Weil-McLain Ultra-80, Ultra -105 User Manual
NOTICE:
Series 1/Series 2 identification
Read the boiler rating plate to
determine the series number. The
rating plate is located on the right
side of the boiler.
Gas-fired
Water boiler
Series 2
Control Supplement
Ultra-80, -105, -155, -230 & -310
• Wiring
• Operation
• Troubleshooting
with
Instructions in this supplement are based on factory default parameter settings.
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.
Part number 550-100-029/0404
Contents
Please read before proceeding ............................................................. 3
Hazard definitions ................................................................................. 3
1 Field wiring ........................................................................................ 4
GAS-FIRED WATER BOILER SERIES 2 — Control Supplement
2 Startup
(
Note 1
) ................................................................................... 6
3 Operating information ...................................................................... 9
4 Troubleshooting .............................................................................. 21
Note 1:
See Ultra Boiler Manual for installation procedures and
additional startup and operating information, and
replacement parts.
2
Part number 550-100-029/0404
GAS-FIRED WATER BOILER SERIES 2 — Control Supplement
Please read before proceeding
Installer— Read all instructions, including
this manual, Ultra Boiler Manual, and the
Ultra Vent Supplement, before installing.
Perform steps in the order given.
User — This manual is for use only by a
qualified heating installer/service
technician. Refer to User’s Information
Manual for your reference.
User — Have this boiler serviced/
inspected by a qualified service technician,
at least annually.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
When calling or writing about the boiler—
Please have the boiler model number from
the boiler rating label and the CP number
from the boiler jacket. You may list the CP
number in the space provided on the
Installation and service certificate found on
page 27 of the Ultra Boiler Manual.
Consider piping and installation when
determining boiler location.
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by the
consignee.
When servicing boiler —
• To avoid electric shock, disconnect electrical supply before performing
maintenance.
• To avoid severe burns, allow boiler to cool before performing
maintenance.
Commonwealth of Massachusetts
When the boiler is installed within the Commonwealth of Massachusetts:
• This product must be installed by a licensed plumber or gas fitter.
• If antifreeze is used, a reduced pressure back-flow preventer device
shall be used.
Failure to adhere to the guidelines on this page can
result in severe personal injury, death or substantial
property damage.
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various
risk levels or to important information concerning the life of the product.
Indicates presence of hazards that will cause severe personal injury, death or substantial property
damage.
Indicates presence of hazards that can cause severe personal injury, death or substantial property
damage.
Indicates presence of hazards that will or can cause minor personal injury or property damage.
Indicates special instructions on installation, operation or maintenance that are important but not
related to personal injury or property damage.
Part number 550-100-029/0404
3
1
GAS-FIRED WATER BOILER SERIES 2 — Control Supplement
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.
Wiring must be N.E.C. Class 1. If original
wiring as supplied with boiler must be
replaced, use only type 105 °C wire or
equivalent. Boiler must be electrically
grounded as required by National Electrical
Code ANSI/NFPA 70 – latest edition.
Install field wiring before venting to allow
easier access to terminal strips.
Installation must comply with:
1. National Electrical Code and any other national, state,
provincial or local codes or regulations.
2. In Canada, CSA C22.1 Canadian Electrical Code Part 1,
and any local codes.
Line voltage connections
1. Connect 120 VAC power wiring to line voltage terminal
strip in left compartment of electrical entrance, as shown
in Figure 2, page 5, item 1.
Figure 1 Routing field wiring
2. Provide and install a fused disconnect or service switch (15 amp. recommended)
as required by the code. (See Figure 2, item 2)
3. Boiler circulator is shipped loose. Wire Boiler circulator as shown for Figure 2,
item 3.
4. When connecting a DHW circulator, connect wiring to line voltage terminal
strip as shown for Figure 2, item 5.
5. Route all wires and conduits to the jacket openings specified in Figure 1.
Wiring a system circulator
1. To activate a system circulator when the Boiler circulator operates, add a circulator
relay and wire as shown in Figure 2.
