Boiler Manual
* CSA - Low Lead Content only applies to the Combi model
Part number 550-100-325/0419
This manual must only be used by a qualified heating installer/service technician. Failure to comply could result in
severe personal injury, death or substantial property damage.
When calling or writing about the boiler— Please have boiler model number from the boiler rating label.
Aqua Balance
®
80/120/155
Series 2
Wall Mount Gas-Fired
Condensing Boilers – Combi and Heating Only Models
Quick Start Guide
Pages 73 & 74
*
Part number 550-100-325/0419
2
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
INSTALLER — Read all instructions before
installing. Read page 3 first. Follow all instruc-
tions in proper order to prevent personal injury
or death.
-
USER — Please read the following. Failure to
comply could result in severe personal injury,
death or substantial property damage.
This manual is for use only by your qualified
Hazards that will or can cause minor personal
injury or property damage.
Special instructions on installation, operation or
maintenance that are important but not related to
personal injury or property damage.
Hazards that will cause severe personal injury, death
or substantial property damage.
Hazards that can cause severe personal injury, death
or substantial property damage.
Hazard definitions
Contents Page
1 Please read before proceeding . . . . . . . . . . . . . 3
2 Prepare boiler location . . . . . . . . . . . . . . . . . . 4
3 Prepare boiler . . . . . . . . . . . . . . . . . . . . . . . 6
4 Converting boiler to propane . . . . . . . . . . . . . 10
5 Gas piping — sizing gas lines . . . . . . . . . . . . . 14
6 Venting/air piping — general. . . . . . . . . . . . . . 15
7 Commonwealth of Massachusetts installations . . . 18
8 Vent termination requirements. . . . . . . . . . . . . 19
9 Boiler room air openings. . . . . . . . . . . . . . . . 20
10 DIRECT VENT — Sidewall with separate pipes . . . 21
11 DIRECT VENT — Sidewall concentric . . . . . . . . 23
12 DIRECT VENT — Vertical with separate pipes. . . . 25
13 DIRECT VENT — Vertical concentric. . . . . . . . . 27
14 DIRECT VENT — Vertical vent /sidewall air . . . . . 29
15 Concentric termination, typical (sidewall or vertical) . . 31
16 Vent and air piping and boiler connections . . . . . 32
17 Install water piping . . . . . . . . . . . . . . . . . . 35
Domestic Water Piping – Combi Boiler . . . . . . . . . 35
Recirculation (if used) . . . . . . . . . . . . . . . . . . 37
18 Primary/Secondary System Piping . . . . . . . . . . . . 39
System water piping methods . . . . . . . . . . . . . . 39
Expansion Tank Location . . . . . . . . . . . . . . . . 39
Diaphragm- or bladder-type tank: . . . . . . . . . . . . 39
Closed-type expansion tank: . . . . . . . . . . . . . . 41
Install relief valve . . . . . . . . . . . . . . . . . . . . . 42
Zone Valve zoning – primary/secondary . . . . . . . . 43
Circulator zoning – primary/secondary. . . . . . . . . 44
Circulator zoning – Multiple temperature zones with
primary/secondary . . . . . . . . . . . . . . . . . . . . 45
19 Multiple boiler installations . . . . . . . . . . . . . . 46
20 Install condensate line . . . . . . . . . . . . . . . . 49
21 Gas piping . . . . . . . . . . . . . . . . . . . . . . . 50
22 Field wiring. . . . . . . . . . . . . . . . . . . . . . . 52
23 Wiring diagram — AB-80/120C Combi Ladder . . . . 54
23 Wiring diagram — AB-80/120C Combi Schematic. . . 55
24 Wiring diagram — AB-80/120H Heating Only Ladder. . 56
24 Wiring diagram — AB-80/120H Heating Only Schematic . 57
25 Wiring diagram — AB-155C Combi Ladder . . . . . . . . . 58
25 Wiring diagram — AB-155C Combi Schematic . . . . . . . 59
26 Wiring diagram — AB-155H Heating Only Ladder . . . . . 60
26 Wiring diagram — AB-155H Heating Only Schematic . . . 61
27 Controls and operation . . . . . . . . . . . . . . . . 62
28 DHW Settings (Combi Only) . . . . . . . . . . . . . 67
29 Standard Altitude . . . . . . . . . . . . . . . . . . . 69
30 High Altitude . . . . . . . . . . . . . . . . . . . . . . 70
31 Startup — Quick Start Guide using default settings 73
32 Startup . . . . . . . . . . . . . . . . . . . . . . . . . 75
33 Startup — nal checks . . . . . . . . . . . . . . . . 78
34 Startup verication . . . . . . . . . . . . . . . . . . 84
35 Annual startup and general maintenance . . . . . . 85
36 Annual startup . . . . . . . . . . . . . . . . . . . . . 86
37 Troubleshooting . . . . . . . . . . . . . . . . . . . . 89
38 Maintenance . . . . . . . . . . . . . . . . . . . . . .111
39 Replacement parts . . . . . . . . . . . . . . . . . 120
40 Connections, Dimensions and Engineering Data . 132
41 Ratings . . . . . . . . . . . . . . . . . . . . . . . . 135
42 Installation and Service Certicate. . . . . . . . . 136
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.
To avoid electric shock, disconnect all
electrical supplies to the boiler before
performing maintenance.
To avoid severe burns, allow boiler to
cool before performing maintenance.
This boiler contains ceramic fiber and
fiberglass materials. Refer to the WARN-
ING and instructions on page 86.
Do not block flow of combustion or
ventilation air to boiler.
Should overheating occur or gas supply
fail to shut off, do not turn off or discon-
nect electrical supply to pump. Instead,
shut off the gas supply at a location
external to the appliance.
DO NOT install combustion air intake
where there is a risk of combustion air
contamination.
A carbon monoxide detector that is
wired on the same electrical circuit as
the boiler is strongly recommended.
Provide surge protection in the boiler
power supply. This will reduce the pos-
sibility of damage to the boiler control.
*
In some locations, a carbon monoxide
detector is required by the law.
The heat exchanger is made of stainless
steel, and requires that system water
chemistry be within the limits in this
manual. Use Sentinel X100 inhibitor
in the boiler.
. See
page 75 for details.
Thoroughly flush the system (BEFORE
connecting boiler) to remove sediment.
The high-efficiency heat exchanger can
be damaged by build-up or corrosion
due to sediment.
Do not use petroleum-based cleaning
or sealing compounds in boiler system.
Gaskets and seals in the system may be
damaged. This can result in substantial
property damage.
Continual fresh make-up water will
reduce boiler life. Mineral buildup in
heat exchanger reduces heat transfer,
overheats the aluminum heat exchanger,
and causes failure. Addition of oxygen
carried in by make-up water can cause
internal corrosion. Leaks in boiler or
piping must be repaired at once to
prevent make-up water. Use this boiler
ONLY in a closed-loop system.
Do not add cold water to a hot boiler.
Thermal shock can cause heat exchanger
to crack.
NEVER use automotive or standard
glycol antifreeze. Use only freeze-protec-
tion fluids made for hydronic systems.
Follow all guidelines given by the anti-
freeze manufacturer. Thoroughly clean
and flush any replacement boiler system
that has used glycol before installing the
new boiler Use only the products listed
by Weil-McLain for use with this boiler.
See page 121 for details.
Frozen Water Damage
Hazard
Residences or buildings that are unat-
tended in severely cold weather, boiler
system components failures, power out-
ages, or other electrical system failures
could result in frozen plumbing and water
damage in a matter of hours. For your
protection, take preventative actions such
as having a security system installed that
operates during power outages, senses low
temperature, and initiates an effective ac-
tion. Consult with your boiler contractor
or a home security agency.
If any part of a boiler, burner or its controls has
been sprayed with or submerged under water,
either partially or fully, DO NOT attempt to op-
erate the boiler until the boiler has been either
replaced or completely repaired, inspected, and
you are sure that the boiler and all components
are in good condition and fully reliable.
Otherwise, by operating this boiler, you will cause
a fire or explosion hazard, and an electrical shock
hazard, leading to serious injury, death, or substan-
tial property damage. See the instructions at right.
Saltwater Damage — The exposure of boiler components to
saltwater can have both immediate and long-term effects. While
the immediate effects of saltwater damage are similar to those of
freshwater (shorting out of electrical components, washing out of
critical lubricants, etc.), The salt and other contaminants left behind
can lead to longer term issues after the water is gone due to the
conductive and corrosive nature of the salt residue. Therefore, Weil-
McLain equipment contaminated with saltwater or polluted water
will no longer be covered under warranty and should be replaced.
— If any or wiring
came into contact with water, or was suspected to have come into
contact with water, replace the boiler with a new Weil-McLain boiler.
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.
Sidewall vent air installations — see instruction on page 18.
— Read all instructions, including this
manual and all other information shipped with the
boiler, 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.
Write in the Consumer Protection (CP) number in
the space provided on the Installation certificate on
page 136 if not already shown.
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.
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.
1 Please read before proceeding
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Codes and Checklists:
Installations must comply with:
Local, state, provincial, and national codes, laws, regulations and
ordinances.
National Fuel Gas Code, ANSI Z223.1/NFPA 54 - latest edition.
National Electrical Code ANSI/NFPA 70 – latest edition. Electrical
installation and grounding must be in accordance with CSA C22.1,
Part 1, Canadian Electrical Code, and/or local codes.
For Canada only: CAN/CSA B149.1, Natural Gas and Propane
Installation Code, and any local codes.
Where required by the authority having jurisdiction, the installa-
tion must conform to the Standard for Controls and Safety Devices
for Automatically Fired Boilers, ANSI/ASME CSD-1.
The boiler gas manifold and controls met safe lighting
and other performance criteria when boiler underwent
tests specified in ANSI Z21.13 — latest edition.
Flooring
1. The boiler must not be installed on carpeting.
Do not install boiler on carpeting even if foundation
is used. Fire can result, causing severe personal injury,
death or substantial property damage.
1. Wall construction — Make sure the wall construction is
suitable to carry the weight of the boiler and components.
See page 7 for instructions.
2. The boiler is suitable for INDOOR installation
only.
3. Check for nearby connection to:
Condensate drain
4. Check area around boiler. Remove any combustible materials,
gasoline and other flammable liquids.
Failure to keep boiler area clear and free of combustible
materials, gasoline and other flammable liquids and
vapors can result in severe personal injury, death or
substantial property damage.
5. The boiler must be installed so that gas control system components
are protected from dripping or spraying water or rain during
operation or service.
6. If new boiler will replace existing boiler, check for and correct
system problems, such as:
Sediment or corrosion in system piping — clean and flush piping
BEFORE connecting the new boiler. See page 75.
System leaks causing oxygen corrosion or heat exchanger cracks
from hard water deposits.
Incorrectly-sized expansion tank.
Lack of freeze protection in boiler water causing system and
boiler to freeze and leak.
Residential garage installation
1. Take the following special precautions when installing the boiler in
a residential garage. If the boiler is located in a residential garage:
Mount the boiler with its burner and igniter are at least
18 inches above the floor. Follow the National Fuel Gas Code,
ANSI Z223.1 for U. S. installations, or Natural Gas and Pro-
pane Installation Code, CSA B149.1 and B149.2 for
Canadian installations.
Locate or protect the boiler so it cannot be damaged
by a moving vehicle.
Ensure that the installation complies with all applicable
codes.
Prevent boiler water and condensate from freezing.
Provide air openings to room
Boiler alone in boiler room
1. No air ventilation openings into boiler room are needed if
clearances around boiler are at least equal to the SERVICE
clearances shown in Figure 1, page 5.
2. For spaces that DO NOT supply the minimum service clear-
ances, provide two openings as shown in Figure 1, page 5.
Each opening must provide 1 square inch free area per
1,000 Btuh of boiler input.
2 Prepare boiler location
The space must be provided with combustion/
ventilation air openings correctly sized for all
appliances located in the same space as the
boiler.
Reinstall boiler jacket door after servicing. The
boiler jacket door must be securely fastened
to the boiler to prevent boiler from drawing
air from inside the boiler room. This is par-
ticularly important if the boiler is located in
the same room as other appliances.
Failure to comply with the above warnings
could result in severe personal injury, death
or substantial property damage.
1. Follow the sizing requirements shown in Figure 23, page 20.
Vent and air piping
1. The boiler requires a special vent system, designed for
pressurized venting. Boilers are rated ANSI Z21.13
Direct Vent (pressurized vent, likely to condense in the
vent). See instructions beginning on page 15.
2. You must also install air piping from outside to the
boiler air intake adapter. The resultant installation is
categorized as direct vent (sealed combustion). Note
prevention of combustion air contamination on page 6
when considering vent/air termination.
3. Vent and air must terminate near one another unless
otherwise specified in this manual. Vent and air piping
may be routed vertically through the roof or out a side
wall, following the options give in this manual. You may
use any of the vent/air piping methods covered in this
manual. Do not attempt to install the boiler using any
other means.
4. Be sure to locate the boiler such that the vent and air
piping can be routed through the building and properly
terminated. The vent/air piping lengths, routing and
termination method must all comply with the methods
and limits in instructions beginning on page 15.
Figure 1 REQUIRED
(
)
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
2 Prepare boiler location continued
Provide clearances from
combustible materials — REQUIRED
1. See Figure 1 for REQUIRED minimum clearances. ALL
installation must provide at least these minimums.
2. Hot water pipes — at least
1/2” from combustible materials.
3. Vent pipe — at least 3/16” from combustible materials.
4. See Figure 1 for service clearance minimums.
If the unit is enclosed in a cabinet or mounted
alongside, a space must be provided for remov-
ing the casing and for normal maintenance
operations. The minimum measurements to be
respected are given in Figure 1.
Provide clearances for service
access — RECOMMENDED
1. See Figure 1, for recommended service clearances.
2. If you do not provide minimum service clearances shown, it
might not be possible to service the boiler without removing
it from the space.
3. Clearance D, Figure 1 allows for the installation of piping as
shown in Figure 5, page 9, plus a union, close nipple and
elbow.
Clearances
A Provide combustion air/ventilation openings per Figure 23, page 20
or as otherwise directed in this manual or by applicable codes.
If the installation does not provide the minimum clearances,
then the enclosure MUST HAVE air openings located per Figure 2,
above. Each of these air openings must have free area of at least
1 square inch per 1,000 MBH of boiler input.
B Left side clearance to combustibles = 1.0 inches minimum.
C Top of boiler clearance to combustibles = 12.0 inches minimum.
D Right side clearance to combustibles = 1.0 inches minimum.
E Bottom of boiler clearance to combustibles = 12 inches minimum
(must be 18 inches above floor for garage installations).
F Clearance in front of the boiler = 12.0 inches, but 36 inches mini-
mum required for service.
H Vent pipe must be minimum 3/16 inch from combustibles. Opening
in combustible wall, floor, ceiling or roof must be 3/8” larger than
flue pipe diameter, fitted with galvanized steel thimble, or larger if
required by codes or as specified by vent pipe manufacturer.
ADDITIONAL service clearance may be
needed, depending on how piping is routed
to the boiler.
A Provide combustion air/ventilation openings per Figure 23, page 20 or
as otherwise directed in this manual or by applicable codes. NOTE: If
the installation does not provide the minimum clearances in this il-
lustration, then the enclosure must have air openings located and sized
per Figure 1.
B Left side service clearance = 36 inches minimum.
C Service clearance above top of boiler = 24 inches minimum.
D Right side service clearance = 24 inches minimum.
E Service clearance below the boiler = 36 inches minimum.
F Service clearance in front of the boiler = 36 inches minimum.
Minimum
required
for
Combustion
A Minimum 1.00”
B Minimum 12.00”
C Minimum 12.00”
D Minimum 12.00”
Recommended
for
Service
A Minimum 36.00”
B Minimum 36.00”
C Minimum 24.00”
D Minimum 36.00”
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
3 Prepare boiler
Remove boiler from carton
The boiler is heavy. Use caution not to drop the
boiler or cause bodily injury while lifting and han-
dling. Verify that the boiler is securely attached to
prevent possibility of boiler falling after installation.
Do not drop boiler or bump jacket on floor or pallet.
Damage to boiler can result.
Cold weather handling — If boiler has been stored
in a very cold location (below 0°F) before installa-
tion, handle with care until the plastic components
come to room temperature.
1. The boiler is generally easier to handle and maneuver after
removing the shipping container.
2.
and bottom cardboard cap, until ready to place on the wall.
The boiler is arranged and designed for wall
mounting and comes standard with a hanging
bracket. The wall fixture must ensure stable and
effective support for the boiler.
Please review the following information on potential combustion
air contamination problems.
See Table 1 for products and areas which may cause contaminated
combustion air.
To prevent potential of severe personal injury or
death, check for products or areas listed below be-
fore installing boiler. If any of these contaminants
are found:
Air contamination
Table 1
Corrosive contaminants and likely locations
air intake
.
Install air inlet piping for the boiler as described in
this manual.
The air termination fitting must be installed with
the clearances and geometry relative to the vent
outlet depicted in this manual to ensure that flue
products do not enter the air intake.
Ensure that the combustion air will not contain
any of the contaminants in Table 1. Do not pipe
combustion air near a swimming pool, for example.
Avoid areas subject to exhaust fumes from laundry
facilities. These areas will always contain contami-
nants.
Contaminated combustion air will damage the
boiler, resulting in possible severe personal injury,
death or substantial property damage.
2 Prepare boiler location
continued
Figure 2
2 inches
14 inches-center to center of rubber
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Install the wall-mount bracket
1. Locate the studs — must be on 16-inch centers. See previ-
ous instructions if studs are not on 16-inch centers.
2. Place the wall-mount bracket Figure 3, below on the wall,
using a level to align correctly.
3. Place the wall-mount bracket so the mounting slots are
centered over the studs.
4. Level the bracket and trace the outline of the screw slots
with a pencil.
7. Level the wall-mounting bracket. Then tighten lag screws
securely. For drywall or plaster lathe installations, avoid
tightening so much that the bracket digs into the wall
surface.
Place boiler on bracket
1. The wall-mount bracket must be installed before mounting
the boiler.
2. After installing the boiler on the mounting bracket, bend
down the two (2) tabs in order to secure boiler in place,
see Figure 4.
3 Prepare boiler continued
Wall-mounting requirements
DO NOT attempt to attach the wall mount bracket
using anchors or any means other than directly
securing to the wall studs (or equivalent wood
structure if studs are not on 16-inch centers).
-
.
The operating weight for wall-mountable boiler is:
AB-80:
AB-120:
AB-155
:
Failure to comply with above and the procedure
given below could result in severe personal injury,
death or substantial property damage.
1. Stud spacing: Bracket holes are spaced for studs on 16-inch
centers. For other stud spacing, provide secure, solid mounting
surface on which to attach the boiler wall-mounting bracket.
2. Wood stud wall: Install bracket with lag screws (3/8” x 3”)
included in kit, only into the studs.
3. Metal stud wall: Secure bracket and spacer board to studs
with 3/16-inch toggle bolts and 3/16-inch flat washers (not
included with kit).
4. Concrete or block wall: Secure wall bracket with approved
bolts for that application.
Verify that the studs are suitable for carrying a wall-
mounted load. Some metal studs are not designed
for this purpose.
5. If the mounting wall has exposed studs, installer must provide
a backer board to mount boiler. Boiler cannot be leveled
without a backing surface.
6. Mount the boiler on the wall following these instructions.
The boiler mounting studs must engage with the wall-mount
bracket. Make sure the bracket is not just resting on the edge
of the mounting stud or washer. Perform all procedures given
in the Boiler Manual on previous pages before mounting
the boiler.
Install rubber bumpers to back of boiler
1. Remove supplied rubber bumpers from plastic bag and mea-
sure across 14 inches, and up 2 inches from the back of the
boiler bottom edge. Mark these two locations, and peel off
adhesive protection from the rubber bumpers, and mount
the two according to the directions in Figure 2.
2. DO NOT drill holes to mount the rubber bumpers.
Figure 3
Figure 4
5. Remove the mounting bracket and drill holes 1/4” diameter
by 3 inches deep, centered on the screw slot outlines. (For
metal stud walls, using 3/16” toggle bolts, drill required
clearance holes.)
6. Position the wall-mount bracket on the wall. Insert and
loosely tighten the two (2) lag screws (or toggle bolts for
metal studs).
Bend tabs after installation
Lag bolt mounting locations
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Hydrostatic pressure test
-
-
mum allowable relief valve setting for the
. Failure to prevent the
boiler pipes from turning could damage pipes
or heat exchanger, resulting in possible severe
personal injury, death or substantial property
damage.
Pressure test the boiler before permanently attaching water or
gas piping or electrical supply.
Install pipe fittings for relief valve
and P/T gauge
1. Install the reducing tees, and close nipples, field supplied,
located and oriented as shown in Figure 5, page 9. Apply
pipe dope to all fittings sparingly.
. Temporarily install a ¾” pipe
plug in the relief valve location as directed in these
instructions. The plug must be removed after the
test.
the boiler supply. Con-
nect the relief valve only as shown in this manual.
Failure to comply with the above could prevent
the relief valve from operating as needed, resulting
in possibility of severe personal injury, death or
substantial property damage.
2. Install the test pressure/temperature gauge (field supplied)
to the reducing tee as shown in Figure 6, page 9.
Install fittings and valves required for
hydrostatic testing (supplied by installer)
1. The following piping components (supplied by installer)
are required for the test configuration:
a. Two shut-off valves - (1”NPT on the 80/120 boilers,
1
-1/4”NPT on the 155 boiler).
b. Two close nipples - (1”NPT on the 80/120 boilers,
1
-1/4”NPT on the 155 boiler).
c. ¾” NPT pipe plug.
d. Pressure/temperature gauge.
e. ¾” NPT boiler drain valve.
2.
insert a ¾” NPT pipe plug in the relief valve
tapping. After the hydrostatic test, this plug must be removed
and the relief valve must be installed.
Fill and pressure test
1. See Figure 5, page 9, for use with the following instructions.
2. CLOSE the boiler drain valve (item 10). Connect a hose to
fresh water supply and to the drain valve.
3. Place a bucket under the ends of the isolation valves
(item 8 and 9) to catch water drippings.
4. CLOSE isolation valve item 9, then crack open the valve
slightly. Leave top isolation valve item 8 open.
5. Slowly open the boiler drain valve (item 10) and fresh water
supply to fill boiler with water. The boiler and piping will
fill quickly because of the low water content.
6. When water begins to flow from bottom isolation valve
(item 9), close the valve.
7. Continue filling until water flows from top isolation valve
(item 8), then close the valve.
8. When pressure on the pressure/temperature gauge (item
4) reaches at least 45 PSIG, but no higher than 55 PSIG,
CLOSE the boiler drain valve (item 10).
9. Hold at test pressure for 10 minutes.
Do not leave boiler unattended. A cold water fill
could expand and cause excessive pressure, result-
ing in severe personal injury, death or substantial
property damage.
10. Make sure constant gauge pressure has been maintained
throughout test. Check for leaks. Repair if found.
Failure to
do so can damage boiler, resulting in substantial
property damage.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Gaskets and seals
in the system may be damaged. This can result in
substantial property damage.
Drain and remove fittings
1. Disconnect fill water hose from water source.
2. Drain boiler through drain valve
(item 10).
Use caution when releasing pressure from the boiler.
Rapid water flow could cause injury.
3. Remove hose after draining.
4. Remove nipples and valves unless they will remain for use in
the system piping.
5. Remove plug and install relief valve as specified in the fol-
lowing WARNING.
Remove plug from relief valve street elbow. Install
the relief valve in the ¾” street. See page 42 to install
relief valve discharge piping. Failure to install the
boiler relief valve could result in severe personal
injury, death or substantial property damage.
3 Prepare boiler continued
Figure 6
see legend below)
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
1. Boiler Supply (outlet) connection, (male, 1” NPT on the 80/120 boilers, 1” NPT on the 155 boiler).
2. Boiler Return (inlet) connection, (male, 1” NPT on the 80/120 boilers, 1” NPT on the 155 boiler).
Recommend Near Boiler Piping to be 1-1/4” NPT or larger for the 155 boiler. Bushing 1” x 1-1/4” NPT at Supply (outlet) and Re-
turn (inlet) not shown.
(field supplied by installer).
3. Boiler relief valve, shipped loose with boiler — .
3a. Insert a ¾” NPT plug in the relief valve tapping of the reducing tee. This MUST BE REMOVED
after the test and the relief valve mounted here.
4. Pressure/temperature gauge,
(field supplied) by installer, (Optional – can use boiler gauge).
5a. Reducing tee, 1” x 1” x ¼” on
the 80/120 boilers, NPT, 1-1/4” x 1-1/4” x ¼” on the 155 boiler (field supplied) by installer .
5b. Tee, NPT, 1” x 1” x ¾” on
the 80/120 boilers, 1-1/4” x 1-1/4” x ¾” on the 155 boiler (field supplied) by installer.
6. Nipple, NPT, 1” x close on
the 80/120 boilers, NPT, 1-1/4” x close on the 155 boiler (field supplied) by installer.
7. Nipple, NPT, 1” x close on
the 80/120 boilers, NPT, 1-1/4” x close on the 155 boiler (field supplied) by installer.
8. Isolation valve on supply connection,
(field supplied) by installer (1” NPT on the 80/120 boilers, 1-1/4” NPT on the 155 boiler).
9. Isolation valve on return connection, (field supplied) by installer (1” NPT on the 80/120 boilers, 1-1/4” NPT on the 155 boiler).
10. ¾” NPT boiler drain valve, (field supplied) by installer — after hydrostatic testing, move drain valve to lowest point on the return piping
if not already there.
3 Prepare boiler continued
Figure 5
(see
legend below) (Combi boiler shown)
2
3
1
10
Part number 550-100-325/0419
10
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
4 Converting boiler to propane
Prepare boiler for propane (if required)
AquaBalance®
80/120/155
Propane operation
-
.
Converting an existing natural gas-fired
—
For a boiler already
installed, you must turn off gas supply, turn off
power and allow boiler to cool before proceed-
ing. You must also completely test the boiler after
conversion to verify performance and start up the
boiler following instructions beginning on page 79
of this manual.
Verify Conversion kit—See Figure 7.
LP gas venturi will have a black label and will be
clearly labeled “LPG”.
Natural gas venturi will have a white label and
will be clearly labeled “NAT GAS”.
Failure to comply could result in severe personal
injury, death or substantial property damage.
Figure 7
Boiler Model
640-000-022
640-000-024
640-000-023
640-000-025
640-000-082
640-000-133
This conversion kit shall be installed by a qualified
service agency in accordance with the
manufacturer’s instructions and all applicable codes
and requirements of the authority having jurisdiction.
If the information in these instructions is not followed
exactly, a fire, an explosion or production of carbon
monoxide may result causing property damage,
personal injury or loss of life. The qualified service
agency is responsible for the proper installation of this
kit. The installation is not proper and complete until
the operation of the converted appliance is checked as
specified in the manufacturer’s instructions supplied
with the kit.
Follow all instructions in proper order.
Do not tamper with venturi. DO NOT change or modify
venturi in any way.
Do not leave an uninstalled venturi in the building.
Caution the gas supply shall be shut off prior to discon-
necting the electrical power, before proceeding with the
conversion.
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
P/N 640-000-022 LP to Natural Gas Conv. Kit contents:
Venturi - Natural Gas 10.6m
1
Gasket Nitrile Rubber 167 x 63.5X3.53 NBR
1
Label Gas Conversion
1
Label AB-80 Rating Plate Conversion NG
1
Instructions Conversion LP to Natural Gas
1
P/N 640-000-023 LP to Natural Gas Conv. Kit contents:
Venturi - Natural Gas 12.6m
1
Gasket Nitrile Rubber 167 x 63.5X3.53 NBR
1
Label Gas Conversion
1
Label AB-120 Rating Plate Conversion NG 1
Instructions Conversion LP to Natural Gas 1
P/N 640-000-024 NG to Propane Gas Conv. Kit contents:
Venturi - 10.6 GPL
1
Gasket Nitrile Rubber 167 x 63.5X3.53 NBR
1
Label Gas Conversion
1
Label AB-80 Rating Plate Conversion LP
1
Instructions Conversion Nat to LP Gas
1
P/N 640-000-025 NG to Propane Gas Conv. Kit contents:
Venturi - 12.6 GPL
1
Gasket Nitrile Rubber 167 x 63.5X3.53 NBR
1
Label Gas Conversion
1
Label AB-120 Rating Plate Conversion LP
1
Instructions Conversion Nat to LP Gas
1
P/N 640-000-133 NG to Propane Gas Conv. Kit contents:
Venturi -
1
Gasket Nitrile Rubber 167 x 63.5X3.53 NBR
1
Label Gas Conversion
1
Label AB-155 Rating Plate Conversion LP
1
Instructions Conversion Nat to LP Gas
1
P/N 640-000-082 LP to Natural Gas Conv. Kit contents:
Venturi - Natural Gas 16.6m
1
Gasket Nitrile Rubber 167 x 63.5X3.53 NBR
1
Label Gas Conversion
1
Label AB-155 Rating Plate Conversion NG 1
Instructions Conversion LP to Natural Gas 1
Part number 550-100-325/0419
11
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
1. Contact propane gas supplier to size piping, tank and install
a 100% lockup gas pressure regulator, or to verify size and
condition of existing piping and equipment.
requirements
Adjust propane supply regulator provided by gas supplier for 13”
w.c. maximum pressure.
For natural gas or propane, the pressure required at gas valve
inlet pressure port (verify minimum gas pressure when all gas
appliances are in operation):
a. Maximum: 13” w.c. with no flow (lockup) or with boiler on.
b. Minimum: 3.5” w.c. gas pressure, with gas flowing (verify
during boiler startup, while boiler is at high fire).
c. Nominal gas pressure: 11.0” w.c.
2. Install 100% lockup gas pressure regulator in supply
line if inlet pressure can exceed 13” w.c. at any time.
Adjust lockup regulator for 13” w.c. maximum.
3. After connecting propane gas line to boiler, and BEFORE
operating, check gas pressure. If gas pressure is not in the
range above, close manual gas valve and contact gas supplier
to correct the problem before attempting to start or operate
the boiler.
Installing venturi —
— You must turn off
electrical supply to the boiler and close the external
manual gas shut-off valve to isolate the boiler during
conversion. Allow the boiler to cool if it has been
operating.
Following conversion of an installed boiler, follow
all instructions in this manual to start up the boiler
and verify operation of the boiler and all system
components.
The venturi(s) provided with the kit(s) are permanently marked
on labels to indicate gas type “NAT GAS” Natural gas or “LPG”
for Liquefied petroleum (propane) gas and supplier part number.
See Figure 7, page 10 for kit contents.
4 Converting boiler to propane continued
for Figure 11
1 Control module 2 Gas valve
Figure 8
Figure 9
Figure 10
Figure 11
1. Remove two (2) A screws on the bottom flange of front panel,
out and lift up to remove the front panel.
2. Remove the one (1) screw holding control module in place
Figure 11, rotate the control module.
1
2
A
Part number 550-100-325/0419
12
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
3. Loosen the bottom swivel nut of gas pipe and unscrew the
top swivel nut “A” Figure 12, Item 3 from the gas valve venturi
Figure 12, Item 6.
Figure 12
Figure 13
4 Converting boiler to propane continued
for Figures 12, 13, 14, 15 and 16
1 Control panel (page 13)
2 Gas valve
3 Gas pipe
4 Washer
5 Hex head screws
6 Gas valve venturi
7 “O” Ring
8 Blower
4. Remove three (3) Hex head screws holding the venturi,
Item 5 in place, remove venturi, replace with new propane
venturi from kit. Verify the venturi label information
matches the boiler size AB-80/120/155. (Propane venturi
has black label), ensure Item 7, venturi “O” ring is in place
(see Figure 14), re-insert three (3) Hex head screws to
hold new venturi, tighten to hold securely in place.
5. Reassemble gas pipe and new washer to the venturi fitting,
re-connect nut “A” and gas pipe “Item 3” to venturi and
check the seal of the connection.
Inspect the gas pipe fitting connections on
the gas valve and new venturi (Item 3, Fig-
ure 12, page 12) check the seal of the connec-
tions. Failure to comply will cause a gas leak,
resulting in severe personal injury or death.
Figure 14
Figure 15
A
3
6
2
7
4
3
5
8
A
6
3
4
5
Part number 550-100-325/0419
13
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
4 Converting boiler to propane continued
DO NOT operate the boiler with
the jacket door removed except for inspection
and testing as directed in this manual.
Do not check for gas leaks with an open flame —
use bubble test. Failure to use bubble test or check
for gas leaks can cause severe personal injury,
death or substantial property damage.
6. Reinstall control module, reinstall screw to hold control
module securely in place
7. Reinstall jacket door, and secure with two (2) screws.
Mandatory control changes for fuel
conversion - Perform at start-up final checks
8. Adjust parameter for the type of gas:
a. Put the boiler in standby mode.
b. Press the DHW buttons details 1 and 2 - Figure 80, page 62
for 10 seconds: the display shows “b01“ flashing.
c. Press the DHW buttons Figure 80, page 62 details 1 and 2
- to set parameter 00 (for use with natural gas) or 01
(for use with LP).
d. Press the Heating (+) button to scroll to Parameter “b04”.
e. Press DHW (-) to reduce the Maximum Blower
see Figure 128, page 101.
f. Press the (+) button to scroll to Parameter “b05”.
g. Repeat Step “e” above according to your boiler size.
h. Press the Heating (+) button to scroll to Parameter
“b06”.
i. Press DHW (-) to reduce the Minimum Fan Speed,
see Figure 128, page 101:
j. Press the DHW buttons details 1 and 2 -
Figure 80, page 62 for 10 seconds.
k. The boiler will return to standby mode.
9. Turn on gas by opening gas valve, check for leaks and con-
tinue boiler start up and adjustments, staring on page 82.
10. Test ignition system safety shutoff, see page 83.
11. In USA Input rates are derated 4% for each 1000 ft. above
sea level, beyond 2000 ft. in accordance with National Fuel
Gas Code, ANSI Z223.1/NFPA 54 - latest edition, and/or
the Natural Gas and Propane Installation Code, CAN/CSA
B149.1.
12. Using a combustion analyzer insert probe into the flue
test point, check that the CO
2
content in the exhaust, with
the boiler operating at max. and min. firing rate, matches
that given in the technical data Figure 107, page 82 or Fig-
ure 110, page 83, for the corresponding type of gas.
The valve could be
damaged by manometer fluid contamination.
Failure to comply could result in severe personal
injury, death or substantial property damage.
Perform Boiler Manual start-up
Follow all instructions in Boiler Manual to start-up
the boiler after converting for propane. Because the
boiler has been changed, you must verify correct
operation, including checking combustion with
test instruments both at high fire and low fire as
described in the Boiler Manual, pages 81, 82 & 83.
Check the correct ignition sequence of the boiler
after the conversion, as in page 90.
Failure to comply could result in severe personal
injury, death or substantial property damage.
Reinstall boiler jacket front door
Replace boiler jacket front door after servicing. The
boiler front door must be securely fastened to the
boiler frame 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.
Apply installer conversion label
1. Converting to propane firing: After installation is complete,
attach the propane conversion label (from kit) next to the
boiler rating label.
2. Contractor/installer is responsible for completing the in-
formation required on label (provided in kit) and attaching
installer conversion label next to the boiler rating label.
Figure 16
Figure 17
A
3
5
Part number 550-100-325/0419
14
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
5 Gas piping — sizing gas lines
Boiler gas connection is ½” NPT for 80/120 boil-
ers and ¾” NPT for 155 boilers. Size gas lines large
enough to provide gas to all connected appliances.
Natural Gas:
1. Size gas piping from meter outlet to entrance of boiler in
accordance with Figure 18 and Figure 19.
2. Use total input of all connected appliances. Divide total input
in Btuh by 1,000 to obtain cubic feet per hour of natural gas.
a. Pipe lengths in Figure 18 are equivalent length of straight
pipe. Convert pipe fittings to equivalent lengths using
data from Figure 19.
b. Figure 18 is only for natural gas with specific gravity 0.60,
with a pressure drop through the gas piping as listed in
the table.
c. For additional gas pipe sizing information, refer to ANSI
Z223.1 (
Natural Gas and Propane Installation Code, CSA
B149.1 and B149.2 for Canadian installations).
1. Pressure required at gas valve inlet pressure port:
a. Maximum: 13” w.c. with no flow (lockup).
b. Minimum: 3.5” w.c. gas pressure, with gas flowing
(verify during boiler startup, while boiler is at high fire).
Nominal gas pressure: 7.0” w.c.
2. Install 100% lockup gas pressure regulator in supply line if
inlet pressure can exceed 13” w.c. at any time. Adjust lockup
regulator for 13” w.c. maximum.
Propane Gas:
You must follow the instructions, beginning on
page 10, to operate the boiler on propane. Failure
to comply could result in severe personal injury,
death or substantial property damage.
1. Contact gas supplier to size pipes, tanks and 100% lockup
gas pressure regulator.
1. Adjust propane supply regulator provided by gas supplier for
13” w.c. maximum pressure.
2. Pressure required at gas valve inlet pressure port:
a. Maximum: 13” w.c. with no flow (lockup).
b. Minimum: 3.5” w.c. gas pressure, with gas flowing
(verify during boiler startup, while boiler is at high fire).
