Weil-McLain Ultra 80 User manual

Condensing High
Efficiency Gas Boiler
Ratings - (5 sizes)
80 MBH
105 MBH
155 MBH
230 MBH
310 MBH
All with 20-100%
Modulation
Innovative
Innovative combination of appearance, intelligence
and technology.
High Efficiency
Over 92% AFUE and up to 98% for low temperature
applications.
Attractive
The Ultra boiler features a new attractive design for
installation in any setting.
Intelligent
Features PhD Technology - an intelligent system
that delivers Precision Hydronic heating and
hot water needs while maximizing efciency by
measuring and responding to the Data parameters
of your heating system.
High Technology
Cast mono block aluminum heat exchanger. Gas
valve, blower and venturi technology that constantly
maintains optimal air and fuel ratio at all ring
rates.
Condensing High Efficiency
Gas Boiler
20-100% Modulation
SERIES 2
STANDARD EQUIPMENT
Factory Tested
Limited 15 Year Heat Exchange Warranty
Homeowner Protection Plan with
•5 years Parts and Labor
Cast Aluminum Block
30 PSI ASME Relief Valve
Drain Valve
Stainless Steel Burner (80, 105 & 310)
with woven steel ber mesh
(155 & 230)
Direct Spark Ignition
Variable Speed Blower Assembly
Gas/Air Ratio Venturi with Air Silencer
Negative Pressure Regulation Gas Valve
50 VA Transformer
Combination T&P Gauge
Outlet Water Temperature Sensor
Return Water Temperature Sensor
Flue Gas Temperature Sensor
Outdoor Temperature Sensor
12 AMP 110 V Circ. Relay (310 only)
Control Module with
•Digital Display & Data Port
•Ignition Control
•High Limit & Modulating Temp Control
•Low Water Protection
•Outdoor Reset
•DHW Priority
•Two Pump Controls
(Heating & DHW)
Taco Boiler Circulators:
•1” anges (80 & 105) Taco 007
•1” & 1-1/4” anges (155, 230 & 310)
Taco 0011
Complete Jacket Assembly with
Fully Removable Front Jacket Cover
Adjustable Boiler Legs
Sidewall Vent/Air Termination Kit
Line & Low Voltage
Pre-wired Terminal Strips
On/Off Power Switch
Line Voltage Service Receptacle
Condensate Trap
with Drain Tee Assembly
Propane Conversion Orice
(All except Model 80)
boilers are low NOx Certied by the
South Coast Air Quality Management District
(Rule 1146.2) in California.
1 Supply Connection
2 Return Connection
3 Low Voltage Wire Opening
4 Electrical Entrance Openings
5 Vent Connection
6 Air Connection
7 Gas Connection
80 105 155 230 310
Part No. Part No. Part No. Part No. Part No.
PACKAGED BOILER -Natural Gas eld convertible to LP as standard equip. except 80
Natural Gas 383-500-400 383-500-402 383-500-403 383-500-404 383-500-405
Propane Gas 383-500-401 NA
Taco Pump 007 0011
OPTIONAL EQUIPMENT
Wall Mounting Kit 389-900-180 NA
Alarm Control Kit 383-500-080
Indirect-Fired Water Heaters Matching Ultra PLUS 40, 60 and 80 Water Heaters Available
RATINGS
CSA Input (Maximum) 80 MBH 105 MBH 155 MBH 230 MBH 310 MBH
CSA Input (Minimum) 16 MBH 21 MBH 31 MBH 46 MBH 62 MBH
DOE Heating Cap. 71 MBH 94 MBH 139 MBH 207 MBH *289 MBH
Net I=B=R 62 MBH 81 MBH 123 MBH 183 MBH 252 MBH
DOE AFUE 93.0% 92.0% 93.0% 92.8% *93.3%
Weil-McLain Low Temp 98.1% 98.0% 95.6%
Seasonal Efciency Boiler return water temp=90°F and boiler outlet water temp=110°F
*Note: 310 ratings are gross output and combustion efciency.