2. You must install a relay as shown. DO NOT wire in parallel with the Boiler
circulator. See CAUTION in Figure 2.
Low voltage connections
1. Connect low voltage wiring to low voltage terminal strip (Figure 3, page 5,
item 1) as shown 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, item 2, room thermostat or end switch (isolated contact
only) between terminals 5 and 6.
2. Install thermostat on inside wall away from influences of drafts, hot or cold
water pipes, lighting fixtures, television, sunrays, or fireplaces.
3. Thermostat anticipator (if applicable):
a. If connected directly to boiler, set for 0.1 amps.
b. If connected to relays or other devices, set to match total electrical power
requirements of connected devices. See device manufacturers’ specifications
and thermostat instructions for details.
Outdoor temperature sensor
1. Connect outdoor temperature sensor (Figure 3, item 6) between terminals 1
and 2 to enable outdoor reset operation of the Ultra boiler. If fixed-temperature
operation is required, do not install outdoor sensor.
2. Mount sensor on exterior wall, shielded from direct sunlight or flow of heat or
cooling from other sources.
3. If desired, install a summer/winter switch (Figure 3, item 7) across terminals 1
and 2. When the switch is closed, the boiler (space heating) circulator is disabled.
4. Route sensor wires through the hole at the right of the electrical entrance (see
Figure 1).
DHW aquastat
1. Connect storage indirect water heater (DHW) aquastat (Figure 3, item 3) between
terminals 3 and 4.
Additional limits
1. Connect additional limit controls and interlocks between the terminals shown
in Figure 3.
2. Controls connected between terminals 6 and 7 (see Figure 3, item 4) will cause
a soft lockout (automatic reset). When limit(s) closes, boiler will resume normal
operation.
3. Controls connected between terminals 6 and 8 (see Figure 3, item 5) will cause
a hard lockout (manual reset). The boiler will only restart after the Ultra display
panel RESET switch is pressed.
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Part number 550-100-029/0404
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GAS-FIRED WATER BOILER SERIES 2 — Control Supplement
Field wiring
Figure 2 Line voltage field wiring connections (service switch provided by installer)
(continued)
Figure 3 Low voltage field wiring connections
Part number 550-100-029/0404
5
2
Startup
GAS-FIRED WATER BOILER SERIES 2 — Control Supplement
Startup
1. Start the boiler only after completing all instructions
in the Ultra Boiler Manual.
2. To start the boiler, follow the procedure given in
Figure 4, page 7.
3. 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.
(continued from Ultra Boiler Manual)
Instructions in this supplement are based
on factory default parameter settings.
Set space heating operation
Verify space heating mode
1. Press the “Mode” button until the display shows
“Para.” This is the parameter mode.
2. Press the “Step” button until the display first digit
shows “3.”
3. The last digit must show “1.” If any other number
displays, press the “+” button until “1” shows in the
right-hand digit. Press the “Store” button to save this
setting.
4. See page 18 for further information.
Set space heating target temperature
1. Press the Ultra control panel “Step” button until the
display first digit shows “4.” The right 3 digits show
the outlet water temperature setting.
2. Press the “+” or “-” button to change the setting to
the desired outlet water temperature. (The factory
default setting is 190 °F.)
a. Outdoor sensor installed — Setting is the target
temperature for outdoor temperature at or below
(factory setting) 32 °F. At higher outside temperatures,
the Ultra PhD control module calculates the target
temperature. (See pages 9 and 10 for detailed discussion
of outdoor reset.)
When a summer/winter switch is used, closing the switch
will disable the boiler (space heating) circulator during
summer operation.
b. Outdoor sensor not installed — Setting is the target
temperature at all times.
3. Press the “Store” button to save the setting.
Check DHW operation setup
1. Go to step 2 if the control is in Parameter mode
already. Press the “Mode” button until the display
shows “Para” (parameter mode).
