Weil-McLain ULTRA ULTRA-105 Service Manual
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Weil-McLain ULTRA ULTRA-105 Service Manual

Gas-fired water boiler series 1 & 2
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See also: User's Information Manual , Manual
REVISED 2010
Control Supplement & Service Guide
Boiler models: Ultra-80, -105, -155, -230 & -310
Series identification:
Read the boiler rating plate
to determine the series num-
ber. The rating plate is lo-
cated inside the boiler jacket,
on the right rear interior
panel.
Parameters settings:
Instructions in this supple-
ment are based on factory
This document is a supplement to the Ultra Boiler Manual, and must only be
used by a qualified heating installer/service technician. Read all instructions,
including the Ultra Boiler Manual, before installing, starting or servicing the
boiler. Perform all steps in the order given. Failure to comply could result in
severe personal injury, death or substantial property damage.
Gas-fired
Water boiler
Series 1
&
with
Part number 550-100-029/0810
2

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  • Page 1 REVISED 2010 Control Supplement & Service Guide Boiler models: Ultra-80, -105, -155, -230 & -310 Series identification: Read the boiler rating plate to determine the series num- ber. The rating plate is lo- cated inside the boiler jacket, on the right rear interior panel.
  • Page 2 FIRED WATER BOILER SERIES Contents — 1 & 2 Part number 550-100-029/0810...

  • Page 3: Please Read Before Proceeding

    FIRED WATER BOILER SERIES Please read before proceeding — Read all instructions, including this manual, Ultra Boiler Manual, and the Ultra Vent Supplement, before installing. Perform steps in the order given. — This document is for use only by a quali- fied heating installer/service technician.

  • Page 4: Field Wiring

    FIRED WATER BOILER SERIES Field wiring ELECTRICAL SHOCK HAZARD — For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.
  • Page 5 FIRED WATER BOILER SERIES Field wiring (continued) Line voltage field wiring connections (service switch provided by installer) Low voltage field wiring connections Part number 550-100-029/0810 — 1 & 2...
  • Page 6 FIRED WATER BOILER SERIES Startup Startup (continued from Ultra Boiler Manual) Start the boiler only after completing all instructions in the Ultra Boiler Manual. To start the boiler, follow the procedure given in ure 4, page 8. Once the boiler has started and is operating, continue the startup procedure by performing all of the following steps to set and verify operation of the Ultra controls.

  • Page 7: Operating Information

    FIRED WATER BOILER SERIES Startup (continued) [2XXX] (ignition) After prepurge, the control module opens the gas valve and starts ignition spark. If burner flame proves within 4.5 seconds, burner con- tinues to fire. Burner will fire at startup rate — 50% of maximum input —...

  • Page 8: For Your Safety Read Before Operating

    FIRED WATER BOILER SERIES Startup (continued) FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner.
  • Page 9 FIRED WATER BOILER SERIES Operating information Ultra Control Module The Ultra boiler is controlled by a microprocessor electronic con- trol — the Ultra Control Module. The module senses outlet water temperature, return water temperature, flue temperature and outdoor temperature (when outdoor sensor is installed). It uses this information (plus input from external limit and operat- ing controls) to regulate boiler on/off operation and can modulate boiler firing rate to more closely match output to demand.

