Weil-McLain Series 4 Leitfaden

Part number 550-141-893/0800

AHE SERIES 4

Direct Vent Wall-Mounted Boilers

User’s

Information

Manual

Do not store or use gasoline or other flammable vapors and liquids in the

vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

•Do not try to light any appliance.

•Do not touch any electrical switch; do not use any phone in your

building.

•Immediately call your gas supplier from a neighbor’s phone. Follow

the gas supplier’s instructions.

•If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service

technician or the gas supplier.

If the information in this manual is not followed exactly, a fire or

explosion may result, causing property damage, personal injury or

loss of life.

AHE

Part number 550-141-893/0800

AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual

Please read this page first

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of

various risk levels or to important information concerning the life of the product.

Indicates presence of hazards that will cause severe personal injury,death or substantial property

damage.

Indicates presence of hazards that can cause severe 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

Hazard definitions ................................................................................................... 2

Stop!! — Read before proceeding — Important safety information ..................... 3

Boiler maintenance ................................................................................................. 4

User maintenance procedures ............................................................................ 5-8

Operating instructions — Robertshaw 7200 .......................................................... 9

Operating instructions — Honeywell VR8205 and White-Rodgers 36E.............. 10

Common problems and solutions ........................................................................ 11

Warranty ................................................................................................................ 12

Part number 550-141-893/0800 3

AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual

Failure to adhere to the following guidelines can result in severe personal injury,

death or substantial property damage.

When servicing boiler

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow boiler to cool before performing maintenance.

Boiler operation

• Do not block flow of combustion or ventilation air to boiler.

• Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to

circulator. Instead, shut off the gas supply at a location external to the appliance.

• Do not use this boiler if any part has been under 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" or "boiler patent medicines". Serious damage to boiler, personnel and/or

property may result.

• Continual fresh makeup water will reduce boiler life. Mineral buildup in sections reduces heat transfer,

overheats cast iron, and causes section failure. Addition of oxygen and other gases can cause internal

corrosion. Leaks in boiler or piping must be repaired at once to prevent makeup water.

• Do not add cold water to hot boiler. Thermal shock can cause sections to crack.

Glycol — potential fire hazard

All glycol is flammable when exposed to high temperatures. If glycol is allowed to accumulate in or around the

boiler or any other potential ignition source, a fire can develop. In order to prevent potential severe personal

injury, death or substantial property damage from fire and/or structural damage:

• Never store glycol of any kind near the boiler or any potential ignition source.

• Monitor and inspect the system and boiler regularly for leakage. Repair any leaks immediately to prevent

possible accumulation of glycol.

• Never use automotive antifreeze or ethylene glycol in the system. Using these glycols can lead to hazardous

leakage of glycol in the boiler system.

Stop!! — Read before proceeding

Part number 550-141-893/0800

AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual

Boiler service and maintenance

The User’s Information Manual provides information to the boiler owner/user for routine operation and

maintenance and emergency shutdown. Detailed information on boiler installation, operation, start-up, service

and parts is included in the Boiler Manual. The Boiler Manual is intended only for use by a qualified installer/

service technician.

Maintenance schedule

Maintain the boiler using the maintenance schedule below. Have the boiler started up and serviced at least annually

by a qualified service technician to ensure boiler/system reliability.

Boiler maintenance

Service technician

(covered in Boiler Manual —for use only by a

qualified service technician)

Owner maintenance

(see following pages for instructions)

ANNNUAL 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

• Circulator with mixing valve

• Limit controls and cutoffs

• Expansion tank

• Boiler relief valve

Review:

• Review with owner

Daily

• Check boiler area

• Check air openings

• Check boiler pressure/

temperature gauge

Monthly

• Check boiler piping

• Check venting system

• Check boiler relief valve

• Check automatic air vents

• Main burner flames

Periodically

• Test low water cutoff

• Clean vent termination and air

intake screens

Every 6 months • Operate relief valve

End of season • Shut down procedure

Part number 550-141-893/0800 5

AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual

User maintenance procedures

Boiler must be serviced and

maintained

Component information

For detailed illustrations showing boiler assembly parts

and components, refer to the “Replacement parts”

section in the AHE Series 4 Boiler Manual.

Rollout thermal fuse element

Cuts off gas flow should flame rollout occur. See

Figure 1.

Do not attempt to place boiler in

operation if rollout thermal fuse

element cuts off gas flow.

Immediately call a service

technician.Failure to do so can cause

severe personal injury, death or

substantial property damage.

Figure 1 Rollout thermal fuse element

Check boiler area

Check 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 air intake is clean and free of

obstructions. Remove any debris on the air intake

opening.

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, as explained on the following pages, must

be performed to assure maximum boiler efficiency and

reliability. Failure to service and maintain the boiler and

system could result in equipment failure, causing

possible severe personal injury, death or substantial

property damage.