2. Press the “Step” button until the display first digit
shows “2.”
3. The last digit must show “1.” If any other number
displays, press the “+” button until “1” shows in the
right-hand digit. Press the “Store” button to save this
setting.
4. The Ultra PhD control module turns on the DHW
circulator when the indirect water heater operating
control closes. The control module shuts off the boiler
circulator (stops space heating) during calls for DHW
heating.
Verify operation — space heating
NOTE: “[ _ _ _ _ ]” in the following indicates the characters
that should show on the Ultra display panel. “180” in the
right 3 places means the display shows the measured
boiler water temperature. The number shown will not
necessarily be 180.
1. Turn down DHW aquastat on DHW tank (if used).
If necessary, turn off power and remove one of the
DHW aquastat wires to ensure boiler will not receive
a DHW heat call.
2. Turn off power to boiler at service switch.
3. Wait a few seconds, then turn on power to boiler.
[A180] (self-check on power-up, for a few seconds)
[0180] (no call for heat)
4. Raise room thermostat to call for heat.
[5180] (blower/circulator on) The blower and boiler
circulator energize and the control checks for air flow.
[1180] (prepurge) Blower speed will increase to ignition
speed. The blower will run in prepurge for 10 seconds.
[2180] (ignition) After prepurge, the control module opens
the gas valve and starts ignition spark.
a. If burner flame proves within 4.5 seconds, burner
continues to fire. Burner will fire at startup rate
— 50% of maximum input — for about 10
seconds to allow flame to stabilize.
b. If burner flame does not prove within 4.5 seconds,
control module attempts ignition sequence again.
Flame must prove within 5 attempts or control
will lockout (display will show [E 02]).
c. Verify flame failure operation by closing boiler
manual gas cock to prevent gas flow. Open manual
gas valve after testing.
[3180] (burner on, space heating) Once flame is proven
and stable, the burner turns down to low fire for
approximately 2 minutes.
• After this low fire period, the burner is allowed to
modulate. Firing rate depends on actual outlet water
temperature versus target temperature.
6
Part number 550-100-029/0404
2
GAS-FIRED WATER BOILER SERIES 2 — Control Supplement
Startup
Figure 4 Operating Instructions
(continued)
(Read page 7 and the Ultra Boiler Manual before proceeding.)
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. Do
not try to light the burner by hand.
B. Before OPERATING, smell all around the appliance area
for gas. Be sure to smell next to the floor because some gas
is heavier than air and will settle on the floor. See below.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in
your building.
C. Use only your hand to turn the gas control knob. Never use
tools. If the knob will not turn by hand, don't try to repair it;
call a qualified service technician. Force or attempted repair
may result in a fire or explosion.
D. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect the
appliance and to replace any part of the control system and
any gas control, which has been under water.
• Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
OPERATING INSTRUCTIONS
1. Stop! Read the safety information 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 gas valve is open (valve
handle parallel to gas piping).
3. Turn OFF POWER switch on the Ultra control
panel.
4. Rotate two thumb screws at bottom of access
door counterclockwise to release door.
5. Remove boiler access door.
6. Turn boiler manual gas valve knob
counterclockwise to open gas supply.
7. Smell for gas in the boiler enclosure. If you
smell gas, STOP! Follow "B" in the safety
information above. If you don't smell gas, go
to the next step.
TO TURN OFF GAS TO THE APPLIANCE
8. Turn ON POWER switch on the Ultra
control panel.
9. Set thermostat(s) to desired setting.
10. The Ultra control panel display left digit will
show a sequence of numbers (0, 1, 2, etc.)
that indicate boiler control sequence. Digit 3
or 4 indicates boiler is firing. Digit 0 means
there is no call for heat (all room
thermostats and domestic water heater
satisfied).
11. If the appliance will not operate when there
is a call for heat and piping is not hot, follow
the instructions "To Turn Off Gas To
Appliance" below and call your service
technician or gas supplier.
