Weil-McLain AHE Series Page 41 Manual Download

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Part number 550-141-887/0800

AHE

Series 4 Direct Vent Wall-Mounted Boilers

— Boiler Manual

Troubleshooting — charts

continued

12d

CHART 8

— Insufficient heat or no heat to system (POWER light on steady)

Electrical shock hazard — Wherever you see

▲

TURN OFF POWER

▲

, follow the instructions. Failure to follow

instructions could result in severe personl injury, death or substantial property damage.

• Excessive block temperature has been reduced to safe

operating level. Check for low water level or mineral
deposits in sections. Correct before proceeding.

• Restart boiler and check normal sequence of operation.

(See normal sequence of operation, Figure 17, page 22.)

• Boiler is in standby.
• Set thermostat to call for heat

and recheck operation.

• Verify Sequence of operation,

Figure 17, page 22.

• Replace control module.
• Retest.

• Boiler water temperature exceeded setting on limit switch

with thermostat calling for heat. Boiler is OK. (See
normal sequence of operation, Figure 17, page 22.)

• Also check operation of setting on limit switch (should be

above 140˚F.).

• Has it been at least 5 minutes since setting thermostat to

call for heat? If not, wait 5 minutes. Is system heating?

• Is thermostat set to call for heat? Remove thermostat

wires at boiler and check continuity across the two wires.
If circuit isn't closed, check external thermostat (zone
valve, relay, etc.) wiring. Correct problems and retry.

• Reconnect external thermostat wiring at boiler.

Is thermostat circuit closed (continuity across wires)?

• If you have sufficient heat — boiler should be in normal

operating sequence. (See normal sequence of operation,
Figure 17, page 22.)

• If you have less than sufficient heat —

Is vent or combustion air piping free of blockage?

Yes

• Correct conditions and

recheck operation.

• See Figure 17, page

22 for normal
sequence of operation.

Contact your Weil-McLain
sales representative.

• Replace control module.
• Retest.

• Repair/replace

circulator. Retest.

• Repair/replace wiring.

Retest.

• Remove CIRCULATOR harness plug from

CIRCULATOR plug receptacle (

Figure 29, page

34, Item 4). Check with voltmeter across right-side
120 VAC N and 120 VAC H pins of receptacle.

Does voltmeter show 120 VAC across pins?

Yes

Is boiler System circulator operating?

Wait 5 minutes.

Is FLAME light on?

Yes

Wait for boiler water to cool to temperature 20 to 30 ˚F
lower than temperature set on limit switch.

Are limit switch contacts closed?

Check block switch on top of boiler with continuity checker.

Are block switch contacts closed?

Yes

Are all red lights off?

Yes

Wait 30 seconds.

Are all red lights off?

Yes

Replace block
switch. Retest.

Replace control
module. Retest.

Check limit switch contacts
with continuity checker.

Are limit switch

contacts closed?

Yes

Wait for cast iron block to
cool to room temperature.

Are block switch

contacts closed?

Yes

Replace limit
switch. Retest.

Yes

Summary of Contents for AHE Series

Page 1: ......

Page 2: ...evere personal injury death or substantial property damage Indicates presence of hazards that will or can cause minor personal injury or property damage Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Contents Please read before proceeding 3 Prepare boiler location 4 7 Venting 8 13 Prepare boiler 14 Wa...

Page 3: ...r water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water Boiler water Do not use petroleum based cleaning or sealing compounds in boiler system Water seal deterioration will occur causing leakage between sections This can result in substantial property damage Do not use homemade cures o...

Page 4: ...ler check the following 1 Check for nearby connection to System water piping Venting connections Gas supply piping Electrical power 2 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 substanti...

Page 5: ...e following special precautions when installing the boiler in a residential garage If the boiler is located in a residential garage per ANSI Z223 1 paragraph 5 1 9 Mount the boiler a minimum of 18 inches above the floor of the garage to assure the burner and ignition devices will be no less than 18 inches above the floor Table 1 Recommended minimum clearances Service clearances Note 1 Enclosed cab...

