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Weil-McLain ULTRA ULTRA-105 manual

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Table of contents for the manual

  • Page 1

    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. s 7IRING s/PERATION s 4 R OUBLE[...]

  • Page 2

    2 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Contents 0LEASEREADBEFOREPR OCEEDING                 3 (AZARDDElNITIONS  [...]

  • Page 3

    3 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Please r ead befor e pr oceeding When servicing boiler — To avoid electric shock, disconnect electrical supply s before performing maintenance. To avoid severe burns, allow boiler to cool before per- s forming maintenance. F[...]

  • Page 4

    4 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide 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[...]

  • Page 5

    5 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Field wiring (continued)  &IGURE Line voltage field wiring connections (service switch provided b y installer)  &IGURE Low v oltage field wiring connections[...]

  • Page 6

    6 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Star tup Press the “Step” button until the display first digit shows 2. “2.” The last digit must show “1.” If any other number displays, 3. press the “+” or “–” button until “1” shows in the right-hand dig[...]

  • Page 7

    7 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide [ 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- a. tinues to fire. Burner will fire at startup rate — 50% of maximum i[...]

  • Page 8

    8 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Star tup (continued) FOR YOUR SAFETY READ BEFORE OPERA TING OPERA TING INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCE s $ONOTTRYTOLIGHTANYAPPLIANCE s $ONOT TOUCH ANYELECTRIC SWITCH DO?[...]

  • Page 9

    9 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Operating infor mation 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 temperatur[...]

  • Page 10

    10 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Operating infor mation (continued) Outdoor reset operation, if used Setpoint temperature with outdoor r eset All Ultra boilers are shipped with an outdoor temperature sensor. When this sensor is installed (low voltage terminal stri[...]

  • Page 11

    11 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Schematic wiring diagram — Ultra-80 through Ultra-230 &IGURE Operating infor mation[...]

  • Page 12

    12 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Ladder wiring diagram — Ultra-80 through Ultra-230 &IGURE Operating infor mation (continued)[...]

  • Page 13

    13 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Operating infor mation (continued) Schematic wiring diagram — Ultra-310 &IGURE The wire colors shown for the transformer in this wiring diagram supersede those shown on the boiler wiring label.[...]

  • Page 14

    14 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Ladder wiring diagram — Ultra-310 &IGURE Operating infor mation (continued)[...]

  • Page 15

    15 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Operating infor mation (continued) Ultra display overview &IGURE 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 purpo[...]

  • Page 16

    16 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Operating infor mation (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[...]

  • Page 17

    17 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Operating infor mation (continued) Instructions in this supplement are based on factory default parameter settings. Ultra display Standby mode — boiler sequence display &IGURE[...]

  • Page 18

    18 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Operating infor mation (continued) Instructions in this supplement are based on factory default parameter settings. Ultra display Parameter mode (also see refer ence table, &IGURE Figure 13, page 19)[...]

  • Page 19

    19 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Operating infor mation (continued) Instructions in this supplement are based on factory default parameter settings. Parameter Name Range Boiler display Description Details Boiler display Display position 1st 2nd 3rd 4th 1 T3-Set St[...]

  • Page 20

    20 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Operating infor mation (continued) Instructions in this supplement are based on factory default parameter settings. Ultra display Information mode &IGURE[...]

  • Page 21

    21 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Operating infor mation (continued) Instructions in this supplement are based on factory default parameter settings. Ultra display Hard Lockout mode (see &IGURE Figure 18, page 28 for further information) #HECK).&[...]

  • Page 22

    22 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide VERIFY PROPER OPERA TION AFTER SERVICING (see Ultra Boiler Manual for procedur es) T r oubleshooting ,ABEL ALL WIRES prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous opera- tion. [...]

  • Page 23

    23 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide REVIEW OF LAST LOCKOUT CODE MESSAGE T o access parameters, view RPM speed and the last Error Code: The boiler must be in “STBY” mode. 1. Press and hold the STEP button. 2. While holding STEP, press and hold the MODE button. 3. [...]

