Series 3
Thisguidemustonlybeusedbyaqualifiedheatinginstaller/servicetechnician.Readallinstructions,includingthisUltraboilermanualandallotherinformationshippedwiththeboiler,beforeinstalling.Performstepsintheordergiven.Failuretocomplycouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.
Gas-fired water boilers – Series 3
Featuring
Flexibility
Partnumber550-100-110/0411
®
Quick-Reference GuideFor Piping, Wiring & U-Control Setups
Thisguideismeanttobeusedasageneralguideline
forpipingandcontrollingUltraSeries3boilersin
avarietyofapplications.Someinstallationscan
bepipedinnumerousotherwaysthatwillwork
equallyaswellasthesuggestionshere.
Alwaysfollowrecognizedpipingandcontrolprac-
ticesandallapplicablecodes.Provideandinstall
allrequiredcontrolsontheboilerandsystem.
SeetheContentslistingandtheApplicationfinder
toselectthesystemclosesttoyourneeds.
Refer to the Ultra Boiler manual for details on
expansiontankpiping,reliefvalvepipingandpipe
sizing.
Thisguideprovidesapplicationinformationonly.
ItmustbeusedonlyasasupplementtotheUltra
Boilermanualandapplicablecoderequirements.
FollowallinstructionsintheUltraBoilermanual
forinstallationandstart-up.
Hazard definitions
Thefollowingdefinedtermsareusedthroughoutthismanualto
bringattentiontothepresenceofhazardsofvariousrisklevelsor
toimportantinformationconcerningthelifeoftheproduct.
Indicatespresenceofhazardsthatwillcause
severepersonalinjury,deathorsubstantial
propertydamage.
Indicatespresenceofhazardsthatcancause
severepersonalinjury,deathorsubstantial
propertydamage.
Indicatespresenceofhazardsthatwillor
cancauseminorpersonalinjuryorproperty
damage.
Indicatesspecialinstructionsoninstallation,
operationormaintenancethatareimportant
butnotrelatedtopersonalinjuryorproperty
damage.
Partnumber550-100-090/08092
Read before proceeding
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
2
Contents
General piping requirements . . . . . . . . . . . . . . . 4The Ultra boiler must ALWAYS be piped in a secondary loop off of the primary loop
Weil-McLain Easy-Up® Manifold . . . . . . . . . . . . . 5Factory-built manifolds including near-boiler piping and system sec-ondary connection
U-Control Screens . . . . . . . . . . . . . . . . . . . . . 6
U-Control menu access . . . . . . . . . . . . . . . . . . 7BOILER SETTINGS | SYSTEM SETTINGS
Application 1 . . . . . . . . . . . . . . . . . . . . . . . . 8Single-zone BASEBOARD | DHW (Direct-connected)
Application 2 . . . . . . . . . . . . . . . . . . . . . . . .10Single-zone FAN COIL(S) | DHW (Direct-connected)
Application 3 . . . . . . . . . . . . . . . . . . . . . . . .12Single-zone CAST IRON RADIATORS | DHW (Direct-connected)
Application 4 . . . . . . . . . . . . . . . . . . . . . . . .14Multi-zone SPACE HEATING (Circulators + WMCR) | DHW (As zone in system)
Application 5 . . . . . . . . . . . . . . . . . . . . . . . .16Multi-zone RADIANT | DHW (Direct-connected) | HEAT EXCHANGER (WMBP or WMPH) (<30% of total heat loss)
Application 6 . . . . . . . . . . . . . . . . . . . . . . . .18Multi-zone RADIANT | DHW (Direct-connected) | Small BASEBOARD zone (<30% of total heat loss)
Application 7 . . . . . . . . . . . . . . . . . . . . . . . .20Multiple HI-TEMP HEATING zones | DHW (Direct-connected) | Small RADIANT zone (<30 of total heat loss)
Application 7a . . . . . . . . . . . . . . . . . . . . . . .22Multi-zone HI-TEMP HEATING plus RADIANT (with mixing valve) | DHW (Direct-connected) (No limits on the relative heating loads of radiant or hi-temp space heating circuits)
Application 8 . . . . . . . . . . . . . . . . . . . . . . . .24Multi-zone BASEBOARD (Zone valves + WMZV controller) | DHW (Direct-connected)
Application 9 . . . . . . . . . . . . . . . . . . . . . . . .26Multi-zone BASEBOARD (Circulators + WMCR controller) | DHW (Direct-connected)
Application 10 . . . . . . . . . . . . . . . . . . . . . . .28Multi-zone FAN COILS (Circs. + WMCR contr.) | DHW (Direct-con-nected) | Small RADIANT zone (<30% of total heat loss)
Application 11 . . . . . . . . . . . . . . . . . . . . . . .30CAST IRON RADIATORS | DHW (Direct-connected) | Small RADIANT zone (<30% of total heat loss)
Application 12 . . . . . . . . . . . . . . . . . . . . . . .32FAN COIL zone | BASEBOARD zone | Small RADIANT zone (<30% of total heat loss)
Application 13 . . . . . . . . . . . . . . . . . . . . . . .34
Single-zone BASEBOARD | DHW (System, as zone)
Application 14 . . . . . . . . . . . . . . . . . . . . . . .36
Multi-zone BASEBOARD (Zone valves) | Multi-zone RADIANT (Zone valves) | DHW (Direct-connected) (Radiant load must be <30% of total heat loss)
Application 15 . . . . . . . . . . . . . . . . . . . . . . .38
Single-zone BASEBOARD | Single-zone RADIANT | POOL Heat exchanger (Radiant load must be <30% of total heat loss)
Application 16 . . . . . . . . . . . . . . . . . . . . . . .40
Single or Multi-zone SPACE HEATING | DHW (Direct-connected) | ISOLATION Heat exchanger (Tall buildings) (Use where space heating system operating pressure is over 25 PSIG)
Multiple boiler operation options . . . . . . . . . . . . .42
Using the U-Control settings
Application 17 — Multiple heat sources . . . . . . . . .44
ALTERNATIVE Heat source as primary / ULTRA as back-up | Single-zone BASEBOARD or FAN COIL — DHW (Direct-connected)
Application 17a — Multiple heat sources . . . . . . . .46
NON-HYDRONIC PRIMARY Heat source as Type 1 (LEAD) / ULTRA as Type 2 (BACKUP) — Single-zone or multi-zone BASEBOARD or FAN COIL | DHW (Direct-connected)
Application 18 — Multiple boilers . . . . . . . . . . . .48
Multiple Ultra boilers | Multiple-zone SPACE HEATING (Circulators with WMCR) | DHW (Direct-connected)
Application 19 — Multiple boilers . . . . . . . . . . . .52
Multiple Ultra boilers | Multi-zone SPACE HEATING & DHW (In system) (Circulators with WMCR controllers)
Application 20 — Multiple boilers . . . . . . . . . . . .56
Multiple Ultra boilers | Multiple loads on SECONDARY loops | DHW (Direct-connected)
Application 21 — Multiple boilers . . . . . . . . . . . .60
BASE LOADING with ULTRA boilers | DHW (Direct connected)
Appendix A . . . . . . . . . . . . . . . . . . . . . . . . .64
OUTDOOR RESET Settings and Troubleshooting
Appendix B . . . . . . . . . . . . . . . . . . . . . . . . .65
BOILER SETTINGS menu detail
Appendix C . . . . . . . . . . . . . . . . . . . . . . . . .66
SYSTEM SETTINGS menu detail
Partnumber550-100-110/0411 3
gas-fired water boiler — Application Guides
General piping requirementsThe Ultra boiler must ALWAYS be piped in a secondary loop off of the primary loop
INSTALLING THE PRIMARY/SECONDARY TEES
Thenear-boilerpipingmustbeprimary/second-aryasshownaboveandleft,withtheboilerlooppipingentering the tees in thebranchconnec-tion.
DONOTconnectboilerpipingtotheteethroughconnectionsasshownatright.Thesystemwillnotworkcorrectlythisway.
Thecirculatorsuppliedwiththeboiler(a)mustbeusedonly
intheboilersecondaryloopasshownintheschematicabove
andinthemanual.System(b)andzonecirculatorsandDHW
circulator(c)mustbesuppliedbytheinstaller.Aboverightis
atypicalinstallation,showingthenear-boilerpipingandcon-
nectiontothesystem.
Boilerlooppipingmustbesizedtotheminimumslistedintheboilermanual.Usingsmallerpipingwillcauseperformanceproblems.
• Ultra-80/Ultra-105. . . . . . . . . . .use1”orlarger
• Ultra-155/Ultra-230. . . . . . . . . . .use1¼”orlarger
• Ultra-299/Ultra-399. . . . . . . . . . .use1½”orlarger
WRONGRIGHT
DHW
DHW
System
Sensor
Sensor
Gas
System
Typical piping, using zone-valve zoning
Do not exceed 12 inches apart
Do not exceed 12 inches apart
b
a
c
a
b
c
Optional
Easy-Up Manifolds:
(Seenextpagefordetails)
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
4
Easy-Up Manifold
Ultra-80, -105 . . . . . . . . 1¼” Part number 383-500-649
Ultra-155, -230, -299, -399 . . 1½” Part number 383-500-661
Weil-McLain Easy-Up® ManifoldFactory-built manifolds including near-boiler piping and system secondary connection
Primary (system) RETURN
Connect to DHW RETURN
(if used)
Install LOW WATER CUT-OFF (if used)
Connect to DHW SUPPLY (if used)
Primary (system) SUPPLY
FLANGES for boiler circulator
(factory-supplied)
SHUT-OFF VALVES
CHECK VALVE
Connect to BOILER RETURN
Bushings supplied with Easy-Up Manifold for
Ultra-299 and Ultra-399
2” x 1½” reducers supplied with Easy-Up Manifold for
Ultra-299 and Ultra-399
Connect to BOILER SUPPLY
Connect to RELIEF VALVE
FollowallinstructionsintheEasy-UpManifoldInstructionssuppliedwiththekit.Failuretofollowinstructionscouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.
Toensurepropersystemoperation,installsystem headerssizedtotheguidelinesatright:
Ultra-80 . . . . . . . . . .1” or largerUltra-105, -155 . . . . . .1¼” or largerUltra-230 . . . . . . . . .1½” or largerUltra-299, -399 . . . . . .2” or larger
Partnumber550-100-110/0411 5
gas-fired water boiler — Application Guides
U-Control Screens
See individual application instructions for required and optional control settings using the BOILER SETTINGS and SYSTEMSETTINGSmenus.SeeAppendicesforadditionalmenudetails.
ALERT screen
BLUE screen
DHW mode screen
Screen is gray during STANDBY . Blue screen occurs during HEATING mode or when any button is pressed during standby .
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
6
U-Control menu accessBOILER SETTINGS | SYSTEM SETTINGS
See individual application instructions for required and optional control settings using the BOILER SETTINGS and SYSTEMSETTINGSmenus.SeeAppendicesforadditionalmenudetails.
Partnumber550-100-110/0411 7
gas-fired water boiler — Application Guides
Purpose• Spaceheatingwithfinnedtubeorcastironbaseboard,plusDHW
suppliedbyasingleboiler.• DHWpriority—spaceheatingisdisabledduringcallforheat
fromwaterheater.
U-Control settings• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.This
informs thecontrol that theDHWtank isdirectlyconnectedtotheboiler.
Circulators and piping• Piping must be primary/secondary as shown, with the boiler
piped in a secondary loop and the DHW piped to the boilerloop.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
BASEBOARD system• Sizeforrequiredflow.• Systemcirculatorsuppliedbyinstaller.• Singlezoneonly(seeotherapplicationsinthisguideforzon-
ing)• Pipingcanbeone-pipeortwo-pipe(providebalancingvalves
ifneeded).• U-Control is set for DHW priority — space heating will be
discontinuedduringacallforDHW.
BOILER• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• Thisapplicationappliesonlytosingle-zonespaceheating—see
otherapplicationsinthisguideformultiple-zonesystems.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
Application 1Single-zone BASEBOARD | DHW (Direct-connected)
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW DIRECT
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Baseboard (Finned tube or cast iron)
SYSTEM TYPE Select from list FTB or CIB
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
8
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 SYSTEMcirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Housethermostat*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwill
besetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 9
gas-fired water boiler — Application Guides
Application 2Single-zone FAN COIL(S) | DHW (Direct-connected)
Purpose• Spaceheatingwithfancoil(s)andDHWsuppliedbyasingle
boiler.• DHWpriority—spaceheatingisdisabledduringcallforheat
fromwaterheater.
