler is installed within the Commonwealth of Mas-
sachusetts:
y is product must be installed by a licensed plumber or gas
tter.
y Sidewall vent air installations — see instructions on page65.
Sidewall termination
(Weil-McLain sidewall termination cap)
Ultra
models
2”
Plastic
3” Plastic or
3” AL29-4C
4” Plastic or
4” AL29-4C
-80 & -105 Yes Yes No
-155 No Yes No
-230 No Yes Yes
299/399 No No Yes
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 2feet long,
with two (2)elbows if sidewall venting or 1 elbow if
vertical venting.
Vent and air pipe maximum length
1. See Figure69,page68 for maximum length of vent and
air piping using the Weil-McLain sidewall vent cap.
Vent and air pipe termination
options
1. This section covers sidewall termination using the
Weil-McLain sidewall vent cap.
a. Models 80, 105 and 155 requires a 3-inch pipe size kit.
b. Models 230, 299 and 399 requires a 4-inch pipe size kit.
c. e Weil-McLain sidewall vent/air cap kit includes
the termination cap, inside and outside wall plates,
and mounting hardware to secure the plates.
2. For other termination options and parts required,
see page66.
Vent and air pipe requirements
1. Vent and air pipe diameters can be as specified in
Figure67.
Figure 68 Vent and air termination options
Sidewall vent/air termination: Weil-McLain cap
Part number 550-100-440/0723
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Provide pipe adapters as needed where pipe size is
dierent from termination connections or boiler
connections, and for all AL29-4C vent pipe con-
nections at the boiler and the termination.
Allowable vent/air pipe materials
1. Use only the materials listed in Figure13,page19.
Maximum piping length
1. Locate the termination such that the total air piping and
vent piping from the boiler to the termination will not
exceed the maximum length given in Figure69.
2. Maximum lengths listed in Figure69 allow for 2 elbows.
Additional elbows required a reduction in maximum length
as explained in the table notes.
Figure 69 Maximum piping lengths for Weil-McLain sidewall vent/
air plate
Connecting from termination to boiler
1. Install the termination as instructed in the following. en
proceed to page71 to complete the air and vent piping between
the termination and the boiler.
Determine location for termination cap
A gas vent extending through an exterior wall shall
not terminate adjacent to the wall or below building
extensions such as eaves, parapets, balconies or decks.
Failure to comply could result in severe personal
injury, death or substantial property damage.
1. Locate the vent/air terminations using the following guidelines.
2. 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. e ue products will form a noticeable plume as they
condense 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 ue products impinge on building
surfaces or plants.
Boiler
Ultra
Maximum
Piping, 2” *
Maximum
Piping, 3” *
Maximum
Piping, 4” *
Feet Elbows Feet Elbows Feet Elbows
-80 ** 100 2 100 2
Not
allowed
-105 ** 100 2 100 2
-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 allowable length:
• 7 feet for each additional 4-inch elbow (90° or 45°)
• 7 feet for each additional 2 or 3-inch long radius elbow
• 16 feet for each 2 or 3-inch short radius elbow
• 7 feet for each 2 or 3-inch 45-degree elbow.
Figure 70 Termination location – Weil-McLain vent/air plate – height
above grade or snow line
Sidewall vent/air termination: Weil-McLain cap (cont.)
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ADVANCED INSTALLATION
d. Avoid possibility of accidental contact of ue products with
people or pets.
e. Do not locate the terminations where wind eddies could aect
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
nishes.
3. Maintain clearances as shown in Figure70,page68, Figure71,
Figure72 and Figure73. Also maintain the following:
a. Vent must terminate:
• At least 6 feet from adjacent walls.
• No closer than 5 feet below roof overhang.
• At least 7 feet above any public walkway.
• At least 3 feet above any forced air intake within 10feet.
• 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
below) 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
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 Figure73 for U. S. installations. For Canadian installations,
provide clearances required by Natural Gas and Propane Instal-
lation
CAN/CSA
B149.1 or B149.2 Installation Code.
3. e air inlet of an Ultra boiler is part of a direct vent connection.
It is not classied 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 Figure59,page59.
Figure 71 Termination location – Weil-McLain vent/air plate –
clearances to openings
Figure 72 Termination location – Weil-McLain vent/air plate –
clearances to public walkway or forced air intake
Figure 73 Termination location – Weil-McLain vent/air plate –
multiple boilers – clearance from vent to air intake of
the next boiler
Sidewall vent/air termination: Weil-McLain cap (cont.)
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Figure 74 Hole preparation in wall — Weil-McLain vent/air plate
Figure 75 Termination assembly — Weil-McLain vent/air plate
1 Vent termination (3” or 4”)
2 Lock washer, #10 (4)
3 Sheet metal screw, #10 x ½” (4)
4 Plastic wall anchor (8)
5 Sheet metal screw, #10 x 1¼” (8)
6 Outer mounting plate
7 Inner mounting plate
8 Vent pipe (butt to screen in termi-
nation)
9 Air pipe (butt to stops in termina-
tion)
Figure 76 Install termination plate
Weil-McLain sidewall
termination plate
• Install pipe supports every 5
feet on both the horizontal and
vertical runs.
• Install a hanger support within
6inches of any upturn in the
piping.
• e Weil-McLain plate
termination must be installed
before piping from the boiler to
the termination.
• Slope horizontal piping
downward toward the boiler at
least 1/4 inch per foot.
Sidewall vent/air termination: Weil-McLain cap (cont.)
Install terminations — Weil-McLain vent/air cap
e inside and outside cover plates are stamped to
identify 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 mount-
ing holes, ue pipe and air pipe. Level the template with a
spirit level.
For the Weil-McLain plate, the template must be level
to ensure the ue and air pipe will be side-to-side, as
shown in Figure74. Failure to comply could result in
severe personal injury, death or substantial property
damage.
e. Cut holes in the wall as shown in Figure75, using the loca-
tion marks made with the template. For best results, use a
small-diameter, long drill bit to drill centering holes for the
ue and air pipe openings. en drill the large openings from
both the inside and outside.
f. e ue 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 ue 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
(Ultra-230 applications), increase the ue pipe size to 4 inch
before the pipe passes through the wall. is is required to
obtain a seal between the ue pipe and the termination.
d. Temporarily slide the flue and air pipes through the
opening(s). Slide the inside wall plate over the two pipes and
into position on the inside wall.
e. Position the inside plate so the ue pipe and air pipe slope
downward slightly toward the boiler (1/4” per foot).
f. Mark the four (4) mounting holes for the plate.
g. Remove the vent and air pipe, drill the four mounting holes,
and mount the inside plate.
3. Test t the vent/air termination on the vent pipe. Make sure the
vent pipe fully penetrates the termination socket and the air pipe
butts against the interior stops.
4. Apply silicon RTV sealant to the interior of the vent termination
and slide onto vent pipe. Rotate slightly to spread the silicon to
ensure a tight seal around the vent pipe.
5. Secure the termination in place using the four (4) #10 x ½” sheet
metal screws and lock washers (see Figure75).
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ADVANCED INSTALLATION
Install vent/air piping — boiler to W-M termination
Figure 77 Boiler vent and air connections
Air pipe
connector
Vent pipe
connector
U3530
Inserting/securing vent or air pipe into
boiler connectors
AL29-4C vent pipe — If using AL29-4C stainless
vent pipe, you must install a PVC-to-vent pipe
adapter at the boiler vent connection (and at the
termination if using the Weil-McLain plate or the
concentric termination). Use only the adapter made
by the vent pipe manufacturer.
1. PVC/ABS pipe — Clean and chamfer insertion end of pipe.
Deburr inside of insertion end. Clean and deburr inside and
outside of other end of pipe.
e pipe end must be smooth and chamfered to
prevent possible damage to sealing gasket in vent
or air pipe adapter. Failure to comply could result
in leakage, causing possible severe personal injury
or death.
2. Inspect vent or air adapter (above) — verify no obstructions
or foreign objects inside.
3. Loosen clamp screw.
4. Measure 3½ inches from end of pipe and make a mark with
felt-tip pen.
5. Loosen adapter clamp screw.
6. Apply small amount of silicon grease to end of pipe to ease
insertion.
7. Insert pipe into adapter.
8. Slide pipe down until the 3½-inch mark is reached.
Do not apply excessive force or bend the adapter
or ue/air pipe when inserting. e adapter or seal
could be damaged.
9. Secure vent or air pipe by tightening the adapter clamp se-
curely. Do not overtighten. e seal is accomplished with the
internal gasket. e clamp is only to hold the pipe in place.
Complete termination preparation
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.
3. See Figure77 for attaching vent and air pipes at the
boiler.
4. Cut pipe to required lengths.
5. Deburr inside and outside of pipe ends.
6. Chamfer outside of each pipe end to ensure even cement
distribution when joining.
7. Clean all pipe ends and ttings. Dry thoroughly.
8. Dry assemble entire vent or air piping to ensure proper
t before assembling any joint.
9. For each joint:
a. Handle ttings and pipes carefully to prevent con-
tamination of surfaces.
b. Apply primer liberally to both joint surfaces — pipe
end and tting 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 tting, twist-
ing ¼ turn. Make sure pipe is fully inserted.
f. Wipe excess cement from joint. Check joint to be
sure a smooth bead of cement shows around the
entire joint.
10. Install pipe supports as shown in Figure76,page70.
11. Slope vent and air piping continuously toward boiler,
with at least 1/4inch drop per foot of run. Do not allow
sags at any point.
12. Maintain minimum clearance of 3/16 inch between vent
pipe and any combustible wall or material.
13. Seal wall or oor penetration openings following local
code requirements.
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Sidewall vent/air termination: 3” or 4” concentric
Termination kit — 3” or 4” concentric termination
1. e 3” or 4” concentric termination kit must be purchased sepa-
rately. See below.
Use only the vent materials and kits listed in Fig-
ure12, page18 for concentric venting. Provide pipe
adapters as specied in Figure12,page18.
Commonwealth of Massachusetts
When the boiler is installed within the Commonwealth of Mas-
sachusetts:
y is product must be installed by a licensed plumber or gas
tter.
y See instruction in the Boiler manual.
Allowable vent/air pipe materials
Use only the materials listed in Figure13,page19.
Maximum piping length
1. Locate the termination such that the total air piping and vent piping
from the boiler to the termination will not exceed the maximum
length given in Figure12,page18.
2. Maximum lengths listed in Figure12,page18 allow for 1 elbow.
Additional elbows required a reduction in maximum length as
explained in the table notes.
Connecting from termination to boiler
1. Install the termination as instructed in the following.
2. en proceed to page82 to complete the air and vent piping be-
tween the termination and the boiler.
3. The center lines between the air and vent are wider at the
concentric termination connections than at the boiler. See
Figure87,page77 for suggestions on adjusting the spacing when
required. In addition to the method given there, you can rotate the
Y-tting slightly, which will cause the air pipe to be slightly higher
or lower than the vent, but the center lines will match those at the
boiler vent 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.
Locate the vent/air terminations using the following guidelines.
1. 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.
Figure 78 Termination location — 3” or 4” concentric termination
— height above grade or snow line
Figure 79 Termination location — 3” or 4” concentric termination
— clearances to openings
All vent and air pipes require a bird screen
at each termination
. Most kits do not
include the screens. Purchase separately
from WM Technologies or vent kit supplier
if not included.
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ADVANCED INSTALLATION
Sidewall vent/air termination: 3” or 4” concentric (cont.)
b. e ue 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 ue products impinge on building surfaces
or plants.
d. Avoid possibility of accidental contact of ue products with
people or pets.
e. Do not locate the terminations where wind eddies could aect
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
nishes.
2. Maintain clearances as shown in Figure78, page 72, Fig-
ure79,page72, Figure80 and Figure81. Also maintain the fol-
lowing:
a. Vent must terminate:
• At least 6 feet from adjacent walls.
• No closer than 5 feet below roof overhang.
• At least 7 feet above any public walkway.
• At least 3 feet above any forced air intake within 10feet.
• 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.
3. 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
connection as described in this addendum.
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
Figure81 for U. S. installations. For Canadian installations, provide
clearances required by CSA B149.1 or B149.2 Installation Code.
3. e air inlet of an Ultra boiler is part of a direct vent connection.
It is not classied as a forced air intake with regard to spacing from
adjacent boiler vents.
4. Combustion air (NOT vent piping) can be manifolded as shown
on page59.
Figure 80 Termination location — 3” or 4” concentric termination
— clearances to public walkway or forced air intake
Figure 81 Termination location — 3” or 4” concentric termination
— multiple boilers — clearance from vent of one to air
intake of the next
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Sidewall vent/air termination: 3” or 4” concentric (cont.)
Figure 82 Installing and supporting the concentric sidewall vent
assembly
Figure 83
Concentric termination requirements
Ensure that the wall material is strong enough
to prevent the rain cap from being pushed
inward if struck or pushed from the outside.
Install terminations — concentric pipes
1. Assemble the vent termination as described for vertical concen-
tric terminations, beginning on page76.
If necessary, you can shorten the lengths of the inner
and outer pipes for a shorter nished assembly. But
you must ensure the pipes butt correctly at both ends.
Failure to properly assemble the concentric termina-
tion can result in ue gas recirculation, causing possible
severe personal injury or death.
2. Wall penetration:
a. 3” termination: 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.
e nished hole must provide a solid stop for the rain cap
ribs, as shown in the inset to Figure82.
b. 4” termination: Preferably, use a thimble with a 6-inch hole.
If not using a thimble, carefully use a hole saw to cut a hole
not larger than 6¼ inches in diameter through the wall. e
nished hole must provide a solid stop for the rain cap ribs,
as shown in the inset to Figure82.
3. Secure the termination in place so the rain cap will butt against
the outside wall or outer thimble plate as shown in Figure82.
4. Before beginning vent and air piping from the boiler to the con-
centric termination, mount and secure the concentric termina-
tion as shown in Figure82 and Figure105,page92.
e vent and air piping must be securely supported, and
must not rest its weight on the boiler ttings. 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.
e supports/bracing used must support the termina-
tion assembly to prevent slippage or movement.
e 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.
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 pas-
sages 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. e 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
ue product emissions.
When using AL29-4C stainless vent pipe, use the vent
pipe manufacturer’s PVC adapter when connecting to
the concentric vent attachment.
5. Aer the assembly has been positioned in the opening and all
supports have been attached, install a bird screen (purchased
separately if not included with the kit) and rain cap as follows:
a. Place the bird screen on the end of the inner pipe as in Fig-
ure89,page78.
b. Cement the rain cap in place as shown.
Concentric termination
(installing termination — see page 76)
Install pipe supports every 5 feet
on both the horizontal and verti-
cal runs.
• Install a hanger support within
6inches of any upturn in the
piping.
• The concentric termination
assembly must be installed
before piping from the
boiler to the termination.
• Support the termination
at the wall as shown in the
termination instructions.
• Slope horizontal piping
downward toward the boiler at
least 1/4 inch per foot.
• Rotate the concentric
termination Y-tting about 30°
to result in pipe centers the
same as at the boiler.
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ADVANCED INSTALLATION
Vertical vent/air termination: 3” or 4” concentric
Termination kit — 3” or 4” concentric termination
1. e 3” or 4” concentric termination kit must be purchased sepa-
rately. See below.
Use only the vent materials and kits listed in Fig-
ure12, page18 for concentric venting. Provide pipe
adapters as specied in Figure12,page18.
Allowable vent/air pipe materials
Use only the materials listed in Figure13,page19.
Maximum piping length
1. Locate the termination such that the total air piping and vent piping
from the boiler to the termination will not exceed the maximum
length given in Figure12,page18.
2. Maximum lengths listed in Figure12,page18 allow for 1 elbow.
Additional elbows required a reduction in maximum length as
explained in the table notes.
Connecting from termination to boiler
1. Install the termination as instructed in the following. en pro-
ceed to page82 to complete the piping between the termination
and the boiler.
Determine location
Locate the concentric vent/air termination using the following guide-
lines:
1. e concentric vent/air assembly must terminate as shown in
Figure84.
2. e 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:
a. Position the termination where vent vapors will not damage
nearby shrubs, plants or air conditioning equipment or be
objectionable.
b. e ue 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 ue products impinge on building surfaces
or plants.
d. Avoid possibility of accidental contact of ue products with
people or pets.
e. Do not locate the termination where wind eddies could aect
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 nishes.
4. Maintain clearances to termination as given below:
a. Vent outlet must be located:
Figure 84 Vertical termination — 3” or 4” concentric
Figure 85 Vertical termination — 3” or 4” concentric — multiple
boilers
All vent and air pipes require a bird screen
at each termination
. Most kits do not
include the screens. Purchase separately
from WM Technologies or vent kit supplier
if not included.
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• At least 6 feet from adjacent walls.
• No closer than 5 feet below roof overhang.
• At least 7 feet above any public walkway.
• At lease 3 feet above any forced air intake within
10feet.
• 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 12inches above the
roof or snow line as shown in Figure84, page75.
(For Canada, the minimum is 18inches.)
c. Do not terminate closer than 4feet horizontally from any
electric meter, gas meter, regulator, relief valve or other
equipment. Never terminate above or below any of these
within 4feet horizontally.
5. Locate termination so it is not likely to be damaged by for-
eign 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 mul-
tiple boilers to a common vent pipe.
Multiple vent/air terminations
1. When terminating multiple Ultra boilers, install the con-
centric vent/air termination assemblies as described in this
addendum.
All vent outlets must terminate at the same height
to avoid possibility of severe personal injury, death
or substantial property damage.
2. Place roof penetrations to obtain minimum of 12inches
between centers of adjacent vent pipe of another boiler for
U. S. installations (see Figure85,page75).
3. For Canadian installations, provide clearances required by
CSA B149.1 or B149.2 Installation Code.
4. e air inlet of an Ultra boiler is part of a direct vent con-
nection. It is not classied as a forced air intake with regard
to spacing from adjacent boiler vents.
Prepare roof penetrations
1. Roof penetration hole:
a. 3” termination: Cut a 5-inch diameter hole to clear the
4½-inch termination outside diameter.
b. 4” termination: Cut a 6.5-inch diameter hole to clear the
6-inch termination outside diameter.
c. Insert a galvanized metal thimble in the vent pipe hole.
2. Follow all local codes for isolation of vent pipe when passing
through oors, ceilings and roofs.
3. Provide ashing and sealing boots sized for the concentric
termination outside diameter.
Assembling the concentric termination
1. See Figure89,page78 for the dimensions and details of the
termination assembly.
2. Prepare the bird screen (purchased separately if not included
with the kit). Cut the bird screen to size if required. If the
bird screen must be trimmed, cut the bird screen to t the
outside diameter of the PVC inner pipe supplied with the
termination kit.
3. Partially assemble the vent termination kit in the sequence
shown in Figure89,page78.
DO NOT install the rain cap and bird screen until
the assembly has been inserted through the roof
and all supports have been installed. Follow instruc-
tions to cover the end of the assembly with plastic
before inserting through the roof penetration to
prevent debris from blocking the air passages.
4. Use the following procedures to prepare termination com-
ponents and cement together.
5. Deburr inside and outside of pipe ends.
6. Chamfer outside of each pipe end to ensure even cement
distribution when joining.
7. Clean all pipe ends and ttings.
8. Dry thoroughly.
9. Dry assemble entire vent or air piping to ensure proper t
before assembling any joint.
10. For each joint:
a. Handle ttings and pipes carefully to prevent contamina-
tion of surfaces.
b. Apply primer liberally to both joint surfaces — pipe end
and tting 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 tting, twisting
¼turn. Make sure pipe is fully inserted.
If necessary, you can shorten the lengths of the in-
ner and outer pipes for a shorter nished assembly.
