AquaBalance ® 80/120/155 Series 2 Wall Mount Gas-Fired Condensing Boilers – Combi and Heating Only Models Boiler Manual • Installation • Maintenance • Startup • Parts Quick Start Guide Pages 69 & 70 * * 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.
AquaBalance® Contents SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 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 . .
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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 2 Prepare boiler location Codes and Checklists: Installations must comply with: 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. • Local, state, provincial, and national codes, laws, regulations and ordinances.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 2 Prepare boiler location 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 1/2” from combustible materials. 3. Vent pipe — at least 3/16” from combustible materials. 4. See Figure 1 for service clearance minimums.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 2 Prepare boiler location continued Air contamination You must pipe combustion air to the boiler air intake. 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.
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. 1. 2. 3. 4.
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 pressure 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. 1. See Figure 5, page 9, for use with the following instructions.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 3 Prepare boiler Figure 5 continued Install pipe fittings for relief valve and pressure/ temperature gauge — DO NOT mount relief Figure 6 Install piping components required for hydrostatic test (see legend below) valve until AFTER hydrostatic testing (see legend below) (Combi boiler shown) 2 1 3 10 Boiler Return (inlet) Boiler Supply (outlet) 1.
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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 4 Converting boiler to propane Pipe sizing for propane gas continued Figure 9 Liquefied Petroleum (propane) gas venturi label information 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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 4 Converting boiler to propane 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) 6 continued LEGEND for Figures 13, 14, 15.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 4 Converting boiler to propane Figure 16 Gas pipe re-assembled to LP venturi fitting 5 continued 12. Using a combustion analyzer insert probe into the flue test point, check that the CO2 content in the exhaust, with the boiler operating at max. and min. firing rate, matches that given in the technical data Figure 103, page 78 or Figure 106, page 79, for the corresponding type of gas. DO NOT ATTEMPT TO MEASURE VALVE OUTLET PRESSURE.
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 boilers 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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 6 Venting/air piping — general Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.
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 Figure 21, 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).
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.
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.
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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 10 DIRECT VENT — Sidewall with separate pipes Allowable vent/air pipe materials & lengths Figure 24 INSTALLATION SEQUENCE — Separate pipes sidewall 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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 10 DIRECT VENT — Sidewall with separate pipes continued See notices on previous page. Figure 25 Multiple separate pipes sidewall terminations — maintain vertical spacing between vent and air fittings shown in Figure 24, page 21. 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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 11 DIRECT VENT — Sidewall concentric Allowable vent/air pipe materials & lengths Figure 27 INSTALLATION SEQUENCE — Concentric horizontal 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 21, page 17. Provide pipe adapters if specified. 2.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 11 DIRECT VENT — Sidewall concentric (continued) See notices on previous page. Figure 28 Termination location — concentric termination — multiple boilers — clearance from vent of one to air intake of the next Install termination — concentric pipes 1. Assemble the vent termination as described for concentric terminations, on page 29.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 12 DIRECT VENT — Vertical with separate pipes Allowable vent/air pipe materials & lengths Figure 30 Separate pipes vertical termination 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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 12 DIRECT VENT — Vertical with separate pipes (continued) See notices on previous page. Figure 31 Terminations for multiple boilers 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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 13 DIRECT VENT — Vertical concentric Allowable vent/air pipe materials & lengths Figure 32 INSTALLATION SEQUENCE — Concentric vertical 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 21, page 17. Provide pipe adapters if specified. 2.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 13 DIRECT VENT — Vertical concentric (continued) See notices on previous page. Figure 33 Vertical termination — 3” PVC concentric — single or multiple boilers Prepare roof penetrations 1. Roof penetration hole: a. Cut a clearance hole to clear the termination outside diameter as prescribed in the kit instructions. b. Insert a galvanized metal thimble in the vent pipe hole. 2.
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.
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.
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 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.
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 For example: CPVC, Polypropylene, or AL29-4C stainless steel. - Perform at start-up final checks Venting Material Change “b22” parameter See Figure 124, page 97 (boiler default is “1”for PVC vent material) “b22” parameter PVC solid core, ....................................... Select: “1” CPVC only, .......................................
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 automatic mixing valve, selection and installation must comply with valve manufacturer’s recommendations and instructions.
