Temperature Rise Across Boiler Over 58 Degrees F, Occurred 20 Times; Outlet Water Temperature Sensor Short Circuit; Return Water Temperature Sensor Open Circuit; Flue Temperature Exceeded 225 Degrees F - Weil-McLain ULTRA ULTRA-105 Service Manual

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GAS FIRED WATER BOILER SERIES
Troubleshooting
Troubleshooting procedures — when display shows hard lockout code (continued)
HARD LOCKOUT condition
30 Temperature rise across boiler over
58 °F, and occurred 20 times.
31 Outlet water temperature sensor
short circuit.
32 Return water temperature sensor
short circuit.
36 Outlet water temperature sensor
open circuit.
37 Return water temperature sensor
open circuit.
44 Internal control failure
52 Flue temperature exceeded 225 °F.
60 Internal control failure
61 Internal control failure
65 Blower signal too low (not enough
driving force)
32
—
1 & 2
(continued)
[Display flashes first digit, "E" and last two digits (code)]
1
Flow problem through boiler — Temperature rise through boiler should be less than
35 °F.
2
Make sure system does not have trapped air preventing proper flow.
3
Inspect and verify system piping and components.
4
Verify piping agrees with boiler manual recommendations.
5
Verify proper circulator(s) operation.
6
Possible loose connector on boiler supply/return sensor(s). Tighten connector.
7
Possible bad supply/return sensor.
Inspect outlet water temperature sensor and wiring. Replace sensor if wiring correct
1
and in good condition. Replace low voltage wiring harness if problem persists. Replace
control module if harness replacement doesn't resolve.
Inspect return water temperature sensor and wiring. Replace sensor if wiring correct
1
and in good condition. Replace low voltage wiring harness if problem persists. Replace
control module if harness replacement doesn't resolve.
1 Inspect outlet water temperature sensor and wiring.
Replace sensor if wiring correct and in good condition.
Replace low voltage wiring harness if problem persists.
Replace control module if harness replacement doesn't resolve.
Inspect return water temperature sensor and wiring.
1
Replace sensor if wiring correct and in good condition.
Replace low voltage wiring harness if problem persists.
Replace control module if harness replacement doesn't resolve.
1 Reset control and retry. If problem persists, replace control module.
1 Verify flue temperature with thermometer.
If actual temperature does not correlate with Information mode #5, replace flue
sensor
2 Heat exchanger may need to be cleaned — perform the boiler complete maintenance
procedures beginning on page 33 of this guide.
Burner problem — verify gas pressure, burner firing rate, combustion. Correct prob-
3
lems.
If combustion is still unacceptable, follow the procedures beginning on page 38 of this
guide.
Reset control and retry. If problem persists, replace control module.
1
1 Reset control and retry. If problem persists, replace control module.
1 Inspect wiring and connections.
If wiring is correct, replace blower assembly.
If blower assembly replacement is unsuccessful, replace control module.
Instructions in this supplement are based
on factory default parameter settings.
Part number 550-100-029/0810