Ultra Boiler Manual

Contents
(see page 44 and page 46 for details of all models)
e following dened 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.

Part number 550-100-440/0122
2
Ultra at-a-glance
  
Hazard denitions & 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 verication. . . . . . . . . . . . . . . . . . . . . . . . . . 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 Certicate . . . . . . . . . . . . . . . . . . . . . . 140