But you must ensure the pipes butt correctly at both
ends. Failure to properly assemble the concentric
termination can result in ue 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 Fig-
ure106,page92, and Figure88,page77.
e vent and air piping must be securely supported,
and must not rest its weight on the boiler ttings.
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.
Vertical vent/air termination: 3” or 4” concentric (cont.)
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ADVANCED INSTALLATION
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
boiler will not operate. Once the rain cap has been cemented
to the assembly, there is no way to correct the problem. e as-
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 ue product
emissions.
When using AL29-4C stainless vent pipe, use the vent pipe
manufacturer’s PVC adapter when connecting to the concen-
tric vent attachment.
1. Aer the assembly has been positioned in the roof opening and all sup-
ports have been attached, install a bird screen (purchased separately if
not included with the kit) and rain cap as follows:
a. Place the bird screen on the end of the inner pipe as in
Figure89,page78.
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 Figure88.
• e supports/bracing used must support the termination assembly
to prevent vertical slippage or sideways movement.
• e 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.
Figure 86 Concentric termination requirements
U3511-bw
VENT
VENT
AIR
AIR
Concentric termination
(installing termination — see page 75)
• Install pipe supports every 5 feet on
both the horizontal and vertical runs.
• Install a hanger support within 6inches
of any upturn in the piping.
• The concentric termination
assembly must be installed
before piping from the boiler to
the termination.
• Support the termination at the ceiling
and above the roof as shown in the
termination instructions.
• Slope horizontal piping downward
toward the boiler at least 1/4 inch per
foot.
• Use long-radius elbows for air piping
when using 2” or 3” pipe to reduce
pressure drop.
• Rotate the concentric termination
Y-tting about 30° to result in pipe
centers the same as at the boiler.
Figure 87 3” or 4” concentric termination supports
Vertical vent/air termination: 3” or 4” concentric (cont.)
Figure 88 Alternate piping conguration, using three
45-degree elbows to obtain closer pipe centers
U3502
Rotate the Y-fitting about 30
degrees and use (3) 45°
street ells to obtain same
center line as at boiler when
routing piping directly off top
of boiler or when smaller pipe
chase is needed.
Rotate the Y-fitting about 30
degrees and use (3) 45°
street ells to obtain same
center line as at boiler when
routing piping directly off top
of boiler or when smaller pipe
chase is needed.
(3) 45°
streel ells
(3) 45°
streel ells
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Concentric vent/air termination assembly
Figure 89 3” or 4” concentric termination assembly — DO NOT
attach the rain cap until the termination has been
inserted through the roof or wall and all supports have
been installed.
Figure 90 3” or 4” concentric termination assembly (see kit manufacturer’s
instructions for details)
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ADVANCED INSTALLATION
DIRECT VENT: Vertical vent / sidewall air
Determine location
1. Locate the vent termination using the following guidelines:
2. e vent piping must terminate in an up-turned coupling as shown
in Figure92,page80. e top of the coupling must be at least 1 foot
above the air intake.
3. 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. e ue products will form a noticeable plume as they condense 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 ue products impinge on building surfaces or plants.
d. Avoid possibility of accidental contact of ue products with people
or pets.
e. Do not locate the terminations where wind eddies could aect
performance or cause recirculation into building or appliance air
intakes, 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
nishes.
4. Maintain clearances to vent termination as given below:
a. Vent must terminate:
• At least 6feet from adjacent walls.
• No closer than 5feet below roof overhang.
• At least 3feet above any forced air intake within 10feet.
• No closer than 12inches below or horizontally from any door
or window or any other gravity air inlet.
b. Do not terminate vent closer than 4feet 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 terminations so they are not likely to be damaged by foreign ob-
jects, such as stones or balls, or subject to buildup of leaves or sediment.
6. Do not connect any other appliance to the vent pipe. Do not connect
multiple boilers to a common vent pipe.
Prepare roof penetrations
1. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or noncombus-
tible construction, size the vent pipe hole at least 0.4” larger than
the vent pipe diameter:
• 2¾” hole for 2”
• 4” hole for 3”
• 5” hole for 4”
b. Insert a galvanized metal thimble in the vent pipe hole.
2. Follow all local codes for isolation of vent pipe when passing through
oors, ceilings and roofs.
3. Provide ashing and sealing boots sized for the vent pipe and air pipe.
Allowable vent/air pipe materials
1. Use only the materials listed in Figure13,page19.
2. Purchase bird screens for vent and air termina-
tions separately. See the parts list at the end of this
manual.
Maximum piping lengths
1. Locate the terminations such that the total air pip-
ing and vent piping from the boiler to the termina-
tion will not exceed the maximum length given in
Figure12,page18.
2. Maximum lengths listed in Figure12,page18 allow
for 1 elbow in the air piping and 1 elbow in the vent
piping. Additional elbows required a reduction in
maximum length as explained in the table notes.
Figure 91 Direct vent: Vertical vent / sidewall
air
U3505VS-bw
VENT
VENT
AIR
AIR
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DIRECT VENT: Vertical vent / sidewall air (continued)
Termination and ttings
1. Prepare the vent termination coupling by inserting a bird screen.
Bird screens must be purchased separately. See the parts list at the
end of this manual for part numbers.
a. If using 3-inch piping for an Ultra-230, cut a 4-inch bird screen
by placing 3-inch tting on screen and cutting around it as a
template.
2. Maintain the required dimensions of the nished termination
piping as shown in Figure92.
Multiple vent terminations
1. When terminating multiple Ultra boilers, terminate each vent/air
connection as described in this section.
2. Place adjacent terminations at least 6 inches apart.
3. For Canadian installations, provide clearances required by CSA
B149.1 or B149.2 Installation Code.
Connecting from vent termination to boiler
1. Install the termination penetration as instructed in the preced-
ing. en proceed to page82 to complete the piping between the
termination and the boiler.
Determine location for air inlet elbow
1. e air inlet of an Ultra boiler is part of a direct vent connection.
It is not classied as a forced air intake with regard to spacing from
adjacent appliance terminations.
2. Locate the air inlet elbow (termination) using the following
guidelines.
3. e air piping must terminate in a down-turned elbow as shown
in Figure93.
a. Apply the conguration on the le side of Figure93 unless the
terminations would fail to meet minimum clearance to grade
or snow line.
b. Apply the conguration on the right side of Figure93 when
the terminations need to be raised higher to meet clearance to
grade or snow line.
c. e air pipe may run up the side of the building, as shown.
e 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.
4. You must consider the surroundings when terminating the air
connection:
a. Make sure there are no obstructions for air ow. DO NOT
locate the termination where plants could grow and cause
obstruction to air ow.
b. Do not locate the terminations where wind eddies could aect
performance or cause recirculation with exhaust from other
appliances, such as inside building corners, near adjacent build-
ings or surfaces, window wells, stairwells, alcoves, courtyards
or other recessed areas.
c. Locate the air inlet termination at least 12 inches below and 12
inches horizontally from any appliance or building vent outlet.
5. 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.
Figure 92 Vent termination (through the roof) for direct vent:
vertical vent / sidewall air
Figure 93 Sidewall air inlet (termination) for direct vent: vertical
vent / sidewall air
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ADVANCED INSTALLATION
DIRECT VENT: Vertical vent / sidewall air (continued)
Multiple air terminations
1. When terminating multiple Ultra boiler air connections, terminate
each air connection as described in this manual.
2. Place wall penetrations to obtain minimum clearances as instructed
in this manual.
3. Place adjacent air inlets for multiple Ultra boilers at least 6 inches
apart.
4. For Canadian installations, provide clearances required by CSA
B149.1 or B149.2 Installation Code.
5. Combustion air (NOT vent piping) can be manifolded as shown
in the Ultra boiler manual.
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. Seal exterior openings thoroughly with exterior caulk.
Termination and ttings
1. Prepare the air termination elbow (Figure93,page80) by inserting
a bird screen. Bird screens must be purchased separately. See the
parts list at the end of this manual for part numbers.
2. Use metal plates (by installer) at inside and ouside penetrations as
shown in Figure94.
If extending the air pipe out from the wall, install a cou-
pling on each pipe. Mount the piping with the coupling
ush with the outer plate.
Connecting from air termination to boiler
1. Install the terminations as instructed in the following. en pro-
ceed to page82 to complete the air and vent piping between the
termination and the boiler.
Figure 94 Sidewall air inlet installation for direct vent: vertical vent
/ sidewall air
1 Air piping
2 Sidewall plates, by installer
3 Bird screen (air), by installer
4 Air inlet elbow
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Install vent/air piping — boiler to termination
Complete termination preparation
1. Install vent and air terminations before proceeding. See previ-
ous pages for instructions.
Installing vent and air piping
1. For reference in the following see:
a. Sidewall terminations: see Figure105,page92.
b. Vertical terminations: see Figure106,page92.
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 re-
quired, at both the boiler and at the termination assembly.
3. See Figure95 for attaching vent and air pipes at the boiler.
4. Cut pipe to required lengths.
5. Deburr inside and outside of pipe ends.
6. Chamfer outside of each pipe end to ensure even cement
distribution when joining.
7. Clean all pipe ends and ttings. Dry thoroughly.
8. Dry assemble entire vent or air piping to ensure proper t
before assembling any joint.
9. For each joint:
a. Handle ttings and pipes carefully to prevent contamina-
tion of surfaces.
b. Apply primer liberally to both joint surfaces — pipe end
and tting 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 tting, twisting ¼
turn. Make sure pipe is fully inserted.
f. Wipe excess cement from joint. Check joint to be sure a
smooth bead of cement shows around the entire joint.
10. Install pipe supports as shown in Figure105, page 92 or
Figure106,page92.
11. Slope vent and air piping continuously toward boiler, with
at least 1/4inch drop per foot of run. Do not allow sags at
any point.
12. Maintain minimum clearance of
3/16inch between vent pipe
and any combustible wall or material.
13. Seal wall or oor penetration openings following local code
requirements.
Figure 95 Boiler vent and air connections
Inserting/securing vent or air pipe
into boiler connectors
AL29-4C vent pipe — If using AL29-4C stain-
less vent pipe, you must install a PVC-to-vent
pipe adapter at the boiler vent connection
(and at the termination if using the Weil-
McLain plate or the concentric termination).
Use only the adapter made by the vent pipe
manufacturer.
1. PVC/ABS pipe — Clean and chamfer insertion end of
pipe. Deburr inside of insertion end. Clean and deburr
inside and outside of other end of pipe.
e pipe end must be smooth and chamfered
to prevent possible damage to sealing gasket
in vent or air pipe adapter. Failure to comply
could result in leakage, causing possible se-
vere personal injury or death.
2. Inspect vent or air adapter (above) — verify no obstruc-
tions or foreign objects inside.
3. Loosen clamp screw.
4. Measure 3½ inches from end of pipe and make a mark
with felt-tip pen.
5. Loosen adapter clamp screw.
6. Apply small amount of silicon grease to end of pipe to
ease insertion.
7. Insert pipe into adapter.
8. Slide pipe down until the 3½-inch mark is reached.
Do not apply excessive force or bend the
adapter or ue/air pipe when inserting. e
adapter or seal could be damaged.
9. Secure vent or air pipe by tightening the adapter clamp
securely. Do not overtighten. e seal is accomplished
with the internal gasket. e clamp is only to hold the
pipe in place.
Air pipe
connector
Vent pipe
connector
U3530
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ADVANCED INSTALLATION
DIRECT EXHAUST venting — general
Vent and air piping materials
1. See Figure13,page19 for approved vent and air piping materi-
als, for both direct exhaust and direct vent.
Use the same vent or air piping material
throughout.
— Do not connect dierent types of
piping together.
Vent piping
1. Boiler ue gases must be piped from the boiler to outside, fol-
lowing the instructions in this manual, and compliant with all
applicable codes. e vent pipe must terminate either through
the sidewall or through the roof, located with the correct sepa-
ration from the air termination. See the associated instructions
in the following pages.
2. Each Ultra boiler requires a separate vent. DO NOT common
vent.
Combustion air openings for direct
exhaust
Provide combustion air openings to boiler
room and building.
Combustion and ventilation
air for direct exhaust boilers is provided from the
boiler room. Follow all instructions in the Boiler
manual and this addendum plus all applicable codes,
providing combustion air openings as specied.
Failure to comply could result in severe personal
injury, death or substantial property damage.
1. Combustion air must be supplied through openings into the
boiler room, following the instructions in this manual, and
compliant with all applicable codes. Read the warning on
page16, and ensure the air and boiler room will not contain
contaminated air.
2. Where the Ultra boiler shares a space with other appliances, the
combustion air openings must be sized to handle the combined
requirements of all appliances in the space.
SIDEWALL direct exhaust option
1. Read and follow instructions in Boiler manual, including
page65 for Massachusetts installations when applicable.
VERTICAL direct exhaust option
1. Read and follow instructions in Boiler manual, including
page65 for Massachusetts installations when applicable.
SIDEWALL
DIRECT EXHAUST
VERTICAL
DIRECT EXHAUST
Every vent pipe requires a bird screen at its
termination
. Bird screens are not supplied
with the Ultra boiler. Purchase separately from
WM Technologies.
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Special considerations
Tight construction
ANSI Z223.1 denes unusually tight construction where:
1. Walls and ceilings exposed to the outside atmosphere have
a continuous water vapor retarder with a rating of 1 perm
or less with openings gasketed, and . . .
2. Weather-stripping has been added on openable windows
and doors, and . . .
3. Caulking or sealants are applied to areas such as joints
around windows and door frames, between sole plates and
oors, between wall-ceiling joints, between wall panels, at
penetrations for plumbing, electrical, and gas lines, and in
other openings.
For buildings with such construction, provide air openings into
the building from outside, sized per the appropriate case in Fig-
ure96,page85 if appliances are to use inside air for combustion
and ventilation.
Exhaust fans and air movers
e appliance space must never be under a negative pressure
unless all appliances are installed as direct vent. Always provide
air openings sized not only to the dimensions required for the
ring rate of all appliances, but also to handle the air move-
ment rate of the exhaust fans or air movers using air from the
building or space.
Motorized air dampers
If the air openings are tted with motorized dampers, electrically
interlock the damper to:
y Prevent the boiler from ring if the damper is not fully open.
y Shut the boiler down should the damper close during boiler
operation.
To accomplish this interlock, wire an
isolated contact (proving
the damper open) in series with the thermostat input to the
boiler. e boiler will not start if this contact is open, and will
shut down should it open during operation.
Combustion air provision
e Ultra boiler can use inside air if no contaminants are pres-
ent in the boiler space. (If contaminants are likely to be present,
install the boiler as a direct vent appliance, using the appropriate
vent instructions in this manual.)
e boiler room must be tted with combustion air openings large
enough to provide air for all appliances in the room. Use the fol-
lowing information to size the openings. Ensure the installation
complies with all applicable codes and standards.
Sizing combustion air openings
Air openings provide for ventilation (as well as combustion air)
to prevent overheating of the boiler controls and boiler space.
Air is also needed for other appliances located in the same space.
Use Figure96,page85, selecting the appropriate installation
conditions.
Air openings must be sized to handle all appliances
and air movers (exhaust fans, etc.) using the air
supply.
e sizing given in Figure96,page85 is based on the National
Fuel Gas Code, ANSI Z223.1, allowing adequate air openings
for gravity-vented gas appliances (Category I) in addition to that
needed for the Ultra boiler.
e air openings recommended in Figure96,page85 will allow
adequate ventilation and combustion air provided the boiler room
is not subjected to negative pressure due to exhaust fans or other
mechanical ventilation devices.
Refer to the National Fuel Gas Code for dealing with other
conditions.
Free area — louver allowance
e free area of openings means the area aer reduction for any
installed louvers or grilles
. Be sure to consider this reduction when
sizing the air openings.
DIRECT EXHAUST — Boiler room air openings
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ADVANCED INSTALLATION
Figure 96 MINIMUM combustion air openings for direct exhaust applications — ALL OPENING SIZES ARE FREE AREA
Air openings
e required air opening sizes below are FREE AREA,
aer reduction for louver obstruction. Note the ex-
ception below for large spaces.
Ultra boiler
WITH other
appliances in room
Ultra boiler
WITHOUT other
appliances in room
TWO openings, each at least:
1 square inch per 1,000 Btuh
of all appliances in the room
TWO openings, each at least:
1 square inch per 4,000 Btuh
of all appliances in the room
TWO openings, each at least:
1 square inch per 4,000 Btuh
of all appliances in the room
— OR —
ONE opening **, each at least:
1 square inch per 3,000 Btuh
of all appliances in the room
TWO openings, each at least:
1 square inch per 4,000 Btuh
of all appliances in the room
— OR —
ONE opening **, each at least:
1 square inch per 3,000 Btuh
of all appliances in the room
TWO openings, each at least:
1 square inch per 2,000 Btuh
of all appliances in the room
— OR —
ONE opening **, each at least:
1 square inch per 3,000 Btuh
of all appliances in the room
TWO openings, each at least:
1 square inch per 4,000 Btuh
of all appliances in the room
— OR —
ONE opening **, each at least:
1 square inch per 3,000 Btuh
of all appliances in the room
TWO openings, each at least:
1 square inch per 4,000 Btuh
of all appliances in the room
— OR —
ONE opening **, each at least:
1 square inch per 3,000 Btuh
of all appliances in the room
TWO openings, each at least:
1 square inch per 4,000 Btuh
of all appliances in the room
— OR —
ONE opening **, each at least:
1 square inch per 3,000 Btuh
of all appliances in the room
** NOTICE:
Requirements for using the SINGLE air open-
ing option.
A single combustion air opening can be used for cases b, c or d above, sized as listed,
provided that:
y The single opening must communicate directly to the outdoors or to a space that
communicates directly with outdoors (NOT to an interior space).
y The top of the opening must be within 12 inches of the ceiling.
y The free area of the opening must be at least equal to the sum of the areas of all
equipment vent connectors in the space.
SPECIAL EXCEPTION FOR LARGE SPACES:
NO combustion air openings are needed when the boiler (and other appliances) are
installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btuh of all
appliances in the space. That is, total the input of all appliances in MBH (1,000’s of
Btuh), then multiply this total times 50. The building MUST NOT be of tight construction.
Example: For a total input of 1500 MBH (1,500,000 Btuh) and an 8-foot ceiling height,
the minimum volume would be 50 x 1500 x 8 = 60,000 cubic feet.
DIRECT EXHAUST —
Boiler room air openings
(continued)
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DIRECT EXHAUST — Sidewall
Figure 97 DIRECT EXHAUST — Sidewall
termination
DIRECT EXHAUST — Sidewall
termination — installation
sequence overview
Step 1 Install the boiler.
Step 2 Determine the proper location for wall
penetration for each termination.
• Prepare wall penetrations before installing
vent piping.
• Finish by attaching external pipe and
ttings as shown in the termination in-
structions.
• Support vertical runs on the outside of
the building with brackets as shown in the
termination instructions.
Step 3 Install vent piping from boiler to termi-
nation.
• Install a hanger support within 6inches of
any upturn in the piping.
• Install pipe supports every 5 feet on both
the horizontal and vertical runs.
• Slope horizontal piping downward toward
the boiler at least 1/4 inch per foot.
Step 4 Connect the vent piping at the boiler per
instructions in this addendum.
Allowable vent pipe materials
1. Use only the materials listed in Figure13,page19.
2. Install a bird screen in each vent pipe termination (coupling or elbow).
Bird screens are not supplied with the Ultra boiler. Purchase separately
from WM Technologies.
Maximum piping length
1. Locate the termination such that the total vent piping from the boiler
to the termination will not exceed the maximum length given in
Figure12,page18.
2. Maximum lengths listed in Figure12,page18 allow for 2 elbows. Ad-
ditional elbows require a reduction in maximum length as explained
in the table notes.