U-Control settings• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.This
informs thecontrol that theDHWtank isdirectlyconnectedtotheboiler.
Circulators and piping• Piping must be primary/secondary as shown, with the boiler
piped in a secondary loop and the DHW piped to the boilerloop.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
FAN COIL system• Sizeforrequiredflow.• Systemcirculatorsuppliedbyinstaller.• Singlezoneonly(seeotherapplicationsinthisguideforzon-
ing)• Pipingcanbeone-pipeortwo-pipe(providebalancingvalves
ifneeded).• U-Control is set for DHW priority — space heating will be
discontinuedduringacallforDHW.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• Thisapplicationappliesonlytosingle-zonespaceheating—see
otherapplicationsinthisguideformultiple-zonesystems.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW DIRECT
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Fan coils
SYSTEM TYPE Select from list FCL
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
10
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 SYSTEMcirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Housethermostat*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwill
besetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 11
gas-fired water boiler — Application Guides
Application 3Single-zone CAST IRON RADIATORS | DHW (Direct-connected)
Purpose• SpaceheatingwithcastironradiatorsandDHWsuppliedbya
singleboiler.• DHWpriority—spaceheatingisdisabledduringcallforheat
fromwaterheater.
U-Control settings• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.This
informs thecontrol that theDHWtank isdirectlyconnectedtotheboiler.
Circulators and piping• Piping must be primary/secondary as shown, with the boiler
piped in a secondary loop and the DHW piped to the boilerloop.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
RADIATOR system• Sizeforrequiredflow.• Systemcirculatorsuppliedbyinstaller.• Singlezoneonly(seeotherapplicationsinthisguideforzon-
ing)• Pipingcanbeone-pipeortwo-pipe(providebalancingvalves
ifneeded).• U-Control is set for DHW priority — space heating will be
discontinuedduringacallforDHW.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• Thisapplicationappliesonlytosingle-zonespaceheating—see
otherapplicationsinthisguideformultiple-zonesystems.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW DIRECT
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Radiators
SYSTEM TYPE Select from list CIR
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
12
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 SYSTEMcirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Housethermostat*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwill
besetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 13
gas-fired water boiler — Application Guides
Purpose• Spaceheatingwithmultiplezones.Thissystemisapplicableto
anyterminalunittype,includingradiant.• Zoningwithcirculators.• DHWpipedasaseparatezone.• DHWpriority—spaceheatingisdisabledduringcallforheat
fromwaterheater.
U-Control settings• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWSYSTEMfortheDHWBOILERPRIORITY1.This
informsthecontrolthattheDHWtankisasystemzone,notdirectlyconnectedtotheboiler.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbesizedforrequiredflowandheadloss.• DHWcirculatorsuppliedbyinstaller.• U-Control is set for DHW priority — space heating will be
discontinuedduringacallforDHW.
SPACE HEATING• Mutliplezones• Sizecirculatorsforrequiredflow.• Spaceheatingcirculatorssuppliedbyinstaller.• CirculatorscontrolledbyWeil-McLainWMCRcontroller.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• This application applies only to multiple-zone space heating,
usingWeil-McLainzonecontroller.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
Application 4Multi-zone SPACE HEATING (Circulators + WMCR) | DHW (As zone in system)
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW SYSTEM
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Space heating (any type)
SYSTEM TYPE Select from list Select type used
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
As req’dD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
14
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Spaceheatingzonethermostats*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor
11 Lowwatercutoff(ifused)*
12 Circulatorzonecontroller,Weil-McLainWMCR—selectfornumberof
zonesrequired*
16 Spaceheatingzonecirculators*
22 Indirectwaterheater•
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 15
gas-fired water boiler — Application Guides
Application 5Multi-zone RADIANT | DHW (Direct-connected) | HEAT EXCHANGER (WMBP or WMPH) (<30% of total heat loss)
Purpose• Spaceheatingwithmultipleradiantzones(zonevalvezoning).• Heatexchanger,brazedplate(WMBP)orpoolheater(WMPH)
inseparatezone.Heatingloadmustbelessthan30%oftotalheatloss.Alternatively,seeApplication7a,whichdoesnotlimitloadsizes.
• DHWpipeddirectlytotheboiler.• DHWpriority—spaceheatingandheatexchangerheatingare
disabledduringcallforheatfromwaterheater.
U-Control setting notes• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.This
informs thecontrol that theDHWtank isdirectlyconnectedtotheboiler.
• SelectSYSTEMTYPEDHWforBOILERPRIORITY3,theheatexchangercircuit.Thispreventsoutdoorresetregulationofsup-plytemperatureduringheatexchangeroperation.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbe selected tohandle thepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilerman-ualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
RADIANT• Sizecirculatorsforrequiredflow.• Radiantcirculatorssuppliedbyinstaller.
SeeApplication 7a,page22,forradiantheat-ingusingindependenttemperaturecontrolfortheradiantzone.
HEAT EXCHANGER• Heatexchangerloadmustbelessthan30%oftotalheatloss.• Sizecirculatorforrequiredflow.• Typical application shown usingWeil-McLain brazed plate
(WMBP)exchangerorpoolheater(WMBP).• Heatexchangerandcirculatorsuppliedbyinstaller.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• ProvideWMR-21relaytooperateheatexchangercirculatorandprovidecallforheatexchangerheatingtoU-Controlinput.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW DIRECT
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Radiant zones Note 1 — Select system type: RSG = Slab on grade RTS = Thin slab RSU = Below floor RAF = Above floor
SYSTEM TYPE Select from list Note 1 (at left)
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
As requiredD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Heat exchanger (<30% of total heat loss)
SYSTEM TYPE Select from list DHW SYSTEM
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 FDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
16
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 Radiantcirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Radiantzoneendswitches*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
12 Heatexchanger
14 Heatexchangeraquastatorcontroller
15 WMR-21,2-polerelayforheatexchangercirculatoroperation*
16 Heatexchangercirculator*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
34 Zonevalves
35 By-passpressureregulator
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 17
gas-fired water boiler — Application Guides
Application 6
Purpose• Radiant heating circuit with single or multiple zones (zone
valves).Multiple-zonewiringnotshown—mustbeprovidedusingazonecontrollerorconnectingzonevalveendswitches.
• Single-zonebaseboardheatingforasmallspace(heatingloadlessthan30%oftotalheatloss—alternatively,seeApplication7a,whichdoesnotlimitloadsizes).
• DHWpipeddirectlytotheboiler.• DHWpriority—spaceheatingandheaterexchangerheatingare
disabledduringcallforheatfromwaterheater.
U-Control setting notes• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.This
informs thecontrol that theDHWtank isdirectlyconnectedtotheboiler.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
RADIANT• Sizecirculatorsforrequiredflow.• Radiantcirculatorssuppliedbyinstaller.
SeeApplication 7a,page22,forradiantheat-ingusingindependenttemperaturecontrolfortheradiantzone.
BASEBOARD• Baseboardloadmustbelessthan30%oftotalheatloss.• Sizecirculatorforrequiredflow.• Baseboardcirculatorsuppliedbyinstaller.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• ProvideWMR-21 relay to operate baseboard circulator andprovidecallforbaseboardheatingtoU-Controlinput.
• Ifusingmultiplezones,providecomponentsandwiringneededto operate zone components and provide call for heat to theU-controlinput.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW DIRECT
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Radiant
Note 1 — Select system type: RSG = Slab on grade RTS = Thin slab RSU = Below floor RAF = Above floor
SYSTEM TYPE Select from list Note 1 (at left)
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
As requiredD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Baseboard (Finned tube or cast iron)(<30% of total heat loss)
SYSTEM TYPE Select from list FTB or CIB
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Multi-zone RADIANT | DHW (Direct-connected) | Small BASEBOARD zone (<30% of total heat loss)
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
18
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 Radiantcirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Radiantzoneendswitches*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
14 Baseboardthermostat*
15 Weil-McLainWMR-21two-polerelaytooperatebaseboardcirculator*
16 Baseboardcirculator*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
34 Zonevalves*
35 Bypasspressureregulator*
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 19
gas-fired water boiler — Application Guides
Application 7Multiple HI-TEMP HEATING zones | DHW (Direct-connected) | Small RADIANT zone (<30 of total heat loss)
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW Direct
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Hi-temp space htg .
Note 1 — Select system type: FCL = Fan coil FTB = Finned-tube bb CIB = Cast iron bb CIR = Cast iron rad. Use DHW SYSTEM for heat exchangers
SYSTEM TYPE Select from list Note 1 (at left)
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
As requiredD
D (70F) or as req’dD (0F) or as req’d
DD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Radiant (<30 of total heat loss)
Note 2 — Select system type: RSG = Slab on grade RTS = Thin slab RSU = Below floor RAF = Above floor
SYSTEM TYPE Select from list Note 2 (at left)
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
As requiredD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Purpose• Radiantheatingandhi-temp(180°Ftypical)spaceheatingwith
single or multiple zones (circulator zoning). Hi-temp spaceheatingterminalunitscanbebaseboard,fancoil,radiatorsorheat exchangers. Fan coils must be equipped with minimumtemp aquastats, because their circulators can operate duringradiant circuit operation (supply water temperature could betoolowforfancoils).
• DHWpipeddirectlytotheboiler.• DHWpriority—spaceheatingandheaterexchangerheatingare
disabledduringcallforheatfromwaterheater.
U-Control setting notes• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.This
informs thecontrol that theDHWtank isdirectlyconnectedtotheboiler.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
HI-TEMP SPACE HEATING• Multiple zones with circulators controlled byWeil-McLain
WMCRzonecontroller.• Sizecirculatorsforrequiredflow.• Spaceheatingzonecirculatorssuppliedbyinstaller.
RADIANT• Radiantloadmustbelessthan30%oftotalheatloss.
SeeApplication 7a,page22,forradiantheat-ingusingindependenttemperaturecontrolfortheradiantzone,withnolimittotheradiantload.
• Sizecirculatorforrequiredflow.• Radiantcirculatorsuppliedbyinstaller.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• Provide Weil-McLain WMCR circulator zone controller tocontrol all hi-temp zone circulators, sized for the number ofzonesrequired.
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
20
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 Radiantzonecirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Hi-tempzonethermostat*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
14 Radiantzonethermostat*
15 Weil-McLainWMCRcirculatorzonecontroller(selectfornumberofzonesrequired)*
16 Hi-tempzonecirculator*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 21
gas-fired water boiler — Application Guides
Application 7a
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW Direct
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Space heating — select type most typical of hi-temp terminal units and highest supply temp required
SYSTEM TYPE Select from list Select
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
As requiredD
D (70F) or as req’dD (0F) or as req’d
DD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Multi-zone HI-TEMP HEATING plus RADIANT (with mixing valve) | DHW (Direct-connected)(No limits on the relative heating loads of radiant or hi-temp space heating circuits)
Purpose• Radiantheatingandhi-temp(180°Ftypical)spaceheatingwith
single or multiple zones (circulator zoning). Hi-temp spaceheatingterminalunitscanbebaseboard,fancoil,radiatorsorheatexchangers.
• Supply water temperature is selected for the hi-temp zones.The mixing valve regulates supply temperature to the lower-temperatureradiantzones.
• Allcirculators(hitempandradiant)areoperatedbytheWeil-McLainWMCRcirculatorzonecontroller.
• DHWpipeddirectlytotheboiler.• DHWpriority—spaceheatingisdisabledduringcallforheat
fromwaterheater.
U-Control setting notes• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.This
informs thecontrol that theDHWtank isdirectlyconnectedtotheboiler.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
HI-TEMP SPACE HEATING• Multiple zones with circulators controlled byWeil-McLain
WMCRzonecontroller.• Sizecirculatorsforrequiredflow.• All space heating circulators (hi-temp and radiant) supplied
byinstaller.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• Provide Weil-McLain WMCR circulator zone controller tocontrolallspaceheatingzonecirculators(hi-tempandradiant),sizedforthenumberofzonesrequired.
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
22
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Hi-tempzonethermostats*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
15 Weil-McLainWMCRcirculatorzonecontroller*
16 Radiantzonecirculators*
17 Hi-tempzonecirculators*
18 Radiantzonethermostat*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
40 Mixingvalve—controlssupplytemperaturetoradiantzones*
41 Checkvalve*
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 23
gas-fired water boiler — Application Guides
Application 8Multi-zone BASEBOARD (Zone valves + WMZV controller) | DHW (Direct-connected)
Purpose• Spaceheatingwithmultiplebaseboardzones.• Zoningwithzonevalves.• DHWpipeddirectlytotheboiler.• DHWpriority—spaceheatingandheaterexchangerheatingare
disabledduringcallforheatfromwaterheater.
