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Weil-McLain 550 MBH, Nstallation And Operation Manual

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Weil-McLain 550 MBH Nstallation And Operation Manual Download Page 118

Part number 550-100-168/0516

118

&IGURE

   Controls

 

Item

Description

Part Number for 

SlimFit 550/750

1

3-amp, fast-blow ATO (5 fuses)

383-500-603

2

12-amp, slow-blow AG (5 fuses)

383 500 604

3

Control module

383-600-162

4

Kit - Service Conversion Series 1 to Series 2  (Includes items 3, 5, 6, 23, 24 & 27)

383-600-164

5

Expansion module

383-600-160

6

Display board assembly

383-600-159

7

Display bracket kit

383-600-042

8

Supply temperature sensor replacement kit, dual sensor (sensor only)

383-600-072

9

Return temperature sensor replacement kit, single sensor (sensor and bushing)

383-600-071

10

Outdoor temperature sensor

510-312-218

11

System temperature sensors

383-500-601

12

Flue Temperature sensor replacement kit (sensor and grommet)

383-500-600

13

Heat exchanger temperature sensor

383-500-602

14

On/off power switch

383-500-205

15

Transformer, 120v/24v

383-500-628

16

Pressure/temperature gauge assembly

570-218-054

17

120 volt, 3-wire receptacle, pre-wired

591-391-959

18

Air pressure switch kit (includes switch, tube and mounting screws)

383-600-073

19

Hose barb for air pressure switch sensing tube connection (not shown)

562-302-525

20

Air pressure switch sensing tube (included in item 18)

In Item 18

21

Blower power relay

570-350-230

22

SlimFit Control terminal block kit (not shown)

383-500-642

23

Control to Expansion Module wire harness, RS485 (not shown)

383-500-633

24

Expansion module to display harness, Cat-se RJ4S (not shown)

383-600-163

25

Upper line voltage wire harness (EP2, EP4, power input and blower relay) (not shown)

383-600-057

26

Low line voltage wire harness (not shown)

591-391-958

27

Upper low voltage wire harness (not shown)

383-600-158

28

Lower low voltage wire harness (P4 through P9 and other) (not shown)

591-391-956

29

Jumper for low voltage terminal blocks ( 5 jumpers) (not shown)

383-500-641

30

Flue temperature sensor gasket

590-318-011

  

  

'OTOWWWWEILMCLAINCOMTOLOCATE7EIL-C,AINDISTRIBUTORS

SlimFit

®

 Series 3 

COMMERCIAL

 

CONDENSING

 

GAS

-

FIRED

 

WATER

 

BOILER

 — 

Boiler Manual

Replacement parts

 

(continued)

Summary of Contents for 550 MBH

Page 1: ...formation shipped with the boiler before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage s NSTALLATION s 3TARTUP s AINTENANCE s 0ARTS Boiler Manual Part number 550 100 168 0516 Series 3 Models 550 and 750 MBH Commercial Condensing Gas fired water boilers ...

Page 2: ...the boiler assembly around its entire pe rimeter ACKET DOOR LATCHES GNITION ELECTRODE mAME SENSOR The burner flame is ignited by applying a high voltage to the ignition electrode This causes a spark from electrode to ground After igni tion the electrode measures flame signal LAME INSPECTION WINDOW The quartz glass window provides a view of the burner surface and flame INE VOLTAGE TERMINAL STRIP VOLT ...

Page 3: ...Part number 550 100 168 0516 3 SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual The SlimFit Series 3 COMMERCIAL gas fired water boiler ...

Page 4: ...S 72 2 3 44 3 MENU 3 MODE 73 02 2 49 MENUS 3 MODE 74 33 0543 MENU 3 MODE 75 34 MENU 77 4 4 4 MENUS 82 3TARTUP lLL THE SYSTEM 83 3TARTUP lNAL CHECKS 85 PERATING NSTRUCTIONS 88 HECK OUT STARTUP VERIlCATION 89 NNUAL STARTUP AND GENERAL MAINTENANCE 90 NNUAL STARTUP 91 4ROUBLESHOOTING 96 AINTENANCE 105 2EPLACEMENT PARTS 108 IMENSIONS 120 2ATINGS 3LIM IT 3ERIES BOILERS 121 2ATINGS MULTIPLE 3LIM IT 3ERIE...

Page 5: ...H B TFDVSJUZ TZTUFN JOTUBMMFE UIBU PQFSBUFT EVSJOH QPXFS PVUBHFT TFOTFT MPX UFNQFSBUVSF BOE JOJUJBUFT BO FGGFDUJWF BDUJPO POTVMU XJUI ZPVS CPJMFS DPOUSBDUPS PS B IPNF TFDVSJUZ BHFODZ F ANY PART OF A BOILER BURNER OR ITS CONTROLS HAS BEEN SPRAYED WITH OR SUBMERGED UNDER WATER EITHER PARTIALLY OR FULLY 4 ATTEMPT TO OP ERATE THE BOILER UNTIL THE BOILER HAS BEEN EITHER REPLACED OR COMPLETELY REPAIRED ...

Page 6: ...installed so that gas control system components are protected from dripping or spraying water or rain during operation or service 4 If new boiler will replace existing boiler check for and correct system problems such as s System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits s Incorrectly sized expansion tank s Lack of freeze protection in boiler water causing sy...

Page 7: ...in boiler room 1 DIRECT VENT For direct vent installations air piped to boiler no air ventilation openings into boiler room are needed if clearances around the SlimFit boiler are at least equal to the SERVICE clearances shown in Figure 1 page 6 For spaces that DO NOT supply the minimum service access clearances see the direct vent venting instructions in this manual for required openings 2 DIRECT ...