Determine location for sidewall termination
A gas vent extending through an exterior wall shall not ter-
minate adjacent to the wall or below building extensions such
as eaves, parapets, balconies or decks, except as otherwise
instructed in this manual or local codes. Failure to comply
could result in severe personal injury, death or substantial
property damage.
Place the vent terminations using the following guidelines.
3. Terminate the vent piping with a down-turned elbow as shown in
Figure98,page87. e elbow must butt against the outside wall plate.
If vent piping is extended outside, install an elbow at the outer plate
and continue vent piping from the elbow when snorkeling as in Fig-
ure98,page87 right side.
a. Apply the conguration on the le side of Figure98,page87 unless
the termination would fail to meet minimum clearance to grade
or snow line.
b. Apply the conguration on the right side of Figure98,page87
when the termination needs to be raised higher to meet clearance
to grade or snow line.
c. e vent pipe may run up as high as 4 feet, as shown in Fig-
ure98,page87 right side, with no enclosure. e vent pipe must be
secured with braces, and maintain all required clearances.
d. Space braces no further than 24 inches apart. (See WARNING below
for extremely cold climates.)
e. External venting greater than 4 feet requires an enclosure around
the vent pipe. e vent termination must exit through the enclosure
as shown in Figure98,page87, maintaining all required clearances.
Do not exceed the maximum length of the outside vent pip-
ing shown in Figure98,page87. 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 pip-
ing, particularly when using longer lengths. e chase must
allow for inspection of the vent pipe, and insulation must be
protected from water.
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ADVANCED INSTALLATION
DIRECT EXHAUST — Sidewall (continued)
Figure 98 DIRECT EXHAUST — Sidewall — conguration options and
minimum clearances
4. Consider the surroundings when terminating the vent:
a. Position the vent termination where vapors will not damage
nearby shrubs, plants or air conditioning equipment or be
objectionable.
b. e ue 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 ue products impinge on building surfaces
or plants.
d. Avoid possibility of accidental contact of ue products with
people or pets.
e. Do not locate the terminations where wind eddies could aect
performance, such as inside building corners, near adjacent
buildings or surfaces, window wells, stairwells, alcoves, court-
yards 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
nishes.
5. Maintain clearances as shown in the illustrations in this manual
section. Also maintain the following:
a. Vent must terminate:
• At least 6 feet from adjacent walls.
• No closer than 5 feet below roof overhang.
• At lease 3 feet above any forced air intake within 10feet.
• No closer than 48 inches below or horizontally from any
door or window or any other gravity air inlet.
b. Do not terminate closer than 4 feet horizontally from any elec-
tric meter, gas meter, regulator, relief valve or other equipment.
Figure 99 DIRECT EXHAUST — Sidewall — clearances to
openings
Figure 100 DIRECT EXHAUST — Sidewall — clearances from
vent exit to forced air intake
6. Because Ultra boilers are Category IV appliances, the
National Fuel Gas Code, ANSI Z223.1, requires that
the vent must not terminate over a public walkway or
over an area where condensate or vapor could create a
nuisance or hazard, or could be detrimental to the op-
eration of regulators, relief valves, or other equipment.
7. Where the vent penetrates an outside wall, the annular
space around the penetration must be permanently
sealed using approved materials to prevent entry of
combustion products into the building.
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Figure 101 DIRECT EXHAUST — Sidewall — termination
assembly — all parts by installer
1 Vent piping
2 Cover plates
3 Galvanized thimble
4 Vent termination elbow
5 Bird screen
DIRECT EXHAUST — Sidewall (continued)
e Weil-McLain sidewall termination kit sup-
plied with each boiler includes metal plates with
two openings. ese plates can be trimmed and
used for direct exhaust vent termination cover
plates when the vent diameter used matches the
hole size in the plates provided with the boiler.
8. 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.
9. Do not connect any other appliance to the vent pipe. Do not
connect multiple boilers to a common vent pipe.
Completing the vent piping
1. Install vent penetration as explained in the following before in-
stalling vent piping from the boiler to the termination.
2. Insert piping from boiler vent connections, then attach exterior
termination piping.
3. Follow instructions beginning on page91 to complete piping
from boiler to termination.
Multiple vent terminations
1. When terminating multiple direct exhaust Ultra boilers, terminate
each vent connection as described in this manual for individual
vents. Space terminations as required for best installation prac-
tices and required maintenance.
Prepare wall penetrations
1. Wall penetration:
a. Cut a rough opening large enough to clear the diameter of
the metal thimble used.
b. Provide metal cover plates (item2, Figure101). e outer
plate MUST provide a stop to prevent the vent elbow from
being pushed inward. (See NOTICE at right.) Hole diameters
in the metal plates must be:
• 2-inch PVC, CPVC or ABS — 2
11
⁄22” hole diameter.
• 3-inch PVC, CPVC or ABS — 3
55
⁄88” hole diameter.
• 4-inch PVC, CPVC or ABS — 4
55
⁄88” hole diameter.
• AL29-4C vent pipe and elbow — size hole large enough
to clear vent pipe, but small enough to prevent the elbow
from being pushed through.
c. Insert the galvanized metal thimble (by installer) in the vent
pipe hole as shown in Figure101.
2. Follow all local codes for isolation of vent pipe when passing
through oors or walls.
Termination and ttings
1. Prepare the vent termination elbow (Figure98,page87) by in-
serting a bird screen. Bird screens are not supplied with the Ultra
boiler. Purchase separately from WM Technologies.
2. You can install the vent termination using either of the congura-
tions shown in Figure98,page87.
3. Maintain the required dimensions of the nished termination
piping as shown in Figure98,page87.
4. Seal exterior openings thoroughly with exterior caulk.
5. Do not extend exposed vent pipe outside of the building more
than shown in this document. Condensate could freeze and
block vent pipe.
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ADVANCED INSTALLATION
DIRECT EXHAUST — Vertical
Figure 102 DIRECT EXHAUST vertical termination
Allowable vent pipe materials
1. Use only the materials listed in Figure13,page19.
2. Install a bird screen in each vent pipe termination (coupling
or elbow). Bird screens are not supplied with the Ultra boiler.
Purchase separately from WM Technologies.
Maximum piping length
1. Locate the termination such that the total vent piping from the boil-
er to the termination will not exceed the maximum length given in
Figure12,page18.
2. Maximum lengths listed in Figure12,page18 allow for 2 elbows.
Additional elbows require a reduction in maximum length as
explained in the table notes.
Determine location for vertical termination
1. Locate the vent termination using the following guidelines:
2. e vent piping must terminate in a coupling as shown in Fig-
ure103,page90.
3. Consider the surroundings when terminating the vent:
a. Position the vent termination where vapors will not damage
nearby shrubs, plants or air conditioning equipment or be
objectionable.
b. e ue 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 ue products impinge on building
surfaces or plants.
d. Avoid possibility of accidental contact of ue products with
people or pets.
e. Do not locate the termination where wind eddies could aect
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 to prevent condensate damage to ex-
terior nishes.
4. Maintain clearances as shown in the illustrations in this manual
section. Also maintain the following:
a. Vent must terminate:
• At least 12 inches above roof or snow line as shown in
Figure103,page90.
• At least 6 feet from adjacent walls.
• No closer than 5 feet below roof overhang.
• At lease 3 feet above any forced air intake within 10feet.
• No closer than 48 inches below or horizontally from any
door or window or any other gravity air inlet.
b. Do not terminate closer than 4 feet horizontally from any
electric meter, gas meter, regulator, relief valve or other
equipment.
5. Where the vent penetrates the roof, the annular space around the
penetration must be permanently sealed using approved materi-
als to prevent entry of combustion products into the building.
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. Do not
connect multiple boilers to a common vent pipe.
DIRECT EXHAUST — Vertical
termination — installation
sequence overview
Step 1 Install the boiler.
Step 2 Determine the proper location for wall pen-
etration for each termination.
• Prepare roof penetrations before installing vent
piping.
• Finish by attaching external pipe and ttings as
shown in the termination instructions.
• Install terminations as described in this manual.
• Support vertical runs on the outside of the build-
ing with brackets as shown in the termination
instructions.
Step 3 Install vent piping from boiler to termination.
• Install a hanger support within 6inches of any
upturn in the piping.
• Install pipe supports every 5 feet on both the
horizontal and vertical runs.
• Slope horizontal piping downward toward the
boiler at least 1/4 inch per foot.
Step 4 Connect the vent piping at the boiler per
manual instructions.
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DIRECT EXHAUST — Vertical (continued)
Figure 103 DIRECT EXHAUST — Vertical termination
Prepare roof penetration
1. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole at least 0.5” larger than the vent pipe diameter:
• 3” hole for 2”
• 4” hole for 3”
• 5” hole for 4”
b. Insert a galvanized metal thimble in the vent pipe
hole.
2. Follow all local codes for isolation of vent pipe when
passing through oors, ceilings and roofs.
3. Provide ashing and sealing boots sized for the vent
pipe and air pipe.
Termination and ttings
1. Prepare the vent termination coupling (Figure103) by
inserting a bird screen. Bird screens are not supplied
with the Ultra boiler. Purchase separately from WM
Technologies.
2. e vent piping must terminate in a coupling as shown
in Figure103.
3. Maintain the required dimensions of the nished ter-
mination piping as shown in Figure103.
4. Do not extend exposed vent pipe outside of building
more than shown in this document. Condensate could
freeze and block vent pipe.
Multiple vent terminations
1. When terminating multiple Ultra boilers, terminate
each vent connection as described in this section. Space
terminations as required for best installation practices
and required maintenance.
Complete termination preparation
2. Install vent terminations before proceeding. See previous
pages for instructions.
Installing direct exhaust vent
piping
1. For reference in the following see:
a. Sidewall terminations: see Figure97,page86.
b. Vertical terminations: see Figure102,page89.
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 piping.
b. As shown in the maximum length tables, the
Ultra-230 may be installed with either 3-inch or
4-inch vent piping.
c. You must install appropriate pipe reducers, where
required, at the boiler vent connection.
3. See Figure104,page91 for attaching vent and air pipes
at the boiler.
4. Cut pipe to required lengths.
Sidewall terminations: e vent pipe must extend
through the outer cover plate only enough to install
the termination elbow. e plate must provide a stop
to prevent the vent elbow from being pushed inward.
5. Deburr inside and outside of pipe ends.
6. Chamfer outside of each pipe end to ensure even cement dis-
tribution when joining.
7. Clean all pipe ends and ttings. Dry thoroughly.
8. Dry assemble entire vent or air piping to ensure proper t before
assembling any joint.
9. For each joint:
a. Handle ttings and pipes carefully to prevent contamina-
tion of surfaces.
b. Apply primer liberally to both joint surfaces — pipe end
and tting 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 tting, twisting ¼
turn. Make sure pipe is fully inserted.
f. Wipe excess cement from joint. Check joint to be sure a
smooth bead of cement shows around the entire joint.
10. Install pipe supports as shown in Figure105,page92 or
Figure106,page92.
11. Slope vent and air piping continuously toward boiler, with at
least 1/4inch drop per foot of run. Do not allow sags at any
point.
12. Maintain minimum clearance of 3/16 inch between vent pipe
and any combustible wall or material.
13. Seal wall or oor penetration openings following local code
requirements.
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ADVANCED INSTALLATION
Figure 104 Boiler vent and air connections
Inserting/securing vent or air pipe
into boiler connectors
AL29-4C vent pipe — If using AL29-4C stain-
less vent pipe, you must install a PVC-to-vent
pipe adapter at the boiler vent connection (and
at the termination if using the Weil-McLain
plate or the concentric termination). Use only
the adapter made by the vent pipe manufac-
turer.
1. PVC/ABS pipe — Clean and chamfer insertion end of
pipe. Deburr inside of insertion end. Clean and deburr
inside and outside of other end of pipe.
e pipe end must be smooth and chamfered
to prevent possible damage to sealing gasket
in vent or air pipe adapter. Failure to comply
could result in leakage, causing possible severe
personal injury or death.
2. Inspect vent or air adapter (above) — verify no obstruc-
tions or foreign objects inside.
3. Loosen clamp screw.
4. Measure 3½ inches from end of pipe and make a mark
with felt-tip pen.
5. Loosen adapter clamp screw.
6. Apply small amount of silicon grease to end of pipe to
ease insertion.
7. Insert pipe into adapter.
8. Slide pipe down until the 3½-inch mark is reached.
Do not apply excessive force or bend the adapter
or ue/air pipe when inserting. e adapter or
seal could be damaged.
9. Secure vent or air pipe by tightening the adapter clamp
securely. Do not overtighten. e seal is accomplished
with the internal gasket. e clamp is only to hold the
pipe in place.
Air inlet opening protection: Obtain a bird
screen (sized for air inlet opening) the from
WM Technologies. Insert the bird screen into
the air inlet opening to prevent foreign objects
from falling into the opening.
Install vent/air piping — boiler to terminations
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Install vent/air piping — boiler to terminations (cont.)
Figure 105 Sidewall termination methods and
installation requirements
Weil-McLain sidewall
termination plate
(install termination — page 70)
• Install pipe supports every 5 feet
on both the horizontal and vertical
runs.
• Install a hanger support within
6inches of any upturn in the
piping.
• e Weil-McLain plate
termination must be installed
before piping from the boiler to
the termination.
• Slope horizontal piping downward
toward the boiler at least 1/4 inch
per foot.
Weil-McLain 3” or 4”
concentric termination
(install termination — page 72)
• Install pipe supports every 5 feet
on both the horizontal and vertical
runs.
• Install a hanger support within
6inches of any upturn in the
piping.
• e Weil-McLain 3” PVC
concentric termination assembly
must be installed before piping
from the boiler to the termination.
Support the termination at the
wall as shown in the termination
instructions.
• Slope horizontal piping downward
toward the boiler at least 1/4 inch
per foot.
• Rotate the concentric termination
Y-tting about 30° to result in pipe
centers the same as at the boiler.
Sidewall termination with
separate vent and air
pipes
(install termination — page 20)
• Prepare wall penetrations before
installing vent and air piping.
Finish by attaching external
pipe and ttings as shown in the
termination instructions.
• Install pipe supports every 5 feet
on both the horizontal and vertical
runs.
• Install a hanger support within
6inches of any upturn in the
piping.
• Support vertical runs on the
outside of the building with
brackets as shown in the
termination instructions.
• Slope horizontal piping downward
toward the boiler at least 1/4 inch
per foot.
Figure 106 Vertical termination methods and
installation requirements
Weil-McLain 3” or 4”
concentric termination
(install termination — page 75)
• Install pipe supports every 5 feet
on both the horizontal and vertical
runs.
• Install a hanger support within
6inches of any upturn in the
piping.
• e Weil-McLain 3” PVC
concentric termination assembly
must be installed before piping
from the boiler to the termination.
Support the termination at
the ceiling and above the roof
as shown in the termination
instructions.
• Slope horizontal piping downward
toward the boiler at least 1/4 inch
per foot.
• Use long-radius elbows for air
piping when using 2” or 3” pipe to
reduce pressure drop.
• Rotate the concentric termination
Y-tting about 30° to result in pipe
centers the same as at the boiler.
Vertical termination with
separate vent and air
pipes
(install termination — page 23)
• Prepare roof penetrations before
installing vent and air piping.
Finish by attaching termination
ttings as shown in termination
instructions.
• Install pipe supports every 5 feet
on both the horizontal and vertical
runs.
• Install a hanger support within
6inches of any upturn in the
piping.
• Slope horizontal piping downward
toward the boiler at least 1/4 inch
per foot.
• Air piping may be oset as
shown at le so termination can
be located as required in the
installation instructions.
• Use long-radius elbows for air
piping when using 2” or 3” pipe to
reduce pressure drop.
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ADVANCED INSTALLATION
Gas piping — sizing gas lines
Natural Gas:
Pipe sizing for natural gas
1. Size gas piping from meter outlet to entrance of boiler in accor-
dance with Figure108 and Figure109.
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 Figure108 are equivalent length of straight
pipe. Convert pipe ttings to equivalent lengths using data
from Figure107.
b. Figure108 is only for natural gas with specic 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 NFPA 54 (or Natural Gas and Propane Installation
CAN/CSA
B149.1 or B149.2 for Canadian installations).
Natural gas supply pressure
1. Pressure required at gas valve inlet pressure port:
a. Maximum: 13” w.c. with no ow (lockup) or with boiler on
b. Minimum: 4” w.c. (for all except 5” for -299) with gas owing
(verify during boiler startup, while boiler is at high re)
2. Install 100% lockup gas pressure regulator in supply line if inlet
pressure can exceed 13” w.c. at any time. Adjust lockup regulator
for 13” w.c. maximum.
Propane Gas:
You must follow the instructions, beginning on page48,
to operate the boiler on propane. Failure to comply could
result in severe personal injury, death or substantial
property damage.
Pipe sizing for propane gas
1. Contact gas supplier to size pipes, tanks and 100% lockup gas
pressure regulator.
Propane supply pressure
1. Adjust propane supply regulator provided by gas supplier for 13”
w.c. maximum pressure.
2. Pressure required at gas valve inlet pressure port:
a. Maximum: 13” w.c. with no ow (lockup) or with boiler on
• Minimum: 4” w.c. with gas owing (verify during boiler
startup, while boiler is at high re).
Manifolded gas supply lines
1. Construct gas header for multiple boilers using Figure107 and
the sizing tables below. Refer to the National Fuel Gas Code for
other conditions.
2. Provide manual shuto gas valve and ground joint union as shown
in Figure33,page29 and Figure107 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 ring.
Pipe size
inches
Equivalent length, feet
90° Elbow Tee
1 2 62 5 24
1¼ 3 45 6 90
1½ 4 02 8 04
2 5 17 10 3
2½ 6 16 12 3
Figure 107 Common gas line for multiple boilers
Gas pipe
total length,
feet
Capacity
(cubic feet per hour, 0.60 specic gravity)
1” 1¼” 1½” 2” 2½”
10 520 1050 1600 3050 4800
20 350 730 1100 2100 3300
30 285 590 890 1650 2700
40 245 500 760 1450 2300
50 215 440 670 1270 2000
75 175 360 545 1020 1650
100 150 305 460 870 1400
150 120 250 380 710 1130
Figure 108 Pipe capacity for 0.60 specic gravity natural gas
Figure 109 Equivalent lengths of straight pipe for typical gas line
ttings
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Field wiring — advanced
pump or another boiler is available.
Connect to remote alarm, when used
Connect wiring for multiple boiler operation
• e U-Control provides the exibility for control of
multiple Ultra boilers.
• You will need to program the boilers’ U-Controls
based on the interconnection method you choose.
Install system & outdoor sensors, when used
• e boiler is shipped with an outdoor sensor, a
system supply sensor and a system return sensor.
e system supply sensor will be required for most
space heating applications. e system return sensor
must also be installed when using the system supply
sensor. Use of the outdoor sensor is optional.
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
Figure111,page96 and above.
Wiring circulators
1. e U-Control provides for connection of up to three
circulators, one of which must be the boiler circulator.
In addition, you can connect a system circulator and a
DHW circulator, for examples. See Figure110,page95.
The maximum allowable current for each
circulator is 2.2 amps at 120 VAC
. For
circulators with higher amp ratings, you must
install a circulator relay or starter to provide
line voltage to the circulator. For circulators
rated over 2.2 amps, connect only the circula-
tor relay or starter coil to the Ultra circulator
terminals.
2. You can connect any of the circulators you use to any of
the three circulator activation terminals. e U-Control
setup allows you to assign which circulators activate on
a call for heat (this can be customized for each of the
heating systems supplied by the boiler).
3. e U-Control factory
default settings for DHW heat-
ing are congured for direct piping to the boiler, with
Circulator 1 being the only circulator being activated
during DHW heating. To use factory default settings,
Wiring — general
1. e U-Control provides plug-in, color-coded, non-interchange-
able terminal strips for all eld wiring. See the schematic diagram
(Figure111,page96) & ladder diagram (Figure112,page97).