Nominal gas pressure: 11.0” w.c.
Figure 18
Gas
total
feet
½” ¾” 1” 1¼” 1½” 2” 2½”
10
132 278 520 1050 1600 3050 4800
20
92 190 350 730 1100 2100 3300
30
73 152 285 590 890 1650 2700
40
NA 130 245 500 760 1450 2300
50
NA 115 215 440 670 1270 2000
75
NA 105 175 360 545 1020 1650
100
NA 96 150 305 460 870 1400
150
NA 90 120 250 380 710 1130
Figure 19
Equivalent length, feet
90° Elbow Tee
short
radius
long
radius
line
ow
branch
ow
½ 3.62.21.74.2
¾ 4.42.32.45.3
1 5.22.73.26.6
1¼ 6.63.24.68.7
1½ 7.43.45.69.9
2 8.5 3.6 7.7 12.0
2½ 9.3 4.0 9.3 13.0
Part number 550-100-325/0419
15
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
6 Venting/air piping — general
Any improper operation of the common venting system should
be corrected so the installation conforms with the National Fuel
Gas Code, ANSI Z223.1/NFPA 54, and/or the Natural Gas and
Propane Installation Code, CAN/CSA B149.1. When resizing
any portion of the common venting system, the common vent-
ing system should be resized to approach the minimum size as
determined using the appropriate tables in Chapter 13 of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the
Natural Gas and Propane Installation Code, CAN/CSA B149.1.
Do not install the boiler into a common vent
with any other appliance. This will cause flue
gas spillage or appliance malfunction, resulting
in possible severe personal injury, death or sub-
stantial property damage.
Existing common vent systems may be too large
for the appliances remaining connected after the
existing boiler is removed.
Failure to follow all instructions can result in
flue gas spillage and carbon monoxide emissions,
causing severe personal injury or death.
When removing a boiler from an
existing common vent system
-
. When an existing boiler is replaced with a boiler, the boiler
CANNOT use the existing common vent. The boiler requires its
own vent and air piping, as specified in this manual. This may cause
a problem for the appliances that remain on the old common vent,
because the vent may be too large. The following test is intended
to check for proper operation of the appliances remaining on the
old common vent system.
Perform the test sequence below for appliance remaining on
the original common vent system. Operate each appliance indi-
vidually, with other appliances turned off. This procedure will test
whether the common vent system can properly vent each appliance.
Existing vent test procedure
(The following is intended to test whether the appliances
remaining on an existing vent system will operate
satisfactorily.)
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and hori-
zontal pitch and determine there is no blockage or restriction,
leakage, corrosion or other deficiencies which could cause an
unsafe condition.
3. Test vent system — Insofar as is practical, close all building
doors and windows and all doors between the space in which
the appliances remaining connected to the common venting
system are located and other spaces of the building. Turn on
clothes dryers and any appliance not connected to the com-
mon venting system. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, so they will operate
at maximum speed. Do not operate a summer exhaust fan.
Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow
the operating instructions. Adjust thermostat so appliance
will operate continuously.
5. Test for spillage at draft hood relief opening after 5 minutes
of main burner operation. Use the flame of a match or
candle, or smoke from a cigarette, cigar, or pipe.
6. After it has been determined that each appliance remaining
connected to the common venting system properly vents
when tested as outlined herein, return doors, windows,
exhaust fans, fireplace dampers, and any other gas-burning
appliance to their previous conditions of use.
Figure 20 Venting and air piping — DIRECT VENT ONLY
The table below lists the acceptable vent/air pipe terminations described in this manual. Follow all instructions provided to install the
vent/air system. below, but also approved, are the polypropylene piping and terminations listed in Figure 21, page 17.
For these applications, use ONLY the manufacturers’ parts listed and follow all instructions provided by the pipe manufacturer.
Part number 550-100-325/0419
16
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
6 Venting/air piping — general continued
AquaBalance® Model
Maximum vent and air pipe length =
100 feet for all applications
(Minimum length for all applications is 2 feet equivalent plus termination)
(All applications include allowance for the termination fittings plus one elbow in air piping and one elbow in vent piping)
USE
SWEEP
ELBOWS
ONLY
See Figure 21, page 17 for material specifications | See Figure 164, page 121 for part/kit numbers
Vent and air pipe sizes:
Maximum vent lengths apply for 3” vent and air pipe.
Boilers will derate as vent/air pipe length increases —
*
see Rating data on Figure 178, page 135 for derate amounts.
SIDEWALL termination VERTICAL termination
Separate pipes
[Note 1]
PVC or PP Concentric
[Note 1]
Separate pipes
[Note 1]
PVC or PP Concentric
[Note 1]
Vertical vent,
Side Air [Note 1]
See page 21 See page 23 See page 25 See page 27 See page 29
Size,
inches
Materials
Fig. 21, page 19
Size,
inches
Materials
Fig. 21, page 19
Size,
inches
Materials
Fig. 21, page 19
Size,
inches
Materials
Fig. 21, page 19
Size,
inches
Materials
Fig. 21, page 19
80
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
120
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
155
2
CPVC, PP, SS
2
--------
2
CPVC, PP, SS
2
--------
2
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
Equivalent feet for elbows (USE SWEEP ELBOWS ONLY) —
deduct from max equivalent length of piping (does not apply to termination fittings).
tGFFUQFSGPSFBDIBEEJUJPOBM¡TXFFQFMCPXPS¡FMCPX
*GQJQJOHDPOUBJOTNPSFUIBOFMCPXJOBJSPSWFOUQJQJOHPUIFSUIBOUFSNJOBUJPOmUUJOHT
Note 1:
"#4NBZCFVTFEGPSJOUBLFBJS
.BUFSJBMBCCSFWJBUJPOT11QPMZQSPQZMFOF44"-$TUBJOMFTTTUFFM
If using stainless pipe, provide adapters for terminations, if required.
*1&9w17$DPODFOUSJDWFOULJUTDBOCFVTFEXJUITUBOEBSE17$QJQFmUUJOHTBOEDFNFOU"/4*"45.%FYDFQUJG6-$4DPNQMJBODF
JTSFRVJSFE'PS6-$4DPNQMJBODFBMMQJQFmUUJOHTBOEDFNFOUNVTUCF*1&94ZTUFN*GVTJOH*1&9LJUTVTFPOMZ*1&9QSPEVDUDPEF
GPSwWFOUJOH
$POUBDU8FJM.D-BJOGPSPSEFSJOHJOGPSNBUJPOBOEBWBJMBCJMJUZPG8FJM.D-BJOWFOUJOHLJUT
Figure 21 Vent and air piping materials
see Figure 164, page 121 for part/kit numbers).
USE SWEEP ELBOWS FOR ALL VENT AND AIR PIPING — DO NOT use short radius
elbows for vent or air piping. Boiler performance could be affected.
Part number 550-100-325/0419
17
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
6 Venting/air piping — general continued
Material
United States Canada (Note 2)
Vent or air pipe
&
ttings
PVC schedule 40 (Note 1) ANSI/ASTM D1785 ULC S636
ABS,
PVC, PVC-DWV,
CPVC or
polypropylene
PVC-DWV schedule 40 (Note 1) ANSI/ASTM D2665 NA
CPVC schedule 40 (Note 1) ANSI/ASTM F441 ULC S636
ABS-DWV schedule 40 (Intake Only) ANSI/ASTM D2661 ULC S636
PVC & ABS pipe
cement & primer
PVC (Note 1) ANSI/ASTM D2564/F656 ULC S636
Use only cement
and primer suitable
for piping material
used
CPVC (Note 1) ANSI/ASTM F493 ULC S636
ABS schedule 40 (Note 1) ANSI/ASTM D2235 ULC S636
Polypropylene
vent pipe, ttings,
terminations and
cement
Obtain all materials from
M&G Simpson-Duravent
Obtain all materials from Centrotherm
See manufacturer’s literature
for detailed information
MUST USE LOCKING
COLLAR ON EVERY JOINT
ULC S636
PVC, PVC-DWV,
CPVC or
polypropylene
Vent pipe
AL29-4C
stainless
steel
Heat Fab, Inc. — Saf-T-Vent
®
Z-Flex, Inc. — Z-Vent II
Dura-Vent — FasNSeal®
Metal-Fab, Inc. — CORR/GUARD
Certified for direct vent
appliance venting
Certified for direct vent appliance
venting
(purchase separately) — see Figure 164, page 121 for part numbers
Note 1: Weil-McLain concentric vent kits are made from PVC
pipe and fittings.
Note 2: System 636 PVC concentric terminations utilize PVC
pipe/fittings certified to ULC S636.
If ULC S636 compliance is required, use only System
636 pipe, fittings and cement.
DO NOT mix piping from different pipe manufactur-
ers unless using adapters specifically designed for
the purpose by the manufacturer.
Every joint on polypropylene vent piping must
include a locking collar.
DO NOT use cellular core PVC (ASTM F891), cellular
core CPVC, or Radel
®
(polyphenolsulfone) in venting
systems.
DO NOT cover non-metallic vent pipe and fittings
with thermal insulation.
ADAPTERS – The boiler comes with a 3”,
3-in-1 adapter as standard. This adapter allows the
installation of 3” PVC schedule 40, CPVC schedule 40,
PVC-DWV schedule 40, AL29-4C stainless steel and
Polypropylene (from Simpson-Duravent only) piping
without the need for extra adapters.
It may require an adapter at terminations.
If your venting system uses Centrotherm Eco
systems InnoFlue single wall material, then an ap-
proved adapter is required.
If using 2” piping, where approved for the ap-
plication, provide adapters for a 3” pipe material
(mentioned above) connections and at the termi-
nations, if required.
ALL vent and air pipes require a BIRD SCREEN at each termination. Most kits do not include
the bird screens. Purchase bird screens separately from Weil-McLain or vent kit supplier if
not included. [Note — bird screening is integral to the 3" PVC Weil-McLain sidewall vent cap,
available for purchase from Weil-McLain
. No additional screening is required.]
Part number 550-100-325/0419
18
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
7 Commonwealth of Massachusetts installations
(a) For all sidewall horizontally-vented gas-fueled equipment
installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those
owned or operated by the Commonwealth and where the
side wall exhaust vent termination is less than seven (7) feet
above finished grade in the area of the venting, including but
not limited to decks and porches, the following requirements
shall be satisfied:
1.
-
TORS. At the time of installation of the side wall horizon-
tal vented gas fueled equipment, the installing plumber or
gas fitter shall observe that a hard wired carbon monoxide
detector with an alarm and battery back-up is installed on
the floor level where the gas equipment is to be installed.
In addition, the installing plumber or gas fitter shall
observe that a battery operated or hard wired carbon
monoxide detector with an alarm is installed on each ad-
ditional level of the dwelling, building or structure served
by the side wall horizontal vented gas fueled equipment.
It shall be the responsibility of the property owner to
secure the services of qualified licensed professionals for
the installation of hard wired carbon monoxide detectors
a. In the event that the side wall horizontally vented gas
fueled equipment is installed in a crawl space or an
attic, the hard wired carbon monoxide detector with
alarm and battery back-up may be installed on the
next adjacent floor level.
b. In the event that the requirements of this subdivision
can not be met at the time of completion of installa-
tion, the owner shall have a period of thirty (30) days
to comply with the above requirements; provided,
however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an
alarm shall be installed.
2.
. Each
carbon monoxide detector as required in accordance with
the above provisions shall comply with NFPA 720 - latest
edition and be ANSI/UL 2034 listed and IAS certified.
3.
. A metal or plastic identification plate shall
be permanently mounted to the exterior of the build-
ing at a minimum height of eight (8) feet above grade
directly in line with the exhaust vent terminal for the
horizontally vented gas fueled heating appliance or
equipment. The sign shall read, in print size no less than
one-half (1/2) inch in size, “GAS VENT DIRECTLY BE-
LOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”
4.
. The state or local gas inspector of the
side wall horizontally vented gas fueled equipment shall
not approve the installation unless, upon inspection,
the inspector observes carbon monoxide detectors and
signage installed in accordance with the provisions of
248 CMR 5.08(2)(a) 1 through 4.
(b)
: The following equipment is exempt from
248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment
Not Required To Be Vented” in the most current edition
of NFPA 54 - latest edition as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled
equipment installed in a room or structure separate from
the dwelling, building or structure used in whole or in
part for residential purposes.
(c)
. When the manufacturer of
Product Approved side wall horizontally vented gas equip-
ment provides a venting system design or venting system
components with the equipment, the instructions provided
by the manufacturer for installation of the equipment and
the venting system shall include:
1. Detailed instructions for the installation of the venting
system design or the venting system components; and
2. A complete parts list for the venting system design or
venting system.
(d)
. When the manufac-
turer of a Product Approved side wall horizontally vented gas
fueled equipment does not provide the parts for venting the
flue gases, but identifies “special venting systems”, the follow-
ing requirements shall be satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall
be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved
by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved
side wall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance
or equipment at the completion of the installation.
Commonwealth of Massachusetts — 8IFOUIFCPJMFSJTJOTUBMMFEXJUIJOUIF$PNNPOXFBMUIPG.BTTBDIVTFUUT
UIFCPJMFSNVTUCFJOTUBMMFECZBMJDFOTFEQMVNCFSPSHBTmUUFS3FBEBOEDPNQMZXJUIUIFJOTUSVDUJPOTCFMPX
Figure 22
The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). The minimum distance
from adjacent public walkways, adjacent buildings, openable windows and building in the National Fuel Gas Code, ANSI Z223.1/NFPA
54 - latest edition and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1. The vent termination clearances below are
for U.S.A., for Canadian vent termination clearances please refer to the requirements of CAN/CSA B149.1 Natural Gas and Propane
Installation Code. Consideration should be given to avoid possible damage caused by vent plumes and condensate when choosing a
venting conguration and location. aintain a minimum clearance of 4 ft. (1.22m) horiontally from, and in no case above or below, unless
a 4 ft. (1.22m) horiontal distance is maintained, from electrical meters, gas meters, regulators, and relief equipment.
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
8 Vent termination requirements
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
9 Boiler room air openings
Figure 23
The boiler CANNOT be in the same space with other appliances if clearances around the are less than the recom-
mended service clearances shown in Figure 1, page 5.
Air openings
The required air opening sizes below are FREE AREA,
after reduction for louver obstruction. Note the ex-
ception below for large spaces.
Boiler
WITH other
appliances in room
Boiler
WITHOUT other
appliances in room
TWO openings, each at least:
1 square inch per Btuh
of all other appliances in the room
(Unless specified otherwise by
appliance manufacturer)
openings are required if the
boiler installation provides at least the
recommended service clearances
shown in Figure 1, page 5.
Provide openings ONLY as shown
in Figure 1, page 5
.
Each opening must have a free
area no less than 1 square inch per
1,000 Btuh input of the boiler.
TWO openings, each at least:
1 square inch per Btuh
of all other appliances in the room
— OR —
opening **, each at least:
1 square inch per Btuh
of all other appliances in the room
(Unless specified otherwise by
appliance manufacturer)
TWO openings, each at least:
1 square inch per Btuh
of all other appliances in the room
— OR —
opening **, each at least:
1 square inch per Btuh
of all other appliances in the room
(Unless specified otherwise by
appliance manufacturer)
TWO openings, each at least:
1 square inch per Btuh
of all other appliances in the room
— OR —
opening **, each at least:
1 square inch per Btuh
of all other appliances in the room
(Unless specified otherwise by
appliance manufacturer)
A single combustion air opening can be used for cases b, c or d above (boiler with
other appliances in room only), sized as listed, provided that:
The single opening must communicate directly to the outdoors or to a space that
communicates directly with outdoors (NOT to an interior space).
The top of the opening must be within 12 inches of the ceiling.
The free area of the opening must be at least equal to the sum of the areas of all
equipment vent connectors in the space.
NO combustion air openings are needed if the boiler (and other appliances) are
installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btuh of all
appliances in the space. That is, total the input of all appliances in MBH (1,000’s of
Btuh), then multiply this total times 50. The building MUST NOT be of tight construction.
Example: For a total input of 500 MBH (500,000 Btuh), the minimum volume would
be 50 x 500 = 25,000 cubic feet.
Figure 24
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
10 DIRECT VENT — Sidewall with separate pipes
Allowable vent/air pipe materials &
lengths
Use only the vent materials and kits listed in
Figure 21, page 17. Provide pipe adapters if specified.
1. Locate the termination such that the total air piping and vent
piping from the boiler to the termination will not exceed the
maximum length given in Figure 20, page 16.
For polypropylene applications, comply with any
additional requirements in the vent system manufac-
turer’s instructions. (Do Not use 3” PVC transition
pieces at the boiler vent and air connections). Install
a locking collar at every joint.
For AL29-4C vent pipe applications, comply with
any additional requirements in the vent system
manufacturer’s instructions. Provide a AL29-4C
starter piece from the AL29-4C manufacturer for the
transition piece at the boiler vent connection. The
air piping must be PVC or CPVC. Provide a 3” PVC
transition piece at the boiler air connection if using
2” air piping.
1. Wall penetration thickness between 2” to 24”.
2. The air and vent terminations must be installed as shown in
Figure 24, page 21 and Figure 26, page 22.
3. The terminations must comply with clearances and limitations
shown in Figure 22, page 19.
4. Locate the terminations so they are not likely to be damaged
by foreign objects, such as stones or balls, or subject to buildup
of leaves or sediment.
5. Vent and air locations can be on different building walls.
Example: Vent/exhaust can be on North building wall and air
intake can be on South building wall. (Different pressure zone).
Do not exceed the maximum lengths of the outside
vent piping shown in Figure 24. Excessive length
exposed to the outside could cause freezing of
condensate in the vent pipe, resulting in potential
boiler shutdown. In extremely cold climates, install
an insulated chase around the vent piping, particu-
larly if using longer lengths. The chase must allow
for inspection of the vent pipe, and insulation must
be protected from water.
1. When terminating multiple boilers, terminate each vent/air
connection as described in this manual.
2. Place wall penetrations to obtain minimum clearances shown
in Figure 24 for U. S. installations. For Canadian installations,
provide clearances required by CSA B149.1 or B149.2 Instal-
lation Code and a ULC S636 compliant vent kit.
3. The air inlet of a boiler is part of a direct vent connection. It
is not classified as a forced air intake with regard to spacing
from adjacent boiler vents.
1. Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as close as
desired to the air pipe outside diameter.
2. Vent pipe penetration:
Read and follow all instructions in this manual.
See notices at left.
Install the boiler in a location that allows proper routing
of all vent and air piping to the selected sidewall location.
Make sure the selected sidewall termination location com-
plies with Figure 22, page 19. (Multiple boiler sidewall plates
must also comply with Figure 25, page 22.)
Use only the vent materials listed in Figure 21, page 17.
Provide pipe adapters where required. Vent piping and
air piping lengths must not exceed the values shown in
Figure 20, page 16.
Prepare the sidewall penetrations and secure the sidewall
plates as instructed in this section. See “Prepare wall penetra-
tions” on page 21.
See notices at left.
The air piping must terminate in a down-turned elbow as
shown above. The vent piping must terminate in an elbow
as shown
above. See illustration above.
Install vent and air piping between the boiler and the side-
wall openings. Slope horizontal piping downward toward
the boiler at least 1/4 inch per foot. See page 32 for general
guidelines.
See notices at left.
Install pipe supports every 5 feet on both the horizontal
and vertical runs. Install a hanger support within 6 inches
of any upturn in the piping, or per vent pipe manufacturer’s
instructions.
See notices at left.
Attach the vent termination exterior piping: Use either of the
configurations shown above, as needed to ensure clearance
above grade or snow line. Keep vents/air intake area clear
of accumulating snow.
The vent and air pipes may run up as high as 4 feet with
no enclosure. The vent and air pipes must be secured with
braces, and all clearances and lengths must be maintained.
Space braces no further than 24 inches apart.
External venting greater than 4 feet requires an insulated
enclosure around the vent and air pipes. The vent and air
terminations must exit through the enclosure as shown in
the illustration above, maintaining all required clearances.
— DO NOT use short radius
elbows for vent or air piping. Boiler performance
could be affected.
Figure 25
.
Figure 26
See notices on previous page.
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
10 DIRECT VENT — Sidewall with separate pipes continued
a. Cut a hole for the vent pipe. For either combustible or
noncombustible construction, size the vent pipe hole at
least 0.4” larger than the vent pipe diameter.
b. Insert a galvanized metal thimble in the vent pipe hole
as shown in Figure 26.
c. Plate may be field fabricated from corrosion resistant
material of sufficient strength. Plate must allow venting
to maintain minimum clearance to combustibles.
Ensure that the plate material is strong enough to
prevent the termination from being pushed inward
if struck or pushed from the outside.
1. Follow all local codes for isolation of vent pipe when passing
through floors or walls.
2. Seal exterior openings thoroughly with exterior caulk.
Termination and fittings
1. Prepare the vent termination elbow and the air ter-
mination elbow by inserting bird screens.
(See Figure 24, page 21.) Bird screens must be purchased
separately. See the parts list at the end of this manual for
part numbers.
2. Secure the elbows so they will butt against the sidewall ter-
mination plate.
3. When completed, the air termination coupling must be
oriented at least 12 inches below the vent termination and
at least 12 inches above grade or snow line as shown in Fig-
ure 24, page 21.
Keep vents/air intake area clear of accumulating
snow.
4. You can orient the vent termination elbow either directly
outward or 90 degrees away from the air inlet elbow as shown
in Figure 24, page 21.
5. Maintain the required dimensions of the finished termination
piping as shown in Figure 24, page 21.
6. For multiple boiler terminations, see Figure 25.
7. Do not extend exposed vent pipe outside of building more
than shown in this document. Condensate could freeze and
block vent pipe.
If extending the vent and air pipes out from the wall,
install a coupling on each pipe. Mount the piping
with the coupling flush with the outer plate.
Wall penetration thickness between 2” to 24”.
1 Vent piping
2 Air piping
3 Sidewall termination plates: for 3” PVC
or 3” AL29-4C or 2” PVC, (field supplied)
4 Galvanized thimbles, by installer
5 Bird screen, by installer
6 Air inlet elbow
7 Elbow
8 Nipple
9 Vent termination elbow
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
11 DIRECT VENT — Sidewall concentric
Allowable vent/air pipe materials
& lengths
1. The concentric termination kit must be purchased
separately.
Use only the vent materials and kits listed in
Figure 21, page 17. Provide pipe adapters if
specified.
2. Locate the termination such that the total air pip-
ing and vent piping from the boiler to the termina-
tion will not exceed the maximum length given in
Figure 20, page 16.
3. This termination requires a 45-degree elbow that is
not supplied with the termination kit. The maximum
vent/air pipe lengths include allowance for this elbow.
For polypropylene applications, comply
with any additional requirements in the
vent system manufacturer’s instructions.
(Do Not use 3” PVC transition pieces at the
boiler vent and air connections)
and at the
termination if using a 3” PVC concentric
vent kit. Install a locking collar at every joint.
For AL29-4C vent pipe applications, comply
with any additional requirements in the vent
system manufacturer’s instructions.
Provide
a AL29-4C starter piece from the AL29-4C
manufacturer to the
transition at the boiler
vent connection. Air pipe must be PVC or
CPVC. Provide a 3” PVC transition at the
boiler air connection if using 2” air pipe.
Provide transition pieces to PVC at the vent
and air pipe termination connections.
Wall penetration thickness between 2” to
24”.
1. The concentric termination kit must be installed as
shown in Figure 29, page 24.
2. The termination must comply with clearances and
limitations shown in Figure 22, page 19.
3. Locate the termination so it is not likely to be damaged
by foreign objects, such as stones or balls, or subject
to buildup of leaves or sediment.
1. When terminating multiple boilers, install each con-
centric termination as described in this manual.
All vent pipes and air inlets must terminate
at the same height to avoid possibility of
severe personal injury, death or substantial
property damage.
2. Place wall penetrations to obtain minimum clear-
ance as shown in Figure 28, page 24 for U. S. installa-
tions.
For Canadian installations, provide clearances
required by CSA B149.1 or B149.2 Installation Code
and a ULC S636 compliant vent kit.
3. The air inlet of a boiler is part of a direct vent con-
nection. It is not classified as a forced air intake with
regard to spacing from adjacent boiler vents.
Figure 27
Read and follow all instructions in this manual.
See notices at left.
Install the boiler in a location that allows proper routing of all vent
and air piping to the selected sidewall location.
Make sure the selected sidewall termination location complies with
Figure 22, page 19. (Multiple boiler concentric terminations must
also comply with
Figure 28, page 24
.)
Use only the vent materials listed in Figure 21, page 17. Provide pipe
adapters where required.
Vent piping and air piping lengths must not exceed the values shown
in Figure 20, page 16.
The concentric termination must be assembled and installed before
piping from the boiler to the termination.
Prepare the sidewall penetration — assemble the concentric ter-
mination kit and secure the cover plates as instructed in this sec-
tion. Provide the supports indicated and mount the termination
assembly. See “Install termination — concentric pipes” on page 24.
See notices at left.
Install vent and air piping between the boiler and the concentric
vent/air termination. Slope horizontal piping downward toward the
boiler at least 1/4 inch per foot. See page 32 for general guidelines.
Install pipe supports every 5 feet on both the horizontal and vertical
runs.
See notices at left.
Install a hanger support within 6 inches of any upturn in the piping.
See notices at left.
— DO NOT use short radius elbows for vent or
air piping. Boiler performance could be affected.
Figure 28
Figure 29
Figure 29
1 Vent pipe
2 Air pipe
3 Wall
4 Outer thimble plate
5 Supports every 5 feet or
per vent pipe mfg’s in-
structions
6 Wall brace, by installer,
(or see vent pipe mfg’s
instructions)
7 Thimble, by installer
8 Rain cap
9 Rain cap ribs must butt
against outer thimble
plate or wall opening
See notices on previous page.
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Install termination — concentric pipes
1. Assemble the vent termination as described for concentric termi-
nations, on page 31.
If necessary, you can shorten the lengths of the inner and
outer pipes for a shorter finished assembly. But you must
ensure the pipes butt correctly at both ends. Failure to
properly assemble the concentric termination can result
in flue gas recirculation, causing possible severe personal
injury or death.
2. Wall penetration:
a. Preferably, use a thimble with a 4½-inch hole. If not using a
thimble, carefully use a hole saw to cut a hole not larger than
4¾ inches in diameter through the wall. The finished hole
must provide a solid stop for the rain cap ribs, as shown in the
inset to Figure 29.
Wall penetration thickness between 2” to 24”.
Ensure that the wall material is strong enough to pre-
vent the rain cap from being pushed inward if struck or
pushed from the outside.
3. Secure the termination in place so the rain cap will butt against the
outside wall or outer thimble plate as shown in Figure 29.
4. Before beginning vent and air piping from the boiler to the con-
centric termination, mount and secure the concentric termination
as shown in Figure 29.
The vent and air piping must be securely supported, and
must not rest its weight on the boiler fittings. Failure to
properly support the vent and air piping could result in
vent piping damage, resulting in possible severe personal
injury, death or substantial property damage.
The supports/bracing used must support the termination
assembly to prevent slippage or movement. See instruc-
tions provided with concentric kit for details.
The clamps used on the outside of the termination pipe
must not cut into the pipe or contain sharp edges that
could cause a crack to form.
When inserting the partially-assembled termination kit
through the wall penetration, wrap plastic or other pro-
tection over the end of the exposed assembly to prevent
debris from entering the pipes. If the air passages become
blocked, the boiler will not operate. Once the rain cap
has been cemented to the assembly, there is no way to
correct the problem. The assembly would have to be re-
placed if it were cut to be removed and cleaned. Altering
the assembly in any way could result in severe personal
injury or death due to toxic flue product emissions.
If using AL29-4C stainless vent pipe, use the vent pipe
manufacturer’s PVC adapter if connecting to a PVC
concentric vent attachment.
5. After the assembly has been positioned in the opening and all sup-
ports have been attached, install a bird screen (purchased separately
if not included with the kit) and rain cap as follows:
a. Place the bird screen on the end of the inner pipe as in
Figure 38, page 31, or per concentric kit instructions for poly-
propylene kits.
b. Cement the rain cap in place as shown.
11 DIRECT VENT —
(continued)
Figure 30
IS AT LEAST 12 inches below vent outlet
IS NO FURTHER than 12 inches away center to center
IS AT LEAST 12 inches above roof or snow line,
keep vents/air intake area clear of accumulating snow.
Read and follow all instructions in this manual.
with vent/air installation until you have read
See notices at left.
Install the boiler in a location that allows proper routing of all vent
and air piping to the selected sidewall location.
Make sure the selected vertical termination location complies with
Figure 22, page 19. (Multiple boiler terminations must also comply
with Figure 31, page 26.)
Use only the vent materials listed in Figure 21, page 17. Provide pipe
adapters where required. Vent piping and air piping lengths must not
exceed the values shown in Figure 20, page 16.
Prepare the vertical penetrations and secure penetration components as
instructed in this section. See “Prepare roof penetrations” on page 26
and “Termination and fittings” on page 26.
The air piping must terminate in a 180-degree return bend or down-
turned elbow as shown above. The vent piping must terminate in a
as shown above.
Install vent and air piping between the boiler and the vertical termina-
tions. Slope horizontal piping downward toward the boiler at least 1/4
inch per foot. Install pipe supports every 5 feet on both the horizontal
and vertical runs. Install a hanger support within 6 inches of any upturn
in the piping. See page 32 for general guidelines. Also comply with vent
pipe manufacturer’s instructions.
See notices at left.
Insert the vent and air piping through the vertical penetrations and
secure the termination fittings.
Maintain clearances shown above. Vent and air terminations must be
fitted with a bird screen as shown.
— DO NOT use short radius elbows for vent or
air piping. Boiler performance could be affected.
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Allowable vent/air pipe materials
& lengths
Use only the vent materials and kits listed
in Figure 21, page 17. Provide pipe adapt-
ers if specified.
1. Locate the terminations such that the total air piping
and vent piping from the boiler to the termination
will not exceed the maximum length given in Fig-
ure 20, page 16.
For polypropylene applications, comply
with any additional requirements in the
vent system manufacturer’s instructions.
(Do Not use 3” PVC transition pieces
at the boiler vent and air connections).
Install a locking collar at every joint.
For AL29-4C vent pipe applications,
comply with any additional requirements
in the vent system manufacturer’s instruc-
tions. Provide a AL29-4C starter piece
from the AL29-4C manufacturer to the
transition piece at the boiler vent con-
nection. The air piping must be PVC or
CPVC. Provide a 3” PVC transition piece
at the boiler air connection if using 2” air
piping.
1. The air and vent terminations must be installed as
shown in Figure 30.
2. The terminations must comply with clearances and
limitations shown in Figure 22, page 19.
3. Locate the terminations so they are not likely to be
damaged by foreign objects, such as stones or balls,
or subject to buildup of leaves or sediment.
1. When terminating multiple boilers, terminate each
vent/air connection as described in this manual.
Terminate all vent pipes at the same height
and all air pipes at the same height to
avoid possibility of severe personal injury,
death or substantial property damage.
2. Place roof penetrations to obtain minimum clear-
ance of 12 inches between edge of air intake elbow
and adjacent vent pipe of another boiler for U. S.
installations (see Figure 33, page 28).
3. For Canadian installations, provide clearances re-
quired by CSA B149.1 or B149.2 Installation Code
and a ULC S636 compliant vent kit.
4. The air inlet of a boiler is part of a direct vent con-
nection. It is not classified as a forced air intake with
regard to spacing from adjacent boiler vents.
12 DIRECT VENT —
Figure 31
Also maintain maximum distances between the
vent and air pipes for each boiler as shown in
Figure 30, page 25.
See notices on previous page.
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
1. Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole at least 0.4” larger than the vent pipe diameter.
b. Insert a galvanized metal thimble in the vent pipe
hole.
3. Space the air and vent holes
no closer than the minimum
spacings shown in Figure 31.
4. Follow all local codes and vent pipe manufacturer’s
instructions for isolation of vent pipe when passing
through floors, ceilings and roofs.
5. For Canadian installations, provide clearances required
by CSA B149.1 or B149.2 Installation Code and a
ULC S636 compliant vent kit.
6. Provide flashing and sealing boots sized for the vent
pipe and air pipe. Follow all vent pipe manufacturer’s
instructions.
Termination and fittings
1. Prepare the vent termination elbow and the air termina-
tion elbow (Figure 30, page 25) by inserting bird screens.
Bird screens must be purchased separately. See the parts
list at the end of this manual for part numbers.
2. The air piping must terminate in a down-turned 180-de-
gree return bend as shown in Figure 30, page 25. Locate
the air inlet pipe no further than 12 inches from the
center of the vent pipe. This placement avoids recircu-
lation of flue products into the combustion air stream.
3. The vent piping must terminate in an up-turned cou-
pling as shown in Figure 30, page 25. The top of the
coupling must be at least 12 inches above the air intake.
The air inlet pipe and vent pipe can be located in any
desired position on the roof, but must always be no fur-
ther than 12 inches apart (center to center) and with the
vent termination at least 12 inches above the air intake.
4. Maintain the required dimensions of the finished termi-
nation piping as shown in Figure 30, page 25.
5. Do not extend exposed vent pipe outside of building
more than shown in this document. Condensate could
freeze and block vent pipe.
12 DIRECT VENT —
(continued)
Figure 32
Part number 550-100-325/0419
27
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Allowable vent/air pipe materials &
lengths
1. The concentric termination kit must be purchased sepa-
rately.
Use only the vent materials and kits listed in Fig-
ure 21, page 17. Provide pipe adapters if specified.
2. Locate the termination such that the total air piping and
vent piping from the boiler to the termination will not
exceed the maximum length given in Figure 20, page 16.
3. This termination requires a 45-degree elbow that is not
supplied with the termination kit. The maximum vent/air
pipe lengths include allowance for this elbow.
For polypropylene applications, comply with
any additional requirements in the vent system
manufacturer’s instructions. (Do Not use 3” PVC
transition pieces at the boiler vent and air con-
nections)and at the termination if using a 3” PVC
concentric vent kit. Install a locking collar at every
joint.
For AL29-4C vent pipe applications, comply with
any additional requirements in the vent system
manufacturer’s instructions. Provide a AL29-4C
starter piece from the AL29-4C manufacturer to
the transition at the boiler vent connection. Air
pipe must be PVC or CPVC. Provide a 3” PVC
transition at the boiler air connection if using 2”
air pipe. Provide transition pieces to PVC at the
vent and air pipe termination connections.
Locate the concentric vent/air termination using the following
guidelines:
1. The concentric vent/air assembly must terminate as shown
in Figure 34, page 28.
2. The termination must comply with the clearances and
limitations shown in Figure 22, page 19.
3. Locate the termination so it is not likely to be damaged by
foreign objects, such as stones or balls, or subject to buildup
of leaves or sediment.
4. For Canadian installations, provide clearances required by
CSA B149.1 or B149.2 Installation Code and a ULC S636
compliant vent kit.
1. When terminating multiple boilers, install the concentric
vent/air termination assemblies as described in this manual.
All vent outlets must terminate at the same height
to avoid possibility of severe personal injury,
death or substantial property damage.
2. Place roof penetrations to obtain minimum clearance of
12 inches between the edges of adjacent vent pipes of other
boilers for U. S. installations (see Figure 33, page 28).
3. For Canadian installations, provide clearances required by
CSA B149.1 or B149.2 Installation Code and a ULC S636
compliant vent kit.
4. The air inlet of a boiler is part of a direct vent connection. It
is not classified as a forced air intake with regard to spacing
from adjacent boiler vents.
13 DIRECT VENT —
Read and follow all instructions in this manual.
read
See
notices at left.
Install the boiler in a location that allows proper routing of all
vent and air piping to the selected sidewall location.
Make sure the selected vertical termination location complies
with Figure 22, page 19. (Multiple boiler concentric termina-
tions must also comply with Figure 33, page 28.)
Use only the vent materials listed in Figure 21, page 17. Provide
pipe adapters where required.
Vent piping and air piping lengths must not exceed the values
shown in Figure 20, page 16.
The concentric termination must be assembled and installed
before piping from the boiler to the termination.
Prepare the vertical penetration(s) — assemble the concen-
tric termination kit and secure the penetration components
as instructed in this section. Provide the supports indicated
and mount the termination assembly. See “Prepare roof pen-
etrations” on page 28 and “Mount concentric termination”
on page 28.
See notices at left.
Install vent and air piping between the boiler and the concen-
tric vent/air termination. Slope horizontal piping downward
toward the boiler at least 1/4 inch per foot. See page 32 for
general guidelines.
Install pipe supports every 5 feet on both the horizontal and
vertical runs.
See notices at left.
Install a hanger support within 6 inches of any upturn in the
piping.
See notices at left.
— DO NOT use short radius elbows
for vent or air piping. Boiler performance could be
affected.
Figure 33
Figure 34
See notices on previous page.
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1. Roof penetration hole:
a. Cut a clearance hole to clear the termination outside di-
ameter as prescribed in the kit instructions.
b. Insert a galvanized metal thimble in the vent pipe hole.
2. Follow all local codes for isolation of vent pipe when passing
through floors, ceilings and roofs.