  • Page 24

    24 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Boiler not firing and: Check for: Corrective actions: Display first digit shows a number from 1 to 8. Last digits show 2 or 3-digit number (boiler outlet water temperature). This is normal operation. 1 Boiler is in normal operati[...]

  • Page 25

    25 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Boiler not firing and: Check for: Corrective actions: Display first digit shows 0 and last digits show 2 or 3-digit number (boiler outlet water temperature). Are r oom thermostat and DHW aquastat satisfied? 1 If yes, then boiler[...]

  • Page 26

    26 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide T r oubleshooting (continued) Instructions in this supplement are based on factory default parameter settings. SOFT LOCKOUT [Display flashes 9, then b in first position; last two digits on steady (code)] Code Reason for soft lock[...]

  • Page 27

    27 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide T r oubleshooting (continued) Instructions in this supplement are based on factory default parameter settings. SOFT LOCKOUT [Display flashes 9, then b in first position; last two digits on steady (code)] 25 Outlet water temp r os[...]

  • Page 28

    28 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide T r oubleshooting (continued) Instructions in this supplement are based on factory default parameter settings. HARD LOCKOUT condition [Display flashes first digit, “E” and last two digits (code)] Code Reason for soft lockout [...]

  • Page 29

    29 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide T r oubleshooting (continued) Instructions in this supplement are based on factory default parameter settings. HARD LOCKOUT condition [Display flashes first digit, “E” and last two digits (code)] 02 Ignition failed thr ough 5[...]

  • Page 30

    30 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide T r oubleshooting (continued) Instructions in this supplement are based on factory default parameter settings. HARD LOCKOUT condition [Display flashes first digit, “E” and last two digits (code)] 04 V oltage lost after lockou[...]

  • Page 31

    31 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide HARD LOCKOUT condition [Display flashes first digit, “E” and last two digits (code)] 18 Thermal overrun condition – Outlet water temperature above 210 °F . 1 This should only happen when the heat demand is lower than the l[...]

  • Page 32

    32 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide HARD LOCKOUT condition [Display flashes first digit, “E” and last two digits (code)] 30 T emperature rise across boiler over 58 °F , and occurred 20 times. 1 Flow problem through boiler — Temperature rise through boiler sh[...]

  • Page 33

    33 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Boiler maintenance pr ocedur e VERIFY PROPER OPERA TION AFTER SERVICING (see Ultra Boiler Manual for procedur es) Removing and reinstalling components can change boiler behavior. After any maintenance procedure, you must prove the [...]

  • Page 34

    34 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Boiler maintenance pr ocedur e (continued) Perform ALL of the ( 14 ) procedur es listed in the following, in the ORDER SHOWN. (Y ou must have the correct maintenance kit to proceed. See page 33 for details.) Order Pr ocedure Descri[...]

  • Page 35

    35 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Perform ALL of the ( 14 ) procedur es listed in the following, in the ORDER SHOWN. (Y ou must have the correct maintenance kit to proceed. See page 33 for details.) Order Pr ocedure Description 5 Clean the burner . See s Figure [...]

  • Page 36

    36 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Boiler maintenance pr ocedur e (continued) Perform ALL of the ( 14 ) procedur es listed in the following, in the ORDER SHOWN. (Y ou must have the correct maintenance kit to proceed. See page 33 for details.) Order Pr ocedure Descri[...]

  • Page 37

    37 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol 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 tor que reaches 50 inch-pounds[...]

  • Page 38

    38 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Combustion testing and adjustment O Check flame & combustion with instruments Initiate a call for heat on one of the heat demand inputs. 1. Press and hold both the Ultra control panel “Mode” and “+” but- 2. tons simult[...]

  • Page 39

    39 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Combustion testing and adjustment (continued) Measure natural gas input: 7. Operate boiler 10 minutes. a. Turn off other appliances. b. At natural gas meter, measure time (in seconds) required to c. use one cubic foot of gas. Calcu[...]

  • Page 40

    40 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Combustion testing and adjustment (continued) &IGURE Acceptable CO 2 / O 2 and CO values: CO 2 / O 2 values must be within 1.0% of the values listed below — "OILER &UEL (IGHlRE ,OWlRE #/ 2 / 2 ?[...]

  • Page 41

    41 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide 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 (begi[...]