U-Control setting notes• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.This
informs thecontrol that theDHWtank isdirectlyconnectedtotheboiler.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
BASEBOARD• Sizeforrequiredflow.• Systemcirculatorsuppliedbyinstaller.• Multiplezones(withzonevalvesandbypasspressureregulator
byinstaller).
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• This application applies only to multiple-zone space heating,
usingWeil-McLainzonecontroller.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• ProvideWeil-McLainWMZVzonevalvecontroller.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW Direct
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Baseboard (Finned tube or cast iron)
SYSTEM TYPE Select from list FTB or CIB
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
24
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 SYSTEMcirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Baseboardzonethermostats*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
34 Zonevalves*
35 Bypasspressureregulator*
36 Weil-McLainWMZVzonevalvecontroller*
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 25
gas-fired water boiler — Application Guides
Application 9Multi-zone BASEBOARD (Circulators + WMCR controller) | DHW (Direct-connected)
Purpose• Spaceheatingwithmultiplebaseboardzones.• Zoningwithcirculators.• DHWpipeddirectlytotheboiler.• DHWpriority—spaceheatingandheaterexchangerheatingare
disabledduringcallforheatfromwaterheater.
U-Control setting notes• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.This
informs thecontrol that theDHWtank isdirectlyconnectedtotheboiler.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
BASEBOARD• Sizeforrequiredflow.• Baseboardzonecirculatorssuppliedbyinstaller.• Multiplezones.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• This application applies only to multiple-zone space heating,
usingWeil-McLainzonecontroller.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• ProvideWeil-McLainWMCRcirculatorzonecontroller.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW Direct
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Baseboard (Finned tube or cast iron)
SYSTEM TYPE Select from list FTB or CIB
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
26
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Baseboardzonethermostats*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
12 Weil-McLainWMCRcirculatorzonecontroller*
16 Baseboarezonecirculators*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 27
gas-fired water boiler — Application Guides
Application 10Multi-zone FAN COILS (Circs . + WMCR contr .) | DHW (Direct-connected) | Small RADIANT zone (<30% of total heat loss)
Purpose• Spaceheatingwithmultiplefancoilzones,circulatorzoning.• Singleradiantzoneforsmallspace(heatingloadlessthan30%ofto-
talheatloss—alternatively,seeApplication7a,whichdoesnotlimitloadsizes).Fancoilzonesaredisabledduringradiantcallforheat.
• DHWpipeddirectlytotheboiler.• DHWpriority—spaceheatingandheaterexchangerheatingare
disabledduringcallforheatfromwaterheater.
U-Control setting notes• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.
• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.Thisin-formsthecontrolthattheDHWtankisdirectlyconnectedtotheboiler.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbe selected tohandle thepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilerman-ualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
FAN COIL• Multiple zones with circulators controlled byWeil-McLain
WMCRzonecontroller.• Sizecirculatorsforrequiredflow.Fancoilcirculatorssupplied
byinstaller.
RADIANT• Radiantloadmustbelessthan30%oftotalheatloss.• Size circulator for required flow. Radiant circulator supplied
byinstaller.
SeeApplication 7a,page22,forradiantheatingusing independenttemperaturecontrol fortheradiantzone,withnolimittotheradiantload.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• This application applies only to multiple-zone space heating,
usingWeil-McLainzonecontroller.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• ProvideWeil-McLainWMCRcirculatorzonecontrollertocon-trolfancoilzonecirculators.
• Provideasingle-polenormally-closedcontactrelay,120VACcoil,todisablefancoilzonesduringradiantcallforheat.
Thesingle-polerelaycanbeomittedifthefancoilunitsareequippedwithminimumtemperatureaquastats.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW Direct
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Fan coil zones
SYSTEM TYPE Select from list FCL
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Radiant zone <30% of total heat loss
Note 1 — Select system type: RSG = Slab on grade RTS = Thin slab RSU = Below floor RAF = Above floor
SYSTEM TYPE Select from list Note 1 (at left)
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
As requiredD
D (70F) or as req’dD (0F) or as req’d
DD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
28
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 Radiantzonecirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Fancoilzonethermostats*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
12 Weil-McLainWMCRcirculatorzonecontroller*
13 SPSTrelaywith120VACcoil*
14 Radiantzonethermostat*
16 Fancoilzonecirculators*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 29
gas-fired water boiler — Application Guides
Application 11CAST IRON RADIATORS | DHW (Direct-connected) | Small RADIANT zone (<30% of total heat loss)
Purpose• Singlecastironradiatorzone.• Singleradiantzoneforsmallspace(heatingloadlessthan30%
oftotalheatloss—alternatively,seeApplication7a,whichdoesnot limit loadsizes).Radiatorzoneisdisabledduringradiantcallforheat.
• DHWpipeddirectlytotheboiler.• DHWpriority—spaceheatingisdisabledduringcallforheat
fromwaterheater.
U-Control setting notes• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.This
informs thecontrol that theDHWtank isdirectlyconnectedtotheboiler.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
RADIATORS• Sizecirculatorforrequiredflow.• Radiatorzonecirculatorsuppliedbyinstaller.
RADIANT• Radiantloadmustbelessthan30%oftotalheatloss.
SeeApplication 7a,page22,forradiantheatingusing independenttemperaturecontrol fortheradiantzone,withnolimittotheradiantload.
• Size circulator for required flow. Radiant circulator suppliedbyinstaller.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• ProvideWMR-21 relay to operate radiator circulator(s) andprovidecallforradiatorzoneheatingtoU-Controlinput.
• Ifusingmultiplezones,providecomponentsandwiringneededto operate zone components and provide call for heat to theU-controlinput.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW Direct
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Radiator zone
SYSTEM TYPE Select from list CIR
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Radiant zone <30% of total heat loss
Note 1 — Select system type: RSG = Slab on grade RTS = Thin slab RSU = Below floor RAF = Above floor
SYSTEM TYPE Select from list Note 1 (at left)
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
As requiredD
D (70F) or as req’dD (0F) or as req’d
DD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
30
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 Radiantcircuitcirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Radiatorzonethermostat*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
14 Radiantthermostat*
15 Weil-McLainWMR-21relay*
16 Radiatorzonecirculator*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 31
gas-fired water boiler — Application Guides
Application 12FAN COIL zone | BASEBOARD zone | Small RADIANT zone (<30% of total heat loss)
Purpose• Spaceheatingwitha singlezoneofbaseboard, singlezoneof
radiantandsinglezoneoffancoil.• Theradiantloadmustbenomorethan30%ofthetotalheating
loadtousethecontrolstrategyofthisapplication.Alternatively,seeApplication7a,whichdoesnotlimitloadsizes.
• Zoningwithcirculators.
U-Control setting notes• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
FAN COIL• Sizecirculatorforrequiredflow.• Fancoilcirculatorsuppliedbyinstaller.
BASEBOARD• Sizecirculatorforrequiredflow.• Baseboardcirculatorsuppliedbyinstaller.
RADIANT• Radiantloadmustbelessthan30%oftotalheatloss.
SeeApplication 7a,page22,forradiantheatingusing independenttemperaturecontrol fortheradiantzone,withnolimittotheradiantload.
• Size circulator for required flow. Radiant circulator suppliedbyinstaller.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• ProvideWMR-21 relay to operate baseboard circulator andprovidecallforheattoU-Control.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE type 1
ADD’L HEAT DEMAND TIME Default (0 minutes)
SYSTEM SETTINGS
BOILER PRIORITY 1
Fan coil zone
SYSTEM TYPE Select from list FCL
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 FD
DefaultDefault
DD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D (30 minutes)
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Baseboard (Finned tube or cast iron)
SYSTEM TYPE Select from list FTB or CIB
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD
DefaultDefault
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
D (30 minutes)DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Radiant zone <30% of total heat loss Note 1 — Select system type: RSG = Slab on grade RTS = Thin slab RSU = Below floor RAF = Above floor
SYSTEM TYPE Select from list Note 1 (at left)
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
As requiredD
DefaultDefault
DD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
32
*=Supplied by installer
1 Fancoilzonecirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 Radiantzonecirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Baseboardzonethermostat*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 Fancoilzonethermostat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
14 Radiantthermosatat*
15 Weil-McLainWMR-21relay*
16 Baseboardzonecirculator*
21 Ultraboiler
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 33
gas-fired water boiler — Application Guides
Application 13Single-zone BASEBOARD | DHW (System, as zone)
Purpose• Spaceheatingwithsinglezoneofbaseboard(finnedtubeorcast
iron).ThisapplicationcanbeadaptedformultiplebaseboardzonesifpipingcomponentsandcontrolsareaddedtocontrolthezonecirculatorsorzonevalvesandprovideacallforheatsignaltotheU-Control.
• DHWpipedasaseparatezone.• DHWpriority—spaceheatingisdisabledduringcallforheat
fromwaterheater.
U-Control settings• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWSYSTEMfortheDHWBOILERPRIORITY1.This
informsthecontrolthattheDHWtankisasystemzone,notdirectlyconnectedtotheboiler.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbesizedforrequiredflowandheadloss.• DHWcirculatorsuppliedbyinstaller.• U-Control is set for DHW priority — space heating will be
discontinuedduringacallforDHW.
BASEBOARD• Singlezone.Multiplezonescanbeusedifzonecontrollerand
pipingcomponentsareadded.• Sizecirculatorforrequiredflow.• Baseboardcirculatorsuppliedbyinstaller.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• Ifusingmultiplezonesofbaseboard,providecomponentsandwiringneededtooperatezonecomponentsandprovidecallforheattotheU-controlinput.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW SYSTEM
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Baseboard (Finned tube or cast iron)
SYSTEM TYPE Select from list FTB or CIB
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
34
*=Supplied by installer
1 DHWcirculator*2 BOILERcirculator(shippedloosewithboiler)
3 Baseboardcirculator*4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Baseboardthermostat*7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*10 Outdoortemperaturesensor(suppliedwithboiler;install
ifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*21 Ultraboiler
22 Indirectwaterheater*23 Flow/checkvalves*24 Airseparatorwithautomaticairvent*25 Diaphragm-typeexpansiontank*26 Freshwatersupply—installperapplicablecodes*27 Isolationvalves*28 Purge/drainvalves*29 Secondarypipingconnectionforboilerloop*30 Boilerreliefvalve(installperboilermanual)
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 35
gas-fired water boiler — Application Guides
Application 14Multi-zone BASEBOARD (Zone valves) | Multi-zone RADIANT (Zone valves) | DHW (Direct-connected)
(Radiant load must be <30% of total heat loss)
Purpose• Space heating with multiple baseboard (finned tube or cast
iron)zonesandmultipleradiantzones,zoningwithzonevalves.• Theradiantloadmustbenomorethan30%ofthetotalheating
loadtousethecontrolstrategyofthisapplication.Alternatively,seeApplication7a,whichdoesnotlimitloadsizes.
• DHWpipeddirectlytotheboiler.• DHWpriority—spaceheatingisdisabledduringcallforheat
fromwaterheater.
U-Control setting notes• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.This
informs thecontrol that theDHWtank isdirectlyconnectedtotheboiler.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
BASEBOARD• Multiplezonesusingzonevalves.• Sizecirculatorforrequiredflow.• Baseboardcirculatorandzonevalvessuppliedbyinstaller.
RADIANT• Multiplezonesusingzonevalves.Radiantloadmustbelessthan
30%oftotalheatloss.
SeeApplication 7a,page22,forradiantheatingusing independenttemperaturecontrol fortheradiantzone,withnolimittotheradiantload.
• Size circulator for required flow. Radiant circulator and zonevalvessuppliedbyinstaller.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• Zone valve end switches and DHW aquastat activate the
U-Control.TheU-Control activates thecirculators forDHWandradiantcircuits.
• This application applies only to multiple-zone space heating,usingWeil-McLainzonecontroller.
