Weil-McLain Aqua Balance WMB-155 Manual
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Weil-McLain Aqua Balance WMB-155 Manual

Wall mount gas-fired condensing boilers-combi and heating only models
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Aqua Balance
Condensing Boilers – Combi and Heating Only Models
This manual must only be used by a qualified heating installer/service technician. Failure to comply could result in
severe personal injury, death or substantial property damage.
When calling or writing about the boiler— Please have boiler model number from the boiler rating label.
WMB-80/120/155
Wall Mount Gas-Fired
Boiler Manual
• Installation
• Startup
Quick Start Guide
Pages 3 & 4
*
CSA - Low Lead Content only applies to the Combi model
• Maintenance
• Parts
*
Part number 550-100-305/0118

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Summary of Contents for Weil-McLain Aqua Balance WMB-155

  • Page 1 Aqua Balance WMB-80/120/155 Wall Mount Gas-Fired Condensing Boilers – Combi and Heating Only Models Boiler Manual • Installation • Maintenance • Startup • Parts Quick Start Guide Pages 3 & 4 CSA - Low Lead Content only applies to the Combi model This manual must only be used by a qualified heating installer/service technician.

  • Page 2: Table Of Contents

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual Contents Page 21 Field wiring..... . . 50 1 Quick Start Guide — using default settings ..3 22 Wiring diagram —...

  • Page 3: Quick Start Guide - Using Default Settings

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual Quick Start Guide — using default settings Figure 1 Default control settings (see instructions and figures on pages 60-65). Quick Start Guide - QUICK START GUIDE After you have completed the installation of the Combi or Heating Only model by the instructions provided in this manual, pages 5-71 insure the following first before you proceed: All gas lines are connected and tested for leaks, and if the boiler is to operate on LP fuel, and the unit has been converted properly from Natural gas to Liquefied Petroleum (Propane) gas and set up as directed in the boiler...
  • Page 4 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual Quick Start Guide — using default settings QUICK START GUIDE System start (continued) “Test Mode Operation” Proceed to put the boiler into operation as follows: To start, create a demand for heat, open up a hot water faucet or turn up the thermostat. To operate the boiler in test mode, press the CH “-”...

  • Page 5: Please Read Before Proceeding

    See the instructions at right. contact with water, replace the boiler with a new Weil-McLain boiler. Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.

  • Page 6: Prepare Boiler Location

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 2 Prepare boiler location Codes and Checklists: pane Installation Code, CSA B149.1 and B149.2 for Canadian installations. Installations must comply with: • Locate or protect the boiler so it cannot be damaged •...
  • Page 7 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 2 Prepare boiler location continued Clearances A Provide combustion air/ventilation openings per Figure 24, page 22 or as otherwise directed in this manual or by applicable codes. If the installation does not provide the minimum clearances, Provide clearances from then the enclosure MUST HAVE air openings located per Figure 2, combustible materials —...

  • Page 8: Prepare Boiler

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 2 Prepare boiler location continued You must pipe combustion air to the boiler Air contamination air intake Please review the following information on potential combustion Install air inlet piping for the boiler as described in air contamination problems.
  • Page 9 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 3 Prepare boiler continued Wall-mounting requirements Install the wall-mount bracket DO NOT attempt to attach the wall mount bracket 1. Locate the studs — must be on 16-inch centers. See previ- using anchors or any means other than directly ous instructions if studs are not on 16-inch centers.

  • Page 10: Hydrostatic Pressure Test

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 3 Prepare boiler continued Hydrostatic pressure test Fill and pressure test 1. See Figure 6, page 11, for use with the following instructions. DO NOT install a relief valve with a pres- sure higher than 30 PSIG.

  • Page 11: Boiler Supply

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 3 Prepare boiler continued Figure 6 Figure 7 Install pipe fittings for relief valve and pressure/ Install piping components required for hydrostatic test ( temperature gauge — DO NOT mount relief see legend below) valve until AFTER hydrostatic testing (see...

  • Page 12: Converting Boiler To Propane

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 4 Converting boiler to propane Natural to LP Conversion Kit Part Numbers Prepare boiler for propane (if required) AquaBalance 80/120/155 WMB-80 LP P/N 640-000-024 NG to Propane Gas Conv. Kit contents: Venturi - 10.6 GPL Propane operation Gasket Nitrile Rubber 167 x 63.5X3.53 NBR...
  • Page 13 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 4 Converting boiler to propane continued Pipe sizing for propane gas Figure 10 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.
  • Page 14 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 4 Converting boiler to propane continued 3. Loosen the bottom swivel nut of gas pipe and unscrew the LEGEND for Figures 13, 14, 15. 16 and 17 top swivel nut “A” Figure 13, Item 3 from the gas valve venturi Figure 13, Item 6.
  • Page 15 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 4 Converting boiler to propane continued 12. Using a combustion analyzer insert probe into the flue Figure 17 Gas pipe re-assembled to LP venturi fitting test point, check that the CO content in the exhaust, with the boiler operating at max.

