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Weil-McLain ULTRA Ultra-105 User Manual

Weil-McLain ULTRA Ultra-105
60 pages
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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.
s7IRING
s/PERATION
s4ROUBLESHOOTING
s3ERVICE
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

Table of Contents

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Weil-McLain ULTRA Ultra-105 Specifications

General IconGeneral
ModelUltra-105
CategoryBoiler
Efficiency95%
Input BTU/h105, 000
Boiler TypeCondensing
Heat Exchanger MaterialStainless Steel
Fuel TypeNatural Gas
Vent TypeDirect Vent
Dimensions17.5" W
Vent Diameter2 inches

Summary

Please read before proceeding

Hazard definitions

Field wiring

Line voltage connections

Connects 120 VAC power to the line voltage terminal strip.

Low voltage connections

Connects low voltage wiring to the low voltage terminal strip.

Thermostat

Connects room thermostat or end switch between terminals 5 and 6.

Outdoor temperature sensor

Connects outdoor temperature sensor between terminals 1 and 2.

DHW aquastat

Connects storage indirect water heater aquastat between terminals 3 and 4.

Additional limits

Connects additional limit controls and interlocks between terminals.

Startup

Set space heating operation

Guides the user to set the space heating mode and verify settings.

Set space heating target temperature

Instructions for setting the desired outlet water temperature for space heating.

Set DHW target temperature

Steps to set the target temperature for Domestic Hot Water (DHW) heating.

Check DHW operation setup

Steps to verify the setup for Domestic Hot Water (DHW) operation.

Operating information

Ultra PhD Control Module

Overview of the microprocessor control module and its functions.

Electrical specifications

Lists electrical requirements for the Ultra boilers.

Control module specifications

Details specifications for the control module, including fuses and timings.

Boiler temperature regulation

Explains how the control module regulates boiler water temperature.

High limit operation

Describes the high limit safety feature that shuts off the burner.

DHW operation (if used)

Explains how the boiler prioritizes DHW heating calls.

Additional Thermal Overrun Protection

Details the two additional levels of overrun protection provided by the control.

Low water protection

Explains the low water shutdown feature for safety.

Outdoor reset operation, if used

Setpoint temperature with outdoor reset

How to set temperature based on outdoor conditions.

Summer/winter switch option

How to use a switch to disable space heating in summer.

Supply temperature boost

Automatic increase of target temperature for faster system response.

Boiler circulator

Information about the boiler's circulator and its wiring.

Freeze protection

How the control module provides freeze-up protection.

External controls (interlocks) (if used)

How external limit controls are wired for soft/hard lockout.

Troubleshooting

VERIFY PROPER OPERATION AFTER SERVICING

Steps to ensure proper operation after maintenance.

Re-install BOILER JACKET FRONT DOOR AFTER SERVICING

Critical safety step to re-install the boiler's front door.

Always check control module fuses

Importance of checking fuses before replacing components.

Before troubleshooting

List of tools and initial checks before starting troubleshooting.

Check the following

Initial checks for wiring and gas pressures.

Checking temperature sensors

REVIEW OF LAST LOCKOUT CODE MESSAGE

Accessing and viewing the last lockout code from the control module.

To view the last lockout code

Steps to display the last lockout code and related information.

Boiler maintenance procedure

VERIFY PROPER OPERATION AFTER SERVICING

Ensuring correct boiler operation post-maintenance.

OBTAIN REQUIRED MAINTENANCE KIT BEFORE PROCEEDING!

Lists necessary maintenance kits and their part numbers.

Re-install jacket front door

Safety warning about re-installing the boiler's front door.

Clean and treat boiler water

Instructions for cleaning and treating boiler water with inhibitor.

DISCONNECT POWER BEFORE PROCEEDING

Critical safety step to disconnect electrical power before servicing.

Tools needed for troubleshooting

List of tools required for maintenance and troubleshooting.

Combustion testing and adjustment

DO NOT PROCEED WITHOUT COMBUSTION TEST EQUIPMENT

Warning about requiring specialized equipment for combustion testing.

When is adjustment required?

Identifies symptoms that indicate a need for combustion adjustment.

Check flame & combustion with instruments

Step-by-step guide to checking flame and combustion readings.

Throttle screw adjustment procedure

Overview of Ultra Control Module parameters

Parameter descriptions

Explanation of individual adjustable parameters for the control module.