DATA
Vent Size / Material 3” PVC/ABS 3 or 4 in.
PVC/ABS
4 in.
PVC/ABS
Combustion Air Size 3 in. 3 or 4 in. 4 in.
Water Volume .95 Gal. 1.07 Gal. 1.17 Gal. 1.57 Gal. 2.1 Gal.
Approx. Ship. Weight 149 lbs. 154 lbs. 193 lbs. 204 lbs. 254 lbs.
DIMENSIONS
Supply Tapping 1” 1-1/4”
Return Tapping 1” 1-1/4”
Gas Connection Size 1/2” 3/4”
Crate Dimensions 53-1/2”L x 27”W x 23-1/2”H 56”Lx27”Wx27”H
©2004 Weil-McLain Weil-McLain Ultra Boiler Patents Pending Form No. C-995R4(0504)
Locate our Sales Ofces by visiting our website:
www.weil-mclain.com
Weil-McLain
500 Blaine Street
Michigan City, IN 46360-2388
In the interest of continual improvements in product and performance, Weil-McLain reserves the right to change specications without notice.

PhD Technology - Precision Hydronic Data
An intelligent system that delivers Precision Hydronic heating and hot water
needs while maximizing efciency by measuring and responding to the Data
parameters of your heating system.
PhD Technology is built around proven key components that when combined
make the Ultra the most advanced, reliable and efcient boiler available.
The key components
include...
A negative regulated gas valve that
Precisely delivers gas to the boiler;
A variable speed motor that matches
combustion output to your heating needs;
A venturi mixing body that Precisely mixes
air and gas providing higher efciency;
System intelligence with the Ultra Control
Module which maintains proper, efcient
and Precise Hydronic heat through inputs
of all system Data;
A cast aluminum mono block heat
exchanger designed to operate in low
temperature condensing applications;
Pre-mix stainless steel burner designed
for perfect ring rate modulation,
efciency, clean combustion and quiet
operation.
For fast and easy installation, combine an Ultra PLUS
Indirect-Fired Water Heater with your Ultra boiler installation.
Ultra PLUS water heaters come in three sizes:
PLUS 40
PLUS 60
PLUS 80
Combined with an Ultra boiler, the Ultra PLUS water heater
provides more domestic hot water when you need it, while
taking advantage of the extremely high efciency of the Ultra
boiler. A standard feature of the Ultra boiler control module
is domestic hot water priority control, providing quicker
response time for domestic hot water demands, along with
faster recovery times for the hot water tank.
The perfect match for an Ultra boiler is an Ultra PLUS Indirect-
Fired Water Heater.
High Efciency And Environmentally Friendly
All Ultra boilers feature AFUE efciencies in the range of
92.0 - 93.0%. These are some of the highest efciencies in
the industry, however, Ultra boilers, when used in common
low temperature applications have annual efciencies of
98.0%. The Ultra boiler exceeds all of the requirements of
the Department of Energy’s ENERGY STAR program.
Besides being Ultra High Efcient, the Ultra boiler is
environmentally friendly. Through PhD Technology and the
use of our high grade burner, the Ultra boiler produces less
NOx while exceeding all current environmental codes and
is certied by South Coast Air Quality Management District
(Rule 1146.2) in California.
Weil-McLain Boiler
The Weil-McLain Ultra boiler has been designed for easy
installation. The Ultra boiler requires minimal clearance
and minimal oor space, and the same boiler can be
used in oor standing or wall hung applications.
Water and gas piping is conveniently arranged for connection
at the top or bottom of the boiler. In fact, when using the
boiler in a oor standing application, all boiler connections are
on the top of the boiler except for the condensate drain.
The electrical components have been pre-wired and labeled
on separate line voltage and low voltage terminal strips.
Terminal strips are provided for quick and easy eld wiring.
Venting has been simplied by using PVC for both exhaust
and combustion air. Slide the PVC into the top outlet ue
pipe adaptors and tighten the restraining ring. No messy
sealants required. You can even achieve vent runs up to the
equivalent of 100 feet.