3. For Canadian installations, provide clearances required by
CSA B149.1 or B149.2 Installation Code and a ULC S636
compliant vent kit.
4. Provide flashing and sealing boots sized for the concentric
termination outside diameter.
1. Assemble the vent termination as described for concentric
terminations, on page 31.
2. Mount the termination as shown in Figure 34.
3. Support the concentric vent/air termination at the roof pene-
tration as shown in Figure 34 or per concentric kit instructions.
The supports/bracing used must support the termina-
tion assembly to prevent vertical slippage or sideways
movement.
The clamps used on the outside of the termination pipe
must not cut into the pipe or contain sharp edges that
could cause a crack to form.
The vent and air piping must be securely supported,
and must not rest its weight on the boiler fittings.
DO NOT drill or screw into either the vent pipe or
air pipe. Failure to properly support the vent and air
piping could result in vent piping damage, resulting
in possible severe personal injury, death or substan-
tial property damage.
When inserting the partially-assembled termina-
tion kit through the roof penetration, wrap plastic
or other protection over the end of the exposed
assembly to prevent debris from entering the pipes.
If the air passages become blocked, the boiler will
not operate. Once the rain cap has been cemented
to the assembly, there is no way to correct the prob-
lem. The assembly would have to be replaced if it
were cut to be removed and cleaned. Altering the
assembly in any way could result in severe personal
injury or death due to toxic flue product emissions.
If using AL29-4C stainless vent pipe, use the vent
pipe manufacturer’s PVC adapter if connecting to
a PVC concentric vent attachment.
Do not connect any other appliance to the vent pipe
or multiple boilers to a common vent pipe.
4. After the assembly has been positioned in the roof opening and
all supports have been attached, install a bird screen (purchased
separately if not included with the kit) and rain cap as follows:
a. Place the bird screen on the end of the inner pipe as in
Figure 38, page 31, or per kit instructions for polypro-
pylene kits.
b. Cement the rain cap in place.
13 DIRECT VENT — (continued)
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Figure 35
Use only the vent materials and kits listed in Fig-
ure 21, page 17. Provide pipe adapters if specified.
1. Locate the terminations such that the total air pip-
ing and vent piping from the boiler to the termina-
tion will not exceed the maximum length given in
Figure 20, page 16.
For polypropylene applications, comply with any
additional requirements in the vent system manu-
facturer’s instructions. (Do Not use 3” PVC transi-
tion pieces at the boiler vent and air connections).
Install a locking collar at every joint.
For AL29-4C vent pipe applications, comply with
any additional requirements in the vent system
manufacturer’s instructions. Provide a AL29-4C
starter piece from the AL29-4C manufacturer to
the transition piece at the boiler vent connection.
The air piping must be PVC or CPVC. Provide a
3” PVC transition piece at the boiler air connection
if using 2” air piping.
2. For 3” to 2” transitions, must use appropriate vent material.
For polypropylene or stainless steel must use approved sup-
pliers transitions.
1. The air and vent terminations must be installed as shown
in Figure 30.
2. The terminations must comply with clearances and limita-
tions shown in Figure 22, page 19.
3. Locate the terminations so they are not likely to be damaged
by foreign objects, such as stones or balls, or subject to buildup
of leaves or sediment.
1. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or
noncombustible construction, size the vent pipe hole at
least 0.4” larger than the vent pipe diameter.
b. Insert a galvanized metal thimble in the vent pipe hole.
2. Follow all local codes and vent pipe manufacturer’s instruc-
tions for isolation of vent pipe when passing through floors,
ceilings and roofs.
3. For Canadian installations, provide clearances required by
CSA B149.1 or B149.2 Installation Code and a ULC S636
compliant vent kit.
4. Provide flashing and sealing boots sized for the vent pipe and
air pipe. Follow all vent pipe manufacturer’s instructions.
Vent termination and fittings
1. Prepare the vent termination coupling by inserting a bird
screen. Bird screens must be purchased separately. See the
parts list at the end of this manual for part numbers.
2. Maintain the required dimensions of the finished termination
piping as shown in Figure 36.
1. When terminating multiple boilers, terminate each vent/air
connection as described in this section.
2. Place adjacent terminations at least 6 inches apart.
3. For Canadian installations, provide clearances required by
Natural Gas and Propane Installation
CAN/CSA
B149.1 or
B149.2 Installation Code.
14 DIRECT VENT —
Read and follow all instructions in this manual.
read through
See notices at left.
Install the boiler in a location that allows proper routing of
all vent and air piping to the selected locations.
Make sure the selected vertical termination location com-
plies with Figure 22, page 19.
Use only the vent materials listed in Figure 21, page 17.
Provide pipe adapters where required. Vent piping and
air piping lengths must not exceed the values shown in
Figure 20, page 16.
Prepare the vertical penetration (vent) and sidewall penetra-
tion (air) and secure penetration components as instructed
in this section.
The air piping must terminate in a 90-degree down-turned
elbow as shown above. The vent piping must terminate in
a as shown above.
Install vent and air piping between the boiler and the air
and vent terminations. Slope horizontal piping downward
toward the boiler at least 1/4 inch per foot. Install pipe sup-
ports every 5 feet on both the horizontal and vertical runs.
Install a hanger support within 6 inches of any upturn in the
piping. See page 30 for general guidelines. Also comply with
vent pipe manufacturer’s instructions.
See notices at left.
Insert the vent and air piping through the penetrations and
secure the termination fittings.
Maintain clearances shown in this section. Vent and air
terminations must be fitted with bird screens as shown.
— DO NOT use short radius
elbows for vent or air piping. Boiler performance
could be affected.
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14 DIRECT VENT — (continued)
Figure 36
Figure 37
1. The air inlet of an boiler is part of a direct vent connection. It is
not classified as a forced air intake with regard to spacing from
adjacent appliance terminations.
2. Locate the air inlet elbow (termination) using the following
guidelines.
3. The air piping must terminate in a down-turned elbow as shown
in Figure 37.
a. Apply the configuration on the left side of Figure 37 unless
the terminations would fail to meet minimum clearance to
grade or snow line.
b. Apply the configuration on the right side of Figure 37 when
the terminations need to be raised higher to meet clearance
to grade or snow line.
c. The air pipe may run up the side of the building, as shown.
The vent and air pipes must be secured with braces, and all
clearances and lengths must be maintained. Space braces no
further than 24 inches apart.
4. You must consider the surroundings when terminating the air
connection:
a. Make sure there are no obstructions for air flow. DO NOT
locate the termination where plants could grow and cause
obstruction to air flow.
b. Do not locate the terminations where wind eddies could af-
fect performance or cause recirculation with exhaust from
other appliances, such as inside building corners, near adja-
cent buildings or surfaces, window wells, stairwells, alcoves,
courtyards or other recessed areas.
c. Locate the air inlet termination at least 12 inches below and 12
inches horizontally from any appliance or building vent outlet.
5. Locate terminations so they are not likely to be damaged by
foreign objects, such as stones or balls, or subject to buildup of
leaves or sediment.
1. When terminating multiple boiler air connections, terminate each
air connection as described in this manual.
2. Place wall penetrations to obtain minimum clearances as in-
structed in this manual.
3. Place adjacent air inlets for multiple boilers at least 6 inches apart.
4. For Canadian installations, provide clearances required by Natu-
ral Gas and Propane Installation
CAN/CSA
B149.1 or B149.2
Installation Code.
5. Combustion air (NOT vent piping) can be manifolded.
1. Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as close as
desired to the air pipe outside diameter.
2. Seal exterior openings thoroughly with exterior caulk.
Termination and fittings
1. Prepare the air termination elbow (Figure 37) by inserting a bird
screen. Bird screens must be purchased separately. See the parts
list at the end of this manual for part numbers.
2. Use metal plates (by installer) at inside and outside penetrations
using the method shown in Figure 26, page 22.
If extending the air pipe out from the wall, install a cou-
pling on each pipe. Mount the piping with the coupling
flush with the outer plate.
Figure 38 VC
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15 Concentric termination, typical (sidewall or vertical)
1. Follow all instructions provided with the concentric
termination kit. The following are general guidelines
for information only.
2. See Figure 38, for the typical assembly of a concentric
termination assembly.
3. Prepare the bird screen, item 4 (purchase separately if
not included with the kit). Cut the bird screen to size
if required. If the bird screen must be trimmed, cut the
bird screen to fit the outside diameter of the PVC inner
pipe supplied with the termination kit.
4. Partially assemble the vent termination kit in the se-
quence shown in Figure 38, or per the concentric kit
instructions.
install the rain cap and bird screen
until the assembly has been inserted through
the roof (or sidewall) and all supports have
been installed. Follow instructions to cover
the end of the assembly with plastic before
inserting through the roof penetration to
prevent debris from blocking the air passages.
If necessary, you can shorten the lengths of the
inner and outer pipes for a shorter finished
assembly. But you must ensure the pipes butt
correctly at both ends. Failure to properly as-
semble the concentric termination can result
in flue gas recirculation, causing possible
severe personal injury or death.
For polypropylene applications, comply
with any additional requirements in the vent
system manufacturer’s instructions. (Do Not
use 3” PVC transition pieces at the boiler vent
and air connections) and at the termination
if using a PVC concentric vent kit.
Install a
locking collar at every joints.
For AL29-4C vent pipe applications, comply
with any additional requirements in the vent
system manufacturer’s instructions. Provide
a AL29-4C starter piece from the AL29-4C
manufacturer to the transition at the boiler
vent connection. Air pipe must be PVC or
CPVC. Provide a 3” PVC transition at the
boiler air connection if using 2” air pipe.
Provide transition pieces to PVC at the vent
and air pipe termination connections.
Figure 38
1 Inner PVC pipe (vent)
2 Outer PVC pipe (air)
3 Rain cap
4 Bird screen
5 Y fitting
6 Finished assembly
Figure 39
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16 Vent and air piping and boiler connections
Follow termination instructions
1. Read and follow all instructions for the termination type
used before proceeding with this page. Follow all instructions
provided by vent pipe manufacturer.
Use only materials from the manufacturers listed
in Figure 21, page 17.
Installing vent and air piping
For polypropylene applications, comply with any
additional requirements in the vent system manu-
facturer’s instructions. (Do Not use 3” PVC transi-
tion pieces at the boiler vent and air connections).
For AL29-4C vent pipe applications, comply with
any additional requirements in the vent system
manufacturer’s instructions.
1. Work from the boiler to vent or air termination. Do not
exceed the lengths given in the previous pages for either the
air or vent piping.
2. See Figure 39, for locations for attaching vent and air inlet
adapters on to the boiler. Air inlet adapter connection is made
on right side of centered flue adapter.
3. Remove vent/exhaust protective paper prior to mounting
vent adapter.
4. Vent and air inlet adapters needed to be attached to top
securely with four (4) 10-32 large Phillips head screws, see
Figures 41, 42 and 43. Vent adapters (provided with boiler)
are for polypropylene, PVC, and AL29-4C venting.
5. See Figure 41, center flue gasket and insert the extruded flue
vent adapter into the center opening, secure with four (4)
10-32 Phillips head screws.
Figure 40
6. See Figure 43, right air inlet, center gasket and air inlet vent
adapter over right opening, secure with four (4) 10-32 Phil-
lips head screws.
Figure 41
Figure 42
Vent
adapter
Vent
gasket
Air pipe
connection
vent/exhaust
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16 Vent and air piping and boiler connections (continued)
7. The adapter accepts 3” PVC, CPVC, Polypropylene and
AL29-4C material. Use a 2” adapter, if needed.
For AL29-4C vent pipe applications, comply
with any additional requirements in the vent system manu-
facturer’s instructions. Provide a AL29-4C starter piece
from the AL29-4C manufacturer to the transition at the
boiler vent connection.
8. Cut pipe to required lengths.
9. Dry assemble entire vent or air piping to ensure proper fit
before assembling any joint.
10. Maintain minimum clearance of
3/16 inch between vent
pipe and any combustible wall or material.
11. Assembling PVC or CPVC: (
— follow pipe
manufacturer’s instructions for preparation and assembly)
a. Deburr inside and outside of pipe ends.
b. Chamfer outside of each pipe end to ensure even cement
distribution when joining.
c. Clean all pipe ends and fittings. Dry thoroughly.
d. For each joint:
Handle fittings and pipes carefully to prevent con-
tamination of surfaces.
Apply primer liberally to both joint surfaces — pipe
end and fitting socket.
While primer is still damp, lightly apply approved
cement to both surfaces in a uniform coating.
Apply a second coat to both surfaces. Avoid using
too much cement on sockets to prevent cement
buildup inside.
With cement still wet, insert pipe into fitting, twist-
ing ¼ turn. Make sure pipe is fully inserted.
Wipe excess cement from joint. Check joint to be
sure a smooth bead of cement shows around the
entire joint.
12. Seal wall or floor penetration openings following local code
requirements.
ADAPTERS — Use adapters if using 2-inch pipe.
1. Clean and deburr inside and outside of both ends of air and vent
pipes. Chamfer boiler end of vent pipe for ease of insertion.
The vent pipe end must be smooth and chamfered to
prevent possible damage to sealing gasket in vent pipe
adapter.
2. Inspect vent or air adapter (above) — verify no obstructions or
foreign objects inside.
3. Loosen clamp screw (if used).
4. Measure 2¼-inches from end of pipe and make a mark with felt-
tip pen.
5. Apply small amount of silicon grease to end of pipe to ease inser-
tion.
6. Insert pipe into adapter.
7. Slide pipe down until the 2¼-inch mark is reached.
Do not apply excessive force or bend the adapter or
flue/air pipe when inserting. The adapter or seal could
be damaged. If any portion of the vent or air system is
damaged, it must be replaced.
8. The seal is accomplished with the internal gasket.
— DO NOT use short radius
elbows for vent or air piping. Boiler performance
could be affected.
Figure 43
Vent and Air adapters to be installed with test ports facing to
front of boiler. Must be locked closed.
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Control selection for vent material
-
Perform at start-up final checks
Venting Material Change “b22” parameter
Boiler default is “1”for PVC vent material, see
Figure 128, page 101.
If other vent material is used, you program that material via
the control board.
To insure proper boiler operation (Combi and Heating Only
boilers) the boiler control programmed default is for PVC
venting material. You MUST program the boiler control for
any other venting material that you installed other than PVC,
in order to improve operational efficiency.
Refer to “Quick Start Guide” page 73, to first power up the
boiler.
To access the configuration menu:
16 Vent and air piping and boiler connections
(continued)
Push DHW buttons + & -
together for 10 seconds
DHW
Press Heating
buttons + & - to
scroll up or down
the parameter
numbers
1. Press the DHW + and DHW – buttons together for 10
seconds.
2. At the end of the 10 seconds the display will show the mes-
sage “b01”.
3. Press the heating buttons (+ or -) to scroll up or down
the list of parameters in increasing or decreasing order to
parameter “b22”.
4. Press the DHW buttons (+ or -) to view or modify the value
of a parameter: the modification will be automatically saved.
For example: CPVC, Polypropylene, or AL29-4C stainless
steel.
“b22” parameter
PVC solid core, ....................................... Select: “1”
CPVC only, ............................................. Select: “2”
Polypropylene and AL29-4C, ................ Select: “0”
DHW
Use the DHW + or – buttons to
modify the parameter value
Exiting the “User interface setting” menu. Press the “DHW +”
and “DHW -” buttons together for 10 seconds; or switch the
power to the unit o and then on again; or wait for automatic
exiting which occurs aer two (2) minutes
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17 Install water piping
Domestic Water Piping – Combi Boiler
Thermostatic Mixing Valve - A mixing valve (for regulating
domestic heating water) must be used to regulate the water tem-
perature leaving the plate heat exchanger. NOTE: the valve must
be set to supply a domestic water temperature of not more than
120 degrees F. It is the responsibility of the installer to set the valve
and remove the dial.
the entrance of the DHW connection to protect the DHW flow
switch. Failure to install the DHW water filter from dirt and debris
will cause it to malfunction.
Check Valve – A check valve must be field provided
and installed on the outlet of the mixing valve to
prevent expansion devices downstream from back
flowing when the water pressure drops during cold
water draws. Failure to prevent the backflow will
cause water to flow through the flow switch, activat-
ing it, when the cold water draw has ended and the
water pressure increases.
the inlet and outlet of the DHW connections so that the DHW
heat exchanger can be flushed and cleaned from possible build-up
caused by dirty or hard water, which is a maintenance requirement.
Minimum Maximum
DHW
Rating
130
If the boiler piping system is connected to heating coils
located in air handling units where there may be exposed
to refrigerated air circulation then it must be equipped
with flow control valves or other automatic means to
prevent gravity circulation of the boiler water during the
cooling cycle.
1. Size piping for DHW inlet and outlet - 1/2” NPT on
80/120 and 3/4” NPT on the 155 boilers.
2. Additional anti-scald devices may be installed at each
hot water faucet, bath and shower outlet.
3. In hard water areas, soften cold domestic supply water
to heaters to prevent scale build-up.
4. Refer to Figure 44, below for maximum and minimum
domestic water pressure rating for our units, on the
domestic pipes (Combi only).
5. A new approved pressure relief valve that complies with
the standard for relief valves and automatic gas shut-off
devices for Hot Water Supply Systems, ANSI Z21.221
CSA4.4 is required to be installed at the supply DHW
connection (field supplied). This pressure relief valve
Figure 44
Figure 45
6. Combi Boiler: Domestic water inlet connection showing filter
screen to protect paddle flow switch from sand and other
debris.
Pipe in a “union” fitting below this adapter to service
this filter screen.
Use two wrenches when tightening water piping
at boiler, using one of the wrenches to prevent the
boiler interior piping from turning (wrench on both
sides, here and inside boiler). Failure to support the
boiler piping connections to prevent them from
turning could cause damage to boiler components.
should be capable of at least the Maximum input of the boiler
*
and Maximum pressure Not exceeding 130 PSIG. The pressure
relief valve’s discharge should be per instructions in the Warning
box, page 42. DO NOT place any other type valve or shut-off device
between the relief valve and the boiler. The pressure relief valve
must be manually checked once a year to verify correct operation.
*(80 KBTU/hr, 120 KBTU/hr, or 155 KBTU/hr, depending on the
boiler model).
Hot Water Can Scald!
Consumer Product Safety Commission and some
states recommend domestic hot water tempera-
ture of 130°F or less.
When installing an
automatic mixing valve,
selection and installation must comply with valve
manufacturer’s recommendations and instructions.
Water heated to a temperature suitable for clothes
washing, dish washing and other sanitizing needs
will scald and cause injury.
Children, elderly, infirm or physically handi-
capped persons are more likely to be injured by
hot water. Never leave them unattended in or near
a bathtub, shower or sink. Never allow small chil-
dren to use a hot water faucet or draw their own
bath. If anyone using hot water in the building
fits this description, or if state laws or local codes
require certain water temperatures at hot water
faucets, take special precautions:
Install
automatic mixing valve set according to
those standards.
Use lowest practical temperature setting.
Check water temperature immediately after first
heating cycle and after any adjustment.
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17 Install water piping (continued)
This boiler is NOT intended for connection with a
refrigeration system.
General piping information
The control uses temperature sensors to provide
both high limit protection and modulating
temperature control.
. Some codes/
jurisdictions may require additional external
controls for high limit and/or low water cutoff
protection.
Following standard industry practices, if installation is to com-
ply with ASME or Canadian requirements, an additional high
temperature limit may be needed. Consult local requirements
for other codes/standards to determine if needed.
1. Install a manual reset high temperature limit to prevent a
temperature above 200°F in system supply piping between
boiler and isolation valve. (Note that the control operating
limit function shuts the boiler down at 195°F, or lower if set
to a lower value.)
— If the heating sys-
tem includes circuits that require lower temperature
water (radiant slab circuits, for example) as well as
higher temperature circuits, it is recommended to
protect low temperature circuits with limit controls
that are wired to the control external limit circuit
terminals.
— If using temper-
ature-limited materials (such as PEX tubing) in
system piping, it is recommended to protect the
system with limit controls that are wired to the
controls external limit circuit.
2. See instructions beginning on page 52, for wiring information.
3. If using a manual reset limit control or wiring in the manual
reset circuit, set boiler control limit at least 20°F less than the
external manual reset limit (i.e., set control no higher than
180°F for a 200°F external limit, for example).
Use backflow preventer in the cold water supply piping if
required by local codes.
System/zone pipe sizing
For residential space heating applications (other than radiant
heating or unit heaters) ONLY, you can use the sizing suggestions
in Figure 47, page 37.
Studies have indicated that dangerous bacteria
can form in potable water distribution systems
if certain minimum water temperatures are not
maintained. Contact local health department for
more information.
Figure 46
Hard Water- To prevent the formation of scale on the inside
of the plate DHW heat exchanger and other components in
the domestic hot water system, water with hardness higher
than 50 ppm Calcium Carbonate must be treated with a
“Water Softener” prior to entering the boiler. Plugging of the
domestic system by scaling or accumulation of dirt is not
the responsibility of Weil-McLain, and suitable steps must
be taken to avoid it.
section for the proper cleaning procedure for the plate
DHW heat exchanger, and the required cleaning frequency.
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Model
67
104
Figure 47
17 Install water piping
(continued)
Recirculation (if used)
Massachusetts code applications require
recirculation piping or heat-traced piping if the
distance from the water heater to the furthest
fixture exceeds 100 feet.
Maintaining domestic water
temperature in the supply piping
1. Recirculation is used to reduce wait time for water use, to
minimize hot water and energy waste caused during the waiting
period, and to prevent degradation of the system supply water
temperature. ASPE recommends recirculation when the distance
from the water heater to the furthest fixture exceeds 100 feet or
the time lag for hot water to reach a fixture(s) exceeds 30 seconds.
2. Consult local codes and American Society of Plumbing Engineers
(ASPE) Domestic Water Heating Design Manual - latest edition,
for further information.
Recirculation pump (Figure 48, page 38, item 9)
1. Little flow is required to maintain a temperature in the piping.
2. Size of circulator depends on minimum flow requirements of the
tempering valve.
3. Minimum flow rates of the tempering valve must be main-
tained.
Aquastat (Figure 48, page 38, item 10)
1. Used to control the on-off position of the circulator. Aquastat
is set 5° to 10° lower than mixed water outlet of the mixing
valve (item 7).
2. The circulator cannot run continuously as bypass through
the mixing valve will eventually allow the temperature on
the piping to climb to the water heater temperature during
draw periods.
Check valves (Figure 48, page 38, item 8)
1. Assure the flow of water in one direction.
2. Each check valve functions as follows:
a. prevent bypass in the event of pressure drop.
b. prevents thermal siphoning of hot water to the cold water
supply.
c. prevents flow of cold water to the tempered water supply.
A draw of tempered water will not result in flow of cold
water into the return loop.
Controls
1. Aquastat to enable domestic recirculation pump.
2. When using a recirculation set-up, it cannot be constant
circulation (never go to heating) and the Control Parameter
P14 change from 0 to 1.
Domestic water supplied to fixtures that could
pose an injury hazard due to high temperature,
such as showers and faucets, should be equipped
with a temperature regulating device, such as an
anti-scald mixing valve.
Expansion tank (Figure 48, page 38, item 11)
THERMAL EXPANSION TANK — If a backflow
preventer, check valve, or pressure reducing valve is
piped on cold water inlet of water heater, you must
install an expansion tank on cold water supply line
to prevent normal thermal expansion from
repeatedly forcing open T&P relief valve.
The T&P relief valve is not intended for constant
duty, such as relief of pressure due to repeated
normal system expansion. Refer to expansion
tank manufacturer’s instructions for proper siz-
ing.
Failure to comply could result in severe personal
injury, death or substantial property damage.
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17 Install water piping (continued)
Figure 48
Part number 550-100-325/0419
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Figure 49
18 Primary/Secondary System Piping
System water piping methods
Using primary/secondary piping will provide the most efficient
and reliable operation of the boiler and the heating system.
1. Use information beginning on page 35 to size pump for
proper flow through the boiler.
2. Reference suggested piping layouts on pages 40-45.
System water piping methods
1. Connect boiler to system only as shown in Figure 51, page 40.
The primary/secondary piping shown ensures the boiler
loop will have sufficient flow.
2. Install a system circulator or zone circulators as shown in the
piping diagrams in the Primary/Secondary System Piping
section in this manual. These circulators must be supplied
by the installer.
1. Size circulators based on the flow rate required to achieve the
temperature drop required. You can closely estimate temper-
ature rise (or drop) through a circuit by using the following
formula, where TD is temperature rise (or drop), FLOW is
flow rate (in gpm), and BTUH is the heat load for the circuit:
=
BTUH
TD x 500
:
1. Consider a system loop for a system with total heating load
equal to 143,000 Btuh. The desired temperature drop through
the system piping is 20°F. Then the required flow rate is:
=
20 x 500
=
1. The circulator must be capable of delivering the required
flow against the head loss that will occur in the piping.
2. Determine the pipe size needed and the resultant head
loss using accepted engineering methods.
Expansion Tank Location
Figure 51, page 40 show typical installation of the system expansion
tank. It is highly recommended that you locate the air separator
and expansion tank as shown in the suggested piping drawings
on pages 39 - 41.
Ensure that the expansion tank size will handle boiler and system
water volume and temperature. See tank manufacturer’s instruc-
tions and ratings for details. Additional tanks may be added to the
system if needed to handle the expansion. These tanks may be
installed by connecting to tees in the system piping.
Undersized expansion tanks cause system water to
be lost from the relief valve and makeup water to be
added through the fill valve. Eventual boiler failure
can result due to excessive make-up water addition.
Always locate the cold-water fill connection at the
expansion tank. Never locate this elsewhere.
Diaphragm- or bladder-type tank:
Refer to Figure 51, page 40 for suggested piping when using a
diaphragm- or bladder-type expansion tank.
Diaphragm- or bladder-type expansion tank—
Always check pressure and charge tank with tank
removed from system to be sure reading is accurate.
Boiler relief valve is set for 30 PSIG. Operating pres-
sure of system, after temperature expansion above
cold fill pressure, should not exceed 24 PSIG to avoid
weeping of relief valve.
Install an automatic air vent on top of the air separator, per separa-
tor manufacturer’s instructions.
Automatic air vents
1. Remove the cap from any automatic air vent in the system
and check operation by depressing valve “B” slightly with the
tip of a screwdriver.
— Water from air vent may be very
hot. Avoid contact to prevent possible severe per-
sonal injury.
2. If the air vent valve appears to be working freely and not leak-
ing, replace cap “A”, twisting all the way on.
3. Loosen cap “A” one turn to allow vent to operate.
4. Have vent replaced if it does not operate correctly.
Figure 50
85036
A
B
Boiler
Model
MAX
Flow Rate
20° F
temperature
rise
MIN
Flow Rate
50° F
temperature
rise
Flow Rate
Delta T1
protection
67° F
temperature
rise
AB-80
7.9 2.9 2.3
AB-120
12.0 4.3 3.4
AB-155
15.2 6.1 4.5
Part number 550-100-325/0419
40
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
18 Primary/Secondary System Piping (continued)
Figure 51
Figure 52AquaBalance
®
Boiler
Model
BOILER
dT
(ºF)
(GPM)
@
92%
Eff.
Boiler
Head
Loss
(ft. w.c.)
Piping Est. Head Loss -
Ft. (Typical Near Boiler)
Total Loss - Ft.
(Boiler + Near Boiler
Piping)
Recommended
Circulators
3/4” Pipe 1” Pipe 3/4” Pipe 1” Pipe 3/4” Pipe 1” Pipe 1-1/4” Pipe
AB-80
HEAT
ONLY
20 7.4 7.8 12.5 3.0 20.3 10.8 A B,C,D
___30 4.9 4.0 6.0 1.5 10.0 5.5 B,C,D,E B,C,D,E
40 3.7 2.7 3.5 0.8 6.2 3.5 B,C,D,E B,C,D,E
AB-120
HEAT
ONLY
20 11.0 14.4
Not
Recommended
6.0
Not
Recommended
20.4
Not
Recommended
A,F
___30 7.3 7.5 3.0 10.5 B,C,D
40 5.5 4.6 1.8 6.4 B,C,D,E
AB-155
HEAT
ONLY
20 14.3 35.6 9.6 45.8 --- ---
30 9.5 16.4 4.6 21.0 F F
40 7.1 9.2 2.8 12.0 A,B,D A,B,D
Notes:
1. Operating point with current Grundfos pump inside
the boiler.
2. Combi pump included in the boiler is sized properly
for boiler loop.
Circulator Legend:
A - Taco 0014
B - Taco 0015
C - Grundfos UPS 15-58
D - B&G NRF 25
E - Taco 007
F - Taco 0011
Part number 550-100-325/0419
41
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 53
Closed-type expansion tank:
DO NOT use a closed-type tank if connecting to
a water heater that is equipped with an automatic
air vent.
Figure 53, shows suggested piping when using a closed-type
expansion tank, in which the air is directly in contact with
tank water.
Connect piping (½” or ¾”) from the air separator outlet to the
tank fitting. Slope any horizontal piping a minimum of 1 inch
per 5 feet of horizontal pipe.
Always use a tank fitting such as the B&G Tank-trol or Taco
Taco-trol (shown). The fitting reduces gravity flow of water in
the piping to the tank, avoids air bubbling through the tank
water, and provides the proper fill height in the tank.
Correct all leaks in the system or tank piping.
Leaks allow air to escape from the system and will
cause water-logging of the tank. This will result
in water loss through the boiler relief valve due
to over-pressurization. NEVER use an automatic
air vent in a system equipped with a closed-type
expansion tank. The air removed from the system
will cause water-logging of the expansion tank.
Closed-type expansion tank—Follow tank
manufacturer’s instructions for filling the tank.
Typical tank sizing provides for approximately 12
PSIG when the tank is filled to the normal level
and system water is cold. Note that boiler relief
valve is set for 30 PSIG. Operation pressure of
system, after temperature expansion above cold
fill pressure, should not exceed 24 PSIG to avoid
weeping of relieve valve.
Air separator
3
PRV Fill valve
2
Closed-type expansion tank
1
System circulator
5
WM-041a
System
return
System
supply
1
2
3
4
“ 12” Max.
6
Tank fitting
4
Primary/secondary
connection
6
5
Boiler
supply
PRV
Boiler
return
*
Boiler circulator
7
*
Flow/check valve
*
(For Heating Only boilers)
8
7
*
8
*
18 Primary/Secondary System Piping (continued)
PAquaBalance®
Taco 0 0 7
Taco 0 0 14
Grundfos UPS 15-58
(High)
Taco 0015 (High)
B&G NRF 25 (High)
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
01234 56789101112
Total Head - feet water
Flow - gpm
1
1 = Boiler Pressure Drop with 3/4'' near boiler piping (80KBTU and120 KBTU)
2 = Boiler Pressure Drop with 1'' near boiler piping (80KBTU and120 KBTU)
3 = Boiler Pressure Drop with 1 '' near boiler piping (155 KBTU)
4 = Boiler Pressure Drop with 1 1/4'' near boiler piping (155 KBTU)
2
3
4
Taco 0011
Part number 550-100-325/0419
42
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
18 Primary/Secondary System Piping (continued)
Install relief valve
1. Install relief valve in 1 ” x 1” x ¾” (for AB-80/120) or 1
-1/4 ” x 1-1/4” x
¾” (for AB-155) tee piped from boiler return (Figure 5, page 9).
2. Pipe the relief valve only as shown, in the location shown.
3. Connect discharge piping to safe disposal location, following guidelines
in the
below.
:
Install relief valve ONLY with the spindle vertical, as
shown in illustrations in this manual.
Discharge line must be connected to relief valve out-
let and run to a safe place of disposal. Terminate the
discharge line in a manner that will prevent possibility
of severe burns or property damage should the valve
discharge. Locate away from the top of the boiler.
Discharge line must be as short as possible and be the
same size as the valve discharge connection throughout
its entire length.
Discharge line must pitch downward from the valve and
terminate at least 6” above the floor drain where any
discharge will be clearly visible.
The discharge line shall terminate plain, not threaded,
with a material serviceable for temperatures of 375 °F
or greater.
Do not pipe the discharge to any place where freezing
could occur.
No shutoff valve shall be installed between the relief valve
and boiler, or in the discharge line. Do not plug or place
any obstruction in the discharge line.
Test the operation of the valve after filling and pres-
surizing system by lifting the lever. Make sure the valve
discharges freely. If the valve fails to operate correctly,
replace it with a new relief valve.
Failure to comply with the above guidelines could result
in failure of the relief valve to operate, resulting in pos-
sibility of severe personal injury, death or substantial
property damage.
Figure 54
Figure 54.
1 AquaBalance® wall mount boiler
2 Indirect Water Heater, if used
3
Relief valve, field piped — MUST be piped to boiler return
connection on Combi boilers, Heating Only boilers relief
valve field piped on supply.
4 Relief valve piping to drain — see page 42
5 DHW circulator
6 Isolation valves
7 System circulator
8 Expansion tank, diaphragm type, if used
9 Air separator
10 Flow/check valves
11 Purge/drain valves
(Installer supplied)
12 Auto air vent
13 Zone valves
14 Primary/secondary connection (tees no more than
12 inches apart)
15 Expansion tank, closed type, if used (some chiller
systems may use a diaphragm-type expansion tank)
16 Water chiller
17 Check valve
18 Y-strainer
19 Balancing valve
20 Make-up water supply – Use applicable codes to deter-
mine if backflow preventers, pressure reducing valves,
and fill valves may be required
21 By-pass pressure regulator, REQUIRED for zone valve
systems unless other provision is made
22 High limit temperature control
23 Zone circulator
24 Pressure/temperature gauge,
(field supplied), field piped
25 Heating circuits
26 Additional heating circuits, if any
27 Boiler circulator,
*
(For Heating Only boilers, In the
Combi boiler the circulator is already inside the boiler
jacket).
28 Mixing valve, if any
Zone Valve zoning – primary/secondary
(Shown with optional DHW piping)
See Figure 54.
1. This configuration is for zone valve systems using a boiler
loop connected as a secondary circuit off of a primary system
loop. Systems whose flow characteristics do not comply with
those listed in Figure 51, page 40 must pipe the boiler loop as a
secondary circuit as show.
2. Systems zoned with zone valves MUST use a by-pass pressure
regulator.
3. Install a system circulator (supplied by installer) capable of
delivering the proper flow and head as shown.
Expansion Tank required
1. Provide a system expansion tank following the guidelines on
pages 39 or 41.
2. DO NOT use a closed-type tank if connecting to a boiler that
is equipped with an automatic vent.
Domestic Hot Water (DHW) tank, if used
1. DHW direct connection—Pipe from the near-boiler piping to
the DHW tank’s boiler connections as shown.
2. DHW as zone—A DHW tank can be connected as a zone if a
DHW tank is NOT already connected to the boiler. To provide
DHW priority operation, use a zone controller. See notices
on page 53 to ensure compliance with the 2007 Energy Act.
3. DHW Priority operation—The control turns off space heating
to the HEAT zones during domestic water heating calls on the
DHW input. The MAX ON TIME setting can be adjusted to
limit how long this occurs. Set the MAX ON TIME to “0” to
disable domestic priority. See page 67 for setting instructions.
4. If NOT connecting an indirect water heater, do not use the DHW
input or DHW Circulator output on the control.
Overriding the Outdoor Reset function by connecting
space heating zones to inputs and outputs intended
for DHW applications may violate Section 303 of
the 2007 Energy Act. See page 135 for compliance
information and exemptions.
Wiring the Indirect tank aquastat to the Heating Only
Boilers, refer to Section 2 - Field Wiring.
Controlling the Zones
1. The control can be used to control space heating only, domestic
water heating only, or both. Refer to field wiring, beginning
on page 53, for instructions on wiring to zone valves.
2. The boiler and zone valves can also be operated by a zone
controller.
Connect zone valve end switches to HEAT input.
Connect system circulator to HEAT Circ. output.
Use isolation relays if connecting 3-wire zone
valve end switches to the HEAT input.
Part number 550-100-325/0419
43
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
18 Primary/Secondary System Piping (continued)
(See Note,
page 44)
not run in
DHW mode
on Heating
Only Boil-
Do not
install
on
Combi
Boil-
Figure 55
Part number 550-100-325/0419
44
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
18 Primary/Secondary System Piping (continued)
(Applies to Figures 54, 55 & 56)
Add boiler and tank head loss for pump
sizing.
Circulator zoning – primary/secondary
(Shown with optional DHW piping)
See Figure 55.
1. This configuration is for circulator-zoned systems using a boiler
loop connected as a secondary circuit off of a primary system
loop. Systems zoned with circulators must pipe the boiler loop
as a secondary circuit as show.
2. Install a separate circulator (supplied by installer) for each zone
capable of delivering the proper flow and head as shown.
Expansion Tank required
1. Provide a system expansion tank following the guidelines on
pages 39 or 41.
2. DO NOT use a closed-type tank if connecting to a boiler that
is equipped with an automatic vent.
Domestic Hot Water (DHW) tank, if used
1. DHW direct connection — Pipe from the near-boiler piping
to the DHW tank’s boiler connections as shown.
2. DHW as zone—A DHW tank can be connected as a zone if a
DHW tank is NOT already connected to the boiler. To provide
DHW priority operation, use a zone controller. See notices
on page 53 to ensure compliance with the 2007 Energy Act.
