Weil-McLain 640-000-133 User Guide

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Page 1

Aqua Balance

80/120/155

Series 2

Wall Mount Gas-Fired

Condensing Boilers – Combi and Heating Only Models

Boiler Manual

• Installation

• Startup

Quick Start Guide

Pages 69 & 70

• Maintenance

• Parts

* CSA - Low Lead Content only applies to the Combi model

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.

Part number 550-100-325/0718

Page 2

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

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 Concentric termination, typical (sidewall or vertical) . . 29

15 Vent and air piping and boiler connections . . . . . 30

16 Install water piping . . . . . . . . . . . . . . . . . . 33

Domestic Water Piping – Combi Boiler . . . . . . . . . 33

17 Primary/Secondary System Piping . . . . . . . . . . . . 35

System water piping methods . . . . . . . . . . . . . . 35

Expansion Tank Location . . . . . . . . . . . . . . . . 35

Diaphragm- or bladder-type tank: . . . . . . . . . . . . 35

Closed-type expansion tank: . . . . . . . . . . . . . . 37

Install relief valve . . . . . . . . . . . . . . . . . . . . . 38

Zone Valve zoning – primary/secondary . . . . . . . . 39

Circulator zoning – primary/secondary . . . . . . . . . 40

Circulator zoning – Multiple temperature zones with

primary/secondary . . . . . . . . . . . . . . . . . . . . 41

18 Multiple boiler installations . . . . . . . . . . . . . . 42

19 Install condensate line . . . . . . . . . . . . . . . . 45

20 Gas piping . . . . . . . . . . . . . . . . . . . . . . . 46

21 Field wiring. . . . . . . . . . . . . . . . . . . . . . . 48

22 Wiring diagram — AB-80/120C Co mbi Lad der . . . . 50

22 Wiring diagram — AB-80/120C Combi Schematic . . . 51

23 Wiring diagram — AB-80/120H Heating Only Ladder . 52

23 Wiring diagram — AB-80/120H Heating Only Schematic . 53

24 Wiring diagram — AB-155C Combi Ladder . . . . . . . . . 54

24 Wiring diagram — AB-155C Combi Schematic . . . . . . . 55

25 Wiring diagram — AB-155H Heating Only Ladder . . . . . 56

25 Wiring diagram — AB-155H Heating Only Schematic . . . 57

26 Controls and operation . . . . . . . . . . . . . . . . 58

27 DHW Settings (Combi Only) . . . . . . . . . . . . . 63

28 Standard Altitude . . . . . . . . . . . . . . . . . . . 65

28 High Altitude . . . . . . . . . . . . . . . . . . . . . . 66

29 Startup — Quick Start Guide using default settings 69

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32 Annual startup and general maintenance . . . . . . 81

33 Annual startup . . . . . . . . . . . . . . . . . . . . . 82

34 Troubleshooting . . . . . . . . . . . . . . . . . . . . 85

35 Maintenance . . . . . . . . . . . . . . . . . . . . . 107

36 Replacement parts . . . . . . . . . . . . . . . . . 116

37 Connections, Dimensions and Engineering Data . 128

38 Ratings . . . . . . . . . . . . . . . . . . . . . . . . 131

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Hazard deﬁnitions

Hazards that will cause severe personal injury, death

or substantial property damage.

Hazards that can cause severe personal injury, death

or substantial property damage.

INSTALLER — Read all instructions before

installing. Read page 3 ﬁrst. Follow all instructions in proper order to prevent personal injury or death.

• 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.

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.

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 heating installer/service technician.

• Please see the User’s Information Manual for your reference.

• Have the boiler serviced by a qualiﬁed service technician, at least annually.

Part number 550-100-325/0718

Page 3

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

1 Please read before proceeding

Installer— 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.

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 operate 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 substantial property damage. See the instructions at right.

Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.

When servicing boiler —

• 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 82.

Boiler operation —

• 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 disconnect electrical supply to pump. Instead, shut off the gas supply at a location external to the appliance.

Combustion air —

• DO NOT install combustion air intake where there is a risk of combustion air contamination.

Carbon monoxide detector —

• A carbon monoxide detector that is wired on the same electrical circuit as the boiler is strongly recommended.

SURGE PROTECTOR —

• 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.

Boiler water —

• 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.

TREATMENT MAY BE NECESSARY

page 71 for details.

• Thoroughly ﬂush the system ( 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

ADDITIONAL CHEMICAL

Write in the CP number in the space provided on

the Installation certiﬁcate on page 132 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.

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, WeilMcLain equipment contaminated with saltwater or polluted water will no longer be covered under warranty and should be replaced.

Electrical Damage — If any electrical component 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.

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.

Freeze protection ﬂuids —

• NEVER use automotive or standard glycol antifreeze. Use only freeze-protec-

. See

BEFORE

tion ﬂuids made for hydronic systems. Follow all guidelines given by the antifreeze 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 117 for details.

Frozen Water Damage

Hazard

Residences or buildings that are unattended in severely cold weather, boiler system components failures, power outages, 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 action. Consult with your boiler contractor or a home security agency.

Commonwealth of

Massachusetts

Part number 550-100-325/0718

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.

Page 4

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

2 Prepare boiler location

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 installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

Certiﬁcation

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.

Before locating the boiler:

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

3. Check for nearby connection to:

• System water piping • Venting connections

• Gas supply piping • Electrical power

• 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 71.

• 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.

only.

Residential garage installation

Precautions

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 clearances, 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.

Boiler in same space with other gas or oil-ﬁred appliances

1. Follow the sizing requirements shown in Figure 23, page 20.

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 particularly 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.

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.

Part number 550-100-325/0718

Page 5

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

2 Prepare boiler location continued

Clearances

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

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 removing the casing and for normal maintenance operations. The minimum measurements to be respected are given in Figure 1.

Figure 1 REQUIRED minimum clearances

all dimensions are in inches)

(

1/2” from combustible materials.

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.

Minimum

required

for

Combustion

Recommended

for

Service

A Minimum 1.00”

B Minimum 12.00”

C Minimum 12.00”

D Minimum 12.00”

A Minimum 36.00”

B Minimum 36.00”

C Minimum 24.00”

D Minimum 36.00”

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.

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 illustration, 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

Part number 550-100-325/0718

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

2 Prepare boiler location

Air contamination

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 before installing boiler. If any of these contaminants are found:

• remove contaminants permanently. — OR —

• isolate boiler and provide outside combustion air. See national, provincial or local codes for further information.

Table 1

Products to avoid

Spray cans containing chloro/ﬂuorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Excessive dust and dirt

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture reﬁnishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Corrosive contaminants and likely locations

continued

You must pipe combustion air to the boiler

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 contaminants.

Contaminated combustion air will damage the

boiler, resulting in possible severe personal injury, death or substantial property damage.

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 handling. 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 installation, 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.

Leave the boiler resting on the styrofoam protective base

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.

Part number 550-100-325/0718

Page 7

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

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 wall must be vertically plumb and capable of carrying the weight of the boiler and any attached piping components

The operating weight for wall-mountable boiler is:

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.

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.

AB-80: 70 pounds AB-120: 80 pounds AB-155

Failure to comply with above and the procedure given below could result in severe personal injury, death or substantial property damage.

Verify that the studs are suitable for carrying a wallmounted load. Some metal studs are not designed

for this purpose.

: 87 pounds

Install the wall-mount bracket

1. Locate the studs — must be on 16-inch centers. See previous 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.

Figure 3 Wall mount bracket

Lag bolt mounting locations

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).

Figure 4 Wall mount bracket tabs bend over boiler to

secure boiler in place

Bend tabs after installation

Install rubber bumpers to back of boiler

1. Remove supplied rubber bumpers from plastic bag and measure 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 2 Addition of rubber bumper for wall mounting

14 inches-center to center of rubber

2 inches

Part number 550-100-325/0718

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.

Page 8

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

3 Prepare boiler continued

Hydrostatic pressure test

DO NOT install a relief valve with a pres-

sure higher than 30 PSIG. This is the maximum allowable relief valve setting for the boiler. Failure to comply could prevent the relief valve from operating as needed, resulting in possibility of severe personal injury, death or substantial property damage.

Use two wrenches when tightening any pipe

connection to the boiler

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.

. Failure to prevent the

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.

DO NOT install the relief valve until after the

hydrostatic test

plug in the relief valve location as directed in these instructions. The plug must be removed after the test.

Connect the relief valve ONLY on the BOILER

RETURN OUTLET, NOT

nect the relief valve only as shown in this manual. Ensure relief valve is located above heat exchanger.

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.

. Temporarily install a ¾” pipe

the boiler supply. Con-

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, resulting 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.

Leaks must be repaired at once. 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.

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,

-1/4”NPT on the 155 boiler).

b. Two close nipples - (1”NPT on the 80/120 boilers,

-1/4”NPT on the 155 boiler).

c. ¾” NPT pipe plug. d. Pressure/temperature gauge. e. ¾” NPT boiler drain valve.

TEMPORARILY 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.

Drain and remove ﬁttings

1. Disconnect ﬁll water hose from water source.

2. Drain boiler through drain valve

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 following WARNING.

Remove plug from relief valve street elbow. Install

the relief valve in the ¾” street. See page 38 to install relief valve discharge piping. Failure to install the boiler relief valve could result in severe personal injury, death or substantial property damage.

(item 10).

Part number 550-100-325/0718

Page 9

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

3 Prepare boiler continued

Figure 5 Install pipe ﬁttings for relief valve and pressure/

temperature gauge —

valve until AFTER hydrostatic testing

legend below) (Combi boiler shown)

DO NOT mount relief

(see

Figure 6 Install piping components required for

hydrostatic test (

see legend below)

Boiler Return

(inlet)

Boiler Supply

(outlet)

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.

3. Boiler relief valve, shipped loose with boiler — DO NOT mount relief valve until AFTER hydrostatic testing. 3a. TEMPORARILY ONLY — 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,

5a. Reducing tee, 1” x 1” x ¼” on

5b. Tee, NPT, 1” x 1” x ¾” on

6. Nipple, NPT, 1” x close on

7. Nipple, NPT, 1” x close on

8. Isolation valve on supply connection,

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.

(ﬁeld supplied by installer)

(ﬁeld supplied) by installer, (Optional – can use boiler gauge).

the 80/120 boilers, NPT, 1-1/4” x 1-1/4” x ¼” on the 155 boiler (ﬁeld supplied) by installer .

the 80/120 boilers, 1-1/4” x 1-1/4” x ¾” on the 155 boiler (ﬁeld supplied) by installer.

the 80/120 boilers, NPT, 1-1/4” x close on the 155 boiler (ﬁeld supplied) by installer.

(ﬁeld supplied) by installer (1” NPT on the 80/120 boilers, 1-1/4” NPT on the 155 boiler).

Part number 550-100-325/0718

Page 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

ALL boilers must be converted for pro-

pane operation.

Converting an existing natural gas-ﬁred

boiler for propane —

For a boiler already installed, you must turn off gas supply, turn off power and allow boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance and start up the boiler following instructions beginning on page 75 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.

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.

Figure 7 Natural and Liqueﬁed Petroleum (Propane) gas

conversion kits

Natural to LP Conversion Kit Part Numbers

AB-80 LP P/N 640-000-024 NG to Propane Gas Conv. Kit contents:

Venturi - 10.6 GPL Gasket Nitrile Rubber 167 x 63.5X3.53 NBR Label Gas Conversion Label AB-80 Rating Plate Conversion LP Instructions Conversion Nat to LP Gas

AB-120 LP P/N 640-000-025 NG to Propane Gas Conv. Kit contents:

Venturi - 12.6 GPL Gasket Nitrile Rubber 167 x 63.5X3.53 NBR Label Gas Conversion Label AB-120 Rating Plate Conversion LP Instructions Conversion Nat to LP Gas

AB-155 LP P/N 640-000-133 NG to Propane Gas Conv. Kit contents:

Venturi Gasket Nitrile Rubber 167 x 63.5X3.53 NBR Label Gas Conversion Label AB-155 Rating Plate Conversion LP Instructions Conversion Nat to LP Gas

1 1 1 1 1

LP to Natural Conversion Kit Part Numbers

AB-80 NG P/N 640-000-022 LP to Natural Gas Conv. Kit contents:

Venturi - Natural Gas 10.6m Gasket Nitrile Rubber 167 x 63.5X3.53 NBR Label Gas Conversion Label AB-80 Rating Plate Conversion NG Instructions Conversion LP to Natural Gas

AB-120 NG P/N 640-000-023 LP to Natural Gas Conv. Kit contents:

Venturi - Natural Gas 12.6m Gasket Nitrile Rubber 167 x 63.5X3.53 NBR Label Gas Conversion

Label AB-120 Rating Plate Conversion NG 1 Instructions Conversion LP to Natural Gas 1

AB-155 NG P/N 640-000-082 LP to Natural Gas Conv. Kit contents:

Venturi - Natural Gas 16.6m Gasket Nitrile Rubber 167 x 63.5X3.53 NBR Label Gas Conversion

Label AB-155 Rating Plate Conversion NG 1 Instructions Conversion LP to Natural Gas 1

1 1 1 1 1

1 1 1

Boiler Model Kit Part Number

AB-80 NG

AB-80 LP

AB-120 NG

AB-120 LP

AB-155 NG

AB-155 LP

640-000-022

640-000-024

640-000-023

640-000-025

640-000-082

640-000-133

• 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 disconnecting 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.

Part number 550-100-325/0718

Page 11

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

4 Converting boiler to propane continued

Pipe sizing for propane gas

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.

Natural and Propane supply pressure 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.

Figure 9 Liqueﬁed Petroleum (propane) gas venturi label

information

Front panel removal

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.

Figure 10 Removing front panel

Installing venturi —

If boiler is already installed — 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.

Verify proper venturi for gas type

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.

Figure 8 Natural gas venturi label information

Figure 11

Moving control module for access to gas valve

Part number 550-100-325/0718

LEGEND for Figure 12

1 Control module 2 Gas valve

Page 12

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

4 Converting boiler to propane continued

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 Loosen ﬁttings of gas pipe (Control module

removed for clarity)

LEGEND for Figures 13, 14, 15. 16 and 17

1 Control panel (page 13) 2 Gas valve (page 14) 3 Gas pipe 4 Washer

Figure 14

Insure “O” ring is in place

5 Hex head screws 6 Gas valve venturi 7 “O” Ring 8 Blower

Figure 13 Gas valve venturi replacement for propane

conversion

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, Figure 12, page 12) check the seal of the connections. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

Figure 15

New

LP venturi installed to blower

Part number 550-100-325/0718

Page 13

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

4 Converting boiler to propane continued

Figure 16 Gas pipe re-assembled to LP venturi ﬁtting

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 76, page 58

for 10 seconds: the display shows “b01“ ﬂashing.

c. Press the DHW buttons Figure 76, page 58 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 124, page 97. 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 124, page 97: j. Press the DHW buttons details 1 and 2 -

Figure 76, page 58 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 78.

10. Test ignition system safety shutoff, see page 79.

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.

Part number 550-100-325/0718

12. Using a combustion analyzer insert probe into the flue test point, check that the CO the boiler operating at max. and min. ﬁring rate, matches that given in the technical data Figure 103, page 78 or Fig-

ure 106, page 79, for the corresponding type of gas.

