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Weil-McLain ULTRA Ultra-105 Service Manual Download Page 16

16

Part number 550-100-029/0810

 

GAS

-

FIRED

 

WATER

 

BOILER

 

SERIES

  1 & 2

 — 

Control supplement & Service guide

Operating information 

(continued)

  Instructions in this supplement are based 

on factory default parameter settings.

  Ultra display Standby mode — key functions & display

&IGURE

 

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Summary of Contents for ULTRA Ultra-105

Page 1: ...s 4ROUBLESHOOTING s 3ERVICE This document is a supplement to the Ultra Boiler Manual and must only be used by a quali ed heating installer service technician Read all instructions including the Ultra...

Page 2: ...0LEASE READ BEFORE PROCEEDING 3 AZARD DElNITIONS 3 IELD WIRING 4 3TARTUP 6 PERATING INFORMATION 9 4ROUBLESHOOTING 22 OILER MAINTENANCE PROCEDURE 33 OMBUSTION TESTING AND ADJUSTMENT 38 VERVIEW OF 5LTRA...

Page 3: ...This document is for use only by a quali ed heating installer service technician 5SER Have this boiler serviced inspected by a quali ed service technician at least annually Refer to User s Information...

Page 4: ...n in Figure 3 and the boiler wiring diagram 2 Route all low voltage wires through grommeted jacket opening to right of low voltage terminal strip as shown in Figure 1 Thermostat 1 Connect Figure 3 pag...

Page 5: ...0 029 0810 GAS FIRED WATER BOILER SERIES 1 2 Control supplement Service guide Field wiring continued IGURE Line voltage eld wiring connections service switch provided by installer IGURE Low voltage el...

Page 6: ...repurge Blower speed will increase to ignition speed The blower will run in prepurge for 10 seconds Startup continued from Ultra Boiler Manual Start the boiler only after completing all instructions i...

Page 7: ...urge for 10 seconds 2XXX ignition After prepurge the control module opens the gas valve and starts ignition spark If burner ame proves within 4 5 seconds burner con a tinues to re Burner will re at st...

Page 8: ...n above This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 2 Set room thermostat s to lowest setting Verify external manual...

Page 9: ...re exceeds target temperature plus OFF differential or 190 F plus OFF differential whichever is lower high limit action occurs The control module shuts the burner off DHW operation if used The boiler...

Page 10: ...ge terminal strip terminals 3 and 4 When the DHW aquastat calls for heat the module shuts down the boiler circulator activates the DHW circulator and immediately sets target outlet water temperature t...

Page 11: ...11 Part number 550 100 029 0810 GAS FIRED WATER BOILER SERIES 1 2 Control supplement Service guide Schematic wiring diagram Ultra 80 through Ultra 230 IGURE Operating information...

Page 12: ...12 Part number 550 100 029 0810 GAS FIRED WATER BOILER SERIES 1 2 Control supplement Service guide Ladder wiring diagram Ultra 80 through Ultra 230 IGURE Operating information continued...

Page 13: ...ATER BOILER SERIES 1 2 Control supplement Service guide Operating information continued Schematic wiring diagram Ultra 310 IGURE The wire colors shown for the transformer in this wiring diagram supers...

Page 14: ...14 Part number 550 100 029 0810 GAS FIRED WATER BOILER SERIES 1 2 Control supplement Service guide Ladder wiring diagram Ultra 310 IGURE Operating information continued...

Page 15: ...IES 1 2 Control supplement Service guide Operating information continued Ultra display overview IGURE The data port is for use only when connecting a PC to the control using the optional Advance Param...

Page 16: ...ing information continued Instructions in this supplement are based on factory default parameter settings Ultra display Standby mode key functions display IGURE 7HERE TWO KEYS ARE SHOWN PRESSED AT THE...

Page 17: ...S FIRED WATER BOILER SERIES 1 2 Control supplement Service guide Operating information continued Instructions in this supplement are based on factory default parameter settings Ultra display Standby m...

Page 18: ...TER BOILER SERIES 1 2 Control supplement Service guide Operating information continued Instructions in this supplement are based on factory default parameter settings Ultra display Parameter mode also...

Page 19: ...ump This could result in a hazard ous condition it would cause con stant circulation between the boiler and the DHW heater DHW ON 1 DHW OFF pump constant 2 DHW ON pump constant 3 3 CH System CH OFF 0...

Page 20: ...29 0810 GAS FIRED WATER BOILER SERIES 1 2 Control supplement Service guide Operating information continued Instructions in this supplement are based on factory default parameter settings Ultra display...