• For circulators connected to the U-Control, the maximumcirculatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• Provide aWeil-McLainWMR-21 relay to operate baseboardcirculator.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE Type 1
ADD’L HEAT DEMAND TIME Default (0 minutes)
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW Direct
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D (30 minutes)
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Baseboard (Finned tube or cast iron)
SYSTEM TYPE Select from list FTB or CIB
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
D (30 minutes)DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Radiant zones Note 1 — Select system type: RSG = Slab on grade RTS = Thin slab RSU = Below floor RAF = Above floor
SYSTEM TYPE Select from list Note 1 (at left)
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
As requiredD
D (70F) or as req’dD (0F) or as req’d
DD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
36
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 Radiantcircuitcirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Baseboardzonevalveendswitches*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
14 Radiantzonevalveendswitches*
15 Weil-McLainWMR-21relay*
16 Baseboardcircuitcirculator*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
34 Zonevalves*
35 Bypasspressureregulator*
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 37
gas-fired water boiler — Application Guides
Application 15Single-zone BASEBOARD | Single-zone RADIANT | POOL Heat exchanger
(Radiant load must be <30% of total heat loss)
Purpose• Singlezoneofradiant,singlezoneofbaseboard(finnedtubeor
castiron)andsinglezoneforpoolheatexchanger.Thisapplica-tioncanbeadaptedformultiplezonesifpipingcomponentsandcontrolsareaddedtocontrolthezonecirculatorsorzonevalvesandprovideacallforheatsignaltotheU-Control.
• Zoningwithcirculators.
U-Control setting notes• SystemtypeDHWSYSTEMisusedforBOILERPRIORITY3,
theWMPHzone.Thispreventsoutdoorresetregulationofthesupplywatertemperaturetothepoolheater.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
BASEBOARD• Singlezone.Multiplezonescanbeusedifzonecontrollerand
pipingcomponentsareadded.• Sizecirculatorsforrequiredflow.• Baseboardcirculatorssuppliedbyinstaller.
RADIANT• Singlezone.Multiplezonescanbeusedifzonecontrollerand
pipingcomponentsareadded.
SeeApplication 7a,page22,forradiantheatingusing independenttemperaturecontrol fortheradiantzone,withnolimittotheradiantload.
• Sizecirculatorsforrequiredflow.Radiantcirculatorssuppliedbyinstaller.
HEAT EXCHANGER• Sizecirculatorforrequiredflow.• Typical application shown usingWeil-McLain pool heat ex-
changer(WMBP).• Heatexchangerandcirculatorsuppliedbyinstaller.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• ProvideaWeil-McLainWMR-21relaytooperateboilercircula-tor.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE Type 1
ADD’L HEAT DEMAND TIME Default (0 minutes)
SYSTEM SETTINGS
BOILER PRIORITY 1
Baseboard (Finned tube or cast iron)
SYSTEM TYPE Select from list FTB or CIB
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Radiant zone Note 1 — Select system type: RSG = Slab on grade RTS = Thin slab RSU = Below floor RAF = Above floor
SYSTEM TYPE Select from list Note 1 (at left)
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
As requiredD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
WMPH zone
SYSTEM TYPE Select from list DHW SYSTEM
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 FDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
38
*=Supplied by installer
1 BASEBOARDcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 POOLHEATEXCHANGERcirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Baseboardzonethermostat*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
14 Radiantzonethermostat*
15 Weil-McLainWMR-21relay*
16 RADIANTcirculator*
18 Poolheateraquastat*
21 Ultraboiler
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 39
gas-fired water boiler — Application Guides
Application 16Single or Multi-zone SPACE HEATING | DHW (Direct-connected) | ISOLATION Heat exchanger (Tall buildings)
(Use where space heating system operating pressure is over 25 PSIG)
Purpose• Isolationheatexchangerforapplicationswithhighsystempres-
sure(over25PSIG),suchastallbuildings.TypicalapplicationshownusingWeil-McLainWMBPbrazed-plateexchanger.
• Spaceheatingviahotwaterfeedtobuildingterminalunits.• Spaceheatingcirculatorandheatexchangerprimarycirculator
areactivatedoncallforheatbytheheatingsystem.• DHWpipeddirectlytotheboiler.• DHWpriority—spaceheatingandheaterexchangerheatingare
disabledduringcallforheatfromwaterheater.
U-Control setting notes• Seethetableatrightforrequiredandoptionalsettings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.• SelectDHWDIRECTfortheDHWBOILERPRIORITY1.This
informs thecontrol that theDHWtank isdirectlyconnectedtotheboiler.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
HEAT EXCHANGER• Sizecirculatorforrequiredflowandpressuredrop.• Heatexchanger,pipingcomponentsandcirculatorsuppliedby
installer (except the boiler circulator, shipped loose with theboiler).
SPACE HEATING• Sizecirculatorforrequiredflowandpressuredrop.• Terminalunits,pipingcomponentsandcirculatorsuppliedby
installer.
BOILER• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.• Boiler loop piping can be provided using optional Easy-Up
Manifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.• ProvideWeil-McLainWMR-21relay tooperate spaceheating
circulator.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• DONOTconnecttheoutdoorsensortotheU-Controlunlessthewatersupplytotheheatexchangeristoberesetbasedonoutdoortemperature.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW Direct
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Heat exchanger
SYSTEM TYPE Select from list CUS
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F190 F
DDDD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
40
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 HEATEXCHANGERPRIMARYcirculator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
14 Spaceheatingthermostatorcallforheatcontact*
15 Weil-McLainWMR-21relay*
16 SPACEHEATINGcirculator*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Reliefvalves—boiler(installperboilermanual)andheatexchangerspaceheatingside
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 41
gas-fired water boiler — Application Guides
Multiple boiler operation optionsUsing the U-Control settings
ADDITIONAL HEAT DEMAND
BOILER SETTINGS
BOILER MODEL
HIGH ALTITUDE
HIGH LIMIT
WWSD TEMP
ADjUST OUTDOOR
ADD’L HEAT DEMAND TYPE
ADD’L HEAT DEMAND TIME
1. TheADD’LHEATDEMANDsettings(thetworedboxesabove)areformultipleboilersormultipleheatingsources(anUltraboilercollaboratingwithaheatpumporadifferentboiler,forexamples).
Additional heat demand DOES NOT PASS ON if thesystemtypeisDHWDirectorCustom.Donotusethissetting on any boiler unless it is the last in the lead/shadowsequence.
ADDITIONAL HEAT DEMAND settings
OFF
1. Functiondisabled—NOsignalwouldbepassedontootherboilers.
Type 1
1. ThismeanstheUltraboileristheprimaryheatsource.
a. WhentheUltraboilerreceivesacallforheat,itbeginsitsstartupsequenceandalsostartsadelay timer(setasADD’LHEATDE-MANDTIME).
b. When theADD’L HEAT DEMAND TIME has elapsed, the U-Control closes the“Additional heat demand contact,” terminalsP16–6&7.
c. UseP16–6&7tostartthenextheatsource.
d. If the next heat source is an Ultra boiler, connect from the firstboiler’sP16–6&7terminalstothesecondboiler’s“Heatdemand1”terminals(P11–4and5).
e. Program the second boiler’sADD’L HEAT DEMAND TIME tostart a third boiler the same way, and so on to sequentially firemultipleboilers.
Type 2
1. Thismeanstheboileristhesecondaryheatsource.
a. WhentheU-Controlreceivesacallforheat,itimmediatelyactivatesthe“Additionalheatdemandcontact,”terminalsP16–6&7.Thiscontactisusedtostartthenextheatsourceimmediately.
b. WhentheADD’LHEATDEMANDTIMEhaselapsed,theUltraboilerbeginsitsstartupsequenceandcontinuestoheatuntilthedemandissatisfied.
c. Type2assignmentwouldgenerallyonlybeusediftheotherheatsourceisadifferentboileroraheatpump,forexample.
Type 3
1. ThisassignstheboilerastheLEADboilerinamultipleboilersystem.
a. The LEAD boiler must have system supply and return sensorsmountedonthesystemsupplyandreturnpipesandwiredtotheboiler.Anoutdoorsensormustalsobe installed ifoutdoorresetisdesired.
b. WhentheU-Controlreceivesacall forheat, itbeginsitsheatingsequenceandstartstheADD’LHEATDEMANDTIMEdelaytimer.
c. When theADD’L HEAT DEMAND TIME has elapsed, the U-Controlsendsa0–10VDCproportionalsignaloutits0–10VDCoutputterminals,P16–1&2.
d. AdditionalUltraboilersarecalledSHADOWboilers.
e. ConnecttheLEADboileroutputterminals(P16–1&2)tothefirstSHADOWboiler’s0–10VDCinputterminals,P15–5&6.
f. For the LEAD boiler and all additional boilers except the lastSHADOWboiler,connectP16–1&2ofeachboilertoP15–5&6ofthenextboiler.
g. Each SHADOW boiler will start and modulate based on the0–10VDCsignalfromthepreviousboiler.
h. TheSHADOWboilersmustbesetupasType4(seebelow).TheydonotneedtheirADD’LHEATDEMANDTIMEvaluestobeset.
Type 4
1. ThisassignstheboilerasaSHADOWboilerinamultipleboilersystem.
a. ForType4boilers,theADDITIONALHEATDEMANDfunctiononlyappliestothePriority1system.
b. WiretheboilersasexplainedunderType3,above.
c. EachSHADOWboilermusthavesystemsupplyandreturnsensorsmountedonthesystemsupplyandreturnpipesandwiredtotheboiler.Anoutdoorsensormustalsobe installed ifoutdoorresetisdesired.
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
42
Multiple boiler operation options (continued)
Using the U-Control settings
SENSORS1. EachUltraboilerisshippedwiththreeremote-mountedsensors—supply,return
andoutdoor.Supplyandreturnsensorsarestrap-ontype.
a. Supply sensor—Everyboilermusthaveitssupplysensorattachedtothesystemsupplypiping.Itmustsensethetemperatureofthewatergoingtothesystem.(Theboilerhasanintegralsensorthatmonitorsboileroutletwatertemperature.)theLEADboileradjustsfiringrateasneededtomain-tainsystemsupplytemperature.Shadowboilersmodulateaccordingtothe0–10VDCsignal from the leadboiler,but they turn onand offbasedonsystemsupplytemperature.
b. Return sensor—Everyboilermusthaveitssupplysensorattachedtothe system return piping to allow the boiler to monitor temperature risethroughtheboiler.
c. Outdoor sensor—Installanoutdoorsensorforeachboilerifthemultipleboilersystemwilluseoutdoorreset.
Thedescriptionofeachmultipleboilerapplicationinthisguideindicateswhichsensorsarerequiredtoaccomplishtheintentoftheapplication.
ADDITIONAL HEAT DEMAND applications
Type 1 and Type 2 applications
1. Application 17a — Multiple heat sourcesappliesthisoptiontodelayoperationoftheUltraboiler,allowingtimefortheprimaryheatsourcetosatisfythecallforheatfromthethermostat,endswitches,etc.
a. TheUltraboilerissetupasType2.
b. WhentheroomthermostatcallsforheatattheUltraboiler,theU-ControlimmediatelyclosesthecontactacrossP16terminals6and7.
c. Thiscontactisusedtostarttheauxiliaryheatsource(woodstove,etc.)
d. TheU-Controlalso immediatelystarts itsADD’LHEATDEMANDTIMEtimer(setat60minutesforthisapplication).Ifthistimerelapsesandthecallforheatisstillpresent,theUltraboilerwillfire.
e. TheUltraboilerwilloperatetheboilercirculatorandsystemcirculatortoprovideheattothebaseboardunits.
f. ThisapplicationprovidesDHWusingthePriority2functionsoftheUltraboiler.WiththePriority1MAXONTIMEsetto0,theUltraboilerwillim-mediatelyswitchtoDHWoperationonanycallfromtheDHWtank.
2. OtherpossibleapplicationsofType1/Type2—
a. Application 17 — Multiple heat sourcescouldbesetupwiththeUltraboilerspecifiedasType2,withADD’LHEATDEMANDTIMEsetto60minutes,typically.Theaquastat(item14)neartheheatexchangeroutletwouldnotbeusedinthiscase.Thissetupwouldprovide60minutesfortheauxiliaryheatsourcetosatisfydemandbeforetheUltraboilerwouldfireforspaceheating.TheUltraboilerwillalwaysrespondtoacallforheatfromtheDHWtank.
b. Combustion air heater —An Ultra boiler could be set as Type 2, withterminalsP16–1&2usedtostartacombustionairheater.Setthetimedelayto10minutestoallowtimeforcombustionairheatertoreachsteady-stateoperationbeforetheUltraboilerfires.
Type 3 and Type 4 — Sequential operation
1. Sequentialoperationisachievedbysettingatimedelaybe-tweenboilerstart-ups.Thismethodisusedin:
a. Application 18 — Multiple boilersb. Application 19 — Multiple boilersc. Application 20 — Multiple boilers
d. Application 21 — Multiple boilers.