  • Page 10: Boiler Circulator

    FIRED WATER BOILER SERIES Operating information Outdoor reset operation, if used Setpoint temperature with outdoor reset All Ultra boilers are shipped with an outdoor temperature sensor. When this sensor is installed (low voltage terminal strip termi- nals 1 and 2), the control module regulates target outlet water temperature based on outside temperature.
  • Page 11 — 1 & 2 FIRED WATER BOILER SERIES Operating information Schematic wiring diagram — Ultra-80 through Ultra-230 Part number 550-100-029/0810...
  • Page 12 — 1 & 2 FIRED WATER BOILER SERIES Operating information (continued) Ladder wiring diagram — Ultra-80 through Ultra-230 Part number 550-100-029/0810...
  • Page 13 — 1 & 2 FIRED WATER BOILER SERIES Operating information (continued) Schematic wiring diagram — Ultra-310 Part number 550-100-029/0810...
  • Page 14 — 1 & 2 FIRED WATER BOILER SERIES Operating information (continued) Ladder wiring diagram — Ultra-310 Part number 550-100-029/0810...
  • Page 15 FIRED WATER BOILER SERIES Operating information Ultra display overview The data port is for use only when connecting a PC to the control, using the optional Advance Parameter Kit. Do not connect to this port for any other purpose. Part number 550-100-029/0810 —...
  • Page 16 FIRED WATER BOILER SERIES Operating information Ultra display Standby mode — key functions & display — 1 & 2 Instructions in this supplement are based (continued) on factory default parameter settings. Part number 550-100-029/0810...
  • Page 17 FIRED WATER BOILER SERIES Operating information Ultra display Standby mode — boiler sequence display Part number 550-100-029/0810 — 1 & 2 Instructions in this supplement are based (continued) on factory default parameter settings.
  • Page 18 FIRED WATER BOILER SERIES Operating information Ultra display Parameter mode (also see reference table, Figure 13, page 19) — 1 & 2 Instructions in this supplement are based (continued) on factory default parameter settings. Part number 550-100-029/0810...
  • Page 19 DHW temperature. Parameter 2 determines whether DHW heating is activated. Weil-McLain does not recommend setting this parameter either “2” or “3” (continuous DHW pump). This could result in a hazard- ous condition — it would cause con- stant circulation between the boiler and the DHW heater.
  • Page 20 FIRED WATER BOILER SERIES Operating information Ultra display Information mode — 1 & 2 Instructions in this supplement are based (continued) on factory default parameter settings. Part number 550-100-029/0810...
  • Page 21 FIRED WATER BOILER SERIES Operating information Ultra display Hard Lockout mode (see Figure 18, page 28 for further information) Part number 550-100-029/0810 — 1 & 2 Instructions in this supplement are based (continued) on factory default parameter settings.

  • Page 22: Troubleshooting

    FIRED WATER BOILER SERIES Troubleshooting VERIFY PROPER OPERATION AFTER SERVICING (see Ultra Boiler Manual for procedures) Re-install BOILER JACKET FRONT DOOR AFTER SERVICING Re-install boiler jacket front door after servicing. The boiler front door must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room.
  • Page 23 FIRED WATER BOILER SERIES Troubleshooting Checking temperature sensors The boiler temperature sensors (flue, outdoor, return water and supply water) are all resistance-type devices. The table at right shows the correct value for the sensor at various temperatures. Use the resistance values at 32°F, 60°F, 70°F and 212°F to measure the sensor resistance at known temperatures (ice point, room temperature and sea level boiling point).
  • Page 24 FIRED WATER BOILER SERIES Troubleshooting Troubleshooting procedures Boiler not firing and: Check for: Display first digit shows a This is normal operation. number from 1 to 8. Last digits show 2 or 3-digit number (boiler outlet water temperature). Display first digit shows Boiler water temperature may the number 6;...
  • Page 25 FIRED WATER BOILER SERIES Troubleshooting Troubleshooting procedures (continued) Boiler not firing and: Check for: Display first digit shows Are room thermostat and DHW 0 and last digits show 2 aquastat satisfied? or 3-digit number (boiler Is room thermostat or DHW outlet water temperature).

  • Page 26: Soft Lockout

    FIRED WATER BOILER SERIES Troubleshooting Troubleshooting procedures — when display shows soft lockout code SOFT LOCKOUT Code Reason for soft lockout High limit operation — burner off until outlet water temp drops below 203 °F minus the ON differential Return water temperature higher than 203 °F.
  • Page 27 FIRED WATER BOILER SERIES Troubleshooting Troubleshooting procedures — when display shows soft lockout code (continued) SOFT LOCKOUT Outlet water temp rose too quickly — burner off for 10 minute wait (burner recycles, increasing wait 1 minute each attempt, to a max of 15 minutes) External limit open on limit wired in soft lockout circuit (auto reset).