  • Page 16: Gas Piping - Sizing Gas Lines

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 5 Gas piping — sizing gas lines Boiler gas connection is ½” NPT. Size gas lines large Figure 19 Pipe capacity for 0.60 specific gravity natural enough to provide gas to all connected appliances. gas;...

  • Page 17: Venting/Air Piping - General

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 6 Venting/air piping — general mon venting system. Turn on any exhaust fans, such as Any improper operation of the common venting system should range hoods and bathroom exhausts, so they will operate at maximum speed.
  • Page 18 For ULC S636 compliance, all pipe, fittings and cement must be IPEX System 636. If using IPEX kits, use only IPEX product code 196006 for 3” venting. Contact Weil-McLain for ordering information and availability of Weil-McLain venting kits. Part number 550-100-305/0118...
  • Page 19 BIRD SCREEN at each termination the bird screens. Purchase bird screens separately from Weil-McLain or vent kit supplier if not included. [Note — bird screening is integral to the 3" PVC Weil-McLain sidewall vent cap, available for purchase from Weil-McLain.

  • Page 20: Commonwealth Of Massachusetts Installations

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 7 Commonwealth of Massachusetts installations Commonwealth of Massachusetts — When the boiler is installed within the Commonwealth of Massachusetts, the boiler must be installed by a licensed plumber or gas fitter. Read and comply with the instructions below. (a) For all sidewall horizontally-vented gas-fueled equipment .

  • Page 21: Vent Termination Requirements

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 8 Vent termination requirements The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). The minimum distance Figure 23 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.

  • Page 22: Boiler Room Air Openings

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 9 Boiler room air openings Figure 24 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.

  • Page 23: Direct Vent - Sidewall With Separate Pipes

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 10 DIRECT VENT — Sidewall with separate pipes Figure 25 — Separate pipes INSTALLATION SEQUENCE Allowable vent/air pipe materials & sidewall lengths Use only the vent materials and kits listed in Figure 22, page 19.
  • Page 24 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 10 DIRECT VENT — Sidewall with separate pipes continued Figure 26 See notices on previous page. Multiple separate pipes sidewall terminations — maintain vertical spacing between vent and air fittings shown in Figure 25, page 23. a.

  • Page 25: Direct Vent - Sidewall Concentric

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 11 DIRECT VENT — Sidewall concentric Figure 28 — Concentric horizontal INSTALLATION SEQUENCE Allowable vent/air pipe materials & lengths 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 22, page 19.
  • Page 26 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 11 DIRECT VENT — Sidewall concentric (continued) Figure 29 See notices on previous page. Termination location — concentric termination — multiple boilers — clearance from vent of one to air intake of Install termination —...

  • Page 27: Direct Vent - Vertical With Separate Pipes

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 12 DIRECT VENT — Vertical with separate pipes Allowable vent/air pipe materials Figure 31 Separate pipes vertical termination & lengths Use only the vent materials and kits listed in Figure 22, page 19. Provide pipe adapt- ers if specified.
  • Page 28 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 12 DIRECT VENT — Vertical with separate pipes (continued) Figure 32 Terminations for multiple boilers See notices on previous page. Prepare roof penetrations 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.

  • Page 29: Direct Vent - Vertical Concentric

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 13 DIRECT VENT — Vertical concentric Allowable vent/air pipe materials & Figure 33 — Concentric vertical INSTALLATION SEQUENCE lengths 1. The concentric termination kit must be purchased sepa- rately. Use only the vent materials and kits listed in Fig- ure 22, page 19.
  • Page 30 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 13 DIRECT VENT — Vertical concentric (continued) Figure 34 See notices on previous page. Vertical termination — 3” PVC concentric — single or multiple boilers Prepare roof penetrations 1. Roof penetration hole: a.

  • Page 31: Concentric Termination, Typical (Sidewall Or Vertical)

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 14 Concentric termination, typical (sidewall or vertical) Figure 36 PVC concentric termination assembly — DO NOT LEGEND for Figure 36 attach the rain cap until the termination has been 1 — Inner PVC pipe (vent) 4 —...