2. UsetheADD’LHEATDEMANDTIMEsettingtodelayac-tivationofeachsuccessiveboilerinamultipleboilersystem.
a. When one of the boilers receives a call for heat, theU-Control starts theADD’L HEAT DEMAND TIMEtimer.Onlywhenthistimerelapsesisthesignaltostartpassedontothenextboiler—that is,afterthis timeelapses,theU-Controlsendsa0–10VDCsignaloutofP16terminals1and2.
b. Typically, set theADD’L HEAT DEMAND TIME to5minutesforallboilersexceptthelastshadowboiler.
c. Wireeachboilerwith itsP16-1&2output terminals(0–10VDC)going to theP15-5&6 terminalsof thenextboiler.
3. Stagingofboilerscanalsobeimprovedbythesettingofeachboiler’sMODULATEONandMODULATEOFFdifferentials,asexplainedbelow.
4. Set the SHADOW boilers’ MODULATE ON DIFF andMODULATEOFFDIFFsettingsatdifferentvaluestocausetheSHADOWboilerstocycleatdifferentsystemSUPPLYtemperatures. This will improve the sequential firing ofSHADOWboilers.
• The applications in this guide use ON/OFF values of5°F/10°FforthefirstSHADOWboilerand10°F/5°FforthelastSHADOWboiler.
• Forsystemswithmorethanthreeboilers,thesevaluescanbegraduatedtoimprovesequencing.Example:forfourboilers,useMODULATEONDIFFvaluesof3/6/9andOFFDIFFvaluesof9/3/6.
Toeffectivelyuseoutdoorreset,allSHADOWboilers must be have OUTDOOR sensorsinstalled if the LEAD boiler is set up foroutdoorresetoperation.TheMAXSUPPLY,MINSUPPLY,MAXODRESETandMINODRESET values must be set exactly as on theLEADboiler.
DO NOT use outdoor sensors and outdoorresetonmultipleboilerssupplyingasystemthat requires fixed high-temperature water,such as DHW applications with the waterheaters piped in the system, not directly tooneoftheboilers.
Themodulatingsignal fromU-ControlP16ofoneboilertoP15ofthenextispolaritysensitive.
Connectwires+to+and–to–asshown.Thatis,P16–1goestoP15–6andP16–2goestoP15–5.
Partnumber550-100-110/0411 43
gas-fired water boiler — Application Guides
Application 17 — Multiple heat sourcesALTERNATIVE HEAT SOURCE as primary / ULTRA as back-up | Single-zone BASEBOARD or FAN COIL
DHW (Direct-connected)
Purpose• Themainheatsourceforthissystemisawood-firedboileror
otheralternativeheatsource.TheUltraboilerprovidesback-upheating.Inaddition,theUltraboilerprovidesdomestichotwaterviaanindirectwaterheater.
• Spaceheatingiswithbaseboard,fancoilsorother.Thisapplica-tioncanbeadaptedformultiplezonesifpipingcomponentsandcontrolsareaddedtocontrolthezonecirculatorsorzonevalvesandprovideacallforheatsignaltotheU-Control.
• DHWpipeddirectlytotheUltraboiler.
• DHWpriority—spaceheatingisdisabledfortheUltraboilerduringcallforheatfromthewaterheater.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-Control is set for DHW priority — space heating will bediscontinuedduringacallforDHW.
BASEBOARD• Sizecirculatorforrequiredflow.Thecirculatormustbeselected
tohandletheheadlossthroughtheheatexchangerinadditiontothesystemheatlosses.
ALTERNATIVE HEAT SOURCE• Provideaheat source(suchasawood-firedboiler, solarheat
system,etc.)withall controlsandpiping(permanufacturer’sinstructions).Acirculatormustbesuppliedintheheatsourcepiping.
• HEAT SOURCE, associated piping and components, and allcirculators(excepttheboilercirculator)suppliedbyinstaller.
• Selectaheatexchanger for therequired load.Usea shellandtubeexchangerasshowninthepipingdiagram.Abrazed-plateexchangercanbeused,butonlyiftheHEATSOURCEsystemisclosed.
• Ifmoresuitedtotheapplication,swaptheshellsideandtubesideoftheexchangerversusthepipingdiagram.
ULTRA BOILER• Seeboilermanualforsizing.
• Circulatorshippedloosewithboiler.
• Boiler loop piping can be provided using optional Easy-UpManifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.
• ProvideaWeil-McLainWMCR-2circulatorzonecontrollertooperatethebaseboardsystemcirculatorandprovidecallforheattoalternativeheatsourceandtheUltraboiler.
• For circulators connected to the U-Control, the maximumcirculatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• Provideandinstallanaquastatinthesupplylinefromtheheatexchangerasshown.ThisaquastatwillactivatetheUltraboilerifthesupplywatertemperaturefallsbelowtheaquastatsetting.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE D
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW
SYSTEM TYPE Select from list DHW Direct
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Baseboard (Finned tube or cast iron)
SYSTEM TYPE Select from list FTB or FCL
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
44
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Baseboard(orfancoil)thermostat*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforwarmweathershutdown)
11 Lowwatercutoff(ifused)*
14 AquastatinsupplylinefromHEATSOURCEpiping*
15 Weil-McLainWMCR-2circulatorcontrol*
16 Systemcirculator*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
38 Alternativeheatsourceandpipingpermfr’sinstructions*(mustincludea circulator and all piping and components specified in manufacturer’sinstructions)
40 Isolation heat exchanger (DO NOT use a brazed-plate exchanger whenconnectedtoanopensystem)*
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 45
gas-fired water boiler — Application Guides
Application 17a — Multiple heat sourcesNON-HYDRONIC PRIMARY HEAT SOURCE as Type 1 (LEAD) / ULTRA as Type 2 (BACKUP)
Single-zone or multi-zone BASEBOARD or FAN COIL | DHW (Direct-connected)
Purpose• Themainheatsourceforthissystemisanon-hydronicheating
unit,suchasawood-firedstoveorwarm-airfurnace.TheUltraboilerprovidesback-upheating. Inaddition, theUltraboilerprovidesdomestichotwaterviaanindirectwaterheater.
• Spaceheatingiswithbaseboard,fancoilsorother.Thisapplica-tioncanbeadaptedformultiplezonesifpipingcomponentsandcontrolsareaddedtocontrolthezonecirculatorsorzonevalvesandprovideacallforheatsignaltotheU-Control.
• DHWpipeddirectlytotheUltraboiler.
• DHWpriority—spaceheatingisdisabledfortheUltraboilerduringcallforheatfromthewaterheater.
Circulators and piping• Pipingmustbeprimary/secondaryasshown.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• U-ControlPriority1MAXONTIMEissetto0minutes.ThecontrolwillimmediatelyswitchtoDHWheatingoncallfromtheDHWaquastat.
BASEBOARD• Sizecirculatorforrequiredflow.
• Thebaseboardcirculatormustbesuppliedbytheinstaller.
ALTERNATIVE HEAT SOURCE• Provideaheatsource(suchasawood-firedstove)withallcon-
trolsneeded,permanufacturer’sinstructions.
ULTRA BOILER• Seeboilermanualforsizing.
• Circulatorshippedloosewithboiler.
• Boiler loop piping can be provided using optional Easy-UpManifolds,availablefromWeil-McLain(seepage5).
Wiring• Connectfieldwiringasshownonnextpage.
• For circulators connected to the U-Control, the maximumcirculatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• Provideandinstallaroomthermostat.ThethermostatprovidesacallforheattotheUltraboiler.TheUltraboilerissetasADD’LHEATDEMANDType II— itwill immediatelypass thecallforheatontothealternativeheatsource.IftheADD’LHEATDEMANDTIMEelapsesandthethermostatisstillcallingforheat, the Ultra boiler will come on and provide heat to thehydronicsystem.
Set the Ultra boiler Priority 1 MAX ON TIME to 0 minutes.TheboilerwillimmediatelyswitchtoDHWmodeoncallfromtheDHWaquastat.
U-Control settings (see navigation flow below)
xxx
D— value must be set (or verified) as indicated
— default acceptable; change only if desired
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE Type 2 – BACKUP
ADD’L HEAT DEMAND TIME 60 minutes
SYSTEM SETTINGS
BOILER PRIORITY 1
Baseboard (Finned tube or cast iron)
SYSTEM TYPE Select from list FTB or FCL
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD
D (70F) or as req’dD (0F) or as req’d
DD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
0 minutesDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
DHW
SYSTEM TYPE Select from list DHW Direct
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
D60 minutes
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
46
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 System(orzone)circulator*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Roomthermostat*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforwarmweathershutdown)
11 Lowwatercutoff(ifused)*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
38 Alternativeheatsource,installedpermfr’sinstructions*
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 47
gas-fired water boiler — Application Guides
Application 18 — Multiple boilersMultiple Ultra boilers | Multiple-zone SPACE HEATING (Circulators with WMCR) | DHW (Direct-connected)
Purpose• Space heating with multiple Ultra boilers and multi-zone
spaceheatingusingbaseboard,fancoils,orother(zoningwithcirculators).
• DHWpipeddirectlytooneboiler.
• DHWpriority—spaceheatingandheaterexchangerheatingaredisabledduringcallforheatfromwaterheater.
Circulators and piping
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• PipetheindirectwaterheatertothelastSHADOWboiler.TheU-Controlon the lastSHADOWboiler is set to immediatelyswitch to DHW heating on call from the DHW aquastat. SetsystemtypetoDHW-DIRECT.
BASEBOARD or FAN COIL• Multiplezones.
• Sizecirculatorsforrequiredflow.
• Zoningcirculatorssuppliedbyinstaller.
BOILER• Ultraboilerpipingmustbeprimary/secondaryasshown,with
theboilerpipedinasecondaryloopandtheDHWpipedtothelastSHADOWboiler.
• Seeboilermanualforsizing.
• Circulatorshippedloosewitheachboiler.
Wiring• Connectfieldwiringasshownonnextpage.
• This application applies only to multiple-zone space heating,usingWeil-McLainzonecontroller.
• For circulators connected to the U-Control, the maximumcirculatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• ProvideWeil-McLainWMCR circulator zone controller forzonecirculators.
• ConnecttheDHWaquastatonlytothelastboilerintheseries.
LEAD Boiler U-Control settings
xxx
D
— value must be set (or verified) as listed
— default acceptable; change only if desired
See SHADOW boiler settings on pages 50 and 51
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE Type 3 – LEAD
ADD’L HEAT DEMAND TIME 5 minutes
SYSTEM SETTINGS
BOILER PRIORITY 1
Space heating (any type)
SYSTEM TYPE Select from list Select type used
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 F or as req’dD (70f) or as req’DD (0f) or as req’DD or as requireD
DD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
48
*=Supplied by installer
1 DHWcirculator*
2 BOILERcirculator(shippedloosewithboiler)
3 Zonecirculators*
4 120VACpowersupply,15-ampminimumrating
5 U-Control
6 Zonethermostats*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoortemperaturesensor(suppliedwithboiler;installifU-Controlwillbesetforoutdoorresetoperation)
11 Lowwatercutoff(ifused)*
12 Weil-McLainWMCRcirculatorzonecontroller*
21 Ultraboiler
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Freshwatersupply—installperapplicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
40 Manifolds,Weil-McLainEasy-Fitshown*
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 49
gas-fired water boiler — Application Guides
Application 18 — Multiple boilers (continued)
Multiple Ultra boilers | Multiple-zone SPACE HEATING (Circulators with WMCR) | DHW (Direct-connected)
U-Control setting notes (LEAD boiler)• Additionalheattimeisset to5minutestodelaystartofnext
boilerinsequenceenoughtoallowsystemtorespond.Changethissettingvalueifdesired.
• Seefollowingpagesforadditionboilersettinginformation.
DO NOTsettheLEADboilerPRIORITY1SYS-TEMTYPEtoCustomorDHW.ShadowboilerssettoTYPE4willnotworkwiththesesettings.
The modulating signal from U-Control P16of one boiler to P15 of the next is polaritysensitive.
Connect wires + to + and – to – as shown.Thatis,P16–1goestoP15–6andP16–2goestoP15–5.
U-Control setting notes (SHADOW boilers)
The modulating signal from U-Control P16of one boiler to P15 of the next is polaritysensitive.
Connect wires + to + and – to – as shown.Thatis,P16–1goestoP15–6andP16–2goestoP15–5.