DO NOT ATTEMPT TO MEASURE VALVE

OUTLET PRESSURE. The valve could be damaged by manometer fluid contamination. Failure to comply could result in severe personal injury, death or substantial property damage.

content in the exhaust, with

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 77, 78 & 79.

Check the correct ignition sequence of the boiler after the conversion, as in page 86.

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 information required on label (provided in kit) and attaching installer conversion label next to the boiler rating label.

Figure 17 Installer conversion label

The jacket door must be in place during

operation.

the jacket door removed except for inspection and testing as directed in this manual.

DO NOT operate the boiler with

Page 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:

Pipe sizing for 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 (

B149.1 and B149.2 for Canadian installations).

Natural gas supply pressure

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.

Natural Gas and Propane Installation Code, CSA

Figure 18 Pipe capacity for 0.60 speciﬁc gravity natural

gas; pipe length is in equivalent feet

Gas pipe total

length,

feet

100

150

Capacity

Cubic feet per hour, natural gas, 0.60 speciﬁc gravity

Gas pressure 13” w.c. or less Pressure drop 0.3 inches w.c.

½” ¾” 1” 1¼” 1½” 2” 2½”

132 278 520 1050 1600 3050 4800

92 190 350 730 1100 2100 3300

73 152 285 590 890 1650 2700

NA 130 245 500 760 1450 2300

NA 115 215 440 670 1270 2000

NA 105 175 360 545 1020 1650

NA 96 150 305 460 870 1400

NA 90 120 250 380 710 1130

Figure 19 Equivalent lengths of straight pipe for typical

gas line ﬁttings

Equivalent length, feet

Pipe size

(inches)

90° Elbow Tee

short

radius

long

radius

line

ÀRZ

branch

ÀRZ

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.

Pipe sizing for propane gas

1. Contact gas supplier to size pipes, tanks and 100% lockup gas pressure regulator.

Propane supply pressure

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.

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 550-100-325/0718

Page 15

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

6 Venting/air piping — general

mon venting system. Turn on any exhaust fans, such as 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 venting 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 substantial property damage.

Existing common vent systems may be too large

for the appliances remaining connected after the existing boiler is removed.

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.

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

The boiler cannot be common vented with any other appliance

. 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.

Vent system veriﬁcation

Perform the test sequence below for each appliance remaining on the original common vent system. Operate each appliance individually, 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-

Part number 550-100-325/0718

Page 16

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

6 Venting/air piping — general continued

Figure 20 Venting and air piping — DIRECT VENT ONLY — OPTIONS and PIPING LIMITS

The table below lists the acceptable vent/air pipe terminations described in this manual. Follow all instructions provided to install the vent/air system. NOT SHOWN below, but also approved, are the polypropylene piping and terminations listed in For these applications, use ONLY the manufacturers’ parts listed and follow all instructions provided by the pipe manufacturer.

Figure 21, page 17

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)

See Figure 21, page 17 for material speciﬁcations | See Figure 160, page 117 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 —

SIDEWALL termination VERTICAL termination

Separate pipes

[Note 1]

PVC or PP Concentric

[Note 1]

see rating data on Figure 174, page 131 for derate amounts.

Separate pipes

[Note 1]

AquaBalance® Model

See page 21 See page 23 See page 25 See page 27

Size,

inches

Materials

Fig. 21, page 19

Size,

inches

Materials

Fig. 21, page 19

Size,

inches

Materials

Fig. 21, page 19

PVC or PP Concentric

[Note 1]

Size,

inches

Fig. 21, page 19

USE

SWEEP

ELBOWS

ONLY

Materials

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

120

155 3

All elbows in vent and air piping must be sweep elbows ONLY. DO NOT use short-radius elbows.

Equivalent feet for elbows (USE SWEEP ELBOWS ONLY) —

• 7 feet per for each additional 90° sweep elbow or 45° elbow —

ABS may be used for intake air. Material abbreviations: PP = polypropylene, SS = AL29-4C stainless steel.

Note 1:

If using stainless pipe, provide adapters for terminations, if required.

IPEX 3” PVC concentric vent kits can be used with standard PVC pipe, ﬁttings and cement (ANSI/ASTM D1785) except if ULC S636 compliance is required. For ULC S636 compliance, all pipe, ﬁttings and cement must be IPEX System 636. If using IPEX kits, use only IPEX product code 196006 for 3” venting.

Contact Weil-McLain for ordering information and availability of Weil-McLain venting kits.

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

deduct from max equivalent length of piping (does not apply to termination ﬁttings).

If piping contains more than 1 elbow in air or vent piping, other than termination ﬁttings.

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV CPVC,

PP, SS

Part number 550-100-325/0718

Page 17

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

6 Venting/air piping — general continued

Figure 21 Vent and air piping materials — Use only the materials listed below, ensuring that all materials meet local

codes (see Figure 160, page 117 for part/kit numbers).

Item Material

Plastic piping materials Vent or air piping Vent piping Air piping

Vent or air pipe

¿WWLQJV

PVC & ABS pipe cement & primer

Polypropylene

YHQWSLSH¿WWLQJV

terminations and

cement

Vent pipe

PVC-DWV schedule 40 (Note 1) ANSI/ASTM D2665 NA

CPVC schedule 40

Simpson-Duravent — Obtain all materials from M&G Simpson-Duravent

Centrotherm Eco Systems InnoFlue® Singlewall — Obtain all materials from Centrotherm

Heat Fab, Inc. — Saf-T-Vent

AL29-4C

stainless

steel

Metal-Fab, Inc. — CORR/GUARD

Standards for installations in:

United States Canada (Note 2)

PVC schedule 40 ANSI/ASTM D1785 ULC S636

(Note 1) ANSI/ASTM F441 ULC S636

PVC ANSI/ASTM D2564/F656 ULC S636

CPVC (Note 1) ANSI/ASTM F493 ULC S636

See manufacturer’s literature

for detailed information

MUST USE LOCKING

COLLAR ON EVERY JOINT

AL29-4C stainless steel piping materials

Z-Flex, Inc. — Z-Vent II

Dura-Vent — FasNSeal®

Certiﬁed for direct vent appliance venting

ULC S636

PVC, PVC-DWV,

CPVC or

polypropylene

Use only cement and primer suitable for piping material used

PVC, PVC-DWV,

CPVC or

polypropylene

Stainless steel bird screens, 2” or 3” (purchase separately) — see Figure 160, page 117 for part numbers

Note 1: Weil-McLain concentric vent kits are made from PVC

Note 2: System 636 PVC concentric terminations utilize PVC

pipe and ﬁttings.

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.

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.

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

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 approved adapter is required.

If using 2” piping (AB-80/120 only), where ap-

proved for the application, provide adapters for a 3” pipe material (mentioned above) connections and at the terminations, if required.

. No additional screening is required.]

Part number 550-100-325/0718

Page 18

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

7 Commonwealth of Massachusetts installations

Commonwealth of Massachusetts — When the boiler is installed within the Commonwealth of Massachusetts,

the boiler must be installed by a licensed plumber or gas ﬁtter. Read and comply with the instructions below.

(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:

INSTALLATION OF CARBON MONOXIDE DETEC-

TORS

. At the time of installation of the side wall horizontal 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 additional 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 installation, 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.

APPROVED CARBON MONOXIDE DETECTORS. Each

2. carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certiﬁed.

SIGNAGE. A metal or plastic identiﬁcation plate shall

3. be permanently mounted to the exterior of the building 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 BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”

INSPECTION. The state or local gas inspector of the

4. 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)

EXEMPTIONS: 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 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)

MANUFACTURER REQUIREMENTS — GAS EQUIPMENT VENTING SYSTEM PROVIDED

Product Approved side wall horizontally vented gas equipment 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)

MANUFACTURER REQUIREMENTS — GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED

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 following 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.

. When the manufacturer of

. When the manufac-

Part number 550-100-325/0718

Page 19

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

8 Vent termination requirements

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

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Part number 550-100-325/0718

Page 20

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

9 Boiler room air openings

Figure 23 Combustion and ventilation air openings for Direct Vent installations, also follow the National Fuel Gas Code,

ANSI Z223.1/NFPA 54 - latest edition, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1 or applicable provisions of the local building codes.

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 exception below for large spaces.

Boiler

WITH other

appliances in room

TWO openings, each at least:

1 square inch per 1,000 Btuh

of all other appliances in the room

(Unless speciﬁed otherwise by

appliance manufacturer)

TWO openings, each at least:

1 square inch per 4,000 Btuh

of all other appliances in the room

— OR —

ONE opening **, each at least:

1 square inch per 3,000 Btuh

of all other appliances in the room

(Unless speciﬁed otherwise by

appliance manufacturer)

TWO openings, each at least:

1 square inch per 4,000 Btuh

of all other appliances in the room

— OR —

ONE opening **, each at least:

1 square inch per 3,000 Btuh

of all other appliances in the room

(Unless speciﬁed otherwise by

appliance manufacturer)

Boiler

WITHOUT other

appliances in room

NO 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.

** NOTICE: Requirements for using the SINGLE air opening option.

SPECIAL EXCEPTION FOR LARGE SPACES (Boiler WITH other appliances in room only):

TWO openings, each at least:

1 square inch per 2,000 Btuh

of all other appliances in the room

ONE opening **, each at least:

1 square inch per 3,000 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.

— OR —

Part number 550-100-325/0718

Page 21

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 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 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.

Determine termination location

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, particularly if using longer lengths. The chase must allow for inspection of the vent pipe, and insulation must be protected from water.

Multiple vent/air terminations

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 Installation 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.

Prepare wall penetrations

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:

Part number 550-100-325/0718

Figure 24 INSTALLATION SEQUENCE — Separate pipes

sidewall

Step 1 Read and follow all instructions in this manual.

Step 2 Install the boiler in a location that allows proper routing

Step 3 Make sure the selected sidewall termination location com-

Step 4 Use only the vent materials listed in Figure 21, page 17.

Step 5 Prepare the sidewall penetrations and secure the sidewall

Step 6 The air piping must terminate in a down-turned elbow as

Step 7 Install vent and air piping between the boiler and the side-

Step 8 Install pipe supports every 5 feet on both the horizontal

Step 9 Attach the vent termination exterior piping: Use either of the

Step 10 The vent and air pipes may run up as high as 4 feet with

Step 11 External venting greater than 4 feet requires an insulated

DO NOT proceed with vent/air installation until you have read page 17 through page 20.

of all vent and air piping to the selected sidewall location.

plies with Figure 22, page 19. (Multiple boiler sidewall plates must also comply with Figure 25, page 22.)

Provide pipe adapters where required. Vent piping and air piping lengths must not exceed the values shown in Figure 20, page 16.

plates as instructed in this section. See “Prepare wall penetrations” on page 21.

shown above. The vent piping must terminate in an elbow pointed outward or away from the air inlet as shown above. See illustration above.

wall openings. Slope horizontal piping downward toward the boiler at least 1/4 inch per foot. See page 30 for general guidelines.

and vertical runs. Install a hanger support within 6 inches of any upturn in the piping, or per vent pipe manufacturer’s instructions.

conﬁgurations shown above, as needed to ensure clearance above grade or snow line. Keep vents/air intake area clear of accumulating snow.

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.

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.

See notices at left.

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.

Page 22

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

10 DIRECT VENT — Sidewall with separate pipes continued

See notices on previous page.

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 termination 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 termination 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 Figure 24, page 21.

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.

Keep vents/air intake area clear of accumulating

Figure 25

Multiple separate pipes sidewall terminations — maintain vertical spacing between vent and air ﬁttings shown in Figure 24, page 21.

Figure 26 Sidewall termination assembly — using

separate pipes

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 550-100-325/0718

Page 23

AquaBalance® 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 speciﬁed.

2. Locate the termination such that the total air pip ing 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 connections)

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.

a AL29-4C starter piece from the AL29-4C manufacturer to the

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”.

Determine termination location

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

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.

Multiple vent/air terminations

1. When terminating multiple boilers, install each concentric 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-

For Canadian installations, provide clearances

tions.

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 connection. It is not classiﬁed as a forced air intake with regard to spacing from adjacent boiler vents.

. Provide pipe adapters if

transition at the boiler

Figure 22, page 19

and at the

Provide

Figure 27 INSTALLATION SEQUENCE — Concentric horizontal

Step 1 Read and follow all instructions in this manual. DO NOT proceed

Step 2 Install the boiler in a location that allows proper routing of all vent

Step 3 Make sure the selected sidewall termination location complies with

Step 4 Use only the vent materials listed in Figure 21, page 17. Provide pipe

Step 5 Vent piping and air piping lengths must not exceed the values shown

Step 6 The concentric termination must be assembled and installed before

Step 7 Prepare the sidewall penetration — assemble the concentric ter-

Step 8 Install vent and air piping between the boiler and the concentric

Step 9 Install pipe supports every 5 feet on both the horizontal and vertical

Step 10 Install a hanger support within 6 inches of any upturn in the piping.

with vent/air installation until you have read page 15 through page 20.

and air piping to the selected sidewall location.

Figure 22, page 19. (Multiple boiler concentric terminations must also comply with

adapters where required.

in Figure 20, page 16.

piping from the boiler to the termination.

mination kit and secure the cover plates as instructed in this section. Provide the supports indicated and mount the termination assembly. See “Install termination — concentric pipes” on page 24.

vent/air termination. Slope horizontal piping downward toward the boiler at least 1/4 inch per foot. See page 30 for general guidelines.

runs.

See notices at left.

Figure 28, page 24

See notices at left.

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.

See notices at left.

Part number 550-100-325/0718

Page 24

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

11 DIRECT VENT — Sidewall concentric (continued)

See notices on previous page.

Install termination — concentric pipes

1. Assemble the vent termination as described for concentric terminations, on page 29.

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 concentric 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.

Figure 28 Termination location — concentric

termination — multiple boilers — clearance from vent of one to air intake of the next

Figure 29 Installing and supporting the concentric

sidewall vent assembly

The supports/bracing used must support the termination

assembly to prevent slippage or movement. See instructions 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 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 problem. 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.

5. After the assembly has been positioned in the 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 35, page 29, or per concentric kit instructions for polypropylene kits.

b. Cement the rain cap in place as shown.

LEGEND for 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 instructions

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

Part number 550-100-325/0718

Page 25

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

12 DIRECT VENT — Vertical 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 terminations 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 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.

Figure 30 Separate pipes vertical termination

Terminate vent and air pipes such that:

a. AIR INTAKE IS AT LEAST 12 inches below vent outlet b. AIR INTAKE IS NO FURTHER than 12 inches away center to center c. AIR INTAKE IS AT LEAST 12 inches above roof or snow line,

keep vents/air intake area clear of accumulating snow.

d. Vent and air terminations are ﬁtted with bird screens

Determine termination location

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.

Multiple vent/air terminations

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 clearance 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 required by CSA B149.1 or B149.2 Installation Code and a ULC S636 compliant vent kit.

