AHE
SERIES 4
Direct Vent Wall-Mounted Boilers
AHE
User’s
Information
Manual
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.
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.
Part number 550-141-893/0800
AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual
Stop!! — Read before proceeding
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.
Part number 550-141-893/0800
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AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual
Boiler maintenance
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.
Service technician
Owner maintenance
(covered in Boiler Manual — for use only by a
(see following pages for instructions)
qualified service technician)
• Check boiler area
• Check air openings
Inspect:
• Reported problems
Daily
• Boiler area
• Check boiler pressure/
temperature gauge
• Air openings
• Flue gas vent system (and air piping)
• Main burner flames
• Water piping
• Check boiler piping
• Check venting system
• Check boiler relief valve
• Check automatic air vents
• Main burner flames
Monthly
• Boiler heating surfaces
• Burners and base
Service:
• Test low water cutoff
• Cleaning boiler heating surfaces
• Blower motor
Periodically
• Clean vent termination and air
intake screens
• Oiled-bearing circulators
Every 6 months • Operate relief valve
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
End of season
• Shut down procedure
• Boiler relief valve
Review:
• Review with owner
Part number 550-141-893/0800
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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.
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.
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
❑ Daily........................... ❑ Daily.....................
Check boiler area
Check boiler pressure/
temperature gauge
To prevent potential of severe personal injury, death or
substantial property damage, do not store combustible 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.
materials, gasoline or any other flammable vapors or
liquids near the boiler. Remove immediately if found.
2. Contact a qualified service technician if problem
persists.
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.
Part number 550-141-893/0800
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AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual
User maintenance procedures continued
❑ Monthly ..................... ❑ Monthly ...............
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 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:
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.
•
The expansion tank may not be working
properly.
•
Immediately contact your qualified service
technician to inspect the boiler and system.
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 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.
Check venting system
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.
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 2
Figure 3
Relief valve
Automatic air vent
A
B
71036
Part number 550-141-893/0800
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AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual
User maintenance procedures continued
❑ Monthly ..................... ❑ Periodically..........
Main burner flames
Test low water cutoff
Test the low water cutoff periodically during the heating
season, following the low water cutoff manufacturer’s
instructions.
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).
Clean vent termination and air
intake screens
•
Improper main burner flame:
1. Remove all lint and debris from both the boiler air
intake screen and the flue discharge screen.
a. Overfired — Large flames.
b. Underfired — Small flames.
c. Lack of primary air — Yellow tipping on
flames (sooting will occur).
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.
Figure 4
89301
Figure 5
Main burner flame, typical
Transparent
blue flame
Inner flame
26024
Part number 550-141-893/0800
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AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual
User maintenance procedures continued
❑ Every 6 months........... ❑ End of season..............
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
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.
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.
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.
•
•
•
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.
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
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.
Part number 550-141-893/0800
8
AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual
Operating instructions
Robertshaw 7200 gas valve
FOR YOUR SAFETY READ BEFORE OPERATING
If you do not follow these instructions exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
A. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
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.
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.
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.
WHAT TO DO IF YOU SMELL GAS
•
•
Do not try to light any appliance.
•
Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
Do not touch any electric switch; do not use
any phone in your building.
•
If you cannot reach your gas supplier, call the fire department.
OPERATING INSTRUCTIONS
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.
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.
8. Turn selector arm clockwise
to ON.
5. This appliance is equipped with an ignition device
which automatically lights the burner. Do not try to
light the burner by hand.
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.
6. Depress and move selector arm counterclockwise
to OFF. Note: Selector arm cannot be moved to OFF
unless selector arm is depressed slightly. Do not force.
12. Replace control access panel.
Position
indicator
Selector
arm
(shown in
OFF position)
59332
TO TURN OFF GAS TO THE APPLIANCE
1. Set the thermostat to lowest setting.
4. Depress and move selector arm counterclockwise
to OFF.
Do not force.
2. Turn off all electric power to the appliance if service
is to be performed.
5. Replace control access panel.
3. Remove control access panel.
Part number 550-141-893/0800
9
AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual
Operating instructions — Robertshaw 7200 gas valve
Honeywell VR8205 and White-Rodgers 36E gas valves
FOR YOUR SAFETY READ BEFORE OPERATING
If you do not follow these instructions exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
A. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
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.
