Troubleshooting - Weil-McLain Ultra 3 series User Manual

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gas fired water boiler

Troubleshooting

VERIFY PROPER OPERATION AFTER SERVICING. VERIFY PROPER OPERATION AFTER SERVICING.
Before servicing and making connections . . .
ALWAYS TURN POWER OFF TO THE BOILER TO
PREVENT ELECTRICAL SURGES, WHICH CAN
DAMAGE BOILER COMPONENTS.
ELECTRICAL SHOCK HAZARD
OFF switch does not turn off all power to the boiler.
TURN OFF ALL POWER TO THE BOILER WHEN
SERVICING
the switch is off.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dan-
gerous operation. Always disconnect power to boiler
before servicing. Failure to comply could result in
severe personal injury, death or substantial property
damage.
Never jumper (bypass) any device except for momen-
tary testing. Severe personal injury, death or substan-
tial property damage can result.
Before calling, always complete the " Ultra Gas Data
Collection Sheet
and CP number (located on the lower center support
frame in the center of the boiler).
Figure 109
Tools and kits for troubleshooting
Tools needed for troubleshooting
#2 Phillips Screwdriver
U-Control Screwdriver or 1/16" flat blade screwdriver
1/8" Allen Wrench (Hex Key)
7mm Nut driver (Ultra 155/230/299/399)
11mm Nut driver
4mm Allen wrench (long handled preferred)
Multimeter
Manometer (Incline or digital)
Combustion analyzer (Digital preferred)
Contact thermometer
383-500-605 Maintenance Kit (80 and 105)
383-500-620 Maintenance Kit (155/230/299/399)
Part number 550-100-090/0809
— Boiler Manual
— The boiler ON/
. Internal wiring is still powered when
" (page 108). Record the boiler size
Purpose
Remove 4 screws to remove the top front cover
Used for wiring on terminal blocks for the U-Control (comes with boiler)
To add orifice to change from natural to propane
To change the burner (#2 Phillips Screwdriver for the 80 and 105)
To remover the front cover plate on the burner
To remove the blower assembly from the heat exchanger
To take measurement readings on sensors and electrical components
To measure the gas pressure coming to the boiler
For combustion testing
For checking surface temperatures of heat exchanger and pipes
This kit should be on hand when performing annual maintenance in the
event replacement is required
This kit should be on hand when performing annual maintenance in the
event replacement is required
Reinstall boiler jacket front door
Reinstall 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. This is particularly impor-
tant if the boiler is located in the same
room as other appliances. Failure to keep
the door securely fastened could result in
severe personal injury or death.
Before troubleshooting:
1. See Figure 109 for tools and kits recommended for
troubleshooting Ultra boilers.
2. Check for 120 VAC (minimum 102 VAC to maxi-
mum 132 VAC) to boiler.
3. Check the U-Control's last three lockout histo-
ries.
a. See page 83, "ADVANCED SETUP – OVER-
VIEW."
b. Scroll down to DIAGNOSTICS and press the
enter key.
c. Scroll down to ERRORS and press the enter
key.
d. Record the first four data records and then high-
light the history record you want to view.
e. Follow information at the bottom of the screen
to navigate through your lockout histories.
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