2. e U-Control provides programmable exibility in system op-
eration, allowing control of heat supply for up to three dierent
heating systems. Read this manual thoroughly before connecting
the wiring to ensure trouble-free start-up and operation.
Wiring — overview
You will need to make the following connections, some of which
depend on your system and how the U-Control will be programmed.
(See this and following pages for more information.)
Connect 120VAC power (minimum 15-amp source)
Connect wiring for up to three circulators
Connect external limits, if used
• Two dierent circuits are available — e U-Control will
require manual reset for one of these circuits. e U-Control
will automatically reset aer limit operation and re-closure
for limits in the other circuit.
Connect thermostats and/or heat demand contacts
• e U-Control can regulate the boiler for up to three dierent
heating systems.
Connect remote operation input, if used
• e U-Control will operate and modulate the boiler based on
a 0–10 VDC control signal from a remote controller, when
desired.
Connect the “additional heat demand” circuit to a second
heating source, when used
• e U-Control allows the boiler to act as the primary or sec-
ondary heat source when another heat source, such as a heat
ELECTRICAL SHOCK HAZARD — For your
safety, turn o electrical power supply at service
entrance panel before making any electrical connec-
tions to avoid possible electric shock hazard. Failure
to do so can cause severe personal injury or death.
Wiring must be N.E.C. Class 1. If original wiring as
supplied with boiler must be replaced, use only type
105 °C wire or equivalent. Boiler must be electrically
grounded as required by National Electrical Code
ANSI/NFPA 70 – latest edition.
Installation must comply with:
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.
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ADVANCED INSTALLATION
Continued after page 98
Field wiring — advanced (see Figure 111, page 96 & Figure 112, page 97) (cont.)
make sure to connect the DHW circulator to termi-
nals1, 4 and7, as below:
4. e factory
default for space heating is designed for
nned-tube baseboard, and set up to activate Circula-
tor2 and Circulator3 on a call for heat. Connect the
boiler circulator to terminals2, 5 and8 and the system
circulator to terminals3, 6 and9 to use these default
settings.
5. Make sure the U-Control is programmed to activate
the system circulator when it is required (during space
heating, for instance).
Thermostats & DHW tank
temperature control connections
Use isolating relays if using 3-wire zone valves
to avoid damage and nuisance problems due
to stray voltage.
1. e U-Control allows operation by up to three dierent
heating systems.
2. e factory default conguration is for “heat demand1”
to be DHW and “heat demand2” to be space heating.
For factory default operation:
a. Connect the space heating thermostat to terminal
strip P15, terminals1 and2 to use the default setup.
b. Connect the DHW tank temperature control across
terminal strip P11, terminals4 and5 to use the
default setup.
3. Install thermostats on inside walls away from the inuences of
dras, hot or cold water pipes, lighting xtures, television, sun
rays, or replaces.
4. ermostat anticipator (if applicable):
• If connected directly to the boiler, set anticipator for 0.1amps.
• If connected to relays or other devices, set to match total elec-
trical power requirements of connected devices. See device
manufacturers’ specications and the thermostat instructions
for details.
Low water cut-offs
1. See the NOTICE on this page regarding internal low water protec-
tion provided by the U-Control.
2. When an external low water cut-o is installed, connect as shown
in the U-Control wiring diagrams (Figure111,page96 & Fig-
ure112,page97).
3. When possible, use the Weil-McLain Ultra low water cut-o kit
listed in the back of this manual. It includes a probe-type low water
cut-o and provides a simple harness connection for the wiring.
The U-Control module provides
internal low water protection
1. e U-Control and internal sensors in the Ultra boiler provide
both temperature control and low water protection (using
temperature senors), as explained below:
e U-Control module uses temperature sensors to
provide both high limit protection and modulating
temperature control.
e U-Control module also provides
low water
protection
by using a dual sensor to monitor the
temperature of the heat exchanger. [e U-Control
constantly monitors the sensor signals to ensure
they are within 10 °F of one another. If the sensor
dierence exceeds 10 °F, the boiler is shutdown on
automatic reset.] is method is accepted in many
areas as meeting the requirement for a low water
cut-o.
Some codes or jurisdictions may require additional
external controls for high limit and/or low water
cutoff protection. Follow the guidelines in this
manual to install additional controls when required.
Figure 110 Wiring to circulators
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Field wiring — advanced (see Figure 111 & Figure 112) (continued)
Figure 111 Schematic wiring diagram — Ultra-80 through Ultra-399
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ADVANCED INSTALLATION
Figure 112 Ladder wiring diagram — Ultra-80 through Ultra-399
Field wiring — advanced (see Figure 111 & Figure 112) (continued)
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Field wiring — advanced (see Figure 111, page 96 & Figure 112, page 97) (cont.)
Additional limits
1. e U-Control allows connection of external limit controls,
both for manual reset and for automatic reset operation of the
U-Control.
2.
Manual reset of the U-Control on limit action — Connect
external limits across P13, terminals1 and2 if the U-Control is
to require manual reset when a limit opens, even if the limit re-
closes. (Remove the factory jumper when using these terminals.)
e U-Control will lockout when a limit in its manual
reset circuit opens. e U-Control activates its alarm
terminals and shuts the boiler down until an operator
manually resets the U-Control (as explained in this
manual). is reset function can be done by a home-
owner or a service technician.
3.
Automatic reset of the U-Control on limit action — Connect
external limits across P13, terminals3 and4 if the U-Control is to
reset automatically when the limit circuit closes aer a limit con-
dition. (Remove the factory jumper when using these terminals.)
Remote operation/modulation
1. e U-Control module provides terminals to input a remote
0–10VDC operating signal. is can be provided by a separate
controller if the boiler is congured as Type4 (SHADOW boiler
mode).
2. Connect the 0–10VDC signal positive terminal to P15 termi-
nal6, and the signal common to terminal5.
3. When receiving a remote operating signal, the boiler starts when
the signal exceeds 1.0VDC (and shuts o if the signal drops
below 0.5VDC). e boiler remains at low re until the signal ex-
ceeds 2.0VDC. Between 2.0and 10.0VDC, the boiler ring rate
increases with the signal value, reaching full input at 10.0VDC.
4. e U-Control continues to monitor boiler temperatures, based
on the values set up under Priority1 operation. See the following
section for details.
Additional heat demand option
1. e U-Control module can be set up to activate another heat
source using its additional heat demand dry contracts (P16,
terminals6 and7).
2. Connect these terminals to call for heat from the other heat
source. (See the following section to program the boiler to ac-
tivate the other source, either as the primary or secondary heat
source.)
Alarm contacts (low voltage ONLY)
1. e U-Control’s alarm dry contact (P16, terminals4 and5) closes
when the boiler enters lockout.
2. Connect these terminals for remote alarm notication.
Multiple boiler wiring options
1. e U-Control can be programmed to sequence multiple boilers
or operate/modulate in tandem from a 0–10VDC source gener-
ated by the lead boiler or from a remote controller.
2. See “ADDITIONAL HEAT DEMAND” on page99 for recom-
mended wiring.
Outdoor temperature sensor
1. e U-Control provides programmable options when
using an outdoor temperature sensor. is sensor is
supplied with the boiler, and can be used if desired (not
required). See the following section for outdoor tem-
perature options.
The outdoor sensor must be
installed unless specically exempted in the
Energy Act statement on page 137.
2. Mount the outdoor sensor on an exterior wall, shielded
from direct sunlight or ow of heat or cooling from
other sources.
3. Connect the sensor leads to P10, terminals1 and2, as
shown in the wiring diagrams. ermostat wire can be
used to connect the sensor.
System supply & return
temperature sensors
(see Figure 4, page 11 for placement of sensors)
1. e boiler is also shipped with two strap-on temperature
sensors, intended for system supply and return.
2. ese sensors can be attached to piping up to 3-inch
diameter.
3. ermostat wire can be used to connect these sensors.
4. e system supply temperature sensor allows the U-Con-
trol to regulate temperature in the system main piping.
5. Locate the supply sensor at least six pipe diameters, but
no further than 3 feet, downstream from the boiler con-
nection to the main to ensure adequate mixing.
6. e system return sensor allows the U-Control to moni-
tor and display system return temperature.
7. For multiple boiler applications, install a system supply
temperature sensor and system return sensor wired to
the LEAD boiler.
8. e U-Control also compares the system return tem-
perature with the system supply temperature. Should the
return temperature ever exceed the supply temperature,
the U-Control knows there is likely a sensor failure and
will report this problem on the display.
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ADVANCED INSTALLATION
U-Control operation and setup — advanced
Low-temperature systems (radiant
slab, etc.) — DO NOT use the Ultra boiler
control as the only means of water tem-
perature regulation for low-temperature
systems if higher-temperature systems
are also supplied.
ADVANCED SETUP – OVERVIEW
1. Access contractor menus by pressing and holding
the UP and DOWN arrow keys at the same time
for 5 seconds.
2. e contractor screen will show:
a. BOILER SETTINGS
b. SYSTEM SETTINGS
c. DIAGNOSTICS
d. MAINTENANCE INFO
e. SET DATE AND TIME
3. Navigate through the menus as shown in Fig-
ure115,page102. For a description of each of the
menu options, see Figure116,page104.
4. You will need to adjust settings as required for the
systems supplied by the boiler and connect the
wiring accordingly.
ADVANCED SETUP –
BOILER SETTINGS
BOILER MODEL
Check the boiler model against the model
listed on the boiler’s rating plate. Change
the selection to the correct model if not.
Also verify the model number on the
U-Control display at power-up. Failure
to correct could result in severe per-
sonal injury, death or substantial property
damage.
HIGH ALTITUDE
If the boiler is installed at an altitude
above 5,500feet, select YES for high
altitude. e U-Control will automati-
cally adjust ring rates (blower speeds)
to compensate for altitude.
WWSD
1. WWSD stands for “warm weather shutdown.” It
means the boiler will not be allowed to re if the
outside temperature is greater than the WWSD
setting.
2. When the boiler is kept o because the outside
temperature is above WWSD, the graphic display
will show “WWSD,” and the boiler will remain in
standby until the outside temperature drops below
WWSD temperature.
3. WWSD does not apply to DHW systems.
4. e outdoor sensor must be installed to use this
function.
ADJUST OUTDOOR
1. Use this setting to adjust the outdoor sensor temperature
to account for solar or other eects that would cause the
sensor to read incorrectly.
ADDITIONAL HEAT DEMAND
1. is setting is for multiple boilers or multiple heating
sources (an Ultra boiler collaborating with a heat pump
or a dierent boiler, for examples).
2. For Type 4 boilers, this function only applies to the
Priority1 system.
3. OFF — Function disabled.
4. Type 1 — is means the Ultra boiler is the primary
heat source.
a. When the Ultra boiler receives a call for heat, it be-
gins its startup sequence and also starts a delay timer
(set as ADD’L HEAT DEMAND TIME).
b. When the delay timing is reached, the U-Control
closes the “Additional heat demand contact,” ter-
minals P16 #6 and#7. Use this contact to start the
next heat source.
c. If the next heat source is an Ultra boiler, connect this
contact to the boiler’s “heat demand1” terminals
(P11 #4 and #5). Program the second boiler’s delay
timer to start a third boiler the same way, and so on
to sequentially re multiple boilers.
5. Type 2 — is means the boiler is the secondary heat
source.
a. When the U-Control receives a call for heat, it im-
mediately activates the “Additional heat demand
contact,” terminals P16 #6 and#7. is contact is
used to start the next heat source immediately.
b. When the delay timing is reached, the Ultra boiler
begins its startup sequence and continues to heat
until the demand is satised.
c. Type 2 assignment would generally only be used if
the other heat source is a dierent boiler or a heat
pump, for example.
6. Type 3 — is assigns the boiler as the LEAD boiler in
a multiple boiler system.
a. is LEAD boiler must have system supply and
return sensors mounted on the system supply and
return pipes and wired to the boiler.
b. When the U-Control receives a call for heat, it begins
its heating sequence and starts the additional heat
demand delay timer.
c. When the delay timing is reached, the U-Control
sends a 0–10 VDC proportional signal out its 0–10
VDC output terminals, P16 #1 and#2.
d. If the heat demand is satised before the timer runs
out, the next boiler is not started.
e. Connect these output terminals to the SHADOW
boilers’ 0–10 VDC input terminals, P15 #5 and#6.
e SHADOW boilers will start and modulate based
on the signal strength. e SHADOW boilers must
be set up as Type4 (see below). ey do not need
their additional heat timers to be setup.
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f. An alternate method is to daisy chain the other
boilers. at is, connect the output of each to the
input of the next. Each of these boilers would be
set up as a Type4 (see below), and each needs
its additional heat timer set for the desired delay
between boilers.
7. Type 4 — is assigns the boiler as a SHADOW boiler
in a multiple boiler system.
a. The boiler can be wired and setup to run in
parallel with the other SHADOW boilers as in
6c, above. Or they can be set up for sequential
operation following 6d, above.
b. When the boiler receives a 0–10 VDC input on
terminals P15 #5 and #6, it starts up and modu-
lates ring rate according to the signal.
c. If wired and setup per 6d above, it also starts its
additional heat delay timer immediately. When
the delay timing is reached, the U-Control sends
out a 0–10 VDC signal (on terminals P16 #1
and#2) for the next boiler.
d. e boiler uses the settings for Priority1 while
receiving the 0–10 VDC signal.
ADVANCED SETUP –
PRIORITY 1, 2, 3
1. Priority1, 2 and3 refer to the three possible heating
inputs that can be handled by the U-Control.
2. Select the priority level desired for the application.
Priority1 is usually assigned to domestic water heat-
ing, because of the need for quick response. Priority2
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
Figure115,page102.
4. e inputs to the U-Control are:
a. Priority 1 — P11 #4 and#5, “heat demand1”
b. Priority 2 — P15 #1 and#2, “heat demand2”
c. Priority 3 — P15 #3 and#4, “heat demand3”
ADVANCED SETUP –
SYSTEM TYPE
1. For each priority being used, select the appropriate
system type. See Figure114,page101 for system op-
tions and preset temperatures.
2. e temperature presets are chosen based on normal
best setting for these systems. e temperature val-
ues can be changed, if desired, under “TEMPERA-
TURES.”
ADVANCED SETUP –
TEMPERATURES
1. Setup desired temperatures for each of the priorities
used.
2. For an explanation of the target temperatures and
associated outdoor temperatures, see Figure113.
a. Outdoor temp for max target means the outdoor temperature
at which the target temperature reaches its maximum value. In
the example of Figure113, this occurs at 25 °F outside.
b. Outdoor temp for min target means the outdoor temperature
at which the target temperature reaches its minimum. In the
example of Figure113, this occurs at 70 °F.
c. Note that the reset lines are curved. e shape of this curve is
matched (or characterized) to the response of the system type
chosen to ensure the most eective reset operation.
Figure 113 Typical outdoor reset curves
3. Modulate on differential — e temperature must drop this
many degrees below target temperature for the boiler to come on.
4. Modulate off differential — While the boiler is ring, as the
temperature increases above the target temperature, the boiler
ring rate is reduced. At this many degrees above the target tem-
perature, the boiler shuts down.
U-Control operation and setup — advanced (continued)
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ADVANCED INSTALLATION
ADVANCED SETUP –
CIRCULATOR EXERCISING
1. For each circulator, select whether you want the U-Control to
automatically start the circulator and run for 10 seconds for each
72-hour period of inactivity.
Figure 114 U-Control system types and preset parameters
System type Display Preset temperatures Note
8-character 3-char
Max Target
Temp
Outdoor Temp
for Max Target
Min Target
Temp
Outdoor 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 oor
(staple up)
RADFLOOR RSU 160 0 90 70
Radiant – above oor
(sleeper system)
RADFLOOR RAF 140 0 90 70
Custom CUSTOM CUS 190 0 70 70 • Does not pass along Add’l Heat Demand
DHW – system DOMESTIC DHW 190
DHW heating ignores outdoor reset and warm
weather shutdown
• U-Control modulates to system temperature sen-
sors.
DHW – direct DOMESTIC DHW 190 • U-Control modulates to boiler temperature sensors.
• Does not pass along Add’l Heat Demand
ADVANCED SETUP –
FREEZE PROTECTION
CIRCULATORS
1. is function automatically res the boiler at low re
and starts the circulators chosen if the heat exchanger
sensor detects a temperature less than 40 °F. e circu-
lators turn o 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.
U-Control operation and setup — advanced (continued)
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U-Control operation and setup — advanced (continued)
Menus Next screen Next screen Next screen Next screen
Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data
BOILER SETTINGS BOILER MODEL ##### 80
105
155
230
299
399
Carefully verify that the boiler model
number on the display now agrees
with the boiler rating plate. Setting
these incorrectly could result in
severe personal injury, death or
substantial property damage.
HIGH ALTITUDE ### NO
YES
HIGH TEMP LIMIT ###
WWSD SETTING ### °F
ADJUST OUTDOOR ### °F
###
###
ADD’L HEAT DEMAND
TYPE: ###########
OFF
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: ### °F
MAX OUTDOOR: ### °F
MIN OUTDOOR: ### °F
MODULATE ON DIFF: ### °F
MODULATE OFF DIFF:### °F
MIN SUPPLY, MAX
OUTDOOR AND MIN
OUTDOOR are not
shown for DHW types
TIMES MAX ON TIME: ### MIN
MIN ON TIME: ### MIN
BOOST INTERVAL: ### MIN
PRE PUMP TIME: ### SEC
POST PUMP TIME: ### SEC
not on Priority 3
not on Priority 1
CIRCULATORS: # # # CIRCULATOR 1: ###
CIRCULATOR 2: ###
CIRCULATOR 3: ###
ON/OFF
ON/OFF
ON/OFF
MAXIMUM RATE: ___%
MINIMUM RATE: ___%
### %
### %
BOILER PRIORITY 2
BOILER PRIORITY 3
SAME MENUS AS FOR PRIORITY 1
SAME MENUS AS FOR PRIORITY 1
CIRCULATOR EXERCISING CIRCULATOR 1: ###
CIRCULATOR 2: ###
CIRCULATOR 3: ###
ON/OFF
ON/OFF
ON/OFF
FREEZE PROTECT CIRCS CIRCULATOR 1: ###
CIRCULATOR 2: ###
CIRCULATOR 3: ###
ON/OFF
ON/OFF
ON/OFF
MAINTENANCE INFO NAME
PHONE
MODEL
CP#
INSTALLED
LAST DATE
NEXT DATE
INTERVAL SETTINGS
RESET REMINDER
################
###-###-####
ULTRA #####
##########
MM/DD/YY
MM/DD/YY
DD/MM/YY
## MONTHS
PRESS ENTER TO RESET
SET DATE AND TIME SET YR/MN/DAY/HR/MIN
Figure 115 U-Control menus (press and hold the UP and DOWN arrow keys for 5 seconds to enter contractor menus)
Part number 550-100-440/0723
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ADVANCED INSTALLATION
U-Control operation and setup — advanced (continued)
Menus Next screen Next screen Next screen Next screen
Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data
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
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
AUTO RESET
INPUTS
OUTPUTS
TEMPERATURES
LIST OF LOCKOUTS
LIST OF LOCKOUTS
INPUT STATUS
OUTPUT STATUS
TEMPERATURES
LOCKOUT HISTORY 2
LOCKOUT HISTORY 3
. . . SAME AS HISTORY 1
. . . SAME AS HISTORY 1
SOFTWARE VERSIONS DISPLAY V#.##
MAIN MICRO V#.##
SECOND MICRO V#.##
NOTE: Display will show C#.##
for CSD-1 control.
