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Weil-Mclain Ultra 230 Serie 3 Boiler Specifications
Specification
Value
Notes
DOE Heating Capacity
207,000 Btuh
CSA Input
230,000 Btuh
Ratings are for sea level applications only.
CSA Output
207,000 Btuh
Ratings are for sea level applications only.
Net I=B=R
183,000 Btuh
Based on piping and pickup allowance of 1.15.
Boiler Water Content
1.57 Gallons
AFUE
95.4%
Energy Star Partner; adjusting firing rate affects AFUE.
Vent/Air Pipe Size
3" or 4"
Vent/air pipe length limits for 3" are not as long as for 4". Must be direct-vented, Category IV.
Shipping Weight
246 Pounds
Per boiler.
Operating Weight
192 Pounds
Per boiler, includes water.
Water Flow Rate @ 20°F rise
20.7 GPM
Per boiler.
Water Flow Rate @ 40°F rise
10.4 GPM
Per boiler.
Electrical Service Required
15.0 Amps
Per boiler, includes up to three circulators (max 2.2 amps each).
Weil-Mclain Ultra 230 Serie 3 Boiler Details
The Weil-McLain Ultra 230 Series 3 boiler is engineered with a cast aluminum heat exchanger, renowned for its excellent heat transfer properties and lightweight design. This high-efficiency component is central to the boiler's condensing operation, optimizing energy usage across various heating demands. A crucial aspect of its longevity is the requirement to maintain system water pH between 7.0 and 8.5, and to use approved Sentinel X100 inhibitor and X400 cleaner, as common cleaning agents like TSP are incompatible with aluminum.
This boiler features an advanced blower design coupled with an air inlet silencer, resulting in exceptionally quiet operation. The blower and venturi system work in tandem to precisely mix gas and air before combustion, ensuring efficient and consistent performance. An integrated U-Control Module acts as the brain of the boiler, offering extensive programmability for up to three different heating systems and modulating the firing rate to match specific heating or domestic hot water (DHW) demands.
The U-Control provides a graphic and robust text display for easy monitoring and troubleshooting. It manages up to three circulators, allowing for flexible configuration based on system needs, such as dedicated DHW or multi-zone space heating. Advanced features include integral outdoor reset capabilities with matched curves for various system types, programmable priority assignments for heat inputs, and options for sequencing or parallel modulation in multiple boiler installations using a 0-10 VDC signal generator.
Safety is paramount, with the U-Control incorporating dual temperature sensors for boiler outlet and flue temperature, offering redundant protection against overheating. It also provides integral low water protection by monitoring the heat exchanger temperature. The boiler is shipped with an outdoor sensor, a system supply sensor, and a system return sensor, all crucial for advanced control strategies like outdoor reset and accurate system temperature regulation.
For ease of maintenance, the control panel assembly is designed to swing away, providing convenient access to electrical connections. A line voltage receptacle is also included for powering tools or a condensate pump during service. The boiler's front door is securely sealed, preventing internal air draw and ensuring optimal combustion, especially when other appliances are in the same room. The robust stainless steel burner further enhances durability and modulating firing capability.
Frequently Asked Questions (FAQs)
Can't find the answer you need? Here are some frequently asked questions about the Weil-Mclain Ultra 230 Serie 3 Boiler, and we answer them below.
Can the Weil-McLain Ultra 230 Series 3 Boiler be common vented with other appliances?
No, the Ultra 230 Series 3 boiler requires its own dedicated vent and air piping system. It cannot be common vented with any other appliance due to its specific Category IV venting requirements.
What materials are approved for the vent and air piping for this boiler?
Only PVC Schedule 40, PVC-DWV, CPVC Schedule 40, ABS-DWV Schedule 40 plastic piping (certified to UL S636 where required), or AL29-4C stainless steel piping are approved. Mixing different types of plastic piping is not allowed.
What are the maximum allowable current for the circulators connected to the U-Control module?
Each circulator connected to the U-Control module has a maximum allowable current of 2.2 amps at 120 VAC. For circulators with higher amp ratings, a circulator relay or starter must be installed.
What are the specific water chemistry requirements for the Ultra 230 Series 3 boiler?
The boiler water pH must be maintained between 7.0 and 8.5, hardness should be less than 7 grains, and chlorine concentration must be less than 200 ppm. Softened water should not be used, and Sentinel X100 inhibitor is supplied and recommended.
Can automotive antifreeze be used in the Weil-McLain Ultra 230 Series 3 boiler system?
No, never use automotive or standard glycol antifreeze, even those made for hydronic systems. Only freeze-protection fluids specifically recommended by Weil-McLain for Ultra Gas Boilers should be used, and the system should not exceed 50% antifreeze by volume.
How do I perform a hydrostatic pressure test on the boiler before permanent installation?
The boiler should be filled with fresh water (not softened water) to a test pressure of at least 45 psig, but no higher than 55 psig, and held for 10 minutes. Ensure all air is bled from the system and check for leaks. Refer to page 8 of the manual for detailed steps.
What should I do if the U-Control displays a 'TEMP RISE TOO QUICKLY' error?
This error indicates the water temperature in the heat exchanger is rising faster than 2°F per second. Verify that water piping is installed correctly using primary/secondary connections, ensure proper circulator sizing, and check for correct placement of system sensors. The boiler will automatically reset after a 1-minute delay, but repeated occurrences require troubleshooting.
How often should the boiler be serviced/inspected?
The boiler should be serviced and inspected by a qualified service technician at least annually. A special first-year inspection is recommended no later than 12 months after installation, involving detailed checks of the heat exchanger, burner, and condensate system.
What clearances are required for the Weil-McLain Ultra 230 Series 3 boiler from combustible materials?
Hot water pipes require at least ½” clearance, and the vent pipe requires at least ¼” clearance. Other specific minimum clearances for service access and proximity to other building features are detailed in Figure 1 on page 5 of the manual.
Can the Ultra 230 Series 3 boiler be wall-mounted?
Yes, Ultra boilers can be wall-mounted using an optional Weil-McLain wall-mounting kit, which must be purchased separately. Instructions for wall-mounting are provided on page 46 of the manual, and specific weight limits and wall construction requirements apply.
What should be done if a gas leak is detected during installation or servicing?
If any indication of a gas leak is found (odorant or bubble test), the boiler must be shut down immediately. The leak source must be found using a bubble test and repaired at once. Do not attempt to start the boiler until the leak is corrected.
How does the U-Control module handle low water protection?
The U-Control module provides internal low water protection by using a dual temperature sensor to monitor the heat exchanger's temperature. If the sensor difference exceeds 10°F, the boiler will shut down on automatic reset. External low water cut-offs may still be required by local codes.
What is the purpose of the 'WWSD' setting on the U-Control?
WWSD stands for 'warm weather shutdown'. This setting prevents the boiler from firing if the outside temperature exceeds a specified value, conserving energy during warmer periods. This function requires the outdoor temperature sensor to be installed and does not apply to DHW systems.
How should the condensate trap be maintained?
The condensate trap must be cleaned and refilled with fresh water annually. It is crucial for the trap to remain filled with water at all times of boiler operation to prevent flue gas emission from the condensate drain line. Inspect for blockages and flush thoroughly.
What should I do if the boiler's flue gas temperature is too high?
If the flue gas temperature is more than 54°F higher than the boiler return temperature, the boiler should be shut down, allowed to cool, and then the heat exchanger should be cleaned following the procedure on page 109 of the manual. This indicates potential fouling.