  • Page 32: Vent And Air Piping And Boiler Connections

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 15 Vent and air piping and boiler connections Follow termination instructions Figure 38 Flue and vent adapter and gasket 1. Read and follow all instructions for the termination type used before proceeding with this page. Follow all instructions Vent provided by vent pipe manufacturer.
  • Page 33 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 15 Vent and air piping and boiler connections (continued) Figure 41 Vent (flue) and air adapters in place ADAPTERS — Use adapters if using 2-inch pipe, (WMB-80/120 only) 1. Clean and deburr inside and outside of both ends of air and vent pipes.
  • Page 34 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 15 Vent and air piping and boiler connections (continued) For example: CPVC, Polypropylene, or AL29-4C stainless Control selection for vent material steel. Venting Material Change “b22” PVC solid core, .......... Select: “1” (boiler is defaulted for PVC vent material) CPVC only, ..........

  • Page 35: Install Water Piping

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 16 Install water piping Domestic Water Piping – Combi Boiler should be capable of at least the Maximum input of the boiler Hot Water Can Scald! and Maximum pressure Not exceeding 130 PSIG. The pressure relief valve’s discharge should be per instructions in this manu- •...
  • Page 36 2. See instructions beginning on page 50, for wiring information. not the responsibility of Weil-McLain, and suitable steps 3. If using a manual reset limit control or wiring in the manual must be taken to avoid it.

  • Page 37: Primary/Secondary System Piping

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 17 Primary/Secondary System Piping System water piping methods Expansion Tank Location Near boiler piping Figure 47, page 38 show typical installation of the system expansion tank. It is highly recommended that you locate the air separator and expan- 1.
  • Page 38 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 17 Primary/Secondary System Piping (continued) Figure 47 Piping to diaphragm (or bladder) expansion tank Figure 48 AquaBalance Pressure drop through 80/120/155 heat exchanger (graphs and table) (GPM) Total Loss - Ft. Boiler Piping Est.

  • Page 39: Closed-Type Expansion Tank

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 17 Primary/Secondary System Piping (continued) Closed-type expansion tank: 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.

  • Page 40: Install Relief Valve

    — AquaBalance OUNT 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 WMB-80/120) or 1 ” x 1 ” -1/4 -1/4 x ¾” (for WMB-155) tee piped from boiler return (Figure 6, page 11). 2.

  • Page 41: Zone Valve Zoning - Primary/Secondary

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 17 Primary/Secondary System Piping (continued) Zone Valve zoning – primary/secondary Figure 50 Zone valve zoning — primary/secondary connection — a system circulator is required (Shown with optional DHW piping) See Figure 50. 1.

  • Page 42: Circulator Zoning - Primary/Secondary

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 17 Primary/Secondary System Piping (continued) Figure 51 Circulator zoning plus optional DHW piping Circulator zoning – primary/secondary (Shown with optional DHW piping) See Figure 51. This configuration is for circulator-zoned systems using a boiler loop connected as a secondary circuit off of a primary system loop.

  • Page 43: Circulator Zoning - Multiple Temperature Zones With Primary/Secondary

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 17 Primary/Secondary System Piping (continued) Figure 52 Circulator zoning with high- and low- temperature Circulator zoning – Multiple heating zones temperature zones with primary/ secondary (Shown with optional DHW piping) See Figure 52 1.

  • Page 44: Multiple Boiler Installations

    — AquaBalance OUNT 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 ser- vicing.
  • Page 45 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 18 Multiple boiler installations (continued) Figure 54 Piping schematic –– typical piping for multiple Heating Only boilers Legend for Figure 54 1 Flow/check valve 10 Cold water supply 11 Supply water temperature control (when used) 2 Isolation valves (when used) 12 Low water cutoff (when used) (place above primary 3 Cap...
  • Page 46 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 18 Multiple boiler installations (continued) When using a multiple-boiler control with lead boiler DHW tank piping with multiple rotation, it is recommended that the boiler connected to WMB boilers the DHW tank is always set as the last boiler to operate in the sequence so that space heat can be maintained during times of DHW demand.

  • Page 47: Install Condensate Line

    See ual. Failure to comply could result in severe per- Replacement parts section at the end of this sonal injury, death or substantial property damage. manual for the Weil-McLain kit. Part number 550-100-305/0118...

  • Page 48: Gas Piping

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 20 Gas piping Figure 59 Connect gas supply piping Boilers are shipped ready to fire natural gas (Combi boiler shown). ONLY. You must install the propane venturi if the boiler will be connected to propane. See page 12.
  • Page 49 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 20 Gas piping (continued) Gas pipe sizing For natural gas or liquefied petroleum (propane) gas, the pres- sure required at gas valve inlet pressure port (verify minimum 1. See page 16 for gas line sizing information. gas pressure when all gas appliances are in operation): a.