The following information provides detailed

instructions for completing the maintenance items listed

in the maintenance schedule on page 4. In addition to

this maintenance, the boiler must be serviced and started

up at the beginning of each heating season by a qualified

service technician.

To prevent potential of severe personal injury, death or

substantial property damage, do not store combustible

materials, gasoline or any other flammable vapors or

liquids near the boiler. Remove immediately if found.

❑Daily ........................... ❑Daily .....................

Check boiler pressure/

temperature gauge

1. Make sure the pressure reading on the boiler

pressure/temperature gauge does not exceed 24

psig. Higher pressure may indicate a problem with

the expansion tank or gauge.

2. Contact a qualified service technician if problem

persists.

Part number 550-141-893/0800

AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual

User maintenance procedures continued

Check boiler piping

Visually inspect for leaks around piping, circulators,

relief valve and other fittings. Immediately call a

qualified service technician to repair any leaks.

Check automatic air vents

1. See Figure 3.

2. Remove the cap from any automatic air vent in the

system and check operation by depressing valve“B”

slightly with the tip of a screwdriver.

3. If the air vent valve appears to be working freely

and not leaking, replace cap“A”,twisting all the way

on.

4. Loosen cap “A” one turn to allow vent to operate.

5. Have vent replaced if it does not operate correctly.

Check boiler relief valve

1. Inspect the boiler relief valve (see Figure 2) and the

relief valve discharge pipe for signs of weeping or

leakage.

2. If the relief valve often weeps:

• The expansion tank may not be working

properly.

• Immediately contact your qualified service

technician to inspect the boiler and system.

❑Monthly ...............❑Monthly .....................

Have leaks fixed at once by a qualified service technician.

Continual fresh makeup water will reduce boiler life.

Minerals can build up in sections, reducing heat transfer,

overheating cast iron and causing equipment failure.

Leaking water may also cause severe property damage.

Do not use petroleum-based cleaning or sealing

compounds in boiler system. Severe damage to boiler

and system components can occur, resulting in possible

severe personal injury, death or substantial property

damage.

Check venting system

Failure to inspect the vent system as noted below and

have them repaired by a qualified service technician can

result in vent system failure, causing severe personal

injury or death.

1. Visually inspect the gas vent system for any signs

of blockage, leakage of joints or deterioration of

the piping. Figure 3

Automatic air vent

71036

Figure 2

Relief valve

Part number 550-141-893/0800 7

AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual

Main burner flames

1. See Figure 4. Remove burner input plenum cover

plate “A”.

2. Visually inspect burner flames:

•Proper main burner flame (see Figure 5):

a. Yellow-orange streaks may appear (caused

by dust).

•Improper main burner flame:

a. Overfired — Large flames.

b. Underfired — Small flames.

c. Lack of primary air — Yellow tipping on

flames (sooting will occur).

Figure 5 Main burner flame, typical

26024

Transparent

blue flame

Inner flame

User maintenance procedures continued

Test low water cutoff

Test the low water cutoff periodically during the heating

season, following the low water cutoff manufacturer’s

instructions.

Clean vent termination and air

intake screens

1. Remove all lint and debris from both the boiler air

intake screen and the flue discharge screen.

2. The boiler control module will sense blockage of

the air intake or flue and lockout if the blockage is

excessive. It will signal by flashing the appropriate

indicator lights on the control board.

3. If removing the debris does not allow the boiler to

operate correctly afterwards,contact your qualified

service technician to inspect the boiler and vent/

air systems.

❑Periodically ..........❑Monthly .....................

89301

Figure 4

Part number 550-141-893/0800

AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual

User maintenance procedures continued

Operate relief valve

To avoid water damage or scalding due to valve

operation, a metal discharge line must be

connected to relief valve outlet and run to a

safe place of disposal. This discharge line must

be installed by a qualified heating installer or

service technician in accordance with the

instructions in the AHE Series 4 Boiler

Manual. The discharge line must be

terminated so as to eliminate possibility of

severe burns should the valve discharge.

1. Before proceeding, verify that the relief valve outlet has been

piped to a safe place of discharge, avoiding any possibility of

scalding from hot water.

2. Read the boiler pressure/temperature gauge to make sure the

system is pressurized.

3. Lift the relief valve top lever slightly,allowing water to relieve

through the valve and discharge piping.

4. If water flows freely, release the lever and allow the valve to

seat.Watch the end of the relief valve discharge pipe to ensure

that the valve does not weep after the line has had time to

drain. If the valve weeps,lift the seat again to attempt to clean

the valve seat. If the valve continues to weep afterwards,

contact your qualified service technician to inspect the valve

and system.

5. If water does not flow from the valve when you lift the lever

completely, the valve or discharge line may be blocked.