Page 6: ...enting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers Wall thickness See Table 2 below for wall thicknesses for venting Wall Sleeve Wall Thickness Minimum Maximum 5 9 5 9 9 13 9 13 13 24 13 24 d Place in operation the appliance being inspected Follow the operating instructio...

Page 7: ...or each 1 000 Btuh of total input of all appliances 1 Provide two openings into the space each opening providing at least 1 square inch free area per 1 000 Btuh of all appliances in the space Locate one opening within 12 inches of the ceiling the other opening within 12 inches of the floor 2 For larger spaces over 50 cubic feet total volume per 1 000 Btuh of all appliances no additional air openin...

Page 8: ...termination to prevent condensate from damaging exterior surfaces 6 Do not terminate vent above any door or window Condensate can freeze causing ice formations 7 Do not terminate vent in window well or stairwell 8 Vent must terminate a AHE 45 9 from any opening where gases could enter building b AHE 60 12 from any opening where gases could enter building c Bottom of vent air intake terminal 12 abo...

Page 9: ...nting only 6 min clearance to slide panel over tubes left venting only 38 maximum including wall thickness Exterior room wall Exterior room wall Note Tubes can be enclosed minimum of 1 clearance from tubes to combustible material Select location Review all connection clearance and vent air intake considerations before selecting location See Figure 1 for side venting clearance access to outside wal...

Page 10: ...template on side wall Height of top exhaust center line is distance in step b Note correct up position for right or left side venting 9 Mark location of vent air intake opening through template on side wall 10 Remove template and cut opening in wall Outside 11 The following material is required a outside wall plate assembly see Figure 4 on this page and Figure 8 page 11 b silicone sealant c 4 10 x...

Page 11: ...ly generous bead of silicone sealant around insertion end of tubes 1 from end of tube 22 Place tubes in openings See Figure 8 23 Place inside wall plate see Figure 32 page 44 item 3 over tubes against wall 24 Slide mounting panel Figure 32 page 44 item 5 over tubes Tubes will extend into plenum box openings 25 Securing mounting panel to studs with 2 5 16 x 2 lag screws provided Use toggle bolts on...

Page 12: ...aration on page 8 Failure to mount panel properly can result in severe personal injury death or substantial property damage 2 Mark location on wall of vent air intake opening small rectangle in template Remove template 3 Cut opening in wall Outside 4 Take the following materials outside a outside wall plate assembly see Figure 4 on page 11 b silicone sealant c level d 4 10 x 1 common screws provid...

Page 13: ...ng See Figure 9 14 Fit inside wall plate into opening See step 8 above Tubes should protrude from plate Do not fasten plate to wall See Figure 9 15 Apply continuous bead of silicone sealant around junctions of tubes and inside cover plate Smooth sealant to provide thorough seal See Figure 10 16 Using mounting panel as template align 2 plenum box openings over intake and exhaust tubes Level and mar...

Page 14: ...boiler See Figure 11 Inspect orifices and burners 1 Remove burner inlet plenum cover see Figure 30 item 9 page 42 2 Carefully remove ignitor and ignitor gasket Use caution ignitor is brittle and can break Wait several minutes until ignitor coolsdown beforeremoving Failure to do so will cause severe personal injury 3 Check for correctly size burner orifices See Table 3 for sizing The orifice size i...

Page 15: ... zone valves for multiple zone applications Refer to manufacturer s literature for wiring and application To avoid water damage or scalding due to relief valve operation Discharge line must be connected to relief valve outlet and run to a safe place of disposal Terminate the discharge line to eliminate possibility of severe burns should the valve discharge Discharge line must be as short as possib...

Page 16: ...ge 3 for important information regarding glycol hazard Do not use ethylene glycol automotive or undiluted antifreeze Severe personal injury or death can result 4a Water piping general information con t 1 Determine antifreeze quantity according to system water content Boiler water content is listed on page 47 2 Follow antifreeze manufacturer s instructions 3 A 50 solution of propylene glycol water ...