SettheADD’LHEATDEMANDTIMEto5min-utes,orlongerifpossible.Thisisthetimedelaybeforethemodulatingsignalwillbepassedontothenextboilerinseriesforadditionalspaceheatingcapacity.
InstallsystemSUPPLYandRETURNsensorsand OUTDOOR sensor for every boiler, asshown in the piping and wiring diagramsforthisapplication.ShadowboilerswillonlystartandstopbasedontheirMODULATEONorOFFDIFF.Thisreducesthe likelihoodofexcessivecyclingasheatdemandchanges.
Non-DHW SHADOW Boiler U-Control settings
xxx
D
— value must be set (or verified) as listed
— default acceptable; change only if desired
See other boiler settings on pages 48 and 51
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE Type 4 – SHADOW
ADD’L HEAT DEMAND TIME 5 minutes
SYSTEM SETTINGS
BOILER PRIORITY 1
Space heating (any type)
SYSTEM TYPE Select from list SAME AS LEAD
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
SAME AS LEADSAME AS LEADSAME AS LEADSAME AS LEAD
5 F10 F
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
50
Application 18 — Multiple boilers (continued)
Multiple Ultra boilers | Multiple-zone SPACE HEATING (Circulators with WMCR) | DHW (Direct-connected)
U-Control setting notes (LAST SHADOW boiler)
The modulating signal from U-Control P16of one boiler to P15 of the next is polaritysensitive.
Connect wires + to + and – to – as shown.Thatis,P16–1goestoP15–6andP16–2goestoP15–5.
TheindirectwaterheatermustbeconnectedtotheLASTboilerinthesequence.Thisensuresthatthemodulatingsignalfrompreviousboilerswillbepassedalongtothenextboiler.
Set the last SHADOW boiler Priority 1 MAX ON TIME to 0 minutes.Theboilerwill im-mediatelyswitchtoDHWmodeoncallfromtheDHWaquastat.MAXONTIMEisthemaximumtimetheboilerwillcontinuetooperateunderthecurrentPRIORITYifalowerpriorityiscallingforheat.
Install system SUPPLY and RETURN sen-sorsandOUTDOORsensorforeveryboiler.Shadowboilerswill start and stopbasedontheir MODULATE ON or OFF DIFF. Thisreducesthelikelihoodofexcessivecyclingasheatdemandchanges.
SelectDHWDIRECTfortheDHWBOILERPRIORITY2.ThisinformsthecontrolthattheDHWtankisdirectlyconnectedtotheboiler.
DHW SHADOW Boiler U-Control settings
xxx
D
— value must be set (or verified) as listed
— default acceptable; change only if desired
See other boiler settings on pages 48 and 50
BOILER SETTINGS SET TO
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP opt
ADjUST OUTDOOR opt
ADD’L HEAT DEMAND TYPE Type 4 – SHADOW
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS NEXT MENU NEXT MENU SET TO
BOILER PRIORITY 1
Space heating
SYSTEM TYPE Select from list SAME AS LEAD
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
SAME AS LEADSAME AS LEADSAME AS LEADSAME AS LEAD
10 F5 F
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
0 minutes
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
DHW
SYSTEM TYPE Select from list DHW–DIRECT
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
D60 minuntes
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411 51
gas-fired water boiler — Application Guides
Application 19 — Multiple boilersMultiple Ultra boilers | Multi-zone SPACE HEATING & DHW (In system) (Circulators with WMCR controllers)
Purpose• SpaceheatingwithmultipleUltraboilers,andbaseboardorfan
coils,withDHWsuppliedbysystempiping.• DHWconnectedtoprimarywithasecondaryconnection.Mul-
tipleDHWtanksarezonedwithcirculators.• DHWpriority(accomplishedusingaSPSTrelay,item42,not
throughtheU-Control)—spaceheatingisdisabledduringcallforheatfromwaterheater.
Circulators and piping
DHW• DHWcirculatorssuppliedbyinstaller.• TheSPSTrelay(item42)setforDHWprioritydisablesspace
heatingaslongastheU-ControlCirculator3outputisactivated—thedurationofthisdomesticpriorityoperationisdeterminedbytheLEADboiler’sPriority1MAXONTIMEsetting.Setthisvalue to 60 minutes for typical application. This time can bechanged to suit job requirements.OMITrelay42 ifdomesticpriorityisnotrequired.
BASEBOARD• Sizecirculatorsforrequiredflow.• Allzonecirculatorssuppliedbyinstaller.
* =Supplied by installer
1 DHWcirculators*
2 BOILERcirculators(shippedloosewithboiler)
3 Zonecirculators*
4 120VACpowersupply,15-ampminimumrat-ing
5 U-Control
6 Zonethermostats*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastats*
10 Outdoor temperature sensor (supplied withboiler;installifU-Controlwillbesetforout-doorresetoperation)
11 Lowwatercutoff(ifused)*
12 Weil-McLainWMCRcirculatorzonecontrollerforbaseboardorfancoilzones*
13 Weil-McLainWMCRcirculatorzonecontrollerforDHWcirculators*
21 Ultraboilers
22 Indirectwaterheaters*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Fresh water supply — install per applicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
40 Weil-McLain Easy-Fit headers (or field-fabricatedequivalent)forconnectionofboilerorwaterheaterpipingtoprimaryloop*
41 Distributionmanifoldsforpipingtobaseboardorfancoilzones*
42 SPST relay, 120VAC coil, normally open —whenclosed,thespaceheatingWMCRsensesthepriorityzoneisactiveandwillpreventotherspace heating zones from running until theclosureonthepriorityzoneends
LEGEND
continued
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
52
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 53
gas-fired water boiler — Application Guides
Application 19 — Multiple boilers (continued)
Multiple Ultra boilers | Multi-zone SPACE HEATING & DHW (In system) (Circulators with WMCR controllers)
BOILER
• Piping must be primary/secondary as shown, with the boilerpipedinasecondaryloopandtheDHWpipedinasecondaryloopwithconnectionsspanningtheboilerconnections.
• Seeboilermanualforsizing.
• Circulatorshippedloosewitheachboiler.
Wiring
• Connectfieldwiringasshownonpage52.
• For circulators connected to the U-Control, the maximumcirculatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• Provide twoWeil-McLainWMCR circulator zone controllers—oneforDHWcirculatorzoningandtheotherforbaseboardorfancoilzoning.
• ProvideSPSTrelay,120VACcoil,normallyopencontactifdo-mesticpriorityisrequired.(ThisconfigurationusesthepriorityzoneofthespaceheatingWMCRzonecontroller.)
U-Control setting notes
• See the tables on pages 54 and 55 for required and optionalsettings.
• ToseethenavigationsequencetoaccesstheBOILERSETTINGSandSYSTEMSETTINGSmenus,seepage7.
Themodulatingsignal fromU-ControlP16ofoneboilertoP15ofthenextispolaritysensitive.
Connectwires+to+and–to–asshown.Thatis,P16–1goestoP15–6andP16–2goestoP15–5.
DO NOTsetanyboiler’sPRIORITY1SYSTEMTYPE to Custom or DHW–DIRECT. Shadowboilers set toTYPE4willnotworkwith thesesettings.
DONOTset theU-Controls foroutdoorresetoperation.ThesystemmustprovideboilerwatersuitableforDHWoperation.
InstallsystemSUPPLYandRETURNsensorsforeveryboiler.
SettheADD’LHEATDEMANDTIMEto5min-utes,orasdesired.Thisisthetimedelaybeforethemodulatingsignalwillbepassedontothenextboilerinseriesforadditionalheatingcapacity.
DHW OPERATION — ADDITIONAL HEAT DEMAND TIME:Theadditionalheatdemandtimesettingmayhavetobe0minutesiftheDHW demand is large compared to totalboilercapacity.Ifthetimingistoolong,theboilerswillnotprovidefastenoughresponse.
The MAX ON TIME setting for Priority 1willdisablespaceheatingforthisamountoftime.Attheendofthistime,theU-ControlwillswitchtoPriority2
LEAD Boiler U-Control settings
xxx
D
— value must be set (or verified) as listed
— default acceptable; change only if desired
See SHADOW boiler settings on pages 55
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE Type 3 – LEAD
ADD’L HEAT DEMAND TIME 5 minutes (see NOTICE on page 54)
SYSTEM SETTINGS
BOILER PRIORITY 1
DHW (must be set up as DHW–SYSTEM)
SYSTEM TYPE Select from list DHW–SYSTEM
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
60 minuntes
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Space heating (baseboard or fan coil)
SYSTEM TYPE Select from list FTB or FCL
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F190 F
DDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
54
Application 19 — Multiple boilers (continued)
Multiple Ultra boilers | Multi-zone SPACE HEATING & DHW (In system) (Circulators with WMCR controllers)
SHADOW Boiler U-Control settings
xxx
D
— value must be set (or verified) as listed
— default acceptable; change only if desired
See LEAD boiler settings on pages 54
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP opt
ADjUST OUTDOOR opt
ADD’L HEAT DEMAND TYPE Type 4 – SHADOW
ADD’L HEAT DEMAND TIME 5 minutes (see NOTICE on page 54)
SYSTEM SETTINGS
BOILER PRIORITY 1
Space heating (baseboard or fan coil)
SYSTEM TYPE Select from list FTB or FCL
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 FDDDDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411 55
gas-fired water boiler — Application Guides
Application 20 — Multiple boilersMultiple Ultra boilers | Multiple loads on SECONDARY loops | DHW (Direct-connected)
Purpose• SpaceheatingwithmultipleUltraboilers,withmultiple-zone
baseboardspaceheating.• DHWpipeddirectlytooneboiler.• DHWpriority—spaceheatingandheaterexchangerheatingare
disabledduringcallforheatfromwaterheater.
Circulators and piping
PRIMARY PIPING• Provides crossover-style connection for multiple subsystems.
Eachsubsystemconnectsviaasecondarylooptake-off.• Sizecirculatorforrequiredflow—primary(system)circulator
suppliedbyinstaller.
SUBSYSTEMS• Subsystemsupply/returnpipingmustbeconnectedtocrossover
bridgeswithsecondaryconnectionsspacedapartasshown.• Subsystemscanuseanymeansdesired,suchasbaseboard,cast
ironradiators,fancoils,heatexchangerorradiant.• Providecontrolsandcomponentsneededforzoning(asshown
intypicalsubsystemexample).
* =Supplied by installer
1 DHWcirculator*
2 BOILERcirculators(shippedloosewithboiler)
3 Systemcirculator*
4 120VACpowersupply,15-ampminimumrat-ing
5 U-Control
6 Zonethermostats,typical*
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoor temperature sensor (supplied withboiler;installifU-Controlwillbesetforout-doorresetoperation)
11 Lowwatercutoff(ifused)*
12 Typical—Weil-McLainWMCRcirculatorzonecontrollerforbaseboardorfancoilzones*
16 Baseboardzonecirculators*
21 Ultraboilers
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Fresh water supply — install per applicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
40 Weil-McLain Easy-Fit headers (or field-fabricatedequivalent)forconnectionofboilerorwaterheaterpipingtoprimaryloop*
41 Distributionmanifoldsforpipingtobaseboardorfancoilzones*
43 Balancingvalves*
45 Secondaryconnectionstoheatingsubsystems*
continued
LEGEND
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
56
Piping overview• Pipingusesacrossoverbridgeforeachsub-
system.Thesubsystemsupplyandreturnpipesmustbeconnectedusingasecondaryconnectionfromthebridgeasshown.
• Use thebalancingvalves in thecrossoverbridgelinestobalanceflowasneeded.
• A typical subsystem comprised of base-boardheatingzoneswithzonecirculatorsis illustrated.Thewiringdiagramon theoppositepageshowsthecirculatorzoningpanelforthissubsystem.
• Other subsystemscouldprovideheat forradiant heating, fan coil units, pool heatexchangers,etc.
• Domestichotwaterissuppliedbyanindi-rectwaterheaterpipedtothelastboilerintheLEAD/SHADOWsequence.WhentheDHW aquastat calls for heat, the boilercirculatorturnsoffandtheDHWcirculatorturnson.Otherboilerscontinuetoprovideheattothesystem.
• Themajoradvantagetothetwo-pipepri-mary/secondarymethodshownhereisthatallsubsystemsreceivesupplywateratthesametemperature.Temperaturecanthenbe regulated in the subsystemasneeded.Incontrast,aone-pipeprimary/secondarysystem loses temperature as heat is ex-tractedbysubsystemsarounditsperimeter.