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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 17 Primary/Secondary System Piping System water piping methods Expansion Tank Location Primary/secondary piping to boiler 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.
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® 80/120/155 heat exchanger (graphs and table) Boiler Model BOILER dT (ºF) 20 AB-80 HEAT ONLY AB-120 HEAT ONLY AB-155 HEAT ONLY Notes: 1. 2. 36 (GPM) @ 92% Eff. 7.4 Boiler Piping Est. Head Loss Head Ft. (Typical Near Boiler) Loss (ft. w.c.) 3/4” Pipe 1” Pipe 7.8 12.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 17 Primary/Secondary System Piping Closed-type expansion tank: (continued) Figure 49 Piping to 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.
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 in the WARNING below.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 17 Primary/Secondary System Piping Zone Valve zoning – primary/secondary (continued) Figure 50 Zone valve zoning — primary/secondary connection — a system circulator is required (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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 17 Primary/Secondary System Piping Circulator zoning – primary/secondary (continued) Figure 51 Circulator zoning plus optional DHW piping (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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 17 Primary/Secondary System Piping Circulator zoning – Multiple temperature zones with primary/ (continued) Figure 52 Circulator zoning with high- and low- temperature heating zones 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.
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.
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 Legend for Figure 54 2 Isolation valves (when used) 10 Cold water supply 11 Supply water temperature control (when used) 3 Cap 12 Low water cutoff (when used) (place above primary header) 4 Primary circulator 13 Water flow switch (when used) 5 Expansion tank (diaphragm type) 14 Boiler circ
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 18 Multiple boiler installations 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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 19 Install condensate line Prepare condensate trap assembly Figure 58 Filling the 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 A and gasket as shown. Finger tighten securely. 4.
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. Figure 59 Connect gas supply piping (Combi boiler shown). Connecting gas supply piping 1. Remove jacket door and refer to Figure 59 to pipe gas to boiler. a.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 20 Gas piping (continued) 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): 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.
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. Wiring must be N.E.C. Class 1. If original wiring as supplied with boiler must be replaced, use only type 105 °C wire or equivalent.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 21 Field wiring (continued) Outdoor temperature sensor Central Heating Boilers Wiring the Circulators (Heating Only Boiler) (optional for Combi Boilers) 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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 22 Wiring diagram — AquaBalance 80/120C Combi Ladder ® Figure 68 AquaBalance® 80/120C –– Combi Ladder Wiring Diagram 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.
32 16 81 42 186 114 44 95 FRG 0 278 X3 - 9 X3 - 21 X3 - 20 X3 - 8 X3 - 7 X3 - 19 X4 - 4 X4 - 12 X4 - 5 X4 - 13 X2 - 5 X2 - 11 GROUND X4 - 8 X4 - 17 X3 - 1 X3 - 13 X3 - 2 GROUND X3 - 16 X3 - 4 X3 - 5 X3 - 17 GROUND X2 - 10 X2 - 4 X3 - 24 X3 - 22 X3 - 23 X3 - 12 X3 - 10 X3 - 11 X2 - 1 X2 - 12 X2 - 6 X2 - 7 X2 104 (1) 6 1 X1 12 X2 - 5 X2 - 11 2 ABM08 X3 - 5 X3 - 17 X3 - 4 373 1 1 12 X4 - 15 X4 - 6 9 13 18 7 24 X3 X3 - 6 X3 - 18 136 X3 - 2 X3 - 13 X3 - 1 X
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 23 Wiring diagram — AquaBalance 80/120H Heating Only Ladder ® Figure 70 AquaBalance® 80/120H –– Heating Only Ladder Wiring Diagram 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.