Page 8: ...dwithablowerplatethatis used for natural gas and propane The blower plate must be left in place for propane applications Vent and air piping requirements page 20 1 The SlimFit boiler requires a special vent system designed for pressurized venting a SlimFit boilers are rated ANSI Z21 13 Category IV pres surized vent likely to condense in the vent b SlimFit commercial boilers can be either DIRECT EX...

Page 9: ... the propane blower plate and gaskets 1 See Figure 2 page 10 2 Disconnect the two wire harnesses connected to the blower 3 SF 750 natural gas boilers do not use a blower plate The boiler is shipped with a blower plate and gaskets that must be installed to operate the boiler on propane 4 Obtain the two 2 gaskets item 3 and blower plate item 4 shipped with the boiler 5 Check the blower plate to ensu...

Page 10: ...he SF 550 and SF 750 to operate on propane LOWER PLATE MOUNT WITH STAMPING LOCATED AS SHOWN s Verify model number fuel 0 or 0 s Install plate with I D stamping toward front of boiler and facing blower 0ROPANE ORIlCE Verify model number 0 or 0 Heat exchanger BACK SIDE 1 8 9 13 12 11 10 14 3 4 5 6 7 3 2 SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Prepare boiler contin...

Page 11: ...ets beneath 10 If convenient install any other piping compatible with Fig ure 3 that would still allow bleeding air from shutoff valves Fill and pressure test 1 Open the shutoff valves you installed on supply and return connections 2 Slowly open boiler drain valve and fresh water supply to fill boiler with water The boiler will fill quickly because of its low water content 3 When water reaches the s...

Page 12: ...wrenches to prevent the boiler interior piping from turning Failure to support the boiler piping connections to prevent them from turn ing could cause damage to boiler components General piping information Additional controls when required The Control module uses temperature sensors to provide both high limit protection and modulating temperature control and is UL353 Limit Controls certified to mee...

Page 13: ... the range listed above 65 21 4 20 7 70 19 9 23 6 DO NOT design for flow rates above or below the range listed above Suggested design flow rates 30 F temperature rise Size the piping and the boiler circulator to provide the required temperature rise through the boiler loop See Figure 5 for the head loss through the boiler and minimum maximum flow rates 4 design the piping and components for a boiler ...

Page 14: ...air separator to expansion tank and make up water line using a closed type expansion tank 5 Most chilled water systems are piped using a closed type tank as shown in Figure 11 page 19 Diaphragm or bladder expansion tank 1 Figure 6 Always install an automatic air vent on top of the air separator to remove residual air from the system When using diaphragm or bladder tanks only when the boiler is ins...

Page 15: ...ge 13 on all boiler loop piping connecting boiler to and from the primary secondary connection item 21 0RIMARY SECONDARY PIPING SHOWN ensures the boiler loop will have sufficient flow For other piping methods see guides on page 13 Expansion Tank required 1 Provide a system expansion tank following the guidelines on page 14 2 DO NOT use a closed type tank if connecting to a water heater that is equip...

Page 16: ...rities simultaneously b Space Heating Priority Space heating is priority over DHW UsePriorities1and or2forspaceheating Priority3forDHW The control will not run multiple priorities simultaneously Controlling the circulators 1 The control can control up to four circulators boiler circulator and three others Refer to Field wiring beginning on page 50 for instructions on wiring to circulators Legend 8...

Page 17: ...g connecting boilertoandfromtheprimary secondaryconnection item 21 0RIMARY SECONDARY PIPING SHOWN ensures the boiler loop will have sufficient flow For other piping methods see guides on page 13 Expansion Tank required 1 Provide a system expansion tank following the guidelines on page 14 2 DO NOT use a closed type tank if connecting to a water heater that is equipped with an automatic vent Domestic ...

Page 18: ...ultiple priorities simultaneously b Space Heating Priority Space heating is priority over DHW Use Priorities 1 and or 2 for space heating Priority 3 for DHW The control will not run for DHW The control will not run multiple priorities simultaneously Controlling the circulators 1 The control can control up to four circulators boiler circulator and three others Refer to Field wiring beginning on pag...

Page 19: ...G SHOWN ensures the boiler loop will have sufficient flow For other piping methods see guides on page 13 If antifreeze is used in the system consider the effects of anti freeze on circulator sizing and DHW performance Some local codes may require double wall DHW heat exchanger design Use only the antifreeze listed by Weil McLain for use with this boiler See page 109 for details Chilled medium if use...

Page 20: ... of the build ing at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BE LOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 30 4 The state or local gas inspector of the side wall horizontally vented gas fueled...

Page 21: ...pace with other appliances the combustion air openings must be sized to handle the combined requirements of all appliances in the space SIDEWALL direct exhaust option s 2EAD PAGE THROUGH PAGE 4HEN GO TO PAGE VERTICAL direct exhaust option s 2EAD PAGE THROUGH PAGE 4HEN GO TO PAGE DIRECT VENT OPTIONS DIRECT EXHAUST OPTIONS Venting combustion air general Vent and air piping materials 1 See Figure 13 ...

Page 22: ...neral continued 3LIM IT OILERS MUST BE VENTED AND SUPPLIED WITH COMBUSTION AND VENTILATION AIR USING PIPING AND METHODS DESCRIBED IN THIS MANUAL DO NOT COMMON VENT VERY BOILER MUST HAVE ITS OWN VENT 4 common vent with any other appliance See page 23 for checking appliances remaining on a common vent INSPECT VENT AIR COMPONENTS Inspect finished vent and air piping thoroughly to ensure all are airtig...

Page 23: ...to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the com mon venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 3 Place in operation the appliance being inspected Follow the lighting instru...

