Weil-McLain New Series 3 Installation, Start-Up, And Operating Instructions Manual Download Page 24

®

Series 3 

WATER

 

BOILER

 — Boiler Manual

Check-out procedure

  1.  Boiler and heat distribution units fi lled with water?

  2.  Automatic air vent, if used, opened one full turn?

  3.  Air purged from system? Piping checked for leaks?

  4.  Air purged from oil piping? Piping checked for leaks?

  5.  Burner door closed, sealed and bolts tight? Observation 

port bolt tight? Burner harness plugged in and boiler 
ON/OFF switch on?

  Obtain gas-tight seal to prevent possible fl ue gas 

leakage and carbon monoxide emissions, leading 
to severe personal injury or death.

  6.  Proper draft and burner fl ame? Final adjustment made 

with combustion test equipment?

  7.  Test limit control: While burner is operating, adjust limit 

control below actual boiler water temperature. Burner 
should go off while circulator continues to operate. Raise 
setting on limit control above water temperature and 
burner should re-ignite.

  8.  Test additional fi eld-installed controls:  If boiler has a low 

water cutoff, additional high limit or other controls, test 
for operation as outlined by manufacturer.  Burner should 

be operating and should go off when controls are tested. 
When controls are restored, burner should re-ignite.

  9.  Limit control set to system temperature requirements 

(max. 220 °F)?

  10. For multiple zones, fl ow adjusted to distribute heat in all 

zones?

  11. Thermostat heat anticipator setting (if available) set 

properly? Refer to “Thermostat wiring,” page 19.

  12.  Boiler cycled with thermostat? Raise to highest setting and 

verify boiler goes through normal start-up cycle. Lower 
to lowest setting and verify boiler goes off.

  13. Observed several operating cycles for proper operation?

  14. Set room thermostat(s) to desired room temperature?

 15. Completed 

Installation Certifi cate

 below?

  16. Reviewed User’s Information Manual with owner or 

maintenance person and instructed person to keep for 
future reference?

  17. Returned all instructions provided with boiler to its en-

velope and placed with boiler for future reference?

Installation Certifi cate

Boiler model  

__________________________  Series  _________

CP number 

_______________________

Date installed 

__________________________________________

Nozzle size, GPH ____________  Fuel unit pressure, PSIG __________

 ❏ 

Installation instructions have been followed.

 ❏ 

Check out sequence has been performed.

 ❏ 

Above information is certifi ed to be correct.

 ❏ 

Information received and left with owner/maintenance person.

Installer   

________________________________  (company)          ________________________________  (phone)

 

 

 

________________________________  (address)

 

 

 

________________________________  (address) 

        _______________________________________

 

                     (Installer’s signature)

Comments:

_______________________________________

_______________________________________

_______________________________________

_______________________________________

_______________________________________

_______________________________________

Part number 550-142-182/1014

24

Summary of Contents for New Series 3

Page 1: ...all instructions includ ing this manual and all other information shipped with the boiler before installing Perform steps in the order given Failure to comply could result in severe personal injury d...

Page 2: ...osen the center mounting bolt and rotate so the sight glass is in the 6 00 position 17 Over re pressure tapping 1 8 npt with plug 18 Jacket cross tie 19 Sensor wells Boiler limit temperature sensor an...

Page 3: ...Series 3 WATER BOILER Boiler Manual THE WATER BOILER Part number 550 142 182 1014 3...

Page 4: ...boiler Please have the boiler model number from the boiler rating label and the CP number from the boiler jacket You may list the CP number in the space provided on the Instal lation Certi cate found...

Page 5: ...boilerheatexchanger can be damaged by build up or corrosion due to sedi ment Do not use petroleum based cleaning or sealing compounds in boiler system Gaskets and seals in the system may be damaged Th...

Page 6: ...fied service technician to perform annual service Every day during heating season Keep area free of combustible materials Check that boiler area is free of combustible materials gasoline and other amm...

Page 7: ...e combustion air and ventilation Unless burner uses ducted outside air for combustion the boiler room must provide combustion air openings See manual page Venting Chimney venting Ensure the vent pipe...

Page 8: ...iler jacket surfaces Top of Control Pod cover 12 inches Sides and back 2 inches 5 Burner cover All directions 2 inches Combustible clearances always take pre cedence over service clearances For servic...

Page 9: ...dryer and replace Air from outside the building When outside air is used connect each opening directly or by ducts to the outdoors or to crawl or at tic space that freely connects with outdoors Size p...

Page 10: ...oiler leg Place the channel directly over the crate base runner as shown 5 Figure 3 With the boiler resting securely on the two 2 shipping channels screw a leveling leg in each boiler leg hole Screw l...

Page 11: ...temporarily The burner door is heavy Handle carefully to avoid potential for personal injury Do not damage the burner door insulation when han dling 5 The hinge bracket has keyhole slots Loosen the tw...

Page 12: ...ation in chimney Table 2 Chimney venting vent sizing Install the burner 1 Secure the burner ange to the burner door using the three 3 bolts provided 2 Check for secure placement of insulation and seal...

