Specifications

Contents Ultra at-a-glance
(see page 40 and page 42 for details of all models)
The following defined 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 definitions
Part number 550-100-090/0809
g a s -f i r e d w a t e r b o i l e r
2
Hazard definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Ultra at-a-glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Please read before proceeding . . . . . . . . . . . . . . . . . . . . . . 4
Prepare boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Prepare boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install water piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install water piping — typical systems . . . . . . . . . . . . . . . . . .12
Using with Weil-McLain PLUS water heaters . . . . . . . . . . . . . . . 14
Venting/air piping — general . . . . . . . . . . . . . . . . . . . . . . . 16
Sidewall vent/air termination: Weil-McLain cap. . . . . . . . . . . . . . 18
Install vent/air piping — boiler to W-M termination . . . . . . . . . . . . 22
Install condensate line . . . . . . . . . . . . . . . . . . . . . . . . . .23
Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Field wiring — basic system . . . . . . . . . . . . . . . . . . . . . . .26
U-Control operation and setup . . . . . . . . . . . . . . . . . . . . . . 28
Startup — fill the system . . . . . . . . . . . . . . . . . . . . . . . . . 31
Startup — final checks . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Check-out/startup verification. . . . . . . . . . . . . . . . . . . . . . . 38
The
Gas-fired water boiler, Featuring Flexibility . . . . . 40
Prepare boiler — convert for propane . . . . . . . . . . . . . . . . . .44
Placing boiler — wall-mounting option . . . . . . . . . . . . . . . . . . 46
Install water piping — advanced . . . . . . . . . . . . . . . . . . . . .48
Sizing direct-connected DHW piping . . . . . . . . . . . . . . . . . . . 52
Multiple boiler installations . . . . . . . . . . . . . . . . . . . . . . . .54
Prepare boiler location — multiple boilers . . . . . . . . . . . . . . . .55
Multiple boiler water piping . . . . . . . . . . . . . . . . . . . . . . . . 56
Venting/air piping — Massachusetts installations. . . . . . . . . . . . . 61
Vent/air piping — options . . . . . . . . . . . . . . . . . . . . . . . . . 62
Sidewall vent/air termination: 3” PVC concentric . . . . . . . . . . . . . 63
Sidewall vent/air termination: Separate pipes . . . . . . . . . . . . . .66
Vertical vent/air termination: 3” PVC concentric . . . . . . . . . . . . . 69
Vertical vent/air termination: Separate pipes . . . . . . . . . . . . . . . 73
Install vent/air piping — boiler to termination . . . . . . . . . . . . . . . 75
Gas piping — sizing gas lines . . . . . . . . . . . . . . . . . . . . . .77
Field wiring — advanced . . . . . . . . . . . . . . . . . . . . . . . . . 78
U-Control operation and setup — advanced . . . . . . . . . . . . . . . 83
Annual startup and general maintenance. . . . . . . . . . . . . . . . . 92
Annual startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Ratings — Ultra boilers . . . . . . . . . . . . . . . . . . . . . . . . . 121
Ratings — multiple Ultra boilers . . . . . . . . . . . . . . . . . . . . 122
Installation and Service Certificate . . . . . . . . . . . . . . . . . . . 124