Page 24: ...del Input Stack Vent Negative Pressure to be maintained at Vent Connection of the boiler SlimFit Vent Adapter required for Category II Btuh scfm See Note 1 SF 550 550 000 128 0 001 to 0 100 6 8 SF 750 750 000 175 0 001 to 0 100 6 8 Note 1 8 to 6 bell adapters are required for Category II venting Table 1 Rating and Vent Data for Category II boilers NQSPQFS OTUBMMBUJPO PG B BUFHPSZ WFOU TZTUFN SFTVM...

Page 25: ...D METHODS DESCRIBED Inspect finished vent and air piping thoroughly to ensure all are water tight and comply with the instructions provided and with all requirements of applicable codes Failure to provide a properly installed vent and air system will cause severe personal injury or death If the vent air piping configurations covered in the SlimFit boiler manual cannot be applied for a particular ins...

Page 26: ...ces Refer to the National Fuel Gas Code for dealing with other con ditions Free area louver allowance The free area of openings means the area after reduction for any installed louvers or grilles Be sure to consider this reduction when sizing the air openings Special considerations Tight construction ANSI Z223 1 defines unusually tight construction where 1 Walls and ceilings exposed to the outside ...

Page 27: ...window or any other gravity air inlet b Do not terminate closer than 4 feet horizontally from any electric meter gas meter regulator relief valve or other equipment 5 Where the vent penetrates the roof the annular space around the penetration must be permanently sealed using approved materials to prevent entry of combus tion products into the building 6 Locate terminations so they are not likely t...

Page 28: ...iler vent connection 3 Cut pipe to required lengths 4 Deburr inside and outside of pipe ends 5 Chamferoutsideof eachpipeendtoensureevencement distribution when joining 6 Clean all pipe ends and fittings Dry thoroughly 7 Dry assemble entire vent or air piping to ensure proper fit before assembling any joint 8 For each PVC CPVC joint a Handle fittings and pipes carefully to prevent con tamination of su...

Page 29: ...ld it open during operation Combustion air provision The SlimFit Commercial boiler can use inside air if no contaminants are present in the boiler space If contaminants are likely to be present install the boiler as a direct vent appliance using the appropriate vent instructions in this manual see Figure 12 page 22 The boiler room must be fitted with combustion air openings large enough to provide ...

Page 30: ...nch per Btuh of all appliances in the room 47 openings each at least 1 square inch per Btuh of all appliances in the room OR opening each at least 1 square inch per Btuh of all appliances in the room 47 openings each at least 1 square inch per Btuh of all appliances in the room OR opening each at least 1 square inch per Btuh of all appliances in the room 47 openings each at least 1 square inch per...

Page 31: ...ght side a Apply the configuration on the left side of Figure 18 unless the termination would fail to meet minimum clearance to grade or snow line b Apply the configuration on the right side of Figure 18 when the termination needs to be raised higher to meet clearance to grade or snow line SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual DIRECT EXHAUST Sidewall Allowable v...

Page 32: ...rby shrubs plants or air conditioning equipment or be objectionable b The flue products will form a noticeable plume as they con dense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with p...

Page 33: ...e permanently sealed using ap proved materials to prevent entry of combustion products into the building 6 Locate termination so it is not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves or sediment 7 Do not connect any other appliance to the vent pipe Do not con nect multiple boilers to a common vent pipe Completing the vent piping 1 Install vent pe...

Page 34: ...s Support vertical runs on the outside of the building with brackets as shown in the termination instruc tions 3TEP Install vent piping from boiler to termi nation s Install a hanger support within 6 inches of any upturn in the piping s Slope horizontal piping downward toward the boiler at least 1 4 inch per foot 3TEP Connect the vent piping at the boiler per manual instructions Allowable vent pip...

Page 35: ...oof penetrations 1 Vent pipe penetration a Cut a hole for the vent pipe For either combustible or non combustible construction size the vent pipe hole at least 0 5 larger than the vent pipe diameter s 7 hole for 6 PP and PVC s 9 hole for 8 PP and PVC b Insert a galvanized metal thimble in the vent pipe hole 2 Follow all local codes for isolation of vent pipe when passing through floors ceilings and...

Page 36: ...ate installation conditions Air openings must be sized to handle all appliances and air movers exhaust fans etc using the air supply The sizing given in Figure 27 page 37 is based on the National Fuel Gas Code ANSI Z223 1 allowing adequate air opening for gravity vented gas appliances Category I when located in the same space as the SlimFit boiler When outside air is ducted as directed in this man...

Page 37: ...in the room openings are required if the boiler installation provides at least the Recommended service clearances shown on page 6 If the space is smaller provide ONE opening to a larger room with at least 1 square inch per Btuh of SlimFit boiler input 47 openings each at least 1 square inch per Btuh of all other appliances in the room OR opening each at least 1 square inch per Btuh of all other ap...

Page 38: ...lbows Additional elbows require a reduction in maximum length as explained in the table notes Connecting from termination to boiler 1 Install the terminations as instructed in the following Then proceed to page 45 to complete the air and vent piping between the termination and the boiler IGURE Maximum piping lengths for DIRECT VENT sidewall termination OILER 8 5 PIPING LENGTH FOR PIPE DIAMETER INC...

Page 39: ...using longer lengths The chase must allow for inspection of the vent pipe and insulation must be protected from water IGURE DIRECT VENT Sidewall configuration options and minimum clearances from vent to air terminations 4 Consider the surroundings when terminating the vent and air a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be o...

Page 40: ...ermanently sealed using approved materials to prevent entry of combustion products into the building 8 Locate terminations so they are not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves or sediment 9 Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe Completing the vent air piping 1 Install vent air penetra...

Page 41: ...ent termination elbow either directly outward or 90 degrees away from the air inlet elbow as shown in Figure 30 page 39 4 Maintain the required dimensions of the finished termination piping as shown in Figure 30 page 39 5 Do not extend exposed vent pipe outside of building more than shown in this document Condensate could freeze and block vent pipe If the vent air pipes are extended out beyond the ...