12. Replace jacket front panel. Make sure panel
is seated firmly in place and all joints are
visually sealed. Then tighten the two thumb
screws at bottom of access door firmly.
Boiler manual
gas valve
1. Set room thermostats to lowest setting.
2. Turn off all electric power to the boiler if service is to be
performed. Turn OFF POWER switch on the Ultra control
panel.
Part number 550-100-029/0404
3. Close external manual gas cock (valve handle perpendicular
to gas piping). Remove boiler access door. Turn boiler manual
gas valve knob clockwise to close gas supply.
4. Replace boiler access door.
7
2
GAS-FIRED WATER BOILER SERIES 2 — Control Supplement
Startup
(continued)
Verify operation — space heating
(continued from previous page)
5. Allow boiler to bring water temperature to target
temperature.
[6180] (target temperature reached) The burner will shut
down. The blower will run in postpurge (see below),
then turn off. The boiler circulator continues to run as
long as there is a call for heat.
6. Lower room thermostat to stop call for heat.
[1180] (postpurge) When the room thermostat is satisfied
(call for heat ended), the burner turns off. The blower
will continue for a 15-second postpurge, then turn off.
(If another call for heat occurs, the boiler will remain
off for one minute before starting again, and the display
will show [6180].)
[0180] (no call for heat) Boiler is now in standby mode
(waiting for heat call).
7. Repeat above steps several times to verify operation.
8. Return the room thermostat to normal setting.
Verify operation — DHW
1. Reconnect DHW aquastat wiring to boiler if
necessary.
2. Turn off power to boiler at service switch.
3. Wait a few seconds, then turn on power to boiler.
[A180] (self-check on power-up, for a few seconds)
[0180] (no call for heat)
4. Raise DHW aquastat above tank temperature, to call
for heat.
[5180] (blower/circulator on) The blower and DHW
circulator energize and the control checks for air flow.
[1180] (prepurge) Blower speed will increase to ignition
speed. The blower will run in prepurge for 10 seconds.
[2180] (ignition) After prepurge, the control module opens
the gas valve and starts ignition spark.
a. If burner flame proves within 4.5 seconds, burner
continues to fire. Burner will fire at startup rate
— 50% of maximum input — for about 10
seconds to allow flame to stabilize.
b. If burner flame does not prove within 4.5 seconds,
control module attempts ignition sequence again.
Flame must prove within 5 attempts or control
will lockout (display will show [E 02]).
c. Verify flame failure operation by closing boiler
manual gas valve to prevent gas flow. Open gas
cock after testing.
[4180] (burner on, DHW) Once flame is proven and stable,
the burner is allowed to modulate. Firing rate depends
on actual outlet water temperature versus target
temperature.
5. Allow boiler to bring water temperature to target
temperature.
[6180] (target temperature reached) The burner will shut
down. The blower will run in postpurge (see below),
then turn off. The DHW circulator continues to run as
long as there is a call for DHW heating.
6. Lower DHW aquastat to stop call for heat.
[1180] (postpurge) When the room thermostat is satisfied
(call for heat ended), the burner turns off. The blower
will continue for a 15-second postpurge, then turn off.
(If another DHW call for heat occurs, the boiler will
begin the heating cycle immediately.)
[8180] (DHW circulator run-on) The DHW circulator
continues to run for 30 seconds.
[0180] (no call for heat) Boiler is now in standby mode
(waiting for heat call).
7. Repeat above steps several times to verify operation.
8. Return the DHW aquastat to normal setting.
Operating information
1. To check operating conditions (actual and target
temperatures, for example), see page 15 for an
explanation of the Ultra control module Information
mode.
2. During normal operation (no shutdown or lockout),
the right 3 display digits show actual boiler outlet
water temperature.
Perform Check-out procedures
1. Perform all steps of the Check-out/startup verification
listed in the Ultra Boiler Manual.