3. DHW Priority operation—The control turns off space heating
to the HEAT zones during domestic water heating calls on the
DHW input. The MAX ON TIME setting can be adjusted to
limit how long this occurs. Set the MAX ON TIME to “0” to
disable domestic priority. See page 67 for setting instructions.
4. If NOT connecting an indirect water heater, do not use the
DHW input or DHW Circulator output on the control.
Overriding the Outdoor Reset function by connecting
space heating zones to inputs and outputs intended
for DHW applications may violate Section 303 of
the 2007 Energy Act. See page 135 for compliance
information and exemptions.
Wiring the Indirect tank aquastat to the Heating Only
Boiler, refer to Section 22 - Field Wiring.
Controlling the Zones
1. The control can be used to control space heating only, domestic
water heating only, or both. Refer to field wiring, beginning
on page 53, for instructions on wiring to circulators.
2. The boiler and circulators can also be operated by a zone
controller.
Do not
install
on
Combi
Boil-
Figure 55 and Figure 56
1 AquaBalance® wall mount boiler
2 Indirect Water Heater, if used
3
Relief valve, field piped — MUST be piped to boiler return
connection on Combi boilers, Heating Only boilers relief
valve field piped on supply.
4 Relief valve piping to drain — see page 42
5 DHW circulator
6 Isolation valves
7 System circulator
8 Expansion tank, diaphragm type, if used
9 Air separator
10 Flow/check valves
11 Purge/drain valves
(Installer supplied)
12 Auto air vent
13 Zone valves
14 Primary/secondary connection (tees no more than
12 inches apart)
15 Expansion tank, closed type, if used (some chiller
systems may use a diaphragm-type expansion tank)
16 Water chiller
17 Check valve
18 Y-strainer
19 Balancing valve
20 Make-up water supply – Use applicable codes to deter-
mine if backflow preventers, pressure reducing valves,
and fill valves may be required
21 By-pass pressure regulator, REQUIRED for zone valve
systems unless other provision is made
22 High limit temperature control
23 Zone circulator
24 Pressure/temperature gauge, (field supplied), field piped
25 Heating circuits
26 Additional heating circuits, if any
27 Boiler circulator,
*
(For Heating Only boilers, In the
Combi boiler the circulator is already inside the
boiler jacket).
28 Mixing valve, if any
(See Note,
below)
not run in
DHW mode
on Heating
Only Boil-
Figure 56
Part number 550-100-325/0419
45
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
18 Primary/Secondary System Piping (continued)
Circulator zoning – Multiple
temperature zones with primary/
secondary
(Shown with optional DHW piping)
See Figure 56.
1. This configuration is for circulator-zoned systems with
high- and low- temperature heating zones using a
boiler loop connected as a secondary circuit off of a pri-
mary system loop. Systems zoned with circulators must
pipe the boiler loop as a secondary circuit as shown.
2. Install a separate circulator (supplied by installer) for
each zone capable of delivering the proper flow and
head as shown.
Expansion Tank required
1. Provide a system expansion tank following the guide-
lines on pages 39 or 41.
2. DO NOT use a closed-type tank if connecting to a boiler
that is equipped with an automatic vent.
System setup and settings
1. Hi-temp emitters may be baseboards, radiators, fan
coils, or heat exchangers.
For cast iron radiation and old black iron pip-
ing systems a “Dirt separator with a magnet”
must be installed on the return piping to
protect the boiler heat exchanger.
2. Add a mixing device (Figure 56, item 28) to help ensure
supply water temperature will not exceed the maximum
allowable for the radiant system.
3. Heating zone supply water temperature settings should
be selected for the hi-temp zones. The mixing device
regulates supply temperature to the lower-temp zones.
Boiler operation for fan coil only applica-
tions, parameter P02 (page 99) may be set
to 20 for faster “ramp up” to boiler set point
temperature.
Domestic Hot Water (DHW) tank, if used
1. DHW direct connection—Pipe from the near-boiler
piping to the DHW tank’s boiler connections as shown.
2. DHW as zone—A DHW tank can be connected as a
zone if a DHW tank is NOT already connected to the
boiler.
To provide DHW priority operation, use a zone
controller. See notices on page 53 to ensure compliance
with the 2007 Energy Act.
3. DHW Priority operation—The control turns off space
heating to the HEAT zones during domestic water
heating calls on the DHW input. The MAX ON TIME
setting can be adjusted to limit how long this occurs. Set
the MAX ON TIME to “0” to disable domestic priority.
See page 67 for setting instructions.
4. If NOT connecting an indirect water heater, do not
use the DHW input or DHW Circulator output on the
control.
Overriding the Outdoor Reset function by connecting
space heating zones to inputs and outputs intended for
DHW applications may violate Section 303 of the 2007
Energy Act. See page 135 for compliance information and
exemptions.
Wiring the Indirect tank aquastat to the Heating Only
Boiler, refer to Section 22 - Field Wiring.
Controlling the Zones
1. The control can be used to control space heating only, domestic
water heating only, or both.
2. The boiler and circulators can also be operated by a zone control-
ler and in some installations may be needed.
(See Note,
page 44)
This
not run in
DHW mode
on Heating
Do
not in-
stall on
Combi
Part number 550-100-325/0419
46
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Placing multiple boilers
1. Locate multiple boilers with spacings shown in Figure 57.
2. Provide indicated clearances around boilers for access and ser-
vicing. If recommended dimensions are not possible, provide
at least the minimum clearances given on page 5. Also follow
local codes.
3. Provide a minimum 36-inch walkway in front of the boilers to
ensure accessibility.
4. Unpack, assemble and mount boilers according to instructions
in this manual.
5. Provide clearance for installation of venting, air piping, gas pip-
ing, expansion tank, primary circulator and other accessories.
19 Multiple boiler installations
Figure 57
Part number 550-100-325/0419
47
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
19 Multiple boiler installations (continued)
Figure 58
AquaBalance
®
Figure 58
1 Flow/check valve
2 Isolation valves (when used)
3 Cap
4 Primary circulator
5 Expansion tank (diaphragm type)
6 System air eliminator
7 System automatic air vent
8 Pressure reducing valve
9 Check valve or backflow preventer, as required by appli-
cable codes
10 Cold water supply
11 Supply water temperature control (when used)
12 Low water cutoff (when used) (place above primary
header)
13 Water flow switch (when used)
14 Boiler circulators
15 System supply
16 System return
17 Boiler P/T gauge (field supplied), relief valve and discharge
piping, installed per this manual.
18 Purge/drain valve
Part number 550-100-325/0419
48
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
19 Multiple boiler installations (continued)
Figure 59
DHW tank piping with multiple
boilers
DHW direct connection—single tank
1. If BTUH output of a single boiler is sufficient for the
DHW tank/demand, pipe the indirect water heater to
the last boiler in the firing sequence. This will allow the
previous boilers to continue space heating while the last
boiler delivers DHW priority.
2. Pipe from the near-boiler piping to the DHW tank’s
boiler connections as shown in Figure 54, page 43.
3. Connect the DHW tank aquastat directly to the DHW
input on the last boiler in the sequence.
When using a multiple-boiler control with lead boiler
rotation, it is recommended that the boiler connected to
the DHW tank is always set as the last boiler to operate
in the sequence so that space heat can be maintained
during times of DHW demand.
DHW tanks as zone—multiple tanks
1. If using multiple DHW tanks or multiple banks of tanks, pipe the
tanks to the primary system loop with a secondary connection as
shown in Figure 59.
2. DHW tanks are zoned with circulators as shown.
3. If DHW priority is required, use separate zone controllers for
DHW and space heating.
Figure 60
Figure 61
Figure 62
Part number 550-100-325/0419
49
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Prepare condensate trap assembly
This boiler is equipped with an internal air-trap to drain off con-
densate.
1. Remove the condensate trap kit from the accessories bag.
2. See Figures 60, 61 and 62. The figures below shows the installa-
tion of the condensate trap connections.
3. Install the inspection coupling A and gasket as shown. Finger
tighten securely.
4. Slide the clamp (from the condensate trap kit) onto the flexible
drain tube (item B), See Figure 61. Push the flexible tube (item B)
approximately 1-3/4” (Figure 61) onto the end of the tube (bottom
of boiler) as shown in Figure 60.
20 Install condensate line
Condensate drain system
1.
. The
flexible drain line will fit in a ¾” PVC coupling. Run
minimum ½” PVC for the piping to drain or condensate
pump.
Use materials approved by the authority having
jurisdiction. In the absence of other authority,
PVC and CPVC pipe must comply with ASTM
D1785, F441 or D2665. Cement and primer
must comply with ASTM D2564 or F493. For
Canada, use CSA or ULC certified PVC or
CPVC pipe, fittings and cement.
2. Select a condensate pump (if used) that is approved for
use with condensing boilers and furnaces. The pump
should have an overflow switch to prevent property
damage from condensate spillage. The pump should
have a minimum capacity of 2 GPH for the AB-80,
3 GPH for the AB-120 or 4 GPH for the AB- 155.
3. When sizing condensate pumps, make sure to include
the total load of all appliances connected to it.
The condensate line must remain unob-
structed, allowing free flow of condensate. If
condensate is allowed to freeze in the line or
if the line is obstructed in any other manor,
condensate can exit from the boiler tee, result-
ing in potential water damage to property.
Condensate from the boiler will be slightly
acidic (typically with a pH from 3.2 to 4.5).
Install a neutralizing filter when draining into
metal pipe and if required by local codes. See
Replacement parts section at the end of this
manual for the Weil-McLain kit.
5. Fill the air-trap with approximately 1/2 quart (0.5
liters) of water and connect the condensate drain tube
to the condensate drain system.
The condensate trap must be in place during all op-
eration. Make sure the trap is securely attached to the
condensate outlet and that the condensate discharge
line is in good condition and installed per this man-
ual. Failure to comply could result in severe per-
sonal injury, death or substantial property damage.
Figure 63
Part number 550-100-325/0419
50
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
21 Gas piping
Boilers are shipped ready to fire natural gas
ONLY. You must install the propane venturi
if the boiler will be connected to propane.
See page 10. Failure to comply could result in
severe personal injury, death or substantial
property damage.
Connecting gas supply piping
1. Remove jacket door and refer to Figure 63 to pipe gas to
boiler.
a. Place a pipe wrench on the gas line inside the jacket
when tightening the gas line assembly to the boiler gas
connection (item 1).
b. Install steel pipe fittings as shown in Figure 63. All pipe
fittings and gas cock are supplied by the installer.
c. In Canada — The gas shut-off valve (item 2) must be
identified by the installer.
2. Use pipe dope compatible with propane gases. Apply spar-
ingly only to male threads of pipe joints so that pipe dope
does not block gas flow.
Failure to apply pipe dope as detailed above can
result in severe personal injury, death or substan-
tial property damage.
3. Connect gas supply piping to the ½” NPT gas cock for
80/120 boilers and ¾” NPT for 155 boilers (item 2).
4. Support gas piping with hangers, not by boiler or its ac-
cessories.
5. Purge all air from gas supply piping.
6. Before placing boiler in operation, check boiler and its gas
connection for leaks.
a. During any pressure testing at less than 13” w.c., close
the gas shutoff valve and disconnect system gas piping.
At higher test pressures, disconnect boiler and gas valve
from gas supply piping.
Do not check for gas leaks with an open flame
— use bubble test. Failure to use bubble test or
check for gas leaks can cause severe personal
injury, death or substantial property damage.
DO NOT adjust or attempt to measure gas valve
outlet pressure. The gas valve is factory-set for the
correct outlet pressure. This setting is suitable for
natural gas and propane. Attempting to alter or
measure the gas valve outlet pressure could result
in damage to the valve, causing potential severe
personal injury, death or substantial property
damage.
Flexible appliance gas connectors are NOT rec-
ommended.
when tightening gas pip-
ing at boiler, using one wrench to prevent the
boiler gas line connection from turning. Failure
to support the boiler gas connection pipe to
prevent it from turning could damage gas line
components.
1 Boiler gas supply connection, ½” NPT male for 80/120 boilers
and ¾” NPT for 155 boilers.
2 T-handle gas cock, ½” NPT for 80/120 boilers and ¾” NPT for 155 boilers.
3 Nipple, ½” NPT for 80/120 boilers and ¾” NPT for 155 boilers.
4 Unions, ½” NPT for 80/120 boilers and ¾” NPT for 155 boilers.
5 Nipple, ½” NPT for 80/120 boilers and ¾” NPT for 155 boilers.
6 Tee, ½” NPT for 80/120 boilers and ¾” NPT for 155 boilers.
7 Nipple, ½” NPT x 6” for 80/120 boilers and ¾” NPT x 6” for 155 boilers,
for drip leg.
8 Cap, ½” NPT for 80/120 boilers and ¾” NPT for 155 boilers.
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
21 Gas piping (continued)
1. See page 14 for gas line sizing information.
1. See Figure 64 for location of the gas inlet pressure test port.
1. Set up the boiler to operate at maximum rate as described in
section “ Test mode” Figure 104, page 79.
2. With the boiler operating at maximum rate check that the op-
erational (working) gas pressure at the inlet gas pressure test
port (see above) complies with the requirements of Table 2 .
3. Ensure that this inlet pressure can be obtained with all other
gas appliances in the property working.
Measure the gas rate
Measure the gas rate and check against following Table 2:
For natural gas or liquefied petroleum (propane) gas, the pres-
sure required at gas valve inlet pressure port (verify minimum
gas pressure when all gas appliances are in operation):
a. Maximum: 13” w.c. with no flow (lockup) or with boiler
on.
b. Minimum: 3.5” w.c. gas pressure, with gas flowing (verify
during boiler startup, while boiler is at high fire)
c. Nominal gas pressure: 11.0” w.c.
4. Install 100% lockup gas pressure regulator in supply
line if inlet pressure can exceed 13” w.c. at any time.
Adjust lockup regulator for 13” w.c. maximum.
Figure 64
Gas Rate
Combi
Boiler
model
Maximum rate Minimum rate
ft
3
/h ft
3
/h
AB-80
AB-120
AB-155
Table 2
Figure 65
Part number 550-100-325/0419
52
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Combi and Heating Only boiler
wiring
The boiler is pre-wired and is ready to be plugged into your
electrical supply. Receptacle must be a grounded and polar-
ized circuit. Recommend GFI outlet.
22 Field wiring
HAZARD — For your
safety, turn off electrical power supply at service
entrance panel before making any electrical con-
nections to avoid possible electric shock hazard.
Failure to do so can cause severe personal injury
or death.
The installation must comply with: National
Electrical Code and any other national, state,
provincial or local codes or regulations. In
Canada, CSA C22.1 Canadian Electrical Code
Part 1, and any local codes.
Wiring must be N.E.C. Class 1. If original wir-
ing 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 – lat-
est edition, and/or the Canadian Electrical Code
Part I, CSA C22.1, Electrical Code.
The boiler when installed, must be electri-
cally bonded to ground in accordance with the
requirements of the authority having jurisdiction
or, in the absence of such requirements, with the
National Electrical Code, ANSI/NFPA 70
– latest
edition, and/or the Canadian Electrical Code
Part I, CSA C22.1, Electrical Code.
All field wiring is made through the bottom of the boiler
through two (2) black grommets shown in Figure 65.
The electrical connections terminal block can be accessed
after removing the front jacket panel. The layout of the ter-
minals for the various connections are shown in the wiring
diagram in the following pages.
Room thermostat
When connecting a room thermostat, connect the thermo-
stat across terminals R and W for a two (2) -wire thermostat
or optional R,W and C for a three (3) -wire thermostat, see
Figure 66, Item 72. The thermostat connector is located on
the right side of the boiler.
Either a voltage free thermostat or a 24VAC
thermostat can be connected to the boiler.
Figure 67
Wire grommets
Figure 66
Outside of
Thermostat-Relay
Box
Thermostat-Relay
Box
Transformer
Relay
Fuse
Part number 550-100-325/0419
53
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 68
22 Field wiring (continued)
Outdoor sensor uses the back connection block,
see Figure 66,
Item 138, (right side of block … terminals 5 and 6).
-
stat wire 22 gauge).
shielded from direct sunlight or
flow of heat or cooling from other sources, approximately 10 feet
above ground level.
-
ly
Figure 69
Wiring the indirect tank aquastat to the Heating Only Boiler, will fire the
boiler to provide heated boiler water to the indirect tanks heating coil.
Field supplied; zone panel, with priority zone, indirect circulator,
zone valve for indirect tank.
Connect indirect aquastat N/O contact wires to boiler connections
#7 and #8, see Figure 69 below.
Boiler must be in the “comfort mode” (not “eco” mode) push eco/
comfort button to exit “eco” mode, display will Not show “eco”
on display when in correct mode, when using an Indirect Water
Heater Tank.
The control of the Heating Only model of the boiler is ca-
pable of managing two (2) separate circulators, one for the
Heating circuit and one for the Domestic Hot water circuit.
The connections are located on the rear part of the con-
trol case. In order to access the connector you will have to
unscrew the screw located on the lower right corner of the
control to enable you to rotate the control and access the
connectors. See Figure 70 and Figure 71.
Figure 70
Figure 71
In Figure 71, terminals 9, 10 and 11 (Item 32) are for con-
necting the Heating circuit circulator.
Terminals 11, 12, and 13 (Item 130) are for connecting the
Domestic Hot water circuit circulator.
The common terminal 11 is ground.
Only one circulator may be wired to each con-
nection point.
7
8
Part number 550-100-325/0419
54
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
23 Wiring diagram — AquaBalance
®
80/120C Combi Ladder
Figure 72 AquaBalance
®
Legend
16 Fan
32 Central heating pump
42 DHW temperature sensor
44 Gas valve
72 Room thermostat (not included)
81 Ignition electrode
95 Mixing (diverting) valve
104(1) Fuse 3.15A
104 (1) Fuse 630mA
114 Water pressure switch
136 Flow meter
138 Outside temperature sensor (optional on Combi)
186 Return temperature sensor
191 Exhaust temperature sensor
278 Double sensor (heating + safety)
279 Transformer 115-24 VAC
284 Relay SPST-Coil 24 VAC
370 LWCO (not included)
373 “OPENTHERM” communication (Not used)
cod. 3541M910
L
N
NOTES:
1. All wiring must be installed in
accordance with N.E.C. and
any other national state or local
requirements.
2. Room thermostat should be a
dry contact type and should draw
power from the control board:
should not be greater than 24
VAC and 500 mA.
3. Terminals 1 & 2 are powered
with 120 VAC for LWCO, 3
Amps Max.
4. In case of questions during
installation please contact W-M
Tech Services.
Part number 550-100-325/0419
55
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
23 Wiring diagram — AquaBalance
®
80/120C Combi Schematic
Figure 73 AquaBalance
®
ABM08
X3 - 12
X3 - 10
X3 - 11
X3 - 24
X3 - 22
X3 - 23
X3 - 6
X3 - 2
X3 - 13
X3 - 1
X2 - 5
X2 - 11
X4 - 8
X4 - 17
X4 - 5
X4 - 13
X4 - 12
X4 - 4
X2 - 7
X3 - 12
X3 - 24
X3 - 11
X3 - 23
X3 - 10
X3 - 6
X3 - 13
X3 - 2
X3 - 1
X4 - 8
X4 - 17
X2 - 11
X2 - 5
X4 - 13
X4 - 5
X4 - 4
X4 - 12
X2
112
1324
X3
19
1018
X4
61
12 7
191
136
44
32
114
X3 - 18
X3 - 18
95
X3 - 5
X3 - 17
X3 - 4
X3 - 16
X3 - 4
X3 - 17
X3 - 5
X3 - 22
X3 - 8
X3 - 20
X3 - 7
X3 - 19
X3 - 8
X3 - 20
X3 - 7
X3 - 19
X2 - 4
X2 - 10
X2 - 10
X2 - 4
GROUND
X3 - 9
X3 - 21
186
X3 - 9
X3 - 21
42
278
16
GROUND
X4 - 6
X4 - 15
X4 - 6
X4 - 15
GROUND
X2 - 12
X2 - 6
X1 - 1
X1 - 2
X4 - 3
X4 - 11
X4 - 2
X4 - 10
X1
81
373
1
2
GROUND
GROUND
GROUND
X2 - 1
GROUND
120Vac
60Hz
GROUND
370
138
(see note 3)
M
1
610
5
279
284
104 (2)
X4 - 7
X4 - 1
72
(see note 2)
X0
RWC
TT
X0 - 10
X0 - 9
X0 - 8
X0 - 1
X0 - 6
X0 - 5
X0 - 4
104 (1)
123 4 56
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=
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Part number 550-100-325/0419
56
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
24 Wiring diagram — AquaBalance
®
80/120H Heating Only Ladder
Figure 74 AquaBalance
®
Legend
16 Fan
32 Central heating pump
42 DHW temperature sensor
44 Gas valve
72 Room thermostat (not included)
81 Ignition electrode
95 Mixing (diverting) valve
104 (1) Fuse 3.15A
104 (1) Fuse 630mA
114 Water pressure switch
130 DHW pump (not included)
136 Flow meter
138 Outside temperature sensor (optional on Combi)
186 Return temperature sensor
191 Exhaust temperature sensor
278 Double sensor (heating + safety)
279 Transformer 115-24 VAC
284 Relay SPST-Coil 24 VAC
370 LWCO (not included)
373 “OPENTHERM” communication (Not used)
cod. 3541M870
L
N
NOTES:
1. All wiring must be installed in
accordance with N.E.C. and
any other national state or local
requirements.
2. Room thermostat should be a
dry contact type and should draw
power from the control board:
should not be greater than 24
VAC and 500 mA.
3. Terminals 1 & 2 are powered with
120 VAC for LWCO. Combined
current draw for LWCO, Boiler
and DHW Pumps should not
exceed 3 Amps Max.
4. In case of questions during instal-
lation please contact W-M Tech
Services.
Part number 550-100-325/0419
57
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
24 Wiring diagram — AquaBalance
®
80/120H Heating Only Schematic
Figure 75 AquaBalance
®
RWC
TT
X0 - 10
X0 - 9
X0 - 8
72
(see note 2)
X3 - 6
X4 - 8
X4 - 17
X4 - 13
X4 - 5
X4 - 4
X4 - 12
191
44
114
X3 - 18
X3 - 16
X3 - 4
X3 - 17
X3 - 5
X3 - 8
X3 - 20
X3 - 7
X3 - 19
X2 - 10
X2 - 4
GROUND
186
278
16
81
GROUND
X3 - 6
X4 - 8
X4 - 17
X4 - 5
X4 - 13
X4 - 12
X2 - 7
X3 - 18
X3 - 5
X3 - 17
X3 - 4
X3 - 16
X3 - 8
X3 - 20
X3 - 7
X3 - 19
X2 - 4
X2 - 10
X2 - 12
X2 - 6
X2 - 1
X4 - 4
X4 - 7
X4 - 1
X1 - 1
X1 - 2
X4 - 3
X4 - 11
X4 - 2
X4 - 10
X3 - 9
X3 - 21
X2 - 5
X2 - 11
GROUND
X2 - 3
X2 - 9
GROUND
GROUND
GROUND
GROUND
370
(see note 3)
X2
112
1324
X3
19
1018
X4
61
12 7
X3 - 9
X3 - 21
X4 - 6
X4 - 15
X1
1
2
X4 - 6
X4 - 15
373
ABM08
120Vac
60Hz
X2 - 5
X2 - 11
X2 - 3
X2 - 9
138
143
32 130
1
M
610
5
X0 - 6
X0 - 1
X0 - 5
X0 - 4
279
284
104 (2)
910111213123 4 5678
104 (1)
X0
.(<
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Only one circulator may be wired to
each connection point. Maximum
amp load per pump 3.0 amps.
Part number 550-100-325/0419
58
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
25 Wiring diagram — AquaBalance
®
-155C Combi Ladder
Figure 76 AquaBalance
®
Legend
16 Blower
32 Central heating pump
42 DHW temperature sensor
44 Gas valve
72 Room thermostat (not included)
81 Ignition electrode
95 Mixing (diverting) valve
104(1) Fuse 3.15A
104 (2) Fuse 630mA
114 Water pressure switch
136 Flow meter
138 Outside temperature sensor (optional on Combi)
186 Return temperature sensor
191 Exhaust temperature sensor
278 Double sensor (heating + safety)
279 Transformer 115-24 VAC
284 Relay SPST-Coil 24 VAC
370 LWCO (not included)
373 “OPENTHERM” communication (Not used)
L
N
NOTES:
1. All wiring must be installed in
accordance with N.E.C. and
any other national state or local
requirements.
2. Room thermostat should be
a dry contact type and should
draw power from the control
board: should not be greater
than 24 VAC and 500 mA.
3. Terminals 1 & 2 are powered
with 120 VAC for LWCO, 3
Amps Max.
4. In case of questions during
installation please contact W-M
Tech Services.
Part number 550-100-325/0419
59
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
25 Wiring diagram — AquaBalance
®
-155C Combi Schematic
Figure 77 AquaBalance
®
Legend
16 Blower
32 Central heating pump
42 DHW temperature sensor
44 Gas valve
72 Room thermostat (optional)
81 Ignition electrode
95 Mixing (diverting) valve
104 (1) Fuse 3.15A
104 (2) Fuse 630mA
114 Water pressure switch
136 Flow meter
138 Outside temperature sensor (optional on Combi)
186 Return temperature sensor
191 Exhaust temperature sensor
278 Double sensor (heating + safety)
279 Transformer 115-24 Vac
284 Relay SPST-Coil 24 Vac
370 Low Water Cutoff (not included)
373 “OPENTHERM” communication (Not used)
Part number 550-100-325/0419
60
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
26 Wiring diagram — AquaBalance
®
-155H Heating Only Ladder
Figure 78 AquaBalance
®
Legend
16 Fan
32 Central heating pump (not included)
44 Combination gas valve
72 Room thermostat (not included)
81 Ignition electrode
104(1) Fuse 3.15A
104(1) Fuse 630mA
114 Water pressure switch
130 DHW pump (not included)
138 Outdoor sensor
143 DHW tank thermostat (not included)
186 Return temperature sensor
191 Exhaust temperature sensor
278 Double sensor (heating + safety)
279 Transformer 115-24 VAC
284 Relay SPST-Coil 24 VAC
370 LWCO (not included)
373 “OPENTHERM” communication (Not used)
cod. 3541M950
LN
NOTES:
1. All wiring must be installed in
accordance with N.E.C. and
any other national state or local
requirements.
2. Room thermostat should be
a dry contact type and should
draw power from the control
board: should not be greater
than 24 VAC and 500 mA.
3. Terminals 1 & 2 are powered
with 120 VAC for LWCO. Com-
bined current draw for LWCO,
Boiler and DHW Pumps should
not exceed 3 Amps Max.
4. In case of questions during
installation please contact W-M
Tech Services.
Part number 550-100-325/0419
61
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 79 AquaBalance
®
26 Wiring diagram — AquaBalance
®
-155H Heating Only Schematic
cod. 3541M930
Only one circula-
tor may be wired to
each connection point.
Maximum amp load
per pump 3.0 amps.
Figure 80
10
Part number 550-100-325/0419
62
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
27 Controls and operation
Control Introduction
This boiler is a high-efficiency condensing pre-mix appliance
for central heating and hot water production, running on
Natural gas or Liquefied Petroleum (Propane) gas, generating
extremely low emissions.
The boiler is constructed with a stainless steel heat exchanger
providing effective condensation of the water vapor contained
in the flue gases, permitting extremely high efficiency.
Inside the boiler there is a premix burner with a large stainless
steel surface.
The boiler is sealed from the installation room: the air needed
for combustion is drawn from outside. The boiler also includes a
gas valve, pump, safety valve, flow sensor, dual safety and control
temperature sensor, a safety thermostat and a low water pressure
switch.
Thanks to the microprocessor control and adjustment system
with advanced self-diagnosis, unit operation is for the most part
automatic. The system heating temperature is automatically
governed by the control system.
The display continuously provides information on the unit’s
operating status and it is easily possible to obtain and adjust
temperature set-points, etc. or configure them. Any operating
problems associated with the boiler are immediately signalled by
the display and, if possible, corrected automatically.
LEGEND for Figure 80
1 — Domestic Hot Water temperature setpoint decreasing
button
2 — Domestic Hot Water temperature setpoint increasing
button
3 — Central Heating Water temperature setpoint decreas-
ing button
4 — Central Heating Water temperature setpoint increasing
button
5 — LCD Display
6 — Reset / OTC button
7 — Economy-Comfort On-Off -Power button
8 — Domestic Hot Water symbol
9 — Domestic Hot Water mode operation
10 — Multi-function indication (Flashing during heat
exchanger protection)
11 — Economy symbol
12 — Central Heating mode operation
13 — Central Heating symbol
14 — Burner on and actual load indication
(Flashing during flame current supervision)
15 Service tool connection
16 Temperature-Pressure gauge
Figure 81
Figure 82
Figure 83
Boiler without Power
Part number 550-100-325/0419
63
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
27 Controls and operation (continued)
Central heating operation
The Central Heating heat demand (generated by the Room Thermostat) is indicated by the flashing of the Hot Air symbol over
the radiator (Items 12 and 13 - Figure 80, page 62). The display indicates the actual Central Heating water temperature (Item 10 -
Figure 80, page 62) and when the required set point temperature is reached “d2” will be displayed.
NOTE: Heating Only boilers must be in “eco mode’. (with NO Indirect Water Heater Tank)
Domestic hot water operation
The Domestic Hot Water heat demand (generated by the DHW flow sensor) is indicated by the flashing of the Hot Water symbol
under the tap (Items 8 and 9, Figure 80, page 62). The display indicates the actual Domestic Hot Water temperature (Item 10,
Figure 80, page 62 and after Hot set point temperature is reached “d1” will be displayed.
NOTE: Combi boilers recommended to be in “comfort” mode.
Part number 550-100-325/0419
64
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
27 Controls and operation (continued)
Figure 84
Initial power up mode
Ensure the power is on to the boiler
During the first 5 seconds, the display shows the software version of the control module.
For the first 300 seconds, the display shows FH that identifies the Air purge function.
When the FH disappears, the boiler is ready to function automatically whenever the external controls are calling for heat.
Figure 85
Power down mode
Press the on/off button (Item 7 - Figure 80, page 62) for 5 seconds.
To totally isolate, close the gas cock before the
boiler and disconnect electricity supply.
When the boiler is turned off with “eco”/power button, the control
module is still powered, heating operation is disabled and the display
is off, however the frost protection will still be active.
To turn boiler on again, press the on/off button
(Item 7 - Figure 80, page 62) hold for 5 seconds
The boiler is ready to function automatically whenever the external controls are calling for heat.
Software version
On/Off button
Part number 550-100-325/0419
65
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
27 Controls and operation (continued)
Figure 86
To set the system Heating temperature, use the CH buttons, “-” to reduce water setpoint “+” to increase water setpoint (Items 3
and 4 - Figure 80, page 62). It can be set from a minimum of 68° F to a maximum of 190° F.
Adjustments
Room temperature adjustment (using a
room thermostat
1. Using the room thermostat, set the temperature desired.
Controlled by the room thermostat, the boiler heats the system
water to the system delivery setpoint temperature. The boiler
shuts down when the desired temperature in the room is reached.
Economy/Comfort selection
1. The unit is equipped with a special internal device that ensures a
high hot-water delivery speed and excellent user comfort. When
comfort mode is active the water in the boiler is maintained at
a pre-determined temperature, which means that hot water is
available at the boiler outlet as soon as a tap is opened, i.e. with
no waiting.
2. The user can turn the device off (“eco” mode, is a “cold
start” boiler) by pressing economy/comfort button
(Item 7 - Figure 80, page 62).
3. In “eco” mode the display shows the relevant symbol
(Item 12 - Figure 80, page 62). To turn on “comfort”
mode, press economy/comfort button (Item 7 -
Figure 80, page 62), again, the “eco” symbol will vanish
from the display.
4. Heating Only boilers must use “eco” mode.
5. Heating Only boilers with Indirect Water Heater Tank,
“eco” mode must be off.
Figure 87
To set the Domestic hot water temperature, use the DHW buttons, “-” to reduce water setpoint “+” to increase water setpoint
(Items 1 and 2 - Figure 80, page 62). It can be set from a minimum of 104° F to a maximum of 131° F.
Part number 550-100-325/0419
66
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
27 Controls and operation (continued)
Adjustments for - Heating Only Boilers
with Outdoor sensor
Optional for Combi with Outdoor sensor
Theory of Outdoor Reset Control
One of the key points to boiler efficiency, is to match the
heat generated by the boiler to the heat loss of the building
to be able to obtain a given comfort level in the living space.
You can obtain this efficiency by selecting a scale within an
operating programmed range of the boiler water tempera-
ture. These scale ranges are related to the outdoor tempera-
tures, and boiler water temperatures for the installed radiation.
These “Outdoor Reset Control” curves are graphed (and pro-
grammed into the control board) by outside temperature from
68 degrees to -4 degrees F and boiler water target tempera-
tures from 86 to 194 degrees F (see Figure 90, page 67), where
the heat loss of the home, will match the gradual increase in
boiler water temperature as the outside temperature drops.
The average heat loss of a home may meet the needs (boiler wa-
ter temperatures) of offset curve number 6 (Figure 92, page 67)
to meet the heat loss at given outdoor temperatures.
Another example would be a high heat loss structure, where
curve number 10 would drive up the boiler water temperature
with a slight drop in outdoor temperature. (from 68 degrees
F outside temperature to just a drop to 50 degrees F outdoor
temperature, see Figure 92, page 67).
An example of a structure with very little heat loss, (such as
a super insulated, high efficiency building) would be curve
number 1, where the outdoor temperatures continue to drop,
and the boiler water temperatures are in the low range from 86
degrees to 104 degrees F.
Outdoor Reset Control
1. When the external outdoor sensor is attached to the boiler,
the system can work in Outside Temperature Compensation
mode. In OTC mode the temperature of the heating system
is controlled according to the external climate conditions,
this will insure a high degree of comfort and energy saving
all year round.
2. By using the CH buttons (Items 3 and 4 - Figure 88) it is pos-
sible to set the maximum system water flow temperature for
the installation.
OTC setting - with Outdoor sensor
1. To enter the OTC - reset mode, press “reset” button for 5
seconds, takes you to Curve menu.
2. The display shows “CU” flashing Figure 88; to set Curve, use
the DHW buttons (Items 1 and 2 - Figure 88) pushing CH +
or - buttons switches your screens between CU (Curves) or
OF (Offset). Display “CU” allows Curves value adjustment,
value can be varied from 1 to 10, in accordance with the
charts on page 67. “O” means no OTC mode.
3. By pressing the CH push buttons (Items 3 and 4 - Figure 88,
the display shows “0F” flashing Figure 89; to set Offset, use
the DHW push buttons (Items 1 and 2 - Figure 88).
Figure 88
Figure 89 OFFSET
4. It can be 68 to 104, in accordance with the chart Figure 91
or Figure 92, page 67.
5. To exit the OTC mode, press OTC button “reset” button for
5 seconds.
In the case of an outdoor sensor failure, the control
will continue to operate the boiler, but without the use of
the Compensation Curves, and an error message will flash
on the display (Fault 39 -please see Figure 122, page 97).
Upon replacement of the defective sensor the boiler will re-
sume the use of Compensation Curves
.
OTC Exempt mode
By pressing the DHW+ and eco buttons together for 10 sec-
onds, it is possible to enter the OTC Exempt menu. The display
starts showing the value of the parameter OTC Exempt (See
parameter Number 163, page 109) flashing. By means of the
CH - push button it is possible to change value.
(Selecting 0 - allows you to Select the Compensation curve for
your individual home heating needs). By pressing DHW+ and
eco buttons together for 10 seconds, it is possible to leave the
OTC Exempt Menu. If no action has been taken, the control
automatically leaves this mode after 2 minutes.
- 0 = installation non exempt from outside sensor connection;
- 1 = installation exempt for outside sensor connection;
Compensation curves
Curve numbers below refer to Figures 90, 91, & 92, page 67.
Curve number 1 is for a high efficiency home with very
low heat losses. (Least aggressive curve).
Curve number 6 is for an average home heat losses.
Curve number 10 is for a home with high heat losses.
(Most aggressive curve).
CH
OTC/RESET
DHW
OTC/reset
1
2
3
4
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
28 DHW Settings (Combi Only)
Boiler must be set on comfort mode
Figure 91
Figure 92
27 Controls and operation
Adjustments for Heating Only Boilers
with Outdoor sensor
Figure 93
Boiler
Model
[GPM with
T 30F
[GPM with
T 50F
[GPM with
T 70F
[GPM with
T 90F
AB-80 4.7 2.8 2.0 1.6
AB-120 7.2 4.4 3.2 2.4
AB-155 9.2 5.6 4.0 3.1
DHW SETTINGS
1. The DHW SETTINGS menus are for setting control opera-
tion during DHW operation. The settings apply ONLY to
DHW Zone.
2. If DHW is used, the settings for control operation during
DHW calls for heat are set under the DHW SETTINGS menus
(Figure 82, page 63).
DHW TEMPERATURES
— The control gives priority to DHW
operation. During DHW call for heat, the
heating zone output is disabled. This continues
until the DHW call ends or the DHW MAX ON
TIME has elapsed which is 30 minutes.