Page 42: ...building with brackets as shown in the termination instruc tions 3TEP Install air and vent piping from boiler to termination s Install a hanger support within 6 inches of any upturn in the piping s Slope horizontal piping downward toward the boiler at least 1 4 inch per foot 3TEP Connect the vent and air piping at the boiler per manual instructions Allowable vent air pipe materials 1 Use only the ...

Page 43: ...c tric meter gas meter regulator relief valve or other equipment 5 Where the vent or air pipe penetrates the roof the annular space around the penetration must be permanently sealed using ap proved materials to prevent entry of combustion products into the building 6 Locate terminations so they are not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves ...

Page 44: ...tain the required dimensions of the finished termination piping as shown in Figure 38 page 43 6 Do not extend exposed vent pipe outside of building more than shown in this document Condensate could freeze and block vent pipe Multiple vent air terminations Figure 39 1 When terminating multiple SlimFit boilers terminate each vent air connection as described in this section Terminate all vent pipes at...

Page 45: ...page 35 c DIRECT VENT Sidewall terminations see Figure 28 page 38 d DIRECT VENT Vertical terminations see Figure 36 page 42 2 Work from the boiler to vent or air termination Do not exceed the lengths given in the previous pages for either the air or vent piping a As shown in the maximum length tables the SF 550 must be installed with only 6 inch vent and air piping b As shown in the maximum length...

Page 46: ...heck joint to be sure a smooth bead of cement shows around the entire joint 6 Assemble the 1 PVC nipple to the PVC condensate drain tee item 2 Insert the nipple completely into the tee socket 7 Allow joint to dry completely 8 Slide the finished nipple tee assembly into the condensate drain hole 9 Slide the gasket item 3 over the nipple 10 Cement the 1 coupling item 4 to the protruding 1 nipple Pre...

Page 47: ...uld have an overflow switch to prevent property damage from condensate spillage See Figure 43 for required flow capacity 4 When sizing condensate pumps make sure to include the total load of all SlimFit boilers connected to it The condensate line must remain unobstructed allow ing free flow of condensate If condensate is allowed to freeze in the line or if the line is obstructed in any other manor co...

Page 48: ...s pressure regulator in the gas supply line if inlet pressure can exceed 14 w c at any time Adjust the lockup regulator for 7 to 10 w c inlet pressure This setting provides a cushion below the set ting of the high gas pressure switch Failure to comply could result in shutdown by the high gas pressure switch resulting in possible serious property damage due to freeze up Natural Gas Pipe sizing for ...

Page 49: ... connection see Figure 46 page 48 a Maximum 14 w c with no flow lockup or with boiler on b Minimum 3 5 w c with gas flowing verify during boiler startup while boiler is at high fire c If no external pressure tap is available connect manometer to the gas pressure switch tee Fig ure 47 page 48 At this point the minimum gas pressure required is 3 0 w c Manifolded gas supply lines 1 Construct gas header ...

Page 50: ...s that are not listed in this manual Wire entrances Eight knockouts are provided in the top of the cabinet for line and low voltage wiring See Figure 51 for locations NSTALLER 534 USE A STRAIN RELIEF through jacket knockouts Failure to do so can cause severe personal injury death or sub stantial property damage Wiring overview See details on the following pages for the wiring connections outlined ...

Page 51: ...air damper 6 When using inputs outputs for heat DHW demands each input Input 1 Input 2 and Input 3 controls its respective 120 VAC output Output 1 Output 2 and Output 3 Outputs are energized only when BOTH condi tions below are met a The corresponding input indicates a call for heat DHW i e contact closure b The PRIORITY assigned to the Input Output pair is ACTIVE i e the zone may be calling but t...

Page 52: ...The control default setting is for three space heating zones tied to PRIORITY 2 which is defaulted to FINNED TUBE BASEBOARD system type 6 For DHW applications the aquastat can be connected to one of the three input output pairs Take advantage of factory default settings by using PRI ORITY 1 for the DHW system The default control setting for PRIORITY 1 is a direct piped DHW system type 7 The defaul...

Page 53: ...es the system return temperature with the system supply temperature Should the return temperature ever exceed the supply tempera ture the Control knows there is likely a sensor failure and will report this problem on the display All heating systems shown in this manual require the System Sup ply and Return sensors to be installed for proper control function System will not properly provide heat if...

Page 54: ...and shuts the boiler off An operator user or technician must manually reset the control to resume heating Cycling power on and off will NOT reset the control See Figure 52 page 60 for details 4O CAUSE AUTOMATIC RESET 4ERMINAL LOCK 0 SlimFit control module left side 3LIM IT CONTROL WILL RESET AUTOMATICALLY AFTER CIRCUIT IS INTERRUPTED 1 Remove factory installed jumper and connect isolated contacts ...

Page 55: ...OT clip wires attached to other pins on P7 Only clip purple wire attached to PIN 3 Damaging the other wires will cause boiler fault and will require part repair or replacement 2 No control settings are required when using a flow switch 3 Recommended configuration of the SlimFit control for a CAD interlock a Assign 054 as a 58 05 0 54054 function b For the 58 05 0 54054 operating mode select 9 52 2 T...

Page 56: ...T during the WIZARD or manually in the PRIORITY SETTINGS menu for the desired PRIORITY a Many options are available for configuring the control The following is a suggested setup that uses factory default settings as much as possible b Use PRIORITY 1 for the DHW heating system when used This priority s default values are set for DHW direct piped to the boiler Verify that set tings are suitable for ...

Page 57: ...ossible b If DHW is required use PRIORITY 1 to minimize setup steps s Connect the DHW aquastat to INPUT 2 or INPUT 3 and assign the input used to PRIORITY 1 s Verify that control settings are suitable for the application changing if necessary c Use PRIORITY 2 for the system to be remote modulated s The factory default settings for this priority are best suited for space heating s Assign INPUT 1 to...