  • Page 28: Hard Lockout Condition

    FIRED WATER BOILER SERIES Troubleshooting Troubleshooting procedures — when display shows hard lockout code HARD LOCKOUT condition Code Reason for soft lockout Flame detected on startup Ignition failed through 5 attempts: Ignition failed through 5 attempts: — 1 & 2 (continued) [Display flashes first digit, “E”...
  • Page 29 FIRED WATER BOILER SERIES Troubleshooting Troubleshooting procedures — when display shows hard lockout code (continued) HARD LOCKOUT condition Ignition failed through 5 attempts: Ignition failed through 5 attempts: ( less than 4 vdc between low voltage terminal strip terminal 9 and ground): Ignition failure or gas valve electrical problem Part number 550-100-029/0810...
  • Page 30 This can occur due to power failure, brown-out or poor electrical input from a back- up generator. To reduce shutdowns due to poor power conditions, install Weil-McLain part number 383-500-021, Time Delay Relay (3 minute incoming power time delay) to give incom- ing power time to stabilize before powering boiler.
  • Page 31 FIRED WATER BOILER SERIES Troubleshooting Troubleshooting procedures — when display shows hard lockout code (continued) HARD LOCKOUT condition Thermal overrun condition – Outlet water temperature above 210 °F. Thermal overrun condition – Return water temperature above 210 °F. Temperature rise > 58°F Blower not running Blower signal not zero when it should be...
  • Page 32 FIRED WATER BOILER SERIES Troubleshooting Troubleshooting procedures — when display shows hard lockout code (continued) HARD LOCKOUT condition Temperature rise across boiler over 58 °F, and occurred 20 times. Outlet water temperature sensor short circuit. Return water temperature sensor short circuit. Outlet water temperature sensor open circuit.
  • Page 33 X100 inhibitor if the need is indicated. — Disconnect all If antifreeze is used, use only antifreeze listed by Weil-McLain as suitable for use with Ultra Gas Boilers. Follow all guidelines provided. A list of approved antifreeze products is available at www.Weil-McLain.com.
  • Page 34 FIRED WATER BOILER SERIES Boiler maintenance procedure Perform ALL of the ( (You must have the correct maintenance kit to proceed. See page 33 for details.) Order Procedure Description Shut down the boiler. Clean or replace the igniter. Remove combustion chamber cover plate, gas valve / venturi and blower Clean the venturi.
  • Page 35 NOTE: Series 1, Ultra-155 or Ultra-230 only — Examine plug seals. If there is evidence of weeping, replace all plugs using Weil-McLain plug kit, part number 383-500-345. If not already removed in the previous step, disconnect the condensate line at the bottom of the heat exchanger.
  • Page 36 FIRED WATER BOILER SERIES Boiler maintenance procedure Perform ALL of the ( (You must have the correct maintenance kit to proceed. See page 33 for details.) Order Procedure Description Re-install the combustion chamber cover plate assembly and igniter. You must have the maintenance kit specified on page 33.
  • Page 37 FIRED WATER BOILER SERIES Boiler maintenance procedure Burner access and assembly (you must use the Maintenance Kit listed on page 33) Gradually tighten the nuts, repeating the sequence shown below until the torque reaches 50 inch-pounds (+/- 10 inch-pounds) Part number 550-100-029/0810 —...
  • Page 38 40 for adjusting the throttle screw on the venturi. If throttle screw adjustment does not correct the problem, then shut down the boiler and contact your local Weil-McLain repre- sentative. Throttle screw adjustment must be done only by a qualified technician, using calibrated test instruments.
  • Page 39 40 for adjusting the throttle screw on the venturi. If throttle screw adjustment does not correct the problem, then shut down the boiler and contact your local Weil-McLain repre- sentative. Throttle screw adjustment must be done only by a qualified technician, using calibrated test instruments.
  • Page 40 Then press and hold the “+” and “-” buttons to return boiler to automatic firing. If results are not acceptable, shut down the boiler. Contact your Weil-McLain representative immediately. You must re-install the flue gas temperature sensor to prevent flue gas spillage into the boiler enclosure. Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 41 FIRED WATER BOILER SERIES Overview of Ultra Control Module parameters Ultra Control Module parameters See information beginning on page 44 for detailed informa- tion on all Ultra control module parameters. Parameter descriptions 1. This section includes explanations of the adjustable parameters (begin- ning on page 44).
  • Page 42 FIRED WATER BOILER SERIES How to set parameters Using the boiler display With the six buttons on the front of the boiler and the proper code the boiler can be both monitored and modified using the digital display (Figure 25). Perform the following steps with the boiler powered and in a standby condition.
  • Page 43 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Default parameter settings — Par. Parameter description T3set DHW DHW System CH System T1 Top CH-mode T1 Foot CH-mode T4 minimum T4 maximum T4 frost protection T4 correction T blocking Booster time...