1. The control will regulate boiler firing to provide outlet water
at this temperature.
2. For most DHW applications, set this to 190°F. A lower supply
temperature can be used, but will reduce the indirect water
heater heating capacity.
Figure 94
80
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
7.5
8
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105
AquaBalance 80 - DHW PRODUCTION
Delta T (ºF)
G.P.M.
AquaBalance 80
Figure 90
68
86
104
122
140
158
176
194
-42814202632384450566268
BOILER FLOW TEMPERATURE (°F)
OUTSIDE AIR TEMPERATURE (°F)
OTC CURVES
1
2
3
4
5
6
78910
OFFSET 104
OFFSET 68
Starting temperature
Part number 550-100-325/0419
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®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 95
120 Figure 96
155
28 DHW Settings (Combi Only)
(continued)
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
7.5
8
8.5
9
9.5
10
10.5
11
11.5
12
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100105
AquaBalance 120 - DHW PRODUCTION
G.P.M.
Delta T (ºF)
AquaBalance 120
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
7.5
8
8.5
9
9.5
10
10.5
11
11.5
12
12.5
13
13.5
14
14.5
15
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Freestyle 155 - DHW PRODUCTION
Freestyle 155
Delta T (ºF)
G.P.M.
AquaBalance 155
AquaBalance 155 -
The “D” Parameter codes below are part of the normal Control Operation and typically appear during Start Up.
This a “Timed” or “Auto Recycle” event.
D1….the boiler is / has finished the call for Domestic Water heating, and is in the transition to either
standby mode or central heating mode.
D2….the boiler has reached the required water set point, and the firing has stopped / with a call for Cen-
tral Heating still applied by the T-Stat to the boiler. Circulators will continue to operate and the boiler is
monitoring the two internal water sensors (return & discharge) waiting for a water “Delta-T” to return…at
that time the boiler will re-fire if need be.
D3….the boiler has made 3 tries for ignition and has failed to ignite. A re-trial ignition cycle / delay is in
effect for 3 more tries to ignite/restart boiler operation.
Parameter Description
D1
After cycle of Domestic water mode, D1 will be displayed.
D2
When required boiler water set - point is reached D2 will be displayed.
D3
After an attempt for ignition, re-trial ignition delay is in effect (D3 is displayed).
* Check for proper fuel supply.
* Remove and check ignitor for proper gap, 5/32”, replace if disgured, check combustion setting Natural gas or LP.
* Insure condensate is draining properly.
* Insure venting size and length are correct and unobstructed.
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
29 Standard Altitude
Figure 97
()
Standard Altitude Boiler Adjustment
1. Press DHW- and DHW+ buttons together for 10 seconds
to enter the parameter setup menu. The standard values for
parameter “b04”, “ b05” and “b06”, are shown in Table.
2. Roll down the menu by pressing the CH button until the
parameter “b04” is on the screen.
3. Set parameter “b04” to parameter in Table.
4. Repeat steps 2 and 3 above to also adjust parameter “b05”
and “b06”, according to Table.
5. Press DHW- and DHW+ buttons together for 10 seconds
to leave the menu. The values are automatically saved.
The Ignition speeds are the same for Standard
and High Altitude, there’s no need to change.
In USA Input rates are derated 4% for each 1000
ft. above sea level, beyond 2000 ft. in accordance
with National Fuel Gas Code, ANSI Z223.1/NFPA
54 – latest edition, and/or the Natural Gas and
Propane Installation Code, CAN/CSA B149.1.
For elevations above 10,000 feet, please contact
Weil-McLain Technical Support for details.
In Canada, Input rates are derated 10% for altitudes
of 2000 ft. to 4500 ft. above sea level. Please use
appropriate Fan Speed Settings for High Altitude
provided in the following pages of this manual.
In Canada for elevation beyond 4500 feet. Please
consult Provincial Authorities having jurisdiction
and/or local codes.
Perform Boiler Manual Start-up
Follow all instructions in the start-up section
for boiler start-up after converting for High
Altitude. Because the boiler has been changed,
you must verify correct operation, including
checking combustion with test instruments
both at high fire and low fire as described in
the this manual, pages 81, 82 & 83.
Check the correct ignition sequence of the
boiler after the conversion, as in page 90.
Failure to comply could result in severe per-
sonal injury, death or substantial property
damage.
Model
Standard Altitude
Low
Fire
(b06)
Ignition
(Can't
Change
- Needs
PC)
High Fire
In
CH Mode
(b05)
High Fire
In
DHW
Mode
(b04)
35 80% 155 155
35 80% 145 145
40 60% 200 200
40 60% 185 185
39 50% 210 210
40 50% 220 220
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
30 High Altitude
HIGH ALTITUDE BOILER ADJUSTMENT
1. Press DHW- and DHW+ buttons together for 10 seconds
to enter the parameter setup menu. The standard values for
parameter “b04”, “ b05” and “b06”, are shown in Table below
and the following pages.
2. Roll down the menu by pressing the CH button until the
parameter “b04” is on the screen.
3. Set parameter “b04” to parameter in Table below.
4. Repeat steps 2 and 3 above to also adjust parameter “b05”
and “b06”, according to Table above.
5. Press DHW- and DHW+ buttons together for 10 seconds to
leave the menu. The values are automatically saved.
The Ignition speeds are the same for Standard and
High Altitude, there’s no need to change.
Figure 98 AquaBalance
®
80 boilers
80KBTU - Natural Gas
ALTITUDE
LOW FIRE HIGH FIRE (CH & DHW)
Blower Speed
(b06)
CO2 (%) CO (PPM)
Blower Speed
(b04 & b05)
CO2 (%) CO (PPM)
0 - 2,000' 35 8.0 - 9.0 <20 155 9.0 - 9.5 <110
2,000' - 4,000' 42 8.0 - 9.0 <20 155 9.0 - 9.5 <110
4,000'-5,000' 43 8.0 - 9.0 <20 155 9.0 - 9.5 <110
5,000'-6,000' 44 8.0 - 9.0 <20 155 9.0 - 9.5 <110
6,000' - 7,000' 45 8.0 - 9.0 <20 155 9.0 - 9.5 <110
7,000' - 8,000' 46 8.0 - 9.0 <20 155 9.0 - 9.5 <110
8,000' - 9,000' 47 8.0 - 9.0 <20 155 9.0 - 9.5 <110
9,000' - 10,000' 48 8.0 - 9.0 <20 155 9.0 - 9.5 <110
80KBTU - LP Gas
ALTITUDE
LOW FIRE HIGH FIRE (CH & DHW)
Blower Speed
(b06)
CO2 (%) CO (PPM)
Blower Speed
(b04 & b05)
CO2 (%) CO (PPM)
0 - 2,000' 35 9.0 - 9.8 <20 145 10.2 - 10.7 <110
2,000' - 4,000' 42 9.0 - 9.8 <20 145 10.2 - 10.7 <110
4,000'-5,000' 43 9.0 - 9.8 <20 145 10.2 - 10.7 <110
5,000'-6,000' 44 9.0 - 9.8 <20 145 10.2 - 10.7 <110
6,000' - 7,000' 45 9.0 - 9.8 <20 145 10.2 - 10.7 <110
7,000' - 8,000' 46 9.0 - 9.8 <20 145 10.2 - 10.7 <150
8,000' - 9,000' 47 9.0 - 9.8 <20 145 10.2 - 10.7 <150
9,000' - 10,000' 48 9.0 - 9.8 <20 145 10.2 - 10.7 <150
In USA Input rates are derated 4% for each 1000
ft. above sea level, beyond 2000 ft. in accordance
with National Fuel Gas Code, ANSI Z223.1/NFPA
54 - latest edition, and/or the Natural Gas and
Propane Installation Code, CAN/CSA B149.1.
For elevations above 10,000 feet, please contact
Weil-McLain Technical Support for details.
In Canada, Input rates are derated 10% for altitudes
of 2000 ft. to 4500 ft. above sea level. Please use
appropriate Fan Speed Settings for High Altitude
provided in this manual.
In Canada for elevation beyond 4500 feet. please
consult Provincial Authorities having jurisdiction
and/or local codes.
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 99 AquaBalance
®
120 boilers
120KBTU - Natural Gas
ALTITUDE
LOW FIRE HIGH FIRE (CH & DHW)
Blower Speed
(b06)
CO2 (%) CO (PPM)
Blower Speed
(b04 & b05)
CO2 (%) CO (PPM)
0 - 2,000' 40 8.0 - 9.0 <20 200 9.0 - 9.5 <110
2,000' - 4,000' 43 8.0 - 9.0 <20 200 9.0 - 9.5 <110
4,000'-5,000' 46 8.0 - 8.5 <20 200 8.7 - 9.0 <150
5,000'-6,000' 49 8.0 - 8.5 <20 200 8.7 - 9.0 <150
6,000' - 7,000' 51 8.0 - 8.5 <20 200 8.7 - 9.0 <150
7,000' - 8,000' 52 8.0 - 8.5 <20 200 8.7 - 9.0 <180
8,000' - 9,000' 53 8.0 - 8.5 <20 200 8.7 - 9.0 <180
9,000' - 10,000' 54 8.0 - 8.5 <20 200 8.7 - 9.0 <180
120KBTU - LP Gas
ALTITUDE
LOW FIRE HIGH FIRE (CH & DHW)
Blower Speed
(b06)
CO2 (%) CO (PPM)
Blower Speed
(b04 & b05)
CO2 (%) CO (PPM)
0 - 2,000' 40 9.0 - 9.8 <20 185 10.2 - 10.7 <110
2,000' - 4,000' 43 9.0 - 9.8 <20 185 10.2 - 10.7 <110
4,000'-5,000' 46 9.0 - 9.4 <20 185 10.0 - 10.2 <180
5,000'-6,000' 49 9.0 - 9.4 <20 185 10.0 - 10.2 <180
6,000' - 7,000' 51 9.0 - 9.4 <20 185 10.0 - 10.2 <180
7,000' - 8,000' 52 9.0 - 9.4 <20 185 10.0 - 10.2 <200
8,000' - 9,000' 53 9.0 - 9.4 <20 185 10.0 - 10.2 <200
9,000' - 10,000' 54 9.0 - 9.4 <20 185 10.0 - 10.2 <200
30 High Altitude Blower Speeds
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
30 High Altitude Blower Speeds
Figure 100 AquaBalance
®
155 boilers
Perform Boiler Manual Start-up
Follow all instructions in the start-up section for boiler start-up after converting for High
Altitude. Because the boiler has been changed, you must verify correct operation, including
checking combustion with test instruments both at high fire and low fire as described in this
manual, pages 81, 82 & 83.
Check the correct ignition sequence of the boiler after the conversion, as in page 90.
Failure to comply could result in severe personal injury, death or substantial property damage.
155KBTU - Natural Gas
ALTITUDE
LOW FIRE HIGH FIRE (CH & DHW)
Blower Speed
(b06)
CO2 (%) CO (PPM)
Blower Speed
(b04 & b05)
CO2 (%) CO (PPM)
0 - 2,000' 39 8.0 - 9.0 <7 210 9.0 - 9.5 <120
2,000' - 4,000' 40 8.0 - 9.0 <7 210 9.0 - 9.5 <120
4,000'-5,000' 41 8.0 - 8.5 <10 210 8.7 - 9.0 <150
5,000'-6,000' 42 8.0 - 8.5 <10 210 8.7 - 9.0 <150
6,000' - 7,000' 43 8.0 - 8.5 <10 210 8.7 - 9.0 <150
7,000' - 8,000' 45 8.0 - 8.5 <10 210 8.7 - 9.0 <180
8,000' - 9,000' 46 8.0 - 8.5 <10 210 8.7 - 9.0 <180
9,000' - 10,000' 48 8.0 - 8.5 <10 210 8.7 - 9.0 <180
155KBTU - LP Gas
ALTITUDE
LOW FIRE HIGH FIRE (CH & DHW)
Blower Speed
(b06)
CO2 (%) CO (PPM)
Blower Speed
(b04 & b05)
CO2 (%) CO (PPM)
0 - 2,000' 44 9.0 - 9.8 <7 220 10.2 - 10.7 <120
2,000' - 4,000' 46 9.0 - 9.8 <7 220 10.2 - 10.7 <120
4,000'-5,000' 46 9.3 - 9.5 <10 220 9.7 - 9.9 <150
5,000'-6,000' 46 9.3 - 9.5 <10 220 9.7 - 9.9 <150
6,000' - 7,000' 48 9.3 - 9.5 <10 220 9.7 - 9.9 <150
7,000' - 8,000' 48 9.3 - 9.5 <10 220 9.7 - 9.9 <180
8,000' - 9,000' 48 9.3 - 9.5 <10 220 9.7 - 9.9 <180
9,000' - 10,000' 50 9.3 - 9.5 <10 220 9.7 - 9.9 <180
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
QUICK START GUIDE
After you have completed the installation of the Combi or Heating Only model by the instructions provided in
this manual, pages 5 - 75 insure the following first before you proceed:
All gas lines are connected and tested for leaks, and if the boiler is to operate on LP fuel, and the unit has been
converted properly from Natural gas to Liquefied Petroleum (Propane) gas and set up as directed in the boiler
manual.
All water piping is installed correctly and free of leaks with the proper accessories; proper sized expansion tank,
water feed valve adjusted, low water cut-off devices installed and tested, all operation control exterior to the boiler
installed such as thermostats, and zone control panels.
al Heating only boilers, Outdoor sensor MUST be installed and connected to the boiler control.
(See page 53)
System start
1
Push eco / comfort / Power button; to start boiler.
2
NOTE: if A-16 error code is displayed (Central Heating Only boiler) when unit is powered up,
the outdoor sensor is not installed. Install outdoor sensor and push the reset button to reset
error code. A faulty outdoor sensor will give an “F-39” error code.
3
04 “shows on the display” (control software version).
4
FH “shows on the display” (Blower /inducer operating in purge mode of combustion chamber and venting for 5 minutes).
5
With no “call for heat” (current boiler water temperature will be shown in degrees F).
6
To Change “Central Heating water temperature set-point” (from 68 F to 190 degrees F) use the bottom set
of “+” or “–” keys to raise or lower the set point temperature.
7
To change “Domestic water temperature set-point” (Combi Boiler set from 104 F to 131 degrees F ).
NOTE: Insure that the operating temperature is at a safe set-point temperature. Use the top set of “+” or “–” keys to raise or lower the set point.
8
To Change “Control Selection for vent material” See instructions on page 34. This is necessary only if using a
venting material other than the default PVC.
Figure 10160-70
31 Startup — Quick Start Guide using default settings
Part number 550-100-325/0419
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AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
31 Startup — Quick Start Guide using default settings (continued)
QUICK START GUIDE
System start (continued)
9
“Test Mode Operation”
Proceed to put the boiler into operation as follows:
1. To start, create a demand for heat, open up a hot water faucet or turn up the thermostat.
2. To operate the boiler in test mode, press the CH “-” and “+” keys together for 5 seconds
(See below and Figure 104, page 79) to activate the TEST mode.
3. The boiler lights at the maximum heating 100% rate displayed on the LCD display.
4. The high fire (large) flame symbol will be displayed once the boiler has lit.
5. Use DHW “_” button to drop firing rate to low fire.
6. To exit the “Test mode”, press the CH keys (Items 3 and 4, Figure 80, page 62) together for 5 seconds, or
leave the boiler to automatically switch off after 15 minutes or stopping DHW flow.
7. This TEST procedure is used to check/adjust combustion CO and CO
2
per specifications, Figure 107, page 82
and Figure 110, page 83.
Liquefied Petroleum (Propane) Gas — Propane conversion kit (optional - sold separately, see Figure 163, page 120 .
High altitude — High altitude (over 2,000 feet) requires only changing the altitude setting on the control. (See page 70).
Equipment that maybe required for installation
Digital or U-tube manometer for checking gas line pressure.
Volt-ohmmeter may be required for troubleshooting.
Combustion Analyzer to verify and adjust combustion.
This unit must only be used for its intended purpose. This unit is designed to heat water to a temperature below
boiling point and must be connected to a heating system and/or a water supply system for domestic use, compatible
with its performance, characteristics and heating capacity. Any other use is deemed improper.
Incorrect installation can cause damage or injury for which the manufacturer cannot be deemed responsible.
The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions
on page 86 of this manual. Failure to comply could result in severe personal injury.
Pay attention when handling the boiler insulation panels as they contain materials that could irritate the skin. No
part of the boiler contains asbestos, mercury or Chlorofluorocarbons (CFC’s).
Part number 550-100-325/0419
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®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Use the correct amount of antifreeze
1. Determine the freezing temperature needed (to protect
against lowest likely temperature the system water will en-
counter).
2. Find the antifreeze concentration by volume needed for this
temperature from the antifreeze manufacturer’s data on the
antifreeze container.
3. Add up the volume (gallons) of all system piping and com-
ponents, including the expansion tank and boiler.
a. Boiler water content is listed in Figure 177, page 134.
b. Remember to include expansion tank water content.
4. Multiply this volume by the (percent) antifreeze needed to
find the number of gallons of antifreeze to add.
Fill and test water system
1. Fill system only after ensuring the water meets the require-
ments of this manual.
2. Close manual and automatic air vents and boiler drain valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. Typical cold water for a residential system is 12 psi mini-
mum fill pressure.
Boiler water pressure switch is set for 9 psi (±2)
minimum pressure. A low water pressure will give
“F37” fault code.
b. Pressure will rise when boiler is turned on and system
water temperature increases. Operating pressure must
never exceed 25 PSIG.
4. At initial fill and during boiler startup and testing, check
system thoroughly for any leaks. Repair all leaks before pro-
ceeding further.
Clean system to remove sediment
1. You must thoroughly flush the system (without boiler
connected) to remove sediment. The high-efficiency heat
exchanger can be damaged by buildup or corrosion due
to sediment.
If the system needs to be cleaned, use only Sen-
tinel X400 cleaner, available from Weil-McLain.
See Figure 164, page 121 for information. Follow
instructions supplied with the X400 cleaner and
cleaning instructions on page 115. For zoned
systems, flush each zone separately through a
purge valve. (If purge valves and isolation valves
are not already installed, install them to properly
clean the system).
2. Flush system until water runs clean and you are sure piping
is free of sediment.
Do not use petroleum-based cleaning
or sealing compounds in boiler system.
Damage to elastomer seals and gaskets in
system could occur, resulting in substan-
tial property damage.
Before filling the boiler and system with
water, verify the following. Boiler corrosion
can occur.
Failure to comply could result in boiler
failure or unreliable operation.
Water chemistry
1. Maintain boiler water pH between 7.0 and 8.5. Check with
litmus paper or have chemically analyzed by water treat-
ment company.
2. If pH differs from above, consult local water treatment
company for treatment needed.
CIRCULATOR EXERCISING and
FREEZE PROTECTION
CIRCULATOR EXERCISING
The control will automatically start the circulator output and run
for 10 seconds for each 72-hour period of inactivity.
FREEZE PROTECTION
This function automatically fires the boiler and starts the
HEAT circulator when the heat exchanger sensor detects a
temperature less than 40 °F. The circulator turns off when the
temperature rises above 45 °F.
Hardness less than 7 grains
Consult local water treatment companies for unusually hard
water areas (above 7 grains hardness).
1. Filling with chlorinated fresh water should be acceptable since
drinking water chloride levels are typically less than 5 ppm.
2. Do not use the boiler to directly heat swimming pool or spa
water.
3. Do not fill boiler or operate with water containing chloride
in excess of 50 ppm.
Verify that the water chemistry meets the limita-
tions and requirements of all other equipment in
the system.
Antifreeze
1. Use only antifreeze listed by Weil-McLain as suitable for
use with Combi boilers. See Figure 164, page 121 for infor-
mation.
2. See Replacement parts at the end of this manual for part
numbers to obtain antifreeze through a Weil-McLain
distributor.
32 Startup
Freeze protection (if used)
Follow these guidelines to prevent possibility of
severe personal injury, death or substantial property
damage:
for informa-
before installing the new boiler.
are available online. The MSDS contains informa-
tion on potential hazards and first aid procedures
for exposure or ingestion.
-
nually
. Glycol concentration and inhibitor levels
may change over time. Add antifreeze to increase
concentration if necessary. Add inhibitor as needed
to bring to acceptable level, using inhibitor test kit
to verify.
In addition to antifreeze and inhibitor, use and
maintain minimum level of Sentinel X100 inhibitor
as directed on this page.
If using freeze protection fluid with automatic fill,
.
Freeze protection fluid may leak before the water be-
gins to leak, causing concentration to drop, reducing
the freeze protection level.
.
Antifreeze moves more sluggishly than water and
can interfere with heat transfer. At antifreeze con-
centrations higher than 50%, sludge can develop in
the boiler, potentially causing damage to the heat
exchanger.
Clean the system before filling. Always drain
and flush the system thoroughly before filling with
antifreeze. Sludge, iron oxide deposits and other
sediment in the system inhibit flow and can cause
rapid breakdown of inhibitors.
Use only antifreeze recommended by
Weil-McLain.
Weil-McLain provides information for application
of the antifreeze products listed in this document
only for use in boilers. Do not apply these products
or instructions for other applications. Local codes
may require a backflow preventer or actual discon-
nection from city water supply.
Part number 550-100-325/0419
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®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
32 Startup (continued)
Eliminate all system leaks. Continual fresh make-
up water will reduce boiler life. Minerals can
build up in the heat exchanger, reducing heat
transfer, overheating heat exchanger, and causing
heat exchanger failure.
Purge air from water system
1. Connect a hose to the drain valve (see drain valves, item
10, in piping diagrams beginning on page 9). Route hose
to an area where water can drain and be seen.
2. Close the boiler or system isolation valve between the drain
valve and fill connection to the system.
3. Close zone isolation valves.
4. Open quick-fill valve on cold water make-up line.
5. Open drain valve.
6. One zone at a time, open the isolation valves. Allow
water to run through the zone, pushing out the air. Run
until no noticeable air flow is present. Close the zone iso-
lation valves and proceed with the next zone. Follow this
procedure until all zones are purged. Follow the same
procedure to purge air from the boiler and its internal
piping.
7. Close the quick-fill water valve and drain valve and remove
the hose. Open all isolation valves. Watch that system pres-
sure rises to correct cold-fill pressure.
8. Using the manual air vents located throughout the system.
9. If purge valves are not installed in system, open manual
air vents in system one at a time, beginning with lowest
floor. Close vent when water squirts out. Repeat with
remaining vents.
10. Open automatic air vent (diaphragm-type or bladder-type
expansion tank systems only) one turn.
11. Starting on the lowest floor, open air vents one at a time
until water squirts out.
12. Repeat with remaining vents.
13. Refill to correct pressure.
14. When the boiler is turned on it cycles the pump to eliminate
any air in system, per Figure 84, page 64.
Part number 550-100-325/0419
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®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
32 Startup (continued)
Figure 102
X100 inhibitor is required
1. It is required that the boiler have Sentinel X100 inhibi-
tor added to the system to prevent damage to the boilers’
heat exchanger. Failure to comply may result in accelerated
corrosion of the heat exchanger and system components.
See Replacement Parts section at the end of this manual for
ordering information.
2. After filling the system as directed in this manual, and the air
purge has been completed, release the system water pressure
to 0 psi. Drain a small amount of water out of a convenient
boiler drain to insure the system water pressure is at 0 psi.
Use a (field supplied-if needed) Dishwasher elbow / hose 3/4
to 3/8 compression adapter (See Figure 102 below) to the
white Sentinel hose, and screw it to the tube of Sentinel X100.
Insert it into your caulk gun, and fit the washing machine
hose adapter to a boiler drain connection. Open the drain,
and inject the complete tube of X100 to the system. Close the
drain valve, and remove the injection fitting.
3. Fill system water to required pressure, and start a heating
zone to circulate system water. Allow time for the water to
circulate and mix. Then check the inhibitor level with a test
kit. Add additional inhibitor if necessary.
Check/verify water chemistry
1. The system may have residual substances that could affect
water chemistry.
2. After the system has been filled and leak tested, verify water
pH and chloride concentrations are acceptable.
3. Verify antifreeze concentration, if used.
4. Follow the instructions on the Sentinel test kit to sample the
system water and verify inhibitor concentration.
Check inhibitor concentration
annually
1. Test the pH of a sample of system water at least annually.
The pH of the water mixture must be between 7.0 and 8.5.
(Or use the Sentinel inhibitor test kit to check concentra-
tion.)
2. If pH is outside this range (or inhibitor test kit indicates
low level), the inhibitor level may not be sufficient to pre-
vent corrosion.
3. Test antifreeze concentration.
Test antifreeze concentration at least annually.
If concentration is low, add antifreeze or drain
system and refill with correct mixture.
4. Follow instructions on antifreeze container to determine
the amount of antifreeze needed. exceed 50% by
volume concentration of antifreeze.
Check inhibitor level after adjustments are made.
Check thermostat circuits
1. Disconnect wires connected to the thermostat terminals
(see Field wiring, beginning on page 52 for low voltage
terminal locations and application information). Mark
the wires before removing to avoid wiring errors when
re-connecting them.
2. Connect a voltmeter across each pair of incoming wires.
Close each thermostat, zone valve and relay in the external
circuits one at a time and check the voltmeter reading across
the incoming wires.
3.
4. If a voltage does occur under any condition, check and
correct the external wiring.
to 3-wire zone valves
. This could cause con-
trol damage.
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires.
Figure 103
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33 Startup — nal checks
Check for gas leaks
Before starting the boiler, and during initial opera-
tion, use a leak detector or smell near the floor and
around the boiler for gas odorant or any unusual
odor. Remove boiler jacket door and smell the inte-
rior of the boiler jacket.
.
The gas valve is factory-set for the
correct outlet pressure. This setting is suitable for
natural gas and propane, requiring no field adjust-
ment. Attempting to alter or measure the gas valve
outlet pressure could result in damage to the valve,
causing potential severe personal injury, death or
substantial property damage.
— Your propane supplier
mixes an odorant with the propane to make its pres-
ence detectable. In some instances, the odorant can
fade, and the gas may no longer have an odor. Be-
fore startup (and periodically thereafter), have the
propane supplier verify the correct odorant level in
the gas.
Inspect/fill condensate system
1. Inspect the condensate drain line, condensate PVC fittings and
condensate trap. (See page 49 for component locations).
1. Loosen the nut that secures the condensate trap body to the
boiler condensate connection (see Figure 103). Pull the trap
down to disengage from heat exchanger. Pull the trap body
forward enough to allow pouring water into the top of the trap.
2. Fill the trap with fresh water until water begins to run into the
condensate drain tube.
3. Reattach the trap body by sliding onto the boiler condensate
outlet, then retightening the trap body nut.
The condensate trap must be filled with water during
all times of boiler operation to avoid flue gas emission
from the condensate drain line. Failure to fill the trap
could result in severe personal injury or death.
If it is suspected that the condensate drain con-
nection is or was blocked, then boiler components
like the gas valve, blower venturi, igniter and heat
exchanger need to be inspected. Check for damages
occurring from water accumulation in this cabinet.
Any damaged components need to be replaced.
Failure to replace water damaged components
could result in severe personal injury or death.
Figure 104
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33 Startup — nal checks(continued)
CONTINUED AFTER NEXT PAGE
Final checks before lighting the boiler
Open any on-off valves between boiler and the systems.
Verify that there are no leaks of the gas system.
Verify that the boiler and system are full of water and all
system components are correctly set for operation.
Verify that condensate trap drain line is filled with water.
Verify that there are no leaks in the system, DHW piping,
connections or boiler.
Verify electrical connections are correct and securely
attached.
Inspect vent piping and air piping for signs of deteriora-
tion from corrosion, physical damage or sagging. Verify air
piping and vent piping are intact and correctly installed
per this manual.
Read the instructions to adjust and set up the boiler
control.
Verify that the boiler model is set correctly in the boiler
control, and that it displays correctly.
To start the boiler
Having checked:
That the boiler has been installed in accordance with
these instructions.
The integrity of the flue system and the flue seals.
The integrity of the boiler combustion circuit and the
relevant seals.
1. Apply power to the boiler.
2. Follow the Operating Instructions, Figure 105, page 80.
Test Mode Operation
When entering Test mode operation the boiler will
fire without a call for heat.
Proceed to put the boiler into operation as follows:
1. To start create a demand for heat, open up a hot water faucet(s)
or turning up the thermostat. This way you will ensure that
during the “Test Mode” a heat load is created to “Dump” the
energy from the boiler.
2. To operate the boiler in test mode, press the CH “-” and
“+” keys together for 5 seconds (See below) to activate the
“” mode.
3. The boiler lights at the maximum heating 100% rate displayed
on the LCD display.
4. The high fire (large) flame symbol will be displayed once the
boiler has lit.
5. Use DHW “-” button to drop firing rate to low fire.
6. To exit the “” mode, press the CH keys (Items 3 and
4 Figure 80, page 62) together for 5 seconds, or leave the
boiler to automatically switch off after 15 minutes or stop-
ping DHW flow.
7. This TEST procedure is used to check/adjust combustion
CO and CO
2
per specifications Figure 107, page 82 and
Figure 110, page 83.
If boiler does not start correctly
1. Check for loose connections, blown fuse or is boiler Not
plugged in?
2. Are external limit controls (if used) open? Is boiler water
temperature above 200°F?
3. Are thermostats set below room temperature?
4. Is gas turned on at meter and boiler?
5. Is incoming gas pressure less than the minimum values given
on page 14?
6. Are boiler control settings correct for the application?
7. If none of the above corrects the problem, refer to Trouble-
shooting, beginning on page 89.
Check system and boiler
❏
1. Check system piping for leaks. If found, shut down boiler and
repair immediately. (See WARNING on page 76 regarding
failure to repair leaks.)
2. Vent any remaining air from system using manual vents. Air
in the system will interfere with circulation and cause heat
distribution problems and noise.
❏
1. Check for gas-tight seal at every connection and seam of air
piping and vent piping.
Venting system must be sealed gas-tight to prevent
flue gas spillage and carbon monoxide emissions
which will result in severe personal injury or death.
❏
1. Check around the boiler and inside the boiler jacket for gas
odor following the instructions in “Warning”on page 50 of
this manual.
If you discover evidence of any gas leak, shut
down the boiler at once. Find the leak source
with bubble test and repair immediately. Do
not start boiler again until corrected. Failure
to comply could result in severe personal in-
jury, death or substantial property damage.
Figure 105
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
33 Startup — nal checks(continued)
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33 Startup — nal checks(continued)
❏
Verify boiler has been converted for propane, See page 10.
DO NOT attempt to mea-
sure gas valve outlet pres-
sure
DO NOT adjust or attempt to measure gas valve outlet
pressure. The gas valve is factory-set for the correct outlet
pressure. This setting is suitable for natural gas and propane,
requiring no field adjustment.
Attempting to alter or measure the gas valve outlet pressure
could result in damage to the valve, causing potential severe
personal injury, death or substantial property damage.
Boilers are shipped ready to fire natural gas ONLY.
Failure to comply could result in severe personal injury,
death or substantial property damage.
❏with instruments
When entering Test mode operation the boiler will
fire without a call for heat.
1. To start create a demand for heat, open up a hot water faucet
or turning up the thermostat.
2. Enter into the “” Mode to check combustion on High
Fire and Low Fire.
3. To operate the boiler in test mode, press the CH “-” and
“+” keys together for 5 seconds (See Figure 104, page 79)
to activate the “” mode.
4. The boiler lights at the maximum heating 100% rate dis-
played on the LCD display.
5. The high fire (large) flame symbol will be displayed once the
boiler has lit.
6. Use DHW “_” button to drop firing rate to low fire.
7. To exit the “” mode, press the CH keys (Items 3 and
4 Figure 80, page 62) together for 5 seconds, or leave the
boiler to automatically switch off after 15 minutes or stop-
ping DHW flow.
8. This TEST procedure is used to check/adjust combustion
CO and CO
2
per specifications Figure 107, page 82 and
Figure 110, page 83.
9. — Remove the flue access
fittings/turn to remove (see Figure 43, page 33) from the flue
pipe and insert a combustion test probe.
10. Test for CO
2
(or O
2
) and for CO. The CO
2
values must comply
with or Figure 110, page 83. If results are acceptable, proceed
to step 7. , follow the instructions under “Throttle
Screw Adjustment” on page 82 to set the throttle screw posi-
tion. See below.
11. Measure natural gas input for High and Low Fire:
a. Operate boiler 10 minutes. Turn off other appliances.
b. At natural gas meter, measure time (in seconds) required
to use one cubic foot of gas.
If combustion at either high or low fire is out-
side the range given in Figure 107, page 82 or
Figure 110, page 83, follow the procedure given
on below, “Setting the Air/Gas Ratio Valve” for
adjusting the throttle screw on the gas valve.
If throttle screw adjustment does not correct
the problem, then shut down the boiler and
contact your local Weil-McLain Technical Sup-
port. Throttle screw adjustment must be done
only by a qualified technician, using calibrated
test instruments. Failure to comply could result
in severe personal injury, death or substantial
property damage.
c. Calculate gas input:
3600 x 1000
= Btuh
number of seconds from step b
d. Btuh calculated should approximate input rating on
boiler rating label.
12. Use the control display to navigate to Manual Test mode (see
Figure 104, page 79) and force the firing rate to LOW (low
fire). Push DHW “-” button only to drop to low fire.
13. Look at the flame through the flame inspection window. The
low fire flame should be stable and evenly distributed over
burner surface with a uniform orange color.
14. If combustion testing in low fire meets the specification
range - Exit “” Mode by pressing the CH “+” and “-”
keys together for 5 seconds.
15. Reinstall the flue access fittings, (see Figure 43, page 33) used
for combustion analyzer probe and lock it in closed position.
You must reinstall the flue access fittings to the flue
adapters, to prevent flue gas spillage from the vent
adapter test ports . Failure to comply could result in
severe personal injury, death or substantial property
damage.
Table 2
Gas Rate
Boiler
model
Maximum rate Minimum rate
ft
3
/h ft
3
/h
AB-80
78.4 7.8
AB-120
117.6 11.8
AB-155
151.9 15.2
Figure 106Throttle a
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
33 Startup — nal checks(continued)
Figure 107Maximum rate combustion values –
measured values must be within the ranges
given below
Using a combustion analyzer check the CO
2
values at low and high fire. It should be within
values from the table in Figure 107. The differ-
ence of CO
2
from high fire to low fire should
be below 0.2% or above 1%.
attempt to adjust the throttle screw
unless by a qualified technician, and with the
use of calibrated combustion test instruments.
Adjust the throttle screw only as needed to meet
the combustion values given in Figures 107 and
110, page 83.
Adjust in steps of no more than 1/8 of a turn and
wait 1 minute after each adjustment to allow the
setting to stabilize. Turning the screw too far will
cause the adjustment to reverse behavior.
4. In the event that the CO
2
setting level with an acceptable
CO/CO
2
ratio cannot be obtained please contact your
Weil-McLain Technical Support for details.
5. Should you require any assistance during the set up pro-
cedure contact your Weil-McLain Technical Support if
the problem cannot be addressed with the information
provided in this manual.
6. Remove T-40 cap, see Figure 108, below, for Offset screw
adjustment.
Combustion Range
Boiler Model
CO/(PPM) CO
2
NG % CO
2
LP %
AB-80
110
AB-120
110
AB-155
120
Setting the Air/Gas Ratio valve
There are two adjustments possible on the air/gas ratio valve,
the throttle setting at Maximum rate and the offset setting at
Minimum rate. If either setting is adjusted the combustion values
must be rechecked at both rates.
At Maximum Rate:
1. Adjust the boiler to Maximum rate in Figure 104, page 79,
Test Mode.
2. Wait 10 minutes to allow the boiler to stabilize.
3. Now adjust the Throttle setting (Figure 106 - screw A) until
the CO
2
is at the correct SETTING LEVEL (see Figure 107),
below confirm that the CO/CO
2
ratio is within limits (clock-
wise to increase gas).
Figure 108
A
CO
2
Max. Regulating screw
Test at Max Power 100%
Turn clockwise (open gas)
for “MA gas ow”
Turn counter-clockwise
(close gas)
for “MIN gas ow”
Rough start point
For LP Start up ONLY
Adjust gas valve
HIGH FIRE
screw on right with
Allen wrench turn
Counter-Clock wise
1-1/8 turns.
Final Combustion values
MUST BE checked with
Combustion Analyzer.
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
At Minimum Rate:
1. Remove T-40 cap, see Figure 108, page 82, for Offset screw
adjustment. Adjust the boiler to minimum output and allow
the boiler to stabilize.
2. Now adjust the offset pressure setting (Figure 109 - screw B)
Torx (T-40 male driver) until the CO
2
is at the correct SET-
TING LEVEL (see Figure 110), confirm that the CO/CO
2
ratio is within limits (clockwise to increase gas).
33 Startup — nal checks
(continued)
Re-check the Maximum and Minimum
Rate
3. After the gas valve is adjusted, please check one more
time that the Maximum and Minimum rate CO/CO
2
to ensure that the values have not changed.
4. In the event that the CO
2
setting level with an acceptable
CO/CO
2
ratio cannot be obtained please contact your
Weil-McLain Technical Support.
❏
1. Operate the boiler on HIGH fire.
2. A leak would appear as vapor on the surface of the
mirror.