Immediately shutdown the boiler, following the Operating

Instructions on the inside of the jacket top panel or on pages

10 and 11 of this manual. Call your qualified service

technician to inspect the boiler and system

❑Every 6 months ........... ❑End of season..............

Shut down procedure

1. Follow “TO TURN OFF GAS TO THE APPLIANCE”

instructions found in the Operating Instructions located on

the inside of the jacket top panel. You will also find these

instructions on pages 9 and 10 of this manual. Use the

Operating Instructions for the gas valve model installed on

the boiler.

2. Do not drain system unless exposure to freezing temperatures

will occur.

3. Do not drain the system if it is filled with an antifreeze

solution.

4. Do not shut down boilers used for domestic water heating.

They must operate year-round.

Propane boilers only — Your propane

supplier mixes an odorant with the propane

to make its presence detectable. In some

instances, the odorant can fade and the gas

may no longer have an odor.

• Propane gas can accumulate at floor

level. Smell near the floor for the gas

odorant or any unusual odor. If you

suspect a leak, do not attempt to light

the pilot.

• Use caution when attempting to light

the propane pilot. This should be done

by a qualified service technician,

particularly if pilot outages are

common.

• Periodically check the odorant level of

your gas.

• Inspect boiler and system at least yearly

to make sure all gas piping is leak-tight.

• Consult your propane supplier

regarding installation of a gas leak

detector. There are some products on

the market intended for this purpose.

Your supplier may be able to suggest

an appropriate device.

Part number 550-141-893/0800 9

AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual

FOR YOUR SAFETY READ BEFORE OPERATING

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO THE APPLIANCE

• Do not try to light any appliance.

• Do not touch any electric switch; do not use

any phone in your building.

• Immediately call your gas supplier from a neighbor's phone.

Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

WHAT TO DO IF YOU SMELL GAS

If you do not follow these instructions exactly, a fire or explosion may result

causing property damage, personal injury or loss of life.

1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electrical power to the appliance.

4. Remove control access panel.

5. This appliance is equipped with an ignition device

which automatically lights the burner. Do not try to

light the burner by hand.

6. Depress and move selector armcounterclockwise

to OFF. Note: Selector arm cannot be moved to OFF

unless selector arm is depressed slightly.Do not force.

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.

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 use

tools. If the knob will not turn by hand, don't try to repair it,

call a qualified service technician. Force or attempted repair

may result in a fire or explosion.

D. Do not use this appliance if any part has been under water.

Immediately call a qualified service technician to inspect the

appliance and to replace any part of the control system and any

gas control, which has been under water.

7. Wait five (5) minutes to clear out any gas. Then smell for gas,

including near the floor. If you smell gas, STOP! Follow "B" in

the safety information above. If you don't smell gas, go to the

next step.

8. Turn selector arm clockwise to ON.

9. Turn on all electric power to the appliance.

10. Set thermostat to desired setting.

11. If the appliance will not operate, follow the instructions "To

Turn Off Gas To Appliance" below and call your service

technician or gas supplier.

12. Replace control access panel.

4. Depress and move selector arm counterclockwise to OFF.

Do not force.

5. Replace control access panel.

Position

indicator

Selector

arm

(shown in

position)OFF

59332

Operating instructions

Robertshaw 7200 gas valve

Part number 550-141-893/0800

AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual

Honeywell VR8205 and White-Rodgers 36E gas valves

FOR YOUR SAFETY READ BEFORE OPERATING

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO THE APPLIANCE

• Do not try to light any appliance.

• Do not touch any electric switch; do not use

any phone in your building.

• Immediately call your gas supplier from a neighbor's phone.

Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

WHAT TO DO IF YOU SMELL GAS

1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electrical power to the appliance.

4. Remove control access panel.

5. This appliance is equipped with an ignition device which automatically

lights the burner. Do not try to light the burner by hand.

6. Turn gas control knob clockwise to OFF.

7. Wait five (5) minutes to clear out any gas. Then smell for gas, including

near the floor. If you smell gas, STOP! Follow "B" in the safety information

above. If you don't smell gas, go to the next step.

8. Turn gas control knob counterclockwise to ON.

9. Turn on all electric power to the appliance.

10. Set thermostat to desired setting.

11. If the 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. 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 use

tools. If the knob will not turn by hand, don't try to repair it,

call a qualified service technician. Force or attempted repair

may result in a fire or explosion.

D. Do not use this appliance if any part has been under water.

Immediately call a qualified service technician to inspect the

appliance and to replace any part of the control system and any

gas control, which has been under water.

If you do not follow these instructions exactly, a fire or explosion may result

causing property damage, personal injury or loss of life.

88731

White-Rodgers

36E Gas valve

Honeywell

VR8205

Gas valve

Position indicator

(shown in "ON" position)

Gas control knob

Position indicator

(shown in "ON" position)

Operating instructions — Robertshaw 7200 gas valve

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