Page 58: ...nother heat source using its ad ditional heat demand dry contacts through terminal block P16 pins 6 7 2 Connect these terminals to call for heat from the other heat source 3 Contact electrical ratings 24VAC or less 0 5 amp or less 4 Set the control to activate the heat demand contacts as needed 5 See SlimFit Advanced Manual to configure See Figure 52 page 60 for details O 0 10 VDC Output Section 4E...

Page 59: ...Part number 550 100 168 0516 59 SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Notes ...

Page 60: ...umber 550 100 168 0516 60 Field wiring SEE IGURE IGURE continued IGURE Schematic wiring diagram SF 550 SF 750 continued on next page SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual ...

Page 61: ...er 550 100 168 0516 61 IGURE continued from previous page Schematic wiring diagram SF 550 SF 750 SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Field wiring SEE IGURE IGURE continued ...

Page 62: ...number 550 100 168 0516 62 IGURE Ladder wiring diagram SF 550 SF 750 continued on next page SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Field wiring SEE IGURE IGURE continued ...

Page 63: ...ber 550 100 168 0516 63 Field wiring SEE IGURE IGURE continued IGURE continued from previous page Ladder wiring diagram SF 550 SF 750 SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual ...

Page 64: ...hat matches the heating system during the WIZARD setup or manually in the PRIORITY 2 menu 4 Assign INPUT 1 to PRIORITY 1 which is factory default configured for DHW applications 5 Use the factory default settings for DHW and for the heating system type chosen or change if needed 6 Factory defaults should work for other settings not listed above WMCR circulator zone controller plus DHW controlled by...

Page 65: ...ed con nection as shown at right because it is being used in the control setup to run the system circulator 7 Factory defaults should work for other settings not listed above Thesystemmustbeequippedwithaby pass pressure regulating valve Flow can occur with zone valves closed WMZV zone valve zone controller plus DHW controlled by boiler DHW piped directly to boiler P15 P11 and P2 are terminal strip...

Page 66: ...firing sequence s Blower to ignition speed for prepurge GNITION s After prepurge times out begin ignition cycle s Activate gas valve and ignition spark s Continue ignition spark for ignition period s Turn off spark and use electrode to check for flame signal 3PACE EATING s Flame detected s Release boiler to modulation s NOTE If flame is not detected the gas valve is turned off blower turns on postpur...

Page 67: ...MANCE IT IS RECOMMENDED TO INSTALL THE SYSTEM SUPPLY AND RETURN SENSORS s The control automatically adjusts blower speed and gas flow rate to match boiler output to space heating and or DHW heating demand s The control provides three inputs and three outputs for circula tors or auxiliary devices plus a fourth boiler circulator output s The outdoor temperature is used for supply temperature reset op...

Page 68: ...re 55 this occurs at 0 F outside the fac tory default setting 3 OD RESET MIN should equal the ODT outdoor design tem perature for the installation s location Remote target operation 0 10VDC input 1 This function allows a remote analog input to regulate the sup ply temperature for control operation modulation This can be done for any priority including network and local priorities for multiple boil...

Page 69: ... 0516 69 SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual IGURE SlimFit single boiler essential settings 2 15 2 on initial start up see page 71 for explanation Control operation and setup continued ...

Page 70: ...68 0516 70 IGURE SlimFit control display screens and typical navigation SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Control operation and setup continued Control operation and setup continued ...

Page 71: ...n selectable s Target Mod Sensor non selectable s System Type s Target Adjust non selectable AINTENANCE NFO MENU s Target Mod Sensor non selectable s Supply Max s See Figure 72 page 82 for details s Target Adjust non selectable s Supply Min not available for DHW s Supply Max s OD Reset Max or Volts for Max 3ET ATE AND 4IME MENU s Supply Min not available for DHW s OD Reset Min or Volts for Min s S...

Page 72: ... manual reset high limit and WWSD temperature settings outdoor sensor temp adjustment circulator exercising freeze protection setup and restore to factory default option See page 73 PRIORITY 1 s These settings control operating tempera tures and behaviors for systems that are assigned to PRIORITY 1 See page 74 PRIORITY 2 s These settings control operating tempera tures and behaviors for systems th...

Page 73: ...r lockout Changing this setting is NOT recommended 773 4 0 s WWSD stands for warm weather shut down It means the boiler will not be allowed to fire if the out side temperature is greater than the WWSD setting When the boiler is kept off because the outside tem perature is above WWSD the graphic display will show WWSD and the boiler will remain in standby until the outside temperature drops below WW...

Page 74: ...t sensor in place of system sensor s Not adjustable in Basic Mode see Advanced Manual for information on adjusting this parameter TARGET ADJUST s Select how target temperature is calculated by control NONE no reset fixed target temperature 0 10V target temperature based on analog input from remote source ODT outdoor reset operation default setting s Not adjustable in Basic Mode see Advanced Manual ...

Page 75: ...For DHW priority make sure PRIORITY 1 is defined for a DHW system s If DHW priority is required and analog input is used for space heating assign INPUT 2 to the DHW aqua stat TT2 and INPUT 1 as PRIORITY 2 and SOURCE set to 0 10V INPUT 1 s Assign priority system type for INPUT 1 options are s PRIORITY 1 assigns INPUT 1 to PRIORITY 1 system s PRIORITY 2 assigns INPUT 1 to PRIORITY 2 system s PRIORITY...

Page 76: ... 054 s The assigned output is energized if there is an input closure on this boiler s The assigned output will de energize once there are no input on this boiler post purge has finished and post pump time has expired s If the closed input is configured for a heat demand its output will de energize after post purge and post pump s Energize a system pump relay if pump must run during all heating calls...