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)
Figure 115 U-Control menus, continued (press and hold the UP and DOWN arrow keys for 5 seconds to enter contractor menus)
Part number 550-100-440/0723
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U-Control operation and setup — advanced (continued)
Menu/Item Units Low
Value
High
Value
Default Comment
Boiler Settings
Boiler Model
80, 105, 155,
230, 299, 399
factory
THIS MUST BE SET CORRECTLY FOR SAFE OPERATION. Adjusts blower
speeds and ame sense (Display will show “HA” aer the model number if high altitude
has been selected, below.)
High Altitude
yes or no no Adjusts ignition and low re 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 O, 50 100 70 Boiler will not respond to heating calls above this outdoor temp
Adjust Outdoor
°F
(dierence)
-10 +10 0 is value plus outdoor sensor reading equals outdoor temp (Use this setting to
compensate for solar gain or other factors that cause a shi in sensor temperature.)
Add’l Heat Demand Type
Types O Type 4 O Type 1 — Ultra is primary source, starts secondary aer 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
System Settings
Boiler Priority 1
System Type
Types O 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 dierential on
Modulate Off Diff
°F 2 10 5 Boiler shuts down if modulates past target plus dierential o
Max On Time
minutes o 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 o 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 o 240 30 Circulator run time aer call for heat ends
Circulator 1
on-o o on on Circulator activates on this call for heat if on
Circulator 2
on-o o on o Circulator activates on this call for heat if on
Circulator 3
on-o o on o Circulator activates on this call for heat if on
Maximum Rate
%Rate 21% 100% 96% Boiler Model and altitude specic (derated to 96% from factory)
NOTE: Adjusting boiler ring rate will aect AFUE rating.
Minimum Rate
%Rate 20% 99% 33% (80-299)
20% (399)
Boiler Model and altitude specic
Boiler Priority 2
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 dierential on
Modulate Off Diff
°F 2 10 5 Boiler shuts down if modulates past target plus dierential o
Figure 116 U-Control setup options (see Figure 115, page 102 for location in menu sequence)
Part number 550-100-440/0723
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ADVANCED INSTALLATION
U-Control operation and setup — advanced (continued)
Menu/Item Units Low
Value
High
Value
Default Comment
Max On Time
minutes o 240 30 Longest time boiler will satisfy this system before switching to an active lower priority
Min On Time
minutes o 240 15 Time boiler will satisfy this system before switching to the next active priority
Boost Interval
minutes o 240 o 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 o 240 30 Circulator run time aer call for heat ends
Circulator 1
on-o o on o Circulator activates on this call for heat if on
Circulator 2
on-o o on on Circulator activates on this call for heat if on
Circulator 3
on-o o on on Circulator activates on this call for heat if on
Maximum Rate
%Rate 21% 100% 96% Boiler Model and altitude specic (derated to 96% from factory)
NOTE: Adjusting boiler ring rate will aect AFUE rating.
Minimum Rate %Rate 20% 99% 33% (80-299)
20% (399)
Boiler Model and altitude specic
Boiler Priority 3
System Type
Types Custom
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 dierential on
Modulate Off Diff
°F 2 10 5 Boiler shuts down if modulates past target plus dierential o
Max On Time
— — — — Priority 3 does not have this setting
Min On Time
minutes o 240 15 Time boiler will satisfy this system before switching to the next active priority
Boost Interval
minutes o 240 o 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 o 240 30 Circulator run time aer call for heat ends
Circulator 1
on-o o on on Circulator activates on this call for heat if on
Circulator 2
on-o o on on Circulator activates on this call for heat if on
Circulator 3
on-o o on on Circulator activates on this call for heat if on
Maximum Rate
%Rate
21% 100%
96% Boiler Model and altitude specic (derated to 96% from factory)
NOTE: Adjusting boiler ring rate will aect AFUE rating.
Minimum Rate
%Rate
20% 99% 33% (80-299)
20% (399)
Boiler Model and altitude specic
Circulator Exercising
Circulator 1
on-o o on on Circulators exercise 10 seconds every 72 hours of inactivity if on
Circulator 2
on-o o on on Circulators exercise 10 seconds every 72 hours of inactivity if on
Circulator 3
on-o o on on Circulators exercise 10 seconds every 72 hours of inactivity if on
Freeze Protect Circs
Circulator 1
on-o o on o If HxOut sensor out falls below 40F boiler res low and turns on this circ until 45F
Circulator 2
on-o o on on If HxOut sensor out falls below 40F boiler res low and turns on this circ until 45F
Circulator 3
on-o o on o If HxOut sensor out falls below 40F boiler res low and turns on this circ until 45F
Figure 116 U-Control setup options (see Figure 115, page 102 for location in menu sequence), continued
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U-Control operation and setup — advanced (continued)
Figure 117 U-Control diagnostic information (see Figure 115, page 102 for location in menu sequence
Menu/Item Units Low
Value
High
Value
Default Comment
Diagnostics
Temperatures
Status
Text data Current operating status of the boiler. Prepurge, Ignition, Name of the system Type
being satised, 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 rst 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 rst sensing element of the boiler’s ue gas sensor
Flue2
°F data Temperature of the second sensing element of the boiler’s ue gas sensor
Outdoor
°F data Temperature of the remote outdoor air temperature sensor
Inputs
Status
Text data Current operating status of the boiler. Prepurge, Ignition, Name of the system Type
being satised, post purge, Warm Weather Shutdown, Trouble
Priority 1
on-o data Call for heat status on Priority 1 Input
Priority 2
on-o data Call for heat status on Priority 2 Input
Priority 3
on-o 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 cuto 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 ame used to shutdown boiler
Outputs
Gas Valve
on-o data Control’s gas valve circuit status
Circulator 1
on-o data Control’s circulator 1 relay status
Circulator 2
on-o data Control’s circulator 2 relay status
Circulator 3
on-o data Control’s circulator 3 relay status
Blower Signal
% of rate data Control’s signal controlling the blower speed
Add’l Heat Demand
on-o data Control’s signal controlling the additional heat demand
Alarm
on-o data Control’s alarm contact status
Analog Output
vdc data Value of 0–10 VDC output signal on P16 #1 and #2
Errors
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
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
Part number 550-100-440/0723
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ADVANCED INSTALLATION
U-Control operation and setup — advanced (continued)
Figure 117 U-Control diagnostic information (see Figure 115, page 102 for location in menu sequence), continued
Menu/Item Units Low
Value
High
Value
Default Comment
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
Software Versions
Display #.## format data Soware version of the microprocessor on the display circuit board
Main Micro #.## format data Soware version of the main microprocessor on the control circuit board
Second Micro #.## format data Soware version of the second microprocessor on the control circuit board
Manual Test Mode
Status text data Current operating status of the boiler. Prepurge, Ignition, Name of the system Type
being satised, 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 ame 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.
Manual Reset
Reset selected condition
Maintenance Info
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.
Set Time and Date
Year text 2017 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 550-100-440/0723
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Annual startup and general maintenance
Figure 118 Service and maintenance schedules
Service technician
(see following pages for instructions)
Owner maintenance
(see Ultra User’s Information Manual for instructions)
ANNUAL START-UP (See First-year special inspection)
General:
• Reported problems.
• Inspect interior; clean and vacuum if
necessary; WARNING — no solvents.
• Clean condensate trap and ll with fresh water.
• Check for leaks (water, gas, ue, condensate).
• Check system water chemistry, inhibitor level
and antifreeze concentration.
• Verify ue and air lines in good condition and
sealed tight.
• Check system water pressure/system piping/
expansion tank.
• Check control settings.
• Ignition electrode (clean with steel wool and
reposition) — replace if worn.
• Ignition and ground wiring.
• Wiring and connections.
• Perform start-up checkout and performance
verication beginning with “Startup — ll the
system” on page 35.
• Flame inspection (stable, uniform).
• Flame signal (see Figure 119, page 112).
• Clean Nanogate coated heat exchanger if ue
temp is more than 54°F above return water
temp.
• Inspect jacket front door gaskets; replace if
necessary.
Additional if combustion or
performance indicate need:
• Clean heat exchanger, page 126
• Remove and clean burner using compressed
air only.
• Vacuum the blower.
Review:
• Review with owner.
Daily
• Check boiler area.
• Check air openings.
• Check pressure/temperature gauge.
• Verify boiler front door is securely in
place.
Monthly
• Check vent piping.
• Check air piping.
• Check relief valve.
• Check condensate drain system.
• Check automatic air vents (if used).
Periodically
• Test low water cutoff (if used).
Every
6 months
• Check boiler piping (gas and water)
• Operate relief valve.
End
of season
• Shut boiler down (unless boiler used
for domestic water).
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.
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MAINTENANCE & SPECIFICATIONS
Annual startup
HANDLING CERAMIC FIBER
MATERIALS
REMOVING BURNER GASKET or
COVER PLATE INSULATION
e Ultra burner gasket (models80
and 105) and cover plate insula-
tion (all models) contain ceramic
ber material. Ceramic bers can
be converted to cristobalite in very
high temperature applications. e
International Agency for Research
on Cancer (IARC) has concluded,
“Crystalline silica inhaled in the
form of quartz or cristobalite from
occupational sources is carcinogenic
to humans (Group 1).”:
Avoid breathing dust and contact with skin
and eyes.
• Use NIOSH certied dust respirator (N95).
This type of respirator is based on the
OSHA requirements for cristobalite at the
time this document was written. Other
types of respirators may be needed depend-
ing on the job site conditions. Current
NIOSH recommendations can be found on
the NIOSH web site at http://www.cdc.gov/
niosh/homepage.html. NIOSH approved
respirators, manufacturers, and phone
numbers are also listed on this web site.
• Wear long-sleeved, loose tting clothing,
gloves, and eye protection.
Apply enough water to the combustion
chamber lining or base insulation to prevent
airborne dust.
Remove combustion chamber lining or base
insulation from the boiler and place it in a
plastic bag for disposal.
Wash potentially contaminated clothes sepa-
rately from other clothing. Rinse clothes
washer thoroughly.
NIOSH stated First Aid
Eye: Irrigate immediately
Breathing: Fresh air.
FIRST-YEAR SPECIAL INSPECTION
It is recommended that you obtain a Weil-McLain
Ultra Boiler Maintenance kit before attempting
the rst-year inspection, to ensure all parts that
may be needed are available
. is kit includes a
heat exchanger cover plate gasket, burner gasket (80
and 105 only), new ignitor, and ignitor gasket. See list-
ing in Replacement parts section of this manual. ese
parts must be on hand when you perform the rst-year
inspection in the event they must be replaced.
Failure to replace the items above when needed could
result in severe personal injury, death or substantial
property damage.
1.
No later than 12 months aer the boiler is installed, perform
a rst-year inspection of the boiler. is must include the fol-
lowing in addition to routine annual start-up procedures.
a. Remove the heat exchanger cover plate (see page112 for
instructions on removal and replacement).
b. Inspect the heat exchanger and clean if necessary (see
“Cleaning the heat exchanger — pin side when required” on
page125, and all referenced illustrations and instructions).
c. Inspect the cover plate insulation and gasket. Replace if not
in good condition.
d. Remove the burner and inspect carefully. Clean the burner
thoroughly using a vacuum cleaner and a so brush if
needed. Make sure there is no blockage or accumulation of
debris in the burner or the burner ports. Replace the burner
if necessary.
e. Models 80 and 105 only — inspect the burner gasket, and
replace if the gasket is not in good condition. Make sure
the burner is clean. en securely fasten it tightly to the
cover plate.
f. Disconnect condensate trap and drain lines. Inspect, then
ush thoroughly.
2. Determine follow-up maintenance and service needs based on
the condition of the heat exchanger and condensate lines.
a. If the heat exchanger shows substantial fouling, or if con-
densate lines show accumulation of sediment, schedule a
follow-up service call to perform the rst-year inspection
again, sooner than the normal twelve months between.
b. Heavy fouling of the exchanger or condensate lines indicates
possible combustion air contamination. Inspect the air in-
take area carefully, and remove possible contaminants. See
Figure11,page16, for products to avoid.
You must eliminate causes of corrosion and contami-
nation to ensure reliable operation of the boiler and
system.
Part number 550-100-440/0723
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Annual startup (continued)
e boiler should be inspected and started
annually, at the beginning of the heat-
ing season, only by a qualied service
technician. In addition, the maintenance
and care of the boiler designated in Fig-
ure118,page108 and explained on the
following pages must be performed to
assure maximum boiler eciency and
reliability. Failure to service and main-
tain the boiler and system could result
in equipment failure.
Electrical shock hazard — Turn o power
to the boiler before any service operation
on the boiler except as noted otherwise
in this instruction manual. Failure to
turn o electrical power could result in
electrical shock, causing severe personal
injury or death.
Address reported problems
1. Inspect any problems reported by owner and correct before
proceeding.
Inspect boiler area
1. Verify that boiler area is free of any combustible materials,
gasoline and other ammable vapors and liquids.
2. Verify that air intake area is free of any of the contaminants
listed on page16 of this manual. If any of these are present
in the boiler intake air vicinity, they must be removed. If
they cannot be removed, reinstall the air and vent lines per
this manual.
Inspect boiler interior & door gaskets
1. Remove jacket front door and inspect interior of boiler.
2. Visually inspect the door gaskets. Make sure all are in good
condition. Obtain replacements if any gasket is damaged.
Door gaskets must be intact, and must provide a
reliable seal. Replace any damaged gasket.
3. Remove the venturi air inlet silencer and clean if necessary.
Replace silencer.
4. Vacuum any sediment from the inside of the boiler and
components. Remove any obstructions.
Do not use solvents to clean any of the boiler
components. e components could be damaged,
resulting in unreliable or unsafe operation.
Clean condensate trap
1. Loosen condensate trap line hose clamps and remove trap
line.
2. Empty water from trap line and inspect. Flush out if needed
with fresh water.
3. Check condensate elbow and tee and condensate line to drain.
Flush if necessary to clean.
4. Reinstall condensate trap line and tighten hose clamps.
5. Fill trap with fresh water by pouring into upturned end of
PVC condensate tee.
Check all piping for leaks
Eliminate all system or boiler leaks. Continual fresh
make-up water will reduce boiler life. Minerals
can build up in sections, reducing heat transfer,
overheating heat exchanger, and causing heat
exchanger failure. Leaking water may also cause
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.
3. Check gas line using procedure on page29.
Check air openings
1. Verify that combustion and ventilation air openings to the
boiler room and/or building are open and unobstructed.
Check operation and wiring of automatic combustion air
dampers, if used.
2. Verify that boiler vent discharge and air intake are clean and
free of obstructions.
Flue vent system and air piping
1. Visually inspect entire ue gas venting system and combus-
tion air piping for blockage, deterioration or leakage. Repair
any joints that show signs of leakage in accordance with vent
manufacturer’s instructions. When air is ducted to boiler,
verify that air inlet hose is connected and properly sealed.
Failure to inspect for the above conditions and have
them repaired can result in severe personal injury
or death.
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold ll pressure for the system. Verify it is correct
(usually around 12 psig).
3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure doesn’t rise too high. Excessive
pressure rise indicates expansion tank sizing or performance
problem.
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MAINTENANCE & SPECIFICATIONS
Annual startup (continued)
4. Inspect automatic air vents and air separators. Remove air vent caps
and briey press push valve to ush vent. Reinstall caps. Make sure
vents do not leak. Replace any leaking vents.
5. Check system water chemistry (pH, hardness and inhibitor level). See
page35.
Check expansion tank
1. Expansion tanks provide space for water to move in and out as the
heating system water expands due to temperature increase or contracts
as the water cools. Tanks may be open, closed or diaphragm or bladder
type. See page11 of this manual for suggested location of expansion
tanks and air eliminators.
• Open-type — located above highest radiator or baseboard unit,
usually in the attic or closet. Has a gauge glass and overow pipe
to a drain.
• Closed-type — welded gas tight and located above boiler. Tank is
partially lled with water, leaving an air cushion for expansion.
• Make sure this type of tank is tted with a tank tting, such
as the B & G Tank-Trol or Taco Taco-Trol. is tting reduces
gravity circulation of air-saturated tank water back to the system
and prevents the air from bubbling up through the water as it
returns from the system.
• Do not use automatic air vents in systems with closed-type
tanks. e air will escape from the system instead of returning
to the tank. Eventually, the tank will waterlog and no longer con-
trol pressurization. e boiler relief valve will weep frequently.
•
Diaphragm- or bladder-type — welded gas tight with a rubber
membrane to separate the tank pressurizing air and the water. May
be located at any point in the system, but most oen found near
the boiler.
• Systems with this type of expansion tank require at least one
automatic air vent, preferably located on top of an air eliminator,
as shown in examples in this manual.
2. If relief valve has tended to weep frequently, the expansion tank may
be waterlogged or undersized.
• Closed-type tank — tank is most likely waterlogged. Install a
tank tting if not already installed. en check ll level per tting
manufacturer’s instructions. If ll level is correct, check tank size
against manufacturer’s instructions. Replace with a larger tank if
necessary.
• Diaphragm- or bladder-type — rst, check tank size to be sure it
is large enough for the system. If size is too small, add additional
tank (or tanks) as necessary to provide sucient expansion. If tank
size is large enough, remove tank from system and check charge
pressure (usually 12 psig for residential applications). If tank won’t
hold pressure, membrane has been damaged. Replace tank.
Inspect ignition electrode
1. Remove the ignition electrode from the boiler heat
exchanger access cover.
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.
3. Reinstall ignition electrode, making sure gasket is
in good condition and correctly positioned.
4. Make sure the electrodes are parallel to each other.
Check ignition wiring
1. Check ignition cable electrical resistance. A good
cable will have resistance between 900 and 1000
ohms. Replace if not acceptable.
2. Inspect boiler ground wire from heat exchanger
access cover to ground terminal strip.
3. Verify all wiring is in good condition and securely
attached.
4. Check ground continuity of wiring using continu-
ity meter.
5. Replace ground wires if results are not satisfactory.
Check all boiler wiring
1. Inspect all boiler wiring, making sure wires are in
good condition and securely attached.
Check control settings
1. Use the U-Control display to navigate through all
settings. Adjust settings if necessary.
2. Check settings of external limit controls (if any)
and adjust if necessary.
Perform startup and checks
1. Start boiler and perform checks and tests specied
in this manual.
2. Verify cold ll pressure is correct and that operating
pressure does not go too high.
3. Complete the check-out procedure on page42.
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Annual startup (continued)
Figure 120 Burner assembly
Check burner ame
e boiler contains ceramic ber materials.
Use care when handling these materials per
instructions on page109 of this manual. Fail-
ure to comply could result in severe personal
injury.
1. Inspect ame through observation window using the
procedure on page40.
2. If ame is unsatisfactory at either high re or low re,
turn o boiler and allow boiler to cool down. en re-
move 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 page125.
4. When replacing burner, ensure gasket is in good condi-
tion and correctly positioned. Aer tightening the three
retainer screws, bend up the retainer tabs as shown in
Figure120 to prevent screw rotation.
5. Reattach the cover plate using the method given in
Figure126,page126 or Figure128,page127.
6. Aer servicing, reinstall boiler components. Retest
boiler.
Check ame signal
1. Navigate to Diagnostics/Inputs on the U-Control display (see
Figure115,page102). e ame signal value must be at least 20
above the Shutdown values given in Figure119.
Figure 119
Flame signal shutdown values
Model
Ultra –
Shutdown
ame signal
Model
Ultra –
Shutdown
ame signal
80 95 230 100
80 HA 95 230 HA 100
105 135 299 130
105 HA 135 299 HA 130
155 80 399 120
155 HA 80 399 HA 120
NOTE: “HA” means high altitude, 5500 feet or more above seal level.
2. If the ame signal drops to less than 20 above the Shutdown
values, the U-Control will attempt to correct by increasing the
boiler ring rate to increase ame signal.