3. If there is any indication of a leak at any joint, immedi-
ately shut down the boiler.
a. If possible, tighten the retaining screws or nuts
(without over-tightening).
b. If this does not correct the problem, disassemble
the components where the leak appeared. Use the
procedures given in the Maintenance section of
this manual.
c. When disassembling components, inspect gaskets to
see if there is damage. Replace any damaged gasket.
d. Contact your Weil-McLain Technical Support if the
problem cannot be addressed with the information
provided in this manual.
❏
1. After the boiler has been installed, turn off the boiler.
2. Shut off the manual gas valve located on the gas line to
cut flow of fuel to the boiler.
3. Turn on the boiler. It will start to ignite and a “d3” code
will flash. After the “d3” code flash for some time the
boiler will go into a Lockout condition and a “A01” code
will show in the display. It means that the boiler tried to
ignite without success (code “d3”) for three (3) times
and when into Lockout mode(code “A01”). This means
that the ignition system safety device worked properly.
4. Open the manual gas valve located on the gas line to
resume fuel supply to the boiler.
5. Hit the “” button once to Clear the Lockout code
“A01”.
Figure 110Minimum rate combustion values –
measured values must be within the ranges
given below
Adjust in steps of no more than 1/8 of a turn and
wait 1 minute after each adjustment to allow the
setting to stabilize. Turning the screw too far will
cause the adjustment to reverse behavior.
Combustion Range
Boiler Model
CO/(PPM) CO
2
NG % CO
2
LP %
AB-80
20
AB-120
20
AB-155
7
Figure 109Offset
Offset Regulating screw
Test at MIN. Power 00%
Turn clockwise (open gas)
for “MA gas ow”
Turn counter-clockwise
(close gas)
for “MIN gas ow”
Rough start point
For LP Start up ONLY
Adjust gas valve
LOW FIRE
screw on left with
Allen wrench
turn
Counter-Clock wise
- turn.
Final Combustion values
MUST BE checked with
Combustion Analyzer.
B
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34 Startup verication
Adjust and test boiler controls
1. Follow instructions in this manual to set and verify operation
of the boiler controls.
2. Follow low water cutoff manufacturers instructions
(if used).
Check-out procedure
Have the following been done?
❏
Boiler and heat distribution units filled with water?
❏
Water chemistry verified per page 75?
❏
Sentinel X100 corrosion inhibitor added and water tested
to be within range?
❏
Air purged from system?
❏
Air purged from gas piping? Piping checked for leaks?
❏
Condensate trap primed?
❏
If boiler has been converted to Liquefied Petroleum (LP) Gas
is propane conversion label affixed to jacket?
Boilers are shipped ready to fire natural gas ONLY.
To fire on propane, you must follow the instruc-
tions in this manual to install the propane venturi,
see page 10. Failure to comply could result in severe
personal injury, death or substantial property dam-
age.
❏
Thermostat circuit wiring checked to ensure there are no
stray voltages?
❏
Followed Operating Instructions, Figure 105, page 80?
❏
Burner flame and combustion verified per page 81?
❏
Control operation for space heating and DHW (if used)
verified per this manual?
❏
Additional field-installed controls tested as outlined by
control manufacturers? (Boiler should be operating and
should go off when controls are tested. Verify controls cause
automatic reset lockout or manual reset lockout as desired.)
❏
Additional field-installed limit control(s) set to system
temperature requirements? Balancing valves and controls
adjusted to provide design temperature to system?
❏
Flow adjusted/balanced for each zone of multiple zones
systems?
❏
Thermostat heat anticipator (if available) set properly?
❏
Boiler cycled with thermostats — Raised to highest setting
and verified boiler goes through normal startup cycle? Low-
ered to lowest setting and verified boiler goes off?
❏
Natural gas input measured? (page 81)
❏
Incoming gas pressure checked by connecting manometer to
gas valve ahead of boiler? (Gas pressure must be at least the
minimum values given on page 14, with boiler operating at
high fire, and no more than 13 inches (330 mm) w.c. with
boiler operating or boiler off.)
❏
Observed several operating cycles for proper operation?
❏
Room thermostats set to desired room temperature?
❏
All instructions shipped with this boiler reviewed with owner
or maintenance person?
❏
Ignition system safety shutoff device tested?
Before leaving:
❏
Fill in , page 136.
❏
Return instructions to envelope and give to owner.
Fill out start-up data on the In-
stallation and Service Certificate,
page 136.
Figure 111
Daily
Monthly
Every
6 months
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
35 Annual startup and general maintenance
Follow the service and maintenance procedures given throughout this manual and in component literature shipped
with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to
follow the directions in this manual and component literature could result in severe personal injury, death or substantial
property damage.
86
86
87
87
87
87
87
87
87
87
87
87
88
88
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36 Annual startup
HANDLING CERAMIC FIBER
MATERIALS
The heat exchanger refractory contain
ceramic fiber
materials that have been
identified as carcinogenic, or possibly
carcinogenic, to humans).
Ceramic fibers
can be converted to cristobalite in very
high temperature applications.
The International Agency for Research on
Cancer (IARC) has concluded, “Crystal-
line silica inhaled in the form of quartz or
cristobalite from occupational sources is
carcinogenic to humans (Group 1).”:
■ Avoid breathing dust and contact with skin and eyes.
Use NIOSH certified dust respirator (N95).
This type of respirator is based on the OSHA
requirements for cristobalite at the time this
document was written. Other types of respira-
tors may be needed depending on the job site
conditions. Current NIOSH recommendations
can be found on the NIOSH web site at http://
www.cdc.gov/niosh/homepage.html. NIOSH
approved respirators, manufacturers, and phone
numbers are also listed on this web site.
Wear long-sleeved, loose fitting clothing,
gloves, and eye protection.
■ Handle carefully to minimize dust that could be
caused by abrasion.
■ If replacement is necessary, remove the refractory
from the boiler and place it in a plastic bag for
disposal.
■ Wash potentially contaminated clothes separately
from other clothing. Rinse clothes washer thor-
oughly.
■ Eye: Irrigate immediately.
■ Breathing: Fresh air.
FIRST-YEAR SPECIAL INSPECTION
1. after the boiler is installed, per-
form a first-year inspection of the boiler. This should include
the following
.
a. The integrity of the flue system and the flue seals;
b. The integrity of the boiler combustion circuit and the
relevant seals;
c. The operational (working) gas inlet pressure at
maximum rate, as described on pages 51 and 82;
d. The gas rate, as described on page 51;
e. The combustion performance, as described on pages 81,
82 and 83 for combustion check.
f. Competence to carry out the check of combustion per-
formance.
g. The person carrying out a combustion measurement
should have been assessed as competent in the use of a
flue gas analyzer and the interpretation of the results;
Periodical check
h. To keep the unit working properly over time, it is necessary to
have qualified personnel make an annual check that includes
the following tests:
i. The control and safety devices (gas valve, flow meter,
thermostats, etc.) must function correctly.
j. The flue pipes must be fully intact, secure and clear.
k. The airtight chamber must be sealed.
l. The air-flue terminal and ducts must be free of obstructions
and leaks.
m. The condensate evacuation system must be efficient with no
leakage or obstructions and drain condensate without back-
ing up.
n. The burner and heat exchanger must be clean and free of scale.
When cleaning, do not use chemical products or wire brushes.
o. The electrode must be free of scale and properly positioned.
p. The gas and water systems must be leak free.
q. The water pressure in the heating system must be minimum of
12 PSI, do not exceed 25 PSI. Fill the boiler to that pressure or
the system design pressure.
r. The circulation pump must not be blocked.
s. The expansion tank must be filled.
t. The gas flow and pressure must correspond to that given in the
respective tables.
2. Determine any follow-up maintenance and service needs based on
the condition of the heat exchanger and condensate lines.
a. If the heat exchanger shows substantial fouling, or if condensate
lines show accumulation of sediment, schedule a follow-up
service call to perform the first-year inspection again, sooner
than the normal twelve months between.
b. Heavy fouling of the heat exchanger or condensate lines indi-
cates possible combustion air contamination. Inspect the air
intake area carefully, and remove possible contaminants. See
page 6, for products to avoid.
You must eliminate causes of corrosion and con-
tamination to ensure reliable operation of the boiler
and system.
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
36 Annual startup(continued)
The boiler should be inspected and started
annually, at the beginning of the heating
season, only by a qualified service technician.
In addition, the maintenance and care of the
boiler designated in Figure 111, page 85 and
explained on the following pages must be per-
formed to assure maximum boiler efficiency
and reliability. Failure to service and maintain
the boiler and system could result in equip-
ment failure.
Electrical shock hazard — Turn off power to
the boiler before any service operation on the
boiler except as noted otherwise in this in-
struction manual. Failure to turn off electrical
power could result in electrical shock, causing
severe personal injury or death.
Address reported problems
Inspect any problems reported by owner and correct before
proceeding.
Inspect boiler area
1. Verify that boiler area is free of any combustible materials,
gasoline and other flammable vapors and liquids.
2. Verify that air intake area is free of any of the contaminants
listed on page 6 of this manual. If any of these are present in the
boiler intake air vicinity, they must be removed. If they cannot
be removed, reinstall the air and vent lines per this manual.
Inspect boiler exterior
1. The boiler door, panels and aesthetic parts can be cleaned
with a soft damp cloth, possibly soaked in soapy water. Do
not use any abrasive detergents and solvents.
Inspect boiler interior
1. Remove jacket door and inspect interior of boiler.
2. Vacuum any sediment from the inside of the boiler and
components. Remove any obstructions.
Do not use solvents to clean any of the boiler
components. The components could be damaged,
resulting in unreliable or unsafe operation.
Check all piping for leaks
Eliminate all system or boiler leaks. Continual fresh
make-up water will reduce boiler life. Minerals
can build up in the heat exchanger, reducing heat
transfer, overheating heat exchanger, and causing
heat exchanger failure. Leaking water may also
cause severe property damage.
1. Inspect all water and gas piping and verify to be leak free.
2. Look for signs of leaking lines in the system and in the boiler
and correct any problems found.
3. Check gas line for leaks, see page 80 for gas safety information.
Check ignition wiring
1. Check ignition cable electrical resistance. A good cable will
have resistance between 950 and 1050 ohms. Replace if not
acceptable.
2. Inspect boiler ground wire from heat exchanger access cover
to ground terminal screw.
3. Verify all wiring is in good condition and securely attached.
4. Check ground continuity of wiring using continuity meter.
5. Replace ground wires if results are not satisfactory.
Check all boiler wiring
1. Inspect all boiler wiring, making sure wires are in good condi-
tion and securely attached.
2. Verify that all connectors are securely inserted.
Check control settings
1. Use the control display to navigate through all settings. Adjust
settings if necessary.
2. Check settings of external limit controls (if any) and adjust
if necessary. Adjust as needed to accommodate the system
design.
Perform startup and checks
1. Start boiler and perform checks and tests specified in this
manual.
2. Verify cold fill pressure is correct and that operating pressure
does not go too high. Adjust water pressure and expansion
tank charge pressure as necessary.
3. Complete the check-out procedure on page 84.
Figure 112
Check burner flame
The boiler contains ceramic fiber materials. Use
care when handling these materials per instructions
on page 86 of this manual. Failure to comply could
result in severe personal injury.
1. Inspect flame through observation window.
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36 Annual startup(continued)
2. If flame is unsatisfactory at either high fire or low fire,
check combustion values. If combustion is properly
adjusted, turn off boiler and allow boiler to cool down.
Then remove burner and clean it thoroughly using a vac-
uum cleaner or compressed air. Do not use compressed
air to clean burner if performed inside a building.
3. To access the burner, remove the heat exchanger cover
plate following the procedure beginning on page 112.
4. If replacing the burner, ensure the burner gasket is in
good condition and correctly positioned. Follow all
instructions on page 113 to reinstall all components.
5. Restart the boiler.
6. Inspect the flame at high and low fire. If flame is still
not acceptable, check combustion values. If combustion
is properly adjusted, obtain a replacement burner from
Weil-McLain.
Check boiler relief valve
1. Inspect the relief valve and lift the lever to verify flow as in the
following warnings, excerpted from a relief valve manufac-
turer’s warning label. Before operating any relief valve, ensure
that it is piped with its discharge in a safe area to avoid severe
scald potential.
2. Read page 42 before proceeding further.
3. Follow instructions below or perform procedures per relief
valve manufacturer’s printed instructions.
Safety relief valves should be reinspected AT LEAST
ONCE EVERY THREE YEARS, by a licensed plumb-
ing contractor or authorized inspection agency, to
ensure that the product has not been affected by cor-
rosive water conditions and to ensure that the valve
and discharge line have not been altered or tampered
with illegally. Certain naturally occurring conditions
may corrode the valve or its components over time,
rendering the valve inoperative. Such conditions are
not detectable unless the valve and its components
are physically removed and inspected. This inspec-
tion must only be conducted by a plumbing con-
tractor or authorized inspection agency — not by
the owner. Failure to reinspect the boiler relief valve
as directed could result in unsafe pressure buildup,
which can result in severe personal injury, death or
substantial property damage.
Following installation, the valve lever must be
operated AT LEAST ONCE A YEAR to ensure that
waterways are clear. Certain naturally occurring
mineral deposits may adhere to the valve, rendering
it inoperative. When manually operating the lever,
water will discharge and precautions must be taken
to avoid contact with hot water and to avoid water
damage. Before operating lever, check to see that a
discharge line is connected to this valve directing
the flow of hot water from the valve to a proper
place of disposal. Otherwise severe personal injury
or property damage may result. If no water flows,
valve is inoperative. Shut down boiler until a new
relief valve has been installed.
4. After following the above warning directions, if the relief
valve weeps or will not seat properly, replace the relief valve.
Ensure that the reason for relief valve weeping is the valve and
not over-pressurization of the system due to expansion tank
waterlogging or under-sizing.
Check automatic air vents (if used
see
Review with owner
1. Review the User’s Information Manual with the
owner.
2. Emphasize the need to perform the maintenance
schedule specified in the User’s Information Manual
(and in this manual as well).
3. Remind the owner of the need to call a licensed
contractor should the boiler or system exhibit any
unusual behavior.
4. Remind the owner to follow the proper shutdown
procedure and to schedule an annual startup at the
beginning of the next heating season.
Reinstall jacket door after
servicing
Reinstall boiler jacket door after start-up or servicing.
The boiler jacket 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 jacket door securely sealed and
fastened could result in severe personal injury or death.
V
ERIFY PROPER OPERATION AFTER SERVICIN
G
VERIFY PROPER OPERATION AFTER SERVICING
Failure to adhere to these guide-
-
ELECTRICAL SHOCK HAZARD
. Internal wiring is still powered when
the switch is off.
DO NOT JUMPER DEVICES
Never jumper (bypass) any device except for mo-
mentary testing.
REINSTALL Jacket door
The boiler jacket 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 ap-
pliances. Failure to keep the jacket door securely fas-
tened could result in severe personal injury or death.
BEFORE SERVICING or
MAKING CONNECTIONS —
LABEL WIRES BEFORE
REMOVING
Label all wires prior to disconnection
when servicing controls. Wiring errors
can cause improper and dangerous
operation.
Before calling for troubleshooting assistance, fill in the
“
” (page 136).
Record the boiler size and CP number (located on the
left side exterior of the boiler jacket).
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37 Troubleshooting
Tool
Multiple uses
Remove heat exchanger cover plate
Remove burner screws
For gas valve Offset Lowfire adjustment
For gas valve Highfire adjustment
Measurements on sensors and electrical components
Measures the INLET gas pressure to the boiler
Combustion testing and boiler adjustments
Checking surface temperatures of heat exchanger and
pipes
Check the following:
1. Make sure thermostat is calling for heat and contacts (including
appropriate zone controls) are closed. Make sure all external limit
controls are either installed (and closed) or temporarily jumpered
for testing.
2. Make sure that connectors to control are securely plugged in at
module and originating control.
3. Gas pressures:
Maximum: 13” w.c. with no flow (gas valve lockup pressure).
Minimum: 3.5” w.c. minimum values given on page 14 while
operating on high fire.
BEF
O
RE TR
OU
BLE
S
H
OO
TIN
G
—
BEFORE TROUBLESHOOTING —
1. Check for 120VAC (minimum 102 VAC to maximum 132 VAC)
to boiler.
2. Check the control for error codes.
3. See Figure 80, page 62 for navigation instructions and the pages
following for the display key identification.
Hold reset button for 20 seconds:
TS Flashing (parameter)
Push heating – button
IN flashing (information)
Push heating – button
HI flashing (history/fault)
Push “Reset” once
Push + to scroll error codes, refer to error code list Table 3,
page 92.
To exit out, hold reset button for 20 seconds.
Figure 113
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Check ignition sequence
The ignition sequence time line and operational description for the Combi and Heating Only boilers below help to understand the
timing of the cycles. In your troubleshooting, refer to the numbers 1 through 7 as they describe each step of the ignition cycle.
37 Troubleshooting
(continued)
Figure 114
1. Heat demand detection time
CH mode: there is a confirming time of 3 seconds during
which the demand has to be always on.
The request switch is sampled every 0.2 seconds, so the
maximum delay is 3.2 seconds.
DHW instant mode: Combi boiler the maximum delay
is 0.2 seconds which is the sample time of the flow sensor.
DHW storage mode: Heating Only boiler with Indirect
tank the maximum delay is 0.2 seconds which is the
sample time of the tank thermostat.
2. Pre-pump time
CH instant mode: CH - Pump time 30 seconds.
DHW instant mode: there is no pre-pump.
DHW storage mode: DHW Pre-pump time 30 seconds.
3. Pre-purge time
It is the time that the fan takes to reach the ignition level
to effectively purge boiler venting.
4. Ignition
There are 0.2 seconds of preignition where the control
checks the status of the gas valve. And then there is the
spark, for a time depends on the gas type:
Natural Gas, 1.6 seconds.
LP Gas, 4.6 seconds.
5. Gas valve safety time
With no flame the gas valve can be kept open for certain time:
Natural Gas, 3 seconds.
LP Gas, 4.8 seconds.
If at the end of this time the flame is not ionized, the gas
valve has to be closed and the inter-purge time for 6 at-
tempts is ran.
6. Inter-purge time for A01 attempts
There is 10 seconds of purge time before a new attempt
after a faulty ignition. After 5 attempts the boiler goes into
Lockout (code “A01”). This error condition is stopping
the boiler and to get to normal operation again, manual
reset is required.
7. Inter-purge time for A06 attempts
There is 1 second of purge time before a new attempt after
a lost flame. If the flame disappeared 3 consecutive times
within 10 minutes, the boiler goes into Lockout (code
“A06”) to get to normal operation again, manual reset is
required.
HEAT DEMAND
DETECTION TIME
PRE-PUMP TIME PRE-PURGE TIME
IGNITION
GAS VALVE SAFETY TIME
IGNITION
INTER-PURGE FOR
A01 ATTEMPTS
IGNITION
INTER-PURGE FOR
A06 ATTEMPTS
FLAME LOSS
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37 Troubleshooting(continued)
Temp
(°F)
Sensor ohms
Temp
(°F)
Sensor ohms
Temp
(°F)
Sensor ohms
Min Max Min Max Min Max
32
31530 33480
100
5608 5954
170
1344 1428
40
25792 27388
110
4590 4874
180
1143 1213
50
19258 20450
120
3636 3860
190
945 1003
60
15218 16160
130
3011 3197
200
810 860
70
11577 12293
140
2417 2567
212
657 697
80
8891 9441
150
1954 2074
-
--
90
7185 7629
160
1644 1746
-
--
Check flame signal
1. Navigate to Diagnostics/Inputs on the control display (see
pages 60 to 66 for navigation instructions.
2. The flame signal value must be at least 25 on low fire. The
flame signal value must be at least 255 on high fire, reading
at times 10 equals microamps of flame signal. If the flame
signal drops below this level, the control will attempt to cor-
rect by increasing the blower speed to increase flame signal.
3. A low flame signal may indicate a fouled ignitor or damaged
ignitor cable insulation.
a. See “Inspect ignition electrode,” page 111 to remove
and inspect the ignitor.
b. If required, clean the ignitor and flame rod as instructed,
see page 111.
c. If cleaning the ignitor does not improve, ground wiring
is in good condition, and ground continuity is satisfac-
tory, replace the ignitor.
4. If flame signal still remains low:
a. Inspect the vent and air piping.
b. Check combustion values.
c. Then inspect the heat exchanger, following the proce-
dures given in this manual for inspecting and cleaning
of the heat exchanger cover plate and other boiler com-
ponents (starting on page 111).
d. Clean the heat exchanger as described in this manual if
necessary, see page 114.
Check control fuse
See Replacement parts for fuses, page 123.
ALWAYS check circuit fuses before replacing
control or any major components (blower, etc.).
If a fuse is blown, it can prevent the control or
other components from operating.
1. Turn OFF power to boiler at external line switch. Then
remove the jacket door.
2. Locate fuses using Figure 115 and Figure 116.
3. Remove and inspect the fuses (Item a, Figure 115 or Item
b, Figure 116).
4. If necessary, replace the fuses:
a. Control circuit fuse is a 250 VAC 3.15-amp rated fuse.
(Weil-McLain part number 640-000-122)
b. Thermostat-relay circuit fuse is a 250 Volt 630mA rated
fuse. (Weil-McLain part number 640-000-123)
Do not jumper fuses or replace with any fuse
except as specified. Failure to comply could result
in severe personal injury, death or substantial
property damage.
Checking temperature sensors
1. The boiler temperature sensors (flue, outdoor, return water
and supply water) are all resistance-type devices. Figure 117
shows the correct value for the sensor at various tempera-
tures. For dual sensors, the temperature difference between
the sensors must be no more than 10 °F. (Supply outlet 200
sensor).
2. Use the resistance values at 32°F, 60°F, 70°F and 212°F to
measure the sensor resistance at known temperatures (ice
point, room temperature and sea level boiling point). For
ice point and boiling point, insert the sensor in water at that
temperature. Use an ohmmeter to read resistance value.
3. To check whether the control is correctly sensing temperature,
you can use a resistance decade box. Connect the decade box
temporarily in place of a sensor and read the corresponding
temperature on the control display. The temperature should
be close to the value corresponding to the input resistance.
Figure 115
Figure 116
Figure 117
Installer/homeowner note,
in case of an “open circuit”
of the Thermostat-relay
fuse the boiler can run in
DHW mode but NOT in
Central Heating mode.
Fuse located on rear of circuit board
a
b
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37 Troubleshooting(continued)
Control diagnosis
1. The boiler control is equipped with an advanced self-diagnosis system. In case of a boiler fault, the display will flash together with
the fault symbol (see Table 3 or Table 4) indicating the fault code.
2. Certain faults cause permanent boiler shutdowns (marked with the letter “A” see Table 3): to restore operation, press the RESET
button (Item 6 - Figure 80, page 62) for 1 second or RESET on the optional remote timer control if installed; if the boiler fails
to start, it is necessary to firstly eliminate the fault.
3. Other faults (indicated with the letter “F”, see Table 4, page 95) cause temporary shutdowns that are automatically reset as soon
as the value returns within the boiler’s normal operating range.
Protection and error conditions
1. Several checks are included to protect the boiler and its environment. Severe error will cause a lockout condition which can only
be cleared by the reset key at the boiler front panel.
2. Non severe errors faults will reset as soon as the cause of the problem disappears/corrects themselves.
3. Number of reset action is limited to 5 in 24 hours. By powering off/on, it is possible to reset this limitation: in this way, another
5 reset per 24 hour can be done.
4. Error codes can be divided in 2 groups:
a. Manual Reset type lock-out codes – “A” codes: (which blocks the heat demand - Press reset button for 1 second to reset).
b. Automatic Reset type lock-out codes – “F” codes: (cause temporary shutdowns that are automatically reset as soon as the
value returns within the boilers normal working range).
Hard Lock-out condition codes
Lock out condition is given with the capital “A” (alarm) on the status display and error code on the
temperature display. The meaning of the error numbers are as follow:
-
Table 3 A
A01 No burner ignition after ve attempts
A02 False ame indication
A03
High limit protection: pump does not run or no
water circulation
A04 F07 repeated 3 times in the last 24 hours
A05 No frequency feedback from fan after 1 hour
A06 6 times ame loss in 4 minutes time frame
A16 Outside sensor is not connected
A23
Nominal water pressure not reached within
maximum allowed time
A26 F40 repeated 3 times in the last hour
A41
Temperature sensor not or bad connected to
the pipe (CH mode)
A42
Too high difference between two CH supply water
temperature sensors
A44
Temperature sensor not or bad connected to
the pipe (DHW mode)
A61 Flame circuit error
A62 Gas valve circuit
A63 E2 prom error
A65 ADC circuit error
Abbreviation
ADC Analog Digital Converter
CH Central Heating
DHW Domestic Hot Water
LP Liqueed Petroleum (Propane) Gas
LWCO Low Water Cut Off
MMI Machine Interface- Control Interface
OTC Outdoor Temperature Sensor
PCB Printed Circuit Board - Control board
PWM
Pulse width modulation - Used for
modulating pumps and motors
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37 Troubleshooting(continued)
Figure 118(continued)
Fault
Code
Fault Condition Correction
A01
No burner ignition
No gas
Check the regular gas ow to the boiler and that
the air has been eliminated from the pipes.
Ignition/detection electrode fault
Check the wiring of the electrode and that it is
correctly positioned and free of any deposits
Electrode fault
Check the ignitor electrode wiring
Electrode deformed/misaligned and/or improper
gap (5/32”)
Combustion incorrect
Natural gas & LP fuel
Perform combustion test for Natural gas & LP
fuel per chart section Figure 107, page 82 and
Figure 110, page 83.
Faulty gas valve Check the gas valve and replace it if necessary
Insufcient gas supply pressure Check the gas supply pressure
Condensate trap blocked and or con-
densate drain hose looped making a
second trap
Check the trap and clean it if necessary
Also inspect gas valve, blower, venturi, igniter,
and heat exchanger, and replace those with
signs of damage.
A02
Flame present signal
with burner off
Electrode fault
Check the ignitor electrode wiring
Electrode deformed/misaligned and/or improper
gap (5/32”)
Ignition cable fault Check the ignition cable
A03
Over temperature pro-
tection activation
Heating sensor damaged
Check the correct positioning and operation of
the heating sensor
No water circulation in the system Check the circulating pump
Air in the system/heat exchanger Vent the system/purge heat exchanger
A04
Exhaust duct safety
device activation
Fault F07 generated 3 times in the last
24 hours
See fault F07
A05
Fan protection activated
Fault F15 generated for 1 hour (con-
secutive)
See fault F15
A06
No ame after igni-
tion stage (6 times in 4
minutes)
Ignitor electrode fault
Check the position of the ignitor electrode and
replace it if necessary
Flame unstable Check the burner
Gas valve Offset fault Check the Offset adjustment at minimum power
Air/fume ducts obstructed
Remove the obstruction from the ue, exhaust
ducts and air inlet and terminals
Condensate trap blocked
Check the trap and clean it if necessary
Also inspect gas valve, blower, venturi, igniter,
and heat exchanger, and replace those with
signs of damage.
F07
High exhaust tempera-
ture
Air trapped in boiler heat
exchanger
Combustion not correct
for Natural gas and LP
fuel
Boiler water piping and
circulator not providing
correct water ow
The exhaust probe detects an excessive
temperature
Check the exchanger
Purge out air in heat exchanger
Check combustion per specication charts
Figure 107, page 82 and Figure 110, page 83.
Check piping sizes and required pump models
F10
Supply sensor 1 fault
Sensor damaged
Check the wiring or replace the sensorWiring shorted
Wiring disconnected
F11
Return sensor fault
Sensor damaged
Check the wiring or replace the sensorWiring shorted
Wiring disconnected
F12
DHW sensor fault
Sensor damaged
Check the wiring or replace the sensorWiring shorted
Wiring disconnected
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37 Troubleshooting(continued)
Figure 119(continued)
*
Boiler water pressure switch is set for 9 psi (±2) minimum pressure.
Fault
Code
Fault Condition Correction
F13
Exhaust probe fault
Probe damaged
Check the wiring or replace the exhaust
probe
Wiring shorted
Wiring disconnected
F14
Delivery sensor 2 fault
Sensor damaged Check the wiring or replace the sensor
Wiring shorted
Wiring disconnected
F15
Fan fault
No 120V power supply Check the 8-pin connector wiring
Tachometric signal interrupted Check the 8-pin connector wiring
Fan damaged Check the fan
Condensate trap blocked and or con-
densate drain hose looped making a
second trap.
Check the trap and clean it if necessary
Also inspect gas valve, blower, venturi, igniter,
and heat exchanger, and replace those with
signs of damage.
F27
Flue temp
Exhaust gas temp too high
Make sure correct vent material was
selected (Parameter List 165)
F34
Supply voltage under 100V
Electric voltage trouble
Check the electrical system (Can’t have
more than 1 pump wired to boiler
F35
Faulty voltage frequency
Electric voltage trouble Check the electrical system
F37
Incorrect system water
pressure
*
Pressure too low < 8 psi
Fill the system
Water pressure switch damaged or not
connected
Check the sensor
Check Heating Only boiler primary loop
pump, must pump towards return side
of boiler.
Check pump location and pump water direc-
tion
F39
Outdoor sensor fault
Sensor damaged or wiring shorted Check the wiring or replace the sensor
Sensor disconnected after activating the
sliding temperature
Reconnect the outdoor sensor or disable the
sliding temperature
A16
Outdoor sensor fault
Outdoor sensor is not connected Check the sensor
A26
System installation
F40 Error repeated 3 times in 1 hour Check the water pressure in the system
A41
Sensor positioning
Supply sensor disconnected from pipe
Check the correct positioning and operation
of the heating sensor
A42
Heating sensor fault
Sensor damaged Replace the sensor
A44
Temp sensor
Temp sensor not connected or
badly connected to pipe (DHW mode)
Check the sensor
F43
Exchanger protection acti-
vation.
No system H2O circulation Check the circulating pump
Air in the system Vent the system
F51
Low water
Low water fault Check boiler installation and water level
F52
Heating sensor fault
Sensor damaged Replace the sensor
F53
Temp sensor
High limit thermostat error Check the sensor. Check boiler installation
A61
Controller ABM08A fault
Controller ABM08 internal error
Check the ground connection and replace the
controller if necessary.
A62
No communication between
controller and gas valve
Controller not connected Connect the controller to the gas valve
Valve damaged Replace the valve
A63
Controller ABM08A fault Controller ABM08A internal error
Check the ground connection and replace
the controller if necessary.
F64
A65
F66
A23
Card parameter fault Wrong card parameter setting
Check the card parameter and modify it if
necessary.
A24
F20
F21
F40
F47
37 Troubleshooting(continued)
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Table 4
F
Blocking codes
The boiler controller recognizes also the fault situations that can block the heat demands but do not lead to lockout condition.
When the error condition becomes resolved, error will disappear but will be also written into the history data. If this is the case,
there is also an “F” on the status display. Temperature display gives an error code. The meaning of the code is as follow:
F07
The Exhaust gases temperature is too high.
F10
The CH supply water temperature sensor 1 error.
F11
The CH return water temperature sensor error.
F12
The DHW water temperature sensor error.
F13
The Exhaust gases temperature sensor error.
F14
The CH supply water temperature sensor 2 error.
F15
Minimum and maximum frequency feedback from fan error.
F20
The water pressure in the CH installation is near the low level.
F21
The water pressure in the CH installation is near the high level.
F27
The exhaust gas temperature is too high (PVC/CPVC/Polypro/AL29-4C - selection).
F34
Low mains voltage.
F35
Frequency error.
F37
The water pressure in the CH installation is too low.
F39
Outside sensor error.
F40
The water pressure in the CH installation is too high or there’s a Control fault.
F43
Heat exchanger protection.
F47
Water pressure sensor not connected.
F50
Variable input switch contact opened.
F51
Low water error.
F52
Too high difference between two CH supply water temperature sensors.
F53
High limit thermostat input error.
F64
5 MicroCom reset in 15 minutes time frame.
F66
Software doesn’t match.
Figure 120(continued)
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Display Condition
FAULT 07 =
If the exhaust gases temperature becomes higher than Maximum exhaust gases temperature and the high tem-
perature is present longer than 5 seconds, controller will stop indicating fault 7, where he will stay for 15 minute.
If the exhaust temperature is within normal levels after this time expired, error 7 will be resolved by itself.
FAULT 10 =
CH supply sensor 1 (Supply Temp sensor) out of normal operating range (short circuit or open circuit). If sensor
goes outside the range, error will be generated. In case sensor is back to the normal operating range, error is
gone. In error mode, heat demands will be disabled. In case 2 or more sensors are broken, controller will pick
up the rst that was outside the operating range. Resolving situation can be achieved only if the sensor is within
operating range again.
FAULT 11 =
CH return sensor out of normal operating range (short circuit or open circuit). If sensor goes outside the range,
error will be generated. In case sensor is back to the normal operating range, error is gone. In error mode, heat
demands will be disabled. In case 2 or more sensors are broken, controller will pick up the rst that was outside
the operating range. Resolving situation can be achieved only if the sensor is within operating range again.
FAULT 12 =
DHW sensor out of normal operating range (short circuit or open circuit). If sensor goes outside the range, error
will be generated. In case sensor is back to the normal operating range, error is gone. In error mode, only DHW
heat demands will be disabled. In case 2 or more sensors are broken, controller will pick up the rst that was
outside the operating range. Resolving situation can be achieved only if the sensor is within operating range again.
FAULT 13 =
Exhaust sensor out of normal operating range (short circuit or open circuit). If sensor goes outside the range,
error will be generated. In case sensor is back to the normal operating range, error is gone. In error mode, heat
demands will be disabled. In case 2 or more sensors are broken, controller will pick up the rst that was outside
the operating range. Resolving situation can be achieved only if the sensor is within operating range again.
FAULT 14 =
CH supply sensor 2 (High Limit sensor) out of normal operating range (short circuit or open circuit). If sensor
goes outside the range , error will be generated. In case sensor is back to the normal operating range, error is
gone. In error mode, heat demands will be disabled. In case 2 or more sensors are broken, controller will pick
up the rst that was outside the operating range. Resolving situation can be achieved only if the sensor is within
operating range again.
FAULT 15 =
Blower driving problem – in case of new burner request the fan is switched on: if the controller measured a
frequency lower than 20Hz or higher than 295Hz, error will be set (with a conrming time of 15 seconds). In
case speed is back to the normal operating range, error is gone. In error mode, heat demands will be disabled.
Resolving situation can be achieved only if the speed is within operating range again.
FAULT 20 =
Warning – The water pressure, measured by the water pressure sensor, is higher than the low level and lower
than the nominal level. This is only an indication, the heat request is not switched off.
FAULT 21 =
Warning – The water pressure, measured by the water pressure sensor, is higher than the high level –4.3 psi
and lower than the high level. This is only an indication, the heat request is not switched off but there is a linear
output reduction in this way: if Water pressure Water pressure high limit-4.3 psi there is no limitation, if Water
pressure Water pressure high limit-2.9 psi then the maximum output is equal to (Blower absolute DHW maxi-
mum speed - Blower absolute minimum speed), if Water pressure Water pressure high limit-1.5 psi then the
maximum output is equal to Blower absolute minimum speed + 20Hz.
FAULT 27 =
With the PVC/CPVC selection parameter equal to:
1. If, during the ue gas protection mode, the power reduction reaches the 0% value and the ue gas tem-
perature is still upper than the PVC maximum temperature, the controller stops indicating fault 27, where it
will stay for 5 minutes. The error solves itself after 5 minutes.
2. If, during the ue gas protection mode, the power reduction reaches the 0% value and the ue gas tem-
perature is still upper than the CPVC maximum temperature, the controller stops indicating fault 27, where
it will stay for 5 minutes. The error solves itself after 5 minutes.
Figure 121(continued)
37 Troubleshooting(continued)
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Display Condition
FAULT 34 =
Low voltage (less than 100VAC) will trigger this error. This is only an indication, the heat request is not switched off.
When voltage brought is back (over 100VAC), error is resolved. (more than 1 pump wired to pump connection point).
FAULT 35 =
The controller measures a voltage supply frequency different from the voltage supply frequency pa-
rameter. This is only an indication, the heat request is not switched off. When the controller will mea-
sure a voltage supply frequency equal to the Voltage supply frequency parameter, error will be resolved.
(Example 60 Hz).
FAULT 37 =
Low water pressure error can be caused by the low water pressure in the central heating system. This can be
detected in 2 ways: via low water pressure switch and via water pressure sensor (with a conrming time of 10
seconds). In error mode, the heat demand and the pumps are switched off. See Pressure supervision of the
central heating installation paragraph.
FAULT 39 =
Outside sensor out of normal operating range (short circuit or open circuit). If sensor goes in short circuit and this
condition lasts for more than 10 seconds, error is generated. In case sensor is back to the normal operating range,
error is gone. Normal operating range for the outside sensor is from -22°F till +158°F. With sensor broken in a way
that he makes an open circuit, error will be generated only if a curve is selected: OTC will be disabled but heating
mode will be possible. In case 2 or more sensors are broken, controller will pick up the rst that was outside the
operating range. Resolving error situation can be achieved only if the sensors is within operating range again.