Page 77: ...V LINKED TO MASTER DEMAND OF MASTER MANUAL LIMIT AUTO LIMIT LOW WTR CUTOFF AIR P SWITCH GAS P SWITCH CLOSURE SWITCH BLOWER SPEED RPM FLAME SIGNAL See following pages for details OUTPUTS STATUS GAS VALVE CIRC OUTPUT 1 CIRC OUTPUT 2 CIRC OUTPUT 3 BOILER CIRC BLOWER SIGNAL ADD L HEAT DEMANDS ALARM 0 10V OUTPUT V See following pages for details RUNTIME BURNER TIME HR ROTATE TIME DAYS INPUT1 TIME HR IN...

Page 78: ... PAST ERRORS CONTROL FAULTS IGNITION RETRIES See following pages for details MANUAL RESET CNT See following pages for details AUTO RESET CNT See following pages for details LOCKOUT HISTORY 1 LOCKOUT HISTORY 2 LOCKOUT HISTORY 3 LOCKOUT HISTORY FAULT NAME FAULT TYPE TIME HH MM AM DATE MM DD YY STATUS TEMPERATURES INPUTS OUTPUTS TEMPERATURES INPUT STATUS OUTPUT STATUS MANUAL TEST MODE Single boiler o...

Page 79: ... boiler Prepurge Ignition Name of the system Type being satisfied post purge Warm Weather Shut down Trouble NPUT Call for heat status on Input 1 Input 1 can be TT1 or 0 10VDC input NPUT Call for heat status on Input 2 NPUT Call for heat status on Input 3 n 6 NPUT Voltage input for target adjust or modulation for single boiler INKED TO ASTER For Multiple Boiler Networks Shows if current control is c...

Page 80: ...IPLE BOILERS ONLY n 3EE 3LIM IT DVANCED MANUAL Shows current rate of boiler Shows Boiler Out temperature of boiler Shows priority being satisfied updated based on active demand Shows system type of call for heat updated based on active demand Shows the sequence position of that boiler in all the boilers available 2 Shows boiler number this data belongs to ETWORK NPUTS OILER NUMBER Displays boiler n...

Page 81: ...ault that occurred 4IME Displays time that lockout occurred ATE Displays date that lockout occurred 3TATUS Displays what the status of the boiler was at the time of the error 4EMPERATURES Choose this to view the Boiler Temperatures at the time of the error NPUTS Choose this to view the status of the Boiler Inputs at the time of the error UTPUTS Choose this to view the status of the Boiler Outputs ...

Page 82: ...ROR screen in Diagnostic Menu AINTENANCE NFO OMMENT Name Contractor name to appear in maintenance reminders and during lockouts Phone Contractor phone number Model Displays the boiler model selected in the boiler setup CP Number Enter the CP of the boiler Installed Enter the date the boiler was installed Last Date Date automatically entered when Reset Reminder is chosen by contractor Next Date Dat...

Page 83: ...to run through the zone pushing out the air Run until no noticeable air flow is present Close the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purged Clean system to remove sediment 1 You must thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by buildup or corrosion due to sedime...

Page 84: ...ystem pressure rises to correct cold fill pressure 8 After the system has operated for a while eliminate any residual air by using the manual air vents located throughout the system 9 If purge valves are not installed in system open manual air vents in system one at a time beginning with lowest floor Close vent when water squirts out Repeat with remaining vents 10 Open automatic air vent diaphragm t...

Page 85: ...leak detector or smell near the floor and around the boiler for gas odorant or any unusual odor Remove boiler front door and smell interior of boiler enclosure Do not proceed with startup if there is any indication of a gas leak Repair any leak at once DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable ...

Page 86: ...ttle screw adjustment does not correct the problem then shut down the boiler and contact your localWeil McLain represen tative Throttle screw adjustment must be done only by a qualified technician using calibrated test instruments Failure to comply could result in severe personal injury death or substantial property damage IGURE Acceptable CO2 and CO values CO2 must be within 1 0 of these values OI...

Page 87: ...stabilize and take another reading Continue until the desired CO2 value is achieved c If the CO2 is LOW turn the throttle screw COUNTER CLOCKWISE to increase the input Allow the boiler to stabilize and take another reading Continue until the desired CO2 value is achieved d Re install the blue cover on the gas valve Adjust valve at low fire 1 Lock the boiler into low fire using the Control module scr...

Page 88: ...8 0516 88 IGURE Operating instructions WARNING Verify that the Control is set for the correct boiler model before proceeding SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Operating Instructions ...

Page 89: ...intenance person Fill in NSTALLATION CERTIlCATE on page 123 Fill out the warranty registration card and send to Weil McLain Return instructions to envelope and give to owner or place inside boiler housing Fill out start up data on the Installation and Service Certificate page 123 Gas valve leakage testing DO NOT connect a manometer to the manual gas valve or the automatic gas valve The high vacuum ...

Page 90: ... inspection stable uniform Flame signal see Figure 81 page 94 Clean heat exchanger if flue temp is more than 54 F above return water temp Inspect jacket front door gaskets replace if necessary Additional if combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Vacuum the blower Review Review with owner AILY s Check boiler area s Check air ope...

Page 91: ...sher thor oughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air FIRST YEAR SPECIAL INSPECTION 1 O LATER THAN MONTHS after the boiler is in stalled perform a first year inspection of the boiler This must include the following IN ADDITION TO ROUTINE ANNUAL START UP PROCEDURES a Remove the heat exchanger cover plate Inspect the heat exchanger and clean if necessary See instruction...

Page 92: ...en condensate trap line hose clamps and remove trap line 4 Empty water from trap line and inspect Flush out if needed with fresh water 5 Check condensate fittings and condensate line to drain Flush if necessary to clean 6 Reinstall condensate trap line and tighten hose clamps 7 Fill trap with fresh water by pouring into flue inspection plug opening 8 Replace flue inspection plug Check all piping for ...