  • Page 50: Field Wiring

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 21 Field wiring Wiring must be N.E.C. Class 1. If original wir- ELECTRICAL SHOCK HAZARD — For your ing as supplied with boiler must be replaced, safety, turn off electrical power supply at service use only type 105 °C wire or equivalent.
  • Page 51 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 21 Field wiring (continued) Wiring the Circulators (Heating Only Boiler) Outdoor temperature sensor Central Heating Boilers (optional for Combi Boilers) The control of the Heating Only model of the boiler is ca- pable of managing two (2) separate circulators, one for the •...

  • Page 52: Wiring Diagram - Wmb-80/120C Combi Ladder

    Max. voltage and electric cur- rent for the LWCO should not be greater than 120VAC and 3 Amp. In case of questions during installation please contact your local Weil-McLain distributor. cod. 3541M910 Legend Water pressure switch Flow meter Central heating pump...

  • Page 53: Wiring Diagram - Wmb-80/120C Combi Schematic

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 22 Wiring diagram — WMB-80/120C Combi Schematic Figure 69 80/120C –– Combi Schematic Wiring Diagram WMB- Part number 550-100-305/0118...

  • Page 54: Wiring Diagram - Wmb-80/120H Heating Only Ladder

    Max. voltage and electric cur- rent for the LWCO should not be greater than 120VAC and 3 Amp. In case of questions during instal- lation please contact your local Weil-McLain distributor. cod. 3541M870 Legend Water pressure switch Flow meter Central heating pump...

  • Page 55: Wiring Diagram - Wmb-80/120H Heating Only Schematic

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 23 Wiring diagram — WMB-80/120H Heating Only Schematic Figure 71 WMB-80/120H –– Heating Only Schematic Wiring Diagram Part number 550-100-305/0118...

  • Page 56: Wiring Diagram - Wmb-155C Combi Ladder

    Max. voltage and electric cur- rent for the LWCO should not be greater than 120VAC and 3 Amp. In case of questions during installation please contact your local Weil-McLain distributor. Legend Water pressure switch Blower Flow meter Central heating pump...

  • Page 57: Wiring Diagram - Wmb-155C Combi Schematic

    — AquaBalance Boiler Manual ount gas fired Water boiler 24 Wiring diagram — WMB-155C Combi Schematic Figure 73 WMB-155C –– Combi Schematic Wiring Diagram Part number 550-100-305/0118...

  • Page 58: Wiring Diagram - Wmb-155H Heating Only Ladder

    + DHW PUMP should not be greater than 120 VAC and 3 Amp. In case of questions during installation please contact your local Weil-McLain distributor. cod. 3541M950 Legend Outdoor sensor Central heating pump (not included) DHW tank thermostat (not included)

  • Page 59: Wiring Diagram - Wmb-155H Heating Only Schematic

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 25 Wiring diagram — WMB-155H Heating Only Schematic Figure 75 WMB-155H –– Heating Only Schematic Wiring Diagram Part number 550-100-305/0118...

  • Page 60: Controls And Operation

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 26 Controls and operation Control Introduction This boiler is a high-efficiency condensing pre-mix appliance Thanks to the microprocessor control and adjustment system for central heating and hot water production, running on with advanced self-diagnosis, unit operation is for the most part Natural gas or Liquefied Petroleum (Propane) gas, generating automatic.
  • Page 61 — AquaBalance OUNT 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 60). The display indicates the actual Central Heating water temperature (Item 10 - Figure 76, page 60) and when the required set point temperature is reached “d2”...
  • Page 62 — AquaBalance OUNT 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.
  • Page 63 — AquaBalance OUNT 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 60).
  • Page 64 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 26 Controls and operation (continued) Adjustments for - Heating Only Boilers Figure 84 OTC settings with Outdoor sensor Optional for Combi with Outdoor sensor Theory of Outdoor Reset Control One of the key points to boiler efficiency, is to match the heat generated by the boiler to the heat loss of the building to be able to obtain a given comfort level in the living space.

  • Page 65: Dhw Settings (Combi Only)

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 27 DHW Settings (Combi Only) 26 Controls and operation Adjustments for Heating Only Boilers Boiler must be set on comfort mode with Outdoor sensor DHW SETTINGS Figure 86 Compensation curves 1. The DHW SETTINGS menus are for setting control opera- tion during DHW operation.