FAULT 40 =
High water pressure error, caused by the water pressure sensor. Water pressure is higher than high level (with
a conrming time of 2 seconds). In error mode, the heat demand and the pumps are switched off. See Pressure
supervision of the central heating installation paragraph.
FAULT 43 =
If the slope temperature felt by the CH supply sensor is greater of Heat exchanger protection parameter, a fault
is generated due to the lack of water of the system. When the temperature felt by the CH supply sensor goes
down under the 113°F, the boiler comes back into the normal operation. Each CH or Installer Test mode demand
the function is disabled for the rst 12 seconds starting from Gas valve opening moment. Each DHW demand the
function is disabled for the rst 20 seconds starting from Gas valve opening moment. Except for comfort Mode
if DHW conguration parameter is set to 1: in this case, the function is active as soon as the Gas valve opening
moment. In case DHW conguration parameter is set to 1 and in case of DHW mode is running and Installer Test
mode demand is created, the function is disabled for the rst 12 seconds.
FAULT 47 =
Water pressure sensor not connected. In error mode, the heat demand and the pumps are switched off.
Resolving error situation can be achieved only if the sensor is connected again.
FAULT 50 =
Variable input switch contact opened. See Variable input switch paragraph.
FAULT 51 =
Low water cutoff sensor open. This error can occur only when the Variable input switch functionality parameter is
set to 3. This is only an indication, the heat request is not switched off.
FAULT 52 =
When the system measures a difference between two CH supply water temperature sensors equal or higher than
18°F (with a conrming time of 10 seconds), error 52 is created. This error condition is stopping the boiler and to
get to the normal operation again, the temperature between the two CH supply water temperature sensors has to
be lower than 14°F for 10 seconds. When this timer is expired, error will be resolved.
FAULT 53 =
High limit thermostat open. This error can occur only when the Variable input switch functionality parameter is set
to 4. During fault the boiler is forced in stand-by mode. Blue jumper wire missing on Heating Only boiler.
FAULT 64 =
5 MicroCom reset in 15 minutes time frame. This error condition is stopping the boiler and to get to the normal
operation again, it is necessary to take out main power supply.
FAULT 66 =
Software doesn’t match. This error condition is stopping the boiler and to get to the normal operation again, it is
necessary to re-program the device or to replace it.
Figure 122(continued)
37 Troubleshooting(continued)
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
37 Troubleshooting(continued)
Figure 123
Configuration mode
By pressing the DHW- and DHW+ push buttons together for 10 seconds, it is possible to enter into the Configuration mode.
The display starts with showing “b01” blinking. By means of the CH “+” and CH “-” push buttons it is possible to select the
parameters; between “b01” and “b28”. Selecting one of these parameters, by means of the DHW “+” and DHW “-” push buttons
it is possible to adjust his value (not flashing). The value is automatically saved.
By pressing the DHW- and DHW+ push buttons together for 10 seconds, it is possible to leave the Configuration mode.
If no action has been taken, the MMI automatically leaves this mode after 2 minutes.
Parameter Description Default Note
b01 Gas type selection (0Natural Gas, 1LPG) 0
b02
DHW conguration
2Storage tank,
3Instantaneous with secondary heat exchanger,
2 - Heating Only
3 - Combi
b03 Water pressure protection (0Switch, 1Sensor) 0
b04 Fan absolute DHW maximum speed (Hz)
See
Figure 128, page 101.
b05 Fan absolute CH maximum speed (Hz)
See
Figure 128, page 101.
b06 Fan absolute minimum speed (Hz)
See
Figure 128, page 101.
b07 Not implemented - DHW cong. 2
DHW maximum output boost/limit level (%) - DHW cong. 3
--
100
DHW conf. dependent
Do Not Adjust
b08 Not implemented - DHW cong. 2
DHW maximum output boost/limit time (Sec) - DHW cong. 3
--
60
DHW conf. dependent
Do Not Adjust
b09 Fan offset low level (Hz) 10 Do Not Adjust
b10 Summer/Winter function (0Sum/Win, 1always Win) 1 Do Not Adjust
b11 Variable input switch functionality (Number) 4 Do Not Adjust
b12 Variable output relay functionality (Number)
See
Figure 128, page 101
Model dependent
b13 External pcb variable output relay functionality (Number) 7 Do Not Adjust
b14 Hours of no DHW ow to set the Economy mode (Hours) 24 Range0-24 hours
b15 Fault F20 function (0disable, 1enable) 0 Do Not Adjust
b16 Maximum exhaust gases temperature (°F) 200
200 PVC/ 212 CPVC
sel. dependent
b17 Main supply frequency (050Hz, 160Hz) 1 Do Not Adjust
b18
Not implemented - DHW cong. 2
Not implemented - DHW cong. 3
--
--
DHW conf. dependent
Not used,
Do Not Adjust
b19 DHW tank prepare mode (Num.) - DHW cong. 2
DHW ow sensor lter (Sec) - DHW cong. 3
0
0
DHW conf. dependent
Do Not Adjust
b20 Fan type selection (0Not used, 1EBM) 1 Do Not Adjust
b21 Pump protection time (Sec) 5 Do Not Adjust
b22 PVC/CPVC/Polypro/AL29-4C Selection 1 See Options on page 34
b23 PVC maximum temperature (°F) 190 Do Not Adjust
b24 CPVC maximum temperature (°F) 200 Do Not Adjust
b25 Pre-purge time between A01 attempts 0 Do Not Adjust
b26 High altitude & Chimney length selection 0 Do Not Adjust
b27 Hydraulic conguration - DHW cong. 2
Not implemented - DHW cong. 3
0
--
DHW conf. dependent
Do Not Adjust
b28 Offset ame current low limit 20 Do Not Adjust
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
37 Troubleshooting(continued)
Figure 124
Installer mode
By pressing the “reset” push button for 20 seconds, it is possible to entered the Installer mode. During this time, the OTC mode
must not be entered. The display starts showing: “tS” flashing. By means of the CH+ and CH- push buttons it is possible to select
“tS” or “In” or “Hi” or “rE”. “tS” means “Transparent parameter”; “In” means “Inquiry”; “Hi” means “History”; “rE” means “reset”.
By means of the “
reset” button (1 activation for 1 second) on “tS” it is possible to enter the “Transparent parameter” mode, on “In”
it is possible to enter the “Inquiry” mode, on “Hi” is possible to enter the “History” mode; by means of the “eco” button (1 activa-
tion for 3 seconds) on “rE” is possible to reset all the History information.
By pressing the “reset” button for 20 seconds, it is possible to leave the Installer mode. If no action has been taken, the control
automatically leaves this mode after 2 minutes.
tS blinking
Transparent parameter mode See Figure 125 thru 128, pages 99-101.
In blinking
Inquiry mode See Figure 129 & 130 pages 101-102.
Hi blinking
History mode See Figure 131, page 102.
rE blinking
Reset all the History information
“tS” as Transparent Parameters mode (TSP)
Selecting “tS” the display starts with showing “P01” blinking. By means of the CH+ and CH- push buttons it is possible to select
the parameters; between “P01” and “P34”. Selecting one of these parameters, by means of the DHW+ and DHW- push buttons is
possible to adjust his value (not flashing). To save, press the DHW- and DHW+ push buttons together.
The default “tS”settings for the boiler have been set by the Manufacturer and there should be no need to change.
Figure 125
Parameter Description Default Notes
P01
Ignition level (%)
60 or 80
or 50
60% - AB-120 / 80% - AB-80
50% - AB-155
P02
CH slope control (°F/min) 6
P03
Minimum Virtual set point (°F) 95 Do Not Adjust
P04
CH OFF time (Min) 2
P05
CH pump over-run time (Min) 15
P06
CH pump selection (0-7) 0 Do Not Adjust
P07
CH modulating pump PWM absolute min (%) 30 Do Not Adjust
P08
CH modulating pump PWM start (%) 75 Do Not Adjust
P09
CH modulating pump PWM absolute max (%) 100 Do Not Adjust
P10
CH supply for CH pump over-run OFF (°F) - DHW cong. 2
CH supply for CH pump over-run OFF (°F) - DHW cong. 3
68
91
DHW conf. dependent
Cong. 2, Heating Only 68
Cong. 3, Combi 91
P11
CH supply for CH pump over-run ON (°F) - DHW cong. 2
CH supply for CH pump over-run ON (°F) - DHW cong. 3
9
18
DHW conf. dependent
Cong. 2, Heating Only 9
Cong. 3, Combi 18
P12
CH set point limit HIGH (°F) 190
P13
CH maximum output (%) 100 Also in Test Mode
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Parameter Description Default Note
P14
Legionella protection - DHW cong. 2 with sensor
Legionella protection - DHW cong. 2 with thermostat
DHW off mode - DHW cong. 3
0
--
0
DHW conf. dependent
P15
DHW Comfort Hysteresis (°F) - DHW cong. 2
DHW Comfort switch on point (°F) - DHW cong. 3
4
104
DHW conf. dependent
P16
CH supply over-temp_burner ON (°F) - DHW cong. 2
DHW Comfort temperature difference (°F) - DHW cong. 3
176
36
DHW conf. dependent
P17
DHW delta (°F) - DHW cong. 2
DHW OFF time (Sec) - DHW cong. 3
18
120
DHW conf. dependent
P18
DHW set point limit HIGH (°F) - DHW cong. 2
DHW set point limit HIGH (°F) - DHW cong. 3
149
131
DHW conf. dependent
P19
DHW pump over-run time (Sec) - DHW cong. 2
DHW pump over-run time (Sec) - DHW cong. 3
30
30
DHW conf. dependent
P20
DHW maximum output (%) 100
P21
Not implemented - DHW cong. 2
Not implemented - DHW cong. 3
--
--
DHW conf. dependent
Not Used
P22
DHW comfort off time2 (Min) - DHW cong. 2
Not implemented - DHW cong. 2
Not implemented - DHW cong. 3
42
--
--
DHW conf. dependent
Not Used
P23
Blower speed in Stand-by mode (Hz) 0
P24
Post-Ventilation time (Sec) 27
P25
Delta T1 (°F) - DHW cong. 2
Delta T1 (°F) - DHW cong. 3
32
32
DHW conf. dependent
P26
Delta T2 (°F) - DHW cong. 2
Delta T2 (°F) - DHW cong. 3
63
255
DHW conf. dependent
P27
Water pressure low limit (psi) 6
Fixed if the Water pressure
protection is set 0Switch
P28
Water pressure nominal (psi) 10
Fixed if the Water pressure
protection is set 0Switch
P29
Not implemented - DHW cong. 2
Heat exchanger protection (°F/Sec) - DHW cong. 3
--
18
DHW conf. dependent
P30
CH hysteresis after burner ignition (°F) 18
P31
CH hysteresis after burner ignition timer (Sec) 60
P32
DHW slope control (°F/min) - DHW cong. 2
Not implemented - DHW cong. 3
9
--
DHW conf. dependent
P33
Priority Over Ride Set (min) - DHW cong. 2
Not implemented - DHW cong. 3
30
--
DHW conf. dependent
P34
Priority Over Ride Reset (min) - DHW cong. 2
Not implemented - DHW cong. 3
15
--
DHW conf. dependent
37 Troubleshooting
(continued)
Figure 126
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
37 Troubleshooting(continued)
t01 blinking
CH Supply sensor1 Temperature (°F) between 32 and 257
t02 blinking
CH Supply sensor2 Temperature (°F) between 32 and 257
t03 blinking
CH Return sensor Temperature (°F) between 32 and 257
t04 blinking
DHW sensor Temperature (°F) between 32 and 257
t05 blinking
Outdoor sensor Temperature (°F) between 22 and 158, blinking if it is negative
t06 blinking
Exhaust sensor Temperature (°F) between 32 and 257
F07 blinking
Actual Blower Speed (Hz) Min00, Maxparameter depending
L08 blinking
Actual burner load (%) 00%Min, 125%Max DHW boost output
F09 blinking
Actual water ow rate (l/min *10) between 00 and 255
“In” as Inquiry mode
Selecting “In” the display starts with showing “t01” blinking. By means of the CH+ and CH- push buttons it is possible to select the
parameters; between “t01” and “F13”. Selecting one of these parameters, by means of the DHW+ and DHW- push buttons is pos-
sible to see his value (not flashing; only in case of negative outdoor temperature the value is flashing).
Figure 127
Figure 128
Figure 129
By pressing the “reset” push button for 1 second, it is possible to escape from the “Transparent parameter” mode. By pressing the
“reset” push button for 20 seconds, it is possible to leave the Installer mode. If no action has been taken, the MMI automatically
leaves this mode after 15 minutes.
Boiler
Model
“b01” “b02” “b04” “b05” “b06” “b10” “b12”
“b22”
“P01” “P02” “P04”
Gas
type
Boiler
type
Fan
Max. Freq.
in DHW
Fan
Max. Freq.
in CH
Fan
Min. Freq.
in CH
S/W mode
selection
button
Var. Out
Relay
Vent
material
Ignition
level
CH Slope
(F/min)
CH
Off Time
AB-80-N-C
0Nat. gas
3 155 155 35 1 0 1 80 6 2
AB-120-N-C
0Nat. gas
3 200 200 40 1 0 1 60 6 2
AB-155-N-C
0Nat. gas
3 210 210 39 1 7 1 50 6 2
AB-80-N-H
0Nat. gas
2 155 155 35 1 0 1 80 6 2
AB-120-N-H
0Nat. gas
2 200 200 40 1 0 1 60 6 2
AB-155-N-H
0Nat. gas
2 210 210 39 1 0 1 50 6 2
AB-80-LP-C
1LPG
3 145 145 35 1 0 1 80 6 2
AB-120-LP-C
1LPG
3 185 185 40 1 0 1 60 6 2
AB-155-LP-C
1LPG
3 220 220 40 1 7 1 50 6 2
AB-80-LP-H
1LPG
2 145 145 35 1 0 1 80 6 2
AB-120-LP-H
1LPG
2 185 185 40 1 0 1 60 6 2
AB-155-LP-H
1LPG
2 220 220 40 1 0 1 50 6 2
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
If a temperature sensor is open or shorted, the display shows “- -”.
Actual blower speed is shown always in terms of Hz.
Actual water flow rate is shown in terms of real l/min *10 and it has to be visualized also with the input switch
contact open. Example: real 1.5 l/min has to be visualized as 15.
Actual Flame Current is shown in terms of real uA*10. Example: real 0.3 uA*10 is shown as 3.
In case of DHW thermostat, t04: “On” means closed, “OFF” means open.
By pressing the “reset” push button for 1 second, it is possible to escape from the “Inquiry” mode. By pressing the “reset” push
button for 20 seconds, it is possible to leave the Installer mode. If no action has been taken, the MMI automatically leaves this
mode after 15 minutes.
P10 blinking
Boiler water pressure switch status Open 00, Closed 20
P11 blinking
Actual PWM modulating Pump (%) Min30, Max100
P12 blinking
Actual Step of Triac mod. mode (Num) Min24, Max59
F13 blinking
Actual Flame Current (uA*10) between 00 and 255
Figure 130
37 Troubleshooting
(continued)
“Hi” as History mode
Selecting “Hi” the display starts with showing “H01” blinking. By means of the CH+ and CH- push buttons it is possible to select
the parameters; between “H01” and “H08”. Selecting one of these parameters, by means of the DHW+ and DHW- push buttons, it
is possible to see the past error codes (not flashing).
By pressing the “
reset” push button for 1 second, it is possible to escape from the “History” mode. By pressing the “reset” push
button for 20 seconds, it is possible to leave the Installer mode. If no action has been taken, the MMI automatically leaves this
mode after 15 minutes.
Figure 131
H01 blinking
History buffer 1 (the latest)
H02 blinking
History buffer 2
H03 blinking
History buffer 3
-------- --------
H08 blinking
History buffer 08
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Table 5 AquaBalance®
Figure 132AquaBalance
®
(continued)
37 Troubleshooting(continued)
System Parameters list (default settings)
There are 4 basic configurations within the DHW mode, selected by parameter DHW configuration (see Parameters list, Num.
1). Default value is model dependent. (2 for Heating Only models, 3 for Combi models). By changing the DHW configuration
number (See Parameter “b01”, Figure 123, page 98), all the data will be automatically set at default condition. Parameters that will
be changed according to the DHW mode are numbered from 9 to 46 (see Parameters list). All the parameters can be accessed with
a communication package running on the PC. Some parameters are available by the installer in the “ts”, Transparent Parameter
mode through the control interface.
Category Unit Range Def
Description
Num. Address Description Low High Value
DHW boiler type 1 CL5 – 05C8 DHW conguration Num 1 4 3
System 2 ML – 80D0 First start-up ag Num 0 1 0
End user setting 3 ML – 80E2 Summer / Winter selection Num 0 1 1
End user setting 4 ML – 80E3 Economy / Comfort selection Num 0 1 0
End user setting 5 CL5 – 0A9D CH set point limit - HIGH °F 68 194 190
End user setting 6 CL5 – 056D CH user set point °F 68 194 158
Exhaust protection 7 CL5 – 050B Maximum exhaust gases temperature °F 32 255 185
Firmware version 8 ML – 80E8 Firmware version Num 0 99 04
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Category Unit Range Def
Description
Num. Address Description Low High Value
DHW cong. 2 9,2 CL5 – 066E DHW P factor Num 0 255 5
DHW cong. 2 10,2 CL5 – 0691 DHW I factor Num 0 255 240
DHW cong. 2 11,2 ML – 80EB DHW FF factor Num 0 255 0
DHW cong. 2 12,2 ML – 80EC Fan absolute DHW maximum speed Hz 0 220 200
DHW cong. 2 13,2 ML – 80ED Fan absolute CH maximum speed Hz 0 220 200
DHW cong. 2 14,2 ML – 80EE Fan absolute minimum speed Hz 0 165 40
DHW cong. 2 15,2 CL5 – 2D89 Fan offset low level Hz 0 220 10
DHW cong. 2 16,2 ML – 80F0 Ignition level % 0 100 60
DHW cong. 2 17,2 Free - TBD
DHW cong. 2 18,2 Free - TBD
DHW cong. 2 19,2 Free - TBD
DHW cong. 2 20,2 Free - TBD
DHW cong. 2 21,2 Free - TBD
DHW cong. 2 22,2 Free - TBD
DHW cong. 2 23,2 Free - TBD
DHW cong. 2 24,2 Free - TBD
DHW cong. 2 25,2 Free - TBD
DHW cong. 2 26,2 ML – 80FA DHW pre-pump time Sec 0 30 30
DHW cong. 2 27,2 ML – 80FB Legionella protection Num 0 7 0
DHW cong. 2 28,2 CL5 – 0A5E DHW comfort hysteresis °F 0 176 4
DHW cong. 2 29,2 CL5 – 0A62 DHW comfort temp difference °F 0 104 0
DHW cong. 2 30,2 ML – 80FE DHW pump start temperature °F 0 255 32
DHW cong. 2 31,2 ML – 80FF DHW pump start waiting time Sec 0 255 0
DHW cong. 2 32,2 CL5 – 05A1 DHW OFF time Sec 30 255 120
DHW cong. 2 33,2 CL5 – 0A04 DHW pump over-run time Sec 0 255 30
DHW cong. 2 34,2 CL5 – 0A6D Delta T1 °F 0 108 32
DHW cong. 2 35,2 CL5 – 0A92 Delta T2 °F 0 255 63
DHW cong. 2 36,2 ML – 8104 CH supply for CH pump over-run OFF °F 32 212 68
DHW cong. 2 37,2 CL5 – 0C94 CH supply for CH pump over-run ON °F 0 200 9
DHW cong. 2 38,2 ML – 8106 CH supply over-temp_burnerOFF °F 0 212 9
DHW cong. 2 39,2 ML – 8107 CH supply over-temp_burnerON °F 32 212 176
DHW cong. 2 40,2 ML – 8108 CH return over-temp_burnerOFF °F 32 212 203
DHW cong. 2 41,2 ML – 8109 CH return over-temp_burnerON °F 32 212 194
DHW con
g. 2 42,2 ML – 810A DHW set point limit – LOW °F 50 104 50
DHW cong. 2 43,2 CL5 – 1E76 DHW set point limit – HIGH °F 104 158 149
DHW cong. 2 44,2 CL5 – 05F4 DHW user set point – Default value °F 50 158 149
DHW cong. 2 45,2 ML – 810D CH pre-pump time Sec 0 60 30
DHW cong. 2 46,2 ML – 810E Minimum virtual set point °F 68 176 95
Figure 133AquaBalance
®
(continued)
37 Troubleshooting(continued)
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Category Unit Range Def
Description
Num. Address Description Low High Value
DHW cong. 3 9,3 CL5 – 066E DHW P factor Num 0 255 20
DHW cong. 3 10,3 CL5 – 0691 DHW I factor Num 0 255 240
DHW cong. 3 11,3 ML – 80EB DHW FF factor Num 0 255 0
DHW cong. 3 12,3 ML – 80EC Fan absolute DHW maximum speed Hz 0 220 200
DHW cong. 3 13,3 ML – 80ED Fan absolute CH maximum speed Hz 0 220 200
DHW cong. 3 14,3 ML – 80EE Fan absolute minimum speed Hz 0 165 40
DHW cong. 3 15,3 CL5 – 2D89 Fan offset low level Hz 0 220 10
DHW cong. 3 16,3 ML – 80F0 Ignition level % 0 100 60
DHW cong. 3 17,3 ML – 80F1 DHW maximum output boost/limit level % 75 125 100
DHW cong. 3 18,3 ML – 80F2 DHW maximum output boost/limit time Sec 0 120 60
DHW cong. 3 19,3 ML – 80F3 DHW over-temp_burnerOFF - xed °F 68 194 167
DHW cong. 3 20,3 ML – 80F4 DHW over-temp_burnerON - xed °F 68 194 163
DHW cong. 3 21,3 ML – 80F5 DHW over-temp_burnerOFF – setpoint °F 0 200 9
DHW cong. 3 22,3 ML – 80F6 DHW over-temp_burnerON – setpoint °F 0 200 0
DHW cong. 3 23,3 ML – 80F7 DHW over-temp_burnerOFF – solar °F 0 200 18
DHW cong. 3 24,3 ML – 80F8 DHW over-temp_burnerON – solar °F 0 200 18
DHW cong. 3 25,3 ML – 80F9 DHW start waiting time – solar1 Sec 0 255 5
DHW cong. 3 26,3 ML – 80FA DHW start waiting time – solar2 Sec 0 255 10
DHW cong. 3 27,3 ML – 80FB DHW start waiting time – solar3 Sec 0 255 20
DHW cong. 3 28,3 CL5 – 0A5E DHW comfort switch on point °F 0 176 104
DHW cong. 3 29,3 CL5 – 0A62 DHW comfort temp difference °F 0 100 36
DHW cong. 3 30,3 ML – 80FE DHW pump start temperature °F 0 255 68
DHW cong. 3 31,3 ML – 80FF DHW pump start waiting time Sec 0 255 1
DHW cong. 3 32,3 CL5 – 05A1 DHW OFF time Sec 0 255 120
DHW cong. 3 33,3 CL5 – 0A04 DHW pump over-run time Sec 0 255 30
DHW cong. 3 34,3 CL5 – 0A6D Delta T1 °F 0 108 32
DHW cong. 3 35,3 CL5 – 0A92 Delta T2 °F 0 255 255
DHW cong. 3 36,3 ML – 8104 CH supply for CH pump over-run OFF °F 32 212 91
DHW cong. 3 37,3 CL5 – 0C94 CH supply for CH pump over-run ON °F 0 200 18
DHW cong. 3 38,3 ML – 8106 CH supply over-temp_burnerOFF °F 0 212 203
DHW cong. 3 39,3 ML – 8107 CH supply over-temp_burnerON °F 32 212 194
DHW cong. 3 40,3 ML – 8108 CH return over-temp_burnerOFF °F 32 212 203
DHW con
g. 3 41,3 ML – 8109 CH return over-temp_burnerON °F 32 212 194
DHW cong. 3 42,3 ML – 810A DHW set point limit – LOW °F 50 104 104
DHW cong. 3 43,3 CL5 – 1E76 DHW set point limit – HIGH °F 104 158 131
DHW cong. 3 44,3 CL5 – 05F4 DHW user set point – Default value °F 50 158 131
DHW cong. 3 45,3 ML – 810D CH pre-pump time Sec 0 60 30
DHW cong. 3 46,3 ML – 810E Minimum virtual set point °F 68 176 95
Figure 134AquaBalance
®
(continued)
37 Troubleshooting(continued)
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 135AquaBalance
®
(continued)
37 Troubleshooting(continued)
Category Unit Range Def
Description
Num. Address Description Low High Value
Central Heating 47 constant CH P factor num 12
Central Heating 48 constant CH I factor num 245
Central Heating 49 ML – 8138 Pre-purge time in CH mode Sec 0 255 0
Central Heating 50 CL5 – 063B CH maximum output % 0 100 100
Central Heating 51 CL5 – 05AE CH OFF time Min 0 10 2
Central Heating 52 CL5 – 05C7 CH pump over-run time Min 0 255 15
Central Heating 53 CL5 – 059D CH pump selection Num 0 7 0
Central Heating 54 CL5 – 0592 CH slope control °F/min 1 20 11
Central Heating 55 CL5 – 055E OTC curve selection Num 0 10 0
Central Heating 56 CL5 – 0562 OTC temperature offset °F 68 104 86
Central Heating 58 ML – 811A Summer/Winter function Num 0 1 1
Central Heating 59 ML – 8129 CH hysteresys after burner ignition °F 11 54 18
Central Heating 60 ML – 8120 CH hysteresys after burner ignition timer Sec 60 180 60
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Category Unit Range Def
Description Num. Address Description Low High Value
Dom. Hot Water 61 CL5 – 06F8 DHW maximum output % 0 100 100
Dom. Hot Water 62 Free - TBD
Dom. Hot Water 63 ML – 80D9 DHW ow sensor type Num 0 1 0
Dom. Hot Water 64 CL5 – 127A Flow sensor ON 10*l/min 0 100 15
Dom. Hot Water 65 CL5 – 1285 Flow sensor OFF 10*l/min 0 100 10
Dom. Hot Water 66 ML – 80DE DHW ow sensor lter Sec 0 10 0
Dom. Hot Water 67 ML – 811F DHW Off mode Num 0 4 0
Dom. Hot Water 68 ML – 813C Hours of no DHW ow to set the Economy mode Hours 0 24 24
System 69 ML – 8122 Variable input switch functionality Num 0 4 4
System 70 ML – 8123 Gas type selection Num 0 1 0
System 71 CL5 – 121C Fan speed in Stand-by mode Hz 0 70 0
System 72 CL5 – 0934 Water pressure low limit psi 0 12 6
System 73 CL5 – 0A38 Water pressure nominal psi 7 29 10
System 74 CL5 – 2EDF Water pressure high limit psi 36 50 41
System 75 ML – 8128 Water lling mode Num 0 1 0
System 76 ML – 811B Main supply frequency Num 0 1 1
System 77 ML – 80DC Variable output relay functionality Num 0 8 0
System 78 ML – 812A External pcb variable output relay functionality Num 0 8 7
System 79 ML – 812B CH supply2 over-temp_burnerOFF °F 194 230 230
System 80 ML – 812C CH supply2 over-temp_burnerON °F 194 230 226
System 81 ML – 812D Water pressure protection Num 0 1 0
System 82 ML – 813B Post-Ventilation time Sec 0 255 27
System 83 ML – 813D Fault F20 function Num 0 1 0
System 84 ML – 80E0 3-way motor valve commutation timer Sec 4 10 4
Delta T protection 85 ML – 812E CH modulating pump PWM absolute min % 0 100 30
Delta T protection 86 ML – 812F CH modulating pump PWM start % 0 100 75
Delta T protection 87 CL5 - 0C64 CH modulating pump PWM absolute max % 0 100 100
Delta T protection 88 constant CH Time loop Sec 2
Delta T protection 89 constant DHW Time loop Sec 2
Delta T protection 90 constant CH modulating pump PWM_decrease step % 1
Delta T protection 91 constant CH modulating pump PWM_update_time Sec 4
Delta T protection 92 constant Virtual set point_decrease step °F 4
Delta T protection 93 constant Virtual set point_decrease time Sec 10
Delta T protection 94 constant DHW Virtual set point_decrease time2 Sec 12
Delta T protection 95 constant DHW Virtual set point_decrease time1 Sec 18
Delta T protection 96 constant DHW Virtual set point_increase time Sec 18
97 Free - TBD
98 Free - TBD
Figure 136AquaBalance
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37 Troubleshooting(continued)
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Category Unit Range Def
Description
Num. Address Description Low High Value
History 99 ML – 8061 Total num. of hours with power supply ON - LSB Num
History 100 ML – 8060 Total num. of hours with power supply ON - MSB Num
History 101 ML – 8020 History buffer 1 (the lastest) Error 0 99
History 102 ML – 8024 History buffer 2 Error 0 99
History 103 ML – 8028 History buffer 3 Error 0 99
History 104 ML – 802C History buffer 4 Error 0 99
History 105 ML – 8030 History buffer 5 Error 0 99
History 106 ML – 8034 History buffer 6 Error 0 99
History 107 ML – 8038 History buffer 7 Error 0 99
History 108 ML – 803C History buffer 8 Error 0 99
History 109 ML – 8022 Hour when History error 1 is happened - LSB Num
History 110 ML – 8021 Hour when History error 1 is happened - MSB Num
History 111 ML – 8026 Hour when History error 2 is happened - LSB Num
History 112 ML – 8025 Hour when History error 2 is happened - MSB Num
History 113 ML – 802A Hour when History error 3 is happened - LSB Num
History 114 ML – 8029 Hour when History error 3 is happened - MSB Num
History 115 ML – 802E Hour when History error 4 is happened - LSB Num
History 116 ML – 802D Hour when History error 4 is happened - MSB Num
History 117 ML – 8032 Hour when History error 5 is happened - LSB Num
History 118 ML – 8031 Hour when History error 5 is happened - MSB Num
History 119 ML – 8036 Hour when History error 6 is happened - LSB Num
History 120 ML – 8035 Hour when History error 6 is happened - MSB Num
History 121 ML –803A Hour when History error 7 is happened - LSB Num
History 122 ML – 8039 Hour when History error 7 is happened - MSB Num
History 123 ML – 803E Hour when History error 8 is happened - LSB Num
History 124 ML – 803D Hour when History error 8 is happened - MSB Num
History 125 ML – 806B Total number of burner switching – LSB Num
History 126 ML – 806A Total number of burner switching – MSB Num
History 127 ML – 8073 Number of CH burner switching - LSB Num
History 128 ML – 8072 Number of CH burner switching - MSB Num
History 129 ML – 8077 Number of DHW burner switching - LSB Num
History 130 ML – 8076 Number of DHW burner switching - MSB Num
History 131 ML – 8079 Number of CH hours – LSB Num
History 132 ML – 8078 Number of CH hours – MSB Num
History 133 ML – 807D Number of DHW hours – LSB Num
History 134 ML – 807C Number of DHW hours – MSB Num
History 135 ML – 8081 Number of Burner off hours – LSB Num
History 136 ML – 8080 Number of Burner off hours – MSB Num
History 137 ML – 8085 Number of CH Pump ON hours – LSB Num
History 138 ML – 8084 Number of CH Pump ON hours – MSB Num
History 139 ML – 808B DHW water usage in liters – LSB Num
History 140 ML – 808A DHW water usage in liters – MSB Num
History 141 ML – 813A Number of Reset of the History Information Num
Figure 137AquaBalance
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(continued)
37 Troubleshooting(continued)
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Category Unit Range Def
Description
Num. Address Description Low High Value
Flame current supervision 142 ML – 80D5 Flame current on level1 offset ADC 0 255 3
Flame current supervision 143 ML – 80DB Flame current on level2 offset ADC 0 255 0
Flame current supervision 144 ML – 8112 Flame current off level offset ADC 0 255 20
System 145 ML – 8134 High altitude & Chimney length selection Num 0 2 0
System 146 ML – 8131 Pre-purge time between A01 attempts Min 0 60 0
System 147 ML – 80D6 Pump protection time Sec 0 20 5
Fan Regulation 148 CL5 – 0AC8 FAN Kp Up Num 0 100 25
Fan Regulation 149 CL5 – 0AF4 FAN Ki Up Num 0 255 220
Fan Regulation 150 CL5 – 1B8C FAN Kp Down Num 0 100 25
Fan Regulation 151 CL5 – 1BB0 FAN Ki Down Num 0 255 250
Heat exchanger protection 152 ML – 80DD Heat exchanger protection °F/Sec 0 27 18
DHW Cong. 2 153,2 ML – 80D2 Priority Over Ride Set °F 0 240 30
DHW Cong. 2 154,2 ML – 80D3 Priority Over Ride Reset °F 0 240 15
System 161 ML – 80D7 Fan type selection Num 0 1 1
System 162 ML - 8121 High limit protection timer Sec 0 20 10
System 163 ML – 80D4 OTC Exempt Num 0 1 0
Chimney material 165 ML – 8110 PVC/CPVC Selection Num 0 2 1
Chimney material 166 ML – 8132 PVC maximum temperature °F 140 212 190
Chimney material 167 ML – 8133 CPVC maximum temperature °F 158 230 200
Wind condition 168 ML - 8135 Wind condition time Sec 0 60 10
Wind condition 169 ML - 8136 Wind condition frequency Hz 0 255 110
Wind condition 170 ML - 8137 Wind condition ADC ADC 0 255 30
DHW Cong. 2 171,2 ML – 8111 DHW thermostat/sensor selection Num 0 1 0
DHW Cong. 2 172,2 ML – 80C7 DHW tank prepare mode Num 0 2 0
DHW Cong. 2 173,2 ML – 80D1 DHW Delta °F 0 35 18
DHW Cong. 2 174,2 ML – 80CC DHW slope control °F/min 1 20 9
DHW Cong. 2 175,2 ML – 813F Hydraulic conguration Num 0 1 0
Flame current supervision 176 CL5 – AAA1 Offset ame current low limit Num 1 20 20
Figure 138AquaBalance
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37 Troubleshooting(continued)
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
37 Troubleshooting(continued)
Category Unit
Description
Num. Address Description
Boiler 1 CL4 – A532 CH supply sensor1 temperature °F *10
Boiler 2 CL4 – A567 CH supply sensor2 temperature °F *10
Boiler 3 CL4 – A55B CH return sensor temperature °F *10
Boiler 4 CL4 -A53D DHW sensor temperature °F *10
Boiler 5 CL4 -A568 Exhaust sensor temperature °F *10
Boiler 6 CL4 -1110 Water pressure sensor Psi *10
Boiler 7 CL4 -A554 Outside temperature sensor °F *10
Boiler 8 CL4 -0FAB MSB Control water set point °F
Boiler 9 CL4 -FC02 MSB CH Virtual set point °F
Boiler 10 CL4 -FC02 LSB DHW Virtual set point °F
Boiler 11 CL4 – 11DC MSB Fan speed -Setpoint Hz
Boiler 12 CL4 – 11DC LSB Fan speed -Feedback Hz
Boiler 13 CL4 – 0364 Flame current uA *10
Boiler 14 CL4 – FAFB MSB PWM modulating pump %
Boiler 15 CL4 – FAFB LSB Step of Triac modulating pump Num
Boiler 16 CL4 – 0F0E DHW ow sensor Hz
Boiler 17 ML -F68B DHW over-temp_burnerOFF-initially_Temperature °F
OpenTherm 18 CL4 – FAF4 MSB OT room setpoint °F Int
OpenTherm 19 CL4 – FAF4 LSB OT room setpoint °F Dec
OpenTherm 20 CL4 – FAC8 MSB OT room temp °F Int
Figure 139AquaBalance
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(continued)
Some informations can be accessed with a communication package running on the PC.
Parameter Description
D1
After cycle of Domestic water mode, D1 will be displayed.
D2
When required boiler water set - point is reached D2 will be displayed.
D3
After an attempt for ignition, re-trial ignition delay is in effect (D3 is displayed).
* Check for proper fuel supply.
* Remove and check ignitor for proper gap, 5/32”, replace if disgured, check combustion setting Natural gas or LP.
* Insure condensate is draining properly.
* Insure venting size and length are correct and unobstructed.
D1….the boiler is / has finished the call for Domestic Water heating, and is in the transition to either standby mode or
central heating mode.
D2….the boiler has reached the required water set point, and the firing has stopped / with a call for Central Heating still
applied by the T-Stat to the boiler. Pumps will continue to operate and the boiler is monitoring the two internal water
sensors (return & discharge) waiting for a water “Delta-T” to return…at that time the boiler will re-fire if need be
D3….the boiler has made 3 tries for ignition and has failed to ignite. A re-trial ignition cycle / delay is in effect for 3 more
tries to ignite.
Condensate
drain line
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
38 Maintenance
Figure 140
Clean condensate trap
1. See Figure 140.
2. Disconnect top clean out cap nut that secures the trap body to
the boiler condensate connection.
3. Remove the clean out cap.
4. Check for any sediment and clean out if necessary.
5. Re-assemble gasket and clean out cap.
6. Fill trap with fresh water by pouring into the condensate drain
line. Make sure the trap line is unobstructed and flows freely.
DO NOT loop condensate drain hose.