Step 1 Read and follow all instructions in this manual. DO NOT proceed

Step 2 Install the boiler in a location that allows proper routing of all vent

Step 3 Make sure the selected vertical termination location complies with

Step 4 Use only the vent materials listed in Figure 21, page 17. Provide pipe

Step 5 Prepare the vertical penetrations and secure penetration components as

Step 6 The air piping must terminate in a 180-degree return bend or down-

Step 7 Install vent and air piping between the boiler and the vertical termina-

Step 8 Insert the vent and air piping through the vertical penetrations and

Step 9 Maintain clearances shown above. Vent and air terminations must be

with vent/air installation until you have read page 17 through page 20.

and air piping to the selected sidewall location.

Figure 22, page 19. (Multiple boiler terminations must also comply with Figure 31, page 26.)

adapters where required. Vent piping and air piping lengths must not exceed the values shown in Figure 20, page 16.

instructed in this section. See “Prepare roof penetrations” on page 26 and “Termination and ﬁttings” on page 26.

turned elbow as shown above. The vent piping must terminate in a coupling pointed upward as shown above.

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 30 for general guidelines. Also comply with vent pipe manufacturer’s instructions.

secure the termination ﬁttings.

ﬁtted with a bird screen as shown.

See notices at left.

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.

Part number 550-100-325/0718

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.

Page 26

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

12 DIRECT VENT — Vertical with separate pipes (continued)

See notices on previous page.

Prepare roof penetrations

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 spacings shown in Figure 25, page 22.

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.

no closer than the minimum

Figure 31 Terminations for multiple boilers

Termination and ﬁttings

1. Prepare the vent termination elbow and the air termination 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-degree 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 recirculation of ﬂue products into the combustion air stream.

3. The vent piping must terminate in an up-turned coupling 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 further 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 termination 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.

Also maintain maximum distances between the

vent and air pipes for each boiler as shown in Figure 30, page 25.

Part number 550-100-325/0718

Page 27

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

13 DIRECT VENT — Vertical 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 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 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.

Determine termination location

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.

Multiple vent/air terminations

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.

Figure 32 INSTALLATION SEQUENCE — Concentric vertical

Step 1 Read and follow all instructions in this manual. DO NOT

Step 2 Install the boiler in a location that allows proper routing of all

Step 3 Make sure the selected vertical termination location complies

Step 4 Use only the vent materials listed in Figure 21, page 17. Provide

Step 5 Vent piping and air piping lengths must not exceed the values

Step 6 The concentric termination must be assembled and installed

Step 7 Prepare the vertical penetration(s) — assemble the concen-

Step 8 Install vent and air piping between the boiler and the concen-

Step 9 Install pipe supports every 5 feet on both the horizontal and

Step 10 Install a hanger support within 6 inches of any upturn in the

proceed with vent/air installation until you have read page 17 through page 20.

notices at left.

vent and air piping to the selected sidewall location.

with Figure 22, page 19. (Multiple boiler concentric terminations must also comply with Figure 33, page 28.)

pipe adapters where required.

shown in Figure 20, page 16.

before piping from the boiler to the termination.

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 penetrations” on page 28 and “Mount concentric termination” on page 28.

tric vent/air termination. Slope horizontal piping downward toward the boiler at least 1/4 inch per foot. See page 30 for general guidelines.

vertical runs.

piping.

USE SWEEP ELBOWS FOR ALL VENT AND

See notices at left.

AIR PIPING — DO NOT use short radius elbows

for vent or air piping. Boiler performance could be affected.

See

Part number 550-100-325/0718

Page 28

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

13 DIRECT VENT — Vertical concentric (continued)

See notices on previous page.

Prepare roof penetrations

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.

Mount concentric termination

1. Assemble the vent termination as described for concentric terminations, on page 29.

2. Mount the termination as shown in Figure 34.

3. Support the concentric vent/air termination at the roof penetration 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 substantial 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 problem. 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.

Figure 33 Vertical termination — 3” PVC concentric —

single or multiple boilers

Figure 34 3” PVC concentric termination supports

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 35, page 29, or per kit instructions for polypropylene kits.

b. Cement the rain cap in place.

Part number 550-100-325/0718

Page 29

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

14 Concentric termination, typical (sidewall or vertical)

Figure 35 PVC concentric termination assembly — DO NOT

attach the rain cap until the termination has been inserted through the roof or wall and all supports have been installed. See LEGEND at right. See kit instructions for details of polypropylene kits.

LEGEND for Figure 35

1 — Inner PVC pipe (vent)

2 — Outer PVC pipe (air)

3 — Rain cap

4 — Bird screen

5 — Y ﬁtting

6 — Finished assembly

Assembling concentric termination

1. Follow all instructions provided with the concentric termination kit. The following are general guidelines for information only.

2. See Figure 35, 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 sequence shown in Figure 35, or per the concentric kit instructions.

DO NOT 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 assemble 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.

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.

Install a

Part number 550-100-325/0718

Page 30

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

15 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 manufacturer’s instructions. (Do Not use 3” PVC transition 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 36, 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 38, 39 and 40. Vent adapters (provided with boiler) are for polypropylene, PVC, and AL29-4C venting.

5. See Figure 38, center ﬂue gasket and insert the extruded ﬂue vent adapter into the center opening, secure with four (4) 10-32 Phillips head screws.

Figure 36 Boiler top opening (out of the carton)

Figure 37 Flue and vent adapter and gasket

Vent

adapter

Vent

gasket

Figure 38 Vent ﬂue adapter into top ﬂue center opening

6. See Figure 40, right air inlet, center gasket and air inlet vent adapter over right opening, secure with four (4) 10-32 Phillips head screws.

vent/exhaust

location

Air pipe

connection

Remove protective paper.

Figure 39 Vent (air inlet) adapter inserted into top right

opening

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

15 Vent and air piping and boiler connections (continued)

Figure 40 Vent (ﬂue) and air adapters in place

Vent and Air adapters to be installed with test ports facing to front of boiler. Must be locked closed.

7. The adapter accepts 3” PVC, CPVC, Polypropylene and AL29-4C material. Use a 2” adapter (AB-80/120 only), if

needed.

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

pipe and any combustible wall or material.

11. Assembling PVC or CPVC: (

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

c. Clean all pipe ends and ﬁttings. Dry thoroughly. d. For each joint:

• Handle ﬁttings and pipes carefully to prevent con

• Apply primer liberally to both joint surfaces — pipe

• While primer is still damp, lightly apply approved

• Apply a second coat to both surfaces. Avoid using

• With cement still wet, insert pipe into ﬁtting, twist

• Wipe excess cement from joint. Check joint to be

12. Seal wall or ﬂoor penetration openings following local code

requirements.

For AL29-4C vent pipe applications, comply

3/16 inch between vent

— follow pipe

distribution when joining.

tamination of surfaces.

end and ﬁtting socket.

cement to both surfaces in a uniform coating.

too much cement on sockets to prevent cement buildup inside.

ing ¼ turn. Make sure pipe is fully inserted.

sure a smooth bead of cement shows around the entire joint.

ADAPTERS — Use adapters if using 2-inch pipe,

(AB-80/120 only)

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 felttip 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.

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 550-100-325/0718

Page 32

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

15 Vent and air piping and boiler connections (continued)

Control selection for vent material

Perform at start-up ﬁnal checks

Venting Material Change “b22” parameter

See Figure 124, page 97 (boiler default is “1”for PVC vent

material)

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 69, to ﬁrst power up the boiler.

To access the conﬁguration menu:

Push DHW buttons + & -

together for 10 seconds

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”

Use the DHW + or – buttons to

modify the parameter value

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 message “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.

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 aer two (2) minutes

Part number 550-100-325/0718

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

16 Install water piping

Domestic Water Piping – Combi Boiler

Hot Water Can Scald!

• Consumer Product Safety Commission and some states recommend domestic hot water temperature of 130°F or less.

• When installing an 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 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

• Use lowest practical temperature setting.

• Check water temperature immediately after ﬁrst

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.

automatic mixing valve set according to

those standards.

heating cycle and after any adjustment.

To pipe DHW, see Figure 43, page 34

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 41, 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 41 Domestic water pressure rating

DHW

Pressure

Rating

automatic mixing valve,

Minimum Maximum

PSIG 4.5 130

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 38. 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).

Figure 42 DHW inlet has a ﬁlter screen - Port 4 - see

Figure 43, page 34

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.

• Thermostatic Mixing Valve - A mixing valve (for regulating

domestic heating water) must be used to regulate the water temperature 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.

• DHW Filter- Installation of a 100 micron or lower water ﬁlter at 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, activating it, when the cold water draw has ended and the water pressure increases.

• Drain and Isolation Valves- Install drain and isolation valves on 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.

• 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

Part number 550-100-325/0718

Page 34

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

16 Install water piping (continued)

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.

• Cleaning- refer to the installation manual maintenance section for the proper cleaning procedure for the plate DHW heat exchanger, and the required cleaning frequency.

Figure 43 Domestic Piping - Brazed Plate Heat

Exchanger - Ports 2 and 4

Additional limit controls

Following standard industry practices, if installation is to comply 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.)

Multi-temperature systems — 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.

Low temperature systems — 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 48, 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).

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.

This boiler is NOT intended for connection with a

refrigeration system.

General piping information

Additional controls, if required

The control uses temperature sensors to provide

both high limit protection and modulating temperature control.

function requires manual reset

jurisdictions may require additional external controls for high limit and/or low water cutoff protection.

The control’s high limit

. Some codes/

Backﬂow preventer

Use backﬂow preventer in the cold water supply piping if required by local codes.

System/zone pipe sizing

(Baseboard, convectors or cast iron radiators ONLY)

For residential space heating applications (other than radiant heating or unit heaters) ONLY, you can use the sizing suggestions in Figure 44.

Figure 44 Suggested pipe sizing for system headers

and zone piping — RESIDENTIAL with baseboard, convectors or cast iron radiators ONLY (20°F temperature rise)

Model

AB-80/120 1” or larger

AB-155 1-1/4” or larger

Recommendations are based on a 20°F temperature drop through the system.

Suggested maximum load per zone

Copper pipe and

baseboard size

¾” 67

1” 104

Size zone circulators to handle the required ﬂow and head loss for each zone.

System header

Maximum recommended

feet of baseboard

Part number 550-100-325/0718

Page 35

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

17 Primary/Secondary System Piping

System water piping methods

Primary/secondary piping to boiler

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 36-41.

System water piping methods

Near boiler piping

1. Connect boiler to system only as shown in Figure 47, page 36. 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.

System or zone circulators ﬂow rates

1. Size circulators based on the ﬂow rate required to achieve the temperature drop required. You can closely estimate temperature 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

FLOW =

Examples:

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:

FLOW =

SIMPLIFIED: For 20° temperature drop, FLOW = MBH / 10.

System or zone circulator head requirement

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.

—–—–—–—–

TD x 500

143,000

—–—–—–—–

20 x 500

= 14 gpm

Expansion Tank Location

Figure 47, page 36 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 35 - 37.

Ensure that the expansion tank size will handle boiler and system water volume and temperature. See tank manufacturer’s instructions 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 49, page 37 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 separator manufacturer’s instructions.

Automatic air vents (if used — automatic air

vents must be used with diaghragm-type expansion tanks only)

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.

Scald hazard — Water from air vent may be very

hot. Avoid contact to prevent possible severe personal injury.

2. If the air vent valve appears to be working freely and not leaking, 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 45 Maximum and minimum ﬂow rates through

boiler heat exchanger

Boiler

Model

AB-80

AB-120

AB-155

Part number 550-100-325/0718

MAX

Flow Rate

20° F

temperature

rise

GPM

7.9 2.9 2.3

12.0 4.3 3.4

15.2 6.1 4.5

MIN

Flow Rate

50° F

temperature

rise

GPM

Flow Rate

Delta T1

protection

67° F

temperature

rise

GPM

Figure 46 Automatic air vent

85036

Page 36

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

17 Primary/Secondary System Piping (continued)

Figure 47 Piping to diaphragm (or bladder) expansion tank

Figure 48 Pressure drop through AquaBalance

Boiler Model

AB-80

HEAT ONLY

AB-120

HEAT ONLY

AB-155

HEAT ONLY

BOILER

(ºF)

(GPM)

92%

Eff.

20 7.4 7.8 12.5 3.0 20.3 10.8 A B,C,D

40 3.7 2.7 3.5 0.8 6.2 3.5 B,C,D,E B,C,D,E

20 11.0 14.4

40 5.5 4.6 1.8 6.4 B,C,D,E

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

Boiler

Head Loss

(ft. w.c.)

Piping Est. Head Loss Ft. (Typical Near Boiler)

3/4” Pipe 1” Pipe 3/4” Pipe 1” Pipe 3/4” Pipe 1” Pipe 1-1/4” Pipe

Not

Recommended

Notes:

1. Operating point with current Grundfos pump inside the boiler.

2. Combi pump included in the boiler is sized properly for boiler loop.

80/120/155 heat exchanger (graphs and table)

Total Loss - Ft.

(Boiler + Near Boiler

Piping)

6.0

Not

Recommended

Circulator Legend:

B - Taco 0015 C - Grundfos UPS 15-58 D - B&G NRF 25 E - Taco 007 F - Taco 0011

20.4

Not

Recommended

A - Taco 0014

Recommended

Circulators

___30 4.9 4.0 6.0 1.5 10.0 5.5 B,C,D,E B,C,D,E

A,F

___30 7.3 7.5 3.0 10.5 B,C,D

Part number 550-100-325/0718

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

17 Primary/Secondary System Piping (continued)

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 49, 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 Tacotrol (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 overpressurization. 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 manufac-

turer’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.

Figure 49 Piping to closed-type expansion tank

Graph 1 Pressure drop through AquaBalance® 80/120/155 heat exchanger

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)

Total Head - feet water

Ta co 0 01 4

B&G NRF 25 (High)

Ta co 0 07

0123456789101112

Taco 0015 (High)

Grundfos UPS 15-58

(High)

Flow - gpm

Taco 0011

Part number 550-100-325/0718

Page 38

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

17 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

WARNING below.

in the

To avoid water damage or scalding due to relief

valve operation, as per local or state codes

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 possibility of severe personal injury, death or substantial property damage.

Part number 550-100-325/0718

Page 39

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

17 Primary/Secondary System Piping (continued)

Zone Valve zoning – primary/secondary

(Shown with optional DHW piping)

See Figure 50.

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 47, page 36 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 35 or 37.

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 49 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 63 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 131 for compliance information and exemptions.

Figure 50 Zone valve zoning — primary/secondary

connection — a system circulator is required

Note: Do not install on Combi Boilers.

(See Note, page 40)

Note: This pump does not run in DHW mode on Heating Only Boilers.

Wiring the Indirect tank aquastat to the Heating Only

Boilers, refer to Section 21 - 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 48, for instructions on wiring to zone valves.

2. The boiler and zone valves can also be operated by a zone controller.

LEGEND for Figure 50.

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 38 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)

Part number 550-100-325/0718

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

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.

Note: This is a common legend for all piping diagrams, Not all

items listed appear in every ﬁgure.

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, 25 Heating circuits 26 Additional heating circuits, if any 27 Boiler circulator,

Combi boiler the circulator is already inside the boiler

jacket).

28 Mixing valve, if any

(ﬁeld supplied), ﬁeld piped

(For Heating Only boilers, In the

Page 40

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

17 Primary/Secondary System Piping (continued)

Circulator zoning – primary/secondary

(Shown with optional DHW piping)

See Figure 51.