3. A lower ame signal may indicate a fouled ignitor or damaged
ignitor insulation. If cleaning the ignitor does not improve, ground
wiring is in good condition, and ground continuity is satisfactory,
replace the ignitor.
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MAINTENANCE & SPECIFICATIONS
Annual startup (continued)
4. If ame signal still remains low, inspect the vent and air
piping. en inspect the heat exchanger, following the pro-
cedures given in this manual for removal and reinstallation of
the head exchanger cover plate and other boiler components.
Clean the exchanger as described in this manual if necessary.
Check blower speeds
1. For installations at altitudes above 5,500 feet, make sure the
control is set up for high altitude in the boiler setup menu.
e U-Control module automatically adjusts low re and
ignition rates to compensate for high altitude conditions.
2. For installations below 5,500 feet, high altitude should NOT
be enabled.
3. Use the U-Control display to navigate to Manual test mode
(see Figure115,page102).
4. Set the ring rate to MINIMUM (low re).
5. Write down the blower RPM value shown and compare to
the value in Figure121. e value should no less than the
“Minimum setting” and no higher than the Ignition “Fac-
tory setting” listed. Low re rate (and corresponding blower
speed) is adjusted in the boiler setup menu.
6. Set the ring rate to MEDIUM (ignition rate).
7. Write down the blower RPM value. It should be within 200
RPM of the value listed in Figure121.
8. Set the ring rate to MAXIMUM (high re).
9. Write down the blower RPM value. It should be within 200
RPM of the value given in Figure121.
10. If any of the values are outside the ranges listed in the previous
steps, contact the factory for technical assistance.
Check ue gas temperature
1. Set the boiler to high re. en adjust the U-Control mod-
ule display to view ue gas temperature and boiler return
temperature.
2. e ue gas temperature should be no more than 54 °F higher
than the boiler return temperature.
3. If the ue temperature is higher than this, shut down the
boiler, allow to cool, and follow the procedure starting on
page125 to clean the Nanogate coated heat exchanger.
Figure 121 Firing rates and corresponding blower speeds (low re, ignition, and high re) — for altitudes up to 5,500 feet
Ultra Model -80 -105 -155 -230 -299 -399
% RPM Btu/Hr % RPM Btu/Hr % RPM Btu/Hr % RPM Btu/Hr % RPM Btu/Hr % RPM Btu/Hr
Low re
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
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 re (adjust if desired to match maximum system load — High re % 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 550-100-440/0723
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Check boiler relief valve
1. Inspect the relief valve and li the lever to verify ow as in
the following warnings, excerpted from a relief valve manu-
facturer’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 page9 before proceeding further.
Safety relief valves should be reinspected AT LEAST
ONCE EVERY THREE YEARS, by a licensed
plumbing contractor or authorized inspection
agency, to ensure that the product has not been af-
fected by corrosive water conditions and to ensure
that the valve and discharge line have not been
altered or tampered with illegally. Certain naturally
occurring conditions may corrode the valve or its
components over time, rendering the valve inopera-
tive. Such conditions are not detectable unless the
valve and its components are physically removed and
inspected. is inspection must only be conducted
by a plumbing contractor or authorized inspection
agency — not by the owner. Failure to reinspect the
boiler relief valve as directed could result in unsafe
pressure buildup, which can result in severe personal
injury, death or substantial property damage.
Following installation, the valve lever must be op-
erated AT LEAST ONCE A YEAR to ensure that
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 ow of hot water from the valve to a proper
place of disposal. Otherwise severe personal injury
may result. If no water ows, valve is inoperative.
Shut down boiler until a new relief valve has been
installed.
2. Aer 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.
Review with owner
1. Review the User’s Information Manual with the
owner.
2. Emphasize the need to perform the maintenance
schedule specified in the User’s Information
Manual (and in this manual as well).
3. Remind the owner of the need to call a licensed
contractor should the boiler or system exhibit
any unusual behavior.
4. Remind the owner to follow the proper shutdown
procedure and to schedule an annual startup at
the beginning of the next heating season.
Annual startup (continued)
Part number 550-100-440/0723
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MAINTENANCE & SPECIFICATIONS
Troubleshooting
Reinstall boiler door
Reinstall boiler door aer servicing. e
boiler door must be securely fastened to
the boiler to prevent boiler from draw-
ing air from inside the boiler room. is
is particularly important if the boiler is
located in the same room as other appli-
ances. Failure to keep the door securely
fastened could result in severe personal
injury or death.
Before troubleshooting:
1. See Figure122 for tools and kits recommended for
troubleshooting Ultra boilers.
2. Check for 120 VAC (minimum 102 VAC to maxi-
mum 132 VAC) to boiler.
3. Check the U-Control’s last three lockout histories.
a. See “ADVANCED SETUP – OVERVIEW” on
page99
b. Scroll down to DIAGNOSTICS and press the
enter key.
c. Scroll down to ERRORS and press the enter key.
d. Record the rst four data records and then
highlight the history record you want to view.
e. Follow information at the bottom of the screen
to navigate through your lockout histories.
VERIFY PROPER OPERATION AFTER SERVICING. VERIFY PROPER OPERATION AFTER SERVICING.
Before servicing and making connections
. . .
ALWAYS TURN POWER OFF TO THE BOILER
TO PREVENT ELECTRICAL SURGES, WHICH
CAN DAMAGE BOILER COMPONENTS.
ELECTRICAL SHOCK HAZARD — e boiler ON/
OFF switch does not turn o all power to the boiler.
TURN OFF ALL POWER TO THE BOILER WHEN
SERVICING
. Internal wiring is still powered when the
switch is o.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dan-
gerous operation. Always disconnect power to boiler
before servicing. Failure to comply could result in
severe personal injury, death or substantial property
damage.
Never jumper (bypass) any device except for momen-
tary testing. Severe personal injury, death or substan-
tial property damage can result.
Before calling, always complete the “Ultra Gas Data
Collection Sheet
” (page124). Record the boiler size
and CP number (located on the lower center support
frame in the center of the boiler).
Figure 122 Tools and kits for troubleshooting
Tools needed for troubleshooting Purpose
#2 Phillips Screwdriver Remove 4 screws to remove the top front cover
U-Control Screwdriver or 1/16" at blade screwdriver Used for wiring on terminal blocks for the U-Control (comes with boiler)
1/8" Allen Wrench (Hex Key) To add orice to change from natural to propane
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
P/N 383-500-605 Maintenance Kit (80 and 105) This kit should be on hand when performing annual maintenance in the event replacement
is required.
P/N 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.
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Troubleshooting (continued)
Check the following:
1. Make sure thermostat is calling for heat and con-
tacts (including appropriate zone controls) are
closed. Check for 24 VAC between thermostat wire
nuts and ground.
2. Make sure all external limit controls are either
installed (and closed) or temporarily jumpered
for testing.
3. Make sure that connectors to control module are se-
curely plugged in at module and originating control.
4. Gas pressures:
• Maximum: 13” w.c. with no ow (lockup) or
with boiler on
• Minimum: 4” w.c. (for all except 5” for -299)
for natural gas, or 4” w.c. for propane, with gas
owing (verify during startup with boiler at
high re)
Always check control module
fuses
ALWAYS check control module fuses
before replacing control module or any
major components (blower, etc.). If one
of these fuses is blown, it can prevent
control module or other components
from operating.
1. Turn OFF power to boiler at external line switch.
2. Remove jacket door and jacket top panel. Rotate
the swing-away control panel forward to expose
the U-Control module.
3. Remove and inspect the two fuses (located as
shown below).
4. If necessary, replace the fuse:
a. Low voltage circuit fuse is 3-amp fast-blow
(Littelfuse 257003).
b. Line voltage circuit fuse is 12-amp slow-blow
(Littelfuse 326012P).
Do not jumper fuse or replace with any
fuse except as specied. Failure to comply
could result in severe personal injury,
death or substantial property damage.
5. Reinstall jacket top panel and boiler jacket door
aer checking the fuses.
6. Restore power to boiler at external line switch and
verify boiler operation after completing boiler
service.
Checking temperature sensors
1. The boiler temperature sensors (flue, outdoor,
return water and supply water) are all resistance-
type devices.
2. Figure123 shows the correct value for the sensor
at various temperatures.
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
level boiling point). For ice point and boiling point,
insert the sensor in water at that temperature. Use
an ohmmeter to read resistance value.
4. To check whether the control module is correctly
sensing temperature, you can use a resistance de-
cade box. Connect the decade box temporarily in
place of a sensor and read the corresponding tem-
perature on the U-Control display. e temperature
should be close to the value corresponding to the
input resistance.
Figure 123 Sensor resistance values
Sensor resistance values
Temp
(°F)
Sensor ohms
Temp
(°F)
Sensor ohms
Min Max Min Max
32 34265 37871 120 4517 4992
40 27834 30764 130 3698 4088
50 21630 23907 140 3043 3364
60 16944 18727 150 2517 2782
70 13372 14780 160 2091 2311
80 10629 11747 170 1744 1928
90 8504 9399 180 1461 1615
100 6847 7568 190 1229 1359
110 5545 6129 200 1038 1147
Part number 550-100-440/0723
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MAINTENANCE & SPECIFICATIONS
Figure 124 U-Control display toggles when in lockout, with screen ashing red to gray
Troubleshooting (continued)
U-Control fault indications
1. e U-Control provides diagnostic information for
both automatic reset conditions and manual reset
conditions. See Figure117,page106 for informa-
tion available on the U-Control display.
2. Figure 124 shows the screen behavior during an
automatic or manual reset condition. e table
below the display illustration lists manual reset conditions and how
to reset from them.
3. Figure125,page118 lists conditions that will cause the control to dis-
play a constant red screen. e boiler will automatically restart if the
condition self-corrects or the technician uses the U-Control’s manual
reset screens to reset.
Make sure to determine the causes of outages. Do not leave the boiler operating without a complete diagnosis.
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Troubleshooting (continued)
Figure 125 Troubleshooting suggestions for Ultra boilers
U-Control Fault Displays, Diagnostics and Suggested Corrective Actions
Display
Condition Diagnostics Corrective Action(s)
Nothing shown
on display
screen and
blower running
at full speed
Control is not receiving 24V
power
Check wiring for short circuit or
incorrect wiring.
Correct wiring per wiring diagram including connection of transformer
to the U-Control.
Check 3-amp low voltage
fuse on U-Control shown on
page116.
Replace fuse with proper part found in replacement part section of this
manual. If fuse blows again recheck wiring per diagram.
Check transformer connection
to the U-control per wiring
diagram. Check for 24V output
of transformer.
Replace transformer if it is receiving 120VAC, but not outputting 24VAC.
U-Control Error Condition Log
e U-control is able to record information about the boiler’s condition at the time of the three previous faults or errors. is
information is available to view in Contractor Menus under “DIAGNOSTICS” by selecting “ERRORS.” e control will display
the following information:
Information Description Action
Control Fault Records the number of internal control faults Select and press the enter key to reset this count
Ignition Retries Displays the number of ignition attempts in the current
ignition sequence.
Manual Reset Count Records number of lockouts that required a manual reset
since this count was last cleared.
Select and press the enter key to reset this count
Auto Reset Count Records number of lockouts that have automatically reset
since this count was last cleared.
Select and press the enter key to reset this count
Lockout History 1 Details of present or last recorded lockout Select and press the enter key for more details
Lockout History 2 Details of boiler during the second oldest lockout still in
memory
Select and press the enter key for more details
Lockout History 3 Details of boiler during the oldest lockout still in memory Select and press the enter key for more details
How to read the last 3 lockout histories:
1. Scroll down to “DIAGNOSTICS” and press the
enter key (Square Key in center)
2. Scroll down to “ERRORS” and press the enter key
(Square Key in center)
3. Scroll down to “LOCKOUT HISTORY #” and press
the enter key.
4. Scroll to choose the either “MANUAL RESET” or
“AUTO RESET” and press the enter key to display
the fault condition that was recorded.
5. Press the left arrow key to return to the LOCKOUT
HISTORY # screen. Scroll up or down to highlight
other choices and press the enter key to view the
details of the boiler’s condition when the lockout
was recorded.
6. TO CLEAR ALL LOCKOUT HISTORIES: While on the
“ERRORS” screen, hold the Left and Right arrow
buttons simultaneously for 5 seconds.
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MAINTENANCE & SPECIFICATIONS
Troubleshooting (continued)
Display
Condition Diagnostics Corrective Action(s)
Nothing
is shown
in display
screen and no
other boiler
components are
operating
Control is not receiving 120V
power.
Check service switch and/or
circuit breaker to boiler turned
is on.
Turn on service switch to power boiler.
Is there 120 Volts at the service
switch?
Troubleshoot and correct the power supply to the service switch.
Is the Ultra's ON/OFF POWER
SWITCH located behind the
control pod turned on?
Turn the Ultra's power switch behind the control pod to ON.
Check for 120 volts at the line
voltage terminal block located
inside the control pod.
Correct wiring inside the control pod using the wiring diagram in this
manual.
Inspect 12-amp fuse as shown
on page116. Replace if
necessary.
Replace the fuse with proper part found in the replacement part section
of this manual. If fuse blows again recheck wiring per diagram.
Nothing is
shown on
display screen,
but boiler is
operating
Occurs when the
communication is lost from
the U-control to the display.
Check for loose connections
and proper pin alignment/
engagement on the U-Control's
plug P9 and the back of the
display circuit board.
Check for continuity on the wire harness from the display to the
U-control. See repair parts section for proper replacement part.
Cycle power o and on using
boiler power switch and check
for operation.
Replace with new display module. See repair parts section for proper
replacement part.
TEMP RISE TOO
QUICKLY
Occurs when supply
water temperature in heat
exchanger rises faster than
2ºF per second during the
rst two minutes the burner
is on.
Automatically resets after 1
minute delay or using manual
reset on display.
Manual reset is necessary after 5
automatic resets have occurred
during the same Priority heat
demand. Reset using manual
reset screen on display.
Verify water pipe is installed correctly using primary/secondary
connection to the boiler loop. Refer to Figure4,page11 for example of
primary/secondary connection.
Minimum pipe sizes
Ultra 80/105 - minimum 1 inch
Ultra 155/230 - minimum 1.25 inch
Ultra 299/399 - minimum 1.5 inch
Verify proper circulator sizing for boiler size and system requirements
starting on page10.
Boiler ship with proper size circulators:
Ultra 80/105 - Taco 007e ECM or 007
Ultra 155/230/299 - Taco 0014
Ultra 399 - Taco 0013
See message displayed TEMPERATURE SENSOR and follow procedure for
loose connections.
SUPPLY 58F >
RETURN
Boiler Out temperature
has exceeded the Boiler In
temperature by more than
58ºF, when burner is on.
Automatically resets after 30
second delay or using manual
reset on display.
Verify water pipe is installed correctly using primary/secondary
connection to the boiler loop. Refer to Figure4,page11 for example of
primary/secondary connection.
Minimum pipe sizes
Ultra 80/105 - minimum 1 inch
Ultra 155/230 - minimum 1.25 inch
Ultra 299/399 - minimum 1.5 inch
Verify proper circulator sizing for boiler size and system requirements
starting on page10.
Boiler ship with proper size circulators:
Ultra 80/105 -Taco 007e ECM
Ultra 155/230/299 - Taco 0014
Ultra 399 - Taco 0013
See message displayed TEMPERATURE SENSOR and follow procedure for
loose connections.
Figure 125 Troubleshooting suggestions for Ultra boilers (continued)
Part number 550-100-440/0723
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Troubleshooting (continued)
Display
Condition Diagnostics Corrective Action(s)
RETURN >
SUPPLY
Occurs when a return water
temperature is greater than
the corresponding supply
temperature by 10ºF or more.
Applies to system sensors or
boiler sensors.
Condition must occur for 10
minutes for system sensors.
Automatically resets when
condition no longer exists.
Verify proper ow direction of the boiler circulator. This circulator should
be installed to push water through the boiler's return pipe as shown in
Figure4,page11.
Verify proper placement of system sensors for single or multiple boiler
systems. System sensors should be on system piping not on the boiler
loop.
System sensors may need located further away from boiler loop
connection to the system if proximity to the boiler loop is causing
sensors to be heated inaccurately.
TEMPERATURE
SENSOR
Occurs when a temperature
sensor has electrically shorted
(SHORT) or has become
disconnected (OPEN).
Automatically resets when
condition no longer exists.
Check all the temperature readings of the boiler on the DIAGNOSTICS -
TEMPERATURES menu to determine if any sensors are currently displayed
as SHORT or OPEN. Compare this to the boiler temperatures recorded
in the DIAGNOSTICS - ERRORS - LOCKOUT HISTORY # - TEMPERATURES
during the last several lockout conditions.
Determine which sensors are suspect and measure their resistance
value and compare it to the values shown in Figure123,page116. If the
resistance 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
U-Control module. Unplug connection at sensor and at U-Control and
check continuity between ends.
If problem persists after checking items above replace U-Control. Refer
to repair parts section for kit number.
FLUE TEMP
TOO HIGH
Occurs when ue
temperature sensor exceeds
216ºF.
Automatic reset occurs if
temperature drops below 216ºF
for 2.5 min.
Manual reset is required if the
temperature rises above 225°F.
Reset using manual reset screen
on display.
Follow procedure for above for SHORT and OPEN sensor conditions
to properly diagnose sensor. In addition inspect heat exchanger
combustion chamber and ueways for abnormal wear or buildup.
Inspect vent system for abnormal wear or damage.
Contact WM Technologies Technical Support.
TEMPERATURE
SENSOR
Occurs when dual
temperature sensors values
have spread by more that
10ºF.
Automatically resets when
sensors are within 10ºF.
Follow procedure for above for SHORT and OPEN sensor conditions
to properly diagnose sensor. If measured resistance values of sensors
convert to temperatures separated by more than 10ºF replace the sensor.
LOW WTR
CUTOFF OPEN
Occurs when Low Water
Cuto Device contacts open
for more than 1 second.
Requires manual reset of
U-Control and may require
manual reset of LWCO device
depending on model.
Check for low water condition in system. Repair system as necessary
refer to piping section of this manual.
If low water condition does not exist check Diagnostics - Inputs screen to
view status of Low Water Cuto. If shown as OPEN check wiring between
LWCO and U-Control.
Troubleshooting (continued)
Figure 125 Troubleshooting suggestions for Ultra boilers (continued)
Part number 550-100-440/0723
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MAINTENANCE & SPECIFICATIONS
Troubleshooting (continued)
Display
Condition Diagnostics Corrective Action(s)
DISPLAY COMM
Occurs when display
communications out for 30
seconds.
Automatically resets when
communication is re-
established.
Check for a loose connection at the molex plug on the control and
connection on the back of the display.
LIMIT OPEN
Occurs when manual or
automatic reset limit opens.
Automatic external limit will
reset 2.5 minutes after external
limit device closes.
Manual limit fault must be reset
by choosing Reset Lockout on
the display.
Is there an external safety device connected? If yes, trouble shoot the
external limit to determine and correct the cause that opened the limit.
Also check for loose wiring connections.
Remove the top front cover and inspect the ORANGE - 4 PIN connector
P13.
Ensure a jumper is installed between pins 1 & 2 if not using a manual
reset external limit.
Ensure a jumper is installed between pins 3 & 4 if not using a automatic
reset external limit.
HIGH TEMP
LIMIT
Boiler temperature sensor
reached High Temp Limit
setting (no higher than 200°F).
Reset using manual reset screen
on display.
Verify all isolation valves are open and circulators are programmed into
the U-Control properly. Each Priority input can be congured to turn
on any combination of three circulator outputs. Refer to the U-Control
Setup section to congure these properly for the system.