81 16 X4 - 12 X4 - 4 FRG 0 278 186 X4 - 5 X4 - 13 X3 - 20 X3 - 8 X3 - 7 X3 - 19 GROUND X3 - 16 X3 - 4 X3 - 5 X3 - 17 GROUND X2 - 10 X2 - 4 X2 - 1 X2 - 12 X2 - 6 6 1 X1 X2 104 (1) 12 2 ABM08 373 1 12 7 24 X3 - 5 X3 - 17 X3 - 4 X3 - 16 X3 - 6 X3 - 18 X3 X4 - 5 1 X4 - 15 X4 - 6 9 1 X4 - 8 X4 - 17 10 X4 - 7 13 18 X4 X4 - 13 114 3 2 X1 - 2 1 X1 - 1 M X4 - 3 8 7 6 5 143 4 138 X4 - 11 370 (see note 3) X4 - 2 X3 - 20 X3 - 8 X3 - 7 X3 - 19 X3 - 21 X3 -
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 24 Wiring diagram — AquaBalance -155C Combi Ladder ® Figure 72 AquaBalance® 155C –– Combi Ladder Wiring Diagram 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.
Blower Central heating pump DHW temperature sensor Gas valve Room thermostat (optional) Ignition electrode Mixing (diverting) valve Fuse 3.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 25 Wiring diagram — AquaBalance -155H Heating Only Ladder ® Figure 74 AquaBalance® 155H –– Heating Only Ladder Wiring Diagram 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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 25 Wiring diagram — AquaBalance -155H Heating Only Schematic ® cod. 3541M930 Only one circulator may be wired to each connection point. Maximum amp load per pump 3.0 amps.
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.
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.
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 Air purge 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.
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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 26 Controls and operation (continued) Adjustments for - Heating Only Boilers Figure 84 with Outdoor sensor DHW Optional for Combi with Outdoor sensor OTC settings eco 1 2 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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 27 DHW Settings (Combi Only) 26 Controls and operation Adjustments for Heating Only Boilers with Outdoor sensor Boiler must be set on comfort mode DHW SETTINGS Figure 86 Compensation curves 1. The DHW SETTINGS menus are for setting control operation during DHW operation. The settings apply ONLY to DHW Zone. 2.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 27 DHW Settings (Combi Only) Figure 91 DHW curve - AquaBalance® 120 Figure 92 DHW curve - AquaBalance® 155 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 AquaBalance 120 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100105 AquaBalance Freestyle 155 - DHW PRODUCTION G.P.M. AquaBalance 120 - DHW PRODUCTION G.P.M. (continued) Delta T (ºF) 15 14.5 14 13.5 13 12.5 12 11.5 11 10.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 28 Standard Altitude Standard Altitude Boiler Adjustment Figure 93 STANDARD Altitude Fan Speeds (for below 4,500’ installations) (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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 28 High Altitude HIGH ALTITUDE BOILER ADJUSTMENT 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. (above 4,500’ installations) 1. Press DHW- and DHW+ buttons together for 10 seconds to enter the parameter setup menu.
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 ALTITUDE HIGH FIRE (CH & DHW) Blower Speed CO2 (%) CO (PPM) (b04 & b05) Blower Speed (b06) CO2 (%) CO (PPM) 0 - 2,000' 40 8.0 - 9.0 <20 200 9.0 - 9.5 <110 2,000' - 4,000' 43 8.0 - 9.0 <20 200 9.0 - 9.5 <110 4,000'-5,000' 46 8.0 - 8.5 <20 200 8.7 - 9.0 <150 5,000'-6,000' 49 8.
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 ALTITUDE HIGH FIRE (CH & DHW) Blower Speed CO2 (%) CO (PPM) (b04 & b05) Blower Speed (b06) CO2 (%) CO (PPM) 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.
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).
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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 29 Startup CIRCULATOR EXERCISING and FREEZE PROTECTION Hardness less than 7 grains CIRCULATOR EXERCISING Chloride concentration must be LESS THAN 50 ppm The control will automatically start the circulator output and run for 10 seconds for each 72-hour period of inactivity. 1. Filling with chlorinated fresh water should be acceptable since drinking water chloride levels are typically less than 5 ppm. 2.
AquaBalance® SERIES 29 Startup 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual (continued) Eliminate all system leaks. Continual fresh makeup 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.
AquaBalance® SERIES 29 Startup 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual (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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 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.
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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 30 6WDUWXS ² ¿QDO FKHFNV (continued) ❏ Propane boilers — verify conversion If combustion at either high or low fire is outside 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.
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.
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 CO2 is at the correct SETTING LEVEL (see Figure 106), confirm that the CO/CO2 ratio is within limits (clockwise to increase gas).
