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Part number 550-100-029/0810

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
default parameter settings.

s7IRING

s/PERATION

s4ROUBLESHOOTING

s3ERVICE

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.

with

Control Supplement & Service Guide

Boiler models: Ultra-80, -105, -155, -230 & -310

Gas-ﬁred
Water boiler
Series 1

&

2

REVISED 2010

1
2
3
...
»

Содержание ULTRA Ultra-105

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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