Verify water pipe is installed correctly using primary/secondary
connection to the boiler loop. Refer to Figure4,page11 for example of
primary/secondary connection.
Minimum pipe sizes
Ultra 80/105 - minimum 1 inch
Ultra 155/230 - minimum 1.25 inch
Ultra 299/399 - minimum 1.5 inch
Verify proper circulator sizing for boiler size and system requirements
starting on page10.
Boiler ship with proper size circulators:
Ultra 80/105 - Taco 007e ECM or 007
Ultra 155/230/299 - Taco 0014
Ultra 399 - Taco 0013
See message displayed TEMPERATURE SENSOR and follow procedure for
loose connections.
FLAME FAULT
Occurs when ame is
detected when there should
be no ame.
Reset using manual reset screen
on display.
Burner may be operating too hot due to incorrect combustion. Inspect
ame and conduct combustion test.
Force boiler into hi-re. Check ue gases with combustion analyzer and
correct using the maintenance and startup procedure in this manual.
Verify FLAME SIGNAL value quickly goes to zero on the DIAGNOSTICS -
INPUTS screen when the gas valve closes.
Check for ame at burner via ame current with burner o. Turn boiler
o and watch ame through observation port. If ame continues after
shutdown replace gas valve and venturi.
Troubleshooting (continued)
Figure 125 Troubleshooting suggestions for Ultra boilers (continued)
Part number 550-100-440/0723
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Display
Condition Diagnostics Corrective Action(s)
BLOWER FAULT
Blower unable to reach
required speed or does not
reach 0 RPM when turned o.
Automatically resets after 1 hour
or can be reset by using manual
reset on screen.
Check wire harness for loose connections and pin engagement at blower
connections, chassis mount connection through sheet metal cabinet,
and U-Control module. Unplug connection at sensor and at U-Control
and check continuity between ends. Blower is connected to both low
voltage and line voltage harness.
Check Diagnostics - Inputs screen with boiler in standby mode and
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
start replace blower. Check power at U-Control. If 120Vac is not present
at U-Control when boiler is powered replace U-Control. Refer to repair
parts section.
IGNITION
FAULT
Boiler went through 5 ignition
attempts and never detected
ame.
Automatically resets after 1 hour
or can be reset by using manual
reset on screen.
Check condensate trap for blockage allowing condensate to accumulate
inside heat exchanger
Fouled, worn, bent, or faulty igniter.
Fouled igniters can be cleaned for additional use with ne grit sand
paper or steel wool.
Worn or badly fouled igniters should be replaced with the proper repair
part.
Igniter rods should be parallel with a 3.5mm (0.138 in) spark gap.
Dirty burner and/or heat exchanger will cause high back pressure and
poor ignition. Follow procedure in the Maintenance section of this
manual to clean burner and heat exchanger using ue cleaning tool and
rinse method.
Visual inspection of ueways will often will not be able to diagnose
condition.
Check combustion settings on high and low re and adjust per setup
instructions if necessary.
Check incoming gas pressure with boiler o and at high re. Adjust
within limits on rating label.
Verify correct boiler model is selected in control and high altitude is
selected for installations 5500 ft above sea level.
Check ignition cable resistance. Should measure 1000 Ohms (+/- 50
Ohms)
Check for ue pipe and intake pipe restrictions or blockage
Check burner fasteners and gaskets
Check venturi gaskets and proper propane orice
Check condensate trap for blockage allowing condensate to accumulate
inside heat exchanger
Troubleshooting (continued)
Figure 125 Troubleshooting suggestions for Ultra boilers (continued)
Part number 550-100-440/0723
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MAINTENANCE & SPECIFICATIONS
Display
Condition Diagnostics Corrective Action(s)
GAS VALVE
FAULT
The U-Control has detected
a problem with it gas valve
output circuit
Automatic retry when condition
exists. Boiler will reset if
conditions clears. If condition
does not clear boiler will retry in
1 hour. If condition is not clear
after 1 hour, boiler will require
manual reset.
Check wire harness connections between gas valve and U-Control.
Check resistance between
If lockout reoccurs replace U-Control.
AIR PRESSURE
SW FAULT
Air Pressure switch is open Ultra residential boilers do not
use an air pressure switch, but
instead have a wire jumper
installed between P7 pins 4 & 5.
Reset using manual reset screen
on display
Check boiler size selected in U-Control against boiler rating label. Correct
if necessary to select the proper boiler size.
Check the P7 connection as seen in Figure111,page96 and
Figure112,page97 to determine proper jumper wire location.
GAS PRESSURE
SW FAULT
Gas pressure switch is open
(high or low)
Residential Ultra Boilers do
not use gas pressure switches.
Requires manual reset.
Check boiler size selected in U-Control against boiler rating label. Correct
if necessary to select the proper boiler size.
HW FAULT
EXPANSION
BRD
Expansion Control Board
hardware has failed.
Residential Ultra Boilers do not
use an Expansion Control Board.
Requires manual reset.
Check boiler size selected in U-Control against boiler rating label. Correct
if necessary to select the proper boiler size.
GV FAULT
EXPANSION
BRD
Gas valve output of the
Expansion Board
Residential Ultra Boilers do not
use an Expansion Control Board.
Requires manual reset.
Check boiler size selected in U-Control against boiler rating label. Correct
if necessary to select the proper boiler size.
EXP BOARD
COM FAULT
Communication between the
Expansion Control Board and
the U-Control Board has failed
Residential Ultra Boilers do not
use an Expansion Control Board.
Requires manual reset.
Check boiler size selected in U-Control against boiler rating label. Correct
if necessary to select the proper boiler size.
Troubleshooting (continued)
Figure 125 Troubleshooting suggestions for Ultra boilers (continued)
Part number 550-100-440/0723
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Ultra Gas Boiler Data Collection Sheet
Customer Info: Maintenance Info:
Contact: Name:
Contractor: Phone:
Job name: Model:
City, state: CP#:
Distributor: Installed:
System Components: Boiler/System Piping Details (Please Sketch)
Near boiler pipe size: Please note the placement of system sensors
Boiler circulator model:
DHW tank (yes/no):
DHW direct/system:
Dhw model:
Dhw pipe size:
DHW circulator model:
Is there air in system?:
Diagnostic Errors:
Control fault:
Ignition retries:
Manual reset CNT:
Auto reset CNT:
Software Versions:
Display:
Main micro:
Second micro:
Lockout History #1 Lockout History #2 Lockout History #3
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:
Outputs: Outputs: Outputs:
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:
Temperatures: Temperatures: Temperatures:
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:
Part number 550-100-440/0723
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MAINTENANCE & SPECIFICATIONS
e boiler contains ceramic ber materials. Use care
when handling these materials per instructions on
page109 of this manual. Failure to comply could
result in severe personal injury.
1. Shut down boiler:
a. Follow “To Turn O Gas to Appliance” instructions on
boiler and Lighting instructions.
b. Do not drain boiler unless it will be exposed to freezing
temperatures. If using freeze prevention uid in system,
do not drain.
2. Allow time for boiler to cool to room temperature if it has
been ring.
3. Remove boiler door by removing two (2) screws at lower front.
Li door away from boiler to remove.
4. Follow the applicable procedures under “Accessing & cleaning
heat exchanger:Ultra-80 and Ultra-105 Only” on page126 or
“Accessing & cleaning exchanger: Ultra-155, -230, -299 and
-399 Only” on page127.
Clean the cast aluminum heat exchanger when
required — water side
1. In order for the eciency of boilers to increase beyond the
condensing limit, new materials have been introduced for the
heat exchanger, including aluminum.
2. Aluminum has excellent heat transfer characteristics and is
light in weight.
3. ese new materials also require cleaning solutions that dier
from those used in conventional cast iron and steel boilers.
One common cleaning method that CANNOT be
used with systems containing aluminum is a solu-
tion of trisodium phosphate, commonly referred to
a s “ T S P.”
The reason that trisodium phosphate cannot be
used is that the cleaning solution has a very high pH
level — while removing the scale in the system, it
also removes the natural protective oxide layer from
the aluminum. e oxide layer will reform, but if
small amounts of the trisodium phosphate remain
in the system, the chemical will continue to remove
the protective oxide layer, leading to reduced heat
exchanger life.
4. Use ONLY the cleaning product available from WM Technolo-
gies, Sentinel X400. See the Repair Parts section at the end of
this manual for ordering information.
General maintenance
1. Oil motor in system requiring regular oiling.
2. See Oiled bearing circulators for motor oiling procedures.
Oiled bearing circulators
1. e circulator shipped with the Ultra boiler is water-lubri-
cated. No oiling is required.
2. Check other circulators in the system. Oil any circulators
requiring oil, following circulator manufacturer’s instruc-
tions. Over-oiling will damage the circulator.
Cleaning the heat exchanger — pin side
when required
Disconnect power
Electrical shock hazard — Disconnect all elec-
trical power to the boiler before attempting
maintenance procedures. Failure to complete
could result in severe personal injury, death
or substantial property damage.
Install boiler jacket front door
after startup or servicing
Reinstall boiler jacket front door aer start-
up or servicing. e boiler front door must
be securely fastened to the boiler to prevent
boiler from drawing air from inside the boiler
room. is is particularly important if the
boiler is located in the same room as other
appliances.
Inspect boiler jacket door gaskets. Gaskets
must be in good condition, with no tears or
gaps. Replace if necessary.
Failure to keep the door securely sealed and
fastened could result in severe personal injury
or death.
Perform start-up and check/out
Removing and reinstalling components can
change boiler behavior. Aer any mainte-
nance procedure, you must prove the boiler
is operating correctly. To do so, follow the
complete procedure for boiler and system
start-up, beginning on page35. Failure to
comply could result in severe personal injury,
death or substantial property damage.
Maintenance
Attention to homeowners and installers
of Ultra Series 4 boilers– see page126
for the latest cleaning information for
our newly coated heat exchangers.
Part number 550-100-440/0723
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Maintenance (continued)
Figure 126 Nut tightening sequence — 80 & 105
Gradually tighten the nuts, repeating
the sequence shown below until the
torque reaches 50 inch-pounds (+/-
10 inch-pounds
For the rst 5 years, vacuum or rinse heat exchanger with water only.
No tool cleaning is necessary.
y This heat exchanger is coated to prevent the formation of Aluminum Oxide. Cleaning the heat exchanger via
mechanical means (cleaning tools, blade, or brush) could shorten the life of the coating.
y Heat exchanger inspection is recommended at yearly intervals. Only clean heat exchanger if soiling is clearly
present. If cleaning is necessary ush only with water and a mild detergent. From the cover plate opening, inspect
the collection area and underneath the vent pipe to ensure that it is free of debris. If cleaning is necessary ush
only with water and a mild detergent.
y Cleaning the heat exchanger should not be necessary until 5 years after commissioning date.
Figure 127 Cleaning the exchanger pin-side
Accessing & cleaning heat exchanger:
Ultra-80 and Ultra-105 Only
1. Close the external manual gas valve.
2. Disconnect the exible gas line at its are tting.
3. Remove the air silencer by separating it from the air adapter on the
blower inlet.
4. Disconnect wiring: •gas valve plug •blower power supply plug
• blower control connector •ignition cable •ground wire.
5. Release the heat exchanger cover plate by removing the nuts securing
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 identication
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 heating
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 Figure127.
See water
spraying notice on next page
.
9. Inspect the heat exchanger cover plate insulation. Replace if insulation
is damaged. Read the ceramic ber WARNING on page109 before
handling or disposing of ceramic ber 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 Ultra-80
and -105, follow the tightening sequence shown in Figure126,
making two or three passes with a torque wrench. e nal
torque MUST NOT exceed 50inch-pounds, +/- 10inch-
pounds.
11. Reconnect wiring: •gas valve plug •blower power supply plug
• blower control connector •ignition cable •ground wire.
If the valve adapter block is removed, carefully inspect the
O-ring that should still be in the gas valve inlet adapter block.
e 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 exible 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 aer starting
the boiler.
Cleaning the heat exchanger — water side (ALL
models)
1. Follow the procedure given in “Clean the cast aluminum heat exchanger
when required — water side” on page125 to clean the water side of
the exchanger.
2. Follow the complete procedure for boiler and system start-up, begin-
ning on page35.
Part number 550-100-440/0723
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MAINTENANCE & SPECIFICATIONS
Maintenance (continued)
Accessing & cleaning exchanger: Ultra-155, -230,
-299 and -399 Only
1. Close the external manual gas valve.
2. Disconnect wiring: •gas valve electrical plug •two electrical Molex
plugs from the blower assembly •ignition cable •ground wire.
3. Disconnect the exible gas line at its are tting.
4. Remove the air silencer by liing the plastic clamp o of the gas
line and then gently sliding the air silencer down and o the valve.
5. Remove hex head nuts (10mm box end wrench) from heat exchang-
er 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-
tication and locations.)
7. Remove three (3) M4 hex head screws (7mm box end wrench) and
burner clips securing burner to cover plate. Remove cover plate.
8. Use a vacuum cleaner to remove any accumulation on the heating
surfaces. Do not use any solvent.
9. If the vacuum cleaner is unable to clean completely, wash the
heating surfaces with clean, warm water. If 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 Figure127,page126.
See water spraying notice.
10. Inspect the heat exchanger cover plate insulation and gasket. Re-
place if damaged. Read the ceramic ber WARNING on page109
before handling or disposing of ceramic ber materials.
11. Replace the burner, hex head screws and burner clips removed in
step 7. See Figure120,page112.
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 tight-
en in a staggering pattern until cover plate is uniformly tightened.
You must gradually tighten the cover plate nuts. For
Ultra-155 through -399, follow the tightening sequence
shown in Figure128, making two or three passes with
a torque wrench. e nal torque MUST NOT exceed
50inch-pounds, +/- 10inch-pounds.
14. Reinstall air silencer by sliding on gas valve venturi and securing
clamp to gas line.
15. Reconnect wiring: •gas valve electrical plug •two electrical Molex
plugs from the blower assembly •ignition cable •ground wire.
16. Reconnect the exible gas line and gas valve electrical plug.
17. Perform a soap suds leak test on all interior gas piping aer start-
ing the boiler.
Cleaning the heat exchanger — water side (ALL
models)
1. Follow the procedure given in “Clean the cast aluminum heat
exchanger when required — water side” on page125 to clean the
water side of the exchanger.
2. Follow the complete procedure for boiler and system start-up,
beginning on page35.
Figure 128 Nut tightening sequence —
155 to 399 — Gradually tighten the
nuts, repeating the sequence shown
below until the torque reaches 50
inch-pounds (+/- 10 inch-pounds)
WATER SPRAY HEAT EXCHANGER PINS
AFTER USING CLEANING TOOL
1. After using the cleaning tool as shown in Fig-
ure127, page126, spray water downward from
above the pins to ush remaining sediment.
2. Remove sediment from the bottom of the heat
exchanger.
3. en disconnect the condensate line at the bottom
of the heat exchanger.
a. Loosen the hose clamps at both ends of the
condensate line.
b. Remove the line and place a pan under the trap
connection.
c. Spray water into the bottom of the heat ex-
changer to ush remaining sediment to the
condensate outlet.
d. Spray water through the condensate line to
clean it thoroughly.
e. Remove pan and replace the condensate line.
f. Follow instructions on page126 or on this
page to check components and replace burner
and cover.
Part number 550-100-440/0723
128
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Replacement parts
Replacement parts must be purchased through a local WM Technologies distributor. When
ordering, specify boiler model and size and include description and part number of replacement
part. Results from using modied or other manufactured parts will not be covered by warranty
and may damage boiler or impair operation.
Weil-McLain part numbers are found in Weil-McLain Boilers and Controls Repair Parts Lists.
The boiler contains ceramic ber materials. Use care when handling these materials per
instructions on page109 of this manual. Failure to comply could result in severe personal injury.
Reinstall boiler door after startup or servicing
Inspect boiler door gaskets and reinstall boiler door aer start or servicing. e boiler door
must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler
room. is 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.
Figure 129 Propane conversion kits and instructions
e conversion kits listed below are only for use with Ultra Series 4 boilers. For series1 or series2 boilers,
refer to the boiler manual or contact WM Technologies for the correct parts.
Natural to propane conversion — SERIES 4 BOILERS ONLY
(not required for Ultra-399 — adjustment is made with throttle screw, not with orice)
Sea level (to 5,500 feet altitude) High altitude (above 5,500 feet)
Model Kit part # Kit location Instructions Model Kit part # Kit location Instructions
Ultra-80 383-501-020
SPECIAL
ORDER
In kit only
Ultra-80LP 383-500-644
SPECIAL
ORDER
See page 48 or kit
Ultra-105
540-100-001
Supplied with boiler
See page 48 Ultra-105 383-500-645
SPECIAL
ORDER
See page 48 or kit
Ultra-155
383-500-115
Supplied with boiler
See page 49 Ultra-155 383-500-646
SPECIAL
ORDER
See page 49 or kit
Ultra-230
383-500-120
Supplied with boiler
See page 49 Ultra-230 383-500-647
SPECIAL
ORDER
See page 49 or kit
Ultra-299
540-202-832
Supplied with boiler
See page 49 Ultra-299 383-500-394
SPECIAL
ORDER
See page 49 or kit
Propane to natural conversion
-80 383-501-021
SPECIAL
ORDER
In kit only
Contact factory
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.
Part number 550-100-440/0723
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MAINTENANCE & SPECIFICATIONS
Figure 130 Miscellaneous parts and kits
Replacement parts (continued)
Go to www.weil-mclain.com to locate WM Technologies distributors
Description
Part Number
CHEMICALS
Antifreeze, aluminum-safe, Sentinel X500 (1 gallon) . . . . . . . . . . . . . . . . . . . .
Antifreeze, aluminum-safe, Sentinel X500 (5 gallon) . . . . . . . . . . . . . . . . . . . .
Corrosion inhibitor, Sentinel X100 (one tube, 275 ml) . . . . . . . . . . . . . . . . . . . .
Inhibitor quick-test kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
592-900-029
592-900-006
592-900-002
592-900-005
BOILER ACCESSORIES AND CONTROLS
Boiler circulator, without anges Ultra-80/105 Taco Model 007e ECM
Ultra-80/105 Taco Model 007
Ultra-155/230/299 Taco Model 0014
Ultra-399 Taco Model 0013
511-405-153
511-405-113
511-405-133
511-405-140
Circulator hardware kit – inlet (1 ange, 2 nuts, 2 screws, and 1 gasket)
1”
1¼”
1½”
381-354-525
381-354-526
381-354-531
Low water cut-off with test button 511-100-005
Heat exchanger cleaning tool 591-706-200
Annual maintenance kit (Igniter, igniter gasket, cover Ultra-80/105
plate gasket, cover plate insulation, burner gasket, Ultra-155 – 399
ue sensor gasket and venturi gasket)
383-500-605
383-500-620
Pressure relief valve, ASME 30 PSI, 3/4” NPT male Ultra-80 – 299
Ultra-80 – 399
383-500-095
511-546-921
Pressure/Temperature gauge, Short Shank 3.12-Inch Diameter 1/4 NPT 510-218-099
Ultra boiler wall-mount kit 389-900-180
VENT / AIR TERMINATIONS
Vent/air termination wall penetrate cover plate (2 are shipped with each boiler) 383-500-100
Vent termination bird screen (2 are shipped with each boiler) 3” vent - Ultra-80/105/155
4” vent - Ultra-230/299/399)
383-500-105
383-500-110
Weil-McLain sidewall vent/air cap termination kit — Includes W-M sidewall vent/air termination cap,
inside and outside cover plates, and mounting hardware; openings are sized for PVC pipe.