  • Page 66: Standard Altitude

    Freestyle 155 For elevations above 10,000 feet, please contact AquaBalance 155 Weil-McLain Technical Support for details. In Canada, Input rates are derated 10% for altitudes of 2000 ft. to 4500 ft. above sea level. Please use appropriate Fan Speed Settings for High Altitude provided in this manual.

  • Page 67: High Altitude

    For elevations above 10,000 feet, please contact 2. Roll down the menu by pressing the CH button until the Weil-McLain Technical Support for details. parameter “b04” is on the screen. In Canada, Input rates are derated 10% for altitudes 3.
  • Page 68 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 28 High Altitude Blower Speeds Figure 95 HIGH Altitude Fan Speeds for WMB-120 boilers 120KBTU - Natural Gas LOW FIRE HIGH FIRE (CH & DHW) ALTITUDE Blower Speed Blower Speed CO2 (%) CO (PPM) CO2 (%) CO (PPM)
  • Page 69 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 28 High Altitude Blower Speeds Figure 96 HIGH Altitude Fan Speeds for WMB-155 boilers 155KBTU - Natural Gas LOW FIRE HIGH FIRE (CH & DHW) ALTITUDE Blower Speed Blower Speed CO2 (%) CO (PPM) CO2 (%) CO (PPM)

  • Page 70: Startup

    45 °F. the system. Antifreeze Clean system to remove sediment 1. Use only antifreeze listed by Weil-McLain as suitable for use with Combi boilers. See Figure 159, page 117 for infor- 1. You must thoroughly flush the system (without boiler mation.
  • Page 71 Purge air from water system Use only the products listed by Weil-McLain for 1. Connect a hose to the drain valve (see drain valves, item use with this boiler. See page 117 for informa- 10, in piping diagrams beginning on page 11).

  • Page 72: Check Thermostat Circuits

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 29 Startup (continued) Use of X100 inhibitor is REQUIRED Check inhibitor concentration annually 1. The boiler is shipped with Sentinel X100 inhibitor and Senti- nel X100 Quick Test Kit. See Repair Parts Figure 159, page 117 1.

  • Page 73: 6Wduwxs ² ¿Qdo Fkhfnv

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 30 6WDUWXS ² ¿QDO FKHFNV Inspect/fill condensate system Check for gas leaks Inspect/check condensate lines and fittings 1. Inspect the condensate drain line, condensate PVC fittings and Before starting the boiler, and during initial opera- condensate trap.
  • Page 74 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 30 6WDUWXS ² ¿QDO FKHFNV (continued) Final checks before lighting the boiler 3. The boiler lights at the maximum heating 100% rate displayed • Open any on-off valves between boiler and the systems. on the LCD display.
  • Page 75 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 30 6WDUWXS ² ¿QDO FKHFNV (continued) Figure 100 Operating instructions (WARNING — Verify that the control is set for the correct boiler model before proceeding.) Part number 550-100-305/0118...
  • Page 76 DO NOT adjust or attempt to measure gas valve outlet contact your local Weil-McLain Technical Sup- pressure. The gas valve is factory-set for the correct outlet port. Throttle screw adjustment must be done pressure.
  • Page 77 Max. Regulating screw 5. Should you require any assistance during the set up pro- cedure contact your Weil-McLain Technical Support if Test at Max Power 100% the problem cannot be addressed with the information provided in this manual.
  • Page 78 When disassembling components, inspect gaskets to see if there is damage. Replace any damaged gasket. Rough start point d. Contact your Weil-McLain Technical Support if the For LP Start up ONLY problem cannot be addressed with the information provided in this manual.

  • Page 79: 6Wduwxs Yhul¿Fdwlrq

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 31 6WDUWXS YHUL¿FDWLRQ ❏ Additional field-installed limit control(s) set to system Adjust and test boiler controls temperature requirements? Balancing valves and controls 1. Follow instructions in this manual to set and verify operation adjusted to provide design temperature to system? of the boiler controls.

  • Page 80: Annual Startup And General Maintenance

    — AquaBalance OUNT 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.

  • Page 81: Annual Startup

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 33 Annual startup HANDLING CERAMIC FIBER FIRST-YEAR SPECIAL INSPECTION MATERIALS after the boiler is installed, per- No later than 12 months form a first-year inspection of the boiler. This should include the following in addition to routine annual start-up REMOVING BURNER GASKET or...
  • Page 82 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 33 Annual startup (continued) Check ignition wiring The boiler should be inspected and started 1. Check ignition cable electrical resistance. A good cable will annually, at the beginning of the heating have resistance between 950 and 1050 ohms.
  • Page 83 109 to reinstall all components. 5. Restart the boiler. 6. Inspect the flame at high and low fire. If flame is still not ac- ceptable, check combustion values. If combustion is properly adjusted, obtain a replacement burner from Weil-McLain. Part number 550-100-305/0118...