Page 93: ...ll level per fitting manufacturer s instructions If fill level is correct check tank size against manufacturer s instructions Replace with a larger tank if necessary s Diaphragm or bladder type first check tank size to be sure it is large enough for the system If size is too small add additional tank or tanks as necessary to provide sufficient expansion If tank size is large enough remove tank from sy...

Page 94: ...burner support stubs on the left end section b Align the burner flange notch with the notch in the casting above the burner opening c Inspect the burner gasket It must be in good condition If not replace with a new gasket see Replacement parts at the end of this manual d Place the gasket over the three studs The burner opening studs are unevenly spaced to ensure the gasket and the mixing tube are p...

Page 95: ...safe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoi...

Page 96: ... tools recommended for trouble shooting SlimFit boilers 2 Check for 120 VAC minimum 102 VAC to maxi mum 132 VAC to boiler 3 Check the Control s last three lockout histories a See Figure 68 page 78 for access information b Scroll down to DIAGNOSTICS and press the enter key c Scroll down to PAST ERRORS and press the enter key d Record the first four data records and then highlight the history record ...

Page 97: ...njury death or substantial property dam age 5 Reinstall jacket top panel and boiler jacket door after check ing the fuses 6 Restorepowertoboileratexternallineswitchandverifyboiler operation after completing boiler service Checking temperature sensors 1 The boiler temperature sensors flue outdoor boiler out boiler in heat exchanger and system are all resistance type devices 2 Figure 83 shows the cor...

Page 98: ...n the Control display 2 Figure 84 shows the screen behavior during an automatic or manual reset condition The table below the display illustration lists manual reset conditions and how to reset from them 3 Figure 85 page 99 lists conditions that will cause the control to display a constant red screen The boiler will automatically restart if the con dition self corrects or the technician uses the C...

Page 99: ...set this count Ignition Retries Displays the number of ignition attempts in the current ignition sequence Manual Reset Count Records number of lockouts that required a manual reset since this count was last cleared Select and press the enter key to reset this count Auto Reset Count Records number of lockouts that have automatically reset since this count was last cleared Select and press the enter...

Page 100: ...tment Correct wiring inside the control pod using the wiring diagram in this manual Inspect 12 amp fuse as shown on page 97 Replace if necessary Replace the fuse with proper part found in the replacement part section of this manual If fuse blows again recheck wiring per diagram Nothing is shown on display screen but boiler is operating Occurs if the communication is lost from the control to the di...

Page 101: ...sets when condition no longer exists Verify proper flow direction of the boiler circulator Verify proper placement of system sensors for single or multiple boiler system System sensors should be on system piping not on the boiler loop Verify sensors are wired to correct terminal locations System sensors may need to be located further away from the boiler loop connection to the system if proximity t...

Page 102: ...tor sizing for boiler size and system requirements See message displayed TEMPERATURE SENSOR and follow procedure for loose connections FLAME FAULT Occurs if flame is detected when there should be no flame Reset using manual reset screen on display Burner may be operating too hot due to incorrect combustion Inspect flame and conduct combustion test Force boiler into high fire Check flue gases with combu...

Page 103: ...inspection of flueways may not be sufficient to diagnose condition Check combustion settings on high and low fire and adjust per setup instructions if necessary Check incoming gas pressure with boiler off and at high fire Adjust within limits on rating label Verify correct boiler model and altitude is selected in control and correct elevation must be entered when operating above 2 00 feet Check ignition...

Page 104: ...sure switches Hardware Fault Occurs when micro controllers on main board have a RAM or ROM error or communication is cut off Check for hardware damages RAM or ROM errors can be reset with the manual reset option If problems persist replace main board ARDWARE AULT 8 The control has detected a problem with its gas valve output circuit Auto reset if condition is clear after lockout then 1 hour automat...

Page 105: ... the aluminum The oxide layer will reform but if small amounts of the trisodium phosphate remain in the system the chemical will continue to remove the protective oxide layer leading to reduced heat exchanger life 4 Use ONLY the cleaning product available from Weil McLain Sentinel X400 See the Repair Parts section at the end of this manual for ordering information General maintenance 1 Oil motors ...

Page 106: ...s 2 Slide the cleaning tool through the heat exchanger pins in the three directions shown in Figure 87 page 107 3 Vacuum most of the debris out of the base through the flue inspection opening Water spray the heat exchanger 1 Disconnect the condensate line at the bottom of the heat exchanger so debris will not clog the trap a Loosen the hose clamps at both ends of the condensate line b Remove the li...

Page 107: ... REACHES INCH POUNDS INCH POUNDS M M 1 8 3 5 10 11 12 2 9 4 7 6 IGURE UT TIGHTENING SEQUENCE 3 RADUALLY TIGHTEN THE NUTS REPEATING THE SEQUENCE SHOWN BELOW UNTIL THE TORQUE REACHES INCH POUNDS INCH POUNDS M M Gasket Silicone cord starts and finishes at the top center Insulation 1 8 3 5 10 12 13 11 14 2 9 4 7 6 SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Maintenance ...

Page 108: ... Reinstall boiler jacket front door after startup or servicing Inspect boiler jacket front door gaskets and reinstall boiler jacket front door after start or servicing The boiler front 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 kee...

Page 109: ... pipe 8 inch for 8 inch vent or air pipe 560 907 633 560 907 634 5 CHEMICALS Antifreeze aluminum safe Sentinel X500 1 gallon Antifreeze aluminum safe Sentinel X500 5 gallon Corrosion inhibitor Sentinel X100 one tube 275 ml Inhibitor quick test kit Cleaner Sentinel X400 one tube 275 ml 592 900 029 592 900 006 592 900 002 592 900 005 592 900 003 6 Annual maintenance kit for SF 550 or SF 750 consisti...