3” kit - Ultra-80 – 155
4” kit - Ultra-230 – 399 383-500-397
383-500-398
Weil-McLain Flue Pipe & Adapter kits — Includes bracket pipe ue, adapter air Inlet, adapter ue pipe,
clamp pipe ue, mounting hardware and Instructions:
70mm kit - Ultra-80/105
80mm kit - Ultra-155
100mm kit - Ultra-230-399
383-500-770
383-500-771
383-500-772
Concentric vent kit (for sidewall or vertical termination) 3” PVC only
Concentric vent kit (for sidewall or vertical termination) 4” PVC only
383-500-350
383-900-075
CONDENSATE HANDLING
Condensate neutralizer kit 383-500-631
Part number 550-100-440/0723
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Replacement parts (continued)
Figure 131 Jacket parts
Go to www.weil-mclain.com to locate WM Technologies distributors
Item
Description
Boiler
models
Part
number
1 Boiler door (Slate gray) All 383-500-136
2 Boiler leg kit (4 required) All 383-500-065
3
Screw at head slotted 17 Series for
jacket front door (2 required)
All 562-650-126
4
Screw clip-on receptacle (not shown)
(2 required)
All 383-500-180
5
Air inlet pipe adapter 3”
3”
4”
80/105
155
230–399
560-907-704
560-907-707
560-907-710
Item
Description
Boiler
models
Part
number
6 Flue outlet pipe adapter 3”
3”
4”
80/105 560-907-771
155 560-907-771
230–399 560-907-773
7 Top cover, front All 383-500-607
8 Top cover, rear 80/230 383-500-608
299/399 383-500-609
9 Door Gasket replacement kit (not shown) All 383-500-610
10 Flue pipe 3”
3”
4”
80/105 560-907-775
155 560-907-772
230–399 560-907-774
Part number 550-100-440/0723
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MAINTENANCE & SPECIFICATIONS
Replacement parts (continued)
Figure 132 Controls
Go to www.weil-mclain.com to locate WM Technologies distributors
Item
Description
Part Number
1 Ultra U-Control module 383-500-658
2 Transformer, 120V/24V 383-500-628
3 Display board assembly (includes plastic and display
screen)
383-500-756
4 On/off power switch 383-500-205
5 Flue temperature sensor replacement kit 383-500-600
6 System temperature sensors (2 required) 383-500-601
7 Outdoor temperature sensor 510-312-218
8 Display to U-Control wire harness (not shown) 383-500-633
9 Line voltage wire harness (male) (not shown) 383-500-639
10 Low voltage wire harness (male) (not shown) 383-500-640
11 120 volt, 3-wire receptacle (not shown) 383-500-638
12 Ultra U-Control module fuses (not shown)
F1 - 3-amp, fast-blow ATO (5 fuses)
F2 - 12-amp, fast-blow AG (5 fuses)
383-500-603
383-500-604
13 Jumper for low voltage terminal blocks, (5 jumpers)
(not shown)
383-500-641
14 Ultra U-Control terminal block kit, (includes 1 high
voltage terminal block, 6 low voltage terminal blocks, and
U-Control screwdriver) (not shown)
383-500-642
15 24V LWCO kit with quick connect harness (not shown) 511-100-005
Part number 550-100-440/0723
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Replacement parts (continued)
Figure 133 Heat exchanger and piping — Ultra-80 and -105
Item Description
Boiler
Models
Part Number
1 Heat exchanger replacement kit - Heat exchanger, cover plate, burner,
electrode, water sensors, compression ttings, condensate tting, gaskets, and
hardware
80
105
383-500-773
383-500-774
2 Cover plate replacement kit - Cover plate, cover plate gasket and hardware 80/105 383-501-022
3 Cover plate gasket/insulation 80/105 383-500-251
4 Burner gasket 80/105 590-300-000
5 Cover plate studs, M6, 1 pitch All 560-340-598
6 Cover plate nuts, M6, 1 pitch All 561-928-449
7 Water compression tting, 28 mm 80–230 383-500-260
8 Water compression tting, 22 mm 80/105 564-100-002
9 Supply water pipe assembly - Pipe, compression tting & plugs 80/105 383-500-760
10 Return water pipe assembly - Pipe, drain valve (assembled) & compression
tting
80/105 383-500-761
11 Boiler drain valve, 3/4” NPT All 511-246-392
12 Blower assembly kit - Blower, gasket, and hardware 80/105 383-501-027
13 Gas pipe 80/105 560-907-682
14 Flexible gas line 80/105 383-500-616
15 Gas Pipe lower pipe clamp and hardware 80/105 383-500-617
16 Gas valve/venturi kit - Gas valve, venturi, 90° elbow, gaskets, and hardware
(assembled) (For LP boilers, make sure to reinstall the existing propane orice)
80
105
383-501-029
383-501-030
17 Gasket cork, for in between gas valve venturi & burner inlet All 590-317-310
18 Air silencer kit - Air silencer and gasket 80/105 383-501-026
19 Air silencer adapter kit - Air silencer adapter and hardware 80/105 383-501-025
20 Condensate trap kit - Condensate trap, hose clamps, pvc ttings, and gasket 80/105 383-501-031
21 Return/supply sensor kit - (1) sensor All 383-500-602
22 Ignition electrode kit - Ignition electrode, suppressor, gasket, and hardware All 383-500-045
Ignition electrode gasket ONLY All 511-330-253
23 Ignition cable kit (not shown) - Ignition cable, suppressor, and wire tie All 383-500-619
24 Inspection glass kit - Bracket, glass, gasket and hardware All 383-500-020
25 Burner replacement kit - Burner, gaskets and hardware 80NG
80LP
105
383-501-032
383-501-033
383-501-034
26 Gasket rubber, blower 80/105 590-300-003
27 Condensate tting 80/105 561-200-000
Part number 550-100-440/0723
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MAINTENANCE & SPECIFICATIONS
U3060
Gas valve sensor
tubing: 5/16"-OD
(from gas valve to
inlet elbow)
Elbow
Venturi
Gas valve
Gas valve inlet
adapter block
Cork gasket
O-ring
3
4
7
8
9
12
22
26
1
2
10
11
13
16
18
24
27
19
21
5
6
14
20
25
17
15
21
Figure 134 Heat exchanger and piping — Ultra-80 and -105
Replacement parts (continued)
Go to www.weil-mclain.com to locate WM Technologies distributors
Part number 550-100-440/0723
134
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Go to www.weil-mclain.com to locate WM Technologies distributors
1
3
10
13
16
18
19
23
8
11
12
14
24
24
20
22
U3035
2
6
5
15
7
9
4
Figure 135 Heat exchanger and piping
Ultra-155 & -230
Replacement parts (continued)
Item
Description
Boiler
models
Part
number
1 Heat exchanger replacement kit - Heat
exchanger, cover plate, burner, electrode,
water sensors, compression ttings,
condensate tting, gaskets, and hardware
155
230
383-500-775
383-500-776
2 Cover plate replacement kit - Cover plate,
cover plate gasket, burner gasket, and
hardware
155/230 383-500-395
3 Cover plate insulation 155/230 383-500-250
4 Cover plate gasket 155/230 383-500-255
5 Cover plate studs, M6, 1 pitch All 560-340-598
6 Cover plate nuts, M6, 1 pitch All 561-928-449
7 Water compression tting, 28 mm 80–230 383-500-260
8 Supply water pipe assembly - Pipe &
compression tting & plugs
155/230 383-500-762
9 Return water bushing, 1 1/4” BSP x 1” BSP
(not use on Ultra-299)
155/230 383-500-280
10 Return water pipe assembly - Pipe, drain
valve, cap (assembled) & compression
tting
155/230 383-500-763
11 Boiler drain valve, 3/4” NPT All 511-246-392
12 Blower assembly kit - Blower, gasket, and
hardware
155
230
383-500-035
383-500-040
13 Gas pipe 155/230 560-907-683
14 Flexible gas line 155/230 383-500-767
15 Gas pipe lower clamp and hardware 155/230 383-500-617
Item
Description
Boiler
models
Part
number
16
Gas valve/venturi kit - Gas valve, venturi,
adapter block, O-ring and hardware
(assembled) be sure to reinstall the existing
propane orice)
155
230
383-500-025
383-500-030
17
Gasket cork, for in between gas valve
venturi & blower inlet (not shown)
All 590-317-310
18 Air silencer kit - Air silencer and gasket 155/230 383-500-295
19
Condensate trap kit - Condensate trap, hose
clamps, pvc ttings, and gasket
155/230 383-500-060
20
Ignition electrode kit - Ignition electrode,
suppressor, gasket, and hardware
All 383-500-045
Ignition electrode gasket ONLY (not shown) 511-330-253
21
Ignition cable kit (not shown) - Ignition
cable, suppressor, and wire tie
All 383-500-619
22
Inspection glass kit - Bracket, glass, gasket
and hardware
All 383-500-020
23
Burner replacement kit - Burner, gaskets
and hardware
155
230
383-500-085
383-500-090
24 Return/supply sensor kit - (1) sensor All 383-500-602
Part number 550-100-440/0723
135
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MAINTENANCE & SPECIFICATIONS
U3537
8
23
7
16
12
24
11
3
1
20
22
25
2
5
6
14
9
10
10
13
24
4
19
17
19
12
16
14
399 components
17
15
Figure 136 Heat exchanger and piping Ultra-299 & -399
Replacement parts (continued)
Item
Description
Boiler
models
Part
number
1 Heat exchanger replacement kit - Heat
exchanger, cover plate, burner, electrode,
water sensors, compression ttings,
condensate tting, gaskets, and hardware
299/399 383-500-777
2 Cover plate replacement kit - Cover plate,
cover plate gasket, burner gasket, and
hardware
299/399 383-500-395
3 Cover plate insulation 299/399 383-500-250
4 Cover plate gasket 299/399 383-500-255
5 Cover plate studs, M6, 1 pitch All 560-340-598
6 Cover plate nuts, M6, 1 pitch All 561-928-449
7 Supply water pipe assembly - Pipe &
compression tting & plugs
299/399 383-500-764
8 Return water pipe assembly - Pipe, drain
valve, cap (assembled) & compression
tting
299/399 383-500-385
9 Supply/Return water piping square cut
EPDM gasket (Ultra-299 only)
299/399 562-248-755
10 Fitting, double nipple for supply/return 299/399 561-326-828
11 Boiler drain valve, 3/4” NPT All 511-246-392
12 Blower assembly kit - Blower, gasket, and
hardware
299
399
383-500-360
383-500-650
13 Gas pipe 299/399 560-907-679
14 Flexible gas line 299/399 383-500-768
Item
Description
Boiler
models
Part
number
15 Gas pipe lower clamp and hardware 299 383-500-625
16 Gas valve/venturi kit - Gas valve, venturi 299 383-500-390
Gas valve kit - Gas valve, venturi, adapter
block, O-ring and hardware (assembled)
399 383-500-652
17 Gas valve outlet adapter/nipple kit 399 383-500-651
18 Gasket cork, for in between gas valve
venturi & blower inlet
All 590-317-310
19 Air silencer kit - Air silencer and gasket 299
399
383-500-355
383-500-654
20 Ignition electrode kit - Ignition electrode,
suppressor, gasket, and hardware
All 383-500-045
Ignition electrode gasket ONLY 511-330-253
21 Ignition cable kit (not shown) - Ignition
cable, suppressor, and wire tie
All 383-500-619
22 Inspection glass kit - Bracket, glass, gasket
and hardware
All 383-500-020
23 Burner replacement kit - Burner, gaskets
and hardware
299 383-500-407
24 Return/supply sensor kit - (1) sensor All 383-500-602
25 Condensate trap kit - Condensate trap, hose
clamps, pvc ttings, and gasket
299/399 383-500-626
Part number 550-100-440/0723
136
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Figure 137 Dimensional data
Dimensions
Notes
1
Boiler supply and return tappings are both 1” NPT (Ultra-80/105/155/230) or 1¼” NPT (Ultra-299/399).
See page10 for recommended piping sizes.
Wall-hung boiler option — water piping and gas pipe can only be routed through top of enclosure using wall-mounting kit. See
page5 for mounting instructions.
2
Boiler circulator is shipped loose.
Circulator must be mounted in the return piping.
Both 1” and 1¼” circulator anges are shipped with boiler on Ultra-80/105/155/230.
Both 1¼” and 1½” circulator anges are shipped with boiler on Ultra-299 and Ultra-399.
3
Relief valve is shipped loose.
See page9 for mounting details. Relief valve mounts on supply pipe o of supply tee and ¾” street elbow as shown.
Part number 550-100-440/0723
137
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MAINTENANCE & SPECIFICATIONS
Ratings — Ultra Series 4 boilers
Figure 138 Ratings and engineering data
AHRI Certied Ratings
Boiler
Model
Number
CSA
Input
Heating
Capacity
Seasonal
Efciency
Net
Rating
(water)
Boiler
Water
Content
Vent/Air
Pipe
Size
Btuh (Note 7) Btuh (Note 2 and 7) AFUE % (Note 1) Btuh (Note 3) Gallons
(Note 4)
Ultra-80 80,000 71,000 93.5 62,000 0.69 2” or 3”
Ultra-105 105,000 94,000 94.0 82,000 0.82 2” or 3”
Ultra-155 155,000 139,000 94.0 121,000 1.17 3”
Ultra-230 230,000 207,000 94.1 180,000 1.57 3” or 4”
Ultra-299 299,000 270,000 92.5 235,000 2.10 4”
Boiler
Model
Number
CSA
Input
Gross
Output
Net
AHRI
Ratings
Combustion
Efciency
Thermal
Efciency
Boiler
Water
Content
Vent/Air
Pipe
Size
Btuh (Note 7) Btuh (Note 7) Btuh (Note 3) % (Note 5) % (Note 6) Gallons
(Note 4)
Ultra-399 399,000 364,000 317,000 91 7 91 3 2 10 4”
Notes
1
As an Energy Star Partner, WM Technologies has determined that Ultra boilers meet the Energy Star guidelines for energy eciency.
NOTE: Adjusting boiler ring rate will aect AFUE rating.
2
Based on standard test procedures prescribed by the United States Department of Energy.
3
Net AHRI ratings are based on net installed radiation of sucient quantity for the requirements of the building and nothing need be
added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15. An additional allowance should be
made for unusual piping and pickup loads.
4
Ultra boilers require special venting, consistent with Category IV boiler.
Use only the vent materials and methods specied 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 eciency is based on AHRI testing procedure BTS-2000, and equal to 100% minus ue loss.
6
ermal eciency is based on AHRI testing procedure BTS-2000.
7
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
modications and automatically derates itself by approximately 4% per 1000 feet above sea level.
THE OUTDOOR SENSOR SUPPLIED WITH THE BOILER MUST BE INSTALLED UNLESS EXEMPTED BELOW:
IMPORTANT
In accordance with Section 303 of the 2007
Energy Act, this boiler is equipped with a
feature that saves energy by reducing the boiler
water temperature as the heating load decreases.
is feature is equipped with an override which
is provided primarily to permit the use of an
external energy management system that serves
the same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING
CONDITIONS IS TRUE:
• An external energy management system is installed that reduces the boiler water temperature
as the heating load decreases.
• is boiler is not used for any space heating.
• is boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/
hr or greater.
• is boiler is equipped with a tankless coil (not applicable to Ultra boilers).
Part number 550-100-440/0723
138
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gas-fired water boiler – boiler manual
Figure 139 Ratings and engineering data Figure 141, page 139 for notes)
Boilers in system
Model Ultra –
Total
CSA
input
DOE
Heating
capacity
Boiler
H.P.
Net
water
ratings
Manifolded
combustion
air duct
size
Foundation size
Side-to-side
arrangement
(height 2” to 4”)
Back-to-back
arrangement
(height 2” to 4”)
Input,
MBH
Output,
MBH
- MBH
Square
inches
Length
(inches)
Length
(inches)
Length
(inches)
Length
(inches)
80 105 155 230
299
399
- Note 1 - Note 2
Figure 59, page 59
Note 3
2 160 142 4 2 123 80
56 23 27 48
2 210 188 5 6 163 105
2 310 278 8 3 242 155
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
85 23 56 48
3 315 282 8 4 245 157
3 465 417 12 5 363 232
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
114 24 56 49
4 420 376 11 2 327 210
4 620 556 16 6 483 310
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
143 24 85 49
5 525 470 14 409 267
5 775 695 20 8 604 387
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
172 24 85 49
6 630 564 16 8 490 315
6 930 834 24 9 725 465
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
201 24 114 49
7 735 658 19 7 572 367
7 1085 973 29 1 846 542
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
230 24 114 49
8 840 752 22 5 654 420
8 1240 1112 33 2 967 620
8 1840 1656 49 5 1440 920
8 2392 2160 64 5 1872 1196
8 3192 2920 87 2 2536 1539
Ratings — Multiple Ultra Series 4 boilers
Part number 550-100-440/0723
139
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MAINTENANCE & SPECIFICATIONS
Ratings — Multiple Ultra Series 4 boilers (continued)
Figure 140 Engineering data (see Figure 141 for notes)
Boiler
Model
Ultra
Shipping
weight
Operating
weight
Water
content
Water ow rate
per boiler
Vent/air pipe
size —
Provide a
separate vent
for each boiler
Electrical
service
required
Pounds
per boiler
Pounds
per boiler
Gallons
per boiler
GPM
@ 20°F rise
GPM
@ 40°F rise
Amps
per boiler
Note 4 Note 5 Note 6
-80
199 139 0.7 7.1 3.6 2” or 3” 15.0
-105
207 145 0.8 9.4 4.7 2” or 3” 15.0
-155
234 181 1.2 13.9 7.0 3” 15.0
-230
246 192 1.6 20.7 10.4 3” or 4” 15.0
-299
297 229 2.1 27.9 14.0 4” 15.0
-399
297 229 2.1 36.5 18.2 4” 15.0
Figure 141 Notes for Figure 139 and Figure 140
1
Based on standard test procedures outlined by DOE for individual boilers.
2
Net AHRI ratings are based on piping and pickup allowance of 1.15.
Consult WM Technologies Technical Services for other allowances.
3
Foundation sizes in Figure139,page138 provide 6 inches between boilers and 2 inches from boiler to edge of foundation.
Smaller foundations are possible with reduced service clearances.
See page58 for details.
• For side-to-side installations, see Figure56,page58.
• For back-to-back installations, see Figure57,page58.
4
Operating weight is the total weight of the boiler, including water.
5
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.
All Ultra installations require a separate vent pipe and termination for each boiler.
Vent piping cannot be manifolded. Install and
terminate vents as described in vent/air installation instructions in this manual.
Combustion air piping can be individually piped or manifolded. See Figure59,page59, for manifolded air piping.
6
Total amp requirement includes up to three circulators, not exceeding 2.2 amps per circulator.
series
4
gas-fired water boiler – boiler manual
WM Technologies, LLC
500 Blaine Street
Michigan City, IN 46360-2388
weil-mclain.com
Installation and Service Certicate
START-UP DATA
Boiler Model CO
2
High re % CO
2
Low re %
Fuel Natural ____ LP ____ CO High re ppm CO Low re ppm
Was orice changed? ______________________________________ Was gas valve throttle adjusted (Ultra-399) for propane? __________________
Natural gas input rate measured _________________________ Btuh
U-CONTROL SET-UP DATA
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
PRIORITY 1 Settings PRIORITY 2 Settings PRIORITY 3 Settings
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
Circulator Exercising Freeze Protection Circulators
Circulator 1 on _______ off _______ Circulator 1 on _______ off _______
Circulator 2 on _______ off _______ Circulator 2 on _______ off _______
Circulator 3 on _______ off _______ Circulator 3 on _______ off _______
Boiler Model Series CP Number Date Installed
BTU Input Installation instructions have been followed.
Check-out sequence has been performed.
Above information is certied to be correct.
Information received and le with owner/maintenance person.
Installer
(Company) (Address) (Phone) (Installer's Signature)