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.
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.
WHAT TO DO IF YOU SMELL GAS
•
•
Do not try to light any appliance.
•
Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
Do not touch any electric switch; do not use
any phone in your building.
•
If you cannot reach your gas supplier, call the fire department.
OPERATING INSTRUCTIONS
88731
1. Stop! Read the safety information above on this label.
2. Set the thermostat to lowest setting.
White-Rodgers
36E Gas valve
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.
Position indicator
(shown in "ON" position)
6. Turn gas control knob clockwise
to OFF.
Gas control knob
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.
Honeywell
VR8205
Gas valve
8. Turn gas control knob counterclockwise
9. Turn on all electric power to the appliance.
10. Set thermostat to desired setting.
to ON.
11. If the appliance will not operate, follow the instructions "ToTurn Off Gas
Position indicator
(shown in "ON" position)
To Appliance" below and call your service technician or gas supplier.
Gas control knob
12. Replace control access panel.
TO TURN OFF GAS TO THE APPLIANCE
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.
Part number 550-141-893/0800
10
AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual
Common problems and solutions
Symptom
Common Causes Possible Corrections
Thermostat installed where drafts Locate thermostat on inner wall away from heat sources or cool
Rapid cycling —
boiler turns on and
off frequently
or heat affect reading
drafts.
Heat anticipator in thermostat
adjusted incorrectly
Adjust thermostat per manufacturer's instructions.
Incorrect limit setting
Set limit according to system needs. Maximum setting is 220˚F.
Increase limit setting to decrease cycling.
Insufficient water flow through
boiler
Check all valves to and from boiler. Return to proper setting.
Confirm circulator size.
Expansion tank sized too small
Flooded expansion tank
Call qualified service technician to check expansion tank
operation and size.
Frequent release of
water through relief
valve
Call qualified service technician to check expansion tank
operation.
Inoperative limit control
Leaks in boiler or piping
Call qualified service technician to replace limit control.
Have qualified service technician repair leaks at once to avoid
constant use of makeup water. Makeup water can cause
mineral deposits which, in turn, can cause boiler section failure.
Do not use petroleum-based stop-leak compounds.
Need to frequently
add makeup water
Oxygen corrosion due to leaks in Have qualified service technician repair at once. Keep pH of
Black water
condition
boiler and piping
water between 7.0 to 8.5.
Mineral deposits in sections due
to constant use of makeup water
Call qualified service technician to de-lime boiler, if necessary.
In some cases, deposits will be too heavy to remove with de-
liming procedures.
Popping or
percolating noise
heard in boiler
Have qualified service technician repair leaks to eliminate need
for constant makeup water.
Incorrect pH of boiler water
Call qualified service technician to check pH level and correct.
pH should be maintained between 7.0 to 8.5.
Insufficient water flow through
boiler
Check all valves to and from boiler. Return to proper setting.
Confirm circulator size.
Contaminated combustion air
supply — See page 4 in this
manual.
Remove any contaminating products. See page 3 in this
manual.
Metal flakes found in
vent outlet or vent —
flueway corrosion
Provide outside air for combustion. Kit available through Weil-
McLain distributor. Have qualified service technician pipe-up kit.
Condensation of combustion
gases in boiler sections
Have qualified service technician inspect system piping and
controls to verify proper regulation of return water temperature.
Air in system
Bleed air from system through air vents in radiators or
baseboard units.
Some radiators or
baseboard units do
not heat or are noisy
Low system pressure
Fill to correct pressure.
Check for leaks in boiler or piping. Have qualified service
technician repair at once.
High limit set too low
Adjust high limit to higher setting.
Part number 550-141-893/0800
11
Weil-McLain Limited Warranty for
Residential & Commercial Cast Iron Boilers
RESIDENTIAL WATER WARRANTY—Limited Lifetime
RESIDENTIAL STEAM WARRANTY—Limited 10 Year
COMMERCIAL WARRANTY—Limited 10-Year
These warranties do not cover:
1. Components that are part of the heating systems, but
were not furnished by Weil-McLain as a part of the
boiler.