Page 21: ...ER SERIES 1 2 Control supplement Service guide Operating information continued Instructions in this supplement are based on factory default parameter settings Ultra display Hard Lockout mode see IGURE...

Page 22: ...p or s with boiler on Minimum 5 w c with gas owing verify dur s ing boiler startup with boiler at high re Always check control module fuses ALWAYS check control module fuses before replacing control m...

Page 23: ...tus temperature if connected 22 if not 6 Troubleshooting continued Checking temperature sensors The boiler temperature sensors ue outdoor return water and supply 1 water are all resistance type device...

Page 24: ...ersists obtain a maintenance kit for the boiler page 33 and follow the maintenance procedure beginning on page 33 to remove and service the burner and components Display ashes 9 then b Last two digits...

Page 25: ...hen press Store s Display will blink when setting is accepted and stored s If problem persists replace the control module Is blower running on low 4 From Standby mode press Mode twice and display will...

Page 26: ...loose connector on boiler outlet sensor Tighten connector 8 Possible bad boiler supply outlet sensor 19 Return water temperature higher than 203 F burner off until return water temp drops below 203 F...

Page 27: ...20 times then hard lockout occurs 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 ow 3 Inspect an...

Page 28: ...mage could occur 02 Ignition failed through 5 attempts SPARK OCCURS 1 Check ignition electrode cable electrode connector spade connection at MCBA and other connections Inspect ignition electrode cable...

Page 29: ...clean ignition electrode per Ultra Boiler Manual Clean white oxides if necessary Replace ignition electrode if in poor condition or cannot be cleaned 3 Inspect and clean burner if necessary perform t...

Page 30: ...eplace display and display ribbon cable 2 Replace control module 06 Internal Control Failure 1 Reset control and retry If problem persists replace control module 07 Gas valve relay error 1 Gas valve w...

Page 31: ...reventing proper ow Inspect and verify system piping and components Verify piping agrees with boiler manual recommendations Verify proper circulator s operation and direction Possible loose connector...

Page 32: ...dition s Replace low voltage wiring harness if problem persists s Replace control module if harness replacement doesn t resolve s 37 Return water temperature sensor open circuit 1 Inspect return water...

Page 33: ...must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room This is particularly important if the boiler is located in the same room as other appliances Fai...

Page 34: ...silencer by separating it from the air adapter on the blower inlet s Disconnect the gas valve plug blower power supply plug and blower control connector s Release the exchanger cover plate by removing...

Page 35: ...arm water If further cleaning is necessary use the Heat ex s changer cleaning tool see illustration at right or a piece of 20 gauge or lighter sheet metal wide by about 18 inches long to loosen deposi...

Page 36: ...ne s 2ECONNECT WIRING s GAS VALVE ELECTRICAL PLUG s TWO ELECTRICAL OLEX PLUGS FROM THE BLOWER ASSEMBLY s s IGNITION CABLE s GROUND WIRE Perform a soap suds leak test on all interior gas piping after s...

Page 37: ...l supplement Service guide IGURE Burner access and assembly you must use the Maintenance Kit listed on page 33 IGURE Gradually tighten the nuts repeating the sequence shown below until the torque reac...

Page 38: ...TEST INSTRUMENTS DO NOT PROCEED WITHOUT COMBUSTION TEST EQUIPMENT The combustion testing and adjustment procedures on this and the following pages are intended only for a quali ed technician using co...

Page 39: ...ge 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 sc...

Page 40: ...e rst digit of the display means the boiler will operate 5 at high re when the blower speed reaches maximum After the boiler has had time to stabilize take a CO 6 2 reading If the CO a 2 is HIGH turn...

Page 41: ...oor reset High altitude installations 1 Minimum fan speed parameter 17 and ignition fan speed param eter 9 MUST be changed for operation at altitudes over 5 500 feet 2 See the High Altitude Kit instru...

Page 42: ...P XX is displayed The XX represents the parameter that will be changed The parameter s value will then be displayed 9 Use the or buttons to adjust to the desired value 10 Press the button Steps 8 thro...

Page 43: ...fanspeed 27 00 35 00 23 00 32 00 20 CH postpump time 0 0 0 0 21 DHW postpump time 03 03 03 03 22 CH modulation hysteresis on 8 8 8 8 23 CH modulation hysteresis off 4 4 4 4 24 DHW modulation hysteresi...

Page 44: ...Make sure to set parameters 4 and 6 so the outlet water temperature is at design water temperature when outside temperature drops to the ODT outdoor design temperature or lower Boiler setpoint tempera...