  • Page 84: Check Automatic Air Vents

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 33 Annual startup (continued) Check automatic air vents (if used Check boiler relief valve — automatic air vents must be used with diaghragm-type expansion tanks only) 1. Inspect the relief valve and lift the lever to verify flow as in the see page 37.

  • Page 85: Troubleshooting

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting VERIFY PROPER OPERATION AFTER SERVICING VERIFY PROPER OPERATION AFTER SERVICING BEFORE TROUBLESHOOTING — BEFORE TROUBLESHOOTING — BEFORE TROUBLESHOOTING — BEFORE TROUBLESHOOTING — Before calling for troubleshooting assistance, fill in the “...
  • Page 86 — AquaBalance OUNT 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 109 Time line of ignition sequence for the Combi and Heating Only boilers.
  • Page 87 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) Check flame signal Figure 110 Control circuit fuse location 1. Navigate to Diagnostics/Inputs on the control display (see pages 60 to 64 for navigation instructions. Fuse located on rear of circuit board 2.
  • Page 88 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) Make sure to determine the causes of outages. Do not leave the boiler operating without a com- plete diagnosis. Control diagnosis 1. The boiler control is equipped with an advanced self-diagnosis system. In case of a boiler fault, the display will flash together with the fault symbol (see Table 3 or Table 4) indicating the fault code.
  • Page 89 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) Figure 113 Troubleshooting suggestions — Fault displays and diagnostics (continued) Fault Code Fault Condition Correction &KHFN WKH UHJXODU JDV ÀRZ WR WKH ERLOHU DQG WKDW No burner ignition No gas the air has been eliminated from the pipes.
  • Page 90 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) Figure 114 Troubleshooting suggestions — Fault displays and diagnostics (continued) Fault Code Fault Condition Correction Probe damaged Exhaust probe fault Check the wiring or replace the exhaust Wiring shorted probe Wiring disconnected Sensor damaged...
  • Page 91 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) Figure 115 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.
  • Page 92 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) Figure 116 Troubleshooting suggestions — Fault displays and diagnostics (continued) Display Condition FAULT 11 = CH return sensor out of normal operating range (short circuit or open circuit). If sensor goes outside the range, error will be generated.
  • Page 93 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) Figure 117 Troubleshooting suggestions — Fault displays and diagnostics (continued) Display Condition FAULT 37 = Low water pressure error can be caused by the low water pressure in the central heating system. This can be GHWHFWHG LQ  ZD\V YLD ORZ ZDWHU SUHVVXUH VZLWFK DQG YLD ZDWHU SUHVVXUH VHQVRU ZLWK D FRQ¿UPLQJ WLPH RI  seconds).
  • Page 94 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) Figure 118 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”...
  • Page 95 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) Figure 119 Installer mode Installer mode reset By pressing the “ ” push button for 20 seconds, it is possible to entered the Installer mode. During this time, the OTC mode must not be entered.
  • Page 96 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) Figure 121 “tS” - Transparent Parameter mode (continued) Parameter Description Default Note DHW conf. dependent '+: RII PRGH  '+: FRQ¿J  /HJLRQHOOD SURWHFWLRQ  '+: FRQ¿J  ZLWK VHQVRU /HJLRQHOOD SURWHFWLRQ  '+: FRQ¿J  ZLWK WKHUPRVWDW '+: RII PRGH  '+: FRQ¿J  /HJLRQHOOD SURWHFWLRQ  RII  RQ  '+: FRQ¿J ...
  • Page 97 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) Figure 122 “tS” - Transparent Parameter mode (continued) Parameter Description Default Note DHW conf. dependent 1RW LPSOHPHQWHG  '+: FRQ¿J  3ULRULW\ 2YHU 5LGH 6HW PLQ  '+: FRQ¿J  1RW LPSOHPHQWHG  '+: FRQ¿J  3ULRULW\ 2YHU 5LGH 6HW PLQ  '+: FRQ¿J  DHW conf.
  • Page 98 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) Figure 125 “In” - Inquiry mode (continued) blinking Actual water pressure (psi) blinking Actual PWM modulating Pump (%) 0LQ  0D[  blinking Actual Step of Triac mod. mode (Num) 0LQ  0D[  blinking $FWXDO )ODPH &XUUHQW X$  ...
  • Page 99 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) ™ AquaBalance Figure 127 Troubleshooting suggestions for 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).
  • Page 100 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) ™ AquaBalance Figure 128 Troubleshooting suggestions for boilers — Fault displays and diagnostics (continued) Category E2 prom parameters Unit Range Description Num. Address Description High Value '+: FRQ¿J  36,1 ML –...
  • Page 101 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) ™ AquaBalance Figure 129 Troubleshooting suggestions for boilers — Fault displays and diagnostics (continued) Category E2 prom parameters Unit Range Description Num. Address Description High Value '+: FRQ¿J  42,2 ML –...
  • Page 102 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) ™ AquaBalance Figure 130 Troubleshooting suggestions for boilers — Fault displays and diagnostics (continued) Category E2 prom parameters Unit Range Description Num. Address Description High Value '+: FRQ¿J  CL5 –...
  • Page 103 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) ™ AquaBalance Figure 131 Troubleshooting suggestions for boilers — Fault displays and diagnostics (continued) Category E2 prom parameters Unit Range Description Num. Address Description High Value Central Heating CL5 –...
  • Page 104 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) ™ AquaBalance Figure 132 Troubleshooting suggestions for boilers — Fault displays and diagnostics (continued) Category E2 prom parameters Unit Range Description Num. Address Description High Value History ML – 8061 Total num.
  • Page 105 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) ™ AquaBalance Figure 133 Troubleshooting suggestions for boilers — Fault displays and diagnostics (continued) Category E2 prom parameters Unit Range Description Num. Address Description High Value Flame current supervi- ML –...
  • Page 106 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 34 Troubleshooting (continued) ™ AquaBalance Figure 134 Troubleshooting suggestions for boilers — Fault displays and diagnostics (continued) Some informations can be accessed with a communication package running on the PC. Category E2 prom parameters Unit Description...