Page 17: ...t 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 Severe damage to boiler will occur resulting in substantial property damage 5 With shutoff valves still closed attach hose adapter and hose to one drain valve and discharge water throug...

Page 18: ...ply pipe dope as detailed above can result in severe personal injury death or substantial property damage 3 Install drip leg at inlet of gas connection to boiler See Figure 15 Where local utility requires drip leg to be extended to the floor use appropriate length of pipe between cap and tee 4 Install manual main shutoff gas valve and ground joint union in gas piping according to local utility req...

Page 19: ... to wiring diagram inside jacket door or on page 23 For addition of zone valves to system a separate transformer is required to power zone valves Refer to manufacturer s recommendations for sizing requirements and wiring recommendations Zoning with circulators requires a relay for each circuit Thermostat 1 Connect thermostat to control wire harness inside boiler as shown on wiring diagram inside j...

Page 20: ...vel in the gas Start the boiler Follow the Operating instructions found on pages 24 25 to start the boiler Refer to Section 8b below if boiler fails to start Check burner flames 1 Refer to Figure 30 item 9 on page 42 Remove burner input plenum cover 2 Visually inspect burner flames Proper main burner flame see Figure 16 a Yellow orange streaks may appear caused by dust Improper main burner flame a...

Page 21: ...system temperature requirements Adjust balancing valves and controls to provide design temperature to system Verify thermostat heat anticipator set properly Refer to Thermostat on page 19 and wiring diagram on jacket door or in manual page 23 Cycle boiler with thermostat Raise to highest setting and verify boiler goes through normal start up cycle Lower to lowest setting and verify boiler goes off...

Page 22: ...n Ignitor remains on Boiler producing heat 6 Limit cycle Limit circuit open Gas valve closed 7 Flame outage Flame out Boiler recycles 8 Thermostat satisfied Circulator off Blower postpurge If flame is not proven in 4 seconds boiler recycles 2 times to retry for ignition before going into lockout Recycle igniter timing is 30 seconds Postpurge and prepurge are performed on every cycle In event of lo...

Page 23: ...NDUCER MOTOR TRANSFORMER Part Number 550 223 787 0800 AHE Series 4 Hot surface ignition Natural or propane gas Forced hot water Legend 120 VAC FACTORY WIRING LOW VOLTAGE FACTORY WIRING 120 VAC FIELD WIRING LOW VOLTAGE FIELD WIRING Plug in connectors Red White BL BL EQUIPMENT GROUND N G H note 6 note 10 note 3 note 8 note 7 BLOCK TEMPERATURE SWITCH R R R R BK BK G W W G W BK G G G BK BK A United Do...

Page 24: ...e performed 3 Remove control access panel A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand B Before OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor See below C Use only your hand to turn the gas control knob Never ...

Page 25: ... appliance will not operate follow the instructions ToTurn Off Gas To Appliance below and call your service technician or gas supplier 12 Replace control access panel 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Remove control access panel 4 Turn gas control knob clockwise to OFF Do not force 5 Replace control access panel A ...

Page 26: ...NNNUAL START UP Inspect Reported problems Boiler area Air openings Flue gas vent system and air piping Main burner flames Water piping Boiler heating surfaces Burners and base Service Cleaning boiler heating surfaces Blower motor Oiled bearing circulators Start up Perform start up per manual Check test Gas piping Cold fill and operating pressures Air vents and air elimination Blower motor assembly...

Page 27: ...r liquids near the boiler Remove immediately if found Air openings 1 Verify that combustion and ventilation air openings to the boiler room and or building are open and unobstructed 2 Verify that boiler vent discharge is clean and free of obstructions Flue gas vent system and air piping 1 Visually inspect entire flue gas venting system and air piping for blockage deterioration or leakage Repair an...

Page 28: ...gnitor see Figure 20 and ignitor gasket Use caution ignitor is brittle and can break Do not touch ignitor surface with bare hands Body oils can cause failure of the carbide Replace ignitor gasket if original gasket is frayed or damaged Wait several minutes until ignitor coolsdown beforeremoving Failure to do so will cause severe personal injury 3 Inspect burners and all other components in the boi...

