WEIL-McLAIN AB-80 NG Boilers and Controls Instruction Manual

WEIL-McLAIN AB-80 NG Boilers and Controls

Replacement parts

REPLACEMENT PART NUMBERS
WM Technologies part numbers are found in this manual and in Weil-McLain Boilers and Controls Repair Parts Lists.

WHEN OPERATING THE BOILER ON PROPANE GAS

WARNING
ALL boilers must be converted in order to operate with propane gas.

Figure 163 Propane conversion kits and instructions

See Pages 10 – 15.

AB-80 LP| 640-000-024
AB-120 NG| 640-000-023
AB-120 LP| 640-000-025
AB-155 NG| 640-000-082
AB-155 LP| 640-000-133

• Failure to adhere to these guidelines can result in severe personal injury, death or substantial property damage.

Obtain parts only through WM Technologies
Replacement parts must be purchased through a local WM Tech-nologies distributor. When ordering, specify boiler model and size and include description and part number of replacement part. Re-sults from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation. The boiler contains ceramic fiber materials The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on page 86 of this manual. Failure to comply could result in severe personal injury.

Reinstall jacket door
Inspect boiler jacket door front of cabinet and reinstall boiler jacket door after start or servicing. The boiler jacket door must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room. This is particularly important if the boiler is located in the same room as other appliances. Failure to keep the

jacket door securely fastened could result in severe personal injury or death.

BEFORE SERVICING or MAKING CONNECTIONS
ALWAYS TURN POWER OFF TO THE BOILER TO PREVENT ELECTRICAL SURGES, WHICH CAN DAMAGE BOILER COMPONENTS.

Label wires

CAUTION
Label all wires prior to disconnection when servic-ing controls. Wiring errors can cause improper and dangerous operation.

Figure 164 Miscellaneous parts and kits

640-000-044
---|---
Condensate trap kit (supplied with boiler) —

condensate trap assembly and flexible line

| 640-000-073

Condensate neutralizer kit| 383-500-631
Annual Maintenance Kit 80/120| 640-000-114
Annual Maintenance Kit 155| 640-000-112
Direct Exhaust Venting Kit

Includes: Cover plates, vent screens and mounting hardware for 2” and 3” vent sizes.

| 640-000-135
Sidewall separate pipes vent/air termination kits (includes two cover plates)

Kit for 2” PVC vent and air pipes. . . . .

Kit for 3” PVC vent and air pipes. . . . .

Kit for 3” AL29-4C and air pipe. . . . . .

|

383-700-171

383-500-100

383-700-172

PVC concentric vent kit — horizontal or vertical (includes components for concentric assembly)

Kit for 2” PVC vent and air pipes. . . . .

Kit for 3” PVC vent and air pipes. . . . .

|

383-700-167

383-500-350

Bird screens (1 screen each)

For 2” PVC vent and air pipes . . . . . .

For 3” PVC vent and air pipes . . . . . .

|

383-500-106

383-500-105

M&G Simpson-Duravent PolyPro VERTICAL concentric vent/air kit; color = black (part number shown) or terra cotta (add -TC suffix)

2” polypropylene pipe . . . . . . . . .

3” polypropylene pipe . . . . . . . . .

|

2PPS-VK

3PPS-VK

M&G Simpson-Duravent PolyPro SIDEWALL separate air and vent pipes

2” polypropylene pipe . . . . . . . . .

3” polypropylene pipe . . . . . . . . .

|

2PPS-HTP

3PPS-HTP

Centrotherm INNOFLUE SIDEWALL concentric|
vent/air kit|
3” polypropylene pipe . . . . . . . . .| ICWT352
2” stainless steel/pp pipe . . . . . . .| ICWS2413
3” stainless steel/pp pipe . . . . . . .| ICWS3513
Centrotherm INNOFLUE VERTICAL concentric|
vent/air kit|
2” polypropylene pipe . . . . . . . . .| ICRT2439
3” polypropylene pipe . . . . . . . . .| ICRT3539