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
Partnumber550-100-110/0411 57
gas-fired water boiler — Application Guides
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• PipetheindirectwaterheatertothelastSHADOWboiler.TheU-Controlon the lastSHADOWboiler is set to immediatelyswitch to DHW heating on call from the DHW aquastat. SetsystemtypetoDHW-DIRECT.
BOILER• Ultraboilerpipingmustbeprimary/secondaryasshown,with
theboilerpipedinasecondaryloopandtheDHWpipedtothelastSHADOWboiler.
• Seeboilermanualforsizing.• Circulatorshippedloosewithboiler.
Wiring• Connectfieldwiringasshownonpage56.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• Provide all piping and controls needed for each subsystemconnected.
U-Control setting notes• See the tables on pages 58 and 59 for required and optional
settings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.
Themodulatingsignal fromU-ControlP16ofoneboilertoP15ofthenextispolaritysensitive.
Connectwires+to+and–to–asshown.Thatis,P16–1goestoP15–6andP16–2goestoP15–5.
SettheADD’LHEATDEMANDTIMEto5min-utes,orasdesired.Thisisthetimedelaybeforethemodulatingsignalwillbepassedonto thenextboilerinseriesforadditionalspaceheatingcapacity.
DO NOTsettheLEADboilerPRIORITY1SYS-TEMTYPEtoCustomorDHW.ShadowboilerssettoTYPE4willnotworkwiththesesettings.
LAST SHADOW boiler only—SelectDHWDIRECT for the DHW BOILER PRIORITY 2.ThisinformsthecontrolthattheDHWtankisdirectlyconnectedtotheboiler
InstallsystemSUPPLYandRETURNsensorsand OUTDOOR sensor for every boiler, asshown in the piping and wiring diagramsforthisapplication.ShadowboilerswillonlystartandstopbasedontheirMODULATEONorOFFDIFF.Thisreducesthe likelihoodofexcessivecyclingasheatdemandchanges.
Set the last SHADOW boiler MAX ON TIME to 0 minutes. The boiler will immediatelyswitchtoDHWmodeoncallfromtheDHWaquastat.
Application 20 — Multiple boilers (continued)
Multiple Ultra boilers | Multiple loads on SECONDARY loops | DHW (Direct-connected)
LEAD Boiler U-Control settings
xxx
D
— value must be set (or verified) as listed
— default acceptable; change only if desired
See SHADOW boiler settings on page 59
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE Type 3 – LEAD
ADD’L HEAT DEMAND TIME 5 minutes
SYSTEM SETTINGS
BOILER PRIORITY 1
Select system type most rep-resentative of subsystems con-nected
SYSTEM TYPE Select from list Select
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
180 FD (70f) or as req’DD (0f) or as req’DD or as requireD
DD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
58
Application 20 — Multiple boilers (continued)
Multiple Ultra boilers | Multiple loads on SECONDARY loops | DHW (Direct-connected)
DHW SHADOW Boiler U-Control settings
xxx
D
— value must be set (or verified) as listed
— default acceptable; change only if desired
See LEAD boiler settings on page 58
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP opt
ADjUST OUTDOOR opt
ADD’L HEAT DEMAND TYPE Type 4 – SHADOW
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
Space heating
SYSTEM TYPE Select from list SAME AS LEAD
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
SAME AS LEADSAME AS LEADSAME AS LEADSAME AS LEAD
10 F5 F
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
0 minutes
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
DHW
SYSTEM TYPE Select from list DHW–DIRECT
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
D60 minuntes
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Non-DHW SHADOW Boiler U-Control settings
xxx
D
— value must be set (or verified) as listed
— default acceptable; change only if desired
See LEAD boiler settings on page 58
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP opt
ADjUST OUTDOOR opt
ADD’L HEAT DEMAND TYPE Type 4 – SHADOW
ADD’L HEAT DEMAND TIME 5 minutes
SYSTEM SETTINGS
BOILER PRIORITY 1
Space heating
SYSTEM TYPE Select from list SAME AS LEAD
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
SAME AS LEADSAME AS LEADSAME AS LEADSAME AS LEAD
5 F10 F
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Partnumber550-100-110/0411 59
gas-fired water boiler — Application Guides
Application 21 — Multiple boilersBASE LOADING with ULTRA boilers | DHW (Direct connected)
Purpose• Onanexistingornewinstallation,providebase loadingwith
high-efficiencyUltraboilers.• Usealargeboileronlyasneeded,suchasduringhighheat
demandperiods(lowoutdoortemperatureperiods).• TheWMR-21relay,SPSTrelayandoutdoortemperature
controlshowninthisapplicationautomaticallyenableordisablethelargeboiler—atoutdoortemperaturesabovetheoutdoortemperaturecontrolsetting,thelargeboilerisnotenabled.Atcolderoutdoortemperatures,whentheloadishigher,thelargeboilerisenabled.
• AnalternatemethodistouseaMOD-CON-CNCcontrol-ler.Thisdeviceprovidesautomaticswitchingofbaseloadboilers based on outdoor temperature and also providesboilersequencing.
• Therecommendedtemperaturesettingsinthisapplicationarebased on typical baseboard, radiator or fan coil systems. Forradiant systems or any other lower temperature installation,settheU-Controlandsystemaquastattemperaturesasneeded.
DO NOT set the system aquastat (item 46) higher than 180°F.TheUltraboilerswilllockoutiftemperatureexceeds190°F.SettheUltraLEADboilerPriority1MAXSUPPLYtemperature20°Flowerthanthesystemaquastatsetting.
• DHWispipeddirectlytooneoftheUltrabaseloadboilers.IfadditionalDHWcapacityisrequired,pipetheDHWunitsinasecondaryloopasinApplication19—Multipleboilers,page52.DHWpriority—spaceheatingisdisabledontheDHWboilerduringcallforheatfromthewaterheater.
* =Supplied by installer
1 DHWcirculator*
2 UltraBOILERcirculators(shippedloosewithboiler)
3 System circulator (typical in-line pumpshown)*
4 120VACpowersupply,15-ampminimumrat-ing
5 U-Control
7 Supplytemperaturesensor—straptosupplyline
8 Returntemperaturesensor—straptoreturnline
9 DHWtankaquastat*
10 Outdoor temperature sensor (supplied withboiler;installifU-Controlwillbesetforout-doorresetoperation)
11 Lowwatercutoff(ifused)*
13 Relay,120VACcoil,SPST*
15 Weil-McLainWMR-21relay*
21 Ultraboilers
22 Indirectwaterheater*
23 Flow/checkvalves*
24 Airseparatorwithautomaticairvent*
25 Diaphragm-typeexpansiontank*
26 Fresh water supply — install per applicablecodes*
27 Isolationvalves*
28 Purge/drainvalves*
29 Secondarypipingconnectionforboilerloop*
30 Boilerreliefvalve(installperboilermanual)
40 Weil-McLain Easy-Fit headers (or field-fabricatedequivalent)forconnectionofUltraboilerpipingtoprimaryloop*
45 Largeboiler,eitherexistingornewinstallation— typically a commercial-sized forced draftboileronexistinginstallations—canbeoneor more forced draft boilers or one or moreUltra Commercial boilers for new or boilerreplacementinstallations
46 Systemaquastat—See NOTICE at left
47 Outdoor temperature control (HoneywellT6031Aorequivalent)—breakonrise—toshut off large boiler(s) above the outdoorcontrol setpoint (typically between 40°F and50°F)
46 System thermostat or system heat demandcontact
continued
LEGEND
Partnumber550-100-110/0411
gas-fired water boiler — Application Guides
60
Recommended sizing• Forbestresultsinheatingresponse,andtoavoidexcessivecyclinginchangeoverbetween
boilers,sizetheUltraboilertotalinputtoatleasttheminimuminputofthelargeboiler.
• IfaddingUltraboilersforbaseloadingwithanexistinglargeboiler,considerreplacingtheforceddraftburnerwithahi-loormodulatingburner.Thiswillprovideaturndowninboilerfiringrateandreducetherecommendedinputforthebaseloadboilers.Itwillalso improve the large boiler’s efficiency since the combustion efficiency will usuallyincreasenoticeablyatlowfire.
Piping overview• Thisexamplecanapplytoanexistinglargeboiler,suchasacommercial-sizedforceddraft
castironsectionalboilerliketheWeil-McLain80or88series.
• Foranewsysteminstallation,youcoulduseoneormoreUltraCommercialboilersforthelargeboiler,withoneormoreUltraResidentialboilersforthebaseloadunits.
MINIMUMBoiler loop pipe size
Ultra-80, 105Ultra-155, 230Ultra-299, 399
1”1¼”1½”
• Thepipingisshownwithaconventionaldirect-connectedsystem.Thepreferredmethodwouldbetopipethelargeboiler(s)onasecondaryloopasshownintheinset,upperright.TheUltraResi-dentialboilersmustbepipedonasecondaryloopasshownabove.
• TheindirectwaterheaterisconnectedtooneoftheUltraboilers,ensuringthatDHWgenerationalwaystakesadvantageoftheUltraboiler’shighefficiency.
• ForeachUltraboiler,strapasupplysensorandreturnsensortothesystempipingasshown.
Partnumber550-100-110/0411 61
gas-fired water boiler — Application Guides
SYSTEM PIPING• Size system circulator for required flow — system circulator
suppliedbyinstaller.• Pipingshowninthisexampleisdirect-connected,andisaccept-
ableforanexistinginstallation,butprimary/secondarypipingispreferred.Forboilerreplacementandnewinstallations,useasecondarycircuitforthelargeboiler(s)asshowninthepipingdiagraminset.
DHW• DHWcirculatormustbeselectedtohandlethepressuredrop
throughtheUltraboiler,waterheaterandpiping—seeboilermanualforrecommendedsizing.DHWcirculatorsuppliedbyinstaller.
• Forsomelargeindirectwaterheaters,therequiredflowratemayrequirepipingthewaterheaterdifferently—seeboilermanualandotherapplicationsinthisguide.
• PipetheindirectwaterheatertothelastSHADOWboiler.TheU-Controlon the lastSHADOWboiler is set to immediatelyswitch to DHW heating on call from the DHW aquastat. SetsystemtypetoDHW-DIRECT.
BOILER• Ultraboilerpipingmustbeprimary/secondaryasshown,with
theboilerpipedinasecondaryloopandtheDHWpipedtothelastSHADOWboiler.
• Seeboilermanualforsizingpiping.
• Circulatorshippedloosewithboiler.
Wiring• Connectfieldwiringasshownonpage60.• For circulators connected to the U-Control, the maximum
circulatorloadis2.2ampseach—ifloadishigher,provideacirculatorrelayorcontactorforcirculatorpower.
• ProvideandinstallaWMR-21relay,aSPSTrelaywith120VACcoilandanoutdoortemperaturecontrol(HoneywellT6031Aorequivalent).Set the outdoor temperature control be-tween 40°F and 50°F for most installations.Mountthesensingbulboutsideusinganoutdoorshield.Locatethebulbawayfromdirectsunlightandinalocationnotsubjecttosnow,iceordebrisaccumulation.
U-Control setting notes• See the tables on pages 62 and 63 for required and optional
settings.• ToseethenavigationsequencetoaccesstheBOILERSETTINGS
andSYSTEMSETTINGSmenus,seepage7.
ThemodulatingsignalfromU-ControlP16ofoneboilertoP15ofthenextispolaritysensitive.
Connectwires+to+and–to–asshown.Thatis,P16–1goestoP15–6andP16–2goestoP15–5.
DO NOT set the LEAD boiler PRIORITY 1SYSTEM TYPE to Custom or DHW DIRECT.ShadowboilerssettoTYPE4willnotworkwiththesesettings.
Install system SUPPLY and RETURN sen-sorsandOUTDOORsensorforeveryboiler.Shadowboilerswill start and stopbasedontheir MODULATE ON or OFF DIFF. Thisreducesthelikelihoodofexcessivecyclingasheatdemandchanges.
Set the ADD’L HEAT DEMAND TIME to5 minutes, or longer if possible. This is thetimedelaybeforethemodulatingsignalwillbepassedontothenextboilerinseries.
Set the last SHADOW boiler Priority 1 MAX ON TIME to 0 minutes.Theboilerwillim-mediatelyswitchtoDHWmodeoncallfromtheDHWaquastat.