Page 110: ...iler Manual Replacement parts continued Item Description Part Number for SlimFit 550 750 1 Jacket front door 383 600 052 2 Door seal 383 600 022 3 Handle 2 required 383 500 611 4 Back Jacket 426 700 044 5 Jacket seal kit base seal door seal grommets and gaskets 383 600 053 6 Plastic top cover includes cover gaskets and hardware 383 600 054 7 Inlet outlet adapter 593 000 052 ...

Page 111: ...Part number 550 100 168 0516 111 IGURE Jacket parts SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Replacement parts continued ...

Page 112: ... distribution tube o ring and nuts 550 383 600 033 12 6 section supply distribution tube kit distribution tube o ring and nuts 750 383 600 032 13 5 section return distribution tube kit distribution tube o rings and nuts 550 383 600 031 14 6 section return distribution tube kit distribution tube o rings and nuts 750 383 600 030 15 Return manifold casting kit includes manifold o ring and nuts 550 75...

Page 113: ...Part number 550 100 168 0516 113 IGURE Heat exchanger SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Replacement parts continued ...

Page 114: ... also see Item 6 Figure 95 page 113 550 750 590 318 039 8 Supply return pipe grommet 2 NPT x 3 diameter included in Item 1 550 750 562 248 747 9 P T gauge pressure sensor line check valve 550 750 383 500 275 10 Plug NPT 550 750 In Item 1 11 Low water cut off 550 750 383 600 069 12 P T gauge temperature sensor well 550 750 383 500 270 13 Supply temperature sensor See Figure 101 page 119 14 Return p...

Page 115: ...Part number 550 100 168 0516 115 IGURE Piping SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Replacement parts continued ...

Page 116: ...ent kit includes switch and nipple 383 600 049 11 High gas pressure switch replacement kit includes switch and nipple 383 600 048 12 Gas pressure switch piping 383 600 047 13 Gas pressure switch harness not shown 383 600 059 14 Gas valve harness not shown 591 391 960 15 Flexible gas line 560 900 021 16 Air silencer 560 900 020 17 Inspection glass kit includes retainer glass gasket and screws 383 5...

Page 117: ...Part number 550 100 168 0516 117 IGURE Burner blower venturi and gas train SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Replacement parts continued ...

Page 118: ...8 054 17 120 volt 3 wire receptacle pre wired 591 391 959 18 Air pressure switch kit includes switch tube and mounting screws 383 600 073 19 Hose barb for air pressure switch sensing tube connection not shown 562 302 525 20 Air pressure switch sensing tube included in item 18 In Item 18 21 Blower power relay 570 350 230 22 SlimFit Control terminal block kit not shown 383 500 642 23 Control to Expa...

Page 119: ...Part number 550 100 168 0516 119 IGURE Controls SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Replacement parts continued ...

Page 120: ... both 2 NPT 2 Circulator must be mounted in the return piping 3 Relief valve is shipped loose See page 12 for mounting details Relief valve mounts on supply pipe off of supply tee as shown 4 Boiler gas connection 1 NPT SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Dimensions ...

Page 121: ... Ratings are based on a piping and pickup allowance of 1 15 An additional allowance should be made for unusual piping and pickup loads 2 Combustion efficiency and thermal efficiency are based on AHRI testing procedure per BTS 2000 3 Ratings shown are for sea level applications only For altitudes above sea level the SlimFit boiler requires no modifications and automatically derates itself by approxima...

Page 122: ...ght 2 to 4 Input MBH Output MBH MBH Square inches Length inches Width inches Length inches Width inches SF 550 SF 750 Figure 26 page 36 Note 1 2 1100 1034 900 30 9 550 106 21 51 40 2 1500 1404 1220 41 9 750 3 1650 1551 1350 46 3 825 165 21 110 40 3 2250 2106 1830 62 9 1125 4 2200 2068 1800 61 8 1100 224 21 110 40 4 3000 2808 2440 83 9 1500 5 2750 2585 2250 77 2 1375 283 21 169 40 5 3750 3510 3050 ...

Page 123: ... exceeding 2 2 amps per circulator Electrical service required is the minimum recommended breaker or fuse size DO NOT use larger than a 30 amp breaker or fuse In addition circulator 4 requires a separate power supply for circulator amperage not to exceed 10 amps Electrical service required is the recommended breaker size of 15 amps DO NOT use a higher amp rated breaker or fuse Boiler Model Shippin...

Page 124: ...oost Time ___________ Mins Circulator 2 ON___ OFF___ Rotate Frequency ____Days System Off Diff Circulator 3 ON___ OFF___ Force Lead Rotation YES or NO System On Diff Boiler Circ ON___ OFF___ Modbus Settings Add BLR Diff Freeze Protection Enable YES___ NO___ Drop BLR Diff Circulator 1 ON___ OFF___ Address __________ Mod Delay Time ___________ Mins Circulator 2 ON___ OFF___ Parity Bit __________ Sta...

Page 125: ...od Delay Time ___________Mins Stabilization Time ___________ Mins Stabilization Time ___________ Mins Stabilization Time ___________Mins Add Delay Time ___________Sec Add Delay Time ___________Sec Add Delay Time ___________Sec Drop Delay Time __________Sec Drop Delay Time ___________Sec Drop Delay Time ___________Sec Max BLR Temp Max BLR Temp Max BLR Temp Boiler On Diff Boiler On Diff Boiler On Di...

Page 126: ...Part number 550 100 168 0516 126 SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Notes ...

Page 127: ...Part number 550 100 168 0516 127 SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual Notes ...

Page 128: ...GAS FIRED WATER BOILER Boiler Manual SlimFit Series 3 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Boiler Manual ...

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