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 35 or 37.

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.

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 131 for compliance information and exemptions.

Figure 51 Circulator zoning plus optional DHW piping

Note: Do not install on Combi Boilers.

(See Note,

below)

Note: This pump does not run in DHW mode on Heating Only Boilers.

Wiring the Indirect tank aquastat to the Heating Only

Boiler, refer to Section 21 - 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 48, for instructions on wiring to circulators.

2. The boiler and circulators can also be operated by a zone controller.

LEGEND for Figure 51 and Figure 52

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 38

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

NOTE: (Applies to Figures 50, 51 & 52)

Add boiler and tank head loss for pump sizing.

Note: This is a common legend for all piping diagrams, not

all items listed appear in every ﬁgure.

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,

Combi boiler the circulator is already inside the

boiler jacket).

28 Mixing valve, if any

(For Heating Only boilers, In the

Part number 550-100-325/0718

Page 41

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

17 Primary/Secondary System Piping (continued)

Circulator zoning – Multiple

temperature zones with primary/

secondary

(Shown with optional DHW piping)

See Figure 52.

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 primary 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 guidelines on pages 35 or 37.

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.

Figure 52 Circulator zoning with high- and low- temperature

heating zones

Note: Do not install on Combi Boilers.

2. Add a mixing device (Figure 52, 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 95) 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 48 to ensure compliance with the 2007 Energy Act.

4. If NOT connecting an indirect water heater, do not use the DHW input or DHW Circulator output on the control.

Part number 550-100-325/0718

(See Note,

page 40)

Overriding the Outdoor Reset function by connecting

Note: This pump does not run in DHW mode on Heating Only Boilers.

space heating zones to inputs and outputs intended for DHW applications may violate Section 303 of the 2007 Energy Act. See page 131 for compliance information and exemptions.

Wiring the Indirect tank aquastat to the Heating Only

Boiler, refer to Section 21 - 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 controller and in some installations may be needed.

Page 42

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

18 Multiple boiler installations

Figure 53 Side-to-side mounting of multiple boilers

Placing multiple boilers

1. Locate multiple boilers with spacings shown in Figure 53.

2. Provide indicated clearances around boilers for access and servicing. 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 piping, expansion tank, primary circulator and other accessories.

Part number 550-100-325/0718

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

18 Multiple boiler installations (continued)

Figure 54 Piping schematic –– typical piping for multiple AquaBalance

Heating Only boilers

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

Part number 550-100-325/0718

Legend for Figure 54

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

Page 44

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

18 Multiple boiler installations (continued)

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 50, page 39.

3. Connect the DHW tank aquastat directly to the DHW input on the last boiler in the sequence.

Figure 55 Piping layout—typical piping for multiple boilers (4-boiler system shown) with DHW storage heaters grouped as

zone in secondary loop off primary system loop. (Heating Only)

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 55.

2. DHW tanks are zoned with circulators as shown.

3. If DHW priority is required, use separate zone controllers for DHW and space heating.

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.

Part number 550-100-325/0718

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

19 Install condensate line

Prepare condensate trap assembly

This boiler is equipped with an internal air-trap to drain off condensate.

1. Remove the condensate trap kit from the accessories bag.

2. See Figures 56, 57 and 58. The ﬁgures below shows the installation of the condensate trap connections.

3. Install the inspection coupling tighten securely.

4. Slide the clamp (from the condensate trap kit) onto the ﬂexible drain tube (item approximately 1-3/4” (Figure 57) onto the end of the tube (bottom of boiler) as shown in Figure 56.

Figure 56 Condensate trap assembly

B), See Figure 57. Push the ﬂexible tube (item B)

A and gasket as shown. Finger

Figure 58 Filling the condensate trap assembly

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

Condensate drain system

1. Install condensate drain by connecting tubing or PVC

pipe to the ﬂexible drain line. Run the drain tubing or piping to a ﬂoor drain or condensate pump

ﬂexible drain line will ﬁt in a ¾” PVC coupling. Run minimum ½” PVC for the piping to drain or condensate pump.

. The

Figure 57 Condensate trap connection

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 manual. Failure to comply could result in severe personal injury, death or substantial property damage.

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, resulting 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.

Part number 550-100-325/0718

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

20 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 59 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 59. 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 sparingly 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 substantial 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 accessories.

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.

Figure 59 Connect gas supply piping

(Combi boiler shown).

1 Boiler gas supply connection, ½” NPT male for 80/120 boilers

and ¾” NPT for 155 boilers.

ALL OF THE FOLLOWING ARE SUPPLIED BY THE INSTALLER:

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 Nippl e, 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.

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.

Use two wrenches 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.

Part number 550-100-325/0718

Page 47

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

20 Gas piping (continued)

Gas pipe sizing

1. See page 14 for gas line sizing information.

Check gas pressure at inlet to boiler

1. See Figure 60 for location of the gas inlet pressure test port.

Check the operational (working) gas inlet pressure

1. Set up the boiler to operate at maximum rate as described in section “ Test mode” Figure 100, page 75.

2. With the boiler operating at maximum rate check that the operational (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:

Table 2 Gas rate for Combi and Heating Only boilers

For natural gas or liqueﬁed petroleum (propane) gas, 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.

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 60 Inlet test port on gas valve

Combi

Boiler

model

AB-80

AB-120

AB-155

Gas Rate (Natural Gas)

After 10 minutes from cold

Maximum rate Minimum rate

/h ft3/h

78.4 7.8

117.6 11.8

151.9 15.2

Inlet test port

Part number 550-100-325/0718

Page 48

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

21 Field wiring

ELECTRICAL SHOCK HAZARD — For your

safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

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.

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 polarized circuit. Recommend GFI outlet.

Figure 61 Thermostat or sensor wiring entrances

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 – latest edition

Part I, CSA C22.1, Electrical Code.

, and/or the Canadian 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.

Figure 62 Thermostat terminals Combi and Central Heating

and Outdoor sensor (Heating Only Boilers) See illustrations in the following pages for notes and

numbers.

Wire grommets

Wire entrances

All ﬁeld wiring is made through the bottom of the boiler through two (2) black grommets shown in Figure 61.

Connecting terminals

The electrical connections terminal block can be accessed after removing the front jacket panel. The layout of the terminals for the various connections are shown in the wiring diagram in the following pages.

Room thermostat

When connecting a room thermostat, connect the thermostat 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 62, 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.

Transformer

Relay

Outside of

Thermostat-Relay

Box

Fuse

Inside of

Thermostat-Relay

Box

Figure 63 Thermostat-Relay box terminals Combi and Central

Heating boilers

Part number 550-100-325/0718

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

21 Field wiring (continued)

Outdoor temperature sensor Central Heating Boilers

(optional for Combi Boilers)

• Outdoor sensor uses the back connection block,

Item 138, (right side of block … terminals 5 and 6).

• Recommended wire size 22 AWG (2-conductor shielded thermostat wire 22 gauge).

• Mount on north exterior wall,

ﬂow of heat or cooling from other sources, approximately 10 feet above ground level.

• Do NOT run sensor wires with other electrical wires.

The Outdoor sensor must be installed unless speciﬁcally exempted in the Energy Act statement on page 131.

Figure 64 Outdoor sensor optional for Combi boiler.

shielded from direct sunlight or

see Figure 62,

Wiring the Circulators (Heating Only Boiler)

The control of the Heating Only model of the boiler is capable 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 control 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 66 and Figure 67.

Figure 66 Circulator connectors (Heating Only

boilers)

Wiring the Indirect Tank Aquastat

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 65 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.

Figure 65 Indirect tank aquastat connections

Indirect tank aquastat (N/O) wire connection

points, pins 7 and 8

Figure 67 Circulator connectors detail

In Figure 67, terminals 9, 10 and 11 (Item 32) are for connecting 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.

Part number 550-100-325/0718

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

22 Wiring diagram — AquaBalance® 80/120C Combi Ladder

Figure 68 AquaBalance

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.

80/120C –– Combi Ladder Wiring Diagram

Legend

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

16 Fan

cod. 3541M910

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)

Part number 550-100-325/0718

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

22 Wiring diagram — AquaBalance® 80/120C Combi Schematic

Figure 69 AquaBalance

RWC

(see note 2)

284

279

104 (2)

X0 - 1

GROUND

80/120C –– Combi Schematic Wiring Diagram

X0 - 10 X0 - 9 X0 - 8

610

X0 - 6

GROUND

X0 - 5

138

(see note 3)

370

X0 - 4

 Fan

 Central heating pump

 D.H.W. temperature sensor

 Combination gas valve

 Room thermostat (not included)

 Spark Electrode

.(<

X4 - 10

X4 - 2

X4 - 11

X4 - 3

X3 - 5

X3 - 1 X3 - 13 X3 - 2

X3 - 19 X3 - 7

X3 - 23

X3 - 8 X3 - 9

X3 - 24

X2 - 7

X4 - 12 X4 - 4 X4 - 13 X4 - 5

X4 - 17 X4 - 8

X3 - 18 X3 - 6

X3 - 10 X3 - 11

X1 - 2

X1 - 1

X4 - 1

X4 - 7

X3 - 12

1018

X4 - 6

X4 - 15

1324

112

123 456

X3 - 4 X3 - 17

X3 - 20

X3 - 21

X3 - 22

X2 - 10 X2 - 4

X2 - 11 X2 - 5

104 (1)

12 7

 Diverting valve

 Water pressure switch

 Fuse 3.15A

 Fuse 630 mA

 Flowmeter

 Outdoor sensor

 Return temperature sensor

 Exhaust temperature sensor

 Double sensor (safety + heating)

 Transformer 115-24 Vac

373

X4 - 6 X4 - 15

 Relay SPST-Coil 24 Vac

 Low Water Cutoff (not included)

 “OPENTHERM” communication

ABM08

GROUND

X3 - 6

X3 - 18

191

Part number 550-100-325/0718

136

X3 - 13

X3 - 2

X3 - 1

X4 - 8

X4 - 17

X2 - 5

X2 - 11

GROUND

X2 - 1

114

X2 - 12

X4 - 13

X2 - 6

X4 - 5

186

X4 - 12

X4 - 4

GROUND

X2 - 10

X2 - 4

X3 - 16

X3 - 4

X3 - 5

X3 - 17

278

X3 - 7

X3 - 19

X3 - 20

X3 - 8

60Hz

120Vac

X3 - 12

X3 - 10

X3 - 11

X3 - 24

X3 - 22

X3 - 23

GROUND

X3 - 9

X3 - 21

FRG0

Page 52

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

23 Wiring diagram — AquaBalance

Figure 70 AquaBalance

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 installation please contact W-M Tech Services.

80/120H –– Heating Only Ladder Wiring Diagram

80/120H Heating Only Ladder

Legend

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

16 Fan

cod. 3541M870

Part number 550-100-325/0718

Page 53

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

23 Wiring diagram — AquaBalance

(see note 2)

279

104 (2)

GROUND

80/120H –– Heating Only Schematic Wiring Diagram

RWC

284

1M610

X0 - 1

X0 - 6

GROUND

X0 - 10 X0 - 9 X0 - 8

X0 - 4

X0 - 5

32 130

143

138

(see note 3)

370

7HUPLQDO /LQH

7HUPLQDO 1HXWUDO

7HUPLQDO /LQH

7HUPLQDO 1HXWUDO

3XPS:LULQJ&RQQHFWLRQV

X2 - 9

X2 - 3

GROUND

X2 - 11

X4 - 12

X4 - 5

X3 - 8

X2 - 6

X4 - 17 X4 - 8

X3 - 18 X3 - 6

X2 - 5

X3 - 21

X3 - 9

X4 - 10

X4 - 2

X4 - 11

X4 - 3

X1 - 2

X1 - 1

X4 - 1

X4 - 7

X4 - 4

X4 - 13

X3 - 20

X2 - 7

X2 - 10 X2 - 4

910111213123 456 78

X3 - 16 X3 - 4 X3 - 17

X2 - 1

X3 - 5

X3 - 19 X3 - 7

X2 - 12

Figure 71 AquaBalance

GROUND

80/120H Heating Only Schematic

each connection point. Maximum

amp load per pump 3.0 amps.

Only one circulator may be wired to

 Fan

 Central heating pump (not included)

 Combination gas valve

 Room thermostat (not included)

 Spark Electrode

.(<

1018

X4 - 6

X4 - 15

1324

112

X3 - 9 X3 - 21

 Water pressure switch

 Fuse 3.15A

 Fuse 630 mA

 D.H.W. Pump (not included)

 Outdoor sensor

 D.H.W. tank thermostat (not included)

 Return temperature sensor

 Exhaust temperature sensor

 Double sensor (safety + heating)

 Transformer 115-24 Vac

 Relay SPST-Coil 24 Vac

 Low Water Cutoff (not included)

373

X2 - 3

X2 - 9

12 7

104 (1)

X2 - 5

X2 - 11

X4 - 6 X4 - 15

ABM08

 “OPENTHERM” communication

X3 - 6

191

Part number 550-100-325/0718

X3 - 18

60Hz

120Vac

GROUND

X2 - 10

X2 - 4

X4 - 8

X4 - 17

X4 - 13

X4 - 5

114

186

X4 - 4

X4 - 12

X3 - 16

X3 - 4

X3 - 5

X3 - 17

278

X3 - 7

X3 - 19

X3 - 20

X3 - 8

GROUND

FRG0

Page 54

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

24 Wiring diagram — AquaBalance

Figure 72 AquaBalance

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.

155C –– Combi Ladder Wiring Diagram

-155C Combi Ladder

Legend

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

16 Blower

Part number 550-100-325/0718

Page 55

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

24 Wiring diagram — AquaBalance®-155C Combi Schematic

Figure 73 AquaBalance

155C –– Combi Schematic Wiring Diagram

136 Flow meter

138 Outside temperature sensor (optional on Combi)

186 Return temperature sensor

191 Exhaust temperature sensor

278 Double sensor (heating + safety)

373 “OPENTHERM” communication (Not used)

279 Transformer 115-24 Vac

284 Relay SPST-Coil 24 Vac

370 Low Water Cutoff (not included)

16 Blower

32 Central heating pump

42 DHW temperature sensor

44 Gas valve

72 Room thermostat (optional)

Legend

81 Ignition electrode

95 Mixing (diverting) valve

104 (1) Fuse 3.15A

104 (2) Fuse 630mA

114 Water pressure switch

Part number 550-100-325/0718

Page 56

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

25 Wiring diagram — AquaBalance

Figure 74 AquaBalance

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 installation please contact W-M Tech Services.

155H –– Heating Only Ladder Wiring Diagram

-155H Heating Only Ladder

Legend

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)

16 Fan

cod. 3541M950

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)

Part number 550-100-325/0718

Page 57

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

25 Wiring diagram — AquaBalance

Figure 75 AquaBalance

155H –– Heating Only Schematic Wiring Diagram

tor may be wired to

each connection point.

Maximum amp load

Only one circula-

per pump 3.0 amps.

-155H Heating Only Schematic

Part number 550-100-325/0718

cod. 3541M930

Page 58

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

26 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.