The Ultra comes with a side mounted service receptacle on
a separate circuit for use with a condensate pump, service
equipment or service light.
The Ultra boiler is lightweight compared to a conventional
boiler. Side jacket handles are provided for easy handling
along with four adjustable boiler feet for easy placement and
leveling.
The 4-digit electronic display with
programming buttons and data port make
entering and receiving information very
easy. There are two levels of information:
User Level and Contractor Level. The User
Level is used to: Turn space and DHW
heating “on” or “off”; set space heating
temperature and boiler circulator operation;
display soft and hard lockout codes for easy
troubleshooting. The Contractor Level is
accessible through the use of a special
code that is entered through the front panel
or with a computer interface control kit and a
laptop computer. This access can be used
to customize the Ultra boiler to each specic
job application. Adjustments can be made
for high altitude, outdoor reset, boost timing
and much more...
The cast aluminum heat exchanger features
a mono block design. This low mass heat
exchanger heats faster, providing heat to the
system quicker. This aluminum block has
been specically designed to work in low
return temperature applications in condensing
mode.
The blower, gas valve and venturi all work
in concert to provide the proper fuel and air
mixture for precise combustion. The blower
pulls in air and gas through the venturi. The
air and gas mix inside the blower and are
pushed into the burner for combustion. The
gas valve senses suction from the blower,
allowing gas to ow only if combustion air is
owing and proper combustion is achieved.
The Ultra Control Module, a microprocessor
electronic control, responds to signals
from the room thermostat, supply water
temperature sensor, return water temperature
sensor, ue temperature sensor, domestic hot
water aquastat, summer/winter switch and
outdoor temperature sensor. The module
automatically adjusts blower speed and gas
ow rate to modulate boiler ring rate to closely
match boiler output for space heating or DHW
heating demand.
High grade stainless steel burner with woven
steel ber mesh. Burner uses pre-mixed
air and gas providing for a 20% to 100%
modulating ring rate. The Ultra burner
features long life, quiet operation, high
efciency and cleaner combustion for low
NOx applications.

PhD Technology - Precision Hydronic Data
An intelligent system that delivers Precision Hydronic heating and hot water
needs while maximizing efciency by measuring and responding to the Data
parameters of your heating system.
PhD Technology is built around proven key components that when combined
make the Ultra the most advanced, reliable and efcient boiler available.
The key components
include...
A negative regulated gas valve that
Precisely delivers gas to the boiler;
A variable speed motor that matches
combustion output to your heating needs;
A venturi mixing body that Precisely mixes
air and gas providing higher efciency;
System intelligence with the Ultra Control
Module which maintains proper, efcient
and Precise Hydronic heat through inputs
of all system Data;
A cast aluminum mono block heat
exchanger designed to operate in low
temperature condensing applications;
Pre-mix stainless steel burner designed
for perfect ring rate modulation,
efciency, clean combustion and quiet
operation.
For fast and easy installation, combine an Ultra PLUS
Indirect-Fired Water Heater with your Ultra boiler installation.
Ultra PLUS water heaters come in three sizes:
PLUS 40
PLUS 60
PLUS 80
Combined with an Ultra boiler, the Ultra PLUS water heater
provides more domestic hot water when you need it, while
taking advantage of the extremely high efciency of the Ultra
boiler. A standard feature of the Ultra boiler control module
is domestic hot water priority control, providing quicker
response time for domestic hot water demands, along with
faster recovery times for the hot water tank.
The perfect match for an Ultra boiler is an Ultra PLUS Indirect-
Fired Water Heater.
High Efciency And Environmentally Friendly
All Ultra boilers feature AFUE efciencies in the range of
92.0 - 93.0%. These are some of the highest efciencies in
the industry, however, Ultra boilers, when used in common
low temperature applications have annual efciencies of
98.0%. The Ultra boiler exceeds all of the requirements of
the Department of Energy’s ENERGY STAR program.