  • Page 42

    42 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide 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 wi[...]

  • Page 43

    43 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Default parameter settings — &IGURE $/./ 4 change any parameter unless the application requir es special settings Par . No. Parameter description Ultra-80 thru -230 Ultra-310 ONL Y Standard (to 5500 feet) High alt[...]

  • Page 44

    44 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide 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. Outdoor reset operation The closer t[...]

  • Page 45

    45 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Outdoor reset curve and contr ol module parameters &IGURE T ypical reset curves &IGURE Parameter explanations (continued) See Figure 25, page 42 for procedure to access Parameter settings.[...]

  • Page 46

    46 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide  &IGURE Parameter 11 — Automatic supply temperature boost operation — In the example below , the boiler is operating in outdoor reset mode, with a calculated setpoint temperatur e of 130°F . The call for heat h[...]

  • Page 47

    47 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Parameter explanations (continued) 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 maxim[...]

  • Page 48

    48 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide 3. Acceptable range (altitude 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- pla[...]

  • Page 49

    49 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Space heating on and off dif ferentials (hyster esis) — Parameters 22 and 23 &IGURE Differ ential (hyster esis) settings DO NOT change the differentials (hyster- esis) for DHW operation (parameters 24 25, 26 and 27).[...]

  • Page 50

    50 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Parameter r efer ence table Para. Name Range Boiler display Description Display position: 1st 2nd 3rd 4th 1 T3 set 68 to 142 104 to 150 1 Setting s 4ISTHE$(7TEMPERATUREDETECTEDBYANIMMERSIONSENSOR ?[...]

  • Page 51

    51 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Parameter r efer ence table (continued) Para. Name Range Boiler display Description Display position: 1st 2nd 3rd 4th 7 T4 maximum (see page 44) 60 to 78 Initial reading: s 0ARAMETER4 MAXIMUM APPLIESON[...]

  • Page 52

    52 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Parameter r efer ence table (continued) Para. Name Range Boiler display Description Display position: 1st 2nd 3rd 4th 17 Minimum fan speed DHW (see page 47) 13 to 52  SOFRPM Initial reading: s 5SETHIS?[...]

  • Page 53

    53 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Parameter r efer ence table (continued) Para. Name Range Boiler display Description Display position: 1st 2nd 3rd 4th 23 CH modulation differential OFF (see page 49) 0 to 18 Initial reading: s $IFFERENTIALMAYALSOBERE[...]

  • Page 54

    54 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Parameter r efer ence table (continued) Para. Name Range Boiler display Description Display position: 1st 2nd 3rd 4th 29 Blocking time DHW 0 to 30 TIMES SECONDS Initial reading: s 0ARAMETERIS?[...]

  • Page 55

    55 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Parameter r efer ence table (continued) Para. Name Range Boiler display Description Display position: 1st 2nd 3rd 4th 34 ST DIGIT 2nd CH circuit 0 to 8 Initial reading: First digit (2nd CH circuit): s DO NOT CHANGE PARA[...]

  • Page 56

    56 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Parameter r efer ence table (continued) Para. Name Range Boiler display Description Display position: 1st 2nd 3rd 4th 35 ST DIGIT 3-Way valve 0 to 2 Initial reading: First digit (3-way valve): s 5LTRACONTROLMODULE[...]

  • Page 57

    57 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Parameter r efer ence table (continued) Para. Name Range Boiler display Description Display position: 1st 2nd 3rd 4th 37 ST DIGIT PWM-level CH-pump 1 to 4 Initial reading: s 4HISFUNCTIONISNOTCURRENTLYSUPPORT[...]

  • Page 58

    58 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide Parameter r efer ence table (continued) Para. Name Range Boiler display Description Display position: 1st 2nd 3rd 4th 42 ST DIGIT Special pump CH / DHW 0 to 3 Initial reading: First digit (Special pump CH/DHW): s 0 ?[...]

  • Page 59

    59 Part number 550-100-029/0810 GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide NOTES[...]

  • Page 60

    GAS - FIRED WA TER BOILER SERIES 1 & 2 — Contr ol supplement & Service guide 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 (c[...]