Figure 76 Control panel

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 76

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

Part number 550-100-325/0718

Page 59

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

26 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 76, page 58). The display indicates the actual Central Heating water temperature (Item 10 - Figure 76, page 58) 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)

Figure 77 Central heating mode

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 76, page 58). The display indicates the actual Domestic Hot Water temperature (Item 10, Figure 76, page 58 and after Hot set point temperature is reached “d1” will be displayed.

NOTE: Combi boilers recommended to be in “comfort” mode.

Figure 78 Domestic hot water (DHW) mode

Boiler without Power

Figure 79 Boiler without main power supply

Part number 550-100-325/0718

Page 60

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

26 Controls and operation (continued)

Initial power up mode

Ensure the power is on to the boiler

Figure 80 Initial power up mode

Software version

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.

Air purge

Power down mode

Press the on/off button (Item 7 - Figure 76, page 58) for 5 seconds.

Figure 81 Power down mode

On/Off button

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 totally isolate, close the gas cock before the

boiler and disconnect electricity supply.

To turn boiler on again, press the on/off button (Item 7 - Figure 76, page 58) hold for 5 seconds

The boiler is ready to function automatically whenever the external controls are calling for heat.

Part number 550-100-325/0718

Page 61

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

26 Controls and operation (continued)

Adjustments

Figure 82 Heating temperature settings

To set the system Heating temperature, use the CH buttons, “-” to reduce water setpoint “+” to increase water setpoint (Items 3 and 4 - Figure 76, page 58). It can be set from a minimum of 68° F to a maximum of 190° F.

Figure 83 Domestic hot water temperature settings

To set the Domestic hot water temperature, use the DHW buttons, “-” to reduce water setpoint “+” to increase water setpoint (Items 1 and 2 - Figure 76, page 58). It can be set from a minimum of 104° F to a maximum of 131° F.

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 76, page 58).

3. In “eco” mode the display shows the relevant symbol (Item 12 - Figure 76, page 58). To turn on “comfort” mode, press economy/comfort button (Item 7 - Figure 76, page 58), 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.

Part number 550-100-325/0718

Page 62

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

26 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 temperature. These scale ranges are related to the outdoor temperatures, and boiler water temperatures for the installed radiation.

• These “Outdoor Reset Control” curves are graphed (and programmed into the control board) by outside temperature from 68 degrees to -4 degrees F and boiler water target temperatures from 86 to 194 degrees F (see Figure 86, page 63), 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 water temperatures) of offset curve number 6 (Figure 88, page 63) 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 88, page 63).

• 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 (optional on the Combi)

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 84) 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 84; to set Curve, use

the DHW buttons (Items 1 and 2 - Figure 84) 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 63. “O” means no OTC mode.

3. By pressing the CH push buttons (Items 3 and 4 - Figure 84,

the display shows “0F” ﬂashing Figure 85; to set Offset, use the DHW push buttons (Items 1 and 2 - Figure 84).

Figure 84 OTC settings

DHW

4. It can be 68 to 104, in accordance with the chart Figure 87 or Figure 88, page 63.

5. To exit the OTC mode, press OTC button “reset” button for 5 seconds.

Figure 85 OTC “OFFSET” settings

eco

OTC/reset

OTC/RESET

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 118, page 93). Upon replacement of the defective sensor the boiler will resume the use of Compensation Curves

OTC Exempt mode

By pressing the DHW+ and eco buttons together for 10 seconds, 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 105) 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 86, 87, & 88, page 63.

• 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).

Part number 550-100-325/0718

Page 63

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

26 Controls and operation

Adjustments for Heating Only Boilers with Outdoor sensor

Figure 86 Compensation curves

OTC CURVES

194

176

158

140

122

104

BOILER FLOW TEMPERATURE (°F)

OUTSIDE AIR TEMPERATURE (°F)

Figure 87 Compensation parallel offset curves

Typical low temperature radiant application such as in-ﬂoor tubing.

2))6(7 

78910

-42814202632384450566268

27 DHW Settings (Combi Only)

Boiler must be set on comfort mode DHW SETTINGS

1. The DHW SETTINGS menus are for setting control operation 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 78, page 59).

DHW TEMPERATURES

DHW priority — The control gives priority to DHW

operation. During DHW call for heat, the central heating zone output is disabled. This continues until the DHW call ends or the DHW MAX ON TIME has elapsed which is 30 minutes.

BOILER SUPPLY

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 89 DHW SETTINGS menu (see below for setting

values and descriptions)

Starting temperature

Figure 88 Compensation parallel offset curves

Typical Copper ﬁn tube /cast iron baseboard radiation.

2))6(7 

DHW production rate

Boiler

Model

[GPM with

ǻ7 )@

[GPM with

ǻ7 )@

[GPM with

ǻ7 )@

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

Figure 90 DHW curve - AquaBalance® 80

G.P.M.

7.5

6.5

5.5

4.5

2.5

1.5

0.5

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

[GPM with

ǻ7 )@

AquaBalance 80

Delta T (ºF)

Part number 550-100-325/0718

Page 64

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

27 DHW Settings (Combi Only) (continued)

Figure 91 DHW curve - AquaBalance® 120 Figure 92 DHW curve - AquaBalance® 155

AquaBalance 155 -

G.P.M.

11.5 11

10.5 10

9.5 9

8.5 8

7.5 7

6.5 6

5.5 5

4.5 4

3.5 3

2.5 2

1.5 1

0.5 0

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105

AquaBalance 120 - DHW PRODUCTION

AquaBalance 120

Delta T (ºF)

G.P.M.

14.5 14

13.5 13

12.5 12

11.5 11

10.5 10

9.5 9

8.5 8

7.5 7

6.5 6

5.5 5

4.5 4

3.5 3

2.5 2

1.5 1

0.5 0

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

AquaBalance 155

Delta T (ºF)

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 Central 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

After cycle of Domestic water mode, D1 will be displayed.

When required boiler water set - point is reached D2 will be displayed.

After an attempt for ignition, re-trial ignition delay is in effect (D3 is displayed).

* Check for proper fuel supply.

5HPRYHDQGFKHFNLJQLWRUIRUSURSHUJDS´UHSODFHLIGLV¿JXUHGFKHFNFRPEXVWLRQVHWWLQJ1DWXUDOJDVRU/3

* Insure condensate is draining properly.

* Insure venting size and length are correct and unobstructed.

Part number 550-100-325/0718

Page 65

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

28 Standard Altitude

Standard Altitude Boiler Adjustment

(below 4,500’ installations)

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 above.

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 above.

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.

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.

Figure 93 STANDARD Altitude Fan Speeds

(for below 4,500’ installations)

Model

AB-80-N

AB-80-LP

AB-120-N

AB-120-LP

AB-155-N

AB-155-LP

Low

Fire

(b06)

40 80% 155 155

40 80% 145 145

40 60% 200 200

40 60% 185 185

39 50% 205 205

40 50% 210 210

Standard Altitude

Fan Speed Hz

Ignition

(Can't

Change

- Needs PC)

High Fire

CH Mode

(b05)

High Fire

DHW

Mode

(b04)

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.

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 77, 78 & 79.

Check the correct ignition sequence of the

boiler after the conversion, as in page 86.

Failure to comply could result in severe per-

sonal injury, death or substantial property damage.

Part number 550-100-325/0718

Page 66

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

28 High Altitude

HIGH ALTITUDE BOILER ADJUSTMENT

(above 4,500’ installations)

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 above.

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 94 High Altitude Fan Speeds for AquaBalance® 80 boilers

80KBTU - Natural Gas

LOW FIRE HIGH FIRE (CH & DHW)

ALTITUDE

0 - 2,000' 40 8.0 - 9.0 <20 155 9.0 - 9.5 <110

Blower Speed

(b06)

CO2 (%) CO (PPM)

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.

Blower Speed

(b04 & b05)

CO2 (%) CO (PPM)

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

LOW FIRE HIGH FIRE (CH & DHW)

ALTITUDE

0 - 2,000' 40 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

Blower Speed

(b06)

CO2 (%) CO (PPM)

Blower Speed

(b04 & b05)

CO2 (%) CO (PPM)

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

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

28 High Altitude Blower Speeds

Figure 95 HIGH Altitude Fan Speeds for AquaBalance® 120 boilers

120KBTU - Natural Gas

LOW FIRE HIGH FIRE (CH & DHW)

ALTITUDE

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

Blower Speed

(b06)

CO2 (%) CO (PPM)

Blower Speed

(b04 & b05)

CO2 (%) CO (PPM)

120KBTU - LP Gas

LOW FIRE HIGH FIRE (CH & DHW)

ALTITUDE

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

Blower Speed

(b06)

CO2 (%) CO (PPM)

Blower Speed

(b04 & b05)

CO2 (%) CO (PPM)

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

28 High Altitude Blower Speeds

Figure 96 HIGH Altitude Fan Speeds for AquaBalance® 155 boilers

155KBTU - Natural Gas

LOW FIRE HIGH FIRE (CH & DHW)

ALTITUDE

0 - 2,000' 39 8.0 - 9.0 <7 205 9.0 - 9.5 <120

2,000' - 4,000' 40 8.0 - 9.0 <7 205 9.0 - 9.5 <120

4,000'-5,000' 41 8.0 - 8.5 <10 205 8.7 - 9.0 <150

5,000'-6,000' 42 8.0 - 8.5 <10 205 8.7 - 9.0 <150

6,000' - 7,000' 43 8.0 - 8.5 <10 205 8.7 - 9.0 <150

7,000' - 8,000' 45 8.0 - 8.5 <10 205 8.7 - 9.0 <180

8,000' - 9,000' 46 8.0 - 8.5 <10 205 8.7 - 9.0 <180

9,000' - 10,000' 48 8.0 - 8.5 <10 205 8.7 - 9.0 <180

Blower Speed

(b06)

CO2 (%) CO (PPM)

Blower Speed

(b04 & b05)

CO2 (%) CO (PPM)

155KBTU - LP Gas

LOW FIRE HIGH FIRE (CH & DHW)

ALTITUDE

0 - 2,000' 40 9.0 - 9.8 <7 207 10.2 - 10.7 <120

2,000' - 4,000' 42 9.0 - 9.8 <7 207 10.2 - 10.7 <120

4,000'-5,000' 43 9.3 - 9.5 <10 207 9.7 - 9.9 <150

5,000'-6,000' 44 9.3 - 9.5 <10 207 9.7 - 9.9 <150

6,000' - 7,000' 45 9.3 - 9.5 <10 207 9.7 - 9.9 <150

7,000' - 8,000' 47 9.3 - 9.5 <10 207 9.7 - 9.9 <180

8,000' - 9,000' 48 9.3 - 9.5 <10 207 9.7 - 9.9 <180

9,000' - 10,000' 50 9.3 - 9.5 <10 207 9.7 - 9.9 <180

Blower Speed

(b06)

CO2 (%) CO (PPM)

Blower Speed

(b04 & b05)

CO2 (%) CO (PPM)

Perform Boiler Manual Start-up

Follow all instructions in the start-up section for boiler start-up after convert-

ing for High Altitude. Because the boiler has been changed, you must verify cor-

rect operation, including checking combustion with test instruments both at high fire and low fire as described in the this manual, pages 77, 78 & 79.

Check the correct ignition sequence of the boiler after the conversion, as in page 86.

Failure to comply could result in severe personal injury, death or substantial property damage.

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

29 Startup — Quick Start Guide using default settings

Figure 97 Quick Start Guide - Default control settings (see instructions and ﬁgures on pages 58-68).

QUICK START GUIDE

After you have completed the installation of the Combi or Heating Only model by the instructions provided in this manual, pages 5-71 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.

• Sentinel X100 Inhibitor has been added and the water has been checked with the test kit.

• Condensate trap has been ﬁlled with water.

• Electrical connection for the boiler is grounded and has correct polarity.

• Venting and Intake Air Piping is all secure, sealed and installed as instructed in this boiler manual.

• Central Heating only boilers, Outdoor sensor MUST be installed and connected to the boiler control.

(See page 49)

System start

Push eco / comfort / Power button; to start boiler

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.

The Outdoor sensor must be installed unless speciﬁcally exempted in the Energy Act statement on page 131.

04 “shows on the display” (control software version)

FH “shows on the display”

With no “call for heat”

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.

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.

(Blower /inducer operating in purge mode of combustion chamber and venting for 5 minutes).

(current boiler water temperature will be shown in degrees F).

To Change “Control Selection for vent material” See instructions on page 32. This is necessary only if using a

venting material other than the default PVC.

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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

29 Startup — Quick Start Guide using default settings (continued)

QUICK START GUIDE

System start (continued)

“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 100, page 75) 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 76, page 58) 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 and Figure 106, page 79.

Liqueﬁed Petroleum (Propane) Gas — Propane conversion kit (optional - sold separately, see Figure 159, page 116 .

High altitude — High altitude (over 4,500 feet) requires only changing the altitude setting on the control. (See page 66).

Equipment that maybe required for installation

Digital or U-tube manometer for checking gas line pressure

per speciﬁcations, Figure 103, page 78

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 82 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).

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29 Startup

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.

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 160, page 117 for information. Follow instructions supplied with the X400 cleaner and cleaning instructions on page 111. 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 clean-

ing or sealing compounds in boiler system. Damage to elastomer seals and gaskets in system could occur, resulting in substantial 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

Hardness less than 7 grains

1. Consult local water treatment companies for unusually hard water areas (above 7 grains hardness).

Chloride concentration must be LESS THAN 50 ppm

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 160, page 117 for information.

2. See Replacement parts at the end of this manual for part numbers to obtain antifreeze through a Weil-McLain distributor.

Use the correct amount of antifreeze

1. Determine the freezing temperature needed (to protect against lowest likely temperature the system water will encounter).

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 components, including the expansion tank and boiler. a. Boiler water content is listed in Figure 173, page 130. 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 requirements 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-

Water pH between 7.0 and 8.5

1. Maintain boiler water pH between 7.0 and 8.5. Check with litmus paper or have chemically analyzed by water treatment company.

2. If pH differs from above, consult local water treatment company for treatment needed.

Part number 550-100-325/0718

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 proceeding further.

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29 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 isolation 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 pressure 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 80, page 60.

Freeze protection (if used)

Follow these guidelines to prevent possibility of

severe personal injury, death or substantial property damage:

Thoroughly ﬂush any system that has used

In addition to antifreeze and inhibitor, use and

If using freeze protection ﬂuid with automatic ﬁll,

Use only the products listed by Weil-McLain for use with this boiler. See page 117 for information.

glycol

before installing the new boiler.

Review the material safety data sheets (MSDS)

are available online. The MSDS contains information on potential hazards and ﬁrst aid procedures for exposure or ingestion.

Check antifreeze inhibitor level at least annually

. 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.

maintain minimum level of Sentinel X100 inhibitor as directed on this page.

install a water meter to monitor water make-up.

Freeze protection ﬂuid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.

DO NOT exceed 50% antifreeze by volume.

Antifreeze moves more sluggishly than water and can interfere with heat transfer. At antifreeze concentrations higher than 50%, sludge can develop in the boiler, potentially causing damage to the heat exchanger.

Use only antifreeze recommended by

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.

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 disconnection from city water supply.

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29 Startup (continued)

X100 inhibitor is required

1. It is required that the boiler have Sentinel X100 inhibitor 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 98 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.