Besides being Ultra High Efcient, the Ultra boiler is
environmentally friendly. Through PhD Technology and the
use of our high grade burner, the Ultra boiler produces less
NOx while exceeding all current environmental codes and
is certied by South Coast Air Quality Management District
(Rule 1146.2) in California.
Weil-McLain Boiler
The Weil-McLain Ultra boiler has been designed for easy
installation. The Ultra boiler requires minimal clearance
and minimal oor space, and the same boiler can be
used in oor standing or wall hung applications.
Water and gas piping is conveniently arranged for connection
at the top or bottom of the boiler. In fact, when using the
boiler in a oor standing application, all boiler connections are
on the top of the boiler except for the condensate drain.
The electrical components have been pre-wired and labeled
on separate line voltage and low voltage terminal strips.
Terminal strips are provided for quick and easy eld wiring.
Venting has been simplied by using PVC for both exhaust
and combustion air. Slide the PVC into the top outlet ue
pipe adaptors and tighten the restraining ring. No messy
sealants required. You can even achieve vent runs up to the
equivalent of 100 feet.
The Ultra comes with a side mounted service receptacle on
a separate circuit for use with a condensate pump, service
equipment or service light.
The Ultra boiler is lightweight compared to a conventional
boiler. Side jacket handles are provided for easy handling
along with four adjustable boiler feet for easy placement and
leveling.
The 4-digit electronic display with
programming buttons and data port make
entering and receiving information very
easy. There are two levels of information:
User Level and Contractor Level. The User
Level is used to: Turn space and DHW
heating “on” or “off”; set space heating
temperature and boiler circulator operation;
display soft and hard lockout codes for easy
troubleshooting. The Contractor Level is
accessible through the use of a special
code that is entered through the front panel
or with a computer interface control kit and a
laptop computer. This access can be used
to customize the Ultra boiler to each specic
job application. Adjustments can be made
for high altitude, outdoor reset, boost timing
and much more...
The cast aluminum heat exchanger features
a mono block design. This low mass heat
exchanger heats faster, providing heat to the
system quicker. This aluminum block has
been specically designed to work in low
return temperature applications in condensing
mode.
The blower, gas valve and venturi all work
in concert to provide the proper fuel and air
mixture for precise combustion. The blower
pulls in air and gas through the venturi. The
air and gas mix inside the blower and are
pushed into the burner for combustion. The
gas valve senses suction from the blower,
allowing gas to ow only if combustion air is
owing and proper combustion is achieved.
The Ultra Control Module, a microprocessor
electronic control, responds to signals
from the room thermostat, supply water
temperature sensor, return water temperature
sensor, ue temperature sensor, domestic hot
water aquastat, summer/winter switch and
outdoor temperature sensor. The module
automatically adjusts blower speed and gas
ow rate to modulate boiler ring rate to closely
match boiler output for space heating or DHW
heating demand.
High grade stainless steel burner with woven
steel ber mesh. Burner uses pre-mixed
air and gas providing for a 20% to 100%
modulating ring rate. The Ultra burner
features long life, quiet operation, high
efciency and cleaner combustion for low
NOx applications.

Condensing High
Efficiency Gas Boiler
Ratings - (5 sizes)
80 MBH
105 MBH
155 MBH
230 MBH
310 MBH
All with 20-100%
Modulation
Innovative
Innovative combination of appearance, intelligence
and technology.
High Efficiency
Over 92% AFUE and up to 98% for low temperature
applications.
Attractive
The Ultra boiler features a new attractive design for
installation in any setting.
Intelligent
Features PhD Technology - an intelligent system
that delivers Precision Hydronic heating and
hot water needs while maximizing efciency by
measuring and responding to the Data parameters
of your heating system.
High Technology
Cast mono block aluminum heat exchanger. Gas
valve, blower and venturi technology that constantly
maintains optimal air and fuel ratio at all ring
rates.