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).
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.
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 materials that have been identified as carcinogenic, or possibly carcinogenic, to humans). Ceramic fibers can be converted to cristobalite in very high temperature applications.
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.
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.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 34 Troubleshooting VERIFY PROPER OPERATION AFTER SERVICING Before calling for troubleshooting assistance, fill in the BEFORE TROUBLESHOOTING — “ Boiler Startup Data Collection Sheet” (page 132). 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.
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.
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.
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 complete 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.
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 Fault A01 No burner ignition Condition No gas Ignition/detection electrode fault Electrode fault A02 Flame present signal with burner off Over temperature protection activation &KHFN WKH UHJXODU JDV ÀRZ WR WKH ERLOHU DQG WKDW the air has been eliminated from the pipes.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 34 Troubleshooting (continued) Figure 115 Fault Code Troubleshooting suggestions — Fault displays and diagnostics (continued) Fault Condition F13 Exhaust probe fault F14 Delivery sensor 2 fault F15 Fan fault Probe damaged Wiring shorted Wiring disconnected Sensor damaged Wiring shorted Wiring disconnected No 120V power supply Tachometric signal interrupted Fan damaged Condensate trap blocked and or condensate drain hose loo
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.
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 = 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.
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 = 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).
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”.
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”.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 34 Troubleshooting (continued) Figure 122 “tS” - Transparent Parameter mode (continued) Parameter Description P14 /HJLRQHOOD SURWHFWLRQ '+: FRQ¿J ZLWK VHQVRU /HJLRQHOOD SURWHFWLRQ '+: FRQ¿J ZLWK WKHUPRVWDW '+: RII PRGH '+: FRQ¿J Default 0 -0 Note DHW conf. dependent DHW conf. dependent P15 '+: &RPIRUW +\VWHUHVLV ) '+: FRQ¿J '+: &RPIRUW VZLWFK RQ SRLQW ) '+: FRQ¿J 4 104 DHW conf.
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.
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.
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).
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 Description E2 prom parameters Num.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 34 Troubleshooting (continued) Figure 130 Troubleshooting suggestions for AquaBalance® boilers — Fault displays and diagnostics (continued) Category Description E2 prom parameters Num.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 34 Troubleshooting (continued) Figure 131 Troubleshooting suggestions for AquaBalance® boilers — Fault displays and diagnostics (continued) Category Description E2 prom parameters Num.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 34 Troubleshooting (continued) Figure 132 Troubleshooting suggestions for AquaBalance® boilers — Fault displays and diagnostics (continued) Category Description E2 prom parameters Num. Address Description CL5 – 06F8 DHW maximum output Unit Range Def Low High Value % 0 100 100 Num 0 1 0 Dom. Hot Water 61 Dom. Hot Water 62 Dom. Hot Water 63 ML – 80D9 '+: ÀRZ VHQVRU W\SH Dom.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 34 Troubleshooting (continued) Figure 133 Troubleshooting suggestions for AquaBalance® boilers — Fault displays and diagnostics (continued) Category Description E2 prom parameters Num. Address Unit Description Range Low High History 99 ML – 8061 Total num. of hours with power supply ON - LSB History 100 ML – 8060 Total num.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 34 Troubleshooting (continued) Figure 134 Troubleshooting suggestions for AquaBalance® boilers — Fault displays and diagnostics (continued) Category Description E2 prom parameters Num.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 34 Troubleshooting (continued) Figure 135 Troubleshooting suggestions for AquaBalance® boilers — Fault displays and diagnostics (continued) Some informations can be accessed with a communication package running on the PC. Category Description E2 prom parameters Num.