Figure 98 Hardware ﬁttings to add Sentinel to boiler

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 concentration.)

2. If pH is outside this range (or inhibitor test kit indicates low level), the inhibitor level may not be sufﬁcient to prevent 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. volume concentration of antifreeze.

Check inhibitor level after adjustments are made.

DO NOT exceed 50% by

Check thermostat circuits

5. Disconnect wires connected to the thermostat terminals (see Field wiring, beginning on page 48 for low voltage terminal locations and application information). Mark the wires before removing to avoid wiring errors when re-connecting them.

6. 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.

There should NEVER be a voltage reading.

8. If a voltage does occur under any condition, check and correct the external wiring.

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.

Part number 550-100-325/0718

DO NOT connect the thermostat terminals

to 3-wire zone valves

trol damage.

9. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires.

. This could cause con-

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30 6WDUWXS²¿QDOFKHFNV

Inspect/ﬁll condensate system

Inspect/check condensate lines and ﬁttings

1. Inspect the condensate drain line, condensate PVC ﬁttings and condensate trap. (See page 45 for component locations).

Fill condensate trap with water

1. Loosen the nut that secures the condensate trap body to the boiler condensate connection (see Figure 99). 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.

Figure 99 Disconnect condensate trap assembly to ﬁll

trap body with water

Before starting the boiler, and during initial operation, 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 interior of the boiler jacket.

if there is any indication of a gas leak. Repair any leak at once

DO NOT adjust or attempt to measure gas valve outlet pressure.

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.

Propane boilers only — Your propane supplier

mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.

Check for gas leaks

Do not proceed with startup

The gas valve is factory-set for the

Nut

If it is suspected that the condensate drain connection 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.

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30 6WDUWXS²¿QDOFKHFNV (continued)

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 deterioration 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

The combustion for this boiler has been

checked, adjusted and preset at the factory for operation for Natural Gas.

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 101, page 76.

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 “TEST” mode.

Figure 100 Control in 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 76, page 58) 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 Figure 106, page 79.

per specifications Figure 103, page 78 and

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 Troubleshooting, beginning on page 85.

Check system and boiler

❏ Check water piping

1. Check system piping for leaks. If found, shut down boiler and repair immediately. (See WARNING on page 72 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.

❏ Check vent piping and air piping

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.

❏ Check gas piping

1. Check around the boiler and inside the boiler jacket for gas odor following the instructions in “Warning”on page 46 of this manual.

Part number 550-100-325/0718

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 injury, death or substantial property damage.

CONTINUED AFTER NEXT PAGE

Page 76

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

30 6WDUWXS²¿QDOFKHFNV (continued)

Figure 101 Operating instructions (WARNING — Verify that the control is set for the correct boiler model before

proceeding.)

Part number 550-100-325/0718

Page 77

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

30 6WDUWXS²¿QDOFKHFNV (continued)

❏ Propane boilers — verify conversion

1. Verify boiler has been converted for propane, See page 10.

DO NOT attempt to mea-

sure gas valve outlet pressure

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.

❏ Check ﬂame & combustion 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 “TEST” 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 100, page 75) to activate the “TEST” 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 “TEST” mode, press the CH keys (Items 3 and

4 Figure 76, page 58) together for 5 seconds, or leave the boiler to automatically switch off after 15 minutes or stopping DHW ﬂow.

8. This TEST procedure is used to check/adjust combustion

CO and CO Figure 106, page 79.

Insert combustion analyzer probe — Remove the ﬂue access

ﬁttings/turn to remove (see Figure 40, page 31) from the ﬂue pipe and insert a combustion test probe.

10. Test for CO

with or Figure 106, page 79. If results are acceptable, proceed to step 7. Screw Adjustment” on page 78 to set the throttle screw position. See WARNING 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.

Part number 550-100-325/0718

per speciﬁcations Figure 103, page 78 and

(or O2) and for CO. The CO2 values must comply

IF NOT, follow the instructions under “Throttle

If combustion at either high or low ﬁre is out-

side the range given in Figure 103, page 78 or Figure 106, page 79, 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 Support. 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 100, page 75) 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 “TEST” Mode by pressing the CH “+” and “-”

keys together for 5 seconds.

15. Reinstall the ﬂue access ﬁttings, (see Figure 40, page 31) 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 Combi and Heating Only boilers.

Gas Rate (Natural Gas)

After 10 minutes from cold

Boiler

model

AB-80

AB-120

AB-155

Maximum rate Minimum rate

ft3/h ft3/h

78.4 7.8

117.6 11.8

151.9 15.2

Page 78

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

30 6WDUWXS²¿QDOFKHFNV (continued)

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 100, page 75, Test Mode.

2. Wait 10 minutes to allow the boiler to stabilize.

3. Now adjust the Throttle setting (Figure 102 - screw A) until the CO below conﬁrm that the CO/CO2 ratio is within limits (clockwise to increase gas).

Figure 102 Throttle adjustment screw ––

is at the correct SETTING LEVEL (see Figure 103),

(ONLY for use by a qualiﬁed technician, using calibrated combustion test instruments).

CO2 Max. Regulating screw

Test at Max Power 100%

Turn clockwise (open gas)

IRU³0$;JDVÀRZ´

Turn counter-clockwise

(close gas)

IRU³0,1JDVÀRZ´

Rough start point

Using a combustion analyzer check the CO

values at low and high ﬁre. It should be within values from the table in Figure 103. The difference of CO2 from high ﬁre to low ﬁre should NEVER be below 0.2% or above 1%.

DO NOT 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 103 and

106, page 79.

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

setting level with an acceptable

CO/CO2 ratio cannot be obtained please contact your Weil-McLain Technical Support for details.

5. Should you require any assistance during the set up procedure 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 104, below, for Offset screw adjustment.

Figure 104 Remove

wrench for adjustment

T-40 cover cap with supplied Torx

For LP Start up ONLY

Adjust gas valve

HIGH FIRE

screw on right with

Allen wrench turn

Counter-Clock wise

1-1/8 turns.

Throttle adjustment

screw

Figure 103 Maximum rate combustion values –

measured values must be within the ranges given below

Natural Gas/LP Acceptable Combustion Range

Maximum Rate after 10 minutes from cold

Boiler Model

AB-80

AB-120

AB-155

CO/(PPM) CO

110 9.0 – 9.5 10.2 – 10.7

120 9.0 – 9.5 10.2 – 10.7

Final Combustion values

MUST BE checked with

Combustion Analyzer.

NG % CO2 LP %

Part number 550-100-325/0718

Page 79

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

30 6WDUWXS²¿QDOFKHFNV (continued)

At Minimum Rate:

1. Remove T-40 cap, see Figure 104, page 78, for Offset screw adjustment. Adjust the boiler to minimum output and allow the boiler to stabilize.

2. Now adjust the offset pressure setting (Figure 105 - screw B) Torx (T-40 male driver) until the CO

is at the correct SET-

TING LEVEL (see Figure 106), conﬁrm that the CO/CO2 ratio is within limits (clockwise to increase gas).

Figure 105 Offset adjustment screw ––

(ONLY for use by a qualiﬁed technician, using calibrated combustion test instruments).

Offset Regulating screw

Test at MIN. Power 00%

Turn clockwise (open gas)

IRU³0$;JDVÀRZ´

Turn counter-clockwise

(close gas)

IRU³0,1JDVÀRZ´

Rough start point

For LP Start up ONLY

Adjust gas valve

LOW FIRE

screw on left with

Allen wrench

Counter-Clock wise

ǩó turn.

Final Combustion values

MUST BE checked with

Offset adjustment B

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.

Figure 106 Minimum rate combustion values –

measured values must be within the ranges given below

Combustion Analyzer.

turn

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/CO2 to ensure that the values have not changed.

4. In the event that the CO

setting level with an acceptable

CO/CO2 ratio cannot be obtained please contact your Weil-McLain Technical Support.

❏ Check Heat exchanger and vent seals

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, immediately 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.

❏ Check ignition system safety shutoff device

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 “Reset” button once to Clear the Lockout code “A01”.

Natural Gas/LP Acceptable Combustion Range

Minimum Rate after 10 minutes from cold

Boiler Model

AB-80

AB-120

AB-155

Part number 550-100-325/0718

CO/(PPM) CO

20 8.0 – 9.0 9.0 – 9.8

7 8.0 – 9.0 9.0 – 9.8

NG % CO2 LP %

Page 80

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

31 6WDUWXSYHUL¿FDWLRQ

Additional field-installed limit control(s) set to system

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).

Have the following been done?

Boiler and heat distribution units ﬁlled with water?

❏

Water chemistry veriﬁed per page 71?

❏

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 instructions in this manual to install the propane venturi, see page 10. Failure to comply could result in severe personal injury, death or substantial property damage.

Thermostat circuit wiring checked to ensure there are no

❏

stray voltages?

❏

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? Lowered to lowest setting and veriﬁed boiler goes off?

Natural gas input measured? (page 77)

❏

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?

Followed Operating Instructions, Figure 101, page 76?

❏

Burner ﬂame and combustion veriﬁed per page 77?

❏

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.)

Fill out start-up data on the In-

stallation and Service Certiﬁcate, page 132.

Ignition system safety shutoff device tested?

❏

Before leaving:

Fill in Installation certiﬁcate, page 132.

❏

Return instructions to envelope and give to owner.

❏

Part number 550-100-325/0718

Page 81

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

32 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.

Figure 107 Service and maintenance schedules

Service technician

(see page numbers indicated for details)

• Handling ceramic ﬁber materials. . . . . . . . . . . . . . . . . 82

• First-year special inspection . . . . . . . . . . . . . . . . . . . 82

• Address reported problems . . . . . . . . . . . . . . . . . . . 83

• Inspect boiler area . . . . . . . . . . . . . . . . . . . . . . . . 83

• Inspect boiler exterior . . . . . . . . . . . . . . . . . . . . . . 83

• Inspect boiler interior . . . . . . . . . . . . . . . . . . . . . . 83

• Check all piping for leaks . . . . . . . . . . . . . . . . . . . . 83

• Check ignition wiring . . . . . . . . . . . . . . . . . . . . . . . 83

Owner maintenance

(see User’s Information Manual)

• Check boiler area.

• Check air openings.

Daily

Monthly

• Check pressure/ temperature gauge.

• Verify boiler jacket door is securely in place.

• Check vent piping.

• Check air piping.

• Check condensate drain system.

• Check for leaks.

• Check all boiler wiring . . . . . . . . . . . . . . . . . . . . . . 83

• Check control settings . . . . . . . . . . . . . . . . . . . . . . 83

• Perform startup and checks . . . . . . . . . . . . . . . . . . . 83

• Check burner ﬂame . . . . . . . . . . . . . . . . . . . . . . . 83

ANNUAL START-UP (See First-year special inspection)

• Check boiler relief valve . . . . . . . . . . . . . . . . . . . . . 84

• Reinstall jacket door after servicing . . . . . . . . . . . . . . . 84

• Review with owner . . . . . . . . . . . . . . . . . . . . . . . . 84

Part number 550-100-325/0718

Every

6 months

• Verify that domestic hot water is being supplied to ﬁxtures at the correct temperature.

• Check boiler piping (gas and water).

• Operate relief valve.

Page 82

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

33 Annual startup

HANDLING CERAMIC FIBER

MATERIALS

REMOVING BURNER GASKET or COVER PLATE INSULATION

The heat exchanger refractory contain

ceramic ﬁber identiﬁed as carcinogenic, or possibly

carcinogenic, to humans). can be converted to cristobalite in very high temperature applications.

The International Agency for Research on

Cancer (IARC) has concluded, “Crystalline 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 respirators 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 thoroughly.

NIOSH stated First Aid

■ Eye: Irrigate immediately.

■ Breathing: Fresh air.

materials that have been

Ceramic ﬁbers

FIRST-YEAR SPECIAL INSPECTION

1. No later than 12 months after the boiler is installed, per-

form a ﬁrst-year inspection of the boiler. This should include the following in addition to routine annual start-up

procedures

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 47 and 78; d. The gas rate, as described on page 47; e. The combustion performance, as described on pages 77,

78 and 79 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 550-100-325/0718

Page 83

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

33 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 107, page 81 and explained on the following pages must be performed to assure maximum boiler efﬁciency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

Electrical shock hazard — Turn off power to

the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

Address reported problems

1. 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.

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 condition 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 80.

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 76 for gas safety information.

Check burner ﬂame

The boiler contains ceramic ﬁber materials. Use

care when handling these materials per instructions on page 82 of this manual. Failure to comply could result in severe personal injury.

1. Inspect ﬂame through observation window.

Figure 108 Observation window

Part number 550-100-325/0718

Page 84

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

33 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 vacuum 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 108.

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 manufacturer’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.

4. If replacing the burner, ensure the burner gasket is in good condition and correctly positioned. Follow all instructions on page 109 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 automatic air vents (if used

— automatic air vents must be used with diaghragm-type expansion tanks only)

see page 35.

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.

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).

2. Read page 38 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 plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive 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 inspection must only be conducted by a plumbing contractor 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.

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.

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.

Part number 550-100-325/0718

Page 85

VERIFY PROPER OPERATION AFTER SERVICING

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

—

34 Troubleshooting

ERIFY PROPER OPERATION AFTER SERVICIN

Before calling for troubleshooting assistance, ﬁll in the

“

Boiler Startup Data Collection Sheet” (page 132).

Record the boiler size and CP number (located on the

left side exterior of the boiler jacket).

Failure to adhere to these guide-

lines can result in severe personal injury, death or substantial property damage.

ELECTRICAL SHOCK HAZARD

TURN OFF ALL POWER TO THE BOILER WHEN SERVICING

the switch is off.

. Internal wiring is still powered when

DO NOT JUMPER DEVICES

Never jumper (bypass) any device except for momentary 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 appliances. Failure to keep the jacket door securely fastened could result in severe personal injury or death.

BEFORE SERVICING or MAKING CONNECTIONS —

EFORE TROUBLESHOOTING

1. Check for 120VAC (minimum 102 VAC to maximum 132 VAC) to boiler.

2. Check the control for error codes.

3. See Figure 76, page 58 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 88.

To exit out, hold reset button for 20 seconds.

Figure 109 Tools and kits needed for troubleshooting.

Tool Purpose

#2 Phillips screwdriver

10mm wrench

#20 long-handled Torx driver

T-40 Torx driver

4mm Allen wrench

Multimeter

Manometer (Inclined or digital)

Combustion analyzer (Digital preferred)

Contact thermometer

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

ALWAYS TURN POWER OFF TO THE BOILER TO PREVENT ELECTRICAL SURGES, WHICH CAN DAMAGE BOILER COMPONENTS.

LABEL WIRES BEFORE REMOVING

Label all wires prior to disconnection

when servicing controls. Wiring errors can cause improper and dangerous operation.

Part number 550-100-325/0718

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.

Page 86

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

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.

Figure 110 Time line of ignition sequence for the Combi and Heating Only boilers.

HEAT DEMAND

DETECTION TIME

PRE-PUMP TIME PRE-PURGE TIME

IGNITION

GAS VALVE SAFETY TIME

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

INTER-PURGE FOR

A01 ATTEMPTS

IGNITION

INTER-PURGE FOR

FLAME LOSS

A06 ATTEMPTS

IGNITION

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 attempts 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.

