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Part number 550-141-887/0800

34

AHE

Series 4 Direct Vent Wall-Mounted Boilers

— Boiler Manual

Troubleshooting — control module

12c

Make sure ground wiring is installed
per wiring diagram. Good
grounding is extremely important
for proper operation.

Solder  or  water  splatter  between
plugs  and  circuit  board  can  cause
improper  operation  of  control
module.  Place  a  shield  over  the
boiler  internal  controls  and
components during installation.

Control indicator lights

Lockout modes

See Charts 1 through 8 in this manual section for
detailed troubleshooting procedures.
To reset control after a lockout, turn off power at the
120 VAC service switch or turn down all thermostats.
Wait 45 seconds. Then restore power or call for heat.
After an over-temperature lockout (

POWER

and

LIMIT

lights flashing), the control will only reset after
interruption of 120 VAC for 45 seconds.

POWER light flashing alone

Usually indicates reversed polarity of 120 VAC power
wires.

POWER and TSTAT CIRC lights flashing

Usually indicates stray voltage on external thermostat circuit wires or return
water temperature entering boiler sections has not reached 130 °F within
20 minutes.

POWER and LIMIT lights flashing alternately

Usually indicates that limit circuit failed to cut off boiler at high temperature
— return water temperature sensor has sensed water over 235 °F.

POWER and PRESS SWITCH lights flashing

Usually 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 boiler
return pipe less than 40 °F. Both internal circulators will run continuously,
even with no call for heat, until temperature rises.

LIMIT light flashing alone

Usually indicates an open or shorted return water temperature sensor.

Troubleshooting the control module

See Figure 29 for location of harness plug receptacles and plugs on the
control module.

Figure 29

Control module harness plug receptacle and indicator light locations

Indicator lights

POWER

TSTAT CIRC

LIMIT

PRESS SWITCH

FLAME

120 VAC IN

120 VAC to transformer

120 VAC to igniter

24 VAC from transformer

47K resistor

24 VAC control circuits

120 VAC to circulators

120 VAC to blower motor

88738

120 VAC to

transformer

120
VAC H

120
VAC N

White

Black

120 VAC IN

120
VAC H

120
VAC N

Ground

White

Green

Black

120 VAC to

blower motor

120
VAC H

120
VAC N

Ground

White

Green

Black

Red wires
to pressure
switch

Blue wire
to gas valve

Yellow wires to

limit control

and block

temp switch

Black wires to

thermostat

circuit

24 VAC control circuits

47K resistor

24 VAC from transformer

24 VAC

Brown

Red

120 VAC to ignitor

120 V

A

C H

120 V

A

C N

White

Black

120 VAC

to circulator

White

Green

Ground

120
VAC N

120
VAC H

Black

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Содержание AHE Series

Страница 1: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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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