7. Reattach the trap to the boiler condensate drain outlet. Check
for secure connection.
Inspect and clean ignition electrode
Wait until heat exchanger/boiler is cooled down
before proceeding. Failure to do so can cause severe
injury.
1. Disconnect the ground wire and ignition cable connected to
the electrode. Ignition wire pulls out of back of control module.
Remove the ignitor wire by pulling on the connector, not the wire.
Figure 141
Disconnect power
Electrical shock hazard — Discon-
nect all electrical power to the boiler
before attempting maintenance pro-
cedures. Failure to complete could
result in severe personal injury, death
or substantial property damage.
Jacket side panels are now
remove able for servicing
The boiler’s right and left side jacket panels
are remove able, and can be removed by
removing the screws on the top and bot-
tom of each panel.
Re-install boiler jacket door
after startup or servicing
Reinstall boiler jacket door after start-
up or servicing. The boiler jacket door
must be securely fastened to the boiler to
prevent boiler from drawing air from in-
side the boiler room. This is particularly
important if the boiler is located in the
same room as other appliances.
Failure to keep the jacket door securely
sealed and fastened could result in severe
personal injury or death.
Start-up and check/out
Removing and reinstalling components
can change boiler behavior. After any
maintenance procedure, you must prove
the boiler is operating correctly. To do
so, follow the complete procedure for
boiler and system start-up, beginning on
page 73
Failure to comply could result in severe
personal injury, death or substantial
property damage.
Label wires
Label all wires prior to disconnection
when servicing controls. Wiring errors
can cause improper and dangerous
operation.
Ground Wire
Ground Wire
Cable
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
38 Maintenance (continued)
Figure 142
2. Remove two (2) Phillips head screws securing the ignition
electrode to the boiler heat exchanger.
3. Carefully slide the igniter out of its mounting slot.
Use care when removing and handling igniter.
Igniter is very brittle and can break if not handled
carefully.
4. Remove and inspect the ignitor gasket. Replace with new if
necessary.
5. Inspect the ignitor ceramic and electrodes, 5/32” gap and not
bent or disfigured/warped.
6. Remove any white oxides accumulated on the ignition elec-
trode using steel wool. If the ignition electrode cannot be
cleaned satisfactorily, replace ignitor. If the igniter ceramic
is cracked or damaged, replace.
7. Reinstall ignition electrode, making sure gasket is in good
condition and correctly positioned.
— Use a torque wrench when tight-
ening the two (2) ignition electrode retainer screws.
DO NOT exceed 20 inch-pounds.
8. Re-attach the ground wire to the electrode assembly.
9. Re-connect ignition wire in the back of control module.
Figure 143
Inspect and clean the burner
Wait until heat exchanger/boiler is cooled down
before proceeding. Failure to do so can cause
severe injury.
1. See Figures 144 and 149, for removing heat exchanger
cover plate to access burner.
2. Use a 10mm wrench or socket to remove the five (5) nuts
that secure the heat exchanger cover plate to the heat
exchanger.
Figure 144
Figure 145
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
38 Maintenance (continued)
Figure 146
Figure 147
3. Remove the heat exchanger cover plate and the gasket.
4. Remove the burner and burner gasket from the heat
exchanger cover plate if still in place. Do not let fragments
drop into the heat exchanger if the gasket pulls apart dur-
ing removal. Replace the gasket with a new one during
reassembly.
5. Inspect the burner gasket. Discard and use a new gasket
during re-assembly if the gasket is damaged in any way.
6. Inspect the interior of the burner. Brush and vacuum the
interior if needed to remove lint or sediment. Alternative
swirl the burner thoroughly in a bucket of mild liquid
laundry detergent water, then rinse thoroughly. Use ONLY
a non-metallic brush.
7. Inspect the burner exterior. It must be in good condition,
with no visible damage.
8. Clean the underside of the burner flange with a soft brush
to remove any gasket fragments remaining.
9. Reinstall spring, if removed.
10. Reinstall the burner and burner gasket to heat exchanger
cover plate.
11. Reinstall heat exchanger cover plate and gasket to heat
exchanger.
12. Tighten the heat exchanger cover plate’s five (5) 10mm
nuts using a torque wrench. The nuts must be secure,
torque to 20 inch-pounds
Perform a complete start-up procedure when put-
ting the boiler back into service. See page 75 and all
instructions for start-up and verification. Include a
soap suds leak test on all interior and exterior gas
piping after starting the boiler.
Figure 148
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
38 Maintenance (continued)
Figure 149
Inspect and clean the heat exchanger
Wait until heat exchanger/boiler is cooled down
before proceeding. Failure to do so can cause
severe injury.
1. See Figures 149 and 153.
2. Use a 10mm wrench or socket to remove the five (5) nuts that
secure the burner cover plate to the heat exchanger.
3. Remove the heat exchanger cover plate, gasket, burner and
its gasket.
4. Inspect the refractory for any damage, replace if necessary.
5. Remove ignitor.
6. Before using water to clean the heat exchanger, remove the
control module. Label wires if they are not labeled. Set aside.
Remove all connectors and wire harnesses from the control
module and then remove the screw securing it to the bracket.
7. Use a vacuum cleaner to remove any accumulation on the
heating surfaces. This includes removing any pieces of refrac-
tory that may have dropped into the heat exchanger.
Figure 150
Figure 151
Figure 152
11. Dry with a clean rag.
12. Reinstall the spring.
13. Reinstall the burner, the burner gasket and ignitor.
14. Reinstall heat exchanger cover plate and gasket to heat
exchanger.
15. Tighten the heat exchanger cover plate’s five (5) 10mm
nuts using a torque wrench. The nuts must be secure, to a
torque of 20 inch-pounds.
Perform a complete start-up procedure when
putting the boiler back into service. See page 75
and all instructions for start-up and verification.
Include a soap suds leak test on all interior and
exterior gas piping after starting the boiler.
8. Lightly spray clean water on all of the boiler coils and
clean any residue off with (plastic only) brush. (Be careful
not to damage back refractory wall).
9. Wipe any residue off coils with a clean rag.
10. Spray clean water, to finish flushing combustion chamber.
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
38 Maintenance (continued)
Procedure For Cleaning Heat Exchanger
Waterways
This procedure is intended as a guideline for a correct restoration
of the functionality of the boiler as a result of operation with
untreated water, very hard water feeding conditions, debris, lime
scale, sludge, metal oxides and, in low temperature systems, also
biomass in the heat exchanger water circuit.
Carefully read and follow the instructions below.
Cleaning and maintenance must be carried out by profes-
sionally qualified personnel, in compliance with the current
regulations and according to the manufacturer’s instructions.
Do not carry out any operation on the sealed control parts.
Before carrying out any cleaning or maintenance operation,
disconnect the unit from the electrical power supply using
the switch and/or the special cut-off devices.
The disposal of chemicals and residues of cleaning should
be carried out in an appropriate manner, in accordance with
current standards.
Before installation of the boiler, carefully flush all the pipes of
the system to remove residues or impurities that could affect
the proper operation of the unit. Use chemical conditioners
and cleaners listed on Pages 77 and 121.
If it is necessary a cleaning of the heat exchanger circuit to
recovery the functionality of the boiler as a result of opera-
tion with untreated water, very hard water feeding condi-
tions, sludge, metal oxides and, in low temperature systems,
also biomass in the heat exchanger water circuit, is allowed
the use of chemical products for the cleaning, if and only if
the manufacturer of these fluids provides a guarantee which
ensures that its products are suitable for use and cause no
damage to the heat exchanger or other components and /
or materials of the boiler and system.
Burner and
burner gasket
Figure 153
Figure 154
3 Gas inlet
5 System return
1
2
3
4
5
6
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
38 Maintenance (continued)
Procedure for chemical cleaning of
DHW circuit
Carefully read and follow the instructions contained instruction.
Chemical cleaning and maintenance must be carried out by pro-
fessionally qualified personnel, in compliance with the current
Actions For Cleaning Of Heat Exchanger
Water Circuit
Disconnect the unit from the electrical power supply using
the switch and/or the special cut-off devices.
Close the valve of Heat exchanger system supply (1) and
return (5) placed before the boiler connections.
Release the pressure of Heat exchanger circuit by loosen the
plastic screw placed next to the Heat exchanger return (6).
Disconnect the system piping from Heat exchanger system
supply (1) and Heat exchanger system return (5).
Tighten the plastic screw placed next to the Heat exchanger
return (6).
Connect the pipe fittings and hoses for cleaning to the Heat
exchanger system supply (1) and Heat exchanger system
return (5) connections on the bottom of the boiler.
Fill the pump tank with water and, if necessary, with chemi-
cal conditioners. Use chemical conditioners that are able to
remove from the walls of the pipe of the heat exchanger de-
bris, lime scale, sludge, metal oxides and, in low temperature
systems, also biomass, with just the circulation of the water,
with system hot and/or cold. The products used must not be
corrosive and/or aggressive for metals and plastics and must
not significantly alter the natural pH of the water.
The processing time must be chosen according to the amount
of deposits present in the exchanger and however such time
must always be less than the maximum treatment time speci-
fied by the manufacturer on the product data sheet.
At the end of the cleaning cycle, empty the pump from the
washing water with chemical and recover the product in
appropriate containers for disposal.
Fill the pump with water and perform a washing cycle in
order to remove the chemical conditioner still present within
the coils of the heat exchanger, recovering the liquid in suit-
able containers for disposal.
Disconnect the pipe fittings and hoses of the pump from
the Heat exchanger system delivery (1) and Heat exchanger
system return (5) connections.
Reconnect the system piping to Heat exchanger system de-
livery (1) and Heat exchanger system return (5).
Open the valve of Heat exchanger system supply (1) and
return (5) placed before the boiler connections.
Reconnect the unit to the electrical power supply using the
switch and/or the special cut-off devices and turn it ON.
Purge air from Heat exchanger water system of the boiler
as described in User Manuals for the first installation of
the boiler.
Refill to correct pressure the Heat exchanger circuit.
Check the correct operation of the boiler.
Figure 155
3 Gas inlet
4 Cold water inlet
5 System return
6
Before you start, check the compatibility of chemi-
cal cleaning product with the material of the heat
exchanger. The material of domestic hot water
circuit is stainless steel, class AISI 316.
regulations and according to the manufacturer’s instructions.
Do not carry out any operation on the sealed control parts.
Before carrying out any cleaning or maintenance operation,
disconnect the unit from the electrical power supply using the
switch and/or the special cut-off devices.
The disposal of chemicals and residues of chemical cleaning
should be carried out in an appropriate manner, in accordance
with current standards.
In the presence of water harder than 15 grains, use suitably treated
water in order to avoid possible scaling in the boiler.
If it is necessary a chemical cleaning of the heat exchanger to
recovery the functionality of domestic hot water production as
a result of prolonged boiler operation with untreated water and
/ or very hard water feeding conditions, is allowed the use of
products for the chemical cleaning, if and only if the manufac-
turer of these fluids provides a guarantee which ensures that its
products are suitable for use and cause no damage to the heat
exchanger or other components and / or materials of the boiler
and potable DHW use.
This procedure is intended as a guideline for a correct restora-
tion of the functionality of domestic hot water production after
prolonged boiler operation with untreated water and/or very
hard water feeding conditions.
1
2
3
4
5
6
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
38 Maintenance (continued)
Hot Water Can Scald!
Consumer Product Safety Commission and some states
recommend domestic hot water temperature of 130°F or
less.
When installing an
automatic mixing valve, selection
and installation must comply with valve manufacturer’s
recommendations and instructions.
Water heated to a temperature suitable for clothes wash-
ing, dish washing and other sanitizing needs will scald and
cause injury.
Children, elderly, infirm, or physically handicapped
persons are more likely to be injured by hot water. Never
leave them unattended in or near a bathtub, shower or
sink. Never allow small children to use a hot water faucet
or draw their own bath. If anyone using hot water in the
building fits this description, or if state laws or local codes
require certain water temperatures at hot water faucets,
take special precautions:
Install
automatic mixing valve set according to those
standards. (If used).
Use lowest practical temperature setting.
Check water temperature immediately after first heating
cycle and after any adjustment.
Studies have indicated that dangerous bacteria can
form in potable water distribution systems if certain
minimum water temperatures are not maintained.
Contact local health department for more information.
These single wall heat exchangers comply with National
Standard Plumbing Code, provided that:
Boiler water (including additives) is practically non-toxic,
having a toxicity rating or class of 1, as listed in Clinical
Toxicology of Commercial Products.
Boiler water pressure is limited to max. 30 psig by approved
water relief valve.
Actions for disassembling of the
Domestic hot water flat plate heat
exchanger
Consider removing side panels as noted on page 111.
1. Disconnect the unit from the electrical power supply using the
switch and/or the special cut-off devices.
2. Close the valve of cold water inlet placed before the boiler inlet.
3. Release residual pressure in domestic hot water circuit in the
boiler by opening a hot water tap downstream of the boiler.
Wait until heat exchanger/boiler is cooled down
before proceeding. Water in brazed plate heat
exchanger may still be HOT!
Failure to do so can cause severe injury.
4. Close the valve of CH system supply (1) and return (5)
placed before the boiler connections.
Actions for chemical cleaning of
Domestic hot water circuit
1. Disconnect the unit from the electrical power supply
using the switch and/or the special cut-off devices.
2. Close the valve of cold water inlet placed before the
boiler inlet.
3. Release residual pressure in domestic hot water
circuit in the boiler by opening a hot water tap
downstream of the boiler.
4. Disconnect the piping from cold water inlet (4) and
domestic hot water outlet (2).
5. Connect the pipe fittings and hoses of the pump
for chemical cleaning to the cold water inlet (4) and
domestic hot water outlet (2).
6. Fill the pump tank with the de-scaling chemical that
is NSF approved.
7. Circulate the fluid within the domestic hot water
circuit by activating the pump switch.
8. The processing time must be chosen according to
the amount of scale deposits present in the heat
exchanger and however such time must always be
less than the maximum treatment time specified by
the manufacturer on the product data sheet.
9. At the end of the cleaning cycle, empty the pump
from chemical and recover the product in appropri-
ate containers for disposal.
10. Fill the pump with water and perform a washing
cycle in order to remove the chemical product still
present within the coils of the heat exchanger, recov-
ering the liquid in suitable containers for disposal.
11. Repeat the washing with water more than once if
necessary.
12. Disconnect the pipe fittings and hoses of the pump
for chemical cleaning from the cold water inlet (4)
and domestic hot water outlet (2).
13. Reconnect the piping to cold water inlet (4) and
domestic hot water outlet (2).
14. Open the valve of cold water inlet placed before the
boiler inlet.
15. Reconnect the unit to the electrical power supply
using the switch and/or the special cut-off devices
and turn it ON.
16. Check the correct operation of the boiler and func-
tionality of production of domestic hot water.
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
38 Maintenance (continued)
Figure 156
3 Gas inlet
5 System return
1
2
3
4
5
6
Combi 155 flat plate heat exchanger
removal for cleaning
1. For the Combi-155, release the pressure from system.
2. Release residual pressure in domestic hot water circuit in the boiler
by opening a hot water tap downstream of the boiler.
3. Loosen four (4) fittings of brazed plate heat exchanger to the
DHW Outlet (diverter valve - left side) and to the DHW Inlet
(right side), see Figure 160, these release the brazed plate heat
exchanger.
Pull out the flat plate heat exchanger pulling out and
up from the rear of the boiler. (The left jacket panel and blower
motor maybe removed to facilitate removal).
The gas valve does NOT need to be removed to
replace brazed plate heat exchanger.
4. Flat plate heat exchanger can be immersed in a chemical clean-
ing bath.
Combi 80/120 flat plate heat
exchanger removal for cleaning
5. Release the pressure of CH circuit by loosing the plastic
screw placed next to the CH return (6), see Figure 156.
Release Heat Exchanger pressure in the
boiler by loosing the plastic screw of the pump
placed next to heat exchanger return.
6. For the Combi Only 80/120, remove the two (2) screws
securing the plate heat exchanger to the diverter valve
and to the DHW inlet.
7. Pull out the flat plate heat exchanger pulling out and
up from the side or front of the boiler.
The gas valve does NOT need to be
removed to replace brazed plate heat
exchanger.
Figure 157
Figure 158
Figure 159
3 Gas inlet
5 System return
1
2
3
4
5
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
38 Maintenance (continued)
DHW Outlet
(diverter valve)
DHW Inlet
5. The treatment time must be chosen according to the
amount of scale deposits present in the exchanger and
however such time must always be less than the maxi-
mum treatment time specified by the manufacturer on
the product data sheet.
6. At the end of the cleaning cycle recover the chemical
product in appropriate containers for disposal.
7. Perform a washing bath with potable water in order
to remove the chemical product still present within
the coils of the heat exchanger, recovering the liquid in
suitable containers for disposal.
8. Repeat the washing with water more than once if neces-
sary.
9. The cleaned brazed plate heat exchanger can now be
installed.
e brazed plate heat exchanger must be
reinstalled in the same orientation.
e direction of arrows on heat exchanger.
Figure 160
Figure 161
Figure 162
Combi 80/120 flat plate heat exchanger
reinstalled
e four (4) new gaskets must be placed in the
DHW inlet and DHW return plate connections to
seal brazed plate heat exchanger.
1. Slide the brazed plate heat exchanger into rear of enclosure
(orientation arrows pointing down).
2. Lift brazed plate heat exchanger slightly up and align with DHW
connections, reinstall the two (2) Phillips head screws, tighten
securely. (Torque to 3.3 lb-ft. +/- 0.37 lb-ft.)
When re-installing components, make sure gas-
kets are in good condition and properly aligned
before tightening screws.
3. Be sure the pressure relief (plastic) screw has been made tight,
Location(6), see Figure 156.
Combi 155 flat plate heat exchanger reinstalled
1. For the Combi-155, slide the cleaned brazed plate heat exchanger
into rear of enclosure (orientation as shown in Figure160).
2. Lift brazed plate heat exchanger slightly up and align with DHW
connections, reinstall the fittings. e four (4) gaskets must be
placed in the DHW inlet and DHW return plate connections to
seal brazed plate heat exchanger.
1. Reassemble boiler components check seals for any leaks.
2. Open the valve of cold water inlet placed before the boiler inlet.
Run water until all air is purged from both the brazed plate heat
exchanger and the primary heat exchanger.
3. At initial fill and during boiler startup and testing, check system
thoroughly for any leaks. Repair all leaks before proceeding further.
Eliminate all system leaks. Continual fresh make up
water will reduce boiler life. Minerals can build up in the
heat exchanger, reducing heat transfer, overheating heat
exchanger, and causing heat exchanger failure.
4. Reconnect the unit to the electrical power supply using the switch
and/or the special cut-off devices and turn it ON.
5. Check the correct operation of the boiler and functionality of
production of domestic hot water.
DHW returns
(diverter valve)
DHW inlet
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 163
Boiler
model
Kit
640-000-022
10-15
640-000-024
640-000-023
640-000-025
640-000-082
640-000-133
REPLACEMENT PART
NUMBERS
WHEN OPERATING THE
BOILER ON PROPANE GAS
gas
.
Obtain parts only through
Weil-McLain
Replacement parts must be purchased through a local Weil-McLain
distributor. When ordering, specify boiler model and size and include
description and part number of replacement part. Results from us-
ing modified or other manufactured parts will not be covered by
warranty and may damage boiler or impair operation.
The boiler contains ceramic fiber
materials
. Use care when
handling these materials per instructions on page 86 of this manual.
Failure to comply could result in severe personal injury.
Reinstall jacket door
Inspect boiler jacket door front of cabinet and reinstall boiler jacket
door after start or servicing. The boiler jacket 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 jacket door
securely fastened could result in severe personal injury or death.
BEFORE SERVICING or MAKING
CONNECTIONS —
Label wires
Label all wires prior to disconnection when servic-
ing controls. Wiring errors can cause improper and
dangerous operation.
39 Replacement parts
Figure 164
Part number 550-100-325/0419
121
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
39 Replacement parts(continued)
Antifreeze, Sentinel X500. . . . . . . . .
Corrosion inhibitor, Sentinel X100 . . . .
Quick Test Kit, Sentinel X100 . . . . . . . . .
Cleaner, Sentinel X400 . . . . . . . . . .
592-900-029
592-900-002
592-900-005
592-900-003
Wall-mount kit (supplied with boiler ) —
wall mount bracket and hardware
640-000-044
Condensate trap kit (supplied with boiler) —
condensate trap assembly and exible line
640-000-073
Condensate neutralizer kit 383-500-631
Annual Maintenance Kit 80/120 640-000-114
Annual Maintenance Kit 155 640-000-112
Direct Exhaust Venting Kit
Includes: Cover plates, vent screens and
mounting hardware for 2” and 3” vent
sizes.
640-000-135
Sidewall separate pipes vent/air
termination kits (includes two cover plates)
Kit for 2” PVC vent and air pipes . . . . .
Kit for 3” PVC vent and air pipes . . . . .
Kit for 3” AL29-4C and air pipe. . . . . .
383-700-171
383-500-100
383-700-172
PVC concentric vent kit — horizontal
or vertical (includes components for
concentric assembly)
Kit for 2” PVC vent and air pipes . . . . .
Kit for 3” PVC vent and air pipes . . . . .
383-700-167
383-500-350
Bird screens (1 screen each)
For 2” PVC vent and air pipes . . . . . .
For 3” PVC vent and air pipes . . . . . .
383-500-106
383-500-105
M&G Simpson-Duravent PolyPro
SIDEWALL concentric vent/air kit
(color: white)
2” polypropylene pipe . . . . . . . . .
3” polypropylene pipe . . . . . . . . .
2PPS-HK
3PPS-HK
M&G Simpson-Duravent PolyPro VERTICAL
concentric vent/air kit color black (part number
shown) or terra cotta (add -TC sufx)
2” polypropylene pipe . . . . . . . . .
3” polypropylene pipe . . . . . . . . .
2PPS-VK
3PPS-VK
M&G Simpson-Duravent PolyPro SIDEWALL
separate air and vent pipes
2” polypropylene pipe . . . . . . . . .
3” polypropylene pipe . . . . . . . . .
2PPS-HTP
3PPS-HTP
Centrotherm INNOFLUE SIDEWALL concentric
vent/air kit
3” polypropylene pipe . . . . . . . . .
2” stainless steel/pp pipe . . . . . . .
3” stainless steel/pp pipe . . . . . . .
ICWT352
ICWS2413
ICWS3513
Centrotherm INNOFLUE VERTICAL concentric
vent/air kit
2” polypropylene pipe . . . . . . . . .
3” polypropylene pipe . . . . . . . . .
ICRT2439
ICRT3539
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
39 Replacement parts(continued)
Item Name Part Number
100
Jacket door 640-000-067
110
Jacket left side 640-000-065
120
Jacket right side 640-000-066
Figure 165
Part number 550-100-325/0419
123
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
39 Replacement parts(continued)
Figure 166
Item Name
Part Number
100 Control module assembly
640-000-003
110 Control module display cover
640-000-004
120 Pressure-temperature assembly
640-000-006
130
Wire harness assembly - Combi - 80/120
640-000-005
Wire harness assembly - Combi - 155
640-000-085
Wire harness assembly - Heating Only
640-000-053
Blower wiring adapter - Heating Only - 155
640-000-103
140
PCB only (includes Circuit board, Transformer, Relay,
Terminal strip, Fuse Holder & Fuse)
640-000-062
150 Thermostat relay box and cover
640-000-131
160 Board fuse 3.15 Amp (Package of 5) (not shown)
640-000-122
170 Thermostat board fuse 630ma (Package of 5) (not shown)
640-000-123
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
39 Replacement parts(continued)
Figure 167 AB- (Combi)
Item Name
Part Number
Model
AB-80
|
AB-120
100 Heat Exchanger
640-000-116
640-000-117
110 Flue Sensor Temperature 640-000-011
120 Blower Assembly 640-000-020
130 Blower Gasket 640-000-021
140 Ignitor 640-000-109
150 Central Heat Exchanger Insulation 640-000-010
160 Burner 640-000-012
170 Burner Gasket Set 640-000-013
180 Burner Cover 640-000-016
190 Inspection Glass 640-000-015
200 Kit - Natural Gas Conversion
640-000-022
640-000-023
210 Kit - Liqueed Petroleum (Propane) Gas Conversion
640-000-024
640-000-025
220 Gas Valve VK8205V 640-000-037
230 Circulator FX3-FP 640-000-017
240 Air Separator 640-000-018
250 Water Pressure Switch 640-000-019
260 Flow Meter 640-000-026
270 Water Filter 640-000-027
280 Valve 3- Way 640-000-028
290 Motor 3- Way Valve 640-000-029
300 N/R Valve Fitting 640-000-030
310 DHW R. Plate Connection 640-000-031
320
Plate Exchanger 16P. 640-000-032
Plate Exchanger 20P. 640-000-033
330 CH Temperature Probe DP 640-000-034
340 CH Temperature Probe US 640-000-035
350 DHW Temperature Probe US 640-000-036
360 Relief Valve 3/4” 640-000-038
370 NPT Adapters 640-000-039
380 Gasket Set 640-000-007
390 Condensate Drain Trap 640-000-068
400 Vent Adapters (2 adapters in kit) 640-000-107
410 Gaskets - Vent Adapter (2 gaskets in kit) 640-000-108
420 Wall Mount Bracket 640-000-044
430 Outdoor Temperature Sensor 640-000-043
440 CH - Flow Pipe
640-000-124
640-000-125
450 CH - Return Pipe 640-000-126
460 Bypass Pipe 640-000-049
470 Flow Meter Pipe 640-000-050
480 DHW Outlet Pipe 640-000-051
490 Gas Pipe
640-000-072
640-000-130
500 Flow Regulator (4 GPM) (Restrictor) 640-000-110
510 Gasket - Heat Exchanger Vent 640-000-136
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
39 Replacement parts(continued)
Figure 168 AB- (Combicontinued
100
390
120
WM-155
350
320
210
200
300
150
170
160
220
310
290
370
270
280
230
180
260
240
140
190
130
330
250
380
470
360
490
460
430
420
480
110
500
410
400
440
340
450
510
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
39 Replacement parts(continued)
Figure 169 AB- (Heating Only)
Item Name
Part Number
Model
AB-80 AB-120
100 Heat Exchanger
640-000-116
640-000-117
110 Flue Sensor Temperature 640-000-011
120 Blower Assembly 640-000-020
130 Blower Gasket 640-000-021
140 Ignitor 640-000-109
150 Central Heat Exchanger Insulation 640-000-010
160 Burner 640-000-012
170 Burner Gasket Set 640-000-013
180 Burner Cover 640-000-016
190 Inspection Glass 640-000-015
200 Kit - Natural Gas Conversion
640-000-022
640-000-023
210 Kit - Liqueed Petroleum (Propane) Gas Conversion
640-000-024
640-000-025
220 Gas Valve VK8205V 640-000-037
230 Water Pressure Switch 640-000-019
240 CH Temperature Probe DP 640-000-034
250 CH Temperature Probe US 640-000-035
260 Relief Valve 3/4” 640-000-038
270 NPT Adapters 640-000-039
280 Gasket Set 640-000-055
290 Condensate Drain Trap 640-000-073
300 Vent Adapters (2 adapters in kit) 640-000-107
310 Gaskets - Vent Adapter (2 gaskets in kit) 640-000-108
320 Wall Mount Bracket 640-000-044
330 Outdoor Temperature Sensor 640-000-043
340 CH - Flow Pipe
640-000-127
640-000-128
350 CH - Return Pipe 640-000-129
360 Gas Pipe
640-000-072
640-000-130
370 Gasket - Heat Exchanger Vent 640-000-136
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
39 Replacement parts(continued)
Figure 170 AB-(Heating Onlycontinued
100
290
WM-156
110
120
210
200
150
170
160
220
180
140
190
130
340
360
250
330
320
310
300
230
350
270
280
260
240
110
370
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 171 AB-155C Combi
39 Replacement parts
(continued)
Item Name
Part Number
100 Heat Exchanger 640-000-118
110 Flue Sensor Temperature 640-000-011
120 Blower 640-000-081
130 Blower Gasket 640-000-021
140 Ignitor 640-000-109
150 Central Heat Exchanger Insulation 640-000-010
160 Burner 640-000-012
170
Burner Gasket Set
Burner Gasket Premix 1 Piece
Burner Cover Gasket 1 piece
640-000-013
180 Burner Cover 640-000-016
190 Inspection Glass 640-000-015
200 Kit - Natural Gas Conversion 640-000-082
210 Kit - Liqueed Petroleum (Propane) Gas Conversion 640-000-133
220 Gas Valve VK8205V 640-000-037
230 Circulator UPS2578 640-000-086
240 Air Separator 640-000-087
250 Water Pressure Switch 640-000-019
260 DHW Inlet Pipe 640-000-098
270 Water Filter 640-000-027
280 Valve 3-Way 640-000-088
285 Valve 3-Way Motor 640-000-134
290 3-Way Valve-PHE Pipe 640-000-095
300 N/R Valve Fitting 640-000-030
310 Flow Meter 640-000-084
320 Plate Exchanger PFH30 640-000-089
330 CH Temperature Probe DP 640-000-034
340 CH Temperature Probe US 640-000-035
350 DHW Temperature Probe US 640-000-036
360 Relief Valve 3/4” 640-000-038
370 NPT Adapters 640-000-090
380
Gasket Set
O-Ring 167 ID 63.5mm X 3.53mm NBR 5 pcs
O-Ring 21.89mm X 2.62mm EPDM 5 pcs
O-Ring 23.81mm X 2.62mm EPDM 5 pcs
Gasket OD 12.5mm x ID 8.5mm Silic. 10 pcs
Gasket OD 24 X ID17mm X 2mm 10 pcs
Gasket OD18.5 X ID12.5mm X 2mm 10 pcs
Gasket OD14.5 X ID8.5mm X 2mm 10 pcs
Gasket OD45 X ID33.5mmX2mm EPDM 10 pcs
640-000-101
390 Condensate Drain Trap 640-000-073
400 Vent Adapters (2 adapters in kit) 640-000-107
410 Gaskets - Vent Adapter (2 gaskets in kit) 640-000-108
420 Wall Mount Bracket 640-000-044
430 Outdoor Temperature Sensor 640-000-043
440 Heat Exchanger Flow Pipe 640-000-091
450 CH - Return Pipe 640-000-097
460 Bypass Pipe 640-000-093
470 Flow Meter PHE Pipe 640-000-099
480 DHW Outlet Pipe 640-000-096
490 Gas Pipe 640-000-100
500 Heat Exchanger Return pipe 640-000-092
510 CH Flow Pipe 640-000-094
520 Gasket - Heat Exchanger Vent 640-000-136
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 172 AB-155C Combi
39 Replacement parts
(continued)
100
390
W-T-158
510
120
210
200
300
150
410
170
160
220
500
350
370
270
290
230
180
260
240
140
190
130
330
380
470
360
440
490
450
340
460
430
420
480
110
310
400
280
320
330
250
520
285
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 173 AB-155H Heating Only
39 Replacement parts
(continued)
Item Name
Part Number
100 Heat Exchanger 640-000-118
110 Flue Sensor Temperature 640-000-011
120 Blower Assembly 640-000-081
130 Blower Gasket 640-000-021
140 Ignitor 640-000-109
150 Central Heat Exchanger Insulation 640-000-010
160 Burner 640-000-012
170 Burner Gasket Set 640-000-013
180 Burner Cover 640-000-016
190 Inspection Glass 640-000-015
200 Kit - Natural Gas Conversion 640-000-082
210 Kit - Liqueed Petroleum (Propane) Gas Conversion 640-000-133
220 Gas Valve VK8205V 640-000-037
230 Water Pressure Switch 640-000-019
240 CH Temperature Probe DP 640-000-034
250 CH Temperature Probe US 640-000-035
260 Relief Valve 3/4” 640-000-038
270 NPT Adapters 640-000-104
280 Gasket Set 640-000-102
290 Condensate Drain Trap 640-000-073
300 Vent Adapters (2 adapters in kit) 640-000-107
310 Gaskets - Vent Adapter (2 gaskets in kit) 640-000-108
320 Wall Mount Bracket 640-000-044
330 Outdoor Temperature Sensor 640-000-043
340 CH - Flow Pipe 640-000-106
350 CH - Return Pipe 640-000-105
360 Gas Pipe 640-000-100
370 Gasket - Heat Exchanger Vent 640-000-136
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 174 AB-155H Heating Only
39 Replacement parts
(continued)
100
290
W-T
-159
110
120
150
170
160
220
270
180
140
190
130
210
200
240
230
280
260
340
360
350
250
330
320
310
300
370
Part number 550-100-325/0419
132
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 175 AB-80/120
40 Connections, Dimensions and Engineering Data
Part number 550-100-325/0419
133
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
40 Connections, Dimensions and Engineering Data (continued)
Figure 176 AB-155
Part number 550-100-325/0419
134
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Figure 177
Boiler
Model
weight
weight
Water
required
AB-80C Combi
77 86 1.110 2” or 3” 15.0
AB-120C Combi
80 91 1.306 2” or 3” 15.0
AB-155C Combi
87 98 1.331 2” or 3” 15.0
AB-80H Heating Only
64 73 1.030 2” or 3” 15.0
AB-120H Heating Only
67 77 1.226 2” or 3” 15.0
AB-155H Heating Only
67 77 1.231 2” or 3” 15.0
1
Total amp requirement includes up to one Circulator, Low Water Cutoff, 3-Way Valve motor not to exceed 3.0 amps total.
2
Operating weight is the total weight of the boiler, including water.
3
Vent pipes can be either 2” or 3” pipe.
All of the boilers will automatically de-rate as vent/air pipe length increases, due to the pressure loss through the piping.
See Figure 178, page 135 for details.
All installations require a separate vent pipe and termination for each boiler. .
Install and terminate vents as described in vent/air installation instructions in this manual.
Combustion air piping can be individually piped. See venting section in this manual.
40 Connections, Dimensions and Engineering data
(continued)
Part number 550-100-325/0419
135
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
41 Ratings
Notes
1 As an Energy Star Partner, Weil-McLain
has determined that boilers meet the
Energy Star guidelines for energy ef-
ficiency.
NOTE: Adjusting boiler firing rate will
affect AFUE rating.
2 Based on standard test procedures
prescribed by the United States Depart-
ment of Energy.
NOTE that only Heating Capacity and
AFUE are certified by AHRI. AFUE is
also know as Annual Fuel Utilization
Efficiency or Seasonal Efficiency.
3 Net ratings are based on net installed
radiation of sufficient quantity for the
requirements of the building and noth-
ing need be added for normal piping
and pickup. Ratings are based on a pip-
ing and pickup allowance of 1.15. An
additional allowance should be made
for unusual piping and pickup loads.
4 Boilers designed to be direct-vented.
Boilers require special venting. Use
only the vent materials and methods
specified in this manual.
Boilers may be direct exhaust vented.
Vent pipes can be either 2” or 3”.
All vent and air pipe elbows must
be sweep elbows, NOT short-radius
elbows.
5 Ratings shown are for sea level applica-
tions only. For altitudes from sea level
to 4,500 feet above sea level, please refer
to page 70.
6 All of the boilers will automatically
de-rate as vent/air pipe length increases,
due to the pressure loss through the
piping. For vent/air pipe lengths less
than the maximum, the derate equals
the value above times vent length ÷ 100.
7 CSA - Low Lead Content only applies
to the Combi boiler models.
THE OUTDOOR SENSOR
IMPORTANT
In accordance with
, this boiler is equipped
with a feature that saves energy by re-
ducing the boiler water temperature as
the heating load decreases. This feature
is equipped with an override which is
provided primarily to permit the use of
an external energy management system
that serves the same function.
An external energy management system is installed that reduces the boiler water tem-
perature as the heating load decreases.
This boiler is not used for any space heating.
This boiler is part of a modular or multiple boiler system having a total input of 300,000
BTU/hr or greater.
This boiler is equipped with a tankless coil (not applicable to Combi).
AHRI Certified Ratings
Boiler
Model
Input
Heating
Capacity
Seasonal
Efficiency
Net
Water
Rating
% Input derate vs vent length
(Values shown are at MAX vent/air pipe length —
See Note 6)
Vent/
Comb. Air
Connection
Diameter
(Note 5)
(Note 2)
(Note 1)
(Note 3)
(Note 4)
AB-80
75 65 12 12 3" PVC/PP/SS
AB-120
112
3” PVC/PP/SS
AB-155
144
125 3” PVC/PP/SS
Figure 178
See (Note 7)
Part number 550-100-325/0419
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Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Boiler Start-Up Data
Boiler Model / Series AB-__________ / Series ____
Date installed ________________ CO
2
: High re ______% Low re ______%
Part Number ____________ FUEL: Natural ____ LP ____ Btu Input ___________________ CO : High re ____ ppm Low re ____ ppm
Natural gas input rate measured HIGH________ CFH / LOW________ CFH
42 Installation and Service Certicate
Boiler model _______________________________________________________________ Series ____________
Consumer Protection (CP) Number _______________________________________ Date installed ______________________________
Measured Btuh input ____________
Installer _______________________ ______________________________ ____________________________
_____________________________________
Installation instructions have been followed.
Checkout sequence has been performed.
Above information is certified to be correct.
Information received and left with owner/maintenance person.