Figure 165 Jacket parts

Figure 166 Control and electrical assemblies

130

| Wire harness assembly – Combi – 80/120| 640-000-005
Wire harness assembly – Combi – 155| 640-000-085
Wire harness assembly – Heating Only| 640-000-053
Blower wiring adapter – Heating Only – 155| 640-000-103
140| PCB only (includes Circuit board, Transformer, Relay, Terminal strip, Fuse Holder & Fuse)|

640-000-062

150| Thermostat relay box and cover| 640-000-131
160| Board fuse 3.15 Amp (Package of 5) (not shown)| 640-000-122
170| Thermostat board fuse 630ma (Package of 5) (not shown)| 640-000-123

Figure 167 Boiler replacement kits and parts AB-80/120C (Combi)

Figure 168 Boiler replacement kits and parts AB-80/120C (Combi) continued

Figure 169 Boiler replacement kits and parts AB-80/120H (Heating Only)

Figure 170 Boiler replacement kits and parts AB-80/120H (Heating Only) continued

Figure 171 Boiler replacement kits and parts AB-155C Combi

Burner Gasket Premix                1 Piece      Burner Cover Gasket 1 piece

| 640-000-013
180| Burner Cover| 640-000-016
190| Inspection Glass| 640-000-015
200| Kit – Natural Gas Conversion| 640-000-082
210| Kit – Liquefied Petroleum (Propane) Gas Conversion| 640-000-133
220| Gas Valve VK8205V| 640-000-037
230| Circulator UPS2578| 640-000-086
240| Air Separator| 640-000-087
250| Water Pressure Switch| 640-000-019
260| DHW Inlet Pipe| 640-000-098
270| Water Filter| 640-000-027
280| Valve 3-Way| 640-000-088
285| Valve 3-Way Motor| 640-000-134
290| 3-Way Valve-PHE Pipe| 640-000-095
300| N/R Valve Fitting| 640-000-030
310| Flow Meter| 640-000-084
320| Plate Exchanger PFH30| 640-000-089
330| CH Temperature Probe DP| 640-000-034
340| CH Temperature Probe US| 640-000-035
350| DHW Temperature Probe US| 640-000-036
360| Relief Valve 3/4”| 640-000-038
370| NPT Adapters| 640-000-090

380

| Gasket Set

O-Ring 167 ID 63.5mm X 3.53mm NBR 5 pcs  Gasket OD 24 X ID17mm X 2mm 10 pcs O-Ring 21.89mm X 2.62mm EPDM  5 pcs  Gasket OD18.5 X ID12.5mm X 2mm  10 pcs O-Ring 23.81mm X 2.62mm EPDM  5 pcs  Gasket OD14.5 X ID8.5mm X 2mm  10 pcs Gasket OD 12.5mm x ID 8.5mm Silic. 10 pcs   Gasket OD45 X ID33.5mmX2mm EPDM 10 pcs

| ****

640-000-101

390| Condensate Drain Trap| 640-000-073
400| Vent Adapters (2 adapters in kit)| 640-000-107
410| Gaskets – Vent Adapter (2 gaskets in kit)| 640-000-108
420| Wall Mount Bracket| 640-000-044
430| Outdoor Temperature Sensor| 640-000-043
440| Heat Exchanger Flow Pipe| 640-000-091
450| CH – Return Pipe| 640-000-097
460| Bypass Pipe| 640-000-093
470| Flow Meter PHE Pipe| 640-000-099
480| DHW Outlet Pipe| 640-000-096
490| Gas Pipe| 640-000-100
500| Heat Exchanger Return pipe| 640-000-092
510| CH Flow Pipe| 640-000-094
520| Gasket – Heat Exchanger Vent| 640-000-136

Figure 172 Boiler replacement kits and parts AB-155C Combi

Figure 173 Boiler replacement kits and parts AB-155H Heating Only

Figure 174 Boiler replacement kits and parts AB-155H Heating Only

Documents / Resources

| WEIL-McLAIN AB-80 NG Boilers and Controls [pdf] Instruction Manual
AB-80 NG, AB-80 LP, AB-120 NG, AB-120 LP, AB-155 NG, AB-155 LP, AB-80 NG Boilers and Controls, AB-80 NG, Boilers and Controls, Controls
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