NOTE: The residential steam and water warranties do not
cover residential boilers installed in buildings other than one
or two family dwelling units, unless they are buildings with
individual boilers for each dwelling unit.
2. The workmanship of any installer of Weil-McLain’s
boilers. In addition, this warranty does not assume any
liability of any nature for unsatisfactory performance
caused by improper installation.
First Year-(All Residential & Commercial Cast Iron
Boilers)
3. Any costs for labor for removal and reinstallation of the
alleged defective part, transportation to Weil-McLain, if
necessary, and any other materials necessary to
perform the exchange.
Limited Warranty for Cast Iron Boilers:
Weil-McLain warrants that its cast iron boilers are free from
defects in material and workmanship for one year from the
date of installation. If any parts are found to be defective in
manufacture, Weil-McLain will provide replacement of such
defective parts.
4. Improper burner adjustments, control settings,care or
maintenance. Information is included in the installation
Instructions, Owner’s Information Manual and/or Start-
up, Service and Maintenance Instructions, and other
printed technical material furnished by Weil-McLain with
the boiler.
Second Through Tenth Year-(Residential Water/Steam)
Second Through Tenth Year-(Commercial Water/Steam)
Limited Warranty for cast iron sections:
Weil-McLain warrants that the cast iron sections of its water
and steam boilers are free from defects in material and
workmanship from the date of installation for the second
through the tenth year. If, during such time period, any section
is found to be defective, Weil-McLain will provide replacement
for the original cast iron section(s).
5. Boilers operated with combustion air contaminated
externally by chemical vapors or with improper fuel
additives, or with water conditions which may have
caused unusual deposits in the cast iron sections.
These warranties extend only to the first retail purchaser of the boiler
and only to a boiler that has not been moved from its original
installation site.
Eleventh Year and Beyond - (Residential Water Only)
Limited Warranty for Cast Iron Sections:
Weil-McLain warrants that the cast iron sections of its
residential water boilers are free from defects in material and
workmanship for the eleventh year and beyond from the date
of installation.If, during such time period, any section(s) is
found to be defective, Weil-McLain will provide replacement
for the original cast iron section(s) upon the payment of a
proportionate charge based on the time the boiler has been
in service. The proportionate charge will be equal to the
appropriate percentage of the list price of such section(s) at
the time the warranty claim is made, and will be determined
as follows:
THE WARRANTIES DESCRIBED ABOVE ARE IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO ANY IMPLIED WARRANTIES OF FITNESS FOR
A PARTICULAR PURPOSE AND MERCHANTABILITY. WEIL-
McLAIN EXPRESSLY DISCLAIMS AND EXCLUDES ANY
LIABILITY FOR CONSEQUENTIAL, INCIDENTAL, INDIRECT OR
PUNITIVE DAMAGES FOR BREACH OF ANY EXPRESS OR
IMPLIED WARRANTY.
For prompt product warranty claims, notify the installer who, in turn,
will notify the Weil-McLain distributor from whom he purchased the
boiler. If this action does not result in warranty resolution, contact
Weil-McLain Consumer Relations Department, 500 Blaine Street,
Michigan City, Indiana 46360-2388, with details in support of the
warranty claim. Alleged defective part or parts must be returned
through trade channels in accordance with the Weil-McLain
procedure currently in force for handling returned goods for the
purpose of inspection to determine cause of failure. Weil-McLain
will furnish new part(s) to an authorized Weil-McLain distributor who,
in turn will furnish the new part(s) to the heating contractor who
installed the boiler. If you have any questions about the coverage of
this warranty, contact Weil-McLain at the address above.
11th year - 5%; 12th year - 10%; 13th year - 15%;
14th year - 20%; 15th year - 25%; 16th year - 30%;
17th year - 35%; 18th year - 40%; 19th year - 45%;
20th year - 50%; 21st year - 55%; 22nd year - 60%;
23rd year - 65%; 24th year - 70%; 25th year and
beyond - 75%.
All Residential & Commercial Cast Iron Boilers
These warranties are subject to the condition that the boiler
must have been installed by a heating contractor whose
principal occupation is the sale and installation of plumbing,
heating and/or air conditioning equipment.
Weil-McLain
500 Blaine Street
Michigan City, IN 46360-2388
A United Dominion Company
Part number 550-141-893/0800
12
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