Condensing High Efficiency
Gas Boiler
20-100% Modulation
SERIES 2
STANDARD EQUIPMENT
Factory Tested
Limited 15 Year Heat Exchange Warranty
Homeowner Protection Plan with
•5 years Parts and Labor
Cast Aluminum Block
30 PSI ASME Relief Valve
Drain Valve
Stainless Steel Burner (80, 105 & 310)
with woven steel ber mesh
(155 & 230)
Direct Spark Ignition
Variable Speed Blower Assembly
Gas/Air Ratio Venturi with Air Silencer
Negative Pressure Regulation Gas Valve
50 VA Transformer
Combination T&P Gauge
Outlet Water Temperature Sensor
Return Water Temperature Sensor
Flue Gas Temperature Sensor
Outdoor Temperature Sensor
12 AMP 110 V Circ. Relay (310 only)
Control Module with
•Digital Display & Data Port
•Ignition Control
•High Limit & Modulating Temp Control
•Low Water Protection
•Outdoor Reset
•DHW Priority
•Two Pump Controls
(Heating & DHW)
Taco Boiler Circulators:
•1” anges (80 & 105) Taco 007
•1” & 1-1/4” anges (155, 230 & 310)
Taco 0011
Complete Jacket Assembly with
Fully Removable Front Jacket Cover
Adjustable Boiler Legs
Sidewall Vent/Air Termination Kit
Line & Low Voltage
Pre-wired Terminal Strips
On/Off Power Switch
Line Voltage Service Receptacle
Condensate Trap
with Drain Tee Assembly
Propane Conversion Orice
(All except Model 80)
boilers are low NOx Certied by the
South Coast Air Quality Management District
(Rule 1146.2) in California.
1 Supply Connection
2 Return Connection
3 Low Voltage Wire Opening
4 Electrical Entrance Openings
5 Vent Connection
6 Air Connection
7 Gas Connection
80 105 155 230 310
Part No. Part No. Part No. Part No. Part No.
PACKAGED BOILER -Natural Gas eld convertible to LP as standard equip. except 80
Natural Gas 383-500-400 383-500-402 383-500-403 383-500-404 383-500-405
Propane Gas 383-500-401 NA
Taco Pump 007 0011
OPTIONAL EQUIPMENT
Wall Mounting Kit 389-900-180 NA
Alarm Control Kit 383-500-080
Indirect-Fired Water Heaters Matching Ultra PLUS 40, 60 and 80 Water Heaters Available
RATINGS
CSA Input (Maximum) 80 MBH 105 MBH 155 MBH 230 MBH 310 MBH
CSA Input (Minimum) 16 MBH 21 MBH 31 MBH 46 MBH 62 MBH
DOE Heating Cap. 71 MBH 94 MBH 139 MBH 207 MBH *289 MBH
Net I=B=R 62 MBH 81 MBH 123 MBH 183 MBH 252 MBH
DOE AFUE 93.0% 92.0% 93.0% 92.8% *93.3%
Weil-McLain Low Temp 98.1% 98.0% 95.6%
Seasonal Efciency Boiler return water temp=90°F and boiler outlet water temp=110°F
*Note: 310 ratings are gross output and combustion efciency.
DATA
Vent Size / Material 3” PVC/ABS 3 or 4 in.
PVC/ABS
4 in.
PVC/ABS
Combustion Air Size 3 in. 3 or 4 in. 4 in.
Water Volume .95 Gal. 1.07 Gal. 1.17 Gal. 1.57 Gal. 2.1 Gal.
Approx. Ship. Weight 149 lbs. 154 lbs. 193 lbs. 204 lbs. 254 lbs.
DIMENSIONS
Supply Tapping 1” 1-1/4”
Return Tapping 1” 1-1/4”
Gas Connection Size 1/2” 3/4”
Crate Dimensions 53-1/2”L x 27”W x 23-1/2”H 56”Lx27”Wx27”H
©2004 Weil-McLain Weil-McLain Ultra Boiler Patents Pending Form No. C-995R4(0504)
Locate our Sales Ofces by visiting our website:
www.weil-mclain.com
Weil-McLain
500 Blaine Street
Michigan City, IN 46360-2388
In the interest of continual improvements in product and performance, Weil-McLain reserves the right to change specications without notice.