Default parameter settings

Lists the factory default settings for various models and altitudes.

When to change parameters

Situations where changing default parameters is necessary or desirable.

Typical parameter changes

Common parameter adjustments for specific applications like outdoor reset.

Outdoor reset applications

How outdoor reset parameters can be adjusted for better performance.

High altitude installations

Requirements for adjusting fan speeds at high altitudes.

DO NOT Change the following

Critical warning against changing specific parameters without understanding risks.

How to set parameters

Using the boiler display

Detailed instructions on navigating the display and setting parameters.

Parameter explanations

Outdoor reset operation

How outdoor reset adjusts water temperature based on ambient conditions.

Boiler setpoint temperature (T1set)

Explanation of how the control module regulates boiler outlet water temperature.

Parameter 9 (T4 correction)

Adjusting outdoor sensor readings to correct for location.

Parameter 10 (Tblocking)

Setting a minimum standby temperature to prevent boiler shutdown.

Suggested outdoor reset parameter settings

Recommended parameter settings for outdoor reset configurations.

Automatic temperature boost

Boost operation

Details on how the control module automatically increases target temperature.

Maximum fan speed

Minimum fan speed – parameter 17

Setting the minimum fan speed for low fire and ignition.

Differential (hysteresis) settings

Space heating differentials (parameters 22 and 23)

How ON and OFF differentials affect boiler turn-on/turn-off points.

Setting "OFF” differential (parameter 23)

Adjusting the OFF differential for better performance in low-mass systems.

Parameter reference table

T3set DHW

DHW temperature detected by immersion sensor.

DHW System

Parameter to activate or deactivate DHW heating.

CH System

Parameter to activate or deactivate central heating.

T1top

Target temperature for all outside temperatures or max target at ODT.

T1foot

Minimum target temperature for outdoor reset when outside temp is above balance point.

T4 minimum

Outside temperature at which target outlet water temperature is at maximum.

T4 maximum

T4 frost protection

Boiler circulator runs constantly when outside temperature drops to this number.

T4 correction

Modifies outside temperature reading to correct for sensor location.

T blocking

Minimum target outlet water temperature; boiler shuts off if below this.

Booster time

Time before control module increases target temperature for heat calls.

T parallel shift

Reduces calculated setpoint temperature based on outdoor temperature.

Maximum fan speed CH

Sets maximum boiler input for central heating by limiting fan speed.

Maximum fan speed DHW

Sets maximum boiler input for DHW by limiting fan speed.

Minimum fan speed DHW

Ignition fan speed

Sets fan speed during ignition; used for high altitude.

Postpump time CH

Length of time boiler circulator continues after central heating cycle.

Postpump time DHW

Length of time boiler circulator continues after DHW cycle.

CH modulation differential ON

Temperature boiler water must drop below setpoint to turn boiler on.

CH modulation differential OFF

DHW modulation differential ON

Temperature boiler water must drop below setpoint to turn boiler on (DHW).

DHW modulation differential OFF

Temperature boiler water must rise above setpoint to turn boiler off (DHW).

DHW detection differential ON

Temperature DHW water must drop below DHW setpoint to turn boiler on.

DHW detection differential OFF

Temperature DHW water must rise above DHW setpoint to turn boiler off.

Blocking time CH

Minimum time between consecutive central heating cycles.

Blocking time DHW

Blocking time DHW to CH

Minimum wait time after DHW call before starting central heating.

T1-T2 difference for modulating back

Forces boiler to low fire if outlet-return temp difference is large.

RMCI address

Parameter for RMCI interface device, currently not available.

Tplus (Setvalue addition for DHW)

Sets target boiler outlet water temp in DHW mode; added to parameter 1.

3-Way valve

Manual fanspeed

Manually sets boiler input at a fixed rate for 15 minutes.

PWM-level CH-pump

T hold

Sets a minimum standby temperature for the boiler.

T6 top 2nd CH circuit

Sets maximum target boiler temperature for 2nd CH circuit.

T6 foot 2nd CH circuit

Sets minimum target boiler temperature for 2nd CH circuit.

T6 differential 2nd CH circuit

Differential for 2nd CH circuit call when it is the master.

Special pump CH/DHW

Low/Off cycle

Manages boiler cycling when firing at low fire for extended periods.

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