  • Page 107: Maintenance

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 35 Maintenance Clean condensate trap Disconnect power 1. See Figure 135. 2. Disconnect top clean out cap nut that secures the trap body to Electrical shock hazard — Discon- the boiler condensate connection. nect all electrical power to the boiler 3.
  • Page 108 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 35 Maintenance (continued) Figure 137 Figure 139 Removal of Ignition electrode Boiler front panel removed 2. Remove two (2) Phillips head screws securing the ignition electrode to the boiler heat exchanger. 3.
  • Page 109 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 35 Maintenance (continued) Figure 141 Figure 143 Inspection and removal of burner and gasket Inspecting exterior and cleaning the burner Remove the heat exchanger cover plate and the gasket. Inspect the burner exterior. It must be in good condition, with no visible damage.
  • Page 110 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 35 Maintenance (continued) Inspect and clean the heat exchanger Lightly spray clean water on all of the boiler coils and Wait until heat exchanger/boiler is cooled down clean any residue off with (plastic only) brush. (Be careful before proceeding.
  • Page 111 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 35 Maintenance (continued) Procedure For Cleaning Heat Exchanger Figure 148 Heat exchanger components Waterways 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.
  • Page 112 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 35 Maintenance (continued) regulations and according to the manufacturer’s instructions. Actions For Cleaning Of Heat Exchanger Do not carry out any operation on the sealed control parts. Water Circuit Before carrying out any cleaning or maintenance operation, disconnect the unit from the electrical power supply using the •...
  • Page 113 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 35 Maintenance (continued) Actions for chemical cleaning of Hot Water Can Scald! Domestic hot water circuit • Consumer Product Safety Commission and some states recommend domestic hot water temperature of 130°F or 1.
  • Page 114 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 35 Maintenance (continued) ombi 80/120 flat plate heat Figure 153 Removal of flat plate heat exchanger exchanger removal for cleaning (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 151.
  • Page 115 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 35 Maintenance (continued) Combi 80/120 flat plate heat exchanger reinstalled Figure 155 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.