Page 13: ...d breeching draft will be approximately 0 01 to 0 02 W C Install barometric control in breech ing per control manufacturer s instructions when excess draft needs to be relieved or to comply with appli...

Page 14: ...for manufac turer s instructions Relief valve discharge piping To avoid water damage or scalding due to relief valve operation Discharge line must be connected to relief valve outlet and run to a safe...

Page 15: ...valve and makeup water added through ll valve Eventual section failure can result CLOSED expansion tank Figure 7 Ensure expansion tank size will handle boiler and system water volume and temperature...

Page 16: ...all zones Figure 8 Multiple zoning with circulators Temperatures 140 F and higher Figure 9 Multiple zoning with zone valves Temperatures 140 F and higher d Separate relay is required for each circula...

Page 17: ...to distribute heat to all zones b Separate transformer is required to power zone valves Refer to Weil McLain Zone Valve Wiring Guide for details 6 To set the valves 7a and 7b a Set the valves while th...

Page 18: ...l Code ANSI NFPA 70 latest edition and any additional national state or local codes Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Figure 13 Terminal strip access Connect wiring...

Page 19: ...t installed or wired Wire the circulator to the boiler terminal strip as shown on the boiler wiring diagram Provide hot neutral and ground wires routed in metal conduit Thermostat wiring Install therm...

Page 20: ...iler Manual Connect wiring continued Figure 15 Boiler and burner wiring standard equipment This wiring diagram is for standard boiler equipment For wiring with optional AFM see AFM instructions Part n...

Page 21: ...Series 3 WATER BOILER Boiler Manual Connect wiring continued Part number 550 142 182 1014 21...

Page 22: ...device must be used to prevent ow of oil in case of oil line break Support oil lines as required by codes Make tank connections with swing joints or copper tubing to prevent breaking in case the tank...

Page 23: ...ombustion test equip ment to assure proper operation Do not re boiler without water Sections will overheat damaging boiler and resulting in substantial property damage 5 Vent air from system Repeat st...

Page 24: ...ly Refer to Thermostat wiring page 19 12 Boiler cycled with thermostat Raise to highest setting and verify boiler goes through normal start up cycle Lower to lowest setting and verify boiler goes off...

Page 25: ...oil burner motor if required clean air inlet clean or change fuel filter and strainer 8 Make sure boiler is filled with water 9 Start unit and verify combustion settings with combustion test equipment...

Page 26: ...NIOSH recommendations can be found on the NIOSH web site at http www cdc gov niosh homepage html NIOSH approved res pirators manufacturers and phone numbers are also listed on this web site Wear long...

Page 27: ...a ture increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type Follow guidelines in this manual for the best location of the expansion tank Open type located abo...

Page 28: ...ore operating lever check to see that a discharge line is connected to this valve directing the ow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result...

Page 29: ...the cleaning process 7 Remove the ue baf es 8 Starting at the top of the boiler use a wire ue brush to thoroughly clean all ns 9 Once the ueways are cleaned carefully remove the paper from the oor of...

Page 30: ...iring harness at the jacket cross tie located beneath the burner door Failure to disconnect the burner wiring har ness before opening the burner door can cause damage to the burner and boiler wiring T...

Page 31: ...ve the electrical tray in position 15 Remove the jacket side panels by pulling back edge away from the back of the boiler and then disengag ing the keyholes from the jacket front screws 16 Remove the...

Page 32: ...or well 592 300 026 9 Mounting clip for P T gauge and limit well 512 400 001 10 P T gauge pressure sensor check valve 512 400 000 11 Boiler relief valve 3 4 NPT 30 PSI 511 546 920 12 Flue collar 446 9...

Page 33: ...Series 3 WATER BOILER Boiler Manual Replacement parts continued Boiler section assembly parts Part number 550 142 182 1014 33...

Page 34: ...2 required 3 8 16 x 1 Purchase locally 5 Observation port assembly includes observation port bolt observation port gasket sight glass gasket sight glass water glass 386 902 000 6 Observation port gask...

Page 35: ...Series 3 WATER BOILER Boiler Manual Replacement parts continued Burner door parts Part number 550 142 182 1014 35...

Page 36: ...6 900 007 6 Jacket rear panel if required order insulation below 426 900 001 7 Jacket rear panel insulation 591 222 181 8 Jacket cross tie 426 900 009 9 Boiler insulation Not shown UO 3 UO 4 UO 5 591...

Page 37: ...Series 3 WATER BOILER Boiler Manual Replacement parts continued Jacket and control parts Part number 550 142 182 1014 37...

Page 38: ...ons 1 Boiler circulator is shipped loose Circulator may be mounted on either boiler supply or return piping 2 Relief valve is shipped loose supplied with elbow and nipple to install in rear section ta...

Page 39: ...y at combustion condition of 13 0 CO2 and 0 02 w c breeching draft 2 Ratings shown are for sea level applications only For altitudes above 2 000 feet derate the product capacity by 4 per 1 000 feet ab...

Page 40: ...40 Series 3 WATER BOILER Boiler Manual 40...

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