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 35 Maintenance Disconnect power Electrical shock hazard — Disconnect all electrical power to the boiler before attempting maintenance procedures. Failure to complete could result in severe personal injury, death or substantial proper t y damage.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 35 Maintenance (continued) Figure 138 Removal of Ignition electrode Figure 140 Boiler front panel removed 2. Remove two (2) Phillips head screws securing the ignition electrode to the boiler heat exchanger. 3. Carefully slide the igniter out of its mounting slot. Use care when removing and handling igniter. Igniter is very brittle and can break if not handled carefully. 4. Remove and inspect the ignitor gasket.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 35 Maintenance (continued) Figure 142 Inspection and removal of burner and gasket Figure 144 Inspecting exterior and cleaning the burner 3. 4. 7. 5. Remove the heat exchanger cover plate and the gasket. Remove the burner and burner gasket from the heat exchanger cover plate if still in place. Do not let fragments drop into the heat exchanger if the gasket pulls apart during removal.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 35 Maintenance (continued) Inspect and clean the heat exchanger Wait until heat exchanger/boiler is cooled down before proceeding. Failure to do so can cause severe injury. 1. See Figures 145 and 149. 2. Use a 10mm wrench or socket to remove the five (5) nuts that secure the burner cover plate to the heat exchanger. 3. Remove the heat exchanger cover plate, gasket, burner and its gasket. 4.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 35 Maintenance (continued) Procedure For Cleaning Heat Exchanger Waterways Figure 149 Heat exchanger components This procedure is intended as a guideline for a correct restoration of the functionality of the boiler as a result of operation with untreated water, very hard water feeding conditions, debris, lime scale, sludge, metal oxides and, in low temperature systems, also biomass in the heat exchanger water circuit.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 35 Maintenance (continued) Actions For Cleaning Of Heat Exchanger Water Circuit • • • • • • • • • • • • • • • • • Disconnect the unit from the electrical power supply using the switch and/or the special cut-off devices. Close the valve of Heat exchanger system supply (1) and return (5) placed before the boiler connections.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 35 Maintenance (continued) Actions for chemical cleaning of Domestic hot water circuit Hot Water Can Scald! • 1. Disconnect the unit from the electrical power supply using the switch and/or the special cut-off devices. 2. Close the valve of cold water inlet placed before the boiler inlet. 3. Release residual pressure in domestic hot water circuit in the boiler by opening a hot water tap downstream of the boiler. 4.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 35 Maintenance (continued) Combi 80/120 flat plate heat exchanger removal for cleaning Figure 154 Removal of flat plate heat exchanger (screw on right side) (Combi Only 80/120 shown) 5. Release the pressure of CH circuit by loosing the plastic screw placed next to the CH return (6), see Figure 152. Release Heat Exchanger pressure in the boiler by loosing the plastic screw of the pump placed next to heat exchanger return.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 35 Maintenance (continued) Combi 80/120 flat plate heat exchanger reinstalled Figure 156 Removal of flat plate heat exchanger by loosening the four fittings. Combi-155 The four (4) new gaskets must be placed in the DHW inlet and DHW return plate connections to seal brazed plate heat exchanger. 1. Slide the brazed plate heat exchanger into rear of enclosure (orientation arrows pointing down). 2.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 36 Replacement parts REPLACEMENT PART NUMBERS Failure to adhere to these guidelines can result in severe personal injury, death or substantial property damage. Weil-McLain part numbers are found in this manual and in Weil-McLain Boilers and Controls Repair Parts Lists. WHEN OPERATING THE BOILER ON PROPANE GAS ALL boilers must be converted in order to operate with propane gas.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 36 Replacement parts (continued) Figure 160 Miscellaneous parts and kits Description Antifreeze, Sentinel X500. . . . . Corrosion inhibitor, Sentinel X100 Quick Test Kit, Sentinel X100 . . . . . Cleaner, Sentinel X400 . . . . . . Part Number . . . . . . . . . . . . . . . .