  • Page 44: Outdoor Reset Operation

    FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter explanations Fixed-temperature operation (outdoor tem- perature sensor not installed) — To operate with constant outlet temperature, set parameter 4 to the required supply water temperature for the system.
  • Page 45 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter explanations Outdoor reset curve and control module parameters Typical reset curves Part number 550-100-029/0810 — 1 & 2 (continued)
  • Page 46 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter explanations Automatic temperature boost 1. If the target temperature happens to be too low for the heating units to supply sufficient heat within ten minutes (default setting), the control “boosts”...
  • Page 47 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter explanations Maximum fan speed 1. Parameters 13 and 15 can be set to limit the maximum boiler firing rate. Boiler firing rate is proportional to the fan speed, so reducing the maximum fan speed reduces maximum input.
  • Page 48 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter explanations Firing rates and corresponding blower speeds (low fire, ignition, and high fire) — Minimum Low fire (Factory default setting) Minimum (over 5,500 feet) Ignition fanspeed (up to 5,500 feet) Ignition (Factory default setting)
  • Page 49 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter explanations Differential (hysteresis) settings DO NOT change the differentials (hyster- esis) for DHW operation (parameters 24 25, 26 and 27). Always use only the factory default settings for these parameters.
  • Page 50 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter reference table Para. Name Range Display position: 68 to 142 104 to 150 DHW System CH System 70 to 192 (see page 44) foot 60 to 140 (see page 44) After 2 to 3 seconds:...
  • Page 51 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter reference table Para. Name Range Display position: maximum 60 to 78 (see page 44) After 2 to 3 seconds: frost -22 to 50 protection After 2 to 3 seconds: correction - 8 to 10...
  • Page 52 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter reference table Para. Name Range Display position: 13 to 52 Minimum fan speed After 2 to 3 seconds: (see page 47) 14 to 58 13 to 52 Ignition fan speed...
  • Page 53 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter reference table Para. Name Range Display position: modulation differential 0 to 18 After 2 to 3 seconds: (see page 49) modulation differential -2 to 54 After 2 to 3 seconds: (see page 49) modulation...
  • Page 54 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter reference table Para. Name Range Display position: 0 to 30 Blocking time After 2 to 3 seconds: 0 to 30 Blocking time After 2 to 3 seconds: DHW to CH T1–T2 difference...
  • Page 55 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter reference table Para. Name Range Display position: 2nd CH 0 to 8 circuit 0 to 6 After 2 to 3 seconds: type Part number 550-100-029/0810 —...
  • Page 56 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter reference table Para. Name Range Display position: 3-Way valve 0 to 2 0 to 9 After 2 to 3 seconds: type Manual fanspeed 0 to 100 After 2 to 3 seconds: —...
  • Page 57 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter reference table Para. Name Range Display position: 1 to 4 PWM-level After 2 to 3 seconds: CH-pump 1 to 4 hold After 2 to 3 seconds: 32 to 176 2nd CH 50 to 176...
  • Page 58 FIRED WATER BOILER SERIES See Figure 25, page 42 for procedure to access Parameter settings. Parameter reference table Para. Name Range Display position: Special 0 to 3 pump CH / DHW Low/Off 0 or 1 After 2 to 3 seconds: cycle —...
  • Page 59 — 1 & 2 FIRED WATER BOILER SERIES NOTES Part number 550-100-029/0810...
  • Page 60 FIRED WATER BOILER SERIES Installation information Boiler model Boiler CP number Boiler location Boiler location (continued) Altitude of location System type (brief description) Is an AM-4 installed? Installer/technician Installer/technician company name Company address Company address (continued) Installation or service date Installation or service date Installation or service date Parameter...

This manual is also suitable for:

Ultra-155Ultra-230Ultra-310Ultra-80

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