Page 29: ... continue to the next step 6 Remove entire blower assembly a Remove 2 screws on mounting plate b Remove white and red tubing c Pull unit from boiler 7 Thoroughly clean all visible heating surfaces and remove soot See Figure 22 8 Replace blower motor assembly a Reseal all surfaces for gas tight seal b Replace screws and tubing 9 Clean burners See Burners and base on page 28 10 Replace burners See S...

Page 30: ...blower mounting plate 2 Disconnect 2 black wires from junction box to blower motor at wire nuts 3 Remove 3 10 x Phillips screws from blower backing plate 4 Break silicone seal and remove entire blower assembly 5 Remove excess silicone sealant from mounting and backing plates 6 Reseal around blower backing plate with silicone sealant including the covers Boiler must besealed gas tight Failure to do...

Page 31: ...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 tine 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 c...

Page 32: ...uity checker d Inclined manometer with 0 2 w c range 2 Check for 120 VAC minimum 102 VAC to maximum 132 VAC to boiler 3 Make sure thermostat is calling for heat and contacts including appropriate zone controls are closed Check for 24VAC between thermostat wire nuts and ground VERIFY PROPER OPERATION AFTER SERVICING Check the following 1 Wire connectors to control module are securely plugged in at ...

Page 33: ...eter reading is at least 0 55 w c pressure but there is not 24 VAC across normally open terminal on pressure switch and ground replace the pressure switch 2 If manometer reading is lower than 0 55 w c look for possible causes blockage in hoses obstruction in blower housing outlet loose blower wheel on motor shaft blower back plate not sealed properly blockage in exhaust air intake pipe or terminat...

Page 34: ...ually indicates pressure switch is closed when it should not be or pressure switch failed to close within 5 minutes of blower starting POWER and FLAME lights flashing Usually indicates control has had three unsuccessful ignition attempts or sensed flame when it shouldn t be there Non lockout modes TSTAT CIRC light flashing alone Usually indicates return water temperature sensor detects water at bo...

Page 35: ...voltmeter indicate 120 VAC No Yes Reconnect 120 VAC IN plug Remove 120 VAC transformer PRIMARY plug Figure 29 page 34 Item 2 on control module Using voltmeter check across top and bottom pins of PRIMARY receptacle Does voltmeter indicate 120 VAC No Yes Reinstall 120 VAC transformer PRIMARY plug Remove 24 VAC transformer plug Figure 29 page 34 Item 7 on control module Using voltmeter check across p...

Page 36: ...ormal sequence of operation shown in Figure 17 page 22 if wiring was corrected Check the boiler internal return pipe where it enters the boiler sections The TSTAT CIRC and POWER lights will flash as long as the return water temperature is less than 130 F Wait up to 20 minutes to give the boiler and system a chance to respond Does problem persist No Yes Boiler may now be operating normally Verify a...

Page 37: ...ance Does the ohmmeter indicate a shorted sensor zero ohms No Yes No Yes Replace the 47K resistor Retest Close the external manual gas valve Remove one wire from the limit control space connector Set a thermostat to call for heat Then turn on power to the boiler at the 120 VAC service switch The boiler system circulator should come on and the control module should try to cycle the boiler Allow the...

Page 38: ... Also check blower housing assembly Replace if necessary Retest Properly position blower wheel on blower motor shaft and tighten set screw Or replace blower housing assembly Retest No Yes Wait 45 seconds Does blower motor operate No Yes Remove BLOWER plug Figure 29 page 34 Item 3 from plug receptacle of control module Place voltmeter leads across the 120 VAC N and 120 VAC H pins of the BLOWER rece...