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 36 Replacement parts (continued) Figure 161 118 Jacket parts Item Name Part Number 100 Jacket door 640-000-067 110 Jacket left side 640-000-065 120 Jacket right side 640-000-066 Part number 550-100-325/0718
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 36 Replacement parts (continued) Figure 162 Control and electrical assemblies Item Name Part Number 100 Control module assembly 640-000-003 110 Control module display cover 640-000-004 120 Pressure-Temperature assembly 640-000-006 Wire harness assembly - Combi - 80/120 640-000-005 Wire harness assembly - Combi - 155 640-000-085 Wire harness assembly - Heating Only 640-000-053 Blower wiring adapter - Heating Only -
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 36 Replacement parts (continued) Figure 163 Boiler replacement kits and parts AB-80/120C (Combi) Item Name 100 Heat Exchanger Part Number 640-000-116 640-000-117 110 Flue Sensor Temperature 640-000-011 120 Blower Assembly 640-000-020 130 Blower Gasket 640-000-021 140 Ignitor 640-000-109 150 Central Heat Exchanger Insulation 640-000-010 160 Burner 640-000-012 170 Burner Gasket Set 640-000-013 180 Burner Cove
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 36 Replacement parts (continued) Figure 164 Boiler replacement kits and parts AB-80/120C (Combi) continued Part number 550-100-325/0718 121
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 36 Replacement parts (continued) Figure 165 Boiler replacement kits and parts AB-80/120H (Heating Only) Item Name 100 Heat Exchanger Part Number AB-80 640-000-116 640-000-117 110 Flue Sensor Temperature 640-000-011 120 Blower Assembly 640-000-020 130 Blower Gasket 640-000-021 140 Ignitor 640-000-109 150 Central Heat Exchanger Insulation 640-000-010 160 Burner 640-000-012 170 Burner Gasket Set 640-000-013 1
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 36 Replacement parts (continued) Figure 166 Boiler replacement kits and parts AB-80/120H (Heating Only) continued Part number 550-100-325/0718 123
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 36 Replacement parts (continued) Figure 167 Boiler replacement kits and parts AB-155C Combi Item Name 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 Part Number Heat Exchanger Flue Sensor Temperature Blower Blower Gasket Ignitor Central Heat Exchanger Insulation Burner Burner Gasket Set Burner Gasket Premix 1 Piece 640-000-118 640-000-011 640-000-081 640-000-0
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 36 Replacement parts (continued) Figure 168 Boiler replacement kits and parts AB-155C Combi Part number 550-100-325/0718 125
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 36 Replacement parts (continued) Figure 169 Boiler replacement kits and parts AB-155H Heating Only Item Name Part Number 100 Heat Exchanger 640-000-118 110 Flue Sensor Temperature 640-000-011 120 Blower Assembly 640-000-081 130 Blower Gasket 640-000-021 140 Ignitor 640-000-109 150 Central Heat Exchanger Insulation 640-000-010 160 Burner 640-000-012 170 Burner Gasket Set 640-000-013 180 Burner Cover 640-0
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 36 Replacement parts (continued) Figure 170 Boiler replacement kits and parts AB-155H Heating Only Part number 550-100-325/0718 127
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 37 Connections, Dimensions and Engineering Data Figure 171 128 Connections, Dimensions and Engineering data — AB-80/120 (all dimensions in inches) Part number 550-100-325/0718
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 37 Connections, Dimensions and Engineering Data Figure 172 (continued) Connections, Dimensions and Engineering data — AB-155 (all dimensions in inches) Part number 550-100-325/0718 129
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 37 Connections, Dimensions and Engineering data (continued) Figure 173 Engineering data Shipping weight Boiler Model Pounds per boiler Operating weight Pounds per boiler Note 2 Water content Vent/air pipe size: (Provide a separate vent for each boiler) Electrical service required Note 3 Note 1 Gallons per boiler Amps per boiler AB-80C Combi 77 86 1.110 2” or 3” 15.0 AB-120C Combi 80 91 1.306 2” or 3” 15.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 38 Ratings Figure 174 Ratings and engineering data See (Note 7) AHRI Certified Ratings Boiler Model % Input derate vs vent length Heating Capacity Input Seasonal Efficiency Net Water Rating (Values shown are at MAX vent/air pipe length — See Note 6) Direct Vent Category ONLY Natural gas Vent/ Comb.
AquaBalance® SERIES 2 WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 39 ,QVWDOODWLRQ DQG 6HUYLFH &HUWL¿FDWH Boiler Start-Up Data Boiler Model / Series AB-__________ / Series ____ Part Number ____________ FUEL: Natural ____ LP ____ Date installed ________________ CO2 # +LJK ¿UH BBBBBB /RZ ¿UH BBBBBB Btu Input ___________________ &2 # +LJK ¿UH BBBB SSP /RZ ¿UH BBBB SSP Natural gas input rate measured HIGH________ CFH / LOW________ CFH ,QVWDOODWLRQ DQG VHUYLFH FHUWLÀFDWH Boiler model