Application 21 — Multiple boilers (continued)
BASE LOADING with ULTRA boilers | DHW (Direct connected)
LEAD Boiler U-Control settings
xxx
D
— value must be set (or verified) as listed
— default acceptable; change only if desired
See SHADOW boiler settings on page 59
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP Default (70 °f) or as requireD
ADjUST OUTDOOR Default (0 °f) or as requireD
ADD’L HEAT DEMAND TYPE Type 3 – LEAD
ADD’L HEAT DEMAND TIME 5 minutes
SYSTEM SETTINGS
BOILER PRIORITY 1
Large boiler enabled
Select system type most representa-tive of subsystems connected
SYSTEM TYPE Select from list Select
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
160 F140 f70 f0 fDD
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
15 minutes
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Large boiler NOT enabled
Select system type most representa-tive of subsystems connected
SYSTEM TYPE Select from list Select
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F70 f70 f0 fDD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
15 minutesDDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONON
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
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Application 21 — Multiple boilers (continued)
BASE LOADING with ULTRA boilers | DHW (Direct connected)
DHW SHADOW Boiler U-Control settings
xxx
D
— value must be set (or verified) as listed
— default acceptable; change only if desired
See LEAD boiler settings on page 58
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP opt
ADjUST OUTDOOR opt
ADD’L HEAT DEMAND TYPE Type 4 – SHADOW
ADD’L HEAT DEMAND TIME D
SYSTEM SETTINGS
BOILER PRIORITY 1
Space heating
SYSTEM TYPE Select from list SAME AS LEAD
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
SAME AS LEADSAME AS LEADSAME AS LEADSAME AS LEAD
10 F5 F
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
0 minutes
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
DHW
SYSTEM TYPE Select from list DHW–DIRECT
TEMPERATURES
Max Supply
Max OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F
DDDD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
D60 minuntes
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
ONOFFOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
Non-DHW SHADOW Boiler U-Control settings
xxx
D
— value must be set (or verified) as listed
— default acceptable; change only if desired
See LEAD boiler settings on page 58
BOILER SETTINGS
BOILER MODEL Verify model number is correct
HIGH ALTITUDE Set to YES if high altitude
HIGH LIMIT D
WWSD TEMP opt
ADjUST OUTDOOR opt
ADD’L HEAT DEMAND TYPE Type 4 – SHADOW
ADD’L HEAT DEMAND TIME 5 minutes
SYSTEM SETTINGS
BOILER PRIORITY 1
Space heating
SYSTEM TYPE Select from list SAME AS LEAD
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
190 F70 f70 f0 f5 F
10 F
TIMES
Max On Time
Boost IntervalPrepump Time: Postpump Time:
D
DDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
OFFONOFF
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 2
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMES
Max On TimeMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
BOILER PRIORITY 3
Not used
SYSTEM TYPE Select from list D
TEMPERATURES
Max SupplyMin SupplyMax OD ResetMin OD ResetModulate On DiffModulate Off Diff
DDDDDD
TIMESMin On TimeBoost IntervalPrepump Time: Postpump Time:
DDDD
CIRCULATORSCirculator 1Circulator 2Circulator 3
DDD
MAXIMUM RATE DMINIMUM RATE D
CIRCULATOR EXERCISINGCirculator 1Circulator 2Circulator 3
DDD
FREEZE PROTECT CIRCSCirculator 1Circulator 2Circulator 3
DDD
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gas-fired water boiler — Application Guides
Appendix AOUTDOOR RESET Settings and Troubleshooting
Outdoor reset control settings Outdoorresetcanimprovecomfortandoperatingefficiency,
makingthebestpossibleuseoftheUltraboiler’scondens-ingability.ImproperlysettingoutdoorresetsettingsintheU-Control can result in insufficientheat.FactorydefaultsettingsfortheU-Controlwillworkinmanyinstances,butnotall.Usetheinformationbelowtosetthecontroltomeettheinstallationconditions.
1. Outdoor reset tries to match heat input to the system heat loss.Asoutdoortemperaturerises(heatlossdecreases),theU-Controlreducesthesupplywatertemperaturetothesystem,thusreducingheatinput.
2. Setupdesiredsettingsforeachoftheprioritiesused
3. MIN and MAX SUPPLY temperatures—Foranexplanationof the target temperaturesandassociatedoutdoor temperatures, seeFigure1.
a. MAX OD RESETmeanstheoutdoortemperatureatwhichthetarget temperaturereaches itsmaximumvalue(MAXSUPPLY).IntheexampleofFigure1,thisoccursat0°Foutside(thefactorydefaultsetting).
MAXODRESETshouldequaltheODT(outdoordesigntempera-ture)fortheinstallation’slocation.
b. MAX SUPPLYshouldequaltherequiredsupplywatertempera-tureforthesystematdesignmaximumheatloss(typically180°Fforfinnedtubebaseboardonnewinstallations).
c. MIN OD RESETmeanstheoutdoortemperatureatwhichthetargettemperaturereachesitsminimum(MINSUPPLY).IntheexampleofFigure1,thisoccursat70°F(thefactorydefault).
d. MIN SUPPLYshouldequalthedesiredminimumsupplywatertemperatureforthesystem.Thefactorydefaultis130°F.Thiscouldbesetaslowas70°F,whichwouldsupply“zeroheat”whenoutdoortemperatureis70°F,becausesupplywatertempwouldequalroomtemp.SeeexamplesinFigure1.
e. Note that the reset lines are curved. The shape of this curve ismatched(characterized)totheresponseofthesystemtypechosen.Thisensuresthemosteffectiveresetoperation.
4. Modulate on differential—Thetemperaturemustdropthismanydegreesbelowtargettemperaturefortheboilertocomeon.
5. Modulate off differential —While the boiler is firing, as thetemperature increasesabovethetarget temperature, theboilerfiringrateisreduced.Atthismanydegreesabovethetargettemperature,theboilershutsdown.
6. Boost interval—ThisadjustmentislocatedintheTIMESmenus.Theboosttimerstartsonacallforheat.Iftheboostintervaltimepassesandthecallforheatisstillon,theU-Control“boosts”thesupplywatertemperaturesetpointby10°F.Thisoccursagainifanotherboostintervalelapses.BoostwillcontinueuntilthesetpointreachestheMAXSUPPLYsetting.Thepurposeofboostistocompensateforchangesindemandnotaddressedbytheresetcurve.Typically,setboostto30minutes.Thefactorydefault is“OFF”—that is,boost isnotenabledwithdefaultsettings.
Troubleshooting insufficient heat calls1. Insufficientheatcanoccurifthesupplywatertemperaturetotheheating
unitsisnothotenough.Possiblyreasonsare:
a. Thefactorydefaultsettingsforoutdoorresetarenotagoodmatchtothesystemneeds.
b. Thebaseboardmayhavebeensizedforhigherwatersupplytem-perature. Older systems were often sized for baseboard supplytemperatureof210°F(averagewatertemperatureof200°F).
c. SeeadditionalpotentialcausesintheNOTICEbelow.
2. Onewaytocheckwhetherwatersupplytemperatureistheproblemistomeasurethewatertemperaturegoingtotheheatingunits.Thenseeifthisisreasonableby:
a. Lookuptheheatingunitoutputratingat190°F.
b. Lookuptheheatingunitoutputratingatthewatertemperatureyoumeasured.
c. Measurethecurrentoutsidetemperature.
d. LookuptheODT(outdoordesigntemperature)forthearea.
e. Atthisoutsidetemperature,theheatingunitoutputshouldbeaboutequalto:
Output=(outputat190°F)x(70–outsidetemp)/(70–ODT)
3. Makesuretheoutdoorsensorisproperlyshieldedsoitisn’theatingupduetosolargain.Toverify,measureoutsidetemperatureandcomparetothevalueshownontheU-Controldisplay.Ifthesensorisshieldedandstillreadingincorrectly,changetheADJUSTOUTDOORsettingintheBoilerSettingsmenu.
4. Intheeventofaninsufficientheatcall,makethefollowingadjustmentstoensuretheU-Controlisdeliveringthebestpossibleperformancefortheapplication.
a. MAX OD RESET—Set toavalueofODT(outdoordesigntempforthelocation)PLUS15°F.(Example:foranODTof10°F,setto10°+15°=25°F.)
b. MAX SUPPLY—Setto190°F.(Exception:Forradiantsystems,settodesignoperatingtemperatureatmaximumheatload.)
c. MIN OD RESET—Setto70°F(factorydefault).
d. MIN SUPPLY — Set to 70°F (increase value to 130°F if theproblempersists).
e. BOOST INTERVAL—Setto30minutes.
Iftheinsufficientheatissuepersistsaftermakingtheadjust-mentsrecommendedhere,lookforotherpossiblecauses,suchas:
Iftheproblemonlyoccursinsomeareasofthehome,theheatingunitstheremaybeundersized,ortheproblemareamay not have control over boiler operation.Additionalheatingunitsorazoningchangemaycorrecttheproblem.
Otherissues,suchasairinthesystem,poorflowdistributionortoolittleflowcanalsocauseinsufficientheat.
Figure 1 Typical outdoor reset curves
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Appendix BBOILER SETTINGS menu detail
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Appendix CSYSTEM SETTINGS menu detail
= SELECT button(press to select ahighlighted entry andmove to next screen)
Use and keys tohighlight the desireditem on a screen.
Note 2 Use and keys tochange the values on thesescreens. Use key to save thevalue.
Note 1 The menus for priority 1,2 and 3 are the same. Dependingon System Type chosen, defaultvalues will vary and some menuitems may be omitted.
SYSTEM SETTINGS
CHANGE SETTINGPREVIOUS ENTER
BOILER PRIORITY 1
BOILER PRIORITY 2
BOILER PRIORITY 3
CIRCULATOR EXERCISING
FREEZE PROTECT CIRCS
FREEZE PROTECTIONCIRCULATORS
CHANGE SETTINGPREVIOUS ENTER
CIRCULATOR 1: ON
CIRCULATOR 2: ON
CIRCULATOR 3: ON
CIRCULATOR EXERCISING
CHANGE SETTINGPREVIOUS ENTER
CIRCULATOR 1: ON
CIRCULATOR 2: ON
CIRCULATOR 3: ON
BOILER PRIORITY X
CHANGE SETTINGPREVIOUS ENTER
SYSTEM TYPE: OFF
TEMPERATURES
TIMES
CIRCULATORS
MAXIMUM RATE: 94%
MINIMUM RATE: 33%
BSX SYSTEM SETTING
CHANGE SETTINGPREVIOUS ENTER
OFFFAN COILFINNED TUBE BASEBOARDCAST IRON BASEBOARDCAST IRON RADIATORRADIANT — SLAB ON GRADERADIANT — THIN SLABRADIANT — BELOW FLOORRADIANT — ABOVE FLOORCUSTOMDHW – DIRECTDHW – SYSTEM
PRIORITY XDESIGN TEMPERATURES
CHANGE SETTINGPREVIOUS ENTER
MAX SUPPLY: ### °FMIN SUPPLY: ### °F
MAX OUTDOOR: ### °FMIN OUTDOOR: ### °F
MODULATE ON DIFF: ###°FMODULATE OFF DIFF:###°F
PRIORITY X TIMES
CHANGE SETTINGPREVIOUS ENTER
MAX ON TIME: ### MIN
MIN ON TIME: ### MIN
BOOST INTERVAL:### MIN
PRE PUMP TIME: ### SEC
POST PUMP TIME:### SEC
BOILER PRIORITY XCIRCULATOR SETTINGS
CHANGE SETTINGPREVIOUS ENTER
CIRCULATOR 1: ###
CIRCULATOR 2: ###
CIRCULATOR 3: ###
PRIORITY X MAX RATE
CHANGE SETTINGPREVIOUS ENTER
XX
PRIORITY X MIN RATE
CHANGE SETTINGPREVIOUS ENTER
XX
CIRCULATOR EXERCISINGCIRCULATOR X
CHANGE SETTINGPREVIOUS ENTER
ON
OFF
FREEZE PROTECTIONCIRCULATOR X
CHANGE SETTINGPREVIOUS ENTER
ON
OFF
Note 1
XXXXXXXXXXXXXXXXX
CHANGE SETTINGPREVIOUS ENTER
XX°
XXXXXXXXXXXXXXXXX
XXXXXXXXXXX
CHANGE SETTINGPREVIOUS ENTER
XX
Note 3
Note 3 Screen headings andvalue units (degrees, minutes,seconds, etc.) will depend onitem selected.
Note 2
Note 2 Note 2
BOILER PRIORITY XCIRCULATOR X
CHANGE SETTINGPREVIOUS ENTER
ON
OFF
Note 2
Note 3
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