Part number 550-100-325/0718

Page 87

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Check ﬂame signal

1. Navigate to Diagnostics/Inputs on the control display (see pages 58 to 62 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 correct 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 107 to remove

and inspect the ignitor.

b. If required, clean the ignitor and ﬂame rod as in-

structed, see page 107.

c. If cleaning the ignitor does not improve, ground wiring

is in good condition, and ground continuity is satisfactory, 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 components (starting on page 107).

d. Clean the heat exchanger as described in this manual if

necessary, see page 110.

Check control fuse

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 111 and Figure 112.

3. Remove and inspect the fuses (Item a, Figure 111 or Item b, Figure 112).

4. If necessary, replace the fuses: a. Control circuit fuse is a 250 VAC 3.15-amp rated

fuse. (Littelfuse 326012P)

b. Thermostat-relay circuit fuse is a 250 Volt 630mA rated

fuse. (Littelfuse 071-852 Type 5 x 20mm).

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 113 shows the correct value for the sensor at various temperatures. 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.

Figure 111 Control circuit fuse location

Fuse located on rear of circuit board

Figure 112 Thermostat-relay circuit fuse location

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.

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 113 Sensor resistances values

Temp

Sensor ohms

(°F)

Min Max Min Max Min Max

31530 33480

25792 27388

19258 20450

15218 16160

11577 12293

8891 9441

7185 7629

Temp

(°F)

100

110

120

130

140

150

160

Sensor ohms

5608 5954

4590 4874

3636 3860

3011 3197

2417 2567

1954 2074

1644 1746

Temp

(°F)

170

180

190

200

212

Sensor ohms

1344 1428

1143 1213

945 1003

810 860

657 697

Part number 550-100-325/0718

Page 88

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Make sure to determine the causes of outages. Do not leave the boiler operating without a com-

plete diagnosis.

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 76, page 58) 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 91) 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 lockout codes – “A” codes: (which blocks the heat demand - Press reset button for 1 second to reset) b. Automatic Reset type lockout 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” codes – Hard Lock-out – Manual Reset

Error code Description

A01 1REXUQHULJQLWLRQDIWHU¿YHDWWHPSWV

A02 )DOVHÀDPHLQGLFDWLRQ

A03

A04 F07 repeated 3 times in the last 24 hours

A05 No frequency feedback from fan after 1 hour

A06 WLPHVÀDPHORVVLQPLQXWHVWLPHIUDPH

A16 Outside sensor is not connected

A23

A26 F40 repeated 3 times in the last hour

A41

A42

A44

A61 Flame circuit error

A62 Gas valve circuit

A63 E2 prom error

A65 ADC circuit error

High limit protection: pump does not run or no water circulation

Nominal water pressure not reached within maximum allowed time

Temperature sensor not or bad connected to the pipe (CH mode)

Too high difference between two CH supply water temperature sensors

Temperature sensor not or bad connected to the pipe (DHW mode)

Abbreviation Description

ADC Analog Digital Converter

CH Central Heating

DHW Domestic Hot Water

LP /LTXH¿HG3HWUROHXP3URSDQH*DV

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

Part number 550-100-325/0718

Page 89

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Figure 114 Troubleshooting suggestions — Fault displays and diagnostics (continued)

Fault Code

A01

A02

A03

A04

A05

A06

F07

F10

F11

F12

Fault Condition Correction

No burner ignition

Flame present signal with burner off

Over temperature protection activation

Exhaust duct safety device activation

Fan protection activated

1RÀDPHDIWHULJQLtion stage (6 times in 4 minutes)

High exhaust temperature Air trapped in boiler heat exchanger Combustion not correct for Natural gas and LP fuel Boiler water piping and circulator not providing

FRUUHFWZDWHUÀRZ

Supply sensor 1 fault

Return sensor fault

DHW sensor fault

No gas

Ignition/detection electrode fault

Electrode fault

Combustion incorrect Natural gas & LP fuel

Faulty gas valve Check the gas valve and replace it if necessary

,QVXI¿FLHQWJDVVXSSO\SUHVVXUH Check the gas supply pressure

Condensate trap blocked and or condensate drain hose looped making a second trap

Electrode fault

Ignition cable fault Check the ignition cable

Heating sensor damaged

No water circulation in the system Check the circulating pump

Air in the system/heat exchanger Vent the system/purge heat exchanger Fault F07 generated 3 times in the last

24 hours

Fault F15 generated for 1 hour (consecutive)

Ignitor electrode fault

Flame unstable Check the burner

Gas valve Offset fault Check the Offset adjustment at minimum power

Air/fume ducts obstructed

Condensate trap blocked

The exhaust probe detects an excessive temperature

Sensor damaged

Wiring disconnected

Sensor damaged

Wiring disconnected

Sensor damaged

Wiring disconnected

&KHFNWKHUHJXODUJDVÀRZWRWKHERLOHUDQGWKDW

the air has been eliminated from the pipes. Check the wiring of the electrode and that it is

correctly positioned and free of any deposits Check the ignitor electrode wiring

Electrode deformed/misaligned and/or improper gap (5/32”)

Perform combustion test for Natural gas & LP fuel per chart section Figure 103, page 78 and Figure 106, page 79.

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.

Check the ignitor electrode wiring Electrode deformed/misaligned and/or improper gap (5/32”)

Check the correct positioning and operation of the heating sensor

See fault F07

See fault F15

Check the position of the ignitor electrode and replace it if necessary

5HPRYHWKHREVWUXFWLRQIURPWKHÀXHH[KDXVW

ducts and air inlet and terminals

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.

Check the exchanger

Purge out air in heat exchanger

&KHFNFRPEXVWLRQSHUVSHFL¿FDWLRQFKDUWV Figure 103, page 78 and Figure 106, page 79.

Check piping sizes and required pump models

Check the wiring or replace the sensorWiring shorted

Part number 550-100-325/0718

Page 90

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Figure 115 Troubleshooting suggestions — Fault displays and diagnostics (continued)

Fault Code

F13

F14

F15

F27

F34

F35

F37

F39

A16

A26

A41

A42

A44

F43

F51

F52

F53

A61

A62

A63 F64 A65 F66 A23 A24 F20 F21 F40 F47

Fault Condition Correction

Exhaust probe fault

Delivery sensor 2 fault

Fan fault

Flue temp

Supply voltage under 100V

Faulty voltage frequency

Incorrect system water pressure

Outdoor sensor fault

System installation

Sensor positioning

Heating sensor fault

Temp sensor

Exchanger protection activation.

Low water

Heating sensor fault

Temp sensor

Controller ABM08A fault

No communication between controller and gas valve

Controller ABM08A fault Controller ABM08A internal error

Card parameter fault Wrong card parameter setting

Probe damaged Wiring shorted Wiring disconnected Sensor damaged Check the wiring or replace the sensor Wiring shorted Wiring disconnected 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 condensate drain hose looped making a second trap.

Exhaust gas temp too high

Electric voltage trouble

Electric voltage trouble Check the electrical system

Pressure too low < 8 psi

Water pressure switch damaged or not connected

Check Heating Only boiler primary loop pump, must pump towards return side of boiler.

Sensor damaged or wiring shorted Check the wiring or replace the sensor

Sensor disconnected after activating the sliding temperature

Outdoor sensor is not connected Check the sensor

F40 Error repeated 3 times in 1 hour Check the water pressure in the system

Supply sensor disconnected from pipe

Sensor damaged Replace the sensor

Temp sensor not connected or badly connected to pipe (DHW mode)

No system H2O circulation Check the circulating pump

Air in the system Vent the system

Low water fault Check boiler installation and water level

Sensor damaged Replace the sensor

High limit thermostat error Check the sensor. Check boiler installation

Controller ABM08 internal error

Controller not connected Connect the controller to the gas valve

Valve damaged Replace the valve

Check the wiring or replace the exhaust probe

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.

Make sure correct vent material was selected (Parameter List 165)

Check the electrical system (Can’t have more than 1 pump wired to boiler

Fill the system

Check the sensor

Check pump location and pump water direc tion

Reconnect the outdoor sensor or disable the sliding temperature

Check the correct positioning and operation of the heating sensor

Check the sensor

Check the ground connection and replace the controller if necessary.

Check the card parameter and modify it if necessary.

Boiler water pressure switch is set for 9 psi (±2) minimum pressure.

Part number 550-100-325/0718

Page 91

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Figure 116 Troubleshooting suggestions — Fault displays and diagnostics (continued)

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:

Table 4 “F” codes – Soft Lock-out – Automatic Reset

Error code Description

F07

F10

F11

F12

F13

F14

F15

F20

F21

F27

F34

F35

F37

F39

F40

F43

F47

The Exhaust gases temperature is too high.

The CH supply water temperature sensor 1 error.

The CH return water temperature sensor error.

The DHW water temperature sensor error.

The Exhaust gases temperature sensor error.

The CH supply water temperature sensor 2 error.

Minimum and maximum frequency feedback from fan error.

The water pressure in the CH installation is near the low level.

The water pressure in the CH installation is near the high level.

The exhaust gas temperature is too high (PVC/CPVC/Polypro/AL29-4C - selection).

Low mains voltage.

Frequency error.

The water pressure in the CH installation is too low.

Outside sensor error.

The water pressure in the CH installation is too high or there’s a Control fault.

Heat exchanger protection.

Water pressure sensor not connected.

F50

F51

F52

F53

F64

F66

Part number 550-100-325/0718

Variable input switch contact opened.

Low water error.

Too high difference between two CH supply water temperature sensors.

High limit thermostat input error.

5 MicroCom reset in 15 minutes time frame.

Software doesn’t match.

Page 92

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Figure 117 Troubleshooting suggestions — Fault displays and diagnostics (continued)

Display Condition

FAULT 07 =

FAULT 10 =

FAULT 11 =

FAULT 12 =

FAULT 13 =

FAULT 14 =

If the exhaust gases temperature becomes higher than Maximum exhaust gases temperature and the high temperature 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.

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

XSWKH¿UVWWKDWZDVRXWVLGHWKHRSHUDWLQJUDQJH5HVROYLQJVLWXDWLRQFDQEHDFKLHYHGRQO\LIWKHVHQVRULVZLWKLQ

operating range again.

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

GHPDQGVZLOOEHGLVDEOHG,QFDVHRUPRUHVHQVRUVDUHEURNHQFRQWUROOHUZLOOSLFNXSWKH¿UVWWKDWZDVRXWVLGH

the operating range. Resolving situation can be achieved only if the sensor is within operating range again.

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

KHDWGHPDQGVZLOOEH GLVDEOHG,QFDVHRU PRUHVHQVRUVDUHEURNHQFRQWUROOHUZLOOSLFNXSWKH¿UVWWKDWZDV

outside the operating range. Resolving situation can be achieved only if the sensor is within operating range again.

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

GHPDQGVZLOOEHGLVDEOHG,QFDVHRUPRUHVHQVRUVDUHEURNHQFRQWUROOHUZLOOSLFNXSWKH¿UVWWKDWZDVRXWVLGH

the operating range. Resolving situation can be achieved only if the sensor is within operating range again.

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

XSWKH¿UVWWKDWZDVRXWVLGHWKHRSHUDWLQJUDQJH5HVROYLQJVLWXDWLRQFDQEHDFKLHYHGRQO\LIWKHVHQVRULVZLWKLQ

operating range again.

FAULT 15 =

FAULT 20 =

FAULT 21 =

FAULT 27 =

Blower driving problem – in case of new burner request the fan is switched on: if the controller measured a

IUHTXHQF\ORZHUWKDQ+]RU KLJKHU WKDQ +] HUURU ZLOO EH VHW ZLWK D FRQ¿UPLQJ WLPHRIVHFRQGV,Q

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.

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.

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

RXWSXWUHGXFWLRQLQWKLVZD\LI:DWHUSUHVVXUH! :DWHUSUHVVXUHKLJKOLPLWSVLWKHUHLVQROLPLWDWLRQLI:DWHU SUHVVXUH! :DWHUSUHVVXUHKLJKOLPLWSVLWKHQWKHPD[LPXPRXWSXWLVHTXDOWR%ORZHUDEVROXWH'+:PD[LPXPVSHHG%ORZHUDEVROXWHPLQLPXPVSHHGLI:DWHUSUHVVXUH! :DWHUSUHVVXUHKLJKOLPLWSVLWKHQWKH

maximum output is equal to Blower absolute minimum speed + 20Hz.

With the PVC/CPVC selection parameter equal to:

1. ,IGXULQJWKHÀXHJDVSURWHFWLRQPRGHWKHSRZHUUHGXFWLRQUHDFKHVWKHYDOXHDQGWKHÀXHJDVWHP-

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. ,IGXULQJWKHÀXHJDVSURWHFWLRQPRGHWKHSRZHUUHGXFWLRQUHDFKHVWKHYDOXHDQGWKHÀXHJDVWHP-

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.

Part number 550-100-325/0718

Page 93

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Figure 118 Troubleshooting suggestions — Fault displays and diagnostics (continued)

Display Condition

FAULT 34 =

FAULT 35 =

FAULT 37 =

FAULT 39 =

FAULT 40 =

FAULT 43 =

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).

The controller measures a voltage supply frequency different from the voltage supply frequency parameter. This is only an indication, the heat request is not switched off. When the controller will measure a voltage supply frequency equal to the Voltage supply frequency parameter, error will be resolved. (Example 60 Hz).

Low water pressure error can be caused by the low water pressure in the central heating system. This can be

GHWHFWHGLQZD\VYLDORZZDWHUSUHVVXUHVZLWFKDQGYLDZDWHUSUHVVXUHVHQVRUZLWKDFRQ¿UPLQJWLPHRI

seconds). In error mode, the heat demand and the pumps are switched off. See Pressure supervision of the central heating installation paragraph.

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

PRGHZLOOEHSRVVLEOH,QFDVHRUPRUHVHQVRUVDUHEURNHQFRQWUROOHUZLOOSLFNXSWKH¿UVWWKDWZDVRXWVLGHWKH

operating range. Resolving error situation can be achieved only if the sensors is within operating range again.

High water pressure error, caused by the water pressure sensor. Water pressure is higher than high level (with

DFRQ¿UPLQJWLPHRIVHFRQGV,QHUURUPRGHWKHKHDWGHPDQGDQGWKHSXPSVDUHVZLWFKHGRII6HH3UHVVXUH

supervision of the central heating installation paragraph.

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

WKHIXQFWLRQLVGLVDEOHGIRUWKH¿UVWVHFRQGVVWDUWLQJIURP*DVYDOYHRSHQLQJPRPHQW(DFK'+:GHPDQGWKH IXQFWLRQLVGLVDEOHGIRUWKH¿UVWVHFRQGVVWDUWLQJIURP*DVYDOYHRSHQLQJPRPHQW([FHSWIRUFRPIRUW0RGH LI'+:FRQ¿JXUDWLRQSDUDPHWHULVVHWWRLQWKLVFDVHWKHIXQFWLRQLVDFWLYHDVVRRQDVWKH*DVYDOYHRSHQLQJ PRPHQW,QFDVH'+:FRQ¿JXUDWLRQSDUDPHWHULVVHWWRDQGLQFDVHRI'+:PRGHLVUXQQLQJDQG,QVWDOOHU7HVW PRGHGHPDQGLVFUHDWHGWKHIXQFWLRQLVGLVDEOHGIRUWKH¿UVWVHFRQGV

FAULT 47 =

FAULT 50 =

FAULT 51 =

FAULT 52 =

FAULT 53 =

FAULT 64 =

FAULT 66 =

Part number 550-100-325/0718

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.