Page 39: ...erating properly See normal sequence of operation Figure 17 page 22 Call your local Weil McLain sales representative Check and or replace gas valve Recycle boiler by thermostat or service switch Thermostat should call for heat and appropriate zone valves close Wait 5 minutes Are FLAME POWER lights flashing No Yes Check and or replace igniter Recycle boiler by thermostat or service switch Thermosta...

Page 40: ...at Verify by removing thermostat wirings at boiler and checking continuity across external wires This is normal operation for water less than 40 F at boiler internal return pipe Condition should change after a call for heat when the boiler will heat up the water Wait 10 minutes to allow heat from the boiler to raise the water temperature Does LIMIT light quit flashing and pipes begin to heat up No...

Page 41: ... valve relay etc wiring Correct problems and retry Reconnect external thermostat wiring at boiler Is thermostat circuit closed continuity across wires If you have sufficient heat boiler should be in normal operating sequence See normal sequence of operation Figure 17 page 22 If you have less than sufficient heat Is vent or combustion air piping free of blockage No Yes Correct conditions and rechec...

Page 42: ...10 Gasket burner inlet plenum cover AHE 45 AHE 60 590 317 605 590 317 606 11 Gasket ignitor 590 317 599 12 Ignitor silicone carbide Norton 271 511 330 145 Item number Description Manufacturer Manufacturer s part number Weil McLain part number 13 Burner manifold AHE 45 7 50 AHE 60 10 63 591 126 572 591 126 573 14 Junction box 4 x 2 12 591 804 610 15 Bottom insulation retainer 450 030 769 16 Transfo...

Page 43: ...88740 1 2 3 4 5 Item number Description Boiler model number Weil McLain part number 1 Jacket door All 421 400 009 2 Jacket side panel left AHE 45 AHE 60 421 400 010 421 400 011 3 Jacket side panel right AHE 45 AHE 60 421 400 012 421 400 013 4 Jacket top panel AHE 45 AHE 60 421 400 030 421 400 035 5 Jacket bottom panel AHE 45 AHE 60 421 400 040 421 400 045 ...

Page 44: ...over plate for side venting 450 030 725 450 030 725 450 030 725 5 Mounting panel 450 030 781 450 030 781 450 030 781 6 Exhaust box bottom and back 450 030 772 450 030 772 450 030 772 7 Exhaust box top and front 450 030 773 450 030 773 450 030 773 8 Exhaust box cover plate 450 030 716 450 030 716 450 030 716 9 Exhaust box gasket 590 317 600 590 317 600 590 317 600 10 Air intake cover plate 450 030 ...

Page 45: ... Gauge Ametek ENFM 199980 4104 2 CBM 510 218 099 8 Circulator pump with mixing valve Taco 005 RFI 2W 511 405 008 9 Strain relief bushing obtain locally 10 Strain relief adapter obtain locally 11 Nipple x 13 black obtain locally Item number Description Manufacturer Manufacturer s part number Weil McLain part number 12 Tee black obtain locally 13 Drain valve Conbraco Hammond Matco Norca Watts 31 606...

Page 46: ...5 See Figure 1 page 10 6 23 8 diameter exhaust vent 7 23 8 diameter intake vent 8 Boiler depth AHE 45 147 8 AHE 60 177 8 Boiler model Boiler crate dimensions outside measurement inches Note 1 Approximate weight boiler only pounds Length Width Height Shipping Uncrated AHE 45 36 19 24 145 132 AHE 60 36 19 24 177 166 Note 1 Boiler and components shipped in separate cartons 3 4 5 6 7 1 3 10 Outside ve...

Page 47: ...HE 45 45 000 38 000 40 500 34 500 33 000 1 15 85 3 AHE 60 60 000 51 000 54 000 46 000 44 000 1 73 85 5 Notes 1 Based on standard test procedures prescribed by the United States Department of Energy 2 Net I B R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup Ratings are based on a piping ...

Page 48: ...orne dust Remove combustion chamber lining or base insulation 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 REMOVAL OF FIBERGLASS WOOL OR INSTALLATION OF FIBERGLASS WOOL COMBUSTION CHAMBER LINING OR BASE PANELS This pr...

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