Page 45: ...D WATER BOILER SERIES 1 2 Control supplement Service guide Outdoor reset curve and control module parameters IGURE Typical reset curves IGURE Parameter explanations continued See Figure 25 page 42 for...

Page 46: ...d supply water too hot for low temperature systems such as slab type radiant heating On hybrid systems with nned tube radiation and radiant slab provide additional low temperature protection for the r...

Page 47: ...iler display Ultra 310 1400 to 5800 rpm 14 to 58 on boiler s display Boiler display shows fan speed in 100 s of rpm s A value of 48 would mean a speed of 100 x 48 or 4800 rpm 2 Factory default see Fig...

Page 48: ...IGH ALTITUDE applications 3 Acceptable range up to 5 500 feet ONLY Ultra 80 to 230 s TO RPM 13 to 52 on boiler display Ultra 310 s TO RPM 14 to 58 on boiler dis play Boiler display shows fan speed in...

Page 49: ...setpoint temperature for the boiler to turn off 4 See Figure 31 for an explanation of the ON and OFF differentials of the Ultra control module Note that the differentials are greater when a heat call...

Page 50: ...E IN MODE IF PARAMETER IS SET TO h v s 3ELECT h v TO CYCLE THE BOILER CIRCULATOR ON CENTRAL HEATING CALLS FOR HEAT 7EIL C AIN DOES NOT RECOMMEND SETTING THIS PARAMETER 6 5 TO EITHER h v OR h v CONTINU...

Page 51: ...TINUES THE SETPOINT IS INCREASED ANOTHER NEVER EXCEEDING 0ARAMETER 0ARAMETER HYSTERESIS OFF s 4O DEACTIVATE BOOSTER OPERATION SET THIS PARAMETER TO P 1 1 After 2 to 3 seconds LANK LANK Setting 12 T pa...

Page 52: ...E BOILER IS USED AT HIGH ALTITUDE PER THE HIGH ALTITUDE INSTRUCTIONS IGH ALTITUDE CONTROL MODULES ARE FACTORY SET WITH THE CORRECT VALUE s NCREASING FAN SPEED INCREASES BOILER INPUT DECREASING FAN SPE...

Page 53: ...TER MUST RISE ABOVE SETPOINT TEMPERATURE TO TURN THE BOILER OFF S OUTLET TEMPERATURE INCREASES THE CONTROL MODULE REDUCES BOILER INPUT F TEMPERATURE CONTINUES TO RISE WITH BOILER AT MINIMUM INPUT THE...

Page 54: ...ING TIME BEFORE STARTING P 3 0 After 2 to 3 seconds LANK LANK Setting 31 T1 T2 difference for modulating back 9 to 72 Initial reading s F THE DIFFERENCE BETWEEN BOILER OUTLET WATER TEMPERATURE 4 AND R...

Page 55: ...TERMINED BY POTENTIOMETER s 8 ND CIRCUIT AS MASTER 4SET ALSO BY POTMETER ACTIVE DURING 7 ND HEATING CIRCUIT AS SLAVE DURING 7 WITH SETPOINT TEMPERATURE DETERMINED BY POTENTIOMETER Second digit CH type...

Page 56: ...3TORAGE TANK WITH SENSOR NOT CURRENTLY SUPPORTED s 3 STORAGE TANK WITHOUT 4 DO NOT CHANGE 3TORAGE TANK WITH AQUASTAT s 4 INSTANT WATER HEATER WITH 4 ANTI CONDENSING DO NOT SELECT NSTANTANEOUS WATER HE...

Page 57: ...uit 50 to 176 Initial reading s 4HIS FUNCTION IS NOT CURRENTLY SUPPORTED s 3ETS MAXIMUM TARGET BOILER TEMPERATURE DURING CALL FOR HEAT FROM ND CIRCUIT SAME FUNCTION AS 4 TOP FOR lRST CIRCUIT P 3 9 Aft...

Page 58: ...2 RECOMMENDED SETTING OILER CIRCULATOR NORMAL OPERATION 7 CIRCULATOR SECOND DELAY BEFORE STARTING s 3 NOT RECOMMENDED OILER CIRCULATOR OFF ON CALL FOR HEAT 7 CIRCULATOR SECOND DELAY BEFORE STARTING S...

Page 59: ...59 Part number 550 100 029 0810 GAS FIRED WATER BOILER SERIES 1 2 Control supplement Service guide NOTES...

Page 60: ...inued 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 d...

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