  • Page 116: Replacement Parts

    Controls Repair Parts Lists. Obtain parts only through Weil-McLain Replacement parts must be purchased through a local Weil-McLain WHEN OPERATING THE distributor. When ordering, specify boiler model and size and include description and part number of replacement part. Results from us- BOILER ON PROPANE GAS ing modified or other manufactured parts will not be covered by...
  • Page 117 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 36 Replacement parts (continued) Figure 159 Miscellaneous parts and kits Description Part Number Description Part Number M&G Simpson-Duravent PolyPro VERTICAL FRQFHQWULF YHQWDLU NLW FRORU EODFN SDUW QXPEHU Antifreeze, Sentinel X500..592-900-029 VKRZQ RU WHUUD FRWWD DGG 7&...
  • Page 118 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 36 Replacement parts (continued) Figure 160 Jacket parts Item Name Part Number Jacket door 640-000-067 Jacket left side 640-000-065 Jacket right side 640-000-066 Part number 550-100-305/0118...
  • Page 119 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 36 Replacement parts (continued) Figure 161 Control and electrical assemblies Item Name Part Number Control module assembly 640-000-003 Control module display cover 640-000-004 Pressure-Temperature assembly 640-000-006 Wire harness assembly - Combi - 80/120 640-000-005 Wire harness assembly - Combi - 155 640-000-085...
  • Page 120 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 36 Replacement parts (continued) Figure 162 Combi Boiler replacement kits and parts WMB-80/120C ( Model Item Name Part Number WMB-80 WMB-120 640-000-008 — Heat Exchanger 640-000-009 — Flue Sensor Temperature 640-000-011 Blower Assembly 640-000-020 Blower Gasket...
  • Page 121 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 36 Replacement parts (continued) Figure 163 Combi Boiler replacement kits and parts WMB-80/120C ( ) continued Part number 550-100-305/0118...
  • Page 122 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 36 Replacement parts (continued) Figure 164 Heating Only Boiler replacement kits and parts WMB-80/120H ( Model Item Name Part Number WMB-80 WMB-120 640-000-008 — Heat Exchanger 640-000-009 — Flue Sensor Temperature 640-000-011 Blower Assembly 640-000-020...
  • Page 123 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 36 Replacement parts (continued) Figure 165 Heating Only Boiler replacement kits and parts WMB-80/120H ( ) continued Part number 550-100-305/0118...
  • Page 124 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 36 Replacement parts (continued) Figure 166 Boiler replacement kits and parts WMB-155C Combi Item Name Part Number Heat Exchanger 640-000-080 Flue Sensor Temperature 640-000-011 Blower 640-000-081 Blower Gasket 640-000-021 Ignitor 640-000-109 Central Heat Exchanger Insulation 640-000-010 Burner...
  • Page 125 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 36 Replacement parts (continued) Figure 167 Boiler replacement kits and parts WMB-155C Combi Part number 550-100-305/0118...
  • Page 126 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 36 Replacement parts (continued) Figure 168 Boiler replacement kits and parts WMB-155H Heating Only Item Name Part Number Heat Exchanger 640-000-080 Flue Sensor Temperature 640-000-011 Blower Assembly 640-000-081 Blower Gasket 640-000-021 Ignitor 640-000-109 Central Heat Exchanger Insulation...
  • Page 127 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 36 Replacement parts (continued) Figure 169 Boiler replacement kits and parts WMB-155H Heating Only Part number 550-100-305/0118...

  • Page 128: Connections, Dimensions And Engineering Data

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 37 Connections, Dimensions and Engineering Data Figure 170 Connections, Dimensions and Engineering data — WMB-80/120 (all dimensions in inches) Part number 550-100-305/0118...
  • Page 129 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 37 Connections, Dimensions and Engineering Data (continued) Figure 171 Connections, Dimensions and Engineering data — WMB-155 (all dimensions in inches) Part number 550-100-305/0118...
  • Page 130 — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 37 Connections, Dimensions and Engineering data (continued) Figure 172 Engineering data Shipping Operating Water Vent/air pipe size: Electrical weight weight content (Provide a service separate vent for each required Boiler boiler) Model Pounds Amps...

  • Page 131: Ratings

    ---- ---- 3” PVC/PP/SS WMB-155 Notes As an Energy Star Partner, Weil-McLain requirements of the building and noth- 5 Ratings shown are for sea level applica- has determined that boilers meet the ing need be added for normal piping tions only. For altitudes from sea level Energy Star guidelines for energy ef- and pickup.

  • Page 132: Qvwdoodwlrq Dqg 6Huylfh &Huwl¿Fdwh

    — AquaBalance OUNT GAS FIRED WATER BOILER Boiler Manual 39 ,QVWDOODWLRQ DQG 6HUYLFH &HUWL¿FDWH Boiler Start-Up Data WMB-__________ Date installed ________________ # +LJK ¿UH BBBBBB /RZ ¿UH BBBBBB Boiler Model / Series / Series ____ Part Number ____________ FUEL: Natural ____ LP ____ Btu Input ___________________ &2 # +LJK ¿UH BBBB SSP /RZ ¿UH BBBB SSP Natural gas input rate measured HIGH________ CFH / LOW________ CFH...

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