Variable input switch contact opened. See Variable input switch paragraph.

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.

When the system measures a difference between two CH supply water temperature sensors equal or higher than

)ZLWKDFRQ¿UPLQJWLPHRIVHFRQGVHUURULVFUHDWHG7KLVHUURUFRQGLWLRQLVVWRSSLQJWKHERLOHUDQGWR

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.

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.

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.

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.

Page 94

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Figure 119 Conﬁguration mode — Parameters, Descriptions, Default displays and Notes

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.

Parameter Description Default Note

b01 *DVW\SHVHOHFWLRQ 1DWXUDO*DV /3* 0

'+:FRQ¿JXUDWLRQ

b02

b03 :DWHUSUHVVXUHSURWHFWLRQ 6ZLWFK 6HQVRU 0

b04 Fan absolute DHW maximum speed (Hz)

b05 Fan absolute CH maximum speed (Hz)

b06 Fan absolute minimum speed (Hz)

b07 1RWLPSOHPHQWHG'+:FRQ¿J

 6WRUDJHWDQN  ,QVWDQWDQHRXVZLWKVHFRQGDU\KHDWH[FKDQJHU

'+:PD[LPXPRXWSXWERRVWOLPLWOHYHO'+:FRQ¿J

2 - Heating Only

3 - Combi

See

Figure 124, page 97.

See

Figure 124, page 97.

See

Figure 124, page 97.

100

DHW conf. dependent

Do Not Adjust

b08 1RWLPSOHPHQWHG'+:FRQ¿J

b09 Fan offset low level (Hz) 10 Do Not Adjust

b10 6XPPHU:LQWHUIXQFWLRQ 6XP:LQ DOZD\V:LQ 1 Do Not Adjust

b11 Variable input switch functionality (Number) 4 Do Not Adjust

b12 Variable output relay functionality (Number)

b13 External pcb variable output relay functionality (Number) 7 Do Not Adjust

b14 +RXUVRIQR'+:ÀRZWRVHWWKH(FRQRP\PRGH+RXUV 24 5DQJH KRXUV

b15 )DXOW)IXQFWLRQ GLVDEOH HQDEOH 0 Do Not Adjust

b16 Maximum exhaust gases temperature (°F) 200

b17 0DLQVXSSO\IUHTXHQF\ +] +] 1 Do Not Adjust

b18

b19 '+:WDQNSUHSDUHPRGH1XP'+:FRQ¿J

b20 )DQW\SHVHOHFWLRQ 1RWXVHG (EP 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 32

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 +\GUDXOLFFRQ¿JXUDWLRQ'+:FRQ¿J

b28 2IIVHWÀDPHFXUUHQWORZOLPLW 20 Do Not Adjust

'+:PD[LPXPRXWSXWERRVWOLPLWWLPH6HF'+:FRQ¿J

Figure 124, page 97

1RWLPSOHPHQWHG'+:FRQ¿J 1RWLPSOHPHQWHG'+:FRQ¿J

'+:ÀRZVHQVRU¿OWHU6HF'+:FRQ¿J

1RWLPSOHPHQWHG'+:FRQ¿J

See

0 0

DHW conf. dependent

Do Not Adjust

Model dependent

200 PVC/ 212 CPVC

sel. dependent

DHW conf. dependent

Not used,

Do Not Adjust

DHW conf. dependent

Do Not Adjust

DHW conf. dependent

Do Not Adjust

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.

Part number 550-100-325/0718

Page 95

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Figure 120 Installer mode

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 “

tS blinking

Transparent parameter mode See Figure 121 thru 124, pages 95-97.

In blinking

Inquiry mode See Figure 125 & 127, pages 97-98.

Hi blinking

History mode See Figure 127, page 98.

rE blinking

Reset all the History information

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 activation 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” 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 121 “tS” - Transparent Parameter mode

Parameter Description Default Notes

P01

P02

P03

P04

Ignition level (%)

CH slope control (°F/min) 6

Minimum Virtual set point (°F) 95 Do Not Adjust

CH OFF time (Min) 2

60 or 80

or 50

60% - AB-120 / 80% - AB-80

50% - AB-155

P05

P06

P07

P08

P09

P10

P11

P12

P13

Part number 550-100-325/0718

CH pump over-run time (Sec) 15

CH pump selection (0-7) 0 Do Not Adjust

CH modulating pump PWM absolute min (%) 30 Do Not Adjust

CH modulating pump PWM start (%) 75 Do Not Adjust

CH modulating pump PWM absolute max (%) 100 Do Not Adjust

&+VXSSO\IRU&+SXPSRYHUUXQ2)))'+:FRQ¿J &+VXSSO\IRU&+SXPSRYHUUXQ2)))'+:FRQ¿J

&+VXSSO\IRU&+SXPSRYHUUXQ21)'+:FRQ¿J &+VXSSO\IRU&+SXPSRYHUUXQ21)'+:FRQ¿J

CH set point limit HIGH (°F) 190

CH maximum output (%) 100 Also in Test Mode

68 91

DHW conf. dependent

&RQ¿J+HDWLQJ2QO\ 

&RQ¿J&RPEL 

DHW conf. dependent

&RQ¿J+HDWLQJ2QO\ 

&RQ¿J&RPEL 

Page 96

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Figure 122 “tS” - Transparent Parameter mode (continued)

Parameter Description Default Note

P14

P15

P16

P17

P18

P19

P20

P21

P22

P23

P24

P25

P26

P27

P28

P29

P30

P31

P32

P33

P34

/HJLRQHOODSURWHFWLRQ'+:FRQ¿JZLWKVHQVRU /HJLRQHOODSURWHFWLRQ'+:FRQ¿JZLWKWKHUPRVWDW '+:RIIPRGH'+:FRQ¿J

'+:&RPIRUW+\VWHUHVLV)'+:FRQ¿J '+:&RPIRUWVZLWFKRQSRLQW)'+:FRQ¿J

&+VXSSO\RYHUWHPSBEXUQHU21)'+:FRQ¿J '+:&RPIRUWWHPSHUDWXUHGLIIHUHQFH)'+:FRQ¿J

'+:GHOWD)'+:FRQ¿J '+:2))WLPH6HF'+:FRQ¿J

'+:VHWSRLQWOLPLW+,*+)'+:FRQ¿J '+:VHWSRLQWOLPLW+,*+)'+:FRQ¿J

'+:SXPSRYHUUXQWLPH6HF'+:FRQ¿J '+:SXPSRYHUUXQWLPH6HF'+:FRQ¿J

DHW maximum output (%) 100

1RWLPSOHPHQWHG'+:FRQ¿J 1RWLPSOHPHQWHG'+:FRQ¿J

'+:FRPIRUWRIIWLPH0LQ'+:FRQ¿J 1RWLPSOHPHQWHG'+:FRQ¿J 1RWLPSOHPHQWHG'+:FRQ¿J

Blower speed in Stand-by mode (Hz) 0

Post-Ventilation time (Sec) 27

'HOWD7)'+:FRQ¿J 'HOWD7)'+:FRQ¿J

'HOWD7)'+:FRQ¿J 'HOWD7)'+:FRQ¿J

Water pressure low limit (psi) 6

Water pressure nominal (psi) 10

1RWLPSOHPHQWHG'+:FRQ¿J +HDWH[FKDQJHUSURWHFWLRQ)6HF'+:FRQ¿J

CH hysteresis after burner ignition (°F) 18

CH hysteresis after burner ignition timer (Sec) 60

'+:VORSHFRQWURO)PLQ'+:FRQ¿J 1RWLPSOHPHQWHG'+:FRQ¿J

3ULRULW\2YHU5LGH6HWPLQ'+:FRQ¿J 1RWLPSOHPHQWHG'+:FRQ¿J

3ULRULW\2YHU5LGH5HVHWPLQ'+:FRQ¿J 1RWLPSOHPHQWHG'+:FRQ¿J

-0

104

176

120

149 131

30 30

32 32

255

DHW conf. dependent

Fixed if the Water pressure

SURWHFWLRQLVVHW 6ZLWFK

Fixed if the Water pressure

SURWHFWLRQLVVHW 6ZLWFK

DHW conf. dependent

Not Used

Part number 550-100-325/0718

Page 97

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Figure 123 “tS” - Transparent Parameter mode (continued)

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.

Figure 124 Default Control Board “Transparent Parameters”

Boiler

Model

AB-80-N-C

AB-120-N-C

AB-155-N-C

AB-80-N-H

AB-120-N-H

AB-155-N-H

AB-80-LP-C

AB-120-LP-C

AB-155-LP-C

AB-80-LP-H

AB-120-LP-H

AB-155-LP-H

“b01” “b02” “b04” “b05” “b06” “b10” “b12”

Gas type

 1DWJDV

 /3*

Boiler

type

3 155 155 35 1 0 1 80 6 2

3 200 200 40 1 0 1 60 6 2

3 205 210 39 1 7 1 50 6 2

2 155 155 40 1 0 1 80 6 2

2 200 200 40 1 0 1 60 6 2

2 205 210 39 1 0 1 50 6 2

3 145 145 35 1 0 1 80 6 2

3 185 185 40 1 0 1 60 6 2

3 210 220 40 1 7 1 50 6 2

2 145 145 35 1 0 1 80 6 2

2 185 185 40 1 0 1 60 6 2

2 210 220 40 1 0 1 50 6 2

Fan

Max. Freq.

in DHW

Fan

Max. Freq.

in CH

Fan

Min. Freq.

in CH

S/W mode

selection

button

Var. Out

Relay

“b22”

Vent

material

“P01” “P02” “P04”

Ignition

level

CH Slope

(F/min)

Off Time

Figure 125 “In” - Inquiry mode

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) 0LQ 0D[ SDUDPHWHUGHSHQGLQJ L08 blinking Actual burner load (%)  0LQ 0D['+:ERRVWRXWSXW F09 blinking $FWXDOZDWHUÀRZUDWH OPLQ 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).

Part number 550-100-325/0718

Page 98

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Figure 126 “In” - Inquiry mode (continued)

P10 blinking

Boiler water pressure switch status 2SHQ &ORVHG 

P11 blinking

Actual PWM modulating Pump (%) 0LQ 0D[ 

P12 blinking

Actual Step of Triac mod. mode (Num) 0LQ 0D[ 

F13 blinking

$FWXDO)ODPH&XUUHQW X$ between 00 and 255

• If a temperature sensor is in an open circuit or short circuit condition, 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.

“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).

Figure 127 “Hi” - History mode

H01 blinking

History buffer 1 (the latest)

H02 blinking

History buffer 2

H03 blinking

History buffer 3

-------- --------

H08 blinking

History buffer 08

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.

Part number 550-100-325/0718

Page 99

AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Figure 128 Troubleshooting suggestions for AquaBalance

boilers — Fault displays and diagnostics (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 118, page 94), 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.

Table 5 AquaBalance® list of System parameters (default settings)

Category E2 prom parameters Unit Range Def

Description

DHW boiler type 1 CL5 – 05C8 '+:FRQ¿JXUDWLRQ Num 1 4 3

System 2 ML – 80D0 )LUVWVWDUWXSÀDJ 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

Num. Address Description Low High Value

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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AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual

34 Troubleshooting (continued)

Figure 129 Troubleshooting suggestions for AquaBalance

boilers — Fault displays and diagnostics (continued)

Category E2 prom parameters Unit Range Def

Description

'+:FRQ¿J 9,2 CL5 – 066E DHW P factor Num 0 255 5

'+:FRQ¿J 10,2 CL5 – 0691 DHW I factor Num 0 255 240

'+:FRQ¿J 11,2 ML – 80EB DHW FF factor Num 0 255 0

'+:FRQ¿J 12,2 ML – 80EC Fan absolute DHW maximum speed Hz 0 220 200

'+:FRQ¿J 13,2 ML – 80ED Fan absolute CH maximum speed Hz 0 220 200

'+:FRQ¿J 14,2 ML – 80EE Fan absolute minimum speed Hz 0 165 40

'+:FRQ¿J 15,2 CL5 – 2D89 Fan offset low level Hz 0 220 10

'+:FRQ¿J 16,2 ML – 80F0 Ignition level % 0 100 60

'+:FRQ¿J 17,2 Free - TBD

'+:FRQ¿J 18,2 Free - TBD

'+:FRQ¿J 19,2 Free - TBD

'+:FRQ¿J 20,2 Free - TBD

'+:FRQ¿J 21,2 Free - TBD

'+:FRQ¿J 22,2 Free - TBD

'+:FRQ¿J 23,2 Free - TBD

'+:FRQ¿J 24,2 Free - TBD

'+:FRQ¿J 25,2 Free - TBD

'+:FRQ¿J 26,2 ML – 80FA DHW pre-pump time Sec 0 30 30

'+:FRQ¿J 27,2 ML – 80FB Legionella protection Num 0 7 0

'+:FRQ¿J 28,2 CL5 – 0A5E DHW comfort hysteresis °F 0 176 4

'+:FRQ¿J 29,2 CL5 – 0A62 DHW comfort temp difference °F 0 104 0

'+:FRQ¿J 30,2 ML – 80FE DHW pump start temperature °F 0 255 32

'+:FRQ¿J 31,2 ML – 80FF DHW pump start waiting time Sec 0 255 0

'+:FRQ¿J 32,2 CL5 – 05A1 DHW OFF time Sec 30 255 120

'+:FRQ¿J 33,2 CL5 – 0A04 DHW pump over-run time Sec 0 255 30

'+:FRQ¿J 34,2 CL5 – 0A6D Delta T1 °F 0 108 32

'+:FRQ¿J 35,2 CL5 – 0A92 Delta T2 °F 0 255 63

'+:FRQ¿J 36,2 ML – 8104 CH supply for CH pump over-run OFF °F 32 212 68

'+:FRQ¿J 37,2 CL5 – 0C94 CH supply for CH pump over-run ON °F 0 200 9

'+:FRQ¿J 38,2 ML – 8106 CH supply over-temp_burnerOFF °F 0 212 9

'+:FRQ¿J 39,2 ML – 8107 CH supply over-temp_burnerON °F 32 212 176

'+:FRQ¿J 40,2 ML – 8108 CH return over-temp_burnerOFF °F 32 212 203

'+:FRQ¿J 41,2 ML – 8109 CH return over-temp_burnerON °F 32 212 194

'+:FRQ¿J 42,2 ML – 810A DHW set point limit – LOW °F 50 104 50

'+:FRQ¿J 43,2 CL5 – 1E76 DHW set point limit – HIGH °F 104 158 149

'+:FRQ¿J 44,2 CL5 – 05F4 DHW user set point – Default value °F 50 158 149

'+:FRQ¿J 45,2 ML – 810D CH pre-pump time Sec 0 60 30

'+:FRQ¿J 46,2 ML – 810E Minimum virtual set point °F 68 176 95

Num. Address Description Low High Value

100

Part number 550-100-325/0718