Replace boiler jacket front door
Replace 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 important
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.
8
Part number 550-100-029/0404
3
GAS-FIRED WATER BOILER SERIES 2 — Control Supplement
Operating information
Ultra Control Module
The Ultra boiler is controlled by a microprocessor
electronic control — the Ultra
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 operating
controls) to regulate boiler on/off operation and can
modulate boiler firing rate to more closely match output
to demand.
Control Module.
Electrical specifications
Ultra boilers require 120 VA C /60 HZ power supply and are
not polarity sensitive.
Control module specifications
• Supply voltage 120 vac / 60 hz
• Electrical demand 10 va
• Prepurge timing 10 seconds
• Postpurge timing 15 seconds
• Min. off time, space heating 1 minute
• Pump run on after space htg. 10 seconds
• Min. off time, DHW 0 seconds
• Pump run on after DHW 30 seconds
• Line voltage fuse, F1 5 amp fast-blow
• Low voltage fuse, F3 4 amp slow-blow
Boiler temperature regulation
Additional Thermal Overrun Protection
High limit operation shuts down the burner when the
outlet water temperature exceeds the target temperature.
However, adverse conditions could cause the water
temperature to rise too quickly, overshooting this
temperature. The Ultra control module’s technology
provides advanced protection in the event of thermal
overrun. Using its electronics, the Ultra control module
provides two additional levels of overrun protection:
Level 1 Indication would occur if supply or return
water temperature reached 203°F. The Ultra
control module would display a soft lockout
code (“b” followed by “18” if on the supply, or
“19” if on the return). The module would not
operate the burner again until the water
temperature dropped 9°F below target
temperature.
Level 2 Lockout would occur if supply or return water
temperature reached 210°F. The Ultra module
would enter hard lockout and display an error
code (“E” followed by “18” if on the supply or
“19” if on the return). NOTE: Hard lockout
requires manually pressing the Ultra display
panel reset button to restart operation. Service
technician must troubleshoot the cause of the
problem and correct it before placing the boiler
back in operation.
Operating temperature (target)
The Ultra control module senses outlet water temperature
and regulates boiler firing rate to achieve a target
temperature, set by installer, by setting Parameter 4.
Temperature can be set between 70°F and 190°F. See
page 18 for procedure.
• Space heating — Target temperature is fixed (equal
to Parameter 4) when outdoor reset is not installed.
• Space heating — Target temperature is calculated as
described under “Outdoor reset operation” when
outdoor sensor is connected. Exception: See
explanation of “Supply temperature boost.”
• DHW heating — Target temperature is 50°F +
Parameter 1. Do not change parameter 1 from the
factory default setting of 140°F unless the application
is specially engineered for other temperature.
High limit operation
If outlet water temperature exceeds target temperature
(or 190°F, whichever is lower), high limit action occurs.
The control module shuts the burner off.
DHW operation (if used)
The boiler is factory set to immediately change target
outlet water temperature to 190°F on a call for heat from
the DHW aquastat.
Low water protection
1. The control module uses temperatures sensed at
both supply and return areas of the heat exchanger.
If the flow rate is too low (temperature difference too
high) or either temperature is too high, the control
module shuts the boiler down. This ensures boiler
shutdown in the event of low water or low flow
conditions.
2. Some codes and jurisdiction may accept these integral
features of the control in lieu of requiring an
additional limit control or low water cutoff. Consult
local jurisdiction to determine.
Outdoor reset operation, if used
Target temperature with outdoor reset
All Ultra boilers are shipped with an outdoor temperature
sensor. When this sensor is installed (low voltage terminal
strip terminals 1 and 2), the control module regulates
target outlet water temperature based on outside
temperature.
Set the temperature curve by setting Parameter 4 to:
• ODT (outdoor design temperature for the area).
• For ODT of 32°F or lower:
• Set Parameter 4 to the desired supply temperature at
the